The following general safety precautions should be observed when you make repairs to reinforced plastic components. You should review these safety precautions before attempting any repairs to reinforced plastics.

1. Local station safety regulations as to fire and health hazards must be complied with.

2. All solvents are flammable; therefore, observe proper handling procedures.

3. Personnel involved in the mixing or handling of catalyzed resin prior to the curing operations should wear rubber gloves. After using rubber gloves, personnel should clean their hands with soap and water and rinse with vinegar to neutralize any catalyst particles.

4. Never mix the catalyst and promoter together, as they are explosively reactive as a mixture. Always mix the promoter with the resin first, and then add the catalyst to the mixture.

5. The toxicity of polyester formulation has not been definitely established. Some of the components are known to cause nasal or skin irritation to certain individuals. Adequate ventilation should be provided.

6. The sanding operation on glass cloth reinforced laminates gives off a fine dust that may cause skin, eyes, or respiratory irritations. Inhalation of excessive amounts of this dust should be avoided. Protection should be provided for respiration, eyes, and skin.

7. Do not store catalyzed resin in an airtight container or an unvented refrigerator.

The repairs discussed in this section are applicable to structural-type sandwich construction consisting of aluminum alloy facings bonded to aluminum honeycomb and balsa wood cores.

The most common types of damage to the surface are abrasions, scratches, scars, and minor dents. These minor surface damages require no repair other than the replacement of the original protective coating to prevent corrosion if no breaks, holes, or cracks exist. The procedures and materials used in replacing the original protective coating are outlined later in this chapter.