HAWKER 800 STRUCTURAL REPAIR MANUAL

WINGS
LEADING EDGE AND LEADING EDGE DEVICES
WING LEADING EDGE SKINS
57-41-12

REPAIR SCHEMES
200200

Contents Paragraph
Wing Leading Edge Skin Patch Repair 1
Restoration of Corrosion Protection of Wing Leading Edge 2
Repairs to Distributor Panel Leaks 3
Repair to Joint at Air Bleed Tube 4

Page 201
57-41-12 Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

1. WING LEADING EDGE SKIN PATCH REPAIR

A. General
(1) Figure 201 shows an insert patch repair to a damaged top skin across a nose rib which may also
be applied to the bottom surface. Damage in clear areas may also be repaired in a similar manner.

(2) Figure 201 does NOT apply to the titanium leading edge assembly.

B. Materials
For details of materials used during assembly, refer to AMM Chapter 20, STANDARD PRACTICES -
Airframe Manual 125/H-20.

Equipment/Material Part/Item No.

Polysulfide Sealant 347 (Ref. AMM 125/H-20, 20-95-301)
Epoxy Primer 410A (Ref. AMM 125/H-20, 20-95-401)
Alocrom Film Treatment 504 (Ref. AMM 125/H-20, 20-95-501)

C. Parts List

Item Part Number Nomenclature Material/Specification Qty

1 - Repair, Flange Aluminum Alloy L167, 0.036 in. (0.9mm) AR
Angle
2 - Repair, Landing Aluminum Alloy L167, 0.036 in. (0.9mm) AR
Plate
3 - Repair Insert Aluminum Alloy L167, 0.036 in. (0.9mm) AR
4 - Diaphragm Aluminum Alloy L167, 0.036 in. (0.9mm) 1

D. Procedure
(1) It will be necessary to remove and install the leading edge to do this repair (Ref. 57-41-00, 201).

(2) Extreme care must be taken to make sure that the original profile is maintained.

(3) Seal any gaps with polysulfide sealant (Item 347).

(4) For further particulars or rib repair refer to 57-41-11, 201, Figure 201.

(5) Oversize rivets may be used where necessary (Ref. 51-41-00, 001).

(6) Minimum landing for rivets to be 0.35 in. (8.9 mm) unless shown otherwise.

(7) Carefully remove rivets through skin affected by the repair.

Page 202
Sep.14 57-41-12
 HAWKER 800 STRUCTURAL REPAIR MANUAL

(8) Prepare repair items; forming flange angles (Ref. 51-24-11, 001) for L167. Cut diaphragm to new
profile. Landing Plate must be contained within plain area of etched skin. Deburr all items
(Ref. 51-25-00, 001).

(9) Drill holes for fasteners (Ref. 51-42-00, 001). Spin dimple for 120 head fasteners
(Ref. 51-44-00, 001), (see rivet code).

(10) Apply Alocrom film treatment (Item 504) (Ref. AMM 125/H-20, 20-10-08, 201) and epoxy primer
(Item 410A) (Ref. AMM 125/H-20, 20-10-3527, 201) to all the bare metal parts.

(11) Apply polysulfide sealant (Item 347) to all repair parts and assemble while wet.

(12) Restore paint finish as necessary.

Page 203
57-41-12 Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

Figure 201
Wing Leading Edge - Skin Patch Repair

Page 204
Sep.14 57-41-12
 HAWKER 800 STRUCTURAL REPAIR MANUAL

2. RESTORATION OF CORROSION PROTECTION OF WING LEADING EDGE

A. General
(1) Remove the distributor panels (not the outboard combined distributor / leading edge panels
Mod.253166) from both wings to facilitate the application of the improved protective treatment to
the leading edge rebates and to the distributor panels.

(2) It might be necessary to remove the leading edge assembly to enable inspection and treatment
(Ref. 57-41-00, 201).

(3) Remove all filler adhering to the leading edge skins and distributor panel edges before inspecting
the leading edge assembly for corrosion as given in SB 57-77.

B. Materials
For details of materials used during assembly, refer to AMM Chapter 20, STANDARD PRACTICES -
Airframe Manual 125/H-20.

Equipment/Material Part/Item No.

Degreasing Agent 230 (Ref. AMM 125/H-20, 20-95-201)
Compound, Filling 301 (Ref. AMM 125/H-20, 20-95-301)
Adhesive, Contact 304 (Ref. AMM 125/H-20, 20-95-301)
Adhesive, Polysulphide 314 (Ref. AMM 125/H-20, 20-95-301)
Epoxy Primer 410A (Ref. AMM 125/H-20, 20-95-401)
Primer 413A (Ref. AMM 125/H-20, 20-95-401)
Alocrom Film Treatment 504 (Ref. AMM 125/H-20, 20-95-501)
Tape, P.T.F.E. 620 (Ref. AMM 125/H-20, 20-95-601)
Abrasive Pad 637 (Ref. AMM 125/H-20, 20-95-601)
Tape, P.T.F.E. 666 (Ref. AMM 125/H-20, 20-95-601)
Tape, P.T.F.E. 667 (Ref. AMM 125/H-20, 20-95-601)
3M Scotch-Weld EPX Applicator 686 (Ref. AMM 125/H-20, 20-95-601)

C. Corrosion Removal
(1) Use an abrasive pad (Item 637) to remove paint from upper and lower leading edge skin rebates.
If power tools are used to do this operation, make sure that the adjacent polished area of skin is
not abraded and that there is no local overheating (Ref. Figure 202 and Figure 203).

CAUTION: Do not use a blasting abrasive method. This will cause roughening and discoloration
of the surface which will prevent the correct inspection.
Paint remover is not recommended. If paint remover is used, make sure that it does
not penetrate between the skin layers at the anchor nut and skin joint locations.

Page 205
57-41-12 Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

(2) Make sure that the corrosion damaged area (excluding surface corrosion) is within the following
limits:

(a) The limits shown on Figure 202 and /or,

(b) An accumulative total length of 12 inches (304.8 mm) on both upper and lower rebates for
each leading edge section.

(3) If the corrosion is within limits (Ref. Figure 202), blend only the worst area of corrosion as given
below:

(a) Remove the corrosion, to the limits in step (2) by the minimum of blending and polishing.

(b) Use a dye penetrant and a 10X magnification glass, as detailed in the NTM GENERAL
TECHNIQUES Part C - Liquid Penetrant and make sure that the corrosion has been
removed to the limits in step (2).

(c) The remaining corrosion may be a single or many black or grey lines (Ref. Figure 203).
Where corrosion remains, use the SB 57-77 damage report sheets A and B to report it to
Beechcraft Corporation.

(4) If the area of corrosion is more than the limits given in step (2) refer to Beechcraft Corporation.

0.08(2.03) MAXIMUM
DISTRIBUTOR PANEL

0.04(1.02) MINIMUM RADIUS

0.047(1.19) MINIMUM

DIMENSIONS IN INCHES
MILLIMETERS IN BRACKETS

R87471/1
HA00E998834AA

Figure 202
Blend Limits

Page 206
Sep.14 57-41-12
 HAWKER 800 STRUCTURAL REPAIR MANUAL

SINGLE SHORT FINE LINES FLOWING

IN THE DIRECTION OF THE GRAIN

MULTIPLE SHORT FINE LINES

NORMALLY SEEN AT THE EDGE

R87472
HA00E998835AA

Figure 203
Corrosion Remaining After Removal and Blending

D. Protective Treatment
CAUTION: Make sure that polished areas which are not treated are masked. The chemical treatments
can damage the polished clad surface of the leading edge.

(1) Do the VACU-BLASTING procedure (Ref. Paragraph 2.E.) to the upper and lower distribution
panel rebates (Ref. Figure 204).

(2) Inhibit the area where the corrosion had been present, with chromic acid solution
(Ref. 51-73-00, 001).

(3) Apply Alocrom film treatment (Item 504) (Ref. AMM 125/H-20, 20-10-08, 201) and epoxy primer
(Item 410A) (Ref. AMM 125/H-20, 20-10-3527, 201) to all treated metal parts.

(4) Apply a polyurethane top coat as necessary (Ref. AMM 125/H-20, 20-10-3528, 201).

(5) Apply a minimum of one layer of PTFE tape (Item 620) with polysulfide adhesive (Item 314)
(Ref. AMM 125/H-20, 20-10-4007, 201) to the leading edge rebate for the distributor panel
(Ref. Figure 204).

(6) Mask the porous area of each distributor panel and blank off all pipes.

(7) Remove the cloth tape from the edges of the distributor panels.

(8) Make sure that the distributor panel edge corners which touch the leading edge skins and nose
ribs have a 0.020 to 0.030 in. chamfer along the complete length and at each end
(Ref. Figure 204).

Page 207
57-41-12 Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

(9) Use an abrasive pad (Item 637) to abrade all edges of the distributor panel to remove any PTFE
spray release agent and adhesive that might be remaining.

CAUTION: Make sure that the cleaner does not contaminate the porous area of the distributor
panel and cause damage to the internal plastic seal.

(10) Degrease the repair with degreasing agent (Item 230) or other approved cleaner.

(11) Let the degreased surface remain for 10 to 15 minutes maximum to reach ambient temperature
before the next operation. If it is left for longer there will be an increased risk of contamination.

(12) Apply a protective coat of primer (Item 413A) to all internal mating surfaces of the panel, both
inboard and outboard ends and top and rear edges.

(13) Apply a layer of PTFE tape (Item 666) or (Item 667) with contact adhesive (Item 304).

E. Vacu-Blasting
(1) Do the VACU-BLASTING WITH DRY ALUMINA GRIT procedure (Ref. AMM 125/H-20, 20-10-40,
201) whilst applying the following optimum service conditions to the wing leading edge rebates:

(a) Nozzle pressure between 45 to 60 psi.

(b) The nozzle should be held approximately 6 inches (150mm) from the workpiece surface, with
the nozzle being kept as close to 90 as practicable.

NOTE: Particular care should be taken with root radii in areas where the profile changes
shape.

(c) Nozzle movement rate is to be at a speed that makes sure of complete coverage of the
rebate area in one pass. A second pass is then to be made using the same nozzle travel rate
as the first pass.

(2) Using a vacuum cleaner, make sure that the leading edge assemblies are thoroughly cleaned.

F. Assembly
CAUTION: Make sure that the protective coat is not damaged in the operations that follow.

(1) Assemble the distributor panel to the wing leading edge (Ref. AMM 30-10-72, 401). Make sure that
the edge gap of the panel is as shown on (Ref. Figure 204) except where it is necessary to blend
to remove corrosion. If necessary, apply additional PTFE tape (Item 666) or (Item 667) to adjust
the in to and out of wind profile limits, (Ref. Figure 204). The minimum tape thickness is 0.006 inch
(0.015 mm) and maximum tape thickness is 0.020 inch (0.508 mm), except where blending spans
one or more distributor panel attachment holes when additional layers are required to restore the
original surface position.

WARNING: The filler can be dangerous. Obey the warnings and cautions on the container,
on the safety data sheet and local safety regulations. Make sure that safety
equipment is available.

(2) Fill all gaps around each distributor panel with two part filler (Item 301).

(a) Use a non-metallic spatula to apply the filler to achieve the in-to-wind and out-of-wind limits.

Page 208
Sep.14 57-41-12
 HAWKER 800 STRUCTURAL REPAIR MANUAL

(b) Quick setting filler, with a setting time of 10 minutes, is recommended for repair to in-service
airplanes. This setting time applies to the filler from the time that it is mixed in the applicator
gun nozzle. It might be necessary to replace the nozzle if it becomes clogged with dried filler.

(c) The setting time is affected by temperature. As temperature increases, the work life
decreases and as temperature decreases, the work life increases.

(d) Quick setting filler should be used for small areas and for the lower leading edge where
‘slump’ may occur.

(e) Use the longer setting filler to maximize the smoothing time, when filling the upper gaps of
leading edges fitted to the wing. This filler can also be used on the lower gaps when the
leading edges are removed from the wing as they can be rotated. Before rotating the
removed leading edge, make sure that all applied filler has set.

(f) Use the correct gun and mixing nozzle (Item 686) supplied by the manufacturer.

(g) Cut the plastic nozzle orifice size so that the bead of filler from it, applied into the gap around
the distributor panel, is the correct size. This will minimize waste and reduce the smoothing
required for the correct profile.

Page 209
57-41-12 Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

CHAMFER BEFORE BLENDING

0.02 TO 0.03 NOMINAL GAP
(0.51 TO 0.76) 0.08 TO 0.12 (2.30 TO 3.05)

0.25 (6.35) FILLER

PTFE TAPE
APPLY PROTECTIVE
TREATMENT

ALL INSTRUCTIONS
APPLY TO UPPER
DISTRIBUTOR PANEL
AND LOWER REBATES

DISTRIBUTOR PANEL
REMOVED FOR CLARITY

DISTRIBUTOR PANEL

O/S LINE
EXTENT
OF REWORK

OUT OF WIND 0.02 (0.51)

IN TO WIND 0.01 (0.25) DIMENSIONS IN INCHES
MILLIMETERS IN BRACKETS

R87473/2
LEADING EDGE SKIN HA00E998836AA

Figure 204
Protective Treatment

Page 210
Sep.14 57-41-12
 HAWKER 800 STRUCTURAL REPAIR MANUAL

3. REPAIRS TO DISTRIBUTOR PANEL LEAKS

A. General
(1) The types of leaks that can be found on distributor panels take the forms that follow:

(a) Pinhole leaks at the edges of the backplate panel.

(b) Leakage over a measurable length of the edges (both span and chord).

(c) Visible cracks in the end gaskets.

(d) Loose or missing PTFE strips.

B. Materials
For details of materials used during assembly, refer to AMM Chapter 20, STANDARD PRACTICES -
Airframe Manual 125/H-20.

Equipment/Material Part/Item No.

Adhesive, Contact 304 (Ref. AMM 125/H-20, 20-95-301)
Polysulfide Sealant 314 (Ref. AMM 125/H-20, 20-95-301)
3M Scotch-Weld EPX Applicator 686 (Ref. AMM 125/H-20, 20-95-601)

C. Procedure
(1) Remove all loose and degraded sealant (Ref. Figure 205 and Figure 206).

(2) Do a pressure test of the panel(s) to a governed 20 psi.

(3) Mark the areas where leaks occur.

(4) Where it is known that there is leakage between the inner and outer skins, indicated by leaks
around the edge of the panels. The panels must be observed under flow conditions to make sure
that fluid is not exuded outside of the area covered by the backplate cavity (Ref. Figure 205). If
leaks are found in this area, the distributor panels are non-repairable and must be replaced.

(5) Thoroughly dry the panels.

(6) Remove all remaining sealant near to the leaks.

(7) Where pinhole leaks are identified (Ref. Figure 206) these can be repaired with a compound filler
(Item 301). Thoroughly clean and dry the area around the pinhole and apply a bead of compound
filler to a minimum of 0.125 in. (3.18 mm) to the pinhole.

(8) Where the leak is an extended crack (Ref. Figure 206) with the same width as a pinhole leak.
Thoroughly clean the inside of the crack and force compound filler (Item 301) into the crack with
an application gun (Item 686). Allow to completely cure.

(9) Where the PTFE strips are loose or missing they must be replaced. Install the PTFE strips with
contact adhesive (Item 304).

Page 211
57-41-12 Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

(10) Apply a layer of polysulfide sealant (Item 314) to all repaired areas initially covered by sealant.
Allow to completely cure.

(11) Do a pressure test of the panel(s) to a governed 20 psi, for 2 to 3 minutes to make sure that all
leaks are sealed and that no further leaks have formed.

(12) On successful completion of the pressure test the distributor panels are serviceable and can be
installed.

(13) Install the distributor panels in accordance with (Ref. AMM 30-10-72, 401).

PTFE STRIP (REF)

NO FLUID MUST LEAK

FROM THIS AREA

PTFE STRIP (REF)

RS2047
HA00B998958AA

Figure 205
Section Through Distributor Panel

TYPICAL CRACK

ADHESIVE BEAD
0.125 in. (3.18 MM)
APPROX.
TYPICAL PINHOLE

RS2036
HA00E998948AA

Figure 206
View on Inner Surface of Distributor Panel

Page 212
Sep.14 57-41-12
 HAWKER 800 STRUCTURAL REPAIR MANUAL

4. REPAIR TO JOINT AT AIR BLEED TUBE

A. General
(1) Each de-icing distributor panel has a capillary tube (Ref. Figure 207) to purge air during priming.
The tube enters the rear of the panel at a high point in the cavity, and exits at a low point on the
front face of the panel. This repair is to the joint between the capillary tube and the dimple.

B. Materials
For details of materials used during assembly, refer to AMM Chapter 20, STANDARD PRACTICES -
Airframe Manual 125/H-20.

Equipment/Material Part/Item No.

Cleaner, Solvent 206 (Ref. AMM 125/H-20, 20-95-201)
Compound, Filler 301 (Ref. AMM 125/H-20, 20-95-301)
Polysulfide Sealant 314 (Ref. AMM 125/H-20, 20-95-301)
Abrasive Paper 327 (Ref. AMM 125/H-20, 20-95-301)
3M Scotch-Weld EPX Applicator 686 (Ref. AMM 125/H-20, 20-95-601)

C. Procedure
(1) Remove all sealant from the area immediately around the joint (Ref. Figure 207) to an approximate
radius of 0.25 in. (6.35 mm). Remove all loose sealant from the adjacent area.

(2) Remove all old filler compound from the area around the joint, especially compound that has
become detached from the substrate.

NOTE: It is not necessary to remove all traces, provided that those that remain are firmly
attached. Do not attempt to spring the tube from the hole in the dimple.

(3) Clean the tube for a distance of 0.25 in. (6.35 mm) of the joint and the backplate around it with
abrasive paper (Item 627).

(4) Remove all unwanted material from the cleaned area.

(5) Degrease the cleaned area with cleaner solvent (Item 206) and thoroughly dry.

(6) Mix a small quantity of filler compound (Item 301) in accordance with manufacturers instructions
and apply a bead approximately 0.25 in. (6.35 mm) around the joint. Make sure that the area
between the tube and backplate is treated and there are no bubbles or pinholes in the compound.

(7) Do a pressure test of the panel(s) to a governed 20 psi, for 2 to 3 minutes with a clean water
supply to make sure that all leaks are sealed and that no further leaks have formed.

(8) Mix a small quantity of sealant (Item 314) in accordance with manufacturers instructions and apply
a layer over the repair.

NOTE: If the capillary tube has become detached from the backplate overcoat, apply a layer of
sealant to attach it.

Page 213
57-41-12 Sep.14
 HAWKER 800 STRUCTURAL REPAIR MANUAL

BONDED JOINT DIMPLE

CAPILLARY
TUBE

RS2034
HA00E998946AA

Figure 207
Distributor Panel - View of Capillary Tube Joint

Page 214
Sep.14 57-41-12