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Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Resin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
3. Glass and Carbon Cloth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4. Core Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5. Laminating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
6. Bonding Paste (Thickened Resin) . . . . . . . . . . . . . . . . . . . . . . . . . 207
7. Curing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
8. Exterior Paint Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
9. Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
AIRCRAFT
DA 40 Series
AMM
Standard Practices and
Structures
Doc # 6.02.01
Rev. 5 51-CONTENTS Page 3
20 Sep 2007
Section 51-30
Materials
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Approved Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 51-40
Fasteners
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Replace a Quick Release Fastener Stud . . . . . . . . . . . . . . . . . . . 201
Section 51-60
Control Surface Balancing
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
AIRCRAFT
Standard Practices and
Structures
DA 40 Series
AMM
Page 4
20 Sep 2007 51-CONTENTS Doc # 6.02.01
Rev. 5
Section 51-80
Electrical Bonding
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Maintenance Practices
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2. Test the Electrical Bonding System . . . . . . . . . . . . . . . . . . . . . . . 201
AIRCRAFT
DA 40 Series
AMM
Standard Practices and
Structures
Doc # 6.02.01
Rev. 5 51-00-00 Page 1
20 Sep 2007
CHAPTER 51
STANDARD PRACTICES AND STRUCTURE
1. General
The DA 40 is a single-engine, low-wing monoplane of composite construction. It has a ‘T’ tail and a
fixed tricycle landing gear with a nose wheel that can caster.
The DA 40 fuselage has a semi-monocoque structure. Two glass fiber reinforced plastic (GFRP) halfshells
make the fuselage skin. The fuselage shells have many layers of glass cloth. Rigid foam inserts
give stiffness to the fuselage shells where necessary. All of the main structural components are GFRP
rigid moldings. Many layers of glass cloth bond together to make each molding. Some components
have layers of carbon fiber cloth to give more strength and stiffness.
The DA 40 has a cantilever wing. The wing has top and bottom shells. It has front and rear spars and
a root rib made in three parts. Each shell has a carbon fiber reinforced plastic (CFRP) outer skin, a
rigid foam core and a GFRP inner skin.
The vertical stabilizer is part of the fuselage. The aft part of the left and right fuselage shells make the
left and right shells of the vertical stabilizer.
Each wing has two I-section spars. The front spar on one side is the same as the rear spar on the
opposite side. Many layers of uni-directional carbon fiber make the spar caps. The number of layers
in the spar caps decreases from root to tip. Each spar has a shear web. The shear web has GFRP
skins and a rigid foam core. Glass cloth fillets attach the spar caps to the shear web.
A rear web closes the trailing edge of the wing. An end rib closes the outboard end of the wing. A
removable GFRP tip attaches to the wing shells and outer rib with screws.
The flaps and ailerons have top and bottom shells. Each shell has mixture of CFRP and GFRP cloth.
The shells have rigid foam cores and bond together.
The horizontal stabilizer has top and bottom shells. Each shell has GFRP skins. The horizontal
stabilizer has a front spar and a rear spar. Three pairs of ribs give strength to the center area. The
elevator has top and bottom shells. Each shell has GFRP skins with a rigid foam core.
　
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