DG Flugzeugbau DG-1000 Operating instructions

R E P A I R M A N U A L
F O R S A I L P L A N E S A N D M O T O R G L I D E R S
DG-1000
T Y P E : D G - 1 0 0 0
V A R I A N T : D G - 1 0 0 0 S
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D G - 1 0 0 0 M
T C D a t a S h e e t N o . : E A S A . A . 0 7 2
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DG Flugzeugbau
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FLUGZEUGBAU GMBH

Repair manual DG-1000
Issued December 2010 0.1
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
0General
0.1 Amendments
No.
Page
Description Date
1
all Combination of the initial repair manuals of the Variants DG-1000S
and DG-1000T, inclusion of variant
DG-1000M, new standardized format
December
2000
2 2.1, 4.1 – 4.3, 5.1,
5.3, 6.3 Miscellaneous changes to the contents of the latest amendments of the initial
repair manuals
December
2010

Repair manual DG-1000
Issued December 2010 0.2
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
0.2 List of effective pages
Section
page
issued replaced / replaced / replaced /
0
0.0 December 10
0.1 "
0.2 "
0.3 "
1
1.1 December 10
2
2.1 December 10
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3.1 December 10
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4.1 December 10
4.2 "
4.3 "
5
5.1 December 10
5.2 "
5.3 "
6
6.1 December 10
6.2 "
6.3 "

Repair manual DG-1000
Issued December 2010 0.3
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
0.3 Table of contents
Section Content page
0 General.....................................................................................................0.1
0.1 Amendments ............................................................................................0.1
0.2 List of effective pages..............................................................................0.2
0.3 Table of contents......................................................................................0.3
1 Preface......................................................................................................1.1
2 Repairs of composite structures, General................................................2.1
3 Tools and facilities required ....................................................................3.1
4 Material list for FRP repairs ....................................................................4.1
4.1 Resinsystems for repairs..........................................................................4.1
4.2 Fibre glass fabric......................................................................................4.1
4.3 Fibre Glass Rovings.................................................................................4.1
4.4 Carbonfibre tape.......................................................................................4.1
4.5 Carbonfibre rovings.................................................................................4.1
4.6 Diolen fabric ............................................................................................4.1
4.7 Carbonfibre fabric....................................................................................4.2
4.8 Foam.........................................................................................................4.2
4.9 Tubus – core.............................................................................................4.2
4.10 Paint .........................................................................................................4.2
4.11 Glue for Plexiglas ....................................................................................4.3
4.12 Filler.........................................................................................................4.3
4.13 Sources for material.................................................................................4.3
5 Instructions for FRP repairs.....................................................................5.1
5.1 General.....................................................................................................5.1
5.2 Repairs of a FRP shell..............................................................................5.1
5.3 Repairing the outer skin of a foam sandwich panel................................5.1
5.4 Repair of outer and inner skin of a sandwich panel.................................5.2
5.5 Repair of a sandwich panel with tubus core (fuselage)...........................5.2
5.6 Repairing small dents in a sandwich panel skin (no cracks in the gelcoat)
..................................................................................................................5.2
5.7 Outer skin finish.......................................................................................5.3
5.8 Repairing control surfaces.......................................................................5.3
5.9 Engine bay insulation...............................................................................5.3
6 Types of materials and overlap dimensions.............................................6.1

Repair manual DG-1000
Issued December 2010 1.1
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
1Preface
The purpose of this repair manual is to provide basic repair instructions for
minor damage to GFRP and CFRP gliders. (Glass and Carbon fibre
reinforced plastics). Detailed information regarding all the processing of
GFRP and CFRP is not given in this manual assuming that all repair work
will only be carried out by people with practical knowledge in the use of
these materials.
The repair of gliders should not be used to learn FRP laminating
techniques.
Before beginning any repair work carefully determine what materials, tools,
jigs and repair methods are to be used. The required information can be
found in this manual. To insure that the aircraft performance is maintained,
the surface finish of the repair work should be of the same quality as the
original finish.
When doubts arise as to the repairability of damage, the DG Flugzeugbau
factory should be contacted for further information.
The information in this manual refers only to repairs of minor damage like
holes in the underside of the fuselage resulting from a wheel up landing, or
damage from hangar accidents etc, see section 2.
Major damage which is outside the scope of this manual should only be
repaired by a certified repair station or by an approved mechanic rated for
composite aircraft structure work.
Note: For repair- and servicing work on parts of the equipment and for
motorgliders on the power plant, the instructions in the maintenance manual of
the aircraft and the manuals belonging to the equipment parts are to be followed.

Repair manual DG-1000
Issued December 2010 2.1
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
2Repairs of composite structures, General
Caution: You are only allowed to use the materials specified in section 4.
Use only genuine spare parts.
Warning: Major damage which is outside the scope of the list below should
only be repaired by a certified repair station rated for composite aircraft
structure work.
For all aircraft under EASA regulations the following applies: According to part
21, subpart M to accomplish major repairs an approved repair instruction is
required, see also TN DG-G-01 “Approved repair methods according to EU
Commission Regulation 1702/2003 part 21, subpart M”
Definition of minor damage:
a. All damage to paint and fillers.
b. Holes on the belly of the fuselage if the maximum diameter does not
exceed the following:
Forward fuselage 80 mm
Aft boom 40 mm
Cracks in the belly maximum length:
Forward fuselage 120 mm
Aft boom 80 mm
The blind glue joints of the fuselage boom should not be damaged.
c. Holes, cracks and blisters in the wings, tail, and control surfaces, not in
excess of the following dimensions:
Diameter Length
Wings 100 mm 150 mm
Stabilator 50 mm 80 mm
Aileron 50 mm 80 mm
Rudder 50 mm 80 mm
The parts must not be damaged in the spar area.
d. Replacement of bent fittings (part No.’s see diagrams in the maintenance
manual).
Caution: Damaged fittings should not be repaired but must be replaced.
Note: Special hints for handling FRP repairs are found in the Petite Plane Patch
Primer (Author U. Hänle).

Repair manual DG-1000
Issued December 2010 3.1
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
3Tools and facilities required
Tools
-Accurate weighing scales for the correct mixing of resin and hardener
-Containers and wood mixing sticks
-Brushes (short hair) to apply the resin
-Metal roller to press down the glass cloth and to force the air out to reduce
the formation of bubbles
-Scissors to cut the fabric
-Adhesive tape
-Plastic film for a tempering tent
-Hot air blower
-Abrasive paper - various grades
-Knife
-Saw to cut tough plastic
-Rubber hand gloves
-Accurate thermometer up to 60°C (140° F)
Facilities
To insure proper curing, the room temperature during repair work and at
least 12 hours afterwards should be maintained at 21°C (70° F). After that
the repaired parts are to be tempered. Therefore you may construct a
tempering tent, using plastic film or Styrofoam plates.

Repair manual DG-1000
Issued December 2010 4.1
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
4Material list for FRP repairs
4.1 Resinsystems for repairs
Resin with Hardener mixing ratio by weight
Momentive EPIKOTE
TM
Resin MGS LR 160 (L
160)
EPIKURE
TM
Curing
Agent MGS LH 160 100:28
or
Momentive EPIKOTE
TM
Resin MGS LR 285 EPIKURE
TM
Curing
Agent MGS LH 286 100:40 +2
or
Momentive EPIKOTE
TM
Resin MGS LR 385 EPIKURE
TM
Curing
Agent MGS LH 386 100:35 +2
The repaired areas must be tempered for 20 hours at a min. of 54°C
(129°F) before the next take-off.
Caution for variant DG-1000M: The engine bay walls shall be repaired only
with LR 160/LH 160.
4.2 Fibre glass fabric
Interglas No. US-No. Weave Weight (g/m²)
90 070 1610 Linen 80
92 110 -.- Twill 163
92 125 -.- Twill 280
92 130 -.- Linen 390
92 140 -.- Twill 390
92 145 180-150 unidirectional 220
All fabrics - finish I 550 or FK 144
4.3 Fibre Glass Rovings
Gevetex EC-10-2400 K 92 with Silan finish
4.4 Carbonfibre tape
Sigri KDU 1009 7.5 cm (3 in) wide
4.5 Carbonfibre rovings
TOHO or TENAX HTA 24000 or TENAX HTS 24000
4.6 Diolen fabric
C. Cramer style 14 K (158 g/m²)
(as core in the ailerons of the outboard wings and in the trailing edges of
the stabilizer and the wings in the aileron region)

Repair manual DG-1000
Issued December 2010 4.2
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
4.7 Carbonfibre fabric
Weight g/m² Weave Manufacturer Type
fabric with fibres HTA 3000
appr.205 Linen Sigri KDL 8003
Interglas 98140
C. Cramer C 450
appr.205 Twill Sigri KDK 8042
Interglas 98141
C. Cramer C 452
appr.245 Twill Sigri KDK 8043
Interglas 981541
C. Cramer C 462
appr.120 unidirectional Linen Interglas 04387
C. Cramer Style 763
fabric with fibres M40JB 6000 (high modulus) (Inboard ailerons)
appr.200 Linen Sigri KDK 8040/T
4.8 Foam
Diab GmbH Divinycell H 60 colour green
Röhm GmbH Rohacell 51 colour white
Rohacell 71 colour white
(only for the shear web of the wing spar).
4.9 Tubus – core
Tubus Bauer Tubuswaben B 6 6mm thick, colour grey or white (as core
in the fuselage tail boom)
4.10 Paint
UP (Polyester Gelcoats)
AkzoNobel UP Schwabbellack 4292352 (0369066) with hardener
0720510
mixing ratio: 100:2
up to 10 % thinner 0630260 may be used.
or
Momentive T35 with hardener SF 2
mixing ratio: 100:2-3
up to 10 % thinner SF may be used.
or (available in the USA)
Simtec Prestec 2781 Super White Polyester Coating with catalyst
D MEKP UN3105
mixing ratio: 100:2, no thinner
or
PUR paint
if such paint was optionally applied.

Repair manual DG-1000
Issued December 2010 4.3
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Fire resistant paint for engine bay: see section 5.9
4.11 Glue for Plexiglas
To attach the canopy:
Glue Henkel Teroson Macroplast UK 8303 B60
Hardener Henkel Teroson Macroplast UK 5400
Mixing ratio: 6 : 1 by weight
or
4,4 : 1 by volume
thickened with Aerosil.
To repair cracks in the canopy:
Röhm Acrifix 192 which hardens by exposure to light.
4.12 Filler
For glueing, the resin-hardener mix should be thickened with chopped
cotton fibres FL l f. (add enough so that the resin no longer flows). The
surfaces to be glued should previously be wetted with non-thickened resin
+ hardener.
To glue foam pieces into place when repairing sandwich sections and to fill
in irregularities and gaps etc. around the repair, Microballoon BJO - 0930
can be used mixed with the resin + hardener. Application and mixing is the
same as for the cotton flocks.
4.13 Sources for material
All materials can be obtained from the DG Flugzeugbau Factory.

Repair manual DG-1000
Issued December 2010 5.1
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
5Instructions for FRP repairs
5.1 General
See also section 2 and 3.
Only materials listed in section 4 should be used.
Only damage defined in section 2 should be repaired.
Cut out damaged area, roughen the surrounding area for the overlap
required (see section 6).
Repairs should be made such that bonding is wet over dry. Specific details
concerning handling and using fibre reinforced plastics can be obtained
from various publications ie. "Petite Plane Patch Primer."
The use of Carbonfibre is the same as for glasfibre, except that the
Carbonfibres should not be kinked.
All repairs should be postcured for 20 hours at 54°C (129°F) before the
next take off.
5.2 Repairs of a FRP shell
Prepare the repair area as specified above. Scarf the shell so that the
individual layers of fabric can be seen like plywood layers. Remove the
gelcoat for at least 20 mm (.8 in.) around the damaged area.
New lay-up as shown on the sketch.
5.3 Repairing the outer skin of a foam sandwich panel
Cut out the damaged area, remove the gelcoat over the overlap area +10
mm (0.4 in.) around the damaged area. Fill the damaged foam area with
resin thickened with microballoons (microballoons-resin), let harden. Sand
down.
Heat the area around the hole to approx. 60°C (140°F). Then tap the outer
skin with a round headed hammer so that the foam is somewhat
compressed. Apply the new cloth.
outside

Repair manual DG-1000
Issued December 2010 5.2
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
5.4 Repair of outer and inner skin of a sandwich panel
See section 5.3. Additionally remove as much foam as is needed so that the
entire damage to the inner skin can be seen, plus enough undamaged inner
skin as is required for overlapping. If the inner skin still holds together,
sand properly and lay up the new cloth over it. Insert a suitable cut piece of
foam, 1-2 mm (0.04 to 0.08 in.) thinner than the original, glued in with
microballoons-resin.
Should the inner skin be so damaged that the above process cannot be used,
the inner skin fabric should be applied to the foam first and left to harden
before inserting into the repair area. Microballoons-resin should once again
be used.
For lay up of the fabric to the foam, a layer of microballoons-resin should
be applied first to eliminate the formation of airbubbles.
Apply the outer layers as in section 5.3.
5.5 Repair of a sandwich panel with tubus core (fuselage)
The repair method is similar to a foam core with the following differences:
1. The outside skin can't be pressed into the tubus core. An accurate scarf is
necessary.
2. To get a good bonding to the skin you have to fill the holes of the tubus
core with microballon-resin mixture.
5.6 Repairing small dents in a sandwich panel skin (no cracks in the
gelcoat)
Small dents can usually be removed by heating up to 60° to 70° C (140° -
158°F). Use a hot air blower to heat the area of the dent. The crushed foam
will then spring back to its original form, so that the dent will hardly be
seen. Final sanding with wet sandpaper grade 600 should finish the job. In
more severe cases, one coat of gelcoat will remove all trace of the dent.
outer skin
foam
inner skin
resin thickened with
microballoons
0.04
–
0.12 in.
1-3 mm

Repair manual DG-1000
Issued December 2010 5.3
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
5.7 Outer skin finish
Repairs should be such that the area is exactly level or only slightly higher
than the surrounding skin surfaces. Sand the hardened repair surface with
dry grade 80 sandpaper. Fill with Polyesterfiller, let dry and sand with dry
sandpaper. When the surface is smooth, sand the repair area and at least 5
cm (2 in.) of the surrounding gelcoat with wet sandpaper grade 400. Spray
the repair area with UP gelcoat.
After the gelcoat has hardened, sand with grade 400, 600 and 800 and
eventually 1000 wet sandpaper until the surface is smooth.
Note: In case of Polyurethane painting, the PU paint will be sprayed onto the
UP gelcoat surface after sanding with grade 600. When hardened continue
sanding with grade 800 and 1000.
Polish with a power buffer (electric drill or similar with cloth polishing
wheel). Apply a block of wax onto the rotating polishing wheel and then
polish the repaired area. Do not polish in only one direction, and do not
polish one spot for too long so that overheating occurs, see sect. "general
maintenance" in the maintenance manual.
5.8 Repairing control surfaces
After the repair the mass balance must be checked again with the values
given in the maintenance manual. Should the maximum values be
exceeded, then the parts have to be replaced.
5.9 Engine bay insulation
Damaged fire resistant paint must be removed and repaired:
2 coats of „Pyroplast ST 100“ must be applied. The paint must dry for 24
hours at min. 20°C after each coat has been applied.
Then apply one coat of top coat:
DG-1000T: „Icosit PUR Color“ (Mixing ratio 92:8 by weight).
DG-1000M: „Pyroplast-ST 120 top“. Let dry for another 24 hours at min.
20°C.
Only DG-1000M: Apply aluminium tape (Tesametall 4504, 100 mm wide)
to cover the repaired area.

Repair manual DG-1000
Issued December 2010 6.1
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
6Types of materials and overlap dimensions
The following overlap dimensions are to be maintained. Use the materials
given, see also section 4. (Smaller reinforcements on high stressed areas are
not given in the table below).
Part fabric type, etc.
overlap b d=diagonal + 45°
(cm) (in.) l= 0°, 90°
Inboard wing panel
Exterior skin 3 1,2 1 x 90070 l outside
+1x205g/m² carbonfibre d whole
wing
3 1,2 +1x205g/m² carbonfibre d from root
up to 3160 mm from root
Core / H60 8mm thick up to y= 5240mm,
H60 6mm from y= 5240mm up to
parting
Inner skin 3 1,2 1x205g/m² carbonfibre d whole
wing
+1x carbonfibre 120g/m²
unidirectional l in direction of flight
in the tank area
Outboard wing
Exterior skin 3 1,2 1x90070 l outside
+1x205 g/m² carbonfibre d
Core / H 60 3mm thick
Inner skin 1,5 0,6 1x92110 d
Winglet of the
outboard wing
complete shell 4 1,6 1x90070 l outside
+3x205 g/m² carbonfibre d
Ailerons inboard
wings
Exterior skin 2 0,8 1x90070 l outside
+1x200 g/m² carbonfibre M40J d
Core / H60 3 mm thick
Inner skin 2 0,8 1x200g/m² carbonfibre M40J d
Ailerons outboard wings
Exterior skin 2 0,8 1x90070l
+1x205g/m² carbonfibre d
Core / 1xDiolen fabric 158g/m²l
Inner skin 2 0,8
1x205g/m² carbonfibre d

Repair manual DG-1000
Issued December 2010 6.2
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Part fabric type, etc.
overlap b d = diagonal + 45°
(cm)
(in.) l= 0°, 90°
Stabilizer
Exterior skin 2 0,8 1x90070 d + 1x92110 d
Core / H 60 5 mm thick
Inner skin 1 0,4 1x90070 d whole stabilizer
1 0,4 +1x92110 d in centre 300mm wide
1 0,4 +1x92110 d in centre 200mm wide
Elevator
complete shell 3 1,2 1x92110 d + 1x92140 d whole
elevator
2 0,8 +1x92125 d in centre 300mm wide
2 0,8 +1x92140 d whole elevator
Rudder
Exterior skin 1 0,4 1x90070 d
Core / H60 3 mm thick
Inner skin 1 0,4 1x90070 d
Fuselage and fin l means 0° to fuselage centre line
Fin from outside to inside
l means 90° to fuselage centre line
Exterior skin 2 0.8 1x92110 d
+1x92145 l
Core / / H60-3mm thick
Inner skin 1.5 0.6 1x92110 d
+ 1x92145 l up to 600mm above
fuselage centre line
Fuselage front part from outside to inside
8.5 3.35
1x92110 d
1x92145 l
1x92125 d
1x92140 d
1x92145 l
1x92140 d
1x92145 l

Repair manual DG-1000
Issued December 2010 6.3
Copyright DG Flugzeugbau GmbH - any copy or publishing prohibited
Part overlap b fabric type, etc.
(cm) (in.) d= + 45°
l= 0°, 90°
Fuselage centre
section from from outside to inside
wing leading edge up
8 3.15
1x92110 d
to 130mm (5,1 in.) 1x92145 l
behind rear wing 1x92125 d
suspension 3x92140 d
1x92145 l
Fuselage tail boom from outside to inside
Exterior skin 3.5 1.38
1x92110 d
1x92145 l
1x92125 d
Core / / Tubuscore B6 6mm thick
Inner skin 3.5 1.38
1x92140 d
1x92145 l
Engine bay DG-1000T
Side walls 2 each
0.8
each
1x205g/m² carbonfibre d inside and
outside
Rear engine bay
bulkhead 2,5 each 1,0 each
1x245g/m² carbonfibre d inside and
outside
UD-tapes beside the
engine bay cut out 10 4.0 4 CFRP-UD-tapes 300 g/m² 7.5 cm wide
Fuselage shell
between engine bay
walls additionally
2 each
0.8
each
1x205g/m² carbonfibre d inside and
outside
Engine bay DG-1000M
Side walls 2 each
0.8
each
2x205g/m² carbonfibre d inside and
1x205g/m² outside
Rear engine bay
bulkhead 2,5 each 1,0 each
2x245g/m² carbonfibre d inside and
outside
UD-tapes beside the
engine bay cut out 25 10 10 CFRP-UD-tapes 300 g/m² 7.5 cm wide
Fuselage shell
between engine bay
walls additionally
2 each
0.8
each
1x205g/m² carbonfibre d inside and
outside
Caution: There are several other reinforcements in the fuselage-fin
intersection and near the top of the fin and at the engine bay components.