Damaged radar radome repair method

A method for repair of damaged radome having at least one damaged core play, said core ply having an outer skin of a plurality of fiberglass skin layers affixed to a honeycomb core, the steps comprising:

• making a plurality of respectively ever-increasing concentric cuts into said skin along a depth of cut path established by the local arcuate contour dimension of the radome for each cut, one cut per fiberglass skin layer, wherein the innermost of said cuts is the narrowest cut made and the outermost of said cuts is the narrowest cut made and the outermost of said cuts is the widest cut made, each cut being the thickness of the individual respective fiberglass skin layer being cut, and trimming the sidewalls of said core ply at the site of damage to define a regularly contoured opening;
• affixing a repair core section in said regularly contoured opening, said repair core section, when fully seated in said contoured opening, being greater in height than the adjoining honeycomb core;
• trimming the top surface of said repair core section to the height and contour of said adjoining honeycomb core along a depth of cut path established by the local arcuate contour dimension of the radome;
• and
• affixing a first correspondingly configured fiberglass patch into the innermost of said concentric cuts and affixing a subsequent correspondingly configured fiberglass patch in a like manner to each subsequent ever-wider cut in said fiberglass skin layers, so that if each patch has a thickness substantially equal to the depth of cut thereat, the patch(es) form generally the original radome contour(s).