When replacing a damaged honeycomb core with balsa wood, how should the plug be cut?

When replacing a damaged honeycomb core with balsa wood, the plug should be cut perpendicular to the skin. This orientation is crucial because it ensures that the new core material bonds effectively with the skin of the aircraft structure. When the plug is cut perpendicular, it allows for a stronger and more reliable joint between the balsa wood and the skin.

Cutting the plug in this manner helps maintain the structural integrity of the assembly by allowing for even distribution of stress across the bonded surfaces. It is essential to create a surface that has maximum surface area contact with the skin, promoting better adhesion and reducing the chances of any delamination or separation under load.

Additionally, cutting the plug perpendicular helps to maintain the geometric integrity of the structure, as this alignment matches the load paths. In contrast, other cutting methods could compromise the plug's strength and the overall structural performance of the repair.