Method for in-place fabrication of graphite epoxy bushings in graphite epoxy structures

A method of repairing an existing hole in a graphite/epoxy structure that is either too large or out-of-round, said method comprising:

• providing a cylindrical mandrel having a positive coefficient of thermal expansion, said mandrel having a diameter that is slightly smaller than a desired hole diameter to be formed in said graphite/epoxy structure;
• wrapping a strip of epoxy-impregnated graphite mat around said mandrel to form an assembly having a diameter that is approximately equal to the diameter of said existing hole;
• inserting said assembly into said existing hole;
• heating said mandrel to expand said mandrel, force said mat against the edge of said existing hole, and cure said mat;
• cooling said mandrel after said mat has been cured, thereby causing said mandrel to contract away from said cured mat;
• withdrawing said mandrel from inside said cured mat whereby said mat forms a bushing that is bonded to said graphite/epoxy structure;
• and
• machining said desired hole diameter in said bushing.