Method and apparatus for controlled thickness patch adjacent filleted surfaces

A method for applying a controlled thickness patch of repair material to a damaged surface adjacent a filleted surface disposed between a case surface and a strut of a fan assembly of an aircraft engine, the method comprising:

• positioning a spacer on the case surface at a position adjacent the filleted surface, wherein an outermost surface of the spacer disposed opposite the case surface intersects the filleted surface at a predetermined drop height from the case surface;
• applying repair material to the damaged surface, the repair material being thixotropic;
• and
• screeding the repair material with a straight edge, the straight edge positioned parallel to the strut, a first end of the straight edge positioned against the outermost surface of the spacer and the filleted surface at the drop height, and a second end of the straight edge positioned against the strut or a guide mask disposed on the strut so as to form a controlled thickness patch of repair material to the strut and filleted surface.