Flight Compartment. 1. General

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1 CIRRUS AIRPLANE MAINTENANCE MANUAL Flight Compartment CHAPTER 56-10: FLIGHT COMPARTMENT GENERAL 56-10: FLIGHT COMPARTMENT 1. General The windshield is manufactured of acrylic and is adhesive bonded to the fuselage. Replacement is accomplished by removing the interior trim around the windshield, removing sealant around the windshield, and then removing the windshield from the fuselage. In general, the reverse process is used to install a replacement windshield. This method is literally seamless, and the fuselage will show no marks or evidence of maintenance. 1

2 CHAPTER 56-10: FLIGHT COMPARTMENT 2. Maintenance Practices CIRRUS AIRPLANE MAINTENANCE MANUAL A. Windshield (1) Removal - Windshield (See Figure ) (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Die Grinder (1-inch cut-off disk) - Any Source Cut windshield. Masking Tape 2-inch Any Source Prevent damage to the windshield. Drop Cloth - Any Source Prevent contamination. Isopropyl Alcohol 99% or higher purity Any Source General cleaning. Aluminum Oxide Sandpaper 80-grit Any Source Sealant removal. Phenolic or Hardwood Utility Knife 1-inch Any Source Sealant removal. (b) Remove crew seats. (Refer to 25-10) (c) Remove MFD. (Refer to 31-60) (d) Remove interior trim from around windshield. (Refer to 25-10) (e) Disconnect and remove interior light harness. (f) Cover the interior and instrument panel with a drop cloth to prevent foreign material from contaminating the interior and instruments. Tape drop cloth to fuselage, under windshield bonding flange. (g) Using several pieces of duct tape, make handles on the exterior of the windshield. Exercise care to prevent the removal of laminate from the fuselage when cutting and removing the sealant from between the fuselage and windshield. If laminate is damaged, it must be repaired prior to installing the new windshield. 2

3 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER 56-10: FLIGHT COMPARTMENT (h) (i) If windshield is being replaced, it will be easier to use a die grinder and a cut-off disk to cut out the inner portion of the windshield to gain access to the bonding flange. The windshield should be cut as close as possible to the fuselage. Use care to prevent damage to the fuselage and instruments. Cut sealant loose from between fuselage and windshield using a small pocket knife. While pushing in on the windshield, follow the edge of the fuselage with the tip of the blade, then back cut in towards the fuselage to clean out the sealant. (See Figure ) Using a phenolic or hardwood utility knife, isopropyl alcohol and aluminum oxide sandpaper (80-grit), remove all remaining sealant from the fuselage bonding flange. 3

4 CHAPTER 56-10: FLIGHT COMPARTMENT CIRRUS AIRPLANE MAINTENANCE MANUAL Figure : Windshield Removal Cut windshield out next to bonding flange, do not damage laminate. Any laminate which becomes damaged must be repaired prior to installing the new windshield. BONDING FLANGE ROLL CAGE (REF) WINDSHIELD BONDING FLANGE SEALANT Push windshield inward while cutting sealant between bonding flanges FUSELAGE BONDING FLANGE FUSELAGE (REF) SR22_MM56_4580 4

5 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER 56-10: FLIGHT COMPARTMENT (2) Installation - Windshield (See Figure ) (See Figure ) Windshield sealant is intended to provide a seal between the windshield and fuselage and to prevent the leakage of air through the airframe structure. Window sealant is used in the installation of all windows in the aircraft. Isopropyl alcohol, kerosene, white alptha naptha, mineral spirits, and cotton are acceptable for cleaning acrylic windows. Residue left behind by the Spraylat protective coating may be removed by soaking the area with isopropyl alcohol and rubbing with an alcohol soaked soft flannel cloth. Residue left behind by the adhesive backed paper covering can also be removed by the above method. If, however, the paper covering has been stored on the windshield for an extended period of time, soak paper with kerosene and keep it wet for several hours. Remove any remaining adhesive by using a mixture of equal parts of kerosene and isopropyl alcohol. Soak a soft flannel cloth with this mixture and rub the windshield with the cloth. The windshield should be cleaned after this procedure with a dish washing liquid and plenty of water. Never use organic solvents such as Methyl Ethyl Ketone (MEK), acetone, or lacquer thinner. Do not use jewelry cleaner or paper towels to remove any contaminates. Never use ice scrapers on acrylic windows. Do not store any window outdoors while the protective covering is still on the window. The covering will become very difficult, if not impossible, to remove without damaging the windshield. It is very important to keep the windshield well supported at all times. Warm temperatures are not required during these operations; however, acrylic will take much more abuse at 80 degrees than at 30 degrees. Before final installation, always inspect the windshield for imperfections. Use care to prevent staining or scratching the windshield. (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Padded Cargo Rods - Any Source Temporarily secure windshield. Masking Tape 2-inch Any Source Prevent damage to the windshield. Temperature-Resistant Sealing Compound MIL-S-8802 Type II, Class B (Refer to 51-30) Seal windows. 5

6 CHAPTER 56-10: FLIGHT COMPARTMENT CIRRUS AIRPLANE MAINTENANCE MANUAL Description P/N or Spec. Supplier Purpose Isopropyl Alcohol 99% or higher purity Any Source General cleaning. Cotton Gloves (clean, lint free) - Any Source Protect hands. Cotton Cloth (clean, lint free) - Any Source Clean sealing surface. Application Spatula (non-nylon) 1-inch Any Source Smooth adhesive. Primer MC-145 LP Aero Plastics Aid in adhesion. Protective Coating AC-940 Blue AC Products, Inc. Prevent damage to the windshield. Fine Line Tape (pin stripping) 1/4-inch 3M Company Allow smooth transition between fuselage and windshield. Sandpaper, Aluminum Oxide 80-grit or finer Any Source Abrade acrylic surface prior to adhesion. (b) (c) (d) (e) (f) Exercise care to protect the inner and outer windshield surfaces from damage during the installation process. The stepped area on the edge of the windshield (which is bonded to the fuselage) is called the bonding flange. Verify that sealant is within storage-life requirements. Inspect fuselage bonding flange for any remaining sealant or contaminates, remove and clean as necessary. Remove the protective covering from the windshield and inspect the windshield for damage or defects, never install a defective windshield. Install a continuous piece of fine line tape on the edge of the fuselage windshield opening (next to the bonding flange). (See Figure ) The masking tape will provide a smooth and continuous parting line at the bonding flange. Working in one direction on the fuselage window opening, place 2-inch masking tape on top of the outer edge (the edge furthest away from the bonding flange) of the fine line tape. 6

7 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER 56-10: FLIGHT COMPARTMENT (g) (h) (i) (j) (k) (l) Make a directional mark on the masking tape to indicate the proper direction for removal. (See Figure ) Do not apply protective coating on the windshield bonding flange. Apply three coats (in opposing directions) of protective coating (AC-940 Blue) on the outer windshield surface. Using several pieces of duct tape, make handles on the exterior of the windshield after the protective coating has fully cured. Five or more padded cargo rods may be necessary to hold the windshield into the proper position. Padded cargo rods may be placed on each corner of the windshield and in the center of the windshield. Additional padded cargo rods may be required to prevent the windshield from sliding down. Place windshield into position and secure the windshield into the fuselage using padded cargo rods. (See Figure ) Inspect the windshield for proper fit. The windshield must have equal amounts of space around the perimeter of the windshield. The exterior surface of the windshield should be flush with exterior surface of fuselage skin. The windshield bonding flange must never be trimmed to a thickness less than of an inch. The windshield bonding flange must never be less than ½-inch wide. The windshield bonding flange should have equal amounts of space around it. If the windshield doesn t fit into the fuselage with equal amounts of space around it, the windshield and/or bonding flange will need to be trimmed accordingly. The windshield should be flush with the exterior surface of the fuselage skin. If the windshield cannot be made flush by adding moderate pressure on the padded cargo rods, the thickness of the windshield bonding flange must be trimmed accordingly. Aluminum oxide sandpaper (80-grit) on a sanding board may be used to trim the windshield. Mark and trim the windshield as required to ensure a perfect fit. 7

8 CHAPTER 56-10: FLIGHT COMPARTMENT CIRRUS AIRPLANE MAINTENANCE MANUAL (m) Five or more padded cargo rods may be necessary to hold the windshield into the proper position. Padded cargo rods may be placed on each corner of the windshield and in the center of the windshield. Additional padded cargo rods may be required to prevent the windshield from sliding down. Place the prefit windshield into position and clamp the windshield into position using padded cargo rods. 8

9 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER 56-10: FLIGHT COMPARTMENT Figure : Windshield Alignment ROLL CAGE (REF) 0.080" MINIMUM NOTE Placement of padded cargo rods. Trim windshield thickness as required to obtain a flush fit to fuselage. Trim windshield bonding flange as required to obtain a 0.5 inch flange. Apply protective coating on windshield to prevent damaging windshield during the installation process. WINDSHIELD BONDING FLANGE 0.5" MINIMUM FUSELAGE (REF) HANDLE Trim windshield as required to ensure equal spacing on all sides SR22_MM56_4581 9

10 CHAPTER 56-10: FLIGHT COMPARTMENT CIRRUS AIRPLANE MAINTENANCE MANUAL (n) (o) (p) (q) (r) (s) (t) (u) (v) Remove a small amount (approximately 2-inches wide) of protective coating from around edge of windshield. Install a continuous piece of fine line tape (pinstripe tape) around the edge of the windshield (next to the bonding flange). The fine line tape should be adhered to the windshield with equal amounts of space between the fine line tape on the fuselage and the fine line tape on the windshield. Working in one direction on the windshield, place 2-inch masking tape on top of the inner edge (the edge furthest away from the bonding flange) of the fine line tape. The alignment marks will be used to ensure that the windshield will be installed into the exact location in which it was during prefit. Using a straight edge, make several alignment marks around the edges of the masking tape on the fuselage to the masking tape on the windshield. Carefully remove windshield from fuselage. Using aluminum oxide 80-grit paper, abrade the bonding flange of the windshield in a random pattern. Remove all surface gloss. Wax or grease pencil markings on any part are not allowed. Any such markings inadvertently occurring must be removed prior to application of primer. All surfaces shall be thoroughly cleaned and dried before application of primer. Immediately prior to applying any primer on the windshield bonding flange, solvent clean the flange with isopropyl alcohol. When handling cleaned surfaces, wear clean cotton gloves to prevent surface contamination. Surfaces must be re-cleaned in the event of contamination. Fold cloth in such a manner to eliminate raw edges to reduce the possibility of lint. Always clean an area larger than the application area. Remove contaminates from the windshield bonding flange and the immediate work area using a vacuum and a clean brush attachment. Do not apply primer to the composite bonding surface. Ensure that all surfaces adjacent to the windshield bonding flange are masked to prevent them from coming into contact with any primer or sealant. Using isopropyl alcohol, solvent clean the bonding flange in the fuselage. (Refer to 20-30) 10

11 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER 56-10: FLIGHT COMPARTMENT (w) (x) (y) (z) (aa) Verify all required materials are present and all parts have been prepared and pre-fit. Wearing clean gloves, lightly dampen a cloth with primer. Fold the cloth in such a manner to eliminate raw edges to reduce the possibility of lint. Apply primer to the acrylic bonding flange. Wipe the cloth over the prepared area. Apply as little primer as possible while still wetting the entire surface. Keep primed area clean and free from contaminates while primer is drying. Seal windshield as soon as practical after primer drying period to minimize contamination. Allow the primer to dry for thirty to sixty minutes. Mix sealant per manufacturer's instructions. Mix the required quantity in the ratio specified in the adhesive manufacturer's instructions. (Refer to 20-10) Do not apply sealant to windshield bonding flange. The sealant must be applied to the fuselage bonding flange. (ab) Apply a thin layer of sealant to the outer edge of the fuselage bonding flange. Spread the sealant out using an application spatula. (Refer to 20-10) (ac) When spreading the sealant, ensure all air pockets are removed. If more than one bead is required, apply it immediately adjacent to the prior bead to form one large bead. Glass beads may be applied in the bond line to ensure that minimum sealant thickness is maintained. Add up to 2.3 grams of glass beads per 3 fluid ounces of mixed adhesive. (Refer to 51-30) Directly on top of the sealant previously spread, apply a 1/4-inch to 3/8-inch bead of sealant down the center of the bond area. (Refer to 20-10) Five or more padded cargo rods may be necessary to hold the windshield into the proper position. Padded cargo rods may be placed on each corner of the windshield and in the center of the windshield. Additional padded cargo rods may be required to prevent the windshield from sliding down. 11

12 CHAPTER 56-10: FLIGHT COMPARTMENT CIRRUS AIRPLANE MAINTENANCE MANUAL (ad) (ae) (af) Using padded cargo rods, secure the windshield into position making sure the reference marks made earlier are perfectly aligned and that the contour of the windshield matches the contour of the fuselage. Using a 1-inch application spatula, push sealant into the gap between the windshield and the fuselage. (Refer to 20-10) To prevent sealant from becoming damaged, pull tape towards sealant while the sealant is still damp. Remove masking tape and fine line tape from the perimeter of the windshield and the fuselage. Overheating windshield can cause windshield damage. (ag) Allow the sealant to air dry. Following the manufacturer s instructions, the sealant can be heat cured using a heat gun. (ah) Remove cargo rods. (ai) Route and secure the interior light wiring harness. (aj) Using a vacuum cleaner, remove all debris from the cabin and fuselage. (ak) Remove the drop cloth. (al) Install and secure interior trim. (Refer to 25-10) (am) Install crew seats. (Refer to 25-10) (an) Install MFD. (Refer to 31-60) (ao) Clean windshield. (Refer to 56-10) 12

13 CIRRUS AIRPLANE MAINTENANCE MANUAL CHAPTER 56-10: FLIGHT COMPARTMENT Figure : Windshield Installation WINDSHIELD BONDING FLANGE ROLL CAGE (REF) SEALANT FUSELAGE (REF) DIRECTIONAL ARROW FUSELAGE WINDOW OPENING WINDSHIELD BONDING FLANGE 2" MASKING TAPE 2" MASKING TAPE FINE LINE TAPE FINE LINE TAPE SEALANT Trim windshield as required to ensure equal spacing on all sides HANDLE NOTE Remove approximately 2-inches of protective coating. Make alignment marks to ensure proper alignment after fit up. Remove surface gloss from bonding flange using 80-grit sandpaper. Force the sealant into the bonding flange to ensure no air is trapped in the sealant. SR22_MM56_

14 CHAPTER 56-10: FLIGHT COMPARTMENT CIRRUS AIRPLANE MAINTENANCE MANUAL (3) Windshield - Cleaning (Refer to 12-20) Acrylic windows should be cleaned using the following chemicals, and by following the manufactures instructions for each individual product. (a) Acquire necessary tools, equipment, and supplies. Description P/N or Spec. Supplier Purpose Acrylic Polish and Sealant SP-PL16 LP Aero Plastics, Inc. Polish acrylic. Plastic Cleaner and Polish SP-210A LP Aero Plastics, Inc. Clean acrylic. Plastic Scratch Remover SP-210P LP Aero Plastics, Inc. Remove fine scratches in acrylic. 14

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