Goodrich Aerostructures

850 Lagoon Drive

Chula Vista, California 91910-2098

October 15, 2019

SUBJECT: CF6-80E1 A330 Nacelle Structural Repair Manual

Document Part No. RDN 306, Revision No. 21, Dated October 15,
2019

The subject manual is a complete reissue.

Questions concerning printing and distribution should be directed to

Goodrich Aerostructures, Aftermarket Technical Services at
techpubs@utas.utc.com

Questions or comments concerning the publication, register and log on

to our web portal at www.customers.utcaerospacesystems.com.

This document may contain export

controlled technical data, but
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for export purposes. Do not transfer
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without proper export classification and approval.

This document may contain export
controlled technical data, but
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for export purposes. Do not transfer
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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

HIGHLIGHTS

TO: CF6-80E1 A330 STRUCTURAL REPAIR MANUAL DISTRIBUTION

CONCERNING: Revision No. 21, Dated October 15, 2019

MANUAL UPDATE INSTRUCTIONS

This is a complete reissue of the manual. Discard the old manual upon receipt
of this reissued manual.

Chapter/Section/Subject Page Number Description of Change

LEP Revised the LEP

(CV19-05674)

54-10-00 102, 113-114, Revised the ADL.

129-131 (CV09-02365)

108, 125 Revised ADL illustration and zone

dimension.
(CV19-02894)

54-10-00

Repair No. 16 Added new repair.

(CV09-02365)

54-40-00

Repair No. 3 201, 202 Updated material callouts.

(CV11-05127)

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 ROHR, INC.

INLET COWL
FAN COWL
CORE COWL
CF6-80E1
A330
Document Part No. RDN 306
STRUCTURAL REPAIR MANUAL

THE CONTENT OF REVISION 21 HAS BEEN APPROVED

UNDER EUROPEAN AVIATION SAFETY AGENCY (EASA)
DESIGN ORGANIZATION APPROVAL NO. EASA.21J.031.

TRANSMITTAL OF TECHNICAL DATA (EAR)

THESE COMMODITIES, TECHNOLOGY, OR SOFTWARE ARE CONTROLLED BY THE U.S. EXPORT
ADMINISTRATION REGULATIONS (EAR). DIVERSION CONTRARY TO U.S. LAW IS PROHIBITED.
ECCN: 9E991
Goodrich Aerostructures Proprietary Information
The information contained in this document is Goodrich proprietary information and is disclosed in confidence. It is the property of Goodrich and shall not
be used, disclosed to others or reproduced without the express written consent of Goodrich, including, but without limitation, it is not to be used in the
creation, manufacture, development, or derivation of any repairs, modifications, spare parts, design, or configuration changes or to obtain FAA or any
other government or regulatory approval to do so. If consent is given for reproduction in whole or in part, this notice and the notice set forth on each page
of this document shall appear in any such reproduction in whole or in part. The information contained in this document may also be controlled by the U.S.
export control laws. Unauthorized export or re-export is prohibited.

Copyright License:
Customer is authorized to copy these materials for its own use only, provided that all copyright notices, proprietary legends, confidential markings, and
other restrictive notices appearing on the original materials are preserved on all such copies.

Caution Regarding Use of Materials:

It is customer’s sole responsibility to ascertain and ensure that all materials are current and appropriate for the use to which they are put and Goodrich
assumes no responsibility whatsoever in that regard. Customer agrees to indemnify and save harmless Goodrich against all claims and liability of
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agreement by Goodrich or from the manufacture, sale, delivery, resale of any product by customer. In no event shall Goodrich be liable for any special,
incidental, indirect or consequential or punitive damages

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RECORD OF REVISIONS
REV. DATE DATE REV. DATE DATE
NO. ISSUED INSERTED BY NO. ISSUED INSERTED BY
Initial Jan 1/94
1 Apr 1/94
2 Jul 1/94
3 Apr 1/95
4 Jul 1/00
5 Jan 1/02
6 Oct 1/04
7 Apr 1/05
8 Oct 1/05
9 Apr 1/07
10 Oct 1/09
11 Apr 1/10
12 Oct 1/10
13 Apr 1/11
14 Oct 1/11
15 Apr 1/12
16 Oct 1/13
17 Oct 1/14
18 Dec 1/15
19 Jun 29/18
20 Apr 15/19
21 Oct 15/19

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STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

RECORD OF TEMPORARY REVISIONS

TEMPORARY DATE DATE BY REV. DATE BY DATE

REV. NO. ISSUED INSERTED NO. REMOVED INCORP.
54-1 Aug 15/94 Apr 1/95

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STRUCTURAL REPAIR MANUAL
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SERVICE BULLETIN LIST

SERVICE BULLETIN REVISION DATE BULLETIN

NUMBER NUMBER INCORPORATED INTO MANUAL

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LIST OF EFFECTIVE PAGES

CHAPTER CHAPTER
SECTION FIGURE SECTION FIGURE
SUBJECT PAGE DATE SUBJECT PAGE DATE
Title Page Oct 15/19 54-01-01 1 Oct 15/19
Copyright Note Oct 15/19 Abbreviation 2 Oct 15/19
Definitions
Record of 1 Oct 15/19
Revisions 2 Oct 15/19 54-01-02 1 Oct 15/19
Principal 2 Oct 15/19
Record of 1 Oct 15/19 Dimensions
Temporary 2 Oct 15/19
Revisions 54-01-03 1 Oct 15/19
Station Diagram 2 Oct 15/19
Service Bulletin 1 Oct 15/19 3 Oct 15/19
List 2 Oct 15/19 4 Oct 15/19

List of 1 Oct 15/19 54-01-04 1 Oct 15/19

Effective 2 Oct 15/19 Part Level Depth 2 Oct 15/19
Pages 3 Oct 15/19 of Coverage
4 Oct 15/19
5 Oct 15/19 54-01-05 1 Oct 15/19
6 Oct 15/19 Primary and 2 Oct 15/19
7 Oct 15/19 Secondary 3 Oct 15/19
8 Oct 15/19 Structures 4 Oct 15/19
9 Oct 15/19
10 Oct 15/19 54-01-06 1 Oct 15/19
Zoning and Access 2 Oct 15/19
Table of 1 Oct 15/19 Panel 3 Oct 15/19
Contents 2 Oct 15/19 Identification 4 Oct 15/19
3 Oct 15/19
4 Oct 15/19 54-01-07 1 Oct 15/19
Nacelle Lightning 2 Oct 15/19
Introduction 1 Oct 15/19 Attachment Zones
2 Oct 15/19
3 Oct 15/19 54-02-00 1 Oct 15/19
4 Oct 15/19 General Repair 2 Oct 15/19
5 Oct 15/19
6 Oct 15/19 54-02-01 1 Oct 15/19
General Damage 2 Oct 15/19
54-00-00 1 Oct 15/19 Clean Up 3 Oct 15/19
Nacelle General 2 Oct 15/19 4 Oct 15/19
5 Oct 15/19
54-01-00 1 Oct 15/19 6 Oct 15/19
Nacelle Primary 2 Oct 15/19 7 Oct 15/19
References 8 Oct 15/19

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Document Part No. RDN 306

LIST OF EFFECTIVE PAGES

CHAPTER CHAPTER
SECTION FIGURE SECTION FIGURE
SUBJECT PAGE DATE SUBJECT PAGE DATE
9 Oct 15/19 54-02-06 1 Oct 15/19
10 Oct 15/19 Replace Nacelle 2 Oct 15/19
11 Oct 15/19 Markings 3 Oct 15/19
12 Oct 15/19 4 Oct 15/19
13 Oct 15/19 5 Oct 15/19
14 Oct 15/19 6 Oct 15/19
15 Oct 15/19 7 Oct 15/19
16 Oct 15/19 8 Oct 15/19
17 Oct 15/19 9 Oct 15/19
18 Oct 15/19 10 Oct 15/19
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23 Oct 15/19 15 Oct 15/19
24 Oct 15/19 16 Oct 15/19
17 Oct 15/19
54-02-02 1 Oct 15/19
Composite 2 Oct 15/19 54-02-07 1 Oct 15/19
Structures 3 Oct 15/19 2 Oct 15/19
Tap Testing 4 Oct 15/19
54-03-00 1 Oct 15/19
54-02-03 1 Oct 15/19 Repair 2 Oct 15/19
Protective 2 Oct 15/19 Materials
Treatment of 3 Oct 15/19
Metal Repair 4 Oct 15/19 54-03-01 1 Oct 15/19
Parts 5 Oct 15/19 Forming, 2 Oct 15/19
6 Oct 15/19 Machining and 3 Oct 15/19
7 Oct 15/19 Fabrication 4 Oct 15/19
8 Oct 15/19 Characteristics 5 Oct 15/19
of Metals 6 Oct 15/19
54-02-04 1 Oct 15/19 7 Oct 15/19
Hardness 2 Oct 15/19 8 Oct 15/19
Testing 3 Oct 15/19 9 Oct 15/19
4 Oct 15/19 10 Oct 15/19
5 Oct 15/19 11 Oct 15/19
6 Oct 15/19 12 Oct 15/19
7 Oct 15/19 13 Oct 15/19
8 Oct 15/19 14 Oct 15/19
15 Oct 15/19
54-02-05 1 Oct 15/19 16 Oct 15/19
Test for Alclad 2 Oct 15/19 17 Oct 15/19
Penetration 18 Oct 15/19
19 Oct 15/19
20 Oct 15/19
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CHAPTER CHAPTER
SECTION FIGURE SECTION FIGURE
SUBJECT PAGE DATE SUBJECT PAGE DATE
21 Oct 15/19
22 Oct 15/19 54-03-05 1 Oct 15/19
23 Oct 15/19 Bulk Materials 2 Oct 15/19
24 Oct 15/19 Supplier’s 3 Oct 15/19
25 Oct 15/19 List 4 Oct 15/19
26 Oct 15/19 5 Oct 15/19
27 Oct 15/19 6 Oct 15/19
28 Oct 15/19
54-04-00 1 Oct 15/19
54-03-02 1 Oct 15/19 Mechanical 2 Oct 15/19
Extruded 2 Oct 15/19 Fasteners 3 Oct 15/19
Sections 3 Oct 15/19 4 Oct 15/19
4 Oct 15/19
5 Oct 15/19 54-04-01 1 Oct 15/19
6 Oct 15/19 Fastener Removal 2 Oct 15/19
7 Oct 15/19 and Installation 3 Oct 15/19
8 Oct 15/19 4 Oct 15/19
9 Oct 15/19 5 Oct 15/19
10 Oct 15/19 6 Oct 15/19
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Formed Sections 2 Oct 15/19 15 Oct 15/19
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10 Oct 15/19 Fastener Codes 2 Oct 15/19
11 Oct 15/19
12 Oct 15/19 54-04-03 1 Oct 15/19
13 Oct 15/19 Grip Ranges 2 Oct 15/19
14 Oct 15/19
54-04-04 1 Oct 15/19
54-03-04 1 Oct 15/19 Fastener 2 Oct 15/19
Aluminum Alloy 2 Oct 15/19 Substitutions 3 Oct 15/19
Sheet 4 Oct 15/19
Substitutions 5 Oct 15/19
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CHAPTER CHAPTER
SECTION FIGURE SECTION FIGURE
SUBJECT PAGE DATE SUBJECT PAGE DATE
6 Oct 15/19 21 Oct 15/19
22 Oct 15/19
54-04-05 1 Oct 15/19 23 Oct 15/19
Torque Values 2 Oct 15/19 24 Oct 15/19
3 Oct 15/19 25 Oct 15/19
4 Oct 15/19 26 Oct 15/19
5 Oct 15/19 27 Oct 15/19
6 Oct 15/19 28 Oct 15/19
7 Oct 15/19 29 Oct 15/19
8 Oct 15/19 30 Oct 15/19
9 Oct 15/19 31 Oct 15/19
10 Oct 15/19 32 Oct 15/19
33 Oct 15/19
54-04-06 1 Oct 15/19 34 Oct 15/19
Hole Sizes- 2 Oct 15/19 35 Oct 15/19
Standard and 3 Oct 15/19 36 Oct 15/19
Oversized 4 Oct 15/19 37 Oct 15/19
38 Oct 15/19
54-04-07 1 Oct 15/19 39 Oct 15/19
Edge Margins 2 Oct 15/19 40 Oct 15/19
3 Oct 15/19 41 Oct 15/19
4 Oct 15/19 42 Oct 15/19
5 Oct 15/19 43 Oct 15/19
6 Oct 15/19 44 Oct 15/19
45 Oct 15/19
54-04-08 1 Oct 15/19 46 Oct 15/19
Fastener 2 Oct 15/19 47 Oct 15/19
Determination 3 Oct 15/19 48 Oct 15/19
4 Oct 15/19 49 Oct 15/19
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CHAPTER CHAPTER
SECTION FIGURE SECTION FIGURE
SUBJECT PAGE DATE SUBJECT PAGE DATE
66 Oct 15/19 Alignment

54-04-09 1 Oct 15/19 54-07-00 1 Oct 15/19

Countersinking 2 Oct 15/19 Aerodynamic 2 Oct 15/19
3 Oct 15/19 Smoothness 3 Oct 15/19
4 Oct 15/19 4 Oct 15/19
5 Oct 15/19 5 Oct 15/19
6 Oct 15/19 6 Oct 15/19
7 Oct 15/19 7 Oct 15/19
8 Oct 15/19 8 Oct 15/19
9 Oct 15/19
10 Oct 15/19 54-10-00 1 Oct 15/19
11 Oct 15/19 Inlet Cowl- 2 Oct 15/19
12 Oct 15/19 Structural 3 Oct 15/19
Identification 4 Oct 15/19
54-04-10 1 Oct 15/19 5 Oct 15/19
Hi-Shear Blind 2 Oct 15/19 6 Oct 15/19
Attachments 3 Oct 15/19 7 Oct 15/19
4 Oct 15/19 8 Oct 15/19
5 Oct 15/19 9 Oct 15/19
6 Oct 15/19 10 Oct 15/19
7 Oct 15/19 11 Oct 15/19
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21 Oct 15/19
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Huck Panel 2 Oct 15/19 23 Oct 15/19
Fasteners 3 Oct 15/19 24 Oct 15/19
4 Oct 15/19 25 Oct 15/19
5 Oct 15/19 26 Oct 15/19
6 Oct 15/19 27 Oct 15/19
7 Oct 15/19 28 Oct 15/19
8 Oct 15/19 29 Oct 15/19
9 Oct 15/19 30 Oct 15/19
10 Oct 15/19 31 Oct 15/19
32 Oct 15/19
54-06-00 1 Oct 15/19 33 Oct 15/19
Engine Nacelle 2 Oct 15/19 34 Oct 15/19
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CHAPTER CHAPTER
SECTION FIGURE SECTION FIGURE
SUBJECT PAGE DATE SUBJECT PAGE DATE
35 Oct 15/19 127 Oct 15/19
36 Oct 15/19 128 Oct 15/19
37 Oct 15/19
38 Oct 15/19
39 Oct 15/19 Inlet Cowl - 201 Oct 15/19
40 Oct 15/19 Repair Index 202 Oct 15/19
41 Oct 15/19
42 Oct 15/19 Repair No. 1 201 Oct 15/19
43 Oct 15/19 202 Oct 15/19
44 Oct 15/19 203 Oct 15/19
45 Oct 15/19 204 Oct 15/19
46 Oct 15/19 205 Oct 15/19
47 Oct 15/19 206 Oct 15/19
48 Oct 15/19
49 Oct 15/19 Repair No. 2 201 Oct 15/19
50 Oct 15/19 202 Oct 15/19
51 Oct 15/19 203 Oct 15/19
52 Oct 15/19 204 Oct 15/19
205 Oct 15/19
54-10-00 101 Oct 15/19 206 Oct 15/19
Inlet Cowl - 102 Oct 15/19 207 Oct 15/19
Allowable Damage 103 Oct 15/19 208 Oct 15/19
104 Oct 15/19 209 Oct 15/19
105 Oct 15/19 210 Oct 15/19
106 Oct 15/19 211 Oct 15/19
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108 Oct 15/19 213 Oct 15/19
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111 Oct 15/19 216 Oct 15/19
112 Oct 15/19
113 Oct 15/19 Repair No. 3 201 Oct 15/19
114 Oct 15/19 202 Oct 15/19
115 Oct 15/19 203 Oct 15/19
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123 Oct 15/19
124 Oct 15/19 Repair No. 5 201 Oct 15/19
125 Oct 15/19 202 Oct 15/19
126 Oct 15/19 203 Oct 15/19
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LIST OF EFFECTIVE PAGES

CHAPTER CHAPTER
SECTION FIGURE SECTION FIGURE
SUBJECT PAGE DATE SUBJECT PAGE DATE
204 Oct 15/19 204 Oct 15/19
205 Oct 15/19
Repair No. 6 201 Oct 15/19 206 Oct 15/19
202 Oct 15/19
203 Oct 15/19 Repair No. 14 201 Oct 15/19
204 Oct 15/19 202 Oct 15/19
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211 Oct 15/19
212 Oct 15/19 Repair No.15 201 Oct 15/19
202 Oct 15/19
Rapir No. 10 201 Oct 15/19 203 Oct 15/19
202 Oct 15/19 204 Oct 15/19
203 Oct 15/19 205 Oct 15/19
204 Oct 15/19 206 Oct 15/19
205 Oct 15/19
206 Oct 15/19 Repair No.16 201 Oct 15/19
207 Oct 15/19 202 Oct 15/19
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204 Oct 15/19
Repair No. 11 201 Oct 15/19 205 Oct 15/19
202 Oct 15/19 206 Oct 15/19
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Repair No. 12 201 Oct 15/19 Repair No. 22 201 Oct 15/19
202 Oct 15/19 202 Oct 15/19
203 Oct 15/19 203 Oct 15/19
204 Oct 15/19 204 Oct 15/19
205 Oct 15/19
206 Oct 15/19 Repair No.23 201 Oct 15/19
207 Oct 15/19 202 Oct 15/19
208 Oct 15/19 203 Oct 15/19
204 Oct 15/19
Repair No. 13 201 Oct 15/19
202 Oct 15/19 54-20-00 1 Oct 15/19
203 Oct 15/19 Fan Cowl - 2 Oct 15/19
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LIST OF EFFECTIVE PAGES

CHAPTER CHAPTER
SECTION FIGURE SECTION FIGURE
SUBJECT PAGE DATE SUBJECT PAGE DATE
Structural 3 Oct 15/19 54-20-00 101 Oct 15/19
Identification 4 Oct 15/19 Fan Cowl - 102 Oct 15/19
5 Oct 15/19 Allowable Damage 103 Oct 15/19
6 Oct 15/19 104 Oct 15/19
7 Oct 15/19 105 Oct 15/19
8 Oct 15/19 106 Oct 15/19
9 Oct 15/19 107 Oct 15/19
10 Oct 15/19 108 Oct 15/19
11 Oct 15/19 109 Oct 15/19
12 Oct 15/19 110 Oct 15/19
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15 Oct 15/19 113 Oct 15/19
16 Oct 15/19 114 Oct 15/19
17 Oct 15/19
18 Oct 15/19
19 Oct 15/19
20 Oct 15/19 54-20-00 201 Oct 15/19
21 Oct 15/19 Fan Cowl - 202 Oct 15/19
22 Oct 15/19 Repair Index
23 Oct 15/19
24 Oct 15/19 Repair No. 1 201 Oct 15/19
25 Oct 15/19 202 Oct 15/19
26 Oct 15/19 203 Oct 15/19
27 Oct 15/19 204 Oct 15/19
28 Oct 15/19 205 Oct 15/19
29 Oct 15/19 206 Oct 15/19
30 Oct 15/19 207 Oct 15/19
31 Oct 15/19 208 Oct 15/19
32 Oct 15/19
33 Oct 15/19 Repair No. 2 201 Oct 15/19
34 Oct 15/19 202 Oct 15/19
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37 Oct 15/19
38 Oct 15/19 Repair No. 3 201 Oct 15/19
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LIST OF EFFECTIVE PAGES

CHAPTER CHAPTER
SECTION FIGURE SECTION FIGURE
SUBJECT PAGE DATE SUBJECT PAGE DATE
211 Oct 15/19 212 Oct 15/19
212 Oct 15/19 213 Oct 15/19

Repair No. 4 201 Oct 15/19 Repair No. 7 201 Oct 15/19
202 Oct 15/19 202 Oct 15/19
203 Oct 15/19 203 Oct 15/19
204 Oct 15/19 204 Oct 15/19
205 Oct 15/19
206 Oct 15/19 Repair No. 8 201 Oct 15/19
207 Oct 15/19 202 Oct 15/19
208 Oct 15/19 203 Oct 15/19
209 Oct 15/19 204 Oct 15/19
210 Oct 15/19 205 Oct 15/19
211 Oct 15/19 206 Oct 15/19
212 Oct 15/19 207 Oct 15/19
213 Oct 15/19 208 Oct 15/19
214 Oct 15/19 209 Oct 15/19
Repair No. 5 201 Oct 15/19 210 Oct 15/19
202 Oct 15/19
203 Oct 15/19 54-30-00 1 Oct 15/19
204 Oct 15/19 Thrust Reverser - 2 Oct 15/19
205 Oct 15/19 Structural
206 Oct 15/19 Identification
207 Oct 15/19
208 Oct 15/19 54-40-00 1 Oct 15/19
209 Oct 15/19 Core Cowl - 2 Oct 15/19
210 Oct 15/19 Structural 3 Oct 15/19
211 Oct 15/19 Identification 4 Oct 15/19
212 Oct 15/19 5 Oct 15/19
213 Oct 15/19 6 Oct 15/19
214 Oct 15/19 7 Oct 15/19
215 Oct 15/19 8 Oct 15/19
216 Oct 15/19 9 Oct 15/19
10 Oct 15/19
Repair No. 6 201 Oct 15/19 11 Oct 15/19
202 Oct 15/19 12 Oct 15/19
203 Oct 15/19 13 Oct 15/19
204 Oct 15/19 14 Oct 15/19
205 Oct 15/19 15 Oct 15/19
206 Oct 15/19 16 Oct 15/19
207 Oct 15/19 17 Oct 15/19
208 Oct 15/19 18 Oct 15/19
209 Oct 15/19 19 Oct 15/19
210 Oct 15/19 20 Oct 15/19
211 Oct 15/19 21 Oct 15/19
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CHAPTER CHAPTER
SECTION FIGURE SECTION FIGURE
SUBJECT PAGE DATE SUBJECT PAGE DATE
22 Oct 15/19
23 Oct 15/19 Repair No. 3 201 Oct 15/19
24 Oct 15/19 202 Oct 15/19
25 Oct 15/19 203 Oct 15/19
26 Oct 15/19 204 Oct 15/19
27 Oct 15/19
28 Oct 15/19 Repair No. 4 201 Oct 15/19
29 Oct 15/19 202 Oct 15/19
30 Oct 15/19 203 Oct 15/19
31 Oct 15/19 204 Oct 15/19
32 Oct 15/19
33 Oct 15/19 Repair No. 5 201 Oct 15/19
34 Oct 15/19 202 Oct 15/19
35 Oct 15/19 203 Oct 15/19
36 Oct 15/19 204 Oct 15/19
37 Oct 15/19 205 Oct 15/19
38 Oct 15/19 206 Oct 15/19
39 Oct 15/19
40 Oct 15/19 Repair No. 6 201 Oct 15/19
202 Oct 15/19
54-40-00 101 Oct 15/19 203 Oct 15/19
Core Cowl - 102 Oct 15/19 204 Oct 15/19
Allowable Damage 103 Oct 15/19 205 Oct 15/19
104 Oct 15/19 206 Oct 15/19
105 Oct 15/19 207 Oct 15/19
106 Oct 15/19 208 Oct 15/19
107 Oct 15/19
108 Oct 15/19 Repair No. 7 201 Oct 15/19
202 Oct 15/19
54-40-00 201 Oct 15/19 203 Oct 15/19
Core Cowl - 202 Oct 15/19 204 Oct 15/19
Repair Index 205 Oct 15/19
206 Oct 15/19
Repair General 201 Oct 15/19 207 Oct 15/19
202 Oct 15/19 208 Oct 15/19
209 Oct 15/19
Repair No.1 201 Oct 15/19 210 Oct 15/19
202 Oct 15/19
203 Oct 15/19
204 Oct 15/19

Repair No. 2 201 Oct 15/19

202 Oct 15/19
203 Oct 15/19
204 Oct 15/19
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TABLE OF CONTENTS

Title Subjct Page

Introduction. . . . . . . . . . . . . . . . . . . . 54-00-00 1

Nacelle

General. . . . . . . . . . . . . . . . . . . . . . . 54-00-00 1

Nacelle Primary References 54-01-00 1

Abbreviation Definitions 54-01-01 1

Principal Dimensions 54-01-02 1

Station Diagrams 54-01-03 1

Part Level Depth of Coverage 54-01-04 1

Primary and Secondary Structures 54-01-05 1

Zoning and Access Panel Identification 54-01-06 1

Nacelle Lightning Attachment Zones 54-01-07 1

General Repair Procedures. . . . . . . . . . . . . . 54-02-00 1

General Clean-up 54-02-01 1

Composite Structure Tap Testing 54-02-02 1

Protective Treatment of Metal Repair Parts 54-02-03 1

Hardness Testing 54-02-04 1

Test for Alclad Penetration 54-02-05 1

Replace Nacelle Markings 54-02-06 1

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Title Subjct Page

Repair Materials. . . . . . . . . . . . . . . . . . . 54-03-00 1

Forming, Machining, and Fabrication 54-03-01 1

Characteristics of Metals

Extruded Sections 54-03-02 1

Formed Sections 54-03-03 1

Aluminum Alloy Sheet Substitution 54-03-04 1

Bulk Materials Supplier’s List 54-03-05 1

Mechanical Fastening. . . . . . . . . . . . . . . . . 54-04-00 1

Fastener Removal and Installation 54-04-01 1

Fastener Codes 54-04-02 1

Grip Ranges 54-04-03 1

Fastener Substitution 54-04-04 1

Torque Values 54-04-05 1

Hole Sizes - Standard and Oversized 54-04-06 1

Edge Margins 54-04-07 1

Fastener Determination 54-04-08 1

Countersinking 54-04-09 1

Hi-Shear Blind Attachments 54-04-10 1

Huck Panel Fasteners 54-04-11 1

Engine Nacelle Allignment. . . . . . . . . . . . . . 54-06-00 1

Aerodynamic Smoothness. . . . . . . . . . . . . . . . 54-07-00 1

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Title Subjct Page

Inlet Cowl. . . . . . . . . . . . . . . . . . . . . . 54-10-00 1

Structure Identification 54-10-00 1

Allowable Damage 54-10-00 101

Repairs 54-10-00 201

Fan Cowl. . . . . . . . . . . . . . . . . . . . . . . 54-20-00 1

Structure Identification 54-20-00 1

Allowable Damage 54-20-00 101

Repairs 54-20-00 201

Thrust Reverser . . . . . . . . . . . . . . . . . . . 54-30-00 1

Core Cowl . . . . . . . . . . . . . . . . . . . . . . 54-40-00 1

Structure Identification 54-40-00 1

Allowable Damage 54-40-00 101

Repairs 54-40-00 201

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INTRODUCTION

This manual has been prepared in general accordance with Air Transport
Association (ATA) Specification Number 100, Revision 21. It includes
descriptive information and specific instructions for field repair of
primary and secondary structures of the Rohr Inc. nacelles for General
Electric CF6-80E1 engines. The information given applies to the CF6-80E1
engine nacelles.

Repairs and allowable damage criteria in this manual are based on designed
stress applications with margins of safety equivalent to original
construction. The repairs are general in nature and are given for guidance
purposes only. Specific application of the information should be approved
by local engineering representative to assure compliance with the
guidelines given.

This manual contains material identification and substitution data for

nacelle structure items subject to field repair, typical repairs for
structure most likely to be damaged, fastener selection and installation
data, engine alignment point locations, and structural damage evaluation
information.

As service experience accumulates, this manual will be revised to include

actual, specific structural repairs to the nacelle system. In the event of
major damage, the information in this manual should be supplemented by
reference to customer stress analysis reports and direct liaison with
General Electric Product Support Service Engineering.

This manual is numbered in the conventional Air Transport Association

Specification Number 100 system. The first two digits of the six-digit
group indicate the ATA 100 chapter designation. The second pair of digits
designates the section of the chapter. Specific subject within a
particular section are indicated by the third pair of digits in the six-
digit group. Repair subjects are further subdivided into topics. These
topics are identified by page block subdivision within the subject as
follows:

Page Block Topic

1 - 99 Structure Identification
101 - 199 Allowable Damage
201 - 299 Repairs

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Each page in this manual is identified by chapter/section/subject number,

page number, and the issue or revision date.

A comprehensive table of contents for this manual provides a quick

reference method for locating specific areas of interest.

A service bulletin list in the front of the manual indicates the effect of
the bulletin on the manual, and the incorporation date, if applicable.

Additional information which becomes available at unscheduled intervals

will be provided through temporary revisions. These temprary revisions are
normally incorporated in the manual at the next regularly scheduled
revision.

Cautions, Warnings and Dangers

NOTICE!! Carefully read and obey all CAUTION and WARNING statements in
this manual. Refer to the descriptions of these statements that
follow:
- A "CAUTION" statement is given to prevent damage to equipment.
- A "WARNING" statement is given to prevent personal injury or
illness

CHEMICALS - Obey the warning below for maintenance of components

manufactured or delivered by Rohr.
WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER
ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.
CADMIUM - Obey the warnings below before you touch or do maintenance on
parts that are cadmium plated. Many small steel parts, including fasteners,
are cadmium plated. Stainless steel parts are not cadmium plated. Some
primers and top coat finishes may contain cadmium. The Occupational, Safety,
and Health Administration (OSHA) sets mandatory limits on exposure to
cadmium dust (29 CFR 1910.1027).

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WARNING: DO NOT GET CADMIUM IN YOUR MOUTH. CADMIUM THAT IS SWALLOWED CAN
CAUSE KIDNEY OR REPRODUCTIVE SYSTEM DISEASE. AFTER YOU TOUCH
CADMIUM PLATED PARTS, CLEAN YOUR HANDS BEFORE YOU EAT OR SMOKE.
GET SAFETY INSTRUCTIONS FROM YOUR EMPLOYER. OBEY GOVERNMENT AND
OSHA REGULATIONS WHEN YOU DISCARD PARTS THAT CONTAIN CADMIUM.
WARNING: DO NOT INHALE CADMIUM PARTICLES, FUMES, OR DUST. THESE
PARTICLES, FUMES, OR DUST CAN CAUSE LUNG OR KIDNEY DISEASE. IF
MAINTENANCE PROCEDURES CREATE CADMIUM PARTICLES, FUMES, OR DUST,
TELL YOUR EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION, AND/OR
PROCEDURES TO PREVENT EXPOSURE TO PERSONNEL.
The Occupational, Safety, and Health Administration (OSHA) has an applicable
DANGER warning (29 CFR 1910.1027 (m)(3)(ii)) as follows:
DANGER: CONTAINS CADMIUM. CANCER HAZARD. AVOID CREATING DUST. CAN CAUSE
LUNG AND KIDNEY DISEASE.
ASBESTOS - Obey the warning below before you touch or do maintenance on
parts that contain asbestos. Some old assembly components may contain
asbestos. The Occupational, Safety, and Health Administration (OSHA) sets
mandatory limits on exposure to asbestos dust (29 CFR 1910.1001).
WARNING: DO NOT BREATHE ASBESTOS DUST. THIS DUST CONTAINS ASBESTOS FIBERS
THAT CAN CAUSE CANCER AND LUNG DISEASE. DO NOT USE COMPRESSED
AIR TO CLEAN PARTS OR ASSEMBLIES THAT POSSIBLY CONTAIN ASBESTOS
DUST. IF MAINTENANCE PROCEDURES EXPOSE PERSONNEL TO ASBESTOS
DUST, TELL YOUR EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION,
AND/OR PROCEDURES TO PREVENT EXPOSURE TO PERSONNEL. OBEY
GOVERNMENT AND OSHA REGULATIONS WHEN YOU DISCARD PARTS THAT
CONTAIN ASBESTOS.
The Occupational, Safety, and Health Administration (OSHA) has an applicable
DANGER warning (29 CFR 1910.1001 (j)(4)(ii)) as follows:
DANGER: CONTAINS ASBESTOS FIBERS. AVOID CREATING DUST. CANCER AND LUNG
DISEASE HAZARD.
BERYLLIUM or BERYLLIUM COPPER ALLOYS - Obey the warning below before you
touch or do maintenance on parts that contain beryllium. Bronze bearings and
bushings may contain beryllium or beryllium copper alloys. The Occupational,
Safety, and Health Administration (OSHA) sets mandatory limits on exposure
to dust or fumes from beryllium or beryllium copper alloys (29 CFR
1910.1000).

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WARNING: DO NOT BREATHE BERYLLIUM PARTICLES OR DUST. THESE PARTICLES OR

DUST CAN CAUSE CANCER OR LUNG DISEASE. IF MAINTENANCE PROCEDURES
MAKE BERYLLIUM PARTICLES OR DUST, TELL YOUR EMPLOYER TO SUPPLY
RESPIRATORS, VENTILATION, AND/OR PROCEDURES TO PREVENT EXPOSURE
TO PERSONNEL. OBEY GOVERNMENT AND OSHA REGULATIONS WHEN YOU
DISCARD PARTS THAT CONTAIN BERYLLIUM. READ AND OBEY THE NEWEST
APPLICABLE MATERIAL SAFETY DATA SHEET (MSDS) THAT IS AVAILABLE
FROM BRUSH WELLMAN INC. (REFER TO THE ADDRESS BELOW).
The newest MSDS for beryllium is available from:
Brush Wellman Inc. Tel.: (800) 862-4118
Product Stewardship Department Fax: (419) 862-4414
14710 W. Portage River S. Road www.brushwellman.com
Elmore, Ohio 43416-9502
USA

CERAMIC FIBERS - Obey the warning below before you do maintenance on parts
that contain ceramic fibers. Heat resistant cloth and foil covered heat
shields and thermal blankets may contain ceramic fibers. The Occupational,
Safety, and Health Administration (OSHA) and the Refractory Ceramic Fibers
Coalition (RCFC) have a voluntary personnel protection program (PSP 2002,
Feb. 11, 2002). This program gives limits on personnel exposure to ceramic
fibers.
WARNING: DO NOT BREATHE CERAMIC FIBER DUST. THIS DUST CONTAINS CERAMIC
FIBERS THAT MAY CAUSE CANCER. DO NOT USE COMPRESSED AIR TO CLEAN
PARTS OR ASSEMBLIES THAT POSSIBLY CONTAIN CERAMIC FIBERS. IF
MAINTENANCE PROCEDURES EXPOSE PERSONNEL TO CERAMIC FIBERS, TELL
YOUR EMPLOYER TO SUPPLY RESPIRATORS, VENTILATION, AND/OR
PROCEDURES TO PREVENT EXPOSURE TO PERSONNEL. OBEY GOVERNMENT AND
OSHA REGULATIONS WHEN YOU DISCARD PARTS THAT CONTAIN CERAMIC
FIBERS. READ AND OBEY THE NEWEST APPLICABLE MATERIAL SAFETY DATA
SHEET (MSDS).
CHROMATES (HEXAVALENT CHROMIUM) - Obey the warnings below before you touch
or do maintenance on parts that contain hexavalent chromium. Chromated
primers, Alodines, and corrosion inhibiting sealants used in the manufacture
and assembly of components may contain hexavalent chromium. Emissions that
are created when you weld or thermally cut metal alloys may contain
hexavalent chromium. The Occupational Safety and Health Administration
(OSHA) sets mandatory limits on exposure to chromium dust (29 CFR
1910.1000).

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STRUCTURAL REPAIR MANUAL
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WARNING: DO NOT GET HEXAVALENT CHROMIUM ON YOUR SKIN. REPEATED SKIN

CONTACT CAN CAUSE DERMATITIS AND SKIN ULCERS. DIRECT EYE CONTACT
WITH HEXAVALENT CHROMATE DUSTS CAN CAUSE EYE DAMAGE. AFTER YOU
TOUCH HEXAVALENT CHROMIUM PARTS, CLEAN YOUR HANDS BEFORE YOU EAT
OR SMOKE. GET SAFETY INSTRUCTIONS FROM YOUR EMPLOYER. OBEY
GOVERNMENT AND OSHA REGULATIONS WHEN YOU DISCARD PARTS THAT
CONTAIN HEXAVALENT CHROMIUM.
WARNING: DO NOT BREATHE HEXAVALENT CHROMIUM PARTICLES, FUMES OR DUST.
THESE PARTICLES, FUMES OR DUST CAN CAUSE CANCER OR LUNG DISEASE.
IF MAINTENANCE PROCEDURES MAKE HEXAVALENT CHROMIUM PARTICLES,
FUMES OR DUST, TELL YOUR EMPLOYER TO SUPPLY RESPIRATORS,
VENTILATION AND/OR PROCEDURES TO PREVENT EXPOSURE TO PERSONNEL.

CRYSTALLINE SILICA (Quartz) - Obey the warning below before you touch or do
maintenance on parts that contain crystalline silica. Primers, sealants,
static conditioners, and fillers may contain crystalline silica. The
Occupational, Safety, and Health Administration (OSHA) sets limits on
exposure to crystalline silica dust (29 CFR 1910.1000 Table
Z-3).

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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

NACELLE GENERAL

1. General

A. This structural repair manual presents the following subjects as they

relate to field repair of the nacelle primary and secondary structures.

2. Material Identification

A. Three sections in this manual are devoted to specific repairs of the

Inlet Cowl, Fan Cowl, and Core Cowl. Each of the sections contains
information required to identify specific structures. Associated tables
in each section specify the type of material used in the manufacture
process.

3. Allowable Damage

A. Allowable damage information is contained in the specific repair

sections provided for the Inlet Cowl, Fan Cowl, and Core Cowl.

4. General Repair Procedures and Processes

A. One section of this manual is devoted to General Damage Cleanup,

Protective Treatment of Metal Repair Parts, Hardness Testing, Tests for
Alclad Penetration, Fire Protection Coatings, and Composite Material
Cowling, as these subjects relate to the nacelle in general. These
procedures are supplemented or restricted by the information given in
the specific repair sections for the major nacelle components.

5. Material and Fastener Substitution Data

A. A chart of material substitutions shows the allowable sheet metal

substitutions and the proper material thickness factor used in
alternate stock selections.

B. Substitution data is provided for the rivets, bolts, lockbolts, pins,

and other small standard hardware used to fasten together the various
parts of the nacelle structure.

6. Repair Designs

A. Specific repair designs for the nacelle major components are provided
in the sections for Inlet Cowl, Fan Cowl, and Core Cowl.

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NACELLE PRIMARY REFERENCES

1. General

A. This section describes the primary references utilized in the Nacelle

System.

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ABBREVIATION DEFINITIONS

1. General

A. The following abbreviations are commonly used in the text and

illustrations in the General Electric Structural Repair Manual.

BL - Buttockline A line which represents a vertical plane

parallel to the longitudinal centerline
of the nacelle.
CL - Centerline A line which represents either a vertical
or horizontal plane around which the
structure is usually symmetrical or
around which the mass is centered. Often
used in conjunction with structural
component prefixes to establish center
lines other than that of the entire
nacelle.
FWD - Forward At or toward the front of the nacelle or
structural assembly.
ID - Inside Diameter The measurement across the void center of
a part, or a hole in a part.
LE - Leading Edge The most forward part of a nacelle
component which is exposed to the
airstream along a continuous line.
MAX - Maximum The greatest or ultimate quantity
allowable.
MIN - Minimum The smallest or least quantity allowable.
NAC - Nacelle The aerodynamic structures and equipment
necessary to complete the airframe
installation of the engine.
NAC STA - Nacelle Station Plane perpendicular to nacelle horizontal
centerline, and to nacelle longitudinal
centerline.

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RAD - Radial A longitudinal plane emanating from the

centerline of the engine nacelle
structure. This centerline has been
established as a longitudinal line
running fore and aft through the
structure at WL 100.000 and BL 100.000. It
is designated in degrees synonymous to
the 360 degrees in a full circle. Nacelle
Radial Zero (NR 0.000) occurs at BL
100.000 above WL 100.000 and progresses
to the right (clockwise) when looking
forward of the nacelle. NR 90.000 occurs
at WL 100.000 on the right, NR 180.000
occurs at BL 100.000 below WL 100.000, NR
270.000 occurs at WL 100.000 on the left,
and NR 360.000 is coincident with NR
0.000.
STA - Station A vertical plane perpendicular to
longitudinal axis used as a spatial
reference line for nacelle structure.
Also used as a general term for space
coordinates such as X, Y, Z or water line,
buttockline, stationline.
SL - Stationline A plane perpendicular to nacelle
horizontal centerline and nacelle
longitudinal centerline.
WL - Waterline A horizontal plane (parallel to the
ground) used for height measurement.

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PRINCIPAL DIMENSIONS

1. General

A. Figure 1 shows the principal engine dimensions of the major assemblies

of the A330/CF6-80E1 engine nacelle.

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Nacelle Principal Dimensions

Figure 1

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STATION DIAGRAM

1. General

Nacelle stations of water line, buttock line, and station line are used to
define the location or relative position of structural parts or relative
position of equipment in the nacelle. They consist of three basic
theoretical plane systems which are mutually perpendicular to each other
and provide a three-dimensional space reference system similar to the X,
Y, Z system of the A330 aircraft. The stations define locations in the
nacelle in terms of their vertical, lateral, and longitudinal positions in
the nacelle.

Two basic centerline planes have been established which pass

longitudinally through the nacelle structure and are perpendicular to each
other. They are the vertical centerline plane (NAC BL 100.00) and the
horizontal centerline plane (NAC WL 100.000). The point at which the two
planes intersect is the longitudinal centerline of the nacelle and its
longitudinal axis of rotation. The Nacelle Radials (NAC RAD) originate in
the longitudinal centerline at the intersection of NAC WL 100.000 and NAC
BL 100.000 and radiate outward. Vertical planes (stations) along the
longitudinal axis (and perpendicular to it) are dimensions from a Nacelle
Datum plane established at a point forward of the leading edge of the
Inlet Cowl Lip.

2. Reference Planes

A. Nacelle Waterlines. (See Figures 1)

The nacelle water lines (NAC WL) are the height planes of the nacelle
space coordinate system and correspond to the Z coordinates of the A330
aircraft system. Nacelle Water line 100.000 (NAC WL 100.000) is the
horizontal centerline plane for the nacelle. The waterlines are
dimensioned in inches and are parallel to each other. The numbers
increase above the horizontal centerline and decrease below it, with
NAC WL 130.000 being 30-inches above, and NAC WL 70.000 being 30-inches
below the horizontal centerline.

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Buttockline, Waterline, Stationline System of Spatial Coordinates

Figure 1

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B. Nacelle Buttock lines. (See Figure 1)

The nacelle buttock lines (NAC BL) are the width (lateral) planes of
the nacelle space coordinate system and correspond to the Y coordinates
of the A330 aircraft system. Nacelle Buttock line 100.000 (NAC BL
100.000) is the vertical centerline plane for the nacelle. The buttock
lines are dimensioned in inches and are parallel to each other. The
numbers increase as they progress to the right of vertical centerline
(when looking forward of the nacelle) and decrease to the left, with
nacelle buttock line 130.000 (NAC BL 130.000) being 30-inches to the
right and nacelle buttock line 70.000 (NAC BL 70.000) being 30-inches
to the left of the vertical centerline.

C. Nacelle Station lines. (See Figure 1).

The nacelle Station lines (NAC SL) are the length planes of the nacelle
space coordinate system and correspond to the X coordinates of the A330
aircraft system. The Nacelle Station lines are dimensioned in inches
and are parallel to each other. The numbers increase as they progress
aft.

D. Nacelle Radials. (See Figure 2).

Nacelle Radials (NAC RAD) are the axial orientation planes around the
nacelle longitudinal centerline. They are quantified (dimensioned) in
degrees, minutes, and seconds, with 360-degrees for the full circle.
Nacelle Radial 0-degree (NAC RAD 00) is coincident with the nacelle
vertical centerline (NAC BL 100.000) above the nacelle horizontal
centerline (NAC WL 100.000). The numbers increase as they progress in a
right hand rotation (looking forward of the nacelle) until they return
to Nacelle Radial 360-degrees which is coincident with Nacelle Radial
0-degrees.

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NAC RAD 270°

Nacelle Radial References

Figure 2

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PART LEVEL DEPTH OF COVERAGE

1. General

A. The details of parts, materials, fasteners, locations and processes to

be used in the repairs of structural items of the Rohr nacelle are
shown or referenced in this manual. In the event more specific
information is required to repair or maintain the structure than is
supplied in this manual, it may be necessary to contact Rohr
Incorporated, 850 Lagoon Drive, Chula Vista, CA 91910-2098.

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PRIMARY AND SECONDARY STRUCTURES

1. General

A. Primary structure has been defined as that structure which forms major
load-carrying paths. Primary structure gathers the loads imposed upon
it, and/or transmitted by secondary structure to it, and delivers these
loads to appropriate reaction points.

B. Secondary structure is attached to the primary structure, either

exterior to it or in its interior. It provides the mechanism for
utilizing the structure, supplying the means for enclosure, interior
division, or attachment of parts or equipment. These mechanisms
include: the exterior sheeting (skin), firewall panels (fireseals), and
brackets, attach angles, and clips.

C. In monocoque-type construction the exterior skin is the primary load-

carrying structure. The structural efficiency of the skin is improved
by the addition of frames and stringers, by a secondary stiffened skin
of a waffle type, or by synthetic fabrics and graphite fibers employ a
resin bonding agent and an elevated temperature curing cycle to bind
the materials together. Box frames and stringers on the underside of
the structure add strength and rigidity.

D. The basic design of the nacelle is that of a cowled engine which is to

be installed on a pylon or strut, through which all loads and forces
are transmitted to the aircraft primary structure. Most of the nacelle
structure is attached directly to the engine and any loads incurred,
such as: weight, vibration, turbulence, acceleration, or airloads are
transmitted to the engine case and thereby transferred to aircraft
primary structure through the engine mounts. The engine flanges where
attachment can be made have been identified by the engine manufacturer
as shown in Figure 1. A loading exception exists, however, in that
although the fan cowl and core cowl doors meet and latch beneath the
engine, they are attached to hinges mounted on the pylon, thus
transmitting some of their loads directly into the pylon rather than
all of their loads through the engine case. The areas of the fan cowl
and core cowl doors immediately adjacent to the hinges and latches are
considered primary structure.

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Engine Flange Locations

Figure 1

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SR-224-005

Primary and Secondary Structure

Figure 2

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E. In the establishment of primary and secondary structure, consideration

must be given to the result of the failure of a structural component.
If failure of a component causes damage that would jeopardize the
operation of the engine or the safety of the aircraft it must be
considered primary. Some of this is reflected in designating those
areas of primary and secondary structure, as shown in Figure 2. The
inlet cowl outer barrel, fan cowl doors, and core cowl are secondary
structure except near the hinges or latches.

F. In consonance with the preceding information, a great deal of care must

be exercised in the repair or modification of nacelle structure to
determine whether or not the structural member is primary or secondary
structure; in the selection of the proper materials and methods to be
used; and in determining if the repair or modification is feasible.

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ZONING AND ACCESS PANEL IDENTIFICATION

1. General

A. To facilitate the location of work areas and components and for the
identification of access doors and panels, the nacelle structure has
been divided into zones.

2. Nacelle Zoning (See Figure 1)

A. Zoning of the nacelle has been accomplished by employing a three-digit

numbering system using 400 as the base number. The first digit
represents the major area or major structural component (nacelle). The
major zone is divided into “submajor zones” Identified by the second
digit (airline assigned). Division of submajor zones into zones is
accomplished by the addition of the third (last) digit.

B. Zone numbers progress from forward to aft. Zones on the left side of
the nacelle are designated by the use of odd numbers; right side
nacelle zones are designated by the use of even numbers. Zones are
defined by actual physical boundaries - inlet cowl, fan cowl, thrust
reverser, core cowl, nozzle, plug, pylon forward fairing and pylon aft
fairing. A unit or component mounted on a zone boundary will take its
zone number from the zone in which it is removed.

3. Access Doors and Panels Identification (See Figure 1)

A. Access doors and panels are identified by the three-digit zone number
suffixed with two alpha characters. The first suffix letter is the
primary letter identifying the door in a logical sequence, i.e., top to
bottom, front to rear, starting with the letter -A- within each zone.
The second letter or locator, fixes the door in its relation to the
nacelle, i.e., left hand or right hand.

B. The fan cowl doors, thrust reverser door, core cowl doors, nozzle,
plug, pylon forward fairing, and pylon aft fairing are identified by
zone number only, since each is a zone in itself.

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ILLUSTRATION PENDING

Nacelle Zones and Access Panel Identification

Figure 1

MAJOR ZONE 400

ZONE DESCRIPTION/BOUNDARIES

TBD Inlet Cowl - NAC STA TBD to NAC STA 137.2

TBD Left Fan Cowl Access Door - NAC STA 137.2 to NAC STA 198.0
TBD Right Fan Cowl Access Door - NAC STA 137.2 to NAC STA 198.0
TBD Left Fan Reverser - NAC STA 198.0 to NAC STA 264.4

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TBD Right Fan Reverser - NAC STA 198.0 to NAC STA 264.4
TBD Left Core Cowl Access Door - NAC STA 264.4 to NAC STA 307.0
TBD Right Core Cowl Access Door - NAC STA 264.4 to NAC STA 307.0
TBD Nozzle - NAC STA 305.5 to NAC STA 324.4
TBD Plug and Cone - NAC STA 307.5 to NAC STA 367.2
TBD Pylon Aft Fairing - NAC STA 324.4 to NAC STA 411.0

NACELLE ACCESS PANEL IDENTIFICATION

ACCESS NOMINAL
OPENING OPENING SIZE
NUMBER ACCESS TO (INCHES)

TBD Upper Left Anti-Ice Inspection Port TBD

TBD Anti-Ice Air Supply Tube Access Door TBD

TBD Lower Left Anti-Ice Inspection Port TBD

TBD Interphone and Ground Jacks TBD

TBD Right Anti-Ice Inspection Port TBD

TBD Fan Compartment Pressure Relief Door TBD

TBD Oil Tank Access Door TBD

TBD Core Compartment Pressure Relief Door TBD

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NACELLE LIGHTNING ATTACHMENT ZONES

1. General

A. The use of composite (nonmetallic) materials in the exterior surface of

some of the cowling components of the nacelle affects the lightning
attachment characteristics of the nacelles. Lightning attachment zones
define the surface areas (skins) of the nacelles where the lightning
attachment characteristics differ.

B. The epoxy bonding agent and the Kevlar fabric which may appear as the
surface materials in composite laminate skins are not electrical
conductors. However, graphite fabric and graphite tape incorporated as
composite skin laminate provide excellent conductive paths for the
electrical currents generated by lightning attachment. Electrical
grounding paths to the surrounding metal structure are provided by
metal fasteners which pass through the composite skin and the metal
structure. Fasteners made of titanium, stainless steel, or Monel (which
are electrically compatible with graphite) must be used to prevent
dissimilar metal corrosion.

2. Lightning Attachment Zones (See Figure 1)

A. Metal skin surfaces have the greatest affinity for lightning attachment
and are identified as Zone 1. Zone lA is the aluminum lip of the inlet
cowl. Zone 18 is the aluminum forward bulkhead of the thrust reverser,
and Zone lC is comprised of the aluminum and titanium core cowl, the
titanium nozzle, and inconel exhaust plug and core, the aluminum pylon
forward fairing, and the inconel pylon aft fairing.

B. Composite skin surfaces are identified as Zone 2. An initial lightning

flash attachment in Zone 1 may be swept by airflow into a Zone 2 area.
Zone 2A includes the outer barrel of the inlet cowl and the fan cowl.
Zone 2B includes the composite skin surfaces of the thrust reverser.

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SR-224-007

Nacelle Lightning Attachment Zones

Figure 1

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GENERAL REPAIR PROCEDURES

1. General

This section is divided into five subjects: general damage cleanup,

composite structure tap testing, protective treatment of metal repair
parts, hardness testing, and test for alclad penetration.

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GENERAL DAMAGE CLEANUP

1. General

A. Definition

Damage as considered in this manual is any cross-sectional area change,

permanent distortion, or physical or mechanical characteristic change
of a structural member which affects its functional integrity thereby
reducing its ability to perform the design function. The structure of
the nacelle is subject to damage in six major categories which are
named in accordance with the primary cause or source of the damage. The
six categories are:

(1) Impact

(2) Excess vibration or turbulence

(3) Overstress or overload

(4) Elevated temperature exposure

(5) Corrosion

(6) Normal operation wear

The first four categories normally occur as single incidents or over

short periods of time while the latter two categories normally occur
over extended periods of time during the design life of the structural
member. However, corrosion may under certain circumstances be greatly
accelerated. Damage to a structural member is classified as: allowable
damage, repairable damage, or damage necessitating replacement of the
structural member.

B. Descriptive Terms

(1) Major assemblies or parts

Terms commonly used to describe visible evidence of damage to major

assemblies or structural members are:

(a) Bent - The part has been permanently distorted from its design
shape in one plane even though its cross-sectional area may
remain virtually unchanged.

(b) Broken - The part has fractured or failed resulting in

material separation along the failure plane.

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(c) Crushed - The assembly or part has been permanently deformed

by a force or object which materially reduces its cross-
sectional area.

(d) Distorted - The part or assembly has been permanently bent,

twisted, or deformed from its design shape.

(e) Elongated - The part or assembly has been permanently

stretched along its longitudinal axis.

(f) Failed - The part or assembly has been damaged to the extent
the load carrying capability of the part is reduced such that
it cannot perform its function.

(g) Twisted - The part or assembly has been permanently distorted

along its longitudinal axis.

(2) Panels, Plate, and Sheet Metals

Terms commonly used to describe visible evidence of damage to sheet

metal structural parts and particularly the external skin of the
nacelle in panel areas are:

(a) Abrasion - A damage area of any size due to stuffing, rubbing

or scraping. It is usually rough and irregular.

(b) Corrosion - Chemical or electro-chemical destruction of the

surface or subsurface of a metal part which results in its
partial replacement by the material (such as rust or aluminum
oxide) which is produced by the chemical reaction. Usually
evidenced by a rough, scaly surface in the area affected.

(c) Crack - A partial fracture or complete separation of the

material. It is usually an irregular line and is normally the
result of metal fatigue or static stress failure.

(d) Crease - A damage area which is depressed or folded back upon

itself in such a manner that its boundaries are sharp or well
defined lines or ridges. Its loss of structural integrity is
usually less than that of a crack.

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(e) Dent - A surface area which has been depressed with respect to
its normal contour. The area boundaries are smooth. It is
generally the result of contact with a relatively smooth
contoured object. There is no change in the cross-sectional
area of the part except in the case of honeycomb structure
where the core may crush without bending the opposite surface
sheet. Structural integrity is affected by the loss in
stiffness of the affected panel.

(f) Gouge - A surface area which has been depressed usually with a
loss of material in the affected part and a resulting change
in the cross-sectional area. It is usually caused by contact
with a relatively sharp object which produces a continuous
sharp or smooth channel-like groove in the material. The loss
of structural integrity is less than that of a crack.

(g) Nick - A local gouge with sharp edges. A series of nicks in a

line pattern produces a loss of structural integrity
equivalent to that of a gouge.

(h) Scratch - A sharply defined continuous very narrow line of

damage in the surface of a part or assembly which results in a
cross-sectional area change. It is usually caused by contact
with a very sharp object. Stressing of the part tends to
produce cracking of the material initiating in the scratch.

(3) Composite Structures.

Terms commonly used to describe visible or invisible damage to

laminated composite synthetic fabric and graphite fiber resin or
epoxy bonded structures.

(a) Crack - A fracture or complete separation of the material in

one or more of the laminate plies.

(b) Delamination - A subsurface separation of two or more of the

laminate plies. Visible only if it occurs al.9ng a panel edge.

(c) Dent - A surface area which has been depressed with respect to
its normal contour. The area boundaries are smooth. Structural
integrity is affected by a loss in stiffness of the damaged
panel.

(d) Dimple - A local deformation of a laminated structure panel

caused by fastener loading.

(e) Penetration - An incursion by a foreign object which passes

through two or more plies of a laminated structure.

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(f) Pit - A small local depression in the surface of a laminated

structure.

(g) Puncture - A penetration by a foreign object which passes

through all of the plies of a laminated structure.

(h) Splinter - A small section of a laminated panel adjacent to a

hole or an edge of the part which is isolated by small
parallel cracks through less than the full complement of
laminated plies.

(i) Void - An open space between plies which has never been filled
with bonding agent. Visible only if it occurs along a panel
edge.

(j) Wrinkle - A surface distortion of a laminated structure panel

which appears with an adjacent ridge and depression, or a
series of parallel ridges and depressions. May become
permanent deformation if structure has exceeded its elastic
limits, with a resultant reduction in structural integrity.

2. Preparation

A. Prior to the initiation of major damage clean-up, the structural

assembly should be drained of all liquids, and stripped of all
operation system parts and assemblies. The structural assembly should
be placed in a jig or holding fixture which will permit access to the
affected work areas and hold the structure in the proper relation to
its attach fittings, engineering reference points and structural
coordinates or station lines.

3. Damage Cleanup

A. Impact Damage

Damage to the nacelle structure and surface panels can occur from
contact with foreign objects, either while the nacelle is mounted on
the aircraft during flight, ground operation, ground handling, and
servicing or off the aircraft during buildup, storage, transportation
or installation. Damage will usually be evidenced by a deformation of
one or more of the surface panels in the area of contact. Damage may be
confined to the surface panels but may extend to one or more of the
primary structural members depending on the severity of the impact and/
or the depth of foreign body penetration. If the impact has been severe
enough to permanently distort the structural assembly requiring force
to align the assembly with the jig or holding fixture alignment points
it usually indicates hidden structural damage that must be located. The

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attaching bolts, rivets, screws, etc. which hold the structure together
may be removed at selected locations to relieve the stress and isolate
the damaged structural members. All of the damaged structural members
and panels may then be removed, repaired or replaced, and reinstalled
on the structural assembly.

Check all parts for proper surface finish and condition before
reassembly.

After reassembly of the repaired structure it should contain no built-

in structural preload which causes it to change its shape, rack, twist
or mis-align with its engineering reference points, station lines or
attach fittings.

B. Overstress or Overload

Rarely will violent gusting, aircraft maneuvers or air turbulence

impose air loads or inertial loads on the nacelle structure which will
exceed design loads sufficiently to cause damage. If this does happen
the damage will usually occur in the area in and around the fittings
which attach the nacelle to the primary aircraft structure. It will be
evidenced by engine nacelle misalignment with the aircraft, as shown by
checking the engine alignment reference points.

The nacelle structure must be placed in the proper jig or holding

fixture and the distorted structural members removed and replaced.
Great care must be exercised in the repair of this type of damage since
even a small error or misalignment of the new parts will cause a
greatly magnified misalignment of the nacelle.

Original assembly parts from the immediate damage area which are
considered to be reusable should be checked for hidden structural
damage using the proper nondestructive test such as magnafluxing,
penetrant testing, sonic testing, etc. Avoid the use of dye penetrant
on composite structure as it affects repair bonding characteristics of
the material.

C. Excess Vibration or Turbulence.

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(1) Excess Vibration

High amplitude vibrations due to the imbalance of engine or

accessory rotation parts which are transmitted to the engine
nacelle structure for long periods of time induce fatigue damage.
The damage is usually concentrated in sharp corners in long beam
structures where there is large relative movement between adjacent
parts in eccentrically mounted structures; in scratches or grooves
where there is a sharp change of cross-sectional area; and at the
edges of large panels which do not have sufficient stiffening or
supporting structure to damp-out the oscillations.

Seldom is there any distortion of the structure, but fasteners are

loosened. Rivet holes, bolt holes, and screw holes tend to become
enlarged in any part of the structure where movement between the
attached parts may be induced. The structure members should be
checked for movement at the joints and the fastener holes checked
for enlargement. If the hole sizes have increased beyond allowable
limits oversize fasteners or hole repair may be required to
stabilize the joint. Refer to 54-04-06 for oversize fasteners in
metal parts.

All scratches, nicks, gouges, dents, or other surface

imperfections should be thoroughly checked by X-ray, penetrant
inspection (except composite structures), magnaflux, sonic
testing, or other nondestructive testing for incipient cracks
which may be invisible to the unaided eye. Where there is any
abrupt change in the cross-sectional area of a structural member,
flexing of the material sharply increases at the point of greatest
area reduction or sharpest corner, to produce metal fatigue and
incipient part failure. However, crack propagation in composite
structure due to vibration is much less significant. Repair all
such surface imperfections or replace the affected part.

It may be necessary to remove the surface coating of structural

fittings or assembly attach fittings in order to detect hairline
cracks which do not rupture the protective surface coating.

Replace any damaged fittings which are discovered. If the damaged

fitting interfaces with another assembly or is a major structural
fitting, it maybe necessary to use an assembly jig or an assembly
holding fixture.

Replace any protective coatings or insulating materials removed in

the process of checking and/or replacement.

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(2) Turbulence

The nacelle structure will be exposed to two major types of

turbulence 1 ambient air turbulence or disturbed air through which
the aircraft is flown, and induced turbulence which is a disruption
of smooth air flow over the nacelle exterior surfaces or interior
air passages such as engine air intake cowling, engine fan ducts,
and fan thrust reverser ducts.

Movement of the aircraft through disturbed air produces a

buffeting or shuddering effect as surface airloads shift
momentarily. violent buffeting may occur in a thunderstorm and may
even be occasionally encountered in clear air. The buffeting of
shuddering causes momentary high loads on the nacelle structure
usually concentrated at or near the fittings which attach the major
assemblies of the nacelle to the engine or to the primary
structure.

Induced turbulence is usually a local phenomenon caused by a

damaged or misaligned part which disrupts the local airflow and
induces a local panel oscillation or flutter. The local effect is
quite similar to vibration caused by imbalanced-rotating equipment
and the same methods of clean up and correction can be used.

D. Elevated Temperature Exposure

(1) Hot Gas

Fan air temperature which is only a single stage of compression may

reach a maximum temperature of 267°F. Core engine compressor low
pressure bleed air taken from the 8th stage may reach a maximum
temperature of 770°F. Engine compressor bleed air taken from the
lOth stage and ducted forward for heating the inlet cowl lip may

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reach a maximum temperature of 925°F. High pressure bleed air taken

from the 14th stage may reach a maximum temperature of 1150°F.
Engine turbine gases leaking through ruptured seals may reach
temperatures in excess of 1700°F. Gases escaping a damaged core
engine exhaust nozzle may reach 1024°F.

The impingement of leaking hot compressed air or hot turbine or

exhaust gases on the nacelle structure can damage the protective
coatings which have been applied and especially in the case of
aluminum parts and adhesive bonded assemblies it can cause changes
in the physical and mechanical characteristics of the material and
assemblies, resulting in reduction of strength, delamination,
impairment of corrosion resistance, etc.

Such damage is usually evidenced by discoloration of protective

coating, discoloration of unprotected metals, buckling, warping of
metals, and delamination of composite materials. The effect is
usually greatest at the point of impingement and decreases sharply
as the distance from this point increases. The effect is also
influenced by the heat conduction characteristics of the affected
metals and may be alleviated if the excess temperatures can be
dissipated readily into adjacent structure.

Survey the damaged area prior to removal of any protective coating

of structural parts. A good indication of the extent of the damage
will be found in the discoloration patterns and the degree of
buckling or warpage. It is usually possible to follow the patch of
the escaping gases to determine the extent of damaged area. Refer
to paragraph 3.D.(2) which follows, for discoloration guide lines
for metals. Note the parts or assemblies that will most probably
require repair or replacement.

If major structural parts or attach fittings must be removed or

there is evidence of buckling or warping that will affect the fit
or function of the structural assembly, it should be placed in a
jig or holding fixture while the work is performed.

Remove the damaged parts, strip the protective coating and check
for any exposure to elevated temperature which will affect the
strength or other essential characteristics of the material in the
parts. (See 54-10-00,54-20-00 or 54-30-00 to determine the
material classification of the part.)

Repair those damaged parts that are reusable and replace the
remainder with new parts. Clean the areas adjacent to the damage
area and restore protective coatings.

(2) Techniques for Evaluation of Beat Damage.

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(a) Visual Inspection for Primer Discoloration: Temperatures which

discolor primer will cause the underlying materials to undergo
physical changes. Discolored or scorched primer is usually the
primary evidence of exposure to over-temperature. Determining
general areas of heat damage by comparing scorched or burned
areas to undamaged samples can be reliable when used with
caution. Before a comparison is attempted the damaged area
must be clean, that is, free from dirt, oil, and smoke
deposits. The slightest evidence of primer discoloration
renders the structural integrity of the material questionable
and requires a more accurate type of inspection. (See Table I)

(b) Visual Inspection of Titanium for Discoloration: After

exposure to over-temperature, titanium will exhibit a color
change indicative of the severity of oxidation which forms a
brittle surface coating. See Table II for range of
discoloration.

STANDARD ACTION REQUIRED

PRIMER COLOR DISCOLORATION TEMPERATURE FOR METALS
FR EPOXY GREEN BROWN ABOVE 400°F HARDNESS
(204°C) TEST
PHENOLIC RUST RED BLACK ABOVE 600°F HARDNESS
(316°C) TEST
ZINC LIGHT TAN ABOVE 300°F HARDNESS
CHROMATE GREEN (149°C) TEST
NOTE: If overtemperature occurs in the area of bonded assembly or
composite structure, a delamination test must be conducted.

Primer Discoloration Chart

Table 1

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(c) Eddy Current Testing: Eddy current conductivity testing is a

nondestructive method for detection of overheating or fire
damage to aluminum alloys.

(3) Fire Damage

(a) Electrical fires usually produce a black sooty deposit on

surrounding areas which must be cleaned away with a
nonvolatile solvent (which will not affect the protective
coatings) before the protective coating of the structural
members may be checked for discoloration.

COLOR QUALITY
Metallic ACCEPTABLE
Straw ACCEPTABLE
Gold ACCEPTABLE
Blue ACCEPTABLE
Green ACCEPTABLE
Purple ACCEPTABLE
Reddish Brown REJECT
Dark Gray REJECT
Light Gray REJECT
White REJECT
Acceptance Chart for Titanium Discoloration Table II
Table II

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Cleanup of the structure usually consists only of a survey for

discoloration, evidence of structural damage, and for evidence
of electrical arcing damage to structural components. If
structural members show evidence of damage, they must be
removed and checked for annealment, embrittlement, composite
delamination, or adhesive bond failures which would be cause
for rejection. If the metal parts are within usable temper
limits (See 54-02-04 and 54-03-01, Hardness Testing), they
should have the protective coating replaced and be
reinstalled, otherwise new parts must be used. If the parts
are composite material structures and visual inspection and
tap test disclose no surface damage or delamination they may
be returned to service. If the parts which must be removed are
major structural members or attach fittings which interface
with another assembly, the structure should be placed in a jig
or holding fixture during the repair operation to assure
proper fit and function after the repair.

(b) Flammable Liquid Fire Damage

Ignition of flammable liquids such as engine fuel and

lubricating oils produce intense heat in the confined space of
the engine nacelle, and unless very quickly extinguished,
major structural damage results.

Unless there is an absence of visible evidence of fire damage

indicating the fire was of very low intensity and of short
duration, the complete nacelle structure should be placed in a
jig or holding fixture which will permit the engine nacelle
alignment points and the significant engineering reference
points and structural assembly coordinates or station lines to
be checked with reference to the structural assembly. This
will determine if any major distortion of the structure or the
fittings which attach it to the aircraft primary structure has
occurred.

1 No structural distortion:

a Survey the damaged area to identify the portion where

the greatest heat was concentrated, as evidenced by
smoke contamination and material discoloration.

b Use safety solvent C-SO to remove smoke contamination

from protective coatings and note full extent of
discoloration. Discoloration indicates possible
damage.

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c Remove protective finish as required and check

structural member for change of material
characteristics and delamination of bonded metal or
composite material parts. (See 54-02-04, Hardness
Testing and 54-02-02 Composite Structure Tap
Testing). If damaged parts cannot be properly checked
on the assembly, they must be removed for bench-
check.

d Repair damaged parts if damage is minor or part is

not in primary structure. (See 54-01-05, primary and
Secondary Structures). Perform repair in accordance
with 54-03-00, Repair Materials and 54-05-00, General
Repairs.

e Replace parts that have major damage or are in

primary structure. Replace protective coatings in
accordance with 54-02-03, Protective Treatment of
Metal Repair Parts and replace corrosion preventive
materials between dissimilar metals.

f Check structure reference points to determine that no

distortion of the structure has occurred during the
repair.

2 Structural distortion:

a Survey the damaged area to identify the portion where

the greatest heat was concentrated as evidence by
smoke contamination and discoloration.

b Place the structural assembly in a jig or holding

fixture that will permit checking the nacelle
alignment points and significant engineering
reference points to determine structure distortion
and shift of structural components from their proper
location. (See 54-01-02, Principal Dimensions and 54-
01-03, Station Diagrams).

c Use safety solvent C-SO to remove smoke contamination

from protective finishes and note full extent of
discoloration. Discoloration indicates possible
damage.

d Note parts that have warped or buckled.

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e Loosen or temporarily remove structural fasteners in

the primary and secondary structure which will permit
it to be properly realigned. (See 54-01-02, Principal
Dimensions and 54-01-03, Station Diagrams). Provide
auxiliary support for structure as necessary to
realign it, and to prevent damage during the repair
procedure.

f Note parts that must be replaced due to elongation or

misalignment of attachment holes beyond the allowable
limits for oversize fasteners.

g Note parts that must be removed due to buckling

warpage, cracking or delamination.

h Determine if damaged parts are in primary or

secondary structure. (See 54-01-05, Primary and
Secondary Structures).

i If primary structural members require any repair

other than oversize fasteners, remove and replace the
member.

j Secondary structural members that have incurred minor

damage may be repaired if fastener attachment holes
have not been elongated or misaligned beyond the
allowable limits for oversize fasteners.
(See 54-05-00, General Repairs).

k Replace all parts that have been removed. Replace all

corrosion preventive materials between dissimilar
metals.

l Restore corrosion protective coatings to repaired

structural members in accordance with 54-02-03,
Protective Treatment of Metal Repair parts.

m Remove all auxiliary supports from nacelle structural

assembly and check structure reference points to
determine that no distortion of the nacelle structure
exists.

n Remove nacelle from jig or holding fixture in which

repair was performed and place in storage or
transportation fixture.

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E. Corrosion

(1) Definition

Corrosion is the destruction of metals by chemical or

electrochemical action. The metal is converted into a metallic
compound such as oxide, hydroxide, or sulfate with a resulting loss
of structural integrity in the portion of the metal part that has
undergone the change. The attack on the metal usually starts at the
surface and proceeds across the surface and down into the core
material. It may, however, originate in the core of the material
due to galvanic intergranular corrosion action due to entrapped
impurities.

(2) Types

There are two general types of corrosion. One type is a direct

chemical attack, such as the action of acid on metal, wherein the
anodic and cathodic changes take place at the same point. The other
type is an electrochemical or galvanic attack, wherein the anodic
and cathodic changes in the action occur at perceptible distances
apart. Galvanic action requires an electrolyte (through which a
small electrical current flows), and a mechanical contact to
complete the electrical circuit. This occurs whenever certain
dissimilar metals are joined in a structure without proper
protective insulation. Galvanic action also occurs inside the core
of the material where certain impurities in the metal produce small
local electrical potentials and resulting minute electrical
circuit flow, or when sustained stress has produced a change in the
original molecular structure of the metal.

Both types of corrosion normally depend on moisture to provide a

conductive medium since a dry contaminant will seldom attack
metal. Moisture in the air is often sufficient to start corrosion.
The nacelle structure and surfaces which are exposed to exhaust
gases, engine fuels, lubricating oils, hydraulic fluids, dust, and
a wide range of temperatures have all of the factors necessary for
chemical or galvanic corrosive action.

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(3) Detection

Corrosion is usually evidenced by a change in the surface

appearance of the affected metal. The terms used to describe its
various forms stem both from the underlying cause of the corrosion
and from the extent of its penetration, location, or appearance.
Terms describing the type of corrosion are: inter granular,
dissimilar metal contact, stress corrosion, and chemical attack.

Terms describing location, penetration, and appearance are:

surface, pitting, filiform, intergranular, and exfoliation.

(a) Intergranular Corrosion

Intergranular corrosion is an attack at the grain boundaries

of a metal. Each of these grains has a clearly defined
boundary, which from a chemical point of view, differs from
the metal within the grain center. The grain boundary and
grain center can react with each other as anode or cathode,
similar to opposite poles of a battery (when in contact with
an electrolyte or conductive medium). Rapid selective
corrosion can occur at the grain boundary with subsequent
delamination. The primary cause of this type of corrosion is
either improper heat treatment of the metal or a change in the
original heat treatment condition caused by exposure to high
temperatures, which may be produced locally by grinding or
machining operations subsequent to heat treatment, or during
overhaul.

Aluminum alloys such as 2024 and 2219 are susceptible to this

type of corrosion, the rate of which is usually accelerated by
the presence of a dissimilar metal such as a steel fastener
and a corrosive electrolyte such as salt water. Since the
change in the material starts below the surface, it is not
immediately apparent.

It is most often seen on extruded sections but also occurs in

sheet stock. It appears as a white powdery deposit, or rough
surface often adjacent to a metal fastener. In an advanced
form, it is known as exfoliation corrosion which exhibits
itself by lifting up the surface of the metal by the force of
the expanding corrosion products accumulating at the grain
boundaries just below the surface. Investigation of a rough
surface may disclose extensive damage underneath.

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(b) Dissimilar-Metal-Contact corrosion.

Metals and metal alloys which have different potentials in the

electromotive series (Refer to 54-02-03) and which are placed
in direct contact, or brought into an electrical contact
through the medium of an electrolyte, create a minute
electrical circuit causing galvanic action which results in
corrosion of the metals. The resulting metal decay or
corrosion starts at the surfaces in contact and proceeds
inward. The corrosion first appears at the exposed portions of
the junction or point of contact of the metals; is usually
rough or scaly; and occupies more space than the parent metal.

The corrosion products differ in color depending on the parent

metal and may be either scale or powder. Aluminum corrosion
products are usually white or grayish white; brass, copper, or
lead corrosion products are usually green; and iron or steel
corrosion products (or rust) are usually reddish brown in
color.

When there is surface or external evidence of dissimilar metal

corrosion, the faying or mating parts should be disassembled
to check the full extent of the corrosion damage. If the only
metal contact has been through the medium of an electrolyte,
the damage may be confined to the surfaces which have been in
contact with the electrolyte, but this can only be determined
by a thorough check of the adjacent materials. (See 54-02-03,
Table of Dissimilar Metal Categories).

(c) Stress Corrosion

Stress corrosion occurs in both aluminum alloys and steel. It

is caused by a sustained applied stress on an assembly which
imposes a structural preload on the part. Stress corrosion
manifests itself as surface cracks in the metal, not
necessarily accompanied by the usual obvious indications of
corrosion. It is usually recognized only after cracking has
occurred, and normally requires replacement of the part.

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(d) Chemical Attack

Direct chemical attack caused by spillage or leakage of an

acid or caustic solution produces a uniform etching of the
surface of the material it contacts. It produces a white
powder deposit or residue on aluminum. If the attack is
allowed to continue, the surface will become rough, appear
frosted, and will eventually become pitted.

(e) Surface Corrosion

The exterior surfaces of the nacelle are exposed to the

greatest flow of air and therefore have the greatest exposure
to contaminants and moisture. They are also exposed to the
effects of sun, rain, ice, and the impact of small particles
of flying debris which erode and damage the protective
coatings which have been applied. The engine air intake ducts,
fan ducts, and fan reverser also encounter high airflow.
Exhaust gas deposits occur in the engine exhaust nozzle area.
The interior surfaces of the structure are much more protected
but are still exposed to the effects of dust collection and
internal vapors or leakage. Moisture also condenses on the
internal surfaces due to the abrupt changes of temperature to
which the nacelle is often exposed.

Surface corrosion (oxidation) appears on the surface of

unprotected aluminum surfaces as a general dulling of the
metal with a white powder deposit or residue similar to dust.
On coated surfaces it usually appears as an area of paint or
protective coating damage where moisture has penetrated the
coating and destroyed the adhesion of the coating in small
local areas. The corrosion will continue to spread between the
coating and the metal surface. Oxidation appears on the
surface of steel parts as a reddish brown powder or scale
(rust). If the steel part has been corrosion protected by
cadmium plating or paint and the plating or coating breached,
the corrosion will initiate at this point and continue to
spread between the surface of the part and the plating.

(f) Pitting Corrosion

Pitting is a form of surface corrosion that differs primarily

in that it is not a uniform etching of the surface but tends
to develop in small local areas or tiny pits. In moderate to
severe cases the pits appear as well-defined hills and valleys
when viewed through a magnifying lens. Pitting first appears
as a white powdery deposit on aluminum surfaces but buffing
the surface reveals tiny pits or holes. Contact between a

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material such as asbestos, sponge, rubber, cork, wood, or

certain plastics which absorb and retain moisture can cause
pitting. Metals in contact with this type of material should
be checked whenever it is suspected that they have been
contaminated with water. Chemical-laden moisture originating
in engine exhaust is a strong electrolyte and capable of
producing a galvanic corrosive action.

(g) Filiform Corrosion

Filiform corrosion is caused by high humidity. It occurs

around fasteners, at skin butt joints, or at breaks in coating
films. The attack is electrolytic (galvanic), due to the
presence of moisture, oxygen, and corrosive ions.

This type of corrosion evidences itself in the form of fine

mole-like trenches under the paint that spread out in a
“filiform” or thread-like manner from the fastener, skin butt
joint, or break in the surface coating.

(h) Exfoliation Corrosion

This is an advanced form of intergranular corrosion which

exhibits itself by lifting up the surface of a metal by the
force of expanding corrosion products accumulating at the
grain boundaries just below the surface. It is often seen on
extruded sections but it also occurs in sheet stock. The
corrosion rate is usually accelerated by the presence of a
dissimilar metal such as a steel fastener, and an electrolyte
such as salt water. It derives its name from the fact that the
material tends to slough off in the form of thin sheets or
leaves. The products of aluminum exfoliation corrosion will
appear as a white powder or scale when the unaffected metal
surface has been stripped away. The corrosion will continue to
spread along the grain until it has been removed and the metal
receives a corrosion preventive treatment.

4. Corrosion Removal

A. General

There are two methods of removal of corrosion damage from metal

surfaces: by chemical means, and by mechanical means.

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CAUTION: IN NO CASE SHOULD DEPTH OF CORROSION REMOVAL EXCEED LIMITS OF

GOUGE REMOVAL APPLICABLE TO AREA (NORMALLY 10 PERCENT OF CROSS-
SECTION OF MATERIAL).

B. Chemical Removal - Aluminum

(1) Remove all paint, lacquer or primer from area where corrosion has
been detected. Apply Turco T-5351 (Turco products, Wilmington, CA)
or Cee-Bee A-202 (Cee-Bee Chemical Co., 9520 E. Cee-Bee Dr.,
Downey, CA).

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(2) Allow the stripper to work undisturbed for approximately 15

minutes.

(3) Agitate worked area with a fiber brush.

(4) If paint remains, reapply fresh stripper without rinsing the area.
Allow fresh stripper to work undisturbed for another 15 minutes.
Agitate with fiber brush.

(5) Remove all traces of stripper by scrubbing with water and wiping.

(6) Repair mechanical damage. Rework cuts, gouges, pits, scratches,

and dents by blending and smoothing, as described in general repair
section of the manual.

(7) Mix Cee-Bee B-4, or equivalent, one part to three parts water.

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WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

CAUTION: WHERE CORROSION IS REMOVED BY CHEMICAL MEANS, SPECIAL

PRECAUTIONS MUST BE OBSERVED. ACID CLEANING MATERIALS MUST
NOT BE ALLOWED TO CONTACT HIGH-STRENGTH STEELS OR TO DRIP OR
SPLASH ONTO ADJACENT SURFACES OR TO RUN INTO SEAMS, SKIN
JOINTS, FAYING SURFACES, OR RECESSES. WET CLOTHS SHOULD BE
AVAILABLE TO REMOVE EXCESS ACID. USE WATERPROOF PAPER AND
MASKING TAPE TO PROTECT ADJACENT AREAS.

(8) Apply mixture with a brush or soft cloth. Allow to remain for five
or ten minutes. Then scrub lightly with a bristle brush. Do not use
steel wool or steel wire brushes. Repeat if necessary.

(9) Rinse and apply Cee-Bee A601 Desmut (before surface dries) to parts
that are not to be painted.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.RINSE WITH
CLEAR WATER AND DRY AT ROOM TEMPERATURE. COMPRESSED AIR MAY
BE USED TO SPEED DRYING.

(10) Apply alodine, primer, and finish coat, as required, to the

reworked area in accordance with instructions in 54-02-03,
Protective Treatment of Metal Repair Parts.

C. Mechanical Removal - Aluminum.

(1) Hand Rubbing

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(a) Remove mild surface corrosion and light pitting by hand-

rubbing with aluminum wool and aluminum oxide abrasive paper.
Dip aluminum wool in kerosene before rubbing. This method is
particularly adaptable to items such as aluminum tubing,
stringers, etc.

(2) Removal of Light Surface Corrosion by Buffing.

(a) Using a cloth or brush, spread a thin coat of aluminum

polishing compound over a small area. Avoid coating too large
an area if compound dries out quickly.

CAUTION: EXCESSIVE FRICTION HEATING CAN ALTER HEAT TREATMENT OF

ALUMINUM.

(b) Attach a cotton pad or lamb's wool cover to the buffing

machine. Buff with a side-to-side motion to minimize heat
generation.

(c) Remove residue around rivets and seams by hand polishing with
the same compound.

(d) After buffing, wash the area with a one-to-one mixture of

water and petroleum base solvent. Since such mixtures settle
into two levels, dip cloth through the lighter solvent into
the water below.

(e) Wipe surface dry and polish with soft cloth.

(3) Removal of Deep Pitting and Intergranular Corrosion by Scraping.

(a) Use paint stripper to remove surface coating from area to be

worked. (See Paragraph 4.B., Chemical Removal of Corrosion -
Aluminum).

(b) Remove deep pitting and intergranular corrosion by using a

carbide tip scraper.

(c) Use a 10-power magnifying glass to determine if all corrosion

has been removed.

(d) Scrape away an additional 0.002-inch of clean metal to ensure

that removal was complete.

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CAUTION: TO AVOID SETTING UP STRESS CONCENTRATIONS, BLEND SCRAPED

AREA INTO SURROUNDING METAL TO FORM A SAUCER-SHAPED
DEPRESSION.

(e) After scraping, polish first with 280-grit aluminum oxide

abrasive paper and then with 400-grit.

(f) Apply the chemical surface treatment and final protective

finish indicated for the area.

(4) Removal of Surface Corrosion from Large Areas by Abrasive

Blasting.

NOTE: Abrasive blasting may be considered only if a complete

organic finish is to be applied. This is because of the
possibility of removing cladding from aluminum and
cadmium plating from steel fasteners.

(a) Remove general surface corrosion from large areas, including

fasteners, by using abrasive-air-blasting equipment such as
“Vacu-Blast”.

CAUTION: TO PREVENT INTRODUCTION OF CONTAMINANTS INTO ALUMINUM,

CONTAMINATION OF ABRASIVE SHOULD BE KEPT BELOW TWO
PERCENT. ABRASIVES THAT HAVE BEEN USED ON STEEL MUST
NEVER BE USED ON ALUMINUM.

(b) Use aluminum oxide or glass bead abrasive material (never

silicon carbide) particle-size 180 mesh (0.08 mm) for coarse
rapid removal of heavy corrosion.

(c) Use aluminum oxide or glass bead abrasive material (never

silicon carbide) particle-size 400 to 600 mesh (0.038 to 0.025
mm) for light corrosion and finish cleaning.

(d) If deep pits or sharp edges appear on the surface of the

aluminum after the removal of the corrosion products, blend
into surrounding metal with a carbide tip scraper and 280-grit
aluminum oxide abrasive paper. Finish with 400-grit paper.

(e) Apply Alodine 1200 in accordance with instructions in

paragraph 4 of 54-02-03, Protective Treatment of Metal Repair
Parts.

D. Chemical Removal - Steel

Phosphoric acid-type compounds may be used to remove corrosion on steel

alloy assemblies, or installed parts not readily removable.

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CAUTION: ACIDS AND ACID CONTAINING COMPOUNDS CAUSE SURFACE EMBRIT-

TLEMENT IN HIGH-STRENGTH STEEL ALLOYS THROUGH ABSORPTION OF
HYDROGEN DURING THE CHEMICAL REACTION. DO NOT USE THESE
MATERIALS ON ANY PRIMARY STRUCTURE PARTS.

(1) Mask off adjacent structure to prevent corrosion removal chemicals

from contacting other structure or flowing into joints or
inaccessible areas. Remover will strip cadmium plating.

(2) Lightly apply phosphoric acid-type corrosion remover Turco WO-l

(Turco Products, Inc., Box 1055, Wilmington, CA) to rusted area
with bristle brush or cloth until rust is removed.

(3) Rinse away rust remover with water.

(4) Rinse with denatured alcohol and wipe dry.

(5) Replace corrosion protection coatings removed from part. If re-

plating of previously plated surfaces cannot be accomplished,
apply two coats of FR primer and one coat of FR aluminized finish
coat.

E. Mechanical Removal - Steel

On high-strength steel alloys and primary structure parts only

mechanical means of rust removal may be used.

CAUTION: DO NOT USE CHEMICAL RUST REMOVERS OR OTHER ACIDIC MATERIALS

THAT COULD CAUSE HYDROGEN EMBRITTLEMENT OF HIGH-STRENGTH
STEELS.

(1) Clean surface with safety solvent C-50.

(2) Remove corrosion (rust) damage, and blend out minor scratches and
dings with 150-grit silicon carbide abrasive paper.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(3) Clean surface with methyl ethyl ketone (TT-M-261) or technical

grade toluene, (TT-T-548).

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(4) Replace corrosion protection coatings removed from part. If re-

plating of previously plated surfaces cannot be accomplished,
apply two coats of FR primer and one coat of FR aluminized topcoat.

5. Corrosion Prevention

A. General

Corrosion prevention and control is of prime importance. Corrosion of

parts may cause deterioration of the structure resulting in serious
failure. The nacelle is designed and manufactured with many built-in
corrosion prevention features. To maintain the integrity of the
corrosion prevention systems and methods used, care must be observed
during the repair or replacement of damaged parts through the proper
maintenance of existing protective coatings and the applications of
protective coatings on repaired or replaced parts.

B. Maintenance of Protective Coatings

Check corrosion protection coatings such as primer, finish coat,

cadmium plating and anodizing in all accessible areas of nacelle
structure for indications of damage to the coating. Give special
attention to areas exposed to flying debris, exhaust gases, dust
collection, or moisture collection which tends to break the protective
coating or cause a separation of the coating from the structure.

(1) Clean the structural area to be checked with safety solvent C-50.
In areas of engine exhaust gas impingement remove the exhaust gaS
residue with B&B Carbon Remover (B&B Chemical Co., Inc., P.O. Box
796, Miami, FL) or equivalent cleaner.

(2) Check for chips, cracks, peels, or cuts in the coating, or rough
scaly surface which might indicate corrosion beneath the coating.

(3) Clean up and repair damaged coatings with proper touch-up

procedures.

(4) Replace protective films used on interior surfaces and waxes/

polishes used on exterior surfaces.

C. Corrosion Prevention on Repaired Parts.

Corrosion prevention coatings which have been damaged can be cleaned

and replaced or repaired in accordance with the instructions in 54-02-
03, Protective Treatment of Metal Repair Parts.

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COMPOSITE STRUCTURE TAP TEST

1. General

A. Tap testing or manual sonic testing is used to detect delaminations

which have occurred in epoxy-bonded composite laminate panel
structures. A delamination occurs when the bonding agent between two of
the lamina fails which reduces the strength and rigidity of the
structure. The bonding agent failure is not visible on the surface of
the structure.

B. The test operates on the principle of resonance of the part being

tested. It is confined to the audible range of 16 to 20,000 hertz
(cycles per second). The part is tapped or struck lightly with a small
metal rod containing a smooth round or ball end. The tap rate is
approximately 4 taps per second, while moving the rod in a regular
survey pattern across the surface of the panel being tested. If the
panel material is of solid homogenous construction and thickness in the
area directly beneath the point of impact of the rod, it will emit
uniform sonic vibrations at a pitch which is characteristic for the
material at that thickness. If a void or a delamination (debond) is
present directly beneath the point of impact of the rod it will be
evidenced by an abrupt change in pitch of the sound emitted by the
panel.

2. Equipment for Tap Testing

A. A small rod approximately 0.25-inch in diameter and 2.00-inches in

length with a 0.375-inch diameter ball on one end may be purchased or
locally manufactured from mild steel or brass. The ball end should be
polished and contain no surface imperfections.

3. Tap Test Technique

A. Check under surface of panel for visible evidence of damage, irregular

surface, or discontinuity of material (if under surface is accessible).

B. Test any area of the underside of panel which exhibits visible evidence
of damage or defect. Move the tap test rod slowly over the panel and
tap the panel surface with the ball end of the rod. Use a tap rate of
approximately 4 taps per second. Note any change of pitch in the sound
emitted which would indicate a delamination or a discontinuity.

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C. Test outer surface of panel following a grid survey pattern. Mark the
areas that indicate a change in pitch of the resulting sound. (See
Figure 1)

NOTE: Normal material or thickness transitions that appear on the

underside of panel will show as lines marked on the outer
surface of the panel. Defects will appear as small circles or
irregular areas marked on the outer surface.

D. Check the outer surface markings with the structure seen on the
underside of the panel and note any anomalies.

E. Tap test the tops of the beam (hat section) reinforcements which may
appear on the under side of panel. Do a local search to further define
any area of abrupt pitch change.

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Tap Test Delamination Survey

Figure 1

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PROTECTIVE TREATMENT OF METAL REPAIR PARTS

1. General

A. Any repair process which penetrates the surface of original structure

requires a protective treatment. The following information is provided
to assist in classifying the protective finish required for the type of
repair shown in this manual. These finishes are considered to be
acceptable for field-type repairs where speed and simplicity is
essential.

B. Refer to 54-02-01, General Damage Cleanup, prior to applying the

required protective finish.

2. Faying Surfaces

A. Galvanic corrosion occurs when dissimilar metal (metals having

different electrochemical potentials) are coupled together in the
presence of an electrolyte (electrically conducting solution). To
prevent galvanic corrosion of dissimilar metals, a protective barrier
is required between the contacting surfaces.

B. Dissimilar metals are classified into four groups as shown in Table I.

Classification is determined by the surface material of the part (i.e.,
the base metal of a non-plated part, or the deposited metal of a plated
or coated part).

C. Table II shows the protective finishes which are to be used on faying

surfaces.

3. Fastener Installation

A. The requirement for protection from galvanic corrosion may be

determined from Table III. Fasteners requiring protective coating
should be installed wet with 463 primer with the following exceptions:

NOTE: In areas where temperature exceed 300~, phenolic primer 204-001

(DeSoto Inc., Pacific Plant, 1608 Fourth Street, Berkeley, CA
94710) must be substituted for 463 primer in all cases.

(1) Removable fasteners on exterior unpainted surfaces - Install

fasteners with MIL-G-16173, grade 2, corrosion preventative
compound.

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Group I Magnesium and its alloys

Aluminum alloys 5052,5056,5356,6061 and 6063, Beryllium.
Group II Cadmium, Zinc and Aluminum and their alloys
(including the Aluminum alloys of Group I).
Group III Steel, Lead and Tin and their alloys
(Except Stainless Steel), diffused Nickel-Cadmium.
Group IV Copper, Chromium, Nickel, Silver, Gold, Platinum, Titanium, Cobalt
and Rhodium and their alloys, Stainless Steels, Graphite, Monel,
Iconel, Brass and Bronze.
Members of anyone group are similar.
Members of different groups are dissimilar.
Classification of Dissimilar Metals
Table I

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FINISH ON FAYING SURFACES

MATERIAL SIMILAR METALS* DISSIMILAR METALS*
Bare aluminum alloys Apply Alodine and one coat Apply Alodine and two coats
of CAT-A-LAC 463 primer to of CAT-A-LAC 463 primer to
each surface each surface
Steel (Except stainless Cadmium plate and apply Cadmium plate and apply two
steel) one coat of CAT-A-LAC 463 coats of CAT-A-LAC 463
primer on each primer to each surface
surface
Stainless Steel None Required Apply two coats of CAT-A-
LAC 463 primer to each
surface
Metal listed in Table I None Required Apply two coats of CAT-A-
Group IV other than LAC 463 primer to each
stainless steel surface
Clad aluminum alloy and Apply Alodine and one coat Apply Alodine and two coats
other metals not listed of CAT-A-LAC 463 primer to of CAT-A-LAC 463 primer to
above each surface each surface
NOTE: *See Table I for classifications

NOTE: In the areas where temperatures exceeds 300°F, Phenolic primer

204-001 must be substituted for CAT-A-LAC 463 primer in all cases.

Faying Surfaces Protective Finishes

Table II

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MATERIAL IN CONTACT WITH FASTENERS

FASTENER MAGNESIUM AND ALUMINUM LEAD, TIN, BARE CORROSION RESISTANT
MATERIAL IN MAGNESIUM ALLOYS, IRON AND CARBON STEELS, NICKEL AND
CONTACT WITH ALLOYS CADMIUM AND OR LOW ALLOY COBALT
STRUCTURE ZINC PLATES STEELS BASE ALLOYS,
TITANIUM,
COPPER, BRASS,
CHROME PLATE AND
GRAPHITE
ALUMINUM EXCEPT A B A A
5056
ALUMINUM ALLOY B B A A
5056
CADMIUM OR ZINC A C A A
PLATE
CHROME PLATE A A A B
UN-PLATED A A A B
CORROSION
RESISTANT STEEL
NICKEL OR A A A B
COBALT BASE
ALLOYS
UN-PLATED A A A B
TITANIUM
NOTE:
A - Protective treatment is necessary
B - Protective treatment is not necessary
C - Protective treatment is unnecessary except for cadmium plated alloy steel
bolts through aluminum alloys in critical corrosion areas.

Protective Treatment For Fastener Installation

Table III

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(2) Torqued fasteners not in close tolerance holes - Coat hole with
primer and allow to dry before installing fastener.

(3) Removable close tolerance fasteners - Install fasteners with MIL-

C-16173, grade 2, corrosion preventative compound.

B. Shaved heads of aluminum rivets in unpainted anodized aluminum alloy

surfaces must be coated with Alodine 1000.

4. Brush Alodine Process

A. Bare (non-clad) aluminum alloys and chamfered edges of clad aluminum

alloy repair parts or original structure require Alodine. Treat repair
parts and original structure that has been cut or filed with alodine.
For appearance, use Alodine 1000 when treating exterior unpainted
aluminum surfaces. On internal surfaces the use of Alodine 1200 is
preferred.

B. Alodine Preparation

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

(1) Alodine 1000 solution preparation.

(a) Add 0.5 ounces of Alodine 1000 powder to one gallon of

distilled or de-ionized water in a polyethylene, stainless
steel or equivalent container.

(b) Mix thoroughly until powder is dissolved.

(c) Allow the solution to stand at least one hour before use.

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WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(2) Alodine 1200 solution preparation.

(a) Mix three ounces of Alodine 1200 powder, 1/2 fluid ounce of
concentrated nitric acid and one gallon of de-ionized or
distilled water in a polyethylene, stainless steel or
equivalent container.

(b) Add 1/8 fluid ounce of Activol 1357 wetting agent.

(c) Stir well until powder is dissolved.

(d) Allow the solution to stand at least one hour before use.

C. Surface preparation.

(1) Mask surface as necessary to prevent solution from contacting

surfaces other than those to be treated.

(2) Seal or plug all holes, gaps or inlets to assemblies with suitable
material to prevent entry of solution.

(3) Water-spray area to be treated and thoroughly abrade using

abrasive nylon pads (Scotchbrite, Type A) or 400-grit aluminum
oxide paper. continue to feed spray water while abrading to produce
a water-break-free surface.

(4) Observe surfaces while wet to verify that a water-break-free

condition of the surface has been achieved. While still wet, follow
with the subsequent Alodine procedure.

D. Alodine Application.

(1) Alodine 1000 solution application.

(a) Apply Alodine 1000 solution with a fiber or nylon brush or

clean cotton wipers.

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(b) Agitate to keep the surface wet for approximately three to

four minutes.

(c) Rinse with clean water and wipe dry with clean, cotton wipers.

CAUTION: EXERCISE CARE WHEN RINSING AND DRYING TO AVOID

SCRATCHING OR REMOVING THE COATING WHICH IS SOFT WHEN
FRESHLY APPLIED.

(d) Air-dry one to three hours.

(2) Alodine 1200 solution application.

(a) Apply Alodine 1200 solution with a fiber or nylon brush or

clean cotton wiper.

(b) Agitate to keep the surface wet until a light golden or

iridescent color develops (approximately 30 seconds).

(c) Rinse with clean water and wipe dry with clean, cotton wipers.

CAUTION: EXERCISE CARE WHEN RINSING AND DRYING TO AVOID

SCRATCHING OR REMOVING THE COATING WHICH IS SOFT WHEN
FRESHLY APPLIED.

(d) Air-dry one to three hours.

(e) Apply final finish or commence adhesive bonding as soon as

possible after drying.

5. Primer Application

A. Fluid-resistant epoxy primer is recommended for areas where

temperatures do not exceed 300°F.

(1) Application of primer.

(a) Mix primer and catalyst separately before measuring. To one

part-by-volume of primer (Akzo Coatings INC Aerospace Finishes
DIV, 434 West Meats Avenue, Orange, CA 92865) add one part-by-
volume of catalyst in a metal or glass container.

(b) Stir mixture thoroughly and let stand for 15 minutes. Material
will remain usable for eight hours if stored in closed
container.

(c) Apply mixed primer to prepared surface with brush or spray.

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(d) Air-dry or force dry primer with explosion-proof heat lamp,

using 350-watt infrared bulb.

(e) Where temperatures exceed 300°F, urethane 825-009 primer

(Desoto, Inc., Pacific Plant, 1608 Fourth Street, Berkeley, CA
94710) must be substituted for primer.

6. Steel-Cadmium Plating

A. Alloy steel parts used in repairs (which are not in an environment

above 450°F) must be cadmium plated for maximum corrosion protection.

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HARDNESS TESTING

1. General

A. Hardness refers to the property of a metal that gives it the ability to

resist abrasion, penetration or permanent deformation. Hardness is
closely associated with tensile strength in heat-treated steel, and
gives an indication of temper for aluminum alloys. Since this knowledge
is necessary to insure structural integrity, hardness tests are a
valuable check. Hardness values of stainless steel, titanium, and
nickel base alloys cannot be considered reliable strength indicators
and should be used for reference only.

2. General Requirements

A. Perform hardness tests on single thickness of material only.

B. The material being tested must be of such thickness that no bulge or

other mark showing the effect of the load appears on the reverse side.

C. No impression may be closer than three impression diameters to a

previous impression (center-to-center) or to an edge (center-to-edge).

D. Hardness testing should be performed on a flat surface whenever

possible. Curved surfaces other than tubing and bar must be tested with
the concave face toward the penetrator whenever possible.

E. The surfaces of the part being tested must be free of surface defects,
paint, or any other foreign material which may adversely affect
hardness readings.

3. Equipment for Hardness Testing

A. Brinell Tester: The Brinell tester uses a hardened steel or tungsten

carbide ball, which is forced by hydraulic pressure into the surface of
the metal. The ball is 10-millimeters (0.3937-inch) in diameter. A
pressure of 3,000 kilograms, maintained at least 15 seconds, is used
for nonferrous metals. The diameter of the impression in millimeters is
measured using a calibrated microscope provided with the tester. After
measuring by microscope, the measurement is converted into the Brinell
hardness number on the conversion table furnished with the equipment.

NOTE: Use of the Brinell tester on a part with more than a 250-
microinch surface finish does not produce an accurate reading.

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B. Rockwell Tester: Rockwell hardness numbers are derived from the

difference between the depth of penetration at major and minor loads.
The minor load is the initial pressure applied (10-kilograms) to
securely lock the test specimen in place. The major load is the applied
pressure (60,100 or 150 kilograms) which forces the penetrator into the
metal. The Rockwell tester measures the depth of the impression and
indicates the hardness number by a dial attached to the machine. The
scales, penetrators, major loads, and dial numbers to be read are
listed in Table I.

SCALE SYMBOL PENETRATOR MAJOR LOAD (kg) DIAL NUMBERS

A DIAMOND 60 BLACK
B 1/16-INCH BALL 100 RED
C DIAMOND 150 BLACK
D DIAMOND 100 BLACK
E 1/8-INCH BALL 100 RED
F 1/16-INCH BALL 60 RED
G 1/16-INCH BALL 150 RED
H 1/8-INCH BALL 60 RED
K 1/8-INCH BALL 150 RED
L 1/4-INCH BALL 60 RED
M 1/4-INCH BALL 100 RED
P 1/4-INCH BALL 150 RED
R 1/2-INCH BALL 60 RED
S 1/2-INCH BALL 100 RED
V 1/2-INCH BALL 150 RED
Rockwell Hardness Scales
Table I

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C. Rockwell Superficial Tester: The superficial tester is recommended for

use where a very shallow impression is desired. Rockwell superficial
hardness tests are of value in testing the hardness of thin material,
nitrided or lightly carburized pieces, finished pieces on which large
test marks would be undesirable, areas near edges and extremely small
parts or sections. The Rockwell superficial tester measures hardness by
the same principle as the Rockwell tester except lighter minor and
major loads and a more sensitive depth-measuring system is employed.
The minor load applied is three kilograms. The major loads are 15, 30
or 45 kilograms. Refer to Table II for scales, penetrators, and major
loads employed in the use of the Rockwell superficial tester.

SCALE SYMBOLS
MAJOR LOAD (KG) N T W N Y
15 15N 15T 15W 15X 15Y
30 30N 30T 30W 30X 30Y
45 45N 45T 45W 45X 45Y
PENETRATOR DIAMOND CONE 1/16-INCH 1/8-INCH 1/4-INCH 1/2-INCH
BALL BALL BALL BALL
Rockwell Superficial Hardness Scales
Table II

D. Barcol Tester: The Barcol impressor is a comparison hardness tester,

not ordinarily used as a precise basis for material acceptance. Its
application is limited to aluminum alloys or other relatively soft
materials and should not be used on aircraft steels. The tester is a
hand-held instrument which measures the depth of penetration when force
is applied by hand pressure. The resultant hardness reading, obtained
from the calibrated dial, is produced by a spring-loaded indenter.

E. Webster Gauges The Webster hardness gage or pliers is a portable, hand-

held instrument used as a comparison tester to check strength in
aluminum alloys up to 0.091 gage. It should not be used on aircraft
steels. Penetration is attained by the actuation of a spring-loaded,
blunt-needle penetrators into the material being tested. The resulting
hardness value is indicated on the calibrated dial.

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F. Ames Tester: The Ames tester is a portable unit calibrated in Rockwell

scales defined in Table I. The instrument operate. on the principle of
measuring the depth of penetration between major and minor loads. The
loads are applied by a hardened spherical ball or diamond Brale, and
the value is obtained directly from an attached calibrated dial.

NOTE: Use only Rockwell scale A, B or C with the Ames tester due to
the limitation of the load carrying capacity.

4. Hardness Values

A. Hardness value for various materials used in the construction and for
the repair of the nacelle are a. follows:

(a) Aluminum AlloyTable III

(b) Corrosion-Resistant SteelsTable IV

(c) 4130,4140, 4340, H11 Alloy SteelsTable V

(d) Nickel Base AlloysTable VI

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Hardness Values for Aluminum Alloys

Table III

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ROCKWELL HARDNESS NUMBER

ALLOY TEMPER FORM A C 15N
TYPE 301 1/4 HARD ALL 25-31 73-76
1/2 HARD ALL 32-36 77-79
H (FULL HARD) ALL 32-36 77-79
37 MIN. 80 MIN.
TYPE 302 1/4 HARD ALL 69 MIN. 26-33 74-78
1/2 HARD ALL 34-40 79-82
H (FULL HARD) ALL 41 MIN. 83 MIN.
17-4PH H1150 ALL 65-70 30-35 75-77
AND H1100C CASTINGS 66-68 32-37
15-5PH (1) H1025, H1000, ALL 67-70 35-40 76.5-80
H925 H900 ALL 70-74 40-47 80-83
17-7 PH TH1100 ALL 68-69.5 35-39 77.5-80
TH1050 ALL 70-72 40-44 80-82
TH950 ALL 72-74.5 44-49 82-84.5
TH900 ALL 72.5 MIN. 46 MIN. 83 MIN.
PH15-7MO RH1050 ALL 70-73 40-46 80-83
RH950 ALL 73-75.5 46-51 83-85.5
CH900 ALL 75 MIN. 50 MIN. 85 MIN.
NOTE: (1) AMS5659 is the applicable specification for 15-5PH.

Hardness Values for Corrosion-Resistant Steels

Table IV

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ULTIMATE CORRECTION TO BE
TENSILE ROCKWELL BRINELL ADDED FOR CADMIUM
STRENGTH HARDNESS NUMBER “C” HARDNESS NUMBER PLATING ROCKWELL “C”
1,000 PSI SCALE 3,000 kg LOAD SCALE
90 183 3.0
100 203 3.0
110 21 230 3.0
120 25 253 3.0
125 27 365 3.0
130 28.5 375 2.0
135 30 286 2.0
140 31.5 298 2.0
145 32.5 307 2.0
150 34 319 1.5
155 35 327 1.5
160 36 338 1.5
165 37 347 1.0
170 38 357 1.0
175 39 368 1.0
180 40 375 1.0
185 41 383 0.0
190 41.5 393 0.0
195 42.5 400 0.0
200 43 407 0.0
210 44.5 425 0.0
220 46 438 0.0
230 47 454 0.0
240 48.5 467 0.0
Hardness Values for 4130, 4140, 4340, and H11 Alloy Steels
Table V

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ROCKWELL HARDNESS NO.

SPECIFICATIO
ALLOY TEMPER FORM A C 15N 15T N
INCONEL HARD SHEET 62.5 24 MIN. 93 MIN. MIL-N-6840
MIN.
INCONEL X HEAT SHEET 65.5 30-40 75-80 AMS5667
TREATED MIN.
BAR 30 MIN. 75.5 MIN.
INCONEL SOLUTION HT SHEET 36 MIN. 78 MIN. AMS5596
718 AND AGED
Hardness Values for Nickel Base Alloys
Table VI

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TEST FOR ALCLAD PENETRATION

1. General

This section provides instructions for determining if the clad material on

aluminum has been penetrated to the core alloy by damage.

2. Materials Required

Analytical reagent grade chemicals dissolved in distilled water shall be

used for the sodium hydroxide and nitric acid solutions listed below.
Quality of material must be carefully controlled and solutions over 30
days old are not to be used.

See Table I for list of materials.

COMPOSITION AND
NAME CONCENTRATION USE
SODIUM HYDROXIDE SODIUM HYDROXIDE TEST SOLUTION REACTIVE ON
SOLUTION 10% BY WEIGHT ALL ALUMINUM ALLOYS
NITRIC ACID SOLUTION NITRIC ACID NEUTRALIZING SODIUM
10% BY WEIGHT HYDROXIDE SOLUTION AFTER
TEST
DISTILLED WATER 100% FLUSHING SURFACE TO REMOVE
CHEMICALS AND
CONTAMINATION
SOLVENT P-D-680 100% CLEAN TEST AREA
Material Required for Alclad Penetration Test
Table I

3. Penetration Test

A. Thoroughly clean area to be tested with solvent.

B. Mask and dam off area to be tested. Use masking tape, modeling clay,
etc. Discard after use.

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WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

C. Apply sodium hydroxide solution to prepared area.

D. Check for penetration. A dark gray or black spot will appear within 60
seconds if clad has been penetrated to the core.

E. Blot area with a clean, cotton wiper prior to evaluation of test.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

F. Neutralize area with nitric acid solution and then flush with distilled
water.

G. Dry area with clean, cotton wipers.

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Document Part No. RDN 306

REPLACE NACELLE MARKINGS

1. General

A. This procedure gives instructions to install replacement identification

markings on the nacelle components. It includes the procedures to
prepare the area, to paint the stencils, to apply a polyurethane top
coat, and to install new placards.

NOTE: See chapter 54-03-05 “Bulk Materials Suppliers List” For the
Materials referred to in this chapter.

NOTE: For installation of placards, see Step 6.

2. Preparation for Stencils

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

A. Clean the area with solvent and clean cotton cloth. Wipe dry with a
clean cotton cloth before the solvent dries.

CAUTION: ABRASIVE PAPER WILL REMOVE THE GLOSSY FINISH OF THE NACELLE
PAINT. TURCO WILL REMOVE THE GLOSSY FINISH AND CAN FULLY REMOVE
THE NACELLE PAINT. IF IT IS NECESSARY TO KEEP THE NACELLE PAINT
AND GLOSSY FINISH, ONLY CLEAN THE SURFACE WITH MIBK. THEN PAINT
THE STENCILS ACCURATELY OVER THE DAMAGED ONES.

B. Remove the initial markings with waterproof silicon carbide abrasive

paper. If necessary, use a plastic spatula to remove the remaining
markings. Do not remove the paint under the markings. If the markings
are removed easily go to step “D”.

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WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

CAUTION: WEAR LINT FREE GLOVES WHEN YOU TOUCH THE CLEANED OR TREATED
SURFACES. BARE HANDS CAN CAUSE CONTAMINATION.

C. If the stencil(s) are not easily removed, you will need to apply TURCO
5351 stripper solution to the markings as follows:

(1) Apply permacel P-12 masking tape around the edge of the stencil.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(2) Put Turco 5351 stripper solution on the surface of the stencil
markings with an acid brush. Let the stripper solution stay on the
surface for 15 to 20 minutes. Brush the stripper solution as
necessary to permit clean solution to touch the stencil marking.

NOTE: Do not permit Turco 5351 stripper solution to dry on the

surface.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(3) Apply additional Turco 5351 stripper on the surface to loosen any
remaining stencil markings.

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(4) Remove the Turco 5351 stripper from the surface with a clean cloth
wet with distilled water. Wipe the area dry with a clean cloth.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

D. Clean the area with solvent and clean cotton cloth. Wipe dry with a
clean cotton cloth before the solvent dries.

3. Paint Stencils

A. Get premade stencils or make stencils with the correct equipment.

Stencil letters must be number 3 alternate gothic style. See Table 1 to
find the correct height. If the space between multiple lines of text is
not written, it must be the same as the letter height.

NOTE: You can use a heavy 0.015 inch (0.381 mm) thick stencil board
with an available stencil machine. Disposable stencils are
strong enough to be reused.

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WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

B. Refer to the manufacturer's instructions to mix the paint. Mix the 443-
3 topcoat and X-304 converter with the necessary amount of TL-29
thinner. Use a color of paint that gives a contrast with the surface
color. Let the mixed paint stand for 30 minutes before it is applied.

NOTE: The pot life of mixed paint is 18 hours for temperatures below
80°F (27°C) or 12 hours for temperatures above 80°F (27°C).

NOTE: The positions shown in Figure 1 are approximate. Put the

stencils in the center of the doors. Put the other stencils
adjacent to the features shown. You can change the number of
lines to fit in the space. Make sure the second and following
lines have the same center line as the top line.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

C. Install the stencils over the damaged markings or in the position shown
in Figure 1. Apply one layer of the paint with a brush or a spray gun.
Use cotton swabs to remove any unwanted paint.

WARNING: LET THE PAINT AIR DRY FOR 15 MINUTES BEFORE YOU CURE IT WITH AN
EXPLOSION PROOF HEAT LAMP. IF YOU USE THE HEAT LAMP TOO SOON, IT
CAN CAUSE IGNITION OF THE PAINT.

D. Remove the stencil(s) and remove the unwanted paint with a cotton swab.
Let the paint air dry for 15 minutes before you cure the paint with the
explosion proof heat lamp.

E. Cure the paint for one hour at 140°- 180°F (60°- 82°C) with an
explosion proof heat lamp.

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F. Do an adhesion test after the paint is fully cured. Apply a 1.0 in.
(25.4 mm) wide strip of No. 250 masking tape to the painted surface.
Then remove the tape in a sudden movement vertical to the painted
surface. If any of the paint is removed by the tape, the paint must be
fully removed and applied again.

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24

26
25

Nacelle Markings
Figure 1 (Sheet 1)
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PHONE
JACK

GROUND HERE

CES-155-0

Nacelle Markings
Figure 1 (Sheet 2)

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Document Part No. RDN 306

Nacelle Markings
Figure 1 (Sheet 3)

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Document Part No. RDN 306

Nacelle Markings
Figure 1 (Sheet 4)

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Document Part No. RDN 306

Nacelle Markings
Figure 1 (Sheet 5)

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Document Part No. RDN 306

Nacelle Markings
Figure 1 (Sheet 6)

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Document Part No. RDN 306

4. Apply Polyurethane Coating on Stencils

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

CAUTION: AFTER YOU APPLY POLYURETHANE COATING, IT CANNOT BE REMOVED

WITHOUT USING ABRASIVE PAPER. IF YOU USE ABRASIVE PAPER, YOU
WILL DAMAGE THE FINISH OF THE PAINT AND YOU WILL HAVE TO PAINT
THE NACELLE AGAIN. DO NOT APPLY POLYURETHANE COATING UNLESS IT
IS NECESSARY FOR THE REPAIR TO BE PERMANENT.

A. Refer to the manufacturer's instructions to mix the 683-3-2

polyurethane coating, X-310A catalyst, and TL-59 reducer or
equivalents. Let the mixture stand for 15 minutes.

NOTE: The best conditions to mix and apply the polyurethane coating is
60-95°F (15-35°C) at a relative humidity of 35-75 percent.

NOTE: The pot life of the polyurethane coating mixture is 4 hours at

77°F (25°C).

NOTE: The shelf life of each unmixed polyurethane component in closed

containers at 40-100°F (5-38°C) is:

683-3-2 Polyurethane Coating: One Year

X-310A Catalyst: 1 Year
TL-59 Reducer: 2 Years

NOTE: Do not use a spray gun to apply polyurethane coating.

B. Apply one layer of the polyurethane coating mixture over the new
identification markings with a soft bristle brush.

WARNING: LET THE POLYURETHANE COATING AIR DRY FOR 15 MINUTES BEFORE YOU
CURE IT WITH AN EXPLOSION PROOF HEAT LAMP. IF YOU USE THE HEAT
LAMP TOO SOON, IT CAN CAUSE IGNITION OF THE POLYURETHANE COATING
MIXTURE.

C. Let the polyurethane coating air dry for 15 minutes before you use the
explosion proof heat lamp.

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D. Use the explosion proof heat lamp to cure the polyurethane coating for
one hour at 140-180°F (60-82°C).

NOTE: It is not necessary to fully cure the polyurethane coating after

a repair. The polyurethane coating does not change the strength
of the structure.

E. Make sure the coating is applied correctly. Do a visual examination of

the polyurethane coating. Do an adhesion test after it is fully cured.
Apply a 1.0-inch (25.4 mm) wide strip of No. 250 masking tape to the
coated surface. Remove the tape in a sudden movement vertical to the
coated surface. If any of the coating is removed by the tape, it must
be fully removed and applied again.

5. Apply Aerodur Clearcoat UVR on Transfer

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

CAUTION: AFTER YOU APPLY POLYURETHANE COATING, IT CANNOT BE REMOVED

WITHOUT USING ABRASIVE PAPER. IF YOU USE ABRASIVE PAPER, YOU
WILL DAMAGE THE FINISH OF THE PAINT AND YOU WILL HAVE TO PAINT
THE NACELLE AGAIN. DO NOT APPLY POLYURETHANE COATING UNLESS IT
IS NECESSARY FOR THE REPAIR TO BE PERMANENT.

A. Refer to the manufacturer's instructions to mix Aerodur clearcoat UVR.

B. Wait 15 to 30 minutes after mixing and before applying.

NOTE: Do not use a spray gun to apply clear coating.

C. Apply one layer 35 - 45 microns (1,4 - 1,8 mils) thick of the clear
coating mixture over the new transfer with a soft bristle brush.

D. Allow to air dry 10 to 12 hours before running test.

E. Make sure the coating is applied correctly. Do a visual examination of

the Aerodur clearcoat UVR.

F. Do a dry-adhesion test after it is fully cured.

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(1) Apply a 1.0-inch (25.4 mm) wide strip of 3M Company No. 250 masking
tape (no more than 6 months old from manufacturing date) to the
coated surface. Remove the tape in a sudden movement vertical to
the coated surface.

(2) If any of the coating is removed by the tape, it must be fully

removed and applied again.

6. Installation of Placards

NOTE: The placards are 0.012-inch (0.305 mm) thick anodized aluminum. Do
not replace the metal labels with stencils or transfers.

A. Find the correct placard in Table 1 of this procedure.

B. Lightly abrade the area to be bonded using silicon carbide abrasive

paper.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

C. Clean the area to be bonded with a clean lint-free cloth and Isopropyl
Alcohol. Remove the Isopropyl Alcohol with a clean lint-free cloth
before Isopropyl Alcohol dries.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

D. Apply a thin coat of RTV primer to the surfaces to be bonded. Let dry
for 30 minutes.

NOTE: For RTV DC90-006 use primer DC PR-1200, for RTV 88/9910 use
primer SS4004.

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WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

E. Refer to the manufacturer's instructions to mix DC90-006 adhesive or

RTV 88/9910.

NOTE: Verify the part number and location of the placard to be

replaced.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

F. Apply approximately 5 to 10 ml of the adhesive on the surfaces to be

bonded. Place the placard on the nacelle. Make sure it is correctly
aligned. Hold the label with a constant pressure during the cure
process.

G. Refer to the manufacturer's instructions to cure the DC90-006 adhesive

or RTV 88/9910.

H. Inspect the installation of the placard. Make sure the placard has a
good bond with the fan cowl. If the placard does not have a good bond or
installation is not correct, remove the placard with Solvent. Repeat
the installation procedure.

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LOC. LRT.
NO. HGT. MARKING GENERAL REMARKS
1 1/2” HOIST POINT LOCATED ON INLET COWL, FAN
COWL, AND CORE COWL.
2 1/4” INSPECTION ACCESS LOCATED ON INLET COWL.
3 1/2” PRESSURE RELIEF DOOR LOCATED ON SURFACES OF
PRESSURE RELIEF DOORS ON
INLET COWL, FAN COWL, AND
CORE COWL.
4 1/2” -CAUTION- LOCATED ON INNER SURFACE OF
1/4” CORE COWL MUST BE CLOSED PRIOR TO LH AND RH CORE COWL.
CLOSURE OF FAN REVERSER, FAILURE
TO DO SO WILL RESULT IN DAMAGE TO
CORE COWL.
5 1/4” HOLD OPEN RODS MUST BE ENGAGED LOCATED ON INNER SURFACE OF
WHEN DOOR IS OPEN LH AND RH CORE COWL.
6 1/2” BOTH “HOLD OPEN RODS” MUST BE LOCATED ON INNER SURFACE OF
ENGAGED WHEN DOOR IS OPEN LH AND RH FAN COWL.
7 1/4” INLET COVER RECEPTACLE LOCATED ON INLET COWL.
8 1 1/2” NO STEP LOCATED ON INLET COWL.
9 1/4” INSPECTION ACCESS PANEL LOCATED ON AFT BULKHEAD OF
INLET COWL.
10 1/4” INSPECTION ACCESS LOCATED ON AFT BULKHEAD OF
INLET COWL.
11 1/4” PHONE JACK HARNESS LOCATED ON AFT BULKHEAD OF
INLET COWL.
12 1/4” ANTI-ICE EXHAUST DUCT ACCESS LOCATED ON INLET COWL.
Nacelle Markings
Table 1 (Sheet 1)

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Document Part No. RDN 306

LOC. LRT.
NO. HGT. MARKING GENERAL REMARKS
13 1/4” ENGINE OIL FILL LOCATED ON RH OIL TANK ACCESS
TOTAL CAPACITY - 7.8 GALS, SEE DOOR ON FAN COWL.
MAINTANCE MANUAL FOR APPROVED
SYNTHETIC LUBRICATING OIL
14 PLACARD GEAR BOX LOOKING UP LOCATED ON INNER SURFACE OF
P/N 277-10510-541 LH DOOR ON FAN COWL.
15 PLACARD THRUST REVERSER LHS LOOKING AFT LOCATED ON INNER SURFACE OF
P/N 277-1051-521 LH FAN COWL.
16 PLACARD LEFT SIDE VIEW (ENGINE) LOCATED ON INNER SURFACE OF
P/N 277-1051-537 LH FAN COWL.
17 PLACARD AIRBUS FIN/LOCATION CHART II LOCATED ON INNER SURFACE OF
P/N 277-1051-535 LH FAN COWL.
18 PLACARD AIRBUS FIN/LOCATION CHART I LOCATED ON INNER SURFACE OF
P/N 277-1051-545 LH FAN COWL.
19 PLACARD RIGHT SIDE VIEW (ENGINE) LOCATED ON INNER SURFACE OF
P/N 277-1051-539 RH FAN COWL.
20 PLACARD THRUST REVERSER RHS LOOKING AFT LOCATED ON INNER SURFACE OF
P/N 277-1051-523 RH FAN COWL.
21 PLACARD GEAR BOX LOOKING UP LOCATED ON INNER SURFACE OF
P/N 277-1051-543 RH FAN COWL.
22 PLACARD AIRBUS FIN/LOCATION CHART I LOCATED ON INNER SURFACE OF
P/N 277-1051-545 RH FAN COWL.
23 PLACARD AIRBUS FIN/LOCATION CHART II LOCATED ON INNER SURFACE OF
P/N 277-1051-535 RH FAN COWL.
24 1/4” PRESSURE RELIEF DOOR LOCATED ON INLET COWL
25 1/2” GROUND HERE LOCATED ON INLET COWL
26 1/4” PHONE JACK LOCATED ON INLET COWL.
Nacelle Markings
Table 1 (Sheet 2)

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ACOUSTIC REPAIR LIMITS

1. General

A. This general section gives the limits for an acoustic panel with
decreased acoustic properties because of damages or a repair.

B. Refer to the tables and formula in this section for limits of acoustic
repair areas.

(1) The maximum allowable loss in Table 1 is permitted if the other

acoustic nacelle components in the other zone are free of damage.

ZONE 1 ZONE 2

CES-260-00
ZONE 2
ZONE 1

MAXIMUM PERMITTED
ACOUSTIC ZONE COMPONENT DESCRIPTION AREA LOSSES
1 Inlet 3.5 ft2
(Inner Barrel)
2 Exhaust 6.5 ft2
(Blocker Doors, Tranlating Cowl,
Reverser Core Cowl)
Maximum Acoustic Loss Limits
Table 1

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(2) Use the formula if there is acoustic loss in more than one zone
(refer to the formula and example).

Formula:

(0.286 x Inlet Area Loss) + (0.154 x Exhaust Area Loss)  1.0

Example:

Inlet (ft2) 3.5 3.0 2.5 2.0 1.5 1.0 0.0

Exhaust (ft2) 0.0 0.9 1.9 2.8 3.7 4.6 6.5

(3) Monitor all acoustic repairs and damages in the acoustic zones. If
a nacelle or engine component is interchanged, the replacement
component must follow the limits set in Step B.

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STRUCTURAL REPAIR MANUAL
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REPAIR MATERIALS

1. General

The metals used in the construction of the A330 Nacelle are aluminum
alloys, steel alloys, inconel alloy, and titanium alloys. They are in the
forms of sheet, extrusion, bar, rod, forgings, and castings. They are used
in annealed, work-hardened, and heat-treat hardened condition.

The metals used for repair of the nacelle may be fabricated in the
annealed or soft state but may require heat treatment before installation
in order to meet the strength and/or corrosion resistance requirements of
the part.

The materials used in the construction of the composite structures of the

nacelle are synthetic fabrics, graphite fabrics, graphite tape, and a
bonding agent. The materials are pre-impregnated with the bonding agent,
laminated, and cured at elevated temperatures and pressures in an
autoclave. Repair of damaged composite structure is accomplished using
graphite fabric and resin wet-layup materials and techniques.

2. Fabrication Data

Temper designation charts show the various heat treatment or hardening

states that apply to a particular material and the process by which it is
achieved.

Cross-sections of Rohr standard extrusion shapes are illustrated in 54-03-

02 and the materials from which they are made are identified.

Standard formed sections are listed in 54-03-03, their cross-sections are

illustrated and the materials from which they are made are identified.

The use of aluminum alloy sheet stock in repair parts that differs in
chemical composition or heat treatment from that used in original part is
permitted within the limits specified in 54-03-04.

3. Sheet Metal Substitution Data

To facilitate repairs under conditions in which the correct material is

not available for an urgent repair, a table of allowable aluminum alloy
sheet metal substitution and the applicable substitution factor is
provided in 54-03-04.

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Document Part No. RDN 306

FORMING, MACHINING, AND FABRICATION CHARACTERISTICS OF METALS

1. General

A. This section contains information and requirements utilized in

fabricating repair parts from metal stock.

B. Where a fabrication practice has been excluded or has been deemed not
allowable, it does not follow that a method does not exist, but that it
is beyond the scope of field repair. Any deviation from approved
fabrication methods listed in this manual must be approved by Rohr,
Inc. Any request for deviation should be submitted to Rohr Inc., P.O.
Box 878, Chula Vista, CA 92012-0878, Attn: Technical Services Manager.

2. Aluminum Alloys

A. The versatile properties of aluminum and its alloys make it an ideal

material for use in the construction of the nacelle. It is light in
weight and under the majority of service conditions the metal has a
high resistance to corrosion. Commercially pure aluminum has a
relatively low tensile strength, but by cold-working, alloying and
heat-treating, substantial increases in strength can be obtained.

B. Temper Designations

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(1) The temper designation system used in this manual is based on the
sequence of basic treatments used to produce the various tempers.
The basic tempers are:

“F” As fabricated. Applies to the products of shaping processes

in which no special control over thermal conditions or
strain-hardening is employed. For wrought products, there
are no mechanical property limits.

“O” Annealed (wrought products only). Applies to wrought

products which are fully annealed to obtain the lowest
strength condition.

“H” Strain-hardened (wrought products only). Applies to

products which have their strength increased by strain-
hardening, with or without supplementary thermal treatments
to produce some reduction in strength. The “H” is always
followed by two or more digits.

“W” Solution heat-treated. An unstable temper applicable only

to alloys which spontaneously age at room temperature after
solution heat-treatment. This designation is specific only
when the period of natural aging is indicated for example,
W 1/2 hour.

“T” Thermally treated to produce stable tempers other than F,

0, or B. Applies to products which are thermally treated,
with or without supplementary strain-hardening, to produce
stable tempers. The “T” is always followed by one or more
digits.

C. Fabrication

The ease with which aluminum may be fabricated is one of its most
important characteristics. Specific alloys can be cast, forged, rolled,
stamped, drawn, spun, or roll-formed, and certain of the alloys are
weldable. The following information applies to the fabrication of
aluminum alloys:

(1) Allowable fabrication operations on aluminum alloys are listed in

Table I. Limitations to those operations are described in
paragraph D.

(2) Minimum bend radii for power brake, hydropress, and roll-forming
are listed in Table II.

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(3) Room temperature contouring of aluminum alloy parts is classified

in Figure 1, and the minimum forming radii shown for the various
tempers in Tables III and IV.

(4) Fluorescent penetrant inspection is required subsequent to all

forming operations.

(5) All hot formed parts must be hardness tested. Refer to 54-02-04.

D. Fabrication Operations Limitations

(1) Limits and conditions under which allowable fabrication operations

on aluminum alloys may be performed are as follows:

(a) Immediately after heat-treat quench, refrigerate parts at 20°F

(-6.7°C) for 24 hours or for longer periods at 0°F (-17.8°C)
to retain ‘AO’ temper. Remove and form one part before
withdrawing another part.

(b) Within bend radii limits of Table II.

(c) Contouring is permitted on nonclad basic sections and shapes

as determined by the following procedure:

1 See Figure I for the class corresponding to the section

shape and direction of the forming required.

2 Refer to Table III for 2024 and 2014, Table IV for 2219,
for the minimum radius. If the height of the section lies
between values presented in the table, use the minimum
radius for the next highest section.

(d) Correction of machining di8tortion permitted.

(e) Contouring in the AQ or T4 temper is permitted on basic shapes

as determined by the procedure specified in D(l)(c), except
that the minimum permitted forming radius shall be one-half
the value determined from Table IV.

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3. Beat and Corrosion-Resistant Steels

A. Precipitation hardening corrosion-resistant steels retain a high

percentage of their room temperature strength up to 700°F (371°C), with
a strength-weight ratio superior to most authentic stainless steels.
They have reasonably good formability in the annealed condition, are
readily weldable, and may be heat-treated to above 180,000 psi at
comparatively low heat and/or deep freeze temperature. without the
necessity of liquid quenching, thereby reducing warpage. These alloys
are normally furnished annealed.

B. Fabrication

(1) Allowable fabrication operations for heat and corrosion-resistant

steels are listed in Table V. Limitations to those operations are
described in paragraph C.

(2) When dimensioning parts for layout in the annealed condition,

allowances should be made for dimensional changes which occur
during heat treatment. These changes depend in some degree on the
amount of cold work applied between the annealing and hardening
treatment. Table VI lists the type of heat-treatment, the type of
dimensional change, and the rate of dimensional change which
occurs to most of the heat and corrosion-resistant steels used in
the nacelle.

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ALLOY SPECIFICATION NUMBER 2014

Temper 0 AQ(A) T3, T4 T6 T6
Forming Temperature R.T. R.T. R.T. HOT R.T.
Deleted
Brake Forming
Bare Material YES NO NO NO NO
Alclad Material
Jogging of Flat Parts
(Skins, etc. YES N.A. N.A. NO NO (B)
Others YES YES (B) YES (B) NO YES (B)
Draw Press and Drop Hammer
Forming
First and Intermediate
Stages YES YES NO NO NO
Final Stage for Sizing NO YES NO NO NO
Hydro Press Forming
Bare Material YES NO NO NO NO
Alclad Material YES (B) NO NO NO NO
Punch Press and Bulldozer
Forming
Joggings of Shapes and
Selections YES NO NO NO NO
Other Punch Press and
Bulldozer
Bare Material YES YES (B) NO NO NO
Alclan Material YES (B) YES (B) YES (B) NO YES (B)
Other Press Forming
(Sparcap Bending, etc.) YES NO NO NO NO
Progressive Roll Forming of Alclad
Sheet and Strip (Hats, etc.)
YES NO NO NO NO
NOTES: R.T. - Material formed at Room Temperature without heating.
N.A. - Not Applicable
L - Limited
(a through e) - See Fabrication Operation Limitations

Aluminum Alloy Fabrication Operations

Table I (Sheet 1)

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ALLOY SPECIFICATION NUMBER 2014

Temper 0 AQ(A) T3, T4 T6 T6
Forming Temperature R.T. R.T. R.T. HOT R.T.
Rerolling of Progressive
Rolled
Sections to be Set Beveled
Angle Only N.A. YES YES NO NO
Roll Contouring YES YES L (C) NO L (C)
Roll Forming of Sheet and Plate
(Leading Edge Contours, etc.)
Bare Material YES NO NO NO NO
Alclad Materials YES (B) YES (B) YES (B) NO YES (B)
Stretch Press Forming
Clad Skins Only N.A. YES YES NO YES (B
All Other Sheet, Shapes, or
Sections
First Stage YES NO NO NO NO
Second Stage N.A. YES NO NO NO
Straightening Operations
Stretch Straightening
Heat Treat Distortion N.A. YES YES NO NO
Power Hammer (Planishing,
Yoder)
Recontouring YES NO NO NO NO
Heat Treat Distortation and
Machine Warpage
Bare Material YES YES L (D) NO NO
Alclad Material YES YES L (D) NO NO
NOTES: R.T. - Material formed at Room Temperature without heating.
N.A. - Not Applicable
L - Limited
(a through e) - See Fabrication Operation Limitations

Aluminum Alloy Fabrication Operations

Table I (Sheet 2)

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ALLOY SPECIFICATION NUMBER 2024

Temper 0 AQ(A) T3, T4 T6 T6
Forming Temperature R.T. R.T. R.T. HOT R.T.
Deleted
Brake Forming
Bare Material YES YES (B) YES (B) NO NO
Alclad Material
Jogging of Flat Parts
(Skins, etc. YES YES (B) YES (B) NO YES (B)
Others YES YES (B) YES (B) NO YES (B)
Draw Press and Drop Hammer
Forming
First and Intermediate
Stages YES NO NO NO NO
Final Stage for Sizing NO YES NO NO NO
Hydro Press Forming
Bare Material YES (B) NO NO NO NO
Alclad Material YES (B) YES (B) YES (B) NO YES (B)
Punch Press and Bulldozer
Forming
Joggings of Shapes and
Sections YES NO NO NO NO
Other Punch Press and
Bulldozer
Bare Material YES YES (B) NO NO NO
Alclan Material YES (B) YES (B) YES (B) NO YES (B)
Other Press Forming
(Sparcap Bending, etc.) YES NO L (C) NO NO
Progressive Roll Forming of Alclad
Sheet and Strip (Hats, etc.)
YES NO YES NO NO
NOTES: R.T. - Material formed at Room Temperature without heating.
N.A. - Not Applicable
L - Limited
(a through e) - See Fabrication Operation Limitations

Aluminum Alloy Fabrication Operations

Table I (Sheet 3)

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ALLOY SPECIFICATION NUMBER 2024

Temper 0 AQ(A) T3, T4 T6 T6
Forming Temperature R.T. R.T. R.T. HOT R.T.
Rerolling of Progressive
Rolled
Sections to be Set Beveled
Angle Only N.A. YES YES NO NO
Roll Contouring YES L (C) L (C) NO L (C)
Roll Forming of Sheet and Plate
(Leading Edge Contours, etc.)
Bare Material YES (B) NO NO NO NO
Alclad Materials YES (B) YES (B) YES (B) NO YES (B)
Stretch Press Forming
Clad Skins Only N.A. YES YES NO NO
All Other Sheet, Shapes, or
Sections
First Stage YES NO NO NO NO
Straightening Operations
Stretch Straightening
Heat Treat Distortion N.A. YES YES NO NO
Power Hammer (Planishing,
Yoder)
Recontouring YES NO NO NO NO
Heat Treat Distortation and
Machine Warpage
Bare Material YES YES YES NO NO
Alclad Material YES YES YES NO NO
NOTES: R.T. - Material formed at Room Temperature without heating.
N.A. - Not Applicable
L - Limited
(a through e) - See Fabrication Operation Limitations

Aluminum Alloy Fabrication Operations

Table I (Sheet 4)

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ALLOY SPECIFICATION NUMBER 2219

Temper 0 AQ(A) T3, T4 T6, T81
Forming Temperature R.T. R.T. R.T. R.T.
Deleted
Brake Forming
Bare Material YES (B) NO NO NO
Alclad Material
Jogging of Flat Parts
(Skins, etc. YES (B) N.A. N.A. YES (B)
Others YES (B) YES (B) YES (B) YES (B)
Draw Press and Drop Hammer
Forming
First and Intermediate
Stages YES NO NO NO
Final Stage for Sizing NO YES NO NO
Hydro Press Forming
Bare Material YES (B) NO NO NO
Alclad Material YES (B) YES (B) YES (B) YES (B)
Punch Press and Bulldozer
Forming
Joggings of Shapes and
Selections - - - -
Other Punch Press and
Bulldozer
Bare Material YES (B) YES (B) NO NO
Alclan Material YES (B) YES (B) NO NO
Other Press Forming
(Sparcap Bending, etc.) YES NO NO NO
Progressive Roll Forming of Alclad
Sheet and Strip (Hats, etc.)
YES NO NO NO
NOTES: R.T. - Material formed at Room Temperature without heating.
N.A. - Not Applicable
L - Limited
(a through e) - See Fabrication Operation Limitations

Aluminum Alloy Fabrication Operations

Table I (Sheet 5)

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ALLOY SPECIFICATION NUMBER 2219

Temper 0 AQ(A) T3, T4 T6, T81
Forming Temperature R.T. R.T. R.T. R.T.
Rerolling of Progressive
Rolled
Sections to be Set Beveled
Angle Only NO NO NO NO
Roll Contouring YES L (E) L (E) L (E)
Roll Forming of Sheet and Plate
(Leading Edge Contours, etc.)
Bare Material YES (B) NO NO NO
Alclad Materials YES (B) YES (B) YES (B) YES (B)
Stretch Press Forming
Clad Skins Only N.A. YES YES NO
All Other Sheet, Shapes, or
Sections
First Stage YES NO NO NO
Second Stage N.A. YES NO NO
Straightening Operations
Stretch Straightening
Heat Treat Distortion N.A. YES YES NO
Power Hammer (Planishing,
Yoder)
Recontouring YES NO NO NO
Heat Treat Distortation and
Machine Warpage
Bare Material YES YES YES NO
Alclad Material YES YES YES NO
NOTES: R.T. - Material formed at Room Temperature without heating.
N.A. - Not Applicable
L - Limited
(a through e) - See Fabrication Operation Limitations

Aluminum Alloy Fabrication Operations

Table I (Sheet 6)

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2014 2024
CLAD CLAD AND BARE
GAGE 0 AQ,T3,T4 T6 0 AQ T3, T4 T6, T81
0.012 0.03 0.09 0.09 0.03 0.06 0.09 0.09
0.016 0.03 0.09 0.09 0.03 0.06 0.09 0.09
0.020 0.03 0.09 0.12 0.03 0.06 0.09 0.12
0.025 0.03 0.12 0.16 0.03 0.09 0.12 0.16
0.032 0.03 0.12 0.19 0.03 0.09 0.12 0.19
0.040 0.06 0.16 0.25 0.06 0.12 0.16 0.25
0.050 0.06 0.19 0.31 0.06 0.15 0.19 0.31
0.063 0.09 0.19 0.41 0.09 0.15 0.19 0.41
0.071 0.12 0.22 0.044 0.12 0.18 0.22 0.44
0.080 0.12 0.31 0.50 0.12 0.28 0.31 0.50
0.090 0.16 0.37 0.56 0.16 0.34 0.37 0.56
0.100 0.19 0.41 0.66 0.19 .037 0.41 0.66
0.125 0.22 0.50 0.84 0.22 0.46 0.50 0.84
0.160 0.28 0.66 1.06 0.28 0.56 0.66 1.06
0.190 0.37 0.84 1.37 0.37 0.65 0.84 1.37
0.250 0.62 1.25 2.00 0.62 0.87 1.25 2.00
0.375 1.37 1.87 - - 1.37 1.62 1.87 - -
0.500 2.50 2.50 - - 2.50 - - - - - -
NOTE: 1. All dimensions are in inches.
2. Bend radii are measured to the inside surface of the bend.

Aluminum Alloy Minimum Bend Radii - Power Brake Hydropress and Roll Forming
Table II (Sheet 1)

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2219
BARE CLAD
GAGE 0 0 AQ T31, T42 T62, T81
0.012 0.09 0.03 0.09 0.09 0.09
0.016 0.09 0.03 0.09 0.09 0.09
0.020 0.09 0.03 0.09 0.09 0.12
0.025 0.12 0.03 0.12 0.12 0.16
0.032 0.12 0.03 0.12 0.12 0.19
0.040 0.12 0.06 0.12 0.16 0.25
0.050 0.12 0.06 0.12 0.19 0.31
0.063 0.12 0.09 0.12 0.19 0.41
0.071 0.12 0.12 0.12 0.22 0.44
0.080 0.19 0.12 0.19 0.31 0.50
0.090 0.19 0.16 0.19 0.38 0.56
0.100 0.22 0.19 0.22 0.41 0.66
0.125 0.28 0.22 0.28 0.50 0.84
0.160 0.44 0.31 0.44 0.66 1.06
0.190 0.56 0.38 0.56 0.84 1.37
0.250 0.90 0.90 - - 1.25 2.00
0.375 1.38 1.38 - - 1.87 - -
0.500 2.50 2.50 - - 2.50 - -
NOTE: 1. All dimensions are in inches.
2. Bend radii are measured to the inside surface of the bend.

Aluminum Alloy Minimum Bend Radii - Power Brake Hydropress and Roll Forming
Table II (Sheet 2)

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SR-224-011
Room Temperature Contouring Limitations for 2024 and 2014 Alloy
Table III

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Room Temperature Contouring Limitations for 2019 AL Alloy

Table IV

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SR-224-013
Classification of Forming Operation
Figure 1

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17-7PH 15-5PH & 17-4PH

HT-125
TYPE OF HT-150
OPERATION ANNEALED T HT-170 ANNEALED HT-180
Forming and
Drawing (a) YES L (B) NO (J) YES NO
Straightening (b) YES L (B)(J) NO (K) YES NO
Cutting
Punching YES YES NO L (F) NO
Shearing YES YES NO L (F) NO
Sawing YES YES L (K) YES NO
Blanking YES YES NO L (F) NO
Torch NO NO NO NO NO
Abrasive NO NO NO NO NO
Machining YES YES L (D) YES L (D)
Drilling YES YES (G) YES (G) YES YES
Welding
Metallic Arc YES NO NO YES NO
Gas Shield Arc YES NO NO YES NO
Resistance NO YES NO YES NO
Brazing YES NO NO YES NO
Riveting N.A. N.A. YES (E) N.A. YES (E)
NOTES: T = Austenite condition
L = Limited
N.A. = Not Aplicable
(a thru k) = See Fabrication Operations Limitations.

Fabrication Operations on Corrosion Resistant Steel

Table V (Sheet 1)

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PH15-7MO A286
TYPE OF
OPERATION ANNEALED R-100 RH-190 ANNEALED HT-140
Forming and
Drawing (a) YES L (B) NO (J) YES (C) L (B)
Straightening (i) YES L (B)(J) NO YES L (B)
Cutting
Punching YES YES NO N.A. N.A.
Shearing YES YES NO YES NO
Sawing YES YES NO YES NO
Blanking YES YES NO YES NO
Torch NO NO NO NO NO
Abrasive NO NO NO NO NO
Machining YES YES L (D) YES L (D)
Drilling YES YES (G) YES (G) YES YES
Welding
Metallic Arc YES NO NO YES NO
Gas Shield Arc YES NO NO YES NO
Resistance NO NO NO YES NO
Brazing YES NO NO YES NO
Riveting N.A. N.A. YES (E) N.A. YES (E)
NOTES: L = Limited
N.A. = Not Applicable
(a thru k) = See Fabrication Operations Limitations.

Fabrication Operations on Corrosion Resistant Steel

Table V (Sheet 2)

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DIMENSIONAL CHANGE
ALLOY TREATMENT TYPE INCH/INCH
17-7PH Transformation (1400°F) of Cond. A EXPANSION 0.0045
material to Cond. T
17-7PH Precipitation Heat Treat of Cond. T CONTRACTION 0.0005
to HT-170 or HT 150
17-7PH Precipitation Heat Treat of Cond. C CONTRACTION 0.0005
to HT-240
17-4PH Precipitation Heat Treat CONTRACTION 0.0006
(A to HT-180)
Precipitation Heat Treat CONTRACTION 0.0006
(A to HT-150)
Precipitation Heat Treat CONTRACTION 0.0006
(A to HT-125)
AMS350 Subzero Cool (L to SC) EXPANSION/ 0.003
Temper (SC to HT-180) CONTRACTION 0.0003
Dimensional Changes of Heat and Corrosion-Resistant Steels
Resulting from Heat Treatment
Table VI

(3) Materials should be fluorescent penetrant inspected or magnetic

particle inspected after all fabrication operations are completed.

(4) Hardness test all heat-treated parts. Refer to 54-02-04.

C. Fabrication Operations Limitations

(1) Limits and conditions under which allowable fabrication operation.

on heat and corrosion-resistant steels may be performed are as
follows:

(a) Interstage anneal if necessary,

(b) Limited to minimum to remove heat treat warpage.

(c) Anneal after severe forming.

(d) Limited to final machining only. No rough cuts.

(e) Use Monel rivets only.

(f) Permissible on stock to 0.5-inch thick. Leave 0.25-inch all

sheared edges for final machining.

(g) 0.040-inch minimum diameter.

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(h) Limited to trimming for assembly only. Edge condition

requirements for sawed edges must be maintained.

(i) Rework requiring reverse forming (8uch as flattening of

joggles) is prohibited.

(j) Interrupted quench forming may be performed using the

procedure for the heat treatment of 17-7PB as an example.

1 Soak at 1400°F.± 25°F (760°± 13.9°C) for a minimum of 90

minutes at temperature. Total time in furnace for anyone
part shall not exceed five hours.

2 Quench on die using the following procedure: Total

elapsed time between removal from furnace operating at
1400°F (760°C) to placement in refrigerator at 55°F
(12.7°C) shall not exceed one hour.

(Step A) Parts may be transferred to a holding furnace

operating at 700°-lOOO°F (371.1°-537.8°C) prior
to placing on die.

(Step B) Place part on die. Part temperature should be

approximately 600°F (315.6°C) when placed on
die.

(Step C) Place restraining members (such as pressure

plates, matched half of die) on top of part and
apply minimum pressure required to hold part to
contour of the die.

3 Place part in refrigerator; cool to below 60°F (15.6°C)

but not lower than 32°(0°C) and hold for 30 minutes
minimum.

4 Precipitation harden T to HT-I50 or HT-170. Use of

restraining dies when cooling from precipitation
hardening temperature is permissible provided total time
in precipitation hardening furnace for any part does not
exceed 110 minutes. Parts may be transferred from the
precipitation hardening furnace to a holding furnace
operating at 600°F (315.6°C) and held for a maximum of
five hours.

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(k) Handwork to reset flanges and bevel angles is permitted on

heat treated (HT-I5O, HT-170) 17-7PH at room temperature. On
gages up to 0.063-inch the maximum correction angle is five
degrees. On gages from 0.064-inch to 0.125-inch the maximum
correction angle is three degrees.

4. Inconel

A. Inconel 718 (AMS5596, AMS5662) is an air-melted precipitation hardening

nickel-chromium base alloy with excellent high-strength properties and
good weldability. It has good ductility between 1200°F and 1400°F along
with high yield, tensile and creep rupture strength up to 1300°F. It
may be hardened to 180,000 psi. Outstanding weld characteristics are
due to slow response to aging which keeps restraints to a minimum and
avoids buildup of welding stresses.

B. Inconel 625 (AMS5599) has high tensile, corrosion-fatigue strength and

resistance to chloride-ion stress corrosion cracking. It derives its
strength from stiffening effect of molybdenum and columbium on a
nickel-chromium matrix. It has excellent resistance to corrosion and
oxidation, and is not strengthened by heat treatment. It is readily
welded by the gas-shielded arc process with either a tungsten electrode
or consumable electrode of Inconel filler metal 625.

C. Fabrication Operations Limitations (See Table VII.)

(1) Limits and conditions under which allowable fabrication operations

on Inconel 625 and 718 may be performed are as follows:

(a) Hole diameter must be 1.5 times the thickness of the material
up to 0.1875-inch.

(b) Pilot holes up to 0.060-inch may be punched in a single

thickness attachment flange of brazed and heat-treated Inconel
718, provided holes are subsequently drilled to final size. A
minimum cleanup allowance of 0.040-inch diametrically (0.020
per side) should be allowed for removal of disturbed metal.

(c) 0.020-inch must be removed from edge of material 0.063-inch

and thicker.

(d) Cutting, punching, blanking and shearing is allowed for both

Inconel 625 and 718 in solution treated (ST) and solution
treated and aged (STA) conditions.

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(e) Inconel 625 and 718 machining: Wet grinding is allowed for
both solution treated (ST) and solution treated and aged
(STA). Also, turning, milling, drilling, reaming, etc. is
allowed under ST and STA conditions. Power sanding is not
allowed during STA condition.

(f) Brake forming and roll contouring ia allowed in ST only.

(g) Manual straightening and forming at room temperature (STA) is

allowed for Inconel 718 only, and under limited conditions.
(See Table VII for Fabrications Operations Rework Limitations
and Table VIII, Contour Correction Limitations.)

(h) Welding: Both fusion (Table IX) and resistance spot/seam are
allowed (ST and STA) for both Inconel 625

(i) Wet grinding should be conducted as follows:

Grinding Wheel - Grade J or softer with vitrified bond

Speed - 6500 SFPM maximum
Work Speed - 60 SFPM maximum
Cross Feed - 0.5-inch per pass
Rate of Removal - 0.02-inch per pass up to 0.0l0-inch of
finished size and thereafter 0.00l-inch
per pass to finished size.
Coolant - Rustlick (Cutzol HMP) recommended.

(j) Formed to a minimum of 6t or 6d, whichever is greater for both

Incone1 625 and 718.

(k) Straightening requiring reverse forming (such as flattening of

joggles) is prohibited on Inconel.

(l) Handwork to reset flanges and bevel angles for formed sections
is permitted at room temperature under the following
conditions:

MAXIMUM REWORK
GAGE INCONEL 615 AND 718 INCONEL 718 ONLY
SOLUTION TREATED SOLUTION TREATED
(ST) AND AGED (STA)
UP TO 0.063-INCH 8° 5°
0.064 TO 0.125-INCH 5° 3°
Fabrication Operations Rework Limitations
Table VII

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(m) Contour corrections after aging for formed sections should not
exceed the following limits:

MAXIMUM CONTOUR CORRECTION

WIDTH OF LENGTH OF SELECTION

SECTION 10 20 30 40 50 60
1.0 NONE 1/16 1/8 1/4 5/16 1/2
2.0 NONE 1/32 1/16 1/8 5/32 1/4
3.0 NONE NONE 1/32 1/16 3/32 5/32
4.0 NONE NONE 1/32 1/16 1/16 1/8

NOTE: All dimensions are in inches.

Inconel 718 fabrication Operations -

Contour Correction Limitations
Table VIII

(n) Minor straightening up to 0.030-inch allowed.

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(o) Fusion weldments should be resolution heat-treated subsequent

to welding and prior to aging.

MINIMUM BEND RADIUS

GAGE ROOM TEMPERATURE
0.012 0.03
0.016 0.06
0.020 0.06
0.025 0.06
0.032 0.09
0.036 0.09
0.040 0.09
0.045 0.12
0.050 0.12
0.063 0.16
0.071 0.19
0.080 0.19
0.090 0.22
0.100 0.25
0.112 0.28
0.125 0.31
0.160 0.37
0.187 0.44

NOTE: All dimensions are in inches

Inconel 718 (ST conditions) Minimum Bend Radii Power Brake,

Hydropress and Roll Forming
Table IX

5. Titanium

A. Titanium is a light, moderately strong, corrosion-resistant metal with

limited ductility. Its good strength-to-weight ratio makes it ideally
suited for repairs where aluminum is too weak and stainless steel is
too heavy. Titanium maybe cold or hot formed and most alloys are
readily weldable.

B. Fabrication

(1) Allowable fabrication operations for solution-treated (ST) and

solution-treated-and-aged (STA) material and limitations to those
operations are described in paragraph C and Table X.

(2) Minimum bend radii for power brake, hydropress, and roll forming
sheet material are given in Table XIII.

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(3) All dies and fixtures used in thermal processing of titanium and
its alloys must be made of Meehanite and/or oxidation-resistant
alloys, steel, or ceramic-coated steels. Kirksite and lead dies
may be used for hot drop-hammer forming. The use of zinc, tin or
cadmium-plated tools, fixtures or temporary fasteners on titanium
is prohibited.

(4) Temperature time cycles for processing titanium are given in Table
XIV.

(5) Stress relieve all parts formed below 1000°F (537.8°C) with the
following exceptions:

(a) Stretch or roll contoured exterior skins.

(b) Ductinq systems.

(c) Parts hot-sized after forming.

(d) Parts for fusion-weld assemblies which will be stress-relieved

after welding.

(6) Interstage stress relieving may be performed when severe forming

is required. Time at temperature is cumulative and must not exceed
the limitations in Table XIV.

(7) Edge finish requirements are approximately 0.015-inch radius or

chamfer.

(8) Formed parts and finish-machined parts must be fluorescent-

penetrant inspected.

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Table X

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C. Fabrication Operations Limitations

(1) Limits and conditions under which allowable fabrication operations

on titanium and titanium alloys may be performed are as follows:

(a) Holes 0.5-inch or smaller on stretch formed or flat sheets up

to 0.080 gage. Cutouts greater than 0.5-inches are permitted
provided edge requirements are met.

(b) Up to 0.063 gage on stretch formed or flat sheets. Holes 0.5-

inches or smaller provided 0.020-inches is subsequently
removed on the diameter. Cutouts greater than 0.5-inches are
permitted provided edge requirements are met.

(c) Machine speed must be low enough to prevent an overheated or

burned surface (blue color). Touch temperature must not be
exceeded during machining or five seconds or less after
removal of tool. Do not dwell; keep tool moving across
surface.

(d) Machine speeds must be low enough to prevent sparking.

(e) Time and temperature limitations for hot-forming, hot-sizing

and creep forming are specified in Table XIV.

1 Forming of titanium may be accomplished at temperatures

up to 1200°F (649°C). When elevated temperature ranges
are recommended:

350°F to 500°F (177°C to 260°C)

900°F to 1200°0F (482°C to 649°C) where optimum

formability is attained.

2 When possible, avoid the 550°F to 850°F (288°C to 455OC)

temperature range. The ductility of titanium is lower
here than in other temperature ranges.

(f) Sheet material may be hot-formed in an unheated brake die to a

maximum 950 bend when the following conditions are satisfied:

1 The sheet blank is heated uniformly within the time-

temperature range shown in Table XIV.

2 The heated blank is transferred to the unheated brake die

and formed within 10 seconds. Both form bar and extrusion
per time-temperature limitations are shown in Table XIV.

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(g) Formed to a minimum of 6t or 6d, whichever is greater. May be

accomplished at room temperature provided parts are
subsequently hot sized per Table XIV or stress relieved.

(h) Stress relieve to the following requirements:

1 Temperature - 1025°F + 25°F (551.6 + 13.9°C)

2 Soak - 3/16 inch and under = 1 hour

Over 3/16 inch = 2 hours for the first 1-inch plus 1 hour
for each additional inch or fraction thereof.

3 Cooling Medium - Air

(i) Maximum correction to bevel angles at room temperature should

not exceed the following limits:

GAGE MAXIMUM ANGLE CORRECTION

Up to 0.063 5°
0.064-in. to 0.125-in. 3°
Angular Correction Limitations
Table XI

(j) Contour correction for hydropress formed parts should no

exceed the following limits:

WIDTH MAXIMUM CONTOUR CORRECTION

OF LENGTH OF SECTION
SECTION 10 20 30 40 50 60
1.0 1/32 5/32 3/8 1/2 1/2 1/2
2.0 1/32 1/16 3/16 5/16 1/2 1/2
3.0 None 1/16 1/8 7/32 5/16 1/2
4.0 None 1/32 3/32 1/8 1/4 3/8
Angular Correction Limitations
Table XII

(k) Remove 0.25-inch minimum from all cut edges.

(l) Within bend radii limits of Table XIII.

(m) Heat die and part in an air furnace 1 hour at 1375°F + 25°F
(746.1° ± 13.9°C). Remove die and part from furnace and air
cool to any room temperature below 1000°F (537.8°C). Remove
the part from the die. Remove oxygen diffused layer to a
maximum of 0.003-inch.
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Titanium and Titanium Alloy Minimum Bend Radii

Power Brake, Hydropress and Roll Forming
Table XIII

Hot Forming, Hot Sizing and Creep Forming

Table XIV

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EXTRUDED SECTIONS

1. General

A. This section contains illustrated examples of Rohr Standard Extrusions

used in the construction of the A330 nacelle.

B. When original aluminum alloy extrusions are not available, equivalent

members may be made up from sheet material. The sheet material should
be of the same alloy and temper as the original extrusion, the area of
the cross section should be equal to, or greater than, that of the
extrusion, and the shape should be similar. Refer to 54-03-04 for
material substitution. It is preferable that an equivalent be formed in
one piece. If the nature of the original extrusion makes it necessary
to build up an equivalent from two or more pieces, the gage and
material specified in the applicable illustration should be used. When
the shape of an extrusion makes the building-up of an equivalent from
sheet material impossible, the equivalent may be machined from bar
stock of the same material specification and dimensions as the original
extrusion. It is not permissible to build up an equivalent section from
two or more pieces to replace an extrusion that is used as an
attachment clip or fitting.

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2. Types of Extruded Sections

Extrusion – Angle Figure 1

Extrusion – Blade Figure 2

Extrusion – Channel Figure 3

Extrusion – Hinge Figure 4

Extrusion – Retainer Figure 5

Extrusion - T-Section Figure 6

Extrusion - Z-section Figure 7

3. Extruded Section Index

Extrusion Figure Extrusion Figure

Number Number Number Number

S700EO272 5 8700E0463 1

S700EO275 6 S700EO474 2

S700EO277 3 S700BO475 6

S700EO280 7 S700EO589 6

S700EO284 6 S700EO590 6

S700EO285 6 S700EO700 1

S700EO287 2 S700EO713 1

S700BO290 2 570080271 4

S700EO296 3 5700B0311 4

S700EO301 2 5700B0312 4

S700EO415 7

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Extruded Section - Angle

Figure 1 (Sheet 1)

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0.050

NOTE:
ALL DIMENSIONS ARE IN INCHES

1.250
0.120R
0.100

2.660

AREA
PART NO. MATERIAL SPECIFICATION
SQ. IN.

S700E0700 2024-T3511 0.327 QQ-A-200/3

ALUMINUM
2024-0 QQ-A-200/3
S700E0700-1 0.327
ALUMINUM
C2S-005-00

0.050
NOTE:
ALL DIMENSIONS ARE IN INCHES
CORNER RADII
0.015 MAX.
(TYPICAL)
1.380

0.120R
0.100

2.660

PART NO.: S700E0713-1

MATERIAL: 2024-0 ALUMINUM
AREA: 0.333 SQUARE INCH
SPECIFICATION: QQ-A-200/3
C2S-006-00

Extruded Section - Angle

Figure 1 (Sheet 2)

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Extruded Section - Blade

Figure 2 (Sheet 1)

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Extruded Section - Blade

Figure 2 (Sheet 2)

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Extruded Section - Channel

Figure 3 (Sheet 1)

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Figure 3 (Sheet 2)

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0.220 in. LENGTH CODED

(5,588 mm)
0.156 in. R
(3,962 mm)
1.25 in. R (Typical)
(31,75 mm)
2.570 in.
+ 0.005 in. (65,278 mm)
0.093 in. (0,127 mm)
(2,362 mm) - 0.000 in. 0.312 in.
(7,925 mm)
(0.000 mm) DIA
DIA HOLE

52°
0.250 in.
(6,35 mm)
0.010 - 0.032 in. R
0.156 in. R
(0,254 mm) - (0,813 mm)
(3,962 mm)
(Typical)
0.495 in. +0.000 in.
+ 0.004 in.
(12,573 mm) -0.004 in.
(0.102 mm) 0.505 in. (0,102 mm)
(Typical) (12,827 mm) - 0.000 in.
(0.000 mm)
(Typical)

PART NO.: S700E0474

MATERIAL: 2024-T3511 ALUMINUM
AREA: 0.763 sq in. (492,257 mm2)
SPECIFICATION: QQ-A-200/3

NOTES:
1. ALL DIMENSIONS ARE IN INCHES.
CES-188-00

2. LENGTH CODED IN INCHES AND 1/32 INCH. S700H0271-316

IS HINGE 3 1/2 INCHES LONG.

Extruded Section - Hinge

Figure 4 (Sheet 1)

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1.41 in.
(35,814 mm)

0.941 in.
(23,901 mm)

0.25 in. R 0.25 in. R

(6,35 mm) (6,35 mm)

120°
0.505 in. + 0.004 in.
0.250 in. (12,827 mm) (0,102 mm)
0.312 in. (6,35 mm) - 0.000 in.
(7,925 mm) ± 0.010 in. (Typical)
DIA (0,254 mm)

+ 0.005 in. 0.010 in.

0.093 in. (0,127 mm) 0.495 in. + 0.000 in.
(2,362 mm) (0.254 mm)
- 0.000 in. (12,573 mm) - 0.004 in.
0.032 in. R
(0,102 mm)
(0,813 mm)
(Typical) (Typical)

PART NO.: S700H0311

MATERIAL: 2024-T3511 ALUMINUM
AREA: 0.294 sq. in. (189,677 mm2)
SPECIFICATION: QQ-A-200/3

NOTES:
CES-189-00

1. ALL DIMENSIONS ARE INCHES.

2. LENGTH CODED IN INCHES AND 1/32 INCH. S700H0271-316
IS HINGE 3 1/2 INCHES LONG.

Extruded Section - Hinge

Figure 4 (Sheet 2)

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45°
0.16 in. R OPT
(0,406 mm) 0.250 in. 0.010 in.
(2 locations) ±
(6,35 mm) (0,254 mm)
0.300 in.
(7,62 mm)
1.121 in.
(28,473 mm)

0.010 - 0.032 in. R

0.312 in. (0,254 mm) - (0,813 mm)
(7,925 mm) + 0.005 in. (Typical)
DIA 0.093 in. (0,127 mm)
0.88 in. (2,362 mm) + 0.004 in.
- 0.000 in. 0.505 in. (0,102 mm)
(22,352 mm)
(12,827 mm)
DIA THRU - 0.000 in.
2.25 in. (Typical)
(57,15 mm)

0.495 in. +0.000 in.

(12,573 mm) -0.004 in.
(0.102 mm)
(Typical)

PART NO.: S700H0312

MATERIAL: 2024-T4 ALUMINUM
AREA: 0.550 sq in. (354,838 mm2)
SPECIFICATION: QQ-A-200/3

NOTES:
1. ALL DIMENSIONS ARE IN INCHES.
CES-190-00

2. LENGTH CODED IN INCHES AND 1/32 INCH. S700H0271-316

IS HINGE 3 1/2 INCHES LONG.

Extruded Section - Hinge

Figure 4 (Sheet 3)

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0.562 in.
(14,275 mm)

0.050 in.
(1,27 mm)
(Typical)

0.680 in. 0.190 in. R

(17,272 mm) (4,826 mm)
FULL R
(3 locations)

0.156 in.
0.062 in. R (3,962 mm)
(1,575 mm) (2 locations)
(2 locations)

PART NO.: S700E0272

MATERIAL: 2024-T3511 ALUMINUM
AREA: 0.093 sq. in. (60,000 mm2)
SPECIFICATION: QQ-A-200/3
CES-195-00

Extruded Section - Retainer

Figure 5

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Extruded Section - T-Section

Figure 6 (Sheet 1)

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Extruded Section - T-Section

Figure 6 (Sheet 2)

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2.468

1.326

0.132
0.125 RADIUS (TYPICAL)
1.383

CORNER RADII 0.016 (TYPICAL)

87°

0.071 (TYPICAL 3 PLACES)

PART NO.: S700E0589

MATERIAL: 2024-0 ALUMINUM
AREA: 0.275 SQUARE INCH
SPECIFICATION: QQ-A-200/3
NOTE:
ALL DIMENSIONS ARE IN INCHES MCS-245-00

CORNER RADII 0.016 (TYPICAL)

0.080

92°

0.090 RADIUS 1.67

(TYPICAL)

0.080 0.080
0.040

1.06
2.24

PART NO.: S700E0590

NOTE: MATERIAL: 2024-0 ALUMINUM
ALL DIMENSIONS AREA: 0.288 SQUARE INCH
ARE IN INCHES SPECIFICATION: QQ-A-200/3 C2S-008-00

Extruded Section - T-Section

Figure 6 (Sheet 3)

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Extruded Section - Z-Section

Figure 7

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FORMED SECTIONS

1. General

A. The following Rohr Standard Formed Sections, and Rohr Standard Parts
used in the construction of the nacelle and for repairs are illustrated
in this section.

Metallic Formed Section Figures 1 and 2

Elastic Formed section Figures 3 and 4
Standard Parts Figures 5 through 12

2. Types of Formed Sections

A. Metallic Formed Sections

Formed Section - Stop Figure 1

B. Elastic Formed Sections

Formed Section - Bulb Seal Figure 2

Formed Section - Rubstrip Figure 3

C. Standard Parts

Standard Part - Bushing, Flanged Figure 4

Standard Part - Grid, Conducting Figure 5
Standard Part - Nameplate Figure 6
Standard Part - Washer, Countersunk Figure 7
Standard Part - Shim, Laminated Figure 8

3. Formed Section Index

A. Metallic Formed Sections

Section Number Figure Number

S700F0269 1

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B. Elastic Formed Sections

Section Number Figure Number Section Number Figure Number

S700M0270 3 S700R00ll 2
S700M0293 3 S700R0322 2
S700M0593 3

C. Standard Parts

Section Number Figure Number Section Number Figure Number

S700B0455 4 S700U0314 6
S700E0424 5 S700U0735 6
S700S0497 8
S700W0501 7

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0.062 in. ± 0.010 in. R

(1,575 mm) (0,254 mm)

0.03 in. MAX

0.43 in.
(0,762 mm)
0.06 in. R (10,922 mm)
(1,524 mm)

0.16 in.
(4,064 mm)

PART NO.: S700F0269

MATERIAL: CRES SH, COMP 302
AREA: 0.047 sq. in. (30,323 mm2)
SPECIFICATION: MIL-5059

CES-196-00

Formed Section - Stop

Figure 1

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Formed Section - Bulb Seal

Figure 2

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Formed Section - Rubstrip

Figure 3 (Sheet 1)

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CORNER RADII 0.010 (TYPICAL)

0.251
B

PART NO. A B AREA SQ. IN.

S700M0593 1.40 0.155 0.284

S700M0593-1 1.30 0.163 0.269

S700M0593-3 1.44 0.152 0.290

MATERIAL: EXTRUDED NYLATRON

SPECIFICATION: NYLATRON GS

NOTE:
ALL DIMENSIONS ARE IN INCHES C2S-009-0

Formed Section - Rubstrip

Figure 3 (Sheet 2)

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Standard Part - Bushing, Flanged, Press Fit

Figure 4 (Sheet 1)

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Standard Part - Bushing, Flanged, Press Fit

Figure 4 (Sheet 1)

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0.150 in. (3,810 mm)

(Typical)

0.135 in. (3,429 mm)

0.120 in. (Typical)
(3,048 mm)
(Typical)

0.005 in.
(0,127 mm)
1.680 in.
(42,672 mm)

0.016 in. R
(0,406 mm)
(Typical)

PART NO.: S700E0424

MATERIAL: 5052-H38 OR 5052-H39 ALUMINUM
(ALTERNATE) (5056-H38 OR 5056-H39 ALUMINUM)
AREA: 0.0084 sq. in. (5,419 mm) (SECTION)
SPECIFICATION: QQ-A-250/8
(ALTERNATE) (QQ-A-430)
CES-201-00

NOTE:
DIMENSION TOLERANCE ± 0.015 in. (0,381 mm)

Standard Part - Conducting Grid

Figure 5

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2.188 in.
(55,575 mm) 0.125 in.
(3,175 mm)
(Typical)
0.125 in.
0.098 in. (3,175 mm)
(2,489 mm) (Typical)
0.106 in. DIA.
(2,692 mm)
(4 locations)
ROHR INDUSTRIES, INC.
CHULA VISTA, CALIFORNIA
MFG CODE NO. 51563
PART NO. 0.016 in.
SERIAL NO. 1.625 in. (0,406 mm)
ROHR INSP (41,275 mm) MAX
MODIFICATION INCORPORATED

0.125 in. R
(3,175 mm)
(Typical)
3 SPACES FOR MODIFICATION

PART NO.: S700N0314

MATERIAL: CRES SH, TYPE 321 ANNEALED
AREA: 0.026 sq. in. (16,774 mm2) (Section)
SPECIFICATION: MIL-S-6721

NOTE:
CES-202-00

DIMENSIONAL TOLERANCE ± 0.015 in. (0.381 mm)

Standard Part - Nameplate

Figure 6 (Sheet 1)

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Standard Part - Nameplate

Figure 6 (Sheet 2)

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0.069 in.
(1,753 mm)
0.057 in.
(1,448 mm)
0.437 in. DIA.
(11,100 mm) 2
45°
3

0.255 in. 0.350 in.

(6,477 mm) (8,89 mm)
0.251 in. DIA. 0.340 in. DIA.
(6,375 mm) (8,636 mm)

PART NO.: S700W0501

MATERIAL: CRES STEEL, TYPE 321 OR 347 ANNEALED
AREA: 0.0005 sq. in. (3,226 mm) (Section)
SPECIFICATION: MIL-S-6721 OR QQ-S-763

NOTES:

1. ALL DIMENSIONS ARE IN INCHES.

2. BREAK SHARP EDGES 0.010 INCH X 45° OR 0.010 INCH RADIUS.
3. PART NUMBER TO BE INDENTED 0.010 INCH MAXIMUM.
4. WASHER SHALL BE FREE OF BURNS AND SLIVERS.
5. WASHER FACES TO BE PARALLEL WITHIN 0.002 INCH.
6. DIMENSIONAL TOLERANCE ± 0.010 INCH. ANGULAR TOLERANCE ± 1°.
CES-203-00

7. CLEAN AND PASSIVATE PER MIL-S-5 002.

Standard Part - Washer, Countersunk, 1200°F

Figure 7
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Standard Part - Shim, Laminated

Figure 8 (Sheet 1)

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MIL-S-22499 MATERIAL
CLASSIFICATION

S700S0497 THICKNESS A B COMP TYPE CLASS

-1 0.032 in. (0,813 mm) 1.00 in. (25,4 mm) 10.00 in. (254,0 mm) 1 I 1
-2 0.032 in. (0,813 mm) 2.00 in. (50,8 mm) 24.00 in. (609,6 mm) 1 I 1
-3 0.032 in. (0,813 mm) 2.00 in. (50,8 mm) 24.00 in. (609,6 mm) 3 I 1
-4 0.063 in. (1,600 mm) 1.00 in. (25,4 mm) 10.00 in. (254,0 mm) 1 II 1
-5 0.063 in. (1,600 mm) 2.00 in. (50,8 mm) 10.00 in. (254,0 mm) 1 II 1
-6 0.063 in. (1,600 mm) 3.00 in. (76,2 mm) 12.00 in. (304,8 mm) 1 II 1
-7 0.063 in. (1,600 mm) 1.00 in. (25,4 mm) 10.00 in. (254,0 mm) 3 II 1
-8 0.063 in. (1,600 mm) 2.00 in. (50,8 mm) 10.00 in. (254,0 mm) 3 II 1
-9 0.063 in. (1,600 mm) 3.00 in. (76,2 mm) 12.00 in. (304,8 mm) 3 II 1
-10 0.094 in. (2,388 mm) 1.00 in. (25,4 mm) 5.00 in. (127,0 mm) 3 II 1
-11 0.063 in. (1,600 mm) 1.00 in. (25,4 mm) 10.00 in. (254,0 mm) 3 I 1
-12 0.063 in. (1,600 mm) 2.20 in. (55,88 mm) 4.50 in. (114,3 mm) 1 I 2
-13 0.063 in. (1,600 mm) 1.20 in. (30,48 mm) 2.20 in. (55,88 mm) 1 I 2
-14 0.063 in. (1,600 mm) 3.75 in. (95,25 mm) 5.10 in. (129,54 mm) 1 I 2
-15 0.063 in. (1,600 mm) 1.20 in. (30,48 mm) 5.70 in. (144,78 mm) 1 I 2
-16 0.063 in. (1,600 mm) 3.75 in. (95,25 mm) 4.90 in. (124,46 mm) 1 I 2
-17 0.063 in. (1,600 mm) 0.90 in. (22,86 mm) 5.70 in. (144,78 mm) 1 I 2
-18 0.094 in. (2,388 mm) 0.70 in. (17,78 mm) 1.20 in. (30,48 mm) 1 II 1
-19 0.063 in. (1.600 mm) 1.00 in. (25,4 mm) 2.00 in. (50,8 mm) 1 II 1
-20 0.032 in. (0,813 mm) 1.00 in. (25,4 mm) 5.00 in. (127,0 mm) 1 I 1
-21 0.032 in. (0,813 mm) 1.00 in. (25,4 mm) 2.00 in. (50,8 mm) 1 II 1
-22 0.063 in. (1.600 mm) 1.00 in. (25,4 mm) 4.00 in. (101,6 mm) 1 II 1
-23 0.094 in. (2,388 mm) 4.00 in. (101,6 mm) 7.00 in. (177,8 mm) 1 II 2
-24 0.094 in. (2,388 mm) 4.00 in. (101,6 mm) 7.50 in. (190,5 mm) 1 II 2
-25 0.063 in. (1,600 mm) 0.97 in. (24,638 mm) 4.00 in. (101,6 mm) 1 I 2
-26 0.063 in. (1,600 mm) 0.97 in. (24,638 mm) 7.00 in. (177,8 mm) 1 I 2
-27 0.063 in. (1,600 mm) 1.50 in. (38,1 mm) 2.50 in. (63,5 mm) 3 II 1
-28 0.063 in. (1,600 mm) 3.75 in. (95,25 mm) 6.50 in. (165,1 mm) 1 I 2
-29 0.186 in. (4,724 mm) 0.50 in. (12,7 mm) 9.00 in. (228,6 mm) 1 II 2
-30 0.063 in. (1,600 mm) 1.00 in. (25,4 mm) 24.00 in. (629,6 mm) 1 II 2

TABLE II C2S-012-00

Standard Part - Shim, Laminated

Figure 8 (Sheet 2)

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ALUMINUM ALLOY SHEET SUBSTITUTION

1. General

A. The materials specified in the repair sections have been selected for
desirability and adaptability in effecting repairs. These materials
have been selected with consideration for physical, chemical and
mechanical properties, as well as ease with which they can be
fabricated and installed. Therefore, it is recommended that the
specified materials be used in repairs whenever possible.

B. Since repair facilities may not have all the materials in stock, or the
equipment needed for fabrication may not be available, certain
substitutions may be made. Substitute repair material should be chosen
on the same basis as the material in the original structure.

2. General Requirements

A. Table I lists materials and factors which, when applied, give

equivalent strength substitutes. The table has been prepared by
applying the following rules:

(1) The substitute material shall provide cross-sectional strength in

tension, compression, shear, and bearing at least equal to that of
the original material.

(2) Never substitute a material of thinner gage than the original

material or with a cross-sectional area less than the original even
when using a stronger material. If it is necessary to substitute an
alloy weaker than the original, use a heavier gage to provide the
equivalent cross-sectional strength.

(3) Do not substitute non heat-treated materials

(4) When substituting bare aluminum alloy sheets for clad sheets the
surface must be protected from corrosion through application of an
effective surface coating. Refer to 54-02-03, Protective Treatment
of Metal Parts.

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Aluminum Alloy Sheet Substitution Conversion Table

Table I

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BULK MATERIALS SUPPLIER'S LIST

EUROPEAN
SRM US EUROPEAN SUPPLIER/NATO
MATERIAL CALLOUT SUPPLIER/FSCM EQUIVALENT CODE
ADHESIVE, EA934NA 33564 ADHESIVE, EA934 AND K6714
AND ACTIVATOR ACTIVATOR
ADHESIVE, EA956 AND 33564 ADHESIVE, EA956 AND K6714
L3 CATALYST L3 CATALYST
AERODUR CLEARCOAT AKZO NOBEL 91342 AERODUR CLEARCOAT U2215
UVR UVR
HARDENER S66/22R HARDENER S66/22R
THINNER C25/90S THINNER C25/90S
ALCOHOL, CETYL IMPERIAL CHEMICAL ALCOHOL, CETYL K2054
IND.
444 MADISON AVENUE
NEW YORK, NY 10022
ALCOHOL, DENATURED COMMERCIALLY ALCOHOL, DENATURED COMMERCIALLY
AVAILABLE AVAILABLE
ALODINE NO. 1000 IMPERIAL ALODINE NO. 1000 K2054
CHEMICAL IND.
ALODINE NO. 1200 IMPERIAL ALODINE NO. 1200 K2054
CHEMICAL IND.
ALUMINUM OXIDE 04963 ALUMINUM OXIDE D0551
POWDER POWDER
ALUMINUM WOOL 04963 ALUMINUM WOOL D0551
ARAMID FABRIC 08434 ARAMID FABRIC U0420
B&B CARBON REMOVER B&B CHEMICAL CO. CARBON REMOVER ADROX LIMITED
INC P.O. BOX 796 74 FURLONG RD.
MIAMI, FL BOURNE, ENGLAND
BRUSH, FIBER COMMERCIALLY BRUSH, FIBER COMMERCIALLY
AVAILABLE AVAILABLE
BRUSH, NYLON COMMERCIALLY BRUSH, NYLON MED-LAB,
AVAILABLE LIMITED
CADMIUM PLATE, TYPE CADMIUM PLATE, TYPE TYPE II,CLASS 2
II, CLASS 2 II, CLASS 2 2-6 AGARD ST.
DERBY, ENGLAND
CATALYST, X-310A AKZO NOBEL 98502 CATALYST, X-310A U2215
CEE-BEE A-202 CEE-BEE CHEMICAL CEE-BEE A-202 MCGEAN CHEMICAL
CO. 9520 E. CEE-BEE 2 PALACE GARDENS
DR. Downey, CA ENFIELD, ENGLAND
Table 1:

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BULK MATERIALS SUPPLIER'S LIST

EUROPEAN
SRM US EUROPEAN SUPPLIER/NATO
MATERIAL CALLOUT SUPPLIER/FSCM EQUIVALENT CODE
CEE-BEE A6-1 CEE-BEE CHEMICAL CEE-BEE A6-1 MCGEAN CHEMICAL
CO.
CEE-BEE B4 CEE-BEE CHEMICAL CEE-BEE B4 MCGEAN CHEMICAL
CO.
CHEESECLOTH COMMERCIALLY CHEESECLOTH COMMERCIALLY
AVAILABLE AVAILABLE

CLOTH, ALUMINUM 04963 CLOTH, ALUMINUM D0551

OXIDE OXIDE
CLOTH, BLEEDER WOVEN STRUCTURES CLOTH, BLEEDER K4076
1600 W. 135TH ST
GARDENA, CA 90249
CLOTH, EMERY 04963 CLOTH, EMERY D0551
CONVERTER, X-304 AKZO NOBEL 98502 CONVERTER, X-304 U2215
COTTON SWAB COMMERCIALLY COTTON SWAB COMMERCIALLY
AVAILABLE AVAILABLE
DOW CORNING PR-1200 5D028 DOW CORNING® K7750
PR-1200
DOW CORNING P-5200 5D028 DOW CORNING P-5200 5D028
DOW CORNING 90-006 71984 DOW CORNING 90-006 71984
DOW CORNING 93-076 71984 DOW CORNING 93-076 K7750
DOW CORNING 94-002 71984 DOW CORNING 94-002 K7750
DOW CORNING 94-006 71984 DOW CORNING 94-006 K7750
EC-1022 04963 EC-1022 D0551
EC2216A 04963 EC2216A D0551
EC2216B 04963 EC2216B D0551
FABRIC, FIBERGLASS WOVEN STRUCTURES FABRIC, FIBERGLASS K4076
TYPE 181
FABRIC, GRAPHITE 54339 FABRIC, GRAPHITE K1030
FILM, BAGGING, 2 RICHMOND DIV. FILM, BAGGING, 2 K4076
MIL, NYLON DIXICO INCORP. MIL, NYLON
P.O. BOX 1129
REDLANDS, CA
FILM, PARTING RICHMOND DIV. FILM, PARTING K4076
(NONPOROUS) (NONPOROUS)
Table 1:

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BULK MATERIALS SUPPLIER'S LIST

EUROPEAN
SRM US EUROPEAN SUPPLIER/NATO
MATERIAL CALLOUT SUPPLIER/FSCM EQUIVALENT CODE
FILM, PARTING RICHMOND DIV. FILM, PARTING K4076
(POROUS) (POROUS)
FILM, PEEL PLY B- RICHMOND DIV. FILM, PEEL PLY K4076
100
GLOVES, LINT FREE COMMERCIALLY GLOVES, LINT FREE COMMERCIALLY
AVAILABLE AVAILABLE
KEROSENE COMMERCIALLY KEROSENE COMMERCIALLY
AVAILABLE AVAILABLE
LEFKOWELD 109 AND LEFFINGWELL DC A4000 AND DC K4503
LM52 HARDENER CHEMICAL CO. A4000 CATALYST
MICROBALLOONS UNION CARBIDE CORP. MICROBALLOONS K4076
(PHENOLIC) BOUND BROOK, NJ (PHENOLIC)
08805
NITRIC ACID 82303 NITRIC ACID MED-LAB,
LIMITED
2-6 AGARD ST.
DERBY, ENGLAND
PAPER, ABRASIVE 04963 PAPER, ABRASIVE D0551
180-GRIT 180-GRIT
PAPER, ABRASIVE 04963 PAPER, ABRASIVE D0551
ALUMINUM OXIDE, ALUMINUM OXIDE,
280 AND 400-GRIT 280 AND 400-GRIT
PAPER, ABRASIVE 04963 PAPER, ABRASIVE D0551
SILICON CARBIDE SILICON CARBIDE
150 GRIT 150 GRIT
POLYETHYLENE 71983 POLYETHYLENE K4503
GLYCOL (POWDER) GLYCOL (POWDER)
POLYURETHANE AKZO NOBEL 98502 POLYURETHANE U2215
COATING, 683-3-2 COATING, 683-3-2
PRIMER, 1007 CROWN METRO PRIMER, 1007 U2215
AEROSPACE COATINGS,
0S4B8
PRIMER, CAT-A-LAC AKZO NOBEL 98502 PRIMER, CAT-A-LAC U2215
463 463
PRIMER, EPOXY 71984 PRIMER, EPOXY K7750
PRIMER, RTV SS4004 4PM36 PRIMER, RTV SS4004 U4065
Table 1:

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BULK MATERIALS SUPPLIER'S LIST

EUROPEAN
SRM US EUROPEAN SUPPLIER/NATO
MATERIAL CALLOUT SUPPLIER/FSCM EQUIVALENT CODE
PRIMER, URETHANE DESOTO CHEMICAL CO. PRIMER, URETHANE K7750
825-009 BERKELEY, CA 94710 825-009
PRO-SEAL 735 COAST PRO-SEAL BPR 444 K0113
MFG CO.
LOS ANGELES, CA
REDUCER, TL-59 AKZO NOBEL 98502 REDUCER, TL-59 U2215
RTV 88 4PM36 RTV 88 U4065
CATALYST 9910 CATALYST 9910
RTV1203 SILASTIC 71984 RTV1203 SILASTIC K7750
PRIMER PRIMER
SEALANT, BAG SCHNEE-MOREHEAD 111 SEALANT, BAG EXCLUSIVE, SOLE
(TACKY TAPE) N. NURSERY (TACKY TAPE) SUPPLIER (NOTE
IRVING, TX 76060 US SUPPLIER)
SODIUM HYDROXIDE COMMERCIALLY SODIUM HYDROXIDE MED-LAB,
SOLUTION AVAILABLE SOLUTION LIMITED
SOLVENT, ACETONE COMMERCIALLY SOLVENT, ACETONE COMMERCIALLY
AVAILABLE AVAILABLE
SOLVENT, MIBK COMMERCIALLY SOLVENT, MIBK MED-LAB,
AVAILABLE LIMITED
SOLVENT, ISOPROPYL COMMERCIALLY SOLVENT, ISOPROPYL MED-LAB,
ALCOHOL AVAILABLE ALCOHOL LIMITED
SOLVENT, PD-680 COMMERCIALLY SOLVENT, PD-680 MED-LAB,
AVAILABLE LIMITED
SOLVENT, SAFETY COMMERCIALLY SOLVENT A.S.T.M. MED-LAB,
C-50 AVAILABLE D484-52 LIMITED
TAPE, DOUBLE-BACK 04963 TAPE, DOUBLE-BACK D0551
TAPE, GRAPHITE 54339 TAPE, GRAPHITE K1030
TAPE, MASKING 04963 TAPE, MASKING D0551
TAPE, COMMERCIALLY TAPE, COMMERCIALLY
PERMACEL-P112 AVAILABLE PERMACEL-P112 AVAILABLE
TAPE, TEFLON COMMERCIALLY TAPE, TEFLON K4076
2.00-IN. AVAILABLE 2.00-IN.
THINNER, TL-29 AKZO NOBEL 98502 THINNER, TL-29 U2215
TRICHLOROETHANE 71984 TRICHLOROETHANE K7750
TOLUENE TT-T-548 COMMERCIALLY TOLUENE TT-T-548 MED-LAB,
AVAILABLE LIMITED
Table 1:

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BULK MATERIALS SUPPLIER'S LIST

EUROPEAN
SRM US EUROPEAN SUPPLIER/NATO
MATERIAL CALLOUT SUPPLIER/FSCM EQUIVALENT CODE
TOPCOAT PAINT, AKZO NOBEL 98502 TOPCOAT PAINT, U2215
443-3 443-3
TURCO T-531 95481 TURCO T-531 K4958
TURCO T-5351 95481 TURCO T-5351 K4958
TURCO W0-1 95481 TURCO W0-1 K4958
WATER, DISTILLED COMMERCIALLY WATER, DISTILLED COMMERCIALLY
AVAILABLE AVAILABLE
WIPE, COTTON COMMERCIALLY WIPE, COTTON K6378
AVAILABLE
WETTING AGENT COMMERCIALLY DIVERSEY TIG K3814
AVAILABLE
AERODUR CLEARCOAT 0KXA5 AERODUR CLEARCOAT
UVR UVR

Table 1:

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MECHANICAL FASTENING

1. General

A. The structural parts of the A330 Nacelle are joined together primarily
by mechanical fasteners. Mechanical fasteners, such as bolts, rivets,
screws, lockbolts, and tapered pins may be removed and replaced with
little or no damage to the parts which they join.

This section describes the policy for selection of, and procedures for,
installing bolts, screws, and permanent fasteners in the repair of the
nacelle.

B. Information contained in this section is arranged in the following

manner:

54-04-00 Mechanical Fastening - General

54-04-01 Fastener Removal and Installation
54-04-02 Fastener Codes
54-04-03 Grip Ranges
54-04-04 Fastener Substitution
54-04-05 Torque Values
54-04-06 Hole Sizes
54-04-07 Edge Margins
54-04-08 Fastener Determination
54-04-09 Countersinking
54-04-10 Hi-Shear Blind Attachments
54-04-11 Huck Panel Fasteners

C. The procedures contain information pertinent to installation.

CAUTION: CADMIUM-PLATED TOOLS SHOULD NOT BE USED ON TITANIUM PARTS,

PARTICULARILY IF THE PARTS ARE MOUNTED NEAR THE ENGINE AND SUBJECT
TO HEAT. SMALL CADMIUM DEPOSITS WHICH MAY BE LEFT ON SUCH PARTS WILL
REACT WITH THE TITANIUM WHEN HEATED, RESULTING IN BRITTLENESS AND
POSSIBLY CRACKS. LEAD, ZINC, SILVER, AND TIN REACT IN A SIMILAR
MANNER WITH TITANIUM AT TEMPERATURES ABOVE 250°F.

2. Fastener Usage

A. Fasteners used on the nacelle have been selected to minimize the

variations and to standardize usage. Adherence to these standards will
ease any required repairs.

(1) Bolts and screws

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(a) Bolts are provided in various materials, such as low-strength

steel (below 125,000 psi), high-strength steel (160,000 to
280,000 psi), corrosion resistant steel, and titanium to be
compatible with the materials in which they are installed and
the heat range in which they must operate.

(b) Care must be exercised in the proper selection, corrosion

prevention treatment and installation procedures used to
develop and/or maintain the proper joint characteristics. The
following are standard usages:

BOLT, hex head machine, nonmagnetic and heat NASIOO3-1020

resistant, 160,000 psi
BOLT, hex head, close tolerance, short thread, NASIIO3-1120 Alloy Steel
160,000 psi NAS6303-6320 A286 Cres
NAS6403-6420 6AL-4V Titanium
Alloy
BOLT, 1000 close tolerance head and shank, NAS1202-1210 Alloy Steel
160,000 psi short thread
BOLT, 1000 head, tri-wing recess, close NAS4400-4416 Alloy Steel
tolerance NAS4500-4516 A286 Cres
NAS4603-4616 6AL-4V Titanium
Alloy
BOLT, adjusting crowned hex head NAS428 Alloy Steel
BOLT, 1000 reduced head, tri-wing recess, NAS4903-4916 6AL-4V Titanium
close tolerance, short thread Alloy
BOLT, pan head, close tolerance, short thread, NASSOOO-5OO6 Alloy Steel
tri-wing recess NASSIOO-51O6 A286 Cres
NASS203-5206 6AL-4V Titanium
Alloy
BOLT, drilled head, machine, coarse head MS20074 Steel
BOLT, 12-point, external wrenching, 180,000 MS21250 Alloy Steel
psi
Bolt, shear, 132,000 psi minimum shear EWSB22 Alloy Steel
strength 450°F
BOLT, external wrench - light weight, 220,000 71658 Alloy Steel
psi minimum tensile strength for application
to 900°F
SCREW, hex head, recessed, full thread NASIO96 Alloy Steel
SCREW, hex head, tri-wing, full thread NAS5900-5903 Alloy Steel
NAS6000-6003 A286 Cres
NAS6100-6103 6AL-4V Titanium
Alloy
SCREW, 1000 head, tri-wing recess, full thread NAS5600-5606 Alloy Steel
SCREW, machine, pan head, Phillips recess, NAS600-606 Alloy Steel
short thread 160,000 psi NAS623 Alloy Steel

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SCREW, machine, pan head, cross-recessed MS35206 Carbon Steel

Cres, Brass
SCREW, machine, flat fillister head, full NASSOOO-5306 Steel Alloy
thread, tri-wing recess NASS400-5406 A286 Cres
NASSSO3-5506 6AL-4V Titanium
Alloy
SCREW, machine, drilled fillister head, MS25276 Steel
slotted, UNF-2A
SCREW, drive, round head type U, steel carbon, MS21318 Alloy Steel
cadmium plated
SCREW, thumb, necked AN924
SETSCREW, hex and fluted socket, headless AN565
RIVET, universal head (copper, Cres, Monel, MS20615
steel)
RIVET, universal head, aluminum and aluminum MS20470
alloy
RIVET, blind, protruding head, locked spindle NAS1398 Aluminum, Monel
MS24427 Cres
NOTE: Refer to 54-04-10 for Hi-Shear bolts and 54-04-11 for Huck Panel
Fasteners.

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FASTENER REMOVAL AND INSTALLATION

1. General

Solid shank rivets, blind rivets, pin fastener (Huck) collars, and Hi-Lok
bolt nuts are ordinarily destroyed in the removal process and must be
replaced with new fasteners. Care must be used in the removal process to
avoid enlarging the fastener hole or damaging the surrounding material. If
the fastener must be drilled from the fastener hole, a drill size is
selected that is smaller than the nominal fastener size and the removal
process is often a two or three step procedure.

The various twist drills used to make the holes in the parts for fastener
installation are sized to provide the proper diameter hole for the
different fastener application procedures (i.e., tap drill, clearance
drill, interference fit drill, fastener removal drill). Most of the drills
are under one inch in diameter and they are standardized and identified by
three different systems of overlapping diameter ranges. Fractional-size
drills (graduated in 64th of an inch) range from 1/64-inch to one inch (64/
64). Letter-size drills of 26 different sizes (identified by the different
letters of the alphabet) range from 0.234-inch to 0.413-inch in diameter
and are irregularly graduated. Number size drills range down in diameter
from No.1 which is 0.2280-inch diameter to No. 80 which is 0.0135-inch
diameter in an irregular graduation.

Removal of installed fasteners generally involves the removal of the nut,

collar, or of drilling off the manufactured head of the fastener and
tapping the shank from the fastener hole. Some typical and special removal
techniques are outlined in the following paragraphs.

Fastener installation is generally the reinstallation of fasteners which

have been removed from an assembly or component, and may require reference
to one or more of the following subjects:

Mechanical Fastening 54-04-00

Removal/Installation 54-04-01
Fastener Codes 54-04-02
Grip Ranges 54-04-03
Fastener Substitution 54-04-04
Torque Values 54-04-05
Hole Sizes 54-04-06
Edge Margins 54-04-07
Fastener Determination 54-04-08

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Countersinking 54-04-09
Hi-Shear Bolts Blind Attachments 54-04-10
Huck Panel Fasteners 54-04-11

2. Bolt Removal and Installation

A. Bolt Removal

(1) Remove all loads from the structure joint from which the bolt is to
be removed. Provide adequate support for the attached parts to
prevent inadvertent damage of parts upon separation.

(2) Remove and retain the bolt and nut for reinstallation if they are
undamaged.

B. Bolt Installation

(1) Reuse of Bolts Removed from Structure.

(a) Check the bolts for damage or corrosion.

(b) Check nuts for damage to shell or retainer mechanism and

replace if damaged even though there is not apparent damage to
the retaining mechanism.

(c) Check fastener hole for enlargement or elongation. Refer to

54-04-06, Bole Sizes - Standard and Oversize. If fastener hole
is beyond acceptable limits for the fastener application, a
greater diameter fastener must be substituted and the hole
size increased to accept it. The next greater standard
diameter of the same fastener is used if there is no
intermediate oversize fastener available. Refer to Fastener
Substitution Tables in 54-04-04.

(d) Comply with anti-corrosion requirements of fastener

application. Refer to 54-02-01 and 54-02-03.

(e) Comply with sealing requirements of fasteners application.

Refer to 54-05-05.

(f) If fasteners are damaged and identical replacement parts are

not available, refer to 54-04-04 for acceptable fastener
substitution.

(g) Tighten fasteners to proper torque value for tension

requirements. If specific torque values are not available,
refer to 54-04-05 for typical torque values.
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(h) Install retaining devices such lockwire, cotter pins, or tab

washers which are required for the fastener application.

3. Solid Shank Rivet Removal and Installation

A. Rivet Removal

(1) Remove the manufactured head of the rivet. (See Figure 1)

NOTE: The manufactured head is selected because it is more

consistently concentric with the shank of the rivet than
the formed head.

(2) Use a drift punch smaller than the rivet shank and punch the rivet
from the fastener hole. If the metal sheets in which the rivet is
installed are of light gage, the material around the formed head
may have to be supported to prevent deformation.

(3) There may be difficulty in punching out the rivet because there has
been some swelling of the shank between the metal sheets which are
fastened by the rivet. If so, select a drill which is approximately
0.010-inch smaller in diameter than the rivet shank and drill out
the center of the rivet shank down to the formed head. The trapped
rivet material should shear off and permit the removal of the
rivet.

B. Rivet Installation

(1) Select the proper rivet for attachment of the affected parts:

(a) If a rivet is being installed where one has been removed, and
the hole diameter is still within acceptable limits, use a
rivet identical to the one which was removed.

(b) If the rivet hole has become enlarged or elongated beyond

allowable limits (See 54-04-06), select an oversize rivet if
it is available or increase the fastener and hole diameter to
the next larger standard rivet diameter.

(c) If the identical rivet is not available, refer to Fastener

Substitution Tables in 54-04-04.

(d) Comply with anti-corrosion requirements for rivet

installation. Refer to 54-02-01 and 54-02-03.

(e) Comply with sealing requirements for rivet application. Refer

to 54-05-05.

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CES-204-00

Solid Shank Rivet Removal

Figure 1

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(f) Select the method and equipment which may be most effectively
and efficiently used to install the rivets. Refer to 54-02-02.
Machine installation of rivets using equipment such as
drivmatic riveters, rivet arbor, or portable rivet squeeze is
much more uniform than the manual method using a hand-held
rivet gun and a bucking bar. Use of the machine equipment is
limited by accessibility to the work.

(g) Use temporary fasteners to hold parts together and in proper

position during installation of rivets.

NOTE: If there are gaps between the parts to be riveted, the

rivet will expand between the sheets decreasing the
shear strength of the attachment.

(h) Hold manufactured head of rivet firmly against one face of the
fastener joint and apply the force necessary to create the
formed head on the opposite side. When properly performed, the
rivet shank will be expanded to completely fill and seal the
fastener hole and the remaining shank will expand to
approximately 150-percent of its nominal shank diameter. (See
Figure 2) The formed head bears against one face of the joint
in a clamping action to hold the parts snugly together.

(i) Check the installed rivet to see that the manufactured head
has not been damaged in the process and that the formed head
has been adequately and properly expanded. (See Figure 2)

4. Pin Fastener Removal and Installation

A. Removal of pin Fastener

The following procedure is for removal of pin fasteners similar to the

Hi-Shear rivet and the Huck lockbolt.

(1) Remove the swaged collar from the fastener pin by splitting the
collar with a chisel or shaving it with a special hollow mill
collar cutter. (See Figure 3)

CAUTION: AVOID CONTACTING THE SURFACE OF THE MATERIAL IN WHICH

THE PIN FASTENER IS INSTALLED WITH THE COLLAR CUTTER.

(2) Use a small pin punch to tap the fastener pin from the hole. Pin
may be reused if it has not been damaged in the removal process.

B. Installation of Pin Fastener

(1) Select the proper fastener for attachment of the affected parts:

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CES-205-00

Solid Shank Rivet Installation Criteria

Figure 2

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CES-206-00

Removal of Pin Fastener Collar

Figure 3

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(a) If the fastener is being installed where a clearance-fit

fastener (i.e., Hi-Shear rivet) has been removed and the hole
is still within acceptable limits, use a pin which is
identical in diameter, shape, and length to the one that was
removed. (See 54-04-06, Hole Sizes - Standard and Oversize.)

(b) If the fastener is being installed where an interference-fit

fastener (i.e., Buck lockbolt) has been removed, use an
oversize fastener or use the next larger standard pin diameter
and increase the hole diameter to correspond. (See 54-04-06)

(c) If the identical fastener or oversize fastener is not

available, refer to Fastener Substitution Tables in 54-04-04.

(2) Comply with anti-corrosion requirements for fastener installation.

Refer to 54-02-01 and 54-02-03.

(3) Comply with sealing requirements for fastener installation. Refer

to 54-05-05.

(4) Install clearance-fit type of fastener pin with hand-held

equipment (See Figure 4) or specialized power equipment.

(5) Install interference-fit type of fastener with portable power

equipment. (See Figure 5)

5. Hi-Lok Bolt Removal and Installation

A. General

The Hi-Lok fastener pin is threaded and has a hexagonal wrenching

cavity in the threaded end to aid in preventing the fastener from
turning during installation or removal of the standard collar or the
alternate nut. The threaded collar has smooth sides, but contains a
wrenching device which shears off when the proper installation torque
is reached.

The collars may be removed and the fastener pins reused. Self-locking
nuts may be substituted (preferably of the MS21042L series) if the
proper consideration of the type of fastener application is made, i.e.,
shear, tension, high-temperature, etc. When nuts are used the proper
torque value for the fastener application must also be determined.
NAS1252 washers are used with the MS21042L series of self locking nuts.
When the surface against which the nut is installed tapers more than
1/2-degree, TLN1020 or H39794 self-aligning nuts and companion washers
are recommended.

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CES-207-00

Installation of Clearance - Fit Pin Fastener

Figure 4

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es-208-00

Installation of Interference - Fit Pin Fastener

Figure 5

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Hi-Lok fasteners may be installed with power equipment or manually.

Manual removal and installation instructions are provided in this
manual.

Hi-Lok fasteners are normally installed in interference-fit holes, but

may be installed in clearance-fit applications. In the interference-fit
application, the fastener pin is prevented from turning during collar
installation or removal by friction between the fastener pin and the
material through which it is being installed. In clearance-fit
applications, the pin is prevented from turning by the use of an
internal wrenching tool (allen wrench) inserted into the cavity in the
threaded end of the fastener pin.

Hi-Lok fasteners are made with a radiused intersection between the

fastener shank and the head which requires that the fastener hole be
prepared to accept it. The hole must be chamfered or radiused on the
fastener head side to be compatible with the fastener pin. The chamfer
or radius to the hole edge is at the intersection of the hole and the
material surface on the head-side for protruding head fasteners or the
intersection of the hole and the countersink for the head for flush
head fasteners.

Hi-Lok pin fasteners are manufactured in standard or nominal size and

also in 1/64-inch and 1/32-inch oversize diameters. The fastener pins
require lubrication with cetyl alcohol or equivalent lubricant and
proper seating of the head, before the collar or nut is torqued.

An interference-fit application of the fastener pin will not require

sealing except for corrosion prevention due to dissimilar metal
contact, but Hi-Lok pins installed with clearance-fit should be sealed.

B. Removal of Hi-Lok Fasteners

(1) Insert applicable size of allen wrench into pin wrenching cavity in
threaded end of fastener pin and hold securely to prevent pin
rotation.

(2) Grasp collar with water pump pliers or other tool which will not
damage surface of adjacent material. Rotate collar counter clock-
wise. (See Figure 6)

(3) Back off collar or nut until it is flush with end of fastener pin.

(4) Check pin fastener to see if it is loose in hole:

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CES-209-00

Removal of Hi-Lok Collar

Figure 6

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(a) If pin is loose, continue to rotate collar or nut until it may

be removed from the pin.

(b) If pin is tight in interference-fit hole, remove the allen

wrench and strike the end of the pin with a soft hammer until
the pin breaks loose. Reinstall the allen wrench and continue
to rotate the collar or nut until it may be removed from the
pin.

(c) Remove allen wrench and push or drive the fastener pin from
the hole with a smooth punch of smaller diameter than the
fastener pin.

(5) If several interference-fit pin fasteners are to be removed and the

collars are aluminum, the collars may be removed by milling with a
hollow mill cutter similar to that used for removing the collar
from a Hi-Shear rivet. (See Figure 6)

C. Installation of Hi-Lok Fasteners

(1) Select the proper fastener pin.

(a) If the fastener is being installed in an interference-fit hole

from which a fastener was removed, use a 1/64-inch oversize
diameter fastener pin of the same type and grip length as the
original.

(b) If the fastener is being installed in a clearance-fit hole

from which a fastener was removed, use the original fastener
or an identical new fastener.

(c) If a repair fastener is being installed and there is no

specific instruction available for its selection, See Figure 7
for type, Figure 8 for grip length, and Table I for maximum
loading for various materials. The fastener pin material
should be compatible with the materials through which it is
installed. (See Table I of Section 54-02-03, Classification of
Dissimilar Metals.) If it is imperative that a noncompatible
material be used for the fastener pin due to strength or
temperature requirements, the fastener must be wet-installed
with a protective sealant which will insulate it from
dissimilar metal contact.

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CES-210-00

Hi-Lok Pin Types

Figure 7

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Hi-Lok Fastener Pin Grip Range Tool and Table

Figure 8

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MAXIMUM MAXIMUM
SHEER STRESS TENSILE STRESS MAXIMUM
MATERIAL (ROOM TEMP) (ROOM TEMP( TEMPERATURE
STEEL ALLOY 95 KSI 160 KSI 450°F (232°C)
STEEL-A286 HI-TEMP ALLOY 85 KSI 130 KSI 1200°F (649°C)
UNPLATED
450°F (232°C)
PLATED
STEEL-H-11 ALLOY 156 KSI 260 KSI 900°F (482°C)
132 KSI 220 KSI 900°F (482°C)
125 KSI 210 KSI 450°F (232°C)
PLATED
STEEL-MP35N MULTI-PHASE 135 KSI 220 KSI 700°F (371°C)
ALLOY 600°F (316°C)
STEEL-PH13-8MO STAINLESS 125 KSI 210 KSI 400°F (204°C)
STEEL-431 STAINLESS 125 KSI 210 KSI 650°F (343°C)
TITANIUM-AL-4V 92 KSI 160 KSDI PLATED
(Solution treated and 450°F (232°C)
aged) PLATED
650°F (373°C)
TITANIUM-6AL-2SN 105 KSI 175 KSI
(Solution treated and
aged)

NOTES:
A. KSI = 1000 pounds per square inch load allowable.
B. Load allowable for single fasteners = KSI multiplied by fastener
cross-section area.
EXAMPLE: 95000 X 0.0276 = 2622 pounds of allowable shear load for
3/16 diameter steel alloy Hi-Lok pin.
c. Pin Fasteners with cadmium or other plating should not be used in
applications where temperatures will exceed 450°F (232°C). Above this tempera-
ture, the plating fuses with the base metal changing its mechanical properties.

Hi-Lok Fastener pin Maximum Loading

Table I

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(2) Select pin grip length. Hi-Lok pin grip lengths are designed to
accommodate material thickness from 1/32-inch less to 1/32-inch
greater than the coded nominal grip length, thus giving each grip
length a range of 1/16-inch of material thickness variations which
it will accommodate. It is critical to the effectiveness of the
fastener installation that the grip length be accurate. Too short a
grip length on the fastener pin will leave threads in bearing in
the joint. Too long a grip length will result in the fastener
collar or nut bottoming on the un-threaded shank with little or no
tension applied to the fastener pin and the joint. An adjustment of
grip length may also be made by the use of an NAS1252 spacer washer
or AN960 steel washer.

(a) Clamp tightly together all of the parts which the pin fastener
is to join, so that all gaps are removed.

(b) Carefully measure the total thickness of the material in which

the pin is to be installed and determine the grip range from
Figure 8. If the grip range tool is used, the correct grip
length may be read directly from the tool.

(c) Determine if NASl252 spacer washer or AN960 steel washer is

required for grip adjustment. Use only if acceptable grip
cannot otherwise be obtained.

(3) Determine type of fastener required. If all loads imposed on the

fastener will be shear loads, use a shear-type fastener with a
short-threaded shank end. If some or all of the loads applied to
the fastener will be tension loads, use the long-threaded shank
end.

NOTE: Shear loads are applied across the fastener shank while
tension loads are applied longitudinally or against the
head and collar (or nut).

(4) Determine if interference-fit fastener pin or clearance-type

fastener pin should be used. Hi-Lok pins are normally used in
interference-fit holes which provide optimum joint rigidity. When
one or more members to be joined are steel, stainless steel, or
titanium, clearance-fit holes may be used.

(5) Select fastener collar or nut to match the fastener pin.

(a) Use a shear installation collar if a shear installation Hi-Lok

pin has been selected.

(b) Use a tension installation collar if a tension installation

Hi-Lok pin has been selected.

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(c) Check the fastener installation characteristics to determine

if a self-locking nut must be substituted for the collar which
is normally used. If nuts are required, use MS21042L series
nuts.

NOTE: MS21042L nuts may be required if the joint contains

compressible material which will necessitate
subsequent tightening of the fastener or if the torque
requirements for the fastener cannot be met with a
torque-shear collar.

(6) Determine corrosion prevention requirements of fastener

installation. If the fastener pin, spacer, washer, collar, or nut
are of metal dissimilar to the material to be joined, the fastener
must be wet-installed with a corrosion preventive compound or
primer. (See 54-02-03, Protective Treatment of Metal Repair
Parts.)

(7) Determine pressure sealing requirements of fastener installation.

If a pressure differential is to be maintained between the two
surfaces of the material to be joined or the faying surfaces of the
joint, the fastener must be sealed in accordance with 54-05-05,
Repair Sealing.

(8) Prepare the pin fastener hole for pin installation.

(a) Drill holes normal (90°) to exterior surface.

(b) Ream holes to final size. (See 54-04-06, Hole Sizes Standard
and Oversize.)

(c) If the fastener pin has a flush head, countersink the hole
with a special piloted countersink cutter with a built-in
radius of 0.020-inch to 0.030-inch at the junction of the
cutter and the pilot. If such a cutter is not available, use
60° countersink to chamfer the junction of the hole and the
bottom of the countersink to make a flat area 0.015-inch to
0.025-inch wide. The radius or flat area will permit the head
of the fastener pin to seat properly. (See Figure 9)

(d) If the fastener has a protruding head, chamfer 45° the edge of
the hole (on which the head of the fastener is to be
installed) to provide a flat area 0.020-inch to 0.030-inch in
width. This will accept the radiused junction of the pin
fastener head and shank. (See Figure 9)

(e) Remove burrs from final hole edges.

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Document Part No. RDN 306

Hi-Lok Fastener Hole Preparation

Figure 9

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(f) Perform corrosion prevention and/or sealing operations

required for fastener installation.

(9) Determine that fastener pins and collars meet finish and
lubrication requirements.

(a) Alloy steel Hi-Lok pins should be cadmium plated for corrosion
prevention except when they are to be installed in an area
where temperatures will exceed 450° (232°C).

(b) Titanium Hi-Lok pins should be unplated (bare) when they are
installed in areas where temperatures exceed 450° (232°C).

(c) Alloy steel and titanium alloy Hi-Lok pins and collars must be
lubricated with cetyl alcohol.

CAUTION: DO NOT HANDLE TITANIUM HI-LOK PIN SHANKS AS LOSS OF LUBRICANT

WILL AFFECT INSTALLATION AND HEAD SEATING. RE-LUBRICATION OF
PINS MAY BE ACCOMPLISHED USING CETYL ALCOHOL OR EQUIVALENT.

(10) Place Hi-Lok pin in prepared hole.

(11) Seat head of Hi-Lok pin when installed in an interference-fit hole

before installing collar or self-locking nut. Use smooth set in
rivet gun to avoid damage to head or plating. Support material
through which pin is being installed to prevent deformation.

(12) Verify pin grip length. Install spacer washer if required. Use
NAS1252 washer.

(13) Install Hi-Lok collar.

(a) Use powered collar torquing tool per manufacturer’s

instructions. Torque collar until torquing device shears off.

(b) Use manual installation tools if power equipment is not

available. Use HLH101 modified ratchet wrench, HLH102 modified
socket, and the correct size allen wrench. Insert the allen
wrench through the modified ratchet wrench and into the
hexagonal wrenching cavity in the fastener pin. Prevent the
pin from turning while the collar (or nut) is being torqued
until the torquing device shears from the collar (or the nut
reaches maximum torque value). Remove tools.

(14) Touch up sheared area of all collars with FR primer.

(15) Perform additional sealing of Hi-Lok fastener if required.

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FASTENER CODES

1. General

A. Fastener codes used in this manual and on the engineering drawings of

the nacelle are in accordance with National Aerospace Standard 523.

B. Fasteners used in this manual will usually be referred to by part

number. The engineering drawings normally will locate fasteners by
codes. For convenience, the more common type of fasteners and codes
used in the construction of the nacelle and their oversize replacements
are listed in Table I. For a complete listing of all fastener codes,
refer to NAS523.

C. The method and symbol used to locate the fastener and to indicate
fastener identity, size, and installation requirements is shown in
Figure 1.

Fastener Symbol
Figure 1

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Common Types of Fasteners and Codes

Table I

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GRIP RANGES

Grip Ranges
Table I

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Grip Ranges
Table II

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FASTENER SUBSTITUTION

1. General

Acceptable fastener substitutions for the original attachments used in the

construction of the nacelle are provided in this section.

2. General Requirements

A. The edge distance and spacing for the substitute fastener must be the
same as the original attachment.

B. Substitutions must be made on a basis of the same size and grip length.

C. When pull-type lockbolts cannot be installed due to tool clearance, a

short pintail lockbolt is the preferred substitution. If the short
pintail lockbolt cannot be installed, a Hi-Lok may be substituted if an
interference-fit hole is required. A bolt must be substituted if a
clearance-fit hole is required. When bolts or Hi-Loks are used on a
substitution basis, they must be used with self-aligning nuts.

D. When a Drivmatic-installed stump lockbolt must be replaced, a pull-type

lockbolt maybe installed if tool clearance permits. If clearance does
not permit, a Hi-Lok may be installed.

E. When the required grip length for a bolt, lockbolt or Hi-Lok is not
obtainable, the next grip length may be used and a spacer/washer must
be used under the collar or nut.

F. substitute steel fasteners may be used for steel or titanium bolts

specified in the applicable repair figure, provided they are of
equivalent or greater strength. Tension type fasteners are designed for
use in tension and shear applications, but it is not acceptable to use
shear fasteners in tension.

G. Substitution of rivets may be made, provided proper consideration is

given to the type, size, head style (flush or non-flush), features
(standard or minimum pin clearance), and material.

3. Acceptable fastener substitutions for the nacelle are shown in Tables I,

II and III.

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EQUIVLENT
PART NUMBER VENDOR PART NUMBER
AIC1310-1 SPS 120475-3
AIC1301-2 SPS 120445-1
AIC220-( )( )( ) SPS EWSB22-( )( )( )
AIC658-( )( ) SPS 71658-( )( )
BM33019V( )( )D3 SPS 110173( )UE( (
BM3306-( )-( ) SPS 71658-( )-( )
BM55132( )( )( ) SPS EWSN22-( )( )( )
BM9022-( )( )( ) SPS EWBTM9-( )( )( )
D16043V( )( )UE SPS 001173V( )UE( )
EWBTM9-( )( )( ) SPS
BRILES BM9022-( )( )( )
ROCKFORD R21T5BI-( )( )( )
EWB0420( )( )( )( ) SPS
ROCKFORD R24T-4C1( )( )( )( )
EWSB22-( )( )( ) SPS
AIC AIC220-( )( )( )
BRILES BM55132-( )( )( )
ROCKFORD R21S5B1-( )F( )( )
VOI-SHAN VS3071-( )F( )-( )
PBF22LT( )-( ) SPS 71658-( )-( )
RA11009-10-1 SPS 120475-3
RA11009-10-2 SPS 120455-1
RA11010-12-1 SPS 120478
RA12001-( )V( )M SPS 110173V( )UE( )
RA22021-14-( ) SPS 77458-14-( )
RA22022-10-( ) SPS 121203-10-( )
RA23001-( )-( ) SPS 71658-( )-( )
R21S5B1-( )F( )( ) SPS EWSB-( )( )( )

Bolt Substitutions
Table I (Sheet 1)

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EQUIVLENT
PART NUMBER VENDOR PART NUMBER
R21T5B-( )( )( ) SPS EWBTM9-( )( )( )
R245-4C( )( )( )( ) SPS EWB0420( )( )( )( )
VS3071( )F( )-( ) SPS EWSB22-( )( )( )
VS2988-( )-( ) SPS 71658-( )-( )
VS3104-1 SPS 120475-3
VS3104-2 SPS 120455-1
VS3105-1 SPS 120478
VS3143-14-( ) SPS 77458-14-( )
110173V( )UE( ) SPS
BRILES BM33019V( )( )D3
DEUTSCH D16043V( )( )UE
ROCKFORD RA12001-( )V( )M
121203-10-28 SPS
ROCKFORD RA22022-10-28
120455-1 SPS
AIC AIC1210-2
VOI-SHAN VS3104-2
ROCKFORD RA11009-10-22
120475-3 SPS
AIC AIC1310-1
VOI-SHAN VS3104-1
ROCKFORD RA11009-10-1
120478 SPS
VOI-SHAN VS3105-1
ROCKFORD RA11010-12-1
71658( )-( ) SPS
AIC AIC658-( )-( )
ROCKFORD RA23001-( )-( )
BRILES BM3306-( )-( )
PBF PBF22LT( )-( )
77458-14-( ) VOI-SHAN VS2988-( )( )
SPS
ROCKFORD RA22021-14-( )
VOI-SHAN VS3143-14-( )

Bolt Substitutions
Table I (Sheet 2)

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EQUIVLENT
PART NUMBER VENDOR PART NUMBER
AP2109T( ) LINAIR 15818T( )
AP2132T-( ) LINAIR 15924T( )
EWSN22M-( ) SPS
KAYNAR H29251-( )
ESNA RMLH6520-( )
829251-( ) SPS EWSN22M-( )
829514-4 KAYNAR
REPUBLIC RHIO-C4NL
RMTE9868-( ) ESNA
SPS 73783-( )
SL3415 SPS 48FT720UN
SL4029-10 SPS 77459-1018
VN703B144 SPS 77461-1414
15818T( ) LINAIR
AIRDROME AP2109T( )
15924T( ) LINAIR AP2132T-( )
48FT72OUN SPS
SHUR-LOK SL341S
73783-( ) ESNA RMTE9868-( )
77459-1018 SPS
SHUR-LOK SL4029-10
77461-1414 SPS
VOI-SHAN VN703B144

Nut Substitutions
Table II

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EQUIVLENT
PART NUMBER VENDOR PART NUMBER
AF007M( )( ) NAS1200M( )-( )
AF700M( )C( ) NAS1200M( )-( )P
BR125-6-( )( ) NAS1200M( )-( )
BR125C6-( )( ) NAS1200M( )-( )P
NAS1200M( )-( ) OPEN BID
ALLFAST AF007M( )-( )
BLAKE BR125-6-( )-( )
OLYMPIC RV5928( )-( )
NAS1200M( )-( )P OPEN BID
ALLFAST AF007M( )C( )
BLAKE BR125C6-( )-( )
OLYMPIC RVS5928-( )-( )
RV5928-( )-( ) NAS1200M90-( )
RVS5928-( )-( ) NAS1200M( )-( )P

Rivet Substitutions
Table III

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TORQUE VALUES

1. General

A. Torque is the application of a force which twists or turns the object

to which it is applied. It is measured in pound-inches or pound-feet.
The measurement signifies the force applied to a lever or bar which is
attached at one end of the item being torqued or turned, and is the
multiple of the force in pounds times the distance from the center of
the object being torqued. For example, a force of 10-pounds applied at
a distance of 10-inches is measured as 100 pound-inches of torque.

Torque values are used normally on the nacelle to control the tension
force induced into a single threaded fastener such as a screw, a bolt,
or a bolt and nut combination. Turning the fastener into the helical
thread clamps the attached parts firmly together as the fastener head
is drawn against one of the outer surfaces. When a nut is used on the
bolt or screw (on the side of the joint opposite the fastener head)
threads are not used in the attached parts. The torque is then applied
to the nut with the fastener head being held stationary.

The torque required for a particular fastener varies in accordance with

the materials being attached, the material of the fastener, the
function of the joint, and the fastener lubricants or anti-seize
compounds being used. Too little torque impairs the design function of
the joint. Too much torque tends to crush the parts being joined or
stretch the fastener material beyond its yield point causing permanent
damage to the parts.

2. Methods of Application

A. Torque is applied manually by ordinary hand wrenches, or by torque

wrenches with indicators or scales to show the amount or value of the
torque being applied. (See Figure 1)

Torque may also be applied by power wrenches, but these must

incorporate a torque limiting device which can be preset to the proper
torque for that particular fastener. The power wrench is most useful
for a series of fasteners all requiring the same torque value. It is
much faster and more uniform in the torque value applied.

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CES-212-00

Typical Torque Wrench

Figure 1

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B. Torque wrenches are provided in many sizes, each size covering a range
of torque values. The wrench size selected depends on the torque
required and its ability to fit into the space provided and an adapter
must be used on a manual torque wrench. When this is necessary, the
actual torque applied must be calculated since it will differ
significantly from the torque indicated on the torque wrench indicator
or scale. The effective length of the combination of adapter and torque
wrench is dependent on the resultant of torque wrench length, adapter
length, and angle of adapter installation. It may be measured directly
from the center of the free end of the adapter to the torque wrench
handle pivot pin (or the center of the torque wrench handle if the
torque wrench handle is not pivoted). (See Figure 2)

C. The torque wrench head is normally fitted with an adapter end which
mates with a series of socket wrenches permitting it to be used on a
range of fasteners. The socket wrench is placed on the nut of the
fastener normally, but may be used also on the head of the bolt or
screw. Internal wrenching bolt or screw heads require an adapter
between the socket wrench and the bolt head.

D. The torque wrench is applied after the fastener has been tightened to
remove all gaps from the joint and the fastener is snug or holding the
joint firmly together. If a series of fasteners are being torqued, they
must all be tightened to a value approaching the required torque range
before the final torque is applied.

3. Condition and Limitations

A. Torque values listed in the following tables apply to nut tightening

only, with the bolt or screw head held stationary. When tightening must
be accomplished by bolt or screw rotation, use the high limit of the
applicable range ± 10-percent of the range.

B. All gaps between the members of a joint must be removed before

attempting to torque the fastener.

C. Structural fasteners are ordinarily installed dry or with only the

lubricant applied by the fastener manufacturer and torque values given
in the following tables reflect this condition. When an anti-seize
lubricant is applied to the fastener to prevent galling during
tightening, or the fastener is installed “wet” with a compound intended
to prevent corrosion or to provide a pressure seal, the torque required
to provide proper joint tightening is reduced. If specific torque
values are not provided for the fasteners so installed, use the lower
limit of the applicable range ± 10-percent of the range.

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Torque Wrench Adapter

Figure 2

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D. The torque values given in Tables I through IV differ greatly since

they reflect thread pitch, fastener diameter, fastener material, and
type of nut used. Use only the values listed for the fastener
combination being used.

E. Do not exceed the maximum torque limit of a castle nut, screw, or bolt
in order to align a cotter pin hole or lockwire hole. If alignment
cannot be accomplished within the applicable torque range, replace the
bolt, screw, or nut with a new part.

F. When the joint being torqued contains more than one fastener, the
fasteners must be uniformly loaded by pre-tightening them all
incrementally to a value close to the final torque value.

G. When the joint being torqued contains a compressible member such as a

gasket or seal, it must be uniformly loaded as it is torqued and not
re-torqued after the final torque is applied.

H. Values given in tables are for room temperatures. If the part is to be

tightened while hot, sufficient time should elapse to allow the
temperature of the part to reach a temperature equilibrium with the
surrounding area before final torque.

I. Power tools without a torque-limiting device may not be used for final
tightening.

J. Final torque reading must be taken while the nut actually rotates If
the maximum allowable torque is applied without causing rotation, the
nut must be backed off and re-torqued.

4. Tables

A. The following tables provide the torque values to be used with

different types or classes of nuts used in a nut/bolt type fastener
combination. The torque is applied to the nut when this is feasible,
but when the nut is fixed, as in a nutplate or nut strip, the torque
must be applied to the bolt or screw head. The height and material used
in the nut determines the maximum torque that may be applied to the
nut/bolt or nut/screw fastener combination. The tables are arranged in
the order of increasing nut strength in four tables of low strength,
standard, high strength, and extra-high strength torque values. The
values given are for dry fastener installation.

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TORQUE TORQUE
THREAD SIZE LB. IN. LB.FT.
6-32 5-7
8-32 8-10
10-32 12-15
1/4-28 30-42
5/16-24 60-84
3/8-24 96-114
7/16-20 270-300
1/2-20 288-414
9/16-18 480-600
5/8-18 660-780
3/4-16 114-126
7/8-14 126-150
1-12 186-276
1 1/8-12 249-351
1 1/4-12 450-549
NOTE: For screws, bolts and studs used in conjunction with AN316, AN320,
MS20364, NASI022, NAS509, RMTE9868 shear-type (low height) nuts or
aluminum nuts. Use these torque values for 125,000 to 145,000 psi
screws.

Shear or Low Strength Fastener Torque Values

Table I

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TORQUE TORQUE TORQUE

THREAD SIZE LB. IN. LB.FT. LB. IN.
6-32 8-10
8-32 12-15
10-32 20-25
1/4-28 50-70
5/16-24 100-140
3/8-24 160-190
7/16-20 450-500 350-450
1/2-20 480-690 450-600
9/16-18 800-1000 600-800
5/8-18 1100-1300
3/4-16 190-210
7/8-14 210-250
1-12 310-460
1 1/8-12 415-585
1 1/4-12 790-915
NOTE: For screws, bolts and studs used in conjunction with AN310,
MS20365, MS21042, MS21043, NASI021, NAS679, RS4933653, RS4933816,
TE9925, 48FT, 52LB2935, 52LB4367 nuts and RME9868 castellated nut
low height nut plates and nut strips, and blue colored high
strength aluminum nuts.

Use these torque values for shear head bolts and when titanium
alloy flush shear head bolts are used in net to clearance fit holes
(NAS4907 through NAS4909).

Use these torque values for 125,000 to 145,000 psi screws.

Standard Fastener Torque Values

Table II

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TORQUE TORQUE
THREAD SIZE LB. IN. LB.FT.
10-32 45-50
1/4-28 80-100
5/16-24 145-200
3/8-24 240-280
7/16-20 650-720
1/2-20 700-1000
9/16-18 1200-1440
5/8-18 1620-1860
3/4-16 280-300
7/8-14 300-360
1-12 450-665
1 1/8-12 605-845
1 1/4-12 1085-1320
NOTE: For screws, bolts and studs used in conjunction with HIS, LH3849
and 52N1610 nuts. Use also for EB nuts when used in conjunction
with NAS144 through NAS158 bolts.

DO NOT USE SHEAR HEAD BOLTS.

Refer to Table II, Standard Fastener Torque Values for shear head
bolts.

High Strength Fastener Torque Values

Table III

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TORQUE TORQUE
THREAD SIZE LB. IN. LB.FT.
10-32 45-50
1/4-28 83-115
5/16-24 165-230
3/8-24 260-320
7/16-20 740-820
1/2-20 800-1140
9/16-18 1370-1640
5/8-18 1845-2120
3/4-16 320-340
7/8-14 340-410
1-12 510-760
1 1/8-12 690-965
1 1/4-12 1235-1510

NOTE: For screws, bolts and studs used in conjunction with EB, EWSN22,
FN22, H-20, LH10825T, LH456T, LH461T, NAS577, RMLH7940T, SL7072S,
12B, 2752, 42FW, 48FWL, 7000 and 8000 high strength nuts.

DO NOT USED THESE TORQUE VALUES FOR TITANIUM FASTENERS.

Extra High Strength Fastener Torque Values

Table IV

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HOLE SIZES - STANDARD AND OVERSIZE

1. General

A. When standard size fasteners have been removed and the fastener hole
has been enlarged (either through wear or in the removal process)
beyond the allowable limits for that particular installation, an
oversize fastener may be installed. The fastener hole diameter must be
increased to accept it. The oversize hole diameter to be used depends
on the fastener application as shown in the following tables.

B. Oversize fasteners are manufactured for most of the smaller standard or

nominal fastener sizes and their use avoids the problems which often
result from increasing the fastener and fastener hole size to the next
larger standard or nominal size. These are usually manufactured 1/64-
inch or 1/32-inch larger in diameter than the standard or nominal size
fastener. Special oversize fasteners may be fabricated for a particular
repair, but the installation hole sizes must be determined in
accordance with the particular size and application of the repair
fastener.

2. General Requirements

A. The minimum required edge margin, spacing, and sufficient head

clearance for oversize fastener(s) is obtainable. (See 54-04-07, Edge
Margins.)

B. The skin thickness permits the use of the oversize fastener when
countersinks are enlarged. (See 54-04-09, Countersinking.)

C. Tables I through V show the original nominal or standard fastener

diameter and installation hole size, and the corresponding oversize
fastener diameter and recommended installation hole sizes. The tables
are arranged to reflect the different types of fastener installations.

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ORIGINAL STANDARD HOLE DIAMETER OVERSIZE OVERSIZE HOLE DIAMETER

RIVET RIVET
DIAMETER MINIMUM MAXIMUM DIAMETER MINIMUM MAXIMUM
3/32 0.098 0.106 7/16 0.113 0.118
1/8 0.1285 0.134 9/64 0.145 0.150
5/32 0.161 0.166 11/64 0.177 0.182
3/16 0.192 0.198 7/32 0.224 0.229
1/4 0.255 0.262 9/32 0.286 0.291
5/16 0.317 0.322 11/32 0349 0.354
3/8 0.380 0.385 13/32 0.411 0.419
NOTE: All Dimensions are in inches.

Hole sizes for Standard Solid Shank Rivets

Table I

ORIGINAL STANDARD HOLE DIAMETER OVERSIZE OVERSIZE HOLE DIAMETER

RIVET RIVET
DIAMETER MINIMUM MAXIMUM DIAMETER MINIMUM MAXIMUM
3/32 0.097 0.101
1/8 0.1285 0.132 9/64 0.137 0.141
5/32 0.160 0.164 11/64 0.177 0.181
3/16 0.192 0.196 7/32 0.205 0.209
1/4 0.256 0.261 9/32 0.269 0.273
NOTE: All Dimensions are in inches.

Hole sizes for Blind Rivets

Table II

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HOLE DIAMETER LIMITS

FASTENER STANDARD 1/64 OVERSIZE 1/32 OVERSIZE

DIAMETER MINIMUM MAXIMUM MINIMUM MAXIMUM MINIMUM MAXIMUM
3/16 0.1895 0.1905 0.2026 0.2036 0.2182 0.2192
1/4 0.2495 0.2505 0.2651 0.2661 0.2807 0.2817
5/16 0.3120 0.3130 0.3276 0.3286 0.3432 0.3442
3/8 0.3745 0.3755 0.3901 0.3911 0.4057 0.4067
7/16 0.4370 0.4380 0.4526 0.4536 0.4682 0.4692
1/2 0.4995 0.5005 0.5151 0.5161 0.5307 0.5317
NOTE: 1. All Dimensions are in inches.
2. Applicable for lockbolts installed in steel.

Hole sizes for Close Reamed Holes

Table III

HOLE DIAMETER LIMITS

FASTENER STANDARD 1/64 OVERSIZE 1/32 OVERSIZE

DIAMETER MINIMUM MAXIMUM MINIMUM MAXIMUM MINIMUM MAXIMUM
3/16 0.187 0.190 0.200 0.203 0.216 0.219
1/4 0.247 0.250 0.263 0.266 0.278 0.281
5/16 0.309 0.313 0.325 0.328 0.341 0.344
3/8 0.371 0.375 0.388 0.391 0.403 0.406
7/16 0.434 0.438 0.450 0.453 0.466 0.469
1/2 0.496 0.500 0.513 0.516 0.528 0.531
NOTE:

1. All Dimensions are in inches.

2. Applicable for Hi-Lok bolts installed in aluminum.
3. Where thickness of sheet adjacent to collar in less than 0.25 fastener
diameter, or total material thickness is greater than 4 x fastener diameter, use
clearance fit holes shown in Table V.

Hole sizes for Transition Fit Holes

Table IV

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HOLE DIAMETER LIMITS

FASTENER
STANDARD 1/64 OVERSIZE 1/32 OVERSIZE
DIAMETER
MINIMUM MAXIMUM MINIMUM MAXIMUM MINIMUM MAXIMUM
5/32 0.164 0.168
3/16 0.190 0.194 0.203 0.207 0.219 0.223
1/4 0.250 0.254 0.266 0.270 0.281 0.285
5/16 0.312 0.316 0.328 0.322 0.344 0.348
3/8 0.375 0.379 0.391 0.395 0.406 0.410
7/16 0.4375 0.4425 0.453 0.458 0.469 0.474
1/2 0.500 0.505 0.516 0.521 0.531 0.536
NOTE: 1. All Dimensions are in inches.

Hole Sizes for Clearance Fit Holes

Table V

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EDGE MARGINS

1. General

A. Edge margin for mechanical fasteners is needed to provide adequate

material to resist shear and bearing forces due to static and repeated
loads, avoid undue stress concentrations and to carry the attachment
design loads. When making structural repairs, the original fastener
edge margin should be maintained whenever possible. When the designed
edge margin cannot be determined due to extensive damage and a specific
repair is to be fabricated, it will be necessary to make an accurate
determination of edge margin needed.

Any repair utilizing fasteners with edge margin less than 2.0 times the
fastener diameter must have the approval of a stress engineer.

B. Minimum fastener edge margins to be used for structural applications

are shown in the following tables:

Protruding Bead Bolts in Aluminum Alloys . . . . . . . . Table I

Protruding Bead Rivets in Aluminum Alloys . . . . . . . . Table II
Protruding Bead Rivets in Corrosion-Resistant Steel . . . Table III
Flush Bead Rivets in Aluminum Alloy . . . . . . . . . . . Table IV
Flush Bead Bolts, Lockbolts, Hi-Lok Bolts and
Blind Rivets in Aluminum Alloy, Corrosion-Resistant
Steel and Titanium . . . . . . . . . . . . . . . . . . . Table V

NOTE: Fastener edge margin as used in this manual is the distance from
the center of the hole to the nearest edge of the sheet or
plate.

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PROTRUDING HEAD
STEEL BOLTS (160,000-180,000 PSI)
MATERIAL IN SINGLE SHEAR

BOLT DIAMETERS
ALLOY GAGE 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8
EDGE MARGIN (± 0.05)
0.032 0.37 0.49
0.036 0.37 0.49
0.040 0.37 0.49

0.045 0.37 0.49

0.050 0.37 0.49 0.59
0.056 0.37 0.49 0.59

0.063 0.37 0.49 0.59 0.69

0.071 0.37 0.49 0.59 0.69
ALUMINUM 0.080 0.37 0.49 0.59 0.69 0.79

0.090 0.37 0.49 0.59 0.69 0.79 0.90

0.100 0.37 0.49 0.59 0.69 0.79 0.90 1.01
0.112 0.37 0.49 0.59 0.69 0.79 0.90 1.01

0.125 0.37 0.49 0.59 0.69 0.79 0.90 1.01 1.11

0.140 0.37 0.49 0.59 0.69 0.79 0.90 1.01 1.11
0.160 0.37 0.49 0.59 0.69 0.79 0.90 1.01 1.11

0.180 0.35 0.49 0.59 0.69 0.79 0.90 1.01 1.11

0.190 0.34 0.49 0.59 0.69 0.79 0.90 1.01 1.11
0.200 0.33 0.49 0.59 0.69 0.79 0.90 1.01 1.11

0.224 0.31 0.46 0.59 0.69 0.79 0.90 1.01 1.11

0.250 0.29 0.43 0.59 0.69 0.79 0.90 1.01 1.11
0.313 0.29 0.38 0.53 0.69 0.79 0.90 1.01 1.11

0.375 0.29 0.37 0.48 0.63 0.79 0.90 1.01 1.11

0.600 0.29 0.37 0.46 0.54 0.67 0.82 0.99 1.11
0.625 0.29 0.37 0.46 0.54 0.62 0.72 0.86 1.01
0.750 0.29 0.37 0.46 0.54 0.62 0.70 0.78 0.90

Protruding Head Bolt Edge Margins

in Aluminum Alloy

Table I

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ALUMINUM ALLOY UNIVERSAL HEAD RIVETS

MATERIAL SINGLE SHEAR DOUBLE SHEAR
RIVET DIAMETERS
ALLOY GAGE 3/32 1/8 5/32 3/16 1/4 5/16 3/8 3/32 1/8 5/32 3/16 1/4 5/16 3/8
EDGE MARGIN (± 0.05)
0.012 0.21 0.21 0.27 0.32
0.016 0.21 0.27 0.21 0.27 0.32
0.018 0.21 0.27 0.21 0.27 0.32

0.020 0.21 0.27 0.32 0.21 0.27 0.32

0.022 0.21 0.27 0.32 0.21 0.27 0.32
0.025 0.21 0.27 0.32 0.21 0.27 0.32

0.028 0.21 0.27 0.32 0.21 0.27 0.32

0.032 0.20 0.27 0.32 0.37 0.21 0.27 0.32
0.036 0.19 0.26 0.32 0.37 0.21 0.27 0.32

0.040 0.18 0.26 0.32 0.37 0.48 0.21 0.27 0.32 0.37 0.48
ALL 0.045 0.17 0.24 0.32 0.37 0.48 0.21 0.27 0.32 0.37 0.48
ALUMINUM 0.050 0.17 0.23 0.32 0.37 0.48 0.58 0.21 0.27 0.32 0.37 0.48
ALLOYS
0.056 0.17 0.22 0.29 0.37 0.48 0.58 0.21 0.27 0.32 0.37 0.48 0.58
EXCEPT
0.063 0.17 0.21 0.28 0.36 0.48 0.58 0.69 0.20 0.27 0.32 0.37 0.48 0.58 0.69
CASTINGS 0.071 0.21 0.28 0.33 0.48 0.58 0.69 0.27 0.32 0.37 0.48 0.58 0.69

0.080 0.21 0.26 0.31 0.47 0.58 0.69 0.26 0.32 0.37 0.48 0.58 0.69
0.090 0.21 0.25 0.29 0.44 0.58 0.69 0.25 0.32 0.37 0.48 0.58 0.69
0.100 0.21 0.25 0.29 0.41 0.58 0.69 0.23 0.31 0.37 0.48 0.58 0.69

0.112 0.25 0.29 0.39 0.54 0.69 0.29 0.37 0.48 0.58 0.69
0.125 0.25 0.29 0.37 0.50 0.67 0.28 0.36 0.48 0.58 0.69
0.140 0.25 0.29 0.37 0.47 0.62 0.26 0.33 0.48 0.58 0.69

0.160 0.25 0.29 0.37 0.46 0.57 0.24 0.31 0.47 0.58 0.69
0.180 0.29 0.37 0.46 0.54 0.29 0.44 0.58 0.69
0.190 0.29 0.37 0.46 0.54 0.29 0.43 0.58 0.69

0.200 0.29 0.37 0.46 0.54 0.29 0.41 0.58 0.69

0.224 0.29 0.37 0.46 0.54 0.29 0.39 0.54 0.68
0.250 0.29 0.37 0.46 0.54 0.29 0.37 0.50 0.67
ADD FOR 0.10 0.20 0.30 0.10 0.20 0.30
CASTINGS

Protruding Head Rivet Edge Margins

in Aluminum Alloy
Table II

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MONEL UNIVERSAL HEAD RIVETS

IN SINGLE SHEAR
MATERIAL RIVET DIAMETERS
ALLOY GAGE 3/32 1/8 5/32 3/16 1/4
EDGE MARGINS (± 0.05)
0.010 0.20 0.25 0.30 0.35 0.45
0.012 0.20 0.25 0.30 0.35 0.45
0.016 0.20 0.25 0.30 0.35 0.45

0.018 0.20 0.25 0.30 0.35 0.45

0.020 0.20 0.25 0.30 0.35 0.45
0.022 0.18 0.25 0.30 0.35 0.45

CORROSION 0.025 0.18 0.25 0.30 0.35 0.45

RESISTANT 0.028 0.18 0.24 0.30 0.35 0.45
STEEL 0.032 0.18 0.23 0.30 0.35 0.45
AISI 301
AND 302 0.036 0.18 0.23 0.29 0.35 0.45
0.040 0.18 0.23 0.28 0.35 0.45
ALSO 0.045 0.18 0.23 0.27 0.35 0.45
ALLOY
STEEL 0.050 0.17 0.23 0.27 0.32 0.45
HT TO 0.056 0.17 0.22 0.27 0.32 0.41
100,000 0.063 0.17 0.21 0.27 0.32 0.41
PSI OR
GREATER 0.071 0.17 0.21 0.27 0.32 0.41
0.080 0.17 0.21 0.25 0.32 0.40
0.090 0.21 0.25 0.29 0.40

0.100 0.25 0.29 0.40

0.112 0.25 0.29 0.39
0.125 0.29 0.37

NOTE: All dimensions are in inches.

Protruding Head Rivet Edge Margins

in Corrosion-Resistant Steel
Table III

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100° COUNTERSUNK ALUMINUM

ALLOY RIVETS IN SINGLE SHEAR
MATERIAL RIVET DIAMETERS
ALLOY GAGE 1/8 5/32 3/16 1/4 5/16
EDGE MARGINS (± 0.05)

ALUMINUM 0.31 0.37 0.43 0.55 0.67

ALLOY ALL
EXCEPT CASTINGS
ADD FOR 0.10 0.20
CASTINGS

NOTE: All dimensions are in inches.

Flush Head Rivet Edge Margins in Aluminum Alloy

Table IV

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Flush Head Bolt, Lockbolt, Hi-Lok Bolt,

and Blind Rivet Edge Margins in
Aluminum Alloy, Corrosion-Resistant
Steel, or Titanium
Table V

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FASTENER DETERMINATION

1. General

This section furnishes descriptive data for use in determining the type
and quantity of fastener pins to be used in repairs of the nacelle
structure. The fastener pins include solid rivets, blind rivets, swaged
collar fasteners, and threaded fasteners such as bolts and screws. A
description of the unit joint strength developed by a fastener and sheet
metal combination aids in determining the type of fastener to be used.
Once the type of fastener and material have bee selected the quantity of
fasteners required may be determined by using the formula given: Tabulated
data referenced in the description consists of the mechanical properties
of materials, nominal hole diameters and drill sizes, shear strength of
rivets, bearing strength of sheet metal, rivet shear strength, correction
factors, and joint allowable stresses for specific fastener and sheet
metal combinations.

2. Joint Strengths Using Mechanical Fasteners

A. Solid Rivets in Shear Joints.

(1) Solid rivets are the most commonly used structural fastener and are
one-piece fasteners installed by mechanical upsetting.

(2) Shear strengths for driven rivets may be based on areas

corresponding to the nominal hole diameter provided that the
nominal hole diameter is not larger than the value listed in Table
2. If the nominal hole diameter is larger than the listed value,
the. listed value shall be used. Shear strength values for solid
rivets are presented in Table 3.

(3) For the protruding-head type rivets, the unit load at which the
shear or bearing type of failure occurs is separately calculated
for each fastener and the lower of the two is the allowable for the
fastener. Design ultimate and yield bearing stresses for various
materials are given in Table 1. The strength properties are stated
for each alloy and are applicable to riveted joints wherein
cylindrical holes are used and where D/t is less than or equal to
5.5 and e/D is equal to or greater than 2. These bearing stresses
are applicable only for the design of rigid joints where there is
no possibility of relative motion of the parts joined without
deformation of such parts.

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(4) Unit sheet bearing strengths for rivets, based on a stress of 100
ksi and the nominal hole diameters of Table 2 are given in Table 4.
In computing protruding-head rivet design shear strengths, the
shear strength values obtained from Table 3 should be multiplied by
the correction factors given in Table 5.

This compensates for the reduction in rivet shear strength

resulting from high bearing stresses on the rivet at D/t ratios in
excess of 3.0 for single-shear joints and 1.5 for double-shear
joints (See Table 5).

(5) Example:

Allowable ultimate load per rivet (lb) may be determined using:

Pa=(Unit Value from Table 4) X Fbru of sheet material (ksi)

100

or

Pa= (Unit Value from Table 4) X 1.5 X F

bry of sheet material (ksi)
100

or

Pa = (Rivet shear strength) X (shear strength) correction factor

from Table 5 (Aluminum only from Table 3). The Fbry and Fbru are
from Table 1, whichever is less.

(6) Tables 6 through 26 provide shear joint allowables using

protruding-head solid rivets for some common airframe structural
materials.

(7) The ultimate load per fastener for flush-head solid rivets
installed in airframe structural materials is established from
test data. Shear joint allowables for flush-head solid rivets in
machine-countersunk airframe structural materials are indicated in
Tables 27 through 34.

B. Joints with Threaded Fasteners

(1) Threaded-fastener systems is the general term applied to

protruding or flush-head bolts or screws and to Hi-Lok bolts. Usage
of these threaded fasteners is accompanied by the use of nuts,
threaded collars, and, when applicable, washers.

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(2) The ultimate single shear strength of threaded fasteners is

indicated in Table 35. This shear strength is based on the nominal
shank diameters (left hand column) and on the strength levels
indicated.

NOTE: Table 35 is applicable to the shear strength of all

threaded fasteners except those covered by specific tables
in this section.

(3) The ultimate tensile strengths of threaded fasteners is given in

Table 36. The tensile strength of the fastener system is based on
the strength of the pin or the rating of the mating nut or collar,
whichever is less. As there are many possible combinations of
available threaded pins and nuts, or collars, no values are given
for the tensile strength of fastener systems, with the exception of
alloy steel Hi-Loks, which are covered in Table 38.

NOTE: Table 36 is applicable to the tensile strength of all

threaded fasteners except as covered by specific values
shown elsewhere in this section or except as noted in Table
36.

(4) The ultimate single shear and tensile strength for alloy steel Hi-
Lok fastener system pins (heat treated to 160 ksi minimum) is
presented in Table 38.

(5) Protruding-Head Threaded Fasteners in Shear Joints.

(a) In shear joints, the load per fastener at which the shear or
bearing type of failure occurs is separately calculated for
each fastener, and the lower of the two values so determined
is the allowable for the fastener. Allowable shear loads may
be obtained from Table 35.

(b) The design bearing stresses for various materials are given in
the strength properties stated for each alloy and are
applicable to joints with fasteners in cylindrical holes and
where
D/t is 5.5 or less (See Table 1). These bearing stresses are
applicable only for the design of rigid joints where there is
no possibility of relative motion of the parts joined without
deformation of such parts.

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(c) Unit sheet bearing strengths for threaded fasteners, based on

a stress of 100 ksi and nominal fastener diameters, are given
in Table 39. The strength for a specific combination of
fasteners, sheet thickness,. and sheet material is obtained by
multiplying the proper unit strength by the ratio of the
material allowable bearing (ksi) to 100, see example
following:

Example:

Allowable ultimate load per fastener pin (lb) is the least value of
Pa determined using:
Pa=
(Unit Value from Table 39) X Fbru of sheet material (ksi)
100

or
P a=
(Unit Value from Table 39) X 1.5 X Fbry of sheet material (ksi)
100

or

Pa =Fastener Shear Rating, from Table 35 Fbru and Fbry are from
Table 1.

(d) Shear joint allowables using protruding-head fasteners in some

common airframe structural materials may be determined from
Table 40 through 45.

(6) Flush-Head Fasteners in Shear Joints.

(a) The allowable ultimate loads for flush-head threaded fasteners

installed in airframe structural materials are established
from test data. Shear joint allowables for flush-head threaded
fasteners installed in machine-countersunk airframe structural
alloys are presented in Tables 46 and 47.

C. Blind Fasteners in Shear Joints.

(1) The allowable ultimate load per fastener for any blind-type
fastener, either protruding-head or flush-head, installed in
structural materials is established from test data.

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(2) The allowable ultimate load per fastener for blind, protruding-
head fasteners installed in some commonly used structural alloys
may be determined from Tables 48 through 50.

(3) The allowable ultimate load per fastener for blind, flush-head
fasteners installed in commonly used structural alloys may be
determined from Table 51.

D. Interpolation and Extrapolation of Tabulated Values.

(1) Interpolation

(a) Interpolation between thicknesses is permitted inside any

table to obtain shear joint allowables for non-standard gages
or thicknesses.

(b) Interpolation between standard fastener pin sizes is permitted

inside any table to obtain allowables for first, second, or
third oversize fastener pins of the type covered by a
particular figure.

(2) Extrapolation

(a) For protruding-head solid rivets or for protruding-head,

threaded fastener pins, extrapolation is permitted beyond the
limits of the Shear Joint Allowable Tables by the methods of
paragraphs 2.A. (3 and 4) and 2.B.(5) (a through c),
respectively.

(b) For flush-head fasteners and for all blind attachments,

extrapolation beyond the limits of the Tables is not permitted
for obtaining shear joint allowable strengths.

3. Number of Fasteners Required

A. Fastener Number Formula

(1) The number of fasteners required to attach a repair member to an

existing structural member to provide a joint with the ultimate
strength of the existing structural member may be determined from
the following relationship:

N = t x w x Ftu x 1.15
Pa

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Where:

N =number of attachments required on each side of the joint.

t =thickness of existing structural member or element, such as

flange, web, etc., of the structural member being repaired.

w = (1) width of existing structural member or element of

structural member being repaired; or (2) length of damage, or
cutout removing a damaged area, in existing plating or webs being
repaired with a doubler designed to replace the damaged material.

FtuThe design ultimate tensile strength of the material used or the

existing structural member. This value is obtained from FAA
approved material specifications or from an FAA approved handbook
containing mechanical properties of airframe materials. Such a
handbook is the MIL-HDBK-SE. Table 1 presents Ftu for some of the
commonly used structural materials.

Pa = The allowable shear load per fastener (not necessarily - the

shear rating) which is a function of fastener type and of the
structural material being used. See Table 6 through 51 for
allowables for many fastener-sheet material combinations. See
Tables 52 and 53 for summary of allowables data for rivets and
threaded fasteners.

NOTE: Where the thickness of the structural element varies,

Pa is the average allowable shear load per fastener
for the joint.

B. Structural Member Splice

The number of fasteners required to splice a structural member may be

determined if the following conditions are met:

(1) Splice member materials and thicknesses must be compatible with

those of the existing member being spliced. Each significant
element, i.e., flange or web, of the damaged member must be spliced
so that the total load capability of the splice equals or exceeds
that of the damaged member.

(2) The repair splice fitting must be fatigue resistant using design
features of similar “as designed” splice fittings for similar
structural members. In general, the minimum cross-sectional area
at the center of the repair splice fitting should be at least 1.25
times the cross-sectional area of the structural member being
spliced.
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(3) It may be necessary to use a factor larger than 1.25 if the member
being spliced is large and the ends cannot be tapered, or if the
geometry of the splice fitting induces excessive eccentricities in
the load path.

(4) Determine number of fasteners as follows:

(a) Select the type of fastener system to be used and consider the
initial selection as tentative since a change of size and/or
fastener may be justified by the results of the steps which
follow.

(b) Determine the thickness of the elements on the damaged member

being spliced - (t).

(c) Determine the width of the elements - (w).

(d) Find Ftu of the damaged structural member (See paragraph 3.A
and Table 1).

(e) Select the material and geometry (t’ and w’) of the x splice
elements.

1 Use the same material and geometry as the original

structural element.

2 Changes in geometry and/or material can be made so long as

t’ x w’ x Ftu of the splice material equals or exceeds t x
w x Ftu of the damaged structural element and all other
conditions pertaining to these steps are followed.
However, the substitution of steel or titanium for
aluminum is normally not recommended.

(f) Determine the average fastener allowable Pa from paragraph 3

and Tables 6 through 51 based on the material and thickness of
the damaged structural element.

NOTE: The average fastener allowable in the splice member

must be equal to or exceed the average fastener
allowable in the damaged member.

(g) Using formula in paragraph 3.A for computation, determine the

number of fasteners required for each side of the splice.

(h) The length of the splice is determined by the fastener

arrangement, spacing, and edge distance.

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(i) If the resulting splice design appears to be excessively long

or short when compared to existing designed splices, it may be
necessary to select a different fastener type or size and
repeat the preceding steps.

C. Repair Doubler

The number of fasteners required to attach a repair doubler to a

damaged skin or web may be determined as follows:

The repair doubler material and thickness must be compatible with the
existing skin or web being repaired.

(1) Select the type of fastener system to be used.

(2) Determine the thickness of the damaged skin or web.

(3) Determine the length of the damage or the length of the cutout
which removes the damage.

(4) Determine Ftu for the damaged structural member.

(5) Select the material and thickness of the repair doubler.

(a) Use the same material and thickness as the damaged member.

NOTE: The material of the repair doubler may be different

from the damaged member material so long as t’ x Ftu’
of the repair doubler material exceeds fatigue factor
t x Ftu of the damaged member. However, the
substitution of steel or titanium doublers for
aluminum is not normally recommended.

(6) Determine the average fastener allowable from paragraph 2 based on

the material and thickness of the damaged structural member, Pa.

NOTE: The average fastener allowable in the repair doubler must

equal or exceed the average fastener allowable in the
damaged member.

(7) Referring to formula in paragraph 3.A for method of computation,

determine the number of fasteners required on each side of the
damaged area.

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(8) Determine the size of the repair doubler according to the number of
fasteners required in the fastener pattern.

NOTE: From the number of fasteners determined by step (7),

arrange at least two rows of fasteners along the length of
and on each side of the damaged area. The two-row pattern
must extend around and beyond the ends of the damaged area
by adding additional fasteners to complete the pattern.
Standard fastener edge distances and spacing must be
provided in the pattern layout including the edge margins
from the limits of the damage, the periphery of the stoP.
holes and the trim of any cutouts made to remove the
damaged area.

Fatigue considerations for specific structural members may

require the use of additional rows of fasteners and/or the
use of specific types of fasteners and/or repair doubler
configurations. Refer to the appropriate chapter of the
manual for specific repair requirements.

(9) If the resulting repair doubler design appears to be excessively

large, or too short as indicated by the two-row arrangement of
fasteners not extending the full length of the damaged area, select
a different fastener type and size, as necessary, and repeat the
preceding steps.

4. Tabular Data

A. The following tables should be used for fastener selections as

applicable.

Table 1 - Design Mechanical Properties of Materials.

Table 2 - Standard Rivet Hole Drill Sizes and Nominal Hole Diameters.
Table 3 - Single Shear Strength of Solid Rivets.
Table 4 - unit Bearing Strength of Sheet on Rivets.
Table 5 - Shear Strength Correction Factors for Aluminum Solid,
Protruding-Bead Rivets.
Table 6 - Single Shear Joint Allowables for protruding-Bead MS20470AD
Rivets in Clad 2024-T3 Aluminum Alloy Sheet.
Table 7 - Single Shear Joint Allowables for protruding-Bead MS20470D
Rivets in Clad 2024-T3 Aluminum Alloy Sheet.
Table 8 - Double Shear Joint Allowables for Protruding-Bead MS20470AD
Rivets in Clad 2024-T3 Aluminum Alloy Sheet.

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Table 9 - Double Shear Joint Allowables for Protruding-Head MS20470D

Rivets in Clad 2024-T3 Aluminum Alloy Sheet.
Table 10 - Single Shear Joint Allowables for Protruding-Bead MS20470AD
Rivets in 2014-T6511 Extrusions.
Table 11 - Single Shear Joint Allowables for protruding-Bead MS20470D
Rivets in 2014-T6511 Extrusions.
Table 12 - Double Shear Joint Allowables for protruding-Head MS20470AD
Rivets in 2014-T6511 Extrusions.
Table 15 - Single Shear Joint Allowables for Protruding-Bead MS20470D
Rivets in Clad 2014-T6 Aluminum Alloy Sheet.
Table 16 - Double Shear Joint Allowables for Protruding-Bead MS20470AD
Rivets in Clad 2014-T6 Aluminum Alloy Sheet.
Table 17 - Shear Joint Allowables for Protruding-Head MS20470D Rivets
in 2014-T6 Aluminum Alloy Sheet.
Table 18 - Single Shear Joint Allowables for Protruding-Bead MS20470AD
Rivets in 2024-T42 Extrusions.
Table 19 - Single Shear Joint Allowables for Protruding-Bead MS20470D
Rivets in 2024-T42 Extrusions.
Table 20 - Double Shear Joint Allowables for Protruding-Head MS20470AD
Rivets in 2024-T42 Extrusions.
Table 21 - Double Shear Joint Allowables for Protruding-Bead MS20470D
Rivets in 2024-T42 Extrusions.
Table 22 - Single Shear Joint Allowables for Protruding-Head MS20470AD
Rivets in Clad 2024-T42 Aluminum Alloy Sheet.
Table 23 - Single Shear Joint Allowables for Protruding-Head MS20470D
Rivets in Clad 2024-T42 Aluminum Alloy Sheet.
Table 24 - Double Shear Joint Allowables for Protruding-Head MS20470AD
Rivets in Clad 2024-T42 Aluminum Alloy Sheet.
Table 25 - Double Shear Joint Allowables for Protruding-Head MS20470D
Rivets in Clad 2024-T42 Aluminum Alloy Sheet.
Table 26 - Shear Joint Allowables for Monel Protruding-Head MS2061SM
Rivets in Pure Titanium Sheet.
Table 27 - Single Shear Joint Allowables for Flush-Head Solid
MS20426AD Rivets 100°-Machine-Countersunk Clad 2024-T42
Aluminum Alloy.
Table 28 - Single Shear Joint Allowables for Flush-Bead Solid MS20426D
Rivets in 100°-Machine-Countersunk Clad 2024-T42 Aluminum
Alloy.

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Table 29 - Single Shear Joint Allowables for NASIO97AD Flush Crown-

Head Rivets in 100°-Machine-Countersunk Aluminum Clad 2014-
T6 Alloy.
Table 30 - Single Shear Joint Allowables for NASI097AD Flush Crown-
Bead Rivets in 100°-Machine-Countersunk Clad 2024-T3
Aluminum Alloy.
Table 31 - Single Shear Joint Allowables for MS20470AD or NAS1321AD
Slug NACA Flush-Bead Rivets in 82°-Machine-Countersunk
2014-T6 Aluminum Alloy.
Table 32 - Single Shear Joint Allowables for MS20427M Monel Flush-Head
Rivets in 100°-Machine-Countersunk Commercially Pure
Titanium Alloy.
Table 33 - Single Shear Joint Allowables for MS20427M Monel Flush-
Bead Rivets in 100°--Machine-Countersunk AlSI 301 Annealed
and 1/4 Bard Stainless Steel Sheet.
Table 34 - Single Shear Joint Allowables for MS20427M Monel Flush-Bead
Rivets in 100°- Machine-Countersunk AISI 301 1/2 Bard and
Full Bard Stainless Steel Sheet.
Table 35 - Single Shear Allowables for Steel Threaded-Fastener pins.
Table 36 - Tension Allowables for Steel Threaded-Fastener pins.
Table 37 - Tension Allowables for Nuts and Collars.
Table 38 - Ultimate Single Shear and Tensile Strength for Flush-Head
and Protruding-Head Hi-Lok Fasteners.
Table 39 - Bearing Strength of Sheet in Joints with Threaded Fasteners
and Pins.
Table 40 - Shear Joint Allowables for 125,000 H.T. Protruding-Head,
Threaded Steel Fastener pins in Clad 2024-T42 Aluminum
Alloy Sheet.
Table 41 - Shear Joint Allowables for 160,000 B.T. Protruding-Bead,
Threaded Steel Fastener pins in Clad 2024-T42 Aluminum
Alloy Sheet.
Table 42 - Shear Joint Allowables for 220,000 B.T. Protruding-Bead,
Threaded Steel Fastener Pins in Clad 2024-T42 Aluminum
Alloy Sheet.
Table 43 - Shear Joint Allowables for 125,000 B.T. protruding-Bead,
Threaded Steel Fastener pins in Clad 2024-T3 Aluminum Alloy
Sheet
Table 44 - Shear Joint Allowables for 160,000 H.T. Protruding-Head,
Threaded Steel Fastener pins in Clad 2024-T3 Aluminum Alloy
Sheet.

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Table 45 - Shear Joint Allowables for 220,000 B.T. Protruding-Bead,

Threaded Steel Fastener pins in Clad 2024-T3 Aluminum Alloy
Sheet.
Table 46 - Shear Joint Allowables for 125,000 B.T. 100°-Flush-Bead
Steel Bolts in Machine Countersunk Clad 2024-T3 and Clad
2024-T351 Aluminum Alloy Sheet and Plate.
Table 47 - Shear Joint Allowables for 160,000 B.T. 100°-Flush-Bead
Steel Bolts in Machine Countersunk Clad 2024-T3 and Clad
2024-T351 Aluminum Alloy Sheet and Plate.
Table 48 - Shear Joint Allowables of NAS1398 (CR2563M) Blind,
Protruding-Head, Locked-Spindle Monel Rivets in AISI 301
1/2H Stainless Steel.
Table 49 - Shear Joint Allowables of Blind, Protruding-Bead, Locked-
Spindle A286 Rivets in Alloy Steel.
Table 50 - Shear Joint Allowables of Blind, Protruding-Bead, Locked-
Spindle Aluminum Alloy Rivets in Aluminum Alloy.
Table 51 - Shear Joint Allowables of Blind, 100°-Flush-Bead, Steel
Fasteners in Machine-Countersunk Clad or Bare 2024-T3 or -
T351 Aluminum Alloy.
Table 52 - Summary of Shear Joint Strength Allowables Data for Rivets.
Table 53 - Summary of Shear Joint Strength Allowables Data for
Threaded Fasteners.

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GAGE OR Fbru Fbry

THICKNESS Ftu (ksi) (ksi)
MATERIAL (IN.) (ksi) @ e/D=2 @ e/D=2
Clad 0.010 TO 0.062 60 114 73
2024-T3 0.063 TO 0.249 63 120 75
Clad 0.010 TO 0.062 57 108 54
2024-T42 0.063 TO 0.249 60 114 58
Clad 0.020 TO 0.039 62 118 87
2014-T6 0.040 TO 0.249 65 124 91
Extrusion ALL 57 108 61
2014-T42
Extrusion UP TO 0.499 60 123 87
2014-T6 0.500 TO 0.749 64 115 85
0.750 TO 1.499 68 122 88
Titanium ALL 80 120* 101*
Sheet Pure

NOTE: 1. For materials other than those shown, refer to an approved handbook
containing airframe materials design mechanical properties such as MIL-
HDBK-5B.

2. *e/D = 1.5 for asterisk-marked figures only.

3. e = edge margin from center of hole.

4. D = Diameter of hole.

5. Ftu = Ultimate tensile strength.

6. Fbru = Ultimate bearing strength.

7. Fbry = Yield bearing strength.

Design Mechanical Properties of Materials

Table 1 (Sheet 1)

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GAGE OR Fbru Fbry

THICKNESS Ftu (ksi) (ksi)
MATERIAL (IN.) (ksi) @ e/D=2 @ e/D=2
Stainless ALL
Steel
Annealed
A/S1301 75 150 50
1/4 Hard
AIS1301 124 244 125
1/2 Hard
AIS1301 141 284 167
Steel ALL
Alloy 125 ksi
160 ksi 125 251 180
180 ksi 160 300 251
180 326 256

NOTE: 1. For materials other than those shown, refer to an approved handbook
containing airframe materials design mechanical properties such as MIL-
HDBK-5B.

2. *e/D = 1.5 for asterisk-marked figures only.

3. e = edge margin from center of hole.

4. D = Diameter of hole.

5. Ftu = Ultimate tensile strength.

6. Fbru = Ultimate bearing strength.

7. Fbry = Yield bearing strength.

Design Mechanical Properties of Materials

Table 1 (Sheet 2)

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RIVET SIZE (IN.) 1/16 5/32 1/8 5/32

Drill No. 51 41 30 21

Nominal 0.067 0.096 0.1285 0.159

Hole Dia (in.)

RIVET SIZE (IN.) 3/16 1/4 5/16 3/8

Drill No. 11 F P V

Nominal 0.191 0.257 0.323 0.386

Hole Dia (in.)

Standard Rivet-Hole Drill Sizes and Nominal

Hole Diameters
Table 2

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DIAMETER OF RIVET (IN.) 1/16 3/32 1/8 5/32

RIVET MATERIAL CODE SHEAR ULTIMATE STRENGTH (LB) 1.
Rivet Material
5056 Fsu = 28 ksi 2. B 99 203 363 556

2117-T3 Fsu = 30 ksi 2. AD 106 217 388 596

2117-T3 Fsu = 38 ksi 2. D 135 275 494 755

2024-T31 Fsu = 41 ksi 2. DD 145 296 531 815

3.
A286 Fsu = 90 ksi 317 651 1170 1790

Monel Fsu = 49 ksi 173 355 635 973

DIAMETER OF RIVET (IN.) 3/16 1/4 5/16 3/8

RIVET MATERIAL CODE SHEAR ULTIMATE STRENGTH (LB) 1.
Rivet Material
5056 Fsu = 28 ksi 2. B 602 1450 2290 3280

2117-T3 Fsu = 30 ksi 2. AD 862 1550 2460 3510

2117-T3 Fsu = 38 ksi 2. D 1090 1970 3110 4450

2024-T31 Fsu = 41 ksi 2. DD 1180 2120 3360 4800

3.
A286 Fsu = 90 ksi 2580 4670 7370 10500

Monel Fsu = 49 ksi 1400 2540 4020 5730

NOTE: 1. Based on nominal hole diameter specified in Table 2.

2. Values are for as driven condition, on a probability basis (B

values).

3. Driven in the AQ condition.

Single Shear Strength of Solid Rivets

Table 3

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UNIT BEARING STRENGTH FOR RIVET DIAMETER INDICATED,

Lb
SHEET THICKNESS (IN.) 1/16 3/32 1/8 5/32 3/16 1/4 5/16 3/8
0.012 80
0.016 107
0.018 121 173
0.020 134 192
0.025 168 240 321
0.032 214 307 411 509
0.036 241 346 462 572 688
0.040 268 384 514 636 784
0.045 302 432 578 716 860
0.050 335 480 642 795 955 1285
0.063 422 605 810 1002 1203 1619 2035
0.071 476 682 912 1129 1356 1825 2293 2741
0.080 536 768 1028 1272 1528 2056 2584 3088
0.090 603 864 1156 1431 1719 2313 2907 3474
0.100 670 960 1285 4590 1910 2570 3230 3860
0.125 838 1200 1606 1988 2388 3212 4038 4825
0.160 1072 1536 2056 2544 3056 4112 5168 6176
0.190 1273 1824 2442 3021 3629 4883 6137 7334
0.250 1670 2400 3210 3975 4775 6425 8075 9650

NOTE: Bearing values are based on areas computed using the nominal hole
diameters specified in Table 2, and Fbru = 100 ksi.

Unit Bearing Strength of Sheet on Rivets

Table 4

CF6-80E1
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DIAMETER OF RIVET (IN.) 1/16 3/32 1/8 5/32 3/16 1/4 5/16 3/8
SHEET THICKNESS (IN.) SINGLE-SHEAR RIVET STRENGTH FACTORS
0.016 0.964
0.018 0.981 0.912
0.020 0.995 0.933
0.025 1.000 0.970 0.920
0.032 1.000 0.964 0.925
0.036 0.981 0.946 0.912
0.040 0.995 0.964 0.933
0.045 1.000 0.981 0.953
0.050 0.995 0.970 0.920
0.063 1.000 0.920
1.000 0.961
0.071 0.944 0.979 0.909
0.080 0.964 0.995 0.933
0.090 0.981 1.000 0.953
0.100 0.995 0.972
0.125 1.000 1.000
DOUBLE-SHEAR RIVET STRENGTH FACTORS
0.016 0.687
0.018 0.744 0.518
0.020 0.789 0.585
0.025 0.870 0.708 0.545
0.032 0.941 0.814 0.687 0.560
0.036 0.969 0.857 0.744 0.630 0.518
0.040 0.992 0.891 0.789 0.687 0.585
0.045 1.000 0.924 0.834 0.744 0.653
0.050 0.951 0.870 0.789 0.708 0.545
0.063 1.000 0.937 0.8720 0.808 0.679 0.550
0.071 0.966 .909 0.852 0.737 0.622 0.508
0.080 0.992 0.9410 0.891 0.789 0.687 0.585
0.090 1.000 .969 0.924 0.834 0.744 0.653
0.100 0.992 0.951 0.870 0.789 0.708
0.125 1.000 1.000 0.935 0.870 0.805
0.160 0.992 0.941 0.891
0.190 1.000 0.981 0.939
0.250 1.000 1.000

NOTES: 1. Sheet thickness is that of the thinnest sheet in single-shear joints

and the middle sheet is double-shear joints.

2. Values based on tests of aluminum rivets.

Shear Strength Correction Factors for Aluminum Solid,

Protruding-Head Rivets
Table 5

CF6-80E1
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 ROHR, INC.
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Document Part No. RDN 306

FASTENER PROTRUDING-HEAD AD RIVET, MS20470AD*

FASTENER NOMINAL AD3 AD4 AD5 AD6 AD8
DIAMETER (INCHES) 3/32 1/8 5/32 3/16 1/4
FASTENER SINGLE
SHEAR STRENGTH, Lb 217 388 596 862 1550
MATERIAL CLAD 2024-T3 ALUMINUM ALLOY SHEET
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.016 169
0.020 202 281 348
0.025 211 351 434 522
0.032 217 374 551 669 900
0.036 381 564 753 1013
0.040 386 575 804 1125
0.045 388 585 821 1266
0.050 593 836 1407
0.063 596 862 1490
0.071 1517
0.080 1542
0.090 1550

NOTE: 1. Allowables correspond to shear or bearing, whichever is lower.

2. Bearing allowables based on e/D = 2.0, Fbr = Fbru or 1.5 Fbry,

whichever is lower, and nominal hole diameters.

3. *Also applicable to cylindrical portion of flush rivets.

Single Shear Joint Allowables for Protruding-Head MS20470AD

Rivets in Clad 2024-T3 Aluminum Alloy Sheet
Table 6

CF6-80E1
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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

FASTENER PROTRUDING-HEAD D RIVET, MS20470D*

FASTENER NOMINAL D3 D4 D5 D6 D8
DIAMETER (INCHES) 3/32 1/8 5/32 3/16 1/4
FASTENER SINGLE
SHEAR STRENGTH, Lb 275 494 755 1090 1970
MATERIAL CLAD 2024-T3 ALUMINUM ALLOY SHEET
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.016 169
0.020 210 281 348
0.025 263 351 434 522
0.032 275 450 557 669 900
0.036 485 626 753 1013
0.040 492 696 836 1125
0.045 494 741 940 1266
0.050 751 1045 1407
0.063 755 1090 1797
0.071 1929
0.080 1960
0.090 1970

NOTE: 1. Allowables correspond to shear or bearing, whichever is lower.

2. Bearing allowables based on e/D = 2.0, Fbr = Fbru or 1.5 Fbry,

whichever is lower, and nominal hole diameters.

3. *Also applicable to cylindrical portion of flush rivets.

Single Shear Joint Allowables for Protruding-Head MS20470D

Rivets in Clad 2024-T3 Aluminum Alloy Sheet
Table 7

CF6-80E1
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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

FASTENER PROTRUDING-HEAD D RIVET, MS20470AD*

FASTENER NOMINAL AD3 AD4 AD5 AD6 AD8
DIAMETER (INCHES) 3/32 1/8 5/32 3/16 1/4
FASTENER DOUBLE
SHEAR STRENGTH, Lb 434 776 1192 1724 3100
MATERIAL CLAD 2024-T3 ALUMINUM ALLOY SHEET
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.020 210
0.025 263 351
0.032 336 450 557
0.036 372 507 626 753
0.040 387 563 696 836
0.045 401 633 783 940
0.050 413 675 870 1045 1407
0.063 434 727 1039 1335 1797
0.071 750 1084 1469 2026
0.080 770 1122 1536 2282
0.090 776 1155 1593 2567
0.100 1182 1640 2697
0.125 1192 1724 2899
0.160 3075
0.190 3100

NOTE: 1. Allowables correspond to shear or bearing, whichever is lower.

2. Bearing allowables based on e/D = 2.0, Fbr = Fbru or 1.5 Fbry,

whichever is lower, and nominal hole diameters.

3. *Also applicable to cylindrical portion of flush rivets.

Double Shear Joint Allowables for Protruding-Head MS20470AD

Rivets in Clad 2024-T3 Aluminum Alloy Sheet
Table 8

CF6-80E1
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Proprietary - This document is subject to the controls and restrictions on the title page.
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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

FASTENER PROTRUDING-HEAD D RIVET, MS20470D*

FASTENER NOMINAL D3 D4 D5 D6 D8
DIAMETER (INCHES) 3/32 1/8 5/32 3/16 1/4
FASTENER DOUBLE
SHEAR STRENGTH, Lb 550 988 1510 2180 3940
MATERIAL CLAD 2024-T3 ALUMINUM ALLOY SHEET
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.020 210
0.025 263 351
0.032 336 450 557
0.036 379 507 626 753
0.040 420 563 696 836
0.045 473 633 783 940
0.050 523 703 870 1045 1407
0.063 550 898 1112 1335 1797
0.071 964 1253 1505 2026
0.080 980 1412 1696 2282
0.090 988 1463 1908 2567
0.100 1498 2073 2852
0.125 1510 2180 3565
0.160 3908
0.190 3940

NOTE: 1. Allowables correspond to shear or bearing, whichever is lower.

2. Bearing allowables based on e/D = 2.0, Fbr = Fbru or 1.5 Fbry,

whichever is lower, and nominal hole diameters.

3. *Also applicable to cylindrical portion of flush rivets.

Double Shear Joint Allowables for Protruding-Head MS20470D

Rivets in Clad 2024-T3 Aluminum Alloy Sheet
Table 9

CF6-80E1
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54-04-08 Page 22
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Proprietary - This document is subject to the controls and restrictions on the title page.
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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

FASTENER PROTRUDING-HEAD AD RIVET, MS20470AD*

FASTENER NOMINAL AD3 AD4 AD5 AD6 AD8
DIAMETER (INCHES) 3/32 1/8 5/32 3/16 1/4
FASTENER SINGLE
SHEAR STRENGTH, Lb 217 388 596 862 1550
MATERIAL 2014-T6511 EXTRUSION
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.016 175
0.020 202 293 363
0.025 211 357 454 544
0.032 217 374 551 697 937
0.036 381 564 784 1054
0.040 386 575 804 1172
0.045 388 585 821 1318
0.050 593 836 1426
0.063 596 862 1490
0.071 1517
0.080 1542
0.090 1550

NOTE: 1. Allowables correspond to shear or bearing, whichever is lower.

2. Bearing allowables based on e/D = 2.0, Fbr = Fbru or 1.5 Fbry,

whichever is lower, and nominal hole diameters.

3. *Also applicable to cylindrical portion of flush rivets.

Single Shear Joint Allowables for Protruding-Head MS20470AD

Rivets in Clad 2014-T6511 Extrusions
Table 10

CF6-80E1
This document may contain export
54-04-08 Page 23
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Proprietary - This document is subject to the controls and restrictions on the title page.
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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

FASTENER PROTRUDING-HEAD D RIVET, MS20470D*

FASTENER NOMINAL D3 D4 D5 D6 D8
DIAMETER (INCHES) 3/32 1/8 5/32 3/16 1/4
FASTENER SINGLE
SHEAR STRENGTH, Lb 275 494 755 1090 1970
MATERIAL 2014-T6511 EXTRUSION
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.016 175
0.020 219 293 363
0.025 267 366 452 544
0.032 275 468 580 697 937
0.036 485 652 784 1054
0.040 492 725 871 1172
0.045 494 741 979 1318
0.050 751 1057 1465
0.063 755 1090 1845
0.071 1929
0.080 1960
0.090 1970

NOTE: 1. Allowables correspond to shear or bearing, whichever is lower.

2. Bearing allowables based on e/D = 2.0, Fbr = Fbru or 1.5 Fbry,

whichever is lower, and nominal hole diameters.

3. *Also applicable to cylindrical portion of flush rivets.

Single Shear Joint Allowables for Protruding-Head MS20470D

Rivets in Clad 2014-T6511 Extrusions
Table 11

CF6-80E1
This document may contain export
54-04-08 Page 24
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controlled technical data, but
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for export purposes. Do not
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Proprietary - This document is subject to the controls and restrictions on the title page.
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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

FASTENER PROTRUDING-HEAD D RIVET, MS20470AD*

FASTENER NOMINAL AD3 AD4 AD5 AD6 AD8
DIAMETER (INCHES) 3/32 1/8 5/32 3/16 1/4
FASTENER DOUBLE
SHEAR STRENGTH, Lb 434 776 1192 1724 3100
MATERIAL 2014-T6511 EXTRUSION
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.020 219
0.025 273 366
0.032 350 468 580
0.036 372 528 652 784
0.040 387 586 725 871
0.045 401 647 815 979
0.050 413 675 906 1089 1465
0.063 434 727 1039 1371 1845
0.071 750 1084 1469 2080
0.080 770 1122 1536 2244
0.090 776 1155 1593 2585
0.100 1182 1640 2697
0.125 1192 1724 2899
0.160 3075
0.190 3100

NOTE: 1. Allowables correspond to shear or bearing, whichever is lower.

2. Bearing allowables based on e/D = 2.0, Fbr = Fbru or 1.5 Fbry,

whichever is lower, and nominal hole diameters.

3. *Also applicable to cylindrical portion of flush rivets.

Double Shear Joint Allowables for Protruding-Head MS20470AD

Rivets in 2014-T6511 Extrusions
Table 12

CF6-80E1
This document may contain export
54-04-08 Page 25
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Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
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Proprietary - This document is subject to the controls and restrictions on the title page.
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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

FASTENER PROTRUDING-HEAD D RIVET, MS20470D*

FASTENER NOMINAL D3 D4 D5 D6 D8
DIAMETER (INCHES) 3/32 1/8 5/32 3/16 1/4
FASTENER DOUBLE
SHEAR STRENGTH, Lb 550 988 1510 2180 3940
MATERIAL CLAD 2014-T6 ALUMINUM ALLOY SHEET
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.020 214
0.025 293 392
0.032 375 501 621
0.036 422 565 698 839
0.040 476 637 789 947
0.045 508 717 887 1065
0.050 523 796 986 1184 1593
0.063 550 926 1242 1492 2008
0.071 954 1373 1681 2263
0.080 980 1421 1895 2549
0.090 988 1463 2014 2868
0.100 1498 2073 3197
0.125 1510 2180 3684
0.160 3908
0.190 3940

NOTE: 1. Allowables correspond to shear or bearing, whichever is lower.

2. Bearing allowables based on e/D = 2.0, Fbr = Fbru or 1.5 Fbry,

whichever is lower, and nominal hole diameters.

3. *Also applicable to cylindrical portion of flush rivets.

Double Shear Joint Allowables for Protruding-Head MS20470D

Rivets in 2014-T6 Aluminum Alloy Sheet
Table 13

CF6-80E1
This document may contain export
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controlled technical data, but
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Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
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Proprietary - This document is subject to the controls and restrictions on the title page.
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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

FASTENER PROTRUDING-HEAD AD RIVET, MS20470AD*

FASTENER NOMINAL AD3 AD4 AD5 AD6 AD8
DIAMETER (INCHES) 3/32 1/8 5/32 3/16 1/4
FASTENER SINGLE
SHEAR STRENGTH, Lb 217 388 596 862 1550
MATERIAL CLAD 2014-T6 ALUMINUM ALLOY SHEET
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.016 188
0.020 202 314 388
0.025 211 357 484 582
0.032 217 374 551 745 1003
0.036 381 564 786 1129
0.040 386 575 804 1275
0.045 388 585 821 1392
0.050 593 836 1426
0.063 596 862 1490
0.071 1517
0.080 1542
0.090 1550

NOTE: 1. Allowables correspond to shear or bearing, whichever is lower.

2. Bearing allowables based on e/D = 2.0, Fbr = Fbru or 1.5 Fbry,

whichever is lower, and nominal hole diameters.

3. *Also applicable to cylindrical portion of flush rivets.

Single Shear Joint Allowables for Protruding-Head MS20470AD

Rivets in Clad 2014-T6 Aluminum Alloy Sheet
Table 14

CF6-80E1
This document may contain export
54-04-08 Page 27
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Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
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Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

FASTENER PROTRUDING-HEAD D RIVET, MS20470D*

FASTENER NOMINAL D3 D4 D5 D6 D8
DIAMETER (INCHES) 3/32 1/8 5/32 3/16 1/4
FASTENER SINGLE
SHEAR STRENGTH, Lb 275 494 755 1090 1970
MATERIAL CLAD 2014-T6 ALUMINUM ALLOY SHEET
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.016 188
0.020 234 314 388
0.025 267 392 484 582
0.032 275 476 621 745 1003
0.036 485 698 839 1129
0.040 492 728 947 1275
0.045 494 741 1039 1433
0.050 751 1057 1593
0.063 755 1090 1893
0.071 1929
0.080 1960
0.090 1970

NOTE: 1. Allowables correspond to shear or bearing, whichever is lower.

2. Bearing allowables based on e/D = 2.0, Fbr = 2.0, Fbru or 1.5 Fbry,
whichever is lower, and nominal hole diameters.

3. *Also applicable to cylindrical portion of flush rivets.

Single Shear Joint Allowables for Protruding-Head MS20470D

Rivets in Clad 2014-T6 Aluminum Alloy Sheet
Table 15

CF6-80E1
This document may contain export
54-04-08 Page 28
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controlled technical data, but
has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

FASTENER PROTRUDING-HEAD D RIVET, MS20470AD*

FASTENER NOMINAL AD3 AD4 AD5 AD6 AD8
DIAMETER (INCHES) 3/32 1/8 5/32 3/16 1/4
FASTENER DOUBLE
SHEAR STRENGTH, Lb 434 776 1192 1724 3100
MATERIAL CLAD 2014-T6 ALUMINUM ALLOY SHEET
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.020 234
0.025 293 392
0.032 353 501 621
0.036 372 565 698 839
0.040 387 612 789 947
0.045 401 647 887 1065
0.050 413 675 940 1184 1593
0.063 434 727 1039 1393 2008
0.071 750 1084 1469 2263
0.080 770 1122 1536 2446
0.090 776 1155 1593 2585
0.100 1182 1640 2697
0.125 1192 1724 2899
0.160 3075
0.190 3100

NOTE: 1. Allowables correspond to shear or bearing, whichever is lower.

2. Bearing allowables based on e/D = 2.0, Fbr = Fbru or 1.5 Fbry,

whichever is lower, and nominal hole diameters.

3. *Also applicable to cylindrical portion of flush rivets.

Double Shear Joint Allowables for Protruding-Head MS20470AD

Rivets in Clad 2014-T6 Aluminum Alloy Sheet
Table 16

CF6-80E1
This document may contain export
54-04-08 Page 29
Oct 15/19
controlled technical data, but
has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

FASTENER PROTRUDING-HEAD D RIVET, MS20470D*

FASTENER NOMINAL D3 D4 D5 D6 D8
DIAMETER (INCHES) 3/32 1/8 5/32 3/16 1/4
FASTENER DOUBLE
SHEAR STRENGTH, Lb 550 988 1510 2180 3940
MATERIAL 2014-T6511 EXTRUSION
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.020 219
0.025 273 366
0.032 350 468 580
0.036 394 528 652 784
0.040 438 586 725 871
0.045 492 659 815 979
0.050 523 732 906 1089 1465
0.063 550 922 1142 1371 1845
0.071 954 1287 1546 2080
0.080 980 1421 1742 2344
0.090 988 1463 1969 2637
0.100 1498 2073 2930
0.125 1510 2180 3661
0.160 3908
0.190 3940

NOTE: 1. Allowables correspond to shear or bearing, whichever is lower.

2. Bearing allowables based on e/D = 2.0, Fbr = Fbru or 1.5 Fbry,

whichever is lower, and nominal hole diameters.

3. *Also applicable to cylindrical portion of flush rivets.

Shear Joint Allowables for Protruding-Head MS20470D

Rivets in Clad 2014-T6511 Extrusion
Table 17

CF6-80E1
This document may contain export
54-04-08 Page 30
Oct 15/19
controlled technical data, but
has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

FASTENER PROTRUDING-HEAD AD RIVET, MS20470D*

FASTENER NOMINAL AD3 AD4 AD5 AD6 AD8
DIAMETER (INCHES) 3/32 1/8 5/32 3/16 1/4
FASTENER SINGLE
SHEAR STRENGTH, Lb 217 388 596 862 1550
MATERIAL 2024-T42 EXTRUSION (HEAT TREATED BY USER)
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.016 141
0.020 175 235 291
0.025 211 293 363 436
0.032 217 374 465 559 752
0.036 381 523 629 846
0.040 386 575 699 940
0.045 388 585 786 1057
0.050 593 836 1176
0.063 596 862 1481
0.071 1517
0.080 1542
0.090 1550

NOTE: 1. Allowables correspond to shear or bearing, whichever is lower.

2. Bearing allowables based on e/D = 2.0, Fbr = 2.0, Fbru or 1.5 Fbry,
whichever is lower, and nominal hole diameters.

3. *Also applicable to cylindrical portion of flush rivets.

Single Shear Joint Allowables for Protruding-Head MS20470AD

Rivets in Clad 2024-T42 Extrusions
Table 18

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FASTENER PROTRUDING-HEAD AD RIVET, MS20470D*

FASTENER NOMINAL D3 D4 D5 D6 D8
DIAMETER (INCHES) 3/32 1/8 5/32 3/16 1/4
FASTENER SINGLE
SHEAR STRENGTH, Lb 275 494 755 1090 1970
MATERIAL 2024-T42 EXTRUSION (HEAT TREATED BY USER)
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.016 141
0.020 175 235 291
0.025 219 293 363 436
0.032 275 376 465 559 752
0.036 423 523 629 846
0.040 470 582 699 940
0.045 494 654 786 1057
0.050 727 874 1176
0.063 755 1090 1481
0.071 1670
0.080 1881
0.090 1970

NOTE: 1. Allowables correspond to shear or bearing, whichever is lower.

2. Bearing allowables based on e/D = 2.0, Fbr = 2.0, Fbru or 1.5 Fbry,
whichever is lower, and nominal hole diameters.

3. *Also applicable to cylindrical portion of flush rivets.

Single Shear Joint Allowables for Protruding-Head MS20470D

Rivets in Clad 2024-T42 Extrusions
Table 19

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Document Part No. RDN 306

FASTENER PROTRUDING-HEAD D RIVET, MS20470AD*

FASTENER NOMINAL AD3 AD4 AD5 AD6 AD8
DIAMETER (INCHES) 3/32 1/8 5/32 3/16 1/4
FASTENER DOUBLE
SHEAR STRENGTH, Lb 434 776 1192 1724 3100
MATERIAL 2024-T42 EXTRUSION (HEAT TREATED BY USER)
SHEET NOMINAL
THICKNESS (INCHES) DOUBLE SHEAR ULTIMATE STRENGTH, Lb
0.020 175
0.025 219 293
0.032 281 376 465
0.036 316 423 523 629
0.040 351 470 582 699
0.045 395 529 654 786
0.050 413 587 727 874 1176
0.063 434 727 917 1100 1481
0.071 750 1033 1240 1670
0.080 770 1122 1398 1881
0.090 776 1155 1573 2116
0.100 1182 1640 2351
0.125 1192 1724 2899
0.160 3075
0.190 3100

NOTE: 1. Allowables correspond to shear or bearing, whichever is lower.

2. Bearing allowables based on e/D = 2.0, Fbr = Fbru or 1.5 Fbry,

whichever is lower, and nominal hole diameters.

3. *Also applicable to cylindrical portion of flush rivets.

Double Shear Joint Allowables for Protruding-Head MS20470AD

Rivets in Clad 2024-T42 Extrusions
Table 20

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Document Part No. RDN 306

FASTENER PROTRUDING-HEAD D RIVET, MS20470D*

FASTENER NOMINAL D3 D4 D5 D6 D8
DIAMETER (INCHES) 3/32 1/8 5/32 3/16 1/4
FASTENER DOUBLE
SHEAR STRENGTH, Lb 550 988 1510 2180 3940
MATERIAL 2024-T42 EXTRUSION (HEAT TREATED BY USER)
SHEET NOMINAL
THICKNESS (INCHES) DOUBLE SHEAR ULTIMATE STRENGTH, Lb
0.020 175
0.025 219 293
0.032 281 376 465
0.036 316 423 523 629
0.040 351 470 582 699
0.045 395 529 654 786
0.050 439 587 727 874 1176
0.063 550 740 917 1100 1481
0.071 834 1033 1240 1670
0.080 940 1164 1398 1881
0.090 988 1309 1573 2116
0.100 1455 1747 2351
0.125 1510 2180 2989
0.160 3762
0.190 3940

NOTE: 1. Allowables correspond to shear or bearing, whichever is lower.

2. Bearing allowables based on e/D = 2.0, Fbr = Fbru or 1.5 Fbry,

whichever is lower, and nominal hole diameters.

3. *Also applicable to cylindrical portion of flush rivets.

Double Shear Joint Allowables for Protruding-Head MS20470D

Rivets in Clad 2024-T42 Extrusions
Table 21

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FASTENER PROTRUDING-HEAD AD RIVET, MS20470AD*

FASTENER NOMINAL AD3 AD4 AD5 AD6 AD8
DIAMETER (INCHES) 3/32 1/8 5/32 3/16 1/4
FASTENER SINGLE
SHEAR STRENGTH, Lb 217 388 596 862 1550
MATERIAL CLAD 2024-T42 SHEET (HEAT TREATED BY USER)
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.016 124
0.020 155 208 258
0.025 194 260 321 386
0.032 217 333 412 495 666
0.036 375 463 557 749
0.040 381 515 619 832
0.045 386 579 696 936
0.050 388 593 773 1041
0.063 596 862 1408
0.071 1517
0.080 1542
0.090 1550

NOTE: 1. Allowables correspond to shear or bearing, whichever is lower.

2. Bearing allowables based on e/D = 2.0, Fbr = 2.0, Fbru or 1.5 Fbry,
whichever is lower, and nominal hole diameters.

3. *Also applicable to cylindrical portion of flush rivets.

Single Shear Joint Allowables for Protruding-Head MS20470AD

Rivets in Clad 2024-T42 Aluminum Alloy Sheet
Table 22

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FASTENER PROTRUDING-HEAD AD RIVET, MS20470D*

FASTENER NOMINAL D3 D4 D5 D6 D8
DIAMETER (INCHES) 3/32 1/8 5/32 3/16 1/4
FASTENER SINGLE
SHEAR STRENGTH, Lb 275 494 755 1090 1970
MATERIAL CLAD 2024-T42 SHEET (HEAT TREATED BY USER)
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.016 124
0.020 155 208 258
0.025 194 260 321 386
0.032 248 333 412 495 666
0.036 275 375 463 557 749
0.040 416 515 619 832
0.045 468 579 696 936
0.050 494 644 773 1041
0.063 755 1046 1408
0.071 1090 1588
0.080 1788
0.090 1970

NOTE: 1. Allowables correspond to shear or bearing, whichever is lower.

2. Bearing allowables based on e/D = 2.0, Fbr = 2.0, Fbru or 1.5 Fbry,
whichever is lower, and nominal hole diameters.

3. *Also applicable to cylindrical portion of flush rivets.

Single Shear Joint Allowables for Protruding-Head MS20470D

Rivets in Clad 2024-T42 Aluminum Alloy Sheet
Table 23

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FASTENER PROTRUDING-HEAD D RIVET, MS20470AD*

FASTENER NOMINAL AD3 AD4 AD5 AD6 AD8
DIAMETER (INCHES) 3/32 1/8 5/32 3/16 1/4
FASTENER DOUBLE
SHEAR STRENGTH, Lb 434 776 1192 1724 3100
MATERIAL CLAD 2024-T42 SHEET (HEAT TREATED BY USER)
SHEET NOMINAL
THICKNESS (INCHES) DOUBLE SHEAR ULTIMATE STRENGTH, Lb
0.020 155
0.025 194 260
0.032 248 333 412
0.036 280 375 463 557
0.040 311 416 515 619
0.045 350 468 579 696
0.050 389 520 644 774 1041
0.063 434 704 872 1047 1409
0.071 750 982 1180 1588
0.080 770 1107 1329 1789
0.090 776 1155 1496 2012
0.100 1182 1640 2236
0.125 1192 1724 2794
0.160 3075
0.190 3100

NOTE: 1. Allowables correspond to shear or bearing, whichever is lower.

2. Bearing allowables based on e/D = 2.0, Fbr = Fbru or 1.5 Fbry,

whichever is lower, and nominal hole diameters.

3. *Also applicable to cylindrical portion of flush rivets.

Double Shear Joint Allowables for Protruding-Head MS20470AD

Rivets in Clad 2024-T42 Aluminum Alloy Sheet
Table 24

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FASTENER PROTRUDING-HEAD D RIVET, MS20470D*

FASTENER NOMINAL D3 D4 D5 D6 D8
DIAMETER (INCHES) 3/32 1/8 5/32 3/16 1/4
FASTENER DOUBLE
SHEAR STRENGTH, Lb 550 988 1510 2180 3940
MATERIAL CLAD 2024-T42 SHEET (HEAT TREATED BY USER)
SHEET NOMINAL
THICKNESS (INCHES) DOUBLE SHEAR ULTIMATE STRENGTH, Lb
0.020 155
0.025 194 260
0.032 248 333 412
0.036 280 375 463 557
0.040 311 416 515 619
0.045 350 468 579 696
0.050 389 520 644 774 1041
0.063 550 704 872 1047 1409
0.071 794 982 1180 1588
0.080 894 1107 1329 1789
0.090 988 1245 1496 2012
0.100 1383 1662 2236
0.125 1510 2076 2794
0.160 2180 3577
0.190 3940

NOTE: 1. Allowables correspond to shear or bearing, whichever is lower.

2. Bearing allowables based on e/D = 2.0, Fbr = Fbru or 1.5 Fbry,

whichever is lower, and nominal hole diameters.

3. *Also applicable to cylindrical portion of flush rivets.

Double Shear Joint Allowables for Protruding-Head MS20470D

Rivets in Clad 2024-T42 Aluminum Alloy Sheet
Table 25

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Document Part No. RDN 306

FASTENER PROTRUDING-HEAD MONEL RIVET, MS20615M

FASTENER NOMINAL
DIAMETER (INCHES) 3/32 1/8 5/32 3/16
FASTENER SINGLE
SHEAR STRENGTH, Lb 355 635 973 1400
MATERIAL PURE TITANIUM SHEET (DMS1536 OR EQUIVALENT)
SHEET NOMINAL
THICKNESS (INCHES) DOUBLE SHEAR ULTIMATE STRENGTH, Lb
0.020 230
0.025 288 384
0.032 355 494 610
0.036 555 686 824
0.040 616 763 916
0.045 635 859 1030
0.050 954 1145
0.063 973 1400

NOTE: 1. Allowables correspond to shear or bearing, whichever is lower.

2. Bearing allowables based on e/D = 2.0, Fbr = Fbru or 1.5 Fbry,

whichever is lower, and nominal hole diameters.

3. *Also applicable to cylindrical portion of flush rivets.

Shear Joint Allowables for Monel Protruding-Head MS20615M

Rivets in Pure Titanium Sheet
Table 26

CF6-80E1
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FASTENER PROTRUDING-HEAD MONEL RIVET, MS20615M

FASTENER NOMINAL AD3 AD4 AD5 AD6
DIAMETER (INCHES) 3/32 1/8 5/32 3/16
FASTENER SINGLE
SHEAR STRENGTH, Lb 217 388 596 862
MATERIAL CLAD 2024-T42 ALUMINUM ALLOY SHEET (OR STRONGER)
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.020 123 147
0.025 156 221 165
0.032 178 272 300
0.040 193 309 397 410
0.050 206 340 479 584
0.063 216 363 523 705
0.071 217 373 542 739
0.080 382 560 769
0.090 388 575 795
0.100 587 818
0.125 596 853
0.160
0.190 862

NOTES: Allowables are based on test ultimate/1/15 or 1.5 x test yield,

whichever is lower.

Single Shear Joint Allowables for Flush-Head Solid

MS20426AD Rivets in 100°-Machine-Countersunk
Clad 2024-T42 Aluminum Alloy
Table 27

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FASTENER FLUSH-HEAD D RIVET, MS20426D

FASTENER NOMINAL D5 D6 D8
DIAMETER (INCHES) 5/32 3/16 1/4
FASTENER SINGLE
SHEAR STRENGTH, Lb 755 1090 1970
MATERIAL CLAD 2024-T42 ALUMINUM ALLOY SHEET (OR STRONGER)
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.020
0.025
0.032
0.040 405
0.050 517 629
0.063 600 772 915
0.071 690 835 1059
0.080 720 935 1182
0.090 746 1015 1292
0.100 755 1054 1526
0.125 1090 1773
0.160 1891
0.190 1970

NOTES: Allowables are based on test ultimate/1/15 or 1.5 x test yield,

whichever is lower.

Single Shear Joint Allowables for Flush-Head Solid

MS20426D Rivets in 100°-Machine-Countersunk
Clad 2024-T42 Aluminum Alloy
Table 28

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FASTENER FLUSH-HEAD D RIVET, MS20426D

FASTENER NOMINAL AD4 AD5 AD6
DIAMETER (INCHES) 1/8 5/32 3/16
FASTENER SINGLE
SHEAR STRENGTH, Lb 388 596 862
MATERIAL CLAD 2014-T6 ALUMINUM ALLOY SHEET
HAND DRIVEN RIVETS
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.032 317
0.040 375 489
0.050 388 593 689
0.063 596 805
0.071 835
0.080 862
DRIVEMATIC RIVETS
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.032 298
0.040 375 450
0.050 388 530 680
0.063 596 804
0.071 835
0.080 858
0.090 862

Single Shear Joint Allowables for NAS1097AD Flush

Crown-Head Rivets 100°-Machine-Countersunk
Aluminum Clad 2014-T6 Alloy
Table 29

CF6-80E1
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FASTENER FLUSH-HEAD D RIVET, NAS1097AD

FASTENER NOMINAL AD4 AD5 AD6
DIAMETER (INCHES) 1/8 5/32 3/16
FASTENER SINGLE
SHEAR STRENGTH, Lb 388 596 862
MATERIAL CLAD 2024-T3 ALUMINUM ALLOY SHEET
HAND DRIVEN RIVETS
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.032 300
0.040 359 457
0.050 388 560 702
0.063 596 800
0.071 862
DRIVEMATIC RIVETS
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.032 285
0.040 341 440
0.050 388 540 633
0.063 596 740
0.071 815

Single Shear Joint Allowables for NAS1097AD Flush

Crown-Head Rivets 100°-Machine-Countersunk
Clad 2014-T6 Aluminum Alloy
Table 30

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FLUSH 82° NACA AD RIVET, MS20470AD, OR

FASTENER NAS1321AD SLUG
FASTENER NOMINAL AD4 AD5 AD6 AD7
DIAMETER (INCHES) 1/8 5/32 3/16 1/4
FASTENER SINGLE
SHEAR STRENGTH, Lb 388 596 862 1550
MATERIAL 2014-T6 ALUMINUM ALLOY SHEET
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.040 309 470
0.050 339 516 752
0.063 363 552 824
0.071 372 568 846
0.080 388 580 860 1400
0.090 590 862 1440
0.100 596 1470
0.125 1511
0.160 1540
0.190 1550

Single Shear Joint Allowables for MS20470AD OR NAS1321AD Slug

NACA Flush-Head Rivets in 82°-Machine-Countersunk
2014-T6 Aluminum Alloy
Table 31

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FASTENER FLUSH-HEAD MONEL RIVET, MS20427M

FASTENER NOMINAL
DIAMETER (INCHES) 3/32 1/8 5/32 3/16 1/4
FASTENER SINGLE
SHEAR STRENGTH, Lb 635 973 1400 2540
COMMERCIALLY PURE TITANIUM, Ftu - 80 ksi
MATERIAL (DMS1536 OR EQUIVALENT)
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.020 270
0.025 344 414
0.032 446 546 644
0.040 531 690 819 1064
0.050 573 818 1032 1396
0.063 626 885 1198 1725
0.071 635 926 1242 1950
0.080 973 1302 2090
0.090 1360 2185
0.100 1400 2200
0.125 2460
0.160 2540

Single Shear Joint Allowables for MS20427M Monel

Flush-Head Rivets in 100°-Machine-Countersunk
Commercially Pure Titanium Alloy
Table 32

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Document Part No. RDN 306

FASTENER FLUSH-HEAD MONEL RIVET, MS20427M

FASTENER NOMINAL
DIAMETER (INCHES) 1/8 5/32 3/16 1/8 5/32 3/16
FASTENER SINGLE
SHEAR STRENGTH, Lb 635 973 1400 635 973 1400
STAINLESS STEEL STAINLESS STEEL
MATERIAL AISI 301 ANNEALED AISI 301 1/4 ANNEALED
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.020 194 300
0.025 243 296 361 464
0.032 309 384 453 431 591 705
0.040 389 482 579 439 663 858
0.050 486 603 720 468 673 954
0.063 612 759 906 595 732 972
0.071 635 855 1028 635 830 990
0.080 965 1156 936 1118
0.090 973 1298 973 1255
0.100 1400 1400

Single Shear Joint Allowables for MS20427M Monel

Flush-Head Rivets in 100°-Machine-Countersunk
AISI 301 Annealed and 1/4 Hard Stainless Steel Sheet
Table 33

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FASTENER FLUSH-HEAD MONEL RIVET, MS20427M

FASTENER NOMINAL
DIAMETER (INCHES) 3/32 1/8 5/32 3/16
FASTENER SINGLE
SHEAR STRENGTH, Lb 355 635 973 1400
MATERIAL STAINLESS STEEL AISI 301 1/2H AND FULL H
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.020 231 321
0.025 241 396 496
0.032 245 431 627 765
0.040 251 439 663 917
0.050 322 447 673 954
0.063 355 538 688 972
0.071 615 741 984
0.080 635 850 995
0.090 973 1132
0.100 1280
0.125 1400

Single Shear Joint Allowables for MS20427M Monel

Flush-Head Rivets in 100°-Machine-Countersunk
AISI 301 1/2 Hard and Full Hard Stainless Steel Sheet
Table 34

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MATERIAL HEAT-TREATED STEEL

ULTIMATE SHEAR STRENGTH, ksi 75 95 108 132
ULTIMATE TENSILE STRENGTH, ksi 125 160 180 220
SIZE
OF NOMINAL MOMENT OF ULTIMATE SINGLE SHEAR
PIN OF DIAMETER OF BASIC SHANK INERTIA OR STRENGTH AT FULL
2
BOLT SHANK IN. AREA IN. SHANK, IN.4 DIAMETER OF SHANK, Lb
1/8 0.125 0.012272 0.0000198 920 1166 1325 1620
5/32 0.156 0.019175 0.00002726 1438 1822 2071 2531
#8 0.164 0.021124 0.00003549 1581 2007 2281 2788
3/16 0.188 0.027612 0.00006066 2071 2623 2982 3645
#10 0.190 0.208353 0.00006399 2126 2694 3062 3743
#12 0.216 0.036644 0.0001059 2748 3481 3958 4840
7/32 0.219 0.37582 0.0001125 2819 3570 4060 4960

1/4 0.250 0.049087 0.0001918 3682 4660 5300 6480

5/16 0.312 0.076699 0.0004682 5750 7290 8280 10120
3/8 0.375 0.110450 0.0009710 8280 41490 11930 14580
7/16 0.438 0.150330 0.001797 11270 14280 16240 49840
1/2 0.500 0.196350 0.003069 14730 18650 21210 25920
9/16 0.562 0.248500 0.004914 18640 23610 26840 32800
5/8 0.625 0.306300 0.007492 23010 29150 33130 40500

3/4 0.750 0.441790 0.01553 33430 42000 47700 58300

7/8 0.875 0.601320 0.278 45100 57100 64900 79400
1 1.000 0.785400 0.4708 58900 74600 84800 103700
1 1/8 1.125 0.994020 0.0780 74600 94400 107400 131200
1 1/4 1.250 1.227200 0.1142 92800 116600 132500 162000
1 3/8 1.375 1.484900 0.1750 111400 141100 160400 196000
1 1/2 1.500 1.767100 0.2482 132500 167900 190800 233300

Single Shear Allowables for

Steel Threaded-Fastener Pins
Table 35

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MATERIAL HEAT-TREATED STEEL

ULTIMATE TENSILE STRENGTH, ksi 125 160 160 180 180 220
MIL-S- MIL-S-
THREAD SPECIFICATION MIL-S-7742 8879 7742 MIL-S-8879
BASIC MINOR AREA
OF THREAD, IN.2
NOMINAL
DIAMETER THREAD
FASTENER OF SHANK MIL-S- THREADMI
SIZE IN. 7742 L-S-8870 ULTIMATE TENSILE STRENGTH, ksi
4-40 0.122 0.0050896 0.0054687 636 814 870 916 979 1196

6-32 0.138 0.0076281 0.0081553 960 1229 1305 1383 1469 1794

8-32 0.164 0.12283 0.012843 1529 1957 2056 2202 2313 2827
10-32 0.190 0.018074 0.018602 2259 2892 2976 3253 3848 4090
1/4-28 0.250 0.033394 0.034241 4170 5340 5478 6010 6160 7530

5/16-24 0.312 0.058666 0.054905 6710 8590 8786 9660 9880 12080
3/8-24 0.375 0.082897 0.083879 10300 13180 13420 14880 15100 18450
7/16-20 0.438 0.11115 0.11328 13890 17780 18120 20010 23380 24910
1/2-20 0.500 0.15116 0.15358 18900 24190 24570 27210 27640 33790
9/1618 0.562 0.19190 0.19502 23990 30700 31200 34540 35100 42900

5/8-18 0.625 0.24849 0.24700 30440 38960 39520 43800 44500 54300
3/4-16 0.750 0.35605 0.36082 44500 57000 57730 64100 64900 79400
7/8-14 0.875 0.48695 0.49327 60900 77900 78920 87700 88800 108500
1-12 1.000 0.63307 0.64156 79100 101300 102700 114000 115500 141100
1 1/8-12 1.125 0.82162 0.88129 102700 131500 133000 147900 149000 182900

1 1/4-12 1.250 1.0347 1.0456 129300 165600 167300 186200 188200 230000
1 3/8-12 1.375 1.2724 1.2844 159000 203600 205500 229000 231200 232600
1 1/2-12 1.500 1.5345 1.5477 191800 245500 247600 276200 278600 340500

NOTES: 1. Nuts designed to develop ultimate tensile strength of the fastener

are required to develop the tabulated tension loads. Values shown in
this table are not applicable to reduced-head (shear-head) pins. For
example: NAS4903-Series bolts or screws and shear-head Hi-Lok pins such
as HL329, HLT334, and HLT335.

2. Fastener sizes are shown in diameter and threads per inch. Diameter
is indicated by number or in fractions of an inch.

Tension Allowables for Steel Threaded-Fastener Pins

Table 36

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TYPICAL NUTS AND COLLARS ULTIMATE TENSILE RATING, Lb

NOMINAL
SIZE IN. NUT FOR HI-LOK TAPER-LOK NUT FOR TAPER-LOK
125 ksi BOLT COLLAR NUT 160 ksi BOLT NUT
NAS689A HL75 TLN1000C MS21042L TLN1020D
MS21043 HL86 (HIGH TEMP H39794-*F TLN1020L
52LH2935 HL775 APPLICATION) H541L*F
HL386 * = SIZE
STEEL STEEL A286 STEEL STEEL
5/32 1720 1800 2500 2490
3/16 2460 2820 2850 3470 3500
1/4 4580 5000 4900 6200 6550
5/16 7390 8200 8000 9820 10500
3/8 11450 12100 12500 15200 15800
7/16 17100 16000
1/2 23400 21000

Tension Allowables for Nuts and Collars

Table 37

HI-LOK SINGLE-SHEAR ULTIMATE TENSILE STRENGTH, Lb

FASTENER ULTIMATE TENSION SHEAR
DIAMETER IN. MATERIAL STRENGTH, Lb TYPE TYPE
5/32 HEAT-TREATED 2007 1800 1220
3/16 ALLOY STEEL 2694 2830 1410
1/4 PIN, 160 TO 4660 5000 2560
5/16 180KSI 7290 8200 4100
3/8 (APPLICABLE 10490 12100 6200
7/16 TO T1-6A1-4V 14280 17100 8200
1/2 PINS) 18650 23400 10600

NOTE: The basis for tensile strength is Type 303 Se Stainless steel collars
for tension type and 2024-T6 aluminum alloy collars for shear type.

Ultimate Single Shear and Tensile Strength

for Flush-Head and Protruding Head
Hi-Lok Fasteners
Table 38

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UNIT BEARING STRENGTH OF SHEET FOR FASTENER DIAMETER INDICATED, LB

THICKNESS,
DIAMETER,

MATERIAL
NOMINAL

CES-220-00
PIN

IN.

IN.

NOTE: Bearing strengths shown are based on pin nominal fastener diameter
and Fbru - 100 ksi.

Bearing Strength of Sheet in Joints with Threaded Fasteners Pins

Table 39

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FASTENER 125,000 H.T. PROTRUDING-HEAD THREADED PINS

FASTENER
NOMINAL
DIA., IN. 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1
FATENER
SHEAR
STRENGTH,
Lb 2071 3682 5750 8280 11270 14730 18640 23010 33130 45100 58900
MATERIAL CLAD 2024-T42 ALUMINUM ALLOY SHEET
SHEET
NOMINAL
THICKNESS,
IN. SHEAR ULTIMATE STRENGTH, Lb
0.040 616810 1013 1215 1418 1620 1823 2025 2430 2835 3240
0.050 7701013 1266 1519 1772 2025 2278 2531 3038 3544 4050
0.063 1014
1370 1713 2055 2398 2741 3083 3426 4111 4796 5481
0.071 1174
1544 1930 2316 2702 3089 3475 3861 4633 5405 6177
0.080 1322
1740 2175 2610 3045 3480 3915 4350 5220 6090 6960
0.090 1488
1958 2447 2936 3426 3915 4404 4894 5873 6851 7830
0.100 1653
2175 2719 3263 3806 4350 4894 5438 6525 7613 8700
0.125 2066
2719 3398 4078 4758 5438 6117 6797 8156 9516 10875
0.160 2071
3480 4350 5220 6090 6960 7830 8700 10440 12180 13920
0.190 3682 5166 6199 7232 8265 9298 10331 12398 14464 16530
NOTE: Bearing allowables based on e/D = 2.0 and full diameter.

Shear Joint Allowables for 125,000 H.T. Protruding-Head

Threaded Steel Fastener Pins in Clad 2024-T42
Aluminum Alloy Sheet
Table 40

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FASTENER 160,000 H.T. PROTRUDING-HEAD THREADED PINS

FASTENER
NOMINAL
DIA., IN. 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1
FATENER
SHEAR
STRENGTH,
Lb 2623 4660 7290 10490 14280 18650 23610 29150 42000 57100 74600
MATERIAL CLAD 2024-T42 ALUMINUM ALLOY SHEET
SHEET
NOMINAL
THICKNESS,
IN. SHEAR ULTIMATE STRENGTH, Lb
0.040 616 810 1013 1215 1418 1620 1823 2025 2430 2835 3240
0.050 770 1013 1266 1519 1772 2025 2278 2531 3038 3544 4050
0.063 1041 1370 1713 2055 2398 2741 3083 3426 4111 4796 5481
0.071 1174 1544 1930 2316 2702 3089 3475 3861 4633 5404 6177
0.080 1322 1740 2175 2610 3045 3480 3815 4350 5220 6090 6960
0.090 1488 1958 2447 2936 3426 3915 4404 4894 5873 6851 7830
0.100 1653 2175 2719 3263 3806 4350 4894 5438 6525 7613 8700
0.125 2066 2719 3398 4078 4758 5438 6117 6797 8156 9516 10875
0.160 2633 3480 4350 5220 6090 6960 7830 8700 10440 12180 13920
0.190 4133 5166 6199 7232 8265 9298 10331 12398 14464 16530

NOTE: Bearing allowables based on e/D = 2.0 and full diameter.

This table may be protruding-head lockbolts made of steel or TI-6A1-4V

Shear Joint Allowables for 160,000 H.T. Protruding-Head

Threaded Steel Fastener Pins in Clad 2024-T42
Aluminum Alloy Sheet
Table 41

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FASTENER 220,000 H.T. PROTRUDING-HEAD THREADED PINS

FASTENER
NOMINAL
DIA., IN. 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1
FATENER
SHEAR
STRENGTH, 10370
Lb 3645 6480 10120 14580 19840 25920 32800 40500 58300 79400 0
MATERIAL CLAD 2024-T42 ALUMINUM ALLOY SHEET
SHEET
NOMINAL
THICKNESS
, IN. SHEAR ULTIMATE STRENGTH, Lb
0.040 616 810 1013 1215 1418 1620 1823 2025 2430 2835 3240
0.050 770 1013 1266 1519 1772 2025 2278 2531 3038 3544 4050
0.063 1041 1370 1713 2055 2398 2741 3083 3426 4111 4796 5481
0.071 1174 1544 1930 2316 2702 3089 3475 3861 4635 5405 6177
0.080 1322 1740 2175 2610 3045 3480 3915 4350 5220 6090 6960
0.090 1488 1958 2447 2936 3426 3915 4404 4894 5873 6851 7830
0.100 1653 2175 2719 3263 3806 4350 4894 5438 6525 7613 8700
0.125 2066 2719 3398 4078 4758 5438 6117 6797 8156 9516 10875
0.160 2645 3480 4350 5220 6090 6960 7830 8700 10440 12180 13920
0.190 3141 4133 5166 6199 7232 8265 9298 10331 12398 14464 16530

NOTE: Bearing allowables based on e/D = 2.0 and full diameter.

Shear Joint Allowables for 220,000 H.T. Protruding-Head

Threaded Steel Fastener Pins in Clad 2024-T42
Aluminum Alloy Sheet
Table 42

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FASTENER 125,000 H.T. PROTRUDING-HEAD THREADED PINS

FASTENER
NOMINAL
DIA., IN. 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1
FATENER
SHEAR
STRENGTH,
Lb 2071 3682 5750 8280 11270 14730 18640 23010 33130 45100 58900
MATERIAL CLAD 2024-T3 ALUMINUM ALLOY SHEET
SHEET
NOMINAL
THICKNESS,
IN. SHEAR ULTIMATE STRENGTH, Lb
0.040 832 1095 1369 1643 1916 2190 2464 2738 3285 3833 4380
0.050 1040 1369 1711 2053 2395 2738 3080 3422 4106 4791 5475
0.063 1329 1748 2185 2622 3059 3497 3934 4371 5245 6119 6993
0.071 1497 1970 2463 2955 3448 3941 4433 4926 5911 6896 7881
0.080 1687 2220 2775 3330 3885 4440 4995 5550 6660 7770 8880
0.090 1898 2498 3122 3746 4371 4995 5619 6244 7493 8741 9990
0.100 2071 2775 3469 4163 4856 5550 6244 6938 8325 9713 11100
0.125 3469 4336 5203 6070 6938 7805 8672 10406 12141 13875
0.160 3682 5550 6660 7770 8880 9990 11100 13320 15540 17760
0.190 5750 7909 9227 10545 11863 13181 15818 18454 21090

NOTE: Bearing allowables based on e/D = 2.0 and full diameter.

Shear Joint Allowables for 125,000 H.T. Protruding-Head

Threaded Steel Fastener Pins in Clad 2024-T43
Aluminum Alloy Sheet
Table 43

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FASTENER 160,000 H.T. PROTRUDING-HEAD THREADED PINS

FASTENER
NOMINAL
DIA., IN. 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1
FATENER
SHEAR
STRENGTH,
Lb 2623 4660 7290 10490 14280 18650 23610 29150 42000 57100 74600
MATERIAL CLAD 2024-T3 ALUMINUM ALLOY SHEET
SHEET
NOMINAL
THICKNESS,
IN. SHEAR ULTIMATE STRENGTH, Lb
0.040 832 1095 1369 1643 1916 2190 2464 2738 3285 3833 4380
0.050 1040 1369 1711 2053 2395 2738 3080 3422 4106 4791 5475
0.063 1329 1748 2185 2622 3059 3497 3934 4371 5245 6119 6993
0.071 1497 1970 2463 2955 3448 3941 4433 4926 5911 6896 7881
0.080 1687 2220 2775 3330 3885 4440 4995 5550 6660 7770 8880
0.090 1898 2498 3122 3746 4371 4995 5619 6244 7493 8741 9990
0.100 2071 2775 3469 4163 4856 5550 6244 6938 8325 9713 11100
0.125 2623 3469 4336 5203 6070 6938 7805 8672 10406 12141 13875
0.160 4440 5550 6660 7770 8880 9990 11100 13320 15540 17760
0.190 4660 6591 7909 9227 10545 11865 13181 15818 18454 21090

NOTE: Bearing allowables based on e/D = 2.0 and full diameter.

This table may be protruding-head lockbolts made of steel or TI-6A1-4V.

Shear Joint Allowables for 160,000 H.T. Protruding-Head

Threaded Steel Fastener Pins in Clad 2024-T42
Aluminum Alloy Sheet
Table 44

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FASTENER 220,000 H.T. PROTRUDING-HEAD THREADED PINS

FASTENER
NOMINAL
DIA., IN. 3/16 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1
FATENER
SHEAR
STRENGTH, 10370
Lb 3645 6480 10120 14580 19840 25920 32800 40500 58300 79400 0
MATERIAL CLAD 2024-T3 ALUMINUM ALLOY SHEET
SHEET
NOMINAL
THICKNESS,
IN. SHEAR ULTIMATE STRENGTH, Lb
0.040 832 1095 1369 1643 1916 2190 2464 2738 3285 3833 4380
0.050 1040 1369 1711 2053 2395 2738 3080 3422 4106 4791 5475
0.063 1329 1748 2185 2622 3059 3497 3934 4371 5245 6119 6993
0.071 1497 1970 2463 2955 3448 3941 4433 4926 5911 6896 7881
0.080 1687 2220 2775 3330 3885 4440 4995 5550 6660 7770 8880
0.090 1898 2498 3122 3746 4371 4995 5619 6244 7493 8741 9990
0.100 2109 2775 3469 4163 4856 5550 6244 6938 8325 9713 11100
0.125 2636 3469 4336 5203 6070 6938 7805 8672 10406 12141 13875
0.160 3374 4440 5550 6660 7770 8880 9990 11100 13320 15540 17760
0.190 3645 5273 6591 7909 9227 10545 11863 13181 15818 18454 21090

NOTE: Bearing allowables based on e/D = 2.0 and full diameter.

Shear Joint Allowables for 220,000 H.T. Protruding-Head

Threaded Steel Fastener Pins in Clad 2024-T43
Aluminum Alloy Sheet
Table 45

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125,000 H.T. FLUSH-HEAD STEEL BOLTS

FASTENER (AN509 TYPE)
CLASS III HOLES CONSERVATIVE FOR TIGHTER FITS
FASTENER NOMINAL
DIAMETER (INCHES) 3/16 1/4 5/16 3/8 1/2
FASTENER
SHEAR STRENGTH, Lb 2071 3682 5750 8280 14730
CLAD 2024-T3 SHEET TO 0.249
MATERIAL CLAD 2024-T351 PLATE 0.250 AND OVER
SHEET NOMINAL
THICKNESS (INCHES) SHEAR ULTIMATE STRENGTH, Lb
0.032 493
0.040 657 761
0.050 903 1074 1244
0.063 1116 1439 1690 1887
0.071 1227 1683 1955 2235
0.080 1354 1848 2268 2600
0.090 1483 2031 2449 3022 3590
0.100 1626 2235 2647 3366 4292
0.125 1944 2622 3001 3838 5586
0.160 2071 3174 3501 4408 7482
0.190 3450 4053 5041 9018
0.250 3680 5106 6295 10959
0.312 3682 5550 7638 12678
0.375 5750 8280 13700
0.438 14700

NOTE: For bare sheet, bearing values may be rationed by Fbry (bare)/Fbru
(clad) where the shear ultimate is not exceeded.

Shear Joint Allowables for 125,000 H.T. 100°-Flush-Head

Steel Bolts in Machine Countersunk Clad 2024-T3 and
Clad 2024-T351 Aluminum Alloy Sheet and Plate
Table 46

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160,000 H.T. FLUSH-HEAD STEEL BOLTS

FASTENER (NAS1203, NAS333, NAS4403 TYPES)
CLASS III HOLES CONSERVATIVE FOR TIGHTER FITS
FASTENER NOMINAL
DIAMETER (INCHES) 3/16 1/4 5/16 3/8 1/2
FASTENER
SHEAR STRENGTH, Lb 2623 4660 7290 10490 18650
CLAD 2024-T3 SHEET TO 0.249
MATERIAL CLAD 2024-T351 PLATE 0.250 AND OVER
SHEET NOMINAL
THICKNESS (INCHES) SHEAR ULTIMATE STRENGTH, Lb
0.032 493
0.040 657 761
0.050 903 1074 1244
0.063 1116 1439 1690 1887
0.071 1227 1683 1955 2235
0.080 1354 1848 2268 2600
0.090 1483 2031 2449 3022 3590
0.100 1625 2235 2647 3366 4292
0.125 1944 2622 3001 3838 5586
0.160 2300 3174 3501 4408 7482
0.190 2575 3450 4053 5041 9018
0.250 2620 4155 5106 6295 10959
0.312 2623 4650 5550 7638 12678
0.375 4660 6345 8300 13700
0.438 7280 9090 15000
0.500 7290 10490 16940

NOTE: For bare sheet, bearing values may be rationed by Fbry (bare)/Fbru
(clad) where the shear ultimate is not exceeded.

This table may be used for all flush-type 100° installations, alloy
sheet or TI-6A1-4V pins (bolts, Hi-Loks, Lockbolts or Taper-Loks),
countersunk in aluminum alloys except as covered by other specific
tables in this section.

Shear Joint Allowables for 160,000 H.T. 100°-Flush-Head

Steel Bolts in Machine Countersunk Clad 2024-T3 and
Clad 2024-T351 Aluminum Alloy Sheet and Plate
Table 47

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Document Part No. RDN 306

FASTENER NAS1398 MS OR MW (MONEL), CR2563M*

FASTENER NOMINAL
DIAMETER (INCHES) 3/32 1/8 5/32 3/16
FASTENER
SHEAR STRENGTH, Lb 710 1090 1580
MATERIAL AISI 301 1/2 HARD STAINLESS STEEL
SHEET NOMINAL
THICKNESS (INCHES) SHEAR ULTIMATE STRENGTH, Lb
0.020 378 480 591
0.025 462 584 715
0.032 568 734 894
0.040 594 870 1094
0.050 632 915 1270
0.063 678 971 1335
0.071 706 1009 1380
0.080 710 1048 1428
0.090 1090 1473
0.100 1532
0.125 1580

NOTE: *Indicates Townsend Co. part number.

Shear Joint Allowables for NAS1298 (CR2563M) Blind, Protruding-Head

Locked-Spindle Monel Rivets in AISI 301
1/2 Hard Stainless Steel
Table 48

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NAS1398C (A286)
FASTENER *CR2663 *CR2643 (A286)
FASTENER NOMINAL
DIAMETER (INCHES) 1/8 5/32 3/16 1/8 5/32 3/16
FASTENER SINGLE
SHEAR STRENGTH, Lb 970 1490 2150 1230 1885 2720
ALLOY STEEL ALLOY STEEL
MATERIAL Ftu 180 ksi Ftu 180 ksi
SHEET NOMINAL
THICKNESS (INCHES) SINGLE SHEAR ULTIMATE STRENGTH, Lb
0.020 511 566 591 511 566 591
0.025 697 794 869 697 794 869
0.032 785 1112 1255 807 1112 1255
0.040 860 1211 1628 911 1246 1639
0.050 956 1325 1772 1043 1406 1833
0.063 970 1480 1958 1215 1615 2090
0.071 1490 2070 1230 1748 2240
0.080 2150 1885 2420
0.090 2610
0.100 2720

NOTE: *Indicates Townsend Co. part number.

Shear strength based on areas computed from nominal hole diameters,

Table 2, F.

Shear Joint Allowables of Blind, Protruding-Head

Locked-Spindle A286 Rivets in Alloy Steel
Table 49

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NAS1398B (5056) NAS13988D (2017) NAS11738B

FASTENER CR2263* CR2263* CR2249* (5056)
FASTENER
NOMINAL
DIA., IN. 1/8 5/32 3/16 1/4 1/8 5/32 3/16 1/4 1/8 5/32 3/16
FATENER
SHEAR
STRENGTH,
Lb 388 596 862 1550 494 755 1090 1970 504 784 1026
MATERIAL CLAD 2024-T3 AND HIGHER STRENGTH ALUMINUM ALLOYS
SHEET
NOMINAL
THICKNESS,
IN. SHEAR ULTIMATE STRENGTH, Lb
0.020 167 189 199 167 189 199 199 216 288
0.025 228 262 290 314 228 262 290 314 267 305 330
0.032 289 364 412 479 304 364 412 479 368 428 473
0.040 337 448 553 670 355 470 553 670 427 567 636
0.050 388 521 662 914 418 548 696 914 480 650 815
0.063 596 781 1145 494 647 816 1205 504 735 912
0.071 854 1240 710 894 1303 784 976
0.080 862 1350 755 975 1420 1026
0.090 1475 1069 1545
0.100 1550 1090 1670

NOTE: *Indicates Townsend Co. part number.

NAS1738E (CR2239) fasteners are similar to CR2249. Both have B (5056)

material sleeves; NAS1738E has inconel stem; NAS1738B has alloy steel
stem; therefore, values are applicable to both.

Shear Joint Allowables of Blind, Protruding-Head

Locked-Spindle Aluminum Alloy Rivets in Aluminum Alloy
Table 50

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FASTENER B100-T ALLOY STEEL (MS90353)

FASTENER NOMINAL
DIAMETER (INCHES) 5/32 3/16 1/4 5/16 3/8
FASTENER
SHEAR STRENGTH, Lb 2281 3062 5300 8280 11930
MATERIAL CLAD OR BARE 2024-T3 OR -T351
SHEET NOMINAL
THICKNESS (INCHES) SHEAR ULTIMATE STRENGTH, Lb
0.040 *320 *624
0.050 *586 *823
0.063 *789 *976 *1378
0.071 *945 *1071 *1500
0.080 *1132 *1252 *1638
0.090 *1336 *1492 *1789
0.100 *1543 *1735 *1983
0.125 1914 *2343 *2697 *2829
0.160 2281 2935 *3540 *4290 *3937
0.190 3062 4185 *5542 *5400
0.250 5300 7210 *8400
0.312 8280 *10530
0.375 11930

NOTES: 1. *= Test data based on 1.5 x yield. All other values based on
ultimate.

2. B100-T is Huck Mfg. Co. part number.

3. Substitute MS90354 for protruding head fastener.

Shear Joint Allowables of Blind, 100°-Flush-Head,

Steel Fasteners in Machine-Countersink Clad or
Bare 2024-T3 or T351 Aluminum Alloy
Table 51

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FASTENER SHEET MATERIAL

TI-PURE
TYPE AISI AND ALLOY
TYPE PART NO. MATERIAL HEAD 2014 2024 301 TI-6A1-4V STEEL
TABLE
MS20426AD 2117-T3 100° FLUSH 27
MS20426D 2117-T3 100° FLUSH 28
MS20427M MONEL 100° FLUSH 33 32
SOLID MS20470AD 2117-T3 PROTRUDING 10, 12 6, 8,
RIVET 14, 16 18, 20
MS20470D 2017-T3 PROTRUDING 11, 13 7, 9, 19,
15, 17 21
MS20470D 2024-T42 PROTRUDING 23, 25
MS20615M MONEL PROTRUDING 26
NAS1097AD 2117-T3 100° FLUSH 29 30
NAS1321AD 2017-T3 82° FLUSH 31
CR2643 A-286 PROTRUDING 49 49
MS90353 STEEL PROTRUDING 51
180KSI
NAS1398B 5056 PROTRUDING 50
BLIND NAS1398C A-286 PROTRUDING 49
RIVET NAS1398D 2017-T3 PROTRUDING 50
NAS1398MS MONEL PROTRUDING 48
NAS1398MW MONEL PROTRUDING 48
NAS1398B 5056 PROTRUDING 50

Summary of Shear Joint Strength

Allowables Data for Rivets
Table 52

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FASTENER SHEET MATERIAL

TI-PURE
TYPE AISI AND ALLOY
TYPE PART NO. MATERIAL HEAD 2014 2024 301 TI-6A1-4V STEEL
TABLE
STEEL PROTRUDIN 40, 43
AN# 125 ksi G
100° 46
STEEL FLUSH
BOLTS AN509 42, 45
AND STEEL PROTRUDIN
SCREWS EWSB22 220 ksi G
STEEL 41, 44
NAS1103 160 ksi
STEEL 100° 47
160ksi FLUSH
NAS1203
TI-6A1- 41, 44
4V PROTRUDIN
NAS6403 160 ksi G

Summary of Shear Joint Strength

Allowables Data for Threaded Fasteners
Table 52

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COUNTERSINKING

1. General

A. Countersinking is one method used to place the head of a fastener flush

or level with the exterior surface of a part which the fastener joins
to another part in a structure. The purpose is to provide a smoother
airflow over the exterior surface of an aircraft component or to
provide an even surface upon which another part or a piece of equipment
can bear.

The head of the fastener to be used has an inverted cone type of head
with 100-degree or 82-degree of included angle. Material is removed
from the surface of one of the parts being joined to provide a counter-
sunk recess which mates the head of the fastener. A counter sink
differs from a counterbore in that the counterbore has straight sides
which parallel the fastener hole axis and a bottom surface which is
normal (at 90-degrees) to the hole axis. (See Figure 1)

B. Flush fasteners do not have the same load carrying capabilities as

protruding-head fasteners. Flush fasteners generally carry only 80-
percent of the loads that a protruding-head fastener will bear. If it
becomes necessary to change more than one or two isolated existing
protruding-head fasteners to flush or countersunk fasteners, either the
diameter of the fasteners or their number must be increased by
approximately 25-percent to retain the same joint load-bearing
capabilities.

C. Countersinks may be milled into plate or sheet metal parts using either
stationary or portable hand-held equipment. Countersink milling tools
or cutters are either open or piloted. The piloted cutter has a pilot
pin on its axis which precedes the cutting edges and indexes the
fastener hole. The pilot guides the cutter so that it cuts an
indentation which is concentric with the hole axis and has smooth sides
which are free of tool-chatter marks. Care must be used to prevent the
cutter from penetrating so far into the sheet that the fastener head
will be lower than the sheet surface or that the entire length of the
hole through the sheet has been enlarged beyond the fastener diameter
limits. If the countersink penetrates the sheet too far, the strength
of the joint is reduced. (See Table I.) In general usage “cutter” is
dropped from the name of the tool and it is referred to as a
“countersink”.

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2. Equipment

A. Countersinking tools and equipment are divided generally into

stationary power equipment and hand-held portable equipment. When it is
possible to use stationary power equipment, it produces consistently
good countersinks much more rapidly.

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Countersinking Tools
Figure 1

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SR-224-065

NOTES:
1. AN5O9 head type fasteners include AN5O9, NAS333 through NAS336, NAS560,
NAS583 through NAS586, NAS1202 through NAS1206, NAS1456 through NAS1462,
NASl5O3 through NASl5O6, NAS1603 through NAS1606, NAS1703 through NAS1706
and R3008 screws, bolts, and lockbolts.
2. Where structural bonding in accordance with 54-05-06 metal bonding is
used, the combined thickness of bonded parts may be used for countersink-
ing of fasteners.
3. Minimum sheet thickness is given assuming fasteners are flush with surface
of sheet. Where fasteners are allowed below flush, increase the minimum
sheet thickness accordingly.
Minimum Allowable Sheet Thickness for 100-Degree Countersinking
Table I

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The stationary power equipment has the major disadvantages of requiring

lengthy set up time and disassembly or partial disassembly of parts
being worked. Stationary power equipment varies from drill presses
using open countersinks and movable work tables to sophisticated
Farnham or Sheridan counter sinking machines with foot pedal operation
of a preset automatic cycle, and with chip blowers to remove the
cuttings. Structural repair requirements, however, usually dictate that
part or all of the countersinking be done on the assembly or on parts
on a bench. This makes the use of small hand-held portable equipment
most advantageous.

B. The simplest countersinking equipment and the one which has the most
flexibility of application is the basic open countersink cutter
installed in a hand-held drill motor. Its entire application and
control is manual. Its cutting edges are placed against the edge of the
fastener hole on the surface to be countersunk, and it is rotated by
actuating the drill motor power button. The point of the cutter is
inserted in the fastener hole, and guides the cutter to keep the
countersink concentric with the hole. The operator continues the
cutting operation until he thinks it is sufficiently deep before
withdrawing the cutter. Be checks the countersink produced and repeats
the operation until the countersink depth and surface are acceptable.
The final test usually consists of dropping a sample fastener into the
countersink to check its fit. There are some disadvantages to this
manual operation.

(1) If the operator miscalculates, the countersink may be too deep.

(2) If the drill motor is improperly aligned, the countersink will not
be concentric with the fastener hole axis.

(3) The countersink cutter may not cut smoothly and thus leave chatter
marks on the sides of the countersunk hole.

(4) The number of checks required during the process makes it very time
consuming for large numbers of holes.

C. Use of a small machine-type portable tool called the stop-countersink

seems to be the most efficient method of producing large numbers of
consistently good countersinks. It takes up little more room than the
open countersink cutter, its setting is simple, and it can be used
repeatedly without resetting unless the surface contours of the part on

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which it is being used change. After the depth gage on the tool is set,
the tool does not have to be withdrawn for a depth check until the
operation is complete for each hole. The tool has a pilot on the cutter
which keeps the countersink concentric with the fastener hole and
prevents tool chattering against the countersink sides.

The stop mechanism base keeps the cutter aligned with the hole axis.
The only apparent disadvantage is that it must be periodically cleared
of cuttings and chips.

3. Equipment Use

A. Stationary Power Equipment.

The auxiliary equipment available, set-up procedure, and adjustments

are peculiar to the particular equipment being used, and should be
obtained from the manufacturer or vendor of the equipment such as:

Sheridan-Gray, Inc.

Division of Land M Corp. P.o. Box 40

Huntington Park, California 90255

or

Farnham Division, Lisk-Savory Corp.

901 Fuhrmann Boulevard

Buffalo, New York

B. Open Countersink Cutter.

The open countersink cutter has a smooth shank which fits into the
chuck of a manually operated hand drill, a hand-held portable drill
motor, or a drill press. It has cutting flutes which are sharpened in a
cone shape which ordinarily is at 100-degrees of included angle or
sometimes at 82-degrees. The open countersink has no pilot. Its cutting
edges are placed against the material to be milled or cut away, and the
cutter rotated by the tool in which it is held. (See Figure 1)

(1) Select countersink cutter with proper angle to match the head of
the flush fastener to be used.

(2) Place the countersink cutter shank in the chuck of the tool
selected for its rotation, and tighten the chuck securely. The
order of preference for tool selection is:

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(a) Drill press which provides best control but requires that the
part be disassembled from the other structure.

(b) Drill motor which provides power operation but must be

completely manually controlled for power application, cutting
angle, cutting pressure, and depth of cut.

(c) Hand drill which provides very fine cutting adjustments but is
extremely time consuming.

(3) Countersink one or more holes in a test strip and check the
indentation or cavity produced for angle of sides, depth, and
concentricity with fastener hole by dropping into it a sample of
the fastener to be used or with a Trulok countersink gage (A.G.
Heinze Co., Pasadena, CA.) or an equivalent gage. (See Tables I and
II)

(4) Countersink holes in work material in two or more steps. Check

countersink at each step to assure depth, angle, and concentricity
are correct and that sides of countersink indentation are smooth.

C. Stop-Countersink.

The stop-countersink (See Figure 1) has almost the same flexibility of

use as the open countersink, and is ordinarily used in a drill motor.
After setting and testing for depth of cut, it is almost as fast and
accurate when installed in a drill motor as when installed in a drill
press with the added advantage that it can be used in most applications
on the structure without disassembly. The piloted cutter is removable
and can be changed for cutters with different angle of cut and larger
or smaller pilots. The shaft of the micro-stop counter sinking tool
(stop-countersink) rotates on a bearing inside an adjustable “locking
sleeve and foot piece assembly”. The foot piece (or “stop” as it is
often called) threads onto the shaft bearing, enabling depth
adjustments to be made. Markings, indicating depth differentials in
0.001-inch increments, surround the beveled circumference of the
locking sleeve to aid in depth adjustments.

The pilot pin on the cutter guides it as it cuts into the material. The
pilot pin should be approximately 0.002-inch less in diameter than the
fastener hole. This permits the pilot to spin in the hole without
binding. Cutter pilots which are more than 0.002-inch smaller than the
hole size will allow the cutter to wobble or chatter, and result in a
lopsided or rough countersink.

(1) Check stop-countersink cutter to determine that:

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(a) Cutter angle is same as that of head of fastener to be used in

hole.

(b) Cutter pilot is correct diameter.

(c) Cutter is large enough to complete countersink operation.

(d) Cutter is securely tightened in shaft of tool.

Diameter of 100-Degree Countersink Holes

Table II

(2) Pull back locking sleeve from foot piece and rotate sleeve to
extend cutter. Drop sleeve back into original position to lock the
sleeve in that depth adjustment.

NOTE: Make sure that locking splines on sleeve and foot piece
intermesh; only then is the adjustment securely locked.

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(3) Test stop-countersink on test strip and adjust locking sleeve

until depth of cut is correct. Check countersunk cavity for depth,
angle of sides, and concentricity with fastener hole by dropping
into it a sample of the fastener to be used or with a Trulok
countersink gage (A.G. Heinze Co., Pasadena, CA.) or an equivalent
gage. See Tables I and II for countersink depth and countersink
diameter at surface of sheet.

(4) Use stop-countersink on work material.

(a) Insert cutter pilot into fastener hole.

(b) Rest foot piece against work material to align cutter with
hole axis.

(c) Bold foot piece of stop-countersink by hand to prevent it from

rotating against the work material.

(d) Apply power to drill motor and press down against stop-
countersink.

NOTE: The foot piece is spring loaded to cover the cutting

edges except when pressure is applied.

(e) Let cutter spin until it bottoms against the stop. Countersink
should be complete.

(5) Remove chips from cutter and countersink hole.

(6) Check countersink hole for accuracy before completing balance of

countersinking.

4. Countersink Repair Washer

A. When a flat sheet of material such as a doubler is placed over the top
of a countersunk hole which is used for a fastener, the void or cavity
of the countersink must be filled or the joint strength is reduced. A
special countersink repair washer may be fabricated and bonded into the
countersink cavity to provide the load-bearing surface required for
adequate joint strength. (See Figure 2 and Table III)

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Counter Repair Washer

Figure 2

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Countersink Repair Washer Dimensions

Table III

The repair washer may be fabricated from the head of a rivet which is
made of material that is compatible with the countersunk sheet, or it
may be made from bar stock. The material may be selected by reference
to 54-02-03, Table I and should be anodized or alodized as described in
54-02-03, Protective Treatment of Metal Repair Parts.

B. The washer should be fabricated and installed as follows:

(1) Determine a material that will be compatible to both the parent
material in which the countersink appears and the fastener, which
will occupy the hole.
(2) Fabricate the repair washer either from an acceptable rivet or from
bar stock. See Figure 2 and Table III for dimensions.
(3) Brush alodine on the repair washer as described in 54-02-03,
Protective Treatment of Metal Repair Parts, or use an anodize
process.
(4) Bond the repair washer in place using Type 1 bond as described in
54-05-06, Metal Bonding.

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HI-SHEAR BLIND ATTACHMENTS

1. General

A. It is recommended that installation of Hi-Shear blind attachments be

accomplished by mechanics thoroughly familiar with all requirements and
limitations of Hi-Shear attachments.

2. Selection of Hi-Shear Blind Bolts and Blind Nuts

A. Attachment Identification.

(1) Identification of attachments for a particular installation can be

made by referring to Figures 1 and 2, and Table I.

B. Attachment Grip Length

(1) When selecting a blind attachment, emphasis should be placed on

correct selection of grip length for the specific installation.

(2) The total thickness (determined by measuring the total thickness

of the parts to be attached) will be the grip length. Refer to
Figure 3 for nominal, minimum, and maximum material thickness for
each grip length.

C. Blind Bolt and Blind Nut Assembly Designation Code.

(1) Blind Bolt

-
Example: BB351 - 8 12

12/16 - or 3/4-inch grip length

8/32 - or 1/4-inch nominal diameter
Blind bolt assembly, which includes:
BB301-8-12 core bolt
BB321-8-12 sleeve
BB341-8 expander

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Hi-Shear Blind Bolt - Installation and Dimension

Figure 1

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SR-224-07
Hi-Shear Blind Bolt - Installation and Dimension (Rivet Head Series)
Figure 2

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Grip Variations for Blind Bolts and Blind Nuts

Figure 3

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ASSEMBLY MAXIMUM CORE

NUMBER HEAD TYPE TEMPERATURE BOLT SLEEVE EXPANDER
BB351 AN509 427°C (800°F) BB301 BB321 BB341
BB352 PROTRUDING 427°C (800°F) BB302 BB322 BB341
BB365 AN509 593°C (1100°F) BB309 BB335 BB341G
BB336 PROTRUDING 593°C (1100°F) BB316 BB336 BB341G
BB368 AN426 593°C (1100°F) BB309 BB332 BB341G
BB371 AN426 427°C (800°F) BB301F BB501 BB341
BN359 FLUSH HI-SHEAR 427°C (800°F) --- BN329 BB341
HEAD
BN360 FLUSH SHALLOW 427°C (800°F) --- BN330 BB341
HEAD
BN372 FLUSH SHALLOW 593°C (1100°F) --- BN502 BB341G
HEAD
*BN155 FLUSH SPECIAL 177°C (350°F) --- BN125- BB341-1032
1032
*BN157 FLUSH SPECIAL 177°C (350°F) --- BN127- BB341-1032
1032

* Keylock blind nut (5056 aluminum alloy) is available in -1032 thread only.

Hi Shear Blind Attachment Composite

Table I

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(2) Blind Nut

EXAMPLE: BN360 - 8 - 12

12/16 - OR 3/4-INCH GRIP LENGTH

1/4-inch diameter nut
Blind nut assembly, which includes:
BN330-428-12 sleeve
BB431-8 expander. Expander thread is
1/4-28UNF-3B.

3. Hole Preparation for Blind Attachments

A. Hole preparation for blind attachments must be prepared in accordance

with instructions contained in 54-04-01, and the surface must be free
of chatter marks.

B. When these attachments are used in applications where a close tolerance

fit is required, it is recommended that sleeve diameters of each
individual fastener be checked with a micrometer to determine necessary
hole size required to meet desired fit. Select a drill or reamer that
will produce a final hole of net fit to 0.001-inch clearance.

C. Before installation of the blind attachment, check the hole for proper
size, finish, and alignment. Remove any burrs and clean the chips from
between the faying surfaces.

4. Countersinking for Blind Attachments

A. Countersinks for blind attachments must be prepared in accordance with

the information shown in Figures 1 and 2.

5. Selection of Driving Tools

A. For selection of the proper driving tool for a specific size or type of
blind attachment, refer to:

(1) Blind bolt, Figure 4.

(2) Blind nut, Figure 5.

(3) Offset driving tools for blind bolts or nuts, Figure 6.

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SR-224-072
Driving Tools for Blind Bolts
Figure 4

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Driving Tools for Blind Nuts

Figure 5

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Offset Driving Tools for Blind Bolts and Blind Nuts

Figure 6

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6. Installation of Blind Attachments with Hand Tools

A. Before installation of blind attachments, make a test setup, using the

same hole size and material as the parts being assembled. Install a
blind attachment to check that the torque value of the torque wrench is
correct for an acceptable installation. Refer to Table II for the
correct driving tool and torque value for the blind attachment being
installed. In addition to the driving tools, a torque wrench, socket,
and socket wrench are required. Install blind attachments as shown in
Figure 7.

7. Band Driving Tools and Torque Values

A. Torque values depend on the torque wrench and crowfoot adapter being
used. The torque values shown in Table II are applicable only for the
crowfoot adapter listed.

8. Installation of Blind Attachments with Power Tools

A. Before installation of blind attachments on assembly, make a test

setup, using the same hole size and material thickness as the parts to
be assembled. Install a blind attachment to check the required driving
pressure of the power unit for an acceptable installation.

B. Adjust the pressure control knob on the power unit until the required
driving pressure is indicated on the pressure gage. Cycle the gun until
uniform correct pressure is obtained. Refer to Table II for driving
pressures.

C. Install blind attachments in accordance with Figure 8, steps 4 through

6 inclusive.

CAUTION: DO NOT OPERATE POWER UNIT AT CONTINUOUS HIGH PRESSURES WHEN THE GUN
IS NOT BEING USED.

9. Assembly of Driving Tools to Gun

A. Adjust the pressure control knob on the power unit until the driving
pressure is approximately 1000 psi. Cycle the gun by pressing the red
and blue buttons on the gun alternately until the correct pressure is
obtained.

B. Assemble driving tools to gun in accordance with Figure 8, steps 1

through 3 inclusive.

C. To disassemble tools from gun, refer to the note on Figure 8.

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Hand Tools for Blind Attachments

Figure 7

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Power Tools for Blind Attachments

Figure 8

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(3)0-1 IN. 1-2 IN. ACTUAL

GRIP RANGE GRIP RANGE CROWFOOT TORQUE
BLIND HAND TOOL MANDREL MANDREL ADAPTER VALUE
ATTACHMENTS PART NO. PART NO. PART NO. PART NO. IN-LBS.
(1)BB351-5 BH100-5-M2 M2-5 --- AN8506-6 55-66
BB352-5
(1)BB351-6 BH100-6-M2 M2-6 --- AN8503-6 76-87
BB352-6
(1)BB351-8 BH100-8-M2 M2-8 M3-8 AN8506-6 150-190
BB352-8
(1)BB351-10 BH100-10-M2 M2-10 M3-10 AN8506-6 295-320
BB352-10
(1)BB351-12 BH100-12-M2 M2-12 M3-12 AN8506-10 465-495
BB352-12
BB359-832 BH110-832-M2 M2-8 M3-8 AN8506-6 150-190
(2)BN157-1032 BH110-1032-M2 M2-1032 M3-1032 AN8506-6 216-242
BN359-1032
BN359-428 BH210-428-M2 M2-12 M3-12 AN8506-10 465-495
BN360-832 BH120-832-M2 M2-8 M3-8 AN8506-6 150-190
BN155-1032 BH120-1032-M2 M2-1032 M3-1032 AN8506-6 216-242
BN360-1032
BN360-428 BH220-428-M2 M2-12 M3-12 AN8506-10 465-495
BN361-428 BH230-425-M2 M2-12 M3-12 AN8506-10 465-495

NOTES: 1. Blind bolts BB365, BB366, BB368, and BB371 can be installed with the
same hand driving tools and torque values.

2. Blind nut BN155 can be installed with the same hand driving tools
and torque values.

3. When installation exceed the 1-inch grip range, use M3 series

mandrels in place of M2 series.

Hand Driving Tools and Torque Values

Table I

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10. Power Units for Driving Tools

A. Check power unit to be used for Hi-Shear attachment installations to

ensure that full range of driving pressures can be obtained. Refer to
Table III for correct driving pressures.

NOTE: Calibrate power unit air or hydraulic gages on monthly basis and
check to ensure full range of driving pressures can be obtained.
(Refer to Table III).

B. Start the electric motor to build up hydraulic pressure. Allow the

power unit to run at least 3 minutes before using the gun.

CAUTION: DO NOT OPERATE POWER UNIT AT CONTINUOUS HIGH PRESSURES WHEN GUN IS
NOT BEING USED.

11. Driving Pressures

A. The driving pressures shown in Table III must be used for installation
of Hi-Shear blind attachments.

Blind Nut Size Blind Nut Size BG1750 Gun (PSI) BG2500 Gun
- - - -440 500 - - -
- - - -632 800 - - -
-5 (5/32) - - - 500 250
-6 (3/16) - - - 700 350
-8 (1/4) -832 (8/32) 1100 650
- - - -1032 (10/32) 1850 950
-10 (5/16) - - - 1850 950
-12 (3/8) -428 (1/4-28) - - - 1450
-14 (7/16) -524 (5/16-24) - - - 1900
-16 (1/2) -624 (3/8-24) - - - 2250
- - - -720 (7/16-20) - - - 2250
- - - -280 (1/2-20) - - - 2250

Power Tool Driving Pressures

Table III

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12. Removal of Blind Attachments

A. Drill the sleeve to a depth slightly beyond the head diameter. Use
moderate pressure when drilling to prevent turning of the sleeve.

B. Pry off the head and drive out the sleeve, using punch slightly smaller
than the sleeve diameter.

13. Sources of Tools and Equipment

A. The following sources listed in Table IV may be contacted for

information concerning tools and equipment used for installation of Hi-
Shear blind attachments.

EQUIPMENT SOURCE
Driving tools (anvils, chucks) Hi-Shear Corporation
2600 W. 247th Street
Torrance, CA 90509
Hydraulic unit and gun (Large) Hi-Shear Corporation
BG2500
Hydraulic unit and gun (Small) Hi-Shear Corporation
BG1750
Hydraulic power unit B6701-3 Douglas Aircraft Co.
(0919) manufactured by Douglas 3855 Lakewood Blvd.
Long Beach, CA 90807

Tools and Equipment

Table IV

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HUCK PANEL FASTENERS

1. General

A fastener system called ASP Fasteners supplied by Buck Manufacturing

Company, Detroit, Michigan, 48207, provides a means of fastening metal
surfaces to soft core material in the MD-11 nacelle without crushing the
sandwich honeycomb core, and without the need for potting, bushing,
inserts or step hole preparation. The fasteners are available as either
protruding-head fastener and sleeve, flush fastener and sleeve, or a
combination of protruding and flush components. A shouldered pintailed
threaded fastener is installed in one side of a fastener hole in a
honeycomb sandwich panel, and a threaded sleeve installed over the pintail
from the other side of the panel and tightened until the heads of both
fastener and sleeve are properly seated. A locking collar is placed over
the pintail and swaged into place between the pintail and the sleeve head.
The collar swages into the longitudinal grooves in the fastener threads
and prevents the sleeve from loosening due to rotation on the pin threads.
The pintail breaks off when the locking collar is properly swaged into
place. (See Figure 1).

2. Installation

A. Select fastener pin, sleeve, and collar for installation in accordance

with Table I.

B. Drill fastener installation holes in accordance with instructions in

Table II.

C. Countersink fastener holes for countersunk head pins and sleeves in

accordance with instructions in Figure 2 and Tables III and IV. Apply
relief radius to fastener holes in panel skins for protruding-head
sleeves in accordance with instructions in Figure 3 and Table V.

D. Select fastener pin grip length in accordance with Table VI to provide

installed fastener pin protrusion as shown in Figures 4 and 5.

E. Install threaded fasteners with special installation tools required.

(See Figure 4).

NOTE: Special installation tool information may be obtained from Buck

Manufacturing Company, Detroit Michigan, 48207.

(1) Insert pin from side of assembly which has been prepared to accept
the fastener pin head.

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INSTALLED FASTENER COMBINATIONS C2S-013-00

Huck ASP Panel Fasteners

Figure 1

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1/64 IN.
PART OVERSIZE
CODE NUMBER MATERIAL DESCRIPTION SLEEVE COLLAR PART NO.
100° FLUSH HEAD PIN
AAA ASP-FF-DT STEEL, SHEAR HEAD PIN ASPF-S-DT ASP-LC-2AC 0ASPFF-DT
108 KSI AND SLEEVE, CAD.
PLATE
ASPFP-DT STEEL,
108 KSI SHEAR HEAD PIN ASPP-S-DT ASP-LC-2AC 0ASPFP-DT
PROTRUDING
SLEEVE, CAD.
XW 2ASPFF-DT STEEL, PLATE
108 KSI
SHEAR HEAD PIN 2ASPF-S-DT ASP-LC-2AC 02ASPFF-DT
2ASP509F-DT STEEL, AND SLEEVE, CAD.
108 KSI PLATE

2ASP509F-DT STEEL, TENSION HEAD AND 2ASPF-S-DT ASP-LC-2AC 02ASP509F-DT

108 KSI SLEEVE, CAD.
PLATE

TENSION HEAD 2ASPP-S-DT ASP-LC-2AC 02ASP509P-DT

PROTRUDING
SLEEVE, CAD.
PLATE

Standard and Oversize ASP Fasteners

Table I

DASH NO. NOMINAL SIZE (INCH) ACTUAL SIZE (INCH) HOLE SIZE (INCH)
-6 0.2031 (13/64) 0.2002-0.2025 0.203-0.208

08 0.2656 (17/64) 0.2630-0.2650 0.266-0.271

-10 0.3281 (21/64) 0.3255-0.3275 0.328-0.333

ASP Threaded Fastener Hole Sizes

(ASPFF, 2ASPFF, 2ASP509F, ASPFP, ASP100P. 2ASPFP, 2ASPFP509P)
Table II

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100°

COUNTERSINK
FOR HEAD

R TOP SKIN

CORE
D
BOTTOM SKIN
R

COUNTERSINK
FOR SLEEVE

100°
COUNTERSINK HOLE FOR ASP FASTENER PIN AND SLEEVE

MAX. PIN MAX. SLEEVE HEAD COUNTERSINK DIA. (A) RELIEF RADIUS (R)
DIA. (D) DIA. (D) ANGLE PIN SLEEVE PIN SLEEVE
in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm)
0.2025 (5,144) 0.2025 (5,144) 100° 0.302 (7,671) 0.302 (7,671) 0.025 (0,635) 0.025 (0,635)
0.2650 (6.731) 0.2650 (6,731) 100° 0.399 (10,135) 0.399 (10,135) 0.025 (0,635) 0.025 (0,635)
0.3275 (8,318) 0.3275 (8,318) 100° 0.479 (12,167) 0.479 (12,167) 0.025 (0,635) 0.025 (0,635)

COUNTERSINK DIMENSIONS FOR 2ASP-FF-DT PIN AND SLEEVE

TABLE III

MAX. PIN MAX. SLEEVE HEAD COUNTERSINK DIA. (A) RELIEF RADIUS (R)
DIA. (D) DIA. (D) ANGLE PIN SLEEVE PIN SLEEVE
in. (mm) in. (mm) in. (mm) in. (mm) in. (mm) in. (mm)
0.2025 (5,144) 0.2025 (5,144) 100° 0.386 (9,804) 0.386 (9,804) 0.025 (0,635) 0.025 (0,635)
0.2650 (6.731) 0.2650 (6,731) 100° 0.507 (12,878) 0.507 (12,878) 0.025 (0,635) 0.025 (0,635)
0.3275 (8,318) 0.3275 (8,318) 100° 0.634 (16,104) 0.634 (16,104) 0.025 (0,635) 0.025 (0,635)

COUNTERSINK DIMENSIONS FOR 2ASP-509F-DT PIN AND SLEEVE

C2S-014-00

TABLE IV

Countersink Dimensions for ASP Fasteners

Figure 2

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C2S-015-00
Relief Radius Dimensions for ASP Protruding Head Fasteners
Figure 3

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GRIP RANGE “Z” LENGTH

GRIP
NO. MIN. MAX. -6 -8 -10
05 0.251 0.312 1.09
06 0.313 0.375 1.16
07 0.376 0.438 1.22 1.38
08 0.439 0.500 1.28 1.44
09 0.501 0.562 1.34 1.50 1.63
10 0.563 0.625 1.41 1.56 1.69
11 0.626 0.688 1.47 1.63 1.75
12 0.689 0.750 1.53 1.69 1.82
13 0.751 0.812 1.59 1.75 1.88
14 0.813 0.875 1.66 1.81 1.94
15 0.876 0.938 1.72 1.88 2.00
16 0.939 1.000 1.78 1.94 2.07
17 1.001 1.062 1.84 2.00 2.13
18 1.063 1.125 1.91 2.06 2.19
19 1.126 1.188 1.97 2.13 2.25
20 1.189 1.250 2.03 2.19 2.32
21 1.251 1.312 2.09 2.25 2.38
22 1.313 1.375 2.16 2.31 2.44
23 1.376 1.438 2.22 2.38 2.50
24 1.439 1.500 2.28 2.44 2.57
25 1.501 1.562 2.34 2.50 2.63
26 1.563 1.625 2.41 2.56 2.69
27 1.626 1.688 2.47 2.63 2.75
28 1.689 1.750 2.53 2.69 2.82
29 1.751 1.812 2.59 2.75 2.88
30 1.813 1.875 2.66 2.81 2.94
31 1.876 1.938 2.72 2.88 3.00
32 1.939 2.000 2.78 2.94 3.07
33 2.001 2.062 2.84 3.00 3.13
34 2.063 2.215 2.91 3.06 3.19
35 2.216 2.188 2.97 3.13 3.25
36 2.189 2.250 3.03 3.19 3.32

Grip Length for ASP Threaded Fasteners

ASP-FF, ASP-FP, 2ASP-FF, 2ASP-509F, 2ASP-509P
Table VI

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ASP Fastener Installation Cycle

Figure 4

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Pin Protrusion and Collar Height Limits for ASP Threaded Fasteners
Figure 5
(2) Place sleeve over pintail and torque into position against
opposite side of assembly using pin internal wrench and sleeve
tool.

(3) Place lock collar over pintail.

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(4) Install swaging tool on pintail. Swage collar into sleeve recess
and pin slots to lock sleeve on pin and break-off pintail.

(5) Check that pin protrusion and collar height are within limits shown
in Figure 5 and Tables VII and VIII.

3. Removal

A. Remove fasteners using drill bushing and drill specified in Figure 6.

NOTE: Drill bushing information may be obtained from Buck

Manufacturing company, Detroit 7, Michigan 48207.

(1) Select proper bushing and drill in accordance with Table IX.

(2) Drill fastener pin and collar to depth shown in Table IX to remove
locking feature of collar. Restrain fastener pin from rotating
during drilling operation by use of internal wrench in pin
installation slot.

CAUTION: AVOID EXCESSIVE DRILL PRESSURE AND FIRMLY SUPPORT ALLEN

WRENCH IN PIN INSTALLATION SLOT DURING DRILLING OPERATION.

(3) Hold sleeve stationary with sleeve tool and rotate fastener pin
counterclockwise with internal wrench until pin and sleeve
separate.

(4) Remove fastener pin and sleeve from installation hole.

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C2S-018-00
ASP Threaded Fastener Lock Removal
Figure 6

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ENGINE NACELLE ALIGNMENT

1. General

A. The proper alignment of the CF6-80E1 engine nacelle and its relation to
the airplane is most important in that for each one degree of engine
misalignment approximately 1.75-percent of the engine forward thrust
vector is lost. Alignment of the engine is determined by checking
alignment reference points on each side of the engine to find the
engine longitudinal centerline planes and checking their relation to
the longitudinal centerline planes of the airplane.

B. Alignment of nacelle components such as inlet cowl, core engine exhaust

nozzle and core engine exhaust plug with engine centerline planes are
determined by reference to alignment points identified on each
component structure. Alignment of the fan cowl, core cowl, and thrust
reverser are a function of their hinged attachment to the airplane
engine pylon.

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AERODYNAMIC SMOOTHNESS

1. General

This section covers the requirements for the aerodynamic smoothness of

those portions of the nacelle which are exposed to airflow, both internal
and external. The smoothness requirements are divided into three
categories; mismatch at joints (including latches), waviness of skins, and
protrusion of flush-type fasteners.

2. Class Areas (See Figures 1 and 2)

Smoothness requirements for the nacelle are divided into two classes.
Class I has more stringent requirements than Class II. The classes are
defined as follows:

A. Class I:

(1) Leading edge of the inlet cowl, both internal and external
surfaces, to a station 15.00-inches aft of the leading edge.

(2) External surfaces aft of fan nozzle exit.

(3) External surface of exhaust centerbody aft of exhaust nozzle exit.

B. Class II:All surfaces not specifically included in Class I, including

internal flow lines of exhaust nozzle and centerbody.

3. Mismatch Limitations (See Figure 3)

NOTE: Mismatch is defined as an abrupt interruption in a surface from a

flat or continuously curved contour. Mismatch is plus when an edge
projects into the airstream, and is minus when the edge does not
project into the airstream.

A. Allowable Mismatch at Riveted, Spot-welded or Bolted Joints.

(1) Class I areas: ± 0.002-inches.

(2) Class II areas: ± 0.003-inches.

B. Allowable Mismatch at Specific Critical Points

(1) Fan cowl doors and core cowl doors exposed latch handles: +0.040-
inches, -0.050-inches.

(2) Inner surfaces of inlet cowl to engine fan inlet (at flange joint):
+0.065-inches, -0.085-inches.

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Aerodynamic Smoothness Class Areas

Figure 1

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Aerodynamic Smoothness Class Areas

Figure 2

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Aerodynamic Smoothness Class Areas

Figure 3

(3) Longitudinal joint (at bottom of nacelle) of the fan cowl doors:
0.105-inches maximum.

(4) Inlet cowl lip aft edges to forward edge inlet cowl outer barrel
and to forward edge of inlet cowl inner barrel: +0.000-inches to
-0.030-inches maximum.

(5) Fan cowl door at forward edge joint to inlet cowl and at aft edge
joint to fan reverser: ± 0.120-inches maximum and ± 0.045-inches
average. Average is to be determined as follows:

(a) Treat forward and aft edges separately when calculating

average.

(b) Measure mismatch every 18-inches starting at top. Both left

and right-hand sides.

(c) The average is the sum of the absolute values of the mismatch
measurements (i.e., the measurement without a positive or
negative sign) divided by the number of measurements.

NOTE: Each fan cowl door, left and right hand, is to be

considered separately.

(6) Fan cowl and core cowl to pylon apron longitudinal mismatch +0.000-
inches to +0.046-inches.

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(7) Fan reverser and core cowl mismatch +0.025-inches to -0.060-

inches.

(8) Core cowl wear strip to core cowl outer skin +0.025-inches to
–0.060-inches.

(9) Fan reverser fairing to core cowl fairing 0.000-inches to 0.095-

inches.

(10) Core cowl fairing to pylon fairing +0.000-inches to 0.l05-inches.

(11) Core cowl to forward fairing ± 0.l05-inches maximum.

(12) Fan cowl outer panel to pylon apron 0.000-inches to 0.105-inches.

(13) Inlet cowl inner barrel panel to inner barrel panel 0.015-inches
maximum.

(14) Inlet cowl inner barrel to engine fan case ± 0.075-inches maximum.

(15) Outer barrel lower panel to interphone jack and grounding access
panel 0.015 maximum all around.

(16) Inlet cowl outer barrel to lower panel anti-ice access panel 0.015-
inches maximum.

(17) Inlet cowl outer barrel lower panel exhaust access panel to nose
lip skin ± 0.015-inches maximum.

(18) Fan cowl pressure relief door to fan cowl outer skin 0.025-inches
maximum.

(19) Fan cowl oil tank access door to fan cowl outer skin 0.025-inches
maximum.

(20) Fan cowl ECU cooling inlet scoop to fan cowl outer skin 0.025-
inches maximum all around.

(21) Core cowl pressure relief door to core cowl outer skin 0.025-inches
maximum.

4. Waviness of Skin Limitations

NOTE: Waviness is defined as a smoothly varying interruption in a surface

from a flat or continuously curved contour. The distance between
adjacent high points in this variation is one wavelength. Slope is
defined as the degree of inclination from the nominal surface at
any point on a wave. (See Figure 4)

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A. Waviness Limitations to Class I Areas:

(1) Depth: 0.003-inch per inch of not to exceed 0.064-inch.

(2) Slope: D/X not to exceed 0.0l2-inch per inch

B. Waviness Limitations in Class II Areas:

(1) Depth: 0.006-inch per inch of , not to exceed 0.090-inch.

(2) Slope: D/x not to exceed 0.024-inch per inch

5. Protrusion of Flush Head Fasteners

A. Flush Bead Rivets:

(1) In Class I areas: ± 0.002-inch.

(2) In Class II areas: ± 0.003-inch.

B. Flush Head Bolts/Screws Mismatch:

(1) Flush to 0.011-inches below surface except on the fan cowl pressure
relief door and oil tank access door attach bolts These must be
only flush below the surface as noted.

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Skin Waviness Parameters

Figure 4

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STRUCTURAL IDENTIFICATION - INLET COWL

1. General

The inlet cowl has a lip, an inner barrel, a two-piece upper and lower
outer barrel, and a forward and aft bulkhead. A hexcel CR-3 honeycomb core
is installed between graphite composite plies and construct the inner and
two-piece outer barrels of the inlet cowl. Some of the structures,
including the lip, are made of aluminum. Other parts of the nose cowl are
made of titanium, inconel and clad aluminum.

2. Structure Description

The inlet cowl lip is made of bare aluminum and is attached to the forward
titanium bulkhead. The inlet cowl inner barrel consist of three acoustic
panels that contain a nonperforated hexcel CR-3 honeycomb core. The core
is installed between inner and outer fiberglass and graphite composite
plies. Aft of the inner barrel is the titanium engine attachment ring. The
inlet cowl outer barrel is also made of composite plies and has an upper
and a lower piece. The upper outer barrel has two access panels and an
access door which are made of aluminum. The lower outer barrel has an
aluminum air scoop, static grounding plate and a titanium air duct. The
inner and outer barrels are attached to the titanium forward and aft
bulkheads.

3. Structure Identification

Structures are identified in illustrations (figures) and tables. The

figures and tables do not identify fasteners. The structure is identified
on the figure by a number. The same number appears on the table that
follows the figure. The table gives the component description, gage
(thickness) and material. When a composite fabric ply is identified in the
material column, the warp direction will be given. The warp direction
(angle) is based on the manufacturer's drawings. The full view of the part
has a compass rose to help find the warp direction.

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1 2
8

CES-011-00

Engine Inlet Cowl

Figure 1 (Sheet 1)

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2
7

10

11

CES-012-00

Engine Inlet Cowl

Figure 1 (Sheet 2)

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL

1 ENGINE INLET COWL ASSY (REF)

2 UPPER OUTER BARREL ASSY (REF) (SEE FIGURE 5 FOR DETAILS)

3 INNER BARREL ASSY (REF) (SEE FIGURE 4 FOR DETAILS)

4 LOWER OUTER BARREL ASSY (REF) (SEE FIGURE 6 FOR DETAILS)

5 LIP ASSY (REF) (SEE FIGURE 2 FOR DETAILS)

6 EXHAUST PANEL ASSY (REF)

7 AFT BULKHEAD ASSY (REF) (SEE FIGURE 7 FOR DETAILS)

8 FORWARD BULKHEAD ASSY (REF) (SEE FIGURE 3 FOR DETAILS)

9 SPLICE STRAP (OUTER 0.032 CP-TITANIUM

SHEET, AMS4902 BARREL)

10 SPLICE STRAP (OUTER 0.032 CP-TITANIUM

SHEET, AMS4902 BARREL)

11 SPLICE STRAP (OUTER 0.032 CP-TITANIUM

SHEET, AMS4902 BARREL)

Engine Inlet Cowl

Table 1

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CES-013-00

Inlet Cowl Lip

Figure 2 (Sheet 1)

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9
8 7

2
3
4

1
3
6
NOTE:
TYPICAL
3 PLACES

13 7

NOTE:
TYPICAL
2 PLACES
5 10
6
11

12

4
5

CES-014-00

Inlet Cowl Lip

Figure 2 (Sheet 2)

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 INLET COWL LIP ASSY
2 LIP SKIN SEGMENT 0.095 2219-0 BARE ALUM SHEET,
(2,41) QQ-A-250/30 (HEAT TREAT T62)
3 LIP SKIN SEGMENT 0.095 2219-0 BARE ALUM SHEET,
(2,41) QQ-A-250/30 (HEAT TREAT T62)
4 LIP SKIN SEGMENT 0.095 2219-0 BARE ALUM SHEET,
(2,41) QQ-A-250/30 (HEAT TREAT T62)
5 LIP SKIN SEGMENT 0.095 2219-0 BARE ALUM SHEET,
(2,41) QQ-A-250/30 (HEAT TREAT T62)
6 LIP SKIN SEGMENT 0.095 2219-0 BARE ALUM SHEET,
(2,41) QQ-A-250/30 (HEAT TREAT T62)
7 DOUBLER 0.080 2219-0 BARE ALUM SHEET,
(2,03) QQ-A-250/30 (HEAT TREAT T62)
8 SPLICE 0.080 2219-0 BARE ALUM SHEET,
(2,03) QQ-A-250/30 (HEAT TREAT T62)
9 DOUBLER 0.080 2219-0 BARE ALUM SHEET,
(2,03) QQ-A-250/30 (HEAT TREAT T62)
10 DOUBLER 0.080 2219-0 BARE ALUM SHEET,
(2,03) QQ-A-250/30 (HEAT TREAT T62)
11 DOUBLER 0.080 2219-0 BARE ALUM SHEET,
(2,03) QQ-A-250/30 (HEAT TREAT T62)
12 DOUBLER 0.080 2219-0 BARE ALUM SHEET,
(2,03) QQ-A-250/30 (HEAT TREAT T62)
13 SPLICE 0.080 2219-0 BARE ALUM SHEET,
(2,03) QQ-A-250/30 (HEAT TREAT T62)
Inlet Cowl Lip
Table 2

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45

CES-015-00

Forward Bulkhead
Figure 3 (Sheet 1)

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27
33 28 7
26

29
7
23
25

11

40 41
30
24

34
23 22
16
39

7
38
35
8
9
23

10
21
36
37 13 12

18
19
17

15
14
CES-016-00

Forward Bulkhead
Figure 3 (Sheet 2)

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20

31

42

43

32 43
44

CES-017-0
CES-01 7-00
0

Forward Bulkhead
Figure 3 (Sheet 3)

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 OUTER CAP 0.125 6AL-4V TITANIUM SHEET,
(3,18) AMS4911, ANNEALED
2 OUTER CAP 0.125 6AL-4V TITANIUM SHEET,
(3,18) AMS4911, ANNEALED
3 OUTER CAP 0.125 6AL-4V TITANIUM SHEET,
(3,18) AMS4911, ANNEALED
4 OUTER CAP 0.125 6AL-4V TITANIUM SHEET,
(3,18) AMS4911, ANNEALED
5 OUTER CAP 0.125 6AL-4V TITANIUM SHEET,
(3,18) AMS4911, ANNEALED
6 OUTER CAP 0.125 6AL-4V TITANIUM SHEET,
(3,18) AMS4911, ANNEALED
7 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
8 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
9 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
10 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
11 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
12 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
13 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
Forward Bulkhead
Table 3 (Sheet 1)

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
14 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
15 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
16 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
17 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
18 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
19 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
20 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
21 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
22 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
23 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
24 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
25 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
26 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
Forward Bulkhead
Table 3 (Sheet 2)

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
27 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
28 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
29 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
30 SHIM 0.060 LAMINATED ALUM, MIL-S-22499,
(1,52) COMP 1, TYPE 1, CLASS 1
31 INNER CAP SPLICE 0.125 6AL-4V TITANIUM SHEET,
(3,18) AMS4911, ANNEALED
32 INNER CAP DOUBLER 0.125 6AL-4V TITANIUM SHEET,
(3,18) AMS4911, ANNEALED
33 INNER CAP DOUBLER 0.125 6AL-4V TITANIUM SHEET,
(3,18) AMS4911, ANNEALED
34 INNER CAP 0.125 6AL-4V TITANIUM SHEET,
(3,18) AMS4911, ANNEALED
35 INNER CAP 0.125 6AL-4V TITANIUM SHEET,
(3,18) AMS4911, ANNEALED
36 INNER CAP 0.125 6AL-4V TITANIUM SHEET,
(3,18) AMS4911, ANNEALED
37 INNER CAP 0.125 6AL-4V TITANIUM SHEET,
(3,18) AMS4911, ANNEALED
38 INNER CAP 0.125 6AL-4V TITANIUM SHEET,
(3,18) AMS4911, ANNEALED
39 INNER CAP 0.125 6AL-4V TITANIUM SHEET,
(3,18) AMS4911, ANNEALED
Forward Bulkhead
Table 3 (Sheet 3)

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
40 INNER CAP 0.125 6AL-4V TITANIUM SHEET,
(3,18) AMS4911, ANNEALED
41 INNER CAP 0.125 6AL-4V TITANIUM SHEET,
(3,18) AMS4911, ANNEALED
42 BRACKET 0.071 625 INCONEL SHEET, AMS5599
(1,80)
43 BRACKET 0.063 625 INCONEL SHEET, AMS5599
(1,60)
44 FILLER 0.063 2024-T3 CLAD ALUM SHEET,
(1,60) QQ-A-250/4
45 DOUBLER 0.125 6AL-4V TITANIUM SHEET,
(3.175 mm) AMS4911, ANNEALED
Forward Bulkhead
Table 3 (Sheet 4)

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12 1
RADIAL
11 355°
2

10

9
4

RADIAL
114°
8

RADIAL 5
236° 6

CES-001-00
Inner Barrel
Figure 4 (Sheet 1)

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14
2
13

14

16
15

CES-002-00

Inner Barrel
Figure 4 (Sheet 2)

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14
17
2

14

5
9 3
12

CES-003-00

Inner Barrel
Figure 4 (Sheet 3)

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15
14
16

NOTE: TYPICAL 36 LOCATIONS

CES-004-00

Inner Barrel
Figure 4 (Sheet 4)

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5
9
12

OUTER SKIN
6
8
11

CORE

INNER SKIN

NOTE: TYPICAL 3 PANELS

CES-005-00

Inner Barrel
Figure 4 (Sheet 5)

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PANEL RADIAL
SPLIT

0°

-45° 45°

90°

PLY WARP
DIRECTION

PANEL RADIAL
SPLIT

NOTE: OUTER SKIN, VIEW LOOKING INBOARD

TYPICAL 3 PANELS CES-006-00

Inner Barrel
Figure 4 (Sheet 6)

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18 21
18 21 20 18
19 20

CORE
SURFACE
20

22 18
CORE
21 SURFACE

20

22
19
19
22

20

CORE
21
23 SURFACE
18 21
20

19 18
18 22
CORE 18
SURFACE
20
23
18
CES-007-00

Inner Barrel
Figure 4 (Sheet 7)

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24
PANEL RADIAL
SPLIT

25

30

28
RIBB0N
DIRECTION
27

26

25
PANEL RADIAL
24 SPLIT

NOTE: CORE STRUCTURE, VIEW LOOKING INBOARD

TYPICAL 3 PANELS CES-008-01
Inner Barrel
Figure 4 (Sheet 8)

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PANEL RADIAL
SPLIT

0°
-45° 45°

90°
PLY WARP
DIRECTION

PANEL RADIAL
SPLIT

NOTE: INNER SKIN, VIEW LOOKING INBOARD

TYPICAL 3 PANELS CES-009-00

Inner Barrel
Figure 4 (Sheet 9)

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20 20 18
18 18 23 23
29 20
22
20

23
19
21 22
18 AIR PASSAGE
(7 PLIES) SURFACE
23

20

23
18 (12 PLIES)
22
22
AIR PASSAGE
29 SURFACE 29
AIR PASSAGE
22 SURFACE
22
18
(7 PLIES)

23
20
23
18
23 22 22 (12 PLIES)
18 20 29 21

19
23

20
18
18

AIR PASSAGE
SURFACE
CES-010-00

Inner Barrel
Figure 4 (Sheet 10)

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 INLET BARREL ASSEMBLY
2 ATTACH RING SEGMENT 0.100 2024-0 ALUM EXTRUSION
(2,54) QQ-A-200/3 (HEAT TREAT T62)
3 FRAME 0.050 2024-0 BARE ALUM SHEET,
(1,27) QQ-A-250/5 (HEAT TREAT T42)
4 UPPER LH PANEL ASSEMBLY
5 SPLICE STRAP 0.050 2024-0 BARE ALUM SHEET,
(1,27) QQ-A-250/5 (HEAT TREAT T42)
6 SPLICE STRAP 0.071 2024-0 BARE ALUM SHEET,
(1,80) QQ-A-250/5 (HEAT TREAT T42)
7 LOWER PANEL ASSEMBLY
8 SPLICE STRAP 0.071 2024-0 BARE ALUM SHEET,
(1,80) QQ-A-250/5 (HEAT TREAT T42)
9 SPLICE STRAP 0.050 2024-0 BARE ALUM SHEET,
(1,27) QQ-A-250/5 (HEAT TREAT T42)
10 UPPER RH PANEL ASSEMBLY
11 SPLICE STRAP 0.071 2024-0 BARE ALUM SHEET,
(1,80) QQ-A-250/5 (HEAT TREAT T42)
12 SPLICE STRAP 0.050 2024-0 BARE ALUM SHEET,
(1,27) QQ-A-250/5 (HEAT TREAT T42)
13 SPLICE 0.100 2024-0 BARE ALUM SHEET,
(2,54) QQ-A-250/5 (HEAT TREAT T42)
14 ATTACH BRACKET 7175-T66 ALUM FORGING, AMS4148
15 SHIM 0.050 LAMINATED ALUM, MIL-S-22499
(1,27) TYPE 2, CLASS 1
16 SHIM 0.062 LAMINATED ALUM, MIL-S-22499
(1,57) TYPE 2, CLASS 1
Inner Barrel
Table 4 (Sheet 1)

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
17 SPLICE 0.050 2024-0 CLAD ALUM SHEET,
(1,27) QQ-A-250/5 (HEAT TREAT T42)
18 COMPOSITE PLY 0.005 FIBERGLASS FABRIC, WARP
(0,13) DIRECTION OPTIONAL,
EA-9101/120, V12405
19 COMPOSITE PLY 0.0145 GRAPHITE FABRIC, 90 DEGREE
(0,37) WARP, STYLE AH370-5H/3501-5A,
AS4 FIBER, VOCZA6
20 COMPOSITE PLY 0.0145 GRAPHITE FABRIC, +45 DEGREE
(0,37) WARP, STYLE AH370-5H/3501-5A,
AS4 FIBER, VOCZA6
21 COMPOSITE PLY 0.0145 GRAPHITE FABRIC, -45 DEGREE
(0,37) WARP, STYLE AH370-5H/3501-5A,
AS4 FIBER, VOCZA6
22 COMPOSITE PLY 0.011 GRAPHITE FABRIC, 0 DEGREE
(0,28) WARP, STYLE AH370-5H/3501-5A,
AS4 FIBER, VOCZA6
23 COMPOSITE PLY 0.0145 GRAPHITE FABRIC, 0 DEGREE
(0,37) (0,37) WARP, STYLE AH370-5H/
3501-5A, AS4 FIBER, VOCZA6
24 CORE 1.064 NONPERFORATED HONEYCOMB, 5052
(27,03) AL ALLOY, (OPTIONAL 5056 AL
ALLOY), 1/8 INCH CELL, 0.003
FOIL GAGE, 12 LB/CU FT.,
HEXCEL CR-3, V94566
25 CORE 0.900 NONPERFORATED HONEYCOMB,
(22,86) 6-20RDCB-N, Tl-3AL-2.5V, 3/8
INCH CELL, 0.002 FOIL GAGE,
3.1 LB/CU FT.
Inner Barrel
Table 4 (Sheet 2)

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
26 CORE 1.122 NONPERFORATED HONEYCOMB, 5052
(28,50) AL ALLOY, (OPTIONAL 5056 AL
ALLOY), 1/8 INCH CELL, 0.003
FOIL GAGE, 12 LB/CU FT.,
HEXCEL CR-3, V94566
27 SEPTUM SKIN 0.007 WOVEN WIRE
(0,18)
28 CORE 0.250 NONPERFORATED HONEYCOMB,
(0,64) 6-20RDCB-N, Tl-3AL-2.5V, 3/8
INCH CELL, 0.002 FOIL GAGE,
3.1 LB/CU FT.
29 COMPOSITE PLY 0.011 GRAPHITE FABRIC, 0 DEGREE
(0,28) WARP, STYLE AH370-5H/3501-5A,
AS4 FIBER, VOCZA6
30 CORE 1.079 NONPERFORATED HONEYCOMB, 5052
(27,41) AL ALLOY, (OPTIONAL 5056 AL
ALLOY), 1/8 INCH CELL, 0.003
FOIL GAGE, 12 LB/CU FT.,
HEXCEL CR-3, V94566
Inner Barrel
Table 4 (Sheet 3)

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1
4

2
3

CES-018-00

Upper Outer Barrel

Figure 5 (Sheet 1)

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11

13

12

10

9
7
8

VIEW LOOKS UP AND OUTBOARD

CES-019-00

Upper Outer Barrel

Figure 5 (Sheet 2)

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INLET RADIAL
270°

0°
+45° -45°

90°
1 PLY WARP
DIRECTION

4 PLY
BASIC SKIN

INLET RADIAL
0°

CORE RIBBON
FRAMES DIRECTION

3 PLY
BASIC SKIN

NOTE:
VIEW LOOKING OUTBOARD
INLET RADIAL
90° CES-020-00

Upper Outer Barrel

Figure 5 (Sheet 3)

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17 14
PANEL
EDGE

15 15 17
15 14 15 14
16 14 15 15

14 15 15 14 17

NOTE: FRAME AND DOOR

REMOVED FOR CLARITY
17 15 14 15 15 14
AIR PASSAGE
SURFACE

18
17

3 PLY 20
18 18
BASIC
17 SKIN
PANEL 14 14 17
EDGE

15 15
16 15
15 14 AIR PASSAGE
14
SURFACE

CES-021-01
Upper Outer Barrel
Figure 5 (Sheet 4)

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18

17

20
18 18 17
17 14
14
15

15 16 PANEL
15 15
14 14 EDGE
AIR PASSAGE
SURFACE

17 14 17
DOOR
CUTOUT
EDGE

15
16
AIR PASSAGE 15
14 NAC STA
SURFACE 137.240
NOTE: FRAME REMOVED
FOR CLARITY

CES-022-01
Upper Outer Barrel
Figure 5 (Sheet 5)

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17 NOTE: TYPICAL FOR 3

18
18 FRAME LOCATIONS
18

20

AIR PASSAGE 14 15 PANE

SURFACE 16 EDGE
15
14

NOTE: TYPICAL FOR 3 18 18 18

FRAME LOCATIONS

20
17

14
PANEL 15
15
EDGE 14
15 17
14
15 AIR PASSAGE
15 SURFACE
14

CES-023-01
Upper Outer Barrel
Figure 5 (Sheet 6)

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PANEL
14 EDGE
AIR PASSAGE 15
SURFACE 16
15
14

17 19

14
15 AIR PASSAGE
15
14 SURFACE

CES-024-01
Upper Outer Barrel
Figure 5 (Sheet 7)

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 UPPER OUTER BARREL PANEL
ASSRMBLY
2 ACCSESS PANEL 0.071 2024-0 CLAD ALUM SHEET,
(1.80) QQ-A-250/5 (HEAT TREAT T42)
3 ACCSESS PANEL 0.071 2024-0 CLAD ALUM SHEET,
(1.80) QQ-A-250/5 (HEAT TREAT T42)
4 FRAME 0.071 2024-0 ALUM EXTRUSION
(1.80) QQ-A-200/3 (HEAT TREAT T42)
5 SPLICE 0.071 2024-0 CLAD ALUM SHEET,
(1.80) QQ-A-250/5 (HEAT TREAT T42)
6 DOUBLER 0.032 2024-0 CLAD ALUM SHEET,
(0.81) QQ-A-250/5 (HEAT TREAT T42)
7 SHIM 0.160 2024-T3 BARE ALUM SHEET
(4.06) QQ-A-250/4
8 SHIM 0.063 LAMINATED ALUM, MIL-S-22499,
(1.60) COMP 1, TYPE 1, CLASS 1
9 BRACKET 0.050 2024-T351 ALUM ALLOY,
(1.27) QQ-A-225/6 OR AMS4119
10 WEAR STRIP 0.020 301 CRES STEEL SHEET,
(0.51) MIL-S-5059, FINISH 2B
11 DOOR 0.080 2024-T3 CLAD ALUM SHEET,
(2.03) QQ-A-250/5
12 SPACER 0.050 2024-T3 BARE ALUM SHEET,
(1.27) QQ-A-250/4
13 SPACER 0.050 2024-T3 BARE ALUM SHEET,
(1.27) QQ-A-250/4
Upper Outer Barrel
Table 5 (Sheet 1)

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
14 COMPOSITE PLY 0.0145 GRAPHITE FABRIC, 0 DEGREE
(0,368) WARP, STYLE AH370-5H/3501-5A,
AS4 FIBER, VOCZA6
15 COMPOSITE PLY 0.0145 GRAPHITE FABRIC, 45 DEGREE
(0,368) (0,368) WARP, STYLE AH370-5H/
3501-5A, AS4 FIBER, VOCZA6
16 COMPOSITE PLY 0.0145 GRAPHITE FABRIC, 90 DEGREE
(0,368) (0,368) WARP, STYLE AH370-5H/
3501-5A, AS4 FIBER, VOCZA6
17 COMPOSITE PLY 0.005 FIBERGLASS FABRIC, WARP
(0,13) DIRECTION OPTIONAL,
EA-9101/120, V12405
18 COMPOSITE PLY 0.0055 GRAPHITE TAPE, 0 DEGREE WARP,
(0,139) CYCOM 985-1, AS4 FIBER, V07542
19 COMPOSITE PLY 0.0145 GRAPHITE FABRIC, WARP DEGREE
(0,368) OPTIONAL, STYLE AH370-5H/3501-
5A, AS4 FIBER, VOCZA6
20 FRAME CORE 3.000 NONPERFORATED HONEYCOMB, 5052
(76,20) AL ALLOY, (OPTIONAL 5056 AL
ALLOY), 1/8 INCH CELL, 0.001
FOIL GAGE, 4.5 LB/CU FT.,
HEXCEL CR-3, V94566
Upper Outer Barrel
Table 5 (Sheet 2)

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1 2
2

4
1 5
3

CES-025-00

Lower Outer Barrel

Figure 6 (Sheet 1)

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10
1

9 8

9
9
10

CES-026-00

Lower Outer Barrel

Figure 6 (Sheet 2)

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21
20

22

19
21
18

CES-027-00

Lower Outer Barrel

Figure 6 (Sheet 3)

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INLET RADIAL 90°

1 0°
-45° 45°

90°
PLY WARP
DIRECTION

INLET RADIAL 180°

CORE RIBBOW
DIRECTION

FRAMES

NOTE:
VIEW LOOKING OUTBOARD

INLET RADIAL 270°

CES-028-00

Lower Outer Barrel

Figure 6 (Sheet 4)

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15
14

3 PLY 17
BASIC 15 15
SKIN
11
11 14

PANEL 12
13 11
EDGE 12 12
11 AIR PASSAGE
SURFACE

14 14 14
14

12 11
13 12 12
11 12
AIR PASSAGE NOTE: FRAME REMOVED
SURFACE FOR CLARITY

CES-029-01
Lower Outer Barrel
Figure 6 (Sheet 5)

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14 14
14 14

AIR PASSAGE 11
SURFACE 12 12 13
11 12

238)*6%1)6)13:)(*36'0%6-8=

238)*6%1)6)13:)(*36'0%6-8= 15
14

3 PLY 17
BASIC 15 15
14 SKIN
11 11 14

PANEL 12
EDGE 13 12
11
11 12
AIR PASSAGE
SURFACE

CES-030-0
Lower Outer Barrel
Figure 6 (Sheet 6)

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NOTE: TYPICAL FOR 3

FRAME LOCATIONS 15 15
15

17
14

PANEL
EDGE
12 11
13 AIR PASSAGE
12 SURFACE
11

15 15 15
NOTE: TYPICAL FOR 3
FRAME LOCATIONS

17
14

12 11 PANE
12
11 EDGE
12
11
AIR PASSAGE 12
12
SURFACE 11
CES-031-01
Lower Outer Barrel
Figure 6 (Sheet 7)

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PANEL
11
EDGE 12 AIR PASSAGE
13 SURFACE
12
11

16
14 16

11
AIR PASSAGE 15
11
SURFACE

CES-032-01
Lower Outer Barrel
Figure 6 (Sheet 8)

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 LOWER OUTER BARREL PANEL
ASSRMBLY
2 FRAME 0.071 2024-0 ALUM EXTRUSION
(1,80) QQ-A-200/3, (HEAT TREAT T42)
3 DOUBLER 0.032 2024-T3 CLAD ALUM SHEET,
(0,81) QQ-A-250/5
4 SHIM 0.032 2024-T3 CLAD ALUM SHEET,
(0,81) QQ-A-250/5
5 SCOOP ASSEMBLY 2024-T3 CLAD ALUM SHEET,
QQ-A-250/5
6 SUPPORT 0.063 2024-T3 CLAD ALUM SHEET,
(1,60) QQ-A-250/5
7 DOUBLER 0.090 2024-T3 CLAD ALUM SHEET,
(2,29) QQ-A-250/5
8 PLATE 0.071 LAMINATED ALUM, MIL-S-22499,
(1,80) COMP 1, TYPE 1, CLASS 1
9 BRACKET 0.071 2024-TO BARE ALUM SHEET,
(1,80) QQ-A-250/5 (HEAT TREAT T42)
10 BRACKET 0.050 2024-TO BARE ALUM SHEET,
(1,27) QQ-A-250/5 (HEAT TREAT T42)
11 COMPOSITE PLY 0.050 GRAPHITE FABRIC 0 DEGREE WARP,
(1,27) STYLE AH370-5H/3501-5A, AS4
FIBER, VOCZA6
12 COMPOSITE PLY GRAPHITE FABRIC 45 DEGREE
WARP, STYLE AH370-5H/3501-5A,
AS4 FIBER, VOCZA6
13 COMPOSITE PLY GRAPHITE FABRIC 90 DEGREE
WARP, STYLE AH370-5H/3501-5A,
AS4 FIBER, VOCZA6
Lower Outer Barrel
Table 6 (Sheet 1)

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
14 COMPOSITE PLY 0.005 FIBERGLASS FABRIC, WARP
(0,13) DIRECTION OPTIONAL,
EA-9101/120, V12405
15 COMPOSITE PLY 0.0055 GRAPHITE TAPE, 0 DEGREE WARP,
(0,139) CYCOM 985-1, AS4 FIBER,
V07542
16 COMPOSITE PLY 0.0145 GRAPHITE FABRIC, WARP DEGREE
(0,368) OPTIONAL, STYLE AH370-5H/3501-
5A, AS4 FIBER, VOCZA6
17 FRAME CORE 3.000 NONPERFORATED HONEYCOMB, 5052
(26,20) AL ALLOY, (OPTIONAL 5056 AL
ALLOY), 1/8 INCH CELL, 0.001
FOIL GAGE, 4.5 LB/CU FT.,
HEXCEL CR-3, V94566
18 PANEL 0.071 6AL-4V TITANIUM SHEET,
(1,80) AMS4911, ANNEALED
19 DUCT 0.071 6AL-4V TITANIUM SHEET,
(1,80) AMS4911, ANNEALED
20 DUCT 0.071 2024-T3 CLAD ALUM SHEET,
(1,80) QQ-A-250/5
21 SHIM 0.071 LAMINATED ALUM, MIL-S-22499,
(1,80) COMP 1, TYPE 1, CLASS 1
Lower Outer Barrel
Table 6 (Sheet 2)

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4
3

3 2
3

NOTE: ATTACH RING SEGMENT

REMOVED FOR CLARITY

2
3

CES-033-00

Aft Bulkhead
Figure 7 (Sheet 1)

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7
6
6

355°
6
RADIAL
SPLIT

95° 8
RADIAL
SPLIT

CES-034-00

Aft Bulkhead
Figure 7 (Sheet 2)

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115°
RADIAL
SPLIT

2 6

215°
6
RADIAL
SPLIT
10

6
CES-035-00

Aft Bulkhead
Figure 7 (Sheet 3)

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335°
5 RADIAL
11
SPLIT

295°
RADIAL
SPLIT

7
6

6
235°
RADIAL
SPLIT

8 CES-036-00

Aft Bulkhead
Figure 7 (Sheet 4)

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14

13

12

15

NOTE: TYPICAL 2 PLACES

CES-037-01

Aft Bulkhead
Figure 7 (Sheet 5)

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 WEB 0.050 6AL-4V TITANIUM SHEET,
(1,27) AMS4911, ANNEALED
2 WEB 0.063 2024-T3 BARE ALUM SHEET,
(1,60) QQ-A-250/4
3 LIGHTNING STRIP 0.063 2024-T3 CLAD ALUM SHEET,
(1,60) QQ-A-250/5
4 FILLER 0.250 2024-T351 BARE ALUM SHEET, QQ-
(6,35) A-250/4
5 STIFFENER 0.050 6AL-4V TITANIUM SHEET,
(1,27) AMS4911, ANNEALED
6 STIFFENER 0.050 2024-0 BARE ALUM SHEET,
(1,27) QQ-A-250/4 (HEAT TREAT T62)
7 WEB 0.050 2024-T3 BARE ALUM SHEET,
(1,27) QQ-A-250/4
8 STIFFENER 0.063 2024-0 BARE ALUM SHEET,
(1,60) QQ-A-250/4 (HEAT TREAT T62)
9 COVER 0.050 2024-T3 BARE ALUM SHEET,
(1,27) QQ-A-250/4
10 DOUBLER 0.063 2024-T3 BARE ALUM SHEET,
(1,60) QQ-A-250/4
11 DOUBLER 0.063 6AL-4V TITANIUM SHEET,
(1,60) AMS4911, ANNEALED
12 SUPPORT 0.050 2024-0 BARE ALUM SHEET,
(1,27) QQ-A-250/4 (HEAT TREAT T&2)
13 SUPPORT 0.071 2024-0 BARE ALUM SHEET,
(1,80) QQ-A-250/4 (HEAT TREAT T&2)
14 FILLER 0.071 6AL-4V TITANIUM SHEET,
(1,80) AMS4911, ANNEALED
15 FILLER 0.071 2024-T3 CLAD ALUM SHEET,
(1,80) QQ-A-250/5
Aft Bulkhead
Table 7

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INLET COWL ALLOWABLE DAMAGE

1. General

A. Allowable damage data permits an operator to determine if a damaged

inlet cowl can be returned to service without repair.

Damage permitted by this data will have no significant effect on

the strength or fatigue life of the structure, which will still be
capable of fulfilling its design function.

All damage limits assume that exposed edges do not protrude from
skin contour. Such damage should be reworked to remove or feather
protrusions. Hole and cracks in pressure boundaries must be sealed
with appropriate tape material.

B. Allowable Damage

(1) Unlimited Usage

(a) Minor damage not affecting the structural integrity or

functional capability of the component and requiring no repair
over the aircraft design life.

(2) Time Limited Usage

(a) Minor damage not affecting the structural integrity of the

component in normal operation, that could reduce design life
of component. Damage must be permanently repaired not later
than the next maintenance “C” check. The location and size of
the damage is to be noted and checked to ensure that the
damage has not grown beyond the allowable damage limits.

C. Damage Types

(1) Composite Materials - The types of damage permitted to the inlet

cowl outer barrel are defined below. They do not include damage to
surface finish such as paint. (See Figure 101)

Abrasion - A damaged area which results in a cross-sectional

area change due to scuffing, rubbing, scraping, or
other surface erosion. An abrasion is usually rough
and irregular.

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Gouge - A damaged area of any size which results in a cross-

sectional area change. It is usually caused by
contact with a relatively sharp object which
produces a continuous, sharp or smooth channel-like
groove in the material.

Nick - A local gouge with sharp edges. Consider a series of

nicks in a line pattern to be the equivalent of a
gouge.

Scratch - A line of damage in the material and results in a

cross sectional area change. It is usually caused
by contact with a very sharp object.

Crack - A fracture or complete break in the material. It

appears as an irregular line.

Hole - A complete penetration of the material.

Void/Disbond - Separation of the face sheet from honeycomb core.

Delamination - Separation of the bonded laminated material plies

from each other.

(2) Aluminum Sheet Metal Structures - The types of damage permitted to

the inlet lip are defined below. They do not include damage to
surface finish such as paint. (See Figure 102)

Abrasion/

Chafe/

Wear - A damaged area which results in a cross-sectional

area change due to scuffing, rubbing, scrapping or
other surface erosion. An abrasion is usually rough
and irregular.

Gouge - A damaged area of any size which results in a cross-

sectional area change. It is usually caused by
contact with a relatively sharp object which
produces a continuous, sharp or smooth channel-like
groove in the material.

Nick - A local gouge with sharp edges. Consider a series of

nicks in a line pattern to be the equivalent of a
gouge.

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Scratch - A line of damage in the material and results in a

cross sectional area change. It is usually caused
by contact with a very sharp object.

Crack - A fracture or complete break in the material. It

appears as an irregular line.

Dent - Normally a damage area which is depressed with

respect to its normal contour. There is no cross-
sectional area change in the material. Area
boundaries are smooth, its form is generally the
result of contact with a relatively smooth
contoured object.

Buckle - A buckle is similar to a dent but is caused by an

overload situation or adjacent damage. It may
protrude and/or be indented with respect to the
contour.

Hole - A hole constitutes a complete penetration of the

material.

(3) Titanium Structures - The types of damage permitted to the inlet

cowl forward and aft bulkheads are defined below. (See Figure 102.)
Buckle - Similar to a dent but is caused by an overload
situation or adjacent damage. It may protrude and/
or be indented with respect to the contour.

Crack - A fracture or complete break in the material. It

appears as an irregular line.

Gouge - A damaged area of any size which results in a cross-

sectional area change. It is usually caused by
contact with a relatively sharp object which
produces a continuous, sharp or smooth channel-like
groove in the material.

Nick - A local gouge with sharp edges. Consider a series of

nicks in a line pattern to be the equivalent of a
gouge.

Scratch - A line of damage in the material and results in a

cross sectional area change. It is usually caused
by contact with a very sharp object.

Hole - A complete penetration of the material.

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Dent - Normally, a damage area which is depressed with

respect to its normal contour. There is no cross-
sectional area change in the material. Area
boundaries are smooth, its form is generally the
result of contact with a relatively smooth
contoured object.

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(4) Bonded Acoustic Panel Structures - The types of damage permitted to

the inlet cowl inner barrel acoustic panels are defined below. (See
Figure 103)

Delamination - Separation of the bonded laminated material plies

from each other.

Gouge - A damaged area of any size which results in a cross-

sectional area change. It is usually caused by
contact with a relatively sharp object which
produces a continuous, sharp or smooth channel-like
groove in the material.

Nick - A local gouge with sharp edges. Consider a series of

nicks in a line pattern to be the equivalent of a
gouge.

Rip - Line of damage to woven wire with a continuous

separation of wire fibers.

Scratch - A line of damage in the material and results in a

cross sectional area change. It is usually caused
by contact with a very sharp object.

Tear - A continuous, but ragged, separation of woven wire

fibers.

Void - Separation of the face sheet from honeycomb core.

D. Sealing of Damage Area (Inlet Cowl) - Clean up the damage area and
apply protective sealing tape. (See Figure 104 and 105.)

(1) Remove loose particles from damage area and trim loose ends of
graphite tape, graphite fabric, or fiberglass fabric.

WARNING: SANDING, CUTTING OR DRILLING OF COMPOSITE MATERIALS MAY

PRODUCE DUST IN EXCESS OF ACCEPTABLE EXPOSURE LEVELS.
GLOVES, PROTECTIVE CLOTHING, REGULATORY AGENCY APPROVED DUST
MASKS, AND APPROPRIATE EYE PROTECTION MUST BE WORN WHEN
WORKING WITH THESE MATERIALS. AVOID BREATHING OF DUST OR
PROLONGED CONTACT OF DUST ON SKIN.

(2) Remove raised material to fair with air-wetted surface.

(3) Smooth edges of crack or hole damage and chamfer or radius the
edges adjacent to the air-wetted surface.

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(4) Use 320-grit abrasive paper and remove surface gloss from area at
least one-inch (25,4 mm) beyond cleanup limits.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(5) Clean sanding debris from surface with clean cloth moistened with
isoprophyl alcohol. Wipe dry with clean cloth before the alcohol
evaporates.

(6) Cut sealing patch from aluminum-backed sealing tape.

(a) Cut patch one-inch (25,4 mm) larger all around than damage
cleanup area.

(b) Remove all square corners from patch by trimming to a rounded

configuration.

(c) Apply tape over damage area.

(d) Stretch and smooth tape as it is applied to avoid wrinkles.

(e) Press patch in place with plastic roller or squeegee to remove

trapped air and wrinkles.

(f) Roll edges of patch to assure proper adhesion.

(7) Remove damaged tape patch by peeling from structure surface.

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WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(8) Clean adhesive residue from patch area using a clean cloth
moistened with Isoprophyl alcohol. Wipe area dry with a clean cloth
before alcohol evaporates.

(9) Cut a new patch and install.

E. Damage Zones

(1) Inlet Cowl Inlet Lip Structure - There are three types of damage
zones for the inlet cowl inlet lip.

(a) See Table 101 for the following items:

1 allowable damage types

2 damage zones

3 allowable damage limits

4 cleanup requirements

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(b) Allowable Damage Zones - The allowable damage zones for the
inlet cowl inlet lip are: (See Figure 106.)

CLl Lip segment splice fastener areas and fastener areas

of lip skin to inlet cowl forward bulkhead attachment,
2.0 inches (51 mm) from all edges of the lip skin
segments.

CL2 Lip skin areas within 1.60 inch (40,6 mm) of inlet cowl
forward bulkhead.

CL3 All areas of lip skin not in zones CLl and CL2.

DESCRIPTION CRACK DENT/BUCKLE SCRATCH/GOUGE NICK

ZONE CL1 A B D E
ZONE CL2 A B D E
ZONE CL3 A C D E

NOTE:
Any damage not described in table must be repaired before next flight.
A. Adjacent cracks which are separated by less than the length
of the shortest cracks should be treated as one crack.
Cracks less than 3.00-inches (76,2 mm). Drill stop hole (No.
30 drill) at both ends of crack. Check weekly or every 25
cycles, whichever is less. If crack grows beyond stop holes,
stop drill new crack and install external patch. Check every
“A” check. Do not remove external patch for inspection.
Repair at “C” check.
B. Buckled flange 5.00-inches (127,0 mm) maximum length. Check
at “A” check. Repair at next “C” check.
C. 5.00-inches (127,0 mm) maximum diameter. Depth of dent must
not be more than 10 percent of diameter. Not allowed within
1.60-inches (40,6 mm) of forward bulkhead. Minimum 10.00-
inches (254,0 mm) from other defects.
D. 10.00-inches (254,0 mm) long in any direction. If depth
exceeds 25 percent of material thickness or is wider than
0.10-inch (2,5 mm), consider as crack. Minimum 10.00-inches
(254,0 mm) separation from other defects.
E. Consider as a crack if deeper than 25 percent of material
thickness or wider than 0.10-inch (2,5 mm).
Inlet Cowl Inlet Lip Allowable Damage
Table 101

(2) Inlet Cowl Outer Barrel Structure - There are six types of damage
zones for the inlet cowl outer barrel.

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(a) See Table 102 for the following items:

1 allowable damage types

2 damage zones

3 allowable damage limits

4 cleanup requirements

(b) Allowable Damage Zones - The allowable damage zones for the
inlet cowl outer barrel are: (See Figure 107)

Cl Forward barrel land and aft barrel land, interfacing

with the forward and aft inlet cowl bulkhead.

C2 Horizontal lands of upper barrel half and lower barrel

half in splice areas.

C3 Circumferential frames (containing honeycomb core).

C4 Access panel frames.

C5 Anti-ice air vent frame (lower panel only).

C6 Outer barrel panel composite skins, bound by frames,

bulkhead lands, splice lands, and access panel frames.
Includes all areas not covered in zones Cl through C5.

SCRATCH/
DESCRIPTION ABRASION CRACK DISBOND DELMINATION GOUGE HOLE
ZONE CL A C D
ZONE C2 A C D
ZONE C3 A B C D E
ZONE C4 A D
ZONE C5 A D
ZONE C6 A B F D E

NOTE:
Any damage not described in table must be repaired before next flight.

* Tape - Commonly referred to as “speed tape”, 3M Type 425 or equivalent.

Inlet Cowl Outer Barrel Allowable Damage

Table 102 (Sheet 1 of 2)

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SCRATCH/
DESCRIPTION ABRASION CRACK DISBOND DELMINATION GOUGE HOLE
A. Abrasion damage allowed to face surface only. Fibers must not be
damaged. Treat as scratch if fibers are damaged. Apply tape,
record and check at “A” check. Replace *tape if peeled.
B. Maximum crack length 3.00-inches (76,2 mm) in any direction, more
than 1.00-inch (25,4 mm) from reinforced areas. 10.00-inches
(254,0 mm) separation from other cracks, holes, and disbonds. Five
cracks maximum per barrel half. Cracks wider than 0.10-inch (2,5
mm) are to be treated as holes. Apply tape, record and check at
next “A” check. Repair at “C” check.
C. 1.00-inch (25,4 mm) maximum diameter in stiffeners and lands.
10.00-inches (254,0 mm) minimum separation from other defects.
Five disbonds maximum in area. Record and check at “A” check.
Repair at “C” check.
D. Maximum depth 0.010-inch (0,25 mm) over 10.00-inches (254,0 mm)
length. Apply tape, record and check at next “A” check. Replace
*tape if peeled or damaged.
E. 3.00-inches (76,2 mm) maximum diameter in outer barrel. 1.00-inch
(25,4 mm) from reinforced areas. 0.50-inch (12,7 mm) maximum-in
stiffeners and lands. 10.00-inches (254,0 mm) minimum separation
from other defects. 5 holes maximum in area. Apply tape, record
and check at next “A” check. Repair at “C” check.
F. 5.00-inches (127,0 mm) maximum diameter, 1.00-inch (25,4 mm) from
reinforced areas. 10.00-inches (254,0 mm) minimum separation from
other defects. 5 delaminations maximum in area. Record and check
at “A” check. Repair at “C” check.

* Tape - Commonly referred to as “speed tape”, 3M Type 425 or equivalent.

Inlet Cowl Outer Barrel Allowable Damage

Table 102 (Sheet 2 of 2)

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(3) Inlet Cowl Inner Barrel Structure - There are five types of damage
zones for the inlet cowl inner barrel.

(a) See Table 103 for the following items:

1 allowable damage types

2 damage zones

3 allowable damage limits

4 cleanup requirements

(b) Allowable Damage Zones - The allowable damage zones for the
inlet cowl inner barrel are: (See Figure 108)

CAl Perforated inner face sheet.

CA2 Titanium core and septum.

CA3 Nonperforated outer face sheet.

CA4 Riveted joint.

CA5 Bonded (nonriveted) joint.

DESCRIPTION DISBOND DENT GOUGES NICK SCRATCH

ZONE CAL A D E F G
ZONE CA2 A
ZONE CA3 A D E F G
ZONE CA4 B
ZONE CA5 C

NOTES:
Any damage not described in table must be repaired before next flight. See
Structural Identification for material thickness.
A. 50 square-inches (32258 mm) area maximum, must be separated from
other disbond or voids by four times maximum dimension of disbond.
Must not be opposite void or disbond on other face sheet. Maximum
disbonded length for nonriveted joint is 15-percent of joint
length.
Inlet Cowl Inner Barrel Allowable Damage
Table 103 (Sheet 1 of 2)

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B. A total maximum delamination of six linear inches (152,4 mm) is

allowed.
C. Maximum disbond length is 15 percent of joint length. The disbond
must not extend from one edge of the part to opposite edge. There
must be a minimum of 0.12-inch (3,1 mm) between disbond and edge
of part. Check at “A” check. Repair at “C” check.
D. 1.50-inch (38,1 mm) minimum distance from reinforced area or edge
of honeycomb. 3.00-inches (76,2 mm) minimum separation between
dents. Check at “A” check. Repair at next “C” check.
E. Length 1.00-inch (25,4 mm) maximum, width 0.10-inch (2,5 mm)
maximum, depth 0.10-inch (2,5 mm) maximum, radius 0.05-inch (1,3
mm) minimum. 1.50-inches (38,1 mm) minimum separation from
reinforced area or edges of honeycomb. Minimum of 3.00-inches
(76,2 mm) separation from other defects. Check at “A” check.
Repair at “C” check.
F. 1.50-inches (38,1 mm) minimum distance from reinforced area or
edge of honeycomb. Length 0.75-inch (19,1 mm) inch maximum, depth
0.010-inch (0,25 mm) maximum. Minimum 2.00-inches (50,8 mm)
separation from other defects.
G. Maximum 1.50-inches (38,1 mm) long and 0.005-inch (0,13 mm) deep.
Minimum of 1.50-inches (38,1 mm) from reinforced area or edge of
honeycomb. Minimum 2.00-inches (50,8 mm) separation from other
defects.
Inlet Cowl Inner Barrel Allowable Damage
Table 103 (Sheet 2 of 2)

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(4) Inlet Cowl Bulkhead Structure - There are six types of damage for
the inlet cowl bulkhead.

(a) See Table 104 for the following items:

1 allowable damage types

2 damage zones

3 allowable damage limits

4 cleanup requirements

(b) Allowable Damage Zones - The allowable damage zones for the
inlet cowl bulkhead are: (See Figure 109).

CBl Forward bulkhead panel webs.

CB2 Aft bulkhead panel webs.

CB3 Stiffeners, cap angles, doublers or fittings.

CB4 Forward bulkhead fastener joints.

CB5 Aft bulkhead fastener joints.

CB6 Deicing air exhaust duct.

CB7 Aft bulkhead outer frame.

DESCRIPTION CRACK DENT/BUCKLE SCRATCH/GOUGE NICK ABRASION/

CHAFE/WEAR
ZONE CB1 B D E F
ZONE CB2 B D E F
ZONE CB3 A C E F
ZONE CB4 A C E F
ZONE CB5 A C E F
ZONE CB6 D E F
ZONE CB7 G

NOTES:
Any damage not described in table must be repaired before next flight.
Inlet Cowl Bulkhead Allowable Damage
Table 104 (Sheet 1 of 2)

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A. Cracks between two adjacent fasteners in a joint of 10 or more

fasteners and not within 5.00-inches (127,0 mm) of a stiffener.
Minimum 10.00-inches (254,0 mm) separation from other defects.
Cracks must be stop drilled before next flight.
Cracks less than 1.00-inch (25,4 mm) long between fasteners must be
stop drilled and checked at each “A” check.
Cracks more than 1.00-inch (25,4 mm) and less than 3.00-inches
(76,2 mm) long must be stop drilled and repaired at next “A” check.
Cracks in stiffeners less than 1.00-inch (25,4 mm) long in bend
area or less than 25 percent of flange width. Stop drill and check
at “A” check. Repair at next “C” check.
B. Cracks between two adjacent fasteners in a joint of 10 or more
fasteners. Minimum of 10.00-inches (254,0 mm) from other defects.
Check at “A” check. Repair at next “C” check.
C. Buckled flange 5.00-inches (127,0 mm) maximum length. Check at “A”
check. Repair at next “C” check.
D. 5.00-inches (127,0 mm) maximum diameter. Depth of dent must not be
more than 10 percent of diameter. Not allowed within 1.60-inches
(40,6 mm) of forward bulkhead fastener joint. Minimum 10.00-inches
(254,0 mm) from other defects.
E. 10.00-inches (254,0 mm) long in any direction. If depth exceeds 25
percent of material thickness or is wider than 0.10-inch (2,5 mm),
consider as crack. Minimum 10.00-inches (254,0 mm) separation from
other defects.
F. Consider as a crack if deeper than 25 percent of material thickness
or wider than 0.10-inch (2,5 mm).
G. A/C/W remaining thickness greater than 0.071 in (1,8 mm) accept as
is, less than or equal to 0.071 in (1,8 mm) see Repair 16.
Inlet Cowl Bulkhead Allowable Damage
Table 104 (Sheet 2 of 2)

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Types of Composite Damage to Inlet Cowl

Figure 101 (Sheet 1)

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Types of Composite Damage to Inlet Cowl

Figure 101 (Sheet 2)

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Types of Aluminum/Titanium Sheet Damage to Inlet Cowl

Figure 102 (Sheet 1)

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Types of Aluminum/Titanium Sheet Damage to Inlet Cowl

Figure 102 (Sheet 2)

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Types of Damage to Acoustic Panel

Figure 103 (Sheet 1)

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Types of Damage to Acoustic Panel

Figure 103 (Sheet 2)

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DENT PERIPHERY
B
DENT MAJOR AXIS

B
DENT WIDTH OF DENT
MINOR AXIS A
(MINOR AXIS)
TYPICAL DENTED PANEL Y
DEPTH OF DENT
ORIGINAL
PERFORATED CONTOUR DENT
GRAPHITE FABRIC
FACE SKIN MAJOR
COMPOSITE PLY
AXIS
VOID A SECTION B-B
HFT CORE
WOVEN WIRE
SEPTUM

A GRAPHITE FABRIC
COMPOSITE PLY HFT CORE
PERFORATED
FACE SKIN
ALUMINUM BACK SKIN
VOID
CORE

TYPICAL BONDED PANEL VOID

WOVEN WIRE
SEPTUM ALUMINUM BACK SKIN
CORE SECTION A-A
CES-136-01
Types of Damage to Acoustic Panel
Figure 103 (Sheet 3)

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Damage Clean up of Edges

Figure 104 (Sheet 1)

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Damage Clean Up of Edges

Figure 104 (Sheet 2)

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Application of Tape to Air-Wetted Surfaces

Figure 105
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B ZONE
ZONE CL1 CL2 ZONE
A
CL1
ZONE CL 2 B
INLET COWL

A 2.0 IN
ZONE
ZONE ZONE CL 1 CL1
CL 1 (TYPICAL)

ZONE
CL 2 ZONE CL 2 OUTER
BARREL
2.0 INCH PANEL
INLET
LIP ZONE CL 1
1.60 INCH

LIP SPLICE OUTER

(TYPICAL) CAP ANGLE

LIP FASTENERS

ZONE CL 3 INLET COWL

FORWARD
BULKHEAD

LIP
FASTENERS
INNER BARREL
ACOUSTIC PANEL
INNER CAP
ANGLE
LIP SKIN

ZONE CL 3 ZONE CL 2

1.60 INCH 2.0 INCH

ZONE CL 1
SECTION A-A
CES-137-01

Inlet Cowl Inlet Lip Damage Zones

Figure 106

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Inlet Cowl Outer Barrel Damage Zones

Figure 107 (Sheet 1)

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Inlet Cowl outer Barrel Damage Zones

Figure 107 (Sheet 2)

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SPLICE PLATES
ZONE CA5

SPLICE PLATES
ZONE CA5

ZONE CA1
ZONE CA2
ZONE CA5
ZONE CA4
ZONE CA4

ZONE CA3
SECTION A-A
CES-138-01

Inlet Cowl Inner Barrel Damage Zones

Figure 108
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INLET COWL

INLET ZONE CB3 INNER BARREL

LIP ACOUSTIC PANEL ZONE CB3

ZONE
CB1

ZONE CB5

ZONE CB2
AFT BULKHEAD
FORWARD
BULKHEAD ZONE CB2
WEB
ZONE CB4
ZONE CB6 OUTER ZONE CB7
BARREL SEE FIGURE 110

CES-144-02

Inlet Cowl Bulkhead Damage Zones

Figure 109

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FW
D

INLET COWL

INLET COWL SKIN

ATTACH FASTENER
FRAME WEAR ZONE
ORIGINAL OUTLINE
FAN COWL SKIN
WEAR AREA

INLET COWL SKIN

DETAIL B
AFT BULKHEAD
OUTER FRAME INLET COWL AFT FWD
BULKHEAD WEB AFT BULKHEAD
ATTACH FASTENER OUTER FRAME
INLET COWL AFT
FWD
BULKHEAD WEB B
SECTION A-A TYPICAL WEAR ON OUTER FRAME
(WEB, SKIN AND ATTACH FASTENERS NOT SHOWN)
OUTER FRAME DETAILS
CES-269-00

Damage Area on T-Frame

Figure 110 (Sheet 1)

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20 IN.
508 mm
(19.1 DEG)

12 O'CLOCK ALLOWABLE DAMAGE AREA

L/H FAN COWL DOOR R/H FAN COWL DOOR

OUTER
FRAME OUTER
FRAME

6 O'CLOCK
ALLOWABLE DAMAGE AREA
20 IN.
508 mm
(19.1 DEG)

NOTE: CONTACT UTAS FOR DAMAGE OUTSIDE THE 12 AND 6 O'CLOCK ALLOWABLE DAMAGE AREA.
CES-268-

Allowable Damage Area on T-Frame

Figure 110 (Sheet 2)

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INLET COWL REPAIR INDEX

Title Repair
Surface Finish Restoration . . . . . . . . . . . . . . . Repair No. 1
Full Penetration of Outer Barrel . . . . . . . . . . . . Repair No. 2
Skin Damage Greater Than 0.010 Inch Deep . . . . . . . . Repair No. 3
Skin Damage Less Than 0.010 Inch Deep . . . . . . . . . . Repair No. 5
Frame Outer Cap and Aluminum Honeycomb Core . . . . . . . Repair No. 6
Inlet Lipskin Flush Patch . . . . . . . . . . . . . . . . Repair No.10
Inlet Lipskin External Patch . . . . . . . . . . . . . . Repair No.11
Aft Bulkhead Web Crack . . . . . . . . . . . . . . . . . Repair No.12
Aft Bulkhead Web Puncture . . . . . . . . . . . . . . . . Repair No.13
Aft Bulkhead Splice . . . . . . . . . . . . . . . . . . . Repair No.14
Acoustic Panel Small holes . . . . . . . . . . . . . . . Repair No.15
Aft Bulkhead 6 And 12 O’clock Outer Frame Damage . . . . Repair No.16
Edge Erosion Damage . . . . . . . . . . . . . . . . . . . Repair No.22
Replacement of Sealant . . . . . . . . . . . . . . . . . Repair No.23
Removed . . . . . . . . . . . . . . . . . . . . . . . . . Repair No.24

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REPAIR NO.1
SURFACE FINISH RESTORATION

1. General

This procedure gives the instructions to repair the surface finish of an

area of the outer barrel skin. Do not apply the primer or paint to the
inner barrel acoustic panels.

2. Repair Instructions

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

CAUTION: DO NOT USE THE PAINT REMOVAL COMPOUNDS ON CARBON/EPOXY PARTS

BECAUSE THESE COMPOUNDS CAUSE DAMAGE. DAMAGED PARTS CAN BE
WEAKER THAN THE INITIAL PARTS.

CAUTION: DO NOT BREAK OR MAKE THE CARBON FIBERS THIN IN THE AREA TO BE
PAINTED. IF THE FIBERS ARE DAMAGED, THEN THE PART CAN BE WEAKER
THAN THE INITIAL PART.

CAUTION: DO NOT CAUSE DAMAGE TO THE EXPANDED COPPER SCREEN (ECS) WHEN YOU
REMOVE THE SURFACE FINISH. THE ECS IS NECESSARY FOR LIGHTNING
PROTECTION.

A. Use a 180-grit abrasive paper and remove the surface finishes from the
graphite/epoxy structures. See Table 201.

B. Apply the epoxy filler. Refer to the instructions of the manufacturer.

See Table 201.

NOTE: Do not apply the epoxy filler on the fastener heads. The finish
can break if the epoxy filler is applied to the fastener heads.

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WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Wet a clean cheesecloth pad with the solvent and apply 25-50 grams
of epoxy filler.

(2) Rub the cheesecloth pad on the defective area. Use a strong
circular movement.

(3) Examine the epoxy filler for pin holes.

(a) Examine for pin holes as the epoxy filler is applied.

(b) If there are pin holes in the epoxy filler, go to steps (1)
through (3) to apply and examine the epoxy filler.

(4) Examine the epoxy filler for thickness.

(a) Remove unwanted epoxy filler with a knife, razor blade or

plastic squeegee.

(b) Make sure you can see the surface through the filler.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE MANUFACTURER,
THE MATERIAL SAFETY DATA SHEET (MSDS), AND GOVERNMENT
REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE
YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED. AN
MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

(c) If you cannot see the surface, use a clean cheesecloth moist
with the solvent and remove unwanted filler before filler
becomes hard.

C. Dry the epoxy filler. Refer to the instructions of the manufacturer.

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WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

D. Use 240 - 320-grit abrasive paper on the areas with the epoxy filler.
Make sure that the epoxy filler is only in the defective areas. See
Table 201.

E. Apply the epoxy primer. See Table 201.

(1) Apply the teflon tape to the perimeter of the repair area to
prevent damage to the adjacent surfaces.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU

DO THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY
ALL INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

(2) Use a 180-grit abrasive paper to remove the surface finish in the
repair area.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(3) Clean the repair area with a clean, lint-free cloth and the
solvent. Remove the solvent with a clean lint-free cloth before the
solvent becomes dry.

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WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(4) Mix the epoxy primer. Refer to the instructions of the

manufacturer. See Table 201.

NOTE: Apply two coats before you apply the topcoat. The dried
film thickness must be 0.0006 - 0.0009-inch (0.01524 -
0.02286 mm).

(5) Dry the epoxy primer. Refer to the instructions of the

manufacturer.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

F. Apply the polyurethane topcoat to the external surface of the repair.

(See Airbus Industrie for special operator topcoat instructions.)

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3. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Blade, Razor Commercially Available
Cloth, Lint-Free Cotton Commercially Available
Clothing, Protective Commercially Available
Container Metal or Plastic Commercially Available
Cover, Container Metal or Plastic Commercially Available
Filler, Epoxy 467-9/CA-41B V0KXA5
Akzo Nobel Aerospace Coatings
East Water St.
Waukegan, IL 60085-5563
Phone: (847) 625-4200
Fax: (847) 625-3200
www.anac.com
Glasses, Safety Commercially Available
Gloves Neoprene or Commercially Available
Polyvinyl Chloride
Knife, Utility Commercially Available
Lamp, Heat 75°F-200°F Commercially Available
(23.89°C-93.33°C)
Mask, Dust Regulatory Agency Commercially Available
Approved
Pad, Cheesecloth 6 x 16-Inch Commercially Available
(152.4 x 406.4 mm)
Paper, Abrasive 180-, 240-, 320-Grit Commercially Available
Silicone Carbide
Primer Epoxy Eco-primeTM military V5HCF1
EEAY051A Base PRC-DeSoto International, Inc.
EEAY051B Curing Solution 12780 San Fernando Road
Sylmar, CA 91342
Telephone (818) 240-2060
Toll Free (800) 237-6649
www.ppgaerospace.com
Squeegee, Plastic Commercially Available
Repair Materials and Equipment
Table 201 (Sheet 1 of 2)

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DESCRIPTION DESIGNATION MANUFACTURER

Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
or
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Univar U.S.A., Inc.
Ketone/40% Methyl Ethyl 532 E. Emaus Street
Ketone Middletown, PA 17057-2200
or Phone: (717) 944-7471
www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Tape, Teflon 2-Inches Wide Commercially Available
Repair Materials and Equipment
Table 201 (Sheet 2 of 2)

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REPAIR NO. 2
FULL PENETRATION HOLE IN THE OUTER BARREL SKIN

1. General

A. This procedure gives the instructions to repair the damage to the outer
skin with no access to the back side. A fiberglass backup plate is
prepared and installed. Wet layup carbon fabric fill plies, repair
plies and a fiberglass sanding ply are installed.

B. The damage must be more than 1.0-inch (25.4 mm) away from the frames
and the edges. The damage must be less than 8.0 x 8.0-inches (203.0 x
203.0 mm) in area.

2. Repair Instructions

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

A. Cut and remove the damage area of the skin. See Table 201.

(1) Remove all the loose particles, cracks and delaminations.

(2) Form a 0.5-inch (12.7 mm) minimum radius on all of the corners.

NOTE: The shape of the cutout must be a rectangle or an oval to

put the backup plate through the hole.

(3) Make a 45 degrees chamfer on the sides of the skin cutout that open
to the external surface.

(4) Use an abrasive paper on the edges of the skin cutout. See Table
201.

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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(5) Remove the unwanted material with a clean lint-free cloth and
solvent. Remove the solvent with a clean lint-free cloth before the
solvent becomes dry.

B. Put the teflon tape around the edge of the repair area. See Figure 202
and Table 201.

(1) Measure the dimension of the largest ply to find the dimensions of
the repair area. There are 4 repair plies and 1 fiberglass sanding
ply.

(a) The Repair Ply No. 1 has an overlap of 1.0-inch (25.4 mm) in
all directions from the edges of the skin cutout.

(b) The repair plies No. 2, 3, and 4 have an overlap of 0.75-inch

(19.1 mm) in all direction from the edges of the last ply.

(c) The fiberglass sanding ply has a minimum overlap of 0.75-inch

(19.1 mm) in all directions from the edges of the last ply.

(d) Use the teflon tape and make a mask band around the repair
area. Put the inner edge of the band against the outer edges
of the fiberglass sanding ply.

C. Prepare the repair area. See Table 201.

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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

CAUTION: DO NOT TAPER OR BREAK THE CARBON FIBERS FROM THE TOP SURFACE OF
THE OUTER SKIN PLIES.

(1) Use the abrasive paper (150-grit) to remove all of the surface
finish in the repair area.

(2) Use the abrasive paper (150-grit) on the inner surface of the outer
skin 1.0-inch (25.7 mm) on all sides of the cutout.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(3) Remove the unwanted material with a clean lint-free cloth and
solvent. Remove the solvent with a clean lint-free cloth before the
solvent becomes dry.

D. Prepare the fiberglass backup plate. See Table 201.

(1) Cut three pieces of fiberglass fabric 1.5-inch (114.3 mm) larger on
all sides than the edges of the cutout.

(a) Cut two pieces of fabric with the warp parallel to the longest
dimension of the cutout.

(b) Cut one piece of fabric with a warp 90 degrees to the first
two pieces.

(2) Cut one piece of peel ply (porous parting film) with a 1.5-inch
(114.3 mm) overlap than the edges of the cutout.

(3) Prepare the fiberglass fabric plies.

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 ROHR, INC.
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Document Part No. RDN 306

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE MANUFACTURER,
THE MATERIAL SAFETY DATA SHEET (MSDS), AND GOVERNMENT
REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE
YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED. AN
MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

(a) Mix the adhesive. Refer to the instructions of the

manufacturer.

(b) Put each of the fiberglass fabric plies on a sheet of

nonporous parting film.

(c) Apply the adhesive to one side of each ply.

(d) Put a piece of nonporous parting film on the top of each of

the fiberglass fabric ply.

(e) Use a roller to soak the plies with the adhesive.

(4) Make the fiberglass backup plate.

(a) Put a sheet of nonporous parting film that is larger than the
peel ply on a flat surface. Make sure that the flat surface is
resistant to temperatures more than 210°F (99°C).

(b) Put the peel ply in the center of the nonporous parting film.

(c) Remove the nonporous parting film from the bottom of the
fiberglass fabric ply with the warp parallel to the longest
dimension of the cutout. Put the ply above the peel ply.
Remove the nonporous parting film from the top of the ply.

(d) Remove the nonporous parting film from the bottom of the ply
with the warp 90 degrees to the longest dimension of the
cutout. Put the ply on the first ply. Remove the nonporous
parting film from the top of the ply.

(e) Remove the nonporous parting film from the bottom of the last
ply. Put the ply on the second ply. Remove the nonporous
parting film from the top of the ply.

(f) Put a piece of porous parting film larger than the fiberglass
fabric plies on top of the last ply.

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(g) Use a roller to remove the wrinkles or caught air.

(h) Put three pieces of the bleeder cloth on top of the porous
parting film.

(i) Put the bagging film on top of the bleeder cloth and seal
around the edges of the bagging film.

(j) Insert a temperature probe and the vacuum connectors into the
bagging film and seal the opening.

(k) Use a heat blanket on the bagging film at 190° - 210°F (88° -
99°C) for 220 minutes at 20 inches-of-mercury vacuum pressure.

(l) Remove the vacuum bag and materials. Do not remove the peel
ply.

(m) Cut the backup plate to make an overlap of 1.0-inch (25.4 mm)
on all side of the edges of the cutout.

(n) Drill holes in pairs as necessary near the centerline of the

backup plate. Use a 0.07-inch (1.78 mm) drill bit. Make each
pair of holes 0.375-inch (9.53 mm) apart.

E. Install the backup plate on the inner surface of the skin. See Figure
201 and Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Use the instructions of the manufacturer to mix the adhesive. Add
the phenolic microballoons 20 percent by weight to the adhesive.
Mix the contents until the mixture is a paste.

NOTE: The microballoons are used only in the adhesive mixture

that attach the backup plate to the inner skin.

(2) Remove the peel ply (porous parting film) from the backup plate.

(3) Put a loop of lockwire through the holes in the backup plate.
Loosely twist each loop of the lockwire one turn.

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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(4) Clean the mating surface of the backup plate and inner surface of
the repair area with a clean, lint-free cloth and the solvent.
Remove the solvent with a clean lint-free cloth before the solvent
becomes dry.

NOTE: The peel ply side of the backup plate is the mating
surface.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(5) Apply the adhesive to the mating surface of the backup plate and
the 1.0-inch (25.4 mm) repair area on the inner skin.

(6) Put the backup plate through the cutout and pull the backup plate
into position with the lockwire.

CAUTION: DO NOT MAKE THE LOCKWIRE TOO TIGHT. THE TENSION WILL PREVENT
A GOOD BOND.

(7) Twist the lockwire around the rod. Make sure the backup plate is
tight against the inner side of the skin. Do not pull the backup
plate into the cutout.

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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(8) Apply the adhesive to the holes for the lockwire in the backup
plate.

(9) Use a heat blanket on the repair to 190° - 210°F (88° - 99°C) for
220 minutes.

(10) Remove the rod and cut the lockwire at the surface of the backup
plate.

(11) Remove the unwanted material from the repair area.

F. Cut the filler plies, repair plies and fiberglass sanding ply. See
Figure 202 and Table 201.

(1) Cut a sufficient quantity of filler plies from the carbon fabric.

NOTE: The total number of fill plies are equal to the number of
damaged plies that were removed. See 54-10-00 Structural
Identification.

NOTE: The warp direction of each filler ply is equal to 0

degrees.

(2) Cut 4 repair plies. See Figure 202 for the warp direction.

(a) Cut the repair ply No. 1 to overlap of 1.0-inch (25.4 mm) in
all directions from the edges of the skin cutout.

(b) Cut the repair plies No. 2, 3, and 4 to overlap 0.75-inch

(19.1 mm) from the edges of the last ply.

(c) Cut the corners of the repair plies to 45 degrees by 1.0-inch

(25.4 mm).

(3) Cut 1 fiberglass sanding ply from the fiberglass fabric.

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(a) Cut the fiberglass sanding ply to a minimum overlap of 0.75-

inch (19.1 mm) from the edges of the last ply.

NOTE: Extend the fiberglass sanding ply to the edge of the

teflon tape mask area.

(b) Cut the corners of the fiberglass sanding ply to 45 degrees by

1.0-inch (25.4 mm).

G. Prepare the filler plies, repair plies and fiberglass sanding ply. See
Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Mix the adhesive. Refer to the instructions of the manufacturer.

(2) Put each ply on a sheet of nonporous parting film.

(3) Apply the adhesive to one side of each ply.

(4) Put a piece of nonporous parting film on the top of each ply.

(5) Use a roller to soak the plies with the adhesive.

H. Install the filler plies, repair plies and fiberglass sanding ply. See
Figure 202 and Table 201.

(1) Install the filler plies.

(a) Remove the nonporous parting film from the bottom of the
filler ply. Put the ply into the cutout. Use a roller to
remove the wrinkles or caught air. Remove the nonporous
parting film from the top of the ply.

(b) Do step (a) for all filler plies.

(2) Install the repair plies.

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 ROHR, INC.
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Document Part No. RDN 306

(a) Remove the nonporous parting film from the bottom of the
repair ply No. 1. Put the ply on top of the filler plies. Make
sure there is an overlap of 1.0-inch (25.4 mm) in all
directions from the edges of the skin cutout. Use a roller to
remove the wrinkles or caught air. Remove the nonporous
parting film from the top of the ply.

(b) Remove the nonporous parting film from the bottom of the
repair ply No. 2. Put the ply on top of the last ply. Make
sure there is an overlap of 0.75-inch (19.1 mm) in all
directions from the edges of the last ply. Use a roller to
remove the wrinkles or caught air. Remove the nonporous
parting film from the top of the ply.

(c) Do step (b) for all repair plies.

(3) Remove the nonporous parting film from the bottom of the fiberglass
sanding ply. Put the ply on top of the repair plies. Make sure
there is a minimum overlap of 0.75-inch (19.1 mm) in all directions
from the edges of the last repair ply. Use a roller to remove the
wrinkles or caught air. Remove the nonporous parting film from the
top of the ply.

I. Prepare the repair area for the vacuum bag cover and cure procedure.
See Figure 203 and Table 201.

(1) Put a sheet of porous parting film on the repair materials. Make
sure that the sheet of parting film has an overlap of 3.0-inch.
(76.2 mm) from all edges of the fiberglass sanding ply.

(2) Put the bleeder cloth layers on the parting film.

(a) The number of bleeder cloth layers must be equal to the number
of repair plies.

(b) The bleeder cloth layers must be equal to the dimension of the
porous parting film.

(3) Put a sheet of the nonporous parting film on the bleeder cloth
layers. Make sure the edges of bleeder cloth layers are below the
nonporous parting film.

(4) Put a silicon rubber sheet on the nonporous parting film.

(5) Put a heat blanket on the rubber sheet.

(6) Put two layers of the fiberglass breather cloth on the heat
blanket.

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STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

(7) Put a vacuum bag on the heat blanket.

NOTE: Make sure the vacuum bag has an overlap of approximately

2.0-inch (50.8 mm) from all edges of the heat blanket.

(8) Put a temperature probe below the bag and seal the edges of the
vacuum bag with the double-sided tape.

(9) Put a vacuum connector below the bag and seal the edges with the
double-sided tape.

J. Use a vacuum pump to increase the vacuum pressure in the bag to 20-
inches of mercury (67.7 kPa). See Table 201.

K. Set the switch for the heat blanket to keep the temperature at 190°-
210°F (88°-99°C). Let the repair cure for 220 minutes. See Table 201.

L. Remove the vacuum bag and all of the bag materials from the repair.
Remove the teflon tape from around the repair area.

M. Use 150 - 320-grit abrasive paper and make the surface and the edges of
the repair smooth. Do not go into the graphite ply with the abrasive
paper. See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

N. Remove the unwanted material with a clean lint-free cloth and solvent.
Remove the solvent with a clean lint-free cloth before the solvent
becomes dry. See Table 201.

O. Repair the surface finish. See Repair No. 1 - Surface Finish

Restoration.

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Document Part No. RDN 306

3. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Adhesive, Epoxy EA9390 (Two Part) V33564
Henkel Corporation
2850 Willow Pass Rd.
P.O. Box 312
Baypoint, CA 94565-0031
Phone: (800) 257-7522
www.aerospace.henkel.com
Blanket, Heat 20 x 20 inch V61426
(508 x 508 mm) Atacs Products, Inc.
4344 S. 104th Place, Bldg A
Tukwila, WA 98178
Phone: (206) 433-9000
Cloth, Bleeder Fiberglass Commercially Available
Cloth, Breather RC3000-10 V0F451
Richmond Aircraft Products, Inc.
13503 Pulmice St
Norwalk, CA 90650-5250
Phone: (562) 404-2440
www.richmondaircraft.com
Cloth, Lint-free Cotton Commercially Available
Clothing, Protective Commercially Available
Container Metal or Plastic Commercially Available
Cover, Container Metal or Plastic Commercially Available
Fabric, Fiberglass Type 181 Commercially Available
Fabric, Carbon AH370-5H V2B975
Hexcel Corp
1913 N King St
Seguin, TX 78155-2197
Phone: (800) 688-7734
www.hexcel.com
Film, Bagging 2 mm Nylon V0F451
Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Film, Parting Nonporous V0F451
Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Repair Materials and Equipment
Table 201 (Sheet 1 of 2)
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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

DESCRIPTION DESIGNATION MANUFACTURER

Film, Parting Porous V0F451
Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Lockwire Commercially Available
Glasses, Safety Commercially Available
Gloves Neoprene or Polyvinyl Commercially Available
Chloride
Mask, Dust Regulatory Agency Commercially Available
Approved
Microballoons Phenolic, 135 Micron Commercially Available
Paper, Abrasive 80, 150, 320-Grit Commercially Available
Silicon Carbide
Probe, Temperature 0-250°F (0-121°C) Commercially Available
Pump, Vacuum 0-30 Inches-of-mercury Commercially Available
(0-0.1 MPa)
Rod Metal Commercially Available
Roller 2.0 inch (50.8 mm) Commercially Available
Diameter
Metal or Plastic
Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
or
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Univar U.S.A., Inc.
Ketone/40% Methyl Ethyl 532 E. Emaus Street
Ketone Middletown, PA 17057-2200
Phone: (717) 944-7471
or www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Tape Double Sided Commercially Available
Tape, Teflon 2.0-inch Commercially Available
Repair Materials and Equipment
Table 201 (Sheet 2 of 2)

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 ROHR, INC.
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Document Part No. RDN 306

LOCKWIRE BACKUP
PLATE

0.375 INCH
(9.53 mm)

ROD
LOCKWIRE
(2 PLACES)
A

1.0 INCH
(25.4 mm)
TYPICAL

BACKUP PLATE
(INSTALLED) LOCKWIRE

ROD
45°

SKIN PLIES
CES-241-00

1.0 INCH
BACKUP PLATE
3 FIBERGLASS PLIES A-A (25.4 mm)

Installation of the Backup Plate

Figure 201

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STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

REPAIR PLY NO. 4

REPAIR PLY NO. 3
REPAIR PLY NO. 2
0°
+45° -45°
REPAIR PLY NO. 1

90° FWD
45°
1.0 INCH
(25.4 mm)
x 45°
(TYPICAL)
A A

CUTOUT

TEFLON TAPE
1.0 INCH (25.4 mm)

0.75 INCH (19.0 mm) FIBERGLASS

0.5 INCH SANDING PLY
(12.7 mm) 0.75 INCH (19.0 mm)
RADIUS 0.75 INCH (19.0 mm) BACKUP PLATE
0.75 INCH (19.0 mm) MINIMUM
2.0 INCH (50.8 mm)
FIBERGLASS
SANDING PLY
REPAIR PLY NO. 4 (-45°)
1.0 INCH REPAIR PLY NO. 3 (0°)
0.75 INCH (25.4 mm) REPAIR PLY NO. 2 (+45°)
(19.1 mm) REPAIR PLY NO. 1 (0°)
(TYPICAL)
TEFLON TAPE
CES-242-00

CUTOUT
TEFLON TAPE
CARBON FILL
BACKUP
PLIES A-A PLATE

Repair of the Full Penetration Hole in the Outer Barrel Skin

Figure 202

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Document Part No. RDN 306

BLEEDER
CLOTH
PLIES

SILICONE NON-POROUS
RUBBER PARTING
SHEET FILM
POROUS
PARTING
FILM HEAT BLANKET
VACUUM
BAG
FIBERGLASS FABRIC
BREATHER CLOTH PLIES
VACUUM HOSE
TEFLON TAPE

BAG SEAL
TEFLON TAPE

FIBERGLASS
TEMPERATURE SANDING
PROBE TEMPERATURE
1.0 INCH PLY PROBE
(25.4 mm)
0.75 INCH REPAIR PLY NO. 4
(19.0 mm) REPAIR PLY NO. 3
(TYPICAL) BACKUP
PLATE REPAIR PLY NO. 2
REPAIR PLY NO. 1
CARBON FILL
PLIES CUTOUT
CES-243-00

Vacuum Bag
Figure 203

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STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
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REPAIR NO. 3
CARBON COMPOSITE SKIN DAMAGE MORE THAN 0.010-INCH (0.25 MM) IN DEPTH

1. General

A. This procedure give the instructions to repair the scratches and nicks
to the outer composite skin that is more than 0.010-inch (0.25 mm) in
depth.

B. The damaged area is filled with an adhesive/microballoon mixture and

three repair plies are installed.

C. Do not use this repair at the edges or reinforced areas of the panel.

2. Repair Instructions

A. Clean the damaged area. See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Clean the repair area with a clean, lint-free cloth and the
solvent. Clean the surface with a lint-free cloth before the
solvent becomes dry.

B. Use the teflon tape and make a mask band around the repair area. Put
the inner edge of the band is 3.25-Inches (82.55 mm) from the outer
edge of the damage. See Figure 201 and Table 201.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

C. Use an abrasive paper (150-grit) to remove the surface finish from the
taped area. Make the edges of the damaged area smooth. See Table 201.

NOTE: The outer primer coat is gray and the first coat is yellow.

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WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

D. Remove the unwanted material with a clean lint-free cloth and solvent.
Remove the solvent with a clean lint-free cloth before the solvent
becomes dry. See Table 201.

E. Mix the adhesive. See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Mix the adhesive. Refer to the instructions of the manufacturer.

(2) Add the phenolic microballoons 20 percent by weight to the

adhesive. Mix the contents until the mixture is a paste.

F. Fill the repair area. See Figure 201 and Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Fill the repair area with the adhesive and microballoon mixture
until flush with the skin surface.

(2) Dry the adhesive and micorballoon mixture. Refer to the

instructions of the manufacturer.

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Document Part No. RDN 306

CAUTION: DO NOT TAPER OR BREAK THE CARBON FIBERS FROM THE TOP SURFACE
OF THE OUTER SKIN PLIES.

(3) Use the abrasive paper to make the dry adhesive flush with the skin
surface.

G. Cut three repair plies and a fiberglass sanding ply. See Figure 201 for
the dimension and warp direction.

(1) Cut the first repair ply to a 1.0-inch (25.4 mm) overlap on all
sides of the damage.

(2) Cut the corners of the first repair ply to 45-degrees by 1.0-inch
(25.4 mm).

(3) Cut the second repair ply to a 0.75-inch (19.05 mm) overlap from
the edges of the first ply.

(4) Cut the corners of the second repair ply 45-degress by 1.0-inch
(25.4 mm).

(5) Do steps (3) and (4) again for the last repair ply and the
fiberglass sanding ply.

NOTE: Make sure the fiberglass sanding ply extends to the inner
edge of the teflon tape.

H. Soak the repair plies and the fiberglass sanding ply with the adhesive
See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Mix the adhesive. Refer to the instructions of the manufacturer.

(2) Put the first repair ply on a sheet of nonporous parting film.

(3) Apply the adhesive to one side of the repair ply.

(4) Use the nonporous parting film and put on the top of the repair
ply.

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(5) Use a roller to soak the plies with the adhesive.

(6) Do steps (2) through (5) for the last repair ply and the fiberglass
sanding ply.

I. Put the carbon repair plies on the skin. See Figure 201.

(1) Apply the adhesive to the repair area.

(2) Lift the first repair ply from the bottom parting film and put the
ply in position on the repair area.

NOTE: Make sure that the repair ply has an overlap of 1.0-inch
(25.4 mm) from all edges of the damage.

(3) Put the ply into position with a roller. Make sure that there are
no wrinkles in the ply. Remove the parting film from the top side.

(4) Lift the second repair ply from the bottom parting film and put the
ply in position on the repair area.

NOTE: Make sure that the repair ply has an overlap of 0.75-inch
(19.05 mm) from all edges of the first repair ply.

(5) Put the ply into position with a roller. Make sure that there are
no wrinkles in the ply. Remove the parting film from the top side.

(6) Do Steps (4) and (5) for the last repair ply and the fiberglass
sanding ply.

J. Prepare the repair area for the vacuum bag cover and cure procedure.
See Figure 202 and Table 201.

(1) Put a sheet of porous parting film on the repair materials. Make
sure that the sheet of parting film has an overlap of 3.0-inch.
(76.2 mm) from all edges of the fiberglass sanding ply.

(2) Put the bleeder cloth layers on the parting film.

(a) The number of bleeder cloth layers must be equal to the number
of repair plies.

(b) The bleeder cloth layers must be equal to the dimension of the
porous parting film.

(3) Put a sheet of the nonporous parting film on the bleeder cloth
layers. Make sure the edges of bleeder cloth layers are below the
nonporous parting film.

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(4) Put a silicon rubber sheet on the nonporous parting film.

(5) Put a heat blanket on the rubber sheet.

(6) Put two layers of the fiberglass breather cloth on the heat
blanket.

(7) Put a vacuum bag on the heat blanket.

NOTE: Make sure the vacuum bag has an overlap of approximately

2.0-inch (50.8 mm) from all edges of the heat blanket.

(8) Put a temperature probe below the bag and seal the edges of the
vacuum bag with the double sided tape.

(9) Put a vacuum connector below the bag and seal the edges with the
teflon tape.

K. Use a vacuum pump to increase the vacuum pressure in the bag to 20-
inches of mercury (67.7 kPa). See Table 201.

L. Set the switch for the heat blanket to keep the temperature at 190°-
210°F (88°-99°C). Let the repair cure for 220 minutes. See Table 201.

M. Remove the vacuum bag and all of the bag materials from the repair.
Remove the teflon tape from around the repair area.

N. Use 150 - 320-grit abrasive paper and make the surface and the edges of
the repair smooth. Do not go into the graphite ply with the abrasive
paper. See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

O. Remove the unwanted material with a clean lint-free cloth and solvent.
Remove the solvent with a clean lint-free cloth before the solvent
becomes dry. See Table 201.

P. Repair the surface finish. See Repair No. 1 - Surface Finish

Restoration.

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STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

3. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Adhesive, Epoxy EA9390 (Two Part) V33564
Henkel Corporation
2850 Willow Pass Rd.
P.O. Box 312
Baypoint, CA 94565-0031
Phone: (800) 257-7522
www.aerospace.henkel.com
Blanket, Heat 20 x 20 inch V61426
(508 x 508 mm) Atacs Products, Inc.
4344 S. 104th Place, Bldg A
Tukwila, WA 98178
Phone: (206) 433-9000
Cloth, Bleeder Fiberglass Commercially Available
Cloth, Breather RC3000-10 V0F451
Richmond Aircraft Products, Inc.
13503 Pulmice St
Norwalk, CA 90650-5250
Phone: (562) 404-2440
www.richmondaircraft.com
Cloth, Lint-free Cotton Commercially Available
Clothing, Protective Commercially Available
Container Metal or Plastic Commercially Available
Cover, Container Metal or Plastic Commercially Available
Fabric, Fiberglass Type 181 Commercially Available
Fabric, Carbon AH370-5H V2B975
Hexcel Corp
1913 N King St
Seguin, TX 78155-2197
Phone: (800) 688-7734
www.hexcel.com
Film, Bagging 2 mm Nylon V0F451
Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Film Parting Nonporous V0F451
Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Repair Materials and Equipment
Table 201 (Sheet 1 of 2)
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STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

DESCRIPTION DESIGNATION MANUFACTURER

Film Parting Porous V0F451
Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Glasses, Safety Commercially Available
Gloves Neoprene or Polyvinyl Commercially Available
Chloride
Lamp, Heat 150°-250°F (66°-121°C) Commercially Available
Mask, Dust Regulatory Agency Commercially Available
Approved
Microballoons Phenolic, 135 Micron Commercially Available
Paper, Abrasive 150 - 320-Grit Commercially Available
Silicon Carbide
Probe, Temperature 0-250°F (0-121°C) Commercially Available
Pump, Vacuum 0-30 Inches-of-mercury Commercially Available
(0-0.1 MPa)
Roller 2.0 inch (50.8 mm) Commercially Available
Diameter
Metal or Plastic
Tape Double Sided Commercially Available
Tape, Teflon 2.0-inch Commercially Available
Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
or
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Univar U.S.A., Inc.
Ketone/40% Methyl Ethyl 532 E. Emaus Street
Ketone Middletown, PA 17057-2200
Phone: (717) 944-7471
or www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Repair Materials and Equipment
Table 201 (Sheet 2 of 2)

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0°
+45° -45°
INNER
PANEL 90° FWD
SKIN

SCRATCH/GOUGE

REPAIR PLY NO. 1

REPAIR PLY NO. 2 45°

0.50 INCH
(12.7 mm)

A A

0.50 INCH
REPAIR PLY NO. 3
(12.7 mm)
TYPICAL FOR
TEFLON TAPE REPAIR PLIES
2.0 INCH
(50.8 mm)

FIBERGLASS 0.50 INCH

SANDING PLY (12.7 mm)
TYPICAL
FIBERGLASS REPAIR PLY NO. 1 (0°)
SANDING PLY
REPAIR PLY NO. 2 (45°)
TEFLON TAPE REPAIR PLY NO. 3 (0°)
TEFLON TAPE
CES-251-00

ADHESIVE
A-A

Carbon Composite Skin Damage

More Than 0.010-Inch (0.25 mm) in Depth
Figure 201

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Document Part No. RDN 306

BLEEDER
CLOTH
PLIES

SILICONE NON-POROUS
RUBBER PARTING
SHEET FILM
POROUS
PARTING
FILM HEAT BLANKET
VACUUM
BAG
FIBERGLASS FABRIC
BREATHER PLIES
VACUUM HOSE
TEFLON TAPE

BAG SEAL
TEFLON TAPE

TEMPERATURE TEMPERATURE
PROBE PROBE

CES-250-00

Vacuum Bag
Figure 202

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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

REPAIR NO. 5
CARBON COMPOSITE SKIN DAMAGE LESS THAN 0.010-INCH IN DEPTH

1. General

This procedure give the instructions to repair the damage to the composite
skin that is less than 0.010-inch (0.25 mm) in depth. The depth of the
damage does not include the thickness of the primer and paint layers. The
damaged area is filled with the adhesive and made smooth with the abrasive
paper. Carbon fabric is not used for this repair.

2. Repair Instructions

A. Clean the damaged area. See Table 201.

CAUTION: MAKE SURE YOU DO NOT CAUSE DAMAGE TO THE EXPANDED COPPER
SCREEN (ECS). DECREASE IN THE LIGHTNING PROTECTION CAN
OCCUR IF THE ECS IS DAMAGED.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN

YOU DO THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND
AND OBEY ALL INSTRUCTIONS FOR ITS USE. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE MANUFACTURER,
YOUR EMPLOYER AND GOVERNMENT REGULATIONS. YOU CAN GET
INJURED IF YOU DO NOT USE PPE. GET INSTRUCTIONS FROM
YOUR EMPLOYER ON WHICH PPE IS NECESSARY.

(1) Use a 180-grit abrasive paper on the edges of the damage.

(2) Use a 150-grit abrasive paper to remove the surface finish adjacent
to the repair area.

NOTE: The first primer layer is yellow and the outer primer layer
is gray.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(3) Clean the repair area with a clean, lint-free cloth and the
solvent. Clean the surface with a lint-free cloth before the
solvent becomes dry.

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for export purposes. Do not
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Proprietary - This document is subject to the controls and restrictions on the title page.
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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

B. Mix the adhesive. Refer to the instructions of the manufacturer. See

Table 201.

C. Fill the repair area. See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Fill the repair area with the adhesive until flush with the skin
surface.

(2) Dry the adhesive. Refer to the instructions of the manufacturer.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

D. Use a 180-grit abrasive paper on the surface and the edges of the
repair area. See Table 201.

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for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

E. Remove the unwanted material with a clean lint-free cloth and solvent.
Clean the surface with a lint-free cloth before the solvent becomes
dry. See Table 201.

F. Repair the surface finish. See Repair No. 1 - Surface Finish

Restoration.

3. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Adhesive, Epoxy Paste EA934NA V33564
Henkel Corporation
2850 Willow Pass Rd.
P.O. Box 312
Baypoint, CA 94565-0031
Phone: (925) 458-8000
www.aerospace.henkel.com
Cloth, Lint-free Cotton Commercially Available
Clothing, Protective Commercially Available
Container Metal or Plastic Commercially Available
Glasses, Safety Commercially Available
Gloves Neoprene or Polyvinyl Commercially Available
Chloride
Lamp, Heat 180°-200°F Commercially Available
(83°-93°C)
Mask, Dust Regulatory Agency Commerciallyl Available
Approved
Paper, Abrasive 150 - 180-Grit Commercially Available
Silicon Carbide
Repair Materials and Equipment
Table 201 (Sheet 1 of 2)

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DESCRIPTION DESIGNATION MANUFACTURER

Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
or
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Univar U.S.A., Inc.
Ketone/40% Methyl Ethyl 532 E. Emaus Street
Ketone Middletown, PA 17057-2200
Phone: (717) 944-7471
or www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Repair Materials and Equipment
Table 201 (Sheet 2 of 2)

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REPAIR NO.6
DAMAGE TO THE CORE FRAME OUTER SKIN AND ALUMINUM HONEYCOMB CORE

1. General

A. This procedure gives the instructions to repair the damage to the outer
barrel skin, core frame and honeycomb core.

B. Before you do this procedure, make sure that the core frame inner skin
is not damaged.

C. The core frame outer skin is a fiberglass ply 2.4-inches (60.96 mm)in
width. The core frame outer skin increases the strength of the three
basic skin plies in the core frame area.

2. Repair Instructions

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

A. Cut and remove the damaged area of the skin. See Figure 201 and Table
201.

(1) Remove all loose particles, cracks, and delaminations.

(2) Make a 0.5-inch (12.7 mm) minimum radius on all of the corners.

(3) Make a 45 degrees chamfer on the sides of the skin cutout that open
to the external surface.

(4) Use an abrasive paper on the edges of the skin cutout.

B. Cut and remove the damaged the honeycomb core. See Figure 201 and Table
201.

(1) Remove all of the damaged honeycomb core material.

NOTE: Make sure you do not cut into the core frame inner skin.

C. Put the teflon tape around the edge of the repair area. See Figure 202
and Table 201.

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(1) The teflon tape must have an overlap of 4.0-inches (101.6 mm) from
the edges of the skin cutout.

(a) Repair ply No. 1 must have an overlap of 1.0-inch (25.4 mm) in
all directions from the edges of the skin cutout.

(b) Each subsequent ply must have an overlap of 0.75-inch (19.1

mm) from the edges of the last ply.

(2) Use the teflon tape and make a mask band around the repair area.
Put the inner edge of the band against the outer edge of the
fiberglass sanding ply.

D. Remove all of the surface finish in the repair area.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU

DO THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY
ALL INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

(1) Use the abrasive paper (150-grit) to remove the top surface of the
outer skin ply in the repair area.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(2) Remove the unwanted material with a clean lint-free cloth and
solvent. Remove the solvent with a clean lint-free cloth before the
solvent becomes dry.

E. Cut a sufficient quantity of filler plies.

(1) Make the filler plies to the dimension of the cutout.

(2) To prevent damaged edges, cut the plies approximately 0.5 in (12.7
mm) larger than the cutout dimension.

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(3) Cut a sufficient quantity of plies to make the height of the fill
level with the outer surface of the outer barrel.

NOTE: The warp direction (the direction of the fabric) of each

filler ply is equal to 0-degrees.

F. Cut four repair plies. See Figure 202 for the warp direction.

(1) Cut the repair ply No. 1 to overlap of 1.0-inch (25.4 mm) in all
directions from the edges of the skin cutout.

(2) Cut the repair plies No. 2, 3, and 4 to overlap 0.75-inch (19.1 mm)
from the edges of the last ply.

(3) Cut the corners of the repair plies to 45 degrees by 1.0-inch (25.4
mm).

G. Cut one fiberglass sanding ply from the fiberglass fabric.

(1) Cut the fiberglass sanding ply to a minimum overlap of 0.75-inch

(19.1 mm) from the edges of the last ply.

NOTE: Extend the fiberglass sanding ply to the edge of the teflon
tape mask area.

(2) Cut the corners of the fiberglass sanding ply to 45 degrees by 1.0-
inch (25.4 mm).

H. Fill the core with adhesive. See Figure 202 and Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Mix the adhesive. Refer to the instructions of the manufacturer.

Add the phenolic microballoons 20 percent by weight to the
adhesive. Mix the contents until the mixture is a paste.

(2) Fill the core with the adhesive and microballoon mixture.

(3) Dry the adhesive and microballoon mixture. Refer to the

instructions of the manufacturer.

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I. Soak the filler plies, repair plies and fiberglass sanding ply with the
adhesive. See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Mix the adhesive. Refer to the instructions of the manufacturer.

(2) Put each ply on a sheet of nonporous parting film.

(3) Apply the adhesive to one side of each ply.

(4) Put a piece of nonporous parting film on the top of each ply.

(5) Use a roller to soak the plies with the adhesive.

J. Cut the filler plies to the same dimension of the cutout.

K. Install the filler plies, repair plies and fiberglass sanding ply. See
Figure 202 and Table 201.

(1) Install the filler plies.

(a) Remove the nonporous parting film from the bottom of the
filler ply. Put the ply into the cutout. Use a roller to
remove the wrinkles or caught air. Remove the nonporous
parting film from the top of the ply.

(b) Do step (a) for all filler plies.

(2) Install the repair plies.

(a) Remove the nonporous parting film from the bottom of the
repair ply No. 1. Put the ply on top of the filler plies. Make
sure there is an overlap of 1.0-inch (25.4 mm) in all
directions from the edges of the skin cutout. Use a roller to
remove the wrinkles or caught air. Remove the nonporous
parting film from the top of the ply.

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(b) Remove the nonporous parting film from the bottom of the
repair ply No. 2. Put the ply on top of the last ply. Make
sure there is an overlap of 0.75-inch (19.1 mm) in all
directions from the edges of the last ply. Use a roller to
remove the wrinkles or caught air. Remove the nonporous
parting film from the top of the ply.

(c) Do step (b) for all repair plies.

(3) Remove the nonporous parting film from the bottom of the fiberglass
sanding ply. Put the ply on top of the repair plies. Make sure
there is a minimum overlap of 0.25-inch (6.4 mm) in all directions
from the edges of the last repair ply. Use a roller to remove the
wrinkles or caught air. Remove the nonporous parting film from the
top of the ply.

L. Prepare the repair area for the vacuum bag cover and cure procedure.
See Figure 203 and Table 201.

(1) Put a sheet of porous parting film on the repair materials. Make
sure that the sheet of parting film has an overlap of 3.0-inch.
(76.2 mm) from all edges of the fiberglass sanding ply.

(2) Put the bleeder cloth layers on the parting film.

(a) The number of bleeder cloth layers must be equal to the number
of repair plies.

(b) The bleeder cloth layers must be equal to the dimension of the
porous parting film.

(3) Put a sheet of the nonporous parting film on the bleeder cloth
layers. Make sure the edges of bleeder cloth layers are below the
nonporous parting film.

(4) Put a silicon rubber sheet on the nonporous parting film.

(5) Put a heat blanket on the rubber sheet.

(6) Put two layers of the fiberglass breather cloth on the heat
blanket.

(7) Put a vacuum bag on the heat blanket.

NOTE: Make sure the vacuum bag has an overlap of approximately

2.0-inch (50.8 mm) from all edges of the heat blanket.

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(8) Put a temperature probe below the bag and seal the edges of the
vacuum bag with the double-sided tape.

(9) Put a vacuum connector below the bag and seal the edges with the
double-sided tape.

M. Use a vacuum pump to increase the vacuum pressure in the bag to 20-
inches of mercury (67.7 kPa). See Table 201.

N. Set the switch for the heat blanket to keep the temperature at 190°-
210°F (88°-99°C). Let the repair cure for 220 minutes. See Table 201.

O. Remove the vacuum bag, backup plate and all of the bag materials from
the repair. Remove the teflon tape from around the repair area.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

P. Use abrasive paper (150 - 320-grit) and make the surface and the edges
of the repair smooth. Do not go into the graphite ply with the abrasive
paper. See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

Q. Remove the unwanted material with a clean lint-free cloth and solvent.
Remove the solvent with a clean lint-free cloth before the solvent
becomes dry. See Table 201.

R. Repair the surface finish. See Repair No. 1 - Surface Finish

Restoration.

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3. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Adhesive, Epoxy EA9390 (Two Part) V33564
Henkel Corporation
2850 Willow Pass Rd.
P.O. Box 312
Baypoint, CA 94565-0031
Phone: (800) 257-7522
www.aerospace.henkel.com
Blanket, Heat 0 - 250°F (0 - 121°C) V61426
20 x 20 inch Atacs Products, Inc.
(508 x 508 mm) 850 South Cambridge Street
Seattle, WA 98108-4748
Phone: (206) 433-9000
www.atacs.com
Brush Nylon Bristle Commercially Available
Cloth, Bleeder Fiberglass Commercially Available
Cloth, Breather RC3000-10 V0F451
Richmond Aircraft Products, Inc.
13503 Pulmice St
Norwalk, CA 90650-5250
Phone: (562) 404-2440
www.richmondaircraft.com
Cloth, Lint-free Cotton Commercially Available
Container Metal or Plastic Commercially Available
Cover, Container Metal or Plastic Commercailly Available
Fabric, Fiberglass Type 181 Commercially Available
Fabric, Graphite AH370-5H V2B975
11 x 11 inch Hexcel Corp
(280 x 280 mm) 1913 N King St
Seguin, TX 78155-2197
Phone: (800) 688-7734
www.hexcel.com
Film, Bagging 2 mm Nylon V0F451
Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Repair Materials and Equipment
Table 201 (Sheet 1 of 2)

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DESCRIPTION DESIGNATION MANUFACTURER

Film Parting Nonporous V0F451
Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Film Parting Porous V0F451
Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Gauge, Vacuum 0-20 Inches-of-Mercury Commercially Available
(0-67.5 kPa)
Hose, Vacuum 1/8 in. Diameter Commercially Available
Microballoons Phenolic, 135 Micron Commercially Available
Paper, Abrasive 150 - 320-Grit Commercially Available
Silicon Carbide
Probe, Temperature 0-250°F (0-121°C) Commercially Available
Pump, Vacuum 0-30 Inches-of-mercury Commercially Available
(0-0.1 MPa)
Roller 2.0 in. (50.8 mm) Commercially Available
Diameter, Steel or
Plastic
Rubber Sheet 0.062 - 0.125-inch (1.57 Commercially Available
-3.18 mm) thick,
Silicone
Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
or
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Univar U.S.A., Inc.
Ketone/40% Methyl Ethyl 532 E. Emaus Street
Ketone Middletown, PA 17057-2200
Phone: (717) 944-7471
or www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Tape Double Sided Commercially Available
Tape, Teflon 2.0-inch Commercially Available
Repair Materials and Equipment
Table 201 (Sheet 2 of 2)

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OUTER 0.5 INCH

BARREL (12.7 mm)
SKIN RADIUS

A A

CUTOUT

OUTER
BARREL
SKIN
CUTOUT
45°

CORE FRAME
OUTER SKIN

A-A
CES-249-00

Skin Cutout
Figure 201

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OUTER
FIBERGLASS BARREL
SANDING PLY SKIN

REPAIR
PLY NO. 4 45°
REPAIR
PLY NO. 3

A A

REPAIR REPAIR
PLY NO. 1 PLY NO. 2

CUTOUT 1.0 INCH 1.0 INCH

(25.4 mm) (25.4 mm)

TEFLON TAPE
2.0 INCH 0.75 INCH
(50.8 mm) (19.05 mm)
(TYPICAL)

REPAIR PLY NO. 1 (-45°)

REPAIR PLY NO. 2 (0°)
TEFLON TAPE REPAIR PLY NO. 3 (+45°)
REPAIR PLY NO. 4 (0°)
OUTER
FIBERGLASS SANDING PLY
BARREL
SKIN
TEFLON TAPE

CUTOUT
CORE FRAME OUTER
FILLER PIES SKIN
ADHESIVE/MICROBALLOON
CES-248-00

MIXTURE
FRAME INNER
CAP GRAPHITE
TAPE PLIES A-A HONEYCOMB CORE

Filler and Repair Plies

Figure 202

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BLEEDER
CLOTH
PLIES

SILICONE NON-POROUS
RUBBER PARTING
SHEET FILM
POROUS
PARTING
FILM HEAT BLANKET
VACUUM
BAG
FIBERGLASS FABRIC
VACUUM HOSE
TEFLON TAPE

TEFLON TAPE OUTER

BARREL
SKIN

TEMPERATURE
TEMPERATURE PROBE
PROBE

CES-252-00

Vacuum Bag
Figure 203

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REPAIR NO. 10
INLET LIP FLUSH PATCH

1. General

A. The inlet lip skin is divided into three repair areas. See Figure 201
for allowable repair size limits.

B. This procedure gives the instructions to install a flush patch on the

inlet cowl lip. The flush patch and internal doubler are made from
aluminum and heat treated. Install the flush patch and internal doubler
with rivets.

2. Repair Instructions

A. Clean the area of damage.

(1) Cut and remove the damaged area.

(2) Remove the sharp edges of the cutout.

(3) Make sure the cutout has rounded corners with a 1.0-inch (25.4 mm)
radius. See Figure 202.

(4) Remove all of the loose materials from the inlet lip. The loose
materials can cause damage to the anti-ice vents.

B. Make the flush patch and internal doubler. (A cutout from a spare
lipskin area can be used.)

(1) Make a flush patch and internal doubler for the damaged skin from
2219-0 bare aluminum sheet 0.080-inch (2.0 mm) thick. See Figure
202 and Table 201.

NOTE: Make the flush patch to agree with the surface contour.

(2) Heat treat the flush patch and internal doubler to T62. Refer to
AMS 2770 or equivalent.

C. Prepare the flush patch and internal doubler for installation on the
inlet cowl lip skin.

(1) Use the clamps to put the internal doubler below the inlet lip
skin.

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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

(2) Use a number 40 drill bit to drill pilot holes through the skin and
internal doubler.

NOTE: If necessary, cut the internal doubler. Make the overlap a

distance of two rivets on the adjacent internal doubler
section. See Figure 202.

(3) Attach the internal doubler to the skin with temporary fasteners.

(4) Put the flush patch on the inlet lip. Use a No. 40 drill bit to
drill pilot holes through the flush patch and internal doubler.

(5) Attach the flush patch to the internal doublers with temporary
fasteners.

(6) Use a reamer to increase the holes to 0.205 - 0.209-inch (5.207 -

5.309 mm) diameter through the skin, internal doubler and flush
patch.

(7) Remove the flush patch and internal doubler.

(8) Remove the burrs from the flush patch, skin, and internal doubler.

(9) Countersink the rivet holes in the flush patch and lip skin for
CR3552-6-3 rivets. Countersink to 0.350 - 0.356-inch (8.89 - 9.04
mm) diameter by 100°.

(10) Remove all of the loose materials from the inlet lip skin. The
loose materials can cause damage to the anti-ice vents.

(11) Apply the chemical conversion coating to the flush patch. See Table
201.

(a) Rub each side of the flush patch with an abrasive pad to get a
water-break free surface. See Table 201.

NOTE: A water-break free surface is a surface that can keep a

film of water for 30 seconds.

CF6-80E1
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54-10-00 REPAIR NO. 10
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Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
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Proprietary - This document is subject to the controls and restrictions on the title page.
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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE MANUFACTURER,
THE MATERIAL SAFETY DATA SHEET (MSDS), AND GOVERNMENT
REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE
YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED. AN
MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

(b) Apply the chemical conversion coating on the clean surface.

Refer to the instructions of the manufacturer.

1 Keep the surface wet with new chemical conversion coating

for 2 to 5 minutes.

NOTE: Do not let the solution dry on the surface.

(c) Flush the surface fully with the clean water.

(d) Dry the surface for 30 minutes.

NOTE: The surface must be without color.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(12) Apply the RTV prime coat to the mating surfaces of the skin and
flush patch. Refer to the instructions of the manufacturer. See
Table 201.

(13) Dry the RTV prime coat. Refer to the instructions of the
manufacturer.

CF6-80E1
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54-10-00 REPAIR NO. 10
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Printed in the U.S.A.
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for export purposes. Do not
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Proprietary - This document is subject to the controls and restrictions on the title page.
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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(14) Apply the silicone sealant to the mating surfaces of the skin and
flush patch. Refer to the instructions of the manufacturer. See
Table 201.

D. Install the flush patch on the inlet cowl lip.

(1) Install the flush patch and the internal doubler on the inlet lip
skin with the temporary fasteners.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(2) Install the CR3552-6-3 flush rivets wet with the silicone sealant.
Use the CR3552-6-4 rivets for the overlap. See Figure 202 and Table
201.

(3) Install the rivets -0.004 to 0.000-inch (-0.102 to 0.000 mm) flush
to surface.

(4) Cut or remove the blind rivet stems with a file to make a smooth
surface with the skin surface.

(5) Remove all of the rivet pieces from the inlet lip. The rivet pieces
can cause the airflow blockage in the anti-ice vents.

CF6-80E1
This document may contain export
54-10-00 REPAIR NO. 10
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controlled technical data, but
has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

E. Apply aerodynamic sealant to the gap between the flush patch and the
inlet lip skin. Refer to the instructions of the manufacturer. See
Table 201.

3. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201..

DESCRIPTION DESIGNATION MANUFACTURER

Aluminum, Sheet 2219-0 Bare Commercially Available
Aluminum Alloy
0.080-inch (2.0 mm)
(2219-T62 Alternate)
Coating, Chemical Alodine 1000L V71410
Conversion Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Pad, Abrasive Scotch-Brite pad V76381
3M Corporate Headquarters
3M Center
St. Paul, MN 55144-1000
Phone: (800) 362-3550
www.3m.com/industrial.com
Prime Coat, RTV DOW CORNING® PR-1200 V5D028
Dow Corning Corporation
3901 South Saginaw Road
Midland, MI 48686
Phone: (989) 496-4400
www.dowcorning.com
Repair Materials and Equipment
Table 201

CF6-80E1
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Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

DESCRIPTION DESIGNATION MANUFACTURER

Rivet CR3552-6-3 V11815
CR3552-6-4 Cherry Aerospace LLC
1224 E. Warner St.
Santa Ana, CA 92707
Phone: (714) 850-6086
Sealant, Silicone RTV157 - Gray V01139
Adhesive Momentive Performance Material Inc.
260 Hudson River Rd.
Waterford, NY 12188
www.gesilicones.com
Repair Materials and Equipment
Table 201

CF6-80E1
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54-10-00 REPAIR NO. 10
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Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
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Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

A
REPAIR MAXIMUM SIZE
AREA OF REPAIR

A 60 SQ INCHES
(387 sq cm)
A B 85 SQ INCHES
(548 sq cm)
C 90 SQ INCHES
(580 sq cm)

INLET
COWL

EXTERNAL SURFACE AREA C

8.0-INCHES (203,2 mm)
INLET
LIP OUTER BARREL PANEL

OUTER CAP
ANGLE

LEADING
EDGE
AREA A
CES-229-01

INNER BARREL PANEL

INTERNAL SURFACE AREA B
6.0-INCHES (152,4 mm) A-A
Inlet Cowl Lip Repair Areas
Figure 201

CF6-80E1
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Proprietary - This document is subject to the controls and restrictions on the title page.
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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

0.030 INCH
(0.76 mm)
LIPSKIN A MAXIMUM GAP
1.0 INCH
(25.4 mm)
RADIUS

SEGMENT
B OVERLAP
0.5 INCH
AS NECESSARY
(12.7 mm) (TYPICAL)
RADIUS
(TYPICAL)

A
FLUSH PATCH
2219-0 BARE
AL ALLOY
0.080 INCH DOUBLER SEGMENT
(2.0 mm) 2219-0 BARE AL ALLOY
GAGE HT-T62 0.080 INCH (2.0 mm)
GAGE HT-T62

FLUSH LIP
PATCH SKIN DOUBLER
SEGMENT
DOUBLER
SEGMENT

DOUBLER 2D
SEGMENT 4D
TYPICAL TYPICAL

INLET LIP B-B

REPAIR RIVET CR3552-6-3

A-A REPAIR RIVET CR3552-6-4
(AT SEGMENT OVERLAP)
CES-228-00
Flush Patch Repair
Figure 202

CF6-80E1
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for export purposes. Do not
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Proprietary - This document is subject to the controls and restrictions on the title page.
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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

REPAIR NO. 11
INLET LIP EXTERNAL PATCH

1. General

A. The inlet lip skin is divided into three repair areas. See Figure 201
for allowable repair size limits.

B. Flush patches must be used in area A of the lip and can be used in areas
B and C. Temporary external patches in area A may be installed to
permit ferry of the inlet cowl to a location where it can be repaired.
(See Figure 201).

C. This repair is permanent for areas B and C.

2. Repair Instructions

A. Clean up the damage area.

(1) Use a number 30 drill bit at the ends of cracks or cuts. (See
Figure 202).

(2) Remove the sharp edges.

(3) Remove all of the loose materials from the inlet lip. The loose
materials can cause damage to the anti-ice vents.

B. Make the external patch.

(1) Make an external patch for the damaged skin from 2219-0 bare
aluminum sheet that is 0.080-inch (2.0 mm) thick. See Figure 202.

NOTE: Make the external patch to agree with the surface contour.

(2) Heat treat the external patch to T62. Refer to AMS 2770 or
equivalent.

(3) Make sure the edges of the patch are tapered two times the
thickness from 0.020-inch (0.5 mm) above the skin. See Figure 202,
Section A-A.

C. Prepare the external patch for installation on the inlet cowl lip skin.

(1) Use the clamps to put the external patch in the correct location on
the damaged area of the lip skin.

(2) Use a number 40 bit to drill pilot holes through the external patch
and lip skin.

CF6-80E1
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54-10-00 REPAIR NO. 11
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for export purposes. Do not
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Proprietary - This document is subject to the controls and restrictions on the title page.
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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

(3) Use a reamer to increase the holes to 0.205 - 0.209-inch (5.207 -

5.309 mm) diameter through the lip skin and flush external patch.

(4) Countersink the rivet holes in the external patch and lip skin for
CR3552-6-3 rivets. Countersink to 0.350 - 0.356-inch (8.89 - 9.04
mm) diameter by 100°

(5) Put marks on the lip skin to show the location of the external
patch.

(6) Remove the external patch.

(7) Remove the burrs from the external patch.

(8) Remove all of the loose materials from the inlet lip skin. The
loose materials can cause damage to the anti-ice vents.

(9) Remove the surface finish from the patch area of the lip skin with
a 240 grit abrasive paper.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY

ALL SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE
MANUFACTURER, THE MATERIAL SAFETY DATA SHEET (MSDS),
AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE INJURY
TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE
NOT OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST
SAFELY USE, KEEP, AND DISCARD CHEMICALS. GET
INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU MUST SAFELY
USE, KEEP, AND DISCARD CHEMICALS.

(10) Clean the repair area with a clean, lint-free cloth and the
solvent. Remove the solvent with a clean lint-free cloth before the
solvent becomes dry. See Table 201.

(11) Apply the chemical conversion coating to the external patch. See
Table 201.

(a) Rub each side of the external patch with an abrasive pad to
get a water-break free surface.

NOTE: A water-break free surface is a surface that can keep a

film of water for 30 seconds.

CF6-80E1
This document may contain export
54-10-00 REPAIR NO. 11
Page 202
Oct 15/19
controlled technical data, but
has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE MANUFACTURER,
THE MATERIAL SAFETY DATA SHEET (MSDS), AND GOVERNMENT
REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE
YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED. AN
MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

(b) Apply the chemical conversion coating on the clean surface.

Refer to the instructions of the manufacturer.

1 Keep the surface wet with new chemical conversion coating

for 2 to 5 minutes.

NOTE: Do not let the solution dry on the surface.

(c) Flush the surface fully with the clean water.

(d) Dry the surface for 30 minutes.

NOTE: The surface must be without color.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(12) Apply the RTV prime coat to the mating surfaces of the skin and
external patch. Refer to the instructions of the manufacturer. See
Table 201.

(13) Dry the RTV prime coat. Refer to the instructions of the
manufacturer.

CF6-80E1
This document may contain export
54-10-00 REPAIR NO. 11
Page 203
Oct 15/19
controlled technical data, but
has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(14) Apply the silicone sealant to the mating surfaces of the skin and
external patch. Refer to the instructions of the manufacturer. See
Table 201.

D. Install the external patch on the inlet lip skin.

(1) Install the external patch on the inlet lip skin with the temporary
fasteners.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(2) Install the CR3552-6-3 flush rivets wet with the silicone sealant.
See Figure 202 and Table 201.

(3) Install the rivets -0.004 to 0.000-inch (-0.102 to 0.000 mm) flush
to surface.

(4) Cut or remove the blind rivet stems with a file to make a smooth
surface with the skin surface.

(5) Remove all of the rivet pieces from the inlet lip. The rivet pieces
can cause the airflow blockage in the anti-ice vents.

CF6-80E1
This document may contain export
54-10-00 REPAIR NO. 11
Page 204
Oct 15/19
controlled technical data, but
has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

E. Apply aerodynamic sealant to the gap between the flush patch and the
inlet lip skin. Refer to the instructions of the manufacturer. See
Table 201.

3. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201. .

DESCRIPTION DESIGNATION MANUFACTURER

Aluminum, Sheet 2219-0 Bare Commercially Available
Aluminum Alloy
0.080-inch (2.0 mm)
(2219-T62 Alternate)
Cloth, Lint-free Cotton Commercially Available
Coating, Chemical Alodine 1000L V71410
Conversion Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Coating, Chemical Alodine 1000L V71410
Conversion Henkel Surface Technologies
Henkel Corporation
32100 Stephenson Highway
Madison Heights, MI 48071
Phone: (248) 583-9300
Pad, Abrasive Scotch-Brite pad V76381
3M Corporate Headquarters
3M Center
St. Paul, MN 55144-1000
Phone: (800) 362-3550
www.3m.com/industrial.com
Repair Materials and Equipment
Table 201 (Sheet 1 of 2)

CF6-80E1
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54-10-00 REPAIR NO. 11
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has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

DESCRIPTION DESIGNATION MANUFACTURER

Paper, Abrasive 240 Grit Commercially Available
Aluminum Oxide
Prime Coat, RTV DOW CORNING® PR-1200 V5D028
Dow Corning Corporation
3901 South Saginaw Road
Midland, MI 48686
Phone: (989) 496-4400
www.dowcorning.com
Rivet CR3552-6-3 V05693
Cherry Textron Inc
1224 E. Warner St.
Santa Ana, CA 92705-5484
Phone: (714) 545-5511
www.cherryaerospace.com
Sealant, Silicone RTV157 - Gray V01139
Adhesive Momentive Performance Material Inc.
260 Hudson River Rd.
Waterford, NY 12188
www.gesilicones.com
Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
or
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Univar U.S.A., Inc.
Ketone/40% Methyl Ethyl 532 E. Emaus Street
Ketone Middletown, PA 17057-2200
Phone: (717) 944-7471
or www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Repair Materials and Equipment
Table 201 (Sheet 2 of 2)

CF6-80E1
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54-10-00 REPAIR NO. 11
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has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

A
REPAIR MAXIMUM SIZE
AREA OF REPAIR

A 60 SQ INCHES
(387 sq cm)
A B 85 SQ INCHES
(548 sq cm)
C 90 SQ INCHES
(580 sq cm)

INLET
COWL

EXTERNAL SURFACE AREA C

INLET 8.0-INCHES (203,2 mm)
LIP OUTER BARREL PANEL

OUTER CAP
ANGLE

LEADING
CES-233-01

EDGE
AREA A INNER BARREL PANEL
INTERNAL SURFACE AREA B
6.0-INCHES (152,4 mm) A-A
Inlet Cowl Lip Repair Areas
Figure 201

CF6-80E1
This document may contain export
54-10-00 REPAIR NO. 11
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Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

0.75 INCH
(19 mm)
(TYPICAL) CR3552-6-3
BLIND
RIVETS

DRILL EACH
END OF
1.00 INCH CRACK
(25.4 mm)
(TYPICAL)

TYPICAL TAPER
FOR ALL EDGES.
TAPER MUST NOT
TOUCH RIVET HOLES

2 X THICKNESS

A A

0.020 INCH THICKNESS

(0.508 mm)
THICKNESS

SECTION A-A
CES-234-00

0.40 INCH
(10.2 mm)(TYPICAL)

External Patch Repair

Figure 202

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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

REPAIR NO. 12
AFT BULKHEAD WEB CRACK

1. General

This procedure gives the instructions to repair a crack in the aft

bulkhead web. The cracks are stop-drilled and a repair doubler is
installed with rivets. This repair does not apply to titanium webs. See
the 54-10-00 Structural Identification Figure 7 for the web materials.

2. Repair Instructions

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

A. Prepare the damaged area.

(1) Use a drill bit No. 30, 0.128-inch (3.26 mm) to make the stop holes
at the end of the cracks.

(2) Remove the burrs from the holes and make the edges smooth.

(3) Find the dimension of the repair doubler. See Figure 201.

(a) Use the dimensions on Figure 201 to make an outline of the

repair doubler on the bulkhead.

NOTE: The repair doubler must keep the 2D edge margin for the
blind fastener.

NOTE: Keep a distance of 2D between the edge of the crack and

the crack edge rivets.

NOTE: Keep a corner radius of 0.50-inch (12.70 mm).

CF6-80E1
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Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

B. Make a repair doubler.

(1) Make a repair doubler from a 0.063-inch (1.6 mm) thick 2024-T3
aluminum sheet.

(2) Use a drill bit No. 40, 0.098-inch (2.5 mm) to make the pilot holes
in the repair doubler for the doubler attach rivets. Use the
dimension in Figure 201 for the pilot hole locations.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

C. Make the holes for the doubler attach rivet.

(1) Use the repair doubler as a template and make the pilot holes in
the web for the doubler attach rivets. Use a drill bit No. 40,
0.098-inch (2.5 mm).

(2) Attach the repair doubler to the web with temporary fasteners.

(3) Use a drill bit No. 20, 0.161-inch (4.09 mm) as a reamer to make
the pilot holes larger.

(4) Remove the temporary fasteners.

(5) Remove the burrs from the holes and make the edges smooth on the
repair doubler and web.

CF6-80E1
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Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

D. Make the holes for the crack stabilizing rivets.

(1) Make a paper or clear-plastic template to find the locations for

the crack stabilizing rivets.

(2) Use the template to make a mark of the locations for the crack
stabilizing rivets on the repair doubler.

(3) Attach the repair doubler to the web with temporary fasteners.

(4) Use the repair doubler as a template and make the pilot holes in
the repair doubler and the web for the crack stabilizing rivets.
Use a drill bit No. 40, 0.098-inch (2.5 mm).

(5) Use a No. 27, 0.144-inch (3.7 mm) as a reamer to make the pilot
holes larger.

(6) Remove the temporary fasteners.

(7) Remove the burrs from the holes and make the edges smooth on the
repair doubler and web.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

E. Clean the mating surfaces of the repair doubler and the web with a
clean, lint-free cloth and the solvent. Remove the solvent with a clean
lint-free cloth before the solvent becomes dry.

F. Prepare the repair doubler for installation.

CF6-80E1
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54-10-00 REPAIR NO. 12
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has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Apply the RTV prime coat to the mating surfaces of the repair
doubler and the web. Refer to the instructions of the manufacturer.

(2) Dry the RTV prime coat. Refer to the instructions of the
manufacturer.

(3) Find the grip length of the attaching rivets.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(4) Apply the silicone sealant to the mating surfaces of the repair
doubler and the web.

G. Install the repair doubler on the web. See Figure 201.

(1) Install the repair doubler on the aft bulkhead web with temporary
fasteners.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(2) Install the rivets wet with silicone sealant.

CF6-80E1
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54-10-00 REPAIR NO. 12
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Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
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Proprietary - This document is subject to the controls and restrictions on the title page.
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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

(3) Remove unwanted adhesive with a clean, lint-free cloth.

(4) Dry the silicone sealant. Refer to the instructions of the

manufacturer.

(5) Use a file to remove the blind rivet stems to make the surface
smooth.

3. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Cloth, Lint-free Cotton Commercially Available
Doubler, Repair 2024-T3 Aluminum Commercially Available
0.063 in. (1.60 mm)
Thick Sheet
Drill Bit No. 20, 0.161-inch (4.09 mm) Commercially Available
No. 27, 0.144-inch (3.7 mm)
No. 30, 0.128-inch (3.26 mm)
No. 40, 0.098-inch (2.50 mm)
Prime Coat, RTV DOW CORNING® PR-1200 V5D028
Dow Corning Corporation
3901 South Saginaw Road
Midland, MI 48686
Phone: (989) 496-4400
www.dowcorning.com
Rivet, Blind CR3523-4 V05693
CR3553-5 Cherry Textron Inc
1224 E. Warner St.
Santa Ana, CA 92705-5484
Phone: (714) 545-5511
www.cherryaerospace.com
Sealant, Silicone RTV157 - Gray V01139
Adhesive Momentive Performance
Material Inc.
260 Hudson River Rd.
Waterford, NY 12188
www.gesilicones.com
Repair Materials and Equipment
Table 201

CF6-80E1
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for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

DESCRIPTION DESIGNATION MANUFACTURER

Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
or
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Ketone/ Univar U.S.A., Inc.
40% Methyl Ethyl Ketone 532 E. Emaus Street
Middletown, PA 17057-2200
or Phone: (717) 944-7471
www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Repair Materials and Equipment
Table 201

CF6-80E1
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has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

REPAIR DOUBLER,
0.128 INCH 0.063 INCH (1.60 MM) THICK
ALUM SHEET 0.50 INCH (12.70 MM)
(3.26 MM) RADIUS (MINIMUM)
STOP HOLE 2024-T3

4D-6D
BETWEEN
RIVETS DOUBLER
(TYPICAL) ATTACH RIVET

CRACK EDGE
STABILIZING
RIVET

2D
FROM EDGE
OF CRACK CRACK
(TYPICAL)

2D
EDGE MARGINS
WEB, (TYPICAL)
ALUM SHEET
2024-T3
CES-124-01

ORIGINAL FASTENER LOCATION

CR3523-5 REPAIR FASTENER LOCATION
CR3523-4 REPAIR FASTENER LOCATION

Aft Bulkhead Web Crack Repair

Figure 201

CF6-80E1
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controlled technical data, but
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Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

THIS PAGE INTENTIONALLY LEFT BLANK

CF6-80E1
This document may contain export
54-10-00 REPAIR NO. 12
Page 208
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controlled technical data, but
has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

REPAIR NO. 13

AFT BULKHEAD WEB PUNCTURE

1. General

This procedure gives the instructions to repair a hole in the aft bulkhead
web. The damaged area is cut, removed and a repair doubler is installed
with rivets. This repair does not apply to titanium webs.
See the 54-10-00 Structural Identification Figure 7 for the web materials.

2. Repair Instructions

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

A. Prepare the damaged area. See Figure 201.

(1) Use a drill bit No. 30, 0.128-inch (3.26 mm) to make the stop holes
at the end of the cracks that extend from the hole.

(2) Use a router to remove the cracks and damaged material from the
web. Keep a corner radius of 0.050-inch (12.70 mm).

(3) Use the abrasive paper to remove the burrs and make the edges
smooth.

(4) Find the dimension of the repair doubler. See Figure 201.

(a) Use the dimensions on Figure 201 to make an outline of the

repair doubler on the bulkhead.

NOTE: The repair doubler must keep the 2D edge margin for the
fasteners.

NOTE: Keep a corner radius of 0.50-inch (12.70 mm).

CF6-80E1
This document may contain export
54-10-00 REPAIR NO. 13
Page 201
Oct 15/19
controlled technical data, but
has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

B. Make a repair doubler.

(1) Make a repair doubler from a 0.063-inch (1.6 mm) thick 2024-T3
aluminum sheet.

(2) Use a drill bit No. 40, 0.098-inch (2.5 mm) to make the pilot holes
in the repair doubler for the doubler attach rivets. Use the
dimension in Figure 201 for the pilot hole locations.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

C. Make the holes for the doubler attach rivet.

(1) Use the repair doubler as a template and make the pilot holes in
the web for the doubler attach rivets. Use a drill bit No. 40,
0.098-inch (2.5 mm).

(2) Attach the repair doubler to the web with temporary fasteners.

(3) Use a drill bit No. 20, 0.161-inch (4.09 mm) as a reamer to make
the pilot holes larger.

(4) Remove the temporary fasteners.

(5) Remove the burrs from the holes and make the edges smooth on the
repair doubler and web.

CF6-80E1
This document may contain export
54-10-00 REPAIR NO. 13
Page 202
Oct 15/19
controlled technical data, but
has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

D. Clean the mating surfaces of the repair doubler and the web with a
clean, lint-free cloth and the solvent. Remove the solvent with a clean
lint-free cloth before the solvent becomes dry.

E. Prepare the repair doubler for installation.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Apply the RTV prime coat to the mating surfaces of the repair
doubler and the web. Refer to the instructions of the manufacturer.

(2) Dry the RTV prime coat. Refer to the instructions of the
manufacturer.

(3) Find the grip length of the attaching rivets.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(4) Apply the silicone sealant to the mating surfaces of the repair
doubler and the web.

F. Install the repair doubler on the web. See Figure 201.

CF6-80E1
This document may contain export
54-10-00 REPAIR NO. 13
Page 203
Oct 15/19
controlled technical data, but
has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

(1) Install the repair doubler on the aft bulkhead web with temporary
fasteners.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(2) Install the rivets wet with silicone sealant.

(3) Remove unwanted adhesive with a clean, lint-free cloth.

(4) Dry the silicone sealant. Refer to the instructions of the

manufacturer.

(5) Use a file to remove the blind rivet stems to make the surface
smooth.

3. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Cloth, Lint-free Cotton Commercially Available
Doubler, Repair 2024-T3 Aluminum Commercially Available
0.063 in. (1.60 mm)
Thick Sheet
Drill Bit No. 20, 0.161-inch (4.09 mm) Commercially Available
No. 30, 0.128-inch (3.26 mm)
No. 40, 0.098-inch (2.50 mm)
Paper, Abrasive 180 - 320-Grit Silicone Carbide Commercially Available
Prime Coat, RTV DOW CORNING® PR-1200 V5D028
Dow Corning Corporation
3901 South Saginaw Road
Midland, MI 48686
Phone: (989) 496-4400
www.dowcorning.com
Repair Materials and Equipment
Table 201

CF6-80E1
This document may contain export
54-10-00 REPAIR NO. 13
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controlled technical data, but
has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

DESCRIPTION DESIGNATION MANUFACTURER

Rivet, Blind CR3553-5 V05693
Cherry Textron Inc
1224 E. Warner St.
Santa Ana, CA 92705-5484
Phone: (714) 545-5511
www.cherryaerospace.com
Sealant, Silicone RTV157 - Gray V01139
Adhesive Momentive Performance
Material Inc.
260 Hudson River Rd.
Waterford, NY 12188
www.gesilicones.com
Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
or
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Ketone/40% Univar U.S.A., Inc.
Methyl Ethyl Ketone 532 E. Emaus Street
Middletown, PA 17057-2200
or Phone: (717) 944-7471
www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Repair Materials and Equipment
Table 201

CF6-80E1
This document may contain export
54-10-00 REPAIR NO. 13
Page 205
Oct 15/19
controlled technical data, but
has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

REPAIR DOUBLER,
0.063 INCH (1.60 MM) THICK
ALUM SHEET 0.50 INCH (12.70 MM)
2024-T3 RADIUS (MINIMUM)
STOP HOLE

4D-6D
BETWEEN
RIVETS
(TYPICAL)
DOUBLER
ATTACH RIVET

CUT AND REMOVE

THE DAMAGE

2D
FROM EDGE
OF REMOVED DAMAGE
DAMAGE
(TYPICAL)

2D STOP HOLE
EDGE MARGINS
WEB, (TYPICAL)
ALUM SHEET
2024-T3
CES-235-00

ORIGINAL FASTENER LOCATION

CR3523-5 REPAIR FASTENER LOCATION

Aft Bulkhead Web Puncture Repair

Figure 201

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Document Part No. RDN 306

REPAIR NO.14
AFT BULKHEAD SPLICE

1. General

This procedure gives the instructions to repair the damage in the aft
bulkhead web. The damaged aft bulkhead web is removed and replaced with a
replacement bulkhead web. The replacement bulkhead web is attached with a
splice plate. This repair does not apply to titanium bulkhead webs. See
the 54-10-00 Structural Identification, Figure 7 for the web materials.

2. Repair Instructions

A. Prepare the damaged area. See Figure 201.

(1) Make a mark around the aft bulkhead web adjacent to the zee
stiffener to show the damaged area to cut and remove.

(2) Make a mark around the area to install the splice plates. Make the
splice plates 2.0-inches (50.8 mm) wide for the correct rivet
distance from the edge.

(3) Remove the fasteners and the zee stiffeners in the damaged area.

(4) Cut and remove the damaged aft bulkhead web section.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

B. Prepare the replacement bulkhead web and splice plates.

(1) Make the replacement bulkhead web. See Figure 201.

(a) Make a replacement bulkhead web from the aluminum sheet. See
Table 201.

(b) Use the clamp to put the replacement bulkhead web on the inner
and outer frames.

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(c) Use a drill bit No. 40 to make the pilot holes in the
replacement bulkhead web. Use the holes in the inner and outer
frame for reference to make the pilot holes.

NOTE: Make sure you align the pilot holes with the center of
the holes on the inner and outer frame.

(2) Make the splice plates. See Figure 202.

(a) Make the splice plates from the aluminum sheet. See Table 201.

(b) Put the splice plates on the bulkhead web section with a 1.0-
inch (25.4 mm) overlap on the replacement bulkhead web.

(c) Use a drill bit No. 40 to make the pilot holes in the splice
plates. Use the zee stiffener holes in the bulkhead for
reference to make one row of the pilot holes.

NOTE: Make sure to keep the 2D edge distance for the rivets.

NOTE: Make sure you align the pilot holes with the center of
the zee stiffener holes in the bulkhead.

(3) Attach the splice plates, zee stiffeners and the replacement
bulkhead web with temporary fasteners and remove the clamp.

(4) Use a drill bit No. 40 to make the pilot holes in the splice plates
and replacement bulkhead web.

NOTE: Make sure to keep the 2D edge distance for the rivets.

NOTE: Make sure to keep the 4D-6D distance between rivets.

(5) Use a drill bit No. 16 as a reamer to make all the pilot holes
0.177-inch (4.49 mm) in diameter.

(6) Remove the zee stiffeners, splice plates, and replacement bulkhead
web from the aft bulkhead.

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WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(7) Remove the unwanted material with a clean lint-free cloth and
solvent. Remove the solvent with a clean lint-free cloth before the
solvent becomes dry.

C. Prepare the replacement bulkhead web, zee stiffeners and splice plates
for installation.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Use the instructions of the manufacturer to apply the RTV prime
coat to all the mating surfaces.

(2) Use the instructions of the manufacturer to dry the RTV prime coat.

D. Install the replacement bulkhead web, splice plates and zee stiffeners.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Use the instructions of the manufacturer to apply the silicone

sealant to all the mating surfaces.

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Document Part No. RDN 306

(2) Put the replacement bulkhead web, splice plates and zee stiffeners
in position.

(3) Install the rivets wet with the silicone sealant.

(4) Cut or remove the blind fastener stems with a file to make a smooth
surface.

(5) Use the instructions of the manufacturer to dry the silicone

sealant.

3. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Clamp Commercially Available
Cloth, Lint-free Cotton Commercially Available
Fasteners, Temporary Commercially Available
File Commercially Available
Sheet, Aluminum 2024-T3 Aluminum Commercially Available
0.063-inch (1.62 mm)
Thick
Drill No. 16 Commercially Available
No. 40
Prime Coat, RTV DOW CORNING® PR-1200 V5D028
Dow Corning Corporation
3901 South Saginaw Road
Midland, MI 48686
Phone: (989) 496-4400
www.dowcorning.com
Rivet, Blind CR3553-5 V11815
Cherry Aerospace LLC
1224 E. Warner St.
Santa Ana, CA 92707
Phone: (714) 850-6086
www.cherryaerospace.com
Sealant, Silicone RTV157 - Gray V01139
Adhesive Momentive Performance Material Inc.
260 Hudson River Rd.
Waterford, NY 12188
www.gesilicones.com
Repair Materials and Equipment
Table 201 (Sheet 1 of 2)
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Document Part No. RDN 306

DESCRIPTION DESIGNATION MANUFACTURER

Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
or
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Univar U.S.A., Inc.
Ketone/40% Methyl Ethyl 532 E. Emaus Street
Ketone Middletown, PA 17057-2200
Phone: (717) 944-7471
or www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com

Repair Materials and Equipment

Table 201 (Sheet 2 of 2)

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DAMAGE

REPLACE DAMAGED
WEB SECTION
BETWEEN DOTTED LINES

REPLACEMENT INLET COWL

BULKHEAD WEB AFT BULKHEAD WEB
REMOVE ONE SECTION
ADDITIONAL
RIVET SPLICE
PLATE
(2 PLACES)

OUTER
FRAME

INNER
FRAME
ZEE STIFFENER
(2 PLACES)
CES-254-00

Aft Bulkhead Splice

Figure 201

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Document Part No. RDN 306

2D

4D-6D

2.0 INCH
(50.8 mm)

4D-6D
SPLICE PLATE

EXISTING
BULKHEAD WEB
ZEE STIFFENER
SPLICE PLATE
CES-253-00

2.0 INCH REPLACEMENT BULKHEAD

50.8 mm) WEB SECTION
SECTION THROUGH REPAIR
LEFT SIDE SHOWN

Splice Plate
Figure 202

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Document Part No. RDN 306

REPAIR NO.15
ACOUSTIC PANEL NICK, GOUGE AND SMALL HOLE LESS THAN 1.0-INCH (25.4 MM)

1. General

This procedure gives the instructions to repair cracks or small holes in

the acoustic panel. The damage is removed and the hole is filled with the
adhesive.

2. Repair Instructions

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

A. Remove the damage with the smallest diameter and depth possible to
remove all the damage. See Figure 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

B. Clean the repair area with a clean, lint-free cloth and the solvent.
Remove the solvent with a clean lint-free cloth before the solvent
becomes dry. See Table 201.

C. Use the teflon tape and make a mask band around the repair area. See
Table 201.

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WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

D. Mix the adhesive. Refer to the instructions of the manufacturer. See

Table 201.

E. Use a spatula to fill the repair area with the adhesive. See Table 201.

F. Put a piece of nonporous parting film above the repair, use the tape to
hold the parting film in position. See Table 201.

G. Put the heat blanket above the repair and cure at 190°F - 210°F
(87.8°C - 98.9°C) for 60 minutes. See Table 201

H. Remove the heat blanket and parting film.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY

J. Use a 150 - 320-grit abrasive paper on the surfaces and the edges of
the repair area. See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

K. Remove the unwanted material with a clean lint-free cloth and solvent.
Remove the solvent with a clean lint-free cloth before the solvent
becomes dry. See Table 201.

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3. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Adhesive, Epoxy Paste EA934NA V33564
Henkel Corporation
2850 Willow Pass Rd.
P.O. Box 312
Baypoint, CA 94565-0031
Phone: (925) 458-8000
www.aerospace.henkel.com
Blanket, Heat 0°-250°F 10W/In.² V61426
Atacs Products, Inc.
850 South Cambridge Street
Seattle, WA 98108-4748
Phone: (206) 433-9000
www.atacs.com
Cloth, Lint-free Cotton Commercially Available
Clothing, Protective Commercially Available
Film, Parting Nonporous V0F451
Richmond Aircraft Products, Inc.
13503 Pulmice St
Norwalk, CA 90650-5250
Phone: (562) 404-2440
www.richmondaircraft.com
Glasses, Safety Commercially Available
Gloves Commercially Available
Mask, Dust Commercially Available
Paper, Abrasive 150 - 320-Grit Commercially Available
Silicone Carbide

Repair Materials and Equipment

Table 201 (Sheet 1 of 2)

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DESCRIPTION DESIGNATION MANUFACTURER

Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
or
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Univar U.S.A., Inc.
Ketone/40% Methyl Ethyl 532 E. Emaus Street
Ketone Middletown, PA 17057-2200
Phone: (717) 944-7471
or www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Spatula Metal or Plastic Commercially Available
Tape, Teflon 2-Inch Wide Commercially Available
Repair Materials and Equipment
Table 201 (Sheet 2 of 2)

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Acoustic Panel Nick, Gouge and Small Hole Repair

Figure 201

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REPAIR NO. 16
AFT BULKHEAD 6 AND 12 O’CLOCK OUTER FRAME DAMAGE

1. General

A. This procedure provides a permanent repair for worn Inlet Cowl Aft
Bulkhead Outer Frames.

(1) For Frames with blending limits, blend surface treat per SRM
requirements and paint with Abrasion Resistant Teflon Coating or
fill with Wear Strip. Refer Table 202 and Figure 110.

(2) The maximum width and depth of the allowable rework blend-out
cross-sectional geometry is limited to 22,86 mm (0.90 inch) wide by
0,762 mm (0.030 inch) deep which represents a minimum remaining
thickness of tmin = 1,04 mm (0.041 inch). The arc length along the
circumference of the Tee Frame for the blend-out area is limited to
a maximum 508 mm (20 inches) and limited to the 12 O’clock and the
6 O’clock areas exclusively. Figure 110, Sheet 1 through 3 describe
the allowable damage areas. The blend-out area must taper away at a
10:1 ratio of length to depth and blend into the root fillet
tangentially.

(3) For Frames with cracks exceeding wear limits, replace Frame or
Frame section.

B. For replacement contact Goodrich Aerostructures.

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2. References

Table 201: Reference Documents

Reference Title
NTM 51-80-00 LIQUID PENETRANT TESTING - GENERAL
SRM 51-10-00 INVESTIGATION - CLEANUP AND AERODYNAMIC SMOOTHNESS
SRM 51-21-11 APPLICATION OF PROTECTIVE TREATMENT TO METAL PARTS

SRM 54-23-12 SPECIAL COATINGS

SRM 54-02-06 REPLACE NACELL MARKINGS

SRM 51-78-00 CLEANING PROCESS

AMS 2491 SURFACE TREATMENT OF POLYTETRAFLUOROTHYLENE (PTFE) PREPARATION FOR

BONDING

3. Repair Instructions

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

A. Clean the damage area.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Clean the damaged area with a clean lint-free cotton cloth and the
solvent. Remove the solvent with a dry cloth before the solvent
dries. Refer to SRM 51-78-00 CLEANING PROCESS.

B. Determine damage. Refer to SRM 51-10-00 INVESTIGATION-CLEANUP AND

AERODYNAMIC SMOOTHNESS.

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(1) If remaining thickness is below 0.041 inch (1,04 mm), replace

section or entire aft outer frame. Inspect for crack indications,
refer to NTM 51-80-00 LIQUID PENETRANT TESTING-GENERAL.

(2) If any cracks are found replace section or entire aft outer frame.

C. Remove the damage from aft outer frame. Refer to Figure 110.

(1) Blend surface damage minimum 10:1 ratio.

(2) Minimum remaining thickness 0.041 inch (1,04 mm). See Figure 110
Sheet 2.

(3) Damage width must be no more than 0.9 inch (22,86 mm) distance from
aft edge. See Figure 110, Wear Detail (Sheet 2 of 3).

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(4) Clean the blended area with a clean, lint-free cloth and the
solvent. Remove the solvent with a dry cloth before the solvent
dries Refer to SRM 51-78-00 CLEANING PROCESS.

(5) Inspect the blend area for crack damage. Refer to SRM 51-10-00
INVESTIGATION-CLEANUP AND AERODYNAMIC SMOOTHNESS and NTM 51-80-00
LIQUID PENETRANT TESTING-GENERAL.

(6) If any cracks are found replace section or entire Aft Outer Frame.

(7) If the remaining Material after blend is less than the minimum
thickness in Table 202, replace section of entire Aft Outer Frame.

(8) Apply Protective Treatment to exposed metal on Aft Outer Frame.

Refer to SRM 51-21-11 APPLICATION OF PROTECTIVE TREATMENT TO METAL
PARTS.

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D. Select Surface Treatment, Refer to Table 202.

Table 202: Protective Coating Requirements

Condition Remaining Maximum Coating
Material Total
Thickness Abrasion
Length
Minor 0.071-0.058 20.0 inch Apply
Abrasion inch (1,8- (508 mm) Abrasion
1,47 mm) Resistant
Teflon
Coating
Medium 0.058-0.041 20.0 inch Apply Wear
Abrasion inch (1,47- (508 mm) Strip
1,04 mm)

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE MANUFACTURER,
THE MATERIAL SAFETY DATA SHEET (MSDS), AND GOVERNMENT
REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE
YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED. AN
MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

E. For Minor Abrasion apply Abrasion Resistant Coating.

(1) Apply Abrasion Resistant Lacquer (Abrasion resistant coating)

(Material No. 07-003 Coatings) to blend area. Refer to SRM 51-23-12
SPECIAL COATINGS.

(2) Proceed to step G.

F. For Medium Abrasion apply Wear Strip, Refer to Figure 110.

NOTE: The Wear Strip material is a sheet larger than required.

(1) Clean the area to be stripped with cleaning agent (Material No.
11-003, 11-001 or 11-026) with a clean, lint-free cotton cloth.
Refer to SRM 51-78-00 CLEANING PROCESS

(2) Remove the cleaning agent with a dry cloth before the solvent
dries.

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(3) If surface contains Teflon coating, prepare the surface according

to AMS 2491. Otherwise, abrade blended surface with coarse grit
aluminum oxide abrasive papers.
Clean the repair area with cleaning agent (Material No. 11-003, 11-
001 or 11-026) with a clean, lint-free cotton cloth. Refer to SRM
51-78-00 CLEANING PROCESS

(4) Remove the cleaning agent with a dry cloth before the solvent
dries.

(5) Cut Wear Strip(s) to fill the blended area, use a sharp blade.
Material KWP020-096-192 or KWS200-096-192.

(6) Install Wear Strip with Roll Adhesive, (Material No. 08-042)

(a) Cut adhesive to match prepared Wear Strip.

(b) Apply adhesive to Aft Outer Frame.

(c) Remove gray nylon peel-ply from prepared Wear Strip.

CAUTION: KEEP EXPOSED ROUGH SURFACE CLEAN UNTIL INSTALLED.

(d) Apply Wear Strip Rough Side down (Under removed gray peel-ply)
to Roll Adhesive.

(7) At the ends of the Wear Strip apply Abrasion coating per Table 202
and Figure 110 (Sheet 3 of 3).

G. Mark Repair on Cowl Data Plate with repair no. 16. Refer to SRM 54-02-
06, REPLACE NACELLE MARKINGS.

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4. Repair Materials and Equipment. Refer to Table 203.

Table 203 Repair Materials

DESCRIPTION DESIGNATION MANUFACTURER
Cloth, Lint-free Cotton Commercially Available
Wear Strip KWP020-096-192 Wesco
27727 Avenue Scott
Valencia, CA 91355-1219
Phone: (661) 775-7200
Wear Strip KWS200-096-192 Wesco
(Alternative) 27727 Avenue Scott
Valencia, CA 91355-1219
Phone: (661) 775-7200

Abrasion Resistant AIMS 04-04-007 Akzo Nobel Aerospace

Paint Base: Aerodur ARC Coatings/Netherlands
Hardener: S66/22R https://www.akzonobel.com
Thinner: C25/90S
Marker, Permanent Felt-tip Commercially Available
Paper Abrasive 180-300 grit Commercially Available
Solvent Isopropyl Alcohol (C04- Commercially Available
035)
Solvent (Alternative) MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Univar U.S.A., Inc.
Ketone/40% Methyl Ethyl 532 E. Emaus Street
Ketone Middletown, PA 170537
(C04-001) Phone: (717) 944-7471
Solvent (Alternative) Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Adhesive Film 08-042 Commercially Available
Adhesive Film 250-300 gsm Commercially Available
(Alternative)
Adhesive Film 08-042A FM73 M06 Commercially Available
(Alternative)
Repair Materials and Equipment
Table 201 (Sheet 1 of 2)

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Table 203 Repair Materials

DESCRIPTION DESIGNATION MANUFACTURER
Adhesive Film 08-042B EA9628 NW 06 Commercially Available
(Alternative)
Adhesive Film 08-042X AF163-2K Commercially Available
(Alternative)
Cleaning Agent 11-003 Commercially Available
Cleaning Agent 11-001 Commercially Available
Cleaning Agent 11-026 Commercially Available
Repair Materials and Equipment
Table 201 (Sheet 2 of 2)

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FW
D

INLET COWL

INLET COWL SKIN

ATTACH FASTENER
FRAME WEAR ZONE
FAN COWL SKIN

INLET COWL SKIN DETAIL B

AFT BULKHEAD
OUTER FRAME INLET COWL AFT
BULKHEAD WEB
ATTACH FASTENER
INLET COWL AFT
BULKHEAD WEB
FWD

SECTION A-A
OUTER FRAME DETAILS
ces-264-00

Damage Location
Figure 110 (Sheet 1 of 3)

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ORIGINAL OUTLINE

WEAR AREA

FWD

AFT BULKHEAD
OUTER FRAME

B
TYPICAL WEAR ON OUTER FRAME
(WEB, SKIN AND ATTACH FASTENERS NOT SHOWN)

WEAR DAMAGE

ORIGINAL FRAME SHAPE

MINIMUM THICKNESS
AFTER BLENDING
BLENDED MATERIAL REFER TO TABLE 202

DAMAGE NOT
TO EXCEED
0.90 INCHES
22.86 mm
10:1 BLEND RATIO

FWD
ces-265-00

WEAR DETAILS
Damage Allowable and Repair
Figure 110 (Sheet 2 of 3)
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MINIMUM ORIGINAL FRAME SHAPE

AFT OUTER
THICKNESS WEAR DAMAGE FRAME
0.04 INCH
BLENDED MATERIAL
(1,0 mm)

10:1 BLEND
DAMAGE WIDTH RATIO
NOT TO EXCEED
0.90 INCH (22,86 mm)
DISTANCE FROM AFT EDGE
FWD

WEAR STRIP OR
TEFLON COATING AFT OUTER
MAXIMUM THICKNESS
FRAME
NOT EXCEED
ORIGINAL THICKNESS ROLL ADHESIVE

FWD

DAMAGE NOT TO
EXCEED 0.90 INCH (22,86 mm)
DISTANCE FROM EDGE

CES-267-00

Damage Allowable and Repair

Figure 110 (Sheet 3 of 3)

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20 IN.
508 mm
(19.1 DEG)

12 O'CLOCK ALLOWABLE DAMAGE AREA

L/H FAN COWL DOOR R/H FAN COWL DOOR

OUTER
FRAME OUTER
FRAME

6 O'CLOCK
ALLOWABLE DAMAGE AREA
20 IN.
508 mm
(19.1 DEG)

NOTE: CONTACT UTAS FOR DAMAGE OUTSIDE THE 12 AND 6 O'CLOCK ALLOWABLE DAMAGE AREA.
CES-268-00

Allowable Damage Area on T-Frame

Figure 111

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REPAIR NO. 22
EDGE EROSION DAMAGE

1. General

This procedure gives the instructions to repair the erosion damage to the
composite panel edges. The damage must be less than 0.50-inch (123.7 mm)
long and 0.02-inch (0.50 mm) in depth.

2. Repair Instructions

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

A. Prepare the surface. See Table 201.

CAUTION: DO NOT BREAK OR TAPER THE CARBON FIBERS IN THE REPAIR AREA.
IF THE FIBERS ARE DAMAGED, THE PART CAN BE WEAKER THAN THE
INITIAL PART.

(1) Use the abrasive paper to remove the surface finish.

NOTE: Make a smooth tapered edge on the external coating around

the repair area. Do not go through the composite surface.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(2) Clean the repair area with a clean, lint-free cloth and the
solvent. Remove the solvent with a clean lint-free cloth before the
solvent becomes dry.

(3) Let the surface dry for 30 minutes.

B. Apply the adhesive filler. See Table 201.

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WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Mix the adhesive. Refer to the instructions of the manufacturer.

(2) Use a small brush or a spatula and put the adhesive in the erosion
cavities. Make the adhesive flush to the adjacent area.

(3) Put the teflon tape on the adhesive.

(4) Remove unwanted adhesive.

(5) Dry the adhesive. Refer to the instructions of the manufacturer.

C. Complete the repair.

CAUTION: DO NOT TAPER OR BREAK THE CARBON FIBERS IN THE REPAIR AREA.
IF THE FIBERS ARE DAMAGED, THE PART CAN BE WEAKER THAN THE
INITIAL PART.

(1) Remove the teflon tape.

(2) Use the abrasive paper (150-grit) to rub the adhesive smooth. See
Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(3) Clean the repair area with a clean, lint-free cloth and the
solvent. Remove the solvent with a clean lint-free cloth before the
solvent becomes dry. See Table 201.

(4) Repair the surface finish. See Repair No. 1 - Surface Finish
Restoration.

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3. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Adhesive, Epoxy EA934NA V33564
Paste Henkel Corporation
2850 Willow Pass Rd.
P.O. Box 312
Baypoint, CA 94565-0031
Phone: (925) 458-8000
www.aerospace.henkel.com
Brush Nylon Bristle Commercially Available
Cloth, Lint-free Cotton Commercially Available
Container Metal or Plastic Commercially Available
Glasses, Safety Commercially Available
Gloves Neoprene or Polyvinyl Chloride Commercially Available
Lamp, Heat 150°F-250°F Commercially Available
Mask, Dust Regulatory Agency Approved Commercially Available
Paper, Abrasive 150 - 180-Grit Silicon Carbide Commercially Available
Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
or
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Ketone/40% Univar U.S.A., Inc.
Methyl Ethyl Ketone 532 E. Emaus Street
Middletown, PA 17057-2200
or Phone: (717) 944-7471
www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Spatula Metal or Plastic Commercially Available
Tape, Teflon 2-Inch Wide Commercially Available
Repair Materials and Equipment
Table 201

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REPAIR NO. 23
REPLACEMENT OF THE AERODYNAMIC SEALANT

1. General

This procedure gives the instructions to remove and replace the

aerodynamic sealant. Aerodynamic sealant is applied on the inlet cowl nose
lip, inner barrel, and outer barrel splice joint. See Figure 201.

2. Repair Instructions

A. Remove all of the sealant that is damaged or is not attached to the

surface.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

B. Put the tape 0.25-inches (6.35 mm) from the edges of the joint on the
two sides. See Figure 201 and Table 201.

C. Use the abrasive paper to make the surfaces rough in the joint. See
Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

D. Clean the repair area with a clean, lint-free cloth and the solvent.
Remove the solvent with a clean lint-free cloth before the solvent
becomes dry. See Table 201.

E. Apply the primer to the joint. See Table 201.

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WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Apply the RTV prime coat to the joint. Refer to the instructions of
the manufacturer.

(2) Dry the RTV prime coat. Refer to the instructions of the
manufacturer.

F. Apply the aerodynamic sealant. See Figure 201 and Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Mix the sealant. Refer to the instructions of the manufacturer.

(2) Apply the sealant to the joint in the area between the tape. Use a
plastic spatula or an injection-flow gun.

NOTE: Make sure that the surface is dry. The moisture on the
surface can prevent the bond of the sealant.

(3) Use a plastic spatula to make the surface of the sealant smooth.
Fill the joint -0.10 to 0.00-inch (-0.254 to 0.00 mm) to the
adjacent surfaces.

(4) Remove the tape before the sealant becomes dry.

(5) Dry the sealant. Refer to the instructions of the manufacturer.

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3. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Cloth, Lint Free Cotton Commercially Available
Clothing, Protective Commercially Available
Container Plastic Commercially Available
Cover,Container Plastic Commercially Available
Glove Neoprene or Polyvinyl Commercially Available
Chloride
Injection Flow Gun Commercially Available
Paper, Abrasive 320 -Grit Commercially Available
Aluminum Oxide
Prime Coat, RTV DOW CORNING® PR-1200 V5D028
Dow Corning Corporation
3901 South Saginaw Road
Midland, MI 48686
Phone: (989) 496-4400
www.dowcorning.com
Sealant DC 93-006 (Two Part) V5D028
Sealant and Catalyst Dow Corning Corporation
www.dowcorning.com
Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
or
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Univar U.S.A., Inc.
Ketone/40% Methyl Ethyl 532 E. Emaus Street
Ketone Middletown, PA 17057-2200
Phone: (717) 944-7471
or www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Tape, Masking Commercially Available
Repair Materials and Equipment
Table 201

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Document Part No. RDN 306

LIP SKIN
SPLICE JOINT LIP SKIN TO
(TYPICAL) OUTER BARREL SEALANT
JOINT -0.10 TO 0.00 INCH
(-0.254 TO 0.000 mm)
TO SURFACE
MASKING
TAPE MASKING
TAPE

INNER
BARREL OUTER BARREL A-A
SPLICE SPLICE JOINT
JOINT (TYPICAL)
(TYPICAL)
INLET
LIP SKIN TO COWL
INNER BARREL MASKING
JOINT TAPE
FLOW GUN

DIRECTION OF FILL
A
MASKING
TAPE

0.25 INCH
MASKING (6.35 mm)
TAPE
A

SEALANT
APPLY SEALANT
SPATULA
CES-239-00

SMOOTH SEALANT
SLOT SEAL

Aerodynamic Sealant
Figure 201

CF6-80E1
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STRUCTURAL IDENTIFICATON - FAN COWL

1. General

Left and right fan cowl doors enclose the fan section of the General
Electric CF6-80E1 engine. These doors open to gain access to the engine
fan section. Each door contains three hoist plates, three hinge
assemblies, and four brackets assemblies to install the cowling hold open
rod. The left door has a pressure relief door. The fan cowl doors are
installed at the pylon by three hinge assemblies. The doors have three
latch housings at the bottom centerline of the engine where adjustable
latch hook type hinges hold the fan cowl doors closed.

2. Structure Description

A non-perforated aluminum honeycomb core is installed between an inner

layer of seven carbon/fiber composite plies and outer skins of six single
composite plies and a titanium sheet with an outer lighting protection
ply. The pressure relief door is made of non-perforated honeycomb core and
is installed between two clad aluminum sheets. The fan cowl doors are
approximately 60.76 inches wide X 180 inches high and weight 259 pounds
each.

3. Structure Identification

Structures are identified in illustrations (figures) and tables. The

figures and tables do not identify fasteners. The structure is identified
on the figure by number. The same number appears on the table that follows
the figure. The table gives the component description, gage (thickness)
and material. When a composite fabric ply is identified in the material
column, the warp direction will be given. The warp direction (angle) is
based on the manufacturer's drawings. The full view of the part has a
compass rose to help find the warp direction.

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2
9

11

1
10

13

7
3

12
7
8

7
CES-039-00
LH Fan Cowl
Figure 1 (Sheet 1)

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Document Part No. RDN 306

16 17

14 15

17
16

18 15

17
16

19 15

CES-040-00

LH Fan Cowl
Figure 1 (Sheet 2)

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STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

20

21

21

24
23

22

25

25

CES-041-00
LH Fan Cowl
Figure 1 (Sheet 3)

CF6-80E1
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STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

27

29

28

26

27

CES-042-00

LH Fan Cowl
Figure 1 (Sheet 4)

CF6-80E1
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STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 LH FAN COWL ASSY (REF)
2 HOIST PLATE 0.050 2024-T3 CLAD ALUM SHEET,
(1,27) QQ-A-250/5
3 BRACKET ASSY 0.160 2024-0 CLAD ALUM SHEET,
(4,06) QQ-A-250/5 (HEAT TREAT T42)
4 PLATE 0.040 2024-TO CLAD ALUM SHEET,
(1,02) QQ-A-250/5 (HEAT TREAT T62)
5 PLATE 0.040 2024-TO CLAD ALUM SHEET,
(1,02) QQ-A-250/5 (HEAT TREAT T62)
6 RAMP POLYPROPYLENE, PRO-FAX 7823
(OR EQUIVALENT)
7 BRACKET A356-T6 ALUM INVESTMENT
CASTING
8 PLATE 0.040 2024-TO CLAD ALUM SHEET,
(1,02) QQ-A-250/5 (HEAT TREAT T62)
9 OUTER SKIN ASSY (REF) (SEE FIGURE 3 FOR DETAILS)
10 INNER SKIN ASSY (REF) (SEE FIGURE 5 FOR DETAILS)
11 PRESSURE RELIEF DOOR ASSY (REF) (SEE FIGURE 2 FOR DETAILS)
12 EDGE PROTECTION (REF) (SEE FIGURE 6 FOR DETAILS)
13 CORE ASSY (REF) (SEE FIGURE 4 FOR DETAILS)
14 HINGE ASSY 7075-T651 ALUM ALLOY, AMS4045
15 BLANKET 0.125 FIBERGLASS CLOTH WITH .003
(3,18) THICK SILICONE COATING,
ZZ-R-765, CLASS 2A, GRADE 50
LH Fan Cowl
Table 1 (Sheet 1)

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STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
16 SHIM 0.000 LAMINATED SHIM, S700S04970
(0,00)
17 SHIM 0.000 LAMINATED SHIM, S700S04970
(0,00)
18 HINGE ASSY 7075-T651 ALUM ALLOY, AMS4045
19 HINGE ASSY 7075-T651 ALUM ALLOY, AMS4045
20 LATCH HOUSING 7075-T73 ALUM FORGING, AMS4141
21 GUARD 2024-0 EXTRUDED ALUM ALLOY,
QQ-A-200/3 (HEAT TREAT T42)
22 SHIM 0.063 LAMINATED ALUM, MIL-S-22499,
(1,60) COMP 1, TYPE 1, CLASS 2
23 SHIM 0.063 LAMINATED ALUM, MIL-S-22499,
(1,60) COMP 1, TYPE 1, CLASS 2
24 SHIM 0.063 LAMINATED ALUM, MIL-S-22499,
(1,60) COMP 1, TYPE 1, CLASS 2
25 SHIM 0.063 LAMINATED ALUM, MIL-S-22499,
(1,60) COMP 1, TYPE 1, CLASS 2
26 FLANGE 0.050 2024-T3 CLAD ALUM SHEET,
(1,27) QQ-A-250/5
27 SHIM 0.120 LAMINATED ALUM, MIL-S-22499,
(3,05) COMP 1, TYPE 2, CLASS 2
28 SHIM 0.120 LAMINATED ALUM, MIL-S-22499,
(3,05) COMP 1, TYPE 2, CLASS 2
29 COVER 0.063 2024-T3 CLAD ALUM SHEET,
(1,60) QQ-A-250/5
LH Fan Cowl
Table 1 (Sheet 2)

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10
6
4 12
11

4 7
3
1

2 6

HINGE
ASSEMBLY

CES-043-00
Pressure Relief Door
Figure 2

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 SHIM 0.190 LAMINATED ALUM, MIL-S-22499,
(4.83) COMP 1, TYPE 2, CLASS 1
2 BRACKET 2024-T3511 EXTRUDED ALUM,
QQ-A-200/3
3 BRACKET 0.080 2024-T3 CLAD ALUM SHEET,
(2.03) QQ-A-250/5
4 WEAR STRIP 0.020 301 CRES STEEL SHEET,
(0.51) MIL-S-5059, FINISH 2B
5 DOUBLER 0.032 2024-T3 CLAD ALUM SHEET,
(0.81) QQ-A-250/5
6 BRACKET 2024-T3511 EXTRUDED ALUM,
QQ-A-200/3
7 SPACER 0.250 2024-T351 BARE ALUM SHEET, QQ-
(6.35) A-250/4
10 OUTER SKIN 0.160 2024-0 CLAD ALUM SHEET, QQ-A-
(4.06) 250/5 (HEAT TREAT T42)
11 CORE 0.918 NONPERFORATED HONEYCOMB, 5052
(23.32) AL ALLOY, (OPTIONAL 5056 AL
ALLOY), 1/8 INCH CELL, 0.003
FOIL GAGE, 6.1 LB/CU FT., PAA
CORE, MIL-C-7438, GRADE B
12 INNER SKIN 0.025 2024-T3 CLAD ALUM SHEET, QQ-A-
(0.64) 250/5
Pressure Relief Door
Table 2

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Document Part No. RDN 306

0°
-45° 45°

90°
PLY WARP
DIRECTION

VIEW LOOKING OUTBOARD CES-044-00

LH Fan Cowl Outer Skin
Figure 3 (Sheet 1)

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2 6
6 CORE SURFACE 2 PANEL EDGE
2
5
4
2 CORE SURFACE
5
4
3
2
1 7

ANEL EDGE AIR 6

2 2 7 PASSAGE
SURFACE 2
2

5
6 CORE SURFACE 2 4
2
2 PANEL EDGE
5 2
4 AIR
2
5 5 PASSAG
4 SURFAC
4
3
AIR 2
PASSAGE 7 2 1
SURFACE 2
1
3 2
1
2 3 PLY BASIC SKIN

3
CORE SURFACE 8
2 TYPICAL 3 PLACES
8
2 AIR
PASSAGE
SURFACE
3 PLY BASIC SKIN

CES-045-00
LH Fan Cowl Outer Skin
Figure 3 (Sheet 2)

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PANEL EDGE 6 CORE SURFACE CORE SURFACE PANEL EDGE

2 2
3 2 1 1 2 3
3 PLY BASIC SKIN 3 PLY BASIC SKIN

AIR
PASSAGE AIR
SURFACE PASSAGE
SURFACE

6
PANEL CORE SURFACE 2 2 CORE SURFACE
4 4 PANE
DGE 5 5 EDGE
2 2
4 4
5 5
2 2
3 3
2

AIR 2 1 2 2
1 2
2 2 2 PASSAGE AIR
SURFACE PASSAGE
SURFACE

CES-046-00
LH Fan Cowl Outer Skin
Figure 3 (Sheet 3)

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1 3 PLY BASIC SKIN

2
CORE SURFACE 1
3
2
8
3
8
2
2
5
2
4
ORE 8
URFACE 2
2
5
2 4
2

AIR 5
PASSAGE
SURFACE 4

5 AIR
PASSAGE
SURFACE
PANEL EDGE
TYPICAL 3 PLACES

2 CORE SURFACE
8 2 8 2 2

2
2
PANEL EDGE

8 2 8 3 2 1 AIR 2 2
PASSAGE
SURFACE
CES-047-00
LH Fan Cowl Outer Skin
Figure 3 (Sheet 4)

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Document Part No. RDN 306

GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 LIGHTNING PROTECTION PLY EXPANDED COPPER SCREEN,
FM300M-ECS-.I0, V2B714
2 COMPOSITE PLY 0.0145 GRAPHITE FABRIC, 0 DEGREE
(0,368) WARP, STYLE AH370-5H/3501-5A,
AS4 FIBER, VOCZA6
3 COMPOSITE PLY 0.0055 COMPOSITE PLY GRAPHITE TAPE,
(0,139) CYCOM 985-1, AS4 FIBER, VOCZA6
4 COMPOSITE PLY 0.0145 GRAPHITE FABRIC, -45 DEGREE
(0,368) WARP, STYLE AH370-5H/3501-5A,
AS4 FIBER, VOCZA6
5 COMPOSITE PLY 0.0145 GRAPHITE FABRIC, +45 DEGREE
(0,368) WARP, STYLE AH370-5H/3501-5A,
AS4 FIBER, VOCZA6
6 COMPOSITE PLY 0.005 FIBERGLASS FABRIC, WARP
(0,13) DIRECTION OPTIONAL,
EA-9101/120, V12405
7 CONDUCTOR 0.016 6AL-4V TITANIUM SHEET, AMS4911
(0,41)
8 COMPOSITE PLY 0.0145 GRAPHITE FABRIC, 90 DEGREE
(0,368) WARP, STYLE AH370-5H/3501-5A,
AS4 FIBER, VOCZA6
LH Fan Cowl Outer Skin
Table 3

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STA STA
198.00 137.240
STA STA STA
188.100 168.300 148.500
CL HINGE CL HINGE CL HINGE 1

2
RIBBON
DIRECTION 3 2

1 1 1
STA STA
187.320 150.823

1 STA 295°
163.205 RADIAL
2

284°
279° RADIAL
RADIAL
275°
RADIAL STA
179.000

1 2
253°
RADIAL 3

1 STA 1
167.572 STA
144.000

STA 221°
1
184.578 RADIAL
213°
RADIAL 2 1 STA
153.872 1

1
1

VIEW LOOKING OUTBOARD CES-048-01

LH Fan Cowl Core Assy
Figure 4

CF6-80E1
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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 CORE 0.955 NONPERFORATED HONEYCOMB, 3/32
(24,26) INCH CELL, 0.0055 FOILGAGE,
PAA-CORE, V2B714
2 CORE 0.955 NONPERFORATED HONEYCOMB, 1/8
(24,26) INCH CELL, 0.0015 FOILGAGE,
PAA-CORE, V2B714
3 CORE 0.955 NONPERFORATED HONEYCOMB, 3/16
(24,26) INCH CELL, 0.001 FOILGAGE,
PAA-CORE, V2B714
LH Fan Cowl Core Assy
Table 4

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0°
45° -45°

RADIAL
295° 90°
PLY WARP
DIRECTION
RADIAL
279° CUTOUTS

RADIAL
253°

RADIAL
221°

RADIAL
213°

LH FAN COWL INNER SKIN

VIEW LOOKING INBOARD CES-050-00

LH Fan Cowl Inner Skin
Figure 5 (Sheet 1)

CF6-80E1
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7
6 6 5
7
OUTER 7
SKIN 6 6
7 7
2
6 6
1
7 7
4
3 6
4 3 6
7
7
5 1
6
1 CORE
7 6

OUTER 5
SKIN 7
6
6
2
7
3 1 7
4 4
6
5 1 3
1

CORE

CES-051-00

LH Fan Cowl Inner Skin

Figure 5 (Sheet 2)

CF6-80E1
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5 5 2

2
OUTER
1 SKIN
2 PLY
4 BASIC SKIN
3
3
1
4
5
5 CORE
1 CORE SURFACE
1

5 1
5 2

1
2 PANEL
EDGE
1
5

1
CORE OUTER
SKIN
1
CORE
SURFACE

CES-052-00
LH Fan Cowl Inner Skin
Figure 5 (Sheet 3)

CF6-80E1
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1 5
2 5
CORE
1

2
PANEL
EDGE
OUTER
SKIN
5
5
OUTER CORE
SKIN

5 1
5 2 5

5
PANEL
EDGE

1
2

CORE OUTER
SKIN
5
2 PLY 5
BASIC SKIN
2
5
4

1 5
CORE
SURFACE 5
1
4
3
2

CES-053-00
LH Fan Cowl Inner Skin
Figure 5 (Sheet 4)

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2
1

CORE 1
1 4
1 CORE
3 3
4
2
4
5
5
5
OUTER
5 SKIN
5 5
N0TE: TYPICAL N0TE: TYPICAL
3 LOCATIONS OUTER
SKIN 3 LOCATIONS

PANEL
5 EDGE 1
5 5 5 4
1
3 4
2

5
5

N0TE: TYPICAL OUTER CORE

3 LOCATIONS SKIN
CES-054-00
LH Fan Cowl Inner Skin
Figure 5 (Sheet 5)

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 COMPOSITE PLY 0.0145 GRAPHITE FABRIC, 0 DEGREE
(0,368) WARP, STYLE AH370-5H/3501-5A,
AS4 FIBER, VOCZA6
2 COMPOSITE PLY 0.0055 GRAPHITE TAPE, CYCOM 985-1,
(0,139) AS4 FIBER, VOCZA6
3 COMPOSITE PLY 0.0145 GRAPHITE FABRIC, -45 DEGREE
(0,368) WARP, STYLE AH370-5H/3501-5A,
AS4 FIBER, VOCZA6
4 COMPOSITE PLY 0.0145 GRAPHITE FABRIC, +45 DEGREE
(0,368) WARP, STYLE AH370-5H/3501-5A,
AS4 FIBER, VOCZA6
5 COMPOSITE PLY 0.005 FIBERGLASS FABRIC, WARP
(0,13) DIRECTION OPTIONAL, 1 EA-9101/
120, V12405
6 COMPOSITE PLY 0.005 FIBERGLASS FABRIC, 0 DEGREE
(0,13) WARP, EA-9101/120, V12405
7 CONDUCTOR 0.005 FIBERGLASS FABRIC, +45 DEGREE
(0,13) WARP, EA-9101/120, V12405
LH Fan Cowl Inner Skin
Table 5

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8 8 8
STA STA
198.000 137.240

9 1
9
9

4 2

4
6
1
4

2
4
7
3 1
4
3 3

VIEW LOOKING OUTBOARD

CES-049-01
LH Fan Cowl Edge Protection
Figure 6

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 WEAR STRIP 0.090 TEFLON, AMS3652
(2,29)
2 CONTACT STRIP 0.050 2024-T3 CLAD ALUM SHEET,
(1,27) QQ-A-250/5
3 BUMPER 2024-T3511, ALUM EXTRUSION,
AND10134-0602, QQ-A-200/3
4 RUBSTRIP TEFLON, AMS3667
5 RUBSTRIP TEFLON, AMS3667
6 SEAL 7093-2, Vl1960
ALTERNATE
SEAL 7040-2, V11960
7 RETAINER 0.050 2024-T3 CLAD ALUM SHEET,
(1,27) QQ-A-250/5

8 SEAL 0.016 CRES STEEL SHEET, MIL-S-5059,

(0,41) COND 1/4H
9 ANGLE 0.040 CRES STEEL SHEET, MIL-S-5059,
(1,02) ANNEALED
LH Fan Cowl Edge Protection
Table 6

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2
9

2
11

10

12

13

6
3
5

7 3

7 1
8

CES-055-00

RH Fan Cowl
Figure 7 (Sheet 1)

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16 17

14 15

17
16

18 15

17
16

19 15

CES-040-00

RH Fan Cowl
Figure 7 (Sheet 2)

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20

22

21

CES-056-00

RH Fan Cowl
Figure 7 (Sheet 3)

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 RH FAN COWL ASSY (REF)
2 HOIST PLATE 0.050 2024-T3 CLAD ALUM SHEET,
(1,27) QQ-A-250/5
3 BRACKET ASSY 0.160 2024-0 CLAD ALUM SHEET,
(4,06) QQ-A-250/5 (HEAT TREAT T42)
4 PLATE 0.040 2024-TO CLAD ALUM SHEET,
(1,02) QQ-A-250/5 (HEAT TREAT T62)
5 PLATE 0.040 2024-TO CLAD ALUM SHEET,
(1,02) QQ-A-250/5 (HEAT TREAT T62)
6 RAMP POLYPROPYLENE, PRO-FAX 7823
(OR EQUIVALENT)
7 BRACKET A356-T6 ALUM INVESTMENT
CASTING
8 PLATE 0.040 2024-TO CLAD ALUM SHEET,
(1,02) QQ-A-250/5 (HEAT TREAT T62)
9 OUTER SKIN ASSY (REF) (SEE FIGURE 9 FOR DETAILS)
10 INNER SKIN ASSY (REF) (SEE FIGURE 11 FOR DETAILS)
11 DOOR ASSY (REF) (SEE FIGURE 8 FOR DETAILS)
12 EDGE PROTECTION (REF) (SEE FIGURE 12 FOR DETAILS)
13 CORE ASSY (REF) (SEE FIGURE 10 FOR DETAILS)
14 HINGE ASSY 7075-T651 ALUM ALLOY, AMS4045
15 BLANKET 0.125 FIBERGLASS CLOTH WITH .003
(3,18) THICK SILICONE COATING,
ZZ-R-765, CLASS 2A, GRADE 50
RH Fan Cowl
Table 7 (Sheet 1)

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
16 SHIM LAMINATED SHIM, S700S04970
17 SHIM LAMINATED SHIM, S700S04970
18 HINGE ASSY 7075-T651 ALUM ALLOY, AMS4045
19 HINGE ASSY 7075-T651 ALUM ALLOY, AMS4045
20 LATCH HOUSING 7075-T73 ALUM FORGING, AMS4141
21 SHIM LAMINATED ALUM, S700S0497-12
22 SHIM LAMINATED ALUM, S700S0497-12
RH Fan Cowl
Table 7 (Sheet 2)

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Document Part No. RDN 306

5
4

2
3
6

8
11

4
HINGE 4
ASSEMBLY

CES-057-00
Door Assembly
Figure 8

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 DOOR LAND 0.032 2024-T3 CLAD ALUM SHEET,
(0,81) QQ-A-250/5
2 SHIM 0.250 2024-T351 CLAD ALUM SHEET,
(6,35) QQ-A-250/4
3 SHIM 0.063 LAMINATED ALUM, MIL-S-22499,
(1,60) COMP 1, TYPE 1, CLASS 1
4 WEAR STRIP 0.000 (224-2209-15)
(0,00)
5 OUTER SKIN 0.160 2024-O CLAD ALUM SHEET,
(4,06) QQ-A-250/5 (HEAT TREAT T42)
6 CORE 0.918 NON PERFORATED HONEYCOMB, 5052
(23,32) AL ALLOY, (OPTIONAL 5056 AL
ALLOY), 3/16 INCH CELL, 0.003
FOIL GAGE, 3.1 LB/CU FT., PAA
CORE, MIL-C- 7438, GRADE B
7 INNER SKIN 0.025 2024-T3 CLAD ALUM SHEET,
(0,64) QQ-A-250/5
8 FILLER 0.375 2024-T351 BARE ALUM SHEET,
(9,53) QQ-A-250/4
11 SHIM 0.080 LAMINATED ALUM, MIL-S-22499,
(2,03) COMP 1, TYPE 1, CLASS 1
Door Assembly
Table 8

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Document Part No. RDN 306

0°
-45° 45°

90°
PLY WARP
DIRECTION

VIEW LOOKING OUTBOARD CES-058-00

RH Fan Cowl Outer Skin
Figure 9 (Sheet 1)

CF6-80E1
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CORE SURFACE 6 2
2 PANEL EDGE
5
4 CORE SURFACE
2
5

ANEL EDGE 6
7 1 2 3 4
AIR
PASSAGE 2
SURFACE
2
5
6
2 CORE SURFACE 6 4
2 PANEL EDGE
5 2
4 AIR
2
5 PASSAGE
5
SURFACE
4
3
7 2
4 3 2 1 AIR
PASSAGE 1
SURFACE
1
2 3 PLY BASIC SKIN
3
CORE SURFACE 8
2 TYPICAL 3 PLACES
8
2 AIR
PASSAGE
SURFACE
3 PLY BASIC SKIN

CES-059-00
RH Fan Cowl Outer Skin
Figure 9 (Sheet 2)

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ANEL EDGE CORE SURFACE CORE SURFACE 6 PANEL EDGE

2 2
3 2 1 1 2 3
3 PLY BASIC SKIN 3 PLY BASIC SKIN

AIR
AIR PASSAGE
PASSAGE SURFACE
SURFACE

6
CORE SURFACE 2 2 CORE SURFACE PANE
PANEL 4 4
EDGE 5 5 EDGE
2 2
4 4
5 5
2 2
3 3
2

2 2 1 AIR
2 2 AIR 1
PASSAGE 2 2 2
PASSAGE SURFACE
SURFACE

CES-060-0
RH Fan Cowl Outer Skin
Figure 9 (Sheet 3)

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1
2 3 PLY BASIC SKIN

3
CORE SURFACE 1
8 2
8 3
2 2
5
4
2
5
4
2 6 2
8 2
2 4
2 5 AIR
PASSAGE
AIR SURFACE
PASSAGE PANEL EDGE
3 PLY BASIC SKIN SURFACE TYPICAL 3 PLACES

CORE SURFACE 2 2 8
2 2
8
2
2
PANEL EDGE

2 AIR 1 2 3 8 2 8
2
PASSAGE
SURFACE

CES-061-00
RH Fan Cowl Outer Skin
Figure 9 (Sheet 4)

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Document Part No. RDN 306

GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 LIGHTNING PROTECTION PLY EXPANDED COPPER SCREEN,
FM300M-ECS-.10, V2B714
2 COMPOSITE PLY 0.0145 GRAPHITE FABRIC, 0 DEGREE
(0,368) WARP, STYLE AH370-5H/3501-5A,
AS4 FIBER, VOCZA6
3 COMPOSITE PLY 0.0055 GRAPHITE TAPE, CYCOM 985-1,
(0,139) AS4 FIBER, VOCZA6
4 COMPOSITE PLY 0.0145 GRAPHITE FABRIC, -45 DEGREE
(0,368) WARP, STYLE AH370-5H/3501-5A,
AS4 FIBER, VOCZA6
5 COMPOSITE PLY 0.0145 GRAPHITE FABRIC, +45 DEGREE
(0,368) WARP, STYLE AH370-5H/3501-5A,
AS4 FIBER, VOCZA6
6 COMPOSITE PLY 0.005 FIBERGLASS FABRIC, WARP
(0,13) DIRECTION OPTIONAL,
EA-9101/120, V12405
7 CONDUCTOR 0.016 6AL-4V TITANIUM SHEET, AMS4911
(0,41)
8 COMPOSITE PLY 0.0145 GRAPHITE FABRIC, 90 DEGREE
(0,368) WARP, STYLE AH370-5H/3501-5A,
AS4 FIBER, VOCZA6
RH Fan Cowl Outer Skin
Table 9

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Document Part No. RDN 306

STA STA
137.240 198.000
STA STA STA
148.500 168.300 188.100
CL HINGE CL HINGE CL HINGE 1
2
1

2
3
RIBBON 1
DIRECTION
1 1
STA STA
150.823 187.320

STA 64°
161.385 RADIAL

106°
RADIAL 110°
RADIAL

1 STA
STA 1
167.572
144.000 STA
138°
184.578
RADIAL
1 146°
RADIAL
1 STA
1 153.872 1

1
1
STA
144.000 VIEW LOOKING OUTBOARD 2
CES-062-00
RH Fan Cowl Core Assy
Figure 10

CF6-80E1
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Document Part No. RDN 306

GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 CORE 0.955 NONPERFORATED HONEYCOMB, 3/32
(24,26) INCH CELL, 0.0055 FOILGAGE,
PAA-CORE, V2B714
2 CORE 0.955 NONPERFORATED HONEYCOMB, 1/8
(24,26) INCH CELL, 0.0015 FOILGAGE,
PAA-CORE, V2B714
3 CORE 0.955 NONPERFORATED HONEYCOMB, 3/16
(24,26) INCH CELL, 0.001 FOILGAGE,
PAA-CORE, V2B714
RH Fan Cowl Core Assy
Table 10

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Document Part No. RDN 306

0°
45° -45°

RADIAL 90°
64° PLY WARP
DIRECTION

CUTOUTS

RADIAL
106°

RADIAL
138°

RADIAL
146°

VIEW LOOKING OUTBOARD CES-063-00

RH Fan Cowl Inner Skin
Figure 11 (Sheet 1)

CF6-80E1
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Document Part No. RDN 306

OUTER 5
7
SKIN
6
6
2 7
1 7
3
4 4 6
5 1 3
1

CORE

7
6 6
7 5
OUTER 7
SKIN 6 6
7 7
2
6 6
1
7 7
4
3 6
4 3 6
7
5 1 7
1 6
CORE
7 6

CES-064-00
RH Fan Cowl Inner Skin
Figure 11 (Sheet 2)

CF6-80E1
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5 5 2

2
OUTER
1 SKIN
2 PLY
4 BASIC SKIN
3
3
1
4
5
5 CORE
1 CORE SURFACE
1

1 5
2 5
1
2

1 PANEL
5 EDGE

1 OUTER
CORE CORE
SURFACE SKIN

CES-065-00
RH Fan Cowl Inner Skin
Figure 11 (Sheet 3)

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5 1
5 2

PANEL
EDGE
1
2

OUTER CORE
CORE
SKIN
5
5
1 5
2 5

PANEL
EDGE OUTER
5
SKIN
5

OUTER 2
CORE
SKIN
1

1
2 5
5
5

PANEL
EDGE

OUTER CORE
SKIN
CES-066-00
RH Fan Cowl Inner Skin
Figure 11 (Sheet 4)

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2
2
1 1

4 5

1 4

3 1

4 CORE 3 CORE
5 4

5
5
5
5

OUTER OUTER
SKIN SKIN

CES-067-00
RH Fan Cowl Inner Skin
Figure 11 (Sheet 5)

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Document Part No. RDN 306

GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 COMPOSITE PLY GRAPHITE FABRIC, 0 DEGREE
WARP, STYLE AH370-5H/3501-5A,
AS4 FIBER, VOCZA6
2 COMPOSITE PLY 0.0145 GRAPHITE TAPE, CYCOM 985-1,
(0,368) AS4 FIBER, VOCZA6
3 COMPOSITE PLY 0.0055 GRAPHITE FABRIC, -45 DEGREE
(0,139) WARP, STYLE AH370-5H/3501-5A,
AS4 FIBER, VOCZA6
4 COMPOSITE PLY 0.0145 GRAPHITE FABRIC, +45 DEGREE
(0,368) WARP, STYLE AH370-5H/3501-5A,
AS4 FIBER, VOCZA6
5 COMPOSITE PLY 0.0145 FIBERGLASS FABRIC, WARP
(0,368) DIRECTION OPTIONAL,
EA-9101/120, V12405
6 COMPOSITE PLY 0.005 FIBERGLASS FABRIC, 0 DEGREE
(0,13) WARP, EA-9101/120, V12405
7 COMPOSITE PLY 0.005 FIBERGLASS FABRIC, +45 DEGREE
(0,13) WARP, EA-9101/120, V12405
RH Fan Cowl Inner Skin
Table 11

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STA STA
137.240 198.00

3 5 6 5 6 5 5

7
4

3
1
8

4 1

1
9 3
1

4
10 1

3
1

VIEW LOOKING OUTBOARD CES-068-01

RH Fan Cowl Edge Protection
Figure 12

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 RUBSTRIP TEFLON, AMS 3667
2 RUBSTRIP TEFLON, AMS 3667
3 WEAR STRIP 0.090 TEFLON, AMS3652
(2,29)
4 CONTACT STRIP 0.050 2024-T3 CLAD ALUM SHEET,
(1,27) QQ-A-250/5
5 SEAL 0.016 310 CRES STEEL SHEET, MIL-S-
(0,41) 5059, COND 1/4H
6 ANGLE 0.040 310 CRES STEEL SHEET, MIL-S-
(1,02) 5059, ANNEALED
7 RETAINER 0.050 2024-T3511 ALUM EXTRUSION, QQ-
(1,27) A-200/3
8 SEAL FIBERGLASS FABRIC, IMPREGNATED
WITH SILICONE RUBBER
9 RETAINER 0.050 2024-T3 CLAD ALUM SHEET, QQ-A-
(1,27) 250/5
10 SEAL 7093-2, Vl1960
ALTERNATE
SEAL 7040-2, V11960
RH Fan Cowl Edge Protection
Table 12

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FAN COWL ALLOWABLE DAMAGE

1. General

A. Allowable damage data permits an operator to determine if a damaged fan

cowl can be returned to service without repair.

Damage permitted by this data will have no significant effect on the

strength or fatigue life of the structure, which will still be capable
of fulfilling its design function.

All damage limits assume that exposed edges do not protrude from skin
contour. Such damage should be reworked to remove or feather
protrusions. Hole and cracks in pressure boundaries must be sealed with
appropriate tape material.

B. Allowable Damage Usage

(1) Unlimited Usage

(a) Minor damage not affecting the structural integrity or

functional capability of the component and requiring no repair
over the aircraft design life.

(2) Time Limited Usage

(a) Minor damage not affecting the structural integrity of the

component in normal operation, that could reduce design life
of component. Damage must be permanently repaired not later
than the next maintenance “C” check. The location and size of
the damage is to be noted and checked to ensure that the
damage has not grown beyond the allowable damage limits.

C. Damage Types

(1) Composite Materials - The types of damage permitted to the fan cowl
outer barrel are defined below. They do not include damage to
surface finish such as paint.

Abrasion - A damaged area which results in a cross-sectional

area change due to scuffing, rubbing, scraping, or
other surface erosion. An abrasion is usually rough
and irregular.

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Gouge - A damaged area of any size which results in a cross-

sectional area change. It is usually caused by
contact with a relatively sharp object which
produces a continuous, sharp or smooth channel-like
groove in the material.

Nick - A local gouge with sharp edges. Consider a series of

nicks in a line pattern to be the equivalent of a
gouge.

Scratch - A line of damage in the material and results in a

cross sectional area change. It is usually caused
by contact with a very sharp object.

Crack - A fracture or complete break in the material. It

appears as an irregular line.

Hole - A complete penetration of the material.

Void/Disbond - Separation of the face sheet from honeycomb core.

Delamination - Separation of the bonded laminated material plies

from each other.

(2) Aluminum Sheet Metal Structures - The types of damage permitted to

the inlet lip are defined below. They do not include damage to
surface finish such as paint.

Abrasion - A damaged area which results in a cross-sectional

area change due to scuffing, rubbing, scrapping or
other surface erosion. An abrasion is usually rough
and irregular.

Gouge - A damaged area of any size which results in a cross-

sectional area change. It is usually caused by
contact with a relatively sharp object which
produces a continuous, sharp or smooth channel-like
groove in the material.

Nick - A local gouge with sharp edges. Consider a series of

nicks in a line pattern to be the equivalent of a
gouge.

Scratch - A line of damage in the material and results in a

cross sectional area change. It is usually caused
by contact with a very sharp object.

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Crack - A crack is a fracture or complete break in the

material. It appears as an irregular line.

Dent - Normally a damage area which is depressed with

respect to its normal contour. There is no cross-
sectional area change in the material. Area
boundaries are smooth, its form is generally the
result of contact with a relatively smooth
contoured object.

Buckle - Similar to a dent but is caused by an overload

situation or adjacent damage. It may protrude and/
or be indented with respect to the contour.

Hole - A complete penetration of the material.

D. Sealing of Damage Area (Fan Cowl) - Clean up the damage area and apply
protective sealing tape. (See Figure 101 and 102)

(1) Remove loose particles from damage area and trim loose ends of
graphite tape, graphite fabric, or fiberglass fabric.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU

DO THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY
ALL INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

(2) Remove raised material to fair with air-wetted surface.

(3) Smooth edges of crack or hole damage and chamfer or radius the
edges adjacent to the air-wetted surface.

(4) Use 320-grit abrasive paper and remove surface gloss from area at
least one-inch (25,4 mm) beyond cleanup limits.

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WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(5) Clean sanding debris from surface with clean cloth moistened with
Isoprophyl alcohol. Remove the solvent with a clean lint-free
cloth before the solvent becomes dry.

(6) Cut sealing patch from aluminum-backed sealing tape.

(a) Cut patch one-inch (25,4 mm) larger all around than damage
cleanup area.

(b) Remove all square corners from patch by trimming to a rounded

configuration.

(c) Apply tape over damage area.

(d) Stretch and smooth tape as it is applied to avoid wrinkles.

(e) Press patch in place with plastic roller or squeegee to remove

trapped air and wrinkles.

(f) Roll edges of patch to assure proper adhesion.

(7) Remove damaged tape patch by peeling from structure surface.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(8) Clean adhesive residue from patch area using a clean cloth
moistened with Isoprophyl alcohol. Remove the solvent with a clean
lint-free cloth before the solvent becomes dry.

(9) Cut a new patch and install.

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E. Damage Zones - There are six damage zones for the fan cowl doors. (See
Figure 103)

(1) See Table 101 for the following items:

(a) allowable damage types

(b) damage zones

(c) allowable damage limits

(d) cleanup requirements

(2) The allowable damage zone for the fan cowl doors are:

D1 Area 5.00-inches (127,0 mm) or less from hinge or latch

fittings.

D2 Forward and aft edges of fan cowl door.

D3 Area 3.00-inches (76,2 mm) or less from pressure relief

door, hold-open rod, or hoist point.

D4 The main body of the door which is full depth of sandwich

panel.

D5 The forward and aft fan cowl door lands.

D6 Pressure relief door.

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Type of Damage Zone Requirements and Disposition

Abrasion D1, D2, D3, Damage is allowable to surface finishes only.

D4, D5
Fibers must not be damaged
Apply *tape.
Check at “A” Check. Replace tape if peeled.

Abrasion D6 Unlimited Damage.

Crack D2 Maximum allowable length in fore-aft direction is

0.25-inch (6,4 mm).
No two cracks within 10.00-inches (254,0 mm).
Maximum of five per fan cowl.
Cracks wider than 0.10-inch (2,5 mm) are to be
treated as holes.
Cracks 0.01-inch (0,25 mm) deep or less to be
considered as scratches.
Unlimited use of terminated cracks between two
adjacent fasteners in joint of ten or more fasteners.
Apply *tape.
Check at “A” check.
Repair at “C” check.

Crack D4 Maximum allowable length is 3.00-inches (76.1 mm).

No two cracks within 10.00-inches (254,0 mm).
Maximum of five per fan cowl. Cracks wider than
0.10-inch (2,5 mm) are to be treated as holes.
Cracks 0.01-inch (0,25 mm) deep or less to be
considered as scratches.
Unlimited use of terminated cracks between two
adjacent fasteners in joint of ten or more fasteners.
Apply *tape.
Check at “A” check.
Repair at “C” check.

* Tape - Commonly referred to as “speed tape”, 3M Type 425 or equivalent.

Fan Cowl Allowable Damage

Table 101 (Sheet 1 of 4)

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Type of Damage Zone Requirements and Disposition

Crack D5 Maximum allowable length in fore-aft direction is

0.25-inch (6,4 mm).
Maximum allowable length in circumferential
direction is 1.00-inch (25,4 mm).
No two cracks within 10.00-inches (254,0 mm).
Maximum of five per fan cowl.
Cracks wider than 0.10-inch (2,5 mm) are to be
treated as holes.
Cracks 0.01-inch (0,25 mm) deep or less to be
considered as scratches.
Unlimited use of terminated cracks between two
adjacent fasteners in joint of ten or more fasteners.
Apply *tape.
Check at “A” check.
Repair at “C” check.

Crack D6 Unlimited Damage.

Disbond D2 Maximum allowable length is 0.75-inch (19,05 mm) and

maximum width is 0.25-inch (6,4 mm).
No two disbonds within 10.00-inches (254,0 mm).
Maximum of five disbonds per fan cowl door.
Check at “A” check.
Repair all disbonds at “C” check.

Disbond D4 Maximum allowable length is 3.00-inches (76,2 mm).

No two disbonds within 10.00-inches (254,0 mm).
Maximum of five disbonds per fan cowl door.
Check at “A” check.
Repair all disbonds at “C” check.

Disbond D6 Unlimited Damage.

* Tape - Commonly referred to as “speed tape”, 3M Type 425 or equivalent.

Fan Cowl Allowable Damage

Table 101 (Sheet 2 of 4)

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Type of Damage Zone Requirements and Disposition

Dent D4 Maximum diameter of dents is 12.00-inches (304,8 mm)

with no torn fibers or disbonds.
Dents are to be smooth in appearance with no sharp
edges.
Refer to Figure 101 (Sheet 2), Detail III for depth
and smoothness.

Dent D6 Unlimited Damage.

Scratch/Gouge D1, D2, D3, Maximum allowable limits depth, 0.010-inch (0,25 mm)
D4, D5 length 10.00-inches (254,0 mm) and width 0.10-inch
(2,5 mm).
No two within 10.00-inches (254,0 mm).
Maximum of 10 gouges and 10 scratches per fan cowl
door.
Apply *tape. C
heck at “A” check. Repair at “C” check.
Replace tape if peeled or damaged.

Scratch/Gouge D6 Unlimited Damage.

Nick D1, D2, D3, Maximum allowable limit of 10.00-inches (254,0 mm) in
D4, D5 any direction.
Maximum of 14 nicks per fan cowl door.
Apply *tape.
Check at “A” check. Repair at “C” check.
Replace tape if peeled or damaged.

Nick D6 Unlimited Damage.

Hole D4 Maximum allowable limit is 3.00-inches (76,2 mm).

Apply *tape. Check at “A” check.
Repair at “C” check. Replace tape if peeled or
damaged.

* Tape - Commonly referred to as “speed tape”, 3M Type 425 or equivalent.

Fan Cowl Allowable Damage

Table 101 (Sheet 3 of 4)

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Type of Damage Zone Requirements and Disposition

Hole D5 Maximum allowable limit is 1.00-inch (25,4 mm)

diameter
Apply *tape. Check at “A” check.
Repair at “C” check. Replace tape if peeled or
damaged.

Hole D6 Not Allowed

Test D6 Door must open and close without binding.

Inspect per Aircraft Maintenance Manual.

* Tape - Commonly referred to as “speed tape”, 3M Type 425 or equivalent.

Fan Cowl Allowable Damage

Table 101 (Sheet 4 of 4)

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Damage Clean Up of Edges

Figure 101 (Sheet 1)

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Damage Clean Up of Edges

Figure 101 (sheet 2)

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Application of Tape to Air-Wetted Surfaces

Figure 102

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HINGE FITTING ZONE D1

(TYPICAL 3 PLACES)

EDGE
ZONE D2

DOOR LAND
ZONE D5
5.00 IN.

ZONE D4
A A

DOOR EDGE 3.0 IN.

(TYPICAL FORWARD AND AFT) ZONE D3
ZONE D2
3.0 IN.
ZONE D3

ZONE D6
DOOR LANDS
(TYPICAL FORWARD AND AFT)
ZONE D5 3.0 IN.

SECTION A-A EDGE

ZONE D2
ZONE D3
3.0 IN.

3.0 IN.

3.0 IN.

5.00 IN.

VIEW LOOKING OUTBOARD

LH FAN COWL DOOR SHOWN, RH SIMILAR CES-132-02

Fan Cowl Allowable Damage

Figure 103

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FAN COWL REPAIR INDEX

Title Repair
Surface Finish Restoration Repair . . . . . . . . . . . . Repair No.1
Graphite Composite Skin Damage Less than Repair No.2
.010 Inch Deep Repair . . . . . . . . . .
Graphite Composite Skin Damage Greater than Repair No.3
.010 Inch Deep Repair . . . . . . . . . .
Fan Cowl Edge Damage Repair . . . . . . . . . . . . . . . Repair No.4
Fan Cowl Partial Penetration Wet . . . . . . . . . . . . Repair No.5
Layup Repair . . . . . . . . . . . . . . .
Fan Cowl Full Penetration Wet Layup Repair . . . . . . . Repair No.6
Edge Erosion Repair . . . . . . . . . . . . . . . . . . . Repair No.7
Expanded Copper Screen Repair . . . . . . . . . . . . . . Repair No.8

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REPAIR NO.1
SURFACE FINISH RESTORATION

1. General

This procedure gives the instructions to repair the surface finish of the
inner and outer surfaces.

2. Repair Instructions for Outer Surface. See Step 3. for Repair Instructions
for the Inner Surface.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

CAUTION: DO NOT USE THE PAINT REMOVAL COMPOUNDS ON CARBON/EPOXY PARTS

BECAUSE THESE COMPOUNDS CAUSE DAMAGE. DAMAGED PARTS CAN BE
WEAKER THAN THE INITIAL PARTS.

CAUTION: DO NOT BREAK OR MAKE THE CARBON FIBERS THIN IN THE AREA TO BE
PAINTED. IF THE FIBERS ARE DAMAGED, THEN THE PART CAN BE WEAKER
THAN THE INITIAL PART.

CAUTION: DO NOT CAUSE DAMAGE TO THE EXPANDED COPPER SCREEN (ECS) WHEN YOU
REMOVE THE SURFACE FINISH. THE ECS IS NECESSARY FOR LIGHTNING
PROTECTION.

A. Use a 180-grit abrasive paper and remove the surface finishes from the
graphite/epoxy structures. See Table 201.

B. Apply the epoxy filler on the composite surfaces of the defective area.
See Table 201.

NOTE: Do not apply the epoxy filler on the fastener heads. The finish
can break if the epoxy filler is applied to the fastener heads.

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Document Part No. RDN 306

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Wet a clean cheesecloth pad with the solvent and apply 25-50 grams
of epoxy filler.

(2) Rub the cheesecloth pad on the defective area. Use a strong
circular movement.

(3) Examine the epoxy filler for pin holes.

(a) Examine for pin holes as the epoxy filler is applied.

(b) If there are pin holes in the epoxy filler, go to steps (1)
through (3) to apply and examine the epoxy filler.

(4) Examine the epoxy filler for thickness.

(a) Remove unwanted epoxy filler with a knife, razor blade or

plastic squeegee.

(b) Make sure you can see the surface through the filler.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE MANUFACTURER,
THE MATERIAL SAFETY DATA SHEET (MSDS), AND GOVERNMENT
REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE
YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED. AN
MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

(c) If you cannot see the surface, use a clean cheesecloth moist
with the solvent and remove unwanted filler before filler
becomes hard.

C. Dry the epoxy filler. Refer to the instructions of the manufacturer.

CF6-80E1
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has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

D. Use 240 - 320-grit abrasive paper on the areas with the epoxy filler.
Make sure that the epoxy filler is only in the defective areas. See
Table 201.

E. Apply the epoxy primer to the outer surface. See Table 201.

(1) Apply the teflon tape to the perimeter of the repair area to
prevent damage to the adjacent surfaces.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU

DO THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY
ALL INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

(2) Use a 180-grit abrasive paper to remove the surface finish in the
repair area.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(3) Clean the repair area with a clean, lint-free cloth and the
solvent. Remove the solvent with a clean lint-free cloth before the
solvent becomes dry.

CF6-80E1
This document may contain export
54-20-00 REPAIR NO. 1
Page 203
Oct 15/19
controlled technical data, but
has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(4) Mix the epoxy primer. Refer to the instructions of the

manufacturer. See Table 201.

NOTE: Apply two coats before you apply the topcoat. The dried
film thickness must be 0.0006 - 0.0009-inch (0.01524 -
0.02286 mm).

(5) Dry the epoxy primer. Refer to the instructions of the

manufacturer.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

F. Apply the polyurethane topcoat to the external surface of the repair.

(See Airbus Industrie for special operator topcoat instructions.)

3. Repair Instructions for Inner Surface. See Step 2. for the Repair
Instructions for the Outer Surface.

A. Apply the epoxy primer to the inner surface. See Table 201.

(1) Apply the teflon tape to the perimeter of the repair area to
prevent damage to the adjacent surfaces.

CF6-80E1
This document may contain export
54-20-00 REPAIR NO. 1
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controlled technical data, but
has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU

DO THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY
ALL INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

(2) Use a 180-grit abrasive paper to remove the surface finish in the
repair area.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(3) Clean the repair area with a clean, lint-free cloth and the
solvent. Remove the solvent with a clean lint-free cloth before the
solvent becomes dry.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(4) Mix the epoxy primer. Refer to the instructions of the

manufacturer. See Table 201.

NOTE: Apply crosscoat of epoxy primer 0.0005 - 0.0007 inch

(0.0127 - 0.0178 mm) thick.

(5) Dry the epoxy primer. Refer to the instructions of the

manufacturer.

CF6-80E1
This document may contain export
54-20-00 REPAIR NO. 1
Page 205
Oct 15/19
controlled technical data, but
has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

4. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Blade, Razor Commercially Available
Cloth, Lint-Free Cotton Commercially Available
Clothing, Protective Commercially Available
Container Metal or Plastic Commercially Available
Cover, Container Metal or Plastic Commercially Available
Filler, Epoxy 467-9/CA-41B V0KXA5
Akzo Nobel Aerospace Coatings
East Water St.
Waukegan, IL 60085-5563
Phone: (847) 625-4200
Fax: (847) 625-3200
www.anac.com
Glasses, Safety Commercially Available
Gloves Neoprene or Commercially Available
Polyvinyl Chloride
Knife, Utility Commercially Available
Lamp, Heat 75°F-200°F Commercially Available
(23.89°C-93.33°C)
Mask, Dust Regulatory Agency Commercially Available
Approved
Pad, Cheesecloth 6 x 16-Inch Commercially Available
(152.4 x 406.4 mm)
Paper, Abrasive 180-, 240-, 320-Grit Commercially Available
Silicone Carbide
Primer Epoxy Eco-primeTM military V5HCF1
EEAY051A Base PRC-DeSoto International, Inc.
EEAY051B Curing Solution 12780 San Fernando Road
Sylmar, CA 91342
Telephone (818) 240-2060
Toll Free (800) 237-6649
www.ppgaerospace.com
Squeegee, Plastic Commercially Available

Repair Materials and Equipment

Table 201 (Sheet 1 of 2)

CF6-80E1
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controlled technical data, but
has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

DESCRIPTION DESIGNATION MANUFACTURER

Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Univar U.S.A., Inc.
Ketone/40% Methyl Ethyl 532 E. Emaus Street
Ketone Middletown, PA 17057-2200
Phone: (717) 944-7471
www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Tape, Teflon 2-Inches Wide Commercially Available
Repair Materials and Equipment
Table 201 (Sheet 2 of 2)

CF6-80E1
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54-20-00 REPAIR NO. 1
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controlled technical data, but
has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

THIS PAGE INTENTIONALLY LEFT BLANK

CF6-80E1
This document may contain export
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Page 208
Oct 15/19
controlled technical data, but
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Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

REPAIR NO. 2

CARBON COMPOSITE SKIN DAMAGE LESS THAN 0.010-INCH IN DEPTH

1. General

This procedure give the instructions to repair the damage to the composite
skin that is less than 0.010-inch (0.25 mm) in depth. The depth of the
damage does not include the thickness of the primer and paint layers. The
damaged area is filled with the adhesive and made smooth with the abrasive
paper. Carbon fabric is not used for this repair.

2. Repair Instructions

A. Clean the damaged area. See Table 201.

CAUTION: MAKE SURE YOU DO NOT CAUSE DAMAGE TO THE EXPANDED COPPER
SCREEN (ECS). DECREASE IN THE LIGHTNING PROTECTION CAN OCCUR
IF THE ECS IS DAMAGED.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU

DO THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY
ALL INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

(1) Use a 180-grit abrasive paper on the edges of the damage.

(2) Use a 150-grit abrasive paper to remove the surface finish adjacent
to the repair area.+

NOTE: The first primer layer is yellow and the outer primer layer
is gray.

CF6-80E1
This document may contain export
54-20-00 REPAIR NO. 2
Page 201
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controlled technical data, but
has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(3) Clean the repair area with a clean, lint-free cloth and the
solvent. Clean the surface with a lint-free cloth before the
solvent becomes dry.

B. Mix the adhesive. See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Mix the adhesive. Refer to the instructions of the manufacturer.

(2) Add the phenolic microballoons 20 percent by weight to the

adhesive. Mix the contents until the mixture is a paste.

C. Fill the repair area. See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Fill the repair area with the adhesive and microballoon mixture
until flush with the skin surface.

(2) Dry the adhesive and microballoon mixture. Refer to the

instructions of the manufacturer.

CF6-80E1
This document may contain export
54-20-00 REPAIR NO. 2
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controlled technical data, but
has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

D. Use a 180-grit abrasive paper on the surface and the edges of the
repair area. See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

E. Remove the unwanted material with a clean lint-free cloth and solvent.
Clean the surface with a lint-free cloth before the solvent becomes
dry. See Table 201.

F. Repair the surface finish. See Repair No. 1 - Surface Finish

Restoration.

3. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Adhesive, Epoxy EA9390 (Two Part) V33564
Henkel Corporation
2850 Willow Pass Rd.
P.O. Box 312
Baypoint, CA 94565-0031
Phone: (800) 257-7522
www.aerospace.henkel.com
Cloth, Lint-free Cotton Commercially Available
Clothing, Protective Commercially Available
Container Metal or Plastic Commercially Available
Repair Materials and Equipment
Table 201 (Sheet 1 of 2)
CF6-80E1
This document may contain export
54-20-00 REPAIR NO. 2
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Oct 15/19
controlled technical data, but
has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

DESCRIPTION DESIGNATION MANUFACTURER

Glasses, Safety Commercially Available
Gloves Neoprene or Polyvinyl Commercially Available
Chloride
Lamp, Heat 180°-200°F Commercially Available
(83°-93°C)
Mask, Dust Regulatory Agency Commerciallyl Available
Approved
Microballoons Phenolic, 135 Micron Commercially Available
Paper, Abrasive 150 - 180-Grit Commercially Available
Silicon Carbide
Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Univar U.S.A., Inc.
Ketone/40% Methyl Ethyl 532 E. Emaus Street
Ketone Middletown, PA 17057-2200
Phone: (717) 944-7471
www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Repair Materials and Equipment
Table 201 (Sheet 2 of 2)

CF6-80E1
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54-20-00 REPAIR NO. 2
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controlled technical data, but
has not yet been classified
Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
Goodrich transfer
Proprietary - This document is subject to the controls and restrictions on the title page.
without proper export classification and approval.
 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

REPAIR NO. 3
CARBON COMPOSITE SKIN DAMAGE MORE THAN 0.010-INCH (0.25 MM) IN DEPTH

1. General

A. This procedure give the instructions to repair the scratches and nicks
to the inner or outer composite skin that is more than 0.010-inch (0.25
mm) in depth.

B. The damaged area is filled with an adhesive/microballoon mixture. Use

plain weave carbon fabric for repair plies.

2. Repair Instructions

A. Clean the damaged area. See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Clean the repair area with a clean, lint-free cloth and the
solvent. Clean the surface with a lint-free cloth before the
solvent becomes dry.

B. Find the number of skin plies that are damaged. The total of repair
plies are equal to the number of damage plies plus one ply. See 54-20-
00 Structural Identification.

C. Put the teflon tape around the edge of the repair area. See Figure 201,
202 and Table 201.

(1) Measure the largest repair ply to find the dimensions of the repair
area.

(a) The Repair ply No. 1 is 0.50-inch (12.7 mm) from the edge of
the damage in all direction.

(b) Each subsequent ply is 0.50-inch (12.7 mm) from the edges of
the last ply in all directions.

(c) Only for the outer skin. The expanded copper screen (ECS) ply
is 1.0-inch (25.4 mm) from the edges of the last repair ply.

CF6-80E1
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Printed in the U.S.A.
Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
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Proprietary - This document is subject to the controls and restrictions on the title page.
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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

(2) Use the teflon tape and make a mask band around the repair area.
Put the inner edge of the band against the outer edge of the last
repair ply or ECS ply.

D. Only for the outer skin. Remove the expanded copper screen. See Figure
202.

(1) Remove the expanded copper screen from the area of the repair
plies.

(2) Cut the corners to a 45 degree by 0.5 inch (12.7 mm).

(3) Remove the finish but not the ECS material in the area from the
edges of the last repair ply to the tape.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

E. Use an abrasive paper (150-grit) to remove the surface finish from the
taped area. Make the edges of the damaged area smooth. See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

F. Remove the unwanted material with a clean lint-free cloth and solvent.
Remove the solvent with a clean lint-free cloth before the solvent
becomes dry. See Table 201.

G. Mix the adhesive. See Table 201.

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WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Mix the adhesive. Refer to the instructions of the manufacturer.

(2) Add the phenolic microballoons 20 percent by weight to the

adhesive. Mix the contents until the mixture is a paste.

H. Fill the repair area. See Figure 201, 202 and Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Fill the repair area with the adhesive and microballoon mixture
until flush with the skin surface.

(2) Dry the adhesive and microballoon mixture. Refer to the

instructions of the manufacturer.

I. Cut a sufficient quantity of repair plies. The total of repair plies

are equal to the number of damage plies plus one ply. See Figures 201
and 202.

NOTE: A minimum of three repair plies must be used.

NOTE: The graphite tape layer is equal to one layer of the damaged
ply. The warp direction for this repair ply is equal to 0-
degrees.

NOTE: The warp direction of each repair ply is equal to the warp
direction of the damaged plies that are replaced. See the 54-20-
00 Structural Identification.

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(1) Cut the first repair ply to a 0.50-inch (12.7 mm) overlap on all
sides of the damage.

(2) Cut the corners of the first repair ply to 45-degrees by 0.50-inch
(12.7 mm).

(3) Cut the second repair ply to a 0.50-inch (12.7 mm) overlap from the
edges of the first ply.

(4) Cut the corners of the second repair ply 45-degress by 1.0-inch
(25.4 mm).

(5) Do steps (3) and (4) again for all of the repair plies.

J. Soak the repair plies with the adhesive See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Mix the adhesive. Refer to the instructions of the manufacturer.

(2) Put the Repair ply No. 1 on a sheet of nonporous parting film.

(3) Apply the adhesive to one side of the repair ply.

(4) Use the nonporous parting film and put on the top of the repair
ply.

(5) Use a roller to soak the plies with the adhesive.

(6) Do steps (2) through (5) for all of the repair plies.

K. Put the carbon repair plies on the skin. See Figure 201 and 202.

(1) Apply the adhesive to the repair area.

(2) Lift the repair ply No. 1 from the bottom parting film and put the
ply in position on the repair area.

NOTE: Make sure that the repair ply has an overlap of 0.50-inch
(12.7 mm) from all edges of the damage.

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(3) Put the ply into position with a roller, then remove the parting
film from the top side.

NOTE: Make sure that there are no wrinkles in the ply.

(4) Lift the repair ply No. 2 from the bottom parting film and put the
ply in position on the repair area.

NOTE: Make sure that the repair ply has an overlap of 0.50-inch
(12.7 mm) from all edges of the repair ply No. 1.

(5) Put the ply into position with a roller, then remove the parting
film from the top side.

NOTE: Make sure that there are no wrinkles in the ply.

(6) Do Steps (4) and (5) for all of the repair plies.

L. Prepare the repair area for the vacuum bag cover and cure procedure.
See Figure 203 and Table 201.

(1) Put a sheet of porous parting film on the repair materials. Make
sure that the sheet of parting film has an overlap of 3.0-inch.
(76.2 mm) from all edges of the last repair ply.

(2) Put the bleeder cloth layers on the parting film.

(a) The number of bleeder cloth layers must be equal to the number
of repair plies.

(b) The bleeder cloth layers must be equal to the dimension of the
porous parting film.

(3) Put a sheet of the nonporous parting film on the bleeder cloth
layers. Make sure the edges of bleeder cloth layers are below the
nonporous parting film.

(4) Put a silicon rubber sheet on the nonporous parting film.

(5) Put a heat blanket on the rubber sheet.

(6) Put two layers of the fiberglass breather cloth on the heat
blanket.

(7) Put a vacuum bag on the heat blanket.

NOTE: Make sure the vacuum bag has an overlap of approximately

2.0-inch (50.8 mm) from all edges of the heat blanket.

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(8) Put a temperature probe below the bag and seal the edges of the
vacuum bag with the double sided tape.

(9) Put a vacuum connector below the bag and seal the edges with the
teflon tape.

M. Use a vacuum pump to increase the vacuum pressure in the bag to 20-
inches of mercury (67.7 kPa). See Table 201.

N. Set the switch for the heat blanket to keep the temperature at 190°-
210°F (88°-99°C). Let the repair cure for 220 minutes. See Table 201.

O. Remove the vacuum bag and all of the bag materials from the repair.
Remove the teflon tape from around the repair area.

P. Use 150 - 320-grit abrasive paper and make the surface and the edges of
the repair smooth. Do not go into the graphite ply with the abrasive
paper. See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

Q. Remove the unwanted material with a clean lint-free cloth and solvent.
Remove the solvent with a clean lint-free cloth before the solvent
becomes dry. See Table 201.

R. Only for the outer skin. Replace the ECS. See Repair No. 8 - Expanded
Copper Screen (ECS) Repair.

S. Repair the surface finish. See Repair No. 1 - Surface Finish

Restoration.

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3. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Adhesive, Epoxy EA9390 (Two Part) V33564
Henkel Corporation
2850 Willow Pass Rd.
P.O. Box 312
Baypoint, CA 94565-0031
Phone: (800) 257-7522
www.aerospace.henkel.com
Blanket, Heat 20 x 20 inch V61426
(508 x 508 mm) Atacs Products, Inc.
850 South Cambridge Street
Seattle, WA 98108-4748
Phone: (206) 433-9000
www.atacs.com
Cloth, Bleeder Fiberglass Commercially Available
Cloth, Breather RC3000-10 V0F451
Richmond Aircraft Products, Inc.
13503 Pulmice St
Norwalk, CA 90650-5250
Phone: (562) 404-2440
www.richmondaircraft.com
Cloth, Lint-free Cotton Commercially Available
Clothing, Protective Commercially Available
Container Metal or Plastic Commercially Available
Cover, Container Metal or Plastic Commercially Available
Fabric, Carbon AH370-5H V2B975
Hexcel Corp
1913 N King St
Seguin, TX 78155-2197
Phone: (800) 688-7734
www.hexcel.com
Film, Bagging 2 mm Nylon V0F451
Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Film Parting Nonporous V0F451
Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Repair Materials and Equipment
Table 201 (Sheet 1 of 2)

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DESCRIPTION DESIGNATION MANUFACTURER

Film Parting Porous V0F451
Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Glasses, Safety Commercially Available
Gloves Neoprene or Polyvinyl Commercially Available
Chloride
Mask, Dust Regulatory Agency Commercially Available
Approved
Microballoons Phenolic, 135 Micron Commercially Available
Paper, Abrasive 150 - 320-Grit Commercially Available
Silicon Carbide
Probe, Temperature 0-250°F (0-121°C) Commercially Available
Pump, Vacuum 0-30 Inches-of-mercury Commercially Available
(0-0.1 MPa)
Roller 2.0 inch (50.8 mm) Commercially Available
Diameter
Metal or Plastic
Tape Double Sided Commercially Available
Tape, Teflon 2.0-inch Commercially Available
Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Univar U.S.A., Inc.
Ketone/40% Methyl Ethyl 532 E. Emaus Street
Ketone Middletown, PA 17057-2200
Phone: (717) 944-7471
www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Repair Materials and Equipment
Table 201 (Sheet 2 of 2)

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INNER
PANEL
SKIN

SCRATCH/GOUGE

REPAIR PLY NO. 1

REPAIR PLY NO. 2 0.50 INCH

45° (12.7 mm)

A A

0.50 INCH
REPAIR PLY NO. 3
(12.7 mm)
TYPICAL FOR
TEFLON TAPE REPAIR PLIES
2.0 INCH
(50.8 mm)

0.50 INCH
(12.7 mm)
TYPICAL

REPAIR
PLY NO. 3
REPAIR PLY NO. 1
REPAIR PLY NO. 2
TEFLON TAPE
TEFLON TAPE
INNER
PANEL
SKIN

OUTER
PANEL
SKIN
ADHESIVE
CES-238-00

A-A

Carbon Composite Inner Skin Damage

More Than 0.010-Inch (0.25 mm) in Depth
Figure 201

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OUTER
PANEL
SKIN

SCRATCH/GOUGE

REPAIR PLY NO. 1

45° 0.50 INCH
REPAIR PLY NO. 2
(12.7 mm)

A A

REPAIR PLY NO. 3

0.50 INCH
(12.7 mm)
TEFLON TAPE TYPICAL FOR
2.0 INCH REPAIR PLIES
(50.8 mm)

EXPANDED
COPPER SCREEN
(ECS) 0.50 INCH
USE REPAIR 1.0 INCH (12.7 mm)
NO. 8 TO REPLACE (25.4 mm) TYPICAL
TYPICAL
ECS
USE REPAIR
REPAIR NO. 8 TO REPLACE
PLY NO. 3 REPAIR PLY NO. 1
REPAIR PLY NO. 2
TEFLON TAPE TEFLON TAPE
ECS
OUTER
PANEL
SKIN

INNER
CES-237-00

PANEL
SKIN
ADHESIVE
A-A
Carbon Composite Outer Skin Damage
More Than 0.010-Inch (0.25 mm) in Depth
Figure 202

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BLEEDER
CLOTH
PLIES

SILICONE NON-POROUS
RUBBER PARTING
SHEET FILM
POROUS REPAIR PLIES
PARTING
FILM HEAT BLANKET
VACUUM
BAG
FIBERGLASS FABRIC
BREATHER PLIES
VACUUM HOSE
TEFLON TAPE

BAG SEAL
TEFLON TAPE

TEMPERATURE TEMPERATURE
PROBE PROBE

CES-236-00

Vacuum Bag
Figure 203

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REPAIR NO. 4
FAN COWL EDGE DAMAGE REPAIR

1. General

A. This procedure gives the instructions to repair the damage to the

leading edge, the trailing edge, and edges around the access doors.
Remove the access doors before you do the repair around the edges of
the access door.

B. The damage must be less than 6.0-inches (152.0 mm) long (on the
circumference direction). The damage must be less than or equal to 1.5-
inch (38,1 mm) wide (on the forward and aft direction). The damage must
be more than or equal to 6.0-inches (152.0 mm) from different edge-
repair or damage.

C. Refer to Repair No. 8 to repair damage to the Expanded Copper Screen

(ECS) on the external skin.

D. Refer to Repair No. 1 to repair damage to the paint.

2. Repair Instructions

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

A. Remove the rubstrip, if necessary.

(1) Make a template of the rubstrip and hole location.

(2) Keep the rubstrip to install again.

B. Prepare the damaged area of the panel. See Figure 201 and Table 201.

(1) Cut the damaged area of the panel. Remove all loose pieces, cracks,
and bond separation. Make a 0.50-inch (12.7 mm) minimum radius on
the inner corners of the cutout.

(2) Make the sides of the cutout 45 degrees. Make the edges of the
cutout smooth with 80 - 320-grit abrasive paper.

(3) Put the Teflon tape around the repair area. Put the teflon tape
3.5-inch (88.9 mm) minimum from the edge of the cutout.

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(4) Cut the expanded copper screen (ECS) ply. See Repair No. 8 to
remove the ECS.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU

DO THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY
ALL INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

CAUTION: DO NOT TAPER OR BREAK THE CARBON FIBERS FROM THE TOP SURFACE
OF THE OUTER SKIN PLIES.

(5) Use 150-grit abrasive paper to remove the surface finish.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(6) Remove the unwanted material with a clean lint-free cloth and
solvent. Remove the solvent with a clean lint-free cloth before the
solvent becomes dry.

C. Prepare the repair materials. See Figure 201 and Table 201.

(1) Make a backup plate from 0.090-inch (2.29 mm) thick 2024-T3
aluminum. Make a copy of the contour of the inner edge and ramp
area. Make the backup plate extend a minimum of 2.0-inches (50.8
mm) more than the repair area.

(2) Cut the filler plies.

(a) Make the filler plies to the dimension of the cutout.

(b) To prevent damaged edges, cut the plies approximately 0.5 in

(12.7 mm) larger than the cutout dimension.

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(c) Cut a sufficient quantity of plies to make the height of the

repair level with the inner and outer surfaces of the door
edge.

NOTE: The warp direction (the direction of the fabric of

each filler ply is equal to 0-degrees.

(3) Cut the repair plies. See Figure 201 and Table 201.

NOTE: The warp direction (the direction of the fabric) of all 4

repair plies are equal to 0-degrees.

(a) Cut the repair ply No. 1 to an overlap of 1.0-inch (25.4 mm)
in all directions from the edges of the skin cutout.

(b) Cut the other plies to an overlap of 0.75-inch (19.1 mm) from
the edges of the last ply.

(c) Cut the corners of the repair plies to 45 degrees by 1.0-inch

(25.4 mm).

(4) Cut one fiberglass sanding ply from the fiberglass fabric. See
Figure 201 and Table 201.

(a) Cut the fiberglass sanding ply to a minimum overlap of 0.25-

inch (6.4 mm) from the edge of the last ply.

NOTE: Extend the fiberglass sanding ply to the edge of the

teflon tape mask area.

(b) Cut the corners of the fiberglass sanding ply to 45 degrees by

1.0-inch (25.4 mm).

(5) Soak the filler plies, repair plies and fiberglass sanding ply with
the adhesive. See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(a) Mix the adhesive. Refer to the instructions of the

manufacturer.

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(b) Put each ply on a sheet of nonporous parting film.

(c) Apply the adhesive to one side of each ply.

(d) Put a piece of nonporous parting film on the top of each ply.

(e) Use a roller to soak the plies with the adhesive.

(6) Cut the filler plies to the same dimension of the cutout.

D. Install the filler plies, repair plies and fiberglass sanding ply. See
Figure 201 and Table 201.

(1) Install the backup plate.

(a) Put nonporous parting film between the backup plate and the
inner edge of the door.

(b) Hold the backup plate and parting film in position with the
clamps.

(2) Install the filler plies.

(a) Remove the nonporous parting film from the bottom of the
filler ply. Put the ply into the cutout. Use a roller to
remove the wrinkles or caught air. Remove the nonporous
parting film from the top of the ply.

(b) Do step (a) for all filler plies.

(3) Install the repair plies.

(a) Remove the nonporous parting film from the bottom of the
repair ply No. 1. Put the ply on the top of the filler plies.
Make sure there is an overlap of 1.0-inch (25.4 mm) in all
directions from the edges of the skin cutout. Use a roller to
remove the wrinkles or caught air. Remove the nonporous
parting film from the top of the ply.

(b) Remove the nonporous parting film from the bottom of the
repair ply No. 2. Put the ply on the top of the last ply. Make
sure there is an overlap of 0.75-inch (19.1 mm) in all
directions from the edges of the last ply. Use a roller to
remove the wrinkles or caught air. Remove the nonporous
parting film from the top of the ply.

(c) Do step (b) for all repair plies.

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(4) Remove the nonporous parting film from the bottom of the fiberglass
sanding ply. Put the ply on the top of the repair plies. Make sure
there is a minimum overlap of 0.25-inch (6.4 mm) in all directions
from the edges of the last repair ply. Use a roller to remove the
wrinkles or caught air. Remove the nonporous parting film from the
top of the ply.

E. Prepare the repair area for the vacuum bag cover and cure procedure.
See Figure 202 and Table 201.

(1) Put a sheet of porous parting film on the repair materials. Make
sure that the sheet of parting film has an overlap of 3.0-inch.
(76.2 mm) from all edges of the fiberglass sanding ply.

(2) Put the bleeder cloth layers on the parting film.

(a) The number of bleeder cloth layers must be equal to the number
of repair plies.

(b) The bleeder cloth layers must be equal to the dimension of the
porous parting film.

(3) Put a sheet of the nonporous parting film on the bleeder cloth
layers. Make sure the edges of bleeder cloth layers are below the
nonporous parting film.

(4) Put a silicon rubber sheet on the nonporous parting film.

(5) Put a heat blanket on the rubber sheet.

(6) Put two layers of the fiberglass breather cloth on the heat
blanket.

(7) Put a vacuum bag on the heat blanket.

NOTE: Make sure the vacuum bag has an overlap of approximately

2.0-inch (50.8 mm) from all edges of the heat blanket.

(8) Put a temperature probe below the bag and seal the edges of the
vacuum bag with the double-sided tape.

(9) Put a vacuum connector below the bag and seal the edges with the
double-sided tape.

F. Use a vacuum pump to increase the vacuum pressure in the bag to 20-
inches of mercury (67.7 kPa). See Table 201.

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G. Set the switch for the heat blanket to keep the temperature at 190°-
210°F (88°-99°C). Let the repair cure for 220 minutes. See Table 201.

H. Remove the vacuum bag, backup plate and all of the bag materials from
the repair. Remove the teflon tape from around the repair area.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

I. Use a 150 - 320-grit abrasive paper to make a taper ratio of 4 to 1 on

the external panel edge. See Figure 203 and Table 201.

J. Use 150 - 320-grit abrasive paper and make the surface and the edges of
the repair smooth. Do not go into the graphite ply with the abrasive
paper. See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

K. Remove the unwanted material with a clean lint-free cloth and solvent.
Remove the solvent with a clean lint-free cloth before the solvent
becomes dry. See Table 201.

L. Repair the Expanded Copper Screen. See Repair No. 8 to install the ECS.

M. Prepare the rubstrip for installation, if necessary.

(1) Use the abrasive paper on the bottom side of the rubstrip to make
the rubstrip flush to the adjacent rubstrip.

(2) Use the template to make the holes in the door. Use a 0.160-inch
(4.06 mm) diameter drill bit.

(3) Countersink the two sides of the hole to install the double-flush
rivets. Countersink to 0.283 - 0.289-inch (7.19 - 7.34 mm) diameter
by 100°.

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(4) Remove the replacement rubstrip.

(5) Remove sharp edges and burrs from the replacement rubstrip.

N. Repair the surface finish. See Repair No. 1 - Surface Finish

Restoration.

O. Install the replacement rubstrip, if necessary. See Figure 203 and

Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Apply the sealant to the mating surfaces of the repair and the
replacement rubstrip.

(2) Fill the spaces below the ends of the rubstrips with the sealant.

(3) Put the replacement rubstrip on the door edge. Install the double-
flush rivets wet with the sealant. Use squeeze installation
procedure.

(4) Cut or remove the rivet stems with a file to make a smooth surface.

(5) Use the abrasive paper (150-grit) to make the rubstrip flush to the
adjacent rubstrip.

(6) Remove unwanted sealant.

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3. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Adhesive, Epoxy EA9390 (Two Part) V33564
Henkel Corporation
2850 Willow Pass Rd.
P.O. Box 312
Baypoint, CA 94565-0031
Phone: (800) 257-7522
www.aerospace.henkel.com
Blanket, Heat 0 - 250°F (0 - 121°C) V61426
10 x 10 in. Atacs Products, Inc.
(245 x 245 mm) 850 South Cambridge Street
Seattle, WA 98108-4748
Phone: (206) 433-9000
www.atacs.com
Brush Nylon Bristle Commercially Available
Clamps Commercially Available
Cloth, Bleeder Fiberglass Commercially Available
Cloth, Breather RC3000-10 V0F451
Richmond Aircraft Products, Inc.
13503 Pulmice St
Norwalk, CA 90650-5250
Phone: (562) 404-2440
www.richmondaircraft.com
Cloth, Lint-free Cotton Commercially Available
Countersink, Cutter 0.283 - 0.289-inch Commercially Available
(7.19 - 7.34 mm) diameter
by 100°
Drill, Bit 0.160-inch (4.06 mm) Commercially Available
diameter
Fabric, Fiberglass Type 181 Commercially Available
Fabric, Graphite AH370-5H V52331
11 x 11 inch Hexcel Corporation
(280 x 280 mm) 11711 Dublin Blvd
Dublin, CA 94568-2832
Phone: (203) 696-0666
Fax: (203) 316-5139
www.hexcel.com
Repair Materials and Equipment
Table 201 (Sheet 1 of 3)

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DESCRIPTION DESIGNATION MANUFACTURER

Film, Bagging 2 mm Nylon V0F451
Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Film Parting Nonporous V0F451
Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Film Parting Porous V0F451
Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Gauge, Vacuum 0-20 Inches-of-Mercury Commercially Available
(0-67.5 kPa)
Hose, Vacuum 1/8 in. Diameter Commercially Available
Paper, Abrasive 80, 150, 320-Grit Commercially Available
Silicon Carbide
Plate, Backup 2024-T3 Commercially Available
0.090-inch (2.29 mm)
Aluminum Sheet
Probe, Temperature 0 - 250°F (0 - 121°C) Commercially Available
Pump, Vacuum 0 - 20 Inches-of-mercury (0 Commercially Available
- 67.5 kPa)
Roller 2.0 in. (50.8 mm) Diameter, Commercially Available
Steel or Plastic
Rivet NAS9313-AD-5 Commercially Available
Rubber Sheet 0.062 - 0.125-inch Commercially Available
(1.57 -3.18 mm) thick,
Silicone
Sealant PR1995 V83574
PPG Aerospace
PRC-DeSoto
5430 San Fernando Rd.
Glendale, CA 91203
Phone: (818) 549-7979
www.ppgaerospace.com
Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
Repair Materials and Equipment
Table 201 (Sheet 2 of 3)

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DESCRIPTION DESIGNATION MANUFACTURER

MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Univar U.S.A., Inc.
Ketone/40% Methyl Ethyl 532 E. Emaus Street
Ketone Middletown, PA 17057-2200
Phone: (717) 944-7471
www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Tape Double Sided Commercially Available
Tape, Teflon 2.0-inch Commercially Available

Repair Materials and Equipment

Table 201 (Sheet 3 of 3)

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FIBERGLASS
SANDING PLY 1.0 INCH
25.4 (mm)
REPAIR
PLY NO. 4
REPAIR 45°
PLY NO. 3
2.0 INCH
REPAIR
(50.8 mm)
PLY NO. 2
REPAIR 0.25 INCH
PLY NO. 1 (6.35 mm)
B
MINIMUM
A A
1.0 INCH
(25.4 mm)

FILLER PLIES B
CUTOUT 0.75 INCH (19,05 mm)
TYPICAL ALL AROUND TEFLON TAPE ECS
FOR REPAIR PLIES
45° FIBERGLASS
SANDING PLY
REPAIR PLY NO. 4
REPAIR PLY NO. 3 TEFLON TAPE
B-B REPAIR PLY NO. 2
ECS
REPAIR PLY NO. 1

FILL
PLIES CES-245-00

A-A
BACKUP PLATE
Repair Materials
Figure 201

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VACUUM HOSE
VACUUM BAG
FIBERGLASS FABRIC
BREATHER PLIES
HEAT BLANKET
SILICONE RUBBER SHEET
NONPOROUS PARTING FILM
BLEEDER CLOTH PLIES
POROUS PARTING FILM

TEMPERATURE
PROBE

BAG SEAL
BAG SEAL BACK-UP
TEFLON TAPE CORE
PLATE
CES-246-00

Vacuum Bag
Figure 202

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SEE REPAIR 8
DOUBLE FLUSH
ECS REPAIR PLY OVERLAP
RIVET
WITH EXISTING ECS
TAPER 4:1 2.0 INCH (50.8 mm) MINIMUM

0.40 INCH
(10.16 mm)
FWD
EDGE
PROTECTOR

CES-247-00

Completed Repair
Figure 203

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REPAIR NO.5
FAN COWL PARTIAL PENETRATION WET LAYUP REPAIR

1. General

This procedure gives the instructions to repair the damage to the outer
skin and core. The damage is to one the outer skin and does not go through
the inner skin. The damaged outer skin removed. The core is filled with
the adhesive or is removed and replaced with a repair core plug. Wet layup
carbon fabric fill plies and repair plies are installed on the outer skin.

2. Repair Instructions

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

A. Cut and remove the damaged area of the skin. See Figure 201.

(1) Remove all loose particles, cracks, and delaminations.

(2) Form a 0.5-inch (12.7 mm) minimum radius on all of the corners.

(3) Make a 45 degrees chamfer on the sides of the skin cutout that open
to the external surface.

(4) Use an abrasive paper on the edges of the skin cutout.

B. Find the number of skin plies that were removed to calculate the
dimension of the repair area. The total of repair plies are equal to
the number of damage plies plus one ply.

NOTE: The graphite tape layer is equal to one layer of the skin ply.

C. Put the teflon tape around the edge of the repair area. See Figure 202
and Table 201.

(1) Measure the largest repair ply to find the dimensions of the repair
area.

(a) Repair ply No. 1 must have an overlap of 1.0-inch (25.4 mm) in
all directions from the edges of the skin cutout.

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(b) Each subsequent ply must have an overlap of 0.75-inch (19.1

mm) from the edges of the last ply.

(2) Use the teflon tape and make a mask band around the repair area.
Put the inner edge of the band against the outer edge of the last
repair ply.

D. Remove the expanded copper screen on the outer skin. See Figure 201

(1) Remove the expanded copper screen from the edge of the damage area
to 0.75 inch (19.1 mm) of the teflon tape.

(2) Cut the corners to a 45 degree by 0.5 inch (12.7 mm).

CAUTION: DO NOT TAPER OR BREAK THE CARBON FIBERS FROM THE TOP SURFACE OF
THE OUTER SKIN PLIES.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

E. Remove all of the surface finish in the repair area.

(1) Use the abrasive paper (150-grit) to remove the top surface of the
outer skin ply to the graphite tape in the repair area.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

F. Remove the unwanted material with a clean lint-free cloth and solvent.
Remove the solvent with a clean lint-free cloth before the solvent
becomes dry.

G. Examine the honeycomb core for damage.

(1) If the diameter of the core damage is less than or equal to 1.0-
inch (25.4 mm), go to step I.

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(2) If the diameter to the core damage is more than 1.0-inch (25.4 mm),
go to step H. Then continue with the skin repair at step J.

H. Replace the honeycomb core. To fill the core area with the adhesive, go
to Step I. See Figure 203 and Table 201.

(1) Remove all of the damaged honeycomb core material.

NOTE: Do not remove the adhesive material from the inner skin
panel.

NOTE: Make sure you do not cut into the inner skin panel.

(2) Use an abrasive paper (150-grit) on the inner skin panel.

(3) Find the type of material and density of the honeycomb core. See
the SRM Fan Cowl Structure Identification (54-20-00).

(4) Cut the honeycomb core repair plug to the correct dimension. When
you install the honeycomb core repair plug, make sure that the
ribbon direction is aligned.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(5) Mix the adhesive. Refer to the instructions of the manufacturer.

(6) Use a second container and mix the adhesive with the phenolic
microballoon.

(a) Add the phenolic microballoons 20 percent by weight to the

adhesive.

(b) Mix the contents until the mixture is a paste.

(7) Apply a layer of the adhesive to the bottom of the repair plug.

(8) Apply a layer of the adhesive and microballoon mixture. Refer to

the instructions of the manufacturer.

(a) Apply the adhesive on the surfaces.

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(b) Apply the adhesive in the cutout.

(c) Apply the adhesive on the circumference of the repair plug.

(9) Put the honeycomb repair plug into the cutout.

(a) Use the adhesive and Microballoon mixture to fill all the open
areas between the repair plug and the repair panel.

(10) Dry the adhesive. Refer to the instructions of the manufacturer.

Proceed to step J.

I. Fill the core. See Figure 204 and Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Mix the adhesive. Add the phenolic microballoons 20 percent by

weight to the adhesive. Mix the contents until the mixture is a
paste. Refer to the instructions of the manufacturer.

(2) Make sure that the honeycomb cell walls are straight, then fill
them with the adhesive and microballoon mixture.

(3) Dry the adhesive and microballoon mixture. Refer to the

instructions of the manufacturer.

J. Cut the filler plies and repair plies.

(1) Cut a sufficient quantity of filler plies.

(a) The total of filler plies are equal to the number of damaged
plies.

NOTE: The graphite tape layer is equal to one layer of the

damaged ply.

(b) The warp direction (the direction of the fabric) of each

filler ply is equal to 0-degrees.

(2) Cut a sufficient quantity of repair plies.

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Document Part No. RDN 306

(a) The total of repair plies are equal to the number of damage
plies plus one ply.

NOTE: The graphite tape layer is equal to one layer of the

damaged ply. The warp direction for this repair ply is
equal to 0-degrees.

NOTE: The warp direction of each repair ply is equal to the

warp direction of the damaged plies that are replaced.
See the SRM Fan Cowl Structure Identification (54-20-
00).

(b) Cut the first repair ply to a 1.0-inch (25.4 mm) overlap on
all sides of the skin cutout.

(c) Cut the corners of the first repair ply to 45-degrees by 1.0-
inch (25.4 mm).

(d) Cut the second repair ply to a 0.75-inch (19.1 mm) overlap
from the edges of the first ply.

(e) Cut the corners of the second repair ply 45-degress by 1.0-
inch (25.4 mm).

(f) Do steps J.(2)(d) and J.(2)(e) again for all of the repair
plies.

K. Prepare the filler plies. See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Mix the adhesive. Refer to the instructions of the manufacturer.

(2) Put the filler plies on a sheet of nonporous parting film.

(3) Apply the adhesive to one side of each ply.

(4) Use the nonporous parting film and put on the top of each filler
ply.

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(5) Use a roller to soak the plies with the adhesive.

L. Put the filler plies into position in the skin cutout. See Figure 202
and Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Apply the adhesive to the inner surfaces of the skin cutout.

(2) Lift the first filler ply from the bottom parting film and put the
ply in position in the skin cutout.

(3) Push the ply into position with a roller, then remove the parting
film from the top side.

(4) Do steps L.(2) and L.(3) again for all of the filler plies.

M. Put the first repair ply in position on the skin cutout. See Figure 202
and Table 201.

(1) Put the Repair ply No. 1 on a sheet of nonporous parting film.

(2) Apply the adhesive to one side of the repair ply.

(3) Use the nonporous parting film and put on the top of the repair
ply.

(4) Use a roller to soak the plies with the adhesive.

(5) Lift the repair ply from the bottom parting film and put the ply in
position on the skin cutout.

NOTE: Make sure that the repair ply has an overlap of 1.0-inch
(25.4 mm) from all edges of the cutout.

(6) Push the ply into position with a roller, then remove the parting
film from the top side.

NOTE: Make sure that there are no wrinkles in the ply.

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N. Put the other repair plies in position. See Figure 202.

(1) Put the subsequent repair ply on a sheet of nonporous parting film.

(2) Apply the adhesive to one side of the repair ply.

(3) Use the nonporous parting film and put on the top of the repair
ply.

(4) Use a roller to soak the plies with the adhesive.

(5) Lift the repair ply from the bottom parting film and put the ply in
position on the last repair ply.

NOTE: Make sure that the repair ply has an overlap of 0.75-inch
(19.1 mm) from all edges of the last repair ply.

(6) Push the ply into position with a roller, then remove the parting
film from the top side.

NOTE: Make sure that there are no wrinkles in the ply.

(7) Do steps N.(1) and N.(6) again for all of the repair plies.

O. Prepare the repair area for the vacuum bag cover and cure procedure.
See Figure 205 and Table 201.

(1) Put a sheet of porous parting film on the repair materials. The
sheet of parting film must have an overlap of 3.0-inch. (76.2 mm)
from all edges of the last repair ply.

(2) Put the bleeder cloth layers on the parting film.

(a) The number of bleeder cloth layers must be equal to the number
of repair plies.

(b) The bleeder cloth layers must be equal to the dimension of the
porous parting film.

(3) Put a sheet of the nonporous parting film on the bleeder cloth
layers. Make sure to fully cover the bleeder cloth layers.

(4) Put a silicon rubber sheet on the nonporous parting film.

(5) Put a heat blanket on the rubber sheet.

(6) Put two layers of the fiberglass breather cloth on the heat
blanket.

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(7) Put a vacuum bag on the heat blanket.

NOTE: Make sure the vacuum bag has an overlap of approximately

2.0-inch (50.8 mm) from all edges of the heat blanket.

(8) Put a temperature probe below the bag and seal the edges of the
vacuum bag with the double sided tape.

(9) Put a vacuum connector below the bag and seal the edges with the
teflon tape.

P. Use a vacuum pump to increase the vacuum pressure in the bag to 20-
inches of mercury (67.7 kPa). See Table 201.

Q. Set the switch for the heat blanket to keep the temperature at 190°-
210°F (88°-99°C). Let the repair cure for 220 minutes. See Table 201.

R. Remove the vacuum bag and all of the materials used to cure the repair.
Remove the teflon tape from around the repair area.

S. Use 150-320 grit abrasive paper and make the surface and the edges of
the repair smooth. Do not go into the graphite ply with the abrasive
paper. See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

T. Remove the unwanted material with a clean lint-free cloth and

solvent. Remove the solvent with a clean lint-free cloth before
the solvent becomes dry. See Table 201.

U. Repair the ECS. See Repair No. 8 - Expanded Copper Screen (ECS) Repair.

V. Repair the surface finish. See Repair No. 1 - Surface Finish

Restoration.

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3. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Adhesive, Epoxy EA9390 (Two Part) V33564
Henkel Corporation
2850 Willow Pass Rd.
P.O. Box 312
Baypoint, CA 94565-0031
Phone: (800) 257-7522
www.aerospace.henkel.com
Blanket, Heat 20 x 20 inch V61426
(508 x 508 mm) Atacs Products, Inc.
850 South Cambridge Street
Seattle, WA 98108-4748
Phone: (206) 433-9000
www.atacs.com
Brush Nylon Bristle Commercially Available
Cloth, Bleeder Fiberglass Commercially Available
Cloth, Breather RC3000-10 V0F451
Richmond Aircraft Products, Inc.
13503 Pulmice St
Norwalk, CA 90650-5250
Phone: (562) 404-2440
www.richmondaircraft.com
Cloth, Lint-free Cotton Commercially Available
Core, Honeycomb Aluminum (as required) Commercially Available
3/32-inch cell 0.0055
foil gage
1/8-inch cell 0.0015
foil gage
3/16-inch cell 0.001
foil gage
Fabric, Graphite AH370-5H V2B975
11 x 11 inch Hexcel Corp
(280 x 280 mm) 1913 N King St
Seguin, TX 78155-2197
Phone: (800) 688-7734
www.hexcel.com
Repair Materials and Equipment
Table 201 (Sheet 1 of 2)

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DESCRIPTION DESIGNATION MANUFACTURER

Film, Bagging 2 mm Nylon V0F451
Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Film Parting Nonporous V0F451
Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Film Parting Porous V0F451
Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Microballoons Phenolic, 125 Micron, 40 Commercially Available
lb/cu.ft. (640 kg/m3)
Paper, Abrasive 80, 150, 320-Grit Commercially Available
Silicon Carbide
Probe, Temperature 0-250°F (0-121°C) Commercially Available
Pump, Vacuum 0-30 Inches-of-mercury Commercially Available
(0-0.1 MPa)
Tape Double Sided Commercially Available
Tape, Teflon 2.0-inch Commercially Available
Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Univar U.S.A., Inc.
Ketone/40% Methyl Ethyl 532 E. Emaus Street
Ketone Middletown, PA 17057-2200
Phone: (717) 944-7471
www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Repair Materials and Equipment
Table 201 (Sheet 2 of 2)

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HONEYCOMB
CORE FAN
COWL DOOR

CUTOUT
0.50 INCH
(12.70 mm)
RADIUS MIN.

ECS 45°
CUTOUT ECS
PANEL SKIN

HONEYCOMB
CORE

PANEL SKIN

CES-221-01

Skin Cutout
Figure 201

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0°
-45° +45°
1.00 INCH (25.4 mm)
AFT 0.75 INCH (19.1 mm) (TYPICAL)
90°

TEFLON
TAPE

OUTER 45°
PANEL
SKIN

2.0 INCHES
0.50 INCH (50.8 mm)
(12,70 mm)
REPAIR PLY RADIUS
NO. 1 MIN. DAMAGE
CUTOUT
REPAIR PLY
NO. 2
REPAIR
PLY NO. 3

1.00 INCH
(25.4 mm)
(TYPICAL)
REPAIR PLY NO. 3
REPAIR PLY NO. 1
REPAIR PLY NO. 2 EXPANDED
HONEYCOMB SKIN
TEFLON TAPE COPPER
CORE CUTOUT
SCREEN
TEFLON TAPE (ECS)
OUTER
PANEL
SKIN
GRAPHITE
PLY
CES-222-02

INNER
PANEL
SKIN
FILLER PLIES
Filler and Repair Plies
Figure 202

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ECS ECS
HONEYCOMB
CORE CUTOUT
OUTER
PANEL
SKIN

INNER
PANEL
SKIN
ADHESIVE/
ADHESIVE MICROBALLOON
MIXTURE MIXTURE

CES-223-01

Skin Repair with Honeycomb Plug

Figure 203

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ECS HONEYCOMB ECS

CORE
CUTOUT
OUTER
PANEL
SKIN

INNER
PANEL
SKIN

STRAIGHTEN HONEYCOMB WALLS

AND FILL WITH
ADHESIVE/MICROBALLOON
MIXTURE

CES-224-01

Skin Repair Withough Repair Plug

Figure 204

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BLEEDER
CLOTH
PLIES

SILICONE NON-POROUS
RUBBER PARTING
SHEET GRAPHITE
FILM REPAIR PLIES
POROUS
PARTING
FILM HEAT BLANKET
VACUUM
BAG
FIBERGLASS FABRIC
BREATHER PLIES
VACUUM HOSE
TEFLON TAPE

TEFLON TAPE BAG SEAL

OUTER PANEL
SKIN
EXPANDED
TEMPERATURE COPPER TEMPERATURE
PROBE SCREEN PROBE
EXPANDED
COPPER (ECS)
SCREEN
(ECS)
CES-225-00

Vacuum Bag and Heat Cure Configuration

Figure 205

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REPAIR NO. 6
FAN COWL FULL PENETRATION WET LAYUP REPAIR

1. General

This procedure gives the instructions to repair the panel damage on the
fan cowl. The damage is through the outer skin, the core and the inner
skin. The damage is cut and removed. The damaged core is replaced with a
repair core plug. Wet layup carbon fabric fill plies, repair plies and a
fiberglass sanding ply are installed on the inner skin and outer skin.

2. Repair Instructions

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

A. Cut and remove the damaged area of the inner skin, core and outer skin.
See Figure 201.

(1) Remove all loose particles, cracks, and delaminations.

(2) Make the outer skin cutout 0.25-inch (6.35 mm) larger than the
edges of the inner skin cutout.

(3) Form a 0.5 inch (12.70 mm) minimum radius on all of the corners.

(4) Make a 45 degrees chamfer on the sides of the skin cutout that
opens to the external surface.

(5) Use an abrasive paper (80-grit) on the edges of the skin cutout.

(6) Remove all of the damaged honeycomb core material.

(a) Make the core cutout 0.25-inch (6.35 mm) larger than the edges
of the inner skin cutout.

NOTE: Do not remove the adhesive material from the inner skin
panel.

(b) Use an abrasive paper (150-grit) on the inner edge of the

inner skin.

(7) Use an abrasive paper (150-grit) on the edges of the cutout.

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B. Find the number of skin plies that were removed from the inner and
outer skin to calculate the dimension of the repair area. The total of
repair plies are equal to the number of damage plies plus one ply.

NOTE: The graphite tape layer is equal to one layer of the skin ply.

C. Put the teflon tape around the edge of the repair area on each side of
the panel. See Figure 202.

(1) Measure the largest repair ply to find the dimensions of the repair
area.

(a) Repair ply No. 1 must have an overlap of 1.0-inch (25.4 mm) in
all directions from the edges of the skin cutout

(b) Each subsequent repair ply must have an overlap of 0.75-

inch (19.05 mm) from the edges of the last ply.

(c) The fiberglass sanding ply mush have an overlap of 0.75-inch

(19.05 mm) from the edge of the last repair ply.

(2) Use the teflon tape and make a mask band around the repair area.
Put the inner edge of the band against the outer edge of the
fiberglass sanding ply.

D. Remove the expanded copper screen on the outer skin. See Figure 201.

(1) Remove the expanded copper screen from the edge of the damage area
to the teflon tape.

(2) Cut the corners to a 45 degree by 0.5 inch (12.70 mm).

CAUTION: DO NOT TAPER OR BREAK THE CARBON FIBERS FROM THE TOP SURFACE OF
THE OUTER SKIN PLIES.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

E. Remove all of the surface finish in the repair area.

(1) Use the abrasive paper (150-grit) to remove the top surface of the
outer skin ply and the inner skin ply in the repair area.

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WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

F. Remove the unwanted material with a clean lint-free cloth and solvent.
Remove the solvent with a clean lint-free cloth before the solvent
becomes dry.

G. Make a backup plate from 0.032-inch (0.81 mm) thick 2024-T3 aluminum.
Make a copy of the contour of the outer surface. Make the backup plate
extend a minimum of 2.0-inches (50.8 mm) more than the repair area.

H. Prepare the honeycomb core.

(1) Find the type of material and density of the honeycomb core. See
the SRM Fan Cowl Structure Identification (54-20-00).

(2) Cut the honeycomb core repair plug to the correct dimension. Trim
as necessary to fit on the inner surface of the inner skin and to
be flush with the outer surface of the surrounding core.

(3) When you install the honeycomb core repair plug, make sure that the
ribbon direction is aligned.

I. Cut the filler plies, repair plies and fiberglass sanding ply. See
Figure 202 and Table 201.

(1) Cut a sufficient quantity of filler plies from the carbon fabric.
The total of filler plies are equal to the number of damaged plies.
The warp direction of each filler ply is equal to 0°

NOTE: The graphite tape layer is equal to one layer of the

damaged ply.

(2) Cut repair plies. See Figure 202 for the warp direction.

(a) Cut the repair ply No. 1 to overlap of 1.0-inch (25.4 mm) in
all directions from the edges of the skin cutout. The warp
direction of the repair ply No. 1 is equal to 0°.

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(b) Cut each subsequent repair ply to overlap of 0.75-inch

(19.05 mm) in all directions from the edge of the last repair
ply. The warp direction for the repair plies has the pattern
45°, 0°, 45°, 0°.

(c) Cut the corners of the repair plies to 45 degrees by 1.0-inch

(25.4 mm).

(3) Cut 1 fiberglass sanding ply from the fiberglass fabric.

(a) Cut the fiberglass sanding ply to a minimum overlap of 0.75-

inch (19.1 mm) from the edges of the last ply.

NOTE: Extend the fiberglass sanding ply to the edge of the

teflon tape mask area.

(b) Cut the corners of the fiberglass sanding ply to 45 degrees by

1.0-inch (25.4 mm).

J. Install the honeycomb core. See figure 202.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Mix the adhesive.

(a) Mix the adhesive. Refer to the instructions of the

manufacturer.

(b) Add the phenolic microballoons 20 percent by weight to the

adhesive.

(c) Mix the contents until the mixture is a paste.

(2) Apply the adhesive paste.

(a) Apply a layer of the adhesive to the mating surfaces of the

repair plug and the inner skin.

(b) Apply the adhesive to the sides of the cutout.

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(c) Apply the adhesive on the surfaces of the core plug.

(d) Apply the adhesive on the circumference of the core plug.

(3) Put the core plug into the cutout.

(a) Use the adhesive paste to fill all the open areas between the
repair plug and the repair panel.

(4) Dry the adhesive. Refer to the instructions of the manufacturer.

K. Prepare the filler plies, repair plies and fiberglass sanding ply. See
Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Mix the adhesive. Refer to the instructions of the manufacturer.

(2) Put each ply on a sheet of nonporous parting film.

(3) Apply the adhesive to one side of each ply.

(4) Put a piece of nonporous parting film on the top of each ply.

(5) Use a roller to soak the plies with the adhesive.

L. Install the filler plies, repair plies and fiberglass sanding ply. See
Figure 202 and Table 201.

(1) Install the filler plies.

(a) Remove the nonporous parting film from the bottom of the
filler ply. Put the ply into the cutout. Use a roller to
remove the wrinkles or caught air. Remove the nonporous
parting film from the top of the ply.

(b) Do step (a) for all filler plies.

(2) Install the repair plies.

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(a) Remove the nonporous parting film from the bottom of the
repair ply No. 1. Put the ply on top of the filler plies. Make
sure there is an overlap of 1.0-inch (25.4 mm) in all
directions from the edges of the skin cutout. Use a roller to
remove the wrinkles or caught air. Remove the nonporous
parting film from the top of the ply.

(b) Remove the nonporous parting film from the bottom of the
repair ply No. 2. Put the ply on top of the last ply. Make
sure there is an overlap of 0.75-inch (19.1 mm) in all
directions from the edges of the last ply. Use a roller to
remove the wrinkles or caught air. Remove the nonporous
parting film from the top of the ply.

(c) Do step (b) for all repair plies.

(3) Remove the nonporous parting film from the bottom of the fiberglass
sanding ply. Put the ply on top of the repair plies. Make sure
there is a minimum overlap of 0.75-inch (19.1 mm) in all directions
from the edges of the last repair ply. Use a roller to remove the
wrinkles or caught air. Remove the nonporous parting film from the
top of the ply.

M. Prepare the repair area for the vacuum bag cover and cure procedure.
See Figure 203 and Table 201.

NOTE: The inner skin does not need the ECS ply or the aluminum backup
plate.

(1) Put a sheet of porous parting film on the repair materials. Make
sure that the sheet of parting film has an overlap of 3.0-inch.
(76.2 mm) from all edges of the fiberglass sanding ply.

(2) Put the bleeder cloth layers on the parting film.

(a) The number of bleeder cloth layers must be equal to the number
of repair plies.

(b) The bleeder cloth layers must be equal to the dimension of the
porous parting film.

(3) Put a sheet of the nonporous parting film on the bleeder cloth
layers. Make sure the edges of bleeder cloth layers are below the
nonporous parting film.

(4) Put a silicon rubber sheet on the nonporous parting film.

(5) Put the aluminum backup plate over the rubber sheet.

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(6) Put a heat blanket on the aluminum backup plate.

(7) Put two layers of the fiberglass breather cloth on the heat
blanket.

(8) Put a vacuum bag on the heat blanket.

NOTE: Make sure the vacuum bag has an overlap of approximately

2.0-inch (50.8 mm) from all edges of the heat blanket.

(9) Put a temperature probe below the bag and seal the edges of the
vacuum bag with the double-sided tape.

(10) Put a vacuum connector below the bag and seal the edges with the
double-sided tape.

N. Use a vacuum pump to increase the vacuum pressure in the bag to 20-
inches of mercury (67.7 kPa). See Table 201.

O. Set the switch for the two heat blankets to keep the temperature at
190°-210°F (88°-99°C). Let the repair cure for 220 minutes. See Table
201.

P. Remove the vacuum bag and all of the bag materials from the repair.
Remove the teflon tape from around the repair area.

Q. Use 150 - 320-grit abrasive paper and make the surface and the edges of
the repair smooth. Do not go into the graphite ply with the abrasive
paper. See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

R. Remove the unwanted material with a clean lint-free cloth and solvent.
Remove the solvent with a clean lint-free cloth before the solvent
becomes dry. See Table 201.

S. Repair the ECS. See Repair No. 8 - Expanded Copper Screen (ECS) Repair.

T. Repair the surface finish. See Repair No. 1 - Surface Finish

Restoration.

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Document Part No. RDN 306

3. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Adhesive, Epoxy EA9390 (Two Part) V33564
Henkel Corporation
2850 Willow Pass Rd.
P.O. Box 312
Baypoint, CA 94565-0031
Phone: (800) 257-7522
www.aerospace.henkel.com
Blanket, Heat 20 x 20 inch V61426
(508 x 508 mm) Atacs Products, Inc.
850 South Cambridge Street
Seattle, WA 98108-4748
Phone: (206) 433-9000
www.atacs.com
Cloth, Bleeder Fiberglass Commercially Available
Cloth, Breather RC3000-10 V0F451
Richmond Aircraft Products, Inc.
13503 Pulmice St
Norwalk, CA 90650-5250
Phone: (562) 404-2440
www.richmondaircraft.com
Cloth, Lint-free Cotton Commercially Available
Fabric, Fiberglass Type 181 Commercially Available
Fabric, Carbon AH370-5H V2B975
Hexcel Corp
1913 N King St
Seguin, TX 78155-2197
Phone: (800) 688-7734
www.hexcel.com
Film, Bagging 2 mm Nylon V0F451
Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Film, Parting Nonporous V0F451
Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Film, Parting Porous V0F451
Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Repair Materials and Equipment
Table 201 (Sheet 1 of 2)
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Proprietary - This document is subject to the controls and restrictions on the title page.
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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

DESCRIPTION DESIGNATION MANUFACTURER

Lockwire Commercially Available
Knife, Putty Plastic or metal Commercially Available
Microballoons Phenolic, 135 Micron Commercially Available
Paper, Abrasive 150, 320-Grit Commercially Available
Silicon Carbide
Probe, Temperature 0-250°F (0-121°C) Commercially Available
Pump, Vacuum 0-30 Inches-of-mercury Commercially Available
(0-0.1 MPa)
Rod Metal Commercially Available
Roller 2.0 inch (50.8 mm) Commercially Available
Diameter
Metal or Plastic
Sheet, Rubber 0.062 - 0.125-inch Commercially Available
(1.57 - 3.17 mm) thick
silicone
Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Univar U.S.A., Inc.
Ketone/40% Methyl Ethyl 532 E. Emaus Street
Ketone Middletown, PA 17057-2200
Phone: (717) 944-7471
www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Tape Double Sided Commercially Available
Tape, Teflon 2.0-inch Commercially Available
Repair Materials and Equipment
Table 201 (Sheet 2 of 2)

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OUTER
SKIN

45°
1.0 INCH
(25.4 mm)
(TYPICAL)
A A

CUTOUT

TEFLON TAPE

TEFLON TAPE
TEFLON TAPE
EXPANDED EXPANDED
COPPER SCREEN HONEYCOMB COPPER SCREEN
(ECS) CORE (ECS)

0.25 INCH
OUTER (6.35 mm)
SKIN

45°
INNER
CES-256-01

SKIN
TEFLON TAPE TEFLON TAPE
A-A
Prepare the Damaged Area
Figure 201

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0°
OUTER -45° +45°
SKIN

AFT 90°

45°
1.0 INCH
(25.4 mm) CUTOUT
(TYPICAL)
A A

REPAIR PLY NO. 1

REPAIR PLY NO. 2

REPAIR PLY NO. 3

0.5 INCH FIBERGLASS FABRIC

(12.7 mm) 1.0 INCH (25.4 mm) SANDING PLY
RADIUS
0.75 INCH (19.0 mm)

TEFLON TAPE 2.0 INCH (50.8 mm)

TEFLON TAPE
TEFLON TAPE
ADHESIVE EXPANDED
EXPANDED HONEYCOMB CORE
COPPER SCREEN COPPER SCREEN
REPAIR PLUG
(ECS) (ECS)

OUTER
SKIN

INNER
CES-255-00

SKIN
TEFLON TAPE TEFLON TAPE
A-A ADHESIVE

Filler, Core and Repair Plies

Figure 202

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BLEEDER
CLOTH
SILICONE PLIES BACKUP PLATE
RUBBER
SHEET
POROUS HEAT BLANKET
VACUUM NON-POROUS PARTING
BAG PARTING FILM FIBERGLASS FABRIC
FILM BREATHER PLIES
VACUUM HOSE
TEFLON TAPE

TEMPERATURE
PROBE
TEFLON TAPE

TEMPERATURE BAG
PROBE SEAL

TEFLON TAPE
BAG SEAL

TEFLON TAPE

VACUUM HOSE
FIBERGLASS FABRIC VACUUM
POROUS NON-POROUS
BREATHER PLIES BAG
PARTING PARTING
FILM FILM
HEAT BLANKET SILICONE
RUBBER
CES-257-00

BLEEDER SHEET
CLOTH
PLIES

Vacuum Bag
Figure 203

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THIS PAGE INTENTIONALLY LEFT BLANK

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REPAIR NO. 7
EDGE EROSION REPAIR

1. General

This procedure gives the instructions to repair the erosion damage to the
composite panel edges. The damage must be less than 0.50-inch (12.7 mm)
long from the edge of the composite panel and 0.02-inch (0.50 mm) in
depth. There is no dimension limit on the width of the erosion repair
along the edge of the panel.

2. Repair Instructions

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

A. Prepare the surface. See Table 201.

CAUTION: DO NOT TAPER OR BREAK THE GRAPHITE FIBERS IN THE REPAIR AREA.
IF THE FIBERS ARE DAMAGED, THE PART CAN BE WEAKER THAN THE
INITIAL PART.

(1) Use a abrasive paper (180-grit) and remove the surface finish.

NOTE: Make a smooth tapered edge on the external coating around

the repair area. Do not go through the composite surface.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(2) Clean the repair area with a clean, lint-free cloth and the
solvent. Remove the solvent with a clean lint-free cloth before the
solvent becomes dry. See Table 201

(3) Let the surface dry for 30 minutes.

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B. Apply the adhesive filler. See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Mix the adhesive. Refer to the instructions of the manufacturer.

(2) Use a small brush or a spatula and put the adhesive in the erosion
cavities. Make the adhesive flush to the adjacent area.

(3) Put the teflon tape on the adhesive.

(4) Remove unwanted adhesive.

(5) Dry the adhesive. Refer to the instructions of the manufacturer.

C. Complete the repair.

CAUTION: DO NOT TAPER OR BREAK THE GRAPHITE FIBERS IN THE REPAIR AREA.
IF THE FIBERS ARE DAMAGED, THE PART CAN BE WEAKER THAN THE
INITIAL PART.

(1) Remove the teflon tape.

(2) Use the abrasive paper (150 - 180-grit) to rub the adhesive smooth.
See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(3) Clean the repair area with a clean, lint-free cloth and the
solvent. Remove the solvent with a clean lint-free cloth before the
solvent becomes dry. See Table 201.

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(4) Repair the surface finish. See Repair No. 1 - Surface Finish
Restoration.

3. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Adhesive, Epoxy Paste EA934NA V33564
Henkel Corporation
2850 Willow Pass Rd.
P.O. Box 312
Baypoint, CA 94565-0031
Phone: (925) 458-8000
www.aerospace.henkel.com
Brush Nylon Bristle Commercially Available
Cloth, Lint-free Cotton Commercially Available
Container Metal or Plastic Commercially Available
Glasses, Safety Commercially Available
Gloves Neoprene or Polyvinyl Commercially Available
Chloride
Lamp, Heat 150°F-250°F Commercially Available
Mask, Dust Regulatory Agency Approved Commercially Available
Paper, Abrasive 150 - 180-Grit Silicon Commercially Available
Carbide
Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
or
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Ketone/ Univar U.S.A., Inc.
40% Methyl Ethyl Ketone 532 E. Emaus Street
or Middletown, PA 17057-2200
Phone: (717) 944-7471
www.univarusa.com
Repair Materials and Equipment
Table 201

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DESCRIPTION DESIGNATION MANUFACTURER

Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Spatula Metal or Plastic Commercially Available
Tape, Teflon 2-Inch Wide Commercially Available
Repair Materials and Equipment
Table 201

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REPAIR NO. 8
EXPANDED COPPER SCREEN REPAIR

1. General

A. This procedure gives the instructions to repair damage to the expanded

copper screen (ECS). The ECS gives the lightning protection to the fan
cowl.

2. Repair Instructions

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

A. Remove the damaged ECS.

CAUTION: DO NOT PUT THE TAPE ON THE BARE ECS. WHEN THE TAPE IS REMOVED
IT CAN REMOVE THE ECS.

(1) Use the teflon tape and make a mask band around the repair area.
See Figure 201 and Table 201.

(2) Put the teflon tape 2.0-inches (50.8 mm) from the damaged ECS
material to identify the outline of the repair.

(3) Use a 150-grit abrasive paper and remove the paint, primer, and
sanding adhesive material. See Table 201.

NOTE: Make sure the ECS material shows in the mask band area.

CAUTION: DO NOT CAUSE DAMAGE TO THE PLIES BELOW THE DAMAGED ECS
MATERIAL.

(4) Cut and remove the damaged ECS material.

(a) Cut the corners to a 45 degree by 0.5-inch (12.7 mm). See

Figure 201.

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Rohr, Inc., operating as Goodrich Aerostructures, EXPORT CLASSIFICATION: EAR 9E991
for export purposes. Do not
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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(5) Clean the repair area with a clean, lint-free cloth and the
solvent. Remove the solvent with a clean lint-free cloth before the
solvent becomes dry. See Table 201.

B. Prepare ECS material for installation.

(1) Cut the ECS material to make a 2.0-inch (50.8 mm) overlap on all
sides of the repair area.

(2) Cut the corners of the repair piece at 45 degrees to a length of

0.5 inch (12.7 mm). (See Figure 201.)

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(3) Flush the ECS material with the solvent.

(4) Let the ECS material dry for 30 minutes.

C. Install ECS material on the door panel.

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WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Mix the EA9390 adhesive. Refer to the instructions of the

manufacturer. See Table 201.

(2) Use a spatula and apply the adhesive on the mating surfaces. See
Table 201.

(3) Put the ECS material on the repair area. Make sure the ECS material
fully touches the ECS material with a 2.0-inch (50.8 mm) overlap.
See Figure 201.

NOTE: Do not install a sanding ply above or below the ECS repair
piece.

(4) Use a spatula and apply a thick layer of adhesive to the external
surface of the repair area.

D. Apply the vacuum bag to repair area. See Figure 202 and Table 201.

(1) Put the porous parting film on the repair approximately 3.0-inches
(76.2 mm) larger than the ECS repair ply.

(2) Put two layers of bleeder cloth on the porous parting film.

(3) Put a layer of nonporous parting film on the bleeder cloth.

(4) Put the silicone rubber sheet on the nonporous parting film.

(5) Put the heat blanket on the silicone rubber sheet.

(6) Put two plies of breather cloth on the heat blanket.

(7) Use the teflon tape to position four temperature probes around the
perimeter of the repair.

(8) Apply the bag sealant to the surface of the door approximately 2.0-
inches (50.8 mm) larger around than the porous parting film.

(9) Put the vacuum bag on the repair.

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(10) Put the temperature probe wires and heat blanket wires between the
bag and the tacky tape.

(11) Seal the vacuum probe in the bag.

(12) Seal the edges of the bag to the tacky tape.

E. Cure the ECS repair.

(1) Use a vacuum pump to increase the vacuum pressure in the bag to 20-
inch Hg (67.7 kPa).

(2) Disconnect the vacuum pump and check for leaks.

NOTE: The leakage rate is 5-inch Hg (16.9 kPa) in 5 minutes

maximum.

(3) Increase the temperature on the heat blanket to 190°F - 210°F

(87.8°C - 98.9°C). Let the repair cure for 220 minutes.

NOTE: The rate of heat increase is 2°F - 8°F (1.11°C - 4.44°C)

for each minute. Keep 22-inch Hg (74.5 kPa) vacuum in the
vacuum bag.

F. Finish repair surface. See Table 201.

(1) Remove the vacuum bag and all the materials.

(2) Remove the teflon tape from around the repair area.

G. Apply the sanding adhesive. See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Mix the EA956 adhesive. Refer to the instructions of the

manufacturer.

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(2) Apply EA956 adhesive 0.06 - 0.08-inch (1.52 - 2.03 mm) thick on the
outer surface of cured ECS material.

NOTE: The adhesive will be used as a sanding layer before paint

is applied.

(3) Dry the adhesive. Refer to the instructions of the manufacturer.

H. Use a 320-grit abrasive paper on the repair surface. See Table 201.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

I. Clean the repair area with a clean, lint-free cloth and the solvent.
Remove the solvent with a clean lint-free cloth before the solvent
becomes dry. See Table 201.

J. Use Repair No. 1, Surface Finish Restorations to repair the surface

finish.

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3. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Adhesive, Epoxy EA9390 (Two Part) V33564
Henkel Corporation
2850 Willow Pass Rd.
P.O. Box 312
Baypoint, CA 94565-0031
Phone: (800) 257-7522
www.aerospace.henkel.com
Adhesive, Epoxy EA956 V33564
Base Part A Henkel Corporation
Catalyst Part B www.aerospace.henkel.com
Blanket, Heat 250°F (121.1°C) V61426
10W/Inches Atacs Products, Inc.
850 South Cambridge Street
Seattle, WA 98108-4748
Phone: (206) 433-9000
www.atacs.com
Cloth, Bleeder Fiberglass Commercially Available
Cloth, Breather RC3000-10 V0F451
Richmond Aircraft Products, Inc.
13503 Pulmice St
Norwalk, CA 90650-5250
Phone: (562) 404-2440
www.richmondaircraft.com
Cloth, Wiper Cotton Commercially Available
Clothing, Protective Commercially Available
Connector, Vacuum 1/8-inch (3.175 mm) Dia. Commercially Available
Container Metal or Plastic Commercially Available
Cover, Container Metal or Plastic Commercially Available
ECS Material CU 040 CX Astroseal Products
“Astrostrike” 6 Custom Drive
Old Saybrook, CT 06475
Film, Bagging 0.002-inch (0,0508 mm) V0F451
thick Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Repair Materials and Equipment
Table 201 (Sheet 1 of 3)

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DESCRIPTION DESIGNATION MANUFACTURER

Film, Parting Porous V0F451
Richmond Aircraft Products, Inc.
www.richmondaircraft.com
Film, Parting Nonporous V0F451
Richmond Aircraft Products, Inc.
Gauge, Vacuum 0.0-30.0-inches (0-762 Commercially Available
mm) of Mercury
Glasses, Safety Commercially Available
Gloves Neoprene or Polyvinyl Commercially Available
Chloride
Hose, Vacuum 1/8-inch (3.175 mm) Dia. Commercially Available
Knife, Utility Commercially Available
Mask, Dust Regulatory Agency Commercially Available
Approved
Paper, Abrasive 150-, 320-Grit Silicon Commercially Available
Carbide
Probe, Temperature 0°F-250°F (-18°C-121°C) Commercially Available
Probe, Vacuum 1/8-inch (3.175 mm) Dia. Commercially Available
Roller 2.0-inches (50,80 mm) Commercially Available
Dia., Steel or Plastic
Rubber, Sheet 0.062-0.236-inch (1.57- V85471
5.99 mm) A B Boyd Co.
13885 Ramona Ave.
Chino, CA 91710
Phone: (909) 591-9325
Sealant, Bag Tacky Tape V53309
Schnee-Morehead Chemicals, Inc.
111 N. Nursery Road
P.O. Box 1305
Irving, TX 75060
Phone: (972) 438-9111

Repair Materials and Equipment

Table 201 (Sheet 2 of 3)

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DESCRIPTION DESIGNATION MANUFACTURER

Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
or
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Univar U.S.A., Inc.
Ketone/40% Methyl Ethyl 532 E. Emaus Street
Ketone Middletown, PA 17057-2200
or Phone: (717) 944-7471
www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Spatula Metal or Plastic Commercially Available
Tape, Teflon 2.0-inches (50.80 mm) Commercially Available
Wide
Repair Materials and Equipment
Table 201 (Sheet 3 of 3)

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FAN COWL
(TYPICAL)

BAGGING
MATERIAL A

REPAIR
AREA
REMOVED DAMAGED
HEAT ECS MATERIAL
BLANKET
0.5-INCH
(12.7 mm)
(TYP)

45°

2.0-INCHES
(50.8 mm)

2.0-INCHES
(50.8 mm)

REPAIR ECS MATERIAL

CES-226-00

TEFLON TAPE MASK BAND

A
Fan Cowl Repair Area
Figure 201

CF6-80E1
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NONPOROUS
PARTING
HEAT
FILM SILICON BLANKET
POROUS RUBBER
PARTING SHEET
FILM BLEEDER BREATHER
CLOTH CLOTH
VACUUM VACUUM
PROBE BAG

BAG ADHESIVE
SEAL
ORIGINAL TEMPERATURE 2.00 IN. (50.8 mm)
ECS OVERLAP ALL AROUND
STRUCTURE PROBE

ECS REPAIR ON TOP OF ORIGINAL STRUCTURE

NOTE: BAG SAME AS ABOVE ADHESIVE

2.00 IN.
(50.8 mm) ECS REPAIR PLIES
OVERLAP
CES-227-00

(AS APPLICABLE)

ECS REPAIR ON TOP OF REPAIR PLIES

Repair of Expanded Copper Screen

Figure 202

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THIS SECTION RESERVED FOR

GENERAL ELECTRIC THRUST REVERSER INFORMATION

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THIS PAGE INTENTIONALLY LEFT BLANK

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STRUCTURAL IDENTIFICATION - CORE COWL

1. General

Left and right core cowl door encloses the core section of the CF6-80E1
General Electric engine. These doors open to provide access to the core
section {compressor, intermediate, combustion, turbine and accessory
sections) of the engine. Each cowl door contains a fairing, three hinge
fittings, and a bracket and lug assembly to install the cowling hold open
rods. The doors have 34 aluminum intercostals and supply ventilation for
the core section of the engine. A pressure relief door, three annealed
clad aluminum covers and three latch hinge brackets are installed on the
right door. The doors attach to the pylon with three hinge fittings at the
top of each door. The latch brackets to hold the doors closed are located
on the bottom centerline of the left door.

2. Structure Description

A heat-treated clad aluminum sheet wrapped in a fire shield of 321

corrosion resistant steel sheets construct the core cowl doors. The
pressure relief door on the right door is made of a non-perforated core
wrapped in an inner and outer sheet of clad aluminum sheet. The doors are
approximately 45 inches wide X 100 inches high, and weight 63.5 pounds
each.

3. Structure Identification

Structures are identified in illustrations (figures) and tables. The

figures and tables do not identify fasteners. The structure is identified
on the figure by a number. The same number appears on the table that
follows the figure. The table gives the component description, gage
(thickness) and material. When a composite fabric ply is identified in the
material column, the warp direction (angle) is based on the manufacturer's
drawings. The full view of the part has a compass rose to help find the
warp direction.

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CES-069-00

LH Core Cowl
Figure 1 (Sheet 1)

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11 45
6
9 12
8
44
6
7

4
6
41
24

10

5
11 12
6
6
6

10
42 6

24

6 11

6 CES-070-01

LH Core Cowl
Figure 1 (Sheet 2)

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11
12
4 6

10

6 6
43
24

13
6

6 24

14

15

16

CES-071-01

LH Core Cowl
Figure 1 (Sheet 3)

CF6-80E1
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12
9

10

24

11

17
18 19
18

NOTE: TYPICAL 17 PLACES

CES-072-01

LH Core Cowl
Figure 1 (Sheet 4)

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12

23
20
20

21
23

22

21

20
CES-073-00

LH Core Cowl
Figure 1 (Sheet 5)

CF6-80E1
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24
25
20

25
20

4
25

25
VIEW ROTATED 180°

25 25

25
CES-074-00

LH Core Cowl
Figure 1 (Sheet 6)

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17
19

27

26 23 38
20
4
27
20

36
29
30

37 20

28
27

CES-075-01

LH Core Cowl
Figure 1 (Sheet 7)

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28

12
23

27 12

27 31
12
28 28

12

28
29 36

28
30

37
4
28 38
27

CES-076-01

LH Core Cowl
Figure 1 (Sheet 8)

CF6-80E1
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12

31
27 4 12
28
28

12

28
29 36

21

30

37

38
28

REF

CES-077-01

LH Core Cowl
Figure 1 (Sheet 9)

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24 4

32

12 32

REF
19
12

35

33

33
REF

34

CES-078-00

LH Core Cowl
Figure 1 (Sheet 10)

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 LH CORE COWL ASSY (REF)
2 FAIRING INSTALLATION (REF) (REF) (SEE FIGURE 2 FOR
DETAILS)
3 HOLD OPEN ROD INSTALLATION (REF) (SEE FIGURE 3 FOR DETAILS)
4 SKIN 0.063 2219-T31 CALD ALUM SHEET,
(1,60) AMS4095 (HEAT TREAT T81)
5 PLATE 0.032 A286 CRES STEEL SHEET.
(0,81) AMS5525
6 SHIM 0.063 LAMINATED ALUM, MIL-S-22499,
(1,60) COMP 3, TYPE 2, CLASS 1
7 CLIP 0.063 625 INCONEL SHEET, AMS5599
(1,60) ANNEALED
8 CHANNEL 0.040 625 INCONEL SHEET, AMS5599
(1,02)
9 CLIP 0.063 625 INCONEL SHEET, AMS5599
(1,60)
10 LONGERON 0.063 625 INCONEL SHEET, AMS5599
(1,60) ANNEALED
11 DOUBLER A286 CRES STEEL SHEET AMS5525
12 FRAME 0.063 2219-0 CALD ALUM SHEET,
(1,60) AMS4096 (HEAT TREAT T62)
13 CLIP 625 INCONEL SHEET, AMS5599
ANNEALED
14 SPACER 0.040 2219-T31 CALD ALUM SHEET,
(1,02) AMS4095 (HEAT TREAT T81)
15 SEAL 3 PLY FIBERGLASS RE-ENFORCED,
SILICONE RUBBER

LH Core Cowl
Table 1 (Sheet 1)

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Document Part No. RDN 306

GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
16 RETIANER 0.032 2219-0 CALD ALUM SHEET,
(0,81) AMS4096 (HEAT TREAT T62)
17 HAT 0.040 15-7 PH MO CRES STEEL SHEET,
(1,02) AMS5520, COND A, FINISH 2D
18 SHIM 0.063 LAMINATED ALUM, MIL-S-22499,
(1,60) COMP 3, TYPE 2, CLASS 1
19 FRAME 0.050 2219-0 CALD ALUM SHEET,
(1,27) AMS4096 (HEAT TREAT T62)
20 FRAME 0.063 2024-0 CLAD ALUM SHEET, QQ-A-
(1,60) 250/5 (HEAT TREAT T62)
21 SPLICE 0.063 2219-0 CALD ALUM SHEET,
(1,60) AMS4096 (HEAT TREAT T62)
22 SPLICE 0.050 2219-0 CALD ALUM SHEET,
(1,27) AMS4096 (HEAT TREAT T62)
23 PLATE 0.050 2219-0 CALD ALUM SHEET,
(1,27) AMS4096 (HEAT TREAT T62)
24 FIRE SHIELD 0.005 321 CRES SHEET, MIL-S-6721,
(0,13) TYPE 1, ANNEALED
25 WEAR STRIP 0.063 2024-T3 CLAD ALUM SHEET, QQ-
(1,60) A-250/5
26 TEE 0.063 2024-T3511 ALUM EXTRUSION,
(1,60) QQ-A-200/3
27 LONGERON 0.063 2219-0 CALD ALUM SHEET,
(1,60) AMS4096 (HEAT TREAT T62)
28 SHIM 0.063 LAMINATED ALUM, MIL-S-22499,
(1,60) COMP 3, TYPE 2, CLASS 2
29 SHIM 0.265 LAMINATED ALUM, MIL-S-22499,
(6,73) COMP 3, TYPE 2, CLASS 1

LH Core Cowl
Table 1 (Sheet 2)

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Document Part No. RDN 306

GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
30 PLATE 0.125 15-7 PH MO CRES STEEL SHEET,
(3,18) AMS5520, COND A, FINISH 2D
31 PLATE 0.050 2219-T31 CLAD ALUM SHEET,
(1,27) AMS4095 (HEAT TREAT T81)
32 INTERCOSTAL 0.063 2219-0 CLAD ALUM SHEET,
(1,60) AMS4096 (HEAT TREAT T62)
33 CLIP 0.063 2219-0 CLAD ALUM SHEET,
(1,60) AMS4096 (HEAT TREAT T62)
34 PLATE 0.063 2219-0 CLAD ALUM SHEET,
(1,60) AMS4096 (HEAT TREAT T62)
35 PLATE 0.063 625 INCONEL SHEET, AMS5599
(1,60)
36 PIN, SHEAR LATCH 0.500 A286 CRES BAR, AMS5737
(12,70)
37 KEEPER, LATCH H2928-5 (V83014)
38 BRACKET, LATCH AFT 17-4PH CRES INVESTMENT CLEVIS
CASTING
39 BRACKET, LATCH CENTER 17-4PH CRES INVESTMENT CLEVIS
CASTING
40 BRACKET, LATCH FORWARD 17-4PH CRES INVESTMENT CLEVIS
CASTING
41 HINGE FITTING, AFT 17-4PH CRES INVESTMENT CAST-
ING, AMS5344
42 HINGE FITTING, CENTER 17-4PH CRES INVESTMENT CAST-
ING, AMS5344
43 HINGE FITTING, FORWARD 17-4PH CRES INVESTMENT CAST-
ING, AMS5344
44 INTERCOSTAL 0.063 2219-0 CLAD ALUM SHEET,
(1,60) AMS4096 (HEAT TREAT T62)
45 INTERCOSTAL 0.063 625 INCONEL SHEET, AMS5599
(1,60)

LH Core Cowl
Table 1 (Sheet 3)

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Document Part No. RDN 306

3
1
2

9
7

6 7

6
6

CES-079-00

LH Core Cowl Fairing

Figure 2

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Document Part No. RDN 306

GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 SUPPORT 0.032 625 INCONEL SHEET, AMS5599
(0,81) ANNEALED
2 WEAR PLATE 0.032 301 CRES STEEL SHEET, MIL-S-
(0,81) 5059, 1/4 HARD
3 SEAL 0.020 301 CRES STEEL SHEET, MIL-S-
(0,51) 5059, 1/4 HARD
4 LONGERON 0.032 625 INCONEL SHEET, AMS5599
(0,81) ANNEALED
5 SKIN 0.040 CP-TITANIUM SHEET, AMS4901
(1,02)
6 BRACKET 0.032 625 INCONEL SHEET, AMS5599
(0,81) ANNEALED
7 CLIP 0.032 625 INCONEL SHEET, AMS5599
(0,81) ANNEALED
8 SPACER 1.500 2024-T351 ALUM BAR,
(38,10) QQ-A-225/6
9 FILLER 0.063 301 CRES STEEL SHEET,
(1,60) MIL-S-5059, 1/4 HARD

LH Core Cowl Fairing

Table 2

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Document Part No. RDN 306

6
5

5
7
4

6
3
2

CES-080-00

LH Core Cowl Hold Open Rod Supports

Figure 3

CF6-80E1
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Document Part No. RDN 306

GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 LUG, BASE ASSY 0.063 PH15-7MO CRES SHEET, AMS5520,
(1,60) COND A, FINISH 2D (HEAT TREAT
TH-1110)
2 BASE, BASE ASSY 0.125 PH15-7MO CRES SHEET, AMS5520,
(3,18) COND A, FINISH 2D (HEAT TREAT
TH-1110)
3 WEARPLATE 0.040 321 CRES SHEET, MIL-S-6721,
(1,02) COMP T1, ANNEALED

4 MOUNT 0.063 2219-0 CLAD ALUM SHEET,

(1,60) AMS4096 (HEAT TREAT T62)

5 SUPPORT 0.063 2219-0 CLAD ALUM SHEET,

(1,60) AMS4096 (HEAT TREAT T62)

6 FRAME 0.063 2024-0 CLAD ALUM SHEET, QQ-A-

(1,60) 250/5 (HEAT TREAT T62)
7 FILLER 0.080 2219-0 CLAD ALUM SHEET,
(2,03) AMS4096 (HEAT TREAT T62)
8 FRAME 0.063 2219-0 CLAD ALUM SHEET,
(1,60) AMS4096 (HEAT TREAT T62)
9 BRACKET 0.063 2219-0 CLAD ALUM SHEET,
(1,60) AMS4096 (HEAT TREAT T62)

LH Core Cowl Hold Open Rod Supports

Table 3

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Document Part No. RDN 306

S
CES-081-01

RH Core Cowl
Figure 4 (Sheet 1)

CF6-80E1
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Document Part No. RDN 306

51
12 7
13 10
9
50

7
8

5 7

47
25

11

13 12
7

7
7

11
7 48

25

12 7

7 CES-082-01

RH Core Cowl
Figure 4 (Sheet 2)

CF6-80E1
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Document Part No. RDN 306

12

13
7 5

11

7
7

49

25

12
14
7

7
25

15

16

17

CES-083-01

RH Core Cowl
Figure 4 (Sheet 3)

CF6-80E1
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Document Part No. RDN 306

13 10

11

25

12
18

19
20
19

NOTE: TYPICAL 17 PLACES

CES-084-00

RH Core Cowl
Figure 4 (Sheet 4)

CF6-80E1
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STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

22

20
21

18

23 5

13 24
26
23
27
13 13 28
27

24 28
28 27
23

STA
293.709
5
44

CES-085-01

RH Core Cowl
Figure 4 (Sheet 5)

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Document Part No. RDN 306

29

13
21
5

23

13
30
26
23
27
13 13 28
27

28
28 28

23

STA
5 281.089
45

CES-086-01

RH Core Cowl
Figure 4 (Sheet 6)

CF6-80E1
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30
13

26

23
27

30 13 13 28
27

28

28

46

STA
268.467

REF

CES-087-01

RH Core Cowl
Figure 4 (Sheet 7)

CF6-80E1
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Document Part No. RDN 306

30
34
13

29
13 36
37

35

35
31 32

33
38

32 31
35 13

33
35
38

13

34
30 5 13

36 37
30 13

CES-088-00

RH Core Cowl
Figure 4 (Sheet 8)

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STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

REF

5
40

40

39

39
40 38
38
40

40
REF

40
5

CES-089-00

RH Core Cowl
Figure 4 (Sheet 9)

CF6-80E1
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Document Part No. RDN 306

25
41
42

41
42

41

41

41 41

41
CES-090-00

RH Core Cowl
Figure 4 (Sheet 10)

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CES-145-01

RH Core Cowl
Figure 4 (Sheet 11)

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Document Part No. RDN 306

GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 RH CORE COWL ASSY (REF)
2 FAIRING INSTALLATION (REF) (REF) (SEE FIGURE 5 FOR
DETAILS)
3 HOLD OPEN ROD INSTALLATION (REF) (SEE FIGURE 6 FOR DETAILS)
4 PRESSURE RELIEF DOOR (REF) (SEE FIGURE 7 FOR DETAILS)
5 SKIN 0.063 2219-T31 CLAD ALUM SHEET,
(1,60) AMS4095 (HEAT TREAT T81)
6 PLATE 0.032 A286 CRES STEEL SHEET,
(0,81) AMS5525
7 SHIM 0.063 LAMINATED ALUM, MIL-S-22499
(1,60) COMP 3, TYPE 2, CLASS I
8 CLIP 0.063 625 INCONEL SHEET, AMS5599
(1,60) ANNEALED
9 CHANNEL 0.040 625 INCONEL SHEET, AMS5599
(1,02)
10 CLIP 0.063 625 INCONEL SHEET, AMS5599
(1,60)
11 LONGERON 0.063 625 INCONEL SHEET, AMS5599
(1,60) ANNEALED
12 DOUBLER 0.032 A286 CRES STEEL SHEET,
(0,81) AMS5525
13 FRAME 0.063 2219-0 CLAD ALUM SHEET,
(1,60) AMS4096 (HEAT TREAT T62)
14 CLIP 0.071 625 INCONEL SHEET, AMS5599
(1,80) ANNEALED
15 SPACER 0.040 2219-T31 CLAD ALUM SHEET,
(1,02) AMS4095

RH Core Cowl
Table 4 (Sheet 1)

CF6-80E1
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Document Part No. RDN 306

GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
16 SEAL 3 PLY FIBERGLASS REINFORCED
SILICONE RUBBER
17 RETIANER 0.032 2219-0 CALD ALUM SHEET,
(0,81) AMS4096 (HEAT TREAT T62)
18 HAT 0.040 15-7 PH MO CRES STEEL SHEET,
(1,02) AMS5520, COND A, FINISH 2D
19 SHIM 0.063 LAMINATED ALUM, MIL-S-22499,
(1,60) COMP 3, TYPE 1, CLASS 1
20 FRAME 0.050 2219-0 CALD ALUM SHEET,
(1,27) AMS4096 (HEAT TREAT T62)
21 TEE 0.063 2024-T3511 ALUM EXTRUSION,
(1,60) QQ-A-200/3
22 STOP 0.00 224-2340-507
(0,00)
23 LONGERON 0.063 2219-0 CALD ALUM SHEET,
(1,60) AMS4096 (HEAT TREAT T62)
24 SPLICE 0.063 2219-0 CALD ALUM SHEET,
(1,60) AMS4096 (HEAT TREAT T62)
25 FIRE SHIELD 0.005 321 CRES SHEET, MIL-S-6721,
(0,13) TYPE 1, ANNEALED
26 COVER ALUM INVESTMENT CASTING,
A356-T6, AMS4218
27 SHIM 0.090 2219-0 CALD ALUM SHEET,
(2,29) AMS4096 (HEAT TREAT T62)
28 SHIM 0.063 LAMINATED ALUM, MIL-S-22499,
(1,60) COMP 3, TYPE 2, CLASS 2
29 PLATE 0.050 2219-0 CALD ALUM SHEET,
(1,27) AMS4096 (HEAT TREAT T62)

RH Core Cowl
Table 4 (Sheet 2)

CF6-80E1
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Document Part No. RDN 306

GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
30 PLATE 0.063 2219-0 CLAD ALUM SHEET,
(1,60) AMS4096 (HEAT TREAT T62)
31 WEAR STRIP 0.080 301 CRES SHEET, MIL-S-5059,
(2,03) COND 1/4 H
32 ANGLE 0.063 2219-0 CLAD ALUM SHEET,
(1,60) AMS4096 (HEAT TREAT T62)
33 RETAINER 0.040 2219-T31 CLAD ALUM SHEET,
(1,02) AMS4095
34 GUSSET 0.063 2219-T31 CLAD ALUM SHEET,
(1,60) AMS4095
35 CLIP 0.063 2219-0 CLAD ALUM SHEET,
(1,60) AMS4096 (HEAT TREAT T62)
36 INTERCOSTAL 0.063 2219-0 CLAD ALUM SHEET,
(1,60) AMS4096 (HEAT TREAT T62)
37 CLIP 0.040 2219-0 CLAD ALUM SHEET,
(1,02) AMS4096 (HEAT TREAT T62)
38 RETAINER 0.063 2219-T31 CLAD ALUM SHEET,
(1,60) AMS4095
39 BRACKET 0.063 15-7 PH MO CRES STEEL SHEET,
(1,60) AMS5520, COND A, FINISH 2D
40 CLIP 0.040 15-7 PH MO CRES STEEL SHEET,
(1,02) AMS5520, COND A, FINISH 2D
41 WEAR STRIP 0.063 2024-T3 CLAD ALUM SHEET, QQ-
(1,60) Q-250/5
42 FRAME 0.063 2024-0 CLAD ALUM SHEET, QQ-Q-
(1,60) 250/5 (HEAT TREAT T62)
43 LATCH ASSY H2927-3 (V83014)

RH Core Cowl
Table 4 (Sheet 3)

CF6-80E1
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Document Part No. RDN 306

GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
44 BRACKET, LATCH CLEVIS AFT 17-4 CRES INVESTMENT CASTING
45 BRACKET, LATCH CLEVIS CENTER 17-4 CRES INVESTMENT CASTING
46 BRACKET, LATCH CLEVIS FORWARD 17-4 CRES INVESTMENT CAST-
ING, AMS5344
47 HINGE FITTING, AFT 17-4 CRES INVESTMENT CAST-
ING, AMS5344
48 HINGE FITTING, CENTER 17-4 CRES INVESTMENT CAST-
ING, AMS5344
49 HINGE FITTING, FORWARD 17-4 CRES INVESTMENT CAST-
ING, AMS5344
50 INTERCOSTAL 0.063 2219-0 CLAD ALUM SHEET,
(1,60) AMS4096 (HEAT TREAT T62)
51 INTERCOSTAL 0.063 625 INCONEL SHEET, AMS5599
(1,60)

RH Core Cowl
Table 4 (Sheet 4)

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3
1
2

8
7 6

6
6

CES-091-00

RH Core Cowl Fairing

Figure 5

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 SUPPORT 0.032 625 INCONEL SHEET, AMS5599
(0,81) ANNEALED
2 WEAR PLATE 0.032 301 CRES STEEL SHEET,
(0,81) MIL-S-5059, 1/4 HARD
3 SEAL 0.020 301 CRES STEEL SHEET,
(0,51) MIL-S-5059, 1/4 HARD
4 LONGERON 0.032 625 INCONEL SHEET, AMS5599
(0,81) ANNEALED
5 SKIN 0.040 CP-TITANIUM SHEET, AMS4901
(1,02)
6 BRACKET 0.032 625 INCONEL SHEET, AMS5599
(0,81) ANNEALED
7 CLIP 0.032 625 INCONEL SHEET, AMS5599
(0,81) ANNEALED
8 SPACER 1.500 2024-T351 ALUM BAR,
(38,10) QQ-A-225/6
9 FILLER 0.063 301 CRES STEEL SHEET, MIL-S-
(1,60) 5059, 1/4 HARD

RH Core Cowl Fairing

Table 5

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1 4

5
3
6

1
7

CES-092-00

RH Core Cowl Hold Open Rod Supports

Figure 6

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 FRAME 0.063 2219-0 CLAD ALUM SHEET,
(1,60) AMS4096 (HEAT TREAT T62)
2 SUPPORT 0.063 2219-0 CLAD ALUM SHEET,
(1,60) AMS4096 (HEAT TREAT T62)
3 FILLER 0.080 2219-0 CLAD ALUM SHEET,
(2,03) AMS4096 (HEAT TREAT T62)
4 MOUNT 0.063 2219-0 CLAD ALUM SHEET,
(1,60) AMS4096 (HEAT TREAT T62)
5 WEAR PLATE 0.040 321 CRES SHEET, MIL-S-6721,
(1,02) COMP Tl, ANNEALED
6 BASE, BASE ASSY 0.125 PHI5-7MO CRES SHEET, AMS5520,
(3,18) COND A, FINISH 2D (HEAT TREAT
TH-1110)
7 LUG, BASE ASSY 0.063 PH15-7MO CRES SHEET, AMS5520,
(1,60) COND A, FINISH 2D (HEAT TREAT
TH-1110)
8 BRACKET 0.063 2219-0 CLAD ALUM SHEET,
(1,60) AMS4096 (HEAT TREAT T62)

RH Core Cowl Hold Open Rod Supports

Table 6

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1 1
5

4
7
4
2
3

8 2

2 5

7 4

8
6

11
10

CES-093-00

RH Core Cowl Pressure Relief Door

Figure 7

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GAGE
ITEM DESCRIPTION INCH/(mm} MATERIAL
1 SUPPORT 2024-T8511 ALUM EXTRUSION,
AMS4162 AND 10136-1404
2 SHIM 0.020 ALUM ALLOY, MIL-S-22499, COMP
(0,51) 1, TYPE 1, CLASS 1
3 HINGE 2219-T6 ALUM FORGING, AMS4143
4 SHIM 0.032 ALUM ALLOY, MIL-S-22499, COMP
(0,81) 1, TYPE 1, CLASS 1
5 BUSHING 0.062 15-5 CRES STEEL SHEET, AMS
(1,57) 5659, QQ-P-35, (HEAT TREAT
H900)
6 PLATE 0.050 2219-T31 CLAD ALUM SHEET,
(1,27) AMS4095 (HEAT TREAT T81)
7 SPRING 0.032 301 CRES STEEL SHEET, MIL-S-
(0,81) 5059, COND 1/4
8 SHIM 0.00 ALUM ALLOY, MIL-S-22499, COMP
(0,00) 1, TYPE 1, CLASS 1
9 INNER SKIN, CHEM-MILLED 0.080 2219-T31 CLAD ALUM SHEET,
(2,03) AMS4095 (HEAT TREAT T81)
10 CORE 0.486 NONPERFORATED HONEYCOMB, 5052
(12,34) AL ALLOY, 1/8 INCH CELL,
0.003 FOIL GAGE, 12
LB/CU FT., DURA-CORE, V21078
11 OUTER SKIN, CHEM-MILLED 0.125 2024-T3 CLAD ALUM SHEET, QQ-
(3,18) A-250/5 (HEAT TREAT T-81)

RH Core Cowl Pressure Relief Door

Table 7

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CORE COWL ALLOWABLE DAMAGE

1. General

A. Allowable damage data permits an operator to determine if a damaged

core cowl can be returned to service without repair.

Damage permitted by this data will have no significant effect on the

strength or fatigue life of the structure, which will still be capable
of fulfilling its design function.

All damage limits assume that exposed edges do not protrude from skin
contour. Such damage should be reworked to remove or feather
protrusions. Hole and cracks in pressure boundaries must be sealed with
appropriate tape material.

B. Allowable Damage Usage.

(1) Unlimited Usage

(a) Minor damage not affecting the structural integrity or

functional capability of the component and requiring no repair
over the aircraft design life.

(2) Time Limited Usage

(a) Minor damage not affecting the structural integrity of the

component in normal operation, that could reduce design life
of component. Damage must be permanently repaired not later
than the next maintenance “C” check. The location and size of
the damage is to be noted and checked to ensure that the
damage has not grown beyond the allowable damage limits.

C. Damage Types.

(1) Aluminum Sheet Metal Structures - The types of damage permitted to

the core cowl are defined below. They do not include damage to
surface finish such as paint. (See Figure 101.)

Abrasion - An abrasion is a damage area which results in a

cross-sectional area change due to scuffing,
rubbing, scraping, or other surface erosion. An
abrasion is usually rough and irregular.

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Gouge - A gouge is a damage area of any size which results

in a cross-sectional area change. It is usually
caused by contact with a relatively sharp object
which produces a continuous, sharp or smooth
channel-like groove in the material.

Nick - A nick is a local gouge with sharp edges. Consider a

series of nicks in a line pattern to be the
equivalent of a gouge.

Scratch - A scratch is a line of damage in the material and

results in a cross sectional area change. It is
usually caused by contact with a very sharp object.

Crack - A crack is a fracture or complete break in the

material. It appears as an irregular line.

Dent - A dent is normally a damage area which is depressed

with respect to its normal contour. There is no
cross-sectional area change in the material. Area
boundaries are smooth, its form is generally the
result of contact with a relatively smoothly
contoured object.

Buckle - A buckle is similar to a dent but is caused by an

overload situation or adjacent damage. It may
protrude and/or be indented with respect to the
contour.

Hole - A hole constitutes a complete penetration of the

material.

(2) Titanium Structures - The types of damage permitted to the core

cowl fairing is defined below. (See Figure 101)

Buckle - A buckle is similar to a dent but is caused by an

overload situation or adjacent damage. It may
protrude and/or be indented with respect to the
contour.

Crack - A crack is a fracture or complete break in the

material. It appears as an irregular line.

Gouge - A gouge is a damage area of any size which results

in a cross-sectional area change. It is usually
caused by contact with a relatively sharp object
which produces a continuous, sharp or smooth
channel-like groove in the material.

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Nick - A nick is a local gouge with sharp edges. Consider a

series of nicks in a line pattern to be the
equivalent of a gouge.

Scratch - A scratch is a line of damage in the material and

results in a cross sectional area change. It is
usually caused by contact with a very sharp object.

Hole - A hole constitutes a complete penetration of the

material.

Dent - A dent is normally a damage area which is depressed

with respect to its normal contour. There is no
cross-sectional area change in the material. Area
boundaries are smooth, its form is generally the
result of contact with a relatively smooth
contoured object.

(3) Sheet Metal Structures - The types of damage permitted to the core
cowl are defined below. They do not include damage to surface
finish such as paint. (See Figure 101.)

Abrasion - An abrasion is a damage area which results in a

cross-sectional area change due to scuffing,
rubbing, scraping, or other surface erosion. An
abrasion is usually rough and irregular.

Gouge - A gouge is a damage area of any size which results

in a cross-sectional area change. It is usually
caused by contact with a relatively sharp object
which produces a continuous, sharp or smooth
channel-like groove in the material.

Nick - A nick is a local gouge with sharp edges. Consider a

series of nicks in a line pattern to be the
equivalent of a gouge.

Scratch - A scratch is a line of damage in the material and

results in a cross-sectional area change. It is
usually caused by contact with a very sharp object.

Crack - A crack is a fracture or complete break in the

material. It appears as an irregular line.

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Dent - A dent is normally a damage area which is depressed

with respect to its normal contour. There is no
cross-sectional area change in the material. Area
boundaries are smooth, its form is generally the
result of contact with a relatively smoothly
contoured object.

Buckle - A buckle is similar to a dent but is caused by an

overload situation or adjacent damage. It may
protrude and/or be indented with respect to the
contour.

Hole - A hole constitutes a complete penetration of the

material.

D. Damage Zones - There are five damage zones for the core cowl doors.
(See Figure 102.)

(1) See Table 101 for the following items:

(a) allowable damage types

(b) damage zones

(c) allowable damage limits

(d) cleanup requirements

(2) The allowable damage zones for the core cowl are

CCl Panel skin.

CC2 Frame, longeron, mount and intercostal.

CC3 Fairing.

CC4 Fastener joint.

CC5 Pressure relief door.

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BUCKLE/
DESCRIPTION CRACK DENT GOUGE HOLE NICK SCRATCH TEST
ZONE CCL A C E F G E
ZONE CC2 A D E G E
ZONE CC3 B C E F G E
ZONE CC4 C E F G E
ZONE CC5 I I I I I I H

NOTES:
A. Between fasteners in a joint of 10 or more fasteners. 1.00 in.
(25.40 mm) maximum. Length 1.00 - 3.00 in. (25,4 - 76,2 mm). Stop
drill crack. Check at “A” check. Replace at “C” check.
Crack between two adjacent fasteners in joint containing at least
10 fasteners. Minimum of 10.00 in. (254,0 mm) separation from
other defects. Stop drill crack.
B. Length must be less than 1.00 in. (25,4 mm) in a bend area and
less than 25 percent of the flange width, 3.00 in. (76,2 mm)
allowed in other areas. Stop drill crack.
C. Located minimum of 20 times sheet thickness from edge of panel.
Dent diameter must be at least 10 times larger than dent depth.
Minimum of 10.00 in. (254,0 mm) from other defects. Maximum width
to 5.00 in. (127,0 mm).
D. Located in stiffener flange. Maximum dimension is 5.00 in. (127,0
mm). No dents are allowed closer than 5.00 in. (127,0 mm) to a
stiffener termination point. Check at “A” check. Repair at “C”
check.
E. 10.00 in. (254,0 mm) long in any direction. If depth is greater
than 25 percent of material thickness, regard as crack. Minimum of
10.00 in. (254.00 mm) separation from other defects.
F. Maximum 1.00 in. (25,4 mm) diameter within 20 times material
thickness from panel support members. 3.00 in. (76,2 mm) maximum
diameter other areas. Check at “A” check. Repair at “C” check.
Seal with *tape. Holes in excess of 3.00 in. (76,2 mm) must be
repaired before next flight.
G. 25 percent of material thickness, 0.10 in. (2,5 mm) wide.
H. Door must open and close without binding. Inspect per Aircraft
Maintenance Manual.
I. Unlimited.
* Tape - Commonly referred to as “speed tape”, 3M Type 425 or equivalent.
Core Cowl Allowable Damage
Table 101
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SECTION A-A SECTION B-B

B
A

B
A

SCRATCH
GOUGE

SECTION D-D SECTION C-C

D C

D C

NICK CRACK

CES-128-00

Types of Aluminum/Titanium Damage to Core Cowl

Figure 101 (Sheet 1)

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G
SECTION G-G

DENT
E

F F

ABRASION
BUCKLE

SECTION E-E

SECTION F-F
D

SECTION D-D

HOLE

CES-129-00

Types of Aluminum/Titanium Damage to Core Cowl

Figure 101 (Sheet 2)

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ZONE CC3
(FAIRING)

ZONE CC2
(MOUNT)

ZONE CC1
(PANEL SKIN)
ZONE CC2
ZONE CC1
(FRAME)
(PANEL SKIN)

ZONE CC2
(FRAME)

A
ZONE CC2 ZONE CC2
(FRAME) (LONGERON)
ZONE CC2
(INTERCOSTAL)

ZONE CC5

A
ZONE CC4
(FATHER JOINT)

ZONE CC2
(FRAME)

CES-133-00

Core Cowl Damage Zones

Figure 102

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CORE COWL REPAIR INDEX

Title Repair
Aluminum Hat Frame Crack Repair . . . . . . . . . . . . . Repair No.1
Aluminum Zee Frame Crack Repair . . . . . . . . . . . . . Repair No.2
Aluminum Skin Flush Patch . . . . . . . . . . . . . . . . Repair No.3
Titanium Skin Flush Patch . . . . . . . . . . . . . . . . Repair No.4
Fireshield Repair . . . . . . . . . . . . . . . . . . . . Repair No.5
Wearstrip Plasma Repair . . . . . . . . . . . . . . . . . Repair No.6
Titanium Fairing External Doubler Repair . . . . . . . . Repair No.7

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CORE COWL METALLIC REPAIRS

1. General

A. Repairs supplied in this section are for damage to the core cowl which
exceeds limits shown in the Allowable Damage Section. These repairs
will restore the ability of the affected part to meet 100-percent of
the design strength requirements of the original structure. Procedures
for restoration of aerodynamic smoothness and for appearance
improvement are also supplied.

B. Sheet Metal Structure

The panel skins of the core cowl are of 22l9-T8l clad aluminum sheet
with a smaller pylon fairing skin at the top made from CP-TI titanium
sheet. A fireshield of 0.005-inch thick CRES 321 foil nests between the
frames and skin at the top of each core cowl door. (See Figure 201)

The hoop frames and the longerons at the top and bottom of the panel
are fabricated from 22l9-T62 clad aluminum sheet. The intercostals
which tie the frames together around the pressure relief door on the
right hand core cowl are also fabricated from 22l9-T62 aluminum sheet.

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REPAIR NO.1
ALUMINUM HAT FRAME CRACK REPAIR

1. Repair Instructions

A. Drill (No. 10 drill) stop holes at ends of cracks in damaged area of

frame.

B. Trim damaged area from frame. Round the inner corners to 0.25R minimum
and smooth edges of cutout. (See Figure 201)

NOTE: Cutout must not exceed 25-percent of web cross-sectional area

and must be a minimum of one inch from fittings or other
attachments.

C. Return frame to proper contour

D. Assemble repair materials. (See Table 201)

E. Make an angle patch from 2219-0 Aluminum. (See 54-03-01 - Forming,

Machining, and Handling Characteristics of Metals.)

NOTE: Angle patch must not overlap adjacent doublers or fittings.

F. Clamp angle patch in position on frame and pilot-drill (No. 40 drill)

rivet holes through frame and doubler.

G. Ream rivet holes in patch and frame to 0.177-inch diameter (No. 16

drill) for NAS1738MW5 rivets.

H. Remove doubler and filler from frame. Remove burrs and sharp edges from
parts.

I. Heat-treat patch to T-62 condition.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMIALS. GET INSTRUCTIONS FROM YOUR EMPLOYER
ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

J. Apply chemical conversion coating to all raw edges of frame and patch.
Refer to the instructions of the manufacturer.

K. Install doubler and filler on frame with NAS1738MW5-2 rivets.

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2. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201

DESCRIPTION DESIGNATION MANUFACTURER

Coating, Chemical Alodine 1200S V71410
Conversion Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Drill No. 10 Commercially Available
No. 16
No. 40
Knife, utility Commercially Available
Patch, Angle 2219-0 Clad Aluminum Commercially Available
Alloy BT-T62
0.063-In. Gage
Rivet NAS173BMWS-2 Commercially Available
Repair Materials and Equipment
Table 201

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0.25 RADIUS MINIMUM

(TYPICAL)
REMOVE DAMAGED
AREA

4 RIVET DIAMETERS
BETWEEN RIVETS AND ROWS
2 RIVET DIAMETERS
EDGE DISTANCE
(ALL AROUND)

12 RIVET DIAMETERS
(MINIMUM)

3 ROWS OF RIVETS
ON EACH END OF PATCH

ANGLE PATCH
2219-T62 CLAD
1 2 ALUMINUM
NAS1738MW RIVET
FRAME 2 RIVET DIAMETERS
3 2219-T62 CLAD ALUMINUM (TYPICAL)

2 RIVET DIAMETERS
(TYPICAL)

NOTES:

1 USE NAS1738MW-2 RIVETS ON 0.050 INCH THICK FRAMES

PATCH IS SAME MATERIAL BUT ONE GAGE THICKER

2 HEAT TREAT TO T62 CONDITION AFTER FORMING

FRAME THICKNESS IS O.050 INCH

3 (SEE STRUCTURE INDENTIFICATION) CES-111-00

Repair Of Damaged Aluminum Hat Frame

Figure 201

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STRUCTURAL REPAIR MANUAL
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REPAIR NO. 2
ALUMINUM ZEE FRAME CRACK REPAIR

1. Repair Instructions

A. Drill (No. 10 drill) stop holes at ends of crack in damaged area of

frame.

B. Trim damaged area from frame. Round the inner corners and smooth edges
of cutout. (See Figure 201)

NOTE: Cutout must not exceed 50-percent of web cross-sectional area

and must be a minimum of one-inch from fittings and other
attachments.

C. Return frame flange to proper contour.

D. Assemble repair materials. (See Table 201)

E. Make an angle filler and a repair angle doubler from 2219-0 Aluminum.
Use same gage material as in frame for filler and one gage heavier for
doubler. See 54-03-01 - Forming, Machining, and Handling
Characteristics of Metals.

NOTE: Repair doubler must not overlap adjacent doubler or fittings.

F. Clamp repair doubler in position on frame and pilot-drill (No. 40

drill) rivet holes through frame and doubler. Install temporary
fasteners through frame and doubler.

G. Position angle filler on doubler and pilot-drill (No. 40 drill) rivet

holes.

H. Ream rivet holes in doubler, frame, and filler to 0.177-inch diameter

(No. 16 drill).

I. Remove doubler and filler from frame. Remove burrs and sharp edges from
parts.

J. Heat-treat doubler and filler to T-62 condition.

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WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMIALS. GET INSTRUCTIONS FROM YOUR EMPLOYER
ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

K. Apply chemical conversion coating to all raw edges of frame, doubler,

and filler. Refer to the instructions of the manufacturer.

L. Install doubler and filler on frame with NAS1738MW5 rivets.

2. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201..

DESCRIPTION DESIGNATION MANUFACTURER

Coating, Chemical Alodine 1200S V71410
Conversion Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Doubler, Repair Angle 2219-0 Clad Alum Alloy Commercially Available
BT-T62 0.071-Inch Gage
Drill No. 10 Commercially Available
No. 16
No. 40
Filler, Angle 2219-0 Clad Alum Alloy Commercially Available
BT-T62 0.063-In. Gage
Rivet NAS1738MW5-3 Commercially Available
Repair Materials and Equipment
Table 201

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CES-113-00

Repair of Aluminum ZEE Frame

Figure 201

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 ROHR, INC.
STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

REPAIR NO.3
ALUMINUM SKIN FLUSH PATCH

1. Repair Instructions

A. Drill (No. 10 drill) stop holes at ends of cracks in damaged area of

aluminum skin of core cowl.

B. Remove damaged area from skin. Maintain minimum corner radius of 1.0-
inch and smooth edges of cutout. (See Figure 201)

NOTE: Maintain 1.25-inch distance from fittings or frame members.

C. Assemble repair materials. (See Table 201)

NOTE: Use 0.040-inch thick aluminum patch and 0.050-inch thick aluminum
doubler in chemical-milled section of skin.

D. Make a skin patch and a doubler from 2219-T81 or 2219-T31 and Heat
Treat to T81. Refer to AMS 2770 or equivalent for heat treat. (See 54-
03-01 Forming, Machining, and Handling Characteristics of Metals.)

NOTE: Patch or doubler must not overlap adjacent fittings or frame

members.

E. Clamp doubler in position on skin and pilot-drill (No. 40 drill) rivet

holes through doubler and skin. Install temporary fasteners through
skin and doubler.

F. Position skin patch on doubler and pilot-drill rivet holes through

doubler and patch. Install temporary fasteners through patch and
doubler.

G. Ream rivet holes to 0.162-inch diameter (No. 20 drill) in skin,

doubler, and patch. Countersink rivet holes to accept CR3524-5 rivets.

H. Disassemble parts and remove all burrs and sharp edges.

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STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMIALS. GET INSTRUCTIONS FROM YOUR EMPLOYER
ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

I. Apply chemical conversion coating to all surfaces of patch and doubler

and raw edges of skin. Refer to the instructions of the manufacturer.

J. Install doubler on skin with applicable rivets.

K. Install patch on doubler with applicable rivets.

2. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Coating, Chemical Alodine 1200S V71410
Conversion Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Drill No. 10 Commercially Available
No. 21
No. 40
Patch, Angle 2219-T31 Clad Aluminum Commercially Available
Alloy HT-T81
0.04-Inch gage
Rivet CR3524-5-() Commercially Available
NAS1200M5 (Alternate)
Router Commercially Available
Repair Materials and Equipment
Table 201

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0.50 INCH RADIUS

(TYPICAL MINIMUM) 1.00 INCH RADIUS
(TYPICAL MINIMUM)
0.63 INCH A
(MINIMUM)

0.63 INCH
(MINIMUM) PATCH

0.63 INCH
(MINIMUM)
DOUBLER
0.31 INCH
MINIMUM
EDGE
DISTANCE
TYPICAL O.03
INCH
GAP
(MAX)

PATCH

A SECTION A-A
SKIN
DOUBLER 0.040 INCH (2219-T81
NOTE: = REPAIR RIVET CR3524-5 ALUMINUM ALLOY IN
RIVET CHEM MILLED AREA)
CES-109-00

Core Cowl Aluminum Skin Flush Patch Repair

Figure 201

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STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

REPAIR NO.4
TITANIUM SKIN FLUSH PATCH

1. Repair Instructions

A. Stop drill (No. 10 drill) holes at ends of cracks in damaged area of

titanium fairing skin of core cowl.

B. Trim damaged area from fairing skin. Maintain minimum corner radius of
0.5-inch and smooth edges of cutout. (See Figure 201)

C. Assemble repair materials. (See Table 201)

D. Make a skin patch and a doubler from CP Titanium, AMS4901. (See 54-03-
01 - Forming, Machining, and Handling Characteristics of Metals.)

NOTE: Patch or doubler must not overlap adjacent fittings or frame

members.

E. Clamp doubler in position on fairing skin and pilot-drill (No. 40

drill) rivet holes through doubler and skin. Install temporary
fasteners through skin and doubler.

F. Position fairing skin patch on doubler and pilot-drill attach rivet

holes through doubler and patch. Install temporary fasteners through
patch and doubler.

G. Ream attach rivet holes to 0.159-inch diameter (No. 21 drill) in skin,

doubler, and patch. Countersink rivet holes to accept NAS1200M5 flush
head monel rivets.

H. Disassemble repair parts and remove all burrs and sharp edges from
skin, patch, and doubler.

I. Install doubler on skin with NAS1200MS rivets.

J. Install patch on doubler with NAS1200MS rivets.

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STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

2. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

.
DESCRIPTION DESIGNATION MANUFACTURER
C-Clamp Commercially Available
Doubler CP Titanium, AMS4901 Commercially Available
0.050-Inch Gage
Drill No. 10 Commercially Available
No. 21
No. 40
Patch CP Titanium, AMS4901 Commercially Available
0.040-Inch Gage
Rivet NAS1200MS-6 Commercially Available
Repair Materials and Equipment
Table 201

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0.50 INCH RADIUS 1.00 INCH RADIUS

(TYPICAL MINIMUM) (TYPICAL MINIMUM)
0.63 INCH
(MINIMUM)

0.63 INCH
SKIN (MINIMUM)
CUTOUT

DOUBLER

0.31 INCH
(MINIMUM) PATCH

0.03
INCH
GAP
(MAX)

PATCH

SKIN
DOUBLER (0.040 INCH GAGE
NAS1200M5 CP TITANIUM)
RIVET
NOTE:
REPAIR RIVET
CES-112-00

Core Cowl Titanium Skin Flush Patch Repair

Figure 201

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REPAIR NO. 5
FIRESHIELD REPAIR

1. General

This repair may be used to repair cracked, torn, punctured, or large area
damage to the CRES fireshields.

2. Repair Instructions

A. Drill (No. 31 drill) stop holes at ends of cracks in damaged area of

fire shield. (See Figure 201)

B. Trim damaged area from fire shield. Smooth edges of cutout and remove
old adhesive.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

C. Remove all traces of dirt, oil, hydraulic fluid and other contaminants
with a clean lint-free cloth and the solvent. Remove the solvent with a
clean lint-free cloth before the solvent becomes dry.

D. Mask repair area with 2 in. (5O.8 mm) wide teflon tape.

E. Abrade faying surfaces of fire shield with ISO-grit or finer silicon

carbide abrasive paper.

F. Remove sanding debris from exterior skin surface with a clean lint-free
cloth and the solvent. Remove the solvent with a clean lint-free cloth
before the solvent becomes dry.

G. Form fireshield patch from 321 CRES, to fit. Overlap crack, tear,
puncture, or edge of existing fireshield. (See Figures 201 and 202:)

H. Prefit fireshield patch so that only light pressure is required to give

sufficient contact of the faying surfaces for bonding.

I. Abrade faying surfaces of fireshield patch with ISO-grit or finer

silicon carbide abrasive paper.

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Document Part No. RDN 306

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

J. Apply a thin brush coat of the primer to all faying surfaces. Refer to
the instructions of the manufacturer.

K. Dry the adhesive. Refer to the instructions of the manufacturer.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

L. Mix the adhesive. Refer to the instructions of the manufacturer.

M. Apply a coat of the adhesive 0.010 in. (0.2S4 mm) thick to the primed
faying surfaces of both parts. Refer to the instructions of the
manufacturer.

N. Install fireshield patch. Apply sufficient pressure to maintain proper

alignment and allow direct contact between faying surfaces.

O. Seal edges with a bead of the adhesive sealant.

P. Dry the adhesive. Refer to the instructions of the manufacturer.

Q. Remove teflon tape.

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3. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Cloth, Lint-Free Cotton Commercially Available
Container with Cover Metal or Plastic Commercially Available
Drill No. 31 Commercially Available
Paper, Abrasive 15O-Grit silicon carbide Commercially Available
Patch 321 CRES, 0.005-Inch Commercially Available
(0.127-mm) Gage
Prime Coat, RTV DOW CORNING® PR-1200 V5D028
Dow Corning Corporation
3901 South Saginaw Road
Midland, MI 48686
Phone: (989) 496-4400
www.dowcorning.com
Sealant, Silicone DC 90-006-2 (Two Part) V5D028
Paste, Red Sealant and Catalyst Dow Corning Corporation
www.dowcorning.com
Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
or
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Ketone/ Univar U.S.A., Inc.
40% Methyl Ethyl Ketone 532 E. Emaus Street
or Middletown, PA 17057-2200
Phone: (717) 944-7471
www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Spatula Metal or Plastic Commercially Available
Tape, Teflon 2-In. (50.8-mm) Wide Commercially Available
Repair Materials and Equipment
Table 201

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Document Part No. RDN 306

ADHESIVE SEALANT BEAD

1.0 INCH
1.0 INCH
(TYPICAL)
(TYPICAL)

CRACK OR TEAR FILL

WITH ADHESIVE SEALANT

FIRE SHIELD PATCH

STOP DRILL HOLE
(0.25 INCH DIA)

EDGE OF PART
1.0 INCH
(TYPICAL)
HOLE OR PUNCTURE

FIRE SHIELD PATCH

FILL WITH ADHESIVE
SEALANT

ADHESIVE SEALANT
BEAD TYP

1.0 INCH
(TYPICAL)

CES-114-00

Core Cowl Fireshield Patch Repair

Figure 201

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STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

ORIGINAL FIRE SHIELD ADHESIVE SEALANT

BEAD TYP
FRAME FRAME

1.0 INCH TYP

FIRE SHIELD PATCH

CES-115-00

Core Cowl Fireshield Patch Repair

Figure 202

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REPAIR NO.6
WEARSTRIP PLASMA REPAIR

1. General

A. Remove wears trip from left or right core cowl by drilling out rivets
with a 0.125 in. (3.175 mm) drill.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

B. Remove lubricant by immersion of the wearstrip in a solution of 20

percent chromic acid at 160°F-180°F (71.1°C-82.2°C).

2. Repair Instructions (See Figure 201)

A. Clean up damage area.

(1) Mask area around damage with 2.0 in. (50.8 mm) teflon tape.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU

DO THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY
ALL INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

(2) Grind out damaged area of coating to remove all loose particles,
and cracks.

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WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(3) Remove the unwanted material from the wearstrip surfaces with a
clean lint-free cloth and solvent. Remove the solvent with a clean
lint-free cloth before the solvent becomes dry.

(4) Wear clean cotton gloves while handling cleaned parts. Suitable
holding devices may be used provided they do not contaminate the
surfaces to be plasma sprayed.

B. Preheat area to be sprayed.

(1) The surface to be coated may be preheated to 120°F-150°F (50°C-

65°C) to remove condensation and minimize thermal expansion.
Preheating shall only be accomplished by using the plasma gun with
powder feed turned off.

(2) Plasma spraying shall begin when the part arrives at the selected
preheat temperature.

C. Coating application.

(1) The thickness of the area to be coated shall be measured before and
after plasma spraying.

(2) Coating thickness may be monitored by the use of a test coupon

placed adjacent to the area being coated and which is coated during
the process.

(3) Spray bond coat of Nickel-Aluminum Composite to a thickness of

0.003-0.006 in. (0.076-0.152 mm) and a top coat of Tungsten Carbide
plus 17 percent Cobalt to a thickness of 0.004-0.008 in. (0.102-
0.203 mm).

(4) The coating impingement angle shall be as close to 90 degrees as

possible. At no time shall the impingement angle be less than 45
degrees.

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(5) A constant gun-to-work distance, traverse rate, etc., shall be

maintained throughout plasma spraying by means of the fixture
devices.

(6) Equipment settings shall be monitored continuously and adjusted

for drift as required.

(7) The maximum substrate temperature during spraying any heat-treated

aluminum alloy shall be 225°F (110°C).

(8) Total time at temperature shall not exceed one hour for any
substrate material.

(9) Temperature measurements shall be made while establishing the

spraying parameters part temperature shall be monitored during
spraying.

(10) Coating deposition may be interrupted for thickness measurements

or for cooling cycles. Each interruption shall not exceed five
minutes duration.

(11) The plasma carrier gas shall be argon, nitrogen or mixtures of

argon and up to 20 percent hydrogen by volume.

WARNING: HYDROGEN IS AN EXPLOSIVE AND FLAMMABLE. USE IN A WELL-

VENTILATED AREA. KEEP AWAY FROM OPEN FLAME.

(12) The final surface finish of the coatings shall conform to the
engineering drawing requirement.

(13) Finish by machining and buffing or honing.

D. Apply lubricant.

(1) Anodize the wearstrip.

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WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE MANUFACTURER,
THE MATERIAL SAFETY DATA SHEET (MSDS), AND GOVERNMENT
REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE
YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED. AN
MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

(a) Mix chromic acid (10 percent-by-weight) in demineralized

water.

(b) Apply direct current and raise the voltage at a rate not to
exceed 8 volts per minute until 38-42 volts are obtained.

(c) Lower wearstrips into tank and maintain 38-42 volts for 40-50
minutes.

(d) Remove parts from the tank and rinse with demineralized water
at 95°F (35°C) within 2 minutes after current is turned off.

(e) Dry wearstrips with clean dry air or in an oven at 160°F

(71°C) maximum.

(2) Test the anodize film.

(a) The anodize film shall be uniform in appearance, adherent,

nonpowdery and free from scratches and bare areas, except bare
areas resulting from hooks and wires are acceptable provided
they are kept as small as practical.

(b) The finish may also vary from a bright polish finish to a dull
cast appearance. Color shall not be cause for rejection.

(c) The anodic film over anyone surface area shall be continuous
as determined by a light continuity test. The test shall be
performed by using a 1-1/2 volt flashlight equipped with
external electrode probes. The probes are to be placed against
the test area using only the weight of the probe for pressure.
Inadequate film is indicated by lighting of the lamp and shall
be cause for rejection.

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WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE
INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE MANUFACTURER,
THE MATERIAL SAFETY DATA SHEET (MSDS), AND GOVERNMENT
REGULATIONS. CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE
YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT OBEYED. AN
MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

(d) Parts not meeting the above requirements shall be stripped

using a solution of chromic acid (3.5 percent-by-weight),
phosphoric acid (5.0 percent-by-weight) and demineralized
water at 200°F-210°F (93°C-99°C). Reanodized per steps (a) to
(c).

(3) Test the plasma coating.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(4) Clean wearstrip surfaces with a clean lint-free cloth and the
solvent. Remove the solvent with a clean lint-free cloth before the
solvent becomes dry.

(5) Handle parts with clean cotton gloves through all subsequent
operations.

(6) Mask rivet holes with masking tape and Kraft paper.

(7) Mix lubricant per manufacturer's instructions.

(8) Swirl or stir material in paint cup and or aerosol cans frequently
as settling of the pigment will greatly shorten the lubrication
life. A ball bearing in the gun will aid in mixing the material.

(9) Adjust air pressure to supply a very fine atomization at low

pressure (25-30 psi at gun). Air must be free of oil, grease,
water, and foreign contamination.

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(10) Apply uniform cross coats. The cured film thickness shall be
0.0015-0.003 in. (0.0381-0.0762 mm).

(11) Approximately six to eight light crosscoats should be used to build

up to the specified thickness. Allow each coat to flash dry to
dullness before applying subsequent coats to prevent entrapment of
solvents.

(12) Air dry wearstrips for 30 minutes minimum.

(13) Remove masking tape and Kraft paper.

(14) Cure at 290°F-310°F (143.3°C-154.4°C) for 2 hours.

3. Inspections

A. Appearance of dry film lubricated parts shall be a dull gray to black

which becomes smooth and shiny upon wear-in. Coating shall be
continuous, free of blisters, voids, sags and runs.

B. Thickness measurements may be made by measuring the film with a

micrometer or film meter.

C. The dry film lubricant shall be adherent when tested with 3M Company
250 tape removed abruptly from the surface. Failure is indicated by
exposure of base metal. Particles clinging to the tape do not
constitute a failure unless base metal is visible.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL SAFETY
INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL SAFETY DATA
SHEET (MSDS), AND GOVERNMENT REGULATIONS. CHEMICALS MAY CAUSE
INJURY TO YOU OR MAKE YOU SICK WHEN SAFETY INSTRUCTIONS ARE NOT
OBEYED. AN MSDS GIVES INSTRUCTIONS ON HOW YOU MUST SAFELY USE,
KEEP, AND DISCARD CHEMICALS. GET INSTRUCTIONS FROM YOUR
EMPLOYER ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS.

D. The dry film shall show no loss of adhesion or removal when wiped with
a cloth dampened in the solvent. Cloth may show a slight gray
discoloration after wiping which is not objectionable, but in no case
shall the film be wiped to expose base metal.

E. Install wearstrip on core cowl with MS20426AD4 rivets.

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Document Part No. RDN 306

4. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Acid Chromic Phosphoric Commercially Available
Cloth, Lint-Free Cotton Commercially Available
Coating Nickel-Aluminum Composite Commercially Available
Type 4, Grade B

Tungsten Carbide plus 17 Commercially Available

percent Cobalt Type 9, Grade
A
Gas, Argon MIL-A-18455B Commercially Available
Gas, Hydrogen Fed. Spec. BB-H-886b Type II Commercially Available
Gas, Nitrogen Fed. Spec. BB-H-4llb Type I, Commercially Available
Class, Grade A
Lubricant Everlube 620c Type 1, E/M Core.
MIL-L-8937 6940 Farmdale Ave.
North Hollywood, CA 91605
Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
or
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Ketone/ Univar U.S.A., Inc.
40% Methyl Ethyl Ketone 532 E. Emaus Street
or Middletown, PA 17057-2200
Phone: (717) 944-7471
www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Rivets MS20426AD4 Commercially Available
Tape Teflon Commercially Available
Water Demineralized Commercially Available
Repair Materials and Equipment
Table 201

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RIVET

SKIN
RIVET

WEARSTRIP

SKIN

WEARSTRIP

FRAME

FRAME

CES-116-00

Wearstrip Plasma Repair

Figure 201

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REPAIR NO.7
TITANIUM FAIRING EXTERNAL DOUBLER REPAIR

1. General

CAUTION: USE THE CORRECT MACHINING AND FABRICATION PROCEDURES FOR

TITANIUM.

A. This procedure gives the instruction to repair the Titanium Fairing on

the Core Cowl. The damage is removed and an external Titanium doubler
is installed. Refer to Figure 201.

B. The maximum dimension of the damage must be less than 2.5 inches (63.5
mm).

C. References

REFERENCE TITLE
GE SPM TASK 70-32-02-230-001 FLORESCENT PENETRANT INSPECTION
SRM 54-02-01 GENERAL DAMAGE CLEANUP
SRM 54-03-01 FORMING, MACHINING AND FABRICATION
CHARACTERISTICS OF METALS - TITANIUM
SRM 54-04-09 COUNTERSINKING - COUNTERSINK REPAIR WASHER

2. Repair Instructions

A. Do an inspection of the damage.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Clean the damaged area with a clean lint-free cloth and solvent.
Remove the solvent with a clean lint-free cloth before the solvent
becomes dry.

(2) Do a fluorescent penetrant inspection of the area to find damage.

Refer to SPM TASK 70-32-02-230-001 for penetrant procedures. Make
a mark at the ends of the damage.

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B. Prepare the damage area for repair. Refer to Figure 201 and SRM 54-02-
01.

(1) Make a mark around the damaged area.

(a) Make the mark parallel to the edges of the fairing.

(b) Minimum 0.5 inch (12.5 mm) radius at the corners.

(c) The minimum of two fasteners are necessary. See Figure 201

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO

THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL
INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

C. Cut and remove the damaged area of the fairing skin on the marks. Refer
to SRM 54-03-01 FORMING, MACHINING AND FABRICATION CHARACTERISTICS OF
METALS - TITANIUM SECTION.

(1) Remove sharp edges and burrs. Use the abrasive paper.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(2) Clean the damaged area with a clean lint-free cloth and solvent.
Remove the solvent with a clean lint-free cloth before the solvent
becomes dry.

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STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU

DO THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY
ALL INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

D. Make the repair doubler with the external metallic doubler. Refer to
Table 201.

(1) Cut the repair doubler. Refer to Figure 201 and SRM 54-03-01
FORMING, MACHINING AND FABRICATION CHARACTERISTICS OF METALS -
TITANIUM SECTION.

(a) Cut the doubler to the dimension necessary to install all

fasteners. Refer to Figure 201.

(b) All corners must have a 0.5 inch (12.7 mm) minimum radius.

(2) Make the doubler align with the contour of the fairing with light
finger pressure.

(3) Chamfer the doubler 60 degrees on all edges. Refer to Figure 202.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU

DO THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY
ALL INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

E. Make the filler with the metallic filler. Refer to Table 201.

(1) Make sure the gauge thickness of the filler and the fairing
thickness agree.

(2) Make the filler the same dimension to the cutout damage area with
0.030 inch (0.762 mm) maximum gap between the filler and cutout.

(3) Make the filler align with the contour of the fairing with light
finger pressure.

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STRUCTURAL REPAIR MANUAL
Document Part No. RDN 306

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU

DO THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY
ALL INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE
INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND
GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE
PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS
NECESSARY.

F. Prepare the repair installation. Refer to SRM 54-03-01 FORMING,

MACHINING AND FABRICATION CHARACTERISTICS OF METALS - TITANIUM SECTION.

(1) Hold the doubler in position with the clamps.

(2) Make the marks for the new repair fastener holes. See Figure 201.

(3) Make the pilot holes through the fasteners and doubler as
necessary. Hold the doubler in position with temporary fasteners.
Refer to Figure 201.

(4) Make the pilot holes through the doubler, fairing and filler for
new repair fasteners. Hold the repair in position with temporary
fasteners.

(5) Make the repair holes through the doubler and the fairing
0.129 - 0.132-inch (3.28 – 3.35 mm) diameter.

(6) Countersink the holes in the repair doubler and filler for the
double-flush rivets. Countersink to 0.189-0.195 inch (4.80 – 4.95
mm) diameter by 100°.

(7) Remove sharp edges and burrs. Use the abrasive paper.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(8) Remove unwanted materials with a clean lint-free cloth and

solvent. Remove the solvent with a clean lint-free cloth before the
solvent becomes dry.

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Document Part No. RDN 306

G. Install the repair parts. Refer to Figures 201 and 202.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(1) Mix the RTV prime coat. Refer to the instructions of the
manufacturer.

(2) Apply a thin layer of the RTV prime coat mixture to the mating
surfaces of the bare metal surfaces of the repair area, filler and
doubler.

(3) Remove the RTV prime coat residue with a clean, lint-free cloth.

(4) Dry the RTV prime coat. Refer to the instructions of the
manufacturer.

WARNING: BEFORE YOU USE CHEMICALS, READ, UNDERSTAND, AND OBEY ALL
SAFETY INSTRUCTIONS FOR THE CHEMICALS. THESE INSTRUCTIONS
INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, THE MATERIAL
SAFETY DATA SHEET (MSDS), AND GOVERNMENT REGULATIONS.
CHEMICALS MAY CAUSE INJURY TO YOU OR MAKE YOU SICK WHEN
SAFETY INSTRUCTIONS ARE NOT OBEYED. AN MSDS GIVES
INSTRUCTIONS ON HOW YOU MUST SAFELY USE, KEEP, AND DISCARD
CHEMICALS. GET INSTRUCTIONS FROM YOUR EMPLOYER ON HOW YOU
MUST SAFELY USE, KEEP, AND DISCARD CHEMICALS.

(5) Mix the silicone sealant. Refer to the instructions of the

manufacturer.

(6) Apply a thin layer of the silicone sealant to the mating surfaces.

(7) Attach the filler to the repair doubler with the solid rivets (two
minimum). Refer to Figure 201.

(8) Make and install the countersink repair washers below the repair
doubler. Refer to Figure 202 and SRM 54-04-09 COUNTERSINKING -
COUNTERSINK REPAIR WASHER SECTION.

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(9) Put the repair doubler into position with temporary fasteners to
keep the holes in the doubler holes aligned with the holes in the
fairing.

(10) Install the blind rivets wet with the silicone sealant.

(11) Apply silicone sealant around the edges of the doubler. Refer to
Figure 202.

(12) Remove the unwanted silicone sealant with a clean lint-free cloth
before the silicone sealant becomes dry.

(13) Dry the silicone sealant. Refer to the instructions of the

manufacturer.

3. Repair Materials and Equipment. See Table 201.

NOTE: You can use alternative materials with the same properties to
replace the items shown in Table 201.

DESCRIPTION DESIGNATION MANUFACTURER

Clamp Commercially Available
Cloth, Lint-Free Cotton Commercially Available
Doubler, External 0.050-inch (1.27 mm) thick Commercially Available
Metallic CP Ti, Per AMS4901
Doubler, External 0.050-inch (1.27 mm) thick Commercially Available
Metallic (Alternate) 6AL-4V Per AMS4911
Fasteners, Temporary Commercially Available
Filler, Metallic CRES STeel Sheet, Type 301, Commercially Available
MIL-S-5059, Finish 2B
Lamp, Heat 180°F-200°F Commercially Available
(82.8°C-93.3°C)
Knife, Utility Commercially Available
Knife, Putty Commercially Available
Paper, Abrasive 150 to 400-Grit Commercially Available
Aluminum Oxide
Prime Coat, RTV DOW CORNING® PR-1200 V5D028
Dow Corning Corporation
3901 South Saginaw Road
Midland, MI 48686
Phone: (989) 496-4400
www.dowcorning.com
Repair Materials and Equipment
Table 201

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Proprietary - This document is subject to the controls and restrictions on the title page.
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 ROHR, INC.
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Document Part No. RDN 306

DESCRIPTION DESIGNATION MANUFACTURER

Probe, Temperature 0°F-250°F Commercially Available
(-17.8°C-121.1°C)
Rivet, Blind CR3524-4 V05693
Cherry Textron Inc
1224 E. Warner St.
Santa Ana, CA 92705-5484
Phone: (714) 545-5511
www.cherryaerospace.com
Rivet, Solid NAS1200M-4 Commercially Available
Double-Flush
Sealant, Silicone DC 93-006-6 (Two Part) V5D028
Paste, Gray Sealant and Catalyst Dow Corning Corporation
www.dowcorning.com
Solvent Isoprophyl Alcohol Commercially Available
99 percent pure
or
MIBK/MEK Blend V5E821
(60% Methyl Isobutyl Ketone/ Univar U.S.A., Inc.
40% Methyl Ethyl Ketone 532 E. Emaus Street
or Middletown, PA 17057-2200
Phone: (717) 944-7471
www.univarusa.com
Turco 6646 V71410
Henkel Corporation
32100 Stephenson Hwy.
Madison Heights, MI 48071
Phone: (248) 583-9300
www.aerospace.henkel.com
Spatula Metal or Plastic Commercially Available
Repair Materials and Equipment
Table 201

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A
CUT-OUT AREA

TYPICAL DAMAGE AREA

UPPER TITANIUM FAIRING

CORE COWL
LEFT HAND SHOWN
RIGHT SIDE OPPOSITE
A
0.5-INCH MIN
TYPICAL DAMAGE
RADIUS
DETAILS OMITTED FOR CLARITY
DAMAGE REMOVED

A A

UPPER TITANIUM
FAIRING

REPAIR FASTENER LOCATION-CR3524-4 BLIND RIVETS

EXSITING FASTENER LOCATION-CR3524-4 BLIND RIVETS
EXISTING DOUBLE-FLUSH LOCATION-CR3524-4 BLIND RIVETS
REPAIR DOUBLE-FLUSH LOCATION-NAS1200M-4 SOLID RIVETS
CES-258-00

MAINTAIN 2D EDGE MARGIN EDGES OF PARTS

MAINTAIN 4D-6D FASTENER SPACING
A
TYPICAL REPAIR

External Doubler Repair

Figure 201

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BLIND
RIVET REPAIR DOUBLE-FLUSH
DOUBLER SOLID RIVET

EXISTING REPAIR REPAIR

CLIP WASHER FILLER

MAX 0.030 INCH

GAP ALL AROUND

A-A
(NOT TO SCALE)

DOUBLER
30 DEGREES
FILLET
SEAL
SKIN

CES-259-00

B
CHAMFER DETAIL

External Doubler Repair

Figure 202

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Proprietary - This document is subject to the controls and restrictions on the title page.
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