Patent ID: 6136116
Filing Date: 2000-10-24
Classification: B29C,Y02T,Y10T

Abstract:
A method of filling a gap between adjoining coplanar first and second sheet members, each having opposed inner and outer surfaces, mounted on an outer surface of a common substrate and having juxtaposed first and second edge surfaces, respectively, the method comprising the steps of:(a) providing a permanent gap filler member of predetermined shape and size for partially filling the gap, the permanent gap filler member having an abutting surface for contiguous engagement with the first edge surface of the first sheet member, a mounting surface for contiguous engagement with the outer surface of the common substrate, and a minor gap surface opposite said abutting surface;(b) providing a temporary gap filler tool including a substitute gap filler element having substantially the same predetermined size and shape of the permanent gap filler member, the substitute gap filler element having an abutting surface for contiguous engagement with the first edge surface of the first sheet member and a pair of spaced apart flange members projecting away from the abutting surface, a minor gap surface facing opposite said abutting surface, and means for releasably attaching said gap filler tool to said first sheet member so that the abutting surface of the substitute gap filler element is contiguously engaged with the first edge surface of the first sheet member in the same manner as the permanent gap filler member;(c) temporarily removing the first sheet member from the common substrate;(d) releasably attaching the temporary gap filler tool to the first sheet member by advancing the temporary gap filler tool from a detached position to an attached position whereat the abutting surface of the substitute gap filler element is in contiguous engagement with the first edge surface of the first sheet member such that the flange members are in contiguous slidable engagement, respectively, with the inner and outer surfaces of the first sheet member;(e) defining a minor gap existing between the temporary gap filler element and the second edge surface of the second sheet member;(f) filling with a slurry of fairing material the minor gap existing between the substitute gap filler element and the second edge surface of the second sheet member;(g) curing the slurry of fairing material applied in step (e) until it hardens producing a fairing member having a substitute second edge surface contiguous with the minor gap surface of the substitute gap filler element;(h) after step (d), removing the temporary gap filler tool from the first sheet member;(i) re-attaching the first sheet member to the common substrate; and(j) fixedly attaching the permanent gap filler member to the outer face of the common substrate with the abutting surface in contiguous engagement with the first edge surface of the first sheet member and with the minor gap surface in contiguous engagement with the substitute second edge surface of the fairing member;whereby the entire gap has been filled.