Story ID: 
Reducing Downtime Through Smart Composite Repair
By: Martha Jercinovich
Caption: Replacement isn’t always the best answer. See how DAS Aviation restored a Gulfstream V elevator through precision composite repair—avoiding costly replacement.
Word Count: 356
Composite damage on a flight control surface can sound like a worst-case scenario—especially when the damage goes all the way through the skin. But in many cases, replacement isn’t the only (or best) answer.
In this repair, a Gulfstream V elevator outboard trailing edge came in with a through puncture that penetrated the trailing edge skin. The first step was straightforward: remove the damaged skin from the assembly and prep the affected area so the repair could be built on a clean, stable foundation.
To begin, the puncture was routed until the edges were clean and properly defined. From there, the team performed a scarf repair, tapering the repair area so new material could be bonded securely while maintaining a smooth transition across the surface.
On the inside, the layup started with a repair ply sized wider than the hole, followed by a fill ply in the center. Then the layup was stepped out to build rigidity while keeping the repair controlled and consistent. After cure, the surface was fair-sanded to ensure proper blending and to confirm there were no lifted edges.
One key challenge in this job was applying the right pressure during cure. The part was too fragile to vacuum bag without risking crush damage under vacuum. Instead, the team used a fitted internal wedge combined with clamps and a caul plate on the exterior to keep the surface flat and supported.
From epoxy mixed by ratio to careful wet layup technique, the strength of a composite repair comes down to precision. Even ply orientation matters—offsetting material (like a 45-degree orientation) helps increase strength and durability in the finished repair.
After the composite work was completed, the part moved through QA inspection before reassembly, followed by final checks, then transferred to paint.
Need composite repair support, structural expertise, or parts support to keep your aircraft moving? DAS Aviation is an FAA Part 145 Repair Station with specialized capabilities and fast-turn resources across multiple facilities. Learn more at https://dasaviation.com.