REPAIR INSTRUCTION NO. RI-1078-95/1

GROB G-115 · Service Bulletins

Free account — keep the POHs & checklists you reference in one place.

Overview

This document provides repair instructions for the hinge bracket attachment points of the elevator and horizontal stabilizer on Grob G 115E and G 115EG aircraft. It includes detailed steps for the repair process, necessary materials, and references to concurrent documents.

Applicable to G 115E and G 115EG aircraft.
Focuses on repairing hinge bracket attachment points for elevator and horizontal stabilizer.
Includes detailed repair procedures and curing instructions.
References multiple concurrent documents for maintenance and repair.
Technical content approved under EASA DOA authority.
Curing times vary based on the resin system used.

Document

Source

Originally published by regulations.gov. Sprinkle hosts a reference copy with an added summary, specifications and searchable full text.

View original at regulations.gov

Report a problem or request removal

Document details

Type: Service Bulletins
Year: 2021
File size: 808 KB
Publisher: regulations.gov
Language: en

About this document

What is the REPAIR INSTRUCTION NO. RI-1078-95/1?

The REPAIR INSTRUCTION NO. RI-1078-95/1 is a service bulletins for the GROB G-115, dated 2021.

Where does the REPAIR INSTRUCTION NO. RI-1078-95/1 come from?

This copy of the REPAIR INSTRUCTION NO. RI-1078-95/1 was originally published by regulations.gov and is hosted on Sprinkle as a free, searchable reference copy.

What year was the REPAIR INSTRUCTION NO. RI-1078-95/1 published?

The REPAIR INSTRUCTION NO. RI-1078-95/1 — the GROB G-115 service bulletins on file — is dated 2021.

Documentation completeness

2/7

Most owners only have the POH. Here's the essential set for the GROB G-115.

Pilot's Operating Handbook / AFM
Checklist
Maintenance Manual
Parts Catalog (IPC)
Systems & Wiring
Service Bulletins on file
Type Certificate (TCDS)

More GROB G-115manuals & documents

In this document

Aircraft Affected

G 115E / EG all as affected.

Subject

Repair of hinge bracket attachment points – ELEVATOR and HORIZONTAL STABILIZER.

Repair Instructions

Describes the repair process for hinge bracket attachment points, including safety measures and material specifications.

Concurrent Documents

Lists related documents necessary for the repair process, including maintenance manuals and part catalogues.

Approval Note

The technical content of this document is approved under the authority of the DOA ref. EASA.21J.030.

Limitations

N/A

Safety notes

Ensure the aircraft is safe for parking before starting repairs.
Use caution when cutting access holes; follow Grob's recommendations.
Lightning protection sheets must remain installed during repairs.

Full document text

Repair Instruction RI-1078-95/1 Page 1 of 11 02 June 2021 G 115E / EG Grob Aircraft SE, Lettenbachstrasse 9, 86874 Tussenhausen-Mattsies TE.CAW.003-01 File: RI-1078-95_1 Repair of hinge bracket attachment points - ELEVATOR and HORIZONTAL STABILISER.docx REPAIR INSTRUCTION NO. RI-1078-95/1 1 Aircraft affected G 115E / EG all as affected 2 Subject ATA-Code: 55-00 Stabilisers Repair of hinge bracket attachment points – ELEVATOR and HORIZONTAL STABILIZER 3 Introduction This Repair Instruction provides the instructions to accomplish the final repair for the ailerons and the aileron attachment to wing as defined in MSB1078-205/3 and later revisions. Revision 1 to provide additional information. 4 Concurrent Documents Document No. Rev. / Date Title 115E AMM, Issue 2 Rev 8 or later Grob G 115E Aircraft Maintenance Manual 1T-115E-4, Issue 2 Rev 0 or later Grob G 115E Aircraft Illustrated Part Catalogue 1TG115EG-02-00GV-00-1 7 or later Grob G 115EG Aircraft General Vehicle Manual 1TG115EG-3-00-00-1 7 or later Grob G 115EG Structure Repair Manual 1TG115EG-5-08JG-00-1 3 or later Grob G 115EG Aircraft Weight and Balance Manual 1TG115EG-4-00-00-1 8 or later Grob G 115EG Aircraft Illustrated Parts Breakdown MSB1078-205/2 Rev 2 Special Inspection Control Surface Hinge Bracket Attachment 5 Approval Note The technical content of this document is approved under the authority of the DOA ref. EASA.21J.030. The associated repair design is approved under the authority of the DOA ref. EASA.21J.030. 6 Limitations N/A Repair Instruction RI-1078-95/1 Page 2 of 11 02 June 2021 G 115E / EG Grob Aircraft SE, Lettenbachstrasse 9, 86874 Tussenhausen-Mattsies TE.CAW.003-01 File: RI-1078-95_1 Repair of hinge bracket attachment points - ELEVATOR and HORIZONTAL STABILISER.docx 7 Repair / Instructions Note: The following instructions describe the repair for a single attachment point. The principal repair procedure is applicable for all attachment points. If a single attachment point is treated differently, it is stated in the instructions. The definition and location of the access holes is recommended by Grob only and must not be obeyed. Note: Each chapter and sub-chapter in the following instruction defines the curing process for a specific attachment point. If several locations are repaired at once these curing steps can be combined for the whole repair and must not be followed separately. The repair shall be cured at room temperature for at least 12hrs (GS510020-12) or 6 hrs (GS510020-13) before staring the initial cure. That will prevent the resin from dripping off the repair area. If that is secured, the curing time at room temperature can be adjused. Make sure to follow the curing cycle i.a.w. AMM Chapter 51-20 for the respective resin system. Nevertheless, the inner and outer repair can be post cured together, if the required temperature at the inner repair can also be reached. Note: In case of additional findings which are not covered in the following instructions or when in doubt, please contact Grob. Note: The AMM references in the following instructions are for the G 115E. For G 115EG use the relevant Job Guide. 7.1 Repair of Elevator Hinge Bracket Attachment Points – Control Surface 7.1.1 Make the aircraft safe for parking, refer to AMM Chapter 10-10. 7.1.2 Remove the elevator, refer to AMM Chapter 55-20. 7.1.3 Remove the affected hinge bracket from the elevator. Discard the lock nuts. 7.1.4 Cut an access hole into the elevator surface as small as practical, refer to Figure 1. Grob recommends to cut the access holes into the lower elevator surface. Figure 1: Elevator Access Holes and Hinge Bracket Locations (LH shown, RH mirrored) Repair Instruction RI-1078-95/1 Page 3 of 11 02 June 2021 G 115E / EG Grob Aircraft SE, Lettenbachstrasse 9, 86874 Tussenhausen-Mattsies TE.CAW.003-01 File: RI-1078-95_1 Repair of hinge bracket attachment points - ELEVATOR and HORIZONTAL STABILISER.docx Table 1: Part Numbers Reference Table for Repair Location Elevator Location P/N Repair Plate P/N Bolt 19/26 115E-3763.05RI-0 115E-3103.01RI-0 20/25 115E-3763.04RI-0 21/24 115E-3763.03RI-0 22/23 115E-3763.01RI-0 115E-1263.01RI-0 CAUTION: At location 22/23 a 6mm thick repair plate (instead of 4mm) is installed with longer bolts of a higher strength category. 7.1.5 Remove all hinge bracket bolts and washers at the affected attachment point, refer to AMM Chapter 51-70. Discard the bolts and washers. 7.1.6 Carefully grind away the remaining resin and/or two part structural adhesive holding the bolt heads in position. 7.1.7 Carefully sand the repair area for the overlap repair. 7.1.8 If required, remove the damaged glass layer and plywood material around the bolt holes with a piloted counterbore, refer to Figure 2. Figure 2: Insert damage removed and tapered bolts installed 7.1.9 Remove the grinding dust with a vacuum cleaner. 7.1.10 Install four tapered bolts through holes in the spar. Wax the tapered bolts with release agent e.g. QZ5111 before installation. The tapered end must point to the inside of the elevator, refer to Figure 2. Verify that the repair plate fits in the repair area properly. If required, trim the repair plate to fit. Refer to Figure 1 and Table 1 for the P/N of the Repair Plate. 7.1.11 If required, fill-out the holes where the damaged insert material was removed with thickened resin. Use GS510020-13 with 15-20% cotton flocks GS510060 and 2-3% Aerosil GS510063. 7.1.12 Remove the part number label from the respective repair plate. Make sure to remove any remaining adhesive of the part number label from the repair plate. 7.1.13 Apply thickened resin to the repair plate and to bonding area, refer to Figure 3. Repair Instruction RI-1078-95/1 Page 4 of 11 02 June 2021 G 115E / EG Grob Aircraft SE, Lettenbachstrasse 9, 86874 Tussenhausen-Mattsies TE.CAW.003-01 File: RI-1078-95_1 Repair of hinge bracket attachment points - ELEVATOR and HORIZONTAL STABILISER.docx Figure 3: Thickened resin applied to CFRP repair plate

Show full text

7.1.14 Bond the repair plate with the non-chamfered side through the tapered bolts on top of the repair. If required, smoothen out the excessive resin at the edges of the repair plate to gain a transition to the spar. 7.1.15 Cover the insert along the spar with two layers of glass fabric GS510031 ± 45°, refer to repair schematic in Figure 4. Figure 4: Repair schematic elevator 7.1.16 Remove the tapered bolts. 7.1.17 Install four washers (item 9 of List 9) and four bolts (refer to Table 1 for the P/N of the bolts), refer to Figure 5. If required, clean the thread of the bolts from resin. Repair Instruction RI-1078-95/1 Page 5 of 11 02 June 2021 G 115E / EG Grob Aircraft SE, Lettenbachstrasse 9, 86874 Tussenhausen-Mattsies TE.CAW.003-01 File: RI-1078-95_1 Repair of hinge bracket attachment points - ELEVATOR and HORIZONTAL STABILISER.docx Figure 5: Bolts and washers installed 7.1.18 Re-install the removed hinge bracket to the leading edge rib with the previously removed washers and standard M5 nuts. Tighten the nuts by hand just to keep the bolts heads and washers in position. If required, the length of the bolts shall be adjusted by additional washers under the nut, refer to IPC. 7.1.19 Apply thickened resin around the bolt heads and washers and cover the repair with two layers of glass fabric GS510031 ±45°, refer to Figure 6. Figure 6: Thickened resin around bolt heads and washers with covering layers of glass fabric 7.1.20 Let the repair cure at room temperature for at least 12hrs (GS510020-12) or 6 hrs (GS510020-13); then perform the 1st stage of the post-curing cycle for 8hrs at 60°C according to AMM Chapter 51-20. 7.1.21 Close the access hole and do the final stage of the post curing-cycle at 80°C, refer to AMM Chapter 51-20. 7.1.22 Paint the repair area, refer to AMM Chapter 51-20. 7.1.23 Replace the four standard M5 nuts with four self-locking nuts item 10 of List 9. Torque the self-locking nuts of the repaired attachment point with 3.6Nm plus safety torque (friction torque or braking torque). 7.1.24 Do a control surface balancing, refer to AMM Chapter 51-60. 7.1.25 If required, install the elevator, refer to AMM Chapter 55-20. Repair Instruction RI-1078-95/1 Page 6 of 11 02 June 2021 G 115E / EG Grob Aircraft SE, Lettenbachstrasse 9, 86874 Tussenhausen-Mattsies TE.CAW.003-01 File: RI-1078-95_1 Repair of hinge bracket attachment points - ELEVATOR and HORIZONTAL STABILISER.docx 7.2 Repair of Hinge Bracket Attachment Points – Horizontal Stabiliser 7.2.1 If required, make the aircraft safe for parking, refer to AMM Chapter 10-10. 7.2.2 If required, remove the elevator, refer to AMM Chapter 55-20. 7.2.3 Remove the affected hinge bracket from the horizontal stabiliser. Discard the lock nuts. 7.2.4 If required, cut an access hole into the horizontal stabiliser surface as small as practical, refer to Figure 7. Grob recommends to cut the access holes into the lower stabiliser surface. Figure 7: LH Horizontal Stabiliser Access Holes and Hinge Bracket Locations Figure 8: RH Horizontal Stabiliser Access Holes and Hinge Bracket Locations Repair Instruction RI-1078-95/1 Page 7 of 11 02 June 2021 G 115E / EG Grob Aircraft SE, Lettenbachstrasse 9, 86874 Tussenhausen-Mattsies TE.CAW.003-01 File: RI-1078-95_1 Repair of hinge bracket attachment points - ELEVATOR and HORIZONTAL STABILISER.docx Table 2: Part Numbers Reference Table for Repair Location Horizontal Stabiliser Location P/N Repair Plate P/N Bolt 19/26 115E-3719.05RI-0 115E-3103.01RI-0 20/25 115E-3719.04RI-0 21 115E-3719.03RI-0 22 115E-3719.01RI-0 23 115E-3720.01RI-0 24 115E-3720.03RI-0 7.2.5 Remove all hinge bracket bolts and washers at the affected attachment point, refer to AMM Chapter 51-70. Discard the bolts and washers. 7.2.6 Carefully grind away the remaining resin and/or two part structural adhesive holding the bolt heads in position. Note: Lightning protection is installed at all locations. The lightning protection sheets remain installed and the repair plate is installed to the side without lightning protection. Only the bolts are removed from the lightning protection strip and replaced with bolts (item 1 of List 9) and washers as required (item 9 of List 9). If a damaged lightning protection sheet has caused an additional damage to the plywood sandwich below, please contact Grob. 7.2.7 Carefully sand the repair area for the overlap repair. 7.2.8 If required, remove the damaged carbon layers and plywood material around the bolt holes with a piloted counterbore, refer to Figure 2. 7.2.9 Remove the grinding dust with a vacuum cleaner. 7.2.10 Install tapered bolts through holes in the spar. Wax the tapered bolts with release agent e.g. QZ5111 before installation. The tapered end must point to the inside of the horizontal stabiliser, refer to Figure 2. Verify that the repair plate fits in the repair area properly. If required, trim the repair plate to fit (Refer to Figure 7 or Figure 8 and Table 2 for the P/N of the Repair Plate. 7.2.11 If required, fill-out the holes where the damaged insert material was removed with thickened resin. Use GS510020-13 with 15-20% cotton flocks GS510060 and 2-3% Aerosil GS510063. 7.2.12 Cover the insert along the spar with four layers of carbon fabric GS510040 ± 45° (stagger the layers in span wise direction), refer to Figure 9. Figure 9: Repair schematic horizontal stabiliser Repair Instruction RI-1078-95/1 Page 8 of 11 02 June 2021 G 115E / EG Grob Aircraft SE, Lettenbachstrasse 9, 86874 Tussenhausen-Mattsies TE.CAW.003-01 File: RI-1078-95_1 Repair of hinge bracket attachment points - ELEVATOR and HORIZONTAL STABILISER.docx 7.2.13 Remove the part number label from the respective repair plate. Make sure to remove any remaining adhesive of the part number label from the repair plate. 7.2.14 Apply thickened resin to the repair plate and to bonding area, refer to Figure 3. 7.2.15 Bond the repair plate with the non-chamfered side through the tapered bolts on top of repair, refer to Figure 9. Smoothen out the excessive resin at the edges of the repair plate to gain a transition/chamfer to the spar. 7.2.16 Remove the tapered bolts. 7.2.17 Install the washers (item 9 of List 9) and the bolts (item 1 of List 9), refer to Figure 5. If required, clean the thread of the bolts from resin. 7.2.18 Re-install the removed hinge bracket to the trailing edge rib with the previously removed washers and standard M5 nuts. Tighten the nuts by hand just to keep the bolts heads and washers in position. If required, the length of the bolts shall be adjusted by additional washers under the nut, refer to IPC. 7.2.19 Do a bonding check, refer to AMM 51-80. 7.2.20 Apply thickened resin around the bolt heads and washers and cover the repair with two layer of glass fabric GS510031 ±45°, refer to Figure 9. 7.2.21 Let the repair cure at room temperature for at least 12hrs (GS510020-12) or 6 hrs (GS510020-13); then perform the 1st stage of the post-curing cycle for 8hrs at 60°C according to AMM Chapter 51-20. 7.2.22 Close the access hole and do the final stage of the post curing-cycle at 80°C, refer to AMM Chapter 51-20. 7.2.23 Paint the repair area, refer to AMM Chapter 51-20. 7.2.24 Replace the standard M5 nuts with self-locking nuts item 10 of List 9. Torque the self- locking nuts of the repaired attachment point with 3.6Nm plus safety torque (friction torque or braking torque). 7.2.25 Install the elevator, refer to AMM Chapter 55-20. Repair Instruction RI-1078-95/1 Page 9 of 11 02 June 2021 G 115E / EG Grob Aircraft SE, Lettenbachstrasse 9, 86874 Tussenhausen-Mattsies TE.CAW.003-01 File: RI-1078-95_1 Repair of hinge bracket attachment points - ELEVATOR and HORIZONTAL STABILISER.docx 7.3 Repair of contact surface of hinge bracket attachment Note: The following instructions are only applicable for an uneven surface at the hinge bracket attachment points with a maximum gap of 0.3mm i.a.w. MSB-1078-205/3 or later. If any kind of damage to the laminate is evident or the height of the gap exceeds a maximum of 0.3mm, please contact Grob. 7.3.1 If required, make the aircraft safe for parking, refer to AMM Chapter 10-10. 7.3.2 If required, remove the elevator, refer to AMM Chapter 55-20. 7.3.3 If required, remove the affected hinge bracket from the elevator / horizontal stabiliser. Discard the lock nuts. 7.3.4 Carefully sand the repair area 7.3.5 Fill up the gap with GS510109. Level the adhesive with a spatula. Let the adhesive cure according to manufacturer’s instruction. 7.3.6 If required, grind the adhesive level with the spar. 7.3.7 Install the removed hinge bracket with the previously removed washers and new self-locking nuts item 10 of List 9. 7.3.7.1 If the hinge bracket attachment point has been repaired i.a.w. steps 7.1 or 7.2, torque the self-locking nuts with 3.6Nm plus safety torque (friction torque or braking torque). 7.3.7.2 If the hinge bracket attachment point has not been repaire i.a.w. steps 7.1 or 7.2, torque the self-locking nuts with 1.5Nm plus safety torque (friction torque or braking torque). 7.3.8 Install the elevator, refer to AMM Chapter 55-20. Repair Instruction RI-1078-95/1 Page 10 of 11 02 June 2021 G 115E / EG Grob Aircraft SE, Lettenbachstrasse 9, 86874 Tussenhausen-Mattsies TE.CAW.003-01 File: RI-1078-95_1 Repair of hinge bracket attachment points - ELEVATOR and HORIZONTAL STABILISER.docx 8 Weight and CG Do a control surface balancing, refer to AMM Chapter 51-60. Do a weight and balance, refer to AMM Chapter 08-10. 9 Material and Availability Item P/N Description Qty. per A/C 1 115E-3103.01RI-0 Bolt 60 2 115E-1263.01RI-0 Bolt 8 3 115E-3719.01RI-0 Repair Plate 1 4 115E-3719.03RI-0 Repair Plate 1 5 115E-3719.04RI-0 Repair Plate 2 6 115E-3719.05RI-0 Repair Plate 2 7 115E-3720.01RI-0 Repair Plate 1 8 115E-3720.03RI-0 Repair Plate 1 9 DIN9021-A2-5.3 Washer AR 10 LN9348-05 Self-Locking Nut 68 11 115E-3763.01RI-0 Repair Plate 2 12 115E-3763.03RI-0 Repair Plate 2 13 115E-3763.04RI-0 Repair Plate 2 14 115E-3763.05RI-0 Repair Plate 2 For further repair material, refer to AMM Chapter 51-30 Table 3: Cross Reference List Fiber Materials P/N Grob P/N (Manufacturer) Description GS510030 92110 (P-D Interglas Technolgies GmbH); 917 (Porcher Industries) Glass Fiber Fabric Twill 2/2, 163 g/m2 GS510031 92125 (P-D Interglas Technolgies GmbH); 3063 (Porcher Industries) Glass Fiber Fabric Twill 2/2, 280 g/m2 GS510040* 98141 (P-D Interglas Technolgies GmbH); 3692 (Porcher Industries) 452 (C. Cramer, Weberei, GmbH & Co. KG) KDK 8042 (SGL CARBON GmbH) Carbon Fiber Fabric Twill 2/2, 204 g/m2 GS518002 459 (C. Cramer, Weberei, GmbH & Co. KG) Carbon Fiber Fabric + Alu Mesh for Lightning Protection *HTA Fiber! 10 Special Tools Tapered Bolts 11 Appendices N/A Repair Instruction RI-1078-95/1 Page 11 of 11 02 June 2021 G 115E / EG Grob Aircraft SE, Lettenbachstrasse 9, 86874 Tussenhausen-Mattsies TE.CAW.003-01 File: RI-1078-95_1 Repair of hinge bracket attachment points - ELEVATOR and HORIZONTAL STABILISER.docx 12 Accomplishment The instructions in paragraph 7 have to be accomplished and certified in the logbook by authorized staff: - in EASA countries according to EASA Part 66 - in non-EASA countries according to national regulations with respect to maintenance. 13 Contact For questions and assistance or in case of occurrence please contact: Product Support, phone: +49 8268 998105 fax: +49 8268 998200 e-mail: productsupport@grob-aircraft.com

All GROB G-115 service bulletins