TRENT 700 - N-TRENT-A330 - Chapter 54 PDF

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211 TRENT
STRUCTURAL REPAIR
MANUAL
NACELLE DIMENSIONS AND STATIONS
1. Nacelle Dimensions
A. Refer to Figure 1 for nacelle primary dimensions.

2. Nacelle Stations
A. Refer to Figure 2 for nacelle stations.
B. Definitions:
BL Buttline - a vertical plane, parallel to the vertical centerline of
the nacelle, which is BL100. Additional buttlines are shown at 25
inch internals.
STA Station - a vertical plane, perpendicular to the longitudinal

centerline of the nacelle, located by its distance (in inches) from
a point forward of the engine.
WL Waterline - a horizontal plane, parallel to the horizontal

centerline of the nacelle, which is WL100. Additional waterlines
are shown at 25 inch intervals.
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1371 m m 1676 mm 2489 m m 1778 mm

- (54in) (66 in) (98 in)
-I- -
(70 in)
t
- - - - - - - - - p -
r
1887 m m
(73.30in)
I I I
NOTE: All dimensions are approximate
SECTION SECTION
A-A C-C
Nacelle Primary Dimensions

Figure 1
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STA STA STA STA STA STA

0,OO 2062 m m 3434 mm 5105 mm 7594 mm 9373 mm
(81 in) (135in) (201 in) (299in) (369in)
WL 175
NOTE: Station lines are identical WL 150

for right and left nacelles
WL 125
WL l00
WL 75
\- WL 50
WL 25
Nacelle S t a t i o n s
Figure 2
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NACELLE ZONES AND PANELS
1. General (Refer t o Figures 1 t o 4)
A . The s u r f a c e of t h e n a c e l l e i s divided i n t o zones and sub zones t o h e l p

assign descriptions t o particular p a r t s or locations.
B. Each panel has a unique i d e n t i t y r e f e r e n c e , derived a s follows:
(1) The f i r s t c h a r a c t e r i s always 4 , which shows n a c e l l e .
(2) The second c h a r a c t e r shows l e f t (1) o r r i g h t (2) n a c e l l e .
( 3 ) The t h i r d c h a r a c t e r shows the n a c e l l e zone.
(4) The f o u r t h c h a r a c t e r , a l e t t e r , shows the panel sequence i n t h a t zone.
(5) The f i f t h c h a r a c t e r , a l e t t e r , shows t h e l e f t (L) o r t h e r i g h t (R) s i d e

of the n a c e l l e .
C. A i r i n t a k e cowl a c c e s s doors, l e f t wing n a c e l l e
(1) 411AL Thermal Anti-Icing System
(2) 411AR P2T2 Probe
D. Fan cowl doors, l e f t wing n a c e l l e
(1) L e f t hand 415AL
( a ) 415BL Pressure Relief and S t a r t e r Valve
(b) 415CL I D G O i l F i l l and Level
( 2 ) Right hand 416AR
( a ) 416BR Hydraulic F i l t e r Pop-up I n d i c a t o r and Master Chip Detector.
(b) 416CR O i l F i l l and Level
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E. Thrust Reverser C-duct, l e f t wing n a c e l l e
(1) Left s i d e 417AL
(a) 417BL Thrust Reverser Door P o s i t i o n I n d i c a t o r
(b) 417CL Thrust Reverser Door Pivot
(c) 417DL Hinge Access Cover
(d) 417EL Hinge Access Cover (No.5 Binge)
(e) 417m Upper Door I n h i b i t i o n Bolt Attachment Cover
( f ) 417GL Lower Door I n h i b i t i o n Bolt Attachment Cover
( 2 ) Right s i d e 418AR
(a) 418BR Thrust Reverser Door P o s i t i o n I n d i c a t o r
(b) 418CR Thrust Reverser Door Pivot
(c) 418DR Hinge Access Cover
(d) 418ER Hinge Access Cover (No.5 Hinge)
(e) 418FR Upper Door I n h i b i t i o n Bolt Attachment Cover
( f ) 418GR Lower Door I n h i b i t i o n Bolt Attachment Cover
(g) 418HR Latch Access Door, Forward
(h) 418IR Latch Access Door, Rear
F. A i r i n t a k e cowl a c c e s s doors, r i g h t wing n a c e l l e
(1) 421AL Thermal Anti-Icing System
(2) 421AR P2T2 Probe
G. Fan cowl doors, r i g h t wing n a c e l l e
(1) Left hand 425AL
(a) 425BL Pressure Relief and S t a r t e r Valve
(b) 425CL IDG O i l F i l i and Level
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(2) Right hand 426AR
(a) 426BR Hydraulic Filter Pop-up Indicator and Master Chip Detector
(b) 426CR Oil Fill and Level
H. Thrust reverser C-duct, right wing nacelle

(1) Left side 427AL
(a) 427BL Thrust Reverser Door Position Indicator
(b) 427CL Thrust Reverser Door Pivot
(c) 427DL Hinge Access Cover
( d ) 427EL Hinge Access Cover (No.5 Hinge)
(e) 427FL Upper Door Inhibition Bolt, Attachnnent Cover

( f ) 427GL Lower Door Inhibition Bolt, Attachment Cover
(2) Right side 428AR
(a) 428BR Thrust Reverser Door Position Indicator
(b) 428CR Thrust Reverser Door Pivot
(c) 428DR Hinge Access Cover
(d) 428ER Hinge Access Cover (No.5 Hinge)
(e) 428FR Upper Door Inhibition Bolt, Attachment Cover
( f ) 428GR Lower Door Inhibition Bolt, Attachment Cover
(g) 428HR Latch Access Door, Forward
(h) 428IR Latch Access Door, Rear
I. Common Nozzle Assembly
(1) Zone 414 Left Wing Nacelle
(2) Zone 424 Right Wing Nacelle
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Access Doors - Left Wing Nacelle - L e f t Hand Side

Figure 1
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ZONE 4 1 4 418AR
4 181R
ZONE 4 11
Access Doors - L e f t Wing N a c e l l e - R i g h t Hand S i d e

Figure 2
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Access Doors - Right Wing Nacelle - Left Hand Side

Figure 3
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4281R 1 428GR l
428HR 428JR ZONE 421
426BR
Access Doors - R i g h t Wing N a c e l l e - Right Hand S i d e

Figure 4
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ENGINEERING DRAWINGS
Component Manufacturer Assembly Drawing
Air Intake Cowl Short Brothers

Fan Cowl L.H. BP Chemicals
Fan Cowl R.H. BP Chemicals
Thrust Reverser Hurel-Dubois
Common Nozzle Assembly Rohr Industries
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AERODYNAMIC SMOOTHNESS
1. General
A. The aerodynamic smoothness for the Pylon and Nacelle external

surfaces are defined within the General Aircraft Aerodynamic
Requirements of the Airbus A330 SRM Chapter 51-10-00.
54-01-01
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DAMAGE CLASSIFICATION AND TERMS
1. Damage Classification
A. Damage is any distortion or thickness change of a structural member.
Damage classes are:
Allowable damage
Repairable damage
Damage which makes the replacement of parts necessary
B. Allowable damage
(1) Damage or distortion that can be left as it is or which can be repaired
by a simple procedure.
(2) The limits of allowable damage are given in the allowable damage
section for each of the major assemblies and component parts containec
in this Structural Repair Manual.
C. Repairable damage
(1) There are two types of repairs that can be done on the nacelle. These
are :
(a) Ekternal repair
- Can be quickly applied.
- Can be used to minimize down time of the aircraft.
- Can be above the repair surface.
- Can be replaced later for appearance or for aerodynamic

considerations.
(b) Smooth repair
- The repair makes a continuous surface with the surface of the

component.
- Can be used to replace zri external repair for aerodynamic

reasons.
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(2) External and smooth repairs are structuraily airworthy. However,

aircraft performance may be changed by external repairs in critical
areas.
(3) Some repairs are time limited. These repairs are given as practical
solutions to field repair problems:
(a) Time limited repairs must be replaced with a permanent repair after
a specified time.
(b) Inspection of the repair is necessary at specified times until a

permanent repair is installed.
D. Non-repairable damage
( 1 ) Replacement of the part is recommended when the part is complex or the

damage is so extensive that the repair is not practical or economical.
(2) Items not contained in the repair instructions are non-repairable and
should be replaced.
2. Damage Terms
The terms specified here are guides to help you determine the type of damage
that the component has.
A. Composite structures
Abrasion - damage which causes a thickness change because the part

has been scuffed, rubbed, scraped or other surface erosion
has occurred
Crack - a fracture or complete break in the material
Delamination - a separation of the bonded plies
Disbond - a separation of the bonded skin from the honeycomb core
Gouge - removal of material, usually caused by a sharp object

which hits the material and makes a channel-like groove
Hole - a complete penetration of the material
Nick - a local gouge with sharp edges. A series of nicks in a

line is a gouge
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Scratch - light, narrow, shallow mark or marks in the surface of a

part. It is usually caused by a very sharp object which
passes across the surface. Material is displaced but not
removed
B. Sheet metal structures
Buckle - damage equivalent to a dent but is caused by overstress

has occurred
Dent - a damage area which is pushed in from its normal contour.

There is a no thickness change in the material and the
area edges are smooth. It is usually the result when a
smooth object hits the material

which hits the material and makes a channel-like groove
Nick - a local gouge with sharp edges. A series of nicks in a

line is a gouge

part. It is usually caused by contact with a very sharp
object which passes across the surface. Material is
displaced but not removed
C. Bonded acoustic panels

has occurred
Delamination - a separation of the bonded touching plies from each other
Cisbond - a separation of the bonded skin from the honeycomb core

which hits the material and makes a channei-like groove
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Kick - a local gouge with sharp edges. A series of nicks in a

line is a gouge

part. It is usually caused by contact with a very sharp
object which passes across the surface. Material is
displaced but not removed
Dent - a damage area which is pushed in from its normal contour.

There is a no thickness change in the material and the
area edges are smooth. It is usually the result when a
smooth object hits the material
Rip/Tear - a line of damage to woven wire with a continuous, ragged

separation of wire fibers
Void - separation of the face sheet from honeycomb core or faying

surfaces
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DAMAGE INSPECTION
1. Heat Damage
A. I n s p e c t t h e dzmaged a r e a f o r change i n t h e c o l o r of m e t a l o r p a i n t .
(1) The g e n e r a l h e a t ranges n e c e s s a r y t o change t h e c o l o r of primer p a i n t s

a r e a s follows:
STANDARD HEAT-CHANGED
PRIMER COLOR COLOR TEMPERATURE
FR Epoxy Green Brown Above 400 deg F

(200 deg C)
Phenolic Rust Red Black Above 600 deg F

(315 deg C)
Zinc Chromate L i g h t Green Tan Above 300 d e g F

(150 deg C)
(2) The a c c e p t a b l e c o l o r changes t o t i t a n i u m because of h e a t damage a r e as

follows :
COLOR QUALITY
Metallic Acceptable
Straw Acceptable
Gold Acceptable
Blue Acceptable
Green Acceptable
Purple Acceptable
Reddish Brown Reject
Dark Gray Reject
L i g h t Gray Reject
White Re j e c t
B. I f h e a t damage i s found, a t a p t e s t i s n e c e s s a r y f o r a l l composite p a r t s i n

t h e overheated a r e a (Refer t o 53-01-06).
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Corrosion Damage
A . You w i l l have t o i n s p e c t the p a r t a f t e r i t i s cleaned t o decide i f t h e p a r t

can be r e p a i r e d o r must be replaced.
B. A l l remaining c o r r o s i o n must be removed completely o r t h e corrosion process

w i l l continue even though t h e a f f e c t e d s u r f a c e i s r e f i n i s h e d .
C. Corrosion damage i s grouped a s follows:
(1) Light Corrosion - P i t s o r d i s c o l o r a t i o n t o a depth of 0.001 i n . (0,025

mm) maximum. Remove it w i t h a b r a s i v e paper o r use a minimum of
chemical treatment.
(2) Moderate Corrosion -

B l i s t e r s o r s i g n s of s c a l e o r f l a k e s . P i t depths
may be a s deep a s 0.010 i n . ((0,25 mm). Remove i t with a b r a s i v e paper
e i t h e r by hand o r machine.
(3) Severe Corrosion -

Severe b l i s t e r s , e x f o l i a t i o n , and s c a l e o r f l a k e s .
P i t depths w i l l be deeper than 0.010 i n . (0,25 mm). Remove severe
c o r r o s i o n mechanically w i t h a b r a s i v e paper o r g r i n d e r
NOTE: 1. Refer t o 54-02-02 f o r s e l e c t i o n of a b r a s i v e s .
2. Refer t o 54-02-03 f o r p r o t e c t i v e treatment.
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COMPOSITE STRUCTURE TAP TEST
1. Equipment
A rod, 0.187in. (4,75 mm) diameter with a ball, 0.375in. (9,52 mm) diameter at
one end. Material mild steel or brass, local manufacture.
2. Procedure (Refer to Figure 101)
A. Test the underside of a panel which has visible signs of damage:
(1) Tap the surface of the panel with the ball end of the rod.
(2) Tap the surface of reinforcement sections on the underside of the
panel.
(3) Listen for a change of pitch in the sound, which can indicate a
delamination.
(4) Put marks on the surface to indicate areas of delamination.

B. Test the outer surface of the panel and indicate areas of delamination.
NOTE: It is easier to do the tap test if you make a six inch (150 mm) grid
on the panel surface. This grid controls the search pattern and
makes it less likely that an area will be missed and not searched.
C. Refer to the Allowable Damage limits to find out if the panel is usable or
if it must be repaired.
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AIR INTAKE
SECTION AA
Composite Structure Tap Test

Figure 101
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ACOUSTIC TREATMENT AREAS - REPAIR LIMITS
1. General
A. To ensure compliance w i t h n o i s e c e r t i f i c a t i o n requirements, r e p a i r s i n t h e

a c o u s t i c a l l y t r e a t e d a r e a s ('blockage') must be l i m i t e d .
2. Repair Area Limits (Refer t o Figure 101)
A. Independent r e p a i r s i n each a c o u s t i c t r e a t m e n t zone a r e p e r m i t t e d up t o t h e

l i m i t s p e c i f i e d i n column ( A ) . The r e p a i r l i m i t i n each zone assumes t h a t
a l l o t h e r zones have r e p a i r s up t o t h e i r s p e c i f i e d l i m i t .
B. Larger a r e a s of r e p a i r ( ' b l o c k a g e ' ) i n a g i v e n zone a r e p e r m i t t e d under t h e

cumulative r e p a i r l i m i t . These a b s o l u t e maximum r e p a i r e d a r e a s a r e
s p e c i f i e d i n column (B) and assume t h a t no o t h e r zones a r e r e p a i r e d . Thus
r e p a i r s l e s s than t h e maximum a r e a i n one zone w i l l permit r e p a i r s i n o t h e r
zones, w i t h i n t h e cumulative l i m i t . The cumulative r e p a i r l i m i t i s given
by t h e formula:
1.65 X ( I n l e t a r e a ) +
0.23 X (Thrust r e v e r s e r a r e a ) + 0.52 X (CNA a r e a ) +
0.35 X (Rear f a n c a s e a r e a ) + 1.24 (Front f a n case a r e a upstream of fan) is
l e s s t h a n o r equal t o 1000 sq i n . (6452 s q cm).
NOTE: I f t h e cumulative l i m i t i s invoked, t h e n t h e independent r e p a i r

l i m i t given i n column (A) no l o n g e r a p p l i e s t o any t r e a t m e n t zone.
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MAXIMUM ALLOWED
INDEPENDENT
UNDER CUMULATIVE
REPAIR ZONE LOCATION
REPAIR LlMlT
(A)
REPAIR LIMIT +
cm2(irY)
cm2(inz)
(B)
FAN INLET 1 2323(360) 3903(605)
THRUSTREVERSER 2 21 29(330) 28066(4350)

COMMON NOZZLE
ASSEMBLY 3 1 484(230) 12420(1925)
REAR FAN CASE 4 31 61 (490) 18453(2860)
FRONT FAN CASE

A - UPSTREAM
5A 290(45) 51 94(805)
OF FAN
B - DOWNSTREAM
5B 7097(1100) 7097(1100)
OF FAN
U
0
0
o +# Assumes no other area is repaired
I8
Acoustic Treatment Areas - Repair Limits

F i g u r e 101
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SEAL EXPOSED FIBERS AND MINOR ABRASIONS

ON CARBON REINFORCED COMPOSITE COMPONENTS
1. General
A. This repair gives the procedure to seal exposed fibers with low temperature
cure adhesive.
2. Referenced Information
..............................................................................
REFERENCE DESIGNATION
..............................................................................
TASK 70-42-22-300-001 FRS3254 Standard Practices Manual
54-30-00, Repair No.11 Apply Primer Sealer Paint
3. Equipment and Material
A. Standard equipment
Magnifying glass x7
Scalpel
Spatula
Vacuum cleaner
Heat lamp 100 deg C (212 deg F)
B. Consumable materials
..............................................................................
OMat 11270 SOLVENT

OMat 21101 LINT-FREE CLOTH
OMat 5/33 WATERPROOF SILICON CARBIDE
ONat 5/35 WATERPROOF SILICON CARBIDE
OMat 805 RESIN
OMat 806 HARDENER
or
OMat 8/52 ADHESIVE, 2-PACK
or
OMat 81154 ADHESIVE, 2-PACK
or
OMat 81160 EPOXY ADHESIVE
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4. Examine the Damage

A. Use a magnifying glass and visually examine the surface of the component.
Make sure there are no cracks in the damaged area.
5 . Pre~arethe Damaged Area
A. Use a scalpel to remove all loose fibers.
WARNING: YOU MUST USE PROTECTIVE CLOTHING, GLOVES, DUST MASK AND SAFETY
GOGGLES TO PROTECT YOU AGAINST DUST AND LOOSE PARTICLES WHICH CAN BE
DANGEROUS FOR HEALTH.
WARNING: USE METHYL ETHYL KETONE IN AN AREA OPEN TO THE AIR. THIS MATERIAL
IS FLAMMABLE AND GAS IS DANGEROUS. IT CAN CAUSE IRRITATION OF EYES,
NOSE, THROAT AND SKIN. HIGH CONCENTRATIONS CAN CAUSE WEAKNESS,
HEADACHE, NAUSEA, DIZZINESS AND INCORRECT JUDGEMENT.
B. Use OMat 5 / 3 5 WATERPROOF SILICON CARBIDE, grit size 240, to lightly abrade
the damaged area. Remove the dust with a vacuum cleaner.
C. Clean the repair area with OMat 2 / 1 0 1 LINT-FREE CLOTH soaked with OMat
11270 SOLVENT. Dry the surface before the solvent evaporates.
6. Seal the Exposed Fibers
WARNING: DO NOT PUT MORE THAN 250 G (0.55 LB) OF OMAT 81160 ADHESIVE IN ONE
CONTAINER. IF YOU MIX MORE THAN 250 G (0.55 LB) IN A CONTAINER AN
UNCONTROLLED HEAT BUILD-UP WILL OCCUR. POISONOUS FUMES WILL BE MADE
BY THE HEAT BUILD-UP.
WARNING: USE THE ADHESIVE IN AN AREA OPEN TO THE AIR. CAREFULLY READ THE
APPLICABLE 'MATERIAL SAFETY DATA SHEET' BEFORE YOU USE THE ADHESIVE.
OBEY ALL SAFETY AND HEALTH PRECAUTIONS.
A. Use OMat 805 RESIN and OMat 806 HARDENER, or OMat 8 / 5 2 , OMat 81154 or OMat
8 / 1 6 0 ADHESIVE. Mix the adhesive in accordance with the manufacturers
instructions.
B. With a spatula, apply a thin layer of adhesive to the damaged area.
C. Cure the adhesive in accordance with the manufacturers instructions. The

maximum cure temperature must not be more than 100 deg C ( 2 1 2 deg F).
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7. Make the Adhesive Smooth

A. Use OMat 5/33 WATERPROOF SILICON CARBIDE, grit size 320, to smooth the
adhesive to the contour of the component. Remove the dust with a vacuum
cleaner.
8. Examine the Repair
A. Visually examine the repaired area. Make sure there is no contamination or

delamination. Make sure there are no cracks in the adhesive or in the
component.
9. Apply the Protective Coat
A. Apply primer sealer paint if applicable. Refer to 54-30-00, Repair No.11.
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REPAIR MINOR DAMAGE - METALLIC SURFACES
1. Nick, Scratch and Gouge Removal
A. Aluminum alloys
CAUTION: DO NOT USE CARBON STEEL BRUSH OR STEEL WOOL ON ALUMINUM SURFACES.
TINY DISSIMILAR METAL PARTICLES WILL BECOME INBEDDED IN THE
ALUMINUM CAUSING FURTHER CORROSION AND SUBSEQUENT DAMAGE TO PART.
(1) Sand down any paint film in the damage areas as required to a smooth
base surface and polish out the damage with aluminum wool. Treat the
bare metal exposed (Ref 54-02-03) and finish (Ref 54-02-04).
(2) Scratches which have not penetrated through the clad surface into the
base metal may be reworked by burnishing. A suitable nondestructive
test procedure must be used after rework to ensure that the material is
free from cracks.
(3) For minor scratches or isolated skin defects where the clad surface has
not been completely penetrated, hand burnishing is satisfactory. Treat
the bare metal exposed (Ref 54-02-03) and finish (Ref 54-02-04).
NOTE: During burnishing, if cladded surface is completely penetrated,

damaged area must be rounded out within the allowable damage
limits of the appropriate chapter and the finish restored.
(4) For more extensive scratches or for areas containing multiple small
defects, power burnishing is recommended. Burnish the scratch or
defect as follows:
(a) Remove the paint from the damaged area and a minimum of 1/2 inch
all around.
(b) Burnish out any scratches or small defects from the skin using the
recommended tools. The damaged area must be rounded out within the
allowable damage limits.
(c) Apply a chemical conversion coating to the exposed area of the skin
(Ref 54-02-03).
(d) Restore the finish (Ref 54-02-04).
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WARNING : SMALL PARTICLES AND FINE SHAVINGS OF TITANIUM AND MAGNESIUM IGNITE
EASILY AND PRESENT AN EXTREME FIRE HAZARD. TITANIUM AND MAGNESIUM
DUST I S HIGHLY FLAMMABLE, AND I N THE PROPER CONCENTRATION MAY CAUSE
AN EXPLOSION. WATER I N CONTACT WITH MOLTEN TITANIUM AND MAGNESIUM
PRESENTS A STEAM EXPLOSION IiAZARD. EXTINGUISH FIRES OF TITANIUM AND
MAGNESIUM WITH ABSOLUTELY DRY TALC, CALCIUM CARBONATE, SAND OR
GRAPHITE BY APPLYING THE POWDER TO A DEPTH OF 1 / 2 INCH OR MORE OVER
THE BURNING METAL. DO NOT USE FOAM, WATER, CARBON TETRACHLORIDE, OR
CARBON DIOXIDE.
B. Titanium
( 1 ) Cleanup of damage t o t i t a n i u m p a r t s by g r i n d i n g i s n o t p e r m i t t e d .
Damage removal i s p e r m i t t e d by s a n d i n g manually o r w i t h power t o o l s ,
u s i n g c l o t h o r p a p e r backed s i l i c o n c a r b i d e o r aluminum o x i d e a b r a s i v e ,
80 g r i t o r f i n e r . Wet sanding i s p r e f e r r e d t o minimize r e s i d u a l
s t r e s s e s and p o s s i b l e f i r e hazard. The requirements f o r a b r a s i v e
f i n i s h i n g a r e as f o l l o w s :
( a ) S e l e c t a b r a s i v e s from Fig.201.
(b) Support d i s c s f o r d i s c s a n d e r s must be rubber o r o t h e r f l e x i b l e

material.
( c ) Support drums f o r drum s a n d e r s must have an o u t e r l a y e r of r u b b e r

o r o t h e r f l e x i b l e m a t e r i a l a t l e a s t 0.10 i n c h t h i c k .
( d ) Avoid e x c e s s i v e p r e s s u r e , d w e l l time o r speed (2000 s u r f a c e f e e t

p e r minute, maximum) on l o c a l a r e a s . P a r t s e x h i b i t i n g
d i s c o l o r a t i o n which cannot be removed w i t h MEK a r e t o be r e j e c t e d .
( e ) S u r f a c e f i n i s h t o 32 microinches AA.
( f ) The l a y of a f i n i s h e d sanded edge i s t o be p a r a l l e l t o t h e

d i r e c t i o n of t h e edge, n o t a c r o s s i t .
EFFECTIVITY: TRENT
Page 202
Sept.15/96
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
CAUTION: DO NOT USE CARBON STEEL BRUSH OR STEEL WOOL ON MAGNESIUM SURFACES.
TINY DISSIMILAR METAL PARTICLES WILL BECOME IMBEDDED IN THE
MAGNESIUM CAUSING FURTHER CORROSION AND SUBSEQUENT DAMAGE TO PART.
C. Magnesium
(1) Sand down any paint film in the damage areas as required to a smooth
base surface and polish out the damage with aluminum wool. Protect the
exposed, bare metal with a chromic acid conversion coating (Ref
54-02-03).
2. Corrosion Damage Removal
A. Aluminium and Steel
(1) Mechanically remove the corrosion by using rotary files, rubber backed
disk sanders, carbide tipped scrapers, aluminum wool, aluminum oxide
abrasive paper, etc. Figure 201 lists abrasives. Use air motors for
all power-operated tools.
(2) Group several corrosion spots in a local area such that an elliptical
saucer-like shaped rework surface is obtained. Carefully blend the
edges into the adjoining areas. Make the rework surface equivalent to
125 microinches R2 or better. Consider the reworked depression to be
the equivalent of a gouge.
B. Magnesium
(1) Remove light corrosion by light hand sanding as follows:
(a) Remove the loose corrosion with aluminum wool.
(b) Mask off other materials and parts, especially rubber parts,
bearings and cast or pressed inserts to prevent contact with the
treating solution or its fumes.
(c) Protect reworked surface with chromic acid treatment (Re£

54-02-03).
(2) Mechanically remove moderate or severe corrosion by the following

method:
EFFECTIVITY: TRENT
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Sept.15/96
1 RB.211 TRENT
STRUCTURAL REPAIR
WARNING: GOGGLES OR FACE SHIELD MUST BE USED TO PRECLUDE INJURY FROM

CORROSION PARTICLES BREAKING LOOSE AND FLYING OFF.
CAUTION: DO NOT USE CARBON STEEL WIRE BRUSHES OR SILICONE CARBIDE

ABRASIVES ON MAGNESIUM. PROTECT ADJACENT AREAS TO PREVENT
'
ADDITIONAL DAMAGE FROM CORROSION PRODUCTS REMOVED WHEN USING

THIS PROCESS.
(a) Remove heavy corrosion products by hand wire brushing with a

stainless steel brush.
(b) Remove residual corrosion by hand sanding. Select appropriate

abrasive from Fig.201.
(c) Protect bare metal with chromate acid conversion coating (Ref
54-02-03).
EFFECTIVITY: TRENT
Page 204
Sept.15196
Printed in Great Britain
>
ABRASIVE PAPER OR CLOTH WOOL

PUMICE
'
METALS OR ABRASIVE 350 SCOTCH
MATERIALS FABRIC STAIN MESH BRlTE
TO BE ALUMINUM SILICON OR A L U M 1 LESS OR TYCRO
PROCESSED RESTRICTIONS OPERATION OXIDE CARBIDE GARNET PAD NUM STEEL FINER WHEELS
FERROUS DO NOT USE CORROSION

ALLOYS ACID BASE REMOVAL 150 150. FINE TO
RUST REMOVERS. OR
X X X
HEAT FINER FINER ULTRAFINE
TREATED TO DO NOT USE FAlRlNG
220,000 PSI HAND HELD
A N D ABOVE POWER TOOLS
400 X X X
DOES NOT APPLY CORROSION

TO STEEL HEAT REMOVAL 150 180- FINE TO X 5A OR 7 s
NICKEL T REATED TO OR
X X
FINER FINER ULTRAFINE MEDIUM
AND STRENGTHS TO FAlRlNG
COBALT 220,000 PSI
ALLOYS AND ABOVE
FINISHING 400 X X
,'&E
CORROSION
ALLOYS
D 0 NOT USE
SILICON CARBIDE
:ERMoVAL 60
FINER
7I 0
ER
VERY FlNE
AND X
LtDluM
ABRASIVE. ULTRAFINE
EXCEPT FAlRlNG
GRINDING IS
CLAD
ALUMINUM NOT PERMITTED
FINISHING 400 X X
SANDING LIMITED CORROSION VERY FINE

TO THE REMOVAL REMOVAL 240- 710.
AND X
CLAD OF MINOR OR FINER
FAlRlNG ULTRAFINE
ALUMINUM SCRATCHES.
GRINDING IS
FINISHING 400 X
DO NOT USE
CARBON STEEL CORROSION
REMOVAL 240 VERY FINE
BRUSHES OR AND X
OR FINER X
MAGNESIUM SILICON ULTRAFINE
ALLOYS CARBIDE FAlRlNG
ABRASIVES
GRINDING IS
NOT PERMITTED FINISHING 400 X X
CORROSION
REMOVAL 80 80 5A OR 7 s
0R FINER FINER MEDIUM
TITANIUM GRINDING IS FAlRlNG
NOT PERMITTED
CLEANING
AND 180 7s
FINISHING FlNER FINE
[ RB.211 TRENT
(3 STRUCTURAL REPAIR
MANUAL
PROTECTIVE TREATMENT - METALLIC SURFACES
WARNING: YOU MUST OBEY THE MANUFACTURERS HEALTH AND SAFETY DATA FOR THE SPECIFIED
MATERIALS. YOU MUST ALSO REFER TO LOCAL REGULATIONS 'TO MAKE SURE THAT
THE PROCEDURES ARE DONE SAFELY. IF YOU DO NOT DO THIS AN INJURY CAN
OCCUR.
1. Reason for the Job
A. To prevent corrosion, local surface protection must be applied to light

alloy surfaces after repair.
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

..............................................................................
REFERENCE QTY DESIGNATION
No specific 2 polyethylene containers

No specific 1 stainless steel container
No specific 3 small brushes
No specific A/R lint-free cloth
B. Consumable Materials
P - - - P
.........................................................
OYtt 1/21 TRICHLORETHANE (inhibited and stabilised)
or
OMat 135 METHYL ETHYL KETONE (MEK)
or
OMat 7/176 ACETONE
OMat 2/7 WETTING AGENT
OMat 117 PHOSPHORIC ACID (H3P04)
OMat 175D CHROMATE CONVERSION COATING (brush application)
EFFECTIVITY: TRENT
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Sept.15/96
[ RB.211 TRENT
m(R\ STRUCTURAL REPAIR
MANUAL
Procedure
A. Apply the chromate conversion coating
(1) Clean the repair surface
WARNING: YOU MUST NOT GET THE DEGREASER ON YOUR SKIN OR IN YOUR EYES.
THE DEGREASER IS HARMFUL. USE AN APRON, APPLICABLE GLOVES
AND EYE PROTECTION. IF YOU GET THE DEGREASER ON YOUR SKIN,
REMOVE IT WITH SOAP AND WATER. REMOVE CLOTHING IF
CONTAMINATION HAS OCCURRED. IF YOU GET THE DEGREASER IN YOUR
EYES, FLUSH THEM WITH ISOTONIC SALINE OR WATER FOR 15 MINUTES
MINIMUM. IMMEDIATELY GET MEDICAL AID. IF THE DEGREASER GOES
THROUGH YOUR SKIN THERE CAE BE A HEALTH RISK.
WARNING: YOU MBST NOT BREATHE THE FUMES FROM THE DEGREASER OR GET IT
IN YOUR MOUTH. THE DEGREASER IS HARMFUL. USE THE APPROVED
FACE MASK. ALSO USE THE DEGREASER IN AN AREA THAT HAS A GOOD
FLOW OF AIR. IF YOU GET THE DEGREASER IN YOUR MOUTH, FLUSH
WITH WATER. IMMEDIATELY GET MEDICAL AID. IF THE DEGREASER
IS BREATHED IN OR DRUNX THERE CAN BE A HEALTH RISK.
(a) Use a brush and apply OMat 1/21 trichlorethane (or alternatives) to
remove all grease from the repair surface.
(b) Add the OMat 2/7 wetting agent to water to make a solution that is
one percent by volume. Keep the solution in the stainless steel
container at a temperature between 15 and 25 deg C (59 and 77 deg
F)
(c) Use a brush and apply the OMat 217 solution to clean the repair
surface.
(d) Flush the repair surface with clem, cold water.
(2) Etch the repair surface
WARNING: YOU MUST NOT GET THE PHOSPHORIC ACID ON YOUR SKIN OR IN YOUR
EYES. THE PHOSPHORIC ACID IS CORROSIVE. USE AN APRON,
APPLICABLE GLOVES AND EYE PROTECTION. IF YOU GET THE
PHOSPHORIC ACID ON YOUR SKIN, REMOVE IT WITH SOAP ANTI WATER.
REMOVE CLOTHING IF CONTAMINATION HAS OCCURRED. IF YOU GET
THE PHOSPHORIC ACID IN YOUR EYES, FLUSH THEM WITH ISOTONIC
SALINE OR WATER FOR 15 MINUTES MINIMUM. IMMEDIATELY GET
MEDICAL AID. IF THE PHOSPHORIC ACID TOUCHES YOU IT CAN CAUSE
DAMAGE TO YOUR BODY TISSUES.
EFFECTIVITY: TRENT
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Sept.15196
mm(R)
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
WARNING: YOU MUST NOT BREATHE THE FUMES FROM THE PHOSPHORIC ACID OR
GET IT IN YOUR MOUTH. THE PHOSPHORIC ACID IS CORROSIVE. USE
THE APPROVED FACE MASK. ALSO USE THE PHOSPHORIC ACID IN AN
AREA THAT HAS A GOOD now OF AIR. IF YOU GET THE PHOSPHORIC
ACID IN YOUR MOUTH, FLUSH WITH WATER. IrnDIATELY GET
MEDICAL AID. IF THE PHOSPHORIC ACID IS BREATHED IN OR DRUNK
IT CAN CAUSE DAMAGE TO YOUR BODY TISSUES.
(a) Add 330 m1 of the OMat 117 phosphoric acid (SG 1.65) to 670 m1 of
water. Keep the solution in a polyethylene container at a
temperature between 15 and 25 deg C (59 and 77 deg F).
(b) Use a brush and apply the OMat 117 solution to etch the repair
surface.
(c) Flush the repair surface with clean, cold water.
(3) Apply the chromate conversion coating

WARNING: YOU MUST NOT GET THE CHROMATE CONVERSION SOLUTION ON YOUR
SKIN OR IN YOUR EYES. THE CHROMATE CONVERSION SOLUTION IS
CORROSIVE. USE AN APRON, APPLICABLE GLOVES AND EYE
PROTECTION. IF YOU GET THE CHROMATE CONVERSION SOLUTION ON
YOUR SKIN, REMOVE IT WITH SOAP AND WATER. REMOVE CLOTHING IF
CONTAMINATION HAS OCCURRED. IF YOU GET THE CHROMATE
CONVERSION SOLUTION IN YOUR EYES, FLUSH THEM WITH ISOTONIC
SALINE OR WATER FOR 15 MINUTES MINIMUM. IMMEDIATELY GET
MEDICAL AID. IF THE CHROMATE CONVERSION SOLUTION TOUCHES YOU
IT CAN CAUSE DWAGE TO YOUR BODY TISSUES.
WARNING: YOU MUST NOT BREATHE THE FUMES FROM THE CHROMATE CONVERSION
SOLUTION OR GET IT IN YOUR MOUTH. THE CHROMATE CONVERSION
SOLUTION IS CORROSIVE. USE THE APPROVED FACE MASK. ALSO USE
THE CHROMATE CONVERSION SOLUTION IN AN AREA THAT HAS A GOOD
now OF AIR. IF YOU GET THE CHROMATE CONVERSION SOLUTION IN
YOUR MOUTH, FLUSH WITH WATER. IMMEDIATELY GET MEDICAL AID.
IF THE CHROMATE CONVERSION SOLUTION IS BREATHED IN OR DRUNK
IT CAN CAUSE DAMAGE TO YOUR BODY TISSUES.
(a) Mix equal volumes of OMat 175D chromate conversion solution Parts A
and B in a polyethylene container. Make only sufficient solution
for the area to be treated and use the solution immediately.
EFFECTIVITY: TRENT
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Sept.15196
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
WARNING: YOU MUST NOT LET BRUSHES OR CLOTHS WHICH ARE WET WITH
CHROYATE CONVERSION SOLUTION BECOME DRY, THE SOLUTION IS
OXIDIZING. IF THEY BECOME DRY, THERE IS A RISK OF FIRE
(WITHOUT AN EXTERNAL CAUSE).
(b) Use a brush and apply the OMat 175D chromate conversion coating
solution to the repair surface. Monitor the effect of the solution
on the surface. When the surface shows an irridescent gold to
light golden-brown color, the conversion is complete.
NOTE: The conversion will usually be complete in 2 to 7 minutes.
(c) Flush the repair surface with clean, cold water.
(d) Dry the repair surface with clean, lint-free cloths or with warm
air.
(e) Safely discard the materials used in the chromate conversion

procedure:
(i) Flush the chromate solution from the materials with cold water,
collect the used water in a container
(ii) Put the used materials in sealed plastic bags. Identify the
bags with a label that shows TOXIC CHROME WASTE
(iii) Discard the water, the toxic chrome waste and the unwanted
chromate solution: refer to local safety regulations.
EFFECTIVITY: TRENT
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Sept.15196
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR PAINT FINISH
1. General
A. After a structural repair of a composite component, it is necessary to

restore the paint finish. In the case of damage to paint layers, you must
repair the protection to prevent the entry of water.
2. Consumable Materials
--- - . . -
ANTI-STATIC PAINT (EPOXY):

10-P2-3 - BASE
ECl l0 - HARDENER
TR14 - THINNERS
PRIMER (EPOXY) :
- BASE
- HARDENER
- THINNERS
ANTI-STATIC PAINT (POLYURETHANE):
- BASE
- HARDENER
- THINNERS
PRIMER (POLYURETHANE):
- BASE
- HARDENER
- THINNERS
TOP COAT (POLYURETHANE):
LLT2OOOIXXXX < l > - BASE
ACT2000 - HARDENER
T626 - THINNERS
<l> COLOUR CODES: GREY=1697, RED=3398, WHITE=9193
EFFECTIVITY: TRENT
Page 201
Sept.15196
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
..............................................................................
..............................................................................
O M a t 1/121 TRICHLOROETHANE ( I n h i b i t e d and s t a b i l i s e d l . l. l )
'
or
OMat 11135 METHL ETHYL KETONE (M.E.K.)
or
OMat 11150 ACETONE
MASKING TAPE
ADHESIVE TAPE
OMat 5/53 WATERPROOF SILICON CARBIDE PAPER ( G r i t s i z e 320)
3. Procedure
A. Remove a l l l o o s e p a i n t , u s e a p l a s t i c s c r a p e r i f n e c e s s a r y .
B. Use t h e a d h e s i v e t a p e t o check t h e adhesion of remaining p a i n t . Repeat 3.A.

i f necessary.
C. Clean and d e g r e a s e t h e r e p a i r s u r f a c e w i t h OMat 11121 ( o r a l t e r n a t i v e s . )
D. Use t h e s i l i c o n c a r b i d e paper t o a b r a d e t h e s u r f a c e t o be p a i n t e d . Blend

t h e undamaged p a i n t i n t o t h e r e p a i r s u r f a c e .
E. Rinse t h e abraded a r e a w i t h w a t e r and do a water-break t e s t :
(1) I f t h e water c o v e r s t h e a r e a i n a n unbroken f i l m , t h e a r e a i s c l e a n .
(2) I f t h e water forms d r o p l e t s , a b r a d e and r i n s e t h e a r e a again.
F. Dry and d e g r e a s e t h e r e p a i r s u r f a c e w i t h O M a t 11121 ( o r a l t e r n a t i v e s ) .
G. Mask o f f t h e p a i n t around t h e r e p a i r s u r f a c e .
WARNING: YOU MUST OBEY THE MANUFACTURERS HEALTH AND SAFETY DATA FOR THE
SPECIFIED PAINT YATERIALS. YlANY OF THESE MATERIALS ARE FLAMMABLE
AND DANGEROUS.
H. Apply t h e s p e c i f i e d p a i n t m a t e r i a l s i n t h e c o r r e c t sequence, a c c o r d i n g t o
t h e number of l a y e r s t h a t have damage:
(1) A i r i n t a k e cowl
( a ) A n t i - s t a t i c p a i n t (epoxy)
(b) Primer p a i n t (epoxy)
EFFECTIVITY: TRENT
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[ RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
(c) Primer paint (polyurethane)
(d) Top coat paint (polyurethane)
(2) Fan cowl doors
(a) Primer paint (polyurethane)
(b) Top coat paint (polyurethane)
(3) Thrust reverser ducts

(b) Anti-static paint (polyurethane)
(c) Top coat paint (polyurethane)
(4) Common nozzle assembly

(b) Anti-static paint (polyurethane)

(c) Top coat paint (polyurethzne)
EFFECTIVITY: TRENT
Page 203
Sept. 15/96
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
STOP-DRILLING OF CRACKS
1. General
A. Small c r a c k s t h a t s t a r t a t f a s t e n e r h o l e s can be removed by e n l a r g i n g t h e

h o l e . The growth of a l o n g e r crack can b e stopped by d r i l l i n g a h o l e a t
t h e end (S) .
2. Procedure
A . Enlarge a f a s t e n e r h o l e as follows:
(1) Ream t h e h o l e 1 / 6 4 i n . (0,40 mm) o v e r s i z e
(2) Do a c r a c k d e t e c t i o n t e s t
(3) I f no c r a c k s a r e found, d r i l l t h e h o l e 1116in. (1,58mm) l a r g e r
(4) I f c r a c k s a r e found, d r i l l t h e h o l e l a r g e r by l I l 6 i n . (1,58mm)

increments u n t i l t h e c r a c k s a r e removed
(5) Ream t h e h o l e t o t h e f i n i s h e d s i z e f o r t h e i n s t a l l a t i o n of an o v e r s i z e d
fastener.
B. S t o p - d r i l l t h e e n d ( s ) of a c r a c k a s f o l l o w s :
(1) D r i l l a 1 / 4 i n . (6,12mm) d i a . h o l e whose c e n t e r i s 0 , l O i n . (2,54 mm)

beyond t h e end of t h e c r a c k t o be stopped
(2) Do a c r a c k d e t e c t i o n t e s t
(3) I f t h e c r a c k h a s been stopped, d r i l l t h e h o l e t o 5 / 1 6 i n . (7,93mm) d i a .
(4) I f t h e c r a c k h a s n o t been stopped, d r i l l t h e h o l e l a r g e r by 1/16in.

(1,58mm) increments u n t i l t h e c r a c k does n o t c o n t i n u e a c r o s s t h e h o l e .
EFFECTIVITY: TRENT
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Sept.15196
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
TORQUE TIGHTENING TECHNIQUE
CAUTION: YOU MUST NOT USE UNIVERSAL JOINTS WITH TORQUE WRENCHES. A
UNIVERSAL JOINT WILL GIVE YOU AN INCORRECT TORQUE VALUE.
Self explanatory

..............................................................................
W2446 1 THREAD GAUGE size 0.190-32

HU24462 THREAD GAUGE size 0.250-28
hT24465 THREAD GAUGE size 0.4375-20
No specific torque wrenches
NOTE: The tools specified are the minimum standard for this TASK. For
subsequent standards of tools refer to the Illustrated Tool and
Equipment Manual (ITEM).
..............................................................................
..............................................................................
ONat 1/260 ODOURLESS KEROSINE (Ref 70-30-00)
OMat 101 KEROSINE (Ref 70-30-00)
ONat 1011 ENGINE LUBRICATING OIL (Synthetic) (Ref 70-30-00)
OMat 4/62 HIGH TEMPERATURE ANTI-SEIZE COMPOUND
OMat 4/46 JOINTING COMPOUND PL32 (light) (Ref 70-30-00)
C. Referenced Information
..............................................................................
..............................................................................
70-20-01-100-801 Cold Liquid Degrease - Maintenance Process 101
EFFECTIVITY: TRENT
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Sept.15/96
1m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
3. General
A. A given torque load is applied to nuts, bolts and setscrews to prevent

stressed items and to make sure of maximum security. These torque load
values are given at the point of application in the maintenance manual
procedure. The procedures that follow are for general use.
4. Lubrication
A. Lubrication is important to get the correct tension in a threaded part,
This is because most of the applied torque is absorbed by friction at the
screw threads or the mating faces.
B. The corrosion protection coating on threaded parts, if not removed, can

cause very high end loads. This coating if found must be initially removed
from the part: Use OMat 1/260 ODOURLESS KEROSINE or OMat 101 KEROSINE at a
temperature of 50 to 55 deg C (122 to 133 deg F).
NOTE: The above procedure will not cause damage to silver plating.
C. Before you apply the recommended lubricant to bolts, studs, nuts and other
threaded parts, they must be degreased (Ref TASK 70-20-01-100-801).
D. The standard lubricant to be used is clean OMat 1011 ENGINE LUBRICATING OIL
(one of the approved oils used for the engine lubrication system).
E. OMat 4/62 HIGH TEMPERATURE ANTI-SEIZE COMPOUND is the only lubricant (as an
alternative to engine oil) which is approved for general use on threaded
parts. Other lubricants (which includes solid film lubricants or
lubricants that contain molybdenum disulphide) must not be used unless they
are specified.
F. When a special lubricant is necessary, it will be specified at the point of

application in the maintenance manual procedure.
5. Tighten the Nuts Again
CAUTION: YOU MUST OBEY THE INSTRUCTIONS THAT FOLLOW. IF YOU DO NOT YOU CAN
GET AN INCORRECT CLAMPING LOAD. IF THE CLAMPING LOAD IS INCREASED
WITH MORE THAN THE MAXIMUM TORQUE, DAMAGE TO THE THREADS CAN OCCUR.
THIS CAN CAUSE THE FAILURE OF THE JOINT DURING THE OPERATION OF THE
ENGINE.
A. When it is necessary to tighten nuts again, do the steps that follow:
(l) Remove the nuts.
(2) Clean the threads and the abutment faces.
EFFECTIVITY: TRENT
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[ RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
(3) Lubricate the threads and the abutment faces.
(4) Install the nuts.
(5) TORQUE the nuts to the specified-tarque load.
6. Initially Make the Threads and the Mating Faces Smooth

A. Make the threads smooth
NOTE: It is only necessary to make the threads smooth when you tighten
threaded parts to more than 250 lbf .ft (33,8 m.daN).
(1) Lubricate the threads and the mating faces of the nut and the washer.
(2) Install the nut then tighten it to approximately 50 percent of the full
torque load value.
(3) Remove the nut then lubricate the threads and the mating faces again.
(4) Install the nut and TORQUE it to the full specified torque load value.
B. Make keywashers flat
(1) Shrouded keywashers are not always flat and do not always flatten
satisfactorily with one applied torque load. Where shrouded keywashers
are used, do the procedure to torque the nut again as follows:
(a) Lubricate the screw threads and the mating faces.
(b) Install the nut then TORQUE it to the full specified torque load
value.
(c) Remove the nut then lubricate the threads and the mating faces
again.
(d) Install the nut and TORQUE it to the full specified torque load
value.
7. Toraue Tighten when a Lockinn Device is Used
A. Where locking plates, single-lock keywashers or split cotter pins are used
as locking devices, obey the instructions that follow:
CAUTION: YOU MUST OBEY THE INSTRUCTIONS THAT FOLLOW. IF YOU DO NOT,
FAILURE OF THE UNIT OR THE ENGINE CAN OCCUR.
EFFECTIVITY: TRENT
Page 203
Sept.15/96
B
m3)
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
CAUTION: YOU MUST NOT LOOSEN THE NUT TO LESS THAN THE SPECIFIED MINIMUM
TORQUE LOAD VALUE TO GET THE LOCKING POSITION. IF YOU LOOSEN THE
NUT TO LESS THAN THE MINIMUMVALUE, FAILURE OF THE UNIT OR THE
ENGINE CAN OCCUR.
(1) When you align the parts for these locking devices, the torque load
must be applied as follows:
(a) If the torque load is given as a range, the torque load applied (to
find the position for the locking device) must be in the given
range.
(b) If the torque load is not given as a range (and the locking device
cannot be installed after the load has been applied) the torque can
continue to be applied to find the subsequent locking position.
B. Where double-lock single-hole keywashers are used as locking devices, the

applied torque load must not be more than that specified. These keywashers
are made to be locked at the position set by the given torque load.
8. Seauence to Toraue Close-Pitched Bolts (Ref Fie.201)
A. Where a close-pitched bolt installation is used (and where it is necessary

to make a seal) adjacent fasteners must not be tightened one after the
other. Tighten the fasteners in a symmetrical sequence. This will make
sure that the application of the torque does not cause damage to the
structure. Unless specified at the point of application in the maintenance
manual, do the recommended procedure as follows:
(1) Flanges
(a) On flanges lightly tighten the fasteners in the symmetrical number

sequence (as shown in Fig.201) until the joint faces are in contact
(with all the fasteners lightly tightened).
(b) Apply the specified torque load to each of the fasteners in the
same sequence.
(2) Half-casing split line joints
(a) On half-casing split lines use the same procedure but refer to the
typical sequence shown in Fig. 201.
9. Toraue Tighten Fasteners when a Joint Contains a Gasket (Corruioint Seal)
A. When a joint contains a gasket (corrujoint seal) it is necessary to torque

fasteners continuously (in sequence) until all the fasteners are fully
tightened. This is because the last bolts tightened can compress the
gasket to a point where the initially tightened bolts become loose.
EFFECTIVITY: TRENT
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(R? STRUCTURAL REPAIR
MANUAL
10.Hand Torque Wrenches
A. Flexible beam type (Ref Fig.202)

(1) To get the correct indication, hold the handle lightly with one hand.
To apply the torque, pull at 90 degrees to the center line (AXIS) of
the wrench. This will apply the force or load at the correct point.
Do not move the position of the hand.
(2) Do a test of all wrenches at regular times on the setting rig to make
sure their indications are accurate. Adapters, extension bars and
sockets (which can be changed) can be used with all wrenches.
(3) To make sure of the largest precision possible, use a torque wrench
which will show in the higher range of the scale. The first quarter
and the last quarter of the scale cannot be used for mandatory loads.
This is because the precision of the beam type wrench is not correct at
these positions. Some flexible beam torque wrenches do not have the
first quarter and the last quarter of the scale shown. Set the torque
wrench to the correct zero load before it is used.
B. Screwdriver type (Ref Fig.203)

(1) To get a correct indication the handle must be held as if it were a
screwdriver. To apply the torque it must be turned smoothly until the
necessary torque load value is shown.
(2) Do a test of all screwdriver type wrenches on the setting rig to make
sure their indications are accurate.
(3) Do a check that the torque indication pointer shows zero on the scale
when no load is applied. If necessary adjust the pointer as given in
the torque wrench manufacturers instruction book.
11.Power Wrenches
A. A power wrench must only be used to initially tighten nuts and bolts. You
must not apply more than 50 percent of the specified full torque load value
with a power wrench. Apply the full torque load value with an approved
hand torque wrench.
12.Torque Multiplier
A. The torque multiplier is a mechanical gearbox or hydraulic unit which is

used with the torque wrench. It is used to get higher torque load values
than those possible with the usual range of torque wrenches. It is
important that the torque wrench scale indication agrees with the ratio of
the unit which is used. The torque multiplier must be calibrated at
regular times and kept in a satisfactory condition (Refer to the
manufacturers instructions).
EFFECTIVITY: TRENT
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1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
13.Extension Spanners (Ref Fig.204)
A. The extension spanner must always be used in line with the torque wrench
(unless access prevents this). A corrected torque load value must be
applied when the spanner is in line.
B. Where the extension spanner has to be attached at one of the alternative

positions (because of the limit of access), the shortest possible extension
must be used. The torque load must be applied carefully at the wrench 2
handle at 90 degrees to the length of the wrench. This will prevent
errors. A corrected torque load value is not usually applicable if the
extension spanner is of the correct design.
5
Q
-.
3
C. To find the torque load value which must be used with the extension
spanner, use the formulae:
R = L x T
L - E
R = Corrected torque load value
L = Length of torque wrench
T = Specified torque for the part
E = Length of the extension spanner
Examp le :
A nut is to be tightened to a specified torque of 210 1bf.in (2,37 m.daN)

with a torque wrench 15in. (381 mm) in length. An extension of 3in. (76
mm) is attached in the recommended position to give a total lever length of
18in. (457 mm).
The corrected torque load value is:
NOTE: All lengths are measured with the pivot in the handle as the datum.
NOTE: Lengths L and E must be measured parallel to the torque wrench lever
as shown (Ref Fig.204).
NOTE: The lengths L and E can be in Imperial or Metric ucits, but must be
the same units.
EFFECTIVITY: TRENT
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STRUCTURAL REPAIR
MANUAL
14.In-built (Locking) Torque f o r S e l f - l o c k i n g F a s t e n e r s
A. The i n - b u i l t t o r q u e i s t h e l o a d n e c e s s a r y t o s t a r t t o t u r n t h e n u t o r t h e
s e t s c r e w when:
(1) The nut i s engaged on t h e s t u d o r b o l t ( o r t h e s e t s c r e w i s engaged i n

the i n s e r t or captive nut).
( 2 ) The f u l l chamfer of t h e s t u d o r b o l t ( o r s e t s c r e w ) h a s gone through t h e

l o c k i n g p a r t of t h e nut ( o r t h e i n s e r t o r c a p t i v e n u t ) .
( 3 ) There i s no a x i a l l o a d on t h e n u t o r b o l t .
B. Do n o t change t h e i n - b u i l t torque of a s e l f - l o c k i n g n u t o r i n s e r t . Do not

crimp t h e d e v i c e o r ' e a s e ' i t w i t h a t h r e a d t a p .
C. The range of i n - b u i l t torque i s g i v e n i n Fig.205.
D. Use of Gauges
CAUTION: YOU MUST NOT DO A CHECK OF SILVER PLATED NUTS WITH GAUGES WHICH
HAVE TOUCHED CADMIUM OR MOLYBDENUE DISULPHIDE. CADMIUM OR
MOLYBDENUM DISULPHIDE WILL CAUSE CONTAMINATION OF THE NUTS AND
SUBSEQUENTLY CAUSE THEIR FAILURE.
( 1 ) Do a check of t h e f a s t e n e r s b e f o r e assembly (Refer t o Fig.205). Use

t h e gauges g i v e n i n Job Set-up Information. T h i s w i l l make s u r e of t h e
c o r r e c t l o c k i n g t o r q u e and w i l l p r e v e n t replacement of t h e f a s t e n e r s
d u r i n g assembly.
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STRUCTURAL REPAIR
MANUAL
RING FLANGE HALF - CASING JOINT
Examples of Sequence to Torque Close-Pitched Bolts on

Ring Flange and Half-Casing Joints
Fig. 201
EFFECTIVITY: TRENT
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[ RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
HANDLE PIVOT POINT CENTRE

l
C o r r e c t P r o c e d u r e t o h o l d a F l e x i b l e Beam Torque Wrench

F i g . 202
EFFECTIVITY: TRENT
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m@STRUCTURAL REPAIR
MANUAL
Correct Procedure to hold a Screwdriver Torque Wrench

Fig. 203
EFFECTIVITY: TRENT
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RB.211 TRENT
m(R\ STRUCTURAL REPAIR
MANUAL
CorrectedtorquevalueR = L X T
L - E
A corrected torque value R

is not necessary
T = Specified torque for a part

E = Length of extension or adapter
L = Length of torque wrench
R = Corrected torque value
C o r r e c t Torque V a l u e s
F i g . 204
EFFECTIVITY: TRENT
P a g e 211
S e p t . 15/96
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STRUCTURAL REPAIR
MANUAL
RANGE OF IN-BUILT TORQUE LIMITS FOR SELF-LOCKING

NUTS, WIRETHREAD INSERTS AND CAPTIVE NUTS
Nominal Thread Minimum Maximum

Size Nm lbfin Nm lbfi n
10. 4 UNF 0.056 0.50 0.338 3.00
10. 6 UNF 0.113 1.00 0.676 6.00

10. 8 UNF 0.169 1.50 1.017 9.00
10. 10 UNF 0.225 2.00 2.030 18.00

1.2500 i n . 0.394 3.50 3.390 30.00
1.3125 i n . 0.733 6.50 6.780 60-00

1.3750 i n . 1.070 9.50 9.040 80.00
.4375 i n . 1.580 14.00 11.300 100.00

.S000 i n . 2.030 18.00 17.00 150.00
-5625 i n .
.6250 i n .
-7500 i n . 15.650 50.00 ( 45,200 400.00
.8750 i n . 7.910 70.00 67.800 600.00

Nm lbfft
-0000 i n . 10.4 90.00 90.30 66.60
-
.l250 i n . 113.20 117.00 ] 102.00 75.00
-2500 i n . 16.2 143.00 113.00 83.30
In-Built Torque Limits

Fig.205
EFFECTIVITY: TRENT
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m STRUCTURAL REPAIR
MANUAL
REPLACE DAMAGED OR LOOSE CAPTIVE NUTS
Self explanatory

..............................................................................
..............................................................................
No specific circuit breaker (S) safety clip (S)
No specific access platform 8ft (2,5 m)
No specific hand grinder
B. Referenced Information
..............................................................................
24-42-00-861-801 Energize the Ground Service Network

24-42-00-862-801 De-energize the Ground Service Network
70-20-02-230-803 Water-washable Fluorescent Penetrant Inspection
- Maintenance Process 213
3. Job Set-up
A. Energize the ground service network (Ref TASK 24-42-00-861-801).
B. Safety precautions
(1) Make sure that the engine 1, (2) has been shutdown for at least 5 minutes.
C. Get access to the Avionics Compartment
( 1 ) Put the access platform 8 ft (2,5 m) in position at the access door 811.
(2) Open the access door 811.
(3) Open the protective door of the AC/DC emergency power-center 740W.
EFFECTIVITY: TRENT
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se~t.15196
[ RB.211 TRENTSTRUCTLJRAL REPAIR
MANUAL
D. Open, s a f e t y and t a g t h i s ( t h e s e ) c i r c u i t b r e a k e r ( s )
PANEL DESIGNATION FIN LOCATION

..............................................................................
742W FADEC A ENG l 12KSl
742W FADEC A ENG 2 12KS2
722W FADEC B ENG 1 13KS1
722W FADECBENG2 13KS2
E. Do t h e a p p l i c a b l e p r o c e d u r e s t o g e t a c c e s s t o t h e r e l a t e d work a r e a .
4. Procedure
A. Replace t h e damaged o r l o o s e c a p t i v e n u t (Ref Fig.201).
(1) Use a hand g r i n d e r t o remove t h e r i v e t s from t h e assembly: Do n o t

d e c r e a s e t h e t h i c k n e s s of t h e component when you remove t h e r i v e t s .
(2) Remove t h e n u t and t h e r e t a i n e r p l a t e .
( 3 ) Put a b o l t through t h e component and a t t a c h a new n u t i n t h e c o r r e c t

position.
( 4 ) Put t h e r e t a i n e r p l a t e i n p o s i t i o n and hold i t i n p o s i t i o n w i t h a

c lamp.
(5) I f n e c e s s a r y , d r i l l t h e h o l e s i n t h e r e t a i n e r p l a t e t o a g r e e w i t h t h e
h o l e p o s i t i o n s i n t h e component.
NOTE: D r i l l oversize holes f o r oversize r i v e t s , i f necessary.
(6) I n s t a l l new r i v e t s .
(7) Remove t h e clamp and t h e b o l t , t h e n examine t h e n u t t o make s u r e i t i s

c o r r e c t l y aligned.
(8) Do a f l u o r e s c e n t p e n e t r a n t i n s p e c t i o n of t h e r e p a i r f o r c r a c k s (Ref
TASK 70-20-02-230-803).
5 . Close-up
A. Do t h e a p p l i c a b l e p r o c e d u r e s t o c l o s e a c c e s s t o t h e work a r e a .
B. Remove t h e s a f e t y c l i p ( s ) and t h e t a g ( s ) and c l o s e t h i s ( t h e s e ) c i r c u i t

b r e a k e r (S)
12KS1, 12KS2, 13KS1 and 13KS2.
EFFECTIVITY: TRENT
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STRUCTURAL REPAIR
MANUAL
C. Close a c c e s s t o t h e Avionics Compartment
( l ) Close t h e p r o t e c t i v e door of t h e AC/DC emergency power-center 740W.
(2) Close t h e a c c e s s door 811.
(3) Remove t h e a c c e s s platform.
D. De-energize t h e ground s e r v i c e network (Ref TASK 24-42-00-862-801)
EFFECTIVITY: TRENT
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~ept.15/96
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STRUCTURAL REPAIR
MANUAL
Dimensions in millimeters
Conversions in inches Position nut retainer so that
nut thread axis is CO-incident
with axis of A diameter
within 0,08 (0.003)OT P
REPLACEMENT NUT
A DIAMETER -i -t \
RIVET
Rivet heads are round or countersunk

according to position
Captive Nut and Retaining Plate

Fig. 201
EFFECTIVITY: TRENT
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Sept. 15/96
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR THREADED HOLES BY FITTING WIRETHREAD INSERTS
WARNING: YOU MUST BE CAREFUL WHEN YOU DO WORK ON THE ENGINE PARTS AFTER THE
ENGINE I S SHUTDOWN. THE ENGINE PARTS CAN STAY HOT FOR ALMOST 1 HOUR.
WARNING: YOU MUST OBEY THE MANUFACTURERS HEALTH AND SAFETY DATA FOR THE
SPECIFIED MATERIALS. YOU MUST ALSO REFER TO LOCAL REGULATIONS TO MAKE
SURE THAT THE PROCEDURES ARE DONE SAFELY. I F YOU DO NOT DO THIS AN
INJURY CAN OCCUR.
CAUTION: UNLESS SPECIFIED BY A ROLLS-ROYCE REPAIR: YOU MLTST NOT INSTALL

WIRETHREAD INSERTS INTO MAJOR ROTATING PARTS OR HIGHLY STRESSED AREAS
(SUCH AS ENGINE MOUNTS). OR INTO AREAS WHICE ARE DIRECTLY EXPOSED TO
THE HIGH TEMPERATURE GAS STREAM. I F YOU INSTALL INSERTS INTO THESE
PARTS/AREAS WITHOUT APPROVAL, THE SAFE OPERATION OF THE ENGINE WILL BE
AT RISK.
1. Reason f o r t h e Job
A. T h i s Task g i v e s t h e procedure t o r e p a i r damaged threaded h o l e s i n

components by t h e i n s t a l l a t i o n of w i r e t h r e a d i n s e r t s .
( 1 ) Damaged t h r e a d s and damaged i n s e r t s can be r e p a i r e d by t h e i n s t a l l a t i o n

of new i n s e r t s : But not i n l i g h t a l l o y m a t e r i a l .
(2) Damaged t h r e a d s i n l i g h t a l l o y m a t e r i a l c a n be r e p a i r e d by t h e
i n s t a l l a t i o n of r e p a i r i n s e r t s , i n t o which w i r e t h r e a d i n s e r t s a r e
installed.
(3) I f a w i r e t h r e a d i n s e r t i s damaged d u r i n g assembly, a new w i r e t h r e a d

i n s e r t can be i n s t a l l e d w i t h o u t t h e need f o r disassembly. A
m o d i f i c a t i o n t o t h e t o o l s w i l l p e r m i t t h i s (Ref F i g . 2 0 7 ) .
B. Types of i n s e r t :
( 1 ) Screw l o c k i n s e r t -
one c o i l has an i r r e g u l a r shape which g i v e s a
self-lock function t o the i n s e r t .
( 2 ) Free running i n s e r t - t h i s h a s no s e l f - l o c k device.
(3) Repair i n s e r t - t h i s i s a s o l i d i n s e r t i n t o which a w i r e t h r e a d i n s e r t

is installed.
EFFECTIVITY: TRENT
Page 201
Sept.15196
1 a
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
No specific circuit breaker(s) safety clip(s)

No specific access platform 8 ft (2,5 m)
No specific small clean plastic container
No specific small clean brush
No specific cotton swabs
No specific lint-free cloth
No specific paper tissues
No specific vibration peen equipment
..............................................................................
OMat 175D CHROMATE CONVERSION COATING (Brushing type)

(Ref 70-30-00)
OMat 4/46 JOINTING COMPOUND, PL32 LIGHT
(Ref 70-30-00)
C. Referenced Information
Energize the Ground Service Network

De-energize the Ground Service Network
Post-Emulsified Fluorescent Penetrant Inspection
with Water-Based (Hydrophilic) Penetrant
Removers - Maintenance Process 210
Water-washable Fluorescent Penetrant Inspection
- Maintenance Process 213
3. Job Set-up
A. Energize the ground service network (Ref TASK 24-42-00-861-801).
B. Safety precautions
(1) Kake sure that the engine 1, (2) has been shutdown for at least 5
minutes.
EFFECTIVITY: TRENT
Page 202
Sept.15/96
STRUCTURAL REPAIR
MANUAL
C. Get access to the Avionics Compartment
(1) Put the access platform 8 ft (2,5 m) in position at the access door
811.
(2) Open the access door 811.
(3) Open the protective door of the AC/DC emergency power-center 740VU.
D. Open, safety and tag this(these) circuit breaker(s)

..............................................................................
PANEL DESIGNATION FIN LOCATION
..............................................................................
742VU FADEC A ENG 1 12KS1
742W FADEC A ENG 2 12KS2
E. Do the applicable procedures to get access to the related work area
4. Procedure
A. Repair damaged threads and damaged inserts by the installation of new
inserts: But not in light alloy material
(1) Remove the damaged wirethread insert (Ref Fig.204/): Use the
applicable extraction tool (Item No.1) (Re£ Fig.212).
(2) Drill and tap the hole to permit the installation of the wirethread
insert (if not installed before) (Ref Fig.201 and Fig.202): Use the
applicable roughing tap, plug tap and bottoming tap (Item No.4, 5 and
6) (Ref Fig.212).
(3) Clean the hole and make an inspection of the threads: Use the
applicable special gauge (Item No.7) (Ref Fig.212).
(4) Apply protection to the threads of magnesium components as follows:
WARNING: YOU MUST NOT GET THE CHROMATE CONVERSION COATING SOLUTION ON
YOUR SKIN OR IN YOUR EYES. THE SOLUTION IS CORROSIVE. USE
AN APRON, APPLICABLE GLOVES AND EYE PROTECTION. IF YOU GET
THE SOLUTION ON YOUR SKIN, REMOVE IT WITH SOAP AND WATER.
THE SOLUTION IN YOUR EYES, FJXSH THEM WITH ISOTONIC SALINE OR
WATER FOR 15 MINUTES MINIMUM. IMMEDIATELY GET MEDICAL AID.
IF THE SOLUTION TOUCHES YOU IT CAN CAUSE DAMAGE TO YOUR BODY
TISSUES.
EFFECTIVITY: TRENT
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Sept.15196
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STRUCTURAL REPAIR
MANUAL
COATING SOLUTION OR GET IT IN YOUR MOUTH. THE SOLUTION IS
CORROSIVE. USE THE APPROVED FACE MASK. ALSO USE THE
SOLUTION IN AN AREA THAT HAS A GOOD FLOW OF AIR. IF YOU GET
THE SOLUTION IN YOUR MOUTH, FLUSH WITH WATER. IMMEDIATELY
GET MEDICAL AID. IF THE SOLUTION IS BREATHED IN OR DRUNK IT
CAN CAUSE DAMAGE TO YOUR BODY TISSUES.
(a) Mix equal volumes of OMat 175D CHROMATE CONVERSION COATING Parts A
and B. Make the solution in a plastic container and use
immediately.
NOTE: Only prepare sufficient solution for the area to be treated.
WARNING: YOU MUST NOT LET CLOTHS OR OTHER MATERIALS WHICH ARE SOAKED
WITH THE CHROMATE CONVERSION COATING SOLUTION BECOME DRY.
THE SOLUTION IS OXIDISING. IF THEY BECOME DRY THERE IS A
RISK OF FIRE (WITHOUT AN EXTERNAL CAUSE).
(b) Apply with a small clean brush the OMat 175D CHROMATE CONVERSION
COATING solution. Monitor the effect of the solution on the
threads: The threads are satisfactorily treated when you see an
irridescent gold to light golden-brown color.
NOTE: Usually the surface is satisfactorily treated in

approximately 2 to 7 minutes.
(c) Clean the threads with a swab which has been soaked in clean cold
water.
(d) Clean the threads with a swab which has been soaked in clean hot
water.
(e) Carefully dry the area with clean dry lint-free cloths or paper
tissues.
(f) Safely discard the cloths and materials used during the chromate
conversion coating procedure as follows:
(i) Use cold water to flush the chromate solution from the used
cloths and materials to decrease the risk of fire: Collect the
used water in a container.
(ii) Put the used cloths and materials in sealed plastic bags:
Identify the bags with a label which shows TOXIC CHROME WASTE.
EFFECTIVITY: TRENT
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RB.211 TRENT
mm s STRUCTURAL REPAIR
(iii) Discard the water with chromate contamination, the bags of

toxic chrome waste and the unwanted chromate conversion coating
solution: Refer to local regulations to correctly discard
them.
(5) Make the selection of the applicable wirethread insert for installation
(Ref Fig.214): Screw lock inserts must only be installed when they are
specified in the Power plant Illustrated Parts Catalog (PIPC).
(6) Apply a thin layer of OMat 4/46 JOINTING COMPOUND to the internal
threads of the component and to the external threads of the wirethread
insert.
NOTE: You must do this step immediately before you install the
wirethread insert to the component.
(7) Install the wirethread insert to the component (Ref Fig.201 and
Fig.205): Use the applicable inserting tool (Item No.2) (Ref Fig.212).
(8) Remove the tang from the wirethread insert (Ref Fig.206): Use the
applicable tang removal tool (Item No.3) (Ref Fig.212).
(9) Do a fluorescent penetrant inspection of the repair area for cracks

(Re£ TASK 70-20-02-230-802 or TASK 70-20-02-230-803).
(10) Make sure the wirethread insert is correctly installed (Ref Fig.201 and
Fig.203): Use the applicable cross thread gauge (Item No.8) (Ref
Fig. 212).
(11) Do a check of the in-built torque of screw lock inserts (Ref Fig.209):
Use the applicable torque check plug, torque adapter and torquemaster
(Item No.9, 10 and 11) (Ref Fig.212).
(12) Use vibration peen equipment to write FRS3002 adjacent to the part
number.
NOTE: This step is only applicable to components which have had a

wirethread insert installed where an insert has not been
installed before.
B. Repair damaged threads in light alloy material by the installation of

repair inserts and wirethread inserts
(1) Make a dimensional inspection of the part to make sure the boss size is
sufficient to be machined (Ref Fig.2101TASK 70-42-13-991-010).
(2) If the boss size is satisfactory: Drill the hole for the repair insert
(Ref Fig.210): Use the applicable tools (Ref Fig.213).
EFFECTIVITY: TRENT
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Sept.15196
H p
RB.211 TRENT
STRUCTURAL REPAIR
EClANUAL
(3) Tap the hole for the repair insert: Use the applicable tap (Item
No.11) (Ref Fig.213).
(4) Clean the hole and make an inspection of the threads (Ref.Fig.210).
(5) Apply protection to the threads as follows:
WARNING: YOU MUST NOT GET THE CHROMATE CONVERSION COATING SOLUTION ON
YOUR SKIN OR IN YOUR EYES. THE SOLUTION IS CORROSIVE. USE
AN APRON, APPLICABLE GLOVES AND EYE PROTECTION. IF YOU GET
THE SOLUTION ON YOUR SKIN, REMOVE IT WITH SOAP AND WATER.
THE SOLUTION IN YOUR EYES, FLUSH THEM WITH ISOTONIC SALINE OR
WATER FOR 15 MINUTES MINIMUM. IMMEDIATELY GET MEDICAL AID.
IF THE SOLUTION TOUCHES YOU IT CAN CAUSE DAMAGE TO YOUR BODY
TISSUES.
COATING SOLUTION OR GET IT IN YOUR MOUTH. THE SOLUTION IS
CORROSIVE. USE THE APPROVED FACE MASK. ALSO USE THE
SOLUTION IN AN AREA THAT HAS A GOOD FLOW OF AIR. IF YOU GET
THE SOLUTION IN YOUR MOUTH, FLUSH WITH WATER. IMMEDIATELY
GET MEDICAL AID. IF THE SOLUTION IS BREATHED IN OR DRUNK IT
CAN CAUSE D11E"AGE TO YOUR BODY TISSUES.
(a) Mix equal volumes of OMat 175D CHROMATE CONVERSION COATING Parts A
and B. Make the solution in a plastic container and use
immediately.
NOTE: Only prepare sufficient solution for the area to be treated.
WARNING: YOU MUST NOT LET CLOTHS OR OTHER MATERIALS WHICH ARE SOAKED
WITH THE CHROMATE CONVERSION COATING SOLUTION BECOME DRY.
THE SOLUTION IS OXIDISING. IF THEY BECOME DRY THERE IS A
RISK OF FIRE (WITHOUT AN EXTERNAL CAUSE).
(b) Apply with a small clean brush the OMat 175D CHROMATE CONVERSION
COATING solution. Monitor the effect of the solution on the
threads: The threads are satisfactorily treated when you see an
irridescent gold to light golden-brown color.
NOTE: Usually the surface is satisfactorily treated in

approximately 2 to 7 minutes.
(c) Clean the threads with a swab which has been soaked in clean cold
water.
EFFECTIVITY: TRENT
Page 206
Sept.15/96
1m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
(d) Clean t h e t h r e a d s w i t h a swab which h a s been soaked i n c l e a n h o t

water.
( e ) C a r e f u l l y d r y t h e a r e a w i t h c l e a n d r y l i n t - f r e e c l o t h s o r paper
tissues.
( f ) S a f e l y d i s c a r d t h e c l o t h s and m a t e r i a l s used d u r i n g t h e chromate

c o n v e r s i o n c o a t i n g procedure a s f o l l o w s :
( i ) Use c o l d water t o f l u s h t h e chromate s o l u t i o n from t h e used

c l o t h s and m a t e r i a l s t o d e c r e a s e t h e r i s k of f i r e : C o l l e c t t h e
used w a t e r i n a c o n t a i n e r .
( i i ) P u t t h e used c l o t h s and m a t e r i a l s i n s e a l e d p l a s t i c bags:

I d e n t i f y t h e bags w i t h a l a b e l which shows TOXIC CHROME WASTE.
( i i i ) Discard t h e water w i t h chromate contamination, t h e bags of

t o x i c chrome waste and t h e unwanted chromate c o n v e r s i o n c o a t i n g
s o l u t i o n : Refer t o l o c a l r e g u l a t i o n s t o c o r r e c t l y d i s c a r d
them.
(6) Make t h e s e l e c t i o n of t h e a p p l i c a b l e r e p a i r i n s e r t f o r i n s t a l l a t i o n
(Ref Fig.215).
(7) Apply a t h i n l a y e r of O M a t 4/46 JOINTING COMPOUND t o t h e i n t e r n a l

t h r e a d s of t h e component and t o t h e e x t e r n a l t h r e a d s of t h e r e p a i r
insert.
NOTE: You must do t h i s s t e p immediately b e f o r e you i n s t a l l t h e r e p a i r

insert.
(8) I n s t a l l t h e r e p a i r i n s e r t t o t h e component (Ref Fig.211/): Use t h e

i n s e r t d r i v e r (Item No.12) (Ref Fig.213).
(9) Do a v i s u a l i n s p e c t i o n of t h e r e p a i r i n s e r t t o make s u r e t h e i n s e r t i s
c o r r e c t l y i n s t a l l e d (Ref Fig.211).
(10) Make t h e s e l e c t i o n of t h e a p p l i c a b l e w i r e t h r e a d i n s e r t f o r i n s t a l l a t i o n
(Ref Fig.2141): Screw l o c k i n s e r t s must only be i n s t a l l e d when t h e y
a r e s p e c i f i e d i n t h e Power p l a n t I l l u s t r a t e d P a r t s Catalog (PIPC).
(11) Apply a t h i n l a y e r of O M a t 4/46 JOINTING COMPOUND t o t h e i n t e r n a l

t h r e a d s of t h e r e p a i r i n s e r t and t o t h e e x t e r n a l t h r e a d s of t h e
wirethread i n s e r t .
NOTE: You must do t h i s s t e p immediately b e f o r e you i n s t a l l t h e

w i r e t h r e a d i n s e r t t o t h e component.
EFFECTIVITY: TRENT
Page 207
Sept.15/96
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
(12) I n s t a l l t h e w i r e t h r e a d i n s e r t t o t h e r e p a i r i n s e r t (Ref Fig.201 and

Fig.205): U s e t h e a p p l i c a b l e i n s e r t i n g t o o l ( I t e m No.2) (Re£ F i g . 2 1 2 ) .
(13) Remove t h e t a n g from t h e w i r e t h r e a d i n s e r t (Ref Fig.206): U s e the

a p p l i c a b l e t a n g removal t o o l (Item No.3) (Ref Fig.212).
(14) Do a f l u o r e s c e n t p e n e t r a n t i n s p e c t i o n of t h e r e p a i r a r e a f o r c r a c k s
(Re£ TASK 70-20-02-230-802 o r TASK 70-20-02-230-803).
(15) Make s u r e t h e w i r e t h r e a d i n s e r t i s c o r r e c t l y i n s t a l l e d (Ref Fig.201 and

Fig.203): Use t h e a p p l i c a b l e c r o s s t h r e a d gauge (Item No.8) (Ref
Fig. 212).
(16) Do a check o f t h e i n - b u i l t t o r q u e of screw l o c k i n s e r t s (Ref Fig.209):

Use t h e a p p l i c a b l e t o r q u e check p l u g , t o r q u e a d a p t e r and t o r q u e m a s t e r
( I t e m No.9, 10 and 11) (Ref Fig.212).
(17) Use v i b r a t i o n peen equipment t o w r i t e FRS3002 a d j a c e n t t o t h e p a r t

number.
5. Close-up
A. Do t h e a p p l i c a b l e p r o c e d u r e s t o c l o s e a c c e s s t o t h e work a r e a .
B. Remove t h e s a f e t y c l i p ( s ) and t h e t a g ( s ) and c l o s e t h i s ( t h e s e ) c i r c u i t

breaker (S)
12KS1, 12KS2, 13KS1 and 13KS2.
C. Close a c c e s s t o t h e Avionics Compartment
( 1 ) Close t h e p r o t e c t i v e door of t h e AC/DC emergency power-center 740W.
(2) Close t h e a c c e s s door 811.
( 3 ) Remove t h e a c c e s s p l a t f o r m .
D. De-energize t h e ground s e r v i c e network (Re£ TASK 24-42-00-862-801)
EFFECTIVITY: TRENT
Page 208
Sept.15196
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
DIA E
-4
- +0.015 in (0,40mm) W= W
COUNTERSINK DIA
L--DIA AT 120° +- A
DIM Q A
FULLTHREAD -'-DIA #C-- DIA
(Min) B B
A
1.
DIM
i S DRILL DEPTH
BEFORE INSERT IS INSTALLED
DEPTH OF INSERT
BELOW
D1A THE SURFACE DIA
H - 1 PITCH (Min) H
1% PITCH (Max) DIA
G
-L
AFTER INSERT IS INSTALLED
Wirethread Insert Dimensions - Before and After Installation of Insert

Fig. 201
EFFECTIVITY: TRENT
Page 209
Sept.15196
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
Nominal unified thread size No.4 No.6 No.8 No.10
Minor diameter 'A' (in.) 0.1445 0.1786 0.2001 0.2306
Pitch diameter 'C' (in.)
Minor diameter 'B' (in.)
Countersink diameter 'E'
Q 3,43 4,32 4,83 5,59

Nominal length of 1D insert (0.135) (0.170) (0.190) (0.220)
S 6,35 7,87 8,13 9,14
(0.250) (0.310) (0.320) (0.360)
Q 4,83 6,l 6,98 8,13

Nominal length of 1% insert (0.190) (0.240) (0.275) (0.320)
S 7,75 9,65 10,16 11,68
(0.305) (0.380) (0.400) (0.460)
Q 6,35 7,87 9,14 10,41

Nominal length of 2D insert (0.250) (0.310) (0.360) (0.410)
S 9,27 11,43 12,19 13,97
(0.365) (0.450) (0.480) (0.550)
Q 7,75 9,52 11,18 12,95

Nominal length of 2% insert (0.305) (0.375) (0.440) (0.510)
S 10,67 13,08 14,22 16,51
(0.420) (0.515) (0.560) (0.650)
D = Nominal thread diameter
Dimensions in millimetres (conversions in inches) except where indicated
Threaded Hole Dimensions for Wirethread Inserts

Fig.202 (SHEET 1)
EFFECTIVITY: TRENT
Page 210
Sept.15/96
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
Nominal unified thread size 0.250 0.3125 0.375 0.4375 0.500

(in.)
Major diameter 'A' (in.) 0.2964 0.3666 0.4291 0.5025 0.5650

Pitch diameter 'C' (in.) 0.2754 0.3421 0.4047 0.4731 0.5357
0.2732 0.3395 0.4020 0.4700 0.5325
Minor diameter 'B' (in.) 0.2639 0.3278 0.3899 0.4561 0.5176

0.2559 0.3228 0.3839 0.4491 0.5116
Countersink diameter 'E' 7,92 9,52 11,l 12,95 14,48
(0.312) (0.375) (0.437) (0.510) (0.570)
Q 7,37 8,89 10,67 12,45 13,97
Nominal length of 1D insert (0.290) (0.350) (0.420) (0.490) (0.550)
S 11,43 13-72 15,49 18,03 19,68
(0.450) (0.540) (0.610) (0.710) (0.775)
Q 10,41 12,95 15,24 18,03 20,32

Nominal length of 1% insert (0.410) (0.510) (0.600) (0.710) (0.800)
S 14-48 17,78 20,07 23,62 26,04
(0.570) (0.700) (0.790) (0.930) (1.025)
Q 13,72 17,02 20-07 23,62 26-67

Nominal length of 2D (0.540) (0.670) (0.790) (0.930) (1.050)
S 17,78 21,84 24,89 29,21 32,28
(0.700) (0.860) 0.980) (1.150) (1.275)
Q 16,76 20,83 24,89 29,08 33,02

Nominal length of 2% (0.660) (0.820) (0.980) (1.145) (1.300)
S 20,83 25,65 29,72 34,67 38,74
(0.820) (1.010) (1.170) (1.365) (1.525)
Threaded Hole Dimensions for Wirethread Inserts

Fig.202 (SHEET 2)
EFFECTIVITY: TRENT
Page 211
Sept.15196
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
Threads/in. 40 32 36 32
Minimum minor diameter 'G' (in.) 0.0849 0.1042 0.1339 0.1562
Pitch diameter 'H' (in.)
1D 2,36 2,9 3,63 4,24

(0.093) (0.114) (0.143) (0.167)
1%) 3,78 4,65 5,72 6,65
Minimum length of assembled (0.149) (0.183) (0.225) (0.262)
insert 'K' 2D 5,21 6 94 738 9,07
(0.205) (0.252) (0.307) (0.357)
2% 6,63 8,15 9,88 11,48
(0.261) (0.321) (0.389) (0.452)

(in.)
Minimum minor diameter 'G' 0.2113 0.2674 0.3299 0.3834 0.4459

(in. )
Pitch diameter 'H' (in.) 0.2300 0.2890 0.3516 0.4091 0.4717
0.2268 0.2854 0.3479 0.4050 0.4675
1D 5,66 7,14
(0.223) (0.281)
1%) 8,84 11,13
Minimum length of (0.348) (0.438)
assembled insert 'K' 2D 12,Ol 15,09
(0-473) (0.594)
2% 15,19 19,05
(0.598 (0.750)

Dimensions of Assembled Inserts

Fig.203
EFFECTIVITY: TRENT
Page 212
Sept.15196
m RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
End of the top coil

of the insert
1/4 COIL
p
'' (approx)
VIEW AT A
Push the special extraction tool into the insert

at approx h of a coil from the end of the insert wire
A Turn the tool anti-clockwise to wind the insert out
Discardthe insert
Remove the Existing Insert

Fig. 204
EFFECTIVITY: TRENT
Page 213
Sept.15/96
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
INSERTIONTOOL
Install 1 to 1 % pitches
below face
TANG
Pull backthe mandrel and Engagethe tang in the slot of Put the tool above the tapped
putthe insert in the tool with the mandrel.Turn the mandrel hole. Wind the mandrel until
the tang at the nozzle end clockwise and push it forward the insert is correctly in position
carefully until the insert Forward pressure is not to be
engages in the nozzle. Wind used
the mandrel until the insert
just comes into view
Installation Procedure
F i g . 205 (SHEET 1)
EFFECTIVITY: TRENT
Page 214
Sept.15/96
1
B
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
Removethe threaded mandrel

and put the insert in the insertion tool
Prevent movement of the insert

with the thumb and turn the
threaded mandrel clockwise until
it engages the inserttang
Turn the mandrel clockwise and

push forward carefully until the
insert engages the thread in the
tool nozzle. continue to windthe
insert into the nozzle until the
insert is about to come out of the
open end
Put thetool above thetapped

hole in the component which is
to receivethe insert and turn the
mandrel clockwise until the
insert is at the necessary depth
Turn the mandrel anti-clockwise

until it isclear of the insert
INSERTION TOOL
PREWlNDlNG TYPE
(Threadedmandrel)
Installation Procedure
Fig.205 (SHEET 2 )
EFFECTIVITY: TRENT
Page 215
Sept.15196
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
CENTER SPINDLE
Special tool to break off notched tangs for

inserts up t o 1 inch internal diameter
Vee notch adjacent

to tang Locate the sleeve of this tool so that the
center spindle is on the tang
To break the tang lightly hit the spindle
VIEW AT A For larger inserts use small pliersand bend

the tang up and down, not sideways
Remove the Wirethread Insert Tang

Fig. 206
EFFECTIVITY: TRENT
Page 216
Sept.15196
[ RB.211 TRENT
MANUAL
--
'i- -7
\ l
I
\ 1
\ 1
\ I
t ).
DIA Y
-0.005 in (0,13mm)
EXTRACTION TOOL
DIM X
NYLON INSERTION TOOL
Modification of Tools to Install Wirethread Inserts in Assembled Parts

Fig.207 (SHEET 1)
EFFECTIVITY: TRENT
54-02-09
Page 217
Sept.15/96
1
m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
DIM.X
' W
RAD Z DIA Y
-0.005 in (0,13mm)
Aluminum body and steel nozzle
Modification of Tools to Install Wirethread Inserts in Assembled Parts

Fig.207 (SHEET 2)
EFFECTIVITY: TRENT
Page 218
Sept.15/96
1
m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
Dimension 'X'
Diameter 'y'
Radius '2'

(in.
Dimension 'X'
Diameter 'y'
Radius '2'
y = Minimum diameter for insertion through panels

Dimensions in millimetres (conversions in inches)
Tool Dimensions to Install Wirethread Inserts into Assembled Parts

Fig.208
EFFECTIVITY: TRENT
Page 219
Sept.15196
1
ms
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
Nominal unified Minimum Maximum

thread size Threads/in. 1b.in. Nm . 1b.in. Nm .
Select minimum torque check plug, torque adapter and Torquemaster.
Lubricate minimum torque check plug with engine oil and fit into insert,
engage torque adapter and using a standard key spanner, check for
insert screw-through by spannering torque check plug through grip coil to
full depth of the insert. Reject insert if it has turned more than half a
thread in part.
Unscrew torque check plug sufficient to clear locking coil and remove key
spanner. Set Torquemaster to correct poundage detailed above and check
in-built torque using Torquemaster. Reject insert if torque check plug,
screws through grip coil.
Inserts below minimum torque must be removed and a new insert fitted.
In-built Torque of Screw Lock Inserts

Fig.209
EFFECTIVITY: TRENT
Page 220
Sept.15/96
m
mm
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
DIM E (Min) DIM G (Min)
1
,l, L~$T
L- -
MINIM.UM DIMENSIONS FOR USE

OF REPAIR INSERTS IN LIGHT ALLOY
'A '
THREAD -
RADIUS
DIMENSIONS OF TAPPED HOLES FOR

REPAIR INSERTS
Dimension Standards for Repair Inserts in Light Alloy Materials

Fig.210 (SHEET 1)
EFFECTIVITY: TRENT
Page 221
Sept.15196
1m01
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
BOSS PROPORTIONS - LIGHT ALLOY - PROVISION FOR REPAIR
0.250 0.3125 0.375

Nominal diameter i n s e r t No.10 in. in. in.
Nominal i n s e r t l e n g t h 1D E 13,97
(0.550)
F 13,72
(0.540)
G 6,98
(0.27 5 )
H 6,35
(0.275)
Nominal i n s e r t l e n g t h 1%D E 13,97 16,51 19,05 21,59

(0.550) (0.650) (0.750) (0.850)
F 16,26 20,07 24,13 27,43
(0.640) (0.790) (0.950) (1.080)
G 6,98 8,26 9,52 10,8
(0.275) (0.325) (0.375) (0.425)
H 9,78 11,05 13,21 15,49
(0.385) (0.435) (0.520) (0.610)
D = Nominal t h r e a d diameter
Dimensions i n m i l l i m e t r e s (conversions i n i n c h e s ) except where i n d i c a t e d
Dimension Standards f o r Repair I n s e r t s i n Light Alloy M a t e r i a l s

Fig.210 (SHEET 2)
EFFECTIVITY: TRENT
Page 222
Sept.15/96
[ RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
BOSS PROPORTIONS - LIGHT ALLOY - PROVISION FOR REPAIR

Nominal diameter insert No.10 0.250
in. 0.3125 0.375
in. in.
Nominal insert length 2D E 13,97 16,51 19,05 21,59

(0.550) (0.650) (0.750) (0.850)
F 18,54 23,37 28,19 32,26
(0.730) (0.920) (1.110) (1.270)
G 6,98 8,26 9,52 10,8
(0.275) (0.325) (0.375) (0.425)
H 11,43 13,97 17,27 20,32
(0.450) (0.550) (0.680) (0.800)
Nominal insert length 2 % ~ E 13,97 16,51 19,05 21,59

(0.550) (0.650) (0.750) (0.850)
F 21,08 26,42 32,O 37,08
(0.830) (1.040) (1.260) ( 1.460)
G 6,98 8,26 9,52 10,8
(0.275) (0.325) (0.375) (0.425)
H 13,21 17,02 21,08 25,15
(0.530) (0.670) (0.830) (0.990)


Fig.210 (SHEET 3)
EFFECTIVITY: TRENT
Page 223
Sept.15196
RB.211 TRENT
B STRUCTURAL REPAIR
MANUAL
DIMENSIONS OF TAPPED HOLES FOR REPAIR INSERTS (LIGHT ALLOY)
Special unified thread Wirethread insert D

form 'A' Size Length B C
(in.)
0.3105in. diameter, No.10 1D 8,13

21 threadlin. 32 threadslin. (0.320)
(Light alloy) l@ 9,78
Minor diameter (0.385)
0.2812in. to 0.2862in. 2D 11,43
(0.450)
2 m 13,21
(0.520)
0.4355in. diameter 6,35 1D 9,14

20 threadslin. 0.250in. (0.360)
(Light alloy) 28 threadslin. D 11,05
0.3888111. to 0.3970in 2D 12,95
(0.510)
2 l ~ 16,O
(0.630)


Fig.210 (SHEET 4)
EFFECTIVITY : TRENT
Page 224
Sept.15196
1
r;l.m3 m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
DIMENSIONS OF TAPPED HOLES FOR REPAIR INSERTS (LIGHT ALLOY)
Special unifled thread Wirethread insert D

form 'A' Size Length B C
(in.)
0.4975in. diameter, 0.3125in. 1D 10,29

20 threadslin. 24 threadslin. (0.405)
(Light alloy) 1%) 12,83
0.4513in. to 0.4597in. 2D 16,26
(0.640)
2%) 20,32
(0.800)
0.5600in. diameter, 0.375in. 1D 12,06

20 threadslin. 24 threads/in. (0.475)
(Light alloy) l 15,49
0.5084in. to 0.5172in. 2D 19,56
(0.770)
2 24,38
(0.960)


Fig.210 (SHEET 5)
EFFECTIVITY: TRENT
Page 225
Sept.15196
H
m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
BEFORE REPAIR
UNDERFLUSH
AFTER REPAIR
Repair Inserts - Before and A f t e r Repair

Fig.211
EFFECTIVITY: TRENT
Page 226
Sept.15196
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
WIRETHREAD INSERTS
Nominal unified thread size No.4 No.6 No.8 No.10 Item

No.
Threadslin. 40 32 36 32
Extraction tool HC22912 HC22912 HC22912 HC22913 1
Inserting tool (pre-wind type) 1709101 1709103 3405506 HC22891 2
Tang removal tool 1709121 1709123 3405526 3405527 3
Roughing tap 1709721 1709723 1709502 1709503 4
Plug tap 1709741 1709743 1709522 1709523 5
Bottoming tap 1709761 1709763 1709542 1709543 6

Special gauge for tapped hole 1709581 1709583 1709562 1709563 7
Cross thread gauge - - HCU5035 HCU5036 8

Torque check plug HC7943 HC7941 HC7942 HC21739 9
Torque adapter HC21743 HC21743 HC21743 HC21743 10
Torquemaster RR 1704302 (all thread sizes) 11
Torque setting rig 1702173 1702173 1702173 1702173 12

Tools for Wirethread Inserts

Fig.212 (SHEET l)
EFFECTIVITY: TRENT
Page 227
Sept.15196
m RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
WIRETHREAD INSERTS
Nominal u n i f i e d 6,35 mm 7,92 mm. 9,52 mm. 11,09 7 . I t e m N o .

thread s i z e (0.250in.) (0.3125in.)(0.375in.) (0.4375~1.)
Extraction t o o l HC22914 HC22914 HC22915 1709063 1
Inserting tool HC22892 RC22943 HC25569 3405511 2

(pre-wind t y p e )
Tang removal t o o l 3405528 3405529 3405530 3405531 3
Roughing t a p 1709504 1709505 1709506 1709507 4
Plug t a p 1709524 1709525 1709526 1709527 5
Bo t t oming t a p 1709544 1709545 1709546 1709547 6
S p e c i a l gauge f o r 1709564 1709565 1709566 1709567 7

tapped h o l e
Cross t h r e a d gauge HCU5037 HCU5038 HCU5039 HCU5040 8
Torque check plug HC21740 HC21741 HC21742 HC22844 9
Torque a d a p t e r HC21743 HC21743 HC21743 HC21743 10
Torquemaster RR1704302 ( a l l t h r e a d s i z e s ) 11
Torque s e t t i n g r i n g 1702173 1702173 1702173 1702173 12
Tools for Wirethread I n s e r t s

Fig.212 (SHEET 2)
EFFECTIVITY: TRENT
Page 228
Sept.15/96
1
m m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
WIRETHREAD INSERTS
Nominal u n i f i e d t h r e a d s i z e 12,7 mm. I t e m No.

(0.500in.)
Extraction tool 1709063 1
I n s e r t i n g t o o l (pre-wind t y p e ) 3405512 2
Tang removal t o o l 3405532 3
Roughing t a p 1709508 4
Plug tap 1709528 5
Bottoming t a p 1709548 6
S p e c i a l gauge f o r tapped h o l e 1709568 7
Cross t h r e a d gauge - 8
Torque check p l u g HC22845 9
Torque a d a p t e r HC2 1743 10
Torquemas t e r RR1704302 11
( a l l thread s i z e s )
Torque s e t t i n g r i g 1702173 12
Tools f o r Wirethread I n s e r t s
Fig.212 (SHEET 3 )
EFFECTIVITY: TRENT
Page 229
Sept.15196
RB.211 TRENT
ms STRUCTURAL REPAIR
MANUAL
REPAIR INSERTS
Insert unified Item

No. l0
size No.
Threadslin. 32
Special drill HU12680
Counterbore cutter HU15980
Tap Gull416
Insert driver HU12675
TOOLS FOR HAND CUTTING
Pilot screw HU15963
Counterbore cutter HU15964
Counterbore stop HU15965
Hollow cutter HU15966
Radius cutter HU15967
Tools for Repair Inserts

Fig. 213
EFFECTIVITY: TRENT
Page 230
Sept.15196
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
WIRETHREAD INSERTS
Rolls-Royce Part No.

Nominal unified Threadslin. Length of * Screw lock * Free running
thread size insert type type
U
crr
bc
.-
D = Nominal diameter of insert
* = The part numbers in these columns are not alternatives
Parts (Wirethread Inserts)

Fig.214 (SHEET 1)
EFFECTIVITY: TRENT
Page 231
Sept. 15/96
B
mB
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
WIRETHREAD INSERTS
Rolls-Royce Part No.

Nominal unified ~hreadslin. Length of * Screw lock * Free running
thread size insert type type
D = Nominal diameter of insert

* = The part numbers in these columns are not alternatives
Parts (Wirethread ~nserts)

Fig.214 (SHEET 2)
EFFECTIVITY: TRENT
Page 232
Sept. 15/96
RB.211 TRENT
(Q STRUCTURAL REPAIR
MANUAL
REPAIR INSERTS
Wirethread i n s e r t Length of Rolls-Royce

Threadslin.
unified size insert P a r t No.
D = Nominal d i a m e t e r of i n s e r t
P a r t s (Repair I n s e r t s )
F i g . 2 15
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FASTENERS - INSTALLATION AND REMOVAL
1. R i v e t s ( S o l i d R i v e t s )
A. General
(1) F o r t h e i n s t a l l a t i o n of r i v e t s t h e subsequent methods a p p l y :
- the continuous squeeze r i v e t i n g p r o c e s s ,
- hammering w i t h a pneumatic r i v e t gun,
- hand hammering.
The continuous squeeze method i s recommended, b u t i f t h i s method i s n o t

a v a i l a b l e then pneumatic hammering i s t h e next recommended method. The
hand hammering method i s used p r i m a r i l y f o r s m a l l r e p a i r s t h a t i n c l u d e
v e r y few r i v e t s . It can a l s o be used i f o t h e r methods a r e n o t
available.
(2) A squeeze r i v e t i n g t o o l makes t h e u p s e t head of a r i v e t i n a s i n g l e

continuous a c t i o n . For t h i s e f f e c t t h e t o o l s given below a r e
necessary:
- a hydraulically operated t o o l ,
- o r a pneumatically o p e r a t e d t o o l .
S t a t i c and p o r t a b l e t y p e s of t o o l s a r e a v a i l a b l e .
(3) The r i v e t gun, used w i t h a back-up d o l l y (bucking b a r ) , forms t h e u p s e t

head. T h i s i s known as r e a c t i o n r i v e t i n g . A c o r r e c t l y shaped r i v e t
s e t ( r i v e t snap) i s h e l d i n t h e gun and l o c a t e d on t h e manufactured
head end of t h e r i v e t . A t t h e same t i m e t h e d o l l y i s h e l d a g a i n s t t h e
end of t h e r i v e t t o b e u p s e t . When t h e gun o p e r a t e s , t h e d o l l y
r e a c t i o n t o t h e pneumatic hammering o f t h e gun forms t h e u p s e t head.
(4) Hand hammering i s t h e b a s i c method used t o make t h e u p s e t head of a

r i v e t . For t h i s method do t h e subsequent s t e p s :
( a ) Support t h e manufactured head w i t h a c o r r e c t l y shaped r i v e t s e t ,
(b) Hold a d o l l y a g a i n s t t h e end of t h e r i v e t and h i t i t u n t i l t h e

u p s e t head h a s t h e c o r r e c t shape.
NOTE: Make s u r e t h a t t h e hammer blows a r e heavy and a s few as

p o s s i b l e because a l a r g e number of l i g h t blows work-hardens
t h e r i v e t . T h i s can r e s u l t i n c r a c k s i n t h e u p s e t head.
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(5) Make s u r e t h a t t h e t o o l s a r e s u f f i c i e n t l y l a r g e t o q u i c k l y form t h e

u p s e t head. The subsequent t i m e s f o r t h e f o r m a t i o n of t h e u p s e t head
a r e recommended:
- t h r e e o r f o u r seconds i s t h e optimum time,
- seven seconds i s t h e maximum time.
Hold t h e back-up d o l l y i n p o s i t i o n u n t i l t h e r i v e t i s f u l l y i n s t a i l e d .
(6) Before you i n s t a l l r i v e t s i n t h e a i r c r a f t s t r u c t u r e , make some

t e s t - p i e c e s t o check t h e r i v e t and t o o l p r e c i s i o n . These t e s t - p i e c e s
must have t h e subsequent p r o p e r t i e s :
- for test-pieces, t h e same t y p e of m a t e r i a l and t h i c k n e s s as t h e p a r t

t o be r i v e t e d ,
- f o r r i v e t s , t h e same t y p e of m a t e r i a l , l e n g t h and diameter as t h e

r i v e t s t o be used.
( 7 ) V i s u a l l y check r i v e t s b e f o r e t h e y a r e i n s t a l l e d . I f a r i v e t a p p e a r s
d e f e c t i v e , f o r example, deep s c o r e s o r i n d i c a t i o n of w i r e drawing,
r e j e c t i t . Some a p p a r e n t d e f e c t s , f o r example, i s o l a t e d n i c k s ,
a b r a s i o n s , d i e marks o r f i n s , a r e a c c e p t a b l e up t o a maximum d e p t h of
0.10 mm (0.004in.).
(8) R i v e t s made from 2017A, 3.1324 and 2024 m a t e r i a l s must b e k e p t i n a

r e f r i g e r a t o r a f t e r they have been h e a t - t r e a t e d .
B. I n s t a l l a t i o n ( R e f e r t o F i g u r e 201 and F i g u r e 202)
(1) S e l e c t t h e r e q u i r e d r i v e t . I f f o r any r e a s o n t h e dimensions of t h e

r e q u i r e d r i v e t a r e n o t known proceed a s f o l l o w s :
( a ) Accurately measure t h e d i a m e t e r of t h e h o l e . I f t h e d i a m e t e r of
the hole is within the tolerances f o r a standard r i v e t , s e l e c t a
r i v e t of t h i s d i a m e t e r . I f t h e d i a m e t e r of t h e h o l e i s n o t w i t h i n
t h e t o l e r a n c e s , i n c r e a s e t h e diameter of t h e h o l e t o s u i t a n
oversize r i v e t i f applicable, o r t h e next standard s i z e .
(b) To f i n d t h e r e q u i r e d r i v e t l e n g t h , a c c u r a t e l y measure t h e t o t a l
t h i c k n e s s of t h e m a t e r i a l s t o b e j o i n e d . R e f e r t o F i g u r e 201 t o
f i n d t h e c o r r e c t length t h a t is r e l e v a n t t o t h e r i v e t diameter
found above.
NOTE: I f n e c e s s a r y , t h e r i v e t can b e s h o r t e n e d t o t h e r e q u i r e d
l e n g t h . This does n o t apply t o t i t a n i u m r i v e t s .
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( 2 ) Get t h e c o r r e c t r i v e t s e t and back-up d o l l y f o r t h e r i v e t t y p e and

dimensions (Refer t o F i g u r e 202).
(3) Make s u r e t h a t t h e h o l e , and i f a p p l i c a b l e , t h e countersunk p o r t i o n i s

i n a s a t i s f a c t o r y c o n d i t i o n . T h i s i n c l u d e s c l e a n and f r e e from b u r r s .
( 4 ) Clean t h e p a r t s as n e c e s s a r y . Apply s e a l a n t o r j o i n t i n g compound i f i t

is c a l l e d f o r :
- i n t h e r e l a t e d r e p a i r drawing,
- i n t h e r e l a t e d assembly drawing,
o r i s normally used i n t h e a r e a concerned.
NOTE: I n s t a l l t h e r i v e t s b e f o r e t h e work l i f e of t h e s e a l a n t o r
j o i n t i n g compound ends.
(5) Make s u r e t h a t t h e c o n t a c t s u r f a c e s o f t h e p a r t s a r e f u l l y t o g e t h e r and

t h a t t h e r e a r e no gaps between them. Gaps w i l l p r e v e n t t h e c o r r e c t
forming o f t h e r i v e t and reduce t h e j o i n t s t r e n g t h .
(6) Align t h e h o l e s as n e c e s s a r y and a t t a c h t h e p a r t s t o g e t h e r t e m p o r a r i l y .

Take c a r e n o t t o cause damage t o t h e l o c a l a r e a w i t h t o o l s .
(7) P u t t h e r i v e t f u l l y i n t h e h o l e . For t h i s o p e r a t i o n make s u r e t h a t t h e

p a r t s a r e c o r r e c t l y supported i f n e c e s s a r y .
(8) Form t h e u p s e t head. To do t h i s , use one of t h e methods g i v e n i n

paragraph 1 . A . General. Hold t h e t o o l s a t r i g h t a n g l e s t o t h e
s u r f a c e s . Do n o t compress t h e r i v e t t o o much. I f t h e u p s e t head i s
o v e r compressed, i t i s p o s s i b l e t h a t t h e m a t e r i a l w i l l c r a c k . R e f e r t o
F i g u r e 202 f o r t h e recommended back-up d o l l y dimensions.
C. i n s p e c t i o n ( R e f e r t o F i g u r e 203, F i g u r e 204, F i g u r e 205 and F i g u r e 206)
(1) General
( a ) T h i s s e c t i o n g i v e s i n f o r m a t i o n a b o u t t h e g e n e r a l i n s p e c t i o n limits
for solid rivets.
(b) Nake a n i n s p e c t i o n of t h e r i v e t s a f t e r t h e y a r e i n s t a l l e d . T h i s i s
n e c e s s a r y t o make s u r e t h a t t h e j o i n t i s t i g h t , and t h a t t h e r i v e t s
a r e f u l l y s e a t e d and c o r r e c t l y formed. Make s u r e t h a t t h e a d j a c e n t
a r e a h a s no damage and d i s t o r t i o n s .
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( c ) The acceptance l i m i t s g i v e n i n Paragraph 1.C. ( 2 ) a r e a p p l i c a b l e t o

t h o s e r i v e t s t h a t become p a r t of t h e s t r u c t u r a l s t r e n g t h a f t e r
i n s t a l l a t i o n . For example, r i v e t s t h a t f a s t e n t h e s k i n , formed and
extruded s e c t i o n s . The a c c e p t a n c e l i m i t s of r i v e t s t h a t a r e n o t s o
important s h a l l b e t h e d e c i s i o n of t h e i n s p e c t o r . ~ x a m ~ of l e such
r i v e t s a r e t h o s e used t o f a s t e n i d e n t i f i c a t i o n t a g s and
instruction/information labels.
(d) A l a r g e number of c r a c k s found i n a h i g h p e r c e n t a g e of i n s t a l l e d

r i v e t s i n d i c a t e s t h a t t h e r i v e t s have n o t been c o r r e c t l y
heat-treated. It can a l s o mean t h a t t h e i n s t a l l a t i o n time allowed
f o r h e a t - t r e a t e d r i v e t s h a s been exceeded. It i s n e c e s s a r y t o s c r a p
and r e p l a c e a l l of t h e s e r i v e t s , i n c l u d i n g those which a r e n o t
used, from t h e b a t c h concerned, o r have them h e a t - t r e a t e d a g a i n .
( e ) Deformation o r b u c k l i n g of t h e p l a t i n g i s o n l y p e r m i t t e d w i t h i n t h e
limits g i v e n i n Chapter 54-01-01. T h i s t y p e of damage i s a r e s u l t
of:
- t o o much t o o l p r e s s u r e ,
- r i v e t s expanded between t h e s h e e t s ,
- trapped f o r e i g n m a t e r i a l .
( f ) Make s u r e t h a t t h e head of a countersunk r i v e t i s l e v e l w i t h o r

s l i g h t l y above t h e s u r f a c e of t h e m a t e r i a l . Refer t o Chapter
54-01-01 f o r t h e r i v e t head p r o t r u s i o n l i m i t s .
(2) Acceptance l i m i t s
( a ) O v a l i t y of t h e u p s e t head i s p e r m i t t e d i f t h e dimensions a r e w i t h i n
t h e u p s e t d i a m e t e r l i m i t s . These l i m i t s t o g e t h e r w i t h t h e
a p p l i c a b l e r i v e t m a t e r i a l a r e g i v e n i n F i g u r e 203.
(b) E c c e n t r i c i t y of t h e u p s e t head i s p e r m i t t e d i f t h e r i v e t shank

cannot b e s e e n (Refer t o F i g u r e 204).
( c ) Malformation of t h e u p s e t head i s p e r m i t t e d (Refer t o F i g u r e 204)

i f t h e shape i s w i t h i n t h e dimension limits given i n F i g u r e 203.
(d) Tool impact damage around t h e two heads i s p e r m i t t e d w i t h i n t h e

l i m i t s g i v e n i n F i g u r e 204.
( e ) Cracks i n t h e u p s e t head of aluminum a l l o y 2017 and 2024 r i v e t s a r e

p e r m i t t e d w i t h i n t h e l i m i t s g i v e n i n F i g u r e 205. Cracks i n t h e
u p s e t head of o t h e r aluminum a l l o y r i v e t s a r e not p e r m i t t e d .
Cracks i n t h e s t r u c t u r e m a t e r i a l under e i t h e r head a r e n o t
permitted.
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( f ) Cracks i n t h e heads of t i t a n i u m and monel r i v e t s a r e n o t p e r m i t t e d .
(g) Lack of h e a d l m a t e r i a l abutment ( s e a t i n g ) i s p e r m i t t e d w i t h i n t h e

limits g i v e n i n F i g u r e 206.
D. Removal (Refer t o F i g u r e 207)
CAUTION: CAREFULLY REMOVE THE RIVET TO PREVENT DAMAGE TO THE RIVETED

YiTERIAL. THIS IS SPECIALLY NECESSARY I F IT I S THIN SHEET. MAKE
SURE THAT YOU APPLY TOOLS CORRECTLY TO THE SURFACE DURING USE.
(1) To remove a s o l i d r i v e t , f i r s t remove one of i t s heads, t h e n remove t h e

r e s t of t h e r i v e t o u t of i t s h o l e .
(2) S e l e c t which r i v e t head must b e removed. It i s b e t t e r t o remove t h e

manufactured ( s e t ) head ( t h i s head i s on t h e c e n t e r - l i n e of t h e r i v e t
shank). Hold a d o l l y o r e q u i v a l e n t t o o l a g a i n s t t h e u p s e t head, and
t h e n centre-punch t h e r i v e t head. T h i s w i l l g i v e a l o c a t i o n f o r t h e
t w i s t - d r i l l t i p (Refer t o F i g u r e 207).
CAUTION: MAKE SURE THAT THE RIVET DOES NOT TURN WHEN YOU STEP D . ( 3 ) ,
SPECIALLY I F IT I S LOOSE. GRIP THE RIVET UPSET HEAD WITH
PLIERS OR EQUIVALENT TOOL TO HOLD IT I F NECESSARY. MAKE SURE
THAT YOU DO NOT DAMAGE THE MATERIAL SURFACE.
(3) Use a t w i s t - d r i l l w i t h a s l i g h t l y s m a l l e r d i a m e t e r than t h e r i v e t
shank. P u t t h e t w i s t - d r i l l i n t h e c e n t e r punch i d e n t a t i o n ancl d r i l l
t h e head t o t h e d e p t h as shown i n Figure 207.
NOTE: Make a n e s t i m a t e of t h e d r i l l i n g - d e p t h and u s e , i f p o s s i b l e , a

mechanical s t o p t o make s u r e t h a t t h e d r i l l i n g - d e p t h i s c o r r e c t .
NOTE: Titanium r i v e t s can b e d r i l l e d w i t h a s t a n d a r d high-speed

t w i s t - d r i l l i f t h e t i p of t h e t w i s t - d r i l l is:
- reground t o an a n g l e of 80 degrees,
- and g i v e n a p o i n t c l e a r a n c e of 5 d e g r e e s .
(4) P u t a t i g h t - f i t t i n g p a r a l l e l punch i n t o t h e d r i l l e d h o l e and move t h e

punch a t an a n g l e t o b r e a k o f f t h e r i v e t head.
(5) Support t h e m a t e r i a l around t h e r i v e t and w i t h a punch remove t h e r i v e t

shank o u t of i t s h o l e .
NOTE: It i s p e r m i t t e d t o d r i l l a h o l e i n t h e r i v e t shank t o make t h e

removal of a t i g h t - f i t t i n g r i v e t easy.
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2. Pin (Threaded) Fasteners (HI-LOK and HI-LITE)
A. General
(1) There are two parts of the pin (Threaded) fastener:
- a threaded pin with a head (universal or countersunk),
- a collar with an internal thread and external shear groove.
The pin has an hexagonal recess in the threaded end. This recess
permits the use of an Allen wrench to hold the pin during the
installation. The hexagonal drive-end of the collar breaks off at the
shear groove when the collar is installed to its correct torque value
(Refer to Figure 208).
(2) In some areas with a limited clearance self-locking nuts and washers
are used instead of collars (Refer to Figure 208).
(3) It is not permitted to use standard pin (Threaded) collars or nuts and
washers on tapered surfaces that are more than 3 degrees. Where a
tapered surface is more than this limit, it is necessary to install
self-aligning collars or self-aligning nuts with washers (Refer to
Figure 208).
(4) Pins (Threaded) and collars are usually supplied lubricated and this
lubricant must not be removed.
(5) Before the installation of pin (Threaded) fasteners, make sure that:
- all the necessary pins and collars or nuts are of the correct type,
- the pins and collars or nuts are made of the correct material,
- the pins and collars or nuts have the correct surface protection
andlor lubrication,
- the pins have the correct grip length,
- the thread of the pin has the same diameter as the collar or nut
applicable to the pin.
(6) Install the pin (Threaded) fasteners with power or hand tools (Refer to
Figure 209).
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(7) The c o r r e c t hand t o o l s a r e a v a i l a b l e from t h e v a r i o u s m a n u f a c t u r e r s of

p i n s (Threaded). But a hand t o o l can be made l o c a l l y w i t h a r a t c h e t
h a n d l e t o o l made of hardened s t e e l . It i s n e c e s s a r y t o modify t h i s
t o o l as f o l l o w s :
- remove t h e b a l l i n t h e square d r i v e ,
- d r i l l a h o l e , n e c e s s a r y f o r t h e A l l e n wrench, of t h e c o r r e c t s i z e
through t h e r a t c h e t handle (Refer t o F i g u r e 209).
B. I n s t a l l a t i o n
(1) General
( a ) Before t h e i n s t a l l a t i o n of p i n (Threaded) f a s t e n e r s , make s u r e t h a t

a l l h o l e s a r e c l e a n , smooth, deburred and f r e e from delamination.
NOTE: Use t h e n e x t o v e r s i z e f a s t e n e r t o r e p a i r a damaged o r

over-sized h o l e .
(b) There a r e f o u r t y p e s of p i n (Threaded) f a s t e n e r s . These t y p e s are:
- pin (Threaded) w i t h p r o t r u d i n g head, f o r s h e a r a p p l i c a t i o n only,
- pin (Threaded) w i t h 100 d e g r e e s countersunk head, f o r s h e a r

a p p l i c a t i o n only,
- p i n (Threaded) w i t h p r o t r u d i n g head, f o r t e n s i o n and s h e a r

application,
- p i n (Threaded) w i t h 100 d e g r e e s countersunk head, f o r t e n s i o n and

shear application.
( c ) The p a r t number of t h e p i n (Threaded) i s indented on t h e head.
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(d) A p i n (Threaded) c o l l a r i s f u l l y i d e n t i f i e d w i t h t h e subsequent

data:
- t h e p a r t number,
- t h e m a t e r i a l code,
- t h e m a t e r i a l f i n i s h code,
- the color,
- t h e washer t y p e ( i f a p p l i c a b l e ) ,
- t h e washer m a t e r i a l ( i f a p p l i c a b l e ) ,
- t h e washer m a t e r i a l f i n i s h ( i f a p p l i c a b l e ) .
There a r e many d i f f e r e n t t y p e s of c o l l a r s used w i t h p i n s

(Threaded). There i s no p a r t number on t h e s e c o l l a r s , t h u s they
must be k e p t i n s e p a r a t e c o n t a i n e r s . The c o n t a i n e r s must b e marked
with the applicable part numbers.
NOTE: Some o v e r s i z e c o l l a r s a r e a l s o i d e n t i f i e d by a groove. T h i s

groove can b e around t h e hexagonal o r n e a r t h e c o l l a r s e a t .
( 2 ) I n s t a l l a t i o n w i t h Hand Tools and Power T o o l s
( a ) Make s u r e t h a t a l l f a s t e n e r h o l e s i n t h e r e p a i r a r e c o r r e c t l y
prepared.
(b) Measure t h e t o t a l t h i c k n e s s of t h e i t e m s t o be r i v e t e d . This gives

you t h e c o r r e c t g r i p l e n g t h of t h e p i n .
( c ) I n s t a l l t h e a p p l i c a b l e p i n and c o l l a r assembly a s shown i n F i g u r e

210.
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C . I n s p e c t i o n a f t e r I n s t a l l a t i o n of P i n (Threaded) F a s t e n e r s
(1) V i s u a l I n s p e c t i o n
( a ) Examine t h e p i n head and t h e l o c a l a r e a s u r f a c e ' a r o u n d t h e head f o r

s i g n s of t h e subsequent damage:
- s c o r i n g , d i s t o r t i o n and d e l a m i n a t i o n ,
- damage, caused when t h e head i s h i t ( d i s h i n g ) ,
- p e r i p h e r a l c r a c k s and c o n d i t i o n of t h e cadmium p l a t i n g on t h e
head, where a p p l i c a b l e ,
- a n i n c o r r e c t s e a t of t h e head a n d / o r c o l l a r .
(b) S c o r e s a r e p e r m i t t e d i f they a r e w i t h i n t h e l i m i t s g i v e n below:
- no s h a r p edges o r c o r n e r s a r e p e r m i t t e d ,
- t h e depth of damage must n o t be more t h a n 0.1 mm (0.0039in.).
( c ) A s l i g h t s e p a r a t i o n of t h e p i n head s e a t i s p e r m i t t e d , i f i t i s
w i t h i n i n t h e subsequent liniits:
( i ) The maximum v a l u e of t h e s e p a r a t i o n i s n o t more t h a n 0.04 mm

(0.0016in.) (Refer t o F i g u r e 211).
( i i ) The head i s i n s a t i s f a c t o r y c o n t a c t w i t h a t l e a s t 66 p e r c e n t of
t h e s e a t a r e a c i r c u m f e r e n t i a l l y (Refer t o F i g u r e 211).
( i i i ) Up t o 10 p e r c e n t of t h e p i n s i n a row a r e p e r m i t t e d t h i s
condition.
( i v ) P i n s n e x t t o each o t h e r a r e n o t p e r m i t t e d t h i s c o n d i t i o n .
(d) For t h e l i m i t s on t h e p i n head d i s h i n g , r e f e r t o F i g u r e 211.
( e ) Make s u r e t h a t t h e t h r e a d p r o t r u s i o n through t h e i n s t a l l e d c o l l a r
i s c o r r e c t (Refer t o F i g u r e 212) and t h a t t h e c o l l a r i s c o r r e c t l y
s e a t e d on t h e s t r u c t u r e .
D. Removal
(1) Use o n l y hand t o o l s t o remove t h e s e f a s t e n e r s from composite

structures.
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(2) Use t h e procedure t h a t f o l l o w s :
( a ) I n s e r t t h e c o r r e c t A l l e n wrench i n t o t h e hexagonal r e c e s s i n t h e
p i n end.
(b) Use t h e A l l e n wrench t o p r e v e n t t h e p i n t u r n i n g , and w i t h p l i e r s

( o r similar g r i p p i n g t o o l ) , t u r n t h e c o l l a r counter-clockwise u n t i l
i t i s removed.
( c ) Remove t h e A l l e n wrench and push t h e p i n o u t of t h e h o l e .
(3) It may be n e c e s s a r y i n some c a s e s ( f o r example, l i m i t e d a c c e s s o r

damaged c o l l a r ) , t o remove t h e f a s t e n e r by d r i i l i n g t h e head o f f . Use
s t a n d a r d p r o c e d u r e s and c l e a n d r y a i r o r water i f n e c e s s a r y t o c o o l t h e
a r e a . I f t h e f a s t e n e r i s made of t i t a n i u m make s u r e t h a t :
- you u s e a s l o w d r i l l speed,
- you apply a c o n s t a n t hand p r e s s u r e t o t h e d r i l l .
This i s t o prevent overheating.
NOTE: Standard high-speed t w i s t - d r i l l s can be used t o d r i l l t i t a n i u m

f a s t e n e r s . But t h e t i p of t h e t w i s t - d r i l l must b e re-ground t o
an a n g l e o f 80 d e g r e e s , and w i t h a p o i n t c l e a r a n c e of 5 d e g r e e s .
3 . ASP Threaded F a s t e n e r s
A . General
(1) There a r e t h r e e p a r t s o f t h e ASP t h r e a d e d f a s t e n e r :
- a shouldered, t h r e a d e d p i n
-a s l e e v e w i t h an i n t e r n a l t h r e a d
-a swaged l o c k i n g c o l l a r
(1) ASP f a s t e n e r s are i n s t a l l e d u s i n g s p e c i a l t o o l s s u p p l i e d by t h e

manufacturer. The i n s t a l l a t i o n sequence i s :
( a ) I n s e r t t h r e a d e d p i n from one s i d e of work.
(b) P u t s l e e v e o v e r p i n and t o r q u e a g a i n s t o t h e r s i d e of work.
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( c ) P u t l o c k i n g c o l l a r i n p o s i t i o n and swage w i t h i n s t a l l a t i o n t o o l t o
l o c k s l e e v e and pin.
( 2 ) Make s u r e t h a t p i n p r o t r u s i o n and c o l l a r h e i g h t a r e w i t h i n t h e l i m i t s
g i v e n i n F i g u r e 213.
C. Removal
( 1 ) R e f e r t o F i g u r e 214.
4. R i v e t s ( B l i n d ) (HUCK)
A. General
(1) I n t h i s paragxaph t h e R i v e t (Blind) (HUCK) i s r e f e r r e d t o as t h e hJCK

rivet.
(2) The HUCK r i v e t c o n s i s t s of t h r e e p a r t s . These are:
( a ) A t u b u l a r body t h a t h a s a p r o t r u d i n g o r 100 d e g r e e s countersunk

head.
(b) A mandrel t h a t i s r e t a i n e d i n t h e t u b u l a r body. When t h e HUCK

r i v e t i s i n s t a l l e d , t h e mandrel i s mechanically secured w i t h i n t h e
t u b u l a r body and i s s h e a r e d o f f l e v e l w i t h t h e r i v e t head.
( c ) A l o c k i n g c o l l a r t h a t i s r e t a i n e d on t h e mandrel b e f o r e
i n s t a l l a t i o n . The i n s t a l l a t i o n t o o l pushes t h e c o l l a r i n t o a
l o c k i n g groove d u r i n g i n s t a l l a t i o n . T h i s s e c u r e s t h e mandrel i n
t h e body.
(3) When i n s t a l l e d t h e HUCK r i v e t i s s i m i l a r t o a 'pop' r i v e t . But because

t h e mandrel i s r e t a i n e d i n t h e t u b u l a r body, t h i s r i v e t h a s a l m o s t t h e
same p r o p e r t i e s as a s o l i d r i v e t . The HUCK r i v e t can be i n s t a l l e d from
one s i d e of a r e p a i r o r s u r f a c e .
( 4 ) The HUCK r i v e t can be i n s t a l l e d w i t h hand o r power o p e r a t e d t o o l s .
(5) HUCK r i v e t s must o n l y be used t o r e p l a c e HUCK r i v e t s , o r when c a l l e d up

i n a s p e c i f i c r e p a i r procedure o r o t h e r approved documents.
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(6) Before you i n s t a l l HUCK r i v e t s make s u r e t h a t :
- you have t h e c o r r e c t type of r i v e t ,
- the r i v e t s a r e made of t h e r e q u i r e d m a t e r i a l ,
- the r i v e t s have t h e s p e c i f i e d s u r f a c e p r o t e c t i o n , and t h a t they a r e

n o t corroded o r s c r a t c h e d ,
- t h e r i v e t s have t h e c o r r e c t g r i p l e n g t h and diameter,
- t h e h o l e s f o r t h e r i v e t s a r e c o r r e c t l y prepared.
(7) Before you i n s t a l l HUCK r i v e t s i n t h e s t r u c t u r e you a r e recommended t o

make a t e s t p i e c e . T h i s w i l l check t h e r i v e t , t o o l and h o l e p r e c i s i o n .
The t e s t m a t e r i a l s and r i v e t s must have t h e same p r o p e r t i e s a s t h o s e
required f o r the repair.
(1) The s t e p s t h a t f o l l o w g i v e t h e g e n e r a l sequence f o r t h e i n s t a l l a t i o n of

a HUCK r i v e t .
( a ) Put t h e r i v e t i n i t s h o l e . Make s u r e t h a t t h e l o c k i n g c o l l a r i s i n
its correct position.
(b) Put t h e a p p l i c a b l e i n s t a l l a t i o n t o o l onto t h e r i v e t mandrel. Make

s u r e t h a t t h e t o o l i s p e r p e n d i c u l a r t o t h e s u r f a c e of t h e m a t e r i a l .
CAUTION: OBEY THE MANUFACTURER'S INSTRUCTIONS WHEN USING A POWER

OPERATED TOOL. SOME DOUBLE ACTION TOOLS HAVE A SHIFT
VALVE CARTRIDGE THAT MUST BE ADJUSTED TO A SPECIFIC
PRESSURE BEFORE USE.
( c ) Operate t h e i n s t a l l a t i c n t o o l . This:
- forms t h e u p s e t head,
- s e a t s t h e l o c k i n g c o l l a r i n t o t h e l o c k i n g groove,
- s h e a r s t h e mandrel a t t h e break o f f groove.
(d) Release t h e t o o l t r i g g e r and remove t h e t o o l from t h e r i v e t head.

The broken o f f p a r t of t h e mandrel i s a u t o m a t i c a l l y pushed o u t of
the tool.
( e ) I f r e q u i r e d , m i l l t h e mandrel a t t h e break-off groove t o g i v e a

smooth f i n i s h .
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( f ) I n s p e c t t h e HUCK r i v e t f o r c o r r e c t i n s t a l l a t i o n ( R e f e r t o Paragraph
4.C.).
C. I n s p e c t i o n a f t e r t h e I n s t a l l a t i o n of HUCK R i v e t s
(1) General
( a ) C a r e f u l l y examine t h e i n s t a l l e d r i v e t s .
(b) A v i s u a l i n s p e c t i o n of t h e c o r r e c t shape of t h e formed ( b l i n d ) s i d e

w i t h a probe l i g h t and a m i r r o r i s n e c e s s a r y when t h e a c c e s s i s
possible.
( c ) The i n s t a l l a t i o n of t h e HUCK r i v e t i s c o r r e c t when:
- t h e mandrel i s c o r r e c t l y locked by t h e l o c k i n g c o l l a r ,
- the manufactured head i s f u l l y s e a t e d ,
- t h e b l i n d head i s c o r r e c t l y formed,
- the a d j a c e n t s t r u c t u r e i s f r e e from damage and d i s t o r t i o n .
(d) Deformation o r b u c k l i n g of t h e o u t e r s k i = i s n o t p e r m i t t e d o u t s i d e
t h e l i m i t s g i v e n i n Chapter 54-01-01.
( e ) Make s u r e t h a t t h e head of countersunk r i v e t s a r e i n t h e l i m i t s

g i v e n i n Chapter 54-01-01.
(2) P e r m i t t e d L i m i t s
( a ) For t h e p r o t r u s i o n and i n t r u s i o n limits of t h e p i n r e f e r t o F i g u r e

215.
( b ) The c o r r e c t p o s i t i o r of t h e l o c k i n g c o l l a r i s g i v e n i n F i g u r e 215.
(c) The l i m i t s f o r t h e s e a t i n g of t h e head a r e g i v e n i n F i g u r e 216.
( d ) Cracks and d e l a m i n a t i o n s i n t h e m a t e r i a l around t h e f a s t e n e r a r e

not permitted.
D. Removal of W C K R i v e t s
(1) General
( a ) HUCK r i v e t s can b e removed w i t h a s p e c i a l t o o l k i t . I f t h i s k i t i s

n o t a v a i l a b l e HUCK r i v e t s can b e c a r e f u l l y remove w i t h c o n v e n t i o n a l
twist-drills. I n t h i s Paragraph t h e two procedures a r e given.
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(b) The F i g u r e s r e f e r r e d t o i n t h i s Paragraph show t h e removal o f a

countersunk r i v e t . The removal of a p r o t r u d i n g head r i v e t i s t h e
same.
(2) Removal w i t h a S p e c i a l Tool K i t (Procedure 1)
(a) For t h e s e l e c t i o n of t h e a p p l i c a b l e t o o l k i t u s e t h e subsequent

Table :
RIVET NOMINAL DIAMETER KIT NZIM

' BER NECESSARY
5132in. (4.0 mm)

3/16in. (4.8 mm)
1/4in. (6.4 mm)
5116in. (8.0 mm)
3/8in. (9.6 mm)
( b ) S e t t h e d r i l l bushicg v e r t i c a l l y on t h e r i v e t mandrel s o t h a t i t is
i n f u l l contact with t h e locking c o l l a r .
( c ) Use a power d r i l l w i t h a maximum speed o f 1250 r e v o l u t i o n s p e r

minute (rpm). D r i l l t o t h e d e p t h of t h e l o c k i n g c o l l a r . Cool t h e
d r i l l i n g a r e a w i t h c l e a n , d r y , p r e s s u r i z e d a i r , w a t e r may b e used
i f p r e s s u r i z e d a i r i s n o t a v a i l a b l e . For t h e d r i l l d e p t h and
dimensions r e f e r t o F i g u r e 217.
( d ) Put t h e p i n punch on t h e r i v e t mandrel and push o u t t h e mandrel.
( e ) Remove t h e l o c k i n g c o l l a r w i t h a p o i n t e d t o o l .
( f ) Assemble t h e t o o l t o c o u n t e r b o r e t h e r i v e t body (Refer t o F i g u r e

218) as f o l l o w s :
( i ) I n s t a l l t h e c u t t e r f u l l y i n t o t h e h o l d e r and a t t a c h i t w i t h t h e
s e t screw.
( i i ) Screw t h e c u t t e r h o l d e r f u l l y i n t o t h e n i c r o - l i m i t t o o l .
( i i i ) I n s t a l l t h e m i c r o - l i m i t t o o l i n t h e a n t i - r o t a t i o n cap as f a r a s
p o s s i b l e and s e c u r e i t w i t h t h e s e t screws.
( i v ) I n s t a l l t h e assembled t o o l i n g i n t h e chuck of t h e power d r i l l .
(g) Adjust t h e m i c r o - l i m i t t o o l t o t h e t y p e and s i z e of t h e r i v e t . For

dimensions r e f e r t o t h e t a b l e i n F i g u r e 218.
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( h ) Put t h e c u t t e r i n t h e r i v e t body and p r e s s t h e a n t i - r o t a t i o n cap

t i g h t l y a g a i n s t t h e r i v e t head. Counterbore t o t h e n e c e s s a r y depth
and c a r e f u l l y remove t h e t o o l (Refer t o F i g u r e 218).
CAUTION: BE CAREFUL WHEN YOU USE THE PIN PUNCH,. DO NOT CAUSE
DAMAGE TO THE HOLE AND, I F I T I S APPLICABLE, THE
COUNTERSINK.
( i ) Put t h e p i n punch i n t h e r i v e t body and push o u t t h e lower p a r t .

C a r e f u l l y remove t h e p i n punch.
( j ) I f t h e remaining p a r t of t h e body, f o r example t h e r i v e t head, is

l o o s e , l i f t i s o u t of t h e h o l e . I f t h i s i s n o t p o s s i b l e , p u t t h e
end of t h e p i n punch i n t o t h e head. Move t h e punch a t a n a n g l e t o
one s i d e and remove t h e r i v e t head.
(3) Removal w i t h c o n v e n t i o n a l t w i s t - d r i l l s (Procedure 2)
NOTE: The removal procedure 2 i s n o t i l l u s t r a t e d because i t i s

e q u i v a l e n t t o t h e procedure 1. The n e c e s s a r y i l l u s t r a t i o n s a r e
g i v e n i n procedure 1.
( a ) Use a s h a r p t w i s t - d r i l l . The recommended diameter i s g i v e n i n t h e

subsequent t a b l e f o r t h e a p p l i c a b l e r i v e t diameter.
RIVET NOMINAL DIAMETER RECOMMENDED DRILL DIMENSION
1/8in. (3.2 mm) 5164in. (2.0 mm)

5/32in. (4.0 mm) 7/64in. (2.8 mm)
3/16in. (4.8 mm) 118in. (3.2mm)
1/4in. (6.4mm) 5/32in. (4.0 mm)
5116in. (8.0 mm) 3116in. (4.8 mm)
318i.n. (9.5 mm) 15164in. (6.0 mm)
7/16in. (11.2 mm) 17/64in. (6.8 mm)
1/2in. (12.8 mm) 5116in. (8.0 mm)
(b) Secure t h e t w i s t - d r i l l i n a power t o o l and u s e c l e a n d r y a i r o r

water i f n e c e s s a r y t o c o o l t h e a r e a . D r i l l t h e r i v e t head t o t h e
bottom of t h e l o c k i n g c o l l a r . Make s u r e t h a t t h e t w i s t - d r i l l
remains c o n c e n t r i c on the rivet.
NOTE: Do n o t u s e a d r i l l speed g r e a t e r than 1250 rpm.
NOTE: For t h e l a r g e r s i z e r i v e t you a r e recommended t o d r i l l z

p i l o t hole f i r s t .
( c ) Use a p i n punch t h a t i s t h e same diameter ( o r l e s s ) as t h e

t w i s t - d r i l l used i n S t e p ( 3 ) ( a ) . P u t t h e punch on t h e r i v e t
mandrel and push o u t t h e mandrel.
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(d) Remove t h e l o c k i n g c o l l a r w i t h a pointed t o o l .
CAUTION: DAMAGE MAY BE CAUSED TO THE SKIN/COUNTERSINK I F THE RIVET

TURNS WHEN YOU DO THE NEXT STEP.
( e ) Use a t w i s t - d r i l l w i t h t h e same nominal d i a m e t e r a s t h e r i v e t a t a

d r i l l speed of approximately 250 r e v o l u t i o n s p e r minute (rpm). Use
c l e a n d r y p r e s s u r i z e d a i r o r water i f n e c e s s a r y t o c o o l t h e a r e a .
Counterbore t h e r i v e t head w i t h a l i g h t and c o n s t a n t p r e s s u r e . For
t h e c o u n t e r b o r e d e p t h of t h e a p p l i c a b l e head t y p e and r i v e t
dimensions r e f e r t o t h e t a b l e t h a t follows:
RIVET NOMINAL COUNTERBORE DEPTH
DIAMETER CSK HEAD PROTRUDING HEAD
(3.2 mm) 0.040in. (1.0 mm) 0.045in. (1.2 mm)

(4.0 mm) 0.055in. (1.4 mm) 0.060in. (1.5 mm)
(4.8 mm) 0.070in. (1.8 mm) 0.075in. (1.9 mm)
(6.4 mm) 0.095in. (2.4 mm) 0.130in. (3.3 mm)
(8.0 mm) 0.125in. (3.2 mm) 0.130in. (3.3 mm)
(9.5 mm) 0.155in. (3.9 mm) 0.195in. (5.0 mm)
(11.2 mm) 0.180in. (4.6 mm) 0.195in. (5.0 mm)
(12.8 mm) 0.210in. (5.3 mm) 0.260in. (6.6 mm)
CAUTION: BE CAREFUL WHEN YOU USE THE PIN PUNCH. DO NOT CAUSE
DAMAGE TO THE HOLE AND, I F I T I S APPLICABLE, THE
COUNTERSINK.
( f ) Use a p i n punch t h a t i s t h e sane diameter ( o r l e s s ) a s t h e

t w i s t - d r i l l diameter used i n s t e p ( 3 ) ( a ) . P u t t h i s punch i n t h e
r i v e t body and push o u t t h e lower p a r t . C a r e f u l l y remove t h e p i n
punch.
( g ) I f t h e remaining p a r t of t h e r i v e t , f o r example t h e head, i s l o o s e ,

l i f t i t o u t of t h e h o l e . I f t h i s i s n o t p o s s i b l e , p u t the end of
t h e p i n punch i n t o t h e head. Move t h e punch a t an a n g l e t o t h e one
s i d e and remove t h e r i v e t head.
5. Rivets - Blind (CHERRYMAX AND CHERRYLOCK)
A. General
(1) Cherrymax r i v e t s a r e s u p p l i e d as one p i e c e c o n s i s t i n g of t h r e e p a r t s :
( a ) A t u b u l a r body t h a t h a s a head a t one end. Two types of head a r e

a v a i l a b l e : a 100 degree countersunk head and a p r o t r u d i n g head.
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( b ) A p i n t h a t goes through t h e body. The p i n has a head o p p o s i t e t h e

body head. It a l s o h a s a lock-groove, a break-off groove and
pull-grooves. There i s a l s o a d r i v i n g a n v i l on t h e p i n . T h i s
makes s u r e t h a t t h e l o c k - c o l l a r sits c o r r e c t l y and t h a t t h e p i n
always b r e a k s o f f a t t h e break-off groove.
( c ) A l o c k - c o l l a r on t h e pin. When t h e b l i n d r i v e t i s i n s t a l l e d , t h e
c o l l a r i s swaged i n t o t h e lock-groove on t h e p i n and i n t h e head.
This makes s u r e t h a t t h e p i n i s locked i n t o t h e body.
( 2 ) Cherrylock r i v e t s ( s t a n d a r d o r bulbed t y p e s ) a r e s u p p l i e d as one p i e c e

c o r i s i s t i n g of t h r e e p a r t s :
( a ) A t u b u l a r body t h a t has a head a t one end. Two t y p e s of head a r e

a v a i l a b l e : a 100 degree countersunk head and a p r o t r u d i n g head.
( b ) A p i n t h a t goes through t h e body. The p i n has a head o p p o s i t e t h e

body head. It a l s o has a lock-groove, a break-off groove and
pull-grooves. The p i n head of t h e bulbed type h a s a l s o a s h e a r
r i n g . T h i s makes s u r e t h a t t h e p i n b r e a k s o f f a t t h e break-off
groove i n l i n e w i t h t h e t o p of t h e r i v e t head when t h e r i n g s h e a r s
and r e l o c a t e s on t h e p i n head.
( c ) A l o c k - c o l l a r on t h e pin. When t h e b l i n d r i v e t i s i n s t a l l e d , t h e
c o l l a r i s swaged i n t o t h e lock-groove on t h e p i n and i n t h e head.
T h i s makes s u r e t h a t t h e p i n i s locked i n t o t h e body.
(3) These b l i n d r i v e t s a r e s u p p l i e d w i t h a l z y e r of l u b r i c a n t on them. Do

n o t c l e a n them, o r touch then! more t h a n i s n e c e s s a r y , b e f o r e t h e y a r e
installed.
(4) You can u s e hand o r power o p e r a t e d t o o l s t o i n s t a l l b l i n d r i v e t s .

These t o o l s must have t h e c o r r e c t h e a d s a t t a c h e d t o them.
( 5 ) It i s recommended t h a t you do a t e s t procedure on some unwanted

m a t e r i a l s b e f o r e you i n s t a l l b l i n d r i v e t s . Do t h e t e s t on m a t e r i a l s
t h a t a r e t h e s a m e ( t y p e and t h i c k n e s s ) as t h e r e p a i r m a t e r i a l s . Use
b l i n d r i v e t s t h a t a r e t h e same (head t y p e , diameter and g r i p - l e n g t h ) a s
those f o r the r e p a i r .
(6) A f t e r you have i n s t a l l e d a b l i n d r i v e t , t h e end of t h e p i n can be above

t h e r i v e t head. You can m i l l t h e p i n u n t i l i t i s i n l i n e w i t h t h e t o p
of t h e r i v e t head.
B. I n s t a l l a t i o n Procedure
CAUTION: OBEY THE MANUFACTURER'S INSTRUCTIONS BEFORE YOU USE THESE TOOLS.
THE INSTRUCTIONS WILL GIVE YOU THE NECESSARY PRESSURES. THEY
WILL ALSO GIVE YOU THE CORRECT DRIVING ATTACHMENT TO USE.
EFFECTIVITY: TRENT
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[ RB.211 TRENT
(m STRUCTURAL REPAIR
(1) Get t h e c o r r e c t i n s t a l l a t i o n t o o l . Make s u r e t h a t t h e t o o l h a s t h e

c o r r e c t d r i v i n g a t t a c h m e n t s f o r t h e t y p e and d i a m e t e r of t h e b l i n d
rivet.
NOTE: A s u p p l y of a i r under p r e s s u r e i s n e c e s s a r y f o r power o p e r a t e d

installation tools.
( 2 ) Clamp t h e r e p a i r m a t e r i a l s s o t h a t a l l t h e h o l e s a r e a l i g n e d .
(3) P u t t h e b l i n d r i v e t i n t h e h o l e .
( 4 ) Put t h e i n s t a l l a t i o n t o o l on t h e b l i n d r i v e t . Make s u r e t h a t t h e b l i n d
r i v e t i s c o r r e c t l y s e a t e d on t h e m a t e r i a l f a c e . O p e r a t e t h e t o o l t o
i n s t a l l the blind rivet.
NOTE: The broken p a r t of t h e p i n i s a u t o m a t i c a l l y pushed o u t of t h e

t o o l when t h e i n s t a l l a t i o n o p e r a t i o n i s completed.
(5) M i l l t h e end o f t h e p i n u n t i l i t i s i n l i n e w i t h t h e body head, i f t h i s

is necessary.
NOTE: Special tools are available f o r t h i s step.
(6) Do t h e i n s p e c t i o n procedure t h a t i s g i v e n below.
C. I n s p e c t i o n and P e r m i t t e d L i m i t s
(1) A f t e r you have i n s t a l l e d b l i n d r i v e t s , make an i n s p e c t i o n of them t o

nake s u r e t h a t they a r e c o r r e c t l y i n s t a l l e d . T h i s i n s p e c t i o n must make
sure:
- t h a t t h e body head touches t h e m a t e r i a l c o r r e c t l y . T h i s i s done

v i s u a l l y only,
- that t h e lock-collar is c o r r e c t l y i n s t a l l e d ( R e f e r t o F i g u r e s 219 and

220).
- t h a t t h e p i n i s c o r r e c t l y i n s t a l l e d ( R e f e r t o F i g u r e s 219 and 220),
- t h a t t h e ' b l i n d ' head i s c o r r e c t l y formed. T h i s i s a v i s u a l

i n s p e c t i o n t h a t you do i f you can s e e t h e head,
- t h a t t h e t o p of t h e head of a countersunk b l i n d r i v e t i s i n l i n e
w i t h , o r o n l y a l i t t l e above, t h e t o p f a c e of t h e r e p a i r (Refer t o
Chapter 54-01-01).
NOTE: I f i t i s n e c e s s a r y , u s e equipment ( f o r example, probe-light and

i n s p e c t i o n m i r r o r ) t o do t h e i n s p e c t i o n where you cannot see.
EFFECTIVITY: TRENT
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Sept.15/96
[ RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
(2) Deformation of the repair materials must not be more than the limits
given in Chapter 54-01-01.
(3) No cracks are permitted in any part of the blind rivet, or the adjacent
structure.
D. Removal Procedure (Refer to Figures 221 and 222)
CAUTION: TAKE CARE NOT TO CAUSE DAMAGE TO THE STRUCTURE WHEN YOU DO THIS
PROCEDURE.
(1) Make an accurate mark with a centre punch in the center of the end of
the pin. This will give a location for the twist-drill.
CAUTION: DO NOT LET THE RIVET BODY TURN WHEN YOU DO THESE STEPS.
(2) Drill a hole in the pin to the bottom of the collar. Do this with a
twist-drill that has a dimeter the same as the pin.
(3) Remove the lock-collar (Refer to Figures 221 and 222).

(4) Hit the remaining pin out of the rivet body. Do this with a parallel
pin punch and a hammer.
(5) Get a twist-drill that has a diameter almost as large as the outer
diameter of the rivet body. Make an estimate to find how deep you will
have to drill the hole in the rivet head. Put a mechanical stop on the
twist-drill to give the correct depth (Refer to Figures 221 and 222).
(6) Drill the hole in the head of the rivet.
(7) Put a parallel pin punch in the drilled hole. The diameter of this pin
punch must agree with the hole diameter. Move the pin punch at an
angle to break-off the rivet head.
(8) Hit out the remaining shank of the rivet body. Do this with the same
parallel pin punch used in step (7) and a hammer.
6. Bolt-Blind (COMPOSI-LOK)
A. General
(1) Bolts-Blind (COMPOSI-LOK) are high strength blind fasteners that are
particularly suitable for installation in composite materials.
(2) The Bolt-Blind is a three-part fastener assembly. The parts are:
WFECTIVITY: TRENT
Page 219
Sept.15196
1
m@>
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
(a) A screw with a plain head and a left-hand threaded shank. A

break-off groove is included on the shank. There are two machined
flats along the shank on the end opposite the head.
(b) A hexagonal, protruding or countersunk headed nut, the countersunk

nut is available with a 100 or 130 degree head. The nut shank is
tapered externally. Three identations on the external of the shank
provide a positive locking feature.
(c) A sleeve that is put between the screw head and the nut. The
sleeve shape is deformed during the process of installing the
fastener, this locks the fastener in place. An insert in the
sleeve assists in the deformation of the sleeve.
(3) The nuts are made of titanium, the screw is made of Corrosion Resistant
Steel (CRS) and the sleeve is made of stainless steel. The drive nut
is made of mild steel.
(4) Do not install Bolts-Blind where the surfaces of the materials are more
than 3 degrees out of parallel.
(5) Bolts-Blind are supplied with a layer of lubricant on them (all parts).
Do not clean or touch them nore than is necessary before they are
installed.
(6) Do not install any parts of a Bolt-Blind that are not in a satisfactory
condition. Discard any parts that are not.
(7) You can use hand or power-operated tools, to install Bolts-Blind. The
tool must have the correct drive assembly attached to it.
B. Installation
(1) Refer to Figure 223
C. Inspection
(1) Refer to Figure 224
D. Removal Procedure
(1) General
(a) To remove a bolt-blind it is necessary to drill the head. A

special tool is available to help you to do this procedure. This
tool is available for each type and diameter of bolts-blind. The
tool has a drill guide at each end. One guide is for a
pilot-drill, the other guide is for a final dimension drill. The
guides are made to agree with the type of bolt-blind.
EFFECTIVITY: TRENT
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Sept.15196
RB.211 TRENT
m(R) STRUCTURAL REPAIR
Y i A L
(b) It i s recommended t h a t you u s e 18 p e r c e n t t u n g s t e n t w i s t - d r i l l s for

t h i s procedure and w a t e r as a l u b r i c a n t .
(2) Procedure
(a) Put t h e a p p l i c a b l e t w i s t - d r i l l ( i n a drill-machine) i n t o the hole

i n t h e p i l o t - d r i l l g u i d e end of t h e s p e c i a l t o o l .
NOTE: The a p p l i c a b l e t w i s t - d r i l l i s t h a t which a g r e e s w i t h t h e

i n t e r n a l d i a m e t e r of t h e d r i l l guide.
(b) Put t h e d r i l l guide on t h e n u t head of t h e b o l t - b l i n d . Drill a

h o l e o n l y t o t h e bottom of t h e n u t head, n o t t h e shank. Remove t h e
t w i s t - d r i l l and t h e t o o l from t h e n u t head.
( c ) Do s t e p ( 2 ) ( b ) a g a i n , b u t u s e a f i n a l dimension t w i s t - d r i l l i n the
f i n a l dimension guide of t h e s p e c i a l t o o l .
(d) P u t a p a r a l l e l p i n punch i n t h e d r i l l e d h o l e and h i t t h e p i n punch

w i t h a hammer. T h i s w i l l c a u s e t h e n u t head t o b r e a k - o f f . Push
out t h e b o l t shank.
EFFECTIVITY: TRENT
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Sept.15196
RB.211 TRENT
STRUCTURAL REPAIR
MAMTAL
UNIVERSAL
HEAD COUNTERSUNK
HEAD
l I T
NOTE: To find the required rivet length (L), measure the

total thickness of the materials 0,add to this the
required protrusion (C) (given in the applicable table).
This theoretical length can be adjusted as follows:
-For aluminum alloy rivets use the next shorter

or longer standard length rivet
-For monel or titanium rivets use the next longer

standard length rivet
RIVET
RIVET NOMINAL
pROTRUS,ON
DIAMETER (D)
(C)
mm (in) mm (in)
2,4 3/32 3,6 0.141

32 4,8 0.189
4 'l8
5/32 6 0.236
4,s 3/16 7,2 0.283
5,6 7/32 7,3 0.287
6,4 1 I4 8,3 0.327
8 5/16 10,4 0.409
NOTE; The above given table is applicable to 201 7A, 2024,21 17,3.1124 and 3.1324rivets
Rivet Lengths
F i g u r e 201 Sheet 1
EFFECTIVITY : TRENT
Page 222
Sept.15/96
1m(m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
RlVET
DIAMETER (D) PROTRUSION
(C)
mm (in) mm (in)
2,4 3/32 2,4 0.094

32 1 18 3,2 0.126
4 5/32 4 0.157
48 311 6 4,8 0.189
5,6 7132 5,6 0.22
64 1 14 6,4 0.252
8 511 6 8 0.315
NOTE: The above given table is applicable to cold driven 2017 rivets
RlVET NOMINAL RlVET

DIAMETER (D) PROTRUSION
(C)
mm (in) mm (in)
2,4 3/32 2,4 0.094
32 l 18 32 0.126
3,6 9/64 3,6 0.141
4 5/32 4 0.157
4,8 311 6 4,8 0.189
56 7/32 56 0.22
NOTE: The above given table is applicable to monel or titanium solid

rivets for installation in aluminum alloy structure
RlVET
RlVET NOMINAL
DIAMETER (D)
(C)
mm (in) mm (in)
2,4 313 2 1,g 0.07

32 1 18 2,6 0.102
36 9/64 2,9 0.114
4 5/32 3,2 0.126
43 311 6 3,8 0.149
5,6 7132 4,5 0.177
NOTE: The above given table is applicable to monel or titanium solid

rivets for installation in steel or titanium structure
Rivet Lengths
Figure 201 Sheet 2
EFFECTIVITY : TRENT
Page 223
Sept.15196
1 m)
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
TYPICAL SELECTION OF BACK-UP DOLLIES BACK-UP DOLLY ALIGNMENT
RIVET NOMINAL DIAMETER RECOMMENDED BACK-UP DOLLY WEIGHT

mm (in) kg Ib
1,6 1/ l 6 (0.062) 0,75 to 1,25 1.5 to 2
2,4 3/32 (0.094) 1 to 1,5 2 to 3
32 118 (0.125) 1,5 to 2 3 to 4
3,6 9/64 (0.14) 1,5to2 3 to 4
4 5/32 (0.156) 1,5 to2 3 to 4.5
4,8 3116 (0.187) 2 to 2,5 4 to 5
56 7/32 (0.21 9) 2 to 2,5 4.5 to 5.5
6,4 1I4 (0.25) 2,25 to 3 5 to 6.5
8 511 6 (0.312) 2,75 to 3,5 6 to 8
V)
Q)
CO
_m
0
8
l3
Back-up D o l l i e s
F i g u r e 262
EFFECTIVITY: TRENT
Page 224
Sept.15196
1
mp
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
MANUFACTURED HEAD
(Countersunk or universal)
UPSET HEAD
RIVET NOMINAL RIVET UPSET RIVET UPSET

DIAMETER (D) DIAMETER (C) HEIGHT (H)
MINIMUM MAXIMUM MINIMUM

mm (in) mm (in) mm (in) mm (in)
2,4 3/32 (0.094) 33 0.15 1,6 0.063 1 0.039

32 118 (0.126) 5 0.197 2 0.079 1,3 0.051
4 5/32 (0.157) 6 0.236 2,4 0.094 1,6 0.063
4,8 3/16 (0.189) 7,3 0.287 2,9 0.1 14 1,9 0.075
5,6 7/32(0.219) 84 0.331 3,2 0.126 2,2 0.087
64 114 (0.252) Q,6 0.378 3,8 0.15 2,6 0.102
8 5/16 (0.312) 11,8 0.465 4,6 0.181 3,l 0.122
NOTE: The above given table is applicable to 2017A, 2024, 2117, 3.1 124 and 3.1324 rivets
Upset Head Dimensions

F i g u r e 203 S h e e t 1
EFFECTIVITY : TRENT
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Sept.15196
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL

MINIMUM MAXIMUM MINIMUM .

2,4 3/32 (0.094) 3,1 0.122 1,3 0.051 1 0.039

3,2 118 (0.126) 42 0.165 13 0.07 1,3 0.051
4 5/32(0.157) 5,9 0.232 2,l 0.083 1,6 0.063
4,8 3/16(0.189) 68 0.268 2,7 0.106 1,s 0.075
5,6 7/32 (0.219) T13 0.287 3,2 0.126 2,4 0.094
6,4 114 (0.252) 83 0.327 3,3 0.13 2,5 0.098
8 5/16(0.312) 12,3 0.484 3,8 0.15 3,2 0.126
NOTE: The above given table is applicable to cold driven 2017 rivets


32 118 (0.126) 4 0.157 2.1 0.082 1,2 0.047

3,6 9/64(0.14) 4,5 0.177 2.3 0.09 1,35 0.053
4 5/32 (0.157) 5 0.197 2.5 0.098 1,55 0.061
4,8 3/16 (0.189) 6 0.236 3 0.118 1,85 0.073
5,6 7/32 (0.219) 7 0.276 3.5 0.137 2,l 0.082
NOTE: The above given table is applicable to monel or titanium

solid rivets installed in aluminum alloy structure


32 118 (0.126) 4,3 0.169 1,25 0.049 0,85 0.033

3,6 9/64(0.14) 4,8 0.1 89 1,5 0.059 0,95 0.037
4 5/32 (0.157) 5.3 0.209 1,7 0.067 1,l 0.043
4,8 3/16 (0.189) 6,4 0.252 2 0.079 1,3 0.051
5,6 7/32(0.219) 7,4 0.291 2,3 0.091 1,5 0.059
NOTE: The above given table is applicable to monel or titanium

solid rivets installed in steel or titanium structure
Upset Head Dimensions

Figure 203 Sheet 2
EFFECTIVITY: TREKT
Page 226
Sept.15196
[ RB.211 TRENT
m(m STRUCTURAL REPAIR
YMNUAL
ECCENTRICITY
I l l l
PERMllTED PERMllTED NOT PERMllTED NOT PERMllTED
(rivet shank visible) (rivet shank visible)
MALFORMATION
PERMllTED IF IN PERMITTED IF IN PERMllTED IF IN PERMllTED IF IN

UPSET HEAD UPSET HEAD UPSET HEAD UPSET HEAD
HEIGHT LIMITS HEIGHT LIMITS HEIGHT LIMITS HEIGHT LIMITS
TOOL IMPACT DAMAGE
MAXIMUM 5%
OF TOTAL
PLATE THICKNESS
MAXIMUM 30%
CIRCUMFERENCE
R i v e t D e f e c t s a n d A c c e p tance L i m i t s
Figure 204
EFFECTIVITY: TRENT
P a g e 227
Sept.15/96
1mm
RB.211 TRENT
STRUCTURAL REPAIR
MANUAZ,
NO CRACKS
PERMllTED
IN ZONES 3
AND 4
C (Upset head diameter) -

4
NOTE: Cracks are not permitted in the upset heads of titanium or monel rivets
I RIVET NOMINAL DIAMETER (D) I MAXIMUM WIDTH OF CRACK (W)
C r a c k Limits
Figure 205
EFFECTIVITY : TRENT
Page 228
Sept.15196
1 (g
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
MAXIMUM SEPARATION
(see note)
MAXIMUM SEPARATION
(see note)
L<
f X
NOTE: A 0,04mm (0.001 in) shim, for rivets up to 4,8 mm (0.189 in)
must not penetrate up to the shank
HEAD MUST BE IN HEAD MUST BE IN

ABUTMENT OVER AT ABUTMENT OVER AT
LEAST 60% OF THE LEAST 60% OF THE
CIRCUMFERENCE CIRCUMFERENCE
MAXIMUM
SEPARATION
R i v e t Head Abutment (Seating) Check

F i g u r e 206
EFFECTIVITY: TRENT
P a g e 229
Sept.15/96
[ RB.211 TRENT
@J STRUCTURAL REPAIR
MANUAL
STEP l STEP 2
NOTE: Center punch rivet head to provide NOTE: Drill head only as far as shown below
location for drill tip in dotted line
THE DRILLING
RIVET WITH A
DOLLY OR AN
c
K. l :, /
I
I
,
EQUIVALENT
TOOL
STEP 3 STEP 4
NOTE: Remove the head of the rivet with NOTE: Remove the remainder of the rivet
a tight-fitting parallel drift which is with the parallel drift used before
moved at an angle to one side
Removal o f S o l i d R i v e t s
F i g u r e 207
EFFECTIVITY: TRENT
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Sept.15196
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
COLLAR DRIVE END

COLLAR DRIVE EN
(Sheared off)
SHEAR GROOVE l
EMBOSSED RING
COLLAR
INTERNAL
' RECESS
BEFORE THE ASSEMBLY ASSEMBLED FINGER TIGHT COMPLETED ASSEMBLY

TYPICAL PIN (Threaded) COLLAR ASSEMBLY
PIN (Threaded)
L\ WASHER
1
I
(1 SELF-LOCKING NUT
1
ONE COMPLETE THREAD
PIN (Threaded) WITH SELF-LOCKING
NUT AND WASHER
(Minimum height with no
threads in bearing area)
70 MAxlMud SELF-ALIGNING
COLLAR
PIN (Threaded) WlTH SELF-ALIGNING COLLAR
D e t a i l s of PinICollar Assemblies
F i g u r e 208
EFFECTIVITY: TRENT
P a g e 231
Sept.15196
1 p
RB.211 TRENT
STRUCTURAL REPAIR
ALLEN
WRENCH
l
I APPLICABLE
RATCHET HANDLE
(Modified)
TYPICAL HAND TOOLS FOR

INSTALLATION OF CLEARANCE
FIT FASTENERS
APPLICABLE
SOCKET
(Modified)
TYPICAL HAND TOOLING
METHOD
PIN (Threaded) NOMINAL ALLEN SOCKET RATCHET HANDLE

DASH No DIAMETER l WRENCH HEX SIZE HOLE DIAMETER
~
l
mm (in)
1
-5 ' 5/32 5/64 5116 23 3/32
-5 3116 5/64 5116 2,5 3/32
-8 114 3/32 1 1I32 32 118
-1 0 5116 118 7il6 4,3 11I64
-1 2 318 5/32 112 52 13/64
-1 4 7116 3116 314 6 15/64
-1 6 In 7/32 718 72 9/32
TABLE OF ALLEN WRENCH SOCKET SIZES
Details of Modified Hand Tools

Figure 209
EFFECTIVITY: TRENT
Page 232
Sept.15/96
RB.211 TRENT
m(R> STRUCTURAL REPAIR
MANUAL
1 INSTALL PIN IN ITS HOLE,

MAKE SURE THAT THE HEAD
IS FULLY SEATED RECESS FOR
LLEN WRENCH
2 INSTALL COLLAR ON THE PIN

BY HAND, USE AT LEAST 2 THREADS
TO MAKE CORRECT THREAD
ALIGNMENT
SOCKET
I
3 ENGAGE THE ALLEN WRENCH
INTO THE RECESS IN THE PIN
4 PLACE THE INSTALLATION TOOL

TIGHTLY OVER THE COLLAR
AND TURN UNTIL COLLAR DRlVE
END SHEARS OFF
PIN FllTED
5 DISENGAGE THE INSTALLATION
TOOL FROM PIN, DISCARD COLLAR
DRIVE END -----
NOTE: This illustration shows

a protruding head pin.
Countersunk head pins are
installed in a similar manner
p -----
COLLAR DRIVE END
Installation of a Pin (Threaded) Fastener

Figure 210
EFFECTIVITY: TRENT
Page 233
Sept.15196
1 (3
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
MAXIMUM SEPARATION 0,04mm (0.001in) = - p

-
MAXIMUM
SEPARATION
[ h\ \ ) \
HEAD IN CONTACT
OVER 66% OF
f 1\'<:
CIRCUMFERENCE
LIMITS FOR PIN HEAD SEAT SEPARATION
HEAD DISH
DEPTH 0,076 mm (0.003 in) HEAD DISH
!
i
l
SMOOTH CONTOURED STEP CONTOURED

DISHING ACCEPTABLE DISHING NOT ACCEPTABLE
L i m i t s f o r Head Dishing
F i g u r e 211
EFFECTIVITY: TRENT
Page 234
Sept.15/96
H RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
0,8mm (0.031 in) MINIMUM

THREAD PROTRUSION THROUGH
INSTALLED COLLAR
A MAXIMUM
1 A MINIMUM
MAXIMUM
THICKNESS
MINIMUM THICKNESS MAXIMUM THICKNESS

(Maximum free length) (Minimum free length)
NOTE: This table does not apply to "BULL NOSE" lead in radius bolts
NOMINAL STANDARD DIAMETER I A MAXIMUM A MINIMUM

mm (in) ASN ABS mm (in) mm (in)
ANS DAN
AHL
4 5/32 -2 -5 7,67 0.3 9,75 0.38
43 3116 -3 -6 8 0.31 10,08 0.39
64 1/4 -4 -8 9,78 0.38 11,86 0.46
8 5116 -5 -10 12,44 0.48 1452 0.57
9,6 318 -6 -12 13,59 0.53 15,67 0.61
11,l1 7116 -7 -14 15,87 0.62 17,95 0.7
12,7 1/2 -8 -16 17,14 0.67 19,22 0.75
(0
0
0,
g
0
8
Pin Protrusion Limits
F i g u r e 212
EFFECTIVITY: TRENT
Page 235
Sept.15196
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
B C
MINIMUM PIN MAXIMUM PIN
FASTENER PROTRUSION PROTRUSION
"'")1 1
GRIP 11 1 11 11) MINIMUM
GRIP
DIAMETER ABOVE SLEEVE ABOVE S L E N E
13/64(6) 0.02in 0.107 in

17/64(8) 0.03 in 0.119 in
21/64(l0) 0.035 in 0.129 in
ASP PIN PROTRUSION
PIN PROTRUSION
COLLAR
SLEEVE
PIN
COLLAR HEIGHT
COLLAR/FLASH HEIGHT
A B
MAXIMUM FLASH MAXIMUM COLLAR
FASTENER HEIGHT HEIGHT
DIAMETER (Widest point) (Not including flash)
13/64(6) 0.02 in 0.01 in

17/64(8) 0.03in 0.013 in
21/64(1 0) 0.04in 0.016 in
ASP COLLAR HEIGHT
Pin Protrusion and Collar Height Limits for ASP Threaded Fasteners
Figure 213
EFFECTIVITY: TRENT
Page 236
Sept.15/96
1 e>
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
DRILL B
SLiEVE
DRILL DEPTH C
A
DRILL B C
FASTENER BUSHING DRILL DRILL
DIAMETER HUCK P/N DIAMETER DEPTH
13/64 (6) 1036 17 0.1562 3/64 in

17/64(8) 103618 0.1875 1/16 in
21/64 (10) 103619 0.228 5/64 in
ASP FASTENER LOCK REMOVAL
ASP Threaded F a s t e n e r Lock Removal

F i g u r e 214
EFFECTIVITY: TRENT
Page 237
Sept.15196
m w e )
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
LOCKING
COLLAR
LOCKING
COLLAR
l
MANDREL
LAND l
I
I
I
I
I
NOMINAL DIMENSION DIMENSION NOMINAL DIMENSION

A AND B
DIAMETER A (Maximum) C (Maximum) C (Maximum)
(Maximum)
mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)
3,2 118 0,2 0.007 0.46 0.018 4 5/32 0,25 0.009 0,43 0.016
4 5/32 0,25 0.009 0,56 0.022 4,8 3/16 0,3 0.011 0,56 0.022
4,8 3116 0,3 0.01 1 0,64 0.025 6,4 114 0,38 0.014 0,74 0.029
6,4 114 0,4 0.015 0,81 0.031
NOTE: For the NAS rivets (blind) the locking
collar must be level with or below
the land on the mandrel
Protrusion Data for Rivet (Blind) (HUCK)

Figure 215
EFFECTIVITY: TRENT
Page 238
Sept.15/96
1
m(P
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
A SHIM 0.07mm (0.003in1 THICK

MAXIMUM DISTANCE MUST NOT'PENETRATEUP TO THE
0,l mm (0.004in) SHANK
0,07mm
(0.003in)
THE HEAD MUST BE IN

MAXIMUM ABUTMENT OVER AT
DISTANCE LEAST 60% OF THE
CIRCUMFERENCE
R i v e t (Blind) (HUCK) Abutment ( S e a t i n g ) Check

F i g u r e 216
EFFECTIVITY: TRENT
Page 239
Sept.15196
1-m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
LOCKING
COLLAR RIVET
I BODY
I --I I-
I
DRlLL DIAMETER DRlLL DEPTH
(See table below) (See table below)
DRlLL BUSHING
(See table below)
DRILL DRILL DRILL DEPTH

'lVET
BUSHING
NOMINAL
DIAMETER
PART PART DIAMETER mm (in)
mm (in) NUMBER NUMBER ' mm NOM (in) MINIMUM MAXIMUM MINIMUM MAXIMUM
4 5/32 103615 502999 2,5 7/64 0.098 1,3 18 0.05 0.07
4,8 3/16 103616 503000 3 118 0.12 1,8 23 0.07 0.09
6,4 114 103617 503001 4 5/32 0.1 56 2,3 23 0.09 0.1 1
8 5/16 103618 503003 4,8 3/16 0.188 2,7 32 0.1 05 0.125
9,5 318 103619 503005 5,8 15/64 0.228 3,3 33 0.13 0.15
Remove the Huck Rivet Ma~drel

Figure 217
EFFECTIVITY: TRENT
Page 240
Sept.15/96
RB.211 TRENT
m(P STRUCTURAL REPAIR
MAhrUAL
CUTTER
(See table below)
ANTI-ROTATION CAP
(See table below)
CUTTER HOLDER
(See table below)
CUlTER DEPTH
(See table below)
RIVET ANTI CUTTER C U T E R DIAMETER C U T E R DEPTH (Inches)

NOMINAL ROTATION HOLDER
DIAMETER CAP PART PART DIAMETER CSK HEAD PROT HEAD
.* PART NUMBER NUMBER
mm (in) NUMBER mm (in) MINIMUM MAXIMUM MINIMUM MAXIMUM
4 5/32 103620 103610 103605 4 5/32 0.055 0.065 0.055 0.065
4,8 311 6 103620 10361 1 103606 4,8 3/16 0.065 0.075 0.12 0.13
6,4 114 103621 10361 1 103607 6,4 114 0.09 0.1 0.125 0.135
8 5116 103621 103613 103608 8 5/16 0.12 0.13 0.125 0.135
9,5 318 103622 103613 103609 9,5 318 0.15 0.16 0.19 0.2
Remove the Huck Rivet Body

Figure 218
EFFECTIVITY: TRENT
Page 241
Sept.15/96
mmm
RB.211 TRENT
STRUCTURAL REPAIR
WUAL
DIMENSION A: Is permitted up to a maximum of 0,25 mm (0.01 in)

for all Cherrymax rivets
DIMENSION B: Is permitted up to a maximum of 0,5 mm (0.02 in)

for Cherrymax rivets over 118 in diameter. This dimension
is 0,38 mm (0.015 in) for 118 in diameter rivets
NOTE: The top of the collar must be in line with the top of the rivet head
NOTE: A small burr on the lock-collar caused by the installation tool

is permitted, up to a maximum of 0,5 mm (0.02 in)
Protrusion Limits for Cherrymax Blind Rivets

Figure 219
EFFECTIVITY: TRENT
Page 242
Sept.15/96
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
A CONVEX OR
CONCAVE BREAK
IS ACCEPTABLE
DIMENSION A: Is permitted up to a maximum of 0,5mm (0.02in)

for all Cherrylock blind rivets
DIMENSION B: Is permitted up to a maximum of 0,25mm (0.01in)
DIMENSION C: Is permitted up to a maximum of 0,5mm (0.02in)
DIMENSION D: Is the maximum permitted distance from the
top of the pin to the top of the locking
collar, and varies according to the rivet
diameter as follows:
DIAMETER NOMINAL DIMENSION D MAXIMUM

DASH DIAMETER
NUMBER mm (in) mm (in)
4 32 0.1 25 0,38 0.015
5 4 0.156 0,51 0.02
6 4,8 0.1 87 0,64 0.025
7 6,35 0.25 0,76 0.03
NOTE: A small burr on the locking collar caused by the installation
tool, is permitted up to a maximum of 0,5mm (0.02in)
P r o t r u s i o n L i m i t s f o r Cherrylock Blind R i v e t s
Figure 220
EFFECTIVITY : TRENT
Page 243
S e p t . 15/96
M Le
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
STEP 1: Make a mark with a center punch to give STEP 2: Drill pin to lock collar depth only
a location for the twist-drill tip ~ r )
STEP 4: Drill rivet head only as far as shown

IF POSSIBLE SUPPORT RIVET WITH below dotted line. If available ues a
DOLLY OR EQUIVALENT TOOL mechanical stop to ensure accurate
drilling depth
STEP 3: Remove locking collar using a pointed

tool and hit the pin out
IF POSSIBLE SUPPORT
IF POSSIBLE SUPPORT MATERIAL TO RIVET OR MATERIAL
PREVENT DEFORMATION WHEN DRIFTING
STEP 6: Hit out the remaining rivet shank with
the pin punch used in step 5
STEP 5: Remove rivet head by inserting a tight-fitting
parallel pin punch and move it at an angle
IF POSSIBLE SUPPORT MATERIAL AS

NECESSARY TO PREVENT DEFORMATION
CHERRYMAX Rivet Removal Details

Figure 221
EFFECTIVITY: TRENT
Page 244
Sept.15/96
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
STEP 1: Make a mark with a center punch to give STEP 2: Drill pin to lock collar depth only
a location for the twist-drill
STEP 4: Drill rivet head only as far as shown

below in dotted line. If available use a
IF POSSIBLE SUPPORT RIVET WITH mechanical stop to ensure accurate
DOLLY OR EQUIVALENT TOOL drilling depth
STEP 3: Remove locking collar using a pointed

tool and hit the pin out
IF POSSIBLE SUPPORT
IF POSSIBLE SUPPORT MATERIAL TO RIVET OR MATERIAL
PREVENT DEFORMATION WHEN DRIFTING
STEP 6: Hit out the remaining rivet shank with
STEP 5: Remove rivet head by inserting a tight-fitting the pin punch used in step 5
parallel pin punch and move it at an angle
IF POSSIBLE SUPPORT MATERIAL AS

NECESSARY TO PREVENT DEFORMATION
CHERRYLOCK R i v e t Removal Details

F i g u r e 222
EFFECTIVITY: TRENT
Page 245
Sept.15196
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
STEP l: The bolt-blind assembly is put in to the prepared hole. The installation tool is put on the
screw. The tool engages the flats on the screw and the recesses in the nut head simultaneously
STEP 2: Operation of the installation tool pushes the sleeve over the tapered face of the nut.
The special relationship between the sleeve insert and the nut causes the sleeve to begin
forming the blind head
STEP 3: Further turning of the screw through the nut completes the forming of the large blind head
STEP 4: The screw breaks at the break off groove when this installation is complete and the
correct torque reached
I n s t a l l a t i o n o f Composi-Lok Blind Bolt

F i g u r e 223
EFFECTIVITY: TRENT
Page 246
Sept.15/90
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
!P
I
DIMENSION N IS MEASURED FROM THE STRUCTURE SURFACE TO THE

TOP OF THE SCREW AT THE BREAK-OFF POINT
THE PERMllTED VALUES FOR DIMENSION N ARE:

MINIMUM + 0 mm (0in)
MAXIMUM + 2,62mm (0.103in)
MAXIMUM SEPARATION A SHIM 0,07mm (0.003in) THICK MUST
0,l mm (0.004in) NOT GO IN AS FAR AS THE SHANK ,
MAXIMUM
SEPARATION
- MORETHAN
50% OF THE
CIRCUMFERENCE
NOTE: It is only permitted for as many as 10% of a row, or pattern, of protruding

head blind bolt assemblies to have the maximum head separation
This defect is not permitted on any two adjacent bolts
NOTE: It is only permitted for as many as 20% of a row, or pattern, of countersunk
head blind bolt assemblies to have the maximum head separation
This defect is not permitted on any two adjacent bolts
I n s p e c t i o n o f Composi-Lok B l i n d B o l t s
F i g u r e 224
EFFECTIVITY: TRENT
Page 247
Sept.15/96
RB.211 TRENT
mm8 STRUCTURAL REPAIR
MANUAL
AIR INTAKE COWL - IDENTIFICATION
1. General
A. The air intake cowl is designed to separate the airstream to provide a
smooth airflow through the fan and core engine, and divert the rest of the
air in a smooth flow over the nacelle exterior surfaces. The intake cowl
is attached to the engine fan case. It consists of an inner barrel, an
outer barrel, a rear bulkhead and an intake cowl leading edge (lip)
assembly containing the forward bulkhead. The structure is essentially
cylindrical in shape, and is centered around the intake cowl longitudinal
axis which is pitched down at an angle of 6 degrees from the engine main
centerline, at a point near the aft end of the intake cowl. The only major
system in the intake cowl is the anti-icing system which supplies hot
engine bleed-air to the internal surface of the lip-skin to prevent the
formation of ice on the lip. An interphone jack and various access doors
are installed on the surface of the intake cowl.
B. The intake cowl lip consists of a one-piece pressed C-shaped nose of 2219
aluminum alloy, chemically etched to give differing section thicknesses
ranging from 0.064 to 0.090 in. (1.62 to 2.28 mm). It is attached to
angles which form part of the forward bulkhead. The intake cowl lip
encloses the anti-ice distribution ring which distributes the anti-icing
air to the internal surface of the lip-skin. This tube is mounted onto the
forward bulkhead by ball-jointed connecting rods.
C. The inner barrel structure is the primary load-bearing structure of the

intake cowl. It consists of three acoustic panels (2 side and 1 bottom) of
all-composite construction which provide the sound-absorbent function for
the engine intake area. The three acoustic panels are curved to form the
inside of the engine air intake duct, and are spliced longitudinally by
splice strips of graphite composite material. The inner skins of the
acoustic structure are formed from an open-weave fiber fabric, the
air-wetted surface of which is covered by a corrosion-resistant steel
(CRES) mesh. The acoustic panels are constructed of a single core
reticulated honeycomb sandwiched between the facing sheet and the backing
tray. The two side panels use honeycomb SMS35 CL1 TY6 (23 to 24.5 Kglcubic
meter) and the bottom panel uses SMS35 CL1 TY6 (48 Kglcubic meter). The
three acoustic structure panels are spliced to each other by strips of
graphite composite material. The forward edges of the acoustic structure
panels are attached to the inner edge angle of the aluminum alloy forward
bulkhead, while the rear edges carry the aluminum alloy engine attachment
ring.
EFFECTIVITY: TRENT
Page 1
Apr. 1/94
m 8
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
D. The outer barrel consists of two halves of graphite bonded composite panels
which are jointed at PPR 140, PPR 152 and PPR 335. The panels consist of
outer skins laid up from plies of graphite cloth and are supported
internally by three stiffeners of similar construction around the inner
surface of the outer barrel panels. The forward edge of the pane1.s attach
to an angle on the outer edge of the forward bulkheadllip skin assembly and
the aft edges are fastened to an angle on the edge of the rear bulkhead
assembly.
2. Description
A. Materials used in the construction of the intake cowl consist of aluminum

alloys, corrosion resisting steels and graphite fabric of various weaves
and forms. These forms include honeycomb (Nomex), close-weave fabric,
open-weave fabric, and tape. Fasteners used in the construction and
attachment of the intake cowl range from alloy rivets through HI-LOK pins
and collars to captive KAYNAR type nuts with AS-series bolts and screws.
3. Identification
Structures chosen for field repairs are identified in illustrations (figures)
and tables. The tables list the structural components used in the intake cowl
except for fasteners. Each component is identified by an item number in the
table. The same item number also appears in the figure. The tables give the
component's description, gage (thickness), and material.
The purpose of the tables is to help you to easily locate and identify
components which may be damaged. This is then used to help you to:
A. Determine those parts which an operator should or should not attempt to

fabricate.
B. Select a suitable repair from those given in this manual.
EFFECTIVITY: TRENT
Page 2
R Mar. 1/95
FAN COWL
See 54-20-01
AIR INTAKE COWL

See figures 1,2 and 3
Air Intake Cowl Skin Identification

Figure 1 (Sheet 1 of 3)
EFFECTIVITY: TRENT
54-10-0 1
Page 3
R Mar. 1/95
RB.211 TRENT
-8 STRUCTURAL REPAIR
MANUAL

EFFECTIVITY: TRENT
Page 4
July 1/94
1
m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
ITEM DESCRIPTION GAGE MATERIAL EFFECTIVITY

1 Outer Skin Panel (LH) 4 - Ply (A)
2 Interphone Access Panel 6 - Ply (A)
3 P2T2 Access Panel 10-Ply (A)
.-c
(D
4 Outer Skin Panel (RH) 4 - Ply (A)
.-
G
G R 5 Acoustic Panel (Bottom)
(D
g 6
Acoustic Panel (LH)
0.125 in. 2219-T62
0.064 to 2219-T62
0.090 in.
9 Acoustic Panel (RH) (B)
R (A) Graphite Prepreg as per Shorts Spec S.M.S.30 Type I11 Class 2
Style 3K-135-8H
R (B) Nomex Honeycomb Sandwich as per Shorts Spec S.M.S.35 Class 1

Type 6 23.24.5
R (C) Nomex Honeycomb Sandwich as per Shorts Spec S.M.S.35 Class 1

R Type 6 48-24.5
LIST OF MATERIALS FOR SHEET 2

EFFECTIVITY: TRENT
Page 5
Mar. 1/95
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
NOTE: For fibre orientation refer

to sheets 5 and 6
Air Intake Cowl Skin Identification - Ply Lay-Up

EFFECTIVITY: TRENT
54- 10-0 1
Page 6
July 1/94
Hm@
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
C1B, d2, C3A, C26B, G27A

C1B, C2, C3A, C4N, C26B, G27A C1B, C2, C3A, C26B
O.S.L. TOOLSIDE
0.077in.
l 9 4 1 0.057in.
1.40in.
4.00in.
1101,6mm)
SECTION A-A
CIB, C2, C3A, C26B, G27B

ClB, C2, C3A, C26B ClB, C2, C3A, C4J, C26B, G27B
TOOLSIDE
t
0.057in.
0.063in.
(1.60mm)
SECTION B-B
SECTION C-C

EFFECTIVITY: TRENT
Page 7
July 1/94
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
SECTION D-D
C1 B. C2. C266 0.072in.

I
( O.S.L.
I
TOOLSIDE
I 1
C 1.5in. -C\
1.00in. (38,l mm)
SECTION E-E
(SECTION F-F)
A i r I n t a k e Cowl S k i n I d e n t i f i c a t i o n - Ply Lay-Up

F i g u r e 2 (Sheet 3 of 6 )
EFFECTIVITY: TRENT
Page 8
J u l y 1/94
1 RB.211 TRENT
m @STRUCTURAL REPAIR
MANUAL
CAB, C2, C3A.
-TOOLSIDE
O . S . L .
-C1 B, C2, C26B
SECTION G-G
SECTION H-H
-
Air Intake Cowl Skin Identification Ply Tay-Up
EFFECTIVITY: TRENT
54-10-0 1
Page 9
July 1/94
RB.211 TRENT
-0
STRUCTURAL REPAIR
MANUAL
P l y Number Material N o t e Fiber Orientation Splice

Degrees
SEE NOTE 1 LAP

SEE NOTE 1 NONE
SEE NOTE 1 BUTT
SEE NOTE 1 BUTT
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 LAP
SEE NOTE 4 BUTT
SEE NOTE 3 -
PLY ORIENTATION FOR SECTIONS A-A, B-B, D-D, E-E, F-F, G-G
REFER TO FIGURE 2 (SHEET 6) FOR NOTES.
-
A i r Intake Cowl Skin I d e n t i f i c a t i o n Ply Orientation
F i g u r e 2 (Sheet 5 of 6)
EFFECTIVITY: TRENT
Page 10
Apr. 1 / 9 4
[ RB.211 TRENT
m@STRUCTURAL REPAIR
MANUAL

Degrees
SEE NOTE 1 LAP

SEE NOTE 1 NONE ,
SEE NOTE 1 BUTT

SEE NOTE 1 BUTT
SEE NOTE 1 NONE -
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
PLY ORIENTATION FOR SECTIONS C-C

Degrees
SEE NOTE 1
SEE NOTE 1
-+0 45
- 90
NONE
NONE
SEE NOTE 1 -+ 45 NONE
PLY ORIENTATION FOR SECTION H-H
NOTE: 1. GRAPHITE PREPREG AS PER SHORTS SPEC S.M.S. 30 TYPE I11 CLASS 2 STYLE
3K-135-8H.
2. GRAPHITE PREPREG AS PER SHORTS SPEC S.M.S. 30 TYPE I V CLASS 2 STYLE

3K-70-PW.
3. ADHESIVE S.M.S. 36 TYPE I1 GRADE 03 (REDUX 319).
4. GLASS FABRIC PREPREG AS PER SHORTS SPEC S.M.S. 34 TYPE 120

(0.005 in. THK.).
-
A i r I n t a k e Cowl S k i n I d e n t i f i c a t i o n Ply Orientation
F i g u r e 2 ( S h e e t 6 o f 6)
EFFECTIVITY: TRENT
P a g e 11
Apr. 1/94
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
NOTE: For fibre orientation

refer to sheet 4
-
Air Intake Cowl Skin Identification Ply Lay-Up
EFFECTIVITY: TRENT
Page 12
July 1/94
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
CIA, C2, C3A, C4K, C13A

C I A , C2, C3A, C13A
0.072in.
f R:",:
6 1.5in.
(38, lmm1
4 1.00in.
(25,4mm)
SECTION A-A
O.S.L.
I TOOLSIDE I 0.072in.
ClB, C2, C13B
I
L1 .sin. 4 1.00in.
(38,l mm)
(25,4mm)
Air Intake Cowl Skin I d e n t i f i c a t i o n - Ply Lay-Up

EFFECTIVITY: TRENT
Page 13
July 1/94
m
cam38
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
SECTION C-C
SECTION D-D
2
(38, l mm) 1.00in.
(25,4mm)
SECTION E-E
EFFECTIVITY: TRENT
54-10-0 1
Page 14
J u l y 1/94
RB.211 TRENT
m s STRUCTURAL REPAIR
MANUAL
P l y Number Material Note Fiber Orientation Splice

Degrees
SEE NOTE 1 LAP

SEE NOTE 1 NONE .
SEE NOTE 1 BUTT
SEE NOTE 1 BUTT
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 NONE
SEE NOTE 1 . LAP
SEE NOTE 4 BUTT
SEE NOTE 3 -
PLY ORIENTATION FOR SECTIONS A-A, B-B, D-D, E-E
NOTE: 1. GRAPHITE PREPREG AS PER SHORTS SPEC S.M.S. 3 0 TYPE I11 CLASS 2 STYLE
3K-135-8H.
2. GRAPHITE PREPREG AS PER SHORTS SPEC S.M.S. 3 0 TYPE I V CLASS 2 STYLE

3K-70-PW.
3. ADHESIVE S.M.S. 36 TYPE I1 GRADE 0 3 (REDUX 3 1 9 ) .
4. GLASS FABRIC PREPREG AS PER SHORTS SPEC S.M.S. 3 4 TYPE 1 2 0

(0.005 i n . THK.).
-
A i r I n t a k e Cowl S k i n I d e n t i f i c a t i o n Ply Orientation
F i g u r e 3 ( S h e e t 4 o f 4)
EFFECTIVITY: TRENT
P a g e 15
Apr. 1 / 9 4
RB.211 TRENT
m@)
STRUCTURAL REPAIR
MANUAL
NOTE: Refer to sheets 2 and 3 for fiber orientation

Refer to sheet 4 for table of notes
FACING SHEET
I
@ RIBBON FLOW
SEE NOTE 9 SECTION A-A SEE NOTE 8

C5.C6.C9.C10 G1 ,C2,C3,C4,
BACKIN'GTRAY
~ 5 , ~ 6 , ~ 7 , ~ 8 ,
C9,ClO,G11
A c o u s t i c P a n e l Build-Up
R F i g u r e 4 ( S h e e t 1 of 4)
EFFECTIVITY: TRENT
P a g e 16
July 1/95
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL

Degrees
SEE NOTE 4 NONE

SEE NOTE 3 NONE
SEE NOTE 3 NONE
SEE NOTE 3 NONE
SEE NOTE 3 NONE
SEE NOTE 3 NONE
SEE NOTE 3 NONE
SEE NOTE 3 NONE
SEE NOTE 3 NONE
SEE NOTE 3 NONE
SEE NOTE 4 NONE
SEE NOTE 2 NONE
SEE NOTE 2 NONE
SEE NOTE 7 NONE
SEE NOTE 7 NONE
SEE NOTE 7 NONE
SEE NOTE 7 NONE
SEE NOTE 7 NONE
SEE NOTE 7 NONE
SEE NOTE 6 NONE
SEE NOTE 5 NONE
SEE NOTE 7 NONE
SEE NOTE 6 NONE
R R e f e r t o F i g u r e 4 ( S h e e t 4 ) f o r NOTES.
Acoustic P a n e l Backing Tray - P l y O r i e n t a t i o n

F i g u r e 4 ( S h e e t 2 o f 4)
EFFECTIVITY: TRENT
Page 1 7
J u l y 1/95
1
-(R')
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
R Ply Number Material Note Fiber Orientation Splice

R Degrees
SEE NOTE 12 NONE

SEE NOTE 13 NONE
SEE NOTE 10 NONE
SEE NOTE 10 NONE
SEE NOTE 10 NONE
SEE NOTE 6 NONE
SEE NOTE 11 NONE
SEE NOTE 10 NONE
SEE NOTE 10 NONE
SEE NOTE 10 NONE
SEE NOTE 10 NONE
SEE NOTE 10 NONE
SEE NOTE 10 NONE
SEE NOTE 4 NONE
R Refer to Figure 4 (Sheet 4 ) for NOTES
Acoustic Panel Facing Sheet - Ply Orientation

Figure 4 (Sheet 3 of 4 )
EFFECTIVITY: TRENT
Page 18
July 1/95
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
NOTE: 2. GRAPHITE PREPREG AS PER SHORTS SPEC S.M.S. 30 TYPE 4 CLASS 2 STYLE
3K-70-PW.
3. GRAPHITE PREPREG AS PER SHORTS SPEC S.M.S. 30 TYPE 3 CLASS 2 STYLE
3K-135-8H.
4. GLASS FABRIC PREPREG AS PER SHORTS SPEC S.M.S. 34 TYPE 120 CLASS 1.
5. MESH BACKING SHEET REINFORCING AS PER SHORTS SPEC S.M.S. 54 TYPE 111.
6. ADHESIVE AS PER SHORTS SPEC S.M.S. 36 TYPE I1 CLASS 1 GRADE 03.
7. ARAMID FABRIC PREPREG AS PER SHORTS SPEC S.M.S. 31 STYLE 285.

8. HONEYCOMB HIGH DENSITY MIL-C-7438 1/8 in. CELL 0.006 in. FOIL
2.2 LB/FT 0.086 in. THICK.
R 9. HONEYCOMB AS PER SHORTS SPEC S.M.S. 35 CLASS 1 TYPE 6 23-24.5

R 1.45 LB/FT 1.0 in. THICK.
R 10. GRAPHITE PREPREG AS PER SHORTS SPEC S.M.S. 56 TYPE 1-CLASS2
R STYLE 3K-70-PW.
R 11. BROCHIER AS PER SHORTS SPEC S.M.S. 50/1 TYPE 31 CLASS 1000.
R 12. MESH FACING SHEET REINFORCING AS PER SHORTS SPEC S.M.S. 54
R TYPE IV.
R 13. ADHESIVE AS PER SHORTS SPEC S.M.S. 51 TYPE 11 GRADE 2.
Acoustic Panel Build-Up

R Figure 4 (Sheet 4 of 4)
EFFECTIVITY: TRENT
Page 19
July 1/95
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
AIR INTAKE COWL - ALLOWABLE DAMAGE
1. Introduction
This section contains the allowable damage limits for the air
intake cowl. Damage which is found to be greater than these limit
must be repaired in accordance with the procedures given in Page
Block 201.
2. Zones
The component is divided into zones. The different types of damage

permitted in these zones are identified in the figures and tables
that follow.
3. Section Organization
The information in this section is given in several paragraphs.

Each paragraph gives information about allowable damage, structure
material, and damage types.
A. General
Allowable damage data is intended to permit an operator to

determine whether a damaged nacelle component may continue
in service, or be rejected for repair. Allowable damage
must not compromise the structural integrity of the
component, which could affect the strength or fatigue life.
The types of damage permitted are defined. Brief descriptions
are given of the clean-up procedures needed either to prevent
propagation of the damage or to improve the appearance and
aerodynamic smoothness of the damaged part.
(2) Materials used in many of the components include aluminium

alloy sheet, corrosion resistant steels and composite
materials with varying fabrics and weave forms. These include
honeycomb infill/core structures of different materials,
skin thickness, honeycomb size and material thicknesses.
(3) Damage limits assume that exposed edges do not extend above
the skin surface. Damage that extends above the surface must
be trimmed to remove or feather the protrusion. Holes or
cracks in pressurised panel zones must be sealed using the
applicable tape.
Page 101
P r i n t e d i n Great B r i t a i n July 1/05
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(4) Allowable damage is classified as either unlimited usage

or time limited:
(a) Unlimited usage damage is defined as minor damage

which does not affect the structural integrity or
functional capability of the component. No repairs
are necessary, other than cosmetic, during the
aircraft's design life.
(b) Time limited damage is defined as minor damage which

does not affect the structural integrity of the
component in normal service use, but could reduce
the design life of the component. In this case the
damage must be repaired by next Aircraft 'C" check.
The location and size of the damage must be recorded
and checked at suitable intervals to make sure that
the damage has not grown beyond the allowable time
limited damage.
(5) Damage types permitted on this component are given below.

They apply only to the structural material of the component,
not the surface finishes such as paint.
(a) Abrasion - an abrasion is an area of damage which

results in a cross sectional area change caused by
scuffing, rubbing, scraping or other surface erosion.
An abrasion usually appears rough and irregular.
(b) Gouge - a gouge is a damage area of any size which

results in a cross sectional area change. It is
usually caused by contact with a sharp object which
produces a continuous, sharp or smooth channel-like
groove in the material.
(C) Nick - a nick is a local gouge with sharp edges.
(d) Scratch - a scratch is a line of damage in the

material and results in a cross sectional area
change. Normally caused by a very sharp object.
(e) Crack - a crack is a partial fracture or complete

break in the material and produces a most significant
cross sectional area change. Normally appearing as an
irregular line.
(f) Dent - a dent is a depressed area of damage which,

on metal skins, would not cause cross sectional area
change. On core-filled laminates it may cause
crushing of the core cells. Area boundaries are smooth
because the dent is usually caused by contact with a
Page 102
Printed i n Great B r i t a i n July 1/05
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
smooth contoured object.
(g) Rip/Tear (woven wire) - a rip or tear in the woven

wire of an acoustic bonded panel is a sharp
continuous separation of the wire fibers.
(h) Hole - a hole is a complete penetration through the

material.
(i) Disbond - a disbond is the separation of the face

skin from the honeycomb core of a bonded panel.
(j) Delamination - a delamination is the separation of

two laminate plies or faying surfaces.
(6) The allowable damage zones for the air intake cowl are
shown in Figure 101:
1 - Outer Skin Panels

2 - Inner Barrel Panels
3 - Lip Skin Inner
4 - Lip Skin Outer
5 - Splice Joints
6 - Woven Fiber Inner Face Sheet
7 - Honeycomb Core.
Page 103
Printed in Great Britain July 1/05
STRUCTURAL REPAIR
MANUAL
.......................................................................
INSPECTION
DAMAGE ZONE REQUIREMENTS ALLOWABLE LIMITS INTERVALS
.......................................................................
Abrasion l Confined to surface Maximum depth 0.015 in. "A"
resin over unlimited (0,39 mm) check
area. Protect with
aluminium foil
adhesive tape, OMat
298.
Abrasion 3, 4 Over unlimited area Maximum depth 0.015 in. IIAU

(0,39 mm) check
Gouge 1 No nearer than 8.0 Maximum depth 0.010 in. IlA"

in. (203,2 mm) to (0,254 mm) check
other unrepaired Maximum length 6.0 in.
damage. No more (152,4 mm)
than 6 gouges per Maximum width
barrel half. 0.10 in. (2,54 mm)
Protect with
aluminium foil
adhesive tape, OMat
298.
Gouge 2, 6 No nearer than 6.0 Maximum depth 0.020 in. IIAW

in. (152,4 mm) to (0,50 mm) check
similar damage. Maximum length 0.75 in.
Trim frayed strands (19,05 mm)
of wire mesh. Repair Maximum width 0.10 in.
not later than 'C" (2,54 mm)
check.
Gouge 3, 4 Across rivet heads. Maximum depth 0.005 in. "A"

No nearer than 10.0 (0,127 mm) check
in. (254,O mm) to Maximum length 4.0 in.
other damage (101,6 mm) in any
direction
Gouge 3 All other areas. Maximum depth 0.015 in. WAN

direction
Gouge 4 All other areas. Maximum depth 0.015 in. 11 A II

Page 104
p RB211 TRENT
MANUAL
STRUCTURAL REPAIR
.......................................................................
INSPECTION
.......................................................................
direction
Gouge 5 No nearer than 3.0 Maximum depth 0.010 in. It A II
in. (76,2 mm) to (0,254 mm) check

Repair no later than (127,O mm)
l1Cw check Maximum width 0.10 in.
(2,54 mm)
Nick 1 No nearer than 4.0 Maximum depth 0.010 in. UAII

in. (101,6 mm) to (0,254 mm) check
other damage. Maximum length 1.0 in
Protect with sealing (25,4 mm)
tape. If length
exceeds 1.0 in.
(25.4 mm) consider
as gouge
Nick 2 No nearer than 2.0 Maximum depth 0.010 in. I# A It
in. (50,8 mm) to (0,254 mm) check

No nearer than (6,35 mm)
1.5 in. (38,l mm) Maximum width 0.10 in.
to the core edge. (2,54 mm)
Nicks longer than
0.25 in. (6,35 mm)
consider as a gouge
Nick 3, 4 No nearer than 10.0 Maximum depth 0.015 in. IIAII

in. (254,O mm) to (0,39 m) check
other damage. If Maximum length 1.0 in.
depth exceeds limit (25,4 mm) in any
then consider as a direction
crack
Nick 5 No nearer than 2.0 Maximum depth 0.010 in. IIAV

in. (50,8 mm) to (0,254 mm) check
Repair no later (25,4 mm)
than "C" check Maximum width 0.10 in.
(2,54 mm)
54-10-01
Page 105
Printed i n Great Britain July 1/05
p RB211 TRENT
MANUAL
STRUCTURAL REPAIR
INSPECTION
Scratch 1 No nearer than 8.0 Maximum depth 0.010 in. MA11

i n . ( 2 0 3 , 2 mm) from (0,254 mm) check
other unrepaired Maximum length 6.0 in.
damage. No more (152,4 mm)
than 6 scratches Maximum width 0.10 in.
per barrel half. (2,54 mm)
Protect with
aluminium foil
adhesive tape, OMat
298.
R Scratch 2 Scratches, which do No Limit

R not break the wire
R mesh.
No nearer than 3.0 Maximum depth to full A 11

11
in. (76,2 mm) to thickness of mesh. check

similar damage. No Maximum length 2.5 in.
nearer than 1.5 in. (63,5 mm)
(38,l mm) to core
edge.
Scratch 3, 4 No nearer than 10.0 Maximum depth 0.015 in. ItAI1

in. (254,O mm) to (0,39 mm) check
other damage. If Maximum length 6.0 in.
depth exceeds limit (152,4 mm) in any
then consider as a direction
crack
Scratch 5 No nearer than 3.0 Maximum depth 0.020 in. 11 A 11

in. (76,2 mm) to (0,50 m) check
similar damage Maximum length 5.0 in.
(127,O mm)
Crack 1 No nearer than 10.0 Maximum length 3.0 in. Fly-on limit
in. (254 mm) to (76,2 mm) only. Must
other damage. Stop be repaired
drill crack. Protect at earliest
with aluminium foil opportunity.
adhesive tape, OMat Visually
298. check for
propagation
after every
flight.
Page 106
p RB211 TRENT
MANUAL
STRUCTURAL REPAIR
.......................................................................
INSPECTION
.......................................................................
Crack 3, 4 No nearer than 12.0 Maximum length 2.0 Fly-on limit
in. (304,8 mm) to in.(50,8 mm) in any only. Must be
other damage. Stop direction repaired at
drill crack. earliest
Protect with sealing opportunity.
tape. Visually
check for
propagation
after every
flight.
Dent 2, 6, No nearer than 3.0 Maximum depth 0.080 I I A ~ ~
7 in. (76,2 mm) to in. (2,03 mm). check

similar damage. No Maximum length 0.75
nearer than 1.5 in. in.(19,05 mm) in
(38,l mm) to core any direction
edge. Repair any
damage to wire mesh
layer
Dent 3 No nearer than 1.0 Maximum depth 0.10 in. II A 11
in.(25,4 mm) to any (2,54 mm). check

rivet. Round Maximum length 1.0 in.
bottomed (25,4 mm) in any
direct ion
Dent 4 No nearer than 1.0 Maximum depth 0.20 in. II A 11
in. (25,4 mm) to (5108 mm) check

any rivet Maximum length 2.0 in.
(50,8 mm) in any See Note T
direction
Rip/Tear 2 No delamination from Maximum depth up to 11 A 11

the face sheet. No full thickness of check
nearer than 1.5 in. face mesh.
(38,l mm) to core Maximum length 1.5 in.
edge. No nearer (38,l mm) in any
than 3.0 in. direction
(76,2mm) to similar
damage. Trim frayed
strands of wire mesh.
Repair not later than
"C" check.
54-10-01
Page 107
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
.......................................................................
INSPECTION
.......................................................................
NOTE: If damage has not deteriorated after four consecutive
"A" checks, then do the inspection at every "4A" check.
Hole 1 No nearer than 10.0 Maximum diameter Fly-on limit

in. (254,O mm) to 2.0 in. (50,8 mm) only. Must be
other damage. repaired at
Protect hole with earliest
aluminium foil opportunity.
adhesive tape, Visually check
OMat 298. tape to ensure
no peel back
occurs after
every flight.
Hole 2, 3, No holes allowed

4, 5
Disbond 2 No nearer than 6.0 Maximum width 1.5 in. In A I'
in. (152,4 mm) to (38,l mm) in any check

other disbonds or direct ion
delaminations. No
nearer than 1.5 in.
(38,l mm) to core
edge
No nearer than 8.0 Maximum 2.0 in. l1A l1

in. (203,2 mm) to (50,8 mm) across in check
other damage. No any direction
surface cracking.
Repair no later
than "CM check
Delamin- 2, 6, No nearer than 6.0 Maximum width 0.75 in. WAN
ation 7 in. (152,4 mm) to (19,05 mm) in any check

other delaminations. direction
No nearer than 1.5
in. (38,l mm) to
core edge
Delamin- 5 Extending no more IIAII

ation than 15 percent of check
joint length and
no more than 0.20
in. (5,08 mm) to
edge of joint strip
54-10-01
Page 108
R P r i n t e d i n Great B r i t a i n July 1/05
-.
P
"" RB211 TRENT
MANUAL
STRUCTURAL REPAIR
COMMON NOZZLE ASSEMBLY

See 54-40-01
THRUST REVERSER COWL

See 54-30-01
FAN COWL
See 54-20-01
FOR AIR INTAKE COWL

See detail 1
Air Intake Cowl Skin - Allowable Damage

54-10-01
Page 109
Printed in Great B r i t a i n July 1/05
p
'"" RB211 TRENT
MANUAL
STRUCTURAL REPAIR
ACCESS DOOR
OUTER SKlN I
LOWER INNER ACCESS DOORS

BARREL PANEL
>.:.:.,: DETAIL l
:c+>- -
ZONE 1 OUTER SKlN PANELS
INNER BARREL PANELS
ZONE 2 - INNER BARREL PANELS
I
H ZONE 3 - LlPSKlN INNER
1
-WOVEN FlBER INNER
;;aZONE 4 - LlPSKlN OUTER
:..::.:::.::. ZONE 5 - SPLICE JOINTS
.. ..... SECTION A-A
- FACE SHEET
HONEYCOMB
CORE
ZONE 6 -WOVEN FlBER INNER FACE SHEET
ZONE 7 - HONEYCOMB CORE
Air Intake Cowl Skin - Allowable Damage

EFFECT1VITY:TRENT
54-10-01
Page 110
R P r i n t e d in Great B r i t a i n July 1 / 0 5
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
AIR INTAKE COWL - SKIN - LIST OF APPROVED REPAIRS
REPAIR NO. REPAIR DESCRIPTION
1 LIPSKIN SEGMENT REPLACEMENT REPAIR

(FRS 2001)
2 LIPSKIN INSERT PATCH REPAIR

(FRS 2002)
' i
3 LIPSKIN INNER EDGE PATCH REPAIR

(FRS 2003)
4 AERODYNAMIC SEALANT REPLACEMENT

(FRS 2014)
5 OUTER SKIN DELAMINATION REPAIR

(FRS 2005)
6 OUTER SKIN SURFACE DAMAGE REPAIR

(FRS 2006)
7 OUTER SKIN HOLE REPAIR

(FRS 2007)
8. ACOUSTIC STRUCTURE SURFACE DAMAGE REPAIR

(FRS 2008)
9 REPLACE DEFECTIVE AND/OR MISSING RIVETS

(FRS 2017)
10 ACCESS PANELS SURFACE DAMAGE REPAIR

(FRS 2012)
11 REPLACE DECALS
(FRS 5085)
12 ACOUSTIC PANEL FACING SHEET REPAIR

(FRS 2020)
13 AIR INTAKE COWL - ACOUSTIC STRUCTURE PENETRATION

(FRS 2025) REPAIR
14 AIR INTAKE COWL - LIP SKIN OUTER EDGE. PATCH REPAIR

'l
(FRS 2004)
15 LIPSKIN OUTER EDGE PATCH REPAIR

(FRS 2015)
. ..
,...-I
.T' .
EFFECTIVITY : TRENT LIST OF REPAIRS
Page 201
Printed in Great Britain Mar. 10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
R 16 AIR INTAKE COWL OUTER SKIN SURFACE DAMAGE REPAIR AND

R (FRS 2027) STIFFENER FASTENER RE-INSTALLATION
R 17 AIR INTAKE COWL OUTER SKIN HOLE REPAIR AND

R (FRS 2028) STIFFENER FASTENER RE-INSTALLATION . . .., ,... .
LIST OF REPAIRS
54-10-01
Page 202
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR NO. 1 (FRSZ0011
AIR INTAKE COWL - LIP SKIN SEGMENT REPLACEMENT REPAIR
1. General
A. This repair may be used to repair damage to the lip skin of the
air intake cowl.
B. This repair removes the damaged area and installs a replacement

segment.
Referenced Information
.....................................................................
.....................................................................
54-02-03 Protective Treatment - Metallic
Surfaces
54-02-10 Fasteners - Installation/Removal
54-10-01, Repair No.4 Aerodynamic Sealant Replacement
Suction cleaner
Standard workshop tools
.....................................................................
.....................................................................
Omat 135 METHYLETHYLKETONE
R OMat 150 ACETONE (Alternative to MEK)
OMat 175D CHROMATE CONVERSION COATING
R OMat 2/101 LINT-FREE CLOTH
R LOCAL SUPPLIER ALUMINIUM ALLOY 2219-T31*;0.063 in. (1,60
R mm) THICK
OMat 262 MARKING PEN
OMat 4/47 JOINTING COMPOUND
OMat 5/31 WATERPROOF SILICON CARBIDE ABRASIVE PAPER
R
R NOTE: Aluminium Alloy 2219-0 may be used in lieu of 2219-T31, but a
R different heat treatment procedure will be required. Contact
Shorts Repair Engineering for details.
REPAIR NO. 1
EFFECTIVITY: TRENT
54-10-01
Page 201
R Printed in Great a r i t a l n Mar l0 / O R
~
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
C. Repair parts
.....................................................................
PART NO. PART IDENT
.....................................................................
CR2538-5-4 Cherrylock rivet

CR3552-5-4 (alternative) Cherrymax rivet


Solid monel rivet

Lip skin (undrilled)
Lip skin segment 0°-90" (undrilled)
Lip skin segment 90°-1800(undrilled)
Lip skin segment 180"-270"(undrilled)
Lip skin segment 270"-0" (undrilled)
Alternatives:
Cherrylock rivets CR2538 may be used in lieu of solid monel
rivets MS20427M5, if the hole size is increased to suit (ref.
paragraph 10.E (4) .
Cherrymax rivets CR3552 may be used in lieu of solid monel rivets
MS20427M5 and Cherrylock rivets CR2538.
D. Component Material
.....................................................................
PART IDENT MATERIAL
.....................................................................
Lip skin Aluminium Alloy
REPAIR NO. 1
EFFECTIVITY : TRENT
54-10-01
Page 202
R P r l n t e d in Great Britaln Mar.lo/Oa
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
Clean the Repair Area
WARNING: METHYLETHYLKETONE AND ACETONE ARE CLASSIFIED AS

HAZARDOUS MATERIALS, WHICH MAY CAUSE INJURY OR ILLNESS
IF NOT PROPERLY USED. THESE PRODUCTS SHOULD BE USED
ONLY IN ACCORDANCE WITH THE MANUFACTURER'S SPECIFIC
SAFETY AND HEALTH RECOMMENDATIONS. PRIOR TO USE OF
THESE PRODUCTS, CAREFULLY READ THE APPLICABLE "MATERIAL
SAFETY DATA SHEET" AND FOLLOW ALL LISTED SAFETY AND
HEALTH PRECAUTIONS.
A. Clean the lip skin of the air intake cowl with OMat 135
METHYLETHYLKETONE (or alternative OMat 150 ACETONE) and OMat
2/101 LINT-FREE CLOTH. Wipe the area dry before the solvent
evaporates.
Prepare the Damaged Area for Repair (Ref Fig. 201)
A. Make a mark around the damaged area of the lip skin to be

removed with an OMat 262 MARKING PEN. The cut lines must be
at right angles or parallel to the airflow (except where it
is necessary to have hole edge distances for the rivets).
WARNING: PUT ON PROTECTIVE CLOTHING, GLOVES AND GOGGLES WHEN YOU

USE CUTTING TOOLS.
CAUTION: MAKE SURE THAT YOU DO NOT CAUSE DAMAGE TO THE

DISTRIBUTION RING OF THE ENGINE ANTI-ICING SYSTEM.
B. Drill out the rivets and the Hi-loks within the repair area.
Also drill out approximately 12 off Hi-loks and approximately
12 off rivets either side of the repair area on the inner lip
skin side and approximately 12 off rivets either side of the
repair area on the outer lip skin side, using standard
workshop tools (Ref SRM TASK 54-02-10).
CAUTION: MAKE SURE THAT YOU DO NOT CAUSE DAMAGE TO THE ANTI-
ICING DUCT ANGLES OR THE AIR INTAKE COWL LIP SKIN.
C. Lift the lip skin in the repair area away from the attachment
angle. Use the standard workshop tools.
D. Make a protection plate to go between the lip skin and the

attachment angle. Make sure that the plate is smooth and has
no sharp edges.
REPAIR NO. 1
EFFECTIVITY : TRENT
54-10-01
Page 203
R P r i n t e d in Great Brirain Mar.10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
R E. Carefully put the protection plate between the lip skin and the
R attachment angle. Make sure there is no unwanted material
R between the interfaces.
R 6. Cut Out the Damaged Area of the Lip Skin ( ~ e f

p-pFig.201)
--
R WARNING: PUT ON PROTECTIVE CLOTHING, GLOVES AND GOGGLES WHEN YOU

R USE CUTTING TOOLS.
R CAUTION: MAKE SURE THAT YOU DO NOT CAUSE DAMAGE TO THE ANTI-
R ICING DUCT ANGLES OR THE AIR INTAKE COWL LIP SKIN.
R A. Use standard workshop tools to cut out the damaged area.
R B. Remove the jointing compound from the joint faces.

R C. Trim and deburr the edges of the repair cut-out.
(1) Make sure you keep hole edge distance for the rivets (2 X
dia typ).
(2) Use the OMat 5/31 WATERPROOF SILICON CARBIDE ABRASIVE
PAPER.
R 7. Apply Surface Protection to the Bare Edges
WARNING : CHROMATE CONVERSION COATING IS CLASSIFIED AS A HAZARDOUS

MATERIAL, WHICH MAY CAUSE INJURY OR ILLNESS IF NOT
PROPERLY USED. THIS PRODUCT SHOULD BE USED ONLY IN
ACCORDANCE WITH THE MANUFACTURER'S SPECIFIC SAFETY AND
HEALTH RECOMMENDATIONS. PRIOR TO USE OF THIS PRODUCT,
CAREFULLY READ THE APPLICABLE "MATERIAL SAFETY DATA
SHEET" AND FOLLOW ALL LISTED SAFETY AND HEALTH
PRECAUTIONS.
R A. Apply the OMat 175D CHROMATE CONVERSION COATING to the bare

R edges of the repair cut-out (Ref. 54-02-03, Protective
R Treatment - Metallic Surfaces).
REPAIR NO.1
EFFECTIVITY : TRENT
54-10-01
Page 204
R Erlnted in Great Brltaln M ~ YI n /nn
R8211 TRENT
STRUCTURAL REPAIR
MANUAL
R 8. Examine the Anti-Ice Ring
R A. Examine the anti-ice ring at the repair area for the

R following types of damage: friction, gouged, cracked, nicked,
R scratched, pierced, rubbed, dented, bent.
NOTE: If the depth of the dent damage is more than 0.015

in. (0,38 mm), refer to SHORT BROTHERS Plc., BELFAST.
If any other damage has been sustained to the anti-
ice ring, refer to SHORT BROTHERS Plc.
9. Make the Repair Parts (Ref Fig.203, Fig.204, Fig.205 and Fig.206)
R
A. Mark out the repair segment.
R
R
(1) Refer to the cut-out for the dimensions of the segment.
NOTE: The segment must be taken from the same part of the
replacement lip skin (SJ30060) as the cut-out in the
damaged lip skin. Alternatively the segment may be
taken from the same area on a replacement lip skin
segment as the cut-out in the damaged lip skin (Refer
to Figure 202) .
R (2) Use an OMat 262 MARKING PEN.
R B. Mark out the butt straps.
NOTE: The mark must be more than 3.6 in. (91 mm) away from
the repair segment identified in step 9.A. This will
keep the approved minimum butt strap width.
R C. Mark out the rivet plate.
(1) Use an OMat 262 MARKING PEN and a strip of 0.025 in.
(0,635 mm) thick ALUMINIUM ALLOY 2219-0. Alternatively
use ALUMINIUM ALLOY 7075-0. Any other temper of 2219 or
7075 may also be used.
(2) The rivet plate must be large enough so that all of the
rivet holes are covered. There are approximately 12 of
these holes on each side of the cut-out (where Hi-lok
fasteners were removed in paragraph 5.B).
REPAIR NO. 1
54-10-01
Page 205
Printed i n G r ~ a tR r i t a i n u,, in /no
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(3) Make sure that the edge distance for each rivet is 0.41
in. (10,41 mm) minimum and that the rivet plate has
sufficient clearance all around.
WARNING: PUT ON PROTECTIVE CLOTHING, GLOVES AND GOGGLES

WHEN YOU USE CUTTING TOOLS.
D. Carefully cut out the repair segment and the butt straps from
the lip skin (SJ30060) or correct replacement lip skin
segment. Cut out the rivet plate from the strip of 0.025 in.
( 0,635 mm) thick ALUMINIUM ALLOY.
(1) Use the standard workshop tools.
(2) Leave a trim allowance on the segment.
E. Use an alternative method if necessary to make the butt

straps.
(1) Use a sheet of 0.063 in. (1.60 mm) thick ALUMINIUM

ALLOY 2219-T31 to make the butt straps.
NOTE: ALUMINIUM ALLOY 2219-0 may be used in lieu of

2219-T31, but a different heat treatment
procedure will be required. Contact Shorts Repair
Engineering for details.
(2) Make the butt straps to the contour of the initial lip
skin, which is not damaged.
(3) Do a fluorescent penetrant crack inspection of the butt

straps (Ref AMM TASK 70-20-02-230-803).
(4) Heat treat the butt straps to T81 condition. Do the

precipitation heat treatment, in a forced air
circulation furnace at 177°C (350°F) for 17-19 hours.
NOTE: If using ALUMINIUM ALLOY 2219-0 in lieu of 2219-

T31, a different heat treatment procedure will be
required (to take to T62 condition). Contact
F. Trim and deburr the repair segment to the correct size.
REPAIR NO.1
54-10-01
Page 206
Printed i n Great B r i t a i n
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(2) The clearance between the cut-out and the repair

segment must be between 0.020 to 0.050 in. (0,51 to
1,27 mm).
R G. Trim and deburr the butt straps, to their correct size.
R (1) Use the standard workshop tools.
(2) The clearance between each butt strap and each

attachment angle must be between 0.020 to 0.050 in.
(0,51 to 1,27 mm) .
R H. Deburr the rivet plate.
R (1) Use the standard workshop tools.
R (2) Make sure all of the rivet plate is deburred.
WARNING: CHROMATE CONVERSION COATING IS CLASSIFIED AS A

HAZARDOUS MATERIAL, WHICH MAY CAUSE INJURY OR ILLNESS
IF NOT PROPERLY USED. THIS PRODUCT SHOULD BE USED ONLY
IN ACCORDANCE WITH THE MANUFACTURER'S SPECIFIC SAFETY
AND HEALTH RECOMMENDATIONS. PRIOR TO USE OF THIS
PRODUCT, CAREFULLY READ THE APPLICABLE "MATERIAL SAFETY
DATA SHEET'' AND FOLLOW ALL LISTED SAFETY AND HEALTH
PRECAUTIONS.
I. Apply the OMat 175D CHROMATE CONVERSION COATING (Ref. 54-02-

R 03, Protective Treatment - Metallic Surfaces) to the repair
R segment butt straps and rivet plate.
R
10. Temporarily Install the Butt Straps and the ~ i v e tPlate ( ~ e f
R
R
Fig.203, Fig.204 and Fig.205)
--
R A. Make a mark along the center of each butt strap. Use an OMat
R 262 MARKING PEN.
R B. When you install each butt strap, align the center of the
R strap with the edge of the lip skin. Use soft faced clamps
R to hold the straps and the rivet plate in position.

R C. Drill the holes in the rivet plate to align with the holes in
R the lip skin and the inner barrel.
REPAIR NO.1
EFFECTIVITY : TRENT
54-10-01
Page 207
R P r l n t e d I n Great Brl1:ain M=? I n / n Q
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(1) Use a 0.1875 in. (4,763 mm) diameter drill and a hole
finder if necessary.
(2) Use a 0.205 in (5,20 mm) diameter drill to finish the

holes for Cherrylock rivets CR2538-6.
R D. Drill the rivet holes in the lip skin through the butt
R straps. Make sure that 2D minimum edge distance and 6D - 8D
R pitch are achieved on all fastener holes (D = fastener
R
diameter) .
(1) Do not drill the holes for the repair segment in the
butt straps at this step.
(2) Do not drill the holes in the repair segment at this

step.
(3) Use a 0.094 in. (2,39 mm) diameter drill and follow the
pattern in Fig.203 and Fig.204.
(3) Use a 0.159 in. (4,05 mm) diameter drill to finish the
rivet holes for solid monel rivets MS20427M5.
Cherrylock rivets CR2538-5 may be used in lieu of solid
monel rivets MS20427M5-6, but the holes must be
finished using 0.177 in (4,50 m) drill at this stage.
NOTE: The countersink depth for the CR2538-5 rivets

will be deeper than for the MS20427M5 rivets.
Take care when countersinking the holes (ref.
paragraph 12.D.(2)) that the holes are
countersunk to the correct depth.
R E. Remove and deburr the rivet plate and butt straps.
R 11. Assemble the Repair Segment (Ref Fig.203, Fig.204 and Fig.205)

R A. Drill the rivet holes in the repair segment to match the

R existing holes.
(1) These holes must align with the holes in the attachment
angles and the inner barrel.
REPAIR NO. 1
EFFECTIVITY : TRENT
54-10-01
P a g e 208
R Printed in Great Brltain Mar ln/nR
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(2) Use a 0.1875 in. (4,76 mm) diameter drill and if

necessary use a hole finder or template at the inner
barrel positions. Use a 0.205 in (5,20 mm) diameter
drill to finish the holes for Cherrylock rivets CR2538-
6.

necessary use a hole finder or template at the outer
skin positions. Use a 0.177 in (4,50 mm) diameter drill
to finish the holes for Cherrylock rivets CR2538-5.
R B. Temporarily install the butt straps and the repair segment.
R C. Drill the rivet holes through the repair segment and the butt
R
pitch are achieved on all fastener holes (D = fastener
R
diameter).
rivet holes for Cherrylock rivets CR2538-5.
R D. Countersink the rivet holes on the air-washed surface of the

R lip skin and the repair segment.
R (1) Use a 100 degree countersink tool.
(2) Countersink the holes until the heads of the rivets are
flush with the surface of the lip skin/repair segment.
NOTE: Each type/size of rivet will require a different

countersink depth. Make sure that each hole is
countersunk to suit the correct rivet.
R
R E. Deburr the edges of the holes in the butt straps and in the
repair segment.
R (1) Remove the butt straps and the repair segment.
(2) If it is necessary, deburr the edges of the holes in

the attachment angles.
(3) Use the standard workshop tools to deburr the holes in

the repair segment and the corresponding holes in the
butt straps.
REPAIR NO. 1
EFFECTIVITY : TRENT
54-10-01
Page 209
R Printed in Great Brltain Mar.10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
R 13. Apply the Surface Protection

DATA SHEET" AND FOLLOW ALL LISTED SAFETY AND HEALTH
PRECAUTIONS.
R
A. Apply the OMat 175D CHROMATE CONVERSION COATING to the bare
R edges of the holes in the butt straps, lip skin, attachment
R angles and the repair segment (Ref. 54-02-03, Protective
R 14. Clean the Repair Area
R A. Remove all unwanted material from the repair area with a

R suction cleaner. Make sure that no unwanted material remains
R between the lip skin and the bulkhead.
R 15. Clean the Repair P a r e

HAZARDOUS MATERIALS WHICH MAY CAUSE INJURY OR ILLNESS
HEALTH PRECAUTIONS.
R A. Clean the repair parts and the inner surface of the lip skin
R with OMat 135 METHYLETHYLKETONE (or alternative OMat 150
R ACETONE) and OMat 2/101 LINT-FREE CLOTH. Wipe the area dry
R before the solvent evaporates.
REPAIR NO.1
54-10-01
Page 210
Printed in Great Britain ~ a r 10/08
.
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
16. Attach -the Repair Parts on to the Lip Skin (Ref Fig.203, Fig.204
- - p
-
--
p
and Fig.205)
WARNING: JOINTING COMPOUND IS CLASSIFIED AS A HAZARDOUS

PRECAUTIONS.
A. Apply jointing compound to the interfaces of the repair parts.
(1) Apply the OMat 4/47 JOINTING COMPOUND to all of the

interfaces.
(2) Let the parts dry for 10 minutes before they are
assembled.
B. On the inner side of the lip skin:
(1) Where the Hi-lok fasteners were previously removed from

the lip skin, (ref. paragraph 5.B) approximately 12 off
holes, either side of the cut-out) attach the lip skin
and the rivet plate in position, using Cherrylock
rivets CR2538-6-4. (Ref. SRM TASK 54-02-10).
(2) Where the rivets were previously removed from the lip
skin, (ref. paragraph 5.B) approximately 12 off holes,
either side of the cut-out) attach the lip skin back to
the inner attachment angle with Cherrylock rivets
CR2538-6-3 (Ref. SRM TASK 54-02-10).
C. On the outer side of the lip skin:
(1) Where the rivets were previously removed from the lip
skin, (ref. paragraph 5.B) approximately 12 off holes,
either side of the cut-out) attach the lip skin back to
the outer skin capping-strap & outer attachment angle
with Cherrylock rivets CR2538-5-4 (Ref. SRM TASK 54-02-
10).
REPAIR NO. 1
54-10-01
Page 211
Printed in G r e a t B r i t a i n M=V I n/nR
R8211 TRENT
STRUCTURAL REPAIR
MANUAL
D. Wet assemble the butt straps to the lip skin and attach in
R
position with solid monel rivets MS20427M5-6 (Ref. SRM TASK
R
R 54-02-10).
NOTE: MS20427M5 Rivets must be squeezed. Cherrylock rivets

CR2538-5-4 may be used in lieu of solid monel rivets
MS20427M5-6, if holes have been finished using 0.177 in
(4,50 mm) drill (ref. paragraph 10.E. (4)).
R E. Make sure there is no swarf or any unwanted materials in the

R ' D 1 chamber. Attach the repair segment temporarily with
R clipper pins.
R F. Rivet the repair segment to the inner barrel edge with

R Cherrylock CR2538-6-4 rivets (Ref. SRM TASK 54-02-10).
R G. Rivet the repair segment to the outer skin side with

R Cherrylock CR2538-5-4 rivets (Ref. SRM TASK 54-02-10).
R
H. Rivet the repair segment to the butt straps with Cherrylock
R
CR2538-5-4 rivets (Ref. SRM TASK 54-02-10).
R
R I. Rivet the repair segment to the inner attachment angle repair
with Cherrylock CR2538-6-3 rivets (Ref. SRM TASK 54-02-10).
R
R J. Make sure that the repair segment is flush with the initial
lip skin.
R A. Apply aerodynamic sealant to the repair area (Ref: SRM Repair

R FRSZO14).
R 18. Make an Inspection of the Repair
R A. Do a visual inspection to make sure that the repair has been

R done in accordance with these procedures.
R 19. Record the Repair
R A. Vibro-etch the repair scheme number "FRSZ001" onto the nose

R cowl modification record plate.
REPAIR NO. 1
54-10-01
Page 212
Printed in G r e a t B r i t a i n Mar.10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
Air Intake Cowl Lip Skin - Details of the Repair Cut-out

Figure 201
REPAIR N O . l
EFFECTIVITY : TRENT
54-10-01
Page 213
R Prlnted in Great B r 1 t : a i n 10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
Air Intake Cowl Lip Skin -

Details of the Replacement Lip Skin Segments
Figure 202
REPAIR NO. 1
EFFECTIVITY : TRENT
Page 214
R Printed in Great Britain Mar l 0 / O R
-
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
REPLACEMENT
(Undr'lled) REPLACEMENT LIPSKIN
SEGMENT (Undrilled)
/,---l
I
l
CUT OUT THE

REPAIR SEGMENT
AND BUTT STRAPS
NOTE: D = diameter of repair rivet

2D = minimum edge distance
3D = typical distance between rows
6D = minimum pitch between rivets
6D MINIMUM
l
i
2D MINIMUM P -
CENTER LINE
RIVET PATTERN
l
L
%
R A i r Intake C o w l L i p S k i n R e p a i r S e g m e n t - C u t f r o m R e p l a c e m e n t L i p
R S k i n / L i p S k i n S e g m e n t - D e t a i l s of R e p a i r P a r t s and R i v e t P a t t e r n
R F i g u r e 203
REPAIR NO. 1
54-10-01
P a g e 215
P r l n t e d in Great Britain M=- I n / n R
R8211 TRENT
STRUCTURAL REPAIR
MANUAL
-,
A i r Intake C o w l L i p S k i n R e p a i r S e g m e n t - A s s e m b l y o f t h e R e p a i r P a r t s
F i g u r e 204
REPAIR NO. 1
54-10-01
Page 216
P r l n t e d in Great Britain Mar l n /nQ
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR
SEGMENT
_ 1'
/-
..
+ MS20427M5
SOLID RIVETS
CR2538-5
CHERRYLOCK RIVETS
0 CR2538-6
CHERRYLOCK RIVETS
+ ORIGINAL RIVETS
ORIGINAL HI-LOKS
+by
OUTER SKIN
INTAKE BARREL
, , ,
ATTACHMENT
BUTT STRAP BUTT STRAP ATTACHMENT

PLATE ATTACHMENT ANGLE ANGLE
r
SECTION SECTION
0,51 TO 1,27 mm
F-F
--~ G-G
-
( O02 TO o 05 I")
CLEARANCE
1 , l
LIPSKIN
BUTT STRAP SECTION REPAIR
SEGMENT
H-H
A i r I n t a k e Cowl L i p S k i n R e p a i r S e g m e n t - I n s t a l l a t i o n of the R e p a i r
Parts
F i g u r e 205
REPAIR NO.l
EFFECTIVITY : TRENT
54-10-01
P a g e 217
R Prlnted in Great B r l t a l n Mar 1 n /nF(
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR NO. 2 (FRSZ002)
AIR INTAKE COWL - LIP SKIN INSERT PATCH REPAIR
1. General
air intake cowl.
B. This repair removes the damaged area and installs aluminium

alloy butt straps and an aluminium alloy patch.
.....................................................................
Surfaces
54-02-10 Fasteners - Installation/Removal
AMM TASK 70-20-02-230-804 Water Washable Fluorescent Penetrant
Inspection
A. Standardequipment
Suction cleaner
.....................................................................
.....................................................................
OMat 135 METHYLETHYLKETONE
R OMat 150 ACETONE (Alternative to MEK)
R LOCAL SUPPLIER ALUMINIUM ALLOY 2219-T31*;0.063 in. (1,60
R mm) THICK

R Shorts Repair Engineering for details.
REPAIR N0.2
EFFECTIVITY: TRENT
54-10-01
Page 201
U,
, l n /no
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
C. Repair parts
.....................................................................
PART NO. PART IDENT


Solid monel rivet

Alternatives:
paragraph lO.D(3) 1 .
Cherrymax rivets CR3552 may be used in lieu of Cherrylock rivets
CR2538.
.....................................................................
PART IDENT MATERIAL
.....................................................................
Lip skin Aluminium Alloy
REPAIR N0.2
54-10-01
Page 202
Prlnted ln Great Brltaln Mar.l O / O A
R8211 TRENT
STRUCTURAL REPAIR
MANUAL
WARNING:
-.p
METHYLETHYLKETONE AND ACETONE ARE CLASSIFIED AS
HEALTH PRECAUTIONS.
R
R
R 2/101 LINT-FREE CLOTH. Wipe the area dry before the solvent
R evaporates.
R 5. Examine the Damaged Area (Ref Fig.201)
R A. The damage (which includes cracks) must be more than 5.55 in.
R (139,7 mm) from the edge of the lip skin at the outer skin
R attachment point and 6.25 in. (158,7 mm) from the edge of the
R lip skin at the inner barrel attachment point.
R 6. Removethe Damaged Area (Ref Fig.201)
R A. Make a mark around the damaged area of the lip skin with the
R Omat 262 MARKING PEN. Make sure the area to be removed is
R rectangular in shape.
NOTE: The edge of the area to be removed must be parallel to

the edge of the lip skin.
R
USE CUTTING TOOLS.
R
R CAUTION: MAKE SURE THAT YOU DO NOT CAUSE DAMAGE TO THE
R DISTRIBUTION RING OF THE ENGINE ANTI-ICE SYSTEM. IN SOME
R LOCATIONS THE ANTI-ICE DISTRIBUTION RING IS ONLY 1.18 IN.
R (30,O MM) AWAY FROM THE LIP SKIN.
R B. Use standard workshop tools to cut out the damaged area of

R the lip skin, making sure the corners have a radius of at
R least 0.5 in. (12,7 m m ) .
REPAIR NO.2
54-10-01
Page 203
Mar.10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(1) Make sure you keep the minimum distances from the edges
of the lip skin (ref. Paragraph 5.A).
(2) Use the Omat 5/31 WATERPROOF SILICON CARBIDE ABRASIVE

PAPER.
R D. Remove all unwanted material with a suction cleaner. Make sure
R that no unwanted material remains between the front bulkhead
R
and the lip skin.
R 7. Apply Surface Protection to the Bare Edges.
WARNING: CHROMATE CONVERSION COATING IS CLASSIFIED AS A HAZARDOUS

PRECAUTIONS.
R edges of the repair cut-out (Ref. 54-02-03, Protective
R 8. Examine the Anti-Ice Rinu

R A. Examine the anti-ice ring at the repair area for the
R following types of damage: friction, gouged, cracked, nicked,
R
scratched, pierced, rubbed, dented, bent.
NOTE: If the depth of the dent damage is more than 0.015 in.
(0,38 mm), refer to SHORT BROTHERS Plc., BELFAST. If
any other damage has been sustained to the anti-ice
ring, refer to SHORT BROTHERS Plc.
R
9. Make the Repair Parts (Ref Fig.203)
R A. Mark out the repair patch.
R (2) Refer to the cut-out for the dimensions of the patch.
REPAIR NO.2
EFFECTIVITY : TRENT
54-10-01
Page 204
R Printed in Great B r i t a l n M = r If l /nQ
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(3) The patch must be taken from the same part of the
damaged lip skin. Alternatively the patch may be taken
from the same area on a replacement lip skin segment as
the cut-out in the damaged lip skin (Refer to Figure
202).
B. Mark out the butt straps.
(1) Use an OMat 262 MARKING PEN to mark the outline of the
butt straps.
(2) The marked outline must be more than 2.5 in. (63,s m)
away from the patch identified in step 9.A.. This will

USE CUTTING TOOLS.
C. Use standard workshop tools to cut out the butt straps and
the repair patch.
NOTE: The butt straps can be cut from the repair material as
four pieces (Ref Fig.203).
D. Use an alternative method if necessary to make the butt

straps.


procedure will be required. Contact Shorts Repair
Engineering for details.
skin which is not damaged.

REPAIR N0.2
54-10-01
P a g e 205
U-, 'l n /no
RB211 TRENT
STRUCTURAL REPAIR
MANUAL

circulation furnace at 177OC (350°F) for 17-19 hours.

T31, a different heat treatment procedure will
be required (to take to T62 condition). Contact
E. Trim and deburr the repair patch to the correct size.
(2) The clearance between the cut-out and the repair patch
must be between 0.020 to 0.050 in. (0,51 to 1,27 mm).
F. Trim and deburr the butt straps to their correct size.
(2) Make a mark along the center of the four butt straps
with the OMat 262 MARKING PEN.
(3) Put the two end butt straps on the inner side of the lip
skin and align the center with the edge of the cut-out.
Hold the straps in position with soft-faced clamps, see
fig 203.
(4) Cut the side butt straps and attach them to the lip skin
between the end butt straps. Align the center with the
edge of the cut-out. The clearance between the side and
end butt straps must be between 0.020 to 0.050 in. (0,51
to 1,27 m ) , see fig 203.
( 5 ) Remove and deburr the four butt straps using OMat 5/31
WATERPROOF SILICON CARBIDE ABRASIVE PAPER.
G. Apply the OMat 175D CHROMATE CONVERSIONCOATINGto the repair

patch and butt straps (Ref. SRM TASK 54-02-03).
Temporarily Install the Butt Straps and the ~ e p a i rPatch (Ref

Fig.203)
R
A. Make a mark for two rows of rivets on the lip skin using the
R
OMat 262 MARKING PEN.
REPAIR N0.2
EFFECTIVITY : TRENT
54-10-01
Page 206
Prlnted In Great Brltaln Mar 1 n/nR
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(1) Make a mark for the first row of rivet holes at a pitch
of approximately 0.90in. (22,9 mm) and a distance of
0.350 (8,8 mm) from the edge of the repair cut-out.
(2) Make a mark for the second row of rivet holes

approximately 0.50 in. (12,7 mm) (3D) away from the
first row of rivet holes. Ensure the rivet positions
form a staggered pitch to give 6D - 8D pitch on all
fastener holes (D = fastener diameter).
B. Make a mark along the center of each butt strap. Use an OMat
262 MARKING PEN.
C. Temporarily attach each butt strap, aligning the center of

the strap with the edge of the lip skin. Use soft faced
clamps to hold the straps in position.

USE CUTTING TOOLS.
D. Drill the rivet holes in the lip skin through the butt
straps. Make sure that 2D minimum edge distance and 6D - 8D
diameter).
(1) Do not drill the holes for the repair patch in the butt
straps at this step.
pattern previously marked (ref. Fig.202 and Fig.203).
rivet holes for solid monel rivets MS20427M5. Cherrylock
rivets CR2538-5 may be used in lieu of solid monel
rivets MS20427M5-6, but the holes must be finished using
0.177 in (4,50 m) drill at this stage.

Take care when countersinking the holes that the
holes are countersunk to the correct depth.
E. Use a 100 degree countersink tool to countersink the rivet

holes on the external side of the lip skin. The rivet heads
are to be smooth with the surface of the lip skin.
REPAIR N0.2
54-10-01
P a g e 207
In
. Inn
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
R F. Remove the butt straps and deburr the holes in the lip skin
R and the butt straps. Use standard workshop tools.
R 11. Drill the Rivet Holes for the L ~ D

Skin Patch (Ref Fia.204)
R A. Temporarily install the butt straps, and the repair patch.

R Put the patch onto the repair cut-out in the correct position
R for installation. The clearance between the cut-out and the
R
patch must be between 0.020 to 0.050 in. (0,51 to 1,27 mm).
R
R B. Make a mark for two rows of rivets on the repair patch using
R the OMat 262 MARKING PEN, the rivets should be staggered as
R per fig 204.
(1) Do not make a mark for a rivet hole on the apex of the
lipskin leading edge.
(2) Make a mark for the first row of rivet holes at a pitch
of approximately 0.90in. (22,9 mm) and a distance of
0.350 (8,8 mm) from the edge of the repair cut-out.
( 3 ) Make a mark for the second row of rivet holes

approximately 0.50 in. (12,7 mm) (3D) away from the
first row of rivet holes. Ensure the rivet positions
form a staggered pitch to give 6D - 8D pitch on all
fastener holes (D = fastener diameter).
R
R
USE CUTTING TOOLS.
R
R C. Hold the patch in the correct position and drill the rivet
R holes through the repair patch and the butt straps. Take care
R not to drill into or damage the Thermal Anti-Icing
R disribution ring below. Make sure that 2D minimum edge
R distance and 6D - 8D pitch are achieved on all fastener holes
R (D = fastener diameter).
rivet holes for Cherrylock rivets 2538-5.
R D. Countersink the rivet holes on the external side of the patch
R
using a 100 degree countersink tool. The rivet heads are to
R
be smooth with the surface of the patch.
R
REPAIR N0.2
EFFECTIVITY : TRENT
54-10-01
Page 208
R P r l n t e d in Great Britaln M=+ i n / n n
RB211 TRENT
STRUCTURAL REPAl R
MANUAL
E. Remove the repair patch and the butt straps and deburr the
holes in the lip skin and the butt straps. Use standard
workshop tools.
F. Apply the OMat 175D CHROMATE CONVERSION COATING to the bare

edges of the holes in the repair patch and the butt straps
(Ref. SRM TASK 54-02-03).
12. Clean the Repair Area
A. Remove all unwanted material from the repair area with a

suction cleaner. Make sure that no unwanted material remains
between the lip skin and the bulkhead.
13. Clean the Repair Parts

HEALTH PRECAUTIONS.
A. Clean the inner side of the patch and the four butt straps
using OMat 135 METHYLETHYLKETONE (or alternative OMat 150
ACETONE) and OMat 2/101 LINT-FREE CLOTH. Wipe the area dry
before the solvent evaporates.
14. Install the Butt Straps (Ref Fig.203)
WARNING: JOINTING COMPOUND IS CLASSIFIED AS A HAZARDOUS MATERIAL,

WHICH MAY CAUSE INJURY OR ILLNESS IF NOT PROPERLY USED. THIS
PRODUCT SHOULD BE USED ONLY IN ACCORDANCE WITH THE
MANUFACTURER'S SPECIFIC SAFETY AND HEALTH RECOMMENDATIONS.
PRIOR TO USE OF THIS PRODUCT, CAREFULLY READ THE APPLICABLE
"MATERIAL SAFETY DATA SHEET" AND FOLLOW ALL LISTED SAFETY AND
HEALTH PRECAUTIONS.
A. Apply jointing compound to the interfaces of the repair

parts.

interfaces.
REPAIR N0.2
EFFECTIVITY: TRENT
54-10-01
Page 209
R P r l p t e d I n G r e a t Brlraln MS,- In / n Q
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
assembled.
R B. Use a grip gauge to find the rivet shank length required.
R C. Wet assemble the four butt straps to the lip skin in the
R correct position and attach with squeeze rivets MS20427M5-6
R
(Ref. SRM TASK 54-02-10, FASTENERS - INSTALLATION/REMOVAL).
R
NOTE: Rivets must be squeezed. Cherrylock rivets CR2538-5-
4 may be used in lieu of solid monel rivets
MS20427M5-6, if holes have been finished using 0.177
in (4,50 mm) drill (ref. paragraph 10 .D(3).
Install the Lip Skin Patch (Ref Fig.204)
A. Make sure there is no swarf or any unwanted materials in the

' D f chamber.
WARNING: JOINTING COMPOUND IS CLASSIFIED AS A HAZARDOUS MATERIAL

WHICH MAY CAUSE INJURY OR ILLNESS IF NOT PROPERLY USED.
THIS PRODUCT SHOULD BE USED ONLY IN ACCORDANCE WITH THE
MANUFACTURER'S SPECIFIC SAFETY AND HEALTH
RECOMMENDATIONS. PRIOR TO USE OF THIS PRODUCT,
PRECAUTIONS.
R
B. Apply jointing compound to the interfaces of the repair
parts.

interfaces.
assembled.
R C. Attach the patch to the four butt straps in the correct

R position and install the Cherrylock rivets CR2538-5-3 and
R CR2538-5-4 (Ref. SRM TASK 54-02-10, FASTENERS -
R INSTALLATION/REMOVAL).
REPAIR NO. 2
54-10-01
Page 210
Prlnted in Great Britain Mar. 10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL

SAFETY AND HEALTH RECOMMENDATIONS. PRIOR TO THE USE OF
HEALTH PRECAUTIONS.
A. Remove the unwanted jointing compound from the repair area.
B. Clean the repair area with OMat 135 METHYLETHYLKETONE (or

alternative OMat 150 ACETONE) and OMat 2/101 LINT-FREE CLOTH.
Wipe the area dry before the solvent evaporates.
17. Apply Aerodynamic Sealant
A. Apply aerodynamic sealant to the repair area (Ref: SRM Repair

FRSZ014).
18. Make an Inspection of the Repair
A. Do a visual inspection to make sure that the repair has been

done in accordance with these procedures.
19. Record the Repair
A. Vibro-etch the repair scheme number "FRSZ002" onto the nose

cowl modification record plate.
REPAIR NO.2
EFFECTIVITY : TRENT
54-10-01
Page 211
R Printed in Great S r i t a i n ~ a r10/08
.
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
- ,
AREAOF 1 1 0 ID 1
REPAIR C i,
- >
,, , l
i 0
1
L
1
2
Air Intake C o w l L i p S k i n - D e t a i l s of t h e R e p a i r C u t - o u t
F i g . 201
REPAIR NO. 2
EFFECTIVITY : TRENT
54-10-01
P a g e 212
Printed in Great Britain M a r . 10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
Air Intake Cowl Lip Skin - Details of the Replacement Lip Skin Segments
Fig. 202
REPAIR N0.2
54-10-01
Page 213
P r i n t e d in G r e a t B r i t a i n Mar. 10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
- PATCH IDENTIFICATION
REPLACEMENT LlPSKlN OR
REPLACEMENT SEGMENT
- BUTT STRAP
IDENTIFICATION
- .-

20 = minimum edge distance
6D = minimum pitch between r~vets \
LIPSKI N
POSITION OF CENTER LINE OF

THE RIVETS THE BUTT STRAP
3~ 'b..
,
(D
(D
0
0
E
5 (The dimensions for the rivet THE BUTT STRAPS RIVETED IN POSITION
ON THE LIPSKIN CUT-OUT
holes in the lipskin)
A i r I n t a k e Cowl L i p S k i n - D e t a i l s of the R e p a i r P a t c h and the
B u t t Straps
F i g u r e 203
REPAIR N0.2
54-10-01
P a g e 214
Printed in Great Brltain M=, i n / n ~
RB211 TRENT
STRUCTURAL REPAIR
m MANUAL
.l.
RING
THE PATCH RIVETED IN POSITION THE BUTT STRAPS RIVETED IN POSITION

ON THE LlPSKlN CUT-OUT ON THE LlPSKlN CUT-OUT

6D = minimum pitch between rivet
2D MINIMUM
POSITION OF
THE RIVETS
MAXIMUM DIMENSION
1,27 mm (0.05 in)
6D MINIMUM
LlPSKlN -/-
BUTT STRAP .. ,m I
i\' ; \
3D "--. .. PATCH
THE PATCH IN POSITION ON

(The dimensions for the rivet THE LIPSKIN CUT-OUT
holes in the patch)
A i r I n t a k e Cowl L i p S k i n - A t t a c h the R e p a i r P a r t s
F i g u r e 204
REPAIR N 0 . 2
EFFECTIVITY : TRENT
54-10-01
P a g e 215
R Printed in Great B r i t a l n
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
AIR INTAKE COWL - LIP SKIN INTAKE SIDE EDGE PATCH REPAIR
1. General
A. This repair may be used to repair damage to the lip skin intake
side edge on the air intake cowl.
B. This repair removes the damaged area and installs a repair

patch.
C. Damage extending beyond the highlight cannot be repaired to

FRSZ003.
.......................................................................
54-02-03 Protective Treatment - Metallic Surfaces

54-02-10 Fasteners - ~nstallation/~emoval
Inspection
A. Standardequipment
Suction cleaner
.......................................................................
R OMat 135 METHYLETHYLKETONE
OMat 150 ACETONE (Alternative to MEK)
R OMat 175D CHROMATE CONVERSION COATING
R LOCAL SUPPLIER ALUMINIUM ALLOY 2219-T31*;0.063 in. (1,60 mm) THICK

R Shorts Repair Engineering for details.
REPAIR NO. 3
54-10-01
Page 201
P r i n t e d i n Great B r i t a i n
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
C. Repair parts
.....................................................................
PART NO. PART IDENT
.....................................................................




Solid monel rivet

Lip skin segment 180"-270°(undrilled)
Alternatives:
n
R
paragraph 12.F(4)).
R
R Cherrymax rivets CR3552 may be used in lieu of Cherrylock rivets
R CR2538.
.....................................................................
PART IDENT MATERIAL
.....................................................................
R Lip skin Aluminium Alloy
REPAIR NO. 3
EFFECTIVITY : TRENT
54-10-01
Page 202
R Prlnted In Great E r l t a ~ n Mar.10/08
RB211 TRENT
STRUCTURAL REPAlR
MANUAL
WARNING:
~.. METHYLETHYLKETONE AND ACETONE ARE CLASSIFIED AS
HEALTH PRECAUTIONS.
A. CleanthelipskinoftheairintakecowlwithOMat135
R
R
R 2/101 LINT-FREE CLOTH. Dry the area with a clean OMat 2/101
R LINT-FREE CLOTH while the solvent is still wet.
R 5. Prepare the Damaged Area for ~epair(Ref ~ig.201)
R A. Make a mark around the damaged area of the lip skin to be

R removed with an OMat 262 MARKING PEN. The cut lines must be
R at right angles to the airflow (except where it is necessary
R to have hole edge distances for the rivets). Make sure that
R the corners of the cut out have a minimum radius of 0.50 in.
R (12,7 mm).

R
R
DISTRIBUTION RING OF THE ENGINE ANTI-ICE SYSTEM.
R
R B. Drill out the rivets contained within the repair area joining
R the inner height angles to the lipskins. Also remove
R approximately 12 off rivets either side of the repair area
R using standard workshop tools (Ref. SRM TASK 54-02-10).
R C. Remove all 3/16 Hi-loks HL633-6-5 within the repair area

R joining the intake barrel to the lipskin. Also remove
R approximately 12 off Hi-loks either side of the repair area
R (Ref. SRM TASK 54-02-10).
R CAUTION:
p---p
MAKE SURE THAT YOU DO NOT CAUSE DAMAGE TO THE ANTI-
R ICING DUCT ANGLES OR THE AIR INTAKE COWL LIP SKIN.
R D. Lift the lip skin in the repair area away from the attachment
R
REPAIR N0.3
54-10-01
Page 203
Printed in Great Britaln MS,,- ln / n Q
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
E. Make a protection plate to go between the lip skin and the

no sharp edges.
F. Carefully put the protection plate between the lip skin and
the attachment angle. Make sure there is no unwanted
material between the interfaces.
Cut Out the Damaged Area of the Lip Skin (Re£ Fig.201)

USE CUTTING TOOLS.
A. Use standard workshop tools to cut out the damaged area of

the lip skin, making sure that the corners have a radius of
at least 0.5 in (12,7 mm).
B. Remove the jointing compound from the joint faces.
C. Trim and deburr the edges of the repair cut-out.
(1) Make sure you keep hole edge distance for the rivets
(minimum edge distance = 2D, D = fastener diameter).

PAPER.
Apply Surface Protection to the Bare Edges
WARNING: CHROMATE CONVERSION COATING IS CLASSIFIED AS A HAZARDOUS

PRECAUTIONS.

edges of the repair cut-out (Ref. 54-02-03, Protective
Treatment - Metallic Surfaces).
REPAIR N0.3
54-10-01
Page 204
Prlnted in G r e a t B r i t a i n
RB211 TRENT
STRUCTURAL REPAlR
MANUAL
8. Examine the Anti-Ice Ring

-
A. Examine the anti-ice ring at the repair area for the

following types of damage: friction, gouged, cracked, nicked,

9. Make the Repair Parts (Re£ Fig.203)
A. Mark out the repair patch.
(1) Use an OMat 262 MARKING PEN.
(2) Refer to the cut-out for the dimensions of the patch.
(3) The patch must be taken from the same part of the
damaged lip skin. Alternatively the patch may be taken
from the same area on a replacement lip skin segment as
the cut-out in the damaged lip skin (Refer to Figure
202) .
(2) The mark must be at least 3.6 in. (91 mm) away from the
repair patch identified in step 9.A.

USE CUTTING TOOLS.
C. Carefully cut out the repair patch and the butt straps from
the lip skin (SJ30060) or from the correct lip skin segment.
(2) Leave a trim allowance on the patch.

straps.
REPAIR N0.3
EFFECTIVITY: TRENT
54-10-01
Page 205
P r i n t e d in Great Britain
RB211 TRENT
STRUCTURAL REPAIR
MANUAL


procedure will be required. Contact Shorts
Repair Engineering for details.


Note: If using ALUMINIUM ALLOY 2219-0 in lieu of 2219-

(1) Use standard workshop tools.
F. Trim and deburr the butt straps if used to their correct

size.
(2) The clearance between each side butt strap and the
(0,51 to 1,27 mm).
(3) Cut the top butt strap so that it will fit between the
two side butt straps. The clearance between the top
butt strap and each side butt strap must be between
0.020 to 0.050 in. (0,51 to 1,27 mm).
REPAIR N0.3
EFFECTIVITY : TRENT
54-10-01
Page 206
R P ~ l n t e dIn Great B r l t a l n M=.- i n /nrr
RB211 TRENT
STRUCTURAL REPAIR
m MANUAL
10. Prepare the Rivet Plate (Ref Fig.204)
A. Make the rivet plate.
(1) Use a strip of 0.025 in. (0,635 mm) thick ALUMINIUM

ALLOY 2219-0. Alternatively use 7075-0 material. Any
other temper of 2219 or 7075 may also be used.
(2) The rivet plate must be large enough to cover all the
holes where Hi-lok fasteners were removed in paragraph
5.C (approximately 12 off holes on each side of the
cut-out).
(3) Make sure the rivet plate has sufficient clearance all
around with an edge distance for each rivet of at least
0.41 in. (10,41 m m ) .
B. Use standard workshop tools to deburr all of the rivet plate.
11. Apply Surface Protection to the Rivet Plate, the Butt Straps and
the Packers if used

HAZARDOUS MATERIAL WHICH MAY CAUSE INJURY OR ILLNESS IF
NOT PROPERLY USED. THIS PRODUCT SHOULD BE USED ONLY IN
PRECAUTIONS.
A. Apply the OMat 175D CHROMATE CONVERSION COATING to the rivet

plate, the butt straps (Ref. SRM TASK 54-02-03).
12. Temporarily Install the Butt Straps and the Rivet Plate (Ref
Fig.203, Fig.204, Fig.205 and Fig.206)
A. Make a mark along the center of each butt strap. Use an OMat
262 MARKING PEN.
B. When you install each butt strap, align the center of the
strap with the edge of the lip skin. Use soft faced clamps
to hold the straps in position.
REPAIR NO.3
EFFECTIVITY : TRENT
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Page 207
R P r i n t e d in G r e a t Britain
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
D. Temporarily attach the rivet plate to the outer lip of the

inner barrel.

USE CUTTING TOOLS.
E. Drill the rivet holes in the rivet plate.
(1) The rivet holes must align with the rivet holes in the
lip skin and the inner barrel.

necessary a hole finder.
(3) Use a 0.205 in (5,20 mm) diameter drill to finish the

holes for Cherrylock rivets CR2538-6.
F. Drill the rivet holes through the lip skin and the butt
straps. Make sure that 2D minimum edge distance and 6D-8D
diameter).
(1) Do not drill the rivet holes in the repair patch at

this stage.
(2) Do not drill the rivet holes for the repair patch in
the butt-straps at this stage.
pattern in Fig.203.
rivet holes for solid monel rivets MS20427M5.
Cherrylock rivets CR2538-5 may be used in lieu of solid
monel rivets MS20427M5-6 but the holes must be finished
using 0.177 in. (4.50 mm) drill at this stage.

paragraph 13.C) that the holes are countersunk
to the correct depth.
G. Remove the rivet plate and the butt straps and deburr the
holes in the lip skin, the packers if used, the butt straps
and the rivet plate. Use standard workshop tools.
REPAIR N 0 . 3
54-10-01
Page 208
Printed in C r e ~ tRritaln l,-- 1n / n o
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
13. Assemble the Repair Patch (Ref Fig.203 and Fig.204)

USE CUTTING TOOLS.
A. Make a metal template to determine the rivet pitch on the

attachment angle. Mark the location on the lipskin for
reassembly purposes.
B. Drill the rivet holes through the repair patch and the butt
straps. Temporarily secure with 5/32 in. clipper pins.
pattern in Fig.203.
rivet holes for Cherrylock rivets CR2538-5.
(3) Using the template, drill the hole pattern for the
attachment angle through the repair patch. Use a 0.205
in. (5,20 mm) diameter drill to finish the rivet holes
for Cherrylock rivets CR2538-6.
C. Countersink the rivet holes on the air-washed surface of the

lip skin and the repair patch.
(1) Use a 100 degree countersink tool.
in line with the surface of the lip skin/repair patch.

D. Deburr the edges of the holes in the butt straps and the
repair patch.
(1) Remove the butt straps and the repair patch.
(2) If it is necessary, deburr the hole edges of the

attachment angle.
(3) Use standard workshop tools to deburr the holes in the

repair patch and the corresponding holes in the butt
straps.
REPAIR N0.3
EFFECTIVITY : TRENT
54-10-01
Page 209
R P r i n t e d I n Great Brit-ain
RB211 TRENT
STRUCTURAL REPAIR
m MANUAL

HAZARDOUS MATERIAL WHICH MAY CAUSE INJURY OR ILLNESS IF
NOT PROPERLY USED. THIS PRODUCT SHOULD BE USED ONLY IN
PRECAUTIONS.

R edges of the holes in the butt straps, lip skin, attachment
R angle and the repair patch (Ref. SRM TASK 54-02-03).

R suction cleaner. Make sure that no unwanted material remains
R between the lip skin and the bulkhead.
R 16. Clean the Repair Parts

HEALTH PRECAUTIONS.
R with OMat 135 METHYLETHYLKETONE (or alternative OMat 150
R ACETONE) and OMat 2/101 LINT-FREE CLOTH. Dry the area with a
R clean OMat 2/101 LINT-FREE CLOTH while the solvent is still
R wet.
REPAIR NO.3
54-10-01
Page 210
.
p RB211 TRENT
MANUAL
STRUCTURAL REPAIR
17. Attach the Re~airParts on to the L ~ D

Skin (Ref Fia.204)

PRECAUTIONS.

parts.

interfaces.
assembled.
B. Use a grip gauge to determine the rivet shank length

required. Change the length of the fasteners stated below, if
necessary.
C. Insert the rivet strip behind the intake barrel and temporary
secure with 3/16 in. clipper pins.
D. Where the Hi-lok fasteners were previously removed from the

lip-skin, (ref. paragraph 5.C) approximately 12 off holes
either side of the cut-out) attach the original lip-skin and
the rivet plate in position, using Cherrylock rivets CR2538-
6-4 (Ref. SRM TASK 54-02-10).
E. Where the rivets were previously removed from the lip skin,
(ref. paragraph 5.B) approximately 12 off holes, either side
of the cut-out) attach the original lip skin back to the
inner attachment angle with Cherrylock rivets CR2538-6-3
(Ref. SRM TASK 54-02-10).
REPAIR NO.3
54-10-01
Page 211
P r i n t e d i n Great Britain Mar. 10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
F. Put the buttstraps in position and temporary secure with 5/32

in. clipper pins.
G. Use solid monel rivets MS20427M5-6 to rivet the buttstraps

and packers to the lip skin (Ref SRM TASK 54-02-10).
NOTE: Rivets must be squeezed. Cherrylock rivets CR2538-5-4

may be used in lieu of solid monel rivets MS20427M5-6,
if holes have been finished using 0.177" (4,50 mm)
drill (ref. paragraph 12.F (4)) .
H. Check that there is no swarf, or any foreign materials in the

'D' chamber before temporary securing the repair patch to the
outer angle and butt straps.
I. Where the Hi-lok fasteners were previously removed from the

lip-skin (ref. paragraph 5.C), use Cherrylock rivets CR2538-
6-4 to rivet the repair patch to the inner barrel and the
rivet plate (Ref. SRM TASK 54-02-10).
J. Where the rivets were previously removed from the lip skin,
(ref. paragraph 5.B), use Cherrylock rivets CR2538-6-3 to
rivet the repair patch to the inner attachment angle (Ref.
SRM TASK 54-02-10).
K. Use Cherrylock rivets CR2538-5-4 to rivet the repair patch to

the buttstraps (Ref. SRM TASK 54-02-10).
Apply Aerodynamic Sealant

FRSZ014).
Make an Inspection of the Repair

Record the Repair
A. Vibro-etch the repair scheme number \\FRSZ003"onto the nose

cowl modification recozd plate.
REPAIR NO. 3
EFFECTIVITY: TRENT
54-10-01
Page 212
R Prlnted in Great Britaln Mar. 10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
RIVET POSITIONS
HI-LOK POSITIONS
A i r Intake C o w l Lip S k i n - D e t a i l s of the R e p a i r C u t - O u t

F i g u r e 201
REPAIR NO. 3
P a g e 213
P r i n t e d in G r e a t B r i t a i n Mar I 0 / O R
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
A i r I n t a k e Cowl L i p S k i n - D e t a i l s of the R e p l a c e m e n t L i p S k i n
Segments
F i g u r e 202
REPAIR NO. 3
EFFECTIVITY: TRENT
P a g e 214
R Printed in Great Britaln M a r . 10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
REPLACEMENT
LIPSKIN (Undr~lled)
REPLACEMENT LIPSKIN
SEGMENT (Undr~lled)
LIPSKIN
PROFILE
BUTT
CUT OUT THE
PATCH AND
BUTT STRAPS

6D MINIMUM
\
':
I
.~.
a-:
--
- - -
BUTT STRAP
I-
r !-I l
l
+ + + l I
+ + +
2D MINIMUM -C +I + + +
- - - - - - -
CENTER LINE -
4 + + + + + l
I I
2D MINIMUM L; + + + +PT
rl ~
RIVET PATTERN
A i r Intake C o w l L i p S k i n R e p a i r P a t c h - D e t a i l s of the R e p a i r
P a t c h and the R i v e t P a t t e r n
F i g u r e 203
REPAIR N0.3
EFFECTIVITY : TRENT
54-10-01
P a g e 215
R Printed in Great Britaln M a r . 10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
INTAKE BARREL
LIPSKIN i
',
0 MS20427M5
SOLID RIVETS
CR2538-5
CHERRYLOCK RIVETS
0 CR2538-6
CHERRY LOCK RIVETS
+ ORIGINAL RIVETS
ORIGINAL HI-LOKS
PATCH INTAKE BARREL
RIVET
ATTACHMENT
PLATE
BUTT STRAP ANGLE
SECTION
E-E
Air Intake Cowl Lip Skin Repair Patch - Installation of the
Repair Parts
Figure 204
REPAIR NO. 3
54-10-01
Page 216
P r i n t e d in G r e a t B r l t a i n Mar. l0 / 0 A
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
-- -- REPAIR--NO.
4 (FRSZO14)
AIR INTAKE COWL - AERODYNAMIC SEALANT REPLACEMENT
- 1. General
A. This procedure may be used to repair damage to the aerodynamic sealant of
the air intake cowl.
B. This repair removes the damaged sealant and installs new sealant.
.-C 2. Referenced Information

-a
TBD
.-
Q)
6 3. Equipment and Material
.-
C
-
U
Q)
.-
C
Equivalent materials and equipment may be used.
a' A. Standard Equipment

Suction cleaner
Standard workshop tools and equipment
- -- -- - -- - - - -- - - .--
.....................................................
OMat 2/30 TEFLON TAPE
OMat 212 BRUSH
OMat 2/101 LINT-FREE CLOTH
OMat 876C PRIMER
OMat 8/143 SEALANT (DOW CORNING)
C. Special Tools
None.
D. Repair Parts
None.
REPAIR No.4
Page 201
Dec. 15/96
RB.211 TRENT
ap STRUCTURAZ, REPAIR
MANUAL
E. C o m p o n e n t M a t e r i a l - ---
................................................................
PART D E N T MATERIAL
Air Intake C o w l C o m p o s i t e structure
4. P r e p a r e the repair area (Ref Figure 201)
CAUTION: DO NOT CAUSE DAMAGE TO THE ANODIZED SURFACE OF THE L I P SKIN OR THE
ACOUSTIC STRUCTURE. USE ONLY PLASTIC TOOLS AND PUT PROTECTIVE MATS 2
3
ON THE COWL. G
a
-.
A. Remove the sealant 3
4
CD
(1) U s e a p l a s t i c s p a t u l a t o r e m o v e as m u c h of t h e d a m a g e d o r d i s b o n d e d 2
sealant as you can.
5
E.
B. P u t a s t r i p of t h e T e f l o n t a p e (OMat 2 / 3 0 ) on e a c h side of t h e repair area. 3
5. C l e a n t h e repair area
WARNING: METHYLETHYLKETONE I S CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY
CAUSE INJURY OR ILLNESS I F NOT PROPERLY USED. THIS PRODUCT SHOULD
BE USED ONLY I N ACCORDANCE WITH THE MANUFACTURER'S S P E C I F I C SAFETY
AND HEALTH RECOMMENDATIONS. PRIOR TO USE OF THIS PRODUCT, CAREFULLY
READ THE APPLICABLE "MATERIAL SAFETY DATA SHEET" AND FOLLOW ALL
LISTED SAFETY AND HEALTH PRECAUTIONS.
CAUTION: DO NOT CAUSE DAMAGE TO THE ANODIZED SURFACE OF THE LIPSKIN OR THE
ACOUSTIC STRUCTURE. USE ONLY THE SPECIFIED MATERIALS AND PUT
PROTECTIVE MATS ON THE COWL.
A. Remove t h e r e m a i n i n g sealant and clean the repair area.
(1) S o a k t h e w a t e r p r o o f s i l i c o n carbide a b r a s i v e p a p e r (OMAT 5/31) i n t h e

m e t h y l e t h y l k e t o n e (OMat 135).
( 2 ) Rub t h e repair area w i t h t h e s o a k e d a b r a s i v e p a d a n d f u l l y r e m o v e t h e

sealant a n d c o n t a m i n a t i o n .
(3) Wipe t h e area w i t h a clean piece of l i n t f r e e c l o t h (OMat 2 / 1 0 1 ) before

the f l u i d dries.
.. REPAIR No .4
EFFECTIVITY: TRENT
Page 202
D e c . 15/96
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
6. Apply the primer- - -
ACOUSTIC STRUCTURE. USE ONLY THE SPECIFIED MATERIALS AND PUT
0 PROTECTIVE MATS ON THE COWL.
(D
0
0
o A. Mix the primer (OMat 876C) in accordance with the manufacturer's
0
o
a
instructions. Use the brush (OMat 212) to apply a thin layer of the
U primer.
.-Cm (1) Let the primer dry at ambient temperature. It will dry in
.-
C
approximately 2 hours at 71.6 deg.F (22 deg.C).
L
2
C
m NOTE: When the primer is dry it can have a dull finish or dusty chalk
E
U on the surface.
.-
C
U
P)
7. Prepare the aerodynamic sealant (Method 1)
C
.-C
a' WARNING: AERODYNAMIC SEALANT IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY
CAUSE INJURY OR ILLNESS IF NOT PROPERLY USED. THIS PRODUCT SHOULD
BE USED ONLY IN ACCORDANCE WITH THE MANUFACTURER~SSPECIFIC SAFETY
READ THE APPLICABLE "MATERIAL SAFETY DATA SHEET*^ AND FOLLOW ALL
A. Mix the sealant (OMat 8/143) in accordance with the manufacturer' S
instructions. Do not use a mechanical device to mix the sealant.
(l) Use the sealant, a clean metal or plastic container and a spatula.
(2) Mix the sealant in a proportion of 10 parts by weight of the base (Part
A) to 1 part by weight of the catalyst (Part B). Mix the materials
together fully.
-
NOTE: If the sealant contains air which results in poor adhesive
properties use method 2 to mix a new batch.
8. Prepare the aerodynamic sealant (Method 2) to avoid air entrapment creating
air bubbles in the sealant
WARNING: AERODYNAMIC SEALANT IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY
CAUSE INJURY OR ILLNESS IF NOT PROPERLY USED, THIS PRODUCT SHOULD
BE USED ONLY IN ACCORDANCE WITH THE MANUFACTURER~SSPECIFIC SAFETY
READ THE APPLICABLE "MATERIAL SAFETY DATA SHEET" AND FOLLOW ALL
.-- - REPAIR No.4

EFFEeTIVITY: TRENT
54-10-0 1
Page 203
Der; 15/96
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
A; Mix the s e a l a n t (-OMat--81143) i n a c c o r d a n c e with t h e manufacturer's

instructions. Do n o t u s e a mechanical device t o m i x t h e s e a l a n t .
(1) Use t h e s e a l a n t , a c l e a n m e t a l o r p l a s t i c c o n t a i n e r and a s p a t u l a .
(2) Mix t h e s e a l a n t i n a p r o p o r t i o n of 10 p a r t s by weight of t h e b a s e ( P a r t

A) t o 1 p a r t by weight of t h e c a t a l y s t ( P a r t B). Mix t h e m a t e r i a l s
together f u l l y .
B. Remove t h e a i r from t h e s e a l a n t .
(1) Put t h e s e a l a n t i n a vacuum chamber.
(2) Remove t h e a i r from t h e chamber c r e a t i n g a vacuum p r e s s u r e of 22 i n c h e s

of mercury (minimum) and l e t t h e s e a l a n t s t a y i n t h e chamber f o r 20
minutes.
9. Apply the aerodynamic s e a l a n t (Ref F i g u r e 201)

WARNING: AERODYNAMIC SEALANT IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY
BE USED ONLY I N ACCORDANCE WITH THE MANUFACTURER'S SPECIFIC SAFETY
READ THE APPLICABLE ''MATERIAL SAFETY DATA SHEET" AND FOLLOW ALL
ACOUSTIC STRUCTURE. USE ONLY THE SPECIFIED MATERIAtS AND PUT
PROTECTIVE MATS ON THE COWL.
A. F i l l t h e r e p a i r area with t h e s e a l a n t (OMat 8/143).
(1) Use a p l a s t i c s p a t u l a o r a s y r i n g e ( a s y r i n g e w i l l g i v e t h e b e s t
results).
(2) The t o p of t h e s e a l a n t must be l e v e l with, o r l e s s than 0.010in. (0,25

mm) below t h e s u r f a c e of t h e cowl.
B. Cure t h e s e a l a n t
(1) Let t h e s e a l a n t cure f o r 10 hours a t 77 deg.F (25 deg.C).

(2) A f t e r 1 hour t h e s e a l a n t w i l l be t a c k f r e e ( t h e s e a l a n t w i l l be a t
maximum s t r e n g t h i n 7 days).
-
NOTE: A 9 deg.F (5 deg.C) i n c r e a s e i n t h e cure temperature d e c r e a s e s
t h e c u r e time by one h a l f . A 9 deg.F (5 deg.C) d e c r e a s e i n t h e
c u r e temperature i n c r e a s e s t h e c u r e time by a f a c t o r of 2.
--
REPAIR No. 4
Page 204
Dec. 15/96
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
C . When the s e a l a n t - has-curedi remove the Teflon tape (OMat 2/30) from each
side of the repair area.
10.Examine the repair area (Ref Figure 201)
A. Do a v i s u a l inspection t o make sure that the repair has been done i n

accordance with these procedures.
REPAIR No. 4
Page 205
Dec. 15/96
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
AERODYNAMIC SEALANT
BETWEEN THE LIP SKIN AND
AIR INTAKE COWL
THE ACOUSTIC PANELS
DAMAGED SEALANT
TEFLON TAPE
LIP SKIN ACOUSTIC PANEL
I
I I 1 1 I I , I
l , ,
I /
l
1
I I
SECTION B-B SECTION B-B

(With the damaged sealant removed)
THE SEALANT MUST BE LEVEL WITH,OR LESS THAN

0.010 in. (0,25 mm) BELOW,SURFACE OF THE COWL
SECTION B-B
(With the replacement sealant applied to the repair area)
R e p l a c e Aerodynamic S e a l a n t
Figure 201
REPAIR No.4
54-10-0 1
Page 206
Dec. 15/96
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR N0.5 (FRSZ005)
AIR INTAKE COWL - OUTER SKIN DELAMINATION REPAIR
1. General
A. This repair may be used to contain the early stages of local

delamination in the plies of the outer skin. It applies only
where no actual rupture (discontinuity) of the plies is
evident.
B. Repair must be carried out under controlled conditions:

temperature must be maintained at 68 to 77 deg.F (20 to 25
deg.C) and the humidity at 50 percent or less.
C. Damage is restricted to a maximum of 10 inch dia.
D. Where damage is beyond the scope of this repair, refer to

Rolls-Royce plc. '
None.
Heat lamp
Hand drill
Sonic Test Equipment
.....................................................................
-------.--------------------------------------------------------------
OMat 13 5 METHYLETHYLKETONE
OMat 21114 LINT-FREE GLOVES
R OMat 262 MARKING PEN
OMat 81160 EA 9390 TWO PART EPOXY ADHESIVE
C. Special Tools
None.
REPAIR N0.5
54-10-01
Page 201
Printed in Great B r i t a i n Jun. 10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
D. Repair parts
None.
E. Component Material
.....................................................................
PART IDENT MATERIAL
......................................................................
Air Intake Cowl Composite structure
Clean the Intake Cowl
WARNING: METHYLETHYLKETONE ARE CLASSIFIED AS HAZARDOUS

MATERIALS, WHICH MAY CAUSE INJURY OR ILLNESS IF NOT
PROPERLY USED. THESE PRODUCTS SHOULD BE USED ONLY IN
HEALTH RECOMMENDATIONS. PRIOR TO USE OF THESE
PRODUCTS, CAREFULLY READ THE APPLICABLE 'MATERIAL
HEALTH PRECAUTIONS.
A. Clean the damaged areas of the intake cowl with OMat 135
METHYLETHYLKETONE and OMat 2/101 LINT-FREE CLOTH. Wipe the
area dry before the solvent evaporates.
5. Examine the Outer Skin (Ref. Fig. 201)
A. Determine the amount of delamination using the sonic test

equipment and mark the approximate outline area. Use an OMat
R 2 62 temporary marker.
B. At the two furthest points make a mark for drilling. Use an

R OMat 262 temporary marker.
6. Prepare the Outer Skin for Repair
WARNING: WEAR PROTECTIVE CLOTHING, GLOVES, DUST MASK AND SAFETY

GOGGLES. DO NOT BREATHE THE DUST. WHEN COMPOSITE
MATERIALS ARE CUT OR SANDED, DUST AND LOOSE PARTICLES
ARE MADE WHICH ARE POTENTIAL HEALTH HAZARDS.
CAUTION: USE A DRILL STOP TO PREVENT THE DRILL EXTENDING INTO

THE SOUND BONDED STRUCTURE. DRILL THROUGH ONE PLY AT A
TIME (OR AS NEAR AS POSSIBLE) UNTIL THE START OF THE
DELAMINATION IS REACHED.
REPAIR N0.5
54-10-01
Page 202
Printed in Great Britain Jun. 10/08
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
6. P r e p a r e t h e O u t e r S k i n f o r R e p a i r (Ref Fig.201)
WARNING: WEAR PROTECTIVE CLOTHING, GLOVES, DUST MASK AND SAFETY GOGGLES. DO
NOT BREATHE THE DUST. WHEN COMPOSITE MATERIALS ARE CUT OR SANDED,
DUST AND LOOSE PARTICLES ARE MADE WHICH ARE POTENTIAL HEALTH
HAZARDS.
CAUTION: USE A DRILL STOP TO PREVENT THE DRILL EXTENDING INTO THE SOUND
BONDED STRUCTURE. DRILL THROUGH ONE PLY AT A TIME (OR AS NEAR AS
POSSIBLE) UNTIL THE START OF THE DELAMINATION I S REACHED.
A. Use a hand d r i l l and d r i l l a 0.062 i n . ( 1 , 5 8 mm) d i a m e t e r h o l e a t e a c h of

t h e p o s i t i o n s marked i n s t e p 5.B.
B. Remove a l l unwanted m a t e r i a l from t h e r e p a i r a r e a w i t h a s u c t i o n c l e a n e r .
7 . Dry t h e R e p a i r Area
A. Thoroughly d r y t h e r e p a i r a r e a b e f o r e p r o c e e d i n g t o t h e r e p a i r . With
s u i t a b l e h e a t l a m p s , keep t h e t e m p e r a t u r e of t h e r e p a i r a r e a a t 176 deg F
(80 deg C) f o r s i x h o u r s .
8. F i l l t h e R e p a i r Area (Ref Fig.201)
WARNING: EA 9390 EPOXY ADHESIVE I S CLASSIFIED AS A HAZARDOUS MATERIAL WHICH

MAY CAUSE I N J U R Y OR ILLNESS I F NOT PROPERLY USED. THIS PRODUCT
SHOULD BE USED ONLY I N ACCORDANCE WITH THE MANUFACTURER'S SPECIFIC
SAFETY AND HEALTH RECOMHENDATIONS. PRIOR TO USE OF THIS PRODUCT,
CAREFULLY READ THE APPLICABLE 1 1 SAFETY ~
DATA SHEET"
~ AND ~ ~
FOLLOW ALL LlSTED SAFETY AND HEALTH PRECAUTIONS.
NOTE: The f o l l o w i n g p r o c e s s must b e s t a r t e d b e f o r e t h e end o f t h e d r y i n g

o p e r a t i o n i n s t e p 7.A.
A. Mix t h e E4 9390 epoxy a d h e s i v e P a r t A and P a r t B i n a c c o r d a n c e w i t h t h e

manufacturer's instructions.
B. Remove t h e h e a t l a m p s used p r e v i o u s l y f o r d r y i n g t h e r e p a i r a r e a .
C. F i l l a s u i t a b l e disposable syringe w i t h t h e adhesive.
D. I n s e r t t h e s y r i n g e i n t o one o f t h e d r i l l e d h o l e s and s l o w l y i n j e c t t h e
a d h e s i v e u n t i l i t b e g i n s t o e s c a p e f r e e l y from t h e o t h e r d r i l l e d h o l e .
EFFECTIVITY: TRENT REPAIR N0.5
Page 203
June 15/97
RB.211 TRENT
m STRUCTURAL REPAIR
MANUAL
9. Clean t h e R e p a i r Area
WARNING: METHYL ETHYL KETONE I S CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY

READ THE APPLICABLE "MATERIAL SAFETY DATA SHEET1' AND FOLLOW ALL
A. Remove a l l unwanted a d h e s i v e and d i r t from t h e r e p a i r a r e a u s i n g t h e OMat

135 METHYL ETHYL KETONE and OMat 21101 LINT-FREE CLOTH. Wipe t h e a r e a d r y
before t h e solvent evaporates.
10.Cure t h e F i l l e r M a t e r i a l
Use a h e a t lamp t o keep t h e temperature of t h e r e p a i r a r e a a t 200 deg F (95

deg C) f o r 220 mins. The r a t e of temperature i n c r e a s e and subsequent d e c r e a s e
must n o t be g r e a t e r t h a n 5.5 deg F ( 3 deg C) i n e a c h minute.
11.Examine t h e R e p a i r Area
A. Using t h e s o n i c t e s t equipment examine t h e r e p a i r f o r any s i g n s of

incomplete f i l l i n g o r d e l a m i n a t i o n .
B. I f f i l l i n g i s found t o be incomplete o r delamination i s found, r e p e a t s t e p s

6. through 10.
Page 204
June 15/97
RB.211 TRENT
MANUAL
DR ILL HOLE
0.062in. ( 1,58mmI
AREA OF DELAMINATION
I
ADHESIVE FILL
OUTER SKIN
NOTE: Not all the areas of the outer skin

have the same number of plies
A i r I n t a k e Cowl - D e l a m i n a t i o n R e p a i r
F i g u r e 201
EFFECTIVITY: TRENT REPAIR N 0 . 5
P a g e 205
J u n e 15/97
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
AIR INTAKE COWL - OUTER SKIN SURFACE DAMAGE REPAIR
1. General
A. This repair may be used to repair damage to the composite

layers of the outer skin of the intake cowl where rupture
(discontinuity) of the plies has occurred.

temperature must be maintained at 20 to 25 deg C (68 to 77 deg
F) and the humidity at 50 percent or less.
C. Refer to SRM 54-10-01, Page Block l, structure identification

for correct number and orientation of plies in area of damage.
D. This repair scheme covers damage up to and including 6 inches

dia. For damage greater than this contact Rolls-Royce plc.
E. This repair scheme covers damage restricted to the main area of

the skin. The damage must be separated from other areas of
damage to allow all the repair plies to be seated correctly.
The damage must be far enough from the edges of the skin and
all fastener positions to allow all the plies to seat
correctly.
F. Some cowls may have fasteners in the main area of the outer
skin at the skin stiffener locations (ref. SRM 54-10-01). If
the repair area contains fasteners through the stiffeners,
FRS2027 is to be implemented instead of this repair scheme.
--------------------------*------------------------------------------
.....................................................................
54-02-04 Repair Paint Finish
54-10-01, REPAIR No. 7 Outer Skin Hole Repair (FRSZ007)
54-10-01 Identification
54-01-06 Tap Test
AMM TASK 70-20-01-100-802 Cleaning
Heat blanket, 0 to 120 deg C (32 to 248 deg F)
REPAIR N0.6
54-10-01
Page 201
Printed i n Great B r i t a i n Jun. 10/08
RB211 TRENT
STRUCTURAL REPAIR
Heatlamp, 70 to 90 deg C (158 to 194 deg F)
Vacuum suction pump, 0 to 30 in. (0 to 762 mm) of mercury
Temperature probes, 0 to 120 deg C (32 to 248 deg F)
Steel roller, 2.0 in. (50,8 mm) diameter, 2.0 in. (50,8 mm)
long
Suction cleaner
B. Corlsumable materials
.....................................................................
.....................................................................
OMat 150 ACETONE
OMat 212 BRUSH
OMat 2/31 VACUUM BAG
OMat 2/111 BREATHER CLOTH
OMat 2/112 POROUS PARTING FILM
OMat 2/113 NON-POROUS PARTING FILM
OMat 2/114 LINT-FREE GLOVES
OMat 5/31 WATERPROOF ABRASIVE PAPER
OMat 884 FIBREGLASS FABRIC
OMat 8/206A 8 HARNESS SATIN WEAVE 3K-135-8H CARBON CLOTH
OMat 2/32 SEALING PUTTY
OMat 8/160 EA 9390 EPOXY ADHESIVE
R OMat 262 MARKER PEN
C. Component Material
.....................................................................
PART IDENT MATERIAL
------------.---------------------------------------------------------
Air Intake Cowl Composite Structure
4. Examine the Repair Area (Ref Fig.201)
A. Tap Test in accordance with SRM 54-01-06 to make sure there are
no delaminations and make a visual inspection of the damage.
Using standard workshop tools, measure the depth of the damage.
Make sure that the damage is within the limits of this repair
scheme.
REPAIR N0.6
54-10-01
Page 202
RB211 TRENT
STRUCTURAL REPAIR
B. Make a note of the depth of the damage, and calculate the

number of carbon repair plies necessary to repair the damage as
follows :
-----,----------------------------------------------------------------
DEPTH OF DAMAGE NO. OF PLIES REQUIRED

.....................................................................
Up to 0.013 in. (0,33 mm) 2
0.014 in. (0,35 mm) to 0.026 in. (O,66 mm) 3
0.027 in. (0,68 mm) to 0.039 in. (0,99 mm) 4
0.040 in. (1,Ol mm) to 0.052 in. (1,32 mm) 5
0.053 in. (1,34 mm) to 0.065 in. (1,65 mm) 6
0.066 in. (1,67 mm) to 0.078 in. (1,98 mm) 7
If the damage goes through the panel, do SRM Repair No. 7

(FRSZ007).
If you can not be sure of the depth of the damage install one more
carbon repair ply. For example, if you are not sure if the depth of
the damage is 0.039 in. (0,99 mm) or 0.040 in. (1,Ol mm), use five
carbon repair plies.
WARNING: WHEN YOU DO THIS REPAIR YOU MUST WEAR PROTECTIVE CLOTHING,
GLOVES, DUST MASK AND SAFETY GOGGLES TO PROTECT YOU AGAINST
DUST AND LOOSE PARTICLES, WHICH CAN BE DANGEROUS TO YOUR
HEALTH.
WARNING: WHEN YOU USE CLEANING MATERIALS, COATINGS, ADHESIVES AND

SEALANT, REFER TO THE MANUFACTURER'S CONTROL AND APPLICATION
INSTRUCTIONS AND SAFETY NOTICES.
5. Prepare the Damaged Area for Repair (Ref Fig. 201)
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE PANEL. BE

CAREFUL WHEN YOU REMOVE THE SHARP EDGES OF THE DAMAGE. DO
NOT USE A LIQUID WITH THE ABRASIVE PAPER.
A. Mark out the extent of the repair area on the outer skin using
R an OMat 262 MARKER PEN. To measure the area necessary for the
repair plies, you will need to let 1.0 in. (25,4 mm) from the
edge of the damage for each carbon ply, and add 0.75 in. (19,05
mm) for an outer layer of OMat 884 FIBREGLASS FABRIC.
B. Use OMat 5/31 WATERPROOF ABRASIVE PAPER to remove the paint

from the surface of the outer skin in the repair area. Use the
abrasive paper to make the surface of the repair area rough and
remove the sharp edges of the damage. Take care not to cause
any damage to the carbon plies. Do not increase the dimensions
of the damage.
REPAIR N0.6
Page 203
-H RB211 TRENT
MANUAL
STRUCTURAL REPAIR
R 6. Check the Repair Area for Fasteners
R A. Some cowls can have fasteners installed through the skin

R stiffeners in the main area of the outer skin (refer to SRM 54-
R 10-01 for the locations of the skin stiffeners). If there are
R fasteners installed through stiffeners in the repair area, do
R not continue with this FRS; repair in accordance with FRS027.
R A. Use a suction cleaner to remove dust and debris from the repair
R area (Refer to AMM TASK 70-20-01-100-802).Clean the repair
R area with OMat 150 ACETONE and an OMat 2/101 LINT-FREE CLOTH.
R Wipe the area dry before the solvent dries.
R B. Do a water-break test on the area, apply a water-mist spray to

R the area to ensure that water lays on the surface in an
R unbroken film for 3-5 seconds. If this is not achieved, do the
R cleaning operation and the water-break test again until it is
R successful.
R 8. Dry the Repair Area
R A. Use suitable heat lamps and temperature probes to dry the

R repair area. Keep the temperature at 70 deg C (158 deg F) for a
R minimum of 6 hours. The repair materials must be applied
R immediately after the drying period.
R 9. Mask around the Repair Area (Ref Fig. 201)
R A. Mask around the repair area with OMat 2/30 TEFLON TAPE.
R Calculate the distance that the tape must be from the damage as
R follows:
(1) Measure 1.0 in. (25,4 mm) from the edge of the damage for
each ply of the panel, which is damaged. Add 0.75 in.
(19,05 mm) for an outer layer of OMat 884 FIBREGLASS
FABRIC.
R (2) Carefully apply the teflon tape so that it goes around the
R area in a 2.0 in. (50,8 mm) wide strip.
(3) Make the corners of the strip of tape at an angle of

approximately 45 degrees with a length of approximately
1.0 in. (25,4 mm).
R 10. Cut the Repair Plies (Ref Fig. 201)
R A. Cut the first carbon repair ply.
REPAIR N0.6
54-10-01
Page 204
P r i n t e d i n Great B r i t a i n Oct. 15/05
RB211 TRENT
lml STRUCTURAL REPAIR
MANUAL
(1) Refer to SRM TASK 54-10-01 Identification for ply

orientation. Put on OMat 2/114 LINT-FREE GLOVES and cut
one piece of OMat 8/206A CARBON CLOTH so that it has a 2.0
in. (50,8 mm) overlap all around the damage.
NOTE: One ply of OMat 884 FIBREGLASS FABRIC will also be

necessary in addition to the specified number of carbon
repair plies.
R B. Cut the carbon repair plies that remain.
(1) Put on OMat 2/114 LINT-FREE GLOVES and use OMat 8/206A
CARBON CLOTH, and cut each subsequent repair ply 2.0 in.
(50,8 mm) longer and 2.0 in. (50,8 mm) wider. There must
be one repair ply for each ply of the panel, which is
damaged.
R C. Cut the fibreglass ply.
(1) Put on OMat 2/114 LINT-FREE GLOVES and cut one piece of
OMat 884 FIBREGLASS FABRIC so that it has a 1.0 in. (25,4
mm) overlap around the area identified by the teflon tape.
R NOTE: To prevent fraying, cut the plies to their finished
R dimensions after they are soaked with adhesive.
R D. Cut the filler ply
(1) To replace the missing material in the damaged area, cut

one extra piece of OMat 8/206A CARBON CLOTH approximately
the same size as the smallest repair ply. This piece will
be cut up and used to fill the damaged area.
R 11. Prepare the Repair Materials
R WARNING: EA 9390 ADHESIVE IS CLASSIFIED AS A HAZARDOUS MATERIAL,

R WHICH MAY CAUSE INJURY OR ILLNESS IF NOT PROPERLY USED.
R THIS PRODUCT SHOULD BE USED ONLY IN ACCORDANCE WITH THE
R MANUFACTURER'S SPECIFIC SAFETY AND HEALTH
R RECOMMENDATIONS. PRIOR TO USE OF THIS PRODUCT, CAREFULLY
R READ THE APPLICABLE "MATERIAL SAFETY DATA SHEET" AND
R FOLLOW ALL LISTED SAFETY AND HEALTH PRECAUTIONS.
R A. Mix the OMat 8/160 EPOXY ADHESIVE in accordance with the

R manufacturer's instructions. The weight of adhesive necessary
R is 1.1 times the weight of the OMat 8/206A CARBON CLOTH and
R OMat 884 FIBREGLASS FABRIC.
REPAIR N0.6
54-10-01
Page 205
P r i n t e d in Great B r i t a i n Oct. 15/05
R NOTE:
p
"" RB211 TRENT
MANUAL
STRUCTURAL REPAIR
After the plies are soaked, the adhesive that remains (if it
R is kept cool) can be used in the installation procedure.
R B. Soak the carbon repair plies and the fibreglass ply with the
R mixed adhesive.
(1) Put each ply on a sheet of OMat 2/113 NON-POROUS PARTING

FILM.
(2) Apply the adhesive to both sides of each ply with the OMat
212 BRUSH and cover each ply with another sheet of non-
porous parting film.
CAUTION: DO NOT USE TOO MUCH FORCE WHEN YOU ROLL THE PLIES.
THIS MAY DAMAGE AND/OR REMOVE TOO MUCH RESIN FROM
THE PLIES.
R (3) Use the roller to force the adhesive fully into each ply.
(4) Mark the ply direction of the carbon repair plies on the
parting f ilm.
R C. Cut the carbon repair plies and the fibreglass ply to their
R finished dimensions (Ref. Fig. 201).
(1) Cut approximately 1.0 in. (25,4 mm) off each edge of the
plies.
(2) Make sure that the first ply has a 1.0 in. (25,4 mm)
overlap around the damage.
(3) Make sure that each subsequent ply extends 1.0 in. (25,4
mm) more around the damage.
(4) Cut the corners of the repair plies to an angle of

0.5 in. (12,7 mm).
(5) Cut the fibreglass ply so that it is the same shape as the
area identified by the teflon tape.
R A. Let the repair area cool after it has been dried. Refer to AMM
R TASK 70-20-01-100-802.Clean the repair area with OMat 150
R ACETONE and an OMat 2/114 LINT-FREE CLOTH. Rub the repair area
R with a clean piece of lint-free cloth before the solvent dries.
R 13. Fill the Damaged Area (Ref Fig. 201)
REPAIR N0.6
54-10-01
Page 206
Printed in Great Britain Oct. 15/05
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
WARNING: EA 9390 ADHESIVE IS CLASSIFIED AS A HAZARDOUS MATERIAL,

RECOMMENDATIONS. BEFORE THE USE OF THIS PRODUCT,
CAREFULLY READ THE APPLICABLE 'IMATERIAL SAFETY DATA
SHEETt1AND FOLLOW ALL LISTED SAFETY AND HEALTH
PRECAUTIONS.
R A. Take the carbon filler ply and measure out an applicable amount
R of the mixed OMat 8/160 EPOXY ADHESIVE (EA9390) to fill the
R damaged area. The weight of the mixed resin should be 1.1 times
R the weight of the piece of OMat 8/206A CARBON CLOTH.
R B. Cut the fibres of the OMat 8/206A CARBON CLOTH into short
R lengths approximately 0.12 inches (3,O mm) long. Add the cut
R fibres to the mixed OMat 8/160 EPOXY ADHESIVE and mix fully
R into an even paste.
R NOTE: If there are plies missing from the damaged area and the
R damage is more than 0.4 in. (10 mm) wide, the carbon cloth
R should be cut into strips to fill the damage. Apply the
R resin to the ply in an equivalent manner to the other plies
R ref. step ll.B.
R C. Use a clean spatula to fill the damaged area with resin and
R fibres mixture (or pieces of carbon cloth which have been
R soaked in resin). Make sure the damage has been filled level
R with the top carbon ply of the outer skin.
R 14. Install the Repair Plies (Ref Fig. 201)
WARNING: EA 9390 ADHESIVE IS CLASSIFIED AS A HAZARDOUS MATERIAL,

RECOMMENDATIONS. BEFORE THE USE OF THIS PRODUCT,
SHEET' AND FOLLOW ALL LISTED SAFETY AND HEALTH
PRECAUTIONS.
R CAUTION: DO NOT USE TOO MUCH FORCE WHEN YOU ROLL THE PLIES. THIS
R MAY DAMAGE AND/OR REMOVE TOO MUCH RESIN FROM THE PLIES.
R A. Use an OMat 212 BRUSH to apply an equal layer of OMat 8/160

R EPOXY ADHESIVE to all of the repair area.
R B. Install the first repair ply.
REPAIR N0.6
Page 207
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(1) Remove one sheet of OMat 2/113 NON-POROUS PARTING FILM

from the first repair ply.
(2) Make sure the repair plies are installed with the correct
orientation. Refer to SRM TASK 54-10-01 Identification for
ply orientation. Put the first repair ply, with the
adhesive down, onto the repair area. Make sure that the
location of the damage is in the center of the ply.
(3) Use the roller to remove air and unwanted adhesive from
the first repair ply.
(4) Remove the non-porous parting film that remains from the
first repair ply.
R C. Install the next repair ply
(1) Remove one sheet of non-porous parting film from the next
repair ply.
(2) Put this repair ply, with the adhesive side down, onto the
repair area. Make sure that it has the same overlap around
the repair ply from before.
the ply.
(4) Remove the non-porous parting film that remains from this
repair ply.
R D. Install the subsequent repair plies (if necessary)
R (1) Do step 14.C again for the subsequent repair plies.
R E. Remove the teflon tape from around the repair area.
R F. Install the fibreglass ply
(1) Do step 14.C again for the fibreglass ply. Make sure that
it has an equal overlap around the last carbon fibre
repair ply:
R 15. Prepare to Cure the Adhesive (Ref Fig. 202)
R A. Get a heat blanket, which must be larger all around than the
R repair area.
REPAIR N0.6
54-10-01
Page 208
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
R B. Cut a sheet of OMat 2/112 POROUS PARTING FILM. Make sure that
R it is larger than the heat blanket and has a minimum overlap of
R 3.0 in. (76,2 mm) around the fibreglass ply.
R C. Cut the OMat 884 FIBREGLASS CLOTH into sheets the same size as
R the porous parting film. Use the fibreglass cloth as a bleeder
R cloth. The number of sheets of bleeder cloth must be the same
R as the number of carbon fibre plies used in the repair. With
R the exception of the fibreglass sanding ply.
R D. Put the porous parting film onto the repair area. Make sure
R that it has the same overlap around the repair area. Put the
R temperature probes (the number of probes will depend on size of
R repair) on top of the porous parting film. Do this at the edge
R of the repair area. Put the layers of bleeder cloth on top of
R the porous parting film.
R E. Cut a sheet of OMat 2/113 NON-POROUS PARTING FILM. Make sure

R that it is a minimum of 1.0 in. (25,4 mm) smaller all around
R than the bleeder cloth installed in the step above.
R F. Put the non-porous parting film on the repair area. Make sure
R that it has the same overlap around the repair area.
R G. Put the heat blanket on the repair area.
(1) Put the heat blanket on top of the non-porous parting

film. Make sure that the heat blanket has an overlap all
around the repair area. Make sure the temperature probes
are below the heat blanket.
R H. Put the breather cloth on top of the heat blanket.
(1) Cut two sheets of OMat 2/111 BREATHER CLOTH, a minimum of

1.0 in. (25,4 mm) larger all around than the non-porous
parting film.
R (2) Put the two sheets of breather cloth on the heat blanket.
R I. Put the vacuum bag on the repair area.
(1) Use OMat 2/31 VACUUM BAG MATERIAL and OMat 2/32 SEALING
PUTTY.
(2) Make sure that the vacuum bag has an overlap of

approximately 2.0 in. (50,8 mm) around the breather cloth.
(3) Install the vacuum hose from the suction pump so that it
goes directly onto the top sheet of the breather cloth.
REPAIR N0.6
54-10-01
Page 209
p RB211 TRENT
STRUCTURAL
MANUAL REPAIR
(4) Attach and seal the vacuum bag to the cowl with the
sealing putty.
R J. Put the insulation material onto the repair area.
(1) Cut four to six sheets of OMat 2/111 BREATHER CLOTH the
same size as the heat blanket.
(2) Put the breather cloth on top of the vacuum bag above the
heat blanket and attach it with OMat 2/30 TEFLON TAPE.
NOTE: Insulation can be added or removed to get the correct

rate of temperature increase and decrease (Re£ step
16.C).
R 16. Cure the Adhesive
R A. Use the vacuum pump to decrease the pressure in the repair

R area. Make sure it gives an indication of at least 25.0 in.
R (635,O mm) of mercury while the adhesive cures.
R B. Use the heat blanket to keep the temperature of the repair area
R between 90 to 93 deg C (194 and 199 deg F) for 3 hours and 40
R minutes.
R C. The rate of temperature increase and subsequent decrease must

R not be more than 3 deg C (5.5 deg F) in each minute.
R D. Start to measure the cure time when the temperature reaches 90

R deg C (194 deg F).
R 17. Remove the Repair Equipment
R A. When the cure process is completed, remove the lay-up equipment

R and materials from the repair.
R 18. Prepare the Repair Surface
R CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. ONLY
R REMOVE MATERIAL FROM THE EDGE OF THE OUTER PLY. DO NOT
R USE A LIQUID WITH THE ABRASIVE PAPER.
R A. Make all contours of the repair area smooth with OMat 5/31
R WATERPROOF ABRASIVE PAPER. Make sure there is no edge between
R the repair area and the outer skin.
REPAIR N0.6
54-10-01
Page 210
R A.
P RB211 TRENT
MANUAL
STRUCTURAL REPAIR
Remove all unwanted material from the repair area with a

R suction cleaner.
R B. Refer to AMM TASK 70-20-01-100-802. Clean the repair area with

R OMat 150 ACETONE and an OMat 2/101 LINT-FREE CLOTH. Rub the
R repair area with a clean piece of lint-free cloth before the
R solvent dries.
R A. Apply surface protection to the repair area in accordance with

R the standard painting procedures SRM TASK 54-02-04.
R 21. Make an Inspection of the Repair
R A. Tap Test in accordance with SRM 54-01-06 and make a visual

R inspection to make sure that the repair has been done to these
R procedures.
R A. Vibro-etch the repair scheme number "FRSZ006" onto the nose

REPAIR N0.6
54-10-01
Page 211
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
OUTER
SKIN
c - - - - - -
I
0.75in.- 7 r - - -
(18,0511~1) / . \
I
1 f -l
I I I I
A
t
FILLED DAMAGEDAREA
SECTION A-A
Surface Damage Build-Up

Fig. 201
REPAIR N0.6
54-10-01
Page 212
p
'"" RB211 TRENT
STRUCTURAL
MANUAL REPAIR
INSULATION
I
" -
l VACWIA HO%
VACUUM BAG (zz~----

&
t
U
BREATHER CLOTH (2) t
I& ."..C.w-"
- - " . * - " .%
+,*----
p
i -
"we**- .--L
----.rd
SEAUNG PUW
HEAY BLANKET
(Mm4 a v e r tempratwm probes)
i503mm) l
NW-POROUS PARTlMG FfW

C
PbRWs PARnNC; FILM flBREt&~ CLQTF~

TEMPERATURE PROBE (2) 1 t No dptiesequals
OUTER SURFACE
OF REPAIR PmT
Repair Equipment Installation

Fig. 202
REPAIR N0.6
54-10-01
Pase 213
m1
1 STRUCTURAL REPAIR
MANUAL

AIR INTAKE COWL - OUTER SKIN HOLE REPAIR
General
A. This repair may be used to repair damage to the composite

layers of the outer skin of the intake cowl where a hole has
occurred.

temperature must be maintained at 20 to 25 deg C (68 to 77 deg
F) and the humidity at 50 percent or less.
C. This repair removes the damaged area, applies a support plate,

and installs a carbon fibre repair patch.
D. Refer to SRM 54-10-01 structure identification for correct

number and orientation of plies in area of damage.
E. This repair is limited to a maximum damage diameter of 6 in.

(152,4 mm) .
F. Damage which is not within the limits of these repairs must be
referred to Rolls-Royce plc.
G. This repair scheme covers damage restricted to the main area of

the skin. The damage must be separated from other areas of
damage to allow all the repair plies to be seated correctly.
The damage must be far enough from the edges of the skin and
all fastener positions to allow all the plies to seat
correctly.
H. Some cowls may have fasteners in the main area of the outer
skin at the skin stiffener locations (ref. SRM 54-10-01). If
the repair area contains fasteners through the stiffeners,
FRSZ028 is to be implemented instead of this repair scheme.
R I. Any damage sustained to the stiffeners located on the non-air

R wetted side of the outer skin must be referred to Rolls-Royce
R plc for evaluation.
.....................................................................
.....................................................................
R 54-10-01 Identification
R 54-01-06 Tap Test
R AMM TASK 70-20-01-100-802 Cleaning
REPAIR N0.7
54-10-01
Page 201
R P r i n t e d i n Great B r i t a i n Oct. 15/05
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
Vacuum suction pump, 0 to 30 in. (0 to 762 mm) of mercury
Steel roller, 2.0 in. (50,8 mm) diameter, 2.0 in. (50,8 mm)
long
Suction cleaner
High Speed rotary cutter
-----------..---------------------------------------------------------
.....................................................................
OMat 150 ACETONE
OMat 212 BRUSH
OMat 2381 LOCKWIRE
OMat 8/206A CARBON CLOTH
R OMat 262 MARKER PEN
------------.---------------------------------------------------------
PART IDENT MATERIAL
------------.---------------------------------------------------------
Air Intake Cowl Composite Structure
REPAIR N0.7
EFFECTIVITY: TRENT
54-10-01
Page 202
R P r i n t e d i n Great B r i t a i n Jun.10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
4. Examine the Repair Area
A. Tap Test in accordance with SRM 54-01-06 to make sure there are
no delaminations and make a visual inspection of the damage.
Using standard workshop tools, measure the extent of the
damage. Make sure that the damage is within the limits of this
repair scheme.
B. Check the Repair Area for Fasteners
(1) Some cowls may have fasteners installed through the skin
stiffeners in the main area of the outer skin (refer to
SRM 54-10-01 identification for the locations of the skin
stiffeners). If there are fasteners installed through the
skin stiffeners in the repair area, do not continue with
this FRS; repair in accordance with FRSZ028.
HEALTH.

5. Prepare the Damaqed Area for Repair (Fig. 201)

A. Use an OMat 262 MARKER PEN to mark out as identified when

examining the repair area the damaged area of the outer skin to
be removed.
CAUTION: DO NOT CAUSE DAMAGE TO THE OUTER SKIN STIFFENERS IF THE

DAMAGE IS NEAR TO THEM.
B. Cut out the damaged area of the outer skin as marked in the
step above with a high-speed rotary cutter.
(1) Make the edges of the cut-out have an angle of

approximately 45 degrees.
(2) The corners of the cut-out must have a radius of at least

0.5 in. (12,7 mm).
REPAIR N0.7
54-10-01
Page 203
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(3) The length of the cut-out diagonal must be at least the

same as the width of the cut-out plus 2.0 in. (50,8 mm).
C. Make a note of the number of plies that will be necessary for

the repair. There must be one carbon repair ply for each ply of
the outer skin panel, plus one extra carbon repair ply. An
outer fibreglass ply is also necessary. Refer to SRM 54-10-01
identification for the number of plies in the damaged area of
outer-skin.
R D. Use an OMat 262 MARKER PEN to mark out the full extent of the
repair area on the outer skin. To measure the area necessary
for the repair plies, you will need to let 1.0 in. (25,4 mm)
from the edge of the damage for each carbon ply, and add 0.75
in. (19,05 mm) for an outer layer of OMat 884 FIBREGLASS
FABRIC.
E. Use OMat 5/31 WATERPROOF ABRASIVE PAPER to remove the paint

from the surface of the outer skin in the repair area. Use the
abrasive paper to make the surface of the repair area rough and
remove the sharp edges of the damage. Take care not to cause
of the damage.
6. Clean the Repair Area (Fig. 201)
A. Use a suction cleaner to remove dust and debris from the repair
area. Refer to AMM TASK 70-20-01-100-802. Clean the repair area
with an approved solvent (150 ACETONE) and an OMat 2/101 LINT-
FREE CLOTH. Wipe the area dry before the solvent dries.
7. Water Break Test and Dry the Repair Area (Fiq. 201)
A. To ensure that water lays on the surface in an unbroken film

for 3-5 seconds do a water-break test on the area, apply a
water-mist spray to the area. If you cannot get this, repeat
the cleaning operation and the water-break test until it is
successful.
B. Use the applicable heat lamps and temperature probes to dry the
repair area. Keep the temperature at 70 deg C (158 deg F) for a
minimum of 6 hours. The repair materials must be applied
immediately at the end of the drying period.
8. Mask around the Repair Area (Fig. 201 and 202)
A. Mask around the repair area with OMat 2/30 TEFLON TAPE.
Calculate the distance that the tape must be from the damage
as follows:
REPAIR N0.7
EFFECTIVITY: TRENT
54-10-01
Page 204
R P r i n t e d i n Great B r i t a i n Jun. 10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(1) Measure 1.0 in. (25,4 mm) from the edge of the damage for
each ply of the panel. Add 0.75 in. (19,05 mm) for an
outer layer of OMat 884 FIBREGLASS FABRIC.
(2) Carefully apply the teflon tape so that it goes around the
area in a 2.0 in. (50,8 mm) wide strip.

1.0 in. (25,4 m m ) .
Prepare the Support Plate (Fig. 201)
A. Wear OMat 2/114 LINT-FREE GLOVES and cut three pieces of OMat
8/206A CARBON CLOTH with a 2.0 in. (50,8 mm) overlap around the
damage.
NOTE: To prevent fraying, cut the plies to their finished

dimensions after they are soaked with adhesive.
B. Mix the OMat 8/160 EPOXY ADHESIVE in accordance with the

manufacturer's instructions. The weight of adhesive necessary
will be 1.1 times the weight of the OMat 8/206A CARBON CLOTH.
C. Prepare the support plate plies.
(1) Put each carbon fibre ply on a sheet of OMat 2/113 NON-
POROUS PARTING FILM
(2) Apply the same layer of adhesive to the two sides of each
ply with the OMat 212 BRUSH. Cover each ply with another
sheet of non-porous parting film.
(3) Use the roller to push the adhesive into each ply fully.
Do not use too much force as this may damage and/or cause
resin deficiency in the plies.
(4) Cut each ply so it has an overlap of approximately 1.0 in.

(25,4mm) around the repair cutout.
D. Put the plies together to make the support plate.
(1) Remove one sheet of non-porous film from two of the plies.
(2) Remove both sheets of non-porous film from the third ply.
(3) Align the plies and put them with their adhesive sides
together onto a hard, flat surface.
REPAIR N0.7
54-10-01
Page 205
(4) Use the roller to push the plies together. Do not use too
much force as this may damage and/or cause resin
deficiency in the plies.
R A. Put the temperature probes into position adjacent to the

R adhesive .
R B. Use a heat lamp to keep the temperature of the repair area

R between 90 to 93 deg C (194 to 199 deg F) for 3 hours and 40
R minutes.

R not be faster than 3 deg C (5.5 deg F) in each minute.
R D. Start to measure the time for the adhesive to cure when the
R temperature reaches 90 deg C (194 deg F).
R 11. Prepare to Install the Support Plate (Fig.201)
R A. Drill holes in the support plate and attach lockwire.
(1) When the support plate is cool, remove the two pieces of
non-porous film that remain.
(2) Drill two pairs of holes, 0.040 in. (1,O mm) diameter, and
a sufficient distance apart to attach the support plate to
a clamp bar with OMat 238A LOCKWIRE.
(3) Put a loop of the lockwire, long enough to let the support
plate go through the hole in the outer skin, through each
pair of holes.
R 12. Clean the R e ~ a i rArea
R A. Clean the inner surface of the repair area with an approved

R solvent (150 ACETONE) and an OMat 2/101 LINT-FREE CLOTH. Wipe
R the area dry before the solvent dries.
R 13. Install the Support Plate (Fig. 201)

R manufacturer's instructions
R B. Apply the same layers of adhesive to the interfacecof the

R support plate and the internal skin.
R C. Put the support plate into position.
REPAIR N0.7
54-10-01
Page 206
(1)
p
"" RB211 TRENT
MANUAL
STRUCTURAL REPAIR
Put the support plate through the repair cutout and place
it against the inner surface of the outer skin, making
sure that the support plate has the same overlap around
the repair cutout.
(2) Put a clamp bar across the repair cutout with the ends of
the bar on the teflon tape.
(3) Put the lockwire around the clamp bar and twist the ends
together to hold the support plate in the correct
position.
R A. Put the temperature probes into position adjacent to the

R support plate.
R B. Use a heat lamp to keep the temperature of the support plate

R between 90 to 93 deg C (194 to 199 deg F). Do this for 3 hours
R and 40 minutes.

R D. Start to measure the time for the adhesive to cure when the
R temperature reaches 90 deg C (194 deg F).
R A. When the repair area is cool, remove the lamp, temperature

R probes, clamp bar and lockwire.
R 16. Prepare the Filler Plies and the Repair Plies (Fig. 202)
R A. Cut the carbon filler plies:
(1) Wear OMat 2/114 LINT-FREE GLOVES and cut sufficient pieces
of OMat 8/206A DRY CARBON FIBRE FABRIC as identified in
the step below: This is to make the surface of the repair
cut-out level with the surface of the outer skin. Refer to
SRM 54-10-01, Identification for ply direction.
(a) Use an OMat 2629 MARKER PEN to mark out the full
extent of the repair area on the outer skin. To
measure the area necessary for the repair plies, you
will need to let 1.0 in. (25,4 mm) from the edge of
the damage for each carbon ply, and add 0.75 in.
(19,05 mm) for an outer layer of OMat 884 FIBREGLASS
FABRIC.
REPAIR N0.7
54-10-01
Page 207
-H RB211 TRENT
MANUAL
STRUCTURAL REPAIR
(2) The filler plies must overlap the cut-out in the outer
skin by 1.0 in. (25,4 mm).

R B. Cut the first carbon repair ply.
(1) Wear OMat 2/114 LINT-FREE GLOVES and cut one piece of OMat
8/206A CARBON CLOTH so that it has a 2.0 in. (50,8 mm)
R C. Cut the carbon repair plies that remain.
(1) Wear OMat 2/114 LINT-FREE GLOVES and use OMat 8/206A
CARBON CLOTH, and cut each subsequent repair ply 1.0 in.
(25,4 mm) longer and 1.0 in. (25,4 mm) wider than the ply
from before. There must be one repair ply for each ply of
the panel.
R D. Cut the fibreglass ply.
884 FIBREGLASS FABRIC. This must have a 1.0 in. (25,4 nun)
overlap around the area identified by the OMat 2/30 TEFLON
TAPE.

R 17. Dry the Repair Area
R A. Use the applicable heat lamps to dry the repair area. Keep the
R temperature at 80 deg C (176 deg F) for 6 hours. The repair
R materials must be applied immediately at the end of 6 hours.

R manufacturer's instructions. The weight of adhesive necessary
R will be 1.1 times the weight of the OMat 8/206A CARBON CLOTH
R and OMat 884 FIBREGLASS FABRIC.
R NOTE: After the plies are soaked, the adhesive that remains (if it
R is kept cool) can be used in the installation procedure.
R B. Soak the carbon plies and the fibreglass ply with the mixed
R adhesive .
REPAIR N0.7
54-10-01
Page 208
B RB211 TRENT
MANUAL
STRUCTURAL REPAIR
(1) Put each ply on a sheet of OMat 2/113 NON-POROUS PARTING

FILM.
(2) Apply the adhesive to both sides of each ply with the OMat
212 BRUSH. Cover each ply with another sheet of non-porous
parting film.
(3) Use the roller to force the adhesive into each ply fully.
Do not use too much force as this may damage and/or cause
resin deficiency in the plies.
(4) Mark the ply direction of the carbon repair plies on the
parting film.
R C. Cut the carbon filler plies to their finished dimensions.
(1) Cut each carbon filler ply so that it is a good fit in the
repair cutout. They must be flat on the support plate and
have the same shape as the cutout. The edges of the plies
must not overlap on the sides of the cutout.
R D. Cut the first carbon repair ply to its finished dimensions so

R that it overlaps the cutout in the outer skin by 1.0 in. (25,4
R mm) all around.
(1) Cut each subsequent carbon repair ply to get a 1.0 in.
(25,4 mm) overlap all around the previous ply.
(2) Cut the corners of the repair plies to an angle of

0.5 in. (12,7 mm).
R E. Cut the fibreglass repair ply so that it has the same shape as
R the area specified by the teflon tape.
R A. The repair area must be cool after the drying procedure. Refer
R to AMM TASK 70-20-01-100-802.Clean the repair area with an
R approved solvent (150 ACETONE) and an OMat 2/114 LINT-FREE
R CLOTH. Wipe the repair area dry before the solvent dries.
R 20. Install the Filler Plies and the Repair Plies (Fig.201 and Fig.202)
R A. Use an OMat 212 BRUSH to apply the same layer of the adhesive
R mixed in step 18.A. to all of the repair area.
R B. Put the filler plies into position.
REPAIR N0.7
54-10-01
Page 209
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(1) Remove one sheet of non-porous parting film from the

filler ply.
(2) Put the filler ply in the repair cutout, with the adhesive
side down, on to the support plate. The ply must be
located correctly and flat. Refer to SRM 54-10-01
Identification for ply direction.
filler ply and use a clean metal spatula to keep the ply
flat on the support plate.
(4) Do step 20 .B. (1)- ( 3 ) again for the subsequent carbon

filler plies. Make sure the plies are located correctly
and flat.
R C. Put the first carbon fibre repair ply in position.

carbon fibre repair ply.
(2) Refer to SRM TASK 54-10-01 Identification for ply

orientation. Put the repair ply, with the adhesive side
down, on to the repair area. Make sure the damage is
located in the centre of the ply.
the first repair ply. Do not use too much force as this
may damage and/or cause resin deficiency in the plies.
first repair ply.
R D. Do step 2O.C.(1) thru (4) again for the subsequent repair

R plies.
R E. Remove the teflon tape.
R F. Install the fibreglass ply.
(1) Do step 20.C. (1) thru (4) again for the fibreglass ply,
making sure that it has an equal overlap around the last
R 21. Prepare to Cure the Adhesive
R A. Get a heat blanket, which must be larger all around than the
R repair area.
REPAIR N0.7
54-10-01
Page 210
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
B. Cut a sheet of OMat 2/112 POROUS PARTING FILM. Make sure that
it is larger than the heat blanket and has an overlap of at
least 3.0 in. (76,2 mm) around the fibreglass ply.
C. Cut the OMat 884 BLEEDER CLOTH into sheets the same size as the
porous parting film. The number of sheets of bleeder cloth must
be the same as the number of plies used in the repair.
D. Put the porous parting film onto the repair area. Make sure
that it has the same overlap around the repair area. Put the
layers of bleeder cloth on top of the porous parting film.
E. Cut a sheet of OMat 2/113 NON-POROUS PARTING FILM. Make. sure

that it is at least 1.0 in. (25,4 mm) smaller all around than
the bleeder cloth installed in the step above.
F. Put the non-porous parting film onto the repair area, make sure
that it has the same overlap around the repair area.
G. Put at least two temperature probes adjacent to the repair

area. Ensure that the heat blanket will cover them.
R H. Put the heat blanket onto the repair area.
(1) Put the heat blanket on top of the non-porous parting

film. Make sure that the heat blanket has an overlap all
around the repair area.
R I. Put the breather cloth onto the top of the heat blanket.
(1) Cut two sheets of OMat 2/111 BREATHER CLOTH, at least

1.0 in. (25,4 mm) larger all around than the non-porous
parting film.
(2) Put the two sheets of breather cloth onto the heat
blanket.
R J. Put the vacuum bag onto the repair area.
(1) Use OMat 2/31 VACUUM BAG MATERIAL and OMat 2/32 SEALING
PUTTY.
(2) Make sure that the vacuum bag has an overlap of

approximately 2.0 in. (50,8 mm) around the breather cloth.
(3) Install the vacuum hose from the suction pump so that it
goes directly onto the top sheet of breather cloth.
(4) Attach and seal the vacuum bag to the cowl with the
sealing putty.
REPAIR N0.7
Page 211
Printed i n G r e a t B r i t a i n Oct. 15/05
p"" RB211 TRENT
MANUAL
STRUCTURAL REPAIR
R K. Put the insulation material onto the repair area.
(1) Cut four to six sheets of OMat 2/111 BREATHER CLOTH the
same size as the heat blanket.
(2) Put the breather cloth on top of the vacuum bag above the
heat blanket. Secure this in place with OMat 2/30 TEFLON
TAPE.
R NOTE: Insulation can be added or removed to get the correct

R rate of temperature increase a n d decrease. Ref step
R 22.C.
R A. Use the vacuum pump to decrease the pressure in the repair

R area. Make sure it gives an indication of at least 25.0 in.
R (635,O mm) of mercury while the adhesive cures.
R B. Use the heat blanket to keep the temperature of the repair area
R between 9 0 to 9 3 d e g C ( 1 9 4 and 1 9 9 d e g F ) for 3 hours a n d 40
R minutes.

R D. Start to measure the cure time when the temperature reaches 90

R deg C (194 deg F).
R A. When the cure process is completed, remove the layup equipment

R and materials from the repair.
R 24. Prepare the Repair Surface
R CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. ONLY
R REMOVE MATERIAL FROM THE EDGE OF THE OUTER PLY. DO NOT
R USE A LIQUID WITH THE ABRASIVE PAPER.
R A. Make all contours of the repair area smooth with OMat 5/31
R WATERPROOF ABRASIVE PAPER. Make sure there is no edge between
R the repair area and the outer skin.
R 25. Clean the Repair

R suction cleaner.
REPAIR N0.7
54-10-01
Page 212
RB211 TRENT
STRUCTURAL REPAIR
m MANUAL
R B. Refer to AMM TASK 70-20-01-100-802. Clean the repair area with

R OMat 150 ACETONE and an OMat 2/101 LINT-FREE CLOTH. Wipe the
R area dry before the solvent dries.
R 26. A D D ~ Vthe Surface Protection
R A. Apply surface protection to the repair area (Ref. SRM 51-02-

R 04).
R 27. Inspect, Tap Test and Record the Repair
R A. Do a visual inspection to make sure that the repair has been

R done in accordance with these procedures.
R B. Tap Test the repair area in accordance with SRM 54-01-06
R C. Vibro-etch the repair scheme number "FRSZ007" onto the nose

REPAIR N0.7
54-10-01
Page 213
p
"" RB211 TRENT
MANUAL
STRUCTURAL REPAIR
DAMAGE CUT-OUT
I
MINIMUM RADIUS CLAMP BAR
0.5in. ( 12,7mm)
I
-- P
LOCK WIRE TO HOLD THE SUPPORT

PLATE IN THE CORRECT POSITION
t
OUTER S K l N
l
SUPPORT PLATE - '.
I
1
l1
@
I1 /
I
V U, I
1
ADHESIVE
OVERLAP AROUND THE
REPAIR CUT-OUT
SECTION A-A
CARBON FILLER PLIES -I 1I OUTER SKIN
SUPPORT PLATE ---+L I
SECTION A-A
(With clamp bar removed and filler plies installed)
Support Plate and Filler Ply Installation

Fig. 201
REPAIR N0.7
54-10-01
Page 214
Oct. 15/05
p
"" RB211 TRENT
STRUCTURAL
MANUAL REPAIR
OUTER SKlN
Oin.
8mm
TEFLON TAPE CARBON REPAIR PLIES FIBREGLASS PLY
SUPPORT PLATE - CARBON FILLER PLIES

t
OUTER SKlN
SECTION B-B
DIMENSION C = 1.Oin. (25,4rnm)
DIMENSION D = 0.75in. (1 9,05rnm)
Repair Ply Installation

Fig. 202
REPAIR N 0 . 7
54-10-01
Page 215
H
"" RB211 TRENT
MANUAL
STRUCTURAL REPAIR
INSULRIION
l W W M HOSE
t
VACUUM t38G
.%
F
-
?
-
=
I
*
f
1 1
BREATHER CLOTH (23 t
C SEAUNG w m
k u
--""-6_*_1__1-1
X U I ~ U U I I C -.-
--
I
.* ,-
---m-
--l^
.-L
-__I)
HEAT BLANKET
--c 2.0in. L (M& ewer I~ITLP(IIWUIQ pmbs)
(50,8rnrn)
MINIMUl\rl
---- 1 ...
NW-POROUS PARTING FILM

i I
PORWS PARTING wlrt FlBREdsS
l
t No, af plies egortls
TEMPEMURE PROBE (1) \ M. of repair @as)
.A--
--. d - -.-/--.-
OUTER SURFACE
OF REPAIR PART

Fig. 203
REPAIR N0.7
54-10-01
Page 216
REPAIR NO.8
AIR INTAKE COWL – ACOUSTIC STRUCTURE
SURFACE DAMAGE REPAIR
1. General
A. This repair may be used to repair surface damage to the acoustic

structure of the air intake cowl.
B. This repair fills the damaged area with EA934NA and installs a
R C. To ensure compliance with noise certification requirements,

R repairs in the acoustically treated areas must be limited. Refer
R to Trent SRM 54-01-07 for repair limits to the Acoustic
R Treatment Areas. Refer to Rolls-Royce plc if the required repair
area is more than this.
D. This repair scheme covers damage restricted to the main area of

the acoustic structure. The damage must be separated from other
areas of damage to allow all the repair ply to be seated
correctly. The damage must be far enough from the edges of the
skin and/or fastener positions to allow the ply to seat
correctly.
CAUTION: USE PROTECTIVE MATS WHEN YOU WORK IN THE AIR INTAKE COWL
TO PREVENT DAMAGE TO THE ACOUSTIC STRUCTURE.
R 2. Equipment and Material
A. Standard Equipment
-Heatlamp, 176 to 212 deg.F (80 to 100 deg.C)

-Temperature probes, 32 to 248 deg.F (0 to 120 deg.C)
-Steel roller, 2.0 in. (50.8 mm) diameter, 2.0 in. (50.8 mm)
long
-Syringe
-Suction cleaner
-Standard workshop tools and equipment
R OMat 150 ACETONE

R OMat 1/40 ISOPROPYL ALCOHOL (ALTERNATIVE)
R OMat 1/257 CLEANING SOLVENT (ALTERNATIVE)
OMat 212 BRUSH
REPAIR NO.8
EFFECTIVITY: TRENT
54-10-01
Page 201
R Printed in Great Britain July 01/03

OMat 8/52 EA934NA ADHESIVE
OMat 8/160 EA9390 ADHESIVE
OMat 8/183 DRY CARBON FIBRE FABRIC
PART IDENT MATERIAL
Air intake cowl Composite structure
R 3. Examine the Repair Area (Ref. Fig.201)
A. The damage must have a maximum area of 2.0 by 3.0 in. (50.8 by
76.2 mm).
B. If the damage goes through the outer stainless steel mesh, the
R carbon ply, into the honeycomb and/or through the backing tray,
R refer to Rolls-Royce plc.
R WARNING: YOU MUST FIND AND OBEY THE MANUFACTURER’S HEALTH AND
R SAFETY DATA FOR THE MATERIALS. YOU MUST ALSO REFER TO
R LOCAL REGULATIONS TO MAKE SURE THAT THE PROCEDURES ARE
R DONE SAFELY. IF YOU DO NOT DO THIS, AN INJURY OR
R ENVIRONMENTAL DAMAGE CAN OCCUR.
R A. Clean the repair area with a OMat 2/101 LINT-FREE CLOTH

R moistened with OMat 150 ACETONE, OMat 1/40 ISOPROPYL ALCOHOL or
R OMat 1/257 CLEANING SOLVENT. Wipe the area dry before the
R solvent evaporates.
R 5. Prepare the Damaged Area for Repair (Ref. Fig.201)
A. Mask around the repair area with OMat 2/30 TEFLON TAPE:
(1) Measure 0.5 in. (12.7 mm) from the edge of the damage.
(2) Carefully apply the teflon tape so that it goes around

the area in a 2.0 in. (50.8 mm) wide strip.
REPAIR NO.8
EFFECTIVITY: TRENT
54-10-01
Page 202
0.7 in. (17.8 mm).

GOGGLES. WHEN COMPOSITE MATERIALS ARE CUT OR SANDED, DUST
AND LOOSE PARTICLES ARE PRODUCED WHICH ARE POTENTIAL
HEALTH HAZARDS. DO NOT BREATHE THE DUST.

B. Make the surface of the repair area rough with OMat 5/31
WATERPROOF ABRASIVE PAPER. Remove the sharp edges of the damage.
Do not increase the dimensions of the damage.
6. Dry the Repair Area

R
A. Use suitable heat lamps to dry the repair area. Keep the
temperature at 176 deg.F (80 deg.C) for 6 hours. The repair
materials must be applied immediately at the end of 6 hours.

R
WARNING: YOU MUST FIND AND OBEY THE MANUFACTURER’S HEALTH AND
R
A. Clean the repair area with a OMat 2/101 LINT-FREE CLOTH
R OMat 1/257 CLEANING SOLVENT. Wipe the repair area dry before the
R
8. Fill the Damaged Area (Ref. Fig.202)
R
WARNING: EA934NA ADHESIVE IS CLASSIFIED AS A HAZARDOUS MATERIAL
MANUFACTURER’S SPECIFIC SAFETY AND HEALTH
RECOMMENDATIONS. PRIOR TO USE OF THIS PRODUCT, CAREFULLY
READ THE APPLICABLE “MATERIAL SAFETY DATA SHEET” AND
FOLLOW ALL LISTED SAFETY AND HEALTH PRECAUTIONS.
A. Mix the OMat 8/52 EA934NA ADHESIVE in accordance with the

manufacturer’s instructions.
REPAIR NO.8
EFFECTIVITY: TRENT
54-10-01
Page 203
B. Fill the damaged area with the mixture using a clean metal
spatula or syringe. Make sure the mixture is level with the
outer stainless steel mesh.
C. Cure the OMat 8/52 EA934NA ADHESIVE at room temperature or

accelerate the cure using heat lamps at 100 deg.F (37.8 deg.C)
for 2 hours.
R 9. Cut the Oversize Repair Ply

A. Wear OMat 2/114 LINT-FREE GLOVES and cut one piece of OMat 8/183
DRY CARBON FIBRE FABRIC so that it has a 1.0 in. (25.4 mm)
overlap all round the damage.
NOTE: To prevent fraying, cut the ply to the finished dimensions

after it is soaked with adhesive.
WARNING: EA9390 ADHESIVE IS CLASSIFIED AS A HAZARDOUS MATERIAL

R A. Mix the OMat 8/160 EA9390 ADHESIVE in accordance with the

manufacturer’s instructions. The weight of adhesive required
will be approximately the same as the weight of the OMat 8/183
DRY CARBON FIBRE FABRIC.
NOTE: After the ply has soaked, the remaining adhesive (if it is
kept cool) can be used in the installation procedure.
B. Soak the outer ply with the mixed adhesive:
(1) Put the ply on a sheet of OMat 2/113 NON-POROUS PARTING

FILM.
(2) Apply the adhesive to the two sides of the ply with the
OMat 212 BRUSH and cover the ply with another sheet of
non-porous parting film.
REPAIR NO.8
EFFECTIVITY: TRENT
54-10-01
Page 204
(3) Use the roller to force the adhesive into the ply
thoroughly.
C. Cut the outer ply to its finished dimensions (Ref. Fig.202):
(1) Let the two pieces of the non-porous parting film stay
on the ply until it is to be used in the installation
procedure.
(2) Cut the ply so that it is the same shape as the area
which the teflon tape identifies.
(3) Keep the outer ply and the adhesive mixture cool until
the installation procedure.
R 11. Install the Outer Ply (Ref. Fig.202)
WARNING: EA9390 ADHESIVE IS CLASSIFIED AS A HAZARDOUS MATERIAL

THIS PRODUCT AHOULD BE USED ONLY IN ACCORDANCE WITH THE
A. Use an OMat 212 BRUSH to apply an equal layer of OMat 8/160

R EA9390 ADHESIVE to all of the repair area.
B. Install the outer ply on to the repair area:

outer ply.
(2) Put the outer ply, with the adhesive side down, on to
the repair area. The outer ply must have an equal
overlap all round the repair cut-out and touch the
teflon tape.
(3) Use the roller to remove the air which is caught in the
adhesive and to make the outer ply smooth.
(4) Remove the unwanted adhesive from the teflon tape with a
clean metal spatula.
(5) Remove the remaining non-porous film from the outer ply.
A. Put the temperature probes in position adjacent to the adhesive.

REPAIR NO.8
EFFECTIVITY: TRENT
54-10-01
Page 205
B. Use a suitable heat lamp to keep the temperature of the repair
area between 194 and 199 deg.F (90 and 93 deg.C) for 3 hours and
40 minutes.
C. The rate of temperature increase and subsequent decrease must

not be faster than 5.5 deg.F (3 deg.C) in each minute.
D. Start to measure the time for the adhesive to cure when the
temperature gets to 194 deg.F (90 deg.C).
A. When the repair process is completed, remove the lamp, the

temperature probes and the teflon tape.
R 14. Make the Edges of the Outer Ply Smooth (Ref. Fig.202)

CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE REPAIR

AREA OR THE OUTER SURFACE OF THE ACOUSTIC STRUCTURE. BE
CAREFUL AND ONLY REMOVE MATERIAL FROM THE EDGE OF THE
OUTER PLY. DO NOT USE A LIQUID WITH THE ABRASIVE PAPER.
A. Make the repair area smooth with OMat 5/31 WATERPROOF ABRASIVE
PAPER. There must not be a sharp edge between the repair area
and the acoustic panel.
A. Remove all unwanted material from the repair area with a suction
cleaner.
R ENVIRONMENTAL DAMGE CAN OCCUR.
R B. Clean the repair area with a OMat 2/101 LINT-FREE CLOTH

R OMat 1/257 CLEANING SOLVENT. Wipe the repair area dry before the
R 16. Make an inspection of the Repair
REPAIR NO.8
EFFECTIVITY: TRENT
54-10-01
Page 206
REPAIR NO.8
EFFECTIVITY: TRENT
54-10-01
Page 207
Acoustic Structure Damage Limits
Figure 201
REPAIR NO.8
EFFECTIVITY: TRENT
54-10-01
Page 208
Acoustic Structure Repair Details
Figure 202
REPAIR NO.8
EFFECTIVITY: TRENT
54-10-01
Page 209
REPAIR N0.9 (FRSZ017)
AIR INTAKE COWL - LIPSKIN
1. General
A. This repair procedure replaces defective and/or missing solid

rivets with blind rivets.
B. The rivets that can be replaced by this repair are specified

in Figure 201.
.......................................................................
------,-----------------------------------------------------------------
SRM 54-02-10 Fasteners - Removal/Installation

TASK 71-61-11-300-XXX FRSZ017, Trent Engine Manual
3. Equipment and Materials
-Drills and drilling equipment

-Riveting tools
-Suction cleaner
-Standard workshop tools
.......................................................................
.......................................................................
OMat 150 ACETONE
OMat 1/40 ISOPROPYL ALCOHOL (ALTERNATIVE)
OMat 11257 CLEANING SOLVENT (ALTERNATIVE)
R OMat 262 TEMPORARY MARKER
REPAIR N0.9
54-10-01
Page 201
p
"" RB211 TRENT
MANUAL
STRUCTUAL REPAlR
C. Repair Parts
------------.-----------------------------------------------------------
PART NO. PART IDENT
.......................................................................
CR3522-6 Cherrymax Fastener
CR3552-6 Cherrymax Fastener (Oversize)
CR2538-6 Cherrylok Fastener (Alternative)
CR3524-8 Cherrylok Fastener (1/4 in dia.)
4. Initial Inspection (Ref Figures 201,202)
A. Carefully examine the inner (fan) and outer sides of the intake
cowl for defective and/or missing rivets.
B. If necessary, try to put a feeler gage under the head of rivets

that you think could be unsatisfactory.
R C. Use a OMat 262 TEMPORARY MARKER to make marks on the cowl to

record the positions where rivets are missing or must be
replaced.
5. Prepare the Rivet Holes
A. Remove the defective rivets (Ref SRM 54-02-10).
B. If a rivet is missing or has been removed, first drill the hole

for a Cherrymax CR3522-6 nominal rivet. The drill size for this
rivet is No.10, 0.192 to 0.196 in (4,88 to 4,98 mm) diameter.
C. If the hole is larger than given in 5.B (above), then you can
drill for oversize rivets. The drill size for Cherrymax CR3552-6
rivets is No.5, 0.205 to 0.209 in (5,21 to 5,31 mm) diameter.
The drill size for Cherrylok CR2538-6 rivets is 0.200 to 0.204 in
(5,08 to 5,18 mm) diameter. The drill size for Cherrylock CR3524-
8 rivets is 0.256 in. (6,50 to 6,33mm.) dia.
NOTE: Only use the 1/4 in. dia.Cherrymax fasteners if the hole
size is larger than the size required for 3/16 in. dia.
oversize Cherrymax fasteners.
D. If you have drilled holes for oversize rivets, you must also
increase the depth of the countersink. Use a 100 deg countersink
tool and increase the depth until the rivet heads are flush with
the surface. We recommend that you first use a piece of unwanted
material to find the correct countersink depth for the rivets.
Make sure you do not make a 'knife edge1 or cause a tear.
REPAIR N0.9
54-10-01
Page 202
R WARNING: SOLVENT IS CLASSIFIED AS A HAZARDOUS MATERIAL THAT CAN
R CAUSE INJURY OR ILLNESS IF NOT USED CORRECTLY. BEFORE YOU
R USE THIS PRODUCT, CAREFULLY READ THE APPLICABLE MATERIAL
R SAFETY DATA SHEET AND OBEY ALL THE SPECIFIED HEALTH AND
R SAFETY PRECAUTIONS.
E. Remove all loose material with a SUCT1ON CLEANER and OMat

2/101 LINT-FREE CLOTH soaked in OMat 150 ACETONE or
alternative solvent. Wipe the surfaces dry before the
solvent evaporates.
6. Install the Replacement Rivets
CAUTION: MAKE SURE YOU INSTALL THE CORRECT RIVET. IF YOU INSTALL
A NOMINAL SIZE RIVET IN AN OVERSIZE HOLE,THE REPAIR WILL
BE UNSERVICEABLE.
CAUTION: TO PREVENT POSSIBLE DAMAGE TO THE LOCKING COLLAR, DO NOT

MILL/SHAVE THE RIVET STEM.
A. Use a depth gage to measure the thickness of the materials.

Make sure you have the applicable rivet for this thickness.
B. Install the applicable Cherrymax/Cherrylok rivets in accordance

with the manufacturer's instructions (Ref SRM 54-02-10).
7. Inspection
A. Make sure the rivets are correctly installed (Ref 54-02-10).
EFFECTIVITY: TRENT REPAIR NO.9

54-10-01
Page 203
R Printed in Great Britain Oct 1/02
Replacement of Solid Rivets
R Figure 201,

54-10-01
Page 204
Replacement of Solid Rivets
R Figure 202

54-10-01
Page 205
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR NO.10 (FRSZ012)

AIR INTAKE COWL- ACCESS PANELS- SURFACE DAMAGE REPAIR
1. General
A. This repair may be used to repair damage to the outer composite layers of
the access panels where rupture of the plies has occurred. Do not use this
repair if the damage goes through the panel. The maximum depth of damage
permitted by this repair is 0.104in. (2,64 mm).
B. The repair must be done under controlled conditions: the temperature must
be kept at 68 to 77 deg.F (20 to 25 deg C) and the humidity at 50 percent
or less.
C. Refer to SRM 54-10-01 allowable damage for the correct number and the
position of the plies in area of damage.
D. The maximum area of damage permitted is 6.0in. (152,4 mm) diameter.
E. Where damage is beyond the limits of this repair refer to Rolls-Royce plc.
F. This repair may be used to repair damage to the main area of the panel.
The damage must be a sufficient distance from other areas of damage to let
all the repair plies be correctly installed. The damage must be a
sufficient distance from the edges of the skin and/or fastener positions
to let all the plies be correctly installed.
..............................................................................
Heat blanket, 32 to 248 deg.F (0 to 120 deg.C)
Heatlamp, 176 to 194 deg.F (80 to 90 deg C)
Vacuum suction pump, 0 to 30in. (0 to 762 mm) of mercury
REPAIR No.10
EFFECTIVITY: TRENT
Page 201
Mar. 15/97
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
Temperature probes, 32 to 248 deg.F (0 to 120 deg C)
Steel roller, 2.0in. (50,8 mm) diameter, 2.0in. (50,8 mm) long
Suction cleaner
------------------------------------------------------------------------------
OMat 135 METHYL ETHYL KETONE
OMat 212 BRUSH
OMat 884 FIBERGLASS FABRIC
OMat 81151 CARBON CLOTH
OMat 884 BLEEDER FABRIC
-- -- - -
p
PART IDENT MATERIAL
4. Remove the Damaged Access Panel
A. Remove the fasteners from the access panel and keep them for installation.
Remove the panel from the intake cowl.
REPAIR No.10
EFFECTIVITY: TRENT
Page 202
Mar. 15/97
M RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
5. Examine t h e Repair Area (Ref Fig.201)
A. Use s t a n d a r d workshop t o o l s t o measure t h e d e p t h of t h e damage.
B. Make a n o t e of t h e d e p t h of t h e damage, and c a l c u l a t e t h e number of p l i e s

n e c e s s a r y t o r e p a i r t h e damage a s f o l l o w s :
..............................................................................
DEPTH OF DAMAGE NO. OF PLIES
REQUIRED
Up t o 0.013in. (0,33 mm)

0.014in. (0,35 mm) t o 0.026in. (0,66 mm)
0.027in. (0,68 mm) t o 0.039in. (0,99 mm)
0.040in. (1,Ol mm) t o 0.052in. (1,32 mm)
0.053in. (1,34 mm) t o 0.065in. (1,65 mm)
0.066in. (1,67 mm) t o 0.078in. (1,98 mm)
0.079in. (2,00 mm) t o 0.091in. (2,31 mm)
0.092in. (2,33 mm) t o 0.104in. (2,64 mm)
I f you cannot be s u r e of t h e d e p t h of t h e damage, i n s t a l l one more r e p a i r p l y

( f o r example - i f you a r e not s u r e i f t h e depth of t h e damage i s 0.039in.
(0,99 mm) o r 0.040in. (1,Ol mm), u s e f o u r r e p a i r p l i e s .
6. Clean t h e Repair Area
WARNING: METHYL ETHYL KETONE I S CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY

AND HEALTH RECOMMENDATIONS. PRIOR TO USE OF THIS PRODUCT,
CAREFULLY READ THE APPLICABLE "MATERIAL SAFETY DATA SHEET" AND
A. Clean t h e r e p a i r a r e a with OMat 135 METHYL ETHYL KETONE and OMat 21101
LINT-FREE CLOTH. Rub t h e r e p a i r a r e a w i t h a c l e a n p i e c e of l i n t - f r e e c l o t h
before the solvent d r i e s .
7. P r e ~ a r et h e Damaged A r e a f o r R e ~ a i r(Ref Fin.201)
A. Apply OMat 2/30 TEFLON TAPE around t h e r e p a i r a r e a .
C a l c u l a t e t h e d i s t a n c e t h a t t h e t a p e must be from t h e damage a s follows:
(1) Measure l.Oin. (25,4 mm) from t h e edge of t h e damage f o r each p l y of

t h e p a n e l which i s damaged, and add 0.75 i n . (19,051nm) f o r an o u t e r
l a y e r of OMat 884 FIBERGLASS FABRIC.
REPAIR No.10
EFFECTIVITY: TRENT
Page 203
Mar. 15/97
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
( 2 ) C a r e f u l l y a p p l y t h e t e f l o n t a p e around t h e a r e a i n a 2.0in. ( 5 0 , 8 mm)

wide s t r i p .
( 3 ) Make t h e c o r n e r s of t h e s t r i p of t a p e a t a n a n g l e o f a p p r o x i m a t e l y 45
d e g r e e s w i t h a l e n g t h o f a p p r o x i m a t e l y 1.Oin. (25,4 mm).
WARNING: WEAR PROTECTIVE CLOTHING, GLOVES, DUST MASK AND SAFETY GOGGLES.
WHEN COMPOSITE MATERIALS ARE CUT OR SANDED, DUST AND LOOSE
PARTICLES ARE PRODUCED WHICH ARE POTENTIAL HEALTH HAZARDS. DO NOT
BREATHE THE DUST.
-.
3
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE PANEL. BE CAREFUL S
WHEN YOU REMOVE THE SHARP EDGES OF THE DAMAGE. DO NOT USE A LIQUID -.
P
WITH THE ABRASIVE PAPER. 3
C,
;D'
B. Make t h e s u r f a c e o f t h e r e p a i r a r e a rough w i t h O M a t 5 / 3 1 WATERPROOF 2
ABRASIVE PAPER. Remove t h e s h a r p e d g e s of t h e damage. Do n o t i n c r e a s e t h e
d i m e n s i o n s o f t h e damage.
F-
E.
3
8 . Cut t h e R e p a i r P l i e s ((Ref Fig.201)
BREATHE THE DUST.
A. Cut t h e f i r s t r e p a i r p l y .
( 1 ) Wear O M a t 21114 LINT-FREE GLOVES and c u t one p i e c e o f O M a t 81151 CARBON

CLOTH s o t h a t i t h a s a 2 . 0 i n . (50,8 mm) o v e r l a p a r o u n d t h e damage.
NOTE: I f o n l y one p l y i s n e c e s s a r y t o do t h e r e p a i r , u s e O M a t 884

FIBERGLASS FABRIC.
B. I f n e c e s s a r y , c u t t h e r e m a i n i n g p l i e s .
( 1 ) Wear l i n t - f r e e g l o v e s and u s e c a r b o n c l o t h . Cut e a c h s u b s e q u e n t r e p a i r

p l y 2 . 0 i n . ( 5 0 , 8 mm) l o n g e r and 2.0in. (50,8 mm) w i d e r . There must be
one r e p a i r p l y f o r e a c h p l y o f t h e p a n e l which i s damaged.
C. Cut t h e f i b e r g l a s s p l y .
( 1 ) Wear l i n t - f r e e g l o v e s a n d c u t one p i e c e o f O M a t 884 FIBERGLASS FABRIC

s o t h a t i s h a s a l.Oin. (25,4 mm) o v e r l a p around t h e a r e a i d e n t i f i e d by
the t e f l o n tape.
NOTE: To p r e v e n t f r a y i n g , c u t t h e p l i e s t o t h e i r c o r r e c t d i m e n s i o n s a f t e r
t h e y a r e soaked w i t h a d h e s i v e .
REPAIR No.10
EFFECTIVITY: TRENT
Page 204
Mar. 15/97
RB.211 TRENT
m STRUCTURAL REPAIR
MANUAL
9. Dry the Repair Area
A. Use suitable heat lamps to dry the repair area. Keep the temperature at
176 deg.F (80 deg C) for 6 hours. The repair materials must be applied
immediately at the end of 6 hours.
10.Prepare the Repair Materials
WARNING: EA 9390 ADHESIVE IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY

BE USED ONLY IN ACCORDANCE WITH THE MANUFACTURER'S SPECIFIC SAFETY
CAREFULLY READ THE APPLICABLE FI MATERIAL SAFETY DATA SHEET" AND
A. Mix the OMat 81160 EPOXY ADHESIVE in accordance with the manufacturer's
instructions. The weight of adhesive necessary will be approximately the
same as the weight of the OMat 81151 CARBON CLOTH and OMat 884 FIBERGLASS
FABRIC.
NOTE: After the plies are soaked, the remaining adhesive (if it is kept
cool) can be used in the installation procedure.
B. Soak the carbon fiber and the fiberglass plies with the mixed adhesive.
(1) Put each ply on a sheet of OMat 21113 NON-POROUS PARTING FILM.
(2) Apply the adhesive to each ply with the OMat 212 BRUSH and cover each
ply with another sheet of non-porous parting film.
CAUTION: DO NOT USE TOO MUCH FORCE WHEN YOU ROLL THE PLIES. THIS MAY
DAMAGE AND/OR REMOVE TOO MUCH RESIN FROM THE PLIES.
(3) Use the roller to force the adhesive fully into each ply
C. Cut the plies to their correct dimensions (Ref. Fig.201).
(1) Cut approximately l.Oin. (25,4 mm) off each edge of the plies.
(2) Make sure that the first ply has a l.Oin. (25,4 mm) overlap around the
damage.
(3) Make sure that each subsequent ply extends l.Oin. (25,4 mm) more around
the damage.
REPAIR No.10
EFFECTIVITY: TRENT
Page 205
Mar. 15/97
RB.211 TRENT
MANUAL
( 4 ) Cut the corners of the carbon repair plies to an angle of approximately

45 degrees with a length of approximately 0.5in. (12,7 mm).
(5) Cut the fiberglass piy so that it is the same shape as the area
identified by the teflon tape.
11.Clean the Repair Area
WARNING: METHYL ETHYL KETONE IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY

BE USED ONLY IN ACCORDANCE WITH THE MANUFACTURER'S SPECIFIC SAFETY P
3
AhrD HEALTH RECOMMENDATIONS. PRIOR TO USE OF THIS PRODUCT, iD"
CAREFULLY READ THE APPLICABLE "MATERIAL SAFETY DATA SHEET" AND a
-.
3
-
C,
cd
A. Let the repair area cool after it has been dried. Clean the repair area 2
with OMat 135 METHYL ETHYL KETONE and OMat 21114 LINT-FREE CLOTH. Rub the
repair area with a clean piece of lint-free cloth before the solvent dries. rC
E.
3
12.Fill the Damaged Area (Ref Fig.201)
WARNING: EA 9390 ADHESIVE IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY

A. Mix the OMat 81160 EPOXY ADHESIVE in accordance with the manufacturer's
instructions. Cut the OMat 81151 CARBON CLOTH into small fibers and mix
with the OMat 81160 EPOXY ADHESIVE to make a paste.
B. Use a metal spatula to fill the damaged area with the mixture. Make sure
the mixture is level with the top carbon ply of the cowl.
REPAIR No. l0
EFFECTIVITY: TRENT
Page 206
Mar. 15/97
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
1 3 . I n s t a l l t h e R e p a i r P l i e s (Ref Fig.201)
WARNING: EA 9390 ADHESIVE I S CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY

CAUTION: DO NOT USE TOO MUCH FORCE WHEN YOU ROLL THE PLIES. THIS MAY DAMAGE
AND/OR REMOVE TOO MUCH RESIN FROM THE PLIES.
A. Use a n O M a t 212 BRUSH t o a p p l y a n e q u a l l a y e r of OMat 81160 EPOXY ADHESIVE

t o a l l of t h e r e p a i r a r e a .
B. I n s t a l l t h e f i r s t r e p a i r p l y .
( 1 ) Remove one s h e e t o f O M a t 21113 NON-POROUS PARTING FILM from t h e f i r s t

r e p a i r ply.
( 2 ) P u t t h e f i r s t r e p a i r p l y , w i t h t h e a d h e s i v e down, o n t h e r e p a i r a r e a .
Make s u r e t h a t t h e l o c a t i o n of t h e damage i s i n t h e c e n t e r o f t h e p l y .
(3) Use t h e r o l l e r t o remove a i r and unwanted a d h e s i v e from t h e f i r s t

r e p a i r ply.
( 4 ) Remove t h e r e m a i n i n g non-porous p a r t i n g f i l m from t h e f i r s t r e p a i r p l y .
C. I n s t a l l t h e second r e p a i r p l y ( i f n e c e s s a r y )
( 1 ) Remove one s h e e t of non-porous p a r t i n g f i l m from t h e second r e p a i r p l y .
(2) P u t t h e second r e p a i r p l y , w i t h t h e a d h e s i v e s i d e down, on t h e r e p a i r

a r e a . Make s u r e t h a t i t h a s a n e q u a l o v e r l a p around t h e f i r s t r e p a i r
P ~ Y
( 3 ) Use t h e r o l l e r t o remove a i r and unwanted a d h e s i v e from t h e p l y .
(4) Remove t h e r e m a i n i n g non-porous p a r t i n g f i l m from t h e second r e p a i r

P ~ Y
D. I n s t a l l t h e s u b s e q u e n t r e p a i r p l i e s i f a n y
( 1 ) Do s t e p 13.C a g a i n f o r t h e s u b s e q u e n t r e p a i r p l i e s .
REPAIR No.10
EFFECTIVITY: TRENT
Page 207
Mar. 15/97
[mm
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
E. Remove t h e t e f l o n t a p e from around t h e r e p a i r a r e a .
F. I n s t a l l t h e f i b e r g l a s s p l y
( 1 ) Do s t e p 13.C a g a i n f o r t h e f i b e r g l a s s p l y . Make s u r e t h a t i t h a s an
e q u a l o v e r l a p around t h e l a s t carbon f i b e r r e p a i r p l y .
14.Prepare t o Cure t h e Adhesive (Ref Fig.202)
A. Get a h e a t b l a n k e t , which must be l a r g e r a l l round t h a n t h e r e p a i r a r e a .

n-.
3
B. Cut a s h e e t of O M a t 21112 POROUS PARTING FILM. Make s u r e t h a t i t i s l a r g e r S
t h a n t h e h e a t b l a n k e t and has a minimum o v e r l a p of 3.0in. (76,2 mm) around a
-.
3
the fiberglass ply.
0
;D'
C. Cut t h e O M a t 884 FIBERGLASS CLOTH i n t o s h e e t s t h e same s i z e as t h e porous P;!
p a r t i n g f i l m . Use t h e f i b e r g l a s s c l o t h a s a b l e e d e r c l o t h . The number of F
-.
s h e e t s of b l e e d e r c l o t h must e q u a l t h e number of p l i e s used i n t h e r e p a i r . E.'
h
D. Put t h e porous p a r t i n g f i l m on t h e r e p a i r a r e a . Make s u r e t h a t i t has an

e q u a l o v e r l a p around t h e r e p a i r a r e a . P u t t h e l a y e r s of b l e e d e r c l o t h on
t o p of t h e porous p a r t i n g f i l m .
E. Cut a s h e e t of OMat 2/113 NON-POROUS PARTING FILM. Make s u r e t h a t i t i s a

minimum of l.Oin. ( 2 5 , 4 mm) s m a l l e r a l l around t h a n t h e b l e e d e r c l o t h
i n s t a l l e d i n s t e p 14.D.
F. P u t t h e non-porous p a r t i n g f i l m on t h e r e p a i r a r e a . Make s u r e t h a t i t h a s
a n e q u a l o v e r l a p around t h e r e p a i r a r e a .
G. P u t a minimum of two temperature p r o b e s a d j a c e n t t o t h e r e p a i r a r e a .
H. Put t h e h e a t b l a n k e t on t h e r e p a i r a r e a
(1) Put t h e h e a t b l a n k e t on t o p of t h e non-porous p a r t i n g f i l m . Make s u r e

t h e h e a t b l a n k e t h a s an o v e r l a p a l l around t h e r e p a i r a r e a . Make s u r e
t h e t e m p e r a t u r e p r o b e s a r e below t h e h e a t b l a n k e t .
I. P u t t h e b r e a t h e r c l o t h on top of t h e h e a t b l a n k e t
(1) Cut two s h e e t s of OMat 21111 BREATHER CLOTH, a minimum of l.Oin. (25,4
mm) l a r g e r a l l around than t h e non-porous p a r t i n g f i l m .
( 2 ) Put t h e two s h e e t s of b r e a t h e r c l o t h on t h e h e a t b l a n k e t ,
REPAIR No. l 0
EFFECTIVITY: TRENT
Page 208
Mar. 15/97
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
J. Put the vacuum bag on the repair area
(1) Use OMat 2/31 VACUUM BAG MATERIAL and OMat 2/32 SEALING PUTTY.
(2) Make sure that the vacuum bag has an overlap of approximately 2.0in.
(50,8 mm) around the breather cloth.
(3) Install the vacuum hose from the suction pump so that it goes directly
on the top sheet of breather cloth.
(4) Attach and seal the vacuum bag to the cowl with the sealing putty.
K. Put the insulation material on the repair area
(1) Cut four to six sheets of OMat 21111 BREATHER CLOTH the same size as
the heat blanket.
(2) Put the breather cloth on top of the vacuum bag above the heat blanket
and attach it with OMat 2/30 TEFLON TAPE.
NOTE: Insulation can be added or removed to get the correct rate of

temperature increase and decrease (Re£ step 15.C.).
15.Cure the Adhesive
A. Use the vacuum pump to decrease the pressure in the repair area. Make sure
it gives a minimum indication of 25.0in. (635,O mm) of mercury while the
adhesive cures.
B. Use the heat blanket to keep the temperature of the repair area between 194
and 199 deg.F (90 and 93 deg C) for 3 hours and 40 minutes.
C. The rate of temperature increase and subsequent decrease must not be more
than 5.5 deg.F (3 deg C) in each minute,
D. Start to measure the cure time when the temperature reaches 194 deg.F (90
deg C).
16.Remove the Repair Equipment
A. When the cure process is completed, remove the layup equipment and
materials from the repair.
REPAIR No.10
EFFECTIVITY: TRENT
Page 209
Mar. 15/97
1
m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
17.Prepare the Repair Surface
BREATHE THE DUST.
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE COWL. REMOVE
MATERIAL ONLY FROM THE EDGE OF THE OUTER PLY. DO NOT USE A LIQUID
WITH THE ABRASIVE PAPER.
A. Make all contours of the repair area smooth with OMat 5/31 WATERPROOF
ABRASIVE PAPER. Make sure there is no edge between the repair area and the
outer skin.
18.Clean the Repair Area
A. Remove all unwanted material from the repair area with a suction cleaner.
WARNING: METHYL ETHYL KETONE IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY

B. Clean the repair area with OMat 135 METHYL ETHYL KETONE and OMat 21101
LINT-FREE CLOTH. Rub the repair area with a clean piece of lint-free cloth
before the solvent dries.
19.Apply the Surface Protection
A. Apply surface protection to the repair area (Ref 54-02-04).
20.Make an Inspection of the Repair
A. Do a visual inspection to make sure that the repair has been done to these
procedures.
21.Install the Access Panel
A. Install the access panel with the fasteners that were kept in step 4.A.
REPAIR No. l0
EFFECTIVITY: TRENT
Page 210
~ a r 15/97
.
H RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
I
TEFLON TAPE
I FIBREGLASS PLY / I
CARBON PLY
TOP CARBON PLY
CARBON PLY
I
SECTION A-A
Repair Plies Build-Up

Figure 201
REPAIR No.10
EFFECTIVITY: TRENT
Page 211
Mar. 15/97
RB.211 TRENT
MANUAL
INSULATION
1 VACUUM HOSE
I
VACUUM BAG
1
I
I 7
I \
BREATHER CLOTH (2)
t
SEALING PUrrY
2.0in. HEATBLANKET
(50,8mm) (Must cover temperature probes)
MINIMUM
1
l.Oh. (25,4mrn)
MINIMUM
l - NON-POROUS PARTING FILM
1 1
TEMPERATURE PROBE (2)

L - No. of plies equals
No. of repair plies
OUTER SURFACE
OF REPAIR PART
R e p a i r Equipment I n s t a l l a t i o n
F i g u r e 202
REPAIR No.10
EFFECTIVITY: TRENT
Page 212
Mar. 15/97
RB211 TRENT
STRUCTUAL REPAIR
REPAIR NO.11 (FRS 5085)
AIR INTAKE COWL - REPLACE DECALS
1. General
CAUTION: YOU MUST READ THESE INSTRUCTIONS BEFORE YOU REMOVE A

DECAL FROM ITS POLYTHENE BAG.
A. This repair gives the procedure to replace damaged decals on

the air intake cowl.
B. The decals are supplied in different colors for different

backgrounds. Use black or red decals on light-colored nacelles,
use white or yellow decals on dark-colored nacelles.
C. The minimum air temperature necessary for this repair is 16 deg C

(61 deg F). If possible, do not operate the engine for 48 hours
after the repair has been done.
A. Standard Equipment:
Non-metallic scraper
Plastic squeegee
Rubber roller
.......................................................................
.......................................................................
OMat 150 ACETONE
OMat 262 TEMPORARY MARKER
Omat 2/12 PAINT BRUSH
OMat 7/202 CLEAR VARNISH,2-PACK
OMat 7 /2 03 THINNER
OMat 7/204 THINNER
.......................................................................
PART IDENT MATERIAL
.......................................................................
Air Intake Cowl Carbon Composite
REPAIR NO.ll
54-10-01
Page 201
Jan. 1/00
H R8211 TRENT
MANUAL
STRUCTUAL REPAIR
3. Identify the Decal
A. Refer to Table 1 and Figures 201 thru 205 to identify the correct
replacement decal.
4. Remove the Damaaed Decal
A. Clean the damaged decal and the adjacent cowl with OMat 2/101
LINT FREE CLOTH soaked with OMat 150 ACETONE.
B. Lift the edge of the damaged decal. If necessary, use the non-
metallic scraper.
C. Smoothly pull the decal to remove it from the cowl.
5. PreDare the Cowl Surface
A. Remove all of the damaged decal with the non-metallic scraper.
B. Remove remaining adhesive with OMat 2/101 LINT FREE CLOTH soaked
with OMat 150 ACETONE. Dry the cowl surface with a new piece of
cloth before the acetone evaporates.
6. Make a Location Mark
A. Refer to Figures 201 thru 205 for the correct dimensions. Use the
OMat 262 TEMPORARY MARKER to make a line on the cowl for the top
edge of the replacement decal.
7. A D D ~ Vthe Re~lacementDecal
CAUTION: DO NOT TOUCH THE ADHESIVE SIDE OF THE DECAL.
A. Remove the backing paper for a short distance along the top edge
of the decal.'Flick' the corner of the decal with your finger.
B. Immediately apply the top edge of the decal to the cowl at the
line made in step 6.
C. Lift the bottom edge of the decal, gradually remove the backing
paper while you apply the decal to the cowl. Use the squeegee or
roller from the centre to the edges of the decal to remove
trapped air.
REPAIR NO. l1
54-10-01
Page 202
Jan. 1/00
RB211 TRENT
STRUCTUAL REPAlR
MANUAL
D. If necessary, use a needle to make a hole in bubbles of trapped

air. Then make the decal smooth with the squeegee or the roller.
8. Remove the Location Mark
A. Use OMat 2/101 LINT FREE CLOTH soaked with OMat 150 ACETONE to
remove the location mark from the cowl. Dry the surface with a
new piece of cloth before the acetone evaporates.
9. Do an Inspection
A. Refer to Figures 201 thru 205. Make sure the decal is in the
correct position on the cowl. Make sure there are no bubbles of
trapped air. If unsatisfactory, replace the decal.
10. A P D ~ Y the Varnish
A. Mix equal parts of the OMat 7/202 CLEAR VARNISH 2-PACK. If

thinners are necessary, make a selection as follows:
(1) At temperatures between 16 and 26 deg C (61 anmd 79 deg F),

use OMat 7/203 THINNER
(2) At temperatures more than 26 deg C (79 deg F), use

OMat 7/204 THINNER.
B. Make sure the varnish is fully mixed (approx 15 to 30 minutes) .

The pot life of the mixture is 8 hours.
C. Use the OMat 2/12 SOFT BRUSH to apply a thin layer of the
varnish to the decal, with an overlap of 10 mm (0.4 in.) on
all sides (to prevent peel) .
D. Cure the varnish for 72 hours at 16 deg C (61 deg F) . The
maximum cure temperature is 95 deg C (205 deg F).
11. Do an Inspection of the Decal
A. Make sure that the repair has been done in accordance with
this procedure.
REPAIR NO.ll
54-10-01
Page 203
Jan. 1/00
-p RB211 TRENT
MANUAL
STRUCTUAL REPAIR
ITEM IPC REF PART NO DECAL DESCRIPTION
11-24-71
1 01-406 LJ41906 Black, Hoist-Point (Alt.LJ41907)
2 01-406A L341907 White, Hoist-Point (Alt.LJ41906)
3 01-430 LJ41930 Black, P2T2 Probe Access (Alt.LJ41931)
4 01-430A I,~ 4 1 9 3 1 .
White, P2T2 Probe Access (Alt LJ41930)
5 01-444 1,541944 Black, Anti-Ice Duct Exhaust Access

Panel (Alt .LJ41945)
6 01-444A ~ ~ 4 1 9 4 5 White, Anti-Ice Duct Exhaust Access

Panel (Alt.LJ41944)
7 01-468 L J 1968
~ Red, Prohibited Persons Symbol
(Alt.LJ41969)
8 01-46821 LJ41969 Yellow, Prohibited Persons Symbol

(Alt.LJ41968)
9 01-472 1,541972 Red, Warning-Danger Line (Alt.LJ41973)
10 01-47219 ~ ~ 4 1 9 7 3 Yellow, Warning-Danger Line

(Alt.LJ41972)
11 01-100 ~ ~ 6 1 8 5 0 RR Emblem (Pre SBll-B5201
12 01-105 EU55139 RR Emblem (SBll-B520)
13 01-412 LJ41912 Black, Interphone (Alt.LJ41913)
14 01-412A L~ 4 x 9 1 3 White, Interphone (Alt.LJ41912)
Decal Identification
Table 1
REPAIR NO.11
54-10-01
Page 204
Jan.1/00
M RB211 TRENT
MANUAL
STRUCTUAL REPAIR
V I E W ON F R O N T OF ENGINE
0
N
P
0
0
9 ALL DIMENSIONS ARE IN MlLLlMETERS (INCLHES)
:1LL
Installation of Decals
Figure 201
REPAIR NO. 11
54-10-01
Page 205
Jan.1/00
H RB211 TRENT
MANUAL
STRUCTUAL REPAIR
VIEW - AAA
Figure 202
REPAIR NO. 11
54-10-01
Page 2 0 6
Jan. 1 / 0 0
Printed in G r e a t B r i t a i n
RB211 TRENT
STRUCTUAL REPAIR
(LEADING EDGE
OF THE COWL
DOOR)
, ITEM 3 OR I T E M 4 4
(REFER TO
INSTRUCTIONS1
101.00
99.00 (
3.976
(3.898
VIEW - AC
I T E M I1 OR ITEM l2
(CENTERL ,NE OF /(REFER TO
THE REAR NOSE INSTRUCTIONS)
COWL H O I S T P O I N T Y
t
51.00
49.00 (2l. 0929
08
ITEM I OR I T E M 2
(REFER T O
0 INSTRUCTIONS)
-
- 4
REPEAT VIEW - AA
Figure 203
EFFECTIVITY: TRENT REPAIR NO.ll
54-10-01
Page 2 0 7
Jan. 1/00
l@
m RB211 TRENT
MANUAL
STRUCTUAL REPAIR
Figure 204
REPAIR NO. 11
54-10-01
Page 208
an. 1/00
Printed i n Great ~ r i t a i n
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
- c 2 0 4 . 0 0 B 031
2 0 2 . 0 0 (7.953)
, l6.000.630
14.00 (0.551 )
(LEADING EDGE O F
ITEM II OR ITEM 12 - THE COWL DOOR)
(REFER TO
INSTRUCTIONS)
230.00 9.055
(CENTERL I NE OF 228.00 (8.976)
THE REAR NOSE
COWL HOIST POINT) 51.00 2.008
- 4 9 . 0 0 ( 1.929)
1029.50 40.531
1027.50 ( 4 0 . 4 5 3
1
I
ITEM I OR ITEM 2
(REFER TO
INSTRUCTIONS)
ITEM 13 OR ITEM 14
(REFER TO
INSTRUCTIONS)
ITEM 5 OR ITEM 6
(REFER TO
INSTRUCTIONS)
C - 91.00 3 . 5 8 3
89.00 (3.504)
56.00 2 205
C cl
5 4 . 0 0 (2.126 )
REPEAT VIEW -c- AB
Figure 205
REPAIR NO.11
54-10-01
Page 209
Jan.1/00
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
REPAIR N0.12
AIR INTAKE COWL - SKIN
ACOUSTIC PANEL FACING SHEET REPAIR
1. General
A. This repair gives the procedure to fill small holes in the

acoustic panel facing sheet with structural adhesive.
B. The maximum allowable damage is 5 holes of 0.25 in (6,35 mm)

diameter in each panel. The minimum distance between holes is
12 in (305 mm).
.......................................................................
.......................................................................
TASK 71-61-11-3000-XXX FRSZOZO, Trent Engine Manual
3. Eauivment and Materials
- Drills and drilling equipment

- Rotary file
- Syringe
- Heat lamp, 80 to 100 deg C
- Suction cleaner
.......................................................................
.......................................................................
OMat 135 METHYLETHYLKETONE (MEK)
OMat 2/30 TEFLON TAPE, 0.5 in and 2 in wide
OMat 2/113 PARTING FILM
OMat 5/31 ABRASIVE PAPER, Grit Size 400
OMat 8/52 ADHES IVE
4. Procedure (Ref Figure 201)
A. If necessary, remove 'speed1 tape that has been temporarily

applied to the damage.
REPAIR NO. 12
54-10-01
Page 201
Printed in Great B r i t a i n
May 1/00
B. Clean the repair area
WARNING: MEK IS CLASSIFIED AS A HAZARDOUS MATERIAL THAT CAN

CAUSE INJURY OR ILLNESS IF NOT CORRECTLY USED.BEFORE
YOU USE THIS PRODUCT, CAREFULLY READ THE APPLICABLE
MATERIAL SAFETY DATA SHEET AND OBEY ALL THE HEALTH
AND SAFETY PRECAUTIONS.
(1) Clean the panel surface with OMat 2/101 LINT-FREE CLOTH
soaked with OMat 135 MEK. Dry the surface with a new piece
of the cloth before the MEK evaporates.
C. Mask the panel
(1) Cut a hole in a 2 in wide piece of OMat 2/30 TEFLON TAPE

to give a clearance of 0.25 in (6,3 mm) all around the
damage. Apply the tape to the repair area.
D. Remove the damage
(1) Drill a hole of sufficient diameter to remove all loose

and/or frayed material. Make sure you do not drill through
the bottom of the panel.
(2) Remove sharp edges with the rotary file.
(3) Remove debris with the suction cleaner.
E. Dry the repair area
(1) Use the heat lamp to dry the repair area for 6 hours at
80 deg C (176 deg F).
NOTE: You must apply the repair adhesive immediately after

this step.
F. Apply the adhesive
WARNING: THIS ADHESIVE IS CLASSIFIED AS A HAZARDOUS MATERIAL

THAT CAN CAUSE INJURY OR ILLNESS IF NOT CORRECTLY
USED.BEFORE YOU USE THIS PRODUCT,CAREFULLY READ THE
(1) Mix a sufficient quantity of OMat 8/52 ADHESIVE, refer to

the manufacturer's instructions.
REPAIR N0.12
54-10-01
Page 202
Printed i n Great B r i t a i n May 1/00
-B RB211 TRENT
MANUAL
STRUCTUAL REPAIR
(2) Use the syringe to fill the hole(s) in the facing sheet
with the adhesive, until flush with the surface.
(3) If necessary to prevent spillage, seal the repair with

OMat 2/113 PARTING FILM and 0.5 in OMat 2/30 TEFLON TAPE.
G. Cure the adhesive
CAUTION: YOU MUST CAREFULLY MONITOR THE TEMPERATURE, BECAUSE

THE CHEMICAL REACTION OF THE CURE PROCESS GIVES OFF
MORE HEAT.
(1) Use the heat lamp to cure the adhesive for one hour at
90 deg C (194 deg F). If necessary, refer to the
manufacturer's data sheet for different cure cycles.
H. Make the repair flush
(1) Use OMat 5/31 ABRASIVE PAPER to remove unwanted adhesive

and make the repair flush with the panel contour.
J. Clean the repair area
WARNING: MEK IS CLASSIFIED AS A HAZARDOUS MATERIAL THAT CAN

CAUSE INJURY OR ILLNESS IF NOT CORRECTLY USED.BEFORE
(1) Remove sanding dust with the suction cleaner
(2) Clean the repair area with OMat 2/101 LINT-FREE CLOTH
5. Inspection
A. Visually examine the panel to make sure it has been repaired

in accordance with this procedure.
REPAIR NO. 12
54-10-01
Page 203
Printed i n Great Britain May 1/00
RB211 TRENT
STRUCTUAL REPAIR
v/ ACOUSTIC PANEL
ACOUSTIC PANEL
0.250in.(6,35mm)
MAXIMUM DIMENSION
OF THE DAMAGE
5 off POS. PER PANEL
n n n n
LIP SKlN
El
OUTER STAINLESS
STEEL MESH
CARBON PLY
HONEYCOMB
INTERNAL SKlN
SECTION B B -
Acoustic Panel Facing Sheet Repair

Figure 201, Sheet 1
REPAIR N0.12
54-10-01
Page 204
0.25in.(6,3mm) CLEARANCE
AROUNDTHEDAMAGE
DAMAGED AREA MAXIMUM ALLOWABLE AREA

OF SMALL HOLE IS 0.250in. DIA
TEFLON TAPE WIDTH
2.0in.(50,8mm)
1
\
LIP SKIN C
O O O O
STRUCTURAL
OUTER STAINLESS
TEFLON TAPE 1 STEEL MESH
CARBON PLY
SECTION C-C
(With the repair materials installed)
HONEYCOMB COMPLETELY
FILLED WITH ADHESIVE MIXTURE
I
CARBON PLY OUTER STAINLESS
STEEL MESH
SECTION C-C
(With the completed repair)
Acoustic Panel Facing Sheet Repair

Figure 201, Sheet 2
REPAIR N0.12
54-10-01
Page 205
RB211 TRENT
STRUCTURAL REPAlR
MANUAL
AIR INTAKE COWL-ACOUSTIC STRUCTURE PENETRATION REPAIR
1. General
A. This method of repair can be used when penetration to the

acoustic structure of the air intake cowl occurs. The damage
must be more than 1.5in. (38,lmm) from the edge of the panel,
with a separation of 10 in. (254mm) between centres of other
damage/repair and confined to a 1.Oin. (25,4mm) dia hole. There
must be no damage to the internal skin (Ref. Fig. 201).
B. Damage that is not within the limits of FRSZ025 must be

referred to SHORT BROTHERS PLC.
C. This repair removes the damaged area, fills the honeycomb core
with EA934NA and installs a carbon fibre repair ply.
D. To make sure that noise certification requirements are complied

with, repairs in the acoustically treated areas must be
limited. Refer to Trent SRM 54-01-07,for repair limits to the
acoustic Treatment Areas.
E. This repair scheme covers damage restricted to the main area of

the acoustic structure. The damage must be separated from other
areas of damage to allow all of the repair ply to be seated
correctly. The damage must be far enough from the edges of the
skin and/or fastener positions to allow the ply to seat
correctly.
F. If the hole size is not greater,than 0.25in. (6.35mm) repair in

accordance with FRSZOZO.
N0TE:It can be difficult to install the repair materials if the

damage is on the upper area of the cowl. If this is the case,
the best option is to remove the cowl from the engine and
turn it to suit the repair area. Refer to AMM TASK 71-61-41-
000-802 for removal/installation of the nose cowl.
NOTE: Repair FRSZ020 is limited to a maxim- allowable damage of

5-off 0.25in. (6.35mm) diameter holes per panel, with a
minimum 12.0in. (304.8mm) separation.

54-10-01
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RB211 TRENT
STRUCTURAL REPAIR
MANUAL
CAUTION: USE PROTECTIVE MATS WHEN YOU WORK IN THE AIR INTAKE
COWL TO PREVENT DAMAGE TO THE ACOUSTIC STRUCTURE.
......................................................................
.......................................................................
54-01-07 SRM -acoustic Treatment Areas
54-01-06 SRM Tap Test
54-10-01 SRM Identification Ply Orientation -
54-10-01 SRM Repair No 12 (FRSZO20)
70-20-01-100-802 A M M - Cleaning
AMM - Air Intake Cowl -
71-61-41-000-802
Removal/Installation
Heatlamp, 176 to 212 deg F (80 to 100 deg C)
Temperature probes, 32 to 248 deg F (0 to 120 deg C)
Steel roller, 2.0 in. (50,8 mm) diameter, 2.0 in. (50,8 m)
long
Syringe
Suction cleaner
.......................................................................
.......................................................................
OMat 150 ACETONE
OMat 212 BRUSH
54-10-01
Page 202
May 15/05
R8211 TRENT
STRUCTURAL REPAIR
MANUAL

OMat 8/52 EA934NA ADHESIVE/POTTING COMPOUND
OMat 8/160 EA9390 ADHESIVE
..................................................
PART IDENT MATERIAL
..................................................
Air Intake Cowl Composite structure
4. Procedure
WARNING: WHEN YOU DO THIS REPAIR YOU MUST WEAR PROTECTIVE

CLOTHING, GLOVES, DUST MASK AND SAFETY GOGGLES TO
PROTECT YOU AGAINST DUST AND LOOSE PARTICLES WHICH CAN
BE DANGEROUS TO YOUR HEALTH.
WARNING: WHEN YOU USE CLEANING MATERIALS, COATINGS, ADHESIVES
AND SEALANT, REFER TO THE MANUFACTURER'S CONTROL AND
APPLICATION INSTRUCTIONS AND SAFETY NOTICES.
A. Examine the Repair Area (Ref Fig.201)
(1) Do a Tap test of the damaged area, refer to SRM TASK

54-01-06. Mark the damaged area with an Omat 2628
marking pen. The damage must be more than 1.5in.
(38,lmm) from the edge of the panel, with a separation
of 10 in. (254 mm) between the centres of other
damage/repair. The damage must only be in the area of a
1.0 in (25,4 mm) dia hole.
B. Prepare the Damaged Area for Repair (Re£ Fig.202)
(1) Mask around the repair area with OMat 2/30 TEFLON TAPE:
(a) Leave a minimum of 1.0 in. (25,4 mm) of the surface

(stainless-steel mesh) exposed all around the
damage. Carefully apply the teflon tape so that it
goes around the area in a strip, approximately 2.0
in. (50,8 mm) wide.
(2) Remove the damaged material.

54-10-01
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RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(a) Trim the edge of the stainless-steel mesh and carbon

ply. Cut out the damaged honeycomb. Make sure the
sharp edges of the damage are removed. Do not
increase the dimensions of the damage.
(b) Make the surface of the repair area rough with OMat
5/31 WATERPROOF ABRASIVE PAPER.
D. Clean the Repair Area
(1) Remove unwanted materials from the repair area with a

suction cleaner.
(2) Refer to AMM TASK 70-20-01-100-802. Clean the repair area

with OMat 135 METHYLETHYLKETONE (or alternative OMat 150
E. Dry the Repair Area
(1) Use suitable heat lamps to dry the repair area. Keep
the temperature at 158 deg F (70 deg C) for a minimum of
6 hours. The repair materials must be applied
immediately at the end of 6 hours.
F. Fill the Damaged Area (Ref Fig.202)
(1) Mix the OMat 8/52 EA934NA adhesive/potting compound in

accordance with the manufacturer's instructions.
(2) Fill the damaged area with the Omat 8/52 mixture with a
clean spatula or syringe. Make sure all of the visible
honeycomb cells are filled and the mixture is level with
the outer stainless steel mesh.
G. Cure the Potting Compound
(1) Put the temperature probes in position adjacent to the

potting compound.
(2) Use a heat lamp to keep the temperature of the repair

area at 200 deg F (93.3 deg C) for 60 minutes.
Temperature variation to be within + / - 10 deg F (5.5 deg
C)
(3) The rate of the temperature increase and subsequent

decrease must not be greater than 5.5 deg F (3 deg C) in
each minute.

54-10-01
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RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(4) Do not start to measure the cure time until the

temperatures of all the thermocouples are within the
required temperature band of 190 to 210 deg F (87.8 to
97.8 deg C).
H Cut the Repair Ply (Ref Fig.202)
8/206A CARBON CLOTH so that it has a 1.0 in. (25,4 m)
NOTE: To prevent fraying, cut the plies to their completed

dimensions after they are soaked with adhesive.
I. Prepare the Repair Materials
(1) Mix the OMat 8/160 EPOXY ADHESIVE in accordance with the
manufacturer's instructions. The weight of adhesive
necessary will be approximately 1.2 X the weight of the
OMat 8/206A CARBON CLOTH.
(2) Locate the carbon fibre ply on a sheet of OMat 2/113 NON-
POROUS PARTING FILM and approximately mark the position,
remove the carbon ply.
( 3 ) Apply the epoxy adhesive to the approximately marked area

on the parting film. Position the repair ply on the
adhesive, cover with a second sheet of non-porous parting
film and mark the repair ply direction onto the parting
film.
(4) Use the roller to force the adhesive into the repair ply,
the repair ply must be equally soaked with adhesive.
(5) Mark the required repair ply dimensions on the parting

film and cut the repair ply to its finished size (Ref
Fig.202).
NOTE: Let the two pieces of the non-porous parting film

stay on the ply until it is to be used in the
installation procedure.
(6) Cut the ply so that it is the same shape as the area
which the teflon tape identifies,
(7) Keep the repair ply and the adhesive mixture cool until
the installation procedure.
J. Install the Repair Ply (Ref Fig.202)

54-10-01
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May 15/05
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(1) Use an OMat 212 BRUSH to apply an equal layer of OMat

8/160 EPOXY ADHESIVE to all of the repair area.
(2) Install the repair ply on to the repair area.

(a)Remove one sheet of non-porous parting film from
the repair ply.
(b)Put the repair ply, with the adhesive side down, on
to the repair area. The repair ply must have an
equal overlap around the damaged area.
NOTE: Make sure that the repair ply is located with

a position of 0/90° to the undamaged carbon
ply that exist (refer to SRM 54-10-01 for the
ply position of acoustic panel).
(3) Use the roller to remove the air which is caught in the
adhesive and to make the repair ply smooth.
(4) Remove the unwanted adhesive from the teflon tape with
a clean non-metallic spatula
(5) Remove the non-porous film that remains from the repair
P ~ Y
(6) Apply OMat 2/30 TEFLON TAPE if necessary, to hold the
repair ply in position.
K. Cure the Adhesive

(1) Put the temperature probes in to position adjacent to
the outer ply.
(2) Use a suitable heat lamp to keep the temperature of the

repair area at between 200 deg F (93.3 deg C) for 220
minutes. Temperature variation is to be within + / - 10
deg F (5.5 deg C).
(3) The rate of temperature increase and subsequent

decrease must not be faster than 5.5 deg F (3 deg C) in
each minute.
(4) Do not start to measure the time for the adhesive to

cure until the temperatures of all the thermocouples
are within the required temperature band (190 to 210
deg F, 87.8 to 97.8 deg C).

54-10-01
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R May 15/05
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
L. Remove the Repair Equipment
(l) When the cure process is completed, remove the lamp,

the temperature probes and the teflon tape.
M. Make the Edges of the Outer Ply Smooth (Ref Fig.202)
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE REPAIR

AREA OR THE OUTER SURFACE OF THE ACOUSTIC STRUCTURE.
BE CAREFUL AND ONLY REMOVE MATERIAL FROM THE EDGE OF
THE OUTER PLY. DO NOT USE A LIQUID WITH THE ABRASIVE
PAPER.
(1) Make the repair area smooth with OMat 5/31 WATERPROOF
ABRASIVE PAPER. There must not be a sharp edge between
the repair area and the acoustic panel.
N. Clean the Repair Area
(1) Remove all unwanted material from the repair area with
a suction cleaner.
(2) Refer to AMM TASK 70-20-01-100-802. Clean the surface

with OMat 135 METHYLETHYLKETONE (or alternative OMat
150 ACETONE) and OMat 2/101 LINT-FREE CLOTH. Wipe the
area dry before the solvent dries.
(1) Do a visual inspection to make sure that the repair has

been done in accordance with these procedures.
(2) Refer to SRM TASK 54-01-06, tap test the repair area.
If disbonds or delaminated areas are found, refer to
SHORT BROTHERS PLC.
P. Record the Repair
(1) Vibro-etch the repair scheme number "FRSZ025" onto the

nose cowl modification record plate.

54-10-01
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RB211 TRENT
STRUCTURAL REPAIR
MANUAL
O--.---- A
DAMAGED AREA
ACOUSTIC PANEL
DAMAGE l.Oin. (25.4rnrn)

DIAMETER MAX
.f
- \ n n -
LIP SKlN
El OUTER STAINLESS
STEELMESH
i
CARBON PLY
A------
/ \,
HONEYCOMB . INTERNAL SKIN
SECTION B - B
~ c o u tic
s Structure Damage ~ i m ts
i
Figure 201

54-10-01
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R May 15/05
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
l. O h . (25.4mm) CLEARANCE
,AROUND THE DAMAGE
ACOUSTIC PANEL
DAMAGED AREA -,
TEFLON TAPE WIDTH
2.0in. (50.8rnm)
(APPROX)
MINIMUM RADIUS
0.5in. (12.7rnm)
lBin. (25.4mm)
TEFLON
OVERLAP REPAIR PLY TAPE
(MINIMUM)-l \ / OUTER STAINLESS
CARBON PLY --- /-'

STEEL MESH
/'
I
'
SECTION C C -
POT7 NG *@
' Vtih the repair rnate"als installed)
COMPOUND
CHAMFERED
EDGES
REPAIR PLY /
OUTER STAINLESS
STEEL MESH
CARBON PLY ---- A----
/' SECTION C - C
POTTING (Wth the completed repair)
COMPOUND
Acoustic Structure Repair Details

Figure 2 0 2

54-10-01
Page 209
May 15/05
g STRUCTURAL R E W R
MANUAL
AIR INTAKE COWL - LIP SKIN OUTER EDGE PATCH REPAIR
1. General
air intake cowl.
B. This repair removes the damaged area and installs a repair

patch.
.....................................................................
.....................................................................
Surfaces
54-02-10 Fasteners -
~nstallation/~emoval
Inspection
Suction cleaner
.....................................................................
.....................................................................
OMat 150 ACETONE (Alternative to MEK)
LOCAL SUPPLIER ALUMINIUM ALLOY 2219-T31*;0.063 in. (1,60
mm) THICK
Omat 262 MARKING PEN
NOTE: Aluminium Alloy 2219-0 may be used in lieu of 2219-T31, but a

different heat treatment procedure will be required. Contact
REPAIR N0.14
54-10-01
Page 201
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
C. Repair parts
.....................................................................
PART NO. PART IDENT

R CR3552-5-3 (alternative) Cherrymax rivet
R
R
R CR2538-5-5 Cherrylock rivet
R
R CR2538-5-6 Cherrylock rivet
~ ~ 3 5 5 2 - 5 -(alternative)
6 Cherrynax rivet
R
MS20427M5-5 Solid monel rivet
R MS20427M5-6 Solid monel rivet
SJ30060 Lip skin (undrilled)
R SJ30060A Lip skin segment 0"-90" (undrilled)
R SJ30060B Lip skin segment 90"-180"(undrilled)
R SJ30060C Lip skin segment 180"-270"(undrilled)
R SJ30060D Lip skin segment 270"-0" (undrilled)
SJ30060E Lip skin segment 45"-135" (undrilled)
R SJ30060F Lip skin segment 135"-225"(undrilled)
R SJ30060G Lip skin segment 225"-315"(undrilled)
R SJ30060H Lip skin segment 315"-45" (undrilled)
R
Alternatives:
R Cherrylock rivets CR2538 may be used in lieu of solid monel
R
R paragraph 12. F (4 .
Cherrymax rivets CR3552 may be used in lieu of Cherrylock rivets
CR2538.
R
R D. Component Material
R -------,--------,,,----------------------
R PART IDENT MATERIAL

R .....................................................................
R Lip skin Aluminium Alloy
R
REPAIR N0.14
Page 202
.
RB211 TRENT
STRUCTURAL REPAIR
MANUAL

HEALTH PRECAUTIONS.
2/101 LINT-FREE CLOTH. Dry the area with a clean OMat 2/101
LINT-FREE CLOTH while the solvent is still wet.
Prepare the Damaqed Area for Repair (Ref Fis.201)
A. Make a mark around the damaged area of the lip skin to be
removed with an OMat 262 MARKING PEN. The cut lines must be
at right angles or parallel to the airflow (except where it
is necessary to have hole edge distances for the rivets).
Make sure the corners of the cut out have a minimum radius of
0.50 in. (12,7 m ) .
USE CUTTING TOOLS.

DISTRIBUTION RING OF THE ENGINE ANTI-ICING SYSTEM.
B. Drill out the rivets contained within the repair area joining
the lip skin to the outer attachment angle. Also drill out
approximately 12 off rivets either side of the repair area
using standard workshop tools (Ref. SRM TASK 54-02-10).
C. Lift the lip skin in the repair area away from the attachment
D. Make a protection plate to go between the lip skin and the

no sharp edges.
REPAIR N0.14
54-10-01
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P r i n t e d i n Great B r i t a i n Mar. 10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
E. Carefully put the protection plate between the lip skin and
R the attachment angle. Make sure there is no unwanted
R material between the interfaces.
R
6. Cut Out the Damaued Area of the Lip Skin (Ref Fiu.201)
R
R A. Use standard workshop tools to cut out the damaged area.
R B. Remove the jointing compound from the joint faces.
(1) Make sure you keep hole edge distance for the rivets
(minimum edge distance = 2D, D = fastener diameter).

PAPER.
R
7. Apply Surface Protection to the Bare Edues
R
R HAZARDOUS MATERIAL, WHICH MAY CAUSE INJURY OR ILLNESS
R IN ACCORDANCE WITH THE MANUFACTURER'S SPECIFIC SAFETY
R PRODUCT, CAREFULLY READ THE APPLICABLE "MATERIAL SAFETY
R DATA SHEET" AND FOLLOW ALL LISTED SAFETY AND HEALTH
R PRECAUTIONS.
R
edges of the repair cut-out (Ref. 54-02-03, Protective
R
REPAIR N0.14
54-10-01
Page 204
RB211 TRENT
STRUCTURAL REPAIR
m MANUAL
8. Examine the Anti-Ice Rinq
A. Examine the anti-ice ring at the repair area for the

following types of damage: friction, gouged, cracked, nicked,

9. Make the Repair Parts (Ref Fis.203 and Fis.204)
A. Mark out the repair patch.
(1) Refer to the cut-out for the dimensions of the patch.

NOTE: The patch must be taken from the same part of
the replacement lip skin (SJ30060) as the cut-
out in the damaged lip skin. Alternatively, the
patch may be taken from the same area on a
replacement lip skin segment as the cut-out in
the damaged lip skin. Refer to Figure 202.
NOTE: The mark must be at least 3.6 in. (91 mm) away from
the repair patch identified in step 9.A. This will

USE CUTTING TOOLS.
C. Carefully cut out the repair patch and the butt straps from
the lip skin (S530060) or from the correct lip skin segment.
(2) Leave a trim allowance on the patch.
REPAIR N0.14
54-10-01
Page 205
-@ RB211 TRENT
MANUAL
STRUCTURAL REPAIR

straps.
(1) Use a sheet of 0.063 in. (1,60 mm) thick ALUMINIUM

procedure will be required. Contact Shorts
Repair Engineering for details.

straps (Ref. AMM TASK 70-20-02-230-803).


F. Trim and deburr the butt straps to their correct size.
(2) The clearance between each butt strap and each

(0,51 to 1,27 nun).
REPAIR N0.14
54-10-01
Page 206
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(3) Cut the top butt strap so that it will fit between the
two side butt straps. The clearance between the top
butt strap and each side butt strap must be between
0.020 to 0.050 in. (0,51 to 1,27 mm).
WARNING : CHROMATE CONVERSION COATING IS CLASSIFIED AS A
HAZARDOUS MATERIAL WHICH MAY CAUSE INJURY OR ILLNESS
IF NOT PROPERLY USED. THIS PRODUCT SHOULD BE USED
THIS PRODUCT, CAREFULLY READ THE APPLICABLE "MATERIAL
HEALTH PRECAUTIONS.
G. Apply the OMat 175D CHROMATE CONVERSION COATING to the repair

patch and butt straps (Ref SRM TASK 54-02-03).
10. Tem~orarilvInstall the Butt S t r a ~ s (Ref Fiq.203 and Fiu.204)
A. Make a mark along the center of each butt strap. Use an OMat
262 MARKING PEN.
B. When you install each butt strap, align the center of the
strap with the edge of the lip skin. Use soft faced clamps
to hold the straps in position.
WARNING: PUT ON PROTECTIVE CLOTHING, GLOVES AND GOGGLES

WHEN YOU USE CUTTING TOOLS.
D. Drill the rivet holes in the lip skin through the butt
straps. Make sure that 2D minimum edge distance and 6D - 8D
diameter) .
(1) Do not drill the holes for the repair patch in the butt
straps at this step.
(2) Do not drill the holes in the repair patch at this

step.
(3) Use a 0.094 in. (2,40 m) diameter drill and follow the
REPAIR N0.14
54-10-01
Page 207
R8211 TRENT
STRUCTURAL REPAIR
MANUAL
(4) Use a 0.159 in. (4,05 mm) drill to finish the rivet
holes for solid monel rivets MS20427M5. Cherrylock
rivets CR2538-5 may be used in lieu of solid monel
rivets MS20427M5-6, but the holes must be finished
using 0.177 in (4,50 mm) drill at this stage.
paragraph ll.D.(2)) that the holes are
countersunk to the correct depth.
(5) Remove the butt straps and deburr the holes in the lip
skin, the packers if used and the butt straps. Use
standard workshop tools.
R
R 11. Assemble the Revair Patch (Ref Fis.203 and Fiq.204)
R A. Drill the rivet holes in the repair patch to match the

R existing holes.
(1) These holes must align with the holes in the attachment
angle at the outer akin side.
necessary a hole finder or template.
holes for Cherrylock rivets 2538-5.
R
R B. Temporarily inatall the butt straps and the repair patch.
C. Drill the rivet holes through the repair patch and the butt
R pitch are achieved on all fastener holes (D = fastener
diameter).
rivet holes for Cherrylock rivets 2538-5.
REPAIR N0.14
54-10-01
Page 208
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
D. Countersink the rivet holes on the air-washed surface of the

lip skin and the repair patch.
(1) Use a 100 degree countersink tool.
flush with the surface of the lip skin/repair patch.
E. Deburr the edges of the holes in the butt straps and the
repair patch.
(1) Remove the butt straps and the repair patch.
(2) If it is necessary, deburr the edges of the holes in
the attachment angle.
(3) Use the standard workshop tools to deburr the holes in

the repair patch and the corresponding holes in the
butt straps.
12. Apply the Surface Protection

DATA SHEET" AND FOLLOW ALL LISTED SAFETY AND HEALTH
PRECAUTIONS.

edges of the holes in the butt straps, lip skin, attachment
angle and the repair patch (Ref. SRM TASK 54-02-03).
A. Remove all unwanted material from the repair area with a

suction cleaner. Make sure that no unwanted material remains
between the lip skin and the bulkhead.
REPAIR N0.14
54-10-01
Page 209
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
R 14. Clean the ReQair Parts
R WARNING: METHYLETHYLKETONE AND ACETONE ARE CLASSIFIED AS

R HAZARDOUS MATERIALS WHICH MAY CAUSE INJURY OR ILLNESS
R ONLY IN ACCORDANCE WITH THE MANUFACTURER'S SPECIFIC
R SAFETY AND HEALTH RECOMMENDATIONS. PRIOR TO USE OF
R THESE PRODUCTS, CAREFULLY READ THE APPLICABLE "MATERIAL
R SAFETY DATA SHEETn AND FOLLOW ALL LISTED SAFETY AND
R HEALTH PRECAUTIONS.
R
with OMat 135 METHYLETHYLKETONE (or alternative OMat 150
R
R 15. Attach the ReQair Parts on to the Lir, Skin (Ref Fiu.203 and
R Fiu.204)
SHEETt1AND FOLLOW ALL LISTED SAFETY AND HEALTH
PRECAUTIONS.

parts.

interfaces.
assembled.
R B. Use a grip gauge to find the rivet shank length required.

R
C. Where the rivets were previously removed from the lip skin,
(ref. paragraph 5.B), approximately 12 off holes, either side
R of the cut-out) attach the lip skin back to the outer skin
R capping-strap & outer attachment angle with Cherrylock rivets
CR2538-5-4, CR2538-5-5 and CR2538-5-6 as applicable (Ref. SRM
R TASK 54-02-10) .
R
REPAIR N0.14
54-10-01
Page 210
H FIB211 TRENT
MANUAL
STRUCTURAL REPAIR
D. Wet assemble the butt straps to the lip skin and rivet in
position with solid monel rivets MS20427M5-5 and MS20427M5-6
(Ref. SRM TASK 54-02-10) .
NOTE: Rivets must be squeezed. Cherrylock rivets CR2538-5-4
may be used in lieu of solid monel rivets MS20427M5-6,
if holes have been finished using 0.177 in (4,50 mm)
drill (ref. paragraph lO.D(4)).
E. Make sure there is no swarf or any unwanted materials in the
'D' chamber. Attach the patch temporarily to the outer angle
and butt straps with 5/32 clipper pins.
F. Rivet the patch to the outer attachment angle with Cherrylock
CR2538-5-4 and CR2538-5-5 rivets (Ref. SRM TASK 54-02-10).
G. Rivet the patch to the butt straps with Cherrylock CR2538-5-3
rivets (Ref. SRM TASK 54-02-10).
16. Applv Aerodvnamic Sealant

FRSZO14) .

A. Vibro-etch the repair scheme number "FRSZ004" onto the nose

cowl modification record plate.
REPAIR N0.14
54-10-01
Page 211
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
I
PROTECTION
PLATE
LlPSKlN
OUTER SKlN
CUTTING PRECAUTION
LIPSKIN OUTER SKIN
LIPSKIN
DAMAGE
"o++
0
.+++
+ l
*.
* * ++
++
REMOVE RIVETS
(12 off approx)
*. ++
CUT LINE
c - - -
++ REPAIR AREA
*. ++
LIPSKIN
DAMAGE
MINIMUM RADIUS
12,70 mm (0 50 in)
/---• +, *.
.*
*. ++
++ REMOVE RIVETS
(12 off approx)
**
0
.p++
+
m
a
0
1
0
- l
0
E
E
t
z
Air Intake Cowl Lip Skin - Details of the Repair Cut-Out
Figure 201
REPAIR N0.14
54-10-01
Page 212
Printed i n Great B r i t a i n Mar. 10/08
R8211 TRENT
STRUCTURAL REPAIR
MANUAL
Air Intake Cowl Lip Skin - Details of the Replacement Lip Skin
Segments
Fig. 202
REPAIR N0.14
Page 213
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
REPLACEMENT ., , BUT; STRAP

LIPSKIN (Undrilled) REPLACEMENT LIPSKIN
n / SEGMENT (Undrilled) /' r,
V
CUT OUT THE
PATCH AND
BUTT STRAPS

L PSKIN
PROFILE
1
.--.
e
71
] BUTT STRAP
6D MINIMUM
t-7
- CENTER LINE --
RIVET PATTERN
L
Air Intake C o w l Lip Skin Repair Patch - Details of the Repair

Parts and the Rivet Pattern
Figure 203
REPAIR N0.14
54-10-01
Page 214
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
LIPSKIN OUTER SKIN
- \ ++ ++ A
BUTT +- ++
++
STRAPS
++
=.
'0
++
l0
0
0
0
0
o f *
0
0
0
0
0
O00l0l
* I
%++
0 0 .
0 m
L o o * / - - p E **++ E
0 - * l .
a++
o o * * * * *
. +
I
p
O . . . . .
o o Lo o o0 o 0 o 0 o 0 ' *\l+
.* h p A T c H
o MS20427M5
CO-0 0 0 0'
l +
SOLID RIVETS *D ++
CR2538-5
+
CHERRYLOCK RIVETS
ORIGINAL RIVETS
'.
+ ++
+
\ ++ ++
0,51 TO 1,27 mm OUTER SKlN

Ll PSKl N (0.02 TO 0.05 in)
\ CLEARANCE I
PATCH
PATCH
BUTT STRAP
SECTION
F-F BUTT STRAP
l I ANGLE
SECTION
E=E
Air Intake Cowl Lip Skin Repair Patch Cut from the Replacement
Lip Skin/Lip Skin Segment - Installation of the Repair Parts
Figure 204
REPAIR N0.14
Page 215
Printed in Great Britain Mar. 1 0 / 0 8
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
AIR INTAKE COWL - REPAIR OF SHORCOAT PROTECTIVE COATING ON LIPSKIN
1. General
A. There has been a modification introduced (ref. SB71-B1611 which

applies a protective coating, called Shorcoat, to the air
intake cowl lip-skins. Damage to the protective coating can be
repaired using this repair procedure.
B. This procedure uses a repair coating, Sermatel 1382, which is

similar to the coating used during manufacture, but it can be
cured at room temperature.
C. This procedure may be used for the purposes that follow:-
(1) To repair cosmetic defects such as burnish marks or

stains.
(2) To repair any amount of damage to the coating, at any

location, where there is no damage to the aluminium alloy.
(3) To repair scratches, gouges, and abrasions, which

penetrate into the aluminium alloy with dimensions not
more than the limits given in the allowable damage
section of the Structural Repair Manual 54-10-01, page
block 101.
(4) To apply the protective coating where none has previously

been e.g. if a section of the lip-skin is being replaced
and there is a coating on the repair section but not on
the original lip-skin, it may be necessary for appearance
reasons to apply the matching coating on the original
lip-skin.
D. FRSZOl5 is NOT to be applied for repair if scratches or nicks

have been selected as cracks in accordance with the limits
given in the allowable damage section of the Structural Repair
Manual 54-10-01, page block 101.
E. The temperature of the application environment during coating

application must be 10°C to 35OC (65OF to 95OF) .
F. The surface temperature of the structure must be allowed to
reach k5OC (*g0F) of the application environment before
commencing the coating operation.
G. All equipment must be clean and fully functional.

REPAIR N0.15
54-10-01
Page 201
May 15/05
H. Throughout the repair procedure care must be taken to make sure
that the temperature of any adjacent composite components are
not more than 90°C.
.......................................................................
SRM 54-02-03 Protective Treatment -Metallic Surfaces

SRM 54-02-02 Repair Minor Damage - Metallic Surfaces
AMM 70-20-01-100-802 Cleaning
Equivalent equipment and materials may be used.
A. Standard equipment:
High Volume Low Pressure Paint Spray Gun

Portable Infra-red Heat Lamp with Power Controller
Mechanically operated paint mixer/stirrer.
Thermocouple or digital thermometer, with point probe,
with an accuracy of + 3OC.
Paint Film Thickness Measuring Meter Permascope Type
3e2 TAN B or equivalent
Screen Filter - 100 mesh (0.14m aperture).
...............................................................
...............................................................
OMat 5/33 - 5/48 ABRASIVE PAPER, 320 - 80 GRIT
OMat 583 SCOTCHBRITE PADS, TYPE A, VERY FINE 3M
LTD
OMat 175 CHROMATE CONVERSION COATING
APPROVED SOLVENTS:
OMat 150 ACETONE BS 509 (0-A-51)

OMat 212 PAINT BRUSH
EFFECTIV1TY:TRENT REPAIR N0.15
54-10-01
Page 202
May 15/05
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
OMat 8/244 SERMETEL 1382, COMPONENTS A AND B

OMat 237 MASKING TAPE
OMat 2/171 TACK RAGS, AWLGRIP PRODUCT CODE 73009
OMat 2/172 FLATBACK MASKING TAPE, 1.0 IN. WIDE, 3M
CODE 250
Requirements
A. The temperature of the application environment during coating

application must be 10°C to 35OC (65OF to 95OF) .
B. The surface temperature of the structure must be allowed to
reach k5OC (kg°F) of the application environment before
commencing the coating operation.
C. All equipment must be clean and fully functional.
E. Throughout the repair procedure care must be taken to make sure

that the temperature of any adjacent composite components are
not more than 90°C.
5. Procedure

CLOTHING, GLOVES, DUST MASK AND SAFETY GOGGLES TO PROTECT
YOU AGAINST DUST AND LOOSE PARTICLES, WHICH CAN BE
DANGEROUS TO YOUR HEALTH.

SEALANT, REFER TO THE MANUFACTURER'S CONTROL AND
A. Prepare the surface
(1) Surface preparation for repair of appearance defects

(original coating intact):
(a) Refer to AMM TASK 70-20-01-100-802. Clean the area

with OMat 150 ACETONE) and OMat 2/101 LINT-FREE
CLOTH. To dry, wipe with OMat 2/101 LINT-FREE CLOTH
REPAIR N0.15
54-10-01
Page 203
May 15/05
(b)
P RB211 TRENT
MANUAL
STRUCTURAL REPAIR
Allow a minimum of 30 minutes to dry before the next

operation. Subsequent processing must take place
within 24 hours. Make sure that the prepared area is
kept clean and dry.
(2) Surface preparation for damage to the coating where there

is no damage to the aluminium alloy:
(a) Locally abrade the damaged area using OMat 5/33

ABRASIVE PAPER, 320 GRIT or OMat 583 SCOTCHBRITE PAD
to remove the damaged coating and around the edges
of the coating that remains. Make a smooth blend
with the metal underneath.
NOTE: Any additional, loose or defective coating

should also be removed using OMat 5/48 - 5/33
ABRASIVE PAPER, 80 - 320 GRIT, to achieve a
bare aluminium surface. Take care not to
remove additional aluminium material.
(b) Refer to AMM TASK 70-20-01-100-802. Remove all

traces of abrasive and sanding residues by wiping
the area with OMat 2/101 LINT-FREE CLOTH moistened
with water or OMat 150 ACETONE). To dry, wipe with
OMat 2/101 LINT-FREE CLOTH before the fluid dries.
WARNING : CHROMATE CONVERSION COATING IS CLASSIFIED AS A

HAZARDOUS MATERIAL, WHICH MAY CAUSE INJURY OR
ILLNESS IF NOT PROPERLY USED. THIS PRODUCT
SHOULD BE USED ONLY IN ACCORDANCE WITH THE
RECOMMENDATIONS. BEFORE THE USE OF THIS
PRODUCT, CAREFULLY READ THE APPLICABLE
"MATERIAL SAFETY DATA SHEET" AND FOLLOW ALL
(c) Apply OMat 175 CHROMATE CONVERSION COATING in

accordance with SRM 54-02-03, to any areas where
bare aluminium alloy has been exposed.
(d) Allow a minimum of 30 minutes to dry before the next

kept clean and dry.
(3) Surface preparation for damage, which penetrates into the

aluminium alloy:
REPAIR N0.15
54-10-01
Page 204
May 15/05
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
NOTE: Dimensions must not be more than the limits given

in the allowable damage section. Refer to SRM 54-
10-01.
(a) Refer to SRM TASK 54-02-02. Make sure all damage has
been blended out to a smooth profile. Finish blend
using OMat 5/33 ABRASIVE PAPER, 320 GRIT around the
edges of the coating that remains. Make a smooth
blend with the metal underneath. Care must be taken
to remove the minimum amount of coating and to
expose only the minimum amount of bare aluminium
alloy.
(b) Refer to AMM TASK 70-20-01-100-802. Wipe the area to

remove all traces of abrasive and sanding residues
with OMat 2/101 LINT-FREE CLOTH moistened with water
or OMat 150 ACETONE). Dry by wiping with OMat 2/101
LINT-FREE CLOTH before the fluid dries.

"MATERIAL SAFETY DATA SHEET1' AND FOLLOW ALL
(C) Apply OMat 175 CHROMATE CONVERSION COATING in

accordance with SRM 54-02-03, to all areas where

within 24 hours. Ensure that the prepared area is
kept clean and dry.
(4) Surface preparation for a section of lip-skin which has

not previously had the coating applied.
(a) Abrade the area to remove any anodic coating from

the surface. Use OMat 5/48 - 5/33 ABRASIVE PAPER, 80
- 320 GRIT, to achieve a bare aluminium surface.
REPAIR N0.15
54-10-01
Page 205
May 15/05
H
""
NOTE :
RB211 TRENT
MANUAL
STRUCTURAL REPAlR
When you remove the anodic coating from the

surface, make sure that only the minimum
amount of material is removed to expose bare
aluminium. The anodised surface finish has a
distinct, hard, dull grey appearance.
Complete removal will be indicated by a
bright silver appearance on the bare
aluminium surface. The thickness of the lip-
skin must not be reduced.
(b) Refer to AMM TASK 70-20-01-100-802. Wipe the area to

remove all traces of abrasive and sanding residues
with OMat 2/101 LINT-FREE CLOTH moistened with water
or an approved solvent OMat 150 ACETONE). Dry by
wiping with OMat 2/101 LINT-FREE CLOTH before the
fluid dries.

"MATERIAL SAFETY DATA SHEETn AND FOLLOW ALL
(c) Apply OMat 175 CHROMATE CONVERSION COATING in

accordance with SRM 54-02-03, to all areas where

kept clean and dry.
B. Mask the adjacent areas
(1) Mask off any areas on the outer skin or intake barrel of
the nose cowl, which may be subject to overspray, use
paper or plastic sheeting secured with OMat 237 MASKING
TAPE. Use OMat 2/40 HEAT RESISTANT MASKING TAPE to mask
structures on which the finish will be cured at raised
temperatures.
NOTE: Do not mask off the surface, which immediately

surrounds the repair area, as this is likely to
produce a witness line after recoating.
REPAIR N0.15
54-10-01
Page 206
May 15/05
C.
Hm RB211 TRENT
MANUAL
STRUCTURAL REPAIR
Mixing and Application of the coating
(1) Mixing the Coating
WARNING: SERMETEL 1382 OMAT 8/244 IS CLASSIFIED AS A

ILLNESS IF NOT PROPERLY USED. THIS PRODUCT SHOULD BE
USED ONLY IN ACCORDANCE WITH THE MANUFACTURER'S
SPECIFIC SAFETY AND HEALTH RECOMMENDATIONS. BEFORE
THE USE OF THIS PRODUCT, CAREFULLY READ THE
APPLICABLE "MATERIAL SAFETY DATA SHEET" AND FOLLOW
ALL LISTED SAFETY AND HEALTH PRECAUTIONS.
(a) Mix the OMAT 8/244 SERMETEL 1382, COMPONENTS A AND

B, as follows:
Component A - 2 parts by weight
Component B - 1 part by weight
Pot life at 18OC to 2g°C (65OF to 85OF) = 2 hours
NOTE: Shake the individual components thoroughly,

before they are combined, to put the pigment
in the solution. When a complete kit is used,
scrape out any pigment that remains from the
cans. Stir for at least five minutes after it
is combined.
(b) After mixing, pass the material through a 100 mesh,

(0.14mm aperture) screen filter .
(C) Allow the mixed coating to reach the temperature of
the application environment.
(2) Application of the coating.
(a) Wipe the surface with a clean OMat 2/171 TACK RAG.
(b) Use paint spraying equipment to ensure that the

manufacturers recommended working pressure is used,
apply a light mist coat and allow the coating to air
dry for 5 to 10 minutes. Apply enough double track
coats (typically two coats) to produce a dry film
thickness of 50 to 100 microns (0.002 to 0.004 in.).
Allow the coating to dry at room temperature for 7
to 12 minutes between each coat.
REPAIR N0.15
54-10-01
Page 207
May 15/05
d STRUCTURAL REPAIR
MANUAL
NOTE: When the repair procedure is used to touch up

appearance defects on the surface of the
original coating, apply only the minimum
coating required to restore the original
appearance.
NOTE: A test piece sprayed in the same way as the
repair may be used to determine the coating
thickness.
NOTE: A coating thickness up to 125 microns shall

be acceptable, provided that the appearance
is acceptable.
(3) Cure the coating for a minimum of 48 hours at a

.
temperature of 18OC to 35OC (65OF to 95OF) The cure time
may be reduced by the temperature being raised to 60°C to
70°C (140 OF to 158OF) for a minimum period of 8 hours or
45OC to 55OC (113OF to 131°F) for a minimum period of 16
hours. This may be achieved using a heat lamp.
NOTE: Make sure that the temperature of any adjacent

composite components does not exceed 90°C.
D. Inspect the repair
(1) Appearance
(a) Coated areas must be constant in texture and must be

free from runs, sags, roughness, and wrinkling.
(b) Repairs may have a silvery appearance compared with

the coating that surrounds it. This will dull down
when in-service.
(2) Adhesive Test
(a) There must be no adhesion failure when tested as

follows :
1) Firmly press 6.0 in. (150,O mm) of OMat 2/172

FLATBACK MASKING TAPE, 3M CODE 250, 1.0 in.
(25,4 mm) WIDE, on to the repair site. The age
of the tape must not be more than 6 months.
Press the tape down, use firm hand pressure.
2) Remove the tape with a single, firm, abrupt

perpendicular motion.
REPAIR N0.15
54-10-01
Page 208
May 15/05
RB211 TRENT
STRUCTURAL REPAl R
MANUAL
3) Examine the tape and the repair area for

evidence of coating removal. If coating is
removed, repeat the repair.
E. Record the Repair
(1) Vibro-etch the repair scheme number "FRSZ015" onto the

nose cowl modification record plate.
REPAIR N0.15
54-10-01
Page 209
May 15/05
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR NO. 16 (FRSZ0271
A I R INTAKE COWL OUTER SKIN SURFACE DAMAGE REPAIR AND STIFFENER FASTENER RE-
INSTALLATION
1. General
A. T h i s r e p a i r may b e u s e d t o r e p a i r damage t o t h e composite l a y e r s of

t h e o u t e r s k i n of t h e i n t a k e cowl where r u p t u r e ( d i s c o n t i n u i t y ) o f
t h e p l i e s has occurred.
B. R e p a i r must b e c a r r i e d o u t under c o n t r o l l e d c o n d i t i o n s : t e m p e r a t u r e
must b e m a i n t a i n e d a t 20 t o 25 deg C (68 t o 77 deg F) and t h e
h u m i d i t y a t 50 p e r c e n t o r less.
C. R e f e r t o SRM 54-10-01, Page Block 1, I d e n t i f i c a t i o n f o r c o r r e c t

number and o r i e n t a t i o n of p l i e s i n a r e a of damage.
D. T h i s r e p a i r scheme i n c l u d e s damage up t o and i n c l u d i n g 1 5 2 . 4 mm

( 6 . 0 i n . ) d i a . For damage more t h a n t h i s c o n t a c t Rolls-Royce p l c .
E. T h i s r e p a i r scheme c o v e r s damage r e s t r i c t e d t o t h e main a r e a o f t h e

s k i n . The damage must b e s e p a r a t e d from o t h e r a r e a s of damage t o
let a l l the repair plies s e a t c o r r e c t l y . The damage must b e a
s u f f i c i e n t d i s t a n c e from t h e edges of t h e s k i n and edge f a s t e n e r
positions t o let a l l the p l i e s t o be i n s t a l l e d c o r r e c t l y .
F. T h i s r e p a i r i s f o r cowls t h a t have f a s t e n e r s i n s t a l l e d through t h e

main a r e a of t h e o u t e r s k i n a t t h e s k i n s t i f f e n e r l o c a t i o n s ( r e f .
SRM 54-10-01) a s i d e n t i f i e d i n FRSZ006. The r e p a i r p e r m i t s p l i e s t o
b e i n s t a l l e d where f a s t e n e r s a r e l o c a t e d i n t h e s t i f f e n e r s . The
f a s t e n e r s must b e removed b e f o r e t h e p l i e s a r e a p p l i e d and t h e n re-
i n s t a l l e d a f t e r t h e r e p a i r p l i e s have been c u r e d . T h i s r e p a i r
p r o c e d u r e i n c l u d e s i n s t r u c t i o n s f o r removal and r e - i n s t a l l a t i o n of
t h e s e f a s t e n e r s . To g e t a c c e s s t o t h e s e f a s t e n e r s i t i s n e c e s s a r y
t o remove t h e a i r i n t a k e cowl, r e f e r t o AMM TASK 71-61-41-000-802,
and p l a c e i t i n a " l i p s k i n downN d i r e c t i o n .
2. Referenced I n f o r m a t i o n
.- . .
:,
REFERENCE DESIGNATION . .. . .
.......................................................................
.
.
.. ,. .
):" .L
. ,.
.
SRM 54-02-04 Repair P a i n t F i n i s h
SRM 54-10-01 R e p a i r No. 6 - Outer S k i n ~ o l R
e epair
(FRSZO06)
SRM 54-10-01 R e p a i r No. 7 - Outer S k i n Hole R e p a i r
(FRSZO07)
SRM 54-10-01 Identification
R e p a i r No.16
Page 201
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
SRM 54-02-10 Fasteners-Installation and ~ = m o ~ a l

SRM 54-02-01 Seal Exposed Fibres (FRS3254)
SRM 54-01-06 Tap Test
AMM TASK 70-51-00-910-802 Torque Tightening
AMM TASK 71-61-41-000-802 Air Intake Cowl - Removal
AMM TASK 71-61-41-400-802 Air Intake Cowl - Installation
Vacuum suction pump, 0 to 762 mm (0 to 30 in.) of mercury

$ 1 ; \l
Steel roller, 50,8 mm (2.0 in.) diameter, 50,8 mm (2.0 in.) long
Suction cleaner
.......................................................................
.......................................................................
OMat 150 ACETONE
OMat 212 BRUSH
.-
OMat 2/110 Adhesive Tape, Vacuum Bag Seal
OMat 2/98 Lockwire
1
.
-<
i
-
2 .

OMat 8/247 Epocast 3 5 ~ / 9 2 7EPOXY ADHESIVE
OMat 4/47 PL32M Hylomar
OMat 805 Resin
Repair No.16
54-10-01
Page 202
Printed in Great Britain Mar, 10/07
ri 2
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
OMat 806 Hardener

OMat 262 Marker Pen
Local supplier Aluminium Alloy Sheet (1.27 mm (0.050 in.) approx)
C. Repair Parts
............................................................................
-
PART NUMBER PART IDENT
............................................................................
-
HST315AG6-3 Hi-Lite Pin
. .
HST315WF6-3 (a1ternative) Hi-Lite Pin
HST97DU6 Hi-Lite Collar ... ,
MBF2113-6-250 Composi-Lok ~astenc&
..................................................
PART IDENT MATERIAL
..................................................
.Repair No. 16
Page 203
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
4. E x a m i n e the R e p a i r A r e a ( R e f Fig. 2 0 1 )
A. D o a T a p T e s t , refer t o SRM TASK 5 4 - 0 1 - 0 6 t o m a k e s u r e there are no

delaminations and m a k e a v i s u a l i n s p e c t i o n of t h e d a m a g e . U s i n g
standard w o r k s h o p t o o l s , m e a s u r e t h e depth of t h e d a m a g e . M a k e s u r e
t h a t t h e d a m a g e i s i n t h e l i m i t s of t h i s repair s c h e m e .
B. Make a n o t e of t h e depth of t h e d a m a g e , and calculate t h e number of

..,:.. '
p l i e s necessary t o repair t h e d a m a g e as f o l l o w s ... . ...
I -1.
DEPTH O F DAMAGE N O . O F P L I E S REQUIRED
U p t o 0 , 3 3 mm ( 0 . 0 1 3 i n .) 2
0 , 3 5 mm ( 0 . 0 1 4 i n . ) t o 0 , 6 6 mm ( 0 . 0 2 6 i n.) 3
0 , 6 8 mm ( 0 . 0 2 7 i n . ) t o 0 , 9 9 mm ( 0 . 0 3 9 i n.) 4
1 / 0 1 mm ( 0 . 0 4 0 i n . ) t o 1 / 3 2 mm ( 0 . 0 5 2 i n.) 5
1 / 3 4 mm ( 0 . 0 5 3 i n . ) t o 1 / 6 5 mm ( 0 . 0 6 5 i n.) 6
1 / 6 7 mm ( 0 . 0 6 6 i n . ) t o 1 / 9 8 mm ( 0 . 0 7 8 i n.) 7
If t h e d a m a g e goes through t h e panel, do SRM R e p a i r N o . 7 (FRSZ007).
~f you c a n n o t be s u r e of t h e depth of t h e damage i n s t a l l one m o r e

carbon repair p l y . For example, i f you are n o t s u r e i f t h e depth of t h e
d a m a g e i s 0 , 9 9 mm ( 0 . 0 3 9 i n . ) o r 1 , 0 1 mm ( 0 . 0 4 0 i n . ) , use f i v e carbon
repair plies.
5. Procedure
WARNING: WHEN YOU DO T H I S R E P A I R YOU MUST WEAR P R O T E C T I V E CLOTHING,

GLOVES, DUST MASK AND SAFETY GOGGLES T O PROTECT YOU A G A I N S T DUST
AND LOOSE P A R T I C L E S , WHICH CAN B E DANGEROUS T O YOUR HEALTH.
WARNING: WHEN YOU U S E CLEANING M A T E R I A L S , COATINGS, A D H E S I V E S AND SEALANT,

R E F E R T O THE MANUFACTURER'S CONTROL AND A P P L I C A T I O N I N S T R U C T I O N S
AND S A F E T Y N O T I C E S .
A. Prepare t h e D a m a g e d A r e a f o r R e p a i r ( R e f F i g . 2 0 1 )
CAUTION: DO NOT CAUSE DAMAGE T O THE CARBON P L I E S O F THE PANEL. B E

.' CAREFUL WHEN YOU REMOVE THE SHARP EDGES O F THE .,DAMAGE. DO NOT
U S E A L I Q U I D WITH THE A B R A S I V E P A P E R .
.:;
R e p a i r No.16
54-10-01
Page 2 0 4
R8211 TRENT
STRUCTURAL REPAIR
MANUAL
(1) Put marks on the outer skin using an OMat 262 MARKER PEN to
show the dimensions of the repair area on the outer skin. To
measure the area required for the repair plies, you must let
25,4 mm (1.0 in.) from the edge of the damage stay for each
carbon ply, and add 19/05 mm (0.75 in.) for an outer layer of
OMat 884 FIBREGLASS FABRIC.
(2) Remove the paint from the surface of the outer skin i n - t h e
repair area, using OMat 5/31 WATERPROOF ABRASIVE PAPER. Use
the abrasive paper to make the surface of the repair area
rough and remove the sharp edges of the damage. Do not cause
of the damage.
B. Identify the fastener types located in the Repair Area
(1) Identify the type of fasteners installed through the

stiffeners (03/16 in. Hi-lite or Composi-lok fasteners). Refer
to SRM 54-02-10 for details on fasteners.
C. Get Access to the Stiffeners on the Inner Surface .oE. the.0uter Skin
(Ref Fig 203, 204 and 205) . . ... ..
. ;_I.,
(1) Remove the air intake cowl in accordance with AMM TASK 71-61-
41-000-802. Place the air intake cowl in a "lip-skinN down
direction.
(2) Remove the 44 NAS7204U4 screws to release the TA1 Access

Panel. Remove the access panel from the Air intake cowl. Keep
the screws and panel for re-installation.
(3) Remove the T.A.1 interbulkhead system as instructed in the

steps that follow
NOTE: Care must be taken to make sure that the seals are not
damaged during removal of the interbulkhead system.
(a) Remove the OMat 2/98 lockwire that attaches the

insulation blanket to the outlet duct assembly. I
a m .
.. *
(b) Remove the insulation blanket and keep for;;'re-

installation.
(c) At the forward bulkhead, remove the 35532-700 V-clamp

that attaches the outlet duct assembly to the T.A.I.
shroud duct at the forward bulkhead, keep for re-
installation.
Repair No.16
54-10-01
Page 205
RB211 TRENT , . .,
STRUCTURAL REPAIR .
MANUAL
7,
., f
(d) At the rear bulkhead, remove the five off NAS6704U5 bolts
and AN960C416L washers that attach the inlet duct housing
assembly to the outlet duct shroud assembly, keep for re-
installation.
(e) Remove the inlet duct housing assembly, keep for re-
installation.
(f) Remove the ten off NAS6704U4 bolts and AN960C416L

washers that attach the outlet duct shroud assembly to
the rear bulkhead, keep for re-installation.
(g) Hold the outlet duct assembly and remove the outlet duct
shroud assembly, keep for re-installation.
(h) Release the inlet duct from the spray ring at the
forward bulkhead and remove the complete interbulkhead
duct assembly from the air intake cowl. ~ e e $for re-
installation.
CAUTION: MAKE SURE THAT NO DEBRIS ENTERS THE LIPSKIN/FORWARD BULKHEAD

CHAMBER THROUGH THE T.A.1 INTERBULKHEAD SYSTEM APERTURE. PUT
A PROTECTIVE COVERING OVER THIS APERTURE WHILE THE
INTERBULKHEAD DUCT IS REMOVED, TO PREVENT DEBRIS ENTERING.
D. Remove the Fasteners
(1) Remove the fasteners that were identified in step B.(l), refer
to SRM 54-02-10 Fasteners - Removal and Installation.
E. Make a Template for Fasteners
(1) Where fasteners have been removed, make a template for the
fastener holes
.
(a) Get a piece of aluminium alloy sheet to Ggg:'.as' template 4.
for the fastener hole positions. The alumknium alloy
sheet must be larger than the repair area and
approximately 1.27 mm (0.050 in.) thick. Cold roll the
aluminium sheet to align with the contours of the outer-
skin in the repair area.
(b) Put the template on the outer surface of the outer skin
and temporarily keep it in position. Use an OMat 262
MARKER PEN to put marks on the outer skin to show the
position of the edges of the template on the outer skin
and put a mark on the template to show the direction of
the template.
Repair No.16
54-10,-01
* .
) , , Page 206
Printed in Great Britain +S'>": Mar. 10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(C) Move the fastener holes from the skin into the template
using a drill the same diameter as the fastener hole
(4,83 mm (00.190 in.) drill for 4.76 mm (03/16 in. ) Hi-
lite fasteners and 5 / 1 0 mm (00.201 in.) drill for 4.76
mm (03/16 in. ) Composi-lok fasteners) .
(d) Remove the template and keep for future use.
F. Clean the Repair Area . - ... . .

.., . .
(1) Use a suction cleaner to remove dust and debris 'from the
repair area. Refer to AMM TASK 70-20-01-100-802. Clean the
repair area with OMat 150 ACETONE and an OMat 2/101 LINT-FREE
CLOTH. Wipe the area dry before the solvent evaporates.
(2) Do a water-break test on the area, apply a water-mist spray to

the area, make sure that water collects on the surface in an
unbroken film for 3-5 seconds. If this is not achieved, do
again the cleaning operation and the water-break test until it
is successful.
G. Dry the Repair Area
(1) Use applicable heat lamps and temperature probes to dry the
repair area. Keep the temperature at 70 deg C (158 deg F) for
a minimum of 6 hours. The repair materials must be applied
immediately at the end of the drying period.
I "
H. Mask around the Repair Area (Ref Fig.201) , .

,.: *?
(1) Mask around the repair area with OMat 2/30 TEFLON TAPE.
Calculate the distance that the tape must be from the damage
as follows
(a) Measure 25,4 nun (1.0 in.) from the edge of the damage for
each ply of the panel that is damaged and add 19/05 mm
(0.75 in.) for an outer layer of OMat 884 FIBREGLASS
FABRIC .
(b) Carefully apply the OMat 2/30 TEFLON TAPE so that it goes
around the area in a 50,8 mm (2.0 in.) wide strip.
I. Cut the Repair Plies (Ref Fig.201)
(1) Cut the first repair ply.
Repair No.16
54-10-01
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RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(a) Refer to SRM TASK 54-10-01 Identification for ply

orientation. Put on OMat 2/114 LINT-FREE GLOVES and cut
one piece of OMat 8/206A CARBON CLOTH so that it has a
50,8 mm (2.0 in. ) overlap all around the damage.
NOTE: One ply of OMat 884 FIBREGLASS ~ A B ~ 1 ~ ~ walso

i l lbe
necessary in addition to the specified number of
(2) Cut the remaining carbon repair plies.
(a) Put on OMat 2/114 LINT-FREE GLOVES and use OMat 8 / 2 0 6 ~

CARBON CLOTH, and cut each subsequent repair ply 50,8 mm
(2.0 in. ) longer and 50,8 mm (2.0 in.) wider. There must
be one repair ply for each ply of the panel that is
damaged.
(3) Cut the fibreglass ply
(a) Put on OMat 2/114 LINT-EREE GLOVES and cut one piece of
OMat 884 FIBREGLASS FABRIC so that it has a 25,4 mm (1.0
in.) overlap around the area identified by the teflon
3 .
tape.
. ..,
.
.,.. ....
..
NOTE: To prevent fraying, cut the plies to their la'st dimensions

. .
after they are soaked with adhesive.
(4) Cut the filler ply.
(a) To replace the missing material in the damaged area, cut

one'more piece of OMat 8/206A CARBON CLOTH approximately
the same size as the smallest repair ply. This piece will
be cut up and used to fill the damaged area.
(b) If fasteners were removed from the repair area in step

D.(1), cut one more piece of OMat 8/206A CARBON CLOTH
approximately the same size as the smallest repair ply.
This piece will be cut up and used with adhesive to fill
the fastener holes where fasteners have been removed.
J. Fill fastener holes

. ., .
(1) Where fasteners were removed from any of the sk5n::stiffeners

in the repair area, the holes will need to be f%lled as
follows
(a) On the inner surface, apply OMat 2/30 TEFLON TAPE on the
fastener holes.
Repair No.16
EFFECTIVITY: TRENT
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RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(b) Select one of t h e pieces of O M a t 8/151 . C A p O N .CLOTH,

a p p r o x i m a t e l y t h e s a m e s i z e as t h e s m a l i e s t repair p l y .
(c) U s e O M a t 8 / 2 4 7 EPOXY ADHESIVE ( E p o c a s t 35A/927) to f i l l

the holes.
(d) C u t t h e f i b r e s of t h e O M a t 8 / 2 0 6 A CARBON CLOTH i n t o s h o r t

l e n g t h s a p p r o x i m a t e l y 3 , O mm ( 0 . 1 2 i n . ) l o n g . T h e E p o c a s t
3 5 A r e s i n , 9 2 7 hardener and carbon f i b r e s are t o be m i x e d
t o a r a t i o of 1 0 0 / 2 5 / 2 0 by w e i g h t . A d d t h e c u t f i b r e s t o
t h e m i x e d O M a t 8 / 2 4 7 EPOXY ADHESIVE and m i x f u l l y i n t o an
even paste.
(e) F i l l t h e fastener holes w i t h r e s i n and f i b r e m i x t u r e , u s e

a clean spatula. M a k e s u r e t h e r e s i n m i x t u r e i s l e v e l
w i t h t h e t o p carbon p l y of t h e o u t e r s k i n .
(f) C u t a sheet of O M a t 2/113 NON-POROUS PARTING F I L M t o

cover t h e repair area. P u t t h e non-porous p a r t i n g f i l m on
t h e repair area, m a k e s u r e t h a t a l l t h e . i i i . l e d h o l e s are
covered. A t t a c h i n p o s i t i o n w i t h O M a t 2 / 3 0 TEFLON T A P E .
(g) P u t a t e m p e r a t u r e probe adjacent t o each of t h e f i l l e d

h o l e s i n t h e repair area. K e e p i n p o s i t i o n w i t h O M a t 2 / 3 0
TEFLON TAPE.
(h) G e t an applicable heat b l a n k e t and p u t i t on the repair

area, m a k e s u r e t h a t i t goes on a l l t h e f i l l e d h o l e s .
S a f e t y i t i n p o s i t i o n w i t h O M a t 2 / 3 0 TEFLON T A P E . C u r e
t h e r e s i n i n t h e h o l e s u s i n g a heat b l a n k e t t o keep t h e
t e m p e r a t u r e of t h e repair area a t 85 deg C ( 1 8 5 deg F )
f o r 3 hours. T h e t e m p e r a t u r e change m u s t n o t be m o r e than
+/- 5 . 5 deg C ( 1 0 deg F ) . T h e rate of t e m p e r a t u r e
increase and decrease m u s t n o t be m o r e t h a n 3 deg C ( 5 . 5
deg F ) i n each m i n u t e . D o n o t s t a r t t o m e a s u r e t h e cure
t i m e u n t i l t h e t e m p e r a t u r e i s a t 85 d e g - C ( 1 8 5 deg F ) .
"..
(i) When t h e cure process i s c o m p l e t e , r e m o i e r t h e c u r i n g
e q u i p m e n t and m a t e r i a l s f r o m t h e repair area and the
s t i f f e n e r i n n e r surface.
K. P r e p a r e the R e p a i r M a t e r i a l s
WARNING: EA 9 3 9 0 ADHESIVE I S C L A S S I F I E D A S A HAZARDOUS MATERIAL, WHICH

CAN CAUSE INJURY OR I L L N E S S I F NOT USED CORRECTLY. T H I S
PRODUCT MUST BE USED ONLY THE WAY INSTRUCTED I N THE
MANUFACTURER'S S P E C I F I C SAFETY AND HEALTH RECOMMENDATIONS.
BEFORE USE O F T H I S PRODUCT, CAREFULLY READ THE APPLICABLE
Repair ~ 0 . 1 6
54-10-01
. Page209
'
. .'.$l
<:' .
-. +r ..10/07
RB211 TRENT
"l?
, - - + ,
STRUCTURAL REPAIR
MANUAL
"MATERIAL SAFETY DATA SHEET" AND FOLLOW ALL LISTED SAFETY AND
HEALTH PRECAUTIONS.
(1) Mix the OMat 8/160 EPOXY ADHESIVE, refer to the manufacturer's
instructions. The weight of adhesive required is 1.1 times the
weight of the OMat 8 / 2 0 6 ~CARBON CLOTH and OMat 884 FIBREGLASS
FABRIC .
NOTE: After the plies are soaked, the remaining adhesive (if it is
kept cool) can be used in the installation procedure.
(2) Soak the carbon repair plies and fibreglass ply with the mixed
adhesive.
, ,F.
(a) Put each ply on a sheet of OMat 2/113 NON?POROUS PARTING
FILM.
(b) Apply the adhesive to both sides of each ply with the
OMat 212 BRUSH and cover each ply with another sheet of
non-porous parting film.
CAUTION: DO NOT USE TOO MUCH FORCE WHEN YOU ROLL THE PLIES.
THIS MAY DAMAGE AND/OR REMOVE TOO MUCH RESIN FROM
THE PLIES.
(c) Use the roller to force the adhesive fully into each ply.
(d) Put marks on the parting film to show the ply direction
of the carbon repair plies.
(3) Cut the carbon repair plies and the fibreglass'ply

. ,
to their
last dimensions (Ref. Fig. 201) . . ., S . '
.;. ' ,
, . : ; .
(a) Cut approximately 25,4 mm (1.0 in.) off each edge of the
plies.
(b) Make sure that the first ply has a 25,4 mm (1.0 in.)
(c) Make sure that each subsequent ply extends 25,4 mm (1.0
in.) more around the damage.
(d) Cut the corners of the repair plies to an angle of

12,7 mm (0.5 in.).
(e) Cut the fibreglass ply so that it is the same shape as

the area identified by the Tef lon tape.
Repair No.16
Page 210
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
L. C l e a n the R e p a i r A r e a
(1) L e t t h e repair area cool a f t e r i t has been d r i e d . R e f e r t o AMM

TASK 7 0 - 2 0 - 0 1 - 1 0 0 - 8 0 2 . C l e a n t h e repair area w i t h O M a t 150
ACETONE and an O M a t 2 / 1 1 4 LINT-FREE CLOTH. R u b t h e repair area
w i t h a clean piece of l i n t - f r e e c l o t h before t h e s o l v e n t
evaporates.
M. F i l l the D a m a g e d A r e a ( R e f Fig. 2 0 1 )

CAN CAUSE I N J U R Y OR I L L N E S S I F NOT USED CORRECTLY. T H I S
BEFORE USE O F T H I S PRODUCT, CAREFULLY READ THE APPLICABLE
"MATERIAL SAFETY DATA SHEET" AND FOLLOW ALL L I S T E D SAFETY AND
HEALTH PRECAUTIONS.
(1) Take t h e carbon f i l l e r p l y and m e a s u r e o u t an applicable

a m o u n t of t h e m i x e d O M a t 8 / 1 6 0 EPOXY ADHESIVE ( E A 9 3 9 0 ) t o f i l l
t h e d a m a g e d area. T h e w e i g h t of t h e m i x e d r e s i n should be 1.1
t i m e s t h e w e i g h t of t h e piece of O M a t 8 / 2 0 6 ~CARBON CLOTH.
(2) C u t t h e fibres of t h e O M a t 8 / 2 0 6 ~CARBON CLOTH i n t o s h o r t

l e n g t h s a p p r o x i m a t e l y 3 . 0 mm ( 0 . 1 2 i n . ) l o n g . A d d t h e c u t
f i b r e s t o t h e m i x e d O M a t 8 / 1 6 0 EPOXY ADHESIVE and m i x f u l l y
i n t o an even paste. If there are p l i e s m i s s i n g , , f r o m t h e
d a m a g e d area and t h e d a m a g e i s m o r e t h a n 1 0 . 0 ~ x n m ~ . ~ ( 0 . 3i n9 . )
w i d e , t h e carbon c l o t h s h o u l d be c u t i n t o strjps t o f i l l t h e
d a m a g e . A p p l y the r e s i n t o the ply i n the s a m e w a y as t h e
o t h e r p l i e s , r e f . step K . ( 2 ) .
(3) F i l l t h e d a m a g e d area w i t h r e s i n and fibres m i x t u r e ( o r pieces

of carbon c l o t h , w h i c h have been soaked i n r e s i n ) u s i n g a
c l e a n s p a t u l a . M a k e s u r e t h e d a m a g e has been f i l l e d l e v e l w i t h
t h e top carbon p l y of t h e o u t e r s k i n .
N. I n s t a l l the R e p a i r P l i e s (Ref Fig. 2 0 1 )

MAY CAUSE I N J U R Y OR I L L N E S S I F NOT USED CORRECTLY. T H I S
BEFORE USE OF THIS PRODUCT, CAREFULLY READ THE'APPLICABLE
WATERIAL SAFETY DATA SHEET" AND FOLLOW ALL LISTED SAFETY AND
HEALTH PRECAUTIONS.
i l'?<?,
CAUTION: DO NOT USE TOO MUCH FORCE WHEN YOU ROLL THE P L I E S . T H I S MAY
DAMAGE AND/OR REMOVE TOO MUCH R E S I N FROM THE P L I E S .
Repair ~ 0 . 1 6
54-10-01
Page 211
Printed i n Great B r i t a i n ~ a r1 0. / 0 7
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(1) U s e an OMat 212 BRUSH t o apply an e q u a l l a y e r of OMat 8/160

EPOXY ADHESIVE t o a l l of t h e r e p a i r a r e a .
(2) I n s t a l l the f i r s t repair ply.
(a) Remove one s h e e t of OMat 2/113 NON-POROUS.PARTING

. FILM
, ,
from t h e f i r s t r e p a i r p l y .
(b) Make s u r e t h e r e p a i r p l i e s i n s t e p K . (2) ( d ) - ' . a r ei n s t a l l e d

i n t h e c o r r e c t d i r e c t i o n . Refer t o SRM TASK 54-10-01
I d e n t i f i c a t i o n f o r p l y d i r e c t i o n . Put t h e f i r s t r e p a i r
p l y , with t h e adhesive down, on t h e r e p a i r a r e a . Make
s u r e t h a t t h e l o c a t i o n of t h e damage i s i n t h e c e n t e r of
the ply.
(C) Use t h e r o l l e r t o remove a i r and unwanted adhesive from

the f i r s t repair ply.
(d) Remove t h e remaining non-porous p a r t i n g f i l m from t h e

f i r s t repair ply.
(3) I n s t a l l t h e n e x t r e p a i r p l y ( i f necessary)
(a) Remove one s h e e t of non-porous p a r t i n g f i l m from t h e n e x t

repair ply. I .
(b) Put t h i s r e p a i r p l y , with t h e adhesive side,,:down, on t h e

r e p a i r a r e a . Make s u r e t h a t i t has an e & i l o v e r l a p
around t h e previous r e p a i r p l y .
(C) U s e t h e r o l l e r t o remove a i r and unwanted adhesive from

the ply.
(d) Remove t h e remaining non-porous p a r t i n g f i l m from t h i s

repair ply.
(4) I n s t a l l t h e subsequent r e p a i r p l i e s , i f n e c e s s a r y .
(a) Do s t e p N.(3) a g a i n f o r t h e subsequent r e p a i r p l i e s .
(5) Remove t h e Teflon t a p e from around t h e r e p a i r a r e a .
(6) I n s t a l l the fibreglass ply.
(a) Do s t e p N . ( 3 ) a g a i n f o r t h e f i b r e g l a s s p l y , Make s u r e
t h a t i t has an e q u a l o v e r l a p around t h e l a g t ' . c a r b o n f i b r e
repair ply.
Repair ~ 0 . 1 6
EFFECTIVITY : TRENT
54-10-01
Page 212
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
0. Prepare t o Cure t h e Adhesive (Ref F i g . 202)
(1) G e t a h e a t b l a n k e t , which must be l a r g e r a l l around t h a n t h e

repair area.
(2) Cut a s h e e t of O M a t 2/112 POROUS PARTING FILM. Make s u r e t h a t

i t i s l a r g e r than t h e h e a t b l a n k e t and h a s a minimum o v e r l a p
of 76,2 nun ( 3 . 0 i n . ) around t h e f i b r e g l a s s p l y .
(3) Cut t h e OMat 884 FIBREGLASS CLOTH i n t o s h e e t s t h e same s i z e a s

t h e porous p a r t i n g f i l m . U s e t h e f i b r e g l a s s c l o t h a s a b l e e d e r
c l o t h . The number of s h e e t s of b l e e d e r c l o t h must e q u a l t h e
number of carbon f i b r e p l i e s used i n t h e r e p a i r , n o t c o u n t i n g
t h e f i b r e g l a s s sanding p l y .
(4) Put t h e porous p a r t i n g f i l m on t h e r e p a i r a r e a . Make s u r e t h a t

i t has an e q u a l o v e r l a p around t h e r e p a i r a r e a . P u t t h e
temperature probes ( t h e number of temperature probes i s
p r o p o r t i o n a l t o t h e r e p a i r s i z e ) on t o p of t h e porous p a r t i n g
f i l m a t t h e edge of t h e r e p a i r a r e a . Put t h e l a y e r s of b l e e d e r
c l o t h on t o p of t h e porous p a r t i n g f i l m .
,.
(5) Cut a s h e e t of O M a t 2/113 NON-POROUS PARTING FI&. Make s u r e
t h a t i t i s a minimum of 25.4 nun ( 1 . 0 i n . ) s m a l l e r a l l around
than t h e b l e e d e r c l o t h i n s t a l l e d i n s t e p 0 . ( 4 ) .
(6) Put t h e non-porous p a r t i n g f i l m on t h e r e p a i r a r e a . Make s u r e

t h a t i t h a s an equal o v e r l a p around t h e r e p a i r a r e a .
(7) Put t h e h e a t b l a n k e t on t h e r e p a i r a r e a .
(a) Put t h e h e a t b l a n k e t on t o p of t h e non-porous p a r t i n g

f i l m . Make s u r e t h a t t h e h e a t b l a n k e t h a s an o v e r l a p a l l
around t h e r e p a i r a r e a . Make s u r e t h e temperature probes
a r e below t h e h e a t b l a n k e t .
(8) Put t h e b r e a t h e r c l o t h on t o p of t h e h e a t b l a.n...k e t .
(a) Cut two s h e e t s of OMat 2/111 BREATHER C.&TH, a minimum of

25,4 mm ( 1 . 0 i n . ) l a r g e r a l l around than t h e non-porous
parting film. IT.'>..
(b) Put t h e two s h e e t s of b r e a t h e r c l o t h on t h e h e a t b l a n k e t .
(9) Put t h e vacuum bag on t h e r e p a i r a r e a .
(a) Make s u r e t h a t t h e vacuum bag has an o v e r l a p of

approximately 50,8 mm ( 2 . 0 i n . ) around t h e b r e a t h e r
cloth.
Repair ~ 0 . 1 6
54-10-01
Page 213
RB211 TRENT . .
STRUCTURAL REPAIR
_I t
MANUAL
(b) I n s t a l l t h e v a c u u m hose f r o m t h e s u c t i o n p u m p s o t h a t i t
goes d i r e c t l y on t h e top sheet of breather c l o t h .
(c) U s e O M a t 2 / 3 1 VACUUM BAG MATERIAL and O M a t 2 / 1 1 0 A d h e s i v e

T a p e , V a c u u m B a g Seal t o seal t h e v a c u u m bag.
(10) Put t h e i n s u l a t i o n m a t e r i a l on t h e repair area.
(a) C u t f o u r t o s i x sheets of O M a t 2 / 1 1 1 BREATHER CLOTH the

s a m e s i z e as t h e heat b l a n k e t .
(b) Put t h e breather c l o t h on t o p of t h e v a c u u m bag above t h e

heat b l a n k e t and a t t a c h i t w i t h O M a t 2 / 3 0 .TEFLON T A P E .
.. . .
NOTE: I n s u l a t i o n can be added o r r e m o v e d t o get t h e ' c o r r & t rate of
. .
t e m p e r a t u r e increase and decrease ( R e f s t e p P .:j.(3):)
,.
P. C u r e the A d h e s i v e
(1) U s e t h e v a c u u m p u m p t o decrease t h e pressure i n t h e repair

area. Make s u r e i t gives an i n d i c a t i o n of a t l e a s t 6 3 5 , O nun
( 2 5 . 0 i n . ) of m e r c u r y w h i l e t h e adhesive cures.
(2) U s e t h e heat b l a n k e t t o keep t h e t e m p e r a t u r e of t h e repair

area b e t w e e n 9 0 t o 9 3 deg C ( 1 9 4 and 1 9 9 deg F ) f o r 3 hours
and 4 0 m i n u t e s .
(3) T h e rate of t e m p e r a t u r e increase and subsequent decrease m u s t

n o t be m o r e t h a n 3 deg C ( 5 . 5 deg F ) i n each m i n u t e .
(4) S t a r t t o m e a s u r e t h e cure t i m e w h e n t h e t e m p e r a t u r e reaches 90

deg C ( 1 9 4 deg F ) .
Q. Remove the R e p a i r E q u i p m e n t
(1) When t h e c u r e process i s c o m p l e t e d , r e m o v e t h e layup e q u i p m e n t

and m a t e r i a l s f r o m t h e repair.
R. Prepare t h e R e p a i r Surface
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON P L I E S O F THE COWL. ONLY

REMOVE MATERIAL FROM THE EDGE O F THE OUTER P L Y . DO NOT USE A
L I Q U I D WITH THE ABRASIVE PAPER.
(1) Make a l l contours of t h e repair area s m o o t h w i t h O M a t 5/31

WATERPROOF ABRASIVE PAPER. Make s u r e there i s no edge b e t w e e n
t h e repair area and t h e o u t e r s k i n .
R e p a i r No. 16
E F F E C T I V I T Y : TRENT
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
S. Re-drill the fastener holes
(1) For fasteners that were removed from any of the skin
stiffeners in the repair area, it will be necessary for the
holes to be re-drilled as follows
(a) Use a suction cleaner to remove dust and debris from the
repair area.
(b) Put the template (prepared before) on the outer surface

of the outer skin and temporarily secure it in its
initial position as marked in step E. (1)(b).
1 .
(c) Use the template to drill the fastener holes into the
skin using a drill the same diameter as the fastener
hole (4,83 mm (00.190 in.) drill for 03/16 in. Hi-lite
fasteners and 5 / 1 0 mm (00.201 in.) drill for 03/16 in.
Composi-lok fasteners).
(d) Remove the template from the repair area.
(e) Countersink the outer surface of the skin 130 degrees,

to for the first type of fasteners (HST315AG6 Hi-lite
pins or MBF2113-6 Composi-lok fasteners). Make sure that
the countersink is the correct depth for the head of the
fastener so that it will be installed flush with the
outer surface.
'! -
(f) Use a suction cleaner to remove dust and debri~sfrom the
repair area. ,. r'
, .+
(g) Apply OMat 805 resin/OMat 806 hardener (or an
alternative varnish) to seal the edges of the drilled
holes in the skin, refer to SRM 54-02-01 seal exposed
fibres , (FRS3254).
(h) Using OMat 4/47 PL32M Hylomar, wet install replacement

fasteners the same as the original type, HST315AG6-3 Hi-
lite pins & HST97DU6 collars or MBF2113-6-250 Composi-lok
fasteners. Adjust the fastener length to make it
applicable, Refer to SRM TASK 54-02-10, Fasteners-
Installation and Removal.
T. Re-install the Interbulkhead System and the T.A.I. Access Panel

(Ref Fig 203, 204 and 205).
NOTE: Care must be taken to make sure that the seals,are.,not,damaged

"-'
during re-installation of the interbulkhead syseei.'
. . .. .. 3,
, . .
Repair No. 16
Page 215
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(1) I n s t a l l t h e T . A . 1 InterBulkhead System t o t h e A i r i n t a k e cowl

a s i n s t r u c t e d i n t h e s t e p s t h a t follow:
(a) Put t h e O u t l e t Duct Assembly i n t o t h e A i r i n t a k e cowl

and move t h e forward ends i n t o p o s i t i o n , a r o u n d t h e
Shroud Duct and Spray Ring. .. .
. .
,
(b) Align t h e r e a r end of t h e O u t l e t Duct Assembly w i t h t h e
h o l e i n t h e r e a r Bulkhead.
(c) Apply a t h i n l a y e r of O M a t 4/47 j o i n t i n g compound t o

b o t h s i d e s of t h e o u t l e t d u c t shroud assembly and t h e
mating s u r f a c e s of t h e I n l e t Duct Housing Assembly and
t h e r e a r bulkhead. Assemble p a r t s w h i l e t h e compound i s
still w e t .
(d) P o s i t i o n t h e o u t l e t d u c t shroud assembly from t h e a f t

s i d e of t h e r e a r bulkhead. C a r e f u l l y move i t i n t o t h e
h o l e i n t h e Rear Bulkhead and around t h e O u t l e t Duct end
f i t t i n g . Align t h e h o l e s of t h e o u t l e t d u c t shroud
assembly w i t h t h e h o l e s on t h e Rear Bulkhead.
(e) I n s t a l l t h e t e n o f f NAS6704U4 B o l t s and AN960C416L

Washers t o a t t a c h t h e O u t l e t Duct Shroud A s s e e l y t o t h e
Rear Bulkhead. Torque t h e b o l t s t o 1 1 . 3 Nm (100 1 b f . i n )
r e f e r t o AMM Task 70-51-00-910-802.
(f) P o s i t i o n t h e I n l e t Duct Housing Assembly from t h e a f t

s i d e of t h e Rear Bulkhead. C a r e f u l l y move i t i n t o t h e
h o l e i n t h e O u t l e t Duct Shroud Assembly and around t h e
I n l e t Duct end f i t t i n g . Align t h e h o l e s of t h e I n l e t
Duct Housing Assembly w i t h t h e h o l e s of t h e O u t l e t Duct
Shroud Assembly.
(g) I n s t a l l t h e f i v e NAS6704U5 B o l t s and AN960C416L Washers

t h a t a t t a c h t h e I n l e t Duct Housing Assembly t o t h e
O u t l e t Duct Shroud Assembly. Torque t h e b o l t s t o 1 1 . 3 Nm
(100 l b f . i n ) , r e f e r t o AMM Task 70-51-00-910-802.
CAUTION: MAKE SURE THE PAINT MARKS ON THE OUTLET DUCT

ASSEMBLY AND THE OUTLET DUCT SHROUD ASSEMBLY ARE
ALIGNED BEFORE YOU TIGHTEN THE VEE CLAMP. I F THEY
ARE NOT, THE OUTLET GRILLE SEAL WILL'NOT TOUCH THE
T . A . I . ACCESS PANEL SUFFICIENTLY, AND LEAKAGE WILL
OCCUR.
(h) I n s t a l l t h e 35532-700 V-Clamp around t h e O u t l e t Duct

Assembly and t h e Shroud Duct a t t h e Forward Bulkhead.
Repair No.16
54-10-01
Page 216
RB211 TRENT
STRUCTURAL REPAIR
m MANUAL
(i) P o s i t i o n t h e I n s u l a t i o n B l a n k e t on t h e o u t l e t D u c t
A s s e m b l y and a t t a c h u s i n g O M a t 2 / 9 8 l o c k w i r e .
(j) Make s u r e t h a t t h e w o r k area i s clean f r o m s w a r f and

clear of t o o l s and o t h e r i t e m s .
CAUTION: MAKE SURE THE T . A . I . ACCESS PANEL TOUCHES THE

OUTLET GRILLE SEAL SUFFICIENTLY. I F THE PANEL DOES
NOT SEAL CORRECTLY, LEAKAGE WILL OCCUR AND THE HOT
A I R CAN DAMAGE THE A I R INTAKE COWL.
(k) P u t t h e TA1 A c c e s s P a n e l i n t o p o s i t i o n on the Air i n t a k e

c o w l and i n s t a l l w i t h 4 4 NAS7204U4 S c r e w s . T o r q u e t h e
S c r e w s t o 1 5 , 2 Nm ( 1 3 5 1 b f . i n ) refer t o AMM T a s k 7 0 - 5 1 -
00-910-802.
U. C l e a n the R e p a i r A r e a
(1) R e m o v e a l l u n w a n t e d m a t e r i a l f r o m t h e repair. area w i t h a

s u c t i o n cleaner.
I .
(2) R e f e r t o AMM TASK 7 0 - 2 0 - 0 1 - 1 0 0 - 8 0 2 . C l e a n t h e repair area w i t h

O M a t 1 5 0 ACETONE and an O M a t 2 / 1 0 1 LINT-FREE CLOTH. R u b t h e
repair area w i t h a clean piece of l i n t - f r e e c l o t h before t h e
s o l v e n t evaporates.
V. A p p l y t h e Surface P r o t e c t i o n
(1) A p p l y surface p r o t e c t i o n t o t h e repair area refer t o t h e

standard p a i n t i n g procedures SRM TASK 5 4 - 0 2 - 0 4 .
W. M a k e an I n s p e c t i o n of t h e R e p a i r
(1) D o a T a p T e s t , refer t o SRM 5 4 - 0 1 - 0 6 and m a k e a v i s u a l

i n s p e c t i o n t o m a k e s u r e t h a t t h e repair has been done t o these
procedures.
X. R e c o r d t h e repair
.- .,
.:, c
(1) V i b r o - e t c h t h e repair s c h e m e n u m b e r \IFRSZ027" on t h e a i r

i n t a k e c o w l m o d i f i c a t i o n record p l a t e .
Y. Re-install the a i r i n t a k e c o w l
(1) I n s t a l l t h e a i r i n t a k e c o w l , refer t o AMM TASK 7 1 - 6 1 - 4 1 - 4 0 0 -

802.
R e p a i r N0.16
54-10-01
Page 217
p-----
19,05 mm (0.75 in)
l
FILLED DAMAGED
TEFLON TAPE
\
AREA
\ T O N "'5"
FIBREGLASS PLY
TOP CARBON PLY
/
OUTER SKlN
L'
REPLACEMENT FASTENERS
THROUGH THE REPAIR PLIES,
SECTION OUTER SKlN AND STIFFENER
A-A
Surface Damage Build-Up
Figure 201
Repair No.16
54-10-01
Page 218
P r i n t e d i n Great B r i t a i n Jun. 10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
VACUUM HOSE
l
VACUUM BAG
l
/
l
l INSULATION
I
I SEALING
l I TAPE
'---- 50,8 mm (2.0 in)
MINIMUM HEAT BLANKET
(Must cover support plate and temperature probes)
I
i
BREATHER CLOTH (2 off)
FIBREGLASS
BLEEDERCLOTH
25,4 mm (1.O in) NON-POROUS PARTING FILM (No. of plies equals
MINIMUM I
no. of repair plies)
i
A
TEMPERATURE PROBE
(3 off minimum)
\
POROUS PARTING FlLM
I
-
A
r
7 6 , ; - n y ~ ; ; in)
OUTER EDGE
OF THE REPAIR
TEFLON TAPE
,
\
OUTER SURFACE OF
',
THE REPAIR PART ,\ 1
0
r-
7
7 '
\\ \,l,
W
U
0
0
E
R e p a i r E q u i p m e n t Installation
Figure 202
.R e p a i r No. 1 6
5.4-10-01
Page 219
RB211 TRENT
STRUCTURAL REPAIR
m MANUAL
-
L
V]
+
E
of the T .A.I. Interbulkhead &%tern
~emoval/~nstallation .'
..
. ,.'
.
/ I
Figure 203 . ,.
- . ( . .'\,
5 -
Repair No.16
54-10-01
Page 220
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
OUTER DUCT
ASSEMBLY
A1 8295-2D
ASSEMBLY
INNER DUCT
ASSEMBLY
BULKHEAD
NAS6704U4
AN960C416L 1
BOLT
..
.
( 5 Off) NAS6704U5
(5 off)
L
Removal/Installation of the T.A.I. Interbulkhead System
Figure 204
Repair No.16
Page 221
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
FORWARD
BULKHEAD
\
SPRAY RING
A1 8295-4D
of the T.A.I. Interbulkhead System

~emoval/~nstallation
Figure 205
Repair No.16
,, Page 222
Printed in Great Britain * Mar.10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
AIR INTAKE COWL OUTER SKIN HOLE REPAIR AND STIFFENER FASTENER RE-
INSTALLATION
1. General
A. This repair may be used to repair damage to the composite layers of

the outer skin of the intake cowl where a hole has occurred.
Repair must be carried out under controlled conditions: temperature

must be maintained at 20 to 25 deg C (68 to 77 deg F) and the
humidity at 50 percent or less.
This repair removes the damaged area, applies a support plate, and
installs a carbon fibre repair patch.
Refer to SRM 54-10-01 Identification for correct number and

direction of plies in area of damage.
This repair is limited to a maximum damage diameter of 152.4 mm

(6.0 in.)
Damage, which is not within the limits of these repairs, must be

This repair scheme covers damage only to the main area of the skin.
The damage must be separated from other areas of damage to allow
all the repair plies to be seated correctly. The damage must be at
a sufficient distance from the edges of the skin anh.edge fastener
positions to let all the plies to seat correctly.
This repair is for cowls that have fasteners in the main area of
the outer skin at the skin stiffener locations (ref. SRM 54-10-01)
as identified in FRSZ007. The repair permits plies to be installed
where fasteners are found in the stiffeners. The fasteners must be
removed before the plies are applied and then re-installed after
the repair plies have been cured. This repair procedure includes
details for removal and re-installation of these fasteners. To get
access to these fasteners it is necessary to remove the air intake
cowl, refer to AMM TASK 71-61-41-000-802, and place in a \\lipskin
downw direction.
Any damage to the stiffeners found on the non-air wetted side of

the 'outer skin must be referred to Rolls-Royce plc for evaluation.
Repair No .l7
Page 201
Printed i n Great B r i t a i n ~ a r 10/07
.
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
Ref erenced Information
.......................................................................
SRM 54-02-04 Repair Paint Finish
SRM 54-10-01 Identification
SRM 54-02-10 Fasteners - Installation and
Removal
SRM 54-02-01 Seal Exposed Fibres
SRM 54-01-06 Tap Test
AMM TASK 70-51-00-910-802 Torque Tightening
AMM TASK 71-61-41-000-802 Air Intake Cowl - Removal * .,*
AMM TASK 71-61-41-400-802 Air Intake Cowl Installation '
3. Eauiment and Material
- Heat blanket, 0 to 120 deg C (32 to 248 deg F)
- Heatlamp, 70 to 100 deg C (158 to 212 deg F)
- Vacuum suction pump, 0 to 762 mm (0 to 30 in.) of mercury
- Temperature probes, 0 to 120 deg C (32 to 248 deg F)
- Steel roller, 50,8 mm (2.0 in. ) diameter, 50,8 mm (2.0 in. ) .long
- 'High speed rotary cutter
- Suction cleaner
- Standard workshop tools
.......................................................................
OMat 150 ACETONE

OMat 212 BRUSH 12.7 mm (0.5 in.)
OMat 238A LOCKWIRE
OMat 2 62 Marker Pen
OMat 2/98 Lockwire
Repair No.17
54-10-01
I , F<.
. ~
Page 202
Printed i n Great B r i t a i n . . Mar.10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
oMat 2/101 LINT-FREE CLOTH

oMat 2/110 Adhesive Tape, Vacuum bag seal
oMat 2/111 BREATHER CLOTH
oMat 2/112 POROUS PARTING FILM
oMat 4/47 PL32M Hylomar
OMat 805 Resin . ..
.
'
'
L.
OMat 806 Hardener

OMat 8/247 Epocast 35A/927 EPOXY ADHESIVE
Local supplier Aluminium Alloy Sheet 1.27 mm (0.050
in.) approx
C. Repair Parts
HST315AG6-3 Hi-Lite Pin

HST315WF6-3 (alternative) Hi-Lite Pin
HST97DU6 Hi-Lite Collar
MBF2113-6-250 Composi-Lok Fastener ..
D. Component Material ,, m=
............................................................................
PART IDENT MATERIAL
............................................................................
4. Procedure
HEALTH.
.,. WARNING: WHEN YOU USE CLEANING MATERIALS, COATINGS, ADHESIVES AND
SEALANT, REFER TO THE MANUFACTURER'S CONTROL AND
..
APPLICATION
INSTRUCTIONS AND SAFETY NOTICES. . 7 .
,
. .
A. Prepare the Damaged Area for Repair (Ref Fig;201)
Repair No.17
54-10-01
Page 203
P r i n t e d i n Great B r i t a i n ~ a r10/07
.
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON PLIES OF THE. 'PANEL. BE

CAREFUL WHEN YOU REMOVE THE SHARP EDGES O F THE DAMAGE. DO NOT
U S E A L I Q U I D W I T H THE A B R A S I V E P A P E R .
(1) D o a v i s u a l i n s p e c t i o n of t h e damage and t a p t e s t , refer t o

SRM 5 4 - 0 1 - 0 6 t o i d e n t i f y t h e d i m e n s i o n s of t h e damaged area.
M e a s u r e t h e l e n g t h , w i d t h and depth of t h e damage. Make s u r e
t h a t t h e d a m a g e i s i n t h e l i m i t s of t h i s repair scheme.
(2) U s e an O M a t 262 MARKER P E N t o m a r k o u t t h e d a m a g e d area of t h e

o u t e r s k i n t o be r e m o v e d .
CAUTION: DO NOT CAUSE DAMAGE T O THE OUTER S K I N S T I F F E N E R S I F THE

DAMAGE I S NEAR T O THEM.
(3) C u t o u t t h e d a m a g e d area of t h e o u t e r s k i n w i t h a high-speed

rotary c u t t e r .
(a) M a k e t h e edges of t h e c u t - o u t have a n angle of

.-:
a p p r o x i m a t e l y 4 5 degrees. .: ...S
(b) T h e corners of t h e c u t - o u t m u s t have a radius of a t

l e a s t 1 2 , 7 mm ( 0 . 5 i n . ) .
(c) T h e m i n i m u m l e n g t h of t h e c u t - o u t diagonal m u s t be equal

t o t h e w i d t h o f . t h e c u t - o u t p l u s 5 0 , 8 mm ( 2 . 0 i n . ) , i f
t h e support plate i s t o be i n s t a l l e d through t h e c u t - o u t
( R e f . Fig. 2 0 1 ) .
(4) Make a n o t e of t h e number of p l i e s t h a t w i l l be required f o r

t h e repair. T h e r e m u s t be one carbon repair p l y f o r each p l y
of t h e o u t e r s k i n panel, p l u s one m o r e carbon repair p l y . An
o u t e r f i b r e g l a s s p l y i s a l s o required. R e f e r t o SRM 5 4 - 1 0 - 0 1
i d e n t i f i c a t i o n f o r the number of p l i e s i n t h e d a m a g e d area of
outer-skin.
(5) Mark o u t t h e f u l l e x t e n t of t h e repair area on t h e o u t e r s k i n

u s i n g an O M a t 262 MARKER P E N . T o s h o w t h e a r e a ' r e q u i r e d f o r
t h e repair p l i e s , you m u s t l e t 2 5 , 4 mm ( 1 . 0 i n ' . ) f r o n i t h e edge
of t h e d a m a g e s t a y f o r each carbon p l y , and a d d . 1 9 , 0 5 mm ( 0 . 7 5
i n . ) f o r an o u t e r layer of O M a t 8 8 4 F I B R E G L A S S ' F ~ R I C .
(6) R e m o v e t h e p a i n t f r o m t h e surface of t h e o u t e r s k i n i n t h e
repair area, u s i n g O M a t 5/31 WATERPROOF A B R A S I V E P A P E R . U s e
t h e abrasive paper t o m a k e t h e surface of t h e repair area
rough and remove t h e sharp edges of t h e d a m a g e . T a k e care n o t
t o cause any damage t o t h e carbon p l i e s . D o n o t increase t h e
d i m e n s i o n s of t h e d a m a g e .
R e p a i r No.17
Page 2 0 4
5'.
RB211 TRENT .
- 4 '
. .
,
.
.
. ., ,
,. -~ , .
;. :. l i .
STRUCTURAL REPAIR
MANUAL
(7) Identify the type of fasteners installed through the

stiffeners (03/16 in. Hi-lite or Composi-lok fasteners). Refer
to SRM 54-02-10 for details on fasteners.
B. Get Access to the Stiffeners on the Inner Surface of the Outer Skin
(Ref Fig 204, 205 and 206)
(1) Remove the air intake cowl, refer to AMM TASK 71-61-41-000-
802. Place the air intake cowl in a "lip-skin" down direction.
(2) Remove the 44 NAS7204U4 Screws to release the TA1 Access

Panel. Remove the access panel from the Air intake cowl. Keep
the screws and panel for re-installation.
(3) Remove the T.A.1 interbulkhead system as instructed'in the

, ., I
steps that follow <
(a) Remove the OMat 2/98 lockwire that attaches the

insulation blanket to the outlet duct assembly.
(b) Remove the insulation blanket and keep for re-

installation.
(C) At the forward bulkhead, remove the 35532-700 V-clamp

that attaches the outlet duct assembly to the T.A.I.
shroud duct at the forward bulkhead, keep for re-
installation.
(d) At the rear bulkhead, remove the five off NAS6704U5 bolts
and AN960C416L washers that attach the inlet duct housing
assembly to the outlet duct shroud assembly, keep for re-
installation. . ..
..:-
Remove the inlet duct housing assembly,~,,k~&

(e)
ins tallation.
. - $or re-
. :. . ; I ,
(f) Remove the 10 off NAS6704U4 bolts and ~ 9 6 0 ~ 4 washers

1 6 ~
that attach the outlet duct shroud assembly to the rear
bulkhead, keep for re-installation.
(g) Hold the outlet duct assembly and remove the outlet duct
shroud assembly, keep for re-installation.
(h) Release the inlet duct from the spray ring at the forward
bulkhead and remove the complete interbulkhead duct
assembly from the air intake cowl. Keep for re-
installation.
,Repair No. 17
54-10-01
. d
' , " Page 205

R8211 TRENT
STRUCTURAL REPAIR
MANUAL
CAUTION: MAKE SURE THAT NO DEBRIS ENTERS THE LIPSKIN/FORWARD

BULKHEAD CHAMBER THROUGH THE T.A.1 INTERBULKHEAD
SYSTEM APERTURE. IF THE T.A.1 INTERBULKHEAD SYSTEM
IS NOT BEING RE-INSTALLED IMMEDIATELY, MAKE SURE
THIS APERTURE HAS PROTECTION IN POSITION TO PREVENT
DEBRIS ENTERING.
C. Remove the fasteners and make a template of fastener positions

c.
. I;., -. i .
(1) Remove the fasteners that were identified in step 4.B. (1).
Refer to SRM 54-02-10 Fasteners - Removal and Installation.
(2) Where the fasteners have been removed, make a template for the
fastener holes
(a) Obtain a piece of aluminium alloy sheet to use as a

template for the fastener hole positions. The aluminium
alloy sheet must be larger than the repair area and
approximately 1.27 mm (0.050 in.) thick. Cold roll the
aluminium sheet to match the contours of the outer-skin
in the repair area.
(b) Put the template on the outer surface of the outer skin
and temporarily keep it in position. Use an OMat 262
MARKER PEN to put marks on the outer skin to show the
position of the edges of the template on the outer skin
and put a mark on the template to show fhe direction of
the template. -*
,
: L-
(c) Transfer the fastener holes from the skin' into the
template using a drill the same diameter as the fastener
hole (4,83 mm (00.190 in.) drill for 03/16 in. Hi-lite
fasteners and (5,10 mm 00.201 in.) drill for 03/16 in.
Composi-lok fasteners) .
(d) Remove the template and keep for future use.
D. Clean, Water-break Test and Dry the Repair Area (Ref Fig.201)
(1) Use a suction cleaner to remove dust and debris from the
repair area. Refer to AMM TASK 70-20-01-100-802. Clean the
repair area with an approved solvent (OMat 150 ACETONE) and an
OMat 2/101 LINT-FREE CLOTH. Wipe the area dry before the
solvent dries.
(2) Do a water-break test on the area, applying a water-mist spray

to the area, make sure that water lays on the'surface in an
unbroken film for 3 to 5 seconds. Do the cleaning operation
and the water-break test again until it is successful.
Repair No.17
54-10-01
Page 206
.
P"" RB211 TRENT
MANUAL
STRUCTURAL REPAIR
(3) U s e a p p l i c a b l e h e a t lamps and temperature probes t o t d r y t h e

r e p a i r a r e a . Keep t h e temperature a t 70 deg C..",(i58d e g F) f o r
6 hours minimum. The r e p a i r m a t e r i a l s must b e ; a p p l i e d
immediately a t t h e end of t h e d r y i n g p e r i o d .
E. Mask around t h e Repair Area (Ref Fig.201 and Fig.202)
(1) Mask around t h e r e p a i r a r e a with OMat 2/30 TEFLON TAPE.

C a l c u l a t e t h e d i s t a n c e t h a t t h e t a p e must be from t h e damage
a s follows:
(a) Measure 25,4 mm ( 1 . 0 i n . ) from t h e edge of t h e damage f o r

each p l y of t h e p a n e l , and add 19,05 mm (0.75 i n . ) f o r an
o u t e r l a y e r of O M a t 884 FIBREGLASS FABRIC.
(b) C a r e f u l l y apply t h e t e f l o n t a p e s o t h a t i t goes around

t h e a r e a i n a 50,8 mm (2.0 i n . ) wide s t r i p .
F. F i l l fastener holes .. . , .
.! .
' 3 . '
(1) For f a s t e n e r s t h a t were removed from t h e s k i n s f i f f e n e r s i n
t h e r e p a i r a r e a , t h e h o l e s w i l l need t o be f i l l e d a s f o l l o w s
(a) On t h e i n n e r s u r f a c e , apply O M a t 2/30 TEFLON TAPE t o go

f u l l y on t h e f a s t e n e r h o l e s .
(b) Cut a p i e c e of OMat 8/206A CARBON CLOTH, with

approximately t h e same dimensions a s t h e r e p a i r c u t - o u t .
This p i e c e w i l l be c u t up and used t o f i l l t h e f a s t e n e r
h o l e s where f a s t e n e r s have been removed.
(c) Get O M a t 8/247 EPOXY ADHESIVE (Epocast 3 5 ~ / 9 2 7 ) t o f i l l

the holes.
(d) Cut t h e f i b r e s of t h e OMat 8 / 2 0 6 ~CARBON CLOTH i n t o s h o r t

l e n g t h s approximately 3,O mm (0.12 i n . ) l o n g . The Epocast
35A r e s i n , 927 hardener and carbon f i b r e s a r e t o b e mixed
t o a r a t i o of 100/25/20 by weight. Add t h e c u t f i b r e s t o
t h e mixed OMat 8/247 EPOXY ADHESIVE and.;$gx, f u l l y i n t o an
,
even p a s t e . ". :,.I
(e) F i l l t h e f a s t e n e r h o l e s with r e s i n C f i b r e s mixture u s i n g

a c l e a n s p a t u l a . Make s u r e t h e r e s i n mixture i s l e v e l
with t h e t o p carbon p l y of t h e o u t e r s k i n .
Repair No.17
54-10-01
Page 207
v . .
. .
RB211 TRENT
,:.
.. ,,. .
:: . -... ,.>
. _,..
2-
.. . >
. ..
STRUCTURAL REPAIR
MANUAL
(f) Cut a sheet of OMat 2/113 NON-POROUS PARTING FILM to

cover the repair area. Put the non-porous parting film
onto the repair area, making sure that all the filled
holes have protection on them. Use OMat 2/30 TEFLON TAPE
to keep the non-porous parting film in position
(g) Put a temperature probe adjacent to each of the filled

holes in the repair area. Use OMat 2/30 TEFLON TAPE to
keep the temperature probes in position..
(h) Get an applicable heat blanket and put it on the repair

area, make sure that it covers all the filled holes. Use
OMat 2/30 TEFLON TAPE to keep the heat blanket in
position. Cure the resin in the holes using a heat
blanket to keep the temperature of the repair area at 85
deg C (185 deg F) for 3 hours. Temperature-'variation to
be within +/- 5.5 deg C (10 deg F) . The rake of
temperature increase and subsequent decrease must not be
more than 3 deg C (5.5 deg F) in each minute. Do not
start to measure the cure time until the temperature
reaches 85 deg C (185 deg F) .
(i) When the cure process is complete, remove the curing

equipment and materials from the repair area and the
stiffener inner surface.
G. Prepare the Support Plate (Ref Fig.201)
(1) Wear OMat 2/114 LINT-FREE GLOVES and cut three pieces of OMat
8/206A CARBON CLOTH with a 50,8 mm (2.0 in.) overlap around
the damage.
.. ,
NOTE: To prevent fraying, cut the plies to their c'&*plete: .

,.
dimensions after they are soaked with adhesiGe'::. . '
.. . :? ,
. . .- . :
;
"IJ..
r .
.
(2) Mix the OMat 8/160 EPOXY ADHESIVE in reference'with the

manufacturer ' S instructions. The weight of adh&ve required
will be 1.1 times the weight of the OMat 8/206A CARBON CLOTH.
(3) Prepare the support plate plies.
(a) Put each carbon fibre ply on a sheet of OMat 2/113 NON-
POROUS PARTING FILM
(b) Apply an equal layer of adhesive to the two sides of each

ply with the OMat 212 BRUSH and cover each ply with one
more sheet of non-porous parting film.
Repair
II . ' ..
No.
. .
17
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RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(c) Use a r o l l e r t o f u l l y soak each p l y with a d h e s i v e . Do n o t

u s e t o o much f o r c e a s t h i s may damage and/or cause r e s i n
deficiency i n the p l i e s .
(d) Cut each p l y s o i t h a s an o v e r l a p of approximately 25,4

mm ( 1 . 0 i n . ) around t h e r e p a i r c u t o u t .
-
(4) Put t h e p l i e s t o g e t h e r t o make t h e s u p p o r t
- -. . '
(a) Remove one s h e e t of non-porous f i l m from 'two of t h e

plies.
(b) Remove t h e two s h e e t s of non-porous f i l m from t h e t h i r d

P ~ Y -
(C) Align t h e p l i e s and p u t them with t h e i r adhesive s i d e s
t o g e t h e r on a h a r d , f l a t s u r f a c e .
(d) U s e t h e r o l l e r t o push t h e p l i e s t o g e t h e r . Do n o t u s e t o o
much f o r c e a s t h i s may damage and/or cause r e s i n
deficiency i n the p l i e s .
H. Cure t h e Adhesive
(1) Put t h e temperature probes i n p o s i t i o n a d j a c e n t t o t h e

adhesive. .. ..... . .. S.
.. .
(2) U s e a h e a t lamp t o keep t h e temperature of t h e r e p a i r a r e a
between 90 and 93 deg C (194 a n d 199 deg F) ' f h r "3 hours and 40
minutes.
(3) The r a t e of temperature i n c r e a s e and subsequent d e c r e a s e must

n o t be more than 3 deg C ( 5 . 5 deg F) i n each minute.
(4) S t a r t t o measure t h e time f o r t h e adhesive t o c u r e when t h e

temperature r e a c h e s 90 deg C (194 deg F ) .
I. Prepare t o I n s t a l l t h e Support P l a t e (Ref Fig.201)
(1) D r i l l h o l e s i n t h e s u p p o r t p l a t e and a t t a c h l o c k w i r e .
(a) When t h e s u p p o r t p l a t e i s c o o l , remove t h e two remaining

p i e c e s of non-porous f i l m .
(b) D r i l l two p a i r s of h o l e s , 1 , 0 1 mm ( 0 . 04QY.:in. ) diameter, a

s u f f i c i e n t d i s t a n c e a p a r t t o a t t a c h t h e , :.' s-u:yt;,p p o r t p l a t e t o
a clamp b a r with OMat 238A LOCKWIRE. . ,.
... ?*,
Repair No.17
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RB211 TRENT
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MANUAL
(c) P u t a loop of t h e lockwire, s u f f i c i e n t l y l o n g t o l e t t h e

s u p p o r t p l a t e go through t h e h o l e i n t h e : , o u t e r s k i n ,
through each p a i r of h o l e s . . c? :
.>_.
.! ..
- . .
I.:
(2) Clean t h e i n n e r s u r f a c e of t h e r e p a i r a r e a with gn approved

s o l v e n t (OMat 150 ACETONE) and an OMat 2/101 LINT-FREE CLOTH.
Wipe t h e a r e a d r y b e f o r e t h e s o l v e n t d r i e s .
J. I n s t a l l t h e Support P l a t e (Ref F i g . 201)
(1) M i x t h e OMat 8/160 EPOXY ADHESIVE i n r e f e r e n c e t o t h e

manufacturer's i n s t r u c t i o n s .
(2) Apply e q u a l l a y e r s of adhesive t o t h e i n t e r f a c e of t h e s u p p o r t

p l a t e and t h e i n t e r n a l s k i n .
(3) Put t h e s u p p o r t p l a t e i n t o p o s i t i o n .
(a) P u t t h e s u p p o r t p l a t e through t h e r e p a i r c u t o u t and p l a c e

i t a g a i n s t t h e i n n e r s u r f a c e of t h e o u t e r s k i n , make s u r e
t h a t t h e s u p p o r t p l a t e h a s an e q u a l o v e r l a p around t h e
r e p a i r c u t o u t . A l t e r n a t i v e l y t h e s u p p o r t p l a t e ' c a n be
found on t h e i n n e r s u r f a c e by g e t t i n g a c c e s s through t h e
T . A . I . Access Panel a p e r t u r e .
(b) Put a clamp b a r a c r o s s t h e r e p a i r c u t o u t with t h e ends of

t h e b a r on t h e Teflon t a p e .
(C) Put t h e lockwire around t h e clamp b a r and t w i s t t h e ends

together t o hold the support p l a t e i n t h e c o r r e c t
position.
K. Cure t h e Adhesive
(1) Put t h e temperature probes i n p o s i t i o n a d j a c e n t t o t h e s u p p o r t

plate.
(2) Use a h e a t lamp t o keep t h e temperature of t h e s u p p o r t p l a t e

between 90 t o 93 deg C (194 t o 199 deg F) f o r l3 hours and 40
minutes.
(3) The r a t e of temperature i n c r e a s e and subsequent 'dkcrease must

n o t b e more than 3 deg C ( 5 . 5 deg F) i n each minute.
(4) S t a r t t o measure t h e time f o r t h e adhesive t o c u r e when t h e

temperature r e a c h e s 90 deg C (194 deg F ) .
L. Remove t h e Repair Equipment
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p RB211 TRENT
MANUAL
STRUCTURAL REPAIR
(1) When t h e r e p a i r a r e a i s c o o l , remove t h e lamp, temperature

-, a
p r o b e s , clamp b a r and lockwire.
M. Prepare t h e F i l l e r P l i e s and t h e Repair P l i e s (Ref Fig.202)
(1) Cut t h e carbon f i l l e r p l i e s :
(a) Wear OMat 2/114 LINT-FREE GLOVES and c u t s u f f i c i e n t

p i e c e s of OMat 8/206A DRY CARBON FIBRE FABRIC a s
i d e n t i f i e d i n s t e p 4 . A . ( 4 ) , t o make t h e s u r f a c e of t h e
r e p a i r cut-out l e v e l with t h e s u r f a c e of t h e o u t e r s k i n .
Refer t o SRM 54-10-01 I d e n t i f i c a t i o n f o r p l y d i r e c t i o n .
(b) The f i l l e r p l i e s must o v e r l a p t h e c u t - o u t i n t h e o u t e r

s k i n by 25,4 mm ( 1 . 0 i n . ) .
NOTE: To p r e v e n t f r a y i n g , c u t t h e p l i e s t o t h e i r f i n i s h e d
dimensions a f t e r they a r e soaked with a d h e s i v e .
(2) Cut t h e f i r s t carbon r e p a i r p l y .
(a) Wear OMat 2/114 LINT-FREE GLOVES and c u t one p i e c e of

OMat 8/206A CARBON CLOTH s o t h a t i t h a s a 50,8 mm ( 2 . 0
i n . ) o v e r l a p around t h e damage. Refer t o SRM 54-10-01
Identification f o r ply direction.
(3) Cut t h e remaining carbon r e p a i r p l i e s .
(a) Wear OMat 2/114 LINT-FREE GLOVES and use OMat 8 / 2 0 6 ~

CARBON CLOTH, and c u t each subsequent r e p a i r p l y 25,4 mm
( 1 . 0 i n . ) longer and 25,4 mm ( 1 . 0 i n . ) wider than t h e p l y
b e f o r e . There must be one r e p a i r p l y f o r - e a c h p l y removed
from t h e p a n e l .
, .
(4) Cut t h e f i b r e g l a s s p l y .
S :!
(a) Wear OMat 2/114 LINT-FREE GLOVES and c u t one p i e c e of

O M a t 884 FIBREGLASS FABRIC s o t h a t i t h a s a 25,4 mm ( 1 . 0
i n . ) o v e r l a p around t h e a r e a i d e n t i f i e d by t h e OMat 2/30
TEFLON TAPE.
NOTE: To p r e v e n t f r a y i n g , c u t t h e p l i e s t o t h e i r complete
dimensions a f t e r they a r e soaked with a d h e s i v e .
N. Prepare t h e Repair M a t e r i a l s
'Repair No. 17
54,'i10,101 :;.
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' . .:+'.;.-S:.
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L,. b.
,Page 211
Printed i n Great B r i t a i n ' Mar.10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(1) Mix t h e OMat 8/160 EPOXY ADHESIVE i n r e f e r e n c e t o t h e

m a n u f a c t u r e r ' s i n s t r u c t i o n s . The weight of adhesive r e q u i r e d
w i l l be 1.1 t i m e s t h e weight of t h e OMat 8/206A CARBON CLOTH
and OMat 884 FIBREGLASS FABRIC.
NOTE: A f t e r t h e p l i e s a r e soaked, t h e remaining adhesive ( i f

i t i s k e p t c o o l ) can be used i n t h e i n s t a l l a t i o n
procedure.
(2) Soak t h e carbon p l i e s and f i b r e g l a s s p l y with t h e mixed

adhesive.
(a) Put each p l y on a s h e e t of OMat 2/113 NON-POROUS PARTING

FILM. . .
(b) Apply t h e adhesive t o t h e two s i d e s of e a c h , p l y w i t h t h e

OMat 212 BRUSH and cover each p l y with a n o t h e r s h e e t of
non-porous p a r t i n g f i l m .
(C) U s e t h e r o l l e r t o f o r c e t h e adhesive i n t o each p l y f u l l y .

Do n o t u s e t o o much f o r c e a s t h i s may damage and/or cause
r e s i n deficiency i n the p l i e s .
(d) Put marks on t h e p l y t o show d i r e c t i o n of t h e carbon

r e p a i r p l i e s on t h e p a r t i n g f i l m .
(3) Cut t h e carbon f i l l e r p l i e s t o t h e i r n e c e s s a r y dimensions.
(a) Cut each carbon f i l l e r p l y s o t h a t i t i s a good f i t i n

t h e r e p a i r c u t o u t . They must be f l a t on t h e s u p p o r t p l a t e
and have t h e same shape a s t h e c u t o u t . The edges of t h e
p l i e s must n o t o v e r l a p on t h e s i d e s of t h e c u t o u t .
(4) Cut t h e f i r s t carbon r e p a i r p l y t o i t s f i n i ~ h e d , ~ d + m e n s i o snos

t h a t i t o v e r l a p s t h e c u t o u t i n t h e o u t e r s k i n b y ' 2 5 , 4 mm ( 1 . 0
i n . ) a l l around.
(a) Cut each subsequent carbon r e p a i r p l y t o g e t a 25,4 nun

( 1 . 0 i n . ) o v e r l a p a l l around t h e p l y b e f o r e i t .
(b) Cut t h e c o r n e r s of t h e r e p a i r p l i e s t o an a n g l e of
approximately 45 degrees with a l e n g t h of approximately
1 2 , 7 mm ( 0 . 5 i n . ) .
(5) Cut t h e f i b r e g l a s s r e p a i r p l y s o t h a t i t has t h e same shape a s

t h e a r e a s p e c i f i e d by t h e Teflon t a p e .
~ e ~ a~i0r. 1 7
EFFECTIVITY : TRENT
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(1)
a RB211 TRENT
MANUAL
STRUCTURAL
t o AMM TASK 70-20-01-100-802.

REPAIR
The r e p a i r a r e a must b e c o o l a f t e r t h e d r y i n g procedure, r e f e r

Clean t h e r e p a i r a r e a with an
approved s o l v e n t (OMat 150 ACETONE) and OMat 2/114 LINT-FREE
CLOTH. Wipe t h e r e p a i r a r e a d r y b e f o r e t h e s o l v e n t d r i e s .
P. I n s t a l l t h e F i l l e r P l i e s and t h e Repair P l i e s (Ref . .Fig.201 and

F i g . 202)
:.
, ' .
. ,
(1) Use an OMat 212 BRUSH t o apply an e q u a l l a y e rd . ,. . o.! f .. t h e a d h e s i v e

mixed i n s t e p N . (1) t o a l l of t h e r e p a i r area.:.:; -..'
. (2) Put t h e f i l l e r p l i e s i n t o p o s i t i o n
(a) Remove one s h e e t of non-porous p a r t i n g f i l m from t h e

f i l l e r ply.
(b) Put t h e f i l l e r p l y i n t h e r e p a i r c u t o u t , with t h e

adhesive s i d e down, on t h e s u p p o r t p l a t e . The p l y must b e
p o s i t i o n e d c o r r e c t l y and f l a t .
(c) Remove t h e remaining non-porous p a r t i n g f i l m from t h e

f i l l e r p l y and u s e a c l e a n metal s p a t u l a t o keep t h e p l y
f l a t on t h e p l a t e .
(d) Do s t e p P. (2) again f o r t h e subsequent carbon f i l l e r

p l i e s . Make s u r e t h e p l i e s p u t i n t h e c o r r e c t p o s i t i o n
and a r e f l a t
. .
(3) Put t h e f i r s t carbon f i b r e r e p a i r p l y i n p o s i ' t i o i
(a) Remove one s h e e t of non-porous p a r t i n g f i l m from t h e

carbon f i b r e r e p a i r p l y .
(b) Refer t o SRM TASK 54-10-01 I d e n t i f i c a t i o n f o r p l y

d i r e c t i o n . Put t h e r e p a i r p l y , with t h e adhesive s i d e
down, on t h e r e p a i r a r e a . Make s u r e t h e p l y i s i n t h e
c o r r e c t p o s i t i o n and h a s an e q u a l o v e r l a p a l l around.
(C) U s e t h e r o l l e r t o remove a i r and unwanted adhesive from

t h e f i r s t r e p a i r p l y . Do n o t u s e t o o much f o r c e a s t h i s
may damage and/or cause r e s i n d e f i c i e n c y i n t h e p l i e s .
(d) Remove t h e remaining non-porous p a r t i n g . ..f i l m from t h e

,
f i r s t repair ply. ., . . .
, *.:
(4) Do s t e p P. (3) a g a i n f o r t h e subsequent r e p a i r. p. l.i e s .
- "
-
(5) Remove t h e Tef l o n t a p e .
Repair No.17
54-10-01
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RB211 TRENT
STRUCTURAL REPAIR
m MANUAL
(6) I n s t a l l the fibreglass ply ....

..-
(a) Do s t e p P. (3) again f o r t h e f i b r e g l a s s ,-make s u r e

t h a t i t h a s an e q u a l o v e r l a p around t h e l a s t carbon f i b r e
repair ply.
Q. Prepare t o Cure t h e Adhesive (Ref Fig. 203)
(1) G e t a h e a t b l a n k e t , which must be l a r g e r a l l around t h a n t h e

repair area.
(2) Cut a s h e e t of OMat 2/112 POROUS PARTING FILM, make s u r e t h a t

i t i s l a r g e r than t h e h e a t b l a n k e t and h a s an o v e r l a p of a t
l e a s t 76,2 mm ( 3 . 0 i n . ) around t h e f i b r e g l a s s p l y .
(3) Cut t h e OMat 884 BLEEDER CLOTH i n t o s h e e t s with t h e same

dimensions a s t h e porous p a r t i n g f i l m . The number of s h e e t s of
b l e e d e r c l o t h must equal t h e number of p l i e s used i n t h e
repair.
,...':c' ' .
(4) Put t h e porous p a r t i n g f i l m onto t h e r e p a i r a r e a , make s u r e

t h a t i t h a s an e q u a l o v e r l a p around t h e r e p a i r : - a r e a . Put t h e
l a y e r s of b l e e d e r c l o t h on t o p of t h e porous p a r t i n g f i l m .
(5) Cut a s h e e t of OMat 2/113 NON-POROUS PARTING FILM, make s u r e

t h a t i t i s a t l e a s t 25,4 mm (1.0 i n . ) s m a l l e r a l l around than
t h e bleeder c l o t h i n s t a l l e d i n s t e p Q. ( 4 ) .
(6) Put t h e non-porous p a r t i n g f i l m onto t h e r e p a i r a r e a , making

s u r e t h a t i t h a s an e q u a l o v e r l a p around t h e r e p a i r a r e a .
(7) Put a t l e a s t two temperature probes a d j a c e n t t o t h e r e p a i r

a r e a , make s u r e t h a t t h e h e a t b l a n k e t w i l l go on them f u l l y .
(8) Put t h e h e a t b l a n k e t onto t h e r e p a i r a r e a
(a) Put t h e h e a t b l a n k e t on t o p of t h e non-porous p a r t i n g

f i l m , making s u r e t h a t t h e h e a t b l a n k e t h a s an o v e r l a p
a l l around t h e r e p a i r a r e a . . i*....
: .. .,'. . ' . .
?,
'- , . . '
. I
(9) Put t h e b r e a t h e r c l o t h on t h e t o p of t h e h e a t b l & k e t
(a) Cut two s h e e t s of OMat 2/111 BREATHER CLOTH, a t l e a s t

2 5 , 4 mm ( 1 . 0 i n . ) l a r g e r a l l around than t h e non-porous
parting film.
(b) P u t t h e two s h e e t s of b r e a t h e r c l o t h on t h e h e a t b l a n k e t .
(10) P u t t h e vacuum bag on t h e r e p a i r a r e a
Repair No. 17
EFFECTIVITY : TRENT
54-10-01
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RB211 TRENT
STRUCTURAL REPAIR . '>
MANUAL
(a) Use OMat 2/31 VACUUM BAG MATERIAL and OMat 2/110 Adhesive
Tape, Vacuum bag seal.
(b) Make sure that the vacuum bag has an overlap of

approximately 50,8 mm (2.0 in.) around the breather
c10 th .
(c) Install the vacuum hose from the suction pump so that it
goes directly on the top sheet of breather cloth.
(d) Attach and seal the vacuum bag to the cowl with the OMat
2/110 Adhesive Tape, Vacuum bag seal.
(11) Put the insulation material on the repair area
(a) Cut four to six sheets of OMat 2/111 BREATHER CLOTH with
the same dimensions as the heat blanket.
(b) Put the breather cloth on top of the vacuum bag above the
heat blanket and keep in place with OMat 2/30 TEFLON
TAPE.
NOTE: Insulation can be added or removed to get the correct rate of

temperature increase and decrease. Ref step R.(3).
R. Cure the Adhesive
(1) Use the vacuum pump to decrease the pressure in the repair
area, make sure it gives an indication of at least 635,O mm
(25.0 in.) of mercury while the adhesive cures.
(2) Use the heat blanket to keep the temperature"<£ the repair
area between 90 to 93 deg C (194 and 199 deg,.F)for'3 hours
and 40 minutes. _ . i .1 .::, :.. . . .
. .
(3) The rate of temperature increase and subsequent decrease must

not be more than 3 deg C (5.5 deg F) in each minute.
(4) Start to measure the cure time when the temperature reaches 90
deg C (194 deg F).
S. Remove the Repair Equipment
(1) When the cure process is complete, remove the layup equipment
and materials from the repair.
T. Smooth the Repair Surface
.
Repair
.
No.17
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RB211 TRENT
STRUCTURAL REPAIR
MANUAL
CAUTION: DO NOT CAUSE DAMAGE TO THE CARBON P L I E S O F THE COWL. ONLY

REMOVE MATERIAL FROM THE EDGE O F THE OUTER PLY. DO NOT
USE A L I Q U I D WITH THE ABRASIVE PAPER.
(1) Make a l l c o n t o u r s of t h e repair area s m o o t h w i t h O M a t 5/31

WATERPROOF ABRASIVE PAPER, m a k e s u r e there i s no edge b e t w e e n
t h e repair area and t h e o u t e r s k i n .
U. Re-drill t h e fastener h o l e s +*S
'
(1) For fasteners t h a t w e r e r e m o v e d f r o m any of t h e ;kin .

s t i f f e n e r s i n t h e repair area, t h e h o l e s w i l l need t o be re-
d r i l l e d as f o l l o w s
(a) U s e a s u c t i o n cleaner t o r e m o v e d u s t and debris f r o m t h e

repair area.
(b) P u t t h e t e m p l a t e ( p r e p a r e d b e f o r e ) on t h e o u t e r surface
of t h e o u t e r s k i n and t e m p o r a r i l y keep i t i n p o s i t i o n as
s h o w n i n step C . ( 2 ) ( b ) .
(C) US t h e t e m p l a t e t o d r i l l fastener h o l e s i n t o t h e s k i n
u s i n g a d r i l l t h e s a m e d i a m e t e r as t h e fastener h o l e
( 4 , 8 3 mm ( 0 0 . 1 9 0 i n . ) d r i l l f o r 0 3 / 1 6 i n . H i - l i t e
fasteners and 5 , 1 0 mm ( 0 0 . 2 0 1 i n . ) d r i l l f o r 0 3 / 1 6 i n .
Composi-lok f a s t e n e r s ) .
(d) R e m o v e t h e t e m p l a t e f r o m t h e repair area-.

/ L
(e) C o u n t e r s i n k t h e o u t e r surface of t h e s k i n 1 3 0 degrees, t o

m a k e t h e i n i t i a l type fasteners (HST315AG6 H i - l i t e p i n s
o r M B F 2 1 1 3 - 6 C o m p o s i - l o k f a s t e n e r s ) f l u s h . Make s u r e t h a t
the c o u n t e r s i n k i s t h e correct depth f o r t h e head of t h e
fastener s o t h a t i t w i l l be i n s t a l l e d f l u s h w i t h t h e
o u t e r surface.
(f) U s e a s u c t i o n cleaner t o r e m o v e d u s t and debris f r o m t h e

repair area.
(g) A p p l y O M a t 8 0 5 r e s i n / O M a t 8 0 6 hardener ( o r an a l t e r n a t i v e
v a r n i s h ) t o seal t h e edges of t h e d r i l l e d h o l e s i n t h e
s k i n , refer t o SRM 5 4 - 0 2 - 0 1 seal exposed f i b r e s ,
(FRS3254) .
R e p a i r No. 17
54-10-01
Page 216
Printed in Great Britain ~ a r1 0. / 0 7
R8211 TRENT
STRUCTURAL REPAIR
MANUAL
(h) Using O M a t 4/47 PL32M Hylomar, w e t i n s t a l l r e p l a c e m e n t

f a s t e n e r s t h e same a s t h e i n i t i a l t y p e , .HST315AG6-3 H i -
l i t e p i n s & HST97DU6 c o l l a r s o r MB~2113~&-250 Composi-lok
f a s t e n e r s . A d j u s t f a s t e n e r l e n g t h t o make them
a p p l i c a b l e . R e f e r t o SRM TASK 54-02-10, F a s t e n e r s -
I n s t a l l a t i o n and Removal.
V. R e - i n s t a l l t h e I n t e r b u l k h e a d System and t h e T . A . I . A c c e s s Panel

(Ref F i g 204, 205 and 206)
(1) I n s t a l l t h e T . A . 1 I n t e r B u l k h e a d System t o t h e Air i n t a k e cowl

a s given i n t h e s t e p s t h a t follow
(a) P u t t h e O u t l e t Duct Assembly i n t o t h e A i r i n t a k e cowl and

move f o r w a r d ends i n t o p o s i t i o n around t h e Shroud Duct
and Spray Ring.
(b) A l i g n t h e r e a r end of t h e O u t l e t Duct Assembly w i t h t h e

h o l e i n t h e r e a r Bulkhead.
(c) Apply a t h i n l a y e r of O M a t 4/47 jointing,,~compoundt o t h e

two s i d e s of t h e o u t l e t d u c t shroud asse;;lbly and t h e
m a t i n g s u r f a c e s of t h e I n l e t Duct ~ o u s i r i ~ & s e m band
l~
t h e r e a r bulkhead. Assemble t h e p a r t s w h i l e t h e compound
is still w e t .
(C) P o s i t i o n t h e o u t l e t d u c t s h r o u d assembly from t h e a f t

s i d e of t h e rear bulkhead. C a r e f u l l y move i t i n t o t h e
h o l e i n t h e Rear Bulkhead and around t h e O u t l e t Duct end
f i t t i n g . Align t h e h o l e s of t h e o u t l e t d u c t s h r o u d
assembly w i t h t h e h o l e s on t h e Rear Bulkhead.
(d) I n s t a l l t h e t e n o f f NAS6704U4 B o l t s and AN960C416L

Washers t o a t t a c h t h e O u t l e t Duct Shroud Assembly t o t h e
R e a r Bulkhead. Torque t h e b o l t s t o 1 1 . 3 Nm (100 l b f . i n ) ,
r e f e r t o t h e AMM Task 70-51-00-910-802.
(e) P o s i t i o n t h e I n l e t Duct Housing Assembly. from t h e a f t

s i d e of t h e Rear Bulkhead. C a r e f u l l y move ...i t i n t o t h e
h o l e i n t h e O u t l e t Duct Shroud ~ s s e m b l ~ : ' a ~ d ' a = o ut n
hde
I n l e t Duct end f i t t i n g . A l i g n t h e holes:)$fi.th& I n l e t
Duct Housing Assembly w i t h t h e h o l e s of "th'e O u t l e t Duct
..
Shroud Assembly.
(f) I n s t a l l t h e f i v e NAS6704U5 B o l t s and AN960C416L Washers

t h a t a t t a c h t h e I n l e t Duct Housing Assembly t o t h e
O u t l e t Duct Shroud Assembly. Torque t h e b o l t s t o 11.3 Nm
(100 l b f . i n ) , r e f e r t o t h e AMM Task 70-51-00-910-802.
R e p a i r No.17
54-10-01
Page 217
. "
RB211 TRENT c - -,
STRUCTURAL REPAIR
MANUAL
CAUTION: MAKE SURE THE PAINT MARKS ON THE OUTLET DUCT

ASSEMBLY AND THE OUTLET DUCT SHROUD ASSEMBLY ARE
ALIGNED BEFORE YOU TIGHTEN THE VEE CLAMP. I F THEY
ARE NOT, THE OUTLET GRILLE SEAL WILL NOT TOUCH THE
T . A . I . ACCESS PANEL SUFFICIENTLY, AND LEAKAGE WILL
OCCUR.
(g) I n s t a l l t h e 3 5 5 3 2 - 7 0 0 V - C l a m p around t h e O u t l e t D u c t
A s s e m b l y and t h e Shroud D u c t a t t h e F o r w a r d B u l k h e a d .
(h) P o s i t i o n the I n s u l a t i o n B l a n k e t on t h e O u t l e t D u c t
A s s e m b l y and a t t a c h u s i n g O M a t 2 / 9 8 l o c k w i r e .
(i) Make s u r e t h a t t h e w o r k area i s clean fro? s w a r f and

..,. .
clear of t o o l s and o t h e r i t e m s .
CAUTION: MAKE SURE THE T . A . I . ACCESS PANEL TGUCHES THE

OUTLET GRILLE SEAL SUFFICIENTLY. I F THE PANEL DOES
NOT SEAL CORRECTLY, LEAKAGE WILL OCCUR AND THE HOT
A I R CAN DAMAGE THE A I R INTAKE COWL.
(j) P u t t h e TA1 A c c e s s P a n e l i n t o p o s i t i o n on t h e A i r i n t a k e
c o w l and i n s t a l l w i t h 4 4 NAS7204U4 s c r e w s . T o r q u e t h e
s c r e w s t o 1 5 , 2 Nm ( 1 3 5 l b f . i n . ) , refer t o AMM T a s k 7 0 - 5 1 -
00-910-802.
W. C l e a n the R e p a i r A r e a
(1) R e m o v e a l l u n w a n t e d m a t e r i a l f r o m t h e r e p a i r area w i t h a
s u c t i o n cleaner.
(2) R e f e r t o AMM TASK 7 0 - 2 0 - 0 1 - 1 0 0 - 8 0 2 . C l e a n t h e repair area w i t h

a p e r m i t t e d s o l v e n t O M a t 1 5 0 ACETONE and an O & t 2 / 1 0 1 L I N T -
FREE CLOTH. W i p e the area dry before t h e s o l v e n t dries.
. .
'
,,;
..-.
, -:,yA'
X. I n s p e c t , T a p T e s t and R e c o r d t h e R e p a i r .!
(1) D o a v i s u a l i n s p e c t i o n t o m a k e s u r e t h a t t h e repair has been

done i n reference w i t h these procedures.
(2) T a p T e s t t h e repair area, refer t o SRM 5 4 - 0 1 - 0 6 .
(3) V i b r o - e t c h t h e repair s c h e m e number " F R S Z 0 0 2 8 " onto t h e a i r

i n t a k e c o w l m o d i f i c a t i o n record p l a t e .
Y. A p p l y t h e Surface P r o t e c t i o n
(1) A p p l y surface p r o t e c t i o n t o t h e repair area ( R e f . SRM 5 1 - 0 2 -

04) .
R e p a i r No.17
54'-1
.
o..-01
. . h . :
. - .
,.; .;,.,l.;...
., . Page 218
~ r i n t e d ' i nGreat B r i t a i n Mar. 10/07
K C Z R A L REPAIR
Z. Re-install the air intake cowl
(1) Install the air intake cowl, refer to AMM TASK 71-61-41-400-
802.
Repair No.17
54-10-01
Page 219
OUTER MINIMUM RADIUS
CUT-OUT
-9-
tA
\
/
\
.- - _ _ _ - - - _ _ ,
LOCK WlRE TO HOLD THE SUPPORT

CLAMP BAR PLATE IN THE CORRECT POSITION
OUTER SKIN \ 1
25,40 mm (1.00 in) 4 L- \

OVERLAP AROUND SUPPORT PLATE OUTER SKlN
THE REPAIR CUT-OUT SECTION STIFFENER
A-A
(Support plate installation)
CARBON
FILLER PLIES
'
1 OUTER SKIN
I
I I /
SUPPORT PLATE
SECTION
A-A
(With clamp bar removed and filler plies installed)
Support Plate and Filler Ply Installation

Figure 201
Repair No.17
54-10-01
Page 220
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
DIMENSION C = 25,40 mm (1.00 in)

DIMENSION D = 19,05 mm (0.75 in)
FIBREGLASS PLY CARBON REPAIR PLIES

TEFLON TAPE
\ \ OUTER SKlN
I
SUPPORT PLATE \
CARBON FILLER PLIES REPLACEMENT FASTENERS
THROUGH THE REPAIR PLIES,
SKlN AND STIFFENER
SECTION
B-B
Repair Ply Installation
Figure 202
Repair No.17
54-10-01
Page 221
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
VACUUM HOSE
VACUUM BAG
I I
I INSULATION
1I
, SEALING
TAPE
-- 50,8 mm (2.0 in)
MINIMUM HEAT BLANKET
(Must cover support plate and temperature probes)
l
BREATHER CLOTH (2 off)
1
FIBREGLASS
BLEEDER CLOTH
25,4 mm (l
.O in) NON-POROUS PARTING FlLM (No. of plies equals
MINIMUM no. of repair plies)
1 r- .: :.1 . /
I
M
TEMPERATURE PROBE
(3 off minimum)
\
POROUS PARTING FlLM
I -
J76.2,in,~;; in)
OUTER EDGE
OF THE REPAIR
TEFLON TAPE
OUTERSURFACEOF
THE REPAIR PART
\
R e p a i r E q u i p m e n t Installation
F i g u r e 203
R e p a i r No.17
54-10-01
P a g e 222
R8211 TRENT
STRUCTURAL REPAIR
MANUAL
I
i
I i L o c w l R E oMAT 2/98
BOLT
NAS7204U4 /
W
/'
/
(44 off) -_@'
Figure 204
Repair No.17
54-10-01
Page 223
. --
RB211 TRENT
STRUCTURAL REPAIR
MANUAL

Figure 205
Repair No.17
54-10-01
Page 224
Printed i n Great B r i t a i n ~ a r 10/07
.
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
FORWARD
BULKHEAD
SPRAY RING
A1 8295-4D
INNER DUCT
ASSEMBLY
OUTER DUCT
Removal/Installation of the T.A.I. Interbulkhead System

Figure 206
Repair No.17
54-10-01
Page 225
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
AIR INTAKE COWL - STRUCTURE IDENTIFICATION

1. General
A. The inner and outer barrels are maintained in their correct postions, by
their attachment to the front and rear bulkheads.
R The rear bulkhead is a fire seal between the intake cowl and the engine fan
R case. The bulkhead is made of composite material skin, aluminum alloy foam
R filled honeycomb (aluminum honeycomb SMS58 ISS 1 3/16 cell with potting
R SMS41 TY1 - EPOCAST 1610) core sandwich construction. The inner and outer
R barrels are maintained in their correct positions by their attachment to
R the rear bulkhead at their aft ends, and to the forward bulkhead at their
R forward ends.
EFFECTIVITY: TRENT
Page 1
Mar. 1/95
1 RB.211 TRENT
rxm3@ STRUCTURAL REPAIR
MANUAL

See 54-40-02
t FAN COWL
See 54-30-02
See 54-20-02
FOR AIR INTAKE STRUCTURE

See figures 1 and 2
Air Intake Cowl Structure - Identification

EFFECTIVITY: TRENT
Page 2
July 1 / 9 4
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
-
Air Intake Cowl Structure Identification
EFFECTIVITY: TRENT
Page 3
July 1/94
M RB.211 TRENT
STRUCTURAL REPAIR
MANUAL

1 Engine Ring Forged
2 Rear Bulkhead R/H Honeycomb Sandwich
2 Rear Bulkhead L/H Honeycomb Sandwich
3 Forward Bulkhead L/H 0.025in. AMS4901
3 Forward Bulkhead Bottom 0.025in. M4901
3 Forward Bulkhead R/H 0.025in. M4901
R LIST OF MATERIALS FOR SHEET 2
-
Air Intake Cowl Structure Identification
EFFECTIVITY: TRENT
Page 4
July 1/94
1
m@
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
NOTE: For fibre orientation -45'

refer t o sheet 2
A l , A2, C5B, C6F, C7F, C8J, C9F,

ClOH, C l l F , ClZF, C13A
0.20in.
A3, A4, C5B, C1 3A
HONEYCOMB PANEL
A l , A2, C5B, C6A, C7A, C8B, C9A.

ClOA, C l l A , C12A, C13A, G14A
(22,86mm)
SECTION A-A
D4100
-
A i r I n t a k e Cowl S t r u c t u r e Identification - Ply Lay-Up
EFFECTIVITY: TRENT
54- 10-02
Page 5
J u l y 1/94
1
m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
Ply Number Material Note Fibre Orientation Splice

Degrees
S530303
Al See Note 3
A2 See Note 3
S530344
A3 See Note 3
A4 See Note 3
C5A - C5G See Note 2 Overlap

C6A - C6K See Note 2 Butt
C8A - C8P See Note 2 Butt
ClOA - ClOP See Note 2 Butt
CllA - CllK See Note 2 Butt
C13A - C13G See Note 2 Overlap
G14A - G14G See Note 4 Butt
Ply Orientation for Section A-A
NOTES: 1. Graphite prepreg as per Shorts spec S.M.S. 30 Type 111 class 2
style 3K-135-8H.
2. Graphite prepreg as per Shorts spec S.M.S. 30 type IV class 2

style 3K-70-PW.
3. Adhesive S.M.S. 36 type 11 Grade 03 (Redux 319).
4. Glass fabric prepreg as per Shorts spec S.M.S. 34 type 120

1.005 THK.l.
Air Intake Cowl Structure - Identification - Ply Orientation

EFFECTIVITY: TRENT
Page 6
Mar. 1/95
M s
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
AIR INTAKE COWL STRUCTURE - ALLOWABLE DAMAGE
1. Introduction
This section contains the allowable damage limits for the component covered by
this Chapter-Section.
Any damage which is found to be greater than the allowable damage limits,
should be repaired in accordance with the procedures detailed in the following
Repair Section, Page Block 201.
2. Zones
Each of the individual components is divided into zones. The zones which are
affected by the different types of allowable damage are identified in the
figures and tables which follow.
3. Section Organization
The information in this section is given in several paragraphs. Each

paragraph gives information about allowable damage, structure material, and
damage types.
A. General
(1) Allowable damage data is intended to permit an cperator to determine

whether a damaged nacelle component may continue in service, or be
rejected for repair. Allowable damage must not compromise the
stuctural integrity of the component, which could affect the strength
or fatigue life. The types of allowable damage permitted are defined
and brief descriptions are given of the clean-up procedures needed
either to prevent propagation of the damage or to improve the
appearance and aerodynamic smoothness of the damaged part.
(2) Materials used in many of the components are aluminium alloy sheet,
corrosion resistant steels and composite compositions with varying
fabrics and weave forms. These also include honeycomb infill/core
structures of different materials, skin thickness and densities.
EFFECTIVITY : TRENT
Page 101
Dec. 15/96
( 3 ) Damage l i m i t s assume t h a t exposed edges do n o t extend above t h e s k i n
s u r f a c e . Any damage t h a t does must be trimmed t o remove o r f e a t h e r t h e
p r o t r u s i o n . Holes o r cracks i n p r e s s u r i s e d panel zones must be s e a l e d
u s i n g t h e a p p r o p r i a t e tape.
Allowable damage i s c l a s s i f i e d a s e i t h e r unlimited usage o r time

limited.
( a ) Unlimited usage damage i s d e f i n e d a s minor damage which does not

a f f e c t t h e s t r u c t u r a l i n t e g r i t y o r f u n c t i o n a l c a p a b i l i t y of t h e
component. No r e p a i r s a r e n e c e s s a r y o t h e r than cosmetic, over t h e
a i r c r a f t design l i f e .
(b) Time l i m i t e d damage i s defined a s minor damage which does n o t

a f f e c t t h e s t r u c t u r a l i n t e g r i t y of t h e component i n normal s e r v i c e
u s e , but could reduce t h e d e s i g n l i f e of t h e component. I n t h i s
c a s e damage must be r e p a i r e d by t h e n e x t A i r c r a f t "C" check. The
l o c a t i o n and s i z e of t h e damage should be noted and checked a t
s u i t a b l e i n t e r v a l s t o monitor t h a t t h e damage h a s n o t grown beyond
t h e time l i m i t e d damage allowance.
(4) Damage types p e r m i t t e d on t h i s component a r e l i s t e d below. They only

apply t o t h e s t r u c t u r a l m a t e r i a l of t h e component, n o t t h e s u r f a c e
f i n i s h e s , such a s p a i n t .
( a ) Abrasion - a n a b r a s i o n i s an a r e a of damage which r e s u l t s i n a

c r o s s s e c t i o n a l a r e a change caused by s c u f f i n g , rubbing, s c r a p i n g
o r o t h e r s u r f a c e e r o s i o n . An a b r a s i o n u s u a l l y appears rough and
irregular.
(b) Gouge - a gouge i s a damage a r e a of any s i z e which r e s u l t s i n a

c r o s s s e c t i o n a l a r e a change. I t i s u s u a l l y caused by c o n t a c t with
a s h a r p o b j e c t which produces a continuous, s h a r p o r smooth
channel-like groove i n t h e m a t e r i a l .
( c ) Nick - a n i c k is a l o c a l gouge w i t h s h a r p edges.
(d) S c r a t c h -
a s c r a t c h i s a l i n e of damage i n t h e m a t e r i a l and r e s u l t s
i n a c r o s s s e c t i o n a l a r e a change. Normally caused by a v e r y sharp
object.
( e ) Crack - a c r a c k i s a p a r t i a l f r a c t u r e o r complete break i n t h e

m a t e r i a l and produces a most s i g n i f i c a n t c r o s s s e c t i o n a l a r e a
change. Normally appearing a s a n i r r e g u l a r l i n e .
EFFECTIVITY: TRENT
Page 102
Dec. 15/96
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
( f ) Hole - a hole i s a complete p e n e t r a t i o n of t h e m a t e r i a l .
(g) Delamination - a d e l a m i n a t i o n i s t h e s e p a r a t i o n of two l a m i n a t e

p l i e s o r faying surfaces.
(5) The a l l o w a b l e damage zones f o r t h i s component, as shown i n F i g u r e 101

Sheet 2, a r e :
1 Rear Bulkhead
2 Engine Ring
..........................................................................
INSPECTION
Abrasion 1 Confined t o s u r f a c e Maximum d e p t h 0.015in. A i r c r a f t "A"

r e s i n o v e r u n l i m i t e d (0.39 mm) check
area. P r o t e c t with
s e a l i n g tape
Gouge 1 and 2 No n e a r e r t h a n Maximum depth A i r c r a f t "A"

8.0 i n . 0.010 i n . (0.254 mm) check
(203.2 mm) t o Maximum l e n g t h
other unrepaired 6.0 i n . (152.4 mm)
damage. No more Maximum w i d t h
t h a n 6 gouges p e r 0.10 i n . (2.54 mm)
barrel half.
Protect with
s e a l i n g tape
Nick 1 and 2 No n e a r e r t h a n Maximum d e p t h A i r c r a f t "A"

4.0 i n . (101.6 mm) 0.010 i n . (0.254 mm) check
t o o t h e r damage. Maximum l e n g t h
P r o t e c t with 1.0 i n . (25.4 mm)
s e a l i n g tape. I f
l e n g t h exceeds 1.0
i n . (25.4 mm)
c o n s i d e r as gouge
EFFECTIVITY: TRENT
Page 103
Dec. 15/96
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
INSPECTION
DAMAGE ZONE REQUIREMENTS ALLOWABLE LIMITS INTERVAL S
Scratch 1 and 2 No n e a r e r t h a n 8.0 Maximum d e p t h A i r c r a f t "A"

i n . (203.2 mm) t o 0.010 i n . (0.254 mm) check
other unrepaired Maximum l e n g t h
damage. No more 6.0 i n . (152.4 mm)
than 6 scratches Maximum w i d t h
per barrel half. 0.10 i n . (2.54 mm)
Protect with sealing
tape.
Crack 1 No n e a r e r than 10.0 Maximum l e n g t h Fly-on l i m i t

i n . (254.0 mm) t o 3.0 i n . (76.2 mm) only. Must b e
o t h e r damage. S t o p repaired at
d r i l l crack. earliest
Protect with sealing opportunity.
tape.
Hole 1 No n e a r e r than 10.0 Maximum d i a m e t e r Fly-on l i m i t

i n . (254.0 mm) t o 2.0 i n . (50.8 m) only. Must b e
o t h e r damage. repaired at
Protect hole with earliest
sealing tape opportunity.
Delamin- 1 No n e a r e r t h a n 8.0 Maximum 2.0 i n . A i r c r a f t "A"

ation i n . (203.2 mm) t o (50.8 mm) a c r o s s i n check
o t h e r damage. No any d i r e c t i o n
s u r f a c e cracking.
Repair no l a t e r
t h a n "C" check
EFFECTIVITY: TRENT
Page 104
Dec. 15/96
1
m @
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL

See 54-40-01
See 54-30-01
FAN COWL
See 54-20-01
FOR AIR INTAKE COWL

See detail 1
-
A i r I n t a k e Cowl S t r u c t u r e Allowable Damage
F i g u r e 101 ( S h e e t 1 of 2)
EFFECTIVITY: TRENT
P a g e 105
~ e c15/96
.
RB.211 TRENT
mB STRUCTURAL REPAIR
MANUAL
RING
REAR BULKHEAD
DETAIL 1
-
A i r I n t a k e Cowl S t r u c t u r e A l l o w a b l e Damage
Figure 101 ( S h e e t 2 of 2)
EFFECTIVITY: TRENT
P a g e 106
D e c . 15/96
RB211 TRENT
STRUCTUAL REPAIR
REPAIR NO.l (FRS 2018)

AIR INTAKE COWL - STRUCTURE
REPLACE THE SKIN GUARDS
1. General
A. This repair procedure can be used to replace the skin guards

at radials 351 and 10 degrees.
.......................................................................
.......................................................................
SRM 54-10-02, Repair No.2 Replace the Wear Strip
- Rotary cutter and filing equipment
- Riveting tools
- Suction cleaner
.......................................................................
.......................................................................
OMat 150 ACETONE
C. Repair Parts
.......................................................................
PART NO. PART IDENT
.......................................................................
S530385 Skin Guard
S530386 Skin Guard
NAS1097AD4-6 Reaction Rivet
NAS1097AD4-9 React ion Rivet
REPAIR NO.l
54-10-02
Page 201
Jun. 10/08
ed in Great Britain
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
4. Examine the Damaged Skin Guards
A. You must examine the skin guard S530386 to determine the

confi.gurationtype as per figures 201 and 202.
R 5. Examine Adjacent Damage
R A. You must also examine and, if necessary, replace the wear strip
R (SRM 54-10-02,Repair No.2 - FRSZ019).
6. Remove the Skin Guard (Ref Figures 201 and 202)
A. Drill and remove the rivets that attach the skin guard to the
rear flange of the cowl (Ref SRM 54-02-10). Make sure you do not
increase the diameter of the holes in the rear angle or the
capping strap. Remove the skin guard.
B. Examine the capping strap for damage not visible when the skin
guard was attached.
7. Clean the Repair Surface
GLOVES, DUST MASK AND SAFETY GOGGLES TO PROTECT YOURSELF
AGAINST DUST AND LOOSE PARTICLES, WHICH CAN BE DANGEROUS TO
YOUR HEALTH.

SEALANTS, REFEER TO THE MANUFACTURERS CONTROLAND
.A. Clean the repair surface with OMat 150 Acetone and OMat 2/101
LINT- FREE CLOTH. Dry the surface with a new piece of the cloth
before the Acetone evaporates.
R 8. Re-work the Replacement Skin Guard
R If component S530386 is identified as being the configuration type

R (2) shown in Figure 202, then proceed to re-work as follows:
R A. Mark off the area to be trimmed (ref. Figure 202).
R B. Use a suitable clamp/vice to hold the skin guard in position on

R the workbench.
R C. Use a suitable cutter to trim back the skin guard to the

R dimensions shown in Figure 202.
EFF:ECTIVITY: TRENT REPAIR NO.l
54-10-02
Page 202
Jun. 10/08
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
D. Chamfer the edges to 15 degrees.
E. Radius corner 0.30 in. typ.
F. Remove any sharp edges from the reworked component.
9. Prepare the Replacement Skin Guard
A. Put the skin guard in its applicable position on the rear flange:
- S530385 at radial 10 degrees
-S530386 at radial 351 degrees.
B. Use clamps to hold the skin guard in position, with its pre-
drilled holes aligned with those in the rear flange.
C. Back-drill through the rear flange to get the correct pattern

for the pilot holes.
NOTE: If configuration type (2) shown in Figure 202, then drill

the new pilot hole using a 3.2 mm (0.125 in.) drill, also
by back-drilling through the rear flange
D. Use gripper pins to temporarily attach the skin guard to the

retaining strip. Enlarge the pilot holes to 3.25wn (0.128 in.)
diameter for the rivets.
E. Countersink the holes on the outer face of the skin guard for the
NAS1097AD4 rivet heads.
F. Remove the gripper pins, remove the skin guard from the flange.
G. Remove sharp edges from the new rivet holes.
A. Remove unwanted material with a suction cleaner.
11. Install the Skin Guard (Ref Fig.202)
A. Apply a thin layer of OMat 4/47 JOINTING COMPOUND to the mating

face of the replacement skin guard.
B. Put the skin guard in position and temporarily attach it with

gripper pins.
REPAIR NO.l
54-10-02
Page 203
Jun. 10/08
ed in Great Britain
P RB211 TRENT
STRUCTUAL REPAIR
MANUAL
C. Attach the skin guard to the rear flange with the NAS1097AD4-6
and/or NAS1097AD4-9 rivets (SRM 54-02-10).
NOTE: The three forward holes in skin guard S530386 at radial

351 degrees are for NAS1097AD4-9 rivets.
12. Inspection
A. Make sure that the skin guard is correctly attached in accordance

with this repair procedure.
EFFECTIVITY: TRENT REPAIR NO.l

54-10-02
Page 204
R Jun. 10/08
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
Replace the Skin Guards - Configuration 1

Figure 201
EFFECTIV1TY:TRENT REPAIR NO.l
54-10-02
Page 205
Jun. 10/08
ed in Great Britain
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
TRIM BACK SKIN GUARD AS
7,62 mm (0.30 in)

RADIUS TYPICAL
POSITION OF NEW NASI097AD4-6

HOLE PITCH
NASI097AD4-9
Ct'SK HOLES
SKlN GUARD SJ30386
REWORKED AND
RE-IDENTED AS
S306004428-1
R DRILL 4 C'SK HOLES

TO MATCH EXISTING
SKlN GUARD HOLES
EXISTING NASI 097AD4

RIVETS (2 off) REFERENCE
SKlN GUARD SJ30385

(See Figure 201)
(Serial numbers 1364 & 1365 only)
R Replace the Skin Guards - Configuration 2

Figure 202
54-10-02
Page 206
Jun. 10/08
R6211 TRENT
STRUCTURAL REPAIR
REPAIR N0.2 (FRS 2019)
REPLACE THE WEAR STRIP
1. General
A. The wear strip is on the rear flange of the air intake cowl, at
the 12 o'clock position.
B. SB71-C496 replaces the aluminium wear strip (5530387) with one

made from stainless steel (5530388).
C. The stainless steel wear strip S530388 has been replaced by a

longer version SJ30740, which reduces the gap between the wear
strip and the skin guards. Thia wear strip needs to be trimmed
during installation.
.......................................................................
------,-----------------------------------------------------------------
- Riveting tools
- Suction cleaner
.......................................................................
------*.----------------------------------------------------------------
R OMat 262 TEMPORARY MARKER

OMat 2 /l01 LINT-FREE CLOTH
OMat 150 ACETONE
C. Repair Parts
.......................................................................
PART NO. PART IDENT.
S530740 Wear Strip (Stainless Steel)

EFFECTXV1TY:TRENT REPAIR N0.2
54-10-02
Page 201
Jun. 10/08
~d in Great Britain
P
"" RB211 TRENT
STRUCTURAL REPAIR
MANUAL
Reaction Rivet
Reaction Rivet
HEALTH.

4. Clean the Repair Area (Fig. 202)
A. Clean the wear strip and the adjacent surface with OMat 135 MEK
or OMat 150 ACETONE and OMat 2/101 LINT-FREE CLOTH. Dry the
surface with a new piece of the cloth before the MEK
evaporates.
5. Remove the Wear Strip (Ref Fig.202)

R A. Use the OMat 262 TEMPORARY MARKER to record the position of the
forward and aft edges of the wear strip on the cowl.
B. Drill out and remove the 23 rivets that attach the wear strip
to the cowl (SRM 52-02-10). Make sure you do not increase the
diameter of the holes in the rear flange. Remove the wear
strip.
6. Trim the New Wear Strip (Fig. 202)
A. Locate the new wear-strip S530740 on the capping-strap.

Position one end of the wear-strip to give a gap of 0.010 -
0.030 in. (0,254 - 0,762 mm) with the adjacent skin-guard. Make
sure that the forward and aft edges of the wear-strip are in
the same position as the previous wear-strip, as recorded in
step B1, above.
R B. Use a temporary marker OMat 262 to mark where the wear-strip
overlaps the edge of the other skin-guard.
C. Use suitable hand tools to trim the wear-strip, removing the

extra material marked, to give a gap of 0.010 -
0.030 in.
(0,254 - 0,762 mm) with the skin-guards at both ends. Produce a
radius on each corner 0.3 in. (7,62 mm) typical. Remove all
sharp edges.
REPAIR N0.2
54-10-02
Page 202
Jun. 10/08
A.
p RB211 TRENT
MANUAL
STRUCTURAL REPAIR
Use suitable clamps to temporarily secure the wear strip in

position. Make sure that there is a gap of 0.010 - 0.030 in.
(0,25 - 0,76 mm) between the wear strip and the skin-guards at
both ends. Make sure that the forward and aft edges of the wear
strip are in the same position as the previous wear strip, as
recorded in step B1 above.
B. Use a 0.128in. (3,25mm) diameter drill, drill through the

original holes in the flange to spot-mark the pattern of rivet
holes.
C. Remove the wear strip visor from the cowl.
D. Using the spot-marks for location, drill 23 pilot holes 2,4mm

(3/32in.) diameter through the wear strip. Enlarge the pilot
holes to 3,25mm (0.128in.) diameter.
E. Countersink the 23 holes in the wear strip to suit the

NAS1097AD4 rivet heads.
F. Remove the sharp edges from the new rivet holes in the wear
strip.
A. Clean the new wear strip and the cowl with OMat 135 MEK or h a t
150 ACETONE (MEK alternative) and OMat 2/101 LINT-FREE CLOTH.
Make sure there is no sealant that remains on the rear flange
of the cowl. Dry the surfaces with a new piece of the cloth
before the MEK evaporates.
9. Install the Wear S t r a ~(Ref Fia.202)
A. Apply a thin layer of OMat 4/47 JOINTING COMPOUND to the mating

face of the new wear strip.
B. Install the S530740 wear strip to the cowl with twenty-two

NAS1097AD4-6 rivets and one NAS1097AD4-9 rivet (SRM 54-02-10).
NOTE: Wet-install the rivets with OMat 4/47 JOINTING COMPOUND.
REPAIR NO. 2
54-10-02
Page 203
May 15/05
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
R A. Remove unwanted jointing compound from the repair area by

R cleaning the area with OMat 135 MEK or Omat 150 acetone (MEK
R alternative) and OMat 2/101 LINT-FREE CLOTH. Dry the surfaces
R with a new piece of the cloth before the MEK evaporates.
11. Inspection
A. Make sure the wear strip is correctly attached in accordance

R with this repair procedure. Refer to SRM TASK 54-02-10.
R 12. Record the.Repair
R A. Vibro-etch the repair scheme number FRSZO19 onto the nose cowl
R modification record plate.
R Check the modification plate to make sure that SB 71-C496 has
R been incorporated. Refer to SB 71-C496.
REPAIR N0.2
54-10-02
Page 204
May 15/05
RB211 TRENT
STRUCTURAL REPAIR
NOSECOWL ASSEMBLY
Replace the Wear Strip - Location on the cowl

Figure 201
REPAIR N0.2
54-10-02
Page 205
May 15/05
- -
p
"" RB211 TRENT
MANUAL
STRUCTURAL REPAIR
REMOVE AND INSTALL

NAS1097AD4-9 RIVETS
REMOVE AND INSTALL
NAS1097AD4-8 RIVETS
(22of9
REMOVE
ORIGINAL WEAR STRIP
INSTALL
SKlN QUARD
(Re9
CAPPING STRAP
SKlN GUARD
Replace the Wear Strip - Fasteners to remove and install

Fig. 202
REPAIR N0.2
54-10-02
Page 206
May 15/05
P r i n t e d in Great B r i t a i n
P R8211 TRENT
MANUAL
STRUCTURAL REPAIR
-RADIAL-=!" - - -
L
I
1-
--
- - -I-\- -
0.010 in - 0.030 in
(0,254 mm - 0,762 mm)
GAP BETWEEN
WEAR STRIP AND
SKlN GUARD
OUTER SKlN
I
I
I
I +
I I
I
I
l
I
+ 0.010 in - 0.030 in
(0,254 mm - 0,762 mm)
I I GAP BETWEEN
I I +' WEAR STRIP AND
I l + SKlN GUARD
I l
+
+
RADIAL 10' - -:
I
I
- - -
l
1
l
. - -? > SKIN GUARD
P, \
I
\
l
CAPPING STRAP
8
38
l2
Replace the Wear Strip - Trim to achieve the correct
Fig. 2 0 3
54 -10-02
Page 207
May 1 5 / 0 5
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
REPAIR N0.3 (FRS 2021)
REPLACE THE RFI SEAL
1. General
A. This repair procedure can be used to replace the full RFI seal,
or one segment of it. The length of seal to be replaced will be
found from the dimensions of the damage.
B. SB71-C500 introduced improved seal material and longer retaining

strips to cover deletion of the seal end-plates.
.......................................................................
.......................................................................
3. Emiwment and Materials
- Riveting equipment
- Suction cleaner
.......................................................................

OMat 8723 SILASTIC 732
C. Repair Parts
Retaining Strip
Retaining Strip
RFI Seal
RFI Seal
RFI Seal
Reaction Rivet
REPAIR N0.3
54-10-02
Page 201
Jan. 1/00
RB211 TRENT
STRUCTUAL REPAIR
m MANUAL
4. Inspection
A. Measure the damage and add 6.0in.(152mm) each side to find the
length of the replacement RFI seal.
5. Remove the Damaqed Seal (Ref Fiq. 201)
A. Drill and remove the NAS1097AD4-5 rivets that attach the

retaining strip and RFI seal to the rear flange of the cowl.
(SRM 54-02-10).
NOTE: You must always remove a full segment of retaining strip.
B. Remove and examine the RFI seal and the retaining strip for
damage not visible when they were attached.
C. If the retaining strip is not damaged, you can use it again. If

damaged, replace it with a new segment cut to the correct length.
D. Cut out the RFI seal to remove the damage (if a full segment is
not to be replaced) :
(1) Remove the damage plus 6.0 in. (152 mm) each side
(2) Make sure there is a minimum edge distance of 0.32 in.(8 mm)
from the rivet holes at each end.
WARNING: METHYLETHYLKETONE (MEK) IS CLASSIFIED AS A HAZARDOUS

MATERIAL THAT CAN CAUSE INJURY OR ILLNESS IF NOT USED
CORRECTLY. USE THIS PRODUCT ONLY IN ACCORDANCE WITH THE
MANUFACTURER'S HEALTH AND SAFETY RECOMMENDATIONS. READ
THE APPLICABLE MATERIAL SAFETY DATA SHEET AND OBEY ALL
SPECIFIED HEALTH AND SAFETY PRECAUTIONS.
A. Clean the repair area with OMat 135 MEK and OMat 2/101 LINT-FREE
CLOTH. Dry the surfaces with a new piece of the cloth before the
MEK evaporates.
7. Prepare the Repair Seal
A. Cut a piece of RFI seal to the same length as that removed in

step 5.D (if a full segment is not to be installed).
B. Drill the holes in the repair seal:
REPAIR N0.3
54-10-02
Page 202
Jan. 1/00
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(1) Temporarily install the new RFI seal in position on the rear
flange of the cowl
(2) Back-spot through the flange to get the correct hole pitch
(3) Drill the applicable number of 0.128 in.(3,25 mm) rivet holes
through the RFI seal
(4) Remove the RFI seal from the cowl, remove sharp edges from the
rivet holes.
A. Remove unwanted3material with a suction cleaner.
9. Install the Repair Seal (Ref Fig.201 and Fig.202)
A. If a seal has been cut out and a new piece is to be installed,

apply OMat 872F SILASTIC 732 to all the bare ends.
B. Put the new RFI seal and the seal retainer in position on the
cowl. Attach them to the rear flange with NAS1097AD4-5 reaction
rivets (SRM 54-02-10).
10. Inspection
A. Make sure the RFI seal is correctly attached in accordance with

this repair procedure.
REPAIR N0.3
54 - 10 - 02
Page 203
May 15/05
Printed i n G r e a t Britain
RB211 TRENT
STRUCTURAL REPAlR
m MANUAL
INSTALL
SJ30486 RFI SEAL
INSTALL
SJ30486 RFI SEAL
SEAL RETAINER
S530487 RFI SEAL
lNSTALL
lNSTALL
DOOR LOCATORS (Ref)
SEAL RETAINER
S30661 INSTALL
S30661
SEAL RETAINER SEAL RETAINER
SJ30661
SEAL RETAINER
INSTALL
SJ30661
SEAL RETAINER
INSTALL
SJ30490
SEAL RETAINER
Replace the RFI Seal

Figure 201
REPAIR N0.3
54-10-02
Page 204
May 15/05
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
Replace the RFI Seal

Figure 202
REPAIR N0.3
54-10-02
Page 2 0 5
Jan. 1 / 0 0
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
FAN COWL (PRE SB 71-E107) - IDENTIFICATION
1. General
A. The f a n cowl i s designed t o provide a smoothly contoured l e f t hand

and r i g h t hand cover over t h e engine components, s i t u a t e d between t h e
A i r I n t a k e cowl and t h e Thrust Reverser cowl.
B. The f a n cowl comprises a t r i p l e s k i n s t r u c t u r e bonded around an i n n e r

c o r e with a c e n t r a l septum. The m a t e r i a l s used i n t h i s c o n s t r u c t i o n
a r e l i s t e d i n t h e t a b l e , L i s t of M a t e r i a l s .
C. The cowls a r e suspended from t h e a i r c r a f t pylon a t f o u r hinge p o i n t s

p e r cowl and l a t c h e d t o g e t h e r a t t h e bottom c e n t r e j o i n t by f o u r
latch fasteners.
D. There i s a requirement t o be a b l e t o a c c e s s s e v e r a l engine components

f o r r o u t i n e s e r v i c i n g without t h e need t o hinge t h e cowls open. To
e n a b l e t h i s t o be achieved, s e v e r a l h o l e s a r e c u t through t h e cowl
s k i n s . Small a c c e s s p a n e l s , which a r e q u i c k l y removable, a r e f i t t e d
a t t h e s e p o i n t s , t h e s e a r e f i t t e d with a g r i l l t o p r e v e n t f o r e i g n
o b j e c t damage.
E. For l i g h t n i n g s t r i k e p r o t e c t i o n aluminium and s t a i n l e s s mesh a r e

b u i l t i n t o t h e i n n e r and o u t e r s u r f a c e s .
F. For a c c e s s t o o t h e r components t h a t cannot be reached through an

a c c e s s p a n e l t h e bottom c e n t r e l a t c h e s a r e r e l e a s e d , t h e doors hinged
otwards and supported by hold-open r o d s , two t o each door.
54-20-01
Page 1
Oct. 0 1 / 0 6
RB.211 TRENT
m 8 STRUCTURAL REPAIR
MANUAL
H'- I See 54-40-01
/f THRUST REVERSER COWL

See 54-30-01
T
FOR AIR INTAKE COWL
FAN COWL
See Detail 1
See 54-10-01
Fan Cowl - Identification

EFFECTIVITY: TRENT
Page 2
Oct. 1/94
1
-8
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
ITEM DESCRIPTION MATERIAL EFFECTIVITY
R 1 Inner Skin/Outer Skin See Note 1
R 2 Core See Note 2
R 3 Core See Note 3
R 4 Core See Note 3
R 5 Septum See Note 4
R 6 Lightning Protection See Note 5
R 7 Lightning Protection See Note 6
TABLE 1 LIST OF MATERIALS
R NOTE: l. Carbon/Epoxy Fabric Specification CL251, CYCOM 69/GFE 310511.
R 2. Nomex Honeycomb Specification CL253, HRlllO - 1/8in. Hexcell

R 1.8 lbs/cu.ft.
R 3. Nomex Honeycomb Specification CL260, HRlllO - 1/8in. Hexcell

R 6.0 lbs/cu.ft.
4. Glass/Epoxy Fabric Specification CL254, CYCOM 985/120.
5. Aluminium Mesh Specification CL256, FM 300M 03/EAL 90.
6. Stainless Steel Mesh Specification CL259, FM 300M 03/ESS63.

EFFECTIVITY: TRENT
Page 3
Oct. 1/94
1
-63
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
Left Hand - Fan Cowl - Identification

EFFECTIVITY: TRENT
Page 4
Oct. 1/94
B RB.211 TRENT
W @ STRUCTURAL REPAIR
MANUAL
VIEW
PLY ORIENTATION

EFFECTIVITY: TRENT
Page 5
Oct. 1/94
RB.211 TRENT
m@STRUCTURAL REPAIR
MANUAL
PLY ORIENTATION IN PARENTHESIS

(OUTER SKlN FIRST)
5
v
SECTION A-A
SECTION B-B
SECTION C-C 6 (0)
5
SECTION D-D
OUTER SKlN SHOWN UPPERMOST
R Left Hand - Fan Cowl - Identification

EFFECTIVITY: TRENT
Page 6
Oct. 1/94
1
m@
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL

(OUTER SKlN FIRST)
5
SECTION E-E
i
1 (0112 SECTION F-F
5
SECTION
5
OUTER SKIN SHOWN UPPERMOST SECTION H-H
Left Hand - Fan Cowl -

Identification
EFFECTIVITY: TRENT
Page 7
Oct.1/94
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL

(OUTER SKlN FIRST)
SECTION 1-1
SECTION J-J
OUTER SKlN SHOWN UPPERMOST

EFFECTIVITY: TRENT
Page 8
Oct. 1/94
1-S
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
Right Hand - Fan Cowl - Identification

EFFECTIVITY: TRENT
54-20-0 1
Page 9
Oct. 1/94
1
-63
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
VIEW ON INSIDE OF DOOR
PLY ORIENTATION
]
......
AREASOF DENSE
CORE ITEM 3

F i g u r e 3 ( S h e e t 2 of 4)
EFFECTIVITY: TRENT
Page 10
Oct. 1/94
RB.211 TRENT
mxas STRUCTURAL REPAIR
MANUAL

(OUTER SKlN FIRST)
V
5
SECTION A-A
2
SECTION B-B
5
SECTION C-C
5
OUTER SKIN SHOWN UPPERMOST SECTION D-D
Right Hand -
EFFECTIVITY: TRENT
54-20-0 1
Page 11
Oct. 1/94
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL

(OUTER SKIN FIRST)
5
SECTION E-E
SECTION F-F
5
SECTION
5
SECTION H-H
OUTER SKIN SHOWN UPPERMOST

EFFECTIVITY: TRENT
Page 12
Oct. 1/94
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
FAN COWL DOORS - ALLOWABLE DAMAGE
1. Introduction
This section contains the allowable and the repairable damage

limits for the pre SB 71-E107 fan cowl doors (the doors).
Damage which is found to be greater than the allowable damage limits

must be repaired in accordance with the procedures detailed in the
repair section, page block 201.
2. Zones
The doors are divided into zones (Refer to Figure 101). The zones,
which are affected by the different types of allowable or repairable
damage, are identified in the figures and tables that follow.
A. Zone Positions
N0TE:All the dimensions shown are measured along the outer

surface line (OSL) of each door.
(1) Zone 1 - Leading Edge Flange.

This zone is along the leading edge from the top to the
bottom edges at the dimensions shown.
(2) Zone 2 - Top Edge Flange.

This zone is along the top edge between Zones 1,3,5 at
the dimensions shown.
(3) Zone 3 - Trailing Edge Flange.

This zone is along the trailing edge from the top to the
bottom edges at the dimensions shown.
(4) Zone 4 - Other Flanges.

This zone is the area of the door around the outlets,
breather masts and access panels at the dimensions shown.
The dimensions for the outlet and breather mast flanges

are measured from the flange edges you can see from the
outer side of the door.
The dimensions for the access panel flanges are measured

from the edge of each access panel recess you can see on
the door outer side. The flange behind the access
panels you cannot see from the outer side of the door is
also part of Zone 4.
(5) Zone 5.
54-20-01
Page 101
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
This zone is the honeycomb area around the hinges and

the latches. It is between the Zones 1,2,3,6,7,8 at the
top of the door and 1,3,6,7,8 at the bottom at the
dimensions shown.
(6) Zone 6 - Forward-Flank Honeycomb Area.

This zone is aft from the leading edge, between Zones
1,5,7 5 at the dimensions shown.
(7) Zone 7 - Mid-Flank Honeycomb Area.

This zone is in the center of the door between Zones 5,6,8
at the dimensions shown.
(8) Zone 8 - Rear-Flank Honeycomb Area.

This zone is forward from the trailing edge between Zones
3,5,7 5 at the dimensions shown.
(9) Zone 9 - Thermal Anti-icing Outlet Area

This zone is aft from the leading edge of the left door
between Zones 6 and 7 at the dimensions shown.
B. \Keep-Out' Zones.
Damage in these areas cannot be repaired. You must tell the

manufacturer if you find damage in these areas. There are
different \keep-out1 zones on the doors. These include the
areas around fastener positions, heat affected areas and
around the hold-open rod brackets.
NOTE: The dimensions of the \Keep-Outr Zones around the

fasteners are found when you multiply the diameter
of the plain shank of the fastener by six (6).
C. Access Panels
(1) Monolithic Carbon Flanges (Panel Edges). If you find damage

to the monolithic flange of an access panel, refer to the
data for Zone 4.
(2) Honeycomb Areas (Center Cores). If you find damage to the

honeycomb areas of an access panel, refer to the data for
Zone 7.
N0TE:The areas around the panel hinge and latch fasteners

are \Keep-Out' Zones, thus damage in those areas
cannot be repaired.
54-20-01
Page 102
3.
P
Damage Classification
RB211 TRENT
MANUAL
STRUCTURAL REPAIR
A. Allowable damage - General
(1) Allowable damage limits are intended to permit an operator

to determine whether a damaged nacelle component can
continue in service, or be rejected for repair.
(2) Allowable damage must not compromise the structural

integrity of the component, which could affect the
strength or fatigue life.
(3) The types of allowable damage permitted are defined and,

if applicable, brief descriptions of the clean-up
procedures needed are given. These are either, to prevent
propagation of the damage, or to improve the appearance
and aerodynamic smoothness of the damaged part.
(4) The limits given are for a skin surface with no damage
above the surface. If you find damage above the surface
that damage must be cut back to the surface and
discarded.

or time limited, as follows:
(a) Unlimited usage damage is minor damage, which does

not affect the structural integrity or functional
capability of the component.No repairs are necessary,
other than cosmetic,over the aircraft design life.
(b) Time limited damage is minor damage, which does not

affect the structural integrity of the component in
normal service use. But it could reduce the time
life of the component. In this case the damage must
be repaired by the next Aircraft 'C' check. The
location and size of the damage should be noted.
It should be monitored at suitable intervals to make
sure that the damage has not grown beyond the time
limited damage allowance.
B. Allowable damage - Fan Cowl Doors
(1) When you measure the diameter of the damage you must
measure across its maximum width. The damage will thus
be contained in a circle of maximum diameter.
(2) The minimum distance given between areas of damage is

measured between the nearest adjacent edges of the damage.
54-20-01
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RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(3) Where t h e a r e a s of a d j a c e n t damage a r e of d i f f e r e n t

dimensions, t h e maximum diameters a r e used t o c a l c u l a t e
t h e minimum d i s t a n c e between edges.
(4) A i r c r a f t 'Fly-On1 L i m i t s
To l e t an a i r c r a f t continue a f l i g h t ( ' F l y - O n r ) , s e a l a l l
f i b r e s and honeycomb you can s e e around a l l o w a b l e damage
with t h e a p p l i c a b l e t a p e (speed t a p e ) .
C. Types of Damage
(1) The t y p e s of damage t h a t follow r e f e r only t o t h e

s t r u c t u r e and t h e mesh m a t e r i a l s of t h e components. They
do n o t r e f e r t o t h e s u r f a c e p r o t e c t i o n . I f you t h i n k a
component has damage, you must remove p a i n t and o t h e r
s u r f a c e p r o t e c t i o n and do a f u l l i n s p e c t i o n .
(a) Abrasion - An a b r a s i o n i s s u r f a c e damage t h a t i s

u s u a l l y rough and n o t r e g u l a r . I t i s caused by
s c u f f i n g , rubbing, s c r a p i n g o r o t h e r t y p e s of
surface erosion.
(b) Gouge - A gouge i s s u r f a c e damage t h a t has m a t e r i a l

m i s s i n g . I t i s caused when a s h a r p o b j e c t i s pushed
along t h e surface.
(C) Nick - A n i c k i s a small gouge with s h a r p edges. I t

i s caused when a s h a r p o b j e c t i s pushed a g a i n s t t h e
surface.
(d) S c r a t c h - A s c r a t c h i s l i n e a r damage. I t i s u s u a l l y
caused when a very s h a r p o b j e c t i s pushed along t h e
surface.
(e) Crack - A c r a c k i s s t r u c t u r a l damage t h a t u s u a l l y

shows a s a l i n e t h a t i s n o t r e g u l a r . I t can be a
complete break o r a f r a c t u r e .
(f) Dent - A d e n t i s when an o b j e c t with a smooth

contour pushes i n t h e s u r f a c e . I t can cause damage
t o t h e c o r e and t h e bond of t h e m a t e r i a l .
(g) Hole - A h o l e i s an a r e a of missing m a t e r i a l t h a t

goes f u l l y through t h e component, o r through t h e
outer o r inner skins.
54-20-01
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RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(h) Disbond - A disbond is the separation of the

surface from the core or the area of the sandwich
panel that is filled.
(j) Delamination - A delamination is the separation of

one or more laminations.
D. Identify and Measure the Damage
(1) Do a tap test, refer to 54-01-06.
(2) Make a circular mark around the maximum area of damage.
(3) Identify the type of damage.
(4) Identify the zone.
4. Allowable Damage Limits (Pre SB 71-E107)

. . ~ ~ ~ ~ ~ ~ ~ . ~ ~ ~ ~ ~ ~ - - ~ ~ ~ ~ - - ~ ~ - - ~ - ~ ~ ~
ZONE DAMAGE REQUIREMENTS ALLOWABLE INSPECTION
LIMITS INTERVALS
..................................................................................................................
1,2,3 Abrasion No cracks in Unlimited Aircraft

,4,5, Gouge metallic mesh length and 'C1 check
617 Nick width
and 8 Scratch No cracks in carbon
fibre
1,2,3 Abrasion No cracks in carbon Up to 50,Omm Aircraft

14 Gouge fibre (2.0in) long 'C1 check
Nick in metallic
Scratch mesh
No limit to
number of
occurrences
5,6,7 Abrasion No cracks in carbon Up to 50,Omm Aircraft

18 Gouge fibre (2.0in) long 'C1 check
Nick in metallic
Scratch The minimum mesh
distance between
damaged areas is 5
times the diameter
of the largest
damage
54-20-01
Page 105
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
...................................~~~~~~~~--~-----------------------~--~~~~~-~~-
. . . . . . . . . . . . . . . . . . . . . . . . . ~ ~ - ~ ~
LIMITS
~ ~ - - ~ ~ ~ - ~
INTERVALS
~ ~ ~ ~ ~ - - ~ ~ ~ - - ~ - ~ - ~ - - - - ~
1,2,3 Dent T h e minimum M a x O15mm Aircraft

14 distance b e t w e e n (0.02in) \ C 1 check
d a m a g e d areas i s 5 depth
t i m e s the d i a m e t e r
of t h e largest M a x 30,Omm
damage (1.18in)
diameter
Dent T h e minimum Max 1,5mm Aircraft

distance b e t w e e n (0.06in) \ C 1 check
damaged areas i s 5 depth
damage (1.18in)
diameter
Dent T h e minimum Max 4,2mm Aircraft

distance b e t w e e n (0.17in) \ C 1 check
t i m e s t h e diameter
damage (3.30in)
diameter
Dent T h e minimum Max l 1 9 m Aircraft

distance b e t w e e n (0.08in) 'C1 check
of t h e largest M a x 3 9 , O mm
damage (1.53 in)
diameter
Dent T h e minimum M a x i m u m of Aircraft

distance b e t w e e n 1,65mm \ C r check
d a m a g e d areas i s 5 (0.065in)
t i m e s the d i a m e t e r depth
of t h e largest
damage M a x i m u m of
33, Omm
(1.30in)
diame ter
54-20-01
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Printed in Great Britain O c t . 1/06
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
................................................................................................................
~ ~ ~ ~ ~ ~ ~ ~ ~ ~ . . .
L I.M I .T S . . . .
INTERVALS
. ~ . ~ ~ ~ ~ ~ ~ -
1 Delamin- T h e minimum Up t o 13,5mm Aircraft

ation distance b e t w e e n (0.53in) \ C 1 check
d a m a g e d areas i s 5 (53% f r o m
t i m e s the d i a m e t e r exposed
of t h e l a r g e s t edge)
damage
No l i m i t t o
length along
flange
(around
door)
M a x 30,Omm
(1.18in)
diameter
Delamin- T h e minimum U p t o 19,Omm Aircraft

ation distance b e t w e e n (0.75in) 'C1 c h e c k
of t h e largest edge)
damage
No l i m i t t o
l e n g t h along
flange
(along door)
M a x 30,Omm
(1.18in)
diameter
3 Delamin- T h e minimum Up t o 10,4mm Aircraft

ation distance b e t w e e n (0.41in) \C1 c h e c k
of t h e largest edge)
damage
No l i m i t t o
l e n g t h along
flange
(around
door)
Max 3 0 , O m
( 1 . 1 8 i n ) dia
54-20-01
Page 107
Printed i n Great B r i t a i n 0ct. 1 / 0 6
RB211 TRENT
STRUCTURAL REPAIR
m MANUAL
..................................................................................................................
L I M I T S INTERVALS
.................................................................................................................
4 Delamin- T h e minimum Up to 1 4 , 7 m Aircraft

ation distance (0.58in) (77% ' C f check
b e t w e e n damaged f r o m exposed
areas i s 5 edge)
t i m e s the
d i a m e t e r of t h e No l i m i t to
l a r g e s t damage l e n g t h along
flange ( a r o u n d
feature)
M a x i m u m of
3 0 , O m (1.18in)
diameter
Delamin- T h e minimum M a x i m u m of Aircraft

ation distance 30,Omm ( 1 . 1 8 i n ) \ C 1 check
Disbond between damaged diameter
areas i s 5
t i m e s the
d i a m e t e r of t h e
l a r g e s t damage

ation distance 84,Omm ( 3 . 3 0 i n ) 'C1 check
Disbond b e t w e e n damaged diameter
areas i s 5
t i m e s the
diameter of t h e

ation distance 39,Omm ( 1 . 5 3 i n ) \ C 1 check
Disbond between damaged diameter
areas i s 5
t i m e s the
largest d a m a g e

ation distance 33,Omm ( 1 . 3 0 i n ) 'C1 check
Disbond b e t w e e n damaged d i a m e t e r
areas i s 5
t i m e s the
largest d a m a g e
54-20-01
Page 1 0 8
Printed in Great Britain O c t . 1/06
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
..................................................................................................................
. ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~
LIMITS
- ~ ~ ~ ~ ~
INTERVALS
~ ~ ~ ~ - ~ - ~ ~ ~ ~ ~
1,2,3 Crack The minimum Maximum Aircraft

,4,5 Hole distance length/diameter \ C f check
between damaged 20,Omm (0.7gin)
areas is 5
times the
length/diameter
of the largest
damage
6 Crack The minimum Maximum Aircraft

Hole distance length/diameter \ C f check
between damaged 50,Omm (2.Oin)
areas is 5
times the
length/diameter
of the largest
damage

Hole distance length/diameter \ C f check
between damaged 39,Omm (1.53in)
areas is 5
times the
length/diameter
of the largest
damage

Hole di S tance length/diameter \ C f check
between damaged 33,Omm (1.30in)
areas is 5
times the
length/diameter
of the largest
damage
54-20-01
Page 109
RB211 TRENT
STRUCTURAL REPAlR
MANUAL
R 5. Re~airableDamaoe Limits (Pre SB 71-E1071

.................................................................................................
ZONE DAMAGE REQUIREMENTS REPAIRABLE REPAIR
LIMITS PROCEDURE
1,2, Abrasion Repair is only No limit to FRSWO 10

3,4, Gouge for damage to repair 54-20-01
5,6, Nick inner steel and dimensions Repair
7 Scratch outer aluminium No. l0
and mesh No limit to the
8 number of
Minimum repairs
distance
between
adjacen t damage
127,Onun (5.Oin)
No limit to
distance
between damage
and adjacent
component parts
5 Dent Applicable to Up to 6,Onun FRSWO 0l

(Pandown damage in (0.25in) in 54-20-01
areas) 6,Omm (0.25in) depth Repair
honeycomb No.1
(Pandown areas) Up to 51,Omm
(2.Oin)
Minimum diameter -
distance classified Minor
between damage
and adjacent Up to 76,Omm
component parts (3.Oin)
or "keep outN diameter -
zones - 76,Onun classified Major
(3.Oin)
Minimum
distance
between
adjacent
repaired damage
170,Omm
(6.69in)
54-20-01
Page 110
RB211 TRENT
STRUCTURAL REPAlR
MANUAL
----------------------.-----------------------------------------------
LIMITS PROCEDURE
--------------------------------------------------------------------
Minimum
distance
between
adjacent
unrepaired
damage is 5
times the
diameter of the
largest damage
5 Dent Applicable to Up to 15,Omm FRSWO 01

(Honeycomb) damage in (0.60in) in 54-20-01
30,Omm (1.20in) depth Repair
honeycomb No. l
(Greater than
Minimum this depth,
distance treat as a hole)
between damage
and adjacent Up to 51,Omm
component parts (2.Oin)
or "keep out" diameter -
zones - 76,Omm classified Minor
(3.Oin)
Up to 76,Omm
Minimum (3.Oin)
distance diameter -
between classified Major
adjacent
repaired damage
170,O m m
(6.69in)
Minimum
distance
between
adjacent
unrepaired
damage is 5
times the
diameter of the
largest damage
EFFECTIVITY: TRENT
54-20-01
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R P r i n t e d i n Great B r i t a i n Apr. 1/01
B RB211 TRENT
MANUAL
STRUCTURAL REPAIR
----------.-----------------------------------------------------------------
LIMITS PROCEDURE
6 Dent Applicable t o Up t o 15,Omm mswo01

(Honeycomb) damage i n (0.60in) i n 54-20-01
30, Omm depth Repair No.1
(1.20in)
honeycomb (Greater than
t h i s depth,
Minimum t r e a t as a
distance hole)
between damage
and a d j a c e n t Up t o 128,Omm
component (5.02in) i n
p a r t s o r "keep diameter
out1' zones -
7 6,Omrn ( 3 . Oin)
Minimum
distance
between
adjacent
repaired
damage 170,Omm
(6.69in)
Minimum
distance
between
adj acen t
unrepaired
damage i s 5
t i m e s the
diameter of
the largest
damage
54-20-01
Page 1 1 2
P r i n t e d i n Great B r i t a i n Apr. 1/01
RB211 TRENT
STRUCTURAL REPAIR
................................................................................................................
ZONE DAMAGE REQUIREMENTS RE PAIRABLE REPAIR
LIMITS PROCEDURE
7 Dent (Honey Applicable t o Up t o 15,Omm FRSWO 0 1

comb) damage i n (0.60in) i n 54-20-01
30, Omm depth Repair No.1
(1.20in)
t h i s depth,
Minimum treat as a
d i St a n c e hole)
between damage
and a d j a c e n t Up t o 121,Omm
component (4.77in) i n
p a r t s o r "keep diameter
out" zones -
76,Omm ( 3 . 0 i n )
Minimum
distance
between
adjacent
repaired
damage 170,Omm
(6.69in)
Minimum
distance
between
adjacent
unrepaired
damage i s 5
t i m e s the
diameter of
the largest
damage
EFFECTIVITY : TRENT
54-20-01
Page 113
R Printed i n Great B r i t a i n Apr. 1/01
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
..................................................................................................................
LIMITS PROCEDURE
8 Dent Applicable to Up to 15,Omm FRSWOO1

30 ,Omm depth Repair
(1.20in) No. l
this depth,
Minimum treat as a hole)
distance
between damage Up to 78,Omm
and adjacent (3.07in) in
component diameter -
parts or "keep classified Minor
out" zones -
76,Omm (3.0in) Up to 102,Om
(4.01in) in
Minimum diameter -
distance classified Major
between
adjacent
repaired
damage 170,Omm
(6.69in)
Minimum
distance
between
adjacent
unrepaired
damage is 5
times the
diameter of
the largest
damage
EFFECTIVITY : TRENT
54-20-01
Page 114
R Printed in Great Britain Apr. 1/01
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
-------.----------------------------------------------.--.-------------
LIMITS PROCEDURE
1,2, Delamin- No limit to Up to 30,Omm FRSWOO2

3,4 ation the distance (1.18in) in 54-20-01
(Monolithic between damage diameter REPAIR No. 2
flange) and adjacent
component No limit to the
parts or 'keep number of repairs
outf zones
Minimum
distance
between
adjacent
damage is 5
times the
maximum damage
diameter
Delamin- No limit to Up to 13,5mm FRSWO 02

ation the distance (0.53in) running 54-20-01
(Monolithic between damage from exposed REPAIR No.2
flange) and adjacent flange edge
component
parts or 'keep No limit to the
out' zones length of damage
along the flange
Minimum
distance No limit to the
between number of repairs
adjacent
damage is 5
times the
maximum damage
diameter or
50,Omm
(2.Oin) ,
whichever is
larger
EFFECTIVITY : TRENT
54-20-01
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R Printed i n Great B r i t a i n Apr. 1/01
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
____.______________---------------------------------------------------
ZONE DAMAGE REQUIREMENTS RE PAIRABLE RE PAIR

LIMITS PROCEDURE
2 Delamin- No limit to Up to 19,omm FRSWO02

flange and adjacent flange edge
component
parts or 'keep No limit to the
outt zones length of damage
along the flange
Minimum
adjacent
damage is 5
times the
maximum damage
diameter or
50 ,Omm
(2.Oin) ,
whichever is
larger
54-20-01
Page 116
R8211 TRENT
STRUCTURAL REPAIR
MANUAL

LIMITS PROCEDURE
3 Delamin- No limit to Up to 12,7mm FRSWO 02

component
parts or \keep No limit to the
along the flange
Minimum
adjacent
damage is 5
times the
maximum damage
diameter or
50 ,Omm
(2.0in)'
whichever is
larger
4 Delamin No limit to Up to 14,7mm FRSWO 02

component
parts or \keep No limit to the
along the flange
Minimum
adjacent
damage is 5
times the
maximum damage
diameter or
50 ,Omm
(2.Oin) ,
whichever is
larger
54-20-01
Page 117
Printed in Great Britain Apr. 1/01
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
.--------------------------------------------------------------------------

LIMITS PROCEDURE
5 Delamin- Applicable to Up to 51,Omm FRSWO 01

ation damage in (2.0in) in 54-20-01
Disbond 6,Omm (0.25in) diameter - REPAIR No. l
Crack honeycomb classified Minor
( Pandown ( Pandown
areas) areas) Up to 76,Omm
(3.0in) in
Minimum diameter -
distance classified Major
between damage
and adjacent
component
parts or 'keep
out' zones -
76,Omm (3.0in)
Minimum
distance
between
adjacent
repaired
damage 170,Omm
(6.69in)
Minimum
distance
between
adjacent
unrepaired
damage is 5
times the
diameter of
the largest
damage
EFFECTIVITY: TRENT
54-20-01
Page 118
Printed i n Great B r i t a i n Apr. 1/01
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
------------.---------------------------------------------------------------------------
LIMITS PROCEDURE
5 Delamin- Applicable to Up to 51,Omm FRSWOO 1

Disbond 30 ,Omm diameter - REPAIR No. l
Crack (1.20in) classified Minor
(Honeycomb) honeycomb
Up to 76,Omm
Minimum (3.0in) in
distance diameter -
between damage classified Major
and adjacent
component
parts or 'keep
out' zones -
76,Omm (3.0in)
Minimum
distance
between
adjacent
repaired
damage 170,Omm
(6.69in)
Minimum
distance
between
adjacent
unrepaired
damage is 5
times the
diameter of
the largest
damage
54-20-01
Page 119
RB211 TRENT
STRUCTURAL REPAIR
MANUAL

LIMITS PROCEDURE
6 Delamin- Applicable t o U p t o 128,Omm FRSWOo I

ation damage i n (5.02in) i n 54-20-01
Disbond 30 ,Omm diameter REPAIR No. l
Crack (1.20in)
(Honeycomb) honeycomb
Minimum
distance
between damage
and a d j a c e n t
component
p a r t s o r 'keep
o u t ' zones -
76,Omm ( 3 . 0 i n )
Minimum
distance
between
adjacent
repaired
damage 170,Omm
(6.69in)
Minimum
distance
between
adjacent
unrepaired
damage i s 5
t i m e s the
diameter of
the largest
damage
54-20-01
Page 1 2 0
P r i n t e d i n Great B r i t a i n Apr. 1 / 0 1
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - + A - - - - * * - - - - - - - - . + - + - + - d - - - - - - - - - - - - - - - .

LIMITS PROCEDURE
7 Delamin- Applicable t o Up t o 121,Omm FRSWO 0l

ation damage i n (4.77in) i n 54-20-01
Disbond 30,Omm ( 1 . 2 0 i n ) diameter REPAIR No. l
Crack honeycomb
(Honeycomb)
Minimum
distance
between damage
and a d j a c e n t
component p a r t s
or 'keep o u t '
zones 76,Omm -
( 3 . Oin)
Minimum
distance
between
adjacent
r e p a i r e d damage
170, Omm
(6.69in)
Minimum
distance
between
adjacent
unrepaired
damage i s 5
t i m e s the
diameter of t h e
EFFECTIVITY : TRENT
54-20-01
Page 121
R Printed i n Great B r i t a i n ~ p r1/01
.
RB211 TRENT
STRUCTURAL REPAlR
MANUAL
-.-------------------------.---------------------***---*------------+----*---------------------------------------------.---

LIMITS PROCEDURE
8 Delamin Applicable to Up to 78,Omm FRSWO 01

Disbond 30,Omm (1.20in) diameter - REPAIR No.1
Crack honeycomb classified Minor
(Honeycomb)
Minimum Up to 102,Omm
distance (4.01in) in
between damage diameter -
and adjacent classified Major
component parts
or 'keep out'
zones - 76,Omm
(3.Oin)
Minimum
distance
between
ad jacent
repaired damage
170,Omm
(6.69in)
Minimum
di Stance
between
adjacent
unrepaired
damage is 5
times the
diameter of the
largest damage
54-20-01
Page 122
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
..---------------------------------------------------------------------------------------------------
ZONE DAMAGE REQUIREMENTS REPAIRABLE RE PAIR
LIMITS PROCEDURE
7 Disbond Applicable t o Total a r e a of FRSWO 0 9

(Sling damage around f i l l e d honeycomb 54-20-01
Point) S l i n g Points around REPAIR No. 9
between Outer Sling Point
s k i n and f i l l e d
core area
Minimum
distance
between
adj acen t
76,Omm ( 3 . 0 i n )
Minimum
distance
between
adj acen t
unrepaired
damage i s 5
times t h e
diameter of t h e
54-20-01
Page 1 2 3
Printed in Great Britain Apr. 1 / 0 1
------------------------.--------------------------------.---------------

LIMITS PROCEDURE
5 Hole Applicable to Up to 51,Omm FRSWOO4

(Pandown damage in 6,Omm (2.Oin) in 54-20-01
areas) (0.25in) diameter - REPAIR No. 4
honeycomb classified Minor
(Pandown areas)
Up to 76,Omm
Minimum (3.0in) in
distance diameter -
between damage classified Major
and ad,acent
component parts
or 'keep outr
zones - 76,Omm
(3.Oin)
Minimum
distance
between
adjacent
repaired damage
170,Omm
(6.69in)
Minimum
distance
between
adjacent
unrepaired
damage is 5
times the
diameter of the
largest damage
EFFECTIVITY : TRENT
54-20-01
Page 124
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
. . - - - - - - . - - - - - - - - - - - - - - . * - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

LIMITS PROCEDURE
5 Hole Applicable t o U p t o 51,Omm FRSWO 03

(Honeycomb) damage i n 30.0mm ( 2 . Oin) i n 54-20-01
(1.20in) diameter - REPAIR No.3
honeycomb c l a s s i f i e d Minor
Minimum d i s t a n c e Up t o 76,Omm
between damage (3.0in) i n
and a d j a c e n t diameter -
component p a r t s c l a s s i f i e d Major
o r 'keep o u t f
zones 76.0mm -
(3. Oin)
Minimum d i s t a n c e
between a dj a c e n t
170.0mm ( 6 . 6 9 i n )
Minimum d i s t a n c e
between a d j a c e n t
unrepaired
damage i s 5
t i m e s the
54-20-01
Page 1 2 5
P r i n t e d i n Great B r i t a i n Apr. 1 / 0 1
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - * - - - - * - - + - - - - - - - - - - - - - - - - -

LIMITS PROCEDURE
6 Hole Applicable to Up to 1 2 8 . 0 ~ ~ ~FRSWO 03

30,Omm (1.20in) diameter REPAIR No. 3
honeycomb
Minimum
distance
between damage
and adjacent
component parts
or 'keep outf
zones - 76,Omm
(3.Oin)
Minimum
distance
between
adjacent
repaired damage
170,Omm
(6.69in)
Minimum
distance
between
adjacent
unrepaired
damage is 5
times the
diameter of the
largest damage
54-20-01
Page 126
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
-----------------------..------------------------------------------
LIMITS PROCEDURE
7 Hole Applicable t o Up t o 121,Omm FRSWO 0 3

(Honeycomb) damage i n (4.77in) i n 54-20-01
30,Omm ( 1 . 2 0 i n ) diameter REPAIR N o . 3
honeycomb
Minimum
distance
between damage
and a d j a c e n t
component p a r t s
o r 'keep o u t '
zones - 76,Omm
( 3 . Oin)
Minimum
distance
between
adjacent
170, Omm
(6.69in)
Minimum
distance
between
adjacent
unrepaired
damage i s 5
t i m e s the
diameter of t h e
EFFECTIVITY: TRENT
54-20-01
Page 127
R Printed i n Great B r i t a i n Apr. 1 / 0 1
Z J R I I I REPAIR
.----------------------------------------------------------------. -----------------------.
ZONE DAMAGE REQUIREMENTS REPAIRABLE LIMITS REPAIR
PROCEDURE
8 Hole Applicable to Up to 78,Omm FRSWO 03

(Honeycomb) damage in 30,Omm (3.07in) in 54-20-01
(1.20in) diameter - REPAIR No.3
honeycomb classified Minor
Minimum distance Up to 102,Omm

between damage (4.01in) in
and adjacent diameter -
component parts classified Major
or 'keep out'
zones - 76,Omm
(3.Oin)
Minimum distance
between adjacent
repaired damage
170,Omm (6.69in)
Minimum distance
between adjacent
unrepaired
damage is 5
times the
diameter of the
largest damage
3 Rear RFI Partial Complete RFI Seal FRSWOll

Seal replacement is Strip 54-20-01
(All Damage acceptable REPAIR No.5
Types No limit to the
number of times
this repair can be
carried out
N/A All Damage Replace Hinges No limit to the FRSWO 33

types and Latches number of times 54-20-01
(Access this repair can be Repair No.17
Panel carried out.
Hinges and
Latches)
54-20-01
Page 128
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
AIR INTAKE COWL

See 54-10-01
F a n Cowl D o o r s - Allowable Damage

Figure 101 ( S h e e t 1 of 8 )
54-20-01
P a g e 129
Printed i n Great Britain A p r . 1/01
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
View on outer L*
surface of right door H
surface of left door
Fan C o w l D o o r s - A l l o w a b l e Damage
F i g u r e 101 ( S h e e t 2 of 8 )
EFFECTIVITY : TRENT
54-20-01
Page 13 0
Printed in G r e a t B r i t a i n Apr. 1/01
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
TRAILING EDGE 25,4 mm

(1.0 in)
LEADING EDGE
1422,4 mm
(56.0 in)
A
TOP EDGE
i
- -
A ZONE 2 A
82,6 mm
(3.25 in) I
355,6 mm
(14.0 in) 381,O mm
t
-. ZONE 5 (15.0 in) --.t t-
25,4 mm
(1.0 in)
I
N N
Pm l P
152,4 mm
(6.0 in)
--
U
- 152,4 mm
(6.0 in)
4
266,7 mm
(10.5 in)
F
m
2
-7
ZONE 8 ZONE 7 ZONE 6
BOTTOM EDGE /
View on the outer surface of
the right door to show the zones
Fan C o w l D o o r s -
A l l o w a b l e Damage
EFFECTIVITY : TRENT
Page 1 3 1
25,4 mm TRAILING EDGE
(1.0 in)
TOP EDGE 1422,4 mm
LEADING EDGE
\ I I
4I
A ZONE 2 A
(56.0 in)
I+
25,4 mm
(1.0 in) -Y L' (15.0 in)
38190mm
ZONE 5
152,4 mm
(6.0 in)
@ ZONE 6
'Keep-out' zone
Repairs are not permitted
in this area. If you find damage
tell the manufacturer.
50,8 mm
(2.0 in)
-I
914,4 mm
(36.0 in)
-
z
m 793,75 mm 736,6 mm
(31.25 in)
215,9 mm 76,2 mm
(8.5 in) --C <
(3.0 in)
I 1 I 7
\
' BOTTOM EDGE
View on the outer surface of

the left door to show the zones
Fan C o w l D o o r s -
F i g u r e 101 ( S h e e t 4 of 8 )
EFFECTIVITY: TRENT
54-20-01
P a g e 132
Printed in Great Britain A p r . 1/01
R8211 TRENT
STRUCTURAL REPAIR
MANUAL
12,7 mm
(0.5 in)
I
12,7mm
(0.5 in)
- -t 1 2 , 7 mm
(0.5 in)
12,7 mm
OIL FILLER (0.5 in)
,CCESS PANEL
l
t '
-- 12,7 mm
(0.5 in)
\ J
\
38,l mm HYD. FILTER1MCD
' ENGINEACOC
OUTLET
19,1 mm
(0.75 in)
l
,
ZONE 4
t \
/
CF BREATHER
\
I
' 'VENTILATION
OUTLET
BOTTOM EDGE /
View on bottom part of of right door
to show the zones
F a n Cowl D o o r s -
F i g u r e 1 0 1 ( S h e e t 5 of 8 )
54-20-01
Page 133
R8211 TRENT
STRUCTURAL REPAIR
MANUAL
BOTTOM EDGE /
View on bottom part of left door
to show the zones
Fan Cowl Doors - Allowable Damage
EFFECTIVITY : TRENT
54-20-01
Page 134
R Printed in Great Britain Apr. 1/01
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
4 1 ,FASTENER HOLES
DIA. 9,52 mm
(0.375 in)
57,2 mm
(2.25 in)
57,2 mm
(2.25 in)
'Keep-out' zone
Repairs are not permitted in
this area. If you find damage
I 57,2 mm
(2.25 in) 1
57,2 mm
(2.25 in)
Typical view on hinge positions.

H Typical view on main latch positions.
F a n C o w l D o o r s - A l l o w a b l e Damage
F i g u r e 1 0 1 ( S h e e t 7 of 8 )
EFFECTIVITY : TRENT
54-20-01
Page 135
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
qm (1.6 in)
A-
/
FASTENER HOLES
DIA. 6 7 5 mm
(0.266in)
LEADING EDGE
J Typical view on axial locator positions.
l;:y/
DIAMETER
1
'Keep-out' zone
Typical view on sling point positions.
Fan C o w l D o o r s - A l l o w a b l e D a m a g e
F i g u r e 101 ( S h e e t 8 of 8 )
EFFECTIVITY: TRENT
54-20-01
Page 136
RB211 TRENT
STRUCTURAL REPAIR
PRE SB 71-E107 FAN COWL DOORS - LIST OF APPROVED REPAIRS
-
1 REPAIR OF INDENTED OR PARTIALLY PUNCTURED SKIN

(FRS WO01) (30 mm HONEYCOMB SANDWICH PANEL)
2 REPAIR OF FLANGE EDGE DELAMINATION

(FRS W002) (MONOLITHIC FLANGES)
3 REPAIR OF THROUGH-DAMAGE
(FRS W003) (30 m HONEYCOMB SANDWICH PANEL)
4 REPAIR OF THROUGH-DAMAGE
(FRS W0041 (6 mm HONEYCOMB SANDWICH PANEL)
5 REPAIR RFI SEAL

(FRS WOll)
9 REPAIR OF DISBOND AT SLING POINT

(FRS W009)
10 REPAIR OF DAMAGED SURFACE MESH

(FRS W010)
11 REPLACE DECALS - R.H.

(FRS 5086)
12 REPLACE DECALS - L.H.

(FRS 5087)
13 REPAIR (REPLACEMENT) OF THE RFI SEALS -FCD BOTTOM EDGE

(FRS W013) SEALS - (RR SB71-C663)
15 REPAIR OF WEAR TO FCD LEADING EDGE

(FRS W015)
16 METAL PATCH REPAIR

(FRS W016)
R 17 REPAIR (REPLACEMENT) OF THE ACCESS PANEL HINGES AND

R (FRS W033) LATCHES
EFFECTIVITY: TRENT LIST OF REPAIRS

54-20-01
Page 201
R Printed i n Great Britain Jun. 10/08
RB211 TRENT
STRUCTURAL REPAIR
1. General
A. This repair is used to repair a dent or a not fully punctured

inner or outer skin.
B. This repair is only for the inner or the outer skin with a
related sandwich-panel structure with a thickness of 30,O mm
(1.2 in).
C. This scheme is written to repair isolated incidents of impact

damage or areas of multiple impact damage.
Areas of multiple impact damage can be grouped together and
considered as a single damage area.
(Ref. Figure 204).
This combined damage area must not be more than the maximum
allowable repairable damage size for the zone, as stated in the
Structural Repair Manual (Ref SRM 54-20-01 PB200).
For areas of multiple damage that extend across the zone
boundaries, the repairable damage size must not be more than
the maximum allowable repairable damage size for any affected
zone.
For damage adjacent to or within keep-out zones, not in the
limits of this repair, refer to GKN Aerospace Services.
D. This damage is repaired with these primary materials:
Filler material
Carbon fibre fabric
Glass fabric
Aluminium mesh (outer skin only)
Stainless steel mesh (inner skin only)
Adhesive.
REPAIR NO.l
54-20-01
Page 201
Printed i n Great Britain Jun 10/08
STRUCTURAL REPAIR
L] MANUAL
2. Reference Data
REFERENCE NOMENCLATURE
-------.------------------------------------------------------------------------------------------------------
54-02-04 SRM - Standard Painting Procedure
54-01-06 SRM - Tap Test
54-20-01 SRM - Fan Cowl Identification
70-20-01-100-802 AMM - Cleaning
3. Equipment; and Material
Spatula
Gloves, neoprene or polyvinyl chloride
Roller
Heat lamp/mst, 113 to 176 deg F (45 to 80 deg C)
Suction cleaner
Heat blanket of sufficient size and with a temperature range of
32 to 248 deg F (0 to 120 deg C)
Vacuum suction pump, 0 to 762.0 n a g (0-30 inHg)
Two applicable vacuum fittings
Two temperature probes, 32 to 248 deg F ( 0 to 120 deg C)
Router or Oscillating saw
.................................................................................................................
--------------------------------------------------------------------------
OMat 261 TEMPORARY MARKER, PENCIL/CRAYON
OMat 150 ACETONE
OMat 212 BRUSH
OMat 2/114 GLOVES, LINT FREE
OMat 2/101 CLOTH, LINT FREE
OMat 2/31 BAGGING FILM (CAPRAN SHEETING)
OMat 2/111 BREATHER CLOTH (N10-PR)
OMat 2/113 PARTING FILM - NON-POROUS (234-
TFNP
OMat 2/112 PARTING FILM - POROUS (234-TFP)
ABRASIVE PAPER (GRIT SIZE 240)
OMat 5/97 GARNET PAPER (Grit Size 80)
OMat 8/160 EPOXY ADHESIVE (EA9390)
OMat 2/110 SEALANT TAPE (SM-5127)
OMat 8/115 GLASS FABRIC-PLAIN WEAVE 'E'
( l Bleeder l fabric)
REPAIR NO.l
54-20-01
Page 202
Printed i n Great B r i t a i n Jun 10/08
" STRUCTURAL REPAIR
MANUAL
OMat 874 FILLER, TWO-PACK (EC3524B/A)

OMat 8/89A CARBON FIBRE FABRIC-PLAIN WEAVE
(CL221) - Hexcel
OMat 8/200 ALUMINIUM MESH, RP1 AND LIGHTNING
STRIKE PROTECTION (CL256) (Outer
skin only)
OMat 8/199 STAINLESS STEEL MESH (CL259)
(Inner skin only)
OMat 8/271 ALUMINIUM MESH, RP1 AND LIGHTNING
STRIKE PROTECTION (CL256 ) (Outer
skin only)
OMat 8/270 STAINLESS STEEL MESH - PLAIN
(Inner skin only)
OMat 8/201 GLASS FIBRE SCRIM 20 gsm (CL118) -
Clarke Schwebel
OMat 8/198 NYLON PEEL PLY B100-ASK
OMat 262 MARKER
C. Part Identification
PART NUMBER PART IDENTIFICATION

...............................................................................................................
217-1339-01 Fan Cowl Door Assembly RH
...............................................................................................................
...............................................................................................................
217-0432-01 Fan Cowl Door Assembly LH
...............................................................................................................
4. Clean the Repair Area.
A. Identify the area to be repaired. Make sure the damage is in

the limits of this repair scheme as given in 54-20-01, Page
Block 101.
B. Refer to AMM TASK 70-20-01-100-802. Fully clean the repair

area. Dry the area with a fresh piece of lint free cloth before
the fluid dries.
5. Prepare the Repair Area (Ref Figure 201).
A. Mark out the area of damage with a SOFT PENCIL (OMat 261). Mark
out the cut line by at least 0.25 in. (6,O mm) larger than the
damage. This can be any necessary shape but all sharp corners
must have a minimum radius of 0.25 in. (6,O mm).
B. Apply TEFLON TAPE (OMat 2/30) around the repair area.
REPAIR NO.l
54-20-01
Page 203
P r i n t e d i n Great B r i t a i n Jun 10/08
H
"" RB211 TRENT
MANUAL
STRUCTURAL REPAIR
WARNING: WEAR PROTECTIVE CLOTHING; GLOVES, MASK AND SAFETY

C. Remove the damaged skin to the cut line using a router or

oscillating saw set to cut the skin only. Do not cut the core.
Only remove the worst damage to the core, or loose or
protruding honeycomb core. If necessary, remove water ingress
before you do the repair.
D. Remove water from the damaged area (Ref A330 A/C SRM 51-77-11).
E. Abrade back the damaged area using GARNET PAPER (OMat 5/97) in
accordance with Figure 201.
F. Vacuum and clean to remove dust and debris.

Use a suction cleaner. Refer to AMM TASK 70-20-01-100-802.
Fully clean the repair area using ACETONE (OMat 150) on LINT
FREE CLOTH (OMat 2/101). Dry the area with a fresh piece of
lint free cloth before the fluid dries. Leave to stand for at
least 15 minutes before you continue.
6. Apply the Filler.
A. Mix sufficient TWO PACK FILLER (OMat 874) to completely fill

the exposed honeycomb cells.
Refer to the manufacturers instructions for control and
application of OMat 874. Observe all health and safety
precautions.
B. Fill the exposed core with TWO PACK FILLER (OMat 874)
over-flush with the adjacent skin.
C. Cure the filler for 16 hours minimum at 68 to 77 deg F (20 to

25 deg C). An alternative cure of 1 hour minimum at 122 to 158
deg F (50 to 70 deg C) using a heating lamp or heat mat is
permitted .
D. Abrade filler flush with surface using WATERPROOF SILICON

CARBIDE ABRASIVE PAPER (OMat 5/35) .
Page 204
E. Vacuum and clean to remove dust and debris.
Use a suction cleaner. Refer to AMM TASK 70-20-01-100-802.
Clean the repair area. Dry the area with a fresh piece of lint
free cloth before the fluid dries. Leave to stand for at least
15 minutes before you continue.
F. Water Break test
(1) Brush on or spray a thin layer of distilled water to the

repair area. A continuous layer seen for approximately a
half minute shows that the area has passed the water break
test. Areas that fail this test must be cleaned and tested
again. After testing, the areas must be fully dried before
application of repair plies. This can be done by using the
procedure to remove water from the damaged area (Ref A330
A/C SRM 51-77-11). or by using heating lamps that do not
exceed 158 deg F (80 deg C) to dry the repair area.
7. Lay-up the Repair Plies (Ref Figures 202 and 205) .

A. Apply the repair plies to the details of figure 202.
NOTE: Do not overlap the repair plies of adjacent damaged

areas. If overlap is going to occur, to complete the
repair, cut individual plies to the shape needed to
cover all the adjacent damage areas. Refer to Figure
205.
B. Cut three plies and one extra ply of CARBON FIBRE FABRIC (OMat
8/89A), one ply of GLASS FIBRE SCRIM (OMat 8/201) and one ply
of:
(1) ALUMINIUM MESH - PRE-PREG (OMat 8/200), (outer skin)

or
(2) STAINLESS STEEL MESH - PRE-PREG (OMat 8/199), (inner
skin)
A plain mesh can be used as an alternative to the pre-preg mesh

as follows:
(1) ALUMINIUM MESH -PLAIN (OMat 2/271), (outer skin)

or
(2) STAINLESS STEEL MESH - PLAIN (OMat 2/270), (inner skin)
NOTE: Refer to the ply orientation compass on pages 5

and 10 of SRM 54-20-01. Fan Cowl Identification.
See Figure 201 for dimensions.
REPAIR NO.l
54-20-01
Page 205
Printed in Great Britain Jun 10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
NOTE: Do not do Step 7.C. when using the plain mesh. This step
applies to the pre-preg material only.
C. Refer to AMM TASK 70-20-01-100-802. Wash out the film adhesive

from the mesh by repeated immersion in a bath of ACETONE (OMat
150). Make sure no trace of the film adhesive remains. Fully
dry the mesh with LINT FREE CLOTH (OMat 2/101).
WARNING : EA9390 EPOXY ADHESIVE IS CLASSIFIED AS A HAZARDOUS

MATERIAL WHICH CAN CAUSE INJURY OR ILLNESS IF NOT
ACCOmANCE WITH THE MANUFACTURERS SPECIFIC HEALTH AND
SAFETY RECOMMENDATIONS. PRIOR TO USE OF THIS PRODUCT
CAREFULLY READ THE APPLICABLE MATERIAL SAFETY DATA
SHEET AND FOLLOW ALL LISTED HEALTH AND SAFETY
PRECAUTIONS.
D. Mix the EPOXY ADHESIVE (OMat 8/160). The weight of the adhesive
needed will be approximately the same as the weight of the
carbon, glass scrim and mesh plies. Refer to manufacturers
instructions for control and application of OMat 8/160.
E. Place the first carbon repair ply on a sheet of NON-POROUS

PARTING FILM (OMat 2/113).
F. Apply the adhesive mixture to the carbon ply and spread out
using a spatula. Cover the repair ply with another sheet of
non-porous parting film. Mark the ply orientation on the
parting film.
G. Use a roller to remove trapped air. Do not use too much force,
which can remove adhesive from the repair area.
H. Remove the bottom sheet of the non-porous parting film.
I. Centre the repair ply over the cut-out ensuring correct ply
orientation. Refer to ply orientation compass on pages 5 and 10
of S W 54-20-01 - Fan Cowl Identification section.
J. Smooth out the wrinkles with a roller.
K. Remove the top sheet of non-porous parting film.
L. Do steps 7.D. thru 7.K. again for the other two carbon repair
plies and extra ply.
REPAIR NO.l
54-20-01
Page 206
!l STRUCTURAL REPAIR
MANUAL
M. Apply EPOXY ADHESIVE (OMat 8/160) to the repair area surface

for both the glass scrim and mesh plies to be added. Make sure
the adhesive covers an area larger thAn the size of mesh ply to
be added. The adhesive can be spread out using a spatula.
N. Lay-up the GLASS FIBRE SCRIM (OMat 8/201) on the repair area,
make sure the cloth overlaps the exposed mesh by 0.2 in. (5,O
mm). Stipple the resin into the cloth using a stiff brush.
0. Lay-up either of the following mesh types on top of the glass

scrim ply, making sure the mesh overlaps but does not extend
more than the exposed mesh:
(1) ALUMINIUM MESH - PRE-PREG (OMat 8/200) treated as

described in 7.D. (outer skin only).
or
(2) STAINLESS STEEL MESH - PRE-PREG (OMat 8/199) treated as
described in 7.D. (inner skin only) .
A plain mesh can be used as an alternative to the pre-preg mesh
as follows:
(1) ALUMINIUMMESH - PLAIN (OMat 8/271), (outer skin)

or
(2) STAINLESS STEEL MESH - PLAIN (OMat 8/270) , (inner skin)
See Figure 201 for the position and dimensions of these

plies.
8. Prepare the Vacuum Bag (Ref Figure 203).
A. Cover the repair plies with one layer of PEEL PLY (OMat 8/198)
that is at least 3.0 in. (76,O mm) larger than the repair
plies.
B. Cover this layer with one layer of POROUS PARTING FILM (OMat
2/112) approximately 1.0 in. (25,O mm) larger than the peel
P ~ Y
C. Cover the porous parting film with two layers of GLASS FABRIC
(OMat 8/115) and one layer of NON-POROUS PARTING FILM (OMat
2/112) each being 1.0 in. (25,O mm) smaller than the previous
layer.
D. Cover the non-porous parting film with two layers of BREATHER

CLOTH (OMat 2/111), both layers being larger than all the
previous layers of material.
REPAIR NO.l
54-20-01
Page 207
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
E. Position the heater mat over the repair area. Make sure
temperature probes are positioned to monitor repair
temperature.
F. Cover this with two plies of BREATHER CLOTH (OMat 2/111).
G. Cover the whole of the repair area with BAGGING FILM (OMat
2/31) plus two vacuum fittings.
H. Seal the edges of the bag to the panel using SEALANT TAPE (OMat
2/110).
I. Cure for 220 to 235 minutes at 203 to 239 deg F (95 to 115 deg
C). Heat up at a maximum rate of 9 deg F (5 deg C) per minute.
Vacuum must not fall below 22 in. (559,O mm) of mercury during
cure cycle. Cool to below 140 deg F (60 deg C) before releasing
the ,vacuum.
J. When the cure process is complete, remove the bagging materials

and the Teflon tape from the repair area.
9. Finish the Repaired Surface.

A. Smooth the surface of the repair all around to a feather edge

and to a smooth contour suitable to paint using WATERPROOF
SILICON CARBIDE ABRASIVE PAPER (OMat 5/35). Do not abrade mesh
or carbon.
B. Remove all unwanted material with a suction cleaner. Make sure

no particles of the unwanted material remain.
C. Refer to AMM TASK 70-20-01-100-802. Fully clean the repair

area. Dry the area with a fresh piece of lint free cloth before
the fluid dries.
D. Apply surface protection to the repair area. Refer to the

standard painting procedure 54-02-04.
REPAIR NO.l
54-20-01
Page 208
10. Inspection.
A. Refer to SRM TASK 54-01-06. Do a visual and tap test inspection

to make sure there are no disbonds or delaminations in the
repair area.
11. Identify the repair.
A. Mark FRSWOOl adjacent to the part number of the fan cowl door,
use MARKER PEN (OMat 262) of a contrasting colour.
REPAIR NO.l
54-20-01
Page 209
P RB211 TRENT
STRUCTURAL REPAIR
MANUAL
MESH OVERLAP DISC SANDER
CORE AND FILLER

FLUSH WITH
HONEYCOMB
19.1mm (0.75in) TYPICAL

\ SEPTUM
TOLERANCE
+I-2.5mm (0.lOin)
NB. Number of plies removed diagrammatic only.

Actual number to be determined during repair.
Typical sectional view of

Inner door surface shown
with stepsand repair into
carbon plies of honeycomb area.
Outer door surface similar.
Damaged A r e a for R e p a i r
F i g . 201
REPAIR N O . l
54-20-01
P a g e 210
NEW MESH
NB. Number of plies removed diagrammatic only.

Actual number to be equal to number removed
plus one extra.
Typical sectional view of

Inner door surface shown
with repair installation.
Outer door surface similar.
Damaged Area - Repair

Fig. 202
REPAIR NO.l
54-20-01
Page 211
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
VACUUM PUMP
VACUUM
CONNECTION CONNECTION
TAPE
THERMOCOUPLES
-
76,2 mm
(3.0 in)
LlNE
REPAIR
PLIES
Shows typical vacuum

bag assembly
Repair Area Cure -

F i g . 203
REPAIR N O . l
54-20-01
Page 212
Printed i n Great B r i t a i n Jun 1 0 / 0 8
H RB211 TRENT
MANUAL
STRUCTURAL REPAIR
MULTIPLE DAMAGE SITES

Grouped together and repaired
as a single damage site
c------- Z \
\
\
P Overall damage size to be not more than the

maximum repairable damage size for the zone
Repair of Multiple Damaged Sites

Fig. 204
REPAIR NO.l
54-20-01
Page 213
P RB211 TRENT
MANUAL
STRUCTURAL REPAIR
One layer of mesh

covering complete
damaged area
lndividual damage sites

have individual carbon
repair plies
mesh profile
(filled individually)
Insufficient distance between damage

sites to fit individual repair plies
Carbon and mesh cover

complete damaged area
Application of Repair Plies

Fig. 205
REPAIR NO.l
54-20-01
Page 214
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR NO. 2
PRE SB 71-E107 FAN COWL DOORS
REPAIR OF FLANGE EDGE DELAMINATION ,
IN MONOLITHIC FLANGES A I_
1. General ..
A. This procedure gives instructions for the repair of

delamination damage to monolithic flange areas.
B. Repair is limited to a monolithic flange that has single or

multiple delaminations. Damage must run to an exposed edge.
There is no limit to the length of a repair. The maximum
repairable flange width damage is 0.3 in. (7,6mm) of the flange
width, measured from the free edge.
C. Damage that is not in the limits of this repair must be

.:. .'..
.A
..................................................................
,. -.
..................................................................
71-12-11-300-XXX FRSW002, Trent Engine Manual "
3. Ecrui~ment and Materials
Disposable syringe
Spatula
Gloves, neoprene or PVC
Heat lamp, 113 to 239 deg F (45 to 115 deg C)
Suction cleaner
c',.
.. .. ' 1
.......................................................................
. -
OMat 261 SOFT PENCIL

OMat 1/119 ISOPROPANOL (PROPAN-2-OL)
OMat 2/113 PARTING FILM, NON-POROUS (324-PFNP)
EFFECTIVITY: TRENT
REPAIR NO. 2
Page 201
RB211 TRENT
STRUCTURAL REPAIR
MANUAL

OMat 5/35 WATERPROOF SILICONE CARBIDE ABRASIVE PAPER
(Grit Size 120)
........................................................................
PART IDENT DESIGNATION
Fan Cowl Door Assembly, RH

Fan Cowl Door Assembly, LH
4. P r e ~ a r ethe Area
A. Examine and identify the area to be repaired with the OMat 261
SOFT PENCIL. Make sure the damage is in the limits of this
repair scheme (Refer to 54-20-01, Page Block 101) .
WARNING: ISOPROPANOL IS CLASSIFIED AS A HAZARDOUS MATERIAL THAT
CAN CAUSE INJURY OR ILLNESS IF NOT CORRECTLY USED. THIS
PRODUCT MUST BE USED ONLY IN ACCORDANCE WITH THE
MANUFACTURER'S HEALTH AND SAFETY RECOMMENDATIONS. BEFORE
MATERIAL SAFETY DATA SHEET AND OBEY ALL THE SPECIFIED
HEALTH AND SAFETY PRECAUTIONS.
B. Thoroughly clean the repair area with OMat 1/119 ISOPROPANOL

and OMat 2/101 LINT FREE CLOTH. Dry the repair area with a
fresh piece of cloth before the isopropanol evaporates.
5. Revair Procedure
WARNING: EA 9390 EPOXY ADHESIVE IS CLASSIFIED AS A HAZARDOUS
MATERIAL THAT CAN CAUSE INJURY OR ILLNESS IF NOT
CORRECTLY USED.THIS PRODUCT MUST BE USED ONLY IN
ACCORDANCE WITH THE MANUFACTURER'S HEALTH AND SAFETY
RECOMMENDATIONS. BEFORE YOU USE THIS PRODUCT, CAREFULLY
READ THE APPLICABLE MATERIAL SAFETY DATA SHEET AND OBEY
ALL THE SPECIFIED HEALTH AND SAFETY PRECAUTIONS.
A. Obey the manufacturer's instructions and mix sufficient OMat
8/160 EPOXY ADHESIVE to fill the delaminated area.
B. With a disposable syringe, slowly put the mixed adhesive into

the delaminated area until unwanted adhesive begins to flow
from the exposed edges.
C. Clean unwanted adhesive from the area with OMat 1/119

ISOPROPANOL and OMat 2/101 LINT FREE CLOTH. Dry the area with a
fresh piece of cloth before the isopropanol evaporates.
D. Seal all exposed carbon edges with OMat 8/160 EPOXY ADHESIVE.
EFFECTIVITY: TRENT
REPAIR N0.2
Page 202
STRUCTURAL REPAIR
CAUTION: MAKE SURE THE CLAMP DOES NOT TWIST THE FLANGE.
E. Put OMat 2/113 NON-POROUS PARTING FILM over the repair area.
Use profiled or compliant blocks and clamps to apply even
pressure to the full length of the repair area.
F. Remove unwanted adhesive (Refer to para C).
G. Let the adhesive cure for a minimum of 60 minutes at 68 to 77

deg F (20 to 25 deg C),followed by 220 to 235 minutes at 203 to
239 deg F (95 to 115 deg C).
H. When the cure process is complete, remove the clamps and the
parting film.
6. Rewair the Surface Finish
WARNING: USE PROTECTIVE CLOTHES, GLOVES, MASK AND GOGGLES WHEN YOU
CUT OR ABRADE COMPOSITE MATERIALS. DUST AND LOOSE
PARTICLES ARE PRODUCED THAT ARE DANGEROUS TO HEALTH. DO
NOT BREATHE THE DUST.
A. Use OMat 5/35 WATERPROOF SILICONE CARBIDE ABRASIVE PAPER to

make the repair surface smooth. Do not abrade mesh or carbon.
B. Remove all the dust with a suction cleaner.
WARNING: ISOPROPANOL IS CLASSIFIED AS A HAZARDOUS MATERIAL THAT

CAN CAUSE INJURY OR ILLNESS IF NOT CORRECTLY USED.THIS
PRODUCT MUST BE USED ONLY IN ACCORDANCE WITH THE
MANUFACTURER'S HEALTH AND SAFETY RECCOMMENDATIONS. BEFORE
MATERIAL SAFETY SHEET AND OBEY ALL THE SPECIFIED HEALTH
C. Clean the repair area with OMat 1/119 ISOPROPANOL and OMat
2/101 LINT FREE CLOTH. Dry the surface with a fresh piece of
cloth before the fluid evaporates.
D. Apply the applicable paint finish (Re£ 54-02-04).
A. Do a visual inspection and a tap test (Ref 54-01-06) to make

sure the repair is satisfactory.
EFFECTIVITY: TRENT
REPAIR N0.2
Page 203
-p RB211 TRENT
MANUAL
STRUCTURAL REPAIR
DOOR EDGE
/'
OPERATE SYRINGE UNTIL ADHEISIVE
COMES OUT OF DOOR EDGEE
7,6mm
(03in)
Maximum Delamination
TYPICAL SECTION A-A
, BLOCK MADE TO SAME SHAPE

-
L ,.. AS CONTOUR OF REPAIR AREA
VIEW ON CORNER OF DOOR

cn DURING CURE
V1
N
S
-n-
:
Flange Edge Delamination - Repair

Figure 201
EFFECTIVITY: TRENT
REPAIR N0.2
Page 204
P r i n t e d in Great B r i t a i n July 1/99
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR N0.3
REPAIR OF THROUGH DAMAGE
IN 30,O mm ( 1.2 in) HONEYCOMB SANDWICH PANEL
1. General
A.. This repair gives the procedure for wet lay-up repair
of 30,O mm (1.2 in) thick sandwich panel inner or outer
skins.
B. Damage that is not in the limits of this repair must be

referred to GKN Aerospace.
.------------..-----------------------------------------------------------------------------------------------.
54-02-04 SRM - Repair Paint Finish
70-20-01-100-802 AMM - Cleaning
Equivalent equipment and materials can be used.
A.. Standard equipment
Spatula
Roller
Heat lamps 113 to 176 deg. F (45 to 80 deg C)
Suction cleaner
Hot box bonder with a suitably sized rubber heat
blanket that can operate within 32 to 248 deg F (0 to
120 deg C)
Vacuum suction pump 0 to 30 in. (0 to 762.0 nun) of
mercury
Four suitable vacuum fittings
Rout er
Oscillating saw
Drill bit 0.125 in. (3,O nun) (drill not required)
REPAIR N0.3
54-20-01
Page 201
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
OMat 2/30 TEFLON TAPE, PTFE FILM
OMat 212 BRUSH
OMat 21114 GLOVES, LINT FREE
OMat 21101 ABSORBENT CLOTH, LINT FREE
OMat 2J31 VACUUM BAG MATERIAL (Capran
Sheet ing)
OMat 2/l11 BREATHER CLOTH (N10-FR)
OMat 2 /l13 PARTING FILM - NON-POROUS (324-
TFNP)
OMat 21112 PARTING FILM -
POROUS (234-TFP)
OMat 5/35 WATERPROOF SILICON CARBIDE (GRIT
SIZE 240)
OMat 5/97 GARNET PAPER (GRIT SIZE 80)
OMat 8/160 EPOXY ADHESIVE (W93901
OMat 2/110 ADHESIVE TAPE, VACUUM-BAG SEAL
OMat 8/115 GLASS FABRIC -
PLAIN WEAVE 'E'
OMat 8/89A CARBON-FIBER FABRIC PLAIN WEAVE
(CL221)
OMat 8/200 ALUMINIUM MESH, RFI AND LIGHTNING
STRIKE PROTECTION (CL2561 (Outer
skin only)
OMat 81199 STAINLESS STEEL MESH (CL259)
(Inner skin only)
OMat 8/271 ALUMINIUM MESH - PLAIN, RFI AND
LIGHTNING STRIKE PROTECTION
(Outer skin only)
OMat 8/270 STAINLESS STEEL MESH PLAIN -
(Inner skin only)
OMat 8/201 GLASS FIBRE SCRIM 20gsm (CL118)
OMat 8/198 PEEL PLY B100-ASK
OMat 150 ACETONE

REPAIR N0.3
54-20-01
Page 202
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
A. Identify the area to be repaired. Make sure the damage

is in the limits of this repair scheme as given in 54-
20-01, Page Block 101
B. Refer to AMM TASK 70-20-01-100-802. Fully clean the

repair area. Dry the area with a fresh piece of lint
free cloth before the fluid dries.
5. Prepare the Repair Area (Ref. Figure 201)
A. Mark out the defined area of damage with an OMat 261

SOFT PENCIL. Mark out the cut line by at least 0.25 in.
(6,O mm) greater than the damage. This can be any
convenient shape but all corners must have a minimum
radius of 0.25 in. (6,O mm). Make sure the cut lines on
both the inner and outer surfaces match up.
B. Apply OMat 2/30 TEFLON TAPE around the repair area.
WARNING : WEAR PROTECTIVE CLOTHING; GLOVES, MASK AND

SAFETY GOGGLES. WHEN COMPOSITE MATERIALS ARE CUT
OR SANDED, DUST AND LOOSE PARTICLES ARE PRODUCED
WHICH ARE POTENTIAL HEALTH HAZARDS. DO NOT
BREATHER THE DUST.
C. Remove both the damaged inner and outer skins to the

cut line using a router or oscillating saw set to cut
the skin only. Do not cut the core. Only remove
seriously damaged, loose or protruding honeycomb core.
If necessary, remove water ingress before you do the
repair.
D. Remove standing water from the damaged area:
(1) Remove standing water using water and oil free

compressed air.
(2) Apply OMat 2/111 BREATHER CLOTH over exposed core

(both sides).
(3) Add a thermocouple to the centre of the breather

cloth (one side).
(4) Apply a layer of OMat 8/115 GLASS FABRIC over the

breather cloth and hold in place with OMat 2/30
TEFLON TAPE (one side) .
REPAIR N0.3
54-20-01
Page 203
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
(5) Place a heating blanket over the glass cloth (one
side).
( 6 ) Cover the area with OMat 2/31 BAGGING FILM and

seal using OMat 2/110 SEALANT TAPE (both sides).
(7) Evacuate the lay-up to a vacuum of 22 in. (559 mm)

of mercury minimum. (The vacuum point may be on
the inner or outer face to suit operational
requirements. )
(8) Heat the area for I hour minimum at 176 deg F (80
deg C). do not exceed 212 deg F (100 deg C). The
rate of temperature rise must not exceed 5 deg F)
(3 deg C) per minute.
(9) Remove lay-up materials and continue with the

repair.
E. Puncture the septum in each exposed cell using a 0.125

in (3.0 mm) drill bit.
F. Abrade back the mesh using OMat 5/97 GARNET PAPER to

expose the carbon fibre by 2.25 in. (57.0 mm). Abrade
back the resin using OMat 5/35 WATERPROOF SILICON
CARBIDE ABRASIVE PAPER to expose the mesh by a further
1.5 in. (38.0 mm). Refer to Figure 201 for details.
G. Vacuum to remove dust and debris. Thoroughly clean the

repair area. Refer to AMM TASK 70-20-01-100-802. Dry
the repair area with a fresh piece of lint free cloth
before the fluid evaporates naturally. Leave to stand
for at least 15 minutes before you continue.
6. Apply the Filler (Ref. Figure 202) .

A. Mix OMat 874 TWO-PACK FILLER to the manufacturers
instructions, mix sufficient to completely fill the
exposed honeycomb cells.
B. Fill the exposed core from one side only, to avoid air
entrapment, with OMat 874 TWO-PACK FILLER over-flush
with the surrounding skin. Support must be given to
the core by hand on the opposite side to that being
filled. Filling can stop when it is seen emerging from
this side. The filler must be over-flush with both
surfaces prior to cure.
REPAIR N0.3
54-20-01
Page 204
W RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
C. Cure the filler for 16 hours minimum at 68 to 77 deg F

(20 to 25 deg C). A n alternative cure of 1 hour minimum
at 122 to 158 deg F (50 to 70 deg C) using a heat lamp
or heat mat is permitted.
WARNING : WEAR PROTECTIVE CLOTHING, GLOVES I MASK AND

OR SANDED, DUST AND LOOSE PARTICLES ARE PRODUCED
BREATHE THE DUST.
D. Abrade filler flush with both surfaces using OMat 5/35

E. Vacuum to remove dust and debris. Clean the repair

area. Refer to AMM TASK 70-20-01-100-802. Dry the area
with a fresh piece of lint free cloth before the fluid
evaporates naturally. Leave to stand for at least 15
minutes before you continue.
F. Water break test:
(1) Brush on or spray a thin layer of distilled water

to the repair area. A continuous layer seen for
approximately a half minute shows that the area
has passed the water break test. Areas that fail
this test must be cleaned and tested again. After
testing, the areas must be fully dried before
application of repair plies. This can be done by
using the procedure in para. 5.D. or by using
heating lamps that do not exceed 158 deg F (80 deg
C) to dry the repair area.
7. Lay-up the Repair Plies (Ref. Figure 202).
A. Cut the six plies of OMat 8/89A CARBON FIBER FABRIC,

two plies of OMat 8/201 GLASS FIBER SCRIM and one ply
each of:
(1) OMat 8/200 ALUMINIUM MESH -

PRE-PREG, (outer skin)
and
( 2 ) OMat 8/199 STAINLESS STEEL MESH - PRE-PREG, (inner
skin).
A plain mesh can be used as an alternative to the pre-

preg mesh as follows:
REPAIR N0.3
54-20-01
Page 205
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
(1)OMat 8/271 ALUMINIUM MESH - PLAIN, (outer skin)

or
(2)OMat 8/270 STAINLESS STEEL MESH - PLAIN, (inner
skin).
See figure 202 for dimensions.
N0TE:Do not do Step 7.B. when using the plain mesh. This
step applies to the pre-preg material only.
WARNING : SOLVENT IS CLASSIFIED AS A HAZARDOUS MATERIAL,

WHICH CAN CAUSE INJURY OR ILLNESS IF NOT
PROPERLY USED. THIS PRODUCT SHOULD BE USED ONLY
IN ACCORDANCE WITH THE MANUFACTURERS SPECIFIC
HEALTH AND SAFETY RECOMMENDATIONS. PRIOR TO USE
OF THIS PRODUCT CAREFULLY READ THE APPLICABLE
MATERIAL SAFETY DATA SHEET AND FOLLOW ALL LISTED
B. Wash out the film adhesive from the mesh by repeated

inanersion in a bath of OMat 150 ACETONE. Make sure no
traces of the film adhesive remains. Thoroughly dry the
mesh with OMat 2/101 LINT FREE CLOTH.
BA9390 EPOXY ADHESIVE IS CLASSIFIED AS A

HAZARDOUS MATERIAL, WHICH CAN CAUSE INJURY OR
ILLNES IF NOT PROPERLY USED. THIS PRODUCT SHOULD
ONLY BE USED IN ACCORDANCE WITH THE
MANUFACTURERS SPECIFIC HEALTH AND SAFETY
RECOMMENDATIONS. PRIOR TO USE OF THIS PRODUCT
CAREFULLY READ THE APPLICABLE MATERIAL SAFETY
DATA SHEET AND FOLLOW ALL LISTED HEALTH AND
SAFETY PRECAUTIONS.
C. Mix OMat 8/160 EPOXY ADHESIVE in accordance with the

manufacturers' instructions. Make sure enough is mixed
to cover all carbon, glass scrim and mesh plies.
D. Place the first carbon repair ply on a sheet of OMat

2/113 NON POROUS PARTING FILM.
E. Apply the adhesive mixture to the carbon ply and spread

out using a spatula. Cover the repair ply with another
sheet of non-porous parting film. Mark the ply
orientation on the parting film.
F. Use a roller to remove trapped air. Do not use

excessive force, which may remove adhesive from the
repair area.
Page 206
B
m@
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
G. Remove the bottom sheet of the non-porous parting film.
H. Centre the repair ply over the cut-out ensuring correct

ply orientation. (Ref. Fig. 202).
I. Smooth out the wrinkles with a roller.
Y. Remove the top sheet of non-porous parting film.
K. Do steps 7.D. to 7 . 5 . again for the other carbon repair

plies. (Ref. Fig. 202). Two 'packs' of 3 are required.
L,. Mix and apply sufficient OMat 8/160 EPOXY ADHESIVE to

the repair area surface for both the glass scrim and
mesh plies to be added. Make sure the adhesive covers
an area slightly larger than the size of mesh ply to be
added. The adhesive can be spread out using a spatula.
M. Lay-up the OMat 8/201 GLASS FIBRE SCRIM on the repair

area making sure the cloth overlaps the exposed mesh by
0.2 in (5,O m ) . Stipple the resin into the cloth using
a stiff brush.
N. Lay-up both of the following mesh types on top of the

glass scrim ply, making sure the mesh overlaps but does
not extend beyond the extremity of the exposed mesh:
(1) OMat 8/200 ALUMINIUM MESH - PRE-PREG suitably

treated as described in 7.B. (outer skin only)
or
(2) OMat 8/199 STAINLESS STEEL MESH PRE-PREG -
suitably treated as described in 7.B. (inner skin
only) .
(1) OMat 8/271 ALUMINIUM MESH -

PLAIN, (outer skin)
or
(2) OMat 8/270 STAINLESS STEEL MESH -
PLAIN, (inner
skin).
See Figure 202 for the position and dimension of these

plies.
8. Prepare the Vacuum Bag (Ref. Figure 203).
REPAIR N0.3
54-20-01
Page 207
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
A. Cover both the inner and outer surface repair plies
with one layer of OMat 8/198 PEEL PLY that is at least
3.0 in. (76,O m) larger than the repair plies.
B. Cover these layers with one layer of OMat 2/112 POROUS

PARTING FILM approximately 1.0 in. (25,O mm) larger
than the peel ply.
C. Cover the porous parting film with two layers of OMat

8/115 GLASS FABRIC and one layer of OMat 2/112 NON-
POROUS PARTING FILM, each being 1.0 in. (25,O mm)
smaller than the previous layer.
D. Cover the non-porous parting film with two layers of

OMat 2/111 BREATHER CLOTH, both layers being larger
than all the previous layers of material.
E. Position two heater mats over each of the repair

surfaces. Make sure temperature probes are positioned
to monitor repair temperature.
F. Cover each mat with two plies of OMat 2/111 BREATHER

CLOTH.
G. Cover both of the repair surfaces with OMat 2/31

BAGGING FILM plus 2 vacuum fittings each.
H. Seal the edges of the bag to the panel using OMat 2/110
SEALANT TAPE.
I. Cure for 220 to 235 minutes at 203 to 239 deg F (95 to

115 deg C). Heat up at a maximurn rate of 9 deg F (5 deg
C) per minute. Vacuum must not fall below 22 in. (559,O
nun) of mercury during cure cycle. Cool to below 140 deg
F (60 deg C) before releasing the vacuum.
J. When the cure process is complete, remove the bagging

materials and the Teflon tape from the repair area.
WARNING : WEAR PROTECTIVE CLOTHING; GLOVES, MASK AND

OR SANDED. DUST AND LOOSE PARTICLES ARE PRODUCED
BREATHE THE DUST.
REPAIR N0.3
54-20-01
Page 208
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
A. Smooth both surfaces of the repair all around to a

feathered edge and to a smooth contour suitable to
paint using OMat 5/35 WATERPROOF SILICONE CARBIDE
ABRASIVE PAPER. Do not abrade mesh or carbon.
B. Remove all unwanted material with the suction cleaner.

Make sure no particles of the unwanted material
remain.
C. Refer to AMM TASK 70-20-01-100-802. Fully clean the

repair area. Dry the area with a fresh piece of lint
free cloth before the fluid dries.
D. Apply surface protection to the repair area in

accordance with the standard painting procedure 54-02-
04.
9. Inspection.
A. Do a visual and/or a NDT inspection to make sure the

repair has been done in accordance with these
procedures.
10. 1:dentify the repair.
A. Mark FRSW003 adjacent to the part number of the Fan

Cowl Door. Use a permanent marker pen of a contrasting
colour.
REPAIR N0.3
54-20-01
Page 209
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
ABRADE BACK ABRADE BACK

RESIN TO MESH TO EXPOSE
EXPOSE MESH CARBON SKIN
I (DO NOT DAMAGE)
CARBON
TYP 57,O mm
TYP 38,O mm
(1.5 in) MAXIMUM CUT
l
HONEYCOMB
CORE
IN SKlN AND CORE
/
SEPTUM
MATERIALS REMOVAL FROM THIS SURFACE
TO BE CARRIED OUT AS OPPOSITE SURFACE
LAYER 4 C
TOLERENCE +/- 2,5mm (0.1 in)
MATERIALS TO BE REMOVED
Prepare the Repair Area

Figure 201
54-20-01
Page 210
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
ORIENTATION OF ALL PLIES TO BE 0' (TOWARDS THE HINGE END)
MESH WETTED OUT WlTH

RESIN - MUST SIT FULLY
ON ABRADE AREA
TYP 19,O mm (0.75 in)

1 PLY OF GLASS
-
SCRlM CUT JUST
OVERSIZE OF LAST
TYP 5,O mm (0.2 in) 3 PLIES OF DRY

OVERLAP ONTO CARBON WETTED-
EXPOSED MESH OUT WITH RESIN
-
3 PLIES OF DRY
CARBON - WETTED
OUT WITH RESIN S N c o R u v L L E R FLusn
WlTH SKIN PROFILE
( PLY GLASS SCRlM
PLY MESH
PLIES THIS SlDE TO BE LAID UP

IN THE SAME WAY AS SHOWN
FOR THE OTHER SlDE
TOLERENCE ON PLIES +l-2,5 mm (0.1 in)
MATERIALS TO BE ADDED INC. REPAIR PLY LAY-UP
Repair Ply Lay-up

Figure 202
REPAIR N0.3
54-20-01
Page 211
M RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
2 PLIES OF
RUBBER BREATHER NON POROUS GLASS
HEATER MAT CLOTH PARTING FILM CLOTH
VACUUM
CONNECTOR
BAGGING FlLM
ELECTRICAL
CONNECTOR
THERMOCOUPLE
SEALANT
HONEYCOMB PANEL PEEL PLY REPAIR

TO BE REPAIRED LAY-UP
NOTE: THE BAGGING TECHNIQUE IS SHOWN FOR ONE REPAIRED SURFACE

ONLY. THE OTHER REPAIRED SURFACE MUST BE BAGGED UP AT THE
SAME TIME USING THE SAME BAGGING TECHNIQUE PRIOR TO CURE.
REPAIR EQUIPMENT INSTALLATION

Figure 203
REPAIR N0.3
54-20-01
Page 212
P r i n t e d in Great B r i t a i n Jun 10/08
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR NO. 4 (FRSW004)
REPAIR OF THROUGH DAMAOE IN 0.25 in. (6.0 mm)
HONEYCOMB SANDWICH PANEL
1. General
A. This repair gives the procedure for the wet lay-up repair of
0.25 in. (6,O mm) thick sandwich panel inner or outer skins.
B. Damage that is not in the limits of this repair must be


70-20-01-100-802 AMM - Cleaning
3. Equipment and Materials.
Spatula
Roller
Suction cleaner
Hot box bonder with a suitably sized rubber heat blanket,
that can operate within 32 to 2448 deg F (0 to 120 deg C)
Vacuum suction pump 0 to 762 mm (0 to 30 in.) of mercury
Four suitable vacuum fittings
Rout er
Oscillating saw.
REPAIR N0.4
54-20-01
Page 201
Mm@MANUAL
RB.211 TRENT
STRUCTURAL REPAIR
-.-----------------------------------------------------------------------------------------
...................................................................................................................
OMat 212 BRUSH
OMat 2/101 ABSORBANT CLOTH, LINT FREE
OMat 2/31 VACUUM BAG MATERIAL (Capran Sheeting)
OMat 2/1:11 BREATHER CLOTH (N10-FR)
OMat 2/1:13 PARTING FILM - NON-POROUS (324-TFNP)
OMat 2/1:12 PARTING FILM - POROUS (234-TFP)
OMat 5/35 WATERPROOF SILICON CARBIDE (GRIT SIZE 240)
OMat 2/1:10 ADHESIVE TAPE, VACUUM-BAG SEAL
OMat 8/1:15 GLASS FABRIC - PLAIN WEAVE 'E'
OMat 8/89A CARBON-FIBER FABRIC PLAIN WEAVE (CL221)
OMat 8/200 ALUMINIUM MESH, RFI AND LIGHTNING STRIKE
PROTECTION (CL2561 (Outer skin only)
QMat 8/199 STAINLESS STEEL MESH (CL2591 (Inner skin
only)
OMat 8/271 ALUMINIUM MESH - PLAIN , RFI AND LIGHTNING
STRIKE PROTECTION (Outer skin only)
QMat 8/270 STAINLESS STEEL MESH -PLAIN (Inner skin
only)
OMat 150 ACETONE
D. Part Identification
R 217-0432-01 Fan Cowl Door Assembly LH

R 217-0466-01 Fan Cowl Door Assembly LH
R
R 217-1339-01 Fan Cowl Door Assembly RH
R 217-1366-01 Fan Cowl Door Assembly RH
REPAIR N0.4
54-20-01
Page 202
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL

Block 101.
B. Thoroughly clean the repair area. Refer to AMM TASK 70-20-

01-100-802. Dry the area with a clean lint-free cloth before
the fluid evaporates naturally.
A. Mark out the defined area of damage with a SOFT PENCIL (OMat
261). Mark out the cut line by at least 0.25 in. (6,O mm)
greater than the damage. This can be any convenient shape,
but all corners must have a minimum radius of 0.25 in. (6,O
mm). Make sure the cut lines on both the inner and outer
surfaces match up.
WARNING: USE PROTECTIVE CLOTHES, GLOVES, MASK AND GOGGLES WHEN

YOU CUT OR ABRADE COMPOSITE MATERIALS. DUST AND LOOSE
C. Remove both the damaged inner and outer skins to the cut
line using a router or oscillating saw to cut the skin only.
Do not cut the core. Only remove seriously damaged, loose or
protruding honeycomb core. If necessary, remove water
ingress before you do the repair.
D. Remove water from the damaged area:
(1) Remove standing water using vacuum and oil-free

compressed air.
(2) Apply OMat 2/111 BREATHER CLOTH over exposed core (both
sides) .
(3) Add a thermocouple to the centre of the breather cloth
(one side).
(4) Apply a layer of OMat 8/115 GLASS FABRIC over the

breather cloth and hold in place with OMat 2/30 TEFLON
TAPE.
(5) Place a heating blanket over the glass cloth (one

side).
(6) Cover the area with OMat 2/31 BAGGING FILM and seal
using OMat 2/110 SEALANT TAPE (both sides).
REPAIR N0.4
54-20-01
Page 203
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
(7) Evacuate the lay-up to a vacuum of 22.0 in. (559,O mm)

of mercury minimum. (The vacuum point may be on the
inner or outer face to suit operational requirements).
(8) Heat the area for 1 hour minimum at 176 deg F (80 deg
C), do not exceed 212 deg F (100 deg C). The rate of
temperature rise must not exceed 5 deg F (3 deg C) per
minute.
(9) Remove lay-up materials and continue with the repair.
E. Abrade back the mesh using OMat 5/97 GARNET PAPER to expose
the carbon fibre by 3.75 in. (95,O mm). Abrade back the
resin using OMat 5/35 WATERPROOF SILICON CARBIDE ABRASIVE
PAPER to expose the mesh by a further 1.5 in. (38,O mm).
Refer to Figure 201 for details.
F. Vacuum to remove dust and debris. Refer to AMM TASK 70-20-

R
01.-100-802. Thoroughly clean the repair area. Dry the area
R
with a clean piece of lint free cloth before the fluid
R
R
evaporates naturally. Leave to stand for at least 15 minutes
R before you continue.
6. Apply the Filler (Ref. Figure 202)
A. Mix TWO-PACK FILLER (OMat 874) to the manufacturers

instructions, mix sufficient to completely fill the exposed
honeycomb cells.
A. Fill the exposed core from one side only, to avoid air
entrapment, with OMat 874 TWO-PACK FILLER over-flush with
the surrounding skin. Support must be given to the core by
hand on the opposite side to that being filled. Filling can
stop when it is seen emerging from this side. The filler
must be over-flush with both surfaces prior to cure.
C. Cure the filler for 16 hours minimum at 68 to 77 deg F (20

to 25 deg C). An alternative cure of 1 hour minimum at 122
to 158 deg F (50 to 70 deg C) using a heat lamp or heat mat
is permitted.
WARNING : WEAR PROTECTIVE CLOTHING; GLOVES, MASK AND SAFETY

GOGGLES. WHEN COMPOSITE MATERIALS ARE CUT OR SANDED,
DUST AND LOOSE PARTICLES ARE PRODUCED WHICH ARE
POTENTIAL HEALTH HAZARDS. DO NOT BREATHE THE DUST.
D. Abrade filler flush with both surfaces using OMat 5/35

REPAIR N0.4
54-20-01
Page 204
[ RB.211 TRENT
STRUCTURAL REPAIR
m @ MANUAL
E. Vacuum to remove dust and debris. Fully clean the repair

area. Refer to AMM TASK 70-20-01-100-802. Dry the area with
a fresh piece of lint free cloth before the fluid evaporates
naturally. Leave to stand for at least 15 minutes before you
continue.
F. Water break test:

repair area. A continuous layer seen for approximately a
half minute shows that the area has passed the water
break test. Areas that fail this test must be cleaned
and tested again. After testing, the areas must be fully
dried before application of repair plies. This can be
done by using the procedure in para.5.D. or by using
heating lamps that do not exceed 158 deg F (80 deg C) to
dry the repair area.
7. Lay-,upthe Repair Plies (Ref. Figure 202) .

A. Cut the ten plies of OMat 8/89A CARBON FIBER FABRIC, two
plies of OMat 8/201 GLASS FIBER SCRIM and one ply each of:
(1) OMat 8/200 ALUMINIUM MESH - PRE-PREG, (outer skin)

and
(2) OMat $/l99 STAINLESS STEEL MESH - PRE-PREG, (inner
skin) .
A plain mesh can be used as an alternative to the pre-preg
mesh as follows:
(1) OMat 8/271 ALUMINIUM MESH - PLAIN, (outer skin).

or
(2) OMat 81270 STAINLESS STEEL MESH - PLAIN, (inner skin).
See figure 202 for dimensions.
N0TE:Do not do Step 7.B. when using the plain mesh. This step
applies to the pre-preg material only.
WARNING : SOLVENT IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH

CAN CAUSE INJURY OR ILLNESS IF NOT PROPERLY USED. THIS
SHEET AND FOLLOW ALL LISTED HEALTH AM) SAFETY
PRECAUTIONS.
REPAIR N0.4
54-20-01
Page 205
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
B. Wash out the film adhesive from the mesh by repeated

immersion in a bath of OMat 150 ACETONE. Make sure no traces
of the film adhesive remains. Thoroughly dry the mesh with
OMat 2/101 LINT FREE CLOTH.
WARNING : EA9390 EPOXY ADHESIVE IS CLASSIFIED AS A HAZARDOUS

MATERIAL, WHICH CAN CAUSE INJURY OR ILLNES IF NOT
PROPERLY USED. THIS PRODUCT SHOULD ONLY BE USED IN
ACCORDANCE WITH THE MANUFACTURERS SPECIFIC HEALTH AND
SAFETY RECOMMENDATIONS. PRIOR TO USE OF THIS PRODUCT
SHEET AND FOLLOW ALL LISTED HEALTH AND SAFETY
PRECAUTIONS.
C. Mix OMat 8/160 EPOXY ADHESIVE in accordance with the

manufacturers' instructions. Make sure enough is mixed to
cover all carbon, glass scrim and mesh plies.
D. Place the first carbon repair ply on a sheet of OMat 2/113

NON POROUS PARTING FILM.
E. Apply the adhesive mixture to the carbon ply and spread out
using a spatula. Cover the repair ply with another sheet of
non-porous parting film. Mark the ply orientation on the
parting film.
F. Use a roller to remove trapped air. Do not use excessive

force, which may remove adhesive from the repair area.
G. Remove the bottom sheet of the non-porous parting film.
H. Centre the repair ply over the cut-out ensuring correct ply
orientation. (Ref. Fig. 202) .
I. Smooth out the wrinkles with a roller.
J. Remove the top sheet of non-porous parting film.
K. Do steps 7.D. to 7.5. again for the other carbon repair

plies. (Ref. Figure 202). Two \packsr of 5 are required.
L. Mix and apply sufficient OMat 8/160 EPOXY ADHESIVE to the

repair area surface for both the glass scrim and mesh plies
to be added. Make sure the adhesive covers an area slightly
larger than the size of mesh ply to be added. The adhesive
can be spread out using a spatula.
REPAIR N0.4
54-20-01
Page 206
RB.211 TRENT
STRUCTURAL REPAIR
me MANUAL
M. Lay-up the OMat 8/201 GLASS FIBRE SCRIM on the repair area
making sure the cloth overlaps the exposed mesh by 0.2 in
(5,O mm). Stipple the resin into the cloth using a stiff
brush.
N. Lay-up both of the following mesh types on top of the glass

scrim ply, making sure the mesh overlaps but does not extend
beyond the extremity of the exposed mesh:
(1) OMat 8/200 ALUMINIUM MESH - PRE-PREG suitably treated as

described in 7.B. (outer skin only).
or
(2) OMat 8/199 STAINLESS STEEL MESH -
PRE-PREG suitably
treated as described in 7.B. (inner skin only).
A plain mesh can be used as an alternative to the pre-preg

mesh as follows:
(1)OMat 8/271 ALUMINIUM MESH -

PLAIN, (outer skin)
or
(2)OMat 8/270 STAINLESS STEEL MESH - PLAIN, (inner skin).

plies.
A. Cover both the inner and outer surface repair plies with one
layer of OMat 8/198 PEEL PLY that is at least 3.0 in. (76,O
mm) larger than the repair plies.
B. Cover these layers with one layer of OMat 2/112 POROUS

PARTING FILM approximately 1.0 in. (25,O mm) larger than the
peel ply.
C. Cover the porous parting film with two layers of OMat 8/115
GLASS FABRIC and one layer of OMat 2/112 NON-POROUS PARTING
FILM, each being 1.0 in. (25,O mm) smaller than the previous
layer.
D. Cover the non-porous parting film with two layers of OMat

2/111 BREATHER CLOTH, both layers being larger than all the
previous layers of material.
E. Position two heater mats over each of the repair surfaces.

Make sure temperature probes are positioned to monitor
repair temperature.
F. Cover each mat with two plies of OMat 2/111 BREATHER CLOTH.
REPAIR N0.4
54-20-01
Page 207
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
G. Cover both of the repair surfaces with OMat 2/31 BAGGING

FILM plus 2 vacuum fittings each.
H. Seal the edges of the bag to the panel using OMat 2/110
SEALANT TAPE.
I. Cure for 220 to 235 minutes at 203 to 239 deg F (95 to 115
deg C). Heat up at a maximum rate of 9 deg F ( 5 deg C) per
minute. Vacuum must not fall below 22 in. (559,O mm) of
mercury during cure cycle.Coo1 to below 140 deg F (60 deg C)
before releasing the vacuum.

materials and the Teflon tape from the repair area.
WARNING : WEAR PROTECTIVE CLOTHING; GLOVES, MASK AND SAFETY

GOGGLES. WHEN COMPOSITE MATERIALS ARE CUT OR SANDED.
DUST AND LOOSE PARTICLES ARE PRODUCED WHI CH ARE
A. Smooth both surfaces of the repair all around to a feathered

edge and to a smooth contour suitable to paint using OMat
5/35 WATERPROOF SILICON CARBIDE ABRASIVE PAPER. Do not
abrade mesh or carbon.
B. Remove all unwanted material with a suction cleaner. Make

sure no particles of the unwanted material remain.
C. Thoroughly clean the repair area. Refer to AMM TASK 70-20-

01-100-802. Dry the area with a fresh piece of lint free
cloth before the fluid evaporates naturally.
D. Apply surface protection to the repair area in accordance

with the standard painting procedure SRM 54-02-04
10. Inspection.
A. Do a visual and/or a NDT inspection to make sure the repair

has been done in accordance with these procedures.
11. Identify the repair.
A. Mark FRSWOO4 adjacent to the part number of the Fan Cowl

Door. Use a permanent marker pen of a contrasting colour.
REPAIR N0.4
54-20-01
Page 208
1
m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
ABRADE BACK ABRADE BACK

RESIN TO MESH TO EXPOSE
EXPOSE MESH CARBON SKlN
l
(DO NOT DAMAGE)
CARBON
TYP 38,Omm
(1.5 in) MAXIMUM CUT
IN SKlN AND CORE
/
MATERIALS REMOVAL FROM THIS SURFACE
HONEYCOMB TO BE CARRIED OUT AS OPPOSITE SURFACE
CORE W
TOLERANCE +l-2.5 mm (0.1 in)
MATERIALS TO BE REMOVED
Prepare t h e Repair Area

F i g u r e 201
REPAIR N0.4
EFFECTIVITY: TRENT
P a g e 209
Feb. 1/98
RB.211 TRENT
MANUAL
ORIENTATION OF ALL PLIES TO BE 0" (TOWARDS THE HINGE END)
MESH WETTED OUT WlTH

RESIN - MUST SIT FULLY
ONABRADEDAREA
1 PLY OF GLASS
iI..
SCRlM - CUT JUST
TYP 19,Omm (0.75 in) OVERSIZE OF LAST
CARBON PLY
-cc.-----
------
-----
TYP 5,O mm (0.2 in)
OVERLAP ONTO 5 PLIES OF DRY
EXPOSED MESH CARBON - WElTED
OUT WlTH RESIN
\
5 PLIES OF DRY
CARBON - WETTED
CORE / FILLER - FLUSH
OUT WITH RESIN WITH SKIN PROFILE
1 PLY GLASS SCRlM

/- ,l PLY MESH
PLIES THIS SIDE TO BE LAID UP

IN THE SAME WAY AS SHOWN
FOR THE OTHER SlDE
TOLERANCE ON PLIES +l- 2,5 mm (0.1 in)
MATERIALS TO BE ADDED INC. REPAIR PLY LAY-UP
R e p a i r P l y Lay-up
Figure 202
REPAIR N0.4
EFFECTIVITY : TRENT
Page 210
~ e b 1/98
.
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
RUBBER OF NON POROUS GLASS

BREATHER
VACUUM \ \ I
CONNECTOR
ELECTRICAL
CONNECTOR
THERMOCOUPLE
SEALANT
TAPE
TEFLON OR HIGH
TEMP TAPE
POROUS
PARTING FILM I
HONEYCOMB PANEL PEEL PLY REPAIR
TO BE REPAIRED LAY-UP
NOTE : THE BAGGING TECHNIQUE IS SHOWN FOR ONE REPAIRED SURFACE

ONLY. THE OTHER REPAIRED SURFACE MUST BE BAGGED UP AT THE
SAME TIME USING THE SAME BAGGING TECHNIQUE PRIOR TO CURE.
R e p a i r Equipment I n s t a l l a t i o n
F i g u r e 203
REPAIR N0.4
EFFECTIVITY: TRENT
Page 211
Feb. 1/98
. .
RB211 TRENT . S-
STRUCTUAL REPAIR
MANUAL
REPAIR NO. 5
REPAIR OF THE RFI SEAL
1. General
A. This procedure gives instructions for the repair of RFI seals

post SB71-C586. Refer to Rolls-Royce plc for pre SB components.
B. !Repair is by replacement of the seal or damaged parts of the

seal.There is no limit to the number of repairs or,'theirposition.
', :. . .. ,
,
.
. ,
2. Referenced Information ., ..
,.L.,*.,.. ,
,
........................................................................
. .
Repair Paint Finish

FRS WO11 Trent Engine Manual
-G-clamps
-Plastic spatulas
B. Consumable materials .- :.
.> .
........................................................................
!,S. ..
. ... -.
,.._.>-
.
'
- 1-
REFERENCE DESIGNATION ,..'- . ...
........................................................................
.
., ._ .
I...,.
a-
.., ,
OMat 135 METHYLETHYLKETONE (MEK) . .

OMat 2/101 CLOTH, LINT-FREE ,. .-
OMat 2/114 GLOVES, LINT-FREE
OMat 8/162~ EPOXY ADHESIVE
C. Component material
........................................................................
PART IDENT MATERIAL
........................................................................
RFI Seal Carbon-impregnated PTFE
D. Repair Part
........................................................................
PART NO. PART IDENT QTY
........................................................................
217-045.7-01 RFI Seal Strip - l "-
EFFECTIVITY: TRENT .-.-

- --.--- REPAIR N0.5
54-20-01
Page 201
H
m RB211 TRENT
STRUCTUAL REPAIR
MANUAL
4. Measure the Damaue (Ref Figure 201)
A. Measure the length of the damaged part of the seal.
B. Add 2.0 in (50 mm) at each end of the damage and make marks to
show the length of seal to be replaced.
NOTE: The minimum permitted length of relacement (new) seal is

6.0 in (152 mm), so you must remove at least this length
of the damaged seal.
NOTE: Measure the serviceable length of adjacent seal that has

been repaired before, but has new damage (that will be
part of the new repair). If that length is less than
6.0 in (152 mm), then all of the adjacent seal must be
included as part of the new repair.
5. Remove the Damacred Seal (Ref Figure 202)
CAUTION: MAKE SURE YOU DO NOT CAUSE DAMAGE TO THE SURFACE OF THE
DOOR WHEN YOU CUT THE SEAL.
A. Cut through the seal at the two marks you made in step 4.B above.
Use a sharp knife and cut vertically through the seal. Make sure
the ends are cut at 90 degrees.
B. Move the knife under the damaged seal to remove it from the door.
WARNING: MEK IS CLASSIFIED AS A HAZARDOUS MATERIAL THAT CAN CAUSE

INJURY OR ILLNESS IF NOT USED CORRECTLY. BEFORE YOU USE
THIS PRODUCT,CAREFULLY READ THE APPLICABLE MATERIAL SAFETY
DATA SHEET AND OBEY ALL THE SPECIFIED SAFETY PRECAUTIONS.
C. Use a spatula to remove unwanted adhesive. Clean the repair area

with OMat 2/101 LINT-FREE CLOTH soaked with OMat 135 MEK. Dry the
surface with a new piece of the cloth before the MEK evaporates.
D. Carefully examine the door, make sure there is no surface damage.
6. Prepare the Repair Seal (Ref Figure 203)
A. Measure the length along the door surface between the cut ends of
the serviceable seal.
NOTE: Make sure you measure accurately along the curved surface
of the door. The new seal must bond correctly along the
curve, with no distortion.
REPAIR N0.5
54-20-01
Page 202
RB211 TRENT
STRUCTUAL REPAIR
m MANUAL
B. Cut a piece of new seal to the length measured in step 6.A

above. Make sure you cut the ends with 90 degree corners.
NOTE: The maximum distance between the cut ends of the repair
and the serviceable seals is 0.04 in (1,O m ) .
7. Install the Repair Seal (Re£ Figure 203)
WARNING: EPOXY ADHESIVE IS CLASSIFIED AS A HAZARDOUS MATERIAL THAT

CAN CAUSE INJURY OR ILLNESS IF NOT USED CORRECTLY. BEFORE
SAFETY PRECAUTIONS.
A. Refer to the manufacturer's instructions. Mix sufficient

OMat 8/162B EPOXY ADHESIVE to bond the new seal in position.
B. Apply the adhesive to the mating surfaces of the door and the
repair seal. Make sure there is no adhesive on or between the cut
ends of the seals.
C. Put the repair seal in position and hold it against the door
with clamps and pressure strips, as shown.
D. Seal all around the joints with the adhesive, as shown.
E. Remove unwanted adhesive with OMat 2/101 LINT-FREE CLOTH.
F. Refer to the manufacturer's instructions. Let the adhesive cure.
G. Do a visual inspection to make sure the repair seal is correctly

bonded and has no distortion.
H. Apply the applicable paint finish to the repair area as necessary

(Ref. SRM 54-02-04) .
REPAIR N0.5
54-20-01
Page 203
P r i n t e d in G r e a t Britain May 1/00
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
Typical door
position of
TY PlCAL RFI seal
DAMAGED
Shows typical
damage to
RFI strip
ADD 50,88mm (2.0in)

MORE AT W O ENDS
MEASURE SERVICEABLE
PART OF POSSIBLE
ADJACENT DAMAGE (SEE NOTE) \ REPLACE MlbllMUM
Note: If there is an adjacent repair
with new damage, measure
the serviceable part. If that
part is less than 152,4 mm
OF 152,4mm (6.0in) (6.0 in), do that repair again
as part of the new repair.
Measure t h e Damage
Figure 201, Sheet 1
REPAIR N0.5
54-20-01
Page 204
Note: Use a sharp knife
RFl SEAL \ v\ CUT THROUGH SEAL

VERTICALLY.
MAKE SURE ALL
CORNERS ARE 90'
CAREFULLY CUT DAMAGED

PART FROM SURFACE
DO NOT'DAMAGE
DOOR SURFACE
Shows removal
of damaged part
MEASURE BETWEEN
ENDS ALONG SURFACE
FOR NEW PART
Shows damage
area removed
Remove the Damaged S e a l

Figure 201, Sheet 2
REPAIR N 0 . 5
54-20-01
Page 205
P r i n t e d i n Great B r i t a i n May 1 / 0 0
,MAKE SURE ALL FOUR ENDS
ARE CUT ACCURATELY
Typical door position DO NOT PUT

of RFI seal ADHESIVE ON
ENDS OF NEW
PART AND
RFl SEAL
Note: Make sure you apply sufficient

adhesive to correctly bond
mating surfaces.
Shows installation
of new part
DOOR SURFACE
DOOR SURFACE
PRESSURE STRIPS
SEAL JOINTS AND

MAKE SMOOTH
NEW PART PRESSURE STRIP A

SECTION
C-C
'
DOOR SURFACE I
MAXIMUM DISTANCE BETWEEN
Shows the bond
of new part
ENDS OF PARTS IS l,Omm (0.04in)
I n s t a l l the Repair Seal

Figure 2 0 1 , Sheet 3
REPAIR N0.5
54-20-01
Page 2 0 6
Printed i n Great B r i t a i n May 1 / 0 0
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR NO. 9 (FRSWO09)
REPAIR OF DISBOND AT THE SLING POINT
1. General
A. This repair gives the procedure for the resin injection

repair of a disbond between the carbon skin and the filled
region at the sling point areas.
B. Repair is limited to the Sling Point filled areas only.

Disbond must be between the filler and skin only. Damage is
permitted in all filled Sling Point areas simultaneously.

--------------.-----------------------------------------------------------------
TASK 71-812-11-300-009 FRSWOO9 Trent Engine Manual
Silicone rubber sheet

Suction cleaner
Vacuum suction pump 0 to 30 in. (0 to 762 mm) of mercury
Two suitable vacuum fittings
3/8 X 2 in. (10 X 50 m) steel washer
Drill bit 0.040 in. (1,O mm) and suitable drill.
REPAIR N0.9
54-20-01
Page 201
Printed in Great B r i t a i n Jun 10/08
RB.211 TRENT
MANUAL
-----------------------------------------------------------------------------.-
------------------------------------------------------------------------------
OMat 1/119 ISOPROPANAL (Propan-2-01)
OMat 21114 GLOVES, LINT FREE
OMat 21101 CLOTH, LINT FREE
OMat 2/31 BAGGING FILM (Capran Sheeting)
OMat 21111 BREATHER CLOTH (NlO-FR)
OMat 230 TEFLON TAPE
OMat 81115 GLASS FABRIC
(Grit size 120)
OMat 21110 SEALANT TAPE (SM-5127)
OMat 802 ARALDITE HARDENER HY951
OMat 803C ARALDITE RESIN AY105
OMat 2/88 ADHESIVE TAPE
OMat 21113 PARTING FILM - NON-POROUS (324-TFNP)
..............................................................................
..............................................................................

A. Identify the area to be repaired. Make sure the damage is in the limits of
this repair scheme as given in 54-20-01, Page Block 101.
WARNING: SOLVENT IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH CAN CAUSE INJURY

OR ILLNESS IF NOT PROPERLY USED. THIS PRODUCT SHOULD BE USED ONLY
IN ACCORDANCE WITH THE MANUFACTURERS SPECIFIC HEALTH AND SAFETY
RECOMMENDATIONS. PRIOR TO USE OF THIS PRODUCT CAREFULLY READ THE
APPLICABLE MATERIAL SAFETY DATA SHEET AND FOLLOW ALL LISTED HEALTH
B. Thoroughly clean the repair area using OMat 11119 SOLVENT on OMat 21101
LINT FREE CLOTH. Dry the area with a fresh piece of lint free cloth before
REPAIR N0.9
EFFECTIVITY: TRENT
Page 202
Feb. 1/98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
5. P r e p a r e t h e Repair Area (Ref F i g u r e 201)
A. Mark o u t t h e d e f i n e d a r e a of damage w i t h a OMat 261 SOFT PENCIL.
WARNING: WEAR PROTECTIVE CLOTHING; GLOVES, MASK AND SAFETY GOGGLES. WHEN
COMPOSITE MATERIALS ARE CUT OR SANDED, DUST AND LOOSE PARTICLES ARE
PRODUCED WHICH ARE POTENTIAL HEALTH HAZARDS. DO NOT BREATHER THE
DUST.
B. Refer t o Figure 201. D r i l l t h e r e q u i r e d number of 0.040 i n . (1,O mm) h o l e s

around t h e edge of t h e disbonded a r e a . Take c a r e t o d r i l l through t h e
disbonded carbon l a m i n a t e only. A s m a l l h o l e of maximum d e p t h 0.2 i n . (5,O
mm) i s p e r m i t t e d i n t h e f i l l e r f o r p r a c t i c a l r e a s o n s , b u t must be avoided
i f possible.
C. Vacuum t o remove d u s t and d e b r i s . Thoroughly c l e a n t h e r e p a i r a r e a u s i n g

OMat 11119 SOLVENT on OMat 21101 LINT FREE CLOTH. Dry t h e a r e a w i t h a
f r e s h p i e c e of l i n t f r e e c l o t h b e f o r e t h e f l u i d e v a p o r a t e s n a t u r a l l y .
D. Remove water from t h e damaged a r e a
( 1 ) Remove s t a n d i n g water u s i n g vacuum and o i l - f r e e compressed a i r .
(2) Apply OMat 21111 BREATHER CLOTH over b o t h s i d e s of t h e s l i n g p o i n t

hole.
(3) Add a thermocouple t o t h e c e n t r e of t h e b r e a t h e r c l o t h (one s i d e ) .
( 4 ) Apply a l a y e r of OMat 81115 GLASS FABRIC over t h e b r e a t h e r c l o t h and

hold i n p l a c e w i t h OMat 2/30 TEFLON TAPE (OSL s i d e o n l y ) .
(5) P l a c e a h e a t i n g b l a n k e t over t h e g l a s s c l o t h (OSL s i d e only.
(6) Cover t h e a r e a w i t h OMat 2 / 3 1 BAGGING FILM and s e a l u s i n g OMat 21110

SEALANT TAPE (both s i d e s ) .
( 7 ) Evacuate t h e lay-up t o a vacuum of 22 i n . (559 mm) of mercury minimum.
NOTE: The vacuum p o i n t can be on t h e i n n e r o r o u t e r f a c e t o s u i t

o p e r a t i o n a l requirements.
(8) Heat t h e a r e a f o r 1 hour minimum a t 176 deg F (80 deg C), do n o t exceed
212 deg F (100 deg C). The r a t e of temperature r i s e must n o t exceed 5
deg F) (3 deg C) p e r minute.
(9) Remove lay-up m a t e r i a l s and c o n t i n u e w i t h t h e r e p a i r .
REPAIR N0.9
EFFECTIVITY: TRENT
Page 203
Feb. 1/98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
6. I n j e c t t h e Resin
A. R e f e r t o F i g u r e 201. Apply a l a y e r of OMat 21111 BREATHER CLOTH over t h e

r e a r of t h e m e t a l s l i n g p o i n t i n s e r t .
B. Apply a l a y e r of OMat 2/31 BAGGING FILM o v e r t h e b r e a t h e r c l o t h and s e c u r e

i n t o p o s i t i o n w i t h OMat 21110 SEALANT TAPE. I n c l u d e a vacuum connector i n
t h e vacuum bag m a t e r i a l .
C. Cover t h e s l i n g p o i n t t h r e a d and a l l of t h e d r i l l e d h o l e s , e x c e p t one, w i t h

O M a t 2/88 ADHESIVE TAPE.
D. Apply a minimum vacuum of 1 0 i n . (254 mm) of mercury.
E. Mix s u f f i c i e n t OMat 803C RESIN and OMat 802 HARDENER t o f i l l t h e disbonded

r e g i o n i n accordance w i t h m a n u f a c t u r e r s i n s t r u c t i o n s .
F. Using a s y r i n g e , i n j e c t t h e mixed r e s i n i n t o t h e uncovered h o l e . Let t h e

vacuum p u l l t h e r e s i n through u n t i l t h e a d h e s i v e t a p e shows evidence of
r e s i n f i l l e t a t t h e s l i n g p o i n t h o l e edge.
G. Release t h e vacuum and wipe e x c e s s r e s i n from around t h e h o l e . Cover t h e

f i l l e d hole with adhesive tape.
H. Uncover t h e n e x t h o l e and r e p e a t s t e p s 6.F. and 6.G. u n t i l a l l of t h e h o l e s

have been f i l l e d .
I . Remove t h e vacuum bag and a l l a p p l i e d t a p e .
J . Refer t o F i g u r e 201. Make a n i n t e n s i f i e r u s i n g a s t a n d a r d washer and a

r u b b e r mat. During t h e c u r e p r o c e d u r e , clamp t h e i n t e n s i f i e r t o t h e r e p a i r
u s i n g a s t a n d a r d s l i n g p o i n t l i f t i n g l u g . The l u g must be c o a t e d with a
r e l e a s e a g e n t . Put OMat 21113 NON-POROUS PARTING FILM between t h e rubber
mat and t h e r e p a i r s u r f a c e . T i g h t e n t h e l u g by hand.
7 . Cure t h e Resin
A. Let t h e r e s i n g e l a t 59 t o 77 deg F (15 t o 25 deg C) f o r a minimum of 2

hours.
B. Remove a l l t h e a d h e s i v e t a p e .
C. Using a h e a t lamp, c u r e t h e r e s i n f o r 220 t o 235 minutes a t 203 t o 239

deg F (95 t o 115 deg C ) . Cool t o below 140 deg F (60 deg C) b e f o r e
r e l e a s i n g t h e clamp.
REPAIR N0.9
EFFECTIVITY: TRENT
Page 204
Feb. 1/98
m, RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
8. Finish the Re~aired Surface
WARNING: WEAR PROTECTIVE CLOTHING; GLOVES, MASK AND SAFETY GOGGLES. WHEN
COMPOSITE MATERIALS ARE CUT OR SANDED, DUST AND LOOSE PARTICLES ARE
PRODUCED WHICH ARE POTENTIAL HEALTH HAZARDS. DO NOT BREATHE THE
DUST.
A. Smooth the surface of the repair using OMat 5/35 WATERPROOF SILICON CARBIDE
ABRASIVE PAPER. Do not abrade mesh or carbon.
B. Remove all unwanted material with a suction cleaner. Make sure no

particles of the unwanted material remain.
WARNING: SOLVENT IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH CAN CAUSE INJURY

IN ACCORDANCE WITH THE MANUFACTURERS SPECIFIC HEALTH AND SAFETY
APPLICABLE MATERIAL SAFETY DATA SHEET AND FOLLOW ALL LISTED HEALTH
C. Thoroughly clean the repair area using OMat 11119 SOLVENT on OMat 21101
LINT FREE CLOTH. Dry the area with a fresh piece of lint free cloth before
D. Apply surface protection to the repair area in accordance with the standard
painting procedure 54-02-04.
9. Inspection
A. Do a visual andlor a NDT inspection to make sure the repair has been done
in accordance with these procedures.
REPAIR N0.9
EFFECTIVITY: TRENT
Page 205
Feb. 1/98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
DRILL HOLES- CARBON PLIES

MIN 4 OFF
MAX5OFF 1 l 0.S.L
SLING POINT' FILLER

INSERT
INJECT
HIGH TEMP TAPE RESIN CARBON PLIES
uo-s
OVER HOLES
\
SLING POINT Ell I CD
I ILLLll
INSERT
BREATHER
\VACUUM BAG
CLOTH AND CONNECTORS
WASHER SLING POINT LIFTING LUG
CARBON PLIES
RUBBER MAT
RELEASE FILM
SLING POINT
INSERT FILLER
R e p a i r Disbond a t S l i n g P o i n t
F i g u r e 201
REPAIR N0.9
EFFECTIVITY: TRENT
Page 206
Feb. 1I 9 8
W
m@MANUAL
RB.211 TRENT
STRUCTURAL REPAIR
REPAIR NO.10 (FRSWO10)
REPAIR OF DAMAGED CONDUCTIVE SURFACE MESH
1. General
A. This repair gives the procedure for the wet lay-up repair of
conductive surface mesh.
B. Repair is permitted to both inner steel mesh and outer

aluminium mesh. There is no limit to the size or number of
repairs. The damage is limited to the mesh. The minimum
distance between damage is 127,O mm (5.0 in.).

...................................................................................................................
...................................................................................................................
70-20-01-100-802 AMM - Cleaning
Spatula
Roller
Suction cleaner
Vacuum suction pump 0 to 762 mm (0 to 30 in.) of mercury
Two suitable vacuum fittings
Temperature probes, 32 to 248 deg F (0 to 120 deg C).
REPAIR NO.10
54-20-01
Page 201
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL

OMat 212 BRUSH
OMat 2/114 GLOVES I LINT FREE
OMat 2/101 ABSORBANT CLOTH, LINT FREE
OMat 2/111 BREATHER CLOTH (N10-FR)
OMat 2/113 PARTING FILM - NON-POROUS (324-TFNP)
OMat 2/112 PARTING FILM - POROUS (234-TFP)
OMat 5/35 WATERPROOF SILICON CARBIDE (GRIT SIZE 240)
OMat 2/1:10 ADHESIVE TAPE, VACUUM-BAG SEAL
OMat 8/115 GLASS FABRIC - PLAIN WEAVE 'E'
OMat 8/200 ALUMINIUM MESH, RFI AND LIGHTNING STRIKE
PROTECTION (CL2561 (Outer skin only)
OMat 8/199 STAINLESS STEEL MESH (CL2591 (Inner skin
only)
OMat 8/271 ALUMINIUM MESH -
PLAIN , RFI AND LIGHTNING
STRIKE PROTECTION (Outer skin only)
OMat 8/270 STAINLESS STEEL MESH - PLAIN (Inner skin
only)
OMat 150 ACETONE
OMat 262 MARKER

217-0466--01 Fan Cowl Door Assembly LH
REPAIR NO.10
54-20-01
Page 202
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
4. Clean the R e ~ a i rArea

Block 101.

area. Dry the area with a clean lint-free cloth before the
fluid dries. Leave to stand for at least 15 minutes before
you continue.
A. Mark out the defined area of damage with a SOFT PENCIL (OMat
261). Mark out the cut line by at least 0.25 in. (6,O mm)
greater than the damage. This can be any convenient shape,
but all corners must have a minimum radius of 0.25 in. (6,O
mm).
WARNING: USE PROTECTIVE CLOTHES, GLOVES, MASK AND GOGGLES WHEN

C. Abrade back the damaged mesh to the cut line using

WATERPROOF SILICON CARBIDE ABRASIVE PAPER (OMat 5/35) until
the carbon fibre is exposed. Care must be taken not to
damage the carbon.
D. Abrade back the paint and resin using WATERPROOF SILICON

CARBIDE ABRASIVE PAPER (OMat 5/35) to expose the mesh by a
further 1.0 in. (25,O mm) each side of the repair area.
E. Vacuum to remove dust and debris. Refer to AMM TASK 70-20-

01-100-802. Thoroughly clean the repair area. Dry the area
with a clean piece of lint free cloth before the fluid dries
naturally. Leave to stand for at least 15 minutes before you
continue.
F. Water Break test
(1) Brush on or spray a thin layer of distilled water to

the repair area. A continuous layer seen for
approximately a half minute shows that the area has
passed the water break test. Areas that fail this test
must be cleaned and tested again. After testing, the
areas must be fully dried before application of repair
plies. This can be done by using heating lamps that do
not exceed 158 deg F (80 deg C) to dry the repair area.
EFFECTIV1TY:TRENT REPAIR NO.10
Page 203
RB.211 TRENT
STRUCTURAL REPAIR
@ MANUAL
6. Lay-up the Repair Plies (Ref. Figure 201)
A. Cut one ply of GLASS FIBRE SCRIM (OMat 8/201), and one ply
of either:
(1) ALUMINIUM MESH - PRE-PREG (OMat 8/200), (outer skin)

or
(2) STAINLESS STEEL MESH - PRE-PREG (OMat 8/199), (inner
skin)

(1) ALUMINIUMMESH - PLAIN (OMat 8/271), (outer skin)

or
(2) STAINLESS STEEL MESH - PLAIN (OMat 8/270), (inner
skin).
See Figure 201 for dimensions.
NOTE: Do not do step 6.B. when using the plain mesh.

This step applies to the pre-preg material only.
WARNING: SOLVENT IS CLASSIFIED AS A HAZARDOUS MATERIAL, WHICH

CAN CAUSE INJURY OR ILLNESS IF NOT PROPERLY USED. THIS
RECOMMENDATIONS. PRIOR TO USE OF THIS PRODUCT CAREFULLY
READ THE APPLICABLE MATERIAL SAFETY DATA SHEET AND
FOLLOW ALL LISTED HEALTH AND SAFETY PRECAUTIONS.
B. Wash out the film adhesive (Refer to AMM TASK 70-20-01-100-

802) from the mesh by repeated immersion in a bath of
ACETONE (OMat 150). Make sure no trace of the film adhesive
remains. Thoroughly dry the mesh with LINT FREE CLOTH (OMat
21101).
WARNING: BA9390 EPOXY ADHESIVE IS CLASSIFIED AS A HAZARDOUS

MATERIAL, WHICH CAN CAUSE INJURY OR ILLNESS IF NOT
ACCORDANCE WITH THE WITH THE MANUFACTURERS SPECIFIC
HEALTH AND SAFETY RECOMMENDATIONS. PRIOR TO USE OF THIS
PRODUCT CAREFULLY READ THE APPLICABLE MATERIAL SAFETY
DATA SHEET AND FOLLOW ALL LISTED HEALTH AND SAFETY
PRECAUTIONS.
Mix EPOXY ADHESIVE (OMat 8/160) in accordance with the

manufacturers instructions. Make sure enough is mixed
to cover both the glass scrim and mesh plies.
REPAIR NO.10
54-20-01
Page 204
RB.211 TRENT
STRUCTURAL REPAIR
@ MANUAL
D. Apply sufficient EPOXY ADHESIVE (OMat 8/160) to the repair

area surface for both the glass scrim and mesh plies to be
added. Make sure the adhesive covers an area slightly larger
than the size of mesh ply to be added. The adhesive can be
spread out using a spatula.
E. Lay-up the GLASS FIBRE SCRIM (OMat 8/201) on the repair area
making sure the cloth overlaps the exposed mesh by 0.2 in.
(5.0 mm). Stipple the resin into the cloth using a stiff
brush.
F. Lay-up one of the following mesh types on top of the glass

scrim ply, making sure the mesh overlaps, but do not extend
beyond the extremity of the exposed mesh:
(1) ALUMINIUM MESH -

PRE-PREG (OMat 8/200), (outer skin)
or
(2) STAINLESS STEEL MESH -
PRE-PREG (OMat 8/199), (inner
skin).

(1) ALUMINIUM MESH - PLAIN (OMat 8/271) , (outer skin)

or
(2) STAINLESS STEEL MESH - PLAIN (OMat 8/270), (inner
skin).

plies.
7. Prepare the Vacuum Bag (Ref. Figure 202)
A. Cover the repair plies with one layer of PEEL PLY (OMat
8/198) that is at least 3.0 in. (76,O mm) larger than the
repair plies.
B. Cover this layer with one layer of POROUS PARTING FILM (OMat
2/112) approximately 1.0 in. (25,O mm) larger than the peel
P ~ Y
C. Cover the porous parting film with two layers of GLASS
FABRIC (OMat 8/115) and one layer of NON-POROUS FILM (OMat
2/112) , each being 1.0 in. (25,O mm) smaller than the
previous layer.
D. Cover the non-porous parting film with two layers of

BREATEHR CLOTH (OMat 2/111), both layers being larger than
all the previous layers of material.
REPAIR NO.10
54-20-01
Page 205
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
E. Position the heater mat over the repair area. Make sure the
temperature probes are positioned to monitor repair
temperature.
G. Cover the whole of the repair area with BAGGING FILM (OMat
2/31) plus two vacuum fittings.
H. Seal the edges of the bag to the panel using SEALANT TAPE
(OMat 2/110).
I. Cure for 220 to 235minutes a t 2 0 3 to 239 deg F (95 t o 1 1 5

deg C). Heat up at a rate of 9 deg F (5 deg C) per minute.
Vacuum must not fall below 22.0 in. (559,O mm) of mercury
during the cure cycle. Cool to below 140 deg F (60 deg C)
before releasing vacuum.

material and the Teflon tape from the repair area.
8. Finish the Repaired Surface
WARNING: USE PROTEC TIVE CLOTHES, GLOVES, MASK AND GOGGLES WHEN
A. Smooth the surface of the repair all around to a smooth

contour suitable to paint using WATERPROOF SILICON CARBIDE
ABRASIVE PAPER (OMat 5/35). Do not abrade mesh or carbon.

sure no particles of the unwanted material remain.
C. Thoroughly clean the repair area. Refer to AMM TASK 70-20-

01-200-802. Dry the area with a fresh piece of lint free
cloth before the fluid dries.
D. Apply the surface protection to the repair area in

accordance with the standard painting procedure 54-02-04
9. Inspect ion
A. Do a visual and/or an NDT inspection to make sure the repair

has been done in accordance with these procedures.
10. Identify the Repair
A. Mark FRSWOlO adjacent to the part number of the fan cowl

door, use MARKER PEN (OMat 262) of a contrasting colour.
54-20-01
Page 206
RB.211 TRENT
m STRUCTURAL REPAIR
MANUAL
TYP 38,Omm (1.5in)

MESH-MUST SIT FULLY
TYP 25,O mm (1.0in) ON EXPOSED MESH
TYP 5,Omm (0.2in) GLASS SCRlM

OVERLAP ONTO CUT JUST OVERSIZE
EXPOSED MESH OFEXPOSEDCARBON
EXPOSED REPAIR SURFACE EXPOSED

MESH (INNER/OUTER SKIN) CARBON
TOLERANCE ON PLIES +l- 2,5 mm (0.1 in)
MATERIALS TO BE ABRADED AND ADDED
Prepare t h e Repair Area

Figure 201
REPAIR N0.10
EFFECTIVITY: TRENT
Page 207
Feb. 1 I 9 8
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
RUBBER * OF
NON POROUS GLASS
H EATER MAT BREATHER
CLOTH PARTING FILM CLOTH
VACUUM \ 1 I
CONNECTOR \ \ \ I
BAGGING FlLM
ELECTRICAL
CONNECTOR
THERMOCOUPLE
SEALANT TEFLON OR HIGH POROUS PEEL PLY REPAIR

TAP E TEMP TAPE PARTING FILM LAY-UP
HONEYCOMB PANEL
TO BE REPAIRED

Figure 202
REPAIR NO. 10
EFFECTIVITY: TRENT
Page 208
Feb. 1/98
RB211 TRENT :'
. .
. . . . .. .
STRUCTURAL REPAIR . . .
MANUAL
REPAIR NO.11 (FRS 5086)
PRE SB 71-E107 FAN COWL DOOR - RIGHT HAND
REPLACE DECAL
1. General

A. This repair gives the procedure to replace damaged decals

on the RH Fan Cowl Door.

C. The minimum air temperature necessary for this repair is 16 deg

C (61 deg F). If possible, do not operate the engine for 48
hours after the repair has been done.
Equipment and Materials
A. Standard Equipment :
Plastic squeegee
Rubber roller
......................................................................
REFERENCE DESIGNATION ,4x
......................................................................
-, ,
OMat 150 ACETONE l

OMat 2/12 SOFT BRUSH
OMat 7/203 THINNER
OMat 7/204 THINNER
OMat 296 ADHESIVE TAPE
OMat 5/150 STRIPE OFF WHEEL
REPAIR NO.11
. .
-. Page 201
.... :.;.. .. . . . . . . . . . .
. . . Jun 10/07
1
1 STRUCTURAL REPAIR
MANUAL
R C. Part Identification
...............................................................
R PART NUMBER PART IDENT
...............................................................
R WCA711OE012-041 FAN COWL DOOR ASSEMBLY LH
R WCA7110E013 -041 FAN COWL DOOR ASSEMBLY RH
R 217-0466-01 FAN COWL DOOR ASSEMBLY LH
R 217-1366-01 FAN COWL DOOR ASSEMBLY RH
R 3. Identify the Decal, which requires replacement
A. Refer to Table 1 and Figure 201 (Sheet 1 thru 6) to identify

the correct replacement decal.
4. Remove the Damaged Decal
R A. Clean the damaged decal and the adjacent area. Use OMat 2/101
R LINT FREE CLOTH soaked with OMat 150 ACETONE. Discard the cloth
R after use. Let the part dry and remove the unwanted solvent
R with a clean, dry OMat 2/101 LINT FREE CLOTH.
R B. Measure and keep the distance between the top edge and the
R perpendicular edge of the damaged decal to an applicable fixed
R location on the Fan Cowl Door.
R C. Get the OMat 5/150, STRIPE OFF WHEEL and an applicable hand
R held rotary tool (the hand held tool must have a spindle speed
R of 1800 rpm to 2200 rpm). Refer to the manufacturer's
R instructions for the installation and use of the OMat 1/150,
R STRIPE OFF WHEEL.
R D. While the hand held tool rotates at 1800 rpm to 2200 rpm, move
R the outer edge of the stripe off wheel into contact with the
R damaged decal. Apply light contact pressure on to the damaged
R decal with the OMat 5/150, STRIPE OFF WHEEL.
Move the OMat 5/150, STRIPE OFF WHEEL into contact with the
damaged decal in horizontal and vertical directions. Do this
until the decal has been removed. Do not damage the structure
underneath the decal.
R 5. Prepare the Repair Area
R A. If necessary, remove the remains of the unwanted damaged decal

R from the surface of the Fan Cowl Door with a non-metallic
R scraper. Do not damage the surface of the Fan Cowl Door.
REPAIR NO.11
54-20-01
Page 202
July 1/05
l@ RB211 TRENT
MANUAL
STRUCTURAL REPAIR
R B. Locally degrease the repair area. Use OMat 2/101 LINT FREE
R CLOTH and make moist with OMat 150 ACETONE. Discard the cloth
R after use.
R C. Do a Visual Inspection of the Fan Cowl Door. Make sure all of

R the damaged decal has been removed and there is no damage to
R the surface of the Fan Cowl Door.
R 6. Mark the position of the replacement Decal
R A. Refer to Figure 201 (Sheet 1 thru 6) for the position of the

R replacement decal. The non-hazard warnings are installed to the
R dimensions given in this repair scheme. If the customer logo
R signs prevent installation of the non-hazard warnings, they can
R be installed adjacent to the customer logo.
R B. Measure and keep the distance between the top edge and the
R perpendicular edge of the damaged decal to an applicable fixed
R location on the Fan Cowl Door.
Use the measurements taken from above to mark two perpendicular

lines on the Fan Cowl Door. The marks must show the position of
the top edge and a perpendicular edge of the replacement decal.
Use OMat 262 TEMPORARY MARKER to put the marks on the Fan Cowl
Door.
R C. Use OMat 296 ADHESIVE TAPE to make a continuous frame around

R the repair area. The frame must be 0.39 inch. (10,Omm) larger
R than the replacement decal on all of the edges.
7. Apply the Replacement Decal
A. Remove the backing paper along the top edge of the decal. Only
remove enough backing paper to let the top and the
perpendicular edge of the replacement decal to be aligned with
the marks made on the Fan Cowl Door.
B. Use the marks made on the Fan Cowl Door to help install the
decal. Apply the decal to the surface of the Fan Cowl Door at
the marked position.
Use a plastic squeegee or rubber roller to apply firm strokes

on the decal, overlap each stroke. Start at the centre and move
to the edge of the decal.
REPAIR NO.11
54-20-01
Page 203
July 1/05
p RB211 TRENT
STRUCTURAL REPAIR
MANUAL
R paper to let the decal to be attached to the Fan Cowl Door. Use
R a plastic squeegee or a rubber roller to apply firm overlapping
R strokes from the centre to the outside edges of the decal. Make
R sure that the adhesive surface of the decal and the surface of
R the Fan Cowl Door only touch when pressure is applied.
R 8. Inspect the replacement decal
R A. Refer to Figure 201 (Sheet 1 thru 6). Do an inspection of the

R replacement decal. Make sure that the decal is in the correct
R position given in the repair scheme. Make sure that you get the
R customer's dimensions, for the non-hazardous warnings that have
R been fitted adjacent to the customer's logo.
R B. Do a visual inspection of the replacement decal. If necessary,

R trapped air can be removed from the decal. Use a pin to make a
R small hole in the trapped air in the decal. Press out the
R trapped air in the direction of the hole. Make the decal smooth
R with a plastic squeegee or rubber roller. If the decal is not
R smooth, remove and replace the decal.
9. Apply the Varnish

thinners are necessary, use:
(1) At temperatures between 16 and 26 deg C (61 and 79 deg F),

use OMat 7/203 THINNER.
(2) At temperatures more than 26 deg C (79 deg F), use OMat
7/204 THINNER.
B. Make sure the varnish is fully mixed (approx 15 to 30 minutes).

The pot life of the varnish is 8 hours.
varnish to cover all of the surface of the decal. Make sure the
varnish extends by 0.39 inch. (10,Omrn) from all edges of the
decal over the surface of the Fan Cowl Door.
D. After 30 minutes at room temperature, the varnish can be cured

as follows:
72 hours at a temperature of 16 deg C (61 deg F) or 1 hour at a
temperature of 70 deg C (158 deg F). Do not cure at a
temperature of more than 70 deg C (158 deg F).
REPAIR NO.11
54-20-01
Page 204
July 1/05
H
"" RB211 TRENT
MANUAL
STRUCTURAL REPAIR
R 10. Do a Visual Inspection of the Decal
R A. Do a Visual Inspection of the Decal. Make sure the decal

R surface is fully covered with varnish and the varnish extends
R by 0.39 inch. ( 1 0 , O m ) from all edges of the decal over the Fan
R Cowl Door.
REPAIR NO.11
54-20-01
Page 205
July 1/05
RB211 TRENT
STRUCTURAL REPAIR
MANUAL

11-24-71
Black, Latch Closing Position and Shoot
1 01-402 FW14840 Bolts
White, Latch Closing Position and Shoot

Bolts
3 01-408 FW14846 Black, Hoist Point
4 01-409 FW14847 White, Hoist Point
5 01-422 FW14860 Black, Engine Oil Filler Access
6 01-423 FW14861 White, Engine Oil Filler Access
Black text, Master Chip Detector / Case

7 01-426
FW14864 Drain Filter Access
White text, Master Chip Detector / Case

8 01-427
Drain Filter Access
Warning - Both Rods Must Be Used When

9 01-436
Working On Engine, Red and Black text.
Warning - Both Rods Must Be Used When

10 01-437
Working On Engine, Yellow and White text
11 01-440 FW14878 Black text, Tank Capacity 31.2 Litres
12 01-441 FW14879 White text, Tank Capacity 31.2 Litres
13 01-448 FW14886 Black, Number l
14 01-449 FW14887 White, Number l
15 01-450 FW14888 Black, Number 2
16 01-451 FW14889 White, Number 2
17 01-452 FW14890 Black, Number 3
18 01-453 FW14891 White, Number 3
19 01-454 FW14892 Black, Number 4
20 01-455 FW14893 White, Number 4

54-20-01
Page 206
July 1/05
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
21 01 - 4 62 FW14900 Black, 5-Shoot Bolt
22 01-463 FW14901 White, 5-Shoot Bolt
Warning-Keep Clear Of Hazard Areas While

23 01-464 FW14902
Engine Is Running, Red and Black text

24 01-465 FW14903
Engine Is Running, Yellow and White text
No - Go Areas Symbol, Red nacelle with

25 01-510 FW32620 Black outline on White background and
Imperial Conversion S/B 11-E346,
No - Go Areas Symbol, Yellow nacelle with

26 01-511 FW32621 White outline on Black background and
Imperial Conversion S/B 11-E346
Rolls-Royce - Emblem. Silver text on Black

27 01-100 FW12343 background. Width 419,001~11
& Height
635, OOmm

28 01-102 FW12344 background. Width 216,OOm & Height
305, OOmm.
Rolls-Royce - Emblem. Silver text on Blue

29 01-104 FW12345 background. Width 419,OOmm & Height
635, OOmm.

30 01-106 FW12346 background. Width 216,001~11
& Height
305, OOmm.

31 01-101 FW12347 background. Width 352,001~1& Height
526, OOmm.

526,OOmm.
33 01-466 FW14904 Red, T/R Isolation Switch Symbol
34 01-467 FW14905 Yellow, T/R Isolation Switch Symbol
35 01-550 FW33908 (Chinese) Warning-Keep Clear Of Hazard

54-20-01
Page 207
R July 1/05
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
Areas While Engine Is Running, Red and

Black text, White background S/B 11-E346
(Chinese) Warning-Keep Clear Of Hazard

36 01-555 FW33909 Areas While Engine Is Running, yellow and
White text, grey background S/B 11-E346

37 01-502 FW32457 Engine Is ~unning, Red and Blue text on
White background S/B 11-E346 Alt FW14902

38 01-503 FW33430 Engine Is Running, White text on Black
background S/B 11-E346 Alt FW14903

Blue outline on White background and
39 01-512 FW32463
Imperial Conversion S/B 11-E346 Alt
FW32620

Black outline and White border with
40 01-513 FW32464
FW32620
Table 1
REPAIR NO.11
54-20-01
Page 208
July 1/05
B RB211 TRENT
MANUAL
STRUCTURAL REPAIR
P*,
TYPICAL VlEW ON THE FRONT OF THE ENGINE
TYPICAL VlEW ON THE FRONT OF THE ENGINE

TO SHOW THE FAN COWL DOOR OPEN
In
(U
V FIGURE 201
6
0
DIMENSIONS ARE IN MlLLlMETERS (INCHES)
1L
U
Figure 201 (Sheet 1)
54-20-01
Page 209
July 1/05
APPLY ITEM 5 OR 6
TO THE INSTRUCTIONS
THE LEADING
EDGE OF THE
COWL DOOR
THE CENTERLINE OF
THE REAR NOSE
COWL HOIST POINT
APPLY ITEM 11 OR 12
TO THE INSTRUCTIONS
APPLY ITEM 7 OR 8
TO THE INSTRUCTIONS
+ -
- 620,OO(24.409)
580,OO 22.835
-- 1220.00(48.031)
1 180,OO 46.457
FIGURE 202
REPAIR NO.11
54-20-01
Page 210
July 1/05
H RB211 TRENT
MANUAL
STRUCTURAL REPAIR
APPLY ITEM 27,28,29,

30,31 OR 32 TO THE
INSTRUCTIONS
LAPP
ITEM 25,26,
39 OR 40 TO THE
INSTRUCTIONS
TO THE INSTRUCTIONS
LAPPLY ITEM 35 OR 36
TO THE INSTRUCTIONS
FIGURE 203
Figure 201 (Sheet 3 )
REPAIR NO.11
54-20-01
Page 211
July 1/05
m RB211 TRENT
MANUAL
STRUCTURAL REPAIR
_ 1065,OO 41 929
1025.00(40:354)
c
587.00(23.110)
547,OO 21 535
APPLY ITEM 9 OR 10
TO THE INSTRUCTIONS
APPLY ITEM 17 OR 18 THIS IS ON THE INNER
TO THE INSTRUCTIONS SIDE OF THE COWL DOOR
APPLY ITEM 21 OR 22
APPLY ITEM 19 OR 20 TO THE INSTRUCTIONS
TO THE INSTRUCTIONS
CLOSING LINE
\
APPLY ITEM 15 OR 16
TO THE INSTRUCTIONS
THE LEADING EDGE

OF THE COWL DOOR
v-
0
o FIGURE 204
g Installation of Decals
54-20-01
Page 212
July 1/05
p RB211 TRENT
MANUAL
STRUCTURAL REPAIR
170,00(6.693)
1 7 130,OO 5.118
I - 4
64,OO 2.520
24,OO(0.945)
960,OO 37.795
920,OO( 3 6 . 2 2 0 F
m
APPLY ITEM 1 OR 2 l
TO THE INSTRUCTIONS
- I
I I
THE COWL DOOR 39,OO 1535
CLOSING LINE -0,OO(0:OOO)
APPLY ITEM 13 OR 14
TO THE INSTRUCTIONS
THE LEADING EDGE

OF THE c o w DOOR)
VIEW - A6
FIGURE 205
54-20-01
Page 213
July 1/05
p RB211 TRENT
MANUAL
STRUCTURAL REPAIR
APPLY ITEM 33 OR 34 WITH

THE SYMBOL OF THE HANDLE
POSITIONED DIRECTLY ABOVE
THE ISOLATION UNIT HANDLE
TO THE INSTRUCTIONS
THE COWL DOOR

HINGE LINE
FIGURE 206
REPAIR NO.11
54-20-01
Page 214
July 1/05
p RB211 TRENT
MANUAL
STRUCTURAL REPAIR
L 9
REPAIR NO. 12 (FRS 5087)
PRE SB 71-E107 FAN COWL DOOR - LEFT HAND
REPLACE DECAL
1. General


the LH Fan Cowl Door.


C (61 deg F). If possible, do not operate the engine for 48
Plastic squeegee
Rubber roller
......................................................................
REFERENCE DESIGNATION . . ,. ..,."..
......................................................................
..
..
. -..
..-CC.j,c.,'... ;i
.
..
OMat 150 ACETONE ,

.',
\ , - . ,
' :
. <: :
i. '1,. ,. ..
. -..
OMat 262 TEMPORARY MARKER . .
OMat 2/12 SOFT BRUSH .'<

OMat 7/203 THINNER
OMat 7/204 THINNER
REPAIR N0.12
...
. . Page 201
C*..:i.
..I. .: .
,, -,-,.' Jun 10/07
RB211 TRENT
STRUCTURAL REPAlR
MANUAL
FAN COWL DOOR ASSEMBLY LH

FAN COWL DOOR ASSEMBLY RH
FAN COWL DOOR ASSEMBLY LH
3. Identifv the Decal. which r e m i r e s re~lacement
A. Refer to Table 1 and Figure 201 (Sheet 1 thru 4) to identify

the correct replacement decal.
4. Remove the Damaged Decal
A. Clean the damaged decal and the adjacent area. Use OMat 2/101
LINT FREE CLOTH soaked with OMat 150 ACETONE. Discard the cloth
after use. Let the part dry and remove the unwanted solvent
with a clean, dry OMat 2/101 LINT FREE CLOTH.
B. Measure and keep the distance between the top edge and the
perpendicular edge of the damaged decal to an applicable fixed
location on the Fan Cowl Door.
C. Get the OMat 5/150, STRIPE OFF WHEEL and an applicable hand
held rotary tool (the hand held tool must have a spindle speed
of 1800 rpm to 2200 rpm). Refer to the manufacturer's
instructions for the installation and use of the OMat 1/150,
STRIPE OFF WHEEL.
D. While the hand held tool rotates at 1800 rpm to 2200 rpm, move
the outer edge of the stripe off wheel into contact with the
damaged decal. Apply light contact pressure on to the damaged
decal with the OMat 5/150, STRIPE OFF WHEEL.
Move the OMat 5/150, STRIPE OFF WHEEL into contact with the
damaged decal in horizontal and vertical directions. Do this
until the decal has been removed. Do not damage the structure
underneath the decal.
5. Prepare the Repair Area
A. If necessary, remove the remains of the unwanted damaged decal

from the surface of the Fan Cowl Door with a non-metallic
scraper. Do not damage the surface of the Fan Cowl Door.
REPAIR N0.12
54-20-01
Page 202
July 1/05
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
B. Locally degrease the repair area. Use OMat 2/101 LINT FREE
CLOTH and make moist with OMat 150 ACETONE. Discard the cloth
after use.
C. Do a Visual Inspection of the Fan Cowl Door. Make sure all of

the damaged decal has been removed and there is no damage to
the surface of the Fan Cowl Door.
Mark the position of the replacement Decal
A. Refer to Figure 201 (sheet 1 thru 4) for the position of the

replacement decal. In conditions where customer's logo signs
will not allow the non-hazard warnings to be fitted to the
given dimensions in this repair scheme, they can be fitted
adjacent to the customer's logo.
B. Measure and keep the distance between the top edge and the
perpendicular edge of the damaged decal to an applicable fixed
location on the Fan Cowl Door.
Use the measurements taken from above to mark two perpendicular

lines on the Fan Cowl Door. The marks must show the position of
the top edge and a perpendicular edge of the replacement decal.
Use OMat 262 TEMPORARY MARKER to put the marks on the Fan Cowl
Door.
C. Use OMat 296 ADHESIVE TAPE to make a continuous frame around

the repair area. The frame must be 0.39 inch. (10,Omm) larger
than the replacement decal on all of the edges.
Apply the Replacement Decal
A. Remove the backing paper along the top edge of the decal. Only
remove enough backing paper to let the top and the
perpendicular edge of the replacement decal to be aligned with
the marks made on the Fan Cowl Door.
B. Use the marks made on the Fan Cowl Door to help install the
decal. Apply the decal to the surface of the Fan Cowl Door at
the marked position.
Use a plastic squeegee or rubber roller to apply firm strokes

on the decal, overlap each stroke. Start at the centre and move
to the edge of the decal.
REPAIR N0.12
54-20-01
Page 203
July 1/05
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
paper to let the decal to be attached to the Fan Cowl Door. Use
a plastic squeegee or a rubber roller to apply firm overlapping
strokes from the centre to the outside edges of the decal. Make
sure that the adhesive surface of the decal and the surface of
the Fan Cowl Door only touch when pressure is applied.
Do an Ins~ectionof the re~lacementdecal
A. Refer to Figure 201 (Sheet 1 thru 4). Do an inspection of the

replacement decal. Make sure that the decal is in the correct
position given in the repair scheme. Make sure that you get the
customer's dimensions, for the non-hazardous warnings that have
been fitted adjacent to the customer's logo.
B. Do a visual inspection of the replacement decal. If necessary,

trapped air can be removed from the decal. Use a pin to make a
small hole in the trapped air in the decal. Press out the
trapped air in the direction of the hole. Make the decal smooth
with a plastic squeegee or rubber roller. If the decal is not
smooth, remove and replace the decal.
Apply the Varnish


(2) At temperatures more than 26 deg C (79 deg F) , use OMat

7/204 THINNER.

varnish extends by 0.39 inch. (10,Omm) from all edges of the

as follows:
REPAIR N0.12
54-20-01
Page 204
July 1/05
R
p
'"" RB211 TRENT
MANUAL
STRUCTURAL
10. Do a Visual Inspection of the Decal

REPAIR

R surface is fully covered with varnish and the varnish extends
R by 0.39 inch. (10,Omm) from all edges of the decal over the Fan
R Cowl Door.
REPAIR N0.12
54-20-01
Page 205
July 1/05
RB211 TRENT
STRUCTURAL REPAIR
MANUAL

11-24-71
1 01-408 FW14846 Black, Hoist Point
2 01-409 FW14847 White, Hoist Point
3 01-418 FW14856 Black text, 6 Shoot Bolt
4 01-419 FW14857 White text, 6 Shoot Bolt
Black text, Start Valve O/R, Thrust

5 01-428
Reverser Safety Switch, ATV Access.
White text, Start Valve O/R, Thrust

6 01-429
Reverser Safety Switch, AIV Access.
7 01-432 FW14870 Black text, IDG Oil Filter
8 01-433 FW14871 White text, IDG Oil Filter
Red and Black text, Warning - Both Rods

9 01-436 FW14874
Must Be Used When Working On Engine
Yellow and White text, Warning - Both Rods

10 01-437
Must Be Used When Working On Engine
Red & Black Text, Warning-Keep Clear Of

11 01-464 FW14902
Hazard Areas While Engine Is Running
Yellow & White Text, Warning-Keep Clear Of

12 01-465 FW14903
Hazard Areas While Engine Is Running

13 01-510 FW32620
Black outline & Imperial Conversion
No - Go Areas Symbol, Yellow nacelle with

14 01-511 FW3 62
White outline and Imperial Conversion

15 01-100 FW12343 background. Width 16.5 in. (419,OOmm) &
Height 25 in. (635,OOmrn).

Height 12 in. (305,OOmm).

REPAIR N0.12
54-20-01
Page 206
July 1/05
Printed i n G r e a t B r i t a i n
H
"" RB211 TRENT
MANUAL
STRUCTURAL REPAIR

01-106 FW12346 background. Width 8.5 in. (216,OOmm) &
Height 12 in. (305,001nm).

01-101 FW12347 background. Width 13.9 in. (352,001ntn) &
Height 20.7 in. (526,OOmm).

01-105 FW12348 background. Width 13.9 in. (352,OOmm) &

01-550 FW33908 Areas While Engine Is Running, Red & Black
text on White background

05551- FW33909 Areas While Engine Is Running, yellow &
White text on grey background.

01502 - FW32457 Engine Is Running, Red & Blue text S/B 11-
E346 Alt FW14902
Warning-Keep Clear Of Hazard.Areas While

01-503 FW33430 Engine Is Running, White text on Black
Background S/B 11-E346 Alt FW14903

Blue outline on White background &
01-512 FW32463
FW32620

01-513 FW32464
FW32620
White text, Warning - Both Rods Must Be

01-542
Used When Working On Engine
Table 1
REPAIR N0.12
54-20-01
Page 207
July 1/05
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
TYPICAL VIEW ON THE FRONT OF THE ENGINE
FIGURE 201
0
0
G
REPAIR N0.12
54-20-01
Page 208
July 1/05
RB211 TRENT
STRUCTURAL REPAIR
m MANUAL
THE LEADING EDGE

OF THE COWL DOOR-
18,19 OR 20 TO THE
INSTRUCTIONS
\THE CENTERLINE OF
THE REAR NOSE
COWL HOIST POINT
APPLY ITEM 11,l2,

23 OR 24 TO THE
INSTRUCTIONS
I -APPLY ITEM 21 OR 22
TO THE INSTRUCTIONS
FIGURE 202
REPAIR N0.12
54-20-01
Page 209
July 1/05
H RB211 TRENT
MANUAL
STRUCTURAL REPAIR
m I/ THE LEADING EDGE

OF THE COWL DOOR
APPLY ITEM 3 OR 4
TO THE INSTRUCTIONS
THE COWL DOOR
CLOSING LINE 7
- --
b
428,OO 16 850
l
388.00 (1 51276)
-1 69100(6.654)
29,oo 5.079
APPLY ITEM 7 OR 8
TO THE INSTRUCTIONS
fIIlI 111111
7
--
APPLY ITEM 9,10 OR 27
TO THE INSTRUCTIONS
THIS IS ON THE INNER SIDE
OF THE COWL DOOR
FIGURE 203
REPAIR N0.12
54-20-01
Page 210
July 1/05
H
"" RB211 TRENT
MANUAL
STRUCTURAL REPAIR
380,OO 14.961
340.00(13.386)
THE LEADING EDGE

OF THE COWL DOOR
APPLY ITEM 1 OR 2 TO
THE INSTRUCTIONS
25 OR 26 TO TH THE CENTERLINE OF
INSTRUCTIONS THE REAR NOSE
COWL HOIST POINT
APPLY ITEM 5 OR 6
TO THE INSTRUCTIONS
FIGURE 204
REPAIR N0.12
54-20-01
Page 211
July 1/05
Printed i n Great Britain
RB211 TRENT
STRUCTUAL REPAIR
m MANUAL
REPAIR NO. 13
PRE SB 71-E107 FAN COWL DOORS (FCD) -
REPAIR (REPLACEMENT) OF THE RFI SEALS (FRS W013)
1. General
CAUTION: YOU MUST REFER TO THE ALLOWABLE/REPAIRABLE DAMAGE LIMITS,

PAGE BLOCK 101, TO MAKE SURE THAT THE REPAIR IS PERMITTED.
A. This procedure gives instructions to repair damage to the RR71-

C663 FCD seal strips (the seals) attached to the bottom edge of
the fan cowl doors (the doors).
- -
.......... . .
B. Repair is by replacement, each of the bottom edg.e seals are
. . ~
available individually. . .
...................................................................................................................
...................................................................................................................
54-20-01 SRM - Allowable Damage
A.Standard equipment
(1) Standard workshop tools and equipment
B. Special tools
' (1) Back facing drill . I.
.. , . ., . .
C.Consumable materials :. . .<..
.... . ,. . ........
. . :...-< . . .. . . . . .
.c,. 5 .F : 7
.....................
............................................................................................<:,
.....
.', .. -
OMat 150 ACETONE

OMat 1/40 ISOPROYL ALCOHOL (Alternative)
OMat 1/257 CLEANING SOLVENT (Alternative)
OMat 2/101 ABSORBENT CLOTH, LINT FREE
OMat 5/53 EMERY POLISHING PAPER GRADE 3/0 GRIT SIZE 800
OMat 8/5C SEALANT
OMat 8/197 ADHESIVE
Page 201
D. Replacement Component Parts
PART NUMBER PART IDENTIFICATION QTY
217-0471-01 RFI Seal Strip (Fig 201 item 1) 1

217-0474-03 RFI Seal Strip (Fig 201/202 item 4) 2
NAS9307M-4-04 Rivet (Fig 201/202 item 8) A/R
NAS9308M-4-09 Rivet (Fig 201/202 item 9) A/R
4. Prepare damaged area for repair (Ref Figs. 201/202)
A. Identify the RFI seals that are damaged and must be replaced.
Make sure the damage is in the limits of this repair scheme.
WARNING: THE DUST AND LOOSE MATERIAL FROM THE COMPOSITE MATERIALS
ARE DANGEROUS:
- DO NOT BREATHE THE DUST
- YOU MUST WEAR PROTECTIVE CLOTHING, GLOVES, A FACE MASK

AND GOGGLES WHEN YOU WORK WITH COMPOSITE MATERIALS
- DO WORK IN AN AREA WITH A GOOD FLOW OF CLEAN AIR.
CAUTION: BE CAREFUL THAT YOU DO NOT CAUSE DAMAGE TO THE DOOR OR

THE RIVET HOLES WHEN YOU REMOVE THE RIVETS. IF DAMAGE
DOES OCCUR OR THE HOLES BECOME OVER SIZE:
- RECORD THE DAMAGE AND GET A REPAIR ASSESSMENT
- GET A SEPARATE REPAIR PROCEDURE.
- YOU MUST REPAIR THE DAMAGE BEFORE YOU CONTINUE WITH

THIS TASK.
B. Carefully remove the rivets that hold the damaged seal to the
door. Use hand/air tools and applicable size drill bits. Do not
make the holes oversize.

54-20-01
Page 202
5. Remove the damaged part (Ref Fig. 201/202)
WARNING: SOLVENTS USED FOR CLEANING ARE DANGEROUS. YOU MUST READ AND
OBEY THE MANUFACTURERS HEALTH AND SAFETY INSTRUCTIONS BEFORE
YOU USE IT.
- YOU MUST WEAR PROTECTIVE CLOTHING, GLOVES, A FACE MASK AND

SAFETY GOGGLES WHEN YOU USE THE SOLVENT
- DO THE WORK IN AN AREA WITH A GOOD FLOW OF CLEAN AIR
- DO NOT GET THE SOLVENT ON YOUR SKIN. IF YOU DO, CLEAN YOUR
SKIN IMEDIATELY WITH SOAP AND WATER OR A SALINE SOLUTION
AND GET MEDICAL AID
- DO NOT GET THE SOLVENT IN YOUR EYES. IF YOU DO, FLUSH YOUR
EYES FOR FIFTEEN MINUTES WITH CLEAN WATER AND GET MEDICAL
AID.
A. Carefully remove the damaged seal with OMat 2/101-clean lint-free

cloth moistened with OMat 150-Acetone or OMat 1/40-Isopropyl
Alcohol or OMat 1/257-Cleaning Sovent and a plastic spatula. Make
sure you do not damage the door.
B. Clean the reapir area to remove the unwanted sealant from the
mating surfaces of the door.
(1) Make a clean, dry, lint free cloth (OMat 2/101) moist with
the degreasing fluid.
a) Use this cloth to clean the area that you repair.
b) You must discard this dirty cloth.
c) Use a clean cloth each time you clean a new area that you
repair.
d) Contamination of the bulk liquid is not permitted.
e) Do not let the liquid touch the cloth and return to bulk
liquid container.
C. Use a clean lint-free cloth to remove the OMat 150-Acetone or,

OMat 1/40-Isopropyl Alcohol or OMat 1/257-Cleaning Solvent from
the door before it dries.
D. Do a visual inspection of the repair area. Make sure there is no

damage to the mating surfaces of the door.

54-20-01
Page 203
6. Prepare the replacement seals (Ref Fig 201/202)
A. Prepare the replacement seal (Refer to note 1 on Fig 201 and 202):
(1) Get the correct replacement seal part.
(2) Position the seal on the door and hold lightly with clamps or
pins. Take care not to damage the door with the clamps.
(3) Make sure the holes in the seal align with the holes in the
door.
(4) Cut the seal to give the correct clearances (see note 1 on
Figs 201 and 202).
(5) Remove the seal from the door.
B. Prepare the door (Ref Figs 201 and 202)
(1) Carefully push the old rivet tails that remain in the door
back through their holes into the honeycomb.
(2) Push the rivet tails sufficiently far into the honeycomb to
permit installation of the new rivets. Make sure the rivet
tails are clear of the holes to prevent possible
interference.
WARNING: YOU MUST NOT GET THE ADHESIVE ON YOUR SKIN, IN YOUR
EYES OR IN YOUR MOUTH. YOU MUST NOT BREATHE THE
ADHESIVE FUMES. THE ADHESIVE IS CORROSIVE AND CAN
CAUSE DAMAGE TO YOUR BODY TISSUE. YOU MUST READ AND
OBEY THE MANUFACTURERS HEALTH AND SAFETY INSTRUCTIONS
BEFORE YOU USE IT.
PUT ON PROTECTIVE CLOTHING AND GLOVES, A FACE MASK AND

SAFETY GOGGLES
IF YOU GET ADHESIVE IN YOUR EYES, FLUSH IMMEDIATELY

WITH CLEAN WATER FOR A MINIMUM OF 15 MINUTES. GET
MEDICAL AID IMMEDIATELY
DO THE WORK IN AN AREA WITH A GOOD FLOW OF CLEAN AIR.
(3) Follow the manufacturer's instructions to mix a sufficient

quantity of the adhesive (OMat 8/197) to bond the rivet tails
safely in the honeycomb.

54-20-01
Page 204
(4) Use a syringe to put sufficient of the adhesive in each hole
to bond the rivet tails in the honeycomb. Do not overfill the
holes, the adhesive and rivet tails together can cause
interference with the new rivets during installation.
(5) Where the rivet tails cause interference during installation

of the new rivets, proceed as follows:
(a) Use a Back Facing Drill to carefully remove the

material causing the interference and an additional
small area of the honeycomb. Make sure that you do not
damage the door skin or make the rivet holes larger.
(b) Do Steps B. (3) thru (4) again as necessary.
(6) Deburr the rivet holes in the door.
(7) Make sure the rivet holes are clean and free from unwanted
material.
7. Install the new seals (Ref Fig. 201 and 202)
WARNING: SOLVENT IS CLASSIFIED AS A HAZARDOUS MATERIAL THAT

CAN CAUSE INJURY OR ILLNESS IF NOT USED CORRECTLY.
BEFORE YOU USE THIS PRODUCT, CAREFULLY READ THE
APPLICABLE MATERIAL SAFETY DATA SHEET AND OBEY ALL
THE SPECIFIED HEALTH AND SAFETY PRECAUTIONS.
A. Clean the mating surfaces of the seal and door.
repair.
liquid container.
B. Use a clean lint-free cloth to remove the OMat 150-Acetone or

OMat 1/40-Isopropyl Alcohol or OMat 1/257-Cleaning Sovent from
the components before it dries.

54-20-01
Page 205
C. Apply a thin layer of sealant to the mating surfaces of the
replacement seal and door.
NOTE: Refer to the manufacturer's instructions on the use of

sealant (OMat 8/5C).
D. Put the replacement seal in the correct position on the door and
hold it in position with clamps or pins. Do not tighten the
clamps too tightly, this will prevent possible damage to the door
or to the seal.
E. Attach the seals to the door with the rivets (Item 8) (Ref No
NAS9307M-4-04) left door only and Item 9 (Ref No NAS9308M-4-09)
left and right doors). Use sealant on the rivet tails to make
them secure in the honeycomb structure.
F. Make a smooth fillet of sealant around the edge of the seal.
G. Let the sealant cure completely. Refer to the manufacturer’s

instructions for the correct data.
8. Visual Inspection
A. Do a visual inspection of the repair to make sure it is done

correctly.
A. Record details of the repair No FRSW013. Make a permanent record

on the Mod Plate of the door with an electrical vibro-etching
tool.

54-20-01
Page 206
Left Hand Door - Bottom edge RFI seals replacement
Figure 201

54-20-01
Page 207
Right Hand Door - Bottom edge RFI seal replacement
Figure 202

54-20-01
Page 208
H RB211 TRENT
STRUCTUAL REPAIR
MANUAL
' ": ,-':
R E P A I R NO. 15
P R E S B 7 1 - E 1 0 7 FAN COWL DOORS
R E P A I R O F WEAR T O FCD LEADING EDGE
1. General
CAUTION: YOU MUST R E F E R T O THE ALLOWABLE/REPAIRABLE DAMAGE R E P A I R

L I M I T S I N PAGEBLOCK 1 0 1 , T O MAKE S U R E THAT THE R E P A I R I S
PERMITTED.
A. T h i s procedure g i v e s i n s t r u c t i o n s t o repair w e a r t o t h e Fan

C o w l D o o r ( t h e d o o r ) and restore t h e aerodynamic contour of t h e
l e a d i n g edge of t h e door. . ..
.
. ,. ,. .,,..
, ( .i
,
B. T h e r e i s no l i m i t t o t h e l e n g t h of each repair 'o=' number of

repairs t h a t can be done. T h e d a m a g e i n each area f o r repair
m u s t be i n t h e c o n d i t i o n s t h a t f o l l o w .
(1) D a m a g e on t h e o u t e r surface of t h e door o n l y . W h e r e t h e

depth of t h e d a m a g e does n o t exceed m o r e than half t h e
thickness of t h e m o n o l i t h i c leading edge s t r u c t u r e .
(2) D a m a g e does n o t extend m o r e than 1 2 , 7 mm ( 0 . 5 0 i n . )

r e a r w a r d f r o m t h e l e a d i n g edge w i t h i n t h e area w h e r e t h e
carbon p l i e s are exposed.
(3) If there i s d e l a m i n a t i o n of t h e f o r w a r d edge of t h e door,

i n t h e area of w e a r , and t h e d a m a g e i s w i t h i n l i m i t s . Do
t h e d e l a m i n a t i o n repair f i r s t i n accordance w i t h FRS W 0 0 2
R e p a i r No. 2.
is[.:. -
(4) W h e n the conductive surface m e s h i s d a m a g e d . o r , a f t e r door

repair, repair o r replace t h e m e s h i n accordance w i t h F R S
WO10 SRM R e p a i r N o . 1 0 . ., .
2. R e £ erenced I n f o r m a t i o n
.......................................................................
.......................................................................
SRM - Standard P a i n t i n g Procedure
SRM - A l l o w a b l e D a m a g e
3. E q u i p m e n t and M a t e r i a l s
A Standard E q u i p m e n t :
Standard w o r k s h o p t o o l s and e q u i p m e n t
. . ..*
.!,. -
REPAIR N 0 . 1 5
. ,. .L
.
Page 2 0 1
Printed in Great Britain Jun. 1 0 / 0 7
------------------------------------------------------------------
OMat 150 ACETONE

OMat 1/40 ISOPROPYL ALCOHOL (ALTERNATIVE)
OMat 1/257 CLEANING SOLVENT (ALTERNATIVE)
OMat 2/101 ABSORBENT CLOTH, LINT-FREE
OMat 5/39 WATERPROOF SILICON CARBIDE PAPER –
GRIT SIZE 120
OMat 5/97 GARNET PAPER – GRIT SIZE 80
OMat 8/52 EA934 EPOXY ADHESIVE
4. Identify the Damaged Area for Repair (Ref. Fig.201)
A. Visually inspect the leadingedge for damage and identify each

damaged area. Make sure that the damage is in the limits to
be repaired.
WARNING: SOLVENTS USED FOR CLEANING ARE DANGEROUS. YOU MUST

READ AND OBEY THE MANUFACTURER’S HEALTH AND SAFETY
INSTRUCTIONS BEFORE YOU USE THE SOLVENT.
- DO NOT PUT THE SOLVENT IN YOUR MOUTH

- DO NOT BREATHE THE FUMES
AND SAFETY GOGGLES WHEN YOU USE THE SOLVENT
- DO THE WORK IN AN AREA WITH A GOOD FLOW OF CLEAN AIR
- DO NOT GET THE SOLVENT ON YOUR SKIN. IF YOU DO, CLEAN
YOUR SKIN IMMEDIATELY WITH SOAP AND WATER OR A SALINE
SOLUTION AND GET MEDICAL AID
- DO NOT GET THE SOLVENT IN YOUR EYES. IF YOU DO, FLUSH
YOUR EYES FOR FIFTEEN MINUTES WITH CLEAN WATER AND GET
MAEDICAL AID.
B. Fully clean all of the damaged area. Use a clean, lint-free

cloth (OMat 2/101) moist with ACETONE (OMat 150), or
alternative cleaning solvent. Dry the area with a clean, lint-
free cloth before the solvent dries.
5 Prepare the Damaged Area for Repair (Ref. Fig.202).
A. Measure and mark the area:
(1) Use a soft pencil (OMat 261) to carefully mark a line on

the outer surface of the door to identify the maximum
limit of the damage from the leading edge of the door.
REPAIR NO.15
EFFECTIVITY: TRENT
54-20-01
Page 202
(2) Apply TEFLON TAPE (OMat 2/30) around the repair area.
(3) Attach a dam of TEFLON TAPE (OMat 2/30) to the leading

edge of the repair area.
WARNING: THE DUST AND LOOSE MATERIAL FROM THE COMPOSITE

MATERIALS ARE DANGERIOUS.
- DO NOT PUT THE LOOSE MATERIALS IN YOUR MOUTH.
- DO NOT BREATHE THE DUST
AND GOGGLES WHEN YOU WORK WITH COMPOSITE MATERIALS
- DO THE WORK IN AN AREA WITH A GOOD FLOW OF CLEAN AIR.
CAUTION. TAKE CARE NOT TO CAUSE DAMAGE TO THE EXPOSED CARBON

PLIES.
B Carefully abrade the area of wear to remove any loose material.

Use a sanding disc or hand tool with GARNET PAPER (OMat 5/97).
C. Lightly abrade the area between the Teflon and the area of
damage to remove the surface finish.
(1) Clean the repair area. Use a LINT-FREE CLOTH (OMat

2/101) moist with ACETONE (OMat 150) or alternative
solvent. Dry the the area with a clean, lint-free
cloth before the solvent dries.
(2) Use a heat lamp to fully dry the repair area at 60

degrees C. for 2 hours.
(3) Let the area cool to room temperature before you

continue the repair
REPAIR NO.15
EFFECTIVITY: TRENT
54-20-01
Page 203
6. Prepare the Repair Material and Apply to the Leading Edge (Ref.
Fig.203)
WARNING: YOU MUST NOT GET THE ADHESIVE ON YOUR SKIN, IN YOUR
EYES OR IN YOUR MOUTH. YOU MUST NOT BREATHE THE
ADHESIVE FUMES. THE ADHESIVE IS CORROSIVE AND CAN CAUSE
DAMAGE TO YOUR BODY TISSUE. YOU MUST READ AND OBEY THE
MANUFACTURER’S HEALTH AND SAFETY INSTRUCTIONS BEFORE
YOU USE IT.
- PUT ON PROTECTIVE CLOTHING AND GLOVES, A FACE MASK AND

SAFETY GOGGLES
- IF YOUR CLOTHING BECOMES CONTAMINATED, REMOVE IT

IMMEDIATELY. OBEY THE LOCAL SAFETY REGULATIONS FOR
CLOTHING DISPOSAL
- IF YOU GET ADHESIVE IN YOUR MOUTH, DRINK PLENTY OF CLEAN

WATER AND GET MEDICAL AID IMMEDIATELY
- IF YOU GET ADHESIVE IN YOUR EYES, FLUSH IMMEDIATELY WITH

CLEAN WATER FOR A MINIMUM OF 15 MINUTES. GET MEDICAL
AID IMMEDIATELY.
- IF YOU GET ADHESIVE ON YOUR SKIN, REMOVE IT IMMEDIATELY

WITH SOAP AND WATER OR A SALINE SOLUTION. GET MEDICAL
AID IMMEDIATELY.
- DO THE WORK IN AN AREA WITH A GOOD FLOW OF AIR. IF YOU

BREATHE THE FUMES, GO OUT IN THE FRESH AIR IMMEDIATELY.
GET MEDICAL AID IF THROAT IRRITATION OR CHEST
DISCOMFORT CONTINUES.
A. Refer to the manufacturer’s instructions for the use of the

adhesive (OMat 8/52) and proceed as follows:
(1) Mix a sufficient quantity of adhesive to do the repair.
(2) Use a spatula to apply the adhesive to the area of the

repair.
(3) Apply sufficient adhesive to the area to restore the

original profile.
(4) Allow the adhesive to cure fully.
REPAIR NO.15
EFFECTIVITY: TRENT
54-20-01
Page 204
7. Restore the Repair to the Finished Profile (Ref. Fig.204)
A. Use a sanding or hand tool and 120 WATERPROOF SILICON CARBIDE

PAPER (OMat 5/39) to trim the repair to the door profile.
NOTE: You must take care to make sure that the repair area
matches both the forward edge and the profile around
the front edge of the door on the outer surface. This
will prevent an in-to-wind step and/or a reduction in
the gap between the FCD and the adjacent structure of
the nacelle.
B. Carefully smooth the surface of the repair area to remove all

irregular defects.
NOTE: Irregular defects such as bubble holes or pin holes

must be repaired. Use a fresh mix of adhesive.
C. Chamfer the repair of the leading edge at 45 degrees to a depth

of not more than one-half the thickness of the outer skin of
the leading edge.
(1) Remove the Teflon tape.
8. Inspection of Repair
A. Do a visual inspection and a Tap Test to make sure the repair

is done correctly.
9. Restore the Surface Finish
A. Restore the surface finish (Ref. SRM 54-02-04)
A. Record details of repair FRS W015. Vibro-etch the repair

number on the door mod plate.
REPAIR NO.15
EFFECTIVITY: TRENT
54-20-01
Page 205
Leading Edge Wear – Dimensions of Repair Area Limits
Figure 201
REPAIR NO.15
EFFECTIVITY: TRENT
54-20-01
Page 206
Leading Edge Wear – Prepatation for Repair
Figure 202
REPAIR NO.15
EFFECTIVITY: TRENT
54-20-01
Page 207
Leading Edge Wear – Fill Area of Repair
Figure 203
REPAIR NO.15
EFFECTIVITY: TRENT
54-20-01
Page 208
Leading Edge Wear – Chamfer and Trim Finish of Repair
Figure 204
REPAIR NO.15
EFFECTIVITY: TRENT
54-20-01
Page 209
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
R E P A I R NO. 1 6
PRE S B 7 1 - E 1 0 7 FAN COWL DOORS
METAL PATCH R E P A I R O F DAMAGE I N THE HONEYCOMB SANDWICH
1. General
A. T h i s procedure i s used t o repair d a m a g e w i t h a m a x i m u m d i a m e t e r

of 5 0 . 8 mm ( 2 . 0 i n . ) i n t h e honeycomb s a n d w i c h .
3. .
B. T h i s repair i s only f o r d a m a g e d areas w i t h a m i q i , n u m t ' c l e a r a n c e
of 1 2 . 7 mm ( 0 . 5 i n . ) b e t w e e n t h e i n n e r s k i n a n d , ,:the engine
assembly.
C. T h i s repair i s f o r d a m a g e t o t h e t w o sides of t h e Fan C o w l

D o o r ( t h e d o o r ) and f o r through d a m a g e .
D. D a m a g e t h a t i s n o t i n the l i m i t s of t h i s repair m u s t be
referred t o R o l l s - R o y c e p l c .
2. Reference Information
.......................................................................
F R S W 0 1 6 , T r e n t E n g i n e Manual
R e p a i r P a i n t Finish
3. E q u i p m e n t and Materials
A. Standard E q u i p m e n t . .
D i s p o s a b l e syringe
Spatula
G l o v e s , neoprene o r p o l y v i n y l c h l o r i d e
H e a t l a m p , s u f f i c i e n t t o give 7 7 . 0 deg F ( 2 5 . 0 deg C)
Suction cleaner.
,.
.,
,..i.i:.~ ' ',
.."" ,;. ."
- ,.: q 2 . I ~
- . ".. ,
.p'
E F F E C T I V I T Y : TRENT r. .-:.b.,
.?.&S..
, " R E P A I R NO. 1 6
,.54-20-01
P a g e 201
Printed in Great Britain Jun 1 0 / 0 7
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
----.-------------------
- - - - - - . . . - - - - -~
--~-~
--~-~
-....-
. ~ ~ ~ ~ ~ ~ ~ ~ . . . . ~ ~ . ~ ~ ~ ~ ~ ~ ~ . . - ~ ~ ~ ~ ~ ~ ~ . - - - . - - - - - ~
OMat 262C TEMPORARY MARKER
OMat 1/119 ISOPROPANOL (PROPAN-2-OL)
OMat 5/35 WATERPROOF SILICONE CARBIDE ABRASIVE
PAPER (Grit Size 120)
OMat 8/52 ADHESIVE/FILLER EA934NA
C. Repair Parts
.....................................................................................

Local Manufacture Titanium Repair Patch (MIL-T-9046)
HST10-5-22 High Shear Fastener
HST79 Collar
217-1366-01 Fan Cowl Door Assembly, RH
217-0466-01 Fan Cowl Door Assembly, LH
4. Make the Repair Patches (Ref Figure 201).
A. Make two repair patches (the patches) from 0.50 nun (0.02 in.)
thick titanium sheet. Drill the holes in one patch only at this
step.
B. De-burr the holes and the edges of the patches.
5. Prepare the Damaged Area (Ref Figure 202) .

the limits of the repair scheme as given in para l.A and 1.B.
B. Mark out the defined area of damage with the OMat 262C
TEMPORARY MARKER.
C. Apply OMat 2/30 TEFLON TAPE around the damaged area (the area)
to protect adjacent areas with no damage.
WARNING: USE PROTECTIVE CLOTHING, GLOVES, MASK AND SAFETY GOGGLES.

WHEN COMPOSITE MATERIALS ARE CUT OR SANDED, DUST AND
LOOSE PARTICLES ARE PRODUCED WHICH ARE POTENTIAL HEALTH
HAZARDS. DO NOT BREATHE THE DUST.
EFFECTIVITY : TRENT REPAIR NO. 16

54-20-01
Page 202
Printed In Great Britain July 1/01
RB211 TRENT
STRUCTUAL REPAIR
m MANUAL
D. Carefully remove the damage from the area. Use a suction

cleaner and make sure all loose honeycomb core and dust is
removed.
E. Trim out the area to a smooth circular shape with OMat 5/35
WATERPROOF SILICONE CARBIDE ABRASIVE PAPER.
F. Put the drilled patch in position on the damaged area so that

the damage is in the center of the patch. Attach the patch to
the door with clamps if possible.
G. Use the centers of the holes in the patch as a template. Drill

3.2 mm (0.125 in) dia holes through the outer skin. Make sure
you drill at right angles to the door surface.
NOTE: Drill into the honeycomb core but do not drill through the
opposite skin at this step. This is to get access to put
the adhesive/filler into the core to give support when you
drill through the door.
H. Make marks on the patch and the door so that you can put it
back in the same position. Use the OMat 262C TEMPORARY MARKER.
Remove the patch from the door.
I. Remove all debris from the repair area.
WARNING: ISOPROPANOL IS CLASSIFIED AS A HAZARDOUS MATERIAL THAT CAN

CAUSE INJURY OR ILLNESS IF NOT CORRECTLY USED. ISOPROPANOL
MUST BE USED ONLY IN ACCORDANCE WITH THE MANUFACTURER'S
RECOMMENDATIONS.BEFORE YOU USE ISOPROPANOL,CAREFULLY READ
THE APPLICABLE MATERIAL SAFETY DATA SHEET AND OBEY ALL THE
J. Clean the repair area with OMat 2/101 LINT-FREE CLOTH moist
with the OMat 1/119 ISOPROPANOL. Dry the area with a clean
lint-free cloth before the solvent evaporates.
6. Repair the Damaged Area (Ref Figure 202)
WARNING: EA934NA ADHESIVE/FILLER IS CLASSIFIED AS A HAZARDOUS

CORRECTLY USED. BEFORE YOU USE EA934NA ADHESIVE/FILLER,
CAREFULLY READ THE APPLICABLE MATERIAL SAFETY DATA SHEET
AND OBEY ALL THE SPECIFIED HEALTH AND SAFETY PRECAUTIONS
A. Obey the manufacturer's instructions. Mix a quantity of the

OMat 8/52 ADHESIVE/FILLER sufficient to more than fill the
damage area and the holes you drilled in step 5.

54-20-01
Page 203
RB211 TRENT
STRUCTUAL REPAIR
m MANUAL
B. Use a spatula and fill the damage area with the mixture until
it is more than flush with the surface. Make sure the mixture
is free from air.
C. Fill a syringe with the mixture.
D. Use the syringe and fill each of the drilled holes with the
mixture, until it is more than flush with the surface. Make
sure you use sufficient pressure to fill the honeycomb core
adjacent to each hole.

RECOMMENDATIONS.BEFORE YOU USE ISOPROPANOL,CAREEWLLY READ
E. Clean the area with OMat 2/101 LINT-FREE CLOTH moist with
OMat 1/119 ISOPROPANOL. Dry the area with a clean lint-free
cloth before the solvent evaporates. Make sure all the unwanted
mixture is removed.
F. Use a heat lamp and cure the mixture for a minimum of 8 hours
at 77 deg F (25 deg C). Make sure the mixture is fully cured.
WARNING: USE PROTECTIVE CLOTHING, GLOVES, MASK AND SAFETY GOGGLES.

WHEN COMPOSITE MATERIALS ARE CUT OR SANDED, DUST AND
G. Use OMat 5/35 WATERPROOF SILICON CARBIDE ABRASIVE PAPER and

abrade the mixture flush with the door surface. Use a suction
cleaner to remove the dust.

RECOMMENDATIONS.BEF0RE YOU USE ISOPROPANOL,CAREFULLY READ
H. Clean the area with OMat 2/101 LINT-FREE CLOTH moist with
OMat 1/119 ISOPROPANOL. Dry the area with a clean lint-free
cloth before the solvent evaporates.
REPAIR NO. 16
54-20-01
Page 204
R8211 TRENT
STRUCTUAL REPAIR
MANUAL
7. Install the R e p a i r P a t c h e s . (Figure 202)
A. Put t h e d r i l l e d patch i n p o s i t i o n on t h e repair area. U s e t h e

alignment marks you m a d e i n s t e p 5 . H . M a k e s u r e t h e h o l e s i n
t h e patch a l i g n w i t h t h e h o l e s i n t h e door f i l l e d w i t h t h e
mixture. Attach t h e patch t o t h e door w i t h c l a m p s i f p o s s i b l e .
B. P u t t h e second ( u n d r i l l e d ) patch on t h e opposite side of the

d o o r , aligned w i t h t h e d r i l l e d patch. A t t a c h t h e patch t o t h e
door w i t h c l a m p s i f possible.
C. U s e t h e d r i l l e d patch as a t e m p l a t e . D r i l l holes 4 . 1 6 6 t o 4 . 2 4 2
mm ( 0 . 1 6 4 t o 0 . 1 6 7 i n ) d i a m e t e r through t h e door and t h e o t h e r
patch. M a k e s u r e you d r i l l t h e holes a t r i g h t angles t o t h e
door, and t h a t t h e holes go through t h e filler m i x t u r e .
D. R e m o v e t h e t w o patches f r o m t h e door.
E. De-burr t h e h o l e s i n t h e patches and t h e door surfaces.
F. R e m o v e a l l debris f r o m t h e repair area.
WARNING: ISOPROPANOL I S CLASSIFIED AS A HAZARDOUS MATERIAL THAT CAN

CAUSE INJURY OR ILLNESS I F NOT CORRECTLY USED. ISOPROPANOL
MUST BE USED ONLY I N ACCORDANCE WITH THE MANUFACTURER'S
RECOMMENDATIONS.BEFORE YOU USE ISOPROPANOL,CAREFULLY READ
S P E C I F I E D HEALTH AND SAFETY PRECAUTIONS.
G. C l e a n t h e area w i t h O M a t 2 / 1 0 1 LINT-FREE CLOTH m o i s t w i t h the

O M a t 1 / 1 1 9 ISOPROPANOL. D r y t h e area w i t h a clean l i n t - f r e e
c l o t h before the s o l v e n t evaporates.
H. I n s t a l l t h e t w o repair patches, one on each side of t h e door,

w i t h t h e HI-SHEAR FASTENERS ( H S T 1 0 - 5 - 2 2 ) and t h e COLLARS
( H S T 7 9 ) . M a k e s u r e t h e heads of t h e fasteners are on t h e o u t e r
surface. T i g h t e n each c o l l a r u n t i l i t s shear-neck breaks.
I. Do an v i s u a l i n s p e c t i o n of t h e repair area. M a k e s u r e t h a t t h e
repair has been done i n accordance w i t h these procedures.
J. A p p l y surface p r o t e c t i o n t o t h e r e p a i r area (SRM 5 4 - 0 2 - 0 4 ,

Repair Paint Finish) .
K. W r i t e "FRS W016" adjacent t o t h e Fan C o w l D o o r p a r t n u m b e r .
EFFECTIVITY : TRENT REPAIR NO. 1 6
54-20-01
Page 205
P r i n t e d i n Great B r i t a i n July 1 / 0 1
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
172,O mm
- (6.77 in)
4,O mm dia
(0.16 in)
Typical
++
Note:
The minimum number of
++ ++
holes over the dimension
172,O mm is nineteen (19)
with the corner fasteners
counted twice
++ (6.77 in)
++
I
16,O mm
(0.63in)
Typical Note:
Make two patches from
0,5 mm (0.02 in.)thick
Titanium Sheet
(MIL-T-9046)
Titanium Patch
Figure 201
REPAIR N0.16
54-20-01
Page 206
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
e damage and trim out

to a smooth circular shape
Use patch as a template

Drill hole through centers
t
OUTBOARD
REPAIR PATCH COLLAR

(HST 79)
Typical Patch Repair

Figure 202
54-20-01
Page 207
[ RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR N0.17 (FRSW033)
REPAIR (REPLACEMENT) OF THE ACCESS PANEL HINGES AND LATCHES
1. General
CAUTION: YOU MUST REFER TO THE ALLOWABLE/REPAIRABLE DAMAGE

LIMITS, PAGE BLOCK 101, TO MAKE SURE THAT THE REPAIR IS
PERMITTED.
A. This repair scheme is written for Left and Right Pre SB71-
E107 Fan Cowl Doors. This procedure gives instructions to
remove and replace the Hinges and Latches that attach the
Access Panels on the left hand and right hand pre SB71 -
E107 Fan Cowl Doors.
B. Repair is by replacement, each of the hinges and latches are

available individually.
54-20-01 SRM - Allowable Damage

54-02-10 SRM - Fasteners - Installation and Removal
70-20-01-100-802 AMM - Cleaning
54-02-04 SRM - Restore Paint Finish
B. Special tools
Drills and drilling equipment

Plastic spatula
Suction cleaner
Vibro-etching tool
REPAIR N0.17
54-20-01
Page 201
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
C. Consumablematerials
OMat 150 ACETONE

OMat 1/40 ISOPROPYL ALCOHOL (Alternative)
OMat 1/257 CLEANING SOLVENT (A1ternative)
OMat 8/5C PR1422A-4 TWO-PART BRUSHABLE POLYSULPHIDE
SEALANT

----------------------------------<---------------------------------------------------------------------------.


PROTECT YOU AGAINST DUST AND LOOSE PARTICLES WHICH CAN
BE DANGEROUS TO YOUR HEALTH.
WARNING: WHEN YOU USE CLEANING MATERIALS, COATINGS, ADHESIVES

AND SEALANT REFER TO THE MANUFACTURER'S CONTROL AND
E. Replacement Component Parts

..............................................................................................................
..............................................................................................................
217-0366-01 Hinge, Double Piano (Figs. 203, 205 &
206)
. . 217-0369-01
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hinge,
. . . . . . . . . . . . . Swan
. . . . . . . . . .Neck
. . . . . . . . . .(Fig
. . . . . . . . .204)
................................... AR
. .217-0369-02
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hinge,
. . . . . . . . . . . . . Swan
. . . . . . . . . .Neck
. . . . . . . . . .(Fig
. . . . . . . . . 204)
................................... AR
217-0368-01 Latch Assembly Button (Figs. 203, 205 & AR
206)
..............................................................................................................
. .217-0367-01
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Latch
. . . . . . . . . . .Assembly
. . . . . . . . . . . . . . . . . . (Fig
. . . . . . . . . 204)
....................................... AR
. .NAS9307M4-01
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rivet,
. . . . . . . . . . . . . Blind,
. . . . . . . . . . . . . .Protruding
. . . . . . . . . . . . . . . . . . . . .Hd.
. . . . . . . . (Fig
. . . . . . . . . .205)
........... AR
NAS9308M4-03 Rivet (Figs. 203, 205 & 206) AR
NAS9308M4-04 Rivet (Figs. 203, 204, 205 & 206) AR
REPAIR N0.17
54-20-01
Page 202
M
GEE33@
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
4. Remove the Damaged Part (Ref. Figs. 201 to 206)
A. Identify the Access Panel Hinges and/or Latches that are

damaged and must be replaced.
B. If the IDG Access Panel is found damaged then remove it.

Open the IDG Access Panel on the Left Hand Fan Cowl Door.
Remove the four nuts (3), the four washers (4) and the four
countersunk bolts (5) from the hinge (2) that attach the
access panel (1) to the Fan Cowl Door. Retain the bolts,
washers and nuts for the installation. Ref. Fig. 203.
C. If the Starter Access Panel is found damaged then remove it.

Open the Starter Access Panel on the Left Hand Fan Cowl
Door. Remove the three nuts (61, the three washers (5) and
the three countersunk bolts ( 4 ) from each of the two swan
neck hinges (2 & 3) that attach the access panel (1) to the
Fan Cowl Door. Retain the bolts, washers and nuts for the
installation. Ref. Fig. 204.
D. If the Oil Tank Access Panel is found damaged then remove

it.
Open the Oil Tank Access Panel on the Right Hand Fan Cowl
Door. Remove the four nuts ( 3 ) , the four washers (4) and the
four countersunk bolts ( 5 ) from each of the two hinges (2)
that attach the access panel (1) to the Fan Cowl Door.
Retain the bolts, washers and nuts for the installation.
Using hand/air tool and applicable size drill bit carefully
remove the blind rivet (10) that attaches the lanyard (9) to
the Fan Cowl Door. Refer to SRM TASK 54-02-10, Fasteners -
Installation and Removal. Ref. Fig. 205.
N0TE:Do not enlarge the hole when removing the rivet.
E. If the Hydraulic Filter/ MCD Access Panel is found damaged

then remove it.
Open the Hydraulic Filter/MCD Access Panel on the Right Hand
Fan Cowl Door. Remove the four nuts (3), the four washers
(4) and the four countersunk bolts (5) from each of the two
hinges (2) that attach the access panel (1) to the Fan Cowl
Door. Retain the bolts, washers and nuts for the
installation. Ref. Fig. 206.

DOES OCCUR OR THE HOLES BECOME OVER SIZE THEN CONTACT:-
GKN Aerospace Services, R & 0 Facility, Osborne Works,
Whippingham Road, East Cowes, Isle of Wight, England,
United Kingdom, P032 6LR.
REPAIR N0.17
54-20-01
Page 203
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
F. Remove the damaged hinges from the access panels. Carefully

drill out the rivets (7) that hold the damaged hinge to the
access panel. Use hand/air tools and applicable size drill
bits. Refer to SRM TASK 54-02-10, Fasteners - Installation
and Removal.
G. Remove and discard the hinge.
H. Remove the damaged latches from the access panels. Carefully

drill out the rivets that hold the damaged latch to the
access panel. Use hand/air tools and applicable size drill
bits. Refer to SRM TASK 54-02-10, Fasteners - Installation
and Removal.
I. Remove and discard the latch.
5. Prepare the Repair Area for the Replacement Hinge/~atch.
A. Remove dust and debris from the repair area using a suction
cleaner.

area with a LINT-FREE CLOTH (OMat 2/101) moistened with
ACETONE (OMat 150) or ISOPROPYL ALCOHOL (OMat 1/40) or
CLEANING SOLVENT (OMat 1/257) and a plastic spatula. Remove
any unwanted sealant from the mating surfaces of the door
and the access panel. Make sure you do not damage the door
or the access panel. Dry the area with a clean, lint-free
cloth before the fluid dries.
C. Do a visual inspection of the repair area. Make sure there

is no damage to the mating surfaces of the door or the
access panel.
6. Install the Replacement Hinges (Ref. Fig. 201 to 206)
A. Install the 217-0366-01 Double Piano Hinge (2) on the IDG

Access Panel, Oil Tank Access Panel, Hydraulic Filter/MCD
Access Panel. Ref Figs. 203, 205 & 206.
(1) Wet assemble the hinge using PR1422A-4 TWO-PART

BRUSHABLE POLYSULPHIDE SEALANT (OMat 8/5C). Mix PR1422A-
4 TWO-PART BRUSHABLE POLYSULPHIDE SEALANT (OMat 8/5C) in
accordance with the manufacturers' instructions. Apply a
thin layer of PR1422A-4 SEALANT (OMat 8/5C) to the
mating surfaces of the replacement hinge and the access
panel.
NOTE: Sealant thickness to be no more than 0.76mm

(0.030 in.).
REPAIR N0.17
54-20-01
Page 204
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
(2) Position and temporarily attach the replacement hinge on

the access panel using skin clips or slave bolts.
(3) Install 2 off NAS9308M4-04 rivets (7) at the two inner

positions of the hinge (2) to secure the hinge to the
panel (l). Refer to SRM TASK 54-02-10, Fasteners -
(4) Install 2 off NAS9308M4-03 rivets (6) at the two outer

B. Install the 2 1 7 - 0 3 6 9 - 0 1 S w a n N e c k H i n g e (2) or 217-0369-02

Swan Neck Hinge (3) on the Starter Access Panel. Ref. Fig.
204.
(1) Wet assemble the hinge using PR1422A-4 TWO-PART

accordance with the manufacturers* instructions. Apply a
panel.
NOTE: Sealant thickness to be no more than 0.761nm

(0.030 in.) .
(2) Position and temporarily attach the replacement hinge on
(3) Install 4 off NAS9308M-4-04 rivets (7) at the four

positions on the hinge (2) or (3) to secure the hinge to
the panel (l). Refer to SRM TASK 54-02-10, Fasteners -
C. Remove excess PR1422A-4 POLYSULPHIDE SEALANT (OMat 8/5C)

from the installed hinge before it cures. Use a LINT-FREE
CLOTH (OMat 2/101) moistened with ACETONE (OMat 150) or
ISOPROPYL ALCOHOL (OMat 1/40) or CLEANING SOLVENT (OMat
1/257) .
7. Install the Replacement Latches (Ref. Figs. 201 to 206)
A. Install the 217-0368-01 Latch Assembly Button (8) on the IDG

Access Panel, Oil Tank Access Panel or the Hydraulic
Filter/MCD Access Panel. Ref. Figs. 203, 205 & 206.
REPAIR NO. 17
54-20-01
Page 205
RB.211 TRENT
STRUCTURAL REPAIR
@ MANUAL
(1) Wet assemble the latch using PR1422A-4 TWO-PART

mating surfaces of the replacement latch and the access
panel.

(0.030 in.).
(2) Position and temporarily attach the replacement latch on

(3) Install 4 off NAS9308M4-04 rivets (7) at the four

positions on the latch (8) to secure the latch to the
B. Install the 217-0367-01 Latch Assembly (8) on the Starter

Access Panel. Ref. Fig.204.
(1) Wet assemble the latch using PR1422A-4 TWO-PART

panel.

(0.030 in.).
(2) Position and temporarily attach the replacement latch on

(3) Install 4 off NAS9308M4-04 rivets (7) at the four

positions on the latch ( 8 ) to secure the latch to the
panel (1). Refer to SRM TASK 54-02-10, Fasteners -
C. Remove any excess PR1422A-4 BRUSHABLE POLYSULPHIDE SEALANT

(OMat 8/5C) from the installed latch before it cures. Use a
LINT-FREE CLOTH (OMat 2/101) moistened with ACETONE (OMat
150) or ISOPROPYL ALCOHOL (OMat 1/40) or CLEANING SOLVENT
(OMat 1/257) .
REPAIR N0.17
54-20-01
Page 206
RB.211 TRENT
STRUCTURAL REPAIR
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8. Install the Access Panels on the Fan Cowl Doors (Ref. Figs. 201 to
206)
A. Install the IDG Access Panel, Oil Tank Access Panel,

Hydraulic Filter/MCD Access Panel (as required) on the Fan
Cowl Doors. Ref. Fig. 203, 205 & 206.
(1) Wet assemble the Access Panel Hinge(s) (2) to the Fan
Cowl Door using PR1422A-4 TWO-PART BRUSHABLE
POLYSULPHIDE SEALANT (OMat 8/5C). Mix PR1422A-4 TWO-PART
BRUSHABLE POLYSULPHIDE SEALANT (OMat 8/5C) in accordance
with the manufacturers' instructions. Apply a thin layer
of PR1422A-4 TWO-PART BRUSHABLE POLYSULPHIDE SEALANT
(OMat 8/5C) to the mating surfaces of the Access Panel
Hinge(s) and the Fan Cowl Door.
(2) Put the Access Panel in the correct position on the Fan
Cowl Door.
(3) Attach the Access Panel Hinge(s) to the Fan Cowl Door
with the countersunk bolts (5), the washers (4) and the
nuts (3). Wet assemble the countersunk bolts (5), the
washers (4) and the nuts (3) with PR1422A-4 TWO-PART
BRUSHABLE POLYSULPHIDE SEALANT (OMat 8/5C).
(4) Torque the nuts to 2.5 to 3.0 Nm (20 to 25 lbf in.).
(5) For the Oil Tank Access Panel only - Install the
NAS9307M4-01 blind rivet (10) that attaches the Lanyard
(9) to the Fan Cowl Door.
(6) Close the Access Panel.
B. Install the Starter Access Panel on the Left Hand Fan Cowl
Door. Ref. Fig.204.
(1) Wet assemble the Starter Access Panel Hinges (2 & 3) to

the Fan Cowl Door using PR1422A-4 TWO-PART BRUSHABLE
BRUSHABLE POLYSULPHIDE SEALANT (OMat 8/5C) in accordance
with the manufacturers' instructions. Apply a thin layer
of PR1422A-4 TWO-PART BRUSHABLE POLYSULPHIDE SEALANT
(OMat 8/5C) to the mating surfaces of the access panel
hinges and the Fan Cowl door.
(2) Put the Starter Access Panel in the correct position on

the Left Hand Fan Cowl Door.
(3) Attach the Starter Access Panel Swan Neck Hinges to the
Fan Cowl Door with the six countersunk bolts (4), the
six washers (5) and the six nuts (6) .
54-20-01
Page 207
1 @
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
(4) Wet Assemble the six countersunk bolts ( 4 1 , the six

washers (5) and the six nuts (6) with PR1422A-4 TWO-PART
BRUSHABLE POLYSULPHIDE SEALANT (OMat 8/5C).
(5) Torque the six nuts to 6.0 to 8.0 Nm (50 to 70 lbf in.).
(6) Close the Starter Access Panel.
C. Remove any excess PR1422A-4 BRUSHABLE POLYSULPHIDE SEALANT

(OMat 8/5C) from the installed hinge and door area before it
cures. Use a LINT-FREE CLOTH (OMat 2/101) moistened with
ACETONE (OMat 150) or ISOPROPYL ALCOHOL (OMat 1/40) or
CLEANING SOLVENT (OMat 1/257).
D. Set access panel latch adjustment screws as follows:
(1) Loosen the latch adjustment screws before closing the

latches.
(2) Close the latches and tighten the adjusting screws

finger tight on all latches.
( 3 ) Further tighten the screws a quarter of a turn on all

latches and torque-tighten the lock nuts to 1.4 to 2.0
Nm (12 to 18 lbf in.).
A. Do a visual inspection of the repair to make sure it is done

in accordance with FRSW033 and the fasteners have been
installed to SRM TASK 54-02-10 - Fastener installation and
removal.
B. Restore surface protection treatment as necessary. Refer to

SRM TASK 54-02-04 -
Restore Paint Finish.
A. Record details of the repair No FRSW033. Make a permanent

record on the Mod Plate of the door with an electrical
vi.bro-etchingtool.
REPAIR N0.17
54-20-01
Page 208
RB.211 TRENT
STRUCTURAL REPAIR
@ MANUAL
RTERACCESSPANEL
IDG ACCESS PANEL
Left Hand Door - Access Panel Identification

Figure 201
54-20-01
Page 209
RB.211 TRENT
STRUCTURAL REPAIR
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R Right Hand Door - Access Panel Identification

R Figure 202
54-20-01
Page 210
Printed in Great B r i t a i n Jun 10/08
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
Left Hand Door - IDG Access Panel

Figure 203
54-20-01
Page 211
P r i n t e d in Great B r i t a i n Jun 10/08
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
R Left Hand Door - Starter Access Panel

R Figure 204
54-20-01
Page 212
m
P
P P - - - P
-
RB.211 TRENT
STRUCTURAL REPAIR
me MANUAL
Right Hand Door -

Oil Tank Access Panel
Figure 205
54-20-01
Page 213
~ - pp ~p~- p - - - - - ~
- - - ~
H RB.211 TRENT
STRUCTURAL REPAlR
MANUAL
R Right Hand Door - Hydraulic Filter/MCD Access Panel

R Figure 206
54-20-01
Page 214
RB211 TRENT . -
STRUCTURAL REPAIR
MANUAL
MODIFIED FAN COWL DOORS - IDENTIFICATION
(This S t r u c t u r a l I d e n t i f i c a t i o n i s w r i t t e n f o r t h e L e f t and Right Hand

Fan Cowl Doors t o P o s t SB71-E107)
General
A. The f a n cowl doors make p a r t of t h e Nacelle o u t e r s k i n f o r t h e

T r e n t 700 series engine i n s t a l l e d on t h e Airbus I n d u s t r i e s A330
a i r c r a f t . They g i v e a smoothly contoured aerodynamic s u r f a c e
around t h e engine components t h a t a r e between t h e A i r I n t a k e
cowl and t h e Thrust Reverser cowl.
. The f a n cowl i s made up of an o u t e r s k i n of t h r e e ' c a r b o n f i b r e

l a m i n a t e l a y e r s with a f o u r t h laminate l a y e r a t t h e h i n g e and
l a t c h a r e a s . The i n n e r s k i n i s made of two carbon f i b r e
l a m i n a t e l a y e r s with one more laminate l a y e r a t t h e h i n g e and
latch areas.
C. The f a n cowl doors a t t a c h t o t h e pylon a t t h e t o p with t h r e e of

t h e f o u r t i t a n i u m hinges on each door, a t i e b a r h o l d s t h e
f o u r t h hinge on each door. A t t h e bottom edge t h e two doors
l a t c h t o g e t h e r with f o u r l a t c h e s and f o u r k e e p e r s .
D. I t i s n e c e s s a r y t o a c c e s s some engine components f o r u s u a l

s e r v i c i n g without t h e need t o hinge t h e cowls open. To l e t t h i s
o c c u r , some h o l e s a r e c u t through t h e cowl s k i n s . Small a c c e s s
p a n e l s , which a r e q u i c k l y removable, a r e f i t t e d a t t h e s e
p o i n t s . V e n t i l a t i o n o u t l e t s a r e on t h e d o o r s ; t h e s e a r e f i t t e d
with a g r i l l t o p r e v e n t f o r e i g n o b j e c t damage.
E. - r- -.. is b u i l t i n t o
For l i g h t e n i n g s t r i k e p r o t e c t i o n a copper l a y e
S-.
t h e o u t e r s u r f a c e s of t h e doors. . .-
F. For a c c e s s t o o t h e r components t h a t cannot be a c c e s s e d through

an a c c e s s p a n e l , t h e bottom c e n t r e l a t c h e s a r e r e l e a s e d and t h e
doors hinged outwards and supported by hold-open rods with a
two segment t e l e s c o p i c c o n s t r u c t i o n , two t o each door g i v i n g a
s i n g l e s t a g e opening p o s i t i o n of 52 d e g r e e s .
.. -
Page 1
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
Item Description Material Effectiv_i;

ty
................................................................
.< ,
~ ~ _' ' . ' . .,. .
. . ,m .,
01 Outer Skin See Notes 1,
2 and 3
02 Adhesive Film See Note 1

03 Inner Skin See Note 3
04 Core See Note 4
05 Core See Note 5
06 Inner Skin See Note 6
List of Materials :
NOTE :
1. Film Adhesive FM300-M 0.03
2. Copper Conductive Mesh CU022CX Type 1
3. Carbon Pre-Preg.
4. Honeycomb 25.40mrn (1.00in.) thick Aeroweb AI-6'4-3

1/8 cell
5. Honeycomb 6.35mm (0.25in.) thick Aeroweb A1-96-3

1/8 cell
6. Glass Ply (sacrificial plies) MIL-C-9084 Type

3 Class 2
54-20-02
Page 2
RB211 TRENT
L .
,
STRUCTURAL REPAIR ")'L.
MANUAL
AIR INTAKE COWL

See 54-10-01
Fan Cowl Doors - Identification

Figure 1
'54-20-02
Page 3
Printed in Great Britain ~ a r10/07
.
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
L e f t Hand - Fan Cowl - I d e n t i f i c a t i o n

Figure 2 ( ~ h e e t ' ol f 9 )
EFFECTIV1TY:TRENT
54-20-02
Page 4
.
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
HONEYCOMB
6,251mm
(0.25 in) THICK
6,351 mm (0.25 in) HONEYCOMB
RIBBON DIRECTION (TYPICAL)

Figure 2 (Sheet 2 o f 9)
54-20-02
Page 5
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
., .
03 , :
- - - - - - - - - - - - - - - - - - - - - - X - - - - - - -
TYPICAL PLY
02 ORIENTATION
SECTION FOR INNER SKIN
01
A-A I TYPICAL PLY
I ORIENTATION 1 I

Figure 2 (Sheet 3 o f 9 )
54-20-02
Page 6
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
SECTION
C-C

EFFECTIVITY : TRENT
54-20-02
Page 7
Printed i n Great B r i t a i n ~ a r10/07
.
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
SECTION
(TYPICAL OF VIEWS E-E AND F-F)
I
r----
I
03
01 SECTION 04
G-G

Page 8
. -
. -
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
. - -
SECTION
H-H
SECTION
J-J

. I
Figure 2 (Sheet 6 o f 9 ) r .
Page 9
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
SECTION
K-K
SECTION SECTION
L-L M-M
Left Hand - Fan Cowl - Identification ' .. ,

Figure 2 (Sheet 7 of 9) . . .
: .I':
.$ Q.
Page 10
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
I
/ 0 5 h / A-,(&L
I j \ .Io i
I :: -- - -
I
I
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- - - - - - - - - L I I / / / / / / / / --A
SECTION
N-N
SECTION
P-P . * ,

EFFECTIVITY : TRENT
54-20-02
Page 11
P r i n t e d i n Great B r i t a i n ~ a r 10/07
.
R8211 TRENT
STRUCTURAL REPAIR
MANUAL
TYPICAL PLY ORIENTATION

FOR OUTER SKlN
FILM ADHESIVE
COPPERMESH
SECTION
C-C
TYPICAL SECTION THROUGH OUTER SKlN

Figure 2 (Sheet 9 o f 9)
54-20-02
Page 12
.
RB211 TRENT
STRUCTURAL REPAIR S,' . '
MANUAL
OIL FILLER ACCE

WCA7110E100-04
MCDlHYD ACCESS PANEL ASSY

WCA7110E105-041
m
m
d
d
0
a
0
Is
R i g h t Hand - Fan Cowl - Identification

F i g u r e 3 ( S h e e t 1 of 7 )
54-20-02
P a g e 13
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
L 6,35mm (0.25in)
HONEYCOMB
RIBBON DIRECTION
(TYPICAL)
Right Hand - Fan Cowl - I d e n t i f i c a t i o n

54-20-02
, .
Page 1 4
RB211 TRENT . >
. ,,. .
S..,
I:. .
STRUCTURAL REPAIR . . .
.,
MANUAL , . ..
p , . '
TYPICAL PLY
ORIENTATION
FOR INNER SKlN
SECTION
A-A
SECTION
B-B TYPICAL PLY
ORIENTATION
FOR INNER SKlN
SECTION
C-C

C..
.. .
'
. - . Page 15
.
'8 i
. I ;. ~ a r10/07
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RB211 TRENT
STRUCTURAL REPAIR
MANUAL
SECTION
D-D
SECTION
E-E
R i g h t Hand - Fan Cowl - Identification

1
,
I
F i g u r e 3 ( S h e e t 4 of 7 )
EFFECTIVITY: TRENT
54-20-02
P a g e 16
Printed i n Great Britain M a r . 10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
SECTION
G-G

F i g u r e 3 ( S h e e t 5 of 7 )
54-20-02
Page 17
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
SECTION
H-H
SECTION
J-J

EFFECTIV1TY:TRENT
54-20-02
Page 18
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
TYPICAL PLY
FlLM ADHESIVE
ORIENTATION
COPPER MESH
r
I
- J ,-
FlLM ADHESIVE
SECTION
D-D
TYPICAL SECTION THROUGH OUTER SKIN
R i g h t Hand - F a n Cowl - Identification

F i g u r e 3 ( S h e e t 7 of 7 )
EFFECTIVITY : TRENT
54-20-02
P a g e 19
MODIFIED FAN COWL DOORS – ALLOWABLE DAMAGE
(This Allowable Damages Section is written for the Left and Right Hand Fan
Cowl Doors to Post SB71-E107)
1. Introduction
This section of the SRM contains the allowable and the repairable damage
limits for fan cowl doors to post SB71-E107 Standard.
NOTE: It has been necessary to publish 54-20-02 for fan cowl doors
that are post SB71-E107 because allowable damage and zone areas
are different from fan cowl doors that are to Pre SB71-E107
standard.
This section includes damage to the skins, monolithic and honeycomb

areas of the doors and access panels only.
Damage, which is found to be in the allowable damage limits, must be

repaired in accordance with the procedures given in the repair section,
page block 201.
Fan Cowl Doors to SB71-E107 incorporate the following:
• The use of new carbon material specification.

• Additional plies on the inner and outer skins, giving a total of
16 plies on the inner and 12 plies on the outer skin in monolithic
areas.
• In the honeycomb areas there are 3 plies and 1 copper mesh on the
outer skin and there are 3 plies on the inner skin.
• A single layer of nomex honeycomb core with increased density.
25.40mm (1.0in.) thick Aeroweb A1-64-3 3.20mm cell (0.126in.cell)
• Profiled titanium hinges.
• Monolithic hinge attachment.
• Reinforced Ventilation Outlet.
• Revised hinge bush arrangement.
• Single stage Hold Open Rods.
For a more detailed description refer to SB71-E107.
2. Zones
The doors are divided into zones (Refer to Figure 1 Sheets 3
EFFECTIVITY: TRENT
54-20-02
Page 101
and 4). The zones, which are affected by the different types of allowable
or repairable damage, are identified in the figures and tables, which
follow.
As the Fan Cowl Door structure has been modified, it has been rezoned to
offer increased damage limits whilst keeping the zoning as simple as
possible for ease of maintenance. The zones chosen show the door lay-up
applicable to the types of repair tested. Zones 1 to 5 and zone 9 include
honeycomb areas including ramps and pandowns, zones 6, 7, 8, and 10
include monolithic areas such as flanges.
The damage allowed for access panels will be for that allowed for by the
zone that they are located in. Monolithic areas of access panels should
be identified as zone 8. Ref to Figure 1 sheets 3 & 4 for a guide to the
zone layout.
On Fan Cowl Doors to post SB71-E107, three of the four ‘Keep Out Zones’
have been reclassified to allow limited life damage. The fourth, the
Sling Point, is now in zone 2 on the left hand door and zone 3 on the
right hand door.
A. Zone Positions
NOTE: All the dimensions shown are measured along the outer surface
line (OSL) of each door.
(1) Zone 1 – Hinge Honeycomb Area.

This zone runs parallel with the top edge of the door and
consists of the top 281.94mm (11.1in.) by 1623,06mm (63.9in.)
width of the honeycomb panels.
(2) Zone 2 – Upper Main Honeycomb Area.

This zone is below Zone 1. The zone is smaller on the right
hand door than the left hand door. This zone for the left hand
door is 2452.62mm (96.56in.) by 1623.06mm (63.9in.). The zone
for the right hand door is 1452.88mm (57.2in.) by 1623.06mm
(63.9in.).
(2) Zone 3 – Lower Main Honeycomb Area.

This zone runs below Zone 2. This zone is larger on the right
hand door than the left hand door. This zone for the left hand
door is 1215.14mm (47.84in.) by 1648.46mm (64.89in.). The zone
for the right hand door is 2164.88mm (85.23in.) by 1648.46mm
(64.89in.).
(3) Zone 4 – Forward Latch Honeycomb Area.

This zone is the honeycomb area extending 1117.6mm (44.0in.)
aft of the leading edge around the latch positions.
EFFECTIVITY: TRENT
54-20-02
Page 102
(4) Zone 5 – Aft Latch Honeycomb Area.
This zone is the honeycomb area that is around the aft latch
position. This zone for the left hand door is 660.4mm (26.0in.)
by 490.22mm (19.3in.) and includes the IDG/Oil Filter Access
Panel. The zone for the right hand door is 660,4mm (26.0in.) by
490.22mm (19.3in.) and includes the Ventilation Outlet Panel.
(5) Zone 6 – Leading Edge Flange.

This zone is along the leading edge monolithic area from the
top to bottom edges of the door, 4660.9mm by 25.40mm (183.5in.
by 1.0in.).
(6) Zone 7 – Trailing Edge Flange.

This zone is along the trailing edge monolithic area from the
top to the bottom edges of the door, 4660.9mm by 50.80mm
(183.5in. by 2.0in.).
(7) Zone 8 – Other Flanges.

This zone is the area of the door around the outlets, breather
masts, access panels and along the top edge of the door. It
consists of monolithic areas only.
(8) Zone 9 – Left Hand Door Heat Affect Honeycomb Area.

This zone runs aft from the leading edge of the left hand door
and is fully encompassed by zone 3. The structure of the door
in this area is honeycomb panel.
(9) Zone 10 – Left Hand Door Heat Affect Flange Area.

This zone is defined as the flange area that lies in the heat
affected zone. It is positioned in the lower flange region of
the cut-out for the Starter Valve Access Panel.
A. ‘Keep-Out’ Zones.
Damage in these areas cannot be repaired. You must tell the

manufacturer if you find damage in these areas. There are different
‘keep-out’ zones on the doors. These include the areas around
fastener positions and around the hold-open rod brackets.
NOTE: The dimensions of the ‘Keep-Out’ Zones around the fasteners

are found when the diameter of the plain shank of the
fastener is multiplied by six (6).
B. Access Panels
(1) Monolithic Carbon Flanges (Panel Edges).

If you find damage to the monolithic flange of an access panel
refer to the data for Zone 8.
EFFECTIVITY: TRENT
54-20-02
Page 103
(2) Honeycomb Areas (Centre Cores).
If you find damage to the honeycomb areas of an access panel
refer to the data for Zone 2 or 3.
NOTE: The areas around the panel hinge and latch fasteners
should be treated as ‘Limited Life’ allowable damage
areas.
EFFECTIVITY: TRENT
54-20-02
Page 104
3. List of Approved Repairs Summary
A.
APPLICABLE REPAIR MAJOR /

REPAIR DESCRIPTION
ZONE NUMBER MINOR
Repair of Indented or
1, 2, 3,
1 FRSW017 Partially Punctured Inner or Major
4, 5, 9.
Outer Skin.
Repair of Flange Edge
6, 7, 8,
2 FRSW018 Delamination in Monolithic Major
10.
Flanges.
1, 2, 3, Repair of Through Damage in
3 FRSW019 Major
4, 5, 9. Full Depth of Honeycomb.
Repair of the Rear Edge RFI

7 4 FRSW021 Minor
Shielded Rub Strip.
Repair of a Disbond at the

2, 3. 5 FRSW022 Minor
Sling Point.
1, 2, 3,
4, 5, 6, Repair of Damaged Conductive
6 FRSW023 Minor
7, 8, 9, Surface Mesh.
10.
Repair (Replacement) of the
4, 5. 7 FRSW026 Minor
RFI Seals.
Repair of Wear to the Fan

6. 8 FRSW027 Minor
Cowl Door Leading Edge.
3, 4, 5, Replace decals on right hand

9 FRSJ086 Minor
8. Fan Cowl Door.
3, 4, 5, Replace decals on left hand

10 FRSJ087 Minor
8. Fan Cowl Door.
R Wet lay-up repair to

11 FRSW030 Minor
R Monolithic Carbon Areas.
Repair (replacement) of the
R
12 FRSW032 Access panel Hinges and Minor
R
Latches.
EFFECTIVITY: TRENT
54-20-02
Page 105
A. Allowable damage - General
(1) Allowable damage limits are intended to permit an operator to

determine whether a damaged nacelle component can continue in
service, or be rejected for repair or be replaced with new.
(2) Allowable damage must not weaken the structural integrity of

the component, which could affect the strength or fatigue life.
(3) The types of allowable damage permitted are specified and, if

applicable, brief descriptions of the clean-up procedures
needed are given. These are either, to prevent propagation of
the damage, or to improve the appearance and aerodynamic
smoothness of the damaged part.
(4) The limits given are for a skin surface with no damage below
the surface. If you find damage below the surface that damage
must be cut back to the surface and discarded.
(5) Allowable damage is classified as either unlimited usage or

time limited, as follows:
(a) Unlimited Life damage is minor damage, which does not

affect the structural integrity or functional capability
of the component. No repairs are necessary, other than
cosmetic, during the aircraft design life.
(b) Limited Life damage is minor damage, which does not affect
the structural integrity of the component in normal
service use. But, it could reduce the time life of the
component. In this case the damage must be repaired before
or at the next Aircraft C’ check. The location and size of
the damage should be noted. It should be checked at
applicable intervals to monitor that the damage has not
become more than the time limited damage allowance.
B. Allowable damage – Fan Cowl Doors
(1) When you measure the diameter of the damage you must measure
across its maximum width. The damage will be contained in a
circle of maximum diameter.
(2) The minimum distance given between areas of damage is measured

between the nearest adjacent edges of the damage.
EFFECTIVITY: TRENT
54-20-02
Page 106
(3) Where the areas of adjacent damage are of different dimensions
the maximum diameters of each damaged area are used to
calculate the minimum distance between edges.
EFFECTIVITY: TRENT
54-20-02
Page 107
(4) Aircraft ‘Flying-On’ Limits
To let an aircraft continue a flight (‘Flying-On’) seal all

fibres and honeycomb you can see around allowable damage with
the applicable aluminium tape (speed tape) or an applicable
epoxy resin. Any allowed holes must have aluminium tape (speed
tape) on to prevent water ingress and restore the mould line as
effectively as possible. Any damage to conductive wire mesh on
the outer skin of the door must have aluminium tape (speed
tape) on it and it must overlap onto the existing mesh by a
minimum dimension of 50.8mm (2.00in.).
C. Repairable Damage
(1) Repairable damage limits are to permit an operator to determine

if a damaged nacelle component can be repaired or must be
rejected. The operator must follow the allowable damage section
information to do the repair satisfactorily.
D. Types of Damage
(1) The types of damage that follow refer only to the structure and
the mesh materials of the components. It does not refer to the
surface protection. If there is an indication that a component
has damage you must remove paint and other surface protection
and do a full inspection.
(a) Abrasion – An abrasion is surface damage that is usually

rough and not regular. Scuffing, rubbing, scraping or
other types of surface erosion cause it.
(b) Gouge – A gouge is surface damage of any size that has

material missing. It is caused when a sharp object is
pushed along the surface, producing a continuous sharp or
smooth channel-like groove in the material.
(c) Nick – A nick is a small gouge with sharp edges. It is

caused when a sharp object is pushed against the surface.
(d) Scratch – A scratch is a line of damage. It is usually

caused when a very sharp object is pushed along the
surface.
(e) Crack – A crack is a fracture or complete break causing

structural damage that usually shows as a line that is not
regular. A dent can have a crack in it.
EFFECTIVITY: TRENT
54-20-02
Page 108
(f) Dent – A dent is a depressed area of damage, which, in
core filled laminates can cause crushing of the core cells
creating a disbond. Area boundaries are smooth and dents
are usually caused by contact with a smooth contoured
object. If there is an crack or hole in the skin then the
damage is to be treated as a crack or hole of a diameter
that includes all the damage.
(g) Hole – A hole may be classified as a ‘through hole’ or a

‘single skin hole’. A ‘through hole’ is a hole that
penetrates the entire fan cowl door structure. A ‘single
skin hole’ may occur in the area of the honeycomb
structure and would result in penetration of just one
carbon skin. The specific dimension is a diameter that
includes all the damage connected with the hole such as
indentation and cracking.
(h) Disbond – A disbond is the separation of the face skin

from the honeycomb core or filled area of a sandwich
panel.
(i) Delamination – A delamination is the separation of one or

more lamination plies.
E. Identify and Measure the Damage
(1) Do a tap test, refer to 54-01-06.
(2) Make a circular mark around the maximum area of damage.
EFFECTIVITY: TRENT
54-20-02
Page 109
F. Decision Diagram for Zones 1 to 10.
For damage occurring

in zones 1 to 10,
determine the minimum
diameter of a circle Is the damage Yes
around all the diameter equal to or Unlimited life damage
damage? less than the allowed subject to
allowables in the ‘A’ check inspection.
Unlimited Life
Allowable Damage
section?
Is the damage in the No No

minimum separation
distance if there is
other damage near?
Limited life damage

Is the damage Yes allowed subject to
diameter equal to or repair at next ‘C’
less than the check.
Yes allowables in the
Limited Life
Allowable Damage
Determine the minimum section?
diameter of a circle
around both areas of
damage.
No
No Yes
Is the damage
Damage must be diameter equal to or Repair before the fan
referred to the less than the cowl door is sent
manufacturer / design allowables in the back to flight.
authority. Allowable Repairable
Damage section?
EFFECTIVITY: TRENT
54-20-02
Page 110
G. Allowable Damage Limits – Unlimited Life
ZONE DAMAGE REQUIREMENTS UNLIMITED LIFE INSPECTION

ALLOWABLE LIMITS INTERVALS
1 Abrasion No cracks in carbon- Unlimited length Re-inspect
Gouge fibre and width. at each
Nick Applicable to Aircraft
Scratch Minimum distance inner and outer ‘C’ check.
between adjacent skins. Unless
unrepaired damage is copper mesh is
5 times the diameter damaged. Damage to
of the largest the mesh is
damage. limited to a
maximum 152.4 mm
Minimum 2 times (6.0in.) square,
maximum damage and must be
diameter (2d) edge repaired by “speed
distance tape” before
flying on. Damage
may not extend
beyond the
thickness of the
mesh.
2,3,4, Abrasion No cracks in carbon- Unlimited length Re-inspect

5,7,8, Gouge fibre and width. at each
9,10 Nick Applicable to Aircraft
Scratch inner and outer ‘C’ check.
skins. Unless
copper mesh is
damaged. Damage to
the mesh is
limited to a
maximum 152.4 mm
(6.0in.) square,
and must be
repaired by “speed
tape” before
flying on. Damage
may not extend
more than the
thickness of the
mesh.
6 Gouge No cracks in carbon- Unlimited length Re-inspect

Nick fibre and width. at each
Scratch Applicable to Aircraft
inner and outer ‘C’ check.
EFFECTIVITY: TRENT
54-20-02
Page 111
skins. Unless
copper mesh is
damaged. Damage to
the mesh is
limited to a
maximum 152.4 mm
(6.0in.) square,
and must be
repaired by “speed
tape” before
flying on. Damage
may not extend
beyond the
thickness of the
mesh.

6 Abrasion Abrasion damage to Maximum Width of Re-inspect
the leading edge of 12.70mm (0.50in.) at each
the door must not be Maximum Length of Aircraft
more than 25% of the 165.00mm (6.50in.) ‘C’ check.
thickness of the Note: No damage is
door. permitted 376.00mm
(14.80in.) from
the top edge and
249.00mm (9.80in.)
from the bottom
edge of the RH and
LH door.
EFFECTIVITY: TRENT
54-20-02
Page 112
1 Dent Minimum distance Maximum 50.8mm Re-inspect
between adjacent (2.00in.) in at each
unrepaired damage is diameter. Aircraft
5 times the diameter ‘C’ check
of the largest Applicable to
damage. inner and outer
Minimum 2 times skins
maximum damage
diameter (2d) edge Maximum depth of
distance. dent must not be
more than 1/20 of
Not permitted in its diameter.
12.70mm (0.50in.) of
the centre of any
fastener.

5 times the diameter ‘C’ check.
maximum damage
more than 1/20 of
12.70mm (0.50in.) of
the centre of any
fastener.

maximum damage
more than 1/20 of
12.70mm (0.50in.) of
the centre of any
EFFECTIVITY: TRENT
54-20-02
Page 113
fastener.

maximum damage
more than 1/20 of
12.70mm (0.50in.) of
the centre of any
fastener.
EFFECTIVITY: TRENT
54-20-02
Page 114
5 Dent Minimum distance Inner skin Re-inspect
between adjacent maximum 37.60mm at each
unrepaired damage is 5 (1.48in.) in Aircraft
times the diameter of diameter. ‘C’ check.
the largest damage.
Minimum 2 times maximum Outer skin
damage diameter (2d) maximum 50.8mm
edge distance. (2.00in.) in
diameter.
Not permitted in
12.70mm (0.50in.) of Maximum depth of
the centre of any dent must not be
fastener. more than 1/20 of
its diameter.

unrepaired damage is 5 diameter. Aircraft
times the diameter of Note: The dent ‘C’ check.
the largest damage. may extend across
Minimum 2 times maximum the boundary into
damage diameter (2d) the adjacent
edge distance. zone.
Not permitted in Applicable to

12.70mm (0.50in.) of inner and outer
the centre of any skins.
fastener.
Maximum depth of
dent must not be
more than 1/20 of
its diameter.
EFFECTIVITY: TRENT
54-20-02
Page 115
times the diameter of ‘C’ check.
the largest damage. Applicable to
Minimum 2 times maximum inner and outer
damage diameter (2d) skins.
edge distance.
Maximum depth of
Not permitted in dent must not be
12.70mm (0.50in.) of more than 1/20 of
the centre of any its diameter.
fastener.
EFFECTIVITY: TRENT
54-20-02
Page 116
Minimum 2 times skins.
maximum damage
more than 1/20 of
12.70mm (0.50in.) of
the centre of any
fastener.
Note: The dent may

extend across the
boundary into the
adjacent zone.

maximum damage
more than 1/20 of
12.70mm (0.50in.) of
the centre of any
fastener.

maximum damage
EFFECTIVITY: TRENT
54-20-02
Page 117
more than 1/20 of
12.70mm (0.50in.) of
the centre of any
fastener.
EFFECTIVITY: TRENT
54-20-02
Page 118
1,2,3,4 Crack / N/A. No Unlimited Life N/A.

,5,6,7, Hole damage allowed.
8,9,10
EFFECTIVITY: TRENT
54-20-02
Page 119
H. Allowable Damage Limits – Limited Life (Fly-On's)
ZONE DAMAGE REQUIREMENTS LIMITED LIFE REPAIR

ALLOWABLE LIMITS INTERVAL/
PROCEDURE
1 Dent N/A No Limited Life N/A
damage allowed.
2 Dent Minimum distance Maximum 144.50mm Repair at

between adjacent (5.69in.) in next
times the diameter of ‘A’ check.
the largest damage. FRSW017
54-20-02
Not permitted in Applicable to Repair
12.70mm (0.50in.) of inner and outer No.1.
fastener.

54-20-02
fastener.

54-20-02
fastener.

unrepaired damage is 5 diameter Aircraft
54-20-02
EFFECTIVITY: TRENT
54-20-02
Page 120
fastener.

damage allowed.
EFFECTIVITY: TRENT
54-20-02
Page 121
PROCEDURE
damage allowed.

damage allowed.

5 times the diameter ‘A’ check.
of the largest FRSW017
damage. 54-20-02
Applicable to Repair
Not permitted in inner and outer No.1.
12.70mm (0.50in.) of skins.
the centre of any
fastener.

damage allowed.
EFFECTIVITY: TRENT
54-20-02
Page 122
PROCEDURE
1 Delamination N/A No Limited Life N/A
/ Disbond damage allowed.
2 Delamination Minimum distance Maximum 144.50mm Repair at

/ Disbond between adjacent (5.69in.) in next
of the largest
damage. Applicable to FRSW017
inner and outer 54-20-02
Not permitted in skins. Repair
12.70mm (0.50in.) of No.1.
the centre of any
fastener. Repairs that are FRSW022
only applicable 54-20-02
to Disbonds in Repair
the Sling No.5.
position.
Maximum disbond
between the outer
skin and the
filled honeycomb
core is 76.20mm
(3.00in.)
Maximum disbond
between the inner
skin and the
filled honeycomb
core is 68.58mm
(2.70in.)

of the largest
damage. Applicable to FRSW017
Not permitted in inner and outer 54-20-02
12.70mm (0.50in.) of skins. Repair
the centre of any No.1.
fastener.
Repairs that are FRSW022
only applicable 54-20-02
to Disbonds in Repair
the Sling No.5.
EFFECTIVITY: TRENT
54-20-02
Page 123
position.
Maximum disbond
between the outer
skin and the
filled honeycomb
core is 76.20mm
(3.00in.)
Maximum disbond
between the inner
skin and the
filled honeycomb
core is 68.58mm
(2.70in.)
EFFECTIVITY: TRENT
54-20-02
Page 124
PROCEDURE
of the largest
damage. FRSW017
Applicable to 54-20-02
Not permitted in inner and outer Repair
12.70mm (0.50in.) of skins. No.1.
the centre of any
fastener.

of the largest
damage.
Applicable to FRSW017
Not permitted in inner and outer 54-20-02
12.70mm (0.50in.) of skins. Repair
the centre of any No.1.
fastener.

between adjacent (0.30in.) wide next
unrepaired damage is (forward to aft Aircraft
5 times the diameter (from edge)) ‘A’ check.
of the largest times 12.7mm
damage. (0.50in.) long
Minimum 2 times (around barrel) FRSW018
maximum damage 54-20-02
diameter (2d) edge Applicable to Repair
distance. inner and outer No.2.
skins.
Not permitted in
12.70mm (0.50in.) of
the centre of any
fastener.

damage allowed.

damage allowed.
EFFECTIVITY: TRENT
54-20-02
Page 125
the largest damage.
FRSW017
Not permitted in Applicable to 54-20-02
12.70mm (0.50in.) of inner and outer Repair
the centre of any skins. No.1.
fastener.

damage allowed.
1,2,3,4 Crack / N/A No Limited Life N/A

,5,6,7, Hole damage allowed.
8,9,10
EFFECTIVITY: TRENT
54-20-02
Page 126
I. Repairable Damage Limits

PROCEDURE
1,2,3,4, Abrasion No limit to distance No limit to FRSW023
5, Gouge between damage and repair 54-20-02
Nick adjacent component separation. Repair No.6.
Scratch parts.
No limit to repair No limit to

separation. number of
repairs.
The damage is not to Applicable to

extend to a depth more inner and outer
than the mesh skins.
6 Gouge No limit to distance No limit to FRSW023

Nick between damage and repair 54-20-02
Scratch adjacent component dimensions. Repair No.6.
parts.
No limit to
No limit to repair number of
separation. repairs.

extend to a depth inner and outer
more than the mesh. skins.
EFFECTIVITY: TRENT
54-20-02
Page 127
6 Abrasion Minimum distance Maximum width of FRSW027
between adjacent 12.70mm (0.5in.). 54-20-02
unrepaired damage is Repair No.8.
5 times the diameter Maximum length of
of the largest 165.00mm
damage. (6.5in.).
Note: No damage
is permitted
376.00mm
(14.8in.) from
the top edge and
249.00mm (9.8in.)
from the bottom
edge of the RH
and LH door.
Abrasion damage
to the leading
edge of the door
is not to be more
than 25% of the
thickness of the
door.
7,8,9,10 Abrasion No limit to distance No limit to FRSW023

Gouge between damage and repair 54-20-02
Nick adjacent component dimensions. Repair No.6.
Scratch parts.
No limit to
No limit to repair number of
separation. repairs.

extend to a depth inner and outer
more than the mesh. skins.
EFFECTIVITY: TRENT
54-20-02
Page 128
PROCEDURE
1 Dent Minimum distance Maximum 140.50mm FRSW017
between adjacent (5.53in.) in 54-20-02
unrepaired damage is diameter. Repair No.
5 times the diameter 1.
maximum damage
diameter (2d) edge
distance.
Not permitted in
12.70mm (0.50in.) of
the centre of any
fastener.

maximum damage
diameter (2d) edge
distance.
Not permitted in
12.70mm (0.50in.) of
the centre of any
fastener.
EFFECTIVITY: TRENT
54-20-02
Page 129
maximum damage
diameter (2d) edge
distance.
Not permitted in
12.70mm (0.50in.) of
the centre of any
fastener.

maximum damage
diameter (2d) edge
distance.
Not permitted in
12.70mm (0.50in.) of
the centre of any
fastener.
EFFECTIVITY: TRENT
54-20-02
Page 130
PROCEDURE
maximum damage
diameter (2d) edge
distance.
Not permitted in
12.70mm (0.50in.) of
the centre of any
fastener.
6 Dent Minimum distance Maximum 20.00mm Repair to a

between adjacent (0.79in.) in monolithic
unrepaired damage is diameter. edge area to
5 times the diameter be defined
of the largest in a later
damage. Applicable to revision.
inner and outer
Not permitted in skins.
12.70mm (0.50in.) of
the centre of any
fastener.
7,8 Dent Minimum distance Maximum 30.00mm Repair to a

between adjacent (1.18in.) in monolithic
unrepaired damage is diameter. edge area to
5 times the diameter be defined
of the largest in a later
damage. Applicable to revision.
inner and outer
skins.

maximum damage
diameter (2d) edge
EFFECTIVITY: TRENT
54-20-02
Page 131
distance.
Not permitted in
12.70mm (0.50in.) of
the centre of any
fastener.
EFFECTIVITY: TRENT
54-20-02
Page 132
PROCEDURE
maximum damage
diameter (2d) edge
distance.
Not permitted in
12.70mm (0.50in.) of
the centre of any
fastener.
EFFECTIVITY: TRENT
54-20-02
Page 133
PROCEDURE
1 Delamination Minimum distance Maximum 140.50mm FRSW017
/ Disbond between adjacent (5.53in.) in 54-20-02
maximum damage
diameter (2d) edge
distance.
Not permitted in
12.70mm (0.50in.) of
the centre of any
fastener.

maximum damage FRSW022
diameter (2d) edge Repairs that are 54-20-02
distance. only applicable Repair
to Disbonds in No.5.
Not permitted in the Sling
12.70mm (0.50in.) of position. Maximum
the centre of any size of disbonds
fastener. between outer
skin and filled
honeycomb core is
76.20mm
(3.00in.).
Maximum size of
disbonds between
inner skin and
filled honeycomb
core is 68.58mm
(2.70in.).
EFFECTIVITY: TRENT
54-20-02
Page 134
PROCEDURE
maximum damage FRSW022
diameter (2d) edge Repairs that are 54-20-02
distance. only applicable Repair
to Disbonds in No.5.
Not permitted in the Sling
12.70mm (0.50in.) of position. Maximum
the centre of any size of disbonds
fastener. between outer
skin and filled
honeycomb core is
76.20mm
(3.00in.).
Maximum size of
disbonds between
inner skin and
filled honeycomb
core is 68.58mm
(2.70in.).

maximum damage
diameter (2d) edge
distance.
Not permitted in
12.70mm (0.50in.) of
the centre of any
fastener.

EFFECTIVITY: TRENT
54-20-02
Page 135
maximum damage
diameter (2d) edge
distance.
Not permitted in
12.70mm (0.50in.) of
the centre of any
fastener.
EFFECTIVITY: TRENT
54-20-02
Page 136
PROCEDURE
6 Delamination Minimum distance Up to 7.60mm FRSW018
between adjacent (0.3in.) from the 54-20-02
unrepaired damage is exposed edge. Repair
5 times the diameter No.2.
of the largest
damage.
Up to 330.00mm
Not permitted in (13.0in.) length
12.70mm (0.50in.) of along the flange.
the centre of any
fastener.

between adjacent (0.3in.) from the 54-20-02
unrepaired damage is exposed edge. Repair
5 times the diameter No.2.
of the largest
damage.
Up to 330.00mm
Not permitted in (13.0in.)
12.70mm (0.50in.) of length along the
the centre of any flange.
fastener.

between adjacent (0.225in.) from 54-20-02
unrepaired damage is the exposed edge. Repair
5 times the diameter (Applies to Zone No.2.
of the largest 8 only)
damage.
Not permitted in Up to 330.00mm

12.70mm (0.50in.) of (13.0in.)
the centre of any length along the
fastener. flange.

maximum damage
diameter (2d) edge
distance.
EFFECTIVITY: TRENT
54-20-02
Page 137
Not permitted in
12.70mm (0.50in.) of
the centre of any
fastener.
EFFECTIVITY: TRENT
54-20-02
Page 138
PROCEDURE
of the largest
damage. Up to 330.00mm
Minimum 2 times (13.0in.) length
maximum damage along flange.
diameter (2d) edge
distance.
Not permitted in
12.70mm (0.50in.) of
the centre of any
fastener.
EFFECTIVITY: TRENT
54-20-02
Page 139
LIMITS PROCEDURE
1 Crack / Minimum distance Maximum 140.50mm
Hole between adjacent (5.53in.) in
unrepaired damage is 5 diameter.
times the diameter of
edge distance. FRSW017
Through Single 54-20-02
Not permitted in Skin. Repair No.
12.70mm (0.50in.) of 1.
the centre of any
fastener. FRSW019
Through Both 54-20-02
Skins. Repair
No.3.

edge distance. FRSW017
Through Single 54-20-02
Not permitted in Skin. Repair No.
12.70mm (0.50in.) of 1.
the centre of any
fastener. FRSW019
Through Both 54-20-02
Skins. Repair
No.3.

damage diameter (2d) skins. FRSW017
edge distance. 54-20-02
Through Single Repair No.
Not permitted in Skin. 1.
12.70mm (0.50in.) of
the centre of any FRSW019
EFFECTIVITY: TRENT
54-20-02
Page 140
fastener. 54-20-02
Through Both Repair
Skins. No.3.
EFFECTIVITY: TRENT
54-20-02
Page 141
LIMITS PROCEDURE
unrepaired damage is diameter.
5 times the diameter
Minimum 2 times skins. FRSW017
diameter (2d) edge Through Single Repair No.
distance. Skin. 1.
Not permitted in FRSW019

12.70mm (0.50in.) of 54-20-02
the centre of any Through Both Repair
fastener. Skins. No.3.

distance. Skin. 1.

12.70mm (0.50in.) of 54-20-02
6,8 Crack/ Minimum distance Maximum 20.00mm Repair to a

Hole between adjacent (0.79in.) in monolithic
unrepaired damage is diameter. edge area
5 times the diameter to be
of the largest Applicable to defined in
damage. inner and outer a later
skins. revision.
Not permitted in
12.70mm (0.50in.) of
the centre of any
fastener.
7 Crack/ Minimum distance Maximum 25.40mm Repair to a

EFFECTIVITY: TRENT
54-20-02
Page 142
skins. revision.
Not permitted in
12.70mm (0.50in.) of
the centre of any
fastener.
EFFECTIVITY: TRENT
54-20-02
Page 143
LIMITS PROCEDURE
distance. Skin. 1.

12.70mm (0.50in.) of 54-20-02
10 Crack / Minimum distance Maximum 6.35mm Repair to a

Minimum 2 times skins. revision.
maximum damage
diameter (2d) edge Through Single
distance. Skin.
Not permitted in
12.70mm (0.50in.) of
the centre of any Through Both
fastener. Skins.
EFFECTIVITY: TRENT
54-20-02
Page 144
LIMITS PROCEDURE
4,5 Bottom Edge N/A This repair is FRSW026
Seal applicable to 54-20-02
damaged edge Repair
seals. No.7.
The seal must be
replaced as a
complete part.
7 Aft Edge RFI N/A This repair is FRSW021

Seal applicable to 54-20-02
damage on the Repair
Aft RFI Seal. No.4.
R N/A Access Panel Replace Hinges and No limit to the FRSW032

R Hinges & Latches number of times 54-20-02
R Latches this repair can Repair No
R (all damage be carried out. 11
types)
EFFECTIVITY: TRENT
54-20-02
Page 145
Hinge Attachment Area.
Figure 1 Sheet 8 is a view on the outer skin and specifies the

boundary of the hinge attachment zone. For damage such as a dent or
delamination that is in the hinge attachment area zone, the centre
of a circle made all around the damage must be in the boundary
shown. No dent or delamination is allowed in 12.70mm (0.5in.) of the
centre of a fastener.
.
EFFECTIVITY: TRENT
54-20-02
Page 146
J. Hinge Attachment Area Allowable Damage Limits.
DAMAGE REQUIREMENTS ALLOWABLE LIMITS ALLOWABLE LIFE

Abrasion N/A Unlimited Length 100 Flights.
Gouge and Width.
Nick
Scratch No Cracks in the
Carbon Fibre.
Dent Minimum distance Maximum 1.80mm 100 Flights.

between adjacent (0.07in.) in
unrepaired damage is 5 depth.
the largest damage. Outer Skin Only
Maximum 25.40mm
Not permitted in (1.00in.) in
12.70mm (0.50in.) of diameter.
the centre of any
fastener.
Delamination/ Minimum distance Outer Skin Only 100 Flights.

Disbond between adjacent Maximum 30.00mm
unrepaired damage is 5 (1.18in.) in
times the diameter of diameter.
the largest damage.
Not permitted in
12.70mm (0.50in.) of
the centre of any
fastener.
Crack / N/A None Permitted. Refer to

Hole Manufacturer.
EFFECTIVITY: TRENT
54-20-02
Page 147
Latch Attachment Area.
Figure 1 Sheet 8 shows a view on the outside of the latch assembly

with the latch attachment zonal boundary shown by marks making a
broken line. For damage such as a dent or delamination that is in the
latch attachment area, the centre of a circle made around all of the
damage must be in the boundary shown.
EFFECTIVITY: TRENT
54-20-02
Page 148
K. Latch Attachment Area Allowable Damage Limits.

Abrasion Minimum distance Unlimited Length 100 Flights.
Gouge between adjacent and Width.
Nick unrepaired damage is
Scratch 5 times the diameter No Cracks in the
of the largest Carbon Fibre.
damage.

unrepaired damage is 5 depth.
the largest damage. Outer Skin Only
Maximum 25.40mm
(1.00in.) in
diameter.
Delamination/ Minimum distance Outer Skin Only 100 Flights.

Disbond between adjacent Maximum 30.00mm
unrepaired damage is (1.18in.) in
5 times the diameter diameter.
of the largest
damage.

Hole Manufacturer.
EFFECTIVITY: TRENT
54-20-02
Page 149
Axial Locator Attachment Area.
The Axial Locator attachment zones divide zone 6 up into several

sections on the leading edge. One of the Axial Locator attachment zones
is adjacent to the Heat Affected Zone (HAZ), zone 9. For damage such as
a dent or delamination in the Axial Locator attachment zone, the centre
of a circle made around all of the damage must be in the shaded area
shown in Figure 1 Sheet 10. No dent or delamination is allowed in
12.70mm (0.5in.) of the centre of a fastener. The view shown is from the
inside of the door but the zone is only applicable to the outside skin.
EFFECTIVITY: TRENT
54-20-02
Page 150
L. Axial Locator Attachment Area Allowable Damage Limits.

Abrasion Minimum distance Unlimited Length 100 Flights.
Gouge between adjacent and Width.
Nick unrepaired damage is
Scratch 5 times the diameter No Cracks in the
of the largest Carbon Fibre.
damage.

unrepaired damage is depth.
of the largest Outer Skin Only
damage. Maximum 25.40mm
(1.00in.) in
Not permitted in diameter.
12.70mm (0.50in.) of
the centre of any
fastener.
Delamination Minimum distance Outer Skin Only 100 Flights.

between adjacent Maximum 30.00mm
unrepaired damage is (1.18in.) in
5 times the diameter diameter.
of the largest
damage.
Not permitted in
12.70mm (0.50in.) of
the centre of any
fastener.

Hole Manufacturer.
EFFECTIVITY: TRENT
54-20-02
Page 151
Sling Point Attachment Area.
Any damage that is centred on a point in 57.15mm (2.25in.) of the Sling

Point centre must include the 25.40mm (1.0in.) diameter Sling Point
hole, refer to Figure 1 Sheet 10. The diameter of the area shown must be
compared with that permitted in the zone around the damage. The Sling
Points are located in zone 2 on the left hand door and in zone 3 on the
right hand door. Repair No. 5 (FRSW022) is applicable to the Sling Point
Attachment Area for the repair of disbonds.
EFFECTIVITY: TRENT
54-20-02
Page 152
Fan Cowl Doors – Allowable Damage
EFFECTIVITY: TRENT
54-20-02
Page 153
EFFECTIVITY: TRENT
54-20-02
Page 154
EFFECTIVITY: TRENT
54-20-02
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EFFECTIVITY: TRENT
54-20-02
Page 156
EFFECTIVITY: TRENT
54-20-02
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POST SB 71-E107 FAN COWL DOORS - LIST OF APPROVED REPAIRS
1 REPAIR OF INDENTED OR PARTIALLY PUNCTURED INNER OR

(FRS W017) OUTER SKIN IN HONEYCOMB SANDWICH PANEL
2 REPAIR OF FLANGE EDGE DELAMINATION IN MONOLITHIC

(FRS W018) FLANGES
3 REPAIR OF THROUGH DAMAGE IN THE HONEYCOMB SANDWICH

(FRS W019) PANEL
4 REPAIR OF THE REAR EDGE RFI SHIELDED RUB STRIP

(FRS W021)
5 REPAIR OF A DISBOND AT THE SLING POINT

(FRS W022)
6 REPAIR OF THE DAMAGED CONDUCTIVE SURFACE MESH

(FRS W023)
7 REPAIR (REPLACEMENT) OF THE RFI SEALS

(FRS W026)
8 REPAIR OF WEAR TO THE FAN COWL DOOR LEADING EDGE OUTER

(FRS W027) SURFACE
9 REPAIR OF THE DECAL R:H

(FRS J086)
10 REPAIR OF THE DECAL L:H

(FRS J087)
R 11 FAN COWL DOOR – WET LAY-UP REPAIR TO MONOLITHIC CARBON

R (FRS W030) AREAS
R 12 FAN COWL – REPAIR (REPLACEMENT) OF THE ACCESS PANEL

R (FRS W032) HINGES AND LATCHES

54-20-02
Page 201
R Printed in Great Britain Jun 10/09
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR N O . l (FRSW017)
POST S B 7 1 - E 1 0 7 FAN COWL DOORS
R E P A I R O F INDENTED OR PARTIALLY PUNCURED INNER OR OUTER S K I N I N HONEYCOMB

SANDWICH PANEL.
1. General
A. T h i s repair s c h e m e i s w r i t t e n f o r t h e L e f t and R i g h t hand Fan C o w l

D o o r s t o P o s t S B 7 1 - E 1 0 7 . T h i s i s a h o t bond repair, w h i c h uses
Prepreg p l i e s . I t i s f o r d a m a g e t o curved o r f l a t surfaces w i t h
o u t e r o r i n n e r s k i n and h o n e y c o m b d a m a g e .
B. T h i s repair i s f o r a s a n d w i c h - p a n e l s t r u c t u r e w i t h , , a t h i c k n e s s of
6,35mm ( 0 . 2 5 i n . ) o r 25,4mm ( 1 . O i n . ) .
C. T h i s s c h e m e i s w r i t t e n t o repair i s o l a t e d i n c i d e n t s of i m p a c t
d a m a g e o r areas of m u l t i p l e i m p a c t d a m a g e .
(1) A r e a s of m u l t i p l e i m p a c t d a m a g e can be grouped t o g e t h e r and

thought of as a s i n g l e d a m a g e area ( F i g . 2 0 4 and 2 0 5 ) .
(2) T h i s d a m a g e area m u s t n o t be m o r e than t h e m a x i m u m a l l o w a b l e

repairable d a m a g e s i z e f o r t h e zone ( R e f . T A S K 5 4 - 2 0 - 0 2 / 1 0 1 ) .
(3) For areas of m u l t i p l e d a m a g e t h a t extend across t h e zone

boundaries, t h e repairable d a m a g e s i z e m u s t n o t be m o r e than
t h e m a x i m u m a l l o w a b l e repairable d a m a g e s i z e f o r any affected
zone.
) For d a m a g e adjacent t o o r w i t h i n keep-out z o n e s , n o t i n the

l i m i t s of t h i s r e p a i r , refer t o : .. . C..$ ..
>.
,.;;*5, ;. . ,
../ . . ..
- G., ,:
GKN A e r o s p a c e Services. . J .
. .
E a s t Cowes .
.
., ... . .
Isle of W i g h t
P 0 3 2 6RH .c '
U n i t e d Kingdom
D. T h i s d a m a g e i s repaired w i t h these p r i m a r y m a t e r i a l s
(1) C a r b o n Fibre F a b r i c
(2) Copper Mesh (dry)
(3) Adhesive f i l m
(4) Foaming Adhesive f i l m
'Repair No.1
541-203-02
P a g e 201
R6211 TRENT
STRUCTURAL REPAIR m R;
MANUAL
(5) Nomex honeycomb core
.......................................................................
.......................................................................
54-02-04 Standard Painting Procedure
54-01-06 Tap Test
54-20-01 Fan Cowl Identification
(2) Lint free gloves
(3) Roller
(5) Polythene bag
(6) Suction cleaner
(7) Heat blanket with temperature range of 0 to 130 Deg.C (32

266 Deg.F)
(8) Heat lamp with heating capacity of 80 Deg.C (176 Deg.F)
(9) Consolidation plate or Mozite rubber intensifier .-

(10) Vacuum suction pump, o to 7 6 2 m m ~ g (O to 30in.Hg)"'
(11) Four applicable vacuum fittings
(12) Four temperature probes 0 to 130 Deg.C (32 to 266 Deg.F)
(13) High speed router or Oscillating saw
(14) Disc sander
Repair No.1
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Page 202
RB211 TRENT
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.......................................................................
.......................................................................
OMat 2 61 TEMPORARY MARKER
OMat 150 ACETONE
OMat 2/111 BREATHER CLOTH (NI0 - FR)
OMat 2/113 PARTING FILM-NON POROUS (234-TFNP)
OMat 2/112 PARTING FILMOPOROUS (234-TFNP)
OMat 5/34 WATERPROOF SILICONE CARBIDE ABRASIVE PAPER (GRIT SIZE
280)
OMat 5/31 WATERPROO~SILICONE CARBIDE ABRASIVE PAPER (GRIT SIZE
400)
OMat 8/115 GLASS FABRIC- PLAIN WEAVE 'Er (BLEEDER FABRIC)
OMat 8/242 CARBON FIBRE FABRIC (FIBREDUX ~ 2 0 / 4 0 % / ~ 9 0 4 )
OMat 8/240 DRY COPPER MESH (CU022CX ASTROSEAL PRODUCTS)
OMat 8/241 ADHESIVE FILM (FM300 2M 0.03)
OMat 8/224 FOAMING ADHESIVE FILM (FM410 MAT NO. 08-047A)
OMat 8/243 NOMEX HONEYCOMB CORE (HEXWEB AI-96-3) DEPTH OF 6,35MM
(0.25 IN.)
(1.0 IN.)
OMat 2 62 MARKER

.......................................................................
WCA7110E012-041 FAN COWL DOOR, LEFT HAND
WCA7110E013-041 FAN COWL DOOR, RIGHT HAND
1
!
WARNING: WHEN YOU DO THIS REPAIR YOU MUST WEAR PROTECTIVE CLOTHING, GLOVES,
DUST MASK AND SAFETY GOGGLES TO PROTECT YOU AGAINST DUST AND LOOSE
PARTICLES, WHICH CAN BE HAZARDOUS TO YOUR HEALTH.
'WARNING: :WHEN YOU USE CLEANING MATERIALS, COATINGS, ADHESIVES AND SEALANT,
REFER TO THE MANUFACTURER~S CONTROL AND APPLICATION INSTRUCTIONS
AND SAFETY NOTICES. - .
, ,.
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54-20-02
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A. F u l l y c l e a n t h e r e p a i r a r e a (Ref .AMM TASK 70-20-01-100-802). Dry

t h e a r e a w i t h a f r e s h p i = c e of L I N T FREE CLOTH (0Mat:-2,/lOl) b e f o r e
B. Do a Tap T e s t (Ref.TASK 54-01-06) and mark o u t t h e damaged a r e a

with a MARKER (OMat 2 6 2 ) . I d e n t i f y t h e a r e a t o be r e p a i r e d .
C. Make s u r e t h e damage i s i n t h e l i m i t s of t h i s r e p a i r scheme

(Ref.TASK 54-20-02/101).
5. Prepare t h e Repair Area ( F i g . 201)
A. Mark o u t t h e a r e a of damage with a SOFT PENCIL (OMat 2 6 1 ) .
(1) Mark o u t t h e a r e a of damaged honeycomb c o r e t o be removed,

then o u t l i n e i n 12,Omm ( 0 . 4 7 2 i n . ) s t e p s f o r each p l y of
m a t e r i a l t o be removed from t h e r e p a i r a r e a . This can b e any
: n e c e s s a r y shape b u t a l l s h a r p c o r n e r s must have, a minimum
r a d i u s of 6,Omm ( 0 . 2 5 i n . ) . i .
B. I f t h e damage i s on t h e o u t e r aerodynamic s u r f a c e of t h e Fan Cowl

Door, u s e GARNET PAPER (OMat 5 / 9 7 ) t o abrade back t h e mesh. This i s
t o show t h e carbon f i b r e around t h e o u t e r s t e p by 25,4mm ( 1 . O i n . ) .
Then abrade back t h e r e s i n t o expose t h e mesh by a f u r t h e r 38,lmm
(1.5in.).
C. I f t h e damage i s n o t on t h e o u t e r aerodynamic s u r f a c e of t h e Fan

Cowl Door then only abrade back t h e r e s i n t o expose t h e carbon
f i b r e around t h e o u t e r s t e p by 25,4mm ( 1 . O i n . ) .
D. Apply TEFLON TAPE ( O M a t 2/30) around t h e r e p a i r a r e a .
E. C o r r e c t l y set t h e depth of t h e r o u t e r c u t t e r t o remove t h e damaged

s k i n and c o r e . P o s i t i o n t h e r o u t e r a s n e c e s s a r y t o remove t h e a r e a
marked a s t h e f i r s t c u t . I f n e c e s s a r y , remove water i n g r e s s a t t h i s
s t a g e by Vacuum bagging and d r y i n g ( r e f e r t o S t e p 5 . , I . ) .
F. S e t t h e r o u t e r c u t t e r t o remove t h e n e x t p l y a t t h e ~ s e c o n dc u t
p o s i t i o n . C a r e f u l l y remove each p l y i n 12,Omm ( 0 . 4 7 2 i n . ) s t e p s a t
each marked c u t p o s i t i o n u n t i l t h e s u r f a c e p l y i s reakked.
NOTE: The innermost p l y must have a minimum t h i c k n e s s of 0 , 2 m

( 0 . 0 0 8 i n . ) remaining a f t e r r o u t e r i n g and sanding.
Repair No.1
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, 2. :.
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MANUAL ;-i
G. Use a s h a r p k n i f e o r s i m i l a r t o o l t o remove t h e honeycomb from

between t h e two s k i n s of t h e p a n e l . Note t h e ribbon d i r e c t i o n of
t h e removed honeycomb c o r e . This i s t h e d i r e c t i o n of t h e s h e e t
material i n r e l a t i o n t o t h e cells of t h e honeycomb.
H. Remove any water from t h e damaged a r e a . Composites can absorb water

and o t h e r f l u i d s i n s e r v i c e , p a r t i c u l a r l y i n sandwich s t r u c t u r e s .
Absorbed water and o t h e r f l u i d s must be removed by t h e u s e of
h e a t e r lamps o r h e a t i n g b l a n k e t s and vacuum bagging a s d e s c r i b e d
below, b e f o r e you s t a r t t h i s r e p a i r .
I. Vacuum bag and d r y t h e component
(1) P o s i t i o n a s h e e t of POROUS PARTING FILM (OMat 2/112) over t h e

damaged a r e a .
(2) P o s i t i o n a BLEEDER CLOTH (OMat 2/111) t h a t i s l a r g e r than t h e

h e a t e r b l a n k e t and porous f i l m t h a t o v e r l a p s alk: s i d e s by a t
l e a s t 15,OOmm ( 0 . 5 9 i n . ) .
(3) P o s i t i o n thermocouples an e q u a l d i s t a n c e a p a r t on t h e B r e a t h e r
Cloth.
(4) P o s i t i o n t h e h e a t e r b l a n k e t i n a c e n t r a l p o s i t i o n on t h e
breather cloth.
(5) The vacuum connectors must be p o s i t i o n e d on t h e b r e a t h e r

cloth.
(6) P o s i t i o n a s h e e t of BAGGING FILM (OMat 2/31) over t h e r e p a i r

area.
(a) This should be l a r g e r than any o t h e r s h e e t s of m a t e r i a l

and should be a t t a c h e d t o t h e Fan Cowl Door with SEALANT
TAPE ( O M a t 2 / 1 1 0 ) . ,+.. .
: ... ;,p. .
. ' .".,
(7) Apply a vacuum of 6OOmmHg (23.6in.Hg), set th;"temperature of
t h e h e a t e r mat o r h e a t i n g lamp t o 70 Deg.C (158 Deg.F) f o r 6
hours minimum.
(8) When t h e d r y i n g p e r i o d h a s ended, remove t h e vacuum bagging

m a t e r i a l s and examine t h e b l e e d e r c l o t h .
(9) I f t h e b l e e d e r c l o t h shows s i g n s of contamination then do t h i s

p r o c e s s a g a i n u n t i l t h e b l e e d e r c l o t h shows no s i g n s of
contamination.
Repair No.1
EFFECTIVITY : TRENT
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RB211 TRENT
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MANUAL
(10) When t h e p r o c e s s i s done a g a i n t h e t i m e p e r i o d can be reduced

t o one hour.
(11) The r e p a i r m a t e r i a l s must be a p p l i e d s t r a i g h t a f t e r t h e end of

t h e drying period.
J. U s e a s u c t i o n c l e a n e r t o remove d u s t and d e b r i s (Ref-AMM TASK 70-

20-01-100-802). U s e ACETONE ( O M a t 150) on L I N T FREE CLOTH (OMat
2/101) t o f u l l y c l e a n t h e r e p a i r a r e a . Dry t h e a r e a . w i t h a f r e s h
p i e c e of L I N T FREE CLOTH (OMat 2/101) b e f o r e t h e f l u i d d r i e s . Leave
t o s t a n d f o r a t l e a s t 15 minutes b e f o r e you c o n t i n u e . ' ,
K. Do a Water Break T e s t . ,
(1) Brush on o r s p r a y a t h i n l a y e r of d i s t i l l e d water t o t h e

repair area.
(2) A continuous l a y e r seen f o r approximately h a l f a minute shows

t h e a r e a h a s passed t h e water break t e s t .
(3) Areas t h a t f a i l t h i s t e s t must be cleaned and t e s t e d a g a i n .
(4) A f t e r t e s t i n g , t h e a r e a s must be f u l l y d r i e d b e f o r e t h e
a p p l i c a t i o n of r e p a i r p l i e s .
(5) Use t h e vacuum bagging and d r y i n g procedure t o d r y t h e r e p a i r

a r e a , o r you can u s e h e a t i n g lamps t h a t a r e no:e:more than 70
' ,
Deg.C (158 Deg. F) t o d r y t h e r e p a i r a r e a .
7 :
.. .. . ~
.. ..
. .
6. Prepare t h e Honeycomb Core Plug . .
A. Note t h e ribbon d i r e c t i o n of t h e replacement honeycomb c o r e .
(1) This i s t h e d i r e c t i o n of t h e s h e e t m a t e r i a l i n r e l a t i o n t o t h e
cells of t h e honeycomb.
(2) Cut t h e r e p a i r honeycomb c o r e p l u g t o t h e necessary

dimensions.
(3) Cut t h e c o r e r e p a i r p l u g s o t h a t i t i s l ,Omm ( 0 . 0 4 i n . ) l a r g e r

i n diameter a l l round than t h e dimension of t h e c o r e t h a t was
removed.
(4) This w i l l make s u r e t h a t t h e c o r e r e p a i r p l u g i s i n t i g h t

c o n t a c t with t h e a d j a c e n t c o r e m a t e r i a l .
B. P l a c e t h e honeycomb c o r e p l u g under a h e a t e r lamp set a t a

temperature of 70 Deg.C (158 Deg.F) f o r 1 hour t o d r y .
Repair No.1
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RB211 TRENT
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MANUAL
C. S t o r e t h e prepared honeycomb core i n a clean polythene bag, i n a

w a r m d r y atmosphere u n t i l i t i s necessary f o r use: - '
. . .. .
: ,.,"
NOTE: R e c o r d t h e batch and m i x numbers. .. ,
CAUTION: MAKE SURE THAT THE MATERIALS HAVE REACHED ROOM TEMPERATURE
BEFORE YOU REMOVE T H E I R P R O T E C T I V E COVERINGS. DO NOT T H I N
T H E A D H E S I V E F I L M BY S T R E T C H I N G OR F O L D I N G . WEAR CLEAN
GLOVES WHEN YOU HANDLE THE A D H E S I V E F I L M OR PREPREG F A B R I C
T O PREVENT CONTAMINATION. COMPLETE THE R E P A I R BEFORE T H E
L I F E O F THE MATERIALS HAVE E X P I R E D . R E F E R T O THE
MANUFACTURERS I N S T R U C T I O N S .
Prepare t h e F i l m A d h e s i v e , Foaming F i l m A d h e s i v e , Prepreg P l i e s and

C o p p e r M e s h ( F i g . 2 0 1 and 2 0 2 )
A. U s e clean sharp scissors o r a k n i f e t o c u t t h e F I L M A D H E S I V E ( O M a t

8/241) t o t h e correct s i z e s . Make s u r e you get t h e necessary
overlaps ( F i g . 2 0 1 ) . K e e p t h e prepared sheets f l a t , a n d both release
papers i n t a c t , u n t i l t h e f i l m i s necessary f o r use.':
NOTE: C l e a n w h i t e , L I N T F R E E GLOVES ( O M a t 2 / 1 1 4 ) ,should be w o r n

w h e n you handle t h e f i l m adhesives.
B. U s e clean sharp scissors o r a k n i f e t o c u t t h e FO&NG FILM

A D H E S I V E ( O M a t 8 / 2 2 4 ) t o a s i z e t h a t i s t h e s a m e as t h e depth and
c i r c u m f e r e n c e of t h e h o n e y c o m b core plug. K e e p t h e prepared sheet
f l a t and release papers i n t a c t , u n t i l t h e f i l m i s necessary f o r
use.
NOTE: O n l y one s i n g l e layer of FOAMING F I L M A D H E S I V E ( O M a t 8 / 2 2 4 )

w i l l be necessary around t h e c i r c u m f e r e n c e of t h e r e p l a c e m e n t
honeycomb core plug.
C. B e f o r e you c u t t h e prepreg repair p l i e s , c a r e f u l l y peel back t h e

t o p release paper enough t o f i n d t h e f i b r e d i r e c t i o n , 0 degrees i s
p a r a l l e l t o t h e r o l l l e n g t h . R e p l a c e t h e release paper and u s e an
applicable MARKER P E N ( O M a t 2 6 2 ) t o m a r k t h e 0 degrees d i r e c t i o n on
t h e release f i l m . T h e release paper m u s t be replaced before you c u t
t o s t o p t h e prepreg s t i c k i n g t o t h e c u t t i n g t e m p l a t e .
, /_ "I
NOTE: Prepare as m a n y p l i e s as those c u t f r o m t h e panel being

repaired p l u s t w o m o r e repair p l i e s ( F i g . 2 0 1 ) .
D. U s e sharp scissors o r a k n i f e t o c u t t h e m a t e r i a l t o t h e necessary

p r o f i l e and f i b r e o r i e n t a t i o n
R e p a i r No.1
54-20-02
Page 207
P r i n t e d i n Great B r i t a i n ~ a r1 0. / 0 7
RB211 TRENT
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MANUAL
. L'
(1) For the ply orientation of each layer, refer to.the ply
orientation compass (Ref.TASK SRM 54-20-02, Fan Cowl
Identification section).
(2) Do the cutting on a cutting bench, not on the component to be

repaired.
(3) Cut the material to make sure you get the necessary overlaps
(Fig. 201) .
(4) Keep the prepared sheets flat and the release papers intact
until the material is necessary for laying up.
NOTE: Store the prepared adhesive film and the prepreg plies in
separate clean polythene bags. This should be :in a warm dry
atmosphere until they are necessary for use.. - .
..
. . .? . .
CAUTION: IN THE UNCURED STATE SOME CONSTITUENTS OF ADHESIV~SARE SENSITIVE
TO MOISTURE. THIS CAN HAVE AN EFFECT ON THE FINAL,PROPERTIES OF
THE BOND. RECOMMENDED STORAGE AND REMOVAL PROCEDURES MUST ALWAYS
BE STRICTLY OBEYED.
CAUTION: THE MATERIAL SPECIFICATION FOR PREPREGS STATES THAT THE

RECOMMENDED LOW TEMPERATURE STORAGE CONDITION IS -18 DEG.C (-0.4
DEG-F) THRU -25 DEG.C (-13 DEG.F). WHEN THE MATERIAL IS REMOVED
FROM REFRIGERATED STORAGE YOU SHOULD LET IT REACH ROOM TEMPERATURE
BEFORE THE MOISTURE IMPERMEABLE SEALS ARE BROKEN. THIS PREVENTS
MOISTURE CONDENSATION FORMING ON THE MATERIAL.
CAUTION: UNUSED MATERIAL MUST BE SEALED AGAIN AND RETURNED TO STORAGE UNDER
REFRIGERATED CONDITIONS. THE TIME IN AND OUT OF REFRIGERATED
STORAGE CONDITIONS MUST BE RECORDED. FOR 'OUT TIME' LIMITS, REFER
TO THE RELATED MATERIAL SPECIFICATIONS. .,, . .
, .
8. Install the Honeycomb Core Repair Plug for Stage 1 of the
..
Repair
. ',: 1:
;. 4 ..\ ;.. .
A. Remove the prepared honeycomb core repair plug from the protective
. .
polythene bag.
BEFORE YOU REMOVE THEIR PROTECTIVE COVERINGS. DO NOT THIN THE
ADHESIVE FILM BY STRETCHING OR FOLDING. WEAR CLEAN GLOVES
WHEN YOU HANDLE THE ADHESIVE FILM OR PREPREG FABRIC TO PREVENT
CONTAMINATION. COMPLETE THE REPAIR BEFORE THE LIFE OF THE
MATERIALS HAVE EXPIRED. REFER TO THE MANUFACTURERS
INSTRUCTIONS.
Repair No.1

RB211 TRENT
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B. Remove t h e r e l e a s e papers from t h e f i l m adhesive and p o s i t i o n one

l a y e r of t h e f i l m adhesive i n t h e bottom of t h e c u t o u t i n t h e
honeycomb c o r e .
C. Wrap one l a y e r of t h e prepared FOAMING ADHESIVE FILM (OMat 8/224)

around t h e circumference of t h e c u t o u t i n t h e damaged p a n e l .
D. P o s i t i o n t h e honeycomb c o r e r e p a i r p l u g i n t o t h e c u t o u t i n t h e
damaged p a n e l . Make s u r e t h e honeycomb c o r e ribbon i s i n t h e
c o r r e c t d i r e c t i o n . Do t h i s by g e n t l y squeezing t h e c o r e p l u g i n t o
p o s i t i o n . When r e l e a s e d t h i s w i l l cause t h e r e p a i r c o r e p l u g t o
expand a g a i n s t t h e FOAMING FILM ADHESIVE (OMat 8 / 2 2 4 ) .
E. Check t h a t t h e honeycomb depth does n o t s t i c k o u t more than t h e

i n n e r most p l y and i f necessary may be trimmed back t o g e t t h e
necessary depth.
9. Prepare t h e Vacuum Bag f o r Stage 1 of t h e Repair Cure Cycle ( F i g . 203)
NOTE : I f t h e p a n e l t h i c k n e s s i s more than 10,Omm (0.393in. ) , t h e r e p a i r

should have a h e a t e r mat i n s t a l l e d on both s i d e s of t h e r e p a i r .
I f h e a t i n g lamps a r e used t o c u r e t h e m a t e r i a l s , then t h e 6 s t e p s
t h a t f o l l o w a r e n o t necessary.
A. Cover t h e porous p a r t i n g f i l m with two l a y e r s of GLASS FABRIC (OMat

8/115) o r two l a y e r s of PEEL PLY (OMat 8/198) .
B. cdver t h e g l a s s f a b r i c with one l a y e r of NON-POROUS '.PARTING FILM

(OMat 2/112) . This should be a t l e a s t 25,4mm ( l .0ii':':)- s m i i l e r than
z ,.'c: .. ;:... ,
the layer before.
C. P o s i t i o n t h e h e a t e r mat over t h e r e p a i r a r e a . Make s u r e t h a t t h e

b l a n k e t e x t e n d s f o r a minimum of 50,Omm ( 1 . 9 7 i n . ) beyond each s i d e
of t h e m a t e r i a l t o be cured. Make s u r e t h e temperature probes a r e
p o s i t i o n e d t o monitor t h e r e p a i r temperature.
D. Cover t h e h e a t e r mat with two l a y e r s of BREATHER CLOTH ( O M a t

2 / 1 1 1 ) . These l a y e r s must be l a r g e r than a l l of t h e l a y e r s t h a t a r e
below them. This i s t o i n s u l a t e t h e o r i g i n a l s t r u c t u r e i n t h e
repair.
E. Cover t h e whole of t h e r e p a i r a r e a with BAGGING FILM ( O M a t 2 / 3 1 ) .
F. Use SEALANT TAPE (OMat 2/110) t o s e a l t h e edges of t h e bag t o t h e

panel.
. I L
' R e p a i r No.1
54-20-02
Page 209
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
G. Heat t h e r e p a i r a r e a up t o 130 Deg.C (266 Deg.F) f o r 60 minutes t o

c u r e t h e FOAMING FILM ADHESIVE (OMat 8 / 2 2 4 ) . The maximum h e a t up
r a t e s h o u l d be 5 Deg. C ( 9 Deg. F) p e r minute. Cool t o room
temperature a t a maximum r a t e of 5 Deg-C (9 Deg.F) p e r ' m i n k t e .
. .
. 'l. .
H. Record t h e c u r e c y c l e .
I. When t h e c u r e p r o c e s s i s complete, remove t h e bagging m a t e r i a l s and

h e a t i n g equipment from t h e r e p a i r a r e a .
1 0 . F i n i s h t h e Honeycomb Core Plug
A. The honeycomb c o r e r e p a i r p l u g w i l l need t o be made f l u s h with t h e

l e v e l of t h e honeycomb i n t h e panel b e f o r e you c o n t i n u e with t h e
n e x t s t a g e of t h i s r e p a i r .
B. Remove t h e unwanted honeycomb c o r e with a d i s c sander u n t i l t h e

c o r r e c t l e v e l i s reached. Remove a l l unwanted m a t e r i a l with a
s u c t i o n c l e a n e r . Make s u r e no p a r t i c l e s of t h e unwanted m a t e r i a l
remain on e i t h e r s i d e of t h e r e p a i r e d p a n e l .
C. F u l l y c l e a n t h e r e p a i r a r e a (Ref.= TASK 70-20-01-100-802). Dry

t h e a r e a with a f r e s h p i e c e of L I N T FREE CLOTH (0~ati"'2/10l'j'b e f o r e
D. Do a Water Break T e s t
(1) Brush on o r s p r a y a t h i n l a y e r o f . d i s t i l l e d water t o t h e

repair area.
(2) A continuous l a y e r seen f o r approximately h a l f a minute shows

t h e a r e a h a s passed t h e water break t e s t .
(3) Areas t h a t f a i l t h i s test must b e cleaned and t e s t e d a g a i n .
(4) A f t e r t e s t i n g , t h e a r e a s must be f u l l y d r i e d b e f o r e
a p p l i c a t i o n of r e p a i r p l i e s .
(5) U s e t h e vacuum bagging and d r y i n g procedure t o . d r y t h e r e p a i r

o r u s e h e a t i n g lamps t h a t a r e n o t more than .7O,:,Deg.
. .. . C , (158
.. .
Deg .F) . .L. ,.. .: . '
8
.,
.
11. Stage 2 Lay-up of PrePreg P l i e s , Film Adhesive and Copper Mesh P l i e s f o r

t h e Repair ( F i g . 202)
Repair No.1
EFFECTIVITY: TRENT
Page 210
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
BEFORE YOU REMOVE T H E I R PROTECTIVE COVERINGS. DO NOT T H I N THE
ADHESIVE F I L M BY STRETCHING OR FOLDING. WEAR CLEAN GLOVES WHEN
' YOU HANDLE THE ADHESIVE F I L M OR PREPREG FABRIC TO PREVENT
CONTAMINATION. COMPLETE THE R E P A I R BEFORE THE L I F E O F THE
MATERIALS HAS E X P I R E D . REFER TO THE MANUFACTURERS
INSTRUCTIONS.
A. A p p l y t h e prepared A d h e s i v e F i l m t o t h e h o n e y c o m b core plug and t h e

c u t o u t i n t h e panel
(1) R e m o v e t h e protective layer f r o m one side of t h e ADHESIVE F I L M

(OMAT 8 / 2 4 1 ) . P o s i t i o n the exposed surface of t h e adhesive
f i l m o n t o t h e repair area.
(2) R e m o v e any w r i n k l e s and any a i r bubbles by m a k i n g s m o o t h w i t h

a roller.
(3) W o r k f r o m t h e centre of t h e adhesive f i l m t o the. edges.

. .
(4) O n c e c o m p l e t e , r e m o v e t h e protective l a y e r .
B. A p p l y t h e prepared P r e P r e g P l i e s
(1) R e m o v e t h e p r o t e c t i v e l a y e r f r o m one side of t h e f i r s t prepreg

CARBON F I B R E FABRIC ( O M a t 8 / 2 4 2 ) ( F i b r e d u x M 2 0 / 4 0 % / ~ 9 0 4 )
r e p a i r p l y . P o s i t i o n t h e prepreg p l y on t h e ADHESIVE F I L M
(OMat 8 / 2 4 1 ) .
(2) M a k e s u r e t h a t t h e prepreg p l y i s c o r r e c t l y p o s i t i o n e d .
(3) R e f e r t o the ply o r i e n t a t i o n c o m p a s s (Ref-TASK 54-20-02).
NOTE : T h e t w o e x t r a prepreg repair p l i e s are l a i d ' a t a p o s i t i o n of

.:! : . ,,
0 degrees.
! : . .
C. R e m o v e any w r i n k l e s and any a i r bubbles by m a k i n g s m o o t h o r

r o l l i n g . W o r k f r o m t h e centre of t h e prepreg p l y t o t h e edges.
O n c e c o m p l e t e r e m o v e t h e r e m a i n i n g protective layer.
D. L a y up t h e r e m a i n d e r of t h e i n d i v i d u a l p l i e s . R e p e a t t h e 2 steps
above f o r each layer.
E. W h e n a copper m e s h i s necessary on t o p of t h e l a s t prepreg p l y , c u t

t h e COPPER MESH ( O M a t 8 / 2 4 0 ) t o t h e correct d i m e n s i o n s f o r t h e
repair area.
Repair No.1

NOTE: COPPER MESH (OMat 8/240) only needs to be replaced if the
repair is done on the aerodynamic surface.
F. The last layer must be ADHESIVE FILM (OMat 8/241)
(1) Apply the prepared adhesive film ply on top of the COPPER MESH
(OMat 8/240) (if necessary) or on the last PREPREG PLY (OMat
8/242) .
(2) Remove the protective layer from one side of the ADHESIVE FILM
(OMat 8/241). Position the exposed surface of the adhesive
film onto the repair area.
(3) Remove any wrinkles and any air bubbles by making smooth with
a roller. Work from the centre of the adhesive film to the
edges.
(4) Once complete, remove the protective layer.
G. Remove all unwanted material with a suction cleaner. Make sure no

particles of the unwanted material remain.
Prepare the Vacuum Bag for Stage 2 of the Repair Cure Cycle (Fig. 203)
NOTE: If the panel thickness is more than 10,Omm (0.393in.) then the
repair should have a vacuum bag and heater mat installed on both
sides of the repair. A consolidation plate/intensifier can be
incorporated.
A. Cover the repair plies with one layer of PEEL PLY (OMat 8/198) that
is at least 76,Omm (3.Oin. ) larger than the repair plies.
B. Cover this layer with one layer of POROUS PARTING FILM (OMat 2/112)
approximately 25,4mm (1.Oin.) larger than the peel ply.
C. Cover the porous parting film with two layers of GLASS FABRIC (OMat
8/115) or two layers of PEEL PLY (OMat 8/198).
D. Cover the glass fabric with one layer of NON-POROUS PARTING FILM
(OMat 2/112). This should be at least 25,4mm (1.Oin.) smaller than
the layer from before.
E. Position the heater mat over the repair area. Make sure that the
blanket extends for a minimum of 50,Omm (1.97in.) each side of the
material to be cured. Make sure temperature probes are positioned
to monitor the repair temperature.
Repair No.1
Page 212
Printed in Great Britain .> Mar. 10/07
1
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
F. C o v e r t h e heater m a t w i t h t w o layers of BREATHER CLOTH ( O M a t

2 / 1 1 1 ) . T h e s e layers m u s t be larger t h a n a l l t h e layers t h a t are
below them.
G. C o v e r t h e w h o l e of t h e repair area w i t h BAGGING F I L M ( O M a t 2 / 3 1 )

p l u s t w o v a c u u m f i t t i n g s . Place t h e v a c u u m f i t t i n g s t o prevent
s i t t i n g t h e m on t h e H e a t e r M a t .
H. U s e SEALANT T A P E ( O M a t 2 / 1 1 0 ) t o seal t h e edges of' t h e bag t o t h e

panel. . . .. .
.
I. T e s t t h e v a c u u m bagging can h o l d a v a c u u m of 6 6 0 1 4 i n m H g ' ( 2 6 : 0 i n . H g ) .

.,
J. C u r e the repair area by h e a t i n g up t o 130 D e g . C ( 2 6 6 D e g . F ) f o r 1 2 0
m i n u t e s . T h e m a x i m u m heat up rate should be 5 D e g . C ( 9 D e g . F ) per
minute.
(1) The v a c u u m m u s t not f a l l b e l o w 660,4mmHg ( 2 6 . O i n . Hg) i n the

c u r e cycle.
(2) C o o l t o r o o m t e m p e r a t u r e a t a m a x i m u m r a t e of 5 D e g . C (9
D e g . F ) per m i n u t e before you release t h e v a c u u m .
(3) Record t h e c u r e cycle.
K. When t h e cure process i s c o m p l e t e , r e m o v e t h e bagging m a t e r i a l s ,

h e a t i n g e q u i p m e n t and t h e t e f l o n tape f r o m t h e repair area.
13. F i n i s h t h e R e p a i r e d Surface
S-'
A. R e m o v e any r e s i n f r o m t h e edge of t h e repair area. S m o o t h t h e

surface of t h e repair a l l around t o a f e a t h e r edge and t o a s m o o t h
contour f o r p a i n t i n g .
(1) S t a r t w i t h WATERPROOF S I L I C O N CARBIDE A B R A S I V E P A P E R ( G R I T

S I Z E 2 8 0 ) ( O M a t 5 / 3 4 ) and f i n i s h o f f w i t h WATERPROOF S I L I C O N
CARBIDE ABRASIVE PAPER ( G R I T S I Z E 4 0 0 ( O M a t 5 / 3 1 ) .
(2) D o n o t abrade m e s h o r carbon.
B. R e m o v e a l l u n w a n t e d m a t e r i a l w i t h a s u c t i o n cleaner. M a k e s u r e no
p a r t i c l e s of t h e u n w a n t e d m a t e r i a l r e m a i n .
C. F u l l y clean t h e repair area ( R e f . A M M TASK 7 0 - 2 0 - 0 1 - 1 0 0 - 8 0 2 ) . Dry

the area w i t h a f r e s h piece of l i n t free c l o t h before t h e f l u i d
dries.
Page 213
P r i n t e d i n Great B r i t a i n Mar. 1 0 / 0 7
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
D. Apply s u r f a c e p r o t e c t i o n t o t h e r e p a i r e d a r e a s (Ref.TASK
1 4 . Inspection.
A. Do a v i s u a l and t a p test i n s p e c t i o n t o make s u r e t h e r e ? , a r e no

disbonds o r d e l a m i n a t i o n s i n t h e r e p a i r a r e a (Ref.TASK 54-01-
06/201).
15. I d e n t i f y t h e r e p a i r .
A. Mark FRSW017 a d j a c e n t t o t h e p a r t number of t h e f a n cowl d o o r , u s e

a MARKER PEN ( O M a t 262) of a c o n t r a s t i n g c o l o u r .
Repair No.1
Page 214
Printed i n Great B r i t a i n M a r . 10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
CONCENTRIC CIRCLES DRAWN DAMAGE AREA

ON PANEL SURFACE
PANEL MARKING
3rd CUT
STEPISCARF PREPARATION
@ EACH STEP 12 mm (0.472 in)

* N.B. @ SCARFSTEPS BY
Number of plies removed diagrammatic only. IF REQUIRED
@ 0,2 mm (0.008 in) TO REMAIN AFTER SANDING
g
S c a r f and P r e p a r a r t i o n for B o n d e d R e p a i r
Fig. 2 0 1
Repair No.1
54-20-02
P a g e 215
Printed i n Great B r i t a i n , &.10/07
R821 1 TRENT
STRUCTURAL REPAIR
MANUAL
38,lO mm
(1 50 in)
ABRADE TO EXPOSE
COPPER MESH ON
AERODYNAMIC SURFACE
FM300 ZM 0 03 FlLM
ADHESIVE
ABRADETOEXPOSE
CARBON FIBRE
OVERLAP ONTO
EXISTING COPPER PREPREG PLIES,
MESH BOTH AT 0
'
ORIENTATION
M20 REPAIR PREPREG
(AS MANY PLIES
AS PARENT SKIN)
FM410 FOAMING
ADHESIVE
FM300 2M 0.03 FlLM

ADHESIVE
N.B. ,.. "-.

Number of plies diagrammatic only. . , . .-. .
Actual number to be determined
during repair.
Damaged A r e a - Repair
F i g . 202
Repair No. l

R8211 TRENT
STRUCTURAL REPAIR
MANUAL
VACUUM PUMP
VACUUM VACUUM -
CONNECTION
I \ I
I
CONSOLIDATION PLATE OR I
I MOZlTE RUBBER INTENSIFIER' I
W "
FABRIC OR NYLON I
PEEL PLY
TAPE / U
THERMOCOUPLES 76,20mm
(3.00 in)
I REPAIR
1 PLIES
CENTER
LINE 'THE CONSOLIDATION PLATE/
MOZITE RUBBER INTENSIFIER AND
CLOTH ARE RECOMMENDED
showstypical vacuum WHEN PANEL THICKNESS IS
bag assembly GREATER THAN lO.,mm (0.40 in)
.
,> ... -
L <
-. L..
.
_ .
..,-
Repair Area - Cure .:. -

. -7"
.., ,
F i g . 203
R e p a i r No.1
P a g e 217
RB211 TRENT
STRUCTURAL REPAIR
MANUAL

I - - 1
Overall damage size to be not more than the
maximum repairabledarnage size for the zone
Repair of Multiple Damage S i t e s j

F i g . 204
Repair No.1
54-20-02
Page 218
.
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
One layer of mesh

covering complete
damaged area
Individual damage sites

repair plies equal to the
number of plies in the skin
being repaired, plus two
extra plies and copper
mesh, if required
mesh profile
(If insufficient distance between damage sites

to fit individual repair plies, as shown above,
then treat as one large damage site, below)
Two extra repair plies cover

the whole damage area
Copper mesh (if requ~red)

on outer aerodynamic
surface only
repair plies equal to the number of plies

in the skin being repaired

Fig. 205
Repair No.1
Page 219
.
p RB211 TRENT
MANUAL
STRUCTURAL
REPAIR N 0 . 2
REPAIR
(FRS W018)
R E P A I R O F FLANGE EDGE DELAMINATION I N MONOLITHIC FLANGES
1. General
A. T h i s repair s c h e m e i s w r i t t e n f o r L e f t and Right ha*d *fan:&owl doors

t o post S B 7 1 - E 1 0 7 .
B. T h i s procedure gives i n s t r u c t i o n s f o r t h e repair o f - delamination

damage t o m o n o l i t h i c flange areas
C. T h i s repair i s f o r a m o n o l i t h i c flange t h a t has s i n g l e o r m u l t i p l e

d e l a m i n a t i o n s . D a m a g e m u s t extend t o an exposed edge.
D. M a k e s u r e t h e damage i s w i t h i n t h e l i m i t s of t h i s repair ( R e f . TASK

54-20-02/101) .
I f t h e damage i s n o t i n t h e l i m i t s of t h i s r e p a i r , refer t o : GKN
A e r o s p a c e Services
E a s t Cowes
I s l e of W i g h t
P032 6RH
...... .-.... .
U .L
n i t e d Kingdom
,' . .
2. R e f e r e n c e d Information + % aym
....................................................................... :.c
........................................................................ ,
54-02-04 Standard P a i n t i n g Procedure
54-01-06 Tap Test
A. Standard E q u i p m e n t :
(1) D i s p o s a b l e syringe
(2) Spatula
(3) N e o p r e n e o r Polyvinyl C h l o r i d e G l o v e s
P .
(4) Standard w o r k s h o p t o o l s and e q u i p m e n t ;.

I".;. <
.
;:;..,-
. U - - - - -
$.;:,,
..'.
(5) H e a t lamp 4 5 t o 115 D e g . C ( 1 1 3 t o 239 D e g . F )
: >.;-
Repair N O . ~
Page 2 0 1
RB211 TRENT
STRUCTURAL REPAIR
MANUAL l
(6) Suction cleaner
(7) Temperature probes 0 to 120 Deg.C (32 to 248 Deg.F)
(8) Vibro-etching tool
.......................................................................
----- .------------------------------------------------------------
OMat ACETONE
OMa t TEMPORARY MARKER
OMat LINT FREE GLOVES
OMa t LINT FREE CLOTH
OMat NON POROUS PARTING FILM (234-TE'NP)
OMat WATERPROOF SILICONE CARBIDE (Grit size 120)
OMat EPOXY ADHESIVE (2 Part)
OMa t MARKER . .. ...
.......................................................................
PART NO. PART IDENT .
.......................................................................
WARNING: WHEN YOU USE CLEANING MATERIALS, COATINGS, ADHESIVES AND SEALANT,
REFER TO THE MANUFACTURER'S CONTROL AND APPLICATION INSTRUCTIONS
AND SAFETY NOTICES.
4. prepare the Damaged Area for Repair
A. Examine and identify the area to be repaired
(1) Mark the area with a SOFT PENCIL (OMat 261) .
(2) Make sure the damage is in the limits of this repair (Ref.
TASK 54-20-02/101) .
B. Fully clean the damaged area with a LINT FREE CLOTH (OMat 2/101)
made moist with ACETONE (OMat 150) (Ref. AMM TASK 70-20-01-100-
802) .
Repair No.2
EFFECTIVITY : TRENT
Page 202
Printed in Great Britain Mar.,10/07
.. .
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
C. D r y t h e area w i t h a clean L I N T FREE CLOTH ( O M a t 2 / 1 0 1 ) before t h e

f l u i d dries. L e a v e t o s t a n d f o r a t l e a s t 15 m i n u t e s before you
continue.
5. R e p a i r the d a m a g e d A r e a ( F i g . 2 0 1 )
A. O b e y t h e m a n u f a c t u r e r ' s i n s t r u c t i o n s and m i x enough EPOXY ADHESIVE

( O M a t 8 / 1 6 0 ) t o f i l l t h e d e l a m i n a t e d area.
B. F i l l t h e disposable s y r i n g e w i t h EPOXY ADHESIVE ( O M a t 8 / 1 6 0 ) .
C. P u t t h e EPOXY ADHESIVE (OMat 8 / 1 6 0 ) i n t o t h e area w i t h t h e s y r i n g e .
(1) C o n t i n u e t o f i l l t h e area w i t h EPOXY ADHESIVE ( O M a t 8 / 1 6 0 )

u n t i l i t c o m e s o u t f r o m t h e door edges.
(2) M a k e s u r e t h e area i s f u l l of t h e EPOXY ADHESIVE ( O M a t 8 / 1 6 0 )

before you s t o p .
C l e a n any u n w a n t e d EPOXY ADHESIVE ( O M a t 8 / 1 6 0 ) f r o m t h e area w i t h a

L I N T FREE CLOTH ( O M a t 2 / 1 0 1 ) m a d e m o i s t w i t h ACETONE ( O M a t 1 5 0 ) .
D r y t h e area w i t h a L I N T FREE CLOTH ( O M a t 2 / 1 0 1 ) before t h e ACETONE

( O M a t 1 5 0 ) dries.
Seal a l l exposed carbon edges w i t h EPOXY ADHESIVE (OMat 8 / 1 6 0 ) .
P u t NON-POROUS PARTING F I L M ( O M a t 2 / 1 1 3 ) over t h e repair area.
CAUTION: MAKE SURE THE CLAMP DOES NOT TWIST THE FLANGE.
C a r e f u l l y c l a m p t h e repair w i t h p r o f i l e d o r c o m p l i a n t blocks t o
apply t h e s a m e pressure t o t h e f u l l l e n g t h of t h e ie6air area ( F i g .
201).
C l e a n any u n w a n t e d EPOXY ADHESIVE ( O M a t 8 / 1 6 0 ) f r o m t h e area w i t h a

L I N T FREE CLOTH ( O M a t 2 / 1 0 1 ) m a d e m o i s t w i t h ACETONE ( O M a t 1 5 0 ) .
D r y t h e area w i t h a L I N T FREE CLOTH ( O M a t 2 / 1 0 1 ) before t h e ACETONE

( O M a t 1 5 0 ) dries.
S e t t h e t e m p e r a t u r e of t h e heat l a m p t o increase a t no m o r e than 3

t o 5 D e g . C ( 5 t o 9 D e g . F ) each m i n u t e .
C u r e t h e EPOXY ADHESIVE ( O M a t 8 / 1 6 0 ) f o r 220 m i n u t e s a t a

t e m p e r a t u r e of 93 D e g . C ( 2 0 0 D e g . F ) .
. . - R e p a i r No. 2
54;-:2.(1- 02
: Page203
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
M. Make s u r e t h e EPOXY ADHESIVE ( O M a t 8 / 1 6 0 ) i s f u l l y cured. T h e n , set

t h e heat lamp t o "OFF" and l e t t h e area b e c o m e c o o l .
N. When t h e cure process i s c o m p l e t e , c a r e f u l l y r e m o v e t h e c l a m p s and

the NON-POROUS PARTING F I L M ( O M a t 2 / 1 1 3 )
6. R e p a i r . - t h e Surf ace F i n i s h
A. U s e WATERPROOF S I L I C O N E CARBIDE ABRASIVE PAPER ( 0 M a t 5 / 3 9 ) ' t o m a k e

t h e repair surface s m o o t h . D o n o t abrade m e s h o r carbon l a y e r s .
B. R e m o v e a l l t h e d u s t and o t h e r u n w a n t e d m a t e r i a l w i t h a s u c t i o n
cleaner.
C. F u l l y clean t h e d a m a g e d area w i t h a L I N T FREE CLOTH ( O M a t 2 / 1 0 1 )

m a d e m o i s t w i t h ACETONE ( O M a t 1 5 0 ) .
D. D r y t h e area w i t h a clean L I N T FREE CLOTH ( O M a t 2 / 1 0 1 ) before t h e

f l u i d d r i e s . L e a v e t o s t a n d f o r a t l e a s t 15 m i n u t e s before you
continue.
7. Inspection
A. D o a v i s u a l i n s p e c t i o n and a t a p test ( R e f . TASK 5 4 - 0 1 - 0 6 / 2 0 1 ) to

m a k e sure t h e repair i s s a t i s f a c t o r y .
NOTE: If you f i n d d a m a g e o r t h e repair has n o t bonded . .. c o ~ r e c t l yi t

. , . " .
m u s t be rejected. . .,
.. ..,:,.-
.,..
T,
.
8. A p p l y t h e Surface F i n i s h
A. A p p l y t h e surface f i n i s h t o g i v e p r o t e c t i o n ( R e f . TASK 5 4 - 0 2 -
04/201).
9. R e c o r d the R e p a i r
A. R e c o r d d e t a i l s of t h e R e p a i r N o . F R S ~ 0 1 8
(1) Make a p e r m a n e n t record on t h e M o d P l a t e of t h e door w i t h an

electrical vibro-etching t o o l .
R e p a i r No.2
Page 204
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
I 'C. .
/
30,Omrn
,,8in) Maximum Delamiriation
OPERATE SYRINGE UNTIL ADHESIVE

COMES OUT OF DOOR EDGE TYPICAL SECTION A-A
BLOCK MADE TO SAME SHAPE

CONTOUR OF REPAIR AREA.
- ,.
.. . .. .
i' , .
. .. .
VIEW ON CORNER OF DOOR :. '; ',,fT',
DURING CURE
Flange Edge Delamination

Figure 201
Repair No.2
54-20-02
Page 205
.
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR NO. 3 (FRS W019)
POST SB 71-E107 FAN COWL DOORS
REPAIR OF THROUGH DAMAGE IN THE HONEYCOMB SANDWICH PANEL.
1. General
A. This repair scheme is written for the Left and Right hand Fan Cowl
Doors to Post SB71-E107. This is a hot bond repair, which uses
Prepreg plies to repair a hole that goes fully through the
honeycomb sandwich panel.
, .
B. This repair is for a sandwich-panel structure with,a thickness of

6 , 3 5 m (0.25in.) or 25,4mm (1.Oin.). t.
C. This scheme is written to repair isolated incidents of impact

damage or areas of multiple impact damage.
(1) Areas of multiple impact damage can be grouped together and

thought of as a single damage area (Fig. 205 and 206).
(2) This damage area must not be more than the maximum allowable
repairable damage size for the zone (Ref.TASK 54-20-02/101).
(3) For areas of multiple damage that extend across the zone
boundaries, the repairable damage size must not be more than
the maximum allowable repairable damage size for any affected
zone.
(4) For damage adjacent to or within keep-out zones, not in the

limits of this repair, refer to:
J
GKN Aerospace Services.
East Cowes - ,.i
Isle of Wight 5
P032 6RH
United Kingdom
D. This damage is repaired with these primary materials
(1) Carbon Fibre Fabric
(2) Copper Mesh (dry)
(3) Adhesive film
(4) Foaming Adhesive film
, Repair No. 3
,. Page 201
Printed i n Great B r i t a i n . Jun.10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(5) Nomex honeycomb core
.......................................................................
_--__-------___------------------------------d-------------------------
54-02-04 Standard Painting Procedure

54-01-06 Tap Test
54-20-01 Fan Cowl Identification
3. ~ q u i ~ i e nand
t Materials
(2) Lint free gloves
(3) Roller
(5) Polythene bag
(6) Suction cleaner
(7) Heat blanket with temperature range of 0 to 130 Deg.C (32 to

266 Deg.F)
(8') Heat lamp with heating capacity of 80 Deg.C (17.6Deg. F)
(9) Support Plate
(10) Consolidation plate or Mozite rubber intensifier
(11) Caul Plate
(12) Vacuum suction pump, 0 to 762mmHg (0 to 30in.Hg)
(13) Four applicable vacuum fittings
(14) Four temperature probes 0 to 130 Deg.C (32 to 266 Deg.F)
(15) High speed router or Oscillating saw
, Repair No.3
<
Page 202
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
.......................................................................
.......................................................................
r
OMat 150 ACETONE i ,
L

OMat 2/111 BREATHER CLOTH (NI0-FR)
OMat 2/113 PARTING FILM-NON POROUS (234-TE"NP)
OMat 2/112 PARTING FILMOPOROUS (234-TFNP)
OMat 2/157 FLASHBREAKER ADHESIVE TAPE
280)
400)
OMat 8/115 GLASS FABRIC-PLAIN WEAVE 'E1 (BLEEDER FABRIC)
OMat 8/198 NYLON PEEL PLY B100
OMat 8/242 CARBON FIBRE FABRIC (FIBREDUX ~20/40%/G904)
OMat 8/240 DRY COPPER MESH (CU022CX ASTROSEAL PRODUCTS)
OMat 8/241 ADHESIVE FILM (FM300 2M 0.03)
OMat 8/224 FOAMING ADHESIVE FILM (FM410 MAT NO. 0 8 - 0 4 7 ~ )
(0.25 IN.)
(1.0 IN.)
OMat 262 MARKER
.......................................................................
FAN COWL DOOR, LEFT HAND

FAN COWL DOOR, RIGHT HAND
PARTICLES, WHICH CAN BE HAZARDOUS TO YOUR HEALTH..:
WARNING: WHEN YOU USE CLEANING MATERIALS, COATINGS, ADHES**S<AND SEALANT,

REFER TO THE MANUFACTURER^ S CONTROL AND APPLICATION INSTRUCTIONS
AND SAFETY NOTICES.
Repair No.3
54-20-02
Page 203
H RB211 TRENT
MANUAL
STRUCTURAL REPAIR
4. Clean t h e R e ~ a i rArea
A. F u l l y c l e a n t h e r e p a i r a r e a (Ref.AMM TASK 70-20-01-100-802). Dry

t h e a r e a with a f r e s h p i e c e of LINT FREE CLOTH ( O M a t 2/101) b e f o r e
3 ,.
B. Do a Tap T e s t (Ref. TASK 54-01-06/201) and mark o u t ...th,e . ..damaged a r e a

1 C
with a MARKER (OMat 2 6 2 ) . I d e n t i f y t h e a r e a t o be re@,aired.
C. Make s u r e t h e damage i s i n t h e l i m i t s of t h i s r e p a i r scheme a s

given i n TASK 54-20-02/101.
5. Prepare t h e Repair Area ( F i g . 201)
A. Mark o u t t h e a r e a of damage with a SOFT PENCIL (OMat 261)
(1) Mark o u t t h e a r e a of damaged honeycomb c o r e t o be removed,

then o u t l i n e i n 12,Omm ( 0 . 4 7 2 i n . ) s t e p s f o r each p l y of
m a t e r i a l t o be removed from t h e r e p a i r a r e a . This can b e any
shape b u t a l l s h a r p c o r n e r s must have a minimum r a d i u s of
6,4mm ( 0 . 2 5 i n . ) .
B. If t h e damage i s on t h e o u t e r aerodynamic s u r f a c e of t h e Fan Cowl

Door, u s e GARNET PAPER (OMat 5/97) t o abrade back t h e mesh. This i s
t o show t h e carbon f i b r e around t h e o u t e r s t e p by 25,4mm ( 1 . O i n . ) .
Then abrade back t h e r e s i n t o expose t h e mesh by a Z u r t h e r 38,lmm
-\:,.13
( 1 . 5 i n . ) around t h e o u t e r p r o f i l e . Do t h i s f o r t h e o u t e r
aerodynamic s u r f a c e of t h e damaged p a n e l .
C. Apply TEFLON TAPE ( O M a t 2/30) around t h e r e p a i r a r e a .
D. C o r r e c t l y s e t t h e depth of t h e r o u t e r c u t t e r t o remove t h e damaged

s k i n and c o r e . P o s i t i o n t h e r o u t e r a s necessary t o remove t h e a r e a
marked a s t h e f i r s t c u t . I f necessary, remove any water i n g r e s s a t
t h i s s t a g e by Vacuum bagging and d r y i n g .
E. S e t t h e r o u t e r c u t t e r t o remove t h e n e x t p l y a t t h e second c u t
p o s i t i o n . Then c a r e f u l l y remove each p l y i n 12,Omm ( 0 . 4 7 2 i n . ) s t e p s
a t each marked c u t p o s i t i o n . Do t h i s u n t i l t h e s u r f a c e p l y i s
reached.
NOTE: The innermost p l y must have a minimum t h i c k n e s s of 0,2mm

( 0 . 0 0 8 i n . ) remaining a f t e r r o u t e r i n g and sanding.
It
F. DO t h e t h r e e s t e p s from above on t h e o t h e r s i d e of t&kpanel i n the

marked o u t a r e a .
Repair No.3
EFFECTIVITY : TRENT
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RB211 TRENT
',STRUCTURALREPAlR
MANUAL
G. U s e a sharp k n i f e o r s i m i l a r t o o l t o remove t h e ho*eycomb from

between t h e two s k i n s of t h e p a n e l . Note t h e r i b b o n , d i r e c t i o n of
t h e removed honeycomb c o r e . This i s t h e d i r e c t i o n of:;the . s h e e t
material i n r e l a t i o n t o t h e c e l l s of t h e honeycomb.
H. Remove any water from t h e damaged a r e a . Composites can absorb water

and o t h e r f l u i d s i n s e r v i c e , p a r t i c u l a r l y i n sandwich s t r u c t u r e s .
Absorbed water and o t h e r f l u i d s must be removed by t h e u s e of
h e a t e r lamps o r h e a t i n g b l a n k e t s and vacuum bagging a s d e s c r i b e d
below, b e f o r e you s t a r t t h i s r e p a i r .
I. Vacuum bag and d r y t h e component
(1) P o s i t i o n a blanking p l a t e o r BAGGING FILM (OMat 2/32) on one

s i d e of t h e r e p a i r a r e a and make s u r e i t i s s e a l e d with
SEALANT TAPE (OMat 2 / 1 1 0 ) . O n t h e s i d e of t h e damaged a r e a , do
t h e s t e p s t h a t follow:
.. ..
(a) P o s i t i o n a s h e e t of POROUS PARTING F I L M.;',,!!...
. (OMat 2/112) over
. .: . ., .
t h e damaged a r e a . -
'. ;. .
."
(
..
'
1?
, , _. .
._
- \;,
L.,,;
(b) P o s i t i o n a BLEEDER CLOTH (OMat 2 i 1 1 1 ) t h a t i s larger than

t h e h e a t e r b l a n k e t and porous f i l m t h a t o v e r l a p s a l l
s i d e s by a t l e a s t 15,OOmm ( 0 . 5 9 i n . ) .
(C) P o s i t i o n thermocouples e q u a l l y spaced on t h e Breather

Cloth.
(d) P o s i t i o n t h e h e a t e r b l a n k e t i n a c e n t r a l p o s i t i o n on t h e
breather cloth.
(e) The vacuum connectors must be p o s i t i o n e d on t h e b r e a t h e r

cloth.
(f) P o s i t i o n a s h e e t of B2iGGING FILM (OMat 2/31) over t h e

repair area.
1) This should be l a r g e r than any o t h e ~ ' s h e e t sof

m a t e r i a l and should be a t t a c h e d t o t h e Fan Cowl Door
with SEALANT TAPE ( O M a t 2/ 110) . ' l
* .; :\ .
(g) Apply a vacuum of 6OOmmHg ( 2 3 . 6 i n . H g ) , set t h e
temperature of t h e h e a t e r mat o r h e a t i n g lamp t o 70 Deg.C
(158 Deg.F) f o r 6 hours minimum.
(h) When t h e d r y i n g p e r i o d has ended, remove t h e vacuum

bagging m a t e r i a l s and examine t h e b l e e d e r c l o t h .
Repair No.3
54-20-02
Page 205
'<. :: :
RB211 TRENT . ,:
:
.
. c.
:
..,..: . %. ,
.:
:
STRUCTURAL REPAIR
MANUAL
(i) If the bleeder cloth shows signs of contamination then do

this process again until the bleeder cloth shows no signs
of contamination.
(j) When the process is done again the time period can be
reduced to one hour.
(k) The repair materials must be applied immediately after

the drying period.
J. Use a suction cleaner to remove dust and debris (Ref.= TASK 70-
20-01-100-802). Use ACETONE (OMat 150) on LINT FREE CLOTH (OMat
2/101) to fully clean the repair area. Dry the area with a fresh
piece of LINT FREE CLOTH (OMat 2/101) before the £luid.dries. Leave
to stand for at least 15 minutes before you continue:':;,
. .:
' ;: ?...
e,7
K. Do a Water Break Test

repair area.
(2) A continuous layer seen for approximately half a minute shows

the area has passed the water break test.
(3) Areas that fail this test must be cleaned and tested again.
(4) After testing, the areas must be fully dried before the
application of repair plies.
(5)
. .
Use the vacuum bagging and drying procedure to dry the repair
area. Or you can use heating lamps set at a temperature that
is not more than 70 Deg.C (158 Deg.F) to dry $he !L,
repai:r
.. area. "
',
..., ..
3 .
6. Prepare the Honeycomb Core Plug . . ,.

, .
. , L ,
A. Note the ribbon direction of the replacement honeycomb core
(1) This is the direction of the sheet material in relation to the

cells of the honeycomb.
(2) Cut the repair honeycomb core plug to the necessary

dimensions.
(3) Cut the core repair plug so that it is l, Omm (0.04in.) larger
in diameter all round than the dimension of the core that was
removed. This will make sure that the core repair plug is in
tight contact with the adjacent core material
'Repair No.3
5 02
0.-
.?.'- , ,
t.:,
.,, ..,',
, ,
.
Page 206
Printed in Great Britain ... Mar. 10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
B. Place t h e honeycomb core plug under a heater lamp set a t a

t e m p e r a t u r e of 7 0 D e g . C ( 1 5 8 D e g . F ) f o r 1 hour t o d r y .
C. S t o r e t h e prepared honeycomb core i n a clean polythene bag, i n a

w a r m dry a t m o s p h e r e u n t i l i t i s necessary f o r use.
NOTE: R e c o r d t h e batch and m i x numbers.
CAUTION: MAKE SURE THAT THE MATERIALS HAVE REACHED ROOM TEMPERATURE BEFORE
YOU REMOVE T H E I R P R O T E C T I V E COVERINGS. DO NOT T H I N , ' T H E A D H E S I V E
F I L M BY S T R E T C H I N G OR FOLDING. WEAR CLEAN GLOVES WHEN YOU HANDLE
T H E A D H E S I V E F I L M OR PREPREG F A B R I C TO PREVENT CONTAMINATION.
COMPLETE THE R E P A I R BEFORE THE L I F E O F THE MATERIALS HAVE E X P I R E D .
R E F E R TO THE MANUFACTURERS I N S T R U C T I O N S .
7. Prepare t h e F i l m A d h e s i v e , P r e p r e g P l i e s and C o p p e r M e s h ( F i g . 202 and

203)
A. U s e clean sharp scissors o r a k n i f e t o c u t t h e F I L M A D H E S I V E ( O M a t

8 / 2 4 1 ) t o t h e correct s i z e s , a l l o w f o r overlap. D o t h i s f o r both
sides of t h e panel t o be repaired. K e e p t h e prepared sheets f l a t
and b o t h release papers i n t a c t , u n t i l t h e f i l m i s necessary f o r
use.
NOTE: C l e a n w h i t e , L I N T F R E E GLOVES ( O M a t 2 / 1 1 4 ) should be w o r n

w h e n you handle t h e f i l m adhesives. ., ......... .
, < .
. .
B. B e f o r e you c u t t h e prepreg repair p l i e s , ~ a r e f u l l ~ ' ~ hack ~ e e 1t h e

top release paper enough t o f i n d t h e f i b r e d i r e c t i o n , 0 degrees i s
p a r a l l e l t o t h e r o l l l e n g t h . R e p l a c e t h e release paper and use a n
applicable MARKER P E N ( O M a t 2 6 2 ) t o m a r k t h e 0 degrees d i r e c t i o n on
t h e release f i l m . T h e release paper m u s t be replaced before you c u t
t h e prepreg t o s t o p t h e prepreg s t i c k i n g t o t h e c u t t i n g t e m p l a t e .
NOTE: Prepare as m a n y p l i e s as those 'cut f r o m t h e panel being

repaired p l u s t w o m o r e repair p l i e s .
C. U s e sharp scissors o r a k n i f e t o c u t t h e m a t e r i a l t o t h e necessary

p r o f i l e and f i b r e d i r e c t i o n .
(1) For t h e p l y d i r e c t i o n of each layer, refer t o t h e p l y c o m p a s s

( R e f . T A S K SRM 5 4 - 2 0 - 0 2 , Fan C o w l I d e n t i f i c a t i o n s e c t i o n ) .
(2) D o t h e c u t t i n g on a c u t t i n g bench, n o t on t h e . k o m p o n e n t t o be
repaired. . ,
' . . .-, %
(3) C u t the m a t e r i a l t o m a k e s u r e t h a t you have ne=&sary

overlaps. , I
Repair No.3
Page 207
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
.. .
(4) Keep the prepared sheets flat and the release.papers intact
.
until the material is necessary for laying up..,';:';:j:,<: ,
,
NOTE: Store the prepared adhesive film and the prepre.g plies in
separate clean polythene bags. This should be in a warm dry
atmosphere until they are necessary for use.
CAUTION: IN THE UNCURED STATE SOME CONSTITUENTS OF ADHESIVES ARE SENSITIVE

TO MOISTURE. THIS CAN HAVE AN EFFECT ON THE FINAL PROPERTIES OF
THE BOND. THE MANUFACTURER'S RECOMMENDED STORAGE AND REMOVAL
PROCEDURES MUST ALWAYS BE STRICTLY OBEYED.
CAUTION: THE MATERIAL SPECIFICATION FOR PREPREGS STATES THAT THE

RECOMMENDED LOW TEMPERATURE STORAGE CONDITION IS MINUS 18 DEG.C
(MINUS 0.4 DEG.F) THRU -25 DEG.C (-13 DEG.F). WHEN THE MATERIAL IS
REMOVED FROM REFRIGERATED STORAGE YOU MUST LET IT REACH ROOM
TEMPERATURE BEFORE THE MOISTURE IMPERMEABLE SEALS ARE BROKEN. THIS
PREVENTS MOISTURE CONDENSATION FORMING ON THE MATERIAL.
.A
CAUTION: UNUSED MATERIAL MUST BE SEALED AGAIN AND RETURNED TO' STORAGE UNDER
REFRIGERATED CONDITIONS. THE TIME IN AND OUT OF REFRIGERATED
STORAGE CONDITIONS MUST BE RECORDED. FOR 'OUT TIME' LIMITS, REFER
TO THE RELATED MATERIAL SPECIFICATIONS.
8. Install the Honeycomb Core Repair Plug and Stage 1 Lay-up of the Repair
Plies (Fig. 202) .
A. Remove the prepared honeycomb core repair plug from the protective
polythene bag.
MATERIALS HAVE EXPIRED. REFER TO THE M A N U F A C T F R S
INSTRUCTIONS. A -7:
2 &
.' Z
B. Prepare enough FOAMING ADHESIVE FILM (OMat 8/224) and,,let it reach

room temperature. Use clean sharp scissors or a knii=' to cut the
FOAMING ADHESIVE FILM (OMat 8/224) and wrap one layer around the
circumference of the cut-out in the panel.
C. Prepare a metal caul plate that is the same as the profile of the
repair area and attach it to the side of the panel opposite to the
first stage of the repair. This is to support the honeycomb core in
the cure cycle.
Repair No.3
EFFECTIVITY : TRENT
54-20-02
Page 208
P RB211 TRENT
MANUAL
STRUCTURAL REPAIR -.
D. With t h e ribbon d i r e c t i o n c o r r e c t , p o s i t i o n t h e honeycomb c o r e

r e p a i r p l u g i n t o t h e c u t o u t i n t h e damaged panel by g e n t l y
squeezing t h e c o r e p l u g i n t o p o s i t i o n . When r e l e a s e d , t h i s w i l l
cause t h e r e p a i r c o r e p l u g t o expand a g a i n s t t h e FOAMING FILM
ADHESIVE (OMat 8 / 2 2 4 ) .
E. Check t h a t t h e honeycomb depth does n o t s t i c k o u t more than t h e

i n n e r most p l y and i f necessary may be trimmed back t o g e t t h e
necessary depth.
F. Apply t h e prepared p r e p r e g p l i e s t o t h e c u t - o u t i n t h e p a n e l .
G. Remove t h e p r o t e c t i v e l a y e r from one s i d e of t h e ADHESIVE.FILM

(OMAT 8 / 2 4 1 ) . Place t h e exposed s u r f a c e of t h e ADHESIVE FILM (OMAT
8/241) o n t o t h e r e p a i r a r e a . Remove any wrinkles arid,,,any . a i r
. . . . v
bubbles by making smooth with a r o l l e r . Work from t h e c e n t r e of t h e

ADHESIVE FILM (OMAT 8/241) t o t h e edges. Once comple.te, remove t h e
protective layer.
H. Remove t h e p r o t e c t i v e l a y e r from one s i d e of t h e f i r s t p r e p r e g

CARBON FIBRE FABRIC ( O M a t 8/242) (Fibredux M20/40%/G904) r e p a i r
p l y . P o s i t i o n t h e p r e p r e g p l y on t h e ADHESIVE FILM (OMat 8/241) .
Make s u r e t h a t t h e p r e p r e g p l y i s c o r r e c t l y p o s i t i o n e d . Refer t o
t h e p l y o r i e n t a t i o n compass (Ref.TASK 54-20-02 - Fan Cowl
Identification) .
NOTE: The two p r e p r e g r e p a i r p l i e s a r e l a i d a t a p o s i t i o n of 0

degrees.
I. Remove any w r i n k l e s and any a i r bubbles by making smooth o r

r o l l i n g . Work from t h e c e n t r e of t h e p r e p r e g p l y $ ? . t h e edges. Once
complete, remove t h e remaining p r o t e c t i v e l a y e r . . . - c
J. lay-up t h e rest of t h e i n d i v i d u a l p l i e s . Do t h e thre'bbsteps above

f o r each p l y l a y e r .
K. When a copper mesh i s necessary on t o p of t h e l a s t p r e p r e g p l y , c u t

t h e COPPER MESH (OMat 8/240) t o t h e c o r r e c t dimensions f o r t h e
r e p a i r a r e a . Apply t h e copper mesh on t h e l a s t p r e p r e g r e p a i r p l y .
NOTE: COPPER MESH (OMat 8/240) only needs t o be r e p l a c e d i f t h e

r e p a i r i s done on t h e aerodynamic s u r f a c e .
L. The l a s t l a y e r must be ADHESIVE FILM (OMat 8 / 2 4 1 ) . Cut an adhesive

f i l m p l y t o t h e c o r r e c t dimensions f o r t h e r e p a i r . This i s t o be
p o s i t i o n e d on t o p of t h e COPPER MESH (OMat 8/240) ( i f n e c e s s a r y ) o r
t h e l a s t prepreg p l y .
.Repair No.3
....
.
L, .S<:
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;A>:~:
Page 209
RB211 TRENT
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m MANUAL
M. R e m o v e t h e p r o t e c t i v e layer f r o m one s i d e of t h e ADHESIVE F I L M

( O M a t 8 / 2 4 1 ) . P o s i t i o n t h e exposed surface of t h e ADHESIVE F I L M
( O M a t 8 / 2 4 1 ) onto t h e repair area. R e m o v e any w r i n k l e s and any a i r
bubbles by m a k i n g s m o o t h w i t h a r o l l e r , w o r k f r o m t h e centre of t h e
ADHESIVE F I L M ( O M a t 8 / 2 4 1 ) t o t h e edges. O n c e c o m p l e t e r e m o v e t h e
protective layer.
...,
3 .
N. R e m o v e a l l u n w a n t e d m a t e r i a l w i t h a s u c t i o n cleaner, Make"sure
there are no particles of t h e u n w a n t e d m a t e r i a l r e m a i n i n g .
9. P r e p a r e t h e V a c u u m B a g f o r Stage 1 of t h e R e p a i r C u r e C y c l e ( F i g . 204)
NOTE: If t h e panel t h i c k n e s s i s m o r e t h a n 1 0 , O m m ( 0 . 3 9 3 i n . ) t h e n t h e
repair should have a v a c u u m bag and heater m a t i n s t a l l e d on both
sides of t h e repair.
A. C o v e r t h e honeycomb w i t h one layer of PEEL PLY ( O M a t 8 / 1 9 8 ) t h a t i s

a t l e a s t 7 6 , O m m ( 3 . 0 i n . ) larger i n d i a m e t e r than t h e l a r g e s t repair
P ~ -Y
B. C o v e r t h i s l a y e r w i t h one layer of POROUS PARTING F I L M ( O M a t 2 / 1 1 2 )

a p p r o x i m a t e l y 2 5 , 4 m m ( 1 . O i n . ) m o r e than t h e peel p l y .
C. C o v e r t h e porous p a r t i n g f i l m w i t h t w o l a y e r s of GLASS FABRIC ( O M a t

8 / 1 1 5 ) o r t w o layers of PEEL PLY ( O M a t 8 / 1 9 8 ) .
' f . .,
. .. .
NOTE: A c o n s o l i d a t i o n p l a t e o r ~ o z i t erubber inten&£jier , , . * .,. m& be
used. T h i s m a y i m p r o v e t h e p r o f i l e of t h e f i n a l f i n i s h of t h e
repair. If a c o n s o l i d a t i o n p l a t e o r M o z i t e rubber i n t e n s i f i e r
i s used, i t should be positioned b e t w e e n t h e t w o layers of
GLASS FABRIC ( O M a t 8 / 1 1 5 ) o r t w o layers of P E E L PLY ( O M a t
8 / 1 9 8 ) . T h e layers m u s t be larger than t h e c o n s o l i d a t i o n
p l a t e by a t l e a s t 2 5 , 4 m m ( l . O i n . ) .
CAUTION: PRESSURE W I L L BE L E S S THAN EQUAL I F THE CONSOLIDATION PLATE

DOES NOT MEET THE CONTOURS O F THE R E P A I R . T H I S MAY CAUSE V O I D S
OR HIGH R E S I N CONTENT I N AREAS I N THE R E P A I R P L I E S . FOR CURVED
AREAS USE A MOZITE RUBBER I N T E N S I F I E R .
D. C o v e r t h e glass fabric w i t h one layer of NON-POROUS PARTING F I L M

( O M a t 2 / 1 1 2 ) . T h i s should be a t l e a s t 2 5 , 4 m m ( 1 . O i n . ) s m a l l e r than
t h e previous l a y e r .
E. P o s i t i o n t h e heater m a t over t h e repair area. M a k e s u r e t h a t t h e

b l a n k e t extends f o r a m i n i m u m of 50,Omm ( 1 . 9 7 i n . ) beyond each side
of t h e m a t e r i a l t o be cured. M a k e s u r e t e m p e r a t u r e probes are
p o s i t i o n e d t o m o n i t o r t h e repair t e m p e r a t u r e .
Repair No.3
P a g e 210
R8211 TRENT
STRUCTURAL REPAIR
MANUAL
F. Cover the heater mat with two layers of BREATHER CLOTH (OMat
2/111). These layers must be larger than all the laxers that are
below them. . .t B,'
-. L
G. Cover the whole of the repair area with BAGGING FILM (OMat 2/31)
plus two vacuum fittings. Make sure the vacuum fittings are placed
so that they do not sit on the Heater Mat.
H. Seal the edges of the bag to the panel with SEALANT TAPE (OMat
2/110).
I. Test the vacuum bagging can hold a vacuum of 660,4mmHg (26.0in.Hg).
J. Cure the repair area by heating up to 130 Deg.C (266 Deg.F) for 120
minutes. The maximum heat up rate should be 5 Deg.C (9 Deg.F). The
vacuum must not fall below 660,4mmHg (26.0in.Hg) in the cure cycle.
Cool to room temperature at a maximum rate of 5 Deg.C (9 Deg.F) per
minute before you release the vacuum.
. ..
. .-S,
...
.. .
.L., . ..
K. Record the cure cycle. . ,. . ..
.. ,, , .
.. :-.
. . , .. '..
' . .
.C..
, ... r, .." ,
l : .
,
L. When the cure process is complete, remove the bagging'materials,

heating equipment, consolidation and support plates,,andthe TEFLON
TAPE (OMat 2/30) from the repair area.
10. Finish the Honevcomb Core Plua
A. The honeycomb core repair plug will need to be made flush with the
level of the honeycomb in the panel before you continue with the
next stage of the repair.
B. Remove the unwanted honeycomb core with a disc sander until the
correct level is reached. Remove all unwanted material with a
suction cleaner. Make sure no particles of the unwanted material
remain on either side of the repaired panel.
C. Fully clean the repair area (Ref.AMM TASK 70-20-01-100-802) . Dry

the area with a fresh piece of LINT FREE CLOTH ( 0 ~ ~ t " 2 /. 1 .'0 1
before
)
. - -..
. -.
. ,." ._. . .&
- .
the fluid dries. .3".
.,.A
I . :
, <.S ,L::
'
1.. ...
D. Do a Water Break Test

repair area.
(2) A continuous layer seen for approximately half a minute shows

the area has passed the water break test.
Repair No.3
54-20-02
Page 211
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(3) Areas that fail this test must be cleaned and tested again
(4) After testing, the areas must be fully dried before

application of repair plies.
(5) Use the vacuum bagging and drying procedure to dry the repair
or use heating lamps that are not more than 70 Deg.C (158
Deg. F) .
11. Stage 2 Lay-up of PrePreq Plies, Adhesive and Copper Mesh Plies for the
Repair (Fig. 202 and 203)
MATERIALS HAS EXPIRED. REFER TO THE MANUFACTURERS
INSTRUCTIONS.
A. Apply the prepared prepreg plies to the honeycomb core plug and the
cut-out in the panel.
B. Do steps 8.G. to 8.1.
C. Lay-up the rest of the individual plies. Do steps 8.G. to 8.1.

again for each ply layer.
NOTE: The two extra prepreg repair plies are laid at a position of
: 0 degrees.
. -.
D. When a copper mesh is necessary on top of the l a s t ' ~ i r ~ p r e ~ l cut

y,
the COPPER MESH (OMat 8/240) to the correct dimensio6s fo;:' the
repair area. Install the COPPER MESH (OMat 8/240) ov$?the layer of
Prepreg ply.
NOTE: COPPER MESH (OMat 8/240) only needs to be replaced if the

repair is done on the aerodynamic surface.
E. The last layer must be ADHESIVE FILM (OMat 8/241). Cut an adhesive
film ply to the correct dimensions for the repair, this is to be
placed on top of the COPPER MESH (OMat 8/240) (if necessary) or the
last prepreg ply.
Repair No.3
. . .,2o,.-
54-.... . 02
.. . .?
: ':L.'!..... . - ,
. , . .U,
:L :
'
..
''.7.':'
\.
. Page
' 212
RB211 TRENT
STRUCTURAL REPAIR
m MANUAL
F. Remove t h e p r o t e c t i v e l a y e r from one s i d e of t h e ADHESIVE FILM

(OMat 8 / 2 4 1 ) . Place t h e exposed s u r f a c e of t h e ADHESIVE FILM (OMat
8/241) o n t o t h e r e p a i r a r e a . Remove any wrinkles and any a i r
bubbles by making smooth with a r o l l e r . Work from t h e c e n t r e of t h e
ADHESIVE FILM ( O M a t 8/241) t o t h e edges. Once complete, remove t h e
protective layer.
G. Remove a l l unwanted m a t e r i a l with a s u c t i o n c l e a n e r. . . + k e \

s u r e no
p a r t i c l e s of t h e unwanted m a t e r i a l remain.
1 2 . Prepare t h e Vacuum Bag f o r Stage 2 of t h e Repair Cure Cycle ( F i g . 204)
A. Cover t h e honeycomb with one l a y e r of PEEL PLY (OMat 8/198) t h a t i s

a t l e a s t 76,Omm ( 3 . 0 i n . ) l a r g e r i n diameter than t h e l a r g e s t r e p a i r
P ~ Y
B. Repeat t h e 'Prepare t h e Vacuum Bag1 s t e p b u t i g n o r e t h e

c o n s o l i d a t i o n p l a t e / M o z i t e rubber i n t e n s i f i e r .
C. Cure t h e r e p a i r a r e a by h e a t i n g up t o 130 Deg.C (266 Deg.F) f o r 120

minutes. The maximum h e a t up r a t e should be 5 Deg.C (9Deg.F). The
vacuum must n o t f a l l below 660,4mmHg (26.0in.Hg) i n t h e c u r e c y c l e .
Cool t o room temperature a t a maximum r a t e of 5 Deg.C (9 Deg.F) p e r
minute b e f o r e you r e l e a s e t h e vacuum.
D. Record t h e c u r e c y c l e .
.'.A
E. When t h e c u r e p r o c e s s i s complete, remove t h e bagging m a t e r i a l s ,

h e a t i n g equipment and t h e Teflon t a p e from t h e r e p a i r a r e a .
1 3 . F i n i s h t h e Repaired S u r f a c e
A. Remove any r e s i n from t h e edge of t h e r e p a i r a r e a . Smooth t h e

s u r f a c e of t h e r e p a i r a l l around t o a f e a t h e r edge and t o a smooth
contour f o r p a i n t i n g .
(1) S t a r t with WATERPROOF SILICON CARBIDE ABRASIVE PAPER ( G R I T

SIZE 280) (OMat 5/34) and f i n i s h o f f with WATERPROOF SILICON
CARBIDE ABRASIVE PAPER ( G R I T SIZE 400 ( O M a t 5 / 3 1 ) .
(2) Do n o t abrade mesh o r carbon.
(3,) Do t h i s f o r both s i d e s of t h e p a n e l .
B. Remove a l l unwanted m a t e r i a l with a s u c t i o n c l e a n e r , Make.sure no

p a r t i c l e s of t h e unwanted m a t e r i a l remain.
.
1 * 1
Repair No.3
Page 213
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
C. Fully c l e a n t h e r e p a i r a r e a (Ref.AMM TASK 70-20-01-100-802). Dry

t h e a r e a w i t h a f r e s h p i e c e o f LINT FREE CLOTH (0e.t 2/101) b e f o r e
' ,)...
the fluid dries. $,. , ' .. -.
_. . . . .
, .
D. Apply s u r f a c e p r o t e c t i o n t o t h e r e p a i r e d areas ( R ~ ~ ? T A S .K .
54-02-04/201) .
14. Inspection.
A. Do a v i s u a l a n d t a p test i n s p e c t i o n t o make s u r e t h e r e are no

d i s b o n d s o r d e l a m i n a t i o n s i n t h e r e p a i r a r e a (Ref.TASK 54-01-
06/201).
15. I d e n t i f y t h e r e p a i r .
A. Mark FRSW019 a d j a c e n t t o t h e p a r t number o f t h e f a n cowl d o o r , u s e

a MARKER PEN ( O M a t 262) o f a c o n t r a s t i n g c o l o u r .
re' I , .
R e p a i r No.3
54-20-02
Page 214
P r i n t e d i n Great B r i t a i n M a r . 10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
,..
CONCENTRICCIRCLES DRAWN DAMAGE AREA
ON PANEL SURFACE
PANEL MARKING
3rd CUT
STEPISCARF PREPARATION
EACH STEP 12 mm (0.472 in)

cu *N.B.
8 Number of plies removed diagrammatic only. @ SCARF STEPS BY S24NDlNG IF REQUIRED
Q @ 0,2 mm (0.008 in) TO REMAIN AFTER SANDING
5
k
Scarf and Step Preparation f o r Bonded Repair of Through Hole Damage
F i g . 201
Repair No. 3
Page 215
.
RB211 TRENT
STRUCTURAL REPAIR
m MANUAL
2 EXTRA M20
-
REPAIR 38,lO mm
PREPREG PLIES, (1.50 in)
BOTH AT 0" SUPPORT PLATE
ABRADE TO EXPOSE
/
ORIENTATION . 25,40 mm (1.0 in) COPPER MESH
ABRADE TO EXPOSE
FILM ADHESIVE \ CARBON FIBRE
ON AERODYNAMIC
SURFACE ONLY
COPPERMESH
(IF REQUIRED)
\
EXISTING COPPER
MESH
M20 REPAIR PREPREG
(AS MANY PLIES
AS PARENT SKIN)
FlLM ADHESIVE
/
FM~IOF O ~ M I N GFILM
SUPPORT
PLATES
\
REPLACEMENT
' ~ ~ 4 1FOAMING
0
ADHESIVE \
FILM.
,. ..
- .. ,', .~.',C..
ADHESIVE CORE PLUG
N.B.
Number of plies diagrammatic only.
during repair.
F i r s t S t a g e P r e p r e g R e p a i r of D o u b l e S k i n and T h r o u g h H o l e D a m a g e
F i g . 202
Repair No.3
P a g e 216
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
FM410 FOAMING
ADHESIVE
FM300 2M 0.03 FILM

ADHESIVE A REPLACEMENT
CORE PLUG
2 EXTRA M20 REPAIR

PREPREG PLIES, BOTH
AT 0" ORIENTATION
COPPER MESH
(IF REQUIRED)
CARBON FIBRE 38,10 mm (1 50 ~ n )
ABRADE TO EXPOSE
COPPERMESHON
AERODYNAMIC
SURFACE ONLY
N. B.
Number of plies diagrammatic only
during repair.
Second Stage Prepreg Repair of Double Skin and Through Hole Damage
, . Fig. 203
.' Repair ,No.3
Page 217
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
VACUUM PUMP
VACUUM
CONNECTION
I
I
l
I
I l
25,40 mm CONSOLIDATION PLATE OR l
I
I -+ ~ ( 1 . 0 in)
0 MOZITE RUBBER INTENSIFIER' I
I
CLOTH' I
,NON- POROUS^
I
I FABRIC NYLON dk
-\ PEELPLY
. . ;
PEEL PLY
I TAPE / U I
THERMOCOUPLES
i \ 76,20 mm
(3.min)
SUPPORT PLATE
I
HONEYCOMB CORE
i
CENTER
\
REPAIR
PLIES SKIN
(FIRST STAGE OF REPAIR ONLY) LINE 'THE CONSOLIDATION PLATE/

MOZITE RUBBER INTENSIFIER AND
CLOTH ARE RECOMMENDED, , ,
Shows t y p i c p u m WHEN PANEL THICKNESS IS :.
bag assem y
GREATER THAN 10,'mm (0.40 in)
. ., ,-);:;.
. . '
Repair Area Cure -

F i g . 204
R e p a i r No.3
54-20-02
Page 218
P r i n t e d i n Great B r i t a i n ~ a r1 0
. /07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL

0
/
------ \
\
\
\
- Overall damage size to be not more than the

C
maximum repairable damage size for the zone
R e p a i r of M u l t i p l e D a m a g e S i t e s
Fig. 2 0 5
R e p a i r No.3
Page 219
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
One layer of mesh

covering complete
damaged area
Individual damage sites

repair plies equal to the
number of plies in the skin
being repaired, plus two
extra plies and copper
mesh, if required
* ,
mesh profile
(filled kdividually)
(If insufficient distance between damage sites

to fit individual repair plies, as shown above,
then treat as one large damage site, below)
Two extra repair plies cover

the whole damage area
Copper mesh,(if required)

on outer aerodynamicT
surface '.*"'c-
repair plies equal to the number of plies

in the skin being repaired

Fig. 206
Repair No.3
54-20-02
Page 220
... ~ a r 10/07
.
,.. .., .
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR NO. 4 (FRS W0211

.' ? -
-C . --
POST SB 71-E107 FAN COWL DOORS j .
REPAIR OF THE REAR EDGE RFI SHIELDED RUB STRIP'
1. General
A. This repair scheme is written for the Left and Right Hand Fan Cowl
Doors to Post SB71-E107. This procedure gives the instructions for
the repair of the Rub Strip, RE'I Shielded to post SB71-C586. Refer
to Rolls-Royce plc for PRE SB components
B. This repair is by replacement of the seal or damaged parts of the

seal. There is no limit to the number of repairs or their position.
C. Damage can be repaired by the replacement of the damaged part of

the seal with a new part.
.......................................................................
,,.
54-02-04/201 Repair Paint Finish

- G-Clamps
- Plastic Spatulas
- Standard Workshop Tools
- Heat lamp/mat, 45 to 80 Deg.C (113 to 176 Deg.F)
- Temperature probe, 0 to 120 Deg.C (32 to 248 Deg.F)
.......................................................................
REFERENCE I' DESIGNATION
.......................................................................
OMat 150 ACETONE
OMat 2/114 GLOVES, FREE CLOTH - --
OMat 8/162B ADHESIVE
OMat 262 MARKER
Repair No.4
54-20-02
Page 201
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
.......................................................................
PART NO. PART I D E N T .
FAN COWL DOOR, L E F T HAND

FAN COWL DOOR, R I G H T HAND
D. R e p a i r Part
.......................................................................
PART NO. PART I D E N T . MATERIAL QTY
RUB S T R I P , R F I S H I E L D E D CARBON 1
IMPREGNATED
PTFE
WARNING: WHEN YOU DO T H I S R E P A I R YOU MUST WEAR P R O T E C T I V E CLOTHING, GLOVES,

DUST MASK AND SAFETY GOGGLES T O PROTECT YOU A G A I N S T DUST AND LOOSE
P A R T I C L E S WHICH CAN B E HAZARDOUS T O YOUR HEALTH. , . .
. . . ,
WARNING: WHEN YOU U S E CLEANING M A T E R I A L S , COATINGS, A D H E S I V E S AND SEALANT,

R E F E R T O THE MANUFACTURER'S CONTROL AND A P P L I C A T I O N I N S T R U C T I O N S
AND S A F E T Y N O T I C E S .
4. M e a s u r e the D a m a g e (Fig. 201)
A. M e a s u r e t h e l e n g t h of t h e d a m a g e d p a r t of t h e s e a l .
B. A d d 5 0 , 8 m m ( 2 . 0 i n . ) a t each end of t h e d a m a g e and m a k e m a r k s t o

s h o w t h e l e n g t h of seal t o be replaced.
NOTE: T h e m i n i m u m p e r m i t t e d l e n g t h of replacement ( n e w ) seal i s 1 5 2 , 4 m

( 6 . 0 i n . ) , s o you m u s t remove a t l e a s t t h i s l e n g t h of t h e damaged
seal.
I '
NOTE: M e a s u r e t h e serviceable l e n g t h of t h e adjacent seal t h a t has been
repaired before, b u t has n e w d a m a g e ( t h a t w i l l b e - p a r t of t h e n e w
r e p a i r ) . If t h a t l e n g t h i s less t h a n 1 5 2 , 4 m ( 6 . 0 i n . ) , t h e n a l l
of the adjacent seal m u s t be included as p a r t of t h e h n e w repair
5. R e m o v e t h e D a m a g e d Seal ( F i g . 202)
CAUTION: MAKE SURE YOU DO NOT CAUSE DAMAGE TO THE SURFACE O F THE DOOR WHEN
YOU CUT THE SEAL.
A. C u t through t h e seal a t t h e t w o m a r k s you m a d e i n t h e s t e p above.

U s e a sharp k n i f e and c u t v e r t i c a l l y through t h e s e a l . M a k e s u r e
t h a t t h e ends are c u t a t 90 degrees.
R e p a i r No.4
54-20-02
- Page 202
I
i:._ . , 10/07
3:", .'S,
H RB211 TRENT
m
STRUCTURAL REPAIR
MANUAL
B. P l a c e t h e k n i f e i n between t h e damaged Rub S t r i p and t h e door.

C a r e f u l l y remove t h e damaged s e a l from t h e door.
C. U s e a s p a t u l a t o remove unwanted adhesive (Ref.= TASK 70-20-01-

100-802). Clean t h e r e p a i r a r e a with LINT-FREE CLOTH ( O M a t 2/101)
made m o i s t with ACETONE (OMat 1 5 0 ) . Dry t h e s u r f a c e with a new
p i e c e of LINT-FREE CLOTH (OMat 2/101) b e f o r e t h e ACETONE ( O M a t 150)
dries.
D. c a r e f u l l y examine t h e door, make s u r e t h e r e i s no s u r f a c e damage.

.. -
-',, ..
6. Prepare t h e Repair S e a l ( F i g . 203)
S..
.
. .,..,...,
.
I _ >
A. Measure t h e l e n g t h along t h e door s u r f a c e between ' t h e :'.cut ends of

the serviceable s e a l .
NOTE: Make s u r e you measure a c c u r a t e l y along t h e curved s u r f a c e of t h e

door. The new s e a l must bond c o r r e c t l y along t h e curve of t h e
door. I t must n o t have d i s t o r t i o n .
B. Cut a p i e c e of t h e new s e a l t o t h e same l e n g t h measured i n t h e s t e p

above. Make s u r e you c u t t h e ends t o a c c u r a t e 90 degree c o r n e r s .
NOTE: The maximum d i s t a n c e between t h e c u t ends of t h e r e p a i r and t h e

s e r v i c e a b l e s e a l s i s 1,02mm. ( 0 . 0 4 i n . ) .
I n s t a l l t h e Repair S e a l ( F i g . 203)
A. Refer t o t h e manufacturerr S i n s t r u c t i o n s . M i x enoubh EPOXY ADHESIVE

(OMat 8 / 1 6 2 ~ )t o bond t h e new s e a l i n t o p o s i t i o n . . : 0 ~ a8/.162B
t is
t h e recommended OMat, b u t OMat 8/162 Epoxy ~ d h e s i v e " 2: ~ 2~
16~/~
(Scotch Weld) may a l s o be used.
S
. -......
. ,
B. Apply t h e adhesive t o t h e mating s u r f a c e s of t h e door and t h e

r e p a i r s e a l . Make s u r e t h e r e i s no adhesive on o r between t h e c u t
ends of t h e s e a l s .
C. Put t h e r e p a i r s e a l i n p o s i t i o n and h o l d i t t i g h t l y a g a i n s t t h e
door with clamps. U s e f l e x i b l e p r e s s u r e s t r i p s between t h e clamps,
t h e new p a r t and t h e o u t e r - s k i n door s u r f a c e a s shown.
D. S e a l a l l around t h e j o i n t s with t h e EPOXY ADHESIVE (OMat 8 / 1 6 2 ~ )a s

shown. Take c a r e n o t t o p u t t h e adhesive on t h e ends of t h e new
s e a l and t h e used s e a l .
E. Remove a l l unwanted s e a l a n t with LINT-FREE CLOTH (OMat 2 / 1 0 1 ) . Make

s u r e t h e adhesive i n t h e j o i n t s i s smooth.
"
i r4
- ~ e ~ a No.
Page 203
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
F. Use a heat lamp/mat to cure the adhesive for 24 hours at room

temperature plus 2 hours at 70 Deg.C (158 Deg.F). Use the
temperature probe to measure the temperature.
8. Inspection
A. Do a visual inspection of the repair to make sure the repair seal

is correctly bonded and has no distortion. -
B. Apply surface protection to the repair area as necessary (Ref.TASK
54-02-04, Standard Painting Procedure).
A. Record details of the repair No FRS W021. Make a permanent record

on the Mod Plate of the door with an electrical vibro-etching tool.
Repair No.4
54-20-02
Page 204
.
R8211 TRENT
STRUCTURAL REPAIR
MANUAL
position of
rub strip,
RFI shielded
POSSIBLE
RUB STRIP: DAMAGE "/K.

RFI +I
Shows typical
damage to
rub strip,
RFI shielded
ADD 50,88mm (2.0in)

MORE AT TWO ENDS
MEASURE SERVICEABLE
PART OF POSSIBLE
ADJACENT DAMAGE (SEE NOTE)
\ REPLACE MINIMUM
Note: If there is an adjacent repair
with new damage, measure
the serviceable part. If that
part is less than 152,4 mm
OF 152,4mm (6.0in) (6.0 in), do that repair again
as part of the new repair.
Rub Strip, RFI Shielded - Prepare Damaged Area

Fig. 201
Repair No.4
Page 205
, . Mar.10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
Note: Use a sharp knife.
CUTI THROUGH SEAL

LU
VERTICALLY.
MAKE SURE ALL
CORNERS
ORNERS ARE SO"
.
T
DO NOT DAMAGE
CAREFULLY CUT DAMAGED
PART FROM SURFACE
DOOR SURFACE
Shows removal
of damaged part
MEASURE BETWEEN
ENDS ALONG SURFACE
FOR NEW PART
Shows damage
area removed
Rub S t r i p , RFI S h i e l d e d - Remove Damagea

F i g . 202
Repair No.4
54-20-02
P a g e 206
Printed in Great Britain - . Mar. 1 0 / 0 7
. -.
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
MAKE SURE ALL FOUR ENDS

ARE CUT ACCURATELY TO 90"
NEW PART
DO NOT PUT
ADHESIVE ON
ENDS OF NEW
PART AN D
RFI SHIELDED RFl SEAL
Note Make sure you apply suffic~ent

adhes~veto correctly bond
mat~ngsurfaces.
Shows installation
DOOR SURFACE
DOOR SURFACE
PRESSURE STRIPS
SEAL JOINTS AND

MAKE SMOOTH
/
NEW PART PRESSURE STRIP
\ /
CLAMP
SECTION
C-C
RUB STRIP,
RFI SHIELDED
Shows the bond

of new part
DOOR SURFACE
MAXIMUM DISTANCE BETWEEN
ENDS OF PARTS IS l,Omm (0.04in)
L
:
Rub Strip, RFI Shielded - Installation of New Part
a
Fig. 203 . ,. >.

..
,
. .
,r . . I '
', ':' Repair,No

>: .. .4
EFFECTIV1TY:TRENT
Page 207
p RB211 TRENT
MANUAL
STRUCTURAL
REPAIR N 0 . 5
REPAIR
(FRS W022)
R E P A I R O F A DISBOND A T THE S L I N G P O I N T
1. General
A. T h i s repair s c h e m e i s w r i t t e n f o r t h e L e f t and R i g h t hand Fan C o w l

D o o r s t o P o s t S B 7 1 - E 1 0 7 . T h i s r e p a i r gives t h e procedure f o r t h e
r e s i n i n j e c t i o n repair of a disbond b e t w e e n t h e carbon s k i n and t h e
f i l l e d r e g i o n a t t h e s l i n g p o i n t areas.
d-- %L
B. T h i s R e p a i r i s l i m i t e d t o t h e S l i n g P o i n t f i l l e d areas o n l y .
D i s b o n d m u s t be b e t w e e n t h e f i l l e r and t h e s k i n o n l y . . D a m a g e i s
permitted i n a l l of t h e f i l l e d S l i n g P o i n t areas a t t h e same t i m e .
C. M a k e s u r e t h e d a m a g e i s w i t h i n t h e a l l o w a b l e damage l i m i t s
(Ref.TASK 54-20-02/101). D a m a g e t h a t i s n o t i n t h e l i m i t s of t h i s
repair m u s t be referred t o GKN A e r o s p a c e .
.......................................................................
.......................................................................
54-02-04/201 Standard P a i n t i n g Procedure
54-01-06/201 Tap Test
AMM TASK 7 0 - 2 0 - 0 1 - 1 0 0 - 8 0 2 Cleaning
. .. ,
3. ~ q u i & & n t and M a t e r i a l s
.-. . .
A. Standard E q u i p m e n t :
S i l i c o n e rubber sheet
G l o v e s , neoprene o r polyvinyl c h l o r i d e
H e a t l a m p / m a t , 4 5 t o 80 D e g . C ( 1 1 3 t o 239 D e g . F )
S u c t i o n cleaner
H e a t blanket, 0 t o 1 2 0 D e g . C ( 3 2 t o 2 4 8 D e g . F )
V a c u u m suction p u m p , 0 t o 762.0mmHg ( 0 t o 3 0 i n . H g )
T w o applicable v a c u u m f i t t i n g s
T w o t e m p e r a t u r e probes, 0 t o 120 D e g . C ( 3 2 t o 2 4 8 D e g . F )
1 0 X 5 0 m m ( 0 . 3 7 5 X 2 . 0 i n . ) Steel w a s h e r
D r i l l b i t 1 , O m m ( 0 . 0 4 i n . ) and applicable d r i l l .
. A .
Page 2 0 1
RB211 TRENT
STRUCTURAL REPAIR
MANUAL 3 -
.......................................................................
.......................................................................
OMat 150 ACETONE
OMat 2/31 VACUUM BAG MATERIAL
OMat 2/88 ADHESIVE TAPE POLYESTER, CLEAR
OMat 2/110 ADHESIVE TAPE, VACUUM-BAG SEAL
OMat 2/113 PARTING FILM - NON-POROUS (234-TEWP)
OMat 5/39 WATERPROOF SILICON-CARBIDE (GRIT SIZE 120)
OMat 802 HARDENER
OMat 803C RESIN (AY105-1) .
.. >
OMat 8/115 PLAIN WEAVE 'Ef GLASS FABRIC
.......................................................................
.......................................................................
PARTICLES WHICH CAN BE HAZARDOUS TO YOUR HEALTH
REFER TO THE MANUFACTURER'S CONTROL AND APPLICATION,INSTRUCTIONS
AND SAFETY NOTICES.
* .'..\.
\
A. Identify the area to be repaired. Make sure the damage is in the

limits of this repair scheme (Ref.TASK 54-20-02/101).
B. Refer to AMP4 TASK 70-20-01-100-802. Fully clean the repair area

with LINT-FREE CLOTH (OMat 2/101) made moist with the ACETONE (OMat
150). Dry the area with a LINT-FREE CLOTH (OMat 2/101) before the
fluid dries. Leave to stand for at least 15 minutes before you
continue.
Repair No.5
54-20-02
.
..
v
Page 202
Printed in Great Britain .' Mar. 10/07
'S-
, .._.-
L..
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
5. P r e p a r e t h e R e p a i r Area ( R e f . F i g . 201 and 2 0 2 )
A. M a r k o u t t h e defined area of d a m a g e w i t h a S O F T P E N C I L ( O M a t 2 6 1 ) .
B. D r i l l t h e necessary n u m b e r of 1 , O m ( 0 . 0 4 0 i n . ) h o l e s around t h e
edge of t h e disbonded area. T a k e care t o d r i l l through t h e
disbonded carbon l a m i n a t e o n l y . A s m a l l h o l e of m a x i m u m depth 5 , O m
( 0 ' . 2 i n . ) i s p e r m i t t e d i n t h e f i l l e r . T h e o u t e r s k i n of t h e Fan C o w l
~ o o rc o n s i s t s of three layers of C a r b o n Fibre and an o u t e r C o p p e r
m e s h , w h i c h g i v e s a t o t a l t h i c k n e s s of 0 , 9 3 m ( 0 . 0 3 6 i n . )
''.
NOTE: I f you do m a k e a h o l e i n t h e f i l l e r i t m u s t n o t be: m o r e t h a n
5,Omm ( 0 . 2 i n . ) deep. If i t i s you m u s t c o n t a c t GKN A e r o s p a c e
Services.
G C . R e m o v e t h e d u s t and debris f r o m t h e area w i t h t h e s u c t i o n cleaner.
D. R e f e r t o AMM TASK 7 0 - 2 0 - 0 1 - 1 0 0 - 8 0 2 . F u l l y clean the repair area

w i t h L I N T - F R E E CLOTH ( O M a t 2 / 1 0 1 ) m a d e m o i s t w i t h t h e ACETONE ( O M a t
1 5 0 ) . D r y t h e area w i t h a clean L I N T - F R E E CLOTH ( O M a t 2 / 1 0 1 ) before
t h e ACETONE ( O M a t 1 5 0 ) dries.
CAUTION: YOU MUST MAKE SURE THE AREA YOU R E P A I R I S FULLY DRY AND CLEAN
BEFORE YOU DO T H I S R E P A I R . I F I T I S NOT, THE R E P A I R W I L L NOT
ETJLLY CURE.
E. R e m o v e a l l w a t e r f r o m t h e damaged area
(1) U s e a v a c u u m and an o i l free c o m p r e s s e d a i r t o r e m o v e any

standing w a t e r . : t
(2) M a k e sure the L i f t i n g L u g i s r e m o v e d f r o m the sling p o i n t .

(3) A p p l y BREATHER-CLOTH (OMat 2 / 1 1 1 ) over both sides of t h e s l i n g
point hole.
(4) A d d a t h e r m o c o u p l e t o t h e centre of t h e breather-cloth on one

side of t h e s l i n g p o i n t . C o n n e c t t h e t h e r m o c o u p l e t o a
t e m p e r a t u r e gauge.
(5) A p p l y a layer of GLASS FABRIC ( O M a t 8 / 1 1 5 ) over t h e breather

c l o t h and hold i n place w i t h TEFLON TAPE ( O M a t 2 / 3 0 ) .
(6) P o s i t i o n t h e h e a t - b l a n k e t over t h e glass c l o t h .
(7) C o v e r t h e area w i t h BAGGING F I L M ( O M a t 2 / 3 1 ) and seal w i t h

SEALANT TAPE ( O M a t 2 / 1 1 0 ) ( b o t h s i d e s ) .
-.R e p a i r N o . 5
54-20-02
P a g e 203
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(8) Evacuate the lay-up to a vacuum of 559,Omm (22.Oin. ) of

. .. mercury minimum.
NOTE : The vacuum point can be on the inner or outer.face to suit

the operational requirements. . .--,. a
. : :\.
<
(9) Heat the repair area for a minimum of 1 hour at 80 Deg.C (176
Deg.F), do not go higher than 100 Deg.C (212 Deg.F) . The rate
of temperature rise must not be more than 3 Deg.C (5 Deg.F)
per minute.
(10) Remove the lay-up materials and visually examine the breather
cloth fabric. If the fabric is contaminated, do the steps that
follow again until it is clean and then continue with the
repair.
(a) Apply BREATHER-CLOTH (OMat 2/111) over both sides of the

sling point hole.
(b) Add a thermocouple to the centre of the breather-cloth on

. one side of the sling point. Connect the .thermocouple to
a temperature gauge. :. . .
.. .
(c) Apply a layer of GLASS FABRIC (OMat 8/115-)';'6ver

the
breather cloth and hold in place with TEFLON TAPE (OMat
2/30) .
(d) Position the heat-blanket over the glass cloth.
(e) Cover the area with BAGGING FILM (OMat 2/31) and seal
with SEALANT TAPE (OMat 2/110) (both sides).
(f) Evacuate the lay-up to a vacuum of 559,Omm (22.0in.) of

mercury minimum.
NOTE: The vacuum point can be on the inner or outer face to

obey the operational requirements.
(g) Heat the repair area for a minimum of 1 hour at 80 Deg.C

(176 Deg.F), do not go higher than 100 Deg.C (212 Deg.F) .
The rate of temperature rise must not bermore than 3
Deg.C (5 Deg. F) per minute. .,: :.,+. . .
.. ,..
(h) Remove the lay-up materials and visually examine the

breather cloth fabric.
6. Inject the Resin (Fig. 202)
Repair No.5
54-20-02
Page 204
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
t
...-., Y.'
A. Apply a l a y e r of BREATHER CLOTH (OMat 2/111) over t h e r e a r of t h e

metal s l i n g p o i n t i n s e r t .
B. Apply a l a y e r of BAGGING FILM (OMat 2/31) over t h e b r e a t h e r c l o t h

and s e c u r e i n t o p o s i t i o n with SEALANT TAPE (OMat 2 / 1 1 0 ) . Include a
vacuum connector i n t h e vacuum bag m a t e r i a l .
C. Cover t h e s l i n g p o i n t t h r e a d and a l l of t h e d r i l l e d h o l e s , e x c e p t
one, with ADHESIVE TAPE (OMat 2/88) .
D. Apply a minimum vacuum of 254,Omm ( 1 0 . 0 i n ) of mercury.
E. Mix enough RESIN (OMat 803C) and HARDENER ( O M a t 802) i n p r o p o r t i o n

b y . w e i g h t , of 100 p a r t s r e s i n t o 10-12 p a r t s of hardener and mix
f o r 3 minutes o r u n t i l a c o n s t a n t mixture i s o b t a i n e d , whichever
t a k e s l o n g e r . The temperature o f t h e s e p a r a t e components ,should be
c l o s e t o room temperature 25 Deg.C (72 Deg.F) b e f o r e you-mix.
Mixing should be done i n accordance with manufacturers
instructions .
NOTE: I n c o l d weather, RESIN ( O M a t 803C) ( A r a l d i t e AY105-1 Epoxy Resin)

i s v i s c o u s and n o t e a s y t o mix. Warm t h e RESIN (OMat 803C) t o 30
Deg.C ( 8 6 Deg.F) t o make t h e Resin e a s i e r t o mix.
F. U s e a s y r i n g e t o i n j e c t t h e mixed r e s i n i n t o t h e uncovered h o l e .
L e t t h e vacuum p u l l t h e r e s i n through u n t i l t h e adhesive t a p e shows
s i g n s of r e s i n f i l l e t a t t h e s l i n g p o i n t h o l e edge.
G. Release t h e vacuum and wipe t h e unwanted r e s i n from around t h e

h o l e . Cover t h e f i l l e d h o l e with adhesive t a p e .
H. Remove t h e cover from t h e n e x t h o l e and do t h e s t e p s t h a t f o l l o w

a g a i n u n t i l a l l of t h e h o l e s have been f i l l e d .
:,'
(1) U s e a s y r i n g e t o i n j e c t t h e mixed r e s i n i n t o tg&'
un'd'o'vered
h o l e . L e t t h e vacuum p u l l t h e r e s i n through G6ti.i '..' S
t h = . adhesive
t a p e shows s i g n s of r e s i n a t t h e s l i n g p o i n t h'ole edge.
.. ; .
(2) Release t h e vacuum and wipe t h e unwanted r e s i n from around t h e

h o l e . Cover t h e f i l l e d h o l e with adhesive t a p e .
I. Remove t h e vacuum bag and a l l a p p l i e d t a p e .
Repair No.5
54-20-02
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
J. U s e a standard w a s h e r and a rubber m a t t o m a k e an i n t e n s i f i e r .

D u r i n g t h e cure procedure, c l a m p t h e i n t e n s i f i e r t o t h e repair w i t h
a standard s l i n g p o i n t l i f t i n g l u g . T h e l u g m u s t be coated w i t h a
release agent. P u t NON-POROUS P A R T I N G F I L M ( O M a t 2 / 1 1 3 ) b e t w e e n t h e
rubber m a t and t h e repair surface. T i g h t e n t h e l u g by hand.
7. C u r e the R e s i n
A. L e t t h e r e s i n gel a t 15 t o 25 D e g . C ( 5 9 t o 77 D e g . F ) for a minimum

of 2 h o u r s .
. ..
B. R e m o v e a l l t h e adhesive tape. .
. .,
.:;:.:;. ,
.. / C.
C. U s e a heat l a m p t o cure t h e r e s i n a t 60 D e g . C ( 1 4 0 D&:'F) f o r 180

m i n u t e s or a t 1 0 0 D e g . C ( 2 1 2 D e g . F ) f o r 20 m i n u t e s . If cured a t 1 0 0
Deg.C (212 D e g . F ) , l e t t h e repair area c o o l t o 6 0 D e g . C ( 1 4 0 D e g . F )
before t h e c l a m p is r e m o v e d .
8. F i n i s h t h e R e p a i r e d Surface
A. U s e WATERPROOF S I L I C O N C A R B I D E A B R A S I V E P A P E R ( O M a t 5 / 3 5 ) to smooth
t h e surface of t h e repair. D o n o t abrade m e s h o r carbon.
B. R e m o v e a l l u n w a n t e d m a t e r i a l w i t h a s u c t i o n cleaner. Make sure no

p a r t i c l e s of t h e u n w a n t e d m a t e r i a l r e m a i n .
C. U s e L I N T - F R E E CLOTH ( O M a t 2 / 1 0 1 ) m a d e m o i s t w i t h t h e ACETONE ( O M a t
1 5 0 ) t o f u l l y clean t h e repair area. D r y t h e area w i t h a clean
L I N T - F R E E CLOTH ( O M a t 2 / 1 0 1 ) before t h e ACETONE ( O M a t 1 5 0 ) d r i e s .
D. . -
A p p l y surface p r o t e c t i o n t o t h e repair area i n acco~dance w i t h the
standard p a i n t i n g procedure ( R e f . TASK 5 4 - 0 2 - 0 4 ) . ' .'
9. Inspection
A. D o an I n s p e c t i o n of t h e repair area ( R e f . TASK 5 4 - 0 1 - 0 6 / 2 0 1 )
(1) D o a v i s u a l and tap t e s t i n s p e c t i o n t o m a k e s u r e there are no

disbonds o r d e l a m i n a t i o n s i n t h e repair area.
1 0 . R e c o r d the R e p a i r
A. R e c o r d d e t a i l s of t h e repair N o FRS W 0 2 2 . Make a p e r m a n e n t record

on t h e M o d P l a t e of t h e door w i t h an e l e c t r i c a l v i b r o - e t c h i n g t o o l .
Page 206
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
TEMPERATURE
GAGE THERMOCOUPLE VACUUM BAG
\ \ (ATTACH TO SKIN WITH TAPE)
HEATER BLANKET
WITH ELECTRICAL GLASS FABRIC
CONNETTION (ASTACH TO SKIN WITH
. TAPE)
I . .
W
DELAMINATED
SKlN
OUTER
BREATHER
- SURFACE
INNER
SURFACE
VACUUM
PUMP
VACUUM BAG
(ATTACH TO SKlN WlTH
. . TAPE)
h 3 .. .. .
.,,;:. ,
. . ., ;
SECTION Shows equipment for ' '. . ,
A-A removal of water . .

Fig. 201
Repair No.5
54-20-02
Page 207
P r i n t e d in Great B r i t a i n Mar. 10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
MAKE 4 OR 5 HOLES IN THE SKlN

AROUND THE DELAMINATEDAREA
,
, DELAMINATED SKlN
DO NOT MAKE
HOLES IN FILLER
FILLER
SECTION Shows delaminated skin with holes

A-A for adhesivelhardener mixture
Use syringe to put

mixture into skin
through each hole
PUT TAPE ON ALL HOLES

BUT ONE
v.. '
. . ..! :,i.<i.
L
PUT TAPE ON SLING

POINT AND THREAD
SLING POlN
INSERT VACUUM BAG
BREATHERCLOTH
VACUUMPUMP
SECTION
Shows repair equipment
A-A
SLlNG POINT LIFTING LUG

RUBBER MAT
RELEASE FIL
REPAIRED SKIN
.%
< .
. .
, .
MIXTURE .. .
.. . .
-:.!,;.::
FILLER
SLING PO1
INSERT
SECTION Shows equipment
A-A for cure of skin
R i g h t Hand Door - B o t t o m edge R F I s e a l s r e p l a c e m e n t

F i g . 202
R e p a i r No.5
54-20-02
P a g e 208
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
R E P A I R NO. 6 ( F R S W 0 2 3 )
POST 7 1 - E 1 0 7 FAN COWL DOORS
R E P A I R O F THE DAMAGED CONDUCTIVE SURFACE MESH
1. General
A. T h i s repair s c h e m e i s w r i t t e n f o r t h e L e f t and R i g h t H a n d Fan C o w l

D o o r s t o P o s t S B 7 1 - E 1 0 7 . T h i s procedure gives i n s t r u c t i o n s f o r t h e
w e t lay-up repair of conductive surface m e s h .
B. T h i s repair i s p e r m i t t e d t o t h e o u t e r copper m e s h . . T h e r e 4s no
l i m i t t o t h e s i z e o r number of repairs. T h e d a m a g e % ; alim=ted to
t h e m e s h . T h e m i n i m u m distance b e t w e e n t h e d a m a g e i s 1 2 7 , O m m
(5.0in.).
Referenced Information
.......................................................................
54-02-04/201 Standard P a i n t i n g Procedure
54-02-04/201 R e p a i r Paint Finish
54-01-06/201 Tap Test
AMM TASK 7 0 - 2 0 - 0 1 - 1 0 0 - 8 0 2 Cleaning
E q u i p m e n t and M a t e r i a l s
A. . ,. ,-
standard Equipment:
..)'."
- spatula . .. . , ...
- G l o v e s , neoprene o r p o l y v i n y l chloride %
. . .G
,iil;':.
>.....":' ! . ,;.C
;:
, .
- Roller ., ...3?. .. ....>. . . , , .. .. ,...
,
>:
I
.
.
j,.+
-. ' .
..
- Standard w o r k s h o p t o o l s and e q u i p m e n t , : q . ,
- H e a t l a m p , 4 5 t o 80 D e g . C ( 1 1 3 t o 1 7 6 D e g . F )
- S u c t i o n cleaner
- H o t box bonder w i t h an applicable s i z e d rubber heat b l a n k e t , t h a t
can operate w i t h i n 0 t o 1 2 0 D e g . C ( 3 2 t o 2 4 8 D e g . F )
- V a c u u m s u c t i o n p u m p 0 t o 7 6 2 , O m ( 0 t o 3 0 . 0 i n . ) of m e r c u r y
- T w o applicable v a c u u m f i t t i n g s T e m p e r a t u r e probes, 0 t o 1 2 0 D e g . C
(32 to 2 4 8 Deg.F)
- V i b r o - E t c h i n g tool
B. Consumable M a t e r i a l s
.......................................................................
.......................................................................
. ,
L; :. .
O M a t 261-.,; TEMPORARY MARKER, S O F T PENCIL/CRAYON
;..~epa+-r
No. 6
5/4y.;2 0r 02
.
,.
,
..,
Page 2 0 1
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
OMat 2/30 TAPE, ADHESIVE PTFE RELEASE FILM -

OMat 150 ACETONE
2 >
OMat 212 BRUSH, PAINTING
OMat 2/114 GLOVES, FREE CLOTH
OMat 2/111 BREATHER CLOTH (NI0-FR)
OMat 2/113 PARTING FILM - NON-POROUS (234 TEWP)
OMat 2/112 PARTING FILM - POROUS (234 TFP)
OMat 5/35 WATERPROOF SILICON CARBIDE ABRASIVE PAPER (Grit
size 240)
OMat 5/97 GARNET PAPER (Grit size 80)
OMat 8/160 EPOXY ADHESIVE, 2 PART (EA9390)
OMat 2/110 ADHESIVE TAPE VACUUM BAG SEAL (SM-5127)
OMat 8/115 GLASS FABRIC - PLAIN WEAVE 'E1 ( 'bleeder1 fabric)
OMat 8/240 COPPER MESH (dry), RFI AND LIGHTNING STRIKE
PROTECTION (CU022CX Type 1) (Astroseal Products)
OMat 8/198 NYLON PEEL PLY B100
.......................................................................
.......................................................................
PARTICLES, WHICH CAN BE DANGEROUS TO YOUR HEALTH.
AND SAFETY NOTICES.

,-
A. Identify the area to be repaired. Make sure the damage is in the
limits of this repair scheme (Ref.TASK 54-20-02/10,1).., , :
B. Refer to AMM TASK 70-20-01-100-802. Fully clean the'-dGagedarea

with LINT-FREE CLOTH (OMat 2/101) made moist with the ACETONE (OMat
150). Dry the area with a clean LINT-FREE CLOTH (OMat 2/101) before
the fluid dries.
5. Prepare the Repair Area (Fig. 201)
Repair No.6
EFFECTIVITY : TRENT
Page 202
" -
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RB211 TRENT
STRUCTURAL REPAIR
MANUAL
A. Mark o u t t h e d e f i n e d a r e a of damage with a SOFT PENCIL (OMat 2 6 1 ) .

Mark o u t t h e c u t l i n e by a t l e a s t 6,Omm ( 0 - 2 5 i n . ) more than t h e
damage. This can be any shape b u t a l l c o r n e r s must have a minimum
r a d i u s of 6,Omm ( 0 . 2 5 i n . ) .
B. Apply TEFLON TAPE (OMat 2/30) around t h e r e p a i r a r e a
C. Use WATERPROOF SILICON CARBIDE ABRASIVE PAPER (OMat 5/35) t o abrade

back t h e damaged mesh t o t h e c u t l i n e u n t i l t h e carbon i s exposed.
Care must be taken n o t t o damage t h e carbon.
D. U s e WATERPROOF SILICON CARBIDE ABRASIVE PAPER (OMat 5/35) t o Abrade

back t h e p a i n t and r e s i n t o expose t h e mesh by a f u r t h e r 25,4mm
( 1 . O i n . ) each s i d e of t h e r e p a i r a r e a .
E. Vacuum t o remove any d u s t and d e b r i s . ~ e f e rt 'o AMM %K 70-20-01-

100-802. Use ACETONE ( O M a t 150) on LINT-FREE CLOTH .(0Mat 2/101) t o
f u l l y c l e a n t h e r e p a i r a r e a . Dry t h e a r e a with a c l e a n p i e c e of
LINT-FREE CLOTH (OMat 2/101) b e f o r e t h e f l u i d d r i e s . When t h e
ACETONE (OMat 150) has d r i e d and t h e r e p a i r a r e a i s f u l l y d r y , do
t h e water break t e s t .
F. Water Break t e s t
(1) Brush on o r s p r a y a t h i n l a y e r of d i s t i l l e d water t o t h e

repair area.
(a) A continuous l a y e r seen f o r approximately h a l f a minute

shows t h a t t h e a r e a h a s passed t h e water break t e s t .
(b) Areas t h a t f a i l t h i s t e s t must be cleaned, and t e s t e d

:
again. ,,.. z
(c) After testing, t h e a r e a s must b e f u l l y .dr,+e.db e f o r e

a p p l i c a t i o n of t h e r e p a i r p l i e s . This ca$ be done by
vacuum bagging t h e a r e a and with e i t h e r ' h e a t e r mat o r
h e a t i n g lamps. Do n o t h e a t h i g h e r than 80 Deg.C (158
Deg .F) .
6. Lay-up t h e Repair P l i e s ( F i g . 201)
A. Cut a p l y of COPPER MESH (OMat 8/240) .

B. Mix EPOXY ADHESIVE (OMat 8/160) 100 P a r t s A t o 56 P a r t s B by
weight.
. ,.Repair No. 6
54-20-02
,
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. . Page 203
Printed i n Great Britain Mar.10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
C. Apply enough EPOXY ADHESIVE (OMat 8/160) to the repair area surface
for the copper mesh plies to be added. Make sure the adhesive
covers an area slightly larger than the size of mesh ply to be
added. The adhesive can be spread out with a spatula.
D. Lay-up the COPPER MESH (OMat 8/240) on the repair area. Make sure
the mesh overlaps the exposed mesh by 20,Omm (0.78in.).
,
E. Use a stiff brush to Stipple the resin into the copper mesh.
- JS,
+-
7. Prepare the Vacuum Bag (Fig. 202)
A. Cover the repair plies with one layer of PEEL PLY (OMat 8/198) that
is at least 76,Omm (3.0in.) larger than the repair plies.
B. Cover this layer with one layer of POROUS PARTING FILM (OMat 2/112)
approximately 25,4mm (1.Oin.) larger than the peel ply.
C. Cover the porous parting film with 2 layers of GLASS FABRIC (OMat
8/115) and one layer of NON-POROUS PARTING FILM (OMat 2/112), each
25,4mm (1.Oin.) smaller than the layer before.
D. Cover the non-porous parting film with two layers of BREATHER CLOTH
(OMat 2/111), both layers must be larger than all the other layers
of material from before.
.. .-
E. Position the heater mat over the repair area. Make:sure temperature
probes are positioned equally to monitor the repair-tempe=gture.
..,, ,.
"' ;'
b..
G. Cover all of the repair area with BAGGING FILM (OMat 2/31) plus two
vacuum fittings.
H. Seal the edges of the bag to the panel with SEALANT TAPE (OMat
2/110) .
I. Cure for 220 to 235 minutes at 95 to 115 Deg.C (203 to 239 Deg.F).
Heat up at a rate of 5 Deg.C (9 Deg.F) per minute. Vacuum must not
fall below 559,Omm (22.0in.) of mercury during the cure cycle. Cool
to below 60 Deg.C (140 Deg.F) before the vacuum is released.
J. When the cure process is complete, remove the bagging material and
the PTFE Teflon tape from the repair area. . L

Repair No.6
54-20-02
Page 204
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
A. U s e WATERPROOF S I L I C O N CARBIDE ABRASIVE PAPER ( O M a t . 5 / 3 5 ) t o m a k e a

s m o o t h surface of t h e repair a l l around. D o n o t abrade m e s h o rS ,
carbon.
B. R e m o v e a l l u n w a n t e d m a t e r i a l w i t h a s u c t i o n cleaner. M a k e s u r e no
particles of t h e u n w a n t e d m a t e r i a l r e m a i n .
C. U s e ACETONE ( O M a t 1 5 0 ) m o i s t on LINT-FREE CLOTH ( O M a t 2 / 1 0 1 ) t o

f u l l y clean t h e repair area (Ref.AMM TASK 7 0 - 2 0 - 0 1 - 1 0 0 - 8 0 2 ) . Dry
t h e area w i t h a f r e s h piece of LINT-FREE CLOTH ( O M a t 2 / 1 0 1 ) before
t h e f l u i d dries.
D. A p p l y surface p r o t e c t i o n t o t h e repair area i n accordance w i t h t h e

standard p a i n t i n g procedure ( R e f . T A S K 5 4 - 0 2 - 0 4 / 2 0 1 ) .
9. Inspection
A. D o a v i s u a l i n s p e c t i o n t o m a k e s u r e t h e repair has been done i n

accordance w i t h these procedures.
1 0 . ~ e c o r dt h e R e p a i r
A. R e c o r d d e t a i l s of t h e repair N o F R S W 0 2 3 . Make a record

on t h e M o d P l a t e of t h e door w i t h an e l e c t r i c a l v i b r o - e t c h i n g t o o l .
Repair No.6
54-20-02
P a g e 205
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
EXISTING
RESIN LAYER -20
25 m m (1.00 in)
m m (0.78 in) / COPPER MESH
.
EXISTING
COPPERMESH
\
\
\
L - -
BASE LAMINATE AIR PLIES
TOLERANCE ON PLIES i 2,5 m m (0.10in)
FOR REPAIRS OF COMPOSITE PLIES SEE SRM 54-20-02
P r e p a r e the R e p a i r A r e a
F i g . 201
R e p a i r No.6
EFFECTIVITY: TRENT
54-20-02
,.; :;
i ''
, P a g e 206
Printed in Great Britain ' . , , . : . M a r .10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
2 PLIES OF
RUBBER BREATHER NON POROUS GLASS
VACUUM
CONNECTOR
NYLON
BAGGING FlLM
ELECTRICAL
CONNECTOR
THERMOCOUPLE
SEALANT TEFLON OR HIGH POROUS PEEL PLY REPAIR

TAP E TEMP TAPE PARTING FILM LAY-UP
BASE LAMINATE
TO BE REPAIRED
Repair Equipment Installation ... . ..-"2.

: ;.,, ,
Fig. 202
Repair No.6
EFFECTIVITY : TRENT
Page 207
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR N0.7 (FRS W026)
REPAIR (REPLACEMENT) OF THE RFI SEALS
CAUTION : YOU MUST REFER TO THE ALLOWABLE DAMAGE LIMITS: TO ,M&E. SURE
THAT THIS REPAIR IS PERMITTED.
A. This repair scheme is written for the Left and Right Fan Cowl Doors
to Post SB71-E107. This procedure gives instructions to repair
damaged seal strips attached to the bottom edge of the fan cowl
doors to SB71-E107 standard.
B. Repair is by replacement of each bottom edge seal that is available

individually.
.......................................................................
54-02-02/1,01 Allowable Damage

54-02-10/201 Fasteners - Installation and Removal
A M M TASK 70-20-01-100-802 Cleaning -
., .
\L
.?,v i1 ,-
~5 I. :
3. Equipment and Materials , i r
,P
B. Special Tools
(1) Back facing drill
C. Consumable Materials
.......................................................................
.......................................................................
OMat 150 ACETONE
OMat 1/40 ISOPROPYL ALCOHOL (A1ternative) , .
OMat 1/25? CLEANING SOLVENT (Alternative)
OMat 2/30 TAPE, ADHESIVE (PTFE) RELEASE FILM" a,
OMat 2/101 ABSORBENT CLOTH< LINT FREE :'. 4 7 , , . L .

OMat 5/53 EMERY POLISHING PAPER GRADE 3/0 GRI? SIZE 800
OMat 8/5C SEALANT
Repair No.7
54-20-02
Page 201
Printed in Great Britain Jun.10/07
.
RB211 TRENT .. . ...
. . ...
-
STRUCTURAL REPAIR
MANUAL
OMat 8/197 EPOXY PASTE ADHESIVE (HYSOL EA9396 (2 PART) )
.......................................................................
.......................................................................

.......................................................................
FIG/ITEM PART NUMBER PART IDENTIFICATION QTY
.......................................................................
201/1 WCA7110G013-101 RFI Seal Strip l
201/2 WCA7110G013-109 RFI Seal Strip 1
201/3 WCA7110G013-107 RFI Seal Strip .- 1
201,202/3 217-0474-01 RFI Seal Strip 2
201/5 WCA7110GO13-105 RFI Seal Strip 1
201/8 NAS9307M-4-07 Rivet A/R
201,202/9 NAS9308M-4-04 Rivet A/R
NOTE: Part number 217-0474-03 may also be used, as it is the same as

part number 217-0474-01. The only difference is that it only has
one location hole and the repairer will have to drill the
remaining holes.
PARTICLES WHICH CAN BE HAZARDOUS TO YOUR HEALTH . ,.
AND SAFETY NOTICES.
4. Remove the Damaged Part (Figs. 201 and 202)
A. Identify the RFI seals that are damaged and must be replaced. Make
sure the damage is in the limits of this repair scheme
CAUTION: BE CAREFUL THAT YOU DO NOT CAUSE DAMAGE TO THE DOOR/DOOR

COMPOSITE PACKER (10) OR THE RIVET HOLES WHEN YOU REMOVE THE
RIVETS. IF DAMAGE DOES OCCUR OR THE HOLES BECOME OVER SIZE
THEN CONTACT:
GKN AEROSPACE SERVICES
R & 0 FACILITY
OSBORNE WORKS
Repair No.7
EFFECTIVITY: TRENT
54:+20-02
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.,F, . '.
- : " " page 202

RB211 TRENT
STRUCTURAL REPAIR
MANUAL
WHIPPINGHAM
EAST COWES
ISLE OF WIGHT
ENGLAND
UNITED KINGDOM
P032 6LR
B. C a r e f u l l y remove t h e r i v e t s t h a t h o l d t h e damaged,.s i a l to: t h e door

o r t h e door composite packer. Use h a n d / a i r t o o l s and ,. . -.a p p l i c a b l e
s i z e d r i l l b i t s . Do n o t make t h e h o l e s o v e r s i z e d . .. .
C. Remove t h e damaged RFI S e a l S t r i p from t h e Fan Cowl Door.
5. Prepare t h e Damaged Area f o r Repair ( F i g . 201 and 202)
A. Refer t o AMM TASK 70-20-01-100-802. Fully clean the r e p a i r area

w i t h a LINT-FREE CLOTH (OMat 2/101) moistened with ACETONE (OMat
150) o r ISOPROPYL ALCOHOL (OMat 1/40) o r CLEANING SOLVENT (OMat
1/257) and a p l a s t i c s p a t u l a . Make s u r e you do n o t damage t h e door
o r t h e door composite p a c k e r . Dry t h e a r e a with a c l e a n LINT-FREE
CLOTH (OMat 2/101) b e f o r e t h e f l u i d d r i e s
B. Clean t h e r e p a i r a r e a t o remove t h e unwanted s e a l a n t from t h e

mating s u r f a c e s of t h e door o r t h e door composite p a c k e r .
C. Do a v i s u a l i n s p e c t i o n of t h e r e p a i r a r e a . Make s u v.:..'
r e t h e r e . i s no
,
damage t o t h e mating s u r f a c e s of t h e door o r t h e doqr composite

L .-.. i ' . . ..
.,
packer. ..... .
.>,I_'
6. Prepare t h e Replacement S e a l s ( F i g . 201 and 202)
A. Prepare t h e replacement s e a l
(1) G e t t h e c o r r e c t replacement s e a l p a r t .
(2) P o s i t i o n t h e s e a l on t h e door o r t h e door composite packer and

h o l d l i g h t l y with clamps o r p i n s . Take c a r e n o t t o damage t h e
door o r t h e door composite packer with t h e clamps.
(3) Make s u r e t h e h o l e s i n t h e s e a l a l i g n with t h e h o l e s i n t h e

door o r t h e door composite packer.
(4) Cut t h e s e a l t o g i v e t h e c o r r e c t c l e a r a n c e s
(5) Remove t h e s e a l from t h e door o r t h e door c o & b s i t e hacker.

.
. .
,
B. Prepare t h e door
Repair No.7
54-20-02
Page 203
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(1) C a r e f u l l y push t h e o l d r i v e t t a i l s t h a t remain i n t h e door

back through t h e i r h o l e s i n t o t h e honeycomb. . *j , . c
(2) Push t h e r i v e t t a i l s f a r enough i n t o t h e honeycomb t o p e r m i t

i n s t a l l a t i o n of t h e new r i v e t s . Make s u r e t h e r i v e t t a i l s a r e
c l e a r of t h e h o l e s t o p r e v e n t p o s s i b l e i n t e r f e r e n c e .
(3) Follow t h e m a n u f a c t u r e r ' s i n s t r u c t i o n s t o mix enough q u a n t i t y

of t h e ADHESIVE (OMat 8/197) t o bond t h e r i v e t t a i l s s a f e l y i n
t h e honeycomb. The mix r a t i o by weight i s 100 p a r t s of P a r t A
with 30 p a r t s of P a r t B .
(4) U s e a s y r i n g e t o i n j e c t enough of t h e ADHESIVE (OMat 8/197)

i n t o each h o l e t o bond t h e r i v e t t a i l s i n t h e honeycomb. Do
n o t o v e r f i l l t h e h o l e s , t h e adhesive and r i v e t t a i l s t o g e t h e r
can cause i n t e r f e r e n c e with t h e new r i v e t s d u r i n g
installation.
(5) Where t h e r i v e t t a i l s cause i n t e r f e r e n c e d u r i n g i n s t a l l a t i o n

of t h e new r i v e t s , continue a s f o l l o w s :
-.
(a) Use a Back Facing D r i l l t o c a r e f u l l y remove t h e m a t e r i a l ,
which has caused t h e i n t e r f e r e n c e and an a d a i t i o n a l s m a l l
a r e a of t h e honeycomb. Make s u r e t h a t you do n o t damage
t h e door s k i n o r make t h e r i v e t h o l e s l a r g e r .
(b) Do t h e S t e p s t h a t f o l l o w a g a i n a s n e c e s s a r y .
1) Follow t h e m a n u f a c t u r e r ' s i n s t r u c t i o n s t o mix enough

of t h e ADHESIVE (OMat 8/197) t o bond t h e r i v e t t a i l s
s a f e l y i n t h e honeycomb. The mix r a t i o by weight i s
100 p a r t s of P a r t A with 30 p a r t s of P a r t B .
2) U s e a s y r i n g e t o p u t enough of t h e ADHESIVE (OMat

8/197) i n t o each h o l e t o bond t h e r i v e t t a i l s i n t h e
honeycomb. Do n o t o v e r f i l l t h e h o l e s , t h e ADHESIVE
(OMat 8/197) and r i v e t t a i l s t o g e t h e r can cause
i n t e r f e r e n c e with t h e new r i v e t s d u r i n g
installation.
(6) Deburr t h e r i v e t h o l e s i n t h e door and t h e dodr.,c?mposite

packer.
(7) Make s u r e t h e r i v e t h o l e s a r e c l e a n and f r e e from unwanted

material.
7. I n s t a l l t h e N e w S e a l s ( F i g . 201 and 202)
Repair No.7
54-20-02
Page 204
RB211 TRENT l
STRUCTURAL REPAIR
MANUAL
A. Clean t h e mating s u r f a c e s of t h e s e a l and door o r t h e door

composite packer. Refer t o AMM TASK 70-20-01-100-802. Fully clean
t h e mating s u r f a c e s of t h e s e a l and door o r t h e door composite
packer with a LINT-FREE CLOTH ( O M a t 2/101) moistened with ACETONE
(OMat 150) o r ISOPROPYL ALCOHOL (OMat 1/40) o r CLEANING SOLVENT
OMat 1/257) and a p l a s t i c s p a t u l a .
B. Apply a t h i n l a y e r of t h e adhesive mix t o t h e mating s u r f a c e s of

t h e replacement s e a l and t h e door o r t h e door composite p a c k e r .
C. Put t h e replacement s e a l i n t h e c o r r e c t p o s i t i o n on t h e door o r t h e

door composite packer and h o l d i t i n p o s i t i o n with clamps o r p i n s .
Do n o t t i g h t e n t h e clamps t o o much, t o p r e v e n t damage t o t h e door
o r t o the seal.
D. A t t a c h t h e s e a l s t o t h e door o r t h e door composite. p a c k e r s with t h e

r i v e t s [Item 8 (Ref No NAS9307M-4-07), l e f t door only.<:and I t e m 9
(Ref No NAS9308M-4-04), l e f t and r i g h t d o o r s ] . U s e SEALANT ( O M a t
8 / 5 ~ )on t h e r i v e t t a i l s t o make them s e c u r e i n t h e honeycomb
structure.
E. Make a smooth f i l l e t of SEALANT (OMat 8/5C) around t h e edge of t h e

seal.
F. Allow t h e ADHESIVE (OMat 8/197) t o c u r e a t room temperature o r ' u s e

h e a t e r lamps and a p p l i c a b l e thermocouples a s f o l l o w s :
(1) 30 Minutes a t 80 Deg.C (180 Deg.F)
(2) 60 Minutes a t 56 Deg.C (150 Deg.F)
(3) 72 Hours a t 25 Deg.C (77 Deg.F).
Visual Inspection
A. Do a v i s u a l i n s p e c t i o n of t h e r e p a i r t o make s u r e i t i s done i n
accordance w i t h FRSW026 and t h e f a s t e n e r s have been i n s t a l l e d t o
54-02-10, F a s t e n e r i n s t a l l a t i o n and removal procedure.
9. Record t h e Repair
A. Record d e t a i l s of t h e r e p a i r No FRS W026. Make a permanent r e c o r d

on t h e Mod P l a t e of t h e door with an e l e c t r i c a l v i b r o - e t c h i n g t o o l .
Repair No.7
F' .:
.. .
.. .
, . -.,,.-. Page 205
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
Note 1:
Cut seals 1, 3, 5 and 7 at these ends only,
to give a clearance. Seals 2 and 6 can be
cut at two ends.
Clearances:
Seals 2 and 6, maximum of 1,4rnm (0.055in)
between seals and latches.
Seals 3 and 5, maximum.of 1,4mm (0.055in)

between seals and seal 4
..
Seals 1 and 7, maxim,um of .l,4mm (0.055in)
between seals and latches .:.'
Note 2:
Counterbore holes for rivets to
maximum depth of 2,5mm (0.lOin).
Do not damage metal strip below rubber.
See note 1 See note 1
See note 2
Countersink holes
to l 0 0 deg
for rivets (9)
0,
m SECTION SECTION
m Remove unwanted material
0
a
0
' B-B before you install new rivets. C-C D-D
0
. ' .,
12
L

Fig. 201
Repair No.7
EFFECTIV1TY:TRENT
54-20-02
Page 206
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
Note 1:
Cut ends of the seal (4), equally,
to give a clearance of between
9 See note 2 0,3 and 1,Omm (0.010 and 0.040in)
and ends of mating seals (on the
left door).
Note 2:
Counterbore holes for rivets to
Countersink holes maximum depth of 2,5mm (0 loin).
to 1OOdeg for rivets (9) Do not damage metal strip below
SECTION rubber
B-B c *
Right Hand Door - Bottom edge RFI seals replacement

Fig. 202
Repair No.7
Page 207
Printed i n Great ~ r i t a i n Mar. 10/07
. % 1
RB211 TRENT
5
) : *
STRUCTURAL REPAIR
MANUAL
REPAIR N0.8 (FRS W027)
REPAIR OF WEAR TO THE FAN COWL DOOR LEADING EDGE OUTER SURFACE
General
CAUTION: YOU MUST REFER TO THE ALLOWAELE/REPAIRABLE DAMAGE LIMITS, TO

MAKE SURE THAT THE REPAIR I S PERMITTED.
A. T h i s r e p a i r scheme i s w r i t t e n f o r t h e L e f t and Right hand Fan Cowl

Doors t o POST SB 71-E107. This procedure g i v e i n s t r u c t i o n s t o
r e p a i r wear on t h e o u t e r s u r f a c e of t h e l e a d i n g edge-ok t h e Fan
Cowl Door on t h e aerodynamic contour. :, , ' ;
B. The damage i n each a r e a of t h i s r e p a i r must obey t h e c o n d i t i o n s

t h a t follow:
(1) Make s u r e t h e damage i s n o t more than t h e a l l o w a b l e damage

l i m i t s (54-20-02/101). Damage t h a t i s n o t i n t h e l i m i t s of
t h i s r e p a i r must be r e f e r r e d t o GKN Aerospace.
(2) Damage on t h e o u t e r s u r f a c e of t h e door on t h e forward l e a d i n g

edge of t h e door o n l y . Where t h e depth of t h e damage does n o t
e x t e n d more than 25% of t h e t h i c k n e s s of t h e m o n o l i t h i c
l e a d i n g edge s t r u c t u r e .
(3) Damage does n o t extend more than 1 2 , 7 mm (0.50 i n . ) back from

t h e l e a d i n g edge w i t h i n .the a r e a of carbon p l i e s .
.: ,. .-.,
. , . . 1.'. ;
...%..<.t:c-.l
... T,,-
(4) I f t h e r e i s delamination of t h e forward leadqng:e,dgel:,of
, . .. the
, U
d o o r , i n t h e a r e a of wear, and t h e damage i s .:het.,:,,. .:mbir'k?

,. -
.,-. t h a n t h e
l i m i t s t h e n c a r r y o u t t h e delamination repairr'(54-20-02/201
FRSW018-Repair No. 2) f i r s t .
(5) When t h e conductive s u r f a c e mesh i s damaged o r a f t e r t h e door

r e p a i r , r e p a i r o r r e p l a c e t h e mesh (54-20-02/201 FRSW023-
Repair No. 6 ) .
.......................................................................
54-02-04 Standard P a i n t i n g Procedure

54-20-02 Allowable Damage
. , Repaj r No . 8
..-. Page 201

RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(2) Plastic spatula
(3) Vibro-etching tool
.......................................................................
OMat 150 ACETONE

OMat 2/101 LINT FREE CLOTH

OMat 2/30 TAPE ADHESIVE, PTFE (TEFLON) RELEASE FILM
OMat 5/39 WATERPROOF SILICONE CARBIDE (Grit size i20) '
OMat 5 / 97 GARNET PAPER (Grit size 80)

OMat 8/197 EPOXY PASTE ADHESIVE, HYSOL EA9396 (2 Part)
.......................................................................
.......................................................................
AND SAFETY NOTICES.
4. Identify the Damaged Area to be Repaired (Fig. 201)
A. Do a visual inspection of the leading edge for damage and identify

each damaged area. Make sure that the damage is not more than the
allowable damage limits (54-20-02/101) to be repaired.
B. Fully clean the area with a LINT FREE CLOTH (OMat 2/101) made moist
with ACETONE (OMat 150) (Ref. AMM TASK 70-20-01-100-802) .
Repair No.8
EFFECTIVITY : TRENT
54-20-02
Page 202
Printed i n Great B r i t a i n ' Mar. 10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
C. Dry t h e a r e a with a c l e a n L I N T FREE CLOTH (OMat 2/101) b e f o r e t h e

f l u i d d r i e s . Leave t o s t a n d f o r a t l e a s t 15 minutes b e f o r e you
continue.
5. Prepare t h e Damaged Area f o r t h e Repair ( F i g , 202)
A. Measure and mark-up t h e r e p a i r a r e a
(1) U s e a s o f t p e n c i l t o c a r e f u l l y mark a l i n e on t h e o u t e r
s u r f a c e of t h e door. This i s t o i d e n t i f y t h e maximum l i m i t of
t h e damage rearwards from t h e l e a d i n g edge of t h e door.
(2) Apply TEFLON TAPE (OMat 2/30) around t h e repiir a r e a .
(3) Attach a Teflon Tape D a m t o t h e l e a d i n g edge of t h e r e p a i r

area.
B. C a r e f u l l y abrade t h e a r e a of wear t o remove any l o o s e m a t e r i a l . U s e

a sanding d i s c o r hand t o o l with GARNET PAPER (OMat 5 / 9 7 ) .
NOTE: Take c a r e n o t t o damage t h e exposed carbon p l i e s
C. L i g h t l y abrade t h e a r e a between t h e TEFLON TAPE ( O M a t 2/30) and t h e

a r e a of damage t o remove t h e s u r f a c e f i n i s h .
(1) F u l l y c l e a n t h e r e p a i r a r e a with a c l e a n , L I N T FREE CLOTH

(OMat 2/101) made moist with ACETONE (OMat 150) (Ref. AMM TASK
70-20-01-100-802) .
(2) Dry t h e a r e a with a c l e a n L I N T FREE CLOTH (OMat 2/101) b e f o r e

t h e f l u i d d r i e s . Leave t o s t a n d f o r a t l e a s t 15 minutes b e f o r e
you c o n t i n u e .
- 7 ,
(3) Use a h e a t lamp t o f u l l y d r y t h e r e p a i r a r e a it ~ o D ~ (140

~ . c
Deg. F) f o r two hours.
(4) L e t t h e a r e a cool t o room temperature b e f o r e you c o n t i n u e t h e

repair.
6. Prepare t h e Repair M a t e r i a l and Apply t o t h e Leading Edge ( F i g . 203)
A. Refer t o t h e m a n u f a c t u r e r r s i n s t r u c t i o n s f o r t h e u s e of t h e
ADHESIVE (OMat 8/197) and continue a s f o l l o w s :
(1) Mix enough ADHESIVE (OMat 8/197) t o c a r r y o u t t h e r e p a i r . The

p r o p o r t i o n of mix by weight i s 1 0 0 p a r t s of P a r t A with 30
p a r t s of P a r t B .
Page 203
R8211 TRENT
STRUCTURAL REPAIR
MANUAL
(2) Use a s p a t u l a t o apply t h e ADHESIVE ( O M a t 8/197) t o t h e r e p a i r

area.
(3) Apply enough ADHESIVE (OMat 8/197) t o t h e a r e a t o g e t t h e

i n i t i a l p r o f i l e back.
(4) Let t h e ADHESIVE ( O M a t 8/197) c u r e a t room temperature o r u s e

h e a t e r lamps and a p p l i c a b l e thermocouples a s
..,.'A.
£allows.: '
(a) 30 minutes a t 80 Deg.C (176 Deg.F)
Or
(b) 60 minutes a t 56 Deg.C (133 Deg. F)
Or
(C) 24 hours a t 25 Deg.C (77 Deg.F)
NOTE: This i s t o l e t f u r t h e r work be c a r r i e d o u t , a f t e r

which, c u r e f o r a f u r t h e r 48 hours t o f u l l y c u r e
t h e ADHESIVE (OMat 8/197) .
(5) Remove t h e TEFLON TAPE (OMat 2/30) .

7. Make t h e Repair Area Smooth with t h e c o r r e c t contour ( ~ i g ' .204)'
., ,
A. Use a sanding o r hand t o o l and WATERPROOF SILICON CARBIDE PAPER

(OMat 5/39) t o make t h e r e p a i r f l u s h with t h e door c o n t o u r .
NOTE: You must t a k e c a r e t o make s u r e t h a t t h e r e p a i r a r e a i s made

f l u s h t o both t h e forward edge and t h e contour round the
f r o n t edge of t h e door on t h e o u t e r s u r f a c e . This w i ll
p r e v e n t an in-to-wind s t e p and/or a r e d u c t i o n i n t h e gap
between t h e f a n cowl door and t h e a d j a c e n t s t r u c t u r e of t h e
nacelle.
B. C a r e f u l l y smooth t h e s u r f a c e of t h e r e p a i r a r e a t o remove a l l
irregular defects.
NOTE: I r r e g u l a r d e f e c t s such a s bubble h o l e s o r p i n h o l e s , must be

r e p a i r e d . U s e a f r e s h mix of ADHESIVE (OMat 8 / 1 9 7 ) .
C. Chamfer t h e r e p a i r of t h e l e a d i n g edge a t 45 Deg t o ' a depth of no

l a r g e r than one h a l f t h e t h i c k n e s s of t h e f i l l e d a r e a. of
. the
l e a d i n g edge s k i n . -*
8. V i s u a l I n s p e c t i o n and Tap T e s t
Repair No.8
54-20-02
Page 204
RB211 TRENT
FALJuTLURAL REPAIR
. .. . . . .
. . %
A. Do a v i s u a l i n s p e c t i o n and a t a p t e s t t o make sure;'-the & a i r is

done c o r r e c t l y . ..
9. Apply t h e S u r f a c e F i n i s h
A. Apply t h e s u r f a c e f i n i s h t o g i v e p r o t e c t i o n (54-02-04/201)
1 0 . Record t h e Repair
A. Record d e t a i l s of t h e r e p a i r No. FRS W027. Make a permanent r e c o r d

on t h e Modification P l a t e of t h e door with an e l e c t r i c a l v i b r o -
etching tool.
Repair No.8
54-20-02
Page 205
-p RB211 TRENT
STRUCTURAL REPAIR
MANUAL
.,.,,:
.
.
1
..,
,
Skin
..
A-A
REPAIR LIMITS:
F
o A Extend to no more than 12,70 mm (0.50 in) from leading edge.
p_
0
o B. Extend to no more than quarter the thickness of the skin.
8
Leading Edge Wear - Dimensions of Repair Area ~ i m i t s
Fig. 201
Repair No.8
EFFECTIVITY:TRENT 54'-20-02
Page 206
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
Teflon tape
Lightly abrade to
remove loose and
damaged mater~al
max.
Leading Edge Wear - Preparation and Dimensions for Repair

Fig. 202
Repair No.8
54-20-02
Page 207
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
Repair - fill area with Omat 81197 adhesive Teflon tape dam
...,
Skin
/////////l
'
.
....
Leading Edge Wear - Fill Area of Repair
I ; '
Fig. 203
Repair No.8
54-20-02
Page 208
Mar. 10/07
RB211 TRENT
STRUCTURAL REPAIR
m MANUAL
Leading edge
L e a d i n g E d g e Wear - C h a m f e r and Make F i n i s h e d C o n t o u r of R e p a i r

F i g . 204
Repair No.8
P a g e 209
.
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
.,(.' , . i
,!..
. >.. .,
R .,.. .
. . . .~ REPAIR N 0 . 0 9 (FRS 5 0 8 6 )
. .
, , .... .
POST S B 7 1 - E 1 0 7 FAN COWL DOOR - RIGHT HAND
,v- ;
:..,>
:<.
..
......
,.
,'. . -.
R REPLACE DECAL
R 1. General
R CAUTION: YOU MUST READ THESE INSTRUCTIONS BEFORE YOU REMOVE A

R DECAL FROM I T S POLYTHENE BAG.
R A. T h i s repair gives t h e prqcedure t o replace d a m a g e d decals

R on t h e RH Fan C o w l D o o r .
R B. T h e decals are supplied i n d i f f e r e n t c o l o r s f o r d i f f e r e n t

R backgrounds. U s e black o r red decals on l i g h t - c o l o r e d nacelles,
R u s e w h i t e o r y e l l o w decals on dark-colored nacelles.
,.: ;, . .
" R C.
.,.. T h e m i n i m u m a i r t e m p e r a t u r e necessary f o r t h i s .repair i s 1 6 deg
..
R C ( 6 1 deg F ) . If possible, do n o t operate t h e .engine f o r 4 8
. . . . . .
' ':
R hours a f t e r t h e repair has been done. . ._

..,,-C:.
. . :t; L'; ..!' . .
.....
.U,* . --.". --.i.. . . .- -
... :,
R 2. E q u i p m e n t and M a t e r i a l s . . .- .
..
R A. Standard E q u i p m e n t :
N o n - m e t a l l i c scraper
P l a s t i c squeegee
R u b b e r roller
B. C o n s u m a b l e Materials
......................................................................
OMat 1 5 0 ACETONE
OMat 2 6 2 TEMPORARY MARKER
OMat :2/12 SOFT BRUSH
:.
oMat..i/ioi LINT-FREE CLOTH :',*,. .
.$
OMat' 7 / 2 0 2 CLEAR VARNISH,2-PACK .?. ,fi.z. .: . ., :
..
OMat 7 / 2 0 3 THINNER :.,',..,.(*;.':.:L;,_...-.............
;....... ;; ..', '
. . . . .i.,......
.
OMat 7 / 2 0 4 THINNER ..........
'
OMat 296 ADHESIVE TAPE , f.
O M a t 5/150 S T R I P E OFF WHEEL
E F F E C T I V I T Y : TRENT REPAIR N 0 . 0 9
54-20-02
Page 201
R Jun 1 0 / 0 7
. Printed in Great Britain
., RB211 TRENT
STRUCTURAL REPAIR S, +
MANUAL
Part Identification
...............................................................
PART NUMBER PART I D E N T
FAN COWL DOOR ASSEMBLY L H

FAN COWL DOOR ASSEMBLY L H
I d e n t i f y t h e Decal, which r e q u i r e s replacement
A. Refer t o Table 1 and Figure 201 (Sheet 1 t h r u 6 ) t o i d e n t i f y

t h e , c o r r e c t replacement d e c a l .
c.
. .,.
Remove,"the Damaged Decal +l; ..
. . . . . >
. .
A. Clean t h e damaged d e c a l and t h e a d j a c e n t a r e a . Use 0 ~ a 2/101

t
L I N T FREE CLOTH soaked with OMat 150 ACETONE. D i s c a r d t h e c l o t h
a f t e r u s e . Let t h e p a r t d r y and remove t h e unwanted s o l v e n t
w i t h a c l e a n , d r y O M a t 2/101 L I N T FREE CLOTH.
B. Measure and keep t h e d i s t a n c e between t h e t o p edge and t h e

p e r p e n d i c u l a r edge of t h e damaged d e c a l t o an a p p l i c a b l e f i x e d
l o c a t i o n on t h e Fan Cowl Door.
C. G e t t h e OMat 5/150, STRIPE OFF WHEEL and an a p p l i c a b l e hand

h e l d r o t a r y t o o l ( t h e hand h e l d t o o l must have a s p i n d l e speed
of 1800 r p m t o 2200 rpm). Refer t o t h e m a n u f a c t u r e r ' s
i n s t r u c t i o n s f o r t h e i n s t a l l a t i o n and u s e of t h e OMat 1/150,
STRIPE OFF WHEEL.
D. While t h e hand h e l d t o o l r o t a t e s a t 1800 r p m t o 2200 rpm, move

R $
R - t h e o u t e r edge of t h e s t r i p e o f f wheel i n t o c o n t a c t w i t h t h e
R damaged d e c a l . Apply l i g h t c o n t a c t p r e s s u r e on t o damaged
. . .. ,,"<".'.S'
d e c a l with t h e O M a t 5/150, STRIPE OFF WHEEL. . , .- ,.l'",
.- .
1 3.
$5b:;s;c;-?', ~ L L - . .,.?
k'i. .. .' ,. '
Move t h e OMat 5/150, STRIPE OFF WHEEL i n t o c o n t a c t ,'t;'<th t h e " '

damaged d e c a l i n h o r i z o n t a l and v e r t i c a l d i r e c t i o n s . : " ~t ~ his
u n t i l t h e d e c a l h a s been removed. Do n o t damage t h e s t r u c t u r e
underneath t h e d e c a l .
R 5. Preware t h e R e ~ a i rArea
R A. I f n e c e s s a r y , remove t h e remains of t h e unwanted damaged d e c a l

R from t h e s u r f a c e of t h e Fan Cowl Door with a n o n - m e t a l l i c
R s c r a p e r . Do not' damage t h e s u r f a c e of t h e Fan Cowl Door.
EFFECTIVITY : TRENT REPAIR N0.09
Page 202
, ..A?' .Jun 10/ 07
::KP . ..,.. ...
,
:.' . .-.
-
., -L
... .,. ..
,l' .: .
. .-.,.
RB211 TRENT ,i .,r
,
....
..
'.. L
: : : ; : . ,i .
. .. . . .
, ,
STRUCTURAL REPAIR
MANUAL
R B. L o c a l l y degrease t h e r e p a i r a r e a . U s e OMat 2/101 L I N T FREE

R CLOTH and make m o i s t with OMat 150 ACETONE. D i s c a r d t h e c l o t h
R a f t e r use.
R C. Do a V i s u a l I n s p e c t i o n of t h e Fan Cowl Door. Make s u r e a l l of

R t h e damaged d e c a l has been removed and t h e r e i s no damage t o
R t h e s u r f a c e of t h e Fan Cowl Door.
R 6. Mark t h e p o s i t i o n of t h e replacement Decal

* :,
R A. Refer t o Figure 201 (Sheet 1 t h r u 6) f o r t h e p < s i t i o n of t h e
R replacement d e c a l . The non-hazard warnings a r e i n s t i l l e d t o t h e
R dimensions given i n t h i s r e p a i r scheme. I f thej&stome= logo
R s i g n s p r e v e n t i n s t a l l a t i o n of t h e non-hazard warnings, t h e y can
R be i n s t a l l e d a d j a c e n t t o t h e customer l o g o .
R B. Measure and keep t h e d i s t a n c e between t h e t o p edge and t h e

R p e r p e n d i c u l a r edge of t h e damaged d e c a l t o an a p p l i c a b l e f i x e d
R l o c a t i o n on t h e Fan Cowl Door.
U s e t h e measurements taken from above t o mark two p e r p e n d i c u l a r

l i n e s on t h e Fan Cowl Door. The marks must show t h e p o s i t i o n of
t h e t o p edge and a p e r p e n d i c u l a r edge of t h e replacement d e c a l .
U s e OMat 262 TEMPORARY MARKER t o p u t t h e marks on t h e Fan Cowl
Door.
R C,. U s e OMat 296 ADHESIVE TAPE t o make a continuous frame around

. .
,.:.. R t h e r e p a i r a r e a . The frame must be 0.39 i n c h . (10,Omm) l a r g e r
'. R .,
c',y
. t h a n t h e replacement d e c a l on a l l of t h e e d g e s . ,
* p -
i$?!. ".-,l,._j..
.
I
. ...
.;
.,
.. .--.., :L :' ;-. 1.;- c
R 7. Apply t h e Replacement Decal ,,ic,t+t;.5i
,.... . .. l
, .
,,> ;:-.'i..,j:,, : .' ':",.'
R CAUTION: DO NOT TOUCH THE ADHESIVE SIDE OF THE DE*. . .
R A. Remove t h e backing paper along t h e t o p edge of t h e d e c a l . Only

R remove enough backing paper t o l e t t h e t o p and t h e
R p e r p e n d i c u l a r edge of t h e replacement d e c a l t o be a l i g n e d with
R t h e marks made on t h e Fan Cowl Door.
R B. U s e t h e marks made on t h e Fan Cowl Door t o h e l p i n s t a l l t h e

R d e c a l . Apply t h e d e c a l t o t h e s u r f a c e of t h e Fan Cowl Door a t
R t h e marked p o s i t i o n .
R U s e a p l a s t i c squeegee o r rubber r o l l e r t o apply f i r m s t r o k e s

R on t h e d e c a l , o v e r l a p each s t r o k e . S t a r t a t t h e c e n t r e and move
R t o t h e edge of t h e d e c a l .
.+ .
+>.l
EFFECTIVITY : TRENT , , .,-
'REPAIR NO. 09
;-r:544720-02
^ jF
Page 203
Jun 10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
R C. Lift the bottom edge of the decal, gradually remove the backing
R paper to let the decal to be attached to the Fan Cowl Door. Use
R a plastic squeegee or a rubber roller to apply firm overlapping
R strokes from the centre to the outside edges of the decal. Make
R sure that the adhesive surface of the decal and the surface of
R the Fan Cowl Door only touch when pressure is applied.
l ,: '
R 8. Inspect the replacement decal - L,&-
. I
R A. Refer to Figure 201 (Sheet 1 thru 6). Do an inspection of the

R replacement decal. Make sure that the decal is in the correct
R position given in the repair scheme. Make sure that you get the
R customerls dimensions, for the non-hazardous warnings that have
R. been fitted adjacent to the customerrs logo.
R B. Do a visual inspection of the replacement decal. If necessary,

R trapped air can be removed from the decal. Use a pin to make a
R small hole in the trapped air in the decal. Press out the
R trapped air in the direction of the hole. Make the decal smooth
R with a plastic squeegee or rubber roller. If the decal is not
R smooth, remove and replace the decal.
R 9. Apply the Varnish
R A. Mix equal parts of the OMat 7/202 CLEAR VAFWISH 2-P&. If..
..I
R thinners are necessary, use: ,. ..

, ;,
(1) At temperatures between 16 and 26 deg C (61 ands'79 deg F),

. L>
7/204 THINNER.
R B. Make sure the varnish is fully'mixed (approx 15 to 30 minutes).

R The pot life of the varnish is 8 hours.
varnish extends by 0.39 inch. (10,Omrn) from all edges of the
2'
as follows: ,,!,L :; +
72 hours at a temperature of 16 deg C (61 deg F) or i'hour'at a

.' 1
1- 1
Page 204
Jun 10/07
STRUCTURAL REPAIR
j?,' , . ?
R 10. Do a Visual Inspection of the Decal j .

,a L '
I cr n

R surface i s f u l l y covered with varnish and the varnish extends
R by 0 . 3 9 inch. (10,Omm) from a l l edges of the decal over the Fan
R Cowl Door.
REPAIR N0.09
54-20-02
Page 205
Jun 10/07
p RB211 TRENT
MANUAL
STRUCTURAL REPAIR
ITEM I P C REF PART NO DECAL DESCRIPTION

11-24-71
B l a c k , L a t c h C l o s i n g P o s i t i o n and Shoot
1 01-402
Bolts
W h i t e , L a t c h C l o s i n g P o s i t i o n and Shoot
Bolts
3 01-408 m14846 Black, Hoist Point
4 01-409 m14847 White, H o i s t P o i n t

. . ..
Black, Engine O i l F i l l e r ~cces's:':; , ..L G; ..
. ... ;.' '. . .
, .
White, Engine O i l F i l l e r A c c e s s . ,::"
B l a c k t e x t , Master C h i p ~ e t e c t o r/ C a s e
D r a i n Filter A c c e s s
W h i t e text, M a s t e r C h i p D e t e c t o r / Case
Drain F i l t e r Access
Warning - B o t h R o d s M u s t B e U s e d When
W o r k i n g On E n g i n e , R e d and B l a c k t e x t .
Warning - B o t h R o d s M u s t B e U s e d When
W o r k i n g On E n g i n e , Y e l l o w and W h i t e t e x t
Black text, Tank C a p a c i t y 31.2 L i t r e s
W h i t e t e x t , T a n k C a p a c i t y 3 1 . 2.:.-.i L! l. t, .r e , 5+..,, . ,
1C.:..
1-
,
B l a c k , Number 1
.., , <.G
,' C
. ,
.
>
, ' ,
.4 ,.-
.. .. .
S..
White, N u m b e r l
W h i t e , Number 2
White, N u m b e r 3
REPAIR N 0 . 0 9
54-20-02
, +- . +";,c
3.. ,L
,.:.. '
Page 2 06
.. -.
v
. .,'d...Jun.
'in, 10/07
Printed in Great Britain : , , ' '
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
20 01-455 m14893 White, Number 4
21 01-462 FW14900 Black, 5-Shoot Bolt
22 01-463 FW14901 White, 5-Shoot Bolt

23 01-464 EW14902
Engine Is Running, Red and-. Black text
.t
.'
. .,h .
. . -.:..I. -, :
Warning-Keep Clear Of Hazard .Areas While

24 Engine Is Running, Yelloyand White text

25 01-510 m32620 Black outline on White background and
No -Go Areas Symbol, Yellow nacelle with

26 01-511 FW32621 White outline on Black background and

635,OOmm

28 01-102 m12344 . :. .& Height
background. Width 216,OOb-q
305,OOmm. , '.. :. .
..-. -
1.,
(
:;A
. , cr. >L
Rolls-Royce - Emblem. ~ i .I.
f v;*:-,c<
e rtext
.
on Blue % :
29 01-104 m12345 background. Width 419,OOmm & ~ e i ~ h t

635,OOmm. ... ,

30 01-106 m12346 background. Width 216,OOmm & Height
305,OOmm.

526,OOmm.

526,OOmm.
,. . . .
33 01-466 m14904 , .
Red, T/R Isolation ~witch'j~ymbol
-
.,:.
. . . .,. .":I,,
'
,*
.
. " ' - 9 :-.
:i<?ei; -
EFFECTIVITY : TRENT . .
,; -PAIR NO. 09
: . "?,,
v 54-20-02
Page 207
Jun 10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
FW14905 Yellow, T/R Isolation Switch Symbol

W33908 Areas While Engine Is Running, Red and
Black text, White background S/B 11-E346
(Chinese) Warning-Keep Clear d'fl;~aza,rd

'
W33909 Areas While Engine Is Running,-'yellowand
White text, grey background S/B 11-E346

W32457 Engine Is Running, Red and Blue text on
White background S/B 11-E346 Alt W 1 4 9 0 2

W33430 Engine Is Running, White text on Black
background S/B 11-E346 Alt W 1 4 9 0 3

Blue outline on White background and
"324 63
Tmperial Conversion S/B 11-E346 Alt
W32620
-/ k,
Black outline and White border_whth 3
FW324 64 ' i
Imperial Conversion S/B 1 1 - ~ 3 4 641t

1
W 3 2 620
Table 1
54-20-02
Page 208
R Jun 10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
I ) ..
2 . :
::.i c 2. ?,
I .. .., . : .
:,.a,:',. .<
l
,.i,;.: ;:; y.. : '.
;, . .!'3 ,, :
. ,
! .". -
~.
.
. .....
.
9
TYPICAL VIEW ON THE FRONT OF THE ENGINE, ,'I.-: . , ' .-

,.., . .....,
< ...'?r.:., ,,
I
, . ,'S
I . . .,:
;, , ':.
.. ' i'
.*
TYPICAL VIEW ON THE FRONT OF THE ENGINE. -..,:.

TO SHOW THE FAN COWL DOOR OPEN .;;-,:;
. !2,....,:f$.:3.:.I.. :,c,-:'
FIGURE 201
I n s t a l l a t i o n o f Decals
REPAIR NO. 09
54-20-02
Page 209
Jun 10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
APPLY ITEM 5 OR 6
TO THE INSTRUCTIONS
THE LEADING
EDGE OF THE
COWL DOOR
APPLY ITEM 3 OR
THE INSTRUCTIO
THE CENTERLINE OF
THE REAR NOSE
COWL HOIST POINT
APPLY ITEM 11 OR 12
TO THE INSTRUCTIONS
APPLY ITEM 7 OR 8
-
TO THE INSTRUCTIONS
-- 620.00 24 409. , .
580,00(22.835) 9
- - 1220,OO 48 031
1180.00(46 457)
FIGURE 202
REPAIR N0.09
';,. Page 210

RB211 TRENT
STRUCTURAL REPAIR
MANUAL
1305,OO 51 378
1265.00(49:803)
- C
720,OO 28.346
4 - 680,OO (26.772)
, .
:.::z .: . .
:..c> >,,
, .- ., . ..

30,31OR 32 TO THE
INSTRUCTIONS
. .
APPLY ITEM 35 OR 36
TO THE INSTRUCTIONS
VIEW -
FIGURE 203
AA
S ...., -:
, 5 ~ & , . !
. > .. ' REPAIR NO. 09
.', .... ... . . . _,
,X ..
'
Page 211
Jun 10/07
Printed in Great Britaln
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
_ 1065,OO 41 929
1025.00(40 354)
4
-
- 587.00 23.1 10
547,OO (21.535)
.-
, .
' '.
APPLY ITEM 9 OR 10
TO THE INSTRUCTIONS
APPLY ITEM 17 OR 18 THIS IS ON THE INNER
TO THE INSTRUCTIONS
APPLY ITEM 21 OR 22
APPLY ITEM 19 OR 20 TO THE INSTRUCTIONS
TO THE INSTRUCTIONS
1
1
-
A
83,OO 3 268
CLOSING LINE -43,00(1'693)
\
APPLY ITEM 15 OR 16
TO THE INSTRUCTIONS
X.
"i
THE LEADING EDGE

OF THE COWL DOOR
FIGURE 204
I n s t a l l a t i o n of Decals
Figure 201 (Sheet 4 ) f i, , .
- .:
' , ~ ? , i ;' . ' .IL: . .
.i.lG.
r.
, . . .
REPAIR NO. 09
54;-20-02 . .
Page 212
Jun 10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
APPLY ITEM 1 OR 2
TO THE INSTRUCTIONS
I
169,OO 6.654
129.00 (5.079
- -
>./..
., >
.. . . (
. l$),' .
J , . I
,
..
.
i*j;:qt :. , .'
THE COWL DOOR "'39,.0 1.535
CLOSING LINE -. o,?o (o.ooo)
L~~~~~
ITEM 13 OR 14
TO THE INSTRUCTIONS
I +' THE LEADING EDGE

OF THE COWL DOOR
;. ....,
;.,,r;~$::. , .:
'-".S-
FIGURE 205
'
. : .p:,.' ;' '
. . , .. ! . . . . I .'
. '..
_ ,
54-20-02
Page 213
Jun 10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
APPLY ITEM 33 OR 34 WITH

THE SYMBOL OF THE HANDLE
POSITIONED DIRECTLY ABOVE
THE ISOLATION UNIT HANDLE
TO THE INSTRUCTIONS
LTHE
COWL DOOR
HINGE LINE
VIEW -AC
FIGURE 206
Figure 2 0 1 (Sheet 6 )
54-20-02
Page 214
JU; 10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR NO. 10 (FRS 5087)
POST SB 71-E107 FAN COWL DOOR - LEFT HAND
REPLACE DECAL
1. General


the LH Fan Cowl Door.
.B. The decals are supplied in different colors for different


C (61 deg F) . If possible, do not operate the engine for 48
Plastic squeegee
Rubber roller
......................................................................
......................................................................
-C.< ,
OMat 150 ACETONE - l '4
< .
OMat 2/12 SOFT BRUSH
OMat 7/203 THINNER
OMat 7/204 THINNER
EFFECTIVITY : TRENT REPAIR NO.10
. ..
54-20-02
' ."L Page 201
R .>-l : i
' Jun 10/07
Prlnted In Great Brltain 2
- ,A
P - , P
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
C. P a r t Identification

......................................................................
WCA7110E012-041 FAN COWL DOOR ASSEMBLY LH
,WCA7110E013-041 FAN COWL DOOR ASSEMBLY RH
217-0466-01 FAN COWL DOOR ASSEMBLY LH
217-1366-01 FAN COWL DOOR ASSEMBLY RH
3. I d e n t l f y t h e D e c a l , w h i c h requires r e p l a c e m e n t
. *.
A. R e f e r t o T a b l e 1 and Figure 2 0 1 ( S h e e t 1 t h r u 4 ) to- i d e n t i f y
. ,
t h e correct r e p l a c e m e n t decal.
4. Remove the Damaged D e c a l
A. C l e a n t h e d a m a g e d decal and the adjacent area. U s e O M a t 2 / 1 0 1

L I N T FREE CLOTH soaked w i t h O M a t 150 ACETONE. D i s c a r d t h e c l o t h
a f t e r u s e . L e t t h e p a r t dry and r e m o v e t h e u n w a n t e d s o l v e n t
w i t h a clean, dry O M a t 2 / 1 0 1 L I N T FREE CLOTH.
B. M e a s u r e and keep t h e distance b e t w e e n t h e t o p edge and t h e

perpendicular edge of t h e d a m a g e d decal t o an applicable f i x e d
l o c a t i o n on t h e Fan C o w l D o o r .
C. G e t t h e O M a t 5/150, S T R I P E O F F WHEEL and an applicable hand

held r o t a r y t o o l ( t h e hand h e l d t o o l m u s t have a spindle speed
of 1 8 0 0 r p m t o 2 2 0 0 r p m ) . R e f e r t o t h e m a n u f a c t u r e r ' s
i n s t r u c t i o n s f o r t h e i n s t a l l a t i o n and u s e of t h e O M a t 1 / 1 5 0 ,
S T R I P E O F F WHEEL. ,
- . 0 J ,
.; .
,:,. :.,L
D. while t h e hand held t o o l r o t a t e s a t 1800 r p m t o 2200, r p m , ' move
...I.. ,;. I
t h e o u t e r edge of t h e stripe o f f w h e e l i n t o c o n t a c t , ' w i t h the

d a m a g e d decal. A p p l y l i g h t c o n t a c t pressure on t o thk. . d a m a g e d
decal w i t h t h e O M a t 5 / 1 5 0 , S T R I P E O F F WHEEL.
M o v e t h e O M a t 5/150, S T R I P E O F F WHEEL i n t o c o n t a c t w i t h t h e
d a m a g e d decal i n h o r i z o n t a l and v e r t i c a l d i r e c t i o n s . D o t h i s
u n t i l t h e decal has been r e m o v e d . D o n o t d a m a g e t h e s t r u c t u r e
underneath t h e decal.
5. P r e p a r e the R e p a i r A r e a
A. If necessary, r e m o v e t h e r e m a i n s of t h e u n w a n t e d d a m a g e d decal
f r o m t h e surface of t h e Fan C o w l D o o r w i t h a n o n - m e t a l l i c
scraper. D o n o t d a m a g e t h e surface of t h e Fan C o w l D o o r .
'3* '..,.,.,:
.. ...,. ',
'< J'L? > , . ..... .
. .- .
, .. .. .- .
.-
.,. .,:.;.. , . .::::
:;'
EFFECTIV1TY:TRENT - R E P A I R NO. 1 0
3 .>X
.. P a g e 202
Jun 1 0 / 0 7
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
R B. L o c a l l y degrease t h e r e p a i r a r e a . Use OMat 2/101 L I N T FREE

R CLOTH and make moist with OMat 150 ACETONE. Discard t h e c l o t h
R a f t e r use.
,:, R ,C.
. . Do a V i s u a l I n s p e c t i o n of t h e Fan Cowl Door. Make s u r e a l l of
R . .,..'
,L
t h e damaged d e c a l h a s been removed and t h e r e i s ' . n o damage t o
R . t h e s u r f a c e of t h e Fan Cowl Door. ., .. , . . +
...,
... .,a
.. . _.L
:?,.E,:'.:
%
. . :<
R 6. Mark t h e p o s i t i o n of t h e replacement Decal .. .,,..'.2...q .-
'; ;,'
. . .
. ..: - ...
I
R A. Refer t o Figure 201 (Sheet 1 t h r u 4 ) f o r t h e p o s i t i o n of t h e

R replacement d e c a l . I n c o n d i t i o n s where c u s t o m e r f s logo s i g n s
R w i l l n o t a l l o w t h e non-hazard warnings t o be f i t t e d t o t h e
R given dimensions i n t h i s r e p a i r scheme, t h e y can be f i t t e d
R a d j a c e n t t o t h e c u s t o m e r f s logo.
R B. Measure and keep t h e d i s t a n c e between t h e t o p edge and t h e

R p e r p e n d i c u l a r edge of t h e damaged d e c a l t o an a p p l i c a b l e f i x e d
R l o c a t i o n on t h e Fan Cowl Door.
U s e t h e measurements taken from above t o mark two p e r p e n d i c u l a r

l i n e s on t h e Fan Cowl Door. The marks must show t h e p o s i t i o n of
t h e t o p edge and a p e r p e n d i c u l a r edge of t h e replacement d e c a l .
.. -
j: :
U s e 0 ~ a 262
t TEMPORARY MARKER t o p u t t h e marksl:on . t h. e Fan Cowl
Door. . , . ... ..
-2 :i . . 1:-.i
...,., . ,. ..
C. ,. . ,,,I., , ..
U s e OMat 296 ADHESIVE TAPE t o make a continuou&~"~~~r.am;k~:'around
t h e r e p a i r a r e a . The frame must be 0.39 i n c h .'. ($C<,Om)
. . larger
t h a n t h e replacement d e c a l on a l l of t h e edges.,,:*.. .
R 7. Apply t h e Replacement Decal
R CAUTION: DO NOT TOUCH THE ADHESIVE SIDE OF THE DECAL.
R A. Remove t h e backing paper along t h e t o p edge of t h e d e c a l . Only

R remove enough backing paper t o l e t t h e t o p and t h e
R p e r p e n d i c u l a r edge of t h e replacement d e c a l t o be a l i g n e d with
R t h e marks made on t h e Fan Cowl Door.
R B. U s e t h e marks made on t h e Fan Cowl Door t o h e l p i n s t a l l t h e

R d e c a l . Apply t h e d e c a l t o t h e s u r f a c e of t h e Fan Cowl Door a t
R t h e marked p o s i t i o n .
R U s e a p l a s t i c squeegee o r rubber r o l l e r t o apply f i r m s t r o k e s

R on t h e d e c a l , o v e r l a p each s t r o k e . S t a r t a t t h e : c e n t r e . a n d move
i C 5 L
R t o t h e edge of t h e d e c a l . L*?..
:? .l, I
'
Page 203
R Jun 10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
C. ~ i £ tthe bottom edge of the decal, gradually remove the backing

paper to let the decal to be attached to the Fan C&I Door'. Use
a plastic squeegee or a rubber roller to apply fid;overlapping
strokes from the centre to the outside edges of the decal. Make
sure that the adhesive surface of the decal and the surface of
the Fan Cowl Door only touch when pressure is applied.
Do an Inspection of the replacement decal
A. Refer to Figure 201 (Sheet 1 thru 4). Do an inspection of the

replacement decal. Make sure that the decal is in the correct
position given in the repair scheme. Make sure that you get the
customerfs dimensions, for the non-hazardous warnings that have
been fitted adjacent to the customerrs logo.
B. Do a visual inspection of the replacement decal. If necessary,

trapped air can be removed from the decal. Use a pin to make a
small hole in the trapped air in the decal. Press out the
trapped air in the direction of the hole. Make the decal smooth
with a plastic squeegee or rubber roller. If the d e ~ a l , i s - ~ n o t
'... v? 2; . . . . .L
smooth, remove and replace the decal. ,;',;",$;., ......

. ;,;.,<>
.. ,. . .* .-
1 %
,,-:A-. 7
Apply the Varnish


7/204 THINNER.
B. Make sure the varnish is fully-mixed (approx 15 to 30 minutes).

C. use the OMat2/12 SOFT BRUSH to apply a thin layer of the

+i&iish to cover all of the surface of the decal. Mdke
*CC' .. '
sure the
varnish extends by 0.39 inch. (10,Omm) from all edges' of the
a;,,?; ..--. .:
....,.... *,.:+.,.!A.
,
decal over the surface of the Fan Cowl Door. . .... .,.,.c
,.:,.., ..L
., .. .
'
... . .
. ._
t
. .
<.
"
..
D. After 30 minutes at room temperature, the varnish can,be
.-'
cured
as follows:
54-20-02
Page 204
R Jun 10/07
.::e-.-:,.
;:.
. .
.:,......:p.
RB211 TRENT . . . . ......
-;.. 'r,: . . . . . .:,
2-:
-.:.. . . .. .
%;.,;.
STRUCTURAL REPAIR
. ,'
. L .
I
;
. ..C-
,
. . ..I,.-.. . p
4. ',.
: : _I..(
. . . '
MANUAL . ,
.: .. ;. i '
R 1 0 . Do a Visual Inspection of the Decal

R surface i s f u l l y covered with varnish and the varnish extends
R by 0 . 3 9 i n c h . (10,Omm) from a l l edges of the decal over the Fan
R Cowl Door.
REPAIR NO.10
:,*
I
.:r54-20-02
.
2z.:y <..
..
......,
$
.* .L.4 -
4.
'
I .L;
- . Page 205
. 1......; ' . . ,...,- ..V'
;..:
. .. . .. ..,..;,
. ,..,";'jun 10/07
Printed in Great Britain .... .. . . . . ..-
1st.
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
ITEM I P C REF PART NO DECAL DESCRIPTION

11-24-71
1 01-408 m14846 Black, Hoist Point
2 01-409 m14847 White, Hoist P o i n t
3 01-418 m14856 B l a c k t e x t , 6 Shoot B o l t

.. ,
4 01-419 FW14857 White t e x t , 6 Shoot ~ o l t " I +
B l a c k t e x t , S t a r t V a l v e O/R, T h r u s t
5 R e v e r s e r Safety S w i t c h , ATV A c c e s s .
W h i t e t e x t , S t a r t V a l v e O/R, T h r u s t
6 01-429
R e v e r s e r S a f e t y S w i t c h , ATV A c c e s s .
7 01-432 FW14870 B l a c k t e x t , IDG O i l F i l t e r
8 01-433 FW14871 W h i t e t e x t , IDG O i l F i l t e r
R e d a n d B l a c k t e x t , Warning - B o t h R o d s
9
M u s t B e U s e d When Working O n E n g i n e
Y e l l o w and W h i t e t e x t , Warning - B o t h R o d s
10 01-437
M u s t B e U s e d When Working On E n g i n e
R e d & B l a c k T e x t , w a r n i n g : - K e e p , , ~ l e a r Of
11
H a z a r d A r e a s W h i l e E n g i n e Is R u n n i n g
, ',,
Y e l l o w & White T e x t , w a r n i n g - K e e p C l e a r O f
12
H a z a r d A r e a s W h i l e E n g i n e Is R u n n i n g
No - Go Areas S y m b o l , R e d nacelle w i t h
13 01-510
B l a c k outline & I m p e r i a l C o n v e r s i o n
No - Go Areas S y m b o l , Y e l l o w nacelle w i t h
14
W h i t e o u t l i n e and I m p e r i a l C o n v e r s i o n
Rolls-Royce -
E m b l e m . S i l v e r t e x t on B l a c k
15 01-100 m12343 background. W i d t h 16.5 i n . (419,OOmm) &
H e i g h t 25 i n . (635,OOmm).
. . . R o l l s - R o y c e - E m b l e m . S i l v e r t e x t on B l a c k
. .1.6 01-102 m12344 background. W i d t h 8.5in:..(216,00mm) &
H e i g h t 12 i n . (305,00mm);.l :,.*-..$:;,
.-{,!,L,..: - .
... ' . . . " '2"
;
; 4 , . -*' .
17 01-104 m12345 Rolls-Royce - Emblem. ~ilsr=;i., t & $ o n
.,.:.>.+..'.'. *. ,
Blue
:
EFFECTIV1TY:TRENT :;REPAIR NO. 10
P a g e 206
Jun 10/07
p RB211 TRENT
MANUAL
STRUCTURAL REPAIR
background. Width 16.5 in. (419,OOmm) &


01-106 m12346 background. Width 8 .'5 in. '(216,OOmm) &
.. . ,
Height 12 in. (305,,00mm)
Rolls-Royce - Emblem: Silver text on Blacl

01-101 W12347 background. Width 13.9 in. (352,OOmm) &

01-105 m12348 background. Width 13.9 in. (352,OOmm) &

01-550 W33908 Areas While Engine Is Running, Red & Blacl
text on White background

05551- FW33909 Areas While Engine Is Running, yellow &
White text on grey background. l$'.
..
.: !2 ,
....C..
Warning-Keep ~1ear~:bf , ~ a z = rAreas

d While
. ..,i.i . I
01502- FW32457 Engine Is Running,:k&& Blue text S/B 11.

'
'3 ,' '?

E346 Alt W14902 .. ,..'!. ...,. , "
.;..
01-503 m33430 Engine Is Running, White text on Black
Background S/B 11-E346 Alt m 1 4 9 0 3

Blue outline on White background &
01-512 "32463
m 3 2 620

m32620 ..... .
,!!~.
White text , ~ a r n i n & { ; ~ ~ " ~Rods
o t h .Must
~ Be
01-542 m33429
Used When Working C)nj;;~li~ine it
.,:...E'..
. .:I. ... ..
.. .
. ..
, .,, .
l,.
-
Table 1
REPAIR N0.10
54-20-02
Page 207
Jun 10/07 1
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
TYPICAL VIEW ON THE FRONT OF THE ENGINE
FIGURE 201
0
0
Q
!l
I n s t a l l a t i o n of D e c a l s
F i g u r e 2 0 1 ( S h e e t 1)
EFFECTIVITY: TRENT REPAIR N O . 1 0
54-20-02
Page 208
R Jun 1 0 / 0 7
p
"" RB211 TRENT
MANUAL
STRUCTURAL REPAIR
THE LEADING EDGE I

OF THE COWL DOOR
1 APPLY ITEM 15,16,17,
18.19 OR 20 TO THE
INSTRUCTIONS
: ...
THE-CENTERLINE OF
.THE REAR NOSE
COWL HOIST POINT
-APPLY ITEM 11,l2,

23 OR 24 TO THE
INSTRUCTIONS
I A P P L Y ITEM 21 OR 22
TO THE INSTRUCTIONS
FIGURE 202
I n s t a l l a t i o n of D e c a l s
F i g u r e 2 0 1 ( S h e e t 2)
EFFECTIVITY: TRENT REPAIR N O . 1 0
54-20-02
Page 209
Jun 1 0 / 0 7
RB211 TRENT m
STRUCTURAL REPAl R
MANUAL
m THE LEADING EDGE

OF THE COWL DOOR
FIGURE 203
EFFECTIVITY : TRENT ..REPAIR NO.10

5&-2
,-
o;,-o2
, c,\,
>,.<,
;
.'';.,)?:-'1>:): ' 210
. ; 1 <.:
.. Jun "'10/07
, . ..
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
VIEW - AA
FIGURE 204
54-20-02
Page 211
Jun 10/07
REPAIR NO.11 (FRSW030)
FAN COWL DOORS
WET LAY-UP REPAIR TO MONOLITHIC CARBON AREAS
1. General
A. This repair scheme is written for Left and Right Fan

Cowl Doors to Post SB71-E107. This repair gives the
procedure for the repair of monolithic carbon areas
in the fan cowl doors.
B. This repair procedure gives instructions for the

repair of damage to both the inner and outer
monolithic flange areas.
C. This repair is limited to areas which have a minimum

of 3 plies of the original monolithic flange intact
D. Damage that is not in the limits of this repair must

be referred to GKN Aerospace Services, R & O
Facility:
Osborne Works
Whippingham Road
East Cowes
Isle of Wight
England
United Kingdom
PO32 6LR
E. The damage is repaired with these primary materials:
Carbon fibre fabric

Copper mesh (outer skin only)
Epoxy adhesive
2. Reference Data
REFERENCE NOMENCLATURE
54-02-04 SRM – Standard Painting Procedure
54-01-06 SRM – Tap Test
54-20-02 SRM – Fan Cowl Identification
70-20-01-100-802 AMM – Cleaning

54-20-02
Page 201
JUN 10/09
- Spatula
- Gloves, neoprene or polyvinyl chloride
- Roller
- Standard workshop tools and equipment
- Suction cleaner
- Heat blanket of sufficient size and with a
temperature
range of 32 to 248˚F (0 to 140˚C)
- Heat lamp with heating capacity of 176˚F (80˚C)
- Vacuum suction pump, 0-30inHg (0 to 762.0mmHg)
- Two applicable vacuum fittings
- Two temperature probes, 32 to 248˚F (0 to 130˚C)
- Router or Oscillating saw
- Metal Caul Plate
- Edge Support Plate
- Disc Sander
OMat 2/30 TAPE ADHESIVE, PTFE RELEASE FILM
OMat 150 ACETONE
OMat 212 BRUSH, PAINTING
OMat 2/111 BREATHER CLOTH (N10-FR)
OMat 2/113 PARTING FILM – NON-POROUS (234-
TFNP)
OMat 2/112 PARTING FILM – POROUS (234-TFP)
ABRASIVE PAPER (Grit Size 280)
ABRASIVE PAPER (Grit Size 400)
OMat 5/97 GARNET PAPER (Grit Size 80)
OMat 2/110 ADHESIVE TAPE (VACUUM BAG SEAL)
(SM-5127)
OMat 8/197 EPOXY ADHESIVE (EA9396) (Two Part)
OMat 8/115 GLASS FABRIC-PLAIN WEAVE ‘E’
('Bleeder' fabric)
OMat 8/89A CARBON FIBRE FABRIC-PLAIN WEAVE –
Hexcel AS4W Type 1, Class 1
OMat 8/240 COPPER MESH (dry) (CU022CX
Astroseal Products)
54-20-02
Page 202
JUN 10/09
OMat 2/157 TAPE, POLYESTER, PRESSURE
SENSITIVE
OMat 262 MARKER

WCA7110E012-043 Fan Cowl Door Assembly LH
WCA7110E013-043 Fan Cowl Door Assembly RH
Procedure

CLOTHING, GLOVES, DUST MASK AND SAFETY GOGGLES
TO PROTECT YOU AGAINST DUST AND LOOSE PARTICLES
WHICH CAN BE DANGEROUS TO YOUR HEALTH.
WARNING: WHEN YOU USE CLEANING MATERIALS, COATINGS,

ADHESIVES AND SEALANT REFER TO THE
MANUFACTURER’S CONTROL AND APPLICATION
4. Clean the Repair Area.
A. Identify the area to be repaired. Make sure the damage

is in the limits of this repair scheme as given in 54-
20-02, Page Block 101.
B. Refer to AMM TASK 70-20-01-100-802. Fully clean the

repair area using LINT FREE CLOTH (OMat 2/101) moist
with ACETONE (OMat 150). Fully dry the area with a
fresh piece of lint free cloth before the fluid
dries.
5. Prepare the Repair Area.
The following procedure is for preparation of the repair

area and s similar for inner or outer damage(Refer to
Figures 201 and 202).
A. Mark out the defined area of damage with a SOFT PENCIL

(OMat 261). Mark out the cut line by at least 0.25 in.
(6,0mm) greater than the damage. This can be any
necessary shape but all sharp corners must have a
minimum radius of 0.25in. (6,0mm).
B. Remove the damage making a note of the number of plies

thatare removed and if a conductive mesh is present on
the outersurface.

54-20-02
Page 203
JUN 10/09
C. From the marked out cut line in step 5.A., mark out in
0.5in. (12,7mm) steps a boundary line for each ply that is
to be removed for the repair. The number of lines shall be
the same as the number of plies removed.
D. Apply TEFLON TAPE (OMat 2/30) around the repair area.
E. Working from the centre of the repair outwards set the

router cutter depth to one ply higher than lowest ply at
the centre of the repair. Remove the composite material
to the first inner boundary line.
F. Set the router cutter to the next ply higher and cut to
the next boundary line on each side of the repair area and
remove the composite material. Repeat this for each step
until the outer surface and outer boundary line is reached.
Ref. Figure 201.
NOTE: Removal of the plies may be carried out using a

high-speed hand sander to create steps in each
layer or taper sanding.
For both inner and outer damage, do not expose
the honeycomb core surface when abrading to make
the overlaps for the repair plies.
G. When the last composite ply is removed then the outer area
marked in Section 5.C. should have the paint and copper mesh
removed.
NOTE: Removal and replacement of the copper mesh is

only applicable if the repair is conducted on
the aerodynamic surface.
H. When replacing the copper mesh a further area of 1.0 in.

(25,4mm) must be abraded to expose the existing copper
mesh.
I. Vacuum to remove dust and debris. Refer to AMM TASK 70-20-

01-100-802. Fully clean the repair area using LINT FREE
CLOTH (OMat 2/101) moist with ACETONE (OMat 150). Fully
dry the area with a fresh piece of lint free cloth before
the fluid dries. Leave to stand for at least 15 minutes
before you continue.

54-20-02
Page 204
JUN 10/09
J. Water Break Test
Brush on or spray a thin layer of distilled water to

the repair area. A continuous layer seen for approximately
a half-minute shows the area has passed the water break
test. If the water forms droplets then it must be cleaned
to procedure 4.B and tested again. After testing the areas
must be fully dried before application of repair plies.
Use heating lamps that do not exceed 158˚F (80˚C) to dry
the repair area.
6. Prepare the support and the packing plates (Ref. Figure

202)
A. Measure the width and length of the repair area on

the door surface for the support plate.
B. Cut a piece of aluminium alloy sheet or similar

strength material that is approximately 0,8mm
(0.032in.) thick to a size that is larger than the
area measured in step 6.A.
NOTE: The metal caul plate must be treated by applying

PTFE ADHESIVE TAPE RELEASE FILM (OMat 2/30) on
the contact surface before fitting to prevent
bonding to the door during the cure procedure.
C. Place a metal caul plate to the inside face of the

exposed hole in the panel as a support while
proceeding with the first stage of the repair lay-up.
The caul plate should be formed to shape if
necessary.
D. Attach the metal caul plate to the panel with

PRESSURE SENSITIVE POLYESTER TAPE (OMat 2/157). Ref.
Figure 201.
E. For damage that bridges the edge of the part use an

edge support plate.
F. Measure the depth and length of the repair along the

door edge.
G. Cut another piece of aluminium alloy sheet or similar

strength material that is approximately 0.032in.
(0,8mm) thick to a size that is larger than the area
measured in step 6.F.
NOTE: To prevent the caul plate from bonding to the

door during the cure procedure, the metal caul
support plate must have a layer of PTFE ADHESIVE
TAPE RELEASE FILM (OMat 2/30) applied on the
contact surface before fitting.
54-20-02
Page 205
JUN 10/09
H. Attach the edge support plate to the door edge with
PRESSURE SENSITIVE POLYESTER TAPE (OMat 2/157).
NOTE: The edge support plate is used to seal the edge

of the repair area during operation of the
vacuum equipment.
7. Prepare the Repair Plies and Copper Mesh.
NOTE: Prepare as many plies as those cut from the

panel being repaired plus one extra repair ply
of carbon fibre fabric. Ref. Figure 202.
A. Using clean sharp scissors or a knife cut the CARBON

FIBRE FABRIC (OMat 8/89A). Ensure that the profile is
cut so that the required fibre direction is achieved.
Do the cutting on a cutting bench not on the component
to be repaired. Cut the material to ensure the
required overlaps as indicated for each repair ply is
achieved. Keep the prepared fabric flat until the
material is required for laying-up.
B. The direction of each repair ply to be the same as the

direction of the plies in the component material, plus
one at 0˚.
NOTE: COPPER MESH (OMat 8/240) only needs to be

replaced if the repair is conducted on the
aerodynamic surface.
C. Cut one ply of COPPER MESH (OMat 8/240). Refer to

Figure 201 for dimensions.
8. Lay-up the Repair Plies (Ref. Figures 202).
A. Mix the EPOXY ADHESIVE (OMat 8/197). The weight of

the adhesive needed will be approximately the same as
the weight of the carbon, glass scrim and mesh plies.
The mix ratio by weight is 100 Part A to 30 Part B.
Refer to manufacturers instructions for control and
application of EPOXY ADHESIVE (OMat 8/197).
B. Mix and apply EPOXY ADHESIVE (OMat 8/197) to the

repair area. Make sure the adhesive covers an area
larger then the size of mesh ply to be added. The
adhesive can be spread out using a spatula.
C. Place the first carbon repair ply on a sheet of NON-

POROUS PARTING FILM (OMat 2/113).
D. Apply the adhesive mixture to the carbon ply and

spread out using a spatula. Cover the repair ply with

54-20-02
Page 206
JUN 10/09
another sheet of NON-POROUS PARTING FILM (OMat 2/113).
Mark the ply orientation on the parting film.
E. Use a roller to remove trapped air. Do not use

excessive force, which may remove adhesive from the
repair area.
F. Remove the bottom sheet of the NON-POROUS PARTING FILM

(OMat 2/113).
G. Centre the repair ply over the cut-out ensuring

correct ply orientation. Refer to ply orientation
data in SRM 54-20-02 - Fan Cowl Identification
section.
H. Smooth out any wrinkles with a roller.
I. Remove the top sheet of NON-POROUS PARTING FILM (OMat

2/113).
J. Do steps 8.C. to 8.I. again for all the carbon fibre

repair plies.
NOTE: Copper mesh only needs to be replaced if the

repair is conducted on the aerodynamic surface.
K. Place the COPPER MESH (OMat 8/240) on the repair area

with an overlap on the existing copper mesh around the
outer edge of 0.78in. (20,0mm).
A. Cover the repair plies with one layer of PEEL PLY

(OMat 8/198) that is at least 3.0in. (76,0mm) greater
than the repair plies.
B. Cover this layer with one layer of POROUS PARTING

FILM (OMat 2/112) approximately 1.0in. (25,0mm)
greater than the peel ply.
C. Place three temperature probes evenly around the edge

of the repair.
D. Cover the porous parting film with two layers of

GLASS FABRIC (OMat 8/115) and one layer of NON-POROUS
PARTING FILM (OMat 2/113) each being 1.0in. (25,0mm)
smaller than the previous layer.
E. Cover the non-porous parting film with two layers of

BREATHER CLOTH (OMat 2/111), both layers being larger
than all the previous layers of material.
F. If required a flexible rubber intensifier may be

place over the release film, this will give an even
54-20-02
Page 207
JUN 10/09
pressure on contoured repair areas when a vacuum is
applied.
G. Position the thermocouples equally around the repair

area using PTFE ADHESIVE TAPE RELEASE FILM (OMat
2/30). Position the heater mat over the repair area.
H. Cover this with two plies of BREATHER CLOTH (OMat

2/111).
I. Cover the whole of the repair area with BAGGING FILM

(OMat 2/31) plus two vacuum fittings, one for the
vacuum gauge and the other for the vacuum source.
J. Seal the edges of the bag to the panel using

SEALANT TAPE(OMat 2/110).
K. Connect the vacuum source and smooth the bag by hand

pressure as the air is removed. Check for leaks and
reseal if necessary.
L. A minimum vacuum pressure of 25.0in Hg (635,0mm Hg)is

required during the cure cycle.
M. Cure for a minimum of 60 minutes at 150°F (65°C).

Heat up at a maximum rate of 2 to 6°F (1 to 3°C) per
minute. Cool to room temperature at a maximum rate of
9°F (5°C) per minute before releasing the vacuum.
NOTE: Record the cure cycle.
N. When the cure process is complete, remove the bagging

materials and the TEFLON TAPE (OMat 2/30) from the
repair area.
A. Smooth the surface of the repair all around to a

feather edge and to a smooth contour suitable to paint
using WATERPROOF SILICON CARBIDE ABRASIVE PAPER (OMat
5/35). Do not abrade mesh or carbon.
B. Remove all unwanted material with suction cleaner.

Make sure no particles of the unwanted material
remain.
C. Refer to AMM TASK 70-20-01-100-802. Fully clean the

repair area using LINT FREE CLOTH (OMat 2/101) moist
with ACETONE (OMat 150). Dry the area with a fresh
piece of lint free cloth before the fluid dries.
D. Apply surface protection to the repair area. Refer to

the standard painting procedure 54-02-04.

54-20-02
Page 208
JUN 10/09
11. Inspection.
A. Do a visual and tap test inspection. Refer to SRM

TASK 54-01-06 to make sure there are no disbonds or
delaminations in the repair area.
12. Identify the repair
A. Record the details of the repair No. FRSW030. Make a

permanent record on the Mod. Plate of the door with an
electrical vibro-etching tool.

54-20-02
Page 209
JUN 10/09
Prepare the Area for Repair - Typical Step-Sand Procedure
Figure 201

54-20-02
Page 210
JUN 10/09
Install the Repair Patches - Typical Installation
Figure 202

54-20-02
Page 211
JUN 10/09
Repair Area – Cure
Figure 203

54-20-02
Page 212
JUN 10/09
REPAIR NO.12 (FRSW032)
REPAIR (REPLACEMENT) OF THE ACCESS PANEL HINGES AND LATCHES
1. General
CAUTION: YOU MUST REFER TO THE ALLOWABLE/REPAIRABLE DAMAGE LIMITS; PAGE

BLOCK 101, TO MAKE SURE THAT THE REPAIR IS PERMITTED.
A. This repair scheme is written for Left and Right Post SB71-E107
Fan Cowl Doors. This procedure gives instructions to remove and
replace the hinges and latches that attach the access panels on
the left hand and right hand Post SB71-E107 fan cowl doors.
B. Repair is by replacement, each of the hinges and latches are

available individually.
54-20-02 SRM – Allowable Damage

54-02-10 SRM – Fasteners – Installation and Removal
70-20-01-100-802 AMM – Cleaning
54-02-04 SRM – Restore Paint Finish
B. Special tools
- Back cut drill

- Plastic spatula
- Suction cleaner
- Vibro-etching tool
C. Consumable Materials
OMat 150 ACETONE

OMat 1/40 ISOPROPYL ALCOHOL (Alternative)
OMat 1/257 CLEANING SOLVENT (Alternative)
OMat 8/5C PR1422A-4 TWO-PART BRUSHABLE POLYSULPHIDE SEALANT
EFFECTIVITY:TRENT REPAIR NO.12
54-20-02
Page 201
JUN 10/09

Procedure
DUST AND LOOSE PARTICLES WHICH CAN BE DANGEROUS TO YOUR
HEALTH.

SEALANT REFER TO THE MANUFACTURER’S CONTROL AND APPLICATION
WCA7110G002-001 Hinge, Double Piano (Figures 203, 205 and

AR
206)
WCA7110G004-001 Hinge, Swan Neck (Figure 204) AR
WCA7110G004-002 Hinge, Swan Neck (Figure 204) AR
WCA7110G003-001 Latch Assembly Button (Figures 203, 205 and
AR
206)
WCA7110G005-041 Latch Assembly (Figure 204) AR
NAS9307M4-01 Rivet, Blind, Protruding Head (Figure 205) AR
NAS9308M4-03 Rivet (Figures 203, 205 and 206) AR
NAS9308M4-04 Rivet (Figures 203, 204, 205 and 206) AR
4. Remove the Damaged Part (Ref. Figs. 201 to 206).
A. Identify the Access Panel Hinges and/or Latches that are damaged
and must be replaced. Make sure the damage is in the limits of
this repair scheme.
B. If the IDG Access Panel is found damaged then remove it.

Open the IDG Access Panel on the Left Hand Fan Cowl Door, remove
the four nuts (3), the four washers (4) and the four countersunk
bolts (5) from the hinge (2) that attach the access panel (1) to
the Fan Cowl Door. Retain the bolts, washers and nuts for the
installation. Ref. Figure 203.
C. If the Starter Access Panel is found damaged then remove it.

Open the Starter Access Panel on the Left Hand Fan Cowl Door,
remove the three nuts (6), the three washers (5) and the three
54-20-02
Page 202
JUN 10/09
countersunk bolts (4) from each of the two swan neck hinges (2 and
3) that attach the access panel (1) to the Fan Cowl Door. Retain
the bolts, washers and nuts for the installation. Ref. Figure 204.
D. If the Oil Tank Access Panel is found damaged then remove it.
Open the Oil Tank Access Panel on the Right Hand Fan Cowl Door,
remove the four nuts (3), the four washers (4) and the four
countersunk bolts (5) from each of the two hinges (2) that attach
the access panel (1) to the Fan Cowl Door. Retain the bolts,
washers and nuts for the installation. Using hand/air tool and
applicable size drill bit carefully remove the blind rivet (10)
that attaches the lanyard (9) to the Fan Cowl Door. Refer to SRM
TASK 54-02-10, Fasteners – Installation and Removal. Ref. Figure
205.
NOTE: Do not enlarge the hole when removing the rivet.
E. If the Hydraulic Filter/MCD Access Panel is found damaged then

remove it.
Open the Hydraulic Filter/MCD Access Panel on the Right Hand Fan
Cowl Door, remove the four nuts (3), the four washers (4) and the
four countersunk bolts (5) from each of the two hinges (2) that
attach the access panel (1) to the Fan Cowl Door. Retain the
bolts, washers and nuts for the installation. Ref. Figure 206.

DOES OCCUR OR THE HOLES BECOME OVER SIZE THEN CONTACT:
GKN Aerospace Services, R and O Facility, Osborne Works,
Whippingham, East Cowes, Isle of Wight, England, United
Kingdom, PO32 6LR.
F. Remove the damaged hinges from the access panels. Carefully drill
out the rivets that hold the damaged hinge to the access panel.
Use hand/air tools and applicable size drill bits. Refer to SRM
TASK 54-02-10, Fasteners – Installation and Removal.
G. Remove and discard the hinge.
H. Remove the damaged latches from the access panels. Carefully drill
out the rivets that hold the damaged latch to the access panel.
Use hand/air tools and applicable size drill bits. Refer to SRM
TASK 54-02-10, Fasteners – Installation and Removal.
I. Remove and discard the latch.
5. Prepare the Repair Area for the Replacement Hinge/Latch.
A. Remove dust and debris from the repair area using suction cleaner.
B. Refer to AMM TASK 70-20-01-100-802. Fully clean the repair area

with a LINT-FREE CLOTH (OMat 2/101) moistened with ACETONE (OMat
150) or ISOPROPYL ALCOHOL (OMat 1/40) or CLEANING SOLVENT (OMat
1/257) and a plastic spatula. Remove any unwanted sealant from the
mating surfaces of the door and the access panel. Make sure you
do not damage the door or the access panel. Dry the area with a
clean, lint-free cloth before the fluid dries.
54-20-02
Page 203
JUN 10/09
C. Do a visual inspection of the repair area. Make sure there is no
damage to the mating surfaces of the door or the access panel.
6. Install the Replacement Hinges (Ref. Figs. 201 to 206).
A. Install the WCA7110G002-001 Double Piano Hinge (2) on the IDG

Access Panel, Oil Tank Access Panel, Hydraulic/MCD Access Panel.
Ref. Figures 203, 205 and 206.
(1) Wet assemble the hinge using PR1422A-4 TWO-PART BRUSHABLE

BRUSHABLE POLYSULPHIDE SEALANT (OMat 8/5C) in accordance with
the manufacturers’ instructions. Apply a thin layer of
PR1422A-4 SEALANT (OMat 8/5C) to the mating surfaces of the
replacement hinge and the access panel.
NOTE: Sealant thickness to be no more than 0,76mm (0.030

in.).
(2) Position and temporarily attach the replacement hinge on the

access panel using skin clips or slave bolts.
(3) Install 2 off NAS9308M4-04 rivets (7) at the two inner

panel. Refer to SRM TASK 54-02-10, Fasteners – Installation
and Removal.
(4) Install 2 off NAS9308M4-03 rivets (6) at the two outer

positions of the hinge (2) to secure the hinge to the panel
(1). Refer to SRM TASK 54-02-10, Fasteners – Installation
and Removal.
B. Install the WCA7110G004-001 Swan Neck Hinge (2) or WCA7110G004-002

Swan Neck Hinge (3) on the Starter Access Panel. Ref. Figure 204.
(1) Wet assemble the hinge using PR1422A-4 TWO-PART BRUSHABLE

replacement hinge and the access panel.

in.).
(2) Position and temporarily attach the replacement hinge on the

(3) Install 4 off NAS9308M-4-04 rivets (7) at the four positions

on the hinge (2) or (3) to secure the hinge to the panel (1).
Refer to SRM TASK 54-02-10, Fasteners – Installation and
Removal.
C. Remove excess PR1422A-4 POLYSULPHIDE SEALANT (OMat 8/5C) from the

installed hinge. Degrease and clean the area with a LINT-FREE
CLOTH (OMat 2/101) moistened with ACETONE (OMat 150) or ISOPROPYL
ALCOHOL (OMat 1/40) or CLEANING SOLVENT (OMat 1/257). Refer to AMM
TASK 70-20-01-100-802.
54-20-02
Page 204
JUN 10/09
7. Install the Replacement Latches (Ref. Figures 201 to 206)
A. Install the WCA7110G003-001 Latch Assembly Button (8) on the IDG

Access Panel, Oil Tank Access Panel or the Hydraulic Filter/MCD
Access Panel. Ref. Figures 203, 205 and 206.
(1) Wet assemble the latches using PR1422A-4 TWO-PART BRUSHABLE

replacement latch and the access panel.

in.).
(2) Position and temporarily attach the replacement latch on the

(3) Install 4 off NAS9308M4-04 rivets (7) at the four positions on

the latch (8) to secure the latch to the panel (1). Refer to
SRM TASK 54-02-10, Fasteners – Installation and Removal.
B. Install the WCA7110G005-041 Latch Assembly (8) on the Starter

Access Panel, Ref. Figure 204.
(1) Wet assemble the latch using PR1422A-4 TWO-PART BRUSHABLE

replacement latch and the access panel.

in.).
(2) Position and temporarily attach the replacement latch on the

(3) Install 4 off NAS9308M4-04 rivets (7) at the four positions on

the latch (8) to secure the latch to the panel (1). Refer to
SRM TASK 54-02-10, Fasteners – Installation and Removal.
C. Remove excess PR1422A-4 BRUSHABLE POLYSULPHIDE SEALANT (OMat 8/5C)

from the installed latch before it cures. Use a LINT-FREE CLOTH
(OMat 2/101) moistened with ACETONE (OMat 150) or ISOPROPYL
ALCOHOL (OMat 1/40) or CLEANING SOLVENT (OMat 1/257). Refer to AMM
TASK 70-20-01-100-802.
8. Install the Access Panels on the Fan Cowl Doors (Ref. Figures 201 to
206)
A. Install the IDG Access Panel, Oil Tank Access Panel, Hydraulic/MCD
Access Panel (as required) on the Fan Cowl Doors Ref. Figures 203,
205 and 206.
(1) Wet assemble the Access Panel Hinge(s) (2) to the Fan Cowl
Door using PR1422A-4 TWO-PART BRUSHABLE POLYSULPHIDE SEALANT
(OMat 8/5C). Mix PR1422A-4 TWO-PART BRUSHABLE POLYSULPHIDE
54-20-02
Page 205
JUN 10/09
SEALANT (OMat 8/5C) in accordance with the manufacturers’
instructions. Apply a thin layer of PR1422A-4 SEALANT (OMat
8/5C) to the mating surfaces of the access panel hinge(s) and
the Fan Cowl Door.

in.).
(2) Put the Access Panel in the correct position on the Fan Cowl
Door.
(3) Attach the Access Panel hinge(s) (2) to the Fan Cowl Door with
the four countersunk bolts (5), the four washers (4) and the
four nuts (3). Wet assemble the countersunk bolts (5), the
washers (4) and the nuts (3) with PR1422A-4 TWO-PART
BRUSHABLE POLYSULPHIDE SEALANT (OMat 8/5C)
(4) Torque the four nuts to 2.5 to 3.0 Nm (20 to 25 lbf in.).
(5) For the Oil Access Panel only – Install the NAS9307M4-01 blind
rivet (10) that attaches the Lanyard (9) to the Fan Cowl Door.
(6) Close the Access Panel.
B. Install the Starter Access Panel on the Left Hand Fan Cowl Door.
Ref. Figure 204.
(1) Wet assemble the Access Panel Hinges (2 and 3) to the Fan Cowl
Door using PR1422A-4 TWO-PART BRUSHABLE POLYSULPHIDE SEALANT
(OMat 8/5C). Mix PR1422A-4 TWO-PART BRUSHABLE POLYSULPHIDE
SEALANT (OMat 8/5C) in accordance with the manufacturers’
instructions. Apply a thin layer of PR1422A-4 SEALANT (OMat
8/5C) to the mating surfaces of the Access Panel Hinges and
the Fan Cowl Door.

in.).
(2) Put the Starter Access Panel in the correct position on the
Left Hand Fan Cowl Door.
(3) Attach the Starter Access Panel swan neck hinges to the Fan
Cowl Door with the six countersunk bolts (4), the six washers
(5) and the six nuts (6).
(4) Wet assemble the six countersunk bolts (4), the six washers
(5) and the six nuts (6) with PR1422A-4 TWO-PART BRUSHABLE
POLYSULPHIDE SEALANT (OMat 8/5C).
(5) Torque the six nuts to 6.0 to 8.0 Nm (50 to 70 lbf in.).
(6) Close the Starter Access Panel.
C. Remove excess PR1422A-4 POLYSULPHIDE SEALANT (OMat 8/5C) from the

installed hinge and door area. Degrease and clean the area with a
LINT-FREE CLOTH (OMat 2/101) moistened with ACETONE (OMat 150) or
ISOPROPYL ALCOHOL (OMat 1/40) or CLEANING SOLVENT (OMat 1/257).
Refer to AMM TASK 70-20-01-100-802.
54-20-02
Page 206
JUN 10/09
D. Set access panel latch adjustment screws as follows:
(1) Loosen the latch adjustment screws before closing the latches.
(2) Close the latches and tighten the adjusting screws finger
tight on all latches.
(3) Further tighten the screws a quarter of a turn on all latches

and torque-tighten the lock nuts to 1.4 to 2.0 Nm (12 to 18
lbf in.).
A. Do a visual inspection of the repair to make sure it is done in

accordance with FRSW032 and the fasteners have been installed to
54-02-10 – Fastener installation and removal procedure.
B. Restore surface protection treatment as necessary. Refer to SRM

TASK 54-02-04 – Restore Paint Finish.
A. Record details of the repair No FRSW032. Make a permanent record

on the Mod Plate of the door with an electrical vibro-etching
tool.
54-20-02
Page 207
JUN 10/09
Left Hand Door – Access Panel Identification
Figure 201
54-20-02
Page 208
JUN 10/09
Right Hand Door – Access Panel Identification
Figure 202
54-20-02
Page 209
JUN 10/09
Left Hand Door – IDG Access Panel
Figure 203
54-20-02
Page 210
JUN 10/09
Left Hand Door – Starter Access Panel
Figure 204
54-20-02
Page 211
JUN 10/09
Right Hand Door – Oil Tank Access Panel
Figure 205
54-20-02
Page 212
JUN 10/09
Right Hand Door – Hydraulic Filter/MCD Access Panel
Figure 206
54-20-02
Page 213
JUN 10/09
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
THRUST REVERSER - GENERAL

1. General
R A. The thrust reverser assembly is mounted on the aft flange of the fan frame.
R It is made up of two halves that form kidney shaped bifurcated ducts. Each
R half is hinged to the aircraft pylon in five places. The halves are
.-
C R latched together at the bottom.
Q
.-
U
G R B . Each half has two pivoting doors, two sets of actuation, indication and
U
Q
R locking systems, a bifurcated fan duct and the necessary attachments for
R mounting and latching. (Refer to 54-30-00 Figure 1)
--
C R 2. Structural Description
'0-,
U
.-C R A. Each half thrust reverser has an outer structure and an inner structure.
h
R The outer structure comprises 3 longitudinal beams:
R - 12 o-clock beam (aluminium alloy)

R - 3 or 9 o-clock beam (composite)
R - 6 o-clock beam (aluminium alloy)
R These beams are attached to the front frame (aluminium) and to the rear
R structure (composite). The upper cut corner (composite) is attached to the
R 12 o-clock beam and to the front frame. The lower cut corner (composite)
R is attached to the 6 o-clock beam and to the front frame. The lower and
R upper pivoting doors are supported by the longitudinal beams. The inner
R structure is in one piece and made of sandwich composite honeycomb. The
R inner structure supports metallic ducts and is covered by a thermal
blanket .
R Figure 2 shows typical sections of composite panel and lists the material
R used in composite structure.
EFFECTIVITY: TRENT
Page 1
July 1/94
RB.211 TRENT
-8 STRUCTURAL REPAIR
MANUAL
DOOR SURROUND
STRUCTURE
SEE 54-30-15
FRAME
SEE 54-30-07
I OUTER SKINS
INNER FIXEDSTRUCTURE
SEE 54-30-30
Thrust Reverser - General

Figure 1
EFFECTIVITY: TRENT
Page 2
R July 1/94
1 RB.211 TRENT
MANUAL
MONOLITHIC STRUCTURE
ODD NUMBER LAYERS EVEN NUMBER LAYERS

+X
+ SAME
TOOL SIDE (REV

+ 0"
PLY DIRECTlON X45"
SANDWICH STRUCTURE
LAY UP ORDER INNER SKlN
1 1:
msTl
,\
HONEYCOMB
,
/
/
I - I+
OR:
RRST
FIRST t / t
OUTER SKlN (AIR WASHED SURFACE)
l:
DIFFERENT TYPE OF HONEYCOMB
LOCATION REfERENCE HURL-DUBOIS
SPECIFICATION
STANDARD
ACOUSTIC
NOMM 3-48
METALLIC 5056-4.40
METALLIC 5056-9.85
1 HD-SM 1025
HD-SM 1027
HD-SM 1024
IFS
CURRENT ZONE METALLIC 5056-4.40 HD-SM 1027
ACOUSTIC ZONE METALLIC 5056-9.85 HD-SM 1024
RADIUS ZONE FLEXCORE 5056F40-0026 HD-SM 1026
DIFFERENT TYPE OF SKlN
,
LOCATION REFERENCE HURR-DUBOIS
SPECIFlCATiON
CARBON EPOXY 914/40/6803 HDSM 1016
STANDARD GLASS EPOXY 914/45i759 HD-SM 1017
TEDLAR 100 BS 30 WH HD-SM 1023
IFS
, AUZONES CARBON BM1 5250-Z'G803-40 HD-SM 1010
GMSS BM1 5250-2140-120 HD-SM 1011
Typical Layup
Figure 2
EFFECTIVITY: TRENT
Page 3
July 1/94
l@
""" RB211 TRENT
MANUAL
STRUCTURAL REPAlR
THRUST REVERSER - GENERAL - LIST OF APPROVED REPAIRS
1 NON THROUGH-DAMAGE IN MONOLITHIC OR SANDWICH AREA

(FRS X045)
2 THROUGH-DAMAGE IN MONOLITHIC AREA

(FRS X046)
3 THROUGH-DAMAGE IN SANDWICH AREA

(FRS X047)
4 SKIN AND CORE DAMAGE IN SANDWICH AREA

(FRS X048)
5 THROUGH-DAMAGE c30 mm DIAMETER I N SANDWICH AREA

(FRS X049)
6
(FRS X050)
7 EDGE THROUGH-DAMAGE IN MONOLITHIC AREA

(FRS X051)
8 EDGE DELAMINATION IN MONOLITHIC AREA

(FRS X053)
9 NON THROUGH-DAMAGE IN MONOLITHIC AREA WITH

(FRS X0541 BRONZEMESH LAYER
10 THROUGH-DAMAGE IN MONOLITHIC AREA WITH

(FRS X0551 BRONZEMESH LAYER
11 APPLY PRIMER PAINT COAT

(FRS X056)
12 SKIN AND CORE DAMAGE c15 mm DIAMETER IN SANDWICH AREA

(FRS X057) WITH BRONZEMESH LAYER
13 SKIN AND CORE DAMAGE >l5 mm DIAMETER IN SANDWICH AREA

(FRS X058) WITH BRONZEMESH LAYER
14 THROUGH-DAMAGE c30 m DIAMETER IN SANDWICH AREA WITH

(FRS X059) BRONZEMESH LAYER
LIST OF REPAIRS
Page 201
RB211 TRENT
STRUCTURAL REPAlR
m MANUAL
R 16 THRUST REVERSER - COSMETIC REPAIR OF CARBON COMPOSITE

R (FRS X052) EDGES
17 THROUGH-DAMAGE >30 mm DIAMETER IN SANDWICH AREA WITH

(FRS X061) BRONZEMESH LAYER
18 REPAIR OF DAMAGE TO THE TRAILING EDGE

(FRS X085)
LIST OF REPAIRS
54-30-00
Page 202
P r i n t e d i n Great B r i t a i n May 15/05
RB211 TRENT
STRUCTURAL REPAIR
REPAIR No. 01
THRUST REVERSER
REPAIR OF CARBON COMPOSITE SKIN
FRSX045
1. General
A. This procedure gives the instructions to repair non-through damage to

carbon composite skin that does not have an outer ply of bronzemesh. The
repair can be applied to monolithic areas, or in a sandwich area providing
the honeycomb core is not dented.
B. This procedure gives instruction to:
- Remove the damage
- Add wet lay-up carbon repair plies
2.Referenced information
..........................................................................
..........................................................................
AMM 70-20-01-100-801 Cold liquid degreasing

SRM 54-01-06 Composite Structure Tap Test
SRM 54-30-OO,FRSX056(RepairNo. 11) Apply primer paint coat on carbon/epoxy
- Hot bonder with Curing cycle monitoring and automatic reporting feature
- Heater blanket 32 to 302 deg. F (0 to 150 deg. C)
- Hot air blower 248 deg. F (120 deg. C) maximum
- Pneumatic sander
- Spatula
- Squeegee
- Steel guides 10 in (254 mm) minimum length

- Thermocouples 32 to 302 deg. F (0 to 150 deg. C)
- Vacuum cleaner
EFFECTIV1TY:TRENT REPAIR No.01
54-30-00
Page 201
MAR. 10/09
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
- Vacuum pump to -15 psi (- 1,O bar) capability with vacuum gauge
- Weighing equipment
- Ultrasonic inspection equipment
..........................................................................
OMat 1/257 Cleaning solvent

OMat 261 Temporary marker
OMat 2/110 Adhesive tape vacuum bag seal
OMat 2/126 Vacuum bag
OMat 2/129 Breather cloth
OMat 2/131 Non porous parting film
OMat 5/94 Garnet paper, Grit size 150
OMat 5/121 Abrasive disc, grade 60
OMat 8/160 Epoxy Paste Adhesive
OMat 8/183 Dry Carbon Fabric
OMat 8/198 Nylon Peel Ply
..........................................................................
COMPONENT MATERIAL
..........................................................................
Thrust reverser carbon/epoxy composite
4. Procedure
WARNING: WHEN YOU DO THIS REPAIR YOU MUST WEAR PROTECTIVE CLOTHING, GLOVES DUST
MASK AND SAFETY GOGGLES TO PROTECT YOU AGAINST DUST AND LOOSE
PARTICLES, THAT CAN BE DANGEROUS TO YOUR HEALTH.
WARNING: WHEN YOU USE THE CLEANING MATERIALS, ADHESIVES AND COATINGS, REFER TO
AND OBEY, THE MANUFACTURER'S CONTROL ANJI APPLICATION INSTRUCTIONS AND
HEALTH AND SAFETY NOTICES.
A. Clean the repair area.

CAUTION: WHEN REMOVING LOOSE FIBRES MAKE SURE NO ADDITIONAL MATERIAL IS
REMOVED.
(1) Lightly abrade the surface to remove loose fibres. Use OMat 5/94
Garnet paper.
(2) Use a vacuum cleaner to remove all dust and debris from the repair
area. Use a lint free cloth soaked in OMat 1/257 cleaning solvent to
clean the repair area. Refer to AMM 70-20-01-100-802.
B. Examine the damage.
REPAIR No.01
54-30-00
Page 202
MAR. 10/09
RB211 TRENT
STRUCTURAL REPAIR
(1) Do a tap test. Refer to SRM 54-01-06 Composite Structure Tap Test or use
ultrasonic inspection equipment to determine the damaged area.
(2) Use an OMat 261 temporary marker to mark out the damaged area
(3) Check that the dimensions of the damaged area are within the repairable
limits. Refer to the relevant chapter of the SRM, page block 101.
C. Prepare the damaged area for repair (Ref. to figure 201).
(1) Use an OMat 261 temporary marker to mark out the damaged area that is to
be removed. The removed area should be a smooth rectangular shape with
rounded corners of 0.05 in. (12,5 mm) minimum radius.
(2) Use the marks made at step 1 above to remove the damage. Remove the
material one ply at a time until all damage is removed. Use a pneumatic
sander fitted with OMat 5/121 abrasive disc.
(3) Do a tap test to make sure all damage is removed. Refer to SRM 54-01-06
Composite Structure Tap Test.
(4) Use a lint free cloth soaked in OMat 1/257 cleaning solvent to clean the
repair area. Refer to AMM 70-20-01-100-802.
(5) Use an OMat 261 temporary marker to mark out the area that is to be step
sanded and the area where the extra repair plies are to be installed. The
step sanded area must extend beyond the cutout area, by a minimum of 0.48
in. (12 mm) for each ply that is to be removed. The area where the extra
plies are to be installed must extend for a distance of 0.6 in. (15 mm)
beyond the step sanded area. Refer to figure 201.
CAUTION: MAKE SURE YOU STEP SAND OVER EACH PLY IN INCREMENTS.
(6) Start step-sanding from the centre of damage to the outer edges of each
ply. Use the marks made at step 5 to put the steel guides in position.
Hold the steel guides firmly in position using adhesive tape. Step sand
using a pneumatic sander with OMat 5/121 Abrasive paper disc. Make each
step a smooth rectangular shape with rounded corners of 0.5 in (12,5 mm)
minimum radius.
(7) Remove the adhesive tape and the steel guides.
(8) Lightly abrade the area where the extra repair plies are to be installed.
Use OMat 5/94 Garnet paper.
(9) Use vacuum cleaner to remove all dust and debris from the repair area. Use
a lint free cloth soaked in OMat 1/257 cleaning solvent to clean the
repair area, refer to AMM 70-20-01-100-802.
(10)Dry the repair area for 60 minutes minimum at 200 deg. F (93 deg. C) with
a hot air blower.
REPAIR No.01
54-30-00
Page 203
MAR. 10/09
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
R
D. Prepare the carbon/epoxy repair plies (Ref. to figure 201).
CAUTION: THE ORIENTATION OF THE REPAIR PLIES MUST BE THE SAME ORIENTATION
AS THE ORIGINAL PLIES THEY ARE REPLACING.
(1) Make a template for each step in the step sanded area and for the area
where the extra plies are to be installed. Determine the fibre
orientation for each step and mark this on the templates. The
orientation of the extra plies must be the same as the orientation of
the ply below (surface ply).
(2) Cut out a piece of OMat 8/183 dry carbon fabric that is large enough
to make all the required repair plies. Use two carbon/epoxy repair
plies for each damaged carbon/epoxy ply of the original structure. Use
two extra carbon/epoxy repair plies for the outer surface. Add
sufficient margin for further adjustment.
R (3) Weigh the dry carbon fabric.
(4) Cut 2 pieces of OMat 2/131 Non-porous parting film each approximately
3 in (80 mm) larger, all round, than the Dry Carbon repair fabric.
Tape down one piece of the non-porous parting film onto a smooth, flat
surface.
R (5) Put the Dry Carbon fabric onto the non-porous parting film.
(6) Mix a quantity of OMat 8/160 Epoxy paste adhesive that is equal in
mass to the dry carbon fabric weighed at step 3. Refer to
manufacturer's instructions for mixing instructions.
R (7) Use a spatula to apply the adhesive evenly onto the dry carbon fabric.
(8) Put the second piece of non-porous parting film on the Carbon fabric.
Use a squeegee to impregnate the Carbon fabric evenly with adhesive
and remove trapped air.
(9) Use the templates made at step 1 to cut out the carbon/epoxy repair
plies.
R E. Lay up the repair plies (Ref. to figure 201).
(1) Remove the non-porous parting film from one side of one of the
smallest repair plies.
(2) Position the carbon/epoxy fabric repair ply adhesive side down in the
step sanded area. Make sure that the orientation of the carbon/epoxy
repair ply matches that of the existing adjacent structure.
(3) If necessary, trim the Carbon/epoxy fabric ply edge to the same
dimension as the cut-out without any clearance.
R (4) Use a squeegee to remove any wrinkles and trapped air.

R NOTE: Do not apply excessive pressure to avoid squeezing out adhesive.
REPAIR No.01
54-30-00
Page 204
MAR. 10/09
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(5) Remove the non-porous parting film from the top of the installed
Carbon/epoxy fabric repair ply.
(6) Remove the non-porous parting film from one side of the next repair
ply and repeat steps 2 to 5 until all the repair plies are installed
in the step sanded area and the two extra repair plies are installed
on the outer surface.
F. Cure the repair area (Ref. to figure 202)
(1) Install the thermocouples adjacent to the repair plies.
(2) Position the OMat 2/129 Breather cloth around the repair plies.
(3) Cut and install a piece of OMat 8/198 Nylon peel ply allowing 1.0 in
(25 mm) excess around the edges of the repair plies.
(4) Put OMat 2/110 Adhesive tape vacuum bag seal all around the lay-up
area.
(5) Cut a suitably sized piece of OMat 2/126 vacuum bag and install a
vacuum fitting. Make sure that when installed the vacuum fitting will
sit on the breather cloth. Install the vacuum bag.
(6) Connect the vacuum bag to the vacuum pump.
( 7 ) Evacuate the lay-up to a vacuum of -10.0 psi ( - 0.7 bar) inside the
bag.
NOTE: Maintain vacuum of -10.0 psi (- 0.7 bar) inside the bag for the
required cure period.
(8) Use a squeegee to remove any wrinkles and trapped air.
(9) Position a suitably sized heat blanket over the repair area.
(10) Put a layer of OMat 2/129 Breather cloth that is larger than the heat
blanket over the heat blanket.
(11) Put OMat 2/110 Adhesive tape vacuum bag seal all around the area.
(12) Cut a suitably sized piece of OMat 2/126 vacuum bag and install a
vacuum fitting. Make sure that when the vacuum bag is installed the
vacuum fitting will sit on the breather cloth. Install the vacuum bag.
(14) Evacuate the lay-up to a vacuum of -10.0 psi (- 0.7 bar) inside the
bag.
CAUTION: THE RATE OF TEMPERATURE INCREASE AND SUBSEQUENT DECREASE MUST NOT
BE GREATER THAN 5 DEG F (3 DEG C) PER MINUTE.
REPAIR NO.01
54-30-00
Page 205
MAR. 10/09
RB211 TRENT
STRUCTURAL REPAIR
(15) Cure the repair plies. Refer to figure 202 for the cure cycle details.
NOTE: The cure dwell shall start when the lowest reading thermocouple
reaches the correct temperature.
(16) Allow the repair area to cool to room temperature and carefully remove
the lay-up materials from the repair plies.
G. Examine the completed repair
(1) Visually examine the repair to make sure it has been satisfactorily
completed.
(2) Do a tap test. Refer to SRM 54-01-06 Composite Structure Tap Test or
use ultrasonic inspection equipment to make sure the repaired area has
no voidage or delamination. If any damage is found, refer to page block
101 to make sure that it is within the permitted limits.
(3) If necessary apply primer and finish paint coat, refer to SRM Chapter
54-30-00, FRSX056 Repair No.11.
H. Identify the repair.
(l)Use a permanent marker pen of a contrasting colour to write FRSX045

next to the existing part number.
REPAIR No.01
54-30-00
Page 206
MAR. 10/09
RB211 TRENT
STRUCTURAL REPAIR
SANDER
PLY
OR1ENTPirlON
SANDING OPERATION
I
0.60 0.48 0.48 EXTRA CARBON PLY
(15) (12) (12)
CARBON
REPAIR PLIES
i DIMENSIONS ARE IN INCHES N T H MlLLlMETERS IN PARENTHESES
Preparation and Repair Ply Lay-up
Figure 201
REPAIR No.01
54-30-00
Page 207
MAR. 10/09
VACUUM BAG
.BREATHER
CLOTH
VACUUM BAG
BREATHER
CLOTH
NYLON PEEL PLY
I
THERMOCOUPLE
ADHESIVE TAPE
TEMPERATURE
I
+5" Flrnin MAX -5' Flrnin MAX
(+3' Clrnin) (-3' Clmin)
239" F1257' F -
( l 15' C1125' C)
131" FI149" F --
(55' Cl65' C)
ROOM TEMPERATURE
* TIME
420 to 1440 rnin
. . U
150 to 165 rnin
60 to 75 min
CURING CYCLE
Bagging Operation and Cure Cycle
Figure 202
REPAIR No.01
54-30-00
Page 208
MAR. 10/09
RB211 TRENT
STRUCTURAL REPAlR
MANUAL
R E P A I R NO. 2
THRUST REVERSER
R E P A I R O F THROUGH DAMAGE I N CARBON COMPOSITE S K I N
1. General
A. T h i s procedure g i v e s t h e i n s t r u c t i o n s t o repair t h r o u g h - d a m a g e
t o m o n o l i t h i c carbon c o m p o s i t e s k i n t h a t does n o t have an o u t e r
p l y of bronze m e s h .
B. T h i s procedure can be applied w h e n t h e rear side of the panel

i s n o t accessible.
C. T h i s procedure gives i n s t r u c t i o n t o :
- R e m o v e the d a m a g e
- I n s t a l l a backup p l a t e
- A d d w e t lay-up carbon repair p l i e s
2. Referenced information
......................................................................
AMM 7 0 - 2 0 - 0 1 - 1 0 0 - 8 0 2 C o l d l i q u i d degreasing
SRM 5 4 - 0 1 - 0 6 C o m p o s i t e Structure T a p T e s t
SRM 5 4 - 3 0 - 0 0 , F R S X 0 5 6 ( R e p a i r No. 1 1 ) A p p l y p r i m e r p a i n t c o a t on
carbon/epoxy
A. Standard e q u i p m e n t
H o t bonder w i t h C u r i n g cycle m o n i t o r i n g and a u t o m a t i c

r e p o r t i n g feature
D r i l l b i t 0 . 0 4 i n ( l mm) d i a m e t e r
H e a t e r b l a n k e t 32 t o 3 0 2 deg F ( 0 t o 1 5 0 deg C )
H e a t L a m p 32 t o 3 0 2 deg F ( 0 t o 1 5 0 deg C )
H o t a i r b l o w e r 2 4 8 deg F ( 1 2 0 deg C ) m a x i m u m
Lockwires
P n e u m a t i c sander
P r o t e c t i v e pads ( 2 o f f )
Spatula
Squeegee
54-30-00
REPAIR N o . 2
Page 201
Printed in G r e a t B r l t a i n Mar. 10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
- Steel guides loin (254 mm) minimum length

- Square section rod
- Thermocouples 32 to 302 deg F (0 to 150 deg C)
- Vacuum cleaner
- Vacuum pump to -15 psi (- 1,O bar) capability with vacuum
gauge
.......................................................................
--_------------------*-------------------------------------------------

OMat 262 Marker
OMat 8/182 Dry Glass Fabric
.......................................................................
COMPONENT MATERIAL
.......................................................................
REPAIR No. 2
Page 202
P r i n t e d i n G r e a t Britain M ~ Y-in /nn
R8211 TRENT
STRUCTURAL REPAIR
MANUAL
R 4. Procedure
R
R WARNING: WHEN YOU DO T H I S R E P A I R YOU MUST WEAR PROTECTIVE
R CLOTHING, GLOVES, DUST MASK AND SAFETY GOGGLES TO PROTECT
R YOU AGAINST DUST AND LOOSE P A R T I C L E S , WHICH CAN BE
R DANGEROUS TO YOUR HEALTH.WARNING: WHEN YOU USE CLEANING
R MATERIALS, ADHESIVES AND COATINGS, REFER TO, AND OBEY,
R THE MANUFACTURER'S CONTROL AND A P P L I C A T I O N INSTRUCTIONS
R AND HEALTH AND SAFETY N O T I C E S .
R
R A. C l e a n t h e repair area.
R
R (1) L i g h t l y abrade t h e surface t o r e m o v e l o o s e f i b r e s . U s e
R O M a t 5 / 9 4 garnet paper.
R
R (2) U s e a v a c u u m cleaner t o r e m o v e a l l debris f r o m t h e repair
R area. U s e a l i n t free c l o t h soaked i n O M a t 1/257 c l e a n i n g
R s o l v e n t t o clean t h e d a m a g e area ( R e f AMM 7 0 - 2 0 - 0 1 - 1 0 0 -
R 802) .
R
R B. Examine the damage.
R
R (1) D o a tap t e s t . R e f e r t o SFW 5 4 - 0 1 - 0 6 C o m p o s i t e S t r u c t u r e
R T a p T e s t o r use u l t r a s o n i c i n s p e c t i o n e q u i p m e n t t o
R d e t e r m i n e t h e damaged area.
R
R (2) U s e a t e m p o r a r y m a r k e r such as O m a t 2 6 1 t o m a r k o u t t h e
R d a m a g e d area.
R
R (3) C h e c k t h a t t h e d i m e n s i o n s of t h e d a m a g e d area are w i t h i n
R t h e repairable l i m i t s . R e f e r t o t h e r e l e v a n t chapter of
R t h e S W , page b l o c k 1 0 1 .
R
R C. P r e p a r e t h e d a m a g e d area f o r repair (Ref Fig 2 0 1 ) .
R
R CAUTION: DO NOT DAMAGE THE UNDAMAGED P L I E S AND SURROUNDING
R MATERIAL.
R
R (1) U s e a t e m p o r a r y m a r k e r such as O M a t 2 6 1 t o m a r k o u t t h e
R damaged area t h a t i s t o be r e m o v e d . T h e c u t - o u t area
R s h o u l d be a s m o o t h rectangular shape w i t h rounded c o r n e r s
R of 0 . S i n . ( 1 2 , 5 m m ) m i n i m u m r a d i u s .
R
R NOTE: If access t o t h e rear side of t h e panel i s n o t
R a v a i l a b l e , t h e d i m e n s i o n s of t h e c u t - o u t m u s t be
R large enough t o a l l o w t h e backup p l a t e t o be
R i n s t a l l e d through i t . T h e backup p l a t e m u s t be 0 . 4
R i n ( 1 0 mm) larger a l l round t h a n t h e c u t - o u t .
REPAIR No. 2
P a g e 203
Printed ~n Great Rritqln =a-- 1n / n o
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(2) U s e t h e m a r k s m a d e a t s t e p ( 1 ) above t o t r i m o u t t h e
d a m a g e d area. U s e a v a c u u m cleaner t o r e m o v e t h e d u s t
w h i l e c u t t i n g . Make s u r e a l l d a m a g e i s r e m o v e d .
(3) U s e a l i n t free c l o t h soaked i n O M a t 1 / 2 5 7 c l e a n i n g

s o l v e n t t o clean t h e repair area ( R e f AMM 7 0 - 2 0 - 0 1 - 1 0 0 -
802) .
(4) U s e a t e m p o r a r y m a r k e r such a s O M a t 2 6 1 t e m p o r a r y m a r k e r
t o m a r k o u t t h e area t h a t i s t o be s t e p sanded and t h e
area w h e r e t h e e x t r a repair p l i e s are t o be i n s t a l l e d .
T h e s t e p sanded area m u s t e x t e n d beyond t h e c u t - o u t area
by a m i n i m u m of 0 . 4 8 i n . (12mm) f o r each p l y t h a t i s
r e m o v e d . T h e area w h e r e t h e e x t r a r e p a i r p l i e s are t o be
i n s t a l l e d m u s t e x t e n d f o r a d i s t a n c e of 0 . 6 i n . m i n i m u m
beyond t h e step sanded area ( R e f Figure 2 0 1 ) .
CAUTION: MAKE SURE YOU S T E P SAND OVER EACH PLY I N INCREMENTS
(5) Step-sand f r o m t h e d a m a g e centre t o t h e o u t e r face. U s e

the m a r k s m a d e a t step ( 4 ) t o p u t t h e steel guides i n
p o s i t i o n . H o l d t h e steel guides f i r m l y i n p o s i t i o n u s i n g
adhesive tape. S t e p sand u s i n g a p n e u m a t i c sander w i t h
O M a t 5 / 1 2 1 abrasive paper d i s c . M a k e each s t e p a s m o o t h
rectangular shape w i t h rounded corners of 0 . 5 i n ( 1 2 , 5 mm)
m i n i m u m radius.
(6) R e m o v e t h e adhesive tape and t h e s t e e l guides.
(7) L i g h t l y abrade t h e area w h e r e t h e e x t r a repair p l i e s are

t o be i n s t a l l e d . U s e O M a t 5 / 9 4 G a r n e t paper.
(8) U s e a v a c u u m cleaner t o r e m o v e a l l d u s t and debris f r o m

t h e repair area. U s e a l i n t free c l o t h soaked i n O M a t
1/257 c l e a n i n g s o l v e n t t o clean t h e repair area. R e f e r t o
AMM 7 0 - 2 0 - 0 1 - 1 0 0 - 8 0 2 .
CAUTION: THE RATE O F TEMPERATURE INCREASE MUST NOT BE MORE

THAN 5 DEG F ( 3 DEG C ) P E R MINUTE.
(9) D r y t h e repair area f o r 6 0 m i n u t e s m i n i m u m a t 2 0 0 deg F

( 9 3 deg C) w i t h a h o t a i r b l o w e r .
REPAIR No. 2
Page 2 0 4
*X-, 1n /no
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
D. P r e p a r e t h e Glass/Epoxy backup p l a t e (Ref F i g u r e 201, 202 &

203) .
(1) Cut a p i e c e of OMat 8/182 Dry G l a s s F a b r i c of s u f f i c i e n t

s i z e t o make 5 ~ l a s s / E p o x yp l i e s . The Glass/Epoxy p l i e s
must b e 0 . 4 i n (10 mm) l a r g e r a l l round t h a n t h e c u t - o u t .
Cut two p i e c e s of O M a t 2/131 Non-porous p a r t i n g f i l m each
a p p r o x i m a t e l y 3 i n (80 mm) l a r g e r , a l l round, t h a n t h e
Glass f a b r i c .
(2) Tape down one p i e c e of non-porous p a r t i n g f i l m o n t o a

f l a t , smooth s u r f a c e .
(3) Weigh t h e OMat 8/182 Dry G l a s s F a b r i c .
(4) Mix a q u a n t i t y of O M a t 8/160 Epoxy p a s t e a d h e s i v e t h a t i s

e q u a l i n mass t o t h e d r y g l a s s f a b r i c weighed a t s t e p ( 3 )
above. R e f e r t o m a n u f a c t u r e r ' s i n s t r u c t i o n s f o r mixing
i n s t r u c t i o n s and h e a l t h and s a f e t y p r e c a u t i o n s
(5) P u t t h e d r y g l a s s f a b r i c o n t o t h e non-porous p a r t i n g f i l m .
Apply t h e s e l e c t e d q u a n t i t y of a d h e s i v e e v e n l y o n t o t h e
dry g l a s s f a b r i c using a s p a t u l a .
(6) P u t t h e second p i e c e of non-porous p a r t i n g f i l m on t h e d r y

g l a s s f a b r i c . U s e a squeegee t o impregnate t h e d r y g l a s s
f a b r i c e v e n l y w i t h a d h e s i v e and remove t r a p p e d a i r .
(7) Cut o u t t h e 5 p i e c e s of ~ l a s s / E p o xf~a b r i c . The

~ l a s s / E p o x yp l i e s must b e 0 . 4 i n . (10mm) l a r g e r a l l round
t h a n t h e c u t - o u t (Ref F i g u r e 203) .
E. Lay up t h e Glass/Epoxy f a b r i c backup p l a t e (Ref F i g u r e 202)
(1) Cut a p i e c e of OMat 2/131 Non-porous p a r t i n g f i l m 0 . 4 i n

(10 mm) l a r g e r , a l l round t h a n t h e Glass/Epoxy f a b r i c
p l i e s . Put t h e OMat 2/131 Non-porous p a r t i n g f i l m o n t o a
b a s e p l a t e t h a t i s t o be u s e d when c u r i n g t h e backup
p l a t e . The b a s e p l a t e must be of an a p p r o p r i a t e s i z e and
have a h a r d , smooth, f l a t s u r f a c e .
(2) Remove t h e non-porous p a r t i n g f i l m from one s i d e of one of

t h e g l a s s / e p o x y f a b r i c p l y . Put i t a d h e s i v e s i d e down on
t h e l a r g e r non-porous p a r t i n g f i l m c u t i n s t e p (1).
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(3) U s e a squeegee t o remove any w r i n k l e s and t r a p p e d a i r .

Do n o t a p p l y e x c e s s i v e p r e s s u r e t o a v o i d squeeze o u t of
adhesive.
(4) Remove t h e second p i e c e of non-porous p a r t i n g f i l m from

t h e g l a s s / e p o x y f a b r i c p l y i n s t a l l e d . Remove t h e non-
porous p a r t i n g f i l m from one s i d e of t h e n e x t g l a s s / e p o x y
f a b r i c p l y and l a y t h i s a d h e s i v e s i d e down o n t o t h e
p r e v i o u s l y i n s t a l l e d p l y . U s e a squeegee t o remove any
w r i n k l e s and t r a p p e d a i r .
(5) Repeat s t e p ( 4 ) above u n t i l a l l 5 g l a s s / e p o x y p l i e s have

been l a i d u p .
NOTE: Remove t h e non-porous p a r t i n g f i l m o f f t h e l a s t

g l a s s / e p o x y p l y b e f o r e t h e bagging and c u r i n g
procedure.
(6) Cure t h e backup p l a t e u s i n g t h e p r o c e d u r e i n s t r u c t e d i n

o p e r a t i o n F below.
F. Vacuum Bagging and c u r i n g p r o c e d u r e (Ref F i g u r e 202 and 2 0 4 ) .
(1) I n s t a l l t h e thermocouples a d j a c e n t t o t h e r e p a i r p l i e s .
(2) P o s i t i o n t h e O M a t 2/129 B r e a t h e r c l o t h around t h e r e p a i r

plies.
(3) Cut a p i e c e o f OMat 8/198 Nylon p e e l p l y a l l o w i n g 1 . 0 i n

(25 mm) e x c e s s around t h e edge of t h e r e p a i r p l i e s .
(4) P u t O M a t 2/110 Adhesive t a p e vacuum bag s e a l a l l around

t h e lay-up a r e a .
(5) Cut a s u i t a b l y s i z e d p i e c e of OMat 2/126 vacuum b a g and

i n s t a l l a vacuum f i t t i n g . Make s u r e t h a t when t h e vacuum
bag i s i n s t a l l e d , t h e vacuum f i t t i n g w i l l s i t on t h e
b r e a t h e r c l o t h . I n s t a l l t h e vacuum b a g .
(6) Connect t h e vacuum bag t o t h e vacuum pump.
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(7) E v a c u a t e t h e lay-up t o a v a c u u m of - 1 0 . 0 psi (- 0.7 bar)

i n s i d e t h e bag.
NOTE: M a i n t a i n v a c u u m of - 1 0 . 0 p s i ( - 0 . 7 b a r ) inside
the bag f o r t h e required c u r e p e r i o d .
(8) P o s i t i o n a s u i t a b l y s i z e d heater b l a n k e t over t h e r e p a i r

area.
(9) P u t a layer of O M a t 2 / 1 2 9 B r e a t h e r c l o t h t h a t i s l a r g e r
than t h e heater b l a n k e t over t h e heater b l a n k e t .
(10) P u t O M a t 2 / 1 1 0 A d h e s i v e tape v a c u u m bag seal a l l around

t h e area.
(11) C u t a s u i t a b l y s i z e d piece of O M a t 2 / 1 2 6 v a c u u m bag and

i n s t a l l a v a c u u m f i t t i n g . M a k e sure t h a t w h e n the v a c u u m
bag i s i n s t a l l e d , t h e v a c u u m f i t t i n g w i l l s i t on t h e
breather c l o t h . I n s t a l l t h e v a c u u m bag.
( 1 2 ) C o n n e c t t h e v a c u u m bag t o t h e v a c u u m p u m p .
( 1 3 ) E v a c u a t e t h e lay-up t o a v a c u u m of - 1 0 . 0 psi (- 0.7 b a r )

CAUTION: THE RATE O F TEMPERATURE INCREASE AND SUBSEQUENT

DECREASE MUST NOT BE GREATER THAN 5 DEG F (3 DEG C )
PER MINUTE.
(14) C u r e t h e repair p l i e s . R e f e r t o f i g u r e 2 0 4 f o r t h e cure

cycle d e t a i l s .
NOTE: T h e cure cycle d w e l l s h a l l s t a r t w h e n t h e l o w e s t

reading t h e r m o c o u p l e reaches t h e correct
temperature.
( 1 5 ) A l l o w t h e repair area t o c o o l t o r o o m t e m p e r a t u r e and

c a r e f u l l y r e m o v e t h e lay-up m a t e r i a l s f r o m t h e repair
plies.
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G. I n s p e c t t h e backup p l a t e .
(1) Do a v i s u a l i n s p e c t i o n and t a p t e s t t o make s u r e t h e c u r e d

backup p l a t e h a s no d e l a m i n a t i o n o r voidage (Ref SRM 54-
01-06).
H. I n s t a l l t h e backup p l a t e (Ref F i g u r e 201 & 203) .
(1) T r i m t h e backup p l a t e i n t o a r e c t a n g u l a r s h a p e w i t h 0 . 4 i n
(10 mm) minimum c o r n e r r a d i u s .
(2) D r i l l 2 p a i r s of h o l e s n e a r t h e c e n t r e l i n e of t h e backup
p l a t e . U s e a 0 . 0 4 i n ( l mm) d i a m e t e r d r i l l b i t . The h o l e s
need t o b e a s u f f i c i e n t d i s t a n c e a p a r t t o a t t a c h t h e
backup p l a t e t o a clamp b a r u s i n g l o c k w i r e and h o l d i t
firmly i n place.
(3) Abrade t h e s u r f a c e of t h e backup p l a t e t h a t i s t o b e

bonded t o t h e r e p a i r a r e a and t h e i n n e r s i d e o f t h e r e p a i r
a r e a , i f p o s s i b l e , up t o a d i s t a n c e of 0 . 8 i n (20 mm) from
t h e c u t - o u t e d g e . U s e O M a t 5/94 G a r n e t p a p e r .
(4) Mark t h e c o n t o u r of t h e c u t - o u t w i t h OMat 262 Temporary

marker i n t h e m i d d l e of t h e backup p l a t e .
(5) P u t a l o o p of t h e l o c k w i r e through t h e h o l e s i n t h e backup

p l a t e . Loosely t w i s t e a c h l o o p of l o c k w i r e one t u r n . The
w i r e must b e l o n g enough t o p a s s through t h e r e p a i r a r e a
and around t h e clamp b a r and f a s t e n s e c u r e l y .
(6) U s e vacuum c l e a n e r t o remove a l l d u s t and u s e a l i n t f r e e

c l o t h soaked i n O M a t 1/257 c l e a n i n g s o l v e n t t o c l e a n t h e
r e p a i r a r e a and t h e backup p l a t e (Ref AMM 70-20-01-100-
802) .
(7) Mix a s u i t a b l e q u a n t i t y of OMat 8/192 Epoxy p a s t e a d h e s i v e

t o bond t h e backup p l a t e i n p o s i t i o n . R e f e r t o
m a n u f a c t u r e r ' s i n s t r u c t i o n s f o r mixing i n s t r u c t i o n s and
h e a l t h and s a f e t y p r e c a u t i o n s .
(8) Apply OMat 8/192 Epoxy p a s t e a d h e s i v e a l l o v e r t h e s i d e of

t h e backup p l a t e t h a t i s t o b e bonded t o t h e r e p a i r a r e a
and t h e bond a r e a on t h e i n n e r s i d e of t h e s k i n .
(9) I n t r o d u c e t h e backup p l a t e through t h e c u t - o u t . P o s i t i o n

t h e backup p l a t e w i t h t h e c o n t o u r marked a t s t e p ( 4 ) .
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(10) P u t a s m a l l squared s e c t i o n rod through t h e l o c k w i r e loops

across t h e repair c u t - o u t and on t h e p r o t e c t i v e pads.
(11) T w i s t t h e l o c k w i r e around t h e squared s e c t i o n rod s o t h a t

t h e backup p l a t e i s c l a m p e d f i r m l y a g a i n s t t h e i n n e r s i d e
of t h e s k i n ( R e f F i g u r e 2 0 3 ) .
(12) I n s t a l l t h e t h e r m o c o u p l e s adjacent t o t h e repair area.

DECREASE MUST NOT BE GREATER THAN 7 . 2 DEG F ( 4 DEG
C ) PER MINUTE.
CAUTION: DO NOT START TO MEASURE THE CURE TIME U N T I L THE

TEMEPRATURE HAS REACHED THE REQUIRED RANGE.
(13) C u r e t h e O M a t 8 / 1 9 2 E p o x y paste adhesive b e t w e e n 1 2 0 and

1 3 0 m i n u t e s a t 1 9 4 t o 2 1 2 deg F ( 9 0 t o 1 0 0 deg C ) . U s e
e x p l o s i o n proof h e a t l a m p s t o cure t h e adhesive.
(14) R e m o v e t h e l o c k w i r e s and t h e r o d .
(15) F i l l t h e h o l e s i n t h e backup p l a t e w i t h O M a t 8 / 1 9 2 E p o x y
paste adhesive.

DECREASE MUST NOT BE GREATER THAN 7 . 2 DEG F ( 4 DEG
C ) PER MINUTE.
(16) C u r e t h e O M a t 8 / 1 9 2 E p o x y paste adhesive f o r b e t w e e n 1 2 0

and 1 3 0 m i n u t e s a t 1 9 4 t o 2 1 2 deg F ( 9 0 t o 1 0 0 deg C ) . U s e
e x p l o s i o n proof heat l a m p s t o cure t h e adhesive.
( 17 Remove the t h e r m o c o u p l e s .
( 1 8 ) Abrade t h e adhesive w i t h O M a t 5 / 1 2 1 G a r n e t paper disc t o

o b t a i n a s m o o t h surface.
(19) U s e a v a c u u m cleaner t o r e m o v e a l l d u s t and u s e a l i n t

free c l o t h soaked i n O M a t 1 / 2 5 7 c l e a n i n g s o l v e n t t o clean
t h e r e p a i r area ( R e f AMM 7 0 - 2 0 - 0 1 - 1 0 0 - 8 0 2 ) .
I. P r e p a r e t h e carbon/epoxy r e p a i r p l i e s (Ref F i g u r e 2 0 1 ) .
CAUTION: THE ORIENTATION O F THE R E P A I R P L I E S MUST B E THE SAME

A S THE ORIENTATION O F THE ORIGINAL P L I E S THEY ARE
REPLACING.
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Make a t e m p l a t e f o r each s t e p i n t h e s t e p sanded a r e a and

f o r t h e a r e a where t h e e x t r a r e p a i r p l i e s a r e t o be
i n s t a l l e d . Determine t h e f i b r e o r i e n t a t i o n f o r each s t e p
and mark t h i s on t h e t e m p l a t e s . The o r i e n t a t i o n of t h e
e x t r a p l i e s must be t h e same a s t h e o r i e n t a t i o n of t h e p l y
below ( s u r f a c e p l y ) .
Cut o u t a p i e c e of OMat 8/183 d r y carbon f a b r i c t h a t i s

l a r g e enough t o c u t o u t a l l t h e r e p a i r p l i e s . U s e two
carbon/epoxy r e p a i r p l i e s f o r each damaged carbon/epoxy
p l y of t h e o r i g i n a l l a m i n a t e . Use two e x t r a carbon/epoxy
r e p a i r p l i e s f o r t h e o u t e r s u r f a c e . Add s u f f i c i e n t margin
f o r f u r t h e r adjustment.
Weigh t h e d r y carbon f a b r i c .
Cut 2 p i e c e s of O M a t 2/131 Non-porous p a r t i n g f i l m each

a p p r o x i m a t e l y 3 i n (80 mm) l a r g e r , a l l round, t h a n t h e Dry
Carbon f a b r i c . Tape down one p i e c e of t h e non-porous
p a r t i n g f i l m o n t o a smooth f l a t s u r f a c e . Put t h e Dry
Carbon f a b r i c o n t o t h e non-porous p a r t i n g f i l m .
Mix a q u a n t i t y of O M a t 8/160 Epoxy p a s t e a d h e s i v e t h a t i s

e q u a l i n mass t o t h e d r y carbon f a b r i c weighed a t s t e p
( 3 ) . Refer t o m a n u f a c t u r e r ' s i n s t r u c t i o n s f o r mixing
i n s t r u c t i o n s and h e a l t h and s a f e t y p r e c a u t i o n s .
U s e a s p a t u l a t o apply t h e adhesive evenly onto t h e d r y

carbon f a b r i c .
P u t t h e second p i e c e of non-porous p a r t i n g f i l m on t h e
carbon f a b r i c . U s e a squeegee t o impregnate t h e carbon
U s e t h e t e m p l a t e s made a t s t e p (1) t o c u t o u t t h e
carbon/epoxy f a b r i c r e p a i r p l i e s .
J. Lay up t h e r e p a i r p l i e s (Ref F i g u r e 201)
(1 Remove t h e non-porous p a r t i n g f i l m from one s i d e of one o f

the smallest repair p l i e s .
P o s i t i o n t h e carbon/epoxy f a b r i c r e p a i r p l y a d h e s i v e s i d e
down i n t h e s t e p sanded a r e a . Make s u r e t h a t t h e
o r i e n t a t i o n of t h e carbon/epoxy r e p a i r p l y matches t h a t of
the existing adjacent structure .
I f n e c e s s a r y t r i m t h e carbon/epoxy f a b r i c p l y t o t h e same
dimension a s t h e c u t - o u t w i t h o u t any c l e a r a n c e .
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(4) U s e a squeegee t o remove any w r i n k l e s and t r a p p e d a i r .
NOTE: Do n o t a p p l y e x c e s s i v e p r e s s u r e t o a v o i d squeeze
o u t of a d h e s i v e .
(5) Remove t h e non-porous p a r t i n g f i l m from t h e t o p o f t h e

i n s t a l l e d carbon/epoxy f a b r i c r e p a i r p l y .
(6) Remove t h e non-porous p a r t i n g f i l m from one s i d e of t h e

n e x t r e p a i r p l y and r e p e a t s t e p s (2) t o ( 5 ) u n t i l a l l t h e
repair p l i e s are installed. I n s t a l l the 2 off extra repair
p l i e s s o t h e p l y o r i e n t a t i o n i s t h e same a s t h e p l y below
(surface ply) .
K. Cure t h e r e p a i r a r e a Ref F i g u r e 2 0 4 ) .
(1) Do t h e bagging and c u r e p r o c e d u r e a s g i v e n i n o p e r a t i o n F
L. Examine t h e completed r e p a i r
(1) V i s u a l l y examine t h e r e p a i r t o make s u r e i t h a s been

s a t i s f a c t o r i l y completed.
(2) Do a t a p t e s t r e f e r t o SRM 54-01-06 Composite S t r u c t u r e

Tap T e s t o r u s e u l t r a s o n i c i n s p e c t i o n equipment t o make
s u r e t h e r e p a i r e d a r e a h a s no damage. I f any damage i s
f o u n d , r e f e r t o page b l o c k 101 t o make s u r e t h a t i t i s
within the permitted l i m i t s .
(3) I f n e c e s s a r y a p p l y primer and f i n i s h p a i n t c o a t , r e f e r t o

SRM Chapter 54-30-00, FRSX056 r e p a i r n o . 1 1 .
M. Identify the repair.
(1) U s e a permanent marker pen of a c o n t r a s t i n g c o l o u r t o

w r i t e FRSX046 n e x t t o t h e e x i s t i n g p a r t number.
54-30-00
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SANDING OPERATION
CARBON REPAIR
ADHESIVE PLIES
5
-
0
v DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESES
1- O
L
Figure 201
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GLASS 1 EPOXY
FABRIC PLIES
NON POROUS
PARTING FlLM
GLASS 1 EPOXY FABRIC PLIES LAY-UP
BREATHER CLOTH
VACUUM BAG
A HEAT BLANKET
CLOTH
UUM FITTING
-
7-
THERMOCOUPLE GLASS I EPOXY NYLON PEEL PLY
FABRIC PLIES
ADHESIVE TAPE NON POROUS

VACUUM BAG SEAL PARTING FILM
DOUBLE BAGGING PROCEDURE
F i g u r e 202
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TlON ROD
(10) BACKUP PLATE INSTALLATION
DIMENSIONS ARE IN INCHES WITH MILLIMETERS IN PARENTHESIS
Figure 203
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VACUUM BAG
VACUUM BAG
BREATHER
CLOTH
NYLON PEEL PLY
DHESIVE TAPE
THERMOCOUPLE
TEMPERATURE
A
t 5 " Fimin
-5" Fimin
(t3" ~ l m i n )
(-30 ~ i m i n )
239" FI257" F
(1 1 5 T C 2 5 " C)
131" F11 49" F .

\i
(55" Cl65' C)
ROOM TEMPERATURE
!
1 - TIME
420 to 1440 min

L L60 to 75 minI I
150to165m1n
CURING CYCLE
Figure 2 0 4
54-30-00
REPAIR No. 2
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M-.. ~n/nct
R
R
REPAIR NO. 03 (FRSX047)
THRUST REVERSER
REPAIR CARBON COMPOSITE SKIN IN SANDWICH AREA

R
1. General
R
R A. This procedure gives instructions to repair through damage to
R a carbon composite skin in a sandwich area. It is not
applicable when the outer skin has an outer ply of bronzemesh.
R
B. This procedure gives the instruction to:
R
- remove the damaged skin
R
- fill honeycomb with adhesive
R
- apply wet lay carbon repair plies to the skin.
R
R ---------------------------------------------------------------
---------------------------------------------------------------
R
AMM 70-20-01-100-802 Cold liquid degreasing
R
SRM 54-01-06 Composite Structure Tap
R
R Test
SRM 54-30-00,FRSX056 (Repair no 11) Apply primer paint coat on
carbon/epoxy
R 3. Equipment and Materials
R A. Standard equipment
R - Hot bonder with curing cycle monitoring and automatic

reporting feature
R
- Heat blanket 32 to 302 deg. F (0 to 150 deg. C)
R
- Heater Lamp 32 to 302 deg. F (0 to 150 deg. C)
R
- Hot air blower 248 deg. F (120 deg. C) maximum
R
- Pneumatic sander
R
- Spatula
R
- Squeegee
EFFECTIVITY: TRENT REPAIR NO 03
54-30-00
Page 201
R Jun 10/09
R - Standard workshop tools and equipment
R - Steel guides 10 in (254 mm) minimum length
R - Thermocouples 32 to 302 deg. F (0 to 150 deg. C)
R - Vacuum cleaner
R - Vacuum pump to -15 psi(– 1,0 bar) capability with vacuum

R gauge
R - Weighing equipment
R
---------------------------------------------------------------
---------------------------------------------------------------
R
R OMat 1/257 Cleaning solvent
R OMat 261 Temporary marker
R OMat 262 Marker
R OMat 2/110 Adhesive tape vacuum bag seal
R OMat 2/126 Vacuum bag
R OMat 2/129 Breather cloth
R OMat 2/131 Non porous parting film
R OMat 5/94 Garnet paper, Grit size 150
R OMat 5/121 Abrasive disc, grade 60
R OMat 8/160 Epoxy Paste Adhesive
R
R
R
R OMat 8/154 Epoxy Paste Adhesive
R
---------------------------------------------------------------
COMPONENT MATERIAL
---------------------------------------------------------------
R Thrust reverser carbon/epoxy composite
R 4. Procedure
R WARNING: WHEN YOU DO THIS REPAIR YOU MUST WEAR PROTECTIVE CLOTHING, GLOVES DUST
R MASK AND SAFETY GOGGLES TO PROTECT YOU AGAINST DUST AND LOOSE PARTICLES,
R WHICH CAN BE DANGEROUS TO YOUR HEALTH.
R WARNING: WHEN YOU USE THE CLEANING MATERIALS, ADHESIVES AND COATINGS, REFER TO, AND
OBEY, THE MANUFACTURER’S CONTROL AND APPLICATION INSTRUCTIONS AND HEALTH
R AND SAFETY NOTICES.
R A. Clean the repair area.
R CAUTION: WHEN REMOVING LOOSE FIBRES MAKE SURE NO ADDITIONAL

R MATERIAL IS REMOVED.
54-30-00
Page 202
R Jun 10/09
R (1) Lightly abrade the surface to remove loose fibres with
R OMat 5/94 Garnet paper.
R (2) Use a vacuum cleaner to remove all debris from the repair
R area. Use a lint free cloth soaked in OMat 1/257 cleaning
R solvent to clean the damage area. Refer to AMM 70-20-01-
R 100-802.
R (1) Do a tap test. Refer to SRM 54-01-06 Composite Structure

R Tap Test or use ultrasonic inspection equipment to
R determine the damaged area.
R (2) Use a temporary marker such as Omat 261 to mark out the
R damaged area that is to be removed. The cut-out area
R should be a smooth rectangular shape with rounded corners
R of 0.5 in. (12,5mm) minimum radius.
R (3) Check that the dimensions of the damaged area are within
R the repairable limits. Refer to the relevant chapter of
R SRM, page block 101.
R C. Prepare the damaged area for repair (Ref. to figure 201).

R
(1) Use the marks made at Operation B, Step 2 to carefully
R
trim out the damaged area. Use a vacuum cleaner to
R
remove the dust while cutting. Make sure all damage is
R
removed.
R
R (2) Use a lint free cloth soaked in OMat 1/257 cleaning
R solvent to clean the repair area. Refer to AMM 70-20-01-
100-802.
R
R (3) Use an OMat 261 temporary marker to mark out the area
R that is to be step sanded and the area where the extra
R repair plies are to be installed. The step sanded area
R must extend beyond the cutout area by a minimum of 0.48
R in. (12 mm) for each ply that is removed. The area where
R the extra repair plies are to be installed must extend
R for a distance of 0.6 in. (15mm) beyond the step sanded
area (Ref. to figure 201).
R
R CAUTION: MAKE SURE YOU STEP SAND OVER EACH PLY IN
INCREMENTS.
R
R (4) Start step sanding from the damage centre to the outer
R face. Use the marks made at step 3 to put the steel
R guides in position. Hold the steel guides firmly in
R position with adhesive tape. Step sand using a pneumatic
R sander fitted with OMat 5/121 Abrasive paper disc. Make
R each step a smooth rectangular shape with rounded corners
of 0.5 in (12,5 mm) minimum radius.
54-30-00
R Page 203
Jun 10/09
R (5) Remove the adhesive tape and the steel guides.
R (6) Lightly abrade the area on the outer skin where the extra
R plies are to be installed. Use OMat 5/94 Garnet paper.
R (7) Use a vacuum cleaner to remove all dust and debris. Use a
R lint free cloth soaked in OMat 1/257 cleaning solvent to
R clean the repair area, refer to AMM 70-20-01-100-802.
R (8) Air dry the honeycomb for 30 minutes minimum at 200 deg F
R (93 deg C) with a hot air blower.
R D. Fill the honeycomb core (Ref. to Figure 201).
R (1) Mix a suitable quantity of OMat 8/154 Epoxy paste

R adhesive parts A and B. Refer to manufacturer’s
R instructions.
R (2) Fill the honeycomb core with OMat 8/154 adhesive paste.
R Use a clean spatula to make the adhesive flush with the
R bottom of the adjacent carbon skin. It is not necessary
R to completely fill the honeycomb cells with adhesive, but
the adhesive must be 0.4 in.(10mm) minimum thickness.
R
(3) Install the thermocouples adjacent to the adhesive.
R CAUTION: THE RATE OF TEMPERATURE INCREASE AND SUBSEQUENT
R DECREASE MUST NOT BE GREATER THAN 5.4 DEG. F (3 DEG
R C) PER MINUTE.
R (4) Cure the OMat 8/154 Epoxy paste adhesive in two stages,
R the first stage for 1 hour at room temperature and then
R the second stage 70 minutes at 158 deg F (70 deg C).
R
(5) Remove thermocouples.
R (6) Abrade the adhesive with OMat 5/121 Garnet paper disc to
R obtain a smooth surface. Refer to figure 201.
R (7) Use vacuum cleaner to remove all dust and use a lint free
R cloth soaked in OMat 1/257 cleaning solvent to clean the
R repair area. Refer to AMM 70-20-01-100-802.
R E. Make templates for the repair plies (Refer to Figure 201).
R (1) Make a template for each step in the step sanded area and
R for the area where the additional repair plies are to be
R installed. Determine the orientation for each step and
R mark this on the templates. The orientation of the extra
R plies must be the same as the orientation of the ply
R below (surface ply).
R
R F. Prepare the Glass/Epoxy ply (Ref to Figure 201).
R NOTE: A Glass/Epoxy ply is necessary only if the honeycomb is

R metallic.
R
54-30-00
Page 204
Jun 10/09
R (1) Cut a piece of OMat 8/182 Dry Glass fabric that is large
R enough to cut out a repair ply using the smallest
R template. Add sufficient margin for trimming.
R (2) Weigh the dry Glass fabric ply.
R (3) Cut two pieces of OMat 2/131 Non porous parting film each
R approximately 3.0 in (80 mm) larger, all around, than the
R Glass fabric.
R
(4) Tape down one piece of the non porous parting film onto a
R
flat and smooth surface.
R
(5) Put the OMat 8/182 Dry Glass fabric onto the non-porous
R
parting film.
R
R (6) Mix a quantity of OMat 8/160 Epoxy paste adhesive that is
R equal in mass to the dry glass fabric weighed at step 2.
R Refer to manufacturer’s instructions for mixing
instructions.
R
R (7) Apply the prepared quantity of adhesive evenly onto the
glass fabric using a spatula.
R
R (8) Put the second non porous parting film on the Glass
R fabric. Use a squeegee to impregnate the glass fabric
evenly with adhesive and remove trapped air.
R (9) Use the smallest template to cut out the glass repair
R ply.
R G. Prepare the carbon/epoxy repair plies (Ref to figure 201).
R CAUTION: EACH PAIR OF REPAIR PLIES MUST BE OF SAME ORIENTATION

R AS THE ORIGINAL PLY BELOW.
R (1) Cut out a piece of OMat 8/183 dry carbon fabric that is
R large enough to cut out all the repair plies. Use two
R carbon/epoxy repair plies for each damaged carbon/epoxy
R ply of the original laminate. Use two extra carbon/epoxy
R repair plies for the outer surface. Add sufficient margin
R for trimming.
R (2) Weigh the dry carbon fabric.
R (3) Cut 2 pieces of OMat 2/131 Non porous parting film each
R approximately 3 in (80 mm) larger, all round, than the
R Dry Carbon repair fabric. Tape down one piece of the non
R porous parting film onto a smooth surface.
R (4) Put the Dry Carbon fabric onto the non-porous parting
R film.
R (5) Mix a quantity of OMat 8/160 Epoxy paste adhesive that is

R equal in mass to the dry carbon fabric weighed at step 2.
54-30-00
Page 205
R Jun 10/09
Refer to manufacturer’s instructions for mixing
R instructions.
R
(6) Use a spatula to apply the adhesive evenly onto the dry
R carbon fabric.
R
(7) Put the second piece of non-porous parting film on the
R Carbon fabric. Use a squeegee to impregnate the Carbon
R fabric evenly with the adhesive and remove trapped air.
R
(8) Use the templates made at operation E to cut out the
R
Carbon/epoxy fabric plies.
R
H. Lay up the Glass/Epoxy ply (Ref. to Figure 201).
R
R NOTE: A Glass/Epoxy ply is necessary only if the honeycomb is

metallic.
R
(1) Remove the non porous parting film from one side of the
R Glass/Epoxy fabric Ply.
R
CAUTION: TO PREVENT ADHESIVE DEFICIENCY, DO NOT APPLY TOO MUCH
R PRESSURE.
R
(2) Put the glass/epoxy ply in position on the filled
R honeycomb core. Use a squeegee to remove wrinkles and
R trapped air.
R
(3) Remove the non-porous parting film from the installed
R glass/epoxy fabric ply.
R
I. Lay up the carbon/epoxy repair plies (Ref to Figure 201).
R
(1) Remove the non-porous parting film from the smallest
R repair ply.
R
(2) Position the carbon/epoxy fabric repair ply adhesive side
R down in the step sanded area. Make sure that the
R orientation of the carbon/epoxy repair matches that of
R the adjacent structure.
R
(3) If necessary trim the Carbon/epoxy fabric ply to the same
R dimension as the cutout without any clearance.
R
R
NOTE: Do not apply excessive pressure to avoid an
R adhesive deficiency in the impregnated plies.
R
(5) Remove the non-porous parting film from the top of the
R installed carbon/epoxy fabric repair ply.
R
(6) Remove the non-porous parting film from one side of the
R next repair ply and repeat steps 2 to 5 until all the
R
54-30-00
R Page 206
Jun 10/09
R repair plies are installed in the step sanded area. Install
R the 2 off extra repair plies so the orientation is the same
R as the ply below (surface ply).
R J. Cure the repair area (Ref to figure 202).
R (1) Install the thermocouples adjacent to the repair plies.
R (2) Position the OMat 2/129 Breather cloth around the repair
R plies.
R (3) Cut and install a piece of OMat 8/198 Nylon peel ply
R allowing 1.0 in (25 mm) excess around the edges of the
R repair plies.
R (4) Put OMat 2/110 Adhesive tape vacuum bag seal all around
R the lay-up area.
R CAUTION: MAKE SURE THE VACUUM FITTING SIT ON THE BREATHER

R CLOTH.
R (5) Cut a suitably sized piece of OMat 2/126 vacuum bag and
R install a vacuum fitting. Make sure that when installed,
R the vacuum fitting will sit on the breather cloth.
R Install the vacuum bag.
R (6) Connect the vacuum bag to the vacuum pump.
R (7) Evacuate the lay-up to a vacuum of -10.0 psi (- 0.7 bar)
R inside the bag.
R
NOTE: Maintain vacuum of -10.0 psi (- 0.7 bar) inside the
R
bag for the required cure period.
R
R
R (9) Position a suitably sized heater blanket over the repair
area.
R (10) Put a layer of OMat 2/129 Breather cloth that is larger

R than the heater blanket over the heater blanket.
R (11) Put OMat 2/110 Adhesive tape vacuum bag seal all around
R the area.
R (12) Cut a suitably sized piece of OMat 2/126 vacuum bag and
R install a vacuum fitting. Make sure that when the vacuum
R bag is installed the vacuum fitting will sit on the
R breather cloth. Install the vacuum bag.
R (13) Connect the vacuum bag to the vacuum pump.
R (14) Evacuate the lay-up to a vacuum of -10.0 psi (- 0.7 bar)

Inside the bag.
54-30-00
Page 207
R Jun 10/09
R CAUTION: THE RATE OF TEMPERATURE INCREASE AND SUBSEQUENT
R DECREASE MUST NOT BE GREATER THAN 7.2 DEG F (4 DEG
R C) PER MINUTE.
R (15) Cure the repair plies. Refer to figure 202 for the cure
R cycle details.
R NOTE: The cure dwell shall start when the lowest reading
R thermocouple reaches the correct temperature.
R (16) Allow the repair area to cool to room temperature and

R carefully remove the lay-up materials from the repair
R plies.
R K. Examine the completed repair
R (1) Visually examine the repair to make sure it has been
R satisfactorily completed.
R
(2) Do a tap test. Refer to SRM 54-01-06 Composite Structure
R
Tap Test or use ultrasonic inspection equipment to make
R
sure the repaired area has no voidage or delamination. If
R
any damage is found, refer to page block 101 to make sure
R
that it is within the permitted limits.
R
(3) If necessary apply primer and finish paint coat. Refer to
R
SRM Chapter 54-30-00, FRSX056 repair no.11.
R
L. Identify the repair.
R
R (1) Use a permanent marker pen of a contrasting colour to write
FRSX047 next to the existing part number.
54-30-00
Page 208
R Jun 10/09
R
Preparation and Repair Ply Lay-up

Figure 201
R
54-30-00
Page 209
Jun 10/09
R
Bagging Operation and Curing Cycle

Figure 202
R
54-30-00
Page 210
Jun 10/09
RB.211 TRENT
m@ STRUCTURAL REPAIR
MANUAL
REPAIR N0.4
THRUST REVERSER
REPAIR CARBON SKIN AND CORE I N SANDWICH AREA
1. G e n e r a l
CAUTION: YOU MUST REFER TO THE ALLOWABLE DAMAGE LIMITS, PAGE BLOCK 1 0 1 , TO
MAKE SURE THAT REPAIR I S PEKVITTED.
CAUTION: OVERLAPPING OF CARBON REPAIR PATCHES I S NOT PERMITTED.
A. T h i s p r o c e d u r e g i v e s i n s t r u c t i o n s t o r e p a i r damage ( o t h e r t h a n a
through-hole) i n a sandwich a r e a when t h e o u t e r s k i n and honeycomb a r e
damaged. The r e p a i r i s n o t a p p l i c a b l e i f t h e s k i n c o n t a i n s a b r o n z e mesh
layer.
B. Damage i s r e p a i r e d by t h e i n s t a l l a t i o n o f a honeycomb p l u g and t h e

a p p l i c a t i o n o f wet lay-up c a r b o n f a b r i c r e p a i r p l i e s o n t o t h e s k i n .
..............................................................................
p
54-30-00, R e p a i r No.11 Apply P r i m e r S e a l a n t P a i n t

TASK 78-33-13-300-007 FRSX048 T r e n t Engine Manual
3. Equipment and M a t e r i a l s
A. S t a n d a r d equipment
S t a n d a r d workshop t o o l s and equipment
Vacuum c l e a n e r
Hot a i r blower 100 deg C (212 deg F) maximum
S t e e l r o l l e r 50.8 mm ( 2 i n . ) d i a m e t e r
P o r t a b l e composite r e p a i r c o n s o l e w i t h t h e f o l l o w i n g f e a t u r e s :
- Heat b l a n k e t 0 t o 120 deg C (32 t o 250 deg F)
- Vacuum pump t o 80 p e r c e n t w i t h vacuum gauge
- C u r i n g power c a p a b i l i t y ( a s a n i n d i c a t i o n ) 6000 w a t t s
REPAIR N0.4
EFFECTIVITY: TRENT
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STRUCTURAL REPAIR
MANUAL
- Thermocouples
Pneumatic sander power 0.16 Kilo Watts
Squeegee
Steel guides of 254 mm (10 in.) minimun length.
..............................................................................
..............................................................................
OMat 135 METHYL ETHYL KETON
OMat 2/110A SEALANT TAPE
OMat 5/94 ABRASIVE PAPER 150 GRIT
OMat 5/121 GARNET PAPER DISC GRADE 60
ONat 8/192 ADHESIVE
OMat 8/160 EPOXY ADHESIVE
OMat 8/180 POUR COAT
OMat 8/183 CARBON FABRIC
OMat 8/187 FLEXCORE HONEYCOMB
OMat 8/188 METALLIC HONEYCOMB
OMat 8/190 NOMEX HONEYCOMB
- P P P P P - --
PART IDENT MATERIAL

..............................................................................
Thrust reverser carbon composite
4. Examine the damage

A. Visually examine the skin to find the type of damage.
B. Do an ultrasonic inspection to measure the damage dimensions. Refer to

allowable damage, page block 101, to make sure the damage is in repairable
limits.
REPAIR N0.4
EFFECTIVITY: TRENT
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Bm
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
C. M a r k o u t t h e area of t h e d a m a g e .
5. P r e p a r e t h e d a m a g e d are f o r r e p a i r ( R e f F i g u r e 2 0 1 )
WARNING: USE METHYL ETHYL KETONE I N AN AREA OPEN TO THE A I R . T H I S MATERIAL

I S FLAMMABLE AND GAS I S DANGEROUS. I T CAN CAUSE I R R I T A T I O N O F EYES,
NOSE, THROAT AND SKIN. HIGH CONCENTRATION CAN CAUSE WEAKNESS,
HEADACHE, NAUSEA, D I Z Z I N E S S AND INCORRECT JUDGEMENT.
A. R e m o v e a l l l o o s e f i b e r s w i t h OMat 5/94 ABRASIVE PAPER a n d c l e a n w i t h a

v a c u u m c l e a n e r a n d OMat 2 1 1 0 1 L I N T FREE CLOTH s o a k e d w i t h OMat 135 MEK.
D r y t h e surface b e f o r e t h e s o l v e n t e v a p o r a t e s .
CAUTION: THE RATE O F TEMPERATURE INCREASE MUST NOT BE MORE THAN 3 DEG C (5
DEG F) PER MINUTE.
B. D r y t h e d a m a g e d area f o r 1 hour m i n i m u m a t 9 1 t o 96 deg C ( 1 9 5 t o 2 0 5 d e g

F) w i t h a hot air b l o w e r .
C. T r i m o u t t h e d a m a g e d c o r e and s k i n t o a r e c t a n g l e o r square w i t h rounded

c o r n e r s of 1 2 . 5 mm (0.5 i n . ) m i n i m u m r a d i u s . D u r i n g t h e t r i m o u t o p e r a t i o n
record t h e n u m b e r a n d o r i e n t a t i o n of p l i e s .
NOTE: T a k e care n o t t o c u t t h e u n d a m a g e d p l y on t h e o p p o s i t e s i d e and t h e

surrounding material.
WARNING: USE METHYL ETHYL KETONE.-IN AN AREA OPEN TO THE A I R . T H I S MATERIAL

I S FLAMMABLE AND GAS I S DANGEROUS. I T CAN CAUSE I R R I T A T I O N O F EYES,
HEADACHE, NAUSEA, D I Z Z I N E S S AND INCORRECT JUDGEMENT.
D. C l e a n t h e area w i t h a v a c u u m cleaner and OMat 2 1 1 0 1 L I N T FREE CLOTH s o a k e d

w i t h O M a t 135 MEK. D r y t h e s u r f a c e before t h e s o l v e n t evaporates.
E . M a s k o f f area around t h e c u t o u t . A d d 1 2 mm (0.48 i n . ) m i n i m u m f o r each

p l y r e p l a c e m e n t p l u s 15 mm (0.6 i n . ) f o r t h e extra p l i e s .
F . L a y o u t t h e zones t o s t e p - s a n d , then i n s t a l l s t e e l g u i d e s w i t h O M a t 2 7 2
ADHESIVE TAPE.
REPAIR N0.4
EFFECTIVITY: TRENT
Page 203
July 1/98
Bm
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
CAUTION: MAKE SURE NOT TO STEP-SAND OVER THE SKIN THICKNESS TO BE SANDED.
STOP SANDING WHEN YOU SEE DIFFERENT PLY ORIENTATION.
G. Start step-sand from the damage centre to the outer face using a sander
with OMat 51121 GARNET PAPER DISC. Each step dimension is a minimum of 12
mm (0.48 in.) wide around the cleaned up damage. Make a smooth rectangular
or square shape with rounded corners of 12.5 mm (0.5 in.) minimum radius.
H. Make the outer skin rough with OMat 5/94 ABRASIVE PAPER to a distance of 27
mm (1.06 in.) minimum, all around the repair edge (for the extra plies
installation).
IS FLAMIW3LE AND GAS IS DANGEROUS. IT CAN CAUSE IRRITATION OF EYES,
I. Removal all sanding dust with a vacuum cleaner and wipe surfaces with OMat
21101 LINT FREE CLOTH soaked with OMat 135 METHYL ETHYL KETONE. Dry the
surface before the solvent evaporates.
WARNING: USE OMAT 81180 POUR COAT IN AN AREA OPEN TO THE AIR. CAREFULLY READ
THE APPLICABLE 'MATERIAL SAFETY DATA SHEET' BEFORE YOU USE THIS
ADHESIVE. OBEY ALL SAFETY AND HEALTH PRECAUTIONS.
J. If the honeycomb is metallic, then apply the OMat 81180 POUR COAT with a
paint brush on all the visible surface of the honeycomb.
NOTE: Unwanted pour coat must be drained from the honeycomb.
K. Air dry the honeycomb, then cure it at 102 to 113 deg C (215 to 235 deg F)
for 30 minutes minimum with a hot air blower.
6. Prepare the plug
A. Find the type of the honeycomb plug from the original honeycomb, the
consumable materials table and the related page block 001.
B. Find the width, length and height of the replacement plug according to the
honeycomb damaged.
NOTE: The replacement honeycomb plug must overlap and make full contact
with the cell walls of the adjacent core material.
C. Find the ribbon direction of the plug in the related page block 001.
NOTE: Mark the ribbon direction on the plug and on the area to be
repaired.
REPAIR N0.4
EFFECTIVITY: TRENT
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July 1/98
I RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
D. Trim t h e c o r e p l u g t o f u l l l e n g t h u s i n g a c u t t e r .
WARNING: USE METHYL ETHYL KETONE I N AN AREA OPEN TO THE AIR. THIS MATERIAL
I S FLAMMABLE AND GAS I S DANGEROUS. IT CAN CAUSE IRRITATION OF EYES,
NOSE THROAT AND SKIN. HIGH CONCENTRATIONS CAN CAUSE WEAKNESS,
E . Clean t h e p l u g i n a n OMat 135 MEK b a t h f o r 60 s e c o n d s o r vapour d e g r e a s e

f o r a maximum of 4 c y c l e s o f 30 s e c o n d s p e r c y c l e .
F. Wipe t h e p l u g d r y w i t h OMat 21101 LINT FREE CLOTH b e f o r e t h e s o l v e n t

evaporates.
NOTE: The p l u g must be f u l l y d r y , c l e a n and f r e e of s o l v e n t s b e f o r e

installation.
7 . I n s t a l l t h e p l u g Ref F i g u r e 201)
WARNING: DO NOT PUT MORE THAN 450 G ( 1 LB) OF OMAT 81192 ADHESIVE I N ONE
CONTAINER. I F YOU M I X MORE THAN 450 G ( 1 LB) I N A CONTAINER AN
WARNING: USE OMAT 8/192 ADHESIVE I N AN AREA OPEN TO THE AIR. CAREFULLY READ
B. Apply a n even c o a t of OMat 8/192 ADHESIVE on t h e c e l l w a l l s of t h e o r i g i n a l

c o r e and t h e i n s i d e s u r f a c e o f t h e i n n e r s k i n .
C. P u t t h e p l u g i n t o t h e r e p a i r c u t - o u t , t h e n f i l l t h e p l u g w i t h O M a t 8/192
ADHESIVE. U s e a c l e a n s p a t u l a t o make t h e a d h e s i v e l e v e l w i t h t h e d e e p e s t
p l y of t h e s k i n cut-out.
8 . Bagging (Ref F i g u r e 202)
A. I n s t a l l t h e thermocouples a d j a c e n t t o t h e p l u g .
B. Cut a p i e c e o f OMat 21130 POROUS PARTING FILM w i t h 80 mm ( 3 i n . ) o v e r l a p

around t h e e d g e s and l a y o v e r t h e p l u g .
C. Overlay w i t h a p i e c e of O M a t 21131 NON-POROUS PARTING FILM c u t t o t h e same

dimensions.
D. Add a l a y e r o f OMat 21129 BREATHER CLOTH and a h e a t b l a n k e t .
NOTE: I f t h e r e p a i r i s i n an a c o u s t i c a r e a , cover t h e f u l l d r i l l e d panel

w i t h s u f f i c i e n t OMat 2/126 VACUUM BAG t o p r e v e n t l e a k a g e .
REPAIR N0.4
EFFECTIVITY: TRENT
Page 205
J u l y 1/98
RB.211 TRENT
a
1-3.3~3 STRUCTURAL REPAIR
MANUAL
E. P u t OMat 2/110A SEALANT TAPE a r o u n d t h e f u l l a r e a . Then, c u t a s u i t a b l e

p i e c e of O M a t 2/126 VACUUM BAG and bag o v e r t h e r e p a i r .
F. Evacuate t h e lay-up t o a vacuum o f 0.7 b a r i n s i d e t h e bag.
9. C u r i n g
CAUTION: THE RATE OF TEMPERATURE INCREASE AND DECREASE MUST NOT BE MORE THAN
3 DEG C ( 5 DEG F) PER MINUTE.
A. Cure t h e a d h e s i v e f o r 7 h o u r s a t 25 deg C (77 deg F ) , p l u s 2 h o u r s a t 93

deg C (200 def F ) .
B. Remove a l l lay-up m a t e r i a l s , t h e n a b r a d e w i t h O M a t 51121 GARNET PAPER DISC

t o o b t a i n a smooth s u r f a c e .
1 0 . P r e p a r e t h e r e p a i r p l i e s (Ref F i g u r e 201)
CAUTION: EACH PAIR OF REPAIR PLIES MUST BE OF THE SAME ORIENTATION AS THE
ORIGINAL PLY BELOW.
A. Find t h e number, t y p e and o r i e n t a t i o n of r e p a i r p l i e s n e c e s s a r y a c c o r d i n g

t o the original structure.
NOTE: Use two O M a t 81183 CARBON FABRIC r e p a i r p l i e s f o r e a c h damaged

carbon p l y o f t h e o r i g i n a l l a m i n a t e . Use two e x t r a r e p a i r p l i e s f o r
the outer surface.
B. Make a t r a c i n g o f e a c h s t e p - s a n d t o f i n d c a r b o n r e p a i r p l i e s d i m e n s i o n s .
C. Cut t h e c a r b o n f a b r i c r e p a i r p l i e s i n a c c o r d a n c e w i t h t h e t r a c i n g s . Cut
two p i e c e s o f O M a t 21131 NON-POROUS PARTING FILM e a c h a p p r o x i m a t e l y 80 mm (
3 i n . ) l a r g e r , a l l round, t h a n t h e carbon f a b r i c . Tape down one non-porous
p a r t i n g f i l m on a f l a t a n d smooth s u r f a c e .
NOTE: Add s u f f i c i e n t m a r g i n t o p e r m i t f u r t h e r a d j u s t m e n t .
WARNING: DO NOT PUT MORE THAN 250 G (0.55 LB) OF OMAT 81160 ADHESIVE I N ONE
CONTAINER. I F YOU M I X MORE THAN 250 G (0.55 LB) I N A CONTAINER AN
UNCONTROLLED HEAT BUILD-UP WILL OCCUR. POISONOUS FUElES WILL BE MADE
BY THE BUILD-UP.
WARNING: USE OMAT 81160 ADHESIVE I N AN AREA OPEN TO THE AIR. CAREFULLY READ
D. Mix t h e OMat 81160 ADHESIVE p a r t s A and B i n a c c o r d a n c e w i t h t h e

manufacturers instructions.
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E . Weigh t h e OMat 8 / 1 8 3 CARBON FABRIC and p r e p a r e a q u a n t i t y o f O M a t 8/160

EPOXY ADHESIVE of e q u a l w e i g h t .
F. P u t t h e r e p a i r p l y o n t o t h e f i r s t non-porous p a r t i n g f i l m . Apply evenly

t h e s e l e c t e d q u a n t i t y o f O M a t 8/160 EPOXY ADHESIVE o n t o t h e r e p a i r p l y
using a spatula.
G. P u t t h e second non-porous p a r t i n g f i l m on t h e r e p a i r p l y . Use a r o l l e r t o

work t h e a d h e s i v e t h r o u g h t h e r e p a i r p l y t o i m p r e g n a t e i t and remove
trapped air.
H. Use a c u t t e r t o c u t o u t t h e n e c e s s a r y number of O M a t 8/183 CARBON FABRIC

r e p a i r p l i e s i n a c c o r d a n c e w i t h t h e t r a c i n g s done i n s t e p 10.B.
11.Lay up of r e p a i r p l i e s (Ref F i g u r e 201)
A. Remove t h e non-porous p a r t i n g f i l m from one s i d e o f t h e s m a l l e s t r e p a i r

p l y . P u t t h e exposed f a c e a g a i n s t t h e r e p a i r a r e a w i t h o r i e n t a t i o n a s i n
o r i g i n a l p l y below.
B. Trim t h e r e p a i r p l y e d g e s t o f i t t h e c u t - o u t w i t h o u t c l e a r a n c e .
C. Use a r o l l e r and a squeegee t o remove any w r i n k l e s and e n t r a p p e d a i r .
NOTE: To p r e v e n t a d h e s i v e d e f i c i e n c y i n p l y , do n o t a p p l y t o o much
pressure.
E. Remove t h e non-porous p a r t i n g f i l m from t h e r e p a i r p l y i n s t a l l e d . Put t h e

second r e p a i r p l y i n p o s i t i o n w i t h t h e same o r i e n t a t i o n .
E. P u t t h e n e x t l a r g e s t r e p a i r p l y and s u b s e q u e n t p l i e s on t h e r e p a i r a r e a
w i t h c o r r e c t o r i e n t a t i o n a s d e s c r i b e d i n s t e p A.
12.Bagging (Ref F i g u r e 202)
A. I n s t a l l t h e thermocouples a d j a c e n t t o r e p a i r p l i e s .
B. Cut a p i e c e of O M a t 2/130 POROUS PARTING FILM w i t h 8 mm ( 3 i n . ) o v e r l a p

a r o u n d t h e edges a n d l a y o v e r t h e r e p a i r p l i e s .
C. O v e r l a y w i t h a p i e c e of OMat 21131 NON-POROUS PARTING FILM c u t t o t h e same

dimensions.
D . P u t a l a y e r of O M a t 21129 BREATHER CLOTH and a h e a t b l a n k e t on t h e r e p a i r

area.
NOTE: I f t h e r e p a i r i s i n a n a c o u s t i c a r e a , cover t h e f u l l d r i l l e d panel

w i t h s u f f i c i e n t OMat 2/126 VACUUM BAG t o p r e v e n t l e a k a g e .
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E. P u t OMat 2/110 SEALANT TAPE a r o u n d t h e f u l l a r e a . Then, c u t a s u i t a b l e

p i e c e of OMat 21126 VACUUM BAG and bag o v e r t h e r e p a i r .
F. Evacuate t h e lay-up t o a vacuum of 0.7 b a r i n s i d e t h e bag.
13.Curing (Ref F i g u r e 202)
A. Cure i n two s t a g e s , t h e f i r s t one f o r 60 t o 70 m i n u t e s a t 55 t o 65 deg C

(131 t o 149 deg F) and t h e second one f o r 150 t o 160 m i n u t e s a t 115 t o 125
deg C (239 t o 257 deg F ) .
NOTE: M a i n t a i n vacuum o f 0.7 b a r i n s i d e t h e bag f o r t h e f u l l t i m e of c u r e .
A. Remove t h e l a y up m a t e r i a l s from t h e r e p a i r .
B. V i s u a l l y i n s p e c t t h e r e p a i r f o r freedom from r e s i n - s t a r v e d a r e a s , b l i s t e r s
o r excessive r e s i n areas.
WARNING: USE OMAT 135 METHYL ETHYL KETONE I N AN AREA OPEN TO THE AIR. THIS
MATERIAL I S FLAMMABLE AND GAS I S DANGEROUS. IT CAN CAUSE IRRITATION
OF EYES, NOSE, THROAT AND SKIN. HIGH CONCENTRATION CAN CAUSE
WEAKNESS, HEADACHE, NAUSEA, DIZZINESS AND INCORRECT JUDGEMENT.
C. Remove a l l unwanted m a t e r i a l s w i t h a s u c t i o n c l e a n e r . C l e a n t h e s u r f a c e
w i t h O M a t 135 MEK and O M a t 21101 LINT FREE CLOTH. Dry t h e s u r f a c e b e f o r e
the solvent evaporates.
D. Do a v i s u a l i n s p e c t i o n t o make s u r e t h a t t h e r e p a i r h a s b e e n done i n
accordance w i t h t h e s e procedures.
E. Do an u l t r a s o n i c i n s p e c t i o n t o make s u r e t h a t t h e r e p a i r e d a r e a i s f r e e
from damage. I f n o t , r e f e r t o a l l o w a b l e damage p a g e b l o c k 101 t o make s u r e
t h e damage i s i n t h e p e r m i t t e d l i m i t s .
F. Apply p r i m e r s e a l e r p a i n t t o t h e r e p a i r a r e a , i f i t i s n e c e s s a r y . Refer t o
54-30-00, R e p a i r No.11.
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TAPE
SANDING OPERATION
EXTRA REPAIR
PLIES
LAY-UP PRINCIPLE
1
0 . 0 . 0.6
(12) (12) (12) (15)
PLIES ADHESIVE
PLUG
m v
c0 POUR COAT
DIMENSIONS ARE IN INCHES
L WITH MILLIMETERS IN PARENTHESES
P r e p a r a t i o n and R e p a i r P l y Lay-Up
Figure 201
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COMPOSITE
TAPE
POROUS PARTING BREATHER

FILM FABRIC
NON POROUS
PARTING FILM THERMOCOUPLE
BAGGING OPERATION
TEMPERATURE
-2 to 3" C h i n
I
I
I
I
I
1 l
I l I
L 6 0 *in/
70 min
I 150 rninI160 min
t
TIME
CURING CYCLE
Bagging O p e r a t i o n and Curing Cycle
F i g u r e 202
R E P A I R N0.4
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54-30-00
210 Page
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REPAIR N0.5
THRUST REVERSER
REPAIR CARBON COMPOSITE SKIN IN SANDWICH AREA
1. General
CAUTION: YOU MUST REFER TO THE APPLICABLE ALLOWABLE DAMAGE LIMITS, PAGE BLOCK
101, TO MAKE SURE THAT REPAIR IS PERMITTED.
A. This procedure gives instructions to repair through-hole damage to the

carbon composite skin in a sandwich area. The repair is not applicable if
the skin has a bronze mesh layer.
NOTE: This repair procedure is applicable only if the damage in the inner
skin is not more than 30 mm diameter. If it is, refer to Repair
No.6.
B. Damage can be repaired by:

- installation of a fiberglass backup plate on the inner side
- installation of a honeycomb plug to replace the damaged sandwich area
- addition of wet lay-up carbon fabric repair plies on the outer skin
..............................................................................
..............................................................................
54-30-00, Repair No.11 Apply Primer Sealer Paint
TASK 78-33-13-300-008 FRSX049 Trent Engine Manual
Equipment and Materials
Vacuum cleaner
Hot air blower 120 deg C (248 deg F) maximum
Steel roller 50,8 mm (2 in.) diameter
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Heat blanket 0 to 120 deg C (32 to 248 deg F)
Pneumatic sander power 0.16 Kilowatts
Squeegee
Steel guides
Protective pads (2 off)
..............................................................................
..............................................................................
OMat 81180 POUR COAT
OMat 8/182 FIBERGLASS FABRIC
OMat 81183 CARBON FABRIC
OMat 8/187 FLEXCORE HONEYCOMB
OMat 81188 METALLIC HONEYCOMB
OMat 81190 NOMEX HONEYCOMB
OMat 8/192 ADHESIVE
..............................................................................
PART IDENT MATERIAL
..............................................................................
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4. Examine t h e Damage
A. V i s u a l l y examine t h e s k i n t o f i n d t h e t y p e o f damage.
B. Do a n u l t r a s o n i c i n s p e c t i o n t o measure t h e damage d i m e n s i o n s . R e f e r t o
a l l o w a b l e damage, page b l o c k 101, t o make s u r e t h a t t h e damage i s i n t h e
repairable l i m i t s .
C . Mark o u t t h e a r e a of t h e damage
5 . P r e p a r e t h e Damaged Area f o r R e p a i r (Ref F i g u r e 201)
DANGEROUS FOR YOUR HEALTH.
NOSE, THROAT AND SKIN. H I G H CONCENTRATIONS CAN CAUSE WEAKNESS,
A . Remove a l l l o o s e f i b e r s w i t h O M a t 5/94 ABRASIVE PAPER a n d a vacuum c l e a n e r .

Clean t h e r e p a i r a r e a w i t h O M a t 2/101 LINT FREE CLOTH s o a k e d w i t h O M a t 135
MEK .
CAUTION: THE RATE OF TEMPERATURE INCREASE MUST NOT BE MORE THAN 3 DEG C (5
DEG F) PER MINUTE.
B. Dry t h e damaged a r e a f o r one hour minimum a t 91 t o 96 deg C (195 t o 205

deg F) w i t h a h o t a i r blower.
C. Trim o u t t h e damaged c o r e and s k i n s t o a smooth r e c t a n g u l a r o r s q u a r e s h a p e

w i t h rounded c o r n e r s of 12,5 mm (0.5 i n . ) minimum r a d i u s . During t h e t r i m
o u t o p e r a t i o n , r e c o r d t h e number and o r i e n t a t i o n of p l i e s .
NOTE: Take c a r e n o t t o c u t t h e undamaged p l i e s and s u r r o u n d i n g m a t e r i a l .
D. Clean t h e a r e a w i t h a vacuum c l e a n e r a n d O M a t 2/101 LINT FREE CLOTH.
E. Mask o f f t h e a r e a around t h e c u t o u t . Add 12 mm (0.48 i n . ) minimum f o r

e a c h p l y r e p l a c e m e n t and 15 mm (0.6 i n . ) f o r t h e e x t r a r e p a i r p l i e s .
F. Lay o u t t h e zones t o s t e p - s a n d , t h e n i n s t a l l s t e e l g u i d e w i t h O M a t 272

ADHESIVE TAPE.
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G. S t a r t s t e p - s a n d from t h e damage c e n t r e t o t h e o u t e r f a c e u s i n g a s a n d e r
w i t h an OMat 5 / 1 2 1 GARNET PAPER DISC. Each s t e p dimension i s a minimum o f
1 2 mm (0.48 i n . ) wide a r o u n d t h e c l e a n e d up damage. Make a smooth s q u a r e
o r r e c t a n g u l a r s h a p e w i t h rounded c o r n e r s o f 12.5 mm (0.5 i n . ) minimum
radius.
H. Make t h e o u t e r s k i n rough w i t h O M a t 5/94 ABRASIVE PAPER t o a d i s t a n c e of 27

mm (1.06 i n . ) minimum a l l round t h e r e p a i r edge.
WARNING: USE METHYL ETHYL KETONE I N AN AREA OPEN TO THE A I R . THIS MATERIAL
I. Remove a l l s a n d i n g d u s t w i t h a vacuum c l e a n e r and wipe s u r f a c e s w i t h O M a t

2/101 LINT FREE CLOTH, soaked w i t h OMat 135 METHYL ETHYL KETONE. Dry t h e
surface before t h e solvent evaporates.
WARNING: USE OMAT 8/180 POUR COAT I N AN AREA OPEN TO THE A I R . CAREFULLY READ
J . I f t h e honeycomb i s m e t a l l i c , t h e n a p p l y O M a t 8/180 POUR COAT w i t h a p a i n t

b r u s h on a l l t h e v i s i b l e s u r f a c e o f t h e honeycomb.
NOTE: Unwanted p o u r c o a t must be d r a i n e d from t h e honeycomb.
K. A i r d r y t h e honeycomb, t h e n c u r e i t a t 102 t o 113 deg C (213 t o 235 deg F)

f o r 30 m i n u t e s minimum w i t h a h o t a i r blower.
6. P r e p a r e t h e F i b e r g l a s s Backup P l a t e
A. Cut a p i e c e of O M a t 81182 FIBERGLASS FABRIC of s u f f i c i e n t s i z e t o make f i v e

fiberglass plies.
NOTE: F i b e r g l a s s p l i e s must be a t l e a s t 20 mm (0.8 i n . ) l o n g e r and 10 mm

(0.4 i n . ) w i d e r t h a n t h e damage d i m e n s i o n s .
B. Cut two p i e c e s o f O M a t 2/131 NON-POROUS PARTING FILM e a c h a p p r o x i m a t e l y 80

mm (3 i n . ) l a r g e r , a l l a r o u n d t h a n t h e f i b e r g l a s s f a b r i c .
C. Tape down one non-porous p a r t i n g f i l m on a f l a t and smooth s u r f a c e .
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THE APPLICABLE 'MATERIAL SAFETY SHEET' BEFORE YOU USE THIS ADHESIVE.
D. Mix t h e OMat 81160 EPOXY ADHESIVE p a r t s A and B i n a c c o r d a n c e w i t h t h e

manufacturers i n s t r u c t i o n s .
E. Weigh t h e OMat 81182 FIBERGLASS FABRIC and p r e p a r e a q u a n t i t y o f O M a t 81160

EPOXY ADHESIVE o f e q u a l w e i g h t .
F. Lay t h e f i b e r g l a s s f a b r i c o n t o t h e non-porous p a r t i n g f i l m . Apply t h e

s e l e c t e d q u a n t i t y of adhesive t o t h e f a b r i c with a s p a t u l a .
G. P u t t h e second non-porous p a r t i n g f i l m on t h e f i b e r g l a s s f a b r i c . Then u s e

a r o l l e r t o work t h e a d h e s i v e t h r o u g h t h e f i b e r g l a s s f a b r i c t o i m p r e g n a t e
i t a n d remove e n t r a p p e d a i r .
H. Use a c u t t e r t o c u t f i v e p i e c e s of t h e f i b e r g l a s s f a b r i c 20 mm ( 0 . 8 i n . )
l a r g e r , a l l round, t h a n t h e damage ( o r 10 mm (0.4 i n . ) minimum i f a c c e s s i s
small)
7. Lay-up t h e f i b e r g l a s s f a b r i c p l i e s (Ref F i g u r e 202)
A. Cut a p i e c e of O M a t 21131 NON-POROUS PARTING FILM 1 0 mm (0.4 i n . ) l a r g e r ,

a l l round, than a f i b e r g l a s s f a b r i c p l y .
B. Remove t h e non-porous p a r t i n g f i l m from one s i d e of t h e f i r s t f i b e r g l a s s

f a b r i c p l y . P u t t h e p l y on t h e l a r g e r non-porous p a r t i n g f i l m c u t i n s t e p
A.
C . Use a r o l l e r t o remove any w r i n k l e s and e n t r a p p e d a i r .
NOTE: To p r e v e n t a p l y d e f i c i e n t i n a d h e s i v e do n o t a p p l y t o o much
pressure.
D. Remove t h e non-porous p a r t i n g f i l m from t h e f i r s t f i b e r g l a s s f a b r i c p l y

i n s t a l l e d . P u t a second f i b e r g l a s s f a b r i c p l y o n t o t h e f i r s t one.
E. P u t t h e remaining f i b e r g l a s s p l i e s i n p o s i t i o n a s g i v e n i n s t e p s B t o D.
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8. Bagging and c u r i n g p r o c e d u r e (Ref F i g u r e 202)
A. I n s t a l l t h e t h e r m o c o u p l e s a d j a c e n t t o t h e f i b e r g l a s s p l i e s .
B. Cut a p i e c e o f O M a t 2/130 POROUS PARTING FILM w i t h 80 mm (3.0 i n . ) o v e r l a p

round t h e e d g e s and l a y i t o v e r t h e f i b e r g l a s s p l i e s .
C. O v e r l a y w i t h a p i e c e of OMat 21131 NON-POROUS PARTING FILM c u t t o t h e same

dimensions.
D. P u t a l a y e r o f O M a t 21129 BREATHER CLOTH and a h e a t b l a n k e t on t h e r e p a i r

area.
E. P u t O M a t 2/110A SEALANT TAPE a r o u n d t h e f u l l a r e a . Then c u t a s u i t a b l e

p i e c e of OMat 2/126 VACUUM BAG and bag o v e r t h e f i b e r g l a s s f a b r i c p l i e s .
F. E v a c u a t e t h e lay-up t o a vacuum of 0.7 b a r i n s i d e t h e bag.
NOTE: Keep a vacuum o f 0.7 b a r i n s i d e t h e bag f o r t h e f u l l time of c u r e .
G. Cure i n two s t a g e s , t h e f i r s t one f o r 60 t o 70 m i n u t e s a t 5 5 t o 65 deg C

deg C (239 t o 257 deg F ) .
H. Remove t h e lay-up m a t e r i a l s from t h e f i b e r g l a s s p l i e s . Trim t h e p l i e s i n t o

a n o v a l o r a r e c t a n g l e w i t h 1 0 mm ( 0 . 4 i n . ) minimum c o r n e r r a d i u s t o make
t h e backup p l a t e .
9. I n s p e c t i o n
A. C l e a n t h e backup p l a t e w i t h O M a t 135 MEK. Dry t h e s u r f a c e b e f o r e t h e

solvent evaporates.
B. Make a v i s u a l i n s p e c t i o n t o make s u r e t h a t t h e backup p l a t e h a s been made

i n accordance w i t h t h e s e procedures.
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1 0 . I n s t a l l t h e backup p l a t e (Ref F i g u r e 203)
A. D r i l l two p a i r s o f h o l e s n e a r t h e c e n t e r l i n e o f t h e backup p l a t e . Use a

1 mm (0.04 i n . ) d r i l l b i t .
B. Abrade t h e s u r f a c e o f t h e backup p l a t e and t h e i n n e r s i d e o f t h e damaged

s k i n ( i f p o s s i b l e ) f o r a d i s t a n c e o f 20 mm ( 0 . 8 i n . ) from t h e c u t - o u t edge.
Use OMat 5/94 ABRASIVE PAPER.
C. D r a w t h e c o n t o u r o f t h e cut-out i n t h e m i d d l e o f t h e backup p l a t e t o be
installed.
D. C l e a n t h e r e p a i r area and t h e backup p l a t e w i t h a vacuum c l e a n e r and O M a t

2/101 LINT FREE CLOTH m o i s t e n e d w i t h O M a t 135 MEK. Dry t h e s u r f a c e b e f o r e
t h e solvent evaporates.
E. P u t a l o o p of t h e l o c k w i r e t h r o u g h t h e h o l e s i n t h e backup p l a t e . Loosely
t w i s t e a c h l o o p of t h e l o c k w i r e one t u r n .
WARNING: USE OMAT 8 / 1 9 2 ADHESIVE I N AN AREA OPEN TO THE AIR. CAREFULLY READ
OBEY ALL SAFETY AND I-?.?.ALTH PRECAUTIONS.
F. Mix t h e OMat 81192 ADHESIVE p a r t s A a n d B i n a c c o r d a n c e w i t h t h e

NOTE: P o t l i f e o f m i x t u r e i s 8 h o u r s a t room t e m p e r a t u r e .
G. Apply s u f f i c i e n t O M a t 8/192 ADHESIVE a l l around t h e backup p l a t e and t h e

i n n e r s i d e of t h e s k i n .
H. P u t t h e backup p l a t e t h r o u g h t h e c u t - o u t . A d j u s t t h e backup p l a t e w i t h t h e
drawn c o n t o u r .
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I. P u t a s q u a r e d s e c t i o n r o d t h r o u g h t h e l o c k w i r e l o o p s , a c r o s s t h e r e p a i r
c u t - o u t and on t h e p r o t e c t i v e pads.
J . T w i s t t h e l o c k w i r e around t h e s q u a r e d s e c t i o n r o d s o t h a t t h e backup p l a t e
i s t i g h t l y p u l l e d a g a i n s t t h e i n n e r s i d e of t h e s k i n .
CAUTION: THE RATE OF TEMPERATURE INCREASE AND DECREASE MUST NOT BE NORE THAN
3 DEG C (5 DEG F) PER MINUTE.
K. Cure t h e a d h e s i v e f o r 2 h o u r s minimum a t 91 t o 96 deg C (195 t o 205 deg F ) .
L. Remove t h e l o c k w i r e , t h e r o d and t h e p a d s .
M. F i l l t h e h o l e s i n t h e backup p l a t e , a n d one l a y e r as t h i c k as t h e f i r s t
skin p l y , w i t h O M a t 81192 ADHESIVE.
N. Cure t h e a d h e s i v e f o r 2 h o u r s minimum a t 91 t o 96 deg C (195 t o 205 deg F).
1 1 . P r e ~ a r et h e f i b e r g l a s s ~ l v
NOTE: A f i b e r g l a s s p l y i s n e c e s s a r y o n l y i f t h e honeycomb i s m e t a l l i c .
A. Cut two p i e c e s o f O M a t 81182 FIBERGLASS FABRIC of t h e same d i m e n s i o n s as

t h e r e p a i r honeycomb p l u g .
NOTE: The second f i b e r g l a s s f a b r i c w i l l be wetted-out and i n s t a l l e d when

t h e honeycomb p l u g i s i n s t a l l e d .
B. Cut two p i e c e s o f O M a t 21131 NON-POROUS PARTING FILM e a c h a p p r o x i m a t e l y

8 0 mm (3.0 i n . ) l a r g e r , a l l around, t h a n t h e f i b e r g l a s s f a b r i c .
D. Lay one f i b e r g l a s s f a b r i c o n t o t h e non-porous parting film.
UNCONTROLLED HEAT BUILD-UP WILL OCCUR. POISONOUS M E S WILL BE MADE
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WARNING: USE OMAT 81160 ADHESIVE I N AN AREA OPEN TO THE A I R . CAREFULLY READ
E. Mix t h e OMat 81160 EPOXY ADHESIVE p a r t s A and B i n a c c o r d a n c e w i t h t h e

F. Weigh t h e f i b e r g l a s s f a b r i c b e f o r e p u t t i n g i t on t h e p a r t i n g f i l m and
p r e p a r e a q u a n t i t y of epoxy a d h e s i v e of e q u a l w e i g h t . Apply e v e n l y t h e
p r e p a r e d q u a n t i t y of a d h e s i v e o n t o t h e f i b e r g l a s s f a b r i c u s i n g a s p a t u l a .
G. P u t t h e second non-porous p a r t i n g f i l m on t h e f i b e r g l a s s f a b r i c . Use a

r o l l e r t o work t h e a d h e s i v e t h r o u g h t h e f i b e r g l a s s f a b r i c t o i m p r e g n a t e i t
and remove e n t r a p p e d a i r .
12.Lay-up the fiberglass ply
A . Remove t h e non-porous p a r t i n g f i l m from one s i d e o f t h e f i b e r g l a s s f a b r i c

P ~ Y
B. P u t t h e f i b e r g l a s s p l y i n p o s i t i o n on t h e i n n e r s k i n . Use a r o l l e r t o
remove w r i n k l e s and e n t r a p p e d a i r .
NOTE: To p r e v e n t a d h e s i v e d e f i c i e n c y , do n o t a p p l y t o o much p r e s s u r e .
C. Remove t h e non-porous p a r t i n g f i l m from t h e f i b e r g l a s s f a b r i c p l y

installed.
13.Prepare t h e p l u g
A. Find t h e t y p e o f honeycomb p l u g from t h e o r i g i n a l honeycomb, t h e consumable

m a t e r i a l s t a b l e and page b l o c k 101.
B. Find t h e w i d t h , l e n g t h and h e i g h t of t h e p l u g a c c o r d i n g t o t h e damaged

honeycomb.
NOTE: The r e p l a c e m e n t honeycomb p l u g must o v e r l a p and make f u l l c o n t a c t

w i t h t h e c e l l w a l l s of t h e a d j a c e n t c o r e m a t e r i a l .
C. Find t h e r i b b o n d i r e c t i o n o f t h e p l u g from page b l o c k 101.
D. Mark t h e r i b b o n d i r e c t i o n on t h e p l u g and on t h e a r e a t o b e r e p a i r e d .
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CAUTION: DO NOT CLEAN THE PLUG WITH OMAT 135 MEK I F THE PLUG I S NOT METALLIC.
E. C l e a n t h e p l u g i n a n OMat 135 MEK b a t h f o r 60 s e c o n d s , o r vapour d e g r e a s e

f o r a maximum of 4 c y c l e s o f 30 s e c o n d s p e r c y c l e .
F. Dry t h e p l u g w i t h O M a t 21101 LINT FREE CLOTH b e f o r e t h e s o l v e n t e v a p o r a t e s .
14.Apply t h e Adhesive
WARNING: USE OMAT 8/192 ADHESIVE I N AN AREA OPEN TO THE AIR. CAREFULLY READ
OBEY ALL SAFETY mTDHEALTH PRECAUTIONS.
A. Mix a s u f f i c i e n t q u a n t i t y o f O M a t 81192 ADHESIVE p a r t s A and B i n

accordance with t h e manufacturers i n s t r u c t i o n s .
NOTE: P o t l i f e of m i x t u r e i s 8 h o u r s a t room t e m p e r a t u r e .
B. P u t t h e honeycomb p l u g on a p i e c e o f non-porous p a r t i n g f i l u i , t h e n f i l l i t
w i t h a d h e s i v e t o a d e p t h of a p p r o x i m a t e l y 5 mm (0.2 i n . ) Make s u r e t h e r e
i s no a d h e s i v e l e a k a g e .
C. I n s t a l l t h e thermocouples a d j a c e n t t o t h e r e p a i r . Cure t h e a d h e s i v e f o r 2
h o u r s a t 91 t o 96 deg C (195 t o 205 d e g F ) .
1 5 . I n s t a l l t h e P l u g (Ref F i g u r e 201)
A. P u t t h e p l u g i n t o t h e r e p a i r c u t - o u t w i t h t h e c o r r e c t r i b b o n d i r e c t i o n .
B. I n s t a l l t h e second O M a t 81182 FIBERGLASS FABRIC o n t o t h e honeycomb plug.

R e f e r t o p a r a g r a p h s 11 and 12.
C. F i l l t h e s p a c e between t h e p l u g and t h e o r i g i n a l c o r e w i t h O M a t 8/192

ADHESIVE. Use a c l e a n s p a t u l a t o make t h e a d h e s i v e l e v e l w i t h t h e d e e p e s t
p l y of t h e s k i n c u t - o u t .
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16.Bagging and Curing P r o c e d u r e s
A. R e f e r t o t h e bagging p r o c e d u r e as g i v e n i n p a r a g r a p h 8.
NOTE: I f t h e r e p a i r i s i n an a c o u s t i c a r e a , c o v e r t h e f u l l d r i l l e d p a n e l
w i t h s u f f i c i e n t O M a t 21126 VACUUM BAG t o p r e v e n t l e a k a g e .
B. E v a c c a t e t h e lay-up t o a vacuum o f 0.7 b a r i n s i d e t h e bag.
C. I n s t a l l t h e thermocouples a d j a c e n t t o t h e r e p a i r . Cure t h e a d h e s i v e f o r
s e v e n h o u r s a t 20 t o 25 deg C (68 t o 77 deg F) p l u s two h o u r s minimum a t 91
t o 96 deg C (195 t o 205 deg F) w i t h a h e a t b l a n k e t .
D. Remove a l l lay-up m a t e r i a l s , t h e n a b r a d e t o g e t a smooth r e p a i r s u r f a c e .
1 7 . P r e p a r e t h e E x t e r n a l R e p a i r P l i e s (Ref F i g u r e 201)
CAUTION: EACH PAIR OF REPAIR PLIES MUST BE OF SAME ORIENTATION AS THE

ORIGINAL PLY BELOW.
A. Find t h e number, t y p e and o r i e n t a t i o n of t h e c a r b o n r e p a i r p l i e s n e c e s s a r y ,

according t o t h e o r i g i n a l s t r u c t u r e of t h e o u t e r s k i n .
NOTE: Use two O M a t 81183 CARBON FABRIC r e p a i r p l i e s f o r e a c h damaged

c a r b o n p l y of t h e o r i g i n a l l a m i n a t e . Use two e x t r a carbon r e p a i r
p l i e s f o r the outer surface.
B. Make a t r a c i n g o f t h e step-sand t o g i v e t h e s h a p e o f t h e r e p a i r p l i e s . Cut

t h e OMat 81183 CARBON FABRIC i n a c c o r d a n c e w i t h t h e t r a c i n g .
C. Cut two p i e c e s of O M a t 21131 NON-POROUS PARTING FILM e a c h a p p r o x i m a t e l y

80 mm ( 3 . 0 i n . ) l a r g e r , a l l round, t h e n t h e c a r b o n r e p a i r p l i e s . Tape down
one non-porous p a r t i n g f i l m on a smooth s u r f a c e .
NOTE: Add s u f f i c i e n t margin t o a l l o w f u r t h e r a d j u s t m e n t .
WARNING: DO NOT PUT MORE THAN 250 G (0.55 LB) OF OMAT 8/160 ADHESIVE I N ONE
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D. Mix t h e OMat 81160 EPOXY ADHESIVE p a r t s A and B i n accordance w i t h t h e

E. Weigh t h e carbon f a b r i c and p r e p a r e a q u a n t i t y of epoxy a d h e s i v e of e q u a l

weight.
F. Lay t h e carbon f a b r i c r e p a i r p l y on t h e f i r s t non-porous p a r t i n g f i l m .

Apply evenly t h e p r e p a r e d q u a n t i t y of a d h e s i v e o n t o t h e carbon f a b r i c u s i n g
a spatula.
G. P u t t h e second non-porous p a r t i n g f i l m on t h e carbon r e p a i r p l y . Then u s e

a r o l l e r t o work t h e a d h e s i v e through t h e carbon r e p a i r p l y t o impregnate
i t and remove entrapped a i r .
H. Use a c u t t e r t o c u t o u t t h e n e c e s s a r y number of carbon f a b r i c r e p a i r p l i e s

i n accordance w i t h s t e p B.
18.Lay-up t h e Repair P l i e s (Ref F i g u r e 201)
A. Remove t h e non-porous p a r t i n g f i l m from one s i d e of t h e s m a l l e s t r e p a i r

p l y . Put t h e exposed f a c e a g a i n s t t h e r e p a i r a r e a w i t h t h e same
o r i e n t a t i o n a s t h e o r i g i n a l p l y below.
B. Trim t h e carbon f a b r i c r e p a i r p l y edges t o f i t t h e cut-out w i t h o u t

clearance.
C. Use a r o l l e r and squeegee t o remove any w r i n k l e s and entrapped a i r .
pressure.
D. Remove t h e non-porous p a r t i n g f i l m from t h e carbon f a b r i c p l y i n s t a l l e d ,

t h e n i n s t a l l t h e second carbon f a b r i c p l y w i t h t h e same o r i e n t a t i o n .
E. P u t t h e n e x t l a r g e s t r e p a i r p l y and subsequent p l i e s on t h e r e p a i r area

with the correct orientation.
19.Bagging and Curing Procedures
A . R e f e r t o t h e bagging and c u r i n g procedure a s g i v e n i n paragraph 8.
NOTE: I f t h e r e p a i r i s i n a n a c o u s t i c a r e a , t h e n cover t h e f u l l d r i l l e d
p a n e l w i t h s u f f i c i e n t OMat 2/126 VACUUM BAG t o p r e v e n t l e a k a g e .
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A. Remove t h e lay-up m a t e r i a l s from t h e r e p a i r .
B. V i s u a l l y i n s p e c t t h e r e p a i r f o r r e s i n - s t a r v e d a r e a s , b l i s t e r s o r excess
r e s i n a r e a s . Remove them i f n e c e s s a r y .
I S FLAMMABLE AND GAS I S DANGEROUS. I T CAN CAUSE IRRITATION OF EYES,
C. Remove a l l unwanted m a t e r i a l s w i t h a s u c t i o n c l e a n e r . Clean t h e s u r f a c e

w i t h OMat 135 MEK and OMat 21101 LINT FREE CLOTH. Dry t h e s u r f a c e b e f o r e
D. Make a v i s u a l i n s p e c t i o n t o make s u r e t h a t t h e r e p a i r h a s b e e n done i n

accordance with t h e s e procedures.
E. Do a n u l t r a s o n i c i n s p e c t i o n t o make s u r e t h a t t h e r e p a i r e d a r e a i s f r e e
from damage. I f n o t , r e f e r t o a l l o w a b l e damage, page b l o c k 101, t o make
s u r e t h e damage i s i n t h e p e r m i t t e d l i m i t s .
F. Apply p r i m e r s e a l e r p a i n t t o t h e r e p a i r a r e a , i f n e c e s s a r y . Refer t o
54-30-00, R e p a i r No.11.
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'APE
!
EXTRA REPAIR
0-5 19-48
(15) (12)
/ .-... . - .
v -----W---
-
REPAIR PLIES
PLIES
PLUG WITH
ADHESIVE
OUTER SKIN
(AIR WASHED SURFACE)
f
l
I
I
l I
m
(D ,....
0)
I>,
0
". ..&
-..:<\y.
ADHESIVE
0
l2 rlBACKUP PLATE
Preparation and Lay-Up of Repair Plies

Figure 201
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FIBERGUSS PLIES
NON POUROUS FIBERGLASS PLIES LAY-UP

PARTING FlLM
HEAT BLANKET
VACUUM BAG BREATHER FABRIC
NON POUROUS
PARTING FlLM
I THERMOCOUPLE 1 FIBERGLASS P~~ROUS

I
VACUUM BAG
SEALANTTAPE
I
NON POUROUS
PLIES PARTING FILM
PARTING FILM BAGGING PROCEDURE
Bagging P r o c e d u r e
F i g u r e 202
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SQUARED SECTION
ROD
g DIMENSIONS ARE IN INCHES BACKUP PLATE INSTALLATION

!- WITH MlLLlMETERS IN PARENTHESES
I n s t a l l a t i o n of Backup Plate
Figure 203
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a STRUCTURAL REPAIR
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REPAIR N0.6
THRUST REVERSER
REPAIR CARBON COMPOSITE SKIN I N SANDWICH AREA
1. G e n e r a l
CAUTION: YOU MUST REFER TO THE ALLOWABLE DAMAGE LIMITS, PAGE BLOCK 101, TO
MAKE SURE THAT REPAIR I S PERMITTED.
NOTE: T h i s r e p a i r p r o c e d u r e i s a p p l i c a b l e i f t h e damage i n t h e i n n e r s k i n i s
more t h a n 30 mm d i a m e t e r . I f t h e damage i s s m a l l e r , r e f e r t o R e p a i r
No.5.
A. T h i s p r o c e d u r e g i v e s i n s t r u c t i o n s t o r e p a i r through-hole damage t o t h e
carbon composite s k i n i n t h e sandwich a r e a . T h i s r e p a i r i s a p p l i c a b l e i f
t h e s k i n h a s a b r o n z e mesh l a y e r .
B. Damage can be r e p a i r e d by:
- i n s t a l l a t i o n o f a f i b e r g l a s s backup p l a t e p l u s carbon p l i e s on t h e i n n e r
side
- i n s t a l l a t i o n of a honeycomb p l u g t o r e p l a c e t h e damaged sandwich a r e a
- a d d i t i o n of wet lay-up c a r b o n r e p a i r p l i e s on t h e o u t e r s k i n .
2. Referenced i n f o r m a t i o n
-- --P
..............................................................................
54-30-00, R e p a i r No.11 Apply P r i m e r S e a l e r P a i n t
Hot a i r b l o w e r 120 deg C (248 deg F) maximum
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S t e e l r o l l e r 5 0 . 8 mm ( 2 i n . ) d i a m e t e r
P o r t a b l e composite r e p a i r console w i t h t h e following f e a t u r e s :
- Vacuum pump t o 8 0 p e r c e n t w i t h vacuum gauge
- Curing c y c l e m o n i t o r i n g and a u t o m a t i c r e p o r t i n g f e a t u r e
- Load power c a p a b i l i t y ( a s a n i n d i c a t i o n ) : 6000 Watts
- Thermocouple
Pneumatic s a n d e r power 0.16 K i l o w a t t s
Squeegee
S t e e l g u i d e s of 254 mm (10 i n . ) minimum l e n g t h
P r o t e c t i v e pads ( 2 o f f )
B. Consumable M a t e r i a l s
..............................................................................
..............................................................................
OMat 21101 LINT FREE CLOTH
OMat 21110A SEALANT TAPE
OMat 21126 VACUUM BAG
OMat 21129 BREATHER CLOTH
OMat 21130 POROUS PARTING FILM
OMat 51121 GARNET PAPER DISC
OMat 81182 FIBERGLASS FABRIC
OMat 81188 METALLIC HONEYCOMB, ACOUSTIC AREA
OMat 8/189 METALLIC HONEYCOMB, STANDARD AREA
OMat 8/192 ADHESIVE
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C. Component m a t e r i a l
..............................................................................
PART IDENT MATERIAL
..............................................................................
Thrust r e v e r s e r carbon composite
4. Examine t h e damage
A. V i s u a l l y examine t h e s k i n t o f i n d t h e t y p e o f damage i n t h e i n n e r s k i n .
B. Do a n u l t r a s o n i c i n s p e c t i o n t o measure t h e damage d i m e n s i o n s . R e f e r t o
a l l o w a b l e damage, p a g e b l o c k 101, t o make s u r e t h a t t h e damage i s i n t h e
repairable l i m i t s .
C. Mark o u t t h e a r e a o f t h e damage.
5. P r e p a r e t h e damaged a r e a f o r r e p a i r (Ref F i g u r e 201)
WARNING: USE YIETHYL ETHYL KETONE I N AN AREA OPEN TO THE AIR. THIS MATERIAL
NOSE, THROAT AN SKIN. HIGH CONCENTRATIONS CAN CAUSE WEAKNESS,
A. Remove a l l l o o s e f i b e r s w i t h OMat 5 / 9 4 ABRASIVE PAPER and c l e a n w i t h a

vacuum c l e a n e r and O M a t 21101 LINT FREE CLOTH soaked w i t h O M a t 135 MEK.
Dry t h e s u r f a c e b e f o r e t h e s o l v e n t e v a p o r a t e s .
CAUTION: THE RATE OF TEMPERATURE INCREASE MUST NOT BE MORE THAN 3 deg c (5
deg F) PER MINUTE.
B. Dry t h e damaged a r e a f o r one hour minimum a t 91 t o 96 deg C (195 t o 205

deg F) w i t h a h o t a i r blower.
C. Measure t h e damage dimension t o t h e i n n e r s k i n . Add 24 mm (0.9 i n . ) more

f o r e a c h damaged p l y o f t h e i n n e r s k i n t o f i n d t h e a r e a t o be trimmed o u t
i n t h e honeycomb a n d o u t e r s k i n .
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D. Trim o u t t h e c a l c u l a t e d c o r e and s k i n d i m e n s i o n s t o a smooth s q u a r e o r

r e c t a n g u l a r s h a p e w i t h rounded c o r n e r s of 12.5 mm (0.5 i n . ) minimum
r a d i u s . During t h e t r i m o u t o p e r a t i o n , r e c o r d t h e number a n d o r i e n t a t i o n
of p l i e s .
NOTE: Take c a r e n o t t o c a u s e damage t o t h e undamaged p l i e s and

surrounding m a t e r i a l .
E. C l e a n t h e a r e a w i t h a vacuum c l e a n e r a n d O M a t 21101 LINT FREE CLOTH soaked

w i t h O M a t 135 MEK. Dry t h e s u r f a c e b e f o r e t h e s o l v e n t e v a p o r a t e s .
F. Mask o f f t h e a r e a around t h e c u t - o u t . Add 12 mm (0.48 i n . ) minimum f o r

e a c h p l y r e p l a c e m e n t p l u s 1 5 mm (0.6 i n . ) f o r t h e e x t r a r e p a i r p l i e s .
G. Lay o u t t h e z o n e s t o s t e p - s a n d , t h e n i n s t a l l t h e s t e e l g u i d e s w i t h O M a t 272
ADHESIVE TAPE
CAUTION: MAKE SURE NOT TO STEP-SAND OVER THE SKIN THICKNESS TO BE SANDED,
H. S t a r t s t e p - s a n d from t h e damage c e n t r e t o t h e o u t e r f a c e u s i n g a s a n d e r
w i t h a n O M a t 51121 GARNET PAPER DISC. Each s t e p dimension i s a minimum o f
1 2 mm (0.48 i n . ) wide a r o u n d t h e cleaned-up damage. Make a smooth
r e c t a n g u l a r o r s q u a r e s h a p e w i t h rounded c o r n e r s of 12.5 mm (0.5 i n . )
minimum r a d i u s .
I. Make t h e o u t e r s k i n rough w i t h O M a t 5 / 9 4 ABRASIVE PAPER t o a d i s t a n c e o f 27

mm (1.06 i n . ) minimum a l l a r o u n d t h e r e p a i r edge ( f o r t h e e x t r a r e p a i r
plies installation).
WARNING: USE METHYL ETHYL KETONE I N AN AREA OPEN TO THE A I R . TEIS MATERIAL
HEADACHE, NAUSEA, DIZZINESS AhD INCORRECT JUDGEMENT.
J. Remove a l l s a n d i n g d u s t w i t h a vacuum c l e a n e r and wipe s u r f a c e s w i t h O M a t

2/101 LINT FREE CLOTH m o i s t e n e d w i t h O M a t 135 METKYL ETHYL KETONE. Wipe
the surface dry before the solvent evaporates.
WARNING: USE OMAT 81180 POUR COAT I N AN AREA OPEN TO THE AIR. CAREFULLY READ
THE APPLICABLE MATERIAL 'SAFETY DATA SHEET' BEFORE YOU USE THIS
ADHESIVE. OBEY ALL SAFETY INSTRUCTIONS.
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K. I f t h e honeycomb i s m e t a l l i c , t h e n a p p l y OMat 81180 POUR COAT w i t h a p a i n t

b r u s h on a l l t h e v i s i b l e s u r f a c e of t h e honeycomb.
NOTE: Unwanted p o u r c o a t must b e removed from t h e honeycomb.
L. A i r d r y t h e honeycomb, t h e n c u r e i t a t 102 t o 113 deg C (215 t o 235 deg F)

f o r 30 m i n u t e s minimum w i t h a h o t a i r blower.
6. P r e p a r e t h e f i b e r g l a s s back-up p l a t e
A. Cut a p i e c e of O M a t 81182 FIBERGLASS FABRIC of s u f f i c i e n t s i z e t o make f i v e

fiberglass plies.
NOTE: F i b e r g l a s s p l i e s must be a t l e a s t 20 mm ( 0 . 8 i n . ) l o n g e r and 10 mm

(0.4 i n . ) w i d e r t h a n t h e damage dimensions.
B. Cut two p i e c e s o f O M a t 21131 NON-POROUS PARTING FILM e a c h a p p r o x i m a t e l y 8 0

mm ( 3 i n . ) l a r g e r , a l l around, t h a n t h e f i b e r g l a s s f a b r i c .
D. Mix t h e O M a t 81160 EPOXY ADHESIVE p a r t s A and B i n a c c o r d a n c e w i t h

manufacturers i n s t r u c t i o n s t o g e t a s u f f i c i e n t quantity.
E. Weigh t h e O m a t 81182 FIBERGLASS FABRIC and p r e p a r e a q u a n t i t y o f OMat 81160

EPOXY ADHESIVE o f e q u a l weight.
F. Lay t h e f i b e r g l a s s f a b r i c o n t o t h e non-porous p a r t i n g f i l m . Apply e v e n l y

t h e s e l e c t e d q u a n t i t y of a d h e s i v e o n t o t h e f i b e r g l a s s f a b r i c u s i n g a
spatula.
G.Put t h e second non-porous p a r t i n g f i l m on t h e f i b e r g l a s s f a b r i c . Then u s e a

r o l l e r t o work t h e a d h e s i v e t h r o u g h t h e f i b e r g l a s s f a b r i c t o impregnate i t
a n d remove e n t r a p p e d a i r .
H. U s e a c u t t e r t o c u t 5 p i e c e s of t h e f i b e r g l a s s f a b r i c 20 mm (0.8 i n . )
l a r g e r , a l l a r o u n d , t h a n t h e damage ( o r 10 mm (0.4 i n . ) minimum i f a c c e s s
is small).
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7. Lay-up of t h e f i b e r g l a s s f a b r i c p l i e s (Ref Figure 204)
A. Cut a p i e c e of OMat 21131 NON-POROUS PARTING FILM 10 mm (0.4 i n . ) l a r g e r ,

a l l round, t h a n t h e f i b e r g l a s s f a b r i c p l i e s .
B. Remove t h e non-porous p a r t i n g f i l m from one s i d e of t h e f i r s t f i b e r g l a s s

f a b r i c p l y . Put t h e p l y on t h e l a r g e r non-porous p a r t i n g f i l m c u t i n s t e p
A.
C. Use a r o l l e r t o remove any w r i n k l e s and entrapped a i r .
NOTE: To p r e v e n t a d h e s i v e d e f i c i e n c y , do n o t apply t o o much p r e s s u r e .
D. Remove t h e non-porous p a r t i n g f i l m from t h e f i r s t f i b e r g l a s s f a b r i c p l y .

P u t a second f i b e r g l a s s f a b r i c p l y o n t o t h e f i r s t oce.
E. P u t t h e remaining p l i e s i n p o s i t i o n as g i v e n i n s t e p s B t o D.
NOTE: Remove t h e l a s t non-porous p a r t i n g f i l m from t h e l a s t f i b e r g l a s s p l y

b e f o r e bagging and c u r i n g p r o c e d u r e .
8. Bagging and c u r i n g p r o c e d u r e (Ref F i g u r e 204)
A. I n s t a l l t h e thermocouples a d j a c e n t t o t h e f i b e r g l a s s p l i e s .
B. Cut a p i e c e of OMat 21130 POROUS PARTING FILM w i t h 80 mm (3 i n . ) o v e r l a p

around t h e edges and l a y i t o v e r t h e OMat 81182 FIBERGLASS FABRIC.
C. Overlay w i t h a p i e c e of OMat 21131 NON-POROUS PARTING FILM c u t t o t h e same

dimensions.
D. P u t a l a y e r of OMat 2/129 BREATHER CLOTH and a h e a t b l a n k e t on t h e r e p a i r

area.
E. P u t OMat 2/ilOA SEALANT TAPE around t h e f u l l a r e a , Then, c u t a s u i t a b l e

p i e c e of O M a t 21126 VACUUM BAG and b a g o v e r t h e f i b e r g l a s s f a b r i c p l i e s .
F. Evacuate t h e lay-up t o a vacuum of 0.7 b a r i n s i d e t h e bag.
NOTE: Keep a vacuum of 0.7 b a r i n s i d e t h e bag f o r t h e f u l l time of c u r e .
3 deg C (5 deg F) PER MINUTE.
G. Cure i n two s t a g e s , t h e f i r s t one f o r 60 t o 70 minutes a t 55 t o 65 deg C

deg C (239 t o 257 deg F.)
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H. Remove t h e lay-up m a t e r i a l s from t h e O M a t 81182 FIBERGLASS FABRIC p l i e s .

Trim them i n t o a s q u a r e o r a r e c t a n g l e w i t h 10 mm (0.4 i n . ) minimum c o r n e r
r a d i u s t o make t h e backup p l a t e .
A. C l e a n t h e f i b e r g l a s s backup p l a t e w i t h O M a t 135 MEK. Wipe t h e s u r f a c e d r y

before t h e s o l v e n t evaporates.
B. Make a v i s u a l i n s p e c t i o n t o make s u r e t h a t t h e backup p l a t e h a s been made

i n accordance w i t h t h e s e procedures.
1 0 . I n s t a l l t h e backup p l a t e (Ref F i g u r e 202)
A. D r i l l two p a i r s o f h o l e s n e a r t h e c e n t r e l i n e of t h e backup p l a t e . Use a 1

mm (0.04 i n . ) d r i l l b i t .
B. With O M a t 5/94 ABRASIVE PAPER, a b r a d e t h e s u r f a c e o f t h e backup p l a t e and

t h e i n n e r s i d e o f t h e damaged s k i n ( i f p o s s i b l e ) f o r a d i s t a n c e of 20 mm
(0.8 i n . ) from t h e c u t - o u t edge.
C. Draw t h e c o n t o u r o f t h e cut-out i n t h e m i d d l e of t h e backup p l a t e t o be

installed .
I S FLAMMABLE AhTD GAS I S DANGEROUS. I T CAN CAUSE IRRITATION OF EYES,
D. C l e a n t h e r e p a i r a r e a and t h e backup p l a t e w i t h a vacuum c l e a n e r and O M a t

21101 LINT FREE CLOTH soaked w i t h O M a t 135 MEK. Dry t h e s u r f a c e b e f o r e t h e
solvent evaporates.
E. P u t a l o o p of t h e l o c k w i r e through t h e h o l e s i n t h e backup p l a t e . Loosely

t w i s t e a c h l o o p o f t h e l o c k w i r e one t u r n .
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F. Mix t h e O M a t 81192 ADHESIVE p a r t s A and B i n a c c o r d a n c e w i t h t h e

NOTE: P o t l i f e o f m i x t u r e i s 8 h o u r s a t 20 deg C (68 deg F) minimum.
G. Apply s u f f i c i e n t O M a t 81192 ADHESIVE a l l around t h e backup p l a t e and t h e

i n n e r s i d e of t h e s k i n .
H. P u t t h e back-up p l a t e t h r o u g h t h e c u t - o u t . A d j u s t t h e backup p l a t e w i t h
t h e drawn c o n t o u r .
I. P u t a s q u a r e d s e c t i o n r o d through t h e l o c k w i r e l o o p s , a c r o s s t h e r e p a i r
c u t - o u t and on t h e p r o t e c t i o n pads.
J. T w i s t t h e l o c k w i r e a r o u n d t h e s q u a r e d s e c t i o n rod s o t h a t t h e backup p l a t e
i s t i g h t l y p u l l e d a g a i n s t t h e i n n e r s i d e of t h e s k i n .
3 deg C ( 5 deg F) PER MINUTE.
K. I n s t a l l t h e thermocouple a d j a c e n t t o t h e r e p a i r a r e a . Cure t h e a d h e s i v e
f o r 7 h o u r s a t 25 deg C (77 deg F) minimum p l u s 2 h o u r s a t 91 t o 96 deg C
(195 t o 205 deg F ) .
L. Remove t h e l o c k w i r e , t h e r o d and t h e p r o t e c t i v e pads.
M. F i l l t h e h o l e s i n t h e backup p l a t e , and one l a y e r as t h i c k as t h e i n n e r

s k i n p l y , w i t h O M a t 81192 ADHESIVE.
N. I n s t a l l t h e thermocouples a d j a c e n t t o t h e r e p a i r a r e a . Cure t h e a d h e s i v e
(195 t o 205 deg F) w i t h a h e a t b l a n k e t .
P. Remove t h e h e a t b l a n k e t a n d smooth a b r a d e t h e unwanted s e a l a n t . Clean t h e

a r e a w i t h a vacuum c l e a n e r and O M a t 21101 LINT FREE CLOTH soaked w i t h O M a t
135 MEK. Wipe t h e s u r f a c e d r y b e f o r e t h i s s o l v e n t e v a p o r a t e s .
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1 1 . P r e p a r e t h e i n t e r n a l r e p a i r p l i e s (Ref F i g u r e 201)
A . Find t h e number and o r i e n t a t i o n of t h e c a r b o n p l i e s n e c e s s a r y , a c c o r d i n g t o

t h e o r i g i n a l s t r u c t u r e of t h e s k i n .
NOTE: F o r e a c h damaged c a r b o n p l y o f t h e o r i g i n a l , u s e one O M a t 8 / 1 8 3

CARBON FABRIC p l y . Each r e p a i r p l y must be 12 mm (0.48 i n . ) l a r g e r
a l l round t h a n t h e o n e b e f o r e .
B. Make a t r a c i n g t o g i v e t h e s h a p e and d i m e n s i o n s of t h e c a r b o n p l i e s .
C. Find t h e s h a p e o f t h e c a r b o n f a b r i c r e p a i r p l i e s from t h e t r a c i n g s made i n

s t e p B, t h e n c u t t h e carbon f a b r i c i n a c c o r d a n c e w i t h t h e t r a c i n g . Cut two
p i e c e s o f O M a t 21131 NON-POROUS PARTING FILM e a c h a p p r o x i m a t e l y 8 0 mm ( 3
i n . ) l a r g e r , a l l round, t h a n t h e OMat 81183 CARBON FABRIC REPAIR p l y . Tape
down one non-porous p a r t i n g f i l m on a smooth s u r f a c e .
NOTE: Add s u f f i c i e n t margin t o p e r m i t f u r t h e r a d j u s t m e n t .
D. Mix t h e O M a t 81160 ADHESIVE p a r t s A a n d p a r t B i n a c c o r d a n c e w i t h t h e

manufacturers i n s t r u c t i o n s t o g e t s u f f i c i e n t adhesive.
E. Weigh t h e O M a t 81183 CARBON FABRIC and p r e p a r e a q u a n t i t y o f O M a t 81160

EPOXY ADHESIVE of e q u a l w e i g h t .
F. Lay t h e c a r b o n f a b r i c o n t o t h e non-porous p a r t i n g f i l m . Apply e v e n l y t h e

s e l e c t e d q u a n t i t y of a d h e s i v e o n t o t h e c a r b o n f a b r i c u s i n g a s p a t u l a .
G. P u t t h e second non-porous p a r t i n g f i l m on t h e carbon f a b r i c p l y . Then, u s e

a r o l l e r t o work t h e a d h e s i v e through t h e p l y t o i m p r e g n a t e i t and remove
entrapped air.
H. Use a c u t t e r t o c u t t h e n e c e s s a r y number of c a r b o n f a b r i c r e p a i r p l i e s i n
a c c o r d a n c e w i t h t r a c i n g done i n s t e p l l . B .
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12.Lay up t h e carbon i n n e r p l i e s
A. Cut a p i e c e of O M a t 21131 NON-POROUS PARTING FILM 10 mm (0.4 i n . ) l a r g e r ,

a l l round, t h a n o n e c a r b o n f a b r i c r e p a i r p l y .
B. Remove t h e non-porous p a r t i n g f i l m from one s i d e of t h e c a r b o n f a b r i c

r e p a i r p l y . P u t i t on t h e l a r g e r non-porous p a r t i n g f i l m c u t i n s t e p A.
C . Use a r o l l e r t o remove any w r i n k l e s and e n t r a p p e d a i r .
NOTE: To p r e v e n t a n a d h e s i v e d e f i c i e n c y , do n o t a p p l y t o o much p r e s s u r e .
D. Remove t h e non-porous p a r t i n g f i l m from t h e f i r s t r e p a i r p l y , t h e n p u t a

second carbon f a b r i c r e p a i r p l y o n t o t h e f i r s t one.
E. P u t t h e r e m a i n i n g r e p a i r p l i e s i n p o s i t i o n as g i v e n i n s t e p s B t o D.
NOTE: Remove t h e l a s t non-porous p a r t i n g f i l m from t h e l a s t c a r b o n f a b r i c

p l y b e f o r e b a g g i n g and c u r i n g p r o c e d u r e .
13.Bagging and c u r i n g p r o c e d u r e (Ref F i g u r e 203)
A. R e f e r t o p a r a g r a p h 8 f o r t h e p r o c e d u r e .
1 4 . F i l l up t h e i n t e r n a l r e p a i r p l i e s (Ref F i g u r e 201)
A. Mix t h e O M a t 81192 ADHESIVE p a r t s A and B i n a c c o r d a n c e w i t h t h e

manufacturers i n s t r u c t i o n s t o g e t s u f f i c i e n t adhesive.
NOTE: P o t l i f e o f t h e m i x t u r e i s 8 h o u r s a t 20 deg C (68 d e g F) minimum.
B. Apply s u f f i c i e n t a d h e s i v e a l l around t h e i n t e r n a l r e p a i r p l i e s . Make t h e

adhesive l e v e l f l u s h w i t h t h e l a s t carbon r e p a i r ply.
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C. I n s t a l l t h e thermocouples a d j a c e n t t o t h e r e p a i r a r e a . Cure t h e a d h e s i v e
(195 t o 205 deg F) w i t h a h e a t b l a n k e t .
D. Abrade t h e a d h e s i v e t o make i t l e v e l .
15.Prepare t h e f i b e r g l a s s p l y ( i f necessary)
A. Cut two p i e c e s of O M a t 81182 FIBERGLASS FABRIC o f t h e same d i m e n s i o n s a s

t h e r e p a i r honeycomb p l u g .
NOTE: The second f i b e r g l a s s f a b r i c w i l l be w e t t e d - o u t and i n s t a l l e d when

t h e honeycomb p l u g i s i n s t a l l e d .
B. Cut two p i e c e s of O M a t 21131 NON-POROUS PARTING FILM e a c h a p p r o x i m a t e l y 80

mm ( 3 i n . ) l a r g e r , a l l a r o u n d , t h a n t h e f i b e r g l a s s f a b r i c .
C. Tape down o n e non-porous p a r t i n g f i l m on a f l a t and smooth s u r f a c e .
WARNING: USE OMAT USE OMAT 81160 ADHESIVE I N AN AREA OPEN TO THE AIR.
CAREFULLY READ THE APPLICABLE 'MATERIAL SAFETY DATA SHEET' BEFORE
YOU USE THIS ADHESIVE. OBEY ALL SAFETY AND HEALTH PRECAUTIONS.
D. Mix t h e O M a t 81160 EPOXY ADHESIVE p a r t s A and B i n a c c o r d a n c e w i t h t h e

manufacturers instructions t o g e t s u f f i c i e n t adhesive.
E. Weigh t h e O M a t 81182 FIBERGLASS FABRIC and p r e p a r e a q u a n t i t y o f O M a t 81160

EPOXY ADHESIVE o f e q u a l w e i g h t .
F. Lay t h e f i b e r g l a s s f a b r i c o n t o t h e non-porous p a r t i n g f i l m . Apply e v e n l y

t h e prepared q u a n t i t y of adhesive onto t h e f i b e r g l a s s f a b r i c u s i n g a
spatula.
G. P u t t h e s e c o n d non-porous p a r t i n g f i l m on t h e f i b e r g l a s s f a b r i c . Then u s e
a r o l l e r t o work t h e a d h e s i v e t h r o u g h t h e f i b e r g l a s s f a b r i c t o i m p r e g n a t e
i t a n d remove e n t r a p p e d a i r .
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16.Lav-UD t h e f i b e r g l a s s ~ l v
A. Remove t h e non-porous p a r t i n g f i l m from one s i d e of t h e f i b e r g l a s s f a b r i c

P ~ Y
B. P u t t h e f i b e r g l a s s p l y on t h e c a r b o n r e p a i r p l i e s i n s t a l l e d . Use a r o l l e r
t o remove any w r i n k l e s and e n t r a p p e d a i r .
NOTE: To p r e v e n t r e s i n d e f i c i e n c y , do n o t a p p l y t o o much p r e s s u r e .
C. Remove t h e non-porous p a r t i n g f i l m from t h e f i b e r g l a s s f a b r i c p l y

installed.
1 7 . P r e p a r e t h e p l u g (Ref F i g u r e 201)
A. Find t h e t y p e of t h e honeycomb p l u g from t h e o r i g i n a l honeycomb, t h e

consumable m a t e r i a l s t a b l e and page b l o c k 001.
B. Find t h e w i d t h , l e n g t h and h e i g h t o f t h e p l u g a c c o r d i n g t o t h e damaged

honeycomb and t h e carbon p l i e s t h i c k n e s s i n s t a l l e d .
NOTE: The replacement honeycomb p l u g must o v e r l a p and make f u l l c o n t a c t

w i t h t h e c e l l w a l l s of t h e a d j a c e n t c o r e m a t e r i a l .
C. Find t h e r i b b o n d i r e c t i o n c f t h e p l u g from page b l o c k 001.
D. Mark t h e r i b b o n d i r e c t i o n on t h e p l u g and on t h e a r e a t o b e r e p a i r e d .
I S FLAMMABLE AND GAS IS DANGEROUS. IT CAN CAUSE IRRITATION OF EYES,
HEADACHE, NAUSEA, DIZZINESS Ah?) INCORRECT JUDGEMENT.
CAUTION: DO NOT CLEAN THE PLUG WITH OMAT 135 MEK I F THE PLUG I S NOT METALLIC.
E. Clean t h e p l u g i n an OMat 135 MEK b a t h f o r 60 s e c o n d s , o r v a p o u r d e g r e a s e

f o r a maximum of 4 c y c l e s , 30 s e c o n d s p e r c y c l e .
F. Dry t h e p l u g w i t h O M a t 2/101 LINT FREE CLOTH
NOTE: The p l u g must be f u l l y d r y , c l e a n and f r e e o f s o l v e n t s b e f o r e

installation.
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STRUCTURAL REPAIR
MANUAL
18.Apply t h e a d h e s i v e
CONTAINER. I F YOU MIX MORE THAN 450 G ( 1 LB) I N A CONTAINER AN
A. Mix a q u a n t i t y of O M a t 81192 ADHESIVE i n accordance w i t h t h e m a n u f a c t u r e r s

instructions.
NOTE: P o t l i f e of m i x t u r e i s 8 h o u r s a t 20 deg C (68 deg F) minimum.
B. P u t t h e honeycombe p l u g on a p i e c e of non-porous p a r t i n g f i l m , t h e n f i l l i t
w i t h a d h e s i v e t o a p p r o x i m a t e l y 5 mm (0.2 i n . ) depth. Make s u r e t h e r e i s no
adhesive leakage.
C. I n s t a l l t h e thermocouples a d j a c e n t t o t h e r e p a i r a r e a . Cure t h e a d h e s i v e
f o r 7 h o u r s a t 25 deg C ( 7 7 deg F) minimum p l u s 2 h o u r s a t 9 1 t o 96 deg C
(195 t o 205 deg F) w i t h a h o t a i r blower.
1 9 . I n s t a l l t h e p l u g (Ref F i g u r e 201)
A. Put t h e p l u g i n t o t h e r e p a i r cut-out w i t h t h e c o r r e c t ribbon d i r e c t i o n .
B. I n s t a l l t h e second OMat 81182 FIBERGLASS FABRIC o n t o t h e honeycomb p l u g .

R e f e r t o t h e p a r a g r a p h s 15 and 16.
C. F i l l t h e s p a c e between t h e p l u g and t h e o r i g i n a l c o r e w i t h O M a t 81192

ADHESIVE. Use a c l e a n s p a t u l a t o make t h e a d h e s i v e l e v e l w i t h t h e d e e p e s t
p l y of t h e s k i n c u t - o u t .
20.Bagging and c u r i n g p r o c e d u r e s
A. R e f e r t o t h e bagging p r o c e d u r e as g i v e n i n p a r a g r a p h 8 .
B. Evacuate t h e lay-up t o a vacuum o f 0.7 b a r i n s i d e t h e bag.
NOTE: I f t h e r e p a i r i s i n a n a c o u s t i c a r e a , cover t h e f u l l d r i l l e d panel

w i t h s u f f i c i e n t OMat 21126 VACUUM BAG t o p r e v e n t l e a k a g e .
REPAIR N0.6
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STRUCTURAL REPAIR
MANUAL
C. Cure t h e a d h e s i v e f o r 7 hours a t 25 deg C (77 deg F ) , minimum, p l u s two

hours a t 91 t o 96 deg C (195 t o 205 deg F) w i t h a h e a t b l a n k e t .
D. Remove a l l lay-up m a t e r i a l s , t h e n a b r a d e t o g e t a smooth r e p a i r s u r f a c e .
21.Prepare t h e e x t e r n a l r e p a i r p l i e s (Ref Figure 201)
CAUTION: EACH PAIR OF REPAIR PLIES MUST BE SAME ORIENTATION AS THE ORIGINAL
PLY BELOW.
A. Find t h e number and o r i e n t a t i o n o f t h e r e p a i r p l i e s n e c e s s a r y , a c c o r d i n g t o

t h e o r i g i n a l s t r u c t u r e of t h e o u t e r s k i n .
NOTE: Use two O M a t 81183 CARBON FABRIC r e p a i r p l i e s f o r each damaged

carbon p l y o f t h e o r i g i n a l l a m i n a t e . Use two e x t r a carbon r e p a i r
p l i e s f o r the outer surface.
B. Make a t r a c i n g of t h e step-sand t o g i v e t h e shape o f t h e r e p a i r p l i e s . Cut

t h e OMat 8/183 CARBON FABRIC i n accordance w i t h t h e t r a c i n g . Cut two
p i e c e s of OMat 21131 non-porous p a r t i n g f i l m each approximately 80 mm (3
i n . ) l a r g e r , a l l round, t h a n t h e carbon r e p a i r p l i e s . Tape down one
non-porous p a r t i n g f i l m on a smooth s u r f a c e .
NOTE: Add s u f f i c i e n t margin f o r f u r t h e r a d j u s t m e n t .
WARNING: DO NOT PUT MORE THAN 250 G (55 LB) OF OMAT 81160 ADHESIVE I N ONE
CONTAINER. I F YOU MIX MORE THAN 250 G (0.55 LB) I N A CONTAINER AN
WARNING: USE OMAT 8/160 ADHESIVE I N AN AREA OPEN TO THE A I R . CAREFULLY READ
ADHESIVE. OBEY ALL SAFETY AND HEALTH INSTRUCTIONS.
D. Mix t h e OMat 81160 EPOXY ADHESIVE p a r t s A and p a r t B i n accordance w i t h t h e

E. Weigh t h e OMat 81183 CARBON FABRIC and p r e p a r e a q u a n t i t y of OMat 81160

EPOXY ADHESIVE of e q u a l weight.
REPAIR NO. 6
EFFECTIVITY: TRENT
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21a STRUCTURAL REPAIR
MANUAL
F. Lay carbon f a b r i c o n t o t h e non-porous p a r t i n g f i l m . Apply e v e n l y t h e

s e l e c t e d q u a n t i t y o f adhesive u s i n g a s p a t u l a .
G. P u t t h e second non-porous p a r t i n g f i l m on t h e carbon f a b r i c p l y . Then use

a r o l l e r t o work t h e adhesive through t h e carbon f a b r i c p l y t o impregnate
i t and remove e n t r a p p e d a i r .
H. Use a c u t t e r t o c u t o u t t h e n e c e s s a r y number of carbon f a b r i c r e p a i r p l i e s

i n accordance w i t h s t e p B.
22.Lay up of r e p a i r p l i e s (Ref F i g u r e 201)
A. Remove t h e non-porous p a r t i n g f i l m fron; one s i d e of t h e smallest r e p a i r

p l y . P u t t h e exposed f a c e of t h e p l y a g a i n s t t h e r e p a i r a r e a w i t h t h e same
o r i e n t a t i o n a s t h e o r i g i n a l p l y below.
B. Trim t h e carbon f a b r i c r e p a i r p l y edges t o f i t t h e c u t - o u t w i t h o u t

clearance.
C. User a r o l l e r and squeegee t o remove any w r i n k l e s and e n t r a p p e d a i r .
NOTE: To p r e v e n t a d h e s i v e d e f i c i e n c y , do n o t a p p l y t o o much p r e s s u r e .
D. Remove t h e non-porous p a r t i n g f i l m from t h e carbon f a b r i c p l y i n s t a l l e d ,

t h e n i n s t a l l t h e second carbon f a b r i c p l y w i t h t h e same o r i e n t a t i o n .
E. P u t t h e n e x t l a r g e s t r e p a i r p l y and subsequent p l i e s on t h e r e p a i r a r e a
with the correct orientation.
.Bagging and Curing p r o c e d u r e s
A . R e f e r t o t h e bagging and c u r i n g procedure a s g i v e n i n p a r a g r a p h 8 .
NOTE: I f t h e r e p a i r i s i n an a c o u s t i c a r e a , t h e n c o v e r t h e f u l l d r i l l e d
p a n e l w i t h s u f f i c i e n t OMat 2/126 VACUUM BAG t o p r e v e n t l e a k a g e .
A . Remove t h e l a y up m a t e r i a l s from t h e r e p a i r .
B. V i s u a l l y i n s p e c t t h e r e p a i r f o r r e s i n s t a r v e d a r e a s , b l i s t e r s o r e x c e s s
r e s i n a r e a s . Remove them i f n e c e s s a r y .
REPAIR N0.6
EFFECTIVITY: TRENT
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1m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
C. Remove all unwanted materials with a suction cleaner. Clean the surface
with OMat 135 MEK and OMat 21101 LINT FREE CLOTH. Dry the surface before
D. Make a visual inspection to make sure that the repair has been done in
E. Do an ultrasonic inspection to make sure that the repaired area is free

from damage. If not, refer to allowable damage, page block 101, to make
sure the damage is in the permitted limits.
F. Apply primer sealer paint to the repair area, if necessary. Refer to

54-30-00, Repair No.11.
REPAIR N0.6
EFFECTIVITY: TRENT
Page 216
July 1/98
mm
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
CARBON PLY
ORIENTATION
OPERATION
ADHESIVE
REPAIRPLIES
GLASS PLY ADHESIVE
OUTER SKIN
(AIR WASHED SURFAC
POUR COAT
8
/014) (12) (12)

' /
...........
7
--BACKUP PLATE
a
8 NOTE : INSTALL GLASS PLY IF HONEY COMB
P IS METALLIC ONLY
P r e p a r a t i o n and Lay-Up o f R e p a i r P l i e s
F i g u r e 201
REPAIR N0.6
EFFECTIVITY: TRENT
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J u l y 1/98
RB.211 TRENT
m STRUCTURAL REPAIR
MANUAL
SQUARED SECTION
ROD
DIMENSIONS ARE IN INCHES BACKUP PLATE lNSTALLATlON

WITH MILLIMETERS IN PARENTHESES
Installation of Backup Plate

Figure 202
REPAIR N0.6
EFFECTIVITY: TRENT
Page 218
July 1/98
1
-a
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
VACUUM BAG
'> CARBON
COMPOSITE
POROUS'PARTING
FILM - I
NON POROUS
BREATHER
FABRIC
BAGGING OPERATION
-2 to 3" Clmin
I
I
I
I
.-
(d
0
b 150 min/l60 min
TIME
U
W
0
0
70 min
0
CURING CYCLE
l2
Bagging O p e r a t i o n and Curing Cycle
F i g u r e 203
REPAIR N0.6
EFFECTIVITY: TRENT
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1 RB.211 TRENT
MANUAL
FIBERGLASS PLIES

PARTING FILM
HEAT BLANKET
NON POUROUS
PARTING FILM
THERMOCOUPLE FIBERGLASS POUROUS

PLIES PARTING FILM
VACUUM BAG
SEALANT TAPE NON POUROUS
PARTING FlLM BAGGING PROCEDURE
Lay-Up o f F i b e r g l a s s P l i e s
F i g u r e 204
R E P A I R N0.6
EFFECTIVITY: TRENT
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J
3
STRUCTURAL REPAIR
MANUAL
REPAIR N0.7
THRUST REVERSER
REPAIR OF EDGE THROUGH-DAMAGE IN CARBON COMPOSITE SKIN
1. General
A. This procedure gives instructions to repair the damaged edge of

carbon composite skin in a monolithic area.
B. To do this repair, you must have access to each side of the
skin.
CAUTION: IT IS NOT PERMITTED TO OVERLAP CARBON REPAIR PATCHES
C. The procedure gives the wet lay-up of carbon fabric repair

plies onto the skin.
........................................................................
........................................................................
54-30-00 Repair No.11 Apply Primer Paint Coat
TASK 78-33-13-300-XXX FRSX051 Trent Engine Manual
Vacuum cleaner
Hot air blower, 100 deg C (212 deg F) maximum
Steel roller,50mm (2in) diameter
Steel guides, 250mm (loin) long
Portable composite repair console with:
-Heat blanket,O-120 deg C (32-250 deg F)
-Vacuum pump to 80 percent, with gage
-Cure cycle monitoring and reporting feature
-Load power indication 6kW
-Thermocouples
Pneumatic sander,O.l6kW
REPAIR N0.7
Page 201
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
--c---------------------------------------------------------------------
........................................................................
OMat 272 ADHESIVE (MASKING) TAPE
OMat 2/110~ SEALANT TAPE
OMat 5/94 GARNET PAPER,Grit Size 150
OMat 5/121 ABRASIVE DISC,60 Grade
OMAT 8/192 PASTE ADHESIVE
........................................................................
PART IDENT MATERIAL
- - - - - C - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Thrust reverser Carbon composite
4. Examine the damaqe
A. Do an ultrasonic inspection to measure the dimensions of the

damage. Refer to page block 101 to make sure that the damage is
in the repairable limits.
B. Mark out the area of damage.
5. Prepare the damased area for r e ~ a i r (Ref Figure 201)
WARNING: YOU MUST USE GLOVES,DUST MASK AND SAFETY GOGGLES TO

PROTECT YOU AGAINST DUST AND LOOSE PARTICLES WHICH CAN BE

CORRECTLY. BEFORE YOU USE THIS PRODUCT,CAREFULLY READ THE
APPLICABLE MATERIAL SAFETY DATA SHEET AND OBEY ALL THE
A. Remove all loose fibers with OMat 5/94 GARNET PAPER and the
vacuum cleaner. Clean the repair surface with OMat 2/101
LINT-FREE CLOTH soaked with OMat 135 MEK. Dry the surface with
a fresh piece of the cloth before the MEK evaporates.
REPAIR NO. 7
Page 202
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
CAUTION: THE RATE OF TEMPERATURE INCREASE MUST NOT BE MORE THAN

B. Dry the damaged area for 30 minutes minimum at 91 to 96 deg C

(195 to 205 deg F) with the hot air blower.
C. With the pneumatic sander, trim out the damaged area to a
smooth rectangular or square shape with rounded corners of
12,5mm (0.5in) minimum. Make a record of the number and the
orientation of the plies.
NOTE: Take care not to cause damage to the undamaged plies and
adjacent material.

CORRECTLY. BEFORE YOU USE THIS PRODUCT, CAREFULLY READ
D. Remove all loose material with a vacuum cleaner. Clean the

repair surface with OMat 135 MEK and OMat 2/101 LINT-FREE
CLOTH. Dry the surface with a fresh piece of the cloth before
the MEK evaporates.
E. Mask off the area around the cut out. Add 12mm (0.48in) for
each replacement ply and 15mm (0.60in) for the extra repair
plies.
F. Lay out the zones to step-sand, then install the steel guides
in position with OMat 272 ADHESIVE TAPE.
CAUTION: MAKE SURE YOU DO NOT STEP-SAND OVER THE SKIN THICKNESS TO
BE SANDED. STOP WHEN YOU SEE A DIFFERENT PLY ORIENTATION.
G. Start to step-sand from the damage center to the outer face.

Use the pneumatic sander with an OMat 5/121 ABRASIVE DISC. Each
step dimension must be a minimum of 1 2 m (0.48in) wide around
the cleaned-up damage. Make a smooth rectangular or square
shape with minimum corner radii of 12,5mm (0.50i.n).
H. Remove the adhesive tape and the steel guides.
J. Make the outer skin rough with OMat 5/94 ABRASIVE PAPER for a
distance of 15mm (0.60in) all around the repair edge (for the
extra repair plies installation).

CORRECTLY. BEFORE YOU USE THIS PRODUCT,CAREFULLY READ THE
SPECIFIED SAFETY PRECAUTIONS.
EFFECTIVITY: TRENT
REPAIR NO. 7
Page 203
H
"" RB211 TRENT
MANUAL
STRUCTURAL REPAlR
K. Remove all sanding dust with the vacuum cleaner. Clean the
repair surface with OMat 2/101 LINT-FREE CLOTH soaked with
OMat 135 MEK. Dry the surface with a fresh piece of the cloth
6. Install the back-up plate (Ref Figure 201)
A. Cut a piece of OMat 2/131 NON-POROUS PARTING FILM that is 50mm

(2.0in) larger'on three sides'than the repair area and 25mm
(1.Oin) larger on the remaining side.
B. Cut a piece of 2mm (0.08in) thick metal sheet to the same

dimensions as the non-porous parting film. Bend the sheet to
suit the contour of the repair surface. This sheet is the back-
up plate.
C. Use metal clamps to install the back-up plate and the parting
film below the repair area.
D. Use OMat 272 ADHESIVE TAPE to install the steel rule on the
parting film.
7. Fill the skin
WARNING: DO NOT PUT MORE THAN 450 G (1 LB) OF OMAT 8/192 ADHESIVE
IN ONE CONTA1NER.IF YOU DO'AN UNCONTROLLED HEAT BUILD-UP
WILL OCCUR AND POISONOUS FUMES WILL BE MADE.
WARNING: OMAT 8/192 ADHESIVE IS CLASSIFIED AS A HAZARDOUS PRODUCT

THAT CAN CAUSE INJURY OR ILLNESS IF NOT USED CORRECTLY.
BEFORE YOU USE THIS PRODUCT'CAREFULLY READ THE APPLICABLE
A. Mix the two- part OMat 8/192 ADHESIVE in accordance with the
B. Fill the skin with the adhesive to the depth of the first ply.
C. Cure the adhesive for a minimum of 2 hours at 91 to 96 deg C

REPAIR N0.7
Page 204
P r i n t e d in G r e a t B r i t a i n July 1/99
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
8. Preware the carbon repair wlies (Re£ Figure 201)
A. Find the number,type and orientation of the carbon repair plies

according to the original structure (refer to page block 001).
NOTE: Use two OMat 8/183 CARBON FABRIC repair plies for each
damaged carbon ply of the original 1aminate.Use two extra
carbon repair plies for the outer surface.
B. Make a tracing of each step-sand to find the dimensions and

shape of the repair plies.
C. Cut the OMat 8/183 CARBON FABRIC repair plies in accordance

with the tracings made in step B.
D. Cut two pieces of OMat 2/131 NON-POROUS PARTING FILM, each a

minimum of 7 5 m (3in) larger all round than the repair plies.
E. Tape down one piece of the parting film to a flat, smooth

surface.
F. Weigh the carbon fabric repair ply to find the necessary

quantity of epoxy adhesive.
G. Put the carbon repair ply flat on the non-porous parting film.
WARNING: DO NOT PUT MORE THAN 250 G (0.55 LB) OF OMAT 8/160
ADHESIVE IN ONE CONTAINERmIF YOU DO,AN UNCONTROLLED HEAT
BUILD-UP WILL OCCUR AND POISONOUS FUMES WILL BE MADE.
WARNING: OMAT 8/160 EPOXY ADHESIVE IS CLASSIFIED AS A HAZARDOUS

PRODUCT THAT CAN CAUSE INJURY OR ILLNESS IF NOT USED
CORRECTLY.BEFORE YOU USE THIS PRODUCT,CAREFULLY READ THE
H. Mix the OMat 8/160 EPOXY ADHESIVE in accordance with the

J. Select a quantity of the adhesive equal in weight to the carbon

fabric repair ply.Use a spatula to apply the adhesive to the
fabric.
K. Put the second piece of parting film onto the carbon fabric
repair ply.Use a roller to work the adhesive through the ply
and remove entrapped air.
REPAIR N0.7
Page 205
July 1/99
l@
"" RB211 TRENT
MANUAL
STRUCTURAL REPAIR
L. Do steps C thru K again to cut and prepare the necessary number

of carbon fabric repair plies.
9. Lav-up the repair lies (Ref Figure 201)

CAUTION: EACH PAIR OF REPAIR PLIES MUST BE IN THE SAME ORIENTATION
AS THE ORIGINAL PLY BELOW.
A. Remove the parting film from one side of the smallest repair
ply. Put the exposed side against the repair surface in the
same orientation as the original ply below.
B. Trim the repair ply to fit the cut-out without clearance.
C. Use a roller and squeegee to remove wrinkles and entrapped air.

To prevent adhesive deficiency,do not apply too much pressure.
D. Remove the parting film from the top of the first and the
bottom of the second repair ply.
E. Put the second repair ply onto the first with the same
orientation.Use the roller to remove wrinkles and trapped air.
F. Do steps A thru E again for the next and subsequent pairs of

repair plies.
10. Baqains ~rocedure (Ref Figure 202)
A. Install thermocouples adjacent to the repair plies.
B. Cut a piece of OMat 2/130 POROUS PARTING FILM with 7 5 m (3in)

overlap,and lay it over the carbon fabric repair plies.
C. Overlay with a piece of OMat 2/131 NON-POROUS PARTING FILM cut

to the same dimensions.
D. Put a layer of OMat 2/129 BREATHER CLOTH and a heat blanket on

the repair area.
E. Put OMat 2/110A SEALANT TAPE around the full repair area on the
two sides of the panel.Cut a piece of OMat 2/126 VACUUM BAG and
lay it over the full repair area.
F. Evacuate the lay-up to a vacuum of 0.7 bar inside the bag.
REPAIR N0.7
Page 206
R6211 TRENT
STRUCTURAL REPAIR
MANUAL
11. Cure procedure (Ref Figure 203)
CAUTION: THE RATE OF TEMPERATURE INCREASE AND DECREASE MUST NOT BE

MORE THAN 3 DEG C (5 DEG F) PER MINUTE.
A. Cure in two stages, the first for 60 to 70 minutes at 55 to 65

deg C (131 to 149 deg F),the second for 150 to 160 minutes at
115 to 125 deg C (239 to 257 deg F).
NOTE: You must keep the vacuum of 0.7 bar during the complete
cure cycle.
12. Inspection and clean-up
A. Remove the lay-up materials,the steel rule and the back-up

plate from the repair area.
B. Do a visual inspection for resin starvation, excess resin or

surface blisters.Abrade with OMat 5/94 ABRASIVE PAPER to remove
defects and make the repair surface smooth.Remove all dust with
the vacuum cleaner.

C. Clean the repair surface with OMat 135 MEK and OMat 2/101 LINT-
FREE CLOTH. Dry the surface with a fresh piece of the cloth
D. Do an ultrasonic inspection to make sure the repaired area is

free from damage. If not, refer to allowable damage, page block
101, to make sure the damage is in the permitted limits.
E. Apply primer sealer paint to the repair area if necessary.

Refer to 54-30-00, Repair No.11.
EFFECTIVITY :TRENT
REPAIR N0.7
Page 207
ADHESIVE TAPE
ADHESIVE TAPE ROUGHEN SURFACE

/
CLAMPS STEEL RULE CLAMPS BACKUP PLATE

EXTRA
REPAIR
0.6 0.48 0.48 0.48 SIZE OF
PLIES
(15)., (12) .. (12) .. (12) DAMAGE
1
CARBON / \ \
REPAIR METALLIC ADHESIVE TEFLON
PLIES PLATE TAPE
Repair edge damage in carbon composite skin

Figure 201
REPAIR N0.7
Page 208
July 1/99
p
'"" RB211 TRENT
MANUAL
STRUCTURAL REPAIR
NON POROUS
HEAT BLANKET PARTING FILM
POROUS PARTING
BREATHER FABRIC FILM
VACCUM BAG FLEXIBLE SEALANT TAPE

BACKUP SHEET
Figure 202
REPAIR N0.7
Page 209
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
VACUUM BAG
POROUSPARTING
FILM -
NON POROUS
I BREATHER
FABRlC
BAGGING OPERATlON
TEMPERATURE
-2 to 3" Chin
I
l
I
I
t
m
7
m 1 6 0 rninld 150 mint160 min TIME
B 70 rnin
g
E CURING CYCLE
Repair edge damage t o carbon composite skin
REPAIR N0.7
Page 2 1 0
1
mB
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR N0.8
THRUST REVERSER
REPAIR EDGE DELAMINATION OF CARBON COMPOSITE SKIN
1. General
A. T h i s p r o c e d u r e g i v e s i n s t r u c t i o n s t o r e p a i r d e l a m i n a t i o n of carbon
composite s k i n edge i n a m o n o l i t h i c a r e a . T h i s procedure i s n o t a p p l i c a b l e
i f t h e carbon p l i e s are broken o r m i s s i n g .
NOTE: Delamination must n o t be more t h a n 10 mm (0.4 i n . ) d e p t h . I f it i s ,

r e f e r t o 54-30-00, Repair No.01.
-
U
a,
C
.-
L
B. The damage a r e a can be r e p a i r e d by f i l l i n g t h e d e l a m i n a t i o n w i t h adhesive.
n 2. Referenced I n f o r m a t i o n
..............................................................................
54-30-00, Repair No.11 Apply Primer S e a l e r P a i n t

TASK 78-33-13-300-011 FRS X053 Trent Engine Manual
Standard workshop t o o l s and equipment
Syringe
Mechanical clamp
Hot a i r blower 100 deg C (212 deg F) maximum
Heat b l a n k e t 0 t o 120 deg C (32 t o 250 deg F)
REPAIR N0.8
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RB.211 TRENT
ma STRUCTURAL REPAIR
MANUAL
..............................................................................
OMAT 135 METHYL ETHYL KETONE
OMAT 272 ADHESIVE TAPE 1 IN. WIDE
OMAT 21101 LINT FREE CLOTH
OMAT 21131 NON POROUS PARTING FILM
OMAT 5/94 ABRASIVE PAPER 150 GRIT
OMAT 81160 EPOXY ADHESIVE
..............................................................................
PART IDENT MATERIAL
..............................................................................
B. Do an ultrasonic inspection to find the area of delamination.

C. Mark out the area of the damage.
5. Prepare the damaged area for inspection
GOGGLES TO PROTECT YOU AGAINST LOOSE PARTICLES WHICH CAN BE
A. Remove all loose fibers with OMat 5/94 ABRASIVE PAPER and clean with OMat
21101 LINT FREE CLOTH and a vacuum cleaner.
NOTE: Make sure that no carbon ply is broken or missing. If it is, refer
to 54-30-00, Repair No.7.
CAUTION: THE RATE OF TEMPERATURE INCREASE MUST NOT BE MORE THAN 3 deg C (5
deg F) PER MINUTE.
B. Dry out the damaged area at 91 to 96 deg C (195 to 205 deg F) for 1 hour
with a hot air blower.
REPAIR N0.8
EFFECTIVITY: TRENT
Page 202
July 1I98
RB.211 TRENT
m STRUCTURAL REPAIR
MANUAL
6. Prepare the adhesive

WARNING: DO NOT PUT MORE THAN 250 G (0.55 LB) OF OMAT 8/160 ADHESIVE IN ONE
CONTAINER. IF YOU MIX MORE THAN 250 G (0.55 LB) IN A CONTAINER AN
WARNING: USE OMAT 8/160 ADHESIVE IN AN AREA OPEN TO THE AIR. CAREFULLY READ
A. Mix the OMat 8/160 ADHESIVE parts A and B in accordance with the
7. Inject adhesive (Ref Figure 201)
A. Put a sufficient quantity of adhesive into the syringe, then inject the
adhesive into the laminated area between plies until it flows out.
WARNING: USE OMAT 135 METHYL ETHYL KETONE IN AN ARE OPEN TO THE AIR. THIS
MATERIAL IS FLAMMABLE AND GAS IS DANGEROUS. IT CAN CAUSE IRRITATION
OF EYES, NOSE, THROAT AND SKIN. HIGH CONCENTRATION CAN CAUSE
B. Remove excess adhesive and clean the surface with OMat 135 MEK and OMat
21101 LINT FREE CLOTH. Dry the surface before the solvent evaporates.
8. Curing (Ref Figure 201)
A. Install the thermocouples adjacent to the repair.
B. Cut a piece of OMat 21131 NON POROUS PARTING FILM sufficient to cover the
full repair area.
C. Install the non porous parting film on the delamination are with OMat 272
ADHESIVE TAPE.
D. Install the thermal blanket on the repair.
E. Hold the plies together with a mechanical clamp.
NOTE: To prevent adhesive deficiency, do not apply too much pressure.
REPAIR N0.8
EFFECTIVITY: TRENT
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1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
F. Cure i n two s t a g e s , t h e f i r s t one f o r 60 t o 70 m i n u t e s a t 55 t o 65 deg C

(131 t o 148 deg F ) , and t h e second one f o r 150 t o 160 m i n u t e s a t 115 t o 125
deg C (239 t o 257 deg F ) .
A. Remove a l l lay-up m a t e r i a l s .
W
-
B. V i s u a l l y i n s p e c t t h e r e p a i r f o r freedom from s t a r v e d a r e a s , b l i s t e r s o r
excess adhesive a r e a s .
C. Use OMat 5 / 9 4 ABRASIVE PAPER t o remove a l l unwanted a d h e s i v e . 0

z
2
WARNING: USE OMAT 135 METHYL ETHYL KETONE I N AN AREA OPEN TO THE AIR. THIS
MATERIAL I S FLAMMABLE AND GAS I S DANGEROUS. IT CAN CAUSE IRRITATION
?!
rC
E.
OF EYES, NOSE, THROAT AND SKIN. H I G H CONCENTRATIONS CAN CAUSE 3
D. Clean t h e s u r f a c e w i t h O M a t 135 MEK and OMat 2/101 LINT FREE CLOTH. Wipe
the surface dry before t h e solvent evaporates.
from damage. I f n o t , r e f e r t o a l l o w a b l e damage, p a g e b l o c k 101, t o make
s u r e t h e damage i s i n t h e p e r m i t t e d l i m i t s .
F. Make a v i s u a l i n s p e c t i o n t o make s u r e t h a t t h e r e p a i r h a s been done i n

accordance with t h e s e procedures.
G. Apply p r i m e r s e a l e r p a i n t t o t h e r e p a i r a r e a , i f i t i s n e c e s s a r y . Refer t o
54-30-00, R e p a i r No.11.
REPAIR N0.8
EFFECTIVITY: TRENT
Page 204
J u l y 1/ 9 8
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
METAL BLOCK
Repair Edge Delamination

Figure 201
REPAIR N0.8
EFFECTIVITY: TRENT
Page 205
July 1/98
RB211 TRENT
STRUCTURAL REPAIR
REPAIR No. 09
THRUST REVERSER
REPAIR DAMAGE ON CARBON COMPOSITE SKIN
1. General
A. This procedure gives the instructions to repair non-through damage to carbon

composite skin when the outer skin has an outer ply of bronzemesh.
B. This procedure gives instruction to:
- Remove the damage
- Add wet lay-up carbon repair plies with a bronzemesh repair ply on the outer
skin.
..........................................................................
..........................................................................
AMM 70-20-01-100-801 Cold liquid degreasing SRM 54-01-06
Composite Structure Tap Test
SRM 54-30-OO,FRSX056(RepairNo. 11) Apply primer paint coat on carbon/epoxy
- Hot bonder with Curing cycle monitoring and automatic reporting feature
- Heater blanket 32 to 302 deg. F (0 to 150 deg. C)
- Hot air blower 248 deg F. (120 deg. C) maximum
- Pneumatic sander
- Spatula
- Squeegee
- Steel guides 10 in (254 mm) minimum length

- Thermocouples 32 to 302 deg. F (0 to 150 deg. C)
- Vacuum cleaner
EFFECTIVITY :TRENT REPAIR N0.09

54-30-00
Page 201
MAR. 10/09
STRUCTURAL REPAIR
- Vacuum pump to -15 psi ( - 1,O bar) capability with vacuum gauge
..........................................................................

OMat 8/191 Bronzemesh fabric
R C. Component material
..........................................................................
COMPONENT MATERIAL
..........................................................................
R Thrust reverser carbon/epoxy composite
R 4. Procedure
R
R
R WARNING: WHEN YOU DO THIS REPAIR YOU MUST WEAR PROTECTIVE CLOTHING, GLOVES DUST
R MASK AND SAFETY GOGGLES TO PROTECT YOU AGAINST DUST AND LOOSE
PARTICLES, THAT CAN BE DANGEROUS TO YOUR HEALTH.
R
R WARNING: WHEN YOU USE THE CLEANING MATERIALS, ADHESIVES AND COATINGS, REFER TO,
R AND OBEY, THE MANUFACTURER'S CONTROL AND APPLICATION INSTRUCTIONS AND
R HEALTH AND SAFETY NOTICES.
R A. Clean the repair area.
CAUTI0N:WHEN YOU REMOVE THE LOOSE FIBRES MAKE SURE YOU DO NOT REMOVE ANY
ADDITIONAL MATERIAL.
(1) Lightly abrade the surface to remove loose fibres. Use OMat 5/94 Garnet
paper.

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RB211 TRENT
STRUCTURAL REPAIR
(1) Do a tap test. Refer to SRM 54-01-06 Composite Structure Tap Test or
use ultrasonic inspection equipment to determine the damaged area.
(2) Use an OMat 261 temporary marker to mark out the damaged area.
(3) Check that the dimensions of the damaged area are within the repairable
limits. Refer to the relevant chapter of SRM, page block 101.
C. Prepare the damaged area for repair (Ref. to figure 201) .
(1) Use an OMat 261 temporary marker to mark out the damaged area that is
to be removed. The removed area should be a smooth rectangular shape
with rounded corners of 0.05 in. (12,5mm)minimum radius.
(2) Use the marks made at step 1 and remove the damage. Remove the material
one ply at a time until all damage is removed. Use a pneumatic sander
fitted with an OMat 5/121 abrasive disc.
(3) Do a tap test to make sure all damage is removed. Refer to SRM 54-01-06
Composite Structure Tap Test.
(4) Use a lint free cloth soaked in OMat 1/257 cleaning solvent to clean
the repair area. Refer to AMM 70-20-01-100-802
(5) Use an OMat 261 temporary marker to mark out the area that is to be
step sanded and the area where the extra plies and bronzemesh layer are
to be installed. The step sanded area must extend beyond the cut out
area by a minimum of 0.48 in. (12 mm) for each ply that is to be
removed. The area where the extra plies and bronzemesh layer are to be
installed must extend for a distance of 1.0 in, (25 mm) minimum beyond
the step sanded area. Refer to figure 201.
CAUTION: MAKE SURE YOU STEP SAND OVER EACH PLY IN INCREMENTS.
(6) Step sand from the damage centre to the outer edges of each ply. Use
the marks made at step 5 to put the steel guides in position. Hold the
steel guides firmly in position using adhesive tape. Step sand using a
pneumatic sander with OMat 5/121 Abrasive paper disc. Make each step a
smooth rectangular shape with rounded corners of 0.5 in(12,5 mm)
minimum radius. Refer to figure 201.
( 7 ) Remove the adhesive tape and the steel guides.
(8) Lightly abrade the area on the outer skin where the extra repair plies
and bronzemesh layer are to be installed. Use OMat 5/94 Garnet paper.
(10) Dry the damaged area for 60 minutes minimum at 200 deg. F (93 deg. C)
with a hot air blower.
EFFECTIVITY :TRENT REPAIR No.09

54-30-00
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RB211 TRENT
STRUCTURAL REPAIR
D. Prepare the carbon/epoxy repair plies and the bronzemesh layer (Ref to
figure 201)
CAUTION: THE ORIENTATION OF THE REPIAR PLIES MUST BE THE SAME ORIENTATION AS
THE ORIGINAL PLIES THEY ARE REPLACING.
(1) Make a template for each step in the step sanded area and for the area
where the extra carbon plies are to be installed. Determine the fibre
orientation for each step and mark this on the templates. The
orientation of the extra pies must be the same as the orientation of
the ply below (surface ply) .
(2) Cut out a piece of OMat 8/183 dry carbon fabric that is large enough to
make all the repair plies. Use two carbon/epoxy repair plies for each
damaged carbon epoxy ply of the original structure. Use two extra
carbon/epoxy repair plies for the outer surface. Add sufficient margin
for further adjustment.
(3) Weigh the dry carbon fabric.
(4) Cut 2 pieces of OMat 2/131 Non-porous parting film each approximately 3
in (80 mm) larger, all round, than the Dry Carbon repair fabric. Tape
down one piece of the non-porous parting film onto a smooth flat
surface. Put the dry carbon fabric onto the non-porous parting film.
(5) Mix a quantity of OMat 8/160 Epoxy paste adhesive that is equal in mass
to the dry carbon fabric weighed at step 3. Refer to manufacturer's
instructions for mixing instructions.
(6) Use a spatula to apply the adhesive evenly onto the dry carbon fabric.
(7) Put the second piece of non-porous parting film on the Carbon/epoxy
fabric ply. Use a squeegee to impregnate the Carbon fabric evenly with
adhesive and remove trapped air.
(8) Use the templates made at step 1 to cut out the carbon/epoxy fabric
repair plies.
(9) Cut a piece of OMat 8/191 bronzemesh fabric to fit the repair area.
When installed the bronzemesh fabric must match the orientation of the
existing material. Add sufficient margin for trimming.
(10) Weigh the bronzemesh fabric.
(11) Mix a quantity of OMat 8/160 epoxy paste adhesive that is equal in mass
to the bronzemesh fabric. Refer to the manufacturer's instructions for
mixing instructions.
(12) Clean the bronzemesh fabric. Use OMat 1/257 cleaning solvent. Refer to
AMM 70-20-01-100-802
NOTE: The bronzemesh repair ply must be fully dry, clean and free of solvent
before installation.
(13) Cut 2 pieces of OMat'2/131 non-porous parting film 3 in. (80 cm) larger
all round than the bronzemesh fabric. Put one piece of non-porous
EFFECTIVITY :TRENT REPAIR No.09

54-30-00
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R8211 TRENT
STRUCTURAL REPAIR
parting film onto a smooth flat surface. Put the Bronzemesh fabric onto
the non-porous parting film.
(14) Remove non-porous parting film from the 2 off extra repair plies.
CAUTION: MAKE SURE THAT THE BRONZEMESH AND THE CARBON/EPOXY EXTRA PLIES ARE
IN THE CORRECT ORIENTATION.
(15) Lay up the carbon/epoxy fabric extra plies onto the bronzemesh fabric.
Make sure the bronzemesh fabric overlap is equal all round.
(16) Put the second piece of non-porous parting film on top of the
carbon/epoxy extra plies.
(17) Use a squeegee to work the adhesive through the Carbon/epoxy fabric
plies into the bronzemesh layer. Remove any wrinkles and trapped air.
(18) Turn the lay up over and remove the non-porous parting film from the
bronzemesh fabric side.
(19) Use a spatula to apply the adhesive onto the bronzemesh fabric. Keep a
thin even layer of adhesive over the bronzemesh.
NOTE: Do not remove excess of adhesive.
(20) Replace the piece of non-porous parting film onto the impregnated
bronzemesh fabric.
E. Laying up of repair plies (Refer to figure 201).
(1) Remove the non-porous parting film from one side of one of the smallest
repair ply.
(2) Position the carbon/epoxy fabric repair ply adhesive side down in the
step sanded area. Make sure that the orientation of the carbon/epoxy
repair ply matches that of the existing adjacent structure.
(3) If necessary trim the Carbon/epoxy fabric ply edge to the same
NOTE: Do not apply excessive pressure to avoid squeezing out of

adheSive .
(5) Remove the non-porous parting film from the top of the installed
Carbon/epoxy fabric ply.
(6) Remove the non-porous parting film from one side of the next repair ply
and repeat steps 2 to 5 until the entire repair plies are installed in
the step sanded area.
NOTE: Keep the extra carbon/epoxy fabric plies incorporated in the

bronzemesh layer for the next step.

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RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(7) Remove the non-porous parting film from the Carbon/epoxy fabric
plies incorporated onto the bronzemesh layer.
(8) Position the repair plies and the bronzemesh layer on the repair
area in the correct orientation.
(9) If required trim the bronzemesh fabric ply to the dimensions of

the repair area.
(10) Use squeegee to remove any wrinkles and trapped air.
NOTE: Do not apply excessive pressure to avoid squeezing out of

adhesive .
(11) Remove the non-porous parting film from the bronzemesh fabric.
F. Cure the repair area (Ref. to figure 202).
(1) Install the thermocouples adjacent to the repair plies
(2) Position the OMat 2/129 Breather cloth around the repair plies.
(3) Cut and install a piece of OMat 8/198 Nylon peel ply allowing 1.0
in (25 mm) excess around the edges of the repair plies.
(4) Put OMat 2/110 Adhesive tape vacuum bag seal all around the lay-up
area.
( 5 ) Cut a suitably sized piece of OMat 2/126 vacuum bag and install a
vacuum fitting. Make sure that when installed the vacuum fitting
will sit on the breather cloth. Install the Vacuum bag.
(7) Evacuate the lay-up to a vacuum of -10.0 psi (- 0.7 bar) inside
the bag.
NOTE: Maintain vacuum of -10.0 psi (- 0.7 bar) inside the bag for
the required cure period.
(9) Position a suitably sized heat blanket over the repair area.
(10) Put a layer of OMat 2/129 Breather cloth that is larger than the
heat blanket over the heat blanket.
(11) Put OMat 2/110 Adhesive tape vacuum bag seal all around the area.
(12) Cut a suitably sized piece of OMat 2/126 Vacuum bag and install a
vacuum fitting. Make sure that when the vacuum bag is installed
the vacuum fitting will sit on the breather cloth. Install the
vacuum bag.

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RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(13) Connect the vacuum bag to the vacuum pump
(14) Evacuate the lay-up to a vacuum of -10.0 psi (- 0.7 bar) inside the
bag.
CAUTION: THE RATE OF TEMPERATURE INCREASE AND SUBSEQUENT DECREASE MUST
NOT BE GREATER THAN 5 DEG F (3 DEG C) PER MINUTE.
(15) Cure the repair plies. Refer to figure 202 for cure cycle details.
Note: The cure dwell shall start when the lowest reading
thermocouple reaches the correct temperature.
(16) Allow the repair area to cool to room temperature and carefuily
remove the lay-up materials from the repair plies.
G. Examine the completed repair.
(1) Visually examine the repair to make sure it has been satisfactorily
completed.
(2) Do a tap test SRM 54-01-06 Composite Structure Tap Test or use
ultrasonic inspection equipment to make sure the repaired area has
no voidage or delamination. If any damage is found, refer to page
block 101 to make sure that it is within the permitted limits.
(3) If necessary apply primer and finish paint coat, refer to SRM
Chapter 54-30-00, FRSX056 Repair No.11.
H. Identify the repair.
(1) Use a permanent marker pen of a contrasting colour to write FRSX054

next to the existing part number.

54-30-00
Page 207
MAR. 10/09
PNEUMATIC
CARBON PLY
ORIENTATION
SANDING OPERATION
BRONZEMESH ORIGINAL
CARBON REPAIR
PLIES
R
E
Repair Preparation and Lay-up
Figure 201.

54-30-00
Page 208
MAR. 10/09
RB211 TRENT
STRUCTURAL REPAIR
VACUUM BAG
. BREATHER
CLOTH
VACUUM BAG
BREATHER
CLOTH
NYLON PEEL PLY 1 ADHESIVE TAPE
I
THERMOCOUPLE
-
ADHESIVE TAPE
TEMPERATURE
+5* Flmin MAX

-5" Flmin MAX
Clmin)
(+3' (-3" Clmin)
239" FI257" F
(1 15" Cl125" C)
131" FH49" F --
(55' C165' C)
ROOM TEMPERATURE .
- 420 to 1440 min 60 to 75 min

U
150 to 165 min
TIME
CURING CYCLE
Bagging and Cure Cycle
Figure 202.
EFFECTIVITY : T R E N T R E P A I R No.09
54-30-00
Page 209
MAR. 10/09
RB211 TRENT
STRUCTURAL REPAl R
MANUAL
REPAIR NO. 10
THRUST REVERSER
REPAIR OF THROUGH DAMAGE IN CARBON COMPOSITE SKIN, FRSX055
1. General
A. This procedure gives the instructions to repair through-damage

to monolithic carbon composite when the outer skin has an outer
ply of bronzemesh.
B. This procedure can be applied when the rear side of the panel
is not accessible.
C. This procedure gives instruction to:
- Remove the damage

- Install a backup plate
- Add wet lay-up carbon repair plies with a bronzemesh repair
ply on the outer skin.
......................................................................
......................................................................
A M M 70-20-01-100-802 Cold liquid degreasing
SRM 54-01-06 Composite Structure Tap Test
SRM 54-30-00,FRSX056 (Repair No. 11) Apply primer paint coat on
carbon/epoxy
Hot bonder with Curing cycle monitoring and automatic

reporting feature
Drill bit 0.04in (lmm) diameter
Heater blanket 32 to 302 deg F (0 to 150 deg C)
Heat Lamp 32 to 302 deg F (0 to 150 deg C)
Hot air blower 248 deg F (120 deg C) maximum
Lockwires
Pneumatic sander
Protective pads (2 off)
Spatula
Squeegee
Steel guides loin (254mm) minimum length
Square section rod
Thermocouples 32 to 302 deg F (0 to 150 deg C)
54-30-00
REPAIR No. 10
Page 2 01
Printed in Great Brltain Mar. 10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
- Vacuum cleaner
- Vacuum pump to -15 psi ( - 1,O bar) capability with
vacuum gauge
.......................................................................
.......................................................................
OMat 2 62 'Marker
OMat 8/191 Bronzemesh fabric
......................................................................
COMPONENT MATERIAL
......................................................................
4. Procedure

CLOTHING, GLOVES DUST MASK AND SAFETY GOGGLES TO PROTECT
YOU AGAINST DUST AND LOOSE PARTICLES, WHICH CAN BE
DANGEROUS TO YOUR HEALTH.WARNING: WHEN YOU USE CLEANING
MATERIALS, ADHESIVES AND COATINGS, REFER TO AND OBEY, THE
MANUFACTURER'S CONTROL AND APPLICATION INSTRUCTIONS AND
HEALTH AND SAFETY NOTICES.
A. Clean the repair area.
CAUTION: WHEN REMOVING LOOSE FIBRES MAKE SURE NO ADDITIONAL

MATERIAL IS REMOVED.
(1) Lightly abrade the surface to remove loose fibres with

OMat 5/94 Garnet paper.
54-30-00
REPAIR No. 10
Page 2 02
Printed in Great Britain Mar. l O / O R
(2)
p
"" RB211 TRENT
MANUAL
STRUCTURAL REPAIR
U s e a v a c u u m cleaner t o r e m o v e a l l debris f r o m t h e repair

area. U s e a l i n t free c l o t h soaked i n O M a t 1 / 2 5 7 c l e a n i n g
s o l v e n t t o c l e a n t h e d a m a g e area ( R e f AMM 7 0 - 2 0 - 0 1 - 1 0 0 -
802) .
B. E x a m i n e the d a m a g e .
(1) D o a tap t e s t . R e f e r t o SRM 5 4 - 0 1 - 0 6 C o m p o s i t e S t r u c t u r e

T a p T e s t o r use u l t r a s o n i c i n s p e c t i o n e q u i p m e n t t o
d e t e r m i n e t h e d a m a g e d area.
(2) U s e a t e m p o r a r y m a r k e r such as O M a t 2 6 1 t o m a r k o u t t h e
d a m a g e d area.
(3) C h e c k t h a t t h e d i m e n s i o n s of t h e d a m a g e d area are w i t h i n

t h e repairable l i m i t s . R e f e r t o t h e r e l e v a n t chapter of
t h e SRM, page block 1 0 1 .
C. Prepare t h e d a m a g e d area f o r r e p a i r (Ref Figure 2 0 1 ) .
CAUTION: DO NOT DAMAGE THE UNDAMAGED P L I E S AND SURROUNDING

MATERIAL.
(1) U s e a t e m p o r a r y m a r k e r such a s O m a t 2 6 1 t o m a r k o u t t h e
d a m a g e d area t h a t i s t o be r e m o v e d . T h e c u t - o u t area
s h o u l d be a s m o o t h r e c t a n g u l a r shape w i t h rounded c o r n e r s
of 0 . 5 i n . ( 1 2 , 5 m m ) m i n i m u m r a d i u s .
NOTE: I f access t o t h e rear side of t h e panel i s n o t

a v a i l a b l e , t h e d i m e n s i o n s of t h e c u t - o u t m u s t be
large enough t o a l l o w t h e backup p l a t e t o be
i n s t a l l e d though i t . T h e backup p l a t e m u s t be 0 . 4
i n ( 1 0 mm) larger a l l round t h a n t h e c u t - o u t .
(2) U s e t h e m a r k s m a d e a t step ( 1 ) above t o t r i m o u t t h e

d a m a g e d area. U s e a v a c u u m cleaner t o r e m o v e t h e d u s t
w h i l e c u t t i n g . Make s u r e a l l d a m a g e i s r e m o v e d .
(3) U s e a l i n t free c l o t h soaked i n O M a t 1 / 2 5 7 c l e a n i n g

s o l v e n t t o clean the r e p a i r area ( R e f AMM 70-20-01-100-
802) .
54-30-00
REPAIR No. 1 0
Page 2 0 3
P r l n t e d In Great Britain M a r 1 0 /Of?
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(4) U s e a t e m p o r a r y m a r k e r such a s O M a t 2 6 1 t e m p o r a r y m a r k e r
t o m a r k o u t t h e area t h a t i s t o be s t e p sanded and t h e
area w h e r e t h e a d d i t i o n a l p l i e s and b r o n z e m e s h l a y e r are
t o be i n s t a l l e d . T h e s t e p sanded area m u s t extend beyond
t h e c u t - o u t area by a m i n i m u m of 0 . 4 8 i n . ( 1 2 mm) f o r each
p l y t h a t i s t o be r e m o v e d . T h e area w h e r e t h e a d d i t i o n a l
p l i e s and b r o n z e m e s h l a y e r a r e t o be i n s t a l l e d m u s t
e x t e n d f o r a distance of 1 . 0 i n . ( 2 5 mm) m i n i m u m beyond t h e
step sanded area ( R e f e r F i g u r e 2 0 1 ) .
CAUTION: MAKE SURE YOU S T E P SAND OVER EACH PLY I N INCREMENTS.
(5) Step sand f r o m t h e d a m a g e centre t o t h e o u t e r face. U s e

t h e m a r k s m a d e a t step ( 4 ) t o p u t t h e s t e e l guides i n
p o s i t i o n . H o l d t h e steel guides f i r m l y i n p o s i t i o n u s i n g
adhesive tape. Step sand u s i n g a p n e u m a t i c sander w i t h
O M a t 5 / 1 2 1 A b r a s i v e paper d i s c . Make each s t e p a s m o o t h
rectangular shape w i t h rounded c o r n e r s of 0 . 5 i n ( 1 2 . 5 mm)
m i n i m u m radius.
(6) R e m o v e t h e adhesive tape and the s t e e l guides.
(7) L i g h t l y abrade t h e area w h e r e t h e a d d i t i o n a l p l i e s and

b r o n z e m e s h l a y e r a r e t o be i n s t a l l e d . U s e O M a t 5 / 9 4
G a r n e t paper.
(8) U s e a v a c u u m cleaner t o r e m o v e a l l d u s t and debris f r o m

t h e repair area. U s e a l i n t free c l o t h soaked i n O M a t
1 / 2 5 7 c l e a n i n g s o l v e n t t o clean t h e r e p a i r area ( R e f AMM
70-20-01-100-802) .
CAUTION: THE RATE O F TEMPERATURE INCREASE MUST NOT BE MORE
THAN 3 DEG C ( 5 DEG F ) P E R MINUTE.
(9) D r y t h e repair area f o r 60 m i n u t e s m i n i m u m a t 2 0 0 deg F

( 9 3 deg C ) w i t h a h o t a i r b l o w e r .
D. Prepare t h e ~ l a s s / ~ p o xbackup
y p l a t e ( R e f Figures 2 0 1 , 2 0 2 and
203).
(1) C u t a piece of O M a t 8 / 1 8 2 dry g l a s s f a b r i c of s u f f i c i e n t

s i z e t o m a k e 5 ~ l a s s / E p o x yp l i e s . T h e ~ l a s s / E p o x yp l i e s
m u s t be 0 . 4 0 i n ( 1 0 mm) l a r g e r a l l round than t h e c u t - o u t .
C u t t w o pieces of O M a t 2 / 1 3 1 non-porous p a r t i n g f i l m each
a p p r o x i m a t e l y 3 i n . (80mm) larger a l l round than t h e g l a s s
fabric .
(2) T a p e d o w n one piece of non-porous p a r t i n g f i l m o n t o a f l a t

and s m o o t h surface.
E F P E C T I V I T Y : TRENT
54-30-00
REPAIR No. 10
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Prlnted in Great Britaln
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(3) Weigh t h e O M a t 8/182 Dry g l a s s f a b r i c .
(4) Mix a q u a n t i t y of OMat 8/160 Epoxy p a s t e a d h e s i v e t h a t i s

e q u a l i n mass t o t h e g l a s s f a b r i c weighed a t step ( 3 )
above. R e f e r t o m a n u f a c t u r e r ' s i n s t r u c t i o n s f o r mixing
i n s t r u c t i o n and h e a l t h and s a f e t y p r e c a u t i o n s .
(5) P u t t h e d r y g l a s s f a b r i c o n t o t h e non-porous p a r t i n g f i l m .
Apply t h e s e l e c t e d q u a n t i t y o f a d h e s i v e e v e n l y o n t o t h e
dry g l a s s f a b r i c using a s p a t u l a .
(6) P u t t h e second p i e c e of non-porous p a r t i n g f i l m on t h e

g l a s s f a b r i c . U s e a squeegee t o impregnate t h e d r y g l a s s
(7) Cut o u t t h e 5 p l i e s of Glass/Epoxy f a b r i c . The G l a s s / ~ p o x y

p l i e s must b e 0 . 4 0 i n (10 mm) l a r g e r a l l round t h a n t h e
c u t - o u t (Ref F i g u r e 203) .
R
R E. Lay up t h e ~ l a s s / ~ p of axb~r i c backup p l a t e (Ref F i g u r e 2 0 2 ) .
R
R (1) Cut a p i e c e of OMat 2/131 non-porous p a r t i n g f i l m 0 . 4 i n
R (10 mm) l a r g e r , a l l round, t h a n t h e ~ l a s s / E p o x yf a b r i c
R p l i e s . P u t t h e OMat 2/131 non-porous p a r t i n g f i l m o n t o a
R b a s e p l a t e t h a t i s t o be u s e d when c u r i n g t h e backup
R p l a t e . The b a s e p l a t e must be of a n a p p r o p r i a t e s i z e and
R have a h a r d , smooth f l a t s u r f a c e .
(2) Remove t h e non-porous p a r t i n g f i l m from one s i d e of one of

t h e g l a s s / e p o x y f a b r i c p l i e s . P u t i t a d h e s i v e s i d e down on
t h e l a r g e r non-porous p a r t i n g f i l m c u t i n s t e p (1).
(3) U s e a squeegee t o remove any w r i n k l e s and t r a p p e d a i r
NOTE: Do n o t a p p l y e x c e s s i v e p r e s s u r e t o a v o i d squeeze
o u t of a d h e s i v e .
(4) Remove t h e second p i e c e of non-porous p a r t i n g f i l m from

t h e g l a s s / e p o x y f a b r i c p l y i n s t a l l e d . Remove t h e non-
porous p a r t i n g f i l m from one s i d e of t h e n e x t g l a s s / e p o x y
f a b r i c p l y and l a y t h i s a d h e s i v e s i d e down o n t o t h e
p r e v i o u s l y i n s t a l l e d p l y . U s e a squeegee t o remove any
w r i n k l e s and t r a p p e d a i r .
(5) Repeat s t e p ( 4 ) above u n t i l a l l 5 g l a s s / e p o x y p l i e s have

been l a i d u p .
NOTE: Remove t h e non-porous p a r t i n g f i l m o f f t h e l a s t

g l a s s / e p o x y p l y b e f o r e t h e bagging and c u r i n g
procedure.
EFFECTIVITY : TRENT
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RB211 TRENT
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MANUAL
(6) Cure t h e backup p l a t e u s i n g t h e p r o c e d u r e i n s t r u c t e d i n

o p e r a t i o n F below.
F. Vacuum bagging and c u r i n g p r o c e d u r e (Ref F i g u r e s 202 and 2 0 4 ) .
(1) I n s t a l l t h e thermocouples a d j a c e n t t o t h e r e p a i r p l i e s .
(2) P o s i t i o n t h e OMat 2/129 B r e a t h e r c l o t h around t h e r e p a i r

plies.
(3) Cut a p i e c e o f O M a t 8/198 Nylon p e e l p l y a l l o w i n g 1 . 0 i n

(25 mm) e x c e s s around t h e edges of t h e r e p a i r p l i e s .
(4) Put OMat 2/110 Adhesive t a p e vacuum bag s e a l a l l around
the lay-up a r e a .
(5) Cut a s u i t a b l y s i z e d p i e c e of O M a t 2/126 vacuum b a g and

bag i s i n s t a l l e d t h e vacuum f i t t i n g w i l l s i t on t h e
(7) Evacuate t h e lay-up t o a vacuum of -10.0 p s i ( - 0 . 7 b a r )

NOTE: M a i n t a i n vacuum of -10.0 p s i ( - 0 . 7 b a r ) i n s i d e

t h e bag f o r t h e r e q u i r e d c u r e p e r i o d .
(8) P o s i t i o n a s u i t a b l y s i z e d h e a t e r b l a n k e t over t h e r e p a i r
area.
(9) Put a l a y e r of OMat 2/129 B r e a t h e r c l o t h t h a t i s l a r g e r

than t h e h e a t e r blanket over t h e h e a t blanket.
(10) Put OMat 2/110 Adhesive t a p e vacuum bag s e a l a l l around

the area.
(11) Cut a s u i t a b l y s i z e d p i e c e of OMat 2/126 vacuum bag and

bag i s i n s t a l l e d t h e vacuum f i t t i n g w i l l s i t on t h e
(13) Evacuate t h e lay-up t o a vacuum of -10.0 p s i (- 0.7 bar)

54-30-00
REPAIR N o . 10
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STRUCTURAL REPAIR
MANUAL
CAUTION: THE RATE OF TEMPERATURE INCREASE AND SUBSEQUENT

DECREASE MUST NOT BE GREATER THAN 5 DEG F ( 3 DEG C )
PER MINUTE.
( 1 4 ) Cure t h e r e p a i r p l i e s (Ref F i g u r e 204)
NOTE: The c u r e d w e l l s h a l l s t a r t when t h e l o w e s t r e a d i n g

thermocouple r e a c h e s t h e c o r r e c t t e m p e r a t u r e
(15) Allow t h e r e p a i r a r e a t o c o o l t o room t e m p e r a t u r e and

c a r e f u l l y remove t h e l a y - u p m a t e r i a l s from t h e c u r e d
repair plies.
G. I n s p e c t t h e backup p l a t e .
(1) Do a v i s u a l i n s p e c t i o n and t a p t e s t t o make s u r e t h e c u r e d

backup p l a t e h a s no d e l a m i n a t i o n o r v o i d a g e . R e f e r t o SRM
54-01-06 - Composite s t r u c t u r e t a p t e s t .
H. I n s t a l l t h e backup p l a t e (Re£ F i g u r e s 201 and 2 0 3 ) .
(1) T r i m t h e backup p l a t e i n t o a r e c t a n g u l a r s h a p e w i t h 0 . 4 i n
(10mm) minimum c o r n e r r a d i u s .
(2) D r i l l 2 p a i r s of h o l e s n e a r t h e c e n t r e l i n e of t h e backup
p l a t e . U s e a 0 . 0 4 i n (1 mm) d i a m e t e r d r i l l b i t . The h o l e s
need t o b e a s u f f i c i e n t d i s t a n c e a p a r t t o a t t a c h t h e
backup p l a t e t o a clamp b a r u s i n g l o c k w i r e and h o l d i t
firmly i n place.
(3) Abrade t h e s u r f a c e of t h e backup p l a t e t h a t i s t o b e

bonded t o t h e r e p a i r a r e a and t h e i n n e r s i d e of t h e r e p a i r
a r e a , i f p o s s i b l e , up t o a d i s t a n c e of 0 . 8 i n (20 mm) from
t h e c u t - o u t e d g e . U s e O M a t 5/94 G a r n e t p a p e r .
(4) Mark t h e c o n t o u r of t h e c u t - o u t w i t h O M a t 262 Temporary

marker i n t h e middle of t h e backup p l a t e .
(5) P u t a l o o p of t h e l o c k w i r e t h r o u g h t h e h o l e s i n t h e backup
p l a t e . Loosely t w i s t e a c h l o o p of t h e l o c k w i r e one t u r n .
The w i r e must b e l o n g enough t o p a s s t h r o u g h t h e r e p a i r
a r e a and around t h e clamp b a r and f a s t e n s e c u r e l y .
(6) U s e vacuum c l e a n e r t o remove a l l d u s t and u s e a l i n t f r e e

c l o t h soaked i n O M a t 1/257 c l e a n i n g s o l v e n t t o c l e a n t h e
r e p a i r a r e a and t h e back-up p l a t e (Ref AMM 70-20-01-100-
802) .
REPAIR No. 10
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U
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STRUCTURAL REPAIR
m MANUAL
(7) M i x a s u i t a b l e q u a n t i t y of O M a t 8 / 1 9 2 E p o x y paste adhesive

t o bond t h e backup p l a t e i n p o s i t i o n . R e f e r t o
m a n u f a c t u r e r ' s i n s t r u c t i o n s f o r m i x i n g i n s t r u c t i o n s and
h e a l t h and s a f e t y p r e c a u t i o n s .
(8) A p p l y O M a t 8 / 1 9 2 E p o x y paste adhesive a l l over t h e side of

t h e back up p l a t e t h a t i s t o be bonded t o t h e repair area
and t h e bond area on i n n e r side of the s k i n .
(9) I n t r o d u c e t h e backup p l a t e through t h e c u t - o u t . P o s i t i o n

t h e backup p l a t e w i t h t h e c o n t o u r m a r k e d a t s t e p ( 4 ) .
(10) P u t a s m a l l squared s e c t i o n rod through t h e l o c k w i r e

l o o p s , across t h e repair c u t - o u t and on t h e p r o t e c t i v e
pads.
(11) T w i s t t h e l o c k w i r e around t h e squared s e c t i o n rod s o t h a t

t h e backup p l a t e i s c l a m p e d f i r m l y a g a i n s t t h e i n n e r side
of t h e s k i n . ( R e f F i g u r e 2 0 3 )
( 1 2 ) I n s t a l l t h e t h e r m o c o u p l e s adjacent t o t h e repair area.

DECREASE MUST NOT BE GREATER THAN 5 DEG F ( 3 DEG C)
PER MINUTE.
CAUTION: DO NOT START TO MEASURE THE CURE TIME U N T I L THE

TEMPERATURE HAS REACHED THE REQUIRED RANGE.
(13) C u r e t h e O M a t 8 / 1 9 2 E p o x y paste adhesive b e t w e e n 1 2 0 and

e x p l o s i o n proof h e a t l a m p s t o cure t h e adhesive.
(14) R e m o v e t h e l o c k w i r e s and t h e r o d .
(15) F i l l t h e h o l e s i n t h e backup p l a t e w i t h O M a t 8 / 1 9 2 E p o x y
p a s t e adhesive.

DECREASE MUST NOT BE GREATER THAN 5 DEG F ( 3 DEG C )
P E R MINUTE.
(16) C u r e t h e O M a t 8 / 1 9 2 E p o x y p a s t e adhesive b e t w e e n 1 2 0 and

explosion proof heat l a m p s t o cure t h e adhesive.
(17) Remove the t h e r m o c o u p l e s .
( 1 8 ) A b r a d e t h e adhesive w i t h O M a t 5 / 1 2 1 G a r n e t paper t o o b t a i n
a s m o o t h surface.
REPAIR N o . 1 0
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RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(19) Use a vacuum cleaner to remove all dust and use a lint
free cloth soaked in OMat 1/257 cleaning solvent to clean
the repair area (Ref AMM 70-20-01-100-802).
Prepare the carbon/epoxy repair plies and the bronzemesh layer

(Ref Figure 201)
CAUTION: THE ORIENTATION OF THE REPAIR PLIES MUST BE THE

SAME ORIENTATION AS THE ORIGINAL PLIES THEY ARE
REPLACING.
(1) Make a template for each step in the step sanded area and
for the area where the extra plies are to be applied.
Determine the fibre orientation for each step and mark
this on the templates. The orientation of the extra plies
must be the same as the orientation of the ply below
.
(surface ply)
(2) Cut out a piece of OMat 8/183 dry carbon fabric that is
large enough to cut out all the repair plies. Use two
carbon/epoxy repair plies for each damaged carbon/epoxy
ply of the original laminate. Use two extra carbon/epoxy
repair plies for the outer surface. Add sufficient margin
for further adjustment
(3) Weigh the dry carbon fabric
(4) Cut 2 pieces of OMat 2/131 Non-porous parting film each

approximately 3in. (80mm) larger, all round, than the dry
carbon fabric. Tape down one piece of the non-porous
parting film onto a smooth flat surface. Put the dry
carbon fabric onto the non-porous parting film.
(5) Mix a quantity of OMat 8/160 epoxy paste adhesive that is

equal in mass to the dry carbon fabric weighed at step
(3). Refer to manufacturer's instructions for mixing
instructions.
(6) Use a spatula to apply the adhesive evenly onto the dry
carbon fabric.
(7) Put the second piece of non-porous parting film on the

carbon fabric. Use a squeegee to impregnate the carbon
fabric evenly with adhesive and remove trapped air.
(8) Use the templates made at step 1 to cut out the

carbon/epoxy fabric repair plies.
54-30-00
REPAIR No. 10
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RB211 TRENT
STRUCTURAL REPAl R
MANUAL
(9) Cut a piece of OMat 8/191 Bronzemesh fabric to fit the

repair area. When installed the bronzemesh fabric must
match the orientation of the existing material. Add
sufficient margin for trimming.
(10) Weigh the bronzemesh fabric.
(11) Mix a quantity of OMat 8/160 epoxy paste adhesive that is

equal in mass to the bronzemesh fabric. Refer to
manufacturer's instructions for mixing instructions. Clean
the bronzemesh fabric. Use OMat 1/257 cleaning solvent
(Ref AMM 70-20-01-100-802).
NOTE: The bronzemesh repair ply must be fully dry, clean

and free of solvent before installation.
(12) Cut 2 pieces of OMat 2/131 non-porous parting film 3in.

(80 mm) larger all round than the bronzemesh fabric. Put
one piece of the non-porous parting film onto a smooth
flat surface. Put the bronzemesh fabric onto the non-
(13) Remove the non-porous parting film from the 2 off extra
repair plies.
CAUTION: MAKE SURE THAT THE BRONZEMESH AND CARJ3ON/EPOXY EXTRA

PLIES ARE IN THE CORRECT ORIENTATION.
(14) Lay up the carbon/epoxy fabric extra plies onto the

bronzemesh fabric. Make sure the bronzemesh fabric overlap
is equal all round.
(15) Put the second piece of non-porous parting film on top of

the carbon/epoxy fabric extra plies.
(16) Use a squeegee to work the adhesive through the

~arbon/epoxyfabric plies into the bronzemesh layer.
Remove any wrinkles and trapped air.
(17) Turn the lay up over and remove the non-porous parting
film from the bronzemesh fabric side.
(18) Use a spatula to apply the adhesive evenly onto the

bronzemesh fabric. Keep a thin even layer of adhesive over
the bronzemesh.
NOTE: Do not remove excess adhesive.
(19) Replace the piece of non-porous parting film onto the

impregnated Bronzemesh fabric.
54-30-00
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RB211 TRENT
STRUCTURAL REPAIR
MANUAL
J. Lay up the repair plies (Ref Figure 201)
(1) Remove the non-porous parting film from one side of one of
the smallest repair plies.
(2) Position the carbon/epoxy fabric repair ply adhesive side

down in the step sanded area. Make sure that the
orientation of the carbon/epoxy repair ply matches that of
the existing adjacent structure.
(3) If necessary trim the Carbon/epoxy fabric ply to the same


adhesive deficiency in the impregnated plies.
(5) Remove the non-porous parting film from the top of the
installed carbon/epoxy fabric repair ply.
(6) Remove the non-porous parting film from one side of the
next repair ply and repeat steps (2) to (5) until all the
repair plies are installed in the step sanded area.
NOTE: Keep the extra carbon/epoxy fabric plies

incorporated in the bronzemesh layer for the next
step.
(7) Remove the non-porous parting film from the Carbon/epoxy

fabric plies incorporated onto the bronzemesh layer.
(8) Position the repair plies and the bronzemesh layer on the
repair area in the correct orientation.
(9) If required trim the bronzemesh fabric ply to the

dimension of the repair area.

adhesive deficiency in plies.
(11) Remove the non-porous parting film from the bronzemesh

fabric .
K. Cure the repair area (Ref Figure 204)
REPAIR No. 10
Page 211
Printed in Great Britain Mar l 0 /nR
STRUCTURAL REPAIR
MANUAL
(1) Do t h e bagging and c u r i n g procedure a s g i v e n i n o p e r a t i o n

F.
L. Examine t h e completed r e p a i r
(1) V i s u a l l y examine t h e r e p a i r t o make s u r e i t h a s been

s a t i s f a c t o r i l y completed.
(2) Do a t a p test SRM 54-01-06 Composite S t r u c t u r e Tap T e s t o r

u s e u l t r a s o n i c i n s p e c t i o n equipment t o make s u r e t h e
r e p a i r e d a r e a h a s no damage. I f any damage i s found, r e f e r
t o page b l o c k 101 t o make s u r e t h a t i t i s w i t h i n t h e
permitted l i m i t s .
(3) I f n e c e s s a r y a p p l y primer and f i n i s h p a i n t c o a t , r e f e r t o

SRM Chapter 54-30-00, FRSX056 r e p a i r n o . 1 1 .
M. Identify the repair.
(1) U s e a permanent marker pen of a c o n t r a s t i n g c o l o u r t o

w r i t e FRSX055 n e x t to t h e e x i s t i n g p a r t number.
EFFECTIVITY : TRENT
REPAIR N o . 1 0
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n U-- '1 n /no
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
ADHESIVE TAPE
SANDER
- CARBON PLY
ORIENTATION
SANDING OPERATION
CARBON REPAIR
EXTRA PLIES
CARBON
BRONZEMESH
REPAIR PLIES
ORIGINAL ------__ -_
1
-
Li
vy-y.. , a v
ADHESIVE A l I
04MINb 0 4 8 +048/048. 060 $ 4 1

(10) (12) (12) (12) (15) 110)
BACKUP PLATE
DIMENSIONS ARE IN INCHES WITH MlLLlMETERS IN PARENTHESES
Figure 201
54-30-00
REPAIR No. 10
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P r l n t e d In Great Brltaln Mar. 10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
GLASS / EPOXY
FABRIC PLIES
NON POROUS
PARTING FlLM
GLASS l EPOXY FABRIC PLIES LAY-UP
BREATHER CLOTH
VACUUM BAG
VACUUM FITTING
A HEAT BLANKET
BREATHERCLOTH
'TING
THERMOCOUPLE GLASS I EPOXY NYLON PEEL PLY

FABRIC PLIES
ADHESIVE TAPE NON POROUS

VACUUM BAG SEAL PARTING FILM
N
F i g u r e 202
EFFECTIVITY : TRENT
54-30-00
REPAIR No. 10
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RB211 TRENT
STRUCTURAL REPAIR
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BACKUP PLATE
SQUARED SECTION ROD
(10) BACKUP PLATE INSTALLATION
Figure 203
E F F E C T I V I TY : TRENT
54-30-00
REPAIR No. 10
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RB211 TRENT
STRUCTURAL REPAIR
MANUAL
VACUUM BAG
VACUUM BAG HEAT BLANKET
BREATHER
CLOTH
NYLON PEEL PLY
THERMOCOUPLE

TEMPERATURE
+5" Flmin MAX

-5" Flmin
(+3" Clmin) MAX
(-3" Clmin)
239" F1257" F
(1 15" Cl1 25" C)
131" F1149" F _-
(55" Cl65" C)
\/
ROOM TEMPERATURE
1
l
4 -: I- -l 1 - 1
t TIME
-
L.,
0
420 to 1440 min 60 to 75 min 150 to 165 min
0
N
CURING CYCLE
a
0
G
R Figure 204
EFFECTIVITY : TRENT
REPAIR No. 10
Page 216
R P r i n t e d i n Great B r l t a i n M a r . 10/08
lul STRUCTURAL REPAIR
REPAIR no-11
APPLY PRXmR PAXUT COAT ON CARBON COMPOSXTB RKII4, PRSXO56
A. This procedure gives instructions to apply primer paint coat on

the finished surfacm of a carbon composite skin,
NOTE: This primes paint coat is nsesasary only when t h e original

protection haa bean w o r n ar rgmaved during a skin repair.
B. This procedure Is applicable for external (air washad ~urfacal

and internal ekins.
R AMM TASK 77-20-01-100-802 Cold Liquid Degreasing

3. Equipment and Matariala
A. Standard %guipmant
Staaderd workahop tools and equipment
Rest lamp 25 to X20 deg C I75 t o 256 deg P)
Paint rpray gun 3 to S bar
B. Consumable makerials
- - - - - e - - - c - t - - - - - - - - - - - r - - - - - - - - - - * - - - - - - - = - - - - - ~ m ~ - - ~ ~ - - - ~ - - - - - ~ - ~ - - - - - ~ -
REFERENCE DES XGNATIOW

- - " - - - L - - - - - l - - - l - - - ~ - - - - m - - - - - - - - - C C C C * - - - - * - ~ = - ~ - - - - - - - - ~ ~ - ~ - - - - - - - - -
OMat: 272 ADRESXVE TAPE 2 5 . 4 MM (1.0 ZNS WIDE

R OMat 7 / 1 9 8 POLYURETHANR COATTNQ, BASE, 5014 15425/6407)
R OMat 7 / 1 9 9 POLYURETHANE COATING, HARbRlVER, 50 1 4
R /0707/9000)
R OMat 7 / 2 0 0 POLYURETHANE COATING, TfIINNFRS, 5014
R (0491/9000)
C, Componant material
- - C - C I - C - - I - - - - - - - - I - 1 - - - - 1 - 1 - - - * - I I I - - I - - - - w - - - - - - - - - - - - - - - - - * - - - - - - - - - - - - - -
PART r ~ m MAT~RXAL
- - - - - - - - - - I - - - L " - - - - - - - - - - - I - - - - - I - - - - - - - - - - - - - - - - - - - - - - - - " - - " - - - - - - - - = - - - - - - -

REPAIR NO.11
54-36-00
Page 201
Feb. 2 5 / 6 5
P t inctd in Great B r i t a i n
RB211 TRENT
STRUCTURAL REPAIR
WARNINQ: WHEN YOU DO THIS REPAIR YOU MUST WEAR PROTECTWE CLOTHING,
GLOVES, DDST MASK AND SAFETY GOGQEES TO PROTECT YOU AGPLZNST
DUST AND LOOSE PARTICLES, WHICH CAN BE DANGEROUS TO Y0WR
HEALTH.
WARNTNa: WREN YOU UdE THE C Z M N d WATERIALS, COATINGS AND SEALANTS,

REFER TO, AND OBEY THE HAMTPACTIJRER4S CONTROL AND APPLICATXOP
INSTRUCTfONS AND H W T H AND SAFETY NQTXCES.
4. Prenare tha damaaed area f o r ~ a i n t
A. G l e a n the repair area 1Rsf. M!X TASK 70-20-01-100-8112).
8. P u t OMat 273 ADfiXSnrP! TAPE around the repair area for

protection of adjacant ~urfaces.
NOTE: Do not touch the aurfaee to be painted.
5. Prepare t h e primer p a i n t
A. M i x the OMat 7 / 1 9 8 POLYWRETRANK COATTNB, BASE with OMat 71199

POEYWRETHANE COATING, FLARDENER. Raf er t o the manufacturer8s
inatructions for h e a l t h precautions and mllx weight r a t i o .
B. Vse OMat 7 / 2 0 0 POLYURETWUE COATING, THZlWERS to make the

mixture aa t h i n aa neceeeary.
6. Apply the prfmsr paint:
A. Apply the primer paint coat on tha repair surface. Do t h s

operation in three layers applied in differant direetiena with
a spray gun.
B. L e t the primer dry Ecrr 3 0 minutes at room temperaturerr then

cure t h e p a i n t c o a t for a minimum of one hour at 511 to 6 4 deg C
(122 to 140 deg F) w i t h a heat lamp,
C. C l e a n the repair area (Rsf, W TASK 70-20-01-100-8021
7. Examine the Cwlpletsd Repair
A. A p p l y OMat 272 ADHESXVg TAPE on one edge of the paintad

eurfaee, then quickly pull away the tape to make aurs af good
t removed. ff it is, remove the
edhestion. Ho p a i n t coat: m t ~ ~ba
paint and do the procedure again.
EFFEmIWTY :TRENT REPAIR P46.11

54-30-00
Page 202
R Feb. 1 5 / 0 6
Printed In Great Britain
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR N0.12
THRUST REVERSER
REPAIR CARBON COMPOSITE SKIN I N SANDWICH AREA

'0
0
o WITH A BRONZE MESH LAYER
0
U
al
-0 1. G e n e r a l
CAUTION: YOU MUST REFER TO THE ALLOWABLE DAMAGE, PAGE BLOCK 1 0 1 , TO MAKE SURE
THAT REPAIR I S PERMITTED.
A . T h i s p r o c e d u r e g i v e s i n s t r u c t i o n s t o r e p a i r damage t o c a r b o n composite s k i n
i n a sandwich a r e a , when t h e s k i n h a s a b r o n z e mesh o u t e r l a y e r .
NOTE: T h i s r e p a i r p r o c e d u r e i s a p p l i c a b l e o n l y i f t h e damage i n t h e o u t e r
s k i n i s n o t more t h a n 15 mm (0.6 i n . ) d i a m e t e r . F o r l a r g e r damage
r e f e r t o r e p a i r no.13.
B. Damage can be r e p a i r e d by t h e u s e o f a d h e s i v e t o f i l l t h e sandwich a r e a ,

and t h e a p p l i c a t i o n o f carbon f a b r i c r e p a i r p l i e s p l u s a b r o n z e mesh p l y .
54-30-00, R e p a i r No.11 Apply p r i m e r s e a l e r p a i n t

TASK 78-33-13-300-015 FRSX057 T r e n t e n g i n e manual
A . S t a n d a r d equipment
Hot a i r b l o w e r 100 deg C (212 deg F) maximum
S t e e l r o l l e r 5 0 . 8 mm (2 i n . ) d i a m e t e r
REPAIR N0.12
EFFECTIVITY: TRENT
Page 201
July 1/98
H RB.211 TRENT
MANUAL
- Vacuum pump to 8 0 percent with vacuum gauge
- Curing cycle monitoring and automatic reporting feature
- Load power capability (as an indication): 6000 Watts
- Thermocouples
Pneumatic sander, power 0.16 Kilowatts
Squeegee
Steel guides of 254 mm ( 1 0 in.) minimum length
..............................................................................
PART IDENT MATERIAL
..............................................................................
OMat 272 ADHESIVE TAPE 1 in. WIDE
OMat 21101 LINT FREE CLOTH
OMat 21126 VACUUM BAG
OMat 21129 BREATHER CLOTH
OMat 21130 POROUS PARTING FILM
OMat 21131 NON-POROUS PARTING FILM
OMat 51121 ABRASIVE DISC GRADE 60
OMat 81192 ADHESIVE
OMat 81160 EPOXY ADHESIVE
OMat 81191 BRONZE MESH FABRIC
------------------------------------------------------------------------------
PART IDENT MATERIAL
------------------------------------------------------------------------------


allowable damage, page block 1 0 1 , to make sure that the damage is in the
repairable limits.
REPAIR N0.12
EFFECTIVITY: TRENT
Page 202
July 1 / 9 8
RB.211 TRENT
MANUAL
5 . P r e p a r e t h e damaged a r e a f o r r e p a i r (Ref F i g u r e 201)

vacuum c l e a n e r and OMat 21101 LINT FREE CLOTH soaked w i t h OMat 135 MEK.
CAUTION: THE RATE OF TEMPERATURE INCREASE MUST NOT BE MORE THAN 3 deg C ( 5
deg F) PER MINUTE.
B. Dry o u t t h e damaged a r e a f o r 1 hour minimum a t 91 t o 96 deg C (195 t o 205

deg F) w i t h a h e a t b l a n k e t .
C . Trim o u t t h e damaged a r e a t o a smooth s q u a r e o r r e c t a n g u l a r s h a p e w i t h

rounded c o r n e r s of 1 2 . 5 mm (0.5 i n . ) minimum r a d i u s . During t h e t r i m o u t
o p e r a t i o n r e c o r d t h e number and o r i e n t a t i o n o f p l i e s .
NOTE: Take c a r e n o t t o c a u s e damage t o t h e undamaged p l i e s and s u r r o u n d i n g

material.
D. C l e a n t h e a r e a w i t h a vacuum c l e a n e r and O M a t 21101 LINT FREE CLOTH soaked

w i t h OMat 135 MEK. Dry t h e s u r f a c e b e f o r e t h e s o l v e n t e v a p o r a t e s .
E. Mask o f f t h e a r e a a r o u n d t h e c u t - o u t . Add 12 mm ( 0 . 4 8 i n . ) minimum f o r

e a c h p l y r e p l a c e m e n t p l u s 15 mm (0.6 i n . ) f o r t h e e x t r a p l i e s i n s t a l l a t i o n .
F. Lay o u t t h e z o n e s t o s t e p - s a n d , t h e n i n s t a l l s t e e l g u i d e s w i t h OMat 272

ADHESIVE TAPE.
G. S t a r t s t e p - s a n d from t h e damage c e n t r e t o t h e o u t e r f a c e u s i n g a s a n d e r
w i t h O M a t 51121 ABRASIVE DISC. Each s t e p dimension i s a minimum of 12 mm
(0.48 i n . ) wide a r o u n d t h e c l e a n e d up damage. Make a smooth r e c t a n g u l a r o r
s q u a r e s h a p e w i t h rounded c o r n e r s of 1 2 . 5 mm (0.5 i n . ) minimum r a d i u s .
REPAIR N0.12
EFFECTIVITY: TRENT
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J u l y 1/ 9 8
RB.211 TRENT
-
B STRUCTURAL REPAIR
MANUAL
H.Make the outer skin rough with OMat 5/94 ABRASIVE PAPER to a distance of 37
mm (1.46 in.) minimum all around the repair edge (for the extra repair plies
and bronze mesh layer).
CAUTION: TAKE CARE NOT TO PUT OMAT 135 MEK INSIDE THE HONEYCOMB.
I. Remove all sanding dust with a vacuum cleaner and wipe surfaces with OMat
21101 LINT FREE CLOTH moistened with OMat 135 METHYL ETHYL KETONE. Dry the
J. If the honeycomb is metallic, then apply the OMat 81180 POUR COAT with a
NOTE: Drain unwanted pour coat from the honeycomb.
6. Fill core with adhesive (Ref Figure 201)
WARNING: DO NOT PUT MORE THAN 450 G (1 LB) OF OMAT 81192 ADHESIVE IN ONE
CONTAINER. IF YOU MIX MORE THAN 450 G (1 LB) IN A CONTAINER AN
WARNING: USE OMAT 9/192 ADHESIVE IN AN AREA OPEN TO THE AIR. CAREFULLY READ
A. Mix the OMat 8/192 adhesive parts A and B in accordance with the
B.Use the adhesive to fill all the honeycomb thickeness until flush with the
deepest carbon ply. Use a clean spatula to make the adhesive level with the
adjacent surface.
CAUTION: THE RATE OF TEMPERATURE INCREASE MUST NOT EXCEED 3 deg C (5 DEG F)
PER MINUTE.
C. Install the thermocouples adjacent to the repair area. Cure the adhesive
for seven hours at 18 to 28 deg C (64 to 82 deg F) plus two hours minimum
at 91 to 96 deg C (195 to 205 deg F) with a heat blanket.
REPAIR N0.12
EFFECTIVITY: TRENT
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1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
D. Remove t h e h e a t b l a n k e t and c l e a n t h e a r e a u s i n g OMat 21101 LINT FREE CLOTH

a n d a vacuum c l e a n e r i f n e c e s s a r y .
7 . P r e p a r e t h e r e p a i r p l i e s (Ref F i g u r e 201)
0
(0
CAUTION: EACH PAIR OR REPAIR PLIES MUST BE OF THE SAME ORIENTATION AS THE
ORIGINAL PLY BELOW.
A . F i n d t h e number, t y p e and o r i e n t a t i o n o f t h e p l i e s t o be p r e p a r e d a c c o r d i n g
t o t h e o r i g i n a l s t r u c t u r e . Two OMat 81183 CARBON FABRIC r e p a i r p l i e s must
b e u s e d f o r e a c h damaged c a r b o n r e p a i r p l y o f t h e o r i g i n a l l a m i n a t e . Use
two e x t r a c a r b o n r e p a i r p l i e s f o r t h e o u t e r s u r f a c e .
B. Make a t r a c i n g o f t h e s t e p - s a n d t o f i n d t h e r e p a i r p l i e s d i m e n s i o n s .
C. From t h e t r a c i n g s made i n s t e p B , c u t t h e OMat 81183 CARBON FABRIC r e p a i r

plies. Cut t h r e e p i e c e s o f OMat 21131 NON-POROUS PARTING FILM e a c h
a p p r o x i m a t e l y 8 0 mm ( 3 i n . ) l a r g e r , a l l r o u n d , t h a n t h e c a r b o n f a b r i c .
Tape down one non-porous p a r t i n g f i l m on a f l a t and smooth s u r f a c e .
NOTE: Add s u f f i c i e n t margin t o p e r m i t f u r t h e r a d j u s t m e n t .
D. P u t t h e r e p a i r f a b r i c o n t o t h e non-porous parting film.
WARNING: DO NOT MORE THAN 250 G (0.55 LB) OF OMAT 81160 ADHESIVE I N ONE
E. Mix t h e OMat 81160 a d h e s i v e p a r t s A and B i n a c c o r d a n c e w i t h t h e

F. Weigh t h e carbon f a b r i c and p r e p a r e a q u a n t i t y o f epoxy a d h e s i v e o f e q u a l

w e i g h t . Apply e v e n l y t h e s e l e c t e d q u a n t i t y of a d h e s i v e o n t o t h e r e p a i r p l y
using a spatula.
G. P u t t h e second non-porous p a r t i n g f i l m on t h e r e p a i r p l y . Then u s e a

r o l l e r t o work t h e a d h e s i v e t h r o u g h t h e r e p a i r p l y t o i m p r e g n a t e i t and
remove e n t r a p p e d a i r .
H. Use a c u t t e r t o c u t o u t t h e r e q u i r e d number o f O M a t 81183 CARBON FABRIC

r e p a i r p l i e s i n a c c o r d a n c e w i t h t r a c i n g done i n s t e p 7.B.
REPAIR N0.12
EFFECTIVITY: TRENT
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J u l y 1/98
RB.211 TRENT
s STRUCTURAL REPAIR
MANUAL
8. Lay up of r e p a i r p l i e s (Ref F i g u r e 201)
A. Remove t h e non-porous p a r t i n g f i l m from one s i d e of t h e s m a l l e s t r e p a i r

p l y . Put t h e exposed f a c e a g a i n s t t h e r e p a i r a r e a w i t h t h e same
o r i e n t a t i o n a s i n o r i g i n a l p l y below.
B. Trim t h e r e p a i r p l y e d g e s t o f i t t h e c u t - o u t w i t h o u t c l e a r a n c e .
C . Use a r o l l e r and a s q u e e g e e t o remove a n y w r i n k l e s and e n t r a p p e d a i r .
pressure.
D. Remove t h e non-porous p a r t i n g f i l m from t h e r e p a i r p l y i n s t a l l e d . Put t h e

s e c o n d r e p a i r p l y i n p o s i t i o n w i t h t h e same o r i e n t a t i o n .
E.Put t h e n e x t l a r g e s t r e p a i r p l y and s u b s e q u e n t p l i e s on t h e r e p a i r a r e w i t h
t h e c o r r e c t o r i e n t a t i o n a s d e s c r i b e d i n s t e p A.
F. Cut a p i e c e o f OMat 81191 BRONZE MESH FABRIC 10 mm (0.4 i n . ) l a r g e r , a l l

around, t h a n t h e e x t r a carbon r e p a i r p l i e s .
G. P u t t h e b r o n z e mesh l a y e r o n t o t h e t h i r d p i e c e o f non-porous parting film.
H. Apply e v e n l y t h e s e l e c t e d q u a n t i t y of O M a t 81160 ADHESIVE o n t o t h e

bronzemesh l a y e r u s i n g a s p a t u l a .
CAUTION: THE DISTANCE BETWEEN THE REPAIR LAYER AND THE ORIGINAL BRONZE MESH
MUST NOT BE MORE THAN 1 , O mm (0.04 i n . )
I. I n s t a l l t h e b r o n z e mesh l a y e r on t h e r e p a i r a r e a , i n a l i g n m e n t w i t h t h e
b r o n z e mesh l a y e r a l r e a d y i n s t a l l e d .
9. Bagging (Ref F i g u r e 202)
A. I n s t a l l t h e thermocouple a d j a c e n t t o t h e r e p a i r p l i e s .
B. Cut a p i e c e o f OMat 21130 POROUS PARTING FILM w i t h 8 0 mm ( 3 i n . ) o v e r l a p

a r o u n d t h e e d g e s and l a y o v e r t h e r e p a i r p l i e s .
C. O v e r l a p w i t h a p i e c e o f OMat 21131 NON-POROUS PARTING FILM c u t t o t h e same

s i z e a s t h e non-porous p a r t i n g f i l m .
D. P u t a l a y e r of OMat 2/129 BREATHER CLOTH and a h e a t b l a n k e t on t h e r e p a i r

area.
REPAIR N0.12
EFFECTIVLTY: TRENT
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RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
E . P u t OMat 2 1 1 1 0 ~SEALANT TAPE around t h e f u l l a r e a . Then c u t a s u i t a b l e

NOTE: I f t h e r e p a i r is i n an a c o u s t i c a r e a , then cover t h e f u l l d r i l l e d

p a n e l w i t h s u f f i c i e n t vacuum bag t o p r e v e n t l e a k a g e .
F. Evacuate t h e lay-up t o a vacuum o f 0 . 7 b a r i n s i d e t h e bag.
10. C u r i n g

deg C (239 t o 257 deg F ) .
A. Remove t h e l a y up o f m a t e r i a l s from t h e r e p a i r .
B. V i s u a l l y i n s p e c t t h e r e p a i r f o r freedom from r e s i n s t a r v e d a r e a s , b l i s t e r s
o r e x c e s s r e s i n a r e a s . Abrade i f n e c e s s a r y .
WARNING: USE OMAT 135 METHYL ETHYL KETONE I N AN AREA OPEN TO THE A I R . THIS
MATERIAL I S FLAMMABLE AND GAS I S DANGEROUS. I T CAN CAUSE IRRITATION
OF EYES, NOSE, THROAT AND SKIN. H I G H CONCENTRATION CAN CAUSE
C . Remove a l l unwanted m a t e r i a l s w i t h a s u c t i o n c l e a n e r . Clean t h e s u r f a c e

w i t h O M a t 135 MEK and OMat 21101 LINT FREE CLOTH. Wipe t h e s u r f a c e d r y
before the solvent evaporates.
D. Make a v i s u a l i n s p e c t i o n t o make s u r e t h a t t h e r e p a i r h a s been done i n

from damage. I f n o t , r e f e r t o a l l o w a b l e damage, page b l o c k 101, t o make
s u r e t h a t damage i s i n t h e p e r m i t t e d l i m i t s .
F. Apply p r i m e r s e a l e r p a i n t t o t h e r e p a i r a r e a , i f n e c e s s a r y . Refer t o
54-30-00, R e p a i r No.11.
REPAIR N0.12
EFFECTIVITY: TRENT
Page 207
J u l y 1/98
RB.211 TRENT
MANUAL
CARBON PLY
ORIENTATION
ADHESIVE TAPE
SANDING OPERATION
BRONZEMESH CARBON BRONZEMESH

LAYER EXTRA PLIES LAYER
CARBON REPAIR
PLIES
DIMENSIONS ARE IN INCHES LAY-UP PRINCIPLE

R e p a i r P r e p a r a t i o n and Lay-Up
F i g u r e 201
REPAIR N0.12
EFFECTIVITY: TRENT
Page 208
July 1/98
1 @
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
VACUUM BAG
L
> CARBON
COMPOSITE
fl 7 SEALANT
POROUSPARTING
Fl LM l
NON POROUS
BREATHER
FABRIC
BAGGING OPERATION
TEMPERATURE
-2 to 3" Clmin
I
I
I
I
I
=,
rO
TIME
-
F
m 150 min/l60 min
CURING CYCLE
Bagging Operation and Cure Cycle
Figure 202
REPAIR N0.12
EFFECTIVITY: TRENT
Page 209
July 1/98
RB.211 TRENT
w s STRUCTURAL REPAIR
MANUAL
REPAIR N0.13
THRUST REVERSER
REPAIR CARBON SKIN AND CORE I N SANDWICH AREA
WITH A BRONZE MESH LAYER
1. General
CAUTION: YOU MUST REFER TO THE ALLOWABLE DAMAGE LIMITS, PAGE BLOCK 101, TO
MAKE SURE THAT REPAIR I S PERMITTED.
A. T h i s p r o c e d u r e g i v e s i n s t r u c t i o n s t o r e p a i r damage ( o t h e r t h a n a
t h r o u g h - h o l e ) i n a sandwich a r e a , when t h e o u t e r s k i n ( w i t h a b r o n z e mesh
l a y e r ) and t h e honeycomb a r e damaged.
B. Damage c a n be r e p a i r e d by t h e i n s t a l l a t i o n o f a honeycomb p l u g and t h e

a p p l i c a t i o n of wet lay-up c a r b o n f a b r i c r e p a i r p l i e s p l u s a b r o n z e mesh
layer.
2. R e f e r e n c e d I n f o r m a t i o n
..............................................................................
54-30-00, R e p a i r No.11 Apply P r i m e r S e a l e r P a i n t

Hot a i r blower 100 deg C (212 d e g F) maximum
S t e e l r o l l e r 50.8 mm (2 i n . ) d i a m e t e r
- Vacuum pump t o 8 0 p e r c e n t w i t h vacuum gauge
REPAIR N0.13
EFFECTIVITY: TRENT
Page 201
J u l y 1/98
RB.211 TRENT
m@STRUCTURAL REPAIR
MANUAL
- Curing cycle monitoring and automatic reporting features
- Load power capability (as an indication): 6000 Watts
- Thermocouples
Pneumatic sander, power 0.16 Kilowatts
Squeegee
Steel guides of 254 mm (10 in.) minimum length.
..............................................................................
..............................................................................
OMat 8/192 ADHESIVE
OMat 8/191 BRONZE MESH FABRIC
..............................................................................
PART IDENT MATERIAL 4
..............................................................................

allowable damage, Page block 101, to make sure that the damage is in the
permitted limits.
REPAIR N0.13
EFFECTIVITY: TRENT
Page 202
July 1/98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
5 . P r e p a r e t h e damaged a r e a f o r r e p a i r (Ref F i g u r e 201)

vacuum c l e a n e r and OMat 21101 LINT FREE CLOTH soaked w i t h OMat 135 MEK.
CAUTION: THE RATE OF TEMPERATURE INCREASE MUST NOT BE MORE THAN 3 deg C ( 5
deg F) PER MINUTE.
B. Dry t h e damaged a r e a f o r 1 hour minimum a t 91 t o 96 d e g C (195 t o 205 d e g

F) w i t h a h o t a i r blower.
C . Trim o u t t h e damaged a r e a t o a smooth s q u a r e o r r e c t a n g u l a r s h a p e w i t h

rounded c o r n e r s o f 1 2 . 5 mm ( 0 . 5 i n . ) minimum r a d i u s . During t h e t r i m o u t
o p e r a t i o n r e c o r d t h e number and o r i e n t a t i o n o f p l i e s .
NOTE: Take c a r e n o t t o c u t t h e undamaged p l i e s and t h e s u r r o u n d i n g

material.
D. Clean t h e a r e a w i t h a vacuum c l e a n e r and OMat 21101 LINT FREE CLOTH s o a k e d

w i t h O M a t 135 MEK. Dry t h e s u r f a c e b e f o r e t h e s o l v e n t e v a p o r a t e s .
E. Mask o f f a r e a a r o u n d t h e c u t o u t . Add 12 mm (0.48 i n . ) minimum f o r e a c h

p l y r e p l a c e m e n t p l u s 15 mm ( 0 . 6 i n . ) f o r t h e e x t r a p l i e s and 1 0 mm (0.4
i n . ) f o r t h e b r o n z e mesh l a y e r .
F. Lay o u t t h e z b n e s t o s t e p - s a n d , t h e n i n s t a l l s t e e l g u i d e s w i t h OMat 272

ADHESIVE TAPE.
REPAIR N0.13
EFFECTIVITY: TRENT
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STRUCTURAL REPAIR
MANUAL
CAUTION: MAKE SURE NOT TO STEP SAND OVER THE SKIN THICKNESS TO BE SANDED.
G. Start step-sand from the damage centre to the outer face using a sander
with an OMat 5/121 GARNET PAPER DISC. Each step dimension is a minimum of
12 mm (0.48 in.) wide around the cleaned up damage. Make a smooth
rectangular or square shape with rounded corners of 12.5 mm (0.5 in.)
minimum radius.
H. Make the outer skin rough with OMat 5/94 ABRASIVE PAPER to a distance of 37
mm (1.46 in.) all around the repair edge (for the extra plies
installation).
I. Remove all sanding dust with a vacuum cleaner and wipe surfaces with OMat
21101 LINT FREE CLOTH soaked with OMat 135 METHYL ETHYL KETONE. Dry the
WARNING: USE OMAT 81180 IN AN AREA OPEN TO THE AIR. THIS MATERIAL IS
FLAMMABLE AND GAS IS DANGEROUS. IT CAN CAUSE IRRITATION OF EYES,
J. If the honeycomb is metallic, than apply the OMat 81180 POUR COAT with a
NOTE: Unwanted pour coat must be drained from the honeycomb.
6. Prepare the plug
A. Find the type of the honeycomb plug from the original honeycomb, the
consumable materials table and the related page block 001.
B. Find the width, length and height of the replacement plug according to the
honeycomb damaged.
NOTE: The replacement honeycomb plug must overlap and make full contact
with the cell walls of the adjacent core material.
C. Find the ribbon direction of the plug in the related Page block 001.
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NOTE: Mark t h e r i b b o n d i r e c t i o n on t h e p l u g and on t h e a r e a t o be r e p a i r e d .
D. Trim t h e c o r e p l u g t o f u l l d e p t h u s i n g a c u t t e r .
7 . Apply a d h e s i v e
A. Mix a s u f f i c i e n t q u a n t i t y o f OMat 81192 ADHESIVE i n a c c o r d a n c e w i t h t h e

CAUTION: MAKE SURE THAT THERE I S NO ADHESIVE LEAKAGE.
B. P u t t h e honeycomb p l u g on a p i e c e o f non-porous p a r t i n g f i l m , t h e n f i l l
w i t h a d h e s i v e t o a d e p t h o f a p p r o x i m a t e l y 5 mm.
C. I n s t a l l t h e t h e r m o c o u p l e s a d j a c e n t t o t h e r e p a i r a r e a . Cure t h e a d h e s i v e
f o r 2 h o u r s a t 91 t o 96 deg C (195 t o 205 d e g F) w i t h a h e a t b l a n k e t .
8 . I n s t a l l t h e p l u g (Ref F i g u r e 201)
A. P u t t h e p l u g i n t o t h e r e p a i r c u t - o u t , t h e n a p p l y O M a t 81192 ADHESIVE on t h e
c e l l w a l l s o f t h e o r i g i n a l c o r e and t o t h e i n s i d e s u r f a c e o f t h e i n n e r
s k i n . Use a c l e a n s p a t u l a t o make t h e a d h e s i v e l e v e l w i t h t h e d e e p e s t p l y
of t h e s k i n cut-out.
9. Bagging (Ref F i g u r e 202)
A. I n s t a l l t h e thermocouples a d j a c e n t t o the plug.
B. Cut a p i e c e of OMat 21130 POROUS PARTING FILM w i t h 8 0 mm ( 3 i n . ) o v e r l a p

a r o u n d t h e e d g e s and l a y o v e r t h e r e p a i r .
C. O v e r l a y w i t h a p i e c e o f O M a t 21131 NON-POROUS PARTING FILM c u t t o t h e same

dimensions.
D. Add a l a y e r o f OMat 21129 BREATHER CLOTH and a h e a t b l a n k e t .
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E . P u t OMat 2/110A SEALANT TAPE a r o u n d t h e f u l l a r e a . Then c u t a s u i t a b l e

NOTE: I f t h e r e p a i r is i n an a c o u s t i c a r e a , then cover the f u l l d r i l l e d

p a n e l w i t h s u f f i c i e n t OMat 21126 VACUUM BAG t o p r e v e n t l e a k a g e .
F. E v a c u a t e t h e lay-up t o a vacuum of 0.7 b a r i n s i d e t h e bag.
10. C u r i n g
A. Cure f o r s e v e n h o u r s a t room t e m p e r a t u r e , p l u s two h o u r s minimum a t 9 1 t o

96 deg C (195 t o 205 deg F ) .
NOTE: Keep a vacuum o f 0 . 7 b a r i n s i d e t h e bag f o r t h e f u l l t i m e o f t h e

cure.
B. Remove a l l lay-up m a t e r i a l s , t h e n a b r a d e t o o b t a i n a smooth r e p a i r s u r f a c e .
1 1 . P r e p a r e t h e r e p a i r p l i e s (Ref F i g u r e 201)
CAUTION: EACH PAIR OF REPAIR PLIES MUST BE THE SAME ORIENTATION AS THE
ORIGINAL PLY BELOW.
A. F i n d t h e number, t y p e and o r i e n t a t i o n o f t h e p l i e s t o be p r e p a r e d a c c o r d i n g
t o t h e o r i g i n a l s t r u c t u r e . Two OMat 81183 CARBON FABRIC r e p a i r p l i e s must
be u s e d f o r e a c h damaged c a r b o n p l y o f t h e o r i g i n a l l a m i n a t e . Use two
e x t r a carbon r e p a i r p l i e s f o r t h e o u t e r s u r f a c e .
B. Make a t r a c i n g o f t h e s t e p - s a n d t o f i n d c a r b o n r e p a i r p l i e s d i m e n s i o n s .
C. Cut t h e c a r b o n f a b r i c r e p a i r p l i e s i n a c c o r d a n c e w i t h t h e t r a c i n g s .
Cut
t h r e e p i e c e s of O M a t 2/131 NON-POROUS PARTING FILM e a c h a p p r o x i m a t e l y 8 0 mm
( 3 i n . ) l a r g e r , a l l r o u n d , t h a n t h e c a r b o n f a b r i c . Tape down one
non-porous p a r t i n g f i l m on a f l a t and smooth s u r f a c e .
NOTE: Add s u f f i c i e n t m a r g i n t o p e r m i t f u r t h e r a d j u s t m e n t .
WARNING: DO NOT PUT MORE THAN 250 G ( 0 . 5 5 LB) OF OMAT 81160 ADHESIVE I N ONE
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D. Mix t h e O M a t 81160 ADHESIVE p a r t s A and p a r t B i n a c c o r d a n c e w i t h t h e

E. Weigh t h e OMat 8/183 CARBON FABRIC and p r e p a r e a q u a n t i t y o f OMat 8/160

ADHESIVE o f e q u a l w e i g h t .
F. P u t t h e r e p a i r p l y o n t o t h e f i r s t non-porous p a r t i n g f i l m . Apply e v e n l y
t h e s e l e c t e d q u a n t i t y of adhesive i n t o t h e r e p a i r p l y u s i n g a s p a t u l a .
G. P u t t h e second non-porous p a r t i n g f i l m on t h e r e p a i r p l y . Use a r o l l e r t o

work t h e a d h e s i v e t h r o u g h t h e r e p a i r p l y t o i m p r e g n a t e i t and remove
entrapped air.
H. Use a c u t t e r t o c u t o u t t h e n e c e s s a r y number of O M a t 81183 CARBON FABRIC

r e p a i r p l i e s i n a c c o r d a n c e w i t h t h e t r a c i n g done i n s t e p ll.B.
12.Lay up o f r e p a i r p l i e s (Ref F i g u r e 201)
A. Remove t h e non-porous p a r t i n g f i l m from one s i d e o f t h e s m a l l e s t r e p a i r

p l y . P u t t h e exposed f a c e a g a i n s t t h e r e p a i r a r e a w i t h o r i e n t a t i o n as i n
o r i g i n a l p l y below.
B. Trim t h e r e p a i r p l y e d g e s t o f i l l t h e c u t - o u t w i t h o u t c l e a r a n c e .
C. Use a r o l l e r and a s q u e e g e e t o remove w r i n k l e s and e n t r a p p e d a i r .
NOTE: To a v o i d a d h e s i v e d e f i c i e n c y i n p l y , do n o t a p p l y t o o much p r e s s u r e .
D. Remove t h e non-porous p a r t i n g f i l m from t h e r e p a i r p l y i n s t a l l e d . Put the

s e c o n d r e p a i r p l y i n p o s i t i o n w i t h t h e same o r i e n t a t i o n .
E. P u t t h e n e x t l a r g e s t r e p a i r p l y and s u b s e q u e n t p l i e s on t h e r e p a i r a r e a
w i t h t h e c o r r e c t o r i e n t a t i o n a s g i v e n i n s t e p A.
F. Cut a p i e c e of O M a t 81191 BRONZE MESH LAYER 10 mm (0.4 i n . ) l a r g e r , a l l

a r o u n d , t h a n t h e e x t r a carbon r e p a i r p l i e s .
G. P u t t h e b r o n z e mesh l a y e r o n t o t h e t h i r d non-porous p a r t i n g f i l m .
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H. Apply e v e n l y t h e s e l e c t e d q u a n t i t y o f OMat 8 / 1 6 0 ADHESIVE o n t o t h e b r o n z e

mesh l a y e r u s i n g a s p a t u l a .
CAUTION: THE DISTANCE BETWEEN THE REPAIR LAYER AND THE O R I G I N A L BRONZE MESH
MUST NOT BE MORE THAN 1 , 0 0 mm ( 0 . 0 4 i n . )
I . I n s t a l l t h e b r o n z e mesh l a y e r on t h e r e p a i r a r e a , a l i g n e d w i t h t h e b r o n z e
mesh l a y e r a l r e a d y i n s t a l l e d .
13.Bagging (Ref F i g u r e 202)
A. I n s t a l l t h e thermocouples a d j a c e n t t o t h e r e p a i r p l i e s .
B. Cut a p i e c e o f OMat 21130 POROUS PARTING FILM w i t h 80 mm ( 3 i n . ) o v e r l a p

around t h e e d g e s and l a y o v e r t h e r e p a i r p l i e s .
C. O v e r l a y w i t h a p i e c e of OMat 2/131 NON-POROUS PARTING FILM c u t t o t h e same

dimensions.
D. P u t a l a y e r o f O M a t 21129 BREATHER CLOTH and a h e a t b l a n k e t on t h e r e p a i r

area.
E. P u t OMat 21110A SEALANT TAPE a r o u n d t h e f u l l r e p a i r a r e a . Then c u t a

s u i t a b l e p i e c e of OMat 21126 VACUUM BAG and b a g o v e r t h e r e p a i r .
NOTE: I f t h e r e p a i r i s i n an a c o u s t i c a r e a , then cover t h e f u l l d r i l l e d

p a n e l w i t h s u f f i c i e n t OMat 21126 VACUUM BAG t o a v o i d a n y l e a k a g e .
F. Evacuate t h e lay-up t o a vacuum o f 0.7 b a r i n s i d e t h e bag.
14. C u r i n g
3 d e g C (5 deg F) PER MINUTE.

(131 t o 149 d e g F ) , and t h e second one f o r 150 t o 160 m i n u t e s a t 115 t o 125
deg C (239 t o 257 deg F ) .
NOTE: Keep a vacuum of 0.7 b a r i n s i d e t h e b a g f o r t h e f u l l time o f c u r e .
A. Remove t h e l a y up m a t e r i a l s from t h e r e p a i r .
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B. V i s u a l l y i n s p e c t t h e r e p a i r f o r freedom from r e s i n s t a r v e d a r e a s , b l i s t e r s
o r excess r e s i n areas.
WARNING: USE OMAT 135 METHYL ETHYL KETONE I N AN AREA OPEN TO THE A I R . THIS
MATERIAL I S FLAMMABLE AND GAS I S DANGEROUS. I T CAN CAUSE IRRITATION
OF EYES, NOSE, THROAT AND SKIN. H I G H CONCENTRATIONS CAN CAUSE
C. Remove a l l unwanted m a t e r i a l s w i t h a s u c t i o n c l e a n e r . C l e a n t h e s u r f a c e
w i t h OMat 135 MEK and OMat 21101 LINT FREE CLOTH. Dry t h e s u r f a c e b e f o r e
D. Make a v i s u a l i n s p e c t i o n t o make s u r e t h a t t h e r e p a i r h a s been done i n

from damage. I f n o t , r e f e r t o a l l o w a b l e damage, Page b l o c k 101, t o make
s u r e t h a t t h e damage i s i n t h e p e r m i t t e d l i m i t s .
F. Apply p r i m e r s e a l e r p a i n t t o t h e r e p a i r a r e a , i f i t i s n e c e s s a r y . Refer t o
54-30-00, R e p a i r No.11.
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RB.211 TRENT
STRUCTURAL REPAIR
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CARBON PLY
ORIENTATION
TAPE
SANDING OPERATION
BRONZEMESH REPAIR EXTRA REPAIR

LAYER PLIES PLIES
I , , ,
I l k \ l
1 1 7
BRONZEMESH
. -.
LAYtH
r \
1
l
J0.48 10.48i 0.48
l
1 0.6 1 0.41
l ADHESIVE
(12) (12) (15) T(lo)'
!
PLUG
DIMENSIONS ARE IN INCHES LAY-UP PRINCIPLE

Preparation and Repair Ply Lay-Up

Figure 201
REPAIR NO. 13
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VACUUM BAG
COMPOSITE
BLANKET
POROUS PARTING BREATHER

FILM FABRIC
NON POROUS
BAGGING OPERATION
TEMPERATURE n -2 to 3" Clmin
I
I
I
I
I
t
TIME
150 min/l60 min
CURING CYCLE
Bagging O p e r a t i o n and C u r i n g Cycle
F i g u r e 202
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REPAIR NO. 14
THRUST REVERSER C-DUCT
REPAIR THROUGH-DAMAGE < 30 MM DIAMETER
IN SANDWICH AREA WITH BRONZEMESH LAYER
1. General
A. This procedure gives instructions to repair through-hole damage

in sandwich areas that have a bronzemesh outer layer.
NOTE: This repair is applicable only if the damage is less than

30mm(l.2in)diameter.For larger holes,refer to Repair No.17.
B. The procedure gives the installation of a fiberglass backup

plate,a honeycomb plug,carbon fabric repair plies and a
bronzemesh layer.
Referenced information
........................................................................
........................................................................
Vacuum cleaner
Hot air blower, l20 deg C(248 deg F) maximum
Steel roller, 50mm (2in) diameter
Steel guides1250mm (loin) long
Steel bar
Protective pads
- Heat blanket,O-l20 deg C (32-250 deg F)
- Vacuum pump to 80 percent,with gage
- Cure cycle monitor with automatic reporting
- Load power indication 6kW
-
Thermocouples
Pneumatic sander, 0.16kW
EFFECTIVITY: TRENT
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d STRUCTURAL REPAIR
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...................................................................
...................................................................
OMat 272 ADHESIVE (MASKING) TAPE
OMat 5/94 GARNET PAPER,Grit Size 150
OMat 5/121 ABRASIVE DISC,Grade 60
OMat 8/191 BRONZEMESH FABRIC
OMat 8/192 PASTE ADHESIVE
........................................................................
PART IDENT MATERIAL
........................................................................
4. Examine the damaue
A. Do an ultrasonic inspection to measure the dimensions of the

damage. Refer to page block 101 to make sure that the damage is
in the repairable limits.
5. P r e ~ a r ethe damased area for r e ~ a i r (Ref Figure 201)
WARNING: YOU MUST USE GLOVES,DUST MASK AND SAFETY GOGGLES TO

PROTECT YOU AGAINST DUST AND LOOSE PARTICLES WHICH CAN BE
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vacuum cleaner-clean the repair surface with OMat 2/101 LINT-
FREE CLOTH soaked with OMat 135 MEK. Dry the surface with a
fresh piece of the cloth before the MEK evaporates.

B. Dry the damaged area for 30 minutes minimum at 91 to 96 deg C

CAUTION: MAKE SURE YOU DO NOT CAUSE DAMAGE TO THE UNDAMAGED PLIES
AM) SURROUNDING MATERIAL.
C. With the pneumatic sander,trim out the damaged area to a smooth

square or rectangular shape with minimum corner radii of 12,5mm
(0.5in) .Make a record of the number and orientation of the
plies.

D. Remove all loose material with the vacuum cleaner.Clean the

repair surface with OMat 2/101 LINT-FREE CLOTH soaked with OMat
135 MEK.Dry the surface with a fresh piece of the cloth before
the MEK evaporates.
E. Mask off the area around the cut out.Add 12mm (0.48in) for each
replacement ply and 15mm (0.60in) for the extra repair plies.
F. Lay out the zones to step-sand,then install the steel guides in

position with OMat 272 ADHESIVE TAPE.
BE SANDED.STOP WHEN YOU SEE A DIFFERENT PLY ORIENTATION.
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G. Start to step-sand from the damage center to the outer face.Use

the pneumatic sander with an OMat 5/121 ABRASIVE DISC.Each step
dimension must be a minimum of 12mm (0.48in) wide around the
cleaned-up damage.Make a smooth square or rectangular shape
with minimum corner radii of 12,5mm (0.50in).
H. Remove the adhesive tape and the steel guides.
J. Make the outer skin rough with OMat 5/94 ABRASIVE PAPER for a
distance of 15mm (0.60in) all around the repair edge (for the

K. Remove all sanding dust with the vacuum cleaner.Clean the

OMat 135 MEK. Dry the surface with a fresh piece of the cloth
WARNING: OMAT 8/180 POUR COAT IS CLASSIFIED AS A HAZARDOUS

L. If the honeycomb is metallic,apply OMat 8/180 POUR COAT with a

brush to all the honeycomb surfaces that you can see.
M. Let the pour coat dry in the air,then cure at 102 to 113 deg C
(215 to 235 deg F) for 30 minutes with the hot air blower.
6. Prepare the fiberqlass back-up plate (Ref Figure 202)
A. Cut a piece of OMat 8/182 FIBERGLASS FABRIC sufficient to make

five plies,each 40mm (1.60in) longer and 2 0 m (0.80in) wider
than the cut-out.
B. Cut two pieces of OMat 2/131 NON-POROUS PARTING FILM

approximately 7 5 m (3.0in) larger,all around,than the
fiberglass fabric.
C. Put one piece of the parting film on a flat,smooth surface.

Hold the film in position with OMat 272 ADHESIVE TAPE.
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D. Weigh the OMat 8/182 FIBERGLASS FABRIC to find the necessary

quantity of adhesive,then lay the fabric on the parting film.
WARNING: DO NOT PUT MORE THAN 250 G (0.55LB) OF OMAT 8/160 EPOXY
ADHESIVE IN ONE CONTAINER-IF YOU DOtAN UNCONTROLLED HEAT

CORRECTLY.BEFORE YOU USE THIS PRODUCTtCAREFULLY READ THE
E. Mix the OMat 8/160 EPOXY ADHESIVE in accordance with the

F. Select a quantity of the adhesive equal in weight to the

fiberglass fabric.Use a spatula to apply the adhesive to the
fabric.
G. Put the second piece of non-porous parting film onto the

fiberglass fabric.Use a roller to work the adhesive through the
fabric to impregnate it and remove entrapped air.
H. Cut five pieces of the impregnated fiberglass fabricteach 40mm

(1.6in) longer and 20mm (0.8in) wider than the repair cut-out.
7. Lay-up the fiberulass plies (Ref Figure 202)
A. Cut and lay flat a piece of OMat 2/131 NON-POROUS PARTING FILM
that is lOmm (0.4in) larger'all round'than the fiberglass
plies.
B. Remove the parting film from the bottom surface of the first
fiberglass ply,then lay it on the larger parting film cut in
step A.
C. Use a roller to remove wrinkles and entrapped air.
NOTE: To prevent adhesive deficiency,do not apply too much

pressure.
D. Remove the parting film from the top surface of the first
fiberglass ply.
E. Remove the parting film from the bottom surface of the second
fiberglass ply,then lay it on the first.
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F. Use a roller to remove wrinkles and entrapped air.
G. Do the same procedure to lay-up the remaining fiberglass plies.
H. Remove the parting film from the top surface of the last(fifth)
fiberglass ply.
8. Baasins and cure ~ r o c e d u r e(Ref Figure 202)
A. Install a thermocouple adjacent to the fiberglass plies.
B. Cut a piece of OMat 2/130 POROUS PARTING FILM with an overlap

of 75mm (3in) and lay it over the stacked fiberglass plies.
C. Overlay with a piece of OMat 2/131 NON-POROUS PARTING FILM of

the same dimensions.

the lay-up area.
E. Put OMat 2/110A SEALANT TAPE around the edges of the lay-up
area.Then cut and install a suitable piece of OMat 2/126 VACUUM
BAG over the full lay-up.

G. Cure in two stages,the first for 60 to 70 minutes at 55 to 65

115 to 125 deg C (239 to 257 deg F).
NOTE: You must keep the vacuum of 0.7 bar during the complete
cure cycle.
H. Remove the lay-up materials from the cured OMat8/182 FIBERGLASS

FABRIC plies. Trim the plies into a square or rectangular shape
with corner radii of lOmm (0.40in) minimum.
EFFECTIVITY: TRENT
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m 1 STRUCTURAL REPAIR
9. Inspection

A. Clean the fiberglass backup plate with OMat 2/101 LINT-FREE

CLOTH soaked with OMat 135 MEK.Dry the surface with a fresh
piece of the cloth before the MEK evaporates.
B. Do a visual inspection to make sure the backup plate has no

delaminations or blisters.
10. Install the backup plate (Ref Figure 203)
A. Drill two pairs of l.Omm (0.4in) diameter holes near the

centerline of the backup plate.
B. Abrade the mating surfaces of the backup plate and the first
20mm (0.8in) of damaged skin from the edge of the cut-out.Use
OMat 5/94 GARNET PAPER.

C. Remove all sanding dust with the vacuum cleaner.Clean the

abraded surfaces with OMat 2/101 LINT-FREE CLOTH and OMat 135
MEK-Dry the surfaces with a fresh piece of the cloth before the
MEK evaporates.
D. With a marker pen,draw the contour of the skin cut-out in the

center of the backup plate.
E. Put a loop of lockwire through the holes in the backup

plate.Loosely twist each loop one turn.
WARNING: DO NOT PUT MORE THAN 450 G (1 LB) OF OMAT 8/192 PASTE
ADHESIVE IN ONE CONTAINER.IF YOU DO,AN UNCONTROLLED HEAT
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m MANUAL
WARNING: OMAT 8/192 PASTE ADHESIVE IS CLASSIFIED AS A HAZARDOUS

F. Mix the OMat 8/192 PASTE ADHESIVE in accordance with the

G. Apply the adhesive to the mating faces of the backup plate and
the skin.
H. Put the backup plate through the skin cut-out and align the
drawn contour.
J. Put a squared section rod through the lockwire loops,across the

repair cut-out and on the two protective pads.
K. Twist the lockwire around the rod to pull the backup plate
tightly against the inner side of the skin.

L. Cure the adhesive for 7 hours at 20 to 25 deg C(68 to 77 deg F)

plus 2 hours at 91 to 96 deg C (195 to 205 deg F) with a heat
blanket.
M. Remove the lockwires'the rod and the pads.
N. Fill the holes in the backup plate'and one layer as thick as

the first ply'with OMat 8/192 PASTE ADHESIVE.
P. Cure the adhesive for 7 hours at 20 to 25 deg C(68 to 77 deg F)

plus 2 hours at 91 to 96 deg C (195 to 205 deg F).
Q. Remove unwanted adhesive with OMat 5/94 GARNET PAPER.Remove all

sanding dust with the vacuum cleaner.

CORRECTLY.BEFORE YOU USE THIS PRODUCTICAREFULLY READ THE
R. Clean the repair area with OMat 2/101 LINT-FREE CLOTH soaked in OMat 135
MEK. Dry the surface with a fresh piece of the cloth before the MEK
evaporates.
EFFECTIVITY: TRENT
REPAIR N0.14
Page 208
-H RB211 TRENT
MANUAL
STRUCTURAL REPAIR
11. P r e ~ a r ethe fiberqlass ply (Ref Figure 201)
NOTE: Fiberglass plies are necessary only if the honeycomb is

metallic.
A. Cut two pieces of OMat 8/182 FIBERGLASS FABRIC of the same

dimensions as the repair honeycomb plug.(The second fiberglass
fabric will be installed after the honeycomb plug).
B. Cut two pieces of OMat 2/131 NON-POROUS PARTING FILM,each

approximately 7 5mm (3 in) larger,all round, than the fiber-
glass fabric.
C. Put one piece of the parting film on a flat,smooth surface.Hold

the film in position with OMat 272 ADHESIVE TAPE.
D. Weigh a piece of the fiberglass fabric (to find the necessary

quantity of adhesive),then lay it on the parting film.
ADHESIVE IN ONE CONTAINER.IF YOU DO AN UNCONTROLLED HEAT


manufacturer' S instructions .
fabric.
12. Lay-UP the fiberulass ~ l v
A. Remove the parting film from one side of the fiberglass fabric.
B. Put the fabric in position on the inner skin.Use a roller to

remove wrinkles and entrapped air.
C. Remove the parting film from the top side of the fabric.
EFFECTIVITY: TRENT
REPAIR N0.14
Page 209
RB211 TRENT
STRUCTURAL REPAIR
m MANUAL
13. Pre~arethe ~ l u q(Ref Figure 201)
A. Refer to page block 101 to find the type and specification of

the original honeycomb.
B. Measure the damage to find the length,width and height of the

replacement honeycomb plug.
NOTE: The replacement plug must overlap and make full contact with
the cell walls of the adjacent core material.
C. Refer to page block 101 to find the ribbon direction of the

honeycomb plug.
D. Mark the ribbon direction on the plug and on the repair area.

CAUTION: DO NOT USE OMAT 135 MEK IF THE PLUG IS NOT METALLIC.
E. Clean the plug in an OMat 135 MEK bath for 60 seconds,or vapour
degrease for a maximum of 4 cycles of 30 seconds per cycle.
F. Fully dry the plug with h a t 2/101 LINT-FREE CLOTH before the
MEK evaporates.
14. A P D ~ Ythe adhesive
ADHESIVE IN ONE CONTAINER.IF YOU D0,AN UNCONTROLLED HEAT

A. Mix a sufficient quantity of OMat 8/192 PASTE ADHESIVE in

EFFECTIVITY: TRENT
REPAIR NO. 14
Page 210
B. Put the honeycomb plug on a piece of non-porous parting film,
then fill it with adhesive to a depth of approximately 5 nun
(0.2 in).Make sure there is no adhesive leakage.
C. Cure the adhesive for 7 hours at 20 to 25 deg C(68 to 77 deg F)

minimumrplus 2 hours at 91 to 96 deg C (195 to 205 deg F) with
a heat blanket.
15. Install the pluq (Ref Figure 201)
A. Put the plug into the cut-out with the correct ribbon direction
as recorded in step 13.D above.
B. Install the second OMat 8/182 FIBERGLASS FABRIC onto the honey-
comb plug.Refer to paras 11 and 12 above.
NOTE: A fiberglass ply is necessary only if the honeycomb is

metallic.
C. Fill the space between the plug and the original core with
OMat 8/192 PASTE ADHESIVE. Use a clean spatula to make the
adhesive level with the deepest ply of the skin cut-out.
16. Basuinu and cure ~rocedure
A. Refer to the bagging procedure given in para 8 above.
B. Evacuate the lay-up to a vacuum of 0.7 bar inside the bag.
NOTE: If the repair is in an acoustic area,cover the full drilled

panel with sufficient OMat 2/126 VACUUM BAG to prevent
leakage.

MORE THAN 3 DEG C (5DEG F) PER MINUTE.
C. Cure the adhesive for 7 hours at 20 to 25 deg C(68 to 77 deg F)

plus 2 hours at 91 to 96 deg C (195 to 205 deg F) with a heat
blanket.
D. Remove all the lay-up materials,then abrade the repair area to

get a smooth surface.
EFFECTIVITY: TRENT
REPAIR NO. 14
Page 211
p
"" RB211 TRENT
STRUCTURAL
MANUAL REPAIR
17. Prepare the external repair plies (Ref Figure 201)

A. Find the number and orientation of the repair plies necessary,

according to the original structure of the outer skin.
B. Make tracings of the step-sands to give the dimensions and

shape of the repair plies.Cut a piece of OMat 8/183 CARBON
FABRIC sufficient to make the total number of repair plies.
C. Cut three pieces of OMat 2/131 NON-POROUS PARTING FILM,each

approximately 7 5 m (3in) larger all round than the carbon
fabric cut in step B.
D. Put one piece of the parting film on a flat,smooth surface.Hold

the film in position with OMat 272 ADHESIVE TAPE.
ADHESIVE IN ONE CONTAINER.IF YOU DO AN UNCONTROLLED HEAT


F. Weigh the carbon fabric and select a quantity of adhesive of

equal weight.
G. Put the carbon fabric onto the first non-porous parting film.
Use a spatula to apply the adhesive to the fabric.
H. Put the second piece of parting film on top of the carbon

fabric.Use a roller to work the adhesive through the fabric and
remove entrapped air.
EFFECTIVITY: TRENT
REPAIR NO. 14
Page 212
RB211 TRENT
STRUCTURAL REPAIR
m MANUAL
J. Cut out the necessary number of repair plies in accordance with

steps A and B above.
18. Lay-up the repair plies (Ref Figure 201)
ply.Put the ply in position,exposed side against the repair
surfacefin the same orientation as the original ply below.
B. Trim the repair ply edges to fit the cut-out without clearance.
CAUTION: TO PREVENT ADHESIVE DEFICIENCY,DO NOT APPLY TOO MUCH

PRESSURE.
D. Remove the parting film from the installed ply,then install the
second ply of the first pair,with the same orientation.
E. Do steps A thru D again to install the next largest and

subsequent carbon repair plies.
F. Cut a piece of OMat 8/191 BRONZEMESH FABRIC,10mm(0.4in)largerf

all round,than the extra carbon repair plies.
G. Put the third piece of OMat 2/131 NON-POROUS PARTING FILM on a

smooth,flat surface,hold down with OMat 272 ADHESIVE TAPE.

H. Lay the bronzemesh fabric on the parting film and apply with a
spatula the selected quantity of OMat 8/160 EPOXY ADHESIVE.
CAUTION: YOU MUST NOT OVERLAP THE BRONZEMESH LAYERS.THERE MUST BE

A CLEARANCE OF NOT MORE THAN 1,o MM (0.04 IN) BETWEEN
THE REPAIR AND THE ORIGINAL LAYER.
J. Install the bronzemesh layer on the repair area,aligned with the

original layer and with a 1 wn(0.04in)clearance all round.
EFFECTIVITY: TRENT
REPAIR N0.14
Page 213
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
19. Baquinu and cure procedure (Ref Figure 204)
A. Install thermocouples adjacent to the repair plies.

of 7 5 m (3in) and lay it over the repair plies.
C. Overlay with a piece of OMat 2/131 NON-POROUS PARTING FILM cut

to the same dimensions.

the lay-up area.
E. Put OMat 2/110A SEALANT TAPE all around the repair area.Then
cut a suitable piece of OMat 2/126 VACUUM BAG and cover the
complete lay-up.
NOTE: If the repair is in an acoustic areanthen cover the full

drilled panel to prevent adhesive leakage.
F. Evacuate the lay-up to a vacuum of 0,7 bar inside the bag.


115 to 125 deg C (239 to 257 deg F).
NOTE: You must keep the vacuum of 0.7 bar during the full cure
cycle.
2 0. Inspection
A. Remove all the lay-up materials from the repair area.
B. Do a visual inspection for resin star~ation~excess resin or

blisters.Abrade with OMat 5/94 GARNET PAPER if necessary.

C. Remove sanding dust with a suction cleaner.Clean the surface

with OMat2/101 LINT-FREE CLOTH soaked with OMat135 MEK.Dry the
surface before the MEK evaporates.
EFFECTIVITY: TRENT
REPAIR N0.14
Page 214
D. Do an ultrasonic inspection to make sure the repaired area is
free from damage. If it is not,refer to page block 101 to make
sure the damage is in the permitted limits.
E. Apply primer sealer paint to the repair area if necessary.

Refer to 54-30-00,Repai.r No.11.
EFFECTIVITY: TRENT
REPAIR N0.14
Page 215
R6211 TRENT
STRUCTURAL REPAlR
MANUAL
REPAIR PLIES
PLUG WITH ADHESIVE
NOTE: INSTALL GLASS O.~MIN-! L1 ADHESIVE

PLY IF HONEYCOMB
g
0
IS METALLIC ONLY. 'l0) sAcKup P w E
E
Repair Preparation and Lay-Up
Figure 201
EFFECTIVITY: TRENT
REPAIR NO. 14
Page 216
July 1/99
R8211 TRENT
STRUCTURAL REPAIR
MANUAL
FIBERGLASS PIES

PARTING FlLM
HEAT BLANKET
VACUUM BAG I BREATHER FABRIC
NON POUROUS
PARTING FlLM
I
VACCUM BAG
THERMOCOUPLE FIBERGLASS
PLIES

Lay-Up of Fiberglass Plies

Figure 202
EFFECTIVITY: TRENT
REPAIR N 0 . 1 4
Page 217
p r i n t e d i n Great B r i t a i n July 1/99
RB211 TRENT
STRUCTURAL REPAIR
m MANUAL
SQUARED SECTION
ROD
PROTECTIVE PAD
2 PLACES
BACKUP PLATE
x 0 . 4 MINI
(10)
BACKUP ARE IN INCHES BACKUP PLATE INSTALLATION
WITH MlLLlMETERS IN PARENTHESES
E
Installation of the Backup Plate

Figure 203
EFFECTIVITY: TRENT
REPAIR NO. 14
Page 218
July 1/99
RB211 TRENT
STRUCTURAL REPAIR
m MANUAL
VACUUM BAG
PARTING F I N THERMOCOUPLE
BAGGlNClG OPERATION
TEMPERATURE
-2 to 3" Chin
I
I
I
I
I
I
I mintJ
70 min
15 50 mint160 mln
t
TIME
CURlNtJG CYCLE
Bagging and Curing Cycle
Figure 204
EFFECTIVITY: TRENT
REPAIR N0.14
Page 219
RB211 TRENT
STRUCTURAL REPAlR
MANUAL
THRUST REVERSER
COSMETIC REPAIR OF CARBON COMPOSITE EDGES
FRSX052
1. General
This procedure gives the instructions to repair edge damage of the

monolithic carbon composite skin.
This procedure covers both through and non-through damage to the

skin edges.
This is not a structural repair. This repair procedure restores the

visual appearance of the panel. It is applicable only when the
damage is classified as an allowable damage.
To do this repair, you must have access to each side of the panel.
...................................................................
SRM 54-30-00, FRSX056 Apply primer paint coat on carbon

composite skin
AMM 70-20-01-100-802 Cold liquid degrease
3. Eaui~mentand Materials
Vacuum cleaner
Steel roller that is 2 inch (50,8 nun) in diameter
Heat blanket with a temperature of 0 to 120 deg C (32 to 250 deg F).
Vacuum pump to 80 % with vacuum gauge
Curing cycle monitoring and automatic reporting feature
Load power capability (as an indication): 6000 Watts
REPAIR N0.16
54-30-00
Page 201
Printed in Great Britain May 15/05
Thermocouples
H RB211 TRENT
MANUAL
STRUCTURAL REPAIR
Pneumatic sander power 0.16 kW
Squeegee
Spatula
Mechanical clamps
..................................................................
..................................................................
OMat 2/110A GS-213 Adhesive tape vacuum bag seal
OMat 2/126 Wrightlon 7400 vacuum bag
OMat 2/129 Airweave SS FR Breather cloth
OMat 2/130 Bleeder lease B parting film porous
OMat 2/131 A4000 parting film non porous
OMat 262 EMS56752 Temporary marker felt/fibre tip
OMat 5/94 150 Grit size garnet paper
OMat 8/117 EA 956 epoxy paste adhesive, (two parts)
OMat 8/182 20759 Glass/Epoxy fabric, dry
OMat 8/183 G806 Carbon epoxy fabric, dry
OMat 8/202 QZ 5111 Release agent
OMat 808 Additive, silica flour
OMat 8/237 71ED Fibres, milled (1/32 in.)
..................................................................
COMPONENT MATERIAL
..................................................................
4. Procedure
HEALTH.
WARNING: WHEN YOU USE THE CLEANING MATERIALS, COATING AND SEALANT,
REFER TO, AND OBEY, THE MANUFACTURER'S CONTROL AND APPLICATION
A. Prepare the damaged area for repair

REPAIR N0.16
54-30-00
Page 202
Refer to figure 201
M RB211 TRENT
STRUCTURAL
MANUAL REPAIR
CAUTION: WHEN YOU REPAIR THE NON-THROUGH DAMAGE DO NOT REMOVE

MORE PLIES THAN IS NECESSARY TO REMOVE THE DAMAGE
CAUTION: MAKE SURE THAT THE DIMENSIONS OF THE CUT-OUT ARE WITHIN
THE DIMENSIONS OF THE ALLOWABLE DAMAGE LIMITS
(1) Use hand tools to dress out the damaged area.
(2) Use a pneumatic sander to apply a 45 deg chamfer around all

of the edges of the cut out.
NOTE: If the damage has extended through the skin, a 45 deg

S chamfer must be applied to both sides of the damaged
skin.
(3) Use a vacuum cleaner to remove all of the dust.
(4) Clean the repair area (refer to AMM TASK 70-20-01-100-802) .

B. Install the lower back-up plate (for through damage only)
Refer to figure 201
(1) Manufacture the back-up plate 2.0 inch. (50,O nun) larger,
on the three sides, than the repair area.
N0TE:Use a metal sheet with a minimum thickness of 0.08

inch. (2,00 m ) .
(2) Apply a layer of OMat 8/202 release agent on the mating

surface of the back-up plate.
CAUTION: DO NOT DAMAGE THE COMPOSITE STRUCTURE WHEN YOU TIGHTEN

THE CLAMPS.
(3) Use mechanical clamps to install the lower back-up plate

below the repair area.
N0TE:Make sure that the edge of the back-up plate aligns

with the monolithic panel edge.
C. Prepare the filling adhesive
Refer to figure 201
REPAIR N0.16
54-30-00
Page 203
CAUTION: YOU MUST USE THE OMAT 8/117 EPOXY PASTE ADHESIVE
WITHIN 15 MINUTES AFTER IT IS MIXED - BEFORE IT STARTS
TO GEL.
(1) Mix the two parts OMat 8/117 epoxy paste adhesive.
N0TE:OMat 8/154 epoxy paste adhesive may be used as an

alternative to OMat 8/117 to repair non through damage
only.
(2) Add up to 40 per cent by weight of OMat 8/237 milled fibres

to the adhesive paste, to get a strong paste.
N0TE:To let the adhesive mixture stay in its required

position, add OMat 808 silica flour to the mixture to
get the necessary consistency.
(3) Fill up the cavity with the adhesive mixture.
N0TE:Make sure that you apply sufficient adhesive mixture

in the cavity.
D. Install the upper back-up plate
Refer to figure 201
(1) Manufacture the back-up plate 2.0 inch. (50,OO mm) larger,
on the three sides, than the repair area.
NOTE: Use a metal sheet with a minimum thickness of 0.08

inch. (2,OO nun) .
(2) Apply a layer of OMat 8/202 release agent on the mating
surface of the back-up plate.
CAUTION: DO NOT DAMAGE THE COMPOSITE STRUCTURE WHEN YOU TIGHTEN

THE CLAMPS.
(3) Use mechanical clamps to install the upper back-up plate

over the adhesive plug.
N0TE:Make sure that the edge of the back-up plate aligns

with the monolithic panel edge.
(4) Use a spatula to fill the adhesive mixture so that the

contour is slightly over-flushed of the skin edge.
REPAIR N0.16
54-30-00
Page 204
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
E. Cure the adhesive
Refer to figure 201 and 203
CAUTION: THE RATE OF TEMPERATURE RISE AND SET MUST NOT BE MORE
THAN 3 deg C (5.4 deg F) PER MINUTE.
CAUTION: THE ROOM TEMPERATURE (RT) CURE TIME MUST NOT BE MORE
THAN 5 HOURS.
(1) Cure OMat 8/117 adhesive for 3 hours minimum at RT 123 deg
C (73.4 deg F)], then for 1 hour at between 95 and 100 deg
C (203 and 212 deg F).
N0TE:Alternatively for non-through damage, cure OMat 8/154

epoxy paste adhesive for 7 hours at RT [23 deg C (73.4
deg F)], use a thermal blanket if necessary and then
for 1 hour at between 95 and 100 deg C (203 and 212 deg
F) .
(2) Remove the back-up plate(s) .
(3) Make sure that the adhesive plug satisfactorily restores
the panel edge profile.
(4) Use OMat 5/94 150 grit garnet paper to repair the edge
profile as required.
(5) Clean the repair area (refer to A M M TASK 70-20-01-100-802).
F. Prepare the cover plies
Refer to figure 202
(1) Cut a piece of OMat 8/183 carbon fabric so that it has a

1.00 inch (25,4 mm) overlap all around the filled area on
both side of the edge.
NOTE: To prevent fraying, the cover plies must be cut to

the finished dimension after they have been soaked
with adhesive.
(1) Weigh the OMat 8/183 carbon fabric cover ply to find the
necessary quantity of OMat 8/160 epoxy adhesive. The mass
of adhesive must be equal to the mass of OMat 8/183 carbon
fabric.
REPAIR N0.16
54-30-00
Page 205
(2)
H RB211 TRENT
MANUAL
STRUCTURAL REPAIR
Cut two pieces of OMat 2/131 non-porous parting film, each

with a minimum of 3 inch. (80,OO m) larger all around the
cover ply.
(3) Put the OMat 8/183 carbon fabric onto the OMat 2/131 non-
(4) Mix the required amount of OMat 8/160 adhesive, refer to

(5) Use a spatula to apply evenly the selected quantity of OMat

8/160 adhesive onto the OMat 8/183 carbon fabric.
CAUTION: DO NOT APPLY EXCESSIVE PRESSURE, IT CAN CAUSE ADHESIVE

DEFICIENCY IN THE PLY.
(6) Put the second piece of OMat 2/131 non-porous parting film
onto the carbon fabric repair ply. Use a roller to work the
adhesive through the OMat 8/183 carbon fabric ply to
impregnate it and remove any entrapped air.
(7) Cut the OMat 8/183 cover ply into two pieces to the
required dimension. The cover plies must have a 0.59 inch.
(15,OO nun) overlap all around the filled area on one side
of the edge.
NOTE: OMat 8/117 epoxy paste adhesive may be used as an

alternative to OMat 8/160 epoxy paste adhesive in the
above procedure.
F. Install the cover plies
Refer to figure 202
(1) Remove OMat 2/131 non-porous parting film from one side of
the cover plies.
(2) Put the exposed face of the cover plies against the
required side of the repair area.
CAUTION: DO NOT APPLY EXCESSIVE PRESSURE, IT CAN CAUSE

ADHESIVE DEFICIENCY IN THE PLY.
(3) Use a roller and a squeegee to remove any wrinkles and any
entrapped air.
(4) Remove the OMat 2/131 non-porous parting film from the OMat
8/183 carbon fabric plies.
REPAIR N0.16
54-30-00
Page 206
G. Bagging operation for cover plies
Refer to figure 202 and 203.
(1) Install the thermocouples near the cover plies.
(2) Install the OMat 2/130 porous parting film on the cover
plies.
NOTE: Make sure that it has an overlap of at least 80 m (3.0

in.) all around the cover plies.
(3) Install theOMat 8/182 glass/epoxy fabric on the porous

parting film.
NOTE: The OMat 8/182 glass/epoxy fabric should not be smaller

than the porous parting film.
NOTE: OMat 8/182 glass/epoxy fabric is used as a bleeder

fabric.
(4) Install the OMat 2/131 non porous parting film on top of
the glass/epoxy fabric.
NOTE: Make sure that theOMat 2/131 non-porous parting film

has an overlap all around the glass/epoxy fabric.
(5) Put the OMat 2/129 breather fabric on the repair area.
NOTE: Make sure that OMat 2/129 breather fabric has an

overlap around the repair area.
(6) Put the heat blanket over the OMat 2/129 breather fabric.
NOTE: Make sure that the heat blanket has an overlap around
the cover plies.
(7) Install another piece of the OMat 2/129 breather fabric on

the heat blanket.
NOTE: The OMat 2/129 breather fabric should not be smaller

than the heat blanket.
(8) Install the vacuum gauge.
(9) Put OMat 2/110A vacuum bag sealant tape all around the
repair area.
(10) Install the OMat 2/126 vacuum bag to cover all the repair
area.
REPAIR N0.16
54-30-00
Page 207
p RB211 TRENT
MANUAL
STRUCTURAL REPAIR
(11) Evacuate the lay-up to a vacuum of 0.7 bar inside the bag.
CAUTION: THE RATE OF TEMPERATURE RISE AND SET MUST NOT EXCEED 3
DEG C (5.4 DEG F) PER MINUTE.
NOTE: Maintain a vacuum of 0.7 bar inside the bag for the
required period of cure.
(12) Cure the OMat 8/160 adhesive impregnated carbon fabric in

two stages, first for 1 hour at between 60 and 65 deg C
(140 and 149 deg F) and then for 150 minutes at between 120
and 125 deg C (248 and 257 deg F).
NOTE: Cure the OMat 8/117 epoxy paste adhesive impregnated

carbon fabric for between 3 and 5 hours at RT 123 deg
C (73.4 deg F)] and 1 hour at between 95 and 100 deg
C (203 and 212 deg F).
(13) Remove the bagging parts.
(14) Clean the repair area (refer to AMM TASK 70-20-01-100-802).
G. Examine the completed repair
(1) Visually examine the repair to make sure it has been

satisfactorily completed. Do a visual inspection for resin
starvation, excess resin or surface blisters.
(2) Use OMat 5/94 150 grit garnet paper to remove any defects
and make the repair surface smooth.
(3) Use a vacuum cleaner to remove all of the dust.
(4) Clean the repair area (refer to AMM TASK 70-20-01-100-802).
(5) Apply primer and finish paint to the surface area (refer to
SRM 54-30-00, FRSX056), if necessary.
H. Identification
(1) Use OMat 262 marker to write FRSX052 adjacent to the

assembly part number.
REPAIR N0.16
54-30-00
Page 208
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
PANEL MONOLITHIC EDGE
SECTION A-A
TYPICAL ON ALL EDGES OF REPAIR AREA
UPPER BACK-UP PLATE

2 mm (0.08 in.) THICK Min CARBON COMPOSITE SKlN
\ I
OMat 8R02
50 mm (2 in.)
I
RELEASE AGENT
PLUG OF FILLING
ADHESIVE
NON THROUGH DAMAGE
SECTION B-B
TYPICAL ON ALL EDGES OF REPAIR AREA
UPPER BACK-UP PLATE

2 mm (0.08 in.) THICK Min CARBON COMPOSITE SKlN
OMat 8R02
RELEASE AGENT
PLUG OF FILLING
~\\\\\\\\\\\\\\\\\\\\\\\\'J
LOWER BACK-UP PLATE ) - 1 5 mm (0.20 in.) Max
THROUGH DAMAGE
Preparation of typical repair for through and non-through damage

Fig. 2 0 1
REPAIR N 0 . 1 6
54-30-00
Page 209
P r i n t e d in Great B r i t a i n May 1 5 / 0 5
R6211 TRENT
STRUCTURAL REPAIR
MANUAL
\
OMat 21126 VACCUM BAG
SECTiON A-A
OMat U129 BREATHER FABRIC,
HEAT BLANKET 80 mm 73 ~n.)
THERMOCOUPLE
OMat 21129 BREATHER FABRIC OMat 2110A
ADHESIVE TAPE
OMat 21131 NON POROUS PARTING FlLM
OMat 81182 FIEERGLASS FABRIC
OMat U130 POROUS PARTING FlLM
COVER PLY
PLUG OF FlLLlNG ADHESIVE

OMat 211 10A
ADHESIVE TAPE
VACUUM HOSE
BAGGING OPERATION - NON THROUGH DAMAGE
OMat =l26 VACCUM BAG

OMat 3129 BREATHER FABRIC \
. SECTION 0-0
HEAT BLANKE JUM HOSE

OMat 21129 BREATHER FABRI
OMat 21131 NON POROUS PARTING FlLM
OMat W182 FIBERGLASS FABRIC
OMat 21130 POROUS PARTING FlLM
PLUG OF FILLING ADHEStVE
CARBON COMPOSITE SKIN OMal Z110A

ADHESIVE TAPE
-
BAGGING OPERATION THROUGH DAMAGE
Bagging Operation
Fig. 202
REPAIR N0.16
54-30-00
Page 210
Printed in Great B r i t a i n May 15/05
p RB211 TRENT
MANUAL
STRUCTURAL REPAIR
TEMPERATURE 30c/fin Max -3'Clmin Max

(-5.4"Flrnin)
I
I
I
I
I
I
I
I
I
1 L 150min
TIME
OMat 81160 EPOXY PASTE ADHE$lVE,CURING CYCLE
TEMPERATURE
3'C/min Max -3"CImin Max
OMat 81117 EPOXY PASTE ADHESIVE CURING CYCLE
Curing Cycle
Fig. 203
REPAIR N0.16
54-30-00
Page 2 1 1
P r i n t e d in Great B r i t a i n May 1 5 / 0 5
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR N0.17
THRUST REVERSER C-DUCT
REPAIR THROUGH-DAMAGE > 30 MM DIAMETER
IN SANDWICH AREA WITH BRONZEMASH LAYER
1. General
A. This procedure gives instructions to repair through-hole damage

in sandwich areas that have a bronzemesh outer layer.
NOTE: This repair is applicable only if the damage is more than

30mm (1.2in) diameter.For smaller through-damage,refer to
Repair No.14.
B. The repair gives the installation of a fiberglass backup plate,

a honeycomb plug,carbon fabric repair plies and a bronzemesh
fabric layer.
........................................................................
........................................................................
3. Eaui~rnentand Materials
Vacuum cleaner
Hot air blower,l20 deg C(248 deg F)
Steel roller, 50mm (2i.n) diameter
Steel guidesf250mm (loin) long
Stee1 bar
Protective pads
Squeegee
-Heat blanket,O-l20 deg C(32-250 deg F)
-Vacuum pump to 80 percent,with gage
-Cure cycle monitor with automatic reporting
-Load power indication 6kW
-Thermocouples
Pneumatic sanderf0.16kW
EFFECTIVITY TRENT
REPAIR NO. 17
Page 201
B RB211 TRENT
MANUAL
STRUCTURAL REPAIR
........................................................................
........................................................................
Omat 2/126 VACUUM BAG
Omat 2/130 POROUS PARTING FILM
OMat 5/94 GARNET PAPER
OMat 5/121 ABRASIVE DISC
OMat 8/154 PASTE ADHESIVE
OMat 8/191 BRONZEMESH FABRIC
........................................................................
PART IDENT MATERIAL
........................................................................
4. Examine the damaue
A. DO an ultrasonic inspection to measure the dimensions of the

damage.Refer to page block 101 to make sure the damage is in
the repairable limits.
5. Prepare the damaqed area for r e ~ a i r (Ref Figure 201)
WARNING: YOU MUST USE GLOVES,MASK AND SAFETY GOGGLES TO PROTECT

YOU AGAINST DUST AND LOOSE PARTICLES THAT CAN BE
EFFECTIVITY TRENT
REPAIR N0.17
Page 202
RB211 TRENT
STRUCTURAL REPAIR
m MANUAL

CORRECTLY.BEFORE YOU USE THIS THIS PRODUCT,CAREFULLY READ
THE APPLICABLE MATERIAL SAFETY DATA SHEET A N D OBEY ALL
vacuum cleaner.Clean the repair surface with OMat 2/101 LINT-
FREE CLOTH soaked with OMat 135 MEK.Dry the surface with a
fresh piece of the cloth before the MEK evaporates.

B. Dry the repair area for 30 minutes minimum at 9 1 to 96 deg C

C. Measure the damage in the inner skin.Add 12 mm (0.48 in) all

round each damaged ply of the inner skin.This will give you the
dimensions to be trimmed out in the honeycomb and outer skin.
CAUTION: MAKE SURE YOU DO NOT CAUSE DAMAGE TO THE UNDAMAGED PLIES
AND ADJACENT MATERIAL.
D. With the pneumatic sander,trim out the core to the dimensions

calculated in step C.Make a smooth square or rectangular shape
with minimum corner radii of 12,s mm (0.5 in).Record the number
and orientation of the plies.

E. Remove all loose material with the vacuum cleaner.Clean the

OMat 135 MEK.Dry the surface with a fresh piece of the cloth
F. Mask off the area around the cut-out.Add 12 mm (0.48 in) for
each replacement ply and 15 mm (0.60 in) for the extra repair
plies.
G. Layout the zones to step-sand,then install the steel guides in

position with OMat 272 ADHESIVE TAPE.
EFFECTIVITY TRENT
REPAIR N0.17
Page 203
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
BE SANDED.STOP WHEN YOU SEE A DIFFERENT PLY ORIENTATION.
H. Start to step-sand from the damage center to the outer face.Use

the pneumatic sander with an OMat 5/121 ABRASIVE DISC.Each step
dimension must be a minimum of 12 mm (0.48 in) wide around the
cleaned-up damage.Make a smooth square or rectangular shape
with minimum corner radii of 12,s mm (0.5 in).
J. Remove the adhesive tape and the steel guides.
K. Use OMat 5/94 ABRASIVE PAPER to make the outer skin rough for a
distance of 15 mm (0.60 in) all around the repair edge (for the

L. Remove all loose material with the vacuum cleaner.Clean the

OMat 135 MEK.Dry the surface with a fresh piece of the cloth
M. If the honeycomb is rnetallic,apply OMat 8/180 POUR COAT with a

brush to all the honeycomb surfaces that you can see.
N. Let the pour coat dry in the air,then cure at 102 to 113 deg C
(215 to 235 deg F) for 30 minutes with the hot air blower.
6. P r e ~ a r ethe fiberalass backuz, late (Ref Figure 202)
A. Cut a piece of OMat 8/182 FIBERGLASS FABRIC sufficient to make

five plies, each 40 mm (1.6 in)longer and 20 mm (0.8 in) wider
than the cut-out.
B. Cut two pieces of OMat 2/131 NON-POROUS PARTING FILM

approximately 75 mm (3.0 in) larger,all round,than the
fiberglass fabric.

Hold the film in position with OMat 272 ADHESIVE TAPE.
EFFECTIVITY TRENT
REPAIR NO. 17
Page 204
RB211 TRENT
STRUCTURAL REPAlR
m MANUAL
D. Weigh the OMat 8/182 FIBERGLASS FABRIC to find the necessary

quantity of adhesive'then lay the fabric on the parting film.
WARNING: DO NOT PUT MORE THAN 250 G (0.55 LB) OF OMAT 8/160 EPOXY
ADHESIVE IN ONE CONTAINER.IF YOU D0,AN UNCONTROLLLED HEAT



fabric.

H. Cut five pieces of the impregnated fiberglass fabric,each 40 mm

(1.6 in) longer and 20 mm (0.8 in) wider than the cut-out.
7. Lav-ux, the fibemlass f lies (Ref Figure 202)
A. Cut and lay flat a piece of OMat 2/131 NON-POROUS PARTING FILM
that is 10 mm (0.4 in) larger'all round'than the fiberglass
plies.
B. Remove the parting film from the bottom surface of the first
fiberglass ply,then lay it on the parting film cut in step A.
CAUTION: TO PREVENT ADHESIVE DEFICIENCY,DO NOT APPLY TOO

MUCH PRESSURE.
C. Use a roller to remove wrinkles and entrapped air.
D. Remove the parting film from the top surface of the first
fiberglass ply.
E. Remove the parting film from the bottom surface of the second
fiberglass ply'then lay it on the first.
EFFECTIVITY TRENT
REPAIR NO. 17
Page 205
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
F. Use a roller to remove wrinkles and entrapped air.
G. Do the same procedure to lay-up the remaining fiberglass plies.
H. Remove the parting film from the top surface of the last(fifth)
fiberglass ply.
8. Bauminu and cure procedure (Re£ Figure 202)
A. Install a thermocouple adjacent to the fiberglass plies.

of 75 nun (3 in) and lay it over the stacked fiberglass plies.
C. Overlay with a piece of OMat 2/131 NON-POROUS PARTING FILM of

the same dimensions.

the lay-up area.
E. Put OMat 2/110A SEALANT TAPE aroud the edges of the lay-up
area.Then cut and install a suitable piece of OMat 2/126 VACUUM
BAG over the full lay-up.


115 to 125 deg C (239 to 257 deg F).
NOTE: You must keep the vacuum of 0.7 bar during the full cure
cycle.
H. Remove the layup materials from the cured OMat 8/182 FIBERGLASS
FABRIC plies.Trim the plies into a square or rectangular shape
with corner radii of 10 mm (0.40 in) minimum.
9. Insvection

EFFECTIVITY TRENT
REPAIR NO. 17
Page 206
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
A. Clean the fiberglass backup plate with OMat 2/101 LINT-FREE

CLOTH soaked with OMat 135 MEK.Dry the surface with a fresh
B. Do a visual inspection to make sure the backup plate has no

delaminations or blisters.
10. Install the b a c k u ~d a t e (Ref Figure 203)
A. Drill two pairs of 1.0 mm (0.4 in) diameter holes near the
centerline of the backup plate.
B. Abrade the mating surfaces of the backup plate and the first
20 mm (0.8 in) of damaged skin from the edge of the cut-out.

C. Remove all loose material with the vacuum cleaner-Clean the

abraded surfaces with OMat 2/101 LINT-FREE CLOTH soaked with
OMat 135 MEK.Dry the surfaces with a fresh piece of the cloth
D. With a marker pen,draw the contour of the skin cut-out in the

center of the backup plate.
E. Put a loop of lockwire through the holes in the backup plate.

Loosely twist each loop one turn.
ADHESIVE IN ONE CONTAINER.IF YOU D0,AN UNCONTROLLED HEAT

F. Mix the OMat 8/154 PASTE ADHESIVE in accordance with the

EFFECTIVITY TRENT
REPAIR N0.17
Page 207
G. Apply the adhesive to the mating faces of the backup plate and
the skin.
H. Put the backup plate through the skin cut-out and align the
drawn contour.
J. Put a squared section rod through the lockwire loops,across the

repair cut-out and on the protective pads.
K. Twist the lockwire around the rod to pull the backup plate
tightly against the inner side of the skin.

MORE THAN 3 DEG C ( 5 DEG F) PER MINUTE.
L. Cure the adhesive for 7 hours at 25 deg C(77 deg F) minimum,

plus 1 hour at 91 to 96 deg C (195 to 205 deg F) with a heat
blanket.
M. Remove the lockwires, the rod and the protective pads.
N. Fill the holes in the backup plateland fill one layer as thick
as the inner skin,with OMat 8/154 PASTE ADHESIVE.
P. Cure the adhesive for 7 hours at 25 deg C(77 deg F) minimum,

plus 1 hour at 91 to 96 deg C (195 to 205 deg F) with a heat
blanket.
Q. Remove unwanted adhesive with OMat 5/94 GARNET PAPER. Remove

all loose material with the vacuum cleaner.

THE APPLICABLE MATERIAL SAFElY DATA SHEET AND OBEY ALL
R. Clean the repair area with OMat 2/101 LINT-FREE CLOTH soaked
with OMat 135 MEK. Dry the surface with a fresh piece of the
cloth before the MEK evaporates.
EFFECTIVITY TRENT
REPAIR N0.17
Page 208
11. Prepare the internal r e ~ a i r lies (Ref Figure 201)
A. Find the number and orientation of repair plies necessary,

according to the original structure of the inner skin.
damaged carbon ply of the original 1aminate.The first pair
must be 12 m (0.48 in) larger,all round, than the filled
hole in the inner skin.
B. Make a tracing of the cut-out to find the dimensions of the

C. Cut a piece of OMat 8/183 CARBON FABRIC sufficient to make the

total number of repair plies measured in step B.
D. Cut two pieces of OMat 2/131 NON-POROUS PARTING FILM,each

approximately 75 nun (3 in) larger,all round,than the carbon
fabric.
E. Put one piece of the parting film on a flat,smooth surface.
ADHESIVE IN ONE CONTAINER. IF YOU D0,A.N UNCONTROLLED HEAT

F. Mix the OMat 8/160 EPOXY ADHESIVE in accordance with the

G. Weigh the piece of carbon fabric and select a quantity of

adhesive of equal weight.
H. Put the carbon fabric onto the first non-porous parting film.
Use a spatula to apply the selected quantity of adhesive.
J. Put the second piece of parting film on top of the carbon

fabric.Use a roller to work the adhesive through the fabric to
impregnate it and remove entrapped air.
K. Cut the necessary number of carbon repair plies in accordance

with steps A and B above.
EFFECTIVITY TRENT
REPAIR NO. 17
Page 209
RB211 TRENT
STRUCTURAL REPAIR
m MANUAL
12. Lay-up the internal r e ~ a i rplies (Ref Figure 201)

A. Remove the parting film from one side of the first carbon
repair ply.Put the ply in position over the filled hole in the
inner skin,in the same orientation as the original skin below.
CAUTION: TO PREVENT ADHESIVE DEFICIENCY, DO NOT APPLY TOO MUCH

PRESSURE.
B. Use a roller and squeegee to remove wrinkles and entrapped air.
C. Remove the parting film from the installed ply,then install the
second ply of the first pair,with the same orientation.
D. Do steps A thru C again to install the subsequent carbon repair

plies in the correct orientation.
E. ~ e m o v ethe parting film from the top surface of the last ply.
13. Bassinu and cure procedure
A. Refer to paragraph 8 for the procedure.
14. Prepare the fiberqlass p l y (Ref Figure 201)
NOTE: Fiberglass plies are necessary only if the honeycomb is

metallic.
A. Cut two pieces of OMat 8/182 FIBERGLASS FABRIC of the same

dimensions as the repair honeycomb plug.(The second fiberglass
fabric will be installed after the honeycomb plug).
B. Cut two pieces of OMat 2/131 NON-POROUS PARTING FILM,each

approximately 75 mm (3 in) larger,all round,than the fiber-
glass fabric.
D. Weigh a piece of the fiberglass fabric (to find the necessary

quantity of adhesive1,then lay it on the parting film.
ADHESIVE IN ONE CONTAINER. IF YOU D0,AN UNCONTROLLED HEAT
EFFECTIVITY TRENT
REPAIR NO. 17
Page 210
F. Mix the OMat 8/160 EPOXY ADHESIVE in accordance with the

G. Select a quantity of the adhesive equal in weight to the fiber-

glass fabric.Use a spatula to apply the adhesive to the fabric.
H. Put the second piece of non-porous parting film on the fiber-

glass fabric.Use a roller to work the adhesive through the
15. Lav-UD the fiberulass ~ l v
A. Remove the parting film from one side of the fiberglass ply.
B. Put the fiberglass ply in position on the installed carbon

repair plies.
CAUTION: TO PREVENT ADHESIVE DEFICIENCIES, DO NOT APPLY TOO MUCH

PRESSURE.
D. Remove the parting film from the top of the fiberglass ply.
16. Prepare the ~ l u a(Ref Figure 201)
A. Refer to page block 001 to find the type,specification and

ribbon direction of the original honeycomb.
B. Measure the damage to find the necessary dimensions of the

replacement plug.
NOTE: The replacement plug must overlap and make full contact with
the cell walls of the adjacent core material.It must also be
flush with the surface of the original core.
C. Make the replacement plug and mark the ribbon direction on the
plug and on the repair area.
EFFECTIVITY TRENT
REPAIR N0.17
Page 211
Printed in G r e a t B r i t a i n July 1/99
RB211 TRENT
STRUCTURAL REPAIR
MANUAL

CORRECTLY-BEFORE YOU USE THIS THIS PRODUCT,CAREFULLY READ
CAUTION: DO NOT USE OMAT 135 MEK IF THE PLUG IS NOT METALLIC.
D. Clean the plug in an OMat 135 MEK bath for 60 seconds,or vapour
degrease for a maximum of 4 cycles of 30 seconds per cycle.
E. Fully dry the plug with OMat 2/101 LINT-FREE CLOTH before the
MEK evaporates.
17. Apvlv the adhesive
WARNING: DO NOT PUT MORE THAN 450 G (1 LE) OF OMAT 8/154 PASTE
ADHESIVE IN ONE CONTAINER.IF YOU DOIAN UNCONTROLLLED HEAT

A. Mix a sufficient quantity of OMat 8/154 PASTE ADHESIVE in

B. Put the honeycomb plug on a piece of non-porous parting film,

then fill it with adhesive to a depth of approximately 5 mm
(0.2 in).Make sure there is no adhesive leakage.
C. Cure the adhesive for 7 hours at 25 deg C (77 deg F) minimum,

plus 1 hour at 91 to 96 deg C (195 to 205 deg F) with a hot air
blower.
18. Install the ~ l u q(Ref Figure 201)
A. Put the plug into the repair cut-out with the correct ribbon
direction as recorded in step 1 6 . A above.
B. Install the second OMat 8/182 FIBERGLASS FABRIC onto the honey-
comb plug. Refer to para.15 above.
C. Fill the space between the plug and the original core with OMat
8/154 PASTE ADHESIVE.Use a clean spatula to make the adhesive
level with the deepest ply of the skin cut-out.
EFFECTIVITY TRENT
REPAIR N0.17
Page 212
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
19. Bauqinu and cure procedure
A. Refer to the bagging procedure given in para.8 above.
NOTE: If the repair is in an acoustic areancover the full drilled

leakage.

C. Cure the adhesive for 7 hours at 25 deg C (77 deg F) minimum,

plus 1 hour at 91 to 96 deg C (195 to 205 dsg F) with a heat
blanket.
D. Remove all the lay-up materials,then abrade the repair area to

get a smooth surface.
20. Prepare the external repair plies (Ref Figure 201)

A. Find the number and orientation of the repair plies necessary,

according to the original structure of the outer skin.
B. Make tracings of the step-sands to give the dimensions and

shape of the repair plies.Cut a piece of OMat 8/183 CARBON
FABRIC sufficient to make the total number of repair plies.
C. Cut three pieces of OMat 2/131 NON-POROUS PARTING FILM,each

approximately 75 mm (3 in) larger,all round,than the carbon
fabric.
D. Put one piece of the parting film on a flat,smooth surface.
ADHESIVE IN ONE CONTAINER.IF YOU DO,AN UNCONTROLLLED HEAT
EFFECTIVITY TRENT
REPAIR NO. 17
Page 213
RB211 TRENT
ImI STRUCTURAL REPAIR
MANUAL


F. Weigh the carbon fabric and select a quantity of the adhesive

of equal weight.
G. Put the carbon fabric onto the first piece of parting film.Use
a spatula to apply the selected quantity of adhesive to the
fabric.
H. Put the second piece of parting film onto the carbon fabric.Use
a roller to work the adhesive through the fabric to impregnate
it and remove entrapped air.
J. Cut out the necessary number of repair plies in accordance with

steps A and B above.
21. Lav-UD the repair lies (Ref Figure 201)

ply.~ut the ply in position,exposed side against the repair
surfacefin the same orientation as the original ply below.
B. Trim the repair ply to fit the cut-out without clearance.
D. Remove the parting film from the installed ply,then install the
second ply of the first pair,in the same orientation.
E. Do steps A thru D again to install the next largest and then

the subsequent carbon repair plies.
F. Cut a piece of OMat 8/191 BRONZEMESH FABRIC, 10 m (0.40 in)

larger,all round,than the extra carbon repair plies.Weigh the
cut fabric to find the necessary quantity of adhesive.
G. Put the third piece of OMat 2/131 NON-POROUS PARTING FILM on a

flat, smooth surface.
EFFECTIVITY TRENT
REPAIR N0.17
Page 214
R8211 TRENT
STRUCTURAL REPAIR

H. Lay the bronzemesh fabric on the parting filmthen use a

spatula to apply the selected quantity of OMat 8/160 EPOXY
ADHESIVE.
CAUTION: YOU MUST NOT OVERLAP THE BRONZEMESH LAYERS.THERE MUST BE
A CLEARANCE OF NOT MORE THAN 1 MM (0.04 IN) BETWEEN THE
REPAIR AND THE ORIGINAL LAYER.
J. Install the bronzemesh layer on the repair areanaligned with

the original layer and with a 1 mm(0.04 inlclearance all round.
22. Bauuinu and cure procedure (Ref Figure 204)
A. Refer to the bagging procedure given in para.8 above.

l
NOTE: If the repair is in an acoustic areancover the full drilled

adhesive leakage.

C. Cure in two stages,the first for 60 to 70 minutes af 55 to 65

deg C (131 to149 deg F),the second for 150 to 160 minutes at
115 to 125 deg C (239 to 257 deg F).
NOTE: You must keep the vacuum of 0.7 bar during the full cycle.
23. Inspection
A. Remove all the lay-up materials from the repair area.
B. Do a visual inspection for resin starvation,excess resin or

blisters.Abrade with OMat 5/94 GARNET PAPER where necessary.
EFFECTIVITY TRENT
REPAIR NO. 17
Page 215
H RB211 TRENT
MANUAL
STRUCTURAL REPAIR

C. Remove loose material with a vacuum cleaner.Clean the surface

with OMat 2/101 LINT-FREE CLOTH soaked with OMat 135 MEK.Dry
the surface with a fresh piece of the cloth before the MEK
evaporates,
D. Do an ultrasonic inspection to make sure the repaired area has

no damage.If it has,refer to page block 101 to make sure the
damage is in the permitted limits.
E. Apply primer sealer paint to the repair area if necessary. Refer to

54-30-00,Repair No.11.
EFFECTIVITY TRENT
REPAIR N0.17
Page 216
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
PNEUMATIC CARBON PLY

"SANDER
ADHESIVE 'T'APE
BRONZEMESH LAYER
EXTRA
REPAIR
PLIES
REPAIR PLIES
BRONZEMESH LAYER
GLASS PLY
' PLUG WITH ADHESIVE
OUTER SKIN
(AIR WASHED SURFAC
BRONZEMESH LAYER
ru
LD
NOTE : INSTALL GLASS

'ois PLY IF HONEYCOMB
LE IS METALLIC ONLY.
Repair Preparation and Lay-Up

Figure 201
EFFECTIVITY TRENT
REPAIR NO. 17
Page 217
l@ RB211 TRENT
MANUAL
STRUCTURAL REPAIR
FIBERGLASS PIES
NON POUROUG FIBERGLASS PLIES LAY-UP

PARTING FILM
HEAT BLANKET
NON POUROUS
PARTING FlLM
I THERMOCOUPLE FIBERGLASS
PLIES
VACCUM BAG
Lay-Up of Fiberglass P l i e s
Figure 202
EFFECTIVITY TRENT
REPAIR NO. 17
P a g e 218
RB211 TRENT
STRUCTURAL REPAIR
m MANUAL
SQUARED SECTION
ROD
Installation of the Backup Plate

Figure 203
EFFECTIVITY TRENT
REPAIR NO. 17
Page 219
Printed i n Great ~ r i t a i n July 1/99
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
VACUUM B A G
COMPOSlTf
BREATHER
NON PORROUS
PARTING5 FILM THERMOCOUPLE
BAGGINOG OPERATION
TEMPERATURE
-2 to 3" Clmin
I
I
I
1
l
I
t
m TIME
v
m 1-60 m i d -- 1150 minll60 min
S
R 70 min
E
CURINEJG CYCLE
l?
Bagging and Cure Cycle
Figure 204
EFFECTIVITY TRENT
54-30-00
REPAIR NO. 17
Page 220
REPAIR NO.18
THRUST REVERSER – C-DUCT
REPAIR OF DAMAGE TO THE TRAILING EDGE
1. General
A. This repair procedure gives the instructions to repair damages

around the rubbing blocks of the C-Duct trailing edge.
CAUTION: THE OVERLAPPING OF REPAIR PATCHES IS NOT PERMISSIBLE.
SRM 54-30-00, Repair No.7 Repair of Edge Through-Damage in Carbon

Composite Skin
SRM 54-30-00, Repair No.8 Repair Edge Delamination of Carbon
Composite Skin
SRM 54-30-01, Repair No.2 Replacement of Rubbing Blocks
SRM 54-30-01, Repair No.5 Damaged Trailing Edge Bottom Corner, with
Loss of one Rubbing Block
SRM 54-02-10 Fasteners – Removal/Installation
AMM TASK 70-20-01-100-802 Non-Aqueous Liquid Degreasing – Maintenance
Process 101
AMM TASK 78-30-00-010-803 Open the Thrust Reverser Cowl Doors
AMM TASK 78-30-00-410-803 Close the Thrust Reverser Cowl Doors

-Mechanical clamps
-Pneumatic riveter
-Heat lamp
REPAIR NO.18
EFFECTIVITY: TRENT
54-30-00
Page 201
OMat 262 TEMPORARY MARKER (Felt/Fibre Tip)

OMat 7/198 POLYURETHANE COATING, BASE
OMat 7/199 POLYURETHANE COATING, HARDENER
OMat 7/200 POLYURETHANE COATING, THINNER
OMat 7/206 POLYURETHANE FINISH COAT (Grey)
OMat 8/106 SEALANT, TWO PART POLYSULPHIDE (Brushable)
OMat 8/107 SEALANT, TWO PART POLYSULPHIDE
C. Repair Parts
ITEM PART NO. PART IDENT. QTY.
1 Local manufacture Titanium strip 1

(Material: TI6AI-4V to AMS Thickness = 1.6 mm
4911 or BSTA 59) (0.063 in.)
2 NAS1921M04S03 to S07 Rivet A/R
According to thickness
3 MS20427-M4-5 or –6 Rivet A/R
According to thickness
4 91A495-00 Laminated shim A/R
COMPONENT MATERIAL
4. Remove the Rubbing Blocks
A. Make a record of the positions of the rubbing blocks before you

remove them.
B. Remove the rubbing blocks (Ref. SRM 54-30-01, Repair No.2).
B. Measure and record the thickness of the laminated shim (4)

associated with each rubbing block.
NOTE: If a laminated shim (4) is thinner than 1.6 mm (0.063

in.), refer to HUREL-HISPANO.
REPAIR NO.18
EFFECTIVITY: TRENT
54-30-00
Page 202
NOTE: The rubbing block and associated laminated shim (4) may
be retained for re-installation if they have not been
damaged during removal.
5. Prepare the Repair Strip (1)
CAUTION: YOU MUST USE ONLY SILICON CARBIDE TYPE WHEELS, STONES OR
ABRASIVE PAPERS TO REPAIR TITANIUM PARTS. ALUMINIUM OXIDE
TYPES WILL CAUSE TOO MUCH HEAT AND CAUSE DAMAGE TO THE
PART. YOU MUST USE WHEELS, STONES, ABRASIVE PAPERS OR
MECHANICAL CUTTERS LIGHTLY OR THE MATERIAL WILL OXIDISE
AND CRACK. THE MATERIAL HAS OXIDISED IF THE COLOUR
CHANGES TO DARKER THAN LIGHT STRAW. YOU MUST REJECT THE
PART IF THIS COLOUR CHANGE OCCURS.
A. Refer to Figure 201 for the dimensions of the strip (1) that is
to be locally manufactured.
NOTE: The titanium strip must have a minimum length of 4

rivets (additional or existing) plus an additional 10 mm
(0.394 in.) either side of the damaged area.
B. Make sure that the strip (1) and the inner side of the outer
fairing skin will fit together with no gap.
CAUTION: YOU MUST BE CAREFUL NOT TO CAUSE DAMAGE TO THE C-DUCT

WHEN YOU TIGHTEN THE CLAMPS.
C. Put the strip (1) into position and clamp it with mechanical
clamps.
6. Installation of the Titanium Strip (1)
A. Use the existing rubbing block holes as a guide to pilot drill

the necessary holes in the strip (1).
B. Drill and countersink the additional rivet holes in the strip

(1) and in the C-Duct skin (Ref. Fig.201).
C. Remove the clamps, then remove the strip (1).
D. Remove all burrs from the strip (1) and the C-Duct fairing.
E. Remove all grease from the mating surfaces of the strip (1) and
the C-Duct fairing (Ref. AMM TASK 70-20-01-100-802).
REPAIR NO.18
EFFECTIVITY: TRENT
54-30-00
Page 203
7. Apply Sealant
SAFETY DATA FOR THE MATERIALS. YOU MUST ALSO REFER TO
LOCAL REGULATIONS TO MAKE SURE THAT THE PROCEDURES ARE
DONE SAFELY. IF YOU DO NOT DO THIS, AN INJURY OR
ENVIRONMENTAL DAMAGE CAN OCCUR.
A. Apply a layer of OMat 8/107 SEALANT, TWO PART POLYSULPHIDE to

the mating surface of the strip (1) in accordance with the
manufacturer’s instructions. Do not apply sealant where the
surface is in contact with the damaged area.
B. Put the strip (1) into position on the inner side of the C-Duct
outer fairing.
C. Make sure that the rivet holes in the strip (1) and the C-Duct
fairing are aligned.
NOTE: At 23 deg.C (73.4 deg.F) temperature and 50 percent

relative humidity, the application time of the sealant
is 30 minutes and the cure time is 24 hours. You must
continue with the next step of this procedure within the
application time of 30 minutes.
8. Fasten the Titanium Strip (1) to the C-Duct
A. Use OMat 8/106 SEALANT, TWO PART POLYSULPHIDE around the

location of the rubbing blocks to wet install the additional
rivets (3).
B. Insert the additional rivets (3) from the outer side of the C-
Duct (Ref. SRM 54-02-10).
C. Make the additional rivets (3) flush with the strip (1).
D. Let the OMat 8/106 SEALANT, TWO PART POLYSULPHIDE cure in

accordance with the manufacturer’s instructions.
E. Make the surface smooth with OMat 5/38 WATERPROOF SILICON

CARBIDE, as necessary.
REPAIR NO.18
EFFECTIVITY: TRENT
54-30-00
Page 204
9. Install the Rubbing Blocks
A. Install the rubbing blocks (Ref. SRM 54-30-01, Repair No.2).
NOTE: The installation of the laminated shims (4) and the

rubbing blocks must be carried out in accordance with
the locations and thicknesses recorded during removal.
Also, it is necessary to remove an additional 1.6 mm
(0.063 in.) from the laminated shims (4) to account for
the thickness of the repair strip (1).
10. Apply Primer
A. Clean the external surface of the repair area (Ref. AMM TASK 70-
20-01-100-802).
B. Mix two parts by volume of OMat 7/198 POLYURETHANE COATING, BASE

with one part by volume of OMat 7/199 POLYURETHANE COATING,
HARDENER.
C. Make the mixture as thin as necessary with OMat 7/200

POLYURETHANE COATING, THINNER, in accordance with the
manufacturer’s instructions for the control and application of
coatings.
D. Use a brush to apply the mixture to the repair area.
E. Let the coating dry for 30 minutes at room temperature.
F. Use a heat lamp to cure the coating for a minimum of one hour at
between 50 and 60 deg.C (122 and 140 deg.F).
G. Use OMat 7/206 POLYURETHANE FINISH COAT to restore the finish

coat in accordance with the manufacturer’s instructions for the
control and application.
REPAIR NO.18
EFFECTIVITY: TRENT
54-30-00
Page 205
H. Visually inspect the paint and make sure that it is bonded to
the surface.
11. Examine the Completed Repair
A. Do a visual examination to make sure that the repair is

satisfactory (Ref. Fig.201).
A. Use an OMat 262 MARKER of contrasting colour to write FRSX085 on

the strip (1).
REPAIR NO.18
EFFECTIVITY: TRENT
54-30-00
Page 206
Trailing Edge Repair, Thrust Reverser C-Duct
Figure 201
REPAIR NO.18
EFFECTIVITY: TRENT
54-30-00
Page 207
1
-S
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
THRUST REVERSER COWL SKINS - IDENTIFICATION
1. General
R This subject contains structure identification, allowable damage limits and

R specific repairs for outer skins.
.-
S
0
R 2. Outer skins general description
.-
& R A. Outer skins of the thrust reverser are those washed by the external air
W
CO R flow. Outer skins described are the 6 and 12 o-clock cut corners, the
E R
R
pivoting door, the 3 or 9 o-clock beams, the access doors and the rear
structure.
.-
C
0
Q,
W R B. The following figures describe the parts and list the material used. The
.-
C R full view of the part has a ply orientation chart to help find the warp
h R direction. Refer to section 54-30-00 to have the full references of these
R materials and sources, and the typical lay up to find the warp direction
R for each ply of the composite skin.
R C. Outer skins are made of carbonlepoxy composite bonded to non metallic
R honeycomb or made of monolithic carbon/epoxy composite. Some access doors
R are made of aluminum alloy.
R D. Each of the individual components is divided into zones which define the
R number of carbon ply andlor the type of honeycomb. These zones are
R identified in figures and tables which follow.
EFFECTIVITY: TRENT
Page 1
July 1/94
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
12 O/C CUT CORNER

SEE FIG. 3
I
6 O!C CU? CORNER

SEE FIG. 6
Skins Identification
Figure l
EFFECTIVITY: TRENT
54-30-01
Page 2
~ p r 1/94
.
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
(SEE SHEET 5)
Doors Identification
EFFECTIVITY: TRENT
Page 3
July 1/95
1
-@I
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
ITEM DESCRIPTION GAGE MATERIAL EQUIVALENCE

1 HINGE ACCESS CARBON COMPOSITE
2 HINGE ACCESS ALUMINUM 2024 AMS4037L
3 RVT ACCESS 0.055 ALUMINUM 2024 AMS4037L
4 PIVOT ACCESS 0.118 T40 ASTM Grade 2
5 PRESSURE DOOR TAGV BSTA 10
6 PRESSURE DOOR TAGV BSTA 10
7 LATCH ACCESS CARBON COMPOSITE
8 PIVOT ACCESS 0.1 18 ALUMINUM 2024 AMS4037L
Doors Identification
EFFECTIVITY: TRENT
Page 4
J u l y 1/95
Mmcm
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
VlEW OF OUTER SKIN
VlEW OF INNER SKIN
AREA No Z1 22
CARBON EPOXY LAYER 5 7
<=3 RIBBON DIRECTION

AREA WITH NON METALLIC HONEYCOMB
lYPE NOMEX 3-64 THICKNESS : 0.5 in. (12,7 mm)
AREA WITH EPOXY HIGH DENSITY RESIN
Hinge Access Cover

Figure 2 ( S h e e t 3 of 5 )
EFFECTIVITY: TRENT
Page 5
July 1/95
1
mB
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
VIEW OF INNER SKlN
AREA WITH NON METALLIC HONEYCOMB TYPE NOMEX 3-48

THICKNESS : 0.5 in (12.7 mm)
YCARBON EPOXY LAYER
VIEW OF OUTER SKlN
YCARBON EPOXY LAYER
RVT Access Panel

EFFECTIVITY: TRENT
Page 6
July 1 / 9 4
1
m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
INTERNAL SIDE VIEW
1 AREA No
1 1 1
l 8 I
LAY UP
ORDER I
CARBON EPOXY LAYER 1 12 1 6 1 ---
I GLASS LAYER I 1 I l.AsT I
L a t c h Access Panel
F i g u r e 2 (Sheet 5 o f 5)
EFFECTIVITY: TRENT
Page 7
July 1 / 9 4
1 RB.211 TRENT
m( ~ 7 STRUCTURAL REPAIR
MANUAL
VlEW OF OUTER ISKlN

90"
AREA No
BRONZE MESH
VlEW OF INNER SKlN
z1
L
El AREA No
LAY UP
ORDER
CARBON
EPOXY LAYER 6 5 2
TEDLAR LAYER 1 1 1 LAST
a RIBBON DIRECTION
NON METALLIC HONEYCOMB TYPE NOMEX 3-48
Outer Panel 12 o-clock Cut Corner

Figure 3
EFFECTIVITY: TRENT
Page 8
July 1/95
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
VlEW OF OUTER SKlN
AREA No
BRONZE MESH
NOTE : UPPER AND LOWER PIVOTING

VIEW OF INNER SKIN DOORS ARE SIMILAR
LAY UP
AREA N o Z1 22 z3 24 25
ORDER
CARBON
EPOXY LAYER 2 4 5 3 7
TEDLAR LAYER 1 1 1 1 1 LAST
NON METALLIC HONEYCOMB

TYPE NOMEX 3-48
THICKNESS : 0.5 in (12.7mm)
..
RIBBON DIRECTION nAGnAC
Outer Panel Pivot Door

Figure 4
EFFECTIVITY: TRENT
Page 9
July 1/95
1
m@
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
VIEW OF OUTER SKIN 9 O/C BEAM
Outer Skins 3 or 9 o-clock Beam

Figure 5
EFFECTIVITY: TRENT
Page 10
J u l y 1/95
[ RB.211 TRENT
MANUAL
VlEW OF INNER SKlN
LAY UP
AREA No z2
ORDER
CARBON
5 2
EPOXY LAYER
TEDLAR LAYER 1 I LAST
A 0
AREA N o Z1
LAY UP
ORDER
CARBON 10
EPOXY LAYER
BRONZEMESH
LAYER
VlEW OF
OUTER SKlN
NON METALLIC HONEYCOMB TYPE NOMEX

a RIBBON DIRECTION
CARBON
EPOXY LAYER 16/5131
O u t e r P a n e l 6 o-clock Cut Corner

Figure 6
EFFECTIVITY: TRENT
Page 11
Sept.15/96
1 (R)
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
PATCH
9 1 A282
I
LAY UP
AREA No AREA No
ORDER
CARBON CARBON
2 EPOXY LAYER
EPOXY LAYER
TEDLAR LAYER 1 LAST

THICKNESS : 0.4 in.(lO mm)
RIBBON DlRECllON
O u t e r P a n e l Rear S t r u c t u r e
Figure 7
EFFECTIVITY: TRENT
Page 12
July 1/95
RB.211 TRENT
-B STRUCTURAL REPAIR
MANUAL
THRUST REVERSER - OUTER SKINS - ALLOWABLE DAMAGE
1. Introduction
This section contains the allowable and repairable damage limits for the
thrust reverser outer skins.
Damage which is found to be greater than the allowable damage limits must be
repaired in accordance with the procedures detailed in the following Repair
Section, Page Block 201. Components not included in this repair
Chapter-Section are not repairable and must be replaced if damaged.
A component with damage more than the repairable damage limits must be
replaced by a new one. It must not be repaired without a Rolls-Royce or
Hurel-Dubois technical statement.
2. Zones
affected by the different types of allowable or repairable damage are
identified in the figures and tables which follow.
A. The allowable and repairable damage zones for these components are:
M Monolithic area
S Sandwich area
E Edge area - attaching area, monolithic/sandwich intermediate area

A. Allowable damage
Allowable damage limits are intended to permit an operator to determine

whether a damaged nacelle component can continue in service, or be rejected
for repair. Allowable damage must not compromise the structural integrity
of the component, which could affect the strength or fatigue life. The
types of allowable damage permitted are defined and, if applicable, brief
descriptions are given of the clean-up procedures needed either to prevent
propagation of the damage or to improve the appearance and aerodynamic
EFFECTIVITY: TRENT
Page 101
~ p r 1/98
.
RB.211 TRENT
MANUAL
Damage limits assume that exposed edges do not extend above the skin
surface. Any damage that does should be trimmed to remove or feather the
protrusion. Holes or cracks in pressurized panel zones must be sealed
using the appropriate tape.
Allowable damage is classified as either unlimited usage or time limited:
( 1 ) Unlimited usage damage is defined as minor damage which does not affect
the structural integrity or functional capability of the component. No
repairs are necessary, other than cosmetic, over the aircraft design
life.
( 2 ) Time limited damage is defined as minor damage which does not affect
the structural integrity of the component in normal service use, but
could reduce the design life of the component. In this case damage
must be repaired by next Aircraft C check. The location and size of
the damage should be noted and checked at suitable intervals to monitor
that the damage has not grown beyond the time limited damage allowance.
NOTE: 1. When two damages are close, the minimum distance to determine
if it is one or two defects is determined as follows:
If the distance between the two damages is greater than the

dimension of the biggest damage, then the two defects are
distinct.
If the distance between damages is smaller than the dimension

of the biggest damage, then the defect is unique.
2. If a damage extends over two zones, you must consider the

smallest allowable damage limits.
3. When two damages are close, the minimum distance for

separation shall be determined by choosing the greatest
distance given in the 'requirements' column for each damage.
B. Repairable Damage
Repairable damage limits are intended to permit an operator to determine

whether a damaged nacelle component can be repaired or must be rejected.
The operator must follow the section organisation to accomplish the repair
satisfactorily.
EFFECTIVITY: TRENT
Page 102
Apr. 1/98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
C. Damage Types
Damage types permitted on this component are listed below. They apply only
to the structural material of the component, not the surface finishes, such
as paint.
(1) Abrasion - an abrasion is an area of damage which results in a cross

sectional area change caused by scuffing, rubbing, scraping or other
surface erosion. An abrasion usually appears rough and irregular.
(2) Gouge - a gouge is a damage area of any size which results in a cross
sectional area change. It is usually caused by contact with a sharp
object which produces a continuous, sharp or smooth channel-like groove
in the material.
(3) Nick - a nick is a local gouge with sharp edges.
(4) Scratch - a scratch is a line of damage in the material and results in

a cross sectional area change. Normally caused by a very sharp object.
(5) Crack - a crack is a partial fracture or complete break in the material

and produces a most significant cross sectional area change. Normally
appearing as an irregular line.
(6) Dent - a dent is a depressed area of damage which, with metal skins
would not cause cross sectional area change. On core filled laminates
it may cause crushing of the core cells. Area boundaries are smooth
and it is usually caused by contact with a smooth contoured object.
(7) Hole - a hole is a complete penetration of the material.
(8) Disbond - a disbond is the separation of the face skin from the
honeycomb core of a bonded panel.
(9) Delamination - a delamination is the separation of two laminate plies

or faying surfaces.
4. Identify and Measure the Damage Extent

A. Do an ultrasonic inspection to determine the damage extent, then mark out
the damage extent on the part.
B. Identify the type of damage.
C. Measure the damage.
EFFECTIVITY: TRENT
Page 103
Apr. 1/98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
INSPECTION
ZONE DAMAGE REQUIREMENTS ALLOWABLE LIMITS INTERVALS
All Abrasion Confined to surface Over an unlimited

resin area
All Scratch, Confined to the Depth <= 0,28 mm

Gouge first outer ply. (0.011 in.)
No nearer than 5
times its size to
other unrepaired
damage or rivet line
All Dent No nearer than 5 Depth <= 2,s mm

times its diameter (0.1 in.)
to other unrepaired
All Hole, No nearer than 5 Diameter or length 'A' check for

Nick times its size to <= 20 mm (0.79 in.) sealed hole
other unrepaired Depth: Confined to
damage or rivet outer skin
line.
Seal the hole with
speed tape
All Delamination, No nearer than 5 Diameter or length

Disbond times its size to <= 30 mm (1.18 in.)
line
EFFECTIVITY: TRENT
Page 104
Apr. 1I98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIRABLE REPAIR
ZONE DAMAGE REQUIREMENTS LIMITS PROCEDURE
E2 Scratch, No more t h a n 4 c u t p l i e s . Depth <= 1.12 mm FRSX054

Nick, D i s t a n c e t o t o p beam must (0.044 i n . ) 54-30-00
Gouge be g r e a t e r t h a n 5 t i m e s REPAIR 09
its size
E2 Dent, D i s t a n c e from o t h e r damage Diameter <= 76 mm FRSX054

Delamination o r r i v e t l i n e must be (3.0 i n . ) 54-30-00
g r e a t e r than 5 times i t s REPAIR 09
size
E2 Hole D i s t a n c e from o t h e r damage Diameter <= 76 mm FRSX055

o r r i v e t l i n e must be (3.0 i n . ) 54-30-00
size
M1 Scratch, No more t h a n 4 c u t p l i e s . Depth <= 1.12 mm FRSX054

its s i z e
M1 Dent, D i s t a n c e from o t h e r damage Diameter <= 75 mm FRSX054

size
M1 Hole D i s t a n c e from o t h e r damage Diameter <= 75 mm FRSX055

size
M3 Scratch, Nomorethan4cutplies. Depth<=l.l2mm FRSX054

its size
M3 Dent, D i s t a n c e from o t h e r damage Diameter <= 76 mm FRSX054

size
EFFECTIVITY: TRENT
Page 105
Apr. 1I 9 8
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
..............................................................................
REPAIRABLE REPAIR
M3 Hole Distance from other damage Diameter <= 76 mm FRSX055

or rivet line must be (3.0 in.) 54-30-00
greater than 5 times its REPAIR 10
size
M4 Scratch, No more than 5 cut plies. Depth <= 1.4 mm FRSX045

Nick , Distance from other damage (0.055 in.) 54-30-00
Gouge or rivet line must be REPAIR 01
greater than 5 times its
size
M4 Dent Distance from other damage Depth <= 2,5 mm FRSX045

size
M4 Delamination Distance from other damage Diameter <= 30 mm FRSX045

size

size

Nick, Distance to top beam must (0.044 in.) 54-30-00
Gouge be greater than 5 times REPAIR 01
its size
M5 Dent, Distance from other damage Diameter <= 56 mm FRSX045

Delamination or rivet line must be (2.2 in.) 54-30-00
size

size
EFFECTIVITY: TRENT
Page 106
Apr. 1/98
RB.211 TRENT
MANUAL
..............................................................................
REPAIRABLE REPAIR
..............................................................................
its size
M6 Dent Distance from other damage Diameter <= 38 mm FRSX045

size

size

size
M7 Scratch, No more than 1 cut ply. Depth <= 0.28 mm FRSX045

Nick, Distance from other damage (0.011 in.) 54-30-00
size
M7 Dent, No more than 1 cut ply. Diameter <= 56 mm FRSX045

Delamination Distance from other damage (2.2 in.) 54-30-00
or rivet line must be REPAIR 01
size
M7 Hole No more than 1 cut ply. Diameter <= 56 mm FRSX046

Distance from other damage (2.2 in.) 54-30-00
or rivet line must be REPAIR 02
size

Gouge or rivet lines must be REPAIR 01
size
EFFECTIVITY: TRENT
Page 107
Apr. 1/98
H RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIRABLE REPAIR

size

size

its size

size

size
S1 Scratch, No more than 1 cut ply. Depth <= 0.28 mm FRSX054

size
S1 Dent Distance from other damage Diameter <= 75 mm FRSX057

size - core undamaged

size - core damaged
EFFECTIVITY: TRENT
Page 108
Apr. 1/98
1 B
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
..............................................................................
REPAIRABLE REPAIR
S1 Delamination Distance from other damage Diameter <= 75 mm FRSX054

size
S1 Disbond Distance from other damage Diameter <= 75 mm FRSX057

size
S1 Hole Distance from other damage Diameter <= 75 mm FRSX061

size -inner skin damage
> dia 30 mm (1.2 in.)
size - inner skin damage
< dia 30 mm (1.2 in.)
size
S3 Dent Distance from other damage Depth <= 2,5 mm FRSX047


size - core damaged

size
EFFECTIVITY: TRENT
Page 109
Apr. 1 I98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
..............................................................................
REPAIRABLE REPAIR

size

size - outer skin damage
< dia 15 mm (0.6 in.)
S2, Scratch, No more than 1 cut ply. Depth <= 0.28 mm FRSX054
S5, Nick, Distance from other damage (0.011 in.) 54-30-00
S6 Gouge or rivet line must be REPAIR 09
size
S2, Dent Distance from other damage Diameter <= 51 mm FRSX057

S5P or rivet line must be (2.0 in.) 54-30-00
S6 greater than 5 times its REPAIR 12
S2, Dent Distance from other damage Diameter <= 51 mm FRSX058

S5, or rivet line must be (2.0 in.) 54-30-00
size - core damaged
S2, Delamination Distance from other damage Diameter <= 51 mm FRSX054

size
S2, Disbond Distance from other damage Diameter <= 51 mm FRSX057

S5P or rivet line must be (2.0 in.) 54-33-00
size
S2, Hole Distance from other damage Diameter <= 51 mm FRSX061

S5S or rivet line must be (2.0 in.) 54-30-00
> dia 30 mm (1.2 in.)
EFFECTIVITY: TRENT
Page 110
Apr. 1/98
RB.211 TRENT
s STRUCTURAL REPAIR
MANUAL
REPAIRABLE REPAIR
S2, Hole Distance from other damage Diameter <= 51 mm FRSX059

< dia 30 mm (1.2 in.)
size


size - core damaged

size

size

< dia 30 mm (1.18 in.)
S9 Scratch, No more than 3 cut plies. Depth <= 0.84 mm FRSX045
size
EFFECTIVITY: TRENT
Page 111
Apr. 1/98
B RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
..............................................................................
REPAIRABLE REPAIR
..............................................................................
S9 Dent Distance from other damage Diameter <= 5 1 mm FRSX047
or rivet line must be ( 2 . 0 in.) 54-30-00
greater than 5 times its REPAIR 0 3
S9 Dent Distance from other damage Diameter <= 5 1 mm FRSX048

size - core damaged
S9 Delamination Distance from other damage Diameter <= 5 1 mm FRSX045

size
S9 Disbond Distance from other damage Diameter <= 5 1 mm FRSX047

size
S9 Hole Distance from other damage Diameter <= 5 1 mm FRSX049

< dia 3 0 mm ( 1 . 2 in.)
> dia 3 0 mm ( 1 . 2 in.)
Gouge or rivet line must be REPAIR 0 1
size
S10 Dent Distance from other damage Depth <= 2 , 5 mm FRSX047

size -core undamaged
EFFECTIVITY: TRENT
Page 112
Apr. 1 / 9 8
1 s
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIRABLE REPAIR
size - core damaged

size

size

< dia 15 mm (0.6 in.)
size

size - core damaged


size
EFFECTIVITY: TRENT
Page 113
Apr. 1 I98
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIRABLE REPAIR

size

< dia 30 mm (1.2 in.)
> dia 30 mm (1.2 in.)
size


size - core damaged

size

size
EFFECTIVITY: TRENT
Page 114
Apr. 1I98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIRABLE REPAIR

< dia 30 mm (1.2 in.)
> dia 30 mm (1.2 in.)
EFFECTIVITY: TRENT
Page 115
Apr.1198
M
m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
f TOP CUT CORNER
AREA M5
.....
0
.*.*.....' AREA S3
....-S....
AREA M9
BOTTOM CUT CORNER

D46370
Thrust Reverser - Outer Skins -A l l o w a b l e and R e p a i r a b l e Damage L i m i t s

F i g u r e 101 ( S h e e t 1 of 4)
EFFECTIVITY: TRENT
54-30-0 1
Page 116
Apr. 1/98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
m AREA S2
m AREA S5
I I AREA E2
PIVOTING DOOR
Thrust Reverser - Outer Skins - Allowable and Repairable Damage Limits

EFFECTIVITY: TRENT
54-30-0 1
Page 117
Apr. 1/98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
AREA M3
3 OR 9 O/C BEAM
Thrust Reverser - Outer Skins -A l l o w a b l e and R e p a i r a b l e Damage L i m i t s

F i g u r e 101 ( S h e e t 3 o f 4 )
EFFECTIVITY: TRENT
Page 118
Apr. 1/98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
OUTER PANEL - REAR STRUCTURE
M
*.:S
AREAS11
..... AREA S12
Thrust Reverser - Outer Skins -

A l l o w a b l e and R e p a i r a b l e Damage L i m i t s
F i g u r e 101 ( S h e e t 4 of 4)
EFFECTIVITY: TRENT
Page 119
Apr. 1/98
B RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
VIEW OF OUTER SKlN
El VIEW OF INNER SKIN
AREA M6
AREA S9
AREA S10
Thrust Reverser - Hinge Access Cover - Allowable and Repairable Damage L i m i t s

Figure 102
EFFECTIVITY : TRENT
Page 120
Apr. 1I 9 8
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
THRUST REVERSER - OUTER SKINS - LIST OF APPROVED REPAIRS
-
1 REPLACEMENT OF OVERPRESSURE LATCH
(FRS X041)
2 REPLACEMENT OF RUBBING BLOCK

(FRS X042)
3 REPLACE DECALS
(FRS 5088)
4 REPLACE RIVETS ON 6 O'CLOCK BEAM EXTENSION

(FRS X084)
5 REPAIR TRAILING EDGE BOTTOM CORNER

(FRS X090)
6 REPLACEMENT OF THE SEALS AND/OR THE SEAL DEPRESSORS

(FRS X115) ATTACHED TO THE HINGE ACCESS COVER
7 THROUGH REPAIR OF THE C-DUCT OUTER FIXED STRUCTURE

(FRS X127) ACOUSTIC AREA DISBOND
R 8 REPLACEMENT OF TERTIARY LOCK ACCESS PANEL FASTENERS

R (FRS X129)
LIST OF REPAIRS
54-30-01
Page 201
p RB211 TRENT
MANUAL
STRUCTURAL REPAIR
REPAIR NO.l
THRUST REVERSER - OUTER SKINS
REPLACEMENT OF OVERPRESSURE LATCH
1. General
A. This procedure gives instructions for the replacement of a

damaged latch on the front or the rear overpressure doors.
------------------------------------*-----------------------------------
........................................................................
54-02-10 Fasteners -
78-33-00-300-XXX FRSX041,Trent Engine Manual
3. E~r~i~Inent
and Materials
A. Consumable Materials
........................................................................

OMat 2/101 CLOTH,LINT-FREE
OMat 8/173 SEALANT
OMat 8/177 SEALING COMPOUND
B. Repair Parts
........................................................................
FIG/ITEM PART NO. DESCRIPTION QTY
........................................................................
HD91B406-00 Repair Kit includes:
201/1 H2546K3231 Latch,Overpressure 1
201/2 NSA5414N40 Rivet 4
4. Remove the Overpressure Latch (Ref Figure 201)
A. Remove the four rivets (2) (Ref 54-02-10).
B. Remove the latch (1) f rum the door.
REPAIR NO.l
Page 201
July 1/99
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
5. Clean the Repair Surface
A. Remove the remaining sealant from the surface of the door. Use
a non-metallic scraper.

CORRECTLY.USE THIS PRODUCT ONLY IN ACCORDANCE WITH THE
MANUFACTURER'S HEALTH AND SAFETY RECOMMENDATIONS. BEFORE
B. Clean the repair surface with OMat 135 MEK and OMat 2/101 LINT-
FREE CLOTH. Dry the surface with a fresh piece of cloth before
the MEK evaporates.
6. Install the Overpressure Latch (Ref Figure 201)
A. Apply OMat 8/177 SEALING COMPOUND to the mating surface of the

latch (l).
B. Put the latch (1) in position on the door.
C. Wet-install the rivets ( 2 ) with OMat8/173 SEALANT(Ref 54-02-10)
D. Remove unwanted sealant with OMat 135 MEK and OMat 2/101 LINT-
FREE CLOTH. Dry the surface with a fresh piece of the cloth
A. Do a visual inspection to make sure the repair is satisfactory.
REPAIR NO.l
Page 202
SEALANT A 2 RIVET
SEALING COMPOUND
l PRESSURE
I DOOR
1 LATCH
Overpressure Latch -
Rernoval/Installation
Figure 2 0 1
EFFECTIVITY TRENT
REPAIR N 0 . 1
Page 2 0 3
RB211 TRENT
STnYCTYRAL REPAIR
REPAIR NO. 2
=PLACEMENT OF RUBBfNt3 BLOCK, IPRSXO42
1. General
A. This procedure gives inetructions for t h e replacement of worn

T/R-CAN i n t e r f a c e blocka installed on the C-Duct rear
atrueture. This repair also givea the iastmetione to repair
oversized r i v m t h o l e d .
- I - l - l - C - - - - - - - - - - - - - - C I 1 1 - - l l - - - l - - - - l - - - - - - - - - - - - - - " " - - - " - - - - - - - - - - - -
REFERENCE DES XGNATf ON
SRM 5 4 - 0 2 - 1 0
M M TASK 70-20-01-100-802
Faa teneru
Non Aqusoue Liquid Degreaaing
- Removal/LaataLlatfon
3. E m i n m e r i t and Material.
A, Standard Work~hopTools and Ekpipmant

Bmt3h
Syringe
Pneumatic riveter-continuous squeeze
Spatula
Palette
PaLstte knife
Cl-
Drills of 3,O mm (0.110 in) snd 5.6 nun ( 0 . 2 2 0 in) diameter
Plug gaugeg er v e r n i e r e a l i p s r
8. Consumable Materials
- - - - l - - - - C I I - - - - - - - * e e - - - - e t t - - " I I - I I I " I - - - - " - " - - - - - - - - - - - - - - - - - - - - - - - -
- - - 1 - 1 - 1 - - - - - - 1 - - - - 1 1 1 1 - - - 1 1 1 1 1 1 1 1 1 1 1 1 - " - - - - - - ~ - - - - - - d - ~ - ~ * - - - - - - - ~ - - ~ -
OMat 5/94 GARNET PAPER, Grit S i z e 150,brade 1 / 0

OMat 7/201 TOUCH-TIP COATkNG,2 part
OMak B / l Q F i SEALANT, PR1436G A 1 1 2
O M a t 8/30? SEALANT, PR14360 BlJ2
OKat: 2 6 2 / A
OMat 8 / 1 5 4
OMat 8 / 5 2
TEMPORARY MARKER
ADHESIVE -
E M 3 9 4 (ALTERNATIVE TO O M a t 8/52)
A D H E S I ~ E (ALTERNATIVE TO 013at 8/154)
REPAIR N0.2
54-30-01
Pagc 201
Princcd in arcat Britain Feb. 25/06
RB211 TRENT
C, Repair Parts
- 1 - - - - - 1 - - - - - - - - - - * - - - - - - 1 1 - - - - 1 - - - - - - * - m - - - - d - - - - - - - * - - - - - - - - - -
FIGITTEEi PART NO. DKSCRIPTfON Olr

- - - - - - - - - - * - - - - * - - - - - - - - - - - 1 - - - - - - - 3 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
201/1 910035-01 T/R-CNA Interface Black A/R
2 0 1/ J ~ ~ 8 1 9 2 W SO3/4/5/6/7
04 Rivet (length A/R)
201J3A CR3522-4-8 Alternative rivet
201/4 RP3508-00 Bus h
WARN1NG: W I m J YOU Do TRIS REPAIR m MPST PRoTEcTTW CLOTHING, m

GLOVES, DUST M S # SAFETY GOGGLES TO PROTECT YOU AGAINST
DUST AHD LOOSE PARTICLES, W f C R CAN BE DANGEROUS TO YOOR
HWTH.
WARNING: WIIEW YOU USE CLBArn'HQ EIATERZALS, COATINGS* mHEsm9 AND

SEALANT, REFER TO THE MhHUFACTIIREa'S CONTROL AND APPLICATfON
4. Remove the Worn BloekIs) IXef Figure 2013

A. Removs the paint from the heads of the rivets ( 3 ) . Abrade
lightly with the O M a t 5 / 9 4 GARNET PAPER.
CAUTION! DO NOT MAKE TRE HOLES LARGER TKAN MREN YOV D R X U OUT TRE
RlYET9.
B. Raaove the tt*o rivets (33 ( S W TASK 5 4 - 0 2 - 1 0 ) . Use a 3 mm

(0,118 in) diameter d r i l l .
C. Rgmove the block (1) and the s h h ( 2 ) from the rear s t r u c t u r e .
D. Meaaure and racotd t h a thieknesa of the ahims ( 2 ) .
5. Clean t h e Repair Surface
A. U s e a non-matallic scraper to remove the unwanted r e r l a n t from

t h e surface of the rear structure.
B. Clean the repair area TASX 70-20-01-100-$02).
Page 202
Feb. 15/06
R6211 TRENT
STRUCTURAL REPAIR
R 6. Meaouxe the dimensions of the hole
R A. Find the dimensions of the rivet holes. Use plug gaugea or

R vernier callipers,
R 8. Mark the locatione of the rivet holes t h a t are more than 3,33
R mm (0.131 in.) iq diameter.
R 7. Repair the Ovsraize Holes {Xf neeaaeasy)
R A. Refer to Figurea 202 and 203.
R E. Uaa a drill guide for drilling the w s r e i z e holes. Rsfex to F i g

R 203 for detsila to laealiy manufacture.
R C. CLllmx, the drill guide in position and drill the worn holee to
R 5 . 6 mm ( 0 . 2 2 0 in). If the worn holea are more than 5 , 6 mm
R ( 0 . 2 2 0 La.] then refer to A i s c f i l l e .
R D. Countereink the hole at 100- to a dfamntar o f 8,T7 nm (0.345

R in) .
R E. Clean the xepairmd holes (AMM TASK 7 6 - 2 0 - 0 1 - 1 0 6 - 8 0 2 ) .
R P. Mix the OMat 8/52 er 8/154 ADKESXVg. Rafer to the

R manufecturer's instruetdona. F u l l y m i x she p a r t s of the
R adhesive until it is a continuous colour.
R d. Put a layer of the mixed adhesive between 0 1 1 3 mm and 4 . 6 1 mm

R ( 0 . 0 0 5 and 0.024 in) thickneae on the surfacea of the holes,
a H. Inetall the b u a h e ~ (41 and raaawa tbs unwanted adheafve (M

R TASK 70-20-01-360-802).
a X. Cure t h e adhesive:
a 1 hour at 6 6 deg C ClCO dug P) or
R 2 hours at 4 5 deg C (113 deg P) or
R 4 hours at 3 5 deg C ( 9 6 dog F) or
R 8 hours at 30 deg C ( 8 6 deg F) or
R 1 6 houra at 2 5 d e g t ( 7 7 deg P) or
R 24 house at 2 2 deg C 172 deg FI or
BEPAIR N0.2
54-30-01
Page 203
Feb. 1 5 / 0 6
RB211 TRENT
STRUCTURAL REPAIA
MANUAL
R 4 0 h a w s a t 2 0 deg C 1 6 9 deg F) or
R 96 houre at ZS deg C ( 5 9 deg F) or
R 168 hours at 12 deg C (S4 dsg P).
R 8. Xnstall, t h e New Block 1 1 ) lRef Figure 2013
R A. G e t the new ~ h ( 2h) and adf ugt to the thickness recorded a t

R step 4 .D (above).
B. U g e a bmsh to apply OMat 0 / 1 0 7 SEALANT to the mating face of

R t h e new block (1) and ehima (2).
R C. W e t - i n s t a l l the s i v s t ~13) w i t h mat 8 / 1 4 6 SEAtANT { S M TA3K

54-02-101.
R D. Maaerure the height of the new block t h a t you just installed,

R between tha tear structure inner kin and the tops of thm
R blocks.
R E. Messura the h s i g h t of each adjacent blackle) between the rear

R a t r j c t u r e inner skin and the tops of t h e blocka,
R P. Check the height diffnrsnca between ths new block and i t s

R adjacant block(e) i a not more than 0,s mn EQ.02 i n ) .
R NOTE: f f not in t h e Zirnite, change the related adjacent block (Ref

3t to step 4 ) .
G. Uaa a syrsnge to apply a bead of OHat 8/107 SgALAKP around the

R edge af the block.
R 8, C l e a n the repair area and rsmove unwanted sealsnt (W TASK 7 0 -

R 20-01-100-802).
J, Mix the OMat 71201 TOUCfI-UP COATmQ in accordanc~with the

mknufaeturer*~~ s t m c t i m a .Apply the coating to thm bsadrt of
t h e rivete. Curs f o r t w o hours at 20 dag C ( 6 8 dsg F).
R X. Clean the repair area ( M M TA8K 70-20-01-100-8102).
L. Da a visual inepection to make sure the repair frr sati~factary

R and that the blocks are installed correctly.
R 9. Identify the Repair
REPAIR NO.2
54-30-01
Page 2 0 4
P r i n t e d in Great B r i t a i n Feb. 1 5 / 0 6
RB211 TRENT
khh! STRUCTURAL
. . REPAIR
MANUAL
A. Mark PRSX042 adjacent t o the sarial/part number of t h e C-Duet.

Use OMat 2 6 2 marker of a contrasting colour.
E F F E m V 3 m : TRENT REPAIR N0.2

54-30-01
Page 205
R PrLuzcd In Great Llrlcsin Feb. 15/06
RB211 TRENT
STRUCTURAL REPAIR
SECTION
OUTER SEAL
I
T R A I L I ~ GEDGE
l B
OUTER PANEL
.d COI~MON
NOZZLE
REARSTRUCTURE ASSEMBLY
2 SHIM PACK 1 RUBBING BLOCK

I
I
3 RtVET SEALANT
Rubbing Block - Removal/mstaLlation
Figure 201
REPAIR NB.2
54-30-01
Pags 2 0 6
Printed i n craat Britain Feb. 1 5 / 0 6
RB211 TRENT
ST AUGTURAL REPAIR
0.1 M hr. (2,mmm)

f
0.51 h.(I.36bm)R
0.131 h. (3.330 mm) MA

0.050 In.(1 27U
0.2797- 0.mh.p.58* 5.mm)MA
BUSH
2 smM PACK 1 RUBBlNG 8LOCK

I t
4 BUSHES
Buah ~ngtallation
Figure 202
REPAIR NO, 2
54-30-01
Page 207
Printed in Creac sritain Feb. 15/06
RB21ITRENT
STPUCTURAL REPAIR
MANUAL
Oetaila of Local Hmufaetursd b r i l l Guide

Figure 203
E F P E m n S r r H : TRENT REPAIR N0.2

54-30-01
Page 2 0 8
R Feb. 15/06
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
REPAIR NO. 3 (FRS J0 8 8 1
REPLACE DECALS
1. General


on the LH Fan Cowl Door.

backgrounds. Use black or red decals on light-colored nacelles;
C. The minimum air temperature necessary for this repair is

16 deg C (61 deg F). If possible, do not operate the engine for
48 hours after the repair has been done.
2. Euuipment and Materials
Plastic squeegee
Rubber roller
......................................................................
......................................................................
OMat 150 ACETONE
OMat 2/12 PAINT BRUSH
OMat 7/203 THINNER
OMat 7/204 THINNER
......................................................................
PART IDENT MATERIAL
......................................................................
Fan Cowl Door Carbon Composite
REPAIR N0.3
54-30-01
Page 201
Jan. 1/00
A. Refer to Table 1 and Figures 201 thru 217 to identify the correct
replacement decal.
4. Remove the Damaqed Decal
metallic scraper.
5. PreDare the Cowl Surface
A. Refer to Figures 201 thru 217 for the correct dimensions. Use the
7. A D D ~ Ythe ReDlacement Decal
of the deca1.'Flickr the corner of the decal with your finger.
trapped air.
REPAIR N0.3
54-30-01
Page 202
Jan. 1/00
p
"" R8211 TRENT
MANUAL
STRUCTUAL REPAIR

A. Use OMat 2/101 LINT FREE CLOTH soaked with OMat 1 5 0 ACETONE to
9. Do an Inspection
A. Refer to Figures 201 thru 217. Make sure the decal is in the
10. ~ p v the
l ~ Varnish


(2) At temperatures more than 26 deg C (79 deg F), use

OMat 7/204 THINNER.

D. Cure the varnish for 72 hours at 16 deg C (61 deg F). The
11. Do an Inspection of the Decal
this procedure.
REPAIR N0.3
54-30-01
Page 203
Jan. 1/00
R8211 TRENT
STRUCTUAL REPAIR
ITEM l IPC REF l PART NO DECAL DESCRIPTION
1 Black, Door Pivot & Position Sensor Access

(Alt.LJ41895)
2 White, Door Pivot & Position Sensor Access

(Alt.LJ41894)
3 Red, Warning - Pivot Door - Keep Away

(Alt.LJ41897)
4 Yellow, Warning - Pivot Door - Keep Away

(Alt.LJ41896)
5 Warning - Red Pin - T/R Manually Deactivated

(Alt.LJ41899)
6 Warning - Red Pin - T/R Manually Deactivated

(Alt.LJ41898)
7 Warning -
Before T/R Maintenance, Lever To
Inhibit Position (Alt.LJ41905)
8 Warning -
Before T/R Maintenance, Lever To
Inhibit Position (Alt.LJ41904)
9 Black, Hoist-Point (Alt.LJ41909)
10 White, Hoist-Point (Alt.LJ41908)
11 Black, Hoist-Point, Pivot Door Only

(Alt.LJ41911)
12 White, Hoist-Point, Pivot Door Only

(Alt.LJ41910)
13 Black, Pivot Door Deactivation Point

(Alt.LJ41915)
14 White, Pivot Door Deactivation Point

(Alt.LJ41914)
Cont'd
Table 1
EFFECTIV1TY:TRENT REPAIR NO. 3
Page 204
Jan. 1/00
RB211 TRENT
STRUCTUAL REPAIR
ITEM IPCREF PARTNO DECAL DESCRIPTION
11-24-71
15 01-416 L541916 Black, Door Position Sensor,Harness Access

(Alt.LJ41917)
16 01-416A L541917 White, Door Position Sensor,Harness Access

(Alt.L5419161
17 01-420 L541920 Black,Latch Closing Sequence 3-4-1-7-6-5-2

Pre SBll-B446 (Alt.LJ41921)
18 01-420A L541921 White,Latch Closing Sequence 3-4-1-7-6-5-2

Pre SBll-B446 (Alt.LJ41920)
19 01-424 L541924 Warning -

Clinch Device To Be Stowed After
Latching (Alt.LJ41925)
20 01-424A L541925 Warning - Clinch Device To Be Stowed After

Latching (Alt.LJ41924)
21 01-434 L541934 Black, Latch Access, Pressure Relief Door

(Alt.LJ41935)
22 01-43414 L541935 White, Latch Access, Pressure Relief Door

(Alt.LJ41934)
23 01-436 L541936 Warning - Both Rods Must Be Used When

Working On Engine (Alt.LJ41937)
24 01-4361 L541937 Warning - Both Rods Must Be Used When

Working ON Engine (Alt.LJ41936)
25 01-438 L541938 Black, Hinge Access Door (Alt.LJ41939)
26 01-438A L541939 White, Hinge Access Door (Alt.LJ41938)
27 01-442B L541996 Black, Latch Closing Sequence, Engage

Cinch Device, SBll-B446 (Alt.LJ41997)
Cont d
Table 1
REPAIR N0.3
54-30-01
Page 205
an. 1/00
RB211 TRENT
STRUCTUAL REPAIR
11-24-71
28 01-442C L541997 White, Latch Closing Sequence, Engage Cinch

Device, SBll-B446 (Alt.LJ41996)
29 01-446 L541946 Black, Lower Door Pivot Access Panel

(Alt.LJ41947)
30 01-446A L341947 White, Lower Door Pivot Access Panel

(Alt.LJ41946)
31 01-450 L541950 Black, Number 2 (Alt.LJ41951)
32 01-450A L541951 White, Number 2 (Alt.LJ41950)
37 01-458 L541958 Black, Number 6 (Alt.L5419591
Table 1
54-30-01
Page 206
Jan. 1/00
P r i n t e d in G r e a t Britain
H"" RB211 TRENT
STRUCTUAL
MANUAL REPAIR
V I E W ON THE FRONT OF THE ENGINE
rO
vl
P
0
0
O ALL DIMENSIONS ARE IN MILLIMETERS [INCHES)
Figure 201
REPAIR N0.3
54-30-01
Page 207
Jan. 1/00
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
ITEM 25 OR I T E M 26
INSTRUCTIONS)
I T E M 9 OR I T E M 10
BOTH SIDES
(REFER TO
INSTRUCTIONS)
I T E M 25 OR l TEM 2 6
l TEM 9 OR I T E M 10 INSTRUCTIONS1
B O T H SIDES
(REFER TO
INSTRUCT! ONS)
FORWARD FACE OF
THRUST REVERSER
P A R T VIEW - AD
Figure 202
REPAIR N0.3
54-30-01
Page 208
Jan. 1/00
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
- - 697.00 (27.441
695.00 27.362
)
223.00
221.00 ( 8.780
8.701 )
LEADING EDGE
OF THRUST REVERSER
PIVOT DOOR
992.00 39.055
990.00 (38.976)-
A 1
-
I
A
7.
t 1' l I
-491.00 (19.331)
489.00 19.252
-506.00 (19.921
5 0 4 . 0 0 19.843
)
C
DIMENSION LINE TAKEN

FROM BOTTOM OF SENSOR
HARNESS ACCESS PANEL
REPEAT VIEW --c- AA

Figure 203
REPAIR NO. 3
54-30-01
Page 2 0 9
Jan.1/00
R8211 TRENT
STRUCTUAL REPAIR
MANUAL
I T E M II OR I T E M 12 I T E M 13 OR I T E M 14
(REFER TO [REFER TO
INSTRUCTIONS) INSTRUCTIONS)
I T E M 3 OR I T E M I T E M 5 OR I T E M 6
(REFER TO (REFER TO
INSTRUCTIONS) INSTRUCTIONS1
I T E M II OR I T E M I T E M 7 OR I T E M 8
(REFER TO (REFER TO
REPEAT VIEW -- AA
Figure 204
REPAIR N0.3
54-30-01
Page 210
Jan. 1/00
H
""" RB211 TRENT
MANUAL
STRUCTUAL REPAlR
DIMENSION LINE TAKEN

FROM BOTTOM OF SENSOR
HARNESS ACCESS PANEL
1651.00 65.000
-1649.00 )
(64.921
LEADING EDGE
OF THRUST
REVERSER
PIVOT DOOR
551.00 21.693
I )
r 5 4 9 . 0 0 (21.614
-746.00 29.370
- 149.00 5.866
744.00 (29.291)
-
223.00
221.00 8.701
REPEAT VIEW 0 AA
Figure 205
REPAIR N0.3
54-30-01
Page 211
Jan. 1/00
H
"" RB211 TRENT
MANUAL
STRUCTUAL REPAIR
I T E M II OR I T E M 12 ITEM 7 OR ITEM 8
(REFER TO (REFER TO
I T E M 3 OR I T E M 4 ITEM 13 OR I T E M 14
(REFER TO (REFER TO
INSTRUCTIONS) \ 1INSTRUCTIONS)
I T E M I1 OR I T E M 12 ITEM 5 OR I T E M 6
(REFER TO (REFER TO
REPEAT VIEW -c- AA
Figure 206
REPAIR N0.3
54-30-01
Page 212
Jan. 1/00
p RB211 TRENT
MANUAL
STRUCTUAL REPAIR
ITEM I OR I T E M 2
(REFER TO
INSTRUCTIONS)
-/\ - 411i0o0o ('ilZdj47)
4 9 . 0 0 1.929
4 7 . 0 0 (1.850)
CENTRELINE OF ITEM 15 OR ITEM 16 rl

UPPER REAR (REFER TO
COWL NOSE INSTRUCTIONS]
H O I S T POINT
REPEAT VIEW -- AA
Figure 207
REPAIR N 0 . 3
54-30-01
Page 213
Jan. 1/00
RB211 TRENT
STRUCTUAL REPAIR
m MANUAL
FROM IBOTTOM OF SENSOR

HARNEISS ACCESS PANEL
REPEAT V I E W -E- A6
Figure 2 0 8
REPAIR N 0 . 3
54-30-01
P a g e 214
Jan. 1 / 0 0
R8211 TRENT
STRUCTUAL REPAIR
MANUAL
ITEM 13 OR ITEM 14 ITEM II OR I T E M

(REFER TO
INSTRUCTIONS) \I /-W
/- (REFER TO
INSTRUCTIONS)
I T E M 5 OR ITEM 6 ITEM 3 OR I T E M
(REFER TO (REFER TO
I T E M 7 OR ITEM 8 ITEM II OR I T E M
(REFER TO (REFER TO
Figure 209
REPAIR N0.3
54-30-01
Page 215
Jan. 1/00
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
REPEAT V I E W -c=, AB
Figure 210
REPAIR N0.3
54-30-01
Page 216
Jan. 1/00
a1 smUCTUAL
MANUAL
ITEM 7 OR ITEM ITEM II OR ITEM 12

(REFER TO (REFER TO
ITEM J3 OR l TEM ITEM 3 OR ITEM 4

(REFER TO (REFER TO
ITEM 5 OR ITEM 6 ITEM II OR ITEM 12

(REFER TO (REFER TO
REPEAT VIEW -- AB
Figure 211
REPAIR N0.3
54-30-01
Page 217
Jan. 1/00
I ITEM 15 OR I T E M 16
179.00 7.047 IllNSTRUCTlONSl
42.00 1.654
I-ITEM 1 OR ITEM 2 CENTRELINE OF

(RREFER TO UPPER REAR
INNSTRUCTIONS) COWL NOSE
H O I S T POINT
Figure 212
REPAIR N0.3
54-30-01
Page 218
Jan. 1/00
printed i n Great Britain
H
"" RB211 TRENT
MANUAL
STRUCTUAL REPAIR
VIEW -- AC
Figure 213
REPAIR N0.3
54-30-01
P a g e 219
Jan. 1/00
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
REPEAT V I E W -
Figure 214
AC
REPAIR N0.3
54-30-01
Page 220
Jan. 1/00
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
REPEAT V I E W -c=- AC
Figure 215
REPAIR N0.3
54-30-01
Page 221
Jan. 1/00
H RB211 TRENT
MANUAL
STRUCTUAL REPAIR
I T E M 21 OR I T E M 22 I T E M 29 OR ITEM 30
(REFER TO (REFER TO
I T E M 3 3 OR ITEM 3 4
(REFER TO
INSTRUCTIONS)
0
Q,
5
REPEAT V I E W -D- AC
Figure 216
REPAIR N0.3
54-30-01
Page 2 2 2
Jan. 1/00
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
I T E M 9 OR I T E M 10
(REFER TO
INSTRUCTIONS)
(REFER TO
INSTRUCTIONS)
-
(REFER TO
-
INSTRUCTIONS) -
-
-
-
=1
I T E M 3 7 OR I T E M 3 8 I T E M 2 9 OR I T E M 3 0
(REFER TO (REFER TO
ITEM 35 OR I T E M 36- -ITEM 9 OR ITEM 10

(REFER TO (REFER TO
REPEAT VIEW -
Figure 217
AC
REPAIR N0.3
54-30-01
Page 223
Jan. 1/00
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
REPAIR NO. 4
REPLACE RIVETS ON 6 O'CLOCK BEAM EXTENSION
1. General
A. This repair gives instructions to replace loose ox missing

rivets through the outer skin and 6 o'clock beam extension.
B. The procedure is applicable to LH or RH thrust reversers.
.......................................................................

TASK 78-33-00-300-XXX FRSX084, Trent Engine Manual
-Rivet gun
-Syringe
.......................................................................
.......................................................................
OMat 2/101 -
LINT FREE CLOTH
OMat 8/107 SEALANT
C. Repair Parts
.......................................................................
ITEM PART NO. DESCRIPTION GRIP RANGE (mm) QTY
1 NAS1921MO5S04W Rivet, standard 3

1A MS21140S0603 Rivet, oversize 3,97 to 5,60 3
1B MS21140S0604 Rivet, oversize 5,60 to 7,16 3
REPAIR N0.4
54-30-01
Page 201
Printed in G r e a t B r i t a i n May 1/00
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
A. Remove loose rivets:
(1) Drill out the rivets (Ref SRM 54-02-10).
NOTE: It is not possible to remove the rivet tails.
(2) Push the rivet tails into the structure.
(3) With the syringe, put OMat 8/107 SEALANT into the holes in
the structure. This will prevent movement of the rivet tails
and possible structural damage.
B. Measure the diameter of the rivet holes. The initial holes were
4,065 to 4,115 m (0.160 to 0.162 in) diameter.
C. If the rivet holes are oval and not more than 5,13 mm (0.202 in)
diameter,drill them 5,05 to 5,13 mm (0.l99 to 0.202 in) diameter.
D. Remove burrs and sharp edges fom the drilled holes.
E. Install the rivets:
(1) For oversize rivet holes, measure the material thickness

through the hole to find the correct grip length.
(2) Wet-install the rivets with OMat 8/107 SEALANT.
WARNING: MEK CAN CAUSE INJURY OR ILLNESS IF NOT USED

CORRECTLY.BEFORE YOU USE THIS MATERIAL,CAREFULLY
READ THE APPLICABLE SAFETY DATA SHEET AND OBEY
ALL THE HEALTH AND SAFETY PRECAUTIONS.
5. Inspect ion
A. Do a visual inspection to make sure the rivets are satisfactorily

installed.
REPAIR N0.4
54-30-01
Page 202
p""" RB211 TRENT
MANUAL
STRUCTUAL REPAIR
OUTER SKlN
TRAILING
EDGE
RIVETS FOUND
LOOSE OR
MISSING
6 O'CLOCK
I
LATCH No 7
SECTION
IFS
RIVETS
FOUND
-
LOOSE
k
BEAM EXTENSION
91 B 477-00
REAR STRUCTURE
OUTER SKlN
Replace Rivets in the 6 o'clock Beam Extension

Figure 201
EFFECT1VITY:TRENT REPAIR N0.4
54-30-01
Page 203
P r i n t e d in G r e a t Britain May 1/00
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
REPAIR N0.5
THRUST REVERSER OUTER SKINS - 'C' DUCT
DAMAGED TRAILING EDGE BOTTOM CORNER, WITH LOSS OF ONE RUBBING BLOCK
l. General
A. This procedure gives instructions for the installation of a

titanium repair strip and a replacement rubbing block.
.......................................................................
SRM 54-02-10 Fasteners - Removal and Installation

SRM 54-30-01, Repair No.2 Replace the Rubbing Block
EM TASK 78-33-00-300-XXX FRSXOSO, Trent Engine Manual
Clamps, gripper pins
Riveting equipment (continuous squeeze)
.......................................................................
.......................................................................
OMat 8/106 SEALANT
OMat 8/107 SEALANT
C. Repair Parts
.......................................................................
ITEM PART NO. PART IDENT (ZTY
.......................................................................
1 Local manufacture Titanium strip 1,6 mm thickness l
(Material:Ti6Al-4V to AMS 4911 or BSTA 59)
2 NAS1921M04S03 to S07 Rivet 4
3 91D135-01 Rubbing block 1
4 91A495-00 Laminated shim 2
5 Local manufacture Shim 2,5 mm thickness (Materia1:TIO) 1
6 CSR90433-5F-7 (6F-7 o/s) Rivet 12
7 CSR90433-5F-5 (6F-5 o/s) Rivet 1
54-30-01
Page 201
RB211 TRENT
STRUCTUAL REPAIR
m MANUAL
.......................................................................
PART IDENT MATERIAL
.......................................................................
Thrust reverser 'CB duct Carbon composite
A. Remove the damage
(1) Record the position, then remove the rubbing block ( 3 )

adjacent to the damage (Ref SRM 54-30-01, Repair No.2) .
(2) Record the thickness of the laminated shim ( 4 ) .
NOTE: If the thickness is less than 1,6 mm (0.063 in) ,

refer to Rolls-Royce plc.
WARNING: PUT ON GLOVES, MASK AND GOGGLES FOR PROTECTION

AGAINST DUST AND LOOSE PARTICLES THAT CAN CAUSE
DAMAGE TO YOUR HEALTH.
(3) Drill out the 11 rivets (6) from the repair area. Be
careful not to cause damage to the outer skin. Remove
sharp edges from the holes (Ref SRM 54-02-10).
(4) Use hand tools to cut out the damaged area of the trailing
edge. Refer to Figure 201 for the trim line.
(5) Use OMat 5/94 GARNET PAPER to remove loose fibres and make
the edges of the cut-out smooth.
NOTE: If you find delamination, refer to Rolls-Royce plc.
B. Prepare the repair strip
CAUTION: ALL WHEELS,STONES AND ABRASIVE PAPERS USED FOR WORK ON

TITANIUM MUST BE OF THE CARBIDE TYPE. IF MECHANICAL
CUTTERS ARE USED, MAKE LIGHT CUTS ONLY TO PREVENT TOO
MUCH HEAT. IF YOU SEE HEAT DISCOLOURATION DARKER THAN
A STRAW COLOUR, YOU MUST REJECT THE PART.
(1) Cut and trim a titanium repair strip, 1,6 mm thickness, to

the shape given in Figure 201.
(2) Put the repair strip in position on the outer skin and
make sure it sits fully flat.
REPAIR N0.5
54-30-01
Page 202
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
(3) Use clamps to temporarily attach the repair strip in its

correct position on the 'C' duct.
(4) Pilot drill 11 holes in the repair strip from the rivet
holes in the outer skin.
(5) Measure and pilot drill the two holes (a) for the new
rivets.
(6) Measure and pilot drill the two holes (b) for the new
rubbing block.
(7) Remove the repair strip from the 'C' duct.
(8) Drill full-size and countersink all the holes in the

repair strip.
(9) Remove burrs from the repair strip and 'C' duct.
C. Install the repair strip
WARNING: MEK AND SEALANT CAN CAUSE INJURY OR ILLNESS IF NOT

USED CORRECTLY. BEFORE YOU USE THESE MATERIALS,
CAREFULLY READ THE APPLICABLE SAFETY DATA SHEET AND
OBEY ALL THE HEALTH AND SAFETY PRECAUTIONS.
(1) Clean the mating faces of the repair strip and the 'C'
duct with OMat 2/101 LINT-FREE CLOTH soaked with OMat 135
MEK. Dry the surfaces with a new piece of the cloth before
the MEK evaporates.
(2) Apply a thin layer of OMat 8/107 SEALANT to the mating

face of the repair strip.
(3) Put the repair strip on the 'C' duct, align the rivet
holes and clamp it in position.
CAUTION: YOU MUST USE A CONTINUOUS SQUEEZE RIVETING PROCESS

WHEN YOU INSTALL THESE RIVETS. HAND HAMMERING OR USE
OF A PNEUMATIC RIVET GUN COULD CAUSE DAMAGE TO THE
COMPOSITE STRUCTURE.
(4) Wet-install the rivets (6) and (7) through the 'C' duct
and the repair strip with OMat 8/106 SEALANT
(Ref SRM 54-02-10).
(5) Seal the edges of the cut-out and the repair strip with
a bead of OMat 8/107 SEALANT.
REPAIR N0.5
54-30-01
Page 203
P r i n t e d i n Great Britain July 1/00
R8211 TRENT
STRUCTUAL REPAIR
MANUAL
(6) Remove unwanted sealant with OMat 2/101 LINT-FREE CLOTH

soaked with OMat 135 MEK. Dry the area with a new piece of
the cloth before the MEK evaporates.
D. Install the rubbing block
(1) Refer to Figure 201. Select a thickness of laminated shim

(4) which, together with the new shim (51, will make
dimension d2 equal to dimension dl.
(2) Install the new rubbing block (3) on the repair strip (1)
(Ref SRM 54-30-01, Repair No.2).
REPAIR N0.5
54-30-01
Page 204
H RB211 TRENT
MANUAL
STRUCTUAL REPAIR
TITANIUM
STRIP (1)
-
.-
8
0
(a) AND (b) ARE ADDITIONAL RIVETS
l2
' C 1 Duct Trailing Edge Repair
Figure 201 Sheet 1
REPAIR N0.5
54-30-01
Page 205
R8211 TRENT
STRUCTUAL REPAlR
MANUAL
SECTION B-B
A
SHlM (5)
41 2,5mm
TOLERANCES ARE 0.2 MM
H SECTION C-C
TITAN1UM
C-DUCT STRIP (1)
TRAILING EDGE I
-
I
I
I 1
I
CV
U
7J
A I
LAMINATED SHIM (4) NEW

EXISTING RUBBING
RUBBING BLOCK BLOCK (3)
HOLE DIMENSIONS
ITEM
X1 x2
I
-Q- (6) 6,21+0,064,08_+0,04
I
(7) 6,21+0,064,08+0,04
-9-
(2) 5,71+0,1 3,31_+0,04
-9-
(6)(7) OVERSIZE 7,59+0,1 4,93+_0,05
.-
.-
g NOTE: ALL DIMENSIONS ARE IN MM
' C ' Duct Trailing Edge Repair
Figure 201 Sheet 2
REPAIR N0.5
54-30-01
Page 206
REPLACEMENT OF THE SEALS AND/OR THE SEAL DEPRESSORS ATTACHED
TO THE HINGE ACCESS COVER - (FRSX115)
1. General
This repair gives the procedure to replace seals and/or seal

depressors attached to the Hinge Access Cover (HAC).
The seals and their related depressors can be replaced individually

or as a set.
2. Reference information
....................................................................
....................................................................
SRM 54-02-10 Removal and installation of fasteners
PPIPC 78-32-49 Power Plant Illustrated Parts Catalogue
AMM TASK 70-20-01-100-802 Non aqueous liquid degreasing
AMM TASK 78-32-49-000-802 Removal of the Hinge Access Cover
AMM TASK 78-32-49-400-802 Installation of the Hinge Access Cover
4.
Pneumatic riveter
Drills - 0.130 in. (3,3 mm), 0.282 in. (7,16 mm)
.................................................................
.................................................................
OMat 8/106 PR 1436 GA 1/2, sealant
OMat 262 Temporary marker felt/fibre tip
OMat 8/107 PR 1436 GB 1/2, sealant
COMPONENT MATERIAL PART NUMBER

.................................................................
Seal, Rear Silicone and fabric 91U063-01
Seal, Front 91U088-00
Seal, Rear cover 91U048-01
REPAIR N0.6
54-30-01
Page 201
Jun. 10/08
I in Great B r i t a i n
Seal Depressors
M RB211 TRENT
MANUAL
STRUCTURAL REPAIR
Stainless Steel 212 CN 18.12 91U046-01

918046-51
91U074-01
91U062-01
91UO62-51
918007- 02
91U007-52
918047- 02
91U047-52
91UO49-02
Plate Stainless Steel 212 CN 18.12 91UO89-00
B. Repair parts
PPIPC 78-32-49
R L - - - - - _ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
PPIPC
FIG/ITEM PART NO PART IDENT QTY
------____-_______---------*-------------------------------------
01/726 91UO46-01 Seal Depressor, L/H (item l) l

02/726 91U046-51 Seal Depressor, R/H (item 1) 1
01/732 91U063-01 Seal, Rear (item 2) 1
01/724 91U074-01 Seal Depressor (item 3 ) 1
01/722 9121062-01 Seal Depressor, L/H (item 4) 1
01/722 918062-51 Seal Depressor, R/H (item 4) 1
01/730 91UO88-00 Seal, Front (item 5) 1
02/730 91U088-00 Seal, Front (item 5) 1
01/718 91UOO7-02 Seal Depressor, L/H (item 6) 1
01/716 91U047- 02 Seal depressor, L/H (item 7) 1
01/728 91UO49-02 Seal Depressor (item 8) 1
02/728 91U049- 02 Seal Depressor (item 8) 1
01/736 91'13048-01 Seal, Rear Cover (item 9) 1
02/736 91U048-01 Seal, Rear Cover (item 9) 1
01/720 91U089-00 Plate (item 10) 1
01/720 91U089-00 Plate (item 10) 1
01/708 NAS1921M04S04AU Rivet (item 11) 64
01/714 NAS1921M04S03AU Rivet (item 12) 3
01/740 91UO90-00 Spacer (item 13) 64
02/740 91UO90-00 Spacer (item 13) 64
-
4. Procedure
HEALTH.
REPAIR N0.6
54-30-01
Page 202
Jun. 10/08
-a RB211 TRENT
MANUAL
STRUCTURAL REPAlR
WARNING: WHEN YOU USE CLEANING MATERIALS, COATING AND SEALANTS,

REFER TO AND OBEY THE MANUFACTURER'S CONTROL AND
A. Remove the HAC
(1) Remove the HAC from the C-Duct (AMM TASK 78-32-49-000-802).
B. Remove the damaged seal and seal depressor from the HAC
CAUTION : DO NOT MAKE THE SIZE OF THE COUNTERSINKS LARGER WHEN

YOU DRILL THE RIVETS.
(1) Refer to Figures 201, 202 and 203.
(2) Drill out the rivets that attach the seal depressor to the
HAC. Refer to SRM 54-02-10 for the removal of the fasteners.
(3) Discard the damaged seal depressor and the damaged seal.
C. Drill the new seal depressor (item 1, 3, 4, 6 and/or 8) and the

new seal (item 2, 5 and/or 9)
N0TE:The seal depressor at item 7 location will be drilled later.
(1) Refer to Figure 201, 202, 203, 204, 205, 206 and 207.
(2) Put the seal depressor and the seal in their position on
the HAC, use mechanical clamps.
CAUTION : DO NOT MAKE THE ORIGINAL HOLES AND COUNTERSINKS OF THE

HAC AND THE SEAL DEPRESSOR LARGER WHEN YOU THROUGH
DRILL.
(3) Drill the seal depressor and the seal through the HAC to a
diameter of 0.130 in. (3,30 mm).
(4) Remove the mechanical clamps.
(5) Increase the size of the holes in the seal to 0.282 in.
(7,16 mm) diameter.
(6) Deburr the holes.
D. Clean the repair area
(1) Clean the repair area (AMM TASK 70-20-01-100-802).
REPAIR N0.6
54-30-01
Page 203
Jun. 10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
E. Install the seal depressor (item 1, 3, 4, 6 and/or 8) and the

seal (item 2, 5 and/or 9) on the HAC
NOTE: Installation of the seal depressor at item 7 location will

be done later.
(1) Refer to Figure 201, 202 203, 204, 205, 206 and 207.
(2) Install the spacers (item 13) in each hole of the new seal.
(3) Use gripper pins to position the seal depressor, the seal
and the plate (item 101, if necessary, on the HAC.
NOTE: If you install a new front seal (item 5), you will
have to install the plate (item 10). The
installation of the plate is the same as for the
seal depressors (Fig. 202, 204, 205 and 207).
(4) Wet-install the fasteners (items ll), use OMat 8/106

sealant. Refer to SRM 54-02-10 for installation of
fasteners.
(5) Remove the gripper pins.
(6) Wet-install the fasteners the remain (items ll), use OMat
81106 sealant. Refer to SRM 54-02-10 for installation of
fasteners.
F. Clean the repair area
G. Install the seal depressor on the HAC at item 7 location
CAUTION : DO NOT MAKE THE ORIGINAL HOLES AND COUNTERSINKS OF THE

HAC AND THE SEAL DEPRESSOR LARGER WHEN YOU THROUGH
DRILL.
(1) Refer to Figure 203 and 204.
(2) Correctly put the seal depressor on the HAC, use mechanical
clamps.
(3) Drill the seal depressor through the HAC to a diameter of

0.130 in. (3,30 mm) .
(4) Remove the mechanical clamps.
REPAIR N0.6
54-30-01
Page 204
Jun. 10/08
(5)
p
"""
Deburr the holes.

RB211 TRENT
MANUAL
STRUCTURAL REPAIR
(6) Apply OMat 8/107 sealant on the surfaces in contact with the
seal depressor and of the HAC.
(7) Correctly put the seal depressor on the HAC, use gripper
pins.
(8) Wet-install the fasteners (item 121, use OMat 8/106 sealant.
Refer to SRM 54-02-10 for installation of fasteners.
(9) Remove the gripper pins.
(10) Wet-install the fasteners that remain (item 12), use OMat
8/106 sealant. Refer to SRM 54-02-10 for installation of
fasteners.
(11) Apply a bead of OMat 8/107 sealant on the edge of the HAC
all along the seal depressor, refer to Figure 204.
(12) Remove all unwanted sealant (AMM TASK 70-20-01-100-802).
H. Clean the repair area
I. Inspection
(1) Examine the repair to make sure the referenced procedures

have been done correctly.
J. Identification
(1) Mark FRSX115 adjacent to the part/serial number of HAC. Use

OMat 262 marker of a contrasting colour.
K. Install the HAC
(1) Install the HAC on the C-Duct (AMM TASK 78-32-49-400-802).
REPAIR N0.6
54-30-01
Page 205
Jun. 10/08
1 in Great Britain
H
"" R8211 TRENT
MANUAL
STRUCTURAL REPAIR
Left hand HAC is shown.

Right hand HAC is the same but opposite.
Hinge Access Cover

Fig. 201
REPAIR N0.6
54-30-01
Page 206
May 15/05
p'"" RB211 TRENT
MANUAL
STRUCTURAL REPAIR
2 SEAL, REAR 1 SEAL DEPRESSOR
9, SEAL. REAR COVER
_ _ _ - - - - - -
,.. 8 SEAL DEPRESSOR
l l RI* (16OFF)
13 SPACER (16 OFF)
10 PLATE 5 SEAL,FRONT 4 SEAL DEPRESSOR 3 SEAL DEPRESSOR
I I RIVET (I 9 OFF)
13 SPACER (19 OFF)
Q Left hand HAC is shawn.
Right hand M C is the same but oppasite.
12
Seals and Seal Depressors Installation
Fig. 202
REPAIR N0.6
54-30-01
Page 207
May 15/05
R8211 TRENT
STRUCTURAL REPAIR
MANUAL
12 RIVET (3 OFF)
l
\7 SEAL DEPRESSOR \
11 RIVET (29 OFF)
13 SPACER (29 O R )
,-.
SECTION
A-A
lOR3OR4OR6OR 5 SEAL, FRONT

SEAL DEPRESSOR
9 SE& REAR COVER
I-
Lelt hand HAG is shawn.

Fig. 203
REPAIR N0.6
54-30-01
Page 208
May 15/05
H RB211 TRENT
MANUAL
STRUCTURAL REPAIR
SECTION
B-B
SECTION
7 SEAL
c-c 2

Fig. 204
REPAIR N0.6
54-30-01
Page 209
May 15/05
RB211 TRENT
STRUCTURAL REPAIR
Left hand HAC is shown.Right hand M C is the same but opposite.

Dimensions are in in. (mm).
Seals and Seal Depressors Locations

Fig. 205
REPAIR N0.6
54-30-01
Page 210
May 15/05
P r i n t e d in Great Britain
H RB211 TRENT
MANUAL
STRUCTURAL REPAIR
SECTION
D-D
a
Left hand HAC is shawn. Right hand HAC is the same but opposite.
g Dimensions are in in. (mm).
E
Fig. 206
REPAIR N0.6
54-30-01
Page 211
May 15/05
p RB211 TRENT
MANUAL
STRUCTURAL REPAIR
SECTION SECTION
E-E F-F
SECTION SECTION
G-G H-H
0)
.o
2
Dimensions are in in. (mm).
'0
-
X

Fig. 207
REPAIR N0.6
54-30-01
Page 212
May 15/05
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
R Repair No.7
R
Thrust Reverser - outer skins
R
Through Repair of the C-Duct outer fixed structure acoustic area Disbond
R
FRSX 127
R
R
R 1. General:
R
R The repair gives the instructions to repair a disbonded C-Duct outer
R fixed structure (OFS) acoustic area. l
R
R This repair is applicable to all pre-S/N 45 C-Ducts standards with
R damage at the 6 O'clock position only. For any damage that is not within
R the limits of this repair scheme refer to Aircelle.
R
R The Fig/Item numbers referred to in the procedures agree with those used
R in the Power Plant Illustrated Parts Catalog (PPIPC). Only the primary
R Fig/Item numbers are used. For different Service Bulletin Standards
R refer to PPIPC.
R
R 2. Referenced information:
R
........................................................................................
SRM 54-02-10 Removal and installation of

fasteners
PPIPC (PP-TRENT-AI) 78-33-13 Power Plant Illustrated Parts
Catalog
AMM TASK 70-20-01-100-802 AMM - Non - Aqueous,,Liquid
Degreasing -
~ainetk&e '
Process 101
3. Equipment and Materials:
: A. Standard equipment
(1) Standard tools:

- Heat blanket, 0-120 deg C (32-250 deg F) or Heat lamp
- Vacuum pump to 80 percent, with gauge
- Cure cycle monitoring and reporting feature
.,..
- Load power indication 6kW .
. ..,
?.
- Thermocouples ,.. .
.- .
, ', L,2.
' . Scraper tool . . .. ' .. , :.:i
_,.. . .
,
Vacuum cleaner ::, ..~:,~,i.~;~..:.
:,:,, . , .
.
, :'
,
. . .;:l.<:,?.
..... -..!. .,.. -. . . :
.: ,
Pneumatic drill . ..:.
.VI ,.:
' REPAIR N0.7
54-30-01
Page 201
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
D r i l l s 2 , 5 mm ( 0 . 0 9 8 i n . ) , 5 , 0 8 mm ( 0 . 2 0 0 i n . ) a n d 6 mm ( 0 . 2 3 6
in.) dia
R
(2) Special tools: .... :::.
..
R .. ,,, .. .
...........................................................
...........................................................
HU87510 Honeycomb c r u s h i n g tool".
R
B. Consumable m a t e r i a l s
R
............................................................
............................................................
O M a t 262 Temporary m a r k e r f e l t / f i b r e t i p , EM56752
O M a t 272 A d h e s i v e Tape, S c o t c h No 27
O M a t 2/110 A d h e s i v e t a p e vacuum b a g s e a l ,
SM-5127
O M a t 2/111 B r e a t h e r C l o t h (N10-FR)
O M a t 2/126 Vacuum b a g , W r i g h t l o n 7400
,.O+t 2/131 Non-porous p a r t i n g f i l m , A4000
oMat 5/94 G a r n e t p a p e r , 150 G r i t s i z e ~ r a d e4/0
O M a t 8/106 S e a l a n t , two p a r t p o l y s u l p h i d e , - PR 14366 A1/2
OMat 8/154 Epoxy p a s t e a d h e s i v e , Hysol EA9394
R
C. Repair p a r t s
R
...-...--------------------.---.----------------------
PPIPC CHAPTER 78-33-13
-.
R PPIPC FIG/ITEM PART NO PART COUNTERSINK QTY
FIG- IDENTITY
ITEM
Blind b o l t 130" AR
9 , 8 0 mm
(0.386 i n . )
204/1A MBF2113S06- Blind b o l t 130 AR
600 9 1 84,:+
(a1t e r n a t i v e ) (0.386ii?5h:) . . :.,;.-l
204/1B FCBF2113-6- Blind b o l t 1 3&;-:.,, .. - ....%
;; ';?
600 . ., .
(alternative) (0 .386 .:,i;:')
204/1C FCBF2113S06- Blind b o l t 1 3 0 ° . . . ' AR
600 9 / 8 0 mm
(a1t e r n a t i v e ) (0.386 i n . )
54-30-01
Page 202
R
D.
p
Material of components
RB211 TRENT
MANUAL
STRUCTUAL REPAIR
. ...,Yd.;
.
..,
.. .
. .
. .>.
,: .J:;:: .
.I. ..l
,-
,, .
.i!<.. .
R ," ,.L,. 1.:"
I,. y:.. '
R .. .-.'y:!.p'
I
.: ., I .
COMPONENT MATERIAL . . . .. . .
R
. .
R
R Outer Fixed Structure Carbon composite
R
R 4. Health and Safety Notices
R
R WHEN YOU DO THIS REPAIR YOU MUST WEAR PROTECTIVE CLOTHING, GLOVES, DUST
R MASK AND SAFETY GOGGLES TO PROTECT YOU AGAINST DUST AND LOOSE PARTICLES,
R WHICH CAN BE DANGEROUS TO YOUR HEALTH.
R WHEN YOU USE CLEANING MATERIALS, COATINGS AND SEALANTS, REFER TO AND
R OBEY, THE MANUFACTURER'S CONTROL AND APPLICATION INSTRUCTIONS AND HEALTH
R AND SAFETY NOTICES.
R
R , . .
R 5. procedure .. .
..
. . .*,.". ..
I.'
:. ~.
A. Prepare the OFS .. ; ...
. L'1 ..>.,. ,
.,I
...
.. ..
l..:.,').::'.
.I
.,,!...,,
_, . .:
L , a . ,..;
(1) Clean the OFS acoustic area. Refer to AMM TASK'70'-20-01-100-
B. Prepare the potting zones
(1) Use an OMat 262 marker to mark out the centre of the zones to
be potted. Refer to figure 201:
- The fasteners are installed on two vertical rows.
- The first fastener line (one pair) must be at least at 25.4
mm (1.00 in.) from the bottom of the acoustic area.
- The last fastener line (one pair) must be outside of the
disbonded area.
CAUTION: DO NOT DAMAGE THE PLAIN SKIN WHEN DRILLING THE ACOUSTIC
SKIN.
.. ...*
f.
CAUTION: MAKE SURE TO DRILL THE HOLES P E R P E N D I C U ~.TO
~ THE ACOUSTIC
, 5''
SKIN SURFACE. . v ,
j* $
i 8 -.
(2) Pilot drill a 6.00 mm (0.236 in.) diameter hole through the
acoustic skin. Use the marks made in operaticin 5 .B. (1). Refer
to figure 202, step 1.
(3) Install the HU87510 honeycomb-crushing tool in the pneumatic

drill, then put the tool in the honeycomb.
CAUTION: DO NOT DAMAGE THE COMPOSITE SKINS WHEN YOU USE THE HU87510
HONEYCOMB CRUSHING TOOL INSTALLED ON THE PNEUMATIC DRILL.
Page 203
P r i n t e d i n Great B r i t a i n . Jun 10/07
. ." - . . ..
.,,*.:
RB211 TRENT . .'.. . :..

, I
: ..
:.. , ........,.
. >..:
%
:'
C)..,'
g. . . -
a
i,.i
,'. . I :
STRUCTUAL REPAIR . ,
,
~
.....
..
MANUAL
(4) U s e t h e HU87510 honeycomb-crushing t o o l i n s t a l l e d i n t h e

pneumatic d r i l l t o break t h e honeycomb c e l l s i n a l l t h e
a p p l i c a b l e l o c a t i o n s . Refer t o f i g u r e 201 and 202, s t e p 2 .
CAUTION: DO NOT USE COMPRESSED A I R TO REMOVE THE PIECES OF HONEYCOMB.

I T CAN CAUSE A FURTHER DISBOND OF THE PANEL.
(5) Remove t h e p i e c e s of honeycomb from between t h e i n n e r and

o u t e r s k i n s . U s e long nosed p l i e r s and a vacuum c l e a n e r .
(6) Clean t h e OFS a c o u s t i c a r e a . Refer t o AMM TASK 70-20-01-100-

802.
C. P r e p a r e t h e adhesive
. ..:...:::i
(1) Mix OMat 8/154 adhesive p a r t s A and B - a s i n i n ..s .t r u c t e d i n t h e
. .. .-
manufacturer i n s t r u c t i o n s . ,, ,-
(2) Use a s y r i n g e t o f u l l y f i l l a l l t h e p o t t i n g h o l e s w i t h t h e
a d h e s i v e . Refer t o f i g u r e 202, s t e p 3 .
D. Bag t h e p o t t i n g zones. Refer t o f i g u r e 203.
(1) I n s t a l l t h e thermocouple n e x t t o t h e p o t t i n g zones.
(2) Cut p i e c e s of OMat 2/131 non-porous p a r t i n g f i l m 50.00 mm

(1.97 i n . ) l a r g e r than an adhesive p l u g . Put one p i e c e of t h e
c u t OMat 2/131 Non porous p a r t i n g f i l m on each h o l e and a t t a c h
. i t with OMat 272 adhesive t a p e .
3) Cut a s u i t a b l e p i e c e of OMat 2/111 B r e a t h e r c l o t h (N10-FR) t o

cover t h e r e p a i r a r e a . Place t h e c u t material,>on:the .., "repair L
a r e a and a t t a c h i t u s i n g O M a t 272 Adhesive t a p e . +

:. :?
;;:,,2-
L>\
il
. ~ . ~ > l . ~ ~ , , : . ' . . -
(4) I n s t a l l t h e h e a t e r b l a n k e t . A h e a t e r lamp may .*be ?<is'ed"asan .

..
alternative.
(5) Apply s t r i p s of O M a t 2/110 adhesive t a p e vacuum bag s e a l

around t h e a c o u s t i c a r e a .
(6) Cut an a p p l i c a b l e p i e c e of OMat 2/126 vacuum bag t o cover t h e

f u l l a c o u s t i c a r e a . Attach two vacuum f i t t i n g s t o t h e vacuum
bag i n a p o s i t i o n where they w i l l s i t on t h e b r e a t h e r c l o t h
and make s u r e t h a t they do n o t s i t on the heater blanket.
(7) Evacuate t h e lay-up g a s e s t o a vacuum of 0.7 b a r s i n s i d e t h e

bag.
:,.: .!
EFFECTIVITY, : TRENT . . .
. , .. . Page 204
Printed in Great Britain ..' Jun 10/07
R821 1 TRENT
STRUCTUAL REPAIR
MANUAL
(8) If t h e heater b l a n k e t i s n o t i n s t a l l e d t h e n place t h e heat

l a m p an applicable distance f r o m t h e c o m p o n e n t .
R
E. C u r e t h e p o t t i n g zones.
R
CAUTION: THE RATE TEMPERATURE INCREASE AND SUBSEQUENT DECREASE MUST
. . .>, NOT BE MORE THAN 3 DEG C (5 DEG F) P E R MINUTE.
., . ,,.
,,.,,/'
, ..:i.. - .*::':.
,
'
CAUTION: DO NOT START TO MEASURE THE CURE TIME UNTIL

I,:
,THE:T?ERATURE
; .....
,.S. W . :
HAS REACHED THE REQUIRED RANGE. 3; . ' . ;
. :, ..+; .
(1) C u r e t h e adhesive f o r 7 hours a t a m i n i m u m r o o m t e m p e r a t u r e of

25 deg C (77 deg F) then 1 hour b e t w e e n 90 and 100 deg C (194
and 212 deg F) i n a v a c u u m of 0.7 bars. U s e a H e a t l a m p o r a
H e a t blanket.
(2) A l l o w t h e repair area t o cool t o r o o m t e m p e r a t u r e .
(3) R e m o v e t h e v a c u u m bagging.
(4) R e m o v e t h e u n w a n t e d adhesive w i t h O M a t 5/94 G a r n e t Paper and

l i g h t l y abrade t h e area t o g e t a s m o o t h surface.
R
(5) C l e a n t h e repair area. R e f e r t o AMM TASK 70-20-01-100-802.
R , ,
R
R
F. kill t h e p o t t i n g zones.
.-,. S, -
(l) P i l o t d r i l l t h e p o t t i n g zones f r o m t h e acoust=b sid2,to a
d i a m e t e r of 2,5 mm (0.098 i n . ) . R e f e r t o f i g u r e '-201.
,:t'
(2) D r i l l t h e p o t t i n g zones t o a f i n a l d i a m e t e r of b e t w e e n 5,05
and 5,13 mm (0.199 and 0.202 i n . ) .
(3) C o u n t e r s i n k t h e h o l e s i n t h e p o t t i n g z o n e s on t h e a c o u s t i c
panel side 130' t o a diameter of b e t w e e n 9,60 and 9,80 mm
(0.378 and 0.385 i n . ) .
R
(4) C l e a n t h e area. R e f e r t o AMM TASK 70-20-01-100-802.
R
R
G. I n s t a l l t h e fasteners.
R
R
(1) U s e O M a t 8/106 t o w e t i n s t a l l t h e fasteners (1) i n t h e p o t t i n g
R
zones h o l e s . R e f e r t o SRM 54-02-10 t o i n s t a l l t h e fasteners.
R
II R e f e r t o f i g u r e 204 f o r t h e fasteners i n s t a l l a t i o n d e t a i l s .
R ,,
R
(2) C l e a n t h e area. R e f e r t o AMM TASK 70-20-01-1007802. l , -
R ., 4c, \ r i l + .,
R ' Li> ;'
H. E x a m i n e t h e c o m p l e t e d repair.
R
R E P A I R N0.7
54-30-01
P a g e 205
RB211 TRENT
STRUCTUAL REPAIR
MANUAL

satisfactorily completed.
I. Identify the repair.

211(
, ' >::>,.' * :: .. . -...
(1) Use OMat 2 62 marker to write FRSX127 adj scent:;c+.,,:the ''C-~uct
modification plate. . . ?., :.. ."..._:.: . I . : .
REPAIR NO. 7
54-30-01
Page 206
p
"" RB211 TRENT
STRUCTUAL
MANUAL REPAIR
TYPICAL A-A SECTION

TORSION BOX
_, _.,.-,.,:
; ,-,., .:
>
.. .. ..
:
PERFORATED
PATTERN
Pottings and holes location

Figure 201
REPAIR N0.7
. ..
54-30-01
. .. Page 207
i.., . '
Printed in GreatBritain
, . Jun 10/07
RB211 TRENT
-,
STRUCTUAL REPAIR
MANUAL
ACOUSTIC SKlN 0.236 in. (6 mm)

DIAMETER
\
PLAIN SKlN
HONEYCOMB CRUSHING TOOL
A'
. .. ~
~ > ~ = ~ i \ ~ ~ i $ #~ + ~~ , ~ ~ ! ~ ~ & ~g~ ~ ~.~$ $~ ~~ ~~ ~: ~~ ~ > ~ $ ~ ~~ ~ : ~ ~ ~ ~ ~ rWE3m{izf;%%

~ ~ j ~hg~xgfl
$W~!$;j.~~+$~$~~~~~$~$;)i~+~i;l;flt!;~~T~p{!,,&t>~~i~~f
STEP 2
0.315 in. (8 mm)
SYRINGE
EPOXY PASTE ADHESIVE
l\'
STEP 3
R Potting zones preparation

R Figure 202
EFFECTIVITY : TRENT REPAIR N 0 . 7
l Page 208
p
'"" RB211 TRENT
MANUAL
STRUCTUAL REPAIR ,
" 3
ADHESIVE TAPE NON-POROUS

VACUUM BAG SEAL PARTING FILM VACUUM BAG
Bagging procedure
Figure 203
REPAIR NO. 7
.A':-
%
-.
01
:
< -
. Page 209
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
PLAIN SKIN /
Fastener installation details

Figure 204
Page 210
R6211 TRENT
STRUCTUAL REPAIR
MANUAL
REPAIR N0.8
THRUST REVERSER -
OUTER SKINS
FRSX 129
R 1. General
R
R A. This repair instructs the installation or replacement of damaged screws
R
R in the tertiary lock access panel (77-33-13 01 410 / 02 410) and
R related receptacles installed in the 3 and 9 o'clock beams. The repair
R
R is in 2 parts: Part 1 instructs the screws and Part 2 the receptacles.
R
R B. The procedure is applicable to LH and RH thrust reverser.
R
R
R C. The Fig/Item numbers referred to in the procedures agree with those
R used in the Power Plant Illustrated Parts Catalog (PPIPC). Only the
R
R primary Fig/Item numbers are used. For different Service Bulletin
R Standards refer to PPIPC.
R
R
R 2. Referenced information
R
R
......................................................................
R REFERENCE
R
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .DESIGNATION
................................
R AMM TASK 70-20-01-100-802 Cold liquid degreasing
R SRM 54-02-10 Fasteners-Installation and removal
R PPIPC (PP-TRENT-AI) 78-33-13 Power Plant Illustrated Parts Catalog
R
R 3. Equipment and Materials
R
R A. Standard equipment
......................................................................
......................................................................
Omat 262 Temporary marker
Omat 81106 Sealant, two part PR14360 A1/2
Omat 8/'107 Sealant, two part PR1436G B1/2
REPAIR N0.8
54-30-01
Page 201
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
C. Repair Parts
......................................................................
Figure/item PPIPC PART NO PART IDENT QTY
......................................................................
78-33-13
01/02-415 FX10-1558-1P Stud assy A/R
01/02-413 FX10-1525 Retaining ring A/R
01/02-417 FX10-1510 Tridair A/R
receptacle
01/02-418 CCR264CS3-2 Rivet A/R
4. Procedure
WARN1NG:WHEN YOU USE CLEANING MATERIALS, COATING AND SEALANT, REFER TO,
AND OBEY, THE MANUFACTURER'S CONTROL AND APPLICATION INSTRUCTIONS
AND SAFETY NOTICES.
WARN1NG:WHEN YOU DO THIS REPAIR YOU MUST WEAR PROTECTIVE CLOTHING, GLOVES
DUST MASK AND SAFETY GOGGLES TO PROTECT YOU AGAINST DUST AND
LOOSE PARTICLES WHICH CAN BE DANGEROUS TO YOUR HEALTH.
-
PART 1: Replace the screw (78-33-13, 01/02-415)
Refer to Figure 201.
A. Remove the access panel (78-33-13, 01/02-410) from the 3 or 9 o'clock

beams.
B. Clean the panel. Refer to AMM TASK 70-20-01-100-802.
C. Remove t,he damaged screw
(1) Use a hand tool to remove the retaining ring.
(2) Remove the screw from the panel.
(3) Repeat this operation for each damaged screw.
D. Install the replacement screw
(1) Install a new screw (78-33-13, 01/02-4151 in the access panel.
REPAIR N0.8
54-30-01
Page 202
p RB211 TRENT
MANUAL
STRUCTUAL REPAIR
(2) Install the retaining ring (78-33-13, 01/02-413) on the screw

until it is in contact with the inner face of the access panel.
NOTE: The retaining ring is on the inner side of the panel.
(3) Repeat this operation for each damaged screw.
E. Make sure the repair has been satisfactorily completed according to

this procedure.
F. Mark FRSX129, Part 1 adjacent to the repair with OMat 262 temporary
marker of a contrasting color.
G. Install the access panel.
PART 2: Replace the receptacle
Refer to Figure 202.
A. Remove the access panel from the 3 or 9 o'clock beams.
B. Remove the damaged receptacle.

CAUTION: YOU MUST TAKE CARE NOT TO ENLARGE THE HOLES OR DAMAGE THE
STRUCTURE WHEN YOU REMOVE THE RIVETS.
(1) Remove the two rivets attaching the damaged receptacle. Refer to
SRM 54-02-10 and Figure 202.
(2) Remove and discard the receptacle.
(3) Repeat this operation for each damaged receptacle.
C. Clean the repair area. Refer to AMM TASK 70-20-01-100-802. Wipe dry
before solvent evaporates.
D. Install. the receptacle (78-33-13, 01/02-4171.
(1) Apply OMat 8/107 sealant on receptacle mating surfaces.
(2) Wet install the rivets (78-33-13, 01/02-418) with OMat 8/106
sealant. Refer to SRM 54-02-10, Figure 202.
REPAIR N0.8
54-30-01
Page 203
Printed in Great Britain ~ u n 10/08
.
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
R
R E. Remove unwanted sealant. Refer to AMM TASK 70-20-01-100-802.
R
R
R F. Make sure the repair has been satisfactorily completed according to
R this procedure.
R
R G. Mark FRSX129, Part 2 adjacent: to the repair with OMat 262 temporary
R marker of a contrasting color.
R
R
H. Install the access panel (78-33-13, 01/02-410).
REPAIR N0.8
54-30-01
Page 204
Printed in Great Britain Jun. lO/O8
M RB211 TRENT
MANUAL
STRUCTUAL REPAIR
. . . .. .
TERTIARY LOCK- / .
ACCES PANEL
Location and details of screw and retaining ring assembly

Figure 201
REPAIR N0.8
54-30-01
Page 205
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
30R9
O'CLOCK BEAM
\
OMAT 811 07
SEALANT
Location and details of Tridair receptacle assembly

Figure 202
REPAIR N0.8
54-30-01
Page 206
1
m@
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
THRUST REVERSER PIVOT DOOR STRUCTURE - IDENTIFICATION
1. General
R A. The subject describes the inner panel, the upper and lower door structure
and the moveable panels: The triangular and the rectangular panels. Refer
to section 54-30-01 for outer panel description of the pivoting door.
B. The following figures describe the parts and list the material used. The
full view of the parts has a ply orientation chart to help find the warp
direction. Refer to section 54-30-00 to have the full references of these
materials and sources, and the typical lay up to find the warp direction
for each ply of the composite skin.
C. The triangular panel, the rectangular panel and the inner panel are made of
carbon/epoxy composite bonded to metallic honeycomb. The structure door is
made of carbon/epoxy composite. Many fittings are made of aluminium alloy.
D. Each of the individual components is divided into zones which define the
number of carbon ply and/or the type of honeycomb. These zones are
identified in figures and tables which follow.
EFFECTIVITY: TRENT
Page 1
July 1/95
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
OUTER PANEL
SEE 54-30-01
RECTANGULAR
El
MOVABLE PANEL
STRUCTURE DOOR NOTE : UPPER AND LOWER PIVOT

SEE FIG 5 DOORS ARE SlMllAR
TRIANGULAR
MOVABLE PANEL
SEE FIG 3 D4613A
Pivot Door Identification

Figure 1
EFFECTIVITY: TRENT
Page 2
July 1/94
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
OUTER SKIN
AREA No Z1 22 23 24 LAY UP ORDER

GLASS LAYER 1 1 LAST
CARBONEPOXYLAYER 3 5 4 5
Inner Panel - Upper Door

EFFECTIVITY: TRENT
Page 3
J u l y 1/95
1
mB
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
INNER SKIN
AREA No 21 22 23 24 25 LAY UP ORDER

GLASS LAYER 1 1 1 FIRST
CARBON EPOXY LAYER 3 2 4 5 5
METALLIC HONEYCOMB TYPE 5056 9-85 THICKNESS 0.5 in (12.7 mm)

METALLIC HONEYCOMB TYPE 5056 4-40 THICKNESS 0.5 in.(12.7mm)
a RIBBON DIRECTION
Inner Panel - Upper Door

EFFECTIVITY: TRENT
Page 4
July 1/95
1
m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
NOTE: The upper PIN is for the upper door

The lower PIN is for the lower door
Inner Panel
EFFECTIVITY : TRENT
Page 5
Sept.15/96
M
m (R\
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
NOTE : THE UPPER PIN IS FOR THE UPPER DOOR

THE LOWERPIN IS FOR THE LOWER DOOR
Inner Panel
R F i g u r e 2 (Sheet 4 of 7)
EFFECTIVITY: TRENT
Page 6
J u l y 1/95
[ RB.211 TRENT
m STRUCTURAL REPAIR
MANUAL

1 ANGLE FITTING ALUMINIUM 7010
2 DOUBLER FllTlNG ALUMINIUM 7175
3 BRACKET ALUMINIUM 2024 PL
4-7 BRACKET ALUMINIUM 2024 PL
5 FAlRlNG ALUMINIUM 2024 PL
6-16 HINGE FITTING ALUMINIUM 7175
8 BRACKET 0.040 ALUMINIUM 2024 PL
9 DOUBLER FITTING ALUMINIUM 7175
10 ANGLE 0.064 ALUMINIUM 2024 PL
11 ANGLE 0.064 ALUMINIUM 2024 PL
12 STOP FITTING ALUMINIUM 7175
13 FITTING ALUMINIUM 7175
15 DEFLECTOR 0.048 ALUMINIUM 2024 PL
17-20 HINGE FITTING ALUMINIUM 7175
18-19 BRACKET ALUMINIUM 2024 PL
21 DEFLECTOR 0.048 ALUMINIUM 2024 PL
23 ACTUATOR FAlRlNG CARBON COMPOSITE
24 FllTlNG ALUMINIUM 7175
25 LOCK FITTING ALUMINIUM 7175
Inner Panel
EFFECTIVITY: TRENT
54-30-02
Page 7
July 1/95
1m m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
OUTER SKIN
AREA N o Z1 22 23 24 25 LAY UP ORDER

GLASS LAYER 1 1 1 LAST
........-.........
.........................
..:.:.:.>:.:.:.:.
............... PERFORATED SKIN
Inner Panel - Lower Door

EFFECTIVITY: TRENT
Page 8
July 1/95
1m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
INNER SKIN
m
AREA N o 21 22 23 24 25 LAY UP ORDER

GLASS LAYER 1 1 1 FIRST
METALLIC HONEYCOMB TYPE 5056 9-85 THICKNESS 0,5 in (12.7 mm)

METALLIC HONEYCOMB
TYPE 5056 4-40 THICKNESS 0.5 in.(12.7mm)
(=3 RIBBON DIRECTION
Inner Panel - Lower Door

EFFECTIVITY: TRENT
Page 9
July 1/95
RB.211 TRENT
(R) STRUCTURAL REPAIR
MANUAL
LEl
INNER SKlN
-
OUTER SKlN
AREA N o Z1 22 23
LAY UP AREA N o Z1 22 23 LAY UP
ORDER ORDER
GLASS LAYER 1 1 LAST GLASS LAYER 1 1 FIRST
CARBON CARBON 3 5 5
3 5 5
EPOXY LAYER EPOXY LAYER
METALLIC HONEYCOMB 1.O in.(25.4 mm) TYPE

METALLIC HONEYCOMB 0.5 in.(12.7 mm) TYPE
PERFORATED SKlN
RIBBON DIRECTION D46156
Triangular Moveable Panel

Figure 3
EFFECTIVITY: TRENT
Page 10
July 1/95
1w e
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
lAI
OUTER SKlN 1 0o INNER SKlN
l AREA N o LAY UP
AREA No z3
LAY UP
ORDER
GLASS LAYER 1 1 GLASS LAYER 1 1 FIRST
CARBON
EPOXY LAYER
1 3 1 5 1 5 1 FIRST I CARBON
EPOXY LAYER
3 5 5
VA METALLIC HONEYCOMB 1.0 in.(25.4 mm) TYPE 5056 9-85

h \ METALLIC HONEYCOMB 0.5 in.(12.7 mm) TYPE 5056 9-85
.................
........
.........
........ PERFORATED SKIN
.........
........
.........
;.............:.
RIBBON DIRECTION
Rectangular Moveable Panel

Figure 4
EFFECTIVITY: TRENT
Page 11
July 1/95
1
m e
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
7 91 E568 6 91 €552 5 91 E594 10 (see table)

91 E839 91 E836 91 E882
NOTE: The upper PIN is for the top door

The lower PIN is for the bottom door
Door S t r u c t u r e
F i g u r e 5 ( S h e e t 1 of 2)
EFFECTIVITY: TRENT
Page 1 2
O c t . 1/95
STRUCTURAL REPAIR
MANUAL
ITEM DESCRIPTION GAGE MATERIAL PIN

1 LATERAL FRAME CARBON COMPOSITE
2 REAR FRAME CARBON COMPOSITE
3 PIVOT FRAME CARBON COMPOSITE
4 CUT CORNER FRAME CARBON COMPOSITE
5 MIDDLE FRAME CARBON COMPOSITE
6 ACTUATOR FITTING ALUMINIUM 7175
7 MIDDLE FRAME CARBON COMPOSITE
8 FRONT FRAME CARBON COMPOSITE
9 SEAL
10 BRACKET, TOP SEAL 5086Hl11 91E462
RETAINER 5086H111 91E572
FITTING AS7G06T6 91E576
10 BRACKET, BOTTOM SEAL 5086H111 91E463
BRACKET 5086H111 91E875
RETAINER AS7G06T6 91E828
Door S t r u c t u r e
EFFECTIVITY: TRENT
Page 13
O c t . 1/95
H RB.211 TRENT
mm@ STRUCTURAL REPAIR
MANUAL
91J414
(SEE SHEET 2)
TOP DOOR
91J420
(SEE SHEET 3)
BOrrOM DOOR
Kicker P l a t e s
EFFECTIVITY: TRENT
Page 14
J u l y 1/95
[ RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
INNER SKIN
n A
OUTER SKlN

THICKNESS : 0.236 in (6 mm)
RIBBON DIRECTION
Kicker P l a t e
EFFECTIVITY: TRENT
Page 15
July 1/95
1 m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
INNER SKlN
/CARBONEPOXY LAYER 15/61

TEDLAR LAYER 1 1 LAST
GLASS LAYER 1 FIRST
OUTER SKlN
m
AREA No
GLASS LAYER
METALLIC HONEYCOMB TYPE 5056 4-50

Kicker Plate
EFFECTIVITY: TRENT
Page 16
July 1/95
1
m(m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
OUTER SKlN
m
.-C
(C)
.-
U
INNER SKlN
AREA No
TEDLAR LAYER

THICKNESS : 0.375 in (9.52mm)
R NON METALLIC HONEYCOMB TYPE NOMEX 3-64

THICKNESS : 0.236 in (6 mm)
Kicker Plate
Figure 6 (Sheet 4 o f 5 )
EFFECTIVITY: TRENT
Page 17
J u l y 1/95
1
ma
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
FOLD BACK
NOT FOLD BACK
SECTION A-A
NON FOLD BACK LAYER
FOLD BACK LAYER
RTM SEALANT
Kicker Plate
EFFECTIVITY: TRENT
Page 18
J u l y 1/95
THRUST REVERSER - PIVOTING DOOR STRUCTURE - ALLOWABLE DAMAGE
1. Introduction
This section contains the allowable and repairable damage limits for
the thrust reverser pivoting doors.
Damage which is found to be greater than the allowable damage limits

must be repaired in accordance with the procedures detailed in the
following Repair Section, Page Block 201. Components not included in
this repair Chapter-Section are not repairable and must be replaced
if damaged.
A component with damage more than the repairable damage limits must
be replaced by a new one. It must not be repaired without a Rolls-
Royce or Hurel-Dubois technical statement.
2. Zones
Each of the individual components is divided into zones. The zones

which are affected by the different types of allowable or repairable
damage are identified in the figures and tables which follow.
A. The allowable and repairable damage zones for these components

are:
A Acoustic area
B Internal side area
M Monolithic area
S Sandwich area
E Edge area, attaching area, monolithic/sandwich intermediate area
A. Allowable damage
Allowable damage limits are intended to permit an operator to

service, or be rejected for repair. Allowable damage must not
compromise the structural integrity of the component, which could
affect the strength or fatigue life. The types of allowable damage
permitted are defined and, if applicable, brief descriptions are
given of the clean-up procedures needed either to prevent
propagation of the damage or to improve the appearance and
aerodynamic smoothness of the damaged part.
EFFECTIVITY: TRENT
54-30-02
Page 101
Printed in Great Britain JUN 10/09
Damage limits assume that exposed edges do not extend above the
skin surface. Any damage that does should be trimmed to remove
or feather the protrusion. Holes or cracks in pressurized panel
zones must be sealed using the appropriate tape.
Allowable damage is classified as either unlimited usage or

time limited:
(1) Unlimited usage damage is defined as minor damage which

does not affect the structural integrity or functional
capability of the component. No repairs are necessary,
other than cosmetic, over the aircraft design life.
(2) Time limited damage is defined as minor damage which does

not affect the structural integrity of the component in
normal service use, but could reduce the design life of
the component. In this case, damage must be repaired by
next Aircraft C check. The location and size of the damage
should be noted and checked at suitable intervals to
monitor that the damage has not grown beyond the time
NOTE:1. When two damages are close, the minimum distance

to determine if it is one or two defects is
determined as follows:
If the distance between the two damages is

greater than the dimension of the biggest damage,
then the two damages are distinct.
If the distance between damages is smaller than

the dimension of the biggest damage, then the
defect is unique.
2. If a damage extends over two zones, you must

consider the smallest allowable damage limits.
3. When two damages are close, the minimum distance

for separation shall be determined by choosing
the greatest distance given in the ‘requirements’
column for each damage.
Repairable damage limits are intended to permit an operator to

determine whether a damaged nacelle component can be repaired
or must be rejected. The operator must follow the section
organization to accomplish the repair satisfactorily.
EFFECTIVITY: TRENT
54-30-02
Page 102
C. Damage Types
Damage types permitted on this component are listed below.

not the surface finishes, such as paint.
(1) Abrasion – an abrasion is an area of damage which results

in a cross sectional area change caused by scuffing.
rubbing, or other surface erosion. An abrasion usually
appears rough and irregular.
(2) Gouge – a gouge is a damage area of any size which results

in a cross sectional area change. It is usually caused by
contact with a sharp object which produces a continuous,
sharp or smooth channel-like groove in the material.
(3) Nick – a nick is a local gouge with sharp edges.
(4) Scratch – a scratch is a line of damage in the material

and results in a cross sectional area change. Normally
caused by a very sharp object.
(5) Crack – a crack is a partial fracture or complete break in

the material and produces a most significant cross
sectional area change. Normally appearing as an irregular
line.
(6) Dent – a dent is a depressed area of damage which, with

metal skins would not cause cross sectional area change.
On core filled laminates, it may cause crushing of the
core cells. Area boundaries are smooth and it is usually
caused by contact with a smooth contoured object.
(7) Hole – a hole is a complete penetration of the material.
(8) Disbond – a disbond is the separation of the face skin

from the honeycomb core of a bonded panel.
(9) Delamination – a delamination is the separation of two

laminate plies or faying surfaces.
4. Identify and Measure the Damge Extent
A. Do an ultrasonic inspection to determine the damage extent,

then mark out the damage extent on the part.
B. Measure the damge.
EFFECTIVITY: TRENT
54-30-02
Page 103
INSPECTION
ZONE DAMAGE REQUIREMENTS ALLOWABLE LIMITS
INTERVALS

resin area

Gouge first outer ply. No (0.01in.)
nearer then 5 times
its size to other
unrepaired damage
or rivet line
All Dent No nearer then 5 Depth <= 2,5 mm

times its diameter (0.1 in.)
to other unrepaired
damage or rivet
line
All Hole, No nearer than 5 Diameter or length ‘A’ check

Nick times its size to <= 20 mm (0.19 for sealed
other unrepaired in.) hole
damage or rivet Depth: Confined to
line. outer skin
Seal the hole with
speed tape

Disbond times its size to <= 30 mm (1.18
other unrepaired in.)
damage or rivet Depth: Confined to
line outer skin
EFFECTIVITY: TRENT
54-30-02
Page 104
REPAIR
ZONE DAMAGE REQUIREMENTS REPAIRABLE LIMITS
PROCEDURE
A1 Scratch, No more than 2 Depth <= 0,56 mm FRSX045

Nick, times cut plies. (0.22 in.) 54-30-00
Gouge Distance from other REPAIR 01
damage or rivet
line must be
greater than 5
times its size
A1 Dent, Distance from other Diameter <= 40 mm FRSX047

Disbond damage must be (1.6 in.) 54-30-00
greater than 5 REPAIR 03
times its size –
core undamaged
A1 Dent Distance from other Diameter <= 40 mm FRSX048

damage must be (1.6 in.) 54-30-00
times its size –
core damaged
A1 Hole Distance from other Diameter <= 40 mm FRSX049

times its size –
inner skin damaged
< dia 30 mm (1.2
in.)

times its size –
inner skin damaged
> dia 30 mm (1.2
in.)
EFFECTIVITY: TRENT
54-30-02
Page 105
REPAIR
PROCEDURE
A1 Delamination Distance from other Diameter <= 40 mm FRSX045

damage or rivet (1.6 in.) 54-30-00
line must be REPAIR 01
greater than 5
times its size
A2 Scratch, No more than 2 cut Depth <= 0,56 mm FRSX045

Nick, plies. Distance (0.022 in.) 54-30-00
Gouge from the other REPAIR 01
damage or rivet
line must be
greater than 5
times its size

Disbond damage or rivet (1.6 in.) 54-30-00
greater than 5
times its size –
core undamaged
R A2 Disbond Confined to disbond Over unlimited FRSX132

of the acoustic area 54-30-20
skin – core REPAIR 08
undamaged
A2 Dent Distance from the Diameter <= 32 mm FRSX048

other damage or (1.26 in.) 54-30-00
rivet line must be REPAIR 04
greater than 5
times its size –
core damaged
A2 Hole Distance from other Diameter <= 32mm FRSX049

greater than 5
times its size –
inner skin damage
< dia 30 mm (1.2
in.)
EFFECTIVITY: TRENT
54-30-02
Page 106
REPAIR
PROCEDURE

greater than 5
times its size –
inner skin damage
> 30 mm (1.2 in.)

greater than 5
times its size
A3 Scratch, No more than 3 cut Depth <= 0.84 mm FRSX045

Nick, plies. (0.033 in.) 54-30-00
Gouge Distance from other REPAIR 01
damage or rivet
line must be
greater than 5
tiomes its size

greater than 5
times its size -
cor undamaged
R A3 Disbond Confined to disbond Over an unlimited FRSX132

of the acoustic area 54-30-02
skin – core REPAIR 08
undamaged
A3 Dent Distance form other Diameter <= 32 mm FRSX048

greater than 5
times its size –
core damaged
EFFECTIVITY: TRENT
54-30-02
Page 107
REPAIR
PROCEDURE

greater than 5
times its size –
inner skin damage
< dia 30 mm (1.2
in.)

greater than 5
times its size –
inner skin damage
> dia 30 mm (1.2
in.)

greater than 5
times its size
E1 Scratch, No more than 4 cut Depth <= 1,12 mm FRSX045

Gouge from other damage REPAIR 01
or rivet line must
be greater than 5
times its size
E1 Dent Distance from other Diameter <= 75 mm FRSX045

times its size –
core undamaged
E1 Hole Distance from other Diameter <= 75 mm FRSX046

times its size
EFFECTIVITY: TRENT
54-30-02
Page 108
REPAIR
PROCEDURE
E1 Delamination Distance from other Diameter <= 75 mm FRSX053

greater than 5
times its size

or rivet line must
be greater than 5
times its size

times its size –
core undamaged
E2 Hole Distance from other Diameter <=36 mm FRSX046

damage must be (1.42 in.0 54-30-00
times its size –
core undamaged

times its size –
core undamaged

or rivet line must
be greater than 5
times its size
EFFECTIVITY: TRENT
54-30-02
Page 109
REPAIR
PROCEDURE
E3 Dent Distance from other Depth <= 2,5 mm FRSX045

greater than 5
times its size

greater than 5
times its size

greater than 5
times its size

or rivet line must
be greater than 5
times its size

times its size

times its size
E4 Delamination Distance from other Diameter <= 36mm FRSX053

times its size –
core undamaged
EFFECTIVITY: TRENT
54-30-02
Page 110
REPAIR
PROCEDURE
M1 Scratch, No more than 4 cut Depth <= 1,12 mm FRSX045

or rivet line must
be greater then 5
times its size
M1 Dent, Distance from other Diameter <= 75 mm FRSX045

Delamination damage must be (3.0 in.) 54-30-00
times its size –
core undamaged
M1 Hole Distance from other Diameter <= 75 mm FRSX046

times its size
S1 Scratch, No more than 1 cut Depth <= 0,28 mm FRSX045

Nick, ply. Distance from (0.011 in.) 54-30-00
Gouge other damage or REPAIR 01
rivet line must be
greater than 5
times its size
S1 Dent, Distance from other Diameter <= 75 mm FRSX047

times its size –
core undamaged
S1 Dent Distance from other Diameter <= 75 mm FRSX048

times its size –
core damaged
S1 Hole Distance from other Diameter <= 75 mm FRSX049

times its size –
inner skin damaged
<dia 30 mm (1.2
in.)
EFFECTIVITY: TRENT
54-30-02
Page 111
REPAIR
PROCEDURE

times its size –
inner skin damaged
> dia 30 mm (1.2
in.)
S1 Delamination Distance from other Diameter <= 75 mm FRSX045

greater than 5
times its size
S2 Scratch, No more than 2 cut Depth <= 0,56 mm FRSX045

or rivet line must
be greater than 5
times its size

greater then 5 REPAIR 03
times its size –
core undamaged

times its size –
core damaged

times its size –
inner skin damaged
< dia 30 mm (1.2
in.)
EFFECTIVITY: TRENT
54-30-02
Page 112
REPAIR
PROCEDURE

greater then 5 REPAIR 06
times its size –
inner skin damaged
> dia 30 mm (1.2
in.)

greater than 5
times its size
S3 Scratch, No more than 1 ply. Depth <= 0,28 mm FRSX045

Nick, Distance from other (0.011 in.) 54-30-00
Gouge damage or rivet REPAIR 01
line must be
greater than 5
times its size

greater tan 5 times REPAIR 03
its size – core
undamaged

times its size –
core damaged

times its size –
inner skin damaged
< dia 30 mm (1.2
in.)
EFFECTIVITY: TRENT
54-30-02
Page 113
REPAIR
PROCEDURE

times its size –
inner skin damaged
> dia 30 mm (1.2
in.)

greater than 5
times its size
B2 Scratch, No more than 3 cut Depth <= 0,84 mm FRSX045

or rivet line must
be greater than5
times its size
B2 Dent, Distance from other Diameter <= 27 mm FRSX047

greater than 5
times its size –
core undamaged
B2 Dent Distance from other Diameter <= 27 mm FRSX048

greater than 5
times its size –
core damaged
B2 Hole Distance from other Diameter <= 27 mm FRSX049

greater than 5
times its size –
inner skin damage
< dia 30 mm (1.2
in.)
EFFECTIVITY: TRENT
54-30-02
Page 114
REPAIR
PROCEDURE
B2 Delamination Distance from other Diameter <= 30 mm FRSX045

greater than 5
times its size
B3 Scratch, No more than 3 cut Depth <= 0,84 mm FRSX045

or rivet line must
be greater than 5
times its size
B3 Dent, Distance from other Diameter <= 30 mm FRSX047

greater than 5
times its size –
core undamaged
B3 Dent Distance from other Diameter <= 29 mm FRSX048

greater than 5
times its size –
core damaged
B3 Hole Distance from other Diameter <= 29 mm FRSX049

greater than 5
times its size –
inner skin damage
< dia 30 mm (1.2
in.)
B3 Delamination Distance from other Diameter <= 30 mm FRSX045

greater tthan 5
times its size
EFFECTIVITY: TRENT
54-30-02
Page 115
Thrust Reverser – Pivoting Door Structure – Allowable Damage Limits
EFFECTIVITY: TRENT
54-30-02
Page 116
Figure 101 (shee 2 of 2)
EFFECTIVITY: TRENT
54-30-02
Page 117
Figure 102
EFFECTIVITY: TRENT
54-30-02
Page 118
THRUST REVERSER - PIVOTING DOORS - LIST OF APPROVED REPAIRS
1 REPAIR OF UPPER STOP - TRIANGULAR MOVEABLE PANEL

(FRS X073)
2 REPAIR OF BRACKET - MOVEABLE PANEL

(FRS X074)
3 REPAIR BORE IN PANEL LEVER FITTING

(FRS X072)
4 REPAIR INNER SKIN LATERAL ANGLE

(FRS X075)
5 REPAIR LATERAL ANGLE ON CUT CORNER SIDE

(FRSX 091)
6 REPLACE BUMPER STOP PAD

(FRS X089)
7 RE-INFORCE THE TRIANGULAR MOVEABLE PANEL LEVER ARM

(FRS X087) FITTING ON A LOWER DOOR
8 THROUGH REPAIR OF THE DOOR MOVEABLE PANLES ACOUSTIC

R
(FRS X132) AREA DISBOND

54-30-02
Page 201
REPAIR NO.1
THRUST REVERSER - PIVOTING DOORS
R REPAIR OF TRIANGULAR MOVEABLE PANEL STOP BRACKET
R WARNING: WHEN YOU DO THIS REPAIR YOU MUST WEAR PROTECTIVE CLOTHING,
R GLOVES, DUST MASK AND SAFETY GOGGLES TO PROTECT YOU AGAINST
R DUST AND LOOSE PARTICLES, WHICH CAN BE DANGEROUS TO YOUR
R HEALTH.
R WARNING: YOU MUST FIND AND OBEY THE MANUFACTURER’S HEALTH AND SAFETY
R DATA FOR THE MATERIALS. YOU MUST ALSO REFER TO LOCAL
R REGULATIONS TO MAKE SURE THAT THE PROCEDURES ARE DONE SAFELY.
R IF YOU DO NOT DO THIS, AN INJURY OR ENVIRONMENTAL DAMAGE CAN
R OCCUR.
1. General
R A. This procedure gives instructions to repair the triangular

R moveable panel upper stop on the pivoting doors.
SRM 54-02-03 Protective Treatment, Metallic Surfaces

R SRM 54-02-10 Fasteners, Installation and Removal
R AMM TASK 70-20-01-100-802 Non-Aqueous Liquid Degreasing – Maintenance
R Process 101
R AMM TASK 78-32-47-000-802 Removal of the Moveable Panels
R AMM TASK 78-32-47-400-802 Installation of the Moveable Panels
R Equivalent materials and equipment can be used.
R A. Standard Equipment
R -Standard workshop tools and equipment

R -Clamps
R -Drilling equipment
R -Torque wrench, range 0 to 8.5 Nm (0 to 75 lbf.in)

54-30-02
Page 201
R B. Consumable Materials
R OMat 175D CHROMATE CONVERSION COATING FOR ALUMINIUM

R (Brushing type)
R OMat 262 TEMPORARY MARKER (Felt/fibre tip)
R OMat 5/31 WATERPROOF SILICON CARBIDE
R OMat 5/40 WATERPROOF SILICON CARBIDE
R OMat 7/201 TOUCH-UP COATING, 2 PART (Direct adhesion)
R OMat 8/106 SEALANT, TWO PART POLYSULPHIDE (Brushable)
R OMat 8/107 SEALANT, TWO PART POLYSULPHIDE
R C. Repair Parts
R Repair kit, part number 91E055-02, for left upper doors or right
R lower doors includes:
R 1 RP3973-01 Repair fitting 1

R 2 PLT210-6-6 Fastener, blind 3
R 3 HDSM5037CC054 Washer 3
R 4 HST10BJ6-3 Pin, hi-lite 3
R 5 HST97DUWU6 Collar, hi-lite 3
R Repair kit, part number 91E055-52, for right upper doors or left
R lower doors includes:
R 1 RP3973-51 Repair fitting 1

R 2 PLT210-6-6 Fastener, blind 3
R 3 HDSM5037CC054 Washer 3
R 4 HST10BJ6-3 Pin, hi-lite 3
R 5 HST97DUWU6 Collar, hi-lite 3
R The items that follow are not part of repair kits. They are listed
R for reference only:
R 6 91E654-00 Stop, Pre SB 78-C806 REF.

R 6 91E654-01 Stop, SB 78-C806 REF.
R 7 NSA5050-3C Nut REF.
R 8 91E601-01 Shim, peelable REF.

54-30-02
Page 202
R 9 HST97DU8 Collar, hi-lite REF.

R 10 ASNA2397C416L Washer, flat REF.
R 11 NAS1587-4C Washer REF.
R 12 HST10-8-6 Pin, hi-lite REF.
R D. Component Material
R COMPONENT MATERIAL
R Fitting, cut corner 7175-T7351 aluminium alloy
R 4. Remove the Triangular Panel
R A. Remove the triangular panel from the pivoting door (Ref. AMM
R TASK 78-32-47-000-802).
R 5. Prepare the Damaged Area for Repair (Ref. Figures 201,202 and 203)
R CAUTION: YOU MUST MAKE SURE THAT YOU DO NOT MAKE THE HOLES LARGER
R WHEN YOU DRILL OUT THE RIVETS.
R A. Drill out the three rivets (2). Use the drilling equipment with
R an applicable drill bit (Ref. SRM 54-02-10).
R NOTE: If necessary for access, remove the hi-lite collar (9),

R the hi-lite pin (12) and the washers (10) and (11) (Ref.
R SRM 54-02-10). Discard the collar (9). Keep the pin (12)
R and the washers (10) and (11), if they are serviceable.
R B. Remove and retain the stop (6), the peelable shim (8) and the
R nut (7).
R NOTE: If the door is PRE SB 78-C806 and the stop (6) is

R unserviceable, it is necessary to refer to SB 78-C806 to
R do the rework instruction. The new stop will be to this
R SB standard.
R C. Locate the cut line. Use an OMat 262 MARKER to identify this
R location.
R NOTE: The cut line must be accurately marked because it is the

R reference point for the installation of the repair
R fitting.

54-30-02
Page 203
R CAUTION: YOU MUST MAKE SURE THAT YOU DO NOT DAMAGE THE CARBON
R PANEL WHEN YOU CUT THE BRACKET. PUT A THIN METALLIC PLATE
R BETWEEN THE CARBON PANEL AND THE BRACKET BEFORE YOU CUT
R THE BRACKET.
R D. Use hand tools to cut the bracket at the location mark. Discard
R the damaged section.
R E. Use a file to make a flat, mating surface on the bracket. Use

R OMat 5/31 WATERPROOF SILICON CARBIDE and OMat 5/40 WATERPROOF
R SILICON CARBIDE to make a surface finish of 3.2 micro m (126
R micro in.). This will allow the fitting (1) to match properly
R with the bracket. Remove all burrs from the bracket.
R F. Clean the bracket (Ref. AMM TASK 70-20-01-100-802).
R G. Apply protective coating to the bracket (Ref. SRM 54-02-03). Use

R OMat 175D CHROMATE CONVERSION COATING and OMat 7/201 TOUCH-UP
R COATING.
R 6. Install the Repair Fitting (Refer to Figures 203 and 204)
R A. Put the fitting (1) into its correct position on the bracket and
R clamp it. Use the pre-drilled hole (2) in the fitting (1) to
R position the fitting on the remaining part of the bracket.
R B. Drill pilot holes for the two remaining holes in the repair
R fitting (1) through the holes of the rivets (2) previously
R removed from the bracket. Use the applicable drill bits to ream
R the holes to a final diameter of between 5.05 and 5.14 mm (0.199
R and 0.202 in.).
R C. Drill pilot holes for the hi-lite pins (4) in the bracket
R through the three pilot holes of the repair fitting (1). Use the
R applicable drill bits. Ream the holes to a final diameter of
R between 4.81 and 4.83 mm (0.189 and 0.190 in.).
R D. Remove the clamps and the fitting.
R E. Remove all burrs from the bracket and the repair fitting, then
R clean them (Ref. AMM TASK 70-20-01-100-802).
R F. Apply protective coating to the inside of the holes (Ref. SRM

R 54-02-03). Use OMat 175D CHROMATE CONVERSION COATING and Omat
R 7/201 TOUCH-UP COATING.
R G. Clean the repair fitting (1) and the bracket (Ref. AMM TASK 70-
R 20-01-100-802).

54-30-02
Page 204
R H. Apply OMat 8/107 SEALANT to the mating surfaces of the repair
R fitting (1) and the bracket.
R NOTE: At 23 deg.C (73.4 deg.F) temperature and 50 percent

R relative humidity, the application time of the sealant
R is 30 minutes and the cure time is 24 hours. You must
R continue with the next step of this procedure within the
R application time.
R I. Put the repair fitting (1) into position on the bracket.
R J. Use OMat 8/106 SEALANT to wet install the the fasteners (2) and
R the washers (3) (Ref. SRM 54-02-10).
R K. Use OMat 8/106 SEALANT to wet install the hi-lite pins (4), the
R washers (10) and (11) and the hi-lite collars (5) (Ref. SRM 54-
R 02-10).
R L. Install the stop (6), the peelable shim (8) and the nut (7).
R NOTE: Refer to SB 78-C806 to adjust the peelable shim and the

R stop, if necessary.
R M. TORQUE the nut (7) to 4 Nm (35 lbf.in).
R N. Remove all unwanted sealant (Ref. AMM TASK 70-20-01-100-802).
R O. Apply a bead of OMat 8/107 SEALANT around the edges of the

R fitting. Smooth it off and remove all unwanted sealant (Ref. AMM
R TASK 70-20-01-100-802).
R P. Install a replacement hi-lite collar (9), washer (10), washer

R (11) and hi-lite pin (12), if necessary (Ref. SRM 54-02-10).
R 7. Examine the Completed Repair
R A. Do a visual examination of the repair to make sure that it has

R been satisfactorily completed:
R (1) Make sure that all fasteners are correctly installed and
R secure.
R (2) Make sure that the edges of the fitting are sealed.
R (3) Make sure that the stop is correctly positioned.

54-30-02
Page 205
R 8. Identify the Repair
R A. Use an OMat 262 MARKER of contrasting colour to write FRSX073

R adjacent to the existing part number.
R 9. Install the Triangular Panel
R A. Install the triangular moveable panel on the pivoting door (Ref. AMM
R TASK 78-32-47-400-802).

54-30-02
Page 206
R
Location of the Damaged Area

Figure 201
54-30-02
Page 207
R
Repair Details and Dimensions

Figure 202
54-30-02
Page 208
R
Installation of the Repair Fitting

Figure 203
54-30-02
Page 209
R
Holes Diameters
Figure 204
54-30-02
Page 210
RB211 TRENT
STRUCTUAL REPAIR
REPAIR NO. 2
REPAIR OF BRACKET, MOVEABLE PANEL
1. General
A. This procedure repairs damage that has caused interference

between the bracket and the link to the lever.
.......................................................................
.......................................................................
SRM 54-02-03 Protective Treatment - Metallic Surfaces
AMM TASK 70-20-02-230-803 Fluorescent Penetrant Inspection
AMM TASK 78-32-47-000-801 Remove the Moveable Panels
AMM TASK 78-32-47-400-801 Install the Moveable Panels
EM TASK 78-33-13-300-XXX FRSX074, Repair No.XX
Suction cleaner
.......................................................................
.......................................................................
OMat 5/28 ABRASIVE PAPER,Grit Size 800
OMat 5/35 ABRASIVE PAPER,Grit Size 240
.......................................................................
PART IDENT MATERIAL
.......................................................................
Pivoting door structure Aluminium alloy
4. Get Access
A. Remove the rectangular moveable panel

(AMM TASK 78-32-47-000-801)
REPAIR N0.2
54-30-02
Page 201
R8211 TRENT
STRUCTUAL REPAlR
MANUAL
CAUTION: THE MINIMUM PROFILE RADIUS PERMITTED BY THIS PROCEDURE

IS 20 MM (0.8 IN). IF THIS RADIUS DOES NOT REMOVE THE
DAMAGE, REFER TO ROLLS-ROYCE FOR INSTRUCTIONS.
A. Use hand tools and OMat 5/35 ABRASIVE PAPER to remove damage
from the angled edge of the bracket. Dress out sufficient
material to remove interference with the lever. Be careful not
to make a radius less than 20 mm (0.8 in).
B. Use OMat 5/28 ABRASIVE PAPER to give a good shape and surface
finish.
B. Use the suction cleaner to remove debris.
C. Do a fluorescent penetrant inspection of the repair area

(Ref AMM TASK 70-20-02-230-803).
(1) No cracks are permitted.
D. Apply protective treatment to the repair (Re£ SRM 54-02-03).
6. Insvec tion
A. Make sure this repair has removed interference between the

bracket and the link to the lever.
7. Close Access
A. Install the rectangular moveable panel

(Ref TASK 78-32-47-400-801).
REPAIR NO. 2
54-30-02
Page 202
R821 1 TRENT
STRUCTUAL REPAIR
BRACKET
\ RECTANGULAR
MOVEABLE PANEL
I PIVOTING DOOR
20 mm (0.8 in) MINIMUM RADIUS

/ACCEPTABLE
PREVIOUS PROFILE
E .E
--€23
c?
'"S
t
NEW PROFILE
Repair t h e Bracket
Figure 2 0 1
REPAIR N0.2
54-30-02
Page 203
May 1 / 0 0
R8211 TRENT
STRUCTUAL REPAIR
MANUAL
REPAIR NO. 3
REPAIR DAMAGED BORE IN PANEL LEVER FITTING
1. General
A. This procedure gives instructions to repair a worn or damaged

bore in the panel lever fitting. If the bore is too large,the
bush will be loose. An oversized bush can be installed to
repair the fitting.
B. This repair is applicable to damage at only one side of the

fitting. If the opposite bush is also loose, you must refer
to Rolls-Royce plc for more instructions
C. This repair is applicable to the rectangular and/or triangular

panels on the upper and/or lower pivoting doors.
2. Referenced Infonnation
.......................................................................
.......................................................................
AMM 78-30-00-010-801 Open the Pivoting Door
AMM 78-30-00-410-801 Close the Pivoting Door
AMM 78-32-47-000-801 Remove the Moveable Panel
A M M 78-32-47 400-801 Install the Moveable Panel
EM 78-33-00-300-XXX FRSX072, Trent Engine Manual
3. Ecruipment and Materials
Tripod boring device with guide bush
Reamer 14,000 to 14,013 mm
Internal micrometer
.......................................................................
.......................................................................
omat 8/176 SEALING COMPOUND
OMat 262M MARKER PEN

54-30-02
Page 201
Printed i n G r e a t Britain July 1/00
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
C. Repair Parts
.......................................................................
FIG/ITEM PART NO. DESCRIPTION QTy
.......................................................................
201/1 RP3858-01 Repair Bush 1
201/2 91E401-00 Shouldered Bush 1
A. Get Access
(1) Open the pivoting door (AMM TASK 78-30-00-010-801)
(2) Remove the moveable panel (AMM TASK 78-32-47-000 801)
(3) Remove the lever from the fitting. Keep all the parts for
subsequent installation.
B. Remove the shouldered bush
(1) Do an inspection of the bush on the opposite side of the

fitting. If it is also loose or damaged, refer to Rolls-
Royce plc for more instructions.
CAUTION: BE CAREFUL NOT TO CAUSE DAMAGE T O THE FITTING WHEN

YOU REMOVE THE BUSH.
(2) Use hand tools to remove the damaged shouldered bush (2)
from the fitting.
C. Measure the bore

CORRECTLY. BEFORE YOU USE THIS MATERIAL,CAREFULLY READ
(1) Clean the repair area with OMat 135 MEK and OMat 2/101
LINT-FREE CLOTH. Dry the surfaces with a new piece of the
(2) Use the micrometer to measure the diameter of the bore in

the fitting :
(a) If the diameter is between 14,000 and 14,013 mm

(0.551 and 0.552 in), go to step 4.E.
REPAIR N0.3
54-30-02
Page 202
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
(b) If the diameter is more than 14,013 mm (0.552 in),

reject the component.
D. Repair the damaged bore
CAUTION: ON THE TRIANGULAR MOVEABLE PANEL OF THE LOWER PIVOTING

DOOR,THE LEVER FITTING HAS THREE FLANGES.THE BORE THAT
IS TO BE REPAIRED IS IN THE MIDDLE FLANGE. BE CAREFUL
NOT TO CAUSE DAMAGE TO THE OTHER FLANGES WHEN YOU DO
THIS REPAIR.
(1) Use the tripod boring device and guide bush to correctly
align the reamer.
(2) Ream the bore to between 14,000 and 14,013 nun (0.551 and
0.552 in) diameter.
(3) Remove the tooling.
(4) Remove sharp edges from the reamed bore.

CORRECTLY.BEFORE YOU USE THIS MATERIAL,CAREFULLY READ
THE APPLICABLE MATERIAL SAFETY DATA SHEET AND OBEY
ALL SPECIFIED HEALTH AND SAFETY PRECAUTIONS.
E. Install the repair bush
WARNING: YOU MUST USE APPLICABLE CLOTHING, GLOVES AND FULL FACE
PROTECTION WHEN YOU USE LIQUID NITROGEN. USE LIQUID
NITROGEN ONLY IN AN AREA THAT HAS A GOOD FLOW OF AIR.
IF YOU GET THE LIQUID NITROGEN ON YOUR SKIN OR IN YOUR
EYES, GET MEDICAL AID IMMEDIATELY.
(1) Put the repair bush (1) in liquid nitrogen for a minimum
of 20 minutes.
(2) Apply OMat 8/176 SEALING COMPOUND to the reamed bore in

the fitting.
(3) Install the repair bush (1) in the fitting, flush with the
inner face. Do not touch the bush for 20 minutes after its
installation.
54-30-02
Page 203
RB211 TRENT
STRUCTUAL REPAIR
m MANUAL
F. Install the shouldered bush

ALL SPECIFIED HEALTH AND SAFETY PRECAUTIONS.
(2) Apply OMat 8/176 SEALING COMPOUND to the new shouldered

bush (2).
(3) Install the shouldered bush (2) in the repair bush (l),
flush with the inner face.
G. Inspection
(1) Do a visual inspection to make sure the repair is

serviceable.
(2) Use the OMat 262M MARKER PEN to write FRSX072 adjacent to
the part number of the fitting.
H. Close Access
(1) Install the lever in the fitting:
(a) Refer to step 4.A. (3) and Figure 201.
(b) Torque the nut to 20 Nm (177 lbf in) . .

(2) Install the moveable panel (AMM TASK 78-32-47-400-801).
(2) Close the pivoting door (AMM TASK 78-30-00-410-801).
REPAIR NO. 3
54-30-02
Page 204
R8211 TRENT
STRUCTUAL REPAIR
MANUAL
SHOULDERED \,
BUSH TO BUSH TIGHT

BE REMOVED
-----
- - - - - - - - - - - - v -
GUIDE PIN
OF BORER
Repair Damaged Bore

Figure 201
REPAIR N0.3
54-30-02
Page 205
RB211 TRENT
STRUCTUAL REPAIR
m MANUAL
REPAIR N0.4
REPAIR OF INNER SKIN LATERAL ANGLE
1. General
A. This procedure gives instructions to cut out the damage and

install a repair angle and doubler.
.......................................................................
SRM 54-02-03 Protective Treatment -

Metallic Surfaces
SRM 54-02-10 Removal/Installation of Fasteners
AMM TASK 78-32-46-000-803 Removal of the Deflector Plates
AMM TASK 78-32-46-400-803 Installation of the Deflector Plates
EM TASK 78-33-300-XXX FRSX075, Trent Engine Manual
3. Eaui~ment and Materials
Mechanical clamps
Suction cleaner
.......................................................................
.......................................................................
OMat 2621 MARKER
OMat 5/94 GARNET PAPER, Grit Size 150
OMat 8/106 SEALANT
OMat 8/107A SEALANT
C. Repair Parts
......................................................................
FIG/ITEM PART NO. IDENTIFICATION QTy
......................................................................
- 913058-50 Repair Kit for RH Lower Door: -
201/1 RP-3887-51 Angle - Repair, RH 1
/2 RP-3887-02 Doubler 1
cont d
REPAIR N0.4
54-30-02
Page 201
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
--------------------------------------------------*--------------------
FIG/ITEM PART NO. IDENTIFICATION QTY

.......................................................................
201/3 NAS1921M05S04W Rivet 4
5 PLT110- 6- 3 Rivet 3
6 PLT210-6-3 Rivet 2
7 MS21141-06-06P Rivet 2
8 NAS1919M05S03W Rivet 2
- 913058-00 Repair Kit for LH Lower Door: -

201/1 RP-3887-01 Angle - Repair, LH
2 RP-3887-02 Doubler
3 NAS1921M05S04W Rivet
5 PLT110- 6- 3 Rivet
6 PLT210-6-3 Rivet
7 MS21141-06-06P Rivet
8 NAS1919MO5S03W Rivet
- 913059-00 Repair Kit for RH Upper Door: -

Angle -
Repair, RH
Doubler
Rivet
Rivet
Rivet
Rivet
Rivet
Screw
Screw
Screw
Nut
Washer
Washer
- 913059-50 Repair Kit for LH Upper Door: -

Angle - Repair, LH
Doubler
Rivet
Rivet
Rivet
Rivet
Rivet
Screw
Screw
Screw
Nut
Washer
Washer
REPAIR N0.4
Page 202
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
4. Measure the Damase

A. Clean the repair area with OMat 2/101 LINT-FREE CLOTH soaked
with OMat 135 MEK. Dry the surface with a new piece of the
B. Visually examine the lateral angle to find the dimensions of

the damage.
C. Do a fluorescent penetrant inspection(AMM TASK 73-20-02-230-803)

to confirm the length of cracks.
D. Use the OMat 262A MARKER to outline the area of damage.
5. Remove the Deflector
NOTE: This step is necessary on the upper doors only.
A. Remove the side deflector plate (AMM TASK 78-32-46-000-803).
6. Prepare the Damased Area
WARNING: USE EYE PROTECTION, FACE MASK AND PROTECTIVE CLOTHING.

DUST AND LOOSE PARTICLES CAN BE DANGEROUS TO YOUR HEALTH.
CAUTION: PUT A METALLIC SHIM BETWEEN THE LATERAL ANGLE AND THE DOOR
INNER SKIN TO PREXEKC DAMAGE TO THE SKIN.
CAUTION: USE A THIN BLADE AND DEBOND THE SEALANT TO PREVENT DELAM-
INATION OF THE CARBON SKIN.
A. Use hand tools to cut out the damage. Remove all sharp edges.
Use the suction cleaner to remove the debris.

B. Clean the repair area with OMat 2/101 LINT-FREE CLOTH soaked
with OMat 135 MEK. Dry the surface with a new piece of cloth
REPAIR N0.4
54-30-02
Page 203
RB211 TRENT
STRUCTUAL REPAIR
C. Apply protective treatment to the cut edges (Re£ SRM 54-02-03).
D. Do an ultrasonic test to make sure there is no damage to the

door panels under the repair area.
NOTE: If you find a delamination, refer to Rolls-Royce plc.
7. Install the Repair Anule and Doubler (Ref Figures 201,202)
A. Put the repair angle (1) and doubler (2) in position, align and
hold them with the clamps.
B. Measure and mark the location of the fastener holes.
C. Pilot drill the fastener holes through the repair angle,doubler

and lateral frame.
D. Drill the fastener holes to these final diameters:

..............................................................
ITEM NO. MINIMUM HOLE DIA. MAXIMUM HOLE DIA.
..............................................................
3 4,06 mm (0.160 in) 4,11 mm (0.162 in)
4 5,05 mm (0.199 in) 5,13 mm (0.202 in)
5 5,05 mm (0.199 in) 5,13 mm (0.202 in)
6 5,05 mm (0.199 in) 5.13 mm (0.202 in)
7 5,05 mm (0.199 in) 5.13 mm (0.202 in)
8 4,06 mrn (0.160 in) 4,11 m (0.162 in)
9 5,05 mm (0.199 in) 5.13 mrn (0.202 in)
10 6,32 mm (0.249 in) 6,40 mm (0.252 in)
11 6,32 mm (0.249 in) 6,35 mm (0.250 in)
12 6,32 mm (0.249 in) 6,35 mm (0.250 in)
E. Remove the repair angle and doubler from the door.
F. Remove sharp edges from all the holes.

G. Clean the repair parts and the repair area with OMat 2/101 LINT-
FREE CLOTH soaked with OMat 135 MEK. Dry the surfaces with a new
REPAIR N0.4
54-30-02
Page 204
9 STRUCTUAL REPAIR
MANUAL
H. Apply OMat 8/107A SEALANT to the mating faces of the repair

angle (1) and doubler (2). Put the repair parts in position on
the door lateral frame.
CAUTION: MAKE SURE THE HEADS OF THE COUNTERSUNK RIVETS ARE SMOOTH
TO PREXENT DAMAGE TO THE MATING DEFLECTOR PLATE.
J. If necessary, use OMat 5/94 GARNET PAPER to make the rivet

heads smooth before installation.
K. Refer to Figures 201 or 202 and wet-install the applicable

fasteners with OMat 8/106 SEALANT (SRM 54-02-10) .
L. Put a bead of OMat 8/107A SEALANT around the edges of the
repair angle and doubler.
M. Remove unwanted sealant with OMat 2/101 LINT-FREE CLOTH.
N. Cure the sealants for 30 minutes at 25 deg C (77 deg F).

with OMat 135 MEK. Dry the surfaces with a new piece of the
B. Do a visual inspection to make sure the repair is satisfactory.
C. Use the OMat 262A MARKER to write FRSX075 adjacent to the door
part number.
9. Install the Deflector
A. If necessary, install the side deflector plate

( A m TASK 78-32-46-400-803).
REPAIR N0.4
54-30-02
Page 205
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
NOTE : LEFT HAND SHOWN

RIGHT HAND IDENTICAL
BUT OPPOSITE
DAMAGED
AREA
VIEW OF DAMAGED AREA

PIVOT DOOR STIFFENER
LATERAL FRAME
LATERAL ANGLE
CRACKED \
IMPACT DAMAGE
CUTOUT LIMIT IF CORNER POST
PIN AXIS
STIFFENER
LATERAL ANGLE \
$ CORNER POST
Repair Lateral Angle, Lower Doors
Figure 2 0 1
54-30-02
Page 2 0 6
Printed i n Great B r i t a i n July 1 / 0 0
p RB211 TRENT
MANUAL
STRUCTUAL REPAIR
NOTE : LEFT HAND SHOWN

RIGHT HAND IDENTICAL
BUT OPPOSITE
VIEW OF DAMAGED AREA

PIVOT DOOR
LATERAL FRAME
I
CRACKED \
IMPACT DAMAGE
CUTOUT LIMIT CORNER POST
PIVOT DOOR STIFFENER

LATERAL FRAME \
p CORNER POST
Repair Lateral Angle, Upper Doors
Figure 202
REPAIR N0.4
54-30-02
Page 207
REPAIR NO.5
REPAIR OF INNER SKIN LATERAL ANGLE ON CUT CORNER SIDE
1. General
A. This repair gives instructions to stop-drill the crack(s) and

install a doubler angle.
-----------------------------------------------------------------------
-----------------------------------------------------------------------
SRM 54-02-06 Stop-Drilling of Cracks
AMM TASK 78-32-46-000-803 Removal of the Deflector Plates
AMM TASK 78-32-46-400-803 Installation of the Deflector Plates
EM TASK 78-33-00-300-XXX FRSX091, Trent Engine Manual
Mechanical clamps
Suction cleaner
-----------------------------------------------------------------------
-----------------------------------------------------------------------
R OMat 150 ACETONE
OMat 262A MARKER
OMat 8/106 SEALANT
OMat 8/107A SEALANT

54-30-02
Page 201
C. Repair Parts
-----------------------------------------------------------------------
-----------------------------------------------------------------------
R 91E061-00 Repair Kit (this includes the items 1
R that follow)
R 201/1 RP-3920-01 Angle – Doubler (part of 91E061-00) 1
R /2 PLT210-6-4 Rivet (part of 91E061-00) 10
R /3 NAS1921M06S04W Rivet (part of 91E061-00) 5
4. Remove the Deflector
NOTE: This step is necessary on the upper doors only.
A. Remove the side deflector plate (AMM TASK 78-32-46-000-803).
5. Measure the Damage
R with OMat 150 ACETONE, OMat 1/40 ISOPROPYL ALCOHOL or OMat
R 1/257 CLEANING SOLVENT. Dry the surface with a new piece of the
R cloth before the solvent evaporates.
B. Visually examine the lateral angle and the adjacent area to

find the dimensions of the damage.
NOTE: If you find a delamination, refer to Rolls-Royce plc.
C. Do a fluorescent penetrant inspection (AMM TASK 73-20-02-230-

803) to confirm the length of cracks.
D. Use the OMat 262A MARKER to outline the area of damage.
6. Stop-Drill the Cracks
A. Stop-drill the cracks (SRM 54-02-06) and remove sharp edges from
the drilled holes.
B. Apply protective treatment (SRM 54-02-03).

54-30-02
Page 202
7. Prepare the Doubler Angle (Ref Figure 201)
A. Cut the doubler angle to give a minimum distance of 25 mm (1 in)

from the end of a crack. The minimum rivet edge distance must be
12 mm (0.5 in). The maximum permitted length of the doubler angle
is 285 mm (11.23 in).
NOTE: If these limits are not possible, refer to Rolls-Royce plc.
8. Install the Doubler Angle (Ref Figure 201)
A. Draw the hole positions on the doubler angle (1).
B. Install the doubler angle in position on the door lateral angle

and hold it with clamps.
C. Drill the rivet holes through the doubler angle and the door:
(1) For rivets Item (2), hole diameters are 5,05 to 5,14 mm
(0.199 to 0.202 in).
(2) For rivets Item (3), hole diameters are 4,85 to 4,90 mm
(0.191 to 0.193 in).
D. Remove the doubler angle from the door, remove sharp edges from
all the rivet holes.
E. Clean the repair area and the doubler angle with OMat 2/101
R LINT-FREE CLOTH soaked with OMat 150 ACETONE, OMat 1/40
R ISOPROPYL ALCOHOL or OMat 1/257 CLEANING SOLVENT. Dry the
R surfaces with a new piece of the cloth before the solvent
evaporates.
F. Apply OMat 8/107A SEALANT to the mating face of the doubler

angle.
G. Install the doubler angle (1) in position on the door lateral

angle. Wet-install the rivets (2) and (3) with the OMat 8/106
SEALANT (Ref SRM 54-02-100.
H. Put a bead of 8/107A SEALANT around the edges of the doubler

angle.

54-30-02
Page 203
J. Remove unwanted sealant with OMat 2/101 LINT-FREE CLOTH soaked
with OMat 135 MEK.
K. Cure the sealants for 30 minutes at 25 deg C (77 deg F).
9. Inspection
R with OMat 150 ACETONE, OMat 1/40 ISOPROPYL ALCOHOL or OMat
R 1/257 CLEANING SOLVENT. Dry the surface with a new piece of the
R cloth before the solvent evaporates.
B. Do a visual inspection to make sure the repair is satisfactory.
C. Use the OMat 262A MARKER to write FRSX091 adjacent to the

door part number.
10. Install the Deflector
A. If necessary, install the side deflector plate

(AMM TASK 78-32-46-400-803).

54-30-02
Page 204
pm RB211 TRENT
MANUAL
STRUCTUAL REPAlR
NOTE : LEFT HAND UPPER

DOOR SHOWN.
RIGHT HAND UPPER
DOOR IS SYMETRICAL
10 mm RADIUS , \M ORIGINAL ANGLE
R e p a i r t o L a t e r a l A n g l e on C u t C o r n e r S i d e
Figure 201, Sheet 1
REPAIR N0.5
54-30-02
Page 205
Printed i n Great B r i t a i n July 1 / 0 0
p RB211 TRENT
MANUAL
STRUCTUAL REPAlR
NOTE : CUT CORNER DEFLECTOR

PLATE NOT SHOWN FOR
CLARITY
' CRACK
IN ORIGINAL
ANGLE
SECTION C SECTION D
INTERNAL
PLATE RADIUS 4 mm
CORNER
PANEL
Repair to Lateral Zmgle on Cut Corner Side

Figure 201, Sheet 2
REPAIR N0.5
54-30-02
Page 206
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
REPAIR NO. 6
REPLACE THE BUMPER STOP PAD - MOVEABLE PANELS
1. General
A. This procedure gives instructions to replace a damaged metal

pad on the bumper stop. The procedure is applicable to the
triangular and rectangular panels of the upper and lower
pivoting doors.
.......................................................................
.......................................................................
AMM TASK 78-32-47-000-801 Remove the Moveable Panels
AMM TASK 78-32-47-400-801 Install the Moveable Panels
EM TASK 78-33-11-300-XXX FRS X089, Trent Engine Manual

OMat 8/107 SEALANT, two-part polysulphide
B. Repair Parts
.......................................................................
FIG/ITEM PART NO. PART IDENT QTY
.......................................................................
91B401-00 Bumper Stop Pad Kit
913194-00 Metal Pad, Bumper Stop
4. Get Access
A. Remove the rectangular or triangular moveable panel as necessary

(Ref.AMM TASK 78-32-47-000-801).
NOTE: There is a bumper stop pad for each moveable panel.

It is attached to the door inner skin, adjacent to
the actuator channel.
EFFECTIVITY: TRElNT REPAIR NO. 6

54-30-02
Page 2 01
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
5. Procedure
A. Use the OMat 262A TEMPORARY MARKER to record the position of the
damaged bumper stop pad. Make sure your marks will not be erased
during the subsequent step.
CAUTION: DO NOT TO CAUSE DAMAGE TO THE CARBON COMPOSITE SKIN.
B. Use a spatula to remove the damaged pad and remaining adhesive.
CAUTION: METHYLETHYLKETONE (MEK) IS CLASSIFIED AS A HAZARDOUS

CORRECTLY. BEFORE YOU USE THIS MATERIAL, CAREFULLY READ
C. Clean the repair area with OMat 2/101 LINT-FREE CLOTH soaked with
OMat 135 METHYLETHYLKETONE. Dry the surface with a new piece of
D. Do an ultrasonic inspection of the door inner skin where the

buffer stop was attached. If you find cracks, reject the door.
E. Install the new stop pad:
(1) Mix the two parts of OMat 8/107 SEALANT in accordance with
(2) Apply a layer of the sealant to the mating face of the new
stop pad.
(3) Put the stop pad on the door at the position recorded in
Step 5.A (above). Apply even pressure with your hand to
make sure of a good bond.
(4) Remove unwanted sealant and clean the repair area with
OMat 2/101 LINT-FREE CLOTH soaked with OMat 135 MEK. Dry
with a new piece of the cloth before the MEK evaporates.
(6) Cure the sealant for 24 hours at 25 deg C (77 deg F).
6. Inspection
7. Close Access
A. Install the rectangular or triangular moveable panel as

necessary (Ref-AMMTASK 78-32-47-400-801).
Page 202
p RB211 TRENT
MANUAL
STRUCTUAL REPAIR
MOVEABLE PANELS REMOVED
BUMPER STOP PAD
R e p l a c e the Bumper Stop P a d

F i g u r e 201
REPAIR NO. 6
P a g e 203
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR NO. 7
THRUST REVERSER - PIVOT DOORS

RE-INFORCE THE TRIANGULAR MOVEABLE PANEL LEVER ARM FITTING ON A LOWER DOOR
FRSXO 87
1. General
This task gives the procedure to re-inforce the lever arm fitting when a
crack occurs at the fastener area that attaches the fitting to the front
frame of a lower door.
It is only applicable to the triangular moveable panel lever arm fitting

of a lower door.
.......................................................................
SRM 54-02-03 Protective treatment of metallic

surfaces
SRM 54-02-10 Fasteners - Removal and Installation
AMM TASK 70-20-02-230-803 Post-Emulsified Fluorescent Penetrant
Inspection with Water-Based
(Hydrophilic) Penetrant Removers.
AMM TASK 70-20-02-230-804 Water-washable Fluorescent Penetrant
Inspection
AMM TASK 78-32-42-010-801 Open the Pivoting Doors (5005EG1,
5005EG2, 5005EG3, 5005EG4)
AMM TASK 78-32-42-410-801 Close the Pivoting Doors (5005EG1,
5005EG2, 5005EG3, 5005EG4)
Approved equivalent materials and equipment may be used.
Vacuum cleaner
Drill bush, 4,9 mm (0.193 in.) external dia, 2,5 mm (0.098 in.) bore
Clamps
REPAIR NO. 7
54-30-02
Page 2 01
Oct.01/06
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
OMat 175D Alocrom 1200 chromate conversion

coating
OMat 262 EMS56752 temporary marker felt/fibre
tip
OMat 5/31 400 grit size waterproof silicon
carbide
OMat 5/62 100 grit size aluminium oxide abrasive
paper
OMat 5/63 150 grit size aluminium oxide abrasive
paper
OMat 7/201 Touch-up coating, two part
OMat 8/106 PR1436G A1/2 sealant, two part
polysulphide (brushable)
OMat 8/107 PR1436G ~ 1 / 2sealant, two part
polysulphide (brushable)
C. Repair parts
(1) Left-hand lower pivot door

.............................................................................
FIG/ITEM PIPC FIG/ITEM PART NO. PART NOMENCLATURE QTY
913054-01. .Kit, triangular moveable 1

panel lever arm fitting
repair FRSX 087
RP3960-51 . .Doubler 1
NAS1919M06S07AU ..Rivet 2
NAS1919MO6SO6AU ..Rivet 1
HSTlOBJ6-3 ..Pin, hi-lite 3
HST97DUWU6 ..Collar, hi-lite 3
NASl919MO5SO4AU ..Rivet 1
(2) Right-hand lower doors :
.............................................................................
FIG/ITEM PIPC FIG/ITEM PART NO. PART NOMENCLATURE QTY
913053-01 .Kit, triangular moveable 1

panel lever arm fitting
repair FRSX 087
RP3960-01 . .Doubler 1
HSTlOBJ6-3 ..Pin, hi-lite 3
HST97DUWU6 ..Collar, hi-lite 3
REPAIR NO. 7
Page 202
Oct. 01/06
Printed i n Great Rritain
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(3) T h e f o l l o w i n g i t e m s are n o t i n t h e repair k i t b u t are l i s t e d

for reference only:
FIG/ITEMPIPC FIG/ITEM PART NO. PART NOMENCLATURE OTY
Moveable p a n e l 1
triangular,
P r e SB78-B517
Moveable p a n e l , 1
triangular,
SB 7 8 - B 5 1 7 , p a r t A ,
P r e SB 78-D014
P r e SB 78-E260
(alternative)
Moveable panel
triangular,
SB 78-D014, p a r t C ,
P r e SB 78-E260
( a 1t e r n a t i v e )
triangular,
SB 78-E260
triangular,
P r e SB 78-B517
triangular,
SB 78-B517, p a r t A ,
P r e SB 78-D014
P r e SB 78-E260
triangular,
SB 78-D014, p a r t C ,
P r e SB 78-E260
triangular,
SB 78-E260
(alternative)
Screw 4
P r e SB 78-B871
Screw 4
SB 78-B871 p a r t 1 2
REPAIR N 0 . 7
54-30-02
Page 203
Oct. 0 1 / 0 6
Printed in C r p a t Rritain
H RB211 TRENT
MANUAL
STRUCTURAL REPAIR
(alternative)
Screw
Pre SB 78-B871
Screw
SB 78-B871 part 12
(a1ternative)
Washer
Nut
Washer
Bush
Pin
Roller
Nut
Washer, flat
Bush, shouldered
Bush, shouldered
Sleeve, spacer
Bush
Pre SB 78-D405
part A
B01 t
Lever actuation
Pre SB 78-C248
moveable panel
Lever actuation
moveable panel
SB 78-C248 part B
D. Expendable parts
.............................................................................
FIG/ITEMPIPC FIG/ITEM PART NO. PART NOMENCLATURE QTY
201/17 02-520 MS24665-153 ..Pin, cotter

201/17 04-520 MS24665-153 ..Pin, cotter
4. Health and Safety Notices
HEALTH.
WARNING: WHEN YOU USE CLEANING MATERIALS, COATINGS AND SEALANTS, REFER
TO, AND OBEY, THE MANUFACTURER'S CONTROL AND APPLICATION
INSTRUCTIONS AND HEALTH AND SAFETY NOTICES.
Page 2 04
Oct. 01/06
P r i n t ~ d in C r ~ a tRritain
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
5. Open t h e applicable l o w e r p i v o t d o o r
A. R e f e r t o AMM TASK 78-32-42-010-801.
6. Procedure
A. Remove t h e t r i a n g u l a r m o v e a b l e p a n e l a n d l e v e r arm
NOTE: A l l F i g / I t e m numbers are 78-32-42 (Power P l a n t

I l l u s t a t e d P a r t s Catalog) .
(1) R e f e r t o F i g 201
(2) Remove a n d discard t h e c o t t e r p i n 02-520 (04-520).
(3) Remove a n d k e e p t h e n u t 02-521 ( 0 4 - 5 2 1 ) , w a s h e r 02-522 (04-

5 2 2 ) , b u s h 02-524 ( 0 4 - 5 2 4 ) , b o l t 02-528 (04-528) a n d r o l l e r 02-
530 (04-530) .
(4) Remove a n d k e e p t h e f o u r s c r e w s 02-031 ( 0 4 - 0 3 1 ) , f o u r s c r e w s

02-032 (04-032) a n d e i g h t w a s h e r s 02-035 (04-035) t h a t a t t a c h
t h e m o v e a b l e p a n e l t o i t s related t o r s i o n b a r .
(5) Remove a n d k e e p t h e n u t 02-571 ( 0 4 - 5 7 1 ) , w a s h e r 02-572 (04-572)

a n d b o l t 02-582 ( 0 4 - 5 8 2 ) .
(6) Remove a n d k e e p t h e b u s h e s 02-573 (04-573) a n d 02-580 (04-580)

two b u s h e s 02-574 (04-574) a n d spacer s l e e v e 02-576 ( 0 4 - 5 7 6 ) .
(7) Remove a n d k e e p t h e l e v e r 02-590 (04-590) a n d a t t a c h e d m o v e a b l e

p a n e l 02-030 ( 0 4 - 0 3 0 ) .
(8) I f t h e s h o u l d e r e d b u s h 02-580 (04-580) i s l o o s e , refer t o SRM

54-30-03 FRSX072 ( r e p a i r No.3) t o replace i t .
B. Examine t h e damage
(1) R e f e r t o F i g 2 0 2 .
(2) Remove t h e t w o r i v e t s 02-564 (04-564) a n d r i v e t 02-565 (04-565)

t h a t a t t a c h the l e v e r arm f i t t i n g t o t h e f r o n t frame o f t h e
d o o r . R e f e r t o SRM TASK 54-02-10 f o r t h e p r o c e d u r e t o remove
the fasteners.
(3) U s e OMat 5 / 6 2 a n d 5 / 6 3 a l u m i n i u m o x i d e papers t o l i g h t l y abrade

t h e c r a c k e d area a n d t h e related r i v e t h o l e t o remove t h e
layers of protection.
REPAIR N0.7
54-30-02
Page 205
O c t . 01/06
P r i n t e d in Great R r i t a i n
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(4) C l e a n t h e area. U s e a vacuum c l e a n e r a n d r e f e r t o AMM TASK 70-

20-01-100-802.
(5) Do a f l u o r e s c e n t p e n e t r a n t i n s p e c t i o n o f t h e c r a c k e d area,
r e f e r t o AMM TASK 70-20-02-230-803 o r 70-20-02-230-804. Make
s u r e t h a t t h e crack has stopped a t t h e r i v e t hole. I f t h e crack
h a s n o t s t o p p e d a t t h e r i v e t h o l e , s e n d t h e d o o r t o a n Overhaul
base f o r t h e r e p l a c e m e n t o f t h e l e v e r arm f i t t i n g .
(6) C l e a n t h e area, r e f e r t o AMM TASK 70-20-01-100-802.
(7) Apply a l a y e r of O M a t 1/175D chromate c o n v e r s i o n t o t h e a b r a d e d

area, r e f e r t o TASK 54-02-03.
C. I n s t a l l t h e doubler
(1) R e f e r t o F i g 202
(2) A l i g n t h e l a r g e h o l e s i n t h e d o u b l e r 02-563 (04-563) a n d l e v e r

arm f i t t i n g a n d i n s t a l l t h e d o u b l e r on t h e l e v e r arm f i t t i n g ,
U s e a clamp t o k e e p i t i n p o s i t i o n .
(3) U s e a 2 , 5 nun ( 0 . 0 9 8 i n . ) d i a m e t e r d r i l l a n d b u s h t o t r a n s f e r
d r i l l t h e d o u b l e r t h r o u g h t h e f r o n t frame (where t h e r i v e t s
w e r e removed) .
(4) Remove t h e d o u b l e r a n d d r i l l t h e t h r e e 2 , 5 nun ( 0 . 0 9 8 i n . ) h o l e s
t o 4 , 9 mm ( 0 . 1 9 3 i n . ) d i a m e t e r .
(5) Deburr t h e h o l e s .
(6) C l e a n t h e d o u b l e r , r e f e r t o AMM TASK 70-20-01-100-802.
(7) I n s t a l l t h e doubler and keep it i n p o s i t i o n w i t h g r i p p e r p i n s .
(8) U s e a 4 , 9 mm ( 0 . 1 9 3 i n . ) d i a m e t e r d r i l l t o d r i l l t h e l e v e r arm
f i t t i n g and doubler through t h e t h r e e p r e - d r i l l e d h o l e s ( f o r
02-566 (04-566)) i n t h e d o u b l e r .
(9) U s e a 4 , l nun ( 0 . 1 6 1 i n . ) d i a m e t e r d r i l l t o d r i l l t h e l e v e r arm

f i t t i n g a n d d o u b l e r t h r o u g h t h e p r e - d r i l l e d h o l e ( f o r 02-568
(04-568) ) i n t h e d o u b l e r .
(10) Remove t h e d o u b l e r , d e b u r r t h e h o l e s i n i t a n d t h e l e v e r arm

f i t t i n g.
54-30-02
Page 2 0 6
O c t . 01/06
RB211 TRENT
STRUCTURAL REPAl R
MANUAL
(11) Clean t h e doubler and l e v e r arm f i t t i n g , r e f e r t o AMM TASK 70-

20-01-100-802.
(12) Apply a l a y e r of O M a t 175D chromate conversion t o t h e d r i l l e d

h o l e s , r e f e r t o TASK 54-02-03.
(13) Apply a l a y e r of O M a t 8/106 s e a l a n t t o t h e mating f a c e s and

i n s t a l l t h e doubler on t h e l e v e r arm f i t t i n g .
(14) U s e OMat 8/106 t o wet i n s t a l l t h e r i v e t s 02-564 (04-564), 02565

(04-565) and 02-568 (04-568), p i n s 02-566 (04-566) and c o l l a r s
02-567 (04-567). Refer t o t o SRM TASK 54-02-10 f o r t h e
procedure t o i n s t a l l t h e f a s t e n e r s .
(15) Apply a bead of OMat 8/107 s e a l a n t around t h e edges of t h e

doubler.
(16) Remove unwanted s e a l a n t , r e f e r t o AMM TASK 70-20-01-100-802.
D. Examine t h e r e p a i r
(1) Examine t h e r e p a i r t o make s u r e t h a t t h e r e f e r e n c e d procedures

have been done c o r r e c t l y .
E. Identify the repair
(1) Mark 'FRSX087' on t h e f i t t i n g with an OMat 262 temporary

marker.
F. I n s t a l l t h e l e v e r arm and t r i a n g u l a r moveable p a n e l .
(1) Refer t o F i g 201.
(2) I n s t a l l t h e s l e e v e 02-576 (04-576) and two bushes 02-574 (04-

574) i n t h e l e v e r arm 02-590 (04-590).
(3) I n s t a l l t h e l e v e r arm (with t h e a t t a c h e d t r i a n g u l a r moveable

p a n e l ) i n t h e l e v e r arm f i t t i n g with t h e b o l t 02-582 (04-582),
washer 02-572 (04-572) and n u t 02-571 (04-571).
(4) Torque t h e n u t 02-571 (04-571) t o 11,3 Nm (100 l b f i n ) .

(5) I n s t a l l t h e bush 02-524 (04-524) i n t h e r o l l e r 02-530 (04-530)
then i n s t a l l them i n t h e l e v e r arm with t h e p i n 02-528 (04-528)
washer 02-522 (04-522) and n u t 02-521 (04-521).
(6) Torque t h e n u t 02-521 (04-521) t o 11,3 Nm (100 l b f i n ) and

s a f e t y i t with a new c o t t e r p i n 02-520 (04-520).
REPAIR NO. 7
54-30-02
Page 2 07
O c t . 01/06
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
G. Close the applicable pivot door, refer to AMM TASK 78-32-42-410-801.
REPAIR N0.7
54-30-02
Page 208
Oct. 01/06
Printed in Great. Rritain
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
4-SCREW
(4 OFF)
3-WASHER , ~;..SCRF~
FITTING (re9 6-TRIANGULAR

7-SLEEVE MOVEABLE PANEL
,8-BUSH (2offj
~ e m o v e / ~ n s t a lthe
l assembled triangular moveable panel and lever arm
Figure 201
REPAIR NO. 7
54-30-02
Page 209
Oct. 01/06
Printed i n Great. R r i t a i n
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
VAN CUT CORNER

DEFLECTOR PLATE (ref)
LEVER
Installation of the doubler

Figure 202
REPAIR N0.7
54-30-02
Page 210
Oct. 01/06
STRUCTURAL REPAIR MANUAL
REPAIR NO. 08 (FRSX 132)

THRUST REVERSER – PIVOTING DOORS
THROUGH REPAIR OF THE DOOR MOVEABLE PANELS ACOUSTIC AREA DISBOND
1. General:
The repair gives the instructions to repair disbonded triangular
and rectangular door moveable panels.
This repair is applicable to all standards.
The fig/item numbers referred to in the procedures agree with
those used in the Power Plant Illustrated Parts Catalog (PPIPC).
Only the primary fig/item numbers are used. For different Service
Bulletin standards refer to the PPIPC.
2. Referenced information:

fasteners
AMM TASK 78-32-47-000-802 Removal of the Moveable Panels
AMM TASK 78-32-47-400-802 Installation of the Moveable Panels
AMM TASK 70-20-01-100-802 Maintenance Manual - Cold liquid
degrease
PPIPC (PP-TRENT-AI)78-32- Power Plant Illustrated Parts
42 Catalog
3. Equipment and Materials:
(1) Standard tools:

- Portable composite repair console with:
- Heat blanket, 32-250 deg F (0-120 deg C) or Heat
lamp
- Vacuum pump to 80 percent, with gage
- Cure cycle monitoring and reporting feature
- Load power indication 6kW
- Thermocouples
EFFECTIVITY:TRENT REPAIR No 08
54-30-02
Page 201
Jun 10/09
- Scraper tool
- Vacuum cleaner
- Pneumatic drill
- Drills 0.098 in (2,5 mm), 0.191 in (4,85 mm) and 0.236
in 6 mm) dia.
(2) Special tools:
HU87510 Honeycomb crushing tool
OMat 2/110 Adhesive tape vacuum bag seal, GS-213

OMat 2/126 Vacuum bag, Wrightlon 7400
OMat 2/131 Non-porous parting film, A4000
OMat 262 Temporary marker felt/fibre tip, EMS6752
OMat 272 Adhesive Tape, Scotch No27
OMat 5/94 Garnet paper, 150 Grit size Grade 4/0
OMat 8/106 Sealant, two part polysulphide, PR 1436G
A1/2
OMat 8/154 Epoxy paste adhesive, Hysol EA9394
C. Repair parts
(1) Repair parts A: Triangular moveable panel
PPIPC FIG/ITE PART NO PART COUNTERSIN QTY

FIG- M IDENTITY K
ITEM
01-320 205/1 HST315-6-18 Hi-Lite pin 130° 6

02-320
03-320
04-326
54-30-02
Page 202
Jun 10/09
01-322 205/2 HST97DUWU6 Hi-Lite 6

02-322 collar
03-322
04-328
01-324 205/3 91B224-00 Cup washer 130° 6

02-324 0.416 in
(10,57 mm)
03-324
04-330
NOTE: If any of the items above 205/1, 205/2 or 205/3 are

not available, use the alternative set of parts
below 205/1A, 205/2A or 205/3A. Single repair parts
from the list above cannot be interchanged with
single repair parts from the list below. The
alternative parts must be fitted as a complete set.

FIG- M IDENTITY K
ITEM
01-326 205/1A NAS1153V18 Screw 100° 6

02-326 (alternative)
03-326
04-332
01-328 205/2A NAS1726C3E Nut 6

02-328 (alternative)
03-328
04-334
01-330 205/3A NAS1169C10 Cup washer 100° 6

02-330 (alternative) 0.389 in
(9,88 mm)
03-330
04-336
54-30-02
Page 203
Jun 10/09
NOTE: Torque the nut NAS1726C3E to between 25 and 35 in.lb

(2,82 – 3,95 Nm).
(2) Repair parts B: Rectangular moveable panel.

FIG- M IDENTITY K
ITEM
01-460 205/1 HST315-6-18 Hi-Lite pin 130° 14

02-460
03-460
04-338
01-462 205/2 HST97DUWU6 Hi-Lite 14

02-462 collar
03-462
04-340
01-464 205/3 91B224-00 Cup washer 130° 14

02-464 0.416 in
(10,57 mm)
03-464
04-342
NOTE: Note: If any of the items above 205/1, 205/2 or

205/3 are not available, use the alternative set of
parts below 205/1A, 205/2A or 205/3A. Single repair
parts from the list above cannot be interchanged
with single repair parts from the list below. The
alternative parts must be fitted as a complete set.
54-30-02
Page 204
Jun 10/09

FIG- M IDENTITY K
ITEM
01-466 205/1A NAS1153V18 Screw 100° 14

02-466 (alternativ
e)
03-466
04-344
01-468 205/2A NAS1726C3E Nut 14

02-468 (alternativ
e)
03-468
04-346
01-470 205/3A NAS1169C10 Cup washer 100° 14

02-470 (alternativ 0.389 in
e) (9,88 mm)
03-470
04-348
NOTE: Torque the nut NAS1726C3E to between 25 and 35 in.lb

(2.82 – 3.95 Nm).
D. Material of components
COMPONENT MATERIAL
Moveable panels Carbon composite

PROTECT YOU AGAINST DUST AND LOOSE PARTICLES,
WHICH CAN BE DANGEROUS TO YOUR HEALTH.
54-30-02
Page 205
Jun 10/09
WARNING: WHEN YOU USE CLEANING MATERIALS, COATINGS AND

SEALANTS, REFER TO AND OBEY, THE MANUFACTURER'S CONTROL
AND APPLICATION INSTRUCTIONS AND HEALTH AND SAFETY
NOTICES
5. Procedure
A. Remove the moveable panel.

(1) Remove the disbonded moveable panel from the pivoting door.
B. Prepare the moveable panel.

(1) Put the moveable panel in a horizontal position, with the
acoustic skin up.
(a) Put the moveable panel on a padded surface and secure
it in position.
(2) Clean the moveable panel acoustic area. Refer to AMM TASK
70-20-01-100-802.
C. Prepare the potting zones.

(1) Mark out the centre of the zones to be potted. 6 zones to
be potted for the Triangular moveable panel, refer to
figure 201. 14 zones for the Rectangular moveable panel,
refer to figure 202. Use an OMat 2/62 marker.
CAUTION: DO NOT DAMAGE THE PLAIN SKIN WHEN DRILLING THE

ACOUSTIC SKIN
(2) Pilot drill a 0.236 in (6 mm) diameter hole through the
acoustic skin. Use the marks made in operation 5.C.(1).
Refer to figure 203, step 1.
(3) Install the HU87510 Honeycomb crushing tool in the
pneumatic drill, then put the key in the honeycomb.
CAUTION: DO NOT DAMAGE THE COMPOSITE SKINS WHEN YOU USE THE
HU87510 HONEYCOMB CRUSHING TOOL INSTALLED ON THE
PNEUMATIC DRILL
(4) Break the honeycomb cells walls with the HU87510 Honeycomb
crushing tool installed in the pneumatic drill in all the
applicable locations. Refer to figure 203, step 2.
CAUTION: DO NOT USE COMPRESSED AIR TO REMOVE THE PIECES OF

HONEYCOMB. IT CAN CAUSE A FURTHER DISBOND OF THE PANEL.
(5) Remove the pieces of honeycomb from between the inner and
outer skins. Use long nosed pliers and a vacuum cleaner.
54-30-02
Page 206
Jun 10/09
(6) Clean the moveable panel. Refer to AMM TASK 70-20-01-100-

802.
D. Prepare the adhesive.

(1) Mix OMat 8/154 adhesive parts A and B in accordance with
the manufacturer instructions.
(2) Use a syringe to fully fill all the potting holes with the
adhesive. Refer to figure 203, step 3.
E. Bag the potting zones. Refer to figure 204.

(1) Install the thermocouple next to the potting zones.
(2) Cut pieces of OMat 2/131 non-porous parting film 1.97 in
(50 mm) larger than an adhesive plug. Put one piece of the
cut Omat 2/131 Non porous parting film on each filled hole
and attach it with OMat 272 adhesive tape.
(3) Apply strips of OMat 2/110 adhesive tape vacuum bag seal
around the acoustic area.
(4) Cut a suitable piece of OMat 2/111 Breather cloth (N10-FR)
to cover the repair area. Place the cut material on the
repair area and attach it using Omat 272 Adhesive tape.
(5) Install the heater blanket. A heater lamp may be used as an
alternative. Attach two vacuum fittings to the vacuum bag
in a position where they will sit on the breather cloth and
make sure that they do not sit on the heater blanket.
(6) Cut a suitable piece of OMat 2/126 vacuum bag to cover the
full acoustic area.
(7) If there is a drainage hole in the moveable panel plain
skin, plug it using a metal plate sealed with OMat 2/110
Adhesive tape vacuum bag seal.
(8) Evacuate the lay-up gases to a vacuum of 0.7 bars inside
the bag.
(9) If heater blanket has not been installed then place the
heat lamp at a suitable distance from the component.
F. Cure the potting zones.
CAUTION: THE RATE TEMPERATURE INCREASE AND SUBSEQUENT DECREASE

MUST NOT BE MORE THAN 5 DEG F (3 DEG C) PER MINUTE
CAUTION: DO NOT START TO MEASURE THE CURE TIME UNTIL THE

TEMPERATURE HAS REACHED THE REQUIRED RANGE.
(1) Cure the adhesive for 7 hours at a minimum room temperature
of 77 deg F (25 deg C), then 1 hour between 194 and 212 deg
54-30-02
Page 207
Jun 10/09
F (90 and 100 deg C) under a vacuum of 0.7 bars. Use a Heat
lamp or a Heat blanket
(2) Allow the repair area to cool to room temperature.
(3) Remove the vacuum bagging.
(4) If applicable, remove the plate used to plug the drainage
hole and remove unwanted sealant using a scraper tool.
(5) Remove the unwanted adhesive with OMat 5/94 Garnet Paper
and lightly abrade the area to obtain a smooth surface.
(6) Clean the repair area. Refer to AMM TASK 70-20-01-100-802.
G. Drill the potting zones.

(1) Pilot drill the potting zones from the acoustic side to a
diameter of 0.098 in (2,5 mm). Refer to figure 201 for the
Triangular moveable panel. Refer to figure 202 for the
Rectangular moveable panel.
(2) Drill the potting zones to a final diameter of between
0.190 and 0.192 in (4,83 and 4,88 mm).
(3) Countersink the holes in the potting zones on the acoustic
panel side as follows:
If HST315-6-18 Hilite Pin and HST97DUWU6 Hilite Collar with

91B224-00 Cup Washer are used then countersink 130° to a
diameter between 0.413 and 0.421 in (10,49 and 10,69 mm).
Refer to Fig 205.
If NAS1153V18 Screw and NAS1726C3E Nut with NAS1169C10 Cup

Washer are to be used then countersink 100° to a diameter
between 0.386 and 0.394 in (9,80 and 10,01 mm). Refer to
Fig 205.
(4) Clean the area. Refer to AMM TASK 70-20-01-100-802.
H. Install the fasteners and washers.

(1) Use OMat 8/106 to wet install the fasteners (1) and (2)
with washers (3) in the potting zones holes. Refer to
figure 205 for the fasteners installation details.
NOTE: If fasteners (1, 2 and 3) are used, refer to SRM 54-
02-10: removal and installation of fasteners (Hi-
lok and Hi-lite) for installation procedure.
NOTE: If fasteners (1A, 2A and 3A) are used, torque the

nuts (2A) to between 25 and 35 in. lb ( 2.82 - 3.95
Nm)
54-30-02
Page 208
Jun 10/09
(2) Clean the area. Refer to AMM TASK 70-20-01-100-802.
I. Examine the completed repair.

satisfactorily completed.
J. Identify the repair.

(1) If the repaired part is a Triangular moveable panel, use
OMat 262 marker to write FRSX132/A adjacent to the door
modification plate.
(2) If the repaired part is a Rectangular moveable panel, use
OMat 262 marker to write FRSX132/B adjacent to the door
modification plate.
K. Install the moveable panel.

(1) Install the repaired moveable panel on the pivoting door.
Refer to AMM TASK 78-32-47-400-802
54-30-02
Page 209
Jun 10/09
Potting and holes location in the Triangular moveable panel

Figure 201
54-30-02
Page 210
Jun 10/09
Potting and holes location in the Rectangular moveable panel

Figure 202
54-30-02
Page 211
Jun 10/09
Potting zones preparation

Figure 203
54-30-02
Page 212
Jun 10/09
Bagging procedure
Figure 204
54-30-02
Page 213
Jun 10/09
Fastener installation details

Figure 205
54-30-02
Page 214
Jun 10/09
1
cEml@
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
THRUST REVERSER COWL, FRAME - IDENTIFICATION
1. General
R A. The frame is composed of two beams, the 12 o'clock beam at the top, and the
R 6 o'clock beam at the bottom, and a front frame that attaches the beams
R together.
.-(21
C
.-
C) R B. The following figures describe the parts and list the material used. Refer
t% R to section 54-30-00 to have the full references of these materials and
U
m R sources.
b R C. All structures aremade ofaluminumalloy.
.-C
EFFECTIVITY: TRENT
Page 1
July 1/94
1
-(R)
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL

1 12 OIC BEAM ALUMINUM 7175 918600-62
2 FRONT FRAME ALUMINUM 7175 91C602-04
3 VEE BLADE ALUMINUM 7175 91C502-02
4 6 O/C BEAM ALUMINUM 7175 91B621-09
5 FITTING ALUMINUM 7175 91A424-51
6 DOUBLER TA6V 91B271-50
7 DOUBLER TA6V 918272-52
8 SHIM CARBON COMPOSITE 918255-51
9 DOUBLER INT TA6V 918273-51
10 SHIM CARBON COMPOSITE 91B275-51
11 DOUBLER AFT TA6V 918274-51
12 DOUBLER FWD TA6V 918269-51
13 DOUBLER FWD TA6V 91B268-51
Frame I d e n t i f i c a t i o n
R F i g u r e 1 ( S h e e t 1 o f 2)
EFFECTIVITY: TRENT
Page 2
July 1/95
RB.211 TRENT
MANUAL

1 12OlCBEAM ALUMINUM 7175 918600-12
2 FRONT FRAME ALUMINUM 7175 91C600-04
3 VEE BLADE ALUMINUM 7175 91C502-02
4 6 O/C BEAM ALUMINUM 7175 9 18620-15
5 FllTlNG ALUMINUM 7175 9 1A424-01
8 SHIM CARBON COMPOSITE 91B255-01
9 DOUBLER INT TA6V 9 18273-01
10 SHIM CARBON COMPOSITE 918275-01
11 DOUBLER AFT TA6V 9 1B274-01
14 DOUBLER AFT TAGV 918267-01
15 DOUBLER AFT TA6V 91B266-01
Frame I d e n t i f i c a t i o n
F i g u r e 1 ( S h e e t 2 o f 2)
EFFECTIVITY: TRENT
Page 3
July 1/95
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL

1 SKIN 0.016 CARBON / PHENOLIC
2 CORE 0.375 PYROPEL F
3 POTTING EPOCAST 1614
4 SEALANT R N 1 06
SECTION A
l
FRONT FRAME
F i r e S h i e l d P a n e l s ( L e f t Hand and R i g h t Hand)

Figure 2
EFFECTIVITY: TRENT
Page 4
J u l y 1/95
M
m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
4 115M1003-004
/J TYPICAL
SECTION B
Thermal Blanket 6 0-Clock Beam (Left Hand and Right Hand)

EFFECTIVITY: TRENT
Page 5
July 1/95
[ RB.211 TRENT
STRUCTURAL REPAIR
MANUAL

1 to 4 THERMAL BLANKET INSULATION
5 INSULATION , 0.38 8PCF, SPCL
1" SQUARE QUILTED MRSI 116
6 INSULATION , 0.19 8PCF,
REFRACTORY AMS 3680
7 COVER EXTERIOR, 0.003 321 , AMS 5510
CRES
8 COVER INTERIOR, 0.001 POLYlMlDE FILM ,
GLASS TYPE 200
9 ADHESIVE FILM AF- 15
10 WIRE CLOTH , VENT CRES
11 COVER,GLASS -
108, MIL Y -1140
12 THREAD ,TEFLON D I E - 181751
COATED GLASS
R Thermal Blanket 6 0-Clock Beam ( L e f t Hand and Right Hand)

R F i g u r e 3 (Sheet 2 and 2)
EFFECTIVITY: TRENT
Page 6
July 1/95
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
THRUST REVERSER - FRAMES - ALLOWABLE DAMAGE
1. Introduction
thrust reverser frames.
2. Zones
S Front surface
E Edge area
TB Thermal blanket
AL Aluminium alloy
A. Allowable damage

EFFECTIVITY: TRENT
Page 101
Apr. 1/98
RB.211 TRENT
-
STRUCTURAL REPAIR
MANUAL
(1) Unlimited usage damage is defined as minor damage which does not affect
life.
(2) Time limited damage is defined as minor damage which does not affect

distinct.

of the biggest damage, then the defect is unique,



satisfactorily.
EFFECTIVITY: TRENT
Page 102
Apr. 1 I 9 8
H RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
C. Damage Types
as paint.

in the material.
( 4 ) Scratch -
a scratch is a line of damage in the material and results in



or faying surfaces.
4 . Identify and Measure the Damage Extent

EFFECTIVITY: TRENT
Page 103
Apr. 1/98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
..............................................................................
INSPECTION
ZONE DAMAGE REQUIREMENTS ALLOWABLE LIMITS INTERVAL S
..............................................................................
S1 Abrasion Confined t o s u r f a c e G r e a t e s t l e n g t h <= 'A' check
resin. Protect with 30 mm (1.2 i n . )
speed t a p e
El Abrasion Confined t o s u r f a c e . Over an u n l i m i t e d 'A' check

P r o t e c t w i t h speed area
tape
E3 Abrasion Not allowed None

Restore p r o t e c t i v e
t r e a t m e n t by a p p l y i n g
Alodine 1200 + Primer
PAC33 + P a i n t PU66
S1 Scratch, Confined t o f i r s t Depth <= 0,28 mm 'A' check

Score ply. Protect with (0.011 i n . )
speed t a p e Length <= 50 mm
(2.0 i n . )
El Score, Not allowed None

Gouge
E3 Scratch Depth Y <= 0,28 mm

(0.011 i n . )
E3 Nick, Not allowed None

Gouge,
Corrosion
AL2, Nick, No n e a r e r than 128 mm Depth Y <= 1 , 6 mm Repair a t n e x t

AL3, Gouge, (5.0in.) toother (0.0625in.) ' A ' check
AL4 Scratch u n r e p a i r e d damage
(ribs Corrosion
only
AL1, Nick, The d i s t a n c e of t h e Depth Y <= 0 , 2 mm Repair a t n e x t

AL2, Gouge, damage from an (0.008 i n . ) ' A ' check
AL3, Scratch, e x i s t i n g hole o r
AL4 Corrosion f a s t e n e r must n o t be
(webs l e s s t h a n 20Y. No
only) n e a r e r than 128 mm
(5.0 i n . ) t o o t h e r
u n r e p a i r e d damage
EFFECTIVITY: TRENT
Page 104
Apr. 1/98
R RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
..............................................................................
INSPECTION
S1 Dent Confined t o 20% of Depth <= 5 mm

the panel surface (0.2 i n . )
E3, Dent Not a l l o w e d None

AL1,
AL2
S1, Hole Not a l l o w e d None

El (Core v i s i b l e )
E3, Crack Not a l l o w e d None

AL1,
AL 2
AL6 Abrasion, Not a l l o w e d None

AL5 Nick,
Gouge,
Scratch,
Corrosion,
Crack,
Dent
EFFECTIVITY: TRENT
Page 105
Apr. 1I 9 8
RB.211 TRENT
m STRUCTURAL REPAIR
MANUAL
REPAIRABLE REPAIR
El Dent, Depth <= 5 mm FRSX069

Score, (0.2 i n . ) 54-30-07
Gouge REPAIR 05
S1 Abrasion, Damage s u r f a c e <= FRSX067

Scratch, 50% of i n s u l a t i o n 54-30-07
Score panel s u r f a c e REPAIR 03
S1 Dent, Damage s u r f a c e <= FRSX068

Hole, 20% of i n s u l a t i o n 54-30-07
Tear panel s u r f a c e REPAIR 04
E3 Abrasion Restore p r o t e c t i v e None

t r e a t m e n t by a p p l y i n g
Alodine 1200 + Primer
PAC33 + P a i n t PU66
AL2, Nick No n e a r e r t h a n 128 mm Depth Y <= 1 , 6 mm Dress t h e

AL3, Gouge, (5.0 i n . ) t o o t h e r (0.0625 i n . ) damage as
AL4 Scratch, u n r e p a i r e d damage shown i n
(ribs Corrosion Figure 102
only Sheet 1 ,
then apply
54-30-07
REPAIR 07
AL1, Nick, The d i s t a n c e of t h e damage Depth Y <= 0 , 2 mm Dress t h e

AL2, Gouge, from an e x i s t i n g h o l e o r (0.008 i n . ) damage a s
AL3, Scratch, f a s t e n e r must n o t be l e s s shown i n
AL4 Corrosion t h a n 20Y. No n e a r e r t h a n Figure 102
(web S 128 mm (5.0 i n . ) t o o t h e r Sheet 1 ,
only u n r e p a i r e d damage then apply
E3 54-30-07
REPAIR 07
E3, Crack Not allowed None

AL1,
AL2
E3, Dent Not allowed None

ALL,
AL2
EFFECTIVITY: TRENT
Page 106
Apr. 1/98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIRABLE REPAIR
AL6 Abrasion Not allowed None

AL5 Nick,
Gouge,
Scratch,
Corrosion,
Crack,
Dent
EFFECTIVITY : TRENT
Page 107
A p r . 1/98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
FIRE SHIELD -PANELS
Thrust Reverser - Fire Shield - Allowable Damage Limits

Figure 101
EFFECTIVITY: TRENT
Page 108
Apr. 1/98
B
m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
TYPICAL SECTION B-B

EXCEPT FOR AREA AL5
RADIUS 1 in. MINI

SECTION A-A
DAMAGE AREA DAMAGE AREA
Y = DEPTH OF DAMAGE
AREA E3
AREA ALI
Thrust Reverser - Frames - Allowable Damage Limits

EFFECTIVITY: TRENT
Page 109
Apr. 1 I 9 8
H
m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
AREA AL3
Thrust Reverser - Frames -Allowable Damage Limits

EFFECTIVITY: TRENT
54-30-07
Page 110
Apr. 1/98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
HINGE # 2 MAXIMUM 10 %
REDUCTION
IN WALL NOMINAL
MAXIMUM 10 %
INCREASE IN HOLE
NOMINAL DIA.
REDUCTION
RADIUS OFF THlS EDGE
MAXIMUM 10 %
INCREASE IN HOLE
NOMINAL DIA.
REDUCTION
MAXIMUM 10 % OF LUG IN WALL NOMINAL
RADIUS OFF THlS EDGE
MAXIMUM 10 O/o
INCREASE IN HOLE
NOMINAL DIA.

EFFECTIVITY: TRENT
Page 111
Apr. 1/98
[ RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
1-1 AREA AL4

EFFECTIVITY: TRENT
Page 112
Apr. 1/98
RB.211 TRENT
m STRUCTURAL REPAIR
MANUAL
OUTER FLANGE
INCLUDED IN
AREA AL5
VISIBLE AREA
GRlBS SURROUNDING
PRIMARY LOCKS
INCLUDED IN AREA AL5
RlBS INCLUDED
IN AREA AL5
VISIBLE AREA RlBS SURROUNDING

PRIMARY LOCKS
OUTER FLANGE
INCLUDED IN
AREA AL5
AREA A12
AREAAL5
NON VISIBLE AREA

EFFECTIVITY: TRENT
Page 113
Apr. 1 /98
STWCRlRALWR
M A N U A L
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR N0.3
THRUST REVERSER - FRONT FRAME
PATCH REPAIR OF FIRE SHIELD BLANKETS
1. General
CAUTION: OVERLAP OF REPAIR PATCHES IS NOT PERMITTED.
A. This procedure gives instructions for the repair of surface

damage to the front (external) skin of the fire shield
blankets. Damage is repaired by the installation of a carbon
epoxy patch.
NOTE: This repair is applicable only if there is no damage to the

fire shield core. If the core is damaged, you must refer to
Repair No.4.
........................................................................
........................................................................
TASK 78-33-13-300-XXX FRSX067,Trent Engine Manual
3. Ecnripment and Materials
-Vacuum cleaner
-Heat blanket
-Spatula
........................................................................
........................................................................
OMat 13 5 METHYLETHYLKETONE (MEK)
OMat 8/184 CARBON EPOXY PATCH
REPAIR N0.3
Page 201
Printed i n Great B r i t a i n Jan. 1/00
-----------------------------------------------------------------------*
PART LDENT MATERIAL

........................................................................
Fire shield L.H. Composite
Fire shield R.H. Composite
4. Examine the damase
A. Do a visual inspection to find the dimensions of the damage.

Refer to page block 101 to make sure the damage is in the
repairable limits.
B. Mark out an area 20 mm (0.8 in) all around the damage.
5. Prepare the surface for repair
WARNING: YOU MUST USE GLOVES,MASK AND SAFETY GOGGLES AS PROTECTION

AGAINST DUST AND LOOSE PARTICLES1 WHICH ARE DANGEROUS.
A. Abrade the area 20 mm (0.8 in) all around the damage with the
OMat 5/93 GARNET PAPER.
B. Lightly abrade the surface for 15 mm (0.6 in) all around the
damage to remove the surface protection. Use OMat 5/38 WATER-
PROOF ABRASIVE PAPER.

CORRECTLY.BEFORE YOU USE THIS PRODUCTICAREFULLY READ THE
C. Remove all loose material with the vacuum cleaner. Clean the
surface with OMat 2/101 LINT-FREE CLOTH soaked with OMat 135
MEK.Dry the surface with a new piece of cloth before the MEK
evaporates.
6. Prepare the repair patch
A. Select and cut the OMat 8/184 CARBON EPOXY PATCH to the correct
shape and dimensions.
NOTE: The repair patch must have an overlap of 15 mm (0.6 in) all
around the damage.
REPAIR N0.3
Page 202
P r i n t e d in Great B r i t a i n Jan. 1/00
1 STRUCTURAL REPAIR
MAN",

B. Clean the two sides of the repair patch with OMat 2/101 LINT-
FREE CLOTH soaked with OMat 135 MEK. Dry the surface with a new
Install the repair vatch

A. Mix the OMat 8/181 EPOXY ADHESIVE in accordance with the

NOTE: The usable life of the mixed adhesive is six minutes only.
B. Apply the adhesive on and all around the damaged area. Use a
clean spatula to make an even layer.
C. Remove the protective film and immediately put the OMat 8/184
CARBON EPOXY PATCH in position on the damaged area.
D. Put OMat 2/110A SEALANT TAPE all around the repair area.Cut and
install two pieces of OMat 2/131 NON-POROUS PARTING FILM, then
fully cover the repair with OMat 2/126 VACUUM BAG.
E. Evacuate the lay-up to a vacuum of 0.7 bar inside the bag.
F. Cure the adhesive for one hour at 25 deg C (77 deg F) minimum
with a heat blanket.
NOTE: You must keep the vacuum of 0.7 bar inside the bag during
the full cure period.
G. Remove all the lay-up materials from the repair area.
REPAIR N0.3
Page 203
Printed i n Great B r i t a i n Jan.1/00
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
WARNING: METHYLETHYLKETONE (MEW IS CLASSIFIED AS A HAZARDOUS

CAUTION: MAKE SURE THAT OMAT 135 MEK DOES NOT GO BETWEEN THE
REPAIR PATCH AND THE ADHESIVE.
H. Remove unwanted adhesive with OMat 2/101 LINT-FREE CLOTH soaked

A. Do a visual inspection to make sure the repair is satisfactory

and there is no damage remaining. If there is, refer to page
block 101 to make sure the damage is in the permitted limits.
REPAIR NO. 3
Page 204
P r i n t e d i n Great B r i t a i n Jan. 1/00
ARBON REPAIR
PATCH
SCRATCH
ABRASION
PYROPEL
I
EXTERIOR
COVER
Patch Repair of Fire Shield Blankets

Figure 201
REPAIR N0.3
Page 2 0 5
Jan. 1/00
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR N0.4
PLUG AND PATCH REPAIR OF FIRE SHIELD BLANKETS
1. General
CAUTION: DO A CHECK TO SEE IF THE DAMAGE IS A THROUGH-HOLE.IF IT

IS,YOU MUST REMOVE THE FIRE SHIELD BLANKET AND EXAMINE
THE FRONT FRAME FOR DAMAGE.
A. This procedure gives instructions for the repair of damage to

the core of the fire shield blankets. Damage is repaired by the
installation of a fire shield plug and a carbon epoxy patch.
NOTE: This repair is applicable only if the depth of the core

damage is less than 5 mm (0.2 in). If it is more,the fire
shield must be replaced.
........................................................................
........................................................................
-Vacuum cleaner
-Heat blanket
-Hot air blower
-Spatula
........................................................................
........................................................................
OMat 8/184 CARBON EPOXY PATCH
OMat 8/185 FIRE SHIELD
REPAIR N0.4
Page 201
-@ RB211 TRENT
MANUAL
STRUCTURAL REPAl R
...................................................................
PART IDENT MATERIAL
...................................................................

repairable limits.
5. Prepare the damaued core
CAUTION: MAKE SURE YOU DO NOT CAUSE DAMAGE TO THE INNER (REAR)
SKIN WHEN YOU CUT THE CORE.
A. Make a square or rectangular cut-out sufficient to remove all

the damaged core material.
B. Remove all loose material with the vacuum cleaner.
6. Make the repair pluq
A. Measure the cut-out in the core.
B. Cut a piece of OMat 8/185 FIRE SHIELD that is 1.5 mm (0.6 in)
larger,all round,than the cut-out. This is the repair plug.
C. Dry the repair plug for 24 hours at 100 deg C (212 deg F) with
a hot air blower, immediately before installation.
7. Install the repair pluq (Ref Figure 201)
A. Align the repair plug with the cut-out,then push it fully into
the core with your hand.
8. Prepare the outer skin
A. Lightly abrade the skin for 15 mm (0.6 in) all around the
repair plug to remove the surface protection. Use OMat 5/38
WATERPROOF ABRASIVE PAPER.
REPAIR N0.4
Page 202
Printed in Great B r i t a i n Jan. 1/00
H RB211 TRENT
MANUAL
STRUCTURAL REPAIR

CORRECTLY.BEFORE YOU USE THIS PRODUCT'CAREFULLY READ THE
B. Remove loose material with the vacuum cleaner. Clean the

surface with OMat 2/101 LINT-FREE CLOTH soaked with OMat 135
MEK. Dry the surface with a new piece of cloth before the MEK
evaporates.
9. Prepare the repair watch (Re£ Figure 201)
A. Select and cut the OMat8/184 CARBON EPOXY PATCH to the correct
shape and dimensions.
NOTE: The repair patch must have an overlap of 15 mm (0.6 in) all
around the installed plug.

B. Clean the repair patch with OMat 2/101 LINT-FREE CLOTH soaked
with OMat 135 MEK.Dry the surface with a new piece of the cloth
10. Install the repair watch

A. Mix the Omat 8/181 EPOXY ADHESIVE in accordance with the

NOTE: The usable life of the mixed adhesive is six minutes.
B. Apply the adhesive on and all around the damaged area. Use a
clean spatula to make an even layer.
C. Remove the protective film and immediately put the repair patch
in position on the damaged area.
REPAIR N0.4
Page 203
P r i n t e d i n Great B r i t a i n Jan.1/00
p"" RB211 TRENT
MANUAL
STRUCTURAL REPAl R
D. Put the Omat 2/110A SEALANT TAPE all around the repair area.
Cut and install two pieces of Omat 2/131 NON-POROUS PARTING
FILM,then fully cover the repair with Omat 2/126 VACUUM BAG.
E. Evacuate the lay-up to a vacuum of 0.7 bar inside the bag.
F. Cure the adhesive for one hour at 25 deg C (77 deg F) minimum
with a heat blanket.
NOTE: You must keep the vacuum of 0.7 bar inside the bag during
the full cure period.
G. Remove all the lay-up materials from the repair area.

SPECIFIED HEALTH AM> SAFETY PRECAUTIONS.
CAUTION: MAKE SURE THAT OMAT 135 MEK DOES NOT GO BETWEEN THE
REPAIR PATCH AND THE ADHESIVE.
H. Remove unwanted adhesive with Omat 2/101 LINT-FREE CLOTH soaked

with Omat 135 MEK.Dry the surface with a new piece of the cloth
Inspection
A. DO a visual inspection to make sure the repair is satisfactory

and there is no damage remaining. If there is, refer to page
block 101 to make sure the damage is in the permitted limits.
REPAIR N0.4
Page 204
Printed in Great Britain Jan. 1/00
p
"" RB211 TRENT
MANUAL
STRUCTURAL REPAIR
PYROPEL PLUG
PYROPEL
15,2mm
(0.60in)
MINIMUM
Plug and Patch Repair of Fire Shield Blankets

Figure 201
REPAIR N0.4
Page 205
Jan. 1/00
H
"" RB211 TRENT
MANUAL
STRUCTURAL REPAIR
REPAIR N0.5
EDGE REPAIR OF FIRE SHIELD BLANKETS
1. General
A. This procedure gives instructions for the repair of damage to

the edge of the fire seal blankets. Damage is repaired with
silicone sealing compound.
NOTE: This repair is applicable only if the depth of the damage in

.
the panel edge is less than 5 mm (0.2 in) If it is more, the
fire shield must be replaced.
........................................................................
........................................................................
3. E~uipmentand Materials
-Vacuum cleaner
-Heat blanket
-Spatula
........................................................................
........................................................................
OMat 872A SEALING COMPOUND
........................................................................
PART IDENT MATERIAL
........................................................................
REPAIR N0.5
Page 201
Jan.1/00
R6211 TRENT
STRUCTURAL REPAIR
MANUAL

repairable limits.
5. Prepare the damaged area
A. Abrade the damaged area with OMat 5/93 GARNET PAPER. Remove
loose material with the vacuum cleaner.

6. Repair the damase (Re£ Figure 201)
A. Fill the hole with OMat 872A SEALING COMPOUND, applied directly
from the tube or cartridge.
B. Use a clean spatula to make the compound smooth and flush with
the face and edge of the fire shield. Remove unwanted compound
with OMat 2/101 LINT-FREE CLOTH.
C. Cut and install a piece of OMat 2/131 NON-POROUS PARTING FILM

over the repaired area. Cure the sealing compound for 24 hours
at 25 deg C (77 deg F) minimum with a heat blanket.
NOTE: The compound will be touch-dry after 30 minutes.
A. Remove the lay-up materials. Do a visual inspection to make sure

the repair is satisfactory and there is no damage remaining. If
there is, refer to page block 101 to make sure the damage is in
the permitted limits.
REPAIR N0.5
Page 202
PYROPEL
3
0
(D
m
E
. Edge R e p a i r of F i r e S h i e l d Blanket
Figure 201
REPAIR NO. 5
Page 203
Printed i n Great Britain Jan. 1 / 0 0
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR N0.6
THRUST REVERSER - FRONT FRAME & VEE BLADE
REPAIR OF METALLIC SURFACE DAMAGE
1. General
A. This procedure gives instructions for the repair of minor

damage to the metallic structure of the front frame and vee
blade. Damage can be removed by abrasion.
B. Types of damage repairable by this procedure are:
C. You must refer to Allowable Damage, page block 101, for the
repairable limits in each zone.
....................................................................
....................................................................
78-33-00-300-XXX FRSX001, Trent Engine Manual
54-02-03 Protective Treatment, Metallic Surfaces
3. Ecruipment and Materials
.....................................................................
.....................................................................
OMat 150 ACETONE
OMat 2/101 CLOTH,LINT-FREE
OMat 2/114 GLOVES,LINT-FREE
OMat 5/94 GARNET PAPER,Grit Size 150,Grade 4/0
OMat 653 FLUORESCENT PENETRANT
REPAIR N0.6
54-30-07
Page 201
M RB211 TRENT
STRUCTURAL REPAIR
MANUAL
B. Component Material
........................................................................
COMPONENT MATERIAL
........................................................................
Front Frame Aluminum Alloy
Vee Blade Aluminum Alloy
4. Prepare the Area
WARNING: ACETONE IS CLASSIFIED AS A HAZARDOUS MATERIAL THAT CAN

CAUSE INJURY OR ILLNESS IF NOT USED CORRECTLY. USE THIS
PRODUCT ONLY IN ACCORDANCE WITH THE MANUFACTURER'S HEALTH
AND SAFETY RECOMMENDATIONS. BEFORE YOU USE THIS PRODUCT,
CAREFULLY READ THE APPLICABLE MATERIAL SAFETY DATA SHEET
AND OBEY ALL THE SPECIFIED HEALTH AND SAFETY PRECAUTIONS.
A. Thoroughly clean the repair area with OMat 150 ACETONE and OMat
2/101 LINT-FREE CLOTH. Dry the surface with a new piece of the
CAUTION: DO NOT TOUCH THE CLEANED SURFACE WITH YOUR HANDS.PUT ON

THE OMAT 2/114 GLOVES FOR SUBSEQUENT OPERATIONS.
B. Apply the OMat 653 FLUORESCENT PENETRANT to find the dimensions

of the damage. Use the OMat 261 SOFT PENCIL to show the edges
of the damage.
5. Repair Procedure (Re£ Fig.201)
WARNING: YOU MUST USE EYE PROTECTION AND A FACE MASK DURING THIS
OPERATION. DUST CAN GET INTO YOUR EYES AND LUNGS AND
CAUSE AN INJURY.
A. Use OMat 5/94 GARNET PAPER to remove the damage and make the
surface smooth. Do not remove more material than is permitted
by Allowable Damage, page block 101.
B. Apply protective treatment to the repaired surface (Refer to

54-02-03, page block 201)
6. Inspection
REPAIR N0.6
54-30-07
Page 202
RB211 TRENT
STRUCTURAL REPAIR
SEE SHEET 2
SECTION B - B
CLEAN OUT BOUNDARY
SECTION A -A
DAMAGE AREA DAMAGE AREA
Y = DEPTH OF DAMAGE
*% I
AREA E3 = Y 6 LIMIT FOR CRACK
m
g AREA AL1 = Y ILIMIT FOR NICK, GOUGE, SCRATCH, CORROSION
0
.-
Q)
0
0
I z
Repair Surface Damage

Figure 201 Sheet 1
REPAIR N0.6
54-30-07
Page 203
W RB211 TRENT
STRUCTURAL REPAIR
MANUAL
OUTER FLANGE
INCLUDED IN NON VISIBLE AREA
AREA AL5
VISIBLE AREA
NON
RIBS SURROUNDING
/ PRIMARYLOCKS
NON VISIBLE AREA
OUTER FLANGE
INCLUDED IN
AREA AL5
Y=DEPTH OF DAMAGE
AREA AL2 ;Y( LIMIT OF LOCAL THICKNESS FOR NICK,
-a GOUGE ,SCRATCH,CORROSION
.-
C
0 AREAAL5;NONREPAIRABLE
0
0
lz
Repair Surface Damage
Figure 201 Sheet 2
REPAIR N0.6
54-30-07
Page 204
Jan. 1/00
P RB211 TRENT
STRUCTUAL REPAIR
MANUAL
REPAIR N0.7
THRUST REWXRSER - FRAMES
REPAIR THE METAL COVER OF THE CNA FITTING
1. General
A. This repair gives instructions to cut out the damaged part of

the cover and attach a repair part with rivets.
.......................................................................
S W 54-02-10 Fasteners - Removal/Installation

Suction cleaner
Drills and riveting equipment
.......................................................................
.......................................................................
OMat 8/173 SEALANT
OMat 262A MARKER
C. Repair Parts
.......................................................................
.......................................................................
W 91A583-00 Repair Kit for Left Hand C-Duct:
201/1 91B842-03 Metal Cover - Fitting

2 NAS1919M04S02 Rivet
- 91A587-00 Repair Kit for Right Hand C-Duct: -

201/1 91B843-03 Metal Cover - Fitting
REPAIR N0.7
54-30-07
Page 201
P r i n t e d in Great Britain July 1/00
R8211 TRENT
STRUCTUAL REPAIR
MANUAL
4. Remove the Damaue (Ref Figure 201)
A. Drill out the four rivets (3) that attach the damaged part of
the cover to the bracket (Ref SRM 54-02-10).
B. Refer to Figure 201 and measure the cut-line as shown.
CAUTION: ALL WHEELS,STONES AND ABRASIVE PAPERS USED FOR DRESSING,

BLENDING OR POLISHING MUST BE OF THE SILICON CARBIDE TYPE.
IF YOU USE MECHANICAL CUTTERS,BE CAREFUL TO MAKE LIGHT
CUTS ONLY TO PREVENT OVERHEATING OF THE MATERIAL-IF THE
MATERIAL IS DISCOLOURED TO DARKER THAN A LIGHT STRAW,THEN
THE COMPONENT IS OVERHEATED AND MUST BE REJECTED.
C. Cut and discard the damaged section of the cover. Remove all
sharp edges from the remaining part.
5. Make the Repair Part (Ref Figure 201)
A. Refer to Figure 201 and measure the cut-line as shown.
CAUTION: ALL WHEELS,STONES AND ABRASIVE PAPERS USED FOR DRESSING,

BLENDING OR POLISHING MUST BE OF THE SILICON CARBIDE TYPE.
IF YOU USE MECHANICAL CUTTERS,BE CAREFUL TO MAKE LIGHT
CUTS ONLY TO PREVENT OVERHEATING OF THE MATERIAL.IF THE
MATERIAL IS DISCOLOURED TO DARKER THAN A LIGHT STRAW,THEN
THE COMPONENT IS OVERHEATED AND MUST BE REJECTED.
B. Cut and discard the unwanted section of the repair part (1).
Remove all sharp edges from the remaining part.
6. Install the Repair Part (Ref Figure 201)
A. Put the repair part (1) in position on the metal cover with a
20 mm overlap, hold it with clamps.
B. Refer to Figure 201. Measure and drill four equispaced holes

4,065 to 4,115 nun (0.160 to 0.162 in) diameter through the two
parts for rivets (2).
C. Counter-drill four holes 3,275 to 3,325 mm (0.129 to 0.131 in)

diameter through the repair part for rivets (3).
D. Remove the repair part from the bracket. Remove sharp edges
from the drilled holes in the two parts.
REPAIR N0.7
54-30-07
Page 202
SPECIFIED HEALTH ANDSAFETY PRECAUTIONS.
E. Clean the repair part and area with OMat 2/101 LINT-FREE CLOTH
soaked with OMat 135 MEK. Dry the surfaces with a new piece of
F. Apply OMat 8/177 SEALING COMPOUND to the mating face of the

repair part.
G. Put the repair part (1) in position on the cover. Wet-install

rivets (2) and (3) with OMat 8/173 SEALANT (Ref SRM 54-02-10).
H. Apply a bead of OMat 8/177 SEALING COMPOUND around the repair

area to seal the edges.
J. Cure the sealing compound for 24 hours at 25 deg C (77 deg F).
NOTE: Refer to manufacturer's instructions to decrease cure time.
7. Inspection
B. Use the OMat 262A MARKER to write FRSX081 adjacent to the cover
part number.
REPAIR NO. 7
54-30-07
Page 203
RB211 TRENT
STRUCTUAL REPAIR
FllTlNG METAL COVER
SECTION TO DISCARD RADIUS
SPARE FITTING METAL COVER

(FLAT PATTERN)
.t
S 4 RIVETS AT EQUAL
?=
0
DISTANCE EACH OTHER
0
4 RIVETS
Repair the Metal Cover
Figure 201
54-30-07
Page 2 0 4
P r i n t e d in Great Britain July 1/00
1
-8
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
THRUST REVERSER DOOR SURROUND STRUCTURE - IDENTIFICATION
1. General
R A. The door surround is composed of two cut corners, the 12 o-clock cut corner
R at the top and the 6 o-clock cut corner at the bottom, a torsion box and a
R 9 o-clock beam.
.-
C
--
U
Q
R B. The following figures describe the parts and list the material used. The
6 R full view of the part has a ply orientation chart to help find the warp
CI
(D R direction. Refer to section 54-30-00 to have the full references of these
6 R
R
--
C
0
Q R C. Door surround are mainly made out of monolithic carbonlepoxy composite or
--
W
c R carbon/epoxy composite bonded to metallic honeycomb.
it
R number of carbon ply andlor the type of honeycomb. These zones are
EFFECTIVITY: TRENT
Page 1
July 1/94
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
TORSION BOX
CUT CORNER SEE FIG 4
FRONT FRAME
9 O/C BEAM
SEE FIG 5
l
6 O/C CUT CORNER
SEE FIG 3
Door Surround - Identification

Figure 1
EFFECTIVITP: TRENT
Page 2
R July 1/94
1
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RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
(SEE SHEET 2)
91G125
ITEM DESCRIPTION GAGE MATERIAL EFFECTlVlTY

1 SIDE BULK HEAD CARBON COMPOSITE
2 SIDE WALL CARBON COMPOSITE
12 0-Clock C u t C o r n e r
F i g u r e 2 ( S h e e t 1 of 3)
EFFECTIVITY: TRENT
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July 1/94
[ RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
VlEW OF OUTER SKlN
VlEW OF INNER SKlN

90" 23
AREA No Z1 22 23 LAY UP ORDER

CARBON EPOXY LAYER 2 5 5 FIRST
GLASS LAYER 1
TEDLAR LAYER 1 1 1 LAST

THICKNESS 0.5 in. (12.7 mm)
RIBBON DIRECTION
12 O-Clock Cut Corner

EFFECTIVITY: TRENT
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July 1/95
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
CARBON EPOXY LAYER

I Z1
10
1 1
22
10
ORDER
---
I
GLASS LAYER 1 LAST
1 2 0 - C l o c k Cut C o r n e r
EFFECTIVITY: TRENT
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O c t . 1/95
1 RB.211 TRENT
mm@ STRUCTURAL REPAIR
MANUAL
I ITEM I DESCRIPTION (GAGE/ MATERIAL I EFFECTIVITY l

1 SIDE BULK HEAD CARBON COMPOSITE
2 SIDE WALL CARBON COMPOSITE
6 0-Clock Cut Corner

EFFECTIVITY: TRENT
Page 6
July 1/94
1
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RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
VlEW OF OUTER SKlN J
AREA No Z1 22
CARBON
3 5
EPOXY LAYER
VlEW OF INNER SKlN
RIBBON DIRECTION
6 0-Clock Cut C o r n e r
EFFECTIVITY: TRENT
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J u l y 1/95
H
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RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
VlEW OF OUTER SKlN
AREA N o Z1 22
VlEW OF INNER SKlN

CARBON EPOXY LAYER 2 5 5
GLASS LAYER 1
TEDLARLAYER 1 1 1 LAST
NON METALLIC HONEYCOMB TYPE NOMU( 3-48
THICKNESS : 0.5 in. (12,7 mm)
# RIBBON DIRECTION
6 0-Clock C u t C o r n e r
EFFECTIVITY: TRENT
Page 8
Sept.15/96
m RB.211 TRENT
STRUCTURAL REPAIR
MANUAL

GLASS LAYER 1 FIRST
CARBON EPOXY LAYER 5 14 10
GLASS LAYER 1 1 LAST
C
AREA WITH GLASS EPOXY

TYPE 9141451759
Torsion Box
Figure 4
EFFECTIVITY: TRENT
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July 1/95
RB.211 TRENT
m m STRUCTURAL REPAIR
MANUAL
ITEM DESCRIPTION GAGE MATERIAL EFFECTlVllY

1 UPPER SIDEWALL CARBON COMPOSITE
2 LOCK FITTING ALUMINIUM 7010
3 PIVOT FITTING ALUMINIUM 7175
4 INNER SKIN CARBON COMPOSITE
5 SOLE PLATE CARBON COMPOSITE
6 FRONT FITTING TA6V
7 LOWER SIDEWALL CARBON COMPOSITE
8 FRAME ALUMINIUM 2024 PLT42
3 or 9 0-Clock Beam
EFFECTIVITY: TRENT
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July 1/95
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
VlEW OF OUTER SKlN
AREA N o Z1 22 23
CARBON
EPOXY LAYER
VlEW OF INNER SKlN
NOTE :
UPPER AND LOWER
SIDNVALLS
ARE SIMILAR

THICKNESS : 0.5 in.(12.7mm)
3 or 9 O-Clock Beam
EFFECTIVITY: TRENT
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RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
AREA No Z1 22 23
CARBON EPOXY LAYER 10 1 1 6
3 o r 9 0-Clock Beam
EFFECTIVITY: TRENT
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R
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STRUCTURAL REPAIR
MANUAL
CARBONEPOXYLAYER 10
3 or 1 9 O-Clock Beam
EFFECTIVITY: TRENT
Page 13
July 1/95
M RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
THRUST REVERSER - DOOR SURROUND STRUCTURE - ALLOWABLE DAMAGE
1. Introduction
thrust reverser door surround structure.
2. Zones
M Monolithic area
S Sandwich area
A. Allowable damage

EFFECTIVITY: TRENT
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Apr. 1/98
3s STRUCTURAL REPAIR
MANUAL
life.

distinct.



satisfactorily.
EFFECTIVITY: TRENT
Page 102
Apr. 1/98
RB.211 TRENT
MANUAL
C. Damage Types
as paint.
- an abrasion is an area of damage which results in a cross

( 1 ) Abrasion
in the material.
- a scratch is a line of damage in the material and results in

( 4 ) Scratch

- a disbond is the separation of the face skin from the

( 8 ) Disbond
- a delamination is the separation of two laminate plies

( 9 ) Delamination
or faying surfaces.
4 . Identify and Measure the Damage Extent

EFFECTIVITY: TRENT
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Apr. 1 / 9 8
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
..............................................................................
INSPECTION
..............................................................................
resin area

Gouge first outer ply. No (0.011 in.)
nearer than 5 times
its size to other
unrepaired damage or
rivet line
All Dent No nearer than 5 Depth <= 2,5 mm

times its diameter (0.l in.)
to other unrepaired
All Hole, No nearer than 5 Diameter or length 'A' check for

Nick times its size to <= 20 mm (0.79 in.) sealed hole
line. Seal the hole
with speed tape

Disbond times its size to <= 30 mm (1.18 in.)
line
EFFECTIVITY: TRENT
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Apr. 1/98
1
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RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
..............................................................................
REPAIRABLE REPAIR
Scratch, No more than 3 cut plies. Depth <= 0.84 mm FRSX045

size
Dent Distance from other damage Diameter <= 65 mm FRSX045

must be greater than 5 (2.4 in.) 54-30-00
times its size REPAIR 01
Hole Distance from other damage Diameter <= 65 mm FRSX046

Delamination Distance from other damage Diameter <= 65 mm FRSX053

size

size
Dent Distance from other damage Diameter <= 25 mm FRSX045

Hole Distance from other damage Diameter <= 25 mm FRSX046

Delamination Distance from other damage Diameter <= 30 mm FRSX053

size

size
EFFECTIVITY: TRENT
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Apr. 1 I 9 8
RB.211 TRENT
m STRUCTURAL REPAIR
MANUAL
..............................................................................
REPAIRABLE REPAIR
..............................................................................
E3 Dent Distance from other damage Diameter <= 28 mm FRSX045
E3 Hole Distance from other damage Diameter <= 28 mm FRSX046

E3 Delamination Distance from other damage Diameter <= 30 mm FRSX053

size
E4 Scratch, No more than 5 cut plies. Depth <= 1.4 mm FRSX045

size
E4 Dent Distance from other damage Diameter <= 76 mm FRSX045

E4 Hole Distance from other damage Diameter <= 76 mm FRSX046

E4 Delamination Distance from other damage Diameter <= 76 mm FRSX053

size
M Scratch, No more than 3 cut plies. Depth <= 0.84 mm FRSX045

size
M Dent, Distance from other damage Diameter <= 65 mm FRSX045

Delamination must be greater than 5 (2.56 in.) 54-30-00
EFFECTIVITY: TRENT
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Apr. 1/98
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
..............................................................................
REPAIRABLE REPAIR
..............................................................................
M Hole Distance from other damage Diameter <= 65 mm FRSX046

size


S1 Scratch, Nomorethan2cutplies. Depth<=0.56mm FRSX045

size
S1 Dent, Distance from other damage Diameter <= 40 mm FRSX047

Disbond must be greater than 5 (1.6 in.) 54-30-00
times its size - core REPAIR 03
undamaged

damaged

times its size - inner skin REPAIR 05
damaged < dia 30 mm (1.2 in.)

damaged > dia 30 mm (1.2 in.)
EFFECTIVITY: TRENT
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Apr. 1 I98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
..............................................................................
REPAIRABLE REPAIR
..............................................................................
size

size

undamaged

damaged

undamaged


size

size
EFFECTIVITY: TRENT
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Apr. 1/98
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
------------------------------------------------------------------------------
REPAIRABLE REPAIR

undamaged

damaged



size

size

undamaged

damaged
EFFECTIVITY: TRENT
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Apr. 1/98
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m STRUCTURAL REPAIR
MANUAL
..............................................................................
REPAIRABLE REPAIR
..............................................................................
times its size -
inner skin REPAIR 05


size
EFFECTIVITY: TRENT
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Apr. 1/98
[ RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
g AREA E l
AREA S1
TOP SlDE WALL
9
:.:.:.:.>
v.....,..
AREA E3
AREA S3 A
BOTTOM SlDE WALL
Thrust Reverser - Door Surround Structure - Allowable Damage Limits

EFFECTIVITY: TRENT
Page 111
Apr. 1 /98
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
AREA M
BOTTOM SIDE
BULK HEAD
AREA M1
Thrust Reverser - Door Surround S t r u c t u r e - A l l o w a b l e Damage L i m i t s

F i g u r e 1 0 1 ( S h e e t 2 of 3)
EFFECTIVITY: TRENT
54-30-15 Page 112
Apr. 1I 9 8
M RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
BOTTOM SlDE WALL
TOP SlDE WALL
Thrust Reverser - Door Surround S t r u c t u r e - A l l o w a b l e Damage L i m i t s

F i g u r e 101 ( S h e e t 3 of 3 )
EFFECTIVITY: TRENT
Page 113
Apr. 1/98
R8211 TRENT
m-AIR
M M u
W .X &..-+d. A-,, L>"L>,.. --.v.* .--,

RB211 TRENT
STRUCTUAL REPAIR
MANUAL
REPAIR NO. 1
THRUST REVERSER - DOOR SURROUND
REPAIR THE DOOR SEAL COMPRESSOR
1. General
A. This procedure gives instructions for the repair (by replacement)

of all or part of the 'P1 section door seal compressor.
B. This repair is not applicable to the seals in the tertiary lock

or pivot access areas. These have a different cross-section.
.......................................................................
.......................................................................
AMM TASK 78-32-42-010-801 Manually Open the Pivoting Door
AMM TASK 78-32-42-410-801 Manually Close the Pivoting Door
Clamps
Riveting equipment
Drill guide and equipment
.......................................................................
.......................................................................
OMat 7/197 THINNERS
OMat 8/106A SEALANT
OMat 8/107 SEALANT
C. Repair parts
.......................................................................
ITEM PART NO. PART IDENT QTY
.......................................................................
Repair kit 91A562-00 comprises:
1 91POO7-00 Seal Compressor 1250 mm (50 in)

2 MS20470AD4-5 Rivet 20
2A MS20470AD4-6 Alternative 20
2B MS20470AD4-7 Alternative 20
2C MS20470AD4-8 Alternative 20
REPAIR NO.l
54-30-15
Page 201
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
4. Get Access
A. Manually open the applicable pivoting door

(AMM TASK 78-32-42-010-801).
5. Damase Limits
A. Dent in the door surround more than 2 mm (0.08 in) depth

that touches the seal, or
B. Crack in the seal more than 8 mm (0.32 in) length, or
C. Crack in the seal that touches a fastener.
A. Remove the damaged seal
CAUTION: BEFORE YOU CUT THE SEAL, MAKE SURE THERE WILL BE A
MINIMUM OF TWO RIVETS IN THE NEW A N D THE REMAINING
(SERVICEABLE) SEAL SEGMENTS.
(1) Put marks on the seal to show the cut lines. There must be:
(a) A minimum of 10 mm (0.4 in) between the cut line and

the nearest rivet hole
(b) A minimum of two rivets in the new and the remaining

(serviceable) seal segments.
(2) Put a blade under the cut line to prevent damage to the
door when you cut the seal.
(3) Cut through the damaged 'P' seal with a sharp knife.
(4) Drill out the rivets that attach the damaged seal to the
seal support.Be careful not to make the rivet holes larger.
(5) Remove and keep the damaged seal segment as a length gage.
(6) Remove sharp edges from the cut ends of the remaining
serviceable seal.
B. Prepare the repair seal
(1) Cut a segment of new seal compressor to the same length as

the seal removed in step A. ( 5 ) above.
REPAIR NO.l
54-30-15
Page 202
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
NOTE: The maximum permitted space between the ends of

the new and serviceable seals is 10 mm (0.04 in) .
(2) Remove sharp edges and make the ends of the replacement
seal the same shape as the removed seal.
(3) If necessary, bend the new seal segment to make the

installation easier.
C. Install the repair seal
(1) Put the repair seal in position on the seal support:
(a) A new seal segment must align with the remaining

seal, with a maximum step of 0,3 mm (0.012 in)
(b) If you replace the seal along one full side of the
door, the seal edge must be 9 mm (0.35 in) from the
rivet centerline.
(2) Hold the seal in position with clamps.
(3) Pilot-drill the seal through the support, then drill the
rivet holes 3,275 to 3,325 m(0.129 to 0.131 in)diameter.
(4) Remove the clamps and the seal from the support.
(5) Remove sharp edges from the rivet holes.
WARNING: THESE MATERIALS CAN CAUSE INJURY OR ILLNESS IF NOT

USED CORRECTLY. BEFORE YOU USE THESE MATERIALS,
CAREFULLY READ THE APPLICABLE SAFETY DATA SHEET
AND OBEY ALL THE HEALTH AND SAFETY PRECAUTIONS.
(6) Clean the repair seal and the seal support with OMat 2/101
LINT-FREE CLOTH soaked with OMat 7/197 THINNERS. Dry the
surfaces with a clean piece of cloth before the thinners
evaporates.
(7) Apply a thin layer of OMat 8/107 SEALANT to the mating

face of the repair seal.
NOTE: At 23 deg C (73 deg F) and 50 percent: relative

humidity, the application time is 30 minutes.
(8) Put the repair seal in position on the seal support. Make
sure the rivet holes are correctly aligned.
REPAIR NO.l
54-30-15
Page 203
P r i n t e d in Great B r i t a i n May 1/00
RB211 TRENT
1
m 1 STRUCTUAL
MANUAL
REPAIR
(9) Measure the thickness of the seal support and find the
correct rivets.
NOTE: The repair kit includes different lengths of rivets

to suit different thicknesses of seal support. Make
sure you use the correct rivets.
(10) Wet-install the rivets with OMat 8/106A SEALANT.
(11) Remove unwanted sealant with an OMat 2/101 LINT-FREE CLOTH

soaked with OMat 7/197 THINNERS. Dry the surface with a
new piece of the cloth before the thinners evaporates.
D. Seal the repair
(1) Fill the spaces between the new and the remaining seals
with OMat 8/107 SEALANT. Make sure the joints are smooth
and fully bonded.
(2) Remove unwanted sealant with an OMat 2/101 LINT-FREE CLOTH

soaked with OMat 7/197 THINNERS. Dry the surface with a
new piece of the cloth before the thinners evaporates.
7. Close Access
A. Manually close the applicable pivoting door

(Ref AMM TASK 78-32-42-410-801).
REPAIR NO.l
54-30-15
Page 204
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
SECTION NOT COVERED
ORIGINAL PROFILE IN CUT

CORNER AREA NOT TO BE
KEPT AFTER REPAIR.
SEAL COMPRESSOR
TYPICAL SECTION --
-
----
-- -
- - -
- -
LOCK AREA
REMAINING
SECTIONS l
/?k$+\p.c-.
NEW SECTION
(ITEM 2)
lMM(O.O4IN)-IL NE&
MAXIMUM SECTION
Repair the Seal Compressor

Figure 201
REPAIR NO.l
54-30-15
Page 205
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
THRUST REVERSER INNER FIXED STRUCTURE - IDENTIFICATION
1. General
A. The IFS is composed of external and internal skins which are bonded
together in our specialized workshop. The external skins of the IFS are
those washed by the external secondary air flow.
B. The following figures describe the parts and list the material used. The
full view of the part has a ply orientation chart to help find the warp
direction. Refer to section 54-30-00 to have the full references of these
materials and sources, and the typical lay up in section 54-30-00 to find
the warp direction for each ply of the composite skin.
C. The IFS is made of carbon/bismaleimide composite bonded to metallic

honeycomb.
D. Each of the individual components is divided into zones which define the
number of carbon ply andlor the type of honeycomb. These zones are
identified in figures and tables which follow.
EFFECTIVITY: TRENT
Page 1
R July 1I95
B-(R)
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
(SEE SHEET 2)
AREA No Z1 22 23 24 25 Z6 27 LAY UP ORDER

CARBONBMILAYER 6 5 4 3 7 9 8
GLASS BM1 LAYER 1 1 1 LAST
Inner Fixed Structure (Left Hand)

EFFECTIVITY: TRENT
Page 2
July 1/95
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
LH - IFS INTERNAL SKIN
23
27
z1 z1
AREA N o Z1 22 23 24 25 Z6 27 LAY UP ORDER
GLASS BM1 LAYER 1 1 1 FIRST
CARBON BM1 LAYER 14 5 6 4 3 8 9
Inner Fixed Structure (Left Hand)

EFFECTIVITY: TRENT
54-30-30
Page 3
July 1/95
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
-THK = 0.59
(15 mm)
-THK : 0.5 in
(12,7 mm)
HONEYCOMB
SECTION
A-A
.1
THICKNESS OF HONEYCOMB IS 1 in (254 mm)

EXCEPT FOR CASES SPECIFIED
AREA WITHOUT HONEYCOMB

..........
1-4
.................
.................
.........
.................
.................
................
........ CURRENT AREA WITH METALLIC HONEYCOMB TYPE 5056 4-40
ACOUSTIC AREA WlTH METALLIC HONEYCOMB TYPE 5056 9-85
-
1 1
RADIUS AREA WlTH METALLIC HONEYCOMB TYPE 5056 F40-65
CURRENT AREA WITH METALLIC HONEYCOMB TYPE 5056 4-50
M THE RIBBON DIRECTION IS HORIZONTAL EXCEPT FOR CASES IDENTIFIED

J0012
I n n e r F i x e d Structure ( L e f t €land)
F i g u r e 1 ( S h e e t 3 of 6 )
EFFECTIVITY: TRENT
54-30-30
4Page
July 1/95
1
m(m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
. RH - IFS EXTERNAL SKIN
Inner Fixed Structure (Right Hand)

EFFECTIVITY: TRENT
Page 5
July 1/95
RB.211 TRENT
MANUAL
RH - IFS INTERNAL SKIN
AREA No Z1 22 23 24 Z5 Z6 27 LAY UP ORDER

GLASS BM1 LAYER 1 1 1 FIRST
CARBONBMILAYER 14 5 6 4 3 7 9
D4619D
I n n e r Fixed S t r u c t u r e (Right Hand)

EFFECTIVITY : TRENT
Page 6
J u l y 1/95
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
THK = 0.5 in
' (12,7mm)
.THK : 0.59 in
(15 mm)
HONEYCOMB
SECTION A-A
THICKNESS OF HONEYCOMB IS 1 in (254 mm)

EXCEPT FOR CASES SPECIFIED
AREA WITHOUT HONEYCOMB
CURRENT AREA WITH METALLIC HONEYCOMB TYPE 5056 4-40

ACOUSTIC AREA WITH METALLIC HONEYCOMB TYPE 5056 9-85
RADIUS AREA WITH METALLIC HONEYCOMB TYPE 5056 F40-65

n
[_ ] CURRENT AREA WITH METALLIC HONEYCOMB TYPE 5056 4-50
THE RIBBON DIRECTION IS HORIZONTAL
EXCEPT FOR CASES IDENTIFIED
I n n e r Fixed S t r u c t u r e ( R i g h t Hand)
F i g u r e 1 ( S h e e t 6 of 6)
EFFECTIVITY: TRENT
Page 7
July 1/95
m
m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
Precooler Duct
EFFECTIVITY: TRENT
Page 8
July 1/95
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
EQUIVALENCE
ITEM DESCRIPTION ZONE / GAGE MATERIAL MATERIAL
1 PRECOOLER 21 / 0.031 A286 AMS 5726
22 / 0.04 BS HR51
2 PRECOOLER 0.048 A286 AMS 5726
JOGGLED SHEET BS HR51
3 THERMAL BLANKET 0.023 T40 ASTM GRADE 2
SUPPORT
4 STRENGTHENER 0.04 A286 AMS 5726
BS HR51
5 DOUBLER 0.04 A286 AMS 5726
BS HR51
6 DOUBLER 0.04 A286 AMS 5726
BS HR51
7 STIFFENER 0.04 A286 AMS 5726
BS HR51
8 STIFFENER 0.04 A286 AMS 5726
BS HR51
P r e c o o l e r Duct
F i g u r e 2 (Sheet 2 o f 2)
EFFECTIVITY: TRENT
Page 9
J u l y 1/95
RB.211 TRENT
m(R) STRUCTURAL REPAIR
MANUAL
AREA WlTH INSULATION, 1 IN SQUARE QUILTED, MIN - K

THICKNESS : 0.4 IN (10.2 mm)
AREA WlTH INSULATION, REFRACTORY, L 0 - CON

CRES FOIL, 0.01 IN (0.25 mm) THICKNESS MORE
0 EDGE AREA WITHOUT INSULATION
CRES FOIL, 0.016 IN (0.40 mm) THICKNESS
Thermal Blanket - IFS (Right Hand) - SB 78-B836

Figure 3 (Sheet i of 3)
EFFECTIVITY: TRENT
Page 10
Sept.15/96
1 RB.211 TRENT
m(H? STRUCTURAL REPAIR
MANUAL
AREA WlTH INSULATION, 1 IN SQUARE QUILTED, MIN - K

22 AREA WlTH INSULATION , REFRACTORY , L 0 - CON

THICKNESS : 0.1 7 IN (4.3 mm)
m CRES FOIL, 0.01 IN (0.25 mm) THICKNESS MORE
EDGE AREA WITHOUT INSULATION
CRES FOIL, 0.016 IN (0.40 mm) THICKNESS

D4692C
-
Thermal B l a n k e t -
IFS ( L e f t Hand) SB 78-B836
F i g u r e 3 ( S h e e t 2 of 3)
EFFECTIVITY : TRENT
Page 11
Sept.15/96
RB.211 TRENT
m@> STRUCTURAL REPAIR
MANUAL
TYPICAL SECTION A TYPICAL SECTION B
10 22
13 12 14
TYPICAL SECTION C

1 to 9 THERMAL BLANKET INSULATION
10 COVER EXTERIOR, CRES 0.02 TYPE 321, AMS 5510
11 ADHESIVE FILM 0.003 POLYlMlDE AF-15
12 COVER INTERIOR, GLASS 0.001 POLYlMlDE TYPE 200
13 TAPE, GLASS P 212, MIL-1-19166
14 CLOTH,GLASS 108, MIL-Y-1140
15 INSULATION PLATE 0.01 TYPE 321, AMS 5510
16 PRECOOLER SUPPORT 118" THK 10 PCF MRS
BRACKET COVER
17 PRECOOLER SUPPORT 118" THK 10 PCF MRS
BRACKET COVER
18 LATCH BRACKET COVER 114 THK 8 PCF MRS
19 HOLD OPEN ROD BRACKET 118" THK 10 PCF MRS
COVER
20 LATCH BRACKET COVER 318" THK 8 PCF
21 HOLD OPEN ROD BRACKET 118" THK 10 PCF MRS
COVER
22 LATCH PIN BRACKET 318" THK 8 PCF
23 LATCH PIN BRACKET 318" THK 8 PCF
Thermal Bianket - IFS (Right Hand and Left Hand) - SB 78-B836

EFFECTIVITY : TRENT
Page 12
Sept.15196
Mm e )
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
EQUIVALENCE
ITEM DESCRIPTION GAGE MATERIAL
MATERIAL
1 ACIAC DUCT 0.047 TU2 BSTAS2
2 JOGGLED SHEET 0.047 TU2 BSTAS2
3 THERMAL 0.4 INSULATION
BLANKET
Air Cooler/Air Cooled Duct

Figure 4
EFFECTIVITY: TRENT
Page 13
July 1/95
[ RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
EQUIVALENCE
ITEM DESCRIPTION GAGE MATERIAL
MATERIAL
1 T.C.C. DUCT 0.059 TU2 BSTAS2
2 JOGGLED SHEET 0.059 TU2 BSTAS2
3 STIFFENER 0.059 TU2 BSTAS2
Turbine Case Cooling Duct

Figure 5
EFFECTIVITY: TRENT
Page 14
July 1/95
THRUST REVERSER – INNER FIXED STRUCTURE – ALLOWABLE DAMAGE
1. Introduction
This section contains the allowable and repairable limits for the
thrust reverser inner fixed structure.
Damage which is found to be greater than the allowable damage

limits must be repaired in accordance with the procedures detailed
in the following Repair Section, Page Block 201. Components not
included in this repair Chapter-Section are not repairable and must
be replaced if damaged.
A component with damage more than the repairable damage limits must
be replaced by a new one. It must not be repaired without a Rolls-
Royce or Hurel Dubois technical statement.
2. Zones
Each of the individual components is divided into zones. The zones

which are affected by the different types of allowable or
repairable damage are identified in the figures and tables which
follow.
A. The allowable and repairable damage zones for these components

are:
M Monolithic area
S Sandwich area
A Acoustic area
B Internal side area
E Edge area, attaching area, intermediate monolithic/sandwich
area
TB Thermal blanket
D Duct
EFFECTIVITY: TRENT
54-30-30
Page 101
A. Allowable damage
Allowable damage limits are intended to permit an operator to

service, or be rejected for repair. Allowable damage must not
compromise the structural integrity of the component, which
could affect the strength or fatigue life. The types of
allowable damage permitted are defined and, if applicable,
brief descriptions are given of the clean-up procedures needed
either to prevent propagation of the damage or to improve the
appearance and aerodynamic smoothness of the damaged part.
Damage limits assume that exposed edges do not extend above the
skin surface. Any damage that does should be trimmed to remove
or feather the protrusion. Holes or cracks in pressurized
panel zones must be sealed using the appropriate tape.
Allowable damage is classified as either unlimited usage or

time limited:
(1) Unlimited usage damage is defined as minor damage which

does not affect the structural integrity or functional
capability of the component. No repairs are necessary,
other than cosmetic, over the aircraft design life.
(2) Time limited damage is defined as minor damage which does

not affect the structural integrity of the component in
normal service use, but could reduce the design life of
the component. In this case, damage must be repaired by
next Aircraft C check. The location and size of the
damage should be noted and checked at suitable intervals
to monitor that the damage has not grown beyond the time
NOTE:1. When two damages are close, the minimum distance

to determine if it is one or two defects is
determined as follows:
If the distance between the two damages is

greater than the dimension of the biggest damage,
then the two damages are distinct.
If the distance between damages is smaller than

the dimension of the biggest damage, then the
defect is unique.
EFFECTIVITY: TRENT
54-30-30
Page 102
2. If a damage extends over two zones, you must
consider the smallest allowable damage limits.
3. When two damages are close, the minimum distance

for separation shall be determined by choosing
the greatest distance given in the ‘requirements’
column for each damage.
Repairable damage limits are intended to permit an operator to

determine whether a damaged nacelle component can be repaired
or must be rejected. The operator must follow the section
organization to accomplish the repair satisfactorily.
C. Damage Types
Damage types permitted on this component are listed below.

not the surface finishes, such as paint.
(1) Abrasion – an abrasion is an area of damage which results

in a cross sectional area change caused by scuffing.
rubbing, or other surface erosion. An abrasion usually
appears rough and irregular.
(2) Gouge – a gouge is a damage area of any size which results

in a cross sectional area change. It is usually caused by
contact with a sharp object which produces a continuous,
sharp or smooth channel-like groove in the material.
(3) Nick – a nick is a local gouge with sharp edges.
(4) Scratch – a scratch is a line of damage in the material

and results in a cross sectional area change. Normally
caused by a very sharp object.
(5) Crack – a crack is a partial fracture or complete break in

the material and produces a most significant cross
sectional area change. Normally appearing as an irregular
line.
(6) Dent – a dent is a depressed area of damage which, with

metal skins would not cause cross sectional area change.
On core filled laminates, it may cause crushing of the
core cells. Area boundaries are smooth and it is usually
caused by contact with a smooth contoured object.
(7) Hole – a hole is a complete penetration of the material.
EFFECTIVITY: TRENT
54-30-30
Page 103
(8) Disbond – a disbond is the separation of the face skin
(9) Delamination – a delamination is the separation of two

laminate plies or faying surfaces.
4. Identify and Measure the Damge Extent
A. Do an ultrasonic inspection to determine the damage extent,

then mark out the damage extent on the part.
C. Measure the damge.
EFFECTIVITY: TRENT
54-30-30
Page 104
--------------------------------------------------------------------
ZONE DAMAGE REQUIREMENTS ALLOWABLE LIMITS INSPECTION
INTERVALS
--------------------------------------------------------------------
All Abrasion Confined to surface Over an
Zones resin unlimited area
except
TB1,
TB2,
TB3
TB4,
TB5,
TB6,
E1
TB1, Scratch, Not allowed None

TB2, Gouge
TBS,
TB4,
TB5,
TB6,
E1
E1 Dent Not allowed None
TB1, Dent Depth <= 5,1 mm

(0.2 in.)

(0.122 in.)
TB3, Dent Depth <= 7 mm

(0.275 in.)

(0.224 in.)
TB5, Dent Depth <= 3 mm

(0.118 in.)

(0.098 in.)
E1 Hole, Not allowed None

Nick
EFFECTIVITY: TRENT
54-30-30
Page 105
-----------------------------------------------------------------------
INTERVALS
-----------------------------------------------------------------------
TB1, Hole Not allowed None
TB2, (core visible)
TBS,
TB4,
TB5,
TB6,
E1
D1, Crack In radius and Length <= 48,3 mm

D2, flat areas Pre (1.90 in.)
D3 SB78-B989 Post
SB78-B705.
Stop drill
crack
D4 Crack In radius and Length <= 8.4 mm

flat areas Post (0.33 in.)
SB78-B989
Stop drill
crack
D5 Crack In radius and Length <= 18.8mm

SB78-B989
Stop drill
crack

SB78-B989
Stop drill
crack

SB78-B989
Stop drill
crack

flat areas Post (1 0 in.)
SB78-B989
Stop drill
crack
EFFECTIVITY: TRENT
54-30-30
Page 106
-----------------------------------------------------------------------
INTERVALS
-----------------------------------------------------------------------
D9 Crack In radius and flat Length <= 23.9 mm
areas Post SB78-B989 (0.94 in.)
Stop drill crack
TB1, Thermal Not allowed None

TB2, coloration
TBS,
TB4,
TB5,
TB6,
E1
E, Scratch, Confined to the Depth <= 0.28 mm

E2, Gouge first outer ply. (0.11 in)
S1, No nearer than 5
S2, times its size to
A1, other unrepaired
A2, damage or rivet line
B1,
B2
E, Dent No nearer than 5 Depth <= 2.5 mm

E2, times its size to (0.1 in)
S1, other unrepaired
S2, damage or rivet line
A1,
A2,
B1,
B2
E, Hole, No nearer than 5 Diameter or

E2, Nick times its size to length <= 20 mm
S1, other unrepaired (0.79 in.
S2, damage or rivet Depth: confined ‘A’
A1, line. to outer skin check
A2, Seal hole with speed for
B1, tape sealed
B2 hole
EFFECTIVITY: TRENT
54-30-30
Page 107
-----------------------------------------------------------------------
INTERVALS
-----------------------------------------------------------------------
E, Delamination, No nearer than 5 Diameter or length
E2, Disbond times its size to <= 30 mm
S1, other unrepaired Depth: Confined to
S2, damage or rivet outer skin
A1, line
A2,
B1,
B2
EFFECTIVITY: TRENT
54-30-30
Page 108
-----------------------------------------------------------------------
LIMITS PROCEDURE
-----------------------------------------------------------------------
TB1, Scratch, Distance from other Size <= 140 mm FRSX065
TB2, Gouge, damage or panel edge x 290 mm (5.5 54-30-30
TBS, Hole, must be greater than in. x 11.4 in.) REPAIR 11
TB4, Abrasion 20 mm. (0.8 mm.)
TB5,
TB6
TB1, Scratch, Distance from other Diameter <=20 FRSX064

TB2, Gouge, damage or panel edge mm (0.8 in.) 54-30-30
TBS, Hole, must be greater than REPAIR 10
TB4, Abrasion 20 mm. (0.8 mm.)
TB5,
TB6
E Dent Distance from other Depth <2.5 mm FRSX054

damage or rivet line (0.1 in.) 54-30-00
must be greater than REPAIR 09
5 times its size
E Delamination Distance from other Diameter <= 30 FRSX054

damage or rivet line mm (1.18 in.) 54-30-00
5 times its size
E Hole Distance from other Diameter <= 28 FRSX055

5 times its size
E2 Dent, Distance from other Depth <= 48 mm FRSX054

Delamination damage or rivet line (1.89 mm) 54-30-00
5 times its size
E2 Hole Distance from other Depth <= 48 mm FRSX055

damage or rivet line (1.89 mm) 54-30-00
5 times its size
EFFECTIVITY: TRENT
54-30-30
Page 109
-----------------------------------------------------------------------
LIMITS PROCEDURE
-----------------------------------------------------------------------
B1 Disbond Distance from other Depth <= 30 mm FRSX047
must be greater than 5 REPAIR 03
times its size. Distance
from other damage or
rivet line must be
greater than 100 mm
(3.96 in.) – core
undamaged
B1 Dent Distance from other Depth <= 2.5 FRSX047

times its size. – core
undamaged

damaged
B1 Hole Distance from other Depth <= 20 mm FRSX049

times its size. –inner
skin damaged
< dia 30 mm (1.2)
B1 Delamination Distance from other Diameter <= 30 FRSX045

times its size

times its size – core
undamaged
EFFECTIVITY: TRENT
54-30-30
Page 110
-----------------------------------------------------------------------
LIMITS PROCEDURE
-----------------------------------------------------------------------

times its size.
Distance from other
must be greater than
89 mm (3.50 in.) –
core damaged
B2 Disbond Distance from other Depth <= 30 mm FRSX047

undamaged
B2 Hole Distance from other Depth <=20 mm FRSX049

skin damage
< dia 30 mm (1.2 in)
B2 Delamination Distance from other Diameter <= 30 FRSX045

times its size
S1 Dent, Distance from other Depth <= 46 mm FRSX047

Disbond damage or rivet line (1.80 in.) 54-30-00
undamaged
S1 Dent Distance from other Depth <= 46 mm FRSX048

damaged
EFFECTIVITY: TRENT
54-30-30
Page 111
-----------------------------------------------------------------------
LIMITS PROCEDURE
-----------------------------------------------------------------------
S1 Hole Distance from other Depth <= 46 mm FRSX049

skin damage
< dia 30 mm (1.2 in.)
Depth <= 46 mm FRSX050
S1 Hole Distance from other (1.80 in.) 54-30-00
damage or rivet line REPAIR 06
must be greater than 5
skin damage
< dia 30 mm (1.2 in.)
S1 Delamination Distance from other Depth <= 46 mm FRSX045

times its size
S2 Dent, Distance from other Diameter <=56 FRSX047

Disbond damage or rivet line mm (2.20 in.) 54-30-00
undamaged
S2 Dent Distance from other Diameter <=56 FRSX048

damaged
S2 Hole Distance from other Diameter <=56 FRSX049

skin damage
< dia 30 mm (1.2 in.)
EFFECTIVITY: TRENT
54-30-30
Page 112
-----------------------------------------------------------------------
LIMITS PROCEDURE
-----------------------------------------------------------------------
S2 Hole Distance from other Diameter <=56 FRSX050

skin damage
< dia 30 mm (1.2 in.)
S2 Delamination Distance from other Diameter <=56 FRSX045

times its size
A1 Dent, Distance from other Diameter <=61 FRSX047

undamaged
A1 Dent Distance from other Diameter <=61 FRSX048

damaged
A1 Hole Distance from other Diameter <=61 FRSX049

skin damage
< dia 30 mm (1.2 in.)

skin damage
< dia 30 mm (1.2 in.)
EFFECTIVITY: TRENT
54-30-30
Page 113
-----------------------------------------------------------------------
LIMITS PROCEDURE
-----------------------------------------------------------------------
A1 Delamination Distance from other Diameter <=61 FRSX045
5 times its size
A2 Dent, Distance from other Diameter <=69 FRSX047

5 times its size –
core undamaged
A2 Dent Distance from other Diameter <=69 FRSX048

5 times its size –
core damaged

5 times its size. –
inner skin damage
< dia 30 mm (1.2
in.)

5 times its size. –
inner skin damage
< dia 30 mm (1.2
A2 Delamination Distance from other Diameter <=69 FRSX050

5 times its size
EFFECTIVITY: TRENT
54-30-30
Page 114
-----------------------------------------------------------------------
LIMITS PROCEDURE
-----------------------------------------------------------------------
D1 Crack In radius and flat areas. Repair
D2 Pre SB78-B819 within 25
D3 Post SB-B705 hours if
crack
length >
48.3 mm
(1.90 in.)
D4 Crack In radius and flat areas Length <=8.4 Reject if

Post SB78-B819 mm(0.33 in.) length >
8.4mm (0.33
in.)

18.8mm
(0.74 in.)

21.1mm
(0.83 in.)

50.8mm
(2.0in.)

25.4mm
(1.0in.)

23.9mm
(0.94 in.)
EFFECTIVITY: TRENT
54-30-30
Page 115
-----------------------------------------------------------------------
R ZONE DAMAGE REQUIREMENTS REPAIRABLE REPAIR
R LIMITS PROCEDURE
R -----------------------------------------------------------------------
R TCC Nicks, In radius and flat areas Less than Refer to
R DUCT Galling & Post SB78-B819 0.25mm 54-02-02
R Scratches (0.010in.) in Repair
R depth minor
R damage
R metallic
R surfaces.
R
R More than FRSX095
R 0.25mm 54-30-30
R (0.010in.) in REPAIR 03
R depth
R
R TCC Dents In radius and flat areas More than FRSX095
R DUCT Post SB78-B819 1.25mm 54-30-30
R (0.050in.) or REPAIR 03
R if it is
R sharp at the
R bottom
R
R TCC Cracked In radius and flat areas No Limit FRSX095
R DUCT Post SB78-B819 54-30-30
R REPAIR 03
EFFECTIVITY: TRENT
54-30-30
Page 116
Thrust Reverser – Inner Fixed Structure – Allowable Damage Limits
EFFECTIVITY: TRENT
54-30-30
Page 117
Precooler Duct – Allowable Damage Limits
EFFECTIVITY: TRENT
54-30-30
Page 118
Precooler Duct – Allowable Damage Limits
EFFECTIVITY: TRENT
54-30-30
Page 119
Thermal Blanket – Inner Fixed Structure (RH) – Allowable Damage
Limits
Figuire 103 (Sheet 1 of 2)
EFFECTIVITY: TRENT
54-30-30
Page 120
Thermal Blanket – Inner Fixed Structure (RH) – Allowable Damage
Limits
Figuire 103 (Sheet 2 of 2)
EFFECTIVITY: TRENT
54-30-30
Page 121
p
;'..l ,;'
"" RB211 TRENT

MANUAL
STRUCTURAL REPAIR
THRUST REVERSER - INNER FIXED STRUCTURE
1 REPLACE RVT INSERT

(FRS X088)
L ATTACHMENT - STOWAGE BRACKET

(FRS X086)
3 REPLACE TCC DUCT

(FRS X095)
4 PRECOOLER DUCT (PRE SB78-B819)

(FRS X063)
5 PRECOOLER DUCT (SB78-B819)

(FRS X100)
6 PYLON SEAL REAR SECTION

(FRS X093)
7 BUMPER 1 THERMAL PROTECTION

(FRS X096)
8 JOGGLE PLATE - PRECOOLER DUCT

(FRS X082)
9 IFS SEAL
(FRS X094)
10 REPAIR THERMAL BLANKET - DAMAGE LESS T& 20 MM MM.

(FRS X064) DIAMETER
11 REPAIR THERMAL BLANKET - DAMAGE MORE THAN 20MM

(FRS X065) DIAMETER
12 PATCH REPAIR OF TURBINE CASE COOLING (TCC) DUCT

(FRS X101)
13 REPLACE THE PRE-COOLER LINK BRACKETS FITTED ON THE

(FRS X102) INNER FIXED STRUCTURE (IFS)
14 REPLACE THE SUPPORT ROD BRACKETS ON THE PRE-COOLER

(FRSX107) DUCT
15 POST SB 78-B819, PRE SB 78-E343: REPAIR OF REAR

(FRS X109) CORNERS ON THE PRE-COOLER DUCT I I
. .
EFFECTIV1TY:TRENT .., .:. . LIST OF REPAIRS
54-30-30
Page 201
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
R 16 POST SB 78-B819: REPAIR OF CRACKED FRONT CORNERS

R (FRS X062) OF THE PRE-COOLER DUCT
LIST OF REPAIRS
54-30-30
Page 202
REPAIR NO.1
THRUST REVERSER
REPLACE THE PIVOTING DOOR RVT INSERT
1. General
This repair provides the instructions to replace a damaged

RVT insert by a new one. This procedure is applicable to all
the thrust reverser pivoting doors.
This repair is the same as FRSX088.
-------------------------------------------------------------------
-------------------------------------------------------------------
AMM TASK 70-20-01-100-801 Maintenance Processes – Stripping and
cleaning
AMM TASK 78-31-12-000-801 Removal of the RVTs
AMM TASK 78-31-12-400-801 Installation of the RVTs
AMM TASK 78-31-12-820-801 Adjustment of the RVTs
3. Equipment and Manual
- E-Z out type tool
- THD1032L installation tool
- Hammer, drill, screw driver
-----------------------------------------------------------------
-----------------------------------------------------------------
OMat 150 Acetone
OMat 1/40 Isopropyl Alcohol (Alternative)
OMat 1/257 Cleaning Solvent (Alternative)
OMat 2/101 Lint free cloth
OMat 2/114 Lint free gloves
OMat 8/176 Mastinox D40, sealant
54-30-30
Page 201
C. Repair parts
-----------------------------------------------------------------
-----------------------------------------------------------------
R KNHL1032J Insert
4. Remove the RVT
A. Remove the access panel.
B. Remove the RVT and the mounting plate from the fitting on the
lateral beam. Refer to AMM TASKS 78-34-12-000-801 and 78-34-12-
820-801.
5. Procedure (Ref. Figure 201)
A. Remove the damaged RVT insert
(1) Use a standard drill bit of 0.28 ± 0.004 in. (7.1 ± 0.1mm)
to remove insert material between keys to a depth of 0.125
± 0.004 in. (3.2 ± 0.1 mm).
(2) Push keys inward and break off.
(3) Unscrew the insert using the E-Z out type tool.

(a) Use this cloth to clean the area that you repair.
(b) You must discard this dirty cloth.
(c) Use a clean cloth each time you clean a new area
that you repair.
(d) Contamination of the bulk liquid is not permitted.

54-30-30
Page 202
R (e) Do not let the liquid touch the cloth and return to
R bulk liquid container.
R (2) Clean the repair area with OMat 150-Acetone, OMat 1/40-
R Isopropyl Alcohol or OMat 1/257-Cleaning solvent and OMat
R 2/101-Cloth. Wipe the area dry before the solvent
R evaporates.
C. Install the new insert
R (1) Apply OMat 8/176 sealant on the external thread of the

insert.
(2) Screw the insert onto the threaded mandrel of the THD1032L
installation tool. Screw the insert into the fitting hole
to the correct depth below the surface and key locations.
CAUTION: MAKE SURE THAT THE INSERT IS INSTALLED TO THE CORRECT

DEPTH, WITH THE KEYS IN THE CORRECT POSITION.
(3) Use the tool to install the insert to a depth of 0.5 ±

0.25 MM (0.02 ± 0.01 in ) below the surface. Set the key
half-way between the marks made by the previous keys.
(3) Remove and reverse the installation tool. Tap down the
keys using the installation tool and a hammer.
(4) Clean the repair area
R WARNING: SOLVENT IS CLASSIFIED AS A HAZARDOUS MATERIAL THAT

R CAN CAUSE INJURY OR ILLNESS IF NOT USED CORRECTLY.
R BEFORE YOU USE THIS PRODUCT, CAREFULLY READ THE
R APPLICABLE MATERIAL SAFETY DATA SHEET AND OBEY ALL
R THE SPECIFIED HEALTH AND SAFETY PRECAUTIONS.
R (a) Make a clean, dry, lint free cloth (OMat 2/101)

R moist with the degreasing fluid.
R 1) Use this cloth to clean the area that you

R repair.
R 2) You must discard this dirty cloth.
R 3) Use a clean cloth each time you clean a new area

R that you repair.

54-30-30
Page 203
R 4) Contamination of the bulk liquid is not
R permitted.
R 5) Do not let the liquid touch the cloth and return

R to bulk liquid container.
R (b) Clean the repair area with OMat 150-Acetone, OMat

R 1/40-Isopropyl Alcohol or OMat 1/257-Cleaning
R solvent and OMat 2/101-Cloth. Wipe the area dry
R D. Install the RVT and the mounting plate
R (1) Refer to AMM TASK 78-31-12-400-801 to install the RVT and

R the mounting plate onto their fitting on the lateral beam.
R (2) Adjust the RVT. Refer to AMM TASK 78-31-12-820-801.
R (3) Install the access panel.
R 6. Inspect the repair
R A Make sure that the new insert keys are at half the angle
R between the marks that were made by the old key inserts.
R Make sure that the insert is 0.03 to 0.01 inches (0.75 to 0.25
R mm) below the fitting surface.
R 7. Close all the doors
R A. Refer to AMM TASK 78-30-00-410-801.

54-30-30
Page 204
Replace the pivot door RVT insert
Figure 201

54-30-30
Page 205
H RB211 TRENT
STRUCTUAL
MANUAL REPAIR
REPAIR N0.2
ATTACHMENT - STOWAGE BRACKET - HOLD OPEN ROD
1. General
A. This repair gives instructions to fill the box section with

resin adhesive and replace the attachment rivets with bolts.
.......................................................................
.......................................................................
SRM 54-30-00,Repair No.3 Repair Carbon Composite Skin, Sandwich Area
AMM TASK 78-30-00-010-803 Open the Thrust Reverser
AMM TASK 78-30-00-410-803 Close the Thrust Reverser
EM TASK 78-33-00-300-XXX FRSX086, Trent Engine Manual
Heat blanket
.......................................................................
.......................................................................
OMat 262A MARKER
OMat 8/173 SEALANT
OMat 8/192 ADHESIVE
C. Repair Parts
.......................................................................
- 91B426-00 Repair Kit includes:
201/4 HST3 15CE8 Bol t
5 91B221-00 CupwaShe r
6 NAS1587-4 Washer
7 HST97DU8 Nut
REPAIR N0.2
54-30-30
Page 201
RB211 TRENT
STRUCTUAL REPAIR
m MANUAL
4. Get Access
A. Open the Thrust Reverser (Ref AMM TASK 78-30-00-010-803)
B. Release the nuts (2) and remove the fairing (1) .

5. Remove the Stowaue Bracket
A. Drill out the rivets (3) (Ref SRM 54-02-10).
B. Remove the stowage bracket from the inner fixed structure (IFS).
C. With the OMat 2621 MARKER, extend the vertical and horizontal
centrelines of the two holes outside the repair area. This will
give the location of the holes after the repair is done.
D. With the OMat 26214 MARKER, draw the location of the box inserts.
E. If the skin of the IFS is damaged, you must step-sand the skin
to remove the damage (Ref SRM 54-30-00, Repair No.3).
6. Fill the Box Inserts
A. Refer to Figure 201, drill a 2 nun (0.08 in) diameter hole in

each of the box inserts.
B. Mix Parts A and B of OMat 8/192 ADHESIVE in the ratio 5:l

(by volume) .
C. Use a syringe to inject the adhesive into the box inserts.
D. Cure the adhesive for 7 hours at 23 k 5 deg C (73 f 9 deg F),

followed by 2 hours at 93 +
5 deg C (200 f 9 deg F). Use the
heat blanket.
E. Make the cured adhesive smooth and level with the OMat 5/35
WATERPROOF SILICON CARBIDE.
F. If necessary, repair the IFS skin that you step-sanded at 5.E

(Ref SRM 54-30-00, Repair No.3).
7. Drill the Bolt Holes
A. Use the marks you made at 5.C to find the centrelines of the
bolt holes. Make sure the hole centre distance agrees with the
stowage bracket.
54-30-30
Page 202
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
B. Drill 2 mm (0.08 in) diameter pilot holes throught the IFS skin
and the box structure. Then counter-drill the bolt holes to a
final diameter of 6,34 to 6,44 mm (0.249 to 0.253 in) .
C. Countersink the bolt holes to 130 degrees (inclusive angle).
D. Remove sharp edges from both ends of the bolt holes.
Install the Stowase Bracket

THE APPLICABLE MATERIAL SAFETY DATA SHEET.OBEY ALL THE
A. Clean the stowage bracket and the repair area with OMat 2/101
LINT-FREE CLOTH soaked with OMat 135 MEK. Dry the surfaces with
a new piece of the cloth before the MEK evaporates.
B. Apply a thin layer of OMat 8/177 SEALING COMPOUND to the mating

face of the stowage bracket.
C. Put the stowage bracket in position on the IFS. Wet-install the

bolts (4), cupwashers (51, washers (6) and nuts (7) with
OMat 8/176 SEALING COMPOUND. Torque the nuts (7) to 1,8 Nm
(16 lbf in) .
D. Apply a bead of OMat 8/173 SEALANT around the stowage bracket.
E. Install the fairing (1). Torque the nuts (2) to 1,8 Nrn
(16 lbf in).
F. Apply a bead of OMat 8/173 SEALANT around the fairing.
B. Use the OMat 262A MARKER to write FRSX086 adjacent to the part
number of the IFS.
Close Access
A. Close the Thrust Reverser (AMM TASK 78-30-00-410-803).
REPAIR N0.2
54-30-30
Page 203
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
VIEW F
I
I TROU s 2 mm
HOLD OPEN
ROD
BOX INSERT
SECTION A
HOLD OPEN ROD

STOWAGE \
Repair the Stowage Bracket Attachment

Figure 201, Sheet 1
REPAIR N0.2
54-30-30
Page 204
Printed in G r e a t B r i t a i n
July 1/00
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
STOWAGE
BRACKET
I
SECTION A
SEALANT
OMat 81173
RESIN
OMat 811 92
Repair the Stowage Bracket Attachment

Figure 201, Sheet 2
REPAIR N0.2
54-30-30
Page 205
REPAIR NO 03 (FRSX095)
THRUST REVERSER – INNER FIXED STRUCTURE
REPLACE THE TCC DUCT
1. General
R
A. This repair gives instructions to replace an
R
unserviceable Turbine Case Cooling (TCC) Duct. The duct
R
is riveted to the Inner Fixed Structure (IFS).
R
B. The Fig/Item numbers referred to in this procedure agree
R
with those used in the Power Plant Illustrated Parts
R
Catalogue (PPIPC) Chapter Section 78-33-13.
R
C. It is permissible to replace the pre SB78-G064 standard
R
of TCC Duct – Part No. 91B782-00 with the post SB78-G064
R
standard of TCC Duct – Part No. 91B782-01. If this is
R
done then the Service Bulletin number must be identified
R
on the modification plate on completion of this repair.
R
R
SRM 54-02-10 Fasteners –
R
R
AMM 70-20-01-100-802 Non Aqueous liquid degrease

R
R A. Standard Equipment
R Drills and drilling equipment
R Non-metallic scraper
R Hand rivet gun
R Dividers
R Gripper pins
R REFERENCE DESIGNATION
R OMat 872A Silicone compound
R OMat 8/173 Sealant
R OMat 262 Marker
R OMat 2/101 Lint-free cloth
54-30-30
Page 201
Jun 10/09
C. Repair Parts
R FIG/ITEM PART NO. IDENTIFICATION QTY

R 02/705 91B782-00 Pre SB78-G604
R TCC Duct
R (includes Joggle 1
R Plate)
R (item 1)
R 02/705 91B782-01 Post SB78-G604
R (alternative) TCC Duct
R (includes Joggle 1
R Plate)
R (item 1)
R 02/707 NAS1921M06S04 Rivet (item 2) 32
R 02/709 NAS1921M06S05 Rivet (item 3) 7
R 02/710 AN960C9 Washer (item 4) 7
R 02/720 HST97DUWU6 Collar (item 5) 16
R 02/715 91B276-00 Seal (item 6) 1
R 02/7125 HST10-6-3 Screw (item 7) 16
4. Remove the Damaged TCC Duct (Ref. Figures 201 and 202)
R A. Remove and discard the collars (5) and screws (7) that
R attach the seal (6) to the duct (1). Refer to SRM 54-02-
R 10. Keep the screws for re-installation if serviceable but
R discard the collars.
R B. Remove and keep the seal (6) if it is not damaged.

R
R C. Before you remove the duct, record its position on the
R IFS. Use dividers to measure these dimensions:
R - L1 between points A1 and B1

R D. Use a 3,20mm (0.126 in.) diameter drill bit to drill out

R the rivets (2) and (3). Refer to SRM 54-02-10. Remove the
R washers (4)
R E. Lift the thermal blanket as necessary and remove the duct

R (1).
R F. Clean the repair area on the IFS. Refer to AMM

R 70-20-01-100-802. Use a non-metallic scraper to remove
R any remaining sealant from the repair area.
54-30-30
Page 202
R Jun 10/09
5. Prepare the new TCC Duct (Ref. Figures 201 and 202)
A. Use points B1 and B2 on the removed duct plus the

dimensions measured in step 4.C. With a 2,50mm (0.010 in)
diameter drill bit, drill two pilot holes A1 and A2 in
the new joggle plate.
54-30-30
Page 203
Jun 10/09
R
R
R
R
B. Put the new duct and joggle plate in position on the IFS.
Align the pilot holes A1 and A2 with the two related
R
holes on the IFS. Make sure there is an equal distance C1
R
at each side of the duct.
R
C. Temporarily attach the new duct and joggle plate to the
R
IFS with gripper pins.
R
D. Use a 2,50mm (0.010 in) diameter drill bit to back-drill
from the IFS to give the position of all the other
R
attachment holes.
R
E. Remove the duct and joggle plate from the IFS
R
R
F. Use a 4,80mm (0.189 in.) diameter drill bit to enlarge
R
the rivet holes to their final diameter. Remove all sharp
edges.
R
G. Clean the repair parts and the mating surfaces. Refer to
AMM 70-20-01-100-802. Use OMat 2/101 LINT-FREE cloth to
R
dry the surfaces before the solvent evaporates.
R
R
6. Install the TCC Duct (Ref Figure 201)
R
A. Apply a thin layer of OMat 8/173 SEALANT to the mating
R
surfaces of the IFS, duct and joggle plate.
R
B. Put the duct and joggle plate in position on the IFS. Wet
install the rivets (2) with OMat 8/173 SEALANT.
R
R
C. Put the thermal blanket and blanket support in position.
Wet install the rivets (3) and washers (4) with OMat
R
8/173 SEALANT.
R
R
D. Apply a bead of OMat 872A SILICONE COMPOUND all around
R
the edge of the thermal blanket support.
E. Put the seal (6) in position and attach it to the duct

(1) with screws (7) and collars (5). Torque the collars
R
until they shear.
F. Cure the sealants for 24 hours at 25 deg C (77deg F).

R
R
R
7. Inspection
R
R
A. Do a visual inspection to make sure the repair is
R
satisfactory.
R
54-30-30
Page 204
Jun 10/09
R
B. Use a permanent marker of a contrasting colour to write
FRSX095 adjacent to the part number on the IFS. If a pre
SB78-G064 TCC Duct – Part No. 91B782-00 is replaced with
a post SB78-G064 TCC Duct – Part No. 91B782-01 identify
the Service Bulletin No. on the modification
identification plate.
54-30-30
Page 205
Jun 10/09
Replace the TCC Duct
Figure 201
R
54-30-30
Page 206
Jun 10/09
Figure 202
54-30-30
Page 207
Jun 10/09
Figure 202
54-30-30
Page 208
Jun 10/09
p R8211 TRENT
MANUAL
STRUCTUAL REPAIR
REPAIR NO. 4
REPAIR OF PRECOOLER DUCT REAR SECTION (PRE SB78-B8191
1. General
A. This procedure gives instructions to (1) stop-drill cracks,

and (2) rivet a pre-formed patch to the rear section of the
steel precooler duct (Pre SB78-B819).
B. The maximum permitted length of a crack is 60 mm (2.36 in).
C. Small and large patches are available to cover different areas

of damage. Each patch is made from two parts, which must be
welded together off-wing.
D. A small patch, installed before and now cracked,can be replaced

by a new small or large patch as applicable.
NOTE: You can use a small patch if it overlaps the crack to

give a minimum edge distance of 30 mm (1.18 in). If you
cannot get this edge distance, use a large patch.
E. This repair is the same as FRS X063.
.......................................................................
.......................................................................
70-20-02-230-803 Fluorescent Penetrant Inspection,Trent AMM
70-00-00-300-409 Argonarc Welding Repairs,Overhaul Processes
78-33-13-300-XXX FRS X063,Trent Engine Manual
- Pneumatic riveter
- Nose assembly P/N 99-1101,HUCK Manufacturing Company
- Clamps and gripper pins
54-30-30
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Printed i n G r e a t Britain Apr. 1/01
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
...................................................................
...................................................................
OMat 262A TEMPORARY MARKER
OMat 3/172 WELDING W I R E , I n c o n e l 6 2 5
OMat 5/35 S I L I C O N CARBIDE
C. Repair Parts
...................................................................
FIG/ITEM PART NO. DESCRIPTION QTY
...................................................................
HD91B425-01 Repair Kit-Small Patch, i n c l u d e s :
Patch, half lower

Patch, half upper
Patch , half lower
Patch, half upper
Rivet
R i v e t, oversize
Rivet
Rivet, oversize
Rivet
R i v e t, oversize
HD91B424-01 Repair Kit-Large P a t c h , includes:
Patch, half lower

Patch, half upper
Patch, half lower
Patch, half upper
Rivet
R i v e t, oversize
Rivet
R i v e t, oversize
Rivet
R i v e t, oversize
Rivet
Rivet
4. R e m o v e t h e cracked patch (Ref.Figure 201)
A. D r i l l o u t t h e rivets ( 3 ) , ( 4 ) and ( 5 ) ( R e f . SRM 5 4 - 0 2 - 1 0 ) . D o n o t

enlarge t h e r i v e t holes o r cause d a m a g e t o t h e i n n e r s k i n s .
B . R e m o v e and discard t h e d a m a g e d p a t c h .
EFFECTIV1TY:TRENT REPAIR N 0 . 4
54-30-30
Page 202
H
Prepare the Repair Area
RB211 TRENT
MANUAL
STRUCTUAL REPAIR
CAUTION : METHYLETHYLKETONE (MEK) IS CLASSIFIED AS A HAZARDOUS

B. Do a fluorescent penetrant inspection of the precooler duct for

cracks (AMM TASK 70-20-02-230-803) .
(1) If you find cracks, mark their position with the OMat262A
TEMPORARY MARKER.
(2) Measure the length of the crack(s) .
NOTE: The maximum permitted length of crack for this

Repair is 60 mm (2.36 in) .
(3) Stop-drill the crack(s) with a 4mm (0.157 in) diameter

drill. Remove burrs from the holes.
CAUTION: METHYLETHYLKETONE (MEK) IS CLASSIFIED AS A HAZARDOUS

C. Clean the repair area again with OMat 2/101 LINT-FREE CLOTH
soaked with OMat 135 MEK. Dry the surfaces with a new piece of
Patch Selection (Ref-Figures201,202)
A. Find the applicable large or small patch to give the necessary

overlap/edge distance.
NOTE: You can use a small patch if it overlaps the crack(s) to

give a minimum edge distance of 30 mm (1.18 in). If you
cannot get this edge distance you must use a large patch.
EFFECTIVITY:TRENT REPAIR NO. 4
54-30-30
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p RB211 TRENT
MANUAL
STRUCTUAL REPAIR
7. R e m o v e t h e R i v e t s ( l a r g e patch o n l y ) (Ref.Figure 202)
CAUTION: THE MINIMUM DISTANCE BETWEEN A CRACK AND A RIVET MUST

BE 8 MM ( 0 . 3 2 I N ) .
A. If a large repair patch i s t o be i n s t a l l e d , d r i l l o u t t h e f o u r

e x t r a r i v e t s (3) (SRM 5 4 - 0 2 - 1 0 ) . D o n o t enlarge t h e r i v e t holes
o r cause d a m a g e t o t h e i n n e r s k i n s . R e m o v e a l l b u r r s .
CAUTION: METHYLETHYLKETONE (MEK) I S C L A S S I F I E D AS A HAZARDOUS

MATERIAL THAT CAN CAUSE INJURY OR ILLNESS I F NOT USED
CORRECTLY.BEFORE YOU USE T H I S MATERIAL,CAREF'ULLY READ
S P E C I F I E D HEALTH AND SAFETY PRECAUTIONS.
B. C l e a n t h e repair area w i t h OMat 2 / 1 0 1 LINT-FREE CLOTH soaked

w i t h O M a t 135 MEK. D r y t h e surfaces w i t h a n e w piece of t h e
c l o t h before t h e MEK evaporates.
8. P r e p a r e the P a t c h
NOTE: T h e large and s m a l l repair patches each have t w o p a r t s , w h i c h

m u s t be w e l d e d together o f f - w i n g . R e f e r t o para 2 . C f o r t h e
applicable P a r t N u m b e r s .
A. P u t t h e t w o patch halves on t h e precooler duct and hold t h e m i n

p o s i t i o n . M a k e s u r e there i s no clearance b e t w e e n t h e patch
halves and t h e d u c t surface over t h e f u l l contour.
B. If necessary, r e m o v e and l i g h t l y ' p l a n i s h ' t h e patches w i t h

hand t o o l s t o g e t t h e correct shape.
C. P u t the t w o patch halves on t h e precooler d u c t . U s e t h e O M a t 2 6 2 A

TEMPORARY MARKER t o m a r k t h e i r p o s i t i o n s .
D. R e m o v e and heat-treat t h e patch halves a t 1065 deg C ( 1 9 5 0 deg F)

f o r b e t w e e n 5 and 15 m i n u t e s , t o relieve stresses.
E. P u t t h e patch halves on t h e precooler d u c t and a l i g n t h e m w i t h

the m a r k s m a d e i n s t e p 8 . C . A g a i n m a k e sure there i s no clearance
b e t w e e n t h e patch halves and t h e duct surface. If necessary, do
steps 8 . A t o 8 . D again.
F. Away f r o m t h e a i r c r a f t , w e l d t h e t w o patch halves together

(Ref.TASK 70-00-00-300-409):
- W e l d process i s T I G
- W e l d r u n i s 4 mm ( 0 . 1 6 i n ) w i d t h
- U s e O M a t 3 / 1 7 2 WELDING W I R E , I n c o n e l 6 2 5 .
54-30-30
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RB211 TRENT
STRUCTUAL REPAIR
MANUAL
G. Do t h e s p e c i f i e d i n s p e c t i o n of t h e weld, which i s c l a s s i f i e d
as a Group 2 b u t t weld.
H. U s e O M a t 5/35 SILICON CARBIDE t o d r e s s t h e weld bead f l u s h on

t h e mating s i d e .
I. P u t t h e p a t c h i n p o s i t i o n on t h e p r e c o o l e r d u c t . Make s u r e i t
i s f l u s h w i t h t h e d u c t s u r f a c e . L i g h t l y rework i f n e c e s s a r y .
J. Do a f l u o r e s c e n t p e n e t r a n t i n s p e c t i o n of t h e p a t c h f o r c r a c k s
(AMM TASK 70-20-02-230-803). No c r a c k s a r e p e r m i t t e d , reject
t h e p a t c h i f a c r a c k i s found.
9. D r i l l t h e R i v e t Holes (Ref. F i g u r e s 201,202)
NOTE: Final r i v e t hole diameters a r e a s follows:
- 4 , 0 6 t o 4,16 mm (0.160 t o 0.164 i n ) f o r r i v e t s NAS1919M05S02

and NAS1919M05S03
- 4 , 4 6 t o 4 , 5 6 mm (0.176 t o 0.180 i n ) f o r r i v e t s OSMLPM05S02C
and OSMLPMOSS03C.
B. Make a t e m p l a t e t o mark t h e r i v e t h o l e p o s i t i o n s i n t h e r e p a i r
p a t c h . D r i l l 4 mm (0.157 i n ) diameter h o l e s i n t h e t e m p l a t e t o
a g r e e w i t h r i v e t h o l e s ( 3 ) , (4) and (5) i n t h e duct ( R e f e r t o
S t e p s 4 . A and 7.A a b o v e ) . Remove b u r r s from t h e h o l e s .
C. U s e t h e template t o p i l o t - d r i l l the repair patch f o r r i v e t s

I t e m (3) ( 8 h o l e s i n a s m a l l p a t c h , l 2 h o l e s i n a l a r g e p a t c h ) .
D. For a s m a l l p a t c h :
(1) Put t h e p a t c h i n p o s i t i o n on t h e p r e c o o l e r d u c t and h o l d

it w i t h g r i p p e r p i n s .
(2) P i l o t - d r i l l t h e p a t c h f o r r i v e t s ( 4 ) and (5) from t h e

r i v e t holes t h a t a r e i n the duct.
(3) R e l e a s e t h e g r i p p e r p i n s , remove t h e p a t c h from t h e d u c t ,

remove b u r r s from t h e h o l e s .
E. For a l a r g e p a t c h :
(1) U s e t h e template t o p i l o t - d r i l l the patch f o r r i v e t s (4)

and ( 5 ) .
(2) P u t t h e p a t c h i n p o s i t i o n on t h e p r e c o o l e r d u c t and h o l d
it with gripper p i n s .
EFFECTIVITY: TRENT REPAIR NO. 4
54-30-30
Page 205
Printed i n Great B r i t a i n Apr. 1 / 0 1
RB211 TRENT
STRUCTUAL REPAlR
(3) Drill the patch and the duct for rivets (6) and (7). Refer
to Figure 202 and the dimensions that follow:
(a) For rivets Item (6):

- The rivet line is 12 mm (0.47 in) from the edge
of the patch
- The first rivet is 12 mm (0.47 in) from the edge
of the patch
- The distance between the three rivets is 20 nun
(0.8 in) .
(b) For rivets Item (7):

- The rivet line is 12 mm (0.47 in) from the edge
of the patch
- The first rivet is 12 mm (0.47 in) from the edge
of the patch
- The seven rivets are at an equal distance from
each other .
(4) Release the gripper pins, remove the patch from the duct,
remove burrs from the holes.
CAUTION : METHYLETHYLKETONE (MEK) IS CLASSIFIED AS A HAZARDOUS

CORRECTLY.BEFORE YOU USE THIS MATERIAL, CAREFULLY READ
F. Clean the repair area with OMat 2/101 LINT-FREE CLOTH soaked
10. Install the Patch (Ref.Figures 201,202)
CAUTION: SEALING COMPOUND IS CLASSIFIED AS A HAZARDOUS MATERIAL

THAT CAN CAUSE INJURY OR ILLNESS IF NOT USED CORRECTLY.
BEFORE YOU USE THIS MATERIAL,CAREFULLY READ THE
A. Mix the OMat 8/177 SEALING COMPOUND in accordance with the

manufacturer's instructions.(These will include the procedure
to deaerate the mixture in a vacuum).
B. Apply the sealing compound to the mating surface of the patch.
C. Put the patch in position on the precooler duct and hold it

with gripper pins or clamps.
REPAIR NO. 4
Page 206
RB211 TRENT
STRUCTUAL REPAl R
MANUAL
D. Wet-install the rivets with OMat 8/177 SEALING COMPOUND.

Install the rivets from the inner side of the duct. Use a
pneumatic riveter with nose tool P/N 99-1101.
E. Apply a bead of OMat 8/177 SEALING COMPOUND all around the

patch to seal the edges.
F. Cure the sealing compound in accordance with the manufacturer's

instructions. Do not touch the compound before 15 minutes.
11. Inspection
B. Write "FRS X063" adjacent to the duct part number.
REPAIR NO. 4
54-30-30
Page 207
H RB211 TRENT
STRUCTUAL REPAIR
MANUAL
WELDED LINE
PRECOOLER
DUCT
Installation of Small Repair Patch

Figure 201
REPAIR NO. 4
54-30-30
Page 208
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
REPAIR NO. 4
54-30-30
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A p r . 1/01
RB211 TRENT
STRUCTUAL REPAIR
MAWUAL
REPAIR N0.5
THRUST RE3ERSER - INNER FIXED STRUCIpRE
REPAIR OF PRECMlLER DUCT REAR SECTION (SBTB-BB19)
R NOTE: This Repair i s cancelled. Refer t o FRSXIO9 for the ssctxmanded

R Repair Ptocadurs.
REPAIR NO.5
54-30-30
PrLarad in Crcnr Britain
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
REPAIR NO. 6
REPAIR THE REAR SECTION OF THE PYLON SEAL
1. General
A. T h i s procedure gives i n s t r u c t i o n s t o replace a d a m a g e d rear

s e c t i o n of t h e pylon seal. T h e damaged seal i s c u t o u t and
a p r e - f o r m e d repair s e c t i o n bonded i n p o s i t i o n .
B. T h e m a x i m u m l e n g t h of seal d a m a g e t h a t can be repaired by

t h i s procedure i s 265 mm ( 1 0 . 4 4 i n ) .
NOTE: T h e f i n a l cure t i m e f o r the sealant used i n t h i s repair

i s 2 4 hours a t 2 3 deg C ( 7 3 deg F ) and 5 0 percent r e l a t i v e
h u m i d i t y . Make s u r e you have s u f f i c i e n t m a i n t e n a n c e t i m e .
TASK 78-33-11-300-XXX F R S X 0 9 3 , T r e n t E n g i n e Manual
A. Standard E q u i p m e n t
Standard w o r k s h o p t o o l s
Sharp k n i f e
Spatula ( i n c l u d e d i n repair k i t )
.......................................................................
.......................................................................
OMat 1013 TEEPOL
OMat 872D SEALANT, RTV159 ( i n c l u d e d i n repair k i t )
R E P A I R NO. 6
54-30-30
Page 20 1
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
C. Repair Parts
.......................................................................
ITEM PART NO. DESCRIPTION QTY
.......................................................................
R e p a i r k i t P/N 4-21-783REP1 f o r l e f t hand C - d u c t i n c l u d e s :
1 4-21-784REP1 Seal, LH R e p a i r S e c t i o n 1
R e p a i r k i t P/N 4 - 2 1 - 7 8 3 R E P 2 f o r r i g h t hand C - d u c t includes:
2 4-21-784REP2 Seal, RH R e p a i r S e c t i o n 1
4. P r o c e d u r e ( R e f Figure 2 0 1 )
A. U s e the repair s e c t i o n as a t e m p l a t e t o m a r k t h e c u t l i n e on
t h e d a m a g e d seal.
NOTE: T h e l e n g t h of seal r e m o v e d m u s t be t h e s a m e as t h e l e n g t h
of t h e repair s e c t i o n .
B. W i t h a sharp k n i f e , c u t o u t and discard t h e d a m a g e d s e a l . Make

s u r e you c u t t h e end a t a r i g h t angle.
C. L o o s e n and l i f t 4 . 0 i n ( 1 0 0 nun) of t h e r e m a i n i n g seal a w a y f r o m

t h e seal support.
D. W i t h a s p a t u l a , r e m o v e r e m a i n i n g sealant f r o m t h e loosened seal

and t h e seal support.
WARNING : METHYLETHYLKETONE (MEK) I S C L A S S I F I E D A S A HAZARDOUS

MATERIAL THAT CAN CAUSE INJURY OR I L L N E S S I F NOT USED
CORRECTLY. BEFORE YOU USE T H I S MATERIAL, CAREFULLY READ
THE S P E C I F I E D HEALTH AND SAFETY PRECAUTIONS.
E. C l e a n t h e loosened seal, t h e seal support and t h e repair s e c t i o n

w i t h O M a t 2 / 1 0 1 LINT-FREE CLOTH soaked w i t h O M a t 135 MEK. D r y
t h e surfaces w i t h a n e w piece of the c l o t h before t h e s o l v e n t
evaporates.
F. A p p l y a t h i n l a y e r of O M a t 8 7 2 D SEALANT t o the sleeve d i a m e t e r

and t h e end face of t h e repair s e c t i o n .
G. P u t t h e sleeve of t h e repair s e c t i o n f u l l y i n t o t h e r e m a i n i n g
seal. M a k e s u r e t h e space b e t w e e n t h e m a t i n g ends of t h e seals
is f i l l e d w i t h sealant.
REPAIR NO. 6
54-30-30
Page 2 0 2
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
H. P a r t - c u r e t h e s e a l a n t f o r 30 minutes a t 21 t o 25 deg C (70 t o

77 deg F) .
CAUTION: YOU MUST PUT ON GLOVES WHEN YOU MAKE THE J O I N T SMOOTH.
I. Moisten your gloved f i n g e r s w i t h O M a t 1013 TEEPOL and w a t e r ,

t h e n make t h e bonded j o i n t smooth.
J. Apply a t h i n l a y e r of O M a t 872D SEALANT t o t h e mating s u r f a c e s

( i n s i d e t h e l i p s ) of t h e s e a l s u p p o r t .
K. P u t t h e r e p a i r e d s e a l , t o g e t h e r with t h e l e n g t h you l o o s e n e d ,
back i n t h e s e a l s u p p o r t . Apply l i g h t p r e s s u r e w i t h your hand
t o remove unwanted a i r .
L. Make s u r e t h e s e a l a n t h a s s t a y e d a l l around t h e j o i n t . If
n e c e s s a r y , do s t e p 4 . 1 a g a i n .
M. Apply a bead of OMat 872D SEALANT a l l round t h e o u t s i d e o f t h e

s e a l where i t touches t h e s u p p o r t .
N. Cure t h e s e a l a n t f o r 24 h o u r s a t 21 t o 25 deg C (70 t o 77 deg F) .

5. Inspection
A. With your gloved f i n g e r s , squeeze t h e s e a l a l l a l o n g t h e l e n g t h

o f t h e bonded r e p a i r . Do t h i s two o r t h r e e t i m e s . The r e p a i r i s
s a t i s f a c t o r y i f no c r a c k s a r e found i n t h e s e a l a n t .
B. Write "FRSX093" a d j a c e n t t o t h e C-duct p a r t number.
REPAIR NO. 6
54-30-30
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Printed i n Great B r i t a i n Apr. 1 / 0 1
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
DAMAGED SECTION
TO REPAIR
U
100 mm (3.937in.)
SECTION
B-B
.R
.2. SUPPORT
(l
-
!I'
\
11 SEALANT
.,--
BEAD OF SEALANT '

"r
R e p a i r the Pylon S e a l
Figure 201
54-30-30
P a g e 204
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
REPAIR NO. 7
APPLY SILICONE RUBBER ON THERMAL PROTECTION - BUMPER 1
1. General
A. This procedure gives instructions to remove damaged Teflon

strip and replace it with a pad of silicone rubber.
.......................................................................
.......................................................................
AMM TASK 78-30-00-010-803 Open the Thrust Reverser Cowl Doors
AMM TASK 78-30-00-410-803 Close the Thrust Reverser Cowl Doors
EM TASK 78-33-13-300-XXX FRS X096, Trent Engine Manual
- Non metallic scraper
- Spatula
- Standard workshop tools

OMat 262A MARKER PEN
OMat 8/138~ SILICONE RUBBER - RTV88
OMat 876D PRIMER - SS4004
OMat 882A CATALYST - DBT
4. Get Access
A. Open the RH Cowl Door ( A M TASK 78-30-00-010-803).
5. Prepare the Repair Area (Ref.Figure 201)
A. Use a non-metallic scraper to remove the damaged Teflon strip

from the thermal blanket at the Bumper 1 position.
54-30-30
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Printed i n Great Britain Apr. 1/01
R8211 TRENT
STRUCTUAL REPAIR
MANUAL

CORRECTLY.BEFORE YOU USE THIS MATERIAL,CAREFULLY READ THE
cloth before the solvent evaporates.
C. Refer to Figure 201, measure and mark out the dimensions given
for the replacement pad.
D. Apply a thin film of OMat 876D PRIMER to cover the area marked
out in Step 5.C (above).
E. Let the primer dry in the air for a minimum of 1 hour.
6. Prepare the Silicone Rubber
CAUTION: YOU MUST MIX THE TWO PARTS FULLY TO GET A HOMOGENEOUS
MIXTURE. DO NOT MIX AT HIGH SPEEDS OR YOU CAN TRAP LARGE
AMOUNTS OF AIR. THIS WILL CAUSE THE TEMPERATURE OF THE
MIXTURE TO BECOME TOO HIGH AND DECREASE THE POT LIFE.
A. Mix the necessary quantity of OMat 8/138A SILICONE RUBBER with

OMat 882A CATALYST in the ratio of 100 grams:25 drops.
7. Apply the Silicone Rubber (Ref.Figure 201)
A. Immediately apply a layer of the silicone rubber, 4 mm (0.157 in)

maximum thickness, to the area marked out in Step 5.C (above).
B. Cure the silicone rubber for 24 hours at 25 deg C (77 deg F) .
8. Inspection
A. Make sure the silicone rubber has a satisfactory bond, and that
it is not more than 4 mm (0.157 in) thick.
B. Write \\FRSX096" adjacent to the Part No. of the thermal blanket.
9. Close Access
A. Close the RH Cowl Door (AMM TASK 78-30-00-410-803).

54-30-30
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RB211 TRENT
STRUCTUAL REPAl R
MANUAL
-
BUMPER 1
n I
BUMPER l
Repair Thermal Protection - Bumper 1

Figure 201
REPAIR NO. 7
54-30-30
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RB211 TRENT
STRUCTUAL REPAIR
MANUAL
REPAIR N0.8
REPAIR THE JOGGLE PLATE ON THE PRECOOLER DUCT
1. General
A. This repair gives instructions to replace loose and/or missing

rivets that attach the joggle plate to the precooler duct.
NOTE: The maximum permitted number of rivets that can be replaced

by this repair is 15. Refer to Rolls-Royce plc if you find
more than 15 loose and/or missing rivets.
.....................................................................
.....................................................................
EMM 78-33-11-300-XXX FRS X082, Trent Engine Manual
.....................................................................
OMat 8/138A SEALANT, RTV8 8
OMat 8/177 SEALING COMPOUND, 93-076-02
C. Repair Parts
.....................................................................
ITEM PART NO. IDENTIFICATION QTY
.....................................................................
91B404-00 Repair Kit includes:
1 MS20427M4-5 Rivet , Standard

2 MS20427M5-5 Rivet, Oversize
REPAIR N0.8
54-30-30
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RB211 TRENT
STRUCTUAL REPAIR
MANUAL
CAUTION: YOU MUST NOT REPLACE MORE THAN 15 RIVETS IN THE JOGGLE
PLATE. REFER TO ROLLS-ROYCE PLC IF YOU FIND MORE THAN
15 LOOSE AND/OR MISSING RIVETS.
A. Use the applicable drill bit to drill-out all loose rivets

(Ref.SRM 54-02-10). Remove burrs and sharp edges.
B. Measure the hole diameter at the removed/missing rivet positions.
(1) The initial rivet hole diameter was 0.131 to 0.134 in.
(3,32 to 3,40 mm).
(2) You can accept oval holes up to 0.167 in.(4,24 nun) across if:
(a) The edge distance is 0.36 in. (9,O mm) minimum, and
(b) The rivet pitch is 0.80 in. (20 nun) minimum.
(3) Refer to Rolls-Royce plc if the holes are more than the
limits given above.
C. If necessary, enlarge the oval holes to 0.162 to 0.167 in.(4,11

to 4,24 mm) diameter. Remove burrs and sharp edges.

D. Clean all the rivet holes with OMat 2/101 LINT-FREE CLOTH soaked
with OMat 135 MEK. Dry the surfaces with a new piece of the cloth
E. Wet-install the applicable rivets (Ref.SRM 54-02-10) with the

OMat 8/177 SEALING COMPOUND:
- Item 1 Rivets for 0.131 to 0.134 in.(3,32 to 3,40 mm) dia.holes
- Item 2 Rivets for 0.162 to 0.167 in.(4,11 to 4,24 mm) dia.holes.
5. Inspection
A. Make sure all the rivets are satisfactorily installed.
B. Write'FRS X082'adjacent to the part number of the Precooler Duct.
REPAIR NO. 8
54-30-30
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RB211 TRENT
STRUCTUAL REPAIR
MANUAL
IFS SKlN
PRE-COOLER DUCT
SECTION
A- A PRE-COOLER DUCT
IFS SKlN
JOGGLE PLATE
THERMAL BLANKET SUPPORT
Replace Rivets on Joggle Plate

Figure 201
54-30-30
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RB211 TRENT
STRUCTUAL REPAIR
MANUAL
REPAIR NO. 9
REPAIR THE IFS SEAL
1. General
A. T h i s procedure gives i n s t r u c t i o n s t o replace a d a m a g e d p a r t

of t h e IFS s e a l . T h e d a m a g e i s c u t o u t and a r e p a i r s e c t i o n
i s bonded i n p o s i t i o n .
NOTE: T h e f i n a l cure t i m e f o r t h e s e a l a n t used i n t h i s repair i s

2 4 h o u r s a t 2 3 deg C ( 7 3 deg F ) and 50 percent r e l a t i v e
h u m i d i t y . Make s u r e you have s u f f i c i e n t m a i n t e n a n c e t i m e .
( R e f e r t o the m a n u f a c t u r e r ' s i n s t r u c t i o n s t o accelerate t h e
cure a t higher t e m p e r a t u r e s ) .
......................................................................
......................................................................
TASK 78-33-11-300-XXX FRS X 0 9 4 , T r e n t E n g i n e Manual
A. Standard E q u i p m e n t
- Metallic spatula ( i n c l u d e d i n repair k i t )
- Sharp k n i f e
- Standard w o r k s h o p t o o l s
......................................................................
......................................................................
OMat 584 TEEPOL
OMat 872D SEALANT, RTV159 ( i n c l u d e d i n repair k i t )
OMat 1013 SCOTCH BRITE
REPAIR NO. 9
54-30-30
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RB211 TRENT
STRUCTUAL REPAIR
MANUAL
C. Repair Parts
HD PN 91B414-00, Repair Kit for position 12H left side, includes:

.......................................................................
.......................................................................
- 4-21-878 Seal repair kit l
1 NAS7203A11 Screw 1
2 NAS7203A-6 Screw 2
or
NAS7203A-5
5 NAS7OO4A-7 Screw 1
6 NAS1169C416 Cupwasher 1
7 NAS5050-4C Nut 1
3 HST315-6-6 Screw 8
or
HST315CE6-6
4 HST97DUWU6 Nut 8
HD PN 91B414-50, Repair Kit for position 12H right side, includes:

.......................................................................
.......................................................................
1 NAS7203All Screw 1
or
NAS7203A
6 Nas1169C416 Cupwasher 1
7 NAS5050-4C Nut 1
or
HST315CE6-6
4 HST97DUWU6 Nut 8
HD PN 91B415-00, Repair Kit for position 6H left side, includes:

.......................................................................
.......................................................................
8 HSTlOBJ8-7 Screw 1
9 HST97DUWU8 Nut 1
or
HST315CE6-6
4 HST97DUWU6 Nut 5
54-30-30
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P r i n t e d in Great Britain Apr. 1/01
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
HD P N 9 1 B 4 1 5 - 5 0 , R e p a i r K i t f o r position 6H r i g h t side, includes:

...................................................................
ITEM PART NO. IDENTIFICATION QTy
...................................................................
- 4-21-883 Seal repair k i t l
8 HSTlOBJ8-7 Screw 1
9 HST97DUWU8 Nut 1
or
HST315CE6- 6
4 HST97DUWU6 Nut 5
HD P N 9 1 B 4 1 6 - 0 0 , R e p a i r K i t f o r E l b o w seal s e c t i o n , i n c l u d e s :
- 4-21-880 Seal repair k i t

3 HST315-6-6 Screw
or
HST315CE-6
4 HST97DUWU6 Nut
HD P N 9 1 B 4 1 7 - 0 0 , R e p a i r K i t f o r S t r a i g h t seal s e c t i o n , i n c l u d e s :
...................................................................
- 4-21-881 Seal repair k i t

3 HST315-6-6 Screw
or
HST315CE-6
4 HST97DUWU6 Nut
4. Procedure ( R e f F i g u r e s 2 0 1 , 2 0 2 )
A. Find the applicable repair k i t f o r t h e d a m a g e area:
(1) If t h e d a m a g e i s i n t h e 6 H 1 1 2 H o r e l b o w areas, you m u s t

i n s t a l l the c o m p l e t e repair seal s e c t i o n .
(2) If t h e d a m a g e i s i n a s t r a i g h t p a r t of t h e IFS s e a l , you

can c u t a l e n g t h of the repair seal t o s u i t .
-
NOTE: Y o u m u s t replace a m i n i m u m 4 0 mm ( 1 . 5 7 i n . ) l e n g t h
of t h e s t r a i g h t s e a l .
B. W i t h a p e n c i l , m a r k t h e c u t l i n e s on t h e d a m a g e d seal.
E F F E C T I V I T Y : TRENT R E P A I R NO. 9
54-30-30
P a g e 203
Printed i n G r e a t B r i t a i n A p r . 1/01
-H RB211 TRENT
MANUAL
STRUCTUAL REPAIR
C. Remove sufficient fasteners and joint plates to release the

seal for an extra 100 mm (4 in.) at each end. Keep the parts
for subsequent installation.
CAUTION: MAKE SURE YOU DO NOT CAUSE DAMAGE TO THE IFS.
D. With a sharp knife, cut out and discard the damaged part of the
IFS seal. Make sure you cut the seal ends at a right angle.
CAUTION: MEASURE AND CUT THE LENGTH ACCURATELY. THIS IS A FIRE

SEAL: NO SPACES ARE PERMITTED.
E. If applicable, cut a length of the straight repair seal to the

same length.
F. Loosen and lift the two cut ends of the IFS seal away from the
seal support for a length of 100 nun (4 in. ) .
WARNING : METHYLETHYLKETONE (MEK) IS CLASSIFIED AS A HAZARDOUS

CORRECTLY. BEFORE YOU USE THIS MATERIAL,CAREE'ULLY READ
G. Clean each end of the loosened seal, inner and outer surfaces,
with OMat 2/101 LINT-FREE CLOTH soaked with OMat 135 MEK. Dry
the surfaces with a new piece of the cloth before the MEK
evaporates.
H. Bond the sleeve(s) to the repair seal:
NOTE: Only one sleeve is used to attach the 6H and 12H repair
seals to the IFS seal.
(1) Use OMat 584 SCOTCH BRITE to lightly abrade the mating
surfaces of the repair seal and the sleeves.
(2) Clean the repair surfaces with OMat 2/101 LINT-FREE CLOTH
soaked with OMat 135 MEK. Dry the surfaces with a new
piece of the cloth before the MEK evaporates. Wait for a
minimum of 5 minutes before you apply the sealant.
(3) Apply a 1,O mm (0.04 in.) layer of OMat 872D SEALANT to

the first sleeve, for a length of 20 mm (0,8 in.). Do the
next step before 10 minutes.
(4) Install the sleeve in the repair seal to a depth of 20 mm

(0.8 in. ) . Remove unwanted sealant.
Page 204
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
(5) If applicable, do steps (3) and (4) again to install the

second sleeve in the repair seal.
(6) Let the sealant part-cure for 30 minutes at 25 deg C

(77 deg F) to form a skin.
I. Install the repair seal:
(1) Apply a layer of OMat 872D SEALANT on the first sleeve of

the repair seal assembly.
CAUTION: MAKE SURE THE REPAIR SEAL IS FULLY ENGAGED-THIS

IS A FIRE SEAL:NO SPACES ARE PERMITTED.
(2) Install the sleeve in the cut end of the IFS seal. Make
sure the sleeve is fully engaged. Remove unwanted sealant.
(3) If applicable, do steps (1) and (2) again to install the

second sleeve in the IFS seal.
(4) Let the sealant part-cure for 30 minutes at 25 deg C

(77 deg F) to form a skin.
CAUTION: YOU MUST PUT ON GLOVES BEFORE YOU TOUCH THE JOINT.
(5) Put on the OMat 2/114 LINT-FREE GLOVES. Moisten your gloved
fingers with water and OMat 1013 TEEPOL. Make the bonded
joint(s) smooth with your gloved fingers.
J. Attach the repaired seal to the IFS:
(1) Put the repaired seal, with the joint plates you removed
at step 4.C, in position on the seal support.
(2) Drill through the repaired seal to match the holes in the
IFS support.
(3) Install the fasteners (Ref Figure 201) to attach the

repaired seal to the IFS support
CAUTION: YOU MUST PUT ON GLOVES BEFORE YOU TOUCH THE JOINT.
(4) Again make the bonded joint (S) smooth with your moistened,
gloved fingers .
(5) Let the sealant cure for 24 hours at 25 deg C (77 deg F).
(Refer to the manufacturer's instructions to accelerate
the cure at higher temperatures).
EFE'ECTIVITY : TRENT REPAIR NO. 9
54-30-30
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RB211 TRENT
STRUCTUAL REPAIR
MANUAL
5. Inspection
A. With your gloved f i n g e r s , squeeze the bonded j o i n t s s e v e r a l

times. T h e repair i s s a t i s f a c t o r y if no cracks are found i n
the s e a l a n t .
B. Write "FRS X094 adjacent t o the IFS p a r t number.
54-30-30
Page 206
R6211 TRENT
STRUCTUAL REPAIR
MANUAL
IFS SEAL
FASTENERS POSITION
l ' , \ I ,
KIT PIN 91B414-00(LH)
KIT PIN91B414-50(RH)
7 3-7
KIT PIN 91B416-00
TYPICAL FOR ITEMS 1 AND 2 TYPICAL
SCREW IFS SUPPORT
IFS SEAL
:::-:;/ 11 SEAL
CAPTIVE NUT \ KIT PIN 91B417-00

PLATE
TYPICAL
TYPICAL FOR OTHER ITEMS

SEAL JOINT PLATE
/
SCREW
IFS SUPPORT
Repair the IFS Seal

Figure 201
54-30-30
Page 207
Apr. 1/01
(-ksCL- IFS SEAL
REMAINING
IFS SEAL
EXTREMITY
REPAIR SEAL
SECTION ASSY
FIRST SLEEVE
REPAIR SEAL
SECTION
SECOND SLEEVE
20 mm (0.787in.)
R e p a i r the I F S Seal
F i g u r e 202
54-30-30
Page 208
P r i n t e d i n Great B r i t a i n A p r . 1/01
RB211 TRENT
STRUCTUAL REPAl R
m MANUAL
REPAIR NO.10
THERMAL BLANKET DAMAGE LESS THAN 20 MM (0.8 IN)
1. General
A. This procedure gives instructions to repair damage to the core

of the thermal insulation blankets.
B. Damage may be repaired by filling the hole with sealant and

riveting a CRES patch over. Damage size must be less than
20 mm (0.8 in) .
NOTE: If the insulation core has a through-hole, refer to

Rolls-Royce/Hurel-Dubois.
C. The damage must be at least 20 mm (0.8 in) from the edge of the
thermal blanket.
.....................................................................
.....................................................................
TASK 78-33-00-300-XXX FRS X064, Trent Engine Manual
Suction cleaner
Riveting gun
Heat blanket
Aluminium plate, 2 to 3 mm (0.08 to 0.12 in) thick
.....................................................................
OMat 5/35 Abrasive paper

OMat 150 Acetone
OMat 872A RTV106, Sealant
OMat 272 Adhesive tape
REPAIR NO.10
54-30-30
Page 201
RB211 TRENT
STRUCTUAL REPAIR
m MANUAL
C. Repair Parts
.....................................................................
ITEM REFERENCE DESIGNATION QTY
.....................................................................
1 OMat 2/156 HTM6008 Texturized CRES foil (12 X 24") l
2 CCR274CS3-1XL Rivets 12
3 ASNA23 97C4 Washers 24
D. Component material
.....................................................................
COMPONENT MATERIAL
.....................................................................
Thermal blanket, L .H. ???
Thermal blanket, R.H. ???
4. Clean the repair area
A. Make a mark around the damaged area.
CAUTION: YOU MUST WEAR SAFETY GOGGLES AND GLOVES FOR ALL THE
SUBSEQUENT OPERATIONS.
B. Clean the area around the rip, tear, puncture or crushed

feature with OMat 5/35 abrasive paper. Clean the CRES foil
surface until free of oxidation. Use a suction cleaner to
remove all dust and particles.
C. Lightly enlarge the hole in the CRES foil if necessary. This

may ease the installation of washers under the metallic cover
at the operation 7.H.
CAUTION: DURING THE CLEANING OPERATION, DO NOT LET THE CLEANING

SOLUTION PENETRATE INTO THE INSULATION CORE POWDER.
D. Clean the repair area with OMat 150 Acetone and OMat 2/101 lint
free cloth. Dry the surface before the solvent evaporates.
5. Prepare the texturized patch
A. Find the size of OMat 2/156 CRES foil to get the required
repair patch.
NOTE: The patch must overlap the damaged area by 20 to 30 mm

(0.8 to 1.2 in) all aroound.
CAUTION: DURING THE CLEANING OPERATION, DO NOT LET THE CLEANING

SOLUTION PENETRATE INTO THE INSULATION CORE POWDER.
REPAIR NO.10
54-30-30
Page 202
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
B. Clean the patch with OMat 5/35 abrasive paper until the surface
is free of oxidation, then clean with OMat 150 Acetone. Wipe
the surface dry before the solvent evaporates.
C. Hold the patch in position over the damaged area. Attach parent
CRES foil and repair patch together with OMat 272 adhesive tape.
D. Mark out the rivet location on the patch. Allow 20 mm between

each rivet. Install 8 rivets minimum (Refer to Fig 201).
E. Lift the patch without moving and slide a plate of aluminium

through the hole below the CRES foil. Position the plate at hole
locations to drill. The aluminium plate is 0.080 to 0.120 in.
(2 to 3 mm) thick.
CAUTION : THE ALUMINIUM PLATE IS TO PROTECT THE INSULATION CORE

WHILE DRILLING. DO NOT DAMAGE THE INSULATION CORE.
F. Drill the rivet holes in both repair patch and original skin
with a 2.5 mm drill bit. Use the aluminium plate. Be careful
not to damage the insulation core.(Refer to Fig.201).
G. Remove the plate of aluminium. Remove burrs.
WARNING: SEALANT IS A DANGEROUS MATERIAL WHICH CAN CAUSE INJ7JRY OR

ILLNESS IF IT IS NOT USED CORRECTLY.
H. Bond a washer at each hole below the original metallic cover

(CRES foil) with OMat 872A sealant(Refer to Fig.201)
NOTE: Make sure that each washer is fully bonded and correctly
aligned with its hole.
6. Fill the hole in the core
WARNING: SEALANT IS A DANGEROUS MATERIAL WHICH CAN CAUSE INJURY OR

ILLNESS IF IT IS NOT USED CORRECTLY.
A. Fill the hole with OMat 872A sealant until flush with surface
of the insulation. Use a clean spatula to make the sealant
level with the adjacent skin. Remove excess of sealant.
7. Rivet the patch on the original cover
A. Apply OMat 872A silicone compound on the mating surface of the

patch. Do the next operation within tack-free time.
NOTE: At 2S°C (77°F) and 50% relative humidity, tack-free time is

15 minutes, and cure time is 24 hours.
REPAIR NO.10
54-30-30
Page 203
Printed in Great Britain Jan.1/02
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
B. Install the repair patch in position over the repair area.
C. Press the repair patch onto the cut out edges and remove excess
of sealant.
CAUTION: DO NOT PERFORATE THE INSULATION CORE DURING RIVETING.

INSTALL THE RIVETS IN STAGES TO GET A GOOD SET UP.
D. Install washers and rivets (Refer to Fig.201).
E. Apply a bead of OMat 872A silicone compound all around the

patch to seal the repair area.
NOTE: At 25OC (77°F) and 50% relative humidity, tack-free time is

15 minutes and cure time is 24 hours.
F. Cure the silicone compound for 30 minutes minimum at 25 deg C

(77 deg F) plus or minus 5 deg C ( 9 deg F) before touching. Use
a heat blanket if the arnbiant temperature is too low.
8. Inspection

REPAIR N0.10
54-30-30
Page 204
RB211 TRENT
STRUCTUAL REPAlR
MANUAL
SECTION
A-A
Atl I
RIVETING
LOCATION
0.8 IN MINI- / EXTERNAL
SIDE
(20mm) INSULATION
0 0 .l
BEAD OF
*--\ SEALANT
0 I' ,--/ 0
t REPAIR
PATCH
0 0 0
I
-7- _ , 1 n 8 IN
0.8 IN
I
' (20rnrn)
g2 A-l
WASHER
RIVET
i OMAT 872 A SEALANT
Thermal Blanket Repair

Damage less than 0.8 in. (20 mm) dia.
Figure 201
REPAIR N0.10
54-30-30
Page 205
Printed i n G r e a t B r i t a i n Jan. 1/02
REPAIR No.11

REPAIR OF THERMAL BLANKETS-DAMAGE MORE THAN 20MM DIAMETER
1. General
This procedure repairs damage to the metal cover, core and

polyimide film of the thermal insulation blanket installed
on the inner fixed structure. (I.F.S.)
The external metal cover is repaired by a patch of CRES

foil that is riveted. The core is repaired by bonding a
plug of insulation core into the damaged area. The
polyimide film is repaired by bonding a polyimide patch
onto the damage area.
The damage must be located at least 20 mm (0.8 in.) from

the edge of the thermal blanket.
CAUTION: IF THE C-DUCT HAS BEEN IN SERVICE WITH A HOLE IN THE

BLANKET CORE, YOU MUST CONTACT HUREL-HISPANO OR ROLLS
ROYCE BEFORE YOU REPAIR OR REPLACE THE THERMAL
BLANKET PANEL. A BOND TEST OF THE I.F.S. COULD BE
NECESSARY.
CAUTION: IT IS NOT PERMITTED FOR REPAIR PATCHES TO OVERLAP. THE

MINIMUM DISTANCE BETWEEN REPAIRABLE DAMAGES IS 40 mm
(1.6 in.).
NOTE: If the damage has a through hole, then remove the

thermal blanket to inspect the I.F.S.
This repair is the same as FRSX 065.
TASK 78-33-00-300-XXX FRS X065, Trent Engine Manual
3. Equipment and Manual

You can use equivalent materials and equipment.
Suction cleaner

54-30-30
Page 201
R Printed in Great Britain July.1/02
Hand rivet gun
OMat 5/35 Waterproof silicon carbide paper
OMat 150 Acetone
OMat 872A RTV106, Sealant
OMat 272 Adhesive tape
COMPONENT MATERIAL
Thermal blanket, L.H. Composite
Thermal blanket, R.H. Composite
D. Repair Parts
Repair kit P/N 91A024-01

FIG/ITEM PART NO PART IDENT QTY
OMat 2/156 Texturized CRES foil 1 (12in.x 24in.)
(HTM6008)
OMat 2/151 Insulation patch 1 (6in.x 12in.)
(HTM5677)
OMat 2/128 Insulation patch 1 (6in.x 12in.)
(HTM5676)
OMat 8/195 Glass cloth 1 (12in.x 38in.)
(HTM5881)
OMat 8/194 Polyimide film 1 (6in.x 12in.)
(Kapton, HTM5674)
CCR274CS3-1XL Rivets 20
ASNA2397C4 Washers 40
4. Repair the Damaged Thermal Blanket when the external skin is damaged
CAUTION: DO NOT LET LIQUIDS GET INTO THE INSULATION

CORE POWDER. DAMAGE TO THE INSULATION CORE
CAN OCCUR.
(1) If the Insulation core has contamination and it is less

than the limit area 260 mm X 560 mm (10.4 in. x 22.4 in.),
then repair to operation 7.

54-30-30
Page 202
(2) If the insulation is more than the limit area 260 mm X 560
mm (10.4 in. x 22.4 in.), then repair to FRSX023.

(a) Use this cloth to clean the area that you repair
(b) You must discard this dirty cloth
(c) Use a clean cloth each time you clean a new area that
you repair.
(d) Contamination of the bulk liquid is not permitted
(e) Do not let the liquid touch the cloth and return to
bulk liquid container.
(2) Clean the repair area with OMat 150-Acetone, OMat 1/40-
Isopropyl Alcohol or OMat 1/257-Cleaning solvent and OMat
2/101-Cloth. Wipe the area dry before the solvent
evaporates.
CAUTION: DO NOT CAUSE DAMAGE TO THE INSULATION CORE UNDER THE SKIN
WHEN THE DAMAGE IS CUT OUT.
C. Cut a square or rectangular shape around the damage. Remove and

discard the damaged cut out CRES section. If the insulation core
is found damaged, refer to paragraph 7.5. Prepare the repair
cover (for the external skin damage)
CAUTION: WHEN YOU TOUCH OMAT 2/156 TEXTURIZED PATCH YOU MUST PUT ON
OMAT 2/114 LINT FREE GLOVES AND SAFETY GOGGLES.
A. Find the size of the OMat 2/156 texturized patch required.
NOTE: Maximum patch size is 12 in. (300 mm) x 24 in. (600 mm)
and patch size must overlap the damage area by 0.8 to 1.2
in. (20 to 30 mm) on each side.

54-30-30
Page 203
WARNING: SOLVENT IS CLASSIFIED AS A HAZARDOUS MATERIAL THAT CAN
CAUSE INJURY OR ILLNESS IF NOT USED CORRECTLY. BEFORE YOU
USE THIS PRODUCT, CAREFULLY READ THE APPLICABLE MATERIAL
SAFETY DATA SHEET AND OBEY ALL THE SPECIFIED HEALTH AND
SAFETY PRECAUTIONS.
CAUTION: DO NOT LET LIQUIDS GET INTO THE INSULATION CORE POWDER.
THIS CAN CAUSE DAMAGE TO THE ISULATION CORE.
B. Clean the metal surface with OMat 5/35 abrasive paper until the
surface has no oxidation, then clean with OMat 150 Acetone, OMat
1/40 Isopropyl Alocohol or Omat 1/257 Cleaning Solvent. Wipe the
surface dry.
6. Rivet the patch (for the external skin damage)
A. Hold the patch in position over the damage area.
B. Mark out the rivet location on the patch and CRES foil. Attach
parent CRES foil and repair patch together with OMat 272
Adhesive tape. Refer to fig 202.
C. Lift the tape from the blanket on one side and slide a sheet of
aluminium between the insulation core and the two metal covers.
The aluminium sheet is 0.080 to 0.120 in. (2 to 3 mm) thick.
CAUTION: WHEN YOU DRILL, USE THE ALUMINIUM SHEET TO PROTECT THE
INSULATION CORE. IF YOU DO NOT, THEN DAMAGE TO THE
INSULATION CORE CAN OCCUR
D. Drill the rivet holes in the repair patch and original skin with
a 2.5 mm drill bit. Allow 20 mm between each rivet. Be careful
not to cause damage to the insulation core. Refer to fig. 203.
E. Remove the sheet of aluminium. Remove burrs.
F. Bond the washers under each hole in the original metallic

texturized cover (CRES foil) with OMat 872A sealant. Refer to
fig 202.
NOTE: Make sure that every washer is bonded and aligned

with the hole.

54-30-30
Page 204
G. Apply OMat 872A Silicone compound on the mating surface of the
insulation core. Proceed to next operation within tack free
time. Refer to fig 202.
NOTE: At 25 deg. C (77 deg. F) and 50% relative humidity, tack

free time is 15 minutes and cure time is 24 hours. Refer
to manufacturer’s instructions.
H. Install the repair patch in position over the repair area.
I. Apply pressure to the repair patch on the cut-out edges and

remove excess of sealant.
CAUTION: DO NOT PUT HOLES THE INSULATION CORE WHEN YOU RIVET.
INSTALL THE RIVETS IN STAGES.
J. Install rivets and washers. Refer to fig. 202.
K. Apply a bead of OMat 872A Silicone compound all around the patch
to seal the repair area.
NOTE: At 25 deg. C (77 deg. F) and 50% relative

humidity, tack free time is 15 minutes and cure
time is 24 hours. Refer to manufacturer’s
instructions.
L. Allow the silicone compound to cure for 24 hours at 25°C.
7. Repair the Thermal Blanket when the insulation core is damaged
CAUTION: IF THE C-DUCT HAS BEEN IN SERVICE WITH A HOLE IN

THE BLANKET CORE, YOU MUST CONTACT HUREL-HISPANO OR
ROLLS ROYCE BEFORE YOU REPAIR OR REPLACE THE
THERMAL BLANKET PANEL. A BOND TEST OF THE I.F.S.
COULD BE NECESSARY.
NOTE: The maximum size of hole in the isulation core that

can be repaired is 260 mm X 560 mm (10.4 in.X 22.4
in.).
B. Clean the area around the damage with OMat 5/35 abrasive paper.
The scrubbed area must extend 7.0 mm (0.275 in.) minimum beyond
the edge of the patch cover on all sides. Use a vacuum cleaner
to remove the loose particles.

54-30-30
Page 205
CAUTION : MAKE SURE NOT TO CUT THE POLYIMIDE FILM UNDER
THE INSULATION CORE.
C. Cut a square or rectangular shape around the damage. Discard the

cut out material.
D. Do an inspection of the polyimide film. If damaged, refer to
paragraph 10.
8. Prepare the repair insulation plug
A. Find the size of the repair plug necessary.
CAUTION: YOU MUST PUT ON OMAT 2/114 LINT FREE GLOVES AND
SAFETY GOGGLES.
CAUTION: YOU CAN FILL THE HOLE IN THE INSULATION CORE WITH
SEVERAL PLUGS. GAPS AND VOIDS ARE NOT PERMITTED
WHEN THE PLUGS ARE INSTALLED IN THE HOLE.
CAUTION: WHEN YOU REMOVE THE INSULATION CORE, BE CAREFUL

NOT TO SPILL INSULATIVE FIBRES WHICH ARE INSIDE THE
CORE.
NOTE: The insulation plug must not be of the same type as the
original core.
B. Cut a plug of OMat 2/128 or OMat 2/151 insulation core, for the
thermal blanket thickness and type, 0.06 in. (1.5 mm) to 0.12
in. (3 mm) larger per side than the hole.
C. Cut a strip of OMat 8/195 glass cloth 1 in. (25 mm) wider than
the insulation plug thickness and as long as its perimeter.
D. Seal the edges of the insulation plug by bonding the glass cloth
strip with OMat 872A sealant. The strip must overlap each side
by 0.5 in. (13 mm). Do the next operation in less than the tack
free time. Refer to fig. 203.
NOTE: At 25 deg. C (77 deg. F) and 50% relative

humidity, tack free time is 15 minutes and cure
time is 24 hours. Refer to manufacturer’s
instructions
9. Fill the repair cut-out (when the insulation core is damaged)
A. Apply OMat 872A sealant to the hole. Continue to next step in

less than the tack free time.

54-30-30
Page 206
CAUTION: THE PLUGS MUST BE INSTALLED TIGHT IN THE HOLE TO GIVE A
CLOSE FIT. GAPS AND VOIDS ARE NOT PERMITTED.
NOTE: At 25 deg. C (77 deg. F) and 50% relative humidity, tack free
time is 15 minutes and cure time is 24 hours. Refer to
manufactures’s instructions.
B. Put the insulation plug in the repair hole.
C. Push the insulation plug until flush with the original thermal
blanket surface.
D. Remove all unwanted materials using a suction cleaner.
E. Apply OMat 872A sealant on the insulation plug. Make sure that
the thermal blanket hole is satisfactorily filled. Proceed to
next operation within tack free time.
.
F. Repair the external skin. Refer to paragraph 5.
10. Repair the polyimide film
CAUTION: DO NOT LET LIQUIDS GET INTO THE INSULATION CORE. THIS CAN
CAUSE DAMAGE TO THE INSULATION CORE.
NOTE: The maximum size of damage to the poloymide flim that can be
repaired is 140 mm X 290 mm (5.6 in. X 11.6 in.). The patch
must overlap the damaged area by a minimum of 5 mm (0.20 in.)
per side.

CAUSE INJURY OR ILLNESS IF NOT USED CORRECTLY. BEFORE YOU
USE THIS PRODUCT, CAREFULLY READ THE APPLICABLE MATERIAL
SAFETY DATA SHEET AND OBEY ALL THE SPECIFIED HEALTH AND
SAFETY PRECAUTIONS.
A. Use OMat 2/101 lint free cloth moistened with OMat 150 acetone,
OMAt 1/40 Isopropyl Alcohol or OMat 1/257 Cleaning Solvent to
clean the repair area. Wipe the surface dry before the solvent
evaporates.
B. Cut a patch of OMat 8/194 polyimide film a minimum of 0.20 in.

(5 mm) larger minimum than the damage area.
C. Use OMat 2/101 lint free cloth moistened with OMat 150 acetone
to clean the patch and the mating surface of the polyimide film.
Wipe surfaces dry before the solvent evaporates.
D. Apply OMat 872A sealant to the mating surface of the polyimide

film inside the thermal blanket.
54-30-30
Page 207
E. Put the patch onto the polyimide film. Gently apply hand
pressure over the patch to remove any entrapped air.
F. Let the sealant cure for 24 hours at 77 deg. F (25 deg. C).
G. Make sure that the repair patch is completely bonded to the

polyimide film.
H. Repair the insulation core. Refer to paragraph 8.
11. Inspection

12. Identification
A. Mark FRSX 065 adjacent to the repair with a permanent marker.

54-30-30
Page 208
Thermal insulation blanket - IFS
Figure 201

54-30-30
Page 209
Repair external skin damage
Figure 202

54-30-30
Page 210
Drill the rivet holes
Figure 203

54-30-30
Page 211
Repair insulation core damage
Figure 204

54-30-30
Page 212
REPAIR NO.12
THRUST REVERSER
PATCH REPAIR OF THE TURBINE CASE COOLING (TCC) DUCT
1. General
A. This procedure gives the instructions to stop-drill cracks and

install, with rivets, a locally manufactured patch at the mid-
stiffener area of the TCC duct.
SRM 54-02-10 Fasteners – Installation and Removal

Inspection – Maintenance Process 213
AMM TASK 70-02-01-100-802 Non-Aqueous Liquid Degreasing – Maintenance
Process 101
Equivalent materials and equipment can be used.

-Drilling equipment
-Pneumatic rivet gun
-Gripper pins to suit 2.5 mm (0.10 in.) diameter holes
-Clamps

OMat 262 TEMPORARY MARKER (Felt/Fibre tip)
OMat 653 FLUORESCENT PENETRANT - MEDIUM SENSITIVITY,
WATER WASHABLE
OMat 8/173 ADHESIVE/SEALANT
REPAIR NO.12
EFFECTIVITY: TRENT
54-30-30
Page 201
C. Repair Parts
2 Local manufacture Patch 1

3 MS20427M5-5 Rivet, solid A/R
NOTE: The repair patch (Item 2) is to be locally manufactured

from CRES A286 of 1.50 mm (0.06 in.) thickness.
WARNING: ALL FURTHER ACTIONS MUST BE CARRIED OUT WEARING PROTECTIVE

CLOTHING, GLOVES, DUST MASK AND SAFETY GOGGLES TO PROTECT YOU
AGAINST DUST AND LOOSE PARTICLES WHICH CAN BE DANGEROUS TO
YOUR HEALTH.
4. Prepare the Damaged Area for Repair
A. Use OMat 653 FLUORESCENT PENETRANT to do a local application

penetrant inspection to find the extent of the cracking of the
TCC duct in the mid-stiffener area (Ref. AMM TASK 70-20-02-230-
804).
B. Clean the repair area (Ref. AMM TASK 70-20-01-100-802).
B. Drill a 5mm (0.2 in.) diameter hole whose centre is 2.5 mm (0.1
in.) beyond the end of the crack (Ref. Fig.201). Remove all
burrs from the hole.
D. Do a second penetrant inspection to make sure that the stop-

drilled hole is in the correct position to prevent growth of the
crack.
E. Clean the repair area (Ref. AMM TASK 70-20-01-100-802).
5. Prepare the Patch (2) (Ref. Figure 201)
A. Make a tracing of the crack. Position the rivet holes on the

tracing as follows:
(1) Minimum pitch of 20 mm (0.8 in.).
(2) Minimum distance to the edges of the crack stop holes and
the edges of the patch of 12 mm (0.48 in.).
NOTE: Do not position any rivets in the duct stiffener.
REPAIR NO.12
EFFECTIVITY: TRENT
54-30-30
Page 202
B. Use the tracing to make the patch (2) from CRES A286 sheet of
1.5 mm (0.06 in.) thickness. Make a rectangular shape with 2 mm
(0.08 in.) radius rounded corners. Remaove all burrs and sharp
edges.
C. Use the tracing and an OMat 262 TEMPORARY MARKER to locate and
identify the rivet holes on the patch (2).
D. Pre-drill the rivet holes in the patch (2) to 2.5 mm (0.10 in.)
diameter. Remove all burrs from the holes.
CAUTION: MAKE SURE THAT YOU DO NOT CAUSE DAMAGE TO THE TCC DUCT
WHEN YOU INSTALL THE CLAMPS.
E. Put the patch (2) into position on the duct (1) and secure it
with clamps. Drill pilot holes in the TCC duct (1) through the
rivet holes in the patch (2). Use a 2.5 mm (0.10 in.) diameter
drill bit. Use gripper pins to secure the patch (2) when you
have drilled sufficient holes.
F. Drill holes in both the duct (1) and the patch (2) to between
4.06 and 4.17 mm (0.160 and 0.164 in.) final diameter. Remove
the patch (2) and remove all burrs from all the holes.
G. Countersink the rivet holes on the airwashed side of the patch

(2) to 1000 angle and to between 5.85 and 6.10 mm (0.23 and 0.24
in.) external diameter. Remove all burrs from the holes.
6. Install the Patch (2)
A. Clean the TCC duct (1) and the patch (2) (Ref. AMM TASK 70-20-
01-100-802).
ENVIRONMENTAL DAMGE CAN OCCUR.
NOTE: Put the sealing compound in a container that is at least 2

times the volume of the sealing compound. This will prevent
spillage when air is removed.
B. Prepare the OMat 8/177 SEALING COMPOUND:
(1) Mix the two component parts of the sealing compound, in the
ratio of one part of catalyst to 10 parts of base by
weight.
REPAIR NO.12
EFFECTIVITY: TRENT
54-30-30
Page 203
(2) Remove all trapped air from the mixture by placing it in a
vacuum of 650 mm.Hg for 30 minutes.
C. Apply a thin layer of the prepared OMat 8/117 SEALING COMPOUND

mixture on the mating surface of the patch (2), then put the
patch into position on the TCC duct(1).
D. Use more of the prepared OMat 8/117 SEALING COMPOUND mixture to

wet install the rivets (3) (Ref. SRM 54-02-10).
E. Remove all excess sealing compound (Ref. AMM TASK 70-20-01-100-

802).
F. Apply a bead of OMat 8/173 ADHESIVE/SEALANT around the edges of

the patch (2).
G. Let the OMat 8/173 ADHESIVE/SEALANT cure for 4 hours at a

temperature of 25 deg.C (77 deg.F).
7. Examine the Repair (Ref. Figure 201)
A. Do a visual examination of the repair to make sure that it is

satifactory.
A. Use an OMat 262 TEMPORARY MARKER of contrasting colour to write

FRSX101 on the repair patch (2).
REPAIR NO.12
EFFECTIVITY: TRENT
54-30-30
Page 204
Patch Repair of Turbine Case Cooling (TCC) Duct – Repair No.12
Figure 201
REPAIR NO.12
EFFECTIVITY: TRENT
54-30-30
Page 205
p RB211 TRENT
MANUAL
STRUCTURAL REPAlR
REPAIR NO. 13
THRUST REVERSER
PRE SB 78-E871: REPLACE THE PRE-COOLER LINK BRACKETS FITTED ON THE

INNER FIXED STRUCTURE (IFS) - FRSXlO2
1. General
A. This procedure gives the instructions to replace the Support

brackets of the two pre-cooler links, which are installed on the
IFS.
B. The Fig/Item numbers referred to in the procedures agree with

those used in the Power Plant Illustrated Parts Catalogue
(PPIPC). Only the primary Fig/Item numbers are used. For
different Service Bulletin standards refer to the PPIPC.
54-02-10 Removal and Installation of Fasteners
54-02-07 Torque Tightening technique
AMM TASK 70-20-01-100-802 Non-Aqueous Liquid Degreasing - Maintenance
Process 101
AMM TASK 20-11-11-911-803 Double Wirelocking

-0-17Nm (0 to 150 lbf in) torque wrench
------------------------------------------------------------.--------
----------------------------------------------------------------..----

OMat 262 TEMPORARY MARKER (Felt/fibre tip)
OMat 8/173 ADHESIVE/SEALANT
OMat 872A COLD CURING SILICONE COMPOUND (Red)
OMat 238 LOCKWIRE
REPAIR N0.13
54-30-30
PAGE 201
RB211 TRENT
STRUCTURAL REPAIR
m MANUAL
C. Repair Parts
ITEM NO. PPIPC FIG/ITEM PART NO. PART IDENT. QTY

9 78-33-13 07-187 HST97-6 Collar 8
8 78-33-13 07-185 91B062-00 Bracket 2
The parts that follow are listed for reference only:
ITEM NO. PART NO. PART IDENT

-------...------- .-----------------------. .- -------.
5 NSA5050-4C Nut REF
6 91B063-00 Bushing, sleeve REF
4 91B064-00 Bush REF
7 91B837-01 Rod, support REF
3 ABS0114-4-13 B01 t REF
11 HST315-6-19 P in REF
10 91B224-00 Cup washer REF
- 115M1029-109 Forward Bracket Cover REF
115M1029-111 Aft Bracket Cover REF
NAS679C3W Nut, self locking REF
HTM10 07 Washer REF
WARNING: ALL FURTHER ACTIONS MUST BE CARRIED OUT WEARING PROTECTIVE

CLOTHING, GLOVES, DUST MASK AND SAFETY GOGGLES TO PROTECT YOU
AGAINST DUST AND LOOSE PARTICLES, WHICH CAN BE DANGEROUS TO
YOUR HEALTH.
4. Prepare the Damaged Area for Repair
A. Remove the cover of the bracket (8) (Ref. Figure 201 Sheet 1):
(1) Remove the two nuts (2) and the two washers (l), and
then remove the cover.
(2) Do the same procedure for the second cover.
(3) If they are not damaged, keep the parts that have been
removed for re-installation.
B. Disconnect the support rods (7) from the Bracket (8) (Ref.
Figure 201 Sheet 2):
(1) Remove the bolt (3), the bushing sleeves (6), the bushes
(4) and the nuts (5) .
(2) Do the same procedure for the second support rod.
REPAIR N0.13
54-30-30
PAGE 202
Printed i n Great B r i t a i n Oct. 15/05
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(3) If they are not damaged, keep the parts that have been
removed for re-installation.
NOTE: Measure and record the length of each support rod (7)
before it is removed. Be careful not to change the
length of the support rods (7) when they are removed.
Use an OMat 262 TEMPORARY MARKER of a contrasting colour
to identify each rod and the location from which it was
removed.
C. Remove the brackets (8) (Ref. Figure 201 Sheet 3):
(1) Remove and discard the collars ( g ) , Pins (11) and Cup
Washers (10). Refer to SRM 54-02-10 for the procedure to
remove the pins and collars.
(2) Remove the brackets (8) from the IFS.
(3) If they are not damaged, keep the pins (11) and the cup
washers (10) for re-installation.
CAUTION: MAKE SURE THAT YOU DO NOT CAUSE DAMAGE TO THE INNER FIXED
STRUCTURE (IFS) WHEN YOU REMOVE THE SEALANT.
D. Use a hand scraper, or equivalent tool, to remove all unwanted

sealant from the repair area on the IFS surface.
E. Remove all grease from the repair area and the replacement
brackets (8) (Ref. AMM TASK 70-20-01-100-802). Wipe the surface
dry before the solvent dries.
NOTE: Use OMat 2/114 LINT FREE GLOVES to touch the parts.
5. Install the Re~lacement Brackets
WARNING: YOU MUST FIND AND OBEY THE MANUFACTURER'S HEALTH AND
DONE SAFELY. IF YOU DO NOT SO THIS, AN INJURY OR
NOTE: Put the sealing compound in a container that is at least 2

times the volume of the sealing compound. This will prevent
spillage when air is removed.
A. Prepare the OMat 8/177 SEALING COMPOUND:
REPAIR N0.13
54-30-30
PAGE 203
Printed in Great B r i t a i n Oct. 15/05
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(1) Mix the two component parts of the sealing compound, in

the ratio of one part catalyst to 10 parts of base by
weight, in accordance with the manufacturer's
instructions.
(2) Remove all trapped air from the mixture by placing it in

a vacuum of 650 m.Hg for 30 minutes.
B. Apply a thin layer of prepared OMat 8/177 SEALING COMPOUND to

the mating surfaces of the replacement brackets (8) (Ref. Figure
201 Sheet 2).
C. Install the replacement brackets (8) (Ref. Figure 201 Sheet 3):
(1) Apply OMat 8/177 SEALING COMPOUND to the mating surfaces

of the pins (ll), the cup washers (10) and new collars
(9)
(2) Put the replacement bracket (8) into position on the

IFS.
(3) Install the pins (11), the cup washers (10) and the new
collars (9).
(4) Torque tighten the collars (9) until shear off.
(5) Do this procedure again for the second bracket (8) .

D. Apply a bead of OMat 8/173 ADHESIVE/SEALANT around the installed
brackets (8).
E. Let the sealing compound cure for 4 hours at 25 deg.C (77

deg.F) .
F. Apply a layer of OMat 872A COLD CURING SILICONE COMPOUND around
the brackets (8) to cover all of the IFS visible surface (Ref.
Figure 201). Let the compound cure in accordance with the
G. Inspect the repair to make sure that the brackets have been
satisfactorily installed in accordance with this procedure.
H. Install the support rods (7) (Ref. Figure 201 Sheet 2):
(1) Put a support rod (7) into position. Make sure that it
is in the same position as that recorded during removal.
(2) If necessary, adjust the rod ( 7 ) to the same length as

that recorded during removal.
REPAIR N0.13
EFFECTIV1TY:TRENT
54-30-30
PAGE 204
RB211 TRENT
STRUCTURAL REPAIR
m MANUAL
NOTE: The support rod ( 7 ) must be fitted without any

preload.
(3) Install the bolt (3), the bush (4), the bushing sleeve
(6) and the nut (5).
R (4) TORQUE the nut (5) to 11.3 Nm (100 lbf-in).
R (5) Do this procedure again for the second support rod (7).
R I. Install the covers (Ref. Figure 201 Sheet 1):
R (6) Put the cover into position over the bracket ( 8 ) .
R (7) Install the nuts (2) and washers (1).
R (8) TORQUE the nuts (2) to 11.3 Nm (100 1bf.in).
(9) Do this procedure again for the second cover.
R 6. Inspect the Repair (Ref. Figures 201 Sheet 1, 2 and 3)

done in accordance with the procedures in this repair scheme.
A. Use an OMat 262 TEMPORARY MARKER of contrasting colour to write

FRSXlO2 adjacent to the assembly part number.
REPAIR N0.13
54-30-30
PAGE 205
Printed in Great B r i t a i n Oct. 15/05
p RB211 TRENT
MANUAL
STRUCTURAL REPAIR
SECTION
A- A
COVER
2 NUT \
THERMAL BLANKET OMAT 872A lFS
R e r n o v e / I n s t a l l the B r a c k e t C o v e r s
Figure 201
REPAIR N 0 . 1 3
54-30-30
PAGE 2 0 6
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
4 BUSH
I LINK ROD LENGTH
3 BOLT
l %-1
/ 6 SLEEVE BUSHING
7 SUPPORT ROD
ROD LENGTH
Rernove/Install the Support Rods

Figure 202
REPAIR N0.13
54-30-30
PAGE 207
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
+ 8 BRACKET
,-
1I --
F
l I
-
\ l
L
\
SECTION
B-B
9 COLLAR
(4 0ff-l
l 1 PIN 10 CUP WASHER

(4 of9 (4 off)
Remove/Install the Brackets

Figure 203
REPAIR N0.13
54-30-30
PAGE 208
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR N0.14
THRUST REVERSER
PRE SB 78-E871: REPLACE THE SUPPORT ROD BRACKETS ON THE PRE-COOLER DUCT
1. General
A. This repair gives the procedures to replace the support rod

brackets installed on the pre-cooler duct.
B. The Fig/Item numbers referred to in the procedures agree with

those used in the Power Plant Illustrated Parts Catalogue
(PPIPC). Only the primary Fig/Item numbers are used. For
different Service Bulletin standards refer to the PPIPC.
54-02-07 Torque Tightening Technique

54-02-10 Removal and Installation of Fasteners
AMM TASK 70-20-01-100-802 Cold Liquid Degrease

.
-0 to 150 lbf in (0-17 Nm) torque wrench
-Right angled pneumatic or electric hand drill
-Drill bush, 0.191 in. (4,85 mm) external dia, 0.098 in. (2,5
mm) internal dia (local manufacture)
-0.098 in (2,5 mm) and 0.191 in (4,5 mm) drills
.....................................................................
.....................................................................
OMat 262 TEMPORARY MARKER FELT/FIBRE TIP
OMat 8/173 FIBRE TIP ADHESIVE
OMat 8/177 SEALING COMPOUND, DC 93-076-2
REPAIR N0.14
54-30-30
PAGE 201
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
C. Repair Parts
.....................................................................
ITEM NO. PPIPC FIG/ITEM PART NO PART IDENT QTY
.....................................................................
10 78-33-13 01-165 HST97DU6 COLLAR, HILITE 8
16 78-33-13 01-170 91B838-00 BRACKET, FRONT 1
12 78-33-13 01-180 91B839-00 BRACKET, REAR 1
D. Referenced Parts
(1) The parts that follow are not repair parts, they are
listed for reference only.
.....................................................................
ITEM NO. PPIPC FIG/ITEM PART NO PART IDENT QTY
.....................................................................
9 78-33-13 01-166 HST12-6-5 PIN-HILITE REF
13 78-33-13 01-167 91B050-00 SHIM REF
15 78-33-13 01-168 91BO53-00 SHIM REF
14 78-33-13 01-172 91BO55-00 SHIM REF
11 78-33-13 01-177 91B052-00 SHIM REF
7 78-33-13 01-178 91B051-00 SHIM REF
8 78-33-13 01-182 91B054-00 SHIM REF
5 78-33-13 01-300 NSA5050-4C NUT, SELF LOCKING REF
3 78-33-13 01-301 91B064-00 BUSH REF
4 78-33-13 01-302 91BO63-00 BUSHING, SLEEVE REF
2 78-33-13 01-303 ABS0114-4-13 BOLT REF
6 78-33-13 01-945 91B837-01 ROD, SUPPORT, ASSY REF
E. Material of Component
.....................................................................
COMPONENT MATERIAL
.....................................................................
PRE-COOLER DUCT A286 STAINLESS STEEL (PRE SB 78-B819) OR
INCONEL 625 (SB 78-B819)
BRACKET, FRONT INCONEL 625
BRACKET, REAR INCONEL 625
HEALTH.
WARNING: WHEN YOU USE CLEANING MATERIALS, COATINGS AND SEALANTS, REFER
TO AND OBEY, THE MANUFACTURER'S CONTROL AND APPLICATION
REPAIR N0.14
54-30-30
PAGE 202
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
4. Disconnect the link rod
CAUTION: IF THE TWO BRACKETS HAVE TO BE REPLACED, ONLY DISCONNECT

ONE SUPPORT ROD AT A TIME AND KEEP THE OTHER CONNECTED TO
ITS BRACKETS. THIS IS TO GIVE SUPPORT TO THE PRE-COOLER
DUCT AND PREVENT DAMAGE TO THE INNER FIXED STRUCTURE. IT
ALSO KEEPS THE DUCT IN ITS CORRECT POSITION TO HELP THE
RE-INSTALLATION OF THE SUPPORT ROD.
A. Refer to Fig. 201 (Sheet 1 and 2)
NOTE: The removal of the two support rods (1) is the same.
B. Remove and keep the nut (5), bush (3), sleeve bushing (4) and
bolt (2).
C. Move the support rod end away from the pre-cooler duct.
5. Remove the Damaged Bracket
B. Remove the four pins ( g ) , four collars (10) and three shims
(13, 14, and 15, or 7, 8 and 11) that attach the bracket to the
pre-cooler. Refer to SRM 54-02-10 for the procedure to remove
the pins and collars.
C. Discard the Collars.
D. Clean and examine the pins and shims, keep them if they are
serviceable for reinstallation. Refer to AMM TASK 70-20-01-100-
802 for the procedure to clean the parts.
6. Drill the Replacement Bracket (12 or 16)
B. Attach the bracket to the support rod with the two bushes (3
.
and 4) , bolt (2) and nut (5) Lightly tighten the bolt.
C. Move the link rod so that the bracket is against the pre-cooler
duct .
NOTE: The pre-cooler duct material is very hard. When it is
possible use a bench drill. A drill speed between 300 and
500 rpm is recommended when you drill the initial holes. Use
1200 rpm when you increment drill the initial holes to make
them larger.
REPAIR N0.14
54-30-30
PAGE 203
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
D. Hold the bracket against the duct and use the right-angled
drill, 0.098 in. (2,5 mm) drill and drill bush to spot drill
the bracket through the four holes in the pre-cooler duct.
E. Remove the bracket from the support rod and through drill it.
Do this at the spot drilled positions with the 0.191 in. (4,85
mm) drill.
F. Deburr the holes and clean the bracket and the pre-cooler duct.
7. Drill the Replacement Shims (7, 8 and 11 or 13, 14 and 15)
NOTE: This operation is necessary if the initially installed shims are

damaged and cannot be installed.
A. Refer to Fig. 201 (sheet 3).
B. Put the replacement shims against the related bracket and mark
the position of the four holes in the bracket onto the shims.
C. Drill the necessary holes in the shims with the 0.191 in. (4,85
mm) drill.
D. Deburr the holes.
8. Install the Replacement Bracket
A. Refer to Fig. 201 (Sheet 1, 2 and 3 ) .
B. Clean the mating faces of the shims, replacement bracket and

pre-cooler duct. Refer to AMM TASK 70-20-01-100-802for the
procedure to clean the parts.
C. Put a thin layer of OMat 8/177 sealing compound on the cleaned

mating faces and on the pins (9) .
D. Install the bracket with the pins (9) and collars (10), refer
to SRM 54-02-10 for the procedure to install the pins.
E. Remove the unwanted sealant, refer to AMM TASK 70-20-01-100-

802.
F. Put a bead of OMat 8/173 sealant around the edges of the

brackets and shims.
9. Connect the Support Rod to the Pre-Cooler Duct
A. Refer to Fig. 201 (Sheet 2).
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STRUCTURAL REPAIR
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B. Connect the support rod to its related bracket with the bolt
( 2 ) , bush (3), sleeve bushing (4) and the nut (5).
C. Torque the nut (5) to 100 lbf. In '(11,3 Nm), refer to SRM 54-
02-07.
10. Examine the Repair
A. Examine the repair to make sure that the referenced procedures

have been completed satisfactorily.
A. Use an OMat 262, TEMPORARY MARKER to write FRSX107 on the

replacement bracket.
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1 SUPPORT RODS
Pre-Cooler Duct
Fig. 201 (Sheet 1)
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2 BOLT
SUPPORT
ASSEMBLY
\
LOCKING 4 BUSHING
SLEEVE
TYPICAL AT
2 POSITIONS
Pre-Cooler Duct
Fig. 201 (Sheet 2)
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BRACK
REAR
9 PIN-HILITE
TYPICAL AT
8 POSITIONS
0 4 , 8 5 mm
/ U (0.191 in)
io COLLOR-HI'LITE TYPICAL AT
TYPICAL AT SECTION 8 POSITIONS
8 POSITIONS A-A
VIEW AT D
WITH COLLOR-HILITE
AND PIN-HILITE REMOVED
TYPICAL FOR ALL HOLES
BRACKET
FRONT
SHIM
U
SECTION
B-B
Pre-Cooler Duct
Fig. 201 (Sheet 3)
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REPAIR NO. 15
THRUST REVERSER
POST SB 78-B819, PRE SB 78-E343: REPAIR OF REAR CORNERS ON THE PRE-
COOLER DUCT
FRSX10 9
1. General
A. T h i s r e p a i r i n s t r u c t s procedures t o r e p a i r c r a c k s i n t h e r e a r
c o r n e r s of t h e Pre-cooler d u c t by s t o p d r i l l i n g and t h e
i n s t a l l a t i o n of t h r e e p i e c e p a t c h e s t o r e - i n f o r c e t h e r e a r
corners.
B. This r e p a i r i s only a p p l i c a b l e t o Post SB78-B819 ( i n c o n e l ) , Pre

SB 78-E343 s t a n d a r d of Pre-cooler d u c t s .
C. The procedures a r e i n two p a r t s
Part 1 - i n s t r u c t s r e p a i r of a cracked p r e - c o o l e r d u c t , t h a t h a s
n o t been r e p a i r e d b e f o r e , by i n s t a l l a t i o n of t h r e e
piece patches.
Part 2 - i n s t r u c t s removal of a p r e v i o u s l y i n s t a l l e d one p i e c e

p a t c h (FRSX100) t h a t i s cracked/uncracked and
i n s t a l l a t i o n of replacement t h r e e p i e c e p a t c h e s .
D. There a r e two r e a r c o r n e r s , an upper and lower
- I f one c o r n e r i s n o t cracked, i t i s recommended t h a t i t i s

r e - i n f o r c e d a t t h e same t i m e a s t h e cracked c o r n e r i s
r e p a i r e d , r e f e r t o SB 78-E343 f o r t h e i n s t r u c t i o n s .
- I f one c o r n e r i s r e p a i r e d with a one p i e c e p a t c h (FRSX100 o r

TVF 27609 o r 31108, o r 32042) t h a t has n o t cracked, i t i s
recommended t h a t i t i s removed and r e p l a c e d with t h r e e p i e c e
p a t c h e s , a t t h e same time a s t h e cracked c o r n e r i s r e p a i r e d ,
refer t o Part 2 for the instructions.
NOTE: The Pre-cooler Duct i n s p e c t i o n i n t e r v a l given i n NMSB

78-B679 i s extended when both c o r n e r s a r e r e p a i r e d / r e -
i n f o r c e d with t h r e e p i e c e p a t c h e s .
E. The f i g / i t e m numbers r e f e r r e d t o i n t h e procedures a g r e e with

t h o s e used i n t h e Power P l a n t I l l u s t r a t e d P a r t s Catalog (PPIPC).
Only t h e primary f i g / i t e m numbers a r e used. For d i f f e r e n t
S e r v i c e B u l l e t i n s t a n d a r d s r e f e r t o t h e PPIPC.
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...................................................................
fasteners
AMM TASK 70-20-01-100-802 Non-Aqueous Liquid Degreasing

- Micrometer 0-25 mm (0-1.0 in.)
- Bench drill, variable speed
- Hand riveting machine
- Gripper pins - 2.5 mm (0.098 in.), 3.3 mm (0.13 in.) and 4.1 mm
(0.161 in) dia
- Hand held drill machine, variable speed
- Drills, 2.5 nun (0.098 in.), 3.0 nun (0.118 in.), 3.17 mm (0.125
in.), 3.3 mm (0.13 in.), 4.0 nun (0.157 in.) and 4.1 mm (0.161
in.) dia (Cleveland cobalt 3713 series or equivalent)
- Flameproof heat lamp or heat blanket and thermocouples 0-250
deg C (optional)
- Drill bush, 4.1 nun (0.161 in.) external diameter and 2.5 mm
(0.098 in.) internal diameter.
...................................................................
OMat 262 Temporary marker felt/fibre tip, EM56752

oMat 2/12 Paint brush 1.0 in.
OMat 508 Polishing bob
OMat 584 Scotch Brite
OMat 8/173 Adhesive/sealant, 44-2817
OMat 8/177 Sealing compound, DC 93-076-2
OMat 8/202 Release agent, QZ 5111
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C. Repair Parts
78-33-13
..........................................................................
F I G ITEM ITEM DESIGNATION P/N QTY USEAGE
..........................................................................
01-810 K i t , re- .91B001-03 l
inforcement, lower
rear corner
202/1 - 01-812 Patch ..RP3020-01 1
203/1
202/2 - 01-814 Patch ..RP3020-02 1
203/2
202/3 - 01-816 Patch ..RP3020-03 1
203/3
203/4 01-825 Rivet ..NAS1919M05S06U 7
203/4 01-826 Rivet ..NAS1919M05S07U 7
(alternative)
203/5 01-828 Rivet ..NAS1919M05S04U 16
203/5 01-829 Rivet ..NAS1919M05S05U 16
(alternative)
203/5 01-830 Rivet ..NAS1919M05S06U 16
(alternative)
203/6 01-821 Rivet ..NAS1919M05S03U 10
203/6 01-822 Rivet ..NAS1919M05S04U 10
203/7 01-844 Rivet ..NAS1919M05S05U 4
NOTE: D o n o t u s e a l t e r n a t i v e s t o N A S 1 9 1 9 series r i v e t s .
78-33-13
.........................................................................
FIG ITEM ITEM DESIGNATION P/N QTY USEAGE
.........................................................................
01-831 Kit, re-inforcement .91B002-03 1
- upper rear corner
202/1 - 01-832 Patch ..RP3020-04 1
203/1
202/2 - 01-834 Patch ..RP3020-05 1
203/2
202/3 - 01-836 Patch ..RP3020-06 1
203/3
203/4 01-845 Rivet ..NAS1919M05S06U 7 (1)
203/4 01-846 Rivet ..NAS1919M05S07U 7 (1
(alternative)
203/5 01-848 Rivet ..NAS1919M05S04U 16 (1
203/5 01-849 Rivet ..NAS1919M05S05U 16 (1
(alternative)
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203/5 01-850 Rivet ..NAS1919M05S06U 16 (1)

(a1ternative)
203/6 01-841 Rivet ..NAS1919M05S03U 10 (1)
203/6 01-842 Rivet ..NAS1919M05S04U 10 (1)
(a1ternative)
203/7 01-854 Rivet ..NAS1919M05S05U 4
NOTE: Do not use alternatives to NAS1919 series rivets.
Usage code
(1) - Use on other applications if not required
D. Local Manufacture Parts

.........................................................................
FIG ITEM ITEM DESIGNATION P/N MATERIAL QTY
..........................................................................
202/4 - N/A Shim Local A286
203/8 Manufacture stainless A/R
0.80 mm
(0.032
in.)
NOTE: The shim will only be required if there is too much clearance
between the patch (01-816, 01-836) and the duct.
E. Material of Component
COMPONENT SYMBOL MATERIAL

...................................................................
Pre-cooler duct
(78-33-13, 01-200) Inconel 625
Patches
(78-33-13, 01-812,
01-814,Ol-816, 01-832,
01-834, and 01-836) Inconel 625
Shim Stainless steel A286
GLOVES, DUST MASK AND SAFETY GOGGLES. THIS IS TO PROTECT YOU
AGAINST DUST AND LOOSE PARTICLES, WHICH CAN BE DANGEROUS TO YOUR
HEALTH.
WARNING: WHEN YOU USE CLEANING MATERIALS, ADHESIVES, COATING AND SEALANT,
REFER TO, AND OBEY, THE MANUFACTURER'S CONTROL AND APPLICATION
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PART 1 PROCEDURE
N 0 T E : T h e procedures t h a t f o l l o w are f o r t h e repair of t h e l o w e r

rear c o r n e r . T h e procedures f o r upper rear corner are t h e
same.
5. Stop D r i l l t h e C r a c k - Part 1
A. D o a penetrant crack t e s t t o f i n d t h e end of t h e crack. R e f e r t o

AMM TASK 7 0 - 2 0 - 0 2 - 2 3 0 - 8 0 4 .
B. U s e a 3 , O mm ( 0 . 1 1 8 i n . ) d i a d r i l l t o s t o p d r i l l t h e crack.
C. D o a penetrant crack test t o m a k e s u r e t h e crack has been

stopped. R e f e r t o AMM TASK 7 0 - 2 0 - 0 2 - 2 3 0 - 8 0 4
(1) If t h e crack has n o t been stopped, ( a n d i f another hole

d i a m e t e r and crack t o g e t h e r w i l l n o t be m o r e t h a n t h e
l i m i t s given i n 5 . B . ( 1 ) , s t o p d r i l l t h e crack again. D o
another p e n e t r a n t crack t e s t .
(2) R e f e r t o A i r c e l l e i f t h e crack has n o t been stopped.
CAUTION: YOU MUST BE CAREFUL YOU DO NOT DAMAGE THE HOLES WHEN YOU
REMOVE THE RIVETS
D. R e m o v e t h e r i v e t s t h a t a t t a c h t h e P r e - c o o l e r d u c t t o t h e joggle
p l a t e , w h e r e the patches are t o be i n s t a l l e d . R e f e r t o f i g u r e
2 0 1 . R e f e r t o SRM 5 4 - 0 2 - 1 0 f o r t h e procedure t o r e m o v e t h e
rivets.
CAUTION: MAKE SURE YOU DO NOT REMOVE MATERIAL FROM THE PRE-COOLER
DUCT FLANGE AND INNER WALL WHEN YOU DRESS THE WELD BEADS.
E. U s e hand t o o l s t o dress t h e w e l d beads ( i n t h e repair a r e a s )

u n t i l they are n o t m o r e than 0 , 2 0 mm ( 0 . 0 0 8 i n . ) i n h e i g h t . T h e n
u s e an O M a t 5 0 8 p o l i s h i n g bob t o m a k e t h e w e l d beads s m o o t h .
F. C l e a n t h e pre-cooler d u c t . R e f e r t o AMM TASK 7 0 - 2 0 - 0 1 - 1 0 0 - 8 0 2 .
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6. Prepare t h e P a t c h e s - Part 1
A. A d j u s t t h e patches t o t h e P r e - c o o l e r d u c t , refer t o F i g u r e 203
(1) T e m p o r a r i l y i n s t a l l t h e patches ( 0 1 - 8 1 2 , 0 1 - 8 1 4 and 0 1 - 8 1 6 )

on t h e P r e - c o o l e r d u c t . C h e c k t h a t t h e clearances b e t w e e n
t h e patches and t h e duct are n o t m o r e t h a n 0 , 4 0 mm ( 0 . 0 1 6
in.).
(2) R e m o v e t h e patches arid i f necessary, u s e hand t o o l s t o

change t h e contours of t h e patches t o g e t t h e correct
clearances. D o n o t r e m o v e m a t e r i a l f r o m t h e patches. If t h e
contours are changed, do a f l u o r e s c e n t p e n e t r a n t crack test
of t h e applicable patch and area. R e f e r t o AMM TASK 7 0 - 2 0 -
02-230-804.
NOTE: If necessary, a l o c a l l y m a n u f a c t u r e d s h i m can be

i n s t a l l e d b e t w e e n t h e patch 3 F i g u r e 2 0 3 and t h e
i n n e r w a l l of t h e d u c t . R e f e r t o F i g u r e 202 ( i t e m
4 ) , 203 ( i t e m 8 ) and 2 . C . R e p a i r P a r t s .
B. D r i l l t h e patches and P r e - c o o l e r duct - P a r t 1
(1) Limits
- M i n i m u m distance b e t w e e n any r i v e t and a crack m u s t be

1 2 , O mm ( 0 . 4 8 i n . )
- M i n i m u m edge distance t o any r i v e t m u s t be 1 0 , O mm ( 0 . 4 0
in.)
- Where possible ( s o m e i n i t i a l r i v e t s i n t h e joggle p l a t e
are 1 5 , O mm ( 0 . 6 0 i n . ) p i t c h ) t h e m i n i m u m p i t c h b e t w e e n
t w o r i v e t s m u s t be 2 0 , O mm ( 0 . 8 0 i n . )
- T h e r e m u s t be a r i v e t l i n e b e t w e e n t h e crack and t h e
edges of t h e patches
- T h e end of t h e crack m u s t n o t be less than 1 2 , O mm ( 0 . 4 8
i n . ) f r o m t h e edge r i v e t l i n e .
(2) D r i l l t h e parts
CAUTION: WHEN YOU USE THE I N I T I A L HOLES OR THE

RECOMMENDED P O S I T I O N S O F NEW HOLES TO MARK AND
SUBSEQUENTLY D R I L L THE PATCHES, YOU MUST MAKE
SURE THE HOLES W I L L AGREE WITH THE L I M I T S GIVEN
I N 5 . B . ( l ) . I F THEY DO NOT AGREE, PUT THE
APPLICABLE HOLES I N ALTERNATIVE P O S I T I O N S .
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Note: U s e an OMat 262 marker o r a s c r i b e r t o mark t h e

hole positions.
Note: The p r e - c o o l e r d u c t and p a t c h m a t e r i a l i s very

h a r d . When i t i s p o s s i b l e u s e a bench d r i l l . A
d r i l l speed between 300 and 500 rpm i s recommended
when you d r i l l t h e i n i t i a l h o l e s . U s e 1200 rpm when
you increment d r i l l t h e i n i t i a l h o l e s t o make them
larger.
(a) Put t h e p a t c h e s (01-812, 01-814 and 01-816) (and, i f

r e q u i r e d , t h e shim) i n p o s i t i o n and i n good c o n t a c t
( c l e a r a n c e s must n o t be more than 0 , 4 mm (0.016 i n . ) )
with each o t h e r , keep them i n p o s i t i o n .
(b) Through mark t h e p a t c h e s (01-814 and 01-816) w i t h t h e

p o s i t i o n s of t h e f o u r i n i t i a l h o l e s A and t h r e e
i n i t i a l h o l e s ' B ' (where t h e joggle p l a t e r i v e t s " A '
and ' B ' were removed i n s t e p 4 . D . ) .
(C) Remove t h e p a t c h e s .
(d) Mark t h e p a t c h (01-814) with t h e p o s i t i o n s f o r t h e

f o u r h o l e s 'C'and s i x h o l e s ' D ' r e f e r t o f i g u r e 202
and 203 f o r t h e dimensions.
(e) U s e a c e n t r e punch t o mark t h e c e n t r e of t h e h o l e s

A ' C ' , and ' D ' .
(f) D r i l l 3,17 mm (0.125 i n . ) diameter h o l e s ('A') i n the

p a t c h (01-814).
(g) D r i l l 2 , 5 mm (0.098 i n . ) diameter h o l e s ( ' C ' and ' D ' )

i n t h e p a t c h (01-814) . U s e 3 , 3 mm (0.130 i n . ) and 4 , l
mm (0.161 i n . ) diameter d r i l l s , i n increments, t o
d r i l l the holes t o f i n a l s i z e .
(h) U s e a c e n t r e punch t o mark t h e c e n t r e of t h e t h r e e

h o l e s ' B ' i n patch (01-816).
( i ) D r i l l 3,17 mm (0.125 i n . ) diameter h o l e s ('B') i n the

p a t c h (01-816).
(j) Mark t h e p a t c h (01-812) with t h e p o s i t i o n s of s i x

h o l e s ' E ' and t e n h o l e s ' F ' , r e f e r t o f i g u r e 203.
(k) U s e a c e n t r e punch t o mark t h e c e n t r e of t h e h o l e s 'E

andlF'.
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(1) D r i l l 2 , 5 nun ( 0 . 0 9 8 i n . ) d i a m e t e r h o l e s i n t h e p a t c h
(01-812) a t s i x p o s i t i o n s ' E ' a n d t e n ' F ' . U s e 3 , 3 nun
( 0 . 1 3 0 i n . ) a n d 4 , l mm ( 0 . 1 6 1 i n . ) d i a m e t e r d r i l l s ,
i n increments, t o d r i l l t o f i n a l s i z e .
(m) Deburr a11 t h e h o l e s .
(n) C l e a n t h e d u c t r e p a i r area a n d t h e p a t c h e s . R e f e r t o
AMM TASK 70-20-01-100-802.
(0) I n s t a l l t h e p a t c h e s (01-814) a n d (01-816) ( a n d , i f

r e q u i r e d , t h e shim) w i t h g r i p p e r p i n s t o k e e p them i n
position.
(p) P u t t h e p a t c h (01-812) i n p o s i t i o n , make s u r e i t h a s

good c o n t a c t ( c l e a r a n c e s must n o t be more t h a n 0 , 4 nun
( 0 . 0 1 6 i n . ) ) with the patches (01-814) and (01-816) .
(q) U s e a 4 , l nun ( 0 . 1 6 1 i n . ) d r i l l b u s h a n d 2,5 nun ( 0 . 0 9 8

i n . ) d r i l l t o t h r o u g h d r i l l t h e p a t c h e s (01-814) ,
(01-816) a n d d u c t from t h e h o l e s ( ' C ' , ' D ' , ' E ' a n d
' F' ) i n t h e p a t c h e s .
(r) U s e a 4 , l mm ( 0 . 1 6 1 i n . ) d i a m e t e r d r i l l t o t h r o u g h
d r i l l t h e h o l e s 'A' a n d ' B ' i n t h e p a t c h e s (01-814
a n d 01-816) and t h e d u c t .
(S) Remove t h e p a r t s from t h e d u c t .
( t ) U s e 3 , 3 mm ( 0 . 1 3 0 i n . ) a n d 4 , l mm ( 0 . 1 6 1 i n . )
diameter drills, i n increments, t o d r i l l t h e h o l e s
( ' C ' , ' D ' , ' E ' and ' F ' ) t o f i n a l s i z e .
(U) Deburr t h e h o l e s .
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7. Liquid Shim t h e Patches - Part 1
A. L i g h t l y abrade t h e mating s u r f a c e s of t h e Pre-cooler d u c t and

t h e p a t c h e s with OMat 584 s c o t c h b r i t e .
B. Clean t h e p a t c h e s and t h e a r e a s where they w i l l be i n s t a l l e d .

Refer t o AMM TASK 70-20-01-100-802.
C. U s e an OMat 2/12 p a i n t brush ( o r e q u i v a l e n t ) t o apply t h r e e

l a y e r s of OMat 8/202 r e l e a s e a g e n t t o one mating s u r f a c e of each
p a t c h (and, i f r e q u i r e d , t h e s h i m ) . Apply t h e l a y e r s a t 10 t o 15
minute i n t e r v a l s . When they a r e d r y p o l i s h them with an OMat
2/101 l i n t f r e e c l o t h . Refer t o Figure 203.
Note: O M a t 8/202 r e l e a s e a g e n t i s a p p l i e d t o one mating f a c e of

each p a t c h (and shim, i f r e q u i r e d ) o n l y , a s t h e OMat
8/154 adhesive w i l l cause t h e p a t c h e s to adhere t o mating
f a c e s of t h e d u c t o r each o t h e r .
D. Put 33 o f f g r i p p e r p i n s f u l l y i n t o OMat 8/202 r e l e a s e a g e n t . Do

t h i s t h r e e t i m e s , l e t them d r y between each l a y e r .
E. Apply a t h i c k l a y e r of O M a t 8/154 adhesive t o one mating s u r f a c e

of each p a t c h (and, i f r e q u i r e d , t h e s h i m ) .
F. Put t h e p a t c h e s (and shim, i f r e q u i r e d ) on t h e Pre-cooler d u c t

and i n s t a l l t h e g r i p p e r p i n s . U s e your hand t o t i g h t e n them a s
much a s p o s s i b l e . Remove t h e unwanted adhesive. Refer t o AMM
TASK 70-20-01-100-802.
G. Cure t h e OMat 8/154 adhesive, u s e a flameproof h e a t lamp o r h e a t

blanket i f necessary.
H. Release t h e g r i p p e r p i n s and remove t h e p a r t s .
8. I n s t a l l t h e Patches - Part 1
A. Apply a t h i n l a y e r of OMat 8/177 s e a l a n t t o t h e mating s u r f a c e s

of t h e p a t c h e s (and shim, i f r e q u i r e d ) .
B. Put t h e p a t c h e s i n t h e i r r e l a t e d p o s i t i o n s on t h e Pre-cooler
duct.
C. I n s t a l l g r i p p e r p i n s t o keep t h e p a t c h e s i n p o s i t i o n while you

i n s t a l l t h e r i v e t s . Refer t o f i g u r e 202.
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D. Refer t o f i g 203 f o r t h e r i v e t p o s i t i o n s . S e l e c t r i v e t s with t h e

a p p l i c a b l e g r i p l e n g t h . U s e OMat 8/177 s e a l i n g compound t o w e t
i n s t a l l them from t h e i n s i d e of t h e d u c t . Refer t o SRM 54-02-10
f o r t h e procedure t o i n s t a l l t h e r i v e t s .
E. Remove any unwanted s e a l i n g compound. Refer t o AMM TASK 70-20-

01-100-802.
F. Put a smooth bead of OMat 8/173 a d h e s i v e / s e a l a n t around t h e

edges of t h e p a t c h e s .
9. Examine t h e Repair - Part 1
A. Examine t h e r e p a i r t o make s u r e t h e referenced procedures have

been done c o r r e c t l y .
1 0 . I d e n t i f y t h e Repair - Part 1
A. I f only one r e a r corner has been r e p a i r e d and t h e o t h e r r e a r

c o r n e r i s n o t r e p a i r e d mark 'FRSX109 P a r t l ' , a d j a c e n t t o t h e
p a r t number of t h e pre-cooler d u c t , use an OMat 262 marker of a
contrasting colour.
B. I f both r e a r c o r n e r s a r e r e p a i r e d with t h r e e p i e c e patches r e f e r

t o SB 78-E343 f o r t h e i d e n t i c a t i o n requirements.
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PART 2 PROCEDURE
NOTE: The procedures t h a t follow a r e f o r t h e r e p a i r of t h e lower r e a r

c o r n e r . The procedures f o r t h e upper r e a r c o r n e r a r e t h e same.
11. Remove t h e One Piece Patch - Part 2
A. Remove t h e r i v e t s t h a t i n s t a l l t h e p a t c h , r e f e r t o SRM 54-02-10.
B. Remove and d i s c a r d t h e p a t c h .
1 2 . Examine t h e Stop D r i l l e d Crack - Part 2
A. Do a f l u o r e s c e n t p e n e t r a n t crack t e s t t o make s u r e t h e c r a c k
c o n t i n u e s t o be stopped, r e f e r t o AMM TASK 70-20-02-230-804.
B. I f t h e c r a c k h a s gone p a s t t h e o r i g i n a l s t o p d r i l l e d h o l e , (and
i f a n o t h e r h o l e diameter and crack t o g e t h e r w i l l n o t be more
t h a n t h e l i m i t s given i n 1 2 . B . ( l ) ) s, t o p d r i l l t h e c r a c k
a g a i n . Do a n o t h e r f l u o r e s c e n t p e n e t r a n t crack t e s t .
(1) Refer t o Aircelle i f t h e crack has n o t been stopped.
C. Clean t h e p r e - c o o l e r d u c t . Refer t o AMM TASK 70-20-01-100-802.
13. Prepare t h e Patches - Part 2
Note: U s e an OMat 262 marker o r a s c r i b e r t o mark t h e h o l e

positions.
A. Adjust t h e p a t c h e s t o t h e Pre-cooler d u c t , r e f e r t o Figures 202

and 203
(1) Temporarily i n s t a l l t h e p a t c h e s (01-812, 01-814 and 01-816)

on t h e Pre-cooler d u c t . Check t h a t t h e c l e a r a n c e s between
t h e p a t c h e s and t h e d u c t a r e n o t more than 0,40 nun (0.016
in.).
(2) Remove t h e p a t c h e s and, i f necessary, u s e hand t o o l s t o

change t h e contours of t h e p a t c h e s t o g e t t h e c o r r e c t
c l e a r a n c e s . Do n o t remove m a t e r i a l from t h e p a t c h e s . I f t h e
c o n t o u r s a r e changed, do a f l u o r e s c e n t p e n e t r a n t crack test
of t h e a p p l i c a b l e p a t c h and a r e a . Refer t o AMM TASK 70-20-
02-230-804.
NOTE: I f n e c e s s a r y , a l o c a l l y manufactured shim can be

i n s t a l l e d between t h e p a t c h (01-816) and t h e i n n e r w a l l
of t h e d u c t .
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B. S e l e c t which i n i t i a l r i v e t h o l e s c a n b e u s e d t o i n s t a l l t h e
patches.
CAUTION: YOU MUST USE THE INITIAL RIVET HOLES WHERE POSSIBLE.
WHEN YOU USE INITIAL HOLES TO MARK AND SUBSEQUENTLY
DRILL THE PATCHES, YOU MUST MAKE SURE THE HOLES AGREE
WITH THE LIMITS THAT FOLLOW. I F THEY DO NOT AGREE, PUT
THE APPLICABLE HOLES I N ALTERNATIVE POSITIONS.
(1) Limits
- Minimum d i s t a n c e between any r i v e t a n d a c r a c k m u s t b e

12,O mm ( 0 . 4 8 i n . ) .
- Minimum edge d i s t a n c e t o any r i v e t must b e 10,O mm ( 0 . 4 0
in.).
- Where p o s s i b l e (some i n i t i a l r i v e t s i n t h e j o g g l e p l a t e
are 15,O mm ( 0 . 6 0 i n . ) p i t c h ) , minimum p i t c h between two
r i v e t s must be 20,O mm ( 0 . 8 0 i n . ) .
- T h e r e must be a r i v e t l i n e between t h e c r a c k a n d t h e
- The e n d o f t h e c r a c k must b e n o t less t h a n 12 mm ( 0 . 4 8
i n . ) from t h e r i v e t l i n e a t t h e e d g e .
C. Mark t h e p o s i t i o n s o f t h e a l t e r n a t i v e h o l e s on t h e d u c t a n d
d r i l l them i n t h e d u c t w i t h . 2,5 mm ( 0 . 0 9 8 i n . ) , 3 , 3 mm ( 0 . 1 3 0
i n . ) a n d 4 , l mm ( 0 . 1 6 1 i n . ) d r i l l s , i n i n c r e m e n t s .
D. Deburr t h e h o l e s a n d c l e a n t h e d u c t r e p a i r areas a n d p a t c h e s .
R e f e r t o AMM TASK 70-20-01-100-802.
E. I n s t a l l t h e p a t c h e s (01-812, 01-814 a n d 01-816) ( a n d , i f

r e q u i r e d , t h e shim) i n p o s i t i o n a n d i n good c o n t a c t ( c l e a r a n c e s
m u s t n o t be more t h a n 0 , 4 mm ( 0 . 0 1 6 i n . ) a n d k e e p them on t h e
duct.
F. U s e a d r i l l b u s h a n d 2 , 5 mm ( 0 . 0 9 8 i n . ) d r i l l t o d r i l l t h e h o l e s
' F ' , from t h e d u c t , i n t h e p a t c h 01-812 ( o r t h e shim a n d p a t c h ) .
R e f e r t o F i g u r e 203.
G. U s e a d r i l l b u s h a n d 2 , 5 mm ( 0 . 0 9 8 i n . ) d r i l l t o t h r o u g h d r i l l
t h e a l t e r n a t i v e h o l e s from t h e d u c t , i n t h e p a t c h e s ( a n d s h i m ) .
H. Through mark t h e p a t c h e s w i t h t h e h o l e p o s i t i o n s t h a t c a n n o t be
accessed f o r d r i l l i n g .
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I. D r i l l t h e Patches and Pre-cooler Duct
(1) D r i l l the parts
NOTE: The p r e - c o o l e r d u c t and p a t c h m a t e r i a l i s very

h a r d . When i t i s p - o s s i b l e u s e a bench d r i l l . A
d r i l l speed between 300 and 500 rpm i s recommended
when you d r i l l t h e i n i t i a l h o l e s . Use 1200 rpm when
you increment d r i l l t h e i n i t i a l h o l e s t o make them
larger.
(a) Remove t h e p a t c h e s and c e n t r e punch a l l t h e marked

p o s i t i o n s i n t h e p a t c h e s (and, i f r e q u i r e d , t h e
shim) .
(b) D r i l l 2 . 5 mm (0.098 i n . ) diameter h o l e s ' B ' i n t h e

p a t c h (01-816) and ' A ' , ' C ' and ' D ' i n t h e p a t c h (01-
8 1 4 ) . Refer t o Figure 203.
(C) Use 3 . 3 mm (0.130 i n . ) and 4 . 1 mm (0.161 i n . )

diameter d r i l l s , i n increments, t o d r i l l t h e h o l e s
'A','B', C ' , ' D 1 and ' F ' t o f i n a l s i z e .
(d) Deburr a l l t h e h o l e s .
(e) Clean t h e d u c t r e p a i r a r e a and t h e p a t c h e s , r e f e r t o

AMM TASK 70-20-01-100-802.
(f) I n s t a l l t h e p a t c h e s (01-814) and (01-816), and, i f

a p p l i c a b l e , t h e shim with g r i p p e r p i n s t o keep t h e
parts i n position.
(g) Put t h e p a t c h (01-812) i n p o s i t i o n with g r i p p e r p i n s ,

make s u r e i t h a s good c o n t a c t ( c l e a r a n c e s must n o t be
more than 0 . 4 mm (0.016 i n . ) ) , with t h e p a t c h e s (01-
814) and (01-816).
(h) Through mark t h e p a t c h (01-812) with t h e p o s i t i o n s of

t h e h o l e s of t h e h o l e s ' E ' . Refer t o Figure 203.
(i) D r i l l t h e a l t e r n a t i v e h o l e s i n t h e p a t c h e s (shim) U s e
2 . 5 mm (0.098 i n . ) , 3 . 3 mm (0.130 i n . ) and 4 , l mm
(0.161 i n . ) diameter d r i l l s , i n increments.
(j) Remove t h e p a t c h e s from t h e d u c t
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(k) Use 2 . 5 mm (0.098 i n . ) , 3 . 3 mm (0.130 i n . ) and 4 . 1 mm

(0.161 i n . ) diameter d r i l l s , i n increments, t o d r i l l
t h e h o l e s ' E ' i n t h e p a t c h (01-812).
(1) Deburr t h e h o l e s .
(m) Clean t h e p a t c h . Refer t o AMM TASK 70-20-01-100-802.
1 4 . L i a u i d shim t h e ~ a t c h e s- P a r t 2
A. L i g h t l y abrade t h e mating s u r f a c e s of t h e Pre-cooler d u c t with

OMat 584 s c o t c h b r i t e .
B. Clean t h e p a t c h e s and t h e a r e a s where they w i l l be i n s t a l l e d .

Refer t o AMM TASK 70-20-01-100-802.
C. U s e an O M a t 2/12 p a i n t brush ( o r e q u i v a l e n t ) t o apply t h r e e l a y e r s

of OMat 8/202 r e l e a s e a g e n t t o one mating s u r f a c e of each p a t c h .
Refer t o f i g u r e 203 f o r t h e l o c a t i o n s . Apply t h e l a y e r s a t 10 t o
15 minutes i n t e r v a l s . When they d r y p o l i s h them with an OMat 2/101
l i n t free cloth.
Note: OMat 8/202 r e l e a s e agent i s a p p l i e d t o one mating f a c e of

each p a t c h (and shim, i f r e q u i r e d ) o n l y , a s t h e OMat 8/154
adhesive w i l l cause t h e p a t c h e s t o adhere t o t h e i r mating
faces.
D. Immerse 33 o f f g r i p p e r p i n s i n OMat 8/202 r e l e a s e a g e n t . Do t h i s

t h r e e t i m e s , l e t each l a y e r d r y b e f o r e you apply t h e n e x t .
E. Apply a t h i c k l a y e r of OMat 8/154 adhesive t o one mating s u r f a c e

of each p a t c h , and, i f r e q u i r e d , t h e shim.
F. Put t h e p a t c h e s (and shim) on t h e Pre-cooler d u c t and i n s t a l l t h e

g r i p p e r p i n s . Use your hand t o t i g h t e n them a s much a s p o s s i b l e .
Remove t h e unwanted adhesive. Refer t o AMM TASK 70-20-01-100-802,
e x c e p t t h e unwanted i n i t i a l r i v e t h o l e s .
G. Cure O M a t 8/154 adhesive, u s e a flameproof h e a t lamp o r h e a t

blanket i f necessary.
H. Release t h e g r i p p e r p i n s and remove t h e p a r t s .
15. I n s t a l l t h e patches - P a r t 2 , r e f e r t o Figures 202 and 203
A. Apply a t h i n l a y e r OMat 8/177 s e a l a n t t o t h e mating s u r f a c e s of

t h e p a t c h e s (01-812, 01-814 and 01-816) (and shim, i f r e q u i r e d ) .
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B. Put them i n t h e i r r e l a t e d p o s i t i o n s on t h e Pre-cooler d u c t .
C. I n s t a l l g r i p p e r p i n s t o keep t h e p a t c h e s i n p o s i t i o n w h i l s t you
i n s t a l l the r i v e t s .
D. Refer t o f i g 203 f o r t h e r i v e t p o s i t i o n s . S e l e c t r i v e t s with t h e

a p p l i c a b l e g r i p l e n g t h . Use OMat 8/177 s e a l i n g compound t o w e t
i n s t a l l them from t h e i n s i d e of t h e d u c t . Refer t o SRM 54-02-10
f o r t h e procedure t o i n s t a l l t h e r i v e t s .
E. U s e O M a t 8/177 s e a l i n g compound t o wet i n s t a l l t h e f o u r r i v e t s

(01-824) ) a t p o s i t i o n s ' G ' .
F. Remove any unwanted s e a l i n g compound. Refer t o AMM TASK 70-20-

01-100-802.
G. Put a smooth bead of OMat 8/173 a d h e s i v e / s e a l a n t around t h e

1 6 . Examine t h e r e p a i r - Part 2
A. Examine t h e r e p a i r t o make s u r e t h e r e f e r e n c e d procedures have

been done c o r r e c t l y .
17. I d e n t i f y t h e r e p a i r - Part 2
A. I f o n l y one r e a r c o r n e r has been r e p a i r e d and t h e o t h e r r e a r

c o r n e r i s n o t r e p a i r e d mark 'FRSX109 P a r t 2 ' a d j a c e n t t o t h e
p a r t number of t h e p r e c o o l e r d u c t , u s e OMat 262 marker of a
contrasting colour.
B. I f both r e a r c o r n e r s a r e r e p a i r e d with t h r e e p i e c e p a t c h e s .
Refer t o SB 78-E343 f o r t h e i d e n t i c a t i o n requirements.
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WELDTO BE 1/
RIVETS TO
BE REMOVED
NOTE: RIVETS ARE REMOVED
FOR PART 1 ONLY
Part 1 - Rivet R e m o v a l
Figure 201
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TWO EQUAL
v
SPACES
+
4-LOCAL MANUFACTURE SHIM
DIMENSIONS AS MATING
SURFACE OF (3)
FIVE EQUAL SPACES
HE CRACK MUST BE 0.48in (12,Omm)

) MINIMUM FROM RIVET LINE.
TYPICAL EDGE DISTANCE
Part 1 and 2 - Dimensions

Figure 202
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> 81202
SURFACE FOR OMAT
RELEASE AGENT
APPLICATION
T-
m
N INSTALL THE RIVETS
6
0
U
0
FROM INSIDE THE DUCT
L
P a r t s 1 and 2
I d e n t i f i c a t i o n of R e p a i r P a r t s .
Figure 203
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Repair No. 16 . , ~..
1. General
T h i s r e p a i r g i v e s t h e procedures t o r e p a i r c r a c k s i n t h e upper
and lower f r o n t c o r n e r s of t h e p r e - c o o l e r d u c t , by i n s t a l l a t i o n
of a pre-formed p a t c h on t h e i n n e r contoured s u r f a c e .
T h i s r e p a i r i s a p p l i c a b l e t o Post SB78-B819 (inconel) pre-

cooler ducts only.
The Fig/Item numbers r e f e r r e d t o i n t h e procedures a g r e e with

t h o s e used i n t h e Power P l a n t I l l u s t r a t e d P a r t s Catalog
(PPIPC). Only t h e primary ~ i g / ~ t enumbers m a r e used. For
d i f f e r e n t S e r v i c e B u l l e t i n s t a n d a r d s r e f e r t o t h e PPIPC.,
........................................................................
SRM 54-02-10 Removal and i n s t a l l a t i o n of f a s t e n e r s
AMM TASK 70-20-02-230-804 Fluorescent penetrant inspection
AMM TASK 70-20-01-100-802 Non aqueous l i q u i d degreasing
PPIPC 78-33-13 Power P l a n t I l l u s t r a t e d P a r t s Catalogue
3. Eauiwment and M a t e r i a l s
Standard workshop t o o l s and equipment.

Flame proof h e a t lamp o r h e a t b l a n k e t and thermocouples, 0 - 120
deg C (32 - 250 deg F ) .
D r i l l s 2 , 5 mm (0.098 i n . ) , 3,2 mm (0.126 i n . ) , 4 , 0 'mm (0 .'l57 i n . ) ,
4 , l mm (0.163 i n . ) and 4 , 8 mm (0.189 i n . ) d i a m e t e r s (Cleveland
c o b a l t 3713 series o r e q u i v a l e n t ) .
Gripper p i n s : 18 o f f 3 . 2 mm (0.126 i n . ) d i a l 18 o f f 4 , l mm (0.163
i n . ) d i a and 21 o f f 4 , 8 mm (0.189 i n . ) d i a m e t e r s .
B. Consumable m a t e r i a l s
......................................................................
......................................................................
O M a t 212 P a i n t brush 1 2 . 7 mm ( 0 . 5 i n . )
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OMat 262 Temporary marker felt/fibre tip

OMat 8/173 Adhesive/Sealant, Q4-2817
OMat 8/177 Sealing compound, DC 93-076-2
OMat 8/202 Release agent, QZ 5111
......................................................................
COMPONENT MATERIAL
Pre-cooler duct Inconel 625

(SB 78-B819) '
.
Patch Inconel 625 (thibkness
= 1,6 mm (0.063 in.)
D. Repair parts
Part 1
PPIPC Chapter 78-33-13
PPIPC
FIG/ITEM ITEM PART NO PART IDENT QTY HOLES
- 91B400-01 .Kit, Lower corner -

repair
07-142 201/1 RP3923-06 ..Lower corner patch 1
07-145 2A NAS1919M06S04 ..Rivet

(a1ternative)
01-147 3A NAS1919M05S04 ..Rivet

(a1ternative)
07-149 4A NAS1919M06S03 ..Rivet

(alternative)
Part 2
PPIPC Chapter 78-33-13
,Repair No. 16
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PPIPC
FIG/ITEMITEM PARTNO PART I D E N T QTY HOLES
......................................................................
- 91B400-51 .Kit, U p p e r corner
repair
. . U p p e r c o r n e r patch
07 1 4 3 201/1 R P 3 9 2 3 - 0 5
.1
..
07-145 2 A NAS1919M06S04 ..Rivet 1 9 . 201/ B , D

(alternative)
07-147 3 A NAS1919M05S04 ..Rivet

(alternative)
07-149 4 A NAS1919M06S03 ..Rivet

(alternative)
4. Procedure
GLOVES, DUST MASK AND SAFETY GOGGLES TO PROTECT .YOU.. AGAINST
DUST AND LOOSE P A R T I C L E S WHICH CAN B E DANGER~US,-]TO'YOUR
HEALTH.
WARNING: WHEN YOU U S E CLEANING M A T E R I A L S , COATINGS AND SEALANTS, R E F E R

T O AND OBEY THE MANUFACTURER'S CONTROL AND A P P L I C A T I O N
I N S T R U C T I O N S AND SAFETY N O T I C E S .
NOTE: T h e procedures t h a t f o l l o w are f o r t h e i n s t a l l a t i o n of t h e l o w e r

c o r n e r patch and t h e f i g i t e m s l i s t e d are only f o r t h e l o w e r
c o r n e r patch. T h e procedure f o r t h e upper corner patch i s t h e
s a m e and t h e i t e m numbers can be found i n t h e r e p a i r p a r t s l i s t .
NOTE: T h e pre-cooler d u c t and patch m a t e r i a l i s very hard. When i t i s

possible use a bench d r i l l . A d r i l l speed b e t w e e n 300 and 500
r p m i s r e c o m m e n d e d w h e n you d r i l l t h e i n i t i a l h o l e s . U s e 1 2 0 0
r p m w h e n you i n c r e m e n t d r i l l t h e h o l e s t o m a k e t h e m l a r g e r .
NOTE: U s e a scriber o r O M a t 262 m a r k e r t o m a r k t h e patch and'pre-

cooler duct. ., ,
7 4.
R e p a i r No.16
Page 203
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
A. Stop D r i l l t h e Crack and Remove t h e R i v e t s i n t h e Repair Area.

Refer t o F i g u r e 201, s h e e t 1
r /
(1) Do a p e n e t r a n t i n s p e c t i o n t o f i n d t h e e n d ( s ) of t h e c r a c k .
Refer t o AMM TASK 70-20-02-230-804.
(2) U s e a 4 , O mm (0.157 i n . ) diameter d r i l l t o d r i l l a h o l e a t t h e

e n d ( s ) of t h e crack t o make s u r e i t cannot become l a r g e r .
(3) Deburr t h e h o l e s
(4) Do a p e n e t r a n t i n s p e c t i o n t o make s u r e t h a t you have c o r r e c t l y

s t o p d r i l l e d t h e c r a c k . Refer t o AMM TASK 70-20-02-230-804.
Make s u r e t h a t t h e crack does n o t go through t h e s t o p d r i l l e d
h o l e . I f n e c e s s a r y , s t o p d r i l l t h e crack a g a i n .
(5) Remove t h e r i v e t s i n t h e r e p a i r a r e a . Refer t o SRM 54-02-10

f o r t h e procedure t o remove t h e r i v e t s
(6) Clean t h e a r e a , r e f e r t o AMM TASK 70-20-01-1OXOc-802.

A * I
B. Prepare t h e Patch. Refer t o Figure 201, s h e e t 2 ,'. 2:
(1) Temporarily i n s t a l l t h e p a t c h (1) on t h e d u c t . Make s u r e t h a t

t h e c l e a r a n c e s between t h e p a t c h and d u c t a r e n o t more than
0,40 mm (0.016 i n . ) .
(2) Remove t h e p a t c h and, i f n e c e s s a r y , u s e hand t o o l s t o change

t h e c o n t o u r s of t h e p a t c h t o g e t t h e c o r r e c t c l e a r a n c e . Do n o t
remove any m a t e r i a l from t h e p a t c h t o g e t t h e c o r r e c t
c l e a r a n c e . I f t h e c o n t o u r s a r e changed, do a f l u o r e s c e n t
p e n e t r a n t t e s t of t h e p a t c h t o make s u r e t h a t i t h a s n o t
cracked, r e f e r t o AMM TASK 70-20-02-230-804.
(3) Clean t h e p a t c h , r e f e r t o AMM TASK 70-20-01-100-802.
C. D r i l l t h e Pre-Cooler Duct. Refer t o Figure 201, s h e e t 2
(1) Put t h e p a t c h i n p o s i t i o n on t h e d u c t , u s e an OMat

-
262 marker
t o mark t h e d u c t with t h e shape of t h e p a t c h .
'*
(2) Remove t h e p a t c h .
CAUTION: YOU MUST USE THE I N I T I A L RIVET HOLES ' B ' I N THE
DUCT, WHERE POSSIBLE, TO INSTALL THE PATCH. WHEN YOU
USE THESE I N I T I A L HOLES TO MARK AND SUBSEQUENTLY
DRILL THE PATCH, YOU MUST MAKE SURE THE HOLES AGREE
Repair No.16
Page 204
Printed i n Great B r i t a i n ~ a.10/07
r
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
W I T H THE LIMITS THAT ARE GIVEN BELOW. I F THEY DO NOT

AGREE, PUT THE HOLES I N AN ALTERNATIVE POSITION.
LIMITS :
- Minimum d i s t a n c e of t h e edges o f t h e p a t c h t o any
f a s t e n e r must b e 10,O mm (0.40 i n . ) .
- Minimum d i s t a n c e between any p a r t of t h e c r a c k and
any f a s t e n e r must b e 12,O mm ( 0 . 4 8 i n . ) .
- Minimum p i t c h between two f a s t e n e r s must b e 19,O mm
(0.75 i n . ) .
- Minimum d i s t a n c e between any p a r t of t h e c r a c k
( i n c l u d e s s t o p d r i l l e d h o l e (S) ) and t h e e d g e s o f t h e
p a t c h must b e 12,O mm ( 0 . 4 8 i n . ) .
- The e n d ( s ) of t h e c r a c k must b e m o r e . t h a n 12,O nun
( 0 . 4 8 i n . ) from f a s t e n e r l i n e s a t t h e e d g e s of t h e
. ... .
, . .
patch.
(3) S e l e c t which of t h e 1 3 o f f i n i t i a l r i v e t h o l e s ' B ' i n t h e d u c t

can b e u s e d t o i n s t a l l t h e p a t c h and, i f n e c e s s a r y , d r i l l
a l t e r n a t i v e h o l e s . R e f e r t o F i g u r e 201, s h e e t 3
(a) Mark t h e p o s i t i o n s of t h e o t h e r h o l e s on t h e d u c t .
(b) U s e 2 ,5 nun (0.098 i n . ) and 3 , 2 nun (0.126 i n . ) d r i l l s t o

d r i l l t h e o t h e r h o l e s i n increments
(C) R e f e r t o t h e LIMITS ( 4 . C . ( 2 ) ) and F i g u r e 201, s h e e t 2 and

3 , mark t h e d u c t w i t h t h e p o s i t i o n s o f t h e o t h e r h o l e s :
two o f f ' A ' and s i x o f f ' D ' .
(d) U s e 2 , 5 nun (0.098 i n . ) and 3 , 2 mm (0.126 i n . ) d r i l l s t o

d r i l l t h e o t h e r h o l e s i n increments.
..':. :.
(e) Deburr t h e h o l e s and c l e a n t h e d u c t , r e f e r t o AMM TASK
70-20-01-100-802.
D. D r i l l t h e P a t c h . . R e f e r t o F i g u r e 201, s h e e t 2
(1) P u t t h e p a t c h (1) i n i t s c o r r e c t p o s i t i o n on t h e d u c t , make

s u r e i t i s i n good c o n t a c t ( c l e a r a n c e must n o t b e more t h a n
0 . 4 mm ( 0 . 0 1 6 i n . ) between t h e p a t c h and d u c t ) . Keep t h e p a t c h
i n position.
(2) P u t marks on t h s p a t c h a t t h e p o s i t i o n s of t h e h o l e s : two o f f

' A ' , 1 3 o f f ' B ' , 18' o f f ' C ' and s i x o f f ' D ' i n t h e d u c t .
(3) Remove t h e p a t c h .
R e p a i r No.16
.-. :. ..
.C ..
, Page 205
Printed in Great Britain ' Mar.10/07
(4)
P RB211 TRENT
MANUAL
STRUCTURAL REPAIR
Centre punch t h e marked p o s i t i o n s .
(5) U s e a 3 , 2 mm (0.126 i n . ) d r i l l t o d r i l l t h e 18 h o l e s ' C ' in

t h e patch
(6) U s e 2 , 5 mm (0.098 i n . ) and 3 , 2 mm' (0.126 i n . ) d r i l l s t o d r i l l

t h e h o l e s ' A ' , ' B ' and ' D ' , i n increments.
(7) beburr t h e h o l e s and c l e a n t h e d u c t , r e f e r t o AMM TASK 70-20-

01-100-802.
E. F i n a l D r i l l t h e Duct and t h e Repair Patch. Refer t o Figure 201,

sheet 2
(1) Put t h e p a t c h on t h e d u c t , i n s t a l l 18 o f f 3 , 2 mm (0.126 i n . )

g r i p p e r p i n s i n h o l e s ' C ' t o keep i t i n p o s i t i o n .
(2) Use a 4 , l mm (0.161 i n . ) and 4 , 8 mm (0.189 i n . ) d r i l l s t o

increment d r i l l t h e h o l e s : two o f f ' A ' , 13 o f f ' B ' and s i x o f f
' D ' , through t h e p a t c h and d u c t . I n s t a l l 4 , 8 mm (0.189 i n . )
g r i p p e r p i n s i n t h e h o l e s a s they a r e d r i l l e d .
(3) Remove t h e g r i p p e r p i n s from t h e h o l e s ' C ' a s each h o l e i s

d r i l l e d . Use t h e 4 , l mm (0.161 i n . ) d r i l l t o d r i l l t h e 18 o f f
h o l e s ' C ' through t h e f l a n g e and d u c t .
(4) Remove a l l t h e remaining g r i p p e r p i n s and t h e p a t c h .
(5) Deburr a l l t h e h o l e s .
. ;. <..:
(6) Clean t h e p a t c h and t h e d u c t , r e f e r t o AMM TASK'~~'O-20-01-100-
802.
F. Liquid Shim t h e Duct
(1) Use OMat 584 s c o t c h b r i t e t o l i g h t l y abrade t h e mating

s u r f a c e s of t h e p a t c h and d u c t .
(2) Clean t h e mating' s u r f a c e s of t h e p a t c h and d u c t , r e f e r t o AMM

TASK 70-20-01-100-802.
(3) U s e an OMat 2/12 p a i n t brush ( o r e q u i v a l e n t ) t o apply t h r e e

l a y e r s of OMat 8/202 r e l e a s e a g e n t t o t h e mating s u r f a c e of
t h e p a t c h . Apply t h e l a y e r s a t 10 t o 15 minute i n t e r v a l s . When
, , t h e y a r e d r y , p o l i s h them with a c l e a n OMat 2/101 l i n t f r e e
' cloth.
. .".p
. . .'
~ e p a i rNo. 16
EFFECTIVITY : TRENT
54-30-30
Page 206
.
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
NOTE: OMat 8/202 r e l e a s e a g e n t i s a p p l i e d t o t h e mating

s u r f a c e of t h e p a t c h o n l y , a s t h e OMat 8/154 adhesive
w i l l cause t h e p a t c h t o bond t o t h e d u c t .
(4) Put 21 o f f 4 , 8 mm (0.189 i n . ) and 18 o f f 4 , l . & n (0;161 i n . )

g r i p p e r p i n s f u l l y i n t o OMat 8/202 r e l e a s e age-ntg.. . ,
:'I
(5) Apply a t h i c k l a y e r of OMat 8/154 adhesive t o . t h e mating

s u r f a c e of t h e p a t c h .
(6) Put t h e p a t c h on t h e d u c t and i n s t a l l t h e p r e p a r e d g r i p p e r

p i n s . Use your hand t o t i g h t e n them a s much a s p o s s i b l e .
(7) Remove t h e unwanted a d h e s i v e , r e f e r t o AMM TASK 70-20-01-100-

802.
(8) Cure t h e OMat 8/154 adhesive f o r 7 hours minimum a t 25 deg C

(77 deg F ) , then f o r 1 hour a t 95 deg C +/- 5 deg C (203 deg F
+/- 9 deg F) u s i n g a h e a t b l a n k e t o r h e a t lamp. Heating r a t e
must n o t be more than 3 deg C ( 5 . 5 deg F) p e r minute.
: A l t e r n a t i v e c u r e t i m e without u s i n g a h e a t b l a n k e t o r h e a t
lamp i s 3 days (minimum) a t 25 deg C (77 deg F ) .
" , .
(9) Remove t h e g r i p p e r p i n s and t h e p a t c h .

.;: .:?l:':r,
S t
G. I n s t a l l t h e Patch. Refer t o Figure 201, s h e e t 2
(1) Apply a t h i n l a y e r of OMat 8/177 t o t h e mating s u r f a c e of t h e

patch.
(2) Put t h e p a t c h i n p o s i t i o n on t h e i n s i d e of t h e d u c t .
(3) I n s t a l l t h e a p p l i c a b l e g r i p p e r p i n s t o keep t h e p a t c h i n
p o s i t i o n while you i n s t a l l t h e f a s t e n e r s .
(4) U s e OMat 8/177 s e a l i n g compound t o wet i n s t a l l (remove t h e

g r i p p e r p i n s a s you i n s t a l l t h e r i v e t s ) 19 o f f r i v e t s (2) i n
h o l e s ' B ' . Then w e t i n s t a l l 18 o f f r i v e t s (3) i n h o l e s ' C ' and
two o f f r i v e t s ( 4 ) i n h o l e s ' A ' . Refer t o SRM 54-02-10 f o r t h e
procedure t o i n s t a l l t h e r i v e t s . . l
, ..,
(5) Remove any unwanted s e a l i n g compound.
:- , is :,
. >:,'!.,
.
(6) Put a smooth bead of OMat 8/173 a d h e s i v e / s e a l ' a n t arbund t h e

edges of t h e p a t c h .
H. Examine t h e Repair
Repair No.16
54-30-30
Page 207
.
RB211 TRENT . .
- .
STRUCTURAL REPAIR
MANUAL ., . .
',>l '
(1) Examine the repair to make sure the referenced.procedures have

been done correctly.
I. Identify the Repair
(1) Mark FRSX062 adjacent to the part/serial number of the duct,

use OMat 262 marker of a contrasting colour.
Repair No. 16
54-30-30
Page 208
P r i n t e d i n Great B r i t a i n .: - Mar;10/07
p
"" R8211 TRENT
MANUAL
STRUCTURAL REPAIR
TYPICAL PATCHES REMOVE THESE

TO BE INSTALLED ON 13 RIVETS
GAS WASHED SURFACE (EACH CORNER)
Pre-Cooler Duct forward patch installation

Figure 201, sheet 1
Repair No.16
54-30-30
Page 209
Mar. 10/07
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
a = 0.315 in (8,O mm)

b = 0.39 in (10,O mm)
c = 0.78 in (20,Omm)
RIVET
ITEM 2
\
'C'
(lgoM (18off)
Pre-Cooler Duct forward patch installation

Figure 201, sheet 2
Repair No. 16
EFFECTIVITY: TRENT
Page 210
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
'B' 'D'
(13off) (6off)
NOTE : UNLESS THE POSITION OF THE CRACK PREVENTS,

NEW HOLES 'D' TO BE EQUALLY SPACED TO EXISTING HOLES 'B'
I
%
. -'.
f
Pre-Cooler Duct forward patch i n s t a l l a t i o n '

Figure 201, s h e e t 3
Repair No.16
54-30-30
Page 211
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
THRUST REVERSER FAIRING - IDENTIFICATION
1. General
R A. Fairings described are the ramp fairing, the duct fairing and the rear
R structure inner panel. Refer to section 54-30-01 for outer panel
R description of the rear structure.
.-CQ
.-
U
R B. The following figures describe the parts and list the material used. The
& R full view of the part has a ply orientation chart to help find the warp
U
Q
R direction. Refer to section 54-30-00 to have the full references of these
6 R
R
.-C
0
W R C. Fairings are made of monolithic carbon/epoxy composite and carbonlepoxy
.-t R composite bonded to non metallic or metallic honeycomb.
h
R number of carbon ply and/or the type of honeycomb. These zones are
EFFECTIVITY: TRENT
Page 1
July 1 / 9 4
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
DUCT FAIRINGS
SEE FIG 4
Fairing Identification
Figure l
EFFECTIVITY: TRENT
Page 2
Apr. 1/94
RB.211 TRENT
m(m STRUCTURAL REPAIR
MANUAL
OUTER SKIN INNER SKIN
AREA N o Z1 22 23 AREA N o Z1 22 23 LAY UP

ORDER ORDER
CARBON GLASS LAYER 1 FIRST
3 5 3
EPOXY LAYER
CARBON
3 5 3
GLASS LAYER 1 LAST EPOXY LAYER
.........
........
.........
[3
.................
................
................ PERFORATED AREA
THICKNESS 0.5 in. (12,7 mm)
C=) RIBBON DIRECTION
Ramp Fairing
Figure 2
EFFECTIVITY: TRENT
Page 3
July 1/95
1 RB.211 TRENT
m( ~ 7 STRUCTURAL REPAIR
MANUAL
AREA No Z1 22 LAY UP
ORDER
GLASS LAYER 1 FIRST
CARBON
3 3
EPOXY LAYER
0
El
INNER SKlN
AREA N o Z1 22 23 24 25 Z6 LAY UP ORDER

CARBON EPOXY LAYER 3 3 4 6 8 10
GLASS LAYER 1 LAST
PERFORATED AREA
THICKNESS 0.5 in. (12,7 mm)
a RIBBON DIRECTION
Inner Panel - Rear Structure
Figure 3
EFFECTIVITY: TRENT
Page 4
July 1/95
RB.211 TRENT
m(R STRUCTURAL REPAIR
MANUAL
1 91A065
(See sheet 5)
4 91A069
(See sheet 6)
ITEM DESCRIPTION GAGE MATERIAL EFFECTlVlTY

1 DUCT FAlRlNG FWD CARBON COMPOSITE
2 DUCT FAlRlNG INT CARBON COMPOSITE
3 DUCT FARING AFT CARBON COMPOSITE
4 DUCT FAlRlNG FWD CARBON COMPOSITE
5 DUCT FAlRlNG INT CARBON COMPOSITE
6 DUCT FARING AFT CARBON COMPOSITE
Duct Fairings
EFFECTIVITY : TRENT
54-30-70
Page 5
Sept.15196
1
m(R\
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
FLAT PATTERN
AREA No Z1 22
Duct Fairings
EFFECTIVITY: TRENT
Page 6
July 1/95
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
-
AREA No Z1 22
Duct F a i r i n g s A f t
F i g u r e 4 ( S h e e t 3 of 7 )
EFFECTIVITY: TRENT
Page 7
Mar. 1/95
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
AREA N o Z1 22
Duct Fairings Aft

EFFECTIVITY: TRENT
Page 8
July 1/95
M 3
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
IAREA No - -
1 2 1 1-2-2- 1
"
Duct F a i r i n g s Forward
EFFECTIVITY: TRENT
Page 9
Mar. 1/95
RB.211 TRENT
MANUAL
r
AREA No Z1 22
Ducl: Pairings Forward

EFFECTIVITY: TRENT
Page 10
Oct. 1/95
Mm
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
l I
CARBON EPOXY LAYER 1 3 1 5
Duct Fairings Intermediate

EFFECTIVITY: TRENT
Page 11
July 1/95
RB.211 TRENT
MANUAL
THRUST REVERSER - FAIRING SKINS - ALLOWABLE DAMAGE
1. Introduction
thrust reverser fairing skins.
2. Zones
A Acoustic area
M Monolithic area
S Sandwich area
A. Allowable damage

EFFECTIVITY: TRENT
Page 101
Apr. 1/98
RB.211 TRENT
m STRUCTURAL REPAIR
MANUAL
life.

distinct.




satisfactorily.
EFFECTIVITY: TRENT
Page 102
Apr. 1/98
g RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
C. Damage Types
as paint.

in the material.
(4) Scratch - a scratch is a line of damage in the material and results in



or faying surfaces.
4. Identify and Measure the Damage Extent


EFFECTIVITY: TRENT
Page 103
Apr. 1/98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
..............................................................................
INSPECTION
All Abrasion Confined t o s u r f a c e Over an u n l i m i t e d

resin area
All Scratch, Confined t o t h e Depth <= 0 , 2 8 mm

Gouge f i r s t outer ply. (0.011 i n . )
No n e a r e r t h a n 5
times i t s s i z e t o
other unrepaired
damage o r r i v e t
line
All Dent No n e a r e r t h a n 5 Depth <= 2 , 5 mm

times i t s diameter (0.1 i n . )
t o other unrepaired
damage o r r i v e t l i n e
All Hole, No n e a r e r t h a n 5 Diameter o r l e n g t h ' A ' check f o r

Nick times i t s s i z e t o <= 20 mm (0.79 i n . ) sealed hole
except other unrepaired Depth: Confined t o
M4, damage o r r i v e t outer skin
M5 l i n e . Seal the
h o l e w i t h speed t a p e
All Delamination, No n e a r e r t h a n 5 Diameter o r l e n g t h

Disbond times i t s s i z e t o <= 30 mm (1.18 i n . )
other unrepaired (Depth: Confined t o
damage o r r i v e t l i n e outer skin
M4, Hole, S e a l hold w i t h speed Diameter o r l e n g t h ' A ' check f o r

M5 Nick tape <= 100 mm (3.94 i n . ) sealed hole
EFFECTIVITY: TRENT
Page 104
Apr. 1/98
m
-s
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
..............................................................................
REPAIRABLE REPAIR
..............................................................................
Al Scratch, No more than l c u t p l y . Depth <= 0 , 2 8 mm FRSX045
Nick, D i s t a n c e from o t h e r damage (0.011 i n . ) 54-30-00
Gouge o r r i v e t l i n e must be REPAIR 0 1
g r e a t e r than 5 times i t s
size
A1 Disbond D i s t a n c e from o t h e r damage Diameter <= 30 mm FRSX047

must be g r e a t e r t h a n 5 (1.18 i n . ) 54-30-00
times i t s s i z e - core REPAIR 03
undamaged
A1 Dent D i s t a n c e from o t h e r damage Depth <= 2,5 mm FRSX047

undamaged
A1 Dent D i s t a n c e from o t h e r damage Depth <= 2 , 5 mm FRSX048

damaged
A1 Hole D i s t a n c e from o t h e r damage Diameter <= 20 mm FRSX049

times i t s s i z e - inner REPAIR 05
s k i n damage < d i a 30 mm
(1.2 i n . )
A1 Delamination D i s t a n c e from o t h e r damage Diameter <= 30 mm FRSX045

g r e a t e r than 5 t i m e s i t s REPAIR 01
size
A3 Scratch, Nomorethan3cutplies. Depth<=0,84mm FRSX045

Nick, D i s t a n c e from o t h e r damage (0.033 i n . ) 54-30-00
Gouge o r r i v e t l i n e must be REPAIR 01
g r e a t e r than 5 t i m e s i t s
size
A3 Disbond D i s t a n c e from o t h e r damage Diameter <= 30 mm FRSX047

undamaged
EFFECTIVITY: TRENT
Page 105
Apr. 1/98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIRABLE REPAIR
A3 Dent Distance from other damage Depth <= 2,5 mm FRSX047

undamaged

damaged
A3 Hole Distance from other damage Diameter <= 25 mm FRSX049

times its size - inner REPAIR 05
skin damage < dia 30 mm
(1.2 in.)
A3 Delamination Distance from other damage Diameter <= 30 mm FRSX045

size
A5 Scratch, No more than 2 cut plies. Depth <= 0,56 mm FRSX045

size
A5 Disbond Distance from other damage Diameter <= 30 mm FRSX047

undamaged

undamaged
A5 Dent Distance from other damage Depth <= 2,s mm FRSX048

damaged
EFFECTIVITY: TRENT
Page 106
Apr. 1/98
RB.211 TRENT
m STRUCTURAL REPAIR
MANUAL
REPAIRABLE REPAIR
..............................................................................
(1.2 in.)

size
A6 Scratch, No more than 1 cut ply. Depth <= 0,28 mm FRSX045

size
A6 Disbond Distance from other damage Diameter <= 30 mm FRSX047

undamaged
A6 Dent Distance from other damage Diameter <= 25 mm FRSX047

undamaged
A6 Dent Distance from other damage Diameter <= 25 mm FRSX048

damaged

(1.2 in.)

size
EFFECTIVITY: TRENT
Page 107
Apr. 1/98
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIRABLE REPAIR
E Scratch, No more than 2 cut plies. Depth <= 0,58 mm FRSX045

size
E Dent Distance from other damage Diameter <= 23 mm FRSX045

E Hole Distance from other damage Diameter <= 23 mm FRSX046

E Delamination Distance from other damage Diameter <= 30 mm FRSX053

size
M1 Scratch, No more than 3 cut plies. Depth <= 0,84 mm FRSX045

size

must be greater than 5 (0.1 in,) 54-30-00


size
M2 Scratch, No more than 2 cut plies. Depth <= 0,56 mm FRSX045

size
EFFECTIVITY: TRENT
Page 108
Apr. 1I98
m RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIRABLE REPAIR

M3 Scratch, No more than 1 cut ply. Depth <= 0,28 mm FRSX045

size



size
M4, Dent, No limit FRSX045

M5 Delamination 54-30-00
REPAIR 01
M4, Hole No limit FRSX046
M5 54-30-00
REPAIR 02
or replace
damaged
section
M4, Scratch, No limit FRSX045

M5 Nick, 54-30-00
Gouge REPAIR 01
EFFECTIVITY: TRENT
Page 109
Apr. 1/98
RB.211 TRENT
m STRUCTURAL REPAIR
MANUAL
12 0 CLOCK
6 0 CLOCK
:.:.;.:.:.
......... A R E A A l
n
.-...'
AREA E
RAMP FAlRlNG
Thrust Reverser - Fairing Skins - Allowable and R e p a i r a b l e Damage L i m i t s

F i g u r e 101 ( S h e e t 1 of 2 )
EFFECTIVITY : TRENT
Page 110
Apr. 1/98
RB.211 TRENT
m STRUCTURAL REPAIR
MANUAL
12 O'C
15.75 in.
(400mm)
15.75 in.
(400mm)
INNER PANEL - REAR STRUCTURE

AREAA3
AREAM1
- AREA M 2
AREAA6
m
.*.'...'.'
.....
.-...S...
AREA A5
Thrust Reverser - F a i r i n g Skins- Allowable and R e p a i r a b l e Damage Limits

F i g u r e 101 ( S h e e t 2 of 2 )
EFFECTIVITY: TRENT
54-30-70 Page 111
Apr. 1/98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
See sheet 3
See sheet 3
See sheet 1
AREA M5
J1080
Thrust Reverser - Fairing Skins - Allowable and Repairable Damage Limits

EFFECTIVITY: TRENT
Page 112
Apr. 1 /98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
AREA M4
AREA M5

EFFECTIVITY: TRENT
Page 113
Apr. 1 /98
[ RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
vfl AREA M5

EFFECTIVITY: TRENT
Page 114
Apr. 1/98
RB211 TRENT
-' STRUCTURAL REPAlR
MANUAL
COMMON NOZZLE ASS-LY - LIST OF APPROVED REPAIRS
R REPATR MO. REPAIR DESCRXPTION
R 1 TfIRDST R&VERSER C-DUCT -

REINFORCEMENT AND REPAIR OP
R (FRS X 0 7 9 1 THE 12B DUCT RgAR PAIRXNQ
EFFECTLVITY: TRENT LIST OF REPAIRS

54-30-70
Sags 201
R Printed in Craar Britain Feb. 1 5 / 0 6
RB211 TRENT
I[tiill STRUCTURAL REPAIR
TKRUST REVERSER C-DUCT
REINFORCEMENT AND bEPAIR OF THE f2# DUCT ReAR F A I R m O CPRE 8 8 7 8 - C 7 0 8 ) .
A, This procedure given the instructions to repair the 12H duct

rear £siring. It i s only applicable to PRE SB78-C708 w r i t i ~ .
B. This procedure in in t h r e e parts:
(1) 5ha replacement of l o o ~ sor missing rivets Wparstioa 4 ) .

This coneist~of t h s ramwal of any looas rivets and the
installation of standard or oversized riveta.
(21 The repair of the forward metion {Operation 5 ) . T h i 8

consists of cutting the damaged fairing section and the
inetallation of a new £ s i r i n g s e c t i o n fnatmned to thm
remaining f a k i n g with the splices,
(3) The repair of t h e front eupport bracket (Operation 6 ) ,

This consists of cutting an accase h o l e in the fairing,
t h e removal of the damagad part of ths support bracket and
the replacement of it w i t h a locally manufactured angle
piece. The accsaa holm i~ then covered with a patch
riveted to t h e fairing.
2. Referenced Xnfasmation
. . . - .. .- -
AMM TASK 70-20-01-100-803 Cold &Squid Degressing

SRM TASK 54-02-10/201 Fastenera - Ramoval and InstaLZation
3. B q u i p e n t and Matarfalti
A, Standard equipment
Standard warkshop toola and equipment
Drill Machine
Vacuum Cleaner
=PAIR NO. 1
54-30-70
Fags 261
Feb. 3 5 / 0 6
m RB211 TRENT
Ic;i;t;Is] MANUAL
Et. Consumabls materials

1---1-1-"11----*--1*--1-----------*---------------------------
REFERENCE DES TBNAm ON

L C - I - - - - - - - - - I - - " - - - - - - - l ) - - - e - - - e - - t l - - - - " - - - " - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
OMat 262 $M556792 Temporary marker fe'bt/fibrs t i p

QHat 5B4 Type No7496 Scotch brite
OMat 81106 PR1436131 k1/2 sealant, two part poly~ulphide
OMat 81167 3R1436G 8112 sealant, two part polysulphide
OMat &/l54 Hysol FA9394 epoxy pamte adhesive
1 1 - - - - 1 - - 3 - - - - - - - - 1 - - - - - - - - - - - - - - - 1 - - - " - - - - - - - - - - - - - - - - - - - - - - - - - - * - -
PART IDENT MATgRXAG

- - - - - - - - - - 1 - - 1 - - 1 1 - - 3 1 - r r - r - - - - r , - r - r - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - * - - - -
Thrustt revaresr Carbon composi t e
D, Repair Parta
(I) Replacement of loose or missing rivets (Operation 4 )
Pairing with cup waahers (PRE SB78-C3971

I - - - - - - - - - - - - - - - - m - - - - - - - - - - l - - - - - - - - " - - - - - - - - - - - - - " - - - - - - - * -
FIG/ITEM PART NO PART IDgUT Q=

- - - - - - - l - " - l - - - - - - - - I - - - - - - l - - - = - - - - d - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
202/2 NAS192~OSSOiATJ Rivet, blind tetnndardl A/R

2 0 2 /3 UAS1169C8L Waaher, dhplmd (standard) A/R
202/2 NAS1921M06306AV Rivst , b l i n d (oversize) A/R
202J3 NAS1169CIOL Washer, dimpled (oversize) A/R
Fairing with nprmader platse (POST 5878-C3971

-*--=---"--"*---"------*---*---------*-*--------*-d-------"------*-----
~ f a f f ~ mP A R T N O PART rbgm QTY

1 - - - 1 - - - - - - - - - - 1 - - 1 " 3 - - l l - - - - - 1 - " - " - - - - - - - - - - - - - - - - - - - - " - - - - - -
202/1 NASlP19MOSS03AU Rivet, b l i n d (atkndatd) A/R

202Jl NAS1919MO6S03AU Rivet, blind loversize) A/R
(21 Repair of the f airing gosward rrectfon (Operation S )
Kit P/N 91A027-00 for left hand C-Duet

-*"-"31rl~-C-IC15---1--)1-)1-1---~--*~~~~~~*~-------~-------~-------~------~--*--
FIQ/XT&H PART NO PART fDENT m

1 - - - 1 1 - - 1 1 - - 1 - - - - - - - - - - - - - - - - - - - - - C - - - - - - - - - - - - m - - - - - - - - - - - - - - - - - - - - - - - - -
203/4 RP3799 -01 Spl ica 1

203/5 ~AS1913M05S02 Rivet, blind 14
203/6 RP3799 - 0 2 splice 2
203/7 9121150-06 Pairfng (to make repair part) 1
203Jl.5 NAS1919MO5503 Rivet, blind 8
203116 NAS1929MOS306 Rivet, blind 2
EFFECPrnTY: TRENT REPAf R NO. I

54-30-70
Page 2 0 2
Printed in Grsar Britain Pab.lSJ06
RB211 TRENT
204/19 NAS1919M04SO4AO Rfvmt, blind 4
Kit P/N 9 1 A 6 2 7 - 5 0 for right hand C-Duet

3e-"-I-ll--~-"---1C--~II1111"-11--1C1III----~"------C--------~------~--
PIQ/XZgM PART NO PART IDEPST W

- - 1 - - - 1 - 1 - * - 1 1 - - 1 1 - m - - - - - - - - 1 1 - - - - 1 - - - - - - - - - - - - - - - - - w w - - - - - * - - - - - -
20314 RP3799-01 Splice 1

203/5 NAS1919MbfS.02 Rivet, blind 14
203/6 RP3799-02 Splice 2
20317 91D150-56 Fairfng ( t o make repair part) 1
2 03/15 NAS1919MQ5803 Rivet, b l i n d B
203/16 NAS2919MQSS05 Rivet, blind 2
204/17 NAS1919M04504AW R k v e t blind 4
(3) Repair of t h e front fatring support (Operatfon 61

- 1 - 1 1 - - - - - 1 - - - - - - - - - 1 - - - - - - - - - - - - - - - - - - - " - - - - - - - - - - - - - - - - " * " - - - - - - - - - - - * - - - -
FXQ/ITEM PART NO PART fDF%T W

-C-"---------c--el------------L-3------"----------------------*-
205/8 Local manuf RC turs Angel, LB CRES IEBW) -

1,6 rma ( 0 . 0 6 3 in) t h i c k 1
26518 Local mahufacture h g % l , RH CRES (EBM) -
26519 Local manuf ac tura Spacer
(0.047
-in) thick
l , 6 ram ( 0 . 0 6 3 in) t h i c k
CRES (EBMI l, 2 m
1
1,
20s/la HSTIOBJS-3 P i n , #i-lite 3
205/11 HST37DU5 Collar, Hi-lita 3
205/12 Local manufaetura Patch - CRES (EBM) f , 2 mm
(0,047 Ln) t h i c k 1.
205/13 NAS1919H05S02 Rivs t * blind 13
205/14 MRSI919M~SS03AU Rivet, blind 3
(4) The parte, which follow, are for reference only:

---I----------"-I--------------------&-*------d---*-----"------"-------
FXG/ITEM PART NO PART XDENT Qm

--------1--1-11----------------"-----*--------------*------------------
204/19 91B294 - 0 0 Spring upp port platm Ref

205/19 91Dlll-00 Fairing support (left hnnd side) Ref
205/19A 9lDlll-02 FaSriag support (left hand s i d a ) Re£
205/19B 91Dlll-P3 Pairing support (left hand aide) Re f
205/13 3 1 D l l . l - 50 Fairing support ( r i g h t hand sida) Ref
2 05/19A 9 1 D l l l - 52 Fairing support [ r i g h t hand side) Ref
2 0 5/19B 91D111-53 Pairing suppart ( r i g h t hand side1 Re f
205/20 9ZDZ48-00 Angle bracket Cleft: hand side) Ref
205/20A 91D248-01 Angle bracket (left hand side) ReL
ZOS/ZO 91D248-50 Angle braekat (right hand aide) Rgf
205/20A 91D248-S1 Angla bracket ( r i g h t hand side} Ref
202/21 91D426 -01) Spreader p l a t e Rsf
202/22 91Ir42T - 0 0 Spreader plate Raf
202/23 91D428-00 Spreader p l a t e Ref
BFFECTIVL'TY: TRENT REPAIR NO, 1
54-30-70
Page 203
Feb. 15/06
RB211 TRENT
STRiJCTiJRAL REPAIR
MANUAL
202/24 91Q429-60 Spreader plate Ref
M W r WREN YOU DO THfS REPATR YOU m S T WgAR PRUTICTXVB CLUTRXNa,

GLOVES, BUST MASK A1TD SAFETY OPdGLES TO PROTECT YOU AGAINST
DUST AND LOOSE PARTICLES, THESE CAN BE DANGEROUS TO Y O m
HEALTH *
WRRNZSJO: HHEN YOD DSE CLEANXNGI MATERrALS AND SEALANT, REFER TO, AMI
OBEY, THE HAWUFACTURER' S CONTROL AND APPLIChTXON SWSTRUCTXONS
AND #ILALTII AND SAFETY NOTICES.
4. Replace the loose ex missing rfvetta

2021
- Operation 4 (Fig. 201 and
PRE 5878-C397
A. Fairinq with Cup Waaher
El) Drill out the rivets ( 2 ) found lmee and discard the
dimplsd washer ( 3 1 (Ref. SRM 5 4 - 0 2 - 1 0 ) .
m: Do not make the holes LARGER when you drill out the
rivets.
(21 Measure the sige o f holes whexa the rivstm ( 2 ) are mierring
or have been ranwved to find if oversized riveta are
neceesary :
(a) If the hole diametsr is between 4,116 and 4,11 m

40.160 and 0,162 in) and the counttarsink for t h e
dimpled wagher ( 3 ) ie bstwean 4 ' 0 6 and 4,11 (0.160
and 0.162 in1 continue to step 4 . A . 5 .
(b) If the diameter ie more than 4,ll m (0.162 in) then

carry out s t e p n 4 - A . 3 arrd 4.A.4.
(3) D r i l l the support bracket (19) and fairing to between 4,87

and 4 , 9 3 m (0.190 and 0 . 1 9 4 in3 diameter.
(41 Countersink the boles to 9 , 9 0 lrnn ( 0 . 3 9 Am) external

diametsr and 100 Degree angle.
(5) Salact a rivat ( 2 ) and washar ( 3 ) of applicable dimmeter

for each hole (Refer to 3 . D . 1 , PRE SB78-C397 Repair
Pastm) ,
46) Clean the repair area (Rsf. AMM TASK 7 0 - 2 0 - 0 1 - 2 0 0 - 8 0 2 ) .

REPAIR NO. 1
54-30-70
Paga 204
Feb. 15/66
RB211 TRENT
MANUAL
(7) W e t install the washer ( 3 ) and rivet ( 2 ) with OMat 8 / 1 0 6

( R d . SRM 5 4 - 0 2 - 1 0 ] .
(a) Refar to the manuPaeturar8e Fnstmetione f o r control

and application of sealant
(81 Clean the rapair area ( R e f . ABM TASK 70-20-01-100-802).
(91 Hake aura tha ri-ts ( 2 ) and the waahsra 13) are
satiefactorily installed
POST S378-C397
B. Fairing with Spreader P l a t s a

(11 Drill out the rivets (1) found loose ( R e f . SRM 54-02-10) .
NOTE: Do not make the halerr larger when you drill out the
rfveta.
(a) R e m o v e uny debria,
(2) Measure t h e d z a of t h e holea whara the rivets (2) are

mlasing or havs basn removed to find o u t if the oversized
rivets ars necaneary.
{a) ltf the hole dfamuters arm between 4 , 0 6 and 4,ll mm

(0.160 and 6.162 in) continue to step 4 . B . 4 .
Ib) X 9 t h e holm dfamatere axe more than 4,11 mn ( 0 . 1 6 2

in) continue to ~ t e p4 - ~ i . 3
NOTE: Tf a sprsader p h t s 12x1 ( 2 2 ) , (23) or ( 2 4 ) is

missing, instaPl the raplacamsnt (Refer to Repair
Partel.
(3) Drall the hole in tha support bracket, fairing and

npreades p l a t e to between 4 , 8 7 and 4 , 9 3 mm ( 0 . 1 9 0 and
6.194 in3 .
(a) ff the hole diameters are more than 4 , 9 3 = (0.194
in) , re£er to A i r e e l S e .
(b3 If tha h o b dimetsrs a r e oversized la tha spreader

p l a t e (21) and the front fairing support (191,
repair the front Earring support (19).
REPAIR NO. 1
54-30-70
MANUAL
J) Rspair the Front Faksing Support (19) a a

described in Operation 6.
21 Rsplsea thr ~prsaderp l a t e (213 { R a f er to Repair

Parts).
3) Replace ths forward eection of t h e 12H sear duct

fairing as deacsibed in Operation S .
(C) X-f the hole diameters are oversized in the other

spreader plates, tafer t o Aircalle .
(4) Select a rivet of applicabls diameter for such holm (Refer
to 3 . D . 1 , POST SB38-C397 Repair P a r k a ) ,
(S) Clsan the repair area ( R e f . M TASK 76-20-01-160-9023.

16) W e t i n a t a l l the rivets (l) w i t h OMat 8/106 SEAfrANT ( S W
54-02-10).
(a) Rsfsr t o the msnuEacturases inatruetiona for eentrol

and application of sealant.
(7) Clsan tha repair srea (Ref. AWM TASK 70-20-01-100-8023.
(8) Maka sure t h e r k v s t i l C11 are ~atisfactsrily inrrtallad.
S. Rmplaea the fotwsrd sect5on of the 12H duct rear fsiring -

Operation 5 (Ref. Fiq. 201, 203 and 2 0 4 ) .
A. Rsnaerve the damaged eeetion
(1) D r i l i out the riveta (171 and sgmove the 2 spring support
platee (18) (Ref. 5RM 54-02-10) .
NOTE: Do not make the halea larger when you drill o u t the
sivete .
(a) Keep the eprixag support: p l a t e s 418) to i n e t a l l them
again after the replacement of the fairing e e e t i a n
12) D r i l l out the riveta (15) and 116) .

(31 Use hand toals to cut the damaged metion. The cut lins
must be a minimum of 33 m ( 1 . 3 0 in) in front of the front
fairing support ( 1 9 1 rivet l i n e ,
Page 206
Prlntcd tn Gxaat Britain F&. s / a 6
RB211 TRENT
lwl STRUCTURAL REPAIR
NOTE: When a straight cut: line fs not possible, rad5ua the

corners to 6mm ( 0 . 2 3 6 in),
(4) Remove the damaged arcsetion. Do not damage t h e structure on

which it ie installed.
(5) Clean the repair area and r-ve sealant (Ref. AMH TASX
70-20-OX-100-$02).
B. Inatall the a p l i c e s ( 4 ) and (65
Ill P u t tha splice ( 4 ) into poaitian and clamp it.
Ca) 'Mark the locstioa of the rivet ( 5 ) holes on t h e

Fairing~l.
Cb) Pxe-drill, then drill h o l m t o a f i n a l diameter of

between 4 , 0 6 and 4,11 nm ( 0 . 1 6 0 m d 0.162 in).
(c) Remove the a p l i c e ( 4 1 , and remove any burrs,

(2) Put the splices ( 6 ) in position and clamp than.
(a) Mark the location of the rivet ( 5 ) holas on t h e

f airinge .
(b) Pra-drill then drill holes to a ffnal diamator of
between 4 , 0 6 and 4,ll mm (0.160 and 6.162 in).
te) R m m e the splices ( 6 ) .
(d) Ranova any burrs.
(3) C l s a n t h s repair armas and splices ( 4 ) and ( 6 ) ( R d . AMM

TASK 70-20-01-100-802),
141 oPotf n e t e l l the s p l i c e s 14) and ( 6 ) with OMat 81107

SBAZANT.
(a) Refar to the murufactuset's i n a t ~ e t i o n sfor control

and application of eealant.
(53 Wet i n s t a l l the rivets ( 5 ) with PMat 8 / 3 0 6 8- (Ref.

SRM 5 4 - 0 2 - 3 0 ) .
(63 Refar ta thcl manufacturer's inatructions ifor control
and application of sealant,
REPAIR NO. 1
54-30-70
Page 207
Prlntcd i n craac Britain Feb. 15/06
RB211 TRENT
STRUCTURAL REPAIR
MAhUAL
(63 Remwa t h s unwanted sealant ( R e f . AHM TASK 70-20-01-100-

802) .
C. Prepare the repair section from the faising ( 7 1 .
(1) C u t the profile for the repair nection fsm t h e upare

falriag ( 7 ) .
-
NOTE: The rspaix rcraetion Isr obtained from
(Refer to the Repair p a r t s ) .
the fairing ( 7 )
(2) Hark the position of the rivete 153, 115) and (16) on the
repair section ( 7 1 .
(3) D r i l l the halme for tha r i v a t s I S ) , (15) and (16) Sn ths
repair section 17 1 and aplicee ( 4 ) and 2 6 ) .
(a) The f i n a l hole diameter should ba between 4 , 0 6 and
4,11 m ( 0 . 1 6 0 and 0.164 in),
(b) R e m w e thm sapair section (73 and the u p l i e a s (4)

and ( 6 ) .
(e) ~aburetall holes
8. Install, the repair aaction ( 7 ) on the tafring

(L) Use O M a t 504 SCOTCH BRTTE to mcaur the titanium stiffenera
and fairing mating autfacse.
NOTE: The eeouring operation is important for a correct

adhesion of OMat 8/L54 ADHESIVE.
(2) Ramws any dust: with a vacuum cleaner.
(33 Clman the repair areas and the repair section 67) ( R e f .
A M TASK 70-20-01-100-802).
4 Apply mat 8/107 SEALANT on the mating surfaces PE t h e

splice8 (41 and; (61 and alao on the repair section ( 7 ) , PO
not apply sealant to the titanium stiffener asaam whare
OMat a l l 5 4 ADHESrCrE is to be applied at n e x t operation.
(a) Refer t o the manufacturer's inatructions for control

and application oE sealant.
(S3 Prepare OMat @/l54 ADFIESIVE in accordance with the

manufacturss'a instructions.
REPAIR NO. X
54-36-70
Page 208
Feb. 15/06
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
66) Apply QMaE $/l54 ADrtgSnrE on the repair asetion ( 7 ) matiag

evrfscea ta the titanium stiffenarm.
(7) Put the repair meetion ( 7 ) i n t o position.
18) Wet inetaI.1 the siveta ( S ) , (15) and 116) w i t h OMat 8 / 1 6 6

eealant (Ref. SRM 5 4 - 0 2 - 1 0 ) ,
(a). Refer to the manufacturerla i n e t a c t i o n s far control

and application of aealant*
(9) Clean the spring support plates 118) (Ref. M M TASK 7 0 - 2 0 -

05-100-802).
(10) Tnstsll the spring support platea (18) with r i v e t 8 (17).
( 1 2 ) Clean repaix area [Ref. N W TASK 7 0 - 2 0 - 0 1 - 1 0 0 - 8 0 2 ) .
(12) Apply a bead of OMat 8/106 -S around the repair

section ( 7 1 to s e a l its edges and make smooth.
(a1 Refer to the mmufacturar'a fnstructionta for t h e

control and application of asalant.
6. Repair the Front Fairinq Suppart - Operation 6 (Pig. 201 and 205
Sheet l and 2 )
NOTE: Repair of the front faising support (391 i a only applicable to

C-Ducts which a r m PRE SB78-C708. If the C-Duct is POST S B J 8 -
C 7 0 8 , refer to A i s c e l f a .
A. brill out tha three r i v e t s (14) which sttaeh the skin to the
fafring eupport and removs t h s aprsader Cif installed).
NOTE: Do not make the holsm larger whm you d r i l l out the r i v e t e .
HOTE: If a aprsadmr plata (211 is installed, keep it for futura

inetallation,
CAWTTOW! ELME SURE YOU DQ NUT CtrS 12R BEAM WHEW YOW m T#E
ACCESS HOLE TRROVGH THE P A I R I N G .
B. Cut an access hole in the faising
(13 Mark a c u t out l i n e around the front f a i r i n g suppart (19)

So the given &ension (Pig, 2 0 5 S h s e t 1).
(2) Urns hand tools to cut the fairing
R E F A I R NO. 1
54-30-70
Printed in Orcat Britain

I u l STRUCTURAL REPAlR
MANUAL
NOTEr If t h e cut-out sectian is f i t t e d with a epreader p l a t e

(211, keep it f a r future instdllatian,
(a1 Sand the edge@ to a amooth shape.
(b) Ramove any burrs
C, T r i m out the damaged front Pairing support Z f 9 ) .
Cl) Meaeura and rncerd the diataness of p o h t e A and B to the

inner akin balow.
(2) Cut the damaged support (19) j u e t below the bend.
(31 Dream the sdgs to get a ermoth and straight shape,
(a3 Use hand toolm
(41. brill out the 2 sfvete, which attach the fairing support
(19) and the angle bracket (20) .
HbTE: Do not make the holes largar when you drill out the
rivets,
NOTE: Do not remove the i n i t i a l support (19) and angle bracket

(20) *
D. Prepass thn repair angle (81 and spaeer 1 9 ) .

l) Make the repair angle ( 8 ) from a 1,6 mm (0.063 in) t h i c k
stainlasE G t e e l rthee t ICRES (EBM)I .
(a) Bend f t ta g e t the uppex section of the faiting
support (191.
(b) The height of the repair angle ( B ) at point A and B

m u a t be 1,2 awi ( 0 . 0 4 7 in) higher than the recorded
readfngs at s t e p 6.C,1,
(c) The mdge distances of the rivet 413) are 9 , d m

(0.354 in).
S21 Manufacture the apacer ( 9 ) from a 1,2 mm ( 0 , 0 4 7 in) thick

stalnlesa steel sheat ICRES (EBMII.
REPAllR NO. 1
54-30-70
Page 210
P r i n t e d in Great Britain Feb. 1 5 / 0 6
RE3211 TRENT
STRUCTURAL REPAIR
MANUAL
(a) The axtstnal d i e t a t in t o ba between 9r9Q and

10,lO m ( 0 . 3 9 0 and 0.398 in) and the internal
diameter is to be between 4,20 end 4 , 4 0 m ( 0 . 1 6 5
and 0.173 in).
(3) Put the angle 1 8 ) and gpaeer ( 9 ) &at6 poaLtian.

m: Ths spaeer ( 9 ) I s inetallad between the angle ( 8 ) and
the support (191,
Cm1 Pas t h s holes in the support 119) as drill guide to

drill the location holes in the angle ( 8 ) for p i n
( 1 0 )*
Ib3 Drill a hale for the pin (10),
(c) Final hole diameters arm to be betwean 4 , l T and 4,24

m (0.164 and 0 . 1 6 7 in].
NOTE: Make m e you do not d e the holea i n t h e support

I193 larger when you drill the holes,
E. I n a t a l l the rspalr angle t 8 ) .

(1) Clean the repair angle ( 8 3 , the spacer ( 9 ) and thm repair
arma {Ref. AMm TASK 7 0 - 2 0 - 0 1 - 2 0 0 - 8 0 2 ) .
(2) Wek install the repair angle ( 0 ) and the spaeer ( 9 ) to the
support ( 1 9 ) with OMat 8JS07 SEAWWT CRaP. SRM 5 4 - 0 2 - 1 6 ) ,
2TUTE: The spaear ( 9 ) is installed between the angle ( 8 ) and

t h e gupport ( 1 9 ) .
(3) Wet install the pin (10) end the: collar I l l ) with OMat
8/106 SEkX*AKT ( R e f . SRM 5 4 - 0 2 - 1 0 ) .
(4) Refer to the manufacturer's instmctions for control and

applieatfon o f sealant.
F. Prepare the eprsader plate
(1) Cl- the upreader plate (211 {Ref. AMH TASK 70-20-01-100-
802) .
42) Do an inspection of the bole d i a m t e r a to f i n d out if the
spreader plata (21) can be uaed again.
Page 211
P r i n t d in Great Britain Pab. 15/06
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(a1 lf the hole diamet.er ia betwsen 4,06 and 4,11 m

10.160 and 0 . 1 6 2 in) than t h e initial apreadsr plate
(21) can be used again.
(b) X f the hale diameter is more than 4'13, mm C0.162

in)# or i f bole has become waL then a new spreader
p l a t e (21) must be installed.
G. Prapara t h e repair patch 1 1 2 ) .

(l1 Was a 1,2 m (0.047 in) thick ~ t a i n l a s ss t e e l aheet ICRES
(EBM) I .
(a? 1 larger all, around
C u t a patch 2 0 , 0 mm C0,73 h than
the access holm with rounded corners of 2 7 , 0 mm
(1.06 in) xadius.
(b) Break any sharp edges.
(2) Mark the location of the rivet holes (13) on the patch
(12).
(a) Pra-drill the patch (121, the Fairing and t h e repair

euppott ( 8 ) .
(bE Drill to a final diametsr of between 4,66 and 4,ll

nrm (0.160 m d 0.162 in).
(3) Put the spreader plate (213. into position.
(a) Counterdrill the 3 holes for the rivet ( 1 4 ) in the

patch 412) and repair the aupports ( 8 ) to t h e i r
final dimater of between 4 , 0 6 and 4,11 m 10.160
and 0 . 1 6 2 in),
C4 1 Drill the pressure hole in the patch ( 1 2 ) to a final

diameter of between 17,90 and 8 , 2 0 m (0,311 and 0,319 in)
( F i g . 205 Sheet 2 ) .
B, Inatal1 the repair patch 212) .

11) Clean the meting sutfacecr of t h e patch (121, £airing and
~ p r e a d e rp l a t e (21) ( R e f . AMM TASK 70-20-01-100-8021,
(2, Apply mat 8/107 S W on the mating nurfaess of t h e

patch 1121 m d spreader plate (21) .
(3) Put the patch 4x2) and the epreader p l a t e (21) into
pus it ion
Page 212
Printed in Oreat B r i t a i n Feb. L5 1 0 6
RB1211TRENT
STFlUCrYRAL REPAIR
4 W e t i n e t a l l the riveta 1131 and ( 1 4 ) with OMat 8/X06

SFSLLANT (Ref. SaM 5 4 - 0 2 - 1 0 ) .
(a3 Refer 20 the manufaetuzer'e inakructionr f a t control

and application of sealant.
(5) Apply a bead of OMat 8/10? S E W a l l around the patch

112) and t h e spreader p l a t e (21) to smel edgee and make
smooth.
Ca) RsLor t o tha manufacturer's instructions f o r contxol,

and applicatlcn of sealant.
(6) Remwe the unwanted mealant ( R e f . AMM TASK 76-20-61-100-

802).
A Do a viirual inapeetion to make Bure that, the repair i a

satiafaetory.
A. U s r OMat 2 6 2 at a contraatLng colour to mark FRSXO79

adjacent to exiating part numbar.
EFPECTXVITY: TRENT
Page 213
Printad in Great: Britain Feb. 15/06
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
12H Duet Rear Fairing [PRE SB78-C7OB)

P i g . 201
EFFEmfVfTY: TRENT REPAIR NO. 1

54-30-70
Page 214
Feb. 1 5 / 0 6
m RB211 TRENT
1
u
1 STRUCTURAL REPAIR
MANUAL
Raplaea Xloose ar Miaeing Rivets

Pig. 262
E P F R e T m T P t TRENT
RB211'TRENT
STRUCTURAL REPAIR
DFTkEL C
1 mm
(0.039 in)
MAX ..
9 I SUPPORT
(0.433inj ' - T,, ,

TYPE
SECTION
A-A
REPAIR SECTION
13mm 11mm
(0.4331n)
, > ." t l l' . . I
I
1
SPLICE '
Po'lward Section of the 12H Duet Rear Pairing

F i g . 203
EFFECTTVfTY :TRENT
Page 216
Printed ia Crsat Britain Feb.lSJO6
RB211 TRENT
STRUCTlJRAL REPAIR
SPRING SUPPORT PLATES

TO REMOVE AND REINSTAL
TITANIUM STRtP
REF.
5.
c:-E
Location t o Apply Adhesive

F i g , 204
EFFECTMTY: TRENT REPAIR NO, 1
54-30-70
R8211 TRENT
STRUCTURAL REPAlR
MANUAL
FAIRING
SUPPORT
RIVETS TO REMOVE
Front Fairing Support of the 12B Duet Rear Pairing IPRE SB70-ef00)
F i g , 2 0 5 (Sheet 1)
RePAfR NO. 1
54-30-70
printed in Great Llsitatn

RB211 TRENT
STRUCTURAL REPAIR
MANUAL
PRESSURE
1 \
h
'
" \
l POINT0 \\
ANGLE
Front Faising Support cf t h e l 2 R Duct Rear Pairing (PRE SBT8-C7001

Fig. 205 ( S h e e t 2 )
EFFECTMTY: TRENT
Page 219
Feb. 1 5 / 0 6
[ RB.211 TRENT
STRUCTURAL REPAIR
w e
MANUAL
COMMON NOZZLE ASSEMBLY - IDENTIFICATION
1. General
A. The assembly forms an aerodynamically smooth fairing where the hot stream
and cold stream airflows converge and pass to atmosphere.
EFFECTIVITY: TRENT
Page 1
Apr. 1/94
1
m m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
Common Nozzle Assembly - Identification

Figure 1
EFFECTIVITY: TRENT
54-40-0 1
Page 2
July 1/95
Hm(RI
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
VIEW
A-A

Figure 2
EFFECTIVITY: TRENT
Page 3
July 1/95
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
, 1 4;
SURFACE
SECTION
B-B
SECTION
C-C

Figure 3
EFFECTIVITY: TRENT
Page 4
July 1/95
1 (n,
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
VIEW
D-D

Figure 4
EFFECTIVITY: TRENT
Page 5
July 1/95
1mcm
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
VIEW
E-E

Figure 5
EFFECTIVITY: TRENT
Page 6
July 1/95
MANUAL
SECTION
INNER
F-F SURFACE
22 20 20 20 20 23
zF
22
20
21
18 18
SECTION
G%
INNER
Common N o z z l e A s s e m b l y - Identification
Figure 6
EFFECTIVITY: TRENT
Page 7
July 1/95
1m R
()
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
INNER
SURFACE
SECTION
H-H
OUTER
SURFACE
INNER
SURFACE
SECTION
J-J

Figure 7
EFFECTIVITY: TRENT
Page 8
July 1/95
H (5
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
VIEW
L-L
Figure 8
EFFECTIVITY: TRENT
Page 9
July 1/95
1m m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
22 20 20 20 20 i9
SECTION
m M-M
N-N

Figure 9
EFFECTIVITY: TRENT
Page 10
Sept.15196
1m(m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
UPPER SIDE STRUT

SECTION
P-P

Figure 10
EFFECTIVITY: TRENT
Page 11
July 1/95
[ RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
SECTION
R-R

Figure 11
EFFECTIVITY: TRENT
Page 12
July 1/95
FIB211 TRENT
STRUCTURAL REPAIR
MANUAL
COMMON NOZZLE ASSEMBLY - LIST OF APPROVED REPAIRS
2 CNA EXIT NOZZLE - SKIN PATCH REPAIR

(FRS Y016)
3 CNA OUTER DUCT - PARTIAL PENETRATION PLUG PATCH REPAIR

(FRS Y003)
4 CNA OUTER DUCT - FULL PENETRATION PLUG PATCH REPAIR

(FRS Y004)
5 CNA OUTER DUCT - WET LAYUP REPAIR

(FRS Y005)
6 REPLACE DECALS
(FRS 5089)
7 AEROSEALANT REPLACEMENT
(FRS Y017)
8 REPLACE DAMAGED SEALS

(FRS Y006)
9 REPLACE DAMAGED FAIRINGS

(FRS Y027)
10 REPAIR WORN SEAL LANDS

(FRS Y021)
11 REPLACE RIVETS
(FRS Y023)
12 REPLACE THREAD INSERTS

(FRS Y026)
13 SURFACE PAINT REPAIR

(FRS Y015)
14 REPLACE SIDE STRUTS END FITTINGS

(FRS Y028)
15 REPLACE TRANSVERSE FIRE SEAL ASSEMBLY AND END SEALS

(FRS Y022)
LIST OF REPAIRS
54-40-01
Page 201
P r i n t e d in Great Brltain Mar. 10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR DISBOND AT UPPER SIDE STRUT FITTING LOCATIONS
REPLACE SIDE STRUT INNER FAIRINGS
REMOVE AND INSTALL THE TROUGH FAIRINGS AND FASTENERS
LIST OF REPAIRS
54-40-01
Page 202
Prlnted in Great Brltain ~ a r 10/08
.
RB.211 TRENT
m,H> STRUCTURAL REPAIR
MANUAL

Figure 1 2
EFFECTIVITY: TRENT
Page 13
July 1/95
RB.211 TRENT
mc) STRUCTURAL REPAIR
MANUAL
ITEM DESCRIPTION GAGE YATERIAL EFFECTIVITY

R 1 Exhaust Nozzle See Detail A
2 Pen-Nib Fairing 62-64 Titanium
R 3 Outer Barrel See View A-A
4 Lower Strut Assembly T64 Titanium
5 Restraint Assembly Stainless Steel A286
6 Drain Assembly Cres Type 321
7 Lower Side Strut 2219-T851 Aluminium

Alloy QQ-A-250/30
8 Upper Side Strut 2219-T851 Aluminium

Alloyy QQ-A-250130
9 Upper Deck Assembly T64 Titanium
R 10 Inner Skin 0.050 2219-0 Aluminium

R (1.270) Sheet Clad
R 11 Frame 0.040 2219-0 Aluminium

R (1.016) Sheet Clad
R 12 Arrowhead Extrusion 2219-T3511 Aluminium

R Alloy
R 13 Outer Skin 0.050 2219-0 Aluminium

(1.270) Sheet Clad
14 Stiffener Ring TI-6A1-4V Titanium
15 Outer Skin TI-6A1-4V Titanium
16 Cone Support TI-6A1-4V Titanium
17 Primary Support TI-6A1-4V Titanium
LIST OF MATERIALS
EFFECTIVITY: TRENT
Page 14
July 1/95
RB.211 TRENT
lm33@ STRUCTURAL REPAIR
MANUAL
18 Surface Doubler Ply 0.011 Graphite Fiber

(2.794) 0 Degree Warp
AH-280-5H/3501-5A
AS4-Fiber
(VOCZA6)
Surface Doubler Ply 0.01 1 Graphite Fiber

AH-289-5HI3501-5A
AS4-Fiber
(VOCZA6)
Inner Doubler Ply 0.0145 Graphite Fiber

(0.3680) -45 Degree Warp
AH-370-5H/3501-5A
AS4-Fiber
(VOCZA6)
Inner Doubler Ply 0.0145 Graphite Fiber

(0.3680) +45 Degree Warp
AH-370-5H/3501-5A
AS4-Fiber
(VOCZA6)
Surface Doubler Ply 0.0045 Glass Fabric

(Warp Optional) (0.1143) 120G/3501-5A
Surface Doubler Ply 0.0 145 Graphite Fiber

AH-370-5H/3501-5A
AS4-Fiber
(VOCZA6)
Surface Doubler Ply 0.0145 Graphite Fiber

AH-370-5H/3501-5A
AS4-Fober
(VOCZA6)
LIST OF MATERIALS
EFFECTIVITY: TRENT
Page 15
July 1/94
1
mcm
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL

25 ~itaniumCore 0.0015 Ti-3A1-2.5V
Material (0.0381) Type 6-35 RDCB-N
(V51563)
26 Core Material 0.0060 5052 Aluminium Foil
(0.1524) 1/8 X 0.006
R 22 LB/FT3
Non-Perforated
27 Seal Carrier 0.032 Cres Sheet Type 321
(0.8128)
28 Core Material Hexcel
1/8-05052-55.0
29 Core Material 0.0030 5052AluminiumFoil
R (0.0762) 1/8 X 0.003
12.0 LB/FT3
Non-Perforated
R 30 Titanium Core 0.0015 Ti-3A1-2.5V
R Material (0.0381) Type 6-35 RDCB-D
R (V51563)
LIST OF MATERIALS
EFFECTIVITY: TRENT
Page 16
July 1/95
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
REPAIR N0.2
EXIT NOZZLE SKIN PATCH REPAIR
1. G e n e r a l
A . T h i s r e p a i r g i v e s t h e p r o c e d u r e t o r e p a i r damage on t h e i n n e r o r o u t e r e x i t
n o z z l e s k i n s u s i n g an e x t e r n a l p a t c h .
This r e p a i r is written i n four parts:
Part 1 P a t c h R e p a i r of Damage i n t h e Areas Not I n c l u d i n g Edges o r

I n t e r m e d i a t e Zee Frames.
Part 2 P a t c h R e p a i r of Damage a t t h e Forward Edge.
Part 3 P a t c h R e p a i r o f Damage a t t h e A f t Edge.
Part 4 P a t c h R e p a i r o f Damage a t t h e Zee Frame L o c a t i o n s .
B. T h i s r e p a i r i s l i m i t e d t o :
( 1 ) The area below t h e 20 d e g r e e r a d i a l from TDC on t h e i n n e r s k i n
( 2 ) The a r e a below t h e 30 d e g r e e r a d i a l from TDC on t h e o u t e r s k i n
( 3 ) The maximum p a t c h p e r m i t t e d by t h i s r e p a i r i s 413 s q cm (64 s q i n ) . A

minimum o f 2 5 , 4 mm (1.0 i n ) s e p a r a t i o n i s r e q u i r e d between p a t c h e s .
C. Aluminum a l l o y s h e e t , c l a d 2024-TO h e a t t r e a t e d t o t h e T42 c o n d i t i o n can

p o s s i b l y be u s e d a s a n a l t e r n a t i v e p a t c h m a t e r i a l ( a l t h o u g h t h e n e c e s s a r y
h e a t t r e a t m e n t (Ref. Mil-H-6088) c o u l d p r e v e n t i t s u s e f o r On-Wing r e p a i r
f o r p r a c t i c a l reasons).
2. R e f e r e n c e d I n f o r m a t i o n
..............................................................................
54-02-10 Fasteners -I n s t a l l a t i o n and Removal

TASK 78-11-14-300-007 FRSY016 T r e n t Engine Manual
REPAIR N0.2
EFFECTIVITY: TRENT
Page 201
July 1/98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
Drill and drilling equipment
Cleco temporary fasteners
Riveting equipment
ASP installation equipment

..............................................................................
..............................................................................
OMat 1/270 SOLVENT
OMat 8/52 ADHE SIVE
..............................................................................
PART IDENT MATERIAL
..............................................................................
Common nozzle assembly Aluminum Alloy 2219-T62
D. Repair Parts
..............................................................................
Rivet (Item 1)
Rivet (Item 2)
Pin (Item 3)
Collar (Item 4)
Sleeve (Item 5)
Rivet (Item 6)
Rivet (Item 7)
Aluminum alloy sheet, clad 2024-T3
0.050 in. (1,27 mm) thick (Item 8)
Aluminum alloy sheet, clad 2024-T3
0.040 in. (1,02 mm) thick (Item 9)
NOTE: Alternate Aluminum alloy 2024-TO may be used, Heat treat to T42,
per Mil-H-6088 after fabrication.
REPAIR N0.2
EFFECTIVITY: TRENT
Page 202
July 1/98
[ RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
P a r t 1: P a t c h R e p a i r o f Damage i n t h e A r e a s Not I n c l u d i n g Edges o r

I n t e r m e d i a t e Zee Frames (Ref F i g u r e 201, 202, 203 and 212)
CAUTION: TAKE CARE NOT TO CAUSE DAMAGE TO STRUCTURE UNDER THE SKIN.
A . Cut o u t t h e damaged s k i n .
( 1 ) Make s u r e t h e damage i s i n t h e p e r m i t t e d a r e a shown f o r t h i s P a r t 1

repair.
( 2 ) Cut o u t t h e damaged s k i n i n a r e g u l a r s h a p e .
( 3 ) Keep a minimum c o r n e r r a d i u s o f 0 . 5 i n . ( 1 2 , 7 mm).
B. Make t h e s k i n p a t c h (Ref F i g u r e 212)
( 1 ) Cut o u t t h e s k i n p a t c h from c l a d 2024-T3 aluminum a l l o y s h e e t ,

0.050 i n . ( 1 , 2 7 mm) t h i c k o r a l t e r n a t i v e .
( 2 ) The s k i n p a t c h must o v e r l a p t h e c u t o u t by 1.0 t o 1.25 i n . ( 2 5 , 4 0 t o

31,75 mm).
( 3 ) Make a 0 . 0 3 i n . (0,76 mm) chamfer around t h e p e r i p h e r y .
( 4 ) Bend t h e s k i n p a t c h t o t h e n o z z l e s k i n c o n t o u r .
C. D r i l l t h e p i l o t h o l e s
( 1 ) Layout a n d d r i l l t h r e e p i l o t h o l e s i n t h e s k i n p a t c h .
( 2 ) Put t h e s k i n p a t c h on t h e c u t o u t and d r i l l t h r e e p i l o t h o l e s i n t h e
nozzle s k i n through the s k i n patch.
D. D r i l l t h e r i v e t h o l e s
( 1 ) Hold t h e s k i n p a t c h i n p l a c e w i t h Cleco t e m p o r a r y f a s t e n e r s .
( 2 ) D r i l l t h e r i v e t h o l e 0.143 t o 0.146 i n . ( 3 , 6 3 t o 3 , 7 1 mm) d i a m e t e r

t h r o u g h t h e s k i n p a t c h and n o z z l e s k i n .
(3) Countersink t h e s k i n patch
E. Deburr t h e h o l e s
( 1 ) Remove t h e s k i n p a t c h and d e b u r r t h e n o z z l e s k i n and s k i n p a t c h h o l e s

and e d g e s .
REPAIR N0.2
EFFECTIVITY: TRENT
Page 203
J u l y 1/98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
WARNING: SOLVENT IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY CAUSE INJURY

IN ACCORDANCE WITH THE MANUFACTURERS SPECIFIC SAFETY AND HEALTH
APPLICABLE MATERIAL SAFETY DATA SHEET AND FOLLOW ALL LISTED SAFETY
AND HEALTH PRECAUTIONS.
F. Use OMat 270 SOLVENT and OMat 21101 CLOTH to clean the repair parts and
area. Dry the parts before the solvent evaporates.
WARNING: ADHESIVE IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY CAUSE

INJURY OR ILLNESS IF NOT PROPERLY USED. THIS PRODUCT SHOULD BE USED
ONLY IN ACCORDANCE WITH THE MANUFACTURERS SPECIFIC SAFETY AND HEALTH
G. Apply the adhesive
(1) Mix the OMat 8/52 ADHESIVE per the manufacturers instructions.
(2) Apply the adhesive to the faying surfaces of the nozzle skin and the
skin patch.
H. Install the rivets
(1) Wet install the NAS1739E4-2 rivets with the adhesive mix through the
skin patch and nozzle.
(2) Wipe off unwanted adhesive with an OMat 2/101 CLOTH.
5. Part 2: Patch Repair of Damage at the Forward Edge (Figure 201, 202, 204,
206, 207, 209 and 212)
A. Remove the fasteners
(1) Make sure the damage is in the permitted area shown for this Part 2
repair.
(2) Remove the existing ASP fasteners, if required, in the damaged area and
one on each side as shown in Views 'B' and 'G' (Ref 54-02-10).
REPAIR N0.2
EFFECTIVITY: TRENT
Page 204
July 1/98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
B . Cut o u t t h e damaged s k i n
( 1 ) Cut o u t t h e damaged s k i n i n a r e g u l a r shape
( 2 ) Keep a minimum c o r n e r r a d i u s o f 0 . 5 0 i n . (12,7 mm).
NOTE: I f t h e damage e x t e n d s o v e r t h e u n d e r l y i n g s t r u c t u r e (View ' G ' ) ,

c u t t h e n o z z l e s k i n t o t h e edge and make a f i l l e r .
C . Make t h e s k i n p a t c h and f i l l e r (Ref F i g u r e 204, 207, 209 and 212)
( 1 ) Cut o u t t h e s k i n p a t c h from aluminum a l l o y s h e e t , c l a d 2024-T3

0.050 i n . (1,27 mm) t h i c k o r a l t e r n a t i v e .
( 2 ) Cut o u t t h e f i l l e r , i f r e q u i r e d , from aluminum a l l o y s h e e t , c l a d

2024-T3 0 . 0 4 0 i n . (1,02 mm) t h i c k o r a l t e r n a t i v e .
( 3 ) The s k i n p a t c h must o v e r l a p t h e c u t o u t by 1.0 t o 1.25 i n . (25,40 t o

3 1 , 7 5 mm).
( 4 ) Make a 0 . 0 3 i n . ( 0 , 7 6 mm) chamfer a r o u n d t h e p e r i p h e r y .
( 5 ) The f i l l e r must b e a t l e a s t 1 . 0 i n . ( 2 5 , 4 mm) wide.
D. D r i l l t h e p i l o t h o l e s
( 1 ) Layout and d r i l l t h r e e p i l o t h o l e s i n t h e s k i n p a t c h .
( 2 ) P u t t h e s k i n p a t c h on t h e c u t o u t and d r i l l t h r e e p i l o t h o l e s i n t h e
e x i t n o z z l e s k i n t h r o u g h t h e s k i n p a t c h . Remove t h e p a t c h .
E. D r i l l t h e r i v e t h o l e s
(1) P u t t h e f i l l e r , i f r e q u i r e d , on t h e e x i t n o z z l e edge s t r u c t u r e and

d r i l l t h e h o l e s 0.203 t o 0.208 i n . ( 5 , 1 6 t o 5 , 2 8 mm) d i a m e t e r t o match
t h e e x i s t i n g ASP f a s t e n e r h o l e s .
( 2 ) P u t t h e s k i n p a t c h i n p o s i t i o n and h o l d s k i n p a t c h and f i l l e r w i t h
Cleco temporary f a s t e n e r s .
REPAIR NO. 2
EFFECTIVITY: TRENT
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J u l y 1/98
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STRUCTURAL REPAIR
MANUAL
(3) Drill the rivet holes 0.143 to 0.146 in. (3,63 to 3,71 mm) diameter
through the skin patch and nozzle skin.
(4) Drill the ASP fastener edge holes in the skin patch. Countersink the
skin patch.
F. Remove the skin patch and filler. Deburr the nozzle skin, skin patch, and
filler holes and edges.
G. Fill countersink holes
(1) Fill the ASP fastener countersink holes in the nozzle skin at the edge
under the skin patch.

INJURY OR ILLNESS IF NOT PROPERLY USED. THIS PRODUCT SHOULD BE
USED ONLY IN ACCORDANCE WITH THE MANUFACTURERS SPECIFIC SAFETY
AND HEALTH RECOMMENDATIONS. PRIOR TO USE OF THIS PRODUCT
CAREFULLY READ THE APPLICABLE MATERIAL SAFETY DATA SHEET AND
(2) Prepare a quantity of OMat 8/52 ADHESIVE per the manufacturers

instructions to do the repair.
(3) Wet install the head of a MS20426E4-3 rivet with the adhesive mix to
fill the countersunk holes.
(4) Drill 0.142 to 0.146 in. (3,63 to 3,71 mm) diameter holes through the
MS20426E4-3 rivet heads.

H. Use OMat 270 SOLVENT and OMat 21101 CLOTH to clean the repair parts and
area. Dry the parts before the solvent evaporates.
REPAIR N0.2
EFFECTIVITY: TRENT
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RB.211 TRENT
MANUAL

INJURY OR ILLNESS IF NOT PROPERLY USED. THIS PRODUCT SHOULD BE USED
ONLY IN ACCORDANCE WITH THE MANUFACTURERS SPECIFIC SAFETY AND HEALTH
G. Apply the adhesive
(1) Mix the OMat 8/52 ADHESIVE per the manufacturers instructions.
(2) Apply the adhesive to the filler, edge structure, and faying surfaces
of the nozzle skin and patch.
J. Put the filler and skin patch in position. Use Cleco temporary fasteners.
K. Install the rivets
(1) Wet install NAS1739E4-2 rivets with the adhesive mix through the patch
and nozzle skin.
(2) Wipe off unwanted adhesive with an OMat 21101 CLOTH.
L. Wet install 2ASPFF-V06-12 pins, ASP-LC-MV06 collars and ASPF-S-V06 sleeves

in the edge with the adhesive mix (Ref 54-02-10).
6. Part 3: Patch Repair of Damage at the Aft Edge (Ref Figure 201, 202, 205,
206. 208. 209 and 212)
A. Remove the fasteners
(1) Make sure the damage is in the permitted area shown for this Part 3
repair.
(2) Remove the existing rivets, if required, in the damaged area only as
shown in view 'G'.
B. Cut out the damaged skin

(l) Cut out the damaged skin in a regular shape
(2) Keep a minimum corner radius of 0.50 in. (12,7 mm).
NOTE: If the damage extends over the underlying structure (View 'G'),
cut the nozzle skin to the edge and make a filler.
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STRUCTURAL REPAIR
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C . Make t h e s k i n p a t c h and f i l l e r (Ref F i g u r e 205, 208, 209 and 212)
( 1 ) Cut o u t t h e s k i n p a t c h from aluminum a l l o y s h e e t , c l a d 2024-T3

0.050 i n . ( 1 , 2 7 mm) t h i c k o r a l t e r n a t i v e .
( 2 ) Cut o u t t h e f i l l e r , i f r e q u i r e d , from aluminum a l l o y s h e e t , c l a d

2024-T3 0 . 0 4 0 i n . ( 1 , 0 2 mm) t h i c k o r a l t e r n a t i v e .
( 3 ) The s k i n p a t c h must o v e r l a p t h e c u t o u t by 1 . 0 t o 1.25 i n . ( 2 5 , 4 0 t o

3 1 , 7 5 mm).
( 4 ) Make a 0 . 0 3 i n . ( 0 , 7 6 mm) c h a m f e r a r o u n d t h e p e r i p h e r y .
(5) The f i l l e r must be a t l e a s t 1 . 0 i n . ( 2 5 , 4 mm) wide.
D. D r i l l t h e p i l o t h o l e s
( 1 ) Layout and d r i l l t h r e e p i l o t h o l e s i n t h e s k i n p a t c h .
( 2 ) P u t t h e s k i n p a t c h on t h e c u t o u t and d r i l l t h r e e p i l o t h o l e s i n t h e
e x i t n o z z l e s k i n t h r o u g h t h e s k i n p a t c h . Remove t h e p a t c h .
E. D r i l l t h e r i v e t h o l e s
( 1 ) P u t t h e f i l l e r , i f r e q u i r e d , on t h e e x i t n o z z l e edge s t r u c t u r e and
d r i l l t h e h o l e s 0.129 t o 0.132 i n . ( 3 , 2 8 t o 3 , 3 5 mm) d i a m e t e r t o match
the existing holes.
( 2 ) P u t t h e s k i n p a t c h i n p o s i t i o n and h o l d s k i n p a t c h and f i l l e r w i t h
Cleco t e m p o r a r y f a s t e n e r s .
( 3 ) D r i l l t h e r i v e t h o l e s 0.143 t o 0.146 i n . ( 3 , 6 3 t o 3 , 7 1 mm) d i a m e t e r

t h r o u g h t h e s k i n p a t c h and n o z z l e s k i n .
( 4 ) D r i l l t h e edge r i v e t h o l e s i n t h e s k i n p a t c h .
( 5 ) Add r i v e t h o l e s mid-spaced between t h e e x i s t i n g u n d e r l y i n g r i v e t s a t

t h e a f t edge.
(6) Countersink t h e s k i n patch.
F. Remove t h e s k i n p a t c h and f i l l e r . Deburr t h e n o z z l e s k i n , s k i n p a t c h and

f i l l e r h o l e s and e d g e s .
REPAIR N0.2
EFFECTIVITY: TRENT
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STRUCTURAL REPAIR
MANUAL
WARNING: SOLVENT I S CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY CAUSE I N J U R Y

OR ILLNESS I F NOT PROPERLY USED. THIS PRODUCT SHOULD BE USED ONLY
I N ACCORDANCE WITH THE MANUFACTURERS SPECIFIC SAFETY AND HEALTH
G. Use OMat 270 SOLVENT and OMat 2/101 CLOTH t o c l e a n t h e r e p a i r p a r t s and

area. Dry t h e p a r t s b e f o r e t h e s o l v e n t e v a p o r a t e s .
WARNING: ADHESIVE I S CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY CAUSE

I N J U R Y OR ILLNESS I F NOT PROPERLY USED. THIS PRODUCT SHOULD BE USED
ONLY I N ACCORDANCE WITH THE MANUFACTURERS SPECIFIC SAFETY AND HEALTH
H. Apply t h e a d h e s i v e
( 1 ) Mix t h e OMat 8 / 5 2 ADHESIVE p e r t h e m a n u f a c t u r e r s i n s t r u c t i o n s .
( 2 ) Apply t h e a d h e s i v e t o t h e f i l l e r , edge s t r u c t u r e , and f a y i n g s u r f a c e s

o f t h e n o z z l e s k i n and p a t c h .
I . P u t t h e f i l l e r and s k i n p a t c h i n p o s i t i o n . Use C l e c o t e m p o r a r y f a s t e n e r s .
J. I n s t a l l t h e r i v e t s
( 1 ) Wet i n s t a l l NAS1739E4-2 r i v e t s w i t h t h e a d h e s i v e mix t h r o u g h t h e p a t c h

and n o z z l e s k i n .
( 2 ) Wipe o f f unwanted a d h e s i v e w i t h a n OMat 2/101 CLOTH.
K. Wet i n s t a l l t h e NAS1097KE4-8 r i v e t s i n t h e edge e x i s t i n g and added h o l e s

w i t h t h e a d h e s i v e mix (Ref F i g u r e 208 and 209).
7. P a r t 4: P a t c h R e p a i r o f Damage a t t h e Zee Frame L o c a t i o n s (Ref F i g u r e 201,

210 and 211)
A. Make s u r e t h a t t h e damage i s i n t h e p e r m i t t e d a r e a shown f o r P a r t 4 r e p a i r .

Remove t h e e x i s t i n g f a s t e n e r s from t h e z e e frame i n t h e damaged a r e a . Do
not enlarge the e x i s t i n g holes.
B. Use s t a n d a r d workshop equipment t o c u t o u t t h e damaged s k i n i n a r e g u l a r

s h a p e . Keep a minimum c o r n e r r a d i u s o f 12,7 mm (0.50 i n . ) .
REPAIR N0.2
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MANUAL
C . Cut o u t t h e s k i n p a t c h from 1,27 mm (0.50 i n . ) t h i c k 2024-T3 c l a d aluminum

a l l o y s h e e t . The s k i n p a t c h must o v e r l a p t h e c u t o u t by 25,40 t o 31,75 mm
(1.00 t o 1.25 i n . ) on a l l s i d e s . Cut t h e s k i n p a t c h s o i t w i l l p i c k up one
e x i s t i n g f a s t e n e r i n t h e z e e frame on e a c h s i d e of t h e i n n e r row of t h e
s k i n p a t c h . Chamfer a l l e d g e s on t h e s k i n p a t c h t o 0 , 7 6 mm ( 0 . 0 3 i n . ) .
Bend t h e s k i n p a t c h t o t h e n o z z l e s k i n c o n t o u r .
D. Cut o u t t h e f i l l e r from 1 , 0 2 mm (0.040 i n . ) t h i c k 2024-T3 c l a d aluminum

a l l o y s h e e t o r a l t e r n a t i v e . Bend t h e f i l l e r t o t h e n o z z l e s k i n c o n t o u r .
E. Layout and d r i l l t h r e e p i l o t h o l e s i n t h e s k i n p a t c h .
F. P u t t h e s k i n p a t c h on t h e c u t o u t and d r i l l a t l e a s t t h r e e p i l o t h o l e s i n
t h e nozzle s k i n through t h e s k i n patch. Remove t h e s k i n p a t c h . Make a
t e m p l a t e of t h e h o l e s i n t h e z e e frame i n c l u d i n g t h e p i l o t h o l e s j u s t
d r i l l e d . Use t h e t e m p l a t e t o t r a n s f e r t h e h o l e s i n t h e z e e frame t o t h e
s k i n p a t c h and f i l l e r . Add one a d d i t i o n a l f a s t e n e r h o l e on e a c h s i d e of
t h e s k i n p a t c h common t o t h e z e e frame.
G. Assemble t h e f i l l e r and s k i n p a t c h on t h e z e e frame. Hold t h e r e p a i r p a r t s

i n p l a c e w i t h C l e c o t e m p o r a r y f a s t e n e r s . D r i l l t h e 3 , 6 3 t o 3 , 7 1 mm (0.143
t o 0.146 i n . ) d i a m e t e r r i v e t h o l e s t h r o u g h t h e f i l l e r , s k i n p a t c h , and z e e
frame. C o u n t e r s i n k t h e s k i n p a t c h h o l e s .
NOTE: Do n o t d r i l l t h r o u g h t h e c o u n t e r s u n k h o l e f i l l e r s .
H. Remove t h e Cleco temporary f a s t e n e r s , s k i n p a t c h , and f i l l e r . Deburr a l l

d r i l l e d holes.
I. F i l l t h e c o u n t e r s u n k h o l e s i n n o z z l e s k i n u n d e r t h e s k i n p a t c h w i t h R e p a i r
p a r t Item 7 r i v e t s .
WARNING: ADHESIVE I S CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY CAUSE

I N J U R Y OR ILLNESS I F NOT PROPERLY USED. THIS PRODUCT SHOULD BE
USED ONLY I N ACCORDANCE WITH THE MANUFACTURERS SPECIFIC SAFETY
AND HEALTH RECOMMENDATIONS. PRIOR TO USE OF THIS PRODUCT
CAREFULLY READ THE APPLICABLE MATERIAL SAFETY DATA SHEET AND
( 1 ) P r e p a r e a q u a n t i t y o f O M a t 8/52 ADHESIVE p e r t h e m a n u f a c t u r e r s
i n s t r u c t i o n s t o do t h e r e p a i r .
( 2 ) Wet i n s t a l l t h e head of a MS20426E4-3 r i v e t w i t h t h e OMat 8/52 ADHESIVE

i n t o t h e countersunk h o l e s .
REPAIR N0.2
EFFECTIVITY: TRENT
Page 210
J u l y 11 9 8
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL

J. Clean the repair parts with an OMat 21101 LINT FREE ABSORBENT CLOTH made
moist with OMat 270 SOLVENT. Rub the surfaces dry before the solvent
evaporates.
K. Use the manufacturers instructions to mix and apply the OMat 8 / 5 2 ADHESIVE
to the filler, skin patch, zee frame, countersunk hole filler rivets, and
the faying surfaces on the zee frame and nozzle.
L. Put the filler and skin patch into position and hold in position with Cleco
temporary fasteners.
M. Install the Item 1 rivets wet with OMat 8/52 ADHESIVE mix through the skin
patch and nozzle skin. Install the Item 2 rivets wet with OMat 8 / 5 2
ADHESIVE mix through the skin patch, filler, and zee frame. Wipe off any
excess adhesive.
8. Examine the Completed Repair
A. Visually examine the repair. Make sure there are no voids between the
filler, skin patch, zee frame, and nozzle. Make sure there are no loose
rivets. Make sure all requirements of this repair procedures are done.
REPAIR N0.2
EFFECTIVITY: TRENT
Page 211
July 1/98
RB.211 TRENT
m STRUCTURAL REPAIR
MANUAL
v EXIT NOZZLE H TRAILING

EDGE
JOINT
FORWARD
JOINT DAMAGE
- - - \
EDGE REPAIR PER
VlEW " A
DAMAGE
REPAIR PER
VlEW "B"
DAMAGE REPAIR OR "G"
llR 1 PER VlEW " K
DAMAGE
REPAIR PER
VlEW "Bn
OR "G"
Damage Repair Areas

Figure 201
REPAIR N0.2
EFFECTIVITY: TRENT
Page 212
J u l y 1/98
RB.211 TRENT
MANUAL
EXIT NOZZLE
REPAIR PER VIEWS
-------------
IF THIS DIMENSION IS LESS THAN

25,40(1.00)CUT OUT
TRAILING EDGE JOINT
AS SHOWN BELOW IN nn
un
VIEW B
FORWARD JOINT EDGE
VlEW A
12,7 (0.50) RADIUS

/
/ EDGE OF
CUT OUT
REPAIR PER VlEW "E"

FOR FORWARD JOINT EDGE
OR VlEW "F" FOR
TRAILING EDGE JOINT
----
TRAILING EDGE JOINT REMOVE MISTING

OR FASTENERS
FORWARD JOINT EDGE FORWARD EDGE ONLY
Damage Cut Out Schemes

Figure 202
R E P A I R N0.2
E F F E C T I V L T Y : TRENT
54-40-01Page 213
July 1/98
1 RB.211 TRENT
MANUAL
7,11 - 6,35
(0.28 - 0.25)
TYPICAL
20,57 - 19,OS
(0.81 - 0.75) 14,22 - 12,70
TYPICAL (0.56 - 0.50)
CONSTANT
DRILL HOLES
/ % 3,71- 3,63
(0.146 - 0.143)
EXIT NOZZLE SKIN DIAMETER
EDGE OF CUT OUT HOLE
PATCH
CUT TO PROVIDE
31,75 - 25,40
VIEW C (1.25 - 1.00)
OVERLAP
WET INSTALL
ABRADE FAYING SURFACES

CLEAN WITH MEK, AND APPLY
ADHESIVE
VIEW D
R e p a i r D e t a i l s and D i m e n s i o n s
F i g u r e 203
REPAIR N0.2
EFFECTIVITY: TRENT
Page 214
July 1/98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
DRILL HOLES
3,71 - 3,63
(0.146 - 0.143)
DIAMETER PATCH
100" COUNTERSINK
CUT TO PROVIDE
31,75 - 25,40
(1.25 - 1.OO)
OVERLAP
(0.81 - 0.75)
TYPICAL H--
14,22 - 12,70 '\ k*

(0.56 - 0.50)
TYPICAL I
I
++
l ++
I ++
0 0
PATCH
- 7,11 - 6,35
5,28 - 5,16
(0.203 - 0.208)
DIAMETER
- 14,22 - 12,70
(0.56 - 0.50)
CONSTANT
(0.28 - 0.25)
TYPICAL
100" COUNTERSINK
FOR ITEMS 3 , 4 , AND
5, PIN, SLEEVE, AND
COLLAR
INSERT COUNTERSINK HOLE VIEW E
FILLER IN NOZZLE SKIN,
ITEM 7 RIVET HEAD
Forward Edge Repair Details and Dimensions

Figure 204
REPAIR N0.2
EFFECTIVITY: TRENT
Page 215
July 1/98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
DRILL HOLES
3,71- 3,63
(0.146- 0.143)
DIAMETER
PATCH
100" COUNTERSINK
CUT TO PROVIDE
31,75- 25,40
TYPICAL
DRILL HOLES
3,35- 3,28
(0.132- 0.129)
DIAMETER
-I I 14,22- 12,70
c- (0.56- 0.50)
(0.28- 0.25)
TYPICAL
100"COUNTERSINK CONSTANT
FOR ITEM 6
RIVET
0 EXISTING LOCATION
8 ADDED LOCATION
Aft Edge Repair Details and Dimensions

Figure 205
REPAIR N0.2
EFFECTIVITY: TRENT
Page 216
July 1/98
[ RB.211 TRENT
MANUAL
EDGE OF CUT OUT

EXIT NOZZLE /
DRILL OUT
EXISTING FASTENERIS)
AT AFT EDGE
IF DAMAGE EXTENDS
INTO THIS
AREA, CUT OUT
AS SHOWN
REPAIR PER VIEWS
mHW OR PSI" AND vJw
REMOVE EXISTING
FASTENERS AT FORWARD
EDGE
Extreme Forward or Aft Edge Damage Cut Out Schemes

Figure 206
REPAIR N0.2
EFFECTIVITY: TRENT
54-40-0 1
Page 217
July 1/98
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
DRILL HOLES
3,71 - 3,63
10.146 - 0.1431
DIAMETER
100' C0UN:ERSINK PATCH
CUT TO PROVIDE
31,75 - 25,40
(1.25 - 1.00)
OVERLAP
20,57- 19,05
(0.81 - 0.75)
TYPICAL
14,22 - 12,70
(0.56 - 0.50)
TYPICAL
++ I I ++
++I I++
t
--
7,11 - 6,35
DRILL HOLES (0.28 - 0.25)
14,22 - 12,70 5,28 - 516 TYPICAL
(0.56 - 0.50) (0.203 - 0.208)
CONSTANT DIAMETER
100' COUNTERSINK
FOR ITEMS 3 , 4 , AND 5,
PIN, SLEEVE, AND COLLAR
INSERT COUNTERSINK HOLE
FILLER IN NOZZLE SKIN,
ITEM 7 RIVET HEAD
Extreme Forward Edge R e p a i r D e t a i l s and Dimensions

F i g u r e 207
REPAIR N0.2
EFFECTIVITY: TRENT
54-40-01
218 Page
J u l y 1I 9 8
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
DRILL HOLES
3,71- 3,63
(0.146- 0.143)
DIAMETER PATCH
100" COUNTERSINK CUT TO PROVIDE
(0.56- 0.50) (0.132- 0.129)

CONSTANT DIAMETER
100' COUNTERSINK
FOR ITEM 6
RIVET
0 EXISTING LOCATION
@ ADDED LOCATION
Extreme Aft Edge Repair Details and Dimensions

Figure 208
REPAIR N0.2
EFFECTIVITY: TRENT
Page 219
July 1/98
RB.211 TRENT
m STRUCTURAL REPAIR
MANUAL
WET INSTALL
EXISTING WET INSTALL
REPLACEMENT
BLIND RIVETS
AS REQUIRED
ABRADE FAYING SURFACES

CLEAN WITH MEK, AND
APPLY ADHESIVE
Extreme Forward o r A f t Edge R e p a i r D e t a i l s a n d Dimensions

F i g u r e 209
REPAIR N0.2
EFFECTIVITY: TRENT
P a g e 220
J u l y 1/98
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
EDGE OF
EDGE OF CUT OUT
REPAIR PER VlEW "L"
ZEE FRAME
VlEW K
Zee Frame Location Damage Cut Out Scheme

Figure 210
REPAIR N0.2
EFFECTIVITY: TRENT
Page 221
July 1/98
[ RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
EXIT NOZZLE SKIN 14,22 - 12,70

(0.56 - 0.50)
CONSTANT
ITEM 2
+ PATCH
RlVET
INSERT
COUNTERSINK HOLE
FILLER IN NOZZLE
SKIN, ITEM 7 RlVET
HEAD (2 PLACES)
7,11 - 6,35 ZEE FRAME

(0.28 - 0.25)
TYPICAL
DOUBLER DRILL HOLES

EDGE 3,71 - 3,63
(0.146 - 0.143)
DIAMETER
ADDED LOCATION FILLER 100" COUNTERSINK
ITEM 1 ITEM 2 ITEM 1

RlVET RlVET RlVET
I
- lilili J\
I-i/ PATcI-,
ZEE FRAME
Zee Frame L o c a t i o n R e p a i r D e t a i l s and Dimensions

F i g u r e 211
R E P A I R N0.2
EFFECTIVITY: TRENT
54-40-01 Page 222
J u l y 1/98
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
PATCH
EXIT NOZZLE
SKIN
Edge S e a l D e t a i l s
F i g u r e 212
REPAIR N0.2
EFFECTIVITY: TRENT
Page 223
J u l y 1/98
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
REPAIR N0.3
COMMON NOZZLE ASSEMBLY - OUTER DUCT
PARTIAL PENETRATION PLUG PATCH REPAIR
1. General
A. This repair gives the procedure for outer duct partial penetration
plug patch repair on the Common Nozzle Assembly (CNA).
B. This repair is limited to a damage size of 12 X 12 in(305 X 305 mm).
.......................................................................
.......................................................................
TASK 78-11-14-300-003 FRSY003, Trent Engine Manual
Brush (nylon bristle)
Cutting tool
Heat blanket
Heat lamp (explosion proof)
Knife
Metal or plastic container
Metal or plastic cover
REPAIR N0.3
54-40-01
Page 201
RB211 TRENT
STRUCTUAL REPAIR
m MANUAL
Spatula
Suction cleaner
Temperature controller
Temperature probe
Temperature recorder/Vacuum gauge
Vacuum hose
Vacuum probe
Vacuum source
.......................................................................
.......................................................................
R OMat135 SOLVENT (MEK)
OMat 299A TEFLON TAPE
OMat 2/110 VACUUM BAG SEAL ADHESIVE TAPE
OMat 2/114 LINT FREE GLOVES
OMat 884 FIBERGLASS CLOTH
OMat 8/156 ADHESIVE
C. Repair Parts
.......................................................................
.......................................................................
R FK16745 Acoustic panel assembly
REPAIR N0.3
54-40-01
Page 202
RB211 TRENT
STRUCTUAL REPAIR
m MANUAL
.......................................................................
.......................................................................
Outer duct NPT carbon skin, titanium core
4. Prepare the am aged Area (Ref Figure 203)
CAUTION: DO NOT CUT INTO THE INITIAL BARE SKIN GRAPHITE FABRIC,
THIS WILL CAUSE DAMAGE TO THE FABRIC.
A. Use a cutting tool to completely remove the damaged perforated

skin and core.
B. Apply OMat 299A TEFLON TAPE around the hole plus a 1.0 in.(25 mm)
wide area on all sides of the hole on the perforated skin.
C. Roughen the top surface of the perforated skin with OMat 5/38
WATERPROOF SILICON CARBIDE ABRASIVE PAPER to remove all of the
surface protection and to lightly roughen the perforated skin.
5. Prepare the Repair Core Plug (Ref Figure 204)
CAUTION: CORROSION TO THE CORE CAN OCCUR IF INSTRUCTIONS ARE NOT

FOLLOWED. USE SILICON CARBIDE WHEELS, STONES AND ABRASIVE
PAPERS TO SMOOTH.
A. Use a cutting tool to cut a repair plug to fit the damaged area.
Keep the outer skin attached.
B. Use a cutting tool to remove core and solid skin 0.75 to l.Oin.
(19 to 25 mm) from the perforated skin plug edge.
C. Place the repair plug in the damaged area. Make sure the repair
plug perforated skin edge and the panel skin touch.
REPAIR N0.3
54-40-01
Page 203
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
WARNING: SOLVENT IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY

CAUSE INJURY OR ILLNESS IF NOT PROPERLY USED. THIS PRODUCT
SHOULD BE USED ONLY IN ACCORDANCE WITH THE MANUFACTURER'S
SPECIFIC SAFETY AND HEALTH RECOMMENDATIONS. PRIOR TO USE
OF THIS PRODUCT, CAREFULLY READ THE APPLICABLE MATERIAL
SAFETY DATA SHEET AND OBEY ALL SAFETY AND HEALTH PRECAUTIONS.
A. Clean the repair area with OMat 135 SOLVENT and OMat 2/101 LINT
FREE CLOTH. Wipe the repair area dry.
B. Use a cutting tool to chamfer the outer edge of the perforated

skin.
7. Clean the Repair Plug

A. Clean the repair plug with OMat 135 SOLVENT and OMat 2/101 LINT
FREE CLOTH. Wipe the plug dry.
8. Install the Repair Plug (Re£ Figure 204)
WARNING: ADHESIVE IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY

A. Mix OMat 8/156 ADHESIVE in accordance with the manufacturer's

instructions.
B. Use a spatula to fill the core edge of the plug and repair area
with adhesive.
C. Use a brush to apply a layer of adhesive to the bottom of the

panel and faying surfaces on the repair plug and the panel.
REPAIR N0.3
54-40-01
Page 204
Printed in Great B r i t a i n Jan.1/02
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
D. Install the repair plug in the cutout. Make sure there is a good
adhesive bond between the repair plug and the cutout. Use a
minimum adhesive thickness of 0.030 in.(0,76 mm) for the outer
skin and core bondline.
NOTE: Do not allow the adhesive to flow away from the core to the
skin bondline.
WARN1NG:SOLVENT IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY

E. Remove unwanted adhesive with OMat 135 SOLVENT and OMat 2/101
LINT FREE CLOTH.
9. Make a Vacuum Bag and Cure the Repair Area (Ref Figure 205)
A. Cover the repair area with a sheet of OMat 2/112 POROUS PARTING
FILM that is 2.0 in.(50,8 mm) larger all around.
B. Cover the porous parting film with two layers of the OMat 884
FIBERGLASS CLOTH as a bleeder cloth and one sheet of OMat 2/113
NON-POROUS PARTING FILM.
C. Cover the non-porous parting film with a silicone rubber sheet

and a heat blanket.
D. Cover the heat blanket with two layers of OMat 2/111 BREATHER
CLOTH.
E. Attach the repair materials all around the edges with OMat 299A
TEFLON TAPE.
F. Cover the breather cloth with OMat 2/31 VACUUM BAG MATERIAL
that is approximately 2.00 in. (50,8 mm) larger all around.
G. Put a temperature probe and a vacuum probe below the vacuum bag
material and seal the edges of the bag to the panel skin with
OMat 2/110 VACUUM BAG SEAL ADHESIVE TAPE.
H. Cure the repair at 190 to 210 deg F (88 to 99 deg C) for 60

minutes while a constant pressure of 22 inches of mercury is
kept inside the vacuum bag. Increase the temperature at 2 to
8 deg F (-17 to -13 deg C) per minute.
REPAIR N0.3
54-40-01
Page 205
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
I. When the cure process is completed, remove the vacuum bag

J. Remove the teflon tape from the repair area.
WARNING: PUT ON PROTECTIVE CLOTHING, GLOVES, DUST MASKS, AND SAFETY

GOGGLES.WHEN COMPOSITE MATERIALS ARE CUT OR SANDED, DUST

and to a smooth contour suitable to paint. Use OMat 5/38
B. Remove all unwanted material with a suction cleaner, make sure

that no particles of the materials stay in the panel.

C. Clean the repair area with OMat 135 SOLVENT and OMat 2/101 LINT
D. Apply surface protection to the repair area in accordance with

standard painting procedures.
A. Make a visual inspection to make sure that the repair has been
done in accordance with these procedures. Do a tap test of the
repair. Make sure you can hear no hollow sounds that show areas
of disbond.
REPAIR N0.3
54-40-01
Page 206
1 p-
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
P a r t i a l P e n e t r a t i o n P l u g Patch R e p a i r
F i g u r e 201
REPAIR N0.3
EFFECTIVITY: TRENT
54-40-01
207
Page
Sept.15/96
M
m
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
ITEM 1
P a r t i a l Penetration Plug Patch Repair

F i g u r e 202
REPAIR NO. 3
EFFECTIVITY: TRENT
P a g e 208
Sept.15196
1m (R)
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
PERFORATED
/ INNER SKlN
' OUTER SKlN
PARTIAL PENETRATION
CUT HOLE THROUGH PERFORATED I I

SKIN. REMOVE DAMAGED CORE WITH
GRINDING DISK. HONEYCO
\ d
GRINDING DISK
DAMAGE REMOVAL
P a r t i a l P e n e t r a t i o n Plug Patch Repair

F i g u r e 203
REPAIR N0.3
EFFECTIVITY: TRENT
54-40-01
Page 209
Sept.15/96
M (R?
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
PERFORATED ITEM 1
INNER SKlN CORE REPAIR PLUG
OUTER SKIN OUTER >KIN EA9321

ON PLUG ADHESIVE MIX
TYPICAL
T FLUSH
WITH INNER SIDE OF
PANEL REPAIR PLUG INSTALLATION OUTER SKlN
P a r t i a l Penetration Plug Patch Repair

F i g u r e 204
REPAIR N0.3
EFFECTIVITY: TRENT
P a g e 210
Sept.15196
1m (R
RB.211 TRENT
STRUCTURAL REPAIR
MUTUAL
BLEEDER CLOTH PLIES (2)

I
POROUS PARTING FlLM
NON-POROUS PARTING FlLM
HEAT BLANKFT
I
SILICONE RUBBER SHEET
REATHER PLIES (2)
I
/ HONEYCOMB CORE ADHESIVE TEMPERATURE
TEMPERATURE REPAIR PLUG
PROBE
PROBE
HEAT BLANKET INSTALLATION
P a r t i a l P e n e t r a t i o n Plug P a t c h Repair
Figure 205
REPAIR NO. 3
EFFECTIVITY: TRENT
Page 2 1 1
Sept. 15/96
R8211 TRENT
ImI STRUCTUAL REPAIR
m MANUAL
REPAIR N0.4
COMMON NOZZLE ASSEMBLY - OUTER DUCT
FULL PENETRATION PLUG PATCH REPAIR
1. General
A. This repair gives the procedure for a full penetration plug patch
repair on the outer duct of the Common Nozzle Assembly (CNA).
B. This repair is limited to a damage size of 12 X 12in.(305 X 305mm).
.......................................................................
.......................................................................
TASK 78-11-14-300-003 FRSY004, Trent Engine Manual
Cutting tool
Heat blanket
Knife
Plastic container
Plastic cover
Roller
REPAIR N0.4
54-40-01
Page 201
Printed in G r e a t B r i t a i n Jan.1/02
R8211 TRENT
STR UCTUAL REPAlR
MANUAL
Spatula
Suction cleaner
Temperature probe
Vacuum hose
Vacuum probe
Vacuum source
.......................................................................
.......................................................................
R OMat135 SOLVENT (MEK)
OMat 8/156 ADHESIVE
OMat 8/171 GRAPHITE FABRIC
C. Repair Parts
......................................................................
PART NUMBER IDENTIFICATION
......................................................................
R FK16745 Acoustic Panel Assembly
REPAIR NO.4
54-40-01
Page 202
RB211 TRENT
STRUCTUAL REPAIR
m MANUAL
......................................................................
......................................................................

CAUSE INJURY OR ILLNESS IF NOT CORRECTLY USED. THIS PRODUCT
SPECIFIC SAFETY AND HEALTH RECOMMENDATIONS. PRIOR TO USE OF
THIS PRODUCT, CAREFULLY READ THE APPLICABLE MATERIAL SAFETY
DATA SHEET AND OBEY ALL LISTED SAFETY AND HEALTH PRECAUTIONS.
5. Prepare the Damaged Area for Repair (Ref Figure 201, 202 and 203)
A. Make a mark for the repair area to the smallest size that will
make sure all damage is removed.
WARNING: WEAR PROTECTIVE CLOTHING, GLOVES, DUST MASKS AND SAFETY

GOGGLES WHEN COMPOSITE MATERIALS ARE CUT OR SANDED. DUST
AND LOOSE PARTICLES ARE PRODUCED WHICH ARE POTENTIAL HEALTH
CAUTION: DO NOT CUT INTO THE INITIAL BARE SKIN GRAPHITE FABRIC, THIS
WILL CAUSE DAMAGE TO THE FABRIC.
B. Cut out the damaged solid and perforated skin with a minimum
radius of 0.50in.(12,7 mm) on all corners. Use OMat 5/38
WATERPROOF SILICON CARBIDE ABRASIVE PAPER and chamfer the sides
of the surface skin.
C. Remove the damaged core from the panel.
D. Apply OMat 299A TEFLON TAPE around the hole plus a 1.0 in.(25,4mm)
wide area on all sides of the hole.
CAUTION: DO NOT TAPER OR BREAK THE CARBON FIBERS OF THE TOP SURFACE
OF THE OUTER SKIN PLY.
REPAIR N0.4
54-40-01
Page 203
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
E. Roughen the top surface of the solid and perforated skin with
OMat 5/38 WATERPROOF ABRASIVE PAPER to remove all of the surface
protection and to lightly roughen the outer surface of the skin.

CAUSE INJURY OR ILLNESS IF NOT CORRECTLY USED. THIS PRODUCT
SPECIFIC SAFETY AND HEALTH RECOMMENDATIONS.PRI0R TO USE OF
THIS PRODUCT CAREFULLY READ THE APPLICABLE MATERIAL SAFETY
F. Clean the repair area with OMat 135 SOLVENT and OMat 2/101 LINT
6. Prepare the Repair Core Plug (Ref Figure 204)
WARNING: PUT ON PROTECTIVE CLOTHING, GLOVES, DUST MASKS AND SAFETY

GOGGLES WHEN COMPOSITE MATERIALS ARE CUT OR SANDED.DUST AND
CAUTION: CORROSION TO THE CORE CAN OCCUR IF INSTRUCTIONS ARE NOT

FOLLOWED. USE SILICON CARBIDE WHEELS, STONES AND ABRASIVE
PAPERS TO SMOOTH.
A. Use a cutting tool to cut a repair plug 0.75 to 1.0in.(19,0 to

25,4 mm) larger all around than the damaged area.
B. Use a cutting tool to remove core and solid skin 0.75 to 1.0 in.
(19,O to 25'4 mm) from the perforated skin plug edge.
7. Clean the Repair Area and the Core Plug

REPAIR N0.4
54-40-01
Page 204
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
8. Cut the Filler and Repair Plies (Ref Figure 205)
A. Cut two OMat 8/171 GRAPHITE FABRIC filler plies with warp 0 and
90 degrees to fill the cutout in the skin.
B. Cut two plies of OMat 8/171 GRAPHITE FABRIC with warp 0 and 90
degrees for repair plies.
(1) Cut the first graphite fabric repair ply 1.0 in.(25,4 mm)
larger all around than the cutout.Trim the corners 45. degrees
by 1.0 in. (25'4 mm).
(2) Cut the second graphite fabric repair ply 0.75in.(19,0 mm)
larger all around than the first ply. Trim the corners 45
degrees by 1.0 in. (25'4 mm).
C. Cut a OMat 884 FIBERGLASS CLOTH sanding ply 0.75in.(19,0 mm)

larger all around than the second repair ply. Trim the corners 45
degrees by 1.0 in. (25,4 mm).
9. Install the Repair Plug (Re£ Figure 205)
WARNING: ADHESIVE IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH MAY

A. Mix OMat 8/156 ADHESIVE in accordance with the manufacturer's

instructions.
B. Use a spatula to fill the core edge of the plug and repair area
with adhesive.
C. Use a brush to apply a layer of adhesive to the bottom of the

panel and faying surfaces on the plug and the panel.

D. Install the repair plug in the repair cutout. Make sure there is
a good adhesive bond between the repair plug core and the
R surrounding core. Use OMat 135 SOLVENT and OMat 2/101 LINT FREE
CLOTH to remove unwanted adhesive.
Page 205
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
10. Install the Filler Plies (Ref Figure 205)
WARNING: EPOXY ADHESIVE IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH

MAY CAUSE INJURY OR ILLNESS IF NOT CORRECTLY USED. THIS
MANUFACTURER'S SPECIFIC SAFETY AND HEALTH RECOMMENDATIONS.
PRIOR TO USE OF THIS PRODUCT, CAREFULLY READ THE APPLICABLE
MATERIAL SAFETY DATA SHEET AND OBEY ALL LISTED SAFETY AND
HEALTH PRECAUTIONS.
A. Mix OMat 8/160 EPOXY ADHESIVE in accordance with the

manufacturer' S instructions.
B. Put the first filler ply on the sheet of OMat 2/113 NON-POROUS
PARTING FILM and apply the adhesive mixture to the top side.
Cover the filler ply with another sheet of non-porous parting film.
C. Use the roller to force the adhesive fully into the filler plies.
D. Remove the top sheet of the non-porous parting film.
E. Do steps 10.B. and 10.C. again for the second filler ply.
F. Remove the bottom non-porous parting film.
G. Center the second filler ply over the first filler ply.
H. Cut the stack of filler plies to the size and shape of the cutout.
I. Apply the adhesive to the inside surface of the cutout.
J. Remove the bottom non-porous parting film.
K. Center the filler plies in the cutout.
L. Smooth out the wrinkles with a roller.
M. Remove the top sheet of non-porous parting film.
11. Install the Repair and Sanding Plies (Ref Figure 205)
A. Put the first repair ply on a sheet of OMat 2/113 NON-POROUS

Cover the repair ply with another sheet of non-porous parting film.
B. Use the roller to force the adhesive fully into the repair plies.
REPAIR N0.4
54-40-01
Page 206
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
C. Remove the bottom sheet of the non-porous parting film.
D. Center the repair ply over the cutout.
E. Smooth out the wrinkles with a roller.
F. Remove the top sheet of non-porous parting film.
G. Do steps ll.A thru ll.F again for the second repair ply and the
sanding ply.
12. Make a Vacuum Bag (Re£ Figure 206)
A. Cover the repair plies with a sheet of OMat 2/112 POROUS PARTING
FILM that is 2.0 in. (50,8 mm) larger all around.
B. Cover the porous parting film with two layers of OMat 884
FIBERGLASS CLOTH as a bleeder cloth, and one sheet of OMat 2/113

and a heat blanket.
D. Cover the heat blanket with two layers of OMat 2/111 BREATHER
CLOTH.
E. Cover the breather cloth with OMat 2/31 VACUUM BAG MATERIAL that
is approximately 2.0 in.(50,8 mm) larger all around.
F. Put a temperature probe and a vacuum probe below the vacuum bag
material and seal the edges of the bag to the panel skin with
OMat 2/110 VACUUM BAG SEAL ADHESIVE TAPE.
G. Do steps 12.A thru 12.F again for the outer skin side, but use
three layers of fiberglass fabric bleeder cloth in step 12.B.
minutes while a constant pressure of 22 inches of mercury is
kept inside the vacuum bag on both sides. Increase the temperature
at 2 to 8 deg F (-17 to -13 deg C) per minute.
I. When the cure process is completed, remove the vacuum bag

REPAIR N0.4
54-40-01
Page 207
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
WARNING: PUT ON PROTECTIVE CLOTHING, GLOVES, DUST MASKS, AND SAFETY

GOGGLES-WHEN COMPOSITE MATERIALS ARE CUT OR SANDED, DUST

and to a smooth contour suitable to paint.Use OMat 5/38 WATERPROOF
SILICON CARBIDE ABRASIVE PAPER.
B. Remove all unwanted material with a suction cleaner. Make sure

no particles of the unwanted materials stay in the panel.

OF THIS PRODUCT CAREFULLY READ THE APPLICABLE MATERIAL
SAFETY DATA SHEET AND FOLLOW ALL LISTED SAFETY AND HEALTH
PRECAUTIONS.
C. Clean the repair area with OMat 135 SOLVENT and OMat 2/101
LINT FREE CLOTH. Wipe the repair area dry.

B. Do a tap test of the repair. Make sure you hear no hollow sounds
that show areas of disbond.
REPAIR N0.4
54-40-01
Page 208
1 RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
O u t e r Duct F u l l P e n e t r a t i o n P l u g R e p a i r
F i g u r e 201
REPAIR N0.4
EFFECTIVITY: TRENT
Page 209
Sept.15/96
M P
,,
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
ITEM 1
Outer Duct Full Penetration Plug Repair

Figure 202
REPAIR N0.4
EFFECTIVITY: TRENT
P a g e 210
Sept.15/96
1
m
RB.211 TRENT
STRUCTURAL REPAIR
YrANUAL
PERFORATED
/ INNER
' OUTER SKlN
FULL PENETRATION
HONEYCOMB
CUT HOLE THROUGH PERFORATE
SKIN. REMOVE DAMAGED CORE WI
GRINDING DISK
GRINDING DISK
PERFORATED
INNER SKlN
@El d
DAMAGE REMOVAL
OUTER SKIN

Figure 203
REPAIR NO. 4
EFFECTIVITY: TRENT
54-40-0 1
Page 211
Sept. 15/96
Hm <R>
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
PERFORATED ITEM 1
INNER SKIN CORE REPAIR PLUG
OUTER SKIN OUTER SKIN EA9321

ON PLUG ADHESIVE MIX
TYPICAL
ITEM 1
REPAIR PLUG APPLY €49321
ADHESIVE MIX
PERFORATED
19.05-25.40mrn
(0.75-1.00in)
OVERLAP
PANEL REPAIR PLUG INSTALLATION

Figure 204
REPAIR N0.4
EFFECTIVITY: TRENT
Page 212
Sept.15/96
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
19.05mm
RIBBON DIRECTION OUTER SKIN (0.75in)
d I I Y '
L ------- J
REPAIR PLY
NO. 2
90 "
FIBERGLASS
SANDING PLY 1 (1.00in)
TYPICAL
I I
PERFORATED
REPAIR PLUG
DHESIVE MIX
REPAIR PLIES
SANDING PLY
A- A
FULL PENETRATION REPAIR
D5526A
Figure 205
REPAIR NO. 4
EFFECTIVITY: TRENT
Page 213
Sept.15/96
RB.211 TRENT
WUAL

REPAIR PLUG SIDE
WET LAY-UP POROUS PARTING FILM
NON-POROUS PARTING FILM HEAT BLANKET

SILICONE RUBBER SHEET
BREATHER PLlES (2)
TAPE BAND
VACUUM HOSE
INNER SKIN
WET LAY-UP
REPAIR PLIES
HEAT BLANKET INSTALLATION

Figure 206
REPAIR N0.4
EFFECTIVITY: TRENT
Page 214
Sept.15/96
REPAIR NO.5
COMMON NOZZLE ASSEMBLY (CNA)
OUTER DUCT WET LAY-UP REPAIR
1. General
A. This repair gives the procedure for outer duct wet lay-up
repair, with or without core damage on the Common Nozzle
Assembly (CNA).
B. This repair is limited to a damage size of 12 x 12 in.(305 x

305 mm).
----------------------------------------------------------------------
----------------------------------------------------------------------
TASK 78-11-14-300-003 FRS Y005, Trent Engine Manual
Cutting tool
Heat blanket
Knife
Plastic container
Plastic cover
Roller
REPAIR NO.5
EFFECTIVITY: TRENT
54-40-01
Page 201
02
Spatula
Suction cleaner
Temperature probe
Vacuum hose
Vacuum probe
Vacuum source
-------------------------------------------------------------------
-------------------------------------------------------------------
R OMat 150 ACETONE
OMat 8/156 ADHESIVE
OMat 8/171 GRAPHITE FABRIC
REPAIR NO.5
EFFECTIVITY: TRENT
54-40-01
Page 202
02
R C. Repair Parts
-------------------------------------------------------------------
R FIG/ITEM PART NUMBER DESCRIPTION QTY
---------------------------------------------------------------
R FK16746 Titanium Core Plug 1
------------------------------------------------------------------
------------------------------------------------------------------

CAUSE INJURY OR ILLNESS IF NOT USED CORRECTLY. BEFORE
R A. Clean the repair area with OMat 150 ACETONE or alternative

solvent and OMat 2/101 LINT FREE CLOTH. Wipe the area dry.
5. Prepare the Damaged Area for Repair (Ref Figure 201 and 202)
A. Make a mark for the repair area to the smallest size that will
make sure all damage is removed.
WARNING: WEAR PROTECTIVE CLOTHING, GLOVES, DUST MASKS AND SAFETY

GOGGLES WHEN COMPOSITE MATERIALS ARE CUT OR SANDED.
DUST AND LOOSE PARTICLES ARE PRODUCED WHICH ARE
B. Cut out the damaged skin with a minimum radius of 0.50 in.
(12,70 mm) on all corners. Use OMat 5/38 WATERPROOF SILICON
CARBIDE ABRASIVE PAPER and chamfer the sides of the surface
skin to 45 degrees.
REPAIR NO.5
EFFECTIVITY: TRENT
54-40-01
Page 203
02
R 6. Damage removal when the core is damaged (Ref. Figures 202 and 203)
R NOTE: If the core is not damaged, go to Step 8.
R A. Remove the damaged core from the panel. Remove the adhesive
R nuggets.
R B. Apply OMat 299A TEFLON TAPE around the hole plus a 2.5 in.
R (63,5 mm) wide area on all sides of the hole.
CAUTION: DO NOT TAPER OR BREAK THE CARBON FIBERS OF THE TOP

SURFACE OF THE OUTER SKIN PLY.
C. Roughen the outer skin of the repair with OMat 5/38 WATERPROOF
SILICON CARBIDE ABRASIVE PAPER to remove all of the surface
protection and to lightly roughen the outer surface of the
skin.

CAUSE INJURY OR ILLNESS IF NOT PROPERLY USED. THIS
MANUFACTURERS SPECIFIC SAFETY AND HEALTH
SHEET AND FOLLOW ALL LISTED SAFETY AND HEALTH
PRECAUTIONS.
D. Clean the repair area with OMat 150 ACETONE or alternative

solvent and OMat 2/101 LINT FREE CLOTH. Wipe the repair area
dry.
R 7. Install the Repair Part Titanium Core Plug (Ref Figure 203)
R A. Cut the repair part to correctly fit the cutout hole
WARNING: ADHESIVE IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH

MAY CAUSE INJURY OR ILLNESS IF NOT PROPERLY USED. THIS
PRECAUTIONS.
B. Mix OMat 8/156 ADHESIVE in accordance with the manufacturer’s

instructions.
REPAIR NO.5
EFFECTIVITY: TRENT
54-40-01
Page 204
02
C. Apply the adhesive to the outer edges and the bottom of the
titanium core repair-plug, and to the mating surfaces in the
cutout. Use a minimum adhesive thickness of 0.030 in. (0,76
mm) for the outer skin and core bondline. Put the core repair
plug into the cutout and fill the open area between the repair
plug and the cutout with adhesive. Do not allow the adhesive
to flow away from the core to the skin bondline.
8. Install the Top Cutout Filler (Ref Figure 203)
A. Cut two OMat 8/171 GRAPHITE FABRIC plies with warp 0 and 90
degrees to fill the cutout in the skin.
WARNING: EPOXY ADHESIVE IS CLASSIFIED AS A HAZARDOUS MATERIAL

PRECAUTIONS.
B. Mix OMat 8/160 EPOXY ADHESIVE in accordance with the

manufacturer’s instructions.
C. Put the first graphite filler ply on the sheet of OMat 2/113
NON-POROUS PARTING FILM and apply the adhesive mixture to the
top side. Cover the filler ply with another sheet of non-
D. Use the roller to force the adhesive fully into the filler
plies.
R E. Do steps 8.C. and 8.D. again for the second filler ply.
F Remove the top sheet of the parting film from both filler
plies.
G. Center the second filler ply over the first filler ply.
H. Remove the bottom sheet of non-porous parting film from the

combined plies.
I. Center the combined filler plies in the cutout.
J. Smooth out the wrinkles with a roller.
k. Remove the top sheet of the non-porous parting film.
REPAIR NO.5
EFFECTIVITY: TRENT
54-40-01
Page 205
02
9. Install the Repair Plies (Ref Figure 203)
A. Cut two plies of OMat 8/171 GRAPHITE FABRIC with warp 0 and 90
degrees.
(1) Cut the first graphite fabric repair ply 1.00 in. (25,4
mm) larger all around than the cutout. Trim the corners
45 degrees by 1.00 in. (25,4 mm).
(2) Cut the second graphite fabric repair ply 0.75 in. (19,1
mm) larger all around than the first repair ply. Trim
the corners 45 degrees by 1.00 in. (25,4 mm).
WARNING: EPOXY ADHESIVE IS CLASSIFIED AS A HAZARDOUS MATERIAL

PRECAUTIONS.
B. Mix OMat 8/160 EPOXY ADHESIVE in accordance with the

C. Put the first repair ply on a sheet of OMat 2/113 NON-POROUS

Cover the repair ply with another sheet of non-porous parting
film.
D. Use the roller to force the adhesive fully into the repair
plies.
E. Remove the bottom sheet of the non-porous parting film.
F. Center the repair ply over the cutout.
G. Smooth out the wrinkles with a roller.
H. Remove the top sheet of non-porous parting film.
R I. Do steps 9.C. thru 9.H. again for the second repair ply.
10. Make a Vacuum Bag (Ref Figure 204)
A. Cover the repair plies with a sheet of OMat 2/112 POROUS

PARTING FILM that is 2.00 in. (50,8 mm) larger all around.
REPAIR NO.5
EFFECTIVITY: TRENT
54-40-01
Page 206
02
B. Cover the porous parting film with two plies of OMat 884
FIBERGLASS CLOTH as a bleeder cloth and one ply of OMat 2/113

and a heat blanket.
D. Cover the heat blanket with two plies of OMat 2/111A BREATHER
CLOTH.
E. Cover the breather cloth with OMat 2/31 VACUUM BAG MATERIAL
that is approximately 2.00 in. (50,8 mm) larger all around.
F. Put a temperature probe and a vacuum probe below the vacuum

bag material and seal the edges of the bag to the panel skin
with OMat 2/110 VACUUM BAG SEAL ADHESIVE TAPE.
R G Do steps 10.A. thru 10.F. again for the outer skin side, but
do not include the two plies of fiberglass fabric bleeder
cloth in step 10.B.
minutes and the outer skin side for 60 minutes while a
constant pressure of 22 inches of mercury is kept inside the
R vacuum bag. Increase the temperature at 2 to 8 deg F (1 to 4
R deg C) per minute.
I. When the cure process is completed, remove the lay-up

WARNING: WEAR PROTECTIVE CLOTHING, GLOVES, DUST MASKS, AND

SAFETY GOGGLES. WHEN COMPOSITE MATERIALS ARE CUT OR
SANDED, DUST AND LOOSE PARTICLES ARE PRODUCED WHICH ARE

and to a smooth contour suitable to paint. Use OMat 5/38
WATERPROOF SILICON CARBIDE.

sure no particles of the unwanted material stay in the panel.
REPAIR NO.5
EFFECTIVITY: TRENT
54-40-01
Page 207
02
CAUSE INJURY OR ILLNESS IF NOT PROPERLY USED. THIS
PRECAUTIONS.
R C. Clean the repair area with OMat 1/150 ACETONE or alternative

R solvent and OMat 2/101 LINT FREE CLOTH. Wipe the repair area
dry.

done in accordance with these procedures. Do a tap test of
the repair. Make sure you hear no hollow sounds that show
areas of disbond.
REPAIR NO.5
EFFECTIVITY: TRENT
54-40-01
Page 208
02
Outer Duct Wet Lay-up Repair
Figure 201
REPAIR NO.5
EFFECTIVITY: TRENT
54-40-01
Page 209
02
Figure 202
REPAIR NO.5
EFFECTIVITY: TRENT
54-40-01
Page 210
02
Figure 203
REPAIR NO.5
EFFECTIVITY: TRENT
54-40-01
Page 211
02
p RB211 TRENT
MANUAL
STRUCTUAL REPAIR
POROUS PARTING FlLM

BLEEDER CLOTH PLIES (2) REPAIR PLIES
NON-POROUS PARTING FlLM
SILIC:ONE RUBBER SHEET
TAPE BAND
VACUUM HOSE PERFORATED
INNER SKIN
VACUUM HOSE
BREATHER PLIES (2)
NON-POROUS PARTING FILM HEAT BLANKET

POROUS PARTING FlLM

Figure 204
REPAIR N0.5
54-40-01
Page 212
RB211 TRENT
STRUCTUAL REPAIR
m MANUAL
REPAIR NO. 6 (FRS J0 89)
REPLACE DECALS
1. General


on the Common Nozzle Assembly.

backgrounds. Use black or red decals on light-colored nacelles;
C. The minimum air temperature necessary for this repair is

16 deg C (61 deg F). If possible, do not operate the engine for
48 hours after the repair has been done.
2. Eauipment and Materials
Plastic squeegee
Rubber roller
......................................................................
......................................................................
OMat 150 ACETONE
OMat 7/203 THINNER
OMat 7/204 THINNER
......................................................................
PART IDENT MATERIAL
......................................................................
Fan Cowl Door Carbon Composite
54-40-01
Page 201
Jan. 1/00
p
" RB211 TRENT
MANUAL
STRUCTUAL REPAIR
A. Refer to Table 1 and Figures 201 and 202 to identify the correct
replacement decal.
4. Remove the Damaqed Decal
metallic scraper.
5. Prepare the Cowl Surface
A. Refer to Figures 201 and 202 for the correct dimensions. Use the
7. Avvlv the Replacement Decal
of the decal.'Flick' the corner of the decal with your finger.
trapped air.
REPAIR N0.6
54-40-01
Page 202
Jan. 1/00
RB211 TRENT
STRUCTUAL REPAIR

A. Use OMat 2/101 LINT FREE CLOTH soaked with OMat 150 ACETONE to
A. Refer to Figures 201 and 202. Make sure the decal is in the
10. Apply the Varnish


( 2 ) At temperatures more than 26 deg C (79 deg F) , use

OMat 7/204 THINNER.
B. Make sure the varnish is fully mixed (approx. 15 to 30 minutes).

D. Cure the varnish for 72 hours at 16 deg C (61 deg F) . The
11. Do an Ins~ectionof the Decal
this procedure.
REPAIR N0.6
54-40-01
Page 203
Jan. 1/00
RB211 TRENT
STRUCTUAL REPAlR
MANUAL
11-24-71
1 01-400 LJ41900 Black, Hoist Point - Nozzle Assembly Only

(Alt.LJ41901)
2 01-400A LJ41901 White, Hoist Point - Nozzle Assembly Only

(Alt.LJ41900)
Table 1
REPAIR N0.6
54-40-01
Page 204
Jan. 1/00
RB211 TRENT
STRUCTUAL REPAIR
VIEW ON FR(0NT O F ENGINE
0
ALL DIMENSIONS I N MILLIMETRES ( I N C H E S )
Figure 201
REPAIR N0.6
54-40-01
Page 205
Jan. 1/00
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
VIEW --p- AA
Figure 202
REPAIR NO. 6
54-40-01
Page 2 0 6
Jan. 1/00
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
REPAIR NO.7
AEROSEALANT REPLACEMENT
1. General
A. This repair gives the procedure to replace the aerosealant on the

external and internal surfaces of the Common Nozzle Assembly (CNA).
B. This repair removes the damaged sealant and installs new sealant.
C. The sealant specified for the external surfaces is compatible

with the paint materials, but not with the temperatures of the
internal surfaces. The sealant specified for the internal surfaces
is compatible with the temperatures of those surfaces,but not with
the paint materials on the external surfaces.Use only the sealants
specified for the surfaces as given in paras 5 and 7.
...................................................................
...................................................................
R TASK 78-11-14-300-001 FRS Y017, Trent Engine Manual
Plastic scraper
Spatula
Syringe
Heat lamp (S), explosion-proof
Permanent marker pen
...................................................................
...................................................................
R OMat 135 SOLVENT (MEK)
OMat 212 BRUSH
OMat 5/70 ALUMINIUM OXIDE ABRASIVE CLOTH
OMat 876C PRIMER
OMat 8/136 POLYSULPHIDE COMPOUND
OMat 8/143 SEALANT, DC93-006
R OMat8/138A SEALANT, RTV88 (A1ternative)
REPAIR N0.7
Page 201
RB211 TRENT
Iml
m
STRUCTUAL REPAIR
MANUAL
...................................................................
PART IDENT MATERIAL
...................................................................
Outer duct NPT Carbon skin, titanium core
Inner duct 6AL-4V Titanium
Exit nozzle 2219 Aluminium
4. Prepare the Repair Area
A. Use a plastic scraper to remove as much of the damaged or loose

sealant as you can.
B. Use the OMat 5/70 ALUMINIUM OXIDE ABRASIVE CLOTH to fully remove
the remaining sealant. Use a suction cleaner to remove abrasive
particles.
C. Put a strip of OMat 2/30 TEFLON TAPE each side of the repair area.
WARNING: SOLVENT IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH CAN

MUST BE USED ONLY IN ACCORDANCE WITH THE MANUFACTURERIS
SPECIFIC SAFETY AND HEALTH RECOMMENDATIONS. BEFORE YOU USE
D. Clean the repair area with OMat 2/101 LINT-FREE CLOTH soaked in
OMat 135 SOLVENT. Then wipe the repair area with a clean piece
of OMat 2/101 LINT-FREE cloth before the solvent dries.
5. Apply the Sealant to the External Surfaces (Ref.Figure 201)
WARNING: SEALANT IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH CAN

MUST BE USED ONLY IN ACCORDANCE WITH THE MANUFACTURERIS
A. Mix the 8/136 POLYSULPHIDE COMPOUND in accordance with the

manufacturerls instructions.
B. Use a spatula or a syringe to apply the OMat 8/136 POLYSULPHIDE

COMPOUND to the repair area. Make sure the sealant is flush with
or not more than 0.01 in.(0,25 mm) below the surface.
REPAIR NO.7
54-40-01
Page 202
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
C. Let the sealant stay at ambient temperature for a minimum of two

hours, until it is tack-free. Remove the OMat 2/30 TEFLON TAPE.
D. Use the heat lamps to cure the sealant for a minimum of two hours
at a temperature of 110 deg.F (43 deg.C).
NOTE: Steps C and D will cure the OMat 8/136 POLYSULPHIDE COMPOUND
sufficiently for the aircraft to be dispatched. The sealant
will be fully cured after 72 hours.
6. Apply the Primer to the Internal Surfaces (Ref Figure 201)
A. Mix the OMat 876C PRIMER in accordance with the manufacturerts

instructions.
B. Apply the primer to the repair area with an OMat 212 BRUSH.
C. Let the primer dry at ambient temperature. It will dry in

approximately two hours at 72 deg.F (22 deg.C).
7. Apply the Sealant to the Internal Surfaces (Ref Figure 201)
WARNING: SEALANT IS CLASSIFIED AS A HAZARDOUS MATERIAL WHICH CAN

A. Mix the OMat 8/143 (or OMat 8/138A) SEALANT in accordance with
the manufacturerts instructions.
B. Use a spatula or a syringe to apply the sealant to the repair

area. Make sure the sealant is flush with or not more than 0.01 in.
(0,25 mm.) below the surface.
C. Let the sealant stay at ambient temperature for a minimum of two

hours, until it is tack-free. Remove the OMat 2/30 TEFLON TAPE.
D. Use the heat lamps to cure the sealant for a minimum of two hours
at a temperature of 110 deg.F (43 deg.C) .
NOTE: Steps C and D will cure the OMat 8/143 (or OMat 8/138A) SEALANT
sufficiently for the aircraft to be dispatched. The sealant will
be fully cured after 7 days.
REPAIR N0.7
54-40-01
Page 203
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
Examine the Repair
A. Do a visual inspection to make sure the repair has been done in

A. Use a permanent marker pen of a contrasting color to write

"FRSY017" adjacent to the CNA part number.
REPAIR N0.7
54-40-01
Page 204
RB.211 TRENT
STRUCTURAL REPAIR
MANUAL
MTERNAL
SURFACE
INTERNAL
SURFACE
Aerosealant Locations
Page 205
Dec. 15/96
H RB211 TRENT
MANUAL
STRUCTURAL REPAIR
REPAIR NO. 8
REPLACE DAMAGED SEALS (FRSY006)
1. General
A. This procedure gives instructions to repair or replace the

seals in the Common Nozzle Assembly (CNA). The procedure has
two parts :
- part 1, Repair Items 1 thru 5 (replace seal segment)

- Part 2, Repair Items 1 thru 13 (replace full seal)
B. Refer to Figure 201 and Step 3.C for the identification of the
repair parts necessary at a given location.
C. All these repairs can be done while the CNA is installed on the
engine, if sufficient access is available.
D. Refer to Figure 201 for fire zone location. Missing pieces of

seal in this zone are not permitted because of fire containment
certification. Rips and tears are not permitted in this zone.
All other limits are for areas outside the fire zone. A
decrease in performance can occur if a seal is damaged.
R E. Repair part kits are available for replacement of the fire zone
R seals :-
- Left hand Kit 276K9003-1 Repair Parts - Item 2, 3, 4, 5,

12, 13, 14, 15 and 16.
- Right hand Kit 276K9003-2 Repair Parts - Item 2, 3, 4, 5,
11, 13, 14, 15 and 16.
Items 6 and 7 are not included as part of the kits because

compared to the other kit items, they are a high cost/low
volume requirement.
2. Reference Information
R AMM TASK 70-20-01-100-802 , Cleaning
REPAIR N0.8
54-40-01
Page 201
Equivalent materials and equipment may be used
(1) Standard workshop tools

(2) Palette knife
(3) Permanent marker pen
(4) Scalpel
(5) Sharp knife
(6) Explosion proof heat lamps
...............................................................
...............................................................
OMat 150 Acetone
OMat 2/101 Cloth, lint free
OMat 872F Cold curing silicone rubber
N0TE:To identify the consumable materials refer to the Overhaul

Materials Manual (OMat) .
A. Repair Parts
ITEM PART NUMBER DESCRIPTION IPC REF QTY

.-----------------------------------------------------------------------------------------------
l FK16587 Seal (276-1005-1) 02-890 2
2 FK16588 Seal (276-1005-5) 02-920 2
3 FK16589 Seal (276-1005-3) 02-900 2
4 FK16590 Seal (276-1005-7) 02 -922 2
5 FK16591 Seal (276-1005-9) 02-926 2
6 FK16635 Upper corner seal assembly 02-936 1
7 FK16636 Upper corner seal assembly 02-928 1
8 FK16594 Seal (276-1026-501) 02-942 1
9 FK16595 Seal (276-1026-502) 02-930 1
Lower seal assembly 02-896 1
(276-1021-501)
Lower corner seal assembly 02-912 1
(276-1023-502)
Lower corner seal assembly 02-904 1
(276-1023-501)
REPAIR N0.8
54-40-01
Page 202
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
Seal (276-1023-5) 02 -924 2

Seal splice (276-1005-11) 02-945 8
Seal splice (276-1005-15) 02-955 8
Seal splice (276-1005-19) 02-965 6
4. Part 1: Repair Seal Items 1 thru 5 (Ref Figures 201 thru 206)

CLOTHING, GLOVES, DUST MASK AND SAFETY GOGGLES TO PROTECT
YOU AGAINST DUST AND LOOSE PARTICLES WHICH CAN BE
WARNING: WHEN YOU USE CLEANING MATERIALS, COATINGS AND SEALANTS,

REFER TO, AND OBEY, THE MANUFACTURER'S CONTROL AND
APPLICATION INSTRUCTIONS AND HEALTH AND SAFETY NOTICES.
A. The maximum permitted damage that can be repaired with this

procedure is half of the seal length. Damage greater than this
can be repaired in accordance with Part 2 of this Repair
Scheme.
B. Refer to AMM TASK 70-20-01-100-802 - Cleaning. Clean the repair

area with OMat 2/101 Lint free cloth soaked with OMat 150
Acetone. Dry the surface with a new piece of cloth before the
solvent evaporates.
C. Put marks on the damaged seal to show the repair area.
D. Cut out and discard the damaged seal segment using a scalpel or
sharp knife. Make sure you remove all the damage.
E. If damage is adjacent to an existing original seal joint, cut

around the joint line, remove the damaged seal and the seal
splice from the end of the adjacent seal.
F. Remove sealant from the seal carrier using a palette knife.
G. Refer to AMM TASK 70-20-01-100-802 - Cleaning. Clean the repair

solvent evaporates.
H. Find the correct repair seal from the Repair Parts section 3.C
(above). Cut the applicable repair seal segment to the
necessary length using a scalpel or sharp knife.
REPAIR N0.8
54-40-01
Page 203
a RB211 TRENT
MANUAL
STRUCTURAL REPAIR
I. Find the correct repair seal splice from the Repair Parts
section 3.C (above). Cut new l-inch (25,4 mm) lengths of the
applicable seal splice using a scalpel or sharp knife.
J. Apply OMat 872F cold curing silicone rubber to the bottom

surface and ends of the repair seal, and to the new seal
splices.
K. Put the repair seal segment in position and push it fully into
the seal carrier with your hand. Leave the ends of the repair
seal segment free from the seal carrier to allow fitting of the
seal splices. Refer to Figure 206 to determine the proper
position of the seal vents.
L. Put the new seal splices into the ends of the repair seal
segment. Make sure the splices are in the middle of the joint.
They must be bonded to the adjacent seals and to the new seal
segment. Pinch the repair seal segment behind the seal splice
with your fingers to make sure the seal splice stays in
position. Install the free ends of the repair seal segment in
to the seal carrier and the seal splices into the adjacent
(serviceable) seals.
M. Fill all spaces in and around the joints with OMat 872F Cold
curing silicone rubber.
N. Let the sealant cure for 8 hours at 15OC (5g°F) minimum before
you touch the repair area. Use explosion proof heat lamps as
required.
NOTE: You can operate the aircraft before the end of the cure
time given above. The silicone rubber is structurally
satisfactory.
5.Part 2: Repair Seal Items 1 thru 13 (Ref. Figures 201 thru 206)
R WARNING: WHEN YOU DO THIS REPAIR YOU MUST WEAR PROTECTIVE CLOTHING,
R GLOVES, DUST MASK AND SAFETY GOGGLES TO PROTECT YOU AGAINST
R DUST AND LOOSE PARTICLES WHICH CAN BE DANGEROUS TO YOUR
R HEALTH.
R WARNING: WHEN YOU USE CLEANING MATERIALS, COATINGS AND SEALANTS,

R REFER TO, AND OBEY, THE MANUFACTURER'S CONTROL AND
R APPLICATION INSTRUCTIONS AND HEALTH AND SAFETY NOTICES.
R
NOTE : Items 1 to 13 are too short to permit a joint. Repair is by
replacement.
REPAIR N0.8
54-40-01
Page 204
U
d STRUCTURAL REPAIR
MANUAL
A. Cut around the joint lines and remove the damaged seal.
B. Remove the seal splices from the ends of the adjacent seals.
C. Remove sealant from the seal carrier using a palette knife.
D. Refer to A M M TASK 70-20-01-100-802 - Cleaning. Clean the repair

solvent evaporates.
E. Find the correct repair seal splice from the Repair Parts
section 3.C (above). Cut new 1 inch (25,4 mm) lengths of the
applicable seal splice using a scalpel or sharp knife.
F. Find the correct repair seal from the Repair Parts section 3.C
(above) .
G. Apply OMat 872F cold curing silicone rubber to the bottom
surface and ends of the repair seal, and to the new seal
splices.
H. Put the repair seal in position and push it fully into the seal
carrier with your hand. Leave the ends of the repair seal
segment free from the seal carrier to allow fitting of the seal
splices. Refer to Figure 206 to determine the proper position
of the seal vents.
I. Put the new splices into the ends of the repair seal. Make sure
the seal splices are in the middle of the joint. They must be
bonded to the adjacent seals and the new seal.Pinch the repair
seal segment behind the seal splice with your fingers to make
sure the seal splice stays in position. Install the free ends
of the repair seal segment in to the seal carrier and the seal
splices into the adjacent (serviceable) seals.
J. Fill all the spaces in and around the joints with OMat 872F
Cold Curing Silicone Compound.
K. Let the sealant cure for 8 hours at 15OC (5g°F) minimum before
you touch the repair area. Use explosion proof heat lamps as
required.
NOTE: You can operate the aircraft before the end of the cure
time given above. The silicone rubber is structurally
satisfactory.
6 . Inspect ion
REPAIR N0.8
54-40-01
Page 205
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
A. Make sure the repair seal is correctly installed in accordance

with this procedure.
R A. Vibro-etch the repair scheme number "FRSY006" onto the

R modification record plate.
REPAIR N0.8
54-40-01
Page 206
P r i n t e d in Great B r i t a i n May 15/05
P R5211 TRENT
MANUAL
STRUCTURAL REPAIR
Seal Locations
Figure 201
REPAIR N0.8
54-40-01
Page 207
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
Seal Joint Locations

Figure 202
REPAIR N0.8
54-40-01
Page 208
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
ITEM 14
ITEM 16
Seal Joint Locations

Figure 203
REPAIR N0.8
54-40-01
Page 209
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
BOND AND
WITH SEAIANT
SECTION SECTION
A-A B-B
JOINT LOCATIONS SHOWN

IN FIGURES 201,202,203
Seal Sleeve Installation

Figure 204
REPAIR N 0 . 8
54-40-01
Page 210
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
CUT ALONG ALL EXISTING

SPUCE UNES TO REMOVE
DAMAGE !XAL
RIP OR TEAR
REMOVE DAMAGE SEAL

AND SPLICE SEALS
REPLACE Wm4 NEW SPUCE SEALS

AND NEW SEAL . .
NOTE: SEE DETAIL A, B, AND C FOR PROPER SEAL AND SPLICE SEAL IDENTIFICATION.
Seal Replacement
Figure 205
REPAIR N0.8
54-40-01
Page 211
- VENTS IN NON FIRE ZONE
VENTS IN FIRE ZONE

SEAL FACE AFT
SECTION
D- D
Seal Vent Locations

Figure 206
REPAIR N0.8
Page 212
B
""" RB211 TRENT
MANUAL
STRUCTUAL REPAIR
REPAIR N0.9
REPLACE DAMAGED FAIRINGS
1. General
A. This repair gives the procedure to replace the Upper or Lower

Fairings on the Common Nozzle Assembly (CNA) .
B. You must open the Thrust Reverser to get access for this repair.
.......................................................................
.......................................................................
54-40-01, Repair N O . ~ Aerosealant Replacement
78-11-14-300-XXX FRSY027 Trent Engine Manual
3. Eauipment and Materials
Drill and drilling equipment

Riveting tools
10X Magnifier
.......................................................................
-----_----------------------------------*-"----------------------------
OMat 1/270 SOLVENT

OMat 2/101 CLOTH, LINT - FREE
OMat 872B COLD CURING SILICONE RUBBER
OMat 876C PRIMER
OMat 8/138 SEALANT
OMat 8/143 SEALANT
.......................................................................
PART IDENT MATERIAL
.......................................................................
Upper & Lower Fairings Aluminium Alloy 2219-T62
REPAIR N0.9
54-40-01
Page 201
RB211 TRENT
STRUCTUAL REPAIR
D. Repair Parts (Ref Figures 201,202)

.......................................................................
ITEM PART NO. PART IDENTIFICATION
.......................................................................
l CR3553-5-2 Rivet , blind
1A CR3523-6-2 Alternative rivet
2 CR3553-5-3 Rivet , blind
2A CR3523-6-3 Alternative rivet
3 MS20615-5M Rivet, solid
4 FK16637 Lower Fairing, LH
5 FK16638 Lower Fairing, RH
6 NAS17 3 8M5 - 2 Rivet
7 FK16629 Upper Fairing, LH
8 FK16630 Upper Fairing, RH
4. Procedure (Re£ Figures 201,202)
A. Remove the Lower Fairing
(1) Move the seal to get access to the rivet (3). You can use a
non-metallic tool to move part of the seal away from the CNA.
(2) Drill out the rivet ( 3 ) . Take care not to enlarge the hole.
(3) Drill out the rivets (6) that attach the fairing to the
structure. Take care not to enlarge the rivet holes.
(4) Remove the lower fairing (4) or (5) from the CNA. Keep the
fairing to use as a hole gauge.
WARNING: THESE PRODUCTS ARE CLASSIFIED AS HAZARDOUS

MATERIALS THAT CAN CAUSE INJURY OR ILLNESS IF NOT
USED CORRECTLY. BEFORE YOU USE THESE PRODUCTSIREAD
(5) Put OMat 8/138 SEALANT in those rivet holes that go into
honeycomb panels.
OMat 2/101 LINT-FREE CLOTH soaked with OMat 1/270 SOLVENT.
Dry the surface with a new piece of the cloth before the
solvent evaporates.
(7) Use 10X magnification to examine the structure that was under
the fairing. No cracks are permitted.
REPAIR NO. 9
54-40-01
Page 202
M
m RB211 TRENT
MANUAL
STRUCTUAL REPAlR
B. Install the Lower Fairing
(1) If necessary, use the removed fairing as a gauge to put

pilot holes in the new fairing.
(2) Put the new fairing (4) or (5) in position on the CNA
structure. Align as many holes as possible. Temporarily
attach the fairing with gripper pins.
(3) Drill the rivet holes 4,5 to 4,6 mm (0.177 to 0.180 in)
diameter. If the rivet holes do not align, you can drill
them 4,9 to 5,O mm (0.192 to 0.197 in) diameter.
(4) Remeve the fairing from the CNA.
(5) Mix OMat 876C PRIMER in accordance with the manufacturer's

instructions. Apply the primer to the mating surfaces.
(6) Put the fairing in position on the CNA. Wet install the
rivets (1) and (2) (or oversize alternatives if necessary)
with OMat 8/138 SEALANT.
(7) Wet install the rivet ( 3 ) , double flush, manufactured head

on the fairing side, with OMat 8/138 SEALANT.
WARNING: THIS PRODUCT IS CLASSIFIED AS A HAZARDOUS

USED CORRECTLY. BEFORE YOU USE THIS PRODUCT, READ
THE APPLICABLE MATERIAL SAFETY DATA SHEET AND
OBEY ALL THE HEALTH AND SAFETY PRECAUTIONS.
(8) Apply OMat 872F COLD CURING SILICONE RUBBER to the mating
faces of the joint. Put the seal back in position.
(9) Let the silicone rubber cure for 8 hours at 15 deg C

(59 deg F) minimum before you touch the repair area.
NOTE: You can operate the aircraft before the end of the
cure time given above. The silicone rubber is
structurally satisfactory.
C. Remove the Upper Fairing
(1) Drill out the rivets (6) that attach the fairing to the
structure. Take care not to enlarge the rivet holes.
(2) Remove the upper fairing (7) or ( 8 ) from the CNA. Keep the
fairing to use as a hole gauge.
Page 203
May 1/00
H RB211 TRENT
MANUAL
STRUCTUAL REPAIR
WARNING: THESE PRODUCTS ARE CLASSIFIED AS HAZARDOUS

MATERIALS THAT CANCAUSE INJURY OR ILLNESS IF NOT
USED CORRECTLY. BEFORE YOU USE THESE PRODUCTS,
READ THE APPLICABLE MATERIAL SAFETY DATA SHEET
AND OBEY ALL THE HEALTH AND SAFETY PRECAUTIONS.
(3) Put OMat 8/138 SEALANT in those holes that go into the
honeycomb panels.
OMat 2/101 LINT-FREE CLOTH soaked with OMat 1/270 SOLVENT.
Dry the surface with a new piece of cloth before the
solvent evaporates.
(5) Use 10X magnification to examine the structure that was

under the fairing. No cracks are permitted.
D. Install the Upper Fairing
(1) If necessary, use the removed fairing as a gage to put

pilot holes in the new fairing.
(2) Put the new fairing (7) or (8) in position on the CNA.
Align as many holes as possible. Teamporarily attach the
fairing with gripper pins.
(3) Drill rivet holes 4,s to 4,6 nun (0.177 to 0.180 in)
diameter. If the rivet holes do not align, you can drill
them 4,9 to 5,O nun (0.192 to 0.197) diameter.
(4) Remove the fairing from the CNA.
(5) Mix OMat 876C PRIMER in accordance with the manufacturer's

instructions. Apply the primer to the mating surfaces.
(6) Put the new fairing (7) or ( 8 ) in position on the CNA. Wet
install the rivets (6) (or oversize alternatives if
necessary) with OMat 8/13 8 SEALANT.
(7) Mix and apply OMat8/143 SEALANT to the mating faces of the
joint (Re£ 54-40-01,Repair N0.7, Aerosealant Replacement) .
5. Insvec t ion
A. Make sure the fairing has been installed in accordance with

these procedures.
REPAIR N0.9
54-40-01
Page 204
p RB211 TRENT
STRUCTUAL REPAIR
MANUAL
Replace Upper and Lower Pairings

Figure 201
REPAIR N0.9
54-40-01
Page 205
R6211 TRENT
STRUCTUAL REPAIR
MANUAL
ITEM 3
(1 PLACE)
o o O o o o O
q o O O O o o O O O O O O O
ITEM 2 OR
El ITEM 2A
(FOR OVERSIZE ALTERNATE)
(3 PLACES)
FIGURE 202
ITEM 6 OR
ITEM 1 OR
ITEM 1A
(36 PLACES)
ITEM 6 OR
ITEM 1 OR
ITEM 1A
(20 PLACES)
FIGURE 203
Replace Upper and Lower Fairings

Figure 202
REPAIR N0.9
54-40-01
Printed i n G r e a t B r i t a i n
Page 206
May 1/00
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
REPAIR NO.10
REPAIR OF WORN SEAL LANDS
1. General
A. This procedure gives instructions for the repair of s ~ a llands,

worn by contact with the thrust reverser rubbing blodks.
B. The maximum permitted depth of damage is 0,50 mm (0.020 in).
.......................................................................

SRM 54-02-04 Repair Paint Finish
REFEpENCE DESIGNATION
.......................................................................
OMat 135 METHYLETHYLKETONE (MEK) - .
OMat 2/101 LINT-FREE CLOTH _ '.,.,_ $3 '
<*,A'>
,LI ,: -
OMat 5/62 ABRASIVE PAPER,180 grit
OMat 8/93 EPOXY PUTTY
OMat 262A MARKER
B. Component Material
.......................................................................
.......................................................................
CNA Seal Land Aluminium Alloy 2219-T62
A. Examine the damage
; .
' . (l) Use OMat 5/62 ABRASIVE PAPER to remove the surface finish
:? :,c-
in the worn areas. Be careful not to abrade the aluminium.
--.. .. __I*-
(2) Examine the worn areas. If the depth is.?:ore: thap .. . 0 ,.50mm
(0.020 in) , refer to Rolls-Royce plc. . -, ,:-.4 : .: ;
...
54-40-01
Page 201
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
B. Prepare the repair area
(1) Lightly abrade the damage with OMat 5/62 ABRASIVE PAPER to
make the area smooth. Be careful not to increase the depth
of damage.

(2) Clean the repair area with OMat 2/101 LINT-FREE CLOTH soaked
(3) Apply protective treatment to the exposed aluminium

(Ref SRM 54-02-03).
C. Repair the damage
(1) Mix the necessary quantity of OMat 8/93 EPOXY PUTTY (refer
to the manufacturer's instructions).
(2) Apply sufficient putty to the repair area to make a flush

or slightly convex contour (not underflush) .
(3) Cure the putty (refer to the manufacturer's instructions).
(4) Use OMat 5/62 ABRASIVE PAPER to make the putty smooth and
flush with the contour of the seal carrier. Be careful not
to abrade adjacent surfaces.
(5) Repair the paint finish (Ref SRM 54-02-04).
5. Inspection
B. Use the OMat 262A MARKER to write FRSYO2l adjacent to the part
number of the CNA.
REPAIR NO. 10
54-40-01
Page 202
RB211 TRENT
STRUCTUAL REPAIR
Repair Worn S e a l Lands

Figure 2 0 1 , S h e e t 1
EFFECTIVITY :TRENT REPAIR NO. 10

54-40-01
Page 203
Printed in Great B r i t a i n July 1 / 0 0
-p RB211 TRENT
MANUAL
STRUCTUAL REPAIR
SEAL
CARRIER
TYPICAL WEAR
SECTION THROUGH DEFECTIVE AREA
DEPTH OF WEAR
Repair Worn Seal Lands

Figure 201, Sheet 2

54-40-01
Page 204
P r i n t e d in G r e a t Britain July 1/00
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
REPAIR NO.11
REPLACE DEFECTIVE AND/OR MISSING RIVETS
1. General
A. This repair identifies and gives instructions to replace rivets

in different areas of the CNA.
.......................................................................
.......................................................................
AMM 70-20-03-300-803 Application of Two-Pack Epoxy Finish
EM 78-11-41-300-XXX FRSY023, Trent Engine Manual
3. E~lUi~Inent
and Materials
Drills and equipment
Blind and driven riveting tools
.......................................................................
.......................................................................
OMat 8/52 ADHESIVE
OMat 2621 MARKER
C. Repair Parts
.......................................................................
FIG/ITEM PART NO. DESCRIPTION
* / l NAS13 98M6-3 Rivet, blind protrusion

* / 1A CR3523-6-3 Alternative rivet
* / 2 NAS1398C6-3 Rivet, blind protrusion
* / 2A CR2663-6-3 Alternative rivet
The above items are shown on Figures 202,203 and 205
2021 3 NAS1398C6-4 Rivet, blind protrusion

2021 3A CR2663-6-4 Alternative rivet
202/ 4 NAS1398M6-4 Rivet, blind protrusion
202/ 4A CR3523-6-4 Alternative rivet
REPAIR NO.11
54-40-01
Page 201
p RB211 TRENT
MANUAL
STRUCTUAL REPAIR
.......................................................................
FIG/ITEM PART NO. DESCRIPTION
.......................................................................
202/ 5 NAS1398M6 -6 Rivet, blind protrusion
202/ 6 NAS1398M6-5 Rivet, blind protrusion
203/ 7 MS20615M-6 Rivet, driven
204/ 8 CR2545-6-2 Rivet, blind
205/ 9 NAS114 9C0332R Washer
206/10 CR3555-4-3 Rivet, blind, unisink
207/11 NAS1097KE-4 Rivet, clsink, shear hd, driven
NOTE: The above list gives the identity of replacement rivets for the
different areas of the CNA.
.......................................................................
Fairings, trailing edge, Aluminium Alloy 2219-T62

struts and pans
Trough Titanium 6A1-4V
Bond Panel Graphite Epoxy

A. Clean the applicable repair area with OMat 2/101 LINT-FREE

CLOTH soaked with OMat 135 MEK. Dry the surface with a new
5. Replace Rivets in Pen Nib Fairinq (Ref Figure 201, Figure 202)
A. Use a No. 16 drill 4,47 to 4,57 mm (0.176 to 0.180 in) diameter.

Drill out the rivet heads, then push the pins into the holes
(Ref SRM 54-02-10).
B. Use a No. l0 drill 4,87 to 4,97 mm (0.l92 to 0 .l96 in) diameter

to make the rivet holes larger.
C. Wet-install rivets Item 1,Item 2,Item 3,Item 4,Item 5 or Item 6

as applicable with OMat 4/47 JOINTING COMPOUND.
REPAIR NO. 11
54-40-01
Page 202
6. Replace Rivets in Bifurcation Fairinus (Re£ Figure 201, Figure 203)
A. Use a No. 20 drill 4,06 to 4,16 mm (0.160 to 0.164 in) diameter.

(Re£ SRM 54-02-10).
B. Use a No.10 drill 4,87 to 4,97 m (0.192 to 0.196 in) diameter

to make the rivet holes larger. For rivet Item 7 (driven rivet
in seal land), countersink both sides 100 degrees.
C. Wet-install rivets Item 1,Item 2 or Item 7 as applicable with

OMat 4/47 JOINTING COMPOUND.
7. ReDlace Rivets in Wear Strip S u ~ ~ o r(Re£

t Figure 201, Figure 204)
A. Use a No.30 drill 3,27 to 3,35 mm (0.129 to 0.132 in) diameter.

(Ref 54-02-10).
B. Fill the rivet holes with OMat 8/52 ADHESIVE. Use a syringe and
refer to the manufacturer's instructions.
C. Use a No.10 drill 4,87 to 4,97 mm (0.192 to 0.196 in) diameter.

Drill new rivet holes 12,7 mm (0.50 in) forward or aft of the
holes you filled in step 7.B above.
D. Wet-install rivet Item 8 with OMat 4/47 JOINTING COMPOUND.
8. Replace Rivets at End of Seal S u p ~ o r t (Re£ Figure 201, Figure 205)

(Ref SRM 54-02-10).
B. Use a No.10 drill 4,87 to 4,97 mm (0.192 to 0.196 in) diameter

C. Wet-install rivet Item 1, together with washer Item 9 under the

head, with OMat 4/47 JOINTING COMPOUND.
9. Replace Rivets in Aft Aluminium Section (Ref Figure 201,Figure 206)

(Re£ SRM 54-02-10).
B. Use a No.27 drill 3,63 to 3,70 mm (0.143 to 0.146 in) diameter

REPAIR NO.ll
54-40-01
Page 203
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
C. Wet-install rivet Item 10 with OMat 4/47 JOINTING COMPOUND.
10. Replace Rivets in Trailinq Edqe (Ref Figure 201, Figure 207)

(Ref SRM 54-02-10).
NOTE: Do not make these rivet holes larger.
B. Countersink both sides of rivet Item 11. Wet-install with

OMat 4/47 JOINTING COMPOUND.
11. Paint the Rivet Heads
A. Apply two-pack Epoxy Finish to the replacement rivet heads

(Ref AMM 70-20-03-300-803).
12. Inspection
B. Use the OMat 262A MARKER to write FRSY023 adjacent to the part
number of the CNA.
REPAIR NO.11
54-40-01
Page 204
RB211 TRENT
SfRUCTUAL REPAIR
MANUAL
CNA Rivet Repair Areas

Figure 201
REPAIR NO.11
54-40-01
Page 205
July 1/00
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
Rivets in Pen Nib Fairing

Figure 202
REPAIR NO.11
54-40-01
Page 2 0 6
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
ITEM 1
LOWER
FAlRlNG
ITEM 1
Rivets in Bifurcation Fairings

Figure 2 0 3
REPAIR NO.11
54-40-01
Page 207
Printed in Great B r i t a i n July 1 / 0 0
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
ITEM 8
0.5 in. (12,7mm)

ITEM 8
Rivets i n Wear Strip Support

Figure 204
REPAIR NO.11
54-40-01
Page 2 0 8
July 1 / 0 0
RB211 TRENT
STRUCTUAL REPAIR
ITEM 1
ITEM 9
Rivets in Seal Support

Figure 205
REPAIR NO.11
54-40-01
Page 2 0 9
July 1/00
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
ITEM 10
CTypical)
Rivets in Aft Aluminium Section

Figure 206
54-40-01
Page 210
RB211 TRENT
STRUCTUAL REPAIR
SECTION
F-F
ITEM l1
Rivets in Trailing Edge

Figure 2 0 7
REPAIR NO. l1
54-40-01
Page 211
July 1/00
R8211 TRENT
STRUCTUAL REPAIR
MANUAL
REPAIR NO. 12
REPLACE THE HOIST-POINT THREAD INSERTS
1. General
A. This repair gives instructions to replace unserviceable thread

inserts. A special installation tool is necessary.
.......................................................................
.......................................................................
EM TASK 78-11-14-300-XXX FRS Y026, Trent Engine Manual
EZ-out tool
KT9000-4 installation tool
.......................................................................

OMat 766C EPOXY PRIMER
C. Repair Parts
.......................................................................
ITEM PART NO. PART IDENT
.......................................................................
- MS51830CA202 THREAD INSERT
4. Procedure (Ref Fig.201)
A. Remove the damaged insert
CAUTION: BE CAREFUL NOT TO DRILL INTO THE PANEL. USE A DRILL

STOP IF NECESSARY.
(1) With a 'K' drill 7 ,l4 mm (0.28 in) diameter, drill the
insert to a depth of 9,52 mm (0.375 in) .
54-40-01
Page 201
P r i n t e d i n Great Britain Apr. 01/01
R8211 TRENT
STRUCTUAL REPAIR
MANUAL
(2) Use a scriber or similar tool to push the keys inwards

until they break off.
(3) Use the EZ-out tool to remove the insert.

SPECIFIED HEAXlTH AND SAFETY PRECAUTIONS.
C. Install the new insert
(1) Mix the OMat 766C EPOXY PRIMER in accordance with the
(2) Apply a thin layer of the primer to the external threads

of the insert.
(3) Put the insert onto the threaded mandrel of the KT9000-4
installation tool.
CAUTION: MAKE SURE THE INSERT IS INSTALLED TO THE DEPTH

SPECIFIED, WITH THE KEYS IN THE CORRECT POSITION.
(4) Use the tool to install the insert to a depth of 0,25 to

0,75 mm (0.01 to 0.03 in) below the surface. Set the keys
half-way between the marks made by the previous keys.
(5) Remove the installation too1,then use the opposite (spring-

loaded) end to drive the keys into the parent material.
WARNING: METHYLETHYLKETONE (MEK) IS CLASSIFIED AS A

HAZARDOUS MATERIAL THAT CAN CAUSE INJURY OR
ILLNESS IF NOT USED CORRECTLY.BEFORE YOU USE
THIS MATERIAL,CAREE'ULLY READ THE APPLICABLE
MATERIAL SAFETY DATA SHEET AND OBEY ALL THE
Page 202
R8211 TRENT
STRUCTUAL REPAIR
m MANUAL
5. Inspection
A. Make sure the the new i n s e r t i s i n s t a l l e d t o a depth of 0,25 t o

.
0 , 7 5 mm ( 0 . 0 1 t o 0 . 0 3 i n ) Make sure the keys are set h a l f -way
between the marks made by the previous keys.
B. Vibro-etch "FRS Y026" adjacent t o the CNA part number.
54-40-01
Page 2 0 3
p RB211 TRENT
MANUAL
STRUCTUAL REPAIR
THE HOIST POINT
THE HOIST POINT
THE HOIST POINT
THE REMOVAL
/-
THE STANDARD DRILL THE E-Z OUT
TYPE TOOL 7
2. DEFLECT THE KEYS 3. UNSCREW THE INSERT

1. DRILL THE INSERT
INWARD AND BREAK
OFF
THE HAMMER
THE INSTALLATION
1. INSTALL THE INSERT ON

THE INSTALLATION TOOL
THE INSTALLATION
THE INSTALLATION
3. REVERSE THE
2. THE SCREW INSTALLATION TOOL
AND TAP DOWN
R e p l a c e the T h r e a d Inserts
Figure 201
P a g e 2 04
P r i n t e d in Great B r i t a i n Apr. 01/01
RB211 TRENT
STRUCTUAL REPAIR
REPAIR N0.13
OUTER SKIN - SURFACE PAINT REPAIR
1. General
A. This repair gives the procedure to repair the surface paint on

the CNA outer skin.
B. The procedure includes:
(1) The application of filler to minor surface damage, and
(2) The application of primer and finish to the outer skin.
EM TASK 78-11-14-300-XXX FRS Y015, Trent Engine Manual
- Suction Cleaner
- Weighing Scales
- Soft Brush
- Palette ~nife/Trowel
- Heat Lamps
- Spray Equipment
.......................................................................
.......................................................................
OMat 1/176 ACETONE
Omat 2/101 LINT-FREE CLOTH
OMat 270 SOLVENT
OMat 583 SCOTCH BRITE
OMat 5/31 thru WATERPROOF SILICON CARBIDE,
OMat 5/36 grit sizes 400 thru 220 (alternatives)
OMat 641 SURFACE INSPECTION FLUID
cont' d
54-40-01
Page 201
P r i n t e d In G r e a t B r l t a i n July 1/01
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
.......................................................................
_____------------------------------------------------------------------
OMat 7/151 POLYUReTHANE PRIMER CATALYST, or
910 X 456 Rohr/Boeing alternative
OMat 7/152 or POLYURETHANE PRIMER BASE, or
513 X 329 Rohr/Boeing alternative
OMat 7/153 POLYURETHANE THINNERS
OMat 7/154 TYFLEX FINISH BASE, or
643-3 Rohr/Boeing alternative
OMat 7/155 TYFLEX FINISH CATALYST, or
310A Rohr/Boeing alternative
OMat 7/156 TYFLEX FINISH THINNERS, or
TL5 9 Rohr/Boeing alternative
OMat 874 FILLER, TWO-PACK
OMat 1222 W C SHEETING
.......................................................................
PART IDENT MATERIAL
.......................................................................
CNA Outer Skin Carbon fibre composite
4. Procedure
A. Prepare the Damaged Area

YOU USE THIS MATERIAL, CAREFULLY READ THE APPLICABLE
soaked with OMat 1/270 SOLVENT. Dry the surface with a new
piece of the cloth before the solvent evaporates.
WARNING: YOU MUST USE PROTECTIVE CLOTHING, DUST MASK AND SAFETY
GOGGLES FOR PROTECTION. THE DUST AND LOOSE PARTICLES
ARE DANGEROUS. DO NOT BREATHE THE DUST.
(2) Use OMat 5/31,5/32 or 5/33 WATERPROOF SILICON CARBIDE as

applicable. Lightly abrade the repair area with circular
sanding movements. Do not sand into the composite fibres.
(3) Use OMat 583 SCOTCH BRITE to remove the gloss from the
indentations and depressions.
54-40-01
Page 202
H RB211 TRENT
MANUAL
STRUCTUAL REPAIR
(4) Remove all sanding debris and unwanted material with the
suction cleaner.

BEFORE YOU USE THIS MATERIAL, CAREFULLY READ THE
soaked with OMat 1/270 SOLVENT. Dry the surface with a
new piece of the cloth before the solvent evaporates.
(6) Use the soft brush to apply a thin layer of OMat 641
SURFACE INSPECTION FLUID to the repair area. Look for
breaks in the continuity of the film layer. If breaks
occur in less than 30 seconds,do Steps A. (1) thru A. (5)
again and, if necessary, again.
WARNING: ACETONE IS CLASSIFIED AS A HAZARDOUS MATERIAL THAT

(7) Use OMat 2/101 LINT-FREE CLOTH soaked with OMat 1/176
ACETONE to remove the surface inspection fluid. Let the
repair surface dry in the air.
(8) If the subsequent repair is not to be done immediately,

cover the prepared area with OMat 1222 PVC SHEETING.
Make sure the sheeting is clean and does not cause
contamination of the prepared area.
B. Apply the Filler
WARNING: FILLER IS CLASSIFIED AS A HAZARDOUS MATERIAL THAT

(1) Mix the OMat 874 TWO-PACK FILLER in the ratio of 100 parts
A (blue) to 94 parts B (white). Use the weighing scales
and obey the manufacturer's instructions. Make sure the
mixture is homogeneous and free from streaks.
(2) If applicable, remove the PVC sheeting from the prepared

repair area.
54-40-01
Page 203
Prlnted i n Great B r i t a i n July 1/01
RB211 TRENT
STRUCTUAL REPAlR
MANUAL
(3) Use a palette knife or trowel to apply the filler to the

repair surface. Make sure the surface indentations are
slightly overfilled.
(4) Let the filler cure to the "gel" stage.
(5) Use a clean warm palette knife or trowel, in a planing or

burnishing movement, to remove unwanted filler. Clean the
blade before you reheat it.
(6) Continue to cure the filler at:
(a) 22 deg C (72 deg F) for 24 hours, or
(b) 60 deg C (140 deg F) for one hour (use heat lamps).
(7) Use the OMat 5/34,5/35 or 5/36 WATERPROOF SILICON CARBIDE as

necessary to make the filler smooth with the surface contour
(8) Use the suction cleaner to remove all the sanding debris.

soaked with OMat 1/270 SOLVENT. Dry the surface with a
new piece of the cloth before the solvent evaporates.
(10) If the subsequent step is not to be done immediately,

cover the prepared area with OMat 1222 PVC SHEETING.
Make sure the sheeting is clean and does not cause
contamination of the prepared area.
C. Apply the Primer
WARNING: POLYURETHANE PRIMER IS CLASSIFIED AS A HAZARDOUS

CORRECTLY. BEFORE YOU USE THIS MATERIAL, CAREFULLY
OBEY ALL THE SPECIFIED HEALTH AND SAFETY PRECAUTIONS.
(1) Mix the OMat 7/151 POLYURETHANE PRIMER CATALYST and the
OMat 7/152 POLYURETHANE PRIMER BASE (or alternatives) in
accordance with the manufacturer's instructions. Adjust
the viscosity with OMat 7/153 POLYURETHANE THINNERS.
54-40-01
Page 204
Printed In Great Britain July 1/01
RB211 TRENT
STRUCTUAL REPAIR
NOTE: T h i n n e r s are n o t available f o r t h i s p r i m e r i n t h e

a l t e r n a t i v e ~ o h r / B o e i n gs y s t e m .
NOTE: T h e p r i m e r p o t l i f e i s e i g h t hours a t room

temperature.
(2) If aplicable, r e m o v e t h e PVC s h e e t i n g f r o m the prepared

repair area.
(3) U s e spray e q u i p m e n t t o apply t h e p r i m e r t o the repair

surface. L e t t h e p r i m e r d r y i n t h e a i r f o r a m i n i m u m of
f o u r hours before t h e f i n i s h coat i s applied.
D. A p p l y the E x t e r i o r P a i n t
WARNING: POLYURETHANE PAINT I S C L A S S I F I E D AS A HAZARDOUS

MATERIAL THAT CAN CAUSE INJURY OR I L L N E S S I F NOT USED
CORRECTLY. BEFORE YOU USE T H I S MATERIAL, CAREFULLY
OBEY ALL THE S P E C I F I E D HEALTH AND SAFETY PRECAUTIONS.
(1) M i x t h e O M a t 7 / 1 5 4 TYFLEX F I N I S H BASE and the O M a t 7 / 1 5 5

TYFLEX F I N I S H CATALYST ( o r a l t e r n a t i v e s ) i n accordance
w i t h the m a n u f a c t u r e r ' s i n s t r u c t i o n s . A d j u s t t h e v i s c o s i t y
w i t h O M a t 7 / 1 5 6 POLYURETHANE THINNERS ( o r a l t e r n a t i v e ) .
(2) U s e spray e q u i p m e n t t o apply t h e e x t e r i o r p a i n t t o t h e

repair surface. A p p l y one w e t - o n - w e t l a y e r , w i t h a m i n i m u m
of t e n m i n u t e s b e t w e e n l a y e r s .
(3) L e t t h e e x t e r i o r p a i n t dry i n t h e a i r f o r a m i n i m u m of s i x
hours a t r o o m temperature before you touch i t .
5. Inspection
A. M a k e sure there i s no l o o s e f i l l e r , and t h a t there i s f u l l

p a i n t coverage of t h e repair surface.
B. W r i t e "FRS Y015" adjacent t o t h e CNA p a r t number.
E F F E C T I V I T Y : TRENT REPAIR N 0 . 1 3
54-40-01
P a g e 205
Prlnted i n Great Britain July 1/01
COMMON NOZZLE ASSEMBLY – ALLOWABLE DAMAGE
1. Introduction
This section contains the allowable damage limits for the Common
Nozzle Assembly (CNA).
Damage which is found to be greater than the allowable damage

limits, should be repaired in accordance with the procedures
detailed in the Repair Section, Page Block 201. Damage not covered
should be described in detail, as to amount and location, and
forwarded to the manufacturer for evaluation.
2. Zones
The CNA is divided into zones (Refer to Figure 101). These zones
determine the extent of the allowable damage.
A. The allowable damage zones for this component are:

1A Exit Nozzle (refer to figure 101)
1B Exit Nozzle (refer to figure 101)
2 Pen Nib Fairing Assembly
3 Outer Barrel, Outer Skin
4 Outer Barrel, Inner Skin
5 Lower Strut Assembly
6 Inner Annulus
7 Primary Nozzle Inner Surface
8 Side Struts Upper and lower
9 Forward Seal Carrier
10 Trough, pylon
11 Thrust link
12 Seals
A. General
(1) Allowable damage data is intended to permit an operator

to determine whether a damaged nacelle component may
continue in service, or be repaired. Allowable damage
does not compromise the structural integrity of the
component.
EFFECTIVITY: TRENT
54-40-01
Page 101
Printed in Great Britain Aug.15/02
B. Allowable Damage - CNA
or time limited.
(a) Unlimited usage damage is defines as minor damage,

which does not affect the structural integrity or
functional capability of the component. No repairs
are necessary other than cosmetic, over the aircraft
design life.
(b) Time limited damage is defined as minor damage that

does not affect the structural integrity of the
component in normal service use, but could reduce
the design life of the component. In this case
damage must be repaired by next Aircraft C check.
The location and size of the damage should be noted
and checked at suitable intervals to monitor that
the damage has not grown beyond the time limited
damage allowance.
C. Types of Damage
(1) Damage types permitted on this component are listed below.

They only apply to the structural material of the
component, not the surface finishes, such as paint.
(a) Abrasion - an abrasion is an area of damage that

results in a cross sectional area change caused by
scuffing, rubbing, scraping or other surface
erosion. An abrasion usually appears rough and
irregular.
(b) Gouge - a gouge is a damage area of any size that

results in a cross sectional area change. It is
usually caused by contact with a sharp object that
produces a continuous, sharp or smooth channel-like
groove in the material. Gouge maximum depths are
defined as 0,508 mm (0,020 in.)
(c) Nick - a nick is a local gouge with sharp edges.

Nick maximum depths are defined as 0,508 mm (0.020
in.) Maximum width 0,254 mm (0.10 in.).
(d) Scratch - a scratch is a line of damage in the

material and results in a cross sectional area
change. Normally caused by a very sharp object.
Scratch depths are defined as a maximum of 0,13 mm
(0.005 in.)
EFFECTIVITY: TRENT
54-40-01
Page 102
(e) Crack - a crack is a partial fracture or complete
break in the material and produces a most
significant cross sectional area change. Normally
(f) Dent - a dent is a depressed area of damage, which

with metal skins would not cause cross sectional
area change. On core filled laminates it may cause
crushing of the core cells. Area boundaries are
smooth and it is usually caused by contact with a
smooth contoured object.
(g) Hole - a hole is a complete penetration of the

material.
(h) Disbond - disbond is the separation of the face skin

(i) Missing fastener - the whole, or any part of the

fastener, broken or missing.
1) Missing fasteners in the described zones are

covered for continuous fastener lines only.
Missing fasteners at corners especially of
multiple part attachments are not allowed.
(2) (E.D.) Edge Distance- The minimum distance allowed from

the edge of a, hole, crack, gouge, nick, dent, disbond or
other damage to an installed fastener, edge of a panel,
skin or discontinuity in the structure
D. Identify and Measure the Damage
(1) Do a tap test, refer to 54-01-06
(2) Make a circular mark around the maximum area of the

damage.
EFFECTIVITY: TRENT
54-40-01
Page 103
DAMAGE ZONE REQUIREMENTS ALLOWABLE INSPECTION
LIMITS INTERVALS
Scratch 1A & Exit Nozzle Outer Maximum length Aircraft
1B skin - 95,25 mm (3.75 ‘A’ check
in.)
Fig.
101
&
102
Gouge/ 1A Outer skin - no Maximum length Aircraft

Nick two within 25,4 mm 38,1 mm (1.50 ‘A’ check
1B (1.0 in.) of each in.)
other.
Hole 1A Outer skin- no two Maximum Aircraft

within 76 mm (3.0 diameter ‘A’ check
in.) of each 25,4mm (1.0 Repair by
other. 25,4 mm in.) next
(1.0 in.) min. aircraft
E.D. ‘C’ check
Hole 1B Outer skin - no Maximum Aircraft

two within 76 mm diameter ‘A’ check
(3.0 in.) of each 50,8 mm (2.0 Repair by
other, a minimum in.) Smooth next
of 25,4mm (1.0 edges and aircraft
in.) from speed tape. ‘C’ check
fasteners.
Dent 1A Outer skin - Maximum depth Aircraft

between frames and 2,54 mm (0.10 ‘A’ check
trailing edge. No in.) Repair by
two within 76,2 mm Maximum next
(3.0 in.) of each diameter 50,8 aircraft
other. Smooth and mm (2.0 in.) ‘C’ check
free of sharp
edges, gouges and
cracks
EFFECTIVITY: TRENT
54-40-01
Page 104
LIMITS INTERVALS
Dent 1B Outer skin - Maximum depth Aircraft
between frames and 3,05 mm (0.12 ‘A’ check
trailing edge. in.) Repair by
next
No two within 76,2 aircraft
mm (3.0 in.) of Maximum ‘C’ check
each other. Smooth diameter 76,2
and free of sharp mm (3.0 in.)
edges, gouges and
cracks
Crack 1A Outer skin - no Maximum length Aircraft

two within 76,2mm 25,4 mm (1.0 ‘A’ check
(3.30 in.) of each in.)
other. Stop drill
with No.30 drill.
Crack 1B Outer skin - no Maximum length Aircraft

two within 76 mm 63,5 mm (2.50 ‘A’ check
(3.0 in.) of each in.)
other. Stop drill
with No.30 drill
Missing 1A Outer/Inner skin - Item 1, None

attach attach fasteners allowed
Fasteners Fig. to outer barrel
102
Missing 1B Outer/Inner skin- Item 1, Aircraft

attach attach fasteners 1 missing in ‘A’ check
fasteners to outer barrel any 5
consecutive
Missing 1A Outer skin- Item 2, and 4

frame missing/loose None allowed
fasteners Fig. frame fasteners
102 and missing/loose
horseshoe fitting.
EFFECTIVITY: TRENT
54-40-01
Page 105
LIMITS INTERVALS
Missing 1A Inner skin- Item 5 and 6, Aircraft
frame missing/loose none allowed ‘A’ check
fasteners Fig. frame fasteners
102 and missing/loose
horseshoe fitting.
Missing 1B Outer skin- 1 in 5 no 2 Aircraft

frame missing/loose adjacent ‘A’ check
fasteners Fig. frame fasteners.
102
Missing 1A & Outer and inner None allowed

splice 1B skins- missing
fasteners fasteners at
Fig. fairing skin
102 splices Al to Ti
or Al to Al
Gouge/ 1A Inner skin - upper Aircraft

Nick titanium. No two Maximum length ‘A’ check
Fig. within 25,4 mm 25,4 mm (1.0
101 (1.0 in.) of each in.)
& other.
102
Gouge/ 1B Inner skin - Aircraft

Nick aluminum. No two Maximum length ‘A’ check
within 76 mm (3.0 38,10 mm (1.50
in.) of each in.)
other. 25,4 mm
(1.0 in.) min.
edge distance
EFFECTIVITY: TRENT
54-40-01
Page 106
LIMITS INTERVALS
Dent 1A Inner skin - upper Maximum depth Aircraft
titanium No two 2,54 mm (0.10 ‘A’ check
within 76,2 mm in.) Repair by
(3.0 in.) of each Maximum next
other. 25,4 mm diameter 50,8 aircraft
(1.0 in.) min. mm (2.00 in.) ‘C’ check
edge distance
Dent 1B Inner skin - Maximum depth Aircraft

aluminum. No two 3,05 mm (0.12 ‘A’ check
within 76,2 mm in.) Repair by
(3.0 in.) of each Maximum next
other. 25,4 mm diameter 76,2 aircraft
(1.0 in.) min. mm (3.00 in.) ‘C’ check
edge distance
Crack 1A Inner skin - Maximum length Aircraft

Titanium. No two 25,4 mm (1.0 ‘A’ check
within 76,2 mm in.)
(3.0 in.) of each
other. Stop drill
with No.30 drill
Crack 1B Inner skin - Maximum length Aircraft

aluminum. No two 63,5 mm (2.50 ‘A’ check
within 76,2 mm in.)
(3.0 in.) of each
other. Stop drill
with No.30 drill
Dent 1B Trailing Edge Maximum depth Aircraft

Extrusion - must 6,35 mm (0.25 ‘A’ check
Fig. be smooth and free in.) Repair by
102 of sharp edges, Maximum length next
gouges and cracks 127 mm (5.0 aircraft
in.) Depth to ‘C’ check
length ratio 1
to 20
EFFECTIVITY: TRENT
54-40-01
Page 107
LIMITS INTERVALS
Missing 1B Trailing Edge A=12,7mm (0.50 Aircraft
area Extrusion no two in.) max. ‘A’ check
Fig. within 76,2 mm
102 (3.0 in.) of each B=76,2 mm
other. (3.00 in.)
max.
Crack 1B Trailing Edge 2,54 mm (0.10 Aircraft

Extrusion no two in.) length. ‘A’ check
Fig. within 76,2 mm
102 (3.0 in.) of each
other.
Missing 1B Trailing Edge Item 3, 1 in Aircraft

Fasteners Fig. Extrusion - 12, no 2 ‘A’ check
102 attachment adjacent
Holes 2 Pen nib fairing No holes

Fig. skins allowed
103
Gouge/ 2 No two within 76 Maximum length Aircraft

Nick mm (3.0 in.) of 38,10 mm (1.50 ‘A’ check
each other. 38 mm in.)
(1.5 in.) min.
edge distance
Crack 2 Pen nib Bottom None allowed

riveted joint of
Fig. forward titanium
103A fairing skins
Crack 2 Area 1 titanium Maximum length Aircraft

fairing. No two 25,4 mm (1.0 ‘A’ check
Fig. within 76,2 mm in.)
103 (3.0 in.) of each
other. Stop drill
with No.30 drill
Maximum length
Area 2 upper 31,75mm (1.25
aluminum fairing in.)
EFFECTIVITY: TRENT
54-40-01
Page 108
LIMITS INTERVALS
Missing 2 Bottom riveted None allowed
Fasteners Fig. joint fairing
103A skins
Area 1 Titanium 1 in 5 row
Missing 2 Aircraft
fairing (1), except
Fasteners Fig. ‘A’ check
none in lower
103
fairing upper
or aft fairing
attach line
Area 2 Aluminum 1 in 5 except

upper fairing none in lower
attachment forward
fairing attach
line
Gouge/ 3 Outer barrel Outer Maximum depth Aircraft
Nick skin - no two 0,51 mm (0.02 ‘A’ check
Fig. within 76 mm (3.0 in.)
104 in.) of each Maximum length
other. 38 mm (1.5 76,2 mm (3.00
in.) min. edge in.)
distance
Except, none
allowed under
lower strut
attach area
and 25,4 mm
(1.0 in.)
maximum length
within 508 mm
(20.0 in.)
each side of
bottom
centerline.
EFFECTIVITY: TRENT
54-40-01
Page 109
LIMITS INTERVALS
Hole/ 3 Outer barrel Outer Maximum Fly-on
Crack skin - no two diameter or limit
Fig. within 76 mm (3.0 length of only. Must
104 in.) of each crack 69.85 mm be
other. Protect (2.75 in.) repaired
damage with at
appropriate Except, none earliest
sealing tape allowed within opportunit
127mm (5.0 y.
in.) of panel Visually
edge and under check tape
forward to ensure
sections of no peel
strut attach back
(see fig 104). occurs
Aft sections after
of lower side every
struts flight.
attachments
the maximum
diameter hole
or length of
crack to be
25,4 mm (1.0
in.)
Dent 3 Outer skin - must Maximum depth Aircraft

be smooth and free 6,35 mm (0.25 ‘A’ check
of sharp edges, in.) Repair by
gouges and cracks. Maximum next
Core crush is diameter 76,2 aircraft
allowable. No two mm (3.00 in.) ‘C’ check
within 76,2 mm
(3.0 in.) of each Except, 25,4
other mm (1.0 in.)
maximum Aircraft
diameter ‘A’ check
within 508 mm Repair by
(20 in.) each next
side of bottom aircraft
centerline ‘C’ check
EFFECTIVITY: TRENT
54-40-01
Page 110
LIMITS INTERVALS
Disbond 3 Outer skin - no Maximum Aircraft
two within 152,4 diameter ‘A’ check
mm (6.0 in.) of 69.85mm (2.75
each other. No in.)
similar damage on
opposite face
sheet. No damage
within 25,4 mm
(1.0 in.) of panel
edges
Gouge/ 4 Outer barrel Inner Maximum depth Aircraft

Nick skin - no two 0,51 mm (0.02 ‘A’ check
Fig. within 76 mm (3.0 in.)
105 in.) of each Maximum length
other. 38 mm (1.5 50,8 mm (2.0
in.) min. edge in.)
distance
Except, none
allowed 152 mm
(6.0 in.)
either side of
centerlines of
struts
EFFECTIVITY: TRENT
54-40-01
Page 111
LIMITS INTERVALS
Hole/ 4 Inner skin - no Maximum Aircraft
crack two within 76 mm diameter or ‘A’ check
(3.0 in.) of each length of Repair by
other crack 20,32 mm next
(0.80 in.) aircraft
‘C’ check
Except, none
allowed within
127mm (5.0
in.) of panel
edge and under
forward
sections of
strut attach
(see fig 105).
Dent 4 Inner skin - must Maximum depth Aircraft

be smooth and free 3,05 mm (0.12 ‘A’ check
of sharp edges, in.) Repair by
gouges and cracks. Maximum next
Core crush is diameter 50,8 aircraft
allowable. No two mm (2.0 in.) ‘C’ check
within 76,2 mm
(3.0 in.) of each Except, none
other within 152 mm
(6.0 in.)
either side of
centerlines of
struts
Disbond 4 Inner skin - no Maximum length Aircraft

two within 152,4 69.851mm (2.75 ‘A’ check
mm (6.0 in.) of in.)
each other. No
similar damage on
opposite face
sheet. No damage
within 25,4 mm
(1.0 in.) of panel
edges
EFFECTIVITY: TRENT
54-40-01
Page 112
LIMITS INTERVALS
Gouge/ 5 Lower strut No two Maximum length Aircraft
Nick within 76,2 mm 38,10 mm (1.50 ‘A’ check
Fig. (3.0 in.) of each in.) Not
106 other. 38,1 mm allowed at
(1.5 in.) min. attach flange
edge distance
Hole 5 Lower strut None allowed
Fig.
106
Dent 5 Must be smooth and Maximum depth Aircraft

free of sharp 3,05 mm (0.12 ‘A’ check
edges, gouges and in.) Repair by
cracks. No two Maximum next
within 76,2 mm diameter 50.8 aircraft
(3.0 in.) of each mm (2.0 ‘C’ check
other in.)Not
allowed at
attach flange
Crack 5 No two within 76,2 Maximum length Aircraft

mm (3.0 in.) of 38,10 mm (1.50 ‘A’ check
each other. Stop in.) Not
drill with No.30 allowed at
drill attach flange
Missing 5 Fairings 5 off, none Aircraft

Fasteners Fig. consecutive ‘A’ check
107
Side skins
Fig. 10 off, 3
106 consecutive
limit
Gouge 6 Primary nozzle Aircraft
/Nick outer surface-No Maximum length ‘A’ check
Fig. two within 76,2 mm 38,10 mm (1.50
108 (3.0 in.) of each in.)
other. 38,1 mm (1.5
in.) min. edge
distance
EFFECTIVITY: TRENT
54-40-01
Page 113
LIMITS INTERVALS
Dent/ 6 None allowed
hole
Crack 6 No two within 76,2 Maximum length Aircraft

mm (3.0 in.) of 38,10 mm (1.50 ‘A’ check
each other. Stop in.)
drill with No.30
drill
Missing 6 Within every 60°° on Item 1 -2 off

Aircraft
Fasteners fwd frame attach, ‘A’ check
Fig. row (1)
Item 2 -3 off
108
Within every 60°° on
aft frame attach,
row (2)
Gouge/ 7 Primary nozzle Aircraft
Nick inner surface No Maximum length ‘A’ check
Fig. two within 76,2 mm 38,10 mm (1.50
108 (3.0 in.) of each in.)
other. 38,1 mm
(1.5 in.) min.
edge distance
Hole 7 None allowed

cracks. No two next
with 76,2 mm (3.0 Maximum aircraft
in.) of each diameter 50,8 ‘C’ check
other. mm (2.0 in.)
Crack 7 No two within Maximum length Aircraft

254,0 mm (10 in.). 38,1 mm (1.5 ‘A’ check
Stop drill with in.)
No.30 drill
EFFECTIVITY: TRENT
54-40-01
Page 114
LIMITS INTERVALS
Gouge/ 8 Side struts-No two Maximum length Aircraft
Nick within 76,2 mm 38,10 mm (1.50 ‘A’ check
Fig. (3.0 in.) of each in.)
109 other. 38,1 mm (1.5
in.) min. edge
distance
Hole 8 None allowed

cracks. One per Maximum next
panel. diameter 38,1 aircraft
mm (1.5 in.) ‘C’ check
Crack 8 Side strut skins - Maximum length Aircraft

No two within 76,2 38,10 mm (1.50 ‘A’ check
mm (3.0 in.) of in.)
each other. Stop
drill with No.30
drill
Missing 8 Side strut attach Item 1, 1 off Aircraft

Fasteners fittings at (1) ‘A’ check
Fig. inner annulus,
109 forward
Attach flange, at Item 2, 1 off

(2) inner annulus,
aft
Attach flange, at Item 3, 1 off

(3) outer barrel
Strut halves Item 4, 2 off

attachment
EFFECTIVITY: TRENT
54-40-01
Page 115
R6211 TRENT
STRUCTUAL REPAIR
MANUAL
- - - - - - - - . . - - - -...-..-----
---- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
DAMAGE Z O N E REQUIREMENTS ALLOWABLE INSPECTION
LIMITS INTERVALS
- -- - - - - -
------------------ . - - ..-. - - - - . - - - -
Worn 8 All side strut 'B' Max 3 If TIR
side fittings Total 0,508 mm reading is
strut Fig. Dial Indicator (0.020 in.) If 0,381nmr
fitting 109 Reading (TIR) of TIR equal to (0.015in)
bolt bolt centerline or over 'B' to 0,483
attach radial movement nun (0.019
using hand force disassemble in )
inspect parts: inspect
every 2
Pin Min Dia = 'A'
9,322 lam checks.
(0.367 in.)
Bushing Min
0.D = 12,24 nun
(0.482 in.)
Max I.D.
9,7536 mm
Upper and lower (0.384 in.)
strut fittings
except lower strut
slotted fitting.
Fitting hole
Max I.D. =
13,33 lam
(0.525 in.)
Worn 8 ~ o w e rstrut Slot width Max Inspect

lower slotted fitting 15,36 mm every 2
side Fig. Measure strut slot (0.605 in.) ' A f checks
strut 109 if slot
fitting Max Aft slot width is
slot length 24,24 fram
mm (0.955 in.) 13,33mm
(0.525 in)
Max Forward to 15.34rmma
slot length (0.604i.n)
21,70 XIXI
(0.855 in.)
Page 116
Printed i n Great B r i t a i n MAR.10/09
LIMITS INTERVALS
Gouge/ 9 Seal Carrier No Maximum length Aircraft
Nick two within 76,2 mm 7,62 mm (0.30 ‘A’ check
Fig. (3.0 in.) of each in.)
110 other. 38,1 mm
(1.5 in.) min.
edge distance
Crack 9 No cracks allowed
Missing 9 Inspect for 3 out of 10- Aircraft

Fasteners missing fasteners Replace at ‘A’ check
earliest
opportunity
Abrasion 9 Contact from ‘A’= Maximum Aircraft

thrust reverser depth 0,51 mm ‘A’ check
rub blocks. Wear (0.020 in.)
from original
surface at deepest
wear location
Spring Seal
Abrasion 10 Completely Aircraft
worn through ‘C’ check
Fig. in damage zone
111
Abrasion 10 Cross flow seal Maximum depth Aircraft

Contact with pylon 0,51mm (0.020 ‘C’ check
Fig. in.)
111
10 Forward Entire Teflon Aircraft

seal/Teflon rubstrips are ‘C’ check
rubstrips & allowed to be
rubstrip supports missing.
Contact with pylon Maximum wear
skirt. depth of
0,51mm (0.020
in.) to
rubstrip
supports.
Missing/ 10 Bulb seal Entire bulb None

torn seal seal is required
allowed to be
missing
EFFECTIVITY: TRENT
54-40-01
Page 117
LIMITS INTERVALS
Nick/ 11 Thrust Link Maximum depth Aircraft
Gouge Contact with bolts 0,51mm (0.020 ‘A’ check
Fig in.) depth.
112
Cut/tear 12 Seals Inner annulus

- No tears,
Fig. cracks or
113 missing seals
allowed Check at
‘A’ check
Outer annulus
Total missing
seal 1016 mm
(40 in.)
Maximum length
of missing
seal segment
254 mm (10
in.). Minimum
separation
between
damages 152,4
mm (6.0 in.).
EFFECTIVITY: TRENT
54-40-01
Page 118
Common Nozzle Assembly – Allowable Damage
Figure 101
EFFECTIVITY: TRENT
54-40-01
Page 119
Figure 102
EFFECTIVITY: TRENT
54-40-01
Page 120
Figure 103
EFFECTIVITY: TRENT
54-40-01
Page 121
Figure 103A
EFFECTIVITY: TRENT
54-40-01
Page 122
Figure 104
EFFECTIVITY: TRENT
54-40-01
Page 123
Figure 105
EFFECTIVITY: TRENT
54-40-01
Page 124
Figure 106
EFFECTIVITY: TRENT
54-40-01
Page 125
Figure 107
EFFECTIVITY: TRENT
54-40-01
Page 126
Figure 108
EFFECTIVITY: TRENT
54-40-01
Page 127
Figure 109
EFFECTIVITY: TRENT
54-40-01
Page 128
Figure 110
EFFECTIVITY: TRENT
54-40-01
Page 129
Figure 111
EFFECTIVITY: TRENT
54-40-01
Page 130
Figure 112
EFFECTIVITY: TRENT
54-40-01
Page 131
Figure 113
EFFECTIVITY: TRENT
54-40-01
Page 132
REPAIR NO. 14
REPLACE SIDE STRUTS END FITTINGS
1. General
A. This repair gives the procedure to replace the outer, upper and
lower end fittings on the side struts.
B. This repair is in two parts

(1) Part 1 – Replacement of the lower strut outer end fittings.
(2) Part 2 – Replacement of the upper strut outer end fittings.
---------------------------------------------------------------------
---------------------------------------------------------------------
RR SB RB211-78-B605 Exhaust – Introduction of slots in the lower
strut attachment fittings.
RR SB RB211-78-C411 Exhaust - Introduction of revised side strut
attaching washers.
RR SB RB211-78-C011 Exhaust - Introduction of revised attachment
fittings for the lower strut mounting.
78-11-14-300-XXX FRSY028, Trent Engine Manual
- Standard shop tools
- ASP fastener removal and installation equipment
B. Consumable Equipment
--------------------------------------------------------------------
--------------------------------------------------------------------
OMat 150 Acetone
OMat 1/40 Isopropyl Alcohol (Alternative)
OMat 1/257 Cleaning Solvent (Alternative)
OMat 2/101 Clean cotton cloth
OMat 8/52 Adhesive
OMat 8/143 Sealant
OMat 876C Primer
OMat 4/47 Jointing Compound
OMat 8/202 Release Agent
OMat 8/132 Release Agent (Alternative)

54-40-01
Page 201
-----------------------------------------------------------------------
PART IDENT MATERIAL
-----------------------------------------------------------------------
Fittings 17-4PH CRES, H900
D. Repair Parts
-----------------------------------------------------------------------
-----------------------------------------------------------------------
1 ASP-LC-2AC06 Collar
2 ASPF-S-EU06 Sleeve
3 ASPFF-V06-16 Pin
4 ASPFF-V06-8 Pin
5 FK16665 Fitting, Outer, Upper
6 FK16573 Fitting, Outer, Lower
7 FK16666 Shim, Laminated
8 FK16574 Shim, Laminated
9 HL10V-12-16 Pin
10 MS21043-6 Nut
11 KJT816906V Washer
4. Procedure (Ref. Figs. 201, 202, 204 & 206)
Part 1: Replacement of the lower strut outer end fittings
A. Remove the Lower strut (Figs. 201, 202 and 204)

(1) Remove the lock nuts, pins and washers at the locations that
secure the lower struts.
(2) Remove the bushes (Qty 16).
(3) Remove the lower side strut and save for installation.
B. Remove the lower strut outer fitting (Ref. Figs. 202 and 206)
CAUTION: TO AVOID DAMAGE TO THE COMPOSITE OUTER BARREL, DRILL

FASTENERS FROM INSIDE THE BARREL AT THE FITTING.
(1) Remove the fasteners (Qty 12) on each outer fitting.

54-40-01
Page 202
CAUTION: THE LIQUID SHIMS CAN BE BONDED TO THE INNER SKIN OF THE
BARREL, DO NOT ATTEMPT TO REMOVE THEM.
(2) Remove the outer fitting and save the laminated or liquid
shims.
NOTE: It may be necessary to replace the laminated or liquid

shims with the new fitting.
C. Clean the area and remove damaged sealant
WARNING: SOLVENT IS CLASSIFIED AS A HAZARDOUS MATERIAL THAT CAN CAUSE

INJURY OR ILLNESS IF NOT USED CORRECTLY. BEFORE YOU USE THIS
PRODUCT, CAREFULLY READ THE APPLICABLE MATERIAL SAFETY DATA
SHEET AND OBEY ALL THE SPECIFIED HEALTH AND SAFETY
PRECAUTIONS.
(1) Make a clean, dry, lint free cloth (OMat 2/101) moist with the
degreasing fluid.

repair.
liquid container.
(2) Clean the repair area and remove damaged or residual sealant
from the repair area with OMat 150-Acetone, OMat 1/40-Isopropyl
Alcohol or OMat 1/257-Cleaning solvent and OMat 2/101-Cloth.
Wipe the area dry before the solvent evaporates.
D. Temporarily install the new lower strut outer fitting.
(1) Temporarily install the strut in the inner fittings with new or
serviceable hardware but use a standard non-locking nut on each
pin.
(2) Temporarily install the new fitting (item 6) fitting on the

outer end of the lower strut with new or serviceable hardware
but use a standard non-locking nut on each pin.
E. Measure the gap between the new fitting and the original mounting
surface of the outer barrel.
(1) Move the fitting inward on the lower strut toward the engine
centerline. The bushings must touch against the outboard edge of
the slot.
54-40-01
Page 203
(2) Check and measure the gap.
a) For gaps up to 0.030 in (0.762 mm),use OMat 8/52 adhesive as

a liquid shim.
b) For gaps from 0.030 to 0.090 in (0.762 to 2.286 mm),use

laminated shim (item 8), in combination with the liquid shim.
NOTE: Liquid shim must be limited to 0.030 mm (0.762 mm)

maximum thickness.
(3) Mask surfaces adjacent to the shimmed area to control possible

excess squeeze out.
NOTE: Adjust and/or taper the shims as required.
F. Drill holes in the new fitting.
(1) With the new fitting temporarily installed with the strut
a) Transfer drill locator marks from the outer barrel holes

onto the new fitting.
(2) Remove the strut and new fitting.
(3) Drill (Qty 12) holes, 0.203 to 0.208 in (5.16 – 5.28 mm)
diameter in the fitting.
a) Use the fitting as a template and back drill same holes in

the shim (if used).
b) Countersink fitting holes 100 degrees and deburr.

G. Clean the area and remove residual sealant
degreasing fluid.

repair.
54-40-01
Page 204
liquid container.
(2) Wipe the area dry before the solvent evaporates.
H. Apply the liquid shim as required.
(1) Remove the fitting (item 6) from the strut and apply OMat
8/202 or alternate OMat 8/132 release agent.
a) Apply to the mating surface of the new fitting and the

outer barrel.
b) Apply to the laminated shims.
c) Apply to the outer barrel.
(2) Mix OMat 8/52 liquid shim to manufacturer’s instructions and

apply with a brush or spatula to surface of the outer barrel
to eliminate the gap measured in step E.
(3) Temporarily install the new fitting in the strut, to bring it

into contact with the laminated / liquid shim.
(4) With temporary fasteners, position and with care secure the
new outer fitting into position without excessive squeezing
of the shim.
a) Tighten the fastener sufficiently enough to make sure of

complete contact and to eliminate trapped air.
I. Temporarily assemble strut and new fitting into position.
(1) Install the strut into the inner fitting. Do not to disturb
the new outer fitting.
(2) Install the bushes against the outboard edge of the fitting
slots in the new outer fitting.
(3) Check the bushes hole alignment in the strut bearing hole.
a) Check the alignment visually or by the insertion of the

pin through the hole with no pre-load to the assembly.
b) Adjust the shims, if required with the laminated shims.
(4) Remove the lower side strut from the assembly.

54-40-01
Page 205
J. Let the liquid shim cure.
(1) Allow the liquid shim to cure at 88 to 100 Degs. C (190 to

212 Degs. F) for 120 minutes minimum.
(2) Use heat lamps as required.
K. Clean the repair area

.
(1) Remove the temporary fasteners.
(2) Clean fastener holes and countersinks of excess cured liquid
shim.
L. Install the fasteners (Ref. Figs. 202 & 206)
(1) Wet install collar (item 1), sleeve (item 2), and pin (item
3) (12 places).
(2) Install the pins from the inner side of the outer barrel.
NOTE: Use OMat 4/47 to manufacturer’s instructions for the

wet installation.
M. Install the lower side strut. (Ref. Fig. 206)
(1) Install bushes in the inner fitting.

(2) Install the lower side strut into the inner position.
a) Secure in place with pin (item 9), nut (item 10), and
washer (item 11).
(3) Install bushes in the outer fitting.

(4) Install the side strut into outer position.
a) Secure in place with. pin (item 9), nut (item 10), and
washer (item 11).
(5) Torque nut (item 10) to 160 to 190 lbf-in (18.08 to 21.47
Nm).
WARNING: THESE PRODUCTS ARE CLASSIFIED AS HAZARDOUS MATERIALS THAT

YOU USE THESE PRODUCTS, READ THE APPLICABLE MATERIAL SAFETY
DATA SHEET AND OBEY ALL THE HEALTH AND SAFETY PRECAUTIONS.
N. Apply aerodynamic filler to the edges of the new outer fitting.

(Ref. Fig.204).
(1) Apply OMat 876C Primer as indicated (Ref. Fig. 204).

54-40-01
Page 206
(2) Apply OMat 8/143 Sealant as a fillet bead as indicated (Ref.
Fig. 204).
(3) Repair the surface finish on the outer surface of the outer
barrel. Ref. repair No. 13 (FRS Y015).
5. Part 2: Replacement of the Upper Strut Outer End Fittings. (Ref.

Figs. 201, 203, 205 & 206)
A. Remove the upper side strut (Ref. Figs 201, 203 and 205).
(1) Remove the lock nuts, pins and the washers at the eight
locations that secure the upper struts.
(2) Remove the (Qty 16) bushes.
(3) Remove the upper side strut.
B. Remove the upper strut outer fitting (Ref. Figs. 203 and 206).
CAUTION: TO AVOID DAMAGE TO THE COMPOSITE OUTER BARREL, DRILL

FASTENERS FROM INSIDE THE BARREL AT THE FITTING.
(1) Remove fasteners (Qty 12) on each fitting.
CAUTION: THE LAMINATED SHIMS OR LIQUID SHIMS CAN BE BONDED TO

THE INNER SKIN OF THE BARREL, DO NOT ATTEMPT TO REMOVE
THEM.
(2) Remove the outer fitting and save the liquid or laminated
shim.
C. Clean the area and remove residual sealant

degreasing fluid.

repair.
liquid container.
f) Wipe the area dry before solvent evaporates.

54-40-01
Page 207
D. Temporarily install the new upper strut outer fitting (Item 5)
(1) Temporarily install the upper strut into the inner fitting
with standard non-locking nuts on each pin.
(2) Temporarily install the new fitting (item 5) to the outer end
of the upper strut with standard non-locking nuts on each
pin.
E. Measure the gap between the new fitting and the original mounting
surface of the outer barrel.
(1) Check and measure the gap.
a) For gaps up to 0.030 in (0.762 mm),use OMat 8/52 adhesive

as a liquid shim.
b) For gaps from 0.030 to 0.090 in (0.762 to 2.286 mm),use

Laminated shim (item 8), in combination with the liquid
shim.
NOTE : Liquid shim must be limited to 0.030 in (0.762 mm)

maximum thickness.
(2) Mask surfaces adjacent to the shimming area to control

possible excess sqeeze out.
NOTE : Adjust and/or taper the shims as required.
F. Drill holes in the new fitting.
(1) With the new fittiing temporarily installed with the strut
a) Transfer drill locator marks from the outer barrel holes

onto the new fitting.
(2) Remove the strut and new fitting.
(3) Drill (Qty 12) holes, 0.203 to 0.208 in (5.16 – 5.28 mm)
diameter in the fitting.
a) Use the fitting as a template and back drill same holes in

the shim (if used).
b) Countersink fitting holes 100 degrees and deburr.

54-40-01
Page 208
G. Clean the area and remove residual sealant.

repair.
liquid container.
(2) Wipe the area dry before the solvent evaporates.
H. Apply the liquid shim as required.
(1) Remove the fitting (item 5) from the strut and apply OMat
8/202 or alternate OMat 8/132 release agent.
a) Apply to the mating surface of the new fitting and the

outer barrel.
b) Apply to the laminated shims.
c) Apply to the outer barrel.
(2) Mix OMat 8/52 liquid shim to manufacturer’s instructions and

apply with a brush or spatula to surface of the outer barrel
to eliminate the gap measured in step E.
(3) Temporarily install the new fitting in the strut, to bring it

into contact with the laminated / liquid shim.
(4) With temporary fasteners, position and with care secure the
new outer fitting in position without excessive squeezing of
the shim.
a) Tighten the fastener sufficiently enough to make sure of

complete contact and to eliminate trapped air.

54-40-01
Page 209
I. Temporarily assemble strut and new fitting (item 5) into position
(1) Temporarily install the strut in the inner fitting.
NOTE: Do not disturb the new outer fitting.
(2) Install the bushes in the new outer fitting.
(3) Check the bush hole alignment in the strut bearing hole
visually or by the insertion of the pin through the hole with
no pre-load to the assembly.
(4) Adjust shimming as required with laminated shim (item 7).
(5) Remove the upper side strut from the assembly.
J. Let the liquid shim cure.
(1) Allow the liquid shim to cure at 88 to 100 Degs. C (190 to

210 Degs. F) for 120 minutes minimum.
(2) Use heat lamps as required.
K. Clean the repair area.
(1) Remove the temporary fasteners.
(2) Clean fastener holes and countersinks of excess cured liquid

shim.
L. Install the fasteners on the new outer fitting (Ref. Figs. 203
and 206).
(1) Wet install collar (item 1), sleeve (item 2) and pin (item 3)
(11 places).
(2) Wet install collar (items 1), sleeve (item 2) and pin (item
4) (1 place).
(3) Install the pins from the inner side of the outer barrel.
NOTE: Use OMat 4/47 to manufacturer’s instructions for the

wet installation.
M. Install the lower side strut. (Ref. Fig. 205)
(1) Install bushes in the inner fitting.

54-40-01
Page 210
(2) Install the side strut into the inner position.
a) Secure in place with pin (item 9), nut (item 10) and
washer (item 11).
(3) Install bushes in to the outer fitting.
(4) Install the side strut into the outer position.
a) Secure in place with pin (item 9), nut (item 10) and
washer (item 11).
(5) Torque nut (item 10) to 160 to 190 lbf-in. (18.08 to 21.47
Nm.).
WARNING: THESE PRODUCTS ARE CLASSIFIED AS HAZARDOUS MATERIALS THAT

YOU USE THESE PRODUCTS, READ THE APPLICABLE MATERIAL SAFETY
DATA SHEET AND OBEY ALL THE HEALTH AND SAFETY PRECAUTIONS.
N. Apply aerodynamic filler to the edges of the new outer fitting.

(Ref. Fig. 205).
(1) Apply OMat 876C Primer as indicated (Ref. Fig. 205).
(2) Apply OMat 8/143 Sealant as a fillet bead as indicated (Ref.

Fig. 205).
(3) Repair the surface finish on the outer surface of the outer
barrel. (Ref. repair No. 13 (FRS Y015).
7. Inspect and identify the repair.
A. Make a visual inspection of the repair and that it has been done
in accordance with these procedures.
B. Identify the repair by vibro-etching “FRS Y028” adjacent to the

assembly number.

54-40-01
Page 211
Figure 201
Common Nozzle Assembly
Side Strut End Fitting Replacement

54-40-01
Page 212
FIGURE 202
Side Strut End Fittings Replacement

54-40-01
Page 213
FIGURE 203
Side Strut Fitting Replacement

54-40-01
Page 214
FIGURE 204

54-40-01
Page 215
FIGURE 205

54-40-01
Page 216
FIGURE 206

54-40-01
Page 217
REPAIR NO. 15
COMMON NOZZLE A S S E m L Y
REPLACE TRANSVERSE FIRE SEAL ASSEMBLY AND END SEALS
1. General Data
0
A. This repair gives the procedure to remove and replace a damaged

Transverse Fire Seal Assembly and the End Seals Assemblies if
they are also damaged.
B. The procedure assumes the Common Nozzle Assembly has been

removed from the engine.
C. Refer to Fig. 201 for general repair area.
.....................................................................
.....................................................................
SRM TASK 54-02-10 Fasteners - Installation and Removal
Equivalent materials and equipment can be used
- Standard shop tools
- Vibro - etching equipment
OMat 2/101 Clean cotton cloth

OMat 8/143 Sealant DC93-006
OMat 876C Primer DC1200
NOTE: To identify the consumable materials refer to the Overhaul

Materials Manual (OMat) .
REPAIR N0.15
54-40-01
Page 201
May 15/05
p RB211 TRENT
MANUAL
STRUCTURAL REPAIR
.......................................................................
PART IDENT MATERIAL
.......................................................................
Fire Seal 15-5 PH Steel (Tungsten Carbide Coated)
End Seal Silicone Rubber
D. Repair Parts
.......................................................................
FIG/ITEM PART NO. PART IDENTIFICATION Q ~ Y
.......................................................................
202/1 MS20615-5M5 Rivet, Prot A/R
202/2 FK16607 Transverse Fire Seal Assembly 1
202/3 FK16670 Seal Assy. L.H end 1
202/4 FK16671 Seal Assy. R.H end 1
202/5 nas1198-5-5 Rivet, Prot A/R
4. Procedure
A. Remove the damaged Transverse Fire Seal Assembly (Fig. 201 and
Fig. 202) (SRM TASK 54-02-10).
B. Remove the damaged End Seal Assemblies (Fig. 201 and Fig.
202) (SRM TASK 54-02-10).
C. Prepare the new Transverse Fire Seal and End Seal Assemblies
(Fig. 201 and Fig. 202).
(1) Drill the rivet holes in items 2, 3 and 4 (Fig. 202) .

(a) Put the new end seal assemblies, item 3 and item 4
in the same location as the original and move the
drill holes from the mating hole locations.
(b) Put the new Transverse Fire seal assembly, item 2 in
the same location as the original and move the drill
holes from the mating hole locations.
(C) Use a #20 drill size [4,09 mm (0.161 in)l and
drilling equipment.
(d) Deburr all the drilled holes.
(2) Clean the repair areas (AMM TASK 70-20-01-100-802).
(a) Clean the mating surfaces of the repair parts and

the common nozzle assembly. Remove all oils and
debris
REPAIR N0.15
54-40-01
Page 202
May 15/05
WARNING:
H"" RB211 TRENT
MANUAL
STRUCTURAL REPAIR
DOW CORNING 1200 PRIMER (OMAT 876C) AND DOW CORNING

93-006 SEALANT (OMAT 8/143) ARE FLAMMABLE AND THE
VAPOURS ARE HARMFUL. USE IN A WELL-VENTILATED AREA.
WORK PERFORMED IN CONFINED AREAS REQUIRES THE USE OF
ADDITIONAL FORCED MECHANICAL VENTILATION. AVOID
BREATHING OF VAPOUR OR PROLONGED OR REPEATED CONTACT
WITH SKIN. MAY CAUSE IRRITATION TO SKIN, EYES, NOSE
AND THROAT. HIGH CONCENTRATIONS MAY CAUSE IMPAIRED
JUDGEMENT. PROTECTIVE GLOVES SHOULD BE WORN DURING
USE. MAY CAUSE DERMATITIS BY REMOVING SKIN OILS.
(3) Apply OMat 876C primer to the mounting surfaces of the

Transverse Fire Seal and End Seal Assemblies (Items 2, 3
and 4), in accordance with the manufacturers instructions
(4) Air-dry the primer at room temperature for (1) hour. If a

chalky residue is evident, remove with a clean OMat 2/101
lint free cloth.
(5) Apply OMat 8/143 sealant to the mounting surfaces of the

End Seal Assemblies (items 3 and 4) in accordance with the
(6) Install the rivets (Fig. 202) (SRM TASK 54-02-10).

(a) Wet install item 5 (4 places) rivets.
Use OMat 4/47 jointing compound as per
manufacturer's instructions for wet install.
D. Install the New Transverse Fire Seal Assembly (Fig. 201 & 202)
WARNING: DOW CORNING 1200 PRIMER (OMAT 876C) AND DOW CORNING
93-006 SEALANT (OMAT 8/143) ARE FLAMMABLE AND THE '
VAPOURS ARE HARMFUL. USE IN A WELL-VENTILATED AREA.

WORK PERFORMED IN CONFINED AREAS REQUIRES THE USE OF
ADDITIONAL FORCED MECHANICAL VENTILATION. AVOID
BREATHING OF VAPOUR OR PROLONGED OR REPEATED CONTACT
WITH SKIN. MAY CAUSE IRRITATION TO SKIN, EYES, NOSE
AND THROAT. HIGH CONCENTRATIONS MAY CAUSE IMPAIRED
JUDGEMENT. PROTECTIVE GLOVES SHOULD BE WORN DURING
USE. MAY CAUSE DERMATITIS BY REMOVING SKIN OILS.
(1) Apply OMat 876C primer to the mounting surfaces of the

Transverse Fire Seal Assembly, (Item 2).
(2) Air-dry the primer at room temperature for (1) hour. If a

chalky residue is evident, remove with a clean OMat 2/101
lint free cloth.
REPAIR N0.15
54-40-01
Page 203
May 15/05
(3)
p R8211 TRENT
MANUAL
STRUCTURAL REPAIR
Apply OMat 8/143 sealant to the mounting surfaces of the

Transverse Fire Seal Assembly, (Item 2).
(4) Install rivets (Fig. 202) (SRM TASK 54-02-10)
(a) Wet install item 1 (15 places) rivets.

Use OMat 4/47 jointing compound as per
manufacturer's instructions for wet install.
E. Visually Inspect the repair to make sure it has been completed
as directed
F. Identify the Repair
(1) Mark FRSY022 adjacent to the assembly number. To do this,

use vibro-etching engraving equipment
REPAIR N0.15
54-40-01
Page 204
May 15/05
COMMON NOZZLE
ASSEMBLY
UPPER DECK ASSEMBLY
Common Nozzle Assembly - Replace Transverse Fire Seal Assembly

and End Seals Repair
Fig. 201
REPAIR NO. 15
54-40-01
Page 205
May 15/05
p RB211 TRENT
MANUAL
STRUCTURAL REPAIR
(Left side shown) 1

4 END SEAL
8 ASSEMBLY
8 (Right side opposite)
t
IL
U
LEFT SlDE SHOWN
RIGHT SIDE OPPOSITE
Common Nozzle Assembly -Replace Transverse Fire Seal Assembly
and End Seals Repair
Fig. 202
REPAIR N0.15
54-40-01
Page 206
May 15/05
RB211 TRENT
STRUCTURAL REPAIR
Repair Number 1 6
Cwmnon Nozzle Aammhly
Outer Barrel - Repair bfsbond at Uppar Side S t r u t Pittinq Locations,

FRSY032
1. General Data
A. This repaSx is applicable t o the Common Nozzle Assembly ICNA)

aeoustic panel outer barrel in the area adjacent to the uppar
s i d e g t r u t attaehmenta,
B. This repair ia limited to a disbond s i z o no more than S O 8 m x

5 0 8 m ( 2 0 in. w i d e by 20 in. long) on the inner and/or outsr
ekine of t h e outer barrel.
C. Fastener grip langtha listad are nominal, A t installation of

t h s fagtenets the actual g r i p langth ahould be meaauxed and the
correct grip length fastener installed.
D. The repair contains optional procedures to paint the rmpafr

area to match t h e exiatkng colour scheme of tha CNA.
E. This repair is in 2 parts.
(1) Part 1: Xnetalls sepair doublers at the footpxint of t h e

upper side etrut outer fitting (inner and outer skins).
The repair doublera ehould be the same size as ehom in
F i g . 201 S h e e t 3 and 4 and are not altered to ronfonn to
the s i z e of t h e diebond. Any dieboad, which extends more
than the doublar. i e repairad i n Part 2 .
(23 Part 2 : Pot and install repair pins through amy disbanded
area, which extenda more than the repair doubler.
2. Referenced Tnformation
1 - 1 1 - - - - - - - - - 1 - - 1 - - - - - - - - - * - - - - - - - - - - - - * - - - - - - - - - - - - = - - - - - - - * - - " - - " - -
REFERENCE DESIGNAT1ON
- - 1 - - - 1 - - - - - * - " - - " " 1 - ) 1 ) - - - - - - - - 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
M TASK 70-20-01-100-902 Cbanhg

SRM TASK 5 4 - 0 2 - 1 0 Faatanera - fnetallation and R ~ v a l
S W TASK 5 4 - 0 1 - 0 6 ComporrJte Btzuetura Tap Test
3. Ecruiament and Materials
A, Standard Equipment
- Clampl4
REPAfR H0.16
54-40-01
Page 261
Feb. 1 5 / 0 6
1 RB211 TRENT
STRUCTURAL REPAIR
MANUAL
-
-- Pegreaging Equipment
Vacuum Equipment
Standard Shop Tools
- Drilla Drilling Equipment
-- Explosion Proof Heat Lamp
Spatula
&
- Vibro-etch equipment
B. Consumbla Watexfals
----1---1----11--1-----*--""*-----11"I-----------"-----*"-------"----
REFERKNCE DBSfONATTON
- - - - - - - - - - 1 - 1 - - - * * - - - - - 3 3 " I * I - I I I I - - - - - - - - - - - - * - " * - - * * - " * - - - - - * " - - - - - - *
OMat 2 6 1 Temporary Marker Pen

OMat 2 9 9 Teflon Tape
OMat 2/101 Lint Free Cloth
OMat 2/114 Lint Free Gloves
OMat: 8/130 Filler, Elaea Fibre
OMat 8/154 Adhesive m 9 3 9 4 ( 2 Pack)
O M a t 1/301 Pasa-Jell 107
OMat 0 / 2 3 8 BR 127 Primer
OMat 5 J 3 8 Abrasive Paper
C. Companent Material
------------------------------------*-----------*----------------------
PART 1bENT MATSRXRL
-------------------------------------------------------------------*---
Outer Barrel Graphite Composite
D. Repair Parts
- - - - - - - - - - - - - - - - - - - - - - 1 - - - - - - - - - I - I - - - - - - - - - " - - - - - - - - - - - - - - - - - - - * - - " - - - - - -
FXO/ITEM PART HQ. PART IDEMTIFXCXTXON Q ~ Y
-
1---1------*---1-e-----------------------------------------------------
AMS4900 CP Titanium 8heek 1,6 amr AIR

( 0 . 0 6 3 ia) t h i c k
- M4901 CP Titanium S h e e t 1,6 mm A/R
(0.063 in3 t h i c k
201J1 2ASPFF-V06-15 P in A/R
201/2 ASPF-S-V06 Sleeve A/R
201/3 ASP-GC-2AC06 Lock Collar A/R
201/4 ASPFP-V06-16 Pin A/R
20115 M16759 Waahsr, Repair A/R
WARNING: m THIS R E P A ~ R YOU MUST WEAR PaoTgtTNg ~ t ~ m m o

YOU ,
GLOVES, DUST MASK ANIE SAFETY GOGGLES TO PROTECT YOU AGAINST
DUST ANL) LOOSE PARTICLES, FIHlCH CAN BE DANGEROUS TO YOUR
REPAIR NO. 16
54-40-01
Page 202
Feb. 15/06
RB211 TRENT
STRUCTURAL REPAIR
hqANUAL
WARWINO: WH&N YOU USE CLgANfNb MATERIALS, COATXNQS AND S-S, fiEFER
TO, m ORKJY, TKE M W N O F X C T ~ E RC~ SO ~ O m
L APPLICATION
INSTRUCTIOUS AND HEALTH AM3 SAFETY NOTICES.
4. Procedure
A, J n s t a l l the Rapair Troublere - Part 1
41) Remove and keap thm affected side strtrt and the fasterrerg,
( P i g . 2 0 1 S h e e t 1 and 2).
(2) Rermovm the fastener5 from the outer fitting of the Side
S t r u t (Ref, S W TASK 5 4 - 0 2 - 1 0 ) .
(a) Remove and diaeard sight ASP fasteners which attach
the s i d e s t r u t fitting to the outer barrel that will
be included in the outer repair dovblss (Fig 2 0 1
Sheet 3 ) .
/b) Leave the four forward ASP fsetsners in position.

(3) Exmina the size of t h e disband
{a) Tap teat the part t o find the disbond { R e f . S W TASK

.
54 - 0 1 - 0 6 )
(b) Do not mark or damage the eurface. A change in aound

that t h e tool m a k e s will nhow where the dimbond is.
Ic) Find the; ~ i z eof disbond on the inner and outer

skins.
td) U s e an OMat 261 TEMPORARY =ER of contracting

colour to make a mark t o outline the damaged area on
the inner and outer surfaces,
(4) Remove the paint and filler layer on the external surCses
of the outer barrel fa the clisbonded area.
(a1 Extend the paint removal 25,4 m 11.0 in.) o u t ~ f d e

t h e disbanded area.
(b) Use O M a t 5/38 ABRASIVE PAPER to expose t h e compoeita

structure. Do not damage the p l i s a of tha eomposita.
15) Vsa OMst 2 / 1 0 1 LfNT FREE CSOTH: to locally clean the repair
area and w i p e bafore solvent driea (Ref. RMK TASK T O - 2 0 -
01-100-802).
EPFECTTVTTY t TRENT REPAIR NO-16

54-40-01
Page 203
a F e b . 15/06
Printed i n C f e a t Britain
RB211 TRENT
STRUCTURAL REPAIR
(61 Examine the dfmbond area after paint ramavsl
(a) Tap t e s t t h e part to find tha digbond ( R e f . SRM TASK

54-03-063 .
(b) Do not mark or damage the surfaes. A change in sound
that the tool. maksm will i n d i c a t e where the dimbond
i ~ .
(cl Find the a i z e of dfsbond on the inner and outer

akin6 .
(d? Oar an O M a t 261 TEMPORARY MARXER of contrasting
colour to make a mark to outline the damaged arma on
the inner and outer s w f a c e e .
(7) Wee O M a t 2110% LINT FREE CLOTH to locally clean tho repair
area and w i p e befors eofvsnt dries (Ref. AMM TABK 70-20-
-
01-100 802 ) .
t8) Maka the inner repair doubler tFig. 201 Sheet 4 1 .
(a) U a e 1,6 nm ( 0 . 0 6 3 in.) thick cbmmarcially pure
Titanium sheet AM34 9 0 0 .
(b) Make the doubler the naccrmsary shape to fit the

inner aurfaee contour of the outer barrel.
Ic)
t h e e i d e strut fitting, leave a 2 . 5 4
lO.100 -
-
Hake a cut-out in the doubler to f i t the rtfapa of
3.81 rmn
0 . 1 5 0 in.) gap between the doubler and
fitting.
Id1 Chamfer the edgels et the doubler.
(e) Lay out faatensr pattern ae shown ( F i g , 201 Sheet 4 )

and drill 3,175 xtnn ( 0 . 1 2 5 in.) diameter p i l o t holae
through the inner doubler.
1 Deburr the halea.
(9) Maka the outer repair doubler {Fig. 201 Sheet 3 )
I&) Uae 1,6 m (0.063 in.) t h i c k ebmmareially pure

Titanium shast RMS4900.
(b) Make the doubler t h e necessary ahage to fit tha

external contour of the outer b a r r e l .
REPAXR rP0,15
54-40-01
Page 2 5 4
Feb. 15/66
minted In Grsac B r i t a i n
STRUCTURAL RFPYR
MANUAL
Cc) Chamfer the edges of the doubler.

I101 Prepare the outsr doubler for painting.
NU=: This step f~ optianfil snd only netsasary i f the

doublmr ia to be painted to match the colour
scheme of thm CNA.
(a} V e e OMat 'i/IOf, PASA-JELL 107 to prepare the exterior

~ u t f a c eaf o u t e r d o u b l e r .
IbF Use O M a t 2/114 LINT FREE GSUWS to prsvgnt murfaee

contamination.
(c) Apply one cast of OMat BJ238 BR127 PRIMER to the

exterior surface of the doubler.
(11) Temporarily i n s t a l l . the doublera ( P i g . 201 Shmat 3 a d 4 ) .
Is) Positinn the inner doubler around the ~ i d es t r u t

Zittfng attachment and hold fn glace,
Ib) Poeition the outer doubler on the external rurtmce

of the outer barrel.
(E) Position the centerline of the doubler on thm

centerline of the aids strut fitting holes.
(dl Clamp the doublers in place,
112) D r i l l Pilot holes
(a) Wee the p i l o t holas on the inner dovblrr to back

d r i l l 3 , 2 7 5 m (0.125in.1 diametar holes through the
inner daublss, outer barrel and outer doubler.
(13) R m s the inner and outer doublers from the outsr barrel.
(14) Remove the core from the faatener loeatfona in the outer
barral ( F i g . 2 0 1 Shest 6 ) .
Em. Do not Deeoss holes in the high-density cora area

( F i g . 201 Sheet 4 1 , The boundary of t h e high-
denerty core ran bs found by observing the arma of
the inner s k i n tbat is not perforated.
(a1 Make an "L* ahaped or *hockey ertiekWehapsd tool

from a modified A l l a n K e y tool, stainless ~ t e e w
l ire
or equivalent.
RPFECZ.XVXTY: TRENT REPAIR NO. l6
54-40-05.
Page 205
R Feb. 1 5 / 0 6
Printed in Crear Britain
R821l TRENT
(b) a guide tnmplate for t h s hockay stick tool to

protect the face s h e e t of t h e panel.
(c) The hole in the tmmplate should be t h e same s i z e aa

the fastener bole drilled before.
(d) Carefully start to remove the corm up to 19,O rm

( 0 . 7 5 in.) diameter.
(e) Different length of hockey e t h k tool may be

necessary to get the f u l l dimetar.
) Vacuum corn reaiduse from the area.
(15) Vae OMst 2 / l O f LXHT FREE CLOTH to locally clean the repair
area and wipe dry befsre solvent dries (Ref. M M TASK 70-
20-01-100-802).
(161 Cover the b l m e

with OMat 299 TEFLON TAPE to prevent
adhesive from expanding out: of t h e h o l e s in t h s perforated
skin.
(17) Z n j e ~ tsdheeiva i n t o t h e fantener helee In the f i e l d core

arsa and f i l l countsreiake for the eSght ASP fasteners
( P i g . 201 Sheet 65
(a) Mix 0Mat 8/154 AP#ESIVlZ and add approximately 20

percent volume by weight of OMat &/l30 FIBRES to the
adhesive as a filler.
(bl Rnfar to the manufacturers instructions for eantrol

and applicetian of OMsr 8/154 ADFfESXVE m d OMat
8/130 FILLER, GLASS FIBRE.
(c) Obgrawe all health and aafety preeautionbs.
Id) f n j e c t ths a e e e i v e snd fibre nixtura into the

decored holes u n t i l flush with surface.
(a) Tap t h s area around the patting to remove trapped

air.
(t) Apply the adhesive and fibre aixtura t o the eight

countereinks e o m n to t h e aide strut fitting.
to locally clean the repair

( 1 0 ) Use OHat 2/101 LINT PRgE CLOTS
asoa and wipa dry before erolvent dries (Ref. AMM TASK 70-
20-01-1oo-ao21.
EFPECFIVfTY: TRENT REPAIR UO.16
54-40-03.
Page 206
R Feb. 15JO6
Prinred ia Great Bri t r i n
RB211 TRENT
m MANUAL
(19) Curs the adhesive for I hour st 93 D e g , ~( 2 0 0 ~ e g . ~ ) .
(a) Use an explosion proof h e s t lamp
(20) Make the repair area f l u s h
(a) R e m o v e the OMbt 2 9 9 3g?LON TAPE.
Cb) O8e O M a t 5/38 PgTCASfVF: PAPER

to abrade the adhsaive
on the outer surface flush to thta contour of the
outer barrel.
(c) Use caution not to damage the outer barrel p l i e s .
6211 Tap taet the part to find diebond ( R e f . SRI4 TASK 54 -01-
06) m
(a) Do not mark or damage the surface. A ehangm In mound

that the tool makes will ethow where the dltrpbond i 6 .
(bl Make aure there are no voids in the patted core.
(C) ~f voids are found, i n j e c t additional adhesive again

as nacesasry in referenes with step 4,A.(175 through
the perforatione on tha inner skin.
(d) Make sure that the core ham been filled enough by
tap testing again.
(22) Uue OMat 2/101 LfNT FREE CLDTH t o locally clean the rspair
mrea and w i p e dry before aolvant dries (Ref. M TASK 7 0 -
20-01-100-8021 ,
(23) Temporarily h a t a l l inner skin and outer skin doublers

(Fig. 201 Sheet 3 sad 4 1 ,
(a) Center the doublars w e t repair aurfaeea.
Ib) Alfgn aria match the pilot holes in the outer doubler
w i t h the 8 off ASP Eaatenar h o l e in the a i d e etrut
fitting.
(c) U s e clamps.
( 2 4 ) Drill and countereink eight h o l m for the s i d e s t r u t

fitting Eaetsnera Fn the outer doubler,
REPAfR N0.16
54-40-01
Page 207
Feb. 15/06
RB211 TRENT
(a) Use the side strut fitting holes, drill might 5,16 -
5 , 2 8 m 10.203 - 0 , 2 0 8 in.) diameter holes through
the outer doubler.
(bE Countersink hclea t o 9,80 -

1 0 , 0 6 m (0,386 0.396 -
in.) diameter on the outer surface of the outer
akin.
NOTE: Tha countersinks extend into t h e adhesive

filled area under the doubler.
(251 Drill and countersink the holes that r a i n in doubler

( P i g . 201 Sheet 3 and 4 1 .
(a) brill 4,83 -

4 , 9 0 nrm ( 0 . 1 9 0 -
1 9 3 in.) diameter
hole8 through the p i l o t holea the inner a k i n
doubler, outer barrel and outer skin doublar.
tb) Countersink halea on orstar doubles to 7 , 6 5

10,301 - 0,306 in.) diameter.
- 7,77 m
(26) Remove the doublers from inner and outer surface of outer
barrel.
( 2 7 ) Deburx the full sits holas in the inner and outer

doublers.
128) Increase the sight ASP fagtener holao to ramPve tha knife
edges in thm outer doubler,
(a) Drill C,99 -

7 , 0 6 mm ( 0 . 2 7 5 - 0 , 2 7 9 in. 1 diamatsr
holea in the outer doubler though the eight
fastener locations for t h e outer s t m t fitting.
Cb) Deburx the hoXee.
129) Prepare the Innar and Outer skin surfaces of the outor
barrel.
(a1 Use OMat 5/38 ABRASXVE PAPER to abrade the xepair

surfaces to r-ve the gloaay finieh of the graphite
skin.
CLOTH to l o c a l l y clean the repsir

1 3 0 ) Usa OKat: 2/201, LINT FREE
area and wipe dry before eolvent dries ( R s f . AMM TASK 70-
20-01-ioo-eoz) .
(31) Inatall the davblers
RTWAXR N0.16
54-40-01
Page 2 0 8
F e b . 15/06
RB211 TRENT
.(a) Apply a t h i n layer of OMat 8/154 AbHgSfVE t o the

repair mrfacee, U s a a clean metal spatula,
(b) Spread the adhesive at l e a s t 6,35 m (0.25 i n , )

larger than the dovblers t o be bonded. Use the
epatula to remove unwanted adhesive on repair
surfaces.
Ic3 Refsr to manufacturers i n ~ t m c t i o nfor control and

application oL OMst 8/X54 ADHESIVe, Obsetsve a l l
health and safety prscautione
(d) Apply a thin layer of OMst 8/54 AIImSfVg to the

doubler bonding ~ u r f a c eand use t h e spatula to
ramwe unwanted adhsieive fram surface.
1131) Position the doublers on the repair area
(a1 Canter t h e d o u b l e t s aver thm repair surfaces and

press firmly.
(b) Align and match ths holea d r i l l e d before.
(CS The mating muxfaces e m have a maximum gap of 0,25

mm I0.010 in.).
(a) Install temporary bolts a t some fastener locations

to stop the repair doublera from moving during the
installation of tha fasteners.
(b) Wet install the e i g h t ASP tsstensss at the a i d e

strut fitting positions (Ref. SRM TASK 5 4 - 0 2 - 1 0 ) .
{c) Use OMat 81154 A P H E S m and repair t h e P i n (ftarn 1 1 ,

Sleeve (Item 2 ) and Lock Cellar (Itam 3 5 . W e t
install t h e doubler fasteners that sgmafn (Item 21,
(It- 3 1 , 1 1 t a 4 ) and (Xtm 5 ) (Raf. SRM TASK 54-
02-16).
(d) Waehsr (ftm 5 ) i n s t a l l e d on the Fnner doubler side

on1y .
(e) Do not install the washer (Item 51 on the outer
doubler.
REPAfR N0.16
54-40-101
Page 2 0 9
Feb. 15/06
printed in Great Britain
R6211 TRENT
I[iiijl STRUCTURAL REPAIR
MANUAL
(g) Rafer to manufacturers inutructiona for control and

application of OMat 8/254 ADHESIVE. Observe a l l
h e a l t h and a a f e t y precautions.
(h) Remove the tamprary b o l t a and i n s t a l l tha

applicable fasteners that remain.
(i) R e K n r e y n w t m d adhemfve from the periphery.
FREE CLOTH to local-ly clean the raplair

(341 U s e OMat 2 J 1 0 1 bS?V
area and w i p e dry before solvent dxfea (Ref. AMM TASK 7 0 -
20-01-100-802).
(a) Make muse unwanted adheaivle is removed from the gap

between t h e inner doubler a d the s i d e atrut
fitting.
135) Cure the adhaa5ve for 1 hour at 93 beg,C 5200 Deg.P). Uae
an explosion proof heat lamp.
I361 U a s mat 5/38 ABRASXVg PAPER to abrade thm edges of the

repair doubler lightly.
(a) Wipe w i t h OHat 2/101 dry, c l a m LINT FREE CLOTFC to

ramove dust.
137) Cheek around the doublers tor disbond
(a) Tap teet the part ta ffnd diabond (Ref. SRH TASK 54-
01-06).
/bl Do not mark or damage the aurfaes. A change in m u d

t h a t the tool makea will show where t h e disbond i a .
Cc) Check the adjacent area around the edge of the

doubler installation for disbond.
Id) If disband is f b w d , continue to 4 . E (Part 21 of

t h i s repair.
(m1 Xf no diabond i r r found, complete the crtsp that:

folloore and continue the repair from 4 , a . ( 1 9 ) .
138) I n s t a l l the g i d e strut and fasteners again retafned at

4.A. ( 2 )
(a) Torqus tha nut to 18.08 to 2 3 . 4 7 Nm (166 to 190 IbF-

in).
REPAIR R0.16
54-40-01
Page 210
Feb. 15/06
Printed in Graat Rritsin
R6211 TRENT
MANUAL
B. Xnstall the additional Repair Paetenars - Part 2 (If

necsemary)
VQTE:; This part of the repair An to be performed if the area

of dksband axtenda more than the outer edge of t h e
repair doublers installed in Fart 1.
(1) Wse OHat 2/201 LXNT FREE CXIOTR to locally clean thm repair
area and w i p e dry before aolvent dries ( R e f . AHM TASK 7 0 -
20-01-100-802).
(1) Examine the area of Diebond
(a) Tap t e a t the part: to f i n d the disbond ( R e f . S W ThSK

54-01-06) .
Cb) Do nat mark or danrage the surface. A change fn sound
that t h e tool makes will show w h e r e the diabond in.
(c) Wse an OMat 261 TEMPORARY MARXER of contrasting

colout to make a mask t o outline the damaged arma an
the inner and outar surfaces,
(3) Drill pilot holes around the d i s b n d e d area
(a) UBB a drill of 3,175 mm (0.125 in.) dfmeter to

drill a row of holes 1 9 ' 0 5 mm ( 0 . 7 5 in.) outaide tha
marked area of disbond.
(b) Space tha faatanera 4 0 , 6 4

apat t ,
- SD,0 mm (1.6 - 2 . 0 in.)
(c) Drill through both sides of the panel.
(4) Drill p i l o t holas inside t h s dtsbonded area
(a1 Use a drill of 3,175 nm C0.125 in.) diameter t o

drill holee i n s i d e the diebonded area (Fig, 201
Sheet 3 a d 4 ) .
(h) Keap a hole spacing of 76,2 mm (3.0 in.) minimum

from sdjacent faatanere.
(c) D r i l l through both efdea of panel.
(5) Decore the holea
EFFECTIVZTY: TRENT REPAZR WD.16

54-40-01
Page 211
R Feb, l5 J 0 6
Printed i n Ersat Rrzt~in
RB211 TRENT
Ca) Make an "Ln or *hockey a t i c k * shaped tool From s

modified Allan Key t o o l , atainlese steel w i r e or
squivalent,
Ib) U e e a g u i d e templats far the hockey s t i c k tool ts

protect t h e face sheet of the panel.
{cl The hole in the template should be the aame size a e

the fastenar hale drilled before.
{d) C a r e f u l l y s t a r t ta remove the core up to 19,05 mm

20.75 in.) dimater, Different langth of hockey
e t i e k tool may be necsasary t o get the full
diameter.
(a) Vacuum core rnsidueo from area.
(61 Use sn Olst 2/101LXWT FREE CXlOTR t o locally clean the

repair area and w i p e dry before salvent driem ( R e f . AHM
TASK 70-20-01-100-802) .
(7) Apply Tape
[a) Cover the lrolele w i t h O M a t 2 9 9 TEFZlOH TAPE to stop

adheaivr from expanding out o f t h s holes in the
perforated s k i n .
18) Inject adhesive into the fastenor holae in the f f s l d corm

area
(a) H i x OMat 8 / 1 5 4 ADHESIVE a8 per the manufacturer*^

instructions,
(b) Add 20 pmrcent v o 2 w e by weight of OKat 8 / 1 3 O FfBRRS

to the adhesive am a filler,
Ie) Refar ta manufacturers inetmetion far control and

application of OMat 8 1 1 5 4 ADHESIVE and OMat 8 1 1 3 0
FIBRES,
(d) Observe a l l health and aafety pxeeaution~,
(eE r n j e e t the ndhsaivs and fibre mixture into the

decored holes until. it: is fluah with the mutfecs.
(f) Tap the area around the petting t o r e m w a any

unwanted air.
REPAIR N0.16
54-40-01
Page 212
Feb. 15/66
Printed i n Grwst Britain
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(91 nae an OMat 2/101 ];TNT FREE CLOTH to locally clean the
repair area and wipe dry before solvent driee (Ref. AMH
TASK 70-20-01-100-802).
41-01 Cure the adhasivs for 1 hour a t 93 l3eg.c ( 2 0 0 ~eg.P). U s e

an explosion proof beat lamp.
(11) Wake the repair area flush
(a) Use mat: 5 / 3 8 ABRASW FAPER to abrade t h e adhesive

on the outer aurface flush to the contour of t h e
outmr barrel.
(b) Wae caution not to damage the outar barrel plias
( 1 2 ) Tap t ~ s tthe potted helea IRef, SRM TASK 54-01-06) .

a Tap test the part: to find disbond.
(b) Da n o t mark er damage the surfacs, A change in sound

thak the tool makes will slhaw w h e t s the disbund is.
(C) DO a tap t e s t around the potted hole locations t o

rnaks aura t h a t Eherle are no voids fn the p t t a d
car€i.
Id1 X f vofda are found, i n j e c t additional adhaniva again

aa neceesary in reference to step 4 . 8 . t B S through
the perforations i n the inner akin.
ie! Make eure that the core ham been filled enough by
another tap t e s t .
(13) Brill faetaner holea
(a1 Drill 1 , 8 3 - 4,90 m (0.190

h o l e 8 through the potting compound.
- 0,193 in,) diameter
114) Wae an OMat 2/101 Lf#T PREg CLOTH to clean the repair
eurfacmm and dauhlsrs ( R e f . AMM TASK 7 0 - 2 0 - 0 3 - 1 0 0 - 8 0 2 ) .
Ia) Wipe area dry before ~olventd r i e s .
(15) Install the rapair faetanars and waarhars ( F f g . 201 Sheet

3 , 4 and 5 ) (Ref. S W TASK 5 4 - 0 2 - 1 0 ) ,
REPAIR N0.16
54-40-01
Page 213
Feb. 1 5 / 0 6
P r i n t 4 i n G m r t Britain
RB21i(TRENT
STRUCTURAL REPAIR
(bj The pins are t o be wet installed from the outaide a£

the o u t e r barrel.
(c) Install pinm w i t h the waehare shown in view DD { F i g .

201 Sheet 5 ) .
(16) U s s an O M a t 2/101 LINT FREE CLOTH t o locally clean tha

repair area and w i p e dry before aolvant dries ( R e f . AMM
TASK 70-20-61-106-8023.
(17) CtZra the adhasrive for 1 hour n t 93 D9g.C 1200 Deg.F). Uate
an explosion proof heat lamp.
(18) Install the efde strut and faatmnere again rstained at

4 . B . (1)
(a) Torque t h e nut to 18.08 to 21.47 Wm (160 to l90 lbf-

in) .
(19) Paint the Repair Area
{a) Locally prepare and clean the repair area t o be

paintd.
11 Lightly abrade the area to be pePnted w i t h m a t

5 / 3 8 ABaASZvE PAPER,
21 Remove debria and unwanted materials. Wsa an

OMat 2/101 LfNT FREE CLOTH { R e f . AMK TASK 700-20-
01-loo-eoa) .
3) Wipe area d r y before eolvent dries.
tb) P s i n t the exterior surface of Doubler (Optional, do

thia step only if the repair area ia t o ba paintod
to match the colour schame of t h e CNAl Refer to
4 .X. 1 3 0 ) , Repair Part I.
11 A p p l y a f i n a l coat of OHat 81238 BR127 PR= to

t h e w t s r doubler.
2) Apply paint to the exterior taarface OF the

doubler.
3) If repair Part 2
warn implemented spply p a i n t to
the outer surface of the outer barrel. if t o
match t h e eolour echeme of t h e a i r c r a f t .
EFFECTLVITY :TRENT REPAfR NB.36

54-46-01
Page 2 1 4
Feb. 1 5 / 0 6
RB211 TRENT
Iw( STRUCl U R N REPAIR
MANUAL
KC: P r i m e r m e t be applied to the doubler before

the paint e m be applied,
( 2 0 ) Examine the Completed Repair
Is) Du a ViauaL fnepection of the Repair.
1) Do an Inepsction of t h s completed rapair t o make

g w e it obeys compliance with tha requfrsments
of this repafs.
2) Maka sure the ASP fastenere are fitted to t h e

repframenta of SRM TASK 5 4 - 0 2 - 1 0 Fastener
ramoval/installation.
(b) Calculstm the a e w n t i e treatment: area braekage
11 To ealculats thgl A c m s t l c Treatment blockage use

the Formulae that folluws:
Acnuetic Treatment B l o c k a g e (in.eq) r CfL x W ) - 4 4 in.uq1 4 0.916 x N
Acaustic Treatment Blockaga Cm.aq) m [(L x W] - 28307 nrm.sq1 + 591 x rJ
L r Is ths length of the P n n m r repair doubler 5n the Eomard/aft

diree tion
W = Is the width df the inner repair doublet measuxed
circumfarentially
N = The number of additional faeteners inetalled in Part 2 of t h i e

repair
The blockags maximum a r e a nllowed is 148400 m . a q I 2 3 0 in.nq).
M a k m a note of the blockage axea and make a r e it is n o t more than

the liait.
(213 Xdantffy the Rspair
( 1 Mark FRS3932 on the Idantiffeation P l a t e of the m
EPFEmIVITY: TRENT REPAIR NO. 16

54-40-101
Page 215
R Feb. 15/06
Printcd in Grcmr Britain
Rapnir Details and Dirnensfone
Pig. 201 (Sheet 1)
EFFBCTrnTY: TRENT REPAIR NO.16

54-40-101.
Page 216
Peb. 15/06
Print& i~ Crcar B r i t a i n
R8211 TRENT
STRUCTURAL REPAln
m MANUAL
Repair D e E a i L e and Piraension~

Fig. 201 ( S h e e t 2)
EFFEmWITY: TRENT REPAIR NQ.16

54-40-01
Page 217
R Feb. 1 5 / 0 6
Printed in Oreat Britain
RB211TRENT
STRUCTURAL REPAIR
MANUAL
EDGE OF DISBOND
1 .&2.0in.
(40.64.50,B mm)
@I ,' 3 l.lA In.

28.95 mm)
OUTER REPAIR
DOUBLER
7p 0.62 in. (0'5 mm)

0.063 in.
0.02 in.
(0,5tmm) ".ym""' / 7 G 5 a
0
PI
CV
m
L/
I
4 CT BOND PANEL'
SIDE WPICAL
? A- d l ALL PLATES
2 (WP.LEADING AND TRAILING EDGES) B-B
k
Repair D e t a i l s and D h e n s i o n a
F i g . 201 (9hemt 3 )
REPAIR N0.16
54-40-01
Page 218
Feb. 15/06
Printed in Groat Britain
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
0.75 In.
tlB,Ob mm) 3.0 h.
0 MINIMUM
@ (19,05 mm
0.75 h.
{10,05 mm}
: m
1 L
1 .Q in.
I , # L
/ @ (25C mm)
MlNlMUM
-=W
""I". W
>
1
1.20 in.
(30,4a
MIN. P
mm)
P)
\BOUNDARY OF
HK3H DENSITY
...C
>$;y
C
0.063 In.
1
-
MNER REPAIR
DOUBLER
BOND PANEL
F
L SIDE TYPiCAL
$ 7
0
P A- A
f ALL PLATES
8-8
Q WP-L€AOlNO AN0 TRALfN6 EDGES)
I
E

Fig. 201 ( S h e e t 4 )
EFFeCT3TITY: TRENT REPAIR HO.16

54-40-01
Page 219
Feb. 1 5 / 0 6
R8211:TRENT
STRUCTURAL REPAIR
MANUAL

F i g . 201 {Sheet 5 )
REPAXR m, 16
54-40-61
Page 220
Feb. 15/06
R6211 TRENT
STRUCTURAL REPAIR
H O C K M STICK
DUUBLE SIDED TOOL (REF)
l PLUG IF REOUIRED 1
0.75 INCH DIAMFER-
Rapair D~tailsand Dhanadona

P i g . 201 (Sheet 6 )
REPAIR N0.16
54-40-01
Pagei 221
Feb. 1 5 / 0 6
Ptintud f a Great B r i t a i n
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
REPAIR No. 17
REPLACE SIDE STRUT INNER FITTINGS
FRSY03 6
1. General
A. This repair gives the procedure to replace the Side Strut Inner
Fittings on the Common Nozzle Assembly.
.......................................................................
SRM 54-02-10 Fastener Installation and Removal
AMM 70-20-01-100-802 Cleaning

Riveting equipment
Vibro peening equipment
.......................................................................
OMat 8/52 Adhesive
OMat 8/143 Sealant
OMat 87 6C Primer
OMat 8/32 Release Agent
.......................................................................
PART IDENT MATERIAL
........................................................................
Side Strut Inner Fitting 17-4PH CRES, H900
RAPAIR NO. 17
EFFECTIVITY: TRENT
54-40-01
Page 201
Printed in Great B r l t a ~ n Mar. 10/08
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
D. R e p a i r Parts
.......................................................................
ITEM PART NO. PART I D E N T I F I C A T I O N
.......................................................................
1 HLllV-6-7 Pin
2 HL97DU6 Collar
3 CR3522-5-5 Rivet, Blind
4 FK16662 Inner F i t t i n g
5 HL10V-12-16 Pin
6 MS21043-6 Nut
7 KJT816906V Washer
8 FK16744 Bushing
9 MS21141U0604 Rivet, Blind
10 FK16664 Laminated Shim
11 FK16667 Laminated Shim
4. Procedure (Fig. 2 0 1 , 2 0 2 and 2 0 3 )
A . R e m o v e t h e Side S t r u t ( F i g . 2 0 1 , 2 0 2 and 2 0 3 )
( 1 ) R e m o v e t h e l o c k n u t s , p i n s and w a s h e r s t h a t a t t a c h t h e Side
S t r u t t o t h e I n n e r and O u t e r F i t t i n g s
( 2 ) R e m o v e t h e bushings.
( 3 ) R e m o v e and r e t a i n t h e Side S t r u t .
B . R e m o v e t h e I n n e r F i t t i n g ( F i g . 2 0 1 , 2 0 2 and 2 0 3 )
(1) R e m o v e t h e fasteners t h a t a t t a c h t h e I n n e r F i t t i n g t o t h e
P r i m a r y N o z z l e assembly. R e f e r t o SRM TASK 5 4 - 0 2 - 1 0
C A U T I O N : THE L I Q U I D S H I M MAY B E BONDED T O THE PRIMARY NOZZLE

ASSEMBLY, DO NOT ATTEMPT TO REMOVE I T .
( 2 ) C a r e f u l l y r e m o v e t h e I n n e r F i t t i n g and a t t e m p t t o save any

l a m i n a t e d o r liquid s h i m .
NOTE: T h e l a m i n a t e d s h i m m a y need t o be replaced w i t h t h e

r e p l a c e m e n t Inner F i t t i n g .
C . Make a T e m p l a t e of t h e I n n e r F i t t i n g
( 1 ) U s e t h e r e m o v e d I n n e r F i t t i n g t o m a k e a t e m p l a t e t h a t can be
used t o d e t e r m i n e fastener h o l e p o s i t i o n s w h e n d r i l l i n g t h e
fastener h o l e s i n t h e r e p l a c e m e n t I n n e r F i t t i n g .
R A P A I R NO. 17
EFFECTIVITY: TRENT
54-40-01
Page 202
P r l n t e d in Great Brltaln M a r . 10/08
RB211 TRENT
STRUCTUAL REPAIR
MANUAL
D. Clean t h e r e p a i r a r e a and remove s e a l a n t
(1) R e f e r t o AMM TASK 70-20-01-100-802. Remove r e s i d u a l s e a l a n t

from t h e r e p a i r a r e a . Wipe t h e r e p a i r a r e a d r y b e f o r e t h e
solvent evaporates.
E. Temporarily i n s t a l l t h e replacement I n n e r F i t t i n g ( F i g . 201, 202

and 203)
(1) Temporarily i n s t a l l t h e replacement I n n e r F i t t i n g ( i t e m 4 ) .

P l a c e t h e I n n e r F i t t i n g o v e r t h e o r i g i n a l mounting p o s i t i o n .
S l i d e t h e S i d e S t r u t i n t o t h e I n n e r and Outer F i t t i n g .
( 2 ) U s e new o r s e r v i c e a b l e hardware t o a t t a c h t h e S i d e S t r u t t o t h e
I n n e r and Outer F i t t i n g b u t u s e a non-locking n u t on each p i n .
F. Measure t h e gap between t h e replacement I n n e r F i t t i n g and t h e

o r i g i n a l mounting s u r f a c e on t h e Primary Nozzle Assembly.
(1) Ensure t h e I n n e r F i t t i n g i s i n t h e c o r r e c t p o s i t i o n o v e r t h e
o r i g i n a l mounting p o s i t i o n .
(2) Check and measure t h e gap between t h e I n n e r F i t t i n g and t h e

o r i g i n a l mounting s u r f a c e on t h e Primary Nozzle Assembly.
a) For gaps up t o 0.030 i n . (0,762 mm) OMat 8/52 a d h e s i v e w i l l

b e u s e d a s a l i q u i d shim.
b) For gaps 0.030 i n . t o 0.090 i n . ( 0 , 7 6 2 mm t o 2,286 mm)

l a m i n a t e d shims ( i t e m 1 0 & 11) w i l l b e u s e d i n combination
w i t h l i q u i d shim. L i q u i d shim must be l i m i t e d t o 0.030 i n .
( 0 , 7 6 2 mm) maximum t h i c k n e s s when u s e d w i t h t h e l a m i n a t e d
shims.
c) A d j u s t o r t a p e r t h e shims a s r e q u i r e d .
G. D r i l l f a s t e n e r h o l e s i n t h e replacement I n n e r F i t t i n g ( F i g . 202 and

203)
(1) With t h e replacement I n n e r F i t t i n g t e m p o r a r i l y i n s t a l l e d on t h e

S i d e S t r u t t r a n s f e r d r i l l l o c a t o r marks, where f a s t e n e r h o l e s
a r e a c c e s s i b l e , from t h e e x i s t i n g s t r u c t u r e o n t o t h e I n n e r
Fitting.
( 2 ) Remove t h e S i d e S t r u t from t h e I n n e r and Outer F i t t i n g .
( 3 ) Remove t h e I n n e r F i t t i n g from t h e r e p a i r a r e a .
RAPAIR NO. 17
EFFECTIVITY : TRENT
54-40-01
Page 203
Printed i n Great B r l t a i n Mar. 10/08
p
"" RB211 TRENT
MANUAL
STRUCTUAL REPAIR
R (4) Use the template made at Step C to mark the position of any
R remaining fastener holes on the Inner Fitting.
R
R (5) Drill 0.191 in. to 0.195 in. (4,85 mm to 4,90 mm) diameter
R holes through the Inner Fitting for Hi-Lok pins (item l) .
R
R (6) Drill 0.160 in. to 0.164 in. (4,06 mm to 4,16 mm) diameter
R holes through the Inner Fitting for rivets (item 3).
R
R (7) Drill 0.199 in. to 0.202 in. (5,051mm to 5,13 mm) diameter
R holes through the Inner Fitting for rivets (item 9 )
R
( 8 ) Countersink the holes for item 1 and item 3.
(9) Deburr all drilled holes and countersinks.
R H. Drill fastener holes in the Laminated Shims (if required)

R
R (1) Use the replacement Inner Fitting as a template to transfer
R drill the hole positions into the laminated shims.
R
R I. Clean the repair area.
R
R
(1) Refer to AMM TASK 70-20-01-100-802. Wipe area dry before the
R
R J. Apply Liquid Shim as required (Fig. 202 and 203)
R
R (1) Apply OMat 8/32 release agent to the mating surface of the
R replacement Inner Fitting and Primary Nozzle Assembly or if
R laminated shims are required, apply release agent to the mating
R surface of the laminated shims and the Primary Nozzle Assembly.
R
R (2) Mix OMat 8/52 liquid shim to the manufacturer's instructions
R and apply to the Primary Nozzle Assembly. Apply sufficient
R adhesive to eliminate the gap measured in Step E.
R
R
( 3 ) Temporarily install the replacement Inner Fitting and laminated
R shims (if required) .
R
R
(4) Apply OMat 8/32 release agent to temporary fasteners and use
R
these to carefully secure the Inner Fitting to the Primary
R Nozzle Assembly without excessive squeezing of the liquid shim.
R Tighten the fasteners only tight enough to ensure complete
R
contact and elimination of any trapped air.
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.
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STRUCTUAL REPAIR
MANUAL
K T e m p o r a r i l y i n s t a l l t h e S i d e S t r u t ( F i g . 202 and 203)
(1) S l i d e t h e S i d e s t r u t i n t o t h e I n n e r and Outer F i t t i n g s . Take

care not t o d i s t u r b the Inner F i t t i n g .
(2) I n s t a l l t h e bushings ( i t e m 8) i n t h e replacement I n n e r F i t t i n g .
( 3 ) Check t h e b u s h i n g h o l e a l i g n m e n t i n t h e S i d e S t r u t b e a r i n g
hole.
a) Check t h e a l i g n m e n t v i s u a l l y o r by i n s e r t i n g t h e p i n through
t h e h o l e w i t h no p r e - l o a d t o t h e assembly.
b ) A d j u s t shimming i f r e q u i r e d .
(4) Remove t h e S i d e S t r u t from t h e assembly.
L. Cure t h e L i q u i d Shim
(1) Cure a t 190 t o 210 deg F . (88 t o 100 d e g C) f o r 120 m i n u t e s

U s e e x p l o s i v e p r o o f h e a t lamps.
NOTE: Remove any e x c e s s l i q u i d shim from t h e r e p a i r area b e f o r e

curing.
M. Clean t h e r e p a i r a r e a
(1) Remove t h e temporary f a s t e n e r s .
( 2 ) C l e a r t h e f a s t e n e r h o l e s and c o u n t e r s i n k s of any c u r e d
adhesive.
N. I n s t a l l t h e f a s t e n e r s ( F i g . 202 and 203)
(1) W e t i n s t a l l t h e r i v e t s ( i t e m 3 & i t e m 9 ) t h a t a t t a c h t h e I n n e r
F i t t i n g t o t h e Primary Nozzle Assembly. R e f e r t o SRM TASK 54-
02-10.
( 2 ) W e t i n s t a l l t h e p i n s ( i t e m 1) and c o l l a r s ( i t e m 2 ) t h a t a t t a c h
t h e I n n e r F i t t i n g t o t h e Primary Nozzle Assembly. R e f e r t o SRM
TASK 54-02-10
NOTE: U s e OMat 4 / 4 7 j o i n t i n g compound t o m a n u f a c t u r e r l s

instructions for w e t installation.
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R
0. I n s t a l l t h e S i d e S t r u t ( F i g . 202 and 203)
R
R
(1) I n s t a l l t h e b u s h i n g s i n t h e O u t e r F i t t i n g s .
R
R
( 2 ) S l i d e t h e S i d e S t r u t i n t o t h e I n n e r and Outer F i t t i n g s
R
R
(3) A t t a c h t h e S i d e S t r u t t o t h e I n n e r and Outer f i t t i n g s u s i n g P i n
R
( i t e m 5) Nut ( i t e m 6) and Washer ( i t e m 7) . Torque t i g h t e n t h e
R
n u t t o 160 t o 190 l b f . i n (18.08 t o 21.47 Nm)
R
R
P. Apply Aerodynamic s e a l a n t t o t h e e d g e s of t h e r e p l a c e m e n t I n n e r
R
F i t t i n g ( F i g 202 and 203)
R
R
(1) Apply OMat 876C p r i m e r t o t h e f a y i n g s u r f a c e of t h e f i l l e t
R
s e a l i n g a r e a . Refer t o manufacturers i n s t r u c t i o n s f o r mixing,
R
a p p l i c a t i o n and c u r i n g of t h e p r i m e r .
R
R
( 2 ) Apply OMat 8/143 s e a l a n t a s a f i l l e t bead a l l around t h e I n n e r
R
F i t t i n g . Refer t o manufacturers i n s t r u c t i o n s f o r mixing,
R
a p p l i c a t i o n and c u r i n g of t h e s e a l a n t .
R
R
Q. I n s p e c t and i d e n t i f y t h e r e p a i r
R
R
R
(1) V i s u a l l y i n s p e c t t h e r e p a i r t o make s u r e i t h a s been c a r r i e d
o u t i n accordance with t h e s e procedures.
R
R
R
(2) Vibro - e n g r a v e FRSY036 a d j a c e n t t o t h e assembly p a r t number.
RAPAIR NO. 17
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FIB211 TRENT
STRUCTUAL REPAIR
MANUAL
I
VIEW LOOKING AFT
INNER FITTING (4)
Common N o z z l e A s s e m b l y
S i d e S t r u t Inner F i t t i n g R e p l a c e m e n t
Figure 201
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RB211 TRENT
STRUCTUAL REPAl R
MANUAL
REMOVE AND INSTALL

ITEM 9 (5 PLACES PER FITTING) m
(D
-2
0
0
U
0)

Side Strut Inner Fitting Replacement
Figure 202
RAPAIR NO. 17
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RB211 TRENT
STRUCTUAL REPAIR
MANUAL
APPLY
SEALANT
ALL AROUND
ITEM 7
(2 OFF)
A-A
REMOVE AND INSTALL

ITEM 3
REMOVE AND INSTALL
ITEMS 1 AND 2
B-B
REMOVE AND
INSTALL
ITEMS 1 AND 2

Side Strut Inner Fitting Replacement
Figure 203
RAPAIR NO. 17
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RAPAIR NO. 17
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RB211 TRENT
STRUCTURAL REPAIR
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Repair No. 18
REMOVE AND INSTALL THE TROUGH FAIRINGS AND FASTENERS

FRSY03 4
1. General
A. This repair gives the procedure to remove and install the

Trough Fairings on the Common Nozzle Assembly.
B. For fairings that have 23 off CR3524 fairing rivets installed

at the original positions, this repair removes them and
installs ASP fasteners at the same location.
C. Assemblies may have 23 off CR3524 rivets relocated by previous

rework or other repair instruction, this repair removes the
relocated rivets and installs ASP fasteners at the original
production locations and fills the relocated positions with
adhesive.
D. After FRSY034 has been implemented, the repair is repeatable

without further need for fastener hole relocation.
.......................................................................
SRM 54-02-10 Fastener Installation and Removal
AMM 70-20-01-100-802 Cleaning
AMM 70-51-00-910-802 Torque Tightening Techniques

Bushing tool - Huck part number 103617
Standard plug gauge
Degreasing equipment
Explosion proof heat lamps
Sleeve driver - Huck part number 106524
Installation tools - Huck part numbers 200, 352, 229, 210 or
2702
Nose assembly - Huck part number 99-895
Vibro peening equipment
Repair 18
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RB211 TRENT
STRUCTURAL REPAIR
m MANUAL
.......................................................................
.......................................................................
OMat 8/52 Adhesive
OMat 5/38 Abrasive paper
.......................................................................
PART IDENT MATERIAL
.......................................................................
Trough Fairing Aluminium Alloy 2024-T42, 0.050 in. thick
Bond Panel Graphite Epoxy/ A1 honeycomb
D. Repair Parts

.......................................................................
1 FK16755 Trough Fairing, LH
2 FK16756 Trough Fairing, R H
3 ASPLCMVO 6 Collars
4 2ASPFFV06-12 Pins
5 ASPFSVO 6 Sleeves
6 NAS8702U1 Screws
7 NAS1738C6-3 Rivets
8 NAS1149C0332R Washers
4. Procedure (Fig. 201, 202, 203 and 204)
A. Do a visual inspection of the trough fairing to identify

fastener type and location (Fig. 201, 202 and 203)
(1) Inspect the CNA identification plate to determine if ASP

fasteners have previously been installed in accordance
with FRSY034.
(2) If CR3524 are installed, determine if they are in the

original or relocated positions.
B. Remove the screws (Fig. 201, 202 and 203)
(1) Use standard workshop tools. Remove the 24 off NAS8702U1

Screws (6) from each trough fairing. Retain the screws for
use as temporary fasteners in step H.
Repair 18
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STRUCTURAL REPAIR
MANUAL
R C. Remove t h e r i v e t s and washers ( F i g 201, 202 and 203)

R
R (1) U s e s t a n d a r d workshop t o o l s . Remove t h e 1 o f f NAS1738C6-3
R R i v e t ( 7 ) and 1 o f f S1149C0332R Washer ( 8 ) from e a c h
R t r o u g h f a i r i n g (Ref SRM 54-02-10).
R
R NOTE: The washer i s o n l y a p p l i c a b l e t o P o s t SB 78-D441
R s t a n d a r d of CNA.
R
R D. Remove t h e f a s t e n e r s ( F i g . 201, 202 and 204)
R
R NOTE: This s t e p i s only a p p l i c a b l e t o trough f a i r i n g s t h a t
R have n o t had FRSY034 p r e v i o u s l y a p p l i e d .
(1) U s e s t a n d a r d workshop t o o l s . Remove t h e 23 o f f CR3524-5-3

r i v e t s from e a c h t r o u g h f a i r i n g (Ref SRM 54-02-10).
(2) Remove t h e 1 o f f ASP f a s t e n e r from t h e f o r w a r d edge of

e a c h t r o u g h f a i r i n g . U s e a 3 / 7 9 mm (0.1562 i n . ) d i a m e t e r
d r i l l and d r i l l b u s h i n g t o o l - Huck p a r t number 103617 and
s t a n d a r d workshop t o o l s . Remove and r e t a i n t h e t r o u g h
fairings.
E. Remove t h e ASP f a s t e n e r s ( F i g . 201, 203 and 204)
NOTE: This s t e p i s only a p p l i c a b l e t o trough f a i r i n g s t h a t

have p r e v i o u s l y been r e p a i r e d t o FRSY034.
(1) Remove t h e 24 o f f ASP f a s t e n e r s from e a c h t r o u g h f a i r i n g .

U s e a 3 , 7 9 mm (0.1562 i n . ) d i a m e t e r d r i l l and d r i l l
b u s h i n g t o o l - Huck p a r t number 103617 and s t a n d a r d
workshop t o o l s . Remove and r e t a i n t h e t r o u g h f a i r i n g s .
F. I n s p e c t t h e trough f a i r i n g s
(1) U s e an a p p l i c a b l e s i z e d s t a n d a r d p l u g gauge. I f t h e
f a s t e n e r h o l e s have been damaged d u r i n g removal o r a r e
worn more t h a n 5 , 2 8 mm ( 0 . 2 0 8 i n . ) d i a m e t e r d i s c a r d t h e
fairing.
(2) D i s c a r d t h e f a i r i n g i f t h e 23 o f f f a s t e n e r h o l e s have been

relocated.
G. Clean t h e r e p a i r a r e a
(1) U s e OMat 2/101 l i n t f r e e c l o t h t o wipe t h e r e p a i r a r e a d r y

b e f o r e t h e s o l v e n t e v a p o r a t e s (Ref. AMM TASK 70-20-01-100-
802) .
R e p a i r 18
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STRUCTURAL REPAIR
MANUAL
D r i l l t h e f a s t e n e r h o l e s i n t h e t r o u g h f a i r i n g ( F i g . 201 and
203)
NOTE: This s t e p i s only applicable i f t h e trough f a i r i n g has

p r e v i o u s l y been i n s t a l l e d u s i n g CR3524 r i v e t s .
(1) U s e t h e s c r e w s r e t a i n e d i n s t e p B t o temporarily i n s t a l l
t h e trough f a i r i n g s i n p o s i t i o n . U s e t h e trough f a i r i n g s
r e t a i n e d a t s t e p D o r use r e p a i r p a r t s :
- FK16755 Trough F a i r i n g , L H
- FK16756 Trough F a i r i n g , R H .
(2) D r i l l t h e h o l e s f o r t h e ASP f a s t e n e r s . I f a new f a i r i n g i s

t o b e u s e d , d r i l l through t h e f a s t e n e r p i l o t h o l e s i n t h e
t r o u g h f a i r i n g and t h e common n o z z l e s t r u c t u r e . I f t h e
e x i s t i n g f a i r i n g i s t o b e u s e d , d r i l l through t h e e x i s t i n g
f a s t e n e r h o l e s and t h e common n o z z l e s t r u c t u r e . D r i l l 5,15
mm t o 5 , 2 8 mm (0.203 t o 0.208 i n . ) d i a m e t e r h o l e s .
(3) Remove t h e temporary f a s t e n e r s and remove t h e t r o u g h

f airings.
(4) C o u n t e r s i n k t h e ASP f a s t e n e r h o l e s i n t h e f a i r i n g s and

o u t e r b a r r e l i n n e r s k i n 100 Deg. by 1 , 9 8 mm ( 0 . 0 7 8 i n . ) .
Deburr t h e f a s t e n e r h o l e s .
F i l l t h e f a s t e n e r h o l e s i n t h e Outer B a r r e l ( F i g . 201 and 203)
NOTE: T h i s s t e p i s o n l y a p p l i c a b l e t o f a i r i n g s t h a t have had

CR3524 r i v e t s i n s t a l l e d i n r e l o c a t e d p o s i t i o n s .
(1) Clean t h e r e p a i r a r e a . U s e OMat 2/101 t o wipe t h e r e p a i r

a r e a d r y b e f o r e t h e s o l v e n t e v a p o r a t e s (Ref AMM TASK 70-
20-01-100-802).
(2) Use OMat 8/52 a d h e s i v e t o f i l l t h e r e l o c a t e d f a s t e n e r

h o l e s i n t h e o u t e r b a r r e l . The f i r s t of t h e 23 o f f e q u a l l y
spaced f a s t e n e r h o l e s t o be f i l l e d i s 0.90 i n . forward
from t h e r e a r edge of t h e t r o u g h f a i r i n g . I n j e c t t h e
adhesive i n t o t h e f a s t e n e r h o l e s u n t i l t h e adhesive i s
over f l u s h with t h e surrounding m a t e r i a l . Refer t o
m a n u f a c t u r e r s i n s t r u c t i o n s f o r mixing and a p p l i c a t i o n o f
t h e OMat 8/52 a d h e s i v e . Observe a l l h e a l t h and s a f e t y
precautions.
(3) Cure t h e a d h e s i v e a t 200 deg F (96 deg C ) f o r 1 h o u r . U s e

an e x p l o s i o n p r o o f h e a t lamp.
EFFECTIVITY: TRENT
54-40-01
Repair 18
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P r i n t e d in Great B r i t a i n M
,, i n / n ~
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
(4) Use OMat 5/38 abrasive paper to abrade the adhesive flush
with the surrounding material.
NOTE: Do not damage the plies of the outer barrel.
K Clean the repair area
(1) Use OMat 2/101 to wipe the repair area dry before the
solvent evaporates (Ref AMM TASK 70-20-01-100-802).
L. Install the trough fairings (Fig. 201, 203 and 204)
(1) Put the fairings in the correct position. Install the 24

off NAS8702U1 screws (6) in each fairing. TORQUE to
between 14.0 and 15.0 in.lbs (Ref AMM TASK 70-51-00-910-
802).
(2) Install the 1 off NAS1738C6-3 rivet (7) and 1 off

NAS1149C0332R washer (8) in each fairing. (Ref. S W 54-02-
10).
NOTE: The washer is only applicable to Post SB 78-D441

standard of CNA.
(3) Wet install the 24 off ASP fasteners in each fairing (Ref
S W 54-02-10)
(a) Use Omat 4/47 jointing compound and repair items:
- ASPCMV06, Collars (item 3 )

- 2ASPFFV06-12, Pins (item 4)
- ASPFSVOG, Sleeves (item 5)
(b) Use ASP fastener installation tools:
- Sleeve Driver - Huck part number 106524

- Installation tools - Huck part numbers 200, 352,
229, 210 or 2702
- Nose assembly - Huck part number 99-895.
(c) Refer to manufacturers instructions for control and

application of OMat 4/47 jointing compound. Observe
all health and safety requirements.
54-40-01
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P"" RB211 TRENT
MANUAL
STRUCTURAL REPAIR
M. Examine the r e p a i r .
(1) Do a v i s u a l inspection t o make sure a l l the procedures

contained i n t h i s repair have been completed
s a t i s f a c t o r i l y . Make sure a l l the f a s t e n e r s are f i t t e d
correctly.
N. I d e n t i f y the repair
(1) Use vibro-peening equipment. Engrave FRSY034 on the

i d e n t i f i c a t i o n p l a t e of the Common Nozzle Assembly.
54-40-01
Repair 18
Page 206
.
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
Repair Details
Fig. 201
54-40-01
Repair 18
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RB211 TRENT
STRUCTURAL REPAIR
MANUAL
C-C
4>$=({ { E f ; F \ ' ~ \ - l ; ~
R e p a i r Details
F i g . 202
R e p a i r 18
P a g e 208
Printed in Great Britain M a r . 10 / O B
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
Repair Details
Fig. 203
54-40-01
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P r i n t e d i n Great. B r i t a i n Mar. 10/08
RB211 TRENT
STRUCTURAL REPAIR
MANUAL
DRILL 3,97mm (0.1562 in.) DIA

/
HUCK
l
LOCK REMOVAL
PIN IS INSERTED LOCK COLLAR HUCK INSTALLATION HUCK INSTALLATION

FROM ONE SIDE OF IS PLACED TOOL LOCKS FASTERNER TOOL BREAKS
THE WORK. SLEEVE OVER PINTAIL. IN PLACE. PINTAIL FLUSH
IS PLACED OVER AT THE SHEET LINE.
PlNTAlL AND TIGHTENED
INTO POSITION. INSTALLATION SEQUENCE
Repair Details
Fig 204
Repair 18
Page 210
P r l n t e d i n Great B r i t a i n Mar 1 n / O R
All enquires regarding this manual
should be addressed to:-
TECHNICAL PUBLICATIONS DEPARTMENT

ROLLS-ROYCE plc
DERBY
PO BOX 31 : DERBY : ENGLAND DE24 8BJ

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H RB.

NACELLE DIMENSIONS AND STATIONS

A. Refer to Figure 1 for nacelle primary dimensions.

A. Refer to Figure 2 for nacelle stations.

STA Station - a vertical plane, perpendicular to the longitudinal

WL Waterline - a horizontal plane, parallel to the horizontal

1371 m m 1676 mm 2489 m m 1778 mm

NOTE: All dimensions are approximate

Nacelle Primary Dimensions

STA STA STA STA STA STA

NOTE: Station lines are identical WL 150

NACELLE ZONES AND PANELS

1. General (Refer t o Figures 1 t o 4)

A . The s u r f a c e of t h e n a c e l l e i s divided i n t o zones and sub zones t o h e l p

B. Each panel has a unique i d e n t i t y r e f e r e n c e , derived a s follows:

(1) The f i r s t c h a r a c t e r i s always 4 , which shows n a c e l l e .

(2) The second c h a r a c t e r shows l e f t (1) o r r i g h t (2) n a c e l l e .

( 3 ) The t h i r d c h a r a c t e r shows the n a c e l l e zone.

(4) The f o u r t h c h a r a c t e r , a l e t t e r , shows the panel sequence i n t h a t zone.

(5) The f i f t h c h a r a c t e r , a l e t t e r , shows t h e l e f t (L) o r t h e r i g h t (R) s i d e

C. A i r i n t a k e cowl a c c e s s doors, l e f t wing n a c e l l e

(1) 411AL Thermal Anti-Icing System

(2) 411AR P2T2 Probe

D. Fan cowl doors, l e f t wing n a c e l l e

(1) L e f t hand 415AL

( a ) 415BL Pressure Relief and S t a r t e r Valve

(b) 415CL I D G O i l F i l l and Level

( 2 ) Right hand 416AR

( a ) 416BR Hydraulic F i l t e r Pop-up I n d i c a t o r and Master Chip Detector.

(b) 416CR O i l F i l l and Level

E. Thrust Reverser C-duct, l e f t wing n a c e l l e

(1) Left s i d e 417AL

(a) 417BL Thrust Reverser Door P o s i t i o n I n d i c a t o r

(b) 417CL Thrust Reverser Door Pivot

(c) 417DL Hinge Access Cover

(d) 417EL Hinge Access Cover (No.5 Binge)

(e) 417m Upper Door I n h i b i t i o n Bolt Attachment Cover

( f ) 417GL Lower Door I n h i b i t i o n Bolt Attachment Cover

(a) 418BR Thrust Reverser Door P o s i t i o n I n d i c a t o r

(b) 418CR Thrust Reverser Door Pivot

(c) 418DR Hinge Access Cover

(d) 418ER Hinge Access Cover (No.5 Hinge)

(e) 418FR Upper Door I n h i b i t i o n Bolt Attachment Cover

( f ) 418GR Lower Door I n h i b i t i o n Bolt Attachment Cover

(g) 418HR Latch Access Door, Forward

(h) 418IR Latch Access Door, Rear

F. A i r i n t a k e cowl a c c e s s doors, r i g h t wing n a c e l l e

(1) 421AL Thermal Anti-Icing System

(2) 421AR P2T2 Probe

G. Fan cowl doors, r i g h t wing n a c e l l e

(1) Left hand 425AL

(a) 425BL Pressure Relief and S t a r t e r Valve

(b) 425CL IDG O i l F i l i and Level

(2) Right hand 426AR

(b) 426CR Oil Fill and Level

H. Thrust reverser C-duct, right wing nacelle

(a) 427BL Thrust Reverser Door Position Indicator

(b) 427CL Thrust Reverser Door Pivot

(c) 427DL Hinge Access Cover