This leaf issited with AL. No. 8: AP, 28508, June, 1945 Volume 11, Part 8 SECTION 3 INSTRUCTIONS FOR REPAIR OF COOLANT RADIATORS (SECONDARY-SURFACE TYPE) y-SURFAGE” TORSAP.2B504, Vol 6, Part 2(AL.22) SECTION 3 INSTRUCTIONS FOR REPAIR OF COOLANT RADIATORS (SECONDARY-SURFACE TYPE) LIST OF CHAPTERS Note —A list of contents appears at the beginning of each chopter 1 General instructions on repair of secondary-surface radiators 2. Gallay secondary-surface radiators 3 Marston secondary-surface radiators 4 Morris secondary-surface radiators 5. Serck secondary-surface radiators (AL.22, Oct 56) RESTRICTEDTv AIR MINISTRY April, 1945 This is A.L. No. 5 to A.P. 2850A, Vol. II, Part 3, and concerns Sect. 3 Delete after title of Chap. 2 in the List of the outer margin of the list, insert this in tl } To be issued later" write “AL, chapter, and make an entry in the Amendment Record Sheet, Chapters, use only) This leaf issued with A.L: No. 5 April, 1945 AP. 2850A, Vol. II, Part 8, Sect. 3 CHAPTER 2 INSTRUCTIONS FOR REPAIR OF GALLAY SECONDARY-SURFACE RADIATORS LIST OF CONTENTS Para. General Antroauction s,s Repairs to the Gallay secondary-surface matrix Description oo 4 Tools and equipment .. 2 8 Repairing leak at tube seam 2 9 Leaks at sides of tubes... 10 Patch repair of damaged tubes . -u Blanking-off damaged tubes 14 ‘Tube to tube-plate leaks. 7 Repair notes of individual Gallay assemblies Introduction =... 19 Para. Assembly E. 2018-1 and E, 2018-2 (Stores Ref, 258/213-4) LIST OF ILLUSTRATIONS Fig. Section of the Gallay secondary surface ‘matrix Cutting tool for Gallay matrix repairs Repairing leak at tube seam Cutting away section of airway corrugation Extracting airway corrugation from matrix Solder-blocking leak at side of tube Fitting new section of airway corrugation. . Repair of damaged tube by patching ‘Damaged tube blanked off Key $0 repair operations (E, 2018-1 and , 2018-2) 10 Removing mounting channels (E. 2018-1 and E. 2018-2) .. 0 Removing centre Joint step (E. 2018-1 and FE, 2018-2) 12 General 2. 20 Parts and materials. oo a Key to repair operations... 0 Leak at centre joint strip + 26 Damage to tanks... “2 Dismantling and fitting tanks. 29 Leak at joint of tank and collector plate 31 Damaged inlet and outlet pipes. . 32 Renewing outlet pipe... 0s. 33 Renewing inlet pipe .. + 36 Damaged locating brackets 37 ‘Renewing locating brackets 38 Drain plug and flange... - 40 ‘Damaged channels 41 Data for testing «. . 2 Standard packing case .. 0... 43 Fis. Removing tanks (E. 2018-1 and E. 2018-2) 13 Dimensions for fitting mounting channels 1E. 2018-1 and E. 2018-2) 4 Fitting mounting channels (E. 2018-1 and F, 2018-2) 15 Repairing leak at joint of tank and collector Plate (E. 2018-1 and E. 2018-2) + 16 Sectional view showing location of internal wechannel (F, 2038-f and E, 2018 7 Unsweating, ontet pipe & 2018-1 and E, 2018-2) .. 18 Removing outlet pipe (E.2018-1 and E. 2018-2) . 19 Dimensions for fitting locating brackets and drain plug (F. 2018-1 and E. 2018-2) .. 20This leaf issued with A.L. No. 5 ALP. 2850A, Vol. II, Part 3, Sect. 3, Chap. 2 April, 1945 GENERAL Introduction 1, Gallay secondary-surface radiators are made in a variety of patterns to suit the requirements of the different aircraft for which they are designed, and are described in Vol. I, Sect. 3, of this publication. 2. When undertaking repairs reference should first be made to Chap. | of this Section, and the instructions given there on the preliminary cleaning and testing, general repair and final testing ‘of secondary-surface radiators should be followed. 3. The information in this Chapter is supplementary, and covers (i) general instructions for the repair of the Gallay secondary-surface matrix, which are applicable to all Gallay radiators ‘of this type; and (ii) any additional information necessary for the dismantling, repair and re-assembly of particular Gallay secondary-surface radiators REPAIRS TO THE GALLAY SECONDARY-SURFACE MATRIX Deseription 4, The Gallay secondary-surface matrix consists of a series of coolant tubes or “envelopes’’, intersected by airway corrugations, as shown in fig. 1. Note that in this matrix each tube extends from the front to the rear face of the matrix. It differs in this respect from most matrices of the secondary-surface type, in which the depth from face to face is made up of two or more banks ‘of tubes. Gallay tubes are open at the top only, and are divided by a baffle which directs the ‘coolant flow down one side of the tube and up the other side. () PUY 7 JRE Yh HRY SVEVNY 4, Coolant tube, 2, Alrway corrugation and fin. 3. Tube seam. 4. Internal stiffener or flow-plate. ‘8. Tube seam. 6. Internal baffle. Fig. 4—Seetion of the Gallay secondary-surface matrix 5. The tube envelopes are made of tinned copper, 0-006 in, thick, and are seamed at their front and rear edges. Each tube is strengthened by an internal stiffener, or flow-plate, of 0-006 in. thick-tinned copper. The stiffener is corrugated and perforated, and runs the full length of the tube, The external airway corrugations on either side of each tube consist of a vertical fin of 0-005 in. thick tinned copper, flanked by corrugated strips of the same material, which are perforated to set up turbulence in the air stream passing through the air passages and thus assist in the rapid dissipation of heat. 6. Anend plate, or collector plate, is fitted to the top of the matrix, and is built up of strips of 20 S.W.G. sheet brass inserted between the ends of the tubes and soldered to the upper edge of ‘each section of airway corrugation. Flanges on the edges of the collector plate strips fit against the sides of the tubes and the joint is heavily soldered. 7. As with other secondary-surface matrices, the matrix is not stripped down in the course of normal repair, and it is not possible to remove tubes or to fit new tubes, extensive damage cannot, therefore, be rectified unless facilities are available for major repair, as explained in Chap. 1. Much can be done, however, to maintain the serviceability of the radiator by solder~ blocking leaks, and by carefully patching or blanking-off tubes when only one or two are affected, and repairs of this nature are dealt with in the following paragraphs.‘Tools and equipment, fig. 2 8. For the repairs dealt with here general tools and equipment are required as listed in Chap. 1. In addition, ‘the special cutting tool illustrated in fig. 2 is needed for -removing sections of airway corrugation, as explained in para. 10. This tool can be made up from }-in. dia. silicon steel rod, the end of which should be flattened and knife-edged as shown. The length of the tool, excluding the handle, should be approximately 10 in., and the maximum width at the forked’end must not exceed # in. INSIDE OF “W'KNIFE EDGE Fig. 2.—Outting too! for Gallay snatrix repairs Repairing leak at tube seam, fig. 3 9, The most likely place for a leak to occur is along the seams at the edges of the tubes. Such leaks can be solder-blocked without difficulty, using a gas/air blow-pipe adjusted to give a small, concentrated “pencil” flame (see fig. 3). Care must be taken not to burn the tube, and the flame shouldbe concentrated on the area of therepair, avoiding the airwaycorrugationsasmuch as possible. Fig. 8.—Repairing leak at tube seamThis leaf issued with A.L. No. 5 A.P. 2850A, Vol. II, Part 3, Sect. 3, Chap. 2 April, 1945 Leaks at sides of tubes, fig. 2, 4, 5, 6 and 7 10. Minor leaks at the sides of tubes can sometimes be “caught” with solder and the blow-pipe, but it is necessary to remove a section of the airway,corrugatjon to obtain access to the damaged area. To effect this repair proceed as follows:— (i) Locate the defective tube, and determine the approximate position of the leak, by air- under-water pressure tests, as described in Chap. 1 (ii) Cut away a section of the airway corrugation, to a depth of about 1} in., adjacent to the leak, using the special cutting tool illustrated in fig. 2. Hold the tool at right-angles to the matrix face, as shown in fig. 4, and cut through each gill as close as possible to the tube, running the knife edge of the tool carefully along the length of the gill from the Fig. 4—Cutting away section of airway corrugation front to the rear face of the matrix, When all gills in the section to be removed have been cut, sever the vertical fin, and this will enable the section of airway corrugation to be withdrawn from the matrix with a pair of pliers, see fig. 5. Note.—When cutting the gills great care must be taken to avoid puncturing the tubes. \iii) The operation described in the preceding sub-para, will leave short ends of the corrugation attached to the tubes on either side, as shown in inset to fig. 5. These must be removed, Each piece of metal should be “peeled” off by gripping one end with a pair of fine-pointed pliers and gently pulling it away from the tube, at the same time heating it slightly with a very fine blow-pipe flame. As the corrugation comes away from the tube, move the flame gradually forward, and continue pulling until the whole length is removed. This should be done without allowing the flame to remain at one point for more than a few seconds.mvt YAVAYAVAYAVAY VAY AY APY YY AYA AY AY A AY AYAYAYAY A VIVIAN Ni Fig. 5.—Extracting airway corrugation from matrix. Inset on right is an enlarged view of matrix section as it should appear when the corrugation Is removed, showing ‘short lengths of metal still adhering to the tubes. Fig, 6.~Solder-blocking leak at side of tubeThis leaf issued with AL. No. 5 AP. 28504, Vol. I, Part 3, Sect. 3, Chap. 2 April, 1945 (iv) The leak can now be located exactly and repaired. Find the exact posigion of the leak by connecting the radiator to an ais-line and applying an internal pressure up to 50 Ib. per sq. in, Then turn the radiator on its side (that is, so that the tubes are horizontal) and, working from the face of the matrix nearer to the leak, solder-block the leak, using a long, and very fine blow-pipe flame not exceeding } in. dia., as shown in fig. 6. Note.—Extreme care must be used not to burn or over-heat the tube. Confine the flame to the area of the repair (¥) Test that the leak has been caught by applying an internal air pressure of 50 Ib. per sq. in, and immersing the radiator in water (vi) Cut a new strip of airway corrugation of the correct length and insert in place of that removed (fig. 7). Solder bgth ends of the corrugated strip to the adjacent tubes and airway corrugation, (sui) Thoroughly cieanse the radiacu ‘1 «yaa tl ‘vaces of flux; dry, and apply final tests in accordance with the instructions in Chap. 1 Fig. 7.—-Fitting new section of airway corrugation Patch repair of damaged tubes, fig. 8 II. A tube which has been damaged and is beyond the repair described in para, 10 may sometimes be repaired efficiently by patching, providing that the damage is not excessive and is confined to an area within an inch or two of either face of the matrix. Such patches should not in general, exceed 2 in, in length To patch a tube, proceed as follows-— ()) Cut away a section of the airway corrugation from around the damaged area, as explained in para. 10, sub-para. (ii) and ii), but removing the corrugation on doth sides of the damaged tube (sce(ii) Thoroughly clean and flux the area to be patched and heavily tin it, using a 3 in. dia. blow-pipe flame, which must be concentrated on the repair. (Avoid over-heating or burning adjacent tubes or airway corrugation.) (iii) Cut the patch to the appropriate size from copper foil, 0-008 in. thick (Stores Ref. 308/484) and well tin the patch on both sides. Form the patch to the correct shape, seat it over the area of the damage, and firmly sweat into position, using a fine blow-pipe flame as described in the preceding sub-para, JASSoSa ZEESIESIER) SSeS ES iSs) SSIES ISS iss ESIESISS IES) SSISSiSeies SSIS iSeiss ESESIEE SS SI SiS SSISSS6 SEISSSS SSSR SSIRSIg ESESR SSS RSISSIg H RSIES|a J SSiSsiS «a SSice ete fsS == hers SciSSiSS SS SeIER ISS IES COPPER FOIL PATCH: Fig. 8.—Repair of damaged tube by patching (iv) Fit a new section of airway corrugation on each side of the patched tube, and solder into position, as explained in para. 10, sub-para. (vi) 12, As an alternative to removing the airway corrugation, it is sometimes possible to apply the patch by carefully bending the corrugations in the area of the repair so that a slight gap is left on each side of the tube. 13, Upon completion of the repair all traces of flux must be removed i instructions in Chap. 1. Final tests must be applied with especial care. accordance with the Blanking-off damaged tubes, fig. 9 14. When tubes are too badly damaged to be repaired the radiator can be restored to serviceable condition by sealing the open ends of the tube or tubes concerned so that they are blanked off from the coolant flow. It should be carefully noted, however, that no more than 2 per cent. of the total number of tubes in any one matrix may be blanked off, and the repaired radiator must conform with the flow-test requirements for repaired radiators. 15, To seal the tube-ends it is necessary to remove the tanks (see the instructions on the partial dismantling of Gallay radiators later in this chapter). The top of the tube should then be thoroughly cleaned and fluxed and blocked with solder along its full length (see fig. 9). A hole should be pierced through the faulty tube so that subsequent air pressure tests will show whether the tube end has been efficiently sealed. No air should escape from the test hole when pressure is applied. This test should be made before replacing the tanks, a sheet of brass of the appropriate size being soldered in position to provide a temporary airtight and watertight casing.This leaf issued with A.L. No. 5 A.P. 2850A, Vol. II, Part 3, Sect. 3, Chap. 2 April, 1945 _ 16. The usual cleansing and testing operations should be carried out carefully when the repair is completed, in accordance with the instructions in Chap. 1. Fauiry TUBE. ‘BLANKED OFF TAYANAVAVAVAV/; AAA Vv Fig. 9.—Damaged tube blank Tube to tube-plate leaks 17. Leaks between the tubes and the collector plate can usually be solder-blocked without removal of the top tanks, access to the defective joint being obtained by cutting away a portion of the airway corrugation of the matrix in the area concerned. The repair is effected as follows:— (i) Locate the leaking joint by air-under-water pressure tests, a maximum pressure of 50 Ib. per sq; in, being applied. (ii) Cut away approximately 1} in. of airway corrugation immediately under the leak, using the special cutting tool, and clean up the sides of the tubes, as described in para. 10, sub-para. (ii) and (ii). (iii) Invert the radiator, and clean the joint a5 thoroughly as possible. Heavily tin the joint, using a fine, carefully-controlled blow-pipe flame not exceeding } in. dia., and being careful not to burn the tube. (iv) Test the repair by immersing the radiator in water and applying an air pressure of 50 Ib. per sq. in. (v) When tests show that the leak has been completely sealed, fit and solder in a new section of airway corrugation. 18. Upon completion of the repair all traces of flux must be removed and final tests applied in accordance with the general instructions in Chap. 1. REPAIR NOTES ON INDIVIDUAL GALLAY ASSEMBLIES Introduction 19. The following notes are supplementary to the instructions in the earlier part of this chapter, and will be of assistance in dealing with particular Gallay radiator assemblies. The radiators are identified by their assembly part numbers and Stores References, which are given on the data plate affixed to the case of each radiator.This leaf issued with A.L. No. 6 April, 1945 A.P. 28504, Vol. IT, Part 3, Sect. 3, Chap. 2 Fig. 10.—Key to repair operations om Gallay radiator assembly 3 REPAIRING LEAK AT. ‘COLLECTOR PLATE 4: REPAIRING DAMAGE TO LOWER SHELL 5 REPAIRING DAMAGED CHANNEL RENEWING CHANNEL 6 REPAIRING DAMAGED FRONT TANK REMOVING AND REFITTING FRONT TANK 7 RENEWING DRAIN 3 REPAIRING OR RENEWING FRONT LOCAT- ING. BRACKET 9 REPAIRING OR. RENEWING REAR LOCAT. ING BRACKET. Par 36/6 ois si nym Bm sm 79/00 79/00 (&,2018-1 and E, 2018-2) KEY TO Fic. 10 Chap. 1 Chap. 2 ae 718 Cp Crp? era, Para. 10 REPAIRING LEAK AT CENTRE JOINT STRIP e REMOVING AND REFITTING CENTRE JOINT ‘STRIP ~ 2/0 17 REPAIRING DAMAGED REAR TANK sir 28 REMOVING AND REFITTING REAR TANK 29/30 42 REMOVING AND REAITTING PIPE SUPPORT — 36 4 REPAIRING DAMAGED OUTLET PIPE ws RENEWING OUTLET PIPE = sas 144 REPAIRING DAMAGED INLET PIPE aes RENEWING INLET PIPE we 15 REPAIRING DAMAGEO CHANNEL ny RENEWING CHANNEL 5/77 29/38ASSEMBLY E. 2018-1 AND E, 2018-2 (STORES REF. 25B/213-4) General 20. These assemblies are respectively port and starboard radiators of the same aircraft, and differ only in the relative positions of the inlet and outlet pipes. A description of the radiators is given in A.P. 2850A, Vol. I, Section 3. Parts and materials 21. The following spares for these radiators have been provisioned for the use of Repair Depots and Maintenance Units equipped to undertake radiator repairs:— coe | sone boo Pot sale Ref No | Fig. 10 ‘Airway corrugation | SS6C | Xéimo coupling] 61/72 Bracket Agos25° eet int ti Eaoie-t5 Channel aoie-13 Bape, inlet C0180. Me outlet | Coie | | Support 21) Ba01gt6 Pig, drain Lin BSP. with colar Tank, frost Eoie-s rear E 20184 Wisner drain 1) fim BSP. soft a 22. Quantities of brass sheet of the appropriate gauge and other materials should be available for patch repairs. The following may be required for this purpose:— Mid Steel, 18 saw.c. [1] $.3 | Psteh Siar of chant | | Heo. | Nomenclature Sp. Required for 308/108 | Bras steet 20 sige | SS 208 | FAG soir of sl and of ill and ober pps Sop/ase | Copper to o08 i S255 | Patch repair of tubes sony 23. General materials are required as listed in Chap. 1 of this Section. Key to repair operations, fig. 10 24. Matrix repairs are dealt with in-the same manner as those of other Gallay secondary- surface radiators and are explained in the earlier part of this Chapter. The following notes deal with other repair operations which may be necessary, including the repair of leaks in or minor damage to the case, and the fitting of new tanks, inlet and outlet pipes, and other components. 25. A keyed diagram to the repair operations dealt with here, and to any general information on the same operations given in Chap. 1, is in fig. 10, which shows the port radiator assembly partially dismantled. This figure also shows the maximum extent of dismantling permissible in normal repair work, from which it will be seen that the matrix and lower shell are not stripped down, Leak at centre joint strip 26. A leak at the centre joint strip (10 in fig. 10) can usually be repaired by re-sweating the defective joint. Thoroughly clean the area of the repair with a wire brush, apply flux and run solder into the faulty joint. Avoid overheating the shell, or the internal joints will run, necessitat~ ing dismantling the caseThis leaf issued with A.L. No. $ April, 1945 Damage to tanks, 6 and 11 in fig. 10 AP. 2850A, Vol. I, Part 3, Sect. 3, Chap. 2 27. Cracks and splits, holes, dents and similar damage to the shell of the tanks, or to the lower shell, can be dealt with in accordance with the general instructions on these repairs in Chap. 1. 28, Where damage is too extensive to be repaired by patching ot other external treatment, it may be rectified by removing the damaged section of shell and fitting a new section, providing that the damage is confined to the top tanks. The lower tank shell must not be removed unless jigs are available, and any damage to this shell which cannot be repaired in sifw should be treated as requiring major repair. As any extensive damage to the case is likely also to affect the matrix or other internal components.the entire radiator assembly must be very carefully examined before purely external repairs are carried out. Dismantling and fitting tanks, fig. 11, 12, 13, 14 and 15, 29, When it is necessary to fit a new top tank, an appropriate spare should be used if available (sce list of spares earlier in these notes). Ifa'spare is not obtainable within a reasonable time, the part can be manufactured locally from the details and dimensions on the approved drawing. ,To renew either or both of the top tank shells, proceed as follows:— () Remove the mounting channels by cuttin, off the rivet heads (I in fg. 11) and unsweating all round. If difficulty is experienced in removing a channel in one piece. the operations can be simplified by cutting it with a hacksaw at four points (2) and unsweating and removing it in 1, Drive off rivet heads. 2. Cut ehannols with hacksaw and unsweat in sections. Fig, 14.—Romoving mounting ehanaels = 2018-1 and, 2018-2) sections. When cutting the channel care must be taken not to damage the case. A. Drivé off rivet heads. 2. Unsweat strip. Fig. 12,—Removing centre joint strip (E.2018-1 and , 2018-2) (ii) (iii) (iv) Cut off the heads of ‘tha, pop rivets at both ends of the centre joint strip (I in fig. 12). Un- sweat the strip and remove. Unsweat the ends only of the Jower shell (I in fig. 13) and carefully roll back for a few inches to uncover the ends of the tanks (2). Do not remove the lower shell or unstveat more than is necessary to give access to the ends of the tank shells, and avoid undue bending. The tanks can now be removed by unsweating the following joints:—tank to collector plate (2); front tank shell to front header flange (3); tank flanges to centre baffte (4); and rear tank shell to rear header flange (5). Fit new tank shells and soft solder them to the front and rear header flanges, centre baffie, and collector plate angles (2, 3, 4 and 5).Fig. 14.—Dimensions for fisting mounting channels. (E, 2018-1 and E. 2018-2) Replace the ends of the lower shell and sweat into position. 1. Ends of lower shell unsweated and rolled back. 2. Tank to coll . frontheader Mange jolnt. 4. Tank fanges to of Baffle joint. 6. Hear tank to rear header fange ; ‘elat. (vi) Fit the centre joint strip by soldering and Fig. 18—Removing tanks (B. 2018-1 and riveting, picking up existing holes in foie) Bret ne” PENG NP ssi (vii) Re-fit the channels, or, if necessary, fit new channels, which must be accurately positioned in accordance with the dimensions called for on the approved drawing (see fig. 14). The operation can be assisted by the use of sheet metal distance pieces used as illustrated at | in fig. 15, the channel being lightly tapped into position with a mallet. The channel should be tack-soldered as the position is checked, and the distance pieces moved progressively round its circumference. Finally soft-solder and rivet the channels, picking up existing holes in shell (3 in fig. 15). (viii) Fit locating lugs and drain plug (see para. 38 to 40) 30. Throughout this operation it is essential to avoid overheating the shell, or joints in the collector plate and matrix may run. Upon completion of the work, remove all traces of flux by thoroughly washing all internal and external surfaces, as described in Chap. 1, and carry out all final tests. Leak at joint of tank and collector plate, 3 in fig. 10 and fig. 16 and 17. 31. To repair a leak at the joint of the front and rear tanks and collector plate it is necessary partially to strip down the case, as shown in fig. 16. Proceed as follo () Remove external stiffening channels by cutting off the rivet heads and unsweating all round (see para. 29). (ii) Cut off the heads of the pop rivets at the end of the centre joint strip overlapping the joint to be repaired. ‘Unsweat the end of the centre joint strip only, to enable the strip to be rolled back locally, as shown at 3 in fig. 16. Do not bend the strip more than is necessary. 1. Sheet-metal distance pieces. 2. Solder channels inposition. 3. Rivet, pleking upexisting holesin ease Fig. 15.—Fltting mounting chapnels (E, 2018-1 and E. 2018-2)This leaf issued with A.L. No. 5 April, 1945 1. Infernal stiffening ehannel. 2. Collector Plate angle. 3. Tank. 4. Centre joint strip. 5. Lower shell. Fig. 17.—Sectional view showing location of iniernal_ stifening channel (B, 2018-1 and E, 2018-2) A.P. 28504, Vol, II, Part 3, Sect. 3, Chap. 2 (iii) Unsweat one end only of the lower shell, as shown at Vin fig. 16, and roll back the shell to the extent necessary to give access to the leaking joint. (Do not uunsweat a greater length of shell than that illustrated, and avoid excessive bending.) (iv) Unsweat the internal stiffening channel (1 in fig. 17) and remove, to enable visual inspection of the solder penetration to be made when the joint is re-tinned, as explained below. (v) It should now be possible to block the leak by cleaning and fluxing the area of the shell concerned and running fresh solder through the sweating holes in the lower edges of the upper tank shells (2 in fig. 16). (vi) Replace the stiffening channel and sweat into position,(vii) Carefully replace the end of the lower tank shell and sweat into position. (viii) Replace the end of the centre joint strip, and pop rivet and solder firmly into position, picking up existing rivet holes. (ix) Replace channels by sweating and riveting in position, picking up existing holes. Channels must be accurately fitted in accordance with the dimensions called for in the approved drawing (sce also para. 30). Damaged inlet and outlet pipes, 13 and 14 in fig. 10 32. Small cracks or dents in inlet or outlet pipes can be dealt with according to the general instructions in Chap. 1. If the damage cannot be repaired by these methods new parts should be fitted Renewing outlet pipe, 12 and 13 in fig. 10, and fig. 18 and 19 33. The outlet pipe is mounted in two removable flanges which are riveted and soft-soldered to the rear header and the centre baffle (see fig. 18). The pipe is soft-soldered to the flanges and can be removed without detaching the flanges from the radiator. 434, To detach the pipe from the inner flange it is necessary to remove the tanks, which should be done as explained in para. 29. The pipe ean then be removed, and a new pipe ited, as follows:— ()) Clamp the inner flange of the pipe to the centre baffle (3 in fig. 18). (ii) Unsweat the pipe support (12 in fig. 10) which is soft-soldered over the outer flange of the outlet pipe and the flange of the inlet pipe. 1. Blow-pipe flame concentrated on collar of outer lange. 2. Heating collar of inner flange. 3. Clamp securing inner flange to ballle. Fig. 18.—Unsweating outlet pipe (E. 2018-1 and E, 2018-2) (iii) Using two blow-pipes, heat the collars of both flanges (2 in fig. 18) until the solder has melted sufficiently to allow the pipe to be withdrawn, leaving the flanges still in position, as shown in fig. 19. (iv) Thoroughly clean the inner surfaces of the flanges and remove the old solder. Dress the end of the new pipe to fit and soft-solder into placeThis leaf issued with A.L. No. 5 A.P. 2850A, Vol. II, Part 3, Sect. 3, Chap. 2 April, 1945 (v) Soft-solder the appropriate Avimio coupling to the connection end of the pipe, carefully conforming to the dimensions called for in the approved drawing. 35. When this repair is completed the entire radiator must be washed internally and externally in accord- ance with the genetal instructions, and all final tests must be applied. Renewing inlet pipe, 14 in fig. 10 36. The inlet pipe is soldered into.a removable flange Fig. 19.—Removing outlet pipe (E. 2018-1 which is in its turn riveted and soldered to the rear ‘and E, 2018-2) header. The-pipe can be renewed without removis ‘the flange from the header and without dismantling the radiator, by first unsweating an removing the pipe support (12 in.fig. 10), and then carefully heating the collar of the flange until the solder melts sufficiently to allow the pipe to be withdrawn. A new pipe should then be dressed to fit the flange and soft-soldered into place. Finally the appropriate Avimo coupling should be soft-soldered to the connection end of the pipe, in accordance with the dimensions, called for on the approved drawing. Damaged locating brackets, 8 and 9 in fig. 10 37. Fractured or otherwise damaged locating lugs should be removed and replaced by new parts (see list of available spares). If spares are not immediately available the parts may be manufactured locally from the details on the approved drawing. Renewing locating brackets, fig. 20 38. To renew a locating bracket, proceed as follows:— (@) Cut off the heads of the rivets and heat the bracket flange to unsweat it, using a concentrated blow-pipe flame and observing the. precautions explained in the general instructions to avoid overheating and the running of internal joints. ) With the bracket removed, drill out the lower portion of the rivets and thoroughly clean the shell in the vicinity of the work (iil) Drill the flange of the new bracket for TNP/D422, B.S. yy in. dia. pop rivets, picking up existing holes in shell. . : (iv) Rivet and solder the bracket into position, checking its position against the dimensions called for on the approved drawing, see fig. 20. . 39, Upon completion of the work remove all traces of flux by thoroughly washing the radiator as described in the general instructions, and submit the radiator to all final tests. 40. The drain is a} in. B.S.P. commercial plug with collar, the 2. flange being soft-soldered to the rear tank. shell. It is unlikely to require any attention beyond the replacement of a lost or damaged plug, but if it is necessary to renéw the flange it should be fitted in Drain plug and flange, 7 in fig. 10 and fig. 20 | accordance with the dimensions in fig. 20. I Damaged channels, 5 and 15 in fg. 10 I | _ 41, Minor cracks and other damage to channels may be patch repaired as deseribed in the general instructions in Chap. 1. More aaa extensive damage should be rectified by removing the damaged Pig.20.-—Dimenslons for channel, and fitting a new channel. The method of removing channels ing locating brackets and fitting new channels is described in para. 29. Sad ESove-2)Data for testing 42, The figures called for in the tests described in Chap. 1 are as follows:— () Internal air pressure test at 50 1b. per sq. in. ) Hot bath immersion test at 130°C. (iii) Final air pressure test at 50 Ib. per sq. in. for 15 min. {iv} Water flow test at 56 gals, per min. at 7 ft. effective head. ‘Standard packing case 43. The standard packing case for use with these radiators (sce Chap. 1) is Aircraft Radiator Case (Stores Ref. 40E/136) (15949) WL, T3ITNG.585/ML31297, 2825, 745, ram Geant. G3.