A B737-300 flap was repaired improperly due to structural manual procedures were not followed.

Attributes
ACN	410328
Time
Date	199807
Day	Thu
Local Time Of Day	0601 To 1200
Place
Locale Reference	airport : zzz
State Reference	US
Altitude	agl bound lower : 0 agl bound upper : 0
Environment
Light	Daylight
Aircraft 1
Operator	common carrier : air carrier
Make Model Name	B737-300
Operating Under FAR Part	Part 121
Navigation In Use	Other Other
Flight Phase	other
Flight Plan	None
Person 1
Affiliation	company : air carrier
Function	other personnel other
Qualification	other other : other
ASRS Report	410328
Person 2
Affiliation	company : air carrier
Function	other personnel other
Events
Anomaly	aircraft equipment problem : critical non adherence : published procedure non adherence : far
Independent Detector	other other : unspecified
Resolutory Action	none taken : detected after the fact
Consequence	Other
Supplementary
Air Traffic Incident	other

Narrative:

Recently I was assigned to department xyz/xa, the new air carrier composite repair facility. Today I noted a flap where the old repair had come off. After reflecting it seemed to me I had originally repaired this flap, and clearly the repair was substandard. The flap is a part #xyzyx outboard mid flap position and serial #abc. This flap may be permanently damaged because I used a heat gun to remove the damaged skin and honeycomb. The srm says to use a router and not to exceed 200 degrees F, 51-70-10 paragraph 4B. This was done as nothing else was available and the job was hot. Also in step 8 of B737-300 srm 51-70-10 the primer may have been applied too thick. Had no way of measuring this. And the pressure application requirement srm 51-70- 10 paragraph 10B for contoured panels was not up to the needed 35 psi but only vacuum pressure was used, 10 psi. I think the flap may be unrepairable, or may have future problems because of bond weakening during repair. Also the repair itself may have been bad.

Original NASA ASRS Text

Title: A B737-300 FLAP WAS REPAIRED IMPROPERLY DUE TO STRUCTURAL MANUAL PROCS WERE NOT FOLLOWED.

Narrative: RECENTLY I WAS ASSIGNED TO DEPT XYZ/XA, THE NEW ACR COMPOSITE REPAIR FACILITY. TODAY I NOTED A FLAP WHERE THE OLD REPAIR HAD COME OFF. AFTER REFLECTING IT SEEMED TO ME I HAD ORIGINALLY REPAIRED THIS FLAP, AND CLRLY THE REPAIR WAS SUBSTANDARD. THE FLAP IS A PART #XYZYX OUTBOARD MID FLAP POS AND SERIAL #ABC. THIS FLAP MAY BE PERMANENTLY DAMAGED BECAUSE I USED A HEAT GUN TO REMOVE THE DAMAGED SKIN AND HONEYCOMB. THE SRM SAYS TO USE A ROUTER AND NOT TO EXCEED 200 DEGS F, 51-70-10 PARAGRAPH 4B. THIS WAS DONE AS NOTHING ELSE WAS AVAILABLE AND THE JOB WAS HOT. ALSO IN STEP 8 OF B737-300 SRM 51-70-10 THE PRIMER MAY HAVE BEEN APPLIED TOO THICK. HAD NO WAY OF MEASURING THIS. AND THE PRESSURE APPLICATION REQUIREMENT SRM 51-70- 10 PARAGRAPH 10B FOR CONTOURED PANELS WAS NOT UP TO THE NEEDED 35 PSI BUT ONLY VACUUM PRESSURE WAS USED, 10 PSI. I THINK THE FLAP MAY BE UNREPAIRABLE, OR MAY HAVE FUTURE PROBS BECAUSE OF BOND WEAKENING DURING REPAIR. ALSO THE REPAIR ITSELF MAY HAVE BEEN BAD.

Data retrieved from NASA's ASRS site as of July 2007 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.