Stuctural Repair Manual

ATP
INDEX
COPYRIGHT
2002
COPYRIGHT IS NOT CLAIMED AS TO ANY PART OF AN ORIGINAL WORK

PREPARED BY A UNITED STATES GOVERNMENT OFFICER OR EMPLOYEE AS
PART OF THAT PERSONS OFFICIAL DUTIES OR BY ANY OTHER THIRD PARTY
OFFICER OR EMPLOYEE AS PART OF THAT PERSONS DUTIES.
"ATP" is a registered trademark of Aircraft Technical Publishers. All original
authorship of ATP is protected under U.S. and foreign copyrights and is subject
to written license agreements between ATP and its Subscribers.
ALL RIGHTS RESERVED. NO PART OF THIS PUBLICATION MAY BE
REPRODUCED, STORED IN A RETRIEVAL SYSTEM, OR TRANSMITTED IN ANY
FORM BY ANY MEANS, ELECTRONIC, MECHANICAL, PHOTOCOPYING,
RECORDING OR OTHERWISE, WITHOUT PRIOR WRITTEN PERMISSION OF THE
PUBLISHER.
Customer Service
Aircraft Technical Publishers
6AM-5PM PST M-F
101 South Hill Drive
(800)227-4610
Brisbane, CA 94005
ATP Grid Index to Manufacturers Publications:
Sabreliner
Corp.
NA-265 Series
Structural
Sectipn
Repair Manual
Topic
General Information
Title Page
List of
Chapters (Table
of Contents)
Manufacturers Introduction
Record of Revisions
Record of
Temporary
Revisions
(Highlights of Changes)
of Effective Pages
Letter of Transmittal
List
Aircraft General
06.00.00
Dimensions and Areas
06.00.00
List of Effective
06.00.00
Pages
General
Airframe Systems
32.00.00
Landing Gear
32.00.00
List of Effective Pages
32.00.00
General
32.10.00
Main Gear and Doors
32.10.10
32.20.00
32.20.10
32.30.00
32.30.10
Landing Gear
Nose Gear and Doors
Landing Gear
Extension and Retraction
Landing Gear Shock
Struts
Structures
03/03/2001
Copyright

SE
0001
R3)
Page
of
Section
Topic
51.00.00
Standard Practices
51.00.00
List of Effective
Structures
Pages
51.00.00
General
51.00.10
Flight Limits with Restricted-Life Repairs

Investigation, Cleanup, and Aerodynamic Smoothness
Airframe and Material Inspection
51.10.00
51.10.10
51.10.11
Load and Buckle Patterns
51.10.12
Over-G, Over Pressurization, and Hard Landing Inspection
51.10.30
Overheat
51.10.40
Inspection
Airplane Alignment Inspection
51.10.50
Structural Joint Wear
51.10.60
Aerodynamic Smoothness
51.20.00
51.20.10
Processes
51.20.20
Fuselage and Nacelle Sealing

Adhesive Bonding
51.20.30
Corrosion Control
51.30.00
51.30.00
51.40.00
Materials
Service Information Letter No. 57
Fasteners
51.40.10
Fasteners
51.40.20
Rivets
51.40.30
Mechanical
51.50.00
51.50.00
51.70.00
51.70.00
51.70.10
51.70.20
51.70.30
51.70.40
51.70.50
51.70.60
51.70.70
Torque Values
Fasteners
Support of Airplane for Repair/Alignment Check Procedures

Repair Support and Alignment
Repairs
Typical Repairs
Developing Typical Repairs
Repair Calculations and General Repair Requirements
Material Design Mech Properties
Strength Joint Tables
Typical Repair Examples
General Repair
Restricted-Life Repairs
Negligible Damage Rework
52.00.00
Doors
52.00.00
List of Effective
52.00.00
General
52.10.00
Passenger/Crew
Pages
52.10.00
Main Entrance Door (Structural
52.10.20
Main Entrance Door
52.80.00
03/03/2001
Landing
Identification)
(Repair)
Gear
Copyright
Aircraft Technical
SE
0001
R3)
Publishers
Page
of
Section
52.80.00
52.80.10
52.80.20
Topic
Landing Gear Doors (Structural Identification)

Landing Gear Doors (Allowable Damage)
Landing Gear Doors (Repair)
53.00.00
Fuselage
53.00.00
List of Effective
53.00.00
Pages
General
53.00.10
Fuselage
53.10.00
Main Frame (Structural
53.10.20
Main Frame
53.20.20
Auxiliary Structure
53.30.20
Plates and Skins
53.40.20
Attach Fittings
(Repair)
54.00.00
Nacelles/Pylons
54.00.00
List of Effective
54.00.00
54.00.10
Pages
General
Nacelles and
Pylons
54.20.20
Auxiliary Structure
Auxiliary Structure
54.30.00
Plates and Skins
54.20.00
54.30.20
54.40.00
54.40.20
Plates and Skins

Attach Fittings
Attach fittings
55.00.00
Stabilizers
55.00.00
List of Effective
55.00.00
55.00.10
55.00.20
55.10.00
Identification)
Pages
General
Stabilizers (Allowable Damage)
Stabilizers
(Repair)
Horizontal Stabilizer
or
Canard
55.10.00
Horizontal Stabilizers (Structural
55.10.20
Horizontal Stabilizers
55.30.00
(Repair)
Vertical Stabilizer
55.30.00
Vertical Stabilizer (Structural
55.30.20
Vertical Stabilizer
55.40.00
Rudder (Structural
55.40.20
Rudder
03/03/2001
Identification)
(Repair)
Rudder
55.40.00
56.00.00
Identification)
Identification)
(Repair)
Windows
Copyright

SE
0001
R3)
Page
of
Section
56.00.00
Topic
List of Effective Pages
General
56.00.00
Windshields and Windows
56.00.10
Flight Compartment
Flight Compartment (Structural Identification)
Flight Compartment (Allowable Damage)
Flight Compartment (Repair)
Passenger Compartment
56.10.00
56.10.00
56.10.10
56.10.20
56.20.00
Identification)
56.20.00
Cabin Windows (Structural
56.20.10
Cabin Windows (Allowable Damage)
57.00.00
Wings
57.00.00
List of Effective
Pages
57.00.00
General
57.00.10
Wing Allowable Damage

Center Wing
57.10.00
Main Frame (Structural
57.10.00
Identification)
(Repairs)
Wing Tank Sealing
Wing Tip
Main Frame
57.10.20
57.10.30
57.30.00
Plates and Skins
57.30.20
Trailing Edge and

Flight Surfaces
Flight Surfaces
Flight Surfaces
57.50.00
57.50.00
57.50.10
57.50.20
Trailing Edge Devices

(Structural Identification)
(Allowable Damage)
(Repair)
Power Plant
78.00.00
Exhaust
78.00.00
List of Effective
78.00.00
General
78.30.00
Thrust Reverser
Pages
Identification)
78.30.00
Thrust Reverser (Structural
78.30.10
Thrust Reverser (Allowable Damage)
78.30.20
Thrust Reverser
(Repair)
End of Index
03/03/2001
Copyright

SE
0001
R3
Page
of
NIFG.
INTRO
Report
No. NA-66-1032
Sabreliner
Structural
Repair
Manual
ALL MODELS NA 265 AIRCRAFT
ORIGINAL ISSUE: 1 JAN 1967

REVISION NO. 10
REVISED: 16 MAR 1990
Sabreliner,
o
COPYRIGHT, 1990 BY SABRELINER CORPORATION
RECORD OF REVISIONS
MFG REV
NO
9
10
DESCRIPTION
Intro., Chaps 51 thru 57

See Revision Notice
Page
ISSUEDATE
ATPREVDATE
INSERTEDBY
6/3/1988
7/26/1988
ATP/JLB
3/16/1990
3/28/1990
ATP/JLB
NA-66-1032
STRUCTURAL REPAIR MANUAL
REVISION LOG
Assigned To:
Manual Control No:

Manual Located Al:
REV.
NO.
Basic/
Rev. Date
Insertion
Date
Inserted
By
1/67
Jan
Jul 18/74
Sep 25/75
Feb 27/77
Nov
25/77
Nov
22/78
Aug 14/81
Apr 15/82
Aug 17/84
June
10
Mar 16/90
Remarks
(Inltial)
3/88
Basic Issue Date
Complete Reissue
Chaps.
51 thru 57
Chaps.
6 thru 78
REVISION LOG
0
Page 1/2 Blank

Mar 16/90
RECORD OF TEMPORARY REVISIONS
ATP REV
INSERT
DATE
REV
REMOVE
ISSUE DATE
DATE
BY
REMOVED
INCOR
BY
9/29/00
3/15101
ATP/IB
TEMP
REV NO
9/29/00
DESCRIPTION
51-30-00:6A
(SIL57)
NA-66-1032
gTRUCTURAL BEPAIR NIANUAL
TR 89-1
TEMPORARY REVISION LOG
AselDned To:
Manrl Control Wo:

Msnutl Loalsd At:
Temporary
Rev. Do.
Insertien
Date
Inserted By
Renlerks
Ilnltiel)
TR 89-1
G.
~ai
L5,
891SEPT. 26/89
29/00
03/15/01
JLB
INCOIRP
RA
ATP/IE
I~LT
TEMPORARY REVISIO# LOG

Page 1/2 Blank

Aug 15/89
NA-66-1032
IMPORTANT
READ THIS NOTICE i i i
REVISION NOTICE
~6 MARCH 1990
SABRELINER
STRUCTURAL
REPAIR
MANUAL
ALL MODELS NA 265 AIRCRAFT
REVISION
INSTRUCTIONS
This is the latest Revision dated 16 March 1990, Revision No. 10 to your Sabreliner Structural
NA-66-1032. Insert latest revised pages, remove and destroy superseded pages.
This is a general revision to the manual
the following:
affecting the following chapters: Intro., and
1.
Incorporation of TR89-1,
2.
L.E.P. update (new format).
3.
Revised landing gear shock struts procedure.
4.
Addition of Batts
5.
Acres Fastener Sleeves
6 thru 78.
Specific
to this revision is
repair.
addition of kit numbers.
6.
Revised sealantstable.
7.
Addition of
8.
Revised elevator balance procedure.
9.
Revised damage limits for windshields and windows.
new
Repair Manual, Report No.
main entrance door repair.
10.
Addition of overwing fairing delamination limits.
11.
Addition of
flaps sonic doublers repair.
When revising your manual, the List of Effective Pages

reference for removing obsolete pages and inserting the
material remains in the manual.
Sabreliner,
CORPORATION
appearing in the front of the manual should be used as a cross

new and/or revised material. This ensures that only the latest
NA-66-1032
FRONTAL
LIST OF EFFECTIVE PAGES
Chapter/
Section
Page
TITLE
Date
Mar
16/90
16/90
REVISION LOG
1/2"
Mar
TEMPORARY
REVISION LOG
1/2
Aug 15/89
FRONTAL-L.E.P.
1/2"
Mar
16/90
CH-LIST
1/2"
Mar
16/90
The asterisk indicates pages revised, added,
or
deleted by the current revision.
FRONTAL-L.E.P.
Page 1/2 Blank
0
Mar
16/90
NA-66-1032
CHAPTER LISTING
Chapter
Title
No.
Frontal
Introduction
Dimensions and Areas
6
32
Landing Gear
51"
"2"
~3
Structures
Doors
Fuselage
54
55"
56
57"
78"
Nacelles and Pylons

Stabilizers
Wings
Exhaust
The asterisk indicates
Date
Mar 16/90
Mar 16/90
Mar 16/90
Mar 16/90
Mar 16/90
Mar 16/90
Mar 16/90
Mar 16/90
Mar 16/90
Mar 16/90
Mar 16/90
Mar 16/90
chapters revised, added,
or
CH.-LIST
Page 1/2 Blank
0
1Mar
16/90
NA-CiG-] OS%
INTRODUCTIBN
TABLE OF CONTENTS
Sul,jccl
Chapter/S~3ction/Suhjttct
~;enrral
Format
Pa#e
Intlo.
Repairs
Tat,le of (:ontents
List ol ~:fTeclive I
Part Nunlbers
Kevisions
I
ages
1NTRD.-CONTENTS
a
PaKe Ii" Hlank

AuR 17i84
NA-66-1032
INTRODUCTION
Chapter/
Section
Page
Date
INTRO.-L.E.P.
1/2"
Mar 16/90
INTRO.-CONTENTS
1/2
Aug 17/84
INTRO.
1*
2*
Mar 16/90
Mar 16/90
or
INTRO.-L.E.P.
0
Page 1/2 Blank

Mar 16/90
NA-66-1032
INTRODUCTION
GENERAL
The function of this structural repair manual is to

acquaint maintenance personnel with the approved structural repairs of the SABRELINER and to direct them in
the proper procedures for maintaining the airplane in an
airworthy condition. Only the installations made in the
airplane during manufacture have been reflected in this
manual. Changes made after delivery from the manufacturer are not included. The ability of maintenance personnel is recognized, and those procedures which are
considered common to all aircraft have been briefly refer-
A list of effective pages is provided with each chapter. It is

an inventory of the pages in each chapter with the latest
revision date for each page.
enced
or
omitted,
provides coverage for the following models:

NA 265-40; S/N 282-1 and Subs (Includes airplanes
modified by
STC SA1674CE)
This manual
NA 265-60;
NA 265-65;
NA 265-70;
S/N 306-1 and Subs (Includes airplanes

modified by
STC SA687NW)
LIST OF ILLUSTRATIONS
Each chapter is prefaced with a List of Illustrations identifying the subject in the order of presentation.
LIST OF TABLES
S/N 370-2 thru -6,

PART NUMBERS
S/N 370-1 and -7,

and 380-1 and Subs
This manual is to be used in

able maintenance manual,
(Includes airplanes
modified by
STC SA847NW)
conjunction
with the
applic-
FORMAT
This manual has been prepared in accordance with Air
Transport Association (ATA) Specification No. 100 to
guide the repairman in the inspection and repair of
Sabreliner Airplanes.
REPAIRS
covers repairs that are common to more than
airframe structural group. These repairs are arbitrarily classified as "typical" and "general" in that different approaches were taken in their concept and must
be taken in their execution. The typical repair portion of
the chapter provides that data necessary for the repair-
Chapter 51
one
to develop his own repairs. The general repair por

tion of the chapter covers repairs in a conventional
is conmanner; that is, all data necessary to the repair
tained within the repair illustration, with the exception of
references to materials and processes.
man
Chapters 32, 52 thru 57, and 78 is

repair indexes for each chapter. These
indexes consist of a master group repair index, and component repair indexes as applicable. Repair indexes give
the SABRELINER drawing number, descriptive nomenclature, material data, and figure number(s) for each item
Repair
Th, manual contains a general table of contents listing all

the chapters in the manual; in addition, each chapter is
prefaced with a table of contents identifying the subject
matter within the chapter in the order of presentation.
The table of contents is arranged with the following headinffs: DESCRIPTION, or STRUCTURAL IDENTIFICATION, NEGLIGIBLE DAMAGE, and REPAIRS.
As applicable, the chapter is prefaced with a List of

Tables identifying the subject in the order of presentation.
S/N 465-1 and Subs

-8, and -9
NA 265-80;
TABLE OF CONTENTS
coverage in
found in the
This manual must not be used for identifying spare parts

by number. Consult the SABRELINER Illustrated Parts
Catalog for this information. Part numbers are used in
this manual only as a means of identification when the
nomenclature alone is inadequate. The numbers are often
not complete. Dash numbers are used only when required
because of material, gauge, or geometric differences.
REVISIONS
The "LIST OF E FFE CTIVE PAGE S" with each chapter
serves as a tool for maintaining the manual. The "LIST
OF EFFECTIVE PAGES" will be revised whenever the
material in the affected chapter is revised. When revision
pages are received, the list should be used as a cross
reference for inserting the new/revised material and
deleting obsolete material. This ensures that all obsolete
material is destroyed and the manual is kept current.
Revisions to the text are indicated by change bars (vertical lines) in the margin adjacent to the revised material.
Revisions to illustrations may be indicated by change
on electrical schebars, zip-a-tone shading
matics, andpointingfingers
draulic, and pneumatic diagrams.
on
mechanical, hy-
A "REVISION LOG" page is provided for recording revisions by revision date and the dates they were inserted in
the manual.
A "TEM PORARY REVISION LOG" page is provided for
recording Temporary Revisions (yellow sheets) by reViSiO" number, issue date, and the dates they were
i"serted in the manual.
illustrated.
INTRO.
16/90Page 1I
Mar
NA-66-1023
INTRODUCTION (Contd)
NON-SABRELINER APPROVED PARTS
Only Sabreliner parts or Sabreliner approved parts

obtained from approved sources are to be used in connection with themaintenance and repair of Sabreliner
airplanes.
Genuine Sabreliner parts are manufactured and inspected under rigorous procedures in accordance with a Production Certificate (PC) to insure airworthiness and suitability for use in Sabreliner aircraft application. Parts
purchased from sources other than Sabreliner, or its
approved vendors, may not have the required tests and
inspections performed and may be different in fabrica-
tion techniques and materials. A non-approved part may

seriously compromise the safety of the aircraft.
Government surplus parts, salvaged airplane parts,
reworked parts obtained from non-Sabreliner approved
assemblies
sources, or parts, components or structural
which do not have proper documentation may have a service history which is unknown or cannot be authenticated.
These parts may have been subjected to unacceptable
stresses or temperatures or have hidden damage which is
not discernible through routine visual or usual nondestructive testing techniques. This may render the part,
component or structural assembly unsuitable and unsafe
for aircraft use, even if such part, component or structural
assembly were originally manufactured by Sabreliner or
an
approved
Sabreliner
source.
Corporation expressly disclaims
any respon-
sibility for malfunctions, failures, damage or injury

caused by the use of non-Sabreliner approved parts.
NOTE
Sabreliner Corporation ezpressly
the right to supersede, cancel
andlor declare obsolete, without prior
notice, anil part, part number, kit or publi-
reserves
cation
referenced in this manual.
INTRO.
IMar 16/90c
C H A PT E R
DIMENSIONS
AND AREAS
NA-66-1032
STRUCTURAI, REPAIH MAKUAI,
CHAPTER 6
DIMENSIONS AND AREAS
TABLE OF CONTENTS
Sul,ject
I)imensions and Aleas
Airplane Stations and Measurement
C h apte r/ Sectiu n/Su bjeel
Page
06-00-00
Syslems
(;encral
Fuselaae Refelence Systems

WinR K.efcrence Systems
Empennage Keference System
6-CONTENTS
0
~aKc 1/~ Hlank

AuP; IT/~4
NA-66-1032
STRUCTURAL REPAIR MANUA1,
CHAPTER 6
Section
06-00-00
Figure No.
1
2
3
4
5
6
Page
Title
Fuselage Measurement System

Diagram Model NA 265-40, and -60
Diagram Model NA 265-60A, and -60SC
Diagram Model NA 265-65
Diagram Model NA 265-70 (S/N 370-2 thru -6,
-8,and-9)
Airplane Station Diagram Model NA 265-70 (S/N 370-1 and -7);
Airplane
Airplane
Airplane
Airplane
Airplane
Station
Station
Station
Station
5
6
7
also -80
7
8
9
10
II
Airplane
Airplane
Airplane
Airplane
Airplane
Station Diagram Model NA 265-80A and -80SC

Fuselage Station Diagram Model NA 265-40
Fuselage Station Diagram Model NA 265-60, -60A and -60SC:....
Fuselage Station Diagram Model NA 265-65
Fuselage Station Diagram Model NA 265-70, -80,
1:i
-80A, and -130SC

12
Airplane Wing Measurement System Model NA 265-40, -60,

14
-70, and -80

13
14
15
16
17
18
9
10
11
12
Airplane Wing Measurement System Model NA 265-60A, -60SC,

-65, -80A, and -80SC
Airplane Wing Station Diagram Model NA 265-40, -60, -70, and -80
Airplane Wing Station Diagram Model NA 265-60A, -60SC,
-65, -80A, and-80S(=
Airplane Empennage Station Diagram Model NA 265-40, -60,
-60A, -60SC, and -65
Airplane F,mpennage Station Diagram Model NA 265-70, -80.
80A, and -80SC
Airplane Empennage Station Diagram Model NA 265-60A, -60SC,
-65, -70, -80, -80A, and -80SC
15
16
17
18
19
20
6-ILLUS.
o
Page 1/2 Blank

Aug 17/84
NA-66-1032
CHAPTER 6
Chapter/
Section
Page
Date
16/90
6-L.E.P.
1*
Mar
B-CONTENTS
Aug 17/84
6-ILLUS.
Aug 17/84
06-00-00
1
2
3
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Bug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Bug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
hug 17/84
Aug 17/84
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
or
6-L.E.P.
Page 1/2 Blank
0
COPYRIGHT, 1990 BV SABRELINER CORPORATION
Mar
16/90
CHAPTER 6
AIRFLANE STATIONS AND MEASUREMENT SYSTEM
(;ENERAL
WING REFERENCE SYSTEMS
A brief outline of the airplane measurement system,

(fi#ure 1) is offered to assist the repairman in the use of the
airplane station diagrams shown in figures 2 thru 18.
Only those reference planes from which component
Several reference systems are used to describe the wing

and its various components. The wing reference plane is
an arbitrary plane across the wing cord plane from which
vertical dimensions are taken. Fore and aft dimensions
are taken from the 41.3 0~ element or plane. Wing stations
are normal to, or canted from the 41.3% element. Canted
wing stations are designated by where the canted station
intersects (or would intersect if extended) the 41.3%
element. Dimensions for determining the 41.3% element
are given in the figures as follows for:
stations originate
are
given.
FUSELAGE REFERENCE SYSTEMS

There are two principal reference planes in the fuselage
from which all dimensions relative to the fuselage are
taken: The fuselage vertical center plane, and the fuselage
reference plane (horizonal). The fuselage vertical center
plane divides the fuselage vertically and longitudinally.
The fuselage reference plane divides the fuselage hori-
zontally and longitudinally. The fuselage reference plane

is approximately at the fuselage maximum cross section
and is identifiable by two flush-head screws (painted red)
on the right side of the fuselage,
On all Sabreliner airplanes these screws are located 2.375
in, below the fuselage reference plane at FS 142.375 and
44:~.125.
FuselsRe stations are measured in increments of inches

longitudinally along the fuselage reference plane. (See
fiRu res 8 thru 11.) All stations are normal (at right angles)
to the fuselage reference plane unless otherwise noted,
Canted station locations are determined by where the
canted station intersects (or would intersect if extended)
the fuselage reference plane. All stations are numbered
from station zero aft. Station zero is the forwardmost
point of the fuselage. Any addition to the fuselage fwd of
station zero is considered a minus (negative) station and is
intlicated as such.
planes are longitudinal planes parallel to the

fuselage vertical center plane. Positive (plus) buttock
Huttock
planes
are
to the left of the
(minus) buttock planes

center
vertical center plane; negative

to the right of the vertical
are
I,lane.
longitudinal planes parallel to the

planes
fuselage! reference plane. All water planes above the
reference plane are positive (I,lus): the water
planes below the IuselaRe reference pl;ane are negative
(minus) watel planes,
Water
are
Model NA 265-40, -60, -70, and -80 -(See figure 12.)

Model NA 265-60A, -60SC, -65, -80A, and -80SC
(See figure 13.)

After the 41.3% element of the wing is established from
the dimensions given, any point on the wing can be
located. The point most easily defined is the machined
land for the wing tip attachment, located at the outbd end
of the machined skin. This point is wing station 203.158.
The distance is measured from the point in question to the
machined land. This dimension is subtracted from the
known point (293.317). The result is the wi ng station of the
desired point.
On Model NA 265-40,-60, -70, and -80, the slat stations are
normal to the slat hinge plane. Canted slat stations are
designated by where the canted station intersects (or
would intersect if extended) the slat hinge plane.
Dimensions for locating the slat hinge
figure 14.
plane
are
given in
O, Model NA 265-40, -60, -70, and -80, the centerline of

the flap hinge is the reference plane from which the flap
stations are designated. Flap stations are normal to this
plane unless canted. Canted flap stations are designated
by where the canted station intersects (or would intersect
if extended) the flap hinge plane. Dimensions for locating
the flap station are given in figure 14.
On Model NA 265-60A, -60SC, -65, -80A, and -t)OSC, all
flap stations are normal to the flap leading edge plane
with the exception of the canted flap stations. Canted flap
stations are referenced from the point where the csnte(l
station intersects (or would intersect if extended) the flaE,
leading edge plane.
of the th ree reference systems discussed, any poi nt

within the fuselage may be located. The station lines
furnish the longitudinal dimensions. The buttock planes
indicate horizontal dimensions outbtl from the vertical
center plane; the water planes provide vertical
dimensions above or below the fuselage reference plane.
Ry
u se
on or
06-00-00
0
Page 1
Aug 17/84
NA-(i6-1032
SIKUCTURAL RE:~AIR MANUAIJ
AIRPLANE STATIONS AND MEASUREMENT SYSTEM
(Continued)
WING REFERENCE SYSTEMS (Contd)

For all practical purposes, the aileron hinge plane can be
used to identify aileron stations. Although the aileron
reference plane and the aileron hinge plane are not
absolutely parallel, there is such a slight difference
between the two planes that for field measurements, the
aileron hinge centerline plane should be entirely
satisfactory. All aileron stations can be considered normal
to the aileron hinge plane except those stations which are
canted, Canted aileron stations are designated by where
the canted station intersects (or would intersect if
ext.cnded) the aileron hinge plane. (See applicable figure
14
or
if,.)
EMPENNAGE REFERENCE SYSTEM
Vertical stabilizer and rudder stations are both

designated from the rudder hinge plane, which is alsothe
vertical stabilizer 75"/0 plane. Station lines of both the
vertical stabilizer and the rudder are designated from the
75% plane of the vertical stabilizer and are normal to it.
All canted stations of the vertical stabilizer and the
rudder are designated from the vertical stabilizer 75%
plane.
Horizontal stabilizers and elevator stations are normal to,
designated from, the 75% plane of horizontal
stabilizer. This plane is identical to the elevator hinge
plane. Canted stations of both the horizontal stabilizer
and the rudder are designated from where they intersect
(or would intersect if extended) the 7556 plane of the
horizontal stabilizer.(For station locations, see figures 16
thru 18.)
and
06-00100
Page
Aug 17/84
COPYRIGHT 1984 BY SABRELINER CORPORATION
NA-66-1032
STRUCTURAL REPAIR MANUAI,
41.30io
ELEMENT PLANE
NOTES
[SEE FIGURE 12)
OS/N370-1
00
THRU-6.-8.and-9
SiN 310-1 *ND
51~ 38(1-1
X/
SUBS
lI
VERTICAL STABILIZER
REFERENCE PLANE ANO
260~ 492.07"
FUSELAGE VERTICAL
CENTER PLANE
C,
IC7L
98-7/84
O):tl
b
VERTICAL CENTER PLANE
IBUTTOCK PLANE
HORIZONTAL STABILIZER
REFERENCE PLAWE
004
8087 HINGE PLLNE
NACELLE
ISLAT REFERENCE PLANEI
VERTICAL
CENTER
FLAP HINGE PLANE
3" 835.32"
FLAP
IANO
REFERENCE PLANEI
75% PLANE OF
HORIZ STAB
PLANE
,j
WING REFERENCE PLANE
AILERON REFERENCE PLANE

AILERON HINGE PLANE
STATION PLANES OF THE AIRPLANE COMPONENTS ARE TAKEN NORMAL

IAT RIGHT ANGLES) TO THE VARIOUS REFERENCE PLANES INOICATEO.
28-1/18
FUSELAGE
FUSELAGE CENTER PLANE

WING
(CENTERLINE
OF
AIRPLANE)
...............WING REFERENCE PLANE AND WING

41.3% ELEMENT PLANE
SLAT
AILERON REFERENCE PLANE ANO AILERON
AILERON
VERTICAL PLANE
FLAP
...............FLAP REFERENCE PLANE ANO FLAP

HINGE PLANE (CEITERLINF: OF FLAP HINGE)
ANO ELEVATOR
FUSELAGE REFERENCE PLANE

PLANE O)
\75% PLANE)
....8081208780 STABILIZER REFERENCE PLANE

(75% PLANE) AND ELEVATOR RINGE PLANE
VERTICAL STABILIZER ......VERTICAL STABILIZER CENTER PLANE

ANO RUODER
PLANE) ANO RUDOER RINGE PLANE
(WATER
CENTERLINE RUOBER HINGE PLANE

(VERTICAL STABILIZER
(750/0
NACELLE VERTICAL
CENTER PLAIE
FSO
06.57"~
2~0
3~
Elo;nE
S265-32A
Airplane Fuselage Measurement System
Figure
0
06-00-00
PageS
Aug 17/84
P~
Q)
34
rl
r
x4
ro
ABBREVIATIONS
m
L~
3
CANTED
DC
DOUBLECANTED
AS
AILERON STATION
ES
ELEVATOR STATION
FS
FUSELAGESTATION
FSS
FRONT SPAR STATION
HSS
HORIZONTAL STABILIZER STATION
NS
NACELLESTATION
WP
968
90375
RUDDERSTATION
SS
SLATSTATION
REAR BEAI
TES
TRAILING EDGE STATION
62.50/ePLAIE
VSS
VERTICAL STABILIZER STATION
988
WS
WING STATION
17670
n
I
FS
FS
50
78
b3
too
FS
134
208
Fs
143
~113/70520
CVSS
298
Cp
641175
FS
IS1
ms
41.0311 1
80.108
32.187
392
mw6E UIE
CFS
FS
HDR STAEL
485
75% PUIE
IS
13&813
157.125
IS 99.775
107.750
V)
FUSELAGE
REFEREICE
ETES 51~284
FS
nS 80429
CAS O
AS 12.777
Ilg 72
OUTED
REAR SPAR
PURE
CAS
92802
CWS 291.816
AS 37.150
90.5
PLAIE
WIW6 41.3~/0
c7
PURE
m
~a
Fs
se
o
0
mrs
ss
11.1113
104.750
ass
it
SS
152.718
194.851
D
O
O
p
505
TES 30ffi7
OELEVATDR
FS
457.408
FS
CES 105.711
67.776
FS
PLAIE
519
525
HSS 4.158
11tIs25 IM
FS
FS
HS7.58/~
FS
FS
174
FS
a~
~jYTiy ~--WP32
ES 13~547
~D
RS
Fs
aop
13
RS 28.930
FS\/j\
FS
~3
m
n
RS 281130
357
333.g25
FS
77.847
75% PURE
Isa~
9 rs
caj~
~f
/111
FS
FS
CRS
RUDOER HIIE
AS
--WATERPLANE
6p
WP 108.076
7.5% PLAWE
RS
WP
1251148
FROWT
FS
FS
FS
reo
50
50
98
SPAE PLAIE
oureoFROIT
SPAR PLAIE
SS
236~984
CFSS
283426
306.7279
ABBREVIATIONS
O
a
13
DC
CANTED
AS
n
I
DOUBLECANTED
--AILERON STATION
ES
ELEVATORSTATION
FS
FUSELAGESTATION
FSS
FRONT SPAR STATION
988
90175
WP
HSS
NS
NACELLESTATION
RS
RUDDERSTATION
SS
SLATSTATION
TES
V)
VSS
a
a
WS
m
r
WATER PLANE
FLS
FLAP STATION
244
FS
Z
m
a
206+9
17.070
FS
RS
18.094
10
FS
250
FS
FS
FS
FS\
4!2 /fiS~.781
357
333.625
281
cySs
225
Zp:
/-WP 32
~Y4U
FS
FS 519
ES 13547
206
(p
525
~a
WS
FS
118625
en~
0
Z
RS 28.1130
YSS
FS
FS
a
a
WP 108.076--CRS
77.847
--WING STATION
WP
125.022
FS~
FS
299*21
392
~I
166.75
a~
TES29.169
32.187
3
m
FS299+16
NS
CFS 35.881
72
198 31.00
lo7.5a
CNS 89.429
198 161.122
C?
o
FUSELAGE
I i-1
156.844
CWS 99.775
WS
4111
FS
6a
485
WS136.813
60.108
FS
13
QELEVATOR
RINGE LIRE
FS
457.406
67.776
I,---
505
FS
~C
CES 105.711
FS
~oc
CHSS 105.711
WS 309.00
4812.777
ILH ONLYJ
198 261.788
REFERENCE
PLANE
m
WS 50.099
U
INBO
FROWT SPAR
PLANE
6
~PG71
FS
98
FENCE IWSTL
0UT80 REAR
SPAR PLANE
148 291.250
WING 41.3%
ELEM PLAWE
cl
c3
7;
m
a
~C57
16
FS
50
WS 157.0
c3
a
C
s~
2~
c c
5-;e
rt~
pa,
P
P;P
9~0)
e~
30"6
cctr
ABBREVIATIONS
C
CANTED
AS
ENS
ENGINE STATION
ES
ELEVATORSTATION
FS
FUSELAGESTATION
FSS
FRONT SPAR STATION
HSS
NS
NACELLESTATION
RS
RUDDER STATION
TES
VSS
DC
WS
WP
FLS
DOUBLECANTED
VSS
--AILERON STATION
~a
90975
I
WP 108.078
VSS
17.070
CRS
427.49
WING STATION
FS
-WATERPLANE
88181614
FS
299
FLAP STATION
10
412
RS 1.781
FS
Fs
5:
ra
206
9~
(p
O
73
cr:cp
FS
~Za
67.776
FS
Fs
2~5
FS
208+9
281
eVSS1.781
//FS505
FS 519
250
FS 525
118.625
IS 78563
EWS 236833
Cnti.
g
llII/
1//1
357
ent=
--I
X;
FS 485
FS
LP~
"7
FS
;p
r
RS 28930
333B25
Z
C
77.847
FS
0888105.711
FS
3~2
105.711
CL ELEVATOA
WS41.m
ES
EYlrmm~
Eu
81162 LINE
1.828
CFS 457.408
Fs
13
FS
TES 29.169
299\\
+16
CFS 35.661
o,
FS
20.I)80
EWS 178950
WS31aa~
NS 59.440
ea 212710
168 181.122
198 303.00
dg IP7TI
(U OILYJ
m
Jo
WS 281.788
i, I/
m
r
Z
m
ID
O
O
13
73
O
ra
198 50a99
INRO
FRONT SPAR
PLANE
FUSELAGE
REFERENCE
PLANE
FS
O
Z
FS
50
98
183 157.0
OUTED REAR
FENCE INSTL
SPAR PLANE
138 291.250
WIWG 41.30/a
ELEM PLANE
ABBREVIATIONS
O
n
II
DC
CANTED
DOUBLECANTED
AS
ES
ELEVATORSTATION
FS
FUSELAGESTATION
FSS
FRONT SPAR STATION
VSS
HSS
90375
m
i
V)
m
n
--AILERON STATION
NS
NACELLESTATION
RS
RUDDER STATION
CRS
77.847
SS
SLATSTATION
TES
VSS
WS
WING STATION
FLS
FLAP STATION
/1II
RS 18.094
933
17.070
IIH/
~D
FS
412
FS 485
333.625
jFD
FS 505
Fl
FS
FS
250
FS
FS
~wo
~3
vlo
206+17
299+10
200c9
CES 105.711
118.625
ES
FS
13517
525
ELEVATOR
CFS 457.406
P,
FS
HINGE LINE
WS 166.75
67.776
C~
do
ns
FS
SN318.5
156.844
WS 99.775
13
CNS 89.429
EL
FS 299
TES 30.077
ilo
16
REFERENCE
PLANE
CWS
SS
(LH OWLYI
O,I
FS
98
INRO FRONT
104.750
SPAR PLANE
C3
c3
SS
152.718
SS
AS 12.777 ILR ONLYI

4337.750
74.183
50
CFLS 171.345 CAS O
CWS 291.846
FS
NS 72
FUSELAGE
NS 107.50
CNS
60.108
oo-I
CHSS 105.711
225
FS
CI~-
FS
519
FS
299+21
09~
cvssl.7s1
FS
ul
357
281
SI1
D
/831.781
r/lY
Fs
0
O
RS 28.930
SS
194~851
SPAR PLANE
CFSS
236.984
OUTBO FRONT
OUTBO
CFLS 68.336
REAR SPAR
CTES 51.284
PLANE
306.7279
CFSS
283.626
~Cn
c: O
;p Co
rt5
ED
~d p
ipg)
c~
C
ARBREVI~TIONS
4,
CANTED
DC
DOUBLECANTED
AS
~FI
m
--AILERON STATION
FI
ES
ELEVATORSTATION
FS
FUSELAGESTATION
933
FRONT SPAR STATION
90175
FSS
HSS
Na
NACELLE STATION
RS
RUDDERSTATION
SS
SLATSTATION
TES
77.847
FS
RS 28.930
427.49
RS 18.094
VSS
WS
WING STATION
412
FLS
FLAP STATION
988
171170
no
9~
//~Y//
5
p
FS
FS
llsp25
225
FS 505
FS 519
357
sr~n/ //.FS525
FS
294.10
FS
1~08+17
,FS485
~Y/
FS
281
FS
250
333.625
FS
FS
208+9
Rsl.781
CVSS 1.781
FS
0~
CRS
Z
N
0833 10SJtl
llY751///
/CES105711
O
a
a
n
I
~f
CL
Fs
2981
67.n~FS
Q)Bb
*17
ij
rq
a,
j3
Es
1.620
Fs
CFS 457.406
13
C ELEVATOR
H116E LINE
IS
TES 301117
FUSELABE
REFEREltE
;o
PLANE
WS
FS 299 *16
OS
WS
V,
151812
126.437
85562
WS
CFLS 171.345 043 O
22a
aoo
a
a
m
As 31.750
(LH DWLIJ
AS 12777
ILH ON1Y1
FS
m
30
511
O
0
VI
I
CWS
74.183
FS
98
152.718
SS
104.750
INBD FRONT
JaSPAR
0103 291.846
I-lss
SS
194.861
OUTRO FRONT
~LAWE
SPAR PLANE
GFL3 68.336
CTES 61.284
SS
238~984
I
OUTRO
REAR SPAR
PLANE
CFSS
308.7279
CFSS
283828
Z
e
r
O
o
ABBREVLATIONS
33
C)
I
m
V,
m
IX3
m
CANTED
DC
DOUBLECANTED
AS
AILERON STATION
ES
ELEVATOR STATION
FS
FUSELAGESTATION
FSS
FRONT SPAR STATION
HSS
NS
NACELLESTATION
RS
RUDDER STATION
SS
SLATSTATION
TES
VSS
FS
WS
WING STATION
427.49
FLS
FLAP STATION
988
90.375
CRS
FS
412
118.625
Q,M
FS 485
~oEl
~1
FS
FS
FS
n5
FS
FS 525
299.10
CHSS 105.711
CES 105.711
FS
2981
FS
tl
Fs 519
387
250
206+17
FS 506
Fs
281
206+9
n,
II
RS 1.781
CVSS 1.781
333.625
FS
FS
FS
P,
2:
RS 18.094
17070
FS
0
0
13
/8828.930
988
m
So
77.847
67676:
*17
I-
P,
FS
b~
13
Es
1.826
FS 2I~
15
CFS 4R.406
CL ELEVATOA
HINGE LINE
CFS 35.661
FUSELAGE
WS
TES 30877
IS
WS
WS 31.00
REFERENCE-I
WS
PLANE
IS
151.812
126.437
65.562
22.0
J:
WS 161.122
4812.777
ILH OWLYI
198 501)99
198261.788
llRO
FS
50
1
~v
I
FS
98
FRCWT SPAR
PLANE
Y~
108
rE~
oo
4t0
s~
C~
C
X
3
15~7.0
FEWCEIWSTL
OUTBO REAR
WS 291.250
71
WING 41.3%
ELEM
ep:
SPAR PLANE
168 303.00
PLAIE~CP.
z
t~
~car
n~ CI)
P
0407 STA
0487 STII
457.406
469.75
307.25
26415
~1
2986
432
324.75
257.562
316
215.5
126825
76
1501
90.5
182
401
E
9
Z
C
357
272.5
242
j 1
206
281
198
ga
25.8
co
174
190
143
118.625
a
g
224.5
443~
422
368
379
249.
166.25
390
351
5788~5
33
J~
13
r~-v
166.750
163.750
344
50
g,
m
d
505
412
333.825
~a
519
495
455
333.625
318
30725
O
o
OC~b 6J
;TF
289.53
O
P
j
f
P~ \IrX
264.25
157.150
324~75333.625
137.437147112
316
130.825
30725
84~98996.750
2986
122.688
115.406
108.375
72
V,
a
1]
m
r
m
a
108
99
90
so
O
1]
O
Z
f
50
76
206
NACELLE STATIONS
182
150
134
~D
174
155.251 --16525
143
161.75
~-126.625
NOTE
1~118.625
ALL
STATIONS ARE FUSELAGE
OTHERWISE INDICATED
STATIONS UNLESS
7-1
CANT
874
469
.75
"5
m
298
298
215
z
166
i~J 1~2
1~ 15qi158!
j15! I"
ia1
II
o
O
O
~cl
3
Da
Zs
S~E
5P
i 25
83.5
6;7
90.6
/43 i
i jT28f1143
9~
f
+9
188
.__
.lt5
272
333
.5
316
357 3~
4~1 "g
443~cnlTi
i
374
457
,i
12jf91
125!1~51ei
j242!i$i
fi~13 !+!!7i
i
i
i i
ii
168
;xi
-i
i
Z
1" 519I
r;f~n
357 i
iLE;1
i;t
i
ii
i.
i-
il
"3
i
as:
Izssiil
i-i f
i
i156
5~
b
.7"
333
318 .625
3071
.25 i
teo~i
6
163
378 6
7b
~g
Ilzs 1143f.25
i
!.625 i
118
134
i198i12~ j
285
is;
.25
lj4
1W
2~6
.25
206
.5
298
.5
.5
r\ h
i.l"
!.25!
298
.75
j
13
.625
+215
i
.600
~17
ii
,s i Ijd7i
108
1.625 ~.3121
lh2 la7 1e7
.375
.688
AOS
.750
.437
.750
.625
NOTE
ALL
STATIONS ARE FUSELAGE
STATIONS
UNLESS
NACELLE STATIONS
;f
OTHERWISE INDICATED
j~
G
to
NA-6(i-103~
SIHll("llilii\I, RE:PAIK MANI!AI,
FUSELAGE CAWTED 467.4
U-C-- 519
505
495
485
475
485
cr,
455
449.2
443.5
432
422
i
51
412
401
390
379
a0
388
w~
357
348.5
o
z
333.8
Ow
324.8
RT?
316
3076
F
49
=E
2BB.5*Z1J
298.5+ 10.5
288.5
289.5
281
272.5
284.3
257.8249.1
242
233.5
224.5
2158
206+ 11
O
MB
188
180
182
174
186.3
158.5
150
143
134
128.8
118.6
108
98
90.5
83.5
78
87
50
40.3
33
25.8
4852-m21
Airplane Fuselaffe Station Diagram
06-00-00
Page 12
Aup 17/84
Model NA
erugiFT6-52
10
257
298
.56
n
t)
I
--1
182
166
118
25
.812
13
V)
1-33
76
58
40
90.5
67
.625
143
312
50
150
134
98
83.5
206
190
174
215
233
.5
.5
+9
25
158
)26
206
198
212
249
.125
289
.5
522
.5
499
.OB
509
485
CAIT
443
401
379
.5
.406
.625
.5
.25
367
333
316
298
390
360
15
+10.5.25
298
264
242
260(224
.5
.5
346
324
307
455
432
412
CANT
STA
470
+21
+1715
.25
.62
m
a
m
r
mzn~
O
Z~
a
a
ES
~(P
Ej
rj~p
Is4
oo~
dO~
(P
Oy~
=bB
eg
O
475
449
ill
pp
8~6
78
35.5
t~
.0
a$
do~
0
18(
108
90
;OB
.F*
155
143
126
182
res
150
198
1i4
tao 205
.25
298
.5
.5
.44
206
316
298
324
+21
289
s
298
.5
JOI
.75
JB
.25
.5
465
428
384
406~
.5
.5
.5
.25
MI
.250
+10.5
+17
373
.5
333
.625
417
395
.26
33~
318
.625
351
.625
344
3n
152
.875
.440
147
368
1.586
46
.312
166
.750
.625
398
mJ
21
333
.625
316
.5
C)
307
324
.250
.75
367
342
379
368
412
401
151c:
.5
.812
X
C
C1
S/N 370-2 THRU 6. 8 ANO
65
9
E
aq
22.0
cdr
.562
126
.437
130
.625
p
c6
leB
In
.969
13T
.375
.688
.437
NOTE
NACELLE STATIONS
IACELLE STITIOWS
a
1
4W-
115
.406
Lz
S
~a
96
.750
72
S/N 370-1. -7. AWO S/N 380-1

~wo suss
ALL
STATIONS ARE
FUSELAGE STATIONS
OTHERWISE INDICATED
UNLESS
6:
r
C
rP~S
NA-66-1032
FUEL FILLER
CENTER LINE
OF
FUEL FILLER
WINS 874 281.BW
IQ!
Establish
point
on
the 41.3% element
wing, by drawing
fasteners indicated.
~je
2
18m
at
an
inbd
centers of the two
that it intersects canted
From
point established at
along station 59.095.
wing
at
station 59.095, measure
12-15/16 in.
at which the 41.3% element
IT
12-15/16
o
i
~f
nNs STA
288.850
This establishes the
plane intersects station
point
59.095.
El
Establish the 41.3J6 element plane at outbd end of wing

by drawing a line through center of fuel filler fasteners
41.3%
ELEMENT PLANE approximately parallel to the 41.3% element plane.
0.1 782
0.1762 in. from line
through center of
plane at the
fuel filler. This establishes the 41.34b element
Fl
(W(
fuel filler.
CANTEO
581086
ATS01 W
Draw
inbd
point established
point established on fuel filler to

wing station 59.095. This
locates the 41.31 element plane along the entire wing.
WINS 41.3%
ELEMENT PLANE
BI
line tram Ihe
at canted
OUse
the
plane
inbd lower surface
on
same melnod
element plane
on
pianealan
Outbd
wing by measuring 0.0977
281.850. This establishes the

element plane intersects
wing
point
point
on
in. fwd of the
wing
station
at which the 41.3%
station 281.850.
Locate the 41.3% element plane along entire wing by

WING 878
connecting point established at wing station 281.850 and
85.810
point established at canted wing station 59.095.
CANTEO WIIB
874 69.095
CANTEO WING
STA 69.095
used to locate the 41.3%
inbd upper surface.
seventh from forward-most rib fastener at
UPPER SURFACE
WING 41.39/0
ELEMENT PLANE
lo locate the 413h eiement

as is
Establish the 41 39belement
lower surface of
plane
through
station 59.095
I~?
f.
so
line
CANTEO WING
874 50088
WING STA
WINO STA
85.810
Isl.sso
8.
fBi
6-fi/
WINOSTA281.850
O
;.I
19/32
Q;_,is?
i~
t
FASTENERS
o.oer
LOWER SURFACE
18
z
4
06-00-00
Page 14
Aug 17/84
Ig\
a,
Airplane Wing Measurement System

Model NA 265-40, -60, -70, and
erugiF0812
COPYRIGHT, 1984
BY SABRELINER CORPORATION
NA-66-1032
EJ
Eltabli.h the
surf ace
canted
element
plane
by drawing by a centerline on
wing station 59.095.
O:Extend
centerline afl until
centerline of the fastener
row
it
tne
on
El
wing upper
strip over
the closeout
with
i,,,,,,,,.
the
wing
CLOSE OUT STRIP
B
FUEL FILLER
/13~Y
I 1
~L
\1
1D/a2
28.625
locates the 41
I/
surface.
for
through
center
line from the
point established on the fuel

point established on the closeout strip. This
.3% element plane along the entire wing upper
Establish the41.3% element
surface by drawing
WING
El
112-15/16
(Q
0.1762
~--i
Draw
:1
point
filler to the inbd
~j
Measure fwd 01762 in, from line
OF
FUEL FILLER
I(B
inbd
an
plane.
fuel filler.
CENTER LINE
lo/
28.625 in.fwd along the
of fuel filler. This establishes the 41.3% element plane at the
El
WINGSTA281.850
measure
Establish the 41.3% element plane at outbd end of

wing by drawing a line through centerof fuel fillerfasteners
approximately parallel to the 41.3% element plane.
the
upper skin
to the rear spar.
;-Tasl
intersection,
centerline. This establishes
strip
the 41.3% element
securing
~f
From the
closeout
indicated
41.3%
ELEMENT PLANE
so
line
59.095.
WING STA
point established at station 59.095,

along station 59.095. This establishes
From
12-15/16 in,
286850
at which the 41.3% element
I,
CANTED WING
that it
plane on the wing lower

through the two fasteners
intersects with canted wing station
a
ATS%359.095
.14
WING
ELEMENT PLAIE
on
Ijl
plane
an
wing by measuring 0.0977
seventh from forward-most rib fastener at

231.850. The establishes the
element
plane
intersects
point
at
outbd point
in, fwd of the
wing
station
which the 41.3%
wing station 281.350.
Loc~le Ihe4l.l.element
connecting point established
UPPER SURFACE
point
intersects station 59.095
Establish the 41.3% element plane at
lower surface of
measure
the
at
plsneslong entire wing by

wing station 281.850 and
point established at canted wing station 59.095.
CANTED WING
STA 59.095
85.810
WING 41.3%
ELEMENT
WING STA
PLANE
CANTED WING
STA 59.095
(P
CANTED WING
87450.095
WINOSTA
85.810
~-e,:
WING TA
281.850
I "-t-/)
II
WIND STA 281.850
28.625
ID
18/32
;Qi
iol
iii f
"7248728288
0.097
(B1
LOWER SURFACE
\g
8:
Airplane Wing Measurement System

Figure
0
13
06-00-00
Page 15
Aug 17/84
NA-Gfi-1032
SIHUCTUI1AI, REPAIR MANUAL
FS 128.848
FS 123.840
FS CsT
FS
18991
FS 143.713
FS 148.756
FS 13.789
FS 79.269...FS 84.789
FS 87.393
53 82.333
FS 97.074 r;:
FS 101.914
FS 158.881
~.. ..1: :;."_:.
FS 118.040
162.381
F3 187.881
FS 111.974
:I"~FS
108.774
FS 151.381
FS 171.345
AS 12.584
AS 22.878
CWS 47.890
AS 0
AS 3.500
AS 17.500
AS 27.250
43 37.750
BCWS 0
CTE330,079
0wsln.sn
CWS 24.844
TES 33.884
TLS 38.595
452811
i i
6WS S~085
OCWS39.187
liiire
i i:i
i:
AS 43.000
AS 53.000
AS 84.000
TES 47.987
ii~L. CT~S
CWI IB.BTBi
As 89.250
AS 74.500
11 78.500
AS 81.500
As es.reo
49,818
i...
CrtS 512111
cwS 58.121
CWS 65.501
AS 32.500
ass 89.070
RSS 94.758
43 82.802
CWS 74.183
we
a8.elo
RSS 113.758
163 79.070
RSS 127.758
193 92.230
W8 IObs80
193
A88 152.10
119.850I
RSS 173.685
198 133.910
WS148.480f
se 73.297
193 171.820
88 85.937
css 78.787...
193 211.750
wsli.oaoj
193 239.650
j~
193 185.050
193198.350
.ss113.109
88 75.859
CSS 77.203
193 268.850
FSS 93.421
83 90.499
FSS 113.375
SS 115.871
FFS 137.438
SS 144.380
FSS 180.375
Ss 163.499
FSS 183.082
se 104.438
sJ 111.852
SS 82.065
SS 60.315
SS 97.858
as 105.082
SS 114.702
SS 121.858
SS 129.082
SS 142.797...
SS 153.032"
SS 182.530
SS 189.885
ABHREVIATIONS
SS 179.578
SS 186.859
C
CANTED
DC
DOUBLE CANTED
AS
--AILERON STATION
FS
FLAPSTATION
FSS
FRONT SPAR STATION
RSS
REAR SPAR STATION
SS
SLAT STATION
TES
WS
WIN~ STATION
06-90-00
Page
Aug 17/84
193 225.750
88141.828
193 254.350
38 180.937
198 281.850
CWS 261.848
88 185.140
1~ -J/h
58 202.031
85 227.328
88187.702
FSS 282.484
88 204.593
FSS 224.750."
38 138.285
gS 228.890
88 152.406
FSs 244.781
.""85 181.780
gg 240.208."
FSS 283.875
33 270.265
85 184.109
CSS 278.377
gs 194.539
i""
SS 243.700
z..
LI
SS 287.703
CFSS 308.728
88 2(02.874
SS 228.297
SS 238.872
SS 244.548
SS 288.672
33195.163-SS 203.824
SS 210.780
33221.785
SS 21047
SS 237.286
SS
SS
c.~-
252.451C
SS 282.141
SS 289.422
Ailplane Wing
Station
030 275.874
S265-3-511
Diagntm
Model NA 265-40, -60, -70, and

14
erugiF08-
16
NA-GCi-1032
STHUCrUHAI, REPAIR MANUAI,
WING
303.0
AILERGN
92.8
88.7
81.5
75.5
74.5
283.5
11 n
275.8
U_rn
289.5
75.2 CTD
89.2
84.0
58.1
53.5
482
43.0
37.7
32.5
27.2
22.8
17.5
8.5
TRIM TAB
LH AILERON
ONLY
292.0
CTO,~
324.9
261.7
1.0
~291.2
308.9
74.6 CTD
U_
T1
300.8
281.8
cc-_n
ii
ii
273.3
ii
254.3
287.8
288.8
1_L
71
I
I
17.1 CTD
258.7
12.5
239.8
FLAP
1058 CTO
0.0 CANTED
ii
,244.7
225.7
230.5
163.0
i
157.1
211.7
~1
)Ol.l
217.0
198.3
151.2
145.5
173.8
M3.7
138.9 CTO
129.9
132.7 CTO
158.9
124.1
152.4 ----C--_ I
113.3
1125
108.7
101.0
95.2
34.0 CTO
111.8
11
159.0
185.0
148.4
120.7
89.4
185.0
190.2
137.3 CTO
IIO.BCTO
135.0
127.7
83.8
77.1
71.0
BB.O
82.5
57.0
51.5
48.0
40.5
!_1
-~7-i--
/i
152.3
113.7
i\
138.2
1 19.8
105.0
Bs.O_OO.e
I I
i\
85.6
124.3
105.9
58.9
110.5
48.1, I
\-C--~t--tt--tLFF------
92.2
91.3
79.0
38.4
33.1
84.0
85.8
75.0
87.5
24.0
59.0 CTD
50.0
47.8 CTO
41.8
OUTDO REAR SPAR PLANE
NOI~
1~
41.3% PUN~
ALL WING STATIONS ARE PERPENDICULAR TO 41.3% ELEMENT PLANE
37.1 CTD
LEADING EOOE
OUTBO FRONT SPAR PLANE
4652W-22
Airplane Wing Station Diagram

Model NA 265-60A, -608C, -65, -80A, and -80SC
Fiffure 1Ti
cc,
06-00-00
Page 17
AuR 17/n4
NA-66-1032
0933 80.375
0933 85.000
CAS 77.847 CANTEO
CYSS 78.997
0988 72.170
72.414
933 86.375
AS 88.986
988 59.825
RS 88.154
AS 81.424
993 53.275
AS 58.853
vsS
48!725-
AS 52.282
-~-7ML---,
AS 47.711
988 40.175
AS 43.140
988 33.825
AS 39.100
AS 34.218
Vss 25.345
RS 33.406
AS 28.930
638 17.070
AS 23.824
7/
938
C..--.l(----)-----
11
933 0.520
Re 18.094
E---U--C------ As 14.188
As 8.693
RS 8.288
I~
CVSS
-t.ATs
As 1.781
TYI
68 84.813
ES 30.250
I
68 34.125
ES 38.000
68 78.150
LS 45.275
i 68 49.000
VERTICAL STABILIZER/RUDDER
IMOOEL NA 265-40, -60, -604, -6080 606 -65
52.562 i
68
1ES
i-ES72.888
ES 41.750
CES 13.638
1-~SBB.gBB
--E180.812
r-
68 84.875
i--
ES 89.375
i--
22.260
ES 83.875
-Esss.Ja9
-8.250
ES 89.281
ES 58.094
28.250
68 67.008
CES 105.711-
j
i
CHSS
HSS
23282
13.458
A RH RE V I ATIONS
C
1118
HSS
38.415
49.588
HSS
HSS
HSS
HSS
HsS
ASS
ASS
29.838
4211
58.362
70.256
84.368
98.480
VSS
VERTICAL SfABILIZER STATION

ELEVATOR STATION
RUDDER STATION
CHSS
18.340
CANTED
RS
ASS
91.424
0833
HSS
ES
HSS
77.312
83.200
105.71 1
HORIZONTAL STABILIZER/ELEVATOR
MODEL NA 265-40 AND -60
NO1~F:
SEE FIGURE 18 FOR -60A. -60SC, and -65 HORIZONTAL
S265-3-611
STABILIZER RUDDER
06-00-00
Page 18
Auff 17/114
Airplane Empennage Station Diagram

60A, -60SC and
Model NA 265-461, -60,
eruffiF5616
NA-CiG-103%
KIKI:CTIIKAI, KEII-ZIK MANUAI.
CVSS 90.375
CAS 77.847
CANTEO
cvSS 85.080
cvSS 70997
II
UI1
AS 72.414
-111
CVSS 72.170
RS 66.966
CLq
938 66.375
VSS 63.100
AS 66.154
AS 61.424
VSS 59.825
as 56.853
LUJ c--~t
vSs 58.550
988 53.275
AS 52.282
YSS 50.000
988 48.725
988 43.450
~k;Y/
AS 47.711
I_ILI
II
AS 43.140
988 40.175
AS 39.100
938 36.900
938 3315
\II
Lu~ C--~rsJIb
AS 34.218
AS 33.406
AS 28.930
988 25.345
AS 23.824
VSS 21.208
933 17.070
II
I 1L]
as 18.094
AS 14.188
vSS 8.795
"I\~\
AS 9.693
AS 8.288
YSS 0.520
AS 1.780
933-8.165
AS-2.856
VSS15.559
AHMF1EVIATI()NS
C
VERTICAL STABILIZER AND RUDDER
CANTED
HSS
VSS
VERTICAL STABILIZEH STATION
ES
ELEVATOR STATION
RS
RUDDER STATION
SJlO;iJ

Model NA 265-70, -811, -80A, and -80SC
Figure 17
06-00-00
Page 19
Aug 17/H4
N~-(ifi-1OSL
KII(I:("rllliAI, HEPAIH MANIIAI,
58 52.582
Eg 46.000
A
E145.375-/
ES41.750-1 i
CANTED
HSS
VSS
ES
ELEVATORSTATION
RS
RUDDER STATION
ES 38.000 r
LS30.250~5
i"""" ES57.M~
i"""". 58 64.813
ii
ES 68.888
ii
i Pi
ES 72.888
i i
i i i i
rEseo.eln
i i
lii
i"~""ESB8.315
rLS93.875
~a f
i
ES 76.750
ES 13.547
53 22.250
ES 61. 062
CE3 16.2501
ES18.250i
1 1
I
~S34.1251
I""" 53 58.094
~I
E384.875
ES 28.250
HSS
CHSS
Es 1111.281
29.839
i 1""""50.45
13.456
r-ES98.350
HSS
Q~
HSS
I-hU~3
HSS
:i
49.568
HSS
sa.asn
i
CHSS
18.340
0E3 105.711
i,
i
6
HSS
23.282
HSS
38.703
HSS
HSS
28.550
HSS
52.479
HSS
33.127
63.200
HSS
H~S
70.258
1188
77.312
45.914
HSS
HSS
84.368
MOOEL NA 265-70 18/0 3j0-2 THRU -6, -8. ANO -9)
1188
91.424
0883
se.sso
105.711
ES 52.582
ES48.rm-I
ES 2.120
Ii
ES 38.WO!
"...ES1I.IM
58 41.750
~S 0.744
58 45.375--r
ESI.LSO!
0E3 4.921
i
i
i I i
i~
ES 14.830 -t...,i
63
0833
ES 22.250
i
iii
ii
i
I
i
r~
i
i
i
r-ES84.875
t
i
i
HSS
HSS
36.415
1...-ES
i
883
49.588
~u
6893.075
883
42.991
ES 88.375
20.839
0833
ES 80.812
r
i
68 70.750
1~
ES 72.888
8.686
1.826
ES BLBBB
--i
ES 26.2511
ii
ES 84.813
i...........
iii
i
18.540 --j
ii
i
i
0833
12.503
58 81.082
i
i
ES 57.008
ii
ES 34.125
t
M00EL NA 265-606, -6080. -65, -70
(S/N 370-1 AND -7), -8O, -8OA, AND -OOSC f
jFE8 56.084
r..-
HSS
58.382
0833
18.340 ...........i
i
i
1133
23.282
galBB
ES 98.281
CES 105.711
HSS
39.703
HSS
52.479
HSS
28.550-
HSS
HIS
833
13.200
HSS
70.258
HSS
77.312
45.914
HSS
84.388
33.127
1133
91.424
HSS
98.480
0HSS
i105.711
53103781
06-00-00
Page 20
Aug 17/84

Model NA 265-60A, -60SC, -65, -70, -80, -80A, and
erugiFCSO$18
C H A PT E R
LANDING GEAR
NA-66-1032
CHAPTER 32
LANDING GEAR
TABLE OF CONTENTS
Subject
Chapter/Section/Subject
Landing Gear
Page
32-00-00
Description
General
1
1
Description
Landing Gear
32-10-10
AlignmentInspection
General
101
101
Preparation
Main Landing Gear Procedure
Nose Landing Gear Procedure
Landing Gear
32-20-10
Wear and Rebushing Allowances

General
101
.......................1......................................................
Landing Gear Shock Struts
32-30-10
Introduction
........._
Repair Limits and Procedures
SP-CONTENTS
0
COPYRIGHT,
1990 BY SABRELINER CORPORATION
Page 1/2 Blank

Mar 16/90
NA-66-1032
CHAPTER 32
LANDING GEAR
Section
32-00-00
Page
Title
Figure No.
Typical Landing Gear Arrangement
32-10-10
101
102
103
Main Landing Gear Alignment Models NA 265-40, -60, -60A, -60SC, and -65......
Main Landing Gear Alignment Models NA 265-70, -80, -80A, and -80SC
Nose Landing Gear Alignment
32-20-10
101
102
Nose Wheel Axle Splines

Allowable Wear
Allowable Wear and Rebushing Data Main Landing Gear Trunnion
32-30-10
201
MLG Shock Strut Outer Cylinder 1127L001-3, -5 (LH) and -4, -6 (RH)
202
MLGShock Strut Outer Cylinder 1127L001-3, -5 (LH) and -4, -6 (RH)

Repair Limits and Procedures
103
107
111
102
103
203
InspectionZones
204
32-ILLUS.
0
Page 1/2 Blank

Mar 16/90
NA-66-1032
CHAPTER 32
LANDING GEAR
Chapter/
Section
Page
Date
32-L.E.P.
1/2"
Mar 16/90
32-CONTENTS
1/2"
Mar
32-ILLUS.
1/2"
Mar 16/90
1
2
Aug 17/84
Aug 17/84
32-10-10
101
102
103
104
105
106
107
108
109
110
111
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
32-20-10
101
102
Aug 17/84
Aug 17/84
Aug 17/84
32-00-00
103/104
32-30-10
201"
202"
203/204*
16/90
Mar
Mar
Mar
or
16/90
16/90
16/90
32-L.E.P.
0
Page 1/2 Blank

Mar 16/90
NA-66-1032
CHAPTER 32
LANDING GEAR
DESCRIPTION
(;ENERAL
lhis chapter contains the alignment, repair, and wear
inspection for the main and nose landing gear
assemblies.
DESCRIPTION
The landing gear is an electrically and hydraulically
operated tricycle-type,(See figure 1.)The system receives
28 vdc from the essential de bus and hydraulic pressure
from the hydraulic power system. The landing gear is
fully retractable into the fuselage and wings and is faired
by the nose wheel doors and main gear strut fairing doors.
The subsystems are the landing gear, nose landing gear
door, landing gear position indicating and warning
system; and landing gear emergency system. The landing
gear system contains the necessary electrical wiring and
mechanically actuated electrical switches to control
retraction and extension of the landi ng gear and operation
of the position indicating and warning system. All
sequencing of the landing gear is accomplished with
electricril switches.
32-00-00
0
Page 1
Aug 17/84
NA-66-1032
S7ltlr(lTlrRAL REPAIR MANUAI,
(i)
NOTES
Oi
O
ALL MODELS: DUAL NOSE WHEELS
MODELS NA 265-70. -80. -80A, AND 80SC: DUAL MAIN

WHEELS WITHOUT MAIN WHEEL WELL DOORS.
El
MODELS NA 365-40,
-60. -60A. -60SC. AND -65. SINGLE
MAIN WHEELS WITH MAIN WHEEL WELL DOORS.
32-00-00
Page 2
Aug 17/84
Typical Landing Gear
erugiFtnem gnarA
1
NA-66-1032
LANDING GEAR
ALIGNMENT INSPECTION
(;ENERAL
2.
A carefully performed landing gear alignment check can

be an aid in (1) determining if a component has been
deformed during a landing or taxiing accident and (2)
determining cause of a tendency for the airplane to
deviate from a true course during take-off or landing.
I,evel one set of check points on each wheel and

wedge wheel to prevent rotation after leveling. On
NA 265-40, S/N 282-1 thru -54 without S/B GB-1,
close main wheel doors to improve access to check poi nts
between main landing gear.
3.
Measure between check points 1 and 2 (Z, and R) for

fore and aft positions. (See figure 101 or 102. sheet X,
Note
as
7hiN alignment ehack method iR not

eonxidered an adequate? criterion for
determining structzcral integrity or
urlu,xual tire wear.
A n out-of-tolerance gear does not necessarily i ndicate that
the Rear should be replaced. Give all components of the
ReH1 a thorough visual inspection (minimum), and a
coml.,lete operational check. To determine whether
conditions warrant gear replacement, all data relative to
the alignment problems should be reviewed by qualified
personnel after a satisfactory inspection and operational
check.
equipment listed below
are
used to accomplish
alignment inspection.
Measure between check points 8 and 9(I, and R)antl

5L and 5R for lateral positions.
5.
Measure between check points a and 4 for horizontal

wheel angle (toe-in/toe-out). (See figure 101 ol 102.
sheet 4, as applicable.)
Measure between checkpoints

wheelangle (camber).
7.
Measure position of each wheel i n relation to fuselage

centerline from horizontal wheel angle.
previously
1.
With nose gear down and locked, establish points 10

and 11. (See figure 103, sheet 1.)
2.
Measure and record distance between points 10

and 11.
3.
Check to determine compliance with specifietl

tolerance for airplane being checked.
4.
3 x 41 in.)
28 VDC External Eiectrical Power
x
Hydraulic Power
airplane.(Refer to applicable Maintenance
Manual, (:hapters 7 and 8.)
Partially
rim is
nose Rear until lower edge of wheel

with fuselage mold line.
retract
even
5.
Measure and recold distance between I,oillls ttLI,

and 13L, and between 12R and l:IIt.
Determine differences between measurements.
7.
Check to determine compliance with specifictl

tolerance.
8.
Lower and lock landing gear.
9.
Place wood
Marking Pencil
Jack and level
as
Alignment inspection reference points and procedure are

presented on this and the following pages. (See figure 103,
sheets 1 and 2.)
Jadk and Pad Set

Spirit Level
Exlernal
3 and 4 for vertical
NOSE LANDING GEAR PROCEDURE
Equipment/Tools
SteelTape(BFjft)
Scale(Gorl2in.)
Steel Square (2 ft)
Inside Calipers
Wood WedRe(2each)
Wt~od Straightedge(l
4.
Airplane must be jacked and leveled

directed. (Refer to PREPARATION.)
PREPARATION
Tools and
applicable.)
MAIN LANDING GEAR PROCEDURE
Alignment inspection reference points and procedures

are presented on this and the following pages.(See figures
101 and 102, sheets 1 thru 4,
1.
as
applicable.)
With airplane jacked and leveled (see above) use a

steel square and marking pencil to divide inner face
of each main wheel into quarters. Mark alignment
check points. (See figure 101 or 102, sheet 2, as
straightedge vertically on wheel rim at

wheel, point 13L or 13R. (See figure 103.
sheet 2.) Use suitably sized spacer(s) so straightedge
center of
does not rest

wheel rim.
against tire and
is
parallel
to
plane
of
applicable.)
32-1 0-10
o
Page 101
Aug 17/84
NA-66-1032
BTKUCTURAL REPAIR MANUAL
AI,IGNMENT INSPECTION (Continued)
N()SE LANDING GEAR PROCEDURE (Contd)

10.
Raise straightedge until it is in contact with

beam lower cap.
nose
gear trunnion
11.
Place edge of 6 or 12 in. scale against lower inner face

of nose gear trunnion beam lower cap and
straightedge.
12.
Mark extension of point 12 ledge of scale)
on
straightedae.
Repeat steps 9 through 12 twice more, turningwheel

fiOo each time to account for variations in wheel.
14.
Mark centerline between extreme measured

L2 and 18
I,osilions.rhis will be dimension between

1,5.
RepeatstepJSthrough 14foroppositewheel.
16.
Measure distances found for points 12L to 13L and

12R to 13R. Determine difference between
measurements.
17.
Cheek result fol
compliance with specified tolerance.
32-1 0-10
Page 102
Aug 17/84
COPVRIGHT,
NA-66-1032
CHECK POINTS
12L
11R
13
1TYP)~II
1R
(TYr)
NOTES
POINTS 2 AND 5 ARE LOCATED ON
MAIN
STRUT
POINTS 3. 4, 6. AND 7 ARE USED IN CHECKING MLG

WHEEL ALIGNMENT.
SCISSORS (555 SHEET 3 OF 4).

POINTS 10, 11, 12, AND 13 ARE USED IN CHECKING
DETAILED VIEWS OF APPLICABLE CHECK POINTS ARE

SHOWN
NOSE GEAR ALIGNMENT.
WITH
THE
REFERENCED
CHECK
ILLUSTRATIONS.
5
POINTS i, 2, 5, 5, AND 9 ARE USED IN CHECKING MLG
STRUT ALIGNMENT.
REFERENCE POINT ITYPI

8- DR I2-INCH STEEL SCALE
STEEL TAPE
SUGGESTEO METHOD FOR

TAKING INSIDE DIMENSIONS
Main Landing Gear Alignment

Model NA 265-40, -60, -60A, -60SC, and -65
Figure 101 (Sheet 1 of 4)
0
5265-3-21
32-1 0-10
Page 103
Aug 17/84
NA-66-1032
MLG WHEEL
POINTQITYPI
POIWT31TYP)
POINT41TYP)
POINT 3
(TYPI
7/32(7YPI
OOOOYEAR WHEEL
ruslusrsawlnrrl
POINT 8 FWD CORNER
OF MLO BOOR BEAM
MLO WHEEL RlM

I
POINT4(TYPI
7100 (REF)
POINT 3 ITYPI
POINT 7 AFT CORNER OF

MLO OOOR BEAM
n\
i
LEVEL
BODEB
---0--"I
WEOOE
FLOOR
COO1NG FOR POINTS 3 ANO 4:

LF-LEFT FWO
LT--LEFT TOP
RF--RIGHT FWO
RT--RIGHT TOP
LR--LEFT REAR
LB--LEFT BOTTOM
RR--RIGHT REAR
RE--RIGHT BOTTOM
Divide inner face of each wheel rim into quarters.
Level two
points
on
wheel
Block wheel to retain
as
shown.
leveled
position for
each
measurement.
s?ss-)-?s
32-1 0-10
Page 104
Aug 17/84

Model NA 266-40, -66, -60A, -6680:, and -65
o
NA-66-1032
MLG STRUT
POINT IL
POINT 2L
POINT 1R
POIWTBL
POINT 5L
POINT 9L
POINT 1L
1R
(WINO SPAR SPLICE-LOWER SIRE)
rP9INT2L
~POINT BR
POINT gR
POINT 52
POINT 2L 29
IFWD SIOE OF LOWER
SCISSOR LINK PIN)
POINT 58
5L
IINBO SIRE OF UPPER SCISSOR LINK)
FRONT SPAR FASTENERS

FASTENERS AT WINQ STA 1
SLAT TRACK g
(NBOARD
POINT 9L 8 gR
ALIGNMENT TOLERANCES
POINT
POINT BL
85
1LTOPL
187028
8L TO 9L
88 TO 98
JL TO 58
DIUENSIONS
70-11/32
118-3/8
TOLERANCES
f3/8
f1/4
96-9/32
ILOWEROUTBDFWO
CORNER OF MAIN
REAR STRUT
ASSY)
S265-3-23
Main Landing(;ear Alignment

Model NA 265-40, -60, -(iOA, -60SC, and -Ci5
FiRure 101 (Sheet 3 of 4)
o
COPYRIGHT, 1984 BY SABREL.INER CORPORATION
32-1 0-10
Page 105
Aug 17/84
NA-66-1032
MLG WHEEL
3LF
322
4LF
CHECK NO. 1
4LA
332
31A
VIEW LOOKING GOWN
3LT
327
4LT
CHECK NO. 2
4LB
333
3LB
VIEW LOOKING FWO
3LF
3RF
6L
BR
CHECK N0. 3
333
3LR
7L
72
VIEW LOOKING GOWN
CHECK NO.
TOLERANCE
POINT TO POINT
POINT TO POINT
3LF TO 3RF
3LR TO 388
4LF TO 488
4LR TO 488
-t114
3LB TO 388
~-3/8
4LB TO 382
f3/8
3LR TO 7L
rt1/8
388 TO 78
f118
3LT TO 382
n/32
4LT TO 488
3LF TO 8L
388 TO 88
2-11/18
2-11/18
2265-3-25
32-1 0-10
Page 106
Aug ~7/84
Main I,andinR (;ea~ Alignment

Model NA 265-40, -60, -60A, -60S<I, and -65
Fiyure 101 (Sheet 4 of 4)
o
NA-66-10:I~
STKIT(:TUHAI, HEP~IK
CHECK POINTS
11
ITYP)
NOTES
2
POINTS i, 2, 5, 8, AND 9 ARE USED IN CHECKING MLG
POINTS 3, 4, 6, AND
POINTS 2 AND 5 ARE LOCATED ON MAIN STRUT SCISSORS,

SEE SHEET 3 OF 4 FOR LOCATIONS.
STRUT ALIGNMENT.
7 ARE USED IN CHECKING MLG WHEEL
ALIGNMENT.
DETAILED VIEWS OF APPLICABLE CHECK POINTS ARE

SHOWN WITH THE REFERENCED CHECK ILLUSTRATIONS.
REFEREWCE POIHT (TYPJ

6- OR 12-IN. STEEL SCALE
8TEEL TAPE
SUGGESfED METHOD FOR

TAKING INSIDE DIMENSIONS
5370-3-11
Main Landing GearAlignment

Model NA 265-70, -80, -80A, and -80SC
0
COPYRIGWT, 1984 BY SABRELINER CORPORATION
32-1 0-10
Page 107
Aug 17/84
NA-66-1032
MLG WHEEL
~iFii
POINT 3 ITYPI
POINT 4
POINT
41TYP)
POINT
BITYPJ
(TYP)
D~ii
ssi:i i i
~rr
:::1:1:1:
POINT 7
COO1NG FOR POINTS 3 ANO 4:
LF--LEFT FWD
LT--LEFT TOP
AF--RIGHT FWD
RT--RIGHT TOP
LR--LEFT REAR
LR-LEFT BOTTOM
AA--RIGHT REAR
RE--RIGHT BOTTOM
IBr::w
~III
MLGWHEELRIM
POINTO
POINT41TYPI
TIRE
POINT 3
ITYPI
IREFI
It,
1
LEVEL
90 OEG
-ti----O-i
I.)ivldo illl,or fact! ol nilcll wheel
Level two
OBlock
/rWEDGE
FLOOR
points
on
wheel
wheel to retain
as
rl~ll
into Illl;llltrs
shown
leveled
S370-3-13
position for each
measurement.
32-1 0-10
Page 108
Auff 17/84
Main Landing ~ear Alignment

Model NA 265-70, -80, -80A, and -8080:
Fiffure 102 (5heet 2 of 4)
o
COPYRIGHT, 1984
NA-66-1032
MLG STRUT
POINT 1R
POINT 1L
POINT 2L
POINT 8L
POINT 9L
POINT 5L
POINT IL&1R
IWING SPAR SPLICE--LOWER SIDEI
POINT 25
POINT 85
POINT 95
POINT 55
LP9INT5R&5L
POINT2L&2R
eNBo SIRE OF UPPER SCISSOR LINK)
(FWD SIDE OF LOWER

SCISSOR LINK
FRONT SPAR FASTENERS

FASTENERS AT WINO STA 171.82
SLAT TRACK B
(NBOAID
POINT 9L
98
POINT
DIMENSIONS
1LTO?L IRTOZR
8L TO 9L BR TO gR
5L TO SR
POINT 8L
70
109-3/8
96-1/2
TOLERANCES
f3/8
1
1115
85
CENTER OF OUTRO WHEEL

HUB

Model NA 265-70, -80, -80A, and -80SC
0
32-1 0-10
Page 109
Aug 17/84
NA-66-1032
SIRUCIURAL HEPAIR MANUAI,
MLG WHEEL
3LF
iiiii~
336
It;l4LF
~4AF
4LR
438
CHECK NO. 1
3LR
333
VIEW LOOKING GOWN
3LT
337
4LT
~4RT
iiiiiil41B
433
CHECK NO. 2
3LB
333
VIEW LOOKING
FWO
3LF
3RF
CHECK NO. 3
3LR
333
c~,
VIEW LOOKING GOWN
CHECK NO.
POINT TO POINT
POINT TO POINT
3LF TO 386
3LR TO 388
+1/4
4LF TO 488
4LR TO 486
f1/4
3LB TO 386
+318
4L8 TO 387
+3/8
2-11/16
3L8 TO 7L
i1/8
2-11/16
388 TO 78
t1/8
3LT TO 387
17/32
4LT TO 488
3LF TO 6L
3RF TO 68
TOLERANCE
S370-314
32-1 0-10
Page 110
Auff 17/84
Main L,andinff (;ear Aliffnment

Model NA ~65-70, -80, -HOA, and -80S(1
Fiffure 10~ (Sheet 2 of 4)
o
NA-66-1032
NOSE GEAR
HOSE OEIIR OUTEA CYLINOER
HOSE
WHEE; STOOT ISgY
POINT 10
POINT 10
IOSEOEIIA
INNER CYLINDER
POINT 11
WING 3210
d191
NOSE WHEEL
WELL BEAM
r)(
POINT 11
WING SKID FWO
ATTACH BOLT
NOSE GEAR WHEEL WELL WEB
NOSE GEAR STRUT ASSY
NOSE GEAR STRUT TRUNWIOI
FUSELAGE MOLO LINE
POINT 12L a 120 (01 00003120 SIRES DF WHEEL WELLI

POINT 13L&13R
RIM OF NOSE GEAR WHEEL ION OPPOSITE
SIDES OF WHEEL)
CHECK NO.
POINT
DIMENSION
TOLERANCE
12L TO 13L
EOUAL TO 123
WITHIN 1/16 INCH
TO13R
NOTE
DIMENSIONSININCHES
S265-3-22A
Nose
Landing Gear Alignment

Figure 101.3 (Sheet 1 of 2)
32-1 0-10
Page
COPYRIGHT,
ill
Aug 17/84
NA-66-1032
STHUCTURAL REPAIR MANUAL
NOSE GEAR TRUNNION

BEAM WEB
ITYPI
POINT 123
c OF STRUT
(REFI
r POINT 12L
FUSELAGE 3313
IAEF)
NOSE GEAR
TRUWNION
MEASUREITYP) --~f
Jc--
L,
I\ln
BEAM LOWER
CAP
ITYPI
BOR121N.SCRLE
STRAIOHTEOGE
T#IISRRREOTO
OPPOSITE SIDE.
MIRKALOnGEOO~
OFSCALE
PLACESAMEEOGE
AGAINST WHEEL AS
WAS USEB OH FIRST
SIDE.
STRUT--FULLV
EXTENDED AHO
FREE OF GROUND
LINE
POINT 13L
POINT 133
-Y
WOOOEN STRAIGHTEOOE--1 x 3 9 41 IN.
/m/
mn-
GROUND LINE
IREFI
CHECK NO.
POINT
DIMENSIONS
12L TO 13L
EQUALTO1PR
TOLERANCES
WITHIN1/1GIN.
TO 13R
9285-3329
32-1 0-10
Page 112
Aug 17/84
Nose
Lauding Gear Aliffnment

o
COPYRIGHT, 1984
NA-66-1032
LANDING GEAR
WEAR AND REBUSHING ALLOWANCES
GENERAL
figures 101 and 102 for allowable wear data and

rebushing requirements for the main landing gear and
See
the
nose
gear.
32-20-10
Page
o
101
RuR 17/H4
NA-66-1032
SIKUCTURAL REPAIH MANUAL
T
0.1250 IN.
0111
PIN
0.1250 11.
OIA
0118
l.gWIIW.
/I
MAX
I
DETAIL
MEASURING WHEEL SPLINE WEAR
POSITION TWO 01250 iN.
DIAMETER
PINS IN
SPLINE AS SHOWN.
OINSUAE
THAT
OCLI\NP
PINS FIRMLY IN PLACE ANO MEI\SURE
DIMENSIONS TO OUTSIDE OF PINS.
PINS ARE INSERTED
IN WORN
AREAS OF THE SPLINE ONLY.
A(C-I
OIF
MIS DIMENSION E~CEEOS 1.990 IN. SPLINE
WEAR IS OUT OF TOLERANCE. REPLACE WHEEL.
oc~w
2.1050 1W.
MIN
1B
aEcrl~Na-A
(J
MEASURING AXLE SPLINE WEAR
OPO8ITIC)N
TWO 01200 IN
s29s-3-33a
DIAMETER PINS ON
SPLINE AS SHOWN.
NSURE
THI\T
Page 102
Aug 17/84
GLAUP PINS
FIRMLY IN
PL~CE ANO MEASURE
DIMENSIONS TO OUTSIDE OF PINS.

PINS ARE INSERTED IN WORN
AREAS OF SPLINE ONLY
32-20-10
Allowable Wear
OIF
inls DIMENSION
(AVERAGE OVER LENGTH
IS LESS THAN 21059 IN

OF
SPLINE), REPLACE
AXLE.
Nose Wheel and Axle

101
erugiFsenilpS
COPYRIGHT, 1984
NA-66-11):~
STKUCIIIRAL KE1AIK MANII~I,
~f(
MLG TAUWWION
Lg
WEAR ALLOWANCES
ITEM
NO.
1
IDIMENSIONS
SHAFT
HOLE
SPAR 265-130017
BEARING 265-336123
BEARING 265-336124
INCHESI
IN
MFD ALLOWANCE
WEAR ALLOWANCE
oo(MlN)
(MAX)
(MAX)
3.1880
3.1890
--0.0010
--0.0010
4.0630
4.0650
--0.0020
--0.0020
MFD HOLE
DESCRIPTION
WING SPAR
-A
3~
lD(MAx)
MFD
BEARING 265-336123
TRUNNION
2.8775
2.8732
0.0043
0.0063
BEARING 265-336124
TRUNNION
3.7535
3.7482
0.0053
0.0083
RERUSHING DATA
ITEM
DESCRIPTION
NO,
HOLE
SPAR 265-130017
(DIMENSIONS IN INCHES)
BUSHING
REAM DIA
(MAX)
3.1980
4.0730
HEAT-TREAT
MATERIAL
tT CB
Iii
(PSI)
N.ID(MAX
FIN.ID(MIN)
Al 8lonle
2.8760
2.8770
AIBron~e
3.7520
3.7530
BEARING 265-336123
REPLACE WORN PART,
BEARING 265-336124
REPLACE WORN PART.
NOTES
REFER
TO "WEAR AND
BUSHING
(REBUSHING)
AL BRONZE
OF
CASTING,FED. SPEC QQ-B-671,WITH CLASS 3
HEAT-TREAT
STRUCTURAL JOINTS" FOR ADDITIONAL INSTRUCTIONS.
MAY
BE
SUBSTITUTED
FOR
AMS4631
BRONZE BAR.
ONE HUNDRED PERCENT CLEANUP IS NOT REQUIRED
FOR HONED SURFACES.
CI
AMS4631 AL BRONZE BAR: MIN TENSILE ULTIMATE
65,000
MAX HONED DIAMETER AFTER PRESSING
2.8775.
MAX HONED DIAMETER AFTER PRESSING
3.7535.
PSI, MIN YIELD:32,500 PSI.
lO
AMS4631 AL BRONZE BAR: MIN TENSILE ULTIMATE
PSI; MIN YIELD
55,000
27.500 PSI.
265-3-40
Allowable Wear and Rebushing riata

Main Landing Gear Trunnion
Figure
o
102
32-20-10
Page 10~/104 Blank
Aua 17/H4
NA-66-1032
LANDING GEAR SHOCK STRUTS

REPAIR LIMITS AND PROCEDURES
INTRODUCTIOhT
g.
damage of the main

landing gear outer cylinders, P/N 1127L001-3, -4, -5 and
-6. The procedure for inspection of the MLG assembly is
With a square, measure vertically from point A

down 2 1/4 in. to locate point G on inbd and
outbd surface of trunnion.
h.
Draw
This section sets the limits of crack
found in the applicable Sabreliner Maintenance Manual
Chapter
i.
32.
1.
j.
Blend out all cracks and corrosion using paper

backed abrasive. Keep in mind the following points;
k.
If the detected crack is greater than one

inch, contact Sabrel~ner Corporation Engineering Departmentfor disposition.
i.
All radii to be 0.5 inches or greater and the

surface to be 64 RMS or better.
b.
Keep the temperature of the ground area to a

minimum. The area should be comfortable to
the touch at all times. Limit drill speeds to less
than 400 RPM.
Layout damage
zones,
zone
see
Figure 201,
the crack
occurs
a.
points
point
on
aft
c.
d.
edge of trunnion
e.
f.
Draw
an
arcing line, following
curvature of
Establish
zone
on
inbd
2 for outbd and inbd sides of trunnion
as
follows:
a.
With masking tape, mask a line between points

B and C and around to B. This is line B-C-B.
b.
With masking tape, mask
Point C. Mark point 10 1/2 in. from end of trunnion as measured along trunnion
lower center line. Draw a line connecting point
B to point C around to point B.
line between points
F to E and around to F. This is line F-E-F.
Establish zones 2A, 2B, and 2C on both sides of trunion,

using ridge lines as marked in figure 203.
Establish
follows:
Point B. Mark point 3/8 in. from upper edge of

trunnion open (aft) end as measured along
trunnion upper center line.
Point D. Mark point 3/4 in. aft of point C

measured along trunnion lower center line,
a vertical line, parallel to vertical center

line, through point H on inbd and outbd strut
to
upper center line.
b.
Draw
line F-E-F defining zones 2B and 2C

and outbd strut surfaces.
A thru I
Point A. Mark
Point I. Mark point 2 in, measured from point H

along line connecting point D to point G on inbd
strut, through point I connecting line B-C-B to
in. First
below, then mask using

narrow tape to determine boundary. Use a grease
pencil or equivalent to mark points.
establish
inbd and outbd surface of trunnion.
surfaces.
a.
determine which
point G.
and outbd surface of trunnion.
NOTE
2.
line to connect point D to
Point H. Mark point 1 1/2 in. measured from

point G along line connecting point D to point G
on
REPAIR LIMITS AND PROCEDURES
a.
zone
as
With
masking tape, mask a line at aft edge of

plated bearing surface around strut. This is line
X-X-X.
b.
The
area
Establish
follows:
between line X-X-X and line B-C-B is
i.
zone
zone
as
as
Point E. Mark point 1 1/2 in. aft of point C as

measured along trunnion on lower center line
and passing through point D. Draw a line connecting points B and E and passing through
Point D.
With a square, measure from point A down 4

1/4 in. to locate point F. Mark point F. Draw a
line connecting point F to point E around to
point F.
3.
a.
With masking tape, mask a line running

around strut and located 8.0 in, below trunnion
center line as measured along aft center line of
strut. This is line Y-Y-Y.
b.
The
area
If blend out
between F-E-F and Y-Y-Y is
zone
3.
depths
lengths arewithin limits
presented by Figure 202, then finish per Sabreliner
Maintenance Manual Chapter 32, otherwise, replace
the cylinder or contact Sabreliner Corporation
Engineering Department for disposition.
and
JT
32-30-10
Page
0
201
Mar 16/90
NA;-66-1032
AFTEOGEOF
FLATED BEARING
~--3/81N.FWO
SURFACE
ENO OF
OFAFTEOGE
TRUNNION
21/41N.
TRUNNIONC/L
TRUNNIOW1.0.
G
4 1/4 IN.
2.0 IN.
lO i/3 IN.
D
3/418.
FWD
(FWDI
8611
Q~
3/418.
POINTS
A. B. C. B. E. F. G. H. I
LINES
B-C-B
X-X-X
E-FE
YY-Y
G-O-G
ZONE LOCATIONS
20YI
Btr.(tl I~T tilt O~ EHROMI PLITIO
VERTICAL
BEARING SURFACE ILINE XX-X) AND LINE 3-8-3

2011
WI EH COITnlS IO*tI
QQ
1WO
C/L
IS LOCATED BETWEEN LINE B-C-B ANO
LINE F-E-F.
20L
B~TWILI Lmt
LH MLO STRUT TRUNNION

OUTED SIDE SHOWN
(RH MLG STRUT TRUNNION OPPOSITEJ
1NO LINI I-Y-Y
8.0 In. stLow C~HTER OF TOUWnION srr OPEn

END.
Figure 201
MLG Shock Strut Outer Cylinder 1127L001-3, -5, (LH) and -4, -6 (RH)
Inspection
Zones
32-30-10
Page 202
Mar 16/90
NA-66-1032
POLISH DIRECTION
TRUNNION
I.OlN. (MAX)
IY c~nele
LEHGTH
REFER TO TABLE BELOW

FOR MIX
DEPTH ALLOWEO
POLISH OIHECTIOn
TOREMOVEA
CRACK
L-~l-1-LJ
MLC SHOCK STRUT OUTER CYLINDER
RH OPPOSITg
ILH SHOWN
SECTION A-ii SHOWIHO

ALLOWABLE DEPTH FOR
FILING OUT A CRACK IN
CYLINDER
NOTES
NI
1Masimumallowable lengthbefore blending.
[I1
~fthe max degth required to remove any one
crack exceeds the xone limits listed in table,

contact Sabreliner Engineering Depart-
ALLOWABLE REPAIR LINIITS

CRACK LIMITS
ZONE
mentfor engineering analysis.

O
See Figure 101 for
xone
location.
Figure 202
MAX DEPTH
MAX LENGTH
(IN.)
(IN.)
1.000
0.030
2A
o.oso
28
0.020
1.000
2C
0.050
1.000
0.030
1.000
1.000
MLG Shock Strut Outer Cylinder
1127L001-3, -5 (LH) and -4, -6 (RH) Repair Limits and Procedures
32-30-10
Page 203/204 Blank
~i
Mar 16/90
CHAPTER
STANDARD
PRACTICESSTR U CT U R E S
NA-66-1032
Srlill~"rlrtiAl, HI~PAIH MANUA1,
CHAPTER 51
STRU C TU RE S
TABLE OF CONTENTS
Subject
Structures
Structural Identification
General
Page
51-00-00
.........,.,.,._
.........,.,.,._
........._.,.,.,
........._
TypeofConstruction
Flight Limits With Restricted-Life Repairs
51-00-10
Flight Limits With Structural Damage
Flight Limits With Windshield Damage
Investigation, Clean-up,
And
1
1
Aerodynamic
Smoothness
Allo~able Damage
Damage Classification
Damage Types and Causes
51-10-00
Repair
~01
Classification of Repairs
A
ame And Material Inspection

uLructural Identification
General
Preliminary External Inspection
Detailed Visual Inspection....
........._
Load And Buckle Patterns

General
51-10-10
............_
51-10-II
........._
Over-G, Over Pressurization, And Hard
Landing Inspection...
General
Excessive Load Factor and Critical Areas
51-10-12
........._._._..
........._._._..
........._
........._._._..
Overheat Inspection..
51-10-30
General
Visual Inspection for Buckles. Canning. And Primei Discoloration
Hardness Testing and Tension-Testing
........._
........._._._..
Airplane Alignment Inspection
........._
51-10-40
(;eneral
Sulfacr Alipnmrnt Insl,tclion
51-CONTENTS
Pape
Aug
Ii Xl
NA-66-1032
STRI)CTIIHAL KEPAIR MANUAI,
TABLE OF CONTENTS
(Continued)
Page
Subject
51-10-50
Structural Joint Wear

(;eneral
Allowable Wear and Rebushing Data
(AW
1
201
201
201
206
RD)
Repair
Wear and Bushing (Rebushing) of Structural Joints
Bearing Retainer Flange Expanding Tool
Selection and Installation of Acres Fastener Sleeves
Introduction
206
206
Purpose
Description.......
Oversize Fastener Sleeves, Type 1
Adjusting
to
Length
210
210
210
210
Alternate Method of Adjusting Sleeve to Length in Structure

Procedure for Grinding Sleeve to Proper Length
Flushing Back Side When Necessary.
Sleeves, Fasteners, Design and Usage Limitations
Restricted Applications
Application
Aerodynamic Smoothness
,,.....51-10-60
General
Repair
201
General
Aerodynamic Filler Application

Processes
General
Fuselage And Nacelle Sealing
....61-20-00
1
...51-20-10
General
Cleaning
SealantMixing
Repair
General
Pressuretight and Liquidtight Sealing

Fumetight Sealing (Areas Operating Between -65"
Fumetight Sealing (Areas Operating Between 250"
Flame Resistant and Liquidtight Sealing
201
202
and +225"F)
and 400"F)
202
2(13
Removable Doors Sealing

Faqina Surface Sealing
Esterior Waterti~ht Sealing.

Adhesive Bonding
51-20-20
Repair
(;eneral
Aluminum Alloi Surface Ireparation
Structural Metal-To-Metal Ronding
Repairing Hone\comb Panels With Adhesive F Iller
Remo\inp Metal To-Metal Honded Repairs
i.
~01
"ol
51-CONTENTS
Page
Jun 3/H8
NA-66-1032
TABLE OF CONTENTS (Continued)
Subject
Page
51-20-30
Corrosion Control
General..........
GeneralAirplane
Speed Brake, Landing Gear Doors,
Battery Compartment......
Wing Fuel Tanks and Magnesium
and
Engine Naeelles
Parts..........
Exterior Surfaces. . . "" " " " " " " " " "
Materials
Construction Materials.........
Fabrication Information
51-30-00
Fasteners............51-40-00
General
Threaded Fastener Installation.......
51-40-10
Fasteners Torque Valves
General
Torque Valves
51-40-20
Rivets
General
High Shear Rivets

Driven Pin Rivets............
Blind Pull Rivets
Cherrymax and Bulbed
10
CherrylockRirets
CR-762 Rivet
CCR-264 Rivet.............Chobert Blind Rivets
11
17
51-4030
Mechanical Fasteners
Identification
Structural
High Shear Blind Bolts and Blind Nuts
Internally Threaded Sleeve Fasteners (Jo-Bolts)
Threaded Pin Fasteners(Hi-Lock)
Screws.. . . . . .."""""""""""""""""""""
Turnlock Fasteners
Threadedlnserts
Repair Support and Alignment.........
116
14
16
51-50-00
1
General...........
Typical Repairs
51-70-00
1
General
51-CONTENTS
Page
c
Jun
3(
3/88
NA-66-1032
TABLE OF CONTENTS
(Continued)
Subject
Page
51-70-10
Developing Typical Repairs

Repair
201
General
Typical RepairIndex
Design Mechanical Properties Tables
Symbols Used
Steps In Developing Typical Repair
201
Repair Calculations and General

Repair Requirements
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
51-70-20
201
Basic Fastener Calculations

General Repair Calculations
Design Mechanical Properties and

Strength of Joint Tables
Repair
Material
51-70-30
201
General
Material Design Mechanical Properties
Strength of Joints
201
51-70-40
Typical Repair Examples

Repair
Constant-Thickness Skin Repair Within a Substructure (Includes

Skin and Web Crack Repair
Constant-Thickness Skin Repair Across A Substructure
Chem-milled Skin Repair Between Lands
Nonpressurized
Chem-milled Skin Repair Across A Skin Land
Nonpressurized
201
201
Splices)
201
201
201
51-70-50
General Repair
Repair
201
General
Secondary Structure Repairs

Negligible Hole Repairs
Honeycomb Trailing Edge Repairs
Plastic Repairs
Glass-Fabric-Reinforced
Batts Repair
1,,,,,.
201
201
..,,,,,.,.51-70-60
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,
201
General
Converting Class A and Class B Repairs
Negligible Damage Rework
to Restricted Life
Repairs
201
51-70-70
General
Repair
201
General
Dents
Scratches and Nicks
Negligible Corrosion Damage
Cracks
Holes..............................................................................................
201
201
201
51-CONTENTS
Page
Mar 16/90
NA-66-1032
CHAPTER 51
STRUCTURE S
Section
Title
Figure No.
51-10-11
51-10-12
Fuselage
Excessive Load Factors and Critical Areas
Model NA 265-40, -60, -60A, -60SC, and -65
Fuselage
Model NA 265-70, -80, -80A, and -80SC
Wing
Model NA 265-40, -60, -70, and -80
Wing
Model NA 265-60A, 60SC, -65, -80A, and -80SC
Empennage
Model NA 265-40, -60, -60A, -60SC, and -65
Empennage
Model NA 265-65, -70, -80, -80A, and -80SC
Pylon/Nacelle
Model NA 265-40, -60, -60A, -60SC, and -70
(S/N 370-2 thru -6, -8, and -9)
Pylon/Nacelle
Model NA 265-70 (S/N 370-1 and -7), -80, -80A, and -80SC
Pylon/Nacelle
Model NA 265-65
3
4
5
6
7
8
9
51-10-40
Airplane Geometry Check Diagram Model NA 265-40, -60, -60A,
Airplane Elevation Check Diagram Model NA 265-40, -60, -60A,
Airplane Geometry Check Diagram Model NA 265-70, -80,
51-10-50
51-10-60
3
4
5
6
7
8
9
10
-60SC,and-65
-60SC, and -65
-80A, and -80SC

4
Page
Airplane Elevation Check Diagram Model NA 265-70, -80,

-80A, and -80SC
RD
Wing-to-Fuselage Fittings
Slat and Slat Track Fittings
RD
Aileron Fittings
RD
RD
Flap Fittings
Elevator Attachment Fittings
RD
Horizontal Stabilizer Attachment Fittings
RD
Vertical Stabilizer/Rudder Fittings
RD
Bearing Retainer Flanffe Expanding Tool
Adjusting Sleeve to Length
Grinding Sleeve to Proper Length
installing Fasteners and Sleeves
Bonding Sleeve
1
2
3
4
5
6
7
201
202
203
204
205
AW
AW
AW
AW
AW
AW
AW
101
Aerodynamically
Critical Areas
5
6
2
4
6
8
10
12
14
205
208
210
210
211
101
51-ILLUS
0
Page 1
Jun 3/88
NA-66-1032
Section
Title
Figure No.
1
51-20-10
51-20-20
201
51-30-00
1
2
3
4
5
1
51-40-20
2
3
4
5
6
7
8
9
10
11
12
13
(Continued)
Page
Fuselage and Nacelle Sealing Model NA 265-40, -60,

-60A, -60SC, and -65
Fuselage and Nacelle Sealing Model NA 265-70, -80,
-80A, and -80SC
Typical Sealant Applications and Dimensions
5
8
Sealing Bonded Repairs
203
Shop Mathematics
Trimming Fastener Heads and Filling Countersunk Holes
Locating Skin Trim Lines
Locating Blind Holes
Locating Access For Fastener Locations
Hi-Shear Rivet Assembly
Drive Pin Rivet
Installation
Deutch Drive Pin Rivets
Removal
Deutch Drive Pin Rivet
Cherrymax Rivets
Cherrylock Rivets
Cherry Self-Plugging Rivets
Cherry Pull-Through Rivets
Cherry Rivet Number System
How They Work
Cherrymax Rivets
How They Work
Bulbed Cherrylock Rivets
How They Work
Cherrylock Rivets
CCR-264-3 Cherry Nut-Plate Rivet Pull Thru Stem
13
14
15
16
17
4
6
7
8
12
13
15
16
19
21
22
23
100" Countersunk Head
24
Hi-Shear Blind Bolts and Blind Nuts

Blind Fasteners
Threaded Sleeve(Jo-Bolt)
Ki-Lok Fastener
7S Series Special Fasteners
Camloc Fasteners
Camloc Fastener Installation
RosanInserts
51-70-00
Typical Repair Index
51-70-10
201
Developing
51-70-20
201
202
Basic Fastener Calculations and Constant-thickness Skin

General Repair Requirements
Repair
202
206
51-70-40
201
202
203
204
Skin and Webb Crack Repair

Constant-thickness Skin Repair Across a Substructure
Chem-milled Skin Repair Between Lands
Nonpressurized
Chem-milled Skin Repair Across a Skin Land
Nonpressurized
202
203
204
207
51-70-50
201
202
203
204
205
206
Secondary Structure Repair

Negligible Hole Repair
Honeycomb Trailing Edge Small Hole Repair
Honeycomb Trailing Edge Repair
Glass-fabric-reinforced
Plastic Repair
Batts Repair
204
206
207
208
209
211
51-40-30
1
2
3
4
5
6
7
11
15
16
17
22
2
Typical Repair
204
.........,.,._.,
51-ILIUS
Page
Mar 16/90
NA-66-1032
CHAPTER 51
STRUCTURE S
LIST OF TABLES
Section
51-10-30
51-10-50
Color Hardness
AW
AW
AW
AW
AW
AW
AW
2
3
4
5
6
7
201
202
203
204
205
206
207
208
51-30-00
Title
Table No.
1
2
2A
3
4
5
6
Strength Correlations of 7075-T6 Aluminum
Page
Alloy
RD
RD
Aileron Fittings
RD
RD
Flap Fittings
Elevator Attachment Fittings
RD
RD
RD
Standard Wall Bushing
4B19
Bushing Manufacture and Installation
4B20
Flanged Bushing
Bushing Manufacture and Installation
(Salvage) Bushing
Bushing Manufacture andInstallation-4B26-Thin-Wall
MIL-SPEC Numbers for Acres Fastener Sleeves
Acres Fastener Sleeves Styles
Flush Shear Acres Fastener Sleeves
Dimensions
Dimensions
Protruding Head Acres Fastener Sleeves
Kit Numbers
3
5
7
9
11
1
15
202
203
204
206
207
212
213
214
Metals Used In Airframe Construction and Repair

Sources of Material
Approved Sealants
Aluminum
Minimum Bend Radii
Steel
Minimum Bend Radii
CRES Inconel, and Titanium
Minimum Bend Radii
Bend Allowance Coefficients For Aluminum Alloys, Based On
6A
7
7
8
9
One-Degree Angle
7
8
9
10
11
12
51-40-00
51-40-10
10
Bend Allowance Set Back

Tap Drill Sizes
Machine Screw
11
11
11
11
12
Pipe
Equivalents
Circumference and Area
General FastenerInformation
Torque Values for FIC Klincher Locknuts

Torque Values for Standard Bolts/Nuts 40,000-60,000 PSI and Over
2
3
4
5
6
8
90,000 PSI
3
4
5
6
7
Values
Values
Values
Values
Alternate Part
Torque
Torque
Torque
Torque
for
for
for
for
Bolts/Nuts 125,000-140,000 PSI

Bolts/Nuts 140,000-160,000 PSI and Over 160,000 PSI
Torque-Set Fasteners
Standard
Screw Fasteners
Numbers
51-TABLES
0
Page 1
16/90
Mar
NA-66-1032
LIST OF TABLES
Section
51-40-20
6
7
8
9
10
11
51-40-30
51-70-30
Title
Figure No.
1
2
3
4
1
2
3
(Continued)
Rivet Hole Size

Conventional Rivet Identification and Application
Hi-Shear Rivet, Head and Collar Dimensions
Hi-Shear Rivet Selection
Pull Rivet Selection
NAS Numbers to Cherry Rivet Numbers
Cherrylock Rivets
Recommended Drill Sizes and Hole Size Limits
Material Thickness Chart
Rivet Head Height
CR-762 Cherry Rivet Gun
Pulling Heads
Protruding Head Hi-Lock Fastener Selection

Flush Head Hi-Lok Fastener Selection
7834 Oversize Screws
Page
1
2
5
9
10
17
18
20
20
20
23
12
13
14
202
203
204
205
206
214
Design Mechanical Properties of 2024 Aluminum Alloy

Design Mechanical Properties of Alloy Steels
Design Mechanical Properties of AISI 301 CRES Sheet and Strip
MS20426 Rivets in 2024-T42 Clad
Strength of Joints
land Higher Strength) Aluminum Alloy Sheets
MS20426 Rivets in 7075-T6 Clad
Strength of Joints
MS20470 Rivets in 2024, 7075, and 7178
Strength of Joints
Aluminum Alloy Sheets
NAS1097 Rivets in 2024-T3 Bare
Strength of Joints
NAS1097 Rivets in 7178-16
Strength of Joints
Bare Aluminum Alloy Sheet
HS47 Hi-Shear Rivets, and 7336,
Strength of Joints
7337, and 7339 Screws in 2024-14 Clad land Higher Strength)
HS47 Hi-Shear Rivets, and 7536,
Strength of Joints
7337, and 7839 Screws in 7075-16 Clad land Higher Strength)
Protruding-head Steel Fasteners
Strength of Joints
in 2024-T42 Aluminum Alloy Sheet
Strength of Joints
Alloy Sheet
in 2024-13 Aluminum Alloy Sheet
Strength of Joints
Strength of Joints
MS20601 and MS20603 (Blind) Rivets
Strength of Joints
in 2024-T3 Clad land Higher Strength) Aluminum Alloy Sheets
MS20600 and MS20602 (Blind) Rivets
Strength of Joints
in 2024-T4 Clad land Higher Strength) Aluminum Alloy Sheets
CR2248 (Blind) Rivets in
Strength of Joints
2024-142 Clad land Higher Strength) Aluminum Alloy Sheets
CR2249 (Blind) Rivets in 2024-T42
Strength of Joints
Clad land Higher Strength) Aluminum Alloy Sheet
Huck CKL100V (Blind) Rivets in
Strength of Joints
2024-14 Clad land Higher Strength) Aluminum Alloy Sheets
217
215
Strength of Joints
201
202
203
204
205
206
207
208
209
210
211
212
213
in 2024-14 Aluminum
216
217
218
219
220
221
222
207
209
211
212
213
214
215
216
218
219
220
221
222
223
224
225
51-TABLES
Page
Mar 16/90
NA-66-1032
LIST OF TABLES
Section
51-70-30
223
224
225
226
227
228
229
51-70-60
Title
Figure No.
(Contd)
202
(Continued)
Page
and NAS1399B
NAS1398B (CR2263)
Strength of Joints
(CR2262) (Blind) Rivets in 2024-T3 Clad land Higher Strength)
F Series Jo-bolts (Blind) in 2024-T4 Clad
Strength of Joints
land Bare) Aluminum Alloy Sheet and Plate
F Series Jo-bolts (Blind) in 2024-T3 Clad
Strength of Joints
F Series Jo-bolts (Blind) in 7075-16 Clad
Strength of Joints
land Higher Strength) Aluminum Alloy Sheet and Plate
FA Series Jo-bolts (Blind) in 2024-13 Clad
Strength of Joints
FA Series Jo-bolts (Blind) in 7075-16 Clad
Strength of Joints
P Series Jo-bolts (Blind) in 2024-14 Clad
Strength of Joints
Restricted-Life Repair Fastener Substitution
226
227
228
229
230
231
232
202
51-TABLES
0
Page 3/4 Blank

Mar 16/90
NA-66-1032
CHAP~ER 51
STRUCTURES
Chapter/
Chapterl
Section
51-L.E.P.
Page
1*
2*
3/4"
Date
Section
Mar
Mar
Mar
51-10-40
16/90
16/90
16/90
Page
1
3*
4
3
4*
Aug 17/84
Jun 3/88
Jun 3/88
Mar 16/90
51-ILLUS.
1
2
Jun 3/88
Jun 3/88
51-TABLES
1*
2*
3/4*
Mar
Mar
Mar
1/2
Aug 17/84
51-00-10
1/2
Aug 17/84
51-10-00
101
102
201/202
Aug 17/84
Aug 17/84
Jun 3/88
1/2
Aug 17/84
51-CONTENTS
1
2
51-00-00
51-10-10
51-10-11
1
2
3
4
5/6
51-10-12
51-10-30
Aug
Aug
Aug
Aug
Aug
6*
7/8
1
2
Aug 17/84
Aug 17/84
Aug 17/84
Mar 16/90
Mar 16/90
215/216*
51-10-60
1/2
101/102
201/202
Aug 17/84
Aug 17/84
Jun 3/88
51-20-00
1/2
Aug 17/84
10
11
12
13
14
15/16
Added
Added
Aug 17/84
or
Aug 17/84
Jun 3/88
Mar 16/90
Jun 3/88
Aug 17/84
Mar 16/90
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Jun 3/88
Mar 16/90
Jun 3/88
Jun 3/88
Jun 3/88
Jun 3/88
Jun 3/88
Mar 16/90
Mar 16/90
Mar 16/90
Mar 16/90
4
5
6
7
8
9
17/84
17/84
17/84
17/84
17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
1*
2*
3
51-10-50
16/90
16/90
16/90
1
2
3
4
5
6
7
8
9
10
3/4
Date
201
202
203
204
205
206
207
208
209
210
211
212*
213"
214"
51-L.E.P.
0
Page 1
16/90
Mar
NA-66-1032

Chapter/
Chapterl
Section
51-20-10
Date
Section
Aug 17/84
51-40-20
Jun 3/88
Jun 3/88
Jun 3/88
Jun 3/88
Jun 3/88
Jun 3/88
Jun 3/88
Jun 3/88
Jun 3/88
Jun 3/88
Jun 3/88
Jun 3/88
Page
3
4
5
6
7
8
201
202
203
204
205/206
51-20-20
201
202
203
204
205/206
51-20-30
51-30-00
1/2
1
2
3
4
6"
6A/6B*
7
8
9
10
11
12
13
14
15
16
17/18
51-40-00
1
2
3
4
51-40-10
51-40-20
21
22
23
24
25/26
51-40-30
Aug 17/84
Mar 16/90
Mar 16/90
Aug 17/84
Aug 17/84
Aug17/84
Aug 17/84
Aug 17/84
Aug17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug
Aug
Aug
Aug
Aug 17/84
Aug 17/84
Aug 17/84
or
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
17/84
17/84
17/84
17/84
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
17/84
17/84
17/84
17/84
17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
5*
6
7
(Contd)
Aug
Aug
Aug
Aug
Bug
Aug 17/84
Jun 3/88
Aug17/84
Aug 17/84
Mar 16/90
Aug17/84
Aug 17/84
Aug 17/84
1
2
3
4
Page
51-50-00
51-70-00
Date
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug17/84
Aug 17/84
Aug 17/84
Aug17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug
Aug
Aug
Aug
17/84
23/24
1/2
17/84
17/84
17/84
Aug17/84
Aug 17/84
1
2
3
4
5
6
Aug 17/84
Aug17/84
Aug 17/84
Aug 17/84
Aug 17/84
Jun 3/88
51-L.E.P.
Page
Mar 16/90
NA-66-1032

Chapterl
Chapter/
Page
Section
51-70-00
51-70-10
7
8
9
10
(Contd)
201
202
203
204
205/206
51-70-20
201
202
203
204
205
206
207/208
51-70-30
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
*The asterisk indicates pages revised,
Date
Section
3/88
Aug 17/84
Aug 17/84
Aug 17/84
51-70-40
Jun
Aug
Aug
Aug
Aug
Aug
17/84
17/84
17/84
17/84
17/84
added,
or
Aug
Aug
Aug
Aug
Bug
Aug
Aug
Aug
201
202
203
204
205
206
207
208
51-70-50
Aug 17/84
Aug 17/84
Aug 17/84
Aug17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Bug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Date
Page
201
202
203"
204
205
206
207"
208"
209
210
211/212*
17/84
17/84
17/84
17/84
17/84
17/84
17/84
17/84
Aug 17/84
Aug 17/84
Mar 16/90
Aug 17/84
Aug 17/84
Aug17/84
Mar 16/90
Mar 16/90
Aug 17/84
Aug 17/84
Mar 16/90
51-70-60
201
202
Aug 17/84
51-70-70
1/2
201/202
Aug 17/84
Aug 17/84
Aug 17/84
51-L.E.P.
0
Page 3/4 Blank

Mar 16/90
NA-G6-1032
STRIICTURAL KEPAIR MAh~UAL
CHAPTER 51
STRUCTURES
STRUCTURAL IDENTIFICATION
GENERAI,
major structural groups of the ai rplane are the doors,

fuselage, nacelles/pylons, stabilizers, windows, and
wings. (Refer to Master Repair Index, table 1 in the
Introduction.)
The
TYPE OF CONSTRUCTION
This is an all-metal airplane with full-cantilever wings
and horizontal stabilizer. The fuselage is of semimonocoque construction and supports an engine nacelle
on each side in the area above and aft of the wing.
()n Model NA 265-40, -60, -70 and -80, the basic structure
of the wing consists of front and rear spars. transverse
Iibs, and upper and lower machine-milled skins. This
forms the main box beam, which extends from wing tip to
w i ng tip. The slats and lead i na edge are made of conven
tional sheet-metal rib and skin construction. Chem-milled
skins are used on the underslat leading edge. The trailing
edge cantilevers from the rear spar of the main box
section and is constructed of beams, ribs, skins, and
honeycomb sandwich panels. The flaps and ailerons
primarily of beams, transverse ribs, skins,

honeycomb sandwich panel trailing edges.
consist
and
265-60A, -60SC, -65, -80A, and -80SC, the

basic Sabreliner wing has been modified by replacing the
existing leading edge and slats with a new extended
lead i ng edge. This modification forms an additional fuel
tank. The modified wing also incorporates a new trailing
edge which is cantilevered from the rear spar. The
()n Model NA
are replaced with larger Fowler-type

completely covered by the trailing edge
existing wing flaps
flaps which
are
when the flaps are in the retracted position. The trailing

edge also contains hydraulically operated spoilers.
and horizontal stabilizers are fully

cantilevered structures consisting of beams, transverse
ribs, stringers, and skins. The vertical stabilizer trailing
edge, above the rudder, is honeycomb sandwich panel.
The vertical
The rudder and elevators consist of
stringers,
transverse
real
beam, fwd
ribs, skins, and honeycomb
sandwich panel trailing edges.

The fuselage basic structure consists of four main
longerons,severalsecondarylongerons,variousstringers
The principal structure of each engine nacelle for Model

-8
NA 265-40, -60, -60A, -60SC, and -70 (S/N ~70-2 thru
and -9) consists of the main engine support beam, a fixed
stainless-steel fire wall, three upper fairing doors. one
lower fairing door, and an aluminum nose section. Each
nacelle is supported by an airfoil pylon made up of leading
edge, chem-milled upper and lower skins, transverse
frames, and a honeycomb trailing edge beam.
The principal structure of engine nacelles on Model
NA 265-70 (S/N 370-1 and -7), -80, -80A. and 80SC
consists of a nose section secured directly to the front face
of the engine, three engine access doors (upper, lower i nbd
and lower outbd), and the aft fairing bolted to the fwd
frame of the engine aft fan housing. The aft fairin~ also
contains the thrust
reversel.
The principal structure of the engine nacelles foi the

Model NA 265-65 consists of the nose section secured to
the fwd face of the engine, upper and lower cowl tloors.
and the aft fairing section which contains the thrust
reverser blocker doors and thrust reverser operating
mechanism.
The
complete nacelle assembly
is cantilevered from the
pylon by engine support fittings, and stluctural carr!through fittings which extend inbd from the nacelle,
through the pylon, and attach
to the
fuselage
structure.
ensurinb the
are two basic design approaches
structural integrity of an airplane during its service life:
the "safe-life" and "fail-safe" concepts. The design of the
Sabreliner incorporates the concept of "safe-life." To
clarify the differences in the two basic approaches.
definitions are presented in the following paragraphs.
for
There
A "safe-life" airplane structure is defined as beingcapable

of withstanding, without failure, the repeated loads of
variable magnitudes expected during the defined service
life of the airplane. "Safe-l ifc" is proved by cithcl an;~lysis
or tests that include all scatter factors on matelial an~l
load spectrums. Recause of the proof of "safe-life."
alternate load
paths
are
not
necessarily
provided.
The concept of "fail-safe" design differs in that
load paths are specifically provided and methocts fol
limiting crack propagation are employed.
and intercostals, conventional frames, and chem-milled

aluminum alloy stressed skins.
51-00-00
Page 1/2 Blank

Aug 17/84
NA-66-1032
STRUCTURAL KEPAIR MANliAI,
FI,I(:HT I,IMITS WlrH ItI~:STRICTEI)-I,I1(E
REPAIKS
STRUCTURAI, IDE:NII~IIC:ATION
FLIGHT LIMITS WITH STRUCTURAL DAMAGE
a structurally damaged airplane is to be flown to a
Iepair facility "as is" or with restricted-life repairs
incorporated, the following flight restrictions must be
4.
Maintain the minimum altitude per abo\e

and othrl
condition three as permitted by
flight conditions.
5.
A placard clearly stating the folegoing flight

restrictions must be conspicuously posted in the
When
observed:
Maximum load factor for
and -0.5G.
1.
symmetrical flight is +1.5G
cockpit.
Maximum load factor for roll conditions is +1.3G and

no more than one-half aileron deflection.
2.
-0.5C;, with
The flight is made at a maximum airspeed of 225

KIAS or Mach 0.50, whichever is lower. Airspeed
should be reduced to 150 KIAS when entering
turbulent air.
4.
Maximum flight altitude is 30,000 ft.
5.
No intentional
abrupt maneuvers of any type are to be
performed.
6.
Horizontal stabilizer trim may be used only to trim

the ailplane (reduction in required pilot effort) in
level flight, scheduled climbs, letdowns, landings,
and takeoffs. The horizontal stabilizer must not be
used to maneuver the airplane or in conditions
resulting in an increase in pilot effort.
7.
For landing conditions, the sinking speed is to be

minimized, particularly when damage has affected
landing year carry-through structure. The most
critical regions for landing gear loads are the nose
gear beam, main Rear attach region of the rear spar,
and main gear supporting wing rib.
8.
If the damage is in the region of the fuselage affected

by cabin pressure, the flight must be made %ul:thout
pressurization.
H.
placard, clearly stating the foregoing flight

limitations, must be conspicuously posted in the
cockl,it.
FI,IGHT I,IMITS WITH WINDSHIELID DAMAGE
following flight restrictions apply to flights with

wintlshield damage within the limits defined in 56-00-20.
lhe
i.
Donotusewindshield heat.
2.
Maximum
airspeed is
200 KIAS.
Maintain altitude of 6000 ft above local
ground
level.
51-00;10
Page 1/2
Blank
Aug 17/84
NA-6(i-103~
STRUCTUHAL KEPAIR MANIIAL
INVESTIGATION, CLEAN-UP,
AND
AERODYNAMIC SMOOTHNESS
AI,LOWABLE DAMAGE
DAMAGE CLASSIFICATION
or
In th is manual, dam age is broken down into the fol lowing

four basic types:
One-time
Negligible Damage
One-timtt
which do not interfere with the function of a component

areas and fueltight areas), ma!: be
(including pressurized
considered negligible,
Flight Damage
One-time flight damage is damage which can be left "a~

is" or requires only minor repairs to allow the airplane to
be flown to a repair facility.
Fliffht Damage
Kcpairable narna)ge
~arts IZeDlacementDamage
Repairable Damage
Negligible Damage
Negligible damage is damage which
be permitted to
remain "as is," or which may be corrected by a simple
procedure, without restricting flight. In most cases, a
corrective action must be taken to keep the damage from
spreading. Frequent inspection of areas with negligible
and minor damage is necessary to ensure that the damage
does not spread. Limitations regarding the extent of
can
negligible damage vary in different locations throughout

the airplane. These limitations are shown on the illustrations of negligible damage for the various components.
The following are examples of negligible damage:
Repairable damage is danlage which may be ~epai2ed so

as to make the strength of the repaired structure equal to,
or greater than, that, requ i red to maintain the structural
capability of the airplane.
Replacement Damage
Parts
A damaged component must be replaced if the location ol

the extent of damage makes it impractical to repair.
When a damaged component or part is replaced, care
should be taken to avoid damage to adjacent or attac h ing
structure.
DAMAGE TYPES AND CAUSES
I)cnts
generally smooth and without abrupt

chanaes in contour may be considered negligible damage
and left "as is" or bumped back to mold line.
Dents which
are many causes and degrees of damage that may

to an airplane. However, for purposes of description,
of the causes are:
There
are
occur
some
Collision
Sclatchess and Nicks
A tlamaae which does not 5$0 through the protective
coali nR of the material, or through the cladd ing on alclad
sheet, is not considered a scratch.
rel,air information.)
Cracks
This type of damage usually originates at edges, holes, or
points where concentrated loads are applied or abrupt
changes occur in the cross-sectional area. All cracks
should he stop-drilled at each end.
I~oles
holes that do not reduce the cross-sectional
nlatcrial enough to introduce prohibitive stress,
(:leanetf-up
alea
of
Impact Damage
Fatigue Damage
Corrosion Damage
Erosion Damage
Negligible Corrosion Damage

Corrosion damage which does not exceed the prescribed
limits for scratches and nicks may be considered
negligible if the corrosion is cleaned out and the area is
chemical-fil m-treated. (Refer to Sabreliner Corrosion
Control Manual, Report No. SR-76-023 for corrosion
or
Stress Damage
Overheat Damage
Collision
or
Impact Damage
This type of damage varies from minor damage, such as a

small hole or dent, to extensive damage, sucth as torn.
crushed, or burned skin and structural membels, and
misalignment of the airplane. Damage such as this can
occur anywhere on the airplane.
Stress Damage
This type of damage generally consists of loosened,
sheared, or popped fasteners, wrinkled skin or webs, and
cracked or deformed structural members. This type of
damage is caused by abnormal stresses imposed upon the
members.
51-10-00
o
COPYRIGHT, t 984 BY SABRELINER CORPORATION
Page 101
Aug 17/84
RT A-6fj-10%2
S1RI("IUKAI, HEPAIR MANUAL
ALLOWABLE DAMAGE (Continued)
Faaifgue Damage
Galvanic Corrosion
This t!ipe of damage generally consists of small cracks

which are caused by ~ibration. "oil cans," and variable
loads imposed on skin, fittings, and load-bearing members
n~hele fittings are attached. Damage of this type occurs
mole frequently as the operation time of the airplane
In the presence of moisture, when two d ifferent metals are

in contact, an electric current flows from one to the other,
resulting in corrosive attack on one of the materials. This
is similar to the action that takes place within a common
storage battery. In galvanic corrosion, the more active of
the two dissimilar metals serves as the anode, the moistu re
becomes the electrolyte, and the less active metal acts as
the cathode. The more active of the two metals su ffers the
corrosive attack.
accumulates.
Corrosion
Damage
(ol1osion may be defined as the gradual chemical or

electromechanical attack on a metal by atmosphere,
moist~ll.e, and other agents. lhh! types of corrosive attack
Corrosive Effects of Dry Chemical Powder
(Sodium Bicarbonate)
conimoniy encountered are ordinary corrosion,

pesu ItillR in a uniform deterioration of pitting attack on
the surface: jntergranular corrosion, resulting in a grain
bountlal.y attack; and stless corrosion and galvanic
col.ro~ion, resulting in the deterioration of the more active
Iiic,st
Dr!, chemical powtler is a specially prepared grade

of sodium bicarbonate. When sodium bicarbonate is
heated, it decomposes and releases carbon dioxide gas and
water vapor. The declomposed product is sodium eart,o-
of t\vo dissimilar metals in contact. Corrosion products

from the deterioration of the more active metal will
sometimes corrode the other dissimilar metal (for
instance, magnesium and alunlinum). Corrosion caused
bv foreign materials such as battery acid and fireextinguishing agents may be encountered under certain
conditions. When corrosion of any type is discovered, only
sound iudffment can determine whether or not the entire
part should be replaced, the area reworked, or the
corlodecl area cut out and a new section spliced in. (Refer
to Sabreliner Corrosion Control Manual, Report No.
SR-ifi-OZS for corrosion repair information.)
nate
(soda ash).
In the dry state, sodium bicarbonate is harmless anti

sodium carbonate is relatively so. In the wet state tin
solution with water), sodium bicarbonate is mildly
corrosive to most aircraft metals, and sodium carbonate is
extremely caustic and will rapidly attack most aircraft
metals.
Corrosive Effects of Mechanical Foam
The agent combined with water to produce foam is a
harmless vegetable compound. The only corrosive action
of this combination is that caused by the water used.
()rdinary Corrosion
Corrosive Effects of Chlorobromomethane
C)ltiinary corrosion may be recognized by a dulling or

pittina of the surface, accompanied by white powdery
deposits on aluminum and by a reddish rust coating on
steel. C:orrosion cannot always be detected by a visual
examination alone, but may sometimes be discovered
undel paint M~here the paint flakes off under pressure.
Chlorobromomethane is highly corrosive, It evaporates
rapidly, but if any of this substance is trapped
pockets,
Corrosive effects of Dibromodifluoromethane

(I)HF),
Carbon Dioxide, Carbon Tetrachloride, and
Manobromotriflourumethane
(CR,F:I)
Inlerpramllar Curmsil,n
These fire-extinguishing agents evaporate rapidly and

are relatively harmless.
Inttl)rr;~nular corrosion is corrosion occurring along the

grain boundaries of the material resulting from a
diffelence in corrosion (or electrochemical) potential
bet~:een the grain boundary material and the matrix (or
centel of the grains). This corrosion cannot be readily
1ecognized during a surface examination until actual
failure of the material. Th is failure then shows up much
a crack might appear.
in
it must be cleaned out immediately.
Erosion Damage
Erosion damage is usually encountered on reinforced
glass-fabric components such as antennas, radomes, and
wing tips. While this material is resistant to rain, weather,
and aging, it may be eroded by hail, sharp objects, flying
stones, or sharp blows.
as
Stress Corrosion
lhis type of corrosion occurs as a result of the
susceptibility of materials to intergranular corrosion
conlt,incd with presence of internally or externally
;Ipylied stresses snch as residual stlesses tleveloped from
yuenching, welding,
severe
severe
forming, or externally applied
Overheat Damage
Overheat, damage is most likely to occur in the engine
nacelle structure and skins. Overheat damage may be
detectetf by skin and web I,uckles, canning, and primcl
discoloration.
stress.
51-10-00
Page 102
Aug. 17/84
NA-66-1032
INVESTIGATION, CLEAN-UP,
AND
REPAIR
CLASSIFICATION OF REPAIRS
In this manual, repairs
follows:
are
broken down into two types as
Standard(permanent) Repairs
Special (restricted-life) Repairs
Standard Repairs
Standard repairs
B."
are
designated
as
"Class A" and "Class
Class A Repairs
Class A repairs are those which put the airplane, both
structurally and aerodynamically, back to its original
configuration. Generally, these repairs are one of the
following types:
1.
2.
A splice across, or completely encircling, the damaged area with splice material of the same type as
the original.
Repair made by splicing in a section of new material

replace the damaged material.
to
3.
Repair made by replacing the damaged part

assembly with a new one.
or
Class B Repairs
Class B
repairs provide the structural integrity of Class A

repairs but sacrifice appearance and aerodynamic cleanness. Class B repairs should not be installed on aerodynamically critical areas. (Refer to AERODYNAMIC
SMOOTHNESS 51-10-60.)
Restricted-life repairs are repairs that will enable a damaged airplane to be flown (under restricted conditions) to
a place where permanent repair can be made.
For fliff ht limitations with restricted-life
rated, refer to 51-00-10.
repairs incorpo-
51-10-00
0
Page 201/202
Jun 3/88
NA-66-1032
STRUCTURAL REPAIR MA~IIAL
AIRFRAME
AND
MATERIAL INSPECTION
Ihe primary structure of an airplane is designed to resist

V;ll.iRble forces imposed upon it in operation. The
S1I.LlctUre must distribute these forces to the principal
wing and fuselage.

member has been tlamaged, a complete and
strength
When
bintii nl5 or
They should operate freely and
chafing. Check the units in the zero or closed positions for
proper alignment with adjacent members.
travel.
(;ENEKAL
members of the
thorough inspection must be made. This inspection should

i nclutf e the damaged structu ral member and the adjacent
or attaching members. It is possible that the damaging
~orce might have been transmitted over the surrounding
structure, causing secondary damage in areas other than
the primary damage area. Should the secondary damage
not be tliscovered, forces distributed through the
structure during normal airplane operations may cause
DETAILED VISUAL INSPE(:TI()N
Carefu Ily i nspect all aieas adJacent to the obv ious dam age.
Inspect foraings and other machined palts for cracks anti
for evidence of thei r hav i ng been moved. Th is can of te n I,e
done by observing the paint around the edges, by tipl,ed
bolt; or rivet heads, or by a slight space at the edge of
faying surfaces. When possible, remove two bolts from a
suspected fitting and examine bolts for e\-idencle of
shearing or bending. Check boltholes for elongation.
this structure to fai I. Careful investigation must be made

of all structure across which the forces must travel, and
p arts m ust be checked for possi ble m i sal ignm ent. (An aid
in the search for secondary damage is presented in
"C()AD AND RUCKI,F: PATTERNS.")
Inspect supporting structures for buckling. warpage. and

joggles. Check for sheared, loose, or tipped fasteners.
Alignment with adjacent members is also important.
Using a straightedge, check known flat areas such as spar
webs, frame webs, and bulkheads. Any deviation should
be thoroughly investigated.
PRELIMINARY EXTERNAL INSPECTION
When
A great deal may be learned about the condition of the

i ntern al structure of an airplane by a careful examination
on the wings, stabilizers, and fuselage. Some
indications might be buckle patterns on surface skin of
sl;lb i I i zers and along the sides, top, and bottom of fuselage.
I,oost!, tipped, or sheared fasteners, and joffffles or bulges
in the skin at structural joints or where heavy fittings are
attached, indicate that a thorough inspection of the
underneath structure should be made. Inspect fairings
and other nonstructural parts for tears, cracks, buckles,
and misalignment. Any unusual appearance of these
parts i s reason for a close i nspection of the structu res they
of the skin
an airplane has been damaged, or damage is

suspected, a close examination is justified for all alrau
where major components are joined or where heavy
weights are supported, The principal areas of this natule.
with their supporting structures, are as folloas:
Wing-to-fuselage
attachments
Vertical stabilizer attachment!:

Rudtler hinge
Landing
gear trunnions and bIaces
Pylon and nacelle attachments

Engine
mounts
cover,
Check also the fit of doors, covers, canopy, etc, Anything

unusual about their fit or alignment may indicate a
w;lrped or sprung structure, and is cause for inspection of
that structure.
Continue inspection throughout disassembl3 and

repair of airplane. During this time, indications of
unsuspected damage are often revealed. When new l,arts
being installed do not fit properly, find out why. It may be
because of damage which has been overlooked.
actuate control
When
possible,
brake,
etc. Observe these units
surfaces, flaps, speed

closely throughout their
51-10-10
Page
II;! Illank
Aug 17/84
NA-fiG-1032
STRUCTURAL REPAIK R~IANUAL
LOAD AND BUCKLE PATTERNS

(;E:NE:RAL
initial load and possible resultant buckle patterns
figure I are typical of those frequently occurring
in airl,lane accidents and high-G pull-outs. The initial
load or ),oint of contact is represented by a broken arrow.
Ihe tl i Iections, and in some instances magnitudes, of the
resultant inertia loadings are indicated by solid arrows
shown in
within shaded
areas.
When the load and buckle pattern diagrams are used as a

guide in determining which areas should be more
carefully inspected, it must be remembered that each
illustration represents but one given load. In any given
acclitlent, there may be secondary loadings which would
load and possible buckle I,atterns. An
of this could be when an airplane makes a hard
t\Yo-c\~heel landing, runs off the runway during roll-out,
and is spun around by contact with another object, or
Icsult in
compound
e?taml,lr
because
one
wheel sinks into
soft surface,
The load and buckle pattern diagrams present only a few

of the I,ossihle conditions. However, they do show how an
external load applied to one area is transferred
th rouff hout the airframe. A careful analysis of the type of
accident or unusual maneuver, and the probable resultant
loadings, is important in performing
thorough
inspection.
51-10-11
a
COPYRIGHT, f 984 BY SABRELINER CORPORATION
PaKt 1
Aug 17/84
NA-66-1032
STtllr(TI!RAL REPAIK MANUAL
LOADS
LOAD PATTERNS
TRANSITION
POINT
INITIAL LOADS
INERTIA
RESULTANT
LOADING
OF
DISTRIBUTION
~u I
AIR-
OF
THESE
LOADING
~I
e,--~------
LOADS
FRAME. LOADS ARE THE PRODUCT
INTENSITIES
_::::-::i::i:~
AND THE LOCAL DISTRIBUTED MASS
WITH
(WEIGHT), COMBINED
THE
INITIAL EXTERNAL LOADS.
oZ~o
BUCKLES
BUCKLE PATTERNS
NO?%S
BUCKLE
PATTERNS
SHOWN
IN
THE
II
DIAGRAMS
INI:)ICA1E ~HE DIHFCTIONS OF THE BUCKLES THAT

WOIILD TEND TO FORM IN THE SKIN AS A RESULT OF
~tli:
L.OADS
IMPOStn
IN
HARD
TWO-WHEEL
BUCKLES
LANDING
LOCATION OF
IRANSITION OF BUCKLE DIRECTION
MATCHES LOADING TRANSITION POINT. THIS POINT

MAY
BE
IN
LANDING.
DIFFERENT
DEPENDING
LOCATION.
SINKING
LOCATION
ON
GROSS
SPEED.
FOR
EACH
WEIGHT
ANGLE
CG
FROM
HORIZONTAL ETC
5265-3-9
BUCKLES SHOWN ARE FOR FUSELAGE ONLY
51-1 0-1 1
~aac
Arig 17iH4
I,aad and Buckle latterns

Fiffurc!l(Sheet 1 of It)
o
NA-fifi-1032
S1KUC"IURAI, RE:PAIR MANUI~I,
LOADS
BUCKLES
HARD THR~EIWHEEL LANDING
BUCKLES
HARD NOSE WHEEL LANDING

O
0\
TRANSITION POINT
LOADS
I
I
I1111
1)
INITIAL LOADS
INERTIA
RESULTANT
LOADING DISTRIBUTION ON AIRFRAME. LOADS ARE THE PRODUCT

OF THESE LOADING INTENSITIES
WITH
(WEIGHT), COMBINED
THE
TRANSITION POINT
NO1~S
BUCKLE
PATTERNS
SHOWN
IN
THE
DIAGRAMS
INDICATE THE DIRECTIONS OF THE BUCKLES
THAT
WOULD TEND TO FORM IN THE SKIN AS A RESULT OF

THE
LOADS
IMPOSED
IN
THE
L.ANDING
CONFIGURATIONS SHOWN
LOCATION OF TRANSITION OF BUCKLE DIRECTION
MATCHES LOADING TRANSITION POINT
MAY
LOADS
BE
LANDING
IN
DIFFERENT
DEPENDING
LOCATION,
SINKING
LOCATION
ON
GROSS
SPEED.
THIS POINT
FOR
EACH
WEIGHT.
ANGLE
CG
FROM
HORIZONTAL. ETC
SUDDEN STOP--LEFT WHEEL

(RIGHT WHEEL OPPOSITE)
52653:0

Fiffure 1 (Sheet 2 of 4)
0
COPYR(GHT, 1984 BY SABRELINER CORPORATION
51-10-11
Paffe 3
Auff 17/84
NA-66-1032
MANI1I\II
LOADS
HIGH \\G"
Ii::F::i i i i i i ;iiiiitii
PULLIOUT
iliiiii
:::::::~]18%1 ;i~i :i i i i i :i i
::::::i:i::::::l::
IIIIII)
INITIAL LOADS
RESULTANT
LOADS
INERTIA

(WEIGHT),
COMBINED
WITH
THE
NOTES
BUCKLE
PATTERNS
SHOWN
IN
THE
DIAGRAMS
INDICATE THE DIRECTIONS OF THE BUCKLES THAT

THE LOADS IMPOSED IN A HIGH G PULL-OUT.
BUCKLESSHOWNAREFORFUSELAGEONLY
BUCKLES
BUCKLES
5265-3-11
51-10-11
Page 4
Aug ~7/84

o
NA-66-1032
STKUCTUKAL REPAIR MANUAI,
INITIAL LOADS
TRANSITION POINT
RESULTANT
INERTIA

(WEIGHT), COMBINED
WITH
THE
SUDDEN STOP--RIGHT WING

(LEFT
WING
OPPOSITE)
NO TE:S
BUCKLE
PATTERNS
SHOWN
IN
THE
DIAGRAMS
INDICATE THE DIRECTIONS OF THE BUCKLES THAT

COMPRESSION
THE LOADS IMPOSED UNDER THE CONDITIONS GIVEN
BUCKLES--ONE
SIDE ONLY
BUCKLES MAY BE OF EITHER TYPE SHOWN. OR
COMBINATION OF BOTH
~jPIOI
SIDE TOW TOWARD READER-SIDE DRIFT TOWARD READER-YAW
(TAIL AWAY FROM READER)
SIDE TOW TOWARD READER-YAW
(TAIL
AWAY FROM
READER)
SIDE DRIFT LANDING

AND SIDE TOW
DIAGONAL SMEAR BUCKLES ON BOTH SIDES, BUT
OPPOSITE IN DIRECTION
5265-3-12
Load and Ruckle Patterns

(c
51-10-11
Page 5:6 Blank
Aug 17/84
NA-66-103~
STRIICTURAI, REPAIR MANUAI,
OVER-G, OVER PRESSURIZATION, AND HARD LANDING INSPECTION

(;E:NE:RAL
When;ln
airplane
has been
subjected
to overloads from
hard landing, a careful
inst,ection of the structure should be made to determine
whether damage was sustained. Inspection of the structure should be concentrated on
fintling fractures, ol parti;ll fractures (appearinff as
cracks), sheared oi I,artially sheared fasteners,
cr;lcked or l,roken lugs (or other fittinlSs), clacked or
t,roken spars, longerons, etc.
over-(;, overpressurization,
or
EX(:ESSIVE LOAD FACTOR

AND CRITICAL AREAS
Areas of major structural components that are
critically loaded by high load factor from over-G, overpressurization, or hard landing are shown in figures 1
Ihru 9. Coding is used to indicate the overload condition
for which each
area
is critical. Where there has been
overpressurization, the entire pressurized section of the

frlselage, including skins and attaching substructure, is
critical, as pressure is equal on all areas.
51-10-12
o
COPYRIGHT, 1984
~aBc 1
Aug 17/811
pacn
*g~
APPLIES TO
rAPPLIES
SKIN, LONGERON,
TO SKIN
STP.
AT SPLICE.
AND FRAME SPLICES
443.5
APPLIES TO SKINS
333.625
AT SPLICE
STA
432
357
STA
CANTED STA
457.406
sm
sm
e:
:i"
307.25
A
264.25
C~
206
7!
;i
174
STA
Co
/i
STA
STA
~O
143
;sw/-
iTA
t~
So
i\
76
STA
lil
e
7./
APPLIES TO SKIN
AND LONGERON
SPLICES
I
a
i,
\i
El
~I
zp:r
4 j.j-
P"
t;~:
nNo
ii
I:::::-:--::-:
_::
iii
ct"
as m~
oooYep1,
AND
I~
P~
Ip
-j
Za
F,
03
im
PRESSURIZED FUSELAGE AREA
;-1
V,
NOTES
~o
SPECIAL ATTENTION SHOULD
BE GIVEN TO THE
ATTACHMENT OF CREW AND CABIN SEATS. GENERA-
50
TORS.
-D
AND BALLAST WEIGHING OVER 10 POUNDS
O
n
INVERTERS,
BATTERIES.
OXYGEN
INDICATES THAT PORTION OF STRUCTURE WHICH IS
PARTICULAR ATTENTION SHOULD BE GIVEN TO THE
INSPECTION OF THESE AREAS
AFFECTED BY OVER-G MANEUVERS
(INCLUDES
HIGH
GUSTS).
BOTTLES,
CRITICALLY LOADED BY HIGH LOAD FACTOR.
IP
O
AFFECTED BY HARD LANDING.

AFFECTED BY OVERPRESSURIZATION
SKIN AND SUBSTRUCTURE).
(INCLUDES
STA
APPLIES TO SKIN. LOnbm~N.

0
29&5t-21
STA
ST~
t)
APPLIES TO SKINS
I
--I
AT SPLICE
STA
STA
STA
143
co
P
298.5
i
206
STA
co
307.25
264.25
STA
MWTEO STA
457.406
357
STA
206+17
443.5
432
STA
STA
STA
333.625
ANOFRAMESPLICES
~V I I
174
I~
STA
STA
V,
76
APPLIES TO SKIN
ANO LONGERON
50
m
a
a
SPLICES
m
m
Z
m
a
i/i
a
(P
O
a
C"
OF,
asJ
C
APPLIES TO SKIN
i~
O
a
nND
P)
a
t~R
11-1-1-~
I
doP~
do 3.
o=r
n
~Eo
AND
O1
AT SPLICE
Tfll I
a~
do6o~::
aj8P
PRESSURIZEO FUSELAGE AREA
m
E
Lil
~I
P,
II~
~s
Ri
i~
cl
c3
c
~a
NOTES
SPECIAL
ATTENTION
SHOULD
BE
GIVEN
TO
THE
TORS.
INVERTERS.
BATTERIES. OXYGEN
BOTTLES.
AND BALLAST WEIGHING OVER 10 POUND~
3
75

AFFECTED BY OVER-G MANEUVERS
(INCLUDES
HIGH
GUSTS)
ATTACHMENT OF CREW AND CABIN SEATS. GENERA-
O
O
-j
AFFECTED E3Y HARD LANDING
AFFECTED
SKIN AND
BY
OVERPRESSURIZATION
SUBSTRUCTURE)
(INCLUDES
Q,
P,
-339
s
h3
to
NA-66-1032
SIKICTURAL REPAIR MANUAL
UPPER SURFACE
WING MAIN BOX

SKIN (TYP UPPER
AND
LOWER)
FLAP
WING BOX
LOWER SURFACE
O O
R1B-
Rie-
DOUBLE
STA37.161
CANTED STA
0.000
\~--RIBSTA 59.095
I~
O
IC1
El
II~
o
O
O
nND
L~y
(TYPICAL)
FWD AND AFT WING-
TO-FUSELAGE
ATTACH FITTINGS
NOTES
PARTICULAR ATTENTION SHDULD BE GIVEN TO THE
INSPECTION OF THESE AREAS.
*FFEGTED
SEVERE
BY
OVER-G
MANEUVERS
(INCLUOES
GUSTS).
AFFECTED BY HARD LANDINGS
FROM OVERSPEED WITH FLAPS DOWN
S265-3-13A
51-10112
E:xcessive Load Factors and Critical Areas

Model NA 288-48, -60, -70, and
Wing
elugiF083
Ia~e 1
;2ug 17/84
NA-66-1032
STRUCTURAI, REPAIR MANIAL
SPOILER ACTUI\TOR
ATTICH FITTING
(TYPI
OB
~illLLLLi
m:IN,ox
ANO
SPOILER HINGE
WING BOX
wile
SKIN ITYP UPPER
El
LOWERJ
ITYP)
I liliil tt---- ~LIPTRbCKS ----eIlll( I
51
01 O
o
FLAP
RIOSTA 37.161
RIB--
Rle-
II
"1 B.5
8PD!tIlCS
FUP
0.000
IG~J
and
ITyplcpl)
FWO ANO AFT WING-
WING
NOIE~S
TO-FUSELAGE
I\TTACH FITTINGS

CRITICALLY LOADED BY HIGH LOAD FACTOR
AFFECTED
BY
OVER-G
MANEUVERS
(INCLUDES
SEVERE GUSTS)
AFFECTED BY HARD LANDINGS.
FROM OVERSPEED WITH FLAPS DOWN
Wing
Fig~ure
o
51-10-12
Page ii
Aug 17/84
NA-66-1032
STKCI("IUKAL REPAIR MANUAL
Iii
[il
o
o
VERTICAL STABlllZER/RUOOER
MODEL NA 265-40, -60, -604, -60SC, AND -65
III
MODEL NA 265-40 AND -60
O
NOTES
,,,,CATES THAT PORTION OF STRUCTURE WHICH IS

AFFECTED
BY
OVER-G
MANEUVERS
(INCLUDES
SEVERE GUSTS)
51-10-12
Paffe 6
AuRR 17/((4
AFFECTED BY EXCESSIVE YAW.
E:xcessive Iluad Factors and Critical Areas

Empennaffe
Model NA 266-40, -60, -60A, -60SC, and
eruffiFSif.5
COPYRIGHT,
NA-Gfi-10:32
111
mo--
VERTICAL STABlLlZER/RUDDER
MODEL NA 265-70, -80, -80A, AND -8080
O
MODEL NA 265-60A, -60SC, -65, -70, -80, -80A, AND -8080
NO TES

AFFECTED
SEVERE
BY
OVER-G
MANEUVERS
(INCLUDES
GUSTS)
AFFECTED BY EXCESSIVE YAW
Empennage
Model NA 265-60A, -60SC, -65, -70, -80, -80A, and
erugiFCS086
51-10-12
Page 7
Aug 17/84
NA-66-1032
SIWlr("lliRAI, KEPAIK M 12 NUA1,
O
~E,
FUS STA
357.000
FUS STA
333.625
FUS STA
318.586
FUS STA
307.250
tL
(UPPER SKIN)
10
i//
ii
\I
I,
ENGINE TRUNNION
FITTING
(TYP
OUTED)
INED AND
NOTES
IF
FAILURE OF ANY TYPE IS FOUND AT FS 33.625,
i;ili;lZ:i8~i : :il$i :
INTERNAL INSPECTION MUST BE MADE OF PYLON-TO-
NACELLE ATTACHMENTS AT STATIONS 318 586 AND

33625
I~
JATTACHMENTS
ARE
BETWEEN
OUTER SKINS IN NACELLE
STRUCTURE)
AFFECTED
MANEUVERS
SEVERE
BY
OVER-G
INNER
AND
PARTICULAR ATTENTION SHOULD BE G(VEN TO THE
(INCLUDES
GUSTS)
51-10-12
Pag~8
Aug 17/84
E:Kcessive Load Factors and Critical Areas

Pylon/Nacelle
Model NA 265-40, -60, -60A, -60SC, and -70
(S/N 370-~ thru -6, -8 and
erugiF)97
NA-66-1032
STRUCTUKAL REPAIR MANIAI,
NOTES
AFFECTED
BY
OVER-G
MANEUVERS
(INCLUDES
SEVERE GUSTS)
PylonlNacelle
Model NA 265-70 (S/N 370-1 and -7), -80, -80A, and
erugiFCS088
51-10-12
Paffe~
Aug 17jt34
NA-fi6-108~
SIHl(lliKAI, REPAIR MANIIAI,
I\
L)
SKIW UPPER/LOWER
O
O
NOTES

AFFECTED
BY
OVER-G
MANEUVERS
(INCLUDES
SEVERE GUSTSI.
51-10-12
Pa)Se 10
AuR 17/84
E:xcessive Load Factors and Critical Areas

Model NA
9
Pylon/Nacelle
265-Figure
NA-66-1032
STRUCTUKAL REPAIR MANUAL
OVERHEAT INSPECTION
Determining the
(;ENERAL
Ihrcr methods are used in checking airplane structures

after overheating: Visual inspection for buckles, canning,
and primer discoloration; hardness-testing of questionable parts with a portable or a stationary hardness tester;
and tension-testing of specimens taken from areas of
doubtful values.
VISUAL INSPECTION FOR BUCKLES,
CANNING, AND PRIMER DISCOLORATION
In the visual inspection of an airplane, the search for
buckles or canning is primarily concerned with the
possibly weakent:d condition of primary internal
structures. This is especially important when the
ovclrhealina has been in the wing area. It is possible that
an area u naffected d i rectl~ by a fire may have been bent
enough
to receive
permanent
set.
IlarlSe (or thick)aluminum parts, such as forgings, are not

quickly affected by heat as are thinner and smaller
components. However, when heat has been great enough
to damage the sheet and extruded parts, all heavy fittings
as
in the area should be removed and hardness-tested.

Similar parts from unaffected areas may be used for a
comparison.
chromate
covers
in the overheated
area are
damage by zinc-
be reliable when used
be free of dirt, oil, and smoke.

Untinted chromate primer is a slightly greenish vello~.
When exposed to about 300"F of heat for a few minutes, it
turns a light tan color. Temperatures which discolol
chromate primers will change the physical properties of
2024-T4, 7075-T6, 7178-T6, and 7079-T6 alloys. The 7000
Series alloys which are already in the Tfi. or artificially
aged, condition are softened and weakened. The 2084 -T4
is artificially aged and hardened until the lemper;tturr
reaches 500"F; then, with incleased heat, this metal also
softens and weakens. When the temperature of 2023-r~ is
raised to 300 to 500"F for a short period under
uncontrolled conditions, as is the case in an airplane fi re.
the inherent corrosion-resisting properties are seriousl3
affected.
Both 2024-T4 and 7000 Series alloys (T6 condition) are of
questionable value and should be subjected to more
accurate methods of testing when the slightest discolor
ation of the primer is evident.
manual.
Access hole
can
carefully. A clean sample of the primer known to be

unaffected by heat is compared with chromate in the
heated area. The sample should be from the same general
area of the structure in question. The suspected area Inust
It is often necessary to remove sample discs from sheetmetal parts in order to test them on a bench-type hardness
tester. Discs for this purpose should be removed with a
one-in. hole saw. If the parts are to be retained in use,
make repairs as directed in the applicable chapter of this
excellent
samples for hardness sampling. They also provide

easily replaceable part for tlestructive testing.
extent of overheat
primer comparison
an
I:~ble I tihow~i a la,ulal correlation of Illimer color.

Rockwell hardness (clad removed), and ultimate tensile
strenath of 707r,-Tfi samples taken from an overheat-
damaged airplane. II should be noted that tests were

made on a relatively small number of specimens, and the
limits on the scatter band shown are not necessarily those
which could be found with a greater number of samples,
When tension bars from sheet-metal parts are taken for
laboratory testing, the blanks removed should measure
1 x 7 in. However, pieces measuring 1 x 5 in, are
acceptable. They should be cut with the long edges in line
with the grain, whenever possible.
When parts or samples are sent to a laboratory for
analysis, information as to the type and duration of the
overheating should be included. Also, the part number,
whether metal or alloy, grain direction, etc., should be
includeci wherever determinable.
HARDNESS-TESTING AND TENSION-TESTIN(;

Reliable limits of correlation between hardness tests and
tensile tests have been established for the 7000 Series
aluminum alloys. Materials that meet the following
minimum Rockwell "R" scale readings may be considered
acceptable:
(1)
7075-T(i
RR
(2)
7079-T6
KU
R4 (min)
(3)
717X-T6
RR
89
88
(min)
(min)
that falls below the minimum shoultl

spec i mens shou Id be removed from the ;Irc~;ls
with the lowest Roc kwe ii read i ngs an tl sent to a I aborator)
for tension tests.
Material
replaced,
or
Hardness test readings are not accurate indications of

heat damage on 2024-T4 because of the corrosion factol. A
quick heating to 3000F may not raise the hardncss
number above normal but will affect the corrosion
resistance. Therefore, if chromate primer discoloration
i ndicates that heat has affected the material, the material
should be replaced or a specimen should be removetl and
sent to a laboratory for tension and corrosion-
susceptibility
tests.
51-10-30
PageI
o
Aug 17/84
NA-66-103~
S1111(17liKAL REPAIK MANIIAI,
SrRlr("lUKAL IDENTIFICATION (Cantinued)
I1AKI)NESS-TESTIN(; AND TENSION-IESTING
((lontd)
If a decision is made to retain in use a section of 2024-T4
that has undergone slight mechanical change due to
effort should be made to protect the

should be stripped, treated with
and rephosphoric cleaner, chemical-film-treated,
pain led. Surfaces not normally painted should be treated
~ith phosphoric cleaner.
ovelheating,
every
metal. Painted
areas
51-10-30
Paffe
Aug 17/84
Correlations of 7()75-16 Aluminum Alloy
C:olor H:lldntss-SlrenRth
SAMPLES FROM ONE FIRE-DAMAGED AIRPLANE

ROCKWELL
PRIMER
HARDNESS
COLOR
838-40
BLACK
838-40
BLACK
852-56
BLACK
8-57
BLACK
861 64
878-80
868-72
880-82
ULTIMATE
TENSILE
STRENGTH
BROWN
TAN
BROWN
YELLOW
(NORMAL)
Minimum values for 7075-T6

Federal Spec QQ-A-250/13
STRENGTH
ELONGATION
PERCENT
IN 1 INCHES
43,000
43,400
23,100
17,050
12
47,700
47,100
24,000
24,600
53,800
54,200
27,500
17,100
54,000
27,500
18,600
14.5
54,300
56,100
56,500
41,700
43,300
6.5
7.5
64,500
61,600
51,600
47,700
74,800
74.100
63,400
65,400
71,000
62,000
VICLD
11
11
12
16.5
16
IS
13.5
12
B
ROCKWELL "B" SCALE--CORE HARDNESS

se
45
35
Ts
65
MI
(rELLOW)
NO~M*L
TO
iilii-iiiii
(3
ii it:i-ii
ii
~6(qRqWN)
:I::-
v,60
~t:
~u
I:i:ii~iiiiigiiiiiiiiY-i
iiii-i_tiiiiiiiliiiii fiii
rarrOWu)
t!(!L?CK~)
:::-_ii-:::r iii: aiiiiciiiisiii:-iii
so
(BLACK)
Si6j-3-lj
40
51-10-30
Page ~iii Rlank
c
Aug
li84
NA-66-1032
AIRPLANE ALIGNMENT INSPECTION

GENERAL
airplane alignment data contained in figures 1 thru 4

used in identifying deformed structure after a hard
landing or over-G maneuver. The alignment data should
not be considered a criterion for determining structural
integrity. In some instances, field checks indicate that an
airplane is out of established tolerances. Experience
shows that the airplane may be aerodynamically
acceptable because flying qualities, performance, and
handling characteristics meet established criteria.
The
a spirit level may precede the actual leveling of the

airplane with a transit to place the airplane in a level
position.
with
ale
Perform a thorough and searching inspection of the

airframe. Give particular attention to fittings where
heavy weight masses are carried. Remove and examine
sampling of fasteners for evidence of shear and tension
deformation. Buckling of stressed skins, which did not
exist before the hard landing or high-G maneuver, is
cause for careful inspection of the substructure and of the
pressurized skins for crack propagation. Skin buckling in
itself is not necessarily detrimental structurally if the
buckles do not cross a raw of rivets and have not loosened
any rivets. Make a check flight when adequate inspection
reveals the structure to be sound and functional checks of
the controls and landing gear (after hard landings) are
normal.
The airplane is acceptable for flight status if the results of
the structural inspection and flight test are satisfactory.
Make a complete alignment check if flight tests indicate
the airplane is either laterally or directionally out of
tolerances and cannot be corrected by rerigging within
the tolerances given in the applicable maintenance
manual. Forward results of the alignment check and the
flight test to Sabreliner Corporation for engineering
evaluation.
SURFACE ALIGNMENT INSPECTION
Geometry Check
The geometry check can be made with the airplane
resting on the ground (see figures 1 and 4 as applicable),
Set horizontal stabilizer at -40 30 incidence before
measurements are taken. Make all measurements with a
steel tape from the points illustrated. If all measurements
are within the tolerances given on the illustration, the
airplane can be considered symmetrical.
Personnel must not be permitted on or in

the airplane while it iszc~onjacks and the
alignment check is in progress.
To level airplane with a spirit level, support airplane,
using the two wing jack points and the fwd fuselage jack
point. (Refer to the applicable maintenance manual for
jacking and leveling instructions.) Adjust jacks until
airplane is level laterally as indicated by a spirit level
resting on lateral leveling lugs located one on each
landing gear trunnion beam on each side of nose wheel
well. Longitudinal leveling is done by using a spirit level
resting on the longitudinal leveling lugs on the left side of
the nose wheel well. Recheck lateral leveling after leveling
longitudinally.
airplane using an engineers level (dumpy style)
tr""sit, support airplane on jacks, using the two wing
To level
0
jack points and the fwd fuselage jack point. Position

transit in a level position, aft and to either left or right side
of the airplane. The position must be such that a scale
dropped from all alignment points will be visible. To
laterally level airplane, drop scales from points 2L and 2R
underside of wing. (See figures 1 and 2 for Model NA
265-40, -60, -60A, -60SC, and -65, and figures 3 and 4 for
Model NA 265-70, -80, -80~, and -80SC. Adjust jacks
until readings on both scales are identical. To longitudinally level airplane, drop scales from point 1 and
point 5 on the fuselage. Adjust nose jack until readings on
scales show point 5 to be 20-5/8 in. higher than point i.
Recheck lateral leveling after leveling longitudinally.
Without disturbing setting of transit or engineers level,
take vertical dimension readings from remainder of
elevation check points. Figures 1 thru 4 give the relative
positions of the check points tin respect to the zero point)
on
a"d
permissible deviations.
Elevation Check
Drain all fuel to satisfactorily perform an elevation check.
Refer to the applicable maintenance manual for defueling
instructions. Use an engineers level or transit to ensure
that correct readings are obtained. Preliminary leveling
51-10-40
Page
0
Aug 17/84
NA-66-1032
DIMENSIONS BETWEEN POINTS

MODEL NA 255-55, -555, -WOSC, -65
1-2 35FT 0-3/15(+1131.
MODEL NA 265-40
1-2
33FT
2-3
24FT
2-4
27FT
10-5/81f1)IN.
5-3/161~13 IN.
3-5/81~1] IN.
4-5
I1FT
91~3/4)11.0
2-3
25FT
2-4
28FT
4-5
I1FT
4-5
12FT
3-5/16(~Jl) IN.
1-5/16(+1) IN.
9[~3/4)IN.OC11
5-1/8(~3/4)IN.PO
~2m\L_1,
x-
OP
j
:j
I
I
I
i"
T~
11
L_
r?
0_
I
I
afo
o~x O
C-;l C\~o"
S
3
.ii3
~o
3\3
C~JIl
~s
n~n
\L i\o
i
~_
.3J
o
D
-o~e
NOTES
Dimensions are typicalfor bothsides. Steel

tape should be taut, and measurements
should be taken in the same manner on each
side.
The
airplane
I~
need not be leveled to take
With horixontal stabilixer set at -4.5".

Model NA ~65-60.
Eztended wing tips, (shaded area), Model

NA ~ss-soA, -BoSC, -fis.
these dimensions.
Airplane Geometry Check Diagram Model

Figure
51-10-40
Page
June
3/88
NA 265-40, -60, -60A,
-60SC, and -65
NA-66-1032
oo
CELLS,
THE DIMENSIONS ARE FOR AN AIRPLANE WITH EMPTY FUSELAGE AND WING FUEL
LEVEL AIRPLANE LITERALLY ANO LONGITUOINALLV. USING
POIWTS
O 1WO~FOR
O
OAHO~
8 Ano
ZERO BIMEWSION
20-5/811.
4-7/8
I~1/1BIIW.
18-13/161~1n1ln.
LATE8IL LfVELIWO 888 POIOTS
0110 O
POINT O IS THE ZERO OIMENSION. OIMENSIONS GIVEN FOR THE
OTHER POINTS ARE AOOEO TO THE OIMENSION IIT POINT O
IOR LOlOlrUDI*II LIYILIYI
SET HORIZOITAL STABILIZER AT -4-1/2 BEFORE CHECIING
81-3/15 1+1/211W.
3813118 (+1/811n.
~Ano
401511111+1/4)111.
CII
IILLOWIBL~ DIFAREYCE OETWEEII

OIMEllSIOnS
188
LNO
10
AIO
~-1/411.
ALLOWIBLE OIFRREICE BETWEEI
NOTES
Ig
EXTENDED WING TIPS, MODEL NA 26560A. -60SC, AND -65.
DOES NOT APPLY TO MODEL NA 265-55.
Airplane Elevation Check Diagram

Figure 2
Model NA 265-40, -60, -60A,-60SC, -65 (Sheet 1 of 2)
51-10-40
Page 3
Mar
16/90
NA-66-1032
~::i:
;LB
aL
~s
5
c,
7L 3 73
(CENTER OF PYLON JACKING FOINTl

3R
411
r8L88R
323
3L&3R
4L 3 46
NOTE
E~tended
51-10-40
Page 4
3/88
Jun
wing tips,
Model NA
865-60A, -60SC and
-65.
Elevation Check Diagram Model NA 265-40, -60, -60A, -60SC, -65

NA-66-1032

MOOEL nA 285-85, -BOA, -8580
MOOEL IA 285-70
1-2 35 FT 0-3/16 11.

2-3 25 FT 5-1/8 In.
2-4 28 FT 11-5/18 IN.
45512TO-55l18l.
1-2 35 FT 0-3/16 In.

2-3 25 FT 5-1/5 IN.
2-4 28 FT 11-5/18 IW.
~3
4-512 FT 8-1/8 IN.
II)
\I
82
I~IJI
:a
a
O
:D
ili~
:3
(3
;:i~.
f
e
NOTES
DIMENSIONS ARE TYPICAL FOR BOTH SIDES. STEEL
TAPE SHOULD
BE
TAUT, AND MEASUREMENTS
SHOULD BE TAKEN IN THE SAME MANNER ON EACH
El
WITH HORIZONTAL STABILIZER SET AT -4.5".
EXTENDED WINGTIPS, MODEL NA 265-80A and -BOSC.
SIDE.
THE AIRPLANE NEED NOT BE LEVELED TO TAKE THESE
DIMENSIONS.
Airplane Geometry Check Diagram

Model NA 265-70, -80, -80A, and -80SC
Figure
0
51-10-40
Page 5
Aug 17/84
NA-66-1032
2L
O~o Pq
THE DIMENSIONS ARE FOR AN AIRPLANE WITH EMPTY FUSELAGE ANO WING FUEL CELLS.
O
0888 O
8 ANO
O LIO O
O
LEVEL AIAPLAWE LATERALLY ANO LONGITUOINALLY. USING

POIITS
310
PRINT
LnO
~FOR
LLTERIL LEYELIWG 110 POIHTS
FOR LOWOITUOIIIIL LEVELIIO.

18 THE ZERO OIMENSIDH. OImEHPIONs 61VEll FOR THE
OTHER POIITS LRE IDOEO TO THE OIMEWSIOn LT POINT

SET HORIZONTAL STABILIZER AT -41/2
OIMENSIONS
ZERO OIIIIEIIIOW
47/8 IN.
18-13/16 IN.
195/8 IN.
205/8 1O.
LNO
-70. 703/16 IN.: 110. 709/18
uo
-70. 36-13/18 IH.: 80. 38-118 IW.

-70.40-15/18 IW.: -30. 42-1116 IH.
BEFORE CHECKIHO
ALLOWABLE OIFFEREICE BETWEEN
ANO
LID
LWO
LNO
1/418.
ALLOWABLE OIFFERENCE BETWEEN

1!218.
NOTE
EXTENDED WING TIPS, MODEL NA 265-80A AND -80SC.
Figure
Airplane Elevation Check Diagram

-80A, and -80SC (Sheet 1 of 2)
Model NA 265-29, -80,
51-10-40
Page
Mar
16/90
NA-66-1032
STHUCTUHAL REPAIR MA1LUAI,
ELEVATION CHECK WIMS
3L
2L
7L 4 78
28
(CENTER OF PYLON JACKING rOlWT)
3R~4R
BL&8R
2L 4 28
3L 4 38
4L 4 48
NOTE
EXTENDED
WINGTIPS, MODEL NA 265-80A AND -80SC.
Elevation Check Point Diagram

Model NA 265-70, -80, -80A, and -80SC
51-10-40
Page 7/8 Plank
Aug 17/84
NA-66-1032
STRUCTURAL JOINT WEAR

GENERAL
The maximum wear allowance of ajoint as given in tables

1 thru 7 is the total clearance between the shaft and hole.
All wear may be in one part or divided between the two,
except that bolt wear must not exceed 3% of bolt diameter
for bolts less than or equal to 1/4 in, diameter. Bolts over
1/4 in. must not be worn more than 0.004 in. When the
wear allowance has not been exceeded, the part may be
retained in service. When the wear allowance has been
exceeded, the part must be bushed (when permissible) or

replaced. For bushing and rebushing data, refer to Wear
and Bushing (Rebushing) of Structural Joints.
ALLOWABLE WEAR AND REBUSHING
DATA (AW
RD)
See figure 1 and table i.
See figure 2 and table 2.
Aileron
See
Fittings
figure
3 and table 3.
Flap Fittinffs
See
figure
4 and table 4.
Elevator Attachment
Fittings


See
figure 7 and table 7.
51-10-50
0
Page 1
16/90
Mar
NA-66-1032
A:
~II :
~csl
FORWARD WINO-TO-FUSLLAOP ATTACH FITTING
AFT WING-TO-FUSELAGE AnACH FITTING
Ii
AW
RD
Figure
51-10-50
Page 2
Jun 3/88
NA-66-1032
Table i.
AW
RD
WEAR ALLOWANCES
ITEM
SUPPORT
265-130924
RETAINER
265-130913
BEARING
OR
MFD HOLE
MFD SHAFT
MFD ALLOWANCE
WEAR ALLOWANCE
ID(MAX)
OD(MIN)
(MAX)
(MAX)
1.3130
1.3120
0.0010
0.0020
HSBG-IO
11875
1.1870
0.0005
0.0010
265-100038
0.6250
0.6215
0.0035
0.0055
SHAFT
HOLE
DESCRIPTION
NO,
RETAINER 265-130923
OR 265-130938
BEARING
IBOLT
OR265-100042
4
IFITTING
265-311209
BOLT
265-100038
0.6255
0.6215
0.0040
0.0060
FITTING
265-312262
BUSHING 265-312261
1.5630
1.5619
0.0011
0.0016
BUSHING
265-312261
BEARING HSBG-12SA
1.4383
1.4370
0.0013
0.0020
BEARING
HSBG-12SA
BOLT
265-100039
0.7500
0.7425
0.0075
0.0090
INBOARD REAR SPAR 165-130017
BUSHING 265-130751
0.9380
0.9380
0.0000
0.0000
265-1 30751
BOLT
165-1 00039
0.7505
0.7425
0.0080
0.0100
BOLT
NAS624H36
0.2760
0.2485
0.0275
0.0350
BOLT
265.100038
0.6255
0.6215
0.0040
0.0060
AND
IBUSHING
265-130752
AND 265-130752
10
265-100039
BOLT
CAP ANGLE
11
265-312205
REBUSHING DATA
BUSHING
REAM DIA
ITEM
HOLE
DESCRIPTION
NO.
(MAX)
MATERIAL
SUPPORT
265-)30924
WORN PART
RETAINER
265-130923
CE WORN PART
BEARING
HSBG-IO
WORN PART
FITTING
265-31 1 209
FITTING
265-312262
CE WORN PART
IBUSHING
265-312261
CE WORN PART
BEARING
HSBG-12SA
WORN PART
SPAR
265-1 30017
BUSHING
0.751
HEAT-TREAT
(PSI)
FIN.ID(MIN)
FIN, ID
(MAX)
0.6255
160.180.000
0.6245
40.000 TO 160,
0.7495
0.7505
160-180. 000
0.6245
0.6255
4130 STEEL BAR
1.0015
265-130751
AND 165-130752
10
BOLT
265-100039
11
CAP ANGLE
265-312205
4130 STEEL BAR

WORN PART
0.751
4130 STEEL BAR
NOTES
9
REFER TO "WEAR AND BUSHING
STRUCTURAL
JOINTS"
AND
(REBUSHING)
SEE
OF
"BUSHING
BUSHINGS
TO
CLEARANCE
BE
FIT;
INSTALLED
USE
WITH
LOCTILE
0.001
IN
RETAINING
MANUFACTURE AND INSTALLATION" ILLUSTRATION
COMPOUND 35, MIL-R-46082A (MR), TYPE III, AND
FOR ADDITIONAL INSTRUCTIONS.
LOCQUIK PRIMER ~N". OR EQUIVALENT
51-10-50
o
Paae 8
AuR 17/H4
NA-66-1032
SrKI~("IUIIAL REPAIII MANUAL
(j)
A
BA
ii\
A
[2
t~
TYPICAL SLAT TRACK

5265-3-28
51-10-50
Page
AW
RD
Slat and Slat Track

2
erugiFsgnittiF
Aug 17/84
COPYRIGHT, 1984
NA-66-I 032
STRUCTU1I~AL HEPAIH MANIAL
Tahle
AW
RD
WEAR ALLOWANCES
MFD HOLE
ITEM
265-130918
AFT SUPPORT
YR137CP-X
BEARING
SHAFT
HOLE
DESCRIPTION
NO.
ID(MAX)
MFD SHAFTI MFD ALLOWANCE
OD(MIN)
WEAR ALLOWANCE
(MAX)
(mnx)
BOLT NAS1304-43H
0.1505
0.2485
0.0020
0.0030
BOLT NAS1305-43H
0.3130
0.3110
0.0020
0.0030
0.0050
SCREW NAS221-15
0.1920
0.1900
0.0020
BOLT NAS1305-43H
0.3128
0.3110
0.0018
0.0028
0.2485
0.0615
0.0025
0.0030
BEARING
4NBF614-YJ
BOLT NAS1304-43H
0.2500
FORWARD SUPPORT
265-130917
BOLT NAS1305-43H
0.3130
0.3110
0.0020
BOLT NAS1304-43H
0.1505
0.2485
0.0020
0.0030
0.1900
0.0010
0.0050
SCREW NAS221-15
0.1910
3NBF51 2-YJ
SCREW NAS221-15
0.1900
0.1900
0.0000
0.0010
BOLT NAS-1304-43H
0.2500
0.2485
0.0015
0.0025
0.4380
0.4337
0.0043
0.0070
BEARING
5
6
BEARING
YR213
SLAT TRACKS
265-170006
BUSHING 246-17065
265-170010
BUSHING 246-17065
0.4380
0.4337
00043
0.0070
246-17065
BOLT NAS1104-12
0.2505
0.2485
0.0020
0.0040
265-1 70007
265-1 70008
265-1 70009
BUSHING
REBUSHING DATA
HOL6
DESERIPrlON
NO.
1
265-130918
AFT SUPPORT
(MPIX1
(MAX
0.3765
0.3120
0.3130
0.3140
0.1880
0.1920
0.3765
0.3120
0.3130
0.3750
0.2495
0.2505
0.3140
o.lsBo
0.1920
4NBF614-YJ
FORWARD SUPPOR7
265-130917
REPLACE WORN PART.
REPLACE WORN PART.
B
C
SLAT TRACKS
ID
YR137CP-X
BEARING
(MIN)
0.2505
BEARING
IBEARING
FIN. ID
0.2495
BEARING
(PII)
0.3750
M*IEII~L
BUSHING
REAM DIA
ITEM
3NBFS12-Y~
REPLACE WORN PART.
YR213
REPLACE WORN PART.
265-170006
REPLACE WORN PART.
265-170010
REPLACE WORN PART.
246-17065
REPLACE WORN PART.
265-170007
265-1 70008
265-170009
BUSHING
NOTES
STRUCTURAL
JOINTS"
FOR
(REBUSHING)
OF
ADDITIONAL
INSTRUCTIONS.
USE 4826
(SALVAGE) BVSHING.
USE 4819 BUSHING.
SEE ~BUSHING MANUFACTURE AND INSTALLATION"
ILLUSTRATION.
51-10-50
Paffe
0
Auff 17/84
NA-fifi-1032
SIRl("rllllAL HEIA[R M~NIIAI,
-A
A
A-
INBD AILEHON HINGE ASSY
~b
~--A
TRIM TAB ATTACHMENT ASSEMBLIES
13)
11
7
OUTED AILERON HINGE ASSY
S2~6-330A
51-10-50
AW
RD
Aileron
3
erugiFsgnit iF
Page6
Aug 17/84
NA-6(i-1():~2
STKIICI~URAI, KEPAIR MANIIAI,
AW Kr. I1I)-- Aileron Fitting~s
Iatllt:~.
WEAR ALLOWANCES
ITEM
DESCRIPTION
NO.
INBOARD SUPPORT
HOLE
SHAFT
265-160050
MFD HOLE
MFD SHAFTIMFD ALLOWANCE
WEAR ALLOWANCE
ID(MAX)
OD(MIN)
(ML\X)
(MAX)
TNAS1105-42W
0.3130
0.3110
0.0020
0.0040
NAS 1104-4W
0.2540
0.2485
0.0055
0.0090
NASIIO1
0.2540
0.2485
0.0055
0.0090
1.2501
1.2495
0.0006
0.0012
0.0040
LINK
246-16530
A
B
T NAS1105-42\1(1
0.3130
0.3110
0.0020
BEARING
DSRPS
T AN175H-17A
0.3125
0.3112
0.0013
0.0023
SUPPORT
265-1 60071
0.4380
0.4385
--0.0005
-0.0005
0.3130
0.3112
0.0018
00030
0.3755
03760
0.0005
0.0005
N 265-160038
0.2505
0.2470
0.0035
0.0040
PIN 265-1 60038
0.2480
0.2470
0.0010
0.001 5
4820M-S4-004
PIN 246-16056
0.2505
0.2470
0.0035
0.0040
246-1 6054
0.3755
0.3760
--0.0005
-0.0005
T NAS1106-29
0.3755
0.3735
0.0020
0.0040
T NAS1106-29
0.3755
0.3735
0.0020
0.0040
RING DSRPS
1.2501
1.2495
0.0006
0.0012
0.3125
0.3106
0.0019
0.0029
BUSHING
4820M-S5-005
INBOARD FITTING
265-160070
BUSHING
4820M-S4-006
HORN ASSY
265-1 6003 8
BUSHING
10
FITTING
11
OUTBOARD SUPPORT 265-160051
12
TAN175H-17A
4820M
246-16531
LINK
NG4820M-S
SHING 4820M
DSRP5
13
BEARING
DSRP5
IPIN 246-16548-11
N 265-160074
0.3125
0.3112
0.0013
0.0023
14
SUPPORT
265-160066-5
PIN 265-160074
0.3130
0.3112
0.0018
0.0028
IS
INTERCOSTAL
265-160060-2
PIN 265-160074
0.3130
0.3112
0.0018
0.0028
REBUSHING DATA
ITEM
INBOARD SUPPORT
265-160050
BUSHING
REAM DIA
HOLE
DESCRIPTION
NO.
(MAX)
MATERIAL
0.3750
246-16530
REPLACE WORN PART.
0.3250
BEARING
SUPPORT
265-160071
REPLACE WORN PART.
BUSHING
4820M-S5-005
REPLACE WORN PART.
FITTING
265-160070
BUSHING
4820M-S4-006
HORN ASSY
265-160038
4130 STEEL BAR
4130 STEEL BAR
10
FITTING
256-1 6054
0.5000
11
OUTBOARD SUPPORT 265-160051
0.5000
12
LINK
BEARING
DSRPS
14
ISUPPORT
265-1 60066-5
IS
IINTERCOSTAL
265-160060-2
125,000 TO 145.000
0.4390
(MAX
0.2490
0.2540
0.3130
0.3120
0.2495
0.2505
0 2410
0.1480
0.2495
0.2505
0.3745
0.3755
0.3745
0.3755
REPLACE WORN PART.
13
125,000 TO 145,000
0.3110
4820M-S4-004
246-1 6531
ID
0.3130
0.5000
BUSHING
(MIN)IFIN.
0.3120
REPLACE WORN PART.
LINK
DSRPS
FIN. ID
USE NEXT LARGER SIZE FASTENER.
0.3150
HEAT-TREAT (P5I)
REPLACE WORN PART.
O
N02~8
STRUCTURAL
JOINTS.
FOR
(REBUSHING)
OF
SEE..BUSHING MANUFACTURE
AND INSTALLATION~ ILLUSTRATION
ADDITIONAL
INSTRUCTIONS.
USE 4826
(SALVAGE) BUSHING.
USE 4819 BUSHING.
REFER
OUTED
TO
"BUSHING
HINGE
AILERON
FITTING.~
51-10-50
PaRe 7
AuR 17/R4
NA-66-1032
STK~("rUKAL REPAIK MANUAL
1)
\/W
C3A
Ij
O
A
j;i:3Avn/i~.
INBD FLAP ROLLER ASSY
B
B
C
INBD FLAP TRACK ASSY
~D
b
c
I
A
to
CA
C,BA
A
OUTED FLAP ROLLER ASSY
13
1~
OUTED FLAP TRACK
51-10-50
Page I!
Aug 17/84
AW X. K.D
ASSY
Flap
erugiFsgnit F
4
NA-66-10~2
SIKU(ITURAI, REPAIK MANUAI,
lat,le 4.
AW
Flap Fittings
Ri)-
WEAR ALLOWANCES
ITEM
SHAFT
HOLE
DESCRIPTION
NO.
1
2
3
4
265-180077
PLATE
MFD ALLOWANCE IWEAR ALLOWANCE
MFD HOLE
MFD SHAFT
ID(MAX)
OD(MIN)
(MAXJ
(MAX)
0.6890
--0.0010
--0.0010
BUSHING
246-18045
0.6880
STUD
265-1 80079
0.3745
0.3725
0.0020
0.0030
BOLT
NAS1105-13D
0.3130
0.3110
0.0020
0.0030
265-180078
0. 5005
0.5010
-0.0005
--0.0005
BUSHING
48198-6-.015
STUD
265-1 80079
0.3755
0.3725
0.0030
0.0040
IBEARING
YR~37CP-X
BOLT
NAS1105-23D
0.3128
0.3110
0.0018
0.0028
265-180050
BOLT
NAS110B-13W
0.5005
0.4985
0.0020
0.0030
SCREW
7535-5A6
0.3165
0.3110
0.0055
0.0070
1 INBOARD REAR SPAR 265-130017
BOLT
NAS1108-13W
0.5005
0.4985
0.0020
0.0030
7535-5A6
0.3165
0.3110
0.0055
0.0080
246-18045
0.6880
0.6890
--0.0010
--0.0010
ROLLER
FLAP TRACK
BUSHING 48198-6-.015
LOWER WING SKIN
265-130102
SCREW
PLATE
265-180086
BUSHING
STUD
265-1 80079
0.3745
0.3725
0.0020
0.0030
BOLT
NAS1105-28D
0.3130
0.3110
0.0020
0.0030
265-180078
0.5005
0.5010
--0.0005
--0.0005
10
BUSHING
481 98-6-.015
STUD
265-180079
0.3755
0.3725
0.0030
0.0040
11
BEARING
YR137CP-X
BOLT
NAS1105-28D
0.3128
0.3110
0.0018
0.0028
BOLT
NAS1105-8W
0.3130
0.3110
0.0020
0.0030
SCREW
7535-5A7
0.3165
0.3110
0.0055
0.0070
BOLT
NAS1105-8W
0.3130
0.3110
0.0020
0.0030
SCREW
7535-5A7
0.3165
0.3110
0.0055
0.0080
12
13
14
IROLLER
265-180051
FLAP TRACK
OUTBOARDREAR SPAR 265-130004

265-130102
LOWER WING SKIN
BUSHING 48198-6-.015
REBUSHING DATA
ITEM
HOLE
DLSCRIPTION
NO.
PLATE
265-180077
BUSHING
REAM DIA
(MAX)
MATERIAL
ROLLER
BUSHING
8EARING
FLAP TRACK
FIN.ID(MAX)
0.3120
0.3165
REPLACE WORN PART.
FIN.ID(MIN)
REPLACE WORN PART.
HEAT-TREAT(PSI)
0.4375
REPLACE WORN PART.
265-180078
48198-6-.015
REPLACE WORN PART.
YR137CP-X
REPLACE WORN PART.
265-180050
WEAR NOT ANTICIPATED.
1 INBOARD REAR SPAR
265-130017
0.5640
0.4990
0.5005
LOWER WING SKIN
265-130102
0.4375
0.3115
0.3165
PLATE
265-180086
0.3120
0.3130
REPLACE WORN PART.

REPLACE WORN PART.
ROLLER
0.4375
265-180078
REPLACE WORN PART.

REPLACE WORN PART.
10
BUSHING
48198-6-.015
11
BEARING
YR137CP-X
REPLACE WORN PART.
12
FLAP TRACK
265-180051
13
OUTBOARD REAR SPAR
265-130004
14
WING LOWER SKIN
265-130102
B
A
0.3765
0.3115
0.3130
0.4375
0.3115
0.3165
NO TE~
STRUCTURAL
JOINTS"
FOR
(REBUSHING) OF
ADDITIONAL
INSTRUCTIONS.
USE 4826
(SALVAGE) BUSHING
USE 4819 BUSHING.
SEE "BUSHING MANUFACTURE AND

ILLUSTRATION
51-10-50
Page 9
Aug 17/84
NA-66-1032
A
A
51-10-50
Page 10
Aug 17/84
AW
RD
INTERMEDIATE HINGE
Elevator Attachment
5
eruffiFsgnittiF
NA-66-1032
Table 5.
AW
RD
Fittings
Elevator Attachment
WEAR ALLOWANCES
ITrm
HOLE
DESCRIPTION
SHAFT
NO.
MFD HOLI
MFD SHIFT
ID
OD
(MAX)
(MIN)
M~D
WEAR
ALLOWANCE
ALLOWANCE
(MAX)
(MIIX)
SUPPORT
265-110419
BOLT
NAS1104-6W
0.2540
0.2485
0.0055
0.0070
SUPPORT
265-220429
BOLT
NASI 104-6W
0.2540
0.2485
0.0055
0.0070
BEARING AN2060SP4
0.9014
0.9009
0.0005
0.0005
BEARING
AN206DSP4
PIN
265-220423-11
0.2500
0.2487
0.0013
0.0013
CLIP
265-220316-5
PIN
265-220423-11
0.2510
0.2487
0.0023
0.003
SUPPORT
265-210418
BOLT
NAS1106-12W
0.3790
0.3745
0.0045
0.0055
BOLT
NAS1106-12W
0.3790
0.3745
0.0045
0.0055
BEARING
0.9014
0.9009
0.0005
0.0005
SUPPORT
265-220418
OR
285-220418
0SP4
BEARING
05P4
PIN
265-220424
0.2500
0.2487
0.0013
0.0013
CLIP
265-220318
PIN
265-220424
0.2510
0.2487
0.0023
0.003
REBUSHINO DATA
REAM
ITEM
DESCRIPTION
NO.
HOLE
BUSHING
DIA
(MAX)
MATERIAL
HEAT-TREAT
(PSI)
FIN.
ID(MIN)
FIN. ID
(MAX)
SUPPORT
265-21041)
0.2820
0.1490
0.2540
SUPPORT
16S-220429
P.
0.1820
0.2490
0.2540
0.3740
0.3790
REPLACE WORN PART.
BEARING
AN2060S04
REPLACE WORN PART.
CLIP
265-220316-5
REPLACE WORN PART.
SUPPORT
265-210418
SUPPORT
265-220418
0.4070
REPLACE WORN PART.
REPLACE WORN PART.
BEARING
0584
REPLACE WORN PART.
CLIP
265-220318
REPLACE WORN PART.
NOTE~
REFER TO "WEAR AND BUSHING (REBUSHING) OF
STRUCTURAL
JOINTS"
FOR
ADDITIONAL
INSTRUCTIONS.
USE 4826
(SALVAGE) BUSHING. (SEE..BUSHING

ILLUSTRATION.)
MANUFACTURE AND INSTALLATION"
51-1 0-50
Papc~e
o
11
qup 17/84
NA-66-1032
STKUCTURAL REPAIR MANUAL
c---f-"
ii
i
(5
A
I/ t\~a
12
13
15
n
A
51-10-50
Page 12
Aug 17/84
AW
RD
Horizontal Stabilizer Attachment
erugiFsgnittiF
6
NA-66-1032
Table 6.
AW
Horizontal Stabilizer Attachment
RD
Fittings
WEAR ALLOWANCES
ITEM
MFD HOLEIMFD
5HI\~T
DESCRIPTION
(MAX)
ID
NO.
OD
(MIN)
MFD
WEAR
ALLOWANCE
ALLOWANCE
(MP~X)
(MAX)
SUPPORT
265-210401
IBUSHING
4820M-S4-004
0.3755
0.3760
0.0005
0.0005
BUSHING
4820M-S4-004
IBOLT
NASIIOI-IBW
0.2505
0.2485
0.0010
0.0030
1.0640
0.0010
0.0010
SUPPORT
IBUSHING
BEARING
165-110411
IBUSHING
246-14419
1.0630
246-24429
IBEARING
88-4
0.9014
09009
0.0005
0.0005
88-4
IBOLT
NAS1104-1BW
0.1505
0.2485
0.0020
0.0020
IBOLT
M520012-92
0.7505
0.7468
0.0037
0.0037
CAP
265-110401
BEAM
2OC2104~2
BOLT
MS20012-92
0.7505
0.7468
0.0037
0.0037
380-210(12
RETAINER
246-21408-3
1.5630
).5620
0.0010
0.0010
IBEARING
HSB6IPSA
1.4375
1.4370
0.0005
0.0010
RETAINER
146-21408-3
BEARING
HSBL-I1SA
BOLT
265-110414
0.7505
0.7480
0.0015
0.0035
10
SUPPORT
265-313459(LH)
BUSHING
265-210413
0.8755
0.8735
0.0010
0.0020
10
SUPPORT
265-313463(RH)
BUSHING
265-313488
0.8755
0.8760
0.0005
0.0a05
11
BUSHING
265-210413(LH)
BOLT
265-110414
0.7505
0.7480
00015
0.0035
11
BUSHING
4819-S12-008(RH)
BOLT
265-110414
0.7505
0.7480
D.M)25
0.0035
RETAINER
265.-521100
0.7813
07808
0.0005
0.0010
1?
FITTING
265-522098
13
RETAINER
265-522100
IBEARING
HU-5S
0.6875
0.6870
0.0005
0.0005
14
BEARING
HU-SS
IBOLT
NAS625H 18
0.3125
0.3110
00015
0.0015
15
SUPPORT
265-210403
IBUSHING
4820M-S5-006
0.4380
0.4385
0.0005
0.0005
BUSHING
482181-55-013
0.4380
0.4355
0.0025
0.0035
16
BUSHING
482lM-S5-013
IBOLT
NAS625H18
0.3130
0.3110
0.0020
0.0030
17
BUSHING
482016-55-006
BOLT
NAS625H18
0.3130
0.3110
0.0020
0.0030
REBUSHING DATA
ITEM
HOLE
DESCRIPtlON
NO.
SUPPORT
0.3850
4820M-S4-004
00
1.0725
IBUSHING
1 SUPPORT
265110417
IBU1HING
246-2~429
BEARING
88.4
CAP
265-110402
IBEAM
265-210411
RETAINER
IBEARING
BUSIIING
(mAx)
265-120401
DIA
REAM
HEAT-TREAT
MATERIAL
4130 OR 4135
STEEL TUBING
125.000 TO 145.000
4110 O1 4135
I 131tl
STEEL
TUBING
1
1
0.8130
).8130
1
1
I
I
1
1
REPLACE WORN PART.
146-91408-3
REPLACE WORN PART.
HSB6-llSA
REPLACE WORN PART.
ISUPPORT
265-313459 (LH)
10
ISUPPORT
265-313463 (RH)
BUSHING
265-210413 (LH)
14130
STEEL BAR
11
BUSHING
4819-512-008 (RH)
14130
STEEL TUBING
12
FITTING
265-522098
REPLACE WORN PART.
13
RETAINER
265-522100
REPLACE WORN PART.
14
BEARING
HU-5S
SUPPORT
165-1)0403
II
BUSHING
BUSHING
482061-55-006
4B10M-55-WB
0.1505
0.900P
11..014
0.7495
0.7505
0.7495
0.7505
0.7500
0.7505
0.8850
1140.000
TO
160,0001
115,000 TO 145
REPLACE WORN PART.
0.4485
0.4485
g
16
0.2500
0.8850
10
15
FIN. ID
REPLACE WORN PART.
1,
ID(MIN)
FIN.
(PSI)
00
I II10
4130 OR 4135
SIEELTUBING
4130 01(
125,000 TO 145,
1125,00070
145,000
0.3130
0.3110
0.3120
0.3130
NOTES
STRUCTURAL
JOINTS"
(REBUSHING)
FOR
OF
ADDITIONAL
INFORMATION
OUSE
4826
REPLACE WITH LIKE PART WHEN BUSH NG 1S WORN
REPLACE WITH
BUSHING IS PRESS FIT.
~O
REFER TO .HORIZONIAL STABILIZER CENTERBEAM

-BUSHING REPAIR" IN CHAPTER 55
(SALVAGE) BUSHING. (SEE "BUSHING

MANUFACTURE AND INSTALLATION" ILLUSTRATION.)
OVERSIZE OD BUSHING
O
O
MOOtL NA 265-60A
-8OBG. -55. -80. -8~A. AND -BOSC
WHEN
BUSHING HOUSING IS WORN.
MODEL NA 265-40. -80, AND -70.
COPYRIGHT. 1984 BY SABRELINER CORPORATION
51-10-50
PaRr! 13
AuK 17/X4
NA-66-1032
A
A
oyo2
A
12
Q
4
~X
10)
P
P\
(14)
(13
15
\/A
06
A1 1I
21
19~
51-10-50
Page 14
Aug 17/84
AW
RD
/~A
Vertical
Fittings
CC~PYRIGHT,
NA-66-1032
AW
Table 7.
RD
Vertical Stabilizer/Rudder
Fittings
WEAR ALLOWANCES
ITEM
DESCRIPTION
NO.
SUPPORT
265-240419
HOLE
SHAFT
HOLE
leou
ID(MAX)
NAS1104-bW
AN200KS4
BEARING
MFD SHAFT
OD(MIN)
MFD
WEAR
ALLOWANCE
ALLOWANCE
(MAX)
(MAX)
0.2540
0.1485
0.0055
00070
0.9014
0.9009
0.0005
0.0005
0.0013
BEARING
AN200KS4
IPIN
265-240422-3
0.2500
0.2487
0.0013
BRACKET
165-240209-5
PIN
265-240422-3
0.2510
0.2487
0.0023
0.0033
SUPPORT
265-230321
BOLT
NAS1104-6W
0.2540
0.1485
0.0055
0.0065
SUPPORT
265-230322
BOLT
NAS11046W
0.1540
0.1485
0.0055
0.0065
SUPPORT
265-240428-11
BOLT
NAS1104-12W
0.2540
0.2485
0.0055
0.0070
BEARING
1.0000
0.9995
0.0005
PIN
165-240411-3
0.2500
0.2487
0.0013
0.0013
4
5
8-4
0.0005
BEARING
8-4
BRACKET
165240209-3
PIN
165-240412-3
0.2510
0.2487
0.0023
0.0030
SUPPORT
265-230427
BOLT
NAS1104-12W
0.2540
0.2485
0.0055
0.0070
10
SUPPORT
265-230428
BOLT
NAS1104-12W
0.2540
0.1485
0.0055
0.0070
11
CLEVIS
265-140425
BEARING
0.6250
0.6145
0.0005
0.0005
12
BEARING
AN200KS3L
0.1900
0.1875
0.0025
0.0025
13
RETAINER
265-240426
BEARING AN200KS3L
0.6250
0.6245
0.0005
0.0005
14
BEARING
AN200KS3L
PIN
0.1900
0.1875
0.0025
0.0025
)5
SUPPORT
265-140417
BEARING
3.2535
3.2490
0.0045
0.0045
16
BEARING
KP378S
SUPPORT
2.3130
1.3090
0.0040
0.0040
17
SUPPORT
265-240406
IBEARING
KP218S
2.1510
2.1490
0.0020
0.0020
18
BEARING
KP?IBS
265-240407
1.3130
1.3090
0.0040
0.0040
19
SUPPORT
165-313424
0.5010
0.5010
0.0000
0.0010
20
BUSHING
4819-56-005
BOLT
0.3155
0.3717
0.0028
0.0040
BEAM
265-230301
BUSHING4BM2O
0.5005
0.5010
0.0005
0.0005
BUSHING
48M10-56-OD5
BOLT
0.3755
0.3727
0.0028
0.0040
11
22
IPIN
AN200KS3L
165-240427-5
265-240424-5
HORN
KP378S
265-240409
IBUSHING4B19-56-005
MS20006-8
MS20006-8
REBUSHING DATA
ITEM
SUPPORT
BUSHING
DIA
REAM
DESCRIPTION
NO.
(MAX)
A
265-240419
0.282
MATERIAL
1
NEAT-TREAT(PSI)
REPLACE WORN PART.

REPLACE WORN PART.
BEARING
AN?0OKS4
BRACKET
265-240209-5
SUPPORT
265-230231
SUPPORT
265-230322
SUPPORT
265-240428-11
USE NEXT LARGER SIZE
0.182
REPLACE WORN PART.
BEARING
8-4
BRACKET
265-240209-3
SUPPORT
265-130427
10
SUPPORT
265-130428
REPLACE WORN PART.
11
CLEVIS
265-240425
REPLACE WORN PART.
BEARING
AN?OOKS3L
REPLACE WORN PART.
RETAINER
265240426
REPLACE WORN PART.
14
BEARING
ANSODKS3L
REPLACE WORN PART.
IS
SUPPORT
165-140417
REPLACE WORN PART.
16
BEARING
KP378S
REPLACE WORN PART.
17
SUPPORT
265-240406
REPLACE WORN PART.
18
BEARING
KP2IBS
A
A
10
BVSHINC
4819-56-005
1\
21
BEAM
265-230301
22
BUIHIND
48120-56-005
0.2540
REPLACE WORN PART.
12
265-313424
0.2490
REPLACE WORN PART.
13
SUPPORT
FASTENER.
I
REPLACE WORN PART.
0.2540
REPLACE WORN PART.
19
0.2490
USE NEXT LARGER SIZE FASTENER.
~IN.ID(MAX)
FIN.ID(MIN)
1
0.1540
0.2490
REPLACE WORN PART.
0.5115
lil
1
~30 01 4135
STEEL TUBING
125.000 TO 145,0001
0.3745
125,000 TO 145,000
0.3145
0.3755
0.5115
4130 OR 4135
STEEL TUBING
03~55
NOTES
STRUCTURAL
JOINTS"
FOR
(REBUSHING)
OF
ADDITIONAL
INFORMATION.
I~
USE 4826
(SALVAGE) BUSHING. (SEE ..BUSHING
MANUFACTURE AND INSTALLATION" ILLUSTRATION.)
REPLACE WITH LIKE PART WHEN 8VSHING IS WORN.

REPLACE WITH
OVERSIZE OD BUSHING
BUSHING HOUSING IS WORN.
WHEN
51-10-50
PaRe 1.5/16 Blank
Aug 17/N4
NA-66-1032
STRUCTURAI, REPAIR MANUAL
STRUCTURAL JOINT WEAR

REPAIR
WEAR AND BUSHING (REBUSHING) OF
STRUCTURAL JOINTS
Details necessary for the manufacture and installation of
bushings referenced in figures 1 thru 7 are given in tables
201 thru 203. Two of the bushings shown (4B19 and 4B20)
are NAA standard parts used in the original design. The
third bushing (4B26) is an NAA thin-wall "salvage"
bushing that may have been used when a hole was
inadvertently made too large.
Proeedure
1.
2.
NOTE
~f the flange is to be formed inwa,d, the

initial position of theformin9 balls should
be at a diameter slightlll barger than the
outside diameter ofthaflctnge b4ingfor*ned.
If the flange is being formed outlc~ard, fhc
initial location of theformang balls should
be a diameter sli.ghtly smaller than the
inside diameter oftheflange beingformed.
oversize bushing must be used. The permissible oversize

is given in tables 1 thru 7. Worn holes not previously
bushed may be bushed with either a 4B19 or a 4B20
bushing as directed in tables 1 thru 7.
Preparation
Position three steel forming balls in indexed holes of
forming head.
Worn 4B19 and 4B20 bushings would normally be

replaced with bushings of like dimensions; however, if the
hole receiving the bushing is worn or corroded, an
Hole
Assemble bearing flange expander tool through

bearing, bearing retainer, and structure cantaining~
bearing retainer.
3.
Ream holes to accommodate oversize (OD) bushings

(bearings) as indicated in table 1 thru 7. (Refer to
interference fit chart in tables 201 thru 203. The inside
surface of the reamed hole should have a 125 (or finer)
microinch finish. When bushing is to be staked, break
shoulder 0.005 in. (maximum). When bushing is not to be
staked, break shoulder 0.005 to 0.015 in.
4.
5~
joint.
6.
Details and dimensions of the bearing retainer flange

expander tool components are shown in figure 201. To use
bearing retainer flange expander tool, proceed as follows:
i th
light
forming difficult.
Lul>ricate parts with wet zinc-chromate primer and press

bushing or bearings into place. Stake bearing when
rerluired and line-ream to finish size. Paint outer edges of
bu:;hing (bearing) with zinc-chromate primer to seal
HEARING RETAINER FLANGE EXPANDING

TOOI,
If excessive pressure is applied on the

compression nut, it will result in
indentions to the flange, which will make
Hushing Installation
To Iac:ilitate installation, the bushing or bearing may be

sh Iu nk t,y means of;l dry-ice soak. A Ilow part to remain in
dry ice until it is thoroughly chilled.
Coat steel form i ng balls and th rust ~rashel

grease.
Tighten compression nut so that a slight.

pressure is applied to flange being formed.
Using
tool
a socket and ratchet handle, rotate

minimum of five revolutions.
e\.en
expandel
Tighten compression nut and repeat forming

operation until flanRe is formed as far as possible
with forming balls at present location.
7.
compression nut and relocate forming bat is to

position (eithel inward or outward, as
required).
Iloosen
next indexed
8.
Continue forming aperation until retainer flarl#e is
tight against surface.
51-1 0-50
0
Page 801
Aug 17/84
NA-66-1032
KIRI(TI-KAI, KEPAIR MANUAI,
lable 801,
nushing Manufacture and Installation-4B1S-Standard
Wall Bushing
DIMENSIONS APPLY BEFORE PLATING.
L--0.010
125
(1O.0OO. --0.005) --r---------~1
~L
DIMENIIONI
FltJI
Dl~n
125
om
ID
1
3
0.1900
10.3140
+0.0000
-0.0001
0.1500
0.3765
+0.0000
-0.0005
0.3125
0.4390
+0.0000
--0.0005
0.3750
9.5815
+0.0000
-0.0005
0.4375
0.5645
+0.0000
-0.0010
0.5000
0.6170
0.5625
0.6895
+0.0000
--0.0010
10
0.6250
0.7510
+9.9969
-0.0010
MATERIAL
11
0.6875
0.8145
+0.0000
-0.0010
12
0.7500
10.6770
+0.0000
-0.0010
4135 STEEL TUBING, 6836372
14
0.8750
1.0010
+0.0000
-0.0010
HEAT-TREAT: HEAT-TREAT STEEL 125 TO 145 KSI ACCORDING TO MIL. SPEC MlL-H-6S75.
16
1.0000
)1.1275
+0.0010
-0.0010
18
1.1150
1.2525
10
1.1500
1.3775
12
1.3750
1.5025
+9.9000
-0.0010
14
1.5000
1.6275
+0.0000
-0.0010
26
1.6250
1.7515
+0.0000
-0.0010
1.7500
11.8775
+0.0000
-0.0010
30
1.8750
1.0015
+0.0000
-0.0010
31
2.0600
1.1115
+0.0000
-0.0010
36
2.1500
2.3775
+0.0000
-0.0010
r
to
(+o.oooq
BREAK 0.0385 TO 0.015
1
OO.
-ft
MAX ECCENTRICITY 0.003 TIR
MATERIAL: AS OESIGNATEO BY SYMBOL IN PART NUMBER
+0.0000
-0.0010
SYMBOL
B
C
AL BRONZE BAR, 65134631

17-488 CRES BAR, NAA SPEC LBO16O-133
4130 STEEL TUBING. MIL. SPEC Mll-T-6736. CONO N
HEAT-TREAT 174PH CRES 155 TO 185 KSI ACCORDING TO MIL. SPEC MILH6875.
+0.0000
-0.0010
FINISH: AL BRONZE OR 4130 ANO 4135 STEEL
CAOIMUM-PLATE ACCORDING TO FEO. SPEC 00-8-416, TYPE II. CLASS 3. ALL SURFACES
+9.9699
-0.0010
EXCEPT 1B.
MAGNETIC INSPECTION: ACCOROING TO MIL. SPEC MIL-I-6868 IF INDICATEO BY SUMBOL IN PART
NUMBER.
PART NUMBER CODE:
18
DRAWING NO.
MAGNETIC INSPECTION FOR STEEL BUSHING ONLY WHEN REOO.

MATERIALSYMBOL.
FIRST BASH NO. INDICATES OIAMETRAL DIMENSIONS. PEE TABLE.)
LAST DASH NO. INDICATES L IN 1N. AND 32888.
4819M-S12-102
FOR EXAMPLE: 102 INDICATES 1-1/16
lOOINOICATES 1
40
1.5000
+0.0000
(1.6175 -0.0010
010 INDICATES 5/16
INTERFERENCE FIT.
INTERFERENCE
BUSHING OD
(IN.)
UP TO
NO
1/2
1/2 To
MIN
MAX
0.0005
0.0020
0.0005
0.0025
0.0010
0.0030
OD OF A REPLACEMENT BUSHING MAY BE INCREASED TO
OVER
ACCOMMODATE WORN HOLE WHEN PERMITTED, AND TO

THE EXTENT
PERMITTED. IN WEAR AND REBUSHING DATA
CHARTS
2
SURFACE ROUGHNESS IS 125 FOR BUSHINGS WITH L EQUAL

TO
(OR LESS THAN) THREE TIMES THE ID; 250 WHEN
INSTALLATION DATA
L IS
GREATER THAN THREE TIMES THE ID

DIMENSION L IS 0.010 TO 0.015 IN. SHORTER THAN THE
THICKNESS OF THE BUSHED PART.
51-10-50
False 202
Auff 17/84
COPYR IGHT 1984 BY SABRELIN ER COR PORATION
NA-66-1032
STH17CrllRAI, REIAIK MANI:,~I,
lable ~()2.
13ushing Manufacture and Installation-4R20-FIanffed
1O.OOO.
0.062
--0.005)1
L(t0,OO5)
GROOVE OPTIONAL
0.062 MAX WIOTH
0.003 MAX DEPTH
125
Rushing
FIRST
DIMENSIONS
DASH
8.865 MIN R FILLETS
NO.
FD
ID
0.005
TO 0.0158
1.10.00051
MAX ECCENTRICITY 8.8113 TIR
--~L
01900
0.3140
0.2500
0.3765
+0.0000
-0.0005
+0.0000
-0.0005
+0.0000
0.3115
0.4390
0.3750
105015
0.4375
0.5645
0.5000
0.6270
-0.0005
+0.0000
-0.0005
+0.0000
-0.0010
MATERIAL: AS OESIGNATED BY SYMBOL IN PART NUMBER

SYMBOL
B
AL BRONZE BAR, AMS4631
17-488 CRES BAR, NAA SPEC LBO16O-133
4130 STEEL TUBING, MIL. SPEC Mll-T-6736. CONO N

4135 STEEL TUBING, AMSO372
0.5615
0.6895
10
0.7510
0.6250
CAOIMUM-PLATE ACCORDING TO FEB. SPEC 00-P-418, TYPE II, CLASS 3, ALL SUAFACES
EXCEPT 1B.
0.8146
11
0.7500
0.8770
14
0.87H)
1.0010
,.oooo
1.1275+0.0000
1.1150
1.2525
18
MAGNETIC INSPECTION: ACCORDING TO MIL. SPEC Mil-1-6888 IF INDICATED BY SUMBOL IN PART

NUMBER.
1.2500
1.3775
12
1.3750
1.5025
no.
MAGNETIC INSPECTION FOR STEEL BUSHING ONLY WHEN REOO.
14
1.5000
11.6275
16
1.6150
11.7525
1.7500
1.8775
MATERIAL SYMBOL.
FIRST DASH NO. INDICATES DIAMETRAL DIMENSIONS.
(SEE TABLE.)
LAST DASH NO. INDICATES L IN IN. AND 32883.

18
1OO1NDICATES 1
30
1.8750
1.0025
31
2.0000
2.1275
36
2.2500
2.3775
010 INOICITES 5/16
40
-0.0010
+9.0000
-0.0010
+0.0000
-0.0010
-0.00~0
26
PART NUMBEB CODE:
+0.0000
0.6875
16
1.6275
1.5000
+0.0000
-0.0010
+0.0000
-0.0010
+0.0000
-o.~olo
+0.0000
-0.0010
+9.9999
-0.0010
+0.0000
-0.0010
+0.0000
-0.0010
9.6999
-0.0010
+0.0000
-0.0010
+0.0000
-0.0010
INTERFERENCE:
(IN.)
MIN
UPTOI/2
0.0005
1/2
NOTE~S
~ODOF AREPLACEMENTBUSHINGMAYsEINCAEASEDTO
ACCOMMODATE
AND
TO
THE
WORN
EXTENT
HOLES
10 1
OVIR
WHEN
PERMITTED,
IN
0.43)
0.500
0.561
0.611
0.668
0.750
0.811
0.875
0.93(
1.000
1.115
1.259
1.375
1.509
1.625
1.750
1.875
1.000
2.125
2.250
2.500
1.750
F1T
INTERFERENCE
BUSHING OD
INSTALLATION DATA
iD
+0.0000
-0.0010
11
FINISH: AL BRONZE OR 4130 AND 4135 STEEL
4820M-512-102
+0.0000
-0.0010
HEAT-TREAT: HEAT-TREAT STEEL 125 TO 145 KSI ACCORDING TO MIL. SPEC MIL-H-6B75.
HEAT-TREAT 17-488 CRES 155 TO 185 KSI ACCORDING TO MIL. SPEC MlL-H-6B75.
IJIhj
+0.0000
--0.0010
MATERIAL
op~wsl
OD
00.
~(ti
BREAK 0.0005 TO 0.015
ID
MAX
0.0010
0.0005
0.0025
0.0010
0.0030
PERMITTED.
WEAR
AND
REBUSHING DATA CHARTS.
SURFACE ROUGHNESS IS 125 FOR BUSHINGS WITH L
EQUALTO(ORLESSTHAN)THREETIMESTHEID;250
WHEN L IS GREATER THAN THREE TIMES THE ID.
51-10-50
g
Paffc L03
Aug lii84
NA-66-103~
STKI(TIRAL REPAIR MANCIAI,
?able 208.
BushinR Manufacture and Installation-4B26-Thin-Wall
L-O.Olo 1O.0OO. --0.005)
(Salvage) IBushinff
125
DIMENSIONS
FIRST
DASH
ID
NO.
OD
oo
01900
102515
0.2500
10.3140
0.3125
10.3765
0.3750
10.4390
0.4375
0.5015
0.5000
0.5645
0.5625
10.6270
MAX ECCENTRICITY 8.883 Tlff ---r
BREAK 0.0005 TO 0.015
MATERIAL: 4130 STEEL BAR MIL. SPEC
Mll-S6758
HEAT-TREAT: 160,881 to 180.000 PSI I\CCOROING TO MIL. SPEC Mll-S-6758.
+0.0000
0.0005
+0.0000
-0.0005
0.0000
-0.0005
+0.0000
-0.0005
0.0000
-0.0010
0.0000
0.6250
10.6895
11
0.6875
0.7520
+0.0000
-0.0010
12
0.7500
0.8145
+0.0000
-0.0010
14
0.8750
0.9395
FINISH: CAOIMUM-PLATE 0.0002 TO 0.0004
THICKNESS. ACCOROING TO FEO SPEC
-0.0010
+0.0000
-0.0010
90-P416 ALL SURFACES EXCEPT 10.

MAGNETIC INSPECTION: ACCORDING TO MIL. SPEC Mil-1-6868
BY SUMBOL IN PART NUMBER.
PART NUMBER CODE:
1 I~DRIWING
NO.
16
MLGNETIC INSPECTION WNEN REOOIAEO.
FIRST BASH HO. INDICATES OIAMETRAL OIMENSIONS.
1.0000
1.0650
+0.0000
-0.0010
- 0.0010+0.0000
ISEE TABLE)
LAST DASH NO. INOICATES L IN IN. AND 32888.

INTERFERENCE FIT
016 INDICATES 1/2
16
BUSHINGOD
(IN.)
UP TO
1/2
1/2 TO
OVER
INiERFERENCE
MIN
1
1
MAX
0.0005
0.0020
0.0005
0.0025
0.0010
0.0030
INSTALLATION OATA
DIMENSION L IS 0010 TO 0.015 IN. SHORTER THAN THE
THICKNESS OF THE BUSHED PART.
NO?~S
SURFACE ROUGHNESS IS 125 FOR BUSHINGS WITH L EOUAL
TO (OR LESS
THAN) THREE TIMES THE ID;
250 WHEN L IS
GREATER THAN THREE TIMES THE ID

THE 4826 BUSHING IS NOT CALLED OUT ON MANUFACTUR-
ING DRAWINGS
HOWEVER. IT MAY HAVE BEEN USED AS A
SALVAGE BUSHING. THIS BUSHING MAY ALSO BE USED TO
BUSH WORN HOLES (NOT PREVIOUSLY
BUSHED)
WHEN SO
DIRECTED IN WEAR AND REBUSHING DATA CHARTS.
51-10-50
Pal$e 804
Auff 17/84
NA-66-1032
3 EACH 1/4 IN.

STEEL BALLS
THRUST EARING
i NAASININ.HEX READ BOLT
IORIVEN WITH
RATCHET WRENCHI
INITIAL POSITION FOR FORMING
FLANOEOUTWARO
f
3/4 IN. HEX NUT
INITIAL POSITION FOR FORMING FLANGE INWARD
FORMING HEAD
BACKUP~PLATE
1/845~
30" TYP
90.2,3,4,5
----Y/
CHAMFER
AND 6 HOLES
10"TYP
BETWEEN
NO. 1
NO, 5 HOLES
0.220 IN.
ANDt
OQ
-J:
QQ-1
1.90 IN."
OIA
NO, 1 HOLES
0.975 IN. OIA HOLE CIRCLE
NO, 2 HOLES
1.125 IN, OIA HOLE CIRCLE
NO. 3 HOLES
NO. 4 HOLES
1.250 IN. OIA HOLE CIRCLE

NO. 5 HOLES
0.125 IN.
0.75 IN,
1.1OIN.
_1
iA
o
I
sn
TYPE
c/
ic., d
NO. 6 HOLES --1.625 IN. OIA HOLE CIRCLE

1.675 IN. 0111 HOLE CIRCLE
NO, 7 HOLES
15" TYP
1.
FOAMING HEAD
NO, 7 HOLES
t
1.90 IN.
r---I
t
0.75 IN,
NOTES
t-
Break all sharp
edges.
Cadmiumplateper QQ-P-416,
1.251N.
Heat-treat to Roekwell CS6-40 per

1MIL-H-68r5.
Eachseries of three countersunkholesto be
the same depth as nearly as possible.
This assembly can be adapted for use to
other bearing installations,
0.125 IN.
it
;t
o.rao
BACKUP PLATE
Bearing Retainer Flange Expanding Tool

Figure 201
51-10-50
Page 205
Jun 3/88
NA-66-1032
SELECTION AND INSTALLATION

OF ACRES FASTENER SLEEVES
1MIL-S-85069
51-1.
51-2.
into areas where holes need protection such as vent

holes, drain holes, or through composite structure.
ACRESFASTENER SLEEVES.
INTRODUCTION. Acres Fastener Sleeves
are
51-4.
precision formed, thin wall, tubular elements with

to meet
a flared end. These sleeves were developed
several specific needs such as bushing oversize
holes, protecting from corrosion, and to aid sealing,
51-3.
The first reason is to trap sealant in

between the sleeve and the wall of the hole to
afford better seals. The second reason being to aid
in adjusting the sleeve to length. MIL-S-85069 and
associated slash pages cover the fastener sleeves as
shown in Table 204.
reasons.
PURPOSE. The primary purpose for Acres Fas-
repair enlarged holes. The

in standard fastener diameters with
standard fastener heads. The sleeves are generally
1 inch long and are adjusted to the length of fastener being used. Acres Sleeves may be bonded
tener Sleeves is to
sleeves
come
Table 204.
DESCRIPTION. Acres Fastener Sleevesaremanufactured from A286 stainless steel. There are in
general four head styles; three flush and one protruding.(See Table 205.) The sleeves have grooves
on the shank spaced 1/16 of an inch apart for two
MIL-SPEC Numbers for Acres Fastener Sleeves
MIL-S-85069/2
Sleeves, fastener, grooved, protruding head (shear and tension),

1/64 oversize.
MIL-S-85069/3
Sleeves, fastener, grooved, 1000 flush reduced head (shear),
1/64 oversize.
1/64
MIL-S-85069/4
Sleeves, fastener, grooved, 100" flush head (i.e., MS20426),
1/64
MIL-S-85069/5
Sleeves, fastener, grooved, 100" flush full head (tension, i.e., AN509),
1/64
oversize.
MIL-S-85069/6
Sleeves, fastener, grooved, protruding head, (shear and tension),

1/32 oversize.
MIL-S-85069/7
Sleeves, fastener, grooved, 1000 flush reduced head (shear),

1/32 oversize.
MIL-S-85069/8
Sleeves, fastener, grooved, 100" flush head (i.e., MS20426),

1/32 oversize.
MIL-S-85069/9
Sleeves, fastener, grooved, 100" flush full head (tension, i.e., AN509),
1/32 oversize.
1/32
oversize.
Acres sleeves
are
ETON.srenetsaf
not to be used with
ezpandable type
51-10-50
Page 206
Mar 16/90
NA-66-1032
Table 205.
For Fart.
MIL-S-85069
Configuration
Acres Fastener Sleeves Styles
Sleeve
With
Vendor
Part
Number
These
Head
Descrip
T~oling
tion
Tool
Part
Number
Styler
Step
FaltanersShear
Plate
JK5517CXX
Mit-5-85069/2
~nrama
Step
05,55
and
w
vl
Plot. Hd.
Plate
Dia
Tension
JK6555-XX
JK6557-05
JK6557-55
Only
Break
Off
Reduced
1N
JKISIZCXXI
JK654&XX
Handle
(NAS1097)
J~-I MILS-85069/3
z
Inserting
Sheat
Flush
Head
er
Tool
JK5514CXX
II
Interference
[MS20426
IL
JK6536XX
Only
MIL-S85069/4
Tension
Flush
Head
~IID
JK5516CXX
Removing
Tool
JK6526-XX
(AN 509)
MIL-S-85069/5
W
N
v,
a:
~rm
MIL-S-85069/6
Prot. Hd.
FastenersShaar
Plate
JK6556-XX
and
Tension
Reduced
Sheer
Flush
Head
Wcu
Step
JK5577C XX
I
I
I
I
JK5572C
XXI
I
I
Break
I /V
Handle
JK6546-XX
MIL-S85069/7 I(NAS1097)
Sheat
HeadFlush
I MIL-S-85069/8
L-SS5069/9
ToolInserting
JK6536-XX
M520426)
Tension
Flush
Head
MI
JK5574C XX
JK5576C XX
~ZS)
Removing
Tool
JK6524-XX
(AN509)
51-10-50
6
Page 207
Jun 3/88
NA-66-1032

MIL-S-85069
51-5.
OVERSIZE FASTENER SLEEVES, TYPE I.
51-7.
Sleeve shall correspond to the fastener configuration (flush or protruding head), fastener application (tension or shear), and fastener diameter. See
slash sheet. Each type of sleeve is stocked in only
one length. Diameters #10 through 3/8 inch have
a i-inch grip length. All sleeves have external
circumferential grooves spaced 1/16 inch apart
over the straight portion of their grip length.
51-8.
Sleeves shall be prepared for installation by breaking or grinding them off at a groove so that the
grip length will be the same as the fastener grip
length. If the grip length or the fastener is longer
than the maximum length of the sleeves as listed
in paragraph 51-7, an additional cylindrical sec-
TypeI, Classl,
a.
First Oversize, 1/64
MIL-S-85069/(2-5)
TypeI, ClassZ,
b.
Second Oversize, 1/32

MIL-S-85069/(0-9)
51-6.
Drill or ream the hole for the application fastener

and sleeve in accordance with applicable slash
sheet. If flush head fasteners are to be installed,
the countersink in the material will have to be
deepened 0.005 for 1/64 and 0.010 for 1/32 oversize to accommodate the countersunk portion of
the sleeve. The installed sleeve and fastener shall
meet the applicable aerodynamics smoothness requirements on exterior surfaces. Except where a
smoother finish is specified on the engineering
drawing or in the fastener installation document,
the surface finish of the hole shall not exceed 125
RHR as defined in ANSI-B-46.1.
tion broken from a second sleeve may be used to

make up the required fastener grip length. Do
not use a section of sleeve less than 1/4 of an inch
long. Break off tools listed in Table 205 must be
used.
51-9.
51-10.
ADJUSTINGTO LENGTH.
Using step plate (see Table 205) and breakoff

handle (see Table 205), break sleeve to length per
Figures 202 and 203.
00 NOT BREAK OFF SLEEVES IN

COLOREO AREA. ORI#O OFF.
PROT. HO.
FLUSH REOUCEO SMEAR
FLUSH. I.E., AW509
~r-
PLUIH. I.E. MB0121
INSERT SLEEVE IN PROPER HOLE

FOR HEAO STYLE. SELECT
STEP FORCORRECTORIP.
INSERT SLEEVE INTO HOLE OF
OESIREO LENGTH SO THAT
BREAKOFF GROOVE OW SLEEVE IS

FLUSH WITH BACK SURFACE OF
II
STEP PLATE.
FIT COLLAR OVER SLEEVE UNTIL
FLUSH WITH STEP PLATE.
~ET
51-10-50
Page
Adjusting Sleeve to Length

208
Jun 3/88
NA-66-1032
FIT BREAKOFF HAWDLE
FLUSH AGAINST COLLAR.
/e
ADJUST BREAKOFF HAROLE OOWNWARO

WITH BRISK MOTIOH.
ROLO SLEEVE
FIRMLV IH PLACE.
1
ROTATE UPWARO TO COMPLETE
BREAKOFF OF SLEEVE.
mt~llrma
Remove remaining portion of sleeve in collar b21 withdrawing breakoff handle then
pushingforward to ejectfrom collar.
Adjusting Sleeve to Lenffth

51-10-50
0
Page 209
Jun 3/88
NA-66-1032

MIL-S-85069
ALTERNATE METHOD OF ADJUSTING
SLEEVE TO LENGTH IN STRUCTURE. To
adjust sleeve to length in a structure, be sure the
structure sheets are firmly held together. Insert
the sleeve into the hole until the head is fully
seated. Examine the rear protrusion of the sleeve.
If a groove is barely visible on thesleeve next to
the sheet, use the breakoff handle to break off the
protruding section of sleeve. If the back surface of
the sheet falls inbetween grooves, use a standard
washer, 1/32 inch thick, with the hole enlarged
with the same drill or reamer used to manufacture
the hole to accept the sleeve. Place this washer on
the sleeve and push securely against the back
sheet. Then using the breakoff handle, break off
the portion of the sleeve standing above the
washer. This will always leave the sleeve protruding slightly from the back sheet. The washer may
be left on or may be removed and a nut or collar
with the proper counterbore used on the bolt.
51-11.
51-12.
PROCEDURE FOR GRINDING SLEEVE TO

PROPER LENGTH. (See Figure 203.)
51-13.
INSTALLATION
51-14.
Fastener sleeves must be installed with reasonable care to insure that they function properly in
inhibiting corrosion, sealing, and in serving to
restore the structural integrity of joints in modification, repair or in the original manufacture of
JKB538-XX
JK853CXX
Installing
or military hardware. The installation

information available and the processing specification should be followed. Various tools are available which facilitate and insure that the sleeve
installations may be properly performed.
aerospace
51-15.
sleeve and the sleeve inserted into the hole. If

there is an interference fit between the sleeve and
the hole, inserting tool JK6536-XX shall be used
to install the sleeve into the hole. The same material shall be applied to the shank of the fastener
and the fastener inserted or driven into the
sleeve. Do not allow the compound to cure before
completing the i~lstallation. (See Figure 204.)
r COARECT
GRIP
Fasteners and sleeves shall be installed wet with
sealing compounds as required. A thin coat of

material shall be applied to the exterior of the
Fasteners and Sleeves

Figure 204
LENGTH
61-16.
STEP PLATE
51-17.
WHEN
.YRASSE-CEN
BACK
SIDE
Normally thesleeve doesnotneed tobeflushon

the backside. The sleeve protrusion will fit into
the same counterbore in the attaching nut or collar as an oversize bolt. A washer may be used
SLEEVE
when necessary.
51-18.
When the sleeve must be flush on the back side it

may be trimmed by using a counterbore or countersink in a cage. Adjust the cage to cut flush. A
pilot on the cutting tool to fit the sleeve hole must
be used. Cut slowly.
51-19.
To keep the sleeve from turning it is helpful to

have it in an interference fit. It may be bonded
into the material and held by tools as shown in
Figure 205.
O
BELT SANDER
NOTES
dise sander.
i.
1May also be ground
W.
Deburrinside and out.
3.
Donotgrindthe bottomofthestepplate.
Grinding Sleeve to Proper Length
I,,,,,,,
on
51-20.
SLEEVES, FASTENERS, DESIGN AND

USAGE LIMITATIONS.
FigureZOB
51-10-50
Page
210
Jun 3/88
NA-66-1032

MIL-S-85069
51-21.
Fastener sleeves replace oversize shank fastenUse the sleeves with standard diameter
straight fasteners. Use fastener sleeves under the
same restrictions as oversize fasteners and in
compliance with the specific users repair procedures and restrictions.
ers.
51-22.
A.
In fluid
B.
Fatigue and fracture critical locations.
C.
Edge distance, measured from the center of

the hole, is less than 1-1/2 diameter.
D.
The number of discrepant holes being repaired in the pattern is greater than 10% of
the total number of holes in the pattern.
RESTRICTED APPLICATIONS.
A.
Fastenersleevesshall notbeused inthoseapplications utilizing tapered shank fasteners.
E.
applications.
More than three (3) adjacent holes
are
dis-
crepant.
51-24.
Deviation from any of the above requirements

approved by the procuring agency.
must be
51-25.
APPLICATION.
A.
When the edge distance measured from the

center of the holes is 2D or greater, there is
no restriction on the number or location of
fasteners installed with sleeves.
B.
Sleeves are to be used only on/with fasteners

ranging from 5/32 through 3/8 inch nominal
C16E
COUITERSIWK
SLEEYE
PILOT
diameter and up to 2 inches thick stack up.
HOLDIIG TOOL
,..,.~-.-.f
JKO5O4-XX
Bonding Sleeve
Figure 205
B.
Fastener sleeves shall not be used in interference that exceeds 0.003 (hole to sleeve).
C.
These repair sleeves will not be used with

blind fasteners.
D.
The fastener or attaching element (nut or

collar) must contain a counterbore to accept
the protrusion of the sleeve or a washer must
be used or the sleeve may be flushed on the
backside.
51-23.
Procuring activity or the appropriate engineering organization (i.e., stress, strength, fatigue/
fracture) approval is required for the following

applications:
let
51-10-50
a
Page 211
Jun 3/88
NA-66-1032
Table 206.
Flush Shear Acres Fastener Sleeves
Dimensions
.OMR f.M5
111
111
ill
111
=.M)BIREFI
1~1,1
111
111
111
111
111
ill
10
1000
/I
a
BROOVES .0825
6--t(
~OWCEWTER
FOR
BOLT(REF) f.005A
SIZE
APPROVED
CALLOUT
DIA.
JKS514( )05(
5/92
.282
JK5514( )55( Ii)
#8
29~
JK5514( )Og( Ii)
#10
.347
JK5514( )08(
114
.470
JK5514( )l0( Il)
5/10
.558
JK5514( )12(
3/8
.688
DI
Do
DIA.
DIA.
.1585
.1730
.1550
.1120
.1635
.1800
.1620
.1790
.1895
.2055
.1880
.2015
.2495
.2656
.2480
2646
.3120
.3281
.3105
.3271
.3745
.3908
.3730
.3896
HF
(REF)
He
(REF)
DRILL
NO.
DRILL
DIA.
DRILL
NO.
DRILL
DIA.
11/84
.1119
.125
12
.053
.051)
17
.1730
.l25
12
.055
.060
15
.1800
.1785
.2055
.2040
.125
Is
.OT1
.076
.108
is
.098
.103
17/84
.2858
.2848
.250
18
.109
.114
21/84
.3281
.3285
.312
16
.137
.142
25/64
.3908
3890
SPECIAL DRILL
under one or more of the foIlowIng U.S. Pat~nb: 3,835,815;
ACRES FASTENER SLEEVES, J.O. KING, INC., manufeofured
and patent pending.
and
foreign
3,835,688;
3,805,578;
3,879,109; 3,873,895;
3,835,525;
PART NUMBER BREAKDOWN
7"JK5514
BASIC PART NUIIIIBER
MATERIAL: B
C
(OPTIONAL)
B= NONE
PER
INCH INDREMENTS
DlOlfS~\
LENGTH IN 1/16
8081 AL, T8 COND.
A286(PASSIVATED
CETYL ALCOHOL LUBRICANT
(ALWAVS
QQ-P-35)
SURFACE FINISH: N
C
FASTENER SHANK DIAMETER IN 32NDS

(ALWAYS 2 DIGITS; SEE TABLE)
~h
~2,
P=CAD. PLATE,
00-0-418
CLASS 2, TYPE II
i?cetrudions.
Lelyth repllired created ~y breakoff at proper groove. See
For metal-to-metal to
For
light interference
Sleeves 05-55
clearancefit of sleeve
to
ungrooved
to hole.
last
5/16~
CHEMICAL FILM
(PER MIL-C-5541)
NOTES
NONE
06-08
to
hole, stainless only.
ungrooved last 1/4",
10-18
ulylrooved
last
6/16".
JKBb55-XX
length: Use Step Plate JK6655r-XXfor sizes Ob-bb; use Step Plate
sizes.
for sizes 06-08-10-1L use Breakoff Handle JK8548-XXJor all
identification 1/64 oversize.
treatment-usedfor
ehromate
Plating Class 5 Type II, with supplementary
Toolingfor adjusting sleeves to
SLEEVE
JKSS14
GROOVED, 1000426 FLUSH SMEAR
1/64 OVERSIZE
JKSSla
NOTE
manzcSact~rers tablesfor current data.

This table is not being updated!
r51-18r5.
J.O. King, Incorporated nr Trabert Ave., N. W. Atlanta, Georgia, 30318 (404;)
Obtain
51-10-50
Page
212
Mar
16/90
NA-66-1032
Table 207.
Protruding Head Acres Fastener Sleeves
Dimensions
.OMR f .005
01
111
111
IJT/III
111
111
111
=.OOB(REEJ
III
111
r"l
.M15
GROOVES .0825
.010
OW CEITLR
APPROVED
CALLOUT
OPTONU
FOR
BOLT
SIZE
DIA.
DI
Do
(REF)
f.005
DIA.
DIA.
.1585
.1730
.1550
.1720
.1835
.1800
.1620
.1790
.1895
.2055
.1880
.2045
.2495
.2858
.2480
.2848
.3120
.3281
.3105
.3271
.3745
.3908
.3730
.3898
JK5517( )05( ill
5/32
.312
JK5517( )55(
#8
.325
JK5517( )06(
#10
.380
JK5517( )08(
1/4
.500
JK5517( )10(
5/18
.820
JK5517( )12( ill
3/8
.750
HOLEDRILL
DRILL
NO.
DRILL
DIA.
NO.
DRILL
DIA.
11/64
.1719
.125
12
17
.1730
.125
12
15
.1800
.125
16
.2055
.188
18
17/64
.2656
.2840
.250
16
21/64
.3281
.3265
.312
16
25/84
.3908
3890
.1785
.2040
SPECIAL DRILL
ACRES FASTENER SLEEVES, J.O. KING, INC., manufactured under
3,835,525; 3,879,109; 3,873,895; 3,805,578; 3,835,688;
end
one or more
of the
following
U.S. Patents:
3,835,815;
foreign patents and patent pending.
PART NUMBER BREAKDOWN
TJKJ51T
BASIC PART NUMBER
MATERIAL: B
C
(OPTIONAL)
B= NONE
LENGTH IN 1/18
(ALWAYS 2
6061 AL, T8 COND.
A2se(PASSIVATED
PER
CETYL ALCOHOL LUBRICANT
00-9-35)
SURFACE FINISH: N
C
FASTENER SHANK DIAMETER IN 32NDS

(ALWAYS 2 DIGITS; SEE TABLE)
Length required created by breakoff at proper groove. See instructions.
For metal-to-metal to
R
n
light interference
Sleeves 05-55
elearancefit of sleeve
to
ungrooved
3/16",
06-08
NONE
CHEMICAL FILM
P=CAD. PLATE,
00-9-416
CLASS2,TPYEIi
to hole.
last
INCREMENTS
(PER MIL-C-5541)
NOTES
For
INC~
to
hole, stainless only.
ungrooved last 1/4",
10-11
ungrooved
last
Toolingfor adjusting sleeves to length: Use Step Plate JK655r-XXfor sixes 05-55; use
sixes 06-08-10-1~2,use Breakoff Handle JK6548-XXfor all sizes.
5/1 6".
Step Plate JK6555-XXfor
Plating Class L Type II, with supplementary chromate treatment-usedfor identification 1/64 oversize.
JKSS17
SLEEVE
GROOVED, PROTRUDING HEAD TENSION TYPE
1/64 OVERSIZE
JK5Sf7
NOTE
This table is not being updated! Obtain manufacturers tablesfor current data.
J.O. King, Incorporated, nr Trabert Ave., N. W. Atlanta, Georgia, 30918 (404) r51-18r5.
51-10-50
0
Page 213
16/90
Mar
NA-66-1032
Kit Numbers
Table 208.
(Sheet
1 of
2)
ACRES FASTENER SLEEVES

KITS
MILITARY KITS FOR MIL-S-85069
KIT NUMBER
M 32
MILITARY
1/32 OVERSIZE
KIT
05
IZE
ADD "P" FOR PLATED
(QQ-P-41 6)
ARE A-286
IN PLASTIC BOX
EACH KIT CONTAINS THE FOLLOWING SLEEVES
SIZE 06
50 Ea.
MIL-S-85069/6
MIL-S-85069/8
MIL-S-85069/7
MIL-S-85069/9
SIZE 08
50 Ea.
MIL-S-85069/6
MIL-S-85069/8
MIL-S-85069/7
MIL-S-85069/9
SIZE 10
30 Ea.
lllllL-S-85069/6
MIL-S-85069/8
MIL-S-85069/7
MIL-S-85069/9
SIZE 12
30 Ea.
MIL-S-85069/6
MIL-S-85069/8
MIL-S-85069/7
MIL-S-85069/9
EACH KIT CONTAINS THE FOLLOWING TOOLS
1 Ea.
Step
Plate JK6556-xx
i Ea. Bleak O11 Handle JK6546-xx

i Ea. Sleeve Inserter JK6536-xw
1 Ea.
Removing
Tool JK6524-xx
FOR THE ABOVE TOOLING IN A PLASTIC BOX WITHOUT SLEEVES,

ADD A "T" ABOVE THE "M" BEFORE THE KIT PART NUMBER
EXAMPLE: MT32KCO5
51-10-50
Page 214
Mar 16/90
NA-66-1032
Table 208.
Kit Numbers
(Sheet
2 of
2)
ACRES FASTENER SLEEVES

KITS
MILITARY KITS FOR MIL-S-85069
KIT NUMBER
M 64
OVERSIZEj
MILITARY
1/64
KIT
05
"IZE
ADD "P" FOR PLATED
(Q -P416)ARE
IN PLASTIC BOX
286
EACH KIT CONTAINS THE FOLLOWING SLEEVES
SIZE 05
100 Ea.
MIL-S-85069/2
MIL-S-85069/4
lllllL-S-85069/3
MIL-S-85069/5
SIZE 55
100 Ea.
MIL-S-85069/2
MIL-S-85069/4
MIL-S-85069/3
MIL-S-85069/5
SIZE 06
100 Ea.
MIL-S-85069/2
MIL-S-85069/4
MIL-S-85069/3
MIL-S-85069/5
SIZE 08
90 Ea.
MIL-S-85069/2
MIL-S-85069/4
MIL-S-85069/3
SIZE 10
50 Ea.
MIL-S-85069/2
MIL-S-85069/4
NllL-S-85069/3
MIL-S-85069/5
MIL-S-85069/2
MIL-S-85069/4
MIL-S-85069/3
MIL-S-85D69/5
SIZE 12
30 Ea.
MIL-S-85069/5
EACH KIT CONTAINS THE FOLLOWING TOOLS

1 Ea.
Step
Plate JK6557 for 05 and 55 Sizes
JK6555for05-08-10-12
1 Ea. Break Ot1 Handle JK6548-xx
1 Ea. Sleeve Inserter JK6536-xx
1 Ea.
Removing Tool JK6526-xx
SLEEVES,
FOR THE ABOVE TOOLING IN A PLASTIC BOX WITHOUT
NUMBER
ADD A "T" ABOVE THE "M" BEFORE THE KIT PART
EXAMPLE: MT64KCO5
51-10-50
a
Page 215/216 Blank

Mar 16/90
1VA-fi6-103~
STRU(TUKAI, KEPAIR MAKIAI,
STKUCTUI1AL II)ENTIFI~:A?ION
(;I;NERAI,
Modern airplane specifications require that the airplane
exterior surfaces be of extremely smooth construction to
obtain design performance. The structural repairman
must keep this in mind when making repairs or changes.
FiSSure 101 shows the areas that are most critical aerotlynamically; however, smoothness of the entire airplane
surface area is a critical requirement from the
performance standpoint. The seriousness of th is condition
is I,roportional to the airflow disturbance created.
prime considerations of aerodynamic smoothness are

parasite d rag (draR caused by skin friction and nonliftinff
surfaces of an airl,lane) and the aerodynamic load
distribution on the surface. Any repair or change which
increases parasite drag will reduce the top speed of the
airplane. Also, range will be reduced, since more power,
and thus more fuel, is required to maintain cruising
speed.
7he
Any change which disturbs the smooth flow of air over a

critical surface will change the load on that surface, as
well as increase the drag. This effect is greatly increased
speeds because of shock-wave formation in

these speed regions. Since, in most cases, a shock wave
resultsin a radical change of the load distribution and an
increase in drag, a patch that will cause no difficulty
(disturbance) at low speed may become critical when a
shock wave is produced by this patch in the transonic
speed regions. If this flow change occurs on the wing, a
wins-heavy condition proportional to the amount of
disturbance will result. If this condition is on the vertical
stabilizer, a yawed flight condition will result. These
conditions become increasingly serious as control
efTcctiveness tlrops off at high Mach numbers. Any
in the ailflow around thtl control surfaces is
at transonic
c:1ilic;ll, sincr Iht~ contr,ol effectiveness, particularly at

high Mach numbers, may t,e affected.
Another problem that may arise at the high speeds is
bu ffeti ng. Ruffeti ng can be caused by airflow separation
around an abruptchange, such as a nonflush patch, in the
mold line.
51-10-60
C~aar l/d Hlank
o
Aug 17iX3
NA-(i6-103~
STKUCTUKAL KEPAIK MAhUAL
AI,LOWABI,E DAMAGE
RUDDER LEAOING
EOGE SKIN ANO
6 IN. FWO OF
CUTOUT
FUSELAGE SKIN AREAS ADJACENT TO
PYLON.PYLON.ANOINBOHALFOF
NACELLE
50
FUSELAGE
REFERENCE
PLANE IREF)
LEIOING
EDGE SKIN ANO 6 IN.
FWOOFCUTOUT
FLAP LEADING EDGE SKIN
-r
I
L,
AILERON LEADING
EDGE ANO UPPER ANO
STATIC PORTS
2 EACH SIDE
L-
INBO LEADING EDGE

ANO FILLET
MODEL NA 265-40
ANO -60 ONLY
LOWER MAIN BOX

SKINS FWO OF AILERON
TYPICAL FOR MODEL NA265-40,
WING
-60, -70, ANO -80
FUSELIICL-TYPICAL ~OA RLL SIBRELINEA

AIRPLANES EXCEPT AS NOTED.
SPOILERS ANO
FLAP LEADING
AILERON
EDGE
FILLET AREA
(EXCEPT
LEADING EDGE]
AILERON LEADING
TYPICAL FOR MODEL NA 285-608,

-6080, -65, -808, AND -8080
WING
STALL FENCE
EDGE. UPPER ANO

LOWER MAIN BOX
SKINS FWO OF AILERON
NOTES
TEMPORARY
(NONFLUSH)
REPAIRS
ARE
NOT
PER-
MITTED IN THESE AREAS.
F~
FLIGHT CHARACTERISTICS COULD BE AFFECTED BY

TEMPORARY
(NONFLUSH)
REPAIRS IN THESE AREAS
IF TEMPORARY REPAIRS ARE
SHOULD BE PERFORMED.
IN
MADE, A FLIGHT TEST

PERFORMING
FLIGHT
TEST: Il) CHECK FOR BUFFET UP TO LIMIT SPEED: (2)

WITH NONFLUSH REPAIRS ON FLAP LEADING EDGE.
CHECK FOR BUFFET WITH FLAPS DOWN AT SPEEDS
BELOW 130 KIAS.
Aerodynamically Critical Areas
Figure 101
0
51-10-60
Paffe 101/102 Blank
Aua 17i84
NA-66-1032
AERODYNAMIC SMOOTWNE SS
REPAIR
GENERAL
3.
Paste-type fillers that
hard-rubber-like consistency are used to fill skin and door gaps, to blend overlapcure
to
Cure filler for 24 hours and sand to blend with surround-
i"g
"eas.
NOTE
ping surfaces, and in other similar conditions to achieve a

satisfactory degree of aerodynamic smoothness.
Cure time may be accelerated with heat

Do not heat over I BO"F.
lamps
AERODYNAMIC FILLER APPLICATION
4.
Sand smooth and clean
Consumables
5.
Refinish to match surrounding
MATERIAL
Sealing Compound,
Sealing Compound,
Sealing Compound,
Sealing Compound,
SOURCE KEY
PR340
PR341
PS247
PS895
area
with MEK.
area.
es
002
001
002
002
001
014
Methyl Ethyl Ketone, (MEK)

Cleaning Compound 5381
NOTES
Class B
(non-flush) repairs should not be

on areas designated "critical "in
51-10-60, figure 101.
installed
Class B repairs provide the structural integritll of Class A repairs, but sacrifice
appearance and aerodynamic cleanliness.
Filler Preparation
Mix
according
to
manufacturers instructions.
Surface Preparation
1.
If surface is painted, remove all paint for a distance

of one in, along each side of area to be filled.
2.
If surface is not
MEK.
3.
Wipe cleaned
4.
Leave cleaner
5.
Rinse
6.
Allowsurface todry thoroughly.
Filler
1.
area
painted, clean
area
on
with
area
to be filled with
cleaning compound.
surface for 2 to 3 minutes.
with tap water.
Appplication
Apply filler
to gap
or
form fillet with putty knife
or
spatula.
2.
Smooth out filler, leaving bead or fillet slightly oversanding when cured.
full to allow for
Refer to 51-30-00 Table 2 for manufacturer.
51-10-60
0
Page 201/202 Blank

Jun 3/88
NA-fiG-1032
STRUCTIIRAL REIAIK MANC.2L
PROCESSES
STRUCTURAL IDENLIFICAI()N
(;ENERAL
Information pertaining to special processes used in the
of Sabreliner airplanes are contained in this
section. General engineering practices are not included;
however. deviations from general engineering practices
repair
are
provided. Unique repair procedures are incorporated

only referenced in this
in the repair information and

section.
51-20-00
P;lar 1;" lilank

AuR 17X1
NA-66-1032
FUSELAGE AND NACELLE SEALING

GENERAL
Fuselage and nacelle sealing is accomplished with

hardening sealing compounds, pressure-sensitive tapes,
and inflatable rubber and noninflatable rubber seals.
Sealing compounds may be spread with spatulas or knives

injected with hand-operated or pneumatically operated
guns. For a diagram of fuselage and nacelle sealed areas,
see figure 1 for Model NA 265-40, -60, -60A, and -60SC
and figure 2 for Model NA 265-70, -80, -80A, and -t)OSC.
or
CLEANING
a satisfactory seal, the area to be sealed must be
thoroughly cleaned before the application of the sealing
compound. With a vacuum cleaner or by wiping with a
clean, dry cloth, remove all dust and foreign matter from
To obtain
a clean cloth saturated with

ketone (MEK) or its equivalent, wipe the
area to be sealed. Before the MEK has evaporated
completely, dry the surface with a clean cloth. Repeat this
cleaning procedure until it is certain that no oil, grease, or
the
area
to be sealed. With
methyl ethyl
other contaminating substances are left on the surface to

be sealed. It is important that only clean cloths be used.
When a cloth becomes soiled, it should be discarded. To
avoid contaminating the solvent, the solvent should
always be poured from the container onto the cloth; never
dip the cloth into the container of solvent. If the sealing
compound is to be applied to surfaces that have been
primed, check the primed surface for lack of adhesion by
scratching the surface with the thumbnail. If the primer
is easily removed, its adhesion is considered unsatisfactory, and will necessitate removal of the primer before
the sealing compound is applied.
SEALANT MIXING
Mix the base compound and the accelerator together in
the proportions recommended by the manufactures. The
two components must be thoroughly mixed to completely
disperse the accelerator throughout the base compound.
If the mixture is not thoroughly blended there will be
areas where the cure will be incomplete. At room
temperature (approx. 770F) the blended sealant has a pot
life of three hours. Any sealant that has been exposed to
the atmosphere for a period of over three hours must be
discarded. The blended sealant may be stored at 0 to
-10"F for a period not to exceed 72 hours providing the
sealant is refrigerated immediately after blending.
51-20-10
0
Page 1
Aug 17/84
NA-66-1032
FUEL TANK BAY
LIPUIO SEAL
STA
PRESSURE SEAL
STA 76 TO STA 333-5/8
357
STA
PYLON-TO-FUSELAGE ATTACHMENTS
PRESSURE SEAL-STA 307-1/4
333-5/8
STA
FUMETIGHT SEAL-STA 333.5/8
301-7/8
STA
FLAMESEAL--STA357
206
PYLON-TO-NACELLE
ATTACHMENTS
ic
FUMETIGHT SEAL
76STA
DI
STA
DI
50
STA
25-13/16
G(
A~ilT
i;-7G
BC~
(~j
FIAE W~LLS
NAC
LIOUIR ANO
STA
FLAMESEAL
108.4
LIOUID SEAL
STA
33
ELECTRONIC ANO OXYGEN BAYS

FUMETIGHT SEAL
SEALANT
SEALANT
STA
333-5/8
SECTION
A-A
SECTION
:i
B-B
LIOUIO
STA
sra~
re
LIOUIOSEAL
rIYLON
~J;
FS 368
C
NOTE
Refer to "Fuselage and Nacelle Sealing"

repairfor detailed instructions.
Fuselage
and Nacelle
Sealing Model NA 265-40, -60, -60A, -60SC,

and -65
51-20-10
Page
June
3/88
NA-66-1032
STRUCTURAL KEPAIR MANUAI,
IIILIYT
SEALANT
LIOUIO SEAL
SLIOING WINDOW
SECTIONc-c
LH ONLY
IREFI
n~
SECTIOIIC-C
\Y
Y(
RH ONLY
FILLET SEAL
AROUND FLANGE
PRESSURE SEAL WITH
C-IR
PRESSURE SEAL
FILLET SEAL
15 PLACESI
SECTION
SECTION
E-E
IloulnsEnl
DD
INFLATABLE RUBBER SEAL
SECTION
R-R
EXTRUDED RUBBER SEAL
NOTE
to %uselage and Nacelle
detailed instrmetions.
Refer
Sealing" for
GROUNDESCAPEOOOR
ENTRANCEOOOR
(PRESSURE SEAL)
IPRESSURE SEAL)
Fuselage and Nacelle Sealing Model NA 265-40, -60, -60A, -60SC, and
-65
51-20-10
0
Page 3
3/88
Jun
NA-66-1032
U~P J
SECTION
PAESSURE SEnslTIVE TIPE
PRESSURE SEHSITIYE TAPE
PRIS)URI IIEISITIUE TL,,
F-F
SECTION
G-G
SECTION
H-H
STA 301-7/8 AT
PRESSURE SEAL
AIAPLANE CENTERLINE
SECTIONK~K
SECTIDNJ~J
PRESSURE SEAL
PRESSURE SEAL.
FILL JUGGLE FLUSH.
N~
N~7
SECTION
L-L
SECTION
M-M
PRESSURE SEAL.
FILL JUGGLE FLUSH.
PRESSURE SEAL
SECTION
SECTION
P-P
N-N
Fuselage and Nacelle Sealing Model NA 265-40, -60, -60A, -60SC, and -65
Figure
(Sheet
3 of
3)
51-20-10
Page 4
3/88
Jun
NA-66-1032
STRUCTURAI, REPAIR MANUAI,
STA
PYLON-TO-NACELLE
i
ALL ELECTRICAL
357
FUEL TANK BAY
CONNECTORS ANO FLUID LINE FLANGE
STA
333-5/8
FLAME SEAL
LIOUID SEAL
PRESSURE SEAL
STA 76 TO STA 333-5/8
STA
206+17
STA
STA
76
so
SSD
/3
iA
H
PYLON-TO-NACELLEINTERFACE
BETWEEN STA 357 AND 395.5
L
FLAME SEAL
LIOUID SEAL
ELECTRONIC ANB OXYGEN BAYS
FUMETIGHT SEAL
PRESSURE SEAL
PRESSURE
Sf~LIIIT
SEAL
SEALANT
PRESSURE SEAL
PRESSURE SEAL
STA
333-5/8
SECTION
A-A
SECTION
STA
B-B
LIOUIO
SEAL
LIOUIO
SEAL
=J
PYLON
FLAME SEAL
FS 344 ANO 368
(MOBEL NA 265-70 AIRPLANES)
NOTE
Refer to %uselage and Nacelle Sealing"

repairfor detailed instructions.
Fuselage and Nacelle Sealing Model NA 265-70, -80, -80A, and -80SC
51-20-10
Page 5
3/88
Jun
NA-6(i-1032
S1KUCTURAL REPAIH. MANUAI,
PRESSURE SEAL
PRESSURE SEAL
PRESSURE SEAL
SEALANT
SEALANT
SLIOING WINOOW IREF)
PRESSURE SEAL
SECTION
SEALANT
C-C
AH ONLY
SECTION
CC
LH ONLY
LIOUIO SEAL
SEALA#T
PRESSURE SEAL
i : -(
SEALANT
SECTION
DD
SECTION
E-E
INFLATI\BLE AUBBER SEAL
EXTRUOED RUBBER SEAL
NOTE
Refer to %uselage and Naeelle Sealing"for

detailed instruetions.
E,
51-20-10
Page 6
3/88
Jun
GRDUND ESCAPE DOOR
ENTRANCE 0O0R
(PRESSURESEAL]
(PRESSUAESEAL)
Fuselage and Nacelle Sealing 1Model NA 265-70, -80, -80A, and -80SC
COPYRIGHT, 1988
NA-66-1032
STRUCTUKAL KEPAIR MANUAI,
PRESSURE SENSITIVE TAPE 2 IN. WIOE BY 0.010 IN.

THICK. COVER GAP AWO FASTENER HEAOS.
PRESSURE SENSITIVE TAPE 2 IN. WIDE BY 0.010 IN.
PRESSURE SENSITIVE TAPE 2 IN. WIOE BY 0.010 IN.
THICK. COVER GAP ANO FASTENER HEARS.
THICK. COVER GAP AND FASTENER HEADS.
i
SECTION
F-F
SECTION
(TYPICAL
G-G
AT FS 247 ANO
SECTION
H-H
IFS 206
264.251
17]
PRESSURE SEAL.
FILL JOGGLE FLUSH
Al
L~
SECTION
JJ
SECTION
PRESSURE SEAL
K-K
PRESSURE SEAL.
FILL JOGGLE FLUSH
SECTION
L-L
SECTION
M-M
Fuselage and Nacelle Sealing Model NA 265-70, -80, -80A, and -80SC
51-20-10
Page 7
3/88
Jun
NA-6(i-1032
S1RUCTURAL REPAIR MANUAL
NOTE
Unless otherwise noted, all dimensions are
shown in inches.
JOGGLES
NO. 40 HOLE
GAPS
SEALAIT
~i JI
sra~wr
1/16
NOTE
HOLESI/BMI\X
i~ Jr SE~LANT1/16
~au
Ifjoggle cannot be sealedfrom sides, drill

No. 40 hole and ir4iect sealant.
HOLLS liBT(11/4
1/BMAI
PRESSURE-SENSITIVE TAPE
C,.UYI~1/8
1/8
1/2 MIN
1/8 MIN
FILLETS ANO JOINTS
SELFCONTOURING SEALING PADS

MATING SURFACE
IIL
SEALANT
1/16 ---1
1/8
STRUCTURE
It
~I
1/8
REMOVABLE PANEL
1/16
SEALANT DIMENSIONS FOR PRESSURE, VAPOR, AND LIQUID SEALS

(USE HBO12O-OO2 SEALING COMPOUND, EXCEPT WEHRE NOTEO.I
FILLETS ANO JOINTS
1/
HOLESI/BMAX
te
1/4(TYPI
I,s
1/8
,,,,,x
1/8 11/16.--0]
1/8
SEALING COMPOUNO
HOLES 1/8 MAX
GROOVE
1/8 MIN
1/8 MAX
INJECTIONOVERCOAT
FILLETS ANO JOINTS
3/4 MAX
SEALING COMPOUND
1/4 ITYPI
I
Iziz
yl
It-~
1/4 MAX
HIGH TEMPERATURE SEALANT DIMENSIONS FOR PRESSURE,
51-20-10
.r 1/4 MAX
IMAX
LIOUID AND FLAME RESISTANT SEALS
Typical Sealant Applications and Dimensions

Figure 3
Page 8
Jun 3/88
I,
IMAX
NA-66-1032
FUSELAGE AND NACELLE SEALING

REPAIR
B.
GENERAL
The following procedure provides the materials and processes for the airtight sealing of all joggles, seams, butt
and lap joints, holes, slots, and fasteners in the pressurized
area where the normal operating temperatures are
between -650F and +225"F.
fuselage structure and all seals in the pressurized

designed to withstand a maximum pressure differential of 18.4 psi. A maximum allowable leakage of 144
cubic feet per minute at 8.81 psi may exist before repairs
or resealing procedures are necessary.
C.
Holes and Slots
(1)
(2)
Build up a bead to a minimum thickness of

1/16 in, and a width or diameter of 3/8 in.
Type,
SOURCEKEY
(2)
Cover tape with

thick.
(3)
Extend sealant
all directions.
refer to 51-30-00 Table 2A.

D.
043
SensitiveTape
Methyl Ethyl Ketone (MEK)

(or equivalent)
Holes Greater Than
tape
1~ in.
layer of sealant 1/8 in.
1/8 in. beyond tape edge in

1/4-In. Diameter
plug hole with
rivet or balsa wood.
Fill
001
(2)
Apply a minimum of 1/16 in. layer of sealing compound.
001
(3)
Extend sealant
the hole.
(4)
Clean surface and surrounding
pressure sensitive
(1)
Procedures
1.
layer of
The tape should eztend at least
equivalent)
Pressure
hole.
NOTE
Consumables
Sealant Gun, Model 250 (or
slot with sealant.
beyond the hole in ad directions.
PRESSURETIGHT AND LIQUIDTIGHT

SEALING
For Sealant
Apply
over
area are
MATERIAL
or
Holes 1/8 To 1/4-In. Diameter
(1)
The
Up To 1/8-In. Width
Fill hole
area.
(Refer
to
or
1/8 in, beyond the edges of
Before sealing, close out oversized slots
or
joggles.
Cleaning, 51-20-10.)
(Refer
to Sealant
2.
Mix sealant.
3.
Apply sealing compound

A.
as
NOTE
Mixing, 51-20-10.)
Do not drill holes in chem-milled
follows (see figure 3):
areas
to
fastenfillers in place.
Joggles
jo~gles before joints
(1)
Seal all
(2)
Completely fill joggles with sealant.
(3)
Force sealant under joggle from either

both sides of the joggle.
(5)
or seams.
Secure filler in position,
using existingfas-
teners.
E.
or
Riveted Putt and
(1)
Lap
Sealseamsand
Seams
rivetedjointswith pressure
gun.
(4)
If the joggle cannot be force-filled, drill a

No. 40 (0.098) hole in the center of the joggle
run
(5)
out.
Inject sealant through
hole to seal
joggle.
NOTE
A bead of sealing compound should be continuous and even. The final bead dimension should confomz to the dimensions
shown in figure 3.
51-20-10
0
Page 201
Jun 3/88
NA-66-1032
STRUCTURAL REPATR MANUAL
REPAIR (Continued)
NOTE
PRESSURETIGHT AND LI&UIDTIGHT

SEALING (Contd)
Sealant may be applied to either

painted surfaces as applicable.
Procedures (Contd)
(2)
Apply a
pound to
continuous bead of
seams and joints.
sealing
com-
Procedures for sealant
NOTES
B.
room
NOTES
Thismethodshould beusedonlywhen
the pressure sensitive tape method cannot be used
temperature.
Naphtha, toluol or IMEKshould be used

as a cleaning material.
Clean excess sealantfrom
and sealing equipment.
(4)
pressurizedarea
FUMETIGHT SEALING
(Areas Operating Between -650 and +2250F)
Consumables
SOURCEKEY
Type, refer
to 51-30-00 Table 2A.
Pressure Sensitive Tape
001
For Sealant
Sealant Gun, Model 250
Methyl Ethyl
Ketone
or
equivalent
(MEK)
(2)
Form a fillet or bead extending 1/4 in.

beyond edges of hole or slot in all directions.
(3)
Apply 1/8 in, thick coating of general purpose sealing compound over the groove
injection sealing compound. (See figure 3.)
The following procedure is &pplicable to the sealing of

joggles, cutouts, holes, slots, and hat sections where excessive leakage of air or fumes must be avoided, where pressure differentials do not exceed 5 psi and where the operating temperatures extend from 250 to 4000F and where
peak temperatures do not exceed 5009F.
043
Procedures
NOTE
Consumables
Sealing compounds are dependent upon

the opertilzg temperatures of the area being
MATERIAL
For Sealant
sealed.
2.
Clean surface and surrounding area. (Refer

CLEANING.)
Mixsealant.(Referto SEALANTMIXING.)
3.
pound.
FUMETIGHT SEALING
(Areas Operating Between e66" and 400"F)
001
as
Fill the hole or slot on the pressure side of

the area with groove injection sealing com-
I~
(or equivalent)
1.
Groove irqjection sealingcompoundmay

be softened for easier application by
warming or working with hands. i~lake
certain hands arefree of grease and oil.
(1)
The following procedure is applicable to the sealing of

joggles, cutouts, holes, slats and hat sections in areas
where excessive leakage of air, fumes, and smoke could
prove dangerous,
MATERIAL
identical
In addition to the procedures for holes 1/8 to 1/4

Inch Diameter a second method is offered
Groove Injection Sealing Compound Coated with
General Purpose Sealing Compound.
should be removed within three hours after ezpoto
are
LI&UIDTIGHT SEALING with the additional

information contained in step B.
E~cess sealing compound

sure
application
or
to those outlined in PRESSURETIGHT AND
Seal rivets and bolts, when necessary, by

brushing a coat of EC776R sealing compound on all rivets and bolts in the pressurized area.
(3)
A.
bare
follows
to
Type, refer
SOURCEKEY
to 51-30-00 Table 2A.
Sealant Gun, Model 250 (or equivalent)
043

(or equivalent)
001
(see Figure 3):
51-20-10
Page 202
3/88
Jun
NA-66-1032
REPAIR (Continued)
FUMETIGHT SEALING (Contd)
Procedures
Procedures
1.
i.
area.
(Refer
Cleaning.)
2.
Clean surface and
2.
Apply sealant
A.
Sealant preparation:
NOTES
Do not allow sealant container to remain

open any longer than necessary. The sol-
evaporates
vezy
Obtain a bead or button of sealant

cated in figure 3.
(3)
If
follows:
Apply sealant only in a well ventilated

area or use air supply respirators.
as
indi-
only one side of the area to be sealed is

accessible, seal the hole or gap by forcing
an excessive amount of sealant through the
Holes
(1)
or
Locate areastobesealed.
(2)
Shine a light on one side of the surface to be
sealed and inspect the opposite side for
(3)
Slots Greater Than One In.
Holes
slots greater than one in. in diamwidth must first be plugged or filled
with metal clips or snap-in plugs.
eter
NOTE
or
or
Apply sealant at least 1/8 in. thick over the

plugged hole or gap and extend at least 1/4
in. beyond the edge of the plug.
Ensure there
are no
gaps
or
bridges
in the
sealant.
light passage,
B.
follows (see figure 3):
hole to form a button or grommet of sealant

on the inaccessible side of the area being
sealed.
B.
A.
as
(2)
consistency.
as
to
Seal all holes, slots and gaps less than 1/8

in. in diameter or width with PR810 high
temperature sealing compound from both
sides of the bulkhead, web, or firewall.
Do not thin sealant beyond its original
Apply sealant
(Refer
(1)
rapidly.
Sealant may be thinned with MEK if it

becomes thick.
3.
area.
Holes, Slots, and Gaps Less Than 1/8 In.
Sealantisready;foruse asis.
vent
surrounding
Cleaning.)
to
application are identical

Pressuretight and Liquid-
Procedures for sealant

to those outlined in
C.
tight Sealing.
FLAME RESISTANT AND LIQUIDTIGHT
SEALING
This procedure outlines the procedures and materials
used to seal joggles, holes, cut-outs, etc. in areas where
leakage of fluids must be avoided and where a flametight
seal is necessary in case of fire. The sealing methods provided are applicable to areas where the temperature may
be as high as 400"F during normal operation and with
occasional temperature increases to 5000F for short peri-
ods of time.
Seamsand RivetedJoints
(1)
Seal seams and riveted joints with PR810

high temperature sealing compound.
(2)
Apply sealant using
(3)
Apply 1/8 in. thick bead of sealant with 1/4

in, minimum overlap on each side of seam
being sealed.
sealant gun.
NOTES
When afilletofPR810 sealingcompoundis
required, thefillet legs must be at least 1/4.
in. in length as shown infigure 8.
beingsealed,
injected with
sealant, then both sides of the stiffelzer must
be sealed for a minimum distance of 6 in.
from the seam, or the entire length of the
sCiffner, whichever is shorter.
seam
the
Consumables
SOURCEKEY
MATERIALS
For Sealant
Type, refer
to 51-30-00 Table 2A.
Sealant Gun, Model 250 (or
equivalent)

(or equivalent)
I~
043
001
joggle
(4)
or
gap must be
Apply sealant with

securing seam.
spatula
over
rivets
51-20-10
0
Page 203
Jun 3/88
NA-66-1032
REPAIR
(Continued)
FLAME RESISTANT AND LI&UIDTZGHT

SEALING (Contd)
E.
Assemble parts being sealed.
F.
Allow a minimum of eight hours

until compound is cured.
Procedures (Contd)
(5)
Clean excess sealant from

and MEK.
D.
area
The following procedure should be used to provide a satisfactory faying surface seal between mating surfaces of the
airplane structure. This procedure is applicable to areas
of the airplane which operate in the temperature range of
-650 to +2250F.
Consumables
MATERIAL
SOURCE KEY
MATERIAL
Far Sealant
refer to 51-30-00 Table 2A.
Type,
Petrolatum, Technical Grade
SensitiveTspe
001
(or equivalent)
SOURCE KEY
043
001
to 51-30-00 Table 28.
001
(or equivalent)
Sealant Gun, Model

(or equivalent)
043
250
Procedures
1.
Procedures
area.
(Refer
to
CLEANING.)
Clean surfa~ce and surrounding

CLEANING, 51-20-10.)
(Refer
to SEALANT
2.
Mix sealant.
3.
as
area.
(Refer
to
MIXING.)
follows
(Refer
to SEALANT
2.
Mix sealant.
3.

A.
Apply sealant
spatula.
(see figure 3):
with
as
a
MIXING.)
follows:
sealant gun
or
wooden
A.
Apply sealant using

spatula.
wooden
B.
B.
If sealant gun is used, smooth out sealant bead

with wooden spatula to a 1/8 in. uniform thick-
If sealant gun is used, smooth out sealant bead

with wooden spatula to a 1/32 in. uniform thickness to both faying surfaces.
C.
Join faying surfaces

sealant application.
sealant gun
or
ness.
C.
Ensure that sufficient sealant has been
applied
D.
to fill all gaps and voids.
D.
Apply petrolatum
to all
Secure
as soon
as
possible after
faying surfaces with applicable fasten-
ers.
portions
parts of the assembly that will
of removable
in contact
come
with
sealing compound (i.e., panels,

quick-disconnects, etc.).
Type, refer
001
(or equivalent)
i.
After sealant has cured, disassemble parts, trim

sealing compound, wipe petrolatum from
surfaces with a clean, dry cloth, and wash
screws, quick-disconnects, etc. with MEK or
FAYINGSURFACESEALING
Consumables
Pressure
or
equivalent.
The following procedures are used to provide synthetic

rubber self-contouring sealing pads to the stationary
structure located under removable doors or panels, and
between normally separable sections of the structure
where the operating temperatures range from -650 to
+2250F.
For Sealant
time
excess
with clean cloth
REMOVABLE DOORS SEALING
G.
Sealant should extend 1/8 in, beyond edge

of rivet in all directions.
cure
8E.
Clean
sealant from faying surfaces and

with clean cloth and MEK.
excess
equipment
screws,
5120-10
Page
204
Jun 3/88
NA-66-1032
REPAIR (Continued)
B.
EXTERIOR WATERTIGHT SEALING

The following procedure is applicable to the sealing of the
exterior surfaces of the airplane where normal operating
temperatures do not exceed 225"F.
C.
Consumables
SOURCEKEY
MATERIALS
D.
Pressure
spatula is used, apply an excess of sealant at

point of the seam and work the sealant into
After the compound has been applied using the

sealant gun, use a spatula and press the compound into the seam, removing the excess from
the sealed area.
F.
If
001
043
(or equivalent)
spatula
remove
the
Procedures
paint and primer (except epoxy polyamide primer) using a stiff bristle brush and MEK.
2.
Remove paint and primer a distance of

directions from the gap being sealed,
Remove all
1/2 in,
in all
G.
Remove tape after the seam is sealed and the

compound is removed.
excess
NOTES
applied to a clean epo~y

polyamide primed surface without adverse
effects.
Sealants may be
area.
(Refer
nlloi8terti~g the fi~yrer with water will

minimixe sticking of the compound to
tkefinger.
to
Do not
CLEANING.)
as
Do not usefingers to press the masking tape

in place or allowfingers to touch the cleaned
surface. Oilfrom thefingers will contaminate the cleaned su~face and necessitate
that the surface be re-cleaned.
in. wide strip of masking tape to

the skin on each side of the skin gap being
sealed, leaving 1/16 1/32 in, of skin exposed on
each side of the skin gap.
Apply a 3/4 to 1
use
soap
on
thefingers as this
of the compound
may impair adhesion

to the structure.
follows:
NOTE
A.
used to apply the sealant,

compound with the spatula.
It is essential that the tape be removed

before the compound sets up.
NOTE
4.
was
excess
NOTE
i.
3.
seam.
E.
or
If a
and along the
001
SenaitiveTape
If the sealant gun is used, place the opening of

the tip flat against the seam and apply a slight
excess of compound, moving the gun as the joint
fills up.
one
For Sealant Type, refer to 51-80-00 Table 2A.

(or equivalent)
Apply the sealant by using either the sealant

or a clean wooden spatula.
gun
H.
Immediately after removing the tape, feather

edges of the compound. This may be done by
drawing one finger along the edge.
the
I.
Allow the compound to cure a minimum of 24

hours at room temperature before covering or
disturbing the surface.
J.
Clean up excess sealing

sealant gun using MEK or
compound
equivalent.
and the
51-20-10
0
Page 205/206 Blank

Jun 3/88
NA-66-1 032
STRUCTUHAL HEPAIR MANI!~I,
ADHESIVE BONDING
REPAIR
NOTE
GENERAI,
possible cnr~e m,rst he takerc in

performing cutting a.nd d,illing
operations after cleaning to prev4nt
All
The bontiing process described in the following

paragraphs may be used structurally when specific repair
instructions so direct.
contamination of the cleaned and etched

ALUMINUM ALLOY SURFACE PREPARATION
strength of bonded joints depends largely on the

preparation and cleanness of the surfaces to be
bonded. To ensure adequate adhesion, the procedures
given must be followed ezactl21. Cleaned surfaces should
be handled with clean white gloves and protected in all
The
proper
surfaces.
4~
Trim out damage and
5.
Trialfithoneycomb repairplugs.
the
Do not allow
honeycomb
bonding material is applied,
Consumables
SOURCE KEY
MATERIAL
or
Paint Remover,
Striprite
103
cleaning agent
to
into
run
core.
6.
Clean honeycomb panels and repair plugs with

MEK or equivalent prior to bonding.
7.
Wipe surfacedry.
8.
Repeat steps 6 and

thoroughly clean.
9.
Clean the face sheets and repair doublers.
001
Methyl Ethyl
Ketone (MEK)
Acetone
rivets.
NOTE
ways from contamination. Whenever there is any doubt as

to the cleanness of a part, the cleaning procedure must be
repeated before
remove necessary
045
as
required until repair
area
is
E:poxy Stripper, A202
016
Toluene
001
repairs other than honeycomb

sandwich panel after all trimming, fitting, and
Specific Gravity
001
drilling operations.
Sodium Dichromate, Technical

Grade
001
Talc, White Powder, Technical
001
Use only clean MEK in clea.n
Sandpaper, :120 (;rit,

Wet or Dry
001
Do not contaminate IMEK by

soiled clothing into container.
Glass Wool
001
Sulfuric Acid,
1.84 Grade
10.
Clean and etch
Sheet-Metal Surface Cleaning Procedures
NOTES
(;racle
Cellulose Tissues
cans.
dipping
Use clean lint-free cloth.

044
(or
equivalent)
1.
Remove all
2.
Apply MEK
paint.
to
bonding surface by either of the
following:
Refer to 51-30-00 table 2 for manufacturer.
A.
Pour MEK
onto
clean lint-free cloth and
wipe
surface.
NOTE
(:ertccin specific safety precautions are
noted in Iha following procedures. In
addition, all normal safety lorccautions
should be observed in the handling and
storing ofPammable and tozic materials.
Honeycomb Sandwich Panel Cleaning Procedures

i.
Evaluate damage.
2.
Fabricate
3.
Strip, clean, and etch damaged and repair parts.
B.
PourMEK ontosurface.
3.
Remove dirt, grease, and other surface contaminants

from unpainted surfaces.
4.
Wipe surface dry with clean lint-flee cloth. I)o

allow ME:K to ait dty on surface.
5.
Lightly sand bonding surface with clean. 320-grit

sandpaper and wipe off loose particles nith clean
not
lint-free cloth.
repairdoublers.
51-20-20
Page 201
Aug 17/84
NA-66-1032
REPAIR (Continued)
Sheet Metal Surface

Procedures (Contd)
Io uvoid
Cleaning
possible s:~plouion, sulfuric acid
the ruz,erue,
ErcRssiz,4 heat buildup can result i~f
sulfulic acid is added too guickl;ll to water.
nLlc.sl be added to water,
Clean area to remove dust and metal chips with

either a vacuum cleaner or by blowing with waterand oil-free air.
3.
After final shaping and fitting, vapor-degrease the

honeycomb repair plug if possible, or rinse it in
MF,K or equivalent.
never
STRUCTURAL METAL-TO-METAL BONI)INC;
Cse rubber gloves and adeguate cue

protection when handling acid cleaner.
6.
2.
Consumables
MATERIAL
cleaner to the following
Mix sulfuric acid
EA 934 NA
specification:
Sodium clichromate
10 parts
by weight
Epoxy Stripper, A-202
016
Water
80 parts
by weight
Acetone
001
glass, rubber,
NOTE
Certain sloecific sc4fet?l precautions
run
@ammable
sag.
permit cleaner to run

cannot beflushed with water.
Sodium diehromate should be added to

acid-water mix.
i.
Clean all surfaces to be bonded.
2.
Mix adhesive per manufacturers recommendation.
3.
Apply adhesive with either a spatula, putty knife,

glue spreader, or other suitable means.
Stir acid cleaner thoroughly to mix ingredients. Use

aglass, plastic, or rubber rod or paddle for stirring.
8.
Apply acid cleaner to bonding surface by either

immersing or swabbing with glass wool.
9.
Allow acid cleaner to stand

minutes.
on
5.
water.
~heck surface for water-break-free surface.
12.
sulface tends to form

cleaning and rinsing procedure until
free sulfuttt! is obtained.
Trim out damaged

tools.
core
not, hp;lt
area
and
thickly enough
to fill
(See figure 201).
Clamp bonding surfaces together as soon as possible

begins
to avoid contamination and before adhesive
set-up.
water-break-
over
NOTE
(:onluct pressure as adecluatc! for a good
bond, Additional pressure mag be applied
~f bond is not starved through el:c~.ss7:l,e
sgueexe-ozct or damage to parts
1500F.
Honeycomb Core Cleaning Procedures

i.
Spread adhesive evenly
drops, repeat
on
I),y s~llfacc!s thorouahly. I,o
surface for 20 to 30
11.
If water
NOTE
A dhesive should be applied to both bonding
surfaces when possible.
any voids.
thoroughly with
and toxic materials,
Procedures
Do not
into areas that
or
ara
following procedures. In
addition, all normal safetl/ precautions
should be observed in handling and storing
noted in the
When applying ac~id cleaner to vertical

surfaces or areas near cracku or holes, add
sufficient talc to cleaner to form a thick
Rinse surface
EC776R
or
Sulfuric acid solution should be 70"F

m.inimuln.
paste that will not
or
pRefer~ to 51-30-00 table 2 for manufacturer.
suitable plastic
container must be used for holding
ingredientsfor ~mizing and using.
A clean
10.
005
55 parts
type, EC776
058
Sealing Compound, Buna-N
by weight
Sulfuric acid, specific

gravity 1.84
NOTES
7.
SOURCE KEY
with clean, oil-free
6.
Cure(harden) bonding surfaces for 48 hours at 70"F

8 hours at 140"F, including clamping time.
or
Maintain selected temperature for duration of
cure
phase.
51-20-20
Page 802
Aug 17/84
NA-66-1032
STRUCTURRL REPAIR MA~UAL
BONOED REPAIR ODUOLER
OAMAOEO SKIN
BONOEO
REPAIR DOUBLER
/J
1/R1W. IMlnl
TOP COATING
IlslN.lmlN1
A-A
SECTION
EPOXY BONO LINE
OAMAGEO SKIN
SEAL WHEN EXPOSED.

I.E.. WHEN NOT A
HONEYCOMB
SEALALLEXPOSED
EOCES OF BONOED
JOINT WITH 3 COATS
OF TOP-COATING COMPOUND
REFER
MlL-S-4aR31.
BONDING" FOR ADDITIONAL INSTRUCTIONS.
SANOW1CH REPAIR
NI)Tlcl
TO
"STRUCTURAL
METAL-TO-METAL
SEALING INTERIOR REPAIRS
OAMAGEO SKIN
BC~
I
REPAIR
OOUBLER
EPOXY BOND LINE
rl~
SULEAITYP)
BCJ
at
IILL LLL IXIOSEO EOG~S

OF BONOED REPAIR WITH
SECTION
B-B
AEROOYNAMIC
SMOOTHING COMPOUNO
SEALING NONFLUSH (TEMPORARY) EXTERNAL REPAIRS

DAMAGEO SKIN
YI
REPAIR OOURLER
21IMINJ
alm~Y1
SEALEXPOSEOEOGES
WITH COMPOUNO.
MIL-S-4383. [REFER TO
SEALING INTERIOR REPAIRS)
1_
RIA00rWIMIC
SMOOTHING COMPOUND
EPOXY BONO LINE I
FILLER
c=c-l
FILL GROOVE AROUHO

FILLER WITH AEROOYNAMIC
SECTION
C..C
SMOOTHING COMPOUNO
NO?%
REMOVE EXTRUOEO EPOXY AFTER

RIVETING REPAIR. BUT WHILE EPOXY
IS STILL SOFT. WITH A NONMETALLIC
REFER
TO.AERODYNAMIC SMOOTH NG. (TEXTI FOR
MATERIALS AND SEALING INSTRUCTIONS
SCRAPER. DO NOT USE SOLVENTS.
SEALING FLUSH EXTERNAL REPAIRS

Sealing Bonded H.epairs
Figure 201
0
COPYRIGHT, 1984 BYSABRELINER CORPORATION
51-20-20
Page 203
Aug 17/84
NA-66-1032
SrRUCI~UKAL REPAIR MANUAI,
REPAIR (Continued)
STRUCTURAL METAL-TO-METAL
BONDING (Contd)
All tools used in
Proc:edures
crushing operations
i.
NOTE
(Contd)
Itemove
excess
adhesive with clean rags soaked in
ttcetone.
4.
NOTE
spatula, putty knife,
6.
Fill hole slightly above skin surface

sanding flush after cure.
NOTE
7.
IS Qdkesive has hardened before it could ha

rem.oz,ed, it can be removed with a suitahle
st,ipper. (RqSer to REMO~IING IMETALTO-METAL BONI)ING REPAIRS).
Remove
MEK.
8.
Allow filler to
mixing anti sl,reading tools with clean
st,ako(l in acelone.
B1ush three
st,ucture.
or
similar
excess
area
with filler. Work out any
filler from
cure
to allow fol
surrounding
area
(hardened) far 4 hours
with
at 7(10F.
NO TE
Stlal all exposed edges of bonded repairs after repair

has culetl and metal has been chemical-film -treated.
exposed edges
II.
Apply filler with

Fill damaged
entrapped air.
r.;lKs
core-
Mix filler per manufacturers recommendations.

Filler has a pot life of 20 to 30 minutes.
5.
(Ilcan all
Ill.
and
must ha clean.
tool.
(.lean-up must be accomplished as soon as

possible r4fter parts are! clamped together.
t).
trimming
~fambient temperature is below r0"~ place

a ~50-watt heat lamp about
St from
repair. Do not permit temperatures of
filler to ezceed 180"F.
of topcoating compound on
of bonded repairs inside the
(See figure 201.)

REMOVING METAL-TO-METAL
BONDED REPAIRS
Seal exposed edges of bonded repairs on the outside

of the structure with aerodynamic smoothing
compound. (Refer to AERODYNAMIC
SMOOTHNESS fol required materials and
The following procedure may be used to I.emove

unsatisfactory, damaged, and restricted-life repairs.
instructions.)
Consumables
NOTE
MATERIAL
The compound may be applied directly to

the chemical-film-treated surface without
SOURCE KEY
Epoxy Stripper, Cee-Bee
further preparation
A-202
KEIAIRIN(; HONEYCOMB PANELS

WITH ADHESIVE FILLER
Acetone or Methyl Ethyl

Ketone (MEK)
This bonding process may be used

in specific repair instructions.
I~ Refer to 51-30-00 table
only when authorized
MATERIAL
SOURCE KEY
Filler, Corefil 615
or
1.
NOTE
Be
006
Methyl Ethyl
001
(MF,K)
to r,1-~0-00
i.
;~lca
table 2 for manufacturer.
c,f
out
careful
or
are~se in
damaged
not to
mar
surrounding
area.
2.
Raise
3.
Grip loosened corner with pliers and peel by rolling

and curling sheet away from item to which it is
one corner
of item to be removed.
attached.
thoroughly.
liemove dirt, oil,
trimming
2 for manufacturer.
Heat repair to 2250F to soften and weaken adhesive.
039
Agent U
Ketone
001
Procedures
Consumables
Acetone
016
NOTE
area
befole
Do not
damage.
use
wedges
to
separate items,
51-20-20
Page 204
Aug 17/84
NA-CiCi-IO:3~
STRUCTUR~L KEF~IR MANCAI.
REPAIK. (C:ontinued)
Ik not
hrantkc?,tuporsfrom the stripper,
Avo%d.Ykin contact ?ubth, stripper, IrL

skin conlacl, ~Alash affected
u,ith soap and water
I)o not
permit A-BOR stripper
4.
r,.
Rrush
or
of
area
to contact
epoxll which is not to be removed
cleanup around
ease
las in
repair),
spread stripper
over
the epoxy.
Allow several minutes for the stlipper to soften the

then remove material with a wooden or
micarta scraper. Ilepeat operation if necessary.
epoxy;
NOTES
CEE-BEE A-LOX stripper is
corrosive to aluminum alloys,
permit stripper
painted surfaces,
I)o not
onto
fj.
or
non-
solvent to
run
Rinse stripped surface with fresh water and

with a dry solvent (MEK or acetone),
wipe
51-20-20
Paac
("j
COPYRIGHT, 1984 BY SABRELINER CORPORAIION
~()5i20(i I~lank
AuR 17!X1
NA-66-1032
CORROSION CONTROL
(;ENERAL
EXTERIOR SURFACES
Interior protective treatments and finishes used on the

Sabreliner airplane are identified below. Exterior
aluminum alloy surfaces are chemical-film-treated by the
manufacturer; prime and finish materials are options of
the owner.
All painted exterior surfaces of the airplane

tected by:
Material required and application instructions for the

finishes noted in the following paragraphs are given in the
Corrosion Control Manual, SR-76-023.
1.
Chemicalfilm treatment.
2.
Epoxy polyamideprimer.
3.
Polyurethane topcoat.
are
pro-
CENERALAIRPLANE
general, aluminum alloy parts
In
1.
Chemical film treatment.
2.
Epoxy polyamide primer.
are
protected by:
SPEED BRAKE, LANDING GEAR DOORS, AND

ENGINE NACELLES
The! interior areas of the speed brake, landing gear doors,
and engine nacelles are protected by:
Chemical film treated (aluminum alloy parts).
I.
2.
Epoxy polamide primer.
3.
Two coats of
polyurethane topcoat.
BATTERY COMPARTMENT
exposed and fayinff surfaces within one foot of the

areas subject to battery
spillage, are protected by:
All
storage batteries, and other
Chemical filmtreatment.
i.
2.
Epoxy polyamideprimer.
insignia white Everlube No. 13-511,
Hi-Impact polyurethane.
Two coats of
special
or
WING FUEL TANKS AND MAGNESIUM PARTS

All interior
areas
maffnesium parts
i.
2.
of the wing integral fuel tanks and all

are
protected by:
Chemical film treatment (aluminum alloy parts).

Dow No.
17 and/or
19 chemical treatment
(magnesium parts).
3.
Polyurethane coatings for integral fuel tanks, De

Soto, Inc. kit #827x376.
51-20-30
0
Page 1/2 Plank

Aug 17/84
NA-66-1032
STRUCTURAL REPAIH MANCAL
MATERIALS
CONSTRUCTION MATERIALS
7178 of the
same
gauge
or
7075
one
gauge heavier.
Aluminum alloy TENS 50-T6 is used for sand structural
Most of the materials used in the construction and repair

of the Sabreliner airplane may be listed in the following
categories: metals (aluminum alloys, steels, etc.),
transparent glass and plastic, glass fabric, and fasteners.
Much of the aluminum alloy skin, and some of the steel
skin, is machine-milled and chem-milled. All detail parts
are to assemble without forcing, bending, prying, etc. On
parts made to normal allowable tolerances which do not
achieve satisfactory fits, a maximum shimming up to
0.064 in. with compatible material, is permissible. The
wing attach fittings, the vertical and horizontal stabilizer
attach fittinffs, and the members to which these fittings
attach, are not to be shimmed in the area of the attach
fittings without specific engineering approval.
castings. Alloy 6061

welding is required.
is used in
areas
where extensive
Steel
The principal steel alloy used in this airplane is 17-7PH
corrosion-resistant.
Glass and Plastic
Transparent glass and plastics
are
used in this
airplane
for windshields and cabin windows. Glass fabric is used

for radomes and antenna covers.
Fasteners
Metals used in construction and repair of the airplane are

presented in table 1. All repairs presented in this manual
depend upon the use of materials conforming to the
specifications referenced in these lists.
The majority of the structure of this airplane is assembled

with conventional fixed and removable fasteners, such as
standard aluminum alloy and steel rivets (driven and
blind), screws, bolts, nuts, and quick-acting fasteners. For
more details concerning fasteners, refer to 51-40-00
thru 51-40-30.
Sources of materials and tools referenced in repair

instructions throughout the manual (except metals and
common fasteners) are presented in table 2. The "Source
Key" number referenced in the instructions is found in a
numerical listing in the "Source Key" column. Each
number, except 001, is "keyed" to a manufacturer; 001
indicates that the material may be obtained from any
supply house that handles the particular commodity.
FABRICATION INFORMATION
Tables
Information providing the necessary data to accomplish

the layout and fabrication of repair parts is presented in
tables 3 thru 12.
Aluminum
Special Tools and Procedures
As a general-purpose material, 2024 aluminum alloy is

used; where greater strengthisrequired,7075aluminum
Locally manufactured special tools, and/or methods and

procedures, are shown in figures 1 thru 5. The special
tools/procedures provide methods of reducing the head
size of flush rivets, picking up the location of blind or
hidden fastener holes, locating hidden skin trim lines, and
using drilled out heads of flush fasteners fol fillers in
dimpled or countersunk holes.
is used. Aluminum alloy 7079 is used for die forgings

and in place of 7075 where very thick plate is required,
and 7178 is used in place of 7075 where greater strength is
needed. If there is a doubt as to the identity of sheet metal
or extrusion that is damaged, it should be repaired with
alloy
NOTE
The
following materials listed in table 1 are used in the construction of the Sabreliner.
Repair materials must conSorm to the refereneed ~ecifications, as al~plicable.
Table 1.
Metals Used In Airframe Construction and Repair
MATERIAL
SPECIFICATION
REMARKS
ALUMINUM BARS AND SHAPES

2024-0or2024-T4
bar
alalloy
I
I
Fed.
Spec qq-A-225/6
I
I
Roiledbar. General-purposeailoy. Use202400nly if

forming is too severe for 2024-14. Do not weld.
51-30-00
0
Page 1
Aug 17/(34
NA-66-103~
Sllt~lCTURAL HEPAIR M~NUAI,
STRUCTURAL IDENTIFICATION (Continued)
Metals Used In Airframe Construction and
Table 1.
Repair (Contd)
REMARKS
SPECIFICATION
MATERIAL
ALUMINUM BARS AND SHAPES
alloy
Fed.
Spec QQ-A-200/3
Extruded bar or shape. Use 2024-0 only if forming is too

severe for 2024-14. Heat-treat all 2024-0 parts to
2024-T42 condition after forming. Do not weld.
7075-T6 al alloy
Fed.
Spec &&-A-225/9
Rolled bar. Do not use where 2024 bar is suitable.

7075-T6 is difficult to form. Heat treat all 707.5-0
parts to 7075-T6 condition after forming. Do not weld.
Fed.
Spec QQ-A-200/11
Extruded bar or shape. Do not use where 2024 bar is

suitable. 707Fi-T6 is difficult to form. Heat-treat all
7075-0 parts to 707Fj-T6 condition after forming. I~o
not weld.
Fed.
Spec &G~-A-200/1X
Extruded bars and shapes are used in place of 7075

where higher strength is required. Heal-treat all
7178-0 parts to 7178-Tfi condition after forming.
2024-0 ol 2024-T4 al
bar or shape
7D75-()
bat
or
7075-0 or iOiT,-Tfi at
ha, ol shape
alloy
71SX-() and 7178-T6 bar
ol
shape
ALUMINUM CASTINGS
TENS 50-T6 al
alloy sand
High-strength structural casting alloy.
NA2-7152, Temp T6
Heat-treatable
and weldable.
casting
ALUMINUM FORGINGS
7079-T652
blocker-type die
Fed.
High-strength casting heat-treated and mechanically
Spec Q&-A-367
stress-relieved. Not weldable.
forging
ALUMINUM HONEYCOMB CORE

HCB honeycomb
material in adhesive bonded sandwich

use where temperature exceeds
350"F. Available in various core sizes.
Used
NA2-7110
as a core
structures. Do not
core
ALUMINUM SHEET AND PLATE

2024-0
ol
2024-T8
al
Fed.
to 0.250. Use 2024-0 when part:

cannot be made from 2024-T3. Heat-treat all 2024-0
parts to 2024-T42 condition after forming. Not
Gauges from 0.010
Spec QQ-A-250/4
alloy sheet
weldable.
2024-0, 2024-T8, 2024-14,
and 2024-T42 bare al
Fed.
Spec &d2-A-BTjOl/i
Plate thicknesses from 0.250 to 3.000. Use 2024-0 when

parts cannot be formed from 2024-14. Heat-treat all
2024-0 parts to 2024-T42 condition after forming. Not
weldable.
Fed.
Spec &&-A-250/5
Gauges from 0.010
alloy plate
2024-0, 2024-T3, and
2024-T4 clad al allov
only when part
treated to T42 condition. May be spotbut not fusion-welded.
sheet
2()211-0, 2024-T3, 2020-T4,

anti 2024-1-12 clad al
to 0.250. Use 2024-0
cannot be made from 2024-T42. Parts must be heat-
Fed.
Gauges from 0.250
Spec QQ-A-250/6
to 3.000. Use 2024-0
or
seam-welded
only when part
cannot be made from 2024-142. Parts must be heattreated to T42 condition. Not to be fusion-welded.
:Illoy plate
51-30-00
Page 2
Aug 17/84
NA-66-1032
Table 1.
Repair (Contd)
REMARKS
SPECIFICATION
MATERIAL
ALUMINUM SHEET AND PLATE (Continued)

Fed.
6061-0, 6061-T4, and

6061-T6 al alloy sheet
or
Spec QQ-A-250/11
plate
Sheet gauges from 0.010 to 0.250. Plate thicknesses

from 0.250 to 3.000. Not to be used where other alloys
cannot be made
are suitable. Use 6061-0 only if part
from 6061-T4. Use 6061-T4 only if part cannot be
made from 6061-T6. Heat-treat 6061-0 and 6061-T4 to
T6 condition when required. May be spot- or seamwelded in the treated condition, and fusion-welded if
resultant annealed condition in area of weld is
acceptable.
Spec &&-A-250/13

from 0.250 to 3.000. Used where 2024 is not suitable.
Use 7075-0 only if part cannot be made from 7075-16.
Parts must be heat-treated to T6 condition after
forming. May be spot- or seam-welded in the T6
condition. Not to be fusion-welded.
&&-A-250/12
Bare material used where clad material is undesirable.
7075-0 and 7075-T6 alclad

al alloy sheet and plate
Fed.
707ri-T6 bare al alloy plate
Fed. Spec
707.5-T6 bare al alloy plate
NA2-7138
7079-0 and 7079-16 bare
Used
for wing and empennage machined
Used in place of 7075 where material 3.000 in. in

thickness is required.
LBO-170-125
plate
7178-0 and 7178-T6 bare
and clad al alloy sheet
and plate
primarily
skins.
Fed.
Spec Q&-A-250/14
Sheet gauges from 0.010 to 0.250. Plate thickness

from 0.250 to 3.000. Used in place of 7075 where
higher strength is required.

1MAGNESIUM ALLOYS
Magnesium alloy bar

shape
NA2-7166 ZKGOA-F
or
M;llSnesium alloy sheet

I,late A%:I1R-O or
or
Fetf. Sl,ec Q&-M-44
A%S1B-H24
General-purpose alloy. Not
to be \velded.
Sheet gauges from 0.020 to 0.250. Use condition 0 fo~

moderately formed parts. Condition H24 is more
difficult to form, generally recluilina heat, which hxe
annealing effect. Not
an
to be
dimpled.
STEEL BARS
1018 steel bar cold finished
Fed. Spec &&-S-634
Low-carbon steel may be brazed
4130 condition D,
condition F
Spec MIL-S-6758
Low-alloy steel. Not
to be
or
fusion-welded.
surface-hardened. Condition
copper-brazed or fusion
welded, but not spot-welded or seam-welded. MaY
D
(normalized)
may be
be
heat-treated.
4340 steel bar,
condition D
Spec MIL-S-5000
Low-alloy steel. Not to be surface-hardened, May be

fusion-welded, but not spot- or seam-welded.
51-30-00
0
Page 3
Aug 17/84
NA-66-1032
STHCCTUKAL REPAIH MANUAL
Table 1.
Repair (Contd)
REMARKS
SPECIFICATION
MATERIAL
STEEL SHEET AND PLATE

li-7PH CKF,S sheet
or
Spec MIL-S-25043

from 0.187 to 0.250. May be used where higher
strength formability than can be obtained with
Specification MIL-S-5059 1/2 hard is required. Must
be heat-treated. Maximum service temperature
is 550"F. May be spot- or seam-welded after heattreating, or fusion-welded before heat-treating.
Spec MIL-S-5059

from 0.250 to 2.000. Unstabilized. Maximum service
temperature is 700"F. Annealed material is
nonmagnetic. May be spot- or seam-welded but not
Spec MIL-S-fi721

from 0.150 to 1.000. Use Specification MIL-S-50Ti9 if
possible. Forms easily, annealed and nonmap~netic.
Not to be heat-treated. Can be spot- or seam-welded,
fusion-welded, or silver-brazed.
plate
301 (:RES sheet and
plate,
annealed and 1/2 hard
brazed
heal-resistant and
CKE:S sheet and plate
1010 steel sheet, condition 5
41.30 steel sheet and

condition A or N
plate,
Fed.
or
fusion-welded.
Sheet gauges from 0.025 to 0.125. Low-carbon steel.

Annealed. May be brazed or fusion-welded. May be
surface-hardened but not heat-treated.
Spec &Q-S-698

from 0.250 to 1.000. Low-alloy steel. May be copperbrazed or fusion-welded, but not spot- or seamwelded. Not to be surface-hardened. May be
Spec MIL-S-18729
heat-treated.
4340 steel
plate
Plate thicknesses from 0.250 to 1.000. Low-alloy steel.

May be copper-brazed or fusion-welded, but not spotor seam-welded. Can be heat-treated to 200,000 to
AMS6359
220,000 psi.
STEEL TUBING
4130 steel tube
Spec MII,-T-6736
Used in the manufacture of steel bushings.
or
AM S6371
413r, mechanical steel tube
Used in the manufacture of steel bushings.
AMS6372
BRONZE BAR AND CASTINGS

Aluminum-bronze bar
AMS4631
Aluminum-bronze castings
Fed.
Used in the manufacture of bushings and bearings.
May be used as a substitute for aluminum-bronze bar

(AMS4631) in the manufacture of bearings and
bushings.
Spec Q~-B-671
51-30-00
Page
Aug 17/84
NA-66-1032
NOTE
key numbers listed in table

throughout the manual.
Source
Table 2.
correspond to those referenced in "Consumables" lists
Sourcesof Materials
SOURCE
SOURCE
KEY
MANUFACTURER
MANUFACTURER
KEY
National Screw
Mfg Co, Calif. Div
Los Angeles, Calif.
001
Obtainable from applicable

vendors
020
002
Products Research Co
Burbank, Calif.
021
003
B.F. Goodrich
Akron, Ohio
022
004
American Latex Products Corp

Hawthorne, Calif.
023
Standard Pressed Steel Co

Santa Ana, Calif.
005
Minnesota Mining
St. Paul, Minn.
024
Cherry Rivet Div of Townsend Co

Santa Ana, Calif.
006
Shell Chemical Corp

New York, N.Y.
025
Avdel, Inc
Burbank, Calif.
007
Pyles Industries, Inc

Detroit, Mich.
026
E.I. du Pont de Nemours
008
009
010
011
012
013
014
01.5
Corp
Elastic
Stop Nut Corp of America
Union, N.J.
Mfg. Co.
027
Brooklyn Varnish Mfg Co

Brooklyn, N.Y.
028
United States Rubber Co

New York, N.Y.
Olympic Screw
Downey, Calif.
029
Air Industries of Calif.
Coast Pro Seal

Mfg Co
Los Angeles, Calif.
030
Churchill Chemical Corp

Los Angeles, Calif.
Rubber Teck, Inc

Gardena, Calif.
031
Co
W. P. Fuller
Los Angeles, Calif.
Parker Seal Co
Culver City, Calif.
032
Everlube Corp
Turco Products, Inc

Los Angeles, Calif.
033
Magnaflux Corp
Chicago, Ill.
034
Phillips International Co
Div of Phillips Screw Co
Cee Bee Chemical Co, Inc

Downey, Calif.
017
Rockwell International
Los Angeles, Calif.
018
Huck Mfg Co
Detroit, Mich.
Rivet
Corp
Gardena, Calif.
North
Sherwin-Williams Co
016
Hollywood, Calif.
Natick, Mass.
035
Riehle Testing Machines

Div of Ametek, Inc
East Moline, Ill.
Newton Insert Co
Los Angeles, Calif.
036
Carnloc Fastener Corp

Paramus, N.J.
Rosan, Inc
037
Newport Beach, Calif.
Co Inc
Explosives Department
Wilmington, Del.
Chemical Co
Finch Paint
Torrance, Calif.
Cleveland, Ohio
019
Hi-Shear
Torrance, Calif.
Barber-Colman Co
Rockford, Ill.
51-30-00
0
Page 5
Aug 17/84
NA-66- 1032
Table 2.
Sources of Materials
SOURCE
KEY
038
(Contd)
SOURCE
KEY
MANUFACTURER
050
Bauer and Black Division of

Kendall Co
Chicago, Ill.
051
Permacel Tape Corp

New Brunswick, N.J.
052
Grover Manufacturing Co.

620 South Vail Street
Montebello, Calif.
053
Lok-Fast, Inc
Torrance, Calif.
Ambler, Pa.
054
Semco Sales and Service, Inc

Infflewood, Calif.
DeSoto Incorporated
Des Plains, Ill.
055
Deft Chemical Coatings

Irvine, Calif.
Plainville, Conn.
056
National Research and Chemical Co

Hawthorne, Calif.
Sterling Laquer Mfg. Co.

St. Louis, Mo.
057
US Paint, Laquer
Nuodex Products Co, Inc.

Elizabeth, N.J.
058
Cordo Molding Products, Inc

New York, N.Y.
Hysol Division Dexter Corp.

Pittsburgh, Calif. 94565
059
Orcon Corp.
1570 Atlantic Street
Union City, Ca., 94587-3299
Newage Industries, Inc

Jenkintown, Pa.
039
Bloomingdale Department of American

Cyanamid Co
Havre de Grace, Md.
040
Cabot
Corp
Boston, Mass.
041
042
043
044
045
046
047
MANUFACTURER
Allied Research Products, Inc

Baltimore, Md.
ANCHEM Products, Inc.
Nu-Wipe
Inc
048
J. P. Stevens and Co, Inc

New York, N.Y.
049
Deutsch Fastener Corp

Los Angeles, Calif.
Chemical Co.
St. Louis, Mo.
51-30-00
Page 6
Mar 16/90
SABRELINER
CORPORATION
SIL
SERVICE INFORMATION LETTER
SIL: 57
REV: Basic
DATE: 9-29-00
PAGE: 1 of 1
APPLICABLE:
Model NA265 Series
All Models
SUBJECT:
Sealant
DISCUSSION:
manufacturing environmental restrictions,

most sealants specified in the Sabreliner Corrosion
Control and Structural Repair Mlanual are obsolete.
Replacement sealants have been developed.
INSTRUCTIONS:
Attached
Due to sealant
are
applicable
two
copies
of the current sealant list
to all models of the Sabreliner Aircraft
one copy to SR-76-023,

3
chapter 20-20-02, page (Corrosion Control Manual)
and the other copy to NA-66-10132, chapter 51-30-00,
NA265 Series. Please attach
page 6A
(Structural Repair Manual)
as a
temporary revision until the next manual revision.
SEALANTS
Applicable
Application
Approved
Reference
Materials
Specification
Skin Seams 8
PIS870B
1 PIS 8958
Antennas
I CS 24108
Sealing
Exterior
Cabin Pressure
Liquid Tight
Sealing
and
Fay Surface
Sealing: Aircraft
Structure 8 Aux
Fuel Tank Cmpt.
SAOI 06-1 06
Bay Bead
Sealing: Wing 8
Fuel
Aux Fuel Tank

Structure
Fuel
Bay Sealing
AC-632
P/S 8708
PIS 8908
CS 32048
AC-632
MllS-81733
1 MlL-S8802
MIL-S-8802
MILS-38228
Sealant
Pylon 8 Firewall
High Temp.
MllS-8802
MllS-Bi733
MllS-8802
PIS 690C
PIS 870C
AC236C
PIS 6908
PR-1422B
CS 32048
AC275B
AC-2368
I MILS-8802
I MlL-S-8802
P/S 690A
CS 3204A
AC-275A
I MlL-S-8802
I MllS-8802
1 MlL-S-8802
AMS 3276
DC94-011
I DC94-031
MlLS-8802
AMS 3276
Mll-SS802
All Models
Availability
BYz, &2,84
8-/t, 82
P-Part
Can 8 Kit
2-Part
Can 8 Kit
&2
2-Fart
Can 8 Kit
2-Part
Can 8 Kit
B~z, 82
I B~, 8-2, &4
~I, B2, 8-4
B-~1, B-~C.S2, 8-4
B34, 8-2
C-20, C-80
C-i2, C-24, C48
C-20, C-80
B~z, 8-2, 84
BH, &1, B2
B~, &W, Ed, &4
B~I, 8-2, 8-6
BW, &i, 8-2, &4, 8-6
A-M, A-2
I A-/z, A-2
A-~z.A-1,A-2,A4
A-%, A-2
I
MIL-S-36249
CS 1900
Condition
Available Class
I MILS-81733
Mll-S38228
I MlL-S-38228
Mll-S-38228
PR-1422A
Wing Injection
to Aircraft NA265 Series
P-Part
2-Part
2-Pall
5-Part
Can 8 Kit
8 Kit
Can 8 Kit
Can 8 Kit
1 Can
P-Part
2-Part
Can 8 Kit
2-Part
Can 8 Kit
P-Part
5-Part
Can 8 Kit
2-Part
2-Part
2Part
Can 8 Kit
Can 8 Kit
Can 8 Kit
2-Part
P-Part
2-Part
P-Part
Can 8 Kit
I Pre-Mix
Can 8 Kit
I Pre-Mix
Can 8 Kit
S-Part
Can 8 Kit
Can 8 Kit
Can 8 Kit
Can 8 Kit
Can 8 Kit
Can 8 Kit
PR-812
I MIL-S-38249
P-Part
Can 8 Kit
PR-19948
CS 55008
1 8-2
1 ~2, 8-2, B6
2-Part
Can 8 Kit
5-Part
Can 8 Kit
I MIL-S-8784
1 Mll-S-8784
I MIL-S-8784
B-K, 82
B%, 8-2
B-%, 8-2
P-Part
5-Part
Can 8 Kit
Can 8 Kit
Can 8 Kit
Sealant
W~ng Leading
Edge Anti-ice
High Temp.
1 Mll-S-83430
I Sealant
Cabin 8
Cockpit
PR-1428B
Window
Faying
CS 33308
Surface, Access
AC-215B
5-Part
Panel 8
Removable Door
Sealant
PR-1425B
PR-1725B
CS 32478
AC251B
1 8-/1, 8-2
P-Part
Can a Kit
1 &2
2-Part
Sealant
PIS 8958
CS 24108
AC-632
1 MlL-S-38228
1 MllS-38228
Mll-S-38228
I SW,
&Y4
~a.
I 8-2
BW,
Quick Repair of
Integral Fuel
CS 32048
AC250A
1 MllS8802
B-/4
I MILS-83318
MlLS-8302
A-1/6, 8-1/6
BA, 8-2
Cockpit 8 Cabin
Acrylic 8 Window
Installation
Aerodynamic
Smoothing
Tanks
I AC240B
Reference Sabreliner information Letter 57
82
P-Part
BK &1,&2
P-Part
Can 8 Kit
Can 8 Kit
Can 8 Kit
2-Part
Can 8 Kit
I 2-Part
Can 8 Kit
Can 8 Kit
8-2
8-2
2-Part
2-Part
Can 8 Kit
Can 8 Kit
2-Part
Can 8.Ka
I S-Part
I APPLICATION
O
O
-O
MIL SPEC AND/OR COMMERCIAL SPEC.
ALTERNATE
PRIMARY
PR341
CABIN PRESSURE AND LIQUID

TIGHT SEALANT
PR1422GBI
I
--I
PR1431G
FAYING SURFACE SEALANT, A/C STRUC-
(D
Ip
A+B
B
B
PS890B1/2-2-4
PR1422GB1/2-82
PS870B1/2-2-4
A+B
A+B
A*B
PS8908
MIL-S-8802
MIL-S-8802 AND MIL-7502
PR1422GB
MIL-S-81733 Type II
PS870B
PR1431G= MIL-S-81733
PR1431GTYPE1-4
PR1422GB1/2-62
PR14366B1/2-2-4
PR1750B1/2-2-46
MIL-S-I1OB18 and MIL-S-7502
K
C
K
C
C*K
C+K
PS8908
PR1422GB
PS8708
MIL-S-38228
PR341B1/2-82
PR895B1/2-B2
PS24782
PR30081/2-62
PS247
PR340
CLASS
PS895
PS247
PR340
PR341
PRESS
SEALING EXTERIOR SKIN SEAMS

AND ANTENNAS
C
C
C
K
K
O
p
C+K
TURE AND AUX. FUEL TANK COMPT.
m
i
O.
PR1436GB
PR1422GB
FUEL BAY BEAD SEALANT, WING STRUCTURE AND AUX. FUEL TANK STRUCTURE
PRi422GB
PR1436GB
PR1750B

MIL-S-83430C
MIL-S-81733/PR1750B
0,
A+B
A+B
A+B
K
C
K
C
C*K
A
A
A
K
C
C
C+K
~Ue
gp
PR1422GAI
FUEL BAY COVER COATING
I
I
n
m
I
I
I
I
PR1422GA
PR1436G= MIL-S-81733/PR1750A =MIL-S-83430CA
PR1436G
PR1750A
i
I
PR1422GA1/2-A2
PR1436G
PR1750A1/2-A2
6:
WING INJECTION SEALANT
PR703
PYLON AND FIREWALL HIGH

TEMP SEALANT
PR810
PR702
PR703 AND PR702
MIL-A-8625
PR703 PRE MIX

PR702 PRE MIX
PRB12
PS700
PR812 AND PS700

PR810 MIL-------
MIL-S-38249
PR812 PRE M1X
m
n
C]
O
n
WING LDG EDGE ANTI-ICE HIGH

TEMP. SEALANT
PR17508
CABIN AND COCKPIT WINDOW FAYING

SURFACE, ACCESS PANEL AND
REMOVABLE DOOR SEALANT
PR1321B
COCKPIT AND CABIN

ACRYLIC WINDOW INSTALLATION
PR1725
WINDSHIELD SEALANT
PR1422G8I
PR810 PRE MIX

PS700 PRE MIS
PR17508
MIL-S-83430
PR1321B
PRi403G
MIL-S-8784 i PS7068
MIL--------
C
C
C
C
C
K
K
PR1150B1/2-2-4-6
A+B
PR1321B1/2-82
PS70681/2-B2
PR1403GB1/2-82
A+B
PR1725B2
PR1425 82
C
C
PR1725B-2
PR1422G82
B
B
C
C
K
K
--I
O
Z
CLASS A
CLASS B
PR1403G
PS7068
PR1425
PR17258
PS8708
PR17258
PS8708
MIL---------/ PR1223B
MIL-S-81733 TYPE II
NOTE
BRUSH APPLICATION
INJECTION OR SPATULA
Application life and cure time
vary be-
~heek
tween
sealer manufacturers datafor each spe-
SHORT APPLICATION TIME

81/4
81/2
82
84
LONG APPLICATION TIME
eifie application requirement.
NOTE
The selection of B1~2 through B4 is
made by the user and is determined by
the type of application requirement.
MIL-S-8784
LAG-40-1035
FOR SEALER APPLICATION PROCEDURES,

CHECK THE CORROSION CONTROL MANUAL
68-76-023 CHAPTER 20-20-00 THROUGH 2620-32
AND THE STRUCTURAL REPAIR MANUAL
NA-66-1032 CHAPTERS 51-10-60 PAGE 201,
51-20-10 PAGES 1 THROUGH 8, 51-20-10 PAGES
201 THROUGH 205.
K
C
K
C
C+K
A+B
51-20-10 PAGES 1 THROUGH

BS1-plOPAGES201 THROUGH
205.
AVAILABLE:
C
K
CAN TYPE CONTAI~MeR

SEAMKIT CARTRIDGE
IF TOP COATING IS REQUIRED, USE PR-1005-L.

APPLY PER 68-76-023, CHAPTER 20-20-02 PAGE
2 AND THE SEALER MANUFACTURERS RECOMMENDATION.
~d
e,1Cn
O~.
Cd
~Cr3
2
rm
X&~
$ih
NOTE: please
see
the
TEMPORARY
REVISION
that revises this page
co
~ew
r~S
NA-66-1032
STHI~CrlJRAI, RE:IAIR MANUAI,
Minimum Bend Itadii-Aluminum
?able 3.
SWEET
6)61-T1
6061-0
7178-T6
7075-0
7075-Td
7178-0
1/16
1/8
1/16
1/8
1/16
1/8
1/16
1/8
1/16
1/16
1/8
1/16
1/8
1/16
1/16
1/8
1/16
5/?2
7/32
M)61-T6
5052-0
5052-1134
1/16
1/32
V32
1/16
1/16
1/32
1/16
1/32
1/16
3/32
1/16
1/32
1/32
1/16
1/16
1/16
16
3/32
1/16
3/32
V16
1/16
3/32
1/16
1/16
3/32
1/8
1/4
1/8
1/8
3/32
5/32
3/16
1/8
9/32
1/8
y16
3/16
7/32
0.102
5/32
11/32
3/32
5/32
1/4
9/32
16
0.125
3/16
7/16
5/32
7/32
1/4
9/32
11/32
3/4
3/8
0.156
1/4
9/16
5/32
7/32
3/8
15/32
15/32
15/16
1/2
7/32
3/8
15/32
9/16
1-1/8
19/32
1-3/16
5/16
1/2
5/8
3/4
1-1/2
25/32
1-9/16
2024-0
M2~-TI
0.012
1/32
1/16
0.016
1/32
1/16
0.020
1/32
0.025
0.032
0.040
1/16
0.051
1/16
1/8
0.064
3/32
5/32
0.072
1/8
7/32
0.081
1/8
0.091
TnlCKNESS
0.188
11/32
0.250
15/32
PL*TE
?T
1/4
5/32
27/32
1-1/4
5T
I-v?r~
?r~
1/16
3/16
3/32
3/32
1/4
I/B
9/32
3/32
5/16
1/8
11/32
5/32
3/8
3/16
lyn?
3/16
7/16
7/32
15/32
1/4
1/2
9/32
17/32
3TO
2-1/2TO
19/32
9/16
67
1V~6
O 13-1/2TO 16- I/Z
Minimum Bend Radii-Steel
Table 4.
4130, 4137, 4340, AND 8630
CARBON STEEL
1020 AND
1010
ANNEALED
NORMALIZED
1095
THICKNESS
180"
90~
180~
900
900
180D
1/16
3/32
90
180~
0.010
0.012
1/32
16
0.016
1/32
1/16
0.018
1/32
1/16
1/32
1/16
1/32
1/16
1/16
0.020
0.024
3/32
0.030
0.032
0.035
1/16
0.036
1/16
1/16
3/32
1/16
1/16
3/32
1/16
1/8
I/a
16
1/16
1/8
I/a
3/16
3/32
1/8
1/8
3/16
1/8
3/16
1/8
0.040
0.042
0.045
0.048
1/8
1/16
0.049
0.050
0.060
SHEET
1/8
1/16
0.063
0.065
0.072
0.075
3/32
3/32
1/8
1/8
3/16
3/16
0.078
5/32
1/4
5/32
1/4
16
3/8
3/32
5/32
7/16
1/8
3/16
1/2
1/8
3/16
0.080
1/8
3/16
3/16
1/4
Y16
1/4
3/16
1/4
1/4
3/8
0.156
1/4
3/8
5/16
5/8
5/32
0.188
5/16
3/8
3/8
3/4
0.250
3/8
1/2
1/2
2T
I-IRT
0.083
0.090
0.093
0.095
0.104
1/8
1/4
0.109
7/32
0.112
0.119
1/4
1/8
0.120
1/4
0.125
0.134
3/16
3/8
ELITE
)-1/2T
1/4
9/32
3/8
1/4
5T
IIRT
IP
27
NOTE
MATERIAL THICKNESS
TO NEXT LARGEST
(ROUND OFF
BEND RADIUS
1/32.)
51-30-00
Page 7
Aug 17/84
NA-66-1032
RE:PAIK MANIIAI,
Minimum Bend Radii-Cres,
lable 5.
Incond, and Titanium

PURE
AISI-302
AISI-X0Z
AISI-321
350
INCONEL
19-9DL
19-901.
17-7PH
INCONELX
19-9DX
I9-9DX
AISI-317
THICKEIESS
U(UPOO
U(U901
ALLOY
AMS4908
NAS7115
NAS7113
Y1 nCIRD
~HNEILED
1800
90~
90
STRESS RELIEVED
ANNEALED
1800
90
P00
90"
900
o.o12
1/32
1/32
1/32
1/16
0.016
1/32
1/3 2
1/32
1/16
900
1/32
1/16
1/16
3/32
1/16
1/32
1/16
1/16
1/32
1/16
1/16
3/32
1/16
1/32
1/16
1/16
1/16
1/16
0.018
0.020
900
16
0.010
1/16
0.024
0.025
0.028
3/32
1/8
3/32
V32
0.030
0.032
16
1n2
3/32
1/16
1/16
3/32
1/8
y32
0.035
0.036
1/16
1/8
1/8
3/16
3/32
1/16
3/32
3/32
1/8
Y32
0.340
1/16
1/8
1/8
3/16
3/32
1/16
3/32
1/8
1/8
3/16
1/16
1/8
1/8
3/16
V32
3/16
1/16
1/8
1/8
3/16
0.042
0.045
0.048
0.049
0.050
1/8
1/16
1/8
1/8
0.056
5/32
7/32
3/16
1/4
3/16
9/32
0.060
0.063
1/8
1/16
1/8
3/16
1/8
1/16
1/8
5/31
0.065
1/4
0.071
SnEET
0.072
0.075
0.078
0.080
3/32
3/16
3/16
5/16
3/16
3/32
1/4
9/32
3/32
3/16
3/16
5/16
3/16
3/32
9/32
5/16
9/32
13/32
0.083
0.090
15/32
0.093
0.095
3/8
0.100
1/2
0.104
0.109
0.112
1/8
1/4
1/4
3/8
1/4
1/8
3/8
13/32
13/32
9/16
1/8
1/4
1/4
Y8
1/4
1/8
3/8
7/16
7/16
5/8
1/2
23/32
0.119
0.120
0.125
0.134
0.140
0.156
0.160
9/16
ly16
0.180
21/32
29/32
0.188
3/16
3/8
D. 190
PLATE
0.250
1/4
1/2
~gff
zr
2TO
3/8
3/16
9/16
11/14
13/32
3/16
5/8
11/16
1/2
1/4
3/4
7/8
?rO
1T
NOTE
MATERIAL SHICKNESS
(ROUND
OFF BEND RADIUS
TO NEXT LARGEST 1/32.)
51-30-00
Page 8
Aug 17/84
NA-66-1032
STRUCTURAL REIAIR MANIAL
Table ii.
Bend Allowance Coefficients For Aluminum Alloys. Based On One-Dearee Angle

METAL THICKNESS
RADII
0.016
0.020
0.012
0.025
0.032
0.040
0.050
0.013
0.080
0.090
0.125
0.180
1/31
0.00067
0.00070
0.00071
0.00074
0.00079
0.00016
0.00094
0.00104
0.00117
0.001 25
0.00154
0.00100
1/16
0.00111
0.00115
0.00116
0.00119
0.00135
0.00140
0.001 49
0.00159
0.00171
0.00180
0.00109
0.002)5
9/31
0.D01 76
6.001 79
0.00180
0.001 83
0.00118
0.00195
0.00103
0.6011 3
0.00116
0.00134
0.00163
0.00309
1/1
0.00130
0.00134
0.0013S
0.0013B
0.00143
0.00149
0.0015(
0.0016B
0.00181
0.00189
0.00317
0.003M
5/32
0.001B1
0.0011)1
0.00190
0.00191
0.00197
0.00304
0.00311
0.00311
0.00335
0.00393
000372
000418
3/16
0.0DJJP
0.00341
0.00344
0.00347
0.0035~
0.003S8
0.00367
0.003;rT
0.00390
0.00398
0.00426
00W73
7/32
0.00394
0.00397
O.M)39B
0.00401
0.00406
0.00411
0.00421
0.00444
0.00451
0.00481
0.00511
1/1
0.00111
O.OM51
0.0~54
0.00456
0.00461
0.00467
0.00476
0.00486
0.00499
0.00507
0.005JS
0.0051)9
9/31
0.0050j
0.00506
a.00507
0.00)10
0.00515
0.00111
0.00530
0.00540
0.D055J
0.00561
0.00590
0.006M
0.a0)57
0.00560
0.00561
0.00564
0.00570
0.00576
0.00584
0.00S95
0.00608
0.00616
0.00644
0.00691
11/31
0.00612
0.00615
0.00616
0.00619
0.00624
0.00630
0.00639
0.00649
0.00661
0.00670
0.00699
0.00745
3/8
0.00666
0.00669
0.00671
0.00613
0.00679
0.0061)5
0.00693
0.00704
0.00717
0.00715
0.00753
0.008M
13/1?
0.00111
0.00714
0.00715
0.00728
0.00733
0.00739
0.0074(
0.00~5)
0.00771
0.00719
0.00808
O 00854
7/16
0.00771
0.00778
0.00780
0.00781
0.00787
0.00791
0.001)01
0.00)11
0.00826
0.00834
0.00862
O 00908
11/31
000119
0.001133
0.00834
0.00137
0.001)41
0.0084)
0.008S7
0.00067
0.00880
0.00888
0.00917
0.00965
1/2
0.001))4
0.00(87
0.001)89
0.00(191
0.00896
0.00903
0.00911
0.00911
0.0093S
0.00943
000911
0.01017
17/j1
0.00938
0.00942
0.00943
0.00946
0.00951
0.00957
0.00966
0.00976
0.00989
0.00991
0.01025
O 01071
9/16
0.00993
0.00996
0.00998
0.01000
0.01005
0.01011
0.01010
0.01030
0.01043
0.01051
0.01080
001116
19/31
0.01047
0.01051
0.01 051
0.01055
0.01058
0.01065
0.01073
0.01083
0.0I09E
001105
0.01133
001179
5/8
0.01101
0.01105
0.01107
0.01109
0.01114
0.01111
0.01119
0.01139
0.01151
0.011b0
001189
00113)
0.01156
0.01160
0.01161
0.0116(
0.01170
0.01175
0.011B3
0.01193
0.0110~
0.01114
001145
001289
0.01111
0.01114
0.01116
0.01118
0.01113
0.01130
0.01138
0.01 248
0.01161
0.01169
001198
001344
11/16
13/31
0.01161
D.0116B
0.01169
0.01173
0.01176
0.01183
0.01191
0.01301
0.01316
0.01311
0.01351
001397
3/4
0.01 520
0.01 313
0.01 314
0.01 327
0.01 331
0.01 338
0.01 347
0.013S7
0.01370
0.01378
0.01407
0.01453
25/32
0.01 374
0.01 37)
0.01 379
0.01 381
001 386
0.01 392
0.01401
0.01411
a.01415
0.01432
0.01461
001507
13/16
001419
0.01431
0.01433
0.01436
0.014)1
0.01447
0.01456
0.01466
0.01479
0.01487
O 01516
O 01562
27/32
0.014B3
0.0141)6
0.01487
0.01490
0.01494
0.01501
0.0IS09
0.01519
0.01534
001540
001569
001615
7/11
0.0I 538
0.01541
0.01542
0.01545
0.01550
0.0I1S6
0.01565
0.01575
0.015811
0.01596
0.01625
001671
19/31
0.01 592
0.01 595
0.01 596
0.01599
0.01 604
0.01610
0.01619
0.01 619
0.01643
0.01650
0.01679
001727
1S/16
0.01646
0.01 650
0.01651
0.01654
0.01 659
0.01 665
0.01 674
0.01684
0.01697
0.01 705
0.01734
001780
31/32
0.01701
0.01704
0.01705
0.01708
0.01711
0.0171)
0.01717
0.01737
0.01751
0.01758
0.01787
O 01833
0.01 755
0.01 759
0.01160
0.017~3
0.01 768
0.01 774
0.01 783
0.01 793
0.01806
0.01814
0.01 843
0.01 BBB
O
THE EMPIRICAL FORMULA FOR FINOING THE BENO ALLOWANCE OF
REOUIREO FOR A BEND ;10.01743

THICKNESSI
MATERIAL
THIS
EOUALS THE MATERIAL REOUIREO FOR
RAOIUSI
10.0078
Muilipy
the numbers
In
the Inb
by the degr.es
of bend to determine the amount of material required for the

bend
Example:
I" OF BENO.
95" bend. 1/8
For benos
material
MOLD LINES
DEGREE OF BEND
0040 irl
In.
mnli!rial 0.00249
required
02365 in
95
larger
tnan
one
rartius the nlnount at
for the bend is calculated
circle, the radius of which
Is
taken
as
the
are
of
to the center of the
material
Example:
BEND LINES
90" bend. 1 in
radius,0.064in, material.
Radius to center of material

1/2 material thickness
anaus
bend radius (1 in)
0.032
1.032in
(R)
Circumference of
2R
are
360
degree of bend
(total degrees
in
circle)
(T)
51-30-00
Aug
17iX1
NA-Ci6-1032
$I tll(llTKAL KEPAIK MANU AL
Bend Allowance Set Back
Tahle i.
ANGLE
ANGLE
DEGREE
DEGREE
ANGLE
DEGREE
ANGLE
DEGREE
ANGLE
DEGREE
ANGLE
DEGREE
000873
31
017732
61
0.58905
91
1.0176
1~1
1.76TS
151
3.8667
0.01145
31
0.18674
62
0.~00116
92
1.0355
11?
1.8040
151
4.0108
002618
33
0.19611
63
0.6110(1
93
1.0538
123
1.8418
1S3
4.1653
0.03493
34
050S73
64
0.61487
94
1.0724
114
1.8107
154
4.3315
004366
35
0.31530
65
6.63707
95
1.0913
115
1.9110
155
4.5107
0.05141
56
0.31491
66
0.64941
91
1.1106
116
1.9616
156
4.7046
0.06116
37
0.33459
67
0.661 88
97
1.1303
1.0057
IST
4.9151
0.06993
38
0.54433
68
0.67451
98
1.1504
118
2.0503
151)
5.1455
0.07870
39
0.35411
69
0.68718
99
1.1708
)19
1.0965
159
5.3995
)O
0.08749
40
0.36397
70
0.70011
100
1.1917
130
1.1445
160
5.6713
11
0.09629
41
O 37388
71
0.71319
101
1.1131
131
1.1943
161
5.9758
12
0.10510
42
038386
71
0.72654
101
1.2349
131
1.1460
161
6.3137
13
0.11393
43
0.39391
13
0.73996
103
1.1571
133
1.)998
163
6.6911
14
0.11278
44
0.40403
74
0.75355
104
1.2799
134
2.5558
164
1.1154
15
0.13165
45
0.41411
75
0.76733
105
1.3031
1JS
1.4141
165
7.5957
16
0.14054
46
0.42447
76
0.78128
106
1.3P70
136
1.4751
166
8.1443
17
0.14945
47
0.45481
77
0.79543
107
1.3S14
137
2.5386
167
8.7769
18
0.15838
48
0.44513
78
0.80978
108
1.3764
1J8
1.6051
168
19
0.16734
49
0.45573
79
0.11434
109
1.4019
139
2.6746
169
10.385
11.430
117
9.5144
10
0.17633
50
0.46631
80
0.83910
110
1.41(1
140
2.7475
170
21
0.18534
51
0.47647
BI
0.85408
111
I.4SS0
141
1.(139
171
11.706
22
0.19438
51
0.48773
81
0.86919
11?
1.1816
141
1.9042
171
1~.301
16.350
23
0.20345
53
0.49858
83
0.1)(471
113
1.5101)
143
2.9887
173
14
0.21256
54
0. 50951
84
0.90040
114
I.S399
114
3.0777
174
19.081
25
0.22169
55
0.51057
85
0.91 633
115
1.5697
145
3.1716
1TS
11.904
16
0.13087
56
0.55171
86
0.93151
116
1.6003
146
5.1701
176
16.636
27
0.24008
57
0.5419)
87
0.94896
117
1.6318
147
3.37)9
117
38.188
18
0.24933
5(1
0.55431
88
0.96569
118
1.6643
148
3.4874
178
57.290
29
0.15861
)9
0.56577
89
0.91)170
119
).69T7
149
3.6059
179
114.)90
30
0.26795
60
0.57735
90
1.00000
110
1.7310
1S0
3.7310
180
INFINITE
cz~
i- SETBACK3
Example:
;If_1
Angle of bend (A) 140"

Material thicknerl (T)
0.064 in.
Radiu~ (R) =0.125 in.
K-fram table
1.7475
SETBACK
2.7475 X
1.7475 X
SETBACK
KX(TS-R)
(0.064
0.125)
0.189
0.509
0.509
IN.
51-30-00
raac~ to
An# 17/H4
NA-66-1032
STHIICTURAL KEPAIH MANUAI,
OECIMAL
TAP
GRILL SIZES
Table 8.
NC
Coane Thrcld
TAP
DRILL
SCREW
SIZE
EBUIVALENTS
NF
Fin Thread
SCREW
SIZE
TAP
DRILL
I Table
11.
SIZE
DRILL
7/)6-10
15/64
1/1-10
19/61
1/1-13
17/64
9/1611
31/64
9/16-18
33/64
5/8-11
17/31
5/8-18
11/1611
19/31
1/8
0.1110
11/64
0.0145
30
0.1285
0.3310
1/64
0.0156
1
1
19
0.1360
11/31
0.3451
37/64
77
11.0186
9/64
0.1406
0.0200
17
0.1440
0.31(0
5/8
76
75
0.0210
26
0.1470
1j/~4
0.3594
74
0.0125
25
0.1495
73
0.0140
14
0.1520
0.0250
13
0.1540
5/jl
0.1 562
3/416
11/16
7/8-14
13/16
1/8 9
49/64
15/16
13/64
1-1/+
-14
63/64
1-7/64
11/E 6
71
0.0266
1-11/31
1/3)
0.0330
1
1
ND. 43
-48
No. 47
NO. 40
-40
NO. 32
-32
1
1
No. 43
No.
36
NO. 28
-32
No.
19
No.
19
10
-24
No 15
No.
10
NO.
10
1
1
1
1
1
1
1
1
1
-32
No.
11
12
14
No
16
1/4
-?O
No.
/4
1/4
-28
I
1
No.
/4
5/16 -18
5/6
5/16
24
3/8
-16
5/16
1
1
1
3/8
-14
7/32
5/16
3/8
s/s
1
1
TAP
DRILLS_FOR
1 CLEARANCE
11/31
7/16
7/16
7/16
0.1730
7/16
0.4375
0.0360
16
0.1770
29/64
0.4531
0.0370
IS
0.1800
15/31
0.4667
0.0380
14
0.1810
31/64
0.1850
o.le9o
58
0.0410
11
0.1910
35/64
0.5469
57
0.0430
10
0.1935
9/16
0.5616
56
0.0465
8.1968
37/64
0.5781
3/64
0.0469
0.1990
19/31
0.5437
55
0.0520
02010
39/61
0.6094
54
0.0550
0.~OJ1
1/8
0.62)0
53
0.9595
0.2040
41/64
0.6496
1/16
0.0625
0.2055
21/32
0.6562
51
0.0635
02090
43/64
0.6719
51
0.0670
0.2130
11/16
0.6875
50
0.0700
49
0.0730
48
0.0760
5/64
13/64
0.1875
45/64
0.7031
13/32
0.7187
01280
47/64
0.7344
0.2340
5/4
0.7500
49/64
0.7656
25/32
0.7811
00781
0.0785
15/64
0.2344
1
1
0.0810
0.2380
45
0.0820
0.2420
51/64
0.7969
44
O.O8M)
02460
11/16
0.8125
53/64
8.8281
17/32
0.8437
0.25M)
43
8.8896
42
0.0935
0.1570
0.0957
0.2610
41
0.0960
17/64
40
0.0980
39
0.0995
38
0.1015
J/jz
1/4
57/Y1
0.8906
0.2720
29/32
0.1770
59/64
37/64
7/8
37
0.0140
0.281 1
)4
1
1
1
23/32
3/4-
59/64
1-3/16
36
0.0165
9/32
0.1811
5/32
1-7/16
7/64
0.1093
02900
13/4
35
0.1100
34
19/64
33
0.1130
1
1
32
0.1IM)
5/16
0.12W
031M)
0.3230
21/2-
2-
11-1/1
2- 5/8
3-1/2-
1
1
7/32
2-1/2
3
1/4
33/4
3- 3/4
4-1/4
1/4
4-3/4
4-
1
1
0.8594
02660
55/64
0.8750
18
1
1
7/8
0.2656
3/8-
1-47/64
0.5311
18
1-1/2-11-1/2
0.2210
27
1-1/411-1/1
17/32
0.2187
3/4
05156
33/64
1/11
1
1
1
1
1/4-
1-
0.)000
12
1/8-
-11-1/1
0.4843
3/16
PIPE
I
17
0.0410
0.4219
0.)130
8.6486
46
DIAMETER
OF TAP
17/64
59
47
Table 10.
60
15/31
13
to
0.1695
0.1719
04040
0.4642
1
1
0.0350
18
11/64
0.3970
0.03W
CLEARANCE
No. 50
0.1660
0.0320
0.3860
0.3906
61
DRILLS FOR
1
19
66
62
-56
67
63
0.1610
64
MACHINE SCREW
SCREW
SIZE
0.1590
20
0.0315
65
Table 9.
21
0.0310
0.3770
0.0192
69
0.3750
15/64
0.0280
0)680
3/8
0.1570
68
0.3480
22
70
1-17/64
1-1/1-11
71
1-1/4-11
7/8
03390
01405
-8
o.Jall
0.0135
28
23/32
I.l/e- 7
DECIMAL
SIZE
DRILL
11/31
DECIMAL
0.0160
11/1611
53/64
SIZE
DRILL
3/410
78
13/1610
15/16
DECIMAL
79
86
7/1614
FRACTIDNAL SIZE DRILLS
0.9061
0.9219
09375
61/64
0.9531
31/32
0.9687
0.1950
1
1
1
63/64
0.9844
0.2968
1.000
0.3020
0.3125
51-30-00
o
Page 11
Aug 17/84
NA-66-1032
SIRU(:TITRAL REPAIK MANUAL
Circumference and Area
Table 12.
OF ONE
INCH
FEET
INCHES OR
ollmrrtR
DtCIM*L
1/64
0015625
1/31
1
1
1
1
003125
rRICIION
3/64
1/16
5/64
3/31
1/64
natn
004909
00001P
0.09818
1
1
1
1
000077
0.14716
0.046875
0 0615
0078125
0.09375
1
1
019635
0.24545
0.109375
I/a
9/64
clacum.
5/31
11/64
28.174
63.617
72
31.416
O 02310
)1
34.558
13/32
12
37.699
1131
75
235.61
4417.86
0.63817
13
40.841
132.75
76
138.76
4556.46
068722
003758
14
43.981
153.94
77
14190
4656.6)
004314
IS
47.124
17671
78
145.04
4778.36
004909
1
1
16
101 06
79
14819
4901 67
17
1
1
50.265
126.98
so
251 33
18
56.549
254 47
81
19
1
1
59.690
1
I
a?
62.832
31416
83
1
1
65.973
1
1
1
346.36
84
380.13
415.48
0 06922
098175
1
1
1.0309
0 08456
10799
0 09281
O 07670
279.60
13~54
013979
282 74
13744
015033
18
87.965
615 75
91
O 16126
1
1
66052
92
289 03
6647.61
29217
6791.91
295.J1
6939.7)
14236
14726
011157
15218
1
1
O 18427
15708
16199
16690
1
1
0 10880
17181
0.23489
0.24850
18653
19145
1
1
1
016148
0.17688
0.19164
0.30680
1
1
0.65625
1
1
20617
033824
1.9635
0.671875
0.32231
0.35453
2.1108
?1
14
75.598
78.540
22
1
1
94.148
706.86
97389
1
1
7S4.77
94
31
33
35
36
37
1
1
125.66
31~32
L3iM
319 87
8659.01
135.09
1452.10
106
333 01
8819.73
43
8494.07
8992.01
138.13
151053
107
336 IS
14137
159045
108
339.19
9160(8
109
34143
933132
34871
1
1
1
35186
Ilo
1809.56
111
0.46038
49
15394
1885.74
112
1
1
1
047937
1
1
1
50
1
1
1
157.08
1
1
1963.50
113
355
100111.75
1042.81
114
35814
1020703
16336
1~23 71
115
361 18
1038~.89
1
1
1
053862
1
1
1
1
1
53
1
1
1
1
1
166.50
2106.18
116
36441
1056(.31
169.65
1190.22
117
36757
171.79
2375.83
049872
051849
055914
2.8471
OMS04
0.921875
28959
066748
0.9375
29452
O 69029
Oiameler
8332.29
1734.94
0.90625
30928
8011.81
8171.1(
062298
320 44
15080
0.60132
0984375
147 65
27981
30434
101
48
27489
0 96875
1194.59
47
2.6999
29945
7853.9)
1
1
1
1
1
1
1
7691.69
1
1
317.30
1
1
1
1
0953125
314.lb
lot
044179
311.01
1134.11
I
1
105
61164
too
138544
0.41356
99
1075.21
23072
59/64
1017.88
13195
0734375
29/32
307.88
98
7001.21
7131.13
7289.81
754).96
30473
41
46
0.890625
1
1
316.73
1
1
0875
97
323.5L
0.40574
0.859375
907.92
1
1
1
1
85530
301 .59
2.1580
26507
290.4)
104
0.71875
0 84375
95
103
1
1
26017
6503.8(
1310.25
25525
6361.73
1156.64
25036
122.52
6982 12
1
1
1
1
6111.14
128.81
0.703125
0828115
119.38
185 BE
96
594468
17646
804.25
96111
113.~0
08125
1
1
1
5B08.e0
41
45
0796875
109.96
40
44
24544
10367
106.81
39
1
1
1
1
116.14
0 38828
078115
1M).SJ
1
1
1
38
0.37122
1.4054
91.106
1
1
81.681
22090
0765625
88
490.87
31
21598
23562
30
452.39
93
0.6875
0.75
71.157
29
1
1
1
69.115
23
34
0.22166
17671
18163
019635
1
1
15/16
273.32
20127
7/8
57/64
SC74.50
87
90
0.610625
55.64
270. 18
89
0.625
1
1
261 04
32
86
0.609375
5541 77
as
5281.02
57256
0.578125
13.16
530 93
059375
531M
263 89
51/M
541061
84.823
0546875
1
1
053115
25/32
160 75
27
0.5625
49/64
5153
25761
26
5/4
?8353
23/32
10
0515625
45/64
1
1
502655
1
1
154 47
0 11961
12763
9/16
27
0.01113
)3.407
25
35/64
47/64
0.05541
05
4300.84
011984
0.484375
11116
12273
1
1
43/64
23248
21/32
0.390625
046875
s/e
74
0.375
41/64
4185.39
011045
15/32
010161
39/64
119.34
11781
0.453125
19/32
1.1291
4071.50
22619
73
78.540
D 03141
0.93171
19164
37/60
3959.19
3848.45
001761
0.88357
04375
17/31
1
1
0421875
33i64
21305
3611.68
083453
0.40625
3739.1)
119.91
0.78540
31/64
1/2
3~15.65
1
1
1
1
1
1
0.359375
71/a4
341119
1
1
058905
1
1
1
1
0.25
25/60
0.73635
5/8
70
)D
0234375
23/64
38.485
001917
0 34375
0.015S)
15/64
18.850.
216.77
71
11132
21363
69
0.2~875
0.318125
3318.31
110 49
50.266
0312~
68
95 033
3216.99
053999
204.10
25.133
201 06
67
107 35
0171875
11991
CIeCUM.
5/16
19.635
28.274
65
001227
015625
211~4
15.7080
64
1
1
049087
1
1
12 5664
11.56M
70666
044181
0.296875
31416
I
1
07(154
1
1
I
7/31
19/64
6.2831
0140625
028125
31416
1
1
1
DIAM.
000939
13/64
9/31
94148
000690
0.39270
1
1
nard
0265615
1
1
1
1
01875
1/4
0.00479
CIIICUM.
0.34363
o11S
0.203115
0.00306
019451
1
1
3/16
0.00173
oIIm.
058003
1
1
1
51
52
54
55
56
51~
M)
1
1
61
073708
07M)P7
63
071349
IM)?2
175.93
62
1
1
179.07
182.21
58
59
1661.90
144.51
1
I
)85.35
IBB.SO
i
1
191.64
19478
197.91
1
1
1
1
1
345.58
9851.03
10751.31
370.71
1093~.118
119
11122.02
120
1
1
37385
2642.08
121
380 13
2733.97
122
383.17
1817.43
123
1
1
2922.47
38956
125
301907
1
1
124
311715
126
multiplied by 3.1416 clrcumlarsnce. Clrcumlarenee mulliplled by 0.3183

Square ol the dlameIer mulllpliad by 0.1854 area.
9676(19
118
2551.76
2463.01
9503.31
11309.73
376.99
11499.0)
11689.87
391.70
1
1
1
1
395.84
1?46898
386.42
11882.19
12076.211
12271 85
diameter.
51-30-00
Page 12
Aug 17/84
NA-6(i-1082
STRUCTURAL REPAIR MA~lrAI,
PLANE FIGURES
C
Ilo
TRAPEZOID( plnllsl
AREA
RECTANGLE
RREA= bh
to
OIAGONAL d
l~b
=\lb2
(h
h?
Id is perpsndiculer
lc 1 and
bl
RIGHT TRIANGLE
CIRCLE
AREA=
AREA-- rr?
CIRCUMFERLICE rd
2nr
5~dZ
Circumlannce
n=
b)
~t-
--L
HYPOTENUSE-e
-~ite
4"+6"+0"=180 degrees
10.7854d2
dltmalar
-3.1416
ELLIPSE
AREA-
/_P
n(OA)xlOC)
h
B
=_nyBlx(co)
ABI
AREA
bh
Id is perpendicular
le
bl
D
b
A"
SOLID FIGURES
a"
CO c DO
360 degrees
FUNCTIONS OF ANGLES
SPHERE
YDLU*I
lopposite
nrz(engle AOO)
360 degrees
bl
PARALLELOGRAM
sides parallsll
ItC
to
8"+2"+0"=180 degrees
SECTOR
AREA
Id it perpendicular
ANY TRIANGLE
bh
AREA
-2
SIOE
fnrl-n~
HYPOTENUSE
OPPOSITE
Iltl. InP- nd,
CYLINDER
ANGLE
YOLUM~o xr2=0.1854dzL
SIOE ADJACENT
AREA OF CYLIWORICAL SURFACE ~srOL

SINE
CYLINDER
VOLUML
(area bsselh
Opposite
Hypotenuse
TANGENT
AREA OF CYLIWORICAL
SURFACE
SECANT
Iparimater bsse)h
Adjacenl
Hypotenusa
Side Adjlcenl
COTANGENT
Side Oppoeite
Side
Side
Side
COSIWE
Opposite
Adllcent
Hypotenu~eSide Adiacenl
Side
g~,
COS~CLWI;
fh
CONE
VOLUME(OFEITHER)
Inr2h
3
AREA IOF RIGHT COWE)= nrl
~iir:
CONVERSION OF FRACTION TO DECIMAL

TO CONVERT FRACTION TO DECIMAL
CUBE
VOLUME =a,
DIVIDE NUMERATOR
01~60111L36=l\lj
EXAMPLE:q
TOTAL AREA l;ge 2
(TOP)
elsmoo
48
5=0.625
20
40
OIIGOIAL=d~
I
2(tb
he
40
cal
Shop Mathematics
Figure 1
16
=abc
TOTAL AREA
(BOTTOM)
0.82~5
RECTANGULAR PRISM
VOLUME-- (srea ol end)C
BY DENOMINATOR
51-30-00
Page 13
Aua 17!84
NA-fiG-1032
STRUCTIIRAL REPAIK MANIIAL
DIMPLE OR
COUNTERSINK FILLER
DIMPLE TO
BE FILLED
INSTALL HEAT-TREATED FLUSH RIVET.
SELECT DRILL SAME DIAMETER AS RIVET.
TYPICAL APPLICATION
DRILL THROUGH HEAO.
FILLING DIMPLED AND COUNTERSUNK HOLES

I
IN CASES WHERE A DIMPLED OR COUNTERSUNK HOLE HAS BECOME

ENLARGED, ANO IT IS NOT POSSIBLE TO REOIMPLE OR COUNTER-
existing
SINK FOR THE NEXT SIZE LARGER FASTENER, THE FOLLOWING

METHOD MAY BE USED TO TRIM THE NEXT SIZE LARGER FASTENER
HEAD TO MATCH THE EXISTING DIMPLES OR COUNTERSINKS.
hole in
stee
block the
lame
sire
as
Ihe
fastener.
Countersink the drilisd hote
so
Ihal the exist ng
size fastener head is flush with the surface of the steel block.
O
O
COUNTERSINK TO MATCH
EXISTING FASTEIIEA
STEEL BLOCK
Dri I
OHILL TO MATCH EXISTING
Redrill hole to next Jils larger fssfsner diameter
Place the Isstener to be used in the oounle~unk
hole in the steel block, and file
SIZE OF FASTENER
or
grind off
head flush with
the surface of the block.
REDRILL TO MATCH NEXT

SIZE LARGER FASTENER
Install the tsstensr to be used in red.lled holes
After installation, coat head of fastener with two coats of zincchromate
primer, and paint
to match
surrounding
area.
1--J
FASTENER
BEFORE TRIMMING
FASTENER
AFTER TRIMMING
j
NOTE
THIS METHOD TO BE USED ONLY FOR THE NEXT SIZE
LARGER FASTENER.
TRIMMING FASTENER READS
51-30-00
Pagcl 14
Aua 17/84
Irimming Fastener Heads and FillinR Countersunk
eruKiFseloi)
2
NA-fiCi-10~2
NOTES
STK~CIUKAI, HE:IAIH
PERFORM ALL FASTENING OPERATIONS ON COVERS

AND DOORS. AND SECURE PART FIRMLY IN PLACE
RADIUS (REFER TO
--C--
XL
CI
LI
c
C
EDGE OF CUTOUT
r5J)
V
U
jJ
OVERSIZE FILLER
(REF)
Iii
III!L;
c
C
:II
C~
C,
I1I
_----~
;II
.oc
OUU
----r-__------\,
!11
c,
11I
I II
I;I
I I
II
I,
REPAIR DOUBLER
OR DOOR LAND
!.n
MASKING TAPE
~C
NOTJ.)~
U
CCODCC
IDGT OF OPINING
SECOND TAPE (RER
US~: RADIUS GAUGE OR DISK TO DUPLICATE RADIUS
FIRST TAPE (REF)
BE) ORE TRIMMING.
1II:
Cc(
;rl
17~
CL-
O
o
L,
PLACE SECOND
TAPE OVER COVER,
MATCHING IT
LTRACE
OVERSIZE FILLER MATERIAL

PLACED OVER TAPED
ACCURATELY WITH
OUTER EDGES OF
FIRST TAPE.
TRIM LINE
INSIDE OUTER
CUTOUT
(SECOND) TAPE.
WITH MASKING TAPE

NOTES
TRIM OUT DAMAGED AREA. CUT FILLER OVERSIZE
PLACE
c~
FILLER
OVER
CUTOUT. AND INSERT SKIN
SCRIBE. HOLD FILLER FIRMLY IN PLACE. AND SLIDE

SCRIBE AROUND CUTOUT
THIS TRIM MARKING METHOD IS NOT RECOMMENDED
(3
FOR FITTING COVERS AND DOORS
DIMENSIONS ARE SHOWN IN INCHES
1/2
SKIN SCRIBE
SCRIBE LINE
OVERSIZE FILLER
SPACER
ANY ALLOY STEEL
scsle~(REF)7
II
IAPPROX. 0.040 IN.)

OR HACKSAW BLADE
SKIN CUTOUT
WITH SKIN SCRIBE
Locating Skin Trim

Figure 3
Lines
51-30-00
PaKe 1.~
AuK 17/X4
NA-66-1032
STKUCTIKAL REPAIR MAPVUAI,
NO. 30 0140
DRILL RUSHING
~/BIN(APPROX)
PEEN PRORE STEM FLUSH
~)ICIR-0.010
(01
AS
NO 40 DRILL RUSHING
REOD)
SCREW LOCATOR
THIS VARIATION OF HOLE FINDER
MATERIAL-o.oSo
(Ipnox)
MAY BE
STEEL OR HEAT-TREATED
USED FOR LOCATING

HOLES OF VARIOUS
LARGER
ALUMINUM ALLOY
O
SIZES, SUCH AS SCREW HOLES IN

UNDRILLED
STRUCTURAL
DOORS AND COVERS.

SWEAT SOLDER
NO. ~O
01
DRILL RUSHING
1/1 RIVET
II
EITHER MEMRER MIY

M FORMED 10 CLEAR
OILfllVCTIONS II
mrSSL~llr.
OR
SIAKESWUT
1/410.
SOLDER
17/32
1/4 IN.
*5 REOD Foa EDGE
IN.
01 MID-PANEL HOLES
CAMLOCSTUDLOCATOR
LOCATING BLIND HOLES WITH HOLE FINDERS
THIS VARIATION OF HOLE FINDER
MAY BE USED FOR LOCATING

CAMLOC STUDS
UNDRILLED
NOTE
(4002 SERIES)
COVERS
IN
AND
DOORS.
SHAPES OF THE HOLE FINDERS SHOWN ARE ONLY
WHEN FREQUENT FITTING OF BLANK
EXAMPLES. OTHER CONFIGURATIONS WILL BE RE-
COVERS
AND
QUIRED FOR ACCOMPLISHING MANY JOBS. MAIN
PECtED,
A SET OF LOCATING
POINTS TO KEEP IN MIND WHEN MAKING A HOLE
TOOLS SIMILAR TO CAMLOC
FINDER ARE(1)
AND
(2)
STUD
PROBE MUST FIT SNUGLY IN HOLE.
DOORS IS EX-
LOCATOR
IS
RECOM-
MENDED.
DRILL BUSHING OR TRANSFER PUNCH HOLE
MUST BE ACCURATELY CENTERED OVER PROBE. TO
ACCOMPLISH LATTER, ASSEMBLY SHOULD BE LINEDRILLED.
METHOD
OWI1W
METHOD
LHIIIN
~L*CI. ~LIOll
SCALE ALONG UNCOVERED PORTION

OF LINEi THEN PROJECT LINE ONTO
REPAIR SHEET. CAREFULLY
MARK
/CHOIEN DISTANCE. CENTER-PUNCH
AND DRILL HOLE.
DRAW LINE THROUGH CENTER OF

RIVET. MARK A SELECTED DISTANCE
ON LINE FROM CENTERLINE OF RIVET.
c~3
~3
ro LOCATE
ei
CENTER,
INSERT AD RIVET IN HOLE.
sY
~e
METHOD
O DI*W TWO LINII
INTERSECTING AT
METHOD
CENTEROFRIVET.
rj INSTALL
REPAIR SHEET. ACCLIRATELY

SCALE ALONG UNCOVERED
PORTION OF LINES AND PROJECT
ALIGN
LOCATING BLIND HOLES WITH

A SCALE--TWO METHODS
51-30-00
PaRc
LINES ONTO REPAIR SHEET. CENIEI

PUNCH AT INTERSECTION AND DRILL
PILOT HOLE.
Locatinff Rlind
eruf iFseloH
4
16
AoR 17/84
NO
THIS TYPE OF CAMLOCK STUD LOCATOR IS RECOM
1-1/4
MENDED WHEN REGULAR REPLACEMENT OF DOORS
ANDCOVERSISEXPECTEDALOCATORISINSTALLED
IN
1-1/4
DIMENSIONS
--L,----
EACH CAMLOC RECEPTACLE
UNDER
DOOR
OR
COVER BEING FITTED

IN
INCHES
OTHERWISE
UNLESS
INDICATED.
FABRICATION
DRILL I/P--CSK
140 OEC X 5/8
(150 in 2024T4
Fabricate all parts tram
or
/075-76
clad material
P
O
5/32 RIVET
NO. 21
LLIAD-
RIO PIN HOLE.
6111 sheet-metal st~lpr and npscers
Joggle lower (collar-retaining) strip
ORILLNO.~ZITYP)
and
Align
DRILL NO. 30
clamp strips
spacer in drill
and 0050 in
vise, and insert a0.100in.spacerbetweenstripsatjoggled
RIG PIN
RIVET
end
15/32 RIV~TJ
(LOOSELY ORIVENJ
RIG-PIN HOLE ITYPI
TRANSFER-PUNCH HOLE
O
lower
a
O
0.050
0.050 SPACER
CLIL~ 0l0lln
Through
rig-pin hole,
-1
1YO RIWO
parts dr II
No 30
Remove upper
strip
No
21 rivet hoe
21
No
hole
and spacers from
v se
Rec smp
in Camloc collar hole.
Install Gamloc collar
Assemblepans sndriuellhzm Taensurealighmenf

be in
place during riveting operation
RIG PIN IN PLACE
CAMLOC RECEPTACLE (TYPI)~
CAMLOC STUD LOCATOR ALIGNED
CAMLOC STUD
LOCATOR ITYP)
transter-punch
strip; drill and countersink 1/2
rig pin should
CAMLOC GfUD rocAroR
all
and
MARK HOLE CENTER

WITH 1/0 IN.
TRANSFER PUNCH
TAPE DOOR SECURELY

IN PLACE
(TYP)
CAMLOC OROMMET AND STUD ITYPI
CAMLOC RECEPTACLE ITYPI
UNTRIMMEOOOOR
\J
DOOR LAND
LOCATING CAMLOC STUDS
O
SKIN
Inlta I C.mloc.tud locator in8ach
receptacle
around
opening.
O
tape
SKIN
Align untrimmed
place.
door
over
opening,
and
securely
(REFI
DOOR LAND
(REFI
it in
Align locator, install rig pin, and mark center of

Repeat procedure on each locator around
opening.
location.
LocatinR~ Access I)oor Fastener Locations
FiRure
o
COPYRIGHT, 1984 BY SABRELIN~R CORPORATION
51-30-00
Paffe 1~
Aua ITi84
NA-66-1032
FASTENERS
The fasteners used in this airplane are for the most part
the conventional fixed and removable types and are
installed in accordance with accepted practice. However,
specific instructions concerning fasteners in the repair
illustrations should be strictly observed. Unless otherwise
noted in this manual, the minimum fastener edge distance
is two fastener diameters from the center of the hole to the
edge of the material, and minimum spacing is 5-1/2
fastener diameters. For

refer to table 1.
general
fastener
descriptions,
Structural bolts or screws one dash number above or

below that called out on the drawing and not more than
three washers of same style and material as drawing
callout may be used providing no interference occurs as a
result, to produce proper grip conditions and meet the
limitations of threads in bearing.
Non-structural bolts or screws three dash numbers above

below that called out on the drawing may be used,
providing no interference occurs as a result.
or
approved by Engineering, deviation will not be

permitted from the number of washers or the dash
Unless
in
specified on
conjunction with
the
drawing for bolts
screw
Particular attention must be given to the use of specially

nuts and plate nuts for use with bolts and screws
with 0.003 undersized pitch diameters. These screns are
used in temperature areas above I~OO"F. Using standard
nut elements with these screws will result in loosening; of
the connection. These nuts will always be designated by a
commercial nut callout of special configuration at the
crimped
locking element.
THREADED FASTENER INSTALLATION
number
determined by adding 1/4, for the No. 4 and No. 6

screws, and 5/16, for No. 8 and No. 10, to the total material
thickness.
may be
I;ENERAL
or screws
used
thread inserts.
Bolts and screws with drilled heads may be used in

of bolts or screws without drilled heads.
place
Bolts 1/4 in, in diameter and smaller used with selflocking nuts must; be without cotter pin holes,
Unless otherwise specified on the engineering drawing,
corrosion resistant steel fasteners only shall be used
together,
Bolts and screws shall run free enough to engage the
threads of threaded parts by hand without using a
wrench.
Navy models only, aluminum alloy parts shall be

separated from cadmium-plated bolts, screws (except
flush head fasteners) and nuts (except plate nuts) by using
On
P/N LD153-0011 aluminum alloy washers,
Excessive tightening of nut will overstress the fastener,

causing distortion or stripping of the threads, while
insufficient tightening produces loose joints. Imperfect
threads shall not be jam-tightened, unless otherwise
shown
on
the drawing.
For speed nut installations, tighten screw until arch base

of nut is flat against the work surf ace and the lowest prong
is flush with the base of the nut. Speed nuts depend upon
the axial tension of the screw to be self-locking.
not be used on any threaded parts, unless
otherwise shown on the drawing.
Taps shall
Bolts, studs, and other threaded parts having holes for

safetying shall be safetied. Threaded parts having no
holesforsafetying in the head shall be used in self-locking
devices or parts identified by a ring of dots on the head
(which identifies them as parts eyuipped with self-locking
means on the thread shank) shall be used.
When
one
fastener is installed in
nut, at least
portion of
thread, preferably one full thread, shall be above the
top of the nut.

The surfaces under the nut and head of the fastener should
provide a complete seat for same and be reasonably
smooth.
and where no conflict with the
will occur, the heads of threaded
fasteners should be located up and/or forward to preclude
their loss in event of malfunction. The heads are also
understood to be on the near side unless otherwise
Wherever
practical
engineering drawing
specified
on
the drawing.
Machine screw type speed nuts shall not be used with

sheet metal screws or vice versa. The screw type and size
is usually stamped on the top side of the nut. Screw length
51-40-00
0
Page 1
Aug 17/84
NA-66-1082
SIIIIICTUKAL REPAIH MAIVIIAI,
Table I. General Fastener Information

SKETCH OF
FASTENER
MINIMUM
MAX
TEMP
MATERIAL
CALLOUT
(KSI)
REMARKS
CONVENTIONAL
THREADED
M520004
I MIGB-7838(
160 TS
01260PC (5000F) I
INTERNAL WRENCHING BOLTS
M521250
180 TS
012600C (5000F)I
12-POINT EXTERNAL WRENCHING

BOLTS
AN3, AN4, ETCI
I MIL-Bd812(
125
b(
fD
IMILB-~B39
NASI 2921(
NAS12925
I RENE 41
NASI 3228
*NIOP
H-ll
7532
01
RNIION HE*D
IHILLlrS
871"0 116000F)I
4270C (8000F)
SOLID SMEAR HEAD

SOLID SMEAR HEAD
10055~ r~18710C (16000F)I
SOLID SMEAR HEAD

SOLID SMEAR HEAD
L~
156551
4270C (8000F)
(5000F)
160
4130
IsCESI.
2~0C LSW~R
1 10055
15655
H-ll
2600C (5000F)
2600C 1500"F)
125 TI
I RENE 41
NAS1322J
~fiiD
TS\I?II
125
9555
NASI 103
TORO-SET RECESS, FILLISTER HEAD

TORO-SET ROCESS, FILLISTER HEAD
TORO-SET RECESS, FILLISTER HEAD
TORO-SET RECESS, FILLISTOR HEAD
1 A286
7533
H-ll
4130
4270C (8000F)
260 TS
160 TS1~12600C (5000F)I
7533(3
A2~6
140
TSI
16490C (12009r)l
7533J
H-ll
260
TSJ
14270
7534
75340
7534J
7535
1
I
1
1
1
1
I
1
4130
A286
H-ll
4130
1
1
1
1
160
140
260
160
TSI
1260"0
iS 1
(6490C
TSI
14270C
TS1~12600C
7535(3
A286
140
TSl
75351
H-ll
1260 TSl
14270C
(8000FI
TORO-SET RECESS, TENSION HEAD

SHORTER THREAD LENGTH
7536
75360
75361
75365
7536J
7537
4130
12600C
ISOOOF)
A286
I RENE 41
I ii-4-PH
I H-ll
1 4130
7537(3
I A2E6
TORO-SET RECESS, SMEAR HEAD

5HORTER THREAD LENGTH
75371
1
1
1140 TS:I
16490C (12000F)
75320
7532J
9555 1
9055
1 10055 1
12055 1
156551
19555
(8000F)
I500OF)I
(1200Fll
(B000F)I
15000F)I
16490C (12000Fll
C 112000F)
1B710C r16000F)
13430C
(4270C
(6500F)
18000F)
12600C
(5000FI
19055
(12000F)

TORO-SET RECESS, ALLISTLR HEAD
TORO-SET RECESS, FILLISTER HEAP

TORO-SET RECESS,TENSION HEAD

RENE
75375
117-4
7537J
41
PH
110055 1
18710C (16000F)I

I 12055)
13430C
14270C (8000FI I

(bSODFI
156551
H-ll
S265-3-44
51-40-00
P:~ae
AuR 17/84
STKUCrllRAI, KEPAIR MAKliAI,
Table 1. General Fastener Information (Contd)

SKETCH OF
FASTENER
MATERIAL
CALLOUT
MINIMUM
STRENGTH
MAX
IKSI)O
TEMP
REMARKS
CONVENTIONAL
RIVETS
MS2W70AD
MS2047000
IMS20615M
I
I
I
8J
CX
BO
MM
1
1
1
30
SS~
551
551
1930C (2000F)
1930C (2000F)
1538"C (10000F)
90 sSl
54 551
16490C (12000F)
2117-73
2024-T31
MONEL
A286
A286
I
1
I
NAS119B
2816
MS204268
MS20426AD
MS2042600
MS20427M
BC
5056
BE
NAS1199
NAS1200
NAS1097DD
CY
BF
MN
MO
MC
2117-T3
2024-T31
MONEL
A286
1
1
A286
1024-731
2814
2815
MONEL
A286
NAS1054
HS6B
HS92
HS128
I
I
1
1
NASIOSS
HJ67
HS91
HS127
I
I
I
HO
HR
CA
HP
41
49
16490C (12009
28
30 SSJ
41 SSI
49
1930C
(200aF)
(2000F)
1930C (2000F)
90
SSI
SSI
15380C
16490C
90
551
1649"C 112000F)ISHEAR
HEAD
49
SS~
1
15380C (10000F)(SHEAR
HEAD
54 55
4130
431
1
1
A286
17-4PH
95 SS I
(2600C (5000F) USE
USE
125 SSI_ 14270C (8000FI
95 SS ZCi16490C (12000F~IUSE
USE
120 55(~4270C (BOOOF)
4130
431
A286
17-4PH
95 SS I
125 551
95 SS
120
SY
(l0000F)
(1200"F)
16490C
112000
NAS528 OR HS32 COLLAR.

HS60M COLLAR.
WITH HS60M COLLAR.
WITH
WITH
WITH
HSIOM COLLAR.
USE WITH NAS528 OR HS32 COLLAR.

USE WITH HSIOM COLLAR.
6490C (12000FllU5E WITH HS60M COLLAR.
14270t (8000FI USE WITH HS60M COLLAR.
11600C (5000F)
14270C (8000F)
BLIND FASTENERS
F
~b
(MmU*Xlm
(2000FI
5056
MS20600B
MS20600AD
,,1
OC (2000F)
2117-T3
MO.n
AA
(10000F)IALSO
5380C
AVAILABLE WITH CAD PLATING
(MP).
OC (200PF)
5056
MS206018
MS20601AD
MS10601M
AC
1930C (2000F)
2117-73
(1000"FllALSO
5380C
MONEL
AVAILABLE WITH CAD PLATING
IMP).
AF
KX
MS20603AD I
PA286
)100
AH
MS20602AD
PA286()A
(2000F)
2017-T4
1930C
A286
16490C 112000F)IDUPONT
2017-74
A286
193"0
EXPLOSIVE RIVETS
(BLAST-FREE)
(2000F)
6490C
112000F~IDUPONT EXPLOSIVE RIVETS

(BLAST-FREE)
CR6624
CR6626
JN
A286
A286
JL
ML
A286
A286
AW
303
HT
17-4PH
(6490C (12000F)IHARD-STEM
CHERRY RIVETS
6490C 11200PF)ISOFT-STEM CHERRY RIVETS
P\
I
,Ir
CR6634
CR6636
6951-5-
7951-H-
~83
Bt~
6950-5-
AV
303
7950-11-
HS
174PH
SVP-
H-l 1
649"0
C
112000F)IHARD-STEM
DEUTSCH DRIVE PIN RIVETS
13430C
16500F)
14270C
(8000FL
JDEUTSCH
DRIVE PIN RIVETS
13430C
(6500F1
IDEUTSCH
DRIVE PIN RIVETS
427"0 18000F)
CHERRY RIVETS
(12000FllSOFT-STEM CHERRY RIVETS
14270C
(BOODF)
DEUTSCH DRIVE PIN RIVETS
SPS SLEEV-LOCK RIVETS
5265-3-45
51-40-00
Pa~1
0
AuR 17/X4
NA-fi6-1032
SII~II("IITRAL KEPAIK MANUAL
Iable 1. General Fastener Information

SKETCH OF
FASTENER
(Contd)
MINIMUM
STRENGTH
(KSII
MATERIAL
CODE
CALLOUT
MAX
REMARKS
TEMP
BLIND FASTENERS
SVF-
DR
P---
H-ll
14270C
(8000FI
SPS SLEEV-LOCK RIVETS
4037
1260DC
(500PF)
JO-BOLT RIVETS
649"0 (12000F)
~O-BOLI RIVETS
4286
JP
P---A
H-l 1
DK
F---
F---A
14270C
(8000F)
JO-BOLT RIVETS
930C
(2000F)
JO-BOLT RIVETS, MILLABLE HEAD
7075-T6
FA---
JR
F---J
4037
2600C
(5000F)
JO-BOLT RIVETS
AZB6
649"0
112000RI
JO-BOLT RIVETS
H-ll
4279C
(8000F)
JO-BOLT RIVETS
930C
12000F)
HUCK RIVETS (CKL)
CE
IALUMINUM I
looV
CD
(ALUMINUM
93"0
(2000F1
HUCK RIVETS (CKL)
ALUMINUM
930C
I2000FI
HUCK RIVETS, OVERSIZE
OS
FASTENER INSTALLATION CODING USED ON ASSEYBLY DRAWINGS.
NOTES
FASTENER CODING
O FASTENER BASIC CODE LETTERS

USED
ON
NAA
DRAWINGS
OI~SI--KIP
CONVENTIONAL AND BLIND RIVETS SHALL

BE INSTALLED PER NAA SPECIFICATION
ASSEMBLY
(1000 LB) PER SOUARE
SPECIFICATION LA0101-001.
ILA0101-004.
HI-SMEAR RIVETS, BOLTS, NUTS, SCREWS,

AND STUDS SHALL BE INSTALLED PER NAA
DASH NO.
BASIC CODE LETTERS (II
OTENSILE
OSINGLE SMEAR
STRENGTH
DASH NO. FOR DIA (2)

MFD HEAD NEAR SIDE 13)
5
3 REOD
3 REQD
II
FORD~1!
MFD HEAD FAR SIDE (3)
FLU~H ILIVETIHG OPIIICITIONI Y)
~(D*5H
NO. K)I LENOTn 01 ORI~ I~)
ARE OBTAINED
(2) DASH NUMBERS FOR RIVET DIAMETER, LENGTH, OR GRIP
FROM RIVET DRAWINGS.
(31 MANUFACTURED RIVET HEADS ARE UNDERSTOOD TO BE ON THE NEAR

SIDE OF THE DRAWING, UNLESS AN "F" IS SHOWN IN THE NORTHEAST
QUADRANT OF THE CODE. SHEETS ARE NUMBERED AWAY FROM THE
MANUFACTURED HEAD, SHEET ONE BEING ADJACENT TO THE HEAD.
(41 FLUSH RIVETING OPERATIONS
D--DIMPLE SHEET 1
DR-DIMPLE SHEET 1
8 2
DB--DIMPLE SHEET i, 2 a 3
D4--DIMPLE SHEET
i, 2, 3 a 4
C--COUNTERSINK SHEET 1
DC--DIMPLE SHEET i, SUBCOUNTERSINK SHEET 2
02C-0DIMPLE SHEETS 1 a 2, SUBCOUNTERSINK SHEET 3
DEC--DIMPLE SHEETS i, 2 a 3,
SUBCOUNTPRSINK SHEET 4
51-40-00
Paae4
Aua 17/84
NA-66-1032
FASTENERS TORQUE VALUES

GENERAL
A threaded fastener is used to create a clamping force on
component parts. When this clamping force is
created, there is a tensile stress set up in the body of the
fastener. This is generally referred to as initial tension
and causes elongation or stretch of the fastener. It is this
stretch which maintains the clamping force. So that each
fastener will carry its full share of the load, the clamping
forces must be equally distributed.
one or more
Since torque may be defined as a force that tends to

produce rotation, the amount of torque applied to a
threaded fastener will govern the amount of initial stretch
or clamping action of that fastener. This force (torque) can
be measured by multiplying the length of the lever arm by
the force applied at 900 to the axis of the lever. Through
the use of this law, torque wrenches were developed.
Engineers have calculated the exact amount of torque

that must be applied to threaded fasteners for each
specific size, material type, and installation method. This
information may be found in the following torque tables.
It is self-evident that over-torquing or under-torquing a
threaded fastener is a direct invitation for a structural
failure.
TORQUE VALUES
All threaded parts except as noted, shall be installed in
accordance with tables 2 thru 7, unless otherwise shown
be used except on
on the drawing. Lubrication shall not
corrosion resistant steel and H-ll steel threaded parts,
which shall be lubricated with MIL-T-5544 compounds to
prevent seizure and galling. Specific torques on the
engineering drawing are to be met dry, unless the
lubricated condition is specified in the ca;llout. Tightening
shall be accomplished by rotating the nut if possible.
Recessed head screws shall be free of burrs and roughness
at
recess
edges.
Table 6 provides quick reference for torque values of

fastener part numbers in the Sabreliner airplane. These
torque values are also listed in the other torque tables;
however, the fastener part number and tensile strength
must first be obtained.
51-40-10
Page 1
Aug 17/84
NA-66-1032
STRUCTURAL IDENT~FICATION (Continued)
Table i.
Torque Values for FIC Klincher Locknuts

TOROUE
SIZE a THHEAO
INCHES-POUNDS
10-32
24-40
FOOT-POUNDS
5/1624
130-170
(I1
11-14
3/8-24
255-340
21-28
7/1 6-20
420550
35-45
1/2-20
720-960
80-80
1080-1404
90-117
9/18-18
5/8-18
1538-2040
12&170
3/4-18
2700-2880
228-240
6480-8840
540-570
1-14
95-125P
1/4-28
NOTES
m3mra
To o8taim, values
ilefoot-pounds, diwide ilech-~oacnds by 18.

Recommend
use
of wrench graduated in ineh-po~ndsfor these
O
fasteners,
Table 2.
For proper locking action, the lock

nuts must be assembled as above.
Torque Values for Standard Bolts/Nuts 40,000-60,000 PSI and Over 90,000 PSI
BOLT
STANOARO BOLTS. STUDS. AND

SCREWS HAVING A TENSILE
STUD.
STRENGTH OF 40
SCREW
SIZE
SMEAR TYPE
HIGH STRENGTH BOLTS. STUBS. ANO

SCREWS HAVING I TENSILE STRENGTH OF
80,000 PSI
98.800 PSI ANO OVER
TENSION TYPE NUTS

ANO THREAOEO
MAEHIH~ PIRT(
SMEAR TYPE
IIUT(
IY
TENSION TYPE NUTS

ANO THBEAOED
MACHINE PARTS
0-80
5.8-
7.5
8.5- 13.0
7.5 11.5
1-64
1-72
9.0- 13.5
15.0 22.5
13.5- 20.0
15.5- 23.0
22.8- 33.0
25.0 31.5
25.5- 38.5
37.0- 55.0
42.0- 62.5
35.5- 53.0
32.8- 47.5
53.0- 79.0
39.5- 59.0
35.5- 53.5
51.5- 77.0
46.5- 69.0
59.9- 89.0
77.0-115.0
60.8- 89.5
97.5-145.5
119.0-177.5
54.8- 80.5
90.0-134.5
88.0-131.0
146.5218.5
107.0-180.0
178.5-286.5
2-56
2-64
3-48
356
440
448
1O.O- 15.0
17.0 25.5
15.0- 22.0
18.5- 25.0
21.0- 31.5
24.5- 37.0
24.0- 35.5
31.0- 48.0
38.0- 53.5
58.5- 87.5
71.5-108.5
6-32
8-40
28.8- 41.5
13.8- 19.0
22.5- 33.5
NOTES
To obtain values in inch-pounds, divide

inch-ounce values by 16.
together have sufficient area, thickness,

strength to resist breaking, warping,
approached whenever possible when it is

head side.
necessary to tig~ltelzfastenerfrom
Do not e~ceed
torque by more
plastic.
than 109/0 above high side of selected torque

range listed in Table 3, unless otherwise
on
or
other daneage.
E~ample: No attempt should be made to
reach ma~imum torque value when bolting
through very thin sections ofglass, metal, or
O Higlsside ofseleeted torpuerangeskould~e
shown
or
drawing.
sixefastenershavingan
ultimate tensile strength of40,000 to 64000
psi shall be installed to torque values given
in Table 4for 125,000 to 140,000 psifasteners with shear type nuts.
IMaximum torque values are to be used onlly

when materials and surfaces beingfastened
51-40-10
Page 2
3/88
j,,
NA-66-1032
STHII(:TURAI, KEPAIR MANlr~l,
Torque Values for Standard Bolts/Nuts 125,000-140,000 PSI
Table
ON STANOABO BOLTS, STUDS. ANO SCREWS

140,900 PSI
MAYING A TENSILE STRENGTH OF 125.000
SMEAR TYPE NUTS
BOLTS,
STUDS,
PARTS
(A13M.AN383.OR
EOUIVALENTI
OR
SCREW
MS21843 OR
EOUIVIILEHT)
IN.
8-38
7-9
10-24
10-32
12-15
I
1/4-28
7/18-14
FT--LBS
LBS
12-15
20-25
25-30
40"
30-48
50-70
80-90
49-55
IN
LBS
FT
LBS
&32
5/re-is
[8N31O,AN355.
8836794,84312918.
SIZE
1/4-20
(i)O
TENSION-TYPE NUTS
THREAOEO MACHINE
11O
110
II
20-21
160-1
160-1
140-155
235-255
240-290
20-24
290-418
24-34
-42
13
1
1/2-20
9/16-12
1
9/18-18
5/8-11
1
5/8-18
3/4-10
3/4-18
7/a-a
1
7/8-14
1"-B
1
1"-14
I-l/R-B
1
1-1/8-12
1-1/4-8
1
1-1/4-12
488-890
40-59
42-58
87-83
300-420
25-35
500-700
480-840
40-50
800-1.000
420-540
3545
708-988
58-75
880-780
55-85
1.100-1.300
92-108
700-950
58-79
1.150-1.800
96-133
1,300-1,500
108-125
2.300-2.500
192-208
1,300-1,800
108-150
2.200-3.000
1,500-1,890
125-150
2.500-3.000
208-250
2.200-3,000
183-250
3.700-5.000
308-416
2.200-3300
183-275
3.700-5,500
308-460
3,300-4,800
275-333
5.500-6,500
480-540
3,000-4,MO
250-350
5,000-7,900
416580
4,000-5.000
333418
8.500-8,000
540-670
5,400-6,680
450550
9.MIG-11.000
750-920
183-250
NOTES
WHEN NUTS ARE TO BE SECURED TO FASTENER WITH
hi
COTTER PINS OR SAFETYWIRE, TIGHTEN NUT TO LOW

SIDE OF SELECTED TORQUE RANGE, UNLESS OTHERWISE SHOWN ON DRAWING, AND IF NECESSARY
CONTINUE TIGHTENING UNTIL NEXT SLOT ALIGNS
WITH
HOLE.
NUTS SHALL NOT BE LOOSENED TO
OBTAIN ALIGNMENT.
ta
WHEN NECESSARY TO TIGHTEN FASTENER FROM

HEAD SIDE. HIGH SIDE OF SELECTED TOROUE RANGE
SHOULD BE APPROACHED WHENEVER POSSIBLE, BUT
IN NO CASE SHALL MAXIMUM TORQUE EXCEED 10%
ABOVE HIGH SIDE OF SELECTED TORQUE RANGE

LISTED IN TABLE 3, UNLESS OTHERWISE SHOWN ON
DRAWING.
FOR HEAT TREATED CORROSION RESISTANT STEEL

NUTS, TORQUE VALUES SHOWN FOR "TENSION-TYPE"
NUTS SHALL BE USED AND FOR NON-HEAT TREATED
CORROSION RESISTANT STEEL NUTS, TORQUE

VALUES FOR SMEAR TYPE NUTS SHALL BE USED.
USE OF SMEAR TYPE NUTS REQUIRES USE OF TORQUE

VALUES GIVEN FOR SMEAR TYPE NUTS.
TO OBTAIN VALUES IN FOOT-POUNDS. DIVIDE INCHPOUND VALUES BY 12
131
RECOMMEND USE OF WRENCH GRADUATED IN INCHPOUNDS FOR THESE FASTENERS.
51-40-10
0
Page 3
Aug 17/84
NA-66-1032
STK~CTURAL REPAIR MANUAL
Tahle 4.
Torque Values for Bolts/Nuts 140,000
160,000 PSI and Over 160,000 PSI

ON HIGH STRENGTH BOLTS. STUDS, AND
SCREWS HAVING A STRENGTH OF 180,000
ON BOLTS, STUDS, ANO SCREWS

HAVING A TENSILE STRENGTH OF
seas.
14c.walao.mopJI
AWI NUT.
sTuos.
SCREW
P81 m0 DYIR
INY NUT. EXCEPT SHELA-TYPE
SHEAR
OR
EXCEPT
(NAS1291, MS21042 OR
FNO26, Heel ETc., UNLESS OTHERWISE

SPECIFIED ON THE DRAWING
EOUIVALENT)
SIZE
IN.
FT
LBS
8-32
8-36
14-17
10-24
1032
23-30
IN
LBS
25-35
56-68
1/4-28
5/16-24
120-172
140-203
173217
185-248
85-117
3/8-16
90-144
PP
190-351
175-271
3/8-24
70-60
W)-80
5/16-18
FT--LBS
LRS
15-18
45-59
1/4-20
(NAS1291, MS218421
ICOMMERCIAL NUTS, E.G., 42 FW, FN2O.
245-342
20-29
259-423
2136
475-628
40-52
500-158
42-63
440-636
37-53
480-792
40-86
585-810
49-70
890-990
5863
800-845
50-70
700-980
58-63
9/16-18
900-1.220
75-102
1.0001.440
831M
800-1.125
67-94
900-1.350
75-112
5/8-18
1.200-1,730
100-144
1.300-2.1 WI
108-180
1,380-1.925
115-160
1.800-2,250
133-168
3/4-16
2,400-3,500
200202
2,500-4,500
M&375
2.800-3,570
218-298
3.0004.140
250-345
2.750-4.850
229-388
3,000-8,300
250-525
4,350-5,920
362-495
5.0008.840
7/16-14
7/1620
1/2-13
1/2-20
9/16-12
5/8-11
3/4-10
7/89
7/8-14
1"-8
I-l/s-a
1-1/8-12
1-1/4-8
1-1/4-12
4.600-7,250
1"-14
386g05
s,soo-s,ooO
418-570
480-750
6,000-8.850
500720
5,500-10,810
540-900
8.000-10,250
500855
7.000-13.500
580-1.120
8,000-14.000
BgSI,1WI
7.250-11.MIG
805-818
10.000-16,750
833-1 ,395
11
NOTES
WHEN NUTS ARE TO BE SECURED TO FASTENER WITH

COTTER PINS OR SAFETYWIRE, TIGHTEN NUT TO LOW
SIDE OF SELECTED TORQUE RANGE, UNLESS OTHERWISE
SHOWN ON DRAWING. AND IF NECESSARY CONTINUE
TIGHTENING UNTIL NEXT SLOT ALIGNS WITH HOLE. NUTS
SHALL NOT BE LOOSENED TO OBTAIN ALIGNMENT.
WHEN NECESSARY TO TIGHTEN FASTENER FROM HEAD
HI-LOK SERIES SMEAR PINS HL18, HL19, HL30, AND HL31

WHEN USED WITH MS21042, MS21043, OR EQUIVALENT
NUTS SHALL BE TIGHTENED TO TORQUE VALUE SHOWN
IN TABLE 4 FOR BOLTS OF 140,000 TO 160,000 PSI TENSILE
STRENGTH.
SIDE. HIGH SIDE OF SELECTED TORQUE RANGE SHOULD

BE APPROACHED WHENEVER POSSIBLE, BUT IN NO CASE
SHALL MAX TORQUE EXCEEDTENPERCENTABOV
SIDE OF SELECTED TORQUE RANGE LISTED IN TABLE 3,
UNLESS OTHERWISE SHOWN ON DRAWING.
I~
USE OF SMEAR TYPE NUTS REQUIRES USE OF TORQUE

VALUES GIVEN FOR SMEAR TYPE NUTS.
TO OBTAIN VALUES IN
POUND VALUES BY 12.
FOOT-POUNDS, DIVIDE INCH-
RECOMMEND USE OF WRENCH GRADUATED IN INCHPOUNDS FOR THESE FASTENERS.
NAS1292 AND NAS1322 SERIES SMEAR PINS USED WITH

NAS1237 AND NAS1288 NUTS SHALL BE CONSIDERED IN
THIS CATEGORY AND TIGHTENED TO TORQUE ACCORDINGLY IN AREAS WHERE 8-32 AND 10-32 SIZE NUTS ARE
USED WITH NAS1292 AND NAS1322 SMEAR PINS AND ARE
INACCESSIBLE FOR TORQUE READING TOOLS, TORQUE
MAY BE SIMULATED BY MEANS OF A BENCH TEST TO GAIN
A FEEL FOR AMOUNT OF TORQUE REQUIRED AND APPLY
TH IS WITH REGULAR WRENCHES TO ACTUAL APPLICATI ON.
WHEN TIGHTENING VLTRA HIGH TENSILE BOLTS r0

VALUES GREATER THAN INDICATED IN TABLE, OR TO
SPECIAL DRAWING TORQUE CALLOUTS. CARE MUST BE
TAKEN TO USE HEAVY ENOUGH SOCKETS TO PREVENT
SOCKET BREAKAGE THAT MAY RESULT IN HEAVY
DAMAGE TO ADJACENT STRUCTURE.
7S29, 7836, 7837 REDUCED HEAD AND RECESS SERIES

SCREWS SHALL BE TIGHTENED TO TORQUE VALUES OF
NEXT LOWER THREAD SIZE THAN THAT OF SCREW PART
NUMBER CALLOUT. EXAMPLE: 7S37J6A12 SCREW REQUIRES 140-203 INCH-POUNDS TORQUE.
51-40-10
Page 4
Aug 17/84
NA-66-1032
Table 5.
Torque Values for Torque-Set Fasteners

TOROUE INCH-POUNOS
IFOR TENSION-TYPE NUT,
POLL, THO LENDTH)
MACHIIE SCREWS
SADRELINER STD
COML NO.
7834-3
7835-3
7529-10
SIZE
TORO-SET
800685 DRIVE
SCREWORIYER
ADAPTER
10-32
25-35
EX-170-10
SC-108
1/4-28
7690
EX-I 70-1 /4
50-114
5/18-24
140-203
EX-170-5/18
SC314
3/8-24
180-351
EX-170-3/8
SC-314
TS7
78287
7834-7
78357
7829-718
78397
7/16-20
500-156
EX-170-7/18
SC-314
788
78281
78348
78358
7829-818
7839-8
1/2-20
690-980
~X1701/2
HC~-3320
9/15-18
1.610-1,440
EX-I 70-9/1g
HE-3320
TS3
TS3O-3
78284
7834-4
7535-4
7529-415
78394
TS4
1828-5
75345
7535-5
7529-516
75395
TS5
7528-8
7334-6
5535-8
7829-516
7839-8
TSB
7828-9
7534-9
7S359
TSg
7529-916
7539-9
SELF-TAPPING SCREW
SC-108
EX-170-6
5-32
COML NO.
AIC114-00-2.5C1
SPECIAL PHILLIPS RECESS
PER AMERICAN SCREW CO.
919860.582208
----i
1839
7834
7835
7828
AIC114-00-2.5C1
7329
TS4
DRIVER BIT
FASTENERS
ADAPTER
NOTES
torq~Le-set data ta6lefor 1000P168h
sereurr (heated to 180,000-184000p~ Torque
values apply to all nuts ereept shear type.
This is
Higher values should he used when torpuing

heads of serew8; however, these values should
not be exceeded by more than 10%.
7SS5fa8tene7. has shorter threaded length to

weight and is used with low-profile nuts.
save
For 75~9 screaus, use torque values and drivebit size ofnezt size smallerfastemer.
AIC114-00-~.5C1 screwis used toplugsealant

injection, holes,
sles-a-sl~
51-40-1 O
Page 5
16/90
Mar
NA-66-1032
Table 6.
Torque Values for Screw Fasteners

TCROUE 8ET
TCROUE 8ET
ICAEWORIYER
TCROUE IIICHPOUIOS)
PART
NUMBEA
AWY WUT EXCEPT BHEAR TYPE
AOAPTER
PSI
7313-832
7514-632
711
WIII
7814-832
7816-8
&12
W/1
W/1
1620
H/A
W/A
7813-1032
7514-1032
7818-1032
I/A
125,000-140,000 PSI
7815-8
7515-10
7533 A3
LO 112M102-03XX
LD112-000303XX
7835 A3
LOt 121103503XX
L0112-0035-13XX
12-15
W/II
20-25
W/A
20-25
EXI 70-10
W/A
H/A
80-108
O1
80-308
7839-3
7515-416
7833 A4
L0112-0002-04XX
L0112-W0304XX
783544
LD112-003504XX
L01120036-04XX
7836-4
SC-i 14.
80-314.
EX1701/4
50-70
7833 A5
L0112-M)02-05XX
L0112-0003-05XX
7835 A5
L01120035-05XX
L0112-003805XX
100-140
EX70-5/8
or
86-514
SC114.
80-314.
or
8C514
7839-5
EX170-3/S
180-190
7839-1
180,000-180.000 PSI
NAS110CE06
7837-08
L0112-0033-01XX
L0112-0034-01XX
HAS 1100E-OB
7837-08
L0112-0033-02XX
LD112-W34-02XX
I
s
5-8
EX170-6
SC-tOB or
SC-308
1518
EX170-B
SC-1OBor
SC-308
51-40-10
Page 6
Aug 17/84
COPYRIGMT, 1984 BY SABRELINER CORPORATION
NA-66-A032
Lahle Ci,
Torque Values for Screw
PART
NUMBER
Fasteners
(Contd)
TOROUE (IICHPOUWDSI
TOROUE SET
TORPUE SET
ANY NUT EXCEPT SMEAR TYPE
SCREWORIYER
AOAPTER
lsO.WO-180.000 PSI IContd)

948110063
78 32-3
L0112-W28-01 XX
78 33-3
LD1120W6-03XX
LD112-0007-03XX
78 343
OI
1
I
25-35
I
EX170-10
SC-IOB
or
L0112-0021-01XX
L0112-0022-01 XX
WI
SC-308
CCI
I
I
I
I
I
I
80-114,
73 35-3
L0112-0039-03XX
LD112-0040-03XX
78 36-3
L0112-M115-01XX
78 373
LD112-0033103XX
L0112-W34-03XX
73 29-416
78 32-4
L0112-0028-02XX
78 33-4
L01120006-OQXX
L0112-0007-04XX
75 34-4
L31
I
I
I
1
709O
EX170-1/4
30-314,
or
SC-514
L0112-M121-02XX
L0112-0022-02XX
73 354
L0112W3g-04XX
LD112-0040-04XX
73 37-4
L0112-0033-04XX
L0112-0034-14XX
78 33-5
LD112-0006-C5XX
L0112-0007-05XX
78 34-5
SC-I 14,
80-314.
LD112-W121-03XX
LE1
SC-514
L0112-0022-03XX
73 35-5
140-203
EX 170-5/16
or
LD112-0039-05XX
LD112-0040-05XX
75 29816
7828-5
t01120016deXX
C~
180351
EX 1703/8
SC-314
140-203
EX 170-5/16
SC-314
EX 170-3/8
SC-314
EX 170-5/8
HE-3320
78 28-6
L0112-0016-03XX
73 28-10
13
O
L0112-0016-07XX
190-351
1300-2160
NOTES
TORQUE RANGE FOR 7S39 REDUCED HEAD SCREWS
SMALL BE THAT USED FOR TENSION TYPE FASTENERS
OF THE 125,000-140.000 PSI HEAT TREATMENT LEVEL.
(AEFER TO TABLE 3)
O
O
SEEALTERNATEPARTSLIST
7829, 7S36, 7837 REDUCED HEAD AND RECESSED

SERIES SCREWS SHALL BE TORQUED TO VALUES OF
NEXT LOWER THREAD SIZE THAN THAT OF SCREW
PART NUMBER CALLOUT
EXAMPLE: 7S37J6A12
SCREW REQUIRES 140-203 IN.--LBS TORQUE (REFER
TOTABLE4
XX GRIP LENGTH IN 1/16 IN.
51-40-10
0
Page 7
Aug 17/X4
NA-66-1032
numbers are also listed in table 6

and torque value.
Table i provides alternate part numbers for Itockwell

International 7S special series screws. These part
Table 7,
by size, tensile strength,
Alternate Part Numbers
PART NUMBER
ALTERNATE PART NUMBER
7814-632
NAS1100EOg
7814-832
HA31100E87
7814-1032
H1S1100E3
7832-3
L0112-0128-81XX
7832-4
LD112-W28-02XX
L0112-0008-83XX
L01120007-03XX
L0112-0002D3XX
L0112-000303XX
LD112-OM18-04XX
L8112-8002-04XX
LD112-M10704XX
LD112M103-04XX
7333-5
733345
LD112-000805XX
L01120007-05XX
L0112-9002-05XX
LB112-0003-05XX
7834-3
L01 12002101XX
LO1 i 2-0022-01 XX
78344
L0112-002102XX
L0112-0022-02XX
7834-5
L0112-0021-03XX
LD112-0022-03XX
7835-3
L0112M13903XX
L0112-0035-03XX
LD112-0I)3603XX
L0112-0039-04XX
LD112-0035-84XX
L01120040MXX
L0112~03&01XX
L0112-001M15XX
L01 i 2-OMI&OSXX
7833-3
783313
7833-4
733364
733563
7835-4
733544
10112M140-03XX
7335-5
LD112-0a39-05XX
733545
L81 12W35-05XX
7836-3
LD1120015-01XX
78371
L0112-0I)33-01XX
L0112-003401XX
7837-08
L0112-0033-02XX
L01120a7602XX
7837-3
L0112-003303XX
L0112M13603XX
7837-4
L0112-W33-04XX
LD112M13404XX
7828-5
L0112-001602XX
7128-6
L0112-0018-03XX
7828-10
L0112-0016-07XX
NOTE
lil
THE..A" INDICATES A286 STEEL. HEAT TREATMENT OF
140,000 PSI MINIMUM THE DASH INDICATES 4130

STEEL, HEAT TREATMENT OF 160.000-180,000 PSI
MINIMUM DO NOT SUBSTITUTE AN A286 STEEL SCREW
FOR A 4130 STEEL SCREW
51-40-19
Page X
Aug 17/H4
COPYRIGHT, 1984 BY SABRELINER CORPORAT~QN
NA-66-1032
RIVETS
STRUCTURAL IDENTIFICATJON
GENERAL
special types are used in the Sabreliner

airplane. Refer to the applicable table or figure for more
specific information on installation and usage, Standard
AN, MS, and NAS rivets are not included. (See figures 1
thru 13, and refer to tables 1 thru 11.)
Common and
Table i, Rivet Hole Size

HOLE SIZE
BLINO FASTENERS
FIWIL HOLE SIZE
PULL
ORIVE PIN RIVET
FASTENER
SIZE
3/32
1/8
5/32
3/18
1/4
IOEUTSCH)
HUCK
CHERRY a OLYMPIC
BL SERIES
OS OSR
SERIES
RIVET
PILOT-GRILL
FINAL
BEFORE
HOLE
OIMPLIWG
SIZE
EXPLOSIVE
STAWOARO
IDUWITJ
RIVET
OVERSIZE
RIVET
0.129011.1305
0.135-0.139
0.128-0.132
0.1370.141
0.097-0.100
(NO, 30)
(WO. 29)
11O. 301
ING. 29)
(nO. 40]
0.160-0.162
0.1720.176
8,160-0.164
0.177-0.181
(NO. 21)
IHO, 17)
(1O, 20)
1HO. 181
0.192-0.194
0.203-0.207
0.182-0.198
0.2080.210
(NO.ll)
110.6)
INO.1O1
(10.5)
CONVEWTIOIIIIL
RIVET
BLIIO
LOCK BOLT
JO-BOLT
8.897-0,100
(nO. 40)
0.184-0.186
0.199-0.202
0.258-0.281
0.256-0.281
0.280-0.285
0.271-0.276
SI
19
(61
0.280-0.263
0.31 2-0.315
3/8
0.375-0.379
0.128-0.132
INO. 301
0.172-0.176
(NO.171
0.227-0.231
(NO. II
0.2802
19/32)
0.1255-0.0.1265
B. 15650.1 575
0.191-0.193
0.259-0.262
0.31 50.318
0.3851.388
NOTES
HOLES AFTER DIMPLING MUST NOT EXCEED THE
IF HOLE SIZE EXCEEDS LIMITS GIVEN FOR STANDARD
NOMINAL DRILL SIZE BY MORE THAN 1596.
RIVET BUT IS WITHIN LIMITS GIVEN FOR OVERSIZE
RIVET, USE
THE OVERSIZE RIVET.
HOLES TO BE DIMPLED FOR EXPLOSIVE AND PULL

FASTENERS MUST BE PILOT-DRILLED USING
NOMINAL DRILL SIZE GIVEN FOR CONVENTIONAL
RIVETS, DIMPLED. AND REDRILLED TO SIZE.
51-40-20
0
Page 1
Aug 17/84
NA-66-1032
Table 2.
Conventional Rivet Identification and
RIVET
MATERIALS
HEAD MIRKINOS
-~9-
UNIVHIlI
ALLOI
2117-14
AL
AL
LARGE
HEAD
MS10416AD
SMALL
HEAD
NASIOPIAD
AL
ALLOI
1016
AL ALLOI I
MILD STEEL
1100-C
CAD-FLATED
Rhd
Doub~
o\ 96194
Pkln
Crou
Trlm(ll
Dnh
A2S6
CRES
MONEL
A Dlmple~
Rlrd
ODl.pl.
MS2047040
ALLOI
2024-14
Applications
MS1OIITODD
MS2042600
NAS1097M)
MS10470*
M5~0416*
TIT
Rl"
NASW)(M
48427
4841711
NASIIPP
NAS1100
NAS119(
FLUSH
NASIOPIR
48435
AVAILAILE SIZES
65/32019
MAXIMUM TEMPERAIURE
FOR SIIENGIH
3/19 DI
3/32, 1/3
I
~Ovr
93.3C
(200FI
93.3"2
(?OO"F)
NoLlmlt
93.30t
I?oon
3/16 Dr
5/18 DI
9/11) DI
Mx
Ylx
Yx
1490
csooF,
426.7"0
I~ooF,
619C
clloon
No Limit
5265-3-48
51-40-20
Page 2
Aug 17/84
NA-66-1032
Conventional Rivet Identification and Applications (Contd)
Table 2.
AL
ALLOY
RIVEI
MATERIALS
2117-24
AL ALLOY
TO
AL ALLOY
I PREFERRED
I
1
PRIFERRID
I
TO
CAD-PLATED STEEL
AL
ALLOY
5016
I
i
AL ALLOY
1100-F
IB)
(A)
PERMISSIBLE
IIUf
UNDESIRABLE
(DD)
(ADI
AL ALLOY
AL ALLOY
2026-24
MONEL
(MI
li:iil:i::iii:
,i,.iil:_:,---:ii::_-i:i::
PERMISSIBLE
BUT
PREFERRED
A-286
CRES
MILD STEEL
I CAD-PLATED
i: :i:i: ~:ii i i -:a: :i:i:i:i:i j.i ;i i
:):i i i : ;..:i: :. jili: : : : : : i: :i
UNDESIRABLE
AL ALLOY
PREFERRED
PERMISSIBLE
To
CRES
BUT
UNDESIRABLE
AL ALLOY
PREFERRED
iiiiiiij:iii:iiaiiiii
PERMISSIBLE
III~ UND~1:AILT
to
TITANIUM
CAD-PLATED STEEL
TO
CAD-PLATED STEEL
BUT
PERMISSIBLE
BUT
UNDESIRABLE
UNDESIRABLE
CAD-PLATED STEEL
PERMISSIBLE
TO
CRES
BUT
PERMISSIBLE
UNDESIRABLE
CAD-PLATED STEEL
PERMISSIBLE
BUT
UNDESIRABLE
10
TITANIUM
PREFERRE~
PERMISSIBLE
PREFERRED
BUT
10
UNDESIRABLE
.;~;i-ii
PERMISSIBLE
BUT
lii:fiiilkiii:: :i:,i-:iiiiiii:i
ii.~i:i-:ii:ii:-ii
UNDESIRABLE
PERMISSIBLE
BUT
PERMISSIBLE
BUT
UNDESIRABLE
UNDESIRABLE
PERMISSIBLE
PERMISSIBLE
BUT
BUT
UNDESIRABLE
UNDESIRABLE
i:iiiiiii
::i:i:li:i:i:i:(:-:iii~ii
i i irii -.i:i:i li:ii
CRES
TO
CRES
PREFERRED
PREFERRED
PREFERRED I
PERMISSIBLE
BUT
UNDESIRABLE
PREFERRED
PERMISSIBLE
BUT
UNDESIRABLE
CRES
TO
TITANIUM
i i i iji iji :i i i i li ~i :i:ifi i i
TITANIUM
tO
TITANIUM
: -.: :i -:iii iili~.i i i .

:i:
:::i::c:il:a:i:::::i:i:i
i-i"iii::ii:i -i i i:i i i i i i i i i ii iili:i:i
MAGNESIUM ALLOY
iiii-i-::li---
:i:i -i i i -i:ili i i i i i i i
PREFERRED
TO
iji:iiiiii
:i::ii:i~i::ii ::;;i.i :i i i
i:i::?:c:j,:i-:c:i:i
AL ALLOY
PREFERRED
M*OHTTIUM *lLOr
TO
MAGNESIUM ALLOY
PREFERRED
i-:iiii:i-:iiiii::iiii
i
i:~iiii-i::1:i-i-:
i
::i:i i:i:i:i:i:iii
::::j::::::
iiiii-i:iii;iiiiiliiii ii
:I:I::::: r:,iii-:::i:,i:c:I:ij:i:i
MAGNESIUM ALLOY
TO
CAD-PLATED STEEL
:i: i:i:iii;i i i ,i i i li i -i ;i i i i-
~iiiiiiiiiii
::--:"::::::::::::i:::i:-::r
i:i
_:::iii:i:
i i:i.ii:iii.i.i i; iiiiii::i.:li:i2i,
i i si8.ii~i.i ii i i iji i
PERMISSIBLE
sin
5081 MATERIAL
(PLASTIC, FABRIC,
iiiiiil~liliiii:i : : : : : i-i i ;~i .i:i-i:i:i i i:-i
iii; i i ii;:ii i :i :i:i i i i i i

iiiiiii:ii iiiiiii:i:
::i:i:::ii.:i-iii i:::::
i:l:iii:i:i:ii
iiiiii:i::iii
i:.ii-ii-i:l iiiiii-: ::ii i i i i i ";Z"i"i:""
~RERIIED
ji:ii: i ;:-i::-iii!i i i-ii:ii-i::i:

:i:li: ::::i::
i-::i:iiliiii
ETC,
":ii:iiiiiii:
iiiiiiii iii:iiki~iiii
5265-3-49
NOTES
SHADED AREAS INDICATE COMBINATIONS THAT ARE
NOT
PERMISSIBLE
BECAUSE
OF
ELECTROLYTIC ACTION OR BECAUSE OF SOME

MECHANICAL LIMITATION SUCH AS RELATIVE MATER-
WELDING, WHERE EXTRA SOFTNESS
MAY BE USED FOR
MAY BE USED, BUT MUST NOT BE USED TO REPLACE A
INTERMATERIAL
IS REOUIRED, OR FOR PLUGGING HOLES.
HIGHER STRENGTH RIVET.
IAL HARDNESSES
A286 RIVETS ARE MORE DIFFICULT TO DRIVE AND
SHOULD BE USED ONLY IN PREFERENCE TO MONEL

WHEN HIGHER SMEAR STRENGTH IS A NECESSITY.
PREFERRED
FOR
ELECTROLYTIC
REASONS.
BUT MUST NOT BE USED TO REPLACE MONEL OR CRES

RIVETS.
51-40-20
0
Page 3
Aug 17/84
NA-66-1032
(Continued)
The rivet is identified by separate part numbers

consisting of one number for the pin and another number
for the collar. (See table 4.)
HIGH SMEAR RIVETS

The Hi-Shear rivet is a permanent fastener used to resist
shear load. The rivet consists of two pieces, a headed pin
having an annular grooved shank, and a tubular collar.
Since the pin does not swell during assembly, continuous

support is not needed. Thus, hollow sections that are
sufficiently rigid to withstand the axial pressure of the
collar upsetting operation may be successfully riveted.
Figure 1 shows the Hi-Shear rivet assembly before and

after driving. When assembled, the pin retains its original
shape and the collar is swaged to the shape of the groove in
the pin and to the shape of the conical rivet set, with the
excess portion of the collar trimmed and ejected
automatically.
BEFORE ORIVIWG
AFTER DRIVING
oRIPlm~xl
F-l
=Lr~
0.OB
O
B
~1
SWAGEO COLLAR
tSCOLLAR
F-J
COLLAR.TRIMMEOPORTION
NOTE
I~
GRIP VARIATION FOR ANY ONE LENGTH OF RIVET.
51-40-20
Page 4
Aug 17/84
Hi-Shear Rivet
erugiFylbmsA
NA-66-1032
STRUCT~rHAL KEPAIR
Table 8. Hi-Shear Rivet, Head and Collar Dimensions
SHANK OIAMETER
OFSCRIPTION
1"
3/16
1/4
5/16
3/8
7/16
0.31
0.41
aw
o.w,
O.Ml 1 0.71
BI 0.08
0.07
0.OB
0.09
0.10
0.12
0.23
(L2~
0.34
0.41
0.47
0.63
010.12
0.18
0.20
0.25
0.90
534
1/2
FLAT HEAR
100"
~r)r
1O0"FLUSH HEAR
80"
A
r~
C
7-T
MAX
GRIP
IT
O SPHEA R
MIN
OR1P
COLLAR
51-40-20
0
Page 5
Aug 17/84
NR-66-1 032
DRIVE PIN RIVETS

Drive pin rivets are a mechanically expanding blind rivet
consisting of a pre-assembled pin and sleeve. The pin is
driven into the sleeve, thereby expanding the sleeve to
form a blind pin. An integral locking ring in the manufactured head is simultaneously peened over to lock the
pin in the sleeve as shown in figure 2.
Deutsch Drive Pin Rivets
See figures 3 and 4.
FLUSH HEAD
INSTALLEO
INSERTEO
BRAZIEA HEAD
IISEHTED
51-40-20
Page
Aug 17/84
IWSTALLED
Drive Pin
erugiFtvR
NA-66-1032
NOTE
TOTAL THICKNESS OF MATERIAL BEING
JOINED
SHOULD BE MEASURED TO DETERMINE CORRECT

LENGTH RIVET TO USE. IF MEASUREMENT snows A
LOCKING
LIP
PIN
BORDERLINE CASE BETWEEN
TWO
DIFFERENT
LENGTHS, ALWAYS USE SHORTER LENGTH RIVET.
SLEEVE
DIMPLING TOOLS FOR HI-SMEAR RIVETS MAY BE USED
LAST MEMBER
Select
pioperlengln nvel (relern, not
FOR DEUTSCH BLIND
IAEF)~
R~IVETS.
eO) and place in
hole.
MIN THICKNESS
OF LAST
FASTENER
52E-NCH
)I II-
MEMBERO I
3/16
O,1?1
1/4
0.10
1/16
0,250
II
U.e
II
ORIFT
hollov drift that wll chess
drive Deutsch drive
hammering
on
loc~ing lip
blind rivets into
pin
do not
tight holes by
pin.
MIN ONE
RIVET
OIA
Rivets may be driven with air gun or hammer
NOTE
WHEN RIVET IS.INSTALLED IN A BURIED HOLE. AT
After pin has been seated in recess, smooth out the

locking lip with a rotary or rolling action of the driving tool. If
shaving is necessary for flushness, make certain that
locking lip is not cut awaytoextenthatlockisdamagedor
destroyed.
LEAST ONE TIMES RIVET DIAMETER (INCLUDING

LOCKING
RINGS) MUST EXTEND INTO HOLE.
1
LENGTH
NOTE
CODING FOR SELECTION OF PROPER FASTENERS
6950 DESIGNATES FLUSH HEAD
Ciaessa
8861
6951 DESIGNATES PROTRUDING BRAZIER HEAD.
LENGTH ANO GRIP RANGE CHART
FIRST LETTER INDICATES SLEEVE MATERIAL,

LENGTH
S-STEEL
FlffST DASH NUMBER INDICATES RIVET DIAMETER IN
DASH
NOMINAL
NO,
GRIP
GRIP RANGE
3/16 1
DIA
1/32 NDS.
SECOND DASH NUMBER INDICATES NOMINAL GRIP IN
0.166--0.117
3/16
-3
1/161hs.
I
-6
6950-S-06-10 FLUSH nEAD--CRES--3/16 DIA--5/8 NOMINAL GRIP
FINAL HOLE SIZES
3/8
DIAMETER
REAM
0 191-0.193
0315
0295
0329
0.190-0.153
10.3571031910391
0.353-0.415
0.420
O 437
0 453
O 468
-7
7/16
0.41 5-0.471)
0.482
0.500
0.516
0530
-1
1/2
0478-0.540
0.545
0.561
0.578
0 593
0.607
1 0.61~1
0141
0656
0.670
0.687
D 703
0.718
-P
9/16
0.540-0.603
0.603-0.665
1 0.766j01780
-11
.1?
3/4
0.718-0.796
0. 795
0.817
0811)
0843
-13
13/16
0790-0.853
O 857
0877
0891
O 905
0,159-0,161
.14
7/1
0.853-0.915
0920
0940
0953
0968
0.316
0.311-0.511
-15
15/16
0.915-0.976
0981
1.000
1016
1030
0.316
0.3)5-0.3)(
-16
0.978-1.040
11045
1Dll
1.078
1093
0.1915
1/4
1
1
1
0.160
3/6
3/E
D1A
3/16
5/16
DIA
-10
RIVET SIZE
5/16
DIA
0.133
0.117-0.190
EXAMPLE:
1/4
11/16
0.665-0.711
0731
0749
s285-3-56
Deutsch Drive Pin Rivets

Figure 3
Installation
51-40-20
Page 7
Aug 17/84
NA-66-1032
STKICTUKAL REPAIH MANUAI,
NOTE
e$-
DIMENSIONS ARE IN INCHES.
GRILL A
SLEEVE
PIN
GRILL A
1_
NOMINAL
169501FLUSH-HEAO RIVET
DRILL
RI;ET
PIN HE*O oFF.
---1
-06
_r
3/16
oc
-010
TI/Tr
or?
E-l]IZ
-16
A PILOTEO GRILL
DRILL
SIZE
A
DEUTSCH RIVET
DASH NO.
PUNCHO
SLEEVE. USING DRILL SIIE
DRILL
OAILL 10
NOMINAL GRIP DEPTH ONLY.
USING DRILL SIZE A.
13/16)
NO. 21
(1/4)
NO. 1
NO.
(3/)1
0.1115
5/31
0.1621
7/32
1/4
5(0.3450)
0.1411
11/32
(0.46)7)
0.3135
15/32
(1/11
PUNCH
SIZE
0.1975
9/31
15/16)
(0.1590)
(0.1110)
PIN
SIZE
C
(0.9~11)
DRIVE REMAINDER OF
SLEEEVE THROUGH.
mAv BE USEO.
PROCEDURE FOR REMOVAL WHERE RIVET DOES NOT EXTEND THROUGH MATERIAL
orill out rival
pin
about hali the
dept h
Its
ng
Ol
recom-
Tap
i eeve,
Insert Pillsn-hesd
sleeve, and tighten
mended drill size,
uning
recammenried tap li2s
B1
COntinYB
screw
Ihrough
spacer into
tapped
nut.
tighteninp
nut
until rivet sleeve is removed
from work.
Or II out remainder of
pin
Hole is rs-ussble wilh
RIVET
DIA
1O0,O00, 180,M10-PSI
HEAT-TREATEEO SCREW
(INCHES)
NUT
RIVET PIN
SPACER JACK
RIVET
same
I\S SHOWN, OR
BUILT UP WITH
WISHERS.ETC.
si~B rivet.
SCREW AND
DRILL
SIZE
3/16
19
1/4
19
5/16
TAP SIZE
10-32
1
1/4-18
5/1614
3/6
7/16
3/6-24
1/2
15/64
7/16-10
RIVET
NOTES
USE MINIMUM OF 1-1/2 TIMES SCREW DIAMETER
THREAD ENGAGEMENT IN RIVET SLEEVE.
IF RIVET SLEEVE ROTATES DURING TAPPING OPERA-
TION, USE SLIGHTLY LARGER DRILL FOR

PROVIDING LESS CUTTING EFFORT OF TAP.
STEPO,
5265-3-57
Deutseh Drive Pin Rivet
51-40-20
Pagc~8
Aug 17/84
Figure
Removal
NA-66-1032
Table 4, Hi-Sheer Rivet Selection

PARTNUMBER
TYPE
PIN
COLLAR
USING
DIVISION
NASIOS4
NASS28
MATERIAL
FINISII
(OLLAK
PIN
I SIZEKANCE
1/8
TO
3/8
95 KSI
2500F
95 KSI
8000F
7S KSI
1 MOlcFI. UYED
8000F
1~5 KSI
MONEL I)Yt;l)
800"F
95 KSI
12000F
95 I;SI
2500F
95 KSI
2500F
95 KSI
2500F
95 KSI
8000F
1 ~5 KSI
TJ
STEEL
ALALLOY
(ADPL
ANOI)I%1~
?024
r4
NAS1806
I
I
44Ti
THRU
6-4Ti
ALALLOY
NAS1816
NONE
ANODIZE
NAS528
HS60M
HS60M
HS68
302
3~1 (RES
(KES
PASS
PASS
MONEL I)YED
I/B TO 3/8
HS60
HE 1?1-0007
3/16TO 1/2
431
3/16 TO 3/8
ISTRENGTH
2500F 1
~0?4
1 ALLOY
3/16 ~r0 3/8
SHF.AR
TEMP
(DIA)
H,L,S
APPLI(ATION
MAX
(KES
HE121-0008
COLLAR
HS92
HS60M
1/810 3/8
5/3?
PASS
?80
(RES
PROTRUDING HEAD
HI
HEI?I
SMEAR RIVET
00?6
HS92
I
I
tiS90
HE1?1-0026 I
NASS29
NAS528
1/8
TO
PASS
3/8
5/3?
A-?8h
(KES
(KES
PASS
1/8TO3/8
PASS
7/16 TO 5/8
ALLOY
STEEL
!073
NASS?8
I/S TO 3/8
H,L,S
ANODIZE
NAS5?8
THRU
PIN
NAS1916
HS67
HS60M
3/16 TO 1/2
ALALLOY
(AL)PL.
ANO[)IZE
4 Ti
T4
STEEL
20?4
T4
6- 4 Ti
ALALLOY
NONE
ANODIZE
3/16 TO 3/8
?0?4
ALLOY
3/16 TO 3/8
NAS1906
T4
ALALLOY
<AD FL.
NASIOS5
~X6
431
1 MONEL UYEU
CRES
HEI?I -00?3
1
HS60M
HS9 I
COLLAR
HEI?I -0025
P,\SS
1/8 TO 5/8
1
5/3?
I/B TO 3/8
5/3?
?8h
I MONEL I)YEU I 8000F 1
95 liSI
I 1200"F 1
95 Ksl
95 ~SI
(KES
PASS
1000 FLUSH IIEAD

HI
SI1EAR RIVET
HS91
IIEI?I
HS90
NASSZS
1/8
00?5
NAS5?8
TO
(KES
(KES
PASS
3/8
7/16 70 5/8
~sh
1 ALLOY
xc,
0~4
~4
STEEL
ALAI.LOY
(AnPL
ANOI)IZE
2500F
51-40-20
o
Page 9
Aup 17/84
NA-66-1032
STRICTURAL REPAIR MANUAL
HI,IND PITI,L, RIVETS
spindle type provides for flush break-off and positive

retention of the stem by means of a locking ring in the
head. (See table 5.)
Blind pull rivets are the most commonly used type of blind
fastener. The rivet is expanded mechanically by pulling
the stem in to the final position. The locked
Table Fj.
(Continued)
Pull Rivet Selection

RASI(
"~Ar,
TYPI
PART
STYCli
NIIMBER
PHOTRIIUIN(;
MSZOliO1
I
I
MATERIAL
ANI)
~:!N!SH.
SO.ShAI.ALY
?117
H~AL)
~olm
I MAX
ISERVI(.EI
I~TEMP F
1
CHAK~(:1EKISTICS
?50
T4 Al. ALY
250
MONII. (~Al) FL,
400
MONELtBAR~)
800
,ilh
I[llrnl h~,le Ii Iliny ch;trartcristi~;. I istl~l
for nl,nslrllclllral
1,1
sllrh
Rell-l,luyying Ly~xl is
rrrlllirc~l. Sul?icr(
hy,lllicxti~lns
as
nam~l,l;lte attachment wl,~.t.tl hi~h shtal
to usayu
n~lt
limilati~,ns
iml,l,sed hy usinll I)i~isiun Rntl;la

100 UE(;
MS21)60h
MS2060()
ill
FLUSH
lIEAL)
PULL-THRU
PROTRUDING;
?50
Structural.
74 AL. ALY
?50
Stem
MONEL tCAD FL)
400
ing ability
MONFL(BAREI
ROO
sheets is mediocre. Not to be
5056 AL ALY
?117
H[:AD
Sell--plugg~ng.
must he
trimmed.
even
Clamp
with thin
used where tluid
tight joints
required. Subject to
usage limirationa outlined
are
100 DEC
in MS335??.
MS20601
FLUSH
HEAD
SELF-PLUGGING
NAS1398
PROTRUDING,
HEAD
5056 AL ALY
1
1 2017-T4 AL ALY
250
Structural. Loclred
250
Automatic stem brrll~- off.
MONEL (CAD FL)
400
Good
MONEL(SIL FL)
800
~-286 CRES
1?00
Used to provide increased

joint reliability under
clamp
critical
LGCKlNG
coLun
IOODEG
such
as
Ipindle.
up and hole-fill.
loading conditions
fatigue and sonic
vibration.
NAS1399
FLUSH
HEAD
LOCKED SPINDLE
PK()TRUDIN(:
HEAD
INASII:(X
5056ALALY
?50
9me
MONFL ((Al) FL)
400
used for veru thin sheet and double
MONI:L(BAKFI
800
applications due
as
NAS1888 and NA91999 except also
to
dimple
large head formed on
blind aide of joint.
100 I)E(;
NAS113Y
FI.USH
LO(KI~D SPINI)I.E BULBED
51-40-20
Pane 10
Aun 17/84
NA-66-1032
CHERRYMAX AND BULBED CHERRYLOCK

RIVETS
Cherrymax and Bulbed Cherrylock rivets
are the most

blind fastener used on the Sabreliner airplane.
Sec the applicable table and figure for additional
information.
common
CR-762 RIVET
The Cherry CR-762 rivet is a wide-grip range, positivehole-fill, high-clinch type blind fastener. The rivets may
be installed with standard Cherry hand-powered or
pneumatic guns. Modified controlled-stroke pulling
heads for H80 series and H90 series are used. They are
provided with replaceable spacer sleeves for positively
controlling the length of pull. When the rivet is set, the
shank is expanded against the face of the back material.
This results in a drawing action and clinches the two
materials together. The pull is stopped at a predetermined point without breaking the stem. When the
rivet is set, the stem protrudes 1/16 in. above the rivet
head and gives a visual indication that the upset is
properly formed, the hole is filled, and the rivet is
properly set. The stems of installed rivets are trimmed
with standard trimming equipment. (See table 11.)
CCR-264 RIVET
See figure 13.
51-40-20
0
Page 11
Aug 17/84
NA-6fi-1032
STRCT(TURAL HEPAIK MANUAL
CR2252 Nomin~l
5056F Rivet L 157 CRES Stem
CR3553P Ovenise
CR3552P Ovenire
15-7 CRES Stem
Monel Rivet Cad Plated
Cherrymax Rivets
Figure 5
51-40-20
Page 12
Aug 17/84
NA-66-1032
FLUSH FRACTURE
LOCKED SPINDLE
INCONEL 600
MONEL
BULBED CHERRYLOCK~
BULBED CUEBBYLOCK"
C82838
C82839
C82538 (NAS 173985)
lncone1600 Rivet 8 A286 Stem

CR2838CW
Inconel 600 Rivet Cad Plated
C82539
(NAS 173885)
Monel Rivet 6 Inconel 600 Stem
calajpcw
C~n538P(NAS 1739MW)ICR1539P (NAS 1738MW)
A286 Stem
Monel Rivet Cad Plated 8 Inconel 600 Stem
ALL(MINUM
BULBED CHERRYLOCK"
CR2238
(NAS1739E)
CR2239
(NAS1738E)
5056-F Rivet and Inconel 600 Stem
Cherrylock Rivets
0
51-40-20
Page 13
Aug 17/84
NA-66-1032
FLUSH FRACTURE
LOCKED SPINDLE
A286 STAINLESS STEEL
MONEL
CHERRYLOCK"
CR2562M
(NAS1399M)ICR2563M (NAS1398M)
4286 Rivet and 4286 Annealed Stem,
Monel Rivet 8 Monel Stem
CR25625(NAS1399MS)
C815635(NAS1398MS)
eR2653
C82652
Monel Rivet Silver Plated 8 Monel Stem

CR2562 (NP~S1399MW)
CR2663 (NAS1393C)
CR2662 (NAS1399C)
4286 Rivet 8 4286 Annealed Stem

CR26~2
CR~563 (NA11398MW)
CR2643
4286 Rivet and 4286 Hard Stem.
Monel Rivet Cad Plated 8 Monel Stem
ALUMINUM
CHLRRYLOCKe"
CR2163 (NAS1398D)
CR2162 (NAS139913)
2017-T4 Rivet and 7075 Stem.

C112a~Z (N*S139Pll)
C112269
(N~S1398n
5056F Rivet and 7075 Stem.
51-40-20
Page 14
Aug 17/84
Cherrylock Rivets
NA-(j6-1032
STRIICTURAL REPAIR MANUAL
CHERRY SELF-PLU661NG
MONEL RIVETS
MS20600M
MONEL
MS20600MP
MONEL, CAD PLATED
MS20601M
MONEL
MS20601MP--MONEL, CAD PLATED
CHERRY SELF-PLUGGING
ALUMINUM RIVETS
MS20600AD
^"111~
MS20601AD
MS20601BMS206008 )--~056
02
156
02
157
PILUMINVM
CR 9156
02 9157
MS206018
MS20600B
MS206018
MS20600B
CR 162
CR 163
CR 9162
CR 9163
MS20600AD
MS20601AD
MS20600A0
MS20601AD
02 562
CR 563
CR 9562
MS20601MP
MS20600MP
MS20601MP
CR 56261
02 56316
CR 9562M
02 956316
MS20601M
MS20600M
MS20601M
MS20600M
Cherry Self-Plugging Rivets

Figure 7
0
02 9563
MS20600MP
51-40-20
Page 15
Aug 17/84
NA-66-1032
STRUCTUHAL REPAIR MANUAL
NUT-PLATE RIVETS
ALUMINUM RIVETS
MILD
STEEL, CAD PLATED
A286 STAINLESS STEEL

MS20604AD
MS20605AD
.,,,,,,llM
MS20604BMS20605B
5056 ~LUMINUM
b:
CCR274SS
CCR264SS
02
116
MS20605AD
02
126
MS20605B
02
117
MS20604AD
02
127
MS20604B
02 9116
CR 9117
MS20605AD
MS20604AD
02 9126
02 9197
MS20605B
MS20604B
Mild
Steel, Cad. Plated

CCR274CS
CCR264CS
A286 Stainless Steel
YONEL RIVETS
MS20604M
-MONEL
MS20604MP -MONEL, CAD PLATED

MS20605M
-MONEL
MS20605MP -MONEL, CAD PLATED
CR 516
02 517
02 9516
CR 9517
MS20605M
MS20604M
MS20605M
MS20604M
CR 5162
MS20605MP
51-40-20
Paffe
C2 517P
MS20604MP
CR 95162
02 9517P
MS20605MP
MS20604MP
Cherry Pull-Through
erugiFsteviR
8
16
Aun 17/84
NA-66-103~
STRUCTUHAL REPAIR MANLAL
Table 6.
Cherrylock Rivets
Bulbed
UNIVERSAL
HEAD
UNISINK
Alloy Steel, Cad. Pltd.
2219 Aluminum
Inconel 600
5056 Aluminum
Inconel 600
Inconel 600
1738MW
2539P
Monel Cad. Pltd.
Inconel 600
2839
2839CW
Inconel 600
A286 CRES
CR2248
2A38
2238
Inconel
600,
Cad. Pltd.
5056 Aluminum
2219 Aluminum
A286 CRES
Alloy Steel, Cad.
5056 Aluminum
Inconel 600
Inconel 600
17391\/1
2538
Monel
Inconel 600
1739MW
2538P
Monel, Cad. Pltd.
Inconel 600
2838
2838CW
Inconel 600
A286 CRES
Inconel 600, Cad. Pltd.
A286CRES
CR2235
5056 Aluminum
Inconel 600
2245
5056 Aluminum
Alloy
2545
Monel
Inconel 600
Monel
Inconel 600
Inconel 600
A286CRES
UNTE RSU NKI
HEAD
5056 Aluminum
17381\11
1739E
HEAD
STEM MATERIAL
Monel
RIVET MATERIAL
2539
NAS1739B
Numbers
17385
(MS20426)
Cherry Rivet
CR2249
2A39
2239
NAS17388
NTERSUNKI
HEAD
CHERRY NUMBER
NAS NUMBER
HEAD STYLE
NAS Numbers to
CR2540
2840
Steel
Pltd.
Cad. Pltd.
(156")
51-40-20
0
Page 17
Aug 17/84
NA-66-1032
REPAIR MANUAL
Table 7.
Cherrylock Rivets
NAS 13988
UNIVERSAL
HEAD
CR2263
1398C
1398CW
1398D
2219 Aluminum
2653
2663
A286 CRES
A286 CRES
A286 CRES, Annld. Plug

A286 CR ES, Annld. Plug
2663CW
2163
A286 CRES, Cad. Pltd.

2017 Aluminum
A286
Monel
Monel
25638
1398MW
2563
Monel, Silver Pltd.

Monel, Cad. Pltd.
7075 Aluminum
A286
25631\/1
NAS 13995
A286 CRES
1398MS
13981\/1
(MS20426)
5056 Aluminum
2219 Aluminum
2643
COUNTERSUNKI
I
HEAD
2A63
STEM MATERIAL
RIVET MATERIAL
CHERRY NUMBER
NAS NUMBER
HEAO STYLE
CRES, STA
CRES, Annld. Plug
7075 Aluminum
Monel
Monel
1
1
CR2262
5056 Aluminum
7075 Aluminum
2A62
2219 Aluminum
2219 Aluminum
2642
A286 CRES
A286 CRES
A286 CRES
A286 CR ES, Cad. Pltd.
2017 Aluminum
A286 CRES, STA

2652
13996
2662
1399CW
2662CW
1399[3
2162
1399M
2562M
1399MS 1
1399MW 1
2562S
2562
NTERSUNKI
HEAD
CR2164
2A64
(NAS1097)
2664

7075 Aluminum
Monel
Monel
Monel, Silver Pltd.

Monel, Cad. Pltd.
Monel
2017 Aluminum
2219 Aluminum
7075 Aluminum
A286 CRES
A286 CR ES, Annld.
Monel
2219 Aluminum
Plug
NOTE
95KSI
FASTENER
FOR
USE IN HIGH BEARING
STRENGTH MATERIAL. STEEL, CRES. Ti, ETC
51-40-20
Page 18
Aug 17/84
NA-66-1032
CR 3242-6-4
II
MAXIMUM GRIP LENGTH IN

1GTHS OF AN IN. (-4
Numbering
System
4/16)
SHANK DIAMETER IN 32NDS OF AN iN. (-6
3/16)
000 NUMBER;PROTRUOING
nE~DSTYLE
EVEN NUMBER :COUNTERSINK
MATERIAL COMBINATION
RIVET TYPE
(SEE FIGURE 5)
CHERRYMAX RIVET
GRIP RANGE OF ALL CHERRYMAX RIVETS ARE IN INCREMENTS OF 1/16TH IN., WITH
Grip
Length
HAS GRIP RANGE OF 3/16 IN. TO 1/4
MAX.
GRIP
GRIP
I_J
-4 GRIP RIVET
(EXAMPLE:
IN.)
REFER TO T~BLE BELoW
_L
-f
ULTIMATE DASH NUMBER INDICATING MAX GRIP IN 1/1GTHS.
~1
r--1
_L
3/16 IN.
1/4 IN.
MIN.
GRIP
TO DETERMINE PROPER GRIP RIVET TO USE, MEASURE MATERIAL THICKNESS
MATERIAL THICKNESS
WITH A 269C3 CHERRY SELECTOR GAUGE AS SHOWN BELOW. ALWAYS READ
RANGE
TO NEXT HIGHER NUMBER.
MINIMUM
See Stds.
See Stds.
1/8
3/16
READREAD
1/4
5/16
3/8
RIVET GRIP
7/16
NUMBER TO
Pages
Pages
RIVET
(IN.)
GRIP
NO.
MAXIMUM
1/16
1/8
3/16
1/4
5/16
3/8
7/16
1/2
3
5
6
8
9/16
5/8
10
TO FIND RIVET GRIP NUMBER, DETERMINE TOTAL THICKNESS OF MATERIAL
1/2
9/16
5/8
11/16
11
TO BE FASTENED; LOCATE BETWEEN MINIMUM AND MAXIMUM COLUMNS ON
11/16
3/4
12
BE USED: -4
MATERIAL THICKNESS CHART. READ DIRECTLY ACROSS TO RIGHT TO FIND
GRIP NUMBER.
FOR
DOUBLE
DIMPLED SHEETS, ADD
CTSK.
HEAD
HEIGHT TO MATERIAL THICKNESS.
Cherry Rivet Number System
Figure 9
0
51-40-20
Page 19
Aug 17/84
N h-fi6-1032
STK~CT1IKAL HEPAIH MANIIAL
Recommended Drill Sizes and Hole Size Limits
Table 8.
RIVET SHAHK
OIAMLTER
CHERRI RIVET
(IWi)
NUMBPR
DIAMETER DASH
IHSRECTION LMIIITS
Rt(OMMENbEb
FINISH
MINIMUM
(II.I
MAxlMuM (IN.)
3,32
-3
lt40
0.097
0.101
1/8
-4
ft30
0.129
0.1 52
5/32
-5
#20
0.160
a.~64
3/16
-6
#10
0.192
0.196
7/32
-7
#2
0.220
0.225
1/4
-8
flF
0.256
0.261
9/32
-9
#L
0.21)9
0.295
-4
#29
0.137
0.111
1/8
overtire
5/31
ovcr1iic
-5
#16
0.177
0.111
3/16
ovar1i1e
-6
tS
0.206
0.210
Moncl
-P
#84
0.294
0.300
9/31
Table 10.
Material Thickness Chart
Table 9.
RIVET GRIP NO.
MATERIAL THICKIESS RANGE

MINIMUM
MAXIMUM
IIN.)
SLL
STLNDIROS
PICES
SEr
STINOIROS
PACIS
SERRATED
KNOR
STEM
IIN.I
1/16
RivetHeatHeight
RIVET
HEAR
SIZE
HEIGHT
3/32
0.038
1/8
0.042
5/32
0:055
3/16
0.070
7/32
0.082
1/4
0.095
9/32
0.100
STEM
1/8
3/16
3/16
1/4
1/4
5/16
10
5/16
3/1
12
3/8
7/16
14
7/16
1/2
16
1/2
9/16
18
9/16
5/5
20
10
5/8
11/16
22
11
11/16
3/4
24
12
3/4
13/16
26
13
13/16
7/1
28
14
7/8
15/16
30
IS
15/16
32
16
NOTES
01
DRILL
SIZES NOTED ARE THOSE THAT NORMALLY
DRILLING
ALL CHERRY RIVETS MAY BE USED IN MATERIAL 1/64
IN. THICKER THAN SHOWN IN MAXIMUM COLUMN AND
PROVIDE HOLES WITHIN LIMITS LISTED WHEN PRE-
THUS COMPLY WITH GRIP REQUIREMENTS.
IS NOT USED. WHEN A CHECK REVEALS
UNDERSIZE OR OVERSIZE HOELS ARE RESULTING.

DRILL SIZE SHOULD BE ADJUSTED ACCORDINGLY.
FOR
DOUBLE DIMPLED SHEETS, ADD RIVET HEAD
HEIGHT TO MATERIAL THICKNESS. SEE TABLE 11

TO
FIND
RIVET GRIP NUMBER.
DETERMINE TOTAL
THICKNESS OF MATERIAL TO BE FASTENED; LOCATE

BETWEEN
MINIMUM
AND
MAXIMUM
DIMENSIONS ARE IN INCHES.
COLUMNS ON
MATERIAL THICKNESS CHART THEN READ DIRECTLY

ACROSS TO RIGHT TO FIND GRIP NUMBER.
51-40-20
PaRe 20
AuR 17/84
NA-Ci6-1032
SIRU(:TITKAI, REPAIK MANI~AI,
FULLY SERRATEO
STEM
Cherry MAX consists of four components

assembled as a single unit:
1
fully serrated fastener stem with

ring and plug section.
locking
collar tllat
provides
IPULL GAoOVESI
break notch, sheer
IIff
mechanical lock to
DAIVING ANVIL
stent
BREAKNOTCH
3
The fastener sleeve with
The
receive
locking collar dimple
to
II~
locking collar.
CherryMAX driving anvil,
stem breaks and
LOCKING COLLAR
which insures flush
LOCKING COLLAR
flush installed collar at all times.
GROOVE
II
it
FASTENER SLEEVE
II
II
SMEAR RING
GRIP RANGE
CONE
STEM STOP
HOW THEY WORK
O
I
Stem is
pulled
into rivet sleeve and starts to
large bulbed blind head: seats manufactured head: clamps sheets tightly together
and hole filling action begins.
lorm
BEFORE PULLING BEGINS
Engage pulling serrations of stem with laws of

pulling head.
Pressure of driving anvil forms locking collsr

Into collar recess, locking stem and sleeve
together.
Formation of blind held and hole fililng

are
completed.
Continued pulling fractures stem, providing

lush, burr-lree inslallltlon.
Shear ring shears from cone to allow stem

to pull further Into rivet sleeve.
INSTALLATION COMPLETE
Cherrymax Rivets
Figure
0
How
10
They Work
51-40-20
Page 21
Aug 17/84
NA-66-1032
SrflUc~rURAL HEPAIK MANUAL
PO
BEFORE
PULLING
BEGINS
Stem is
pulled into rlvalsleeve and
iris to form bulbed blind head
Sheet gap
Clamp-up
and hole IIII action
begin
O
Clamp-up completed
Formation or blind head and hole

as
stem con-
tilling
linues to bulb out blind head
are
completed
ShearrlngnowbagQtoshearfrom
stem cone to allow stem to
pull
further into rivet

Rivet head
lirmly sealed
Sheer
minimum
ring guaranlaas blind side

grip sppll
bulbed held in minimum
Blind side bulb head is tmed below
cation.
grip.
(In minimum grip

sheer)
shear
ring
may not
Q
Shear
cone
COMPLETELY INSTALLED
BULBED CHERRYLOCK
ring has moved down stem

pulling head automstlcslly
until
slops stem break notch flush with top

ol rivet head
Locking
collar is
now
reldy
Pulling head has inserted locking

collar and stem has Ireclured fluah
with rivet head
to be
inserted
IMllXlhtllhl GRIP
ILLUSTRATEO)
Blind side bulbed head.
51-40-20
Page 2~
Aug 17/84
erugHow
iFkThey
roW
11
COPYRIGHT, 1984
NA-66-1032
PO
PQ
BEFORE
PULLING
Pulling headpullsstem
BEGINS
In and blind haad forms

agalnsl blind sheet
Blind head
sheets
clamps
together
Rivet head is
--lheetgap
firmly
seated
Blind head
09
Hole 1II Is completed
and pulling head auto-
Slam
begins
matically stops
to wire-
stem
Q
COMPLETELY INSTALLEO
CHERRYLGCK
with break-noteh flush
draw and fill hole
with rival head
in
Pulling head has
sorted locking collar

and stem has fractured
Locking colC is now

ready to be Inserted
Ilush with rival head
(MAXIMUM
GRIP
ILLUSTRATEO)
How They Work

Cherrylock Rivets
Figure 12
Table 11.
C:R-762
Cherry Rivet Gun
Pulling Heads
RIVET SIZE
PULLING HEAB NUMER
IINCHI
HSO SERIES
R804U Universal head
1/8 dia
88040 Counlersunk head

HB04U Universal head
5/32 die
88040 Countarsunk head

HBWU Universal head
3/16 dia
HB04C Countersunk head

090 SERIES
1/8 dia
89040 Universal head

R904C Countersunk head
5/32 dla

Hg04C Counlersunk head
3/16 dir

H904C Counlersunk head
7/32 dia

89040 Caunlersunk head
1/4 dia

H904C Countersunk head
9/32 dla
Hg04U Universal head

89040 Countersunk head
NOTE
REFER TO SOURCE KEY 024 IN 51-30-00 TABLE 2 FOR
MANUFACTURER.
51-40-20
0
Page 23
Aug: 17/84
NA-66-1032
STKU("rURAL REPAIR MANUAL
0.750
_L-[IMIH
0.1MAX.
0.010 R
MRX
100~
1
NOT TO EXCEEO
RIVET OIA
0.062IRE
FIOAIP0.006 1
0.036
0.092
IREFJ
0.097
0.004
GASH NO.
GRIP LIMITS
1/16 IN RANGE
c-lOls
A-pas
ORES
IIN.)
Iln.l
MAX
MAX
0.140
0.218
3-2
0.203
0.281
3-3
0.265
0.343
3-4
3-4
0.328
0.405
0.312
3-5
3-5
0.390
0.488
0.313
0.375
3.6
0.453
0.530
0.376
0.437
3-7
0.515
0.563
0.438
0.500
3-8
0.578
0.656
MlN
MAX
STEEL
0.046
0.082
3-1
0.063
0.125
3-2
0.126
0.187
3-3
0.188
0.250
0.251
NOTES
DIMENSIONSARE IN INCHES.
HEAD DIAMETERS ARE TO THEORETI-
CALSHARPCORNERSASMEASUREDBY
PROJECTION
FEDERAL SUPPLY CODE IDENT NO. 11815

SERIES NO.
RIVET
STEM
A-286 ORES
305 CRES
RIVET
Solid Film Coat

CCR 26403
CHERRY
Spec. C-48
AMS 5736
CCR264SS
C-1018 Steel
Page 24
Aun 17/X4
PASSIVATE
PO-P-35
Cadmium Plate
Rud
00-P-416
Preventive
C-1OO8 Steel
Annealed
51-40-20
STEM
Type
II
CI
Basel
CCR-264-3 Cherry Nut-Plate Rivet

Pull Thru Stem 100" Countersunk
13
erugiFdaeH
NA-66-1032
CHOBERT BLIND RIVETS

The 224/000 series of Chobert blind rivets are the only
rivets of this type used on the airplane. This type of rivet is
lower in tensile strength than the conventional AD3 rivet,
and is used exclusively for the attachment of nut plates in
specific area. Chobert blind rivets are not to be used in
integral fuel tank areas, pressure barriers, blind close-out
areas, or exterior skins. A restriction is also placed on the
use of Chobert blind rivets in areas where the
temperature is expected to exceed 260"C (500"F). Chobert
blind rivets are installed with a special Chobert blind

rivet gun containing the rivets to be installed in a special
tubular magazine. Each magazine contains from 23 to 95
rivets, depending upon the length of the rivet. Chobert
blind rivets are obtained in increments of 1/16 inch. Refer
to Source Key 026 in 51-30-00 table 2.
51-40-20
0
Page 25/26 Plank

Aug 17/84
NA-66-1032
MECHANICAL FASTENERS
HIGH SMEAR BLIND BOLTS AND BLIND NUTS
The Hi-Shear blind bolt and blind nut fastener consists of

three parts: a core bolt, a sleeve, and an expander, or nut.
A special tool is used to accomplish installation. The bolts
and other parts, with installation tools, are shown in
figure
1.
51-40-30
0
Page 1
Aug 17/84
NA-66-1032
SIKII("I~URAL REPAIR MANUAL
CORE BOLT
WORK
SLEEVE
CORE BOLT HEAD MARKING-ONE DOT, RAISED OR DEPRESSED
~O
EXPANDER
"HI-TORCIUE"
RECESS
"PHILLIPS"
RECESS
BLIND
88351
BOLT
88351
88321
CORE 8OLI
88301
DIA
FIRST
DASH
NO.
(IN.)
NO.
-5
5/32
-6
FIRST
DASH
NOMINAL
88341
SLEEVE
BOLT ASSr
FIRST
EXPANDER
FIRST
SIZE/
HEAD
SIZE/
RECESS
THREAD
-5
PHILLIPS
NO. 1
4-40NC-3A
~5
0.169
0.166
-5
4-40NC-38
3/16
-6
PHILLIPS
NO. 1
5-40NC-3A
-6
0.196
0.193
-6
5-40NC-3B
.g
1/4
-8
PHILLIPS
NO. 2
8-32NC-3A
-8
-8
8-32NC-3B
-10
5/16
-10
12-28NF-3A
-10
0.338
0.335
-10
12-28NF-3B
-12
3/8
-12
1/4-28UNF-3A
-12
0.390
0.387
-12
1/4-28UNF-38
HI-TOROUE
NO,
HI-TOROUE
NO. 4
OD
DASH
(IN.)
NO.
0.257
0.254
DASH
NO.
THREAD
WORK
81351
CODE:
BOLT ASSEMBLY
first dash number indicates nominal diameter of
blind bolt asrembly in 32nds, Second dash number
indicates assembly grip length (thiekness of work)
in 161hs.
EXAMPLE:
ASSY GRIP LENGTH--NOMINAL
GRIP LENGTH 1+1/32
-1/16 IN.)
88351-8-12
IN.,L
3/4 ~SSEMBLY OR*P LEHQTH
111132 IN, 11(8 IN.)
114 NOMINAL DIAMETER BLIND BOLT ASSEMBLY
BLIND 86LT ASSEMBLY, WHICH INCLUDES

88301 CORE BOLT, 88321 SLEEVE, AND 88341 EXPANDER
_52_65-3-52
51-40-30
Page 2
Aug 17/84

a
NA-66-1032
REMOVABLE PART
REMOVABLE PART
IREF)
WORK
RETENTION BOLT
(REF)
SLEEVE
EXPANDER
WORK
BLIND NUT INSTALLATION
881359 AND
8N359 BLIND NUT

WITH SMEAR-TYPE
8N360 BLIND NUT

WITH SHALLOW
COUNTERSUNK HEAD
COUNTERSUNK HEAD
(BN329 SLEEVE)
IBN330 SLEEVE)
881329 SLEEVE
AND
BN36D
BLIND NUT ASSr
Flasr D*SH
BN39D
FIRST
DASH
NO.
NO.
-832
-832
-1032
-1032
-424
-428
-524
-624
88341
985359 BLIND NUT ASSEMBLI
EXPANDER
SLEEVEO
OD
(IN.)
0.257
0.255
0.312
CODE:
FIRST
DASH
NO.
-8
~HREID
--j
8-32NC-3B
-10
10-32NC-3B
0.390
0.387
.12
1/4-28NF38
-524
0.468
0.465
-14
5/1 6-24NP-38
-624
0.530
0.527
-16
3/8-24NF-38
0.309
First dash number indicclter rise of bolt to be used.

Serond darh number indi~a,er arrembly grip
Iength
(thicknesz of work) in 161hr.
EXAMPLE: 881369-499-19
L tt
3/4 ASSEMBLY GRIP LENGTH
(+1/321N,-1/161N.)
KOR 1/4-28 BOLT
BLIND NUT ASSEMBLY, WHICH INCLUDES

8N329 SLEEVE AND 88341 EXPANDER
WORK
NOTES
~USED ON BN359 BLIND NUT ASSY

II1 USED ON BN360 BLIND NUT ASSY
ASSY GIIIP LENGTH-NOMINAL GRIP LENGTH (+1/32 IN.,
--1/16 IN.)
5265-3-53
Hi-Shear Blind Baits and Blind Nuts

51-40-30
Page 3
Aug 17/84
NA-66-1032
MANDREL
CHUCK BOLT
ANVIL
-7
O
~SLERIE
EXPANDER
Hand IoolI
crow loot
urod in combination with standard torqm ond

with socket or open-nd
are
Turn ehuek bolt
ccw to fully engage

n body. Slip
Spin expander onto threaded end of
sleeve onto mandrel.
O
El
SOCKET WRENCH
INSTALLATION INSTRUCTIONS
CROW FO~T
WRENCH
C
l(r
anvil (~n
Turn FhyEk bolt
bolt Cv
ta gest
5ealanu
CW to
(On body) firmly
lirmly Onto
TORQUE WRENCH
Insert
expander and sleeve ton mandrel) fully into hole
in work.
Using
wrench to hold chucl bolt turn hsnon
body n
torq us wrench with crowfoot wrench
a cow
d i rection with
until
expander resists wrenching action. To prevent

breakage from overtorquing (particularly on -5, -6
mandrel
and -8
sizes), do
not exceed
torque loads listed below.
TORQUE VALUES
BLIND
BLIND
BOLT
SIZE
NUT
SIZE
TORQUELOADS
TORQUEWRENCH
(IN.-LB)
WITH ANBJ8B CROWF06T
-440
-5
(IN.
65-75
BLIND NUT
HOLE DIA
SIZE
SIZE
(IN.)
-5
0.173
0.170
-6
0.201
0.197
80-90
90-100
97-108
-632
BLIND BOLT
60-70
85-95
-6
HOLE PREPARATION
-8
-832
~g
-832
175-200
190-215
0.345
0.339
-10
-1032
270-295
250-275
-12
-428
-12
-1032
0.319
0.313
-428
0.397
0.391
275-300
295-320
-10
425-450
465-495
-524
NOTE7
OIF
OTHER CRoWFOoT WRENCHES ARE
VSED. THE
-624
INDICATED TORQUE MUST BE CALCULATED.
TO rem0ve
loosen
and
lool.lurn hex
unscrew
on
chuck
body
bolt
cw a
hsif turn to
from
expander
Page 4
Aug 17/84
0.477
0.469
0.539
0.531
5265-3-5+
threads.
51-40-30
0.264
0.258

o
COPYRIGHT, 1984 BY ~ABRELINER CORPORATION
NA-66-1032
HAND TOOLS
HAND TOOL PART NO.
I)LIND 8OLT OR
CROWEOOT
~LIND NUT PART NO.
PART
GRIP RANGE)
(0-1
WRENCH
NO.
11-2 GRIP RANGE~
88351-5
BH100-5-M2
ANBS06-6
88351-6
8H100-6-M2
AN8506-6
88351-8
BW100-8-M2
8H 100-8-613
AN85066
88351-10
~H100-10-M2
BW100-10-M3
AN8506-6
88351-12
8H200-12-M2
8H200-12-813
AN8506-10
8N359-832
8H110-832-M2
8H110-832-M3
AN85066
8N359-1032
llH110-1032-M2
8H110-1032-M3
AN8506d
8#359428
BH210428-MZ
8H210928-M3
AN8506-10
llN360-440
8H 120-440-612
8H 120-440-813
AN8506-6
8N360-632
8H120-632-M2
8H 120-632-M3
AN8506a
l)N360-832
BH150-832-M2
8H 120-832-M3
AN8506d
lN3601031
BH120-1032-M2
BN120-1032-M3
ANB5066
~N36Q418
8H220-428-M2
8H220-428-813
AN0506-10
RLIND I)OL1 CORE DOLT DRIVERS

HI-TOROUE
ONE-PIECE DIIIVER
CORE 80LT
8LIND ~OL1
RECESS
FIRST DASH NO.
PIPE
SQUARE
DRIVE
PART NO.
socrn
-5
PHILLIPS NO.
-6
PHILLIPS NO. 1
-8
PHILLIPS NO. 2
-10
HI-TORQUE
1/4
HTSB
-12
HI-TORQUE
3/8
HTS4
-14
HI-TORQUE
3/8
HTSS
-16
HI-TOROUE
31~
HTS6
RLIND ROLT AND bLIND NUT REMOVAL

Untcnw con bolt when applicable. Uling a drill one rice
~maJ)er than OD of dv~, drilluntil it~ counterrunk or protruding hal bnoLI out. ura a I,r.igh~ pin punch ~o )op oul
nmaindr of drv~ and expander.

51-40-30
Page
Aug 17/84
NA-66-1032
STRII1:TURAI, REPAIR MANUAL
INTERNALLY THREADED SLEEVE

FASTENERS (JO-BOLTS)
Internally threaded, self-locking, blind fasteners consist

of three parts: a threaded nut, screw, and an expandable
sleeve. Installation is accomplished by a special tool that
allows the screw to be turned while the nut is held
stationary. The turning action draws the sleeve over the
tapered portion of the nut and against the underside of the
surfaces being joined. The slabbed portion of the screw is
snapped off flush or below the head of the nut. Milling
operations are therefore not normally required. The
primary use of this fastener is in shear type applications
\Yhere access to the blind side is limited. (See figure 2.)
51-40-30
Page 6
Aug. 17/84
NA-66-1032
PART NO.
DIAYETER(IN.)
164
HOLE
COUNTERSINK DIAMETER
SIZE(IN.)
0.1640-0.1660
100
Deg
0.328
100
3/16
0.19909.1010
100 Deg
0.381
266
1/4
0.16000.1~30
100
Deg
0.503
0.31100.3155
100
Deg
0.630
0.37HM.3790
100 Deg
0.757
311
0/5
375
CODING FOR SELECTION OF PROPER FASTENERS
indicatestlush head.
indicates protruding heed.
260 indicates diameter in
Last dash number indicates nominal grip length in 1/161hs.
EXAMPLE: 52611-4 flush head--0.260 dia--1/4 nominal grip
STEM BREAK-OFF TOLERANCES
SPILE
Flush
Protruding
3/8
5/32
3/16
1/4
5/16
+0.010
+0.000
+0.000
-0.060
-0.075
+0.000
-0.071
+0.078
+0.000
+0.093
+0.015
+0.115
+0.130
+0.0371+0.047
-0.003
+0.000
-0.083
+0.141
+0.059
NOTE
DIMENSIONS SHOWN ARE IN INCHES.
TABLE OF GRIP LENGTHS
DASH NO.
lo,
Drip Length Min
0.094
0.1S6
0.119
0.351
0.344
0.406
0.469
0.131
0.594
Grip Length Max
0.156
0.119
0.181
0.344
0.406
0.469
0.531
0.594
0.616
SPRING
t~l- -IES1 rWRENCHING

,IF~Y I aNo or so~r
sPalNG
DEIRESSED
4047115
fi~l
ADAPIER
rlh~l
55545 OFF-
SB 14515
NUI
SLEEVP
)OLT
L,J
~--UEEVC
IX)1110~0
Oln~t.lld
MlLLABLE
End of bolt brolrn

broken oH
off and
/eckd
FLUSH HEAD
PROTRUDING HEAD INSTALLED
MILLABLE HEAD
Blind Fasteners
Figure
0
INSTALLED
Threaded Sleeve
2 (Sheet 1 of 4)
HEAD MILLED
(Jo-Bolt)
51-40-30
Page 7
Aug 17/84
NA-66-1032
OISASSEMBLY OF BLIND FASTENER FOR INSTALLATION IN FUEL SEALED AREA
DiS8E5emb18 bind
thoroughly
fastener
as
.hown
and
clean
in toluol.
[Ig
COLLAR
NUT
SCREW
Reassemble blind laslensr.nd apply sealant
as
WHEN INSTALLING BLINO FASTENER WITH 1 HAND

TOOL. AVOIB ABRUPT APPLICATION OF TOROUE. A
shown.
SLOW, STEAOY MOTION WILL PREVENT PREMASCREW
I:
TURE SMEAR FAILURE OF SCREW.
SCREW
NUT
NUT
TO AVOID POSSIBILITY OF SEALANT
GETTING INTO SEALANT GROOVE, 00

NOT PERMIT COATING TO EXTENO
OEYONO SHANK DIAMETER OF
iYh
FASTENER.
C~--
SEALANT
NUT
COLLAR
COLLAR
SEALANT
j I
COLLAR
FORCE COLLAR AGAINST NUT, ANO

COAT OPPOSITE ENO OF COLLAR WITH
IN FULLY INSTALLEO POSITION, SEALANT SHOULD

PENETRATE NUT 1/4 IN. MINIMUM.
SEALANT
SEALANT.
PREPAAATIOWOFBLIIOFASTLHERTHATCANWOTBEOISASSEMBLEOFOR118TILLATIOI
IH FUEL-SEALED AREA
SEALANT
SEALANT
o.
FISTEWEA
(EJ
Move collar down
~n
Ehank and
COLLAR
cover area
FASTENER
beluesn
51-40-30
Page 8
Aug 17/84
Move Eal$r up
collar and
collar and fastener with sealant,
Blind Fasteners
Figure
screw
COLLAR
on
shan~ and cover
NUT
area
between
with sealant.
Thread~ Sleeve (Jo-Bolt)

2 (SheeB 2 ot 4)
o
1984 BY S~BRELINER CORPQRATION
NA-Ci6-1032
STRU(:T URAI, REPAIR MA N II A I,
Hand fool may be looally Isbricaled. I\ aloch

adapter and wrench adapter will be used.
1/416.
nose
SOCKET
1/416.66195
RATCHET
SCREWS
GRILL TO
MAX DIAMTER OF
1/418.
DRILL TO FIT
WRENCH
ADAPTER.
JO-BOLT
WRENCH ABAPTER
WELD HANOLE
TO BARREL
-ss~
NOSE
vno TOOL
BOLT
ADAPTER
1:
When installing Jo-bolts with hand tool, avoid abrupt

application of torque. A steady torque will prevent premature breaking of screw.
EXPLOOEO VIEW OF PNEUMATIC

POWER TOOL SHOWING ASSEMBLY
OF NOSE ANO WRENCH ADAPTERS
SLEEVE
NUT
SPAINGNOSE
ABAPTER
RETAINER
ADAPTER HOUSING
IPART OF POWER TOOL)
WRENCH
ADAPTER
VOI-SHAN BLIND FASTENER INSTALLATION TOOLS

PNEUMATIC
POWER TOOL
5/32
3/16
1/4
5/16
3/8
JO-BOLT FASTENER INSTALLATION TOOLS

HANG TOOLS
PART NO.
HANG DRIVER
616300
RAND ADAPTER
(F2M)1
IP2OOI
IF28O)
(PZBO)
RAND ADAPTER (F312)
RW 2000
RAND ABAPTER
HAND ADAPTER
HAND ADAPTER
HW 2000P
RW 2800
HW 2600P
HW 3120
POWER TOOLS
302
PW300
POWER ADAPTER
POWER ADAPTER
POWER ADAPTER
PW 300P
Blind Fasteners
PISTOL
GRIP
FASTENER
HEAD
RIGHT
ANGLE
HANO
TOOL
HWF 165
FLUSH
PT 165
PT 485
PROTRUOING
PT 185P
PT 485P
HWP 165
FLUSH
PTMO
PT400
HWF 200
PROTRUBING
PT MOP
PT 400P
HWP MO
FLUSH
PT280
PT 480
HWF 280
PROTRUDING
PT 2606
PT 480P
HWP 260
FLUSH
PT 312
PROTHUDING
PT 312P
HWP 312
FLUSH
PT 375
HWP 375
PT 975P
HWP 315
IPROTRUOW"
RWF 312
PART NO.
POWER DRIVER
POWER ADAPTER
%200)
(PMO)
IF280)
(P28B)
POWER ADAPTER (F3121
TOOL
FASTENER
FASTENER
DIA
PW3WI
PW 3WIP
PW 312
SZh5-i-60h
Threaded Sleeve (Jo-Bolt)
51-40-30
Page
Aug 17/84
NA-66-1032
NOTE
REMOVAL
DIMENSIONS SHOWN ARE IN INCHES.
SELECT GRILL IN ACCORGANCE WITH

TABLE I. GRILL TO BELOW HEAGSHANK
SELECT GRILL IN ACCORGAICE WITH

TABLE II. GRILL TO DEPTH OF PILOT HOLE.
WITH HAMMER AtlO #OMIIIAL SIZE
PUNCH, SEVER HEAo AnG DRIVE OUT

SHANK ANG GLIIo HEAO.
JUNCTURE.
REMOVAL WHEN BOLT TURNS IN HOLE WHILE DRILLING
PREVENT HUT FROM TURIIIWG BY EnOAoING ORIVIWO TOOL nDSE AGAPTER. HOLD
NOSE AOAPTER WITH HAND TOOL MANGLE
OR VISE-GRIP PLIERS.
PICK NUT OUT OF HOLE WITH PUNCH.
SELECT GRILL II ICCOROIIWCE WITH

TABLE I. GRILL THROUGH SHARK, sEVERING BOLTHEAO.
SELECT DRILL WITH 500 RPM MAXIMUM

TABLE I
NO. 43 IGOOOI
3/16
50.35101101
Ho. 24 10.1621
Page 10
Aug 17/84
5/16
no. 17
3/8
no. 510.20551
Blind Fasteners
Figure
TABLE H
GRILL SIZE
5/32
1/4
51-40-30
GRILL Sltf
FASTENER OIA
(0.173)
5/32
12101651
O
M
23/84
Threaded Sleeve (Jo-Bolt)

2 (Sheet 4 of 4)
o
5265-361 A
NA-66-1 032
STRUCTURAL REPAIR MANIJRL
THREADED PIN FASTENERS (HI-LOK)

Hi-Lok fasteners (figure 3) are a threaded-pin type
fastener with a self-torquing nut that automatically
shears the wrenching head off when the proper torque
value! is reached. The nuts or collars are obtainable in
either aluminum or stainless-steel alloys, and the pins are
obtainable in various alloys, such as steel, titanium, and
aluminum. Aluminum alloy pins and collars may be used
as replacement for DD6 rivets or where higher shear
allowables are necessary than can be obtained with the
conventional DD6 rivets. Advantages of the Hi-Lok
fasteners are that they can be held and torqued from the
same side with either the special driving tool or with a hex
Alien wrench and an open-end or box wrench. Another
distinct advantage is the absence of heavy driving blows
during installation. Hi-Loks may be procured with either
a 100" countersunk head or a modified flat head. Refer to
tables 1 and 2 for rivet head style, type, and part numbers.
Refer to Source Key 021 in 51-30-00, table 2 for manufacturer.
MS~ALLED HI-L)K FASTENER
HI-LOK PIN AND COLLAR

HEX RECESS
WRENCHING ELEMENT
IN PIN END
bn
THIN WALL SHEARS

WHEN PREL)AD IS
COUNTERSUNK
PROTRUDING
HI-UIK
HEAD STYLE
READ STYLE
COLLAR
ATTAINED DURING
INSTALLATION
COLLAR
AFTER INSTALLATION
Hi-Lok Fastener
Figure 3
0
51-40-30
Page 11
Aug 17/84
NA-66-1032
REPAIR MANUAI,
Table 1. Protruding Head Hi-Lok Fastener Selection

HI
LOK FASTENERS
MATING
AND
(KSI MIN)
95
3?5
303
95
600
303
95
I
I
COLLAR
PIN
HLIOV
HL70
6AL-4V
2024-T6
~(LIOV
HL8?-(
6A L-4V
2024-T6
PIN
TYPE
MAX
SERVICE
TEMP (DF)
I
I
MATERIAL
BASIC PART NO.
HEAD STYLE
SMEAR
STRENGTH
COLLAR
ADW
HLIOV
~1L94DU
6AL-4V
HL40
HL94DU
A--286
HL40
HLIISDU
A-286
303
95
700
A-286
A-286
95
1200
A--286
A-286
95
]200
P1113-8Mo
303
125
600
2024-T6
95
3?5
135
700
PROTRUDIN<;
HEAD
SI1EAR
-c,Aow
1(L97DI
HL40
H 1.40
HLlsS1)U
-()ADW
HL94DU
lil.o44LL
I~ L644LL
PH 13-8Mo
I1L175DU
303
-()ADW
HElll-0011
HE114-0032
HE111-0018
HE114-0032
HE 111-0027
HE114-0032
STEEL
431
1
2024-T6
20?4-T6
431
MD114-002?
6AL-4V
2024-T6
MF111-0013
ME114-0024
6AL-4V
20?4-T6
HLI?V
HL73DY
6AL-4V
17--41H
HL89 DU
6AL-4V
17-4PH
-()ADW
HL78
A--286
H 1.646 L L
HL73DY
PMI 3-8Mo
17-4PH
1116461.1.
I1LH9DU
PIII318Mo
17-4P11
ME112-0013
325
95
350
95
600
95
1?00
1?5
600
95
1?00
PROTRUI)IN(;
HL17V
HEAD
TENSION
I(L48
A--?86
()ADW
MI:II ?-0006
ME114--M)19
A--286
A-2B6
MI 11 ~-0000
Mti114-00?0
A-?86
A-286
NOTES
SELF-ALIGNING COLLAR ASSEMBLY. FOR USE ON
SLOPED SURFACES UP TO 70 MAXIMUM.
H(-LOK SMEAR HEAD FASTENERS SHALL NOT BE USED

IN TENSION APPLICATIONS.
51-40-30
Page 12
Aug 17/84
CO.PYRIGHT, 1984 BY ~BRELINER CORPORATION
NA-66-1032
Table 2. Flush Head Hi-Lok Fastener Selection
HEAD STYLE
AND
BASIC PART NO.
I
I
COLLAR
HLIIV
HL70
HLIIV
PIN
TYPE
HLIIV
HL41
100 FLUSH
HEAD
SMEAR
MATING
HL41
SMEAR
MATERIAL
I
PIN
STRENGTH
(KSI MIN)
MAX
SERVICE
TEMP ("F)
?024-T6
ML82-()
ADW
6AL-4V
2024-T6
95
325
HL94DU
6AL-4V
303
95
600
95
700
HL94DU
COLLAR
6AL-4V
I
I
A-?86
HL175DU
303
A-286
303
HL97D J
A-286
A-?86
HLI8SDU
A--?86
I~
HL41
HL41
95
1?00
1?5
600
95
325
125
325
A-~86
-()ADW)
HL64SLL
11L645LL
HL94DU
PH13-WMo
303
HLI5SDU
PHI3-BMo
30)
-()ADW
HE114-0032
STEEL
?0!4-T6
HEIII-0019
11EII4-0032
431
~0;14-Th
HEIII-0028
IIE1I4-0032
431
20?4--T6
ME112-0014
ME114-00??
6AL-4V
L0?4--Tb
MF. 112-0014
ME114-00?4
6AL-4V
204-T6
HLI)V
HL731)Y
6/\L-4V
17-4P11
HE111-0015
125
95
11L13V
100
11L49
HL78
A--?86
A-~R6
HL647LL
HL73Dy
P1113-XMo
1 7- 4P11
11L89DU
)ADW
P1113-nMo
ME112-0007
ME114-0019
ME112-0007
ME114-00?0
A-?B6
350
1 7- 4pI(
bAL-4V
~1L891)U
-1 )ADW
FLUSH
HEAD
TENSION
325
17-4PII
95
bOO
4s
1200
12.5
600
A- 286
95
1200
A- 2116
NOTES
O SELF ALIGNING COLLAR ASSEMBLY. FOR USE ON SLOPED SURFACES UP TO 70 MAXIMUM.

O HI-LOK SMEAR HEAD FASTENERS SHALL NOT BE VSED IN TENSION APPLICATIONS.
51-40-30
Page
0
13
Aug 17/84
NA-66-1032
STHCCIUHAL REPAIR MANUAL

Oversize screws must be replaced with oversize screws of
the same diameter. Using a standard screw in place of an
oversize screw will result in weakened structure. In
addition, if the screw is used in a sealed area, a poor seal
will result.
SCREWS
Rockwell International 7S series special screws are highstrength, close-tolerance fasteners with Toro-Set heads.
These screws are used extensively in the wing panels and
other structural components. Most of these screws have a
standard diameter. However, when necessary for salvage
0.031 in.
purposes, screws having either a 0.015- or a
oversize shank are used. Table 3 shows the thread size and
part numbers for standard diameter and oversize 7334
the
screws. The part number of each screw is stamped on
Because these screws are similar in appearance, the only

method of identification is the number on the head.
Screws should be checked carefully before being replaced.
sure
See figure 4 for 7834 and 7839
screw
description.
head.
Table 3.
7534 Oversize Screws

OVERSIZE SHANK
THREAD
10-32 NF-3A
1/4-28 UNF-3A
5/16-24 UNF-3A
3/8-24 UNF-3A
7/16-20 UNF-3A
1/20 UNF-3A
9/16-18 UNF-3A
STD DIA
0.015 IN.
0.031 IN.
7834-3
7834-4
7834-5
7834-6
7334-7
7834-8
7834-31
7334-41
7334-51
7834-61
7834-71
7334-81
7534-9
7534-91
7334-32
7534-42
7834-52
7334-62
7834-72
7834-82
7S34-92
NOTES
LENGTH CODE: LAST DASH NUMBER INDICATES
NOMINAL GRIP LENGTH IN IGTHS.
EXAMPLEOFPART NUMBERS. 7S34-41-101NDICATESA

1/4-28 TORO-SET RECESS SCREW WITH A 0.015 IN.
OVERSIZE SHANK AND 5/8 IN. NOMINAL GRIP LENGTH.
REFER TO SOURCE KEY 017 IN 51-30-00 TABLE 2 FOR
MANUFACTURER.
51-40-30
Page 14
Aug 17/84
NA-66-1032
NOTE
DIMENSIONS SHOWN ARE IN INCHES UNLESS OTHERWISE NOTED.
7539508591
7534 SCREW
LEnOTH
SPECIAL PHILLIPS RECESS

PER AMERICAN SCREW CO.
OWO no, SKnOO
LENGTH
TOROIET RECESS
PER 11151078
1// 1
LTHREAO
OIA
HEAD MARKIIIO:
MANUEACTURER"S TRADEMARK AND 34 TO INOICATE BASIC PART NUMBER.
MARK "C" TO INDICATE A2OO CRES, "J" TO INDICATE H-ll STEEL WHERE
APPLICABLE. ND LETTER INDICATES 4130 STEEL.
BASIC
HO.
OIA
L
PART NUMBER. MARK "C" TO INDICATE A2OO CRES WHERE APPLICABLE. NO

LETTER IHOICATES ALLOY STEEL.
THREAD
7534-3
7534-4
10
1/4
32
28
75345
7534-8
5/18
3/8
24
24
7834-7
75348
7534-9
7834-10
7/16
1/2
20
20
9/15
18
5/8
18
~-THAEAO
HEAD MARKINR: MANUFACTURERS TRADEMARK ANO 39 TO INDICATE BASIC
BASIC
OIAMETER
NO.
OIAMETER
THREAO
1/4
32
28
7839-5
7539-6
7839-7
5/16
24
3/8
24
7/16
20
75388
7539-9
1/2
9/16
20
7536-3
73394
10
18
EXAMPLES
EXAMPLES
7834-4-8-1/4 OIA SCREW, 0.500 GRIP, 4130 STEEL WITH COTTER PIN HOLE.
7839-4-8=1 /4 DIA SCREW, 0.500 GRIP, ALLOY STEEL WITH COTTER PIN HOLE.
7534CT5A10=5/16 DY 8CREW. 0.825 GRIP, 8286 STEEL WITHOUT COTTER
753905410=5/15 0111 SCREW, 0.525 GRIP, 4286 STEEL WITHOUT COTTER PIN
PIN HOLE
HOLE
753445-12=3/8 OIA SCREW, 0.750 GRIP, H-l 1 STEEL WITH COTTER PIN HOLE
7339051-14=3/8 DIA SCREW, 0.015 OYERSIZE SHANK OIA 0.875 GRIP, A2B6
STEEL WITH COTTER PIN HOLE.
7534JOi-41=3/8 on SCREW, o;oiS O\IEdLfitE SiAQK LIA, 0.875 GRIP, H-l 1

STEEL WITH COTTER PIN HOLL
100" FLUSH HI-SMEAR HEAD, SPECIAL PHILLIPS RECESS, CLOSE-TOLEBANCE
100" FLUSH HEAO, TORO-SET. CLOSE-TOLERANCE
NOTES
THIS SCREW FOR USE ON T-39 AIRPLANE ONLY
THIS SCREW TO 8E USED WITH LOW-HEIGHT NUTS
AND FOR APPLICATIONS INVOLVING SMEAR LANDING
PRIMARILY.
75 Series Special Fasteners

Figure 4
0
51-40-30
page 15
Aug 17/84
NA-66-1032
STRI!CTURAL REPAIR MANUAL
STRUCTURAL REPAIR (Continued)
TU ttN I,OCK FASTENERS

The Camloc type turnlock fastener consists of a receptacle
that is riveted to the structure and a stud assembly that is
secured to the outer panel by a grommet and snap ring.
The stud locks positively in the receptacle with a quarter
turn that engages the cross pin in a locked position in the
of the receptacle. Typical appearance and
cam
nomenclature for the various parts are shown in figure 5.
The standard Camloc 4002 series stud assembly is
cadmium plated steel. The receptacle is corrosion resistant
steel, and is limited to a maximum service temperature of
450"F because of the cadmium plate on the stud assembly.
Corrosion resistant steel stud assemblies are available
where service temperatures of 7000F are encountered.
See figure 6 for installation and removal information.
CAMLOC 4002 820128

FISTEWER CALLOUT
PAWEL WITH STUO ASSY
REgO(Brommetj
HfgD(Sludi
RfgO(Wahtr,for
4001-40024082-821
stud dash numbsn -18 and
longal)
REOB(Rlnpl
R4T
SUBSTRUCTURE WITH RECEPTLCLE

40817-1...,
40117--2
4088-18-1
51-40-30
Page 16
Aug 17184
Camloc
FastenerFigure
REODIRsPeptlcla,
pllm rival halas)
RL0011ac~p$cls. Ihed,
rival Uw)
RE(lO(ghlm mly ha
rspuiradj
dtlpmld.dexn
COP"IRIGHT, 1984 BY SABRELINER CORPORATION
NA-66-1032
STRUCTURAL REPAJR MANUAL
(OR THE EOUIYALENT)

REOUIRED FOR INSTIILLATIOW
TOOLS
4002 SERIES CAMLIFAITEYER
OF 4002 888188 CAMLOC
FASTEWERS
RUBBER TIP
8708
4085 ICROSS 8E0E88)
-+I
IN.
OR40021sLOTTEO)
Tlg.l AOAPTER
1/4-28 THO
4001 OROMMET
R4T SWAP RIWG

HAWOLE
408018 SHIM
(USED AS RE0O1
4-65-1-500 COUWTERSINK
40817 RECEPTACLE
88-500 HOLE 8AW
T39 SWAP RIWG

TOOLSET
423 STVD PLIERS
rQi
-~--t ~-B--9
I
T1O RECEPTACLE DRILL JIO
S265-3-62

0
51-40-30
Page 17
Aug 17/84
NA-66-1032
NOTE
DIMENSIONS SHOWN IN INCHES UNLESS OTHERWISE

NOTED.
489 STUD PLIERS
RAWRLE
4001 OROMMET
4085 OR 4002;9TUO
MAWOREL
SWAP 9188
OROMMET
INSTALLING STUD
PREPARATION FOR INSTALLATIOM AND

INSTALLATION OF GROMMET AND STUD
INSTILLING GA9MMET
Drill No. 30 (0.1285 in.) diameter pilot hole
~Enlslge
pliat hale with CamloE saw No ~18-500 or its

equal. If final hole size is to be accomplished by drilling, No.
30 pilot hole should first be enlarged to 3/16 in.
OUTER SMELT
140"
ICOVER OR ODOR)
(t 0.825
(cOM~
Using Camloctool No.4-OC-1-5000ritsequal.
countersink
face of panel.
--t~1011a011snap ring.Insert40G1
O
Using
grommet, and, using Camloc tool No. T39, attach
Camlac 4P3 stud
(Ilierr install U196
or
~002
stud.
PREPARATION FOR INSTALLATION ANO

INSTALLATION OF RECEPTACLE
4061 GROMIYIET r
R4T SWAP AIWO
llJ
O
1.00
Locale and
pilot-drill oenter(No 30)
hole
Locate and drill 118 in, rivet hole. Locate holes with
Camloc tool No. T16
its
Countersink for 1/8
.tevequal.
is.ni
.I
0.594
or
(E~
Enlar(le csntsr pilot-drilled hole to 3116 In and tlnishdrill hole until final hole size is 19/32 in.
409818
FREODI
I MIH8
8920428404 RIYET
51-40-30
Page 18
Aug 17/84
OUsing
MS20426AD4 rivets, install
receptacle shims, when

minimum thickness requirements.
40R8-16
40917 RECEPTACLE
receptacle.
Use
necessary, to meet
5265-363
Figure
(Sheet
2 of
4)
COPYRIGHT, 1984 BY ~BRELINER CORPORATION
NA-66-10~2
STHIICrllRA I, KEPAIR MA NITAI.
CAMLOC SMEAR GROMMET PART NO.

INNER SHEET
MINIMUM THICKNESS
INNER SHEET (PLUS 4088-16
OUTER SHEET THICKNESS
PART NO.
(IN.)
NECESSARY)
(IN.)
SHIMS WHEN
0.050
0.071
4061-5
0.063
0.063
4061-6
0.071
0.063
4001-5
4061-6
0.080
4061-8
0.090
4061-8
0.100
0.050
0.063
0.063
0.050
0.112
4001-10
DASH NO. FOR 40SS AND 4002 CAMLOC

STUDS FOR FIXED-TYPE RECEPTACLE 40R17
GRIP
PART NO.
INNER MEMBER
PLUS OUTER MEMBER
IN.
LENGTH
GRIP
PART NO.
"L"
IN.
IN.
LENGTH
"L"
IN.
4002-3
0.111--0.140
0.710
4002-15
0.471 --0.500
1.070
4002-4
0.141--0.170
0.740
4002-16
0.501 --0.530
1.100
4002-5
0.171-0. 200
0.770
4002-17
0.531 --0.560
1.130
4002-6
0.201 --0.230
0.800
4002-18
0.561 --0.590
1.160
4002-7
0.231 --0.260
0.830
4002-19
0.591 --0.620
1.190
4002-8
0.261 --0.290
0.860
4002-20
0.621 --0.650
1.220
4002-9
0.291 --0.320
0.890
4002-21
0.651 --0.680
1.250
4002-10
0.321 --0.350
0.920
4002-22
0.681 --0.710
1.280
4002-11
0.351 --0.380
0.950
4002-23
0.711--0.740
1.310
4002-12
0.381 --0.410
0.980
4002-24
0.741 --0.770
1.340
4002-13
0.411--0.440
1.101
4002-25
0.771 --0.800
1.370
4002-14
0.441 --0.470
1.040

0
INNER MEMBER
OUTER MEMBER
51-40-30
Page 19
Aug 17/84
NA-66-1032
FABRICATION
parts from 0.050 in. 2024-74
Fabricsle all
1-1/4
or
7075-T6
clad material.
Cut sheet-metal slrlps and spacers
OJ09sls
(collar-rstsining)
OAli9nandcismpSlri )SandO(lSOin
11/4
strip
Ower
--i-----
and insert
GRILL 1/5--CSK
OThmugh.il
140" X 5/8
rig-pin hole,
ORemove
5/32 RIVET--
0RlllnO.21
pans,
drill a No
and a No. 30
upper
Iower strip; drill
spaceiindrillriEe.
0.100 in. spacer between strips at
21
riuel
joggled
hale,
end.
No. 21
transfer-punch hole.
strip and spacers from
vise.
Reclamp
and coutnersink 1/2 in. Camloc collar hole.
RIG PIN HOLE-01111 s0. 21
ITYPI
-J
a
OASSBlllblB
install Camloc collar
GRILL NG. 30
RIG PIW
RIVET
(5/32 RIYET)
rig pin
parts. and rivet Ihem To
should be in
ensure alignment.
place during riveting operation.
(LOOSELY GRIVENI
RIG-PIN HOLE
ITYPI
TRANSFER-PUNCH
HOLE
MARK HOLE CENTER
RIO PIN 1N PLACE
WITH 1/8 In.
f~n;0.050
0.050 SPACER
CAMLOC STUO LOCATOR IILIGIEO
TRANSFER PUNCH
TAPE ODOR SECURELY

IN PLACE (TYPJ
CAMLOC GROMMET ANO RINO

CAMLOCSTUOLOCATOR
CIMLOC
AEEEPTICLE(TIP) 7
CAMLOC STUO
UWTRIIWIIEO
LOCATOR (TYP)
CAMLOC OROMMET ANO 8700
ITYPJ
CAMLGC RECEPTACLE
pp)
SKIN
(REFI
GGOH LANG
GOORLANO(REF)
SKIN
NOTES
THIS TYPE OF CAMLOC STUD LOCATOR IS RECOMMENDED WHEN REGULAR REPLACEMENT OF DOORS
LOCATING CAMLOC STUDS

INSTALL CAMLOC STUD LOCATOR IN EACH RECEPTACLE AROUND OPENING.
AND COVERS IS EXPECTED. A LOCATOR IS INSTALLED

IN
ALIGN
EACH CAMLOC RECEPTACLE UNDER DOOR OR
COVER
BEING
FITTED
(LARGEST
DOOR
HAS
CAMLOC FASTENERS.)
OVER
OPENING, AND
ALIGN
LOCATOR,
INSTALL
RIG,PIN,
AND
MARK
ON EACH LOCATOR AROUND OPENING.
NOTED.
Page 20
Aug 17/84
DOOR
CENTER OF STUD LOCATION. REPEAT PROCEDURE
DIMENSION SHOWN IN INCHES UNLESS OTHERWISE
51-40-30
UNTRIMMED
SECURELY TAPE IT IN PLACE.
26

o
COPYRIGHT,
NA-66-1032

THREADED INSERTS
See figure 7 for installation and removal information for

Rosan threaded inserts.
51-40-30
0
Page 21
Aug 17/84
NA-66-1032
SIKuCIURAL REPAIK MANUAL
INSTALLING INSERT
O
HOLE "A"
Dri I hole sho*n in column .V. to
depth
shown
in
column "B.
Counlerb.re diameter shown in column ..C.. j+O 003.
--0.000
in.),
depth shown
to
in column "D." Fillet radius
0.010 to 0.020 in. Counterbore to be concentric with thread
pitch diameter
L- MINIMUM RECOMMEWOEO
EDBEOISTAICE.POSSIBL~
TOLERANCE ACCUMUUTIOI
MUST BE CONSIDERED.
within 0.006 in. total indicator
reading.
El
Countar.ink 909 to full diameter of munlerbore
TBP for Ihr.sd Oi~B shown
in Folumn ..K.. to
depth
shown in column"G.
MIN
t.o.,,
Select
applicable
insert from column "H." Install from
0.010 to 0.020 in, below surface.
--O.OW
I""
Select
applicable
lock
ring from column
"J." Install
from flush to 0.010 in. below surface.
CODE:
LAST DASH NUMBER INDICATES LENGTH II 1/IGTHS. WHEN LOCKING FEATURE IS NOT REOUIREO, OMIT LETTER "L" AFTER PART NUMBERS. EXAMPLE: R020BSBB
TAP
GRILL
DRILL
DEPTH
INSERT
INTERNAL
CRORE DIA
CBORE
IMIW
INSERT
LOCK 8118
TAP
MI# EDGE
CBORE
REMOVAL
DEPTH
FULL
PART
PART
THREAD
GISTANCE
FOR
GRILL
THD
NUMBER
NUMBER
THREAG
4-40 NC38
AL ALLOY
MA6
15/32
0.250
0.258
0.094
1/4
R1(128B4L
AL18885
10-24 80-38
11/64
11/64
810388bl
RLIBsBO
12-24 80-3
13/84
13!64
17/32
0.281
0.280
0.108
5/1
9/16
0.328
0.337
O.1DD
3/8
1032 NF-3B
19/32
0.375
0.381
0.140
11
5/18
21/32
0.438
0,448
0.158
5/16-24 UNFJB
27/84
23/32
0.516
0.172
3/8-24 UNF-3B
31/64
13/16
0.594
0.801
0.172
7/16-20 UWF-)B
17/32
13/16
0.734
0.747
0.188
1/2-20 UNF-3B
41/84
15/16
0.875
1/4-28 UWFIB
A
2510.149)
18(0.177)
8-32 NC-BB
6-32 NC-BB
AN BOLT
0.209
8L2188-8
1/4-20 088-38
A02098SBBL
11
8021088;111.
15/64
1/4
0.082
8/32
3/&16 UWCJB
5/18
0.080
11/32
1/2-13 UICJB
3/8
0.085
27!64
7/18
O,1#O
31/84
5/16-18 080-38
RA020788I
7/32
9/1&12 UWC1B
RL478B10
5/8-11 UWC-QB
1/2
0.1M0
19/32
RLSO8B-II
3/4-10 080-30
5/8
0.108
23/32
REMOVING INGEOT
DRILL OUT SERRATEG COLLAR OF INSERT. USE

GRILL SAME DIAMETER AS SERRATIONS. DRILL TO
DRIVE IN
SOUARE-TYPE "EASE-OUT" TOOL OR

SIMILAR SOUARE TOOL. SCREW OUT INSERT.
IF LOCK R11C FAILS TO COME OUT AS INSERT IS

UNSCREWED, COLLAPSE R~M#IINO PORTION OF
RING WITH PUNCH AID REMOVE.
DEPTH OF LOCK 8118 OILY. USE DRILL AT HIGH
SPEED. FOR CORRECT GRILL SIZES. SEE COLUMN

"X" IN TABLE ABOVE.
NOTE
DIMENSIONS SHOWN ARE ININCHES.
5265-3-66
51-40-30
Page 22
Aug 17/84
Rosan Inserts
7 (Sheet 1 of
Figure
2)
NA-Gti-103L
STRI!CTURAI, REP~IR
NOTES
tl, IE~.
OPERATIONS
AND
CAN BE COMBINED
INTO ONE OPERA TION BY VSING A CHAMFERED STEP
INBOLT
DRILL.
INSERT COUNTERDOREO TO
"RO" SERIES INSERT
LOCKING AIHG
CLEAR IMPERFECT THREADS

01 BOLT.
OPERATIONS
AND
CAN BE COMBINED INTO
ONE OPERATION BY USING A CHAMFERED COUTNERBORE TOOL WITH PILOT

ALL OPERATIONS
MAY
BE ACCOMPLISHED WIIH
SEPARATE TOOLS.
INSTALLING ROSAN INSERTS
O
O
PART OF FIRST THREAO PAST

CRAMFER MUST PENETRATE
TRROUOH INSERT TO OBTAIN
FULL ADVANTAGE OF LOCKING
FEATURE
TaP dril
Counlerhore
Countersink
8
CRAMFEAEO
COUNTERBORE TOOL
I~ IA
CHAMFEREO STEP DRILL
VI
~j
WRENCH
LOCK RING
ORIVE TOOL
Ltii
NOTE
NOTE
LOCK RING IS DESIGNED TO BROACH ITS OWN WAY
SEQUENCES OF OPERATION FOR INSTALLATION OF
INTO PARENT MATERIAL. RING SHOULD BE DRIVEN
ROSAN INSERTS.
STRAIGHT WITH FLAT TOOL.
Rosan Inserts
7 (Sheet 2 of
Figure
0
2)
5265-3-67
51-40-30
Page 23/24 Blank
Aug 17/84
NA-66-1032
REPAIR SUPPORT AND ALIGNMENT

GENERAL
Refer to the applicable chapter for the
the structural components.
required support of
51-50-00
0
Page 1/2 Blank

Aug 17/84
NA-66-1032
STRUCTURAL REPAIR MANUAL,
TYPICAL REPAIRS
STHUCTURAI, IDENTIFICATION
(:ENERAI,
Repair data in this section presents information which

enables development of repairs for various airframe areas
by shop personnel. This data consists of illustrations
which show examples of repair problems and methods of
solution. The typical repair index is presented in figure 1.
Irse of clad instead of bare aluminum alloy is preferred
for all repairs as an additional step for corrosion
protection.
51-70-00
0
Page 1
Aug 17/84
NA-66-1932
STRUCTURAL KEPAIR MANUAL
Y~i;s
ii4
STA
,i
156.99
STA
12.825
I
STA
81.5
USE GL~S-FABRIC
REINFORCEO PLASTIC
REPAIRS
I
:c:i
h~c.i
h;
:,~Fii;;
STA
81.5
irl
e.1
STA
12.6
STA
158.88
MAIN GEAR OOORS-
REFER TO CHAPTER 52
FOR REPAIRS.
COOINO APPLES TO SHINS ONLY

PRMARY STRUCTURE
USE SHEAR-TYPL REPAIRS
PRIMARY STRUCTURE
USE TENSION-TYPE REPAIRS
DIRECTION OF TENSION LOAOS
I SECONOARY STRUCTURE
USE SECONOARY STRUCTURE
REPAIRS, EXCEPT 48 NOTED
NOTES
REFER TO WING GROUP REPAIR INDEXES FOR MATERIAL
PRIMARY STRUCTURE
SPECIAL CONDITIONS
00 NOT PERMIT USE
GAUGES. MEASURE THICKNESS OF CHEM-MILLED

MATERIALS OR REFER TO APPLICABLE DRAWINGS
FOR THICKNESS VARIATIONS.
OF TYPICAL REPAIRS
REFER TO DESIGN MECHANICAL PROPERTIES TABLES
RXS8~8
FOR MATERIAL ALLOWABLES.

FOR NEGLIGIBLE HOLE REPAIR. REFER TO 51-70-50.
mooEL NA265-40, -gD, -101 AND -80
51-70-00
Page 2
Aug 17/84
PAIMARV STRUCTURE
USE NONEYCOMR TRAILING EOOE
REPAIRS
52653-73A
Typical Repair Tndex

COPYRIGHT, 1984 BY SABRELINEP CORPORATION
NA-GCi-I 032
No
Lr.
iu
-c~
~Z
COO1NO APPLES TO SKINS ONLY

PRIMARY STRUCTURE
USE SMEAR-TYPE REPAIRS
~U
PRIMARY STRUCTURE
OIRECTION OF TENSION LOADS
SECONOARY STRUCTURE
USE SECONDARY STRUCTURE
NOTES
REPAIRS. EXCEPT AS NOTED
REFER TOWINGGROUPREPAIR INDEXESFOR MATERIAL
GAUGES
MEASURE
THICKNESS OF CHEM-MILLED
MATERIALS OR REFER TO APPLICABLE DRAWINGS
FOR THICKNESS VARIATIONS.
PRIMARY STRUCTURE
SPECIAL CONDITIONS
00 NOT PERMIT USE
OF TYPICAL REPAIRS
PRIMARY STRUCTURE
USE HONEYCOMR TRAILING EDGE

REPAIRS
MODEL NA 285-688, -6888, -888, -8888, AND -65

0
51-70-00
Paae 3
Aug t7/84
NA-66-1032
USE GLASS-FABRIC-REI#FORCEO
PLASTIC REPAIRS
STRCiCTU KAL REPAIR MANUAL
STA 58.853
I~
VERTICAL STABILIZER/RUDDER
MODEL NA 255-40, -gO, -BOA, -8060, ANO -65
STA 00.261
51(15-3-74*
MODEL NA 285-40 ANO -BO, -BOll, ANO w)se
C0R1NO APPLIES TO SKINS ONLY

PRIMARYSTRUCTURE
USE SHEAR-TYPE REPAIRS
NOTES
PRIIIAISTAUCTURE-REFER
TO
TAIL
GROUP
REPAIR
INOEXES FOR
MATERIALS AND MATERIAL GAUGES.
MEASURE
THICKNESS bF CHEM-MILLED MATERIALS OR REFER

TO
APPLICABLE
DRAWINGS
FOR
DIRECTION OF
THICKNESS
TENSION LOADS
VARIATIONS
1
HtFER TO DESIGN MECHANICAL PROPERTIES TABLES
FOR MATERIAL ALLOWABLES
SECONOARYSTRUCTURE
UL SECONDARY STRUCTURE
REPAIRS, EXCEPT AS NOTED
PRIMARY STRUETURL
USE HONEYCOMB TRAILING 5065
REPAIRS
51-70-00
Page 4
Aug 17/84
Typical Repair: Zndex

o
COPYRIGHT,
NA-66- 1032
USE GLASS-FABRIC-REINFORCEO
PLASTIC REPAIRS
ii
STA 56.853
VEA7ICAL STABILIZER/RUOOER
MOOEL NA 265-70.
iiI
:::~:::::::::j:::i::::::::::::::::::::::
srr ss.zal
MODEL NA 265-506, -GOSC. -65,

-70.-80.-80A.RNO-80SC
CODING APPLIES TO SKINS ONLY

PAIMARYSTAUCTUR~-USE SMEAR-TYPE REPAIRS
465-3-~7
PAIMIIAYSTAUCTUAE--
NOTES
REFER
TO
TAIL
MATERIALS AND
GROUP
REPAIR
MATERIAL
INDEXES
GAUGES.
FOR
DIRECTION OF
MEASURE
THICKNESS OF CHEM-MILLED MATERIALS OR REFER

TO
APPLICABLE
DRAWINGS
FOR
TENSION LOADS
THICKNESS
VARIATIONS.

FOR NEGLIGIBLE HOLE
SECONOIRY STRUCTUAE
USE SECONOARY STRUCTURE
REPAIRS. EXCEPT AS NOTEO
REPAIR, REFER TO 51-70-50.
PAIMIRYSTAUCTUAE-USE HONEYCOMB TRAILING
EOGE REPAIRS

0
COPYRIGHT 1984, BY SABRELINER CORPORATION
51-70-00
Page 5
Aug 17/84
NA-66-1032
w~
REFER
RAOOME
roslloao
~01 RIPIIRS
I~iX?"1
i:~;
1~
!A_
CHEM-MILLED SKIW LAHOS

OVER LOWOERONS ARE
IN TENSION ITYPI
.VI
8;2
;Y~
~=ic.;
HOSE OEAR 000RS--
FUSELAGE
REFER TO CHAPTER
52 FOR REPAIRS
TYPICAL FOR MODEL HA 255-40, -50, -505, -5050, AWO -65
NOTES
Use tension repairs on, all bulkhead and
beam webs that carry cabin pressure loads,
Tension, is distributed un~formly in, member as shown,
Use shear repairs on all
bulkhead and beam webs,
COO1NO APPLIES TO SKINS

OWLY, EXCEPT AS NOTED
rzonpressurixed
PRIMARY STRUCTURE-USE TENSION-TYPE REPAIRS
Refer to body group repair ilzdezes for

materials and material gauges, 1Measure
thickness ofchem-milled materials orrefer
to applicable drawings for thickness
SECONOARY STRUCTURE-USE SECONOARY STRUCTURE REPAIRS,

EXCEPT AS HOTEO
variations,
Refer to design meehanical properties
tadlesfor material allowables.
For
negligible hole repair, refer to
PRIMIRY STRUGTURE--
SPECIAL CONOITIOWS
00 NOT PERMIT USE
OF TYPICAL REPAIRS
5~-r0-50.
PAIM~AY STRUCTURE-SPECIAL COWOIT1018
00 NOT PERMIT USE
OF TYPICAL REPAIRS
PRESSURIZEO BULKHEAD AND

BEAM WEB TENSION OIIGRAM
PRIMARY STRUCTURE
USEHOWEYCOMBREPAIRS
IREFER
51-70-00
Page 6
3/88
Jun
TO CHAPTER
53)

(Figure 1 (Sheet 5 of 9)
NA-66-1032
~T.W
REFER
RAOOME
TO 51-70-50
FOR REPAIRS
CHEM-MILLEO SKIN LANDS

OVER LONGERONS ARE
IN TENSION
(TYPI
st,
FUSELAGE
TYPICAL FOR MODEL NA 205-70. -80, -80A. AND -0000

NOSE DEAR 000AS-REFER TO CHAPTER
NOTES
52 FOR REPAIRS
Use tension repairs on all bulkhead and

beam webs that carr21 cabin pressure loads.
Tension is distributed
in member as shown,
COD1NO APPLIES TO SKINS ONLY. EXCEPT AS NOTED
Use shear repairs on all nonpressurixed

bulkhead and beam webs
Refer
to
body
groUp
PRIMARY STRUCTURE
r~:ixis?::::::::::::::::1
repair iads~es for
SIEOHOIRYSTRUCTUR~
materials and material gauges, Measure

thickness of chem-milled materials or refer
to applicable drawings for thickness
variatio*a.
USE SECONDARY STRUCTURE
REPAIRS. EXCEPT AS NOTED
Refer to design mechanical properties

tablesfor material allowables.
For negligible hole
5~-r0-50.
repair, refer
PRIBIRY STRUCTURE
SPECIAL CONDITIONS
00 NOT PERMIT USE
OF TYPICAL REPAIRS
to
PIIMIRISTRUCTUR~-SPECIAL CONDITIONS
00 NOT PERMIT USE
OF TYPICAL REPAIRS
PRESSURIZEO BULKHEAD ANO
PRIMARY STRUCTURE
BEAM WEB TENSION OIACRAM
USE HONEYCOMB REPAIRS
IREFER TO CHAPTER 531

Figure
(Sheet
6 of
9)
5370-3-17
51-70-00
Page
0
Jun 3/88
NA-66-1032
COOING APPLIES TO SKINS ONLY
PRIMARY STRUCTURE
USE SHEARTYPE REPAIRS
NOTES
REFER
TO REPAIR
MATERIALS AND MATERIAL GAUGES. MEASURE THICKNESS OF CHEM-MILLED MATERIALS OR

APPLICABLE
DRAWINGS
FOR
REFER
SECONOARV STRUCTURE
REFER
TO 50-70-10 FOR REPAIRS
INDEXES IN CHAPTER 54 FOR
PRIMIIRYSTRUCTURE-SPECIAL CONOITIONS 00
NOT PERMIT USE OF
TO
THICKNESS
VARIATIONS.
TYPICAL REPAIRS
688~86
PRIMAAYSTAUCTUAEUSE HONEVCOMB TRAILING
FOR
NEGLIGIBLE
HOLE
REPAIR,
REFER
TO
EOGE REPAIRS
51-70-50.
MODEL NA 265-40, -60, -60A, -6000, AIJD -70 (S/N 370-2 7906 -6, -6, AND -9)
51-70-00
Page 8
Aug 17/84

Figure I (Sheet 7 of 9)
o
NA-66-1032
STRUCTUKAL KEPAIR MANUAL.
i.;..
;:;4
i
COO1N6 APPLIES TO SKIMS ONLY

PRIMARY STRUCTURE
USE SMEAR-TYPE REPAIRS
NOTES
REFER
TO REPAIR
SECONOARY STRUCTURE
REFER
INDEXES IN CHAPTER 54 FOR
MATERIALS AND MATERIAL GAUGES. MEASURE THICK-
PRIMAAY STRUCTURE
SPECIAL CONOITIOWS 00
)IOT PERMIT USE OF
TYPICAL REPAIRS
NESS OF CHEM-MILLED MATERIALS OR REFER TO

APPLICABLE
DRAWINGS
FOR
THICKNESS
VARIATIONS.
REFERTO DESIGN MECHANICAL PROPERTIESTABLES

FOR
NEGLIGIBLE
HOLE
bb~b8d
REPAIR.
REFER
PAIMARY STRUCTURE
USE HONEYCOMB TRAILIMG
TO
EOOE REPAIRS
51-70-50.
MODEL NA 265-65

1 (Sheet 8 of 9)
Figure
0
51-70-00
Page 9
Aug 17/84
ruA-66-1032
C0O1NC APPLIES TO SKINS ONLY
NOTES
REFER
TO
REPAIR
INDEXES
AND
MATERIAL
MATERIALS
THICKNESS OF
IN
USE SHEI\RTYPE REPAIRS
CHEM-MILLED
54
CHAPTER
GAUGES.
FOR
MEASURE
MATERIALS
SECONOARY STRUCTURE
REFER
OR
REFER TO APPLICABLE DRAWINGS FOR THICKNESS
PRIMARY STRUCTURE
VARIATIONS
SPECIAL COWOITIONS 00
NOT PERMIT USE OF
TYPICAL REPAIRS
:PP,,,~,,,
PRIIIAYgTIUETURL--
USE HOILYCOMB TRAILIWG

EOOE REPAIRS
MDDEL NA 265-70
51-70-00
page 10
Aug 17/84
(S/N
370-1 AND -7), -80, 80A, AND -8080

o
COFPYRIGHT, 1984 BY SABRELINER CORPORATION
NA-66-1032
DEVELOPING TYPICAL REPAIRS

REPAIR
STEPS IN DEVELOPING TYPICAL REPAIR
GENERAL
This portion of the section deals with repairing materials
in respect to the manner in which they are being used in
the airframe. The data presented is in keeping with the
"safe-life" conceptof structural design; that is, the ultimate
strength of the material is restored and stress concentrations are not in excess of those in the original design of the
part. In general, repairing the material means repairing
it in respect to its primary loading; i.e., shear or tension.
Primary loading is indicated in the typical repair index,
(Refer
to
1.
Items to Consider
The following general instructions are based on
repair of constant-thickness materials. Necessary
variations for repair of chem-milled materials are
covered in detailed repair examples.
A.
Determine if member to be repaired is a pri

or secondary structure. If member is a
primary structure, determine if principle loading
is shear or tension. To determine type of load.
refer to typical repair index. (Refer to figure i,
mary
figure 1, 51-70-00.)
TYPICAL REPAIR INDEX
51-70-00).
The typical repair index indicates those outer surface

areas of the airframe that are considered primary structure and those that are considered secondary structure.
For purposes here, all substructure must be considered as
primary structure. In addition, the index indicates the
primary (shear or tension) loads carried by the structure,
A reas which, because of peculiarities of design or function,
do not lend themselves to repair by general instructions
are
B.
DESIGN MECHANICAL PROPERTIES TABLES
factors that may dictate use of a substitute

material. For selection of a substitute material,
refer to paragraph 4, "Selecting Repair
are
Data relative to material design mechanical properties

was extracted from Metallic Materials and Elements for
Material.
Flight Vehicle Structures (MIL-HDBKd) and is presented

in simplified form. These tables provide the data necessary
for calculating material loss and material that must be
replaced due to damage,
C.
SYMBOLS USED
SYMBOL
EXPLANATION
Fbru
Area of cross section in square inches

Diameter
The minimum distance from a hole centerline to the edge of the sheet
Allowable stress
Ultimate bearing stress
F,,
Bearing yield stress

Compressive yield stress
F,,
F,
Ultimate shear stress

Ultimate tensile stress
ksi
Rips (1000 pounds)
Radius
Fastener spacing
Thickness
A
D
e
per square inch
Material
Determine material from which damaged member is made by consulting repair index for
applicable component. (Refer to Chapters 27,
and 51 through 57.)
It is mandatory that repair be at least equal in
strength to original part. Material selected for
repair should be of same alloy where possible.
Material availability and fabrication problems
also shown.
The following is a list of the symbols (with explanations)

used in typical repair development examples and accompanying tables.
Loading
2~
Fasteners
Select repair fasteners from strength of joints
tables. (See tables 206 thru 229, 51-70-30.)
Replace all removed fasteners with a like
fastener that will produce a joint equal to, or
stronger than, the original joint.
UseofTables
A.
Material Design Mechanical PropertiesTables

(See tables 201 thru 205, 51-70-30.)
Design mechanical properties tables give values

pounds per square in, of material for (1)
tension, expressed as F,,; (2) compression, expressed as Fcy ;(3)shear, expressed as Fsu; and
(4) bearing, expressed as either Fbru or Fbry
Some values shown are "yield" (y) stresses and
in
remainder
are
"ultimate" (u) stresses.
Developing repairs from data given in this

section does not require decisions as to selection
of ultimate or yield values so terms are not
explained.
51-70-10
0
Page 201
Aug 17/84
NA-66-1032
REPAIR (Continued)
2.
Use of
B.
(11
Tables(Contd)
MakingCalculations From Design Mechanical

Properties Tables
(area)
value of t, calcula-
0.040
(Ix t)
0.160 sq in,
Al(area)
Al
as
0.040
(Ilx t)
reproduced
in
figure
C.
Strength of joints tables give pounds-per-fasstrength allowable for a given fastener in

a specified material. In flush-head fastener
installations, flushing operation (countersunk
or dimple) affects joint strength, and instaltener
lations
are
treated in separate tables. Ultimate

are given in all cases.
strength values
D.
Making Calculations From Strength of Joint

Tables
When material and joint strength have been

determined and a fastener has been chosen,
strength of joint table for that particular material/fastener combination is found. With an
MS20426AD4 rivet selected for a countersunk
installation in 2024-13 bare material, find joint
allowable in figure 206, 51-70-30, which is
201.
partially reproduced in sheet 1 of figure 201.

(See "Example of Strength of Joint Tables.")
Joint allowable found for this combination is
309 pounds per fastener. Number of fasteners
required is found by dividing pounds-perfastener value into material/fastener joint
0.160x40,000 psi
64401bs
These calculations indicate that material/

fastener joint strength must equal 6440 Ibs
(minimum) on each I," or $-inch, sides of the
cutout.
Strength of Joints Tables (See figures 206 thru

229, 51-70-30)
F,, value of 0.040 2024-13 bare material is

40,000 psi. Use following formula to find shear
strength-in-pounds loss.
(Ilx t) F,, or
(4 x 0.040) 40,000 psi
40,000 psi
Material".
0.080 sq in.
Cross-sectional area of material loss is thus

determined. Second step in the calculations is
finding strength loss in Ibs (tension, compression, or shear, as applicable). This is done
by multiplying area by the appropriate Ibs per
square in, value from the applicable design
mechanical properties table. Assuming a rectangular trimmed-out damage (figure 201)
with dimensions given in previous paragraph
and assigning a material of 2024-13 bare material loaded in shear, shear strength loss land
strength that must be replaced) is found by
multiplying 1 x t and 11 x t by F,, value for the
material. F,,value for 2024-13 bare material is
found in figure 205, 51-70-30, a portion of which
is
Shear calculations were used in forelSoing example. Tension (Ft,), compression (Fcy), and
bearing (Fbru OP Fbry) calculations are performed in exactly same way; i.e., cross-sectional
area of material to be replaced is multiplied by
value in table for property in question. Instructions for use of design mechanical properties
tables for calculating material thickness
requirements, as in material substitution, are
given in paragraph 4, "Selecting Repair
Referring to "Calculating Material Loss" in

figure 201 and assigning 4 in. as value of i, 2 in.
and 0.040
0.080
Calculations for "11," or 2 in., sides indicate that

3220 pounds (minimum) is required in material/fastener joint strength for each of those
sides. (See "Repair Joint Strength Distribution," in figure 201.)
find cross-sectional area in square in, of the

material to be replaced. Figure 201 shows
method for calculating areas to be replaced in a
rectangular cutout in sheet metal,
11,
t) F,U or
x 0.040) 40,000 psi
3220 Ibs
Design mechanical properties tables give values

in pounds per square inch. The first step in
determining the requirements of a repair is to
as value of
tions are
(2
strength requirement,
(Ix t) F,,
(See figure 201, 51-70-20.)
Fastener allowable
or
number of fasteners required
51-%0-10
Page 202
Aug 17/84
COPYRIGHT, 1984 BY $ABRELINER CORPQRATION
NA-GCi-103~
REPAIR
2.
Use of Tables
(Continued)
D.
(Contd)
Making Calculations From Strength of Joint
E.
Tables
(Contd)
and fasteners are MS20426AD5 rivets. Installation is countersunk. Gauge required fol
repair material is found as follows:
Assuming a repair problem with material, type

of load, damage, and repair fastener as given in
this paragraph and in paragraph 2B above,
solving for number of fasteners required in
repair is as follows:
(4
0.040) 40,000
(2
0.040) 40,000
3220
_
309
309
3.
309
309
20.8
or
21 rivets
01
10.4
or
11 rivets
83,000 Ib
per sq in.
7075-T6 bare material
Ft,
83,000
76,000
76,000 Ib per
so in.
1.092(increase in
reqd)
thickness
Repair Fastener Distribution
Repair fastener distribution for skin and web repairs

is shown in figure 201, 51-70-20.
4.
7178-16 bare material
Ft,
6440
_
Using as an example a skin splice (figure 201)

involving a 0.050 in. 7178-T6 bare damaged
skin, splice material is 7075-T6 bare damaged
skin, splice material is 7075-T6 bare material
1.092
0.050
0.0546(thickness reyd)
A.
It is generally advisable to select a repair

material that matches material in damaged
member. When to do so is impracticable or
impossible, and a substitute material is to be
used, requirements below must be observed.
First standard gauge heavier than 0.0546 is 0.063

and is indicated as gauge to use at this point. Final
check for fastener joint strength shows the
MS20426AD5 rivets countersunk in 0.050 in.
7178-16 bare material good for 479 Ibs. Same
fastener countersunk in 0.063 in. 7075-T6 bare
material is good for 523 ]bs. Relative fastener joint
strengths show gauge of repair material found in
B.
In skin and web repairs, substitute repair

material must be equal to, or stronger than,
material to be repaired in shear and/or tension
and in bearing. When, gauffe-for-gauge, substitute material is weaker than material to be
repaired, gauge must be increased. amount of
increase necessary to satisfy shear and tension
requirements is found as follows:
tension calculations to be adequate as a splice

member. To check suitability of this gauge as a
splice doubler, protruding-head fastener allowable
must be referred to. An MS20470AD5 rivet is
identical to the MS20426 rivet in material and
hardness, andjointformed with it in repair material
is joint to be checked in this instance. Check reveals
MS20470AD5 rivet goad for 594 Ibs in 0.063 in.
7075-T6 bare material. Findings show this material
Selecting RepairMaterial
F,,
F,,,
or
or
and gauge to be adequate
Ft, (damaKed material)

F1, (rcpair m;llerial)
=increase in thickness
as a
splice doubler.
reqd
I)etermine bearing requirements from fasallowable tables. When a gauge is found

that satisfies shear and/or tension requirements, make a check to determine whether
C.
tener
repair
strong
fasteners to be used will

joint in repair material as
produce as
they will in
damaged material.
I~
Use additional fastener when decimal is 0.15
or
greater.
51-70-10
0
Page 208
aug 17/84
NA-66-1032
STRI.!CI~URAL REPAIR MANUAL
BARE
CONDITION
-73
.I
t
I
0.010 TO
0.149
~HICKNITSS (IN.)
11
III
MECHANICAL
PROPERTIES
F,, (1,i)
AREA OF SIOE
RREAOFSIDEII
""1""""
63
40
",x t
I, xl
Frv (ksi)
AREAS OF UNLETTEREO SIOES
-ti~---
EOUAL THE SIOE OPPOSITE
CALCULATING MATERIAL LOSS
Fbru (ksi)
elD
1.5
e/D
2.0
98
I
113 C
EXAMPLE OF DESIGN MECHANICAL PROPERTIES TABLE
REPAIR OOUBLER
6440 LB
1=4
3220
3220
LB
C,
Iri~
6440
=2
LB
LB;IJ~J
REPAIR JOINT STRENGTH iDISTRIBUTION

S285-3-77
51-70-10
PaRe 204
Aug 17/84
Developing
Typical Repair

o
1984 BY ~BRELINER CORPORATION
NA-6fi-1032
STRIJCTURAL REPAIR MANUAI,
2024-T42 CLAD
COUNTERSUNK
~I
ULTIMATE STRENGTH IN POUNDS

MSZ0426AD
RIVET
RIVET
(IN.)
3/32
1/8
SMELT
THICKNESS
[IN.)
t 32
163
0.025
156
221 1
0.032
178
272 1
0.040 1~
193
o.oso 1
206
0.020
. . . . .1. . . . . ~3.. . .
EXAMPLE OF STRENGTH OF JOINT TABLES
RIYET
MS2O425A85
COUNTERSUIIKITYP)
REPAIR DOOBLER
0.083 7875-78
BARE
DAMAGED SKIN
0.050 7178-75
BARE
+C+
II
.,+I
II
It t+
-t++l
II
!=ct
$~I
It
!1
TENSION
REPAIR SKIN
0.063 7075T8
SUBSTRUCTURE
(REFJ
BARE
SKIN SPLICE
NOTE
(I~
USE FOR ALL HIGHER STRENGTH ALUMINUM ALLOY
SHEET MATERIALS.
5265-3-78
Developing a Typical Repair

o
51-70-10
Page 205/206 Blank
Aug 17/84
NA-66-1032
STRUCTURAL REPAIR MANUAI~
REPAIR CALCULATIONS AND GENERAL REPAIR REQUIREMENTS

REPAIR
RASIC FASTENER CALCULATIONS
Figure 201 deals with the least complex of repairs and

explains basic formulas used in computing requirements
of repair. Only problems involved in repairing damage to
constant-thickness materials between ribs or frames are
treated. These problems are common to all repairs presented, and subsequent repair examples deal only with
problems involved in specific condition. Figure 201 is
referenced for fundamental information necessary for
calculating requirements of all special condition repairs.
GENERAL REPAIR CALCULATIONS

202 deals with selection of repair doubler
materials and gauges, fastener spacing, trim radii and
related data. Figure 202 is referenced on each repair
example, and data contained in this illustration is
applicable whenever specific instructions are not given in
Figure
example.
51-70-20
0
Page 201
Aug 17/84
NA-66-1032
FRIMEOA
SIMBOLS AND TERMS USED IN IHIS ILLUSTRATION
D
ale
(yypl
Diameter
Flu Ultimate
stress
of material
F,. Ultimate tensile
~-----TENslor
of mohriol
stress
design mechanicaI properties

Length of cut
(from
P
dtign mth.nic.I proprtier t~blsd
(from
le
tables)
It
I1
lidl
:I
1_
STRENGTH OF FASTENER AND INSTALLATION
JOINT ALLOWABLE
IN YLITERI*L TO ~C REPIIRED
(SELECTED)
(FROM STRENGTH
OF JOINTS
_I
7;1--REPIIIR BOUBLER
T*sLsS)
BASIC TENSION REPAIR CALCULATIONS
SECTION
No.of
(PXI)IU
on
Joint allowable
MATERIAL
each sheer side
sketchesl and
A-A
SKETCH t
(See
3.1
FRAME OR
(PIX
required
1555
and 3.1
No. of fasteners
t) FI,
on
Joint allowable
ale ITYP~
each tension side
sketches 1
ASSUMING MATERIAL AND TRIMMED-OUT DAMAGE TO BE AS GIVEN

IN SKETCH 2 AND REPAIR TO BE MADE WITH MS20428 ADS RIVETS,
DIMPLED, NUMBER OF FASTENERS REQUIRED WOULD BE FOUND AS
SMEAR SIDES--
14 x 0.0401
0.160 x 38,000
38,000
635
635
MNIO
635
9.57
or
10 rive),
L__
TENSION SIDES-282673 CLAO
0.080 x 58,000
58,000
(2 X 0.0401
0.040
(C
FOLLOWS:
SKETCH 2
635
635
B~J
SECTION
B-B
FRAMEOR
4640
635
7.3
or
8 rivets
ale
(TYP)
NOTES
THIS ILLUSTRATION PROVIDES BASIC INSTRUCTIONS
FOR CALCULATING AND DISTRIBUTING FASTENERS

REQUIRED FOR SKIN AND WEB REPAIRS.
e
ONLY REPAIRS INVOLVING CONSTANT THICKNESS

MATERIALS WITHIN SUBSTRUCTURE BAYS, ARE
COVERED HERE. INSTRUCTIONS FOR VARYING THESE
CALCULATIONS TO PROVIDE FOR REPAIR OF CHEMMILLED MATERIALS AND DAMAGE ACROSS SUB-
STRUCTURE ARE GIVEN SEPARATELY.

A
TENSION REPAIR WITH
(SKETCHES i. 2,
EXAMPLE
IN
AND
3)
IS
REPAIR
ROURLER
EXPLAINING
PRINCIPAL
USED AS
CALCULATION
PRO-
CEDURES AS BOTH TENSION AND SMEAR PROBLEMS

ARE INVOLVED
RECTANGULAR CUTOUT
SWEAR FASTEIERS
tEnION
lTYIl
FASTEIERS
(TYPJ
TENSION IN DIRECTION OF PRIMARY
52(15-3-18
SKETCH 3
LOAD AND SMEAR ON ADJACENT SIDES.
DETERMINATION AS TO WHETHER A SHEAR- OR A
NOTE
TENSION-TYPE REPAIR IS REOUIRED IS MADE BY

REFERRING TO "TYPICAL REPAIR INDEX."
REQU1RED FASTENERS ARE DISTRIBUTED AS SHOWN

IN SKETCH 3.
REFER TO "GENERAL REPAIR REQUIREMENTS" FOR

FASTENER SPACING.
REPAIR
Q-.UdE
DOUBLER REOUIRE-
MENTS, TRIM RADII. AND RELATED DATA
51-70-20
Page 202
Aug 17/84
ADDITIONAL
FASTENER
WHEN
DECIMAL IS 0.15 OR GREATER.
Blsic Fastener Cal~ulations and

Constant-thickness SIhin Repair
of 4)
Figure 201
o
GO~RI;GHT, 1984 BY ~ABRELINER CORPORATION
NA-66-1032
FRAME OR RIB
(TYP)
TENSION REPAIR (SKETCM 4)

Fastener calculations for
ore same a,
excep)
those
giv~n for
tension
a
repair with circular
rectangular
"D" is rubrti(ukd for P and
cutout
cutout
(sketch 1)
P1
1,1
let
tot
tot
Formula for solution Is:
(D X 1) F,.
No. of fasteners
L
Joint allowable
O"
(D X t) F~U
required
Bach shear side of repair
No. of fasteners
_
Joint allowable
Distribute fasteners
loll
lot
as
on
each tension
required
side of repair
I I
lol
Jol
lol
lol
TENSION
FASTENER
i
C~YVJrr
LL/
AA~A ITYPI
lol
!ol
shown in sketch.
o(
REPAIR
OOUBLER
SMEAR FASTENER
AREA
(TYPI
SECTION
CC
FASTENER PATTERN FOR TENSION REPAIR

CIRCULAR CUTOUT
BETWEEN FRAMES OR RIBS
SKETCH 4
I
SMEAR REPAIR (SKETCM 51
X t)
F,,
No. of fasteners
Joint allowable
()I Xt)Flu
No. of fasteners
Joint allowable
as
lol
I"
(OI
Calculate fastener requiremantr

for shear repairs (reckngular
cutout) os follows:
(P
SLe~
l,i
01
01
required
required
each side of
each side of
lip
(ol
a,
naaaat\
101
)t
lol
FASTENER
P-dil8F~
REOB
FOR
lolI
"P1
P1[TYPI
01
FASTENER REOD
FOR
to
I(TYP)
lo
shown in rketch.
SECTION
D-D
FASTENER PATTERN FOR SMEAR REPAIR BETWEEN

FRAMES OR RIBS
RECTANGULAR CUTOUT
SKETCH 5
FRAME OR RIB
Eel
ITYP)
117to
SMEAR REPAIR (SKETCM 6)
lol
Calculate fastener requirementr far shear repairs (circular Eutout) at followr:

(D x tI F,,
Joint allowable
No. of fasteners
required
on
each
ITYPI
(o!
\C~\~90%;
(0)I:(
(4) side of repair.
101
as
-lol
FASTENER REOO FOR
ONE SIOE OF REPAIR
I,
lot
lol
shown in sketch.
I\
//lt
REPAIR BOUBLER
o(
oJ
Il~tlslt
CONFIGURATION
LINE OIVIOES
REPAIR FOR
FOR REPAIR
OOUBLER
FASTENER
-s,~,,
OISTRIBUTION[TYP)
FASTENER PATTERN FOR SMEAR REPAIR BETWEEN
FRAMES OR RIBS
CIRCULAR CUTOUT
SKETCH 6
Basic Fastener Calculations and
Constant-thickness Skin Repair
0
j
E-E
5265-3-80
51-70-20
Page 203
Aug. 17/84
NA-66-1032
SIHII("IU RA, REIA I Ii MANIIAL
SUBSTRUCTURE
REPAIR
ITYPI
Ft(
lo
or
IOIIOI
lo
135
10
T10io el$i
_i
e!
lo
lolle
ololle(e
ol
io
a
a
..n,,F-F
FASTENER PATTERN FOR A CORNER REPAI.R
SMEAR OR TEWSIOW
SKETCH 7
)1
REPIIA
OOUBLER
G+1
;II!
I ollo
lo
VARIATIONS. OF RECTANGULAR
SMEAR OR TENSION
REPAIR
(SKETCHES
7 AND
8)
IOil"i
I o II i
lo a
or cornerer
for(inding lastener
edge repairs are same as for other rectangular
repairs. Replacement fasteners in substructure must be
equal to. or stronger than, those removed.
Caiculations
lo
Oistribule fasteners as shown in referenced sketches.
10
I"ll"i
loIlol
G+I
o~ o
FASTENER PATTERN FOR AN

SMEAR OR
EOOE REPAIR
TENSION
SKETCH 8
SECTION
G-G
snes-1-sl
Basic astener Calculations and
51-70-20
Page 204
Aug 17/84
Figure
201
o
(Sheet 3 of 4)
COPYRIQHT, 1984
NA-66-1032
OAMACEO SKIN
FASTENER THRU SKIN,
SPLICE OOUBLER ANB

COUNT
SUBSTRUCTURE
AS REPAIR FASTENER
or~j
(TYP)
--I
SUBSTRUCTURE
I ,I
ITYP)
lol
i~
~oTolo
Q:---ll~f)j
Is
lo
SPLICE OOUBLER
ol
REPAIR
SKIN OR
WEB
or
(SPLICEI 8KIN
10)
0)
Li,iii::ii-iiiri:-
Calculations for finding fastener requirements for skin and web

splicer are at follows:
t)F,,
or
to
SPLICE--SHLAR OR TENSION
(SKETCHES 9 AND
(IX
II
FIU
Joint allowable
L o~
No. of fasteners required each side of flush

splice or number required thru overlap in
o
O
li:iiilii:iii:iii-
O L O J O
O
overlap splice.
through r~inl, aplte d.ublsr, .nd.ubahuaure in

through skin overlap area and subJtrucoverlap rplice, may be counted among the fasteners
Fa,ensrr
H-H
flush repair, and

ture in
required
for
SMEAR OR TENSION
FLUSH SKIN OR WEB SPLICE
SKETCH 9
splice.
as
shown in referenced sketches.
6+1
O
O
o
-I
oro~o
o
I
SUBSTRUCTURE ITYPJ
iii
O(
101
FASTENER
NIKSURHT
OV~RLAP
O
~uo suesnuc
::=,1~
TENER
I,
ol
REPAIR
I.
(SPLICE) SKIN
---i I:
Ig-l-J
[i-i:l::----__--ili_- i_::ii-:i:i_t
OAMAGED 8KIN
OVERLAP SKIW OR WEB SPLICE

-SHEAR OR TENSION
SKETCH 10
Basic Fastener Calculations and
o
iol
;i;l
(TYPI
O
o
OL-OJO
y o
SECTION
JJ
5265-3-82
51-70-20
Page 205
Aug 17/84
NA-66-1032
STRUC~TURAL REPAIR MANUAL
DOVIIW
-7
(e FASTENER
DAMAGED
STAGGERED ROW
SPACING
A+I
SPACING
--1
r--, Tt
MATERIAL
++t++
SYMBOLS USED IN THIS ILLUSTRATION
D-Diameter lof fastener)
FILLER
e--hninimum distance from
I.adge
1_+
r-Rcldiur
-t
L---
1--hnaterial thickness
_r_
+_
,_
_I
11--Repair doubler thickness

IMIKM
A-A
SKETCH 1
SPACING--Spacing for fasteners carrying tension

loads(skin) shall not be less than spacing of nearest adiacent existing row. Minimum spacing for fasteners carrying
shear loads (skin) is 5.50. Maximum spacing for all fasteners
FASTENER
OTHEII
is 1.5 inches.
FASTENER ROW SPACING--Fastener row spacing (uniform and

staggered) is determined by minimum and maximum fclstener
I-
rpaeing.Protuding
e=20, with following exception:

head fasteners may be installed at 1.50, when
it ba~od
necessary, by reducing joint allowable (~hich
20) in direct proportion to ultimate bearing stress (Fb,l
of the material. (See example with sketch 2.)
1.SD
on
REPAIR
same
DOUBLER--Generally, repair doubler should be of

alloy and heat treat as materiol being repaired
2D (TYPI
with tl one gauge heavier than t. (Refer to "Old Standard"

from "Standard Sheet Metal ThicknesseJ.") When doubler material differs From material being repaired (as when CRES is
used for minimum thickness), it must meet following
conditions:
(II In tention-- F,U (doubler) x t (doubler)X width (doubler)
F~, (skin)X t (zkin) XI (skin). (2) In shear- F,,(doubler)X t
(doubler)X width (doublerl
F,, (skin)X t (skin) XP (skin).
(3) Joint allowable (for the selected fastener in doubler
material) must be ecuual to, or greater than, allowable for
material
I ___1
tff
$_
being repaired.
Fatteners
See theet 2.
e/D
bru~
1.5
2.0
51-70-20
Page 206
Aug 17/84
Fastener
e/D
allowable,
2.0
OTHERI WEB
affected by
Example: Substituting
CALCULATING JOINT ALLOWABLE FOR e/D=1.5 FASTENER

(See sketch 2.)
e/D
BHD (OR
SKETCH 2
inches.
Fbru,
REPAIR
DOUBLER ----I
material within
alloy family of surrounding material. Filler thickness
is equal to t. Filler may be attached to repair doubler
with any structural fastener, spaced at not more than 1.5
FILLER--A nonstructural filler may be of any
COUNTERSINKING
Fastener
e/D
short 11.5)
edge distance.
the allowables for MSZ0470A0J

aly theet
rivet in 0.050 7075-76 bare al
allowable,
1.5
116,000 psi
146,000 psi
X 594 Ib
470 Ib
5265-3-83

FiRure 202 (8heet 1 of 2)
o
NA-66-1032
CONVENTIONAL RIVETS
MIN
RIVET
DIA
THICKNESS
MIN
FOR COUNTERSINK
(ON A58Y)
THICKNESS FOR
COUNTERSINK
DIA
SUBCOUNTERSINK
3/32
SUBCOUNIERSINK
DIA
0.040
0.179
0.184
1/8
0.050
0.225
0.235
5/32
0.063
0. 286
0.296
3/16
0.080
0.353
0.367
1/4
0.100
0.476
0.498
NAS1097 AND
MIN
RIVET
DIL\
FOR
(ON
HS47 HI-SMEAR RIVETS
THICKNESS
(AS APPLICABLE)
MIN
COUNTERSINK
THICKNESS FOR
SUBCOUNTLRSINK
COUNTERSINK
SUBCOUNTERSINK
DIA
DIA
ASSr)
1/8
Ca
0.040
0.179
0.184
5/32
0.050
0.225
0.235
3/16
Ijl
0.063
0.299
0.300
1/4
0.072
0.392
0.390
5/16
0.080
0.471
0.477
SCREWS
MIN
No.
THICKNESS
THICKNESS FOR
IUICOUNTIRSI.Y
M1N
IIZt
SCRrw
[il
10
COUNTERSINK
SUBCOUNTERSINK
DIaO
~laO
0.090
0.378
0.395
0.125
0.499
0.520
1/4
5/16
0.160
0.626
0.645
5265-3-84
NOTES
DIMENSIONS IN INCHES UNLESS OTHERWISE NOTED.
OUSE
MINIMUM THICKNESS
FROM
APPLICABLE
STRENGTH OF JOINTS TABLE.
FOR 7S39 SCREW, USE DIMENSIONS GIVEN FOR HISMEAR RIVETS.

0
51-70-20
Page 207/208 Blank
Aug 17/84
NA-66-1032
STRUCTURAL, REPAIR MANUA1,
MATERIAL DESIGN MECHANICAL PROPERTIES AND

STRENGTH OF JOINTS TABLES
REPAIR
Material design mechanical properties tables and

strength of joint tables are presented in tables 201 thru
229. Table titles
are
216
202
203
204
205
217
TITLE
TABLE
Design Mechanical
Aluminum Alloy
214
215
listed below.
MATERIAL DESIGN MECHANICAL

PROPERTIES
201
Properties of
2024
218
Design Mechanical Properties of 7075

Aluminum Alloy
Design Mechanical Properties of 7178
Aluminum Alloy
Design Mechanical Properties of Alloy Steels
Design Mechanical Properties of AISI 301
CRES Sheet and Strip
219
220
221
STRENGTH OF JOINTS
TABLE
TITLE
206
Strength of Joints MS20426 Rivets in 2024T42 Clad land Higher Strength) Aluminum
Alloy Sheets
MS20426 Rivets in 7075Strength of Joints
T6 Clad land Higher Strength) Aluminum
Alloy Sheets
MS20470 Rivets in 2024,
Strength of Joints
7075, and 7178 Aluminum Alloy Sheets
Strength of Joints NAS1097 Rivets in 2024T3 Bare land Higher Strength) Aluminum
Alloy Sheets)
NAS1097 Rivets in 7178Strength of Joints
T6 Bare Aluminum Alloy Sheet
HS47 Hi-Shear Rivets,
Strength of Joints
207
208
209
210
211
212
and 7336, 7537, and 7339 Screws in 2024-14

Clad land Higher Strength) Aluminum Alloy
Sheets
HS47 Hi-Shear Rivets,
Strength of Joints
and 7836, 7837, and 7839 Screws in 7075-16
Clad land Higher Strength) Aluminum Alloy
222
223
224
225
226
227
228
Sheets
213
TITLE
TABLE
GENERAL
Protruding-head Steel
Fasteners in 2024-T42 Aluminum Alloy Sheet
Strength of Joints
229
Strength of Joints
Strength of Joints
Fasteners in 7075-16 Aluminum Alloy Sheet
Strength of Joints
Fasteners in 7178-16 Aluminum Allay Sheet
MS20601 and MS20603
Strength of Joints
(Blind) Rivets in 2024-T3 Clad land Higher
Strength) Aluminum Alloy Sheets
MS20600 and MS20602
Strength of Joints
(Blind) Rivets in 2024-T4 Clad land Higher
Strength) Aluminum Alloy Sheets
CR2248 (Blind) Rivets in
Strength of Joints
2024-T42 Clad land Higher Strength)
CR284Y (Rlind) Rivets i n
Strength of Joints
Huck CKL 100V (Blind)
Strength of Joints
Rivets in 2024-14 Clad land Higher Strength)
Aluminum Allay Sheets
NAS1398B (CR2263)
Strength of Joints
and NAS1399B (CR2262) (Blind) Rivets in
F Series Jo-bolts (Blind)
Strength of Joints
in 2024-14 Clad land Bare) Aluminum Alloy
Sheet and Plate
Strength of Joints
in 2024-T3 Clad land Bare) Aluminum Alloy
Sheet and Plate
Strength of Joints
in 7075-T6 Clad land Higher Strength)
Aluminum Alloy Sheet and Plate
FA Series Jo-bolts
Strength of Joints
(Blind) in 2024-13 Clad land Rare) Aluminum
Alloy Sheet and Plate
FA Series Jo-bolts
Strength of Joints
(Blind) in 7075-T6 Clad land Higher
Strength) Aluminum Alloy Sheet and Plate
P Series Jo-bolts (Blind)
Strength of Joints
in 2024-T4 Clad land Higher Strength)
Aluminum Alloy Sheet and Plate
Strength of Joints
51-70-30
0
Page 201
Aug 17/84
NA-66-1032
Table 201.
Design 1Mechanical Properties Of 2024 Aluminum Alloy

8A8E
CONDITION
THICKNESS
(IN.)
-73
-74
-142
0.010 TO
0.249
0.250 tO
0.500
UNDER
0.250
MECHANICAL
PROPERIIES
F,, (Lii)
63
60
60
(I(Il)
40
38
40
F,, (~ii)
40
40
37
Cb,u (k~i)
o/D
1.5
e/D
2.0
98
.......118
96
84
111
94
Fbrv (k,i)
do
1.5
69
64
56
do
2.0
79
74
64
CLAD
CONDITION
-73
-14
0.010 TO
0.063
0.064 tO
0.249
F,, (Lli)
58
60
F,r (k~i)
37
F,, (kri)
THICKNESS
(IN.)
-142
0.15010
0.499
0.008 TO
0.061
0.063 tO
0.149
60
51
54
38
38
34
36
38
40
40
34
35
90
95
95
72
75
111
111
81
87
64-
64
48
50
74
74
54
58
MECHANICAL
PROPERTIES
FbN (k,i)
~/D
1.5
e/D= 2.0
e/D
1.5
o/D
2.0
109
64
73
5170-30
Page 202
Aug 17/84
5265385
COPYRIGHT, 1984
BV SABRELINER CORPORATION
NA-66-1032
STRUCTURAL REPAIR MANI!AL
Table ~02.
Design Mechanical Properties ot 7075 Aluminum Alloy

CLAD
8A8L
THICKNESS
(IN.)
0.015 TO
0.039
0.04010
0.250 TO
0.249
0.500
0.015 TO
0.039
0.040 TO
0.061
0.063 TO
0.187
MEEWANICAL
PROPERIIES
F,, (kri)
1(1
(LIi)
76
77
77
70
72
73
67
68
69
62
64
65
46
46
46
42
43
44
Fbn, (kIi)
~/D
1.5
114
116
108
105
108
110
a/D
1.0
144
146
199
133
137
139
94
87
85
88
90
107
100
98
101
101
Fbrv (kli)
/D
1.5
92
s/D
2.0
106
5265-386
51-70-30
0
Page 203
Aug 17/84
NA-6fi-1032
SIRuCTURAL REPAIR MANUAL
Design Mechanical Prbperties Of 7178 Aluminum Alloy
Table 2113.
8I8E
CLAD
0.015 TO
0.045 TO
0.044
0.149
F,, (kri)
83
84
F,y (kii)
73
74
74
50
50
THICKNESS
(IN.)
0.250 TO
0.499
0.015 fO
0.044
0.045 TO
76
78
0.249
0.250 tO
0.499
MECHANICAL
PROPERtllS
F,, (kri)
50
84
67
45
78
69
47
47
114
117
109
144
148
140
96
90
110
104
Fbru (kzi)
h/D
1.5
........124
126
e/D
2.0
158
"160
e/D
1.5
101
104
e/D
2.0
117
118
Fby
118
151
(kIi)
96
111
94
107
5265-3-87
51-70-30
Page
204
Aug 17/84
CO~RIGHT, 1984 BY SABRELINER CORPORATION
NA-66-1032
Table 2114.
Design Mechanical Properties oi Alloy Steels

4130, 4140, 4340, 8630, 8740, 81830, AND 988\140
ALLOI
FORM
ALL WROUOHT FORMS
THICKNESS
HEAT-TREATED (QUENCHED AND

TO O8fAIN THE FI, INDICATED
Nm
CONDITION
I
I
0.188
AND
GREATER
(IN.)
TEMPERED)
LESS
THAN
0.188
MECHANICAL
PROPERTIES
90I
F,, (kIi)
95
)1 25 .1........ 150 ........1........ 1 (O.........1.......
75
t 113 tl 45 11 79 1 198
F,y (kIi)
70
F,, (kIi)
55
1 55
82
t 95
109
200
1.. 160 O
242
1 119 tl 49
Fbn, (kri)
do
1.5
e/D
2.0
Fby
140
140
194
219
250
272
251
1 287t
326
351
230
347
440
312
(ki)
alD
1.5
E ) 1
151
e/D
20
1" " "C" " " " " " t" "
189
BO) 218
.....t........
256t
255
280) 346
NOTES
THIS VALUE
IS APPLICABLE WHEN MATERIAL IS
FURNISHED
IN
CONDITION
MILITARY SPECIFICATION.
OF APPLICABLE
YIELD STRENGTH
5265-3-88
APPLICABLE TO 4340 AND 988\/40 ONLY. ALLOY 4340
SHOULD NOT BE USED BETWEEN 220 AND 260 kis
IS
APPRECIABLY REDUCED WHEN NORMALIZED BY
USEA.
51-70-30
Page 205
Aug 17/(34
NA-6fi-1032
STKII(1URAI, HEPAIRMANUAI~
Tahle 205.
Desiffn Mechanical Properties Of AISI 301 CRES Sheet and Strip

COLD ROLLED
THICKNESS
1/4 H
ANNEALED
CONDITION
(IN.)
TO 0.188
1/2 H
3/4
FULL H
TO 0.188
rO 0.188
TO 0.188
TO 0.188
112
150
175
185
76
85
MECHANICAL
PROPERTIES
F,, (k~i) ~45
F,y (kIi)
35
43
58
F,, (kri)
40
67
80
95
100
Fbru (kri)
e/D
~/D
2.0
2.0
75
50
210
300
140
200
350
240
370
270
5265-3-90
51-70-39
Paffe 206
Aua 17/84
COPYRIGHT, 1984 BYSABRELINER CORPORAflON
NA-66-1032
Table 206.
Strength of Joints
M 520426 Rivets in 2024-T42 C lad
DIMPLED--2024-T42
land Higher Strength) Aluminum Alloy Sheet
CLADlfl
ULTIMATE STRENGTH IN ROUNDS
RIVET DIA (IN.)
SHEET THICKNESS
MS20426D0
MS20426AD
RIVET
3/32
1/8
5/32
1/14
3/16
3/16
(IN.)
0.016
177
0.020
.209
299
0.025
235
360
0.031
257
413
568"""
722
451......
635
839
0.040
273
484
0.050
474
693
736
0.063
755
0.071
0.081
940
.......1012
941
879
1359
1110
1236
1727
1045
1291
1883
1074
.........1340
2025
1382
2150
..1098
0.090
744
2255
0.100
5265-3-91
NOTES
ALLOWABLES APPLY TO DOUBLE DIMPLED SHEETS
AND TO UPPER SHEET DIMPLED INTO A MACHINE-
COUNTERSUNK LOWER SHEET. SHEET GAUGE IS

THAT OF THINNEST SHEET FOR DOUBLE DIMPLED
JOINTS AND OF UPPER DIMPLE SHEET FOR DIMPLED,
MACHINE-COUNTERSUNK JOINTS. THICKNESS OF
MACHINE-COUNTERSUNK SHEET MUST BE AT LEAST

ONE TABULATED GAUGE THICKER THAN UPPER
SHEET.
O)

SHEET MATERIAL.S
51-70-30
0
Page 207
Aug 17/84
NA-66-1032
STRII(:TITRAL REPAIR MANUAL
rahl~, dOti.
M820426 Rivets in 2024-T42 Clad land Hiffher LStrenffth)

Stlenffth of doints
Aluminum Alloy Sheet (Contd)
COUNTEISUNK
20241142 CLAD
ULIIMMT JTRENGTHIN POUND)

MS20426A0
RIVET
RIVET
(IN.)
3/32
1/8
0.020
132
163
0.025
156
0.032
17e t
SHEET THICKNESS
MS20426DD
5/32
3/16
3/16
IIN.)
221
165
272
300
0.040
193
309
397
0.050"""
206
340"""
481
583
0.063
216
363
523
105
373
542
0.071
306
409
0.080
560
769
0.090
575
795
543
75~
#6
891
1116
942
1353
992
1473
1035
1579
0.100
818
1073
1672
0.125
853
1131
18n
0.160
2000
0.190
20(14
Shcl~
117
388
546
862
1180
2120
5165-3-91
NOTES
SHEET GAUGE IS THAT OF COUNTERSUNK SHEET. IN
CASES WHERE LOWER SHEET
IS THINNER
THAN
UPPER, SMEAR-BEARING ALLOWABLE FOR LOWER

SHE ET-RIVET COMBINATION SHOULD BE COMPUTED.
SHEET MATERIALS.
5170-30
Page 208
A,ug 17/84
COPIRIGHT, 1984 BY SABRELINER CORPORATION-
NA-6t;-103~
REPAIR MANIIAI,
Table 207.
Strength of Joints
M520426 Rivets in 7075-T6 Clad
DIMPLED--7075-16
land Higher Strength) Aluminum Alloy Sheet
CLI\D~
RIVET DIA (IN.)
MS1042600
MS20~126AD
RIVET
1/8
3/16
5/32
3/16
5/32
SHEET THICKNESS IIN.)

0.020
301
0.025
383
0.032
454
568
725
786
0.040
505
635
891
982
0.050
548
693
1036
1152
1705
0.063
736
1142
1277
2010
0.071
755
1332
2150
474
1190
1300
0.080
..""1230
1380
2260
0.090
1267
1424
2365
2455
0.100
S265-392
NOTES
9
ALLOWABLES APPLY TO DOUBLE DIMPLED SHEETS

AND TO UPPER SHEET DIMPLED INTO A MACHINE-
COUNTERSUNK LOWER SHEET. SHEET GAUGE
IS
THAT OF THINNEST SHEET FOR DOUBLE DIMPLED

JOINTS AND OF UPPER DIMPLE SHEET FOR DIMPLED,
MACHINE-COUNTERSUNK JOINTS. THICKNESS OF
MACHINE-COUNTERSUNK SHEET MUST BE AT LEAST

ONE TABULATED GAUGE THICKER THAN UPPER
SHEET.
I~

SHEET MATERIALS.
51-70-30
0
Page 209
Aug 17/84
NA-66-1032
Tablt BQ7.
MS20426 Rivets in 7075-TG Clad land Higher Strength)

Stlength of Joints
Aluminum Alloy Sheet (Cantd)
COUNTERSUNK--7075-t6 CLdD
ULTIMATE
RIVET
RIVET DIA
STRENOtH,IN POUNDS
MSZ0426AD
3/32
(IN.)
MJ2W26DD
1/8
5/92
3/16
3/16
SHEET THICKNESS (IN.I
0.020
132
147
0.025
156
121
165
0.032
178
272
300
0.040
193
309
397
0.050
206
340
479
0.063
216
363
523
373
0.071
306
409
543
gg3
75~
891
705
886
:1216
739
942
...1353
1473
0.080
560
769
992
0.090
.575
795
1035
1579
0.100
818
1073
1671
0.125
853
1131
..1877
0.160
2000
0.190
20114
Shear
217
388
862
r"""
1180
1110
5265-3-82
NOTES
SHEET GAUGE IS THAT OF COUNTERSUNK SHEET. IN
CASES WHERE LOWER SHEET IS THINNER THAN
UPPER. SMEAR-BEARING ALLOWABLE FOR LOWER

SHEET-RIVET COMBINATION SHOULD BE COMPUTED.

SHEET MATERIALS.
51-70-39
I-.aRe 210
A~ff 17/84
NA-66-1032
STRUCTURAI, REPAIR MANCAL
Aluminum
StrenRth of Joints
Table 208.
I
1
SHEET THICKNESS
(IN.1
1263
MS10470AD
RIVET
RIVET DIA
3/16
3/32
1/8
(IN.)
RIVET DIA
(MS10470DD I
MS/OI)IOAD
(IN.)
1/8
5/32
210
263
3/16
SHEET THICKNESS
(IN.)
0.020
0.020
...1. . . . 210
0.025
.....1........ 3511374
0.025
1......
260
1 322
389
0.032
374
.C 551
0.032
1..
333
1 412
508
0.040
386
0.040
386
1 515t....."
619
0.050
388
1 594 ...1......" 774
575
0.050
C388 1 594
0.063
I TC....
1
0.071
596
837
1046
........(......11 80
0063
).T. . . . t. . . .
0.071
tI1
0.090
1 1047
1;1
sis I ds I1 ~so
0.125
1180
t
RIVET DIA (IN.)
SHEET THICKNESS
(IN.)
I MSZ0470DD I
MS20470AD
S/JZ
1/8
RIVET DIA (IN.)
3/16
SHEET THICKNESS
(IN.)
0.020
1 294 1........ 339(4022
0.025
357
455
548
0.032
374
1551
777
0.040
C 386 1 575 11 047
0.050
0.063
........C......
1 147
1
1
0.025
357
1 45515488
0.032
1 3741551 t 777
0040
386
0.050
..1....
388
..)......"596 111 80
0.063
0.071
ooso
0.090
oloo
0125
0.090
0.100
C3bB
C 5b6 11 11~0
5/32
294
o.oso
1/8
0.020
0.071
lMS20470DD
MS20470AD
RIVET
ass C 5 94
tl 80
7178-76 CLAD (AND 7178-16 BARE)
596
388
0.125
1015-76 CLAD ~AND 2025-16 BARE)
RIVET
1098
0.090o.loo
0.100
0.1 25
596
0.080
0.OsO
5265-393
Sheet
2024-742 CLAD (AND 2024-742 BARE)
2024-73 CLAD (AND 2024-73 BAREI
RIVET
Alloy
1 575 11 047
t 594
1 147
....596
(11 80
t 388t
596
1 180
51-70-30
Page 211
Aug 17/84
NA-66-1032
SrRUCTURAL REPAIR MANUAL
Table 209.
Strength of Joints
NAS1097 Rivets in 2024-T3 Bare land Higher Strength) Aluminum Alloy Sheet
COUNTEERUNK-2024-r3
BAREO
ULTIMATE STRENGTH ~N POUNDS
RIVET
RIVET
DIA
NASI 09760
1IN.)
1/8
NAS1 09700
5/32
3/16
SHEET THICKNESS
(IN.)
0.032
290
0.040
310
390
0.050
335
440
0.060
680~
810
5265-3-94
NOTES

SHEET MATERIALS.
VALUE APPLIES WHEN
LOWER SHEET IS 0.032 IN.
OR GREATER. USE 600 LBS WHEN SECOND SHEET IS

0.025 IN.
51170130
Page 212
Aug 17/84
COPYRIGHT,
NA-66-1 032
Table E10.
Strenglt~_of Joints
NAS1097 Rivets in 7178-T6 Bare Aluminum Alloy Sheets

COUNTERSUNI<--71 78-76 BARE
ULTIMATE STRENGTH
(IN.)
POUNDS
NAS109700
NAS1097AD
RIVET
RIVET DIA
IN
1/8
5/31
3/16
SHEET THICKNESS
(IN.)
0.025
265
0.032
345
0.040
390
0.050
0.060
475
680
810
5265395
51-70-30
a
Paffe 213
Aug 17/84
NA-CiG-1032
SI~RUCTURAI, REPAIH MANUAL
Table 211.
HS47 Hi-Shear Rivets, and 7S36, 7537, and 7839 Screws in 2024-T4 Clad land
Strenefth of Joints
Hiffher Strength) Aluminum Alloy Sheet
ILUSH HLAD--2024-T4 CLAD
ULTIMATE STRENGTFI IN POUNDS
FASTENER
CIS47 ~I-SCIEAR RIVETS:
INSTALLA~ION
SHEET TCIICKNESS
(IN.)
7536,7537,
AND
DIMPLED AND
SUBCOUNTERSUNK
COUNTERSUNK
HS41-6
7539 SCREWS
HS41-8
HS47-10
HS47-6
0.032
HS47-8
HS41 IO
645
0.040
820
0.050
822
0.063
1047
1369
0.071
1191
1570
1875
0.080
1350
1782
2168
0.090
1515
2000
0.100
1695
0.125
2080
0.160
2648
0.190
1078
1027
1350
1691
1306
1734
2126
1474
1953
2415
1662
2200
2354
2500
2484
3087
2250
2763
2065
2768
3459
2812
3490
2439
3481
4341
3540
4500
4182
5291
5265-3-96
NOTE
IISF;
OH ALL HIGHEH STRENGTH ALUMINUM ALLOY
SHEETS
51-70-30
Page 214
Aug 17/84
COPYRIGHT, 1984 BY SABRELINER CORPORATtON
NA-66-1032
STKUCTURAL KEPAIR MANI~AL
Table 212.
Strength of Joints
HS47 Hi-Shear Rivets, and 7S36, 7837, and 7839 Screws in 7075-T6 Clad
land
Higher Strength) Aluminum Alloy Sheet

FLUSH HEAD--1075-T6 CLAD
ULTIMATE STRENGTH
IN POUNDS
HS41 HI-SMEAR RIVET; 7536, 7537, AND 7539 SCREWS
FASTENER
DIMPUD AND
COUNTERSUNK
INSTALLATION
SHEET THICKNESS
(IN.)
HS47-6
HS41-8
SUBCOUNTERSUNK
HS47-~0
0.040
0.050
1080
0.063
1380
1800
0.071
1575
21
2400
0.080
1770
2400
2775
0.100
HS47-8
HS47-10
801
0.032
0.090
HS47-6
2010
2700
2220
0.125
3900
0.160
4600
1006
1344
1260
1672
2107
1592
2113
2622
1853
2388
2965
2033
2700
3357
2295
3038
3798
3381
4134
3660
2549
4675
2895
250
5291
5950
6750
0.190
52653-97
NOTE

SHEETS.
51-70-30
0
Page 215
Aug 17/84
NA-Gfi-1032
SIHII(TIIKAL IIEPAIH MANIIAI,
Tal,le 213.
Strength of,loints
Protruding-head Steel Fasteners in
2024-T42 Aluminum
Alloy Sheet
STEEL BOLTS AND HI-SMEAR RIVETS IN 2024-742 SHEET
FASTENER
DIA
BARE
SHEET
THICKNESS
(IN.)
FASTENER
3/16
(IN.)
I
I
I
0.03411613
1/4
CLAD
BARE
DIA
CLAD
BARE
1/4
3/16
(IN.)
CLAD
BARE
I
I
I
I
I
I
I
I
I
I
SHEET
I THICKNESS
I
(IN.)
0.056
0.057
1026
0.058
1044
11062 1-I
1416
.I(
Iqqg
0.035
630
0.036
648
0.037
1 666
0.038
)684
0.039
702
0.040
720
547
.~608
1. .. I..
1368
0.059
0.060
0.061~11097 )I
1464
0.061(11
1488
0.063
~1133 C1027 11512 I13f0
10BO
15
C)
738
0.0421
756
0.064
(II
1536
0.043
774
0.065
)I~
1560
0.044
192
0.066
0.045
""t 811
0.067
CII
1608
0.046
829
t1
1104
0.068
tI~
1632
0.047
848
1I
1128
0.069
1 ) I
1656
0.048
866
t1
1152
0.070
0.049
884
1)
1176
0.071
~(I
0.050
902
.......1....................~.....
1200
0.072
0.051
920
t1
1 224
0.073
0.052
938
)f
1248
0.074
0.075
0.076
0.054
648
955
973
CLAD
1009
0.041
0053
)1012
1172
1 t
1296
1584
1704
I1I
11544
1 752
(C(
1776
;1I)
1824
0.055 1991 111320
5265398
51-70-30
Page 216
Aug 17/84
NA-66-1032
Protruding-head Steel Fasteners in 2024-T4 Aluminum Alloy Sheet
Strength of Joints
Table 214.
FASTENER
FASTENER
DIA
1/4
3/16
(IN.)
BARE
SHEET
THICKNESS
I
I
CLAD
BARE
DIA
CLAD
BARE
0.056
t....
1009
1)
0.057
1016
BARE
CLAD
CLAD
SHEET
I
(THICKNESS
I
I
(IN.)
0.0341
0.035
613
630
1.....
0.036
1
597
648
0.037
666
0.038
......C..... 684
0.039
702
0.040
1.....
720
/664
0.059
1062
1080
o.o~ll
0.0611
1115
1488
0.063
1133
11080 11512
756
774
792
0.066
0.067
811
748
829
)t
1104
0.068
0.047
848
1(
1128
0.069
866
)1
1152
0.070
1176
0.071
0.072
0.049
884
1C
o.oso
902
o.osll
920
C~
1224
0.073
0.052
938
)1
1248
0.074
1209
1441
0.065
1.
832
1440
0.064
0.046
o.ose
11
1416
0.060
0.045
1-.
1.... 1368
0.044
1344
1044
0.058
0.041~ 738
0.043
t1106
0.053
955
C~
1272
0.075
0.054
......t..-
973
1t
1296
0.076
0.055
991
5265-3-99
(IN.)
0.042
1/4
3/16
(IN.)
tI..-
....1...............""I""
1624
51-70-30
Page 217
Aug 17/84
NA-66-1032
Strength of Joints
Table 215.
in 2024-T3 Aluminum
Alloy Sheet
STEEL 110175 AND HI-SMEAR RIYETS IN 2024-T3 SHEET
FASTENER
DIA
3/16
(IN.)
SHEET
CLAD
BARE
FASTENER
1/4
I
BARE
olA
CLAD
3/16
(IN.)
I
BARE
CLAD
1/i
BARE
TWICKNESS I
I THICKNESS
(IN.)
757
0.056
0.035 1 777
0.097
1267 1~
1689
0.058
1289
1~
1718
1I
1748
(IN.)
0.0341~
1245
800
0.037
822
0.059 1 1311
0.038
844
0.060
1333 1(
1777
0.039
866
0.061~
1354
)I
1807
o.a6111376
0.063
0040
0.041
889
911
821
1398
1837
F;1310 11866 C1748
0.042
1 933
0.064 ()I
1896
0.043
955
0.065
1II
1926
0.044 1 978
0.066 C~I
1955
0.067
)I1
1985
0.068
""t(1
2014
lool)
0.045
925
0.046
1024
)1
1363
0.047
1046
1I
1392
0.069
t)I
2044
0.048
1069
)1
1422
0.970
)I(
2074
0.049
1091
1t
)452
0.071
)II.
2103
o.oso
1 11141
0.072
1I~
2133
0.051
)I
1511
0.073
)Ili
2163
0.052
158 ....."t..................1.....
1540
0.074
( C (
2192
0.053
1179
)1
1570
0.075
(II
1111
0.054
1202
1t
1600
0.076
) I I
2251
1135
1029
1259
1481t
1369
CLAD
SHEET
0.036
739
1970
0.055 11223
5245-3300
51-70-30
Page 218
Aug 17/84
CQPYRIGHT, 1984 BY SABRELINER CORPORATION
NA-66-1032
Strength of Joints
Table 216.
in 707Fi-T6 Aluminum
Alloy Sheet
STEEL BOLTS AND HI-SWEAR RIVETS IN 7075-76 SHEET
FAStENER
DIA
BARE
SHEET
FAStENER
1/4
3/16
(IN.)
CLAD
BARE
DIA
CLAD
BARE
CLAD
I THICKNESS
(IN.)
0.056
1566
0.057
1593
0.058
)1621 1
0.059
0.060
0.061~1 703
0.062
11730 )I
0.03411
926
0.035
945
0.036
972
0.037
C 999
898
0.038
1025
0.039
1053
0.040
1. 1111~
0.041
1028
BARE
1648
1676
11
1235
1272
2309
0.063
(1758
0.04111 173
0.064
1))
1384
0.043
1201
0.065
)I1. .
1421
0.044
11229
0.066
1 ~ 1 .
2458
0.045
......)..-1259 )1158
0.067
t(1
1496
0.046
(1287 C/
1113
0.068
tI1
2533
0.047 1 1316 (I
1751
0.069
(1344 )1
1788
0.070
)I. 1. .
2607
1825
0.071
)I1
2645
0.072
)I1
2794
0.049
0.050
1372 1)
llsol 1
t 288
~1862 )1712
o.osl) 1427 )I
1900
0.073
)1
1937
0.074
1974
0.075
0.076
0.052
1456
0.053 1 1483
0.054
11511 11
2011
0.055
(1538 1(
2049
5265-3-301
CLAD
2160
1146
0.048
SHEET
THICKNESS I
IIN.)
1/4
3/16
(IN.)
1600
1347
2189
1 2467
51-70-30
Page ~19
Aug 17/84
NA-66-1032
STRUCTURALREPGIR MANUAL
Table 217.
Strength of Joints
Protruding-head Steel Fasteners in 7178-T6 Aluminum Alloy Sheet

FASTENER
DIA
FASTENER
3/16
(IN.)
BARE
1/4
CLAD
BARE
1
CLAD
BARE
1682
THICKNESS
I
I
I
I
I
I
I
I
I
I
THICKNESS
(IN.)
(IN.)
0.0341
1010
0.056
0.035
1036
0.057
1710
0.036
1066
0.058
C1741
0.037
1097
0.038
t1125
0.039
1155
0.040
1185
0.041~
1215
0.042
1243
0.043
11273
0.044
1303
0.045
1352
0.046
1382
t1
1840
0.047
1413
1(
443
t. . . .1. .
SHEET
0.048
972
1080
1251
3/16
DIA(IN.)
CLAD
1/4
BARE
2240
0.059
11770
0.060
t1800 1I
2400
0.06111 829 1I
2440
0.062
~1B58 CI
2480
0.063
~1888 C1746 1
2520
0.064
1 I I
2560
0.065
1 I I
2600
0.066
1 I I
1640
0.067
C I 1.
2680
0.068
.(;II
2710
1880
0.069
1 ) I
2760
1920
0.070
C I I
2800
0.071
C I I
2840
0.072
. ( I ~
2880
2040
0.073
0.074
( C I
2960
0.049
1474
1. . . . . . .). .
1960
0.050
1504
......t.... 1391~
2000
0.051
1533
0.052
1563
t1
2080
0.053
592
t1. . .
2120
0.075
) I I
3000
0.054
1622
1-1. .
2160
0.076
) I I
3040
0.055 1 1651
1)..
1
;)1850
CLAD
2331
SWEE7
1I
1 2627
2200
5265-3-302
51-70-30
Page 220
Aug 17/84
COPYRIGHT, 1984
NA-66-1032
Table 218.
MS20601 and
Strength or Joints
Aluminum Alloy Sheet
MS20603
(Blind) Rivets in 2024-T3 Clad land Higher Strength)
DIMPLLD--2024-T3
CLADO

RIVET
RIVET DIA (IN.)
MSZ0601AD
5/32
1/8
MATERIAL
THICKNESS (IN.)
0.020
200
I.
0.032
335
220t
0.025
..........................t.............."""""260
0.040
0.050
330
0.063
COUNTERSUNK
2024-24
CLADEI
RIVET
(IN.)
RIVET DIA
MS20601 AD
1/8
5/32
MSZ0603AD
3/16
1/4
654
SHEET rH1CKNESS
(IN.10
0.040)159
0.050
236
258
0~063).. . .
327
369
0.071
o.oeo
1.
360
1....
0.100
C I
596
0.125
1 I
596t....
561
NOTES
1........
0.090
see
398
485
439
511
388
577
684
795
768
1~
945
862
11
270
5265-3-303
USE ALSO FOR ALL HIGHER STRENGTH ALUMINUM

ALLOY SHEETS
SHEET THICKNESS OF COUNTERSUNK SHEET.
51-70-30
Page 221
Aug 17/84
NA-66-1032
Table 219.
MS20600 and MS20602

Strength of Joints
(Blind)
PROTRUDING--2024-14
Rivets in 2024-T4 Clad land Higher Strength)
CL4DO
ULTIMATE STRENGTH tN POUNDS

RIVET
RIVET DIA
(fN.)
SHEET THICKNESS
0.032
1/8
3/32
8853060360
3/16
(IN.1
0.020
0.025
AND/OR
8853060060
186
-I
233
286
277
368 1
321
0.040
0.050
0.063
0.071
425
445 )601
544
750
386
506 1
643
961
388
596
753
1110
388
596
823
1200
0.080
I(1
862 -C
1305
0.090
)1~
862 1
1415
o.loo
1548
~1)))
1550
o. 125
5265-3-304
O VSE
PDR ALL HIGHEA:iTRENCiTH ALUMINLIM ALLOY
SHEET MATE171ALS
51-70-30
Page 822
Aug 17/84
COPYRIGHT,
NA-66-1032
STHUCTUKAI, REPAIH MAhUAI,
Table 220.
Strength of Joints
Alloy Sheet
CR22481 (Blind) Rivets in 2024-T42 Clad land Higher Strenffth) Aluminum
DIMPLED--2024-142
CLADO
COUNTFRSUNK
RIVET
RIVET DIA
(IN.I
CR2248-4
1/8
CR2248-5
5/32
CR2248-4
RIVET
RIVET DIA
(IN.)
I THICKNESS (IN.)
251
0.032
199
CR2248-5
5/32
1/8
SHEET
SHEET
THICKNESS (IN.1
0.020
2024-142 CLAD
)149
239
303
0.040
235
0.032
299 1
379
0.050 1
340 1
368
461
0.060
459
536
452
567
0.070
498
636
691
0.080
0.071 1)
727
0.090
o.oeo 1C
767
0.100 1"t
0.040
0.050
0.063
(498
(541
t""""1"" " "
236
0.025
364
)712
773
833
5265-3-305
NOTE
SHEET MATERIALS.
51-70-30
0
Page 223
Aug 17/84
NA-66-1032
Tahle 221.
Strength of Joints
CR2249 (Blind) Rivets in 2024-T42 Clad land Higher Strength) Aluminum Alloy
Sheet
PROTRUDING
2024-142
~CLADO
RIVET
RIVET DIA
(IN.)
SHEET THICKNESS
0.020
1/8
0.060
5/32
~I258
)210
0.040
0.050
(IN.I
0.025
0.032
CR2249
260 "1
324
332
409
1418
515
642
(520
653
0.070
I(
0.080
I,~1024
809
910
0.090
5265-3-306
NOTE
SHEET MATERIALS.
5170-30
Page 224
Aua 17/84
COPYRIGHT, 1984
NA-66-1032
Table 222.
Huck CKL 100V (Blind) Rivets in 2024-T4 Clad land Higher Strength)
Strength of Joints
FLUSH--2024-14 CLAD
ULTIMATE
IN
POUNDS
DIMPLED
COUNTERSUNK
INSTALLATION
RIVET
STRENGTH
100V4
100V5
100V6
SHEET THICKNESS (IN.)
100V4
100V6
100V5
0.015
?d~6 ...........280
0.032
248
324
426
296
390
495
374
466
588
390
554
686
610
755
0.040
159
258
0.050
236
0.063
327
;369
398
0.071
36(3
439
485
0.080
388
511
577
0.090
561
684
0.100
596
862
596
862
0.125
388
........I
800
5265-3-307
NOTE
~3

SHEET MATERIALS.
51-70-30
0
Page 225
Aug 17/84
NA-66-1032
STR~CTURAL REPAIR MANUAL
Table 223.
NAS1398B (CR2263) and NAS1399B (CR2262) (~lind) Rivets in 2024-T3 Clad

Strength of Joints
PROTRUDING HLAP-2024-T3
CLAD~
RIVET
NASI 39884
NASI 39885
NASI 39886
SHEET THICKNESS
(IN.)
0.016
71
0.020
132
111
0.025
203
204
0.032
183
336
292
0.040
323
453
518
0.050
363
498
661
0.063
388
559
737
596
785
596
832
0.071
0.080
388
COUNTERSUNK--~OPI-TJ
CLI\D~
RIVET
NASI 3991)4
NASI 39985
NASI 39986
SHEET THICKNESS
(IN.)
0.032
25
0.040
88
42
0.050
174
144
82
0.063
279
277
241
0.071
345
345
345
0.080
388
451
454
553
574
0.090
0.100
700
0.112
845
0.125
0.140
388
553
NOTE
845
5265-a-308
USE FOR ALL HIGHER STRENGTH ALUMINIIM ALLOY SHEET MATERIACS.
51-70-30
Page 226
Auff 17/84
NA-66-1032
STRUCTURAL REPAIK MANUAL
Table 224.
Strength of Joints
Sheet and
F Series Jo-bolts (Blind) in 2024-T4 Clad land Bare) Aluminum Alloy
Plate
rLUSH HEAD-2024-T4 CLAD (AND BARE)
F164
FASTENER
INSTALLATION
DIMPLED AND
COUNTERSUNK
SUBCOUNTERSUNK
SHEET THICKNESS
(IN.)
0.025
0.032
0.040
289
C................t".."...............""""
..................1..""""""".""""""
240
0.063
780
0.071
930
0,080
0.090
o.loo
377
"""1""""""""""""""""
592
471
375
555
0.050
.............1"..."."""""""""""
746
1.....................".
loeo
841
948
1245
1395
0.125
1680
0.160
1695
5265-3-309
51-70-30
Page 227
Aug 17/84
NA-66-1032
STRUCTUSAL REPAIR MANUAL
Tahle 225.
Strength of Joints
F Series Jo-bolts
Plate
(Blind) in 2024-T3 Clad land Bare) Aluminum Alloy Sheet and
COU,NtERSUNK-2024-T3 GLAD (AND
ULTIMATE STRENGTH IN
BARE)
bbUNPS
SHEET THICKNESS
(IN.)
RIVET
i 200
8260
0.040
445
q80
0.050
510
510
0.063
915
1035
1305
0.071
1027
1 170
i 395
0.080
1155
1320
1500
0.090
1305
0.100
0.032
F312
............420
1635
lqs5
1 470
1680
1800
0.125
1800
2070
2160
0.160
2160
1550
2730
0.190
2400
3015
3300
0.250
2620
3900
4425
5265-3-310
51-70-30
Page 228
Aug 17/84
COPYRIGMT, 1984 BY SABRELINER CORPORA710N
NA-66-1032
Table 226.

Strength of Joints
Alley Sheet and Plate
in 7075-T6 Clad
COUNTERSUNK--7075-T6 CLAD
land Wigher Strength) Aluminum

F 312
F 160
F 200
RIVET
SMELT THICKNESS
(IN.)
0.032
520
0.040
545
580
0.050
645
645
1425
1185
0.063
1155
0.071
1275
0.080
1395
0.090
1537
1665
0.100
1695
1920
1920
0.125
1960
2400
2310
0.160
2200
3075
2970
0.190
2420
3705
0.250
2620
4320
1305
1500
1605
1470
..............1............................
1740
3780
5565
5265-3-311
NOTE

SHEET AND PLATE.
51-70-30
0
Page ~29
Aug 17/84
NA-66-1032
Table ~27.
Strength of
Joints
FA Series Jo-bolts
(Blind)
in 2024-T3 Clad land
and Plate
Bare) Aluminum Alloy Sheet
COUNTERSUNK--)024-T3 CLAD (AWD BARE)

ULTIMATE STRENGTH IN: POYFIDS
SHEET THICKNESS
6IVEf
(IN.)
FA 200
0.032
0.040
FA 960
390
420.. . (. . . . . . . . . . . . . . . .
0.050
500
0.063
640
6.071
I............
620
790
1010
790
0.030
1040
0.090
1150
I;
1310
1270
1430
0.100
1450
I...r..................
0.125
1595
.1...............................
2010
0.160
1595
.i)
2300
1680
0.190
0.250
2520
2790
(..................................I
S265-3.312
51-70-30
Page 230
Aug 17/84
COIPVRIGHT,
1984 BY
SABAELINER CORPORATION
NA-66-1032
Table 228.
FA Series Jo-bolts (Blind) in 7075-T6 Clad land Higher Strength) Aluminum

Strength of Joints
Alley Sheets and Plate
COUNTERSUNK-~C)75-T6 CLAD
FASTENER
FA 200
FA 260
SHCETTHICKNESS
IIN.)
0.032
450
0.040
sooI
740
590
940
0.050
0.063
0.071
750
I
880
1170
I
1310
0.030
1060
1480
0.090)
1 270.. . .C. . . . . . . . . . . . . . . .
1650
0.100
Isso~.
Isso
1595
2250
o. 125
1595
0.160
0.190
2650
2790
5265-3-313
NOTE
SHEET AND PLATE.
51-70-30
Page
"i
~31
Aug 17,84
NG-6-1032
SrKICTI~IRGI, REPAIR MANUAL
Table 229.
P Series de-bolts (Blind) in

Strength of Joints
Alloy Sheet and Plate
2024-T4 Clad
PROTRUDING HEAD--2024-T4 CLAD
land Higher Strength) Aluminum
FASTENER
P164
P 200
P 260
P 312
SHEET THICKNESS
(IN.)
0.025
350
430
574
0.032
450
560
710
875
0.040
565
690
895
1090
0.050
706
864
1115
1338
0.063
888
1080
0.071
1002
1220
1 588
1906
0.080
1 130
1420-
1702
1372
1785
2160
0.090
1 270
1550
2011
2408
0.100
1412
1720
1 620
2130
2788
3356
1695
1440
3565
4305
2580
4008
5098
0.125
0.160
0.190
0.250
2675
5984
$265-3-314
NOTE
S~1EET AND PLATE.
51-70-30
PaRc~ df~2
~iln 17/H1
COPYRIGHT 1984 BY:SABRELINER CORPORATION
NA-66-1032
TYPICAL REPAIR EXAMPLES

REPAIR
CONSTANT-THICKNESS SKIN REPAIR WITHIN

A SUBSTRUCTURE
(INCLUDES SPLICES)
Instructions for developing a constant-thickness skin

repair between frames or ribs are given in the basic
repair calculations. (Refer to figure 201, 51-70-20.)
SKIN AND WEB CRACK REPAIR
Instructions for skin and web crack repair
figure
are
given in
201.
CONSTANT--THICKNESS SKIN REPAIR

ACROSS A SUBSTRUCTURE
See
figure
202.
CHEM-MILLED SKIN REPAIR BETWEEN

LANDS-NONPRESSURIZED
See
figure
203.
CHEM-MILLED SKIN REPAIR ACROSS A SKIN

NONPRESSURIZED
LAND
See figure 204.
51-70-40
0
Page 201
Aug 17/84
NA
SYMBOLS USED IN THIS ILLUSTRATION
P-Length of cut along one side of damage

P1--Length of cut (effective) along a second
EXAMPLE
side of
damage
EXAMPLE
STOP-DRILL
CRACKS (TYP)
11
STOP-DRILL 019
RADIUS-OUT
ANV ABRUPT
CHANOESIN
DIRECTION
CRACK
I
i:i.i 8i i.i i )i i Ii B
ii
i.
Bill
DISTRIBUTE FASTENERS
REOD FOR I EACH SIDE
OF CRACK 1666 SAMPLE
FASTENER PATTERN)
5265.3.315
NOTES
THIS
ILLUSTRATION
PROVIDES SPECIAL INSTRUCTIONS

NECESSARY FOR ADAPTING OTHER REPAIRS SHOWN IN THIS
SECTION TO
CRACKED SKINS AND WEBS.
REPAIR:OF
(REF)
+t++
IT
ESSENTIALLY INDICATES THAT: (1) CRACKS WHICH ARE

GENERALLY STRAIGHT (EXAMPLE 1) HAVE ONE p DIMENSION
AND MAY BE CONSIDERED AS A BUTT JOINT REQUIRING A
SPLICE DOUBLER. (2) CRACKS WHICH ARE NOT GENERALLY
STRAIGHT (EXAMPLE 2) HAVE TWO I DIMENSIONS AND MUST
fSS
-t
Cf+S+SS
BE TREATED AS RECTANGULAR HOLES
THAT IS, A RECTANC,ULAR HOLE WOULD RESULT IF THE STRUCTURALLY NONEFFECTIVF MATFAIAI. WERE REMOVED
STRUC-
FASTENERS REQD FOR I
~UmALLY NONEFFECTIVE MATERIAL IN THIS TYPE OF REPAIR

SERVES fURPOSE OF A FILLER IN A FLUSH REPAIR.
ALL REQUIREMENTS OF REPAIR BEING ADOPTED TO
ARE D1STRIBUTED 80 THAT
EACH:ROW EXTENDS ONE
CRACKED
FASTENER BEYOND END OF
CONDITION MUST BE MET.
CRACK (TYP BOTH ENDS
SEE ~BASIC FASTENER CALCULATIONS" AND "GENERAL

PAIR
RE-;
OF
CRACK)
REOUIREMENTS.~ 51-70-20, FOR GENERAL REPAIR
DEVELOPMENT INSTRUCTIONS
51-70-40
Page ZO~
i\ua 17/H4
Skin end Web C:rcLck

201
eruRiFrircpeR
COPYRIGMT, 1984
NA-66-1032
STHCICrUHAL KEPAIH MANliAI,
SrMBOLS USED IN
THIS ILLUSTRATION
Fl,
Ultimak thear stress
Ftu
Ultimate tensile ttress
Length
of
~P1 Length
RIB OR FRAME
cut
along
one
of cut
along
side of cutout.
REPAIR DOUBLER
second tide of cutout.
--Oliginal fastener spacing
S1 --Repoir fastener spacing

--Thiekners of material
SECTION
(minl
SKIN
\_
being repaired
SAMPLE CALCULATIONS (from data
given
in sketch)
ce x t, x
Ftu
FILLER
RIVET--MS20Q26A05
IASSUMEO TO HAVE
BEEN ORIGINAL RIVET)
TENSION SIDES OF REPAIR--
FASTENERS THRU RIB

OA FRAME ARE NOT
No. of fasteners required

each tension side
of repair
Fastener allowable
A-A
on
COUNTEO AS PART OF
FASTENERS
(2 x 0.040) X
7.14
or
REDO
FAOMCALCUUTIOHS
7 rivets
_
SMEAR SIDES OF REPAIR--
(,41 Xt)X FEU

Fastener clllowable
5 X 0.040 x
NO. 01 fasteners
repair fin addition

thru frame or rib)
38,000
10.3
635
(30t
required
of
or
on
RIVET--MS2D426A05
each side
i
to fasteners
11 rivets
ITYPI
TENSION ARE~A
ITYPJ
t)x
Fl,
7CI
~1
f
dTt
each side of
repair
sl
135
Fasteners
through skin, repair doubler, and substructure (rib or

frame) must have fastener allowables equal to, or greater than,
those removed. Solve for numbers
x
SMEAR AREA
(TYPI
No. of fasteners thru substructure
Fastenero allowoble
1.2 x 0.040
OIMPLED ITYPI
58,000
4.4
635
or
as
f,
Si
follows:
5 rivals
I~
-t
a=i
li_I1 -t
IMIN)
slslmlnl
Ice(
1
T
+/l~-t
1=5
1
NOTES
1
THIS
ILLUSTRATION PROVIDES SPECIAL INSTRUCTIONS

NECESSARY FOR DEVELOPING SMEAR OR TENSION REPAIRS
ACROSS A SUBSTRUCTURE
OR RIB.)
-L
t
t
(FRAME, LONGERON, STIFFENER,

RIB OR FRAME
8
INSTRUCTIONS APPLY TO CONSTANT THICKNESS MATERIALS

AND ONE-PIECE DOUBLERS ONLY.
REPAIR OOURLER0.050 2024--T3 CLAO
A TENSION REPAIR IS USED AS AN EXAMPLE. A SMEAR REPAIR
WOULD BE IDENTICAL TO TENSION REPAIR EXCEPT THAT

FASTENER CALCULATIONS WOULD BE FOR SMEAR VALUES ON
"!k
f-
ALL SIDES OF REPAIR.
SKIN AREAS ADJACENT TO FRAME, LONGERON, STIFFENER, OR

RIB FASTENER ROWS CARRY TENSION LOADS REGARDLESS OF
PRIMARY LOAD IN PANEL. EFFECTIVE DISTANCE OF THIS LOADING IS 15 TIMES SKIN THICKNESS EACH SIDE OF FASTENER
ROW, AND IS EXPRESSED AS 30t. REPAIR DOUBLER TABS, AT 301
LINE SEPARATING SMEAR

ANO TENSION AREAS ITYPI
301
WIDTH OF
SKIN- TYP)TENSIOI(EF ECTIVE
ON 301
SKIN--0.040
2024--T3 CLAD
WIDTH, EXTEND ALONG THESE FASTENERS ROWS PICKING UP

FASTENERS AS REQUIRED TO DEVELOP 301 CAPABILITY OF
MATERIAL
e(
5265-3-316
(SEE SKETCH).
SEE "BASIC FASTENER CALCULATIONS" AND "GENERAL REPAIR REQUIREMENTS."51 -70-20. FOR GENERAL REPAIR DEVELOPMENT INSTRUCTIONS.
Constant-thickness Skin Repair Across A

202
erugiFerutcurtsbuS
51-70-40
Page 203
Aug 17/84
NA-66-1032
STRCTCTURAL REPAIR MANUAL
12 (REPAIR DOUBLER)
FRAME OR RIB
(TYP)
11
BOWDSTRUCTURALSHIM
TO SKIN, AIO
BONO REPAIR DOUBLER

TO STRUCTURAL 5519.
1-0.040
STRUCTURAL
SPICER
I,
Yr
1/2 (MIN)
=2
3
=02 .0
SECTION
I3ISTRUCTURAL)
A-A
EPON 913 EPOXY
BOND LINE
0.040
REPAIR OOUBL~R--
STRUCTURAL
0.025 7175-75 BARE
SPACER--0.020
7175-75 BARE
II= t, PLUS ONE GAGE
C-~
Ilol
OR 0.025
II
SKIN LIND
tj
--3
OR
=t
IROTATEDI
suesreucrunr
ILLUSTRATION
FOR
TO "BASIC
FOR
51-70-20,
FASTENER
GENERAL
CALCULATIONS",
DATA
RELATIVE
TO
II
C%M-MILLEO
sKln-rl 75-75
BARE
LINE SEPARATING
FASTENER AREAS ITVP)
4~
135"
dt
SPECIAL
flel
)lel+
II" 1+
DETERMINING
NONPRESSURIZED CHEM-MILLED AREAS.

REFER
Ilel I+
r?--
REQUIREMENTS FOR SMEAR REPAIRS IN
REPAIR
01
Ilel
Af
PROVIDES
INSTRUCTIONS NECESSARY
888
NOTES
THIS
IITYPI
0.020Ilt~
L~-l1f
VIEW FROM SKETCH 1
(TYPI
1/01
MINUS I,
nEp~lAoaalrR
El
STANDARD)j I
(OLD
RIYET--MS2042BA04
OIMPLEOITYPJ
II
Ilo
FASTEWER--TYPE AkO
SIZE TO MATCH RLMOVEO
FASTENER ITYP)
FRAME OR RIB
St
Ilo
SIMINI
Ilol
IloI
-C~O
Ilo
pp)
FASTENER REQUIREMENTS.
REFER TO "GENERAL REPAIR
SKETCH I--SHEAR REPAIR WITHIN ONE BAY
REOUIREMENTS,"
526513-ii 7
51-70-20, FOR REPAIR DOUBLER INFORMATION. TRIM
RADII, AND RELATED DATA.
LEGEND
IT WILL BE NOTED THAT REPAIR FASTENER REQUIREMENTS ARE COMPUTED FOR
1,,
Rivets required each side of P
Field rivets added to calculated
OR CHEM-MILLED,
requriements
MATERIAL THICKNESS. DOUBLER MUST, EXTEND COM-
Rivets
required each
side of
pi
to
complete
rivet pattern
PL ETELY ACROSS DAMAGED BAY AN D PICK UP R IVETS
THROUGH SKIN LAND AND SUBSTRUCTURE AS

SHOWN
ARRIVED
IN
SKETCH
AT
1.
NUMBER
SIMIOLS USED IN tHIS ILLUSTRAtlON
OF FASTENERS
--Minimum fastener
FROM CALCULATIONS ARE MINIMUM
REQUIRED UNDER
STANCES. ADDITIONAL "FIELD" FASTENERS WILL

USUALLY BE REQUIRED ON ONE OR BOTH SIDES OF
REPAIR BETWEEN CUTOUT AND FRAME OR RIB.
(SEE
SKETCHES.) FIELD FASTENERS
MUST BE SAME AS OTHER FASTENERS USED IN
ACCOMPANYING
REPAIR AND MUST BE SPACED AT 1.5 IN.
REPAIR DOUBLER
DAMAGED
STANDARD)
(12)
ONE GAUGE HEAVIER (OLD
THAN CHEM-MILLED THICKNESS
ttl).
SEE SHEET 2 FOR VARIATIONS OF THIS REPAIR AND

DATA
RELATIVE TO FABRICATION
AND
SAMPLE CALCULATIONS FOR SMEAR REPAIR, USING

DATA FROM SKETCH 1
INSTAL-
(P 11 111
LATION
11
FIu
no,
Fastener allowable
STRUCTURAL SHIM
(13)
MUST BE OF SAME MATERIAL
AS DAMAGED PART AND EQUAL TO CHEM-MILLED
THICKNESS
11
0.020
11
50,006 Ib
302 Ib
(t,).
REFER TO STEPS ON SHEET 2.
PIPARTS
distance
11 --Chem-mllled material thickness

11 -Repair doubler thickness
15 -Structurol,him thickness
(MAXIMUM).
MUST BE OF SAME MATERIAL AS
PART AND
edge
of cut along one side of cutout

of cut along a second side of cutout
Flv--Ultimat shear stress
5 --Original fastener spacing
51 --Repair fastener spacing (minimuml
t -Basic material thickness
--Llngth
Il --Lngth
I
RELATIVELY IDEAL CIRCUM-
6.6
no,
Fastener allowable
of fasteners
or
required
each side of I.
7 rivets
of fasteners
recluired along
each side of It.
TO BE BONDED MUST BE MADE FROM BARE
ALUMINUM ALLOYS.
11
0.020
11
50,000 Ib
302 lit
51-70-40
Page 204
Aug 17/84
Chem-milled Skin
Repair Between Lands

o
9.9
or
10 rivets
Nonpress~rized
COPYRIGHTi 1984 BY SABRELINER CORPORATION
NA-66-1032
VARIATIONS FOR TENSION REPAIR, USING

DATA FROM SKETCH 2
Calculation~ for P (rheor ,ids)
ore os
given for ~har repair.

CHEMMILLLO SKIW-7178-76 BARE (II)
CalculoMon~ forll (ten,ion lidl
(Plxtl)x Ftu
of
no,
rquird each tide of I,.
fastener allowable
(3
0.020)r 83,000
16.4
302
or
STRUCTURAL
SHlm 1131
17 rivets
FIELD RIYET
Sl-Slmln)
~llo
RIB--TYPJ
UP.I,
2
P1
0.040
11
12
.020
=t1PLUSONE
OAUGE(OLD
STANDARD)
OR
I
Sl=Slmlnl
ORIGINAL FASTENER
1(,11It
(ICBI
((OI
REPAIR FASTENER
e
135"
III~I
111
111el
11"11++
8(
I~
Il~el I+
q,
-tlll~l
III 81
II( o I
le
8+
-6 Fasteners
lidel)
requird
complete
rivet
Trim out
each rid of I (sheor lid,)
each tid of
P,
SKETCH P--TENSION REPAIR,

ONE BAY
(tension
STRUCTURAL SHIM
pattern
damage.
SKI)I
SUBSTRUCTURE
ITYPI
Fabricate and fit
repair parts.
SECTIoN
01111 all fastener hales to linel site
B-B
I~PIIR WUILIR
Disassemble repair and burr all parts.
Preparerepairpartsandinnerskinsurfaceforbonding.
(Refer to "Adhesive Bonding" in 91-20-20 for surface
preparation and structural metal-to-metal bonding.)
I~
oi
o
FILLER
O
O
O
ICil
O
ITVP)
III,(
Fild rivets addd to calculakd requirements

to
AREAS
111
LEGEND
required
FASTEWER
1)1~
~I
1;;
8 i;osteners
SREAR AIO
TEISIOW
II "I
SPACING (MIN)
te
1(811++
SPACING
S1
0.025I
=tlOR0.020
tg
S
UYIIB)IRITI*I
6~1
;(1IZMIN)
ALL
RIVETING
EPOXY
Bond and rivet
repairparts
in
place. Bond with Epon 913.
IS
IN
MUST
PLASTIC
BE
ACCOMPLISHED WHILE
STATE.
RIVETING
CURED
REPAIR WILL DESTROY BOND.
NOTE
SEE
SHEET
ADJACENT
FOR
REPAIR
(OR CLOSE) TO
WHEN
A RIB OR
DAMAGE
IS
FRAME,
~hem-milled Skin Repair Between Lands

5265-3-318
Nonpressurized
51-70-40
Page
205
Aug 17/84
NA-66-1032
STRUCTIJRAL REPAIR MANUAL
(1/2MIN)
12
VARIATIONS FOR REPAIR WHEN DAMAGE IS

ADJACENT TO A FRAME OR RIB, USING DATA FROM
SKETCH 3
Pi
0.040
tl
t2
-.020
tlPLUSONE
GAUGE (OLD
A Ihar
is llsod; a lon,ion npair is idntital ollcop(
for fostonor rquirmnt~ on lnsion sides of repair.
Calculations for finding fcl~hnr rquirmnh

given for Iko(th i.
STANDARD)
OR 0.025
13
S
are Iom as
tlOR0.020
ORIGINAL FASTENER
SPACING
S1
REPAIRFASTENER
SPACING (MIN)
SURSTRUCTURE
IFRAMEORRB--TYPJ
EPOXY BONO
I,II
LINE
LI
13
12
SECTION
FASTENERS THRU SKIN, REPAIR
~B
FILLER
CHEM-MILLEO
8KIW--7118TB
BARE (I1I
DOUBLER, AIO SUBSTRUCTURE

MAY BE COUNTED WHLN IECESSARY
ON TH1S1 ANO OPPOSITE. SIOE OF REPAIR
STRUCTURAL SHIM
SUBSTRUCTURE
~IILORIYeT
REPAIR DOUBLER
ITYPI
REPAIROOUBLER
STRUCTURAL
SHIM 1131
--\1- ;13)
o(/
I(TYP)
.f+
il~ll
e
d~
+I:H
II
6e
+111ae
11,,1
ITLI
I"I1 ct,
II
PIISTllfR--TYPE
+II
Ilol
IIloi
f
MLTEH
(,I
Illo,
----~i
m~:
AID SIZE TO
Illol
illol
It
II, is a
-t
LIIE 8EPI8ATII8
FASTEIERS
I
i,
II
II" Ii
"Iiol
Ilo
FASTEWERITIPI
Sl=S(Mlnl
SKETCH 3--SMEAR REPAIR WITH DAMAGE ADJACENT TO FRAME OR RIB
LEGEND
e
Fasteners requiredeachsideofl
Fasteners
required
each side of
Field rivets added to calculated
P1
requirements
to
complete rivet pattern
NOTES
WHEN
REQUIRED FASTENERS CANNOT BE

INSTALLED WITHIN A BAY, REPAIR DOUBLER MUST
EXTEND ACROSS ADJOINING BAY. FIELD RIVETS
MUST BE ADDED AT 15 IN. MAXIMUM SPACING AS
SHOWN.
a
5265-3-319
REFER Tg STEPS ON SHEET 2.
51-70-40
P~ffe 206
Aug 17/84
C:hem-miIied Skin;Repair Between r;ands
Nonpressurized
Fiffure 203 (Sheed 3 of 3)

o
CO-P~R:IGHT, 1984
B S~RELINER CORPORATION:
NA-66-1038
STKUCI~1IHAI, REPAIR MANlr~l,
TENSION IEFFECTIVE ON 311111
EXISTING FASTENER
LAND)
,I~
I I
SUBSTRUCTURE
SKIN LANO REPAIR FASTENER
\I
IREg
(SEE YIEW BI
LINE SEPARATING
FASTENER
OISTRIBUTIOW
AREAS
5~11n
SKIN(111
;I~/r
e
e
-t
~q
tl
8
8
REPAIR BOUBLER
II It
ii
I)1 8
I(TYP)
D8
11
FILLER
8()
135"I/
SHIM
1131
~I11C
II
IILS
i;
+I
LI,
t
Sl--S(MINI
I..
CI,
s(mlnlIt
:tl+
IR(TYP)
I
Sl
)IIIA
RlrIllRTO
MATCH ORIGINAL
~1______
REPAIRDOUBLERTAB
II o
STRUCTURAL
SPICER (12)
II
O
SKIN LAND P)
Il
TENSION (EFACTIVE ON SKIN LAWD)
EWXY BONO
noTH OF LAND (Wj
LINE
SKIN
ITYP)
111)
SKIN LAND Ilj

WIOTH OF REPAIR
DOUBLER TAB IW1I
SECTION
(121
REPAIR DOUBLER
13
A-A
EOUAL TO I MINUS 11
FILLER
STRUCTURAL SPACER
t MINUS 11
te
EOUAL TO 11
HELYIEA TVIII IMII.
SUBSTRUCTURE
(REFI
!1/2MIN)
SECTION
SHlM
II
SUBSTRUCTURE
(REFJ
SECTION
CC
.020
11PLUSONE
t1GAUGE(OLD
t1STANDARD)
tlOR0.025
0.020
13
11 OR
ORIGINAL FASTENER
Fasteners required each side of a

Fasteners required each side of
Skin land repair fasteners required (thru skin
land, repair doubler and substructure)
5265-3-320
SPACING
S1
NOTE
B-B
LEGEND
0.040
11
12
1131
MUST BE ONE GAUGE
REPAIR FASTENER
SPACING
(MIN)
AREA OF REPAIR DOUBLER TAB MUST BE EQUAL TO

"A" OF SKIN LAND.

0
Nonpressurized
51-70-40
Page 207
Aug 17/84
NA-66-1032
STRUCTURAL HEPAIR MANUAL
Trim
damage midway
Lay
Fabncate
out
between
existing fasteners.
BOND STRUCTURAL 8818
TO SKII, AID BOND REPAIR
DOUBLER TO STRUCTURAL
sHlm (TYP).
lastsnerpaltern
SKIN LAND
repairparts.
STRUCTURAL
SRIM
Assemble repair parts and drill fastener holes.
O
for
OisasPembly repair and prrpare skin and repair parts

bonding. (Refer to .Surface Preparation of Aluminum
Alloys
i,, Adhesive
Bonding..,
REPAIR
OOURLER
\2
51-20-20
Bond and rivet repair parts in place. (Refer to
Structural Metal-to-Metal Bonding", 51-20-20.)
ALL
RIVETING
EPOXY
IS
IN
MUST BE ACCOMPLISHED WHILE
PLASTIC STATE.
SUBSTRUCTURE
RIVETING A CURED
REPAIR WILL DESTROY BOND.
FASTENER
NOTES
THIS ILLUSTRATION PROVIDES SPECI*L INSTAUCTloNS
NECESSARY FOR DEVELOPING SMEAR OR TENSION REPAIRS
ACROSS A CHEM-MILLED SKIN LAND AND SUBSTRUCTURE.
II
II
L i
REQUIREMENTS.I
REFER
51-20-20,
TO
..BASIC FASTENER CALCVLATIONS...

GENERAL DATA RELATIVE TO FASTENER
FOR
i~TF=
REFER
TO "GENERAL REPAIR REQUIREMENTS",

51-20-20, FOR FASTENER SPACING TRIM RADII, AND RELATED
DATA.
8818 LAID
8U88TRUCTURE
VIEWD
A SMEAR REPAIR IS USED AS AN EXAMPLE. A TENSION REPAIR
REPAIR
FA8TEnER
WOULD BE IDENTICAL TO REPAIR SHOWN EXCEPT THAT

FASTENER CALCULATIONS WOULD BE FOR TENSION VALUES
ON TENSION SIDES OF REPAIR.

SKIN LAND OVER FRAMES, LONGERONS, STIFFENERS, OR RIBS
CARRY TENSION LOADS REGARDLESS OF PRIMARY LOAD IN
THE PANEL
REPAIRS TO SKIN LANDS MUST DEVELOP FULL

TENSION CAPABILITIES OF LANDS.
REPAIR
DOUBLER MATERIAL AND CONDITION

DAMAGED SKIN.
20
ImiN)
~lnl20
IS SAME AS
AREA
OF REPAIR DOUBLER TAB MUST EQUAL AREA OF

DAMAGED SKIN LAND.
SUBSTRUCTURE
THICKNESS OF REPAIR DOUBLER IS DETERMINED BY REQUIREMENTS FOR REPAIR OF SKIN LAND. THAT IS, SELECTED SKIN
FASTEWER e
LAND REPAIR FASTENER MUST HAVE A JOINT ALLOWABLE IN
REPAIR DOUBLER EQUAL TO, OR GREATER THAN, ALLOWABLE

IN SKIN LAND. USE PROTRUDING-HEAD FASTENER ALLOW-
sECTION
ABLES FOR DETERMINING STRENGTH OF JOINTS IN REPAIR

DOUBLER
ODia
E-E
of skin lend repair fastener relected

requirements shown in section E-C.
must
meet
5265-3-321
51-10-40
P;l)r;t 8()8
~ilR 17iH1
Figure
204
O
(Sheet
2 of
Nonpressurized
2)
GQPRIGMT 1984 BY SABRELINER CORPORATION
NA-66-1032
GENERAL REPAIR
REPAIR
(;ENERAL
8.
(;t?neral repairs di ffer from typical repairs in that instructions are complete on repair illustrations, except for
referc!nces to procedures.
Clean any adhesive from surface of repair doubler

and lightly clamp entire repair to ensure complete
contact of all fayinR surfaces.
9.
Clean all
excess
adhesive from aroultd repair.
10.
Secondary structure repairs (figure 201)are applicable to

secondary structure as indicated in figure 1, 51-70-00.
Cure repair
or 8 hours at 700F
before removing clamps. Remove clamps and carefully scrape off any extruded adhesive.
11.
Refinish repair to match surrounding
NEGLIGIBLE HOLE REPAIRS
12.
Check balanced control surfaces after repair, and

rebalance as necessary. (Refer to applicable com-
SECONDARY STRUCTURE REPAIRS
Negligible hole repairs (figure 202) are primarily

aerodynamic "plugs" and may be used to fill holes defined
as structurally negligible in negligible damage instructions for each component.
GLASS-FABRIC-REINFORCED
1.
NOTE
Repairs are not permitted to elevators with

honeycomb trailing edges.
bonding procedures and materials, refer
to 51-20-20.
Minor damage to surface trailing edges, EXCEPT

ELEVATORS, may be repaired by filling damaged
honeycomb area with a 1 ightweight epoxy (Corefil 615), as
shown in figure 203.
To
see
repair damage exceeding limits given in figure 203,

figure 204 and proceed as follows:
out trim
lines, and bond overlap boundaries.
i.
Lay
2.
Strip finish from area to be bonded, and clean

thoroughly before trimming out damaged material,
to avoid contaminating core at bond line. Trim out
damaged area.
3.
4.
Shape balsa wood filler to closely match removed

trai ling edge section. Side and forward edges should
form a tight fit with the cutout.
Protectbalsawoodfrom all formsof foreignmatter
after
filling.
Form repair doubler to fit snugly over trailing edge

and filler. Clamp repair in place, and drill all rivet
holes. Remove repair doubler, and countersink all
holes.
trailing edge.
Ierform final cleaning operations
7.
Prepare adhesive, and bond all parts in place. Install

rivets while adhesive is wet. Fill hollow rivets with
adhesive after pulling.
on
PLASTIC REPAIRS
General
plastic parts are used for
radio and radar antenna covers and various shields
and covers for electrical equipment. Many of these
parts are small and should be replaced if damaged.
Larger parts may be repaired if necessary, provided
damage is not too great and is not in a critical area.
Damage usually consists of tears, bruised or delami

nated areas, or a combination of these damages.
Most common type of damage is skin fracture or
tears. When cuts or tears extend through several
layers of skin in locations where appearance is not
important, damage may be repaired by bonding a
patch to exterior surface of part. This type of repair
may be used on some of glass-fabric-reinforced-plastic electrical covers, etc, but should not be used on
antenna covers. Repairs shown in figure 205 may be
used on all laminated glass-fabric parts on airplane.
When damage occurs to radome or antenna covers in

area of radio or radar transmission, repair personnel
must take extra care to maintain exact design
thickness and contour of original installation. A
natural tendency to "beef up" repair area must be
avoided. An antenna cover admits a particular
frequency range of electromagnetic spectrum at a
particular angle
or
ray
changes in thickness
(i.
area.
ponent chapter.)
HONEYCOMB TRAINING EDGE REPAIRS
For
for 4 hours at 150" F
on
incidence; therefore,
cover,
in this
any
area, may
distortion of electrical waves. Laminated plastic

may become bruised or delaminated beneath
surface if subjected to a sharp blow. Damage of this
type, which is not over a large area, can often be
repaired by injecting a small quantity of resin
cause
parts
51-70-50
0
Page 201
Aug 17/84
NA-66-1032
S?RUCTURAL REPAIR MANUAL
REPAIR (Continued)
(;I,ASS-FARRIC-REINFORCED
PLASTIC
4.
Preparation of DamagedArea
REPAIRS (Contd)
Clean out damage to
th rough sk i n w i th a hypoderm ic syringe. If

damaged area
is loo lalRe to be fi lied with a hypodermic
syringe, a series
of No. 60 holes, evenly spaced through area of
damage,
ma\i be drilled. Enough resin to ensure
bonding of all
enough
5.
Preparation of Damaged Area

See figure 205, sheet 2.
6.
Mixingof Laminate Resin
not
tool.
2.
SOURCE KEY
Glass fabric. 181 style
!am inating (conforming

Spec MIL-R-767.4)
(0.003
to 0.005
sheet
7.
046
001
001
Equipment Required
Following equipment is suggested to aid in making
this repair. Substitute equipment
may be used as
needed.
Razor
8.
SOURCE
blades(single-edge)
Source of all items is

commercial.
Infrared heat lamp (250watt, 105-to-120 volt
or
equivalent)
Small spatula
Paint blush (1/2onc~ in. width)
IlollinK pin
or
PreparingDry Layer
"Dry" or precured layer is used as a backing layer in
stepped repair. This layer is contoured to match part
being repaired as near as possible. Preparation is
same as for a "wet" layer, except that it is not cut to
size until after it is cured. To cure "dry" layer, lay
fabric smoothly over a contouring block and
expose it
to heat from an infrared heat lamp or equivalent for
one hour. Lamp should be held about 12 to 15 inches
from surface of layer. Surface temperature should be
1500F to 200"F for at least one hour. After layer has
cooled, it should be relatively hard If it is completely
cured. I)o not remove cellophane sheets.
ol
equivalent
ejl Refer to table 2,
PreparingWet Layer
Spread glass fabric on
a sheet, of cellophane on a flat

surface. Saturate fabric with mixed resin, spreading
it uniformly over surfs~e with a spatu la or other flat
tool. Cover saturated fabric with another sheet of
cellophane, and roll gently but firmly to force resin
into fabric. This rolling action forces the excess resin
out to edge of fabric. This impregnated fabric between
sheets of cellophane may then be cut to required size.
To avoid contamination, cellophane should remain in
contact with "wet" fabric until layer is to be used.
001
in.)
EQUIPMENT
Tapered Method
thoroughly for several minutes. Laminating resin

should be mixed in small amounts to minimize waste.
Mixed resin has a pot life of only about 6 hours.
to
Catalyst (liquid), methyl ethyl

ketone peroxide
Cobolt naphthenate (60~)
Cellophane
Polyvinyl alcohol
048
047
Resin, low-pressure
delaminated.
Laminati ng resin must be m ixed with curing agent or

catalyst according to manufacturers instructions
before use. After adding curing agent to resin, mix
Materials Required
MATERIAL
any areas that have
used to cut material. After hole has been sized, correct

amount of overlap for top layer may be determined.
(See figure 205, sheet i). Carefully trim and peel top
layer of cloth from overlap: area. Be careful not to cut
into next layer of cloth, and do not let layers
separate
outside damaged area. This would result in an area
that is structurally weaker than surrounding area.
Cut and peel each layer in stair-step fashion as shown
in figure 205, sheet i. A spatula is often
helpful in
lifting layers and for separating layers for removal.
or
satisfactory for surfaces coated with rain-erasion

protective material because coating dulls sound of coin or
remove
Stepped Method
rectangular shape large
Rectangular shape makes it easier to fit repair layers

of glass cloth. A sharp knife or razor blade
may be
separated surfaces is then injected through holes. Entire

area must be placed under enough
pressure to remove
excess resin. After curing, sand and refinish
area,
Delamination may be visible on surface of part as a bubble
blister. In some cases subsurface delam~ination

may not
be visible. If delamination is suspected, but cannot be
seen, extent of damage may be determined by tapping
surface with a coin or small tool. Undamaged areas will
respond with a sharp metallic ring, whereas delaminated
areas will produce a hollow sound. Tapping
procedure is
to
Iil-YO-00 for manufacturer.
5170-50
Page 202
Aug 17/84
CqBVRIGHT, 1984
BY
ShBRECINER CORPORATION
NA-66-1032
REPAIR
GLASS-FABRIC-REINFORCED
PLASTIC
REPAIRS (Contd)
9.
(Continued)
BATTS REPAIR PROCEDURES
i.
Rebuilding Damaged Area--Stepped Method
When glass fabric has been damaged to extent that

all of fabric laminates have been penetrated, use a
backup layer or plate to make repair. If area to be
repaired is contoured, make a dry backing la3Ter to
match damaged part. If damaged area is flat, a piece
Interior of batt and batting material must be dry

and free of moisture. If batt is not completely dry,
replace.
2.
Apply repairtape perthefollowing:

A.
pressure sensitive tape is applied must

be clean and dry. Surfaces should be wiped with
a clean, lint free cloth. When dust may be present, the surface should also be wiped with a tack
cloth. (see Figure 206)
B.
as
original part.
When last layer is in place, remove outer cellophane

from it and brush a thin coat of resin over outside
layer. Cover repair area with a sheet of polyvinyl
alcohol sheet. Stretch this sheet as tightly as possible, without wrinkles, and secure it with cellophane
with a
or masking tape. Rub repair area gently
smooth tool to remove excess resin and to work any
air bubbles out of layers and onto masking. Avoid
excessive rubbing because it may reduce resin content of fabric enough so that a poor bond results.
Rebuilding Damaged Method

See figure 205, sheet 2.
10.
3.
lift
C.
After Orcotape has been correctly positioned,

uniform and firm pressure should be exerted
over the tape to assure complete contact.
D.
If necessary the surfaces of Orcotape OT-6 and

OT-7 may be cleaned with any cleaner or solvent which does not harm the surface which
either tape is applied.
cellophane from one side of first wet
layer, and place in position with cellophane-covered
layers
Orcotape may be repositioned ashorttimeafter
application. If repositioning is necessary,

the tape by peeling at 180 degrees.
celloing off cutout area to be rebuilt with either

phane or-masking tape, covering an area at least 2 in.
wide around entire cutout. Masking saves considerable time and trouble in cleanup process after repair
side up. Rub cellophane gently, and work any excess

resin and trapped air bubbles to edges. Remove
remaining layer of cellophane, and repeat procedure
for all layers until repaired area has same number of
long lasting adhesion the surOrcotape reinforced, light
an
weight,
equally well as a prepared

dry layer. Backup plate is used to support repair
of
layers as they are placed in position. Place a layer
surand
damaged
cellophane between backup plate
face, and tape backup plate in place. Cellophane
sheet should be large enough to prevent leakage of
laminating resin onto adjacent areas of panel. Mask-
of sheet metal will work
has cured. Peel
For continuous,
face to which
Reinstall batt to airplane structure using Orcotape

OT-22.
Tapered Method
BATTSREPAIR
repair is for fiberglass batts made of Orcon AN-4B or
equivalent (metallic type material).
This
CONSUMABLES
MATERIALS
SOURCE KEY
ORCOTAPE, OT-6
059
ORCOTAPE, OT-7
059
ORCOTAPE, OT-22
059
Refer to 51-30-00 table 2 for m;Fnufacturer.

JT
51-70-50
Page
0
203
Mar 16/90
NA-66-1032
RIVET--MSM42BA04-2 ROWS REOD THRU

8818 1110 REPAIR OOURLER:
ONE ROW REOD IN FILLER
8818
REPAIR DOUBLER
AC
SKIN IREFI
ri+
"t\
:Ir
-t
11/16 MIN, 1-1/2 MAX
ITYP)
REPAIR
OOUDLER
f
~t
(REFI
FIILER
$_
FILLER
CF)
-t
-t
-tI
5/8 FOR STAOGEREO ROWS:

11/16 FOR W8W8TA86E8ED
ROWS ITVP)
-I
IECTION
A-A
FILLER
MATERIAL ANO
GAUGE TO MATCH SKIN
8818
IREFI
REPAIR DOUBLER
TO MATCH SKIN
MATERIAL
ONE
GAUGE HEAVIER THAN SKIN
NOTE
THIS
REPAIR
IS
APPLICABLE TO SECONDARY
STRUCTUREASINDICATEDINTYPICALREPAIRINDEX
5265-3-322
ILLUSTRATION.
51-70-50
Page 204
Aug 17/84

o
NA-Gfi- i 0~2
STRUCTURAL REPAIR MANIIAL
REPAIR OOUBLER
i
Jr
$I
t
FASTENER-TO
MATCH REMOVED
FASTENER (TyP)
II
illolt
ii
Il
SKIN ANO REPAIR DOUBLER:
II
II
II
II
2 HOWS REDO THRU FILLER
-C
AND REPAIR DOUBLER (TIP

EACH SIOE OF SUISTRUCTUAEI
jl+
II
,I
Ct I
f
RIVET--MS2042BR04-2 ROWS REOD THRV
-I!
tl
-C
-C
11/16 MIW--I-1/2 MAX
jlt
-C
+I
FILLER
ii -t-
It
I
-CI
II~I,
i.
t-l
-t
I,
~I
~I
-e
Ilf
II
I
5/6 FOR STAGGEREO ROWS-11/16 FOR NONSTAOGEREO ROWS ITYP)
+I
-t
(TYP FOR ALL RIVETS)
C__
A
t
ti
i
__
__
___
SUBSTRUCTURE
REPAIR OOUBLER
IREF--TYP)~j
SKIN
(REF)
FILLER
MATERIAL AND
GAUGE TO MATCH SKIN
SUBSTRUCTURE IREF)
5ECIION
REPAIR OOURLER
TO MATCH SKIN
A-A
MATERIAL
ONE
GAUGE HEAVIER THAN SKIN
E
SKIN IREFJ
h~
SUBSTRUCTURElREFI
NOTE
THIS
REPAIR
IS APPLICABLE TO SECONDARY
5265.3-323
STRUCTUREASINDICATEDINTYPICALREPAIRINDEX
ILLUSTRATION.

Figure 201 (Sheet 2 ot 2)
0
51-70-50
Page 205
Aug 17/84
NA-66-1032
STRUCTURALREPAIR MANUAL
OOURLER(REFJ
011, FROM WEIILIDIBL~
OAMAGE LIMITS
FILLER
MATERIAL
ANO GAUGE TO MATCH SKIN
RIVET
IREFER TO
IOTE)
-r,/
,I-1/2IMAXJ
SKIN
LF)
SKIN
(REq
OOUBLER
MATERIAL
ANO GAUGE TO
MATCH SKIN
MIX SIZE
WHICH WILL
PASS THRU
HOLE
FIISTEWEA
PEE NOTE)
FILLER
(REFI
OIA FROM
L--
_,_1
SELF
TAPPING
gr) scnrw
A
FILLER
STRAP(REF)
SKIN
SAFETYWIRE
OAMAGE LIMITS
MATERIAL
ANO GAUGE
CFI
STRAP
TO MATCH
MATERIAL ANO
SKIN
OAURETOMATCH
EXISTING SKIN
SECTION
"llRlIrIRFFI
A-A
NOTES
REPAIRS
SHOWN
PLUGS
STRUCTURALLY NEGLIGIBLE HOLES AS
IN
ARE
TO
BE
USED
ONLY
AS
COUNTERS1NK CHARt
DEFINED IN NEGLIGIBLE DAMAGE LIMITS FOR EACH

STRUCTURAL COMPONENT.
RIVET
MATERIAL
a
MATERIALS LESS THAN 0.040 IN. THICK SHOULD BE

DIMPLED
WHEN
ACCESS
PERMIT. WHEN DIMPLING
AND
5OLI0 5HANK
(IN.)
TOOLING
IS NOT PRACTICAL,
THICKNESO
NA51097
USE
COUNTERSINK DATA SHOWN.
0;020
403
0.025
a
FOR FLUSHNESS, USE AERODYNAMIC FILLER WHEN
0.031
REQUIRED.
a
WHEN
1 MSOW26 I
I
P~D1
403
ILIND
PULL
EXPLOSIVE
M590603-4
CR116-38
CR116-3
402
403
AD3
CR116-3
404
404
MS10601-4
0.040 and
APPLICABLE,
Heavier
SEAL
WITH
SEALANT
APPROPRIATE TO REPAIRED AREA.

THE
CIRCULAR
INSTALLED
REPAIR.
NOTE
REPAIR
DOUBLER
EXTERNALLY
RIVETS
SHOULD
AS
BE
MAY
BE
OCOUNTERSINK
TEMPORARY
FLUSHED
AND
TO
DEPTH
OF
MATERIAL
THICKNESS, AND MILL PROTRUDING PORTION OF
EDGES OF PATCH CHAMFEAED.
RIVET HEAD AFTER DRIVING.
5265-3-324
51-70-50
Page 206
Aug 17/84
Negligible Hole Repair

Figure 202
o
COPYRIGHT, 1984
NA-66-1032
Prim
out
damage, and round edges of hole.
Remove
minimum of material.
TRIM our OAmAOE

Crush
core side
I:sPrepare
*alls
as
(Typl
phown.
filler, end fill hole according to procedures in
51-20-20.
sslance aurtacss must be checked tor b.lance 8ft81
repair.
3/4
COREFIL 615 ITYPJ
IMIN--TYPI
HOLE THRU
SLIGHTLY CRUSH CORE

TO "KEY" COREFIL
REPARABLE LIMITS
S--DISIANCE fN INCHES
(I--HOLE DIA (IN.)
BETWEEN HOLES
1/2 TO 3/4
3/4 TO 1-1/2
(MAX)
(MIN)
(MIN)
HOLE THRU BOTH FACE SHEETS
FLAP STA 114.344
FLAP STA 108.774
NOTES
FLAP ACTUATOR
FLAP STA 123.640
IHEF)
Thisis anonstructuralrepair. Itisapplicable to all trailing edges ezcept asfollows.

O
Repairs not allowed to honellcomb elevator

trailing edges (must replace).
On NA a65-40, -BO, -r0, and -80
nonstructural repairs
o
o
airplanes,
must not be made in
00
01O
00
oooooo
and 1~3.840. Nonstructural repairs can be

made aft of shaded area i~fholes do not
ezceed 5/4 in. diameter.
Fiffure
203
-----vvvuwx~WOWx*
Honeycomb Trailing Edge Small Hole Repair
51-70-50
0
Page 207
16/90
Mar
NA-66-1032
-Pfi
RIVET--CRIISB~
IITVPI~
t
3/4 (Mln)
-t
SURFACE 8818 IREFI
k--1/41TYPI
+I
TEBEAMCRAIWEL
5/32
CF)
(TYPCHAMFER)
TE BEAM FACE
88557 IREF)
REPAIR DOUBLER
--3
COREFIL 815
I~
HOWEYCOMB
(REF)
CORE(REq
1 (c-- 3/417YP)
BALSA WOOO BDWO LIRE
REPAIR FILLER
PPI
CHIIINEL
slm4xl
IURFACE 8818
Boaolrt
HOIEYCOMR
FACE SMELT
MOIEICOMB
REPAIRROWB/ _I:1.
REPAIRFILLFR
LIRE
~Y
75 ASSY
REPAIR FILLER
wooo ISPEC
BALSA
SECTION
REPAIR SKIM
A-A
MIL-S-7998)
FLAP STA
FLAP STA
REPAIR DOUILER--0.032 1014-74
114.334-
108.774
CFLAP ICTUATDR
NOTES
FLIP 878
123.840
IREFI
FLIIPRIBIABI
This repair is applicable t~ all Loladed

aluminum honeycomb trailing edges, elceept elevators, and as noted in the flap
trailing edge view.
FLAP SKIM
(RE9
TheremustbeSin. ofundamagedtrailing
edge between repairs.
Refer to "Repairing Honeycomb Trailing
Edges"for additional repair instructions.
FLAP TL WE88E
Balance surfaces must be cheekedfor bal-
STRUCTURAL REPAIRS ARE NOT

PERMITTED BETWEEN FLAP STATIONS
anceafter repair.
Dimensions ah.own
are
in in.
Figure
FLAP TRAILING EDGE
106.774 AND 123.840.
204
Honeycomb Trailing Edge Repair
526~-3326
51-70-50
Page 208
Mar 16/90
NA-66-1032
STEPPEG REPAIR
II
I I
jC1
\_
__________
OVERLAY ITYPI
IREFER TO NOTE)
DRY BACKING LAYER
-I
I-
CELLOPHAIE SHEET
II
GLASS FABRIC
REPAIR LAYER
GLASS FABRIC
I____~
~_
_~___J
L__
EXISTING PART
L---
WET LAYER GLASS FABRIC
WET LAYER
GLASS FABRIC
WET LAYER GLASS FABRIC

Trim out damaged
shown. Do not cut
in..ltair-step.. fashion, a.
into layer below the one being removed.
O
Olnstelldly
O
I
Mix resin and
area
Isyar.
i:iij
Insfalwetlayen.
repair with polyvinyl alcohol sheet. Stretch

tight as possible, and tape it in place.
Cover
until it is
as
it
:j:iilll-l:
ii:i-i:iiiiiiii- iiili
Cure. repair, and refinish
ii::il-iiiiiii-
iiliiiiiiii i
area.
\z
NOTES
HOLES NOT EXCEEDING 2-1/2 BY 4 IN. R~QUIRE 1/2 IN.
OVERLAP; HOLES EXCEEDING 2-1/2 8Y 4 IN., BUT NOT

EXCEEDING 5 BY 8 IN., REQUIRE 3/4 IN. OVERLAP;
DRY BACKING LAYER
HOLES EXCEEDING 5 BY 8 IN. REQUIRE ONE IN.
GLASS FABRIC
OVERLAP.
REFER TO "GLASS-FABRIC-REINFORCED
CELLGPHANE SHEET
PLASTIC
REPAIRS" TEXT.
EXISTIWG FART
5265-3-327
Plastic Repair
Figure 205 (5heet 1 of 2)
0
51-70-50
Page 209
Auff 17/84
NA-66-1032
TAPERED REPAIR
PARTIAL PENETRATION
COMPLETE PENETRATION
CHAMFER APPROX 30"
Cisen out damage to
rounded
or
AREA FROM WHICH PORTION

OF FIRST LAMINATE HAS BEEN
circular-shaped
opening.
FIRST LAMINATE
REMOYEO FOR BACKUP LAYER
Chamfer area around cleaned-up damage

approximately 300 from first laminate.
to
On side
opposite chamfer, carefully remove a

rectangular piece from first laminate of glass cloth,
same length as diameter of chamfered area,
Grind chamfored
shape. This will

laminates
are
area to an
ensure
in proper
ORINO CHAMFER TO A SPHERICAL SHAPE
FIRST LAMINATE
appmximately SphBrioal
glass-fabric repair
position.
of first laminate with a
saturated with
laminating
CLASS-FABRIC REPAIR LAMINATES,

ALLOW AOOITIOHAL MATERIAL 80 THAT
REPAIR MAY BE GROUND AFTER IT HAS
CURED.
resin.
Before
attempting to install
backup layer to cure.
BACKUP LAYER
IRECTIIWGULIA
IN SHAPCI)
that
Replace removed portion

backup layer of glass cloth
any
repair laminates,
allow
THIS OISTANCE MUST

BE MAINTAINEO
(WITHIN
RB.IDIB damaged
filling spherical void
to its original Ihickness by

layers of glass-tabric repair
laminates saturated with laminating resin.
Allow
repair
to
BACKUPLAYER
stea
with
completely
cure.
NOTE
IN
RADOME REPAIRS, THICKNESS OF COMPLETED
REPAIR MUST BE WITHIN 0.010 IN. OF THICKNESS OF

RADOME BEFORE IT WAS DAMAGED. FOR ADDITIONAL
INFORMATION REFER TO TEXT IN THIS SECTION,
51-70-50
PzLp;e 210
Aug 17/84
52653-328
Figure
205
Plastic Repair
(Sheet
2 of
2)
COPVRIGHT, 1984;BY SABRELINER CORPORATION
NA-66-1032
ORCO7APE O7-g OR 07-7
7EIIR IW BA77
r
rs~
BA77
I7YPICAL)
1.
Makesurebattinterior iscompletelydry.
2.
Clean surface of batt with clean lint free cloth.
3.
Apply Orcotape OT-6
4.
Reinstall batt in airplane using Orcotape OT-22

double-faced tape.
or
OT-7
over
tear.
Figure
206
BATTS
Repair
51-70-50
0
Page 211/212 Blank

Mar 16/90
NA-66-1032
RESTRICTED-LIFE REPAIRS
REPAIR
GENERAL
Restricted-life repairs are to be used only for purpose of
preparing a damaged structure for a flight (restricted) to
a facility where permanent repairs can be effected. When
a flight is to be made with restricted-life repairs incorporated, place a suitable placard in cockpit stating flight
limitations. (Refer to 51-00-10.)
CONVERTING CLASS A AND CLASS B REPAIRS

TO RESTRICTED LIFE REPAIRS
Class A and Class B repairs shown in each repair chapter
may be used as guides in design of restricted-life repairs.
Skin repair doublers shown inside skin may be installed
outside skin. Protruding-head fasteners may be used in
place of flush-head fasteners called out. "Restricted-life
Repair Fastener Substitution Table" lists blind, protruding-head fasteners that may be substituted size-forsize for fasteners called out in repairs or used in original
construction.
Repairs to fuel-carrying areas of wing must be fuel tight.

Finish requirements need not be complied with in any
area of airplane.
51-70-60
0
Page 201
Aug 17/84
NA-66-1032
S1HI(TIIRAL REPAIR MANUAL
Table 201.
Restricted-Life Repair Fastener Substitution
ORIGINAL CONSTRUCTION OR REPAIR

CALL-OUT FASTENER(FLUSW)
AL ALY
RIVETS
SUBSTITUTE PR()TRUDING
HEAD BLIND FASTENER
AD
MS2()600AD
MS30600MM
AD
MONEL
RIVETS
CRES
RIVETS
X
i~ I
(:II1)TIYIOCI< tiV(!tS
Monel
(:herrylock ri\ets
CRE:S Cherrvlock rivets
224!)
Cherrylock rivets
MS20602AD
HI-SMEAR
RIVETS
JO-BOLTS
BOLTS
AND
SCREWS I~
P Series Jo-bolts
69jl-S Deutsch drive pins
NOTES
OSUBSTITUTION
PERMITTED
FOR
SHEET-METAL
ATTACHMENT ONLY DO NOT USE FOR ATTACHMENT

FITTINGS.
DO NOT USE EXPLOSIVE RIVfTS IN FUEL AREAS.
51-7060
Page
202
Aug 17/84
oi
COPYRIGMT, 1,984 B~ SABRELINER CORPORATION:
NA-66-1032
NEGLIGIBLE DAMAGE REWORK

STRUCTURAL IDENTIFICAITON
GENERAL
Refer to Tj1-10-00, "Damage Classificaiton," for definition
of dents, scratches and nicks, negligible corrosion, cracks,
and holes.
51-70-70
Page 1/2 Blank

Aug 17/84
NA-66-1032
STR1!CTURAL REPAIR MANUAL
NEGLIGIBLE DAMAGE REWORK

REPAIR
(;ENERAL
NEGLIGIBLE CORROSION DAMAGE
Although certain types of damage may be considered

structurally negligible, in most cases, rework must be
performed to prevent negligible damage from developing
into major damage. With specific limits, the following are
cl;~ssified as negligible damage: dents, scratches, nicks,
If corrosion damage does not exceed the prescribed lim its

for scratches and nicks, clean out corrosion and chemicalfilm-treat and prime area. (Refer to Sabreliner Corrosion
Control Manual, SR-76-023.)
corrosion, cracks, and holes. I,imitations are shown on the

negligible damage illustrations in each structural group
CRACKS
chapter.
Stop-drill negligible cracks
at each end.
HOLES
I)ENTS
M inor dents may be left"as is" or filled with aerodynamic
skin filler. Larger dents should be bumped out to mold
line. No sharp dents or wrinkles are permitted.
Plug all structurally negligible holes in skins for both

weather sealing and aerod~namic reasons.
sc RATCHES AND NICKS

Scratches or nicks are not considered negligible until
after they have been reworked by blending or other
prescribed methods. Scratches or nicks may reduce the
cross-sectional area of a material and produce localized
stress concentration. This condition can lead to fatigue
cracks and possible failure of component,
Blending of scratches or nicks is process of smoothing out

area. To blend properly, a fine-grit (400 or finer)
abrasive cloth or paper, or aluminum wool, should be
used. Do not use crocus cloth or steel wool, since they tend
dam age
or nicks should be smoothed

all damage. Reworked area
must be kept as small as possible and with minimum of
material removed at bottom of damage.
to
cause
corrosion. Scratches
out with abrasive to
remove
In tlertain highly stressed areas, it is necessary to use a

dye-penetrant check after blending to reveal any cracks
which may otherwise be undetected.

After blending, damaged area must be chemical-filmtreated and primed.(Refer to Sabreliner Corrosion Control
Manual, SR-76-023.)
51-70-70
Page 201/202 Blank
c
Aug 17/84
C H A PT E R
DOORS
NA-66-1032
STRUCTURAL REPAIR MANUAI.
CHAPTER 52
DOORS
TABLE OF CONTENTS
Subject
Chapter/Seetian/Subjeet
Doors
General
Door
Skin Gap Diagram
Page
52-00-00
1
..1....
Repai~ ir;d~;
MainEntranceDoor
General
52-10-00
""""""""""""""""..c.......
1
1
Main Entrance Door
52-10-20
Repai r
Main F:n trance Door Stop
Inspection
Inspection
and
Repair
201
201
2()1
Repair
rlandingGearDoors
General
Landing Gear Doors

Allowable Damage
52-80-00
1
1
52-80-10
General
101
Negligible Damage Limits
101
101
Landing Gear Doors

Repair
52-80-20
General"""""""""""""""""""""""""""". . -
201
201
201
Repairs
5P-CONTENTS
"COPYRIGHT,
1984 BY
SABRELINER CORPORATION
Pa~e 1/2
Blank
Aug 17/84
NA-66-1032
CHAPTER 52
DOORS
Section
52-00-00
1
2
3
52-10-20
52-80-10
Title
Figure No.
Page
Model NA 265-40, -60, -60A, -65, and -70

Door Repair Index
(S/N 370-2 thru -6, -8, and -9)
With Modified Entry Door
Door Repair Index
Model NA 265-70
(S/N 370-1 and -7, -80, -80A, and -80SC
Skin Gap Diagram
202
Main Entrance Door

Model NA 265-40
Inspection and Repair
(S/N 282-1 thru -97) and NA 265-60 (S/N 306-1 thru -63)
Main Entrance Door
Repair
101
Negligible Damage
201
Landing Gear Doors
2
5
202
203
Model NA 265-40,
-60, -60A, -60SC, and -65

52-80-20
201
202
Landing Gear Door Outer Skin Repair

-60SC,and-65
Landing Gear Door Inner Skin Repairs
-60SC,and-65
102
Model NA 265-40, -60, -60A,

201
Model NA 265-40, -60, -60A,

203
52-ILLUS
0
Page 1/2 Blank

Mar 16/90
NA-66-1032
CHAPTER 52
DOORS
Chapter/
Date
Page
Section
52-L.E.P.
1/2"
Mar 16/90
52-CONTENTS
1/2
Aug 17/84
52-ILLUS.
1/2"
Mar 16/90
9/10
Aug 17/84
Aug 17/84
Jun 3/88
Jun 3/88
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
52-10-00
1/2
Aug 17/84
52-10-20
201"
202"
Mar 16/90
Mar 16/90
Mar 16/90
52-00-00
3
4
5
6
7
8
Added
203/204*
52-80-00
1/2
52-80-10
101
102
103/104
52-80-20
201
202
203
204
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug
Aug
Aug
Aug
or
17/84
17/84
17/84
17/84
52-L.E.P.
0
Page 1/2 Blank

Mar 16/90
NA-66-1033
STHIICI~URAI, KEPAIR MAN1AI,
CHAPTER 52
DOORS
(;ENEHAI,
Ihis chapter contains repairs,
anti fillinK of airframe doors.
negligible damage limits,
I)OOK. REPAIR INI)EX

Sec? figure 1 for Model NA 265-40, -60, -60A, -60SC, -65,
and -70 (S/N 370-2 thru -6, -8, and -9). See figure 2 for
Motfel NA 265-70 (S/N 370-1 and -7),-80, -80A, and -80SC.
SKIN <;AP DIAGRAM
See tiffure
52-00-00
0
COPYRIGHI", 1984 BY SABRELINER CORPORATION
Page 1
Aug 17/84
NA-66-1032
STRCCTURAL REPAIR,~IANUAL
EWTRY DOOR
IWTERIOR
22
(TYPICAL LH 4 RHJ
STRUCTUAE
12
~a cs,~ c~i
13
14
~C
II
iJ
MODEL NA 265-60
20
17
18
TYPICAL SERYICE 0OCRS

REFER TO CHAPTER
COVERIWO THE 0081808080
TO WHICH DOOR IS ATTACHED
5_
~1
",3
EITRY DOOR
3
EXTERIOR
snlr
03
21
6h
(AH SIOEONLYI
r~(J
2
23
24
28
25
s?ts-3loz
Door
52700-00
Page 2
Aug; 17/84
Repair Index
Model NA 265-40, -60, -60A, -GDSC, -65, and -70
(SiN
a70-2~gCurk6i-8,
o
and
-9)
NA-66-1032
ITEM
NO.
DRAWING
NO.
265-300021
265-300238
265-300209
265-300242
265-300023-5
265-300023-43
265-300023-89
265-300023-3
265-300023-63
265-300023-25
265-300023-27
265-300239
265-300240
6
7
8
9
10
11
12
13
14
15
16
17
18
19
2G
21
265-300234
265-300234-25
265-300234-27
265-300234-29
265-300234
265-300234-3
265-300234-7
265-300234-31
265-300236
265-300236-3
265-300236-7
265-300236-19
265-300237
265-300237-3
265-300237-5
265-300237-15
265-300241
265-300216
265-300023-29
265-300023-45
265-300023-9
265-300025
282-300027-101
22
282-300027-101
282-300027-102
23
265-34301-3
DESCRIPTION
MATERIAL
Fuselage Entrance Door

Skin
Cover
Center Link, Fuselage
Entrance Door
Handle
Inside, Fuselage Entrance
Door
Stair Tread (Rigidized Sheet No. 5WL)
Handle
Cover
Stair Tread
Stair Tread (Rigidized Sheet No. 5WL)
Web
Door Beam
Door Angle
Door Land
Forward
Aft
Door Land
Frame
Entrance Door, FS 146.187
Angle
Doubler
Frame
Frame
Entrance
Frame
Fitting
50-16 Alloy
Cast.
2024-13 Bare
6061-0 Tube
2024-142 Bare
2024-13 Bare
7178-T6 Bare
7178-16 Extr
7178-T6 Extr
Glass Fabric
Glass Fabric
0.040
0.049
0.040
0.040
0.040
6E1006
785
0.010
0.010
7178-16 Extr
7178-16 Bare
7075-T6 Bare
0.025
0.032
7178-16 Bare
7178-16 Extr
7178-16 Bare
0.032
13698
0.025
7178-T6 Bare
7178-T6 Extr
7178-16 Bare
0.032
13698
0.025
7178-16 Bare
7178-16 Extr
7178-16 Bare
6061-0 Tube
7178-T6 Bare
7178-16 Bare
7178-T6 Bare
7178-16 Bare
2024-13 Bare
0.032
13698
0.025
0.049
2.250
0.080
0.050
0.050
1I~
53-30-20Fig. 202
2024-13 Bare
0.050
IP
53-30-20Fig. 202
2024-13 Bare
0.050
53-30-20Fig.
2024-T3 Bare
0.050
53-30-20
2024-142 Clad
0.032
Fig. 202, 203
13698
Door, FS 170.187
Angle
Doubler
Handrail
BaaZUFigZOZI
0.050
0.125
Door, FS 161.75
Angle
Doubler
Frame
Entrance
Frame
2024-13 Bare
7075-T6 Bare
Door, FS 155.25
Angle
Doubler
Frame
Entrance
Frame
GAUGE
REPAIR
FIGURE
NO.
Entrance Door
Attaching Arm Support
Beam
Doubler
Sheet
Door
Ground Escape Hatch
(S/N 282-1 Thru -90)
Door
Ground Escape Hatch
(S/N 282-91 and Later)
Ground Escape Hatch, LH
Door
Door
Ground Escape Hatch, RH
Door
Nose Landing Gear, LH
6E1102
202
Fig. 202
NOTES
Foradditionalrepairs, referto51-r0-00.
Figure number is in this chapter unless Ot~Lerwise noted.
Thisisa ehemmilled ormachinedpart. ~eathinned areas, or refer to drawing

numbersfor thickness variation.
sure
Key to Figure 1
(Sheet 1 of 2)
52-00-00
0
Page 3
Aug 3/88
NA-66-1032
ITEM
NO.
REPAIR
FIGURE
DRAWING
265-34301-4
265-333301-3
265-333301-4
265-333371-1
265-333371-2
266-333351-7
265-333351-8
23
24
25
26
MATERIAL
DESCRIPTION
NO.
Door
Door
Door
Door
Door
Door
Door
Nose Landing Gear, RH

Main Landing Gear, LH
Main Landing Gear, RH
Fixed, Main Landing Gear, LH
Fixed, Main Landing Gear, RH
Movable, Main Landing Gear, LH
Movable, Main Landing Gear, RH
2024-T42 Clad
7075-16 Clad
7075-T6 Clad
2024-T42 Bare
2024-T42 Bare
2024-142 Bare
2024-142 Bare
GAUGE
0.032
0.032
0.032
0.625
0.625
1.000
1.000
NO.
Fig.
Fig.
Fig.
202, 203
202, 203
202, 203
NOTES
For additional
repairs, refer
to 51-70-00.
number is in this chapter unless

otherwise noted.
O Figure
This is
chem-milled
or
machined part.
1Measure thinned areas, or refer to applicable drawing numbers for thickness
variation.
52-00-00
Page 4
3/88
Jun
Key
to
Figure
2 of 2~
teehS(1
NA-66-1 082
STRUCTURAL REPAIR MANUI\I,
10
8
~5
~W
1
I
ENTRY DOOR STRUCTURE
TYPICAL SERVICE O0CRS

RLFFR TO CYPTER COVERIIG
14
COMPOHENT TO WHICH OOOR

IS ATTACHEO
a
Is
17
W
D
r)
20
15
19
18
370-3-19
Door Repair
Tndex
(S/N
Model NA 265-70
With Modified Entry Door
-7), -80, -80A, and -80SC
370-1 and
Figure
0
52-00-00
Page 5
Aug 17/84
NA-6(i-1032
STRUCTURAL RI~PAIK MANUAI,
STRUCTURAL IDENTIFICATION-(Continued)
ITEM
N().
1
GAUGE ()R
EXTRUSION
I)RAWINC~ N().
12Kh-30(3222-281
DESC RIPTION
Angle
Ream
Fitting-attaching
~65-:i1)0215-S1
ci
9
1()
11
1~
1:)
1-1
15
16
17
18
19
205-300219-47
265-300218-35
265-300240-11
265-300222-27
265-300221-23
265-300220-43
3$0-300217-3
380-300260-5
Frame
FS 170.187
Frame
FS 161.750
Reinforcement
Lower
Arm
380-300207-11
380-1300207-3
380-300207-5
265-343301
Step Assy
Lower
Step
Lower Step
Honeycomb Core
Facing Sheets
Door
Nose Landing Gear
Door --Main Entrance
Door
Ground Escape
Door
Strut, ML(;
Door Assy
Wheel, MLG
Plate
Plate
Cover
E:ntry Door Center Link
Upper Cover
Lower Cover
265-300238
370-Y00027
Y70-:33.1351-:3
570-3~3352-11
265-300247
265-300247-3
265-300247-5
7178-T6 Bare
7178-T6 Extr
7178-T6 Bare
0.050
6E1102
2.250
0.041)
0.040
0.032
0.010
7A,I
0.032
0.040
Die Forge
6UV Stab.
7075-T6 Bare
2014-T6 Al.
Molded Nylon
7075-T6 Bare
Stop
Step Assembly
380-300208
NO.
60~1-T6rube
7075-16 Bare
707Fj-T6Rare
Glass Fabric
7178-T6 Extr
7075-T6 Bare
Angle
370-R:13:362-3
370-333352-7
20
support
arm
Handrail
entry door
Frame
FS 155.25
Frame
FS 146.812
Door Land
MATERIAL
5052-1139
2024-T42 Bare
2024-T42 Clad
2024-T3 Bare
Bare
7075T7351
0.250
j/480.004
0.040
0.032
0.050
0.050
1.380
7075-1731
6061-T6 Bare
.0,250
2024-T42 Rare
7178-T6 Rare
0.190
0.100
5370-3-(80
NOTI~
Eor;ultlitional repairs, Iefer t;, 61-70-00.
52-00-00
Iaffe 6
~uR 17/84
Key
to
Fiffure
COPYRIGHT, 1984
NA-66-~ 032
13/16
1/4
1JC
l/s
3/32
1/32
1/16
1/B
CDNSTANT
1/16
1/16
1/8
a/16
-I
"3/16
It
1/16
1/16
3/32~
DOOR
DOOR
GROUND EMERGENCY
MODEL NA 265-40
FUSELAGE ENTRANCE
IKm OARS BETWEEN DOORS

AND ADJACENT PARTS AND
WITRIN TL DOOR ASSEMBLY
ARE SHOWN.
flR
ALL DIMENSIDNS ARE _t1/32 IN.
3/32
+1/32
-1/16
CONSTANT
NOTES
SKIN GAP TOLERANCES NOT SPECIFICALLY SHOWN
ARE O TO 1/16 IN.
SKIN GAP TOLERANCES GIVEN ON THIS ILLUSTRA-
TION ARE FOR THE FITTING OF NEW PARTS. REFER TO

"SKIN GAP TOLERANCES" TEXT FOR PERMISSIBLE
DOOR
GROUND EMERGENCY
MODEL NA 205-00, -60A, AND -0000
TOLERANCES WHEN FITTING PARTS THAT HAVE BEEN
PREVIOUSLY INSTALLED ON ANOTHER AIRPLANE.
8265-3-1008
Skin
Figure
0
~ap Diagram
3 (Sheet t of 3)
52-00-00
Page 7
Aug 17/84
NA-66-1032
STRUCTUHAL REPAIH MANUAL
1/16 TO 3/16 IN. BETWEEN DOORS ANO ADJACENT SKINS
3/16 IN. BETWEEN BOORS
DOOR
NOSE LANDING GEAR
5/is
1/4
LANDING MAIN GEAR

RINGED DOOR
MODEL 265-40, -60, -604, AND -60SC
MAIN LANDING GEAR

WHEEL DOOR
MODEL NA 265-40, -60, -604, AND -6060
SKIN OAF BETWEEN DOOR AND ABJACENT PARTS IS 1/32 TO 5/32 IN.
SKIN OAF BETWEEN OOOR ANO ADJACENT PARTSIS 1/16 TO 3/16 IN.
EXCEPT AS NOTED.
SKIN OAF BETWEEN DOON AND ADJACENT

PARTS IS 1/32 TO 5/32 IN.
NOTES
ARE O TO 1/16 IN.
SKIN GAP TOLERANCES GIVEN ON THIS ILLUSTRATION ARE FOR THE FITTING OF NEW PARTS. REFER TO
~SKIN
GAP TOLERANCES"
TEXT
FOR
PERMISSIBLE
FIXED DOGR
MAIN LANDING GEAR
MODEL NA 265-40, -60, -604, AND -6000
92853-1O1A
52-00-00
Page 8
Aag 17/84
Skin Gap Diaffram

3 (Sheet 2 of 3)
Figure
CDPYRIGHT, 1984 BY SABRELINER CORPORATION
NA-66-1032
STRUT
DOOR
MAII LAW6IW6 GEIA
LOW~R DOOR
3/32
1/32 TO
1/32
1/16
CONSTANT
5/3216.
ITYPICAL
AAOUNO
0OORI
VIEW LOOKING UP
GROUND EMERGENCY
DOOR
MODEL NA 285-70, -80, -808, AND -8080
MAIN LANDING GEAR

STRUT DOORS
MODEL NA 285-70, -80, -808, AND -8080
1/16
11/32
1/16
1/8
,IT;n
1/16
i/is
1/16
1/16
1/16
1116
31/32tl.j
1/18
1/16
1-1/161/8
1/8
I-IN-FLIGHT
OUTER DOOR
ESCAPE ~AfCH
SPEED BRAKE
S370-3-21
Skin Gap Diagram

3 (Sheet 3 of 3)
Figure
0
52-00-00
Page 9,10 Wlank
Aug li,H4
NA-66-1 032
MAIN ENTRANCE DOOR

(;ENERAL
This section contains information on the main entrance
door. For negligible damage limits, refer to section 53-0010. For repairs to the main entrance door, refer to
Fj2-10-20.
52-1 0-00
0
Page 1/2 Rlank

Aug. 17/84
NA-66-1032
MAIN ENTRGNCE DOOR

REPAIR
GENERAL
This section contains
repairs for the main entry door.
MAIN ENTRANCE DOOR STOP

AND REPAIR
INSPECTION
NA 265-40, (S/N 282-1 thru -97, before S/B 3) and NA

265-60, (S/N 306-1 thru 306-63, before S/B 3.)
On affected airplanes, an aluminum extrusion is used for
the mechanical stop on the lower end (closed position) of
the entry door. Repeated door openings (particularly hard
cycles
openings) and pressurization/depressurization
cause stress to the extrusion, sometimes causing longitudinal cracks along bottom side. Once started, these cracks
spread rapidly, causing a complete fracture. If this occurs
during flight, the door is retained by safety latch pins;
however, partial depressurization may occur. To prevent
such an occurence, the lower door stop is dye penetrant
inspected. If no cracks are detected, the inspection is
repeated
at 600 hour intervals.
INSPECTION
Inspect entry door
as
follows:
1.
Open entry door.
2.
Remove all paint and primer from door stop

radius area, the full width of door.
3.
Using non-metallic
scraper and
(MEK) or equivalent,
inspection area.
(beam)
methy ethyl ketone,
remove excess
sealant from
4.
Peform dye penetrant inspection of radius

lower door stop (beam).
5.
If door stop (beam) is cracked, entry door must be

repaired before airplane is flown (except unpressurized flight to repair station).
6.
If no cracks
residue.
7.
Coat bare aluminum surfaces with alodine.
8.
Replace sealant (PR1422GB) removed for
are
area on
found, clean off all inspection
access
to
area.
9.
Prime and
paint
area
to match
entry door finish.
REPAIR
If lower door stop is cracked, two options
1.
Incorporate S/B3.
2.
Replace door stop.
are
available:
52-1 0-20
Page
0
201
Mar 16/90
NA-66-1032
Q
ENTRY DOOR
OYE PENETRANT INSPECT FOR

CRIICKS RUNNING FORE ANO AFT
ALONG THIS RADIUS.
SEALANT
FILLET
AREA
RUBBER STRIP
DOOR STOP
lOEAm)
RUBBER BEAD
AROUND BOOR
ENTRY DOOR
VIEW LOOKING AFT

7e-4o
Main Entrance Door

Inspection and Repair
Model NA 265-40 (S/N 282-1 thru -97) and NA 265-60 (S/N 306-1 thru -63)
Figure 201
52-1 0-20
Page 202
Aug 17/84
NA-66-1032
Repair Doubler
301-0505 1/2 Hard 0.025
o.ruu
Filling 285-300215 IRel.)

Teer out on Frame
(Typlos$
~s
-c-c~
;G
Cracking In Frame Ilypicsll
/je
0.35 Typ
Added Fastlnen 003242-5
Elisling Fastenars locations
O
O
0.35
i- Frame 265500218/221 Rat.
Typ
-I
f-
J-
J-
J-
0.35 Typ
Repair
doubler
Extented Repair Doubler
ro~
P
8\8/8 88 8,
888 818
e
21
/d///
e
lo,
;I
~1
a.
3-/
8
I
a.
Os..
:\s\~
/I
s,,s.
;I
/Y/
s
gQ
?~Y
~-3,
LEGFND
8=
Trim out damaged area and stop drill cracks as required
using #40 drill. Fabricate repair doubler as shown.
Extented doubler may be used if required. Prime repair
doubler and all mating surfaces with Polyamide Epoxy
Primer and assemble using faying surface sealant PR
1431G or equivalent. Install NAS1669-6 fasteners (Jo
Bolt) using
wet
polyamide
epoxy
Repairl
NAS 1669-6 19 EA
8 EA
primer.
Figure
6R3243-520 EA
18 El\ IFxtended
(Extlnded Rapairl
I Irr
202.
Repair
Main Entrance Door
52-1 0-20
Page 203/204 Blank
Mar 16/90
NA-6~-1032
STRI~CTURAL REPAIR MANUAI,
LANDING GEAR DOORS

(;ENERAI,
ltlis section contains information on the landing gear
doors. See section 622t)0-10 for negligible damage limits.
See section 52-80-20 for repairs.
52-80-00
0
Page 1/2 Blank

Aug 17/84
LANDING GEAR DOORS

ALLOWABLE DAMAGE
(;ENE:KAI~
Ihis section contains
landin)S
gear
negligible damage limits for the
doors.
Nfi:(;I,IGIRI,E I)AMAGE LIMIT8
figure 101 (Sheet 1 of 2) for negligible damage limits

NA 26.5-40. -CiO, -60A, -fiOSC:, and -65. See 101
Motlel
for
(Shec\t 2 of 2) for nelSliffible damage limits for Model NA
2fi5-70, -80, -80A, and -80SC.
52-80-10
Page 101
Aug 17,182
NA-66-1032
C:"_~8
5
3
SHADED AREA
CRITICAL FOR WHEEL
CLEARANCE (REFJ
NOSE WHEEL 000RS
c3S
FIXED
STRUT 0ODR
CODE
AREA
SCRATCHES
HOLES
0.004 IN,
UNLIMITED
0.094 In.
ualmlr~o
THICKNESS
Im
UNLIMITED
NONE
NONE
0.008 IN.
0.008 1N.
ACROSS ANY
ISURFACE
0.005 IN.
UNLIMITED
0.004 1N.
UNLIMITED
O.WB IN.
ACROSS ANY
ISURFACE
NONE
11
TYPE A
NO. 40 GRILL
OEPTH
r- TYPL O
NONE
NONE
NONE
(TYP)
lea
NONE
MAIN WHEEL 000RS
FASTENER ROW IREFJ

STOPOAILL WITH
TYPE B
ACROSS ANY
ISUAFI\CE
lo
MOYABLE
STRUT DOOR
1~
UNLIMITED
15% OF SKIN
~Z1
1 IN.
TVPIO.
SECTION
A-AL
rA
IMINI
FROM ANY HOLE
CRACKS
LIA
OEITS
9551
AREA
011
DEPTH In
08 [In.)
IN.
1/4 TO 1/2
1,2. 7.
3&4
5, 5, 9,
1/2 TO 1
0.012
t TO 3
0.020
1/4 TO 1/2
0.012
1/2701
0.015
1 TO 3
0.030
11
DENT
(MAX)
0.008
CRACKS
I:
CORE
AREA
TYPE A
TYPE O
1 PER PANEL
1 PER PANEL
1 PER PANEL
NONE
TYPE O
t PER PANEL
NOT APPLICIIBLE
8
TYPE C
1 PEA PANEL
1 PER PANEL
NOTES
DAMAGE
GIVEN
MAY
BE
CONSIDERED
MUST
BE
GENERALLY
SMOOTH
91
AND
WITHOUT
ABRUPT CHANGES IN CONTOUR.
1:
A COMBINATION OF Two OF THE ABOVE CRACKS MAY EXIST
NONE
PER
BAY
AND THREE OVER
NONE
NONE
1
I
P31
NONE
NONE
I
I
t PER PANEL
ENTIRE
SURFACE
ONE IN
1IN,
NONE
PIIW.
NONE
1
I
FROM ANY STIFFENER OR FASTENER.
I
i
1 PER:PANEL
lo.
1 PER PANEL
1
I
11:
NONE
NONE
NONE
IlN.
NONE
_nOnE
NONE
1PEIP~WEL
I 1
1 PERPANEL
I 1 PERPANEL
I PER PANEL
I
I
I PER PANEL
NONE
NONE
1IN.
1 PEA PANEL
NONE
AT THE SAME TIME IN ONE BAY, EXCEPT FOR TYPE D WHICH
1S LIMITED TO ONE
p; 1 IN1
1 PER PANEL
NEGLIGIBLE
AFTER TR EATMENT DESCRIBED IN 51-70-70.

DENTS
1 In.
1 PER PANEL
1II;
1IN.
III.
IIII.
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
NONE
DIAMETER IS SHORTEST DISTANCE ACROSS DENT

916531103
52-&0-10
Pa%e 102;
Aug T7/84
Negligible Damage
LandE~gGear Doors
-60SC, and -65
Model NA 265-40, -60, -608,
Figure 101 (Sheef 1 of 2)

o
CCiPW~RI-GHT,
1984 BY SA;BRELINER CORPORATION
NA-tiG-1032
STRUCTURAL REPAIK MANUAI,
j
4
fiI
NOSE WHEEL 0O0RS
5B1II
i?
CODE
AREA
HOLES
SCRATCHES
IOWE
O.OOR
0.005
UILIMITEO
0004
UNLIMITEO
0.025
UNLIMITEG
0.025
UNLIMITED
0.025
UWLIMITEOC~I
0,008
ANY
ISOHFACE
NONE
0.008
UNLIMITED
O.OOO
ANY
ISURFACE
1~
o I
FASTENER ROW IREFI

STOP-GRILL WITH
NO 40 DRILL ITYPI
TYPE B
TYPE A
1PI
-i~-
~P
nONE
DEPTH
T- TYPE O
to
llo
SECTION
II
1
oil
29
III.1
O,OO8
1/4701/2
2,3.8
4, 5, 6
CAACKS
DENTS
rA
IW.IMINI
FROM ANY ROLE
TYPE C
1/2 TO
L)A
0.012
30T1
0.020
1/4701/2
0.012
1/2 TO 1
0.015
1 TO 3
0.030
GENT
HOT APPLICARLE
7.8
COOE
AREA
NOTES
TYPEB
TYPEC
NONE
NONE
NOHE
NONE
1 PER PANEL
1 PER PANEL
IpRRIP~nYEL
1 PER PANEL
t PER PANEL
1 PER PANEL
i
1 In,
1 PER PANEL
pr 1 In.
NONE
NONE
NONE
1 PER PANEL
p
1 II.
NONE
NONE
NONE
1 PER PAHEL
Iln.
p
AFTER TREATMENT AS DESCRIBED IN 51-70-70.

DENTS MUST BE GENERALLY SMOOTH AND WITHOUT
A COMBINATION OF TWO
OFTHE ABOVE CRACKS MAY
EXIST AT THE SAME TIME IN ONE BAY, EXCEPT FOR

TYPE D WHICH IS LIMITED TO ONE PER BAY AND
THREE OVER ENTIRE SURFACE.
IS1
lil
TYPED
TYPEA
1IIRPIY~L
P 1IH.
20
DAMAGE GIVEN MAY BE CONSIDERED NEGLIGIBLE
A-A
I
1
ONE IN. FROM ANY STIFFENER OR FASTENER.

DIAMETER IS SHORTEST DISTANCE ACROSS DENT.
a
7
1
1
NONE
1 PER PANEL
I
I
NONE
NONE
NONE
IIDIIE_L~
8088
NONE
HONE
1 PER PANEL
I PER PLIEL
g
IlN.
1 PER PANEL
NONE
NONE
IlN.
NONE
S37(L-3-20
Negliffible Damage
Model NA 265-70,
Figure 101
Landing Gear Doors
-80,-80A,and-80SC
(Sheet 2 of 2)
52-80-10
Page 103!104 Blank
Aug 17/84
NA-66-1032
LANDING GEAR DOORS

REPAIR
(;ENERAL
This section contains repairs to the landing gear doors.
REPAIRS
in this section are applicable for both inner and
outer skins of the main landing gear and nose landing
of repairs, refer to 5200-00.
gear doors. For applicability
Repairs
52-80-20
0
Page 201
Aug 17/84
NA-66-1032
SUBSTRUCTURE IREF)
OUTEB SKIN
REPAIR OOUBLER
II
FILLER
-t
/f
Il \i
~t
t\
I)
(I
RIVET
I?j
II
I~
RIVET THRU SKIN ANO REPAIR

OOURLEB. SEE CHART FOR
RIVET REOUIREMEWTS.
\f+
II
II
AIYET
OIA
ITYPJ
FILLER
MATERIAL
AND GAUGE TO MATCH
5-1/2 x RIVET
OIA 1~-1/321
[TYP FOR ALL
RIVETS)
FILLER IREF)
--7
OUTER SKIN
IRCFI
----:-i:i:_-:- :i-i
L
SUBSTRUCTURE (REF)
REPIIIA OOUOLEB
(RLFJ
A-A
SECTION
REPAIRING OUTER SKIN
,I
Trim out
damage. Shape of the opening may

(with a split circular repair doubler)
rectangular (with a solid one-piece doubler).
circular
as
Provide
outer skin
in.
shown
access
hole in inner skin for
bucking
repair (except when blind rivets are
be
or
OUTER SKIN
rivets in
IREFI
used in 0.040
REPAIR OOUBLER
skins)
O
O
railiiSate and inaal
ouai
MATERIAL TO MATCH
SKIN THICKNESS IS
ONE GAUGE HEAVIER
slin repa r Dsrts
Fabricate and install inner skin repair parts.

Gear Door Inner Skin Aepair")
(See
"Landing
RIVET REQUIREMENTS
NOTES
1 HIS REPAIR
MATERIAL
I$ APPLICABLt: ~O OUTER SKINS ON THE
MAIN AND NOSE LANDING; GEAR DOORS

THE INNER SKIN REPAIR MAY BE USED TO CLOSE OUT
AN
ACCESS HOLE PROVIDED FOR REPAIR OF THE
OUTER SKIN.
GAUGE
RIVET
ROWS
REDO
INSTALLATION
2024T42
0.032
0431097404
7075-75
0.032
NAS1OO7AO4
CSK
7075-~8
0.040
0431097405
CSK
7075-70
0.040
8320001 MP4
CSK
DIMPLE
I1SE TWO ROWS OF RIVETS IN SPLIT REPAIR DOUBLER.
USE ONE ROW OF RIVETS IN SOLID ONE-PIECE REPAIR

DOUBLER. (SEE CHART FOR RIVET
52-80-20
PaRe 202
AuR 17/84
szes-s-lw
OPTIONS.)
I,andina (;ear L)oor ()uter Skin H~epair

Motlel NA 265-40, -60, -60A, -605C, and -65
Fip~ure
o
201
COPYRIGHT,
NA-fiG-10:J~
STRUCTURAI, KEPAIR MANUAL,
INNER SKIN
BELO(TYP)
I II
MAIN OEAR OOOR
1J
REPAIR OOUBLER
INNER SKIN
RIVET
fl
i+
1
Itl
1,1
f,--
MS20600A04
OR MSZOM)2A04
2 ROWS
REOR
-e
I
I
+I
cl
/A
II
~I
ct
I-e
I~
11
j_/
II
REPAIR OOUBLER
IREF)
TRIMMED OUT OAMAGE

OR ACCESS HOLE
FASTENER 0IA
ITYI
1II sUCI81
11/16 TO 3/4 IN. 0.032 MATERIAL

11/1OTO 13/16 IN. 0.025 MATERIAL
(TYP FOR ALL fASTENERSI
SECTION
A-A
mIIIR SKII
b~PI
REPAIR OOUBLER
ONE
2024-T4 CLAD
OAOOE HEIIVIER THAN
INNER SKIN
NOTE
THE REPAIRS SHOWN ARE APPLICABLE TO LANDING
GEAR DOOR INNER SKIN AS
FOLLOWS:
SKETCHI--MAINANDNOSEGEAR.ASREPAIRANDAS
CLOSE-OUT FOR
SKETCH 2
ACCESS HOLE.
MAIN GEAR, WHEN DAMAGE IS ACROSS A

BEAD.
SKETCH 3
SUBSTRUCTUREIAB
NOSE GEAR, WHEN DAMAGE AFFECTS A
LIGHTENING HOLE FLANGE.
INNER SKIN
IREF)
SKETCH 1
BLIND REPAIR DAMAGE BETWEEN
SUBSTRUCTURES AND BETWEEN BEADS
Landing Gear Door Inner Skin Repair

Model NA 265-40, -60, -60A, -60SC, and -65
0
MAIN GEAR OOOR
S265-3-)0~
52-80-20
Page 203
Aug 17/84
NA-6(i-1032
SIKII(:TURAL REPAIR MANUAL
MAIW BEAR BOOR

IIWER SKIW READ
REPAIR AWOLE
MATERIAL
4IOO4U6E TO MATCHSKIH
--7
TRIMMED OUT DAMAGE
RIVET
PICK UP 2 IMIW)
EACH SIDE OF DAMAGE.

SfE SKETCH 1 FOR
REPAIR DOUBLER
RIVET PATTERI
3/4
--~1
AEPIIIAIT~
A
i
oourrs
REPAIR
II+1 iB
AWGLE
II
~I
IREF)
,,,,,,,B-B
41 RIVET
ou ITvP1
IHWER SKIH
SKETCH 2
BLIND REPAIR DAMAGE ACROSS A
SKIN BEAD IMA~W GEAR DOOR)
REPAIR DOUBLER
0.032
20260 CLAD. HEATTREAT TO T42 COIOITIOW
AFTER FORMIWG.
ROBE BEAR BOOR

IIIER 3414
REPAIR OOUDLER
LIOHTEIIWD HOLE
FUNGE
RIVET
MS20473A04
2 ROWS REOB
TRIMMED OUT
-t
i.
-C
11/16 TO 1
~e
Ex RIVET
NOTE
REPAIR AMOLE
ou ITYP)
WHEN DIMENSION "A" EXCEEDS 1-1/4
ROSE OEAR BOOR

IWIIER 3410
IN., FABRICATE
FILLER (MATERIAL AND GAUGE TO MATCH
SKIN) AND
IREF)
L----3~
INSTALL
RIVETS THROUGH ANGLE. FILLER, AND

REPAIR DOUBLER AT 11116 TO 1-1/4 IN. SPACING.
SECTION
CC
SKETCH 3
DAMAGE AT LIGHTENING HOLE FLMigif (NOSf GEAR DOOR)
52-80-20
Page
s?ss.a-1as
Landing %ear Door Inner %kin Repair

Model NA 265-40, -60, -60A, -60SC, and -65
204
Aug 17/84
COP~IGHT, 1984
BY SAB-RELINER CORPORATION
CHAPTER
FUSE LAG E
NA-66-1632
CHAPTER 53
FU SE LAGE
TABLE OF CONTENTS
Subject
53-00-00
Fuselage
General
Fuselage
Page
Master
Repair Index
53-00-10
Fuselage
Allowable Damage
General
Fuselage Negligible Damage
101
101
Limits
Main Frame
General
Forward Fuselage Repair Index
Intermediate Fuselage Repair Index
Aft Fuselage Repair Index
53-10-00
Main Frame
53-10-20
Repairs
General
Repairs
Auxiliary Structure
Repairs
53-20-20
General
PlatesandSkins
201
53-30-20
201
Repairs
General
AttachFittings
Repairs
53-40-20
General
201
53-CONTENTS
0
Page 1/2 Blank

Mar 16/90
NA-66-1032
CHAPTER 53
FUSELA G E
Section
53-00-00
Figure
1
2
53-00-10
101
53-10-00
1
2
3
4
5
6
53-10-20
201
202
203
204
205
No.
Title
Fuselage Master Repair Index

-60SC, and -65
-80, -80A, and -80SC
207
208
209
210
211
212
213
214
215
216
217
53-20-20
201
202
203
204
Model NA 265-70,
3
Fuselage Structure
102
265-40, -60, -60A, -60SC,

2
265-70, -80, -80A,

9
1Fj
NA 265-40
NA 265-60,
-60A, -60SC,
20
Fuselage Repair Index
Model NA 265-70, -80, -80A, and

2~
Repair
Index

and -80SC
Model NA 265-40, -60, SOA, and -60!$C

26
Model NA 265-70, -80, -80A,
Typical Fuselage Frame Repair

Extruded Frame Repairs
C-section Frame Repair
Z-section Frame Repair
Cockpit Enclosure Longeron Repair
(FS)
206
Model NA 265-40, -60, -60A,

Model NA
and -65
Model NA
and -80SC
Model
Model
and-6fi
Intermediate
sosC
Aft Fuselage
and -65
Page
89
g02
203
204
205
Fuselage Station
13 to 50
206
Windshield Center Beam Repair

Fuselage Station (FS) 50 to 143
Cockpit Enclosure Bow Repair
Main Entrance Door Beam Repair
Frame Repairs
Lower
Fuselage Stations (FS) 155.25, 158.5, and
161.75
Lower Longeron Repair at Entrance Door Opening
Frame Repair
Aft Side of Speed Brake Well, Station 188.25
Repair of Fillet Supports
Fuselage Station (FS) 215.5 to 249.125
Repair of Frame and Web at Fuselage Station (FS) 166.25
Frame Repair
Canted Fuselage Station (CFS) 469.75
Upper Close-out Rib Repair
Fuselage Stations (FS) 479-500
UHF Antenna Support and Adjacent Skin Repair
Honeycomb
Repair
Floor Web Repairs-- Fuselage Stations (FS) 298.5
Micarta-faced Cabin Trim Panel Repair
Ground Escape Door Trim Panel Repair
Floor Panel
207
209
211
212
213
220
224
225
226
227
228
230
202
to 333.625
205
207
204
53-ILLUS
0
Page 1
Aug 17/84
NA-66-1032
Section
Figure No.
53-30-20
201
202
203
204
205
206
207
208
209
53-40-20
201
202
203
204
(Continued)
Title
Page
Constant-thickness Skin Repairs

Pressurized Areas
Chem-milled Skin Repairs
Pressurized Areas
Chem-milled Skin Repair
Damage Less than 4 In.
Diameter
Pressurized Area
Non-Pressurized Area
Top Centerline
Between Fuselage Stations (FS) 346.5 and 357
Deleted
Non-Pressurized Areas
Nonstructural Door Repairs
Speed Brake Skin Repairs
One Time Flight Repair
Fuselage Skin
202
206
Wing-to-Forward Fuselage Attach Fitting Repair

Main Landing Gear Door Beam Repairs
Model NA 265-40, -60, -60A, -60SC, and -65
External Power Receptacle Repair
Model NA 265-40,
-60,-60A,and-60SC
Hole Elongation
Model NA 265-40,
Repair of Speed Brake Hinge
-60, -70, and -80
202
211
213
216
217
218
221
204
209
210
53-ILLUS
Page 2
3/88
Jun
NA-66-1032
CHAPTER 53
FUSELAGE
Chapter/
Section
53-L.E.P.
53-CONTENTS
53-ILLUS.
53-00-00
Chapter/
Page
1*
Mar16/90
2*
Mar
Mar 16/90
1
2
Aug 17/84
Jun 3/88
3/4
Aug 17/84
Aug 17/84
Aug 17/84
101
102
103
Aug 17/84
Aug 17/84
Aug 17/84
104"
Mar
53-10-00
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
2
3
4
Aug 17/84
6*
Mar
13*
14
15
16
17
18
19
20
21
22
23
24"
25
26
27"
28
63-10-00
29
Aug 17/84
30*
Mar
(Contd)
31/32
53-10-20
or
hug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
219
220
221
222
223
224
225"
226
227
228
229
230
Jun
201
202
203
204
205
206
207
208
213
214
215
216
217
218
16/90
3/88
Aug 17/84
Aug 17/84
Aug 17/84
Jun 3/88
Aug 17/84
Jun 3/88
Jun 3/88
Aug 17/84
Jun 3/88
Mar 16/90
Aug 17/84
Aug 17/84
Mar 16/90
Aug 17/84
231/232
209
210
211
212
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Mar 16/90
53-20-20
16/90
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Mar 16/90
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
201
202
203
204
205
206
207
208
Jun 3/88
5
7
8
9
10
11
12
Page
16/90
105/106
Date
Section
16/90
1/2"
53-00-10
Date
53-L.E.P.
Page 1
Mar 16/90
NA-66-1032

Chapter/
Section
Page
53-30-20
Deleted
53-40-20
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217"
218
219
220"
Date
Jun 3/88
Jun 3/88
Jun 3/88
Aug 17/84
Aug 17/84
Jun 3/88
Jun 3/88
Aug 17/84
Aug 17/84
Aug 17/84
Jun 3/88
Jun 3/88
Aug 17/84
Aug 17/84
Jun 3/88
Jun 3/88
Mar 16/90
Jun
Jun
3/88
3/88
221/222
Mar 16/90
Jun 3/88
201
202
203
bug 17/84
Aug 17/84
Aug 17/84
204
Aug
Aug
Aug
Aug
Aug
Aug
Aug
205
206
207
208
209
210
The asterisk indicates pages revised, added
or
17/84
17/84
17/84
17/84
17/84
17/84
17/84
53-L.E.P.
Page
Mar 16/90
COPYRIGHT, 1990
NA-66-1032
CHAPTER 53
FUSELAGE
GENERAL
fuselage is of all-metal semimonocoque construction.

Chem-miiled aluminum alloy stressed skins, along with
formed sheet-metal and extruded frames (some of which
are chem-milled), carry the shear loads. The major
portion of the bending loads is carried by the four main
longerons. The remainder of the bending loads is carried
by the various stringers, intercostals, and secondary
longerons. Chem-milling has been utilized throughout the
The
fuselage.
The fuselage illustrations are divided into three sections
for purposes of indexing: the fwd fuselage section(FS 0 to
206), the intermediate fuselage section (FS 206 to 357),
and the aft FS 357. Both the fwd and the intermediate
sections are pressurized. The pressurized area extends aft
from FS 76 in the fwd fuselage to FS 333-5/8 in the
intermediate fuselage.
FUSELAGE MASTER REPAIR INDEX

See figure 1 for model Ne 265-40, -60, -60A, -60SC, and
-65. See figure 2 for model NA 265-70, -80, -80A, and
-80SC.
53-00-00
0
Page 1
Aug 17/84
NA-66-1032
518
FS
357
208
F3
118.825
ITEM
NO.
IoMENCLATURE
FORWARo FUSELAGf ASSY
IWTERMEDIATE FUSEUGE IISSY
IIA 285-40)
FUSELAGE ASSY InA 285-WI,
RfPAIR IWMX
ASSY no.
FIGURE no.
286-311001
53-1000. Fig 1
285-312001
53-1000, Flg 3
308312001
53-10-00, Rg 4
255-313001
5810-00, Fig O
-son-8asc.8n5-ssl
887 FUSECAGE A33Y
NOTE
REFEA TO 53-00-10 FOR NEGLIGIBLE DAMAGE LIMITA-
TIONS.
82(13-107*
53-OQ-00
Page 2
Aug 17/84

Model NA 265-40, -60, -60A, L66SC, and
1
erugiF56-
NA-66-1032
522.5
357
208c17
118.625
c7
FS
13
~-7
REPAIA IIOEX
ITEM
ASSY WO.
FIGURE WO.
FORWARU FUSELAGE ASSY
370311001
53-1000, Flg 2
IWTERMEDIATE FUSELAGE 833Y
370-312001
53-13431, Fig 5
AFT FUSELAGE ASSY
370-313001
53-13481, Fig 7
IOMEICLATUR~
WO.
hPOTE
REFER TO 53-00-10 FOR NEGLIGIBLE DAMAGE LIMITATIONS.
5370-3-23
Fuselage Master
Model NA 265-76,
Repair Index
-80,Figure 2-80A,
and -80SC
53-00-00
Page 3/4 Blank
Aug 17/84
NA-66-1032
FUSELAGE
ALLOWABLE DAMAGE
GENERAL
fuselage.
FUSELAGE NEGLIGIBLE DAMAGE: LIMITS
Negligible damage limitations for the fuselage are given

in figure 101. Damage within limits shown can be
considered negligible only after being treated as
instructed in 51-70-00.
53-00-10
0
Page 101
Aug 17/84
NA-66-1032
STRIJCTURAL REPAIR MANUAL
CFS
457.408
FS
333.625
FS
FS
288
357
D~cD
B
FS
118.625
Fiiiii B:iii~
Fs
B
50
13
FUEL
CELL
A
A\A
CIA
0
0
:s~
FUELc_-~-,_
_1-~
*A
II
C/
A
FS
412
390
HIGHLY LOAOEO 1)10 PRESSURIZEO

HIGHLY LOAOEO
NONPRESSURIZEO
C PRIMARY
WOT HIGHLY LOAOEO
O SECONOARY
-c~-.i
FS
333.825
ALL FUSELAGE SHINS AHE CONSIOEREG TO BE II ONE OF FOLLOWIIG

CATEGORIES:
R PRIMARY
nlc.
FS
357
A PRIMARY
FS
FS
FS
208
102.75
50
IYOWSTRUCTUAAL
NOTE7
AFTER TREATMENT AS DESCRIBED
IN "REPAIR"
IN
51-70-70
MODEL NA 265-40, -60, -D0A, -6086, AND -65

AIRPLANES
s?es-,-loen
53-00-10
Page 102
Aug 17/84

Fuselage Structure
o
COPYRIGHT, 1984
NA-66-1032
FS
333.325
FS
457.408
357
FS
208+17
FS
118.825
FS
FS
13
50
ICil
~D
~CELL
aoA
c7
FUEL
I~B
Ud~/lB
o n
FUEL
CELL
P)
I
C
B
A
C//~/C
412
FS
357
380
FS
FS
333.625
208.+17
102.75
FS
ALLFUSELAO~SKIWSARECOISIOEREOTOBEIWOIEOFFOLLOWIIG
CATEGGHIES:
NOTE
AFTER TREATMENT AS DESCRIBED IN "REPAIR" IN
51-70-70.
HIGHLY LOAOEO A#0 PRESSURIIEG

HIGHLY LGAGEO 4 IOIPRESSURIZEG
WGT HIGHLY LGAOEO
C PRIMARY
HOWSTRUCTURAL
R SECORGARY
A PRIMARY
H PRIMARY
MODEL NA 205-70, -80, -808, AND -8080

5370-3-24
Fuselage Structure
0
53-00-10
Page 103
Aug 17/84
NA-66-1032
CRACKS
TYPE
CATEGORY A
CATEGORY B
CATEGORY C
3/4
TYPEO
NONE
NONE
CATEGORY O
IMAXI
1-1/2
NOnE
(MAXI
1 PER 20 RIVETS
NONE
NONE
1 PER PANEL
1 PER PAnEL
NONE
NONE
1 PER PANEL
1 PER PANEL
NONE
NONE
NONE
1 PER 20 RIVETS
NONE
NONE
IPER20RIVETS
IPERPANEL
o~o
o~o
1-1/2 IMAX)
--/o
o~o
TYPE A
O
TYPEE
TYPEC
fL
P,Gr yypEB:)~::
d
o
Ld
3/8(mAxl
HOLES
CA
CATEGORY
OlA In In.
NONE
NONE
3/4
It: 1
SCRATCHES
OEPTH
LEWGTH
OEPTH
0.002
0.002
0.003
0.003
OMH
0.004
10
0.005
0.005
10
DENTS
u~
STOP DRILL ALL CRACKS WITH A NO. 40
(0.098 IN.)
DRILL.
1/4 TO 1/2
LENGTH
B
O +1/2 TO 1
O +1 TO 3
CATEGORY
CATEGORY
CATEGORY
0.005
0.008
0.012
0.020
0.008
0.012
a012
0.015
a030
0.015
0.020
0.040
HOLES MUST BE A MINIMUM OF 1/2 IN. FROM ANY

FASTENER OR OTHER HOLE.
VERTICAL
CATEGORY
A-A
NOTES
LAX)
LONOITUOINAL
SECTION
no. PER BAY

"D" Is SHORTEST DISTANCE ACROSS DENT.

s?ss-a-loe
Figure 101
Fuselage Structure(Sheet 3 of 4)
53-00-10
Page 104
Mar 16/90
NA-66- 1032
SPEED BRAKE
CENTERLINE AIRPLANE (SYMI
SCRATCHES ON FITTING MUST NOT EXCEED

1/64 IN. DEPTH BY 1/2 IN. LENGTH.
I !I
B
41--
---t~--_
t~-
____E___.-
~L
CATEGORIES
I
B PRIMARY. NONPRESSUAIZEO
HIGHLY LOADED
I
C PRIMARY. HOT HIGHLY LOADED
SCRATCHES
DENTS
CATEGORY
OIA
DEPTH
LENGTH
DEPTH
0.012
0.003
0.003
0.012
0.004
0.004
10
0.015
0.020
0.030
1/2
C
1/2
LENGTH
0.008
CATEGORY
B
1/4
LATERALLY
LONGITUDINALLY
DEPTH
1--3
le----
OIA
----+I
1
DEPTH
NOTES
DAMAGE CANNOT BE CONSIDERED NEGLIGIBLE
SECTION
A-A
UNTIL TREATED AS DESCRIBED IN 51-70-70.

HOLES IN SPEED BRAKE SKINS CANNOT BE CONSIDERED NEGLIGIBLE. ALL HOLES MUST BE STAUCTURALLY REPAIRED.
ALL CRACKS
IN
SPEED BRAKE SKINS ARE TO
BE
TREATED AS HOLES AND STRUCTURALLY REPAIRED.

DENTS 1/4 IN. IN DIA BY 0.020 IN. DEPTH ARE CON-
SIDERED NEGLIGIBLE WHEN LOCATED ON SKIN

LANDS. WHERE DOOR SEATS WITH SURROUNDING
aS
STRUCTURE.
S265-3-110
Fuselaffe Structule
NcRliRible DamaRe Limits
Eiffule 101 (Sheet 4 of 4)
0
53-00-10
Faac 105:106 Illank
AuK 17/84
NA-66-1032
MAIN FRAME
GENERAL
repair indexes for the fwd fuselage,

intermediate fuselage and aft fuselage. Also refer to
58-00-00.
FORWARD FUSELAGE REPAIR INDEX

See figure 1 for model NA 265-40, -60, -60A, -60SC, and
-80SC.
INTERIMEDIATE FUSELAGE REPAIR INDEX

See figure for model NA 265-40. See figure 4 for model
NA 265-60, -60A, -60SC, and -65. See figure 5 for model
NA 265-70, -80, -80A, and -80SC.

AFT FUSELAGE REPAIR INDEX
-soSc.
53-1 0-00
0
Page I
Aug 17/84
NA-66-1032
FS
FS
23
43
Ip
208
25
22
118.825
42
24
15
2P
19
~_
17
41
:1C
It
40
FS
87
FS
8iJ~II
1,
4
3
~pn
37
57
31
28
50
81
B8
70
71
394
58
54
30
29
WI
BI
gs
4a
56
55
28
82
81
59
33
32
38
35
34
83
38
311
17
48
B5
27
44
51
52
53
FS 288.25
49
ASSEMBLY DBAWING NUMBEBSFGB FWB

FUSELAGE SECTIDW FDR MGDEL IA 28540. -WI. WA, -W)SC AIO -65
FAAME ASSEMBLY
285-311001
485-311009
SIDE ASSEMBLY
285-311004
285511005
UPPEA ASSEMBLY 285-311006
285518001
285-318003
LDWERASSEMBLY 285311007
285-311008
285-311009
265311011
s2as-3-~ll
53-10-00
Page 2
Aug 17/84

Model NA 265-40, -60, -60A1 -60SC, and -65
o
COPYRIGHT,
NA-66-1032
FS
206
FS
,16
J5
118.625
17
Fs
74
50
Fs
13
i
73
72
93
92
91
94
95
96
97
98
89
87
90
88
85
78
83
81
88
84
82
FS
118.625
FS
50
FS
INOEX NUMBERS CORRESPOWO TO
i ITEM NUMBERS IN KEY.
80
105
103
101
99
104
102
100
110
FS
206
109
107
FS
10B
106
143
FS
76

Model NA 265-40, -60, -60A, -60SC, and -65
Figure
0
(Sheet
2 of
2)
53-1 0-00
Page 3
Aug 17/84
NA-66-1032
ITEM
NO.
1
2
3
4
5
265-311013
265-318023-15
265-318023-17
265-318023-19
265-311050
265-311050-3
265-318013
265-318014
265-318015
265-318013,
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
265-318015-7
and 8
265-318016
265-318017
265-318018
265-318057
265-318057-3
265-318057-5
265-318066
265-318064
265-318059
265-311144
265-311144-9
265-311144-3
265-311144-11
265-311151
265-311159
265-311167
265-311175
265-311175-17
265-311175-13
265-311183
265-311191
265-311199
265-312207
265-311283
7178-T6
7178-16
7178-T6
7178-16
FS 13
Frame Assy
Frame
Upper, FS 25.8
Frame
Upper, FS 33
Frame
Upper, FS 40.3
FS 50
Bulkhead Assy
Web
Cap Angle
Frame
Upper, FS 58
Frame
Upper, FS 67
Bulkhead Assy
Upper, FS 76
Web
Doublers
Frame
Upper, FS 83.5
Frame
Upper, FS 90.5
Frame
Upper, FS 98
Frame
Upper, FS 118.625
Frame
Cap
Beam
Upper, FS 118.625 to 134
Frame
Upper, FS 126.625
Frame
Upper, FS 134
FS 143
Bulkhead Assy
Web
Channel
Angle
Frame
Upper, FS 150
Frame
Upper, FS 158.5
Frame
Upper, FS 166.25
Frame Assy
Upper, FS 174
Frame
Channel
Frame
Upper, FS 182
Frame
Upper, FS 190
Frame
Upper, FS 198
Frame
Upper, FS 206
Longeron
NO.
MATERIAL
DESCRIPTION
NO.
265-311050-5,
-7, and -9
6
7
8
GAUGE OR
EXTRUSION
DRAWING
Upper,
Bare
REPAIR
FIGURE
NO.
0.025
0.025
0.025
0.025
Bare
Bare
Bare
7178-16 Bare
7178-16 Extr
0.020
43749
7178-T6Bare
7178-T6 Bare
0.025
0.025
2024-T42 Bare
2024-T42 Bare
0.040
0.040
7178-16 Bare
7178-T6 Bare
7178-16 Bare
0.032
0.040
0.100
7178-T6 Extr
7178-T6 Extr
7178-16 Bare
7178-T6 Bare
7178-T6 Bare
6E1090
6E1091
0.040
0.032
0.090
7178-T6
7178-T6
7178-T6
7075-T6
7075-16
7075-16
Bare
Bare
Bare
Bare
Bare
Bare
0.040
0.063
0.040
0.032
0.032
0.032
7178-16
7178-16
7178-T6
7178-T6
7178-T6
7178-T6
7178-T6
Bare
Extr
Bare
Bare
Bare
Extr
Extr
0.063
7178-T6 Bare
0.040
53-10-20
53-10-20
Fig. 204
Fig. 204
53-10-20
Fig.
53-10-20
Fig. 207
23489
0.032
0.032
0.032
3395
43682
FS 118.625 to 211.25
26
27
265-318020-3
265-311281
28
29
265-311281-3
265-311281-5
265-311281-7
265-311025
265-311033
265-311040
265-318020
265-311076
Forward, FS 13
Longeron
Lower, FS
Longeron Assy
to 50
13
205
to 206
30
31
32
265-311076-22
and -23
265-311081
7178-16
7178-16
7075-16
7178-16
7075-T6
7075-T6
7178-T6
Extrusion
Extrusion
Web
Frame
Side, FS 25.8
Frame
Side, FS 33
Frame
Side, FS 40.3
Side, FS 50 to 143
Longeron
FS 76
Bulkhead Assy
Cap Angle
Web
43735
631085
Extr
Extr
Bare
Bare
Clad
Clad
Bare
0.063
0.032
0.040
0.040
0.071
7178-T6 Extr
43643
2024-T3 Bare
0.050
NOTES
Foradditionalre~airs, referto51-r0-00.
chem-milled part. 1Measure thinned
This is
areas or
refer
to
applicable drawing numberfor
thickness variation.
53-1 0-00
Page 4
Jun 3/88
Key
to
Figure
(Sheet
1 of
5)
NA-66-1032
ITEM
NO
33
34
35
36
37
38
39
39~
40
41
42
43
44
45
46
47
B
49
50
51
52
53
54
55
56
DESCRIPTION
DRAWING NO
265-311083
265-311090
265-311098
265-311108
265-311118
265-311118-3
and -4
265-311118-5
and -6
265-311126
265-311134
265-311142
265-311150
265-311158
265-311166
265-311174
265-311173
265-311173-3
265-311173-5
265-311173-45
265-311173-7
265-311182
265-311190
265-311198
265-312206
306-312206
265-311024
265-311011-14
265-311045
265-311226
265-311226-3
and -4
265-311226-55
and -56
265-311226-57
and -58
265-311226-61
and -62
O 265-311058
265-311067
265-311074
265-311074-3
265-311074-5
265-311074-7
265-311075
265-311089
265-311097
265-311097-17
and -18
265-311097-19
and -20
GAUGE OR
EXTRUSION
NO.
MATERIAL
Frame
Side,
Frame
Side,
Frame
Side,
Frame
Side,
Frame Assy
Frame
FS
FS
FS
FS
83.5
90.5
98.2
Side,
Side,
Side,
Side,
Side,
Side,
Side,
Bulkhead Assy
FS 126.625
FS 134
FS 143
RH, FS 150
RH, FS 158.5
RH, FS 166.25
RH, FS 174
FS 174
Cap Angle
Side,
Side,
Side,
Side,
Side,
Frame
Beam
Web
FS 182
FS 190
FS 198
FS 206
FS 206
Lower, FS 25.8
LH Lower, FS 40.3
RH Lower, FS 40.3
Nose Gear, FS 50 to 143
Stringer
7178-T6 Bare
0.063
7178-16 Extr
23489
7178-T6 Bare
7178-T6 Bare
0.032
0.090
7178-16
7178-T6
7178-T6
7178-T6
Bare
Bare
Bare
Extr
0.032
0.032
7178-T6
7178-T6
7178-T6
7178-T6
7178-T6
7178-T6
7178-T6
7178-T6
Bare
Bare
Bare
Extr
Bare
0.025
0.050
0.032
43697
0.032
0.040
0.032
3396
108
Web
Web
Web
Frame
Frame
Frame
Frame
Frame
Frame
Frame
0.032
0.032
0.063
Side, FS 118
Cap Angle
Frame
Frame
Frame
Frame
Frame
Frame
Frame
7178-T6 Bare
7178-T6 Clad
7178-T6 Clad
Center
Bare
Bare
Extr
0.032
6E1115
7178-T6 Bare
2024-T4 Bare
0.032
0.040
2024-T3 Bare
0.040
7178-T6 Bare
785
Cap Angle
Lower
7178-T6 Extr
1E189
Cap Angle
Upper
7178-T6 Extr
43222
7178-16 Bare
7178-T6 Bare
0.025
0.025
7178-T6 Bare
7178-T6 Extr
7178-T6 Bare
7178-T6 Bare
7178-T6 Bare
0.040
7178-T6 Bare
0.050
7178-16 Extr
13697
Frame
Lower, FS 58
Frame
Lower, FS 67
LH Lower, FS 76
Frame Assy
Web
Frame
Angle
Frame Assy
RH Lower, FS 76
Frame
Lower, FS 90.5
Frame Assy
Lower, FS 99
Frame
Angle
REPAIR
FIGURE
NO.
53-10-20, Fig 202
43743
0.063
0.040
0.040
NOTES
For additional
repairs, refer
O Formodel NA265-65
O Except for model NA 265-65
to 51-70-00.
chem-milled part. Measure thinned

refer to applicable drawing numbers
for thickness variations.
This is
areas or
Key
0
to
Figure
(Sheet
2 of
5)
53-10-00
Page 5
Aug 17/84
NA-66-1032

GAUGE OR
DRAWING
ITEM
NO
265-311107
265-311107-3
and -4
265-311107-13
and -14
265-311107-15
and -16
265-311117
58
265-311117-3
and -4
265-311117-5
and -6
265-311117-7
and -8
265-311125
59
265-311133
60
265-311133-5
and -6
265-311133-7
and -8
265-311133-11
and -12
265-311133-19
and -20
265-311141
61
265-311141-5
265-311141-7
265-911141-27
265-311149
62
265-311155-5
63
265-311157
64
265-311157-3
265-311157-9
265-311157-15
65 O 265-311155-3
265-311168
66
265-311168-3
265-311168-5
265-311178
67
265-311171
265-311172
265-311178-3
265-311178-15
and -25
265-311178-19
265-311178-27
265-311181
68
68A M65-311187
265-311189
69
265-311189-3
and -4
265-311189-5
and -6
Frame
Web
Assy
NO.
MATERIAL
DESCRIPTION
NO
57
EXTRUSION
Lower, FS 108
7178-16 Bare
0.040
Cap Angle
Outer
7178-T6 Bare
0.050
Cap Angle
Upper
7178-T6 Bare
0.050
7178-T6 Bare
0.070
Cap Angle
7178-T6 Extr
785
Stiffening Angle
7178-T6 Bare
0.051
7178-16 Bare
0.025
7178-T6 Extr
1E590
Frame Assy
Web
Lower, FS 118.625
Lower, FS 126.625
Frame
Frame
Lower, FS
Assy
Stiffening Angle
134
Cap Angle
Lower
7178-T6 Bare
0.070
Cap Angle
Upper
7178-T6 Extr
13734
7178-T6 Bare
0.040
Web
Bulkhead Assy
Lower, FS 143
Cap Angle
"T" Section
Stiffening
Web
Frame
Frame
Frame
Web
Lower, FS 150
Lower, FS 155.25
Lower, FS 158.5
Assy
7178-T6
7178-T6
7178-T6
7178-T6
7178-T6
Extr
Extr
Bare
Bare
Bare
43315
4ECi43
0.040
0.032
0.025
7178-T6
7178-T6
7178-T6
7178-T6
Bare
Bare
Bare
Bare
0.032
0.032
0.040
0.025
7178-T6 Bare
7178-T6 Bare
0.032
0.040
7178-T6
7178-T6
7178-T6
7178-T6
Bare
Bare
Bare
Extr
0.063
0.063
0.063
785
7178-T6
7178-T6
7178-T6
2024-T3
Extr
Bare
43222
0.063
0.032
0.040
Cap Angle
Angle
Frame
Frame
Web
Lower, FS 161.75
Lower, FS 166.25
Assy
Angle
Bulkhead Assy
RH
Web
LH
Web
Angle
Angle
Angle
Lower, FS 182
Lower, F$ 188.25
Lower, FS 190
Assy
Cap Angle
53-10-00, Fig 210

53-10-00, Fig 210
53-10-00, Fig 210

53-10-00, Fig 214
Lower, FS 174
Web
Frame
Frame
Frame
Web
REPAIR
FIGURE
NO.
Lower
Bare
Bare
7178-T6 Bare
0.032
7178-T6 Bare
0.040
s
58-10-00, Fiff 212
NOTES
This is
areas or
refer to applicable drawing numbersfor
m ExceptformodelNA
Key
to
Figure
(Sheet
3 of
;265-65.
5)
53-1 0-00
Page
Mar
16/90
NA-66-1032
ITEM
NO
265-311189-9
and -10
265-311189-13
and -14
265-311197
265-311197-3
and -4
265-311197-5
and -6
265-311197-11
and -12
265-312205
265-312205-3
265-312205-5
70
71
and -6
265-312205-7
72
111
73
74
75
76
77
78
79
265-311184
265-300238
265-311207
265-311206
265-300062-11
380-300152-11
VTll-388
VT12-388
265-311202
265-300033
265-300034
265-300039
265-311211
265-311218
85
82
83
84
85
86
87
88
89
265-318003
265-300209
PP
265-300247
1~
265-311176
306-311767
265-311185
265-300046
306-300041
265-311204
19
90
g
92
265-312205-15
and -16
265-312205-31
265-300060
265-300019
265-540801
282-300013
265-311205
265-318010
265-311212
REPAIR
FIGURE
NO.
NO.
MATERIAL
DESCRIPTION
DRAWING NO.
GAUGE OR
EXTRUSION
Doubler
7178-T6 Bare
0.032
Stiffening Angle
7178-T6 Bare
0.040
7178-T6 Bare
0.032
7178-T6 Bare
0.040
7178-16 Bare
0.032
7178-16 Bare
7178-T6 Extr
0.040
7178-16 Extr
7178-T6 Bare
4E511
0.063
Stiffener
Nose Assy
Fuselage, FS 0 to 13
Cover
Window
Landing Light
Nose Assy
Fuselage FS 0 to 13
Skin
Upper, FS 13 to 50
Skin
Upper, FS 50 to 98
Skin
Upper, FS 118.625 to 206
Skin
Side, FS 134 to 158.5
Entrance Door
Skin
Skin
Lower, FS 13 to 50
7178-T6 Bare
0.050
Glass Fabric
Acrylic Sheet
0.010
0.125
7178-T6 Bare
2024-T3 Bare
2024-142 Bare
2024-T3 Bare
2024-13 Bare
7178-T6 Bare
0.050
0.050
0.050
0.050
0.050
0.050
Skin
Side, FS 13 to
Door Access, FS 13 to
Skin
Side, FS 50 to
7178-T6 Bare
7075-16 Clad
0.050
7178-16 Bare
7178-16 Bare
7178-T6 Bare
7178-16 Bare
2024-T3 Bare
2024-T42 Bare
7178-16 Bare
7075-T6 Bare
0.050
0.050
0.050
0.125
0.050
0.050
0.050
0.125
7075-16 Bare
0.050
Frame Assy
Web
Lower, FS 198
Lower
Cap Angle
Channel
Frame
Web
Assy
Lower, FS 206
Cap Angle
Outbd
Cap Angle
Upper
Cap Angle
Lower
50
50
50
50
50
76
Door
Access, Equipment
Door
Navigational Equipment
Access
Door
Skin
Side, FS 76 to 155.25
Skin
Side, FS 91.44 to 159.25
Skin
Side, FS98 to 134
Center Link,
Cover
Entrance Door
Center Link,
Cover
Entrance Door
Skin
Lower, FS 161 to 206
Lower Sta 161 to 206
Skin
Skin
Side, FS 158.5 to 206
Door
Door
Skin
Speed Brake Close-out
43746
53-30-20,
53-30-20,
53-30-20,
53-30-20,
53-30-20,
53-30-20,
53-30-20,
0.050
53-30-20, Fig 203

53-30-20, Fig 207
53-30-20, Fig 207
53-30-20, Fig 202
53-30-20, Fig 203
53-30-20, Fig 202
53-30-20, Fig 203
53-30-20, Fig 203

53-30-20, Fig 203
2024-T42 Bare 0.050

0.050
7178-T6 Bare
7178-16 Bare
Fig 203
Fig 203
Fig 202
Fig 202
Fig 202
Fig 203
Fig 203
0.032
NOTES
For additional
repairs, refer
IC~f Except for
to 51-70-00.
Formodel NA265-650nly.

for applicable thickness.
This is
areas or
Key
o
to
model NA 265-65.
[B
Figure 1 (Sheet
On model NA 265-60
only, LH side.
4 9f
5)
(S/N 306-110 and subs)
53-1 0-00
Page 7
Aug 17/84
NA-66-1032
ITEM
NO. DRAWINGNO.
93
114
265-390003-3
265-311220
95
265-311201
96
97
265-343301
265-300016
98
265-311203
265-311261-3
265-311261-31
99
100
101
102
103
104
105
106
107
108
109
265-311226
265-311226-3
and -4
265-311226-55
and -56
265-311226-57
and -58
265-311226-61
and -62
265-300096
265-311230
265-311230-3
265-311230-5
265-311230-7
265-311230-17
265-311266
265-311266-15
265-311266-17
265-311266-25
265-311232
265-311232-5
265-311232-7
265-311232-23
265-311232-25
265-300017
265-311264
265-311262
265-311262-3
and -4
265-311262-27
and -28
265-311271
265-311272-3
ItO
265-311171-5
and -6
265-311267
265-311267-3
26.5-311267-5
265-311267-7
DESCRIPTION
GAUGE OR
EXTRUSION
REPAIR
FIGURE
NO.
NO.
MATERIAL
Skin
Outer, Speed Brake
Skin
Lower, Center
FS 158.25 to 166.25
Skin
Lower, Center
FS 102.813 to 151
Doors
Nose Gear
Skin
Lower, Center,
FS 25.75 to 50
Skin
Lower, FS 16.250 to 25
Floor
Center, FS 76 to 108
Door
Fuselage Floor,
FS 99 to 108
Beam Assy
FS 50 to 143
Web
7178-T6 Bare
7178-T6 Bare
0.063
0.032
7178-T6 Bare
0.050
2024-T3 Bare
7178-T6 Bare
0.032
0.050
Glass Fabric
0.010
2024-T4 Bare
7178-T6 Bare
0.040
0.040
2024-T4 Bare
0.040
53-30-20, Fig 208
53-30-20, Fig 207

53-30-20, Fig 203
Cap Angle
Upper
7178-16 Extr
785
Cap Angle
Lower
7178-T6 Extr
1E189
7178-16 Extr
43222
7178-T6 Bare
0.032
7178-16
7178-T6
7178-T6
7178-T6
0.032
6E 1096
13865
13859
Stiffening Angle
Center
Door
Fuselage Floor,
FS 150 to 167.125
Floor Assy
FS 143 to 174
Web
"T" Angle
Upper
Lower
Cap Angle
Intermediate
Angle
Floor Assy
FS 143 to 206
Web
Web
Door
Beam Assy
FS 174 to 206
"T" Angle
Upper
Intermediate
Angle
Lower
Cap Angle
Web
Door
Fuselage Floor,
FS 98 to 118.625
Floor
Fuselage FS 108 to 143
Floor Assy
FS 76 to 143
Web
Door
Floor Assy
Floor
Floor
Side, FS
Floor Assy
Web
Web
Door
FS 174 to 206
Bare
Extr
Extr
Extr
7178-T6 Bare
7178-T6 Bare
7178-16 Bare
0.040
0.025
0.025
7178-16 Extr
7178-16 Extr
7178-16 Bare
7178-16 Bare
7178-T6 Bare
43737
1E860
7178-16 Bare
0.040
7178-T6 Bare
0.032
7178-16 Bare
0.040
2024-T3 Bare
2024-T3 Bare
0.040
0.040
7178-T6 Bare
7178-16 Bare
7178-T6 Bare
0.032
0.040
0.040
0.071
0.025
143 to 206
0.032
NOTES
For additional
repairs, refer
:p
to 51-70-00.
This is
areas
53-1 0-00
Page 8
Aug 17/84
or
chem-milled part. Measure thinend

refer to applicable
drawing
for
Key
to
Figure
(Sheet 5 of 5)
c~ COPYRIGHT, 1984 BY SABRELINER CORPORATION
NA-66-1032
FS
206
7
27
FS
118.625
24
22
1R
16
4647
45
12
1,3
rli
20
25
26
28
2~
21
Is
17
44
FS
87
\v--
I~
c-~; 7j
II
i
i
ly
FS
O
jl~i
II C
r,
:.I
j
61
WI
29
54
33
32
31
30
55
56
58
57
34
gg
35
36
37
88
86
S28364
38
39
40
41
TO
43
58
67
42
ii? 7a5379
72
73
71
74
75
78
80
77
FS
206
25
26
27
28
ASSEMBLY ORAWING NUMBERS FOR

FWO FUSELAGE SECTION
FRAME ASSEMBLY
SIOE ASSEMBLY
370-311001
UPPER ASSEMBLY
285318003
265-311007
LOWER ASSEMBLY
265-311003
310-311004
370-311005
INDEX NUMBERS CORRESPONO

TO ITEM NUMBERS IN KEY
S370-3-25

Model NA 265-211, -80, -80A, and -80SC
0
53-1 0-00
Page 9
Aug 17/84
NA-66-1032
STKI!CTUHAI, REPAIR MANUAL
INOEX NUMBERS CORRESPONO

TO ITEM NUMBERS IN KEY
FS
206+17
FS
85
118.625
87
86
FS
50
84
FS
01
13
83
82
104
100
88 89
93
9O91
94
95
96
97
102
101
103
105
106
107
IOB
109
99
98
92
110
115
114
113
112
111
110
FS
20617
FS
206
121
120
118
119
117
FS
143
F3
53-1 0-00
Iage 1()
AuR 17/X4
Forward Fusela~e Repair Index

Model NA 265-26), -80, -~OA, and -80!$C
Fiaure 2 (Sheet 2 of 2)
o
COPYRIGHT,
NA-66-1032
GAUGE OR
EXTRUSION
ITEM
NO. DRAWING NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
265-311013-59
265-318023-15
265-318023-17
265-318023-19
265-311050
265-311050-95
265-311050-5
265-318013
265-318014
265-318015
265-318015-15
265-318015-3
265-318016
265-318017
265-318018
370-318052
370-318051
370-318057
370-3180.57-3
Bulkhead
Frame
Frame
Frame
Bulkhead
Web
370-318057-5
370-318064
Cap
370-318066
370-318059
370-311144
370-311144-3
370-311144-9
370-311144-13
370-311151
FS 13
FS 25.8
FS 33
FS 40.3
FS 50
Upper,
Upper,
Upper,
Assy
Cap Angle
Frame
Upper, FS
Frame
Upper, FS
58
67
FS 76
Bulkhead Assy
Bulkhead
Doublers
Frame
Upper, FS 83.5
Frame
Upper, FS 90.5
Frame
Upper, FS 98
Frame
Upper, FS 108
Beam
Cockpit, Upper
FS 118.625
Frame Assy
Frame
7075-16
7178-16
7178-T6
7178-T6
Bare
Bare
Bare
Bare
0.032
7178-T6
7178-T6
7178-T6
7178-T6
Bare
Extr
Bare
0.025
370-311167
370-311175
370-311175-5
Bare
0.025
0.025
0.025
43749
53-10-20, Fig 204

53-10-20, Fig 204
0.025
0.025
2024-142 Bare
2024-T42 Bare
7178-T6 Bare
7178-T6 Bare
7178-T6 Bare
2024-T42 Bare
7178-T6 Bare
0.040
7178-T6 Extr
ST04395211S0002
0.063
0.050
0.063
0.063
Frame
Upper, FS 126.625
FS 118.625 to 126.625
Beam
Frame
Upper, FS 134
Bulkhead Assy FS 143
Channel
Web
Angle
Upper, FS 150
Upper, FS 158.5
Frame
Upper, FS 166.25
Frame Assy
Upper, FS 174
Frame
Frame
370-311159
NO.
MATERIAL
DESCRIPTION
Frame
7178-T6
7178-T6
7178-T6
7178-T6
Bare
Bare
Bare
Bare
7178-T6
7178-16
7178-T6
7178-T6
Bare
Bare
Bare
Bare
REPAIR
FIGURE
NO.
0.040
0.032
0.040
0.100
0.050
0.063
Lg
7178-16 Bare
7178-16 Bare
0.063
0.040
0.063
0.050
0.050
0.050
7178-T6 Extr
ST04385-
53-10-20, Fig 206
53-10-20, Fig 202
21LS0002
23
24
25
26
27
28
370-311175-7
370-311183
370-311191
370-311199
370-312213
370-312225-3
370-311283
Angle
Upper, FS 182
Upper, FS 190
Upper, FS 198
Upper, FS 206
Upper, FS 206 +9
Upper, FS 118.625
Longeron
Frame
Frame
Frame
Frame
Frame
7178-T6 Bare
7178-T6 Bare
0.090
0.063
7178-T6 Bare
7178-T6 Bare
7178-T6 Rare
7178-T6 Extr
0.050
0.080
0.063
43682
7178-T6 Bare
0.040
to 206 +17
29
30
Upper, FS 13 to
Longeron
Lower, FS
Longeron Assy
265-318020-8
265-311281
50
13
to 206 +17
31
32
33
34
265-311281-3
265-311281-5
265-311281-7
265-311025
265-311033-9
265-311040-5
265-318020-63
7178-T6
7178-16
7075-T6
7178-T6
7075-T6
7075-16
7178-T6
Extrusion
Extrusion
Web
Frame
Frame
Frame
Side,
Side,
Side,
Longeron Side,
FS
FS
FS
FS
25.812
33
40.3
50 to 143
Extr
Extr
Bare
Bare
Clad
Clad
Bare
43735
631085
0.063
0.0:$2
0.040
0.040
0.040
NOTES
For additional
repairs, refer
to 51-70-00.

for thickness variation.
This is
areas or
Key
c
to
Fiffure
(Sheet 1 of 4)
53-1 0-00
Page 11
Aug 17/84
NA-66-1032
ITEM
N<). DRAWINGNO.
35
:!65-311076
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
265-311083
265-811090
~fiFi-811098
265-311118
265-311118-3
265-311118-5
265-311126
370-318065
265-311142
26.5-311143
370-311150
370-311158
370-311166
370-311174-3
265-311173
265-311173-3
265-311173-5
265-311173-7
265-311173-45
370-311182
370-311190
370-311198
370-312206
370-312209
265-311024-15
265-311035
265-311045
26.5-311044
265-311226
265-311226-139
265-311226-61
265-311226-55
265-311226-57
59
60
61
265-311058-4
26.5-311067
265-311074
265-311074-23
265-311074-5
265-311074-7
62
63
64
66
265-311089
265-311097
265-311097-17
265-311097-19
21i5-311107
265-311107-3
265-311107-7
265-311107-13
265-311117
265-8 1 11 Z 7-3
265-311117-5
265-811117-9
Web
Frame
Side,
Frame
Side,
FIame
Side,
Frame
Side,
F1ame Assy
Frame
FS
FS
FS
FS
83.5
90.5
98.5
108
Side, FS 126.625
Side, FS 134
LH Side, FS 143
Assy
RH Side, FS 143
Assy
RH Side, FS 150
RH Side, FS 158.5
RH Side, FS 166.25
RH Side, FS 174
Side, FS 174
Assy
Web
Frame
Side, FS 182
Frame
Side, FS 190
Frame
Side, FS 198
Frame
Side, FS 206
Frame
Side, FS 206 +9
Frame
Lower, FS 25.8
Frame
Lower, FS 35.50
Frame
Lower, FS 40.3
Frame
Lower, FS 43.625
Beam Assy
FS 50 to 143
43643
0.050
0.032
0.032
0.063
0.063
7178;T6
7178-T6
7178-T6
7178-16
7178-16
7178-16
7178-16
7178-T6
7178-T6
7178-T6
Bare
Extr
Bare
Bare
Bare
0.063
Bare
Bare
Bare
Bare
Extr
7075-T6 Bare
7075-T6 Bare
Web
Stringer
Upper Cap
Lower Cap
Frame
Lower, FS 58
Frame
Lower, FS 67
Frame Assy
Lower, FS 76
Web
Frame
Angle
Frame
Lower, FS 90.5
Frame Assy
Lower, FS 98
Frame
23489
0.032
0.070
0.040
0.040
0.063
0.063
0.063
6E1115
53-10-20, Fig 202
0.025
0.050
43697
0.032
0.063
0.063
0.063
2E490
0.050
0.032
0.032
0.032
0.032
2024-T6
7178-T6
7178-T6
7178-T6
7178-16
7178-T6
Bare
Extr
Extr
Extr
Bare
Bare
7178-T6
7178-16
7178-T6
7178-T6
Bare
Extr
Bare
Bare
0.050
7178-16 Bare
7178-T6 Extr
0.050
7178-T6 Bare
7178-T6 Extr
7178-T6 Bare
0.040
7178-T6 Bare
7178-T6 Extr
7178-T6 Bare
0.071
785
0.090
0.040
43222
785
1E189
0.040
0.040
43743
0.063
0.063
13697
Lower, FS 108
Web
Upper Angle
Outer Cap
Frame Ass!,
Extr
Bare
Bare
Bare
Rare
Bare
7178-T6 Bare
7178-T6 Bare
7178-T6 Extr
7178-T6 Bare
7178-16 Bare
7178-16 Bare
7178-T6 Bare
7178-T6 Extr
7178-T6 Bare
7178-T6 Bare
7075-T6 Bare
Cap Angle
Angle
Frame Assy
7178-T6
2024-T3
7178-T6
7178-T6
7178-T6
7178-T6
Side, FS 118.62.5
Cap Angle
Frame
Frame
Bulkhead
Bulkhead
Frame
Frame
Frame
Frame
Bulkhead
Web
Web
REPAIR
FIGURE
NO.
Side, FS 76
Cap Angle
;365-:~11081
36
:37
38
39
40
DESCRIPTION
Bulkhead Assy
265-311076-21
GAUGE OR
EXTRUSION
MATERIAL
NO.
13734
0.050
IJower, FS 118.625
Web
Cap Angle
Stiffening Angle
NOTE
For additional
53-1 0-00
Page 12
Aug 17/84
repairs, refer
to 51-70-00.
Key
to
Figure
o
(Sheet
2 of
4)
COPYRIGHT,
NA-66-1032
ITEM
NO.
66
67
DRAWING
NO.
265-311125
265-311133
265-311133-5
265-3111337
265-311133-11
265-311133-19
68
265-311141
265-311141-5
265-311141-7
265-311141-27
69
70
265-311149-15
265-3111fi5-5
71
265-311157
265-311157-37
72
73
74
265-311157-15
265-311155-3
265-311168
265-311168-3
265-311168-5
265-311178
265-311112-57
265-311112-67
265-311178-19
265-311178-7
75
76
77
78
79
80
265-311181
265-311189
265-311189-3
265-311189-63
265-311189-9
265-311189-13
265-311197
265-311197-3
265-311197-27
265-311197-53
370-311205
370-311205-3
370-311205-10
370-311205-7
370-311205-15
370-311205-19
370-312211
370-.112211-3
370-312211-5
370-312211-7
370-312211-19
370-312214
370-312214-3
370-312214-7
370-312214-15
MATERIAL
DESCRIPTION
Frame
Frame
7178-T6 Bare
Lower, FS126.625
Lower, FS 134
Assy
Stiffening Angle
Cap Angle
Upper Cap Angle
Lower
Web
FIGURE
NO.
NO.
0.025
7178-T6
7178-T6
7178-T6
7178-T6
Bare
Bare
Bare
Bare
1E590
0.070
13734
0.040
7178-T6
7178-16
7178-T6
7178-16
7178-T6
Extr
Extr
Bare
Bare
Bare
43315
43643
0.040
0.063
0.032
Lower, FS 143
Bulkhead Assy
Cap Angle
Stiffening Angle
Web
Lower FS 150
Frame
Lower FS 155.25
Frame
Lower FS 158.5
Frame Assy
Web
Angle
Lower FS 161.75
Frame
Lower FS 166.25
Frame Assy
7178-T6 Bare
7178-T6 Bare
7178-T6 Bare
0.063
0.040
0.032
7178-T6 Bare
7178-T6 Bare
0.032
0.040
53-10-20 Fig. 210

53-10-20 Fig. 210
O
53-10-20 Fig. 210
53-10-20, Fig 214
Web
Angle
Lower, FS 174
Bulkhead Assy
Web
Lower
Angle
Angle
Angle
EXTRUSION
Upper
Upper Center
Lower, FS 182
Frame
Lower, FS 190
Frame Assy
Web
Lower
Cap Angle
Doublers
Stiffening Angles
Lower, FS 198
Assy
7178-T6
7178-T6
7178-T6
7178-T6
7178-T6
Bare
Extr
Extr
Extr
Bare
0.063
1E697
7178-T6
7178-T6
7178-T6
7178-Tfi
Bare
Bare
0.032
0.063
Bare
0.032
Bare
0.040
7178-T6 Rare
7178-T6 Bare
7178-T6 Bare
0.032
2024-T42 Bare
7075-T6 Extr
7075-T6 Extr
7178-T6 Bare
7178-T6 Extr
0.040
4F,117
4E117
785
1F,751
0.052
Frame
Web
Lower Cap
Channel
Lower, FS 206
Frame Assy
Web
Outbd
Cap Angle
Cap Angle
Cap Angle
Upper
Lower
Stiffener
Frame Assy
Web
0.070
AND10133-0701
I,ower, FS 206 +9
7178-T6
7178-T6
7178-T6
7178-T6
Upper Cap
Intermediate Anffle
Lower
0.063
0.032
Cap
Rare
F,xtr
Extr
Extr
0.032
AND10133-0702
AND10122-0702
AND10133-0701
Lower, FS 206 +17
Frame Assy
Web
7178-T6 Rare
7178-T6 Extr
7178-T6 Bare
Upper Angle
liower Cap
0.040
4F,611
0.063
NOTES
For additional
repairs, refer
to 51-r0-00.
Key
to
Figure
(Sheet
This is a chem-milled part. Measure

thinned areas or refer to applicable dra?uing numbers for thickness variation.
3 of
4)
53-1 0-00
0
Page 13
16/90
Mar
NA-66-1032
GAUGE OR
ITEM
NO.
DRAWING
NO.
81
370-312208
282-300013
265-311206
265-318010
370-311212
370-311184
265-300238-3
265-311207
265-311206
265-311202
265-300033
265-300034
265-300039
265-311211
265-311218
265-318003
265-300247
306-311176
370-311185
370-300042
306-300041
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
370-312108-21
DESCRIPTION
MATERIAL
Frame
FS 206 +9 (RH)
Nose Assy
FS 6 to 13
Skin
Upper, FS 13 to 50
Skin
Upper, FS 50 to 98
Skin
Upper, FS 118.625 to 206+17
Skin
Side, FS 134 to 158.5
Skin
Entrance Door
Skin
Lower, FS 13 to 50
Door
Side, FS 13 to 50
Skin
Side, FS 50 to 76
Door
Equipment Access
Door
Equipment Access
FS 76 90
Door
Skin
Side, FS 76 to 155.25
Skin
Lower, FS 91.44 to 159.25
Skin
Side, FS 98 to 134
Cover
Center Link, Entry Door
Skin
Skin
Side, FS 158.5 to 206 +17
Door
FS 206 to 208 +17
FS 190 to 206
Door
Door
FS 206 to 206 +17
7178-16 Bare
Glass Fabric
7178-16 Bare
2624-13 Bare
2024-T42 Bare
2624-142 Bare
2024-T3 Bare
7178-T6 Bare
7178-T6 Bare
7178-16 Bare
7178-16 Bare
7178-16 Bare
7178-16 Bare
2924-13 Bare
2924-13 Bare
7178-T6 Bare
2024-T42 Bare
2924-13 Bare
2624-142 Bare
2024-T42 Bare
2024-T42 Bare
2624-142 Bare
0.050
0.010
0.050
0.050
0.050
0.050
0.050
0.050
0.050
0.050
0.050
0.050
0.125
0.050
0.050
0.050
0.190
0.050
0.050
0.050
0.050
0.050
7178-16 Bare
0.032
0.063
0.050
0.050
0.032
0.071
0.050
0.040
103
265-311204
Skin
104
105
106
107
108
109
110
111
112
265-390003
265-300043
265-311201
265-343301
282-300120
282-300119
265-311261-151
265-311261-61
265-311226-411
265-300096
Speed Brake
265-311230
265-311266-131
265-311232
265-311266
265-311264
265-311262-3
265-311271
265-311267-7
Floor Assy
FS 143 to 174
Floor Assy
FS 143 to 206
FS 174 to 206
Beam
Door Assy
FS 98 to 118.625
Floor Assy
FS 108 to 143
Floor assy
FS 76 143
Floor assy
FS 143 to 206
Floor assy
FS 174 to 206
113
115
116
117
118
119
120
121
Speed Brake Closeout
Door
FS 150 to 158.5
FS 102.813 to 151
Skin
Nose Gear
Door
Door
Landing Light
FS 24.625 to 35.5
Door
Floor
Center, FS 76 to 108
Door
Fuselage Floor, FS 99 to 108
Beam Assy
FS 50 to 143
Door
Fuselage Floor, FS 150
to
114
EXTRUSION
NO.
7178-T6 Bare
7178-T6 Bare
7178-T6 Bare
2024-T42 Clad
2024-T42 Clad
6061-T4 Bare
2024-T4 Bare
7178-16 Bare
2024-T42 Bare
7178-T6 Bare
O
O
O
O
O
O
O
O
REPAIR
FIGURE
NO.
53-30-20
53-30-20
53-30-20
53-30-20
53-30-20
53-30-20
53-30-20
53-30-20
53-30-20
53-30-20
Fig. 206
Fig. 206
Fig. 202
Fig. 202
Fig. 202
Fig. 206
Fig. 206
Fig. 206
Fig. 207
Fig. 207
53-30-20
53-30-20
53-30-20
Fig. 202
Fig. 206
Fig. 202
53-30-20
53-30-20
Fig.
Fig.
206
53-30-20
Fig.
208
53-30-20
Fig.
207
53-20-20
53-20-20
Fig.
Fig.
201
201
53-20-20
53-20-20
53-20-20
53-20-20
Fig. 201
Fig. 201
Fig. 201
Fig. 201
206
0.040
0.040
0.032
167-1/8
7178-16
7178-T6
7178-T6
7178-T6
7178-T6
7178-T6
7178-T6
7178-T6
Bare
Bare
Bare
Bare
Bare
Bare
Bare
Bare
0.032
0.040
0.071
0.025
0.040
0.032
0.040
0.040
NOTES
Foradditionalre~pairs, referto
51-r0-00.
This is a chem-milled part. 1Measure

thinned areas or refer to applicable drawing Izumbersfor thickness variation.
Key
to
Figure
(Sheet
4 of
4)
53-1 0-00
Page 14
3/88
Jun
NA-66-1032
STRUCTUHAL REPAIR MANl.rAL
FS
FS
ASSEMBLY DRAWING NUMBEDS FOR

INTERMEDIATE FUSELAGE SECTION
357
333.625
59
FS
206
285-312001
FAAME ASSEMBLY
gO
LOWERASSEMBLY
SIDE ASSEMBLY
1~
UPPED ASSEMBLY
58
265-312002
265-312003
265-312004
INDEX NUMBEDS CORAESPONO

TO ITEM NUMBERS 1)1 KEY.
FS
FS
63
21
13
10
7
18
i 15
14
12
11
62
61
17
333.625
FS
ii
43
42
U1I
~1111
lIYlrl.llllUUt;r~lT1-11
Ilbl~
38
23
45
24
25""
46
~1
FS
1.:
29
30
31
47
36
32
5(
35
33
55
54
FS
53
346.500
52
FS
50
333.625
49
48
57
56
40
39
37
44
41
2!8
264.25
564
FS
333.625
67
7Yr.
65
FS
298.5
66
FS
FS
264.250
247
FS
64
S370-3-25
206
Figure
o
Model NA 265-40
53-1 0-00
Paffe 15
Aug 17/84
NA-66-1032
ITEM
NO. DRAWING NO.
1
2
3
4
5
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
27A
27R
28
265-312216
265-312225
277-312234
877-~12243
265-312250
265-312258
265-312265
265-312273
2(i6-312282-Y
265-312290
265-312282-5
265-312308
265-312282-7
265-312282-9
265-312337
265-931337
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
DESCRIPTION
MATERIAL
Upper, FS 215.5
Upper, FS 224.5
Upper, FS 233.5
Upper,
Upper,
Upper,
Upper,
Upper,
Upper.
Upper,
Upper,
Upper,
Upper,
Upper,
Upper,
FS
FS
FS
FS
242
249.125
257.562
264.25
FS 272.5
FS 281
FS 289.5
FS 298.5
FS 307.250
FS 316
FS 324.75
FS 333.625
Leading Edge FS 333.625
265-313345
Frame
Upper, FS 346.5
265-313007-11
Frame
Dorsal Fin, FS 346.5
265-312357
Bulkhead Assy
FS 357
265-312357-169 Extrusion
Web Cap
Extrusion
265-312357-61
"T" Stiffener
265-312357-75
Web
265-312357-55
Support Angles
265-312357-77
Doublers
265-312357-89
Pan
265-312357-37
Strap
Channel
265-312357-11
265-312357-91
Frame
265-312357-109 Zee
265-312357-133 Doublers
265-312357-120 Channel
265-312357-115 Zee
Frame
265-313007-9
Dorsal Fin, FS 357
265-312035
Longeron
Upper
265-312036
Lower
Longeron
265-312215
Frame
Side, FS 215.5
265-312223
Frame
Side, Upper, FS 224.5
265-312003-9
Intercostal
FS 215.5 to 233.5
265-312003-7
Intercostal
FS 215.5 to 233.5
265-312224
Frame
Side, Lower, FS 224.5
265-312266
FS 264.25
Support
265-312040
Beam
FS 264.25 to 298.460
265-312231
Frame
Side RH, FS 233.5
265-312233
Frame
Side LH, FS 233.5
265-312233-5
-Strap
265-312233-7
Strap
7178-T6
7178-T6
7178T6
7178-T6
7178-T6
7178-T6
7178-T6
7178-T6
Bare
Bare
Extr
Extr
Bare
Bare
Extr
Extr
7178-16 Bare
7178-T6 Bare
7178-16 Bare
7178T6 Bare
7178-T6 Bare
7178-T6 Bare
7178-T6 Extr
Molded Glass Fibre
Reinforced Phenolic
7178-T6 Bare
7178-16 Bare
7178-T6
7178-16
7178-T6
7178-T6
7178-T6
7178-T6
7178-T6
7178-T6
7075-T6
7075-T6
7075-T6
7075-T6
7075-T6
7178-T6
7178-16
7178-16
7178-T6
7178-16
7178-T6
7178-T6
7178-T6
7178-T6
7178-T6
7178-16
7178-16
7178-T6
7178-T6
Extr
Extr
Bare
Bare
Bare
Bare
Bare
Bare
Clad
Bare
Bare
Bare
Bare
Bare
Extr
Extr
Bare
Bare
Bare
Bare
Bare
Bare
Extr
Extr
Bare
Bare
GAUGE OR
EXTRUSION
NO.
REPAIR
FIGURE
NO.
0.080
0.032
631163
53-20-20, Fig 204
23490
53-10-20, Fig 203
0.032
0.032
23,491
6E1092
0.032
0.080
0.032
0.063
0.032
0.032
1E861
0.032
0.025
53-10-20, Fig 203

53-10-20, Fig 201
53-10-20, Fig 203
43750
43222
0.020
0.025
0.032
0.040
0.050
0.063
0.040
0.025
0.032
0.040
0.063
0.025
43682
43699
0.080 O
0.032
0.040
0.040
0.050
0.071
Bar
6E1008
6E1008
0.190
0.062
53-40-20, Fig 202

53-40-20, Fig 202
NOTES
For additional
repairs, refer
to 51-70-00,
This is a chem-milled part. Measure skin

thickness or refer to applicable drawing
numbers for thickness variation.
53-1 0-00
Page 16
Aug 17/84
Key
to
Figure 3 (Sheet
o
1 of
4)
COPYRIGHT,
NA-66-1032
ITEM
NO. DRAWING NO.
29
30
265-312241
265-313242
265-312246
31
265-312249
265-312254
32
33
34
35
36
37
DESCRIPTION
Frame
Side,
Frame
Side,
Frame
Side,
FS 249.125
Frame
Side,
Frame
Side,
FS 257.562
Frame
Side,
Frame
Side,
Frame
Side,
Frame
Side,
265-312257
265-312264
265-312270
265-312272
265-312272-3
265-312272-5
265-312280
265-312003-9
2635-312003-7
GAUGE OR
EXTRUSION
MATERIAL
NO.
RH, FS 242
LH, FS 242
RH Lower,
7178-T6 Extr
7178-T6 Extr
7178-T6 Bare
23486
23485
0.040
LH, FS 249.125
RH Lower,
7178-T6 Bare
7178-T6 Bare
0.040
LH, FS 257.562
FS 264.25
RH, FS 272.5
LH, FS 272.5
7178-T6
7178-T6
7178-T6
7178-T6
7178-T6
7178-T6
7178-T6
7178-T6
Strap
Strap
Frame
Side, Upper, FS 281
Intercostal
FS 275.5 to 289.5
Intercostal
FS 275.5 to 289.5
Frame
Side, Lower FS 281
265-312281
Bare
Extr
Extr
Extr
Bare
Bare
Bare
Bare
7178-T6 Rare
7178-T6 Bare
7075-T6 F,xtr
0.050
REPAIR
FIGURE
NO.
0.050
23450
6E1008
6E1008
0.190
0.063
0.032
0.040
0.040
0.050
AND
10134-0702
38
39
40
41
42
43
265-312289
265-312298
265-312307
Frame
Side,
Frame
Side,
Frame
Side,
Frame
Side,
Frame
Side,
Bulkhead Assy
Channels
265-312316
265-312324
265-312336
26.5-312336-73
FS
FS
FS
FS
289.5
0.080 O
0.040
6FJ1114
7178-T6 Bare
7178-T6 Bare
7178-T6 FJxtr
7178-T6 Bare
7178-T6 Bare
0.040
0.040
7178-T6 Bare
0.025
7178-T6
7178-16
7178-T6
7178-T6
Bare
0.040
0.050
0.063
0.071
Strap
7178-T6 Clad
7178-T6 Clad
7178-T6 Clad
0.032
0.040
0.063
Hat Section
7075-T6 Bare
0.02.5
2024-T42 Bare
2024-142 Bare
2024-T42 Bare
0.0.12
0.025
7178-T6 Extr
7178-T6 Extr
43742
43,753
7178-T6 Bare
0.080
7178-T6 F,xtr
7178-T6 Rare
43742
298.5
307.250
316
FS 324.750
FS 333.625
75,-77,and-79
265-312336-29
26.5-312336-97
265-312336-57
26.5-312336-25
and -27
265-312336-33
265-312336-37
265-312336-35
Angle
Doubler
Shim
Channels
Hat Section
Shim
265-312336-62,
-63.-65,-67,
44
and -68
265-312336-71
266-312336-97
265-313344
45
265-312041
46
265-31204 1-5
265-312041-7
and -8
265-312041-3
and -4
265-312042
265-312042-5
Web
Doubler
Frame
Side, FS 346.5
Beam Assy
FS 206 to 264.25
Cap
Cap
Upper
Lower
Web
Beam
Floor
Support, FS
0.050
53-10-20, Fig- 208
1~
247
Cap Angle
265-312042-3
Bare
Bare
Bare
Web
0.032
NOTES
For additional
This is
repairs, refer
to 51-70-00.

a
areas or
Key
0
COPYRIGHT, 1984
to
Figure
(Sheet
2 of
4)
53-1 0-00
Page 17
Aug 17/84
NA-66-1032
DRAWING
NO.
ITEM
NO.
Frame
265-312263
47
265-312263-5
265-312263-7
265-312263-3
49
50
51
52
53
54
55
56
56A
57
58
59
60
61
62
63
64
REPAIR
FIGURE
NO.
Lower, FS 264.25
Cap Angle
Cap Angle
Web
Wing Attach, FS 264.312
Fitting
265-312260-1
and -2
282-312262-5
48
MATERIAL
DESCRIPTION
GAUGE OR
EXTRUSION
NO.
7178-T6
7178-T6
7178-T6
7075-T6
Extr
Extr
Bare
Al
43741
43742
0.100 O
2.750
Alloy
and -6
265-312284
265-312288
265-312297
265-312297-3
265-312297-27
265-312297-5
265-312296
265-312306
265-312306-3
265-312306-5
265-312315
265-312315-3
265-312315-5
277-312323
277-312323-13
277-312323-5
265-312335
265-312002-65
265-313343
265-312015
265-312016
265-313007
265-300501
265-312018
265-312021
265-312007
265-312007-3
265-312007-5
265-312007-7
Support
Support
Frame
Web
Channel
Fillet, FS 284.437
Fillet, FS 289.5
Lower, FS 298.5
Cap Angle
Fillet, FS
Support
Frame
Web
7071-1651 Bare
2.500
7178-T6 Bare
7178-T6 Bare
0.063
0.063
Bare
Bare
0.032
7178-T6
7178-T6
7178-T6
7178-16
298.5
Extr
Bare
0.071 19
43742
0.050
Lower, FS 307.25
7178-T6 Bare
7178-16 Bare
0.040
0.050
7178-T6 Bare
7178-16 Bare
0.025
0.050
7075-T6 Bare
7178-T6 Bare
7178-T6 Bare
Frame
Lower, FS 333.625
7178-T6 Bare
UHF Antenna
Support
7178-T6 Bare
Frame
Lower, FS 346.5
2024-13 Bare
Skin
Upper, FS 206 to 357
2024-13 Bare
Skin
Side, FS 206 to 357
Dorsal Fin, FS 333.625 to 357 7178-T6 Bare
Skin
2024-13 Bare
Skin
Lower, FS 206 to 258.437
Skin
Lower, FS 257.437 to 308.125 7178-T6 Bare
2024-T3 Bare
Skin
Lower, FS 308.125 to 357
Floor Assy
Side, FS 206 to 264.250
7178-T6 Bare
Upper
Facing Sheet
7178-T6 Bare
Lower
Facing Sheet
5052-H39
Core
0.040
0.063
0.032
0.063
0.032
0.050
0.050
Angle
Frame
Web
Lower, FS 316
Angle
Frame
Web
Lower, FS 324.75
Cap
0.032
0.050
0.050B
0.050
53-10-20
53-10-20
53-10-20
Fig. 203
Fig. 202
Fig. 202
53-10-20
53-10-20
53-10-20
53-10-20
Fig. 201
Fig. 202
Fig. 202
Fig. 201
53-10-20
Fig. 201
53-10-20
Fig.
0.016
0.016
1/8x0.0015
Honeycomb
265-312007-9,
7178-T6 Extr
Zee
631097
-10,-11,-12,-13,
-14,-15,and-16
265-312005
65
265-312005-3
265-312005-5
265-312005-7
Floor Assy
Center, FS 206
to 264.250
Upper
Facing Sheet
Lower
Facing Sheet
Core
7178-16 Bare
7178-T6 Bare
5052-H39
0.016
0.016
1/8
0.0015
Honeycomb
265-312005-9,
-13, -15, and -16
265-312006
265-312006-3
86
Zee
FS 264.25 to 298.5
Floor Assy
Upper
Facing Sheet
7178-T6 Extr
631047
7178-T6 Bare
0.032
201
NOTES
For additional
This is
repairs, refer
thinned
to 51-r0-00.
ing
chem-milled part. Measure
Key
to
Figure
(Sheet
areas or
refer
to
applicable draw-
numbers for thickness variation.
3 of
4)
53-1 0-00
Page 18
3/88
Jun
NA-66-1032
ITEM
NO. DRAWING NO.
67
DESCRIPTION
265-312006-5
Facing Sheet
265-312006-7
Core
and -8
265-312006-17
and -18
265-312006-9
and -11
265-312006-13
and -15
265-312151
GAUGE OR
EXTRUSION
NO.
MATERIAL
7178-T6 Bare
5052-H39
Lower
REPAIR
FIGURE
NO.
0.025
1/8
0.002
Honeycomb
Zee
7178-T6 Extr
53437
Angles
7178-T6 Extr
1E821
Angles
2024-T42 Clad
0.040
2024-T3 Bare
0.040
Floor
Assy
FS 298.5 to 333.625
53-20-20, Fig 202
NOTE
For additional
repairs, refer
to 51-70-00.
Key
0
to
Figure
(Sheet
4 of
4)
53-1 0-00
Page 19
Aug 17/84
NA-66-1032
63
V
62
r,
ASSEMBLY OAAWIIO WUMBERS FOR IWTERIA 28580 110 -85

MEOIATE FUSELAGE
306312001
308312002
306;(12008
308312004
FRAME ASSEMBLY
LOWER ASSEMBLY
SIOE ASSEMBLY
UPPER ASSEMBLY
o~
64
FS
FS
FS
298.5
298.5
357
*21
68
65
66
FS
+9
10
FS
21
307.25
20
19
"ii
;;10.5
344
215.5
8
7
206
206
14
FS
206
FS
FS
298.5
15
67
FS
FS
289.5
t17
5
4
J.i
24
ze
rl
se
42
38
III
I I
I 1
51
55
gb
58
j
57
61
40
44
53
54
35
34
46
49
5B
37
43
145
30
33
41
a~l
2927 2625
39
47
50
56
73
72
598
5308-3-2
70
69
53-1 0-00
Page
Model NA 265-80, -60A, -60S~, and -65

4
Figure
20
Jun 3/88
NA-66-1032
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
DRAWING
NO.
DESCRIPTION
306-312207
306-312210
306-312212
265-312216
265-312225
265-312234
265-312243
265-312250
265-312258
265-312265
265-312273
265-312282
265-312290
306-312305
306-312297
306-312304
265-312308
265-312282
265-312282
265-312337
265-313345
265-312357
306-312035
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Bulkhead
306-312036
265-313334
265-312336
265-313343
265-312324
Longeron
MATERIAL
Upper, FS 206
Upper, FS 206 +9
Upper, FS 206 +17
Upper, FS 215.5
Upper, FS 224.5
Upper, FS 233.5
Upper, FS 242
Upper, FS 249.125
Upper, FS 257.562
Upper, FS 264.25
Upper, FS 272.5
Upper, FS 281
Upper, FS 289.5
Upper, FS 298.5
Upper, FS 298.5 +10.5
Upper, FS 298.5 +21
Upper, FS 307.250
Upper, FS 316
Upper, FS 324.75
Upper, FS 333.625
Upper, FS 346.5
FS 357
Assy
Longeron
Upper, FS 206
7178-16 Extr
7178-16 Bare
7178-16 Bare
7178-T6 Bare
7178-16 Bare
7178-16 Extr
7178-T6 Extr
7178-16 Bare
7178-16 Bare
7178-16 Extr
7178-T6 Bare
7178-T6 Bare
7178-T6 Bare
7178-T6 Bare
7178-16 Bare
7178-16 Bare
7178-16 Bare
7178-T6 Bare
7178-T6 Bare
7178-T6Extr
7178-16 Bare
7178-16 Extr
7178-16 Extr
GAUGE OR
EXTRUSION
NO.
REPAIR
FIGURE
NO.
23485
0.032
3396
0.080
0.032
53-10-20
Fig.
631163
23490
53-10-20
Fig. 201
0.032
0.032
23491
53-10-20
Fig. 201
53-10-20
Fig.
201
0.025
0.025
53-10-20
Fig.
201
0.032
0.040
53-10-20
Fig.
201
201
6E1092
0.032
0.032
0.080
0.032
0.080
0.063
0.032
0.032
1E861
0.032
43750
43682
+5.25 to 357
24
25
26
27
28
29
30
31
32
33
34
265-312332
34A
35
36
37
38
39
40
41
42
43
43A
306-312323
265-312316
265-312307
265-312315
306-312294
306-312295
306-312308
265-312306
306-312302
306-312300
306-312003-17
306-312298
306-312003-19
306-312299
265-312289
265-312260-1
and -2

Frame
Side, FS 346.5
Frame
Side, FS 333.625
Frame
Lower, FS 346.5
Frame
Side, FS 324.750
Frame
Lower, FS 333.625
Frame
Lower, FS 324.750
Frame
Side, FS 316
Frame
Side, FS 307.250
Frame Web
Lower, FS 316
Frame
Side, FS 298.5 +2
Frame
Side, FS 298.5 +19
Frame
Side, FS 298.5 c21
Frame Web
Lower, FS 307.25
Frame
Side, FS 298.5 +10.5
Frame Web
Lower, FS 298.5 +21
Intercostal
Window, Upper
Frame
Side, FS 298.5
Intercostal
Lower, Window
Frame
Lower, FS 298.5 +10.5
Frame
Side, FS 289.5
Fitting
Wing Attach, FS 264.312
7178-16 Extr
2024-142 Bare
2024-142 Bare
7178-T6 Bare
7178-T6 Bare
7178-T6 Bare
7178-T6 Bare
7178-T6 Bare
7178-16 Extr
7178-T6 Bare
7178-T6 Bare
7178-T6 Bare
7178-Tt; Bare
7178-T6 Bare
7178-16 Bare
2024-142 Bare
7178-T6 Bare
0.050
0.040
0.040
7178-T6 Bare
7178-16 Bare
0.080
0.040
7178-16 Bare
7178-~6 Bare
7075-T6A1
0.040
0.080
2.750
43699
0.032
0.040
0.040
6E1114
0.063
0.040
0.040
0.080
0.063
Alloy
or
282-312262-5
and -6
7075-T651 Bare
2.500
NOTES
Key
to
Figure
(Sheet
This is a chem-milled part. IMeasure

thinned areas or refer to applicable drawing numbersfor thicleness variation.
1 of
2)
53-1 0-00
0
Page 21
3/88
Jun
NA-66-1032
GAUGE OR
EXTRUSION
ITEM
NO. DRAWING NO.
45
46
47
48
49
265-312297
265-312281
265-312288
306-312284
265-312270
306-312003-69
50
306-312003-71
51
52
53
54
55
56
265-312264
265-312254
265-312246
265-312241
265-312003
265-312231
265-312224
265-312215
306-312212
306-312209
265-312206
306-312015
306-312016
306-312020-3
306-312020-5
306-312018
265-300501
306-312014
265-312007
44
57
58
59
60
61
62
63
64
65
66
67
68
69
Frame
Frame
Frame
Frame
Frame
7178-16
7178-16
7178-T6
7178-T6
7178-T6
7178-T6
Lower, FS 298.5
Side, FS 281
Lower, FS 289.5
Lower, FS 285.5
Side, FS 272.5
Intercostal
Upper,
FS 242 to 264.50
Intercostal
Lower,
FS 242 to 264.50
Bare
Bare
Bare
Bare
Extr
Extr
7178-16 Extr
Extr
Bare
Bare
Extr
Bare
Extr
Bare
Bare
Extr
Bare
Extr
2024-T3 Bare
2024-13 Bare
FS 206 to 857
Side Skin
2024-T42 Bare
FS 298 to 333
Lower Skin
2024-T42 Bare
FS 333 to 357
Lower Skin
FS 257.562 to 298.5 7178-T6 Bare
Lower Skin
2024-13 Bare
FS 206 to 257.562
Lower Skin
7075-16 Bare
FS 206 to 206 +17
Lower Skin
Floor Assy
Side, FS 206
to 264.250
7178-16 Bare
Facing Sheet
7178-16 Bare
Facing Sheet
5052-H39
Core
7178-T6
7178-16
7178-16
7178-16
7178-16
7178-T6
7178-T6
7178-T6
7178-16
7178-T6
7178-16
Frame
Side, FS 264.25
Frame
Side, FS 257.56
Frame
Side, FS 249.125
Frame
Side, FS 242
FS 215.5 to 233.5
Intercostal
Frame
Side, FS 233.5
Frame
Side, FS 224.5
Frame
Side, FS 215.5
Frame
Side, FS 206 +17
Frame
Side, FS 206 +9
Frame
Side, FS 206
Upper Skin, FS 206 to 359
265-312007-3
265-312007-5
265-312007-7
NO.
MATERIAL
DESCRIPTION
REPAIR
FIGURE
NO.
0.032
0.050
0.063
0.063
6E 1008
6E1109
6E1109
23450
0.040
0.050 O
23485
0.040
6E1008
0.040
0.080 O
3396
0.050
3396
0.050
0.050
0.050
0.050
0.050
0.050
0.050
53-30-20,
53-30-20,
53-30-20,
53-30-20,
53-30-20,
53-30-20,
53-30-20,
53-20-20,
Fig
Fig
Fig
Fig
Fig
Fig
Fig
Fig
206
206
206
206
206
206
206
201
0.016
0.016
1/8
0.0015
Honeycomb
69A 306-312110
70
265-312005
26.5-312005-3
26.5-312005-5
265-312005-7
Floor Assy
Side, FS 206
to 206.17
Floor Assy
Center,
FS 206.17 to 217
Upper
Facing Sheet
I,ower
Facing Sheet
53-20-20, Fig 201

7178-T6 Bare
7178-T6 Bare
5052-H39
Core
0.016
0.016
1/8
0.0015
Honeycomb
71
265-312005-11
265-312005-17
265-312005-19
265-312005-21
53-20-20, Fig 201
Floor Assy
Center,
FS 247 to 264.250
Upper
Facing Sheet
Lower
Facing Sheet
Core
7178-16 Bare
7178-T6 Bare
5052-B39
0.016
0.016
1/8
0.0015
Honeycomb
72
265-312006
265-312006-3
265-312006-5
265-312006-7
FS 264.25 to 298.5
Assy
Upper
Facing Sheet
I,ower
Facing Sheet
53-20-20, Fig 201
Floor
Core
7178-TCi Bare
7178-T6 Bare
5052-H39
0.032
0.025
1/8
0.002
Honeycomb
73
306-312151
Floor Assy
to 333.625
2024-T3 Bare
Web, FS 298.5
0.063
NOTES
For additional
repairs, refer
to 51-70-00.

This is
areas or
53-1 0-00
Page 22
Aug 17/84
Key
to
Figure
o
(Sheet
2 of
2)
NA-66-1032
ASSEMBLY ORAWINO NUMBERS FOR
INTERMEOIATE FUSELAGE
MOOEL
~L\
NA 265-10 ANO -80
FRAME ASSEMBLY
370-312001
LOWER ASSEMBLY
SIBE ASSEMBLY
UPPER ASSEMBLY
370-312002
370-312003
370-312004
FS
FS
298.5
298.5
FS
357
+21
FS
FS
FS
20298.5
289.5
22307.25
+10.5
4j
FS
27
26
25ii
24
23
Is
215.5
14
Fs
-1=
13
206
+17
/L
12
11
10
j:
ki~
41
FS
206
FS
34
,17
215.5
12
to
48
53
62
56
32
45
60
59
47
50
57
40
44
37
38
52
3029
31
35
46
11
33
39
38
378
58
55
FS
63
~35
64
65
66
67
53
54
68
56
FS
206
S370-3-27
17
Model NA 268-20, -80, -80A, and -80SC
Figure
53-1 0-00
Page 23
Aug 3/88
NA-66-1032
ITEM
NO.
(Continued)
DRAWING
NO.
GAUGE OR
EXTRUSION
NO.
DESCRIPTION
MATERIAL
2024-T3 Bare
2024-T3 Bare
7178-T6 Bare
2024-T42 Bare
2024-T42 Bare
0.050
0.050
0.032
0.050
0.050
306-312018
265-300501
370-312207
370-312216-3
Skin
Upper, FS 206 +17 to 357
Skin
Side, FS 206 +17 to 357
Skin
Dorsal, FS 333.625 to 357
Skin
Lower, FS 298.5 +21 to 333.625
Skin
Lower, FS 298.5 to
298.5 t21
Skin
Lower, FS 264.25 to 298.5 +21
Skin
Fairing, FS 206 +17 to 264.25
Frame
Upper, FS 206 +17
Frame
Upper, FS 215.5
7178-T6
2024-T3
7178-16
7178-16
Bare
Bare
Extr
Extr
0.050
0.050
3395
10
11
370-312225-11
370-312290-5
Frame
Frame
Upper, FS
Upper, FS
224.5
233.5
7178-T6 Bare
7178-T6 Extr
0.063
12
370-312243-3
Frame
Upper, FS
242
7178-16 Extr
13
14
15
370-312225-31
370-312225-31
370-312265-3
Frame
Frame
Frame
Upper, FS 249.125
Upper, FS 257.562
Upper, FS 264.25
16
370-312216-5
Frame
17
18
370-312282-11
370-312290-11
19
20
21
370-312305-3
370-312297-3
370-312304-3
1
2
3
4
5
370-312015
370-312016
265-313007
370-312020
370-312019
6
7
8
9
22
23
24
370-312309-3
25
26
27
370-312337
370-312284-11
370-312283-3
370-313345
370-312357
370-312357-5
370-312357-79
370-312035
28
310435521LS0002
ST0435521LS0002
0.063
0.063
ST04355-
Upper, FS 272.5
7178-T6 Extr
21LS0002
8T0435521LS0002
Frame
Frame
Upper, FS 281
Upper, FS 289.5
7178-T6 Bare
7178-16 Extr
Frame
Frame
Frame
Upper, FS 298.5
Upper, FS 298.5 +10.5
Upper, FS 298.5 c21
7178-T6 Bare
7178-T6 Bare
7178-T6 Extr
Upper, FS 307.250
Upper, FS 316
Upper, FS 324.750
Frame
Upper, FS 333.625
Frame
Upper, FS 346.5
Bulkhead hssy
FS 357
Cap Angle
Web
Longeron
Upper, FS 206
+5.25
53-30-20, Fiff 206

53-30-20, Fig 206
53-30-20, Fig 206
53-30-20, Fig 206
53-30-20, Fig 206
ST0435521LS0002
7178-T6 Bare
7178-T6 Bare
7178-T6 Extr
Frame
Frame
Frame
REPAIR
FIGURE
NO
53-20-20, Fig 204

53-10-20, Fig 201
53-10-20, Fig 201
0.063
ST0435521LS0002
0.080
0.063
ST04365-
7178-T6 Bare
7178-T6 Bare
7178-T6 Bare
21LS0001
0.063
0.063
ST0435521LS0002
2024-142 Bare
2024-142 Bare
0.063
0.032
7178-T6 Extr
7178-16 Bare
7178-T6511 Extr
43752
0.020
43682
7178-T6 Bare
7178-T6 Bare
2024-T42 Bare
7178-T6 Bare
7178-T6 Bare
7178-T6 Bare
7178-T6 Bare
7075-T6 Extr
7178-T6 Bare
7075-T6A1
0.032
0.040
0.040
0.063
0.063
0.032
0.040
4E117
0.063
2.750
53-10-20, Fig 201
to 357
29
30
S1
32
33
34
35
36
37
37A
370-313343
370-312332
370-312323
306-312315
370-312306
370-312300
370-312299-5
370-312288
306-312284-11
265-312260-1
and -2
282-312262-3
and -4
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Fitting
Lower,
Lower,
Lower,
Lower,
Lower,
Lower,
Lower,
Lower,
Lower,
Wing
FS 346.5
FS 333.625
FS 324.750
FS 316
FS 307.25
FS 298.5 +21
FS 298.5 c10.5
FS 289.5
FS 285.5
Attach, FS 264.312
53-10-20, Fig 201
alloy
7075-T651 Bale
2.500
NOTES
53-1 0-00
Page
Key
to

thinned areas or refer to applicable drawing numbers for thickness variation.
Figure
(Sheet 1 of 2)
24
Mar 16/90
COPYRIGHT, 1990
NA-66-1032
ITEM
NO
REPAIR
FIGURE
NO.
NO.
MATERIAL
DESCRIPTION
DRAWINGNO.
GAUGE OR
EXTRUSION
7178-T6 Bare
7075-T6 Bare
0.032
0.032
0.032
41
370-312293
370-313344
370-312336
370-312336-3
370-312336-7
370-312324
Frame
Lower, FS 298.5
Frame
Side, FS 346.5
FS 333.625
Bulkhead Assy
Web
Frame
Side, FS 324.750
2024-13 Clad
7075-T6 Bare
7178-T6 Extr
42
370-312316
Frame
Side, FS 316
7178-T6 Extr
43
370-312307
Frame
Side, FS 307.250
7178-T6 Extr
44
370-312308
370-312302
370-312298
370-312289
Frame
Frame
Frame
Frame
Side, FS 298.5 +21

Side, FS 298.5 +10.5
Side, FS 289.5
7178-T6
7178-T6
7178-16
7178-16
48
49
370-312281
370-312270
Frame
Frame
Side, FS 281
Side, FS 272.5
7178-16 Bare
7178-T6 Extr
50
370-312264
Frame
Side, FS 264.25
7178-16 Bare
51
52
53
370-312254
370-312246
370-312241
Frame
Frame
Frame
Side, FS 257.56
Side, FS 249.125
Side, FS 242
7178-T6 Bare
7178-T6 Bare
7178-16 Bare
54
370-312231
Frame
Side, FS 233.5
7178-16 Extr
55
370-312224
370-312215
Frame
Frame
Side, FS 224.5
Side, FS 215.5
7178-16 Bare
7178-16 Extr
Frame
Side, FS 206 +17
58
59
370-312212
306-312036
370-312056-23
3396
7178-16 Extr
7178-T6511 Extr4E699
0.063
7178-16 Bare
60
370-312057-29
61
82
68
64
370-312056-9
370-312057-3
306-312151
265-312006
265-312006-65
265-312006-67
265-312006-69
265-312005-11
265-312005-17
265-312005-19
265-312005-21
265-312005
265-312005-3
265-312005-5
265-312005-7
370-312007
370-312007-3
370-312007-5
370-312007-7
370-312223
38
39
40
45
46
47
56
57
65
66
67
68
Cap
Side, FS 298.5
Longeron
Intercostal
to 307.25
Intercostal
to 307.25
Intercostal
Lower FS 206 to 357

Upper, FS 264.25
Lower, FS 264.25
Upper, FS
198 to 242

FS 298.5 to 333.625
Floor Assy
FS 264.25 to 298.5
Floor Assy
Lower
Facing Sheet
Upper
Facing Sheet
Honeycomb Core
FS 247 to 264.25
Floor Assy
Upper
Facing Sheet
Lower
Facing Sheet
Honeycomb Core
FS 206 to 264.25
Floor Assy
Upper
Facing Sheet
Lower
Facing Sheet
Honeycomb Core
FS 206 +17 to 264.25
Floor Assy
Upper
Facing Sheet
Lower
Facing Sheet
Honeycomb Core
Frame FS 224.5 (RH)
Intercostal
Extr
Bare
Bare
Extr
53-10-20, Fig 201
0.071
ST0435521LS0004
ST0435521LS0011
ST0435521LS0011
631092
0.071
0.091
ST04345
21LS0003
0.063
ST04345
21LS0003
8104345
21LS0006
0.063
0.063
ST04355
21LS0003
ST04345
21LS0003
0.063
ST04345
21LS0003
7178-T6 Bare
0.050
7178-16 Bare
7178-16 Bare
2024-T3 Bare
0.063
0.050
0.063
7178-T6 Bare
7178-T6 Bare
5052-1139
0.025
0.032
7178-T6 Bare
7178-T6 Bare
5052-H39
0.016
0.016
7178-16 Bare
7178-T6 Bare
5052-1139
0.016
0.016
7178-T6 Bare
7178-T6 Bare
5052-H39
7178-16 Bare
0.016
0.016
53-20-20, Fig 201
1/8x0.002
53-20-20, Fig 201
1/8x0.0015
53-20-20, Fig 201
1/8x0.0015
53-20-20, Fig 201
1/8x0.015
0.063
NOTE
For additional
repairs, refer
to 51-70-00.
Key
0
to
Figure
(Sheet
2 of
2)
53-1 0-00
Page 25
Aug 17/84
NA-66-1032
S1RUCTlrRAL REPAIR MANUAI,
CFS
41.406
FS
357
FS
519
44
45
q8
47
48
49
58
54
53
52
FS
FS
CFS
457.406
C;t~
FS
368
FS
412
184
20
FS
390
519
505
11
)O
16
15
14
13
12
21
22
3,
:3"
cl
t
i-
Ir
58
ii
43
H\
-42
31
30
41
29
40
28
27
I/
39
38
25
37
ASSEMBLY ORAWING NUMBERS FOR
AFT FUSELAGE SECTION:
38
35
FRAME ASSEMBLY
34
32
53-1 0-00
Page 26
Aug 17/84
LOWER ASSEMBLY
285-313001
265-313002
SIDE ASSEMBLY
285-313003
UPPER ASSEMBLY
285-313004
INDEX NUMBERS CORRESPOWO
TO ITEM NUMBERS IN KEY.
Aft Fuuelage Repair Index

Model NA 265-40, -60, -60A, -605C, and
erugiF566
CQPYRIGHT, 1984
NA-66-1032
ITEM
NO.
DRAWING
NO.
14
15
16
265-313369
265-313008-13
265-313380
265-313008-11
265-313391
265-313008-9
265-313402
265-313008-7
265-313413
265-313008-5
265-313423
265-313433
265-313444
265-313456
265-313460
265-313015
17
18
265-313469
265-313005-5
1
2
3
4
5
6
7
8
9
10
11
12
13
18A
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
265-313020
265-313485
265-313495
265-313505
265-313006-11
265-313368
265-313379
265-313390
265-313401
265-313412
265-313422
265-313432
265-313443
265-313455
265-313016
265-313367
265-313378
265-313389
265-313400
265-313411
265-313411-3
265-313411-5
265-313421
265-313431
265-313442
265-313465
265-313475
265-313005-3
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Bulkhead
REPAIR
FIGURE
NO.
DESCRIPTION
MATERIAL
Upper, FS 368
7178-T6 Bare
7178-T6 Bare
0.025
0.025
53-10-20, Fig 204
7178-16
7178-16
7178-16
7178-T6
7178-T6
7178-T6
7178-16
7178-T6
7178-T6
7178-T6
7178-T6
7178-T6
7178-T6
7178-16
Bare
Bare
Bare
Bare
Bare
Bare
Bare
Bare
Bare
Bare
Bare
Bare
Bare
Extr
0.025
0.025
0.025
0.025
0.025
0.025
0.025
53-10-20, Fig 204
7178-16 Bare
7178-T6 Bare
0.040
0.032
53-10-20, Fig215
7178-16 Bare
7178-T6 Bare
7178-16 Bare
7178-T6 Bare
7178-16 Bare
7178-T6 Bare
7178-T6 Bare
7178-T6 Bare
7178-T6 Bare
7178-16 Bare
7178-16 Bare
7178-T6 Bare
7178-T6 Bare
7178-T6 Bare
7178-16 Extr
7178-16 Bare
7178-16 Bare
7178-T6 Bare
7178-16 Bare
0.040
0.025
0.025
0.025
53-10-20, Fig216
7178-T6 Bare
0.025
7178-16
7178-16
7178-T6
7178-16
7178-T6
7178-T6
7178-T6
0.032
Dorsal Fin, FS 368

Upper, FS 379
Dorsal Fin, FS 379
Upper, FS 390
Dorsal Fin, FS 390
Upper, FS 401
Dorsal Fin, FS 401
Upper, FS 412
Dorsal Fin, FS 412
Upper, FS 422
Upper, FS 432
Upper, FS 443.5
Upper, FS 455
CFS 457.406
Assy
Upper, FS 357
Longeron
to CFS 457.406
Frame
Upper, CFS 469.75
Longeron
GAUGE OR
EXTRUSION
NO.
Upper Aft,
FS 465 to 505
Rib
FS 485
Frame Assy
FS 495
Frame Assy
FS 505
Frame Assy
FS 519
Frame Assy
Frame
Side, FS 368
Frame
Side, FS 379
Frame
Side, FS 390
Frame
Side, FS 401
Frame
Side, FS 412
Frame
Side, FS 422
Frame
Side, FS 432
Frame
Side, FS 443.5
Frame
Side, FS 455
Lower to CFS 457.406
Longeron
Frame
Lower, FS 368
Frame
Lower, FS 379
Frame
Lower, FS 390
Frame
Lower, FS 401
Frame Assy
Lower, FS 412
Frame
Angle
Lower, FS 422
Lower, FS 432
Lower, FS 443.5
Lower, FS 465
Lower, FS 475
Aft, Lower,
Longeron
Frame
Frame
Frame
Frame
Frame
Bare
Bare
Bare
Bare
Bare
Bare
Bare
0.025
0.032
0.025
0.025
0.025
0.071
43752
53-10-20, Fig 204

53-10-20, Fig 204
53-10-20, Fig 204
0.040
0.025
0.025
0.040
0.025
0.025
0.025
0.025
0.040
0.025
3394
0.025
0.025
0.040
0.025
O
53-10-20, Fig 204
O
53-10-20, Fig 204
53-10-20, Fig 204
53-10-20, Fig204
0.025
0.025
0.025
0.025
0.025
0.032
FS 457.406 to 505
NOTES
For additional
repairs, refer

to 51-r0-00.
Key
to
Figure
(Sheet
1 of
2)
53-1 0-00
Page
0
27
Mar 16/90
NA-66-1032
GAUGE OR
EXTRUSION
ITEM
NO DRAWINGNO.
265-313008-3
265-313104
45
265-313115
46
265-313111
47
48 265-313110
48A 276-484007
265-313006
49
265-300052
50
265-300052-17
and -18
265-300052-19
and -20
44
51
265-313102
52
265-313103
53
54
55
56
57
58
265-313005-17
265-313005-25
265-313105
0.032
0.040
0.040
0.040
0.040
AcrylicSheet 0.125
Mag Aly Sheet 0.040
7178-T6Bare
7178-16 Bare
7178-16 Bare
7178-16 Bare
7178-T6 Bare
Skin
Dorsal, FS 357 to 412
Skin
Top, FS 357 to CFS 457.406
Forward
Fairing
Aft
Fairing
Skin
Top, FS 485 to 505
Cone
Tail, FS 517.750 to 525
Skin
Aft, FS 504 to 519
Access, FS 390 to 412
Door Assy
Inner
Skins
Skin
Skin
CFS
Skin
CFS
Outer
Bottom, FS 357 to
457.406
Side, FS 357 to
457.406
Side, CFS 457.406 to 485
Side, CFS 457.406 to 485
Side, CFS 457.406 to 505
Bottom, 457.406 to 505
265-313109
Skin
Skin
Skin
Skin
265-313005-7,-8
265-313005-9,-10
Stringer
Stringer
NO.
MATERIAL
DESCRIPTION
2024-T42 Clad
0.025
2024-142 Clad
0.025
7178-16 Bare
0.040
7178-16 Bare
0.040
REPAIR
FIGURE
NO.
53-30-20, Fig 206

53-30-20, Fig 206
53-30-20, Fig 206
(1~
53-30-20, Fig 206
53-30-20, Fig 206
53-30-20, Fig 206
53-30-20, Fig 206

53-30-20, Fig 206
Mag Aly Sheet 0.050

Mag Aly Sheet 0.050
7178-T6 Bare
7178-T6 Bare
2024-142
2024-T42
0.040
0.040
0.032
0.032
NOTES
For additional
repairs, refer
1~1
to 51-70-00.

This is
areas or
53-1 0-00
Page 28
Aug. 17/84
Key
to
Figure
o
(Sheet
2 of
2)
NA-66-1032
FS
CFS
FS
457.406
522.5
357
234
13
14
CFS
,g
412FS
522.5FS
509FS
457.406
390
24
i;
20
FS
26
25
23
27
28
29
30
33
32
35
34
36
21
FS
368
31
19
17
15
357
9,
16
3525
I/
2:
ii I
67
60
38
39
40
48
47
46
45
50
43
56
55
54
53
52
FRAME ASSEMBLY
65
64
63
370-313002
SIRE ASSEMBLY
370-313003
370-313004
51
62
61

Model NA 265-70, -80, -80A, and -80SC
Figure
0
370-313001
LOWER ASSEMBLY
INUEX
66
41
ASSEMBLY DRI\WI)IG NUMBERS:
UPPER ASSEMBLY
57
42
58
59
49
44
NUMBERS COBRESPONO TO
ITEM NUMBERS IN I(EY
5370-3-28
53-1 0-00
Page 29
Aug 17/84
NA-66-1032
DRAWING
NO.
ITEM
NO.
1
2
265-313008-3
370-313104-3
3
4
5
6
7
8
370-313115-1
370-313111-3
370-313110-3
265-484113
370-313006-3
370-313109-3
9
10
11
12
13
14
15
16
17
18
19
-2
-4
-20
370-313369-3
265-313008-13
21
22
23
24
25
26
27
28
29
30
31
32
370-313469
370-313005-3
33
34
35
36
37
38
265-313111-5
370-313485
370-313495
370-313505
265-313006-17
370-313005-5
39
40
41
370-313475
370-313465
370-313455
REPAIR
FIGURE
NO.
Skin
Dorsal Fin, FS 357 to 412
Skin
Top, FS 357 to
CFS 457.406
7075-T6 Bare
2024-T3 Bare
0.032
0.040
Fairing Fwd
Fairing Aft
Skin
Top, FS
2024-T3 Bare
2024-T42 Bare
2624-142 Bare
2024-T42 Bare
2024-T42 Bare
0.040
0.040
0.040
0.125
0.040
0.040
53-30-20, Fig 206
2924-142 Bare
0.040
53-30-20, Fig 206
2624-142 Bare
2624-142 Bare
2024-T3 Bare
0.040
0.040
0.040
7178-16 Bare
0.040
2924-142 Clad
0.025
2024-T42 Clad
0.025
7178-T6 Bare
7178-T6 Bare
7178-T6 Bare
7178-16 Bare
7178-T6 Bare
7178-T6 Bare
7178-T6 Bare
7178-16 Bare
2624-142 Bare
7178-T6 Bare
2024-142 Bare
2024-T42 Bare
2024-T42 Bare
2924-142 Bare
7178-T6 Bare
7178-T6 Extr
0.025
0.025
0.025
0.025
0.025
0.025
0.025
0.025
0.025
0.025
0.063
0.025
0.025
0.025
0.071
2924-142 Bare
2024-T42 Bare
0.040
0.032
53-10-20, Fig215
2024-T42 Bare
2024-T42 Bare
2624-142 Bare
2024-T42 Bare
6061-T6 Bare
2024-T42 Bare
0.040
0.032
0.032
0.032
0.040
0.032
53-10-20,
53-10-20,
53-10-20,
53-10-20,
2024-T42 Bare
2924-142 Bare
2924-142 Bare
0.032
0.032
0.050
485 to 509
Tail Cone
-5 Skin
Aft, FS 509 to 522.5
Skin
Bottom, CFS 457.406
to FS 509
Skin
370-313105
Side, CFS 457.406
to FS 509
Door
370-313005-53
Side, CFS 457.406 to FS 485
Door
370-313005-55
Side, CFS 457.406 to FS 485
Skin
370-313103
Side, FS 357 to
CFS 457.406
Skin
265-313102-3
Bottom, FS 357 to
CFS 457.406
FS 390 to 412
Access Door Assy
265-300052
Inner Skin
265-300052-17
-18
Outer Skin
265-300052-19
370-313380
265-313008-11
370-313391-11
265-313008-9
370-313402-3
265-313008-7
370-313413-11
265-313008-5
370-313423-11
370-313433-3
370-313444-3
370-313456-3
370-313460-3
370-313015
20
MATERIAL
DESCRIPTION
GAUGE OR
EXTRUSION
NO.
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Bulkhead
Longeron
Upper, FS 368
Dorsal Fin, FS 368
Upper, FS 379
Dorsal Fin, FS 379
Upper, FS 390
Dorsal Fin, FS 390
Upper, FS 401
Dorsal Fin, FS 401
Upper, FS 412
Dorsal Fin, FS 412
Upper, FS 422
Upper, FS 434.891
Upper, FS 446.241
Upper, FS 455
CFS 457.406
Upper FS
357 to
CFS 457.406
Frame
Upper, FS 470.06
Longeron
Upper Aft, FS 465
to 509
Aft Fairing
Rib
FS 485
Frame Assy
Frame Assy
FS 499
Frame Assy
FS 509
FS 522.5
Frame Assy
Aft Lower, CFS 457.406
Longeron
to FS 509
Frame
Lower, FS 475
Frame
Lower, FS 465
Frame
Lower, FS 455
Acrylic Sheet
53-30-20, Fig 206

53-30-20, Fig 206
53-30-20, Fig 206
53-30-20, Fig 206
53-30-20, Fig 206
53-30-20, Fig 206
53-10-20, Fig 203

53-10-20, Fig 204
53-10-20, Fig 204
53-10-20, Fig 204
53-10-20, Fig 204
53-10-20, Fig 204
53-10-20, Fig 204
53-10-20, Fig 204
53-10-20, Fig 204

53-10-20, Fig 204
53-10-20, Fig 204
53-10-20, Fig 204
43752
Fig216
Fig 203
Fig 203
Fig 203
NOTES
Key
to

Figure
(Sheet 1 of 2)
53-1 0-00
Page 30
Mar 16/90
NA-66- r 032
iP
ITEM
NO. DRAWINGNO.
42
43
44
45
46
47
48
49
50
51
52
53
54
55
.56
.57
58
59
265-313421
2fiR-~IB411
fi7
iC
Side. FS 449.25
Side, FS 443.775
Side, FS 432.4013
FS 428
FS 422
FS 417
FS 412
FS 406..5
Side, FS 401
Frame
Side, FS ~SS.Ci
Frame
Side, FS 390
Stiffener
Side, FS 344.5
Frame
Side, FS 879
Stiffener
Side, FS 373.5
Frame
Side, FS ~68
Stiffener
Side, FS
Frame
I~ower. FS 443.5
Frame
i~ower. FS 432
Frame
Lower, FS 422
Frame
luwer. FS 41L
Assy
Frame
370-813422
60
62
6:1
64
fiT,
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
Frame
370-313449
370-313443
370-313432
370-313427
370-313422
370-313417
370-313412
370-313406
370-813401
870-813395
870-313390
370-813362-9
370-818379
370-813562-7
870-813868
61
DESCRIPTION
Side,
Side,
Side,
Side,
Side,
Anp~le
265-313411-5
265-:(13400
Frame
Frame
Frame
Frame
I~ower, FS 4()1
Inwer. FS ~90
Ilower. FS 378
Ilower. FS:16tl
I~ower, FS:(T,7
IA,nReron
to (:ES 457.7(06
265-:(13367-11
-t(
GAUGE OR
EXTRUSION
MATERIAL
NO.
2024-T42 Bare
2024-T42 Bare
2024-T42 Bare
2024-T42 Bare
2024-T42 Bare
2024-T42 Bare
2024-T42 Bare
2024-T42 Bare
2024-T42 Bare
2024-T42 Bare
2024-T42 Bare
2024-T42Clad
7178-T6 Bare
2024-T42Clad
7178-T6 Bare
2(rL4-T42 Clad
71783-T6 Dare
7178-TR Rare
7178-TCi Bare
71781-T6
7178-T6
7178-16
7178-T6
7178-Tfi
7178-Tfi
Bare
Rare
Bare
Dare
Bare
Dare
2024 -14~
StrinRer
StrinLzer
21124-142
0.050
0.040
0.050
0.0.50
0.050
0.0.50
0.050
0.0.50
0.0.50
0.0.50
0.0.50
0.026
0.02.5
0.025
0.02.5
REPAIR
FIGURE
NO.
53-10-20,
53-10-20,
53-10-20,
53-10-20,
Fig 204
Fie: 204
FiR 204
FiR 204
53-10-20, Fig 204

53-10-21), Fig 204
5:1-10-21), FiR 204

53-10-20, FiR 204
0.1)2f,
0.025
0.025
0.025
5:(-1()-20. FiR 204

.5~-10-LO. FiR 21)4
5:(-10-2(1, FiR 204
O.O~L
0.!)1Ls
0.025
53-10-21), EiK 2()4
().()25
0.025
~R94
5:(-10-2(), FiK 21)4
5:(-10-21), FiR 204

r,:~-10-20. FiR 204
O.I):(2
0.()::2
Nol~
Kc to ~iyure 7 (Shcc( i! or P)
53-1 0-00
Blank
AuR 17/84
NA-66-1032
MAIN FRAME
REPAIRS
GENERAL
This section contains repairs to the fwd fuselage, intermediate fuselage, and aft fuselage. For applicability of
repairs, refer to Fi3-10-00. See figures 201 through 217.
REPAIRS
()n chem-milled skin repairs, the thinned areas of the
chem-milled fuselage skins have been reduced to a
minimum gauge consistent with the applicable load and
fatigue factors and crack propagation resistance. Drilling
holes in the thinned skin for the application of repairs is
not permitted. Chem-milled skin repairs for the pressurized and non-pressurized areas are shown in section
53-30-20.
l[n!1lllll1~l
On airplanes with the remote sensing unit
for the standby compassmounted in the abt
fuselage at FS 5&~5, a minimum of36 in.
must be maintained between Me sensing
unit and any steel or magnetic materials
added in this area. Non magnetic materials are the only acceptable materials that
may be added in this
area.
53-1 0-20
0
COPYRIGHT,
Page Z01
Aug 17/84
N.A-66-1032
TYPICAL FASTENER PATTERN FOR EXTRUOEO FRAME REPAIRS

INNER CAP REPAIR STRAP
2 TIMES FASTENER
~C
(REF)
~t_ -t
i-e
-cl
~t
OAMAGEO FRAME
tt--
1~- FILLER (REFI
OIA [TYPJ
7/318023010
IffEF)
+_i_~
-e
It----
-t
WEB REPAIR STRAP
BECAUSE OF FATIGUE ELEMENT.

RIVETS MUST BE STAGGERED AS
(REEI
sloWw
IREF)
INNER CAP REPAIR STRAP
IREFI
INNER CAP REPAIR
STRAP IREF)
WEB REP~IR STRIIP (REF)
OUTER CAP REPAIR sTRAPIREF)

2 TIMES
~I
_t
OIA[MINI
ITYP)
,x,
~t
iS,
~e
f,
I~A
FRIIMEIREF)
OUTER CAP
REPAIR STRAP
EXISTING FASTENERS
OAMAGEO
FRAME IREFJ
DIA (TYPJ
-e
OIMPGED
2 TIMES FASTENEA
WEB REPAIR
STRAP (REFI
IREg
SECTION
WEB REPAIR
A-A
OAMAGEO FRAME IREF)
STRAPIREF)
FILLER IREFI
PICK UP EXISTING SHIN FASTENERS.

IF FASTENERS ARE 5/32 011 OR
OUTER CIIP REPAIR STRAP (REF)
LESS, REPLACE THEM WITH NEXT SIZE

LARGER RI-SHEAR RIVETS. IF FASTENERS
ARE 3/16 OIA OR LARGER, REPLACE THEM
WITH SAME SIZE HI-SMEAR RIVETS.
INNER CAP REPAIR
WEB REPAIR STRAP
STRAP TYPE 301-1/2 H ORES
TYPE 301-1/2 H CRES
OAMAGEOFRAME
NOTES
BECAUSE OF FATIGUE ELEMENT, RIVETS ON ALL
FRAME REPAIRS MUST BE STAGGERED AS SHOWN.
i/
LENGTH OF WEB REPAIR STRAP SHOULD BE SHORTER

BY
Ai
LEAST TWO RIVETS ON EACH
LENGTH OF OUTER CAP REPAIR

BE
SHORTER
STRAP.
BY ONE RIVET ON
END THAN
AND SHOULD
EACH
END THAN
LENGTH OF INNER CAP REPAIR STRAP

5
NUMBER OF RIVETS SHOWN FOR EACH FLANGE ISYIN
FILLER
SAME MATERIAL
ANO GAUGE AS OAMAGEO
NUMBER REQUIREDTO MAKE SATISFACTORY REPAIR.
FRAME
OUTER CAP REPAIR STRAP

TYPE 301-1/2 H ORES
5285-3-115
53-1 0-20
Page
Aug 17/84
Typical Fuselage Frame
e20t
rugiFriapeR
202
COPYRIGHT, 1984
BY SABRELINER
CORPORATION
NA-66-1032
STKUCTURAI, REPAIR MAN~AI,
PICK UP EXISTING SKIN
FASTENER LOCATIONS
MOLO LIIIE
RUTERCAP
REPAIR STRAP
1._
O
FILLER
0.032
0.090
leo.ss
WEB REPAIR
START TAPER
ITRAP
WEBREPAIR
0.090 (REFI
ITYP EA SIDE OF DAMAGE

INNER ANO OUTER CAP9
STRAP
0.050
SECTION
A-A
FRlmr
IEXTRUSION
NO. 6E11151
INNER CAP
REPAIASTRAP--,
0.125 IRBI
0,032
2 TIMES FASTEDER
OIIIITYP) --~I
~T;Atl
REPAIR FASTENERS ARE 80470006 RIVETS
THIS REPAIR IS APPLICABLE TO RIGHT-HAND FRAME AT FS 174
MOLR LINE
-r
~7-

FLSTEII~R LOCIITIOIIS
HSTEWEALOCIITIOIIS
lea:8 --t~t
Ooso
a61
OUTER CAP
REPAIR STRAP
0.080
o.wa
MOLO LINE
o.oso
OUTER CAP
REPAIR STRAP
0.083
0.063
DAMAGER FRAME
IEXTRUSION
NO.
284901
OI\MAGEO FRAME
WEB REPAIR STRAP
WEB REPAIR
IEXTRUSION NO. 254851
STRAP
INNER CAP
0!
REPAIR STRAP
0.!6
_L
0.160
INNER CAP
le
REPAIR STRAP
2 TIMES FASTENER OIA ITYP)
2 TIMES FASTENER
REPAIR FASTENERS ARE 3/16 IN. BIA HISHEI\R RIVETS
OIA ITYP)
THIS REPAIR IS APPLICABLE TO LEFT-HAND FRAME AT FS
REPAIR FASTENERS ARE 3/18 IN. OIA HI-SMEAR RIVETS
THIS REPAIR IS APPLICABLE TO UPPER FUSELAGE FRAME

AT FS 242.
NOTES
242.
OUTER
RIAPEC
STAAP
ALL REPAIR STRAPS ARE TO BE TYPE 301-1/2H COR-

FASTENER LOCATIONS
MOLO LINE
OUTER CAP
L----
ROSION-RESISTANT STEEL.
REPAIR STRAP
FILLERS ARE TO BE OF SAME MATERIAL, GAUGE, AND

SHAPE AS DAMAGED FRAME. IF LENGTH OF FILLER IS
0.125
0.190
It""
GREATER THAN ONE RIVET SPACING, IT MUST BE
_itoa;-l
LONG ENOUGH TO CONTAIN 10 RIVETS.
0.090
FASTENER PATTERN AND DIMENSIONS FOR FASTENER SPACING AND EDGE DISTANCE MUST CORRES-
POND TO FASTENER LAYOUT AND DIMENSIONS
NINEVIG
WEB REPAIR
FIGURE 201.
PTIM~SFASTEWER
1.44
I
-*I
~e/
STRAP
TAPER ALL REPAIR STRAPS ON FRAME CAPS TO 0.032
AS SHOWN IN REPAIR FOR FS 174.
0.250
IF SKIN
REPLACED ARE 3/16 IN. DIA OR LARGER, REPLACE-
MENT FASTENER MUST BE SAME SIZE HI-SMEAR
REPAIR FASTENERS ARE 3/16 IN. OIA HI-SMEAR RIVETS
THIS REPAIR IS APPLICABLE TO RIGHT-HAND FRAME AT FS

242.
RIVET.
5265-3-116
Extruded Frame Repairs
Figure
ITYPI
OAMAGER FRAME
(EXTRUSION NO. 254861
INNER CAP
REPAIR STRAP
FASTENERS BEING REPLACED ARE 5/32 IN. DIA

OR LESS, REPLACEMENT FASTENER MUST BE NEXT
SIZE LARGER HI-SMEAR RIVET. IF FASTENERS BEING
OIA
202
53-1 0-20
Page 203
Aug 17/84
NA-66- 1032
STKUCTUBAL REPAIR MANUAL
I~
f4
Il/s
ImAx)
~I
~4
Tr)~
FILLERS
IREFJ)--
PICK UP EXISTING SKIN RIVETS
OAMAGEOFRAME
---=-~f=
IREFJ
1--
z~L-
t-
it
-L_
cc
InMrsilsrsm
OIA
ITYPJ
REPAIR ANGELS
I=------~
3/4 APPROX SPACING
/TYP)
2TIMES FASTENER
OIA
IMINI
RIVET
FILLERS
40470405
MlN OF 5 REPO
EA SIOE OF OAMAGE
(REFJ
1-1/4 MAX FOR
REPAIR ANGLE (REF)
OAMAGEO FRAME IREF)
L~A
(REFI
FILLER RIVETS
7/01TYP)
RIVETS
AN470A05
MlN OF 10 REOO
EA SIDE OF OAMAGE
f$--tlt-i-tt
FUSELAGE MOLG LINE
AEPAIRRIGLESIRE9
O
O
O
FILLERSIREF)
Trim out damage miduay ~ef ween existing laaf snerr
SCiOOtn all
edges
and
Make fillers to match
FILLERS
SAME
MATERIAL ANO
GAUGE AS DAMAGEO
corners.
damage cutout
in
FRAMESECTIONA-A
damaged frame.
TOIMWEOFRIIIE
Use same type of material in repairangle as was used in

dan~aged frame; however, use one gauge heavier material.
Repair angles may be made from material in either "T6" or
"Ocondition Use
3/16 in. bend radius for repair
made from material in "T6"
condition;
radius for
made from
repair angles
use a
angles
3/32 in
material
bend
in "O"
condition
NOTE~S
REP,IR ANGLES MADE FROM MATERIAL
IN..O. CONDI-
TION MUST BE HEAT-TREATED TO.T6"

CONDITION
AFTER THEY HAVE BEEN CONTOURED.
THIS REPAIR IS APPLICABLE TO UPPER AND
LOWER
FRAMES AT FS 346.500.
STAGGERED PATTERN OF END RIVETS IS ESSENTIAL

TO MEET FATIQUE REQUIREMENTS
REPAIR ANGLES
SAME MATERIAL kS, DIE
GAUGE HEAYIER THAN,
OAMAGEO FRAME
SZBS-3-117
5310-20
I:IKe 201
17/NI
COPYRilGMT,
1984 BY SABR:ELINER CORPORATION
NA-66-1032
3/4 APPROX SPACING

FOR REPAIR DOUBLER
RIVETS
REPAIR ANGLES
PICKUP EXISTING FASTENERS
SAME MATERIAL AS. OWE
THAOUGH FUSELIGE SRIS
6AUGE HEAVIER TRAN,

OAMAGEDFRAME
OAMAOEO FRAME (REFI
1
-t
-t
-t
2 TIMES FASTEWER
DlllnPI
tlll~
t1-1/4 MAX
FOR FILLEA
nsrrs
OIA
1ID1*1OIORII(
Ilitft
I1I
OAMAGEOFRAWE
ITYP~
t
MIN OF 2
:I
(I
II
I I
REPAIR AnGLES
FILLERS (REF)
REPAIR DOUBLER IREFI
I1I
ttlSECTIOHA~A
III
111
II
fII
-1-
-f
7/8(TYPI
Trim
out
damage
lli
midway
between
existing
fasteners.
Smooth all edges and
Make fillers to match
i-t
ALTERNATE METHOO
1-
;i
FILLERS
111($
IREFI
II
RIVETS REOD TRRU

~litE00rTlllERS
I i
REPAIR AnOLEB
IllcZ~
-I
II
SAME
MATERIAL 1110 GRVGE
III
---1-,7-1--
IIII~
FILLERS
2 TIMES FASTENER
_+
I iilc~
to
Mere
comen
damage
cutout.
~epsir snglesand wpsirdaub
er
Use lable
on
this illustration to determine required material thickness.
Fasten all
repair pertsinplace,usingsizeandlypeof
spacing called
fasteners required and
MIN OF 14 REDO
EA SIDE OF OAMAGE
RIVETS
Prime all materials with epoxy
out.
polyamide primer.
FUS ML
MATL
RHILH
STATION
LOCATION
58
UPPER
0.040
87
UPPER
0.040
388
UPPER, LOWER
THICKNESS
NOTES
IF DAMAGE LENGTH IS LESS THAN TWICE FASTENER
DIA, FILLERS NEED NOT BE USED.

END
RIVETS MUST BE STAGGERED BECAUSE OF
FATIGUE ELEMENT.
ON FRAMES MADE OF 0.026- AND 0.032 IN. MATERIAL,
~1
USE AN470AD5 RIVETS. ON FRAMES MADE OF 0.040AND 0.050 IN. MATERIAL, USE AN470DD6 RIVETS. IF
FASTENER REMOVED IS LARGER THAN THE PRE-
VIOUSLY DESIGNATED FASTENERS, REPLACE IT WITH

A FASTENER OF SAME SIZE.
FRAMES
CODED
UPPER
379
ARE
SINGLE-PIECE,
SYM-
I 1
0.025
0.025
390
UPPER
401
SIDE, LOWER
401
UPPER
0.025
455
UPPER
0.025
455
SIOE
0.025
X
IXI XI
0.025
0.025
METRICAL ABOUT CENTERLINE OF AIRPLANE.

s?es-3-llsA
Z-section Frame Repair

Figure 204
0
53-1 0-20
Page 205
Aug 17/84
NA-66-1032
STHlr(lTUKAL REPAIH MANUAL
DOTER
A(1
FLANGE
IMOLO LINEJ
REPAIR FILLER
-t
IREF)-- OUTER FLANOE OF

REPAIR DOUBLER EXTENDS ONE RIVET
SPACE BEYOND HORIZONTAL FLANGE
$-lt
-t
t-
-CII
LO)IGERON
(REFI
-C+
-C
SKIN FASTENERS
REPAIR OOUBLER
-C
REPAIR DOUBLER
A~1
5/16 MIN
ITYP ill PLLCESI
HORIZONTAL FLANGE
(REF]
5/8
MIN(TYP
ALL ROWS)
SECTION
RIVET
A-A
MS2O47OAO5111 REOO EA SIDE OF FILLER)
SKIN FASTENERS
PICK UP 6 SKIN RIVETS EA SIDE OF FILLER
(EA ROWI.
DOTER FLI\NGE
WHEN ONE ROW CONSISTS OF CAMLOC FASTENERS. INSTALL ONE

MS20424AO5 RIVET BETWEEN EA FASTENER THRU LONGERON.
REPAIR FILLER
REPAIR DOUBLER
IRrrl
REPAIR FILLER
jlTrm
out
SECTION B-B
IRIII
damaged longeron and longeron strap.

so that max edge distance between all
Position trim line
fasteners is maintained.
REPAIR FILLER
Remove
frame
clips
and
file
frame
ends
0.040 7178-76
when
necessary.
O
O
O
O
Fabricate repair parts,
Prime all
including
new
frame clips.
repair parts.
TRIMMED-OUT AREA OF
Install
nstall
repair parts and rivet
new
frame clips,
in
OAMAGED LO)IGERON
place.
picking
up
existing
holes in
frames.
NOTES
THISREPAIR ISAPPLICABLETOCOCKPITENCLOSURE
LONGERON
(WATER
PLANE
-5
APPROXIMATELY),
FROM FS 13 TO 50.
HEPAIR SHOWN MAY BE USED AS A SPLICE WHEN A
SE(:TION OF LONC~EHON MUST HE REPLACED
nlVET
W~-1EHL REPAIR CROSSES A FRAME. REMOVE FRAME

CLIPS AND. WHEN NECESSARY. FILE FRAME ENDS TO
PHOVIDE. SPACE FOR REPAIR PARTS. FABRICATE NEW
FRAME CLIPS TO MATCH THOSE REMOVED, EXCEPT
REPAIR OOUBLER
FOR HOLE LOCATIONS. MAKE CLIPS FROM 0.025 IN. 1/2
0.025 321 CRES 1/2 HARD
HARD CRES
Cockpit Enclosure Longeron ftepair

Fuselag~e Stations (FS) 13 to 50
Finure 205
PaRc
Aua
17/8453-10 ~P(IGIRIAL
ZO(i
RECEI\IEO
COPYRIGHT, 1984
NA-Gfi-103~
STRUCTURAL REPAIR MA~UAI,
EYEBROW WINDOW
SUPPORT ANGLE IREF)
PICKUP FASTENER HOLES FROM
REPAIR ANGLE
EXISTING FASTENER HOLES IN
(REFI
CENTER RETAINER
REPAIR ANGLE
CLIP
RIVET
IREF)
0.44
CLIP
-I
SHIM
(REFI
OAMAGEO WIHOSHIELO
MS2O470A04
[1 REOO1
SC
-I-
-1-
7~
SHIM
RIVETS
-f-
-58-~:7C
PIN
MS20470006 DA 88-92-6
(LENGTH AS REOO) AND
88-15-6 COLLAR. HEAOS ON FAR SIDE
-t
126 REOOJ
13/161TYP)
CENTER BEAM IREFI
RIVET
8892-6-4 PIN
68-15-6 COLLAR
II RE001
FS
118.82
TRIM OFF MOLD LINE FLANGES
FLUSH WITH INBO SURFACES

OF CENTER BEAM WEB
FS
95.88
EYEBROW WINDOW
SUPPORT ANGLE IREFJ

CLIP
0.050 2024-742-
CLAD AL ALLOY SHEET
(SEE DETAILS ON SHEET 2)
WINOSHIELO CENTER
BEAM (REFI
REPAIR ANGLE
SHIM
0.063 2024-T42-
OARE AL ALLOY SHEET
ISEE DETAILS ON SHEET 2)
7075-773 CONDITION AFTER FORMING

ANO CONTDUAIHG. ISEE DETAILS ON
SHEET 2)
Windshield Center Beam Repair

0
0.063 7075-0 BARE
AL ALLOY. HEAT TREAT TO
53-1 0-20
Page 207
Aug 17/84
NA-66-1032
SIIIIJ(:1URAL REPAIR MANUAI,
:1~
094
I\
-5/16A
0.88
DETAIL OF REPAID ANGLE
0.88
jlj
o.ss
-*i
0.25
0.825
1.625
L
IZ
_I_0.3I
lp,
no, lo(o.lsal 1 HOLE
OETAIL OF CLIP
OETAIL OF SHIM
Remove eyobrow uind.ws and ~stsinern
Chapter
56 of
Roler to
Trim rsDa rang eio
applicable Maintenance Manual.
Trim off
damaged
mold ii
ne
on
flange between
:PB
FS 95.88
and 118.062 flush with inbd surface of center beam web,
O
.O
O
angle
Smooth all
Remove
edges of trimmed
clip
vertical
flange
:EP
ensure
!00
positioning
at FS 108.
Secure repair angle in place. Layout and drill 26
Back drill
through
locations
on
upper retainer to pick up

mold line flange of repair
Remove eyebrow window, retainers and

repair
angle.
install eyebrow window and

upper
place using minimum number of fasteners to
proper
ii law ~ulficlent material
repair
Temporarily
retainer in
p,.
clip rivet
angle.
and shim. Form
to match mold line.
up
area
f,om i,,, side of beam web at FS i,,.
repair angle, clip
pick
fastener holes through repair angle and center beam web:

Pick up one fastener hole through
clip, repair angle and
existing fastener
Fabricate
to
I~P
of window.
Remove all
chips
and smooth all
edges of repair
angle.
Check that vertical
against
flange
of
(CDI
repair angle fits flat

flange of repair
center beam web and that mold line
angle fits tight against upper retainer

gap between
flange
and retainer,
O
O
Recheck contour of
repaii
;Ingle
Heat treat
repair angle
Chem film treat repair angle, clip, shim, and all
bare surfaces of center beam assembly.

Apply one coat of
epoxy polyamide primer to all chem film treated surfaces.
with less than 0.010
~1
to 7075-T73 condition.
Install
fasteners called
has
repair angle
warped during
not
I~
to make certain
heat
Hecolllo~lr if necessary to eliminate

any gaps
treatment
repair angle using
size
and
type of
out.
Reinstall eyebrow windows and retainers
as
instructed in Chapter 56 of the applicable Maintenance

Manual.
exceeding
0()10111
NO TEI
IF THIS REPAIR
ISACCOMPLISHED ON ONLY ONE SIDE
OF CENTER BEAM
ASSEMBLY. MOLD LINE FLANGE OF

UNREPAIRED SIDE MUST BE SHIMMED IN
ACCORDANCE WITH INSTRUCTIONS IN CHAPTER 56
THE
OF APPLICABLE MAINTENANCE MANUAL.
53-10-20
Pane
Wiliduhield Center Beam Repair
Fi~ure
206
(Shee~2 of 2)
208
Auff 17/84
GOP~YRIGHT,
1984 BY:SkBRELINER CORPORATION
STHUCTURAI, REIAIR MAN~rAI,
LONGERON STRAP
LONGERON STRAP
INNER REPAIR
TRIM OAMAGE MIOWAY BETWEEN
~XISTINO FAST~)IEAS
WUBLEA
I\t,
I1/IGIAPPROXI
LONCERON
jl~
LONGERON
I+
-I,
-T---
~\\It:
i 1\1
+I f/
It
I t//
-I
It
,t\
-I
A41
PICK UP 13 ORIGINI\L
RIVETS
INSERTS IREF)
/SECTIONA~A
LOYOIROIISTIIP
OUTER REPAIR
DOUBLER
RIVET LOCATIONS IN EA
SKIN EA SIDE OF SPLICE
LONGERON STRAP
OUTER REPAIR
DOUBLER
LONDERON
t
1:+
ANGLES
MS20470A05
(30
LONCERON
REPAIR
Il
fit
RIVETS
REPAIR
DOUBLER
~I
5/16 MIN
15/16 (TYPI
ITYP
AEOD THIIU LOYOEAOII.
ILL
PLIEESI
SECTION
LONGERON REPAIR
ANGLES. ANO LONOERON
(000 SECTION
B-B
A-A FOR
NOMENCLATURE)
REPAIR STRAP)
IWSERTS(R~FI
MS204701105
RIVET
(llRE001
+:li
+I
It
+t+
:II
,II
t_
DOUBLER
C(~
INSERTS
(REFI
LONGERON STRAP
INNER REPAIR
ORIGINAL RIVET
LOCATIONS ITYPI
(SEE VIEW ABOVEI
SECTIONC~C
(800 SECTION A-A AND
NOMENCLATURE)
8-8 FOR
NOTES
THIS REPAIR IS APPLICABLE TO COCKPIT ENCLOSURE
EXTEND REPAIR PARTS EACH SIDE OF FILLER TO PICK
LONGERON (WATER PLANE +O TO APPROXIMATELY
UP FASTENERS SHOWN FOR EACH SIDE OF SPLICE.
c7). FROM FS
50 TO 143.
WHERE REPAIR CROSSES A FRAME. REMOVE FRAME
REPAIR SHOWN IS A SPLICE. WHEN SPLICED MEMBER
CLIPS AND, WHEN NECESSARY. FILE FRAME ENDS TO
IS AN INSERT, JOINTSHOWN IS DUPLICATED AT EACH
PROVIDE SPACE FOR REPAIR PARTS. FABRICATE NEW
END.
FRAME CLIPS TO MATCH THOSE REMOVED, EXCEPT

FOR HOLE LOCATIONS. MAKE CLIPS FROM SAME
WHEN DAMAGED AREA IS
SMALL, A FILLER MATCHING
GAUGE AND MATERIAL AS EXISTING CLIPS
REMOVED SECTION MAY BE USED.

S265-3-120

Fuselage Stations (FS) 50 to 143
0
53-1 0-20
Page 209
Aug li/84
NA-6fi-1032
STKlrCTURAL REPAIR MANUAL
LONGERON STRIP OUTER REPAIR

OOUBLER
0.025 1/2 HARO CRES
LDNGERON REPAIR DOUBLER

0.025 1/2 HARO ORES
~-i::iiiiiiiiiii
liiii:--i-i:-i
-i:_
~iili
w-.:..::_
iii-i~l
~i-: I-_--:i:i, :i i i i i i i i i i:i -i-l:i -
-d:;iiiiiiii i:i:ili i:ii:i-i-i:i:i

~iiiiiiiiii
iiii: :iiiiii.-:-_
iiiiiii:
~iiiiiiiiii
c-iiliLLIWG~RON STR~P
LDHOERON
LONGERON STRAP IIIIER REPAIR

0.071 7178-70
ODUBLER
i:
LONGERON REPAIR AWCLE

0.032 1/2 HARD CRES
Trim out
section.
LONGERDN REPAIR IIWGLE

0.025 1/2 HARD CRES
(O
O
damaged longeron and longeron strap

trim line so that max edge distance
Position
between all fasteners is maintained.
Plimesllreparpart.
Install
new
longeron
section and
splice doublers,
and rivet in place.

Remove frame clips and file frame ends when
necessary.
Install
new
frame clips,
picking
up
existing holes
in
frames.
Fabricate repair parts,
including
new
frame clips.
B?as-3-~21
53-1 0-20
Page 210
Aug 17/84
Cockpit Enclosure
Longeron Repair
FuselageStations (FS
Figure
207
50 to 143
(Sheet -3 of 2)
COPY-RIGHT, 1984
BY
S~RELINER CORPORATION
NA-66-1032
NAS 623-3
SCREW
ANSBOCIO
WASHER
NUT
REPLACE EXISTING FASTENERS
MS21O42-3
IN OOUBLER AREA WITH NEXT
LONGER SIZE
I--
1-1/41N.
MATCH GRILL
8320426404
SPACE 8820428404 RIVETS BETWEEN ANO
on SAME HORIZONTAL Q AS EXISTING
EXISTING BOLT
FASTENERS. DOUBLER ANO RIVETS MUST
HOLES
EXTEND FWO ANO AFT PAST CRACK A
RIVET
OOUBLER
0.063 7178-76
MIN OF TWO IN.
irwoi
iP~
I)A
(Cr
CRACK
0"0
(-t)
--1
rOOUBLER0.063
7178-T5
265-318055
inspecb
Cleanatea, louitscrackendsbvdW-penetrant
BOW BEAM
ion, and stop drill.
SEALANT
Remove all surface corrosion. Treat bow beam and
doubler with chemical-film treatment, and apply one coat of

epoxy
IEl
polyamide primer.
Form doubler to match inside contour of bow beam.
AlUminum shims may be used.
Apply genersl-purpo~e
b.tween
sealant
doubler
and bow beam.
Olnstall
O
Fin sh
VIEW
I-epairdoubler
A-A
SCREWS MAY BE OFFSET FROM

Q OF BOW BEAM TO OBTAIN
completad repai*ta
match
suhounding
area.
CLEARANCE ON LOWER SIOE. A

MIN OF TWO SCREWS ARE
REOUIREO FWO AnO AFT OF
NOTE
THIS REPAIR IS APPLICABLE TO CRACKED LH AND Rn
CRACK, FASTENERS MUST NOT

RIOE IN ANY OF RAOIUS AREA.
COCKPIT ENCLOSURE BOW BEAMS ON MODEL NA 265-
40, -80, -70, -80, -80A, AND -80SC.
5310-3-49*
Cockpit Enclosure Bow Repair

Figure 208
0
53-1 0-20
Page 211
Aug 17/84
NG-66-1032
SIRli(TI:RAI, REPAIK MANUAL
LENGTH
0.194
091.0RO
OIA
MINOFCRACI(2MAX
8 HOLES
AN5O9-IOR
NAS333 CPA SCREWS 18
REOOJ
MS2G364-1032NUT
AN96OO1OWASHER
STOP GRILL
1/8 OIA
ANGLE IREFI
TAPER MACHINE
AS
REOD
1 /1
111
~TALP)FER(
11 REOO)
-~111
~-I--+1-1/8
CRACK
i~i-8
-1IL
2-3/4
7/16
CRACK [REF]
ROUNO
OFFl~u.,
REFORE FORMING
ftlt- 1;4R
AS REOO
1/4
RELOCATE ANGLE ANO CLIPS
AS SHOWN. PLUG HOLES AS

REOO AT FORMER LOCATION
5-7/32
VIEW LOQKING DOWN ON TOP OF

MAIN ENTRANCE DOOR
MAKE PLATE FRDM 7075-T6

PLATE PER SPEC
00-4-250/12
0.220
FINISH: ALOGINE ANO

2 COATS JET SKIN
WHITE PRIMEH
CI
y,,,,,,
strips
from upper end of door.
Remove all sealant and paint from entire

length of
doorstop
O
O
O
Installdoubler
ei
Prime and
paint
reworked
area
with two coats at
epoxy polyamide primer.
Dye-penetrantcheckextentof
crack.
Replace
seal
8lrips, u~inrl
11-109~1
primer and
MIL-A-25457 adhesive.
StopdrlicrsckwithaN~ BOd,iii
Readjust
door.
(Refer
to
applicable maintenance
Fabricate doubler to dimensions given.
NOTE
TnlS REPAIR IS APPLICABLE TO CRACKED
DOOR
BEAM.
53-10-20
PalStrl~
Au~S 17/84
Main Entrance Door Beam

Figure 209
Repair
COPY~LGHT, 1984 BY SABRELINER CORPORATION
NA-66-1032
REPAIR SHIM
7"
REPAIR DOUBLER
F164-2 ITYPJ
CSK REPAIR OOUBLER
JOBOLT
FDRMEAIA~FI
F200-3
JO-BOLT
(TYPJ
1!111
o~,
PLATE --NUT-PLATE MOUNTING
JO-BOLT
\J
F2O0-4 ITYPI
REPAIR SHIM
;T!1
FUS SKIN
--Y
TRIM OUT OAMAGEO
WEB. TRIM DAMAGE

MIDWAY BETWEEN
~XISTIPC
7+
REPAIR STRAP
-t
11/16
~i
::;DBOOLT-
7/8 TO 1-1/8 (TYP~
FRAME WEB
-I,
6861667 2)
SKIN FASTENER LOCATIONS.

SEE SHEET 2 FOR
LEFT SIDE, FS 161-3/4
VIEW LOOKING AFT

Remove nut-plate
P164-I 17Y))-- 2 IOWS
REOUIRE--
MEN TS.
m
mounting plate,
REPAIRSHIM
0.032
2024-T42 BARE
Remove skin fasteners
O
O
O
Trim otf
damaged
as
necessary for access.
Irame web
as
Fabricate and install
repair part.
Re(slrlen r*in panel,
as
Reinstall
shown.
shown.
REPAIR DOUBLER
Di:ii~:,i.iiiiiii-i-- i-:iiii:i~3
0.050 2024 T42

BARE
nut-plate mounting plate.
ijiji:i:ijii:i iiiiiiiiiiii-:iiiiiiiiiil
_i~iiili:i-i ii
I-
311~
NOTES
REPAIRSHOWNONSHEETI ISAPPLICABLETOLOWER
a
FUSELAGE FRAMES AT FS 155-1/4 AND 161-3/4 ON

MODEL NA 265-40 S/N 282-1 THRU -5.
REPAIR STRAP
a
REPAIR SHOWN ON SHEETS 2 THROUGH 5 IS APPLI-
0.025
301 ORES. 1/2 HARO
CABLE TO LOWER FUSELAGE FRAMES AT FS 155-1/4

AND
161-3/4 ON
MODEL
NA 265-40 S/N
PLATE
282-6 AND
NUT-PLATE
MOUNTINGIREFJ
LATER.
REPAIRSHOWNONSHEET7 ISAPPLICABLETOLOWER
FUSELAGE FRAMES AT FS 155-1/4 AND 161-3/4 ON ALL

s265-3-122
AIRPLANES.
Frame
Repairs
Lower

0
161.75
53-1 0-20
Page 213
Aug 17/84
NA-66-1032
BOOR HINGE
ANGLE
ITYP),
ES
FS
FS
155.25
158.5
161.75
III
1
O
O
a
~o
a,
a,
\u
Remove door
hinge angles. beams.

angles (FS 155-1/4 to 161-3/4,.
frame
Trm out or rspsir damaged frame webr

(See sheet 3.)
cable
Fabricate repair beams and
repair angles
and beam-to-
a.
appii
repairangles. Heat-treat
forming,
ill ,A
to -T6 condition after
Prime repair parts and finish to match
LONOERON IAEEI
surrounding
areas
3,
J,~J
Install repair parts
Reinstall door
as
hinge
shown
anglesO
a..
REPAIR BEAM
(TYPJ
REPAIR ANGLE IIYPI
~t,
REPLACE EXISTING FASTENERS ITYP)
-RIVET
MS2047000-8
II
WEBITYPI
VIEW LOOKING INBO
REPAIR AS REOO
(srr SHIA 31
GGoR HINGE ANGLE ITYPJ
AEPLACE(WHEIREPIIR
IS :INCORPOAATEDI WITH
~s
FASTENERSIWDICAT~O
O
~100
REPLACE WITH
NASI 103-5 BOLTS (TYP). USE
EXISTING WASHERS ANO NUTS.
ANGLE (TYPI REPLACE WITH REPAllf

ANGLES SHOWN IN GETAILS B
THRU E AS APPLICABLE
C
-Y
ii
I
FASTENER (TYP)
REPLACE WITH NAS1103-4 BOLT (8 REPOJ.
L0153-0002-1043
18 REOO).
ANO NAS1291-3 NUT 18 REOO).
II
~WASHEA
BEAM.
REPLACE WITH REPAIR BEAM

SHOWN IN OETAIL F.
FS
FS
FS
155.25
158.5
181.75
NOTE
SABRELINER STANDARD NUMBER. SEE DETAIL G FOR
FABRICATION DETAILS.
53-1 0-20
Page %14
Aug 17184
Frame Repairs
8285-3-123
Lower
Fuselage Stations(FS) 155.25,51:58.5,

Figure 210 (5heeti8 of 7)
o
COPYRIGHT.
and 161.7Ci
1984:BY
SABRELINER CORRDRATION
NA-66-1032
1/2 R
IAPPROX
PERMISSIBLE TRIM LINE

FOR CLEANUP WEB DAMAGE
TYPI
1
_I
3/4
I~
/I c
TRIM LINE OF
HINGE ASSY
/2
1/4
CLEARANCE
HOLE ITYP
FUS MOLD
1---,__
_,i
LINE
ly
(REq
FS 155.25
67 A
h
FRAME WEB DAMAGE LIMITS WITHOUT REPAIR
(DlMENSlONS ARE MAXI
REPAIR OOUBLER
~7
/~/1
Y
TRIM MIDWAY BETWEEN
FASTENERS
.)J
REPAIR ANGLE
ITYPI
a~ti
IDETAIL
B OR O AS
a
TRIM REPAIR OOUBLER AS SHOWN.
REPAIR STRAP
-L
~L
1/2 R
TRIM OUT DAMAGED WEB.

TRIM DAMAGE MIDWAY
BETWEEN SKIN-TO-FRAME
FASTENERS.
IRI
REPAIR SHIM
JO-BOLT
IrvPI
~x
88200-2
"/6
5/16
JO-BOLT
FRAME WEB
MSMg0304-8 (TYPJ
DIMPLE REPAIR DOUBLER
ce
5/16
APPLICABLE)
MS2000304-8 (TYP]
TRIM unE OF HOLE IN ORIGINAL WEB.
3/4
PP1B4-2
RIVET
RIVET
f
JO-BOLT
MSMBO3D4-1O ITYPI
DIMPLE REPAIR DOUBLER
le
~o
PILOT HOLE. OMIT FASTENER

WHEN FRAME REPAIR HAS
BEEN INCORPORATEO
RIVET
LEFT SIOE, FS 161.75
VIEW LOOKING AFT
.s...ET6
rla TO
END REPAIR
5/16
DOUBLER MIDWAY
BETWEEN FASTEWERS
(TYP)
I-I/B(TYPI
SKIH
FASTENER
LEFT SIDE, FS 161.75
VIEW LOOKING AFT
REPAIR SHIM
LOCATIONS
(SEE SHEET 6 FOR
(TAPEREDI
0.032 TO 0.0
7178-76 BARE
REPAIR SHIM
ITYP)
PP164-1
~Y
REOUIREMENTS)
I~
0.040
7178-76 BARE
REPAIR ANGLE
0.063
7178-0 BARE. H~ATTREAT TO -76 CONDITION
AFTER
FORMIWG7178-T6
REPAIR STRAP
REPAIR DOUBLER
BARE
NOTE
Remove skin fasteners
WHEN FRAMES AT FS 155.25 AND 161.75 ARE DAMAGED

IN VICINITY OF DOOR HINGE ASSEMBLY CLEARANCE
HOLES. PROCEED AS FOLLOWS:
1
WHEN EXTENT OF DAMAGE PERMITS. TRIM OUT

DAMAGE AS SHOWN.
0.025
301 CRES. 1/2 HARD
0.040
WHEN EXTENT OF DAMAGE REOUIRES A REPAIR.
L~
O
O
Trim off
damaged
Fabrlc.le
as
required for
frame end
as
access
shown
repaii paris
Plimerep.rparts
REPAIR AS SHOWN ON THIS SHEET. ACCESS FOR

R EPAI R AND CLOSE-OUT OF REPAIR ARE SHOWN
~1
ON SHEET 6.
shown,
Fuselage
Install
repair parts
and
refasten
Lower
Frame Repairs
Stations (FS) 155.25, 158.5, and 161.75
skin
panels
as
s265-3-124
53-1 0-20
Page 215
Aug 17/84
NA-66-1032
RI~PAIK MANUAI,
PICK UP HOLES FROM
EXISTING LOCATIONS.
INSTALL ANGLE WITH
SIX PP2OO-2 JOBOLTS.
1-3/16
6 PILOT HOLE
14-
-jj 1/4le~i
B/B(A~FJ
5 EOUIIL SPACES 18 3-23/32
o--I--~-f
11/1 6
DETAIL
1(A
5/8
I~ 1-9/161/1
REPAIRANOLE 1
II REOD AT FS 155.4
lt--"--
5-7/a
/t
3/16
7/8
JJ--------
15/8
+-f-
3/15
7/8
JOGOLE 0.040
f-~
xl1-3/4
I f
51/2
1-7/8
DETAIL C
1-5/16
REPAIR ANGLE 2 11 REDO

FWO SIDE OF FRAME AT FS 158.5)
1/16
=j3/4
PICK UP HOLES FROM
8EPAI8IW8LE31TYP)
3/8(RfFI
P)
a/e(AEq
1-11/16
PICK UP HOLES FROM
5/8
1-3/32
30"
-f-
EXISTING LOCATIONS.
INSTALL ANGLE
3/4
WITHSIXPP200-3
JO-ROLTS.
1-7/8
15/16
1/16
~F
~JiBiAtll3/8
(REFI
1-11/16
j/I$/f~ iii
ZEPUALSPACES
IN 1-7/8
-I-L
15/16
PICK UP IWOD FASTENER

LOCATION IW EXISTING FRAME
REINFORCING AIIOLE. REPLACE
FASTENER WITH 22201-2
(REF)
ir~
4-
1-
DETAIL
3/4
JOBOLT
ANGLE
SfFflA3PERTA
~Lt.
(1 REOO AFT SIOE OF FRAME

1589 O
7/16
~C 161~
5/18
4-1)/32
4 PILOT HOLES
3/16
7/8
f
NOTE
MAKE ANGLES FROM 0.063 7178-0 BARE MATERIAL.
HEAT-TREAT TO -T6 CONDITION AFTER
FORMING.
BEND RADIUS IS 118 IN.
8285-31125
Frame Repairs
53-1 0-20
PaRe
Au
Lower
Fuselage Stations (FS) 155.25, 158.5, and 161.75

Figure 210(8heet 4 of 7)
816
17/84
NA-66-1032
SIKU(III~KAI, K15tA1H MAKIIAI,
PICK UP HOLES FROM
EXISTI#6 LOCATIONS.
PEE SHEET 3 FOR
6-1/32
It
1-19/32
FASTENER REOOI
SEOUAL SPACES
3/8
IW 37/8
5/18
j\/
1-5/16
14/32
-o-
-o_
-+-19/32
3/4
_f~L_-f11/32
3/81REFI13/32
IAEF)
sPI1(1T
HOLIS--_
I3/8
T
7/8
3/16
1
15/8
r;-e
--I
DETAIL
REPAIR ANGLE 4
(1 REOD AT FS 161.79
~lk
3/8
3/8
0.125
f
4 PILOT HOLES
7/8
I-7/a
ct-
0.268
DETAIL
REPAIR REAM
12 REOO1
MAKE FROM 7178-76 EXTRUSION OR

MACHINE FROM 7178-T6 BAR
15/16
DETAIL
11
0.013
0.360
(/)0.203
f
~llt
WASHER
G
L0153-OO02-1403 (B REOOI
MAKE FROM 7178-76 OARE.
CHEMICAL-FILM-TAEAT. (REFER TO SECTION I.~
NOTE
MAKE ANGLES FROM 0.063 7178-0 BARE MATERIAL
HEAT-TREAT
TO -T6 CONDITION
AFTER
FORMING
BEND RADIUS IS 1/8 IN.
S265-3-126
Frame Repairs
Lower
o
161.75
53-1 0-20
Page L17
Aug 17/81
NA-fi6-103~
SIKI!("IITRAL REPAIR MANUAL
RIVET
CR762-5-8 (TYPI
ITYP)
/II
RIVET
CR2248-53
17121
PLATE
111
(AEFI
,_4______
ii
FUS SKI%
SCREW
7S39-3A-3
[TYP)
LOWER L080ER08
SCREW
7S39-3A-217YPJ
REPAIAOOUBLER---/ 1(1 I
RIVET
0881007008
(REF)
RIVET
882080185
(TYP)
FRIIME
REPAIR STRAP
VIEW
A-A
8281-1,117
53-1 0-20
Page 218
Aufi 17/R4
Frame Repairs
Lower
Fuselage Stations (F8) 155.29, 158.5,
Q
COPYRIGHT,
and 161.75
1984 BY SAEIRELINER CORPORATION
NA-66-1032
Remove
REPLACE PROTRUOING-HEAD
RIVETS AT FS 161.75 WITH
nutplate mounting doubter (frame, FS
F164-2ITYPI
2ROWSREOO.CSK
JO-BOLT
161.75.)
F164-2JO-BOLTS.CSK
REPAIR DOUBLER.
REPAIR OOUBLER
Cg
Rsmoveprotruding-head riuelthroughwsbandi.eb
doubler (frame, FS 161.75). Hold web doubler with wire for
FRAME WEB
reassembly.)
5/16
7/8 TO 1
[TYP)
tC
~fPIIIDOUIL[R-0.071
ERAB24T-0
F164-2
JO-BOLT
DOUBLER
MOUIITIRG
1-3/16
DOUBLER WEB
t
ITYP)
IUT-PLATE
CB
I~
COISTANT
SKETCH 1
LEFT HAND SIDE,
15/16
[LDDKING AFT
FS 161.75)
IF, DUF. TO CRACK CDWFIOURIITIOW.
REPAIR RIVET PATTERWLEAVESPIN.
IOR MORE) EGOE OISTANCE TO CRACK,
ADD FIELD RIVETS AT 2 IN. ON
CENTER AS REOG.
t-
~7
B
STOP-GRILL CRACK
wnw wo. 30 ORI11.
X
x
--1
$1
0.071 2024-T42
BARE --7
NECESSARY. USE
110.300RllL
Y/
4
REPAIR DOUBLER
CRACK--STOP-DRILLAS
--1-~
IX
REPAIR STRAP
0.025 301 CRES,
1/2 HARD
7C/~/T;\ O
f
f
O
RIVET
SKIN
082248-3-2. PICK UP 2
EXISTING FASTENER LOCATIONS
EA SIDE OF CRACK. 00 NOT
COUNT FASTENER NEAREST
RIVET
SKETCH 2
LEFT SIDE,
(LDDKING AFT
FS 161.75)
1(
LFRAMFCIP
SECTIONBB
IF164 JO-BOLTS
MAY BE SUBSTITUTEO. MILL OR GRINO
JO-BOLT HEAGS FLUSH WITH SKIN
CRACK.
SEE SKETCH
AFTER INSTALLATION.
1 FOR FASTENERS,
FASTENER SPACING,
ANO EGOE OISTANCE.
Remove fasteners
through
skin and frame cap
as
applicable.
NOTES
(D
O
O
O
REPAIRS SHOWN FOR CRACKS ORIGINATING FROM

WEB DOUBLER OR NUT-PLATE DOUBLER FASTENERS.
IN
USE REPAIR SHOWN IN SKETCH 1 WHEN CRACK IS
SHADED AREA OF WEB.

USE REPAIR SHOWN IN SKETCH 2 WHEN CRACK IS
INBD OF SHADED AREA.
a
WHEN CRACK RUNS INBD OF SHADED AREA, REPAIR

DOUBLER MUST BE EXTENDED TO PROVIDE FOR TWO
STRAP
El
Primerepairpans
Install
repair parts end previously removed pans
During rainotsllation of door,
clearance in area of
IS NOTREQUIRED IN THIS REPAIR.
nl
ncrnln AT
rvn REPAIR
UVUe~Len FOR
WLltJ DOUBLER
REMOVE WEB
DO NOT RtMVVt
Fsbroafarepairparls
lu
repair
DO NOT PICK UP FLUSH RIVETS THROUGH FRAME
INADEQUATE CLEARANCE WILL RESULT

IN DOOR SKIN EDGE BEING TORN.
Repairs
Lower
Fuselage Stations (FS) 155,25, 158.5, and 161.75

0
checit door trim IOI
and retrim if necessary.
m!nlanzl
WEB AND DOUBLER AT FS 168.5.
Frame
as
applicable.
ROWS OF FASTENERS AROUND THE CRACK.

REPAIR
Bsapplicsble
53-1 0-20
Page 219
Aug 17/84
NA-66-1032
RETAINER TRIM LINE
~T7 -~f-
Ac
++I
++I
LPPAOXBIII.
(BOTH SIDESI
DOOR STOP
++I
+4
L/-p+
+t
c
t
a
~e
a
IC+
c++++
+I
I+
+I
I+
+I
I+
4(]
la
"iI
Il"
++1
~s
-C
t-
eef
e++
It
:I+
I-
RADIUS IO MATCH
EXITIIG:PART
3/4
Is RIVETS EA
SIDE OF CUTI
Aemove lower trim
SECTION
panels
an
A-A
nance
hinge mechanism. Refer
to
-I
applicable
fuselage
+If
$I+
Lil
Install
MS208014D4-W5
112 REOD
!O
Mainte-
SIDE)
Replace removed fasteners through fuselage
midway between existing
Reinstall removed section of door seal retainer
with fasteners
Sheet 4.
Install six
through lower section

retainer splice.
of door seal
indicated
as
(below cut) securing
retainer and door seal
door seal
structure and skin,
rm
on
RBBBsI removed sectianof door refa
door:seal retainer
sealant,
procedures.
LB
through fuselage skins

longeron repair angle and
Remove sufficient fasteners
for installation of
00
longeton repair angle
and fillers
as
shown
splice.
install Irim
Refer to
p.nel.
on
Reinstall
Chapter
nar
including
51 for
sealing
FS 143 and 174 bullhBBd.
Use same method of attachment
fillers.
M;tke
EA
spl ice sections at each end of installed door
Remove lower section of door seal retainer, and all
access
ITyPI
seel retainer with six MS20601AD4-W5 rivets.
carefully noting
shown.
Remove all fasteners
to allow
l/4
MS20601AD4-W5 rivets
retainer to
excess
s/s(TvPI
skins. See figure 210 for substitute fasteners.
Cut door seal retainer

as
3-5/8
DODR:SEAL RETAINER DETAILS
Manual,
fasteners
a~
entry door, inflatable seal
method of attachment. Remove
and lower
3/4
aft face ot bulkhead at
FS 143 and fwd face of bulkhead at FS 174
9/16
cs
FASTENERS TO ALLOW ACCESS
RETAINER
SPLICE ANGLE
2024-742
FOR REPAIR.
DOOR SEAL
0.040
I+ RemovE REOUIREO NUMBER DF
e\
FUS SKIN
=1
~___________
O
+4
4 t 4
t
Ti~
F=P~
as:on
original installation.
inflatable door seal, entry door and

to applicable Maintenance
hinge mechanism. Rater
on
Manual.
sheet 3
Install
Idngeron repair angle
and tillers
as
shown
on
slioii
s2es-3-l?e
53-1 0-20
Page 220
Aug 17/84
IJower
Lonaeron ReDair
Figure
211
o
at
Entrance Door Opening
(5heet li:of 4)
COIP~ABGWT, 1984
BY SB:BRELINER CORPORATION
NA-66-1032
FS
150
FS
8831889-088-3
155.25
8431689-38-5
161.75
15 REOO)
(I REOO)
BAMAREB LONGERON
PICK UP EXISTING
8481869-38-4
F18TENER
LOCATION
14 REOOI
AS REOO.
I\+:j
Ir;ll
Ar
/-7
I ~lii
~t
LOIIGEROW
REPAIR ANGLE
_kS~B\
Ir
H-
8831689-088-4
8831889-988-5
832047000-6 14 REOOI
PICK UP EXISTING
FASTENER LOCATION
(MFO HEAO FAR SIUEJ
12
+I
5/16
(1 REOO)
REOO)
FUS ML
PICK UP EXISTIIO
FASTENER LOCATION
8329609405-186
8831103-5 BOLT 12 REOO)
II RE001
ANgBOPOIOL WASHER (2 REPD)

MS21O42L3 NUT 12 REOO1
PICK UP EXISTING
FASTENER
LOCATION
VIEW LOOKING DOWN

LH SIDE
7533-31\-5 SCREW 16 REOO1

ANOeoPOloL WASHER 18 REOO)
88867983 NUT
16 REOO)
TRIM OAMACEO LONOERON AS SHOWN

ANO AUO FILLER 12 PLACES)
RONO IN PLACE WITH EPON 913
SECTION
REFER TO CHAPTER 51.
A-A
2-1/2
(TYPI
EOUAL
SPACES
5/167
5/16
I 1,71 pp)
LONGERON
FILLERS
;t
ITYP)&s
Ilf
I
tii
5/32
5/16
ITYPJ
5/16
8831103-5 BOLT (2 REOO1

ANOOOPolO WASHER 12 REQO)
K1O103 NUT (2
NASlOBO-ORK-S
14 REOO)
REQO)II;I
VIEW LOOKING INDD
NOTES
OAMAOER LONOERON
LONGERON
REPAIR AIIGLE
-t
5/18
n~slsesoslc-a 14 REOOJ
PICK UP EXISTING
FASTENER LOCATIONS
LH SIDE
SEE SHEET 3 FOR DETAILS OF REPAIR PARTS.

S265-3-~30
OKAYNARMFGCO.,
INC.--FULLRTON,CALIF
Lower Longeron
Repair
at Entrance Door

0
Opening
53-1 0-20
Page 221
Aug 17/84
NA-66-1032
S1RII(TITRAI~ REPAIR MANUAI,
C_I
I
N.
"11_...
C1=
TRIM THIS EOOE TO CLEAB

EXISTING FASTENERS. LEAVE
AS WIOE AS POSSIBLE.
1/4 rtl/lB
12 PLACES)
new BIB
15/16
TRIM THIS FLANOE ON
INSTALLATION AS NOTED
IN VIEW A-ii
121/2--i -I-0.080
0,080
0.093 R
5/8
f5/32R
f
0.080
0.125 R
SECTION
(TYP)
CC
LONGERON FILLERS 12 REOOJ
TWICE SIZE
0.080 7075-76
IROTATEO 90" CLOCI(WISE)

LONOfRON REPAIR ANGLE
MACHINE FROM 7178-76 BAR
5265-5il 31
53-1020
PaRt ~22
AuR 1 T/84
Lower
Longeron Repair at Entrance Door Opening

Figure 211 (8heet 3 oi 4)
o
CO~RIGHT, 1984 BY SABRELINER CORPORATION
NA-66-1032
DOOR SEAL RETAINER
ooil
174
lo~o
1T:
BULKHELO
oi
e? 11
I-c-
FPiiJ
I!
~;9
1!
81
11
II
($)I
ilol
a i
II
11
I~II
Ilol
18
II
AT FS 174
Ilo;
msTINo STRUCTURE
ilo
11
1~11
~ilF---
MOLO LINE
I~
I[Oi
el
e;
or~ o
81
FS
161.75
81
LI
CD
LOWER LONGERON
oi
"lr I 1"1
d13 1:
lol
000RSVILR[TAIYIR
BOLKHEAO AT FS 143
Q(
I;
e;;l
CP!1
1!
ii
el 1
II
FS
~IEre
155.25
Ii
Ilo!
I-- 0OORSEALRETAllER
~II 1 le~i
oi
O
e~
REPLACEMENT
FASTENER CODE
cs
0-li~ol
~IJ
I/
ol
EXISTING UWOISTURBEO
FAST~NER
MS20801AD4-W2
o
MS20801A04-W3
:I
olo
MS20803A04-P12
WASIBBsOBK21JO-BOLT)
8431580-0883 IJO-BOLTJ
or
I
00
oC,
MOLD LINE
143
LOWER LONGERON
MS20801A04-W2 RIVETS MAY BE USED

IF CLEARANCE ON BLIND SIDE PERMITS.
S285-3-291
Lower
Longeron Repair at Entrance Door Opening

53-1 0-20
Page 223
Aug 17/84
NA-66-1032
FRAME
STRI~(1TITRAL REPAIR MANUAL

1-15/32
29/32
-1
5/16
7/32
-\I( I
-I
REPAIR AWGLF
ITYPI
RIVET
8320470805-5 REOO
FRAMEIREF)
1-15/16
I
TOOL HOLE (REF)
t
RIVET
TYPE
ANO SIZE TO
MATCH REMOVEO
BUTTOCK PLANE
FISTLWER(TYP) J
21.5/8 IREFI
REPAIR ANGLE
1/0 A
FRAME
r
S
FRAME
CRACK
,I
REPAIR ANGLE
TRIM LINE
NESTER. WBTED
REPAIR AIIGLE
0.050 2024-73
BARE
ANGLE IS IDEW-TICAL TO EXTEA-NALANOLEEXCEPT

AS NOTER.
7/32
I/n(m~xlI _
15/4
-j
STOPDRILL CRACK
~g
WITH WO. 30 OAILL
FRAME
BUTTOCK PLANE
21-5/8 (AEFJ
Ji)
NOTES
P
a
THIS REPAIR IS APPLICABLE TO CRACKED FRAMES AT

FS 188.25. BUTTOCK PLANES 10 TO 21.625.
FRAME
MAY
BE
REPAIRED
BY
Trim oft Oamsged Irame end
or.o~drill craci
applicable.
TRIMMING
OFF
DAMAGED END AND REPLACING IT WITH AN EX-
Fabricate
rapairangle
Installrepsir.ngle
TERNAL REPAIR ANGLE OR BY STOP-DRILLING CRACK

-\UD
YEPTI~UG
53-1 0-20
Page 224
Aup: 17/84
REP41R
ANGLE
II: cRACk:S Wlr~lN
INSIDE
FRAME
LIMITS SHOWN.
Frame Repair
Aft:Side of
Speed Elrake Well, Station 188.25
Figure 212
COPYF(IQMT, 1984 BY SA:bR:ELINER CORPQRATION
NA-66-1032
REPAIR OOUBLER
STIFFEIIWO B~AO
IREFI
r\l
RIVET
0830470400
OnE ROW REOO IT 5/8

TO 7/8 IW. SPACIIO
STOP-DRILL CRACKS
WITH WO. 30 GRILL.
MAX CRACK LEWDTH
Is 1/2 IH.ITYPI
1/7/8
c
~t:
II
5/32
SPACER
~Si
TOOLIWO HOLES
IREF)
f
FLAIIOE TRIM
LIRE AWO EOOE
OF SPACER IREF)
TRIM OFF
FLAWGE OF
OAMAOEO SUPPORT
TYPICAL
VIEW LOOKING FORWARD AT WING FILLET SUPPORT
OAMAOEOSUPPORTI
SECTION
SPACER
0.090 2O24-T3
A-A
SPACER
SUPPORT
\rC1
REPAIA
Section A-A Alternate Method
REPAIR DOUBLER
0.083 2024-742
1.
Stop-drill cracks(s).
2.
Trim off flange.
3.
Fabricate spacer and repair doubler. Form repair

doubler in annealed condition and heat-treat to -T42
condition after forming.
It
Paint spacer, repair doubler, and bare areas of support with two coats of epoxy polyamide primer.
Alternate repair method is identical except delete

spacer and install repair doubler on the opposite side
of stiffener bead protrusion.
NOTE
This
Install repair parts.
repair is applicable
supports at FS ~15.5,
to
crackedfillet
and
~33. 5,
~24.9.1e5.
S265-3-213
Figure 213
Repair of
Fillet
Supports
Fuselage (FS) Station 215.5
to 249.125
53-1 0-20
0
Page 225
16/90
Mar
NA-66-1032
PICK UP EXISTING RIVETS 7 PLACES
ML WING FILLET
OAMACEo WEB IRE9

17 MS2047OAD5 RIVETS EOUALLY SPACER
IN 4 ROWS AS BROWN. MAINTAIN 0.32 EDCE
OISTANCE FROM EDGES ANO SURROUNOIWO
AC
STRUCTURE
C
FILLER
-f;\~*.
(r---
ANGLE
+II+
7 8320470405 RIVETS
EOUALLY SPACED AS SHOWN
(1
II
1/4
1 8320470403 RIVET.
CEWTEA sit twlST1G ~YOLE
L1
I\+
I+
1 8320470405 RIVET.
MAIWTAIW 0.32 EBOE
4\\
OISTANCE
*~t
f
II
Icd
p~
+~N
Q
-I
DOUBLER
II
C,
-e
13
8320470405 RIVETS EOUALLY
SPACED IW 3 ROWS AS SHOWI
PICK UP
EXISTIWC
RIVETS
BPLACES
PICK UP EXISTING RIVETS
18 PLACES
BP 15/1/4
OAMAoEB WEB IREF)
285311137-3
1/B
Trim
doubler. filler and angle
Maintain 1/4 in.
and
surrounding
Prime
coat of epoxy
edge distance
to lit.
between
edge of
I~ifjil
filler
structure.
repair doubler, filler, and repair angle with one

polyamide prior to installation.
REPAIR
DOUBLER
0.040
7075-76
CLAO
7/8
FILLER
Form
angle
0.040 7075-76
CLAD
REPAIR AIOLE
in 7075-0 condition; then heat-treat to
0.040 7075-76
CLAO
7075-T6 condition.
I/B A
Sealentirerepairsrea.
NOTES
SECTION
A-A
THIS REPAIR IS FOR CRACKS OF ONE IN. OR LESS. FOR
REPAIR OF CRACKS GREATER THAN ONE IN. REFER TO

S/B
56.1
DIMENSIONS ININCHES.
53-1 0-20
Page 226 1
Aug 17/84
Repair of Frame and Web
at
Fuselage Station (FS)
erugiF52.661
214
NA-66-1032
STRUCTURAL REPAIR MANUAL.
REPAIR DOUBLER
EXISTIIIG FASTENER ITYP)-REPLACE WITH TYPE AND
FRAMECAPANGLE
STOP-GRILL CRACKS
SIZE REMOVED
TERMINATINOINTHE
MATERIAL WITH A
at
NO. 30 DRILL
t
C
I
I
$I~
EXISTING FASTENER
TEVIR)PYT(
MSM9701105
sREOO
(TYPJ
REPLICE WITHTYP~IWO
SIZE REMOVED
SU\
I~
11/4
II/IGITYPI
tn\
REPAIR ANGLE
f
t
FRAME WEB
-t
5/16 (TYP)
5/16 ITYPI
le/\ I\
II
REPAIR ANGLE
3/4 TO
7/8(TYPI
REPAIR DOUBLER
RIVET
FRAME
MS2O47DAD5
45500
REPAIR OOURLER
0.050 2024-T42 CLAD
FRAME CAP ANGLE
ANGLE MAY BE O)(
O
O
O
~C/
StDpdlillCraCkS
1.
Bq
ANGLE OR REPAIR
DOUBLER, 0.040 BY
Fsbrcsle~pairparts
Install
parts
as
EITHER SIDE OF FRAME

WEB. JOOOLE REPAIR
11/1511.450500.
shown.
rFRAME [REF)
NOTES
THESE
REPAIRS ARE APPLICABLE TO FUSELAGE
FRAME, CANTED FUSELAGE STATION 469.75, AS

FOLLOWS:
CRACKS THAT RUN TO OUTER EDGE OF FRAME
FLANGE AND CRACKS THAT RUN TOWARD, BUT NOT
INTO. FLANGE RADIUS MAY BE REPAIRED BY INSTAL

LATION OF REPAIR ANGLES.
FRAME WEB
IT
IREF)
IS RECOMMENDED THAT REPAIR ANGLES BE
INSTALLED ON BOTH SIDES OF FRAME AT INITIAL

L
FAILURE
(THOUGH THE SECOND SIDE MAY NOT BE

CRACKED).
~Y
REPAIR ANGLE
0.050 2024-T42
CLAD
CRACKS THAT RUN INTO, OR PAST, FLANGE RADIUS
MUST BE REPAIRED BY
INSTALLATION OF BOTH
REPAIR ANGLES PLUS REPAIR DOUBLER.
Frame
Repair
Canted Fuselage Station (CFS)
erugiF57.964
215
53-1 0-20
Page
227
Aug 17/84
NA-66-1032
FS
DRILL NO.
IO(TYPI
EXISTING FASTENER
REPLACE WITH LIKE
FASTENER WHEW SPLIE-INo ON A NEW RIB
485
1/4
r)A
ENO
ITYP)FelME
495
FRIIML(AEF)
(REF)
3/4
s~
+fS
ii
5/16
(MIN)
1/4
IMINTYPI
+I+~
-t
+I------/---C~------
It
$I+
t-
-t
I+
5/16
:I
IMlNII
ii
t
O
~e
IMlN
REPAIR ODUBLER
TYPJ
I/J(MIN]
)A
CRACK
SPLICE DOUBLER
314
RIVET
RIVET
MS2O4070A05
to REOO 12 ROWS)
ITYPI
MSM470A05
9 REDO EA SIDE
OF SPLICE
VIEW IOOKING UP
L~S
ale 15561
REPAIR DOUBLER
SPLICE DOUBLER
RIB REF
SECTION
SECTION
A-A
FRAMEIREF)
SECTIONIWHEN
SPLICINGI
REPLAGE
EXISTING FASTENER
WITH LIKE FASTENERS WHEN
SPLICING ON A NEW RIB END (TYP)
C)
OIL__
____
TO MATCH
REMOVED FASTENER
RIB IREq
oll
Il
__~o
_
RIVET
FRIMEIREq
SPLICEOOUBLER 1
RIB REPAIR
(3
BB
o
_
o
_
ole
_
REPAIR DOUBLER
EXTEND REPAIR
DOUBLER FLANGES
IOR FULL REPAIR

RDUBLERI TO PICK
UP 2 FASTENERS
a
_
e
_
~ioo
II
---~L-
RIVET
PICK UP 4
EXISTING LOCATIONS
CUT RIB MIDWAY

BETWEEN EXISTING
EA SIDE OF SPLICE.
RIVETS TO MATCH
REMOVED FASTENERS
FASTENERS
AFT OF CRACK
3265-3-(34
53-1 Q2Q
Page
Aug )7/84
Upper Clove-out Rih Repair

Fusel~e Station (FS) 479
Figure 216 (Sheet L of 2)
o
SQO
COPYRI:GMT, 1984 BY SAf3RELINER CORPORATION
NA-66-1032
STRUCTURAL REPAIR MAIVI;AL
RIB
(REF)
FRAME
RIB REPAIR SECTION
IWHE)I SPLICIIGI
IAEFI
0.040
7075-0 Gild
SHlM AS
SPLICE DOUBLEA
REOD
0.040
7015-0
ANY GAP OVER
FRAME
1/16 MATERIAL
(REFJ
2024-74
REPAIR DOUBLER
0.040 7075-0
RIB END REPAIR

Stop-drill cracks terminating
Or
El
01
in rib with
No, 30 drill.
Fabrcsle repsir doubler.
Heat-treat
repair
doubler to -T6 condition.
RIB SPLICE
Ino~sll
repair doubler. Check gap before fa.tening

rib to rudder lower hinge support. Shim gap in excess of
1/64 in, to avoid preloading parts.
~I
O
O
NOTES
THESE REPAIRS ARE APPLICABLE TO THE DAMAGED
Remove rib-to-skin fasteners
as
required
Aemoverib-faframefsstenerJatFS485
Srim off
damaged
rib end.
CLOSE-OUT RIB AT FS 479 TO 500.

Fabricate rib repair section and
USERIBENDREPAIRWHEN FOLLOWINGCONDITIONS
EXIST:
(1)
TWO
EXISTING SKIN-TO-AIB
O
0.
FASTENERS CAN BE
PICKED UP IN REPAIR DOUBLER AFT OF CRACK AND

FWD OF FRAME AT FS 485.
(2)
TWO
ROWS OF FASTENERS
CAN
BE
nss(-tresf
Inotall rib
repair section
repair parts
splice doubler
to -T6 condition
repsir.ection
and
rapairdoubler. Align rib
so that a
maximum gap of 1/64 in, exists

between that section and rudder lower hinge support when
INSTALLED
THROUGH RIB WEB AFT OF CRACK AND FWD OF FRAME
fastener edge distance and alignment with other parts

permits, When foregoing tolerance cannot be met, shim gap
AT FS 485.
in
USE SPLICE WHEN DAMAGED CONDITION DOES NOT
excess
of 1/64 in.
ALLOW USE OF RIB END REPAIR.
Upper Close-out Rib Repair
Fuselage Station (FS) 479

a
500
53-1 0-20
Page 829
Aug 17/X4
NA-66-1032
REPAIR CLIP
S1K1I(TlrRAI, REPAIK MANIIAI,

FS
333.625
MS2O470A05 RIVETS
12 REOO) PICK UP
116 6E00)
RIVET (SEE NOTE)
FS
\348.600
51820470405
RIVETS 18 REPOI
51820426403 RIVETS
PICK UP EXISTING
HOLES
AEPAIR CLIP
EXISTING HOLES
+IT-
i +i
13/418.
T----~-
13/8 IN.I
FUSELAGE
7/8 IH. (TRUE)
UHF ANTENNA HOLE

AGO; IN CHANNEL
SKIN JOINT 18821
DRILL HO. 5
REPAIR CLIP
REPLACEMENT CH6WNEL
16.2065 !N.)
HOLE (TYP)
2-s/ra,a N)EFJ
1/81N.
AEPAIR
CLIP
13/16 IN.
5/3211.
EXISTING DAAIW:IR~FJ
_L
1-1/4 IN.
3-
3/416.
--15/8 IN.
L.
REPAIR CLIP
JOGGLE 0.040
REPAIR CLIPS 0.071
JOOGLEO.O57
2024-742 CLAD
(TYPI
REPAIR.CHANNEL
0.032 4130 STEEL SHEET
1/8 R
(TYP)
REPAIR CLIP
0.07:1 2024-742
R,
CLAO
SECTION
:(il
O
.O
FRAME IRF9
FS 346.5
FRAME
(REF)
FS 333.6
FUSELAGE SKIN (REFI
REPAIR
ANTENNA
RBmOYB cracked channel
Fabricals
repair channel,
and
repair clips
HBatfre.t repair clips to T-42 condilion after
forming.
NOI~S
THIS
A-A
IS APPLICABLE TO CRACKED
.:-O
~fter forming repair channel, hesttrsat

-135,000 psi, and cadmium plate.
UHF
BRACKETS, FUSELAGE LOWER CENTER-
to 125.000
LINE BETWEEN FS 333.625 AND 346.500.

IT IS
RECOMMENDED THAT SKIN REPAIR SHOWN ON
SHEET 2 BE INCORPORATED WHEN A NEW
:~E
(REPAIR)
ANTENNA SUPPORT CHANNEL IS INSTALLED. CDNDI-
;-O
TIONS THAT CAUSED CHANNEL TO CRACK AAE

LIKELY TO HAVE DAMAGED SKINS IN AREA OF CHEM-
~;O
WHEN A SKIN REPAIR IS NOT INCORPORATED WITH
CHANNEL REPAIR. REPLACEMENT FASTENERS MUST
:li~
BE OF TYPE AND SIZE REMOVED. WHEN SKIN REPAIR IS
INCORPORATED. USE FASTENERS CALLED OUT ON
ing
SHEET 2
Page 230
Aug 17/84
UHF
Dip fasfenen
between
repair channel and skin,
in rine chromate
primer
and install
wet.
MILLED RADII ALONG CENTERLINE LAND
53-10120
use barrier tape

repairclips.
and
Reinstall
eight existing
nut
plates.
Peiotsntennasupponinsls~lationt0
area.
AntennaSupport aad~djacent Skin Repair

Figure 217,:i%~t 1 of 2)
o
1984 B~SABRELINER CORPORATION
NA-66-1032
FS
FS
333.625
346.500
INNER REPAIR DOUBLER
RIOHTHAWO
SKIN I
CHEM-MILLEO
STOP-GRILL ENDS
OF CRACK WITH
BAY
NO. 30 GRILL
RIVET
MS20426A05
FASTENER LAND
THRU OUTER REPAIR

RIGHT-HAND
00UBLERSKIW.AWO
INNER REPAIR DOUBLER.
CSK OUTER REPAIR GOUBLER (TYPI
SKIN IREF)
1/16
OUTER
2 TIMES RIVET
AGHESIVE
DIA (TYP ALL PLACES)
BGNO LINE
7/8 TO 15/16 ITYP)
++;;I-; ++++~++n,l
O
15
SKIN. DIMPLE DUTER REPAIR

DOUBLER
FUEL OVERBOARD
CRACK
GGUBLER (REFI
ITYP)
(REFJ
-0~
REPLACEEXISTING
FASTENER WITH
HS47 HISHEAR
RIVET. DIMPLE
IR
a.
ORIIIN (REF)
15
++++t
16 PLACESI
ADHESIVE
DONG LINE
OUT~R AEPAIR
Irrrl
lnY~RRLPllAOOUBLtl
CHAMFER
SUBCOUNTERSINK.
REPLACE FASTENER WITH

TYPE ANG SIZE REMOVEG.
DIMPLE GUTER REPAIR
OUTER REPAIR OOUBLER

1
WITH MS2O42BAO5 RIVETS
30;
ALL
L
LEFT-HAND SKIN
OGUBLER. SUBCOUNTERSINK
I4PUE~SI
VIEW LOOKING GOWN III(~EIIWI
GECTION
SUPPORTCHAnNELAWDFRAMES
REMOVED FOR CLARITYI
SUBCGUNTERSINK
IREFI
INNER REPAIR
7/6
FASTENER WITH TYPE

ANO SIZE REMOVEG. CSK
DOUBLER
HI
REPLACE EXISTING
AEPMR
(TYP)
EOGESI
IREF)
A-A
GRILL NO. 510.2056 IN.

HGLE IN OUTER REPAIR
00UBLERCPLACES1
Stop-drill
O
EJ
O
El
Lay
ends of
out and drill
crackle)
repair fastener
holes.
INNER REPAIR GOUBLER

Remove fasteners to be
picked up
in
repair
ITYP)
FabiCatereparps~ts
Prepare inner repair doublers and inner skin

surfaces for bonding. (Refer to ~Adhesive Bonding~ in
Chapter 51.)
RIGHT-HANG
SKIN
R\ I
FRAME [REF
TYPJ
(REF)
Bond and rivet repair parts and other removed items
in
place (Refer
Chapter 51
to
"Structural Metal-to-Metal Bonding~ in
m3mmn
ALL RIVETING MUST BE DONE WHILE ADHESIVE IS IN
INNER REPAIR
PLASTIC
GOUBLER
IN PLACE
STATE
RIVETING A CURED REPAIR
WILL
DESTROY BOND
LEFT-HANG SKIN
IREFI
THIS REPAIR IS APPLICABLE TO CRACKED SKINS AT
FUSELAGE
BOTTOM
FS 333625 AND 346.500

THAT
THIS
REPAIR
CENTERLINE
BETWEEN
BE
IT IS ALSO RECOMMENDED
OUTER REPAIR DOUBLER
0.050 2024-14 CLAD
INCORPORATED WHEN
ANTENNA SUPPORT CHANNEL IS REPLACED.

IF CRACK RUNS LATERALLY ON EITHER SKIN. REPAIR
MUST
BE
EXTENDED.
ON
AFFECTED
SIDE. TO PROVIDE TWO ROWS OF FASTENERS OUTED

OF STOP-DRILLED CRACK
IrHP Antenna
and Adjacent Skin

e17 (Sheet 2 of 2)
Support
Fiffure
Kepail
53-1 0-20
Page 231/232 Blank
Auff 17!X4
STRUCTUKAL REPAIR MANUAI,
AUXILIARY STRUCTURE
REPAIRS
(:ENERAL
Th is section contains repairs for the aux iliary structure of
the fuselage which includes the floor section. See figures
201 through 204. For applicability of repairs refer to
section 53-10-00.
53-20-20
0
Page 201
Aug 17/84
NA-66-1032
STKU(TUHAL REFAIK MANUAI,
EPOXY
i--
Illllii ii
/8MLX
I.LU.i.
CLASS A DAMAGE
SHARP OENT OR SMALL HOLE
Drill out
NOTES
Fil
damage
with 1/8 in
drill
Void With epoxy
THESE ILLUSTRATIONS PROVIDE INSTRUCTIONS FOR
REPAIR OF FUSELAGE HONEYCOMB FLOOR PANELS

a
TOTAL DAMAGED AREA MUST INCLUDE ANY DELAMINATION AROUND A DENT OR PUNCTURE. TO DETERMINE EXTENT OF DELAMINATION. IF ANY, TAP AREA
WITH A COIN. TAPPING

PRODUCES
BONDED FACE SHEET
METALLIC
RING.
TAPPING
AN
UNBONDED FACE SHEET PRODUCES A SOUND THAT

IS DULL BY COMPARISON
REPAIR OOUBLER
0.040 7178-76
BAAE
OOUBLER OVERLAP
1.25 TIMES D (TYP)
I~
OEPTH
Ol ImAxl
O.l Times O
ImAxl
II
tl
ms2oeoaul
orwrs wlrH ~BAUPT CHII(O~S In COWTOUA.
WITHIN THE LIMITS SHOWN.
SCRATCHES, OR CRACKS
COREFIL 815
ends of all crricks with No 40 drill
--J
Smooth and blend all scratches and gauges by
sanding
EPOXY BONO LINE
surrounding
Position repair doubler
area
over
damage
and line-drill
rivet holes.
Fabrcale repairdoubie~
Prepare damaged skin

bonding. (Relerlo51-70-001
and
Inject honeycomb cells under

completely filling voids.
repair doubler for
III
NOTk:
(O
Fill dent with Corefil 815. When Corefil is cured.
sand and blend with
5/16
RIVET
CLASS B DAMAGE
Stop-drill
i~e
ONE
ROW
OF RIVETS
FOUR
Bond and rivet repair doubler in
place. Rivets
must
be installed while epoxy is soft (Refer to 51-70-0.)
REQURIED AROUNO
DOUBLER AT FROM 1-1/2 TO 2 IN
rivet holes with epoxy,
SPACING
REPAIR
MIN OF
RIVETS REQUIRED ON ANY REPAIR; TO BE
PLACED AT CORNERS OF A RECTANGULAR REPAIR

DOUBLER.
NOI%
CLASS C DAMAGE
HOLES OVER 1/8 IN. OIA OEHTS WITH OIA GREATER
CLASS C DAMAGE IS FURTHER DIVIDED INTO FOUR
THAN 1 IN. ANO/OR OEPTH GREATER THAN 0.1 TIMES OIA. HOLES OR GENTS MAY
AFFECT ONE OR BOTH FACE SHEETS. WHEN BOTH FACE SHEETS ARE AFFECTED,
SKETCHES SHOWN FOR CONDITIONS 1 THRU 3 DEAL
REPAIR IS OUPLICATED ON OPPOSITE SIOE OF PANEL.
WITH DIFFERENCES IN REPAIR REQUIREMENTS FOR
CONDITIONS
FOR
REPAIR
PURPOSES
REPAIR
DIFFERENT SIZES OFTRIMMED-OUT DAMAGE. REPAIR
SKETCHES FOR CONDITION 4 DEAL WITH SPECIAL

REQUIREMENTS WHEN
DAMAGE
IS CLOSE TO A
HONEYCOMB SANDWICH PANEL EDGE MEMBER

S185-3-138
53-20-20
Page 202
Aug 17/84
Honeycomb Floor Panel Repair

NA-fi6-1032
RIVET
REPAIR DOUBLER
0.040 7178-78 BARE
MS20600A04
REPAIR DOUBLER (REFI
1-1/2 TO 2
(TYPJ
CW*PIRI/(
HONEYCOMB SANDWICH
FACE SHEET
~/t
RIVET
~i
1 IN.
IMAX)
DOUBLER OVERLAP
LINE
+II
EPOXY BOND
1.25 TIMER B
(RliF)
S/IB(TYPI
L
EPOXY
COREFIL 615
HONEYCOMB CORE
ITvPI
TRIMMED-OUT
CONDITION i-0 of
OAMAGE
REPAIR
1 IN. MAx
FILL CORE EDGE CAVITIES OF BOTH SAnOWICH

AnO PLUG. AND COVER BOTTOM FACE SHEET
GENEROUSLY WITH COREFIL 615 BEFORE IWSTALLIWG REPAIR PLUG. AFTER REPAIR PLUG IS IN PLACE.
FILL PLUG COMPLETELY WITH COREFIL 615.
CLASS C DAMAGE
RIVET(REF)
HOnEYCOmB CORE
EPOXY BOND
LINE
k-
DOUBLER OVERLAP
1.75 TIMES D
REPAIR DOUDLER
"Lo -I
EPOXYITYPI
HOI~YCOMBSAIOWICH
REPAIR PLUG
5052H39
AL HONEYCOMB. 1/8 7 0.0015
OR HEAVIER
2 In. (MAXI
FACE SHEET
CONDITION 2
B of 2 In. MAx
REPAIR DOUBLER
0.040 7178-76 BARE
HONEYCOMB
CORE
EPOXY BOND LINE
AIVET
DOUDLEH OVERLAP
_I
(REF)
HONEYCOMB SANDWICH FACE SHEET
CONDITION 3
1.75 TIMES O
PLUG (SEL COWOITIOW

OFOR IWSTALLATIDN
PITYP)
i
EPOXY
(TYP)
PROCEDURES)
GREATER THAN 2 IN.

S265-3-137

0
53-20-20
Page 203
Aug 17/84
NA-66-1032
LINE-GRILL EXISTING
EDGE MEMBER FASTENER
HOLES [TYP)
TRIMMED-OUT DAMAGE
on
CHAMFERI/8
zj
ce
oullil~c.re:l
or
Ca CUlate doubler
j\ II
overlap and mark overlap
area
damaged face sheet.
O
O
O
I\
Str p
from
paint
Fabricate
lo be banded.
area
repair doubler(o) elcepl for rivet holes.
and
Clean
damaged
--1
dalaminstion and
for
Cheer
damage.
prepare
face sheet for
repair daubler(n)
bonding. (Refer
to
and
51-70-00.)
UldlllQ111
EXTREME CARE MUST BE TAKEN IN ALL OPERATIONS

PERFORMED AFTER CLEANING TO ENSURE THAT
DOUBLER
CLEANED SURFACES DO
NOT BECOME CONTAMI-
NATED. CLEAN COTTON GLOVESMUSTBEWORNAND
ALL TOOLS THAT COME IN CONTACT WITH CLEANED
;e
II
PARTS MUST BE GREASE-FREE.
O
one
Trim oul
damaged
area
remove core in
face sheet only,
When damage sllnctr

area but do not
affected
attempt to remove original adhesive

undamaged face sheet.
O
O
B
OOUBLER OVERLAP
2 TIMES O
plug
as
Position repairdoubler(a) and drill rivet holes.
Fabricate
honeycomb repair plug,
Clasn trimmed-out hole and
applicable. (Refer
al]I
1-1/2 TO 2
In.tsll
to
MS2OOOOAD4 ITYP)
0.040 7178-76
REPAIR DOUBLER
BARE. WHEN O EXCEEDS 2 IN.. 2
CONDITION 4
DAMAGE HEAR ONE OR
MORE EDGE MEMBERS
RIVET(REF)
cavity with
ep8ir.)
0.040 OOUBLERS ARE REOO
00
ISEE CONDITION 31
surrounding
only,
rec(uired.
Donsycomb repair
honeycomb repair plug
Corefil 615
when
51-70-00.)
Corefil 615 as shown in Condition 2 repair

RIVET
inside of
on
as
and fill
or
fill
plug
with
honeycomb
applicable. (See Condition
When Corsfil 615 ir cured, sand and bland with

area.
r EPOXY BONO
REPAIR DOUBLER
LINE
(REF)
(REFI
EDGE MEMBER
ITYP)
COREFILL 615 ONLY WHEN D IS HOT GREATER THAN

I IN. 5052-6-39 AL HONEYCOMR CORE FILLED WITH COREFIL 615 WHEN O IS GREATER
THAN 1 IN. (SEE CONDITION 2.)
REPAIR PLUG
HONEYCOMB SANDWICH
HONEYCOMB CORE
FACE
SECTION
A-A
Peformfinaloleaningorallsurtacaslabebonded
NOTE
by wiping with methyl ethyl ketone (MEK). Repair doublers

may be vapor degreased if equipment is available. (Refer to
51-70-00.)
SEE CONDITIONS 1 THROUGH 3 FOR FILLER PLUG AND

REPAIR DOUBLER REOUIREMENTS 1N RESPECT TO D
(TRIMMED-OUT DAMAGE DIA). THIS REPAIR DIFFERS
IO
FROM THOSE SHOWN IN CONDITIONS 1 THROUGH 3

AS FOLLOWS: (1) WHEN DAMAGE IS NEAR AN EDGE
MEMBER. REPAIR DOUBLER OVERLAP IS 2 TIMES D
REGARDLESS OF
LENGTH
OF
ndbond
Fill
honeycomb coreunder rivet h~leEwifh eWxy
and rivet
repair doubler in place. Rivets

(Refer to 51-70-00.)
must be
installed while epoxy is soft.
D, AND (2) REPAIR
DOUBLER EXTENDS TO EDGE OF PANEL AS SHOWN.
53-20-20
Page 204
Auff 17/84

Figure 201 (Sheet 3 of3)
o
NA-66-1032
FLOOR WEB
jle
II
7/1BITYP)
REPAIRISEXTEHOEO
i)
$II
FUSELAGECEWTERLINE
TO OPPORSITE LO1OEROI
DII
RIVET
lie
F~
e
II
FLOOR WEB
II
ell
OR1O1nlAL
FASTEWER. SEE "RIVETINO

DATA" IW WOTES
REPAIR OOUOLER
811
TAIMMED-OUT
FLOOR WEB
FASTE)IER LAWO
PRESSURETIOHT
FILLET SEAL ITYPI
Ilt~
IREF)
I I~
I~
~II
I~
$II
~II
1/2R
1~
/I~JI
ITYP)
$II
~II
~II
IC1--
SUBSTAUCTUAE
(TYPI
II
FLOOR WEB
(REF)
II
4311
I
FWD
(FWDI
~II
$II
SECTIONA-A
TRIM PAIEL
AIOLE
II~
II~
REPAIR DOUBLER
CLAO
II
I!
Fi,
\ap
0.051 2024-73
CHEMMILL LIRE
CF
TYPI
FLOOR WEB
I--~
(TYPJ
REPIIIR OOUBLER
O1IIOE
ii
9r-
EXISTI)(O FASTEWERS IREF)
LOWER
TO MATCH EXITING
LOWGERON
CIDGE DISTAICL
(MIW
TYP)
IREF)
V-
TRIMMED-OUT OAMAOE
CHEMMILLEO BAY
(TYPJ
NOTES
THIS
REPAIR
IS APPLICABLE TO
CHEM-MILLED
FUSELAGE FLOOR WEB, FS 298.5 TO 333.625.

EACH REPAIR MUST SPAN A CHEM-MILLED BAY
(MIN).
WHEN DAMAGE HAS AFFECTED A WEB
REPAIR
DOUBLER MLIST
BE
til
EXTENDED
BAY.
RIVETING
RIVETS WITH
REPLACE
ALL
Trim out
damaged
area.
Remove all fasteners in and around damaged bay
LAND,
TNECAJDASSORCA
MS20470DD6 OR NAS1054-6
LI
EITHER
O
10
Remove pressure sealant
Fabricate
as
required
repairdaubler
(HS48-6) HI-SMEAR RIVETS.
MS20470DD6 RIVETS WITH
FASTENERS OR WITH NAS1054-6
LIKE
(MS48-6) HI-SMEAR
RIVETS.
A CHEM-MILLED BAY IS A THINNED PORTION OF WEB
BOUNDED BV FASTENER LANDS.
Slide repair doubler under trim panel angle and rivet

in
place.
Fillet seal all edges of repair doubler (Refer

51-20-10, Pressuretight and Liquidtight Sealing.)
to
szss-3-13e
Floor Web
Repairs
Fuselage Stations (FS) 298.5-333.625

202 (Sheet 1 of 2)
Figure
0
53-20-20
Page 205
Aug 17/84
NA-fiG-1032
SIIIII("IIIKAL REIAIR MANUAI,
FLOOR WEB (REF)
SUBSTRUCTURE (TYP)
FUSELAGE CENTERLIIE
(REFJ
REPAIR C0U8lfR
(HtI-)
IOL
;c
---_
8PLCIWC
.i
ct
o/
lol
ol
I~it
CI
cle(+tt
B
.I
cl
01
It
I":
tld
IREF)
SECTION
BI"01
;-I
It
A-A
TRIMMED-OUT
049492
I,I
lo
Ft
10)
t
o(
SUBSTRUCTURE
Oi
$II
~ltBii
!li;
tl
io;
C
1
191
c;l
SEE CHART
It
(TYP)
I,
FASTENER
(O
1/2 R
~I I+
(TYPI
ICI
ol
PRESSURE SEALANT
EO LDltWC~-SE CHART
ly,,
AY
or
ol
SEE CHLRT
REPAIR OOURLER
IAEF)PAESSWAE
(TYPI
)O
SEALANT
FLOOA WEB
10
01
10
01
SUBSTRUCTURE
(O
SECTIONB-B
-C_---
IRIFI
REPLACE EXISTING FASTENER

WITH FASTENER SELECTED
TRIMPANEL
AMOLE [REF)J
FOR REMAINDER OF
REPAIR, THIS ROW MAY
ITVP
REOUIREO
REF)
FASTENER
SPACING
ROWS REQO
MIN
MS20470~05
7/8
0.011
REPAIR DOUBLER
2024-T3 CLAD
BE COUNTED II ROWS
EXISTI)IG FASTENER
FLOOR WEB IRE9
2066 OISTAWCE
MAX
5/is
1-1/8
MS20470DOg
1-5/16
3/8
TRIMMED-OUT
MS2O600AO6
1 I
DAMAGE
3/8
pp)
8431054-6
IHS48-6)
1-1/2
3/8
888139885
7/8
1-1/8
5/16
848139886
3/8
P164
1-1/4
3/8
O
Oi
El
El
OR MS20602
NOTES
THESE REPAIRS ARE APPLICABLE TO CONSTANT
THICKNESS FLOOR WEBS, FS 298.5 TO 333. 625
Trimouldamagedarea.
Remove Pressure sealant
Fabricate
Install
as
reguired.
repairdoublsr.
repair doubler, using repair
fastener from
chart.
TWO REPAIR EXAMPLES ARE SHOWN. BOTH REPAIRS

MAY BE MADE. USING EITHER TWO OR THREE ROWS
OF
FASTENERS,
DEPENDING
UPON
El
FASTENER
53-20-20
Page 206
Aug 17/84
Pressure-seal all
edges
of
repair doubler. (Refer
51-20-10.)
SELECTED FROM CHART
Floor Web
Repairs
Fuselage Stations (FS)
o
to
s1s5-3-140
298.5 to 333.265
COPY~RIGHT, 1984 BY SABRELINER CORPORATION
NA-66-1032
DAMABEO BULKHEAO TRIM 24NEL

3/8 RUBBER PAO
00
BEPAIR DOUBLER
IREF)
REPAIR BOUBLER
0020
2024-T3, 8120 AS REOO
ZIN. OVERLAP
(MIN)
DAMABED BULKHEAD
TRlm PANEL
(AEFJ
0.020 2024-T3,
REPAIR DOUBLER
USED WHEN
SIZE AS REOO
OAMAOE EXTENDS TO BOTH SIOES OF PANEL
----R
OAMAOEO BULKHEAO TRII

PANEL IRE9
Peel back 3/8 in. rubber
damaged
pad
to obtain access to
ALTERNATE METHOD
area.
Make repair doubler from 2024-T3 clad aluminum

alloy sheet. Repair doubler must extend a minimum of 2 in.
on each side of damage.
O
O
O
O
Apply
adhesive to both
Clamprepsirdaublet
in
faying
surf sees
placeand
owrocure(arl
Scufisand faying sumcss to he bonded,
hours.
Pleparesdhssive (Relerto 5120-20. UEemelalto
After clamps have been removed and repair

thoroughly cured, cement rubber pad back in place.
metal bonding procedure.)
has
NO TE7
THIS
TYPE
OF
REPAIR
IS
APPLICABLE
TO
ALL
s265-3-141
MICARTA-FACED TRIM PANELS.
COPYRIGHT, 1984 BY
SABR1
Micarta-faced Cabin Trim Panel Repair

Figure 203
INER CORPORATION
53-20-20
PaKe LOS
Aug 17/84
NA-66-1 032
STRR!CTURAL REPAIR MANUAL
0.063
-~jJe
5/8
(TYP)
1-1/4
30 R
APPROX
L----
REPAIR PLATE
GRILL NO. 12
Io.1RO II.)
GRILL NO.
HOLES IN THIS LOCATION FOR

REPAIR PLATES LOCATEO OR
UPPER ANO LOWER EOGES OF
0.063 2024T3
CLAO SHEET
1210.189 IN.) HOLE
IN THIS LOCATION FOR REPAIR

PLATES LOCATER ON FWO ANO
AFT EOOES OF TRIm PANEL
TRIM PANEL
EXISTING TRIM PANEL IREF) 7
11
EXISTING TRIM PANEL
IREFI
i
At]
REPAIR
)FER(~TILP
A~1
OPrepareadhesive
O
App
REPAIR PLATE
SECURE II POSITIOW FOR 8010116 WITH A
SHORT MACHINE SCREW. 100
nOT ALLOW SCREW TO BOT-
(Relerlo51202(1.)
Tom IN
EXISTIIO TRIM
PAWEL(REFI
IWSERT.J
y adhesive 1a edges of insert and reinstall in
original position.
VINVL TRIM FABRIC
IREF)
Make
repair plates
and drill hole
as
required.
II
Apply adhesive to faying surfaces of repair plate and

panel Secure repair plate in position and allow to cure
a min of 4 hours clamp time and at least 24 hours before
INSERT (REFI
trim
for
8osa
reinstallation.
METAL TRIM STRIP
NOTE
THIS REPAIR
IS APPLICABLE TO GROUND ESCAPE
DOOR TRIM PANELS IN WHICH ATTACHING INSERTS

HAVE PVLLED OUT.
53-P0-20
Page 208
Auff 17/84
SECTION
Ground
A-A
Escape Door Trim Panel
erugiFriapeR
204
COPYRIGHT, 1984
NA-66-1032
PLATES AND SKINS

REPAIRS
GENERAL
This section contains repairs for the exterior surfaces of
the fuselage, including access covers. Refer to section
53-10-00 for applicability of repairs. See Figures 201
thru 209.
NOTES
Prime allrepairpartsand matingsurfaces
with Epozy Polyamide Primer. Install
parts using PR143~Gfa2/ing surface sealant between mating surfaces, ezcept mating
surfaces
to be bonded
For allstructzcrclcl bonding, refer to chapter

pages ~01 thru ~05.
53-30-20
0
COPYRIGHT, 1988
Page 201
Jun 3/88
NA-66-1032
REPAIR OOURLER
~I
1"/7
RIVETS
I
1
REOUIREO FOR EACH
SIDE OF P ARE OISTRIRUTEO

II THIS AREA. RIVETS IN
REPAIR DOUBLER TABS ARE
20
20
(TYP) Y
20
r(TYPI
li
~1
III
/L~il ill
20[TYPI-I I~lii
8I
1/16
II
I I/)18I
MUST BE STAGGERED IN RESPECT TO EXISTING FRAME

FASTENERS.
s BETWEEN EXISTING
FASTENERS [TYPI
[TYP)~J
i,,
I"Tf
or
ta
01
IID
DAMAGED SKIN
il i
LINE SEPAAATING
91
af3
~LiT:Pil
RIVETS THRU REPAIR ANGLE

o
1451
[TYPI
-r
r3
SIDE OF REPAIR
a/
ol
20ITYPI-t/
EXTENDEBACROSSFRAME
AS SHOWN ON OPPOSITE
TI1
\\L
_I
REPAIR DOUBLER MAY BE
[TYP)
AOOED.
EXISTING FASTENER LOCAREPLACEMENT

Tron ITYPI
FASTENER MUST BE EOUAL
5/16 A
FASTENER DISTRIBUTION
AREAS
b [TYPI
nt
IOPTIONALI
REPAIR ANGLE
(TYP)
3/8
-?P-\
c4
3/4
1-3/4 TO
TO. OR STRONGER THAI.

REMOVEDFASTENER
21/4
FRAME
CHAMFER 0.025 TO 0.0 ITYP 2

OR 4 PLACES AS APPLICIIBLg
FRAME
SAMEASFRAMETO
WHICH IT ATTACHES
DAMAGED SKIN
SEALANT ITYP)
FILLEA
0.050
2024-T3 BARE
FRAME FLANGE
MATEAIAL
REPAIR ANGLE
FILLET
3/4
SEAL
3/8
MS2O470A05
RIVET
INSTALL AT 7/8 IN.

SPACING
4aQ,
REPAIR DOUBLER
3/4
I~Uf--
JOGGLE AS REOB
DETAIL
rBSEAL
tF
REPAIR OOUBLER
oa~-
0.025
SECTION
A-A
FILLET SEAL
OPTIONAL REPAIR DOUBLER INSTALLATION WHEN

FRAME FLANOE IS 0.050 IN, (OR LESS) THICK
FILLET
DETAIL
BI
1A [1A EOUALS 1FI
3/8
JOOOLE RUNOUT IS
4 X DEPTH OF JOOOL~
B-B
LEGEhD
NOTES
D
aplolicabletoeonstantUickness shins 012 pressurized areas offuselage,
Rivet dia
are
Material thickness
Sheet 1 is applicable when

trimmed-out damage location permits ilzstallation of requiredfasteners witthin damaged bay,
Use repair oft Sheet when. damage is across a
frame or when fasteners required cannot be
installed ire one bay,
Rivets
reqd
each side of P
Rivets
reqd
each side of
See Sheet tfor orack repairs a~ad Cside wiew of
Rivets in
Repair shoUm
ore
Field rivets added to
complete
other
and
type
to match
REPAIR IN ONE BAY
P1:1-1/2
P: 2 in
Rivet spacing "a" and row spacing "b" equal

nearestezi8ting rivet spacing (min) but not less
than 5-11~ times repair rivet dia ma~ spacing
for both "a" and "b" is 1-11~ in.
pattern
fillel.(MS20426AD4)
EXAMPLE
~bforfastelzer requirements,
rivet
repair doubler tabs (sire

rivets in repair doubler)
Rivets in
repairs,
See Sheet
P1
in.
Rivet= MS20426AD5
From the rivet chart
13.4
or
(sheet 4).
are required each side

required each side of P1
14 rivets
10 rivets
are
of P
Countersilzk shinforall rivets.
53-30-20
Page
Jun
Pressurized Areas
202
3/88
NA-66-1032
STRUCTURAI, REPAIR MANUAI,
EXISTING FASTENER LOCAITYP)-- REPLACEMENT

FASTENER MUST BE EOUAL
TO. OR STRONGER THAN.
REMOVED FASTENEA
I!al
I;o I
OI
llo
20ITYPII
TION
20(TYP)
Yle r,
f/
I; o
Ilol
5/16 R (TYP)
"e I
r20ITYPI I )I
I
lIe
II01
I I
II
lli_-,I
II~I
I3
~ie
llei
II
11~1
e I"
II
1181"
CI
L
ITYP)
1_
III
RIVETS REDO FOR EACH SIDE

O~lilRf OISTRIBUEO In
IIaI
THIS AREA. RIVET IN REPAIR
II8I
DOUBLER TABS ARE AOOEO
01
ol
II
I)
i~
MIDWAY BLTWEEN
iie
I I
EXISTIHC FRSTEIERS
11,1
111,1
:Bt:
II~
TO 0.020 ITYP 2 PLACESI
REPAIR ANGLE
OI
ITYPI
Ilol
01
REPAIR OOUBLER
STAGGERED IN RESPECT TO
1 EXISTIIG FRIME FASTEHItRS
t~ol I
CHAMFER 0.050
1-1/2
11101
itll! I
\1
i~
q BETWELII IXISTInG ~AS-
TENERS (TYPI
RIVETS THRU
REPAIR ANGLE MUST BE
01
\L~i
tl
laI~
ITYPI
a
lie I I
\p~
OUT OAMAGE
Ilol
It
II"
I
ITIPZOAIPUP~I
15 IPPLICIBLB
a111
~"-CO I
1(~1
CHAMFER0.02ST00.0
DAMAGED SKIN
la
/Q
,I oAREAS
,lloI
~jil. I
~P
II~
FASTENER DISTRIBUTION
aill
118 1
Oi
LINE SEPARATING
FILLER
at
ol
;g01
1/8
118
1-3/4 TO 2-1/4 ITYP)
01
IOPTIO)IAL)
REPAIR OOUBLER MAY BE
Ilo I
EXTENDED ACROSS FRAME
U41
AS SHOWN ON OPPOSITE
SIDE OF REPAIR.
REPAIR DOUBLER ARM
FRAME ITYP)
REPAIR ANGLE
DAMAGEO SKIN
SEALANT
MATERIAL SAME AS FRAME
(TYPI
TO WHICH IT ATTACHES
3/4
--*1
RIVET
3/8
MS2O470A05
INSTALL AT 7/8 IN.

SPACING
f
3/4
OOUBLER
FILLER
301 CRES 1/2 HARD 0.025
0.050
14 llA EOUALS 1FI
f-f
2024T3 BARE
1F
3/8
FILLET SEAL
SECTION
FILLET SEAL
C-C
REPAIR DOUBLER
FILLET SEAL
JOGGLE AS
DETAIL
REOO
LEGEN~
JOGGLERUNOUTIS
11
DEPTH OF JOGGLE
OPTIONAL REPAIR DOUBLER INSTALLATION

WHEN FRAME FLANGE IS 0.050 IN. IOR LESSJ THICK
EXAMPLE
Rivet dia
Materialthickness
Rivets
reqd
Rivets
reqd each side ofl:
REPAIR ACROSS A FRAME
each side of P
Field rivets added to
P= 3 in
P1
1-3/4 in
Rivets in
Rivets in skin land
splice
are
Rivets from chart (sheet 4)

From rivet chart (sheet
MS20426AD5
are
repair
other rivets
MS20426AD5
side
required each side otP.

rivets are required each side olPi
are
11 7 or 12
pattern
type
to match
repair doubler)
of
damage
replacement fasteners
20 rivets
rivet
doubler tabs (sire and
Rivets in repair doubler and

each
4)
In
complete
repair doubler arm [7 reqd

existing locations
In
to match removed fasteners but
must be
MS20426AD5 (min)i
Existing
fastener location (to match
Added rivets in filler
original)
(MS20426AD4)
NOTE
COUNTERSINK SKIN FOR ALL RIVETS
5265-3-144
Figure
201
(Sheet
Pressurized Areas
2 of
4)
53-30-20
Page
Jun
203
3/88
NA-66-1032
STOP-DRILL ENDS OF CRACK
WITH NO. 30 GRILL
CRI\CKEO SKIN
FILLET--SEAL ALL
EXPOSED EDGES
DAMAGED SKIN
FBAMEITYPJ
REPAIR ANGLE
ADD RIVETS AS RfDG TO HOLG

GOWN EGGES OF CBACK.
OBSERVE EDGE BISTANCE,

MIN ANG MAX SPACING.
REPAIR DOUBLER
DAMAGE IN ONE BAY
CRACK REPAIR
CRACKED SKIN
STOP-GRILL ENOS OF CRACK

WITH NO. 30 GRILL
II
I+
FILLET-SEAL ALL EXPOSEG EGGES
-r
)I
DAMAGED SKIN
P1
) -P
L
FRAME
FRAMEITYPI
I I II I II
AGD RIVETS AS REOG TO HOLD

DOWN EGGES OF CRACK.
Ii;
OBSERVE EDGE OISTANCE

MIN AND MAX SPACING.
CRACK REPAIR
DAMAGE IN ONE BAY

NOTES
CRACKED DAMAGE TO SKIN 1S EXACTLY SAME AS

OTHER
DAMAGE
EXCEPT
THAT
MATERIAL
IN
DAMAGED AREA NEED NOT BE TRIMMED OUT.

OUTLINE DAMAGED AREA IN A RECTANGULAR
P~
REPAIR ANGLE
PATTERN, PROVIDING AN~PAND A

SHOWN. PERFORM REPAIRS AS DIRECTED ON SHEETS
1 OR 2 AS APPLICABLE, EXCEPT AS NOTED IN
DIMENSION AS
REPAIR DOUBLER
ACCOMPANYING SKETCHES.
S2BS-llS
REFER T051-20-20.
53-30-20
Page 204
Aug 17/84
Figure
201
Pressurized Areas
(Sheet 3 of 4)
NA-66-1032
RIVET CHART
015/32
011/8
4.0
3.5
3.0
2.5
0(
1.5
K~tttti-1
I i :i i tii i r
1.0
:T~f t
i tt---t-i
I~Z
0.5
ur I
I I I 1 I
I I i
rl I r r
10
12
14
16
18
20
22
24
26
28
30
32
34
35
38
40
NUMBER OF RIVETS REOUIREB
HOW TO USE THIS CHART

NO TE,C
Measure trimmed-out
FASTENERS USED IN REPAIRS ARE MS20426AD4 OR

MS20426AD5.
chart).
RIVETS ARE INDICATED FOR
directly
ARE
ANPOF 3 IN.; THEREFORE,
REQUIRED.
(HORIZONTALLY, EACH
SMALL SQUARE EQUALS 0.4)

Figure 201 (Sheet
COPYRIGHT, 1984
Read
below
In vertical column
(left side of
chart to point of intersection of
line; read number of rivets required
point
of intersection.
Repeafstep2lorP~dmension
Pressurized Areas
4)
4 of
P1)
across
applicable diagonal
and
FiilllPdmenSi~n
WHEN DECIMAL IS 0.15 (OR GREATER), READ NEXT

HIGHER FULL NUMBER. FOR EXAMPLE, 28.3 1/8 IN. DIA
29 RIVETS
damage (~e
53-30-20
Paffe205
Aug 17/84
NA-66-1032
STRUCTURAL SHIM
FRAME
OAMAOEO SKIN
REPAIR OOUBLER
2
ITYP)
id
BETWEEN EXISTING FASTEWERS ITYP). RIVETS THAU

STRUCTURAL SHIM MUST BE
CC
mL~b[TYPJII
1/4R_1 rl/4(TYPJ
[TYP)
U.1.~..
.i
"b."
/el
T
II~P1
(TVPI
-EXISTING FASTENER [TYPJ
2 MAx (TYP). SEE

1/4 MlN
EXAMPLE OF "MIN" CONDITION ON OPPOSITE SIOE
e/
21 TO 41
I 1/ c~C
I_1~/4_M_ITYPIIL_I
;i!
818
a
STAGGEREO IW RESPECT TO
EXISTING FRAME FASTENERS
iii
(TYP) L1/2
OF REPAIR.
,45" ITYP)
:;I
REPLACEMENT FASTENERS
LINE SEPARATING FASTEWER

DISTRIBUTION AREAS (TYPI
IN FRAME MUST BE
a
81
0481007404 (TYP
RIVET
ALL PLACE THRU THINWEO
PORTIONS OF 8KIW AND
;i
!lo
TNRU FILLER). ANO

REPAIR DOUBLER
TAPEREO SHIM
EOUAL
TO. OR STRONGER THAN,

REMOVEO FASTENER.
FRAME FASTENERS THRU
REPAIR DOUBLER MAY BE
COUNTED IN AEOUIRE.IYIS ~01 Tnt Eili-
REOO
(SEE DETAIL E. SHEET 3.1

FILLER
2024-T3 BARE
II (THINNED AREA)
STRUCTURAL SHIM
te=tminustl7
BOND 8TRUCTURAL 8010 1
BOND LINE
1Flll
SECTION
D Rivet dia
reqd each side of
reqd
each side of
Rivets added to
II
EXAMPLE
2 in.
tl
From fastener chart

12 rivets
9.2
or
11//~4
FRAME
(TYP)
A-A
are
REPAIR IN ONE BAY

0.025 in
11
Trim outdamage.
Calculate fastener requirements,
Structural shim sizes.
3.
Remove skin-to-substructure fasteners

for installation of repair.
4.
Fabricate and fit
5.
Drill and countersink all fastener holes.
6.
Disassemble repair assembly and prepare parts and

fuselage skin for bonding. (Refer to 51-20-20.)
7.
Bond structural shim and filler in place.
8.
Rivet repair doubler in place using PR1431G sealant

between all mating surfaces.
=1-9/16 in.
required each side of P

are required each side
of
P1
NOTES
sheet 1 and 2.
i.
(sheet 4).
10 rivets
on
2.
complete rivet pattern
Rivets thru filler NAS1097AD4
OAMAGEO SKIN
The following steps apply to repairs
LEGEND
Rivets
(TYP)
2024-T3 BARE
ISTOCK THICKNESS (0.050 REFIJ
1/8
REPAIR DOUBLER
301 ORES 1/2 HARD 0.025
TO 8KIW. BOND FILLER TO

8TRUCTURAL 8Hll.
e Rivets
r t
repair doubler, and

as
necessary
repair parts.
Repairs ire this figure are appliec~le to

chem-milled shins on pressurized areas of
fuselage.
See Sheet 3 for crack repairs and inside

views of repairs.
is applicable
Repair shown on Sheet
when, trimmed-out damage location, permits installation ofrequiredfasteners within damaged bay. Use repair on. Sheet
when damage is across a frame or when
fasteners required cannot be installed in
quirements.
one
See Sheets 4 and 5
for fastener
re-
Rivet spacing "a" and row spacing "b"

equal 5-1~ times fastener dia (min), but
must not be less than spacing in nearest
frame. Mat spaeingfor both "a" and "b" is
1-1~ in.
bay.
~285-3-147
Pressurized Areas
53-30-20
Page 206
3/88
Jun
NA-66-1032
OAMAGEO SKIN
(II
III
EXISTING
FASTENERS (TYP)-- RIVETS

THRU STRUCTURAL SHIM
MUST BE STAGGERED IN
RESPECT TO EXISTING
FRAME FASTENERS WHEN
III
iii
REPAIR
0
r 1/4
111
II)
ill
STRUCTURAL SHIM
LTVPI
a Il ~C
111
(TYP)
LI~
a
1/2 R
oo
(TYPI
TRIM OUT DAMAGE MIDWAY
--I
BETWEEN EXISTING FASTENERS
II~I;
blTYP)
~f-tb"gia
MIN
2 MAX
SEE EXAMPLE OF
a~fL 114
45~
1/4 R
111/$ 111+
re a
111
FASTEIERIljJ:
111
21 TO 41
I~
Q,I
l(lrB
Il
[TYP)
"MIN" CONDITION ON
OPPOSITE SIDE OF REPAIR
ITYPI
ITYPJ
41
ITYP)
LINE SEPARATING
Illo ii
ii
II)
II
AEPAR DOUBLER TAB
OOUBLERII
Zo
)(I
!I
lu_O
"y" IS LESS THAN "b..
STRUCTURAL SHIM
EXISTING FASTENER (TYPJ
Ct BETWEEN
STRUCTUKAL KEPAIR MANUAI,
II~II1
P
DISTRIBUTION AREAS [TYP)
cl 5 lil
bc~-8
II
Rlv~rNlsloaiilo,
(TYP ALL PLACES THRU
ioor;
FRAME (TYPJ
1:t
Lil;
THINNEOPORTIONS
OF SKIN ANO THRU
FILLERI.
)(I O
IIIIIIIIIIIIIIIIIIII111111111111111111111111111111111~
WT
wt
O
1/1
WL [MIN]
SKIN LAND
REPLACEMENT FASTENERS IN FRAME

MUST BE EOUAL TO, OR STRONGER
2024-T3 BARE
THAn.REMOVEOFISTEWER:FRAME
IF
ISTOCK THICKNESS (0.050 REFIJ
II
FASTENERS THRU REPAIR DOUBLER

MAY BE COUNTED IN
IS =12
FILLER
SHIM
REOUIREMENTS FOR SIDE.
DAMAGED SKIN
I2=IMINUS11
L
SKIN
LAND
fit
REPAIR
DOUBLER
TAB
I/B
REPAIR DOUBLER
301 CRES 1/2 HARD 0.025
FRAME
FRAME
SECTION
(TYP)
ALL MATING SURFACES.
LEGE~NI)
EXAMPLE
DRivetdia
P=gin
each side of P
Rivets
reqd
each side of
P1=1-3/4in
Field rivets added to complete rivet pattern
tl=0.030in
are
21 rivets
are
are
73
or
splice
(NAS1097AD4)
required
4)
each side of
Il
5)
8 MS20426AD5 rivets
each side of
W~=lin
MS20426AD5
required each side of P
From fastener chart (sheet
fastener location (to match original)
Fasteners added in filler
or
12 rivets
Rivets reqd for skin land splice
Existing
splice
From fastener chart (sheet
II
20 4
REPAIR ACROSS A FRAME
Rivets in skin land
reqd
[TYPJ
BOND STRUCTURAL SHIM TO SKIN.

RIVET REPAIR OOUBLER IN PLACE
USING 2514310 SEALANT BETWEEN
B-B
SECTION
CC
Rivets
1110
~C
;;d
CSK SKIN.
TAPEREB SHIM
6 REOO
ISEE DETAIL E, SHEET 3.)
STRUCTURAL SHIM
!Illo
L/Itt-
II
are
required
in skin land
damage
NOTE
See sheet 1 for notes and steps.
S265-3-148
Figure
0
COPYRIGHT,
202
Pressurized Areas
(Sheet
2 of
5)
53-30-20
Page
Jun
207
3/88
NA-66-1032
OAMAOED SKIN
STOP-GRILL CRACK WITH

HO. 30 DRILL ITYP)
STOP-GRILL ANY AGRUPT

CHANGES IN DIRECTION
CRACKED SKIN
FRAME ITYP)
TAPEREO SHIM
i ~I(
r-
I)100 RIVETS AS
STRUCTURAL SHIM
REPAIR DOUBLER
REPAIR OF DAMAGE
INSIDE VIEW
IN PLACE
BONDED
IN ONE BAY
REOO TO
HOLO ODWH EDGES OF CRACK.

OBSERVE MIN EDGE DISTANCE
AND MIN AND MAX SPICING.
MAKE
TAPERED SHIM
FROM 0.050 202413 BARE.
TAPER FROM 0.050 TO O.C.
DAMAGE IN ONE BAV
CRACK REPAIR
ITYP)
EXISTING RIVET
LOCATIONS ITYPI
CRACKED SKIN
STOPORILL CRACK
FRAME
FA MEIR F)ITYPI
WITH NO. 30 ORI11.

1 RIVET SPACE
1/2 RIVET SPACE
TAPERED SHIM
FRAME IREF)
ft
fl
II
(I
I
P
DETAIL
TAPERED SHIM
STRUCTURAL SHIM
I
I
REPAIB DOUBLER
DAMAGED SKIN
AOD RIVETS AS
TAPEREB SHIM
REDO TO
ITYPI ----~ir
HDLD DOWN EDGES OF CRACK.

OBSERVE MIN EDGE DISTANCE
ANO M;N AND MAX SPACIHG.
SKIN LAND
ii-
I;-%
FRAME
CRACK REPAIR
[Typl
DAMAGE ACROSS A FRAME
~II"
NOI%J
CRACK DAMAGE TO SKIN IS REPAIRED EXACTLY SAME
THAT
AS OTHER TYPES OF DAMAGE EXCEPT
MATERIAilNDAMAGEDAREANEEDNOTBETRIMMED
OUT
OUTLINE DAMAGED AREA IN A RECTANGULAR

AN PAND ANP1 DIMENSION AS
PATTERN.PROVIDING
SHEETS 1
SHOWN PERFORM REPAIR AS DIRECTED ON
ACCOMOR 2 AS APPLICABLE EXCEPT AS NOTED IN
REPAIR ACROSS
INSIDE VIEW
A FRAME BONDED IN PLACE
PANYING SKETCHES
53-30-20
Page 208
Aug 17iH4
Figure
202
5265-3-149
Pressurized Areas
(Sheet 3 of.i)
NA-66-1032
STRUCTURAL REPAIR MAn;l!AL
RIVET CHART FOR CHEM-MILLED AREAS OF REPAIR
110.025
4.0
11 10.030
3.5
3.0
2.5
2.0
1.5
1.0
0.5
10
12
14
16
18
20
22
24
26
28
NUMBER OF RIVETS REOUIREO

OMeasute Irmmsd-ouldamage IPand~ii
NOTES
FASTENERS USED IN CHEM-MILLED
(THINNED)
AREAS
Measure thichness of
OF SKIN ARE NAS1097AD4 SMEAR HEAD RIVETS.
damaged chem-milled
sklnn
CHEM-MILLED AREAS (11) MAY BE EITHER 0.025 OR

0.030 IN. THICK.
In vertical column (left side of

chart). Read across chart to point of intersection of
applicable diagonal line: read number of rivets required
directly below point of intersection
WHEN DECIMAL IS 0.15 (OR
GREATER), READ NEXT

HIGHER FULL NUMBER. FOR EXAMPLE, 9.2 RIVETS ARE
INDICATED FOR ANPOF 1-9/16 IN (tt
0.025), THEAEFORE, 10 RIVETS AHE REQUIRED. (HORIZONTALLY,
EACH SMALL SQUARE EQUALS 0.4.)
RepestslepsJlolPIdimension
5265-3-150
Chcm-milled 8kin Repairs
Figure
O
COPYRIGHT,
202
(Sheet
PresHurized Areas
4 of Ti)
53-30-20
Page ~09
Aug 17/H4
NA-66-1032
STRI:CTURAL REPAIR MANUAI,
RIVET CHART FOR SKIN LAND SPLICE
11=1/5
0=5/32
0-3/18
3.0
2.5
2.0
1.5
1.0
0.5
O
2
12
10
14
16
18
20
22
24
26
28
30
NUMBER OF RIVETS REOUIRED
NO TES
FASTENERS USED
SKIN-LAND-TO-SUBSTRUC
IN
TURE JOINTS ARE MS20426AD4, MS20426AD5, AND
O
O
NAS1097DDG.REPLACEMENTRIVETSMUSTBEE~UAL
TO, OR STRONGER THAN, ORIGINAL FASTENER.
WHEN
NEXT
(OR GREATER). READ

HIGHER FULL NUMBER. FOR EXAMPLE, 9.2
DECIMAL
IS
0.15
NAS1097DD6 RIVETS ARE INDICATED FOR A
WL OF
chart).
Page 210
Aug 17/84
lo be
spliced
Find
Read
Wl
dimension in vertical column
across chart to
intersection.
Figure
(W~)
[lefl side of
point of intersection of diagonal
line; read number of rivets required directly below point of
IN; THEREFORE, 10 RIVETS ARE REQUIRED. (HORIZONTALLY, EACH SMALL SQUARE EQUALS 0.4.)
53-30-20
Measure width of skin land
202
Pressurized Areas
(Sheet 5 of 5)
NA-66-1032
DAMAGER CHEM-MILLEO
SKIN
FILLER
REPAIR SHILI
IREF)
0.020 2024-T4 CLAO
SAME MATERIAL
ANO GAUGE AS OAMAGEO

SKIN
REPAIR OOUBLER
0.025 301 CRES 1/2 HARO
CHEM-MILLEO SKIN
:il-iii
II
IREF)7
1\
II
II
II
iii
~I
ti
-u_J
1/
REPAIR OOUBLER
ILJ
IREFJ
A1~1"1
-,ii
))I)
iaIri
~,I
~1/
:j
frt
t-
1-1/2 I~YP]
t-t
i
Iii
at
t
k- 1-1/2(TYP)
t
Ij
-t
II1
/C
41MAXJt
REPAIR SHIM
IREF)
Bi
II
I/ii
a
e
FILLER (REFI
II
tj ~~r t,,i ;i IiI
tiIII
le
I+
,liII+
I Ii
~ILIRIREFI
(TYPI
ii
1/32
11
SUBSTRUCTURE
REPAIR DOUBLER (REFJ
~I
i
t
mlN
~s+f
DAMAGER CHEM-MILLEO
SKIN IREF)
2 RIVET DIA
11
I/P(TYPJt_n~
f~i
:ii
jlel+
JIO
(_
-~ili---
(TYPJ
SECTION
SHIM IREFI
IREF]
A-A
Il
I~
2~ I
(I
(B
t-
NOTE
Prepare adhesive bond and rivet repair

assembly in place. Accomplish riveting
while adhesive is soft (refer to
1.
Bond shim to skin.
2.
Rivet filler to shim, using 3/16 in. edge distance and approximately 3/8 in. spacing
NOTE
This
repair
areas
may be used in pressurixed

where damage is not greater than a
4 in. dia hole.
(NAS1097AD5).
3.
Install repair doubler using NAS1097AD5

rivets. Use PR1431G sealant between mating
surfaces.
salo-s-ss

Damage Less than 4 In.
Diameter
Pressurized Area
53-30-20
c
Page 21i
Jun 3/88
NA-66-1032
Al
2 MIW. 4 MAX
W= 1/2
.N12L IMAX)
RIVET
TO MATCH REMOVED FASTENER
(TYPI
LOWOERON
2 TIMES FASTENER
oa
;I/
L
alnlnl
TRRUSKIN,SHIMAHD
REPAIR DOUBLER
3/8 FLANOE
1/32 (TYPI
FRAME
SKIN
REPAIR SRIM IREF)
SECTION
IREF)
A-A
RIVET
MS2O42040a
CSK FILLER
EDGE DISTANCE IS 3/16. SPACIWO IS 3/8.
REPAIR DOUBLER
(REFJ
(REII
EPDYY BPIIO
LINE
)-1/2(TYPJ
-t:AT~I/21TVPI
N1S1097A04
SHlM
(RE9
_1_
RIVETS
FILLER
ITYPJ
ITypl
~f
1-1/2
min
REPAIR DOUBLER
SHlM IREF)
(REFJ
MlN
ADHESIVE BOND LINE
SKIN
FILLER(REF)
SECTION
(TYP)
IREF)
B-B
OAMAGEO CREM-MILLEO SKIN
FILLER
i.
Trim out damage. Damage may be trimmed to a

circular shape, but must not exceed 1-1/2 in. in dia.
2.
Remove rivets through skin and substructure

necessary for installation of repair doubler.
3.
Fabricate repairparts.
4.
Prepare skin and repair shim for bonding (refer

51-20-20).
5.
Rivet repair doubler in place using PR1431G sealant

between all mating surfaces. Accomplish riveting
while bond adhesive is still soft (refer to 51-20-20).
6.
Deleted.
7.
Deleted.
SAME MATERIAL
ANO THICKNESS AS
DAMAGED SKIN
as
REPAIR SHIM
0.020 2024 7-4 CLAO
REPAIR DOUBLER
0.025 301 CRES 1/2 HARO
to
EPOX! BOND
iii-
INSERT REPAIR DOUBLER

BETWEEN SKIN ANB SUBSTRUCTURE
Damage Less Than 4 In. Diameter

Pressurized Area
5370-3-57
53-30-20
Page
212
Jun 3/88
COPYRIGHT,1988 BY SABRELINER CORPORATION
NA-6fj-10~2
STRUCTURAL REIAIR MA~UAL
FS
FS
346.5
357.0
2-3/8
5/8 R 4 PLACES
5-i/8
CL AIRPLANE
ITOP SKIN)
TOP SKIN
CUTOUT
10-1/2
REPAIR OOUOLER
2024-T3 AL,
0.032 THICK
8-1/9
Open aft fuselage

level tank unit
access
access
doors
doors and
adjacent
to
fuselage fuel
leading edge of
dorsal fin.
From inside of aft

from centerline FS 357 to
IEI
fuselage,
top
Remove inlet air duct
Cut out damaged skin
of heat
remove
39/64 R
4 PLACES
5-
7!64
exchanger.
fairing, duct,
as
ram-air duct
i/
and formers.
indicated.
Fabricate repair doubler and cutout filler
as
shown.
6-63/64
NOTE
THIS SKIN AREA FOAMS FLOOR FOR CABIN RAM-AIR
INLET DUCT FWD OF DORSAL FIN. TO GAIN ACCESS
FILLER
2024T3 AL.
0.050 THICK
FROM OUTSIDE, IT IS NECESSARY TO REMOVE RAMAIR INLET DUCT FAIRING, INLET DUCT, AND DUCT
FORMERS.

Non-Yressurized Area
lop Centerline Between Fuselage Stations (FS) 346.6 and
o
~li7
53-30-20
Page 81~
Aug 17/84
NA-Gfi-103~
357.0
IsREOO
I\
PICK UP RIVETS
MS20470-A03
7 REOO EA SIRE
SCARF
EOGE
,L
--L-
-fT, t)
I V+
FS
MS20426-A04
RIVET
FS
346.5
If
Ifl
I."8
REPAIR
OOURLER
f~-
It(_l
~I
f
EL Allllll~
2E0
ITOP SKIW)
SPC
7 EP
~L
REPAIR
I+
FILLER
SKINI$:
CUT OUT TO
PICK UP RIVETS
MS20470-R05
MATCH
GREOO
~B
MS20426L-A04
RIVET
PICK UP RIVETS
MS20470-104
)lRECREASIRE
90500
FILLER
ICONTOUREDI
FS 357
"T" FORMER
SHORT
FILLER
SECTION
A-A
REPAIR OOUBL~A
STRIPS
(AS REOO)
FILLER
0)
REPAIR DOUBLER
SECTION
Insert repair doubler between skin and formers,

adding cutouts necessary to match existing skin. Insert and
tack two short filler strips.
B-B
O
01
O
00
NOTES
REPAIR MEMBERS TO MATCH CONTOUR OF CURVE
LEGENI)
EXISTING RIVETS
ADDITIONAL RIVETS
Finish repair pans pe~ Section 1
tnstall repair parts.
Install removed
system components.
Clean up and close
out
cornpartmenls
5370-3-58
53-30-20
Page 214
AuR 17/84
Non-Pressurized Area
Top Centerline Between Fuselage Stations (FS) 346.5 and 357
o
COPYRIGHT, 1984 BY SABRELINER CORPORATIOW
NA-66-1032
O,~ ~PAIR SHIM IREF)
I\
01
REPAIR DOUBLER IREF)
ol
o%
i
a
o
I
11
ii
FILLER IREF)
1/32iTYP~
aI,,,,,~
il l
lf
1-1/2
+1111
f
41N. OIA
(mAxl
+-t+
t.
-f 1/2 I~
PICK UP
EXISTING RIVETS
(TYP)
FILLER
Q/O
SAME MATERIAL ANO THICKNESS
AS AREA WHERE OAMAGE OCCURRED
3RITYPI
EPUAL TO HOLE OIA IMIN)
DAMAGED CHEM-MILLED SKIN
/lo
II
o_
RIVET
REPAIR SHIM
/6~1_,,-l/ I
NAS1O97A04
0.0202024-T4 CLAD
CSK SKIN
INSERT REPAIR
OOUBLER BETWEEN
SKIN AND SUBSTRUCTURE
0.025 301 CRES 1/2

DAMAGED CHEM-MILLED SKIN
REPAIR SHIM (REFJ 7
FILLER
REPAIR DOUBLER
SECTION
(REF)
IREF]olA ITYP)
IREF)
1.
Install doubler between skin lands and frame flanges.

Install shim between doubler and skin.
2.
Using NAS1097AD4 rivets, attach filler to doubleshim assembly. Use 3/16 in. edge distance and about
3/8 in. spacing.
3.
Pick up existing fasteners through skin, repair

doubler, and frame flanges.
4.
Rivet repair doubler and shim to skin. Rivets

NAS1097AD4 through skin, shim, and repair
doubler.
A-A
NOTE
This rer,air mag be used on non-pressurized
only, where damage is not greater than a 4
in, dia hole.
areas
Chem-milled Skin
53-30-20
Page 216
3/88
Jun
Non-Pressurized Areas
Repair
Figure 206
NA-66-1032
L06E AEPAIR
RIVETS
NAS1OO7A04
)3:)
RIVETS
RIVETS
MSMBOIAD4
+rl
NAS1OO7A04
IOOUOLE-FLUSHEDI
5/8 MIN
7/8 MAX
h
\--yi-2
REPAIR DOUBLER
0.025 301 ORES 1/2 HARO
~pr
DAMAOEO OODR
OUTER SKIN
B~l
FILLER
0.0507178-78
BARE AL ALLOY
B-B
SECTION
REPAIR DOUBLER
0.025 301 ORES 1/2 RARO
B
ACI
DAMAOEO 000R
INNER SKIN
II
FILLER (AEF)
I~JI
REPAIR OOUBLER
~I
BIMAGEO ODOR
INNER SKIN
(REF)
REPAIR OOURLER
IREFI
FILLER IREFI
(REFI
SECTION
A-A
BAMAGEOOOOR
INNER SKIN
IREF)
Trim
OAMAGEOOOOR
iii
damage
Make
to remove any cracks or torn
repair doubler,
size
as
OUTER SKIN (REF]

Drill No. 30 (0.128 in
C
CORNER REPAIR
spot welds
on
dial
edges,
required,
holes
through existing
inner and outer skins that fall under
repair
doubler
NOTES
Insert
doubler between inner and outer skins
and
EDGE REPAIR MAY BE EXTENDED TO PICK UP THREE
El
CAMLOC FASTENERS.
tional rivets would interfere between door and door land
RIVET EDGE DISTANCE IS TWO TIMES FASTENER DIA
IMIN) RIVET SPACING IS
1/2 IN
(MIN).
7/8 IN
(MAX)
pick
required
I~
up drilled
to meet
spot-weld holes, Add

spacing requirements
additional rivets if
Double-flush fasteners indicated by coding if
Make tiller to match trimmed-oft
damaged
conven-
area
and
fasten in place, using size and type of fasteners required.
LEGEND
UJ
NASlOg7AD4 Rivets, Double-Flushed.
Figure 207
repair
REPAIRS SHOWN ARE APPLICABLE TO ALL DOUBLESKIN DOORS AND COVERS INSTALLED WITH CAMLOC
QUICK-ACTING FASTENERS
Reinstall Camloc fastener in
Nonstructural Door Repairs
original position
53-30-20
Page 217
16/90
Mar
NA-66-1032
RIVETS
USE MS2842OAD4 AFT OF
FS 178.887.
USE MSZOBO1-AOO BLIWD RIVETS FWD
OF FS 178.887.
RIVETS
USE MS2O42OAD4 AFT OF
FS 17O.6S7.
USIIIIS~OBOIIDBIUIIORIVTTS
FWO OF FS 178.887.
~k
101
01~
~,1Lx
r
UOI
108/4818
IMAX
X ~r
-r
II
11
10
0)
7~1Z\
10
x\l
ol
I~
I
4\1
I--~-l-C
tlo
\t
~q
10 FILLER(REF)
s/er~-__4;IY
0
REPAIR OOURLER SPLICE PLATE
IIV~
CF) f
(REF)uP,0_4,0,
LA
~t
FILLER
FILLER
IREF)
Or0~
,101
x~;--,x
3/4 MIN
5/8
IREF)
REPAIR
OOURLER
tv-i-3/8
ITYP),
o:
I+ J- oi
)1
C
IIOIIMkX
REPAIR OOURLER 18851
II
r01
II
O O O O
J;t-----,
s/R ppl
SPLICE PLATE
CHIIRA
/-T-O10
REPAIR DOUBLER
IRE9
10
OAMAOED SKln
IREFJ
OAMAOEO SKIW IREF)
SAME MATERIAL
REPAIR OOURLER
OIE OAUOE HEAVIER THAW DAMAOEO
PORTION OF SKIN
FILLER
8485 MATERIAL
AWO GAUGE AS PORTIOW

OF SKIW
SPIRAL REPAIR OOURLER

THROUGH OAMAOE CUTOUT II 8818
SAME
,REPAIR OOURLER
MATERIAL. OWE 64665 HEAVIER
THAN DAMAOEO PORTION
OF SKIW
DAMAGED SKIN
REPAIR DOUBLER SPLICE
SAME MATERIAL OWE GAUGE
PLATE
HEAVIER THAW OAMAGEO PORTION OF
SKIN. MAKE LARGE EWOUGH

TO PICK UP 4 RIVETS EACH
SIDE OF SPLIT IW REPAIR
OOUBLER.
TEMPORARY REPAIR
IWHEN USED ON OUTER SKINI
OAMAGEO SKIW
PERMANENT
1.
Clean out damage. Smooth all edges and
2.
Make filler, repair doublers, and repair doubler

splice plate from material called out as required.
FS 178.887
~rurol
SECTIONA-A
3.
J
Lay
out rivet
pattern
on
corners.
repair doubler and repair
doubler splice plate.

4.
Place repair doubler in position and drill rivet holes

through skin and repair doubler.
5.
If repair istobetemporary, chamferrepairdoubler

and rivet in place, using size and type of rivets
required.
6.
through damage
NOTES
1Mas damage size
after clean-vp is
8 in.
1Min distance of 5/16 in. mwrt be maintairced between repair rivets and
beam webs orflanges.
53-30-20
Page 218
3/88
Jun
For permanent repair, secure repair doubler splice

plate to one end of repair doubler with small flush
tack rivets. Spiral repair doubler into position
7.
cut out.
Rivet repair doubler and repair doubler splice plate

to damaged skin with size and type of fasteners
required.
8.
Fasten filler to repair doubler with size and type of

fasteners and spacing called out.

5285-3-154
NA-66-1032
BEPLACEMENT FASTENERS ARE TO BE OF
SAME SIZE ANO TYPE AS THOSE
ICHEM-MILLEO
REMOYEO FROM
FILLER
SHlM
A OAMAGEO OUTER 8515
FILLER
IREF)
~Al?
IREF)
IREF)
e9$0,O
REPAIR OOURLER
SHlM
TAN LINE
ORIGINAL STRUCTUBE
(REFJ
IREF)
INNER SKIN
AOJACENT TO OHEMMILLED LAWO
050
4t\t
-t
4-
i/is
REPAIR DOUBLER
\Y
oarpc~ a 2 TII~S
FASTENER OIA
t\f
(RE9
RsrEarn roar
ITYPJ
\3
REPAIR
i+
~t
5/8 ITYPJ
IC
-t\i
~(-C
4
3
jI
ill
I
4I
-t-
L9
Il)
I
INNER SKIN
il~l
IREF)
0820425554 OR CR~Q124
2 ROWS THROUGH OAMAGED 8515
AND REPAIR DOUBLER, OWE
OAMAGEO
OUTER SKIN
LF)
ROW THROUGH REPAIR DOUBLER

ANO FILLER
FS 175-11/16
b~FT
AFT
FILLER
0.0507175-T5
BARE SHEET
SHIM
FASTENER EOOE OISTANCE

IS 2 TIMES
AI(TYP)
ORENETSAF
3/4 MIN 7/8 MAX (TYPJ
REPAIR DOUBLER
SAME
MATERIAL AS, ONE GAUGE
HEAYIER THAN, MATERIAL IN
CHEMMILLEO PORTION OF
BAMAOEO SKIN
SAME MATERIAL
555 GAUGE AS RAISED

LANO ON CHEMMILLED SKIN
q AIRPLANE
--i
01116~00UTE18111W
INNER SKIN
1.
Trim out damage midway between existingfasteners.
2.
Smooth all edges and
3.
corners
u,
after trimming.
Make repair doubler and filler. Use
material
this illus-
same
type and material thickness indicated
on
szss-3-~ss
tration.
4.
Fasten repair parts in place, using size and type of

fasteners and spacing called out.
NOTE
This repair is applicable to
bralce c4ft ofFS 125 11/16
areas
ofspeed

53-30-20
Page 219
Jun 3/88
NA-66-1032
CRIICK TYPIC~L
P/N 285-390004-3
REPAIR OOURLER 7178 TO.OO3

OR 301 ORES 1!2 HIIRO .050
118 sHOWY
FABA~TE
I~ 0.505
$I
0.250
I-
818
,ic
I,"
~I
II
RAOIUS TO MATCH
EXISTING SKIN
AOOEOFASTENER
ZEACH
033243-5
3.80
LEGEND
1.
Stop drill crack using No. 30 drill.
2.
Fabricate
3.
Pick up 20
4.
Pick up 2 additional fastener locations.
5.
Prime all parts with epoxy
6.
Install repair doubler using faying surface sealant.
repair doubler
as
PRIMER MIL-P-23377C
shown.
SEALANT PR1431G OR EQUIVALENT
existing fastener locations.
MS90470A05RIVETBEA
VA1023-6JOBOLTBEA
polyamide primer.
Figure 208
Speed
CR3243-5CnERRYMAX2 EA
Brake Skin
CR3243-6 CHERRY MAX 4 EA
Repairs (Sheet
3 of
3)
53-30-20
Page
220
Mar
16/90
NA-66-1032
FUS SKIN
TRIMMEO-OUT
DAMAGE
BOND OVERLAP
5/160
OAMAGE
OVERLAP EACH
OVERLAP IREFER TO
LENGTH "L.
SIDE OF DAMAGE
CHART]
IlN.l
IlN.)
UPTOL
2 TO 4
3-1/2
4706
PITCH
SAME AS
FOR RIVETED REPAIR
BONDED REPAIR
PATCH
2O24-T4 OR 7075-T6
ONE GAUGE HEAVIER THAN CHEMMILLEO THICKNESS OF SKIN
4 TO 6 TIMES RIVET OIA
[TVPI
/oi
/C
:t-
FRAMEIREF]
-e
i 1/4
tl
.I
It+
C
-e
5/160
;J_~_
__
tc~
13
40
NOTES
MS2O6OOAO4
Repairs shown may be used as one-time

(restricted) ferry flight repairs on any
area offuselage. When either repair is used
on areas affected by cabin pressure, flight
must be made without prestrurixation. (Refertosl-oo-lo.)
TRIMMED-OUT
/1"1
RIVET
Ir
/o
OAMAGE
I
a
e
ej
FUS
SKIN
1,1
LOUOEAOII
One ofthefollowing must be considered in

selection of type ofrepair to use: (1) riveted
repair will enlarge damaged area, as that
area will Icave to be tri~med out wkele a
bonded repemzanent repair is made.
pair will require considerably more time
--time for effecting repair and time for
(I
(REFI
oololo
-i
o
o
I
L RIVET
MS2OOO1AO
SIZE TO MATCH REMOVED
FASTENER
repair to cure before airplane can beflown.

(Refer to 51
BONDED REPAIR
3370-3-55
Fuselage
Skin
One Time
Figure
Flight Repair
209
53-30-20
0
Page 221/222
Jun 3/88
NA-66-10~B
STHUCTURAL REPrZIR MAPUCIAI,
ATTACH FITTINGS
REPAIRS
GENERAL
This section contains repairs to the fuselage fittings used
for the attachment of doors, wings, landing gear, etc. See
figure 201 through 204. For applicability of repairs, refer
to section 53-10-00.
53-40-20
0
Page 201
Aug 17/84
NA-66-1032
STRlr(TI!RAI, REPAIR MANUAL
REPAIR ANGLE
WING FITTING
UPPER ANGLE SHOWN. LOWER ANGLE
SUPPORT IREFI
OPPOSITE
MS20470A056.
SKIH
JOOOLE0.1Bsx5/8
5AE00
JOOGLE 0.103
7/8
CHAMFER 0.040
WING FITTING
(REFJ
45"
9/18
L0153-
WASHER
00021404 IREF)
_L1
t
MS2104L4
NUT
3/32 R ITYPI
(REFI
-;j E
8431104-8
BOLT
V
REPAIR
IREF)
WASHER
5-9/32
IREFJ
5-13/16
SECTION
A-A
WING FITTING SUPPORT
WING FITTING IREFI
7/32 R
ITYPI
rr
0.250
1-1/4
7/32
0.0051--
HOLES. EXISTING LOCATIONS.

WITH:
2 REOO
8431104-8 BOLTS
I ~f)l/ll
26/32
4 REQO
L0153M102-1404 WASHERS
(2 UNOER BOLTHEAOS. 2
unoER nunl
2 REOO
MS2104L4 NUTS
TOROUE 50 TD 70 IN.-POUYOI
5/8
0.2501 0.005)- 6
HOLES. EXISTING LOCATIONS.

WITH:
6 REOO
NASllO4-5 BOLTS
L0153-00021604 WASHERS
FS
206;000
WATER PLANE
P
B REOO
(UNOER BOLTHEA09
FUS SKIN
31-7/3216EF)
VIEW LOOKING OUTED, LH SIDE
MS2104L4 NUTS
REPAIR WASHER
6
6
REOO
REOO
(UNOER nuTq. SEE WASHER

OATA CHART.
TOROUE 50 TO 70 IN.-POUNOS
NOTE
LD153-002-1404 IS A SABRELINER PART NUMBER
PROCUREMENT.
REFER
TO
SOURCE
FOR
KEY 017.
IN
51-30-00 WASHER MAY BE LOCALLY MANUFACTURED

SEE WASHER DATA CHART
(SHEET 2)
920~-3-158
53-40-20
Page 202
Aug 17/84
Winff-to-Forward Fuselage Attach Fitting Repair

Figure 201 (Sheet 1 oi 2)
o
COPYRGHT, 1984 BY SABRELINER CO-RPORATION
NA-66-1032
STRUCTIIRAL REPAIR M~NIJAI,
Fabricate and heat-treat repair angles.
Chemical-film-treat and
Line-drill two ollsn holes. Irum repair

angle a os.
with 15/64 in. drill and line-ream holes to 0.250
(f0.0005) in
zinc-chromate-prime
repair angles.
I~
El
0002-1404 washers
Install
repeat step 6
as
Remove either upper
fasteners (water plane
or
lower horizontal
31-7/32)
corresponding repair angle

fastener holes from
tC1
IP
required.
on
fuselage
in
wing fitting.
of
row
Position
inner side of skin and locate
skin.
NAS1101
two
bolts
remaining
in
prepared holes
and
No. 11 holes
Install NAS1104 bolts in two
remaining
holes
Remove
wing fitting.
flanges must
remaining horizontal row of fasteners in

Position second repair angle (horizontal
be in contact), locate fastener holes, and
repeat steps
through
liD
Drill temporary No. 11 holes in repair

angle and bolt
angle in place with 2-3/16 in. bolts.
on
8.
Rivet horizant sl
flangff
ol
repair snglea tagslher
WASHER DATA
~-T-n
0
)1
~(C
~U
2
WASHER
LO153-O002-1404
0.265
0.450
0.083
REPAIR WASHER
0.257
0.375
0.083
MATERIAL
FIWISH
A1O01ZE OR
CHEMICAL FILMTREAT
7075-76
FS 208 BHO
IRtEq
sKa IREF)
REPAIR AHGLES
MAKE FROM 0.063
2024-0. HEAT-TREAT
TO -742 COWOITION
AFTER FORMIHO.
jd
O
NOTE
INSTALL ONE ANGLE AT A TIME. DO NOT REMOVE
MORE THAN FOUR FASTENERS THROUGH WING
FITTING AT ONE TIME.
Wing-to Forward Fuselage AttachFitting Repair

0
5265-3-1 59
53-40-20
Page 203
Aug 17/84
NA-66-1032
STRlr(:TURAL REPAIH MANUAL
WING REAR SPAR

RIVET
MS20470A05
WINO-TO-FUS.
FAIRING FORMER
REMOVE TO PROVIOE ACCESS
(TYPI
t~a
IREF)
o
o
C~3
t~B \-~i
d
,IZ-~d
SUPPORT
SIOE-LOAO, WING-TO-FUSELAGE,
TRIM TO PERMIT INSTALLATION OF BOLTS
IN MAIN OEAR DOOR BEAM WHEN REPAIRS
WING JOINT SPLICE.

PLATE
TRIM OFF ENO TO PERMIT INSTALLATION
OF BOLTS IN MAINGEAR OODR BEAM.
SHOWN ON SHEETS 3 ANO 4 HAVE BEEN

INCORPORATED ISEE OETAIL O. SHEET 4.)
(SEE OETAIL C, SHEET 4.)
VIEW LOOKING FORWARD
NOTES
REPAIRS SHOWN IN THESE ILLUSTRATIONS ARE
APPLICABLE TO FWD END OF MAIN GEAR DOOR BEAM
WHEN A 1/4 IN. DIA HOLE DOES NOT REMOVE ALL

ELONGATION IN BEAM SUPPORT TOP FASTENER
AND BEAM SUPPORT AT FS 264 25.
HOLES. REPLACE BEAM SUPPORT.
MEMBER OF BEAM-
WHEN A 1/4 IN. HOLE DOES NOT REMOVE ALL ELONGABEAMOF

MEMBER
EITHER
IN
TION
REPLACE
SUPPORT-TO-BEAM JOINT, REPLACE AFFECTED MEM-
WHEN RIVET HOLES ARE ELONGATED IN UPPER END

OF BEAM SUPPORT. OR IN EITHER
SUPPORT-TO-BEAM
RIVETS WITH
1/4
IN.
JOINT.
BOLTS
IF
BER(s) AS SHOWN ON SHEETS
ELONGATION IS
3 AND 4.
REMOVED WITH THAT DIA HOLE.
53-40-20
EaKc L04
AuR 17/84

Model NA 265-40, -60, -fiOA, -60SC, and -65
FiRure 202 (Sheet 1 of ii)
o
NA-(iCi-1032
STKUCTURAL HEPAIR MANUAL
BEAM SUPPORT.
REPLACE 3/16 IN. RIVETS THRU BEAM

SUPPORT ANO TEE WITH IAS11042A
BOLTS. 880010418 WASRERS, ANB 882104204 NUTS.
(WHEN REPLACING
THIS
PART. MAKE FROM 0.071 71780-0 BARE.

BENO RAOII ARE 5/32 IN. HEAT-TREAT TO
.Tg CONOITION AFTER FORMING.)
Ji
r -i
-~r
I-
O
O
BEAM SUPPORT
BEAM
lo
oII
Illo
ol
!o
o l1
III c,
ol
REPL~CE
MAIN BEAR OOOR
3/18
dl~
IN.iSiVETSiHRU
BEAM SUPPORT ANO BEAM WITH
8431104-28 BOLTS. 48001014 WASHERS,

ANO 832104204 NUTS.
GRILL SIZE
1/4 IN OIA
Remove wing-to-fuselage side-load support

wing-to-fuselage fairing
former.O
VIEW LOOK1NC AFT. F8 264.25
O
sheet
NOTE
MN
FOR REPAIR OF BIAMSUPPORTTO-BEPIM JOINT
O
O
O
Rework
wing joint spliceplate.
4.)
~(See
and
detail
C,
Drill holes for 1/4 in. bo ts
inslalllnin
bolfsal.n0vn
Repiscs wing-to-fuselage fairing former
to-fuselage
side-load
Main Landinff Gear Door Beam Repairs

Model NA 265-40, -60, -60A, -60SC, and -65
and
wing-
support.O
53-40-20
Page
205
Aug 17/84
NA-66-1032
MAIN GEAR DOOR BEAM
SUPPORT
REPAIR CHAIINEL
0.071 7178-0 BARE.
BEND RADII IS 5/32 IN.
5-1/2
3/8
2-3/4
re
1\11(
M328478A05(TYPI
RIVET
a EOUAL SPACES
t_
STAGGERED
_C
REPAIR CHAWWFL
~t
~t
I-I/IG(TYP)
i-
I-3/161TYPJ
6;8 je
a111
I
-~1,21e
11/(6
DRILL 1/4 IN. HOLES
IW EXISTING 3/16 IW.
HOL~ LOCATION ITYP)
MAIN GEAR OO0R BEAM REPAIR
CHAMFER ICHAMFER OliWIEWSIOIS

ARE TYP ALL PLAC4
Remove wing-io-fu~sage side-load suppon
gear wheel
O
sheet
CHAMFER
Rework
former
detail
wing joint splice plate. (See
?~le
C,
4.)
1/4 R
Rework
detail D, sheet
end
(sheet 1). Remove main

door lock torque tube support as required.
wing-tofuselage fairing
wing-to-fuselage
side-load
main
gear wheel dear lack
torque lube
ie
supportas required.
O
O
after
Fabricate
repair parts
as
repair parts
R(~0. 10
-i1-11/16
0.291 R
1+0.0101
;If
I/B CONSTANT
DETArt A
FABRICATION.OETAICS OF MAIN
GEkR:000R BEAM INNER REPAIR ANGLES
and bare surfaces of reworked
LIFT RAND SHOWN, RIGHT RAND OPPOSITE.
parts
42 MIW
on
forming.
P~imr
88"
0.1OB
1-3/6
CHAMFER
required
Heatlreat farmed repair pans to the -T6 condit
1/a
2-3/8
support. (See
4.)
RewOll
3/32
MACHINE ANGLES FROM 7878-78 BAR.

lllS1ail
repair pans
and lewor~ed
pans See detail F
sheet 4. for bolt installation.
534020
Page 206
Aug 17/84

Model NA 265-40, -60, -60A, -60SC, and -65
o
COP~RIGHT,
NA-66-1032
WING SKIN (REF)
REMOVE MATERIAL IN
SHAOEOAREATOPERMIT
3/"~k-
INSTALLATION OF LOWER
ROW OF BOLTS.
BREAK ALL SHARP EDGES
BOLT
WAS11O4-7
NUT
MS21042L4
WASHER
PLATE
WING JOINT
SPLICE
DETAIL
AlOOOO14
INSTALL AS SHOWN
SUPPORT
SIDELOIID.
WING-TO-FUS IREF)
(TYPI
WING JOINT SPLICE PLATE REWORK
3/16
REMOVE MATERIAL IN
SHAOED AREA TO PERMIT
INSTALLATION OF LDWER
ROW OF BOLTS. BREAK
ALL SHARP EDGES.
WING SKIN
PLATE
IREFI
JOINT SPLICE
IOI
WING
SUPPORT
WING-TO-FUS
TRIM LINE ITYP)
SUPPORT
MAIN GEAR WHEEL
DOOR LOCK TOROUE TUBE
3/16 R !(TYP)
OII
DETAIL F
BOLT INSTALLATION
IN REPAIRED MAIN GEAR DOOR
BEAM AND BEAM SUPPORT
SIDE-LOIIO~
1-11/321TYPI
SUPPORT
MAIN
GEAR DOOR BEAM
I
OUTER REPAIR
DETAIL
WING JOINT SPLICE PLATE AND

WING-TO-FUSELAGE SIDE-LOAD SUPPORT REWORK
SUPPORT
AnGLE
MAIN GEAR WHEEL
OOOR LOEI TDROUL TUBI
[3
Jj I~j
0.011
9/64 A ITYP)
REMOVE MATERIAL
TRIM LINE
TO MAINTAIN ORIGINAL SUPPORT
ALIGNMENT AFTER BEAM OUTER
REPAIR ANGLE HAS BEEN INSTALLEO
OETAIL
REPAIR CHANNEL
L
MAIN GEAH WHEEL O0OH LOCK
IWIEI R~PLIR LIIOL( ITYPI

MAIN GEAR DOOR BEAM
TORQUE TUBE SUPPORT REWORK

Model NA 265-40, -g0, -60A, -60SC, and -65
a
S265-3-163
53-40-20
Page 207
Aug 17/84
NA-66-1032
STRIICI~URAL REPAIR MANUAL
RIVET
MS20470A05-4 REOO
it~INNER REPAIR
ANGLE ITYPI
1/2 R ITYP)
II
ct
II
I
I+
___/,
I
I_
_II
3/8 ITYP)
43/8
I IC
OUTER REPAIR ANGLE

0.071 7178-0 BARE
BENO RAOII ARE 3/16 11.
ALL
(TYP
BRILL TO MATCH HOLES
INNER REPAIR
IN MAIN GEAR BOOR SUPPORT
3/4
--1
f
I
14-
3/8(TYP)
ITVPJ
1/8
PLAGESI
ii
ITYPI
I\NGLE-1TQ
OBILL TWO 3/8 IN. HOLES

IN LINE WITH EXISTING HOLES
SUPPORT
MAIN GEAR WHEEL BOOR
TOROUE TUBE. ISEE OETAIL E.

SHEET 4. FOR REWORK OATA)
OUTER REPAIR ANGLE
ITYP)
OUTER REPAIR ANGLE
3/18
c~l
5/32 R (TYP)
~3
II
I/21%.R(TYPI
I
7/a
5/8
I
\I
OTO1/1O_
t.-
P164-2 JO
BOLT
(TYPI
I/IIITYPI
REOO
1/4
ITYP)
MAIN GEAR OOOR BEAM
~f-- 17/8
INNER REPAIH ANGLE.
OETAIL A. SHEET 31
91
c
s/B
III
(TYP)
Ii
I i
II C)- 3/8
)ITYPI+~
__.__-1II
/~_____,
INNEB BEPAIR ANGLE
(SEE
ITYP)
glYEl-iM(20lrmOl-811fpO
ITvP)
1/817YP)
3/8(TYP)
MAIN GEAR BOOR BEAM
MAIN GEAR DOOR SUPPORT REPAIR

NOTI~
SURFACES OPPOSITE VIEW SHOWN ARE OMITTED
FOR CLARITY
53-40-20
Page 208
AuR 17/84

Model NA 265-40, -60, -60A, -60SC, and -65
Figure 202 (Sheet;S of 5)
o
NA-66-1032
RIVET EXISTIWR WAS1D6SA3
REMDYE AWD RETAII EXISTIHO

HASlOOOAS HuT PLATES 14 PLACESI
WUT PLATES TO RACK OF
OOURLER [4 PLACESI: USE

MS2D428803 RIVETS 18 REOD1
REPAIR DOUBLER
0.051
2024-T4 CLAD
FABRICATE IS SHOWW.
~lf
CUTOUTS 1110 HOLES TO

MATCH CUTOUTS AnO HOLES
IW RECEPTACLE.
--~Js
c~t;
2024-74
SMIH(AS
SDALC REOD)
f~
PI1OTDII11D.W II1 WDL~Y PUE~)I
285-54(1330 OC EXTER#L
POWER RECEPTACLE IREFI
Ic------- 4.82
-F.
MLTCKORYL IXlln~6 HOL~
0.33
(TYP)
t,,
I(c/CIEPS~YIS
0.12 R
I.eT- i~Z J
k-
ITYPI
PILOTORILL 0.08 DIA HOLE

OC
i~-1
pp)l
1.08 -+-F
i-e- i
3E~O
1~11
1.58
-1
le
0.83 R (TYP)
4.58
-C
SPACES
$-.i
It
0.37
PILOT-DRILL O.OB OIA HOLE 14
(TYP)
0.56
----I
HOLE0.50
-e
c
---~1
L
ITYPI
PLACESj
MATCH-DRILL EXISTIWG HOLE
/C--IIOS~CIS
0.12 R
(TYP)
(TYPJ
0.82 DIA HOLE
2.50
0.33
ro.sa[1
:)io.75/TVP)8PACES I
(TYP)
MATCH-DRILL EXISTIIO
Tr
1.25
2.50
0.12 A
13 PLACES)
(TYP)
f 1.08(TYP)
PILOT-GRILL 0.OB DIA HOLE 15 PLACESI
NOTE
TO REPAIR CRACKED EXTERNALPOWERRECEPTACLE
SUPPORT. FABRICATE REPAIR DOUBLER AS SHOWN

AND ATTACH WITH MS20470-AD5 RIVETS.
5265-3-165
External Power Receptacle Repair

Model NA 265-40, -60, -60A, and -60SC
Figure
0
203
53-40-20
Page 209
Aug 17/84
NA-66-1032
Ate]
VIEW
BUSHING
A-A
(VIEW LOOKING FWOJ
C~3
BOLT
""""""7
AC
BUSHING
BUSHING
ENLARGE EXISTING HOLES TO
0.5013 (Lo.oooa. 0.0007)111.

Irurti
BUSHING
IINCREASE
NAS77-610
ID TO 0.3821
2 REOO
1+0.0005.
BOLT
8121104-300
IWTERCOSTAL
IHEFI
2 REOO
EXISTING BUSHING
INCREASE 10 TO 0.3821
1+0.0005.-0.00011
INNER
BUSHING
NAS75-4-125
INTEBCOSTALS
Drill out
SPEED BRAKE HINGE
FS 150 TO 158.50, BP 12-7/8
(il
snisling speed brake hinge pivot holes in
brake
intercostals to 0.500 in. die.
Line-ream 0500 in, dia holes to 0.5013
til
(+0.0000.
126
-0.0007) in. dia.
O
outer
install NAS77-6-10 bushings (with flanges
surfaces)
on
Line-ream installed
0.3821
(+0.0005,-0.0000)
bushings
to
an
to
an
existing bushings (two in each speed

(+0.0005, -0.0000) in.
inside dia of 0.3821
Replace exist ng
inner
bushing dfh
an
NA87b-4
bushing.
the
brake
in line-reamed holes in intercostal.
Line-ream
hinge)
Replace existing bolt through inletcadal end speed

hinge with an NAS1104-30D bolt.
inside dia of
in.
$370-3-80
Repair of Speed Brake Hinge
53-40;29
Page 810
Aua 17/H4
Model NA 265-40,
Hole Elongation
and -80
204-70,
-60,Figure
COP~R:IGHT, 1984 BY SABRELINER CORPORATION
CNAPTE R
NACELLES
PYLONS
NA-66-1032
STRUCTURAL REPAIR MA~UAL
CHAPTER 54
NACELLES AND PYLONS
TABLE OF CONTENTS
Subject
PaRe
Nacelles and Pylons

54-00-00
General
Nacelles and Pylons Repair Index
Nacelles and Pylons Negligible Damage Limits
Replacing Nacelle Doors, Model NA 265-40, -60, -60A,
-60SC, and -70 (S/N 370-2 thru -6, -8, and -9)
Nacelles and Pylons
1
1
1
1
54-00-10
Negligible Damage Limits and Allowable Damage
101
General
101
101
Negligible Damage
AuxilliaryStructure
54-20-00
General
AuxiltiaryStructure
Repair
1
1
54-20-20
L()1
General
2()1
Repairs
201
Plates and Skins
54-30-00
1
1
General
Plates and Skins
54-30-20
Repair
,1...;.
General
201
201
201
Repairs
Attach Fillings
Gene Ial
54-40-00
Attach Fittings
54-40-20
1
1
Repair
201
201
201
General
Repairs
54-CONTENTS
co
COPYRIGHT,
Page 1/2 Hlank
Aug 17/L31
NA-66-1032
CHAPTER 54
NACELLES AND PYLONS
Section
54-00-00
Figure
1
2
3
4
5
6
54-00-10
101
102
103
104
54-20-20
54-30-20
201
201
202
54-40-20
201
202
Title
No.
Page
Model NA 265-40, -60, -60A,

Nacelle and Pylon Master Repair Index
-60SC, and -70 (S/N 370-2 thru -6, -8, and -9)
Model NA 265-70,
Engine and Nacelle Master Index
(S/N 370-1 and -7), -80, -80A and -80SC
Model NA 265-40, -60, -60A, -60SC
Nacelle and Pylon Repair Index
and -70 (S/N 370-2 thru -6, -8, and -9)
Model NA 265-70 (S/N 370-1 and -7),
Nacelle Repair Index
-80, -80A, and -80SC
Model
Engine Air Intake, Diaphragm and Tail-pipe Repair Index
NA 265-40, -60, -60A, -60SC, and -70 (S/N 370-2 thru -6, -8, and -9)
Model NA 265-65
Nacelle and Pylon Repair Index
Model NA 265-4().
Nacelle and Pylon
Negligible Damage
-60, -60SC, and -70 (S/N 370-2 thru -6, -8, and -9)
Model NA 265-70,
Nacelle and Pylon
Negligible Damage
(S/N 370-1 and -7) -80, -80A, and 80SC
Diaphragm Assembly and Tail Pipe
Negligible Damage
Model NA 265-40, -60, -60SC, and -70 (S/N 370-2 thru -6, -8, and -9)
Engine Inner Fairing and Tail Pipe
Negligible Damage
Model NG 265-70 (S/N 370-1 and -7), -80, -80A, and -80SC
Model NA 265-40, -60, -60A
Engine Inlet Air Duct Vane Repair
-60SC, and -70 (S/N 370-2 thru -6, -8, and -9)
Model NA 265-40, -60, -60A, -60SC and

Repair
(S/N370-2thru-6, -8, and-g
Nacelleand PylonSkinRepair
Nacelle Skin
2
4
5
9
1:3
15
102
105
107
108
202
-70
202
204
Model NA 265-40, -60, -60A, -60SC, and -70
Engine Support Beam Repair

(S/N 370-2 thru -6, -8, and -9)
Model NA 265-40, -60, -60A.
Lower Nacelle Door Hinge Bracket Repair
-60SC, and -70 (S/N 370-2 thru -6, -8, and -9)
202
203
54-ILLUS
0
Page 1/2 Blank

Aug 17/84
NA-66-1032
CHAPTER 54
NACELLES AND PYLONS
Chapter/
Section
Chapter
Page
Date
Section
Page
Date
54-L.E.P.
1/2"
Mar
16/90
54-40-00
1/2
Aug 17/84
54-CONTENTS
1/2
Aug 17/84
54-40-20
54-ILLUS.
1/2
Aug 17/84
201
202
Aug 17/84
Aug 17/84
Aug17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Jun 3/88
Jun 3/88
Jun 3/88
Aug 17/84
Aug 17/84
Jun 3/88
Aug 17/84
Aug 17/84
Jun 3/88
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
54-00-00
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
54-00-10
101
203/204
Aug
Aug
Aug
Aug
17/84
17/84
17/84
17/84
Mar 16/90
Aug 17/84
Aug 17/84
Aug 17/84
102
103
104
105"
106
107
108
54-20-00
1/2
Aug 17/84
54-20-20
201
202
203/204
Aug 17/84
Aug 17/84
Aug 17/84
54-30-00
1/2
Aug 17/84
54-30-20
201
202
203
204
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
or
54-L.E.P.
0
Page 1/2 Blank

Mar 16/90
NA-66-1032
STRUCTURAL REPAIR MANIJAI,
CHAPTER 54
NACELLES AND PYLONS
GENERAL
Model NA 265-40,-60, -60A,
thru -6, -8, and -9)
~60SC, and -70 (S/N 370-2
The nacelles
are cantilevered from the fuselage on an

airfoil-shaped pylon. Each nacelle consists of a fixed
stainless-steel fire wall integral with the pylon, three
upper fairing doors, one lower fairing door, and an
aluminum nose section containing the engine air inlet
duct. The nose section assembly is attached directly to the
fwd face of the engine, An engine support frame (saddle),
integral with the pylon, carries the main engine mounts as
well as the engine steady mounts.
Model NA 265-70
and -80SC
(S/N 370-1 and -7), -80, -80A,
Each engine nacelle group consists of
pylon,
nose
section, the upper, lower inbd, and lower outbd access

doors, fire seal, aft fairing and engine support structure.
The
section attaches directly to the front face of the

engine and guides air to the engine by means of the engine
air intake duct mounted internally within the nose
section. The remaining intake air is ducted ta the aft fan
portion of the engine. The three access doors make up the
center portion of the nacelle. The upper door and the lower
inbd door are hinged at the pylon. The lower outbd door is
hinged to the lower edge of the upper door. Each of the
access doors have an internal skin attached to longitudinal door frames to provide air passages between the
nose section and the engine aft fan housing, The aft fairing
is bolted to the fwd frame of the aft fan housing and covers
the aft fan section of the engine and the engine tailpipe.
The thrust reverser is contained in the aft portion of the
aft fairing.
nose
The pylon is cantilevered from the fuselage and serves as a

structural support and fairing for the engine support
fittings which extend through the pylon and attach to the
fuselage structure. All controls, lines, ducts and electrical
wiring associated with the engine are routed through the
pylon. The fwd and intermediate sections of the pylon.
which are secured to the primary engine support fitting,
each contain a sealed firewall to isolate the fuselage
structure from the engine. The complete nacelle assembly
is cantilevered from the pylon by engine support fittinffs
and structural carry-through fittings that extend inbd
through the pylons and attach to the fuselage structure.
NACELLES AND PYLONS REPAIR INDEX

See figures 1 and 3 for Model NA 265-40, -60, -60A, -60SC.
and -70 (S/N 370-2 thru -6, -8, and -9). See figures 2 and 4
for Model NA 265-70 (S/N 370-1 and -7), -80, -8012, and
-80SC. See figure 6 for Model NA 265-65.
NACELLES AND PYLONS NEGLIGIBLE
DAMAGE LIMITS
Refer to section 54-00-10 for negligible damage limits.
REPLACING NACELLE DOORS, MODEL NA 265-
40, -60, -60A, -60SC, AND -70 (S/N 370-2 THRU -6, -8,
AND -9)
Each door is fitted as an individual unit, assuming that all
nacelle are properly fitted and
On the
1.
Fitting
A.
doors are secured in place by quick acting, over-center

type latches. The aft fairing is bolted to the aft face of the
engine and helps to direct the fan bypass air around the
tailpipe of the engine. The aft portion of the aft fairing
supports the thrust reverser assembly and its operating
With
Upper Nacelle Door
undamaged lower nacelle door removed,
place
new
upper nacelle door in proper loca-
tion, making certain that all guide pins of

upper door are properly engaged in guide pin
Model NA 265-65
Each nacelle consists of a fixed nose section, upper and
lower coqrl doors, an aft fairing and the thrust reversers
which are attached to the aft fairing. The nose section
forms the engine air inlet and is bolted to the fwd face of
the engine. The upper and lower cowl dears are hinged to
provide easy access to the engine and are easily removed
by removing the hinge pins, The upper and lower cowl
New
receptacles,
on
upper
longeron of fire wall
assembly.
B.
Engage latching mechanism, and pull tloot

down, overlapping excess skin of upper nacelle
door over existing skin trim of fire wall. As an
aid in overlapping skins, insert thin sttips of
stainless steel between nacelle door and fire
Skins,
C.
to
Ruide naeelle skin
Tighten locking latch;
over
fire wall
mark nacelle door for
trim
mechanisms.
54-00-00
0
COPYRIGHT, f 984 BY SABRELIN~R CORPORATION
Page 1
Aug 17/84
NA-66-1032
SIHUCTURAL REPAIR MANUAL
REPLACING NACELLE: DOORS, MODEL

NA 265-40, -60, -60A, -60SC, AND -70 (S/N 370-2
THRU -6, -8, AND -9) (Contd)
D.
Trim nacelle door, a little at a time, until skin

trims match and nacelle door longeron and fire
wall longeron meet at aft end of fire wall.
E.
Drill a 1/4 in. hole through fwd edge of nacelle

door skin, picking up center Camloc fastener
location on engine saddle.
F.
E.
Remove stainless-steel guide strips; then place

another strip of one in, tape on top of fi rst stri P,
lower door
so that lower edge of tape overlaps
of tape.
lower
skin
edge
door
Mark
along
skin.
G.
Remove tape, lower door, and trim skin along

line. Slight additional trimming may be
required to maintain skin gap tolerances (0 to
1/16 in. gap).
skin
a 1/4 in, bolt through nacelle door
engine saddle, to prevent movement while
marking trim on fwd side of door. (Use largearea washers on each side of bolt to prevent
Install
and
damage
to
door
or
Camloc
receptacle.)
existing
G.
Trim fwd edge of nacelle door to match

skin trim on engine saddle.
H.
I~ock fwd latch; check upper nacelle door tofire

wall t~.im. Retrim if necessary, to maintain
proper gap
I.
(O
to
l/lfi in.).
Reinstall lower nacelle door; engage all latches

and retaining hooks. Raise lower door by
lapping excessive skin on upper door over skin
on lower door and marking for trim.
2.
J.
Trim excess skin on top door, a little at a time,

until longerons on upper and lower door mate,
skin trim on
proper skin gap is maintained, and
fwd edge of upper nacelle door lies tight against
skin land on engine saddle.
K.
Pick up Camloc fastener locations

of upper nacelle door.
on
fwd
edge
FittingLower NacelleDoor
A.
With fitted upper door in place, hang new lower

door on the two inbd hooks and push outbd side
up until safety latch is engaged.
R.
Engage all latches; pull door up close enough to

check skin fit at fwd end. Be careful not to pull
door up too tight, as this will damage skin at
edges of door.
M~tlk and trim skin at fwd end of door to match
leading edge skin.
along both
D.
Place strip of one in. masking tape

lower edges of upper door skin.
E.
Hold thin strips of stainless steel along lower

edges of upper door, so that excess skin on edges
of lower door is forced out and over upper door
skin as lower door is pulled up and latched into
position.
54-00-00
Page 2
Aug 17/84
NA-66-1032
ITEM
REPAIR INDEX
ASSY NO.
FIGURE NO.
265-321200
FIGURE 5
INBO
265-321345
FIGURE 3
OUTBO
265-321349
FIGURE 3
ENGINE SUPPORT
265-321250
FIGURE 3
265-321340
FIGURE 3
265-321244
FIGURE 3
NOMENCLATURE
NO.
NOSE ASSY
DOOR ASSY
ODOR ASSY
REAM
DOOR ASSY NACELLE
PYLON ASSY
ODOR ASSY
UPPER
NACELLE
LOWER
265-321330
FIGURE 3
OIIIPHRAGM ASSY
265-420007
FIGURE 5
TAIL-PIPE ASSY
265-420003
FIGURE 5
REFER TO SECTION 54-00-10 FOR HEGLIGIBLE DAMAGE LIMITS

5265-3-166
Nacelle and Pylon Master Repair Index

Model NA 265-40, -60, -60A, -60SC, and -70
(S/N 370-2 thru -6, -8, and -9)
Figure
0
54-00-00
Paffe
AuR 17/84
NA-Ci6-10:32
SIRI("I1:KAI, KI~PAIK MAN1IAI,
ASSY NO.
REPAIRINOEX
FIGURE NO.
234-22022
FIGURE 4
ITEM
NO.
NOMENCLATURE
ENGINE AIR INTAKE

2
UPPER ACCESS DOOR
MY20.551.30
FIGURE 4
AFT FAIRING
MY2O.551.O0
FIGURE 4
THRUST REVERSER
234-23000
FIGURE 4
INNERFAIRINGBIAEWALLI
234-22033
FIGURE4
LOWER OUTBO ACCESS OOGR
MY20.551.50
FIGURE 4
LOWER INBO ACCESS OOGR
MY2O.551.70
FIGURE 4
S370-3-19
54-00-00
Page
Engine and Nacelle Master Repair Index

Model NA 265-70, (S/N 370-1 and -7, -80, -80A, and
2
erugiFCS08-
Aug 17/84
NA-GB-1032
ASSEMBLY DRAWING NUMBERS
PYLON--265-321226
BEAM. ENGINE SUPPORT
265-321250
10
NACELLE --265-321300
12
11
13
14
INDEX NUMBERS CORRESPONO TO ITEM NUMBERS IN

THE KEY
i-
3
15
16
17
19
20
L
27
26
30
29
28
31
32
33
25
24
23
i\
22
-1/--
z-p
34
35
36
37
38
39
40
49
50
51
47
42
46
45
44
jf
53
54
4s
55
57
60
62
68
67
65
71
59
64
66
i,,
58
63
73
74
72
r
70
89
75
76
77
78
79
80
lie
e5
84
d3
82
5265-3-171
Nacelle and Pylan Repair Index

Model NA 265-40-, -60, -60A, -60SC, and -70
(S/N 370-2 thru -6, -8, and -9)
Figure
0
54-00-00
Page 5
Aug 17/84
NA-66-1032

GAUGE OR
EXTRUSION
ITEM
NO
DRAWING
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
265-321345-11
265-321349-11
265-321306-21
265-321313-12
265-321280-21
265-321340-17
265-321340-19
265-321340-13
265-321312-51
265-321340-11
265-321340-9
265-321340-7
265-321340-5
265-321334
265-321340-53
16
265-321342-5
Stiffener
Stiffener
Nac Sta 115.719
Frame
Nac Sta 123.0
Frame
Nac Sta 130.625
Frame
Nac Sta 136.813
Frame
Nac Sta 147.312
Frame
Nac Sta 158.063
Frame
Nac Canted Sta 163.750
Frame
Nac Sta 156.844 to Canted Sta
Skin
167.960
Nac Sta 136-3/16 to 156.844
Skin
17
18
265-321305-11
265-321340-21
Longn
Longn
19
265-321342-3
Skin
20
265-321341-3
21
22
23
24
25
26
27
28
29
30
31
32
265-321227-3
265-321227-5
265-321228-3
265-321244-7
265-321244-47
265-321244-35
265-321244-23
265-321352-3
265-321244-19
265-321244-17
265-321243-7
265-321243-5
265-321243-3
Canted Nac Sta 98.9 to

Skin
Canted Nac
Skin
Pylon LE
Rib
Pylon LE
Skin
Pylon, Upper Fwd
Pylon to Fus
Angle
Stiffener
Stiffener
Stiffener
Skin
Pylon, Upper Aft
Stiffener
Stiffener
Beam
Pylon TE
Pylon TE
Facing Sheet
Core
Nac Sta 72 to 90.305, Inbd

Nac Sta 72 to 90.305, Outbd
Inbd
Longeron
Nac Canted Sta 101-3/16
Frame
Fire Wall, Nac Sta 108.375
Frame
Door
Door
to
33
Outbd
Inbd Nac Sta 156.844
17-7PH CRES
17-7PH CRES
7178-16 Clad
17-7PH CRES
7178-T6 Clad
17-7PH CRES
17-7PH CRES
17-7PH CRES
17-7PH CRES
17-7PH CRES
17-7PH CRES
17-7PH CRES
0.020
0.020
0.025
0.032
0.025
0.032
0.025
0.032
0.040
0.025
0.025
0.025
0.025
0.040
0.020
7178-16 Bare
0.040
17-7PH CRES
17-7PH CRES
0.025
0.025
7178-T6 Bare
0.040
17-7PH CRES
0.020
2024-T4 Clad
7178-T6 Clad
7178-T6 Bare
7178-T6 Clad
7178-T6 Clad
7178-T6 Clad
7178-T6 Clad
17-7PH CRES
7178-T6 Clad
7178-T6 Clad
7178-T6 Clad
2024-T42 Clad
5052-1134
0.040
0.032
0.050
0.050
1S23
1S23
17-7 PH CRES
17-7PH CRES
17-7PH CRES
163-1/2
Nac Sta 107.688 to
NO.
MATERIAL
DESCRIPTION
NO
136-3/16
REPAIR
FIGURE NO.
54-30-20 Fig. 202
54-30-20 Fig. 202
54-30-20 Fig. 202
1523
0.025
1S23
1S23
54-30-20
202
Fig. 201,
54-30-20
202
54-30-20
Fig. 201,
Fig.
202
54-30-20
Fig.
202
54-30-20
Fig.
202
54-30-20 Fig. 202
0.032
0.012
1/4
0.001
Honeycomb
265-321353
265-321339
265-321244-9
265-321351-3
265-321229-7
265-321354
265-321239
Frame
Frame
41
265-321238
Support
265-321237
265-321-237-5
and -7
42
302 CRES
17-7PH CRES
7178-T6 Clad
17-7PH CRES
7178-T6 Bare
302 CRES
Pylon, Fus Sta 368

Pylon, Fus Sta 357
Pylon to Fus
Angle
Skin
Pylon Lower Aft
Skin
Pylon, Lower Fwd
Frame
Pylon Fus Sta 344
Pylon, Fus Sta 333.625
Support
35
36
37
38
39
40
34
54-30-20
54-30-20
Fig. 202
Fig. 202
7079-T6
Hand Forging
7079-T6
Pylon, Fus Canted Sta
318.586
Frame Assy
0.025
0.032
0.050
0.025
0.100
0.032
Hand
Forging
Fus Sta 307.25
707Fj-T6 Extr
Angle
28554
NOTES
For additional
repairs, refer
01
to 51-r0-00.
chem-milled part. 1Measure thinned
This is
areas or
refer to applicable drawiny numbersfor
Key
to
Figure
(Sheet
1 of
9)
54-00-00
Page 6
3/88
Jun
NA-66-1032
ITEM
NO.
42
43
44
45
46
DRAWING
NO.
265-321237-9
265-32137-13
265-321230-5
265-321226-21
265-321231
47
48
49
50
51
52
53
265-821259-11
265-321252-5
265-321226-11
265-321226-9
265-321226-7
265-321226-5
265-321226-3
265-321233-11
54
265-321234
55
265-321230-7
265-321252-3
265-321226-13
265-321226-19
265-321251-3
265-321313-5
265-321263-5
265-321254
265-321254-3
265-321254-5
265-321255
265-321255-3
265-321255-5
56
57
58
59
60
61
62
63
DESCRIPTION
Bulkhead
7075-16 Bare
2024-14 Clad
Angle
Skin
Hat
Nac Sta 72.062 to 156.781

Nac Sta 74
Nac Sta 74-3/4 to Canted
Longn
Sta 90.034
Beam
EngSpt
Skin
Outer Beam Assy
Hat
Nac Sta 122.687
Zee
Nac Sta 130.625
Zee
Nac Sta 137.437
Zee
Nac Sta 147.312
Channel
Nac Sta 157.125
Longn
Upper, Nac Canted Sta 98.9
to 157-1/8
Longn
Lower, Nac Sta
to 157-1/8
64
265-321256
65
66
67
68
69
70
71
72
73
74
265-321256-3
265-321256-5
265-321258
265-321264-5
265-321232
265-321253
265-321277
265-321331-3
265-321331-5
265-321332-3
265-321332-5
265-321334-21
MATERIAL
104
Skin
Skin
Hat
Zee
Nac Sta 72.062 to 156.781

Outer, Eng Spt Beam
Nac Sta 115.50
Nac Sta 108.375
Nac Sta 102
Angle
Frame
Nac Canted Sta 101-3/16
Frame
Frame Assy
Frame
Frame
Frame Assy
Frame
Frame
Frame Assy
Frame
Frame
Frame
Frame
Nac Sta 72-7/8 to 82-3/16
Longn
Skin
Inner, Eng SDt Beam
Longn
Inbd, Nac Sta 72 to 164
Skin
Inbd Fwd
Skin
Inbd Aft
Skin
Outbd Fwd
Skin
Outbd Aft
Frame
Nac Sta 163.750
GAUGE OR
EXTRUSION
NO
17-7PH CRES
17-7PH CRES
17-7PH CRES
0.032
0.032
0.040
0.040
0.025
17-7PH CRES
17-7PH CRES
17-7PH CRES
17-7PH CRES
17-7PH CRES
17-7PH CRES
17-7PH CRES
17-7PH CRES
0.050
0.050
0.040
0.025
0.025
0.025
0.025
0.025
17-7PH CRES
0.020
17-7PH CRES
17-7PH CRES
7178-T6 Bare
17-7PH CRES
17-7PH CRES
17-7PH CRES
17-7PH CRES
0.040
0.050
0.040
0.032
0.040
7178-16 Bare
7178-T6 Bare
0.050
0.040
7178-T6 Bare
7178-16 Bare
0.050
0.040
7178-T6 Bare
7178-T6 Bare
7178-T6 Bare
17-7PH CRES
17-7PH CRES
17-7PH CRES
17-7PH CRES
17-7PH CRES
17-7PH CRES
7178-16 Clad
7178-T6 Clad
17-7PH CRES
0.050
0.040
0.050
0.050
0.032
0.050
0.025
0.020
0.020
REPAIR
FIGURE NO
111
54-40-20 Fig. 201
0.032
0.050
0.040B
0.040
0.020
54-30-20
54-30-20
54-30-20
54-30-20
Fig. 202
Fig. 202
Fig. 201
Fig. 201
NOTES
Foradditionalrepairs, referto51-r0-00,

thinned areas or refer to applicable drawing numbersfor thickness variation.
8205-3-171
Key
to
Figure
(Sheet
2 of
3)
54-00-00
Page
0
Jun 3/88
NA-66-1032
ITEM
NO
DRAWING
75
76
77
78
79
80
81
82
83
84
85
86
GAUGE OR
EXTRUSION
NO.
DESCRIPTION
MATERIAL
265-321330-83
265-321333-81
Aft
Skin
Nac Sta 157.750
Frame
17-7PH CRES
17-7PH CRES
0.02
0.032
265-321292-41
265-321330-9
15, and -75
Splice
17-7PH CRES
0.020
265-321292-61
265-321292-51
265-321333-61
265-321292-31
265-321280-11
265-321333-51
265-321292-23
265-321333-11
Nac Sta 137.437

Nac Sta 130.625
Nac Sta 122.688
Nac Sta 115.063
Nac Sta 108.375
Nac Sta 96.750
Frame
Nac Sta 84.969
Frame
Frame --NacSta74
17-7PH CRES
17-7PH CRES
17-7PH CRES
7075-T6 Clad
17-7PH CRES
17-7PH CRES
7075-T6 Clad
17-7PH CRES
0.020
NO
Nac Skin
Frame
Frame
Frame
Frame
Frame
REPAIR
FIGURE NO.
54 30-20
Fig.
202
0.020
0.050
0.040
0.025
0.040
0.025
0.032
NOTE
For additional
repairs, refer
to 51-r0-00.
5265-3-171
Key
to
Figure
(Sheet
3 of
3)
54-00-00
Page 8
3/88
Jun
NA-6fi-1032
STRUCTURAI, REPAIH MANUAI,
~B
13
14
16
15
18
12
22
F1_1
11
10
Is
20
n
s
33
32
34
30
29
28
26
21
23
24
25
35
36
37
38
39
40
41
Nacelle Regair Index

Model NA 265-70
(S/N ~70-1 and -7), -80, -80A, and -80SC
0
COPYRIGHT.
S370-3-33
54-00-00
Page 9
Aug 17/84
NA-66-1032
STKII~ITIJRAL REPAIR MANUAL
47
46
45
44
43
42
50
56
57
68
59
60
52
61
53
54
63
74
67
se
se
se
65
gq
r/
1
$i
76
77
3370-3-34
54-00-00
Page 10
Aug 17/84
Rlodel NA 265-70
Nacelle Repair Index
(S/N 370-1 and -7), -80, -8aA, and -80SC
o
NA-66-1032
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
DESCRIPTION
Leading Edge
Leading Edge
Finger Strips
MATERIAL
Outer Skin
Inner Skin
5052-0 Bare
5052-0 Bare
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Bare
2017-T4 Clad
2017-T4 Clad
2017-14 Clad
2017-T4 Clad
2017-T4 Clad
Titanium
Titanium
Titanium
Titanium
Titanium
Titanium
Titanium
Titanium
Titanium
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-14 Clad
2017-T4 Clad
2017-14 Clad
2024-T42 Bare
2017-14 Clad
2017-T4 Clad
2017-T4 Clad
2017-14 Clad
Titanium
2017-T4 Clad
2017-14 Clad
2017-T4 Clad
2017-T4 Clad
2024-T3
2017T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-14 Clad
Nose Section Ribs (Typ)

Nose Section Outer Skin
Nacelle Struts
Air Intake Frame No. 6
Inner Fairing Upper Skin
Upper Stiffener (Typ)
Upper Frame Web
Sealing Strip
Splice Plate
Lower Stiffener (Typ)
Inner Fairing Lower Skin
Lower Frame Web
Transverse Attach Plate
Inner Fairing Strut Skin
Aft Fairing Frame No. 1
Translating Structure Frame No.
Translating Structure Inner Skin
Translating Structure Outer Skin
Aft Fairing Stringers (Typ)
Skin Splice Stiffeners
Aft Fairing Skins
Lower Access Door
Support Skins
Fwd Frame
Upper Door
Inner Skin Stiffening Angle
2
3
4
5
Longitudinal Stringer (Centerline)

Fan Duct Skin
Upper Door Outer
Skin
GAUGE OR
EXTRUSION
NO.
0.065
0.025
0.051
0.040
0.032
0.040
0.051
0.051
0.032
0.040
0.025
0.032
0.025
0.025
0.032
0.025
0.025
0.025
0.025
0.025
0.025
0.032
0.032
0.032
0.032
0.032
0.025
0.025
0.025
0.032
0.032
0.032
0.032
0.032
0.020
0.025
0.032
0.032
0.025
0.081
0.016
0.050
0.050
0.032
0.032
0.025
NOTE
For additional
re~airs, refer
to 51-r0-00.
Key
to
Figure
(Sheet
1 of
2)
54-00-00
0
Page 11
3/88
Jun
NA-66-1032
STRITCTURAL IDENTIFICATION (Continued)
GAUGE OR
EXTRUSION
ITEM
NO.
DESCRIPTION
47
Longitudinal Stringer (Outbd)
48
49
50
Stiffener
Outer Half Strut
51
52
5:3
54
55
Upper
56
57
58
59
60
61
62
63
64
65
66
67
68
69
Longitudinal Stringer (Inbd)

Aft Frame
Door
Hat Section Inner Skin Stiffeners
Inner Half Strut
False Rib
(Typ)
Pylon Mating Strips

Hinge Frame
Half Strut Attach Angle
Half Strut
Upper
Outer Skin Stiffener
Air Duct
Doubler
Outer Skin
Outer Door
Fan Duct Skin
Half Strut Attach Angle
I,ower
Half Strut
Seal Retainer
Inner Door Fan Duct Skin
Outer Skin
Inner Door
70
71
Doubler
72
73
74
75
76
77
78
79
Inner Skin
Half Strut
Upper
Closeout Skin
(Typ)
Pylon Mating Strips
(Typ)
Lower
Half Strut
Half Strut Attaching Angle
Longitudinal Stringer
Inner Door Fwd Frame
MATERIAL
NO.
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-14 Clad
2017-T4 Clad
5062-0 Bare
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-14 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
2017-T4 Clad
0.025
0.040
0.040
0.025
0.050
0.032
0.040
0.050
0.025
0.051
0.032
0.040
0.040
0.070
0.040
0.032
0.032
0.032
0.040
0.040
0.025
0.032
0.025
0.032
0.025
0.040
0.040
0.040
0.032
0.040
0.040
0.025
0.050
NOTE
For additional
54-00-00
Page 12
Aug 17/84
repairs refer
to 51-70-00.
Key
to
o
NA-66-1032
17
18
19
-ii~
ii
,i
NOTE
ASSEMBLY DBAWING NUMBERS
ENGINE
265-400001
NOSE ASSEMBLY
265-321200
S265-3-172
Engine Air Intake, Diaphragm and Tail-pipe Repair Index

Model NA 265-40, -60, -60A, -60SC, and -70 (S/N 370-2 thru -6, -8, and -9)
Figure
54-00-00
Page 13
Aug 17/84
NA-66-1032
ITEM
DRAWING
NO.
NO.
1
2
3
4
5
6
i
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
265-321202-2
265-321201
265-321200-3
265-321200-7
265-321200-5
265-321200-9
265-321200-13
265-321202-1
265-321200-17
265-321200-19
265-321200-29
265-321200-15
265-321200-27
265-321200-59
265-321200-63
265-321200-67
265-321200-75
5353
265-321200-73
265-321200-25
265-321205
265-420007
265-420007-9
265-420007-10
265-420007-11
265-420003
265-420003-13
265-420003-7
265-420004-3
265-420004-7
23
MATERIAL
DESCRIPTION
Nacelle Inbd
Skin
Nacelle Upper
Skin
Skin
Leading Edge Air Intake
Perforated Inner
Skin
Bulkhead
Leading Edge
Skin
Leading Edge Inner
Skin
Leading Edge Inner
Nacelle Outbd
Skin
Bulkhead
Angle
Intercoastal
Skin
Engine Air Intake Inner
Intercoastal
Bulkhead
Skin
Engine Air Intake Inner
Engine Attach
Angle
Seal Support
Seal
Seal Support
Intercoastal
Vane Assy
2024-142 Bare
2024-142 Bare
6061-16 Bare
6061-T6 Bare
6061-16 Bare
2024-142 Clad
2024-142 Clad
2024-T42 Bare
2024-142 Clad
2024-142 Clad
2024-T42 Clad
2024-142 Clad
2024-T42 Clad
Type 321 CRES
Type 321 CRES
Type 321 CRES
Type 301 1/2H CRES
0.040
0.063
0.040
301 1/2H CRES

2024-142 Clad
6061-T6 Bare
0.016
0.040
0.125
Type 321 CRES

Type 321 CRES
Type 321 CRES
0.025
0.025
0.025
Type 321 CRES

Type 321 CRES
Type 321 CRES Bar
Type 321 CRES
0.025
Type
Engine
Diaphragm Assy
Diaphragm Section
Diaphragm Section
Diaphragm Section
Engine
Tail-pipe Assy
Pipe
Doubler
Flange
Sheet
GAUGE OR
EXTRUSION
NO.
0.040
0.040
0.020
0.020
0.040
0.025
0.025
0.020
0.040
0.020
0.020
0.020
0.020
0.016
REPAIR
FIGURE NO.
54-30-20
54-30-20
Fig.
Fig.
202
202
54-30-20
Pig.
202
54-30-20
Fig. 201
0.040
0.8125
0.025
NOTE
For additional
repairs, refer
to 51-r0-00.
Key
to
Figure
54-00-00
P~iffe 14
Jun
3/88
NA-66-1032
STHII("TuKAI,
SEE OETAIL C~
SEE OETAIL B
ii
SEE OETAIL 0
II~
15
14
!8
19
:8
!7
20
12
DETAIL A
PYLON
ILDOKING DOWN)
20
12
21
22
23
24
25
jlb!
33
32
31
30
29
28
27
DETAIL B
PYLDN
(LODKING UP)
Nacelle and Pylon Ilepair Index
Fiffure 6
(Sheet I of 2)
o
Model NA 26Fj-(i5
54-00-00
Iaatl 1~
Au# IilH4
NA-66-1032
RTRUCTURAL REPAIR MANUAL
o
9
36
35
I)
Y-
34
ROTATEO 180~
37
45--~
a~9
41
lol~-sF
;i
a9
ROTATED 90
DETAIL 0
THRUST REVeRSER
(RDTATED 180")
Nacelle and
54-0000
Pylon Repair Index
Model NA 26Ti-65
6
(Sheet 2 of
erugiF)2
16
Page
Aug 17/84
NA-66- 1032

GAUGE OH.
ITEM
NO.
1
3
4
DRAWING
NO,
EXTRUSION
DESCRIPTION
F10A5B20040-1l
F10A5B20040-12
F10A5B20241-15
F10A5B20241-17
F10A5B1Q300-105
F10A5B10300-107
F10A5B10320-105
F10A5B10320-107
FlaA5B20271-15
Skin, Nose Cowl, Nac Sta 3.2
F10A5B20271-1l
F10A5B20271-13
7
8
9
10
F10A5B20284-31
F10A5B20284-32
F10A5B20288-25
F10A5B20284-26
F10A5B20284-43
_
F10A5B20241-ll
F10A5B20241-13
11
F10A5B20242-1
F10A5B20242-2
12
465-820151-011
465-320151-012
13
465-326159-001
465-320159-002
465r320142-O03
465-320142-005
14
15
16
465-820104-003
465-320104-004
17
465-320116-003
465-320116-004
465-320142-007
18
465-320142-008
19
20
21
22
465-380103-011
465-320103-012
465-320103-021
465-320103-022
465-320155-001
465-320160-001
465-320160-002
23
465-320156-003
2/1
25
46.5-320156-004
465-320143-003
465-329195-993
465-320105004
26
465~324132-001
465-320132-002
27
465-320143-007
465320143-008
28
29
30
465-320111-003
485-320111-004
46351320143-013
465-320110-021
MATERIAL
6.8. LH
NO.
302/321
302/321
Skin,
Skin,
Skin,
Skin,
F10A5B20271-17
6
to
Nose Cowl, Nac Sta 3.2 to 6.8, RH

Nose Cowl, Nac Sta 5.41 to 19.6, LH
Nose Cowl, Nac Sta 5.41 to 19.6, RH
Upper Cowl, LH
Skin, Upper Cowl, RH
Skin, Lower Cowl Door LH
Skin, Lower Cowl Door, RH
Skin, Aft Cowl, Upper, Ext. LH
Skin, Aft Cowl, Upper, Ext, RH
Skin, Aft Cowl, Lower Ext. LH
Skin, Aft Cowl, Lower Ext, RH
Cover, Aft Cowl, Ext, LH
Cover, Aft Cowl, Ext, RH
Cover, Aft Cowl, Est, RH
Cover, Aft Cowl, Ext
Skin, Nose Cowl, Nac Sta 5.41 to 19.6, LII
%o~l,
19.6 RH
Skin, Inlet, Nac Sta 6.13 to 28.27, LH
Skin, Inlet, Nac Sta 6.13 to 28.27, RH
Skin, Leading Edge, LH
Skin, Leading Edge, RH
Skin, Upper, Sta 307.25 to 331.33, LH
Skin, Upper, Sta 307.25 to 331.33, RH
Skin, Upper, Sta 334.31 to 381.44
Skin, Upper, Sta 842.21 to 362.83
Door, Upper, Sta 336.38 to 357.39, LH
Door, Upper, Sta 336.38 to 357.39, RH
Door, Access, LH
Door, Access, RH
Skin, Upper, Sta 334.33 to 381.44, LH
Skin, Upper, Sta 334.33 to 381.44, RH
Skin, Pylon, Sta 381.53 to 405.75, LH
Skin, Pylon, Sta 881.53 to 405.75, RH
Door Assy, Sta 381.44 to 405.75, LH
Door Assy, Sta 381.44 to 405.75, RH
Door, Lower, Sta 309.66 to 317.38
Skin, Lower, Sta 307.25 to 331.33, LH
Skin, Lower, Sta 307.25 to 331.33, RH
Door, Lower, Sta 321.48 to 329.61, LH
Door, Lower, Sta 321.48 to 329.61, RH
Skin, Lower, Sta 334.56 to 381.44
Skin, Lower, Sta 337.44 to 357.44, LH
Door, Access LH
Door, Access RH
Skin, Lower Sta 334.56 to 381.44, LH
Door, Lower, Sta 371.00 to 381.44, LH
Door, Lower, Sta 371.00 to 381.44, RH
Skin, Lower Sta 334.56 to 381.44, LH
Door, Lower
0.050
0.050
0.050
0.050
2024-T6 COS
2024-T6 COS
2024-T6 COS
2024-T6 COS
2024-T6 COS
2024-T6 COS
2024-T6 COS
2024-T6 COS
2024-T6 COS
2024-T6 COS
2024 OC
2024 OC
2024-T3 C
2024-T3 C
2024-T3 C
2624-16 COS
2024-T6 COS
2219-T6
2219-T6
2024-T42 Clad
2624-142 Clad
2024-T42 Clad
2924-142 Clad
301 CRES
301 CRES
0.063
0.063
0.063
0.063
0.025
0.025
0.025
0.025
0.050
0.050
0.050
0.050
0.050
0.050
0.050
0.050
0.050
0.040
0.040
0.050
0.050
0.050
0.050
0.050
6.059
301 CRES
301 CRES
301CRES
301 CRES
301 CRES
0.050
0.050
0.050
0.050
0.040
301 CRES
2924-142 Clad
2924-142 Clad
2024-T42 Clad
2024-T42 Clad
2924-142 Clad
2924-142 Clad
2624-142 Clad
2024-T42 Clad
2024-T42 Clad
301 CRES
301 CRES
301 CRES
301 CKF,S
301 CRES
301 CRES
301 CRES
301 CRES
301 CRES
301 CRES
301CRES
0.040
0.040
0.040
0.050
0.050
0.050
0.050
0.050
O.Of,O
0.1).50
().Or,O
0.1)5()
0.050
0.050
0.050
O.OFiO
0.050
0.050
o.ozs
NOTES
tg
This is
Repair using oply solid rivets
Key
Q
areas
for thickness. Take
in inner barrel due to
to
care
when repairing.
potential engine ingestion and subsequent damage.
Figure
(Sheet
1 of
2)
54-00-00
Page 17
Aug 17/84
NA-66-I 082
SIHl("rlTKAI, KEPAIR MANUAL
31
32
33
84
35
36
:17
38
39
40
41
42
43
44
GAUGE OH
EXTRUSION
DRAWING
NO.
ITEM
NO.
4635-320110-031
46.5-320110-032
465-320143-005
465-320143-006
465-320143-009
(:41B30213-3
C41B30213-7
(3~41B30297-37
(3~41B30297-39
F10AT,R20290-41
F10A5B2021)0-42
F10A5H20290-49
F10A5R20290-50
F10AAI3222284-47
F10A5B20284-48
F10A5R20272-3
DESCRIPTION
Sta 363.56 to 371.00, LH
Sta 363.56 to 371.00, RH
Sta 334.56 to 381.44, LH
Sta 334.56 to 381.44, RH
Sta 334.56 to 381.44
Door, Upper, Thrust Reverser
Door, Lower, Thrust Reverser
Thrust Reverser Inner Skin, Upper
Thrust Reverser Inner Skin, Lower
Cover, Aft Nacelle, Sta 252.00 to 274.00,
Cover, Aft Cowl, Ext, RH
Skin, Fan Duct, Outer, LH
Door,
Door,
Skin,
Skin,
Skin,
F10A5B20272-4
F10A5B20272-7
F10A5B20272-8
F10A5B20284-49
F10A5B20284-51
F10A.5B20284-52
F10ATjB20284-45
F10A5B20284-46
F10AFjB20288-13
F10A5B20288-14
F10A5B20290-43
MATERIAL
NO.
CRES
CRES
CRES
CRES
CRES
2024-T6 COS
2024-T6 COS
A286HT
A28(iHT
A286HT
A:!86HT
A286HT
A286HT
2024 OC
0.050
0.050
0.050
0.050
0.050
0.125
0.125
0.020
0.036
0.060
0.050
0.050
0.050
0.050
0.050
0.032
0.032
0.071
0.071
0.032
0.032
0.032
0.032
0.050
301
301
301
301
301
Lower,
Lower,
Lower,
Lower,
I,ower,
LH
RH
LH
RH
Skin, Fan Duct, Outer, RH

Door, Access, Engine Ingitor, LH
Door, Access, Engine Ingitor, RH
Shield, Aft Cowl, Ext, LH
Shield, Aft Cowl, Ext, RH
Shield, Aft Cowl, Ext, LH
Shield, Aft Cowl, Ext, RH
Cover, Aft Cowl, LH
Cover, Aft Cowl, RH
Cover, Aft Nacelle, LH
Cover, Aft Nacelle, RH
Cover, Aft Nacelle, Sta 252.00 to 274.00
2024 OC
2219-T6
2219-T6
2024 OC
2024 OC
321
321
321
321
2024 OC
2024 OC
2024 OC
2024 OC
A286HT
0.050
0.050
0.050
0.050
NOTES
O
O
17se with Grumman Kit 1-24.

Use with Grumman Kit 24 and Subs.
54-00-00
Page
Aug 17/84
Key
to
18
COP~RIGMT, 194 BY SABRELINER CORPORATION
NA-66-1032
NACELLES AND PYLONS

NEGLIGIBLE DAMAGE LIMITS
ALLOWABLE DAMAGE
GENERAL
nacelles and pylons.
negligible damage limits
for the

See figure 101 for Model NA 26,5-40, -60, -60A,-60SC, and
for
-70 (S/N 370-2 thru -6, -8, and -9) and see figure 102
Model NA 265-70(S/N 370-1 and -7),-80,-80A, and -80SC.
54-00-10
Page 101
Aug 17/84
TYP:O
NA-66-1032
jt
SIKUCTCRAL REPAIR MANUAL

TYPEC\
TYPE
TYPE A
Is
U2~)
B~-o
9
7
TYPES OF CRACKS
3
Is
14
2
14
e
a
C
LOWER VIEW
Is
13
1;
CRACKS
PANEL
UPPER VIEW
TYPE A
15
PYLON
WACELLE
TYPE R
TYPE C
TYPE D
NO.
1
[MAX) IN ANY ONE ROW OF
(MAxl
IN ANY ONE ROW OF
1 (MAXJ II ANY ONE ROW OF

RIVETS
P,
NONE FROM STA 307 TO 357

ATTACH ANGLES. 1 WITH 6 0000
HOLES EACH SIDE IN REMAINIWO
AREAS
IONE iROM STA 307 TO 357.1

WITH 4 6000 HOLES EACH SIDE
IN REMAINING AREAS
P;
HONEYCOMB
RONEYCOMB
HDNEYCOhlD
HONEYCOMB
NONE FHOM STA 307 TO 357 IN

FUSELAGE TO PYLON AND PYLON
NOWE FROM 874 307 TO 357

ATTACH ANGLES. 1 WITH 8 6000
HOLES EACH SIDE II REMAIIING
AREAS
NOWE FROM STA ~07 TO 357.1

IN REMAIWIWO IIRCIIS.
1 WITH 6 6000 HOLES EACH SIOE

OFOAMAGE
RIVETS
NONE FROM STA 307 TO 357 IN
FUSELAGE TO PYLON AHO PYLON

TO NACELLE ATTACH ANGLE. 1
WITH 4 6000 HOLES EACH SIRE
IN REMAINING AREAS.
RIVETS
TO NACELLE ATTACH ANGLES. 1

1 IN.
RIVETS
(3 CRACKS MAXI
1 IN. ICRACK MAX PER
ANY OWE BAY
~P1 IN.
I CRACK MAX
PEA:
ANY ONE BAY
OFDAMAGE
5
1 WITH 6 6000 HOLES EACH SIDE

OFDAMAGE
I WITH B 6000 HOLES EACH SIDE

OFDAMAGE
I WITH 6 6000 HOLES EACH SIOE

OFOAMAGE
1 WITH B 6000 HOLES EACH SIDE
OFOAMAGE
OFOAMAOE
1 WITH O 6000 HOLES EACH 810E

OFOAMAGE
OFOAMAGE
1 WITH 6 GOOD HOLES EACH SIDE
OFOAMGE
8
I WITH 6 GOOD HOLES EACH SIDE
1 WITH 6 HOLES EACH SIDE
DFOAMAGE
OFOAMAGE
9
10
11
12
13
NONE
1 WITH 6 6000 HOELS EACH SIDE

OFOAMAGE
NONE
PIIN.
P1
1 (N.
e~l
NONE
1 WITH 6 GOOD HOLES EACH SIDE
OFDAMAGE
OFOAMAGE

OFDAMAGE
I WITH 4 GOOD HOLES EACH SIDE

OFOAMAGE
OFOAMAGE
OFOAMAGE
PIIN.
1 WITH O 0000 HOLES EACH SIOE
OFOAMAGE
OFOAMAGE
OFOAMAOE
I WITH 6 6000 HOLES EACH SIDE
1 WITH s 6000 HOLES EACH SIDE
1 WITH D 0000 HOLES FOR EACH SIOE
OFOAMAGE
OFOAMAGE
OFDAMAGE
IN.
NONE
P=IIH.
e-1IN.
P=l
IN.
P: 1 IN.
14
NONE
NONE
NONE
NONE
15
NONE
NONE
NONE
NONE
16
NONE
NONE
NONE
NONE
NOTE
STOP-DRILL ALL CRACKS WITH A NO. 40 (0.098 IN.) DRILL.
54-00-10
Page 102
Aug 17/84
s?ss-3-~n
Negligihle Damage
Ngcelle and Pylon
265-40, -60, -60A, -60SC, and -70 (S/N 370-2 thru -6, -8, and 9)
Figure 101 (Sh~et 1 of 3)

o
COPYRIGHT,
NA-66-1032
STRUCTURAL REPAIR MA~L;AL
HONEYCOMB DENTS
I MAX
TRAILING
EOOE DENT
3/8 MAX
UNOAMADEO
OIA IN
DEPTH IN
IN.
IN.lm~xl
0.030
31N.
0.050
410.
0.070
5111.
A
-1/2 MAX
MATEAIAL
BETWEEN DENTS
OEPTH
SECTION
A-A
PYLON AND NACELLE

GENTS
SCRATCHES
CIRCUMFEHENTIAL
LENGTH
IN IN.
3 ANO DYER
1D1A
2 DIA
DEPTH
IN II(.
DEPTH
In IN.
OEPTH
IN In.
IN IN.
1/2 OIA
LONGITUOINAL
OEPTH
OEPTH
IN IN.
LENGTH
IN IN.
OEPTH
IN IN.
O.WB
i/is
5/32
3/16
0.006
1/8
200/a SKIN THICKNESS
i/is
5/32
3/16
20% SKIN THICKNESS
1/8
UNLIMITEO
0.002
UNLIMITED
1/32
3/64
1/16
5/64
0.002
0.004
O.D)4
1/16
1/8
5/32
3/18
PANEL
NO.
20% SKIN THICKNESS
200/0 SKIN THICKNESS
20a/, SKIN THICKNESS
1/16
118
3/16
200/a 8KIN THICKNESS
5/32
MO/o 8610 THICKNESS
1/16
5/32
3/16
20B/o SKIN THICKNESS
1/8
30D/s SKIN THICKNESS
11
1116
5/32
3/18
309/a SKIN THICKNESS
1/8
30% SKIN THICKNESS
11
1/16
5/32
3/16
30% SKIN THICKNESS
1/8
20% SKln THICKHESS
1/32
3/32
1/8
20% SKIN THICKNESS
I/is
3/16
10
20% SKIN THICKNESS
20% SKIN THICKNESS
i/is
1/8
5/32
200~ SKIH THICKNESS
1/16
1/8
5/32
3/16
3/16
11
20% SKln THICKNESS
20% SKIn THICKNESS
1/16
1/8
la
20% SKIN THICKNESS
5/32
20% SKIN THICKNESS
1/16
5/32
3/16
20% SKIN THICKNESS
1/8
13
15% SKIN THICKIIESS
1/84
5/64
1/8
15% SKIN THICKNESS
1/32
11
15% SKIN THICKNESS
1/64
5/64
118
15% SKIN THICKNESS
1/32
15
25% 8WIN THICKWESI
1164
5/64
1/8
25% SKII THICKnEgs
1132
Is
5265-3-168
NOTE
NEGLIBEFORE ANY DAMAGE CAN BE CONSIDERED
DELAMINAGIBLE. THE AREA MUST BE TESTED FOR
EDGE
TION. DIMENSIONS SHOWN FOR TRAILING
ALL
DENTS ARE TYPICAL FOR ALL TRAILING EDGES.
HOLES MUST BE PLUGGED.
Nacelle and Pylon

Model NA 265-40, -60, -60A, -60SC, and -70
(S/N :170-~ thlu -6, -X, and -9)
Negligible Damage

o
COPYRIGiHT,
1984 BY
SABRELINER CORPORATION
54-00-10
PaRe 1():1
Aug 17/H4
NA-66-1032
NAC STA 115.5
NAC SIA 84.875
--C---
TYPE "B" CRACK
MAX OF 2
PERMITTEO FROM CONSECUTIVE HOLES.
IREFER TO NOTE.)
TYPE "A" CRACK
MAX OF 3
PERMITTEO FROM CONSECUTIVE HOLES. IREFER
TO NOTE.)
O
O
ol II lo
oi II I~
ol U lo
II
Iii o
o10
Ilo
Q#
II o
NOTES
A MAXIMUM OF SIX RIVET HOLES
(TOTAL FOR ONE OR

BOTH FLANGES) MAY BE AFFECTED BY CRACKS IN
EACH FITTING.
WHEN
DAMAGE
LOWER:NACELLE 0OOR
81168 FITTI#O (TYPICAL
FOR NACELLE STATIONS
84.875 ANO 115.51
EXCEEDS THE LIMITS GIVEN. THE
PART MUST BE REPAIRED OR REPLACED.
s?as3-lee
54-00-10
Page 104
Auff 17/84
Nacelie and Pylon

Negligible Damage
Model NA 265-40, -60, 60A, -60SC, and -70 (S/N 370-2 thru -6, -8, and -9)
Figure
101
(8heet 3of.7)
COPY.RCGHT,
964 BY SkBRELINER -CORPORATION
NA-66-1032
rrPro-
tf
W P
~I
B
TYPE C 7
__1
10
U)
TYPE B
O
TYPE A
TYPES OF CRACKS
CRACKS
PANEL
PYLON El NACELLE
TYPE O
TYPE C
TYPE B
TYPE A
NO.
1
9
10
1 WITH B GOOO HOLES EACH SIOE
OFOAMAGE
OFOAMAGE
OFOAMAGE
1 WITH 6 0000 HOLES EACH 810E
OFOAMAGE
OFOAMAOE
OFDAMAOE
OFOAMAOE
OFOAMAGE
OFOAMAGE
OFOAMAGE
OFBAMAGE
OFDAMAOE
OFOAMAGE
OFOAMAGE
OFOAMAGE
1 WITH O 6000 HOLES EACH SIDE
OFOAMAGE
OFDAMAOE
OFOAMAGE
1 WITH g 6000 HOLES EACH SIDE
OFDAMAGE
OFOAMAOE
OFOAMAGE
(MAxl
IN ANY ONE ROW OF
(MAXl
In ANY ONE ROW OF
IMAXl IN
ANY OWE ROW OF
NONE
WONE
HONEYCOMB
HONEYCOMB
NONE
HONEYCOMB
P= 1 IN.
P= 1 IN.
p=l
P-
IN.
1 IN.
P= 1 IN.
P=1IN.
P
RIVETS
RIVETS
RIVETS
P= 1 IN.
NOTE
1 In.
13 CRACKS MAX)
P=l IN.
HONEYCOMB
8370-3-30
STOP-DRILL ALL CRACKS WITH A NO. 40 (0.098 IN.)

DRILL.
Nacelle and Pylon

Negligible Damage
Figure 102
Model NA 265-70, (S/N 370-1 and -7), -80, -80A, and -80SC (Sheet 1 of 2)
54-00-10
0
Page 105
16/90
Mar
NA-66-1032
HOWEYCOYIB OEYTB
I m~x
TRAILIWG
1~
a18W1X-.
O~YT
DEPTH IW
ill
I(I.(Y~XJ
MATLRIAL
BETWEEW OEWTS
oa3a
alw.
YX
UIDAMAGED
DIA In
1-1/2 MIX
O.OM)
le DIA~
I
I
0.070
418.
5 In.
DEPTH
SECTION
A-A
PYLDN AND IACELLE

SCR~TCHES
DEnTS
CIRCUMFEREITIIL
PIInEL
DEPTH
WO.
LONDITUDINAL
DEPTH
IN IN.
LENGTH
In In.
IW IN.
LENGTH
IIIN.
1/2 Dll
IDIA
2 OIA
DEPTH
IN IN.
DEPTH
IW IN.
DEPTH
In IW.
DEPTH
IN IN.
3 ~WD OVER
200/0 SKIN THICKWESS
20% 8818 THICKnESS
1/ID
1/8
5/32
3/16
20% SKIN THICKnESS
200/p SKIN THICKnESS
i/is
1/8
5/32
3/16
20% SKIN THICKNESS
200/0 SKIn THICKWESS
i/is
1/8
5/32
3/16
30% SKIn THICKWESS
300/0 SKIn THICKNESS
11
i/is
1/B
5/32
3/16
20% SKIN THICKNESS
1/18
1/D
5/32
3/16
20% 3818 THICKWESS
i/is
1/D
5/32
3/16
30% SKIN THICKIESS
300/0 SKIN THICKnESS
II
i/is
1/D
5/32
3/18
0.008
0.008
i/is
1/8
5/32
3/16
nONE
i/is
1/8
5/32
3/18
10
0.002
1/32
3/64
1/18
5/84
NONE
UNLIMITEO
0.012
UWLIMITEO
8370-3-31
NOTE
BEFORE ANY DAMAGE CAN BE CONSIDERED NEGLI-
GIBLE, THE AREA MUST BE TESTED FOR DELAMINATION.
DIMENSIONS SHOWN
FOR
TRAILING
EDGE
DENTS ARE TYPICAL FOR ALL TRAILING EDGES. ALL

HOLES MUST BE PLUGGED.
54-00-10
Page 106
Aug 17/84
Nacelle and Pylon

Negligible Damage
(S/N 370-1 and -7) -80, -80A, and -80SC
Model NA 265-70,
NA-66-1032
STRUCTURAL REYAIR MANUAI,
ENGINE RLEEO DUCT
ENGINE TAIL PIPE
DIAPHRAGM ASSY
I IN. MIN DENT-FREE AREA

FROM ALL JOINTS
A
DENT
_r
1/8 MAX
g3
f-
SECTION
ENGINE BLEED DUCT
A-A
DENTS
ITEM
NO.
NOTES
SCRATCHES
MAX DEPTH
MIN OIA
NONE
__
DAMAGE WITHIN THE LIMITS GIVEN MAY BE CONSIDERED NEGLIGIBLE AFTER BEING TREATED AS
3 OR LARGER
3/8
1/4
20 PERCENT
DESCRIBED IN 51-70-70.
OF
DATA APPLIES TO ITEMS INDICATED ONLY.
INTAKE DUCT NEGLIGIBLE DAMAGE

LIMITATIONS ARE WITH THE NACELLE SKIN NEGLI-
ENGINE AIR
GIBLE DAMAGE LIMITATIONS.
DENTS MUST NOi BE LOCATED OPPOSITE EACH

OTHER SO AS TO REDUCE THE DIAMETER IN EXCESS
/8
1/2
1/16
11/2
1/8
3/4
1/16
SKIN THICKNESS
NONE
NONE
OF 1/8 IN.
S265-3-170
Negligible Damage
Diaphragm Asuembly and Tail Pipe

(S/N 370-2 thru -6, -8,
erugiF)9- 54-00-10
Model NA 2(i5-40, -60, -60A, -608C, and -70

103
0
and
Page 107
Aug 17/84
SIRII(IIUKIZI, REPAIK MANUAI,
02838
ITEM
NOTES
a
80.
1
DAMAGE WITHIN THE LIMITS GIVEN MAY BE CONSIDERED NEGLIGIBLE AFTER BEING TREATED AS
810 Dll
MIX OEPTII
1/4
20 PE30EWT
SKII THI0KIESS
300
DESCRIBED IN 51-70-70.
3/8
LA80ER
a
SCRIITCHES
DATA APPLIES TO ITEMS INDICATED ONLY.
ENGINE AIR INTAKE DUCT NEGLIGIBLE DAMAGE

LIMITATIONS ARE WITH THE NACELLE SKIN NEGLI-
GIBLE DAMAGE LIMITATIONS.
1/2
1/4
8080
1/8
1/18
S3~0-3-32
54-00-10
Page 10S
Aug~ 17/84
NegliRible Damage
Model NA 265-70
Engine Inner Fairing and Tail Pipe

(S/N 370-1 and
-80, -80A, and -80SC
o
COPYRIGHT,
NA-66-1032
AUXILIARY STRUCTURE
GENERAL
This section contains information on the auxiliary
structure of the nacelles and pylons. For negligible
damage limits, refer to 54-00-10. For repairs refer to
54-20-20.
54-20-00
0
Page 1/2 Blank

Aug 17/84
NA-Gfi-IOS%
STKU(:IURAL KEPA[K MA~iUAI,
AUXILIARY STRUCTURE
REPAIR
GENERAL
?his section contains
repairs of Ihe auxiliary structure of
REPAIRS
See
fibrure a01.
54-20-20
Page 201
Aug 17/84
NA-66-1032
STHI_~(1TURAL REPAIR MANUAL
UPPER S1DE
RIGHT-HAND SIDE
GRILL NO. 42 HOLE
GRILL 10; 50 HOLE
PPLACESI
GRILL NO.
30
de
30"IfYP
lTYP2
PLACE9
52 HOLE
GRILL
7-
NO; 35
HOLE
13/32 1+ 1/8,
17/32
11/8,
--1/32)I
OF VANE
1
17/32
GRILL NO. 31
HOLE
"11
8-11/15(+ 1/B)
52 HOLE
-IC
GRILL NO. 50 HOLE
00.31
HOLE
111
DRILL NO. 35 HOLE
0.125 FOR HGLE
HOLELDg1TIOII--~/Jt
GRILL NO. 31 HOLE
(TYP 2 PLACES)
HORIZONTAL VANE
VERTICAL VANE
9/11
0.100
--1)
VAHE LF;AOIWC
RIYET THAUANGLE.~
810 VIIWE
MSZO420408
ITYPI
0.075
0.260 -1
:I
CSlsl
I :f
0.125 FOR
LOCATION
EOOE WELG
GRILL
GRILL NO.
OF YANE
13/32 1+1/8, ;1/32)
"J
UI\
i/BI
8-1/8
1/321
IFLUSH BOTH SIDES
TVP)
sEc~laN:A*A
(TYP FOR:BOTH UERTICAL
ANO HORI3MJITAL YANES)
CRACK IN
FILLET WELO
8-5/8 R
O.OM)
5/8 COISTANT
ig/lB
21822
naTEe
t-
5/818281
B/tO: IREFI
bln~l
IC----3---------~
IIYP)
CRACK II 11400
LEAOlnO EOOE
WBO PVPI
CHILL BAR
2 REOB
IOWE,BIR SHOWN; 280 BAR IS GPPOSITEJ
CLAMP CHILL 8488 ICR YAIE

AIO FWD RIYET 1N AnBLE
MAKE FROM BUS BAR COPPER (FEG SPEC
OO-8-825.HAROTEMPER)
NOTES
bnnd
out
weldmBfil, grinding slightly past ends of
crack.
THIS REPAIR IS APPLICABLE TO LEADING EDGE WELD
IC~
AND FILLET WELD CRACKS IN THE ENGINE INLET
TCUDRIA
VANES.
Rs*eld gmund-ouf
leading edges to
a
WHEN VANE LEADING EDGE CRACKS ARE 2 IN.
(OR
MORE) FROM FWD VANE-TO-ANGLE ATTACH RIVET
(SEE ASSEMBLED VIEW), PROTECT RIVET WITH CHILL
BARS.
WHEN
CRACK
REFERENCED
IS LESS THAN 2
RIVET.
REPLACE
IN.
RIVET
Build up weldment on vane

blending with adjacent
and
FROM
AFTER
WHEN WELDING VANE LEADING EDGES, USE CHILL-
BARS
DUCT VANE MATERIAL IS 6061-T6
WELDS ARE TO BE MADE BY THE TUNGSTEN
ANCE WITH SPECIFICATION MIL-W-8604
FWD
ATTACH
RIVET
AS
(AER) EXCEPT
et
DEPPVANES)
ARTNEEB
USE4043 ALUMINUM
Redrill
leading e~fgeanti-icing
required.
WELDING ROD,
54-20-20
REPLACE
DO NOT FILE INTO PARENT MATERIAL.
THAT FLUX MUST NOT BE USED. (FLUX COULD

WITHIN THE
OR
APPLICABLE.
INERT GAS PROCESS. WELDING IS TO BE IN ACCORD-
Page 202
Aug 17/84
area.
filing
areas.
WELDING.
ALL
allow for
sir outlet holes as

8285-3-17~
IModel NA 265-40, -60,

Engine Inlet Air Duct Vane Repair
-60A; -60SC, and -70 (S/N 3702 thru -6, -8, and -9)
Figure 201 (Sheefl ot 2)
o
NA-66-1032
STRUCTURAL REPAIR MA~VUAL
CRACKS IN FILLET WELD
O
~h
Grind out weldment,
Re*eld
-1
so
/II
past
ground-outarea Conliguration
ment should match
1/8
grinding slight
end of
cack.
at
new
weld-
original weldment
WELO;I
L 1/84
ORIIOIWO OUT
WELOMENT
REWELO
SECTION
Grind
out
SePARATIOW
A-A
weldment,
grinding slightly past
A
I,
ends of
3(MAXI
crack.
O
for
Reweld groun0-out
filing
and
area.
Build up weldment to allow
blending with adjacent
area.
CRACK.
NOTE
GRILL THRU WEAR
SYEET ONLY
SEE SKETCH BELOW FOR VANE-TO-ANTI-ICING

COVER CLEARANCE.
1/84 70 5/32
CRACKS IN SURFACE OF VANE
ENGINL AIIIIICING
CBVLR
i~r
O
O
DI
ITYPJ
~A
Clean areas
adjacentro
cracl
th
garnet cloth arwire
brush.
Stop-dr
I end of crack
Perl~rm welding operation
File weldment to
maximum
height 013184
[when
weldment exceeds that dimension).

r\
VANES
NOTES
B I
~I
_I4-L---"
I
I-~ce
I/I
CAREFVLLY
INSPECT BURN-DOWN WELD ON AFT
EDGE OF VANE WHENEVER CRACKS ARE FOUND ON
SURFACE OF A VANE
ALL WELDS ARE TO
BE MADE BY THE TUNGSTEN
INERT GAS PROCESS. WELDING IS TO BE IN ACCORD-
(TYPI
ANCE WITH MILITARY SPECIFICATION MIL-W-8604
(AER) EXCEPT THAT FLUX MUST NOT DE USED. (FLUX

COULD BE ENTRAPPED WITHIN THE VANES.) USE 4043
T
SECTION
B-B
WELDING ROD.
0.075 ITYP)
5265-3-175
VANE CONSTRUCTION DETAILS

Model NA 265-40, -60, -60A,
Air Duct Vane Repair
-60SC and -70 (S/N 370-2 thru -6, -8, and -9)
Engine Inlet
COPYRIGHT, 1984
54-20-20
Page 203/204 Blank
Aug 17/84
NA-Gfi-l 032
STRIJCTUHAL REPAIR MANUAL
PLATES AND SKINS

(;ENERA I,
This section contains information on the plates and skins
limits refer
on nacelles and pylons. For negligible damage
to Fi4-00-10. For repairs refer to 54-30-20.
54-30-00
0
Page 1/2 Blank

Aug 17/84
NA-66-1032
STRUCTUHAAL REPAIR MANUAL
PLATES AND SKINS

REPAIR
GENERAL
repairs
on
the plates and skins
on
REPAIRS
See figures 201 and 202.
54-30-20
0
COPYRIGHT, 1g84 BY SABRELINER CORPORATION
Page 201
Aug 17/84
NA-66-1032
REPAIR DOUBLER MUST
PICK UP ALL EX1ST1N6
RIVETS IN SURROUWDIWO
STRUCTURE
i-;-~2f
""Ilii
f
~1111
li/I
1+
JA
~C
Il/lt~
J*I
~t
+III
111
OMIT THIS PORTION OF REPAIR IF DISTANCE "X"

Is WIOE EWOUOH FOR OWE ROW OF: FASTEWERS
Ilie
tll,
(I
It
"ilI
11
II
91
tl
:k
II~
.1116
i-
~III:
-t
$I
1/4 MIN TYPE FOR

8881097184 RIVETS
5/16 TYPICAL FOR
SPOT WELOS
3/4 TYPICAL FOR

SPOT WELOS
1 TYPICAL FOR
11
i/
dll
P/
HAS1OO7A04 RIVETS
~I
II! I
II,~I
EXISTING SUBSTRUCTURE
~1
REPAIR OOUBLR-
SAME MATEHIAL
EXISTIWG SUB
STRUCTURE (REF)
EXISTING SUB
STRUCTURE IREF)
AS OWE OAUOE HEAVIER
THAW CH~MMILLEO
OF OAMAOEO SKIW.
ARE?
rREPAIR DOUBLER IREFJ
erlMac AS eEoD
OAMAOEO sKlw IREF)
SHIMSIREF)I
FILLEAIREFI
O
O
SECT!ON
Trim out
damage
to a square or
Smooth al edges and
~FRIIL:
-I~A
~ctanguisr shape.
Corners must have
c~men
SAME
minimum radius of 1/4 in.
Make tiller from
skin. the
same
same
type of material
thickness asthethinned
area
FILLERi SAME: BAUOE

1110 MITERIIL:ASj
damaged
as
of chem-milled
CREM-MILLEOAREA
OF OAMAOED 8818
skin
O
by
Make ehims to match the chem-milled
the
O
skin.
sresa
OllM116EO SKIW
covered
1!4 R
repair doubler
I
Make
one
repair doubler from
same
material
gauge heavier than thinned
areas
as
damaged
of the chem-
milled skin.
Fasten
by riveting
If
repair doubler. shims,
repair
Ilvlls o~,e in
it
repair
or
by spot-welding.
is to be riveted with NAS1097AD4
on-center. 1/4 in minimum
the
and filler in place either
with NAS1097AD4 rivets
rivets. space
edge distance,
iepaii
is to
bk spolwelded,
space
spot.nelds
314
815-3-170
on-center,5/16inedgedistance.
Nacelle Skin
54-30-20
Model NA 265-401 -60; -60A,-60SC, and

Repair
(S/N 370-2:thru -6, -8, and -9)
FiRureeOl (Sheet 1 of 2)
-70
202
Aua 17/84
COPYRII3MT, 1984:BY SABRELINER CORPORATION
NA-fiG-1032
STKUCTURAL REPAIR MANUAI,
EXISTING STRUCTURE
HAT SECTION
(REF)
ol/
REPAIR OOUBLER
[REF)
io
oil
iii
I/
/-DAMAOEDSKIN(RE9
FILLER
rl
3/8 MIN
\x
II
C+ji
IREFJ
.**C
6/18 MIY
PICK UP EXISTING FASTENERS THROUGH

REPAIR OOUBLER. WT SECTION. ANO
011
1 II
OAMAGEO SKIN.
j-
II
;lo;l~
REPAIR OOUBLER MAY BE EITHER SPOT-WELOED IN

PLACE DR RIVETED IN PLACE WITH 8831881134
RIVETS. MAXIMUM SPACING FOR SPOT-WELDS IS
3/8 11. CENTER-TO-CENTER, MAXIMUM SPACING FDR RIVETS IS 3/4 11.
Er(t~lre STRUCTURC
888818 WUCIER
(REF)
Ha SECTION
(REF)
OAMAGEO SKIN (REF)
MOLO LINE Of NACELLE rJ
SECTION
FILLER
SAME MATERIAL AS.

REPAIR OOURLER
ONE GAUGE HEAVIER THAN, CHEMMILLED AREA OF OAMAGEO SKIN
IREF)
A-A
JOGGLE AS REOO.
SAME MATERIAL
ANO GAUGE AS CHEM-MILLEO
AREA OF OAMAOEO SHIN
FILLER
HAT SECTION
EXISTING STRUCTURE
Cil
O
IE~
Trim out damage and smooth all edges and
Male ii ler to match trimma0-oul
M.Xe repsir doubler JOggls

existing skin.
7,
corners.
Irea.
and Contour it ta mfch
OAMAGEO SKIN
~I
Fasten repsirdoublar and filler in plaoe, eilher by spotwelding or by using NAS1097AD4 rivets. Maximum spotweld spacing is 3/8 in. Maximum rivet spacing is 3/4 in.
S265-3-1~7
Nacelle Skin
COPYRIGHT,
Model NA 265-40, -60, -60A, -60SC,

Repair
(S/N 370-2 thru -6, -8, and -9)
Fie~ure 201 (Sheet 2 of 2)
and -70
54-30-20
PaRe 20:J
Auff 17/84
NA-66-1032
S1III~("IURAI, REPAIR MANUAL
I/PMAX(TYP)
JDIAMAX
1/2
1/4 MIN (TYP)
R~PAII 00Ull~R-- Slllt

MATERIALS AS. 110 ONE-GAUGE
-t
HEAVIER THAN. DA#ACEO
t-
SKIN MIITERIIIL
(0.040 MINI
x.
X/
I
DAMAGED SKIN IREF)

~2
REPAIR OOURLER
IREFI
FILLER IREF)
i;:
RIVETS. ON 17-7 PH CRES PYLON
SKINS. USE 0401200-4 CADMIUM

PLATED MONEL RIVETS. ON ALUMINUM
SKINS. USE NAS1097404 RIVETS.
COUNTERSINK SKIN AND FILLER
O
OMeBPUle
Trim UUI
FILLER -:SAME
damage
thickness 01 damaged skin, to determine
required repair doubler
O
O
OIIUOE AnD MATERIAL

.AS DAMIIIED SKIN
to a maximum diameter of 3 in
and filler thicknesses,
DAMAOEO SKIN
Lay
our and drill r vet
Locate
existing
p8ttein
on
damaged
skin
repair daubier
rivet
n correct position, and pick up

pattern from damaged skin
Coulltersink damaged skin, and fasten repair doubler

place. ~sing the required size and type of rivet and
spacing required,
in
C~il
Fasten filler in
place, using required size
and
type of
fasleners. and spacing called out
NO?~
THIS REPAIR IS TO BE USED ON THE DAMAGED AREA
ON THE UPPER AND LOWER PYLON SKINS. ACCESSIO
THE
DAMAGED
AREA
IS
GAINED
THROUGH
THE
ACCESS DOORS ON THE LOWER PYLON SKINS

8281-3-178
54-30120
Ia~e 804
Aup 17/X4
Nacelle and Pylon Skin
erugiFriapeR
L02
COPY-RIGHT, 1984 BY SABRELINER CORPORATION
NA-66-1032
STRIICTURAL KEPAIR MAIVIIAL
ATTACW FITTINGS
STRUCTZ~RAI, II)ENTIFICAIION
(;E:NERAI,
Ihis section contains information on attach fittings on
nacelles and pylons. For negligible damage limits, refer
to 54-00-10. For repairs, refer to 54-40-20.
54-40-00
o
Page 1/2 Blank

Aug 17/84
NA-66-1032
ATTACH FITTINGS
REPAIR
GENERAL
This section contains repairs
on
the attach
fittings
on
REPAIRS
Sec
fiaurea 201
and 202.
54-40-20
0
Page 201
Aug 17/84
NA-66-1032
SIKLICTUKAL REPAIR MANUAI,
GRILL 1/2 11. DIA HOLE IN REPAIR ANGLE TO
MATCH EXISTING HOLE IN BEAM
RIVET
REPAIR IIWGLE
3/4
,STOP-GRILL
NO. 40 HOLE
3/4
15/16
5/161TYPj
mml
NACELLE STA 78.430
3-5/8
ITYP) 1
----L_i
ITYPl
5/16
1-21/32
rI)A
MSMO15M5
ITYP)
f- f
23/32
5/18
""~i
3/8Imrxll+
L~A
REAM EXISTING HOLE IN

BEAM TO 9/15 IH. OIA.
CHACK
i_L
le 25/32
7/16
(TVP)
TRIM OUT DAMAGE
)3/32
23/32
1-1/2
ENGINE SUPPOHT
BEAM 1286-321259 8581
2-7/8
7-7/18
VIEW OF LEFT-BAND BEAM ASSY

5/16---tl
LOOKING OUTED
BNITYPJ
J888LE 01150
Jt-
ITYP)
5/18 ITYPJ
3/8
:iilf
3/4 (REF)
-1
=i
RIVET
SIZE AID TYPE
TO MATCH REMOVED
RIVET
MS2DO15M5
ITYP)
FASTENERITVP)
O.OM) L9
46/16
ENGINE SUPPORT
ENGINE S1IPPORT
BEAM
REAM
1285321259 REF)
1265-321259 859
CRACKIREFJ
REPAIR ANGLE
1/8 A
SECTION
LI
O
O
Trim out
Form
A-A
HEPAIR 4861.6
damageas shown
repair angle
Position and
to fit beam.
n,,,,..l.,,,.
~,.I. 112in
h.ssnl;:.n.driil
hole.
clamp repair angle
on
beam and scribe
Drill rivet holes in wider leg of repair angle.

Reassemble repair angle to beam, aligning angle with a 1/2
circumference of 1/2 in, hole.
8.1150 361 1/28 CRES
IIWIL SPEC RIIL-S-S05B) OH 0.050 17-728

CRES IMIL SPEC MIL-S-2~D441
in. bolt. Line-drill rivet holes in beam web.

Hsst-frest
rep.ir angle
to
180,000-200,000 psi
if
material used is 17-I/PH CRES.
Remove
repair angle
end
enlarge exisling
112 in. hole
in beam web to 9/16 in.
N01~
THIS REPAIR
Respnemble Rp.ir angle Oriil rival h~lea through

repair angle andbeam flange, and rivet repair in place.
IS APPLICABLE TO CRACKED INBD
CHANNELS OF THE ENGINE SUPPORT BEAMS WITHIN

S265-3-179
LIMITS SHOWN.
54-40-20
Page
Aug 17/84
Model NA 265-40, -60, -60A,

Enaine Support Beam Repair
-60SC, and -70 (S/N 370-2 thru -6, -8, and
e201rugiF)9-
202
COPYRIGHT,
1984 BYSABRELINER CORPORAtlON
NA-66-1032
STRUCTURAI, REIAIR MANIIAL
RIVET
TYPE AHO
r,A
slzrronncr
REMOVEOFASTENER(TYP)
ilH
RIVET
2 REOD
9525475555
I/4ll~nl
Q
REPAIR IWGLE
HAT SECTION
HAT sECTIOW
REPLACE ORIGIWAL
FASTENER WITH
I
1
TYPE ANO
RIVET
\I~cn
SIZE To MATCH
P1O4 JO-ROLTS OR
I
CHERRY RIYETS
REMOVEOFASTENER
GECTION
O
for
REPAIR ANGLE
L~
A-A
RBFpve door hinge slide assembly to provide access

bucking rivets inside hat section. To remove cross pin
from slide
assembly:
pin at top of slot in hat section.

assembly outbd to extend cross pin through
slot enough to grip pin with a drill motor chuck.
Fasten drill motor chuck tightly to cross pin and spin pin
out of slide assembly.
Puii slide assembly out through bottom of hinge
a.
Position
b.
Press slide
c.
HAT
cross
AG
II
SECTION
bracket.
Stop-drill
the part.
any cracks that terminate within
Use No. 30 drill.
O
El
rabricst. and inslall
REPAIR AIGLE
0.050 2024T4
CLAO
repair angle(6).
Reinsfall door hing..lide gssembhl To inalall cross

slide
pin in slide assenlbly, wedge, steel bar behind
assembly and tap cross pin in with hammer.
NOTES
w
THIS REPAIR IS APPLICABLE TO CRACKED FLANOES
ON LOWER
NACELLE
DOOR
HINGE
I~
BRACKETS
(NACELLE STATIONS 84.875 AND 115.50).

a
gE FABRICATED FROM 0.040

7178-q MATERIAL. HEAT-TREAT PART TO
A NEW HAT SECTION MAY

IN. 7075-0
or
S2653-173
T6 CONDITION AFTER FORMING. NEW PART MAY BE
INSTALLED WITH
FASTENERS AS CALLED OU7 FOR
REPAIR.
Lower Maoelle Boor Hinge Bracket Repair

Model NA 265-40, -60, -60A, -60SC, and -70
(S/N 370-2 thru -6, -8, and -9)
Figure 202
a
54-40-20
Page 203/204 Hlanki
Aug 17/84
C H A PT E R
STABILIZERS
NA-66-1032
CHAPTER 55
STABILIZERS
TABLE OF CONTENTS
ChapteriSectionlSubject
Subject
Page
55-00-00
Stabilizers
General
Horizontal Stabilizer.........
Elevator...........
Vertical Stabilizer
Rudder.........
Stabilizer Master Repair Index.........
Stabilizer Skin Gap Tolerances.....
55-00-10
Stabilizers
101
Allowable Damage
General
Stabilizer Negligible Damage Limits
101
55-00-20
Stabilizers
201
201
Repair. . . . . . .. . ." " " " " " " " " " " "
General
5-10-00
General
Horizontal Stabilizer Repair Index

5&10-20
201
201
201
227
Repair. . . . . . ."" " " " " " " " " " "
General
Elevator Static Balancing..........
Elevator Balance Procedure.........
Vertical Stabilizer
55-30-00
General
Vertical Stabilizer Repair Index
Vertical Stabilizer.......
55-30-20
201
201
Repair...........
General
Rudder........
55-40-00
General
Rudder
Repair Index
Rudder.......
55-40-20
Repair. . . . . . . " " " " " " " " " " " "
General
Rudder Static Balancing..........
201
201
201
55-CONTENTS
0
Page 1/2 Blank

Mar 16/90
NA-66-1032
STRUCTURAL REPAIR IMANUAL
CHAPTER 55
STABILIZERS
Section
55-00-00
Figure
1
2
3
55-00-10
Page
Title
Model NA 265-40, -60, -60A, -60SC, and

Stabilizer Master Repair Index
-70 (S/N 370-2 thru -6, -8, and -9)
Model NA 265-65, -70 (S/N 370-1 and -7),
-80, -80A, and -80SC
Stabilizer Skin Gap Diagram
Model NA 265-40, -60, -60A,
Stabilizers
Negligible Damage
and -70 (S/N 370-2 thru -6, -8, and -9)
101
102
Negligible Damage
Stabilizers
Model NA 265-65, -70,
1
2
3
4
5
6
55-10-20
102
104
201
202
203
204
205
206
Horizontal Stabilizer Leading Edge Skin Repairs

Horizontal Stabilizer Upper and Lower Skin Repairs
Repairing Cracked Dimples in Horizontal Stabilizer Upper Skins
General
Horizontal Stabilizer Rib Repairs
Bushing Repair
Horizontal Stabilizer Center Beam
207
Replacing
208
209
210
211
212
213
55-30-00
1
2
55-30-20
201
202
203
204
205
55-40-00
1
2
55-40-20
201
202
203
204
205
Repairs
Weights
Elevator, Intermediate and Outboard Hinges, Bushing Repair
Static Balance Checking Equipment
Static Balance Calculations
Adding Rebalance Weights
Adding Balance Weights to Elevator Between Elevator Stations 93.875
Model NA 265-80 Only
and 105.711
Checking Elevator Static Balance

and -65
225
227
Model NA 265-70, -80, -80A, and -80SC
Model NA 265-40, -60, -60A, -60SC, and -65

Model NA 265-70, -80, -808, and -80SC
Leading Edge and Side Skin Repairs
Side Skin and Rib Repairs

Rib Repairs
Root Rib Repairs
Checking Rudder Static Balance
6
8
12
14
Model NA 265-40, -60, -60A, -60SC,
Vertical Stabilizer, Rudder, and Elevator Leading Edge Skin Repairs

Class B
Vertical Stabilizer Side Skin Repairs
General
Vertical Stabilizer Rib Repairs
Station 2.875
Vertical Stabilizer Rib Repair
Station 0.52
Rudder
Rudder
Rudder
Rudder
2
4
202
203
205
209
213
214
215
216
218
219
220
Fasteners in Loose Elevator Balance
Rudder Repair Index

Rudder Repair Index
(S/N 370-1 and -7),
Model NA 265-40, -60, -60A, and -60SC

Model NA 265-70
Model NA 265-65, -80, -80A, and -80SC
Model NA 265-40, -60, -60A, and -60SC
Elevator Repair Index
Model NA 265-70
Model NA 265-65, -80, -80A, and -80SC
Elevator Air Load Rib
-60SC,
-80, -80A, and -80SC

55-10-00
2
4
202
203
204
205
206
2
4
202
204
206
208
211
55-ILLUS
0
Page 1/2 Blank

Mar 16/90
NA-66-1032
CHAPTER 55
STABILIZERS
Chapter/
Chapterl
Section
Page
55-L.E.P.
1/2"
Mar
16/90
55-CONTENTS
1/2"
Mar
16/90
1/2"
Mar
16/90
55-ILLUS.
55-00-00
2*
3*
4
Aug 17/84
Aug 17/84
105/106
Aug 17/84
55-00-20
201/202
Aug 17/84
55-10-00
1
2
Aug 17/84
Aug 17/84
Jun 3/88
Mar 16/90
Jun 3/88
Aug 17/84
Jun 3/88
Aug 17/84
Jun 3/88
Jun 3/88
Jun 3/88
Aug 17/84
Jun 3/88
Aug 17/84
Jun 3/88
4*
5
6
7
8
9
10
11
12
13
14
15/16
55-10-20
201"
202
203
204
205
206
207
208
209
210
211
212
213
(Contd)
221
222
223
224
225
Aug17/84
Aug 17/84
16/90
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
226
227"
228"
55-30-00
1
2
3
4
55-30-20
201
202
203
204
205
206
55-40-00
or
1
2
3
4
5/6
55-40-20
17/84
17/84
17/84
17/84
Mar 16/90
Aug 17/84
Aug 17/84
Aug 17/84
Jun 3/88
Jun 3/88
Aug 17/84
Aug17/84
Jun 3/88
Mar 16/90
Mar 16/90
hug 17/84
Aug 17/84
Jun 3/88
Aug 17/84
Jun 3/88
5/6
Mar
Aug
Aug
Aug
Aug
214
215
216
217
218"
219
220
Aug 17/84
Mar 16/90
Mar 16/90
Aug 17/84
101
102
103
104
55-00-10
55-10-20
Date
Page
Section
Date
201
202
203
204
205
206
207
208
209
210
211
212
Aug
hug
Aug
Aug
Aug
Aug
17/84
17/84
17/84
17/84
17/84
17/84
Aug 17/84
Aug 17/84
Jun 3/88
Aug 17/84
Jun 3/88
Aug 17/84
Bug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
55-L.E.P.
0
Page 1/2 Blank

Mar 16/90
NA-66-1032
CHAPTER 55
STABILIZERS
GENERAL
The empennage group consists of a fixed vertical
stabilizer, a rudder, a rudder trim tab, a trimmable
horizontal stabilizer, an elevator, and fillets. The vertical
25%
and horizontal stabilizers are swept back 30" at the
plane.
RUDDER
The rudder is a single-cell torque box consisting of a rear
beam, two fwd longitudinal stringers, transverse ribs,
and side and leading edge skins. The rear beam consists of
a sheet-metal channel and a honeycomb sandwich panel
trailing edge, except in the area of the trim tab. The trim
tab is a honeycomb sandwich panel structure with a sheet-
metal channel leading edge.
The horizontal stabilizer is of full cantilever construction.

It consists of two neutral (noninterchangeable) panels,
connected by a pivoted beam through the fuselage. The
466.53
complete assembly rotates about a pivot axis at FS
and WP 20 for longitudinal trim. The structure is a single-
The rudder is suspended from the stabilizer rear beam by

three hinges and is rotated by a torque tube attached to
the root rib. The rudder is both aerodynamically and
statically balanced. Static balance is achieved by steel
weights attached to the inside of the leading edge skin.
The trim tab is statically balanced and rotates +15".
cell box with a rear beam, two fwd longitudinal stringers,

and transverse ribs. The structure has upper and lower
skins, a leading edge skin, and a tip.
ELEVATOR
interare neutral interchangeable panels,
connected through a torque tube. The structure is a
single-cell torque box consisting of a rear beam, two fwd
The elevators
longitudinal stringers, and transverse ribs. The rear

beam incorporates a sheet-metal channel and a honeycomb sandwich panel trailing edge. The structure is
covered with upper and lower skins, a leading edge skin,
and
STABILIZER MASTER REPAIR INDEX

-70 (S/N 370-2 thru -6, -8, and -9). See figure 2 for model
NA265-65, -70 (S/N 370-1 and -7), -80, -80A and -80SC.
STABILIZER SKIN GAP TOLERANCES

See figure 3.
tip.
The elevator is suspended from the stabilizer rear beam

by three hinges. The elevator is both aerodynamically and
statically balanced. Static balance is achieved by a series
of steel weights attached to the inner side of the leading
edge skin.
VERTICAL STABILIZER
The vertical stabilizer is an all-metal, fully cantilevered
structure with a laminated glass cloth tip. The main box
structure consists of a full length rear beam, a short lower
front beam, transverse ribs, two longitudinal stringers,
and side and leading edge skins. The box section above the
rudder is formed by the rear beam, a honeycomb panel
trailing edge, and side skins. The vertical stabilizer is
attached to the fuselage by 45 bolts at the rear beam and
one
bolt at the front beam.
55-00-00
0
Page 1
Aug 17/84
NA-66-1032
REPAIRINDEX
ITEM
ASSY HO.
SECTION WO.
VERTICAL STABILIZER
285-230002
55-30-00
FIGURE 1
FIGURE 2 1-701
RUOOER
285240002
5540-00
FIGURE 1
FIGURE 21-701
RUDOER TRIM TAB
285-240501
285-210002
ELEVATOR
285-220002
NOMENCLATURE
NO.
55-10-00
FIGURE 1
FIGURE 2 (-7O)
55-10-00
FIGURE 4
FIGURE
INTERCONNECTING
TOROUETUBE
51-701
o"
265-522098
BEAM ASSY
285-210008
TOROUE TUBE ASSY
265-220008
SEE 55-18-00. FIGURE 101 FOR NEGLIGIBLE OAMAGE LIMITATIONS
snes-,leo

1
Model NA 265-40, -60, -60A, -60SC, and -70
(S/N 370-2 thru -6, -8, and -9)
Figure
55-00-00
Page
Mar
16/90
NA-66-1032
REPAIRINOEX
ITEM
NO.
NOMENCLATURE
VERTICAL STABILIZER
SECTION NO.
55-30-00
FIGURE
1(-85)
FIGURE 2
2
RUDDER
55-40-00
FIGURE
11-851
FIGURE 2
3
RUDDER TRIM TAB
55-10-00
FIGURE 21-70)
FIGURE 3
ELEVATOR
55-10-00
FIGURE 5
I-701
FIGURE 6
INTERCONNECTING
1-b
TDROUE TUBE
7
BEAM ASSY
TOROUE TUBE ASSY

SEE 55-00-10, FIGURE 102 FOR NEGLIGIBLE
DAMAGE LIMITATIONS
s?ss-1-~eo

Fiffure 1
Model NA 265-65, -70, (S/N 370-1 and -7), -80, -80A, and-80SC
55-00-00
Paffe
0
Mar 16/90
NA-66-1032
5/161~1116)
l/BI+1/181
1/6
1+1/161
51161~111811
f,
VERTICAL STABILIZER
NOTES
ARE O TO 1/16 IN.
SKIN GAP TOLERANCES GIVEN ON THIS ILLUSTRATION ARE FORTHE FITTING OF NEW PARTS. REFER TO
"SKIN GAP TOLERANCES" TEXT FOR PERMISSIBLE

5285-3-277
55-00-90
Page 4
Aug. 17/84
Stabilizer Skin Gap
erugiFmargaiD
3
NA-66-1032
STABILIZERS
ALLOWABLE DAMAGE
C;~I:NERAI,
This section contains negligible damage limits for the
stabi I izers.
STABILIZER NEGLIGIBLE DAMAGE LIMITS
Negligible damage limits for Model NA 265-40, -60, -60A,

-60SC, and -70 (S/N 370-2 thru -6, -8, and -9) are given in
figure 101. Negligible damage limits for Model NA 26565, ~70 (S/N 370-1 and -7), -80, -80A and -80SC are given in
figure 102.
55-00-10
0
Page 101
Aug 17/84
NA-66-1032
STKU("IUKAL REPAIR MANUAL
IFIBEROLASSI
s/s(mAxl551,
it
3111.1111
DEPTH
SECTIONA-A
1-1/2 (MAXI
TRAILING EOGE GENTS
ic
ALL TRAILING
(TYPICAL FOR
EOGESJ
12
STA 33
12
I~
io
i,
a~l
DENTS
SCRATCHES
CHDROWISE
GENTS
IPIYWDI
BEPTH IN IN.
LENGTH II IN.
0.002
DEPTH IN IN.
01~1)1
LENGTH IN IN.
0.002
UNLIMITED
BETWEEN DENTS
IMAX)
1/8
HOLES
1-114
0.020
PER
BAY
2 TIMES
0.040
i3bBIIAXI 1
Oi~ln
BENT OIA
3/8
0.063
2 TIMES
0.002
0.002
ONLIMITED
1~2
3/64
sIMAxl
3
ILAMINATION
jO.OlOl
ILAMINATION
(0.010)
ONLIMITED
COMB
aDOr
OM12
UWLIM~TEO
0.004
0.004
UNLIMITED
0.002
0.002
UNLIMITED
2 TIME
NONE
I
0.020
0.035
0.050
:1
1/54
1 2
3/6$
1/18
1/8
0.020
0.002
0.002
UNLIMITED
1 1/4
1
3/81MAXI I
0.040
10
0.005
UNLIMITED
0.005
UNLIMITEO
1 3
1/18
slmi~xl
BE
AFTEH TREASMENT AS DESCRIBED IN 51-7070
EDGE
PARTIALLY
REMOVED)
DENTS
MAY
BE
REMOVED
3/8
112
6D
IMAxl
2 TIMES
DENT DIA
3/8
3/8
2 TIMES
DENT DIA
2 TIMES
DENT IBIA
(MAX)
1/8
ALL SHADED AREAS CAN
SUSTAIN
NO
DAMAGE
OTHER THAN DENTS AND SCRATCHES.
TRAILING
DENT OIA
.1
3164111
NOTES
3/8
1/15
4.6.8.9
HONEY-
DENT DIA
[11
A MINIMUM OF 5 IN. UNDAMAGED MATERIAL BETWEEN
HOLES.
(OR
BY A CLAMPING PRESSURE: DO
NOT HAMMER ON BONDED HONEYCOMB.

ABRUPT CHANGES IN CONTOUR. THE
MEASUREMENT,
"DIA", IS THE SHORTEST DISTANCE ACROSS DENT.
55-00-10
Page 102
Aug 17/84
Stabilizers
Negligible Damage
Model NA 265-40, -fiO, -60A, -60SC and -70
(S/N 370-2 thru -6, -8uand -9)
Figure 101(8heet;l of2)

o
COPYRI:GHT, 1984 BY S~R.ELINER CORPOR~TION
NA-66-1032
STAIB
j/s(mAxl
I/PlmAxl
/f;
STA 28
STA
12
THE mEASUREmEHT, "DIA" IS
THE SHORTEST
DISTANCE I\CROSS
98.83
T)A
DENT
-e
4A
DEPTH
SECTION
AeEA
SPANWISE
CHORDWlSh
LENGTH IN IN.
DEPTH IN iN.
0.002
0.002
0.005
0.002
OIA IN
IN.
DE~TH IN IN.
0.002
0.912
0.DOE
UNLIMITEO
0.002
IF.
IN IN.
UNLImITEO
UNLIIITED
UNLImITEO
HDNEY-
1/8
0.020
1/4
0.040
3/8
0.063
1/84
3/64
3 ImAXI
1/16
1/84
3/64
a(mAxl
I/is
3
1/2
PLUG ALL
0.050
HOLES
UNLIMITED
3
1
1/64
O.DO2
0.002
3/84
almAxl
I/is
0.005
0.012
0.005
UNLIMITED
UNLImITEO
UNLImITED
NOTES
1/8
0.020
1/4
0.040
3/8
0.083
1/84
3/64
a(mAxl
I/is
ALL SHADED
DESCRIBED IN 51-70_70.
AREAS CAN
(MAX)
3/8
3/8
3/8
SUSTAIN
NO
DAMAGE
OTHER THAN DENTS OR SCRATCHES.

AFTER TREATMENT
3/8
0.035
0004
3/8
0.020
PER
BAY
3/8
0.004
0.002
DII\ IN
IN.
MATERIAL
BETWEEN DENTS
Come
SUBSTRUCTURE ITYP]
A-A
DENTS
SCRATCHES
CPOE
t3
jca/alniul
Ci]
A MINIMUM OF 5 IN. UNDAMAGED MATERIAL BETWEEN
HOLES.

s2a53le2
Stabilizers
Negligible Damage
Model NA 265-40, -60, -60A, -60SC and -70
(S/N 370-2 thru -6, -8, and -9)
o
55-00-10
Paffe 10~
Aug 17/X4
NA-66-1032
STKIICTURAL KEPAIR MANURL
(talalmls
It- 01~
3/8(MAX)
(FIBEROLISSI
DEPTH
SECTION
1-1/2
A--A
(MAXI
TRAILING EDGE GENTS
lelo
(TYPICAL FOR ALL TRAILING EDGES)
ST133
1/ 7
-3
/53
to
-II
toe
]43
GENTS
SCRATCHES
CODE
IR~1
SPANWISE
DEPTH IN IN.
LENGTH IN IN.
DEPTH IN IN.
LENGTH IN IN.
0.002
O.W2
UNLIMITED
GENTS
CHDROWISE
0.002
1 LAMINATION
0.002
1 LAMINATION
lo.OtOl
UNLIMITED
O~IN
IN.
IMAx)
COMB
0.040
3/8 IMAxl
D,Gsa
3/64
nlmAxl
I/is
UNLIMITED
0.002
UNLIMITEO
0.004
0.004
UNLIMITEG
0.002
0.002
UNLIMITEG
0.002
P~R
BAY
3/8
GENT OIA
3/8
DENT 011
2TIMES
NONE
3/8
GENT OIA
0.002
O:nlN
2TIMES
lo.otol
0.002
MIITERIIL
BETWEEN DENTS
LTIMES
1/4
4.6.8.9
HONEY
HOLES
UNLIMITEO
0.020
0.035
0.050
1/84
3/64
1/16
t/B
0.020
1/4
0.040
1/2
IMAxl
2 TIMES
3/8
DENT DIA
2TINIE3
3/8
LjEIV I1IA
0.063
10
0.005
UNLIMITED
0.005
UNLIMITEO
1/64
1/16
OIMAx)
NOTES
AFTER TREATMENT AS DESCRIBED IN 51-70-70
IHAILIN~
EDGE
REMOVEDI BY A CLAMPING PRESSURE. DO
DENTS
MAY
BE
REMOVED
IMAXJ
I/a
ALL SHADED AREAS CAN
SUSTAIN NO DAMAGE
OTHER THAN DENTS AND SCRATCHES.
PAHI IAl LY
2 TIMES
DENT OIA
A MINIMUM OF5 IN. UNDAMAGED MATERIAL BETWEEN
HOLES.
(OR
NOT ~-1AMMEH ON BONDED HONEYCOMB

ABRUPT CHANGES IN CONTOUR.THEMEASUREMENT,
DIA", IS THE SHORTEST DISTANCE ACROSS DENT.
55-00-10
Paar 1()4
Aua 17/84
Model NA
5370-3-47
Stabilizers
Negligible Damage
265-65, -70 (S/N 370-1 and -7), -861, -80A,
o
COPYRIGHT,
and -8084:
NA-G6-1082
STKUCTUHAL KEPAIR MA~UAI.
STAIR
_~
ul
3/81MIIXI
11/2
STA 28
IMAX)
Y~
sn4e
4-
THE MEASUREMENT. "DIA" IS

THE SHORTEST
DISTANCE ACROSS
98.83
r,A
DENT
Ti3
L~A
DEPTH
DENTS
SCRATCHES
COqE
SPAWWISE
CHOROWISE
OIA IN
IN.
AREA
DEPTH 111 IN.
LENDTH IN IN.
DEPTH II IW.
LEWOTH II IN.
0.002
0.002
UNLIMITED
0.002
0.005
0.002
UNLIMITED
3
0.002
O.W5
0.002
UNLIMITED
UNLIMITED
HONEY-
1N.
1/8
0.020
0.040
3/8
0.063
1/64
3/64
a(m~xl
I/is
1/54
a (mAxl
1/16
0.020
1/2
0.035
PLUG ALL
0.050
HOLES
UNLIMITED
3
1
1/64
0.002
0.002
3/64
1/16
0.002
UNLIMITED
3/8
3/54
0.004
IMAX)
PER
BAY
3/8
DIA IN
II~
0.004
0.002
HOLES
MATERIAL
BETWEEN DENTS
1/4
COMB
SUISTIIUCTUB IrYPI
I~-
SECTIONA~A
3/8
IMAX)
3/8
1/B
O.OM
1/4
0.040
3/8
0.063
3/84
almAxl
I/is
3/8
1/84
7
5.005
UNLIMITED
5.505
UNLIMITED
NOTES
ALL SHADED
AREAS CAN
SUSTAIN
NO
DAMAGE
OTHER THAN DENTS OR SCRATCHES

3/8
MINIMUM
OF
IN.
OF
UNDAMAGED
MATERIAL
BETWEEN HOLES.

S370-3-48
Model NA
Stabilizers
Negligible Damage
285-65, -70 (S/N 370-1 and -7), -80, -80A,
and -80SC
55-00-10
Page 105/106 Blank
Aug 17/84
NA-66-1032
STABILIZERS
REPAIR
GENERAL
The repairs for the stabilizers
covering each stabilizer.
are
given in section
55-90-20
0
Page 201/202 Blank

Aug 17/84
NA-G(i-103~
STRU<:TURAL REPAIR MANUAL
MORIZONTAL STABILIZERS
GENERAL
lhe information in this section applies to the horizontal
stabilizer. For negligible damage limits, refer to 55-0010, For repairs, refer to 55-10-20.
HORIZONTAL STABILIZER REPAIR INDEX
See figure 1 for model NA 265-40, -60, -60A, and -60SC.

See figure 2 for model NA 265-70. See figure 3 for model
NA 265-65, -80, -80A, and -80SC.
55-1 0-00
0
Page 1
Aug 17/84
NA-66-1032
STRI;(TURAL REPAIR MANUAL
FRAME ASSEMBLY ORAWINC
NO. 255-210102
00
INOEX NUMBERS CORRESPONO TO

THE ITEM NUMBERS IN THE KEY
HS
C;
HS
STA
-r~V
10
14
12
13.456
11
1Si
HS:
j!
la
HS
17
878
32
98.480
31
30
29
28
27
28
24
23
22
20
5215-3-~83
55-1 0-00
Page 2
Auff 17/84

Model NA 265-40, -60i -6~k, and:-60SC
Figure
SPc~EtRELINER CORPORATION
NA-66-1032
ITEM
NO.
DRAWING
NO.
MATERIAL
DESCRIPTION
GAUGE OR
EXTRUSION
NO.
1
2
265-210002-3
265-210421
Skin--LE
Skin
Upper
2024-13 Clad
2024-13 Bare
0.032
0.050
265-210420
265-210421
265-210311
Skin
Skin
2024-T3 Bare
2024-T3 Bare
6061-14 Bare
6061-16 Tube
7079-16 Forging
7075-16 Bar
7075-16 Clad
7075-16 Clad
7075-16 Clad
7075-T6 Clad
7075-T6 Bare
7079-T6 Forging
7075-T6 Bare
7075-T6 Bar
7075-16 Bare
7075-T6 Extr
2024-14 Clad
7075-T6 Extr
7075-T6 Clad
2024-T42 Clad
2024-T42 Clad
2024-142 Clad
2024-142 Clad
2024-142 Clad
2024-142 Clad
2024-T42 Clad
2024-142 Clad
2024-142 Clad
2024-142 Clad
2024-142 Clad
7075-16 Clad
0.050
0.050
0.025
0.150
4
5
6
7
8
9
10
11
12
13
1.4
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Tip
Torque Tube
265-522096
265-210412
265-210401
265-210013
Interconnect
Center Section
Front Beam Actuator
Support
Canted Sta 13.456
Rib
Fwd
Intercostal
Intermediate
Intercostal
Aft
Intercostal
Skin
Doubler
Inbd Hinge
Support
Rear Beam
Cap
Intermediate Hinge
Support
Rear
Beam
Otbd Hinge
Support
Rib
Canted Sta 105.711
Beam
265-210306
265-210307
265-210308
265-210422
265-210417
265-210402
265-210418
265-210302
265-210419
246-21105
265-210408
265-210098-11
265-210091-3
265-210084-3
265-210077-3
265-210070-3
265-210063-3
265-210056-11
265-210049-3
265-210042-3
265-210036-3
265-210029-11
265-210023
265-210018
Lower
Lower
Stringer
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Sta
Sta
Sta
Sta
Sta
Sta
Sta
Sta
Sta
Sta
Sta
Sta
Sta
98.480
91.424
84.368
77.312
70.256
63.200
56.362
49.568
42.991
36.415
29.839
23.262
18.340
~J
P
4.500
0.063
0.032
0.032
0.032
0.063
REPAIR
FIGURE
NOI
55-10-20 Fig. 201
55-10-20 Fig. 202,
203
55-10-20 Fig. 202
55-10-20 Fig. 202
55-10-20
Fig. 205
55-10-20
Fig. 204
55-10-20
Fig.
56-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
Fig. 204
Fig. 204
Fig. 204
Fig. 204
Fig. 204
Fig. 204
Fig. 204
Fig. 204
Fig. 204
Fig. 204
Fig. 204
Fig. 204
Fig. 204
0.9375
1.375
0.063
6E1104
0.020
43756
0.050
0.040
0.040
0.040
0.040
0.040
0.063
0.050
0.050
0.050
0.050
0.050
0.050
204
NOTES

thinned areas or refer to applicable drawing numbersfor thickness.
OnNA
865-44Airplanes~88-9I andsubs.
Key
to
Figure
55-1 0-00
Page3
0
Jun 3/88
NA-66-1032
FRAME ASSEMBLY
ORAWIWO WO. 265-210002

00
I#BEX NUMBERSCORRESPOWOTO
ITEM IUMBERS.IN THE KEY
HS
RORIZOWTAL STABILIZER
HS
STA
13.456
io
9
7
13
14
12
I
1
HS
STA
I~iFI
56.362
15
HS
STA
96.460
36
34
32
30
35
28
33
26
31
25
29
27
24
23
22
20
83~0-338

Model NA 265-70
55-1 0-00
Page ,4
Au 17/84
Figure
NA-66-1032
ITEM
NO.
DRAWING
MATERIAL
DESCRIPTION
NO.
265-210002-3
Skin
265-210421-3
Skin
265-210421-4
265-310311
Tip
Skin
Leading Edge
Upper
Lower
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
265-210412-3
285-210403-3
265-210013
265-210306
265-210307
265-210308
265-210422
265-210417-3
-4
-2
265-210402-1
265-210418
265-210302
265-210419
246-21105
Center Section
Support
Canted Sta 13.456
Rib
Fwd
Intercostal
Intermediate
Intercostal
Aft
Intercostal
Skin
Doubler
Inbd Hinge
Support
Rear Beam
Cap
Support Intermediate Hinge
Rear
Beam
Otbd Hinge
Support
Canted Sta 105.711
Rib
Beam
265-210408-1& -2
Stringer
23
24
25
26
265-210098-21
265-210091-5
265-210084
265-210077-5
265-210070-3
265-210063-5
265-210056-21
27
282-210026-41
28
265-210049-5
282-210026-31
265-210042-5
282-210026-21
265-210036-3
282-210026-11
265-210029-9
282-210026-1
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
22
29
30
31
32
33
34
35
36
37
(Continued)
265-210023
265-210018
Rib
Rib
Rib
Rib
Rib
Sta
Sta
Sta
Sta
Sta
Sta
Sta
98.480
91.424
84.368
77.312
70.256
63.200
56.362
LE, Sta 52.479
Sta 49.568
LE, Sta 45.914
Sta 42.991
LE, Sta 39.703
Sta 36.415
LE, Sta 33.127
Sta 29.839
LE, Sta 26.550
Sta 23.262
Sta 18.340
GAUGE OR
EXTRUSION
NO.
2024-T3 Clad
2024-T3 Bare
0.032
2024-T3 Bare
6961-14
6061-T6 Tube
7079-T6
7075-T6
7075-T6 Clad
7675-16 Clad
7075-T6 Clad
7075-T6 Clad
0.0500
7675-16
7079-T6
7075-T6
7075-T6
7075-T6
7075-T6
2024-T4
7075-T6
7075-T6
Clad
Bare
Bar
Bare
Extr
Clad
Extr
Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2624-142 Clad
2024-T42 Clad
2624-142 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
7075-T6 Clad
0.050
REPAIR
FIGURE
NO.
55-10-20
Fig.
55-10-20
202
Fig. 201,
55-10-20
Fig.
202
55-10-20
Fig.
205
55-10-20
Fig.
204
201
0.025
0.188 Wall
Forging
Die Forge
0.063
0.032
0.032
0.032
0.063
Die Forge
0.9375
0.8125
0.063
6E1104
0.020
43756
0.050
0.040
0.040
0.050
0.050
0.050
0.063
0.025
0.050
0.025
0.050
0.025
0.050
0.025
0.050
0.025
0.050
0.050
55-10-20 Fig. 204

55-10-20 Fig. 204
55-10-20 Fig. 204
55-10-20 Fig. 204
55-10-20 Fig. 204
55-10-20 Fig. 204
55-10-20 Fig. 204
55-10-20 Fig. 204
55-10-20 Fig. 204
55-10-20
Fig.
204
Fig. 204
55-10-20 Fig. 204
55-10-20 Fig. 204
55-10-20 Fig. 204
55-10-20 Fig. 204
55-10-20 Fig. 204
55-10-20 Fig. 204
55-10-20 Fig. 204
55-10-20 Fig. 204
55-10-20 Fig. 204
55-10-20
NOTES

thinned areas or refer to applicable drawing numbers for thickness variations.
Key
to
Figure
55-1 0-00
0
Page 5
3/88
Jun
NA-66-1032
INOEX NUMBERS CORBESPONO TO

THE ITEM NUMBERS II THE nEY
00
HS
HS
STA
13.456
11
12
14
HS
15
STA
56.362
HS
17
STA
98.480
38
36
34
39
32
30
37
28
35
26
33
25
29
24
27
23
22
20
18
55-1 0-00
Page

Model NA 265-65, -80, -80A, and
erugiFCS083
Aug 17/84
NAi66-1032
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
GAUGE OR
EXTRUSION
DRAWING
NO.
MATERIAL
DESCRIPTION
Leading Edge
Upper
265-210002-19
265-210421-5
Skin
Skin
265-210421-6
265-310311
265-522097
380-210412-3
380-210403-3
380-210010-3
380-210306-3
380-210307-3
380-210308-3
380-210422-3
380-210417-11
380-210402-3
265-210418
265-210302-11
265-210419
246-21105
265-210408-3
265-210098-21
265-210091-5
265-210084-5
265-210077-5
265-210070-5
265-210063-5
265-210056-21
282-210026-41
265-210049-5
282-210026-31
265-210042-5
282-210026-21
265-210036-3
282-210026-11
262-210029-9
282-210026-11
265-210023
265-210018-11
380-210012-3
380-210011-3
Lower
Interconnect
Torque Tube
Center Section
Beam
Support
Canted Sta 1.828
Rib
Fwd
Intercostal
Intermediate
Intercostal
Aft
Intercostal
Skin
Doubler
Inbd Hinge
Support
Rear Beam
Cap
Intermediate Hinge
Support
Rear
Beam
Otbd Hinge
Support
Canted Sta 105.711
Rib
Skin
Tip
-4
-4
-4
-4
Stringer
Rib
Rib
Rib
Rib
Rib
Sta
Sta
Sta
Sta
Sta
Sta
Sta
98.480
91.424
84.368
77.312
70.256
Rib
63.200
Rib
56.362
Rib
LE, Sta 52.479
Sta 49.568
Rib
Rib
LE, Sta 45.914
Rib
LE, Sta 42.991
Rib --LE, Sta 39.703
Rib
Sta 36.415
Rib
LE, Sta 33.127
Sta 29.839
Rib
Rib
LE, Sta 26.550
Rib
Sta 23.262
Rib
LE, Sta 18.340
Canted Sta 12.503
Rib
Canted Sta 6.666
Rib
NO.
REPAIR
FIGURE
NO.
55-10-20
55-10-20
203
55-10-20
Fig. 201
Fig. 202,
Fig.
202
0.188 Wall
Hand Forge
Die Forge
55-10-20
Fig.
205
0.063
55-10-20
Fig.
204
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
204
204
204
204
204
204
204
204
204
204
204
204
2624-13 Clad
2624-13 Bare
0.032
0.050
2924-13 Bare
6961-14
6661-16 Tube
7679-1652
7675-16
7975-16 Clad
7675-16 Clad
7075-T6 Clad
7075-T6 Clad
7675-16 Clad
7679-1652
7975-1652 Bare
7675-16 Clad
7075-T6 Bare
7675-16 Extr
2024-T42 Clad
7075-T6A1 Extr
2624-142 Clad
2624-142 Clad
2024-T42 Clad
2624-142 Clad
2024-T42 Clad
2624-142 Clad
2024-T42 Clad
2024-T42 Clad
2924-142 Clad
2024-T42 Clad
2024-T42 Clad
2624-142 Clad
2024-T42 Clad
2624-142 Clad
2624-142 Clad
2624-142 Clad
2024-T42 Clad
7975-16 Clad
7075-T6 Clad
7975-16 Clad
0.050
0.025
0.032
0.032
0.032
0.063
Hand
19
O
Forge
0.125
1.375
0.063
6E1104
0.020
43756
0.050
0.040
0.040
0.050
0.050
0.050
0.063
0.025
0.050
0.025
0.050
0.025
0.050
0.050
0.050
0.025
0.050
0.050
0.050
0.063
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
204
204
204
204
204
204
204
204
NOTES
Foradditionalrepairs, referto
51-r0-00.

thinned areas or refer to applicable drawing numbersfor thidcness variations.
Key
to
Figure
55-1 0-00
0
Page 7
3/88
Jun
NA-66-1032
33
FRAME ASSEMBLY BRAWING
NO. 285-220002
00
INOEX NUMBERSCORRESPONOTO
ITEM NUMBERS IN THE KEY
35
36
34
C
32
30
31
28
29
26
27
24
25
22
20
23
19
16
15
13
11
10
5265-3-184
55-1 Oc00
Page 8
Aug 17/84

Model NA 265-40, -60, -60A, and
eruffiFCS064
NA66-1032
ITEM
NO.
DRAWING
NO.
265-220205
246-22320
DESCRIPTION
Doubler
Beam
Skin
Core
246-22320-3
246-22320-7
MATERIAL
Skin
GAUGE OR
EXTRUSION
NO.
7075-T6 Clad
0.125
2024-T3 Clad
5652-1139
0.010
REPAIR
FIGURE
NO.
Elevator, TE
3/16x0.001
Honeycomb
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
Doubler
26.5-220206
265-220411
246-22311
265-220105
Skin
Stringer
Tip
Rib
Elevator Canted Sta
105.711
Rib
Elevator Sta 99.281
Outbd Hinge
Support
265-220099
265-220419
265-220098
265-220093
265-220089
265-220084
265-220080
265-220076
265-220072
265-220068
265-220064
Rib
Rib
Rib
Elevator Sta 98.369

Elevator Sta 93.875
Elevator Sta 89.375
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
265-220061
265-220057
265-220418
265-220056
265-220052
265-220049
265-220045
265-220041
265-220038
265-220034
265-220030
265-220026
265-220022
265-220018
265-220013
265-220420-1
265-220420-2
265-220002-3
265-220416-3, -5,
Elevator Sta 84.875

Elevator Sta 80.812
Elevator Sta 76.750
Elevator Sta 72.688
Elevator Sta 68.688
Elevator Sta 64.813
Elevator Sta 61.062
Elevator Sta 57.006
Intermediate Hinge
Support
Rib
Elevator Sta 56.094
Rib
Elevator Sta 52.562
Rib
Elevator Sta 49.000
Rib
Elevator Sta 45.375
Rib
Elevator Sta 41.750
Rib
Elevator Sta 38.000
Rib
Elevator Sta 34.125
Rib
Elevator Sta 30.250
Rib
Elevator Sta 26.250
Rib
Elevator Sta 22.250
Rib
Elevator Sta 18.250
Rib
Elevator Sta 13.547
Skin
Elevator, Upper
Skin
Elevator, Lower
Skin
Elevator, LE
Balance
Weight
7075-T6 Clad
7675-16 Extr
6061-T6
2024-T42 Clad
2024-T42 Clad
7675-16 Aly Bar
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2624-142 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
7975-16 Clad
7675-16 Aly Bar
7075-T6 Clad
2924-142 Clad
2624-142 Clad
2024-T42 Clad
2624-142 Clad
2024-T42 Clad
2024-T42 Clad
2924-142 Clad
2624-142 Clad
2024-T42 Clad
7975-16 Clad
7075-T6 Clad
2924-13 Bare
2624-13 Bare
2024-T3
1018 Steel Bar
0.063
43754
0.032
0.020
0.040
9/16x2.00
0.050
0.020
0.020
0.020
0.020
0.020
0.020
0.020
0.020
55-10-20
0.020
0.050
55-10-20 Fig. 206
Fig.
206
3/16x3
0.050
0.020
0.020
0.020
0.020
0.020
0.020
0.020
0.020
0.020
0.050
0.040
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
Fiff.
Fis.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
206
206
206
206
206
206
206
206
206
206
206
206
0.032B
0.032
0.032
0.032
55-10-20 Fig. 212

55-10-20 Fig. 207
and -15
NOTES
For additional
repairs, refer
to 51-r0-00.

thinned areas or refer to applicable drawing numberfor thidcness variations.
Key
to
Model NA 265-40,
Figure 4
(S/N 282-1 thru -53)
55-1 0-00
0
Page 9
3/88
Jun
NA-66-1032
ITEM
NO.
1
DRAWING
NO.
DESCRIPTION
MATERIAL
Skin
Doubler
265-220205
246-22320
246-22320-3
246-22320-7
Beam
Skin
GAUGE OR
EXTRUSION
NO.
7075-T6 Clad
0.125
2624-13 Clad
5052-H39
0.010
REPAIR
FIGURE
NO.
Elevator, TE
Core
3/16x0.001
Honeycomb
3
4
5
6
265-220206
265-220411
246-22311
265-220105
7
8
9
10
11
265-220099
265-220419
265-220098
265-220093
265-220089
265-220034
265-220030
265-220026
265-220022
265-220018
265-220013
265-220420-1
265-220420-2
265-220002-3
265-220416-3, -5,
Weight--Balance
265-220084
13
14
15
265-220080
265-220076
265-220072
16
17
18
19
20
21
22
23
24
265-220068
265-220064
265-220061
265-220057
265-220418
265-220056
265-220052
265-220049
265-220045
25
26
27
265-220041
265-220038
29
30
31
32
33
34
35
36
Stringer
Tip
Rib
Elevator Canted Sta
105.711
Rib
Elevator Sta 99.281
Outbd Hinge
Support
Rib
Elevator Sta 98.369
Rib
Elevator Sta 93.875
Rib
Elevator Sta 89.375
Rib
Elevator Sta 84.875
Rib
Elevator Sta 80.812
Rib
Elevator Sta 76.750
Rib
Elevator Sta 72.688
Rib
Elevator Sta 68.688
Rib
Elevator Sta 64.813
Rib
Elevator Sta 61.062
Rib
Elevator Sta 57.006
Intermediate Hinge
Support
Rib
Elevator Sta 56.094
Rib
Elevator Sta 52.562
Rib
Elevator Sta 49.000
Rib
Elevator Sta 45.375
Rib
Elevator Sta 41.750
Rib
Elevator Sta 38.000
Rib
Elevator Sta 34.125
Rib
Elevator Sta 30.250
Rib
Elevator Sta 26.250
Rib
Elevator Sta 22.250
Rib
Elevator Sta 18.250
Rib
Elevator Sta 13.547
Skin
Elevator, Upper
Skin
Elevator, Lower
Skin
Elevator, LE
12
28
Skin
Doubler
7675-16 Clad
7675-16 Extr
6661-16
2624-142 Clad
0.063
43754
0.032
0.020
2624-142 Clad
7675-16 Aly Bar
2624-143 Clad
2624-124 Clad
2924-142 Clad
2624-142 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2624-142 Clad
0.040
9/16x2.00
0.050
0.025
0.025
0.025
0.025
0.025
0.025
0.025
0.025
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
2024-T42 Clad
0.025
55-10-20
Fig. 206
7675-16 Clad
7675-16 Aly Bar
7975-16 Clad
2624-142 Clad
2924-142 Clad
2624-142 Clad
2624-142 Clad
2924-142 Clad
2624-143 Clad
2634-142 Clad
2624-142 Clad
3924-142 Clad
7075-T6 Clad
7075-T6 Clad
2024-T3 Bare
2624-13 Bare
2024-T3
1018 Steel Bar
0.050
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
Fig. 206
Fig. 206
Fig. 206
Fig. 206
Fig. 206
55-10-20
55-10-20
Fig. 212
Fig. 207
206
206
206
206
206
206
206
206
206
3/16x3
0.050
0.025
0.025
0.025
0.025
0.025
0.025
0.025
0.025
0.025
9.025
0.020
0.032
Fig.
Fig.
206
206
Fig. 206
Fig. 206
Fig. 206
Fig. 206
0.032B
0.032
0.032
and -15
NOTES
For additional
repairs, refer
to 51-r0-00.

thinned areas or refer to applicable drawing numberfor thickness variations.
Key
to
Model NA 265-40,
Figure 4
(S/N 282-54 thru -90)
55-1 0-00
Page
10
Jun 3/88
NA-66-1032
ITEM
NO.
1
2
DRAWING
NO.
MATERIAL
DESCRIPTION
Skin
Doubler
Beam
Elevator, TE
Skin
Core
265-220205
246-22320
246-22320-3
246-22320-7
GAUGE OR
EXTRUSION
NO.
7075-T6 Clad
0.125
2624-13 Clad
5652-1139
0.010
REPAIR
FIGURE
NO.
3/16x0.001
Honeycomb
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
Skin
Doubler
265-220206
265-220411
246-22311
265-220105
Stringer
Tip
265-220099
265-220419
265-220098
265-220093
265-220089
265-220084
265-220080
265-220076
265-220072
265-220068
265-220064
265-220061
265-220057
265-220418
265-220056
265-220052
265-220049
265-220045
265-220041
265-220038
265-220034
265-220030
265-220026
265-220022
265-220018
265-220013
265-220420-1
265-220420-2
265-220002-3
265-220416-3, -5,
Elevator Canted Sta

Rib
105.711
Elevator Sta 99.281
Rib
Outbd Hinge
Support
Elevator Sta 98.369
Rib
Elevator Sta 93.875
Rib
Elevator Sta 89.375
Rib
Elevator Sta 81.875
Rib
Elevator Sta 80.812
Rib
Rib
Elevator Sta 76.750
Elevator Sta 72.688
Rib
Elevator Sta 68.688
Rib
Elevator Sta 64.813
Rib
Elevator Sta 61.062
Rib
Elevator Sta 57.006
Rib
Intermediate Hinge
Support
Elevator Sta 56.094
Rib
Elevator Sta 52.562
Rib
Elevator Sta 49.000
Rib
Elevator Sta 45.375
Rib
Elevator Sta 41.750
Rib
Rib
Elevator Sta 38.000
Elevator Sta 34.125
Rib
Rib
Elevator Sta 30.250
Rib
Elevator Sta 26.250
Elevator Sta 22.250
Rib
Elevator Sta 18.250
Rib
Elevator Sta 13.547
Rib
Skin
Elevator, Upper
Skin
Elevator, Lower
Skin
Elevator, LE
Balance
Weight
7075-T6 Clad
7075-T6 Extr
6061-T6
2624-142 Clad
0.063
2024-T42 Clad
7075-T6 Aly Bar
2924-142 Clad
2924-142 Clad
2024-T42 Clad
2024-T42 Clad
2624-142 Clad
2924-142 Clad
2924-142 Clad
2024-T42 Clad
2024-T42 Clad
2624-142 Clad
7075-T6 Clad
7675-16 Aly Bar
7675-16 Clad
2924-142 Clad
2024-T42 Clad
2924-142 Clad
2624-142 Clad
2924-142 Clad
2024-T42 Clad
2924-142 Clad
2924-142 Clad
2024-T42 Clad
7975-16 Clad
7975-16 Clad
2024-T3 Bare
2024-T3 Bare
2024-T3
1018 Steel Bar
0.040
43754
0.032
0.020
9/16x2.00
55-10-20
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
Fig. 206
Fig. 206
Fig. 206
Fig. 206
Fig. 206
Fig. 206
Fig. 206
Fig. 206
Fig. 206
Fig. 206
Fig. 206
55-10-20
0.050
0.025
0.025
55-10-20
55-10-20
55-10-20
55-10-20
0.025
0.025
0.032
0.032
55-10-20
55-10-20
55-10-20
55-10-20
0.032
0.032
0.032
206
206
206
206
206
206
206
206
206
206
0.050
13/16x3
0.050
0.032
0.032
0.032
0.032
0.032
0.032
0.032
0.025
0.025
0.025
0.025
0.032
0.032
0.032
0.032
O
55-10-20 Fig. 212
55-10-20 Fig. 207
and -15
NOTES
For additional
repair~ refer
to 51-r0-00.

thinned areas or refer to applicable drawing numberfor thickness variations.
Key
to
Figure
IModel NA 265-40, (S/N 282-1 thru -53, changed by

S/L 66-10, 282-91 and Subs), -60, -60A, and -60SC
55-1 0-00
Page
0
11
Jun 3/88
NA-66-1032
FRAME ASSEMBLY
DRAWING NO. 265-220002
00
INDEX NUMBERS CORAESPONO TO

ITEM NUMBERS IN THE KEY
678
38
11
36
34
39
37
32
I I Y~7?LA
35
30
33
28
26
24
29
27
22
25
20
23
18
21
19
16
5370-3-37
55-1 0-00
Paae IZ
Aua 17/84
Elevator
Kepair Index
Model NA
eruffiF07-562
5
NA-66-1032
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
GAUGE OR
EXTRUSION
DRAWING
NO.
265-220405
265220002-17
265-220416
265-220420-5
265-220420-6
370-220205-1
370-220250-3
370-220256
246-22320-41
246-22320-25
246-22320-27
265-220206-3
265-220411-1
246-22311
265-220105-21
265-220099
265-220429-3
265-220098
265-220093-31
265-22089-31
265-220084-31
265-220080-31
265-220076-31
265-220072-41
265-220068-41
265-220064-41
265-220061-41
265-220057-11
285-220418-3
265-220056
265-220052-41
265-220049-41
265-220045-41
265-220041-41
265-220038-41
265-220034-41
265-220030-41
265-220026-31
370-220022-11
370-220018-11
370-220013-11
DESCRIPTION
Elevator
Torque Tube
Skin
Elevator LE
Balance
Weight
Skin
Elevator, Upper
Skin
Elevator, Lower
Doubler
Skin
Beam
Elevator
Inbd
Rib
Elevator
Canted, Inbd
Trailing Edge
Skin
Doubler
2024-T4 Tube
2024T42 Bare
1018-Steel Bar
2024-T3 Bare
2024-T3 Bare
7075-T6 Clad
17-7PH CRES
2024-T42 Clad
NO.
0.109 Wall
0.050
55-10-20
Fig.
212
55-10-20
Fig. 206
(1
0.032a
0.032
0.125
0.063
0.040
Elevator
Honeycomb Core
-2
MATERIAL
REPAIR
FIGURE
NO.
Skin
Stringer
Elevator
Tip
Rib
Rib
Elevator Sta 105.711

Elevator Sta 99.281
Otbd Hinge
Support
Rib
Elevator Sta 98.369
Rib
Elevator Sta 93.875
Rib
Elevator Sta 89.375
Rib
Elevator Sta 84.875
Rib
Elevator Sta 80.812
Rib
Elevator Sta 76.750
Rib
Elevator Sta 72.688
Rib
Elevator Sta 68.688
Rib
Elevator Sta 64.813
Rib
Elevator Sta 61.062
Rib
Elevator Sta 57.006
Intermediate Hinge
Support
Rib
Elevator Sta 56.094
Rib
Elevator Sta 52.562
Rib
Elevator Sta 49.000
Rib
Elevator Sta 45.375
Rib
Elevator Sta 41.750
Rib
Elevator Sta 38.000
Rib
Elevator Sta 34.125
Rib
Elevator Sta 30.250
Rib
Elevator Sta 26.250
Rib
Elevator Sta 22.250
Rib
Elevator Sta 18.250
Rib
Elevator Sta 13.547
2024-T3 Clad
5052-H39 Al
0.010
3/16 x0.001
4130 Steel Sht.

7075-T6 Al Extr
6061-T-6
2024-T42 Clad
2024-T42 Clad
7075-T6 Al Bar
0.050
43754
0.032
0.020 O
0.040
0.500
0.050
0.025
0.025
0.025
0.025
0.025
0.032
0.032
0.032
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
0.032
55-10-20
0.050
Die Forge
55-10-20
55-10-20
55-10-20
55-10-20
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42
Clad
Clad
Clad
Clad
Clad
Clad
Clad
Clad
Clad
2024-T42
2024-T42
2024-T42
2024-T42
2024-T42 Clad
7075-T6 Clad
7075-T6 Al
7075-T6 Clad
2024-T42 Clad
2024-T42 Clad
2924-142 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
7075-T6 Clad
7075-T6 Clad
0.050
0.032
0.032
0.032
0.032
0.032
0.032
0.032
0.025
0.025
0.020
0.040
Fig. 204
55-10-20Fig.203
55-10-20
55-10-20
Fig. 206
Fig. 206
Fig. 208
Fig. 206
Fig. 206
Fig. 206
Fig. 206
Fig. 206
Fig. 206
Fig. 206
Fig. 206
Fiff. 206
Fig. 206
Fig. 206
Fig. 208
Fig. 206
Fig. 206
Fig. 206
Fig. 206
Fig. 206
Fig. 206
Fig. 206
Fig. 206
Fig. 206
Fig. 206
55-10-20
Fig. 206
55-10-20
Fig.
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
206
NOTES
Foradditionalre?lairs, referto51-r0-00.
This is a ehem-milled part. Measure

thinned areas or refer to a2~plicable drawing numberfor thielcness variations.
Key to Figure 5
Model NA 265-70
55-1 0-00
0
Page 13
3/88
Jun
NA-66-1032
STRUCTURAL REPAIR LMANUAL
00
INDEX NUMBERSCDRRESPBNDTD
THE ITEM NUMBERS IN THE KEY
I--~
678
42
41
i
40
38
36
39
11
34
37
32
35
30
33
28
31
26
29
24
27
22
25
20
23
Is
21
19
16
17
55-1 0-00
Page 14
Aug. 17/84
Elevator
Itepair Index
14
1
12
Model NA 265-65, -80, -80A, and
eru~piFCS086
NA-66-1032
IiEM
DRAWING
NO.
NO.
6
7
8
265-220006
265-220002-43
265-220416
265-220420-7
265-220420-8
330-220016-1 &-2
380-220250-3
380-220014-3
380-220320-11&-21
1
2
3
4
5
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
~23
34
35
36
37
38
39
40
41
42
380-220320-3
380-220320-7
265-220206-3
265-220411-3 g~-4
246-22311
265-220105-21
265-220099
265-220429-3
265-220098
265-220093-31
265-220089-31
265-220084-31
265-220080-31
265-220076-31
265-220072-41
265-220068-41
265-220064-41
265-220061-41
265-220057-11
285-220418-3
265-220056
265-220052-41
265-220049-41
265-220045-41
265-220041-41
265-220038-41
265-220034-41
265-220030-51
265-220026-41
380-220022-11
380-220018-11
380-220010-11
380-220011-11
380-220012-11
380-220013-11
MATERIAL
DESCRIPTION
Elevator
Elevator LE
Balance
Torque Tube
Skin
Weight
Skin
Elevator, Upper
Skin
Elevator, Lower
Skin
Doubler
Beam
Elevator, Inbd
Rib
Elevator, Canted, Inbd
TrailingEdge, Elevator
2024-T4 Tube
2024-142 Bare
10l&Steel Bar
2024-T3 Bare
2024-13 Bare
7075-16 Clad
17-7PH CRES
2024-T42 Clad
Skin
Stringer
Elevator
Elevator Sta 105.711
Elevator Sta 99.281
Outbd Hinge
Support
Elevator Sta 98.369
Rib
Elevator Sta 93.875
Rib
Elevator Sta 89.375
Rib
Elevator Sta 84.875
Rib
Elevator Sta 80.812
Rib
Tip
Rib
Rib
Elevator Sta 76.750

Elevator Sta 72.688
Elevator Sta 68.688
Elevator Sta 64.813
Elevator Sta 61.062
Elevator Sta 57.006
Intermediate Hinge
Support
Elevator Sta 56.094
Rib
Elevator Sta 52.562
Rib
Elevator Sta 49.000
Rib
Elevator Sta 45.375
Rib
Elevator Sta 41.750
Rib
Elevator Sta 38.000
Rib
Elevator Sta 34.125
Rib
Elevator Sta 30.250
Rib
Elevator Sta 26.250
Rib
Elevator Sta 22.250
Rib
Elevator Sta 18.540
Rib
Elevator Sta 14.830
Rib
Elevator Sta 11.120
Rib
Elevator Sta 6.744
Rib
Elevator Sta 2.120
Rib
Rib
Rib
Rib
Rib
Rib
Rib
4130 Steel Sht.

7075-T6 81 Extr
6061-T6 Forging
2024-T42 Clad
2024-T42 Clad
7075-16 Al Bar
2024-142 Clad
2024-142 Clad
2624-142 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2624-142 Clad
2024-T42 Clad
2024-142 Clad
2024-T42 Clad
7675-16 Clad
7675-16 Al
7075-T6 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2924-142 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
7075-T6 Clad
7075-T6 Clad
2024-T42 Clad
7075-T6 Clad
7075-T6 Clad
212
55-10-20
Fig.
55-10-20
Fig. 206
0.032
0.032
0.032
0.063
0.040
3/16
Honeycomb Core
REPAIR
FIGURE
NO.
0.109 WOll
0.050
2024-T3 Clad
Skin
Doubler
GAUGE OR
EXTRUSION
NO.
01 .0 10.
0.050
43754
0.032
0.020
0.040
0.500
0.050
0.025
0.025
0.025
0.025
0.025
0.032
0.032
0.032
0.032
0.050
Die Forge
0.050
0.032
0.032
0.032
0.032
0.032
0.032
0.032
0.025
0.025
0.025
0.025
0.025
0.020
0.040
617h60Fig203
55-10-20 Fig. 206

55-10-20 Fig. 206
55-10-20 Fig. 208
55-10-20 Fig. 206
55-10-20 Fig. 206
55-10-20 Fig. 206
55-10-20 Fig. 206
55-10-20 Fig. 206
55-10-20 Fig. 206
55-10-20 Fig. 206
55-10-20 Fig. 206
55-10-20 Fig. 206
55-10-20 Fig. 206
55-10-20 Fig. 206
55-10-20 Fig. 208
55-10-20 Fig. 206
55-10-20 Fig. 206
55-10-20 Fig. 206
55-10-20 Fig. 206
55-10-20 Fig. 206
55-10-20 Fig. 206
55-10-20 Fig. 206
55-10-20 Fig. 206
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
55-10-20
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
206
206
206
206
206
206
206
NOTES
For additional
repairs, refer
to 51-r0-00.

thinned areas or refer to applicable drawing numberfor thickness variation.
Key
to
Figure
55-1 0-00
0
Page 15/16 Blank

Jun 3/88
NA-66-1032
HORIZONTAL STABILIZERS
REPAIR
GENERAL
This section contains repairs for the horizontal stabilizer.
For applicability of repairs, refer to 55-00-00.
ELEVATOR STATIC BALANCING

When a repair is done on the elevator it is necessary that
the surface be static balance checked. All repaired elevators must be rebalanced. The procedure for balancing
elevators is given on page 227. The procedure for the
addition of weights is given in figures 209 thru 212.
55-1 0-20
Page 201
0
Mar 16/90
NA-66-1032
RIYET-8KII-TO-STRIWBEA
MSPOOOIAOS IIO OF STA 70.258:
8820801404 AT, ANO OUTBO OF,
RIVET-REFER TO TABLE 201 FOR
REOUIREMENTS.
STA 70.258, LFER TO NOTES FOR PERMISSIBLE

SUBSTITUTE FISTEIERS.)
o_~--I1_
-t~---"
3
snmn~r,l
OOURLER
-e
LE SKIN
7/161TVPI
~I
3-
LE REPAIR
SKIN
-e
-t
-t-
7/8
n-lJOINTSPLICE
7/8(7181
TABLE 201
SKIN
IREF)
SKIWTOREPAIR-DOUBLEA
1/4 MIW
FASTENER
RIVET CL
STRINGER
ITYP)
AIVETIWG
NO.OFROwSREOO
8820428405
082248-5
F1O4 JO-BOLT
OIMPLE SKINS--CSK REPAIR OOUBLER

1/4 MIN
(TYP)
REPAIR OOUBLER
LE SKIN
--L/
STRINGER IAEF--TYP)
JOOOLE AS
REOO
SECTION
BI
O
Trim
A-A
caornrro,
damage midway between existing fasteners
Fabricate repa
doubler
(or doub ers)
and
repair
skin section.
O
O
Install
repair parts
Refinish
repair
as
shown
to match
ourrounding
areas.
NOTES
REPAIR OOUBLER-0.040 2024-73 CLAO
THIS REPAIR IS APPLICABLE TO ALL AREAS OF THE

HORIZONTAL STABILIZER LEADING EDGE.
A COMPLETE SKIN SPLICE IS SHOWN; HOWEVER, ANY
SMALLER REPAIR INCORPORATING A ONE-PIECE
DOUBLER MAY BE MADE, USING THE REPAIR DATA
REPAIR SKIN--0.032
202473 CLAO
GIVEN.
CR178 OR CR2248 RIVETS MAY BE SUBSTITUTED, SIZE

FOR SIZE, FOR THE RIVET CALLED OUT FOR SKIN-TO-
STRINGER RIVETING.
szes-s-les
55-1 0-20
Page
Horizontal Stabilizer Leading Edge Skin
erugiFsriapeR
201
202
Aug 17/84
COPYRIGHT,
NA-Gfi-103~
II~tAIR MASI.4I~
LEADING EDGE
ale
IREFI
SKIN IREFI
REP~IRANGLE
REPAIR DOUBLER
UPPER SKIN
REAR BEAM
WEB
0\
RB
__1
olO_O
\~_______
fS
-~\\tS
9C~O
O_C~ SHIM
(~7\0
t
fS
)r+
t
L9-$$
fit
t i
C"~"
I
O:
C llr;4 REPAIR
DOUBLER
tld+
-;B
at
kL~
RIVET--MS20428A05-2 ROWS
REOO EA SIDE
~1
RIVET-MS20470A05-6 REDO THRU

REPAIR ANGLE
IMlNI REDO EA SIOE OF

SPLICE. DIMPLE SKINS.
CSK REPAIR ANGLE.
SKIN AND BDUBLER."
REMOVED FASTENERALL PLACES.
SKIN
AIVET--CR22485--
OF SPLICE. DIMPLE
RIVET--TO MATCH
REPAIR
SHIM
TRIM DAMAGE
4--
+i-!cl:$
Q
STRING~R
MIDWAY BETWEEN
EXISTING FASTENERS.
SKIN
000
1
1/1-
--~-kl
-C
ol
3/8 (TYP)
f
-e
og
Oo,
IRE~I 7
ANO BEAM
WEB.
REPAIR SKIN
klr
SECTION
STRINGER
A-A
JOGGLE AS
REDO.
REPAIR DDURLER
SECTION
REPAIR ANGLE
B-B
RIIR 1LIM
REPAIR SKIN--
O
O
0.025
Remove close-out skin fasteners
~i
as
ERAB3T-420
required
oft damsgsd skin,
repair parts,
O
O
P.me
(nstall
fasteners
repair parts
as
88151-0.032
2024-73 CLAD
repair parfs and replace closs-oul skin-
applicable.
UPPER SKIH
areaP.
REPAIR ANGLE--
0.050 2024-74
EXTRUSION
NOTES
EI
THIS REPAIR IS APPLCIAELE TO THE HORIZONTAL
STABILIZER UPPER SKIN OUTED OF STATION
~e
ale
ANY SMALLER REPAIR
EVER. LIMITED TO AREAS WHERE THE SKIN IS 0.025 IN.,

CONSTANT.
STRINGER
LEADING EDGE
SKIN IREFI
REPAIR OOUBLER--
0.032 2624-73 CLAD
REPAIR ANGLE MAY BE MADS FROM 0.050 IN. 2024-0,

HEAT-TREATED TO THE -T4 CONDITION AFTER
FOAMING.
Horizontal Stabilizer Upper and Lower Skin Repairs

0
IREF]
INCORPORATING A ONE-PIECE
DOUBLER CAN BE MADE, USING THE DATA PRESENTED. SMALLER REPAIRS ARE NOT LIMITED TO
AREAS OUTED OF STATION 70.256. THEY ARE, HOW-
REAR BEAM
70.256
5265-3-197
55-10-20
Page ~03
Auff 17/84
NA-66-1032
STRCCTURAL REPAIR MANUAL
TRIM DAMAGE
REPAIR SKIN
MIDWAY BETWEEN
EXISTING FASTENERS.
--I
I
I
ale IREF]
RIYET--TO MATCH
REAR BEAM
REMOVEO FASTEIER-ALLPLACES.
+f+
/t
-Co
-1
lolo
i-T7
lo,
t-
+;f~$l
Ilnrl
SNIM
\o
cl/
~1
RIB
o
2 ROWS
SKIN
REOO TRRU
REPAIR ANGLE
ANB BEAM WEB.
IREFJ
REPAIR
JOOGLE AS
REDO.
A-A
BEC7ION
MS20470008--
SKINS 410 REPAIR OOUBLER.
STRINGER
(REFJ
RILT
REDO EA SIBE
OF SPLICE. OIIYIPLE
LEABINOEOOE
SKIN
+I+lo
117YPI
LOWER SKIN
+1161B
1-
jo
ooo
SHIM
f;9
~t
BLls;1CC
fI
REPAIR
~19
C+
WE~B
Ar~ I+
i3/slrvp,
9/
1
REAR BEAM
7~----- BEAR BEAM
ANGLE
REPAIR DOUBLER
1
SKIN
SECTION
CI
Remove close-out
necessary for
O
O
O
Trim off
0.063 2021-73
CLAO
damaged
ail
R~PIIRIWGLE-2024-r4 ERRUSIOI
UPPER SKIN (REF)
repair panr
REARBEAM
repair part.
Install
as
REPAIR DOUBLER--
as
access.
FaDricale
Prime
(upper) skin fasteners
B-B
repair parts
applicable.
Retinilh
repair
and
to march
replace close-out skinRIB
surrounding
LOWER
SKIW
(REF)
88111-0.003
arsaa
2024-T3 CLAO--
28EO0
NOTES
THIS REPAIR
IS APPLICABLE TO THE HORIZONTAL
S1ABILIZER LOWER SKIN OUTED OF STATION 56.144
ANY SMALLER REPAIR INCORPORATING A ONE-PIECE

DOUBLER
CAN
BE
MADE,
USING
THE
DATA
PRE-
BEPAIR 8818
20141T3:8A8E
SENTED
0.080
s?ss-a-~ea
55-1 0-20
Page 204
Aug 17/84
Horizontal~Stabilizer
Figure
Upper and:lower Skin Repairs

202 (Sheet:e of 2)
o
CO~I;GHT, 1984 BY SABRELINER CORPORATION
NA-GCi-I 0.72
STKUCIIIRAI, KE:IAIH
(i O
1/2 DISTANCE BETWIEEW
ITYPI
EXISTING FASTENERS
,I
RADIUS AS
./rllr
0.025 2024-73
FILLER
I$l
I
\~-Ce
Y
II
t(S
II~
-t
-t
Ilm
1/2-18. RADIUS ON ALL CORNERS,
SAWCUT TERMINATION In O.Oee HOLE

Iti EXACT CENTER Of OOUOLER.
II;1
x/
1101
RIVETS
082248-4
C~
0-.020 5059 1/2 H, TYPE 301 CHES SHEET
OOUBLER
TRIMOUT DAMAGE MIDWAY BETWEEN EXISTING RIYETS
+1
II
-t
REOUIREO FOR DOUBLER. RAOIUS MUST BE
LESS THAN DIAGONAL DIMENSION OF OAMAOE CUTOUT
II
3/8 0062 DISTANCE (TYP ILL NEW FASTENERSI
DOUBLER MUST PICK UP TWO GOOD RIVETS

EACH SIDE OF DAMAGE
1/2 RADIUS OF OOUBLEH
SAME AS RADIUS OF DOUBLER
REPAIRING ONE CRACKED DIMPLE OR TWO CRACKED DIMPLES IN SUCCESSION FOR MS2O426AD4 RIVETS
ATTACHING RIBS RWETWEEN FWD STRINGER AND REAR SPAR IN CONSTANT-GAUGE SKINS
P
~I
,abr c.s doubier to dimensions
Saw-cut doubler
as
given
shown to allow installation
skin cutout.
through
ORemove
rmDimple
rivets that will
existing
be
picked up by
doubler.
OPosition
OLay
O
over
existing
out and
damaged
holes. Drill hales in
pilot-drill added rival
doubler
as
guide,
drill
holes
through
added rivet
through
holes in doubler to locate rivet holes in skin.
Prime all
II"
Cut out
damaged
area
of skin to size shown.
Fabricate liller to match size of
use
draw-dimpling
repair parts
method.
with epoxy
doubler in
position.
through skin and rib if required
IED
Cp
Install CR2248-4 rivets
Install fi lier,
doubler and
O
O
skin. doubler. and filler for CR2248-4 rivets
dimple skin,
polyamide primer.
Install doubler between rib and skin,
rivet locations.
only.
Using
To
(rm
doubler
doubler to match
doubler
Temporarily attach filler to doubler, using existing

locations. Lay out and pilot-drill rivet locations
through filler and doubler.
damage
ED
Refinish
repair
saw
cut to
to install doubler.
through
using CR2248-4
through filler
using
Remove additional rivets
skin and doubler.
rivets
through
tiller and
and rib.
to match
surrounding
area
cutout. Skin
gap tolerance between filler and skin is O to 1/16 in.
Position filler in
damage
cutout and
pick
up
existing
rivet holes in rib.

5370-3-611\
Repairing Cracked DimDles in Horizontal Stabilizer Upper Skins

Fiffure 203 (Sheet 1 of 4)
COPYRIGHT, 1984 BY SABRELINfR CORPORATION
55-1 0-20
Page 205
Aug 17/84
NA-66-1032
OOUBLER MUST PICK UP TWO 6000 RIVETS
EACH SIDE OF OAMIIGE
1 /2 DISTAIICE BETWEEn
ExlsnwomsTErERslTvP1
RADIUS AS REOUIRED FOR DOUBLER.

RADIUS MUST BE LESS THAn
ol
ri)I
/X
0.020 5056 1/2 H,
TYPE 301 CRES SHEET
tX
DOUBLER
-t
x
I
I
II~I
I,
SAWCUTTERMIWAtlnGIN
0.098 HOLE In EXACT CEnTER

OF DOUBLER
:I I
I$
-t
-t-t
II I
+I
I,x
*lili
x
0.025 2024-T3
3/8 EDGE DISTAnCL

(TYP ALL FASTEnERSJ
082248-4
RIVETS
FILLER
1/32
1-3/8
TRIM OUT OAMAOE MIDWAY BETWEEII
1-1/2(TYP)
211/11
EXISTIWG MSTEWERS
1/2.11. IIIIUS OW I1L EORWPRS.
-t)
REPAIRING THREE SUCCESSIVE CRACKED DIMPLES FOR Y520428*04 RIVETS

BETWEEN FWD STRINGER AND REAR 88481-16 %ONSTANTCIAOE 881818
Fabricate doubler to dimansions
Position
given
plug in damage
cutout and
pick up existing
rivet holes in rib.
Saw-cut doubler
rough skin
as
shown
to allow
installation
IJB.:Temporarily
cutout.
attach filler to doubler,
rivet hole locations.
Remove
existing rivets
that will
be
picked
up
rivet locations
by
ler.
F.OlilWn
doUblBrWBrbBm.gsd holes.Ths~
through filler
Lay
out and
using the three

pilot-drill added
and doubler.
Dimple skin, doubler, and filler for CR2248-4 rivets.

use draw-dimpling method.
Todimple skin,
[IB&in snw-cut
terminating hole should be centered over the middle

damaged hole Drill holes in doubler to match existing rivet
Prime all repair parts with spoxy po yamide primer.
locations
ilnstall doublerbetween rib and skin,

ay out and
pilot-drill
added
rivet
holes
through skin
Cising doubler
as
guide,
drill
through
out
damaged
area of skin to s /e
Fabricate tiller to match
gap tolerance between
plug
s ~e
of
cutout
cut to
and rib if
required
to install doubler.
install CA224M rivets through skin and doubisr.
lilies using CRP2484 rivets thraugh tiller and

doubler and through filler and rib.
Ehrrwn.
damage
saw
P~
OQ~n.lall
added rivet
in doubler to locate rivet holes in skin.
O(U1
O
using
doubler in position. Remove additional rivets
through
SL
CQRB(ini.h
repair
to match
surrounding
area
and skin is O to 1/16 in
N01~
IF MORE THAN THREE DIMPLES ARE CRACKED IN A
ROW.
USE
STANDARD
CONSTANT--GAGE
SKIN
8370-3-61*
REPAIR.
55-1 0-20
Paae 206
Auff 17/84
Repairing Cracked I)imples in Hori~ontal Stabilizer UpperSkins

Figure 203 (Sheb: of 4)
198 BY SiaBRELINER CORPORATION
NA-66-10~2
FORWARD STRINGER
,u,
-tl
FORWARD EDGE OF OOURLER ALONG STRINGER.
/-c----------~------
-I
~t-
-t-
OOUBLER MUST PICK UP THREE 6000 EXISTIIG RIVETS ON
4
-t
I
I
InPORIIL10
STOPDRILLEO
RADIIIL CRACK
I/
0.020 5059 1/2 H. TYPE 301 ORES SHEET
i REU.E*TIC CRIEI
OOUBLER
OOURLER MUST PICK UP TWO 6000 EXISTING RIVETS ON

AFT END OE OOURLER.
II+I
3/8 EDGE DISTANCE (TYP ALL FASTENERSJ

LEGENO
~E3
INOICLITES 082248-4 RIVETS
CB
INDICATES 082248-5 RIVETS
RADIALLY CRACKED DIMPLE OR TWO CIRCUMFERENTIALLY CRACKED DIMPLES FOR MS20426AD4 RIVETS
REPAIR OF ONE
AT RIB INTERSECTION WITH FWD STRINGER IN CONSTANTGAGE SKIN
O
~J
Slo~driil
all CrsCks Vith a No. ~O
ODrl
10 098in)drill
approximate Size. Doubler must

good existing fasteners on aft end of doubler
and three good existing fasteners on fwd edge of doubler
along stringer.
pick
O
O
through exinting
9rtenei
ocalons
to
locate
fastener holes in doubler.

Fabricate doubler to
up two
Rpmaue a~l
laptsnerJ
SI de doubler in
to be
picked
up
dimple fastener holesindoubler

existing fastener dimple diameters. Trim to correct
size, allowing 3/8-in. edge distance on all fasteners.
10
by doubler.
place bet*sen damaged skin.nd
tq
rib
Remove doUbler and
to match
Prime d~ub er lui(h spoxy
Rsinat.ll
polysmide primer
doubler between damaged
Install fasteners
as
skin
and
rib.
indicated.
NOTES
RADIAL CRACKS ARE NOT TO EXCEED ONE HALF THE
DISTANCE BETWEEN FASTENERS. IF MORE THAN ONE
DIMPLE IS RADIALLY CRACKED ON ANY RIB FASTENER
ROW, A STANDARD REPAIR FOR CONSTANT-rTHICKNESS

SKINS MUST BE MADE.
CIRCUMFERENTIAL CRACKS ARE NOT TO EXCEED 3/8

IN IN LENGTH. TWO CIRCUMFERENTIAL CRACKS MAY
BE REPAIRED ON EACH RIB.
S370-3-63P~
Repairing Cracked Dimples in Horizontal Stabilizer Upper Skin

55-1 0-20
Page 207
Aug 17/84
NA-66-1032
SrKII(TUKAL REPAIK MANUAL
3/8 EDOE DISTANCE
(TYP
FAST~REASI
ALL
DOUBLER MUST PICK UP TWO 0000810013

FWOOFOAMIGEDSKIN.
Ilfi
1~-h
fj
DOUBLER
0.020 5059 1/2 H. TYPE 301
CRES SHEET
RADIAL CRACK
STOP-GRILLED
CIRCUMFERE)ITIAL CRACK
STOP-ORILLLO
Il
~II
PICKUP THREE GOOORIVETS ON AFT EOGE
OIIOUBURUOYCIIII.II
r-------?-~ILEGEND
INDICATES CR2248-4 RIVET
INDICATES 8431870-088 JOBOLT

822042880-4 RIVET
REPAIR FOR ONE RADIALLY CRACKED DIMPLE OR

AT HORIZONTAL STABILIZER
I/
O
Stop-dlill
crae(is with
No. 40
(DDgs-inJ
TWO CIRCUMFERENTIALLY CRACKED DIMPLES

TRAILIN6, eoaE Jo-BoiT PAGTENERS
dri I
through existing fastener locations
to
locate
fastener holes in doubler.

Fabricate daubls* to
approximate s.e Ooubler mupl

good existing fasteners of damaged fastener
holes and three good existing fasteners on aft edge of
dotlbler along rear spar,
[YRBmove
E1Remove
O
OiPi
pick up
two
sil Isstsner. fu be
S ide doubler in
picx.d
up
by doub
plaoe between damaged
doubler and dimple faotener Aules in doubler
to match
existing fastener dimple diameters. Trim to correct

size, allowing 3/8-in. edge distance on all fasteners.
er
ms doub
IS~Rei.lBII
nlin and rib.
~ii;jtall
arw
th apoxy
palyem
de
primer
doubler between damaged .Xin and
fasteners
as
rib
indicated.
NOTES
HADIAL CRACKS ARE NOT TO EXCEED ONE HALF THE
DISTANCE BETWEEN FASTENERS. IF MORE THAN ONE
DIMPLE IS RADIALLY CRACKED ON ANY RIB FASTENER
ROW. A STANDARD REPAIR FOR CONSTANT--THICKNESS

SKINS MUST BE MADE
CIRCUMFERENTIAL CRACKS ARE NOT TO EXCEED 3/8

IN
IN LENGTH. TWO CIRCUMFERENTIAL CRACKS MAY
BE REPAIRED ON EACH RIB
8310-304*
55-1 0-20
Pag~(tB08
Auff 17/84
Repairinff Cracked Dimples in aorizo~l Stabilizer Upper Skin

COPV"RIGMT, 1984 BY SABRELINER GORPORATION
NA-66-1032
SIHUCTURAL KEPAIR MANUAI,
RIVETS-AN470AD4-THROUGH
GAMAGEG RIB
AND REPAIR ANGLE. NUMBER OF FASTENERS
STABILIZER SKIN
REOUIREO GEPENGENT ON LENGTH OF REPAIR
FWO STRINGER
ANGLE: PICK UP ORIGINAL CLIP FASTENER HOLES.
DAMAGED RIB
REPAIR ANGLE
AC1
&j
1,
IREFI
i-IN. SPACING
ORIGINAL CLIP
FASTENER LOCATIONS
(MAXJ
EXISTING CLIP (REFJ
33
2 TIMES FASTENER
OIAMETER(TYPI
AI-]
SECTION
A-A
PICK UP EXISTING FASTENER LOCATIONS.

REPLACE ORIGINAL FASTENERS WITH SAME SIZE
STOP--GRILL ALL CRACKS

WITH NO. 4010.000100111 --7
ANG TYPE AS REMGVEO FASTENERS.
_-_Lfi~
DAMAGEO RIB IREF)
REPAIR ANGLE
;TI
VIEW LOOKING DOWN
IREFI
RIVET--TO MATCH REMOVED

FASTENERS. PICK UP TWO
EXISTING LOCATIONS THRU
SKIN, RIB. AND REPAIR ANGLE
EACH SIOE OF OAMAGE.
O
O
Rsmove
existing clip
Slopdi
I all crac~s not
Fabricate
on
repair angle
dsmagsd side ~t ri~
extending
lo rib
REPAIR ANGLf--20240--OWE
GAUGE HEAYIER THAN DAMAGEB RIB.
ilBnOe edge
and heat-treat it to the T42
condition after forming
O
O
P,ime
repair sng
(nslall
repair angle
as
DAMAGED RIB IREFI
shown
NOTE
REPAIR ANGLE MUST NEST SECURELY IN DAMAGED
RIB. TO MAINTAIN PROPER EDGE DISTANCE ON
EXISTING FASTENER LOCATIONS.

9265-3-199

FigureiOl (Sheet 1 of 4)
C;eneral
55-1 0-20
Paffe 209
Aug 17/84
NA-fi6-1032
SIKl!("rlTRAL KEPAIK MANUAL
TRIM OAMAOE MIOWAV BETWEEN

EXISTING FASTENERS.
REPAIR
OOUBLER
RIVET(TYPI
rz
REPAIR RI SECTION
e
_
_I_-
-3~
SHIN
ale
IREF)
SPLICE JOINT
A
-tttt
ti;t
t
Ii
IC
i-
1/18
T+
II
5/8 TO 7/8
REPAIR RIB
SECTION
(TYPI
REPAIR
DOUBLER
1 TO 1-1/2
(TYP)
II
-f
-C
ff
;t
JOOOLE AS
II
II
+tt
t
~I
ITYP)
tl_t_-t~
le
i-
REPAIR OOUBLER
SECTION
RIVET--MS20470A06-2 ROWS REOUIREO THRU

REPAIR DOUBLER
OVERLAP
AIYET--MS20470A05-11 REOUIREO IL6W6

EACH RIB FLANGE.
I
I
EACH SIOE OF DAMAGE

AS SHOWN
O
O
O
T42
ir
otl
damaged
Fslicate
psrl.
T6 condition
insl.ll
A-A
REPAIR RIB SECTION;

MATERIAL ANO 68668
TO MATCHORIOINAL
MATERIAL
IPIB
repair palls
Hesl-lreal
or
rib end
REOO.
I TO 1-1/2
-II
made from anneslsd material to Ihe
as
applicable.
iepair pans
NOTE
RIB REPAIR OOUBLER--
MATERIAL TO MATCH
THIS REPAIR IS APPLICABLE TO HORIZONTAL STA-
OAMAOEO RIB. THICKNESS

18 ONE GAUGE HEAVIER.
BILIZER RIBS LISTED IN THE FASTENER TABLE ON

DATA
IN THE
FASTENER TABLE,
(OTHER
HOWEVER, DOES NOT APPLY TO THIS SPLICE.)
SHEET 4.
82(18-3-200
55-1 0-20
Page 210
Auff 17/84
Horizontal Stabilizer Rib Repairs-- General

o
COPYRIGHT, 1984
NA-66-1032
STRUCTUKAL KEPAIR MA~UAL
STOP-GRILL ENG
OF CRACK WITH
NO 30 GRILL ITYP)
OAMAGEG RIB
Ar
r?-
RIVET--TO MATCH
REMOVEOFASTENER
ITYPI
REPAIR ANGLE
rr~B
..i
____/-
-e
COUNT RIVETS
SKIN
-----~lt---
(REFI
3/32
REOUIREO
THAN 3/32. USE
EACH SIOE OF OAMAOE
ALTERNATE REPAIR
ITYP)
IMIN1 TO BENO
RAOIUS WHEN LESS
SKIN
3-
3-
5/B(MIN)
-7Ctl
REPAIR
ANGLE
SECTIONAA
FIITI~I
PREFERRED REP~IR
OAMAOEO RIB 7
REPAIR STRAP
REPAIR STAAP-MATERIAL ANO
GAUGE TO MATCH
GAMAGEG RIB
SKIII
I-.
3-
-t
~t
__1
1...
REPAIR ANGLE
51(15
BC~
J-~HII
SECTION DD
~+---t
t-
-1-
3t
REPAIR AHGLEMATERIAL TO MATCH
OAMAGEO RIB
THICKNESS IS ONE
GAUGE HEAVIER
ALTERNATE REPAIR
C)
P
Slop-driil ail cracls
58 REOUIR~O
IVIEWS ROTATED FOR CLARITY)
which terminate Hithin the part.
RIB
Fabricate and insteil
repair patO;.
NOTES
THIS REPAIR IS APPLICABLE TO HORIZONTAL STABILIZER
RIBS LISTED IN THE FASTENERTABLE ON
SHEET 4.
5
USE NESTED
REPAIR ANGLE
MATERIAL TO MATCH
A-A.)
GAMAGEO RIB. THICKNESS

IS OWE GAUGE HEAVIER.
(PREFERRED) REPAIR WHEN SKIN RIVETTO-RIB-WEB DISTANCE IS ADEQUATE. (SEE SECTION
IF CRACK EXTENDS INTO RIB
5265-3-201
WEB, SEE SHEET 4 FOR
REPAIR.

FLsure i04 (Sheet 3 of 4)
0
General
55-1 0-20
Page 211
Aug 17/84
NA-66-1032
CRACK-SHOWIlAS
AN ALTERNATE CONOITION
OAMABEB RIB
IREFEH
FILLER
TO
RIVET-TO MATCH
REMOVED FASTENER /TVP)
NOTES)
REPAIR ANGLE
I
\I
--J~"
----=i~----
c~
SKIN
(REFJ
\j
C-
3/3215110)70
RENO RAOIUS
SKIN
~1
ANB REPAIR WUILEA.
-t
-t
-t
i ~--FILLER
REPAIR
ANOLE
AI-)
(TYPI
c~
RIVET-MS20470A05-REFER TO TABLE FOR

NO, REOUIREO THRU WEB
AC~
FILLER
tf/
e~
I
_I
I----
ii
COUNT RIVETS
FOR TH18 1111
SECTION
PPI
A-A
FASTENER TABLE
8616
O
O
HOR. STAB.
NO, OF MS2O470A05
RIVETS REOUIREO EA
RIB STA
SIDE OF OAMAGE
18.430
29.839
36.415
42.891
48.589
riim gut
8HIM-2024-T4
OR 7075-T8-THICKNESS AS
REOUIREO
REPAIR TRAP-MATEHML4S
7
7
7
58.382
63.200
70.256
77.312
89.368
91.424
98.980
AllO GAUGE TO MATCH

DANIABEO RIB
REPAIR ANGLE
ISAME MI NESTED
REPAIR ANGLE)
7
7
ALTERNATE REPAIR (REFER TO NOTES)
7
7
damage
or
atop-drill
Fabricate and inst.ll
ersca ar
MATCHFIL ER- MATERIAL
applicable
.64066 TO
OAMAOEO RIB
rspair parts
NOTES
AND
RIB
THIS REPAIR IS APPLICABLE TO HORIZONTAL STABI-
LIZER RIB LISTED IN THE FASTENER TABLE.

USE NESTED
(PREFERRED)
REPAIR IWGL~-MATERIAL TO MATCH
REPAIR WHEN SKIN RIVET
TO-RIB-WEB DISTANCE IS ADEOUATE.
(SEE SECTION
A-A.)
BAMAOEO RIB.
THICKNESS IS ONE
OAUGELEAVIER.
WHEN THE RIB DAMAGE IS IN THE NATURE OF A
CRACK, THE END OF THE CRACK SHOULD BE STOPDRILLED AND ALL MATERIAL LEFT IN
PLACE. ALL
OTHER DETAILS OF THE REPAIR SHOWN REMAIN THE

8165-3-202
SAME.
55-1 0-20

Fiffure 204 (Sheet of 4)
(;eneral
PaRc!212
Auff 17/84
NA-Ci(i-1032
0
COUITERBOREBEAM
0.032 BEEF BY 0.900
O
o
IN. OIAMETER
HORIZOITAL
8TI0ILIZEA
CEWTER BEAM IREF)
--I
REAM
OTELOH
0.8130
I-
REPAIR BUSHIIO
MACHIIE FROM
4130 STEEL BAR
0.875=II0.032
1
FLUSH TO-
0.005 BOTH
SIOES OF BEAM
Remove horizontal stabilizercenter beam from airplane

to
applicable
Maintenance
Manual).
Ream horizontal stabilizer attach holes in
beam, then
Machine repair bushing to dimensions shown
neat treat repair bushing to
Cadmium plate
125-145
0.015 R.
;tl
counterbore upper and lower surfaces of beam as shown.

Apply chemical film treatment to all bare surfaces of beam.
O
O
O
O
6.556 TO
0.75001
0.8145
-0.0010~0.0000
KSI.
repair bushing.
Coat bushing with zinc chromate primer and press into

place while primer is still wet.
S265-3-351
erugiFrBushing
iapeR
Horizontal Stabilizer Center Beam

205
55-1 0-20
Page 213
Aug 17/84
NA-66-1032
SKIN
IREFI
RIB
5 RIVET
SPA~ES
TRIM OAMIGE:MIOWAY
BETWEEN EXISTIIIG FASTENERS
(MAx)
(8
-33 1
-L
ii
a>
CD
~CF
a,
cI~
a,
IELGNA

FASTENER
ITYP)
FILLEA
RIVET--M82W70A06-
RIB REPAIR
IREPLACES ORIGINAL
RIB ANGLE)
le
REOUZD EA SIOE
OF
1/4R
ft~
OLMIOE- EXISTINGLOCATIONS
ct;
SKIN
1~0
RIB WEB
-t
I
3/4 MIN
Im~x
RIVET--MS2M70AD5-RIVET-TO MATCH
1 ROW
REMOYEO FASTENER
AROUND FILLER
?B~L
REBUIREB
SKIN
(RKF)
(TYP)
FILLER
REPIIIR,AIBLE
RIB WEB
SECTION
O
O
Remove
original
rib
angle.
FILIER--
Tr
out
MATERIAL ANO
OAUOE TO MATCH
damage
~BbriCilti
repair palls
MILs
Inalerinl and heat-lreat to the
alter
Oynimro~
A-A
repair from
applicable
annea
1 i
eO
~T" condition
6~
Prime repair partr.
Install repa
parts
NOTE
REPALR IWGLE-MATERIAL TO MATCH
THIS REPAIR IS APPLICABLE TO ALL AIR-LOAD RIBS
EXCEPT TnE FIRST TWO INBD RIBS AND THE TIP RIB
ORlOlNAL RNGLE.
ITHlcEnes Is 2
(ELEVATOR STATIONS 13.547, 18.250, AND 105.711).
TIMES THAT OF
WHEN RIB ANGLE IS DAMAGED, REPLACE ANGLE.
ORIOINAL.ANOLE)
55-1 Q-20
PalSe 214
AuK 17/H4
All
11(15-3-203
Elevator Air Load Rib

21)6
erugiFsriapeR
NA-66-1032
STRUCTURAL REFAIR MANUAL
1/2 IN. STEEL WASHER
LOOSE BLIND
5-40 STEEL
BOLT ASSY
SCREW (REFER
TO STEP 1.I ----C-
B8351-6100R
88351-8-10 BLIND
sau
no, i LIROE AAU
BILAYC~ WIICHT
ITYP)
STEEL WASHER
1/2 IREFI
REMOVE SLEEVE HEAD
WITH NO. 10 GRILL.
TAP SLEEVE OUT OF
WEIGHT.
ITYP1
Q ELEVATOR
BLIND BOLT
SLEEVE
LEADING EDGE SKIN
SECTION
BALANCE
----~it-- tt--
A-A
DIMPLED WASHER
WEIGHTACI
(TYPJ
ISEE OETAIL)
/7/L---
BLIND BOLT INSTALLATION
REMOVE CORE BOLT.

INSTALL WASHERS
AHO 5-40 SCREW.

TIGHTEN SCHEW.
(TYPICAL 2 OPPOSITE
CORWPRJ OI WEIGWT
SEE SECTION A-A.I
8032
\I
JItAolNe
REMOVE CORE BOLT.

GRILL AHO REMOVE
SLEEVE, (SEE
SECTION AR.)
EDGE SKIN IREFI
IC
B--~
SLEEVE OIA
B--OAILL SIZE
3/16
5/8
11/16
1/4
MITERIAL--801 1/2 H CRES 1030, 1035, OR 4130 STEEL. HEAT-
BLIND BOLT REMOVAL
TREAT CAHBON ANO ALLOY STEELS TO 125.000 TO 140,000 PSI.
CADMIUM PLATE CARBON ANO ALLOY STEELS.

Remove
core
bolt from two blind bolts
nstall washers and 5-40
firmly against
screws as
COUNTERSUNK WASHER DATA
shown, and draw weight
skin.
Dril o(l sleeve head and tap sleeve oul of
gf
shown.
as
Countersink skin and
weight
we
DRILL 11/32 HOLE

FOR REMOVAL OF
ght
LOWER SKIN
RIB RIVET ROWS
BLIND BOLT SLEEVE
to receive countersunk
AS
washers. Use 88351-6-10 blind bolt if skin cleans up to fit
ITYP]
HEOUIRED
3/16 in countersunk washer. Use 88351-8-10 blind bolt and

1/4 countersunk washer if condition of skin hole
(F-200-10 and F-~BO-lO
requires.
Jo-boll~may be sub3ituted tor
88351-6-10 and 88351-8-10 bolts, respectively,
necessary.)
washer, in
Install Iasteners and
o~=
Drill
blind bolt sleeves.
one
screws
and washers from
Repeat steps
11/32 in, hole in each rib
through
o
O
prepared
holes.
Remove temporary 540
if
O
c
4.
bay affected for
reinbvsl of tapped-out sleeve end Drill hole in lower skin.
5-1/4
(See sketch.)
1
I
BETWEEN
RIBS
NOTES
THIS ILLUSTRATION PROVIDES INSTRUCTIONS FOR
REMOVAL AND REPLACEMENT OF FASTENERS IN

ELEVATOR BALANCE WEIGHTS.
SUHFACE TRAILING
CONTOUR WASHER EDGES TO MATCH LE CONTOUR
EDGE
(REFJ
BEFORE HEAT-TREATING.
S265-3-204
REFER TO SOURCE KEY 020 AND 021 IN 51-30-20.
Replacinn; Fasteneru in Looue Elevator Ralance
erugiFsthRieW
207
55-1 0-20
Iafft ~15
AuR 17/84
NA-66-1032
WUT
REAM 0.3750 +.0005 OIA

2 HOLES IN LINE
REAM 0.2500
+.0005
.W10
2 HOLES IN LINE IF
NECESSARY AFTER
BUSHING INSTL
PRESS PLATE
IJ
ELEVATOR
STA 98.369
BUSHING
(INBol
ELEVATOR
STA OB.PBl
PRESS NUT
BUSHING
INSTALLING INBD BUSHING

IN ELEVATOR OUTBO HINGE
~I
II
,/IOUTBBI
SPIICER
BOLT
51880.3437 t.000501A
PRESS NUT
1,
2 HOLES IN LINE
BEAM 0.3750 f.0005 OIA
HOLE NEAR SIOE ONLY
INSTALLING OUTED BUSHING

IN ELEVATOR OUTED HINGE
PRESS PLATE
ELEVATOR
STA 58.094
BUSHIWO
BOLT
r
ELEVATOR STA
57.006
INSTALLING INBD BUSHING IN

ELEVATOR INTERMEDIATE HINGE
i/
ELEVATOR
STA 56.084
BUSHING
BOLT
SPACER
NC)?~
SLiEi
SHEET
FOR
INSTALLING OUTED BUSHING IN

ELEVATOR INTERMEDIATE HINCE
DETAILS OF BUSHINGS AND
BUSHING INSTALLATION TOOLS.
8370-3-80
55-3 0-20
Paffe 216
AuR 17/84
Elevator, Intermediate and Outboard Hinges, Bushing Repair

o
NA-66-1032
TAP 1/4 6 28-088-38

CGUNTERBGRE 0.500 DIA 11 0.030
WITH 0.030 FILLET RADIUS OF 0.030
0.250
1/2
W
3/4
SECTION
All
4130 STEEL BAR
A-A
-0.213 +0.003
OllLL1)3
-0.001
PRESS PLATE
o.ooo\
/lo .o,
BII
PROJECTION MAY BE
WELOEO OR RIVETEO
B.ZOO
jeli2
IN PLACE
csartnI
\i
IM.030j
0.125
COUNTEH 8086
0.030 11 45
41 30 STEEL BAR
IB(~;B_1
0.260(
SECTION
B-B
YI~ L~ U.II(III
o.olo\
-O.WO/"
PRESS NUT
0.625 GIA
GRILL F
IHOLE
0.257t.004
-0.001
0.2501+.0005)
SPOTFACE 0.500
SPACER
_____
u.jlal
0.2501-1.00051
Ri~olus.0005
CHAMFER
0.030 x .010
/oooa
0.500
0.438(+.010)
t0000
GIA WITH 0.030 FILLET
4130 STEEL BAR
1.oooo
\-.0005
l~t0.0101
U.J4DJ
1_+.010)
\-.M)05
11.3121_+.0101
0.03 I~011R
450
--*I
0.2501_c.00051I
0.140 lf.O101
0.328 (f.O1O1
-----C--rC
0.020
I-c.005)J~if\
0.2701~.0101
fi,i
CHAMFER
0.030
.010
450
Ie-
Itamol~.osol
14- 0.250 (f.0301

lrt.O10)
0.850
OUTBOARD HINGE BUSHING
INTERMEDIATE HINGE BUSHINGS
NOTES
BUSHING MATERIAL IS 4130 STEEL.
DIMENSIONS ARE BEFORE PLATING
HEAT--TREAT BUSHINGS TO 125
140 KSI
CADMIUM PLATE ALL SURFACES EXCEPT l.D.
Elevator, Intermediate and ()utboard HinRes, Hushinff Hepair

FiRure BOA (Sheet of 2)
0
5370-3-81Ci
55-1 0-20
PaRe 217
AuR 17/84
NA-66-1032
8"
1/2"
e
KNIFE
EOOE
12"
Y/C
SCALE
1/4"
or
3/8"
STEEL PLATE
HINGE BOLTS IW
8U8FICE 8E118
STANDS
CHECKED
12" MIW
(I
AOJUST POINTEH YERTICALLY TO COINCIOE WITH

CENTER OF BOLT; THEW POSITION IT AOJACENT TO
SURFACE TRAILING EDGE
NOTES
Inaddition, tothetoolsshown,
will also be required:
thefollowing
Adhesive Tape
Chalk Line
Carpenters Square
Plastic medicine bottle to hold test
weights (Lead Shot)
til
two ea. mag be local mfgfrom

Stands
1/4" steel plate and 1/4"X 1 1/4" X 1 1/4"
steel angle welded together.
POINTER AND STAND
Scaleshouldhave l0lbcapacitll(min)and
be graduated in 1/100 Ib (graduation in 1~
ox.
is
max).
Figure
209
55-1 0-20
Page 218
Mar 16/90
NA-66-1032
SURFACE TRIIILIWO EO6E
Ilft
CL HIWGE
W2
L~fS1
Wa
02
03
WEIGHT OF HEPAIR AFT OF HIIOE LIIE. (HET WEIGHT OF

REPAIR IS THE TOTAL WEIGHT OF REPAIR MIIUS WEIGHT OF
OI--OISTAICE
FROM CG OF
W1
TO CL OF HI1IGE.
AHY REMOVEO MATERIAL.)
02--OISTAWCE
FROM CO OF
WL
TO CL OF HIWGE.
03--01STAHCE
FROM CG OF
Wg TO CL OF
W1--NET
W2--NET
WEIGHT OF REPAIR FWO OF HIWOE LIWE.
W3-WEIOHT
HIIGE.
Of REPAIR OALAHCE WEIGHT.
CA1CULATINO REBALANCE WEIOIII REQUIREMENTS
weight (Wg). Using
the valves
given
in the first
example
and assigning W =0.4 Ib and 0 =2.5 in., the solution is:

The moment (inch-pound effect) of a repair is found by
multiplying the weight of the repair by the moment arm
(distance from CG of repair to the hinge centerline). The
weight of the rebalance weight required to counterbalance
the repair is found by dividing the inch-pound effect of the
repair by the distance from the CG of the rebalance weight
to the hinge centerline.
Considering repair 181 only

181
01
03
3W
in the
sketch, the formula
is
3.
(W,
.5
10.5
W3
(D1)
(W1) (02)
10.51
10.5
1 0.4
2.5
4.25
4.75
0.89 Ib
4.75
(a3)
ALLOWABLE MOMENT OF INERTIA INCREASE
the allowable moment of inertia increase (expressed in Ib
in.2) determines the permirrible extent of repairs in relation
to the total weight that must be added (repair plus rebalance
weight).
EXAMPLE
The moment of inertia increase is the

from each added weight.
(assigning possible numerical values)
rum
of the increases
0.5 Ib
W1
D1=10.5
Referring
in.
4.75 in.
03
to
the aketch, the formul~ would be:
Moment
(W1
D11)
(W?
D12)
(WJ
31)
SOLUTION
Using the values assigned

requirements:
(W, )(D1)
Vilj
0.5
10.5
4.15
5.25
4.75
=1.1 Ib
Mamnt ol
1031
inertia increase
leading edge repair, represented by Wi in the sketch, is

installed simultaneously with the repair represented by W1,
the counterbalancing effect of W2 is subtracted from the
inchpound effect of W1 before solving for the rebalance
If
=(0.5
in
calculating
10.51)+
55.13
2.5
77.W Ib
(0.4
rebalance
weight
1~51)+ (O~gp.4.751)
20.1
in.2
MOMENT OP INERTIA INCREASE LIMITS
See
"Adding
Rebolance
Weights" i-llustrotions
in this
section.
NOTE
CALCULATION MAY BE MADE USING 0.284 POUND PER
CUBIC IN. FOR STEEL ALLOYS AND 0.1 POUND PER
CUBIC IN. FOR ALUMINUM ALLOYS.

s?ss-s-~as
Static Rebalance Calculations
Figure
0
210
55-1 0-20
Page 219
Aug 17/84
NA-66-1032
Dr)
AOOEB REBALANCE WEIGHT

IMAX 1 LB ON 285-240001-51.
MAX .37 LB ON 285-240001-101,
-201,-211- ANO -311 ANH ON 378-240001-11).
AOO REOUIREOIBIILIIICE WEIGHT TO
:RUDDER LOWER RIB. PLACE WEIGHT
IIS FAR FWO AS POSSIBLE. ATTACH
WITH 5/32 IN JO-BOLTS.
RUDDER
NOTES
LOWER BUOOEH
ADDITIONAL REBALANCE WEIGHT MAY
RIB
BE ADDED
THROUGH THE TRIM ACTUATOR ACCESS DOOR.
MAXIMUM MOMENT OF INERTIA INCREASE IS 171 LBS.
IN2
SECTION
D-D
ON 265-240001-51
MAXIMUM MOMENT OF INERTIA INCREASE IS 86 LBS.

IN
ON 265-240001-101. -201. -211. AND -301 AND ON
370-240001-11.
I
REBALANCING DATA FOR MODEL NA 265-40, S/N 282-1

THRU -53, AND AIRPLANES NOT CHANGEO BY S/L 66-16,
NOTES
FOR REPAIR INBD OF ELEVATOR STATION 26.250, ADD
WEIGHT TO INBD RIB

MORE
WEIGHT
IS
(ELEVATOR
NEEDED,
STATION 13.457). IF
ADD
IT
BETWEEN
ELEVATOR STATIONS 30.250 AND 38.000.
FOR REPAIR BETWEEN

AND
ELEVATOR STATIONS 26.250
ELEV 874
80375
64.813, ADD WEIGHT BETWEEN ELEVATOR
STATIONS 30.250 AND 38.000.

FOR REPAIR OUTED OF ELEVATOR STATION 64.813,
IF MORE WEIGHT
ELEV STA
ELEV STA
13.467
30.250
.;1
ADD WEIGHT BETWEEN ELEVATOR STATIONS 80.812

AND 89.375.
ELEV 878
30000
ELEY 874
80.812
!T i i
IS NEEDED, ADD IT
BETWEEN STATIONS 30.250 AND 38.000. THE WEIGHT

ADDED
BETWEEN
THESE
STATIONS
EXCEED TWO THIRDS OF THAT
MUST NOT
REQUIRED
TO
BALANCE THE ALLOWABLEINERTIAINCREASE.
WEIGHT
MAX.IMUM MOMENT OF INTERTIA INCREASE IS 78 LB
i
~LEV STA
84.813
(N.2
ELEY STA
28.250
WEIBHT
REBALANCING DATA FOR MODEL NA 265-40, S/N 282-1

THRU -53, CHANGED BY S/L 66-10, MODEL NA 265-40, S/N
282-54 AND LATER, AND MODEL NA 265-66, -76, AND -60,
WEIGHT
ELEVATOR
NOTES
ON THE ABOVE NOTED AIRPLANES THE ONLY AREA
IS
AT
MAXIMUM MOMENT OF INERTIA INCREASE IS 56 LB.
11\1.2
WHERE
BALANCE
WEIGHTS
MAY
BE
ADDED
ELEVATOR STATION 13.457
a2es-3-~soe
55-10-20
Page 220
Aug 17/84
Atlc~linff KebalanceWeightH
FiRure 211 (Sheet 1 of 6)
o
COPYRIGHT, 1984 BYSABRELINER CORPORATION
NA-66-1032
REBALANCE
WEIGHT
rLrvlron
ill
SKIN IREFj
1)
F200-3JO-BOLTS
4REOUIREO
ni)HT
IF
WslBWT Is LIS~
0.090 IN. THICK, USE
I)/
RIB
(REF)~I
II
8200-3 JO-BOITS.
APPROX 7 SO IN.
IREF)ELEYATOR
III
SKIN
ROOT RIB-ELEVATOR
STATION 13.547
STA 13.547
REBALANCING ELEVATOR
AT STATION 13.457
SCREWS-7330-3A
WASHERS-LO 153-0002-2203
NUTS-MS21D42L3
RIVETS--CR2248-4.
PICK UP EXISTING HOLES
(4 EACH REOUIREO)
IN RIB
16 PLACES)
1-1/8
47/8
RIVETS-MS20428A04,
2 ROWS
(STAGGEREO SPACING)
r
1
ct
c~
II
IL
)j
D II-t
11/16 APPROX
[TYPI
(~J,
I:
~II--
2-5/16
--lt~r
17
REBALANCE
I;
;I
,I
ACCESS OOUBLER
SCREWS-7S39-3A-I
WASHERS-L0153-OW2-2203
ii
111
I
0.050 7075-76
/i
I
i
rct:
01,-
3/1
Lh___l__
+1
ACCESS COVER-
I1
I/4(TYPJ
I.
II
?-i
0.050 7075-T6
I
1
ACCESS DOUBLER0.050 7075-TO
D
I
I:
B(-1 C~
3085183-7330-38-1
ii
NUT PLATES--WAS696A3
(16 EACH REOUIREOI
WEIGHTS
11
Ii
RIVET-TO MATCH
REMOVEO FASTENERS
,I
t-----
N0T3-M321042L3
EACH
r~
J;;
i,
(8
CC
BC
3/8k
3/4
EACH SIOE OF CUTOUT
REOUIREO)
b/
I
CHAMFER EOGES OFOOUBLER
_I
_...
TO MINIMIZE BUMPING OF SKIN.
ELEViTOR
REBALANCING ELEVATOR
BETWEEN STATIONS 30.250 AND 38.000
STA 38.000
ELEVATOR
STA 30.250
NOTES
DETAILS FOR FABRICATING WEIGHTS ARE ON SHEET 5.
SECTIONSAND PROCEDURESFOR INSTALLING

WEIGHTS BETWEEN STATIONS 30.250 AND 38.000
ARE ON SHEET8
szes-3-19~n

0
55-1 0-20
Page 221
Aug 17/84
NA-66-1032
ACCESS COVER
(REFI
LEADING EDGE SKIN
IREFI
ACCESS COVEA-0.050 2O24-T42
eol51
ACCESS
DOuRLEsS (REFI
~I
-tm
ACCESS
DOuRLERS IREFI
BALANQ WEIGHT
SECTION
A-A
SECTION
B-B
SECTION
C-C
ACCESS COVER IREFI
LEADING EDGE SKIN IREF)
JOGGLE
ACCESS OOUBLERS
(REFJ
SECTION
D-D
RE-BALANCING ELEVATOR BETWEEN

STA 30.250 AND 38.00
1.
Trim section out of
2.
Form access doublers to fit.

doublers as shown.
leading edge skin
shown.
8.
Form
4.
Prime accessdoublers.
5.
Temporarilyinstall accessdoublers.
6.
Locate
9.
accesscover.
access cover on
plates. Remove
doublers, and drill for
nut
access cover.
Temporarily attach rebalance weights to access cover

temporarily install access cover on leading edge.
and
Joggle and chamfer
3.
7.
as
Check static balance of elevator.
10.
Remove access cover, attach weights to cover with

EA934NA adhesive (refer to 51-20-20) and screws as
shown.
11.
Primeaccesscoverand weights.
12.
Install
access cover on
leading edge.
Remove access doublers, install nut plates on doublers

and install doublers in leading edge as shown.
NOTE
Sections shown
are
talcen from sheet

5265-3-192
55-1 0-20
Page 222
3/88
Jun
COPYRIGHT,
NA-66-1032
SCREWS3-7339-3A
WASHERS--LDI 53-0002-2203
NU7S--M321042L3
13 EACH REOUIRED IN EACH WEIGHTI

RIY~T--MS20428AD5. 2 ROWS
1-3/16
5-5/8
I/~I
ISTAGGEAEO SPACING)
EACH SIOE OF CUTOUT AT
RIVETS--CR2248-4.
ACCESS COVEA
0.050 7075-76
AI~
LEAOING
NIKSLGOE
5/161TYP1
+rT~
B(
I~
IL
II~ I
(12
ACCESS COVER-0.050 7075-76
II
(I
~I+
It
]j
6/10 ITYP ALL HIVETSI
WEIGHTS
IL"
0.050 7075-76
J;
i~l
REBALANCE
raa
Access OOUBLEA--
L--
It
SCREWS--7S393A-1
NUT PLATES--NAS698A3
-t
It
Sr~
C-
15/1617YP)
3/5
I)
)I
.leni
5-7/a
-i
L
SCREWS--7S39-3A-2
WASHERS--LOI 53-0002-2203
NUTS--MSZ1042L3
Is EACH REOUIREOI
II
BCJC/
1L
30651113-733936-2
I)
~-TT
ELEV
14 EACH REOUIREO).
HOLES IN STRINGER
HOLES IN STRINGER
It
SCREWS-37S33-3A-1
IlO EACH REOUIREOI.

PICK UP EXISTING
(TYPI
STA 80.812
PICK UP EXISTING
ACCESS
COVER
ACCESS COVER
LEAOING EOGE SKIN IREF)
IAEFI
(REF)
111
ACCESS
OOUBLER
III
90 1+51"
(REF)
EPON913
JUGGLE
0.068
--/II
II
31
JI
(REFJ
REBALANCE
WEIGHT
IHEF)
SPOT-FACE FOR
SECTIONC,C
SECTIONB~B
WASHERS
REBALANCINO ELEVATORS BETWEEN STATIONS 80.812 AND 89.375

i.
2.
Trim section out of
Fabricate and
leading edge
prime
access
skin
as
shown.
doublers and
SECTIONA-A
s2s5-3-~ea
7.
Temporarily attach rebalance weights to access

cover and temporarily install access cover on leading
edge.
8.
Check static balance of elevator.
9.
Remove access cover, attach weights to cover with

EA934NA adhesive (refer to 51-20-20) and screws as
shown.
access
cover.
install
doublers.
3.
Temporarily
4.
Locate access cover on doublers, and drill for fasteners. Remove cover.
5.
Remove access doublers, install nut plates

doublers, and install doublers as shown.
6.
Attach
access
nutplatestostringers.
on
and weights.
10.
Prime
cover
11.
Install
access cover on
leading edge.
NOTE
Detailsforfabricating weights
are on
sheet 5.

55-1 0-20
Page 223
Jun 3/88
NA-66-1032
r(
O1-9/16
2-5/8iU
0.102
ImAxl
L1L. ;.1-1 /16
-IC
9/16
3/8
1-1/2
3/8 A
3-3/4
sym ABOUT
ct;
REBALANCE WEIGHTS
ELEVATOR STATION 13.547
ltl
~""1
AS
TO
I/2(MAXIZ
AEOUIAEO
34.125 ANO 30.250
38.000 ANO 34.125
1-25/64 B
REBALANQ WEIGHTS-ELEVATOA STATIONS 30.250
TO 38.000
1-7/8
k"SRtlYI"
TO 1/2
USE BETWEEN
STATIONS 84.875
ANO 89.375
USE BETWEEN
STATIONS 80.812
ANO 84.875
(MAX)
RERALANCE WEIGHTS
ELEVATOR STATIONS 80.812 TO 89.375
O
O
O
Make
weights
from 1010 steel bar
or
plate
as
applicable
Cadmium plate weights after fabrication.
Prime
weight
for station 13 547
5265-3-194
55-1 0-20
Page 224
Aug 17/84
Weights
gniddA
)5
Balance
Figure 211 (Sheet 5 of

o
NA-66-1032
ELEV
STA
00,201
ELEV
ELEV
STA
98.367
STA
93.875
"1
ELEV
0.43
STA
(TYP)
105.711
it
""I
0.13 YTYP)
-II
STA
88.375
r-1~5
0.38
~1-r-ITYP)
90"
4$
g
ELEV
-I-
ii
-I-
_L~IIL--U
4.1
ol~o
olo
j~j
I~
-I
ii -I-~
-t----lp--i--:cli--
i
O
Il!
SPLICE
I
I
I-
/lol
/o i/
DOUBLER
IRE9
--i--;1~ --i
OUTED WEIGHT IREFI
INBo WEIGHT
IREF)
LEAOINC
FASTENER CGD1NG
EDGE SKIN
SPLICE OOUBLER
0.050 2024-742 CLAO
IREFI
EXISTING FASTENER LOCATIGN

REPLACE WITH NAS 1739-84-2
JOGGLE 0.063
EXISTING FASTENER LOCATION

REPLACE WITH NAS 1739-84-3
gj
EXISTING FASTENER LGCATION
12 PLACESI
CHAMFER EOGE OF
REPLACE WITH MS 20428-4
SPLICE DOUBLER TO
MATCH RAOIUS OF
TEE 12 PLACES)
AODED HAS 1738842 RIVET

AOOEO 7839-3 SCREWS
SECTIONAA
MS21O42-L3 NUTS
OCut
elevator
leading edge skin
midway
O
O
O
O
bay between
leading edge so
in center of
stations 93.875 and 89.375. Make cut 900 to
elevator
that cut is
between fasteners.
Drill out all exist ng fasteners in
Remove
leading edge
ie.ding edge
skin. Smooth
sLin outDO
01
cut
edges of li~in
O
O
O
O
Remove
ostsll
splice
doubler and
prime
splice doubler using Lype
Manuf acture elevator ead ng
On removed
leading edge
with epoxy
de
primer
and sir. of fasteners snown
edge
skin
polym
nbd and ailtbd
l.y
out location
weights
of balance weighl
attachment holes.
Fabricate
splice doubler
PicL up
existing
fasteners,
Position splice doubler Pick up existing faslenerr
S380-3-4
Adding Balance Weights
to Elevators Between Elevator Stations 93.875 and 105.711
Model NA 265-80
Figure
212
(Sheet
only
2)
1 of
55-1 0-20
Page 225
Aug 17/84
NA-66-1032
BALANCE WEIGHT DETAILS
NEAR SIRE
0.31
,In.sfi
FAR SIOE
LI
ITYPI
f0.01
INBD WEIGHT
0.030 ~-O.W15
3.50
0.73
OUTED WEIGHT
0.582 +0.005
3.92
0.55
WEIGHT
-0.00
BALANCE WEIGHT
FASTENERS (TYP)
SCREWS
78-39-3
NUTS
MS21042-L3
0.58 TRUE
0.59 TRUE
14 PLACESI
(4 PLACES)
0.51
0.33
FASTENER LOCATION
10.
Using clamps
outbd balance
skin.
11.
INBD WEIGHT
FASTENER LOCATION
or other methods, secure inbd and

weights in position on leading edge
Pilot drill fastener attachment hole through leading
15.
16.
edge skin and balance weights,

12.
10, 0.190/0.94) in 8 places.
OUTBO WEIGHT
Countersink balance weight fastener holes in leading edge skin so that fasteners are flush in a sparwise
direction.
Coat
faying surfaces of balance weights and leading

purpose sealingeompound.
edge skin with general
(No.
17.
Install balanceweights using size and

type fasteners
shown.
13.
Remove balanceweights from leadingedge skin and

counterbore balance weights to correct depth.
18.
14.
Epoxy polymide prime all surfaces of balance

weights, including the counterbores and fastener
Reinstall removed section of leading edge skin

size and type of fasteners shown.
19.
Balanceelevatoras required.
hales
using
5380-3-5
Adding Balance Weights
to Elevators Between Elevator

Statiohs 93.875 and 105.711 Model NA 265-80 only
55-1 0-20
Page 226
3/88
Jun
COPYRIGHT,
NA-66-1032
9.
ELEVATOR BALANCE PROCEDURE
Adjust pointer
bolt or pin.
10.
This balance procedure is for a complete

elevator including static wicks and final
Place pointer at trailing edge of elevator as shown in

View AA.
11.
Use a plastic medicine bottle tone inch in diameter or

less) as a weight container and lead shot or
equivalent
as
weights.
With the elevator removed from the airplane,

prepare it for balancing as follows:
NOTE
This balance procedure is for a complete
elevator including static wicks and final
Remove center and outbd floating hinge

sections from the elevator,
a.
paint.
1.
Remove elevator
2.
Remove outbd hinge pin,
tip.
remove
hinge and
12.
Place the weight container on the location marker,

and add weight until the elevator trailing edge
aligns with the pointer.
13.
Weigh the weight container. Every ounce is

equivalent to one inch pound. Then compare the inch
pounds to Table 1 to find out if your dash number
reinstallpin.
3.
Removecenterhingepin
cover.
4.
Remove center hinge pin,

reinstall pin.
remove
5.
Reinstall centerhingecover.
hinge and
elevator is within limits.

14.
Remove hinge support from elevator

torque tube universal link and inbd hinge
support.
b.
If elevator static balance does not fall within limit,

add or remove weight per 55-10-20, Figure 211 or
212.
Install inbd hinge pin or bolt in support and

install the hinge support on the root rib of the
elevator.
c.
2.
Table 1
Snap a chalk line between the center line of the outbd

hinge pin and the center line of the elevator hinge
support bearing boss. See Figure 213.
ELEVATOR
265-220001-201
1 to 7.5
IN-LB; L.E. Heavy
1 to 7.5
IN-LB; L.E. Heavy
BALANCE
3.
Installelevatortip.
265-220001-251
4.
Using a carpenters square along the hinge center

line, mark the spot when 16 inches +1/16 -0 falls in
the middle of the trailing edge (forward and aft).
265-220001-261
Iltol2IN-LB;
5.
6.
Make a copy of the balance weight location marker

and center over the 16 inch mark on the trailing
L.E. Heavy
265-220001-311
1 to 12
IN-LB; L.E. Heavy
265-220001-321
1 to 12
IN-LB; L.E. Heavy
5 to 12
IN-LB; L.E. Heavy
265-220001-331
edge.
265-220001-341
5 to 12
IN-LB; L.E. Heavy
Install three static wicks if not installed.
265-220001-342
5 to 12
IN-LB; L.E. Heavy
NOTE
370-220255-11
Iltol2IN-LB;
1Make sure knife edges are sharp and level

with no flat spots, as this will affect the
370-220255-21
balancing.
7.
hinge
NOTE
paint.
1.
to coincide with center line of
Place balance stands on
level bench and level knife
370-220255-31
Raisbeck
Elevators
L.E.
Heavy
1 to 12
IN-LB; L.E. Heavy
1 to 12
IN-LB; L.E. Heavy
7.12 to 12
IN-LB; L.E. Heavy
edges.
-60 models per Raisbeck
NOTE
Elevators
on
S/B
8.
the balance stand should
always assume a trailing edge up attitude,

dfnot add weight per 55-10-RO, Figure III
or
8.
~ld
Place elevator
on
balance stands
as
shown in
Figure
213.
55-1 0-20
0
Page 227
16/90
Mar
NA-66-1032
BTRUCTURAL REPAIR MANUAL
TIPELEVATOR
iP
BALANCE WEIGHT
LOCATION MARKER
CHALK
LINE
CARPENTERS
SOUARE
90"
HINGE
EDGE
IGINCHES
1/180
BEARING
BOSS
ELEVATOR
HINGE SUPPORT
KNIFE
EBGE
RINGE PIN
tA
OABOLT
BALANCE
STANOS
POINTER SEf UP
INSTALL REMOVEO SCREWS
TO SECURE HINGE SUPPORT
TO ELEVATOR.
,0=
ROOT RIB
Figure
213
Checking Elevator Static Balance
55-1 0-20
Paffe
228
Mar
16/90
NA-66-1032
VERTICAL STABILIZER
GENERAI,
applies to the vertical

stabilizer. For negligible damage limits, refer to 55-0010. For repairs, refer to 55-10-20.
The information in this section
VERTICAL STABILIZER REPAIR INDEX
See figure 1 for Model NA 265-40, -60, -60A, -60SC, and

figure 2 for Model NA 265-70, -80, -80A and
-80SC.
-65. See
55-30-00
c
COPYRl~iHT, 1984 BY SABRELINER CORPORATION
Page 1
Aug 17/84
NA-fiG-1032
STRU(TUKAL REPAIR MANUAL
29
.L
15
17
28
14
18
7"
12
13
Is
to
32
7
FRAME ASSEMBLY DHAWING

HO. 265-230002
00
InOEX UUMBERS COHHESPOWO TO

THE ITEM WUMBEHS In THE KEY
20
9~a;r
23
24
25
26
27
sas-s-~ss
55-30100
Page 2
Aug 17/84
Vertical Stabilizer ~tepair Index

Model NA 265-40, -60, -60A, -60SC and
1
eruffiF56-
CQPYRIGMT, 1984 BY SABRECINER;CORPORATION
NA-66-1032
STRUCTURAL IDENTIFICATION (Continudd)
ITEM
NO.
1
DRAWING
NO.
265-230003
MATERIAL
DESCRIPTION
Rib
Canted Sta
7075-T6
7075-T6
7075-T6
7075-T6
7075-T6
7075-T6
7075-T6
2.875
Bare
Clad
Clad
Clad
Clad
Clad
2
3
4
5
265-230005
265-230008
265-230017
265-230025
Rib
Rib
Rib
Rib
Sta
Sta
Sta
Sta
265-230033
Rib
Sta 33.625
7075-16 Clad
265-230040
265-230046
265-230053
265-230059
265-230066
265-230072
265-230079
265-230086
265-230320
265-230320-3
265-230320-5
265-230320-7
265-230090
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Beam
Sta
Sta
Sta
Sta
Sta
Sta
7075-T6
7075-T6
7075-16
7075-16
7075-T6
7075-T6
7075-T6
2024-T4
265-230085
265-230078
265-230408-1
and -2
265-230301
265-230301-9
265-230407-1
and -2
265-250014
265-250013
265-250012
265-230314
265-230315
265-230302
285-230302
265-230402-1
and -2
265-230412
265-230421-1
and -2
Rib
Rib
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
30
31
32
40.175
46.725
53.275
59.825
66.375
72.170
Aft, Canted Sta 78.997
Aft, Canted Sta 85
TE
Assy
Facing Sheet
Channel
Core
Canted Sta 90.375
Rib
265-230423
265-250002
265-250003-1
and -2
Fillet, Upper
Fillet, Intermediate
Fillet, Lower
Intercostal
Intercostal
Intercostal
Beam Assy
Fwd
Intermediate
Aft
Rear
Cap
Web
Skin
Side
Skin
Fillet
Fillet
REPAIR
FIGURE
NO.
55-30-20
Fig.
55-30-20
55-30-20
55-30-20
Fig. 205
Fig. 203
Fig. 203
204
55-30-20Fig.2031
2024-T4 Clad
2024-142 Clad
2024-14 Clad
7075-T6 Clad
7075-16 Bare
7075-16 Bare
7075-16 Bare
0.032
43691
7075-15 Clad
7075-15 Clad
2024-142 Clad
7075-T6 Clad
7075-16 Clad
7075-16 Clad
0.032
0.032
0.032
0.032
0.032
0.032
7075-16 Plate
0.375
7075-T6 Clad
2024-13 Bare
0.071
5530-20
Fig.
203
55-30-20
55-30-20
Fig. 203
Fig. 203
Front
Cap
Frame
Frame
Frame
13863
0.090
0.032
43745
0.032
0.032
0.050
0.032
0.040
0.032
0.025
0.025
0.025
0.025
0.032
0.020
0.025
0.020
0.010
0.020
3/16 X 0.001
0.020
0.020
0.020
0.020
43692
Honeycomb
Fwd, Canted Sta 85

Fwd, Canted Sta 78.997
Beam Assy
Web
Clad
Clad
Clad
Clad
Clad
Clad
Clad
Clad
2024-T3 Clad
2024-142 Clad
Stringer
Tip
29
0.520
8.795
17.070
25.845
GAUGE OR
EXTRUSION
NO.
Laminated Glass
Fabric
2024-T4 Bare
6061-T4 Bare
2024-142 Clad
Antenna
LE
Fwd
Side
0.063B
0.032
0.032
0.020
553020Fig.aOB
55-30-20 Fig.ZO1
NO TES
Foradditionalre~pairs, referto51-r0-00.

thinned areas or refer to aloplieable drawing numberfor thicleness variations.
Key
to
Figure
55-30-00
Page 3
3J88
Jun
NA-66-1032
35
34
33
32
10
31
30
ii
II
\12
a,
28j
37
13
38
39
14
k-E---
40
21
cir_-=r
15
Ij
17
Is
19
:I
00
20
INOEX NUMBEHS COHHESPONO TO
THE ITEM NUMsERS IN THE KEY

21
I
24
25
23
22
s?ss-3-~ss
55-30-00
Page 4
Aug 17/84

Model NA 265-701, -80, -80A and
erugiFCS082
NA-66-1032
STRUCTURAL REPAI:R MANUAL
ITEM
NO. DRAWING NO.
1
2
3
4
5
6
370-230311
370-230421-1 and-e
265-250003-1 and-2
265-230423-3 andd
7
8
9
10
11
265-230090
265-230320
265-230320-3
265-230320-7
265-230086
265-230079-3
265-230072
265-230066
265-230059
12
265-230053
13
14
15
265-230046
265-230040
265-230033
265-230025-11
265-230017-11
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
DESCRIPTION
MATERIAL
Vertical Stabilizer
Tip
Skins
Vertical Stabilizer
Side
Fillet
Skin
LE
Rib
Canted Sta 90.375
GAUGE OR
EXTRUSION
NO.
6061-T4 Bare
2024-T3 Bare
2024-T42 Clad
0.032
0.063
0.020
2024-T3 Bare
2024-T42 Clad
2024T3 Clad
5052-H39
2024-T42 Clad
7075-16 Clad
7675-16 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T5 Bare
REPAIR
FIGURE
NO.
55-30-20
Fig.
0.032
0.020
55-30-20
Fig. 201
0.010
3/16 X 0.001
51-70-50 Fig. 204

51-70-50 Fiff. 203
55-30-20 Fiff. 203
55-30-20 Fig. 203
55-30-20 Fig. 203
55-30-20 Fig. 203
55-30-20 Fig. 203
202
Trailing Edge Assy

Skin
Honeycomb Core
Rib
Rib
Rib
Rib
Rib
Rib
Rib
265-230008
370-230005-11
370-230004-11
370-230003-11
370-230302-11
370-230412-3
370-230402-1 and -2
370-230316-11
370-230315-11
370-230314-11
370-230301-11
370-230301-3
370-230407
282-230021-1
282-230021-11
282-230021-21
282-230021-31
282-230021-41
282-230021-51
265-230078
265-230085
265-230408-11&-12
370-250002-3 and-4
370-250015-11
370-250014-11
370-250013-11
370-250012-1 and-2
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Canted Sta
Canted Sta
Canted Sta
Sta 66.375
Sta 59.825
Sta 53.275
Sta 46.725
Sta 40.175
Sta 33.625
Sta 25.345
Sta 17.070
Sta 8.795
Sta 0.520
Canted Sta
Canted Sta
Rear Beam
Web
85.000
78.997
72.170
4.266
8.269
Intercostal
Aft
Intercostal
Intermediate
Intercostal
Fwd
Front Beam Assy
Web
Cap
Sta 21.208
Sta 36.900
Sta 43.450
Sta 50.000
Sta 56.550
Sta 63.100
Canted Sta 78.997
Canted Sta 85.000
LE,
LE,
LE,
LE,
LE,
LE,
0.025
0.040
0.050
0.032
0.032
0.032
0.050
0.090
7075-T6 Bare
7075-T651 Bare
7075-T6 Clad
7675-16 Clad
7075-T6 Clad
0.071
0.625
0.032
0.032
0.032
7075-16 Clad
7075-T6 Extr
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
0.032
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
7075-T6 Clad
2024-T42 Clad
7075-T6A1Extr
6661-14 Bare
7075-T6 Clad
7075-T6 Clad
2024-T42 Clad
2024-T42 Clad
Stringers
Rib
Fillet,
Rib
Fillet, Sta 8.795
Rib
Fillet, Sta 0.520
Rib
Rib
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
55-30-20 Fig.
55-30-20 Fig.
55-30-20 Fig.
55-30-20
203
55-30-20
55-30-20
55-30-20
55-30-20
55-30-20
55-30-20
203
203
203
203
203
203
203
205
204
Assy
Cap
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
0.020
0.025
0.020
0.032
0.025
0.025
0.025
Fillet, Sta 8.165

Fillet, Sta 15.559
ej
43691
0.025
0.025
0.025
0.025
0.025
0.025
0.020
0.020
43692
55-30-20
55-30-20
Fig.
Fig.
203
203
0.032
0.032
0.032
0.032
0.032
NOTES
Foradditionalrejpairs, referto51-r0-00.
This is a ehem-milled part. IMeasure

thinned areas or refer to applicable drawing numberfor thiclcness variations.
Key
to
Figure
55-30-00
0
Page 5/6 Blank

Jun 3/88
NA-66-1032
VERTICAL STABILIZER
REPAIR
(;ENERAL
This section contains repairs for the vertical stabilizer.
For applicability of repairs, refer to 55-00-00.
55-30-20
0
Page 201
Aug 17/84
NA-66-1032
STRUC:TURAL REPAIR MANUAL
RIVET--MSM601M4
2 RIVET OIAMETERS
mlN
REPAIR OOUBLER
2 ROWS REOUIREO
AAOUW001116E.
COUITERSINK DOILIBLER.
ITYPI
LEAOINO IOOE
SKIN (REFI
sTRlNOERIREF)
1/2 IWIIW
IRITYP)
,_J
IIoo,
IloO
oi
io
or
lo
1O
"Ji;
-7
CHAMFER 30",
ALL EOOES
O1
00
11
/IOI
REPAIR DOUBLER
AIVET--MS~slsll4.
ADO BETWEEH E1I111#O RIVETS
II 8TR1BER.
OI I
0.040 2024-T3 CLAD
REPAIR DOUBLER
TO COVER EXISTIID
RIVETS ALONG STRINGER
LEAOING EOBE
SKIN
IREF)
TRIDnRBECBUTOAMIGE
NOT TO EXCEEOA
2 IN. OIAMETER NOLE
NOTE
THIS REPAIR MAY BE USED ON LEADING EDGE SKINS
ON
THE
VERTICAL
STABILIZER. RUDDER, AND
ELEVATOR.
szss-,-tw
55-30-20
Page
Aug 17/84
Veltical Stabilizer, Rudder, and Elevator Eeadiamg Edge

Skin Repairs
Class
201
eruglFB
202
NA-66-1032
REPAIR 8618
REPAIR DOUBLER
RIB
REAR BEAM
LISKIY
,RIPAIRSKIU
_~
I?-I-
-S1
REPAIR ANGLE
REPAIR OOUBLER
Rlutr-rom~reH
REMOVEOFASTENEB
ill
B1
RIVET-TO MATCH
REMOVEO FASTENER
(yyp)13/lsrTvPI _(
RIVET
asarnuos
RIVET-MS2M28A05-J~D;
-t t f 1
~t
OIIYIPLE 8818 ANO
t -t
-t
3/4
-t
t
-t
111
-t
tit
REPAIR OOUBLER
EXISTIMO SKIN
12 REOO
,71
fl
--~I----t
(TYPJ
7/18
O i)
O O
,O i)
3/8
(TYPI
LI
i)OO O O O
i-
7/8
+jti~
REAR BEAM
+o
EXISTING SKIN
SECTION
A-A
)A
I:
RINGE RIB
REPAIR SKIN
___
IBEFI
REPAIROOOBLER
REPAIRANOLE
STRIIOCA
SSCTIOY
O
O
7/8
B-B
REAA
BEAM
UNSHAOED
AREAIS
0.025 COWSTA)IT
7;f~-J
Hln6~ 111
IREF)
STA
40.175
v~----.
Remove st.bilirar leading edge ILin
CHEM-MILL
DETAIL
Trim damaged ride shin midway betuesn ribs.nd
between existing fasteners.
P
O
O
O
STA
72.170
FabTiCaferBpBilpBlt.
0.032
SHAOED
SIAERA
0.063
CONSTANT.
204-T3REPAI OOUBLEA--
LE(REFIBAAE
Prime repair angle and repair doubler
Install repair parts and rsinrfall leading edge okin
Relinish repaired sultace
to
mslch
surrounding
REPAIR AHGLE--
areas.
0.083 2024-T3
OR 7075-T8 BARE
NOTES
THIS REPAIR IS APPLICABLE TO BOTH SIDE SKINS
SPLICES MUST BE MADE OUTED OF STATION 40.175.
REPAIR SKIN MUST BE 0.063 IN. MATERIAL MACHINED
TO 0.025 IN. TO MATCH REMOVED SKIN SECTION

(REFERENCE DWG 265-230421 OR 370-230421) WHEN
DAMAGE IS I NBD OF STATION 72.170 TWO SPL ICES MAY
BE MADE TO MINIMIZE THE MILLING OPERATION.
(THE
REPAIR 8818-0.083
2024-T3 RARE. IREFER
TO MOTES FOR SKIM
BAUOE OPTIONS.)
SKIN OUTED OF STATION 72.170 IS ALL 0.025 IN.)
SHOWN; HOWEVER. ANY

INCORPORATING A ONE-PIECE
A COMPLETE SKIN SPLICE IS
SMALLER REPAIR

sZB5-3-Z05A
GIVEN.
Vertical Stabilizer Side Skin

Figure 202
Repairs
55-30-20
Page 203
Aug 17/84
NA-66-1032

SKIN
IREF)I
TRIM DAMAGE MIDWAY BETWEEN

EXISTIND FASTENERS
FASTENER(TYPI 1
FILLER
REPAIR STRAP
C:,I_
r---
at
I~
a~l
t
t-
a,
_"1-"~-
Lc--~__
-t
1_
EOUAL TO RIVET
REPAIR
OOUBLER
RIB
SPIICIIG IN RIB
RIVET-TO MATCH RIVETS THRU

SKIN AID RIB. ITYPJ
RIVET-SEE RIVET TABLE

FOR REOUIREMENTS
FILLER
7~18
r+
3/4
~f
tl;t
-e
r~
SKIN IRE9
t-tt
REPAIR
11/81MIWI
7/18(TYPI
9!18118161
I-
1/2
R-IMINI
BEAD
AIl
RIVET-MS20470
8.795
405
17.070
405
40.175
EI
NO. REOUIRED EA
SIDE OF FILLER
404
48.725
404
53.275
404
59.825
404
66.375
AOs
12.170
404
78.997
AW
85.000
TI
out
804
IREq
SECTIONA-A
nsrrns~r
VERT
STAB
STA
8TRAP
REPAIR
DOUBLER
REPAIR ITAAP-MATERIAL ANO
:FILLER;rMATEAIAL
AID BAUBE.~TO
MATCH RIB
RIB
64006 TO
MATCH RIB
damage
Fabricate repair parts
O
.O
III
Prime
-ir pans
REPAIR WUBLER-MATERIAL TO MATCH

RIBr THICKWESS IS
OWEQAUBL HEAVIER
camplefsd re~ir
T I-1IS REPAIR IS APPLICABLE TO VERTICAL STABILIZER
RIRS AT STATIONS IN THE RIVET TABLE
55-30-20
Page 204
Aug 17/84
Vertical Stabilizer Rib
erRepairs
ugiFllareneG
203
COPVRIGHT, 1984 BY SABRELINER CORPORATION
NA-6fi-1082
STRUCIUKAI, REPAIRMANUAI,
CAP REPAIR DOUBLER
TRIM DAMAGE MIDWAV BETWEEN FASTENERS
RIB CAP
RIB CAP REPAIR SECTION
n---
__L
SKIN
ete (8 a a e
---------I
88
d:_
____________!
-----_,,,
(REFJ
CAP REPAIR
RIVET-TO MATCH
REMOVED FASTENER
DOUBLER
ITYP)
IF OAMAOE OCCURS IN
THIS AREA. FABRICATE

A NEW SECTION AWD
SKIN
[REF)
MAKE SPLICE FWD OF
THIS AREA.
8
te
/BITYr
5/8 MIN
CAP REPAIR
DOUBLER
llY~r--118e001(M05--
ALL PLIICB
CAP AND WEB
WO. BEOUIREO EACH

8108 OF DAMAGE EOUALS
THE NUMBER REOUIRED
THRU SKIN ANO OUTER
FILLERI
FLANGE.
RI WEB
1-1/4
-e
a 0 Rt
I--~
(BjB: ~!8
R)
fB B
DOUBLER
0 6
SKIN
is/is
L RIVET
IMAxl
CAP AID WEB
IREFI
CAP FILLER
TO MATCH REMOVED
FASTENER. NO.
REDO IS EOUAL
TO THE NO. BEOD THRU SKIN
REPAIR
DOUBLER
o ea
WEB PILLER
CAP ANB
WEB REPAIR
1/48
IMAxl
-C
RIB CAP
CAP FILLER
~a a
-r-
aia e~a a a a
SKIN (REFJ
110 OUTER FLANGE.
eaI
RIVET-TO MATCH REMOVED FASTENER. 8 REOUIRED

EACH 8105 OF DAMAGE WHEN RIVET Is 0820426805.
WEB FILLER
5 BEOUIREO WHEN RIVET IS MS20420DBO.

Trim off
area as
damaged cap
applicable.
or
trim out
damaged cap
and
RIB CAP REPAIR
CAP REPAIR DOUBLER

0.080 7075-76 BARE
SECTION
repair paW. Form repair doublers Irom

annealed material and heat-treat to the -T6 condition after
FBbriCate
ji
forming.
El
R
BIB CAP
Prime all bare pans.
I
NOTE
WEB FILLER--MATERIIL AND

GAUGE TO MATCH WEB
TWO REPAIRS AR E SHOWN. BOTH ARE APPLI CABLE TO
CAP AND WEB

REPAIR OOUBLEA--
EITHER SIDE OF THE ROOT RIB (STATION 2.875).
CAP FILLEA--MITERIAL ANO

GAUGE TO MATCH CAP
0.080 7075-78 BARE
5265-3-203
Figure
0
204
Station 2.875
55-30-20
Page 205
Aug 17/84
NA-66-1032
SI R1I(IIURAI, I1E:PAIR MANU AL
REPAIR AIIGLE
ale CAP
FILLER
ITYP)
REPAIR I)OUBLER
00
to---
RIB WEB
t-
-t
i-
Iooo
I-~i- IIIBITYPLLL~IFI8]
I
t
-t
FASTEWERS(TYPI
-f
+I$
tlt-
+I~:
-c~-tl
SPACI)IO TO EOUAL
CAPTOWEB
3080188(7201
+I
-tIl,+ I+
I+
I_
RIVET
RIYET--M82M70A05
ITYPJ
PICK UP OWE EXISTIWO RIVET TRRU RIB CAP,

RIB WEB, AWO REPAIR DOUBLER EA BIBE OF
REPAIR, RIVET TO MATCH REMOVED
MS20470AD4
RIB CAP
FILLER
FABTEWER (TYP~
L
REPAIR OOURLER
ale WEB
SCCTION
A-A
*p~lRlwolrauanrurr
FOR REMOVED BEAO)
RI CAP
O
19
Trim out damaged rib web seel
iab~irats and
on
pars
RlB WEB
NOTES
FILLER-MATERIAL AWO
THIS REPAIR IS APPLICABLE TO THE WEB PORTION OF
BAUOE TO MATCH RIB WEB
THE RIB ONLY. IF THE CAP IS DAMAGED, IT MUST BE

REPLACED WITH AN EQUIVALENT EXTRUSION.
COMPLETE SPLICE
IS SHOWN;
HOWEVER,
REPAIB DOUBLER
0.083 7075-70 CLAD
ANY
SMALLER REPAIR THAT INCORPORATES A ONE-PIECE

DOUBLER CAN BE MADE, USING THE DATA GIVEN.
55-30-20
Pap;P ~O(i
Aug 17/84
REPAIR AWBLE
3/4 3 3/4 X 0.039
707STB CLAD
9265-3-201)
BtPtian 0.62
Ver"esl
NA-66-1032
RUDDER
GENERAL
The information in this section applies to the rudder. For
negligible damage limits, refer to 55-00-10. For repairs,
refer to 55-30-20.
RUDDER REPAIR INDEX

See figure 1 for Model NA 265-40, -60, -60A, -60SC, and
figure 2 for Model NA 265-70, -80, -80A and
-80SC.
-65. See
55-40-00
a
Page I
Aug 17/84
NA-Cifi-1032
SIRII(ITUHAL REPAIR MANUAL
38
23
24
37
22
35
20
34
33
25
28
27
9
s
~U ~I
29
-------II!
30
4,
~-1I1WI I
II 1
31
32
FALMX;A8SfAIBLY OA~WING
NO.
00
2851240002
INOEX:NUMBERS CORRESPOIOTO
THE ITEMNUMBERS IN THE KEY
e?es-s-lss
_5540-09
Page 2
Aug 17/84
Rudder
Eeepair Index
-60A, -60SC
eruR
iF56-
Model NA 26fi-40, -60,

1
and
NA-66-1032
ITEM
NO.
1
DRAWING
NO.
DESCRIPTION
GAUGE OR
EXTRUSION
REPAIR
FIGURE
NO.
NO
MATERIAL
265-240003
265-240005
Torque Tube Assy

Rib
Sta 2.625
2024-T42 Tube
7075-T6 Clad
3
4
265-240006
265-240009
5
6
7
265-240014
265-240018
265-240301
265-240416
265-240024
265-240028
265-240033
265-240034
265-240039
265-240043
246-24047
246-24052
246-24056
246-24061
265-240066
265-240067
246-24072
246-24077
265-240411-1 and 2
265-240211-1 and 2
265-240320-1
265-240320-3
265-240320-5
265-240320-7
Rib
Sta
Rib
Sta
Rib
Sta
Rib
Sta
Channel
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
1018 Steel Bar
2024-T42 Clad
2024-142 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Glad
2024-T42 Clad
2024-T42 Clad
7075-T6 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
7075-T6 Extr
2624-13 Clad
0.020
0.020
0.032
0.032
0.020
0.020
0.020
0.020
0.020
0.020
0.032
0.032
0.020
0.020
43740
0.020
2024-T3 Clad
2924-14 Clad
5052-H39
0.010
0.025
3/16 X 0.001
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
6.268
9.693
14.188
18.094
Weight
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Balance
Sta 23.824
Sta 28.930
Sta 33.406
Sta 34.218
Sta 39.1
Sta 43.140
Sta 47.711
Sta 52.282
Sta 56.852
Sta 61.424
Sta 66.154
Sta 66.966
Sta 72.414
Canted Sta 77.847
Stringer
Stiffener
Beam Assy
Skin
Channel
Core
0.032
0.020
0.020
0.020
0.020
0.040
55-40-20
204
55-40-20
55-40-20
55-40-20
55-40-20
Fig. 202, 203

Fig. 202, 203
Fig. 202, 203
Fig. 202, 203
Fig. 202, 203
5/8
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
TE
Honeycomb
26
265-240002-7
265-240207
265-240501
265-240501-3
265-240501-5
Doubler
Doubler
Trim Tab
Skin
Core
265-240501-7
265-240501-9 and 11
265-240206
265-240302
265-240203-1 and -2
265-240320-11
265-240320-13
265-240320-15
65-240320-17
Channel
Rib
Doubler
Beam Assy
33
265-240415-3,
-5, -7, -9, and -11
Weight
34
265-240310
265-240002-5
265-240002-4
265-240002-3
Door
Skin
Skin
Skin
27
28
7075-T6 Clad
2024-T4 Clad
0.025
0.032
2024-T3 Clad
5052-H39
0.010
3/16 X 0.001
Assy
Honeycomb
29
30
31
32
Doubler
Beam Assy
Skin
Channel
Core
2024-T42 Clad
7075-T6 Clad
2024-T42 Clad
2024-T42 Clad
2024-T3 Clad
0.040
0.050
0.032
0.020
0.020
2024-T3 Clad
2024-T4 Clad
5952-1139
0.010
0.020
3!16 X 0.001
TE Lower
Honeycomb
35
36
37
Balance
1018 Steel
Trim Tab Actuator 2024-T3

LE
2624-13
2024-T3
Right Side
Left Side
2024-T3
Clad
Clad
Clad
Clad
1/2
0.040
0.040
0.020
0.020
55-40-20
55-40-20
55-40-20
Fig.201,202
Fig. 202, 203 1
Fig. 202, 203 1
NOTES
For additional
repairs, refer
to 51-r0-00.
A19o refer to 55-30-;20, Figure
Key
to
Figure
55-40-00
0
Page 3
3/88
Jun
NA-66-1032
38
37
~ryl ~plUI
I1I
36
35
34
33
32
30
29
28
27
26
25
ff I
23
22
I/
21
13
14
20
18
16
00

THE ITEM NUMBERS IN THE I(EY
S370-3-39
55*40-00
Page
Rudder
Repair Index
Model NA 266-70, -80, -80A, and
erugiFCS082
Aun 17/84
NA-66-1032
ITEM
NO.
1
2
3
4
DRAWING
NO.
DESCRIPTION
370-240101-1
370-240101-2
370 240002-3
265-240310-11
265-240415-3,
Skin
Skin
Skin
Door
Weight
-5
MATERIAL
RH Side
LH Side
LE
LE Skin
Rudder LE
GAUGE OR
EXTRUSION
NO.
2024-T3 Bare
2024-T3 Bare
2024-T3 Clad
2024-13 Clad
1018 Steel
0.040
0.500
7075-16 Al Extr
2024-T3 Clad
4E74D
0.020
2024-142 Clad
2024-T4 Clad
7075-T6 Clad
2024-T4 Clad
0.020
0.020
0.025
0.032
2024-13 Clad
5052-H39
2024-142 Clad
2024-142 Clad
2024-T42 Clad
2024-13 Clad
0.010
3/16 X 0.010
0.040
0.032
0.020
0.020
2024-T42 Clad
2024-T4 Clad
2024-142 Tube
7075-T6 Clad
2024-T42 Clad
2024-142 Clad
2024-142 Clad
2024-T42 Clad
2024-142 Clad
2024-142 Clad
1018 Steel
2024-T42 Bare
2024-142 Clad
2024-142 Clad
2024-T42 Clad
2924-142 Clad
2024-142 Clad
2024-142 Clad
2024-T42 Clad
2024-T42 Clad
2024-142 Clad
7075-T6 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Bare
0.020
0.020
0.032
REPAIR
FIGURE
NO
55-40-20
55-40-20
55-40-20
Fig.
Fig.
Fig.
201
51-70-50
51-70-50
Fig.
Fig.
204
0.050
55-40-20
Fig. 204
0.025
Fig. 202, 203

55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
0.032
0.040
201
201
-7, -9, -11, -13 and -15

6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
370-240411-1 and -2
265-240211-1 and -2
265-240320
265-240320-19
265-240320-5
370-240002-7
265-240207
370-240501
370-240501-3
370-240501-5
370-240501-7
265-240206
370-240302
265-240002-5 and -6
265-240320-31
265-240320-21
265-240320-15
265-240408-3
370-240004-11
370-240005-3
370-240006-11
370-240009-3
265-240014
265-240018-3
265-240301
265-240416-3
265-240024
265-240028
265-240033-3
265-240034-11
265-240039
265-240043
265-240047
246-24052
246-24056
246-24061
265-240066
265-240067
265-240072-11
246-24077-21
Stringer
Support
Trailing Edge Assy
Upper
Skin
Channel
Doubler
Gusset RH
_Trim Tab Assy
Skin
Honeycomb Core
Channel
Gusset
Beam
Gusset
Trailing Edge bssy
Lower
Skin
Channel
Torque Tube Assy
Rib
Sta 2.856
Rib
Sta 1.780
Rib
Sta 6.268
Rib
Sta 9.693
Rib
Sta 14.188
Rib
Sta 18.094
Support
Weight
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
204
Leading Edge
Sta 23.824
Sta 28.93
Sta 33.406
Sta 34.218
Sta 39.100
Sta 43.140
Sta 47.711
Sta 52.282
Sta 56.853
Sta 61.424
Sta 66.154
Sta 66.966
Sta 72.414
Canted Sta 77.847
0.091 Wall
0.020
0.020
0.020
0.020
0.040
0.625
0.020
0.020
0.050
0.050
0.020
0.020
0.020
0.020
0.020
0.020
0.032
0.032
0.020
0.025
55-40-20
55-40-20 Fig. 202, 203

55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
55-40-20 Fig. 202, 203
NOTE
For additional
reloairs, refer
to 51-r0-00.
Key
to
Figure
55-40-00
0
Page 5/6 Blank

Jun 3/88
NA-66-1032
STRUCTURAI, HEPAIH MANIIAI,
RUDDER
REPAIR
GENERAL
The section contains repairs for the rudder. For
applicability of repairs, refer to 55-00-00.
RUDDER STATIC BALANCING

When a repair is done on the rudder, it is necessary that
the surface be static balance checked. If the repaired
surface is not within specified tolerances, the surface
must be rebalanced. The procedures for checking static
balance and the addition of weights are given in 55-10-20,
figures 209-212. For rudder balance requirements, refer
to figure 205.
55-40-20
0
Page 201
Aug 17/84
NA-66-1032
STKI!("IUKAL REPAIH MANIIAL
C1A
LEAOING EDGE SKIN
LEADING EDGE
RIAPERI KS
DOUBLER
I(,\ TT
i-71=i;-RIVET--MS20426AO--01A
I
y
+I
MATCH EXISTINGt
l~e
HOLE--8 REOUIREO EACH
t
Ii
ri-
OTECILPS
ill
SIDE OF
(SEE
GO
--~lle
6,
~L
I+u:
EXISTING LOCATIONS.
a
tff
+JIn/
1
1/4 ITYP ALL

t
10/
1+
t
t
t
ITYPJ
131
OUT.o
RIVET--MS20601R04
RIVET--MSZOW)IAO--OIA
a,~ IrrPI
I~ RIYET--MS20428104-
i4mj
2 ROWS
REOUIREO
EACH SIDE OF SPLICE
~I
cP
u
ul
SIDE SKIN REPAIR

DOUBLER ITYP)
tll~p
crI
IB/
SIDE REPAIR SKIN
1"
ITVP)
_i-
(1A
LOCATIONS EACH SIOE

OF SPLICE.
PLACESI
:a
cP
TO MATCH EXISTING
HOLE. PICK UP 2 EXISTING
ii.l
tl
SIDE SKIN
USE MIN FOR CLOSE
STRINGER IREF)
.I I.,.I
13!
,I
~I
TO MATCH EXISTING
HOLE. PICK UP ALL
KISEE SHEET 2)
rssnssslutrlrrrl
LE SKIN REPAIR
RI~ET--MS2a426AD--01A
SHEETf- I-iI 21
1-
13/32 MIN
17/32 MIIX ITYP)
3/4 MIN
iii
LEADING EDGE
REPAIR SKIN
HONEYCOMDTEBEAM
IAEq
LE REPAIR SKIN
DOUBLER
STRINGER (TYP)
J880LE 0.082 DEEP
8Y1/4RUN0UTITYP
3PLI0E3)
I
SIDE REPAIR
SKIN
NOTES
SIDE SKIN REPAIR
THIS REPAIR IS APPLICABLE TO ALL AREAS OF

THE
RUDDER. EXCEPT (1) RlB BAYS ADJACENT TO HINGES
AND (2) THE RIB BAY WHICH CONTAINS
THE TRIM
DOUBLER
ACTUATOR ROD
ALL SKINS MAY BE SPLICED IN THE SAME
RIB BAY, IF
ALL REOUIRE SPLICING
JOGGLE 0.030
DEEP BY 1/8
(REFJ
RUNOUT
SECTION
A-A
Rudder
55-40-20
Page ~02
Auff 17/1(4
WHEN SPLICING BOTH SIDE SKINS. USE

MS20426AD
RIVETS THROUGHOUT THE FIRST REPAIR SKIN
AND
REPAIR DOUBLER INSTALLED
HONEYCOMB TE BEAM
Leading Edge and Side Skin Repairs

COPYRIGHT,
szes-3-zos
19814 BV SABRELINER CORPORATION
NA-6(i-1032
STKUCTIJRAL REPAIH MANIIAI,
61137106 RIVET
LOCATIOW (RE9
LE SKIN
(REq
SIDE REPAIR SKIN
--0.020 2024-74
SIOE SKIN
CLAD ITYPI
(REFI
AOOED RIVET
SIDE SKIN REPAIR

OOUBLER
i-~-I I-
1/4-640103 ENO OF REPAIR

DOUBLER IF NECESSARY
~-I
SEC7IONBB
LE SKIN REPAIR DOUBLER
13/32 MIN
17/32 MAX
ITYP)
EWD OF REPAIR DOUBLER

MUST BE RAOIUSEO TO
STRINGER
CLOSELY MATCH STRIWOER

RADIUS. TO OBTAIN MAX
RIVET 6066 DISTANCE
VNOAMAOEO
SIDE SKIN IREq
LE REPAIR SKIN
--0.040 2024-74
CLAO
Tim
between
oil
damagea
existing
Fabricate
repair
repair doubler must

spacing tolerance.
El
9*ln
rl,s me
miduay
fasteners.
doubler and
repair
p~in.
Joggle.
in
fit close to substructure, to obtain rivet
iiijii
Position repair doubler in place and drill all rivet holes
through skin, substructure, and repair doubler.

Position repair skin in place, and drill all required rivet holes.
Remove
repair paris,
and
dimple
vet hoies
exoept
those inside countersunk substructure.
Reinstall repair pert., and rivet them in pace. Rivet
close-out
side
skin
progressing uniformly
to
stringer; continue riveting,
to the
rear.
Use minimum number of
blind fasteners for close-out.
(i~
O
Relininh
repair
surlace to maf0h
Jurrounding
area.
SIDE SKIN REPAIR ODUBLER
LE SKIN REPAIR
Check
rudder.
rudder
(Refer
balance.
ii
necessary
to "AUDDER STATIC
050.0- RELBUOO
BALANCING".)
--0.032 2024-74 CLAD
2024-T4
rebalance
CLAD
S265-3-210
Rudder Leading Edge and Side Skin Repairs

55-40-20
Page 203
Aug 17/84
NA-66-1032
RIVET--MS20428A04--2 ROWS REOUIREO THHU

SKIN ANO REPAIR OOUBLER. BIMPLE ALL PARTS.
1/2 MIN
(TYP)k
1/4 MIN
ITYPI
AIVET--Msi042810-OIA:TO MATCH
-t
EXISTING HOLE
II
--ff++f+lf+f"++fff
I+
3/4
-6
-6
+I
++Lc--l~t
--tl+
tl
+If!
I$
++1
+I+j
18EESHEE72)
~1
+1
I+
It
+I
-6
I+t
+$1
tfiS
fl
i+++t+;++tll+t+
Il
t
I+
tl+
C-_
=---I
RIVET--MS2060~AO-OIA TO MATGH
EXISTING HOLE
+I
~--I
-I,
-B
f+
I
tJ
ll\rET--MS20WllA04-ONE ROW RfOUIREO

SKIN REPAIR OOUBLER
r
SECTION
A-A
SKIN
JOOGLE 0.032 BY
~/B Ruuour
NOTES
THIS REPAIR
IS APPLICABLE TO ALL SIDE PAFjEL
AREAS IF REPAIR DOUBLER OVERLAP REQUIREMENTS

CAN BE MET
WH~N A SKIN REPAIR ONLY IS MADE ACROSS A RIB OR

WHEN A RIB REPAIR IS MADE IN WHICH A RECESS IS
NOT PROVIDED TO ACCOMODATE THE 0.032-IN. SKIN

REPAIR DOUBLER, THE SKIN REPAIR DOUBLER MAY BE
MADE FROM 0.016-IN, TYPE 301,

RESISTANT
STEEL.
THE
USE
1/2H CORROSIONOF THE
THINNER
MATERIAL MINIMIZES MOLD LINE BUMPING.
A SINGLE-PIECE SKIN REPAIR DOUBLER MAY BE
USED,
WHEN ACCESSIBILITY PERMITS
5265-3-211
55-40-20
Page 204
Aug 17/84
Rudder Side Skin and Rib Repairs

Eigure 202 (Sheet 1 of 2)
o
NA-66-1032
RIB REPAIR DOUBLER
RIB
SKIN REPAIR DOUBLER
SKIN
Jr
1/4
ITYPI
iC
1/4
RIVET--~H470A04-2 ROWS REOUIRED AROUND
SKIN FILLER
WEB DPENING, ONE ROW
IN REMAINDER OF REPAIR
1+1,
--T ~t
-e
1/2 MIN
I+~FZ ;7~
f---l~$
t?t
(TYP)
TRIMMEO-OUT 818 DAMAGE
SECTIONBB
SKIN FILLER--0.020 2024-74
RIB FILLER-- 2024-74. GAUGE TO
MATCH SKIN REPAIR DOUBLER
ale
IREF)
TRIMMED-OUT DAMAGE
t
SKIN
P;1.
IREFJ
SKIN REPAIR 00UBLER--0.032 2024-74
(ALTERNATE MATERIAL ANO CONFIGURATION

CONTAINED IN NOTE ON SHEET II
RIB REPAIR DOUBLER--2024-T4, ONE GI\UGE

HEAVIER THAN DAMAGED 818
temporarily install filler.

repair doublers.
Fabricate and
existing
rough
fasteners.
Remove
additional
fiangs,
a,
ns.eplary, to
provide
O
O
Fal)liEBTB and inStBII rib repair doubler
repair doubler.
repair doubler material and configuration
information is contained in note an sheet i.) Drill all holes
through skin and skin repair doubler.
Fabricate and temporarily in3ali skin
(Alterrlate
RBmDuB
Drill all holes
IBmpOld" y inP1BIIEd pans and dimple all
holes.
space to accommodate skin repair doubler.
O
O
filler and
Reinsfal pana and rivet them in
Ref nish pullace.
so
Ih.t it matches
skin
Check rudderbalance If
(Refer
place
to "RUDDER STATIC
surrounding
neoessary.;eba
ance
area
rudder
BALANCING", this section.)
5265-3-212
Rudder Side Skin and Rib Repairs
Figure
202
(Sheet
2 of
2)
55-40-20
Page 205
Aug 17/84
NA-66-1032
RIVET--MS20426AO--DIA TO MATCH EXISTING HOLE

NUMBER AEOUIREO IS CONTAINED IN NOTE.
SKIN
FILLER
OIA TO MATCH EXISTING HOLE.
RIYETi 822042840
NUMBER REOUIREB IS CONTAINEO II NOTE,
IREFI
-t-
~r"""______1/4
-j I\
ale REPAIR
~t
OOUBLER
-1-
R (TYPJ
1/4 MIN
(TYP ALL PLACES)

t
IN:lrlPltt
-t
TAIMMEO-OUT
1/2 MIN
DAMAGE
RIVET--AN470A04--2
AOWSREQUIAEO
RIB
FILLtlA-2024-T4 CLAD
THICKNESS TO MATCH RIB
SKIN-(REFI
REPAIROOUBLER
El
FILLER
RIB
RI:
SECTION
gTllm
~L-FBbriCste
out
REPAIR 00UBLEA--2024T4 CLAD--THICKHESS

ONE OAUOE HEAVIER THIN AIB
Remove repair parf..
THIS REPAIR MAY BE USED ON ALL RUDDER RIBS, IF
flenge
PHYSICAL LIMITATIONS PERMIT.
IF 0.032-IN. RIBS ARE BEING
EXISTING
RIVET
aatuasn ex
rting laalanan
EACH
SIDE OF
DAMAGE. IF 0.020-IN. RIBS ARE BEING REPAIRED, PICK
and
dimple
hole, in dwbler
and filler.
O_ Re~nsfallb.rm,
EICheck
REPAIRED, PICK UP THREE
LOCATIONS ON
damage ml~way
and temporarily install repair doubter and

filler. Drill all rivet holes,
NOTEIS
AA
and nuet
parts in piece.
rudder balance. If rudder is not in balance.
UP TWO EXISTING RIVET LOCATIONS ON EACH SI DE OF
rcbalance it.
DAMAGE.
this
(Refer
to "RUDDER STATIC BALANCING:
section.)
WHEN THIS REPAIR IS PART OF A BLIND SKIN AND RIB
REPAIR,
MS20601AD
FASTENERS
MAY
BE
USED
8205-3-2(3
THROUGH THE SKIN REPAIR FILLER AND RIB REPAIR

FILLER
55-40120
Page 206
Aug 17/84
Rudder Rib Repairs

203 (Sheet 1 of 2)
Figure
COPYRI~MT, 198 BY SAB:RELINER CORPORATIDN
NA-66-1032
STRUCTUKAI, REPAIR MA~iUAI,
RIVET--MS2042BAO--01A TO MATCH EXISTING HOLE

NUMBER REOUIREB BEPENBENT ON RIB THICK)IESS. IREFCR TO
NOTE.)
SPLICE JOIHT
UPPER SKIN (REFI
C
\I
3/4 TO 1
(TYP)
REPAIR RIB ENO
if
BOUBLER
)/4 MIN
(7YP
ALL PLACES)
-f
tj+
t-
REPAIR RIB ENO
-t
LOWER SKIN (REFI
BAMAOEB RIB
SECTION
RIVET--~WQOLW2 ROWS
A-A
REPUIREO
EACH SIOE OF SPLICE

ON 0.020 RIB, 3 ROWS
ON 0.032 RIB
OAMAGEB RIB
Trim afl
damaged
db end
midway between existing
fasteners.
01
Fabricate and
repair
O
and
O
O
tempararily
inotall
repair rib
REPAIR RIB
end and
doubler. Drill all rivet holes.
ENO-4- THICKWESS
TCH RIB
RBmOYe repair parts. and
dimple holes in repair end
repairdoublerflanges.
Reindsll
repair part., and rivet th.m in place.
Check rudder balsnee.ll necessary, reb.lanca rudder
(Refer to "AUDDER STATIC BALANCING",
this
section.)
NOTES
THIS REPAIR IS APPLICABLE TO ALL RUDDER RIBS.
ON 0.032-IN. RIBS, PICK UP THREE EXISTING RIVET
LOCATIONS EACH SIDE OF SPLICE; ON 0.020-IN. RIBS,

PICK UP TWO EXISTING RIVET LOCATIONS EACH SIDE
OF SPLICE.
REPAIR OOUBLER-2024-T4--THICKNESS
ONE GAUGE HEAVIER
THAN RIB
5265-3-214
Rudder Rib Repairs

COPYRIGHT,
55-40-20
Page 207
Aug 17/84
NA-66-1032
STR~CITURAL REPAIR MANUAL
is\
1"1
lol
LEIOIHG
$I
EDGE
101
10!
~I
"ii
loi
SKIN
LEAOIWG EDGE SKIN
jo;
8320426404
RIYET
STRINGER
REOUIREO. CSK SKIN.
I
REPAIR ANGLL
II.H 360106
AH OPPOSITEI
I I
,i
REPAIRDWRLER
r,e
RUDDER
II
5/16n
ale
CFI
2 EOUAL
384023
-I
STRINGER
RIB
IHEFJ
5/16
10
01
I__T__T_j;-i
R0-5/8_
REPAIR CHIWNEL
"li
ol
101Ic!I
s\
Of01
.1
RIB
,I
jo61
10(
JSPACE
L,,
FASTENER (REF)
RIVET
4
MSM428AC4
REOUIRED. CSI( REPAIR AnOI.E
5/18
,ii~I
L1
B
15/16
-8108 8818
II
o
IllsUIK THIS OmIUT. H1~ He HTLLLIII LPElrall
OW IISIDE:OF SKI)I. PLACE REPAIR CHANNEL AND REPAIR

AW(ILE O TO 0.010 IN. INSIDE THIS LINE.
RUDDER SIDE SKIN
IJDENDRADII:
VIEWA
Il.r--IIPIIYO
I; n!
5/18
2EOUAL
lci
3 PLACES. DIMPLE SKIN.
3j4 t
1"
?1
EXISTING
RRACKET(TYP)
Bt\
MOUWTINGB
101
e\
~g
ol
9\
REPMR ANGLE
at
15/16
_4_
0.050
0.050
0.069
0.083
SIZE TO MATCH
REMOYED FASTENER
RUDDER
Fabricate root rib

after
TRAILING
O
O
01
~DOE
NOTE
2024-0 AL ALY 1!18 IW.

7075-0 AL ALY 3/32 IN.
4130 STEEL 1/8 IW.
301
1/2 HARD 1/8 IN.
Prime
CRFS:
repair doubler. Heat-treat it
to -T6
forming.
repairdoubler.
Stop-drill
all cracks in rudder root rib.
Install root rib
repair
doubler and back-drill
mounting
bracket and wire bundle clip attach holes.

THIS REPAIR IS APPLICABLE TO THE RUDDER ROOT
Rie
(RUDDER STATION 2 625).
Fabricate all internal repair parts (channeland angles).
Heat-treat parts to -T42 condition after forming.
O
O
B
I~
rudder roof rlo
Remove the two
root rib (save to
mounting brackets (torque tube) from

templates for new brackets).
rrime sil i~.rnal renair parl.
Caraf ully merli heel line posiiinn of root rih
sl(rRs.
use as
on
insideof
(Sae view A.)

8285-3-215
55-40-20
PaRe
Rudder Root Rib Repairs

208
Aug i 7/84
NA-66-103~
STRUCTURAI, KEPAIR MA~UAL
DRILL OWE NO. 40 HOLE.
3/163/e(rvP1
I1JiJ1
f.
Il/s
I
3/16
SKIN IREF)
3-3/8
5/8
+"-F-~
f
i
I-11/3P
REPAIR AMOLES
5/16
_
1/2
5/8
I
0.3125
(+O.W5)
ale
13/18
TWO HOLES IW LINE
[REFJ
4-1/4
IIIIII -C i
MOUNTIWG BRACKET
111111
RIB REPAIR
\1\1
1(
rlC
2-/8
JOOGLE
0.020 X 19/32
~UJII I -ln
DOUBLER
ROOT RIB IREF)
REPAIR AWOLE
RIVETS--MS204701105--
NO. 40 HOLE
2 REOUIREO EACH AWOLE
(REFJ
3/16
,,1
1-13/32
00
i5CB
SKIN
C1-~s
Ale
IREF)
REPAIR AIOLES
4-9/18
5/8
Pwilion inlernal repsii parto and lemporar iy hold

them with 3/32 in. Cleco fasteners. (The chordwise channel
angle should be O to 0.010

view A.)
ram
S/16
5/16
mTBmPOrarllY
alignment
of
recheck parts
13/16 Ic
MOUWTING
BRACKET
IV
2-9/32
I/
/-JOGOLE
0.020 x 19/32
3/8
(REFJSTRIIGER
DOUeLER
i
I
I s~l J
RIVETS--MS204)OA05-2
e]O
m
repair parts. Realign
and
required.
root rib and
permanently instal
internal
I..1.II root
b.
Fabricate maunling braclel except lar haler
8818 IREFJ
REOUIREO EACH AMOLE
EXTREME CARE MUST BE TAKEN IN LOCATING HOLES
REPAIR CHANNEL
IN
SECTION
install root rb end checl for proper
internal
as
I13Removs
in. from the root rib heel line. See
repair parts.
REPAIR
ROOT Rle(REFJ
51111RB)
B-B
SECTION
A-A
THE
NEW
MOUNTING
BRACKET Tg
ENSURE
ALIGNMENT WITH THE RUDDER TORoVE TUBE.
Locate holes in
the removed
new
mounting brackets from those in
brackets. The 5/16-in
torque tube attach

holes, however, must be 0.050 in, closer to the rib than they
in the original brackets (because of
repair doubler.).
were
CDlnstall
m
NOTE
HEAT-
TREAT.
CADMIUM-PLATE, AND PRIME
E~
MADE FROM 301 CRES.
Rsfi.i.h
surrounding
Rudder Root Rib Repairs
brackets
on
rib
rudder
Reinpta I wire bundle ci p
BRACK ETS MADE FROM 4130 STEEL. PR IME BRACKETS
Figure
mounting
the 0.050 in
204
(Sheet
2 of 3)
repaired
areas
of
rudder
to
match
areas.
s265-3-21BA
55-40-20
Page 209
Aug 17/84
NA-(i6-1032
SIKI:("I~URAL REPAIR MANUAL
REPAIR DOUBLER--0.050 7075-0 CLAG
RIVET-Ms20B770005-9 REOUIREO
EACH ENO OF REPAIR --7
11
EPUAL, 826028 (T~YP

EACH ENO OF REPAIR
7/16(TYPJ
I1
Tt
+L
3/81TYPJ
t
t-
1111
-r
STOPDRILL
NO. 30 (TYP)
I=-
3/4
3/81TYP)
4-3/8
10.090.
Q
-2440
RUOOER HINGE
i"""
WIRE
BUNGLE CLIP
-t-
RIVET-MSMGOOI ITYPI
3/4
P200-2 JOBOLT.
to REOUIREO
CB
3-5/8
f
t
~1
i
NARIE PLATE-ASMOV~ ANG

REINSTALL AFT:OF
REPAIR. FASTEN WITH
08)17-3-2 CHERRY
RIV4TS.IO
Q OF RIB
VIEW CC
REPAIR ANOLEB-O.O50
2024--0 CLAD
RlR-sTA 6020
ROOT RIB:
NOTES
REPAIR CHANNEL--.O50
2024-0 CUd
RIB REPAIR DOUBLER

G.OsO 7076-0 CLAD
REFER TO SOURCE CODE 026 1N 51-30-00.
O HEAT-TREAT TO -T42 CONDITION AFTER FORMING.

El
IREFJ
%OUNTINS RRACKETS-OOOOI
WIRE :BldWCE
CLIP
HEAT-TREAT 4130 STEEL TO 125.0m-140.0W PSI AFTER
FORMING.
55-40-20
Page 210
Aug 17/84
Rudder Hoot Rib Repairs

Figure 204 (Sheet. 8 of 3)
cOa~iGHT, 1984
NA-66-1032
STRUCTURAL REPAIR MANLTAI,
Il
IilOB surlace on suppon sland on a level bench. (See

grooved bolt fabrication sketch, figure 200, 55-10-20.) Tape
wire harness along hinge centerline.
Adjust pointer to height of hinge centerline; then place

adjacent to surface trailing edge. Support center hinge
away from leading edge skin. Trailing edge of rudder should
be even with pointer (0 balance) or below pointer (trailing
it
edge heavy).
Or0
RUOOEB BALANCE REOUIREMENTS

detetmine actual
rudder unbalance
proceed
as
follows.
(a)
Tape test weight container

edge as shown in view "A."
(b)
Add
to rudder
to container until rudder
weights
edge is directly opposite pointer.
leading
-201. -211
0-5.25 IN-LB; T.E. HEAVY
-301
0-5.25 IN-LB; T.E. HEAVY
370-240001-11
Measuredistancefrom centerof containerto
(d)
Weigh
(e)
BALANCE
0-5.25 IN-LB: T.E. HEAVY
trailing
(c)
rudder
RUOOER
285--240001-51.-101
0-5 IN-LR; L.E. HEAVY
hinge line (L).

test container and contents.
Multiply weight by
determine
in.-lbs.
"L"
of
dimension, to
unbalance.
The
unbalance condition must be within tolerance
shown on "RUDDER BALANCE REQUIRE-
MENTS" chart or weights must be added to

bring surface into balance condition. Refer to
"ADDING BALANCE WEIGHTS", figure 211,
55-10-20.
RUOOEH
TAPE
POINTER
e HINGE
5.2
STATIC BALANCE
CHECK BOLT
MAKE FROM
LOWERBUOOER
(e 2.4W
-I
r^n
STRING
HINGE FITTING
5/16 BOLT
LOWER SKIN
TEST WEIGHT
1.220
TRIM
CONTAINER
SUPPORT STANO
VIEW A
MODEL NA 265-40, 60, -604, -6086, AND -65
I! I
SUPPORT STANO
KNIFE EOOE
NOTES
RUDDERS ON MODEL NA 256-40,-00 -60A, -60SC, AND -65 ARE
BALANCED 0-5.25 IN.-LBS. TRAILING EDGE HEAVY.
THE FOLLOWING REBALANCING PROCEDURES ARE FOR A

COMPLETE RUDDER INCLUDING THE TRIM TAB, TRIM TAB
ACTUATOR, STATIC WICKS AND
FINAL PAINT.
5265-3-1888
Checking Rudder Static Balance

55-40-20
PaRe 211
~un 17/X4
NA-66-1032
El
Pisce suiface on support stand on a level bench.

(See
grooved bolt fabrication sketch, figure 209, 55-10-20.) Tape
wire harness
O Adjust
along hinge
pointer
centerline
height of hinge centerline; then place

trailing edge. Support center hinge
away from leading edge skin. Trailing edge of ruddershould
be even with pointer (O balance) or above
pointer (nose
heavy).
it
adjacent
O]Tc
to
to surface
determine actual
rudder unbalance, proceed
as
follows.
(9)
Tape test weight container

edge as shown in view "B.
(b)
Add
(C)
to rudder
trailing
weights to container until rudder trailing

edge is directly opposite pointer.
Measuredistancefrom centerof containerto
to to rudder
hinge
line
(L).
RUOOER
(d)
Weigh
(e)
Multiply weight by .L" dimension, to

determine in. Ibs
of unbalance. The
unbalance condition must be within tolerance
shown on "RUDDER BALANCE REQUIREMENTS" chart or weights must be added to
bring
POIWTER
surface into balance condition. Refer to
"ADDING BALANCE WEIGHTS~, figure 211,

55-10-20.
(1)
If
rudder assumes
trailing edge
7Z"
down
attitude, the rudder balance is unacceptable

and weights must be added. Tape a test
weight
container to leading edge of the rudder as
shown in View A. Add weights to test weight
LOWER SKIW
TRIM
container until
trailing edge matches up with

pointer. Total weight of test weight container
and added weight determine how much
weight must be added to bring rudder into
proper balance.
IUPORT STlnO
VIEW B
MODEL NA 265-70, -00, -80A, AND -8OSC
NOTES
RUDDERS ON MODEL NA 265-70. -80, -80A, AND -BOSC ARE
BALANCED O TO 5 IN.-LBS. NOSE HEAVY.
THE
FOLLOWING REBALANCE PROCEDURES ARE FOR A

COMPLETE RUDDER INCLUDING THE TRIM TAB. TRIM TAB
ACTUATOR. STATIC WICKS AND FINAL PAINT
92(15-3-1888
55-40-20
Page 812
Aug 17/84
Chedking Rudder Static Balance

Figure 205 (Sheet 2,f 2)
COPYR1GHT, 1984
BY SAB:RELINER CORPORATION
CHAPTER
VV IND OVVS
NA-66-1032
STRUCTURAL REPAIR MXIL~LAL
CHAPTER 56
WINDSHIELDS AND WINDOWS
TABLE OF CONTENTS
Subject

General
Master Repair Index
56-00-00

Allowable Damage
General
56-00-10
Flight Compartment
56-10-00
Page
General
Plastic Windshields, Model NA 265-40 (S/N 282-1 thru -85)
Glass Windshields, Model NA 265-40 (S/N 282-36 and Subs), -60, -60A, -60SC, -65. -70, -80, -t30A.
and -80SC:
Cockpit Corner Windows
Cockpit Eyebrow Windows, Model NA 265-40, -60, -60A, -60SC, and -65
Cockpit Eyebrow Windows, Model NA 265-70, -80, -80A, and -80SC
Art Cockpit Windows
Flight Compartment
Allowable Damage
1
1
..,,.,,,,56-10-10
General

Windshield
Corner Windows
Eyebrow Windows, Model NA 265-40, -60, -60A, -60SC, and -65

Eyebrow Windows, Model NA 265-70, -80, -80A, and -80SC
Aft Cockpit Windows
Windshield Damage I,imits for One-Time Flight.
Aft Cockpit and Cabin Windows Damage Limits for One-Time Flight
101
.,......._._.,.,
Flight Compttrtment
Repail
101
10.L
102
56-10-20
General
Cockpit Enclosure, Upl,er Aft Acrylic Panel Repair

Cabin Windows
Structural Idenlification
Cenelal
56-20-00
Cabin Windows
Allowable Damage
General
56-20-10
.1101
56-COIVTENTS
a
COPYRIGHT, 1984
Page 1/2 Hlank

Aug 17/84
NA-66-1032
CHAPTER 56

Section
56-00-00
Figure
1
2
Title
Windshield and Windows Master Repair Index

-60SC, and -65
Windshield and Windows Master Repair Index
and -80SC
Page
Model NA 265-40, -60, -60A,
........._.,._..
Model NA 265-70, -80, -80A,
56-00-10
101
Negligible Damage
Windshield and Windows
56-10-20
202
Cockpit Enclosure, Upper Aft Acrylic Panel, Repair
3
102
201
56-ILLUS
0
~OPVRIGHT, 1984 BY SABRELINER CORPORATION
Page 1/2 Blank

Aug 17/84
NA-66-1032
CHAPTER 56

Chapter/
Section
Page
Date
16/90
56-L.E.P.
1/2"
Mar
56-CONTENTS
1/2
Aug 17/84
56-ILLUS.
1/2
Aug 17/84
56-00-00
1
2
Aug 17/84
Aug 17/84
Aug 17/84
56-00-10
101
102"
103"
104"
105"
3/4
106"
Aug 17/84
Mar 16/90
Mar 16/90
Mar 16/90
Mar 16/90
Mar 16/90
56-10-00
1/2
Aug 17/84
56-10-10
101"
102"
Mar 16/90
Mar 16/90
56-10-20
201
202
203/204
Aug 17/84
Aug 17/84
Aug 17/84
56-20-00
1/2
Aug 17/84
56-20-10
101/102
Aug 17/84
or
56-L.E.P.
0
Page 1/2 Blank

Mar 16/90
NA-66-1 082
STRUCIIJRAI, REPAIR MANUAI,

STRU(:IURAL IDENTIFIC:ATION
GENERAL
This chapter contains repairs and negligible damage
limits for the windshields and windows.
MASTER REPAIR INZ)EX

See figure I for model NA 265-40, -60, -60A, -60SC and
-80SC.
56-00-00
o
CDPYRIOHT,;gg4 gy SABRELINER CORPORATION
Page 1
Aug 17184
NA-66-1032
STRUCI~URAL REPAIR MANUAL
;0.
ITEM
DRAWIIG
WO.
WG.
E1117
265-318202
1
2
3
4
285318372
285-318205
285-318208
265318204
285-300050
DESCRIPTIOI
PUSTIC WIWOSHIELO
GLIISS WIOSHIELO
GORWER WIIIDOW
EYEBROW WIWOOW
UPPER IFT C(CKPITWINGDW
LOWER LFT 6QC#PITW1100W
CABII ll#00WS
MATERRL
REPAIR
FIGURE 10.
ACRYUC
OLA88
ACRYLIe
AeRYLIC
ACRYLIC
AGRYLIC
ACRYLIC
5010-20, F16 201
NOTE
FOR ADDITIONAL
56-00-00
Page
Aug 17/H4
REPAIRS, REFER TO 51-70-00.
Windshields and Windows Master Repair Index

Model NA 265-40, -60, -60A, -605C, and
erugiF561
NA-66-1032
i(
3
,O
ORAWING
ITEM
NO.
1
2
285318202-31 11 .32
26931837251 ILHI
285318208-11 IRHI
310-318205-11 B -12
370318208-11
-12
-12
370318Mll-11
285-300061
5
B
OESCRIPTION
MATERIAL
REPAIR
NO.
GLASS
ACRYLIC
GLASS WIIDSHIELO
CORNER WINOOW
CORNER W1NOOW
EYEBROW WINOOW
ACRYLIC
ACRVLIC
UPPER AFT COCKPIT WINOOW

LOWER AFT COCKPIT W11OOW
CABIN WINOOW8
55-10-20. FIO 201
ACRYLIC
ACRYLIC
ACRYLIC
NOTE
FOR AODITIONAL REPAIRS, REFER TO 51-70-00.
5265-3-213
Windshields and Windows Master Repair Index

Model NA 265-70, -80, -80A, and -80SC
Figure
0
56-00-00
Page 3/4 Blank
Aug 17/84
NA-66-1032

ALLOWABLE DAMAGE
GENERAL
This section contains negligible damage limits for the
windshields and windows.

For
negligible damage limits,
see
figure
101.
56-00-10
0
Page 101
Aug 17/84
NA-66-1032
7178-T8 BABE IWSEBT IRE9
3.
4~
r GL1SS
TRAWSPAREWT CONBUCTIVE
COATIWG
Will Lilt
11~1 7
LAMIIATED
van
LAMIIIATEO VIWYL
PHEHOLIC
L
ICOTTON BASE)
IREFl
GLASS SPALL PLATE
GLASS MAln PLY
GLASS WIWOSHIELO
1288-318282
FACE PLYPLASTIC
FACE PLY I#TEALAYER-VIWYL
TRAWSPAREIT COIOVCTIVE
COATIWG
IWTERPLY-STRECHEB ACRYLIC -7
7178TB BARE
IWSERT
IREFJ
FUSELAGE
moLo LIRE
IREF)
MII#INTEALAY~R--
MIIW PLY-
STRECHEO ACRYLIC
LIIMIWITEO VIYYL
26
PLASTIC WIWOSHI~LO
IE-l 117)
STRETCHEO ACRYLIC
7178TB BARE IISERT
LIIMIWATEO GLASS FABRIC
FUSELAGE
MOLO LIRE
TRANSPAREWT COWBUCTIVE COATIWG
STRETCHEO ACRYLIC
LAMIWATEB VIIYL
LEFTLWD GORYtR WIWOOW-PILOTS SLIOING 1285-3183721
MODEL NA 265-40, -60, -60A, -6080, AND -65

s?as-32~se
Figure
101--
Neffligible Damage
Windshields
and Windows (Sheet 1 of 5)
56-00-10
Page 102
16/90
Raar
COPYRIGWT, 1990 BY SABRELINER CORPORATION
NA-66-1032
STRETCHEG ACRYLIC
O
LAMIIATED GLASS FABRIC
7178-T8 BARE INSERT
LAMINATEO VINYL
O
AIR GAP
STRETCREO ACRYLIC
STRETCHEO ACRYLIC
TRANSPARENT CONOUCTIVE
COATING ON INNER SURFACE
OF ACRYLIC SHEET
FUSELAGE
MOLO LINE
O
LAMIWATED
GLASS FABRIC
COCKPIT RIGHT HANG CORNER WINOOW
1265-3132031
FUSELAGE
MOLO LINE
7178-T8 BARE INSERT
13
AS--CAST ACRYLIC
STRETCHEO ACRYLIC
TRANSPARENT COWOUCTIYE
CCATING ON INNER SURFACE
OF ACRYLIC SHEET
AS--CAST IICAILIC
EYERROW WINOOWS
265-318205 OUTER PANEL
265-318207 INNER PANEL
LAMINATEO
GLASS FABRIC
FUSELIGE
MOLO LINE
LAMINATEO VINYL
LAMIWITED
GLASS FABRIC
LAMINATEO
AS-CAST ACRYLIC
AIR OAF
STRETCREOACRYLIC
GLASS FABRIC
FUSELAGE
MOLD LINE
IREFJ
UPPER AFT COCKPIT WINDOW
I265-31R2OO1
LR OAF
LAMIIIATEO
GLASS FABRIC
AS-CAST ACRYLIC
LOWER AFT COCKPIT WINDOWS (2D5-31R2O4j AND

CABIN WINDOWS
FS 225 AND 281 1265-300050)
MODEL NA 265-40, -60, -608, -6030, AND -65
szss-3-2~se
Figure 101
Windshields
Negligible Damage
56-00-10
0
Page
103
Mar 16/90
NA-66-1032
TRANSPARENT
PARTING AGENT
CONDUCTIVE COATING
(CELLOPHANE TAPE)
SEMITEMPEREO GLASS
7178-76 BARE INSERT
VINYLO
FULLY
TEMPERED GLASS
0.100 VINYL
PHENOLIC (COTTON BASE~
GLASS WINOSHIELO
0.125 SEMI-TEMPERED GLASS
I265-3182021
STRETCHED ACRYLIC
3456
LAMINATED VINYL
O
7178T6
TRANSPARENT
r"
BAREINSERT
CONDUCTIVE
COATING
FUSELAGE
GLASS
FABRIC
STRETCHED
ACRYLIC
iO O
LAMINATED
MOLD LINE
IJ/IO
(3
LEFT-HAND CORNER WINDOW

PILOTS SLIDING 1265-318372)
TWO LAMINATIONS OF
GLASS FABRIC FACING SHEETS

STRETCHED
7178-78 BARE INSERT
ACRYLIC
LAMINATED GLASS FABRIC
STRETCHED
ACRYLICO
BARE INSERT
STRETCHED ACRVLIC SHEET
LAMINATED VINYL
STALTCHEOICAYLIC
(RFFI
717878
13
LAMINATED VINYL
TRANSPARENT CONDUCTIVE
ACRYLIC SHEET TRANSPARENT

CONDUCTIVE COATING TO BE ON INNER
COATING ON INNER SURFACE
SURFACE
OF ACRYLIC SHEET
RIGHT-HAND CORNER WINOOW

MODEL NA 265.70, .80, -80A, AND 8030
Fiffure
EYERROW WINDOWS
I370-3182051
(265-318208)
101--
5370-3-4(
Windshields
Negligible Damage
(Sheet 3 of 5)
and Windows
5600-10
Page
104
Mar
16/90
NA-66-1032
THREE LAMINATES
OF COTTON BASE
PHENOLIC SHEET
ATTACHEO TO
INNER SHEET
OWE LAMINATE
OF COTTON BASE
THREE LAMINATES
PHENOLIC SHEET
OF COTTON BASE
PHENOLIC SHEET
ATTACHEOTO
STRETCHEO
ACRYLIC SHEET
OUTER 2HEET
AIR GAP
TWO LAMINATES
AS--CAST
ICRYLIG SHEFT
OF COTTOY
CILONSHEET
EHP~SIB
UPPER AFT COCKPIT 161600168
1370-318206)
2 PLIES OF LAMINATEO GLASS

FABRIC FACING SHEETS
STRETCHEO
ACRYLIC SHEET
THREE LAMINATIONS
COTTON BASE
FOOT
PHENOLIC SHEET
ATTACHEO
OUTER SHEET
TWO LAMINATIONS
OF COTTON BASE
AIRGAP
PHENOLIC SHEET
ATTACHED TO
INNER SHEET
AS--CAST ACRYLIC SMELT
O
GLASS FABRIC OOUBLER
AFT COCKPIT 161600168
2 LAMINATIONS OF
COTTON BASE PHENOLIC

SHEET
ONE LAMINATION
OFCOTTONBASE
PHENOLIC SHEET
STRETCHED
ACRYLIC SHEET
4 LAMINATIONS OF COTTON
BASE PHENOLIC SHEET

BASE PHENOLIC SHEET
AIR GAP
f
AS--CAST
BASE PHENOLIC SHEET
ACRYLIC SHEET
BIN WINDOWS
MODEL NA 26570, -80, -80A, AND 8080

Figure 101
Windshields
Negligible Damage
8370-3-)2
18"""l";~""
56-00-10
Paffe 105
Mar 16/90
NA-66-1032
CODE
OUTER LAYER OF GLASS OR PLASTIC
IHTERMEOIATE LAYERS OF PLASTIC
INTERMEDIATE LAYERS OF GLASS
CODE
ASSEMBLY
INHERLAVERSOF PLASTIC
SPALLS
SCRATCHES
YES
YES
YES
CRACKS
BUBBLES
YES
IPLAST19
YES
O
EI
P
El
O
I
PI
El
WINOSHIELO
IoLASSl
LH CORNER
WINOOW
WIHOOW
O
O
o
I
IP
O
O
EYEBROW WINOOWS
OUTER PANELS
INNER PANELS
UPPER AFT
COCKPIT WINOOWS
6 1 LOWER AFT
YES
YES
DELAMINATION
WO
YES
RH CORNER
INNER LAYER OF CLASS
NICKS
El
WINDSHIELO
O
O
ALLOWABLE DEFECTS
ITEM
NO.
P
O
I11
NO
YES
YES
YES
HO
NO
HO
NO
NO
YESIIS
YES
YES
YES
YES
YES
YES
YESP
YES
HO
YES~
YES
YES~
vES13
YES ~3
vEs~
vEs~
No
YES
YES
NO
YES
YES
HO
YES~
VESO
YES m
YES
YES
O
13
I
YES
YES
13
YES O
YES O
YES
YES
NO
No
I
YES L~
YES
vES
YES
Cil
YES 13
I~
YES
C~
13
YES O
YES
YES
YES
YES
YES
II
YES
I1I1
NO
No
C~
NO
NO
COCKPIT ANO
CABIN WINOOWS
YES
YES O
YES O
NO
NOTES
Wherespalls, scratches, andnieksarepermitted, land afootnote symbol is used), they
TORTION CAUSES LOSS OF ESSENTIAL VISIBILITY, THE ASSEMBLY MUST BE REPLACED.
the bottom with a minimum apex radius of 0. 030 in. seefootnotes

for allowable depths on individual panels.
must be smooth
on
O
O
O
O
~il
are
IF
BUBBLES BECOME
FERE WITH VISIBILITY, THE ASSEMBLY MUST BE REPLACED.
depth that does not exceed the allowablefor that panel, may be polished out one
time only in anil area.
No damage is anticipated on the layers
that
SMALL BUBBLES ARE PERMISSIBLE.
NUMEROUS ENOUGH OR GROW IN SIZE SO THAT THEY INTER-
Sharp-bottomed "V" scratches and nicks

are not permitted in anil panel where a
footnote symbol is used. Such defects, which
have
WHEN HEATING ABILITY IS LOST AND/OR WHEN OPTICAL DIS-
MUST NOT EXCEED A DEPTH OF 0.016 IN.

LIMITED TO ONE INCH FROM THE EDGE OF THE CLEAR VISION
AREA AROUND THE PERIPHERY OF THE PANEL.
01
O
not coded.
Refer to "Windshields and Windows

General" (text) for definitions of nicks,
scratches, sgalls, delaminations, and
DELETED.
LIMITED TO A DISTANCE OF 2 IN. FROM EDGE OF PANEL.
cracks, andfor additional information.

5285-3-220
Figure 101
56-00-10
Page 106
Mar 16/90

Negligible Damage
(Sheet 5 of 5)
NA-66-1032
FLIGHT COMPARTMENT
GENERAL
COCKPIT EYEBROW
Two types of windshields are used on the Model NA 26540. On S/N 282-1 thru -35, plastic windshields, Part No.
E-1117-1 and E-1117-2 are installed. On Model NA 265-40
S/N 282-36 and subs, glass windshields, Part No. 265318202-13 and 26.5-818202-14 are installed. All other
cockpit and cabin windows are laminated plastic construction. See figure 101, 56-00-10 for sectional views of
windshield and window construction.
PLASTIC WINDSHIELDS, MODEL NA 265-40 (S/N
282-1 THRU
-35)
Plastic windshields (E 1117-land E-1117-2)are laminates

composed of an outer face ply of hard abrasive-resistant
plastic, 0.062 in, thick, a face ply interlayer of 0.025 in.
polyvinY1, and an interply of 0.125 in, stretched acrylic.
These three plies form the outer layer of the windshield,
The main interlayer is 0.325 in. polyvinyl; the main inner
structural ply is 0.750 in. stretched acrylic. The
conductive coating for heating the windshield for anti-icing,
defogging, and birdproofing is deposited on the inside
surface of the 0.062 in. outer ply.
GLASS WINDSHIELDS, MODEL NA 265-40 (S/N

282-36 AND SUBS), -60, -60A, -60SC, -65, -70, -80,
-80A, AND -80SC.
(;lass windshields
(265-318202) are composed of

laminates consisting of an outer ply of 0.188 in, glass, an
interlayel of laminated vinyl, a structural main ply of
0.375 in. glass, another interlayer of laminated vinyl, and
an inner spall plate of 0.125 in, glass. The conductive
coating for heating and birdproofing is deposited on the
inner surface of the outer ply.
WINDOWS, MODEL
NA
265-40, -60, -60A, -60SC, AND -65

The eyebrow windows are composed of two panels
seperated by an air gap 0.010 in. wide. The outer panel
(265-318206-11 or 265-318205-12) is a monolithic sheet of
0.320 in stretched acrylic. The inner panel (265-318207-1
or 265-318207-2) is a laminate consisting of an outer ply of
0.080 in. as-cast acrylic, an interlayer of 0.200 in
laminated vinyl, and an inner ply of 0.125 in, as-cast
acrylic. The conductive coating for heating is deposited on
the inner surface of the outer 0.080 in. as-cast acrylic ply.
COCKPIT EYEBROW WINDOWS, MODEL NA
265-70, -80, -80A, AND -80SC

The eyebrow windows (370-318205) are made up of a 0.275
in. thick panel of laminated vinyl sandwiched
between inner and outer panels of stretched acrylic. The
outer panel is 0.500 in. thick and the outer panel is 0.125
in. thick. The conductive coating for heating is applied to
the inner surface of the outer stretched acrylic sheet.
AFT COCKPIT WINDOWS

The aft cockpit windows consist of two monolithic
structural panels, an outer of stretched acrylic and an
inner of as-cast acrylic. Several layers of laminated glass
fabric are bonded to the edges of innel surface of outer
panel and outer surface of inner panel. The laminates on
these edges serve to space the two panels apart and
provide an air gap between them. The aft upper (2Ci5318206) have a 0.276 in. thick outer ply and a 0.125 in.
inner ply. The aft lower windows (265-318204) have outer
plies 0.320 in. thick and inner plies 0.150 thick.
COCKPIT CORNER WINDOWS

The left
corner window (265-318372) is a laminate

consisting of an outer ply of 0.276 in, stretched acrylic, an
interlayer of 0.275 in. laminated vinyl, and an inner ply of
0.3.50 in. stretched acrylic. The conductive coating for
heating is deposited on the inner surface of the outer ply.
The
right corner window (265-318208) is a laminate

consisting of an outer ply of 0.390 in. stretched acrylic, an
interlayer of 0.275 in. laminated vinyl, and an inner ply of
0.125 in. stretched acrylic. The conductive coating for
heating is deposited on the inner surface of the outer ply.
56-1 0-00
0
Page 1/2 Blank

Aug 17/84
NA-66-1032
FLIGHT COMPARTMENT
ALLOWABLE DAMAGE
GENERAL
are not permitted. Such defects that have a

depth
that does not exceed 0.016 in, may be polished out one
time only in any area.
Negligible damage limits for windshields and cockpit

are given in this section and in section 56-00-10.
windows

Nicks
defined
2.
The outer ply is the main structural ply; cracks are

not permitted. Spalls and smooth-bottomed
scratches and nicks are permitted if they do not
exceed a depth of 0.016 in. Sharp-bottomed ("V")
scratches annd nicks are not permitted. Such
defects that have a depth that does not exceed 0.016
in. may be polished out one time only in any area.
Delamination of the outer ply from the vinyl
interlayer is not permitted.
broken indentations or cavities having sharp edges. Spalls are cavities left by the loss of a
fragment having at least one feathered edge. Scratches
are tears in the surface made by a hard object. They are
shallow marks, grooves, furrows, or channels. Cracks are
fractures which extend partially or completely through a
given member. Delamination is the separation of two layers of a laminated multilayer panel.
are
as
WINDSHIELDS
1.
Spalls, scratches, nicks, and
cracks in the inner ply

permissable. Delamination of the inner ply is
permissable.
are
Plastic Windshields
Spalls, scratches, or nicks are permitted in the outer

ply. Cracks usually cause loss of heating capability
and are cause for replacement. Delamination of
outer ply is permitted.
EYEBROW WINDOWS, MODEL NA 265-40, -60,
60A, -60SC, AND -65

i.
Cracks are not permitted in the main structural

inner ply. Spalls and smooth-bottomed scratches
and nicks are permitted if they do not exceed a depth
of 0.015 in. Sharp-bottomed ("V") scratches and
nicks are not permitted. Such defects that have a
depth that does not exceed 0.016 in. may be polished
out
2.
one
time
only in
any
Glass Windshields
2.
Cracks, scratches, spalls, or nicks are acceptable in

the spall plate (the inner ply of glass windshield).
Delamination of the inner ply from the vinyl
interlayer is permitted,
3.
Left Corner Window
Spalls, scratches, and nicks are permitted in outer

ply. Cracks are not permitted in this ply. Defects on
this surface that interfere with visibility may be
polished out. Delamination is permissable up to 30
percent of the window
area.
Cracks are not permitted in the main structural

inner ply. Spalls and smooth-bottomed scratches
nicks
InnerPanel, OuterPly
No cracks are permitted in the outer ply (0.080 in.)of
this panel. Spalls and smooth-bottomed scratches
nicks are not permitted. Such defects that are not
deeper than 0.025 in. may be polished out one time
only in any area. Delamination of the outer ply from
the vinyl interlayer is perrmissable around the
edges of the panel. This delamination is limited to
one in. from the edge of the clear-vision area around
the periphery of the panel.
Cracks, spalls, or nicks are not allowed in the main

structural ply. This is an internal member, and both
surfaces are protected by other plies of the
windshield.
CORNER WINDOWS
OuterPanel
This is the main structural ply; cracks are not permitted. Spalls and smooth-bottomed scratches and
nicks are permitted if they do not exceed a depth of
0.010 in. Sharp-bottomed ("V") scratches and nicks
are not permitted. Such defects that are not
deeper
than 0.010 in. may be polished out one time only in
any area. Delamination of the glass fabric laminations is not cause for replacement of a panel.
area,
Spalls, scratches, or nicks are permitted in the outer

ply. Cracks usually cause loss of heating capability
and are cause for replacement. Delamination of
outer ply is permitted.
1.
RightCorner Windows
InnerPanel
Cracks are not permitted in the inner ply. Spalls and
smooth-bottomed scratches and nicks are permitted
if they do not exceed a depth of 0.004 in. Sharpbottomed ("V") scratches are not permitted. Such
defects that are not deeper than 0.004 in, may be
polished out one time only in any area. Delamination
of the inner ply from the laminated vinyl innerlayer
is permissable for a distance of2 in, from the edge of
the ply.
56-1 0-10
Page 101
Mar 16/90
NA-66-1032
ALLOWABLE DA1MAGE (Continued)

Because of reduced birdproof capability and a tendency of
the windshield to deflect outward from cabin pressurization at high altitude, it is recommended that the flight be
restricted to the following conditions.
EYEBROW WINDOWS, MODEL NA 265-70, -80,

80A, AND -80SC
Inner and Outer Panels
Cracks are not permitted in either the outer panel (main

structural ply) or the inner ply.(Refer to 56-00-10). Spalls
and smooth-bottomed nicks or scratches are acceptable,
provided the defects do not exceed 0.010 in. in depth in the
outer panel. Sharp-bottomed ("V") type scratches are not
acceptable; such defects which do not exceed 0.010 in. in
the outer panel or 0.004 in. in the inner ply, may be polished out one time only in any area. Delamination of the
glass fabric laminations from the stretched acrylic outer
panel is acceptable and is not cause for replacement of the
window. Delamination of the stretched vinyl inner ply
from the laminated vinyl inner layer is acceptable for a
distance of two in, from the edge of the ply.
2.
Maximumairspeed isZOOKIBS.
3~
Maintain altitude of 6000 feet above local ground

level.
4.
Maintain the minimum altitude above condition 3

permitted by weather and other flight conditions.
5.
A placard clearly stating the foregoing flight restrictions must be conspicously posted in the cockpit.
use
The maximum damage limits of aft cockpit and cabin

windows for one-time flight to repair facility is as follows:
The structural plies of these panels are monolithic and

therefore will not delaminate. Delamination of the glass
fabric edge spacers is not reason for replacement. Cracks
are not allowed in any of these panels. Spalls and smoothbottomed scratches and nicks are permitted if they do not
scratches and nicks are not permitted. Such defects that
are not deeper than 0.025 in. may be polished out one-time
any
D,.,t
AFT COCKPIT AND CABIN WINDOWS DAMAGE

LIMITS FOR ONE-TIME FLIGHT
AFT COCKPIT WINDOWS
only in
windshield heat.
1.
1.
2.
ply or inner ply may have a crack extending across the panel provided the ply cracks clean,
leaving a smooth outer surface.
The outer
Spalls, smooth-bottomed scratches, and nicks, which

repairable limits (0.025 in.).
exceed
3.
Sharp-bottomed ("V") scratches and nicks,

repairable limits.
which
exceed
area,
IW~RIMPI
WINDSHIELD DAMAGE LIMITS FOR ONE-TIME

FLIGHT
Numerous cracks, which radiate outward

a central point will not be allowed
and must be changed before furtherflight.
from
The maximum damage condition of a windshield panel

permitted for a one-time flight to a repair facility is as
follows: The outer ply may be cracked completely across
the panel if (l)the ply cracks clean, leaving a smooth outer
surface, and (2) there is no delamination from the vinyl
interlayer along the edges of the crack,
With the windshield damage condition described in the
preceding paragraph, cabin pressure may be maintained.
The windshield heating capability, however is lost
because of a discontinuity of the conductivecoating
between the outer and intermediate windshield plies. Full
birdproof capability of the windshield plies. Full birdproof capability of the windshield is dependent on heating
of the interlayers. With windshield heating inoperative, it
therefore follows that the windshield will have reduced
capability of withstanding bird impact.
With window damage described in preceeding paragraph, cabin pressurization will not be used for entire
duration of flight. It is recommended that the flight be
restricted to the following conditions.
airspeedatsOOKIAS.
i.
Maximum
2.
Maximum altitude for flight, 10,000 feet, M.S.L.
3.
A placcard clearly stating the foregoing flight restrictions must be conspicuously displayed in the
cockpit.
4.
Minimum flightcrew.
56-1 0-10
Page 102
Mar 16/90
NA-6G-1032
STKUCrURAI, KEPAIK M~IVI;AI,
FLIGHT COMPARTMENT
REPAIR
GENERAL
Ihis section contains repairs for the flight compartment
windows.
COCKPIT ENCLOSURE, UPPER AFT ACRYLIC

PANEL REPAIR
See figure 201.
56-1 0-20
0
Page 201
Aug 17/84
1V A-66- 1032
HI~:IAIK MANIJAL
HEEL LINEUPPER
FS )18625
ADOEO PANEL
-L
LONGERON
EXISTING PANEL
r
II
y-"""
19/32
TRUE
I+
19/32rRUt
265-318206
19i32 TRUE
I
-C-
"1
TRUE
9/32 TRUE
1/4 R
1-0.01D
I---C--------lI
1/4(TYP)
19132
I+
19/32 (TYPI
+I
$I
(TYP)
+i.
TAPER AS SHOWN
IF 0.032 MATERIAL
IS USEO
19/32
TRUE
AOOEO SKIN
EXISTING SKIN
FS)34
SECnONN
O
O
Remove tastensrs around
periphary
ol
damaged
A-A
pane
Plsprrs surlacs for app icsfian of oesisnl. Refer to
5:-~0-10
O
area
Add OU20 stainless steel 112 hard pane to
of
existing panel
Dimple holes
cover
to match
entire
Form to
(Alternate material 0.032 2024-T3. Countersink

Prime and
match
I:oat
screws
to
paint.)
with
sea anf when new skin
apnembled.
Reicl to 51-20-id
Fin sh pei F nish
Spec
24600024
NOTE
THIS REPAIR IS APPLICABLE TO DAMAGED LH AND RH
UPPER AFT ACRYLIC PANELS ON MODEL NA 265-40.;60.
-60A. AND -60SC
56-1 0-20
Page
Cockpit E;nclosure; Upper Aft Acrylic Panel, Repair

Figure201 (Sheet 1 of 2)
202
Aue 17/84
:o
COPYRIGHT, 1984
+0.001
-0.000
NA-66-1032
STRUCIURAI, KEIAIR MANI:.ZL
370-318206
21/321TYPI
HEEL LINE UPPER
LONGERON
$+Y;
ADDEO PANEL
\t
21/32 TRUE
ry
21/32
21/32
i-~ TRUE
\C
oson(rvpl
TRUE
iA
I~t
~-e
TR WP 27
ON ENCLOSED ML
21/32 TRUE
FS 118.825
FS 134
FS 134
21/32
TRUEI- ~
I
ii)
I~
Hemove fasteners around
petiphery
of damaged
0.010
TAPER AS SHOWN
panel
IF 0.032 MATERIAL
Prepare surface for application
IS USED
of sealant. Refer to
5i-20-10.
hi
Add 0.020 stainless steel 1/2 hard panel to
cover
entire
FS 134
of existing panel. Dimple holes to match. Form to

contour. (Alternate material 0.032 2034-T3, countersink to
area
match. Prime and
Coat
screws
ADOEO SKIN
paint.)
with sealant when
new
sltin is assembled.
Refer to 51-20-10.
OFinish
per Flnirh
Spec
216-0~024
NOTE
THISAEPAIA IS APPLICABLE TO DAMAGED LH AND AH
SECTION
A-A
UPPER AFT ACAYLIC PANELS ON MODEL NA 255-80.
-80A, AND -80SC.
Cockpit Enclosure, Upper Aft Acrylic Fanel, Repair

0
56-1 0-20
Paae "(lr~!04 Hlank
AuB 17/81
NA-66-1032
STRUCTURAL REPAIR MANLTAL
CABIN WINDOWS
GENERAL
Each cabin window is composed of two seperate
monolithic structural panels, an outer one of stretched
acrylic and an inner one of as-cast acrylic. Several layers
of laminated glass fabric are bonded to the edges of the
inner surface of the outer panel and the outer surface of
inner panel. The laminates on these edges serve to space
the two outer panels apart and provide an air gap between
them. The cabin windows (265-300050) have outer plies
0.320 in. thick and inner plies of 0.150 in. thick.
56-20-00
Page 1/2 Blank
0
Aug 17/84
NA-66-1032
CABIN WINDOWS
ALLOWABLE DAMAGE
GENERAL
Negligible tlamage lim its for the cahin wi ndows are given
in this section and section 56-00-10.
The structural plies of these panels are monolithic and

therefore will not delaminate. Delamination of the glass
fabric edge spacers is not reason for replacement. Cracks
are not allowed in any of these panels. Spalls and smoothbottomed scratches and nicks are permitted if they do not
scratches and nicks are not permitted. Such defects that
are not deeper than 0.002 in. may be polished out one time
only in
any
area.
56-20-10
0
Page 101/102 Blank

Aug 17/84
C H A PT E R
VVINGS
NA-66-1032
CHAPTER 57
WINGS
TABLE OF CONTENTS
Subject
General
Wing
Page
57-00-00
1
Box Section
Model NA 265-40, -60, -70, and -80

Model NA 265-40, -60, -70, and -80
Slats
Model NA 265-40, -60, -70, and -80
Ailerons
Model NA 265-40, -60, -70, and -80
Flaps
Spoilers
Wing Master Repair Index
Skin Gap Diagram
Model NA 265-40, -60, -70, and -80
Wing Component
Leading Edge
Leading Edge
Trailing Edge
Trailing Edge
Wing Allowable Damage
1
1
2
2
Z
2
2
2
57-00-10
General
101
Overwing Fairing Delamination Limits

Main Frame
General
101
57-10-00
1
Main Frame
Repairs
General
Rotating the Wing
57-10-20
Wing Tank Sealing
57-10-30
201
201
Groove Injection Sealing

Fueltight Faying Surface Sealing, -650F to 200 DF.
Sealing Wing Joint Splices
Stopping Fuel Leaks
202
.........,.,.,._
Sealing Repairs
External Repair of Leaking Fasteners in Fuel Cell Close-out Area
Testing For Leaks
.........,.,.,._
.........,.,.,._
203
....,.,..,.,.,._
Plates and Skins

Repairs
General
Stripping the Wing
Flight Surfaces
57-30-20
201
.........,.,.,._
Structural Identification....
57-50-00
Allowable Damage
57-50-10
General
Flight Surfaces
General
Maximum Wear Allowances
Leading Edge Slat Tracks
Model NA 265-40, -60, -70, and -80
Inboard and Outboard Flap Tracks
101
.........,.,.,._
101
57-CONTENTS
0
Page 1
16/90
Mar
NA-66-1032
TABLE OF CONTENTS
Subject
Flight Surfaces
(Continued)
Repairs
Page
57-50-20
201
General
Static Balancing Ailerons
201
Repairs
Flap Repairs
Slat Repairs..........
Aileron
57-CONTENTS
PaRe 2
Aug 17/84
NA-66-1032
CHAPTER 57
WINGS
Section
2
3
Wing Component Skin Gap Diagram
Model NA 265-40, -60, -70, and -80

Repair Index
Repair Index --Model NA 265-60A, -60SC, -65, -80A,
Wing Master
Wing Master
57-00-00
Page
Title
Figure
and -80SC
Model NA 265-40, -60,
-70, and -80

57-00-10
101
Negligible Damage
Wing
Model NA 265-40, -60, -70,
and -80
57-10-00
57-10-20
202
205
209
210
212
213
201
202
203
204
Wing Fuel Tank Sealing Diagram

Sealing Methods
206
201
Lower Main Box Skin Removal

Machined Box Skin Thickness Diagram
Wing Panel Lower Skin Fastener Diagram
Upper Machine Box Skin Repair
211
212
213
57-30-20
Wing Rotating Fixture

Holding Fixture
Wing Main Box Section
Outboard
Front and Rear Spars Web Repair
Wing Front Spar Air-load Rib Tab Repair
Wing Front Spar Upper Cap Repair
Box Section Rib Repair
Repair of Rear Spar Lug at Rear Spar Stations
(RSS) 63.345, 75.302, 94.758, 127.758, and 152.450
Repair of Rear Spar Lug at Rear Station (RSS) 253.041
Repair of Rear Spar Lug at Rear Spar Station (RSS) 90.582
Wing Inbd Trailing Edge (TE) Rib Repair
Repair of Wing Inbd Trailing Edge (TE) Alignment Fitting
201
202
203
204
205
206
207
208
209
210
57-10-30
Model NA 265-40, -60, -70, and -80

Wing Fixed Structure Repair Index
NA
Model
-60SC, -65, -80A, and -80SC
Index
265-60A,
Wing Repair
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
Sealant Injection Guns

Repair of Stripped Sealant Injection Holes
Class B
Box Skin Repair
Box Skin Land Repair
Blind
Box Skin Repair
Skin Leading Edge Repair
Lower Machined Box Skin Repair
Blind
Class B
Wing Inboard Trailing Edge Skin Repairs
Wing Intermediate Trailing Edge Skin Repair
Wing Underslat Leading Edge Skin Splice Repair
Wing Underslat Leading Edge Skin Repair
Access Hole Repair
Slat Track Attach Bolt
Upper Machined
Upper Machined
Upper Machined
Wing Lower Box
215
216
217
220
221
225
226
208
209
204
202
204
205
207
209
210
212
213
214
217
218
219
213
221
223
224
57-ILLUS
0
Page 1
Mar 16/90
NA-66-1032
Section
1
2
3
4
57-50-10
101
102
57-50-20
Title
Figure
57-50-00
201
202
203
204
205
206
207
208
209
209A
210
211
212
(Continued)
Model NA 265-40, -60, -70, and -80

Wing Slat Repair Index
Aileron Repair Index
Model NA 265-40, 60, -70, and -80
Flap Repair Index
Flap Repair Index
Wing Leading Edge Slat Tracks

Model NA 265-40, -60, -70, and -80
Checking Aileron Static Balance
Static Rebalance Calculations
Aileron Rib Repairs
Aileron Leading Edge Skin Repairs
Aileron Aft Skin Repairs
Aileron Outboard Hinge Fitting Bushing Repair
Flap Skin Repairs
Flap Skin Repairs (Sonic Doublers)
Flap Rib Repairs
Replacing Flap Seals

Slat Skin Repairs
Page
2
5
8
11
102
103
201
203
204
205
209
210
211
212
214
214A/214B
215
216
218
57-lllUS
Page 2
Mar 16/90
NA-66-1032
CHAPTER 57
WINGS
Chapter/
Chapterl
Section
Page
Section
Date
57-L.E.P.
1*
2*
Mar
Mar
16/90
16/90
57-CONTENTS
1*
2*
Mar
Mar
16/90
16/90
57-ILLUS.
1*
2*
Mar 16/90
Mar 16/90
57-00-00
1
2
3
4
Aug
Aug
Aug
Aug
Aug
17/84
17/84
17/84
17/84
17/84
Mar
16/90
17/84
17/84
17/84
17/84
17/84
5/6
57-00-10
57-10-00
57-10-20
101"
102
103
104
105
106
1
2*
3
4
5
6
7
8
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
Aug
Aug
Aug
Aug
Aug
57-10-20
Page
(Contd)
57-10-30
Mar
Aug
Aug
Aug
Aug
Aug
Aug
or
16/90
17/84
57-30-20
17/84
17/84
17/84
17/84
17/84
deleted
Aug
Aug
Aug
Aug
Aug
Aug
Aug
Aug
Aug
Aug
201
202
203
204
205
206
Aug
Aug
hug
Aug
Aug
by the
17/84
17/84
17/84
17/84
17/84
17/84
17/84
17/84
17/84
17/84
208
209
210
17/84
17/84
17/84
17/84
17/84
Jun 3/88
Jun 3/88
Jun 3/88
Jun 3/88
Aug 17/84
Aug 17/84
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
207B
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
219
220
221
222
223
224
225
226
227
228
207/207~
Aug 17/84
Date
current revision.
57-L.E.P.
0
COPYRIGHT,
Page 1
16/90
Mar
NA-66-1032
Chapter/
Page
Section
1
2
57-50-00
3
4
5
6
7
8
9
10
11
12
101
102
57-50-10
103/104
201
202
203
204
205
206
207
208
209
210
211
212
213
214"
57-50-20
Added
214A/214B*
215
216
217
218
219/220
Date
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Bug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Mar 16/90
Mar 16/90
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
The asterisk indicates pages revised, added
or
57-L.E.P.
Page
Mar 16/90
NA-66-1032
CHAPTER 57
WING
GENERAL
integral
On model NA 265-40,-60, -70, and -80, the fixed structure

consists of the structural box section, leading edge,
trailing edge, and wing tips. The slats, ailerons, and flaps
comprise the flight surfaces. The wing is a fully
cantilevered, tapered airfoil section with 00 incident at
the root and a -2.50 incident at the tip. Sweepback is
approximately 28.50, measured at the 25% chord plane,
and wing dihedral is 3" 8.5 minutes. The main box section
and inbd leading edge are sealed and function as a fuel
tank with a capacity of about 446 gallons in each wing
groove injection method along fastener rows.

Individual fastener holes are counterbored, and the
fasteners are sealed with 0-rings.
On model NA 265-60A, -60SC, -65, -80A, and -80SC, a 30

in. wing tip extension has been added to each wing box
section outbd of the fueled area. An overwing fuel tank
has also been added aft of the front spar, between WS
40.812 and 138.264.
Repairs or modifications involving the use

ofsteel or other magnetic materials (including fasteners) are prohibited within a 36
in. radius of the compass syatemFuz gates
in each wing tip. Non-magnetic materials
panel.
On model NA 265-60A, -60SC, -65, -80A, and -80SC, the
fixed structure consists of the structural box section,
leading edge, trailing edge, extended wing tip panels, and
wing tips. The flight surfaces include the ailerons, fowlertype flaps, and the spoilers. The wing is a fully
cantilevered, tapered airfoil section with 1.680 incident at
the root and -4.64" incident at wing tip. Sweepback at the
wing leading edge is 32.79" and the dihedral is 3.14". The
wing and leading edge are sealed and function as a fuel
tank with a capacity of 544 ffal. in each wing panel.
On all
airplanes, the
two wing panels are closed out by a

centerline rib with splice plates on the upper
surfaces. The wings are mated to the fuselage with four
bolts. On model NA 265-40, -60, -60A, -60SC, and -65 the
wing-to-fuselage attach points are at FS 206 and 264.25.
On model NA 265-70, -80, -80A, and -80SC, the wing-tofuselage attach points are at FS 206f17 and 264.25. The
main landing gear, is attached to the rear spar at the
canted wing station (CWS) 59.095. Airplane jacking pads
can be attached to fittings adjacent to the front spar at WS
94.187. A cast aluminum skid is provided under the wing
panel mating joint to preclude structural damage in event
common
of
gear-up
landing.
Wing panels are part-numbered and serial-numbered in

mated pairs only. The identification plate is on the
centerline of the
rear
spar web.
BOX SECTION
The backbone of the wing is a main box beam extending

from wing tip to wing tip. The box is formed by a front and
rear spar, transverse ribs, and upper and lower main
skins, which extend from the front to the rear spar. The
skins are stiffened spanwise by integrally machined
stringers. Chordwise stiffening is achieved by sheet metal
formers. Fueltiffht sealing is accomplished by the
are
the onl~ aeeeptable materials that may
be added in these
LEADING EDGE
AND -80
areas.
MODEL NA 265-40, -60, -70,
leading edge is made up of an inbd, an intermediate

(underslat), and an outbd section. All sections are of
basically the same construction: A chem-milled skin
wrapped around the nose lines from the upper front spar
The
cap to the lower main box skin. Attachment to the lower
skin is just fwd of the lower front spar cap.

The inbd section is sealed and serves as a portion of the
wing fuel tank. The intermediate, or underslat, leading
edge is recessed to accommodate the slats and house the
slat track assemblies. Slat track ribs are removable. A
series of covers along the lower leading edge surface
provides access to slat track assemblies. The outbd section
continues the wing leading edge lines from the outer end
of the slat to the wing tip fairing.
LEADING EDGE
-65, -80A, -80SC
MODEL NA 265-60A, -60SC,
The wing leading edges on model NA 265-60A, -60SC, -65,

-80A, and -80SC have been modified to carry fuel. The
extreme fwd
portion of the leading edges are isolated

from the fuel area by the leading edge spar. A graduated
dia. anti-icing duct is installed on the fwd side of the
leading edge spar. Holes drilled in the anti-icing duct
direct heated engine bleed air against the leading edge
fwd skins to provide anti-icing protection. The fueled area
of the leading edge is protected from the heat of the antiicingductby insulation, installed on the fwd face of the leading
57-00-00
0
Page 1
Aug 17/84
NA-66-1032
SIRU(:TURAL REPAIR MANUAL
265-60A, -60SC,
trailing edge. A trim tab of honeycomb sandwich construction is provided on the left aileron.
spar. The leading edge is fabricated from formed

sheet metal ribs, stringers, and skins, which are secured
in place by sealed fasteners. A series of large sealed access
doors is located on the lower surface of the leading edge to
provide access to the interior of the leading edge.
The aileron is mounted to the wing rear spar by two

hinges. Aerodynamic balance is obtained by a series of
steel weights attached inside the leading edge skin.
LEADING EDGE
MODEL NA
-65, -80A, -80SC (Contd)
edge
TRAILING EDGE
AND -80
FLAPS
The flap is a two-celled torque box consisting primarily of

a spar, a rear beam, and a transverse rib enclosed in
upper, lower, and leading edge skins. The rear beam
incorporates a sheet-metal channel and honeycomb
sandwich trailing edge. The flap operates on two tracks
cantilevered from the wing rear spar.
MODEL NA 265-40, -60, -70,
The trailing edge is divided into three sections: The inbd,

intermediate, and outbd trailing edge assemblies. All are
cantilevered from the rear spar. The inbd trailing edge
assembly consists of front and rear beams, transverse
ribs, and upper and lower skins. The rear beam is made
up of a sheet metal channel and a honeycomb sandwich
panel trailing edge. A heavy honeycomb sandwich panel
bridges the landing gear strut well and connects the
trailing edge assembly to the rear spar,
FLkPS
On model NA 265-60A, -60SC, -65, -80A, and -80SC the
flap is a single-cell torque box consisting of a leading edge

skin, upper and lower machined stringers, upper and
lowejr skins, transverse ribs, rear beam, and a trailing
edge. Flap movement is controlled by two electrically
operated screwjacks mounted adjacent to the two flap
tracks
MODEL NA 265-60A,-605C,-65, -80A,
The spoiler system is installed on the upper surface of the

wing, as the primary means of increasing the rate of
descent (decreasing airspeed) from cruise altitude for
conditions such as emergency descent. The 4 spoiler panel
systems are electrically controlled and hydraulically
actuated to a 430 f30 position. The electrical control
system pro;j~aes for either manual or automatic operation
of the spoilers. The automatic mode is used to extend the
spoilers on touchdown to shorten the landing distance.
MODEL NA 265-60A, -605C,

TRAILING EDGE
-65, -80A, AND -80SC
On model NA 265-60A, -60SC, -65, -80A, and -80SC the

trailing edge consists of formed sheet metal ribs attached
to the rear spar, upper and lower skins, and a honeycomb
sandwich panel attached to the aft end of the ribs. The
honeycomb panel completely covers the flaps when they
are in the retracted position. The spoilers are installed in
the trailing edge structure fwd of the honeycomb panel.
The trailing edge extends from the fuselage mold line to
the outbd end of the flaps (approximately WS 161.122).
WING MASTER REPAIR INDEX

See
iigure
figure
1 for model NA 265-40, -60, -70, and -80. See

2 for model NA 256-60A, -60SC, -65, -80A, and
-805%.
MODEL NA 265-40, -60, -70, and -80
provided over the intermediate wing

leading edge assembly. Each slat is cantilevered from
leading edge ribs by two track and roller assemblies. The
five slats are interconnected and operate as a single
aerodynamic unit.
A set of five slats is
at WS 72 and 132.
SPOILERS
AND -808C
trailing edge.
Slat construction consists of ribs,
MODEL NA 265-60A, -605C, -65, -80A,
AND -805C
The intermediate trailing edge assembly attaches to the

rear spar and consists of ribs, narrow upper and lower
skins, and a honeycomb sandwich panel trailing edge over
the flap. An aerodynamic flap seal is attached to the lower
side of the assembly. The outbd trailing edge assembly
attaches to the rear spar and consists of three ribs, a rear
beam, upper and lower skins, and a honeycomb panel
SLATS
MODEL NA 265-40, -60, -70, AND -80
WING COMPONENT SKIN GAP DIAGRAM

See figure 3.
sheet metal beam, a

upper and lower
honeycomb sandwich trailing edge, and

skins.
AILERONS
The aileron is a single-cell torque box consisting
primarily of a sheet-metal beam, transverse ribs, upper
and lower skins, and a honeycomb sandwich panel
57-00-00
Page 2
Aug 17/84
COPYqlGHT, 1984 BY SABRELINER CORPORATION
NA-Gfi-1032
STRIICTURAL REPAIR MAIUUAI,
i7
ITEM
NO
WING ASSY
NOMENCLATURE.
ASSY NO
FIGURE NO
11
12
14
15
NOTE
REPAIR INDEX
WING JOINT PLATE
265-100026
57-18-00. Fig 1
WING PANEL ASSY
265130023
57-10-00, Fig 1
TE ASSY
265-130005
57-18-00. Fig 1
FLAP ASSY
265-180801
57-58-00, Fig 3
AILERON ASSY
265-180002
57-50-60, Fig 2
TIP FAIRING ASSY
265-150001
57-10-00. Fig 1
LE ASSY
285-130008
57-10-00, Fig I
SLAT ASSY
265-170005
57-50-00. Flg 1
SLAT ASSY
285-170004
57-50-00, Fig 1
10
SLAT ASSY
265170003
5750-00. Fig 1
11
SLIT ASSY
285-170002
57-56-00, Fig 1
12
SLAT ASSV
265-170001
57-50-00. Fig 1
13
LE ASSY
265-130019
57-10-00. Fig 1
14
FAIRING ASSY
285131001
57-10-00, Fig 1
15
SKID
265-100031
57-10-00, Flg 1
16
WING JOINT PLATE
265-100040
57-10-00, Fig 1
17
WING FAIRING ASSY
370-131000
57-10-00, Fig 1
SEE SECTION 57441-10 FOR NEGLIGIBLE DAMAGE LIMITATIONS.
WING ASSEMBLY IDENTIFICATION PLATES ARE ON

THE CENTERLINE OF THE REAR SPAR WEB.
S265-3-221A

Model NA 265-40, -60, -70 and -80
Figure
0
57-00-00
Page
Aug 17/84
NA-66-1032
STRITCTURAL REPAIR MANUAL
g"9
nF/
ITEM
10
57-00-00
Page 4
Aug 17/84
WOMELCLATURE
ASSY 10
WIWO JOIWT PLATE, UPPER
285-100028
TE ASSY
7857304
FLAP
7&57830
SPOILER
78-57375
AILEROW
286-180001
WIW6 TIP
7857238
FEWCE
7857498
LEASSY
7667401
WIW6 PANEL ASSY
285-100002
10
W110 JOIWT PLATE, LOWER
286-100040

265-6qA, -60SC, -65, -801A, and
Model NA
erugiFCS082
NA-66-1032
STKUCICIRAI, KEPAIR MANIIAI,
3/161+1/18)
7/32 TO
3/8
8/5NIM
MIX
CLOSEST POINT ON ARC
(TYP FOR ALL CONTROL SURFICESI
_Sh23/1
5/16 Min
7/16 MAX
3/16 TO 5/16
3/8 MIN
5/8 MAX
3/16 MIN
5/18 MAX
1/16 MIN
3/16 MAX
1/16 Min
3/18 MAX
1/16 MIN
00 HOT MLASURE
3/16 MIX
GIIP IIT TRAILING

EOGEOFSLAT
1/16 MIH
3/16 MIX
SEOMENTS(TIPI
WING
1/A MIN
3/8 MAX
NOTES
ARE O TO 1/16 IN.
2
SKIN GAP TOLERANCES GIVEN ON THIS ILLUSTRATION ARE FOR FITTING OF NEW PARTS.
2266-3-222
Wing Component Skin Cap Diagram

Model NA 205-40, -60, -70, and 80
Figure 3
57-00-00
Page 5/6 Blank
Aug 17/84
NA-66-1032
WING
ALLOWABLE DAMAGE
GENERAL
wing. See Figure 101.
OVERWING FAIRING DELAMINATION LIMITS

MODEL NA 265-60A, -60SC, -65, -80A and -80SC.
If there is any edge delamination or approximately 36 to
40 inches square total delamination, the overwing fairing
is in need of repair before the next flight. Contact Sabreliner Corporation for repair (314) 537-3660.
57-00-10
0
Page 101
16/90
Mar
NA-66-1632
183
000049040
0.000
22
23
03
000091013001001
1~
19.070
15
(TVP)
\I
103
U,
0.900
103
3
79.070
14
Is
is
17
20
19
10
NOTE
82(15-3-223~
Negligible Damage
57-00-10
Page 102
Aug 17/84
Wing
Model NA 265-40, -60, -76, and -80

NA-66-1032
STRUCTURAL REPAIR MANITAI,
HONEYCOMB NEGLIGIBLE DAMAGE

SCRATCHES
CODE
OEWTS
CHOROWISE
AREA
DEPTHIN
LEIGTHIW
DEPTHIW
LEIGTHIH
IN.
IN.
IH.
I11.
0.002
UWLIIVIITEO
0.002
UILIMITEO
0.004
to
0.004
0.002
10
UWLIMITEO
0.004
0.003
11
0.006
22
SPAIWISE
O.W4
UNLIMITED
0.004
10
0.003
0.002
0.002
10
0.006
0.002
UNLIMITED
0.004
OIA IW
DEPTH IN
IW.
IW.(MAXJ
HOLES
UWOAMAOED
O.IMO
0.050
3:148111
0.070
0.030
0.050
0.070
0.030
0.050
3168111
0.075
0.030
O.OOO
0.070
MATERIAL
IN.
BLTWEEII OEWTS
UWOAMAGEB
Dll IN
MATERIAL
DETWEEW HOLES
I(MAX)
IMAxj
1/4 IMAXI
IiMAx)
CRACKS
CODE
AREA
TYPEA
nOlE
TYPEB
TYPEC
TYPED
WOIE
IOrE
IIONE
WOIE
WOIIE
1 WITH 5 6000 HOLES

EA SIDE OF DAMAGE
1 WITH 5 GOOD HOLES

EA SIOE OF DAMAGE
P=IIW.
P
1 MAX EA 8105 OF CL
1 MIX EA SIDE OF CL
1 WITH 5 6000 HOLES

EA 8106 OF
1 WITH 5 GDOO HOLES

EA SIDE OF DAMAGE
WOWE
)IOWE
p,
1 IW.
P=1I1.
:r
HOIEYCOMB
HDIEVCOMB
HOWEYCOMB
WOWE
nOllE
WONE
PERMITTED IN AIY
OWE ROW OF RIVETS
2 PERMITTED IN AIY
OWE ROW OF RIVETS
t WITH 5 0080 HOLE

EA SIDE OF DAMAGE
1 WITH 5 6000 HOLES
10
11
1-1/2
IMAX)
TE OEWTS MAY BE REMOVED
11/211.
IOR PARTIALLY REMOVEOI
EA SIDE OF DAMAGE
314 11. I WITH 5

0000 RIVETS EA SID~
P-l II.
HONEYCOMB
HOWEYCOMB
HOWEYCOMB
HOWEYCOMB
HOWEYCOMB
HOWEYCOMB
rmnEYCOlB
HOIEYCOMB
BY A CLAMPIIIG PRESSURE.
00 NOT HAMMER ON BOWOED
12
WOWE
WOWE
WINE
P-lln.~
13
2 PERMITTED IW AWY
OWE ROW OF FASTEWERS
2 PERMITTED II AIY
OWE ROW OF FASTEWERS
P=1I1.
Pl)ln.
14
NOWE
WOWE
1101E
15
1 WITH 5 6000 HOLES

El SIDE OF DAMAGE
1 WITH 5 6000 HOLES

EA
OF 046402
nBIE
1 WITH 5 GOOD HOLES
EA SIDE OF DAMAGE
1 WITH 5 GOOD HOLES

El SIDE OF DAMAGE
1IOWE
WOIE
17
NOIE
IOIE
nOlr
none
18
1 WITH 5 0000 HOLES

EA SIDE OF DAMAGE
1 WITH 5 6000 HOLES

EA SIDE OF DAMAGE
Is
WOIE
20
2 PERMITTED IN AIY
OWE ROW OF RIVETS
18
ale(MAx)
1 IW.
WOWE
OEIITS
2 IN.
HOIEYCOMB
t IW.
ITEI
1 IN.
TRAILING EDGE
HOIIEYCOMB.
IOIE
TYPE A
P 111n.
TYPE B
P-lln.
Pil IW.
IlOnE
IOlE
IOWE
2 PERMITTED IW AWY
OIE ROW OF RIVETS
P=lln.
P= 1-1/2 IW.
21
SKIO
SKIO
IKIO
SKIO
22
HOWEYCOMB
HOIEYCOMB
HOWEYCOMB
HDIEYCOMB
23
1 WITH 5 0000 HOLES

EA 8105 OF DAMAGE
1 PERMITTED IW AWY
OWE BAY
P.1I.
II
TYPE C
I I
II
I?
TYPE D
1II.
NOTES
IC11
1 ONLY PER PANEL
AFTER TREATMENT AS DESCRIBED in 51-70-70.
Negligible Damage
Wing
Model NA 265-40, -60, -70, and -80

0
5265-3-22(
57-00-10
Page 103
Aug 17/84
NA-66-1032
DENTS
DIA IN
IN.
DEPTH IW
In. ImIxI
olr
II~
3/54
i/is
5/84
7/M
1/8
9/64
8488
LARGER
5/32
3/8(MIN)
1~
DEPTH
SECTION
A-A
SCRATCHES
CDDE
SPANWISE
CHDRDWISE
AREA
DEPTH IW IN.
LEIIGTH In In.
DEPTH I IN.
0.006
D.OOD
0.006
O.DDB
20% SKIW THICKNESS
25% SKIN THICKIESS
25% SKIN THICKNESS
5 IDWE MAX IN
EA BAY)
UILIMITEO
250/0 8816 THICKIE~SS
UILIMITEO
25% SKIN SHICKNESS
MAX IW
#vl
HONEYCOMD
HONEYCOMB
15% SKIN THICKNESS
15% 8810 THICKNESS
26% SKIN THICKNESS
250/, 8818 THICKNESS
25% SKIN THICKWESS
250/0 8810 THICKNESS
250/0 SKINTNICKNESS 1
1 26% SKIN THICKNESS 1
HDNEYCDMS
HONEYCDMS
HCNEYCDMD
HDNEYCOMB
11
D
10
(DNE
10
LENBTH IW IN.
12
1 25% 8816 THICKNESS
13
25% SKIN 781086588
D.DD6
0.008
15
MOlo 8816 THICKNESS
MO/o 8616 THICKNESS
Is
1 25% SKIN THICKNESS
17
1 15% 8818 THICKNESS
150/0 8810 THICKNESS
18
25Jb 8810 THICKNESS
0.015
UNLIMITED
14
UNLIMITED
0.015
)g
20
21
UNLIMITED
22
HONEYCOMB
23
25J6 8818 THICKNESS I
SHORTEST DISTANCE
ACRDSS DENT
DENTS MUST BE GENERALLY 8810078 AND

WITHOUTADHUPT CHIWGESI~COITOUR
UNLIMITED
UNLIMITED
UNLIMITED
25J6 8810 THICKNESS
HONEYCOMB
NOTES
THIS CHART IS APPLICABLE TO ALL AREAS EXCEPT
THOSE CODED 8, 10, 11, and 22.
s~sJ-slls
Negligible Damage
57-00-10
Page 104
Aug 17/84
Wing
Model NA 265-40, -60, -70 and -80

Figure 101,(Sheet 3 of 5)
NA-66-1032
STRUCTURAL REPAIR MGNUAL
92
FS
111 FS
1
2
111W.
FLAP
3
101)1.
9
AS
1:2
LS
n
7
B-
ALL FWO OF THIS LIWE
BS
As
AILEAOI
:10
SLATS
IS COWIIOEREO LE OF SLIT
SECTION
A-A
NOTES
ALL CROSS-HATCHED AREAS CAN SUSTAIN
NO
DAMAGE OTHER THAN DENTS OR SCRATCHES.
S265-3-226
Negligible Damage
Wing
Model NA 265-40, -60, -70, and -80

0
57-00-10
Page 105
Aug 17/84
NA-66-1032
STHU(ITURGL REPAIR MANUAL
HONEYCOMB NEGLIGIBLE DAMAGE

SCRATCHES
CODE
HOLE
CHOROWISE
AREA
DEPTHIN
IN.
LENBTRIN
IN.
UNLIMITED
UNLIMITED
0.002
0.004
3
2
0.002
0.004
UNLIMITED
UNLIMITED
0.002
0.004
UNLIMITED
UNLIMITED
3
2
0.002
0.004
2
q
3
3
4
(MAX]
0.035
0.050
3 IMAXI
0.035
0.050
2
3
2
0.020
0.035
2
3
1 ALLOWED PER
EA 25 6000 RIVETS
1 ALLOWED PER
EA 20 6000 AIVFTS
1 ALLOWED PER
EA 20 6000 RIVETS
C :3/4 IW. LIMIT OF

3 PER EA SURFACE
I ALLOWED PER
EA 25 60DO RIYETS
1 ALLOWED PER
Le. 20 0000 RIVETS
EICH 200000 AIVETS
3/4 IN. LIMIT OF

3 P~A EA SURFICE
NONE
NONE
NONE
NONE
1 ALLOWED PER
EA 20 0000 HIVETS
1 ALLOWED PEA
EA 206000 RIVETS
1 ALLOWED PER
EA 20 0000 RIVETS
I ALLOWED PfR
EA 20 CDDD RIVETS
Ipn~
I ALLOWED PER
EA 20 6000 RIVETS
IlonE
1 ALLOWED PER
EA 20 0000 AIVETS
1 ALLOWED PER
EA 20 GOOD RIVETS
1 ALLOWED PER
EACH 200000_8165_73
1 ALLOWED PEA
I/2(MAXI
5 IN.
(MIN]
I/2(MAX)
5 IN.
(MIN)
1/2
5 IN
(MINJ
YS
TEOENT
1 IN. LIMIT OF 2
PER SLAT
It--
IIN.LIMIIOF
3 PEA EA SURFACE
1 IN. LIMIT OF 2
1 IN. LIMIT OF 2
PER SLAT
PER SLAT
SeCTIDN
II
LEWGTHIWIW.
DEPTH IN IW.
LEWOTH IN II.
0.002
UNLIMITED
0.002
0.002
UNLIMITED
0.002
0.002
0.002
10
0.002
11
0.003 EXCEPT AT
BEAD
O.DOl AT READ
1
1
r TYPEA
0.002
UILIIITEOTYPE
0.002
UHLIMITED
0.002
UWLIMITEO
0.002
UWLIMITEO
O.DOa EXCEPT AT
BEAD
D.DO1ATBEAO
UNLIMITED
r
7
TYPE
CODE
AREA
DAMAGE GIVEN IS CONSIDERED NEGLIGIBLE AFTER

TREATMENT AS DESCRIBED IN 51-70-70
1
2
a(m~xi
COMBINATION OF ONLY TWO OF ABOVE CRACKS
EXIST AT SAME TIME IN ANY ONE. BAY, WITH

EXCE PT ION OF TYPE D. WHICH IS LIMITED TO ONE PER
BAY
NEGLIGIBLE HOLE DIA AND OTHER LIMITS ARE SAME
AS THC)SE GIVEN FOR TYPE D CRACKS

MEASIIRE 0IA OF otNTS AS SHORTEST DISTANCE
ACROSS DE NT DENT S MUST BE G ENERALLY SMOOTH
DEPTHIN
IN.
OIA IN
IN.
MAY
TYPE O
NOTES
A-a
DEPTH
SPANWISE
0.002
I
1
OIA
DEPTH IN II.
IMAXJ
3
4
CHOAOWISE
AREA
(MINJ
scRlITcHES
CODE
5 IN.
3/0181831
TYPE O
1 ALLOWED PER
(MAXI
AND HOLES E1
TYPE C
UNOAMOED
MATERIAL
BETWEEN HOLES
OIA IN
IN.
1/2
3
3
4
TYPE B
1 ALLOWED PER
EA 20 6000 RIVETS
lo
BETWEEN GENTS
0.020
0.035
0.050
TYPE A
IN.lMAXl
2
3
UNLIMITED
UNLIMITED
CRACKS
CODE
AAEA
UNOAMAGED
MATERIAL
DEPTH II
IN.
0.002
0.004
3
2
OIA IN
IN.
LENGTHIN
3
2
0.002
0.004
DEPTHIN
IN.
0.002
6.564
0.002
0.004
SPANWISE
AND WITHOUT ABRUP1 CHANGES IN CONTOUR
(MAX)
1/R
1/4
3/8
2
3
OIA IN
IN.
1/54
3/64
Ille
1/8
1/4
3/8
0.020
0.040
0.083
l/gq
3/84
1/18
10
118
1/4
3/8
0.020
0.040
0.MIS
0.020
0.040
0.083 (MAX)
11
1
2
3
1/64
3/84
1/18
(mAxl
1
OEPTRIN
IN.
CODE
AREA
IMAXl
1/84
3/84
1/18
S285-3-127
57-00-10
Page 106
Aug 17/84
NefflipCible Damage
Wing
Model NA 2(i5-40, -60, -70, and -8Q

Figure J01 (Sheet 5 of 5)
a
;Z2c~i4 e\i SABRFI.INER CORPORATION
NA-66-1032
IMAIN FRA1ME
GENERAL
This section contains the repair index for the fixed
structure of the wing that includes the box section, the
leading edge, trailing edge and the wing tip. See figures 1
and 2.
57-1 0-00
0
Page 1
Aug 17/84
NA-66-1032
CRSS 282.266
RSS
00
INBEX NUMBERS COHHESPONO

TO ITEM HUMBERI IW THE KEY
RRS
173.585
270.37112
CWS 291.848
W8 281.850
55
13
14
ci
5?1
54
53
52
58
51
5(1
CTES
51.284
,,I
~ea\
18
iO
48
62
8.7
s
82
46
21
61
45
22
62
23
/2?
FSS
283.828
47
20
cns
306.727
61
se
58
43
24
44
42
40
ABBREVIATIONS
41
CANTED
37 38
35
3!
DOUBLE CANTED
DC
36
FLAP STATION
FS
62
FSS
34
81
33
30
62
FRONT SPAR STATION
RSS
REAR SPAR STATION
TES
WS
WING STATION
61
76
29
27
62
75
sl70
OCWS
o.ooa
72
73
78
71
s2
26
79
79
61
Is
78
79
n>s(\
62
82
80
79
61
1
2
~
6
6
7
iP
78
79
90
81
62
80
6463
81
89
91
68
65
00163
82
87
WCS
~z7
74.183
39.487
85
Figure
88
86
Wing Fixed Structure Repair Index

Model NA 265-40, -60, -70, and -80
57-1 0-00
Page
Mar
16/90
NA-66-1032
STRUCTURAL REPAIR MANIJAL
STRUCTURAL IDENTIFICATION (Cuntinued)
ITEM
NO, DRAWING NO,
I
3
4
5
6
7
8
9
26.5-130006-49
265-130006-58
265-130006-67
265-130006-55
265-130006-57
265-130006-51)
265-130006-61
265-130006-63
265-130006-65
246-14056-11
246-14056-3
246-14056-13
DESCRIPTION
Beam
Web
GAUGE OR
EXTRUSION
REPAIR
FIGURE
NO.
NO.
MATERIAL
Wing TE
Cap
TECS 30.079
TES 53.884
TES 38.585
TES 43.286
Rib
TES 47.997
Rib
TECS 49.619
Rib
TECS 51.284
Panel
Inbd TE
Skin
Core
Rib
Rib
Rib
Rib
7075-T6 Clad
2024-142 Extr
7075-T6 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-142 Clad
7075-16 Clad
0.032
4E71iij
0.063
0.0:32
0.032
2024-T4 Clad
5052-1139
0.010
57-10-2(),
57-10-20,
57-10-20,
57-10-20,
57-10-20,
57-10-20,
57-10-20,
0.032
0.032
0.032
0.032
3/16
Fie;
212
Fig
212
Fig 212
Fig 212
Fig 212
Fig 212
Fig 212
0.001
Honeycomb
Channel
Panel
Intermediate TE
Skin
Core
246-14056-27
10
265-131103
265-131103-3
265-131103-5
7075-T6 Clad
0.063
2024-T3 Clad
5052-H39
0.010
3/16
0.001
Honeycomb
11
Channel
Outbd TE
Panel
Skin
Channel
Core
265-131103-9
265-131106
265-131106-3
265-131106-5
265-131106-9
2024-142 Clad
0.020
2024-13 Clad
2024-142 Clad
5052-1139
0.010
0.020
3/16
0.001
Honeycomb
12
13
14
16
l(i
17
18
19
20
21
22
23
24
25
26
27
28
29
30
265-130268
265-130267
265-130266
265-1~0007-27
265-130957-4
Rib
RSCS 282.269
Rib
RSCS 275.830
RSCS 269.661
Rib
Seal
Retainer
Seal
265-130007-13
26.5-130007-15
265-130007-17
265-130256
265-130255
265-130254
265-130253
265-130252
266-130303
Angle
Angle
Angle
265-130251
265-130257
265-130257-3
265-130257-5
265-130257-5
265-130073-21
265-130073-41
265-130375-1
265-130051-1
265-180371(-1
265-130052-1
RSS 173.585
Rib
RSS 152.450
Rib
Rib
RSS 127.758
Rib
RSS 113.758
Rib
RSS 94.758
RSS 89.070 to
Intercostal
RSS 94.758
Rib
RSS 89.070
RSS 85.507
Rib Assy
Rib
Doubler
Channel
Rib
WS 0.000
Rib
WS 0.000
WCS 12.322
Rib
Rib
WCS 12.322
Rib
Rib
WCS 24.644
WCS 24.644
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
2024-T42 Clad
Fabric-covered
Sponge Rubber
2024-T42 Clad
2024-T42 Clad
2024-142 Clad
7075-T6 Clad
7075-16 Clad
7075-T6 Clad
7075-16 Clad
7075-16 Clad
2034-143 Clad
0.020
0.020
7075-16 Clad
0.050
7075-16 Clad
2024-T42 Clad
2024-142 Clad
7079-16 Forging
7049-173 Forging
2024-142 Clad
7075-16
Machined Plate
2024-T42 Clad
7075-T6
Machined Plate
0.040
0.040
0.040
0.020
0,032
0.020
0.032
0.025
0.050
0.050
0.050
0.050
0.050
0.040
0.050
57-10-20, Fig 206
0.050
57-10-20, Fig 206
NOTE
For additional
repairs, refer
Key
0
S285-3-240A
to 51-70-00.
to
Figure
(Sheet
1 of
3)
57-1 0;00
Page 3
Aug 17/84
NA-66-1032
ITEM
NO DRAWINGNO.
31
32
33
34
35
36
37
38
39
40
265-130303-1
265-130076-1
265-130353-1
265-130054-11
265-130355-1
265-130258-11
Rib
Rib
Rib
Rib
265133.5551
265-130913
265-130914
265-130915
265-130356
265-130357
Fitting
42
43
44
45
46
47
48
49
50
51
52
53
54
MLG Uplock (Ref)

Upper TE Skin
Lower TF, Skin
Lower TE Skin
Support
WS 79.070
Rib
WS 92.230
Rib
43383
43697
Web
2024-142 Clad
2024-~42 Clad
2024-T42 Clad
Cap
7075-T6:Extr
0.050
0.063
0.063
13733
20241~42 Clad
2024~fl42 Glad
0.050
0.050
Cap
7075~Extr
Doubler
Inbd Rear
Inbd Rear
Outbd Rear
2024~42 Clad
1%733
0.040
WS 105.990
Rib
Web
265-130004-3
Spar
265-130359-1
265-130360-1
265-130361-1
265-130362
265-130363
265-130364
265-130365
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
265-130366
265-130367
265-130368
55
265-130369
265-130370
56
57
265-130371
265-130372-11
58
Tig
60
61
62
63
265-130015-7
26.5-130015-9
265-130015-5
43697
57-10-20, Fig 206

57-10-20, Fig 206
57-10-20, Fig 206
Forging
7049T73 Forging
7079~51
Maehili-edPlate
7075-~73510
MachinedP1Bte
OutbdRear
WS
WS
WS
WS
WS
WS
WS
WS
WS
WS
57-10-20, FiR 206
57-10-20, Pig 214

57-10-20, Fig 214
7075rT6:Extr
7075-T6:Extr
7075-T6:Extr
265-130004-1
265- 130017-31
0.050
0.080
0.050
7079-T851
Support
Support
Spar
SpHr
Spar
265-130017-21
KREAARK
FIGURE
NO.
0.032
Maehined Plate
7049-T73
Machined Plate
WDCS 24.082
Rib
265-130357-5
and -7
265-130358
265-130358-3
265-130358-5
26.5-130358-7
2034-142 Clad
7075,16
Machined Plate
2024-T42 Clad
7075-16 Clad
2024-T42 Clad
WCS 47.890
WCS 59.095
WS 65.810
WDCS 24.082
28.5-130258-11
265-13035?-3
41
M~TERIAL
DESCRIPTION
Fuel-Baffle
Intercostal
WDCS 37.890
Rib
GAUGE OK.
EXTRUSION
NO.
119.85.0
133.910
146;480
2024-P42 Clad
20241a42 Clad
2024-T42 Clad
0.040
0.040
0.040
159.080
171.620
2024-T42 Clad
0.040
2024-1142 Clad
2024-T42 Clad
2024~42 Clad
2024-142 Clad
2024_142 Clad
2024-T42 Clad
2024-T42 Clad
2024-142 Clad
2024-~42 Clad
TE:NS 50-T6
0.063
0.040
0.040
185.050
198.350
211.750
225,750
239.850
WS 254.350
WS 268.850
WS 281.850
WS 291.846
0.040
0.040
0.040
0.050
0.050
0.050
57-10-20, Fig 206
57-10-20, Fig 206
57-10-20,:Fig 206
57-10_20, Fig 206
57-10-20, Fig 206
57-10_20, Fig 206
57-10-20, Fig 206
57-10-20, Pig 206
57-10-201 Fig 206
57-10-20, Fig 206
57-10-20, Fig206
57-10-20, Fig 206
57-10-20, Fig 206
Sand:Casting
265-130214
2(i5-130203-R
FSCS 306.727
Rib
Intercostal
FSS 293.826
Rib
Rib--Track RollerSupport
Air-load
Rib
W(:S 74.183
Rib
265-130203-17
Rib
WCS 741183
%024-T42 Clad
2024-142 Clad
2024-T42 Clad
iOlfjiTfiClad
2024-T42 Clad
7079T651
Machined Plate
7075-T73510
Machined Plate
0.032
0.032
0.032
).049
0.020
NOTE
For additional
51-1. 0-00
Page 4
Aug 17/84
repairs,
refer to 51-70-00.
Key
s2es-3-2~on
to
Figure
o
(Skeet
2 of
3)
COF"YRIGHT,1984 BY S~-BRELINER CORPORATION
NA-Gfi-1032
STRU(:TURAL IDENTIFICATION (Continued)
ITEM
NO. DRAWING NO.
DESCRIPTION
64
265-130202-1,,
Rib
65
265-130003-5
MATERIAL
GAUGE OK
EXTRUSION
NO.
Spar
WCS 65,502
--~Outbd Front
2024-T42 Clad
0.032
7079-T611 Forging
265-3L3003-9
Spar
Outbd Front
Spar
70
265-1:#)01B-11
265-130016-21
265-1:30202-11
265-130202-1
265-130201
265-130201-23
265-100026
Rib
Rib
Rib
Rib
Plate
7075-T73510
Extruded Bar
707n-T611 Forging
7049-T73 Forging
2024-T42 Clad
0.032
2024-T42 Clad
0.032
71
370-130121-1
Skin
86
67
68
69
Spar
Inbd Front
Inbd Front
WCS 56.121
WCS 46.879
WDCS 39.487
WDCS 39.487
Wing Joint Splice
Wing Panel, Upper
REPAIR
FIGURE
NO.
57-10-20, Fig 204,

57-10-20, Fig 206
57-10-20, Fig 20:(
7079-T611 Forging
7049-T73 Forging
7178-T6
Machined Plate
7178-T651
Machined Plate
57-30-20, Fig 205

57-30-20, Fig 204,
Fig
72
265-130103-1
Skin
73
265-131102-11
Panel
Skin
Skin
Core
266-131102-25
265-131102-27
266-131102-23
74
75
265-130006-3
2fi5-1R0007-~
76
77
265-130014-3
265-150002-11
265-150003
265-150004
265-130015-3
265-130806
71)
79
80
Inbd TE, Upper
Wing Inbd TE
Outer
Inner
7075-T6 Bare
7075-T6 Bare
5052B39
81
82
83
370-130122-1
0.040
0.040
Honeycomb
3/16
7075-T6 Clad
2024-T3Clad
0.032
0.020
2024-T42 Clad
0.040
Glass Fabric
6061-T6 Bare
2024-T3 Clad
7075-T6 Clad
0.063
0.063
0.063
(1;1
Skin
2024-T3 Bare
0.063
Stiffener
2024-T42 Clad
0.020
Skin
Wing Inbd LE
Seal Assy
Wing-to-Fuselage
7075-T6 Bare
0.125
Skin
Skin
26.5-130010
265-130010-3
and -5
265-130010-43
thru -99
26.5-130106-11
265-130951-1
206
7075-T6
Machined Plate
Wing Inbd TF,, Upper

-WinglntermediateTE,
Upper
Skin
Wing Outbd TE, Upper
Tip
Wing Panel Assy
Structure Assy
Cap Assy
Skin
Wing Outbd LE
Door
Wing Intermediate LE,
Upper
Wing LE --Intermediate
0.0001
57-30-2(). Fig 20:3

57-30-20, Fig 206
0.125
57-30-20, Fig 214
Fig
21.5
(Ref)
84
265-100040
Skin
Plate
Wing Panel, Lower
Wing Joint Splice
2024-T351
Machined Plate
57-30-20, Fig 208,
Fig 209
57-30-20, FigB10,
Fig 211
7178-T6
Machined Plate
NO TES
For additional
This is
repairs, refer
to 51-70-00,

areas or refer to applicable drawing numbers
a
B?B5-J-240A
Key
0
to
Figure 1 (Sheet
3 of
4)
57-10-00
Page 5
Aug 17/84
NA-66-1032
STRUCTURAL IDENTIFICATION (Cantinued)
ITEM
NO DRAWINGNO
DESCRIPTION
85
265-100031
Skin
86
265-13100117
Skin
87
265-1:10104-1
265-130006-5
88
89
~n
91
GAUGE OR
EXTRUSION
NO.
MATERIAL
TF,NS 50-T6
Sand Casting
2024-T42 Bare 0.063
Wing Panel, Center
265-130007-5, -7
Fairing Wing-toFuselage, Ilower

Skin
Wing Inbd TE, Lower
Skin
Wing Inbd TE, Lower
Skin
Wing Intermediate TFJ
and -9
265-130014-5
Lower
Skin
Wing Outbd
2024-T42 Clad
Y70-1~1001
Fairing
Fiberglass
TE, Lower
Fuselage, Lower
0.0710
0.040
Laminates
FIGURE
NO.
7075-T6 Bare
7075-T6 Clad
2024-T3 Clad
0.032
0.020
REPAIR
57-30-20, Fig 203
51-70-50
NOTES
Fol additional
repairs, refer
to 51-70-00.

refer to applicable drawing nurrtbers
This is
areas or
57-1 0-00
Page 6
Aug 17/84
9285-3-2~0A
Key
to
Figure
o
(S;heet
4 of
4)
1984 BY S~RiELINER %ORPOR~TION
NA-66-103~
SIHli("llrKAI, R~1AIK M~NIIIZI,
NOTE
REFER
TO
FIGURE
FOR
MAIN
BOX
STRUCTURE
BREAKDOWN
Wing Repair Index

Figure
0
COPYRIGHT,
57-10-00
Page 7
Aug 17/84
NA-66- 1 032
SIIIU(IIIIRA I, HEIAIK MANUAI,
STR~r(llllRAI, IDENTIEI(:AIION (Continued)
ITEM DR~WIN(;
I)ESCRIPTI()N
1
7fi-57:175-9, -10
76-r,7~75-3,-4
5
6
7
8
9
10
11
265,-13~0121
26r,-15012~
370-130121
37()-1:30122
76-57201
763-57427
76-57425
76-57402
76-57496
76-57424
76-57426
76-57412
57-1 0-00
PaRe 8
Aug 17/84
Ianel Assy,
Panel Assy.
Spoiler, Inbd
Spoiler, Outbd
I!pper Skin, Inst

I~ower Skin, Inst
Upper Skin, Inst
T~ower Skin, Inst
Extended Wing Assy

Tank Inst LE, Outbd
LE Skin Inst Outbd
Front Spar
Fence Assy
LE Skin Inst Inbd
Tank Inst, LE, Inbd
Overwing Fairing
Key to Figure 2
m
COPYRIGHT, 1984
BY SABRELINER
CORPORATION
NA-66-1032
MAIN FRAME
REPAIRS
GENERAL
This section contains repairs for the fixed structure of the
wing. For applicability of repairs, refer to section
57-10-00.
ROTATING THE WING
wing rotating fixture shown in figure 201 consists

primarily of two sets of wooden cradles that clamp around
The
the main box section at WS 65.81 and 171.62. The fixture

is attached to the wing while it rests on a wing stand
(bottom down). Two slings and two hoists are used for
inverting the wing. One each is attached to the LE and TE
of the fixture. Both hoists lift the wing uniformly off the
stand. Then the leading edge hoist remains fixed while the
TE is raised until the wing is suspended, LE down, from
the single hoist. The LE slings are then removed and
reinstalled on the opposite (lower) side of the wing.
Tension is taken on the LE slings and the TE is lowered
until the wing is in an approximately level position (lower
skin up). The wing is held in this position while the wing
holding fixture is assembled under it. (See figure 202.)
Repair data
is shown in
figures
203 thru 214.
57-1 0-20
0
Page 201
Aug 17/84
NA-66-1032
WS 105.32
SPANWISECG(RLF)
SLING
2 REDO
(SEE DETAIL A)
I)IBD FIXTURE
ISEE RETAILS
B ANO
O)
10411/16,
OUTED FIXTURE
ISEE OEJIIILSCIWO E)
i ~ii i i i i Fi i i i i i i :Fiij.i iji j

i:
iiroa
~,jijiiiiiijjijiii3jij:iii
~:::::::::::i:a
SiiiiliiiiiiB
xiaiiii~
:::...n
~_:1:i:i:i:i:i:i:i:i:u
S~i
i i i i i i i isi i i i i i i i i s
~iiiiiiiiiiiiiiiiiiii
s:~:::::::::::::::::::::::::
41.3 ELEMENT
PLANE(REF)
143
65.61
CONSTRUCTIDN GRADE
DOUGLAS FIR 2 x 4
NAIL (TYPI
IrvPI
142
171.62
104-9/16
117-25/32
BFT
(REFI
NOTE=
SLING DIMENSIONS
THIS
ILLUSTRATION
PRESENTS
SUGGESTED
MAKE SLINGS FROM
METHOD OF BUILDING A FIXTURE FOR INVERTING A
1/4 014 STEEL CAOLE
WING PANEL IN ORDER TO PLACE IT. LOWER SKIN UP.

ON
HOLDING
ROTATING
FIXTURt.
PROCEDURES
(INVERTING) WING
ARE
DETAIL:A
FOR
GIVEN
IN
"ROTATING THE WING".

s2es312le
57-1 0-20
Page
Wing Rotating-;Fixture
Figure 201 (5heet 1 of 3)
~02
Aug 17/84
1984 BY ~BRELINER CORPORATION
NA-66-1032
1/4
22 HOT ROLLED
STEEL PLATE
BOTH SIDES
IC1019
8
REOO
8 12 CONSTRUCTION
GRADE DOUGLAS
FIR
LENGTH
4 REOO
9 FT
INRUBBERIWOT
CEMEIIT
SPONGE
TO TIMBERS ITYP
BOTH FIXTURESI
a ou
1/4 x 6 x 11-1/4 HOT

ROLLED STEEL PLATE
4
161015)
REDO
ITYPI
1/4 GAP
1-5/32
IREFJ
(REFI
O
O
b-~110
;o
Oo
WING REF PLANE
411/2
41.3 REF PLANE

5/16 STEEL
40
BOLTS
------------tl
REOB
58-1/2 (R~FJ
DETAIL
WIB5.81
41.3 REF PLANE
1/4 GAP
1-5/32
(REF)
0"10
0""
To~o
oo
_J
ol
1(3
POSITION FIXTURE ON
WING REF
31-1/2
PLANE
WING AND GLAMP

FIRMLY AT EA ENO.
IA OAF MUST BE
58-1/2
MAINTAINED BETWEEN
IREF)
TIMBERS~LIIE-ORILL
TIMBERS FROM STEEL
DETAIL C
W8171.82
I~IP)
5285-3-229
Wing Rotating Fixture

0
57-1 0-20
Page 203
Aug 17/84
NA-66-1032
STRIICITI~TRAL REPAIR MANUAI~
WING
FRONT
III/ZIRFI
SPAR
PLANE
55-17/3218581
5-13/32
3R(TYPI
13-9/16
1-5/92
I
II
1/4
1+1
11-5/8
-27-15/16-24
-18
-12
12
-6
24
re
2719/32
WING 41.3
ELEMENT PLANE
REF
12 TIMBER
OISTANCE ALONG AXIS IN IN.
AXIS
Y
-6
-12
-18
-24
-271.5/16
12
18
24
27-19/32
UPPER
8-1/32
8-3/32
7-7/8
7-13/32
6-11/16
6-1/32
7-23/32
7-1/4
6-5/8
517/8
55/8
LOWER
-511/32
-5-1 7/32
515/32
-51/4
-4-13/16
-4;3/8
-5
-4-1/2
-3-31/32
-37/16
-3-1/8
DETAIL
WS B5.B1
WING FRONT
61-1/2 IREFI
SPAR PLANE
WING REAR
SPAR PLANE
37-5/32 (REF)
13
1111/32
38ITYPI
1-5/32
z(+)
L,____
-18-1/2
12
-6
12
18-21/32
WING 41.3 ELEMENT PLANE
REF
AXIS
MOLO LIWE
_J
V()
OISTANCE ALONG AXIS IN ]N.
-6
-12
-18-1/2
12
18-21/32
UPPER
5-3/8
5-13/32
5-1/16
4-9/32
4-7/16
3-5/8
LOWER
-3-31/32
-4-1/8
-3-15/16
-37/16
-39/16
-3-1/32
-2-13/32
OIMEWIIDWS ILLOW
4xl2TIMBER
DETAIL
W8171.82
FOR 1/4 IN. RUBBER LINER
5710-20
Page
9269-3-130
Winff Rotatinff,Fixture
204
Aug 17/84
COP~RIGHT, 1984 BY::~BRELINER CORPORATION
NA-66-1032
STRUCTURAL REPAIR MAWUAL
INBD
HOLDING FIXTURE
ABET (SEE
VIEW 1)
OUTED HOLDING
EES(YSS~
FIXTURE
-.:~::i:::
iiiQii
I:i
lisizjiiizii
~iii3iii
VIEW 2)
ji
iiid$iiiziiji~iiiiji
~:i:s:
:I:::::
i ji ijifi ~i i i ifi i j i 5i i ji i 5i i i i j Xi i j
,,,"8L~SI
s:a:
i:
.ii~?,
i:
;:;::::::I~:;
59.406 (REF)
)A
f
AFTRESTR~INING FIXTURE
8.673 IR9
ASSY
FWO
AESTRAIYNGFIXTURE
ASSY
STANO
O
5/16 BOLT
4
REOD
EOUAL-SPACED
721APPROXI
CRAOLE
(SEE VIEW 31
5/16 BOLT
5 REDO
I/PIN.8OLT
WITH EXPAWSION
;1
36
EOUAL-SPACEO
SHIELO OR EOUIVALENT
ITYP ALL STANO
PAVEMfNT
LEGSI
VIEW
HOLOING FIXTURE
IAPPROXI
WS 37.161
NOTES
WING IS LOWERED ONTO CRADLES AND ROTATING
ILLUSTRATION PRESENTS A SUGGESTED

METHOD OF BUILDING A HOLDING FIXTURE FOR
THIS
FIXTURE IS REMOVED.
MAINTAINING WING ALIGNMENT DURING WING MAIN

BOX LOWER SKIN REMOVAL.
L1
THE STANDS ARE ANCHORED TO PAVEMENT. WING IS
HELD
INVERTED
(AND APPROXIMATELY LEVEL)
(SEE FIGURE 201.)
RESTRAINING FIXTURES ARE FITTED TO THE WING

AND TO STANDS AND SECURED IN PLACE.
SEE57-30-20, FIGURE207.
ABOVE STAND, AND CRADLES ARE FITTED TO WING

BEFORE BEING BOLTED TO STANDS.
S265-3-287
Holding Fixture
Figure

(Sheet 1 of 4)
202
57-10-20
Paffe 205
Aug 17/84
NA-66-1032
STKU(:TURAL REPAIR MANUAL
FRONT SPIIR
REAR SFAR
32.5001REF)
t---
FLANEIREFI
FLANEIREFI
4r4x1/4
STEEL ANGLE
WIWG REF-
ERENCE
FLAIL
CRAOLE
ISEE
VIEW
4.509
O)
(REFJ
AFT HOLDING
I Y" o~cSj/
FWO HOLDING
FIXTURE ASSY
FIXTURE ASSY
I
2
;1
D
CRIIOL~
5/16 BOLT
FWOFUS-TO-WING
ATTACH FTG
REDO
x 15/32 x 5/16
STEEL CHANNEL ---I
I II
80LTWIIG-TO-FUS
I)
ATTACH 10.8225
21N.STEEL
PIPE ITYP)
STAND
REF)
:1
LEGS ANO
BRACES ARE 2
111111
2-1/2x3/8BAR--
5/16
STEELANGLEEXCEFT
BEOO
AS NOTED. WELDEO
CO)ISTRUCTION (TYF
BOTH STAIDS)
5/16
iui
5/18 STEEL
5/16 STEEL BOLT

4 REOO
SPACER
5/16 STEEL
00WELPIN--
28200
VIEW
Llt~
4X4x5/l6
STEEL ANGLE
HOLDING FIXTURE
WS 198.350
SECTION
5711 0-20
Page 206
Aug 17/84
A-A
Holding Fixture
o
NA-66-1032
FRONT SPAR
I/
Y
PLANE(REFI
PLAII~IREF)
53-3/8
48
42
36
30
24
18
12
REAR SPAA
WING REF PLANE
llN.PLVW0O0
WING MOLO LINE
DISTANCE ALONG AXIS IN 1N.
AXIS
8-5/32
18
24
30
36
42
48
53-3/8
86/8
8-3/8
115/32
6-27/32
6-1/8
5-3/8
12
821/32
8-15/32
VIEW
3 WING CRADLE
WS 37.161
WING REF PLANE
r---
FRONT SPAR
Y
PLANEIREFJ
24
18
12
REAR SPAR
PLANE(REFI
27-1/2
IlN.PLvwOoo
WING MOLD LINE
OISTIIICE ALONG AXIS IN IN.
AXIS
Y
Z
12
18
24
30
32-1/2
3-9/18
4-1/4
4-1/2
4-3/8
3-29/32
3-1/4
215/16
VIEW
WING CRAGLE
WS 198.350
s2es-a-2se

Holding Fixture
0
57-10-20
Page 207
Aug 17/84
NA-66-1032
1/2 IN. FELT
REAA SPAR
CEMENT TO
1 IN. PLYWOOD
CRADLE --7
CRADLE
IREF)
AFT WING-TO-FUS
ATTACH FTG
4x4x1/4STELL
AIYGLE
BOLT
5/16 BOLT
TT;~
AFT
WING-TO-FUS
ATTACH (0.7665
REF)
SECTION
B-B
2-112
3/8 3TEEL
BAR
5/18 DOWEL
PIN
REOO
5/16 STEEL BOLT
4 REOO
ol
L--J
SECTION
REAR SPAR
C-C
IREF)
LOWEBSKINIAEFI
UPPEB SKIN (REF)
5/16 STEEL BOLT
In
28200
lr
1/418. STEEL BOLT

PICK UP ONE SKIN-
TOSPAA FASTENER
5/16 STEEL OOWEL
PIN
II
LOCATION
2 REOO
5/16 STEEL BOLT
28200
WELO BOTH
SIOES
SECTION
57-1 0-20
Page 208
Auff 17/84
D-D
Holding Fixture
Wing ~ain Box Section
O
COPYRIGHT,
8266-3-288
NA-66- 1032
FAONT SPAR PLANE
UPPER MOLD LINE
Il
I I
OIMIIGED SPIR
WEB /REFI
3/4MAX
3/8[TYP)
1
IN.OIAIMAXI
0.107
I
3-
REPAIR OOUBLER
IREFI
3/RITVP)
I
REPAIROOUBLER(REFJ
REPAIR FASTENERS
O
O
0.107
Trim out
damage
to a max
die of
one
0104 JOBOLTS
in
Oye-penelranl-cnecL area surrounding damage
cul-
OAMAGLO
SPAR WEB
out, to be certain all damage has been removed
Make
repair
Machine boss
damaged
on
FaJlsn repair doub

described in 57-10-30.
to match
spar web.
O
as
aluminum.iloy
damage cutout In
doubler from 7075T8
repair doubler
Seal all
er
in
i: i
plese, using J0-boltssealed
edge. of repair doubler
NOTE
THIS REPAIR
IS APPLICABLE TO BOTH FRONT AND
REAR OUTED SPARS
REPAIR DOUBLER 0.187 7075T6.

MACHINE BOSS TO MATCH OAMOE CUTOUT.
S265-3-247
Front and Rear
Spttrs Web Repair
erugiFdraobtuO
203
57-1 0-20
Page 209
Aug 17/84
NA-66-1032
FRONT SPIIR
PLANE
WING UPPER
MOLD LINE
SPAR WEB IREFI

_
j
:-I
.-c:::::l::::.r:::i
MAKE FULL WIDTH
OF SPAR WEB
1-1/2
N ALL CASES
-1
:i- i- -:l:::iiJ:
s:ii--_:-:i:iiiiiliii:
ii :iiii i iii:-i~i:;i -_-ii i-:;-l-i---i:iiiii: i :i
-:It
g;:~
O.L~3
ro mlrcn
DAMAGEDTAB
i:--t~
J/B[TYP)
I 5/16
--1~
TRi-::-I
i
7/8 APPROX
SPACING
--C
3/8 ITYPI
FASTENERS
P1B4
:I:.
:~1. I
-i -_
i- I-" i-
/B A
l/O a
!i::iiiiiii:~
_i::
ii ii-iiii-:i
JO-BOLTS
WING LOWER MOLO LINE
(SEALEOI
Remove broken stiffener from spar
by grinding
broken stiffener until it is tlush with spar web
Make repair tab from 7075-T6 extrusion,
or
REPAIR TAB
MAKE FROM
707576 EXTRUSION OR
MACHINE FROM 7075-T6
BAR STOCK
machine
it from 7075-T6 bar stock material.
Seal
repair faying surfaces
and
jo-bolts
as
I
1
described
GRINO BROKEN
II
II
STIFFENER FLUSH
WITH SPAR WEB
Ij
in 57-10-30.
NOTE
THIS REPAIR IS APPLICABLE TO WING LEADING EDGE
RIB TABS ON FRONT SPAR. SEE CHART ON SHEET 2
FOR LEADING EDGE STATION NUMBERS.
57-1 0-20
Page
Wing
Spar Air-load Rib Tab Repair

Figure 204 (Sheet r of 2)
Front
210
Aug 17/84
NA-66-1032
STKU(:TIIRAI, REPAIR MANCAI,
WINO UPPER MOLO LINE
OAMAOEO TAB IREF)

REPAIR OOUBLER IREF)
II I
RIVET --SAMLSIZE
ale
ANO TYPE AS
ORIGINAL FASTENER
(REFI
REPAIR OOUBLER
IREFI
0.158
f?C;f,I
2 TIMES FASTENER
ov
Y/
(yyP)
RIVETS --HS485 HI-SMEAR

NUMBER OF RIVETS TO BE USEO
IS SHOWN IN TAB1E
OAMAOEO TAB
IREFI
0.084
SPAR WEB IREF)
RIB(REFJ
SPAR WEB
IREF)
FRONT SPAR PLANE
O
O
all
or file out
damaged
area.
Dyepenetrant-chsckdamaged
damage has been removed.
SPARWEB
Grind
MBCninB
repsirdaublet tomatch area
loDecertsinsl
removed from
tab.
damaged
area
porlionoldsmagedt.b.
Atap~sitionanundamaged
repair doubler, and damaged tab together, using
fasten rib,
HS48-5 Hi-Shear rivets, each
extending through rib,
doubler, and tab.
O
ORIGINAL
NUMBER
ngrivetal
Fastenrbandrepairdoublerlogether.us
same type and size
WS
as
original
rivet
MINIMUM NUMBER OF RIVETS EXTENOING

THRU UNOAMAGEO PORTION OF OAMAGEB
RnP:r,
93.421
1113.375 1
137.438
180.375
183.082
202.484
224.750
244.781
263.875
OAMAOEO TAB IREFI
RIB
REPAIR OOUBLER
0.156 707518 AL ALLOY.
MACHINE TO MATCH AREA
REMOVEO FROM OAMAOEO TAB.
NOTE
I
1
THIS REPAIR IS NOT BE USED IF NUMBER OF RIVETS

EXTENDING THROUGH UNDAMAGED PORTION OF
DAMAGED TAB IS CESS THAN THAT INDICATED.
S285-3-245
Wing Front Spar Air-load Rib Tab Repair

0
57-10-20
Page 211
Aug 17/84
NA-66-1032
STRCTCTUI1AL REPAIR MANUAL
FRONT SPAR REFERENCE PLANE
i;
r~ A
SHIMIAEF)
MACHINED BOX SKIN (R~FI
EXISTING FASTENER LOCATIO~S-
I~
-)I
ii
C:
~1
-t
BIA
IREFJFRONT
SKIN
1--
FILLER
SPAR CAP IREF)
ii
~t
FILLER
belween
fasteners Smooth and round all edges and
damage
from
filler
exsting
called
MACHINEO BOX
WIKS REIROC
ROUND
LE SKIN
corners
out.
length
z~J
TO FIT
~JIJ
1/2
of
SECTIONA~A\I
SHlM (REF)
cutout in front spar cap
REPAIR STRAP
Length 01
equal length of damage plus length of areas
is to
in which either two

either side of
screws or
damage. Make
four rivets
installed
on
shim from 7075-T6 material,
length of repair strap,

of spar in repair area.
same as
by thickness
are
(tC
(REFI
IN AREAS OF ACCESS OOORS, THESE FASTENERS ARE SCREWS,

II THESE AREAS. ATTACH NUT PLATES TO REPAIR STRAPS ANO REPLACE
EXISTING SCREWS WITH SAME TYPE OF SCREWS, 5/32 IN. LONGER.
Make repairslrap tram material called out
repair strap
length
material
C5-\FAoHT SP~RPLAWLIAEFJ
REPLACEMENT SCREW
SAME TYPE AS REMOVED
SCREW. 5/32 IN, LONGER
IREF)
ML
Make
FILLER IREE)
midway
damage
REPAIR:STRAPIR~F)
SIOEMINIMUMOF2SCREWS
t-
REPAIR STRAP(REF)
cut
-J
OR 4 RIVETS EA
-=1-
~t
-I
-----7f-------~
FRONT SPAR WEB [REF)
Trim
L,A
OFOAMAGE
-t
[TYP)
ii
1L
2 TIMES FASTENER
01
II
&t
1L
and gauge determined
GAUGE TO
FILLER7075-T6
MATCH DAMAGED FRONT
n\
SPAR CAP
i\i
Through
machined box skin and front spar,
necessary number of
screws to
FRONT SPAR CAP
remove
accommodate repair strap.
-.i
1~
strap in posit
Place
on
and math
I\i
FRONT SPAR
REFERENCE PLAIE
1!4 R
orduplicste
centers of fastener holes.
Remove
repairslrap
position
chips or shavings could possibly
repair strap is drilled on assembly
spar cap, because
on
drill
enter sealant grooves
Fasten
repair parts
in
place, using
size and
types of
SHIM 7075-70
GAUGE AS REOO
fasteners called out.
01
~G
REPAIR STRAP
RBSBa
machined sLn in
been removed and
and drill taslener neles Do not
drill repair strap while it is in

if
replacedNO
areas
where
rrews
h.ve
0.158 7075iT5
BAREALALLOY
TE~
THIS REPAIR IS APPLICABLE ONLY TO AREAS OUTED

OF WS 65
5285-3-2~g
57-1 0-20
Wing Front Spar Upper Cap
erugiFriapeR
aOEi
Page 212
Aug 17/84
CO,PYRIGHT, 1984 BY SABRELINER CORPORATION
NA-66-1032
RIVET
SEE RIVET TABLE
REPAIR STIFFENER
FOR REOUIREMENTS EA
SIDE OF FILLER IT UPPER
(SEE
"UPPER MACHINED
BOX SKIN LAND
AND LOWER FLANGES
REPAIR")
UPPER SKIN
SHAOEO ITEMS ARE PART

OF A SKIN REPAIR. [SEE
"UPPER MACHINED BOX SKIN
-7
RIB-TO-SKIN
CLIP
LAND REPAIR")
(REF)
RIVET
TYPE, SIZE, ANO
SPACING TO BE SAME AS
IN LOWER CAP ANGLE
O~L/l\
I-~
I
C
SPACING EOUAL
TO THAT IN LOWER
CAP ANGLE
i(\
II
8 TIMES FAS-
TENER OIA
r(
I++I
IC~I
(MIN)
//7
I"I I
1II"/ i~
(MAX)
(I
1+1 !o
$I
(II
4 TIMES FASTENER
a~(Hlnl
1101
L-_-
+I
4/ )$II
1~
qr
I+i 1~
c~l
IC
I~C) 10/C)(I
It
(i
,-~Z
i
o
I;
(O
i.
I~-
FUEL FLOW ANO
FILLER
RIVETS THRU WEB ANO

REPAIR DOUBLER. RIVETS
CODED IN THESE ROWS
Il
Il
FOR BEAD IN
FIELD RIVETS
MAY BE COUNTED, SEE

RIVET TABLE FOR REPUIREMENIS. DISTRI-
STIFFENER ISUBSTITUTES
LIGHTENING HOLE.
IREFER TO NOTESI
TRIM DAMAGE MIDWAY
FILLER)
BETWEEN EXISTING
FASTENERS
TYPE ANO
SIZE TO MATCH THOSE
REDO FOR WEB RIVETING

(FROM TABLE). SPACING
BUTE RIVETS REOO
REPAIR
IS 8 TIMES FASTENER
TWO PLACES EA SIDE
OIA
OF FILLER AS SHOWN
HEPAIR ANGLE
(MAXI
STIFFENER
REPAIR DOUBLER
3/4
1/2
RIB WEB
REPAIR ANGLE
MATERIAL AND
FILLER
MATERIAL
LnD 61UsI TI) MITCH
THAT OF RIB WEB
FILLER
BEAD IAEF)
SECTION
A-A
GAUGETOMATCH
THAT OF WfB
RIB-TO-SKIN
NOTES
CLIP
IREFJ
THIS REPAIR IS APPLICABLE TO WING MAIN BOX RIBS

LISTED IN RIVET TABLES
(SHEET 2)
SEE UPPER MACHINED BOX SKIN LAND REPAIR, 57-30-
/i
20, FIGURE 205 FOR MATERIAL AND FABRICATION

DETAILS OF REPAIR STIFFENER.
THIS REPAIR MAY BE USED IN CONJUNCTION WITH
SKIN REPAIR SHOWN
DO
NOT COVER MORE THAN
J060L~ 15
FOUR
REOD
CONSECUTIVE
RIB LOWER CAP
FUEL FLOW AND LIGHTENING HOLES.
ANGLE
REFER TO SHEET 2 FOR STEPS AND RIVET TABLES.
MATERIAL
ANO GAUGE TO MATCH THAT
OF RIB
REPAIR DOUBLER
szes-3-wa

0
57-1 0-20
Pane 213
Aug 17/84
NA-66-1032
Trim ou~
damaged poll
on or
Prime all
rib web
B
O
Fai~rcateFepaiiparls
Heat-treat parts formed from annealed materials to
applicable
~S.mblerepairp.rts
Touch
upall unpainted
arasa*,ilh CsliCoal
primal
~T" condition.
Remove rib-to-skin
modate
repair parts with Cati-Coat primer
clips
as
necessary to
accom-
repair parts.
RIVET TABLE FOR 265-130023 STRUCTURE A88EM8LIES
CHOROWISE
VERTICALLY
IAT UPPER ANO LOWER FLAHOESI

WS
no.
RIVET
MS2O47O Ijl
12.322
(CJ
405
24.644
IC)O
405
47.89
(C)O
405
ITRRU WEB ANO REPAIR OOUBLER)
REOO EACH
SIRE OF REPAIR
O
6
1:
RIVET
NO. REOO PER
51820470
IN. OF WEB
405
2.862
405
2.862
AOS
2.862
405
2.882
405
79.07
405
405
2.862
92.23
8346
RS48
2.108
105.99
HS48
119.85
405
A05
AO6
85.81
133.91
146.48
8846
1
1105
2.234
2.641
405
2.641
AOS
2.841
159.08
AOS
171.62
405
605
3.699
105
2.841
405
2.841
405
2.841
405
198.35
AO5
211.75
405
405
2.841
225.75
405
405
2.841
239.85
105
II:
405
254.35
105
405
288.85
405
405
2.882
281.85
405
405
2.882
185.05
2.841
2.882
NOTES
O
O
O
EXCEPT FOR HI-SMEAR
(HS SERIES)
RIVETS LISTED.
AT EACH PLACE NOTED ON REPAIR.
CANTED
52853-246
57-1 0-20
Page 214
Aug 17/84

206 (Sheet 2 of 2)
Figure
PICKUP HOLES
REAR SPAR
NA-66-1032
IREFI
IN REPAIR LUG
STKU<:TUHAL KEPAIR MANUAI,
WEB TO MATCH
EXISTING HOLES
IN ATTACHING
COMPONEHTS
II
REPAIR LUG DIMENSIONS
I
ASS
63.345
4.69
1.19
1.38
75.302
4.12
1.12
0.94
0.125
0.093
94.758
2.06
0.12 -0.06
1.03
0.093
113.758
2.06
0.22 ~0.06
0.88
0.093
127.758
2.06
0.28 tO.OB
0.88
0.093
152.450
2.06
0.41 0.06
0.88
0.093
MAKE FROM 7075T6511
REPAIR LUG
EXTRUSION OR MACHINE FROM 7075-T6510

BAA. REFER TO "REPAIR LUG DlMENSIONS"
CHART FOR OIMEWSIOWS OF APPLICABLE
REPAIR LUG.
3/81TYP)
NUMBER OF FASTENERS
REOO
TO PROVIOE APPROX 1 IN.
.I
SPACING BETWEEN FASTENERS
le
-t
lie.
3/8(TYPJ
oapl
0.12
21R
PLCSI
f
BRILL NO. B
e
(0.1991
DIA HOLES
FOR NAS 1669-3K2. 363 OR

3K4 ~LSTEWERS
-i
It 3/4
ILfWGTH Or
FASTENER OETERMIIIEO BY
REPAIR LUG LOCATIONI
OPTIONAL TRIM OF
REPAIR LUG
--I
WING REF
FULL WIOTH OF SPAR WEB
PLANE
UPPER TO LOWER TANGENTS
Tr
oil
damspod ugls)l..h
v.ln rea~
spa.*eb( +0.000O
Prime repair
chromate
Dye-penetrant Inspect
IEl
LUG
rear
or
repair lug(s)
from 7075-T6510 bar
and
tear
spar
areas
using
zinc-
spar for cracks

Place repair
Manufacture
lug
primer
fastener holes in
extrusion
(BOTH ENOS)
from either 7075-T6511
or
plate Refer to "REPAIR
DIMENSION" chart to determine dimensions of
guide
Use
rear
lug
In
position
on
rear
spar web using holes in
sealing compound
on
drill bit to
spar and drill
repair lug for
prevent chips
from entering into fuel cell
Iif
required repair lug
Coat faying surfaces of repair lug and rear spar web

sealing compound (Ptoducts Research PR1422 or
equivalent)
with
Locate and drill fastener holes

In
repair
(number
as
required)
lug
Chemical film treat repair lug and bare surfaces of

rear
spar using Alodine 1200 for
Secure repair lug

Bolts Installed
as
In
position
on rear
spar
using Jo-
indicated in 51-40-30
equivalent)
NOTE
APPLICABLE TO REPAIR LUG AT RSS 75.302 ONLY.
Kepair of Rear Spar Luf at Rear Spar Stations

(KSS)
76.~02, 94.758, 127.758, and
Figure 207
a
5265-3-3338
57-10-20
PaRe~l5
Aug l$./r14
NA-66-1032
COUNTERSINK 100"
THIS HOLE ONLY
1.19
0.332 OIA
CHAHIEER 009x 80
0.31
1.31
1.82
EOUAL
SPICES
2.50
TRACE OF
WING REF
0.31
PLANE
CHAMFER 0.09
DRILL no. Is lo,lsOl

:01A HOLE
SIX PLACES
0.250
45
0:38 R
RS
253.804
JO-ROLT
HAS 1869-081(3
5 REOO
RSS
1 253:041
0,138
JO-BOLT
NAS
fi--l,
~i
PICKUP HOLES IN
REPAIR LUO WEB TO
HATCH EXISTING
HOLES
II ATTACHING
COMPONENTS
Grind off
damaged lug
flush with soar
IF~
web (+O.oOO)
Prime
repairlug
Place repa
Dye-penetrant inspectsparforcracks.
repair tug trom 7075-T651
HACHINEFROM
REAR
7075-7851 RARE
AL ALLOY PLATE
8288
IREF)
and rearspar with zinc-chromate
sealing
entering fuel
lug
in
posilion
rear
esU.llec
lo dimensians
on
rear
spar and drill
spar web using repair lug

compound on drill bit to prevent
fastener holes in
Machine
LREPAIRCLIP
primer.
(+0.005)
1670OBK3IRE0
as a guide.
chips from
shown
:-II~
Remove repair lug (ronl rear spa, end cw~ layins

surfaces of repair lug and rear spar web with sealing
compound (Products Research PR1422 or equivalent).
(0.166dia) holes six places in

hole 1000 x 0.332 x 0.069 deep as
Locate and drill No. 19
repair lug, countersink

shown
on
one
illustration.
repair lug and bare surfaces

using Alodine 1200 (or equivalent).
Chemical film treat

rear
spar web
Secure repair lug in-place on rear spar using Joas indicated in 51-40-30, figure 2.
of
Bolts installed
92(15-3-331I
57-1 0-20
Page
Aug 17/84
Repair of Rear Spar Lug
at
RearSpar Station(RSS)
ffiF140;352
ura ~1)8
216
COQYIRIGHT,.1984 BY SABRELINER CORPORATION
NA-66-1032
COU#TERSIWK EXISTING UPPER HOLE IN AFT
FACE OF REAR SPAR 0.499 OIA BY 100
(ONE PLACEI
REAR SPAR IREFI
IICc,
REMOVE 4 7234-446 SCREWS
oAMAcEO Luc
IREFI
ANO 4 NAS 1291-4 NUTS
WING SKIN IUPPERI

FLIP TRACK ATTACHING
BOLT (REFI
9)
II
REMOVE NAS 1304-5

SCREWS (5 PLACES)
~O
/FLIIPTRIICKIR~r]
LUG IREFI
kl
REMOVE 2 A1C114-00-2.551
SCREWS IRETAIN
II
Olln16EO
INOTALSW~RF
LO
O
WING SKIN
ACCESS 0OOR
REAR SPAR
[LOWERI
IREFJ
FLAP TRACK
ATTACHING SCREWS
WING SKIN ILOWER]
(4 REOD)
REMOVE 6 7834-4116 SCREWS

ANO 6 NAS1291-4 NUTS
COUNTERSINK EXISTING LOWER HOLE
IN MT FACE OF REAR SPAR
RSS 90.582
0.499 OIA BY 100~ (ONE PLACE)
O
O
Remove
flap adjacent
to
damaged
area.
Remove laateneo securing f sp Irsc~ to lower otin.
ppar. Install ilap

lug of fitting. Push fitting
against vertical web and upper flange of rear scar. All gaps
exceeding 0.005 in. between fitting and rear spar must be
removed by blending surface of fitting to match surfaces of
rear spar. Prime all bare surfaces with epoxy polyamide
Check for gaps between flap track and lowerskin. Any gaps
exceeding0.010 must be shimmed using 2024-T3 or 7075T6 aluminum
alloy. Taper shims
as
required,
and
prime
flap track attaching

flap track.
Reinslali lour
skin and
wing
screws
all
Ihrough
perfectly
in
LD
attaching flap track to lug on rear spar,

through flap track and lug on rear spar are not
line, revise shim between flap track and lower
sink,
fitting
rear
flange
spar web
of
rear
spar web to
produce
smooth finish. Prime
web,
00
and
Remove
and drill and counter
fasteners shown
on
Remove flap track, and inat. I Ipacer between

rear spar lower flange. Gaps exceeding 0.005 in.
Prime all
bare
surfaces with epoxy
polyamide primer.
Temporarily inst8
shim, spacer, and fitting
splice joint. Countersink rear spar

install 7S34-4A5 screws in place of removed bolts.
remaining NAS 1304-5 bolts, sealant injection
rear
position.
and
surfaces with epoxy
Remove upperand lower NAS 1304-5 balls through
vertical web of
Clamp spacer in position and inltall ah m

between outbd end of spacer and rear spar lower flange
Gaps exceeding 0.005 in. must be removed Prime all bare
all surfaces.
Clamp fitting
00
spar
rear
on rear
over
polyamide primer.
OnndoflluganrsarsparatRSS90.5B21uphwilhaIt
surface of
posilion
track
required; temporarily install
must be removed.
lug on rear spar. Measure horizontally

and vertically to a fixed point on upper
of 0.500 in. dia hole in

to
as
L9
recordsxsctloEatiun
RemovsflaplracLLocalsend
in
flap
sheet 2.
skin.
fitting
primer.
Remove bolt
If boltholes
Place
track with clevis of
bare surfaces.
lower
Manufacture fitting, spacer, and shim using

on sheet 3.
details and dimensions shown
as
I fasteners
shown
on
through
rear
soar.
on
lug of
sheet 2.
spar
LO
Locate centerline of 0.500 in, dia hole
fitting using previously recorded
screws, and access door,
rm
Install flap track
using
dimensions.
four
screws
through
rear
spar lower flange. Check that centerline of 0.500 in. dia hole
location lines up with hole in flap track. If hole and
centerline do not match, shim flap track

s370-3-ase
Repair
Rear
Spar Lug
at Rear
Spar Station (RSS) 90.582
Figure 209 ($heet
1 of
3)
57-1 0-20
Paffe
217
AuR 17/84
NA-66- 1032
0.234 MIN TO HELI-COIL
Ii
PHENOLIC STRIP
DRILL ANO REAM
IK\
INSTALL MS212OO-F4-15
HELI-COIL IN FITTING TO
MATCH EXISTING HOLE
III
0.5000+G.0008
-0.0010
HOLE THRO LUG OF FITTING
FLAPTRICK(REF)
LOCATIONS
0.219 IMlNJ TO HELI-COIL
-L
PENOLICSTAIPS
Ii
-I--
POIHT Y
RelA SPIIA
SHIM
PLAN~
i
1::::~
A.A
SECTION
ii i
(0.2810)4 HOLES IN FITTING TO MATCH EXISTING HOLES

23.841013594)4 HOLES TO 0.170 DEPTH IN FITTING
GRILL O
DRILL
7334.449 SCREWS
REAM 0.3750 -0.0005 4 HOLES TO 0.135 DEPTH IN FITTING

TAP A HELI-COIL THO (IN. 3) PO 0,273 [cO.O022. -0.0001
14 REOO1
MSe1209-F415 4 REOO INSTALL ANO BREAK OFF TANG

4819-34-004 4 REOO REAM 0.2500 t0.O)O5 IF NECESSARY
WING SKIN
IUPPER) REF
7334-469 4 REOO
A r~
75546115 1 RPOO
FITTING
NAS 1103.4 5 REOO

NAS 159803(5 REDO (SEALING WASHER.
INSTALL AGAINST FWO FACE OF SPAR
i" 52 ~F-15
II
:[I
WEB. WETTEO SURFACE)

OHILL 0.250 9.002 3 PLACES
-O.W1
I;
IN FITTING TO MATCH
II
EXISTING HOLES
nAS 1304-7 3 REOO
.s
Q
DRILL nO. 31
(0.120)2
L0153000212W 5 REOO
9321042 L3 5 REOO
POINT Y
II
PLACES
[L\
IN FITTING TO MATCH
EXISTING HOLES
n~cl,4lm-2-2.5cl SCREW
r
2.497
O II
DRILL 0.250 9.002 IN.

-O.OO1
SPACER TO MATCH EXISTING
1, HOLE LOCATION
7334-46111 HEOD
943 1291-4 1
PREOOJ
7S34-4A51RE00
AECAPSOOEA
AL~
REAM 0.2500 +0.0006 4 HOLES IN SPACERTO MATCH EXISTING HOLES
GRILL G 10.201014 HOLES In FITTING TO MATCH EXISTING HOLES
OHILL
23.8410.3594)4
HOLES TO
0.170 DEPTH. IN FITTING
iO.W05 4 HOLES TO 01335 DEPTH IN FITTING

HELI-COIL THO IlN. 31 PD 0.273 I+O.OOP2, -0.000)
REAM 0.3750
TAP A
9321209-84-15 4 REOO INSTALL ANO BREAK. OFF TANG 48 19-34-004

REOO REAM 0.2500 rt0.00D5 IF NECESSARY 7S344A13 4 REOD
VIEW LOOKINI; FOI%WARD

Sfell Grill end ream 0800 in did
fitting using flap track clevis hole as guide.
rm
spnr
has in
lug
of
Cemsnf
phenolle arips in Dl.ce using sealant:
Reinsiall
HPIII~V*
Apply
Ilnp
Irack and all
sealant to all
faying
repair part
Irom
flap
track and
flail Adjust
as
necasrs~v
~eat
surfaces. Reinstall all repair
parts using size and type of fasteners indicated.

9370-368
57-10-20
Page
Repair of Rear Spar Lug at ~ar ~r Station (RSS) 9.0.582

Figure 209 (~eQ 2. of 3)
218
Aug 17/84
19814 BY SABRELINER ~ORPORATION
NA-66-1032
STRU(:I~IIKAI, REPAIR MANUAI,
POINT "Y"
O.PBg
T -r-
_B~L
0.440
o.ooo
-0.005
POIWT..Y..
14_~r
0.50 A
f-
--lt
0.125 A
--jc--l
f~f--
-L
2" 9 f15
RS STA
t?
90.582 (AEF)
0.50 A
4.38
l~rB1Sr
REAR SPAR
PLANE
8" 1
0.18
~15
0.032
j
A
4.072
APOINT
0.688
0.75 FOA 9.25 A
j:
0.250
0.88
Je
0.50 A
-j-
YalDIO~BI
5" 14 ~15
5 PILOT HOLES
14140 STEEL
i.
DETAIL OF FITTING
HEAT TREAT TO 160,000
O
IC
Ii~
j-7 I
POINT "Y"
ASP
3.344
0.Ega
4.107
2.497
EOUAL
SPACES
0.125
1.945
180,000 PSI)
8.44
0.083
~1
1
.1
B(~?,
O.Og3~Jlt
2.19
IN NOTED
0.44
t
OIA
O.W2
7
1
0.50 R
0.250 R
0.56
(TYPI
0.125
B,B
0.50 A
SHARP EDGES
0.015
1.921
~e
SECTION
"Y"
RAEAK ALL
-~1
1.448
(TYP)4 PLACES
(TYPI1
1.81
t
0.50
t
2.750
0.625
tl-
1"52 ~t15
0.125 R
ITYPI
t
0.53
0.62
0.31
r
-+IJt
It----
4.41
0.62
t
0.63-+IIC
DETAIL OF SHIM
(7D75-T6 BARE AL ALLOY)
4.38
I 0.50t
I
DETAILS OF PHENOLIC STRIPS
(ASBESTOS BASE PHENOLIC SHEET)
1.010
I
i.
B
I
6.44
0.125 R
r 5"1415
e~$
0.343
I
DETAIL OF SPACER
AL ALLOY
I7O75-T651 BARE
PLATE)
5370-3-70
Repair Rear Spar Lug at Rear Spar Station (HSS)

0
90.582
57-10-20
Page 219
Aug 17/84
NA-66-1032
S?RUCTURAL REPAIR FUIANUAL
ORI1L NO. 8 (O.lssl HOLE FOUR

2.06
II
PLRI;ES
1_
FOA NAS 1888-3K2 FASTENERS
,,.,2lals
Pu n9CE
0.093
TO
Y~H EXISTING
HOLES (N ATTACHIHG
CDMPPYENT
INSTALL MS 21870L3
NUT PLATE
0.44
0.88
L~ I_j
0.18
0.19
0.13 R
0.38 TYP
I-
0.44
TYPE
RSS 278.371
REAR SPAR IAEq
0.093
0.13 R
0.083
MAKE
REPAIR LUO
FROM:7O75-TG51 RARE
AL PLATE-
Grind
WSb(+o.ooo
O
El
off
damaged lug
flush
with
O:
Placerepairlu~ in position on rear spar and drill

rear spar web using repair lug ass guide.
Use sealing compound on drill bit to prevent chips from
spar
fastener holes in
-0.005.
entering
P1
Dye-penetrsnt inspect soar web for cracks
Machine
repair lug
plate
from 7075-T651 to dimensions
shown
O
rear
one
No. 12
in
repair lug
using Alodine 1200
or
(four
No. 8
Goat faying surfaces of repair lug and rear spar

sealing compound (Products Research PR1422 or
equivalent).
with
(0.199)
repair lug.
1SD
and bare surfaces d
secure
Jo-Bolts installed
equivalent.
Finish tee with epoxy polyamide
57-1 0-20
Page 220
Aug 17/84
(0.189) hole]
Chemical film beat
spar
Remov~ repairlug from rsarspar and attach nulleg as indicated.
aft
Locate and drill fastener holes
holes and
O)
on
fuel cell.
rBpBir lug in porlton an

as indicated in 51-40-30.
rear. spat
figure
using
2.
primer
Repair of Rear Spar Lug at Rear

Figure 2LQ
o
Station
(RSS) 270.371
CQBVWIGHT, 1984 BY
ezss~3-ule
CORPQRATION
NA-66-1032
Ass
WING M
194.496
ILGWER)
REAR sPAR
DAMAGEO LUG
Drain all luel
Refei to appl cable Malnsafety precautions regarding
Irom.ing
tenance Manual. Observe all
Rem~vs ailsron and
(UPPER)
oyepenetrantinlpectsp8~*eb
O
gain
accea.
lo
damaged
indamagsdareafoi
cracks.
working around fuel tanks.
I3
O
WING M
apply
ante
Chemical film treat bare

zinc chromate
or
epoxy
areas
of
rear
spar, then
to treated
polyamide primer
areas.
Grind on
damaged lab Ilunh with Eu~fsce
+0.000)
-0.005
rliftn.and railalrah
ials and dimensions called out
on
m us
ng mate.
sheet 2
3255-3-365
Repair of
Rear
Spar Lug
at Rear
Figure 211
0
Spar Station (RSS) 194.496

1 of 4)
(Sheet
57-1 0-20
Page 221
Aug 17/84
NA-66-1032
STIIU(IIURAL REPAIR MANUAL
odllL
Iwrr. 1161A THRU
6 HOLES
3.00
0.125
(TRUEI
7007(TAL~EI
2.IT
f
2.441
Ii
3.915
1.474
GRAIN
I.oo
0.19
_I
3.9851REF1
2.406
0.352
0.28 R ITROEI
~fl
(TvP1
1.281
0.25 R PVP)
(TvPI
1.M)
II
1.494
5" 42 ITHWEI
0.19 R
900
IREF)
WING REF LI~E
0.125 (TRUEI
0.812a.lz
ITVP) PAUE)
(TYP) ITAUE)
300 ITypl
0.141 (TYPI
00 10
1.50
.l/e 0.25
0.25 R
ALL MACHIWZD SUAFACfS 125 v/
0.128
f0.082
REPAIR FITTING
MAKE FROM 7[1;7fi-ft1151 BARE AL ALLOY PLATE
0.1 28
CT
-7-- n
1 I
0.81
~U
.:....-..,;1
-liREPAIR GRIM
57-1 0-20
Page 2~22
Aug 17/H4
0.156
MAKE FROM 2g24-t4~ BAR:E AL ALLOY SHEET
8286-3-386
Repair of Rear Spar Lug
%id~re
at Rear 9~r Station

211 (S~&t 2 ~f 4)
o
CO~YRIGHT,
(RSS) 194.496
1984 BY SABWELINiR CORPORATION
NA-66-1032
GRILL ANG REAM 0.189 *0.003
-G.OM1
IPlCn UP EXISTING LGCATIONSI

INSTALL 7334-367 SCREWS (3 REOO)
MS21G42L3 NUT (3 REOGI
LG153-G002-1403 WASHER 13 RE0G1
GRILL 0.199
6 PLACES
j..
0.202
INSTALL
H
FASTEWERSGPLACES
RIPIIR~ITTIIIG
II
U
~b
REAR SPAR (REFI
I~Tf;E-H--
IIILEAOW
SUPPORT IREFI
GRILL ANG REAM 0.189 +0.003

-0.000
REPAIR SHIM
(PICK UP EXISTING LOCATIONSI

INSTALL 7334-399 SCREWS I3 REOD)
MSZ1042L3 NUT 13 REOGI
L0153-W02-1403 WASHER (3 REOG)
Layout
and drill
pilot
hoes
through ueb of repair
Clamp repairtiltlng
in
placeon
rear
8p.r
Clampon
Machine repair shim
clearance between the
so
that wnen
repair fitting
and
installed, the
repair shim
does
I.pall
shim to
m
and
upper flange only.
IEO
repair
fitting,
rear
repair
rear
Pici~up
shim and
clamp repair litlng
and
spar.
lastener locations
through repair (i(ling
spar web.
PiFhUPBliling (8S1BnBrlOCBll.n.lhlOughYppel
flange of repair fitting,
and lower
not exceed 0.002 in.
NOTE
TO PREVENT METAL CHIPS FROM ENTERING FUEL
CELL. COAT DRILL BIT WITH SEALING COMPOUND.
EVERY PRECAUTION SHOULD BE TAKEN TO PREVENT
CONTAMINATION OF FUEL CELLS.

h265-3-367

0
57-10-20
Page 223
Aug 17/84
NA-66-1032
STRI:(?URAL RI~PAIK MANUAI,
~PPEA-SKIN(REF)
II
REAR SPAR
.LOWER-SKIN fREF)
REPAIA FITTING
REPAIR SHIM
Remove
repair fitting and repair shim. Remove

repair fitting, shim, and rear
Install fasteners through upper and lower flanges
burrs from all drilled holes in
of
spar.
LEI
chromate
irni
Chemical film treat repair shim.
or
epoxy
polyamide primer
to
Apply zinc
repair parts.
rear
-LO
using
spar.
Page 224
Aug 17/84
spar.
Secure aileron attaching support in place. Drill

+0.002
Secure aileron
attaching support
to
repair fitting
2 NAS 1104-4 bolts, 2MS21042L4 nuts and 2 LD153-
0002-1404 washers.
1~
Position repair
fitting and repair shim in place.

through repair fitting and rear spar web as
51-40-30, figure 2.
57 ,1: 0-20
rear
through tab on repairfitting

:~:VOYOLO)
using holes in aileronattaching fitting as guide.
Install fasteners
shown in
and
and reamtwoholes(0:250
Apply thin coating of PR-1442 sealing compound

(Or equivalent) to faying surfaces of repair fitting., repair
shim and
repair fitting
Reinstall aileron and any other removed parts
or
components.
s2es-3-3as
Repair of Rear-SDar Luff at Reanspar Station ~RSS) 194.496

Figure 211-(She~et 4 of 4)
i
NERCORPORATION
REMOVED FASTENER
TRIM DAMAGE MIOWAY

BETWEEN EXISTING
(TYPI
FASTENER/S
RIVET
FILLER
RIB
TO MATCH
~t-
rl
NA-6Ci-10S2
STKI!(I11:KIZI, KE:IAIH MANI;AI,
C\ W r,
_t=-
~w-------
SKIN-TO-RIB
SLAUOEIPYTI
SPACING
TO MATCH RIVETS THRU
RIVET
SKIN(REF]
SKIN ANO RIB. HO. REOO DETERMINEB

FROM LENGTH OF OOU8LER. DIMPLE SKIN
REPAIR ANGLE
ANO REPAIR DOUBLER.

4 TIMES RIVET
-e
I>
I
21/2 TIMES
PLACES)
~I-
+I
i/
RIVET DIA (TYP

ALL
OlA
+I
r-f
FILLER
$I
t!
I
~J
AI-]
FILLER
FROM
RIVET TABLE
1-
IMIN)
REPAIR DOUBLER
,/bRln,
1/4A
RIVET
Je
I
-e
EOUALS SKIN-TO-RIB
SPACING (TYP)
SECTIONA-A
RIVET TABLE
WING
NO. REOO IN WEB
RIVET
TES
MS20478
EA SIDE OF DAMAGE
30.079
006
33.884
405
38.585
405
43.288
405
47.997
A05
49.618
405
51.284
405
Raise
or remove
THAT OF RIB
RIB
skin
Instal
repair pans
reparpans
BEAD (TYP
Reinstall skin. CR2248 rivets may be used for skin
trailing edge
MATERIAL
Trimouldamage
Fabricate
IZ~
FILLER
ANO GAUGE TO MATCH
close-out
REFI
REPAIR DOUBLER
MATERIAL
TO MATCH RIB THICKNESS
IS DNE GAUGE HEAVIER

Refinish
repaired surface
to
match
surrounding
area
NOT~V
THIS REPAIR IS APPLICABLE TO WING RIBS AS INDI-
CATED IN RIVET TABLE

NEST REPAIR DOUBLER
INSIDE OF RIB FLANGE ON
RIBS WHICH DO NOT INCORPORATE BEADED WEBS
Wing InhdlrailinR E:dKu (TE) Rib Repair

Figure X1B
o
S265-3-154
57-1 0-20
Page 82.,
Auff 17/84
NA-(i6-103~
SIHII("IITKAII KI~PAIKK MANIIAl,
i
i
!II
01600 (0;002. -0.00)
0.250
5-5/8
1/4
0.252
1.092
7/16
11/32
_L
3/32 R
rl
4 PLACES
3/4
MACHINE-FINISH
T
i
2.050
1-1/4
FITTING REPAIR OOURLER -0.250 17PH

ORES PLATE, CONOITION ANNEALEO:
HEATTREAT TO 180;000 PSI
0.199 (o.ooa. -G.OoOl

OIA 3 HOLES
CSK:100o x 0.381
011\ 3 PLACES TO
32J
MATCH EXISTING
HOLES IN FITTING
-L~-
2-51)
?-I
0.090
1-13/16
-i
3/12 R
1+0.002.-0.001
6/16~
to
app(
cable
~I
5/16
r0 laamo
(Reler
1-1/2
(4PC16ESI
ALIONMEHT PLATE
FABRICATE FROM 0.090
Ilap
TO MATCH PLATE RLMOVEG
Ii/is
0.500
Renloue
GRILL FOUR 0.199 IN~ HOLES
3-1/2
4 PILOT HOLES
3(
--------tl
1
;t/
/cJ/1B
m~cllws-anla
32J
and
replacenlent part
to
Heat-treat repair doubler and
replacement part
to
Fabricate
mil,nlcnancu
repair doubler
dimensions shown.
manual
Remove wing inbd
trailing edge panel assembly
189.000 psi.
~I13
Prime
repair
doubler and
replacement lilting
vith
epoxy polyamide primer.
NOI~
BOTH ALIGNMENT FITTINGS SHOULD BE REPAIRED/
REPLACED AT THE SAME TIME
b370-3-72P1
57-1 0-20
gaRo ~2fi
~un 17/H4
Itepair of WinR
~Ke (TE) Alip;nment ~ittinR

FiRure ~1:2 (Sheet: 1 of 2)
o
COPYRIGHT, 1984 BY:OPiBREL~INER CORPORATION
NA-66- 1032
AFT ALIGNMENT FITTING
HONEYCOMBTE(REFI
PRIME ALUMINUM WITH TWO
COATS OF EPOXY POLYAMIOE
PRIMER BEFORE INSTALLING

DOUBLER
C/
REPAIR
DOUBLER
PRIME ALUMINUM WITH TWO COATS

OF EPOXY POLYAMIOE PRIMER
BEFORE INSTALLING NEW PART
ALIGNMENT
PLATE
-+7
63
NAS1670-3K
FASTENERS
3 REOO EXISTING
RIB. TES 30.079
LOCATIONS
HAS16703K
FASTENER
4
AOOEO
REDO IN EXISTING
LOCATIONS
NASIBBO-BK
FASTENERS
4 REOO
EOUALLY SPACED
O
O
install
repair PB118
and
prime
lapteners
Install
fiap
IRsfer
lo
applicable
maintenance
manual.)
Instali inbd Irailing edge
panel assembly
5370-3-73*
Repair of Wing Inbd Trailing Edge (TE) Alignment Fitting

0
57-10-20
Page 227
Aug 17/84
NA-66-1032
TYPICAL CRACK
_~-----r-
24.082
I~
I,
\I~
SEE STEP 3
TYP
;;h~
CUTLINE~
1R
TYP
SEE STEP 3
~sfl
t
lr-NI
ii
Il
II
ii
TYPICAL CRACK
--i~
ale ASSY
(LOOKIHO Cll;lACI
285-)36258-11 LR gHBWI
285130258-12
AC VjY~bltE
TYPICAL
SEE STEP 3 -t
CRACK
CUT LIRE
Remove cracks
Maintain
by
exi.fing
hand
radii
as
blending.
the minimum red i.
5/8 A
Remove
no more
TYP
than 0.375 in. of material in the
vertical direction.
Dye penetrant inspect blended

complete removal of all cracks.
O
O
area
to be certain of
The finish after rework should be 63 RMS
Finish with epoxy
max.
8EE STEP 3
polyamide primer.
5/8 R
TYP
CUT LIKE
TYPICAL
CRACK
NOTES
THIS REPAIR IS APPLICABLE TO WING TRAILING EDGE
DCTES 24.082).
REMOVE MATERIAL ONLY IN THE VERTICAL DIREC-
SECT16N
TION IN THE RADIUS AT THE INTERSECTION OF LUGS
A-A
AND VERTICAL RIB WEB.
57-10-20
Page 228
Aug 17/84
5285-3-3&1
Wing Trailing Edge (TE) Rib Re;t~Bir

Figure 214
o
Station 24.082
COPYRI:GHT,
1984 BY SA$RELINER CORPORATION
NA-66-1032
WING TANK SEALING

REPAIRS
GENERAL
The wing fuel tank structural joints are, for the most part,
sealed by two methods. Where a faying surface seal is
required, the groove injection method is used. Where the
sealing requirements involve the fastener only, the
sealing is accomplished with an O-ring. In a few internal
joints, a hardening type of sealant is used. The type of seal,
is
or sealant, used for each structural joint and fittings
shown in figure 201. Examples of the sealing methods are
shown in figure 202.
Sealing of the wing fuel tank doors and fittings is
accomplished by "0" rings. The O-rings are either bonded

to grooves in the faying surface of the part, or they are
bonded to either side of a separate seal assembly that
serves as a
sealing washer between the parts. Rubber/
metal washer assemblies (Stat-O-Seal or Due-Seal

washers) are used to seal each attach fastener. (See
figures
201 and
202.)
The groove seal method used for fastener and faying

surface sealing consists of a machined groove in the faying
surface of the under or second member that is continuous
along the fastener row. Continuity of the groove around
each fastener is achieved by spot-facing the holes to the
depth of the groove. Small countersunk holes through the
injection hole screw is removed, contaminates do not enter

into the injection hole.
Materials/Equipment Required
Groove Injection Sealing
Compound Products
PR 703
Research
Groove Injection Sealant Gun
Grover Smith Pump Co.
No. 223 (Air Operated)
052
Loading Sealant Injection Gun

See figure 203.
Air-operated Sealing
Gun
1.
R,,,,, loading chamber from gun barrel and push

loading piston to its fully bottomed position.
2.
Etollsealingcompound intoacylindrical shapeabout

1-3/4
to 2 in. in dia.
NOTE
must be clean and oil-free before

sealing compound is handled.
Hands
shallow counterbore in the base of the countersink. On

installation, the ring is compressed by the screwhead
against the sides and bottom of the counterbored
receptacle, forming the seal. (See figures 201 and 202.)
plug of sealing compound into loading

chamber of gun. Tamp sealing compound with a
wooden stick until all air bubbles are forced out.
3~
Insert
4.
Reassemble loading chamber to gun barrel.
GROOVE INJECTION SEALING
052
001
Cleaning Solvent
Individually (O-ring) sealed fastener installations involve

flush-head fasteners only. The O-ring is formed by a
lil
002
Tip-Sealant Gun
(See figure 203.)
or
The ability of groove injection sealant to seal depends

other
upon its adhesion to metal. Oils, greases or any
contaminates in the sealant grooves or sealant injection
holes could cause a defective seal. If the sealant grooves
are accessible, wipe the grooves with a clean clotht
moistened with cleaning solvent then dry the surfaces
with another clean dry cloth. If the sealant grooves are not
accessible, make certain that the area surrounding the
sealant injection holes are clean and that when the sealant
KEYO
or
Groove Injection Sealant Gun

Grover Smith Pump Co.
No. 225 (Hand Operated)
first member, at approximately 3 in, spacing, are

provided for sealant injection. Sealant injection holes are
in line with, and midway between, structural fasteners.
Flush self-tapping screws are used to plug the injection
holes when the sealing has been accomplished. (See
figures 201 and 202.)
outer
SOURCE
MATERIALS
Hand-operated Sealing
Refer to 51-30-00 for manufacturer.
Gun
1.
Back off "T" handle until spring tension is released

and handle is released and handle is fully extended.
2.
Unscrew pressure head from sealant chamber.
Roll sealing compound into a cylindrical shape about

in, in dia.
one
57-1 0-30
Page 201
Aug 17/84
NA-66- 1032
REPAIRS (Continued)
Hand-operated Sealing Gun (Contd)

4.
Insert plug of sealing compound into barr~l of gun.

Tamp sealing compound with a wooden stick until
all air bubbles
5.
6.
Reassembly
are
forced out.
5.
pressure head to sealant chamber.
Screw "T" handle in until spring tension is felt. As
sealing compound is forced out of gun by this

operation, the "T" handle must be screwed in furthei
to maintainspring tension.
NOTE
Injection of sealant into groove-sealed

areas should not be attempted when temperature of-wing structure is below 40C
(40"F). Whenever possible, it is recommended that temperature
least R50C (r70F).
Remove
areas
self-tapping
of structure beat
screws
must be
NOTE
from injection holes in
(min)each side of hole
Do not use soiled cleaning cloths. When a

becomes contaminated, it should be
discarded. Cloths usedfor cleaning should
never be dipped into solvent. Pour solvent
onto cloth to avoid contamination.
cloth
unplugged,
NOTE
Regular injection
gun tip may be u8ed,

except when injecting through wing joint
splice plates. See figure R03 for details of
special tip reguired
on
Replace all self-tapping screws insealant injection

holes. Remove extruded sealant by carefully
scraping with a non-metallic scraper and wiping
with cleaning solvent.
FUELTIGHT FAYING SURFACE SEALING. -65

to 2009F
to be resealed. One hole
being injected
The area to be sealed must be free of all foreign matter

and c~ntaminates. A vacuum cleaner, air hose, or lint-free
cloth-should be used to remove chips and dust from the
area..Wipe all surfaces to be sealed with a clean cloth
saturated with naphtha. Before naphtha has evaporated,
wipe surface with a clean, dry cloth. If the naphtha is
allo~ived to evaporate, the dissolved contaminates will
remain on the surface.
Sealing Procedures
1.
Move gun to adjacent hole and repeat operation.

Continue foregoing procedure until sealant has been
forced out of all injection holes in affected areas.
4.
thess
Repeat cleaning procedure until there is

evidence of contamination
on
no further
surfacesto be sealed.
M&tePials/Equipment Required
areas.
MATERIAL
Ilace nozzle tip of gun squarely in countersink. Hold
gun firmly in position and depress trigger (airoperated gun) for about 30 seconds. Release trigger
and allow piston to return. Continue sequence until
compound flows out of adjacent injection hole for a
min distance of 1/8 in. (Repair damaged injection
holes as shown in figure 204.)
3.
Move
guntiptooneof adjoining injection holes. Hold

gun firmly in place and depress trigger until sealant
flows out of hole
previously injected.
NOTE
When
injecting sealant into tank grooves,

injection holes to either side of gun, tip must
be unplugged. To decrease time required
for injection, it is permissible to heat guns
to a mat of 110oF.
Sealing Compound,
Temperature Resistant
SOURCE KEY
lil_
002
Products Research
PR 1422, Class B4 and
PR 1422 accelerator
Sealing Compound
Minnesota
or
Topcoat
Mining Co. EC776
005
EC776R
Sealant Gun
Semco 250 or equivalent
043

(olr equivalent)
001
Toluene
001
MI#ing Sealing Compound

Mix the base compound and the accelerator together in
the proportions recommended by the manufacturer; The
two components must be thoroughly mixed to completely
dis~rse the accelerator throughout the base compound.
If the mixture is not thoroughly blended there will be
Refer to 51-30-00 for manufacturer.
57-1 0-30
Page 202
Aug 17/84
1984 BY SASRELINER C~RPORATION
NA-66- 1032
REPAIRS (Continued)
Groove Sealed Areas
Mixing Sealing Compound (Contd)
expired. The blended sealant may be stored at 0 to -100F

for a period of 72 hours providing the sealant is refrig-
Check all bolts in affected area for proper torque before

attempting to reseal area. If torque is low, tightening
fasteners to the proper values may stop the leak. If
fasteners are properly torqued (or tightening does not
effect a cure), the area must be reinjected with PR703
erated immediately after blending,
sealing compound.
areas
where the
cure
will be
incomplete. At
room
temperature (approx. 77"F) the blended sealant has a pot

life of 3 hours, and must be discarded when the pot life has
When
Application of Sealing Compound

Apply sealant in well ventilated areas or use air supplied
respirators. Use a spatula or sealant gun to apply
sufficient sealant to both faying surfaces of components to
be sealed. Make certain that all voids and surface
irregularities are filled prior to the mating of the two
faying surfaces. The fayinff surfaces should be joined as
soon as possible after the application of the sealant.
Excess sealant forced from between the faying surfaces
may be removed or formed into a fillet or bead using a
spatula.
When the sealant has cured, all exposed sealant shall
receive two brush coats of fuel resistant top coating
(EC776R) allowing about 20 minutes between each coat.
Clean up sealing equipment and areas adjacent to sealed
components within the pot life of the sealant (about 3
hours). Use toluene to clean painted surfaces and MEK to
clean bare surfaces.
first attempt to reseal
groove sealed
area
is not
Individually Sealed Fasteners

a leak develops at an individually (O-rinff) sealed
fastener, check fastener for proper torque and proper
seating of fastener head. If screw is too long, the head will
not be drawn fully into the countersink. If the hole in the
When
outer sheet is misaligned with the hole in the second

member, the fastener head will be tilted. If the countersink is elongated, there will be a gap on one side of the
fastener head.
When the fastener installation appears to be satisfactory,
the leak can be considered to be caused by a faulty O-ring.
Correct leak by removing screw and replacing O-ring
with a new one, being very careful not to damage new
O-ring during installation.
SEALING WING JOINT SPLICES
NOTE
When the left and right wing panels have been separated,
for any reason, all residual groove and fillet sealant in the
affected areas must be removed before the assembly is
remated. Use only non-metallic scrapers, toluene or
cleaning solvent, and rags to loosen and remove both types
of sealants. Neither toluene nor cleaning solvent will
dissolve either sealant; they will, however, tend to weaken
adhesion of the sealant to the painted surfaces. By
repeated soaking, scraping, and wiping, the sealants can
be removed.
After all structural fasteners in the centerline rib and
splice plates are in and properly torqued, resealing

may be started. Access covers on each side of the centerline rib in the rear spar must be off to permit sealing of the
baffle-to-centerline rib joint. (See figure 201.) The
sequence of sealing groove-sealed fastener rows is
optional. It is recommended that the sealing of each row
spar
be commenced by starting with the lowest injection hole

and working upward until the entire row is sealed. When
all rows have been thoroughly injected with sealant, as
evidenced by a small amount of extruded sealant from
each injection hole, install injection hole plugs (selftapping screws) and clean up excess sealant. See figure
201 for sealing diagram.
When fastener inz,olved is retained by a

bumper nut that cannot be conveniently
reachedfor reinstallation, fastener may be
backed out just enough to cut used O-ring
loose. New 0-ring may then be carefully
stretched over fastener head. (See figure
eos sr-so-ao for type of nut used on each
fastener installation.)
SEALING REPAIRS
For installation of external sleeve fasteners in fuel sealed
areas, see section 51-40-30.
EXTERNAL REPAIR OF LEAKING FASTENERS
IN FUEL CELL CLOSE-OUT AREA
A satisfactory repair of leaking fasteners in a fuel closedout area may be accomplished using the Semco 400A-1
Field Repair Kit, and the following procedures.
STOPPING FUEL LEAKS

Leaks may develop at either injection groove sealed
at the individually sealed fasteners.
successful, carefully repeat operation. Extrude a greater

amount of sealant from each injection hole than was
forced through them during first reseal operation.
NOTE
ifrepair is to be aecomplis~Led on a painted

surface, an adhesion test must be performed to ensure that painted surface has
retained its adhesion gualities.
areas
or
57-1 0-30
0
Page 203
Aug 17/84
NA-66-1032
REPAIRS (t=ontinued)
Adhesion Test
I.
remove
2.
to be tested with
all contaminates.
Wipe surface
Apply
9.
Mix one kit of sealant, (MIL-S-8802 Class B 1/2)

from repair kit, per manufacturers direction.
10.
If fastener being repaired is leaking fluid, apply

sealant directly to leak then wipe away excess
sealant.
11~
Apply a thin
12i
Center holding fixture assembly over area to be

repaired. Adjust knurled knobs 90 that teflon-coated
die exerts a slight pressure on foil repair patch.
131
Heat cure foil repair patch for a period of 30:minutes

using factory pre-set (1400) heating body.
one
surface.
abrupt upward motion, pull tape from surface.
3.
In
4.
Examine adhesive side of tape for indications that

tape has pulled paint away from painted surface. If
there are no indications of paint adhering to
masking tape, adhesion is acceptable and repair
may be made directly on painted surface.
an
Clean faying surfaces of foil repair patch and area

where repair is to be applied with MEK. Wipe dry
with clean dry cloth.
clean cloth to
in. wide masking tape

to be tested. Firmly press tape down on
strip of fresh,
across area
8.
When there are indications of paint on the masking tape,

the adhesion qualities of the paint are not acceptable and
the finish in the area, of repair must be scuff sanded down
to the bare metal then a new conversion coating (Alodine,
or equivalent) applied before accomplishing the repair.
coat of sealant (0.015 to 0.020) to faying

surface of foil repair patch. Place foil repair patch,
sealant side down, over leaking fastener. Reduce
sealant thickness to about 0.010 by aPplying finger
pressure to foil repair patch.
Repair of Leaking Fastener

NOTE
In eztremely cold areas, cure thefoil repair
patehfor a min of45 minutes.
Airplane must be grounded to preclude

arcing between keating tool and airplane
surface.
i.
Using MEK clean

aroung
2.
3.
an area
of at least 1
14.
1/2 in. in dia
After repair has cured, remove holding fixture

assembly and remove excess sealant from repair
area.
leaking fastener.
15;
From the Semco 400A-1 Sealing Kit, obtain heating

body, holding fixture and applicable size tefioncoated die.
Repair area may be touched-up with applicable

paint/primer immediately after removing holding
fixture; however sealant will not be completely
cured for 72 hours.
Adjust knurled adjusting screws of holding fixture

that they are midway in adjustment range.
TESTING FOR LEAKS
so
Thread teflon-coated die into heater body then screw

heater body into holding fixture,
5.
Position holding fixture assembly over fastener to be

repaired. Turn heater body in holding fixture to
bring teflon-coated die down flush with surface
being repaired.
6.
Remove holding fixture assembly and set aside.

Make certain adjustments are not disturbed,
7.
Obtain foil repair patch material from Semco kit

and trim patch to size. Make repair patch circular in
shape whenever possible to eliminate sharp corners.
Patch should be at least 1/4 in. in dia larger than
head of leaking fastener.
The wing fuel tank assembly must be pressure-checked

for leaks whenefer sealed joints that are inaccessible for
resealing with the wing installed have been disturbed.
Sach inaccessiblejoints include the centerline splicejoint,
the front spar splice joints, and the inbd rib of the inbd
lead:itlg edge. Testing must be accomplished before the
wing is reassembled to the fuselage.
4.
When the pressure test is being conducted, the left-and

right-hand unit interconnecting valve (Whittaker Part
No; 134345-4) must be in the open position. This valve is on
the: left side of the centerline rib. The valve may be
reached through an access hole oil the left side of the
centerline rib in the main spar.
571 0-30
Page 204
Aug 17/84
cdBV~loHTI
1984 BY SRBRELINER CbRPORATION
NA-66-1032
STKIICI1IKAI, KEPAIH MANC!AL
REPAIRS (Continued)
E:rluipment
and Material
NOTE
Required
Rubble-solution check c:sfilzn.l
Air pressure to the wing tank must be controlled b~ a

regulater with a lead-sealed safety valve or similar safety
feature that will prevent pressurization of the tank above
7
psiff.
The air supply filter must contain a tlap fol~ Iemoving

water and oil and must be maintained fol efficient
operation.
Expanding neoprene plugs are recommended for plugaing fuel system fittinlSs in the rear spar. Plugs may be
made from soft(l0 to 20 Shore) neop,ene.
Small-leak detection may be
accomplished by brushing
sealed joints with a detergent or soap solution. Turco
Products No. 598 Bubble Fluid, or equivalent, is recammended.
testfo~rficcl-
tiyh.tness. All sealed fasten.ers and sealed

joints nrp potential so~srres of Ir!aku.ge. A
check 1)2?LSf be
and calefirlb~
perfor~ed.
Cleanup
Kinse bubble solution residue flom structure with tap
as soon as practical after test is complete.
water
Securing Wing
Depressulize tank and remove all test plugs and othel
equipment. If the wing is to stand ol be stored fol any
period following the leak check, all tank openings must be
covered with suitable caps
ol
plugs.
Procedure
Plug all fuel system openings in rear spar with suitable

line caps and plugs. Attach air line from regulator to one
of the two fuel vent fittings on upper wing skin. These
fittings are close to the front spar, just inbd of the uselage
attach rib on either side of the wing.
When the air regulating equipment permits, attach
pressure line to one fuel vent fitting and tank pressuresensing line to the other. When one air line only is used,
cap unused fuel vent fitting,
Preliminary Check
To perform prel im i nary check, pressu ri ze tan k to a m i n of
4 psig and a max of 5 psig. Close inlet valve between air
source and tank structure, thus maintaining a static
pressure in wing during test. Locate and seal any large
leak as evidenced by a rapid pressure drop. These leaks
may ocur where a fitting or fastener has been omitted, or
where a section of the tank has not been injected with
groove-sealant. Repressurize to 4 psig min for 5 psig max.
Close inlet valve and allow tank to stand for 15 minutes. If
pressure has not dropped one psig, continue with test
procedure for fine leaks. Otherwise, recheck structure
until rate of pressure drop is less than one psig per 15
minutes.
Final Check
Fine leaks not readily detectable by a pressure drop are
checked by brushing the resealed area with a soap or
detergent bubble solution. If Turco Products No. 598
Bubble Fluid is used, mix one part of Bubble Fluid to
eight parts of tap water. Pressure must be maintained
between 4 and 5 psiff during the test period. Clearly mark
all leaks as evidenced by soap bubbles with a grease
pencil. Reseal all leaks, depressurizing tank if necessary.
Recheck resealed area(s) after resealing, repressurizing
tank as required.
57-18-30
0
Page 205
Aug 17/84
NA-66-1032
WING UPPER
WS
MOLD LINE
37.161 IREFJ
]P
FUEL FLAPPER
WS
VALVE
j1 I
75.534 IREF]
IRE9
WING LOWER
SECTION
HOLES AND
MOLD LIIE
M-NI
STE1RMOGIV
AROUNDLINESANO
ws
171.620
IREFJ
SECTION
P-P
R-R
D
C
SECTION
OI
I
I
III
FL~
")~s
UPPEA MOLO LIWE
FRONT SPAE
Tr
~;;a
~a
UPPER MOLD LINE
LOWER MOLD LINE
SECTION
LOWER MOLO LIRE
A-A
UPPER MOLD
TYP BOTH ENDS OF WING LE
LINE
INBO REAR SPAR
IREFI
FIXED CLOSE-OUT TUBE
NOTES
All rib-to-skinfastener nuts and otker
hidden nuts are of self-wrenching type,
ezeept as indicated by eode i.
olefast~zers tkrough ssp~ped

fla~aePs nard be leld (or hased) 2oiU a
wrench, e3ccept as indicated by code i.
SEAL CODE
A
withsealingcompound. Forsealanttype, refer
to 51-30-00 Table 2A.
Sealed with bonded

Seal washers.
Sealedwith
All nuts
III
Seal
SPAR
O-ring assembly and Stat-O-
O-ring. Fasteners sealedwith Stat-OSeal washers when required.

an
WS 37.161 AND 75.534 IN THE MAIN BOX SKIN.
by groove injection sealing with

ing compound.
BUMPER NUTS ARE INSTALLED ON TWO 3/16 IN. SCREWS ON
individually sealed fasteners
~I
FRONT
~o:
BUMPER NUTS ARE INSTALLED ON FOUR 5/16 IN. SCREWS IN

VICINITY OF WS 37.161 AND ON ALL 1/4 IN. SCREWS BETWEEN
INBO
Sealed
PR 703 seal-
or
N VIEVB~B
RIB
IECTIONE~E
~llllOrROIT
SPAR PLANE
STAT-O-SEAL
OUTED FRONT SPAR
O-ring sealed.
FWD SIDE OF FRONT SPAR AT WS 171.620.
57-1 Q-30
Page 286
3/88
Jun
(self-wrenching) must be hand-held

threads are engaged during installation.
until
ITYP)
SLAT TRACK
HIDDEN FASTENER CODE
Bumper
.-7
CUP
nut
SECTION
N-N
VIEw
C-C
SECTION DD
SECTION
Wing Fuel Tank Sealing Idiagram

o
F-F
S285-J-233A
NA-66-1032
,AL
O
02 FISTEIERS
2 FASTEWERS FWO
OF SPAR
I
II REIR
SPAR AND FIRST
FASTEIERFWOOF
REAB SPAR IN RIB
STAT-O-SEAL
(TYP 7 PLACES)
S
r
Is
w,-l
1~2
C1~
O\\ 6 Lk~:
LOWER SKIN
SEAL CODE
INBD REAR
A
Seal with
sealing compound.
For sealant type. refer to 51-30-00 Table
SPAB
FUEL TRANSFER
FUEL FLOAT
AUX TANK SIIGLE-
AIO FUEL VENT
SWITCH CABLE
POINT REFUELING
WING UPPER
AUX TANK FUEL
LINE
IREFI
Line
MOLD LINE
TEST LINES IREFI
IREFJ
IIYBO REAR
SPAR
LH
2A.
B
C
AH
WS
Sealed with bonded

Sealed with
when
an
O-ring assembly
O-ring.
65.810
and Stat-O-Seal washers.
Fasteners sealed with Stat-O-Seal washers
required.
-ssai~
by grmve njeCfion 58aling
In P. lm
STAT-O-SEAL
(REFJ
I;
\i
ssanp compound
,I~
;i,
I:I
new
23
08
--Individually
sealed fasteners
O-ring
sealed.
O~".P"
(self-wrenching)
engaged during installation.
nut
~I
HIDDEN FASTENER CODE

must be
hand-held until threads
are
FUEL BOOST
FUEL CAOSS-FEED
PUMP IREFI
VALVE CABLE
-J
FUEL TRAIISFER
FUEL PROBE CDAX

CABLE IREFI
DETAIL
AID FUEL VENT

WING LOWER
FUEL BOOST
MOLD LINE
PumP C9
All rib-to-skin fastener nuts and other

hidden nuts are of self-wrenching ty~e,
as indicated by code i.
All nuts
fasteners through ezposed

flanges must be held (or turned) with a
wrench, elceept as indicated by code i.
p
on
LOWER SKIW
I1EGOE
FASTENERS ARE
DOME NUT SEALED
LINE [REFI
INDD REAR SPAR
NOTES
WING INBD LEADING
2.
O-RIWG
%,R~AR
SPIR
REAR SPAR
BUMPER NUTS ARE INSTALLED ON 114 and 5/16 IN.
SECTI~NK-K
SCREWS INBD OF WS 65.810.
SIIIGLI-POIYT
REFUELING TEST
VALVE
IREFJ
SECTION
L-L
SECTION JJ
VIEW IP
(AH ONLY)

0
COPYRIGHT, 1988
S255-3-2YP.
57-1 0-30
~du
Page20~207ABLank
Jun 3/88
NA-66-1032
I
1
1- WING TANK LOWER SKINS

SEE VIEW T
SEALANT GROOVES
PR1422GB
OA EOUIVALENTJ
VIEW LOOKING GOWN
LOWER LEADING EDGE PANELS

VIEW T
SEALANT
PR1422GB
WING TANK LOWER SKIN
SEALANTPR14220B
OREOUIVALENT
OR
EPUIVALENT
SECTION U-U
(NIODEL NA265-60A,
-60
SC, -65, -80A, and -80SC)

0
Ilcr
57-1 0-30
Page 207B
Jun 3/88
NA-66-1032
NUT PLATE AETAIWER
BONDED O-RINO
OOORASSY
S#IN3
B
Q
a:x
ii~
XI~
BONDED O-RING
DOOR ASSY
SCREW
TAPEREOWASHER
SKIN
DOOR
BONOEO O-RINO SEAL
OR
SPAA
BOLT
OU-SEAL1T-OSEAL0R
WASHER
NUT PLATE RETAINER
PLAIN WASHER
STAT-O-SEAL
FLUSH DOOR INSTALLATION
BONOEO O-RINO SEAL
OR OUO-SEAL
\rl
SCREW
WASHER
NONFLUSH DOOR INSTALLATION

NUT PLATE RETAINER
FRONT SPAR IRE9
FIRST MEMBEA
SPECIAL O-RING
B:"~
BONOED O-RING
SEAL ASSY
(~,Y;i" XI
SLAT TRACK CUP
SECTION
SPECIAL O-RING
1246-14035) NO SCALE
INDIUIOUALLY [O~RINGI SEALEO FASTEHEAS
hB)/
STATO-SE~L OR
OUO-SEAL WASHER
(9
SEALANT
INSTALL SELF-TAPPING
SCREW IN SEALING ROLES
SLAT TRACK CUP
cp
INJECTION GUN
BOLT
cs
Il
NUT PLATE
RETAINER
PLAIN
WASHER
BONOEB O-RING SEAL
GROOVE INJECTION SEALING
SLAT TRACK CUP SEALING
57-1 0-30
Page
3/88
Sealing
MethodsFigure
202
208
Jun
COPYRIGHT,
NA-66-1032
OUW BARREL
INJECTION TIP
SEALIIG COMPOUWB
INJECTION TIP
~I
8EILIW8
cGmPGUNB
LGAGlNs
CHAMBER
i_i
PRESSURE
REIB
II
/I(
V,C
INLET AIRLINE-PRESSURE TO BE
1W 1+25, -IOIPSI
,~I,OUICK
I I
OlScONnECT
~---r-
LOAGIWG
CHAMBER
"T" HIIWOLE
LOADING HANG INJECTION GUN
LOADING AIRINJECTION GUN
BICK-GRILL NO. 50
(oO7O1 HOLE THRU 1/8
GRILL 1/8 GIA X 19/18 OEEP.

GRUNTER GRILL AtlO TAP 1/8-27
ROLE
PIPE fHHEAO
0.010R
A
O.1BI
--I--I-- .-j
,r
Yli-l
1/81-13/16
~lr:0.115 ii
3/16
(REF)
DETAIL
SPECIAL INJECTION TIP
(0)
O
01
MBk8 Irom AISI 1140 sfsel.
HBI-VBLPW.OWLO 2201000pSi.
Clssn No. 50 and 1/B in. holep afl~ heaf-lrealing.
NOTE
HANDS MUST BE CLEAN AND OIL-FREE BEFORE
HANDLING SEALANT.
8185-3-23~
Sealant
Injection Guns
Figure
0
203
57-1 0-30
Page 209
Aug 17/84
NA-66-1032
0.282(REFJ
OUTER MEMBER
EXISTIIG CSK HOLE
T
0.125 MIW
_L_~
~I
0.050
TYP
IEIIUIT GROOVE
1_ 1
TYP
a/re
IREF)
BUBITRUCTURE
TYP
SECTION THROUGH SEALAN~ INi~CTION, HO1E
Drill
(135"),
No. 29
through outer member only, using a flat-angled

(0.136 in, dial drill,
8)
Repeat step 3, extruding

adjacent hole.
(lIN
sealant
through opposite
Clssn seaiantlmm ao~ullera nt at IsPDSd haiBWnh
MEK;
DO NOT DRILL INTO SUBSTRUCTUAE.
DEPTH-GAUGE
EACH HOLE TO DE7ERMINE DISTANCE TO SURFACE
OF SUBSTRUCTURE BEFORE DRILLING. SUBSTRUCTUBE MUST NOT BE DI~ILLED.
N~L28 hole with 8-32
NCJA
plug (modified) and
bottom taps.
Remove
19
PITme and paint mumerrlnl; of I.opad hale
I~
Install NAS10B1-08A3 or NAS1OB1 C08A3L setscrew
in tapped hole.
sealant groove.
P
one
sealant
injection
fsonsd hale Inlec(lrealant to clear
hole
sea
screw
adjacent to
chip~.
gro.u. d
Tighten
setscrew
lightly against bottom of
Where desired for aerodynamic smoothness, fill

aerodynamic filler.
countersink with
IEa:
Reliniah
to matsn
surrounding
area
NOTES
THIS REPAIR
IS APPLICABLE TO STRIPPED OUT

INJECTION HOLES IN WING.
SETSCREWS MUST BE REMOVED WHEN RESEALING

WING.
~I
PLUG TAP MUST BE MODIFIED TO SERVE AS

STARTING
TAP. GRIND TAP SO THAT IT HAS A TWO-THAEADED
LEAD. BEFORE USING MODIFIED TAP ON
WING, EXPERI-
MENT BY TAPPING COUNTERSUNK TRAIL HOLES

IN
0.125 IN. SHEET. PILOT DRILL AND COUNTERSINK
fOOa
BY 0.262 IN. BOTTOMING TAP MAY ALSO BE
MADE BY
GRINDING LEAD END OF PLUG TAP SO THAT ONE
LEAD THREAD REMAINS. AGAIN, EXPERIMENT
BY
FINISH-TAPPING STARTER-TAPPED TRAIL MOLES IN
0.125 IN. SHEET METAL.
63701381
57-1 0-30
i:
Page
Repslr(lf
e2aa;
rugiFaeloH
210
AuR 17/84
CO~RIGWT,
NA-66-1032
PLATES AND SKINS

REPAIRS
GENERAL
The lower skin is the close-out skin on the main box
assembly. Preparations for lower skin removal includes
separation of the panels, and removal of the landing gear,
flight control surfaces, and certain pieces of fixed
structure. A holding fixture to prevent possible warpage
of the structure and a fixture (with slings) for inverting
the wing comprise the special equipment necessary.
Suggested methods for building the wing rotating fixture
and wing holding fixture are shown in section 57-10-20.
Figures 201 thru 216 cover repairs to plates and skins.
STRIPPING WING
Perform the following operations in accordance with
instructions in applicable maintenance manual:
wing panel from airplane.
1.
Remove
2.
Separate wing panels.
3.
Remove slats and slat track rollers.
4.
Remove
5.
Remove aileron and aileron control sector assembly.
6.
Remove flap, flap actuator, and inbd flap track

(latter to permit installation of wing rotating
wingtipfairing.
fixture).
7.
Remove main landing gear chassis and door

assemblies.
8.
Remove main landing gear downlock and strut door

hinge assemblies.
9.
Remove main landing gear uplock actuating

cylinder (to permit installation of wing rotating
fixture).
10.
Remove
following wing assembly components
as
indicated in figure 201: slat track ribs, outbd leading

edge, outbd trailing edge, inbd trailing edge, and
two small trailing edge skin panels tone adjacent to
inbd end of flap and other under landing gear uplock
assembly).
11.
Remove following miscellaneous fasteners through

lower skin (figure 201, this section) underslat
leading edge rivets, intermediate trailing edge rib
rivets, aileron hinge rivets (Hi-Shear), and flap
track bolts. Rivets through underslat leading edge
and lower skin should not be removed, however,
until wing has been turned over and placed in
holding fixture.
ROTATING THE WING
Refer to 57-10-20.
57-30-20
0
Page 201
Aug 17/84
NA-fi6-1032
STHUCTURAI, REPAIR MANUAL
INBD TRAILING
EDGE ISEE VIEW
A)
OUIBD
TRAILING
EOGEILE
VIEW BI
i%
L--
SLAT TRACK
RIBS ITYPJ
(SEE
INBD TAILING
VIEW
C)
RIVETS
LEADING 69GE
ANO LOWEA HIAIN
OUTBO LEAOIWG
EDGE ISEE
VIEW D)
BOXSKINISEE
EDGE
VIEW CJ
BOLT
cSCREWS
(TYP UPPER
AND LOWER
SURFAQSI
ii
OUTBO
TRAILING
EDGE
BOLT
ru~
SCREWS (TYPJ
VIEW A
VIEW
BOCTS
SLAT TRACK
BOLTS
RIBS
;icsCREWslTvp
UPPER AND-LOWER
SKINBI
BOLTS
ci--~
f,:C
i:
~j6:
-a
,,tl-:
i-s
r:
BOLTS
srrws--/
RIWTS TH)U
SCREWS
(TYPI
FIXTURE)
NOTE7
THIS
VIEW
LEAOING EDGE
SKINANDCOHIER
MAINBOXSKI11.
100 NOT REMOVE
UNTIL WING HAS
BEENINVEAT~OANO
PLACED IN HOLOING
(TYP)
VIEW
BOLTS
ILLUSTRATION SHOWS COMPONENTS AND
FASTENERS THAT MUST BE REMOVED BEFORE MAIN

BOX LOWER SKIN CAN BE REMOVED.
57-3929
Page 20
Aug 17/84
521-3231
Lower Main Box $kla ~moval

Figure 201 (She~t 1 of 2)
o
COPYR1GHT, 1984 BY 8ABRELINER CORPORATION
NA-66-1032
OUTBO FLAP
TRACK
AILERON CONTROL
(FOR
INSTALLATION OF
RSCS
LANDINGGEAR
WING ROTATING
75.507
OOWNLOCK
ACTUATING
FIXTUREI
SECTOR
CYLINDER
~V-
AILERON
HINGE FITTING
ISEE
VIEW Fl
TE RIB
RIVETS ISEE
VIEW E)
SKIN ISEE
(SEE
VIEW G)
SKIN
L
VIEW HI
LOWERMAIN
BOX SKIN
SKIN
MS2O426RIVET
[TYPI
HI-SMEAR RIVETS
6 ON INBO HINGE
FITTING. 4 ON
MAIN BOX
SKIN
IZB
OUTED HINGE
FITTING
I,
Obq
MAIN BOX
HI-SMEAR
RIVET (TYP)
SKIN
VIEW
r~ 1113
E
VIEW
it
SKIN
RIVET THRU
SEAL RETAINER
AND RIB (TYPI
~e
~_
MAINBBX
SKIN
\O
RIVETS THRV LOWER

SKIN AND RIB ITYP)
SCREW ITYPI
O
a
VIEW F
m
O
HI-SMEAR RIVET
e
(TYP)
o
000
MAIN BOX SKIN
VIEW
5265-3-232
Lower Main Box Skin Removal

57-30-20
Page 203
Aug 17/84
a
ep,
09
cn
T~Z
WS
WS
WS
WS
WS
WS
CWS
286
244
236
183
127.5
74
C~
SKIN TAPER
SKIN TAPER
0.033 TO 0.050
0.050 TO 0.070
~1
0.070 TO 0.077
STRINGER TAPER
STRINGERS CONSTANT 0.875
UPPER SKIN
0.095TOO.113
MAX
:It--i
2
281.85
CWS
WS
2slas
268LT
I_
vis
WS
WS
254.35
WS
WS
I~gL
1981
WS
185.05
~3
CWS
Esl
36.67r
wS
133.91
105.99
CWS 59.09
WS
65.81
oBe~
WS
79.07
WS
105.99
92.23
119.85
-t-
o,o~
ZS
CWS
O
CWS12.32
WS
WS
WS
133.91
159.08
185.05
WS
WS
WS
198.35
WS
225.75
211.75
WS
WS
239.85
268.85
WS
WS
254.35
i
281.85
te
B
9
a
I]
:CANTEO
\3b_
NUMBERS
\hq;l
b
1
o,
146.48
\h~
F~
CWS 24.&4
CWS 59.09
171.62
12.32
79.07i65.81
STRINGER
WS
WS
WS
CWS
v,
-;nr
CWS36.67
24.64
WS
92.23
CWS 47.89
CWS
i,
P
119.85
CWS 47.89
aoa
n
193
IS
I~
lg
21
;I
146.48
159.08
0
x
F:
i_
UI
171.62
WS
211.75
II
WS
225.75
cz
6
~d
0.088
~1
0.082
0.086
0.520 TO 0580
c-
0.095 MAX
0.580 TO 0.600
STRINGER TAPER
;c~
0.091 TO
0.080
C~
O
0.600 TO 0.800
STRINGER TAPER
"Q,
;i
SKIN TAPER
;6~
STA 291.85
\s
LOWER SKIN
a
m
2~
/L
OII
STRINGER TAPER
STRINGERS CONSTANT 0.875
0.875 TO 0.540
SKIN TAPER
SKIN TAPER
0.042 TO 0.033
0.070 TO 0.042
STRINGER
SKIN TAPER
0.078 TO 0.070
NUMBERS
--I
.i
OCWS
WS
WS
198
WS
WS
63
8$
120
180
275
ABBREVIA TIONS
C
CANTED
DC
DOUBLE CANTED
WS
WING STATION
PASTEIlEA TYPE (WUTI
0
NUT
(Requires wrench)
NUT PLATE
II
(Self-wrenching)
BUMPER NUT
until threads
WHEN
REPLACING ANY SCREW WITH A NEW ONE.

FASTENER BEING REPLACED A
MEASURE DIA OF
must be hand-held
(Self-wrenching
engaged during installation)
"SALVAGE" FASTENER OF EITHER 0.064 OR 0.032 IN

OVERSIZE DIA NIAY HAVE BEEN USED IN INITIAL
are
INSTALLATION.
C
03
Z
m
as
P~
C3~
a
a
09
~F
ii
fA
i"
tO(P
"::i
OX
+A
+c(j:I
3/16
1/4
5/16
5/18
A
h
F1
~7
WS
146.180
:I
,,I
c~
II
B
C
a1-~--Uta
p,:K
j
Btj
B A
c
FASTEIER SIZE
A
7+1
+n
f31
a
C
Ei:
II
--~-11
~p
cn
irA
A
I/
nm
c
A
C
c~J
C
ti-;
NOTES
,-t
C
-J
THIS ILLUSTRATION PROVIDES DATA RELATIVE TO
REMOVING AND REINSTALLING WING MAIN BOX

LOWER SKIN.
WRENCHING INFORMATION IS GIVEN BY CODING
C~3
BLd
TYPE OF NUT USED ON EACH FASTENER.
FASTENER DIA GIVEN PROVIDE HOLE SIZE DATA FOR

FABRICATION OF PI FASTENER PATTERN
75
G-;
BOARD
(REFER TO..REMOVING WING MAIN BOX LOWER SKIN"
r:
IN
TEXT.)
z
c a
t 03
a
~0
WS
cn
C~Z
146.180
g94
e;h
F.
~PC
i;:
ru
7~
FISTEWEA TYPE IYUTJ
NUT(Requireswrench)
NUTPLATE
ES~
Z
(Self-wrenching)
must be hand-held
(Self-wrenching
are engaged during installation)
BUMPER NUT
until threads
B
A
os
~S
ce~
P,
os
A
,s
L;
;Is:
a r
O
0;
n+
o?
om
/a.
t~a
ag
mIJ1
t~
os
A+
V)
t;
O/"
a
a
m
nz
FASTEWER SIZE
O
73
3/16
1/4
5/16
WHEN
REPLACING ANY SCREW WITH A NEW ONE,
MEASURE
DIA
OF FASTENER
BEING
REPLACED.
"SALVAGE" FASTENER OF EITHER 0.064 OR 0.032 IN.
O
D
a
I
,U
5/18
OVERSIZE DIA MAY HAVE BEEN USED IN
INSTALLATION.
INITIAL
NA-fiG-1032
STKII(:IIIKAI, REPAIR MANUAI,
REOUIREMENTS GIVEN ARE FOR EACH REPAIR

CHANNEL AND FOR EACH SIDE OF DAMAGE
RIVET
AI,
ti
41,
r SEE8HEET2
tl,
it,
t
C
It
c
CHANNEL
[REF1
t:
+ID
E\t
SEALING
tl
+I
~I.+
~-r ~7,t t ,f
-t
REPAIR
I-
.+,~t,t,
IB
1C
-t
+,,t
I
JI
~I,++C
-1
2 REDO THRU SKIN LAND ANO

8847-6
REPAIR CHANNEL. PICK UP EXISTING HOLES
WHEW IIPPLICLBL~. CIY WEW HOLES.
RIVETS
ffl,
COMPOUND
SPACF~R(RLFI
ITyP)
FILLER
(REF)
ISHEETI)
SPACER(RI1FI
3/168(7181
-1-:
REPAIR CHANNEL
IffEFI
REPAIR
3/32
CHANNEL
RIVETS THRU SKIN AID REPAIR CHANNEL AND THRU FILLER

ANO REPAIR CHAINEL. SEE FASTENER CHART. CSK SKIN.
DAMAGER
INBD
80470805
RIVETS
(REFJ
SKIN
OF WS 225
40470404 RIVETS
WS 225
4 MIN REDD
SIDE OF OAMAGE
IREFI
OUTRR
FOHCI~
EXBTIWS RII
SECTION
A-A
EXISTING DIE-FORGER CLIP
SECTION B-B
CHIIII(L
3/32
STRINGER
$t
RIBLAIYO
c
-1-1
WING MOLD LIWt
2 TIMES FASTENER DIA (TYPJ
I,,,,
REPAIR CHANNELS
0.080 7075-0 RARE
AL ALLOY. HEAT-TREAT
TO 76 CONDITION AFTER
FORMING
FASTENERS REOUIREO
RETWEEN WS
FASTENER
NO.
AEOD~
DAMAGED SKIN
12(0807801880
2410487801
8847-6
11
ICANTEO) ANO
IBICANTEDJ
0847-6
11
65 AND 185
0847-6
JOOGLE OVER
47
185 AND 225
HAS1097A05
NO1~S
II
SAME!OAUGE AND
SPACERS
MATERIAL AS DAMAGED STRINGER
REPAIR IS APPLICABLE TO AREAS GIVEN

FASTENER REQUIREMENT CHART ONLY
THIS
RIB LANDS
IN
SAME MATERIAL ANO

FILLER
GAUGE IS DAMAGED SKIN
REFER TO SHEET 2 FOR STEPS AND FABRICATION
DETAILS
IN EACH REPAIR CHANNEL. EACH SIDE OF DAMAGE.
Irl,l,er Machine Hox Skin flepail

EiRure ~04 (Sheet 1 of 2)
g
S2653-257
57-30-20
PaRe ~()T
AuR 17/H4
NA-66-1032
OAMACEO SKIN (REFJ
RIVETS
5347-5
(REFI
REPIIRCHANNEL(REF)
EXISTING FORMER
f-iBirlPIF
1-1/2
~c3/4 Ttl J
REPAIRCLIPS
0.083 7075-18
RIVET
45470805
)CI
c
11/32
(TYPJ
1/4
1)
t~
ITYP)
I-- I
ITYPI
STAGGER CENTER
ROW OF RIVETS
REPAIR CHANNEL IREFI
DETAIL OF REPAIR ON 265-130101-1 AND

-2 WINGS
1/4
If
it
a/a (TYPJ
RIB
BEllO LINE
3/16
DETAIL
REPAIR CHANNEL (REF)
GNITSXE9 R(
IREF)
EXISTING CLIP
5/is
-t
SEALING COMPOUNO
SECTION
Dye-penetrant-check damaged
damage.
area
O)
to determine
extent of
Trim out
O
O
damage. Burr
Make spacers to match removed
Make
through
channel in
stringers.
repair
00
to
all
chips
and
matter.
Cati-coat prime spacer, and repair chdnneb
fasten
C~mlllefe sealing operations.
Refinish external surface of
channels and drill fastener holes
Temporarily
repair pans and clean off
SKIN
members.
forming.
repair channel and skin.
RIVET 5847-5
Apply sealing compound to faying surfaces as

instruced in 57-40-30, and rivet repair parts in place. Drive
repair channels from 7075-0 and heat-treat
Position
Aemove
foreign
O
~1
all edges.
Make fiiler lo melch t~immed-ouf nkin
7075-T6 condition after
other
CC
surrounding
repair
repair
to match
area.
place.
Install
filler, and drill fastener holes through repair
channels and tiller.
NOTE
REFERENCED WING SKINS INCORPORATE A SKIN
FOAMER BETWEEN EACH RIB. WHEN REPAIRING
SKINS WITH FORMERS. REMOVE DIE-FORGED CLIPS
THAT ArTACHH FORMER TO SKIN (IN REPAIR AREA)

THEM Wlr~-l SHEETMET~AL CLIPS AS
AND REPLACE
SHOWN. ADJUST RIVET PATTERN AS NECESSARY TO
PICK UP TWO FASTENERS THROUGH SKIN AT EACH

REPAIR CLIP.
57-30-20
Page 208
Aug 17/84
Upper Machined Box Skin Repair

o
NA-66-1032
OAMAGEO MACHINED BOX SKIN
7/8MAX(TYPJ ----*I
It
dl
INTEGRAL STIFFENER
CENTERLINE
I r-
7 -13/8
I
D;
9:_o:cg
\I
B)~
/=~:-d--=-
s~anur
:--$A
I_ ~b
___
INTEGRAL
SECTION
HOLES THROUGH OOUBLER. COUNTERSINK HOLES

1M1" BY 0.282 IN, IN DIA,
PLUG HOLES, USING SELF-TAPPING SCREWS.
0.050
B-B
0.156 ON
285-130101-11 4 -12 AWG

01285-130121 SKINS
OIMIBEO MACHIIIED BOw SKIN
IAEfl -7
CEIITEALI#ESTIFFEIER
0184 JO-BOLTS
INGIVIGUALLY
SEA LEO
GRILL 1/8 IW. OIA SEALANT INJECTION
rough edges in damaged area.

Using dye-penetrant solution,
check whether surrounding area is damaged.
Smooth
WING mt UPR
REPAIR OOUBLER
IRE9
REPAIR OOUBLER IREF)
2.286
I=
GROOVE
SEALANT
-~--rL------
EOUAL
SPACESITYPJ
D~ OrPTH
TYP ALL SEALANT
GROOVES
(TYP)
IREF)
bj?l.lLay
CHAMFER 30" BY 1/4 IW. (TVP ALL SIOES)
or
trim all
out cracks.
grind
repair doubler so that it covers one stringer

damaged section, and extends so that it
existing fasteners in adjacent ribs on remaining
out
and aft of
picks up
INTEGRAL STIFFENER CENTERLINE
two sides.
1.:Machine
as
3/8 (TYP)
sealant goroves
Iaround
fasteners
on
in. in dia
injection
holes in doubler
on
centerline of machined sealant grooves. Distance between

sealant injection holes must not exceed 3 in.
3/8 011 SPOT-FACE 0.050 DEEP

ITYP ALL FISTENER9
O
are
ITYP ALL SEALANT OROOVESI
REPAIR DOUBLER
repair
by 0.050 in.
inner surface of
sealant grooves.
Drill 1/8 in. dia sealant
3/18 WIOTH
on
required. Spot-face area 3/8
Install
repair doubler, using
to be installed
as
Inject sealant
injection holes.
(REF)
F164 Jo-Bolts. Jo-Bolts
instructed in 51-40-30,
into sealant
figure
injection holes,
2.
and
plug
NIACRINEO sox SKIN IREF)
INTEGRAL STIFFENER
CENTERLINE
Ic Ili
mill
lrv4
fi;
NOTE
IF DAMAGE IS LOCATED INBD OF WS 65.00, MAKE
REPAIR DOUBLER ONE GAUGE HEAVIER THAN GAUGE
i-l~
REPAIR OOUBLER
\Cj~
OAMAGED MACHINEO BOX SKIN
0.158 7178-76 AL PLATE
INDICATED.
s265-3-266
Upper Machined Box-Shin Repair
Figure
0
205
Class B
57-30-20
Page 209
Aug 17/84
NA-66-1032
STRUC1UHAL REPAIR MANUAL
Al~
REPAIR STIFFENER
2 TIMES FASTENER
ITYP
PLACESI
0111 MIN
II1L
FILLER
SHlM
f~t
II l+lII
REPAIR CHANNEL IREF)
I+II
f:
t;
I+:l+l;lSl;l+F3~
c/
;t
:tl
~I
+!i+l+l;l+l;l~!-cl
t:
-I
I-J
f:
f~l
FILLER
IREF)
SPACER [REF)
t
REPAIR CHANNEL IREF)
t:t
SPACER (REEI
REPAIR CHANNEL (HEFJ
-t~
+I,
Bf++
tl
IREFI
3/32 R (TYP)
-t
+I
SEAUNT
SPACER IREFI
tft
(REFJ
IREF)
,-t
1
L 0.080
CONSTANT
1/2 R TVP
ITYP)
OAMAGEO SKIN IREFJ
A~l
SECTIONA~A
EXISTING RIB IREFI

REPAIR STIFFENER (REF)
-~L!
REPAIR CHANNELS
(REFI
RIVET
ISEE
SHEET 2)
SPACER (REF)
SEE FASTENER
NOTES
REPAIR CHANNELS. MACHINE
FROM 7075-T6 BARE AL ALLOY
r
I
t,
FILLER
IREF)
SEALANT
SHlM (REFI
SPACER
SECTION
B-B
SIZE ANO TYPE
O~ MATERIAL TO MATCH
OAMAGEO STRINGER
NOTES
REFER TO STEPS ON SHEET 2.
2
RIVET PATTERN SHOULD BE AS SHOWN
USE NAS1097DD6 RIVETS,
ONE IN.
OAMACEO SKIN
SPACING
ON
SHIM. MACHINE FROM
CENTER. I NBD OF WS 133. USE NAS1097AD5 RIVETS, 7/8

IN
lil
SPACING
ON CENTER,
BETWEEN
7075-r6 BARE AL ALLOY
WS 183 AND
211.750. USE NAS1097AD4 RIVETS, 3/4 IN. SPACING ON
FILLER
CENTER, OUTED OF WS 211.750.
ANO GAUGE AS THIN PORTIOII
SAME MATERIAL
OF OAMAGEO WING SKIN
USEAN470AD5 RIVETS INEDOFWS263; USEAN470AD4
SEALANT
RIVETS OUTED OF WS 263.
57-30-20
Page 210
Aug 17/84
Upper Machined Hox 8kin Land Repair

o
NA-66-1032
STRUCTURAL REPAIH MANUAI,
Oye-psnstrant-check damaged
RIVETS
dsfer-
to
area.
01
Trim
EXISTING CLIP
IREFI
PICK VP EXISTING
damage from
are.,
and smooth all edges and
corners.
TO MATCH
REMOVED FASTENER.
mine extent of damage.
LOCATIONS. AOO ONE
Ii
RIVET WHEN SPACING
II
EXCEEOS 11/8 1N.
II
(I
Machine shim
same s 2e as
machined rib land
on
II
inner surface of skin.
ICil
damaged
Make filler
+I!
sire
same
damage cutout
as
in
II
skin.
REPAIR STIFFENER IREF)
Machine
repair chsnnelstocorrespond
cutouts)
SAME SIZE
RIVETS
surface of skin.
Machine
II
repair stiffener (exFept for stringer
and form to match skin contour. Machine
SEALANT
LINE (TYPI
with inner
stringer
ANO TYPE AS ORIGINAL
I:
REPAIR
RIVETS USEO TO ATTACH
I I
CHANNEL
CLIP TO MACHINEO
II
IREF)
STRINGER
cutouts.
C
components and perform

countersinking operations.
AS$embe
09
prime
all
SHiM
os.r
(REF)
I!
FILLER IREF)
arsasot
SPACER (REFI
)I
skin interior.
O
(iO
II
I
ling end
dri
Apply sealing compound to
faying ruriaces
all
1/2 MIN
Rivet
repair parts
in
place
and
(TYP)
complete ~aling
I I
REPAIR
II
CHANNEL
IREF)
operations.
00
Refinish external surfaces of
surrounding
repair
to
melch
SPACER IREF~
area.
I/alTvPI
STRINGER PARTIALLY
II
STRINGER CUTOUT (TYP)
DMITTEO FOR CLARITY
REPAIR
1II
-iIC
CHANNEL
IREFI
REPAIR STIFFENER
7075-76 BARE AL ALLOY
SKIN
ii
II
i
DAMAoEO SKIN IREFJ
RIVETS
DEUTSCH
II
II
REPAIR CHANNEL
(REF)
EXISTING RIB
REPAIR STIFFENER
REPAIRCHINNEL(REFI
STRINGER SPACER IREF]
OAMAGED
STRINGER IREF)
II
11
I)
II
DRIVE PIN
6950-S-0508
112 RE001
3132 Min
II
(REFJ
EXISTING CLIP
I\
1-3/8
7/168
r---
III
REPAIR FILLER
IREFJ
REPAIR SHIM
(REF]
C 5;8
3/8
Upper Machined Box Skin Land Repair

0
SEA;ANT LINE
s255-3-263
57-30-20
Page 211
Aug 17/84
NA-66-1032
UPPER WING SKIN
INTEGRAL STRINGER
3/4
2 TIMES FASTENER OIA

t
[TYP)
--7
SEALANT
f+ ~O_
ITYPJ
DOME NUT
foo
PLACES)
RIB LAND
+--Lf
1/2 (TYP ALL
(TYP)
ANO
-IB
I
RIYET
MS20801AB5
"i
II2-1/4
At-i
REPAIR CHANNEL ITYPI
(MAX)
--r
SCREWINSTRLLATION
ISEEFASTENER
CHART)
BENBLINE
L+
2 TIMES FASTENER
OIA
REPAIR CHAWWEL
0.090 1075-0
(TYP)
BARE
SPACER
(SIZE TO
1~
7075-78
MATCH
REMOVED
REPAIR CHANNEL
(REF
STRINOERJ
RIVET
TYPJ
0.188 R
MS20428404
REPAIR
120200)
CHANNEL
RIB LAND
(REFI
.1
~KIN CUTTEA
SPICER
FILLER
V--
IREF)
SECTION
10
SEALANT LINE
Ii
RABIUS
A-A
SECTION
B-B
FILLER
7075-T8
BARE(THICKNESS
TO MATCH SKINI
IEil
TlimOuldamags
Install
dome
nuts
on
repair channels (when
applicable).
Measure distance between integral stringers and
repair channels. Channel legs should nest close to
fabricate
stringers.
out
and
Temporarily install repair channels and tiller. Lay

drill fastener holes through filler and repair
channels.
Heat-treat repair channel to T-6 condition.
O
O
O[11
OII
Fabricate spacerand tiller
Lay
out fastener
Inslsl
doublerr(one
at a
time)
and line-drillsk
Paint all inlerior palls.
instructed in 57-10-30.
Drill holei for atlarning spacer lo
one
LO
repair
RBfin sh
surrounding
flange,
NOTES
THIS
REPAIR, WITHIN DAMAGE
I
LIMITS SHOWN,
WS
O TB 188
flONT SPAR WHEN ACCESS T HROUGH SKIN
CUTOUT IS INADEQUATE
areas
of
repair
to
maten
REOB EA SIOE OF DAMAGE

THROUGH EA REPAIR CHANNEL
FASTENERS
7834-3 SCREW
ACCESS MAY BE GAINED BY REMOVING SLAT TRACK

F
silerio~
area.
IS
APPLICABLE TO WING MAIN BOX UPPER SKIN.
CUPS IN
CounterJink akin and filler
Prepare sealing compound. Seal over dome nut

retaining rivets and around dome nut mount (when
applicable). Seal all faying surfaces on assembly as
fastener holes.
channel
repair parts
pattern and drill nolen through
skin.
Remove
USE EITHER ESNA A3205-2 OR NUTT SHELL 14633H-02.
I~
F1BO JO-BOLT
IMiNI
IsS TO 225
B IMlNI
225 TO TIP
g(MINI
s285-3-284
57-30-20
Page
Aua 17/84
Upper Machined Box Skin Repair
eruffiFdnilB
207
212
NA-66-1032
STRUCTURAL REPAIR MANIJAI,
LEADING EDGE SKIN(REF)
REPAIR STRAP
IREF)
LEABING EBBE SKIN
FRONT SPAR WEB
FILLER(REF)
___.t__._____
--I-
--r
._._
LF)
PICK UP
EXISTIWO
FILLIR(REF)
4 EA SIBE OF OAMAOE
tti
i:
-ICt_8
IREF)
..~.1
.~_t____:i----1-
-._._.-P_~_4 j
RErllA STR)IP
1~1Ct
IAEFJ
3I-1
MIICHIWED BOX SKIN IREF)
WHEW REPLACING SCREWS THROUGH REPAIR

EXISTING SCBEW LOCATIONS
STRAP, USE SAME TYPE OF 303EWS, 3/16 IN LONGER
SHIM IffEFI
FRONT SPAR
REPAIR STRAP
IREF)
ItH 3/8 MIN
(REF)
SHM
IBEFJ
ROUNO
CORNERS TO FIT
IREFI
LflOlYO
EIO:IKIY IRIrI
FRONT SPAA
SECTION
Trim
~i
A-A
out
MACHIHEO BOX SKIN IREFI
damage midway
fasteners. Smooth and round all
between
edges and
Make filler from material called out,
aviating
corners.
length of
cutout
in machined box skin.
Make
repair strap
Imm 0.156 in, f075-TB materis.
Length of repair strap is to equal length of damage plus

lengths of areas in which 4 screws are installed on either
damage. Make shim from 7075-T6 material, length
length of repair strap and gauge determined by
thicknessofsparinrepairarea.
side of
same as
:W
and macnineo bax.kin
necessary number of
-I
MACHINEO
BOX SKIN
place
to accommodate
repdir.traP in position.
remove
repair strap
and mark location, of
fastener holes.
LEAOING EDGE SKIN
FILLER
screws
--P
I~
7075-76 BARE
AL ALLOY, GAUGE TO MATCH

DAMIIGED MACHINEB BOX SKIN
I
J
REPAIR STRAP
Remove
repair slrap, and drill faptener holes Thin
will eliminate the
possibility
of drill
chips entering
sealant
grooves.
0.158
SHIM
7075-76
BARE AL ALLOY,
GAUGE AS REOO
7075~6 BARE AL ALLOY
NOTE
Fasten
all
repair parts, using sizes, types,
lengths of fasteners called
O
and
In those
areas
and
out.
in which
screws
replaced, reseal machined
box
have been removed
skin
according
to
instructions in 51-70-30.
THIS REPAIR IS LIMITED TO AREAS OUTED OF WS 65.
Wing
5265-3-256
Leading Edge Repair

Figure 208
Lower Bdx Skin
57-30-20
Page 213
Aug 17/84
NA-66- 1032
TRIM OFF RIB
FLANBE IN AREA
a:~
OF HEPAIR CHANNELS.
REPLACE WITH RIB
REPAIR DOUBLER ITYP)
--,a~
J/--L_I.
RIR REPAIR DOUBLER

0.050 2024-0 CLAO
ITYPJ
STRINGER SPLICE
0.090 7075-T6
BARE ITYPI
SKIN REPAIR DOUBLER

0.750 7075-76 PLATE
ale LANO
ITYP)
(TYP)
INTEGRAL STRINGER
TRIM OFF AT INNER
EOOE OF RIB LANO.
MACHINE FLUSH WITH
ADJACENT SKIN (TYPJ
1/2 R
r-
;i
OAMAGEO SKIN
SEALINOCOMPOUNO
7075-TB BARE
FILLER
THICKNESS TO MATCH SKIN
Dye-penetrant-check damage
to
determine
Trim oul
O
(il
O
damage and smoath ail edges
PASTERER CHART
MIN ROWS THRU SKIN INB SKIW
REPAIR DOUBLER EA 8108 OF

OAMAOE. USE SAME FASTENER
WS
I210ANTE0)T0
24(0ANTE0I
47(CANTEO)TO
59 ICANTEO)
ICANTEDJ r,
(2024-0
INFILLER.
O
O
MS2042#05 OR
HAS 10971105
8847-6
65
Trim off
integral stringers flush with
skin
as
shown.
extent of cracks.
holes
dl ri~
flanges
as
necessary
FebriCaterepsirpayts
Heat-treat Parts made Iram anneaed materials

to 2024-T42 and 7075-0 to
Lay
7075-T6).
out and drill fastener holes in skin and filler.
Position skin repair doubler and I ine-d rill fastener

through skin and filler.
and drill
Tr
II~
Temporarilysecurerepsirdaublerin
stringer splices.
Position rib repair doublers
placeandfit
on
ribs and drill all
fastener holes.
198 TO TIP
tZI
Remove all repair parts. Cati-Coat prime repair

parts and all bare interior wing areas.
NOTES
100
THIS REPAIR IS APPLICABLE TO AREAS OF LOWER
secure as shown. Apply

faying surfaces between skin and filler, and
skin repair doubler. Apply sealant over all rivets af ter driving
(wing interior).
WING AS STATED IN FASTENER CHART.

REPARABLE DAMAGE
Install repair parts and
sealant to all
(WITH THIS REPAIR) IS LIMITED

(AS
TO THREE STRINGER BAYS AND ONE RIB BAY
snowhl).
Refinish external surface to match surrounding
REFER TO SHEETS 2 AND 3 FOR FABRICATION AND

area.
ASSEMBLY DETAILS.
57-30-20
Page 214
Aug 17/84
s285-3-259
Lower Machined Box Skin

o
Repair
3)
NA-Cifi-1032
STHUCCUKAI, I1EPAIH MANI!~I,
FASTENER
ISEE FASTENER
CRARTJ
II
JcR,w,ao
D~1--
REPLACE ORIGIWRL
TYPE AID SIZE
LA
3/4(MIN)
1
I /IllctSI
tl+
ISH31
IMAX)
FASTENERS(SCAEWI/IBLONGER)
1-
P9
NUT PLATE
di
(I2ITYPI
F
1B
+il+tB
itc
-1
tt
jL
i
-i
-e
r+
2 TIMES FASTENER
RIA ITYPI
I Is ~I
~jt
-C
-t
-t
STRINGER
SPLICES ITYPI
~j
RIVET
FASTENER AOWI
ISEE FASTENER
CHART FOR REOUIREMENTS)
PATTERNCONTI UE--D)- 1
ISH31
SKIN REPAIR ROURLER
(REFI
Ale REPAIR OOUeLER ~REFI

EXISTING
EXISTING
STRINGER
RAMAOEO SKIN IRE9
IREF)
MS2847OAO4
RIVET
R1R
-e
3/41MIN)1IMAX)
2 TIMES FASTENER
OIA
ALL
(TYP
PUCES)
SECTION
SEALING COMPOUND
A-A
2 TIMES FASTENER
DIA llRO OF WS 239
r STRINGER SPLICE
ITYP)
1-1/2 TIMES FASTENER RIA OUTRO OF
STA 239
(TYPI
5/8
3/4(TYP)
-e
RIY~TS
-e
1)(47*04
48478485
1-1/8
OUTBO OFWS 188

INeO OF WS 198
FILLIR (REFJ
3/8
5/1
5 REDO EA SIRE OF SPLICE
SECTION D-D
szes-3-2eo
Lower 1VLachined Box Skin Repair

57-30-20
Rage 215
Aug 17/84
NA-66-1082
SIKIMIII!KAL HEPAIK MANUAI,
EXISTING RIB
(AEFJ
SKIN REPAIR
OOUBLER
k-
1/8 (TYP),
2;"~/
1-1/4
REPLACE EXISTING
I 1
SKIN
48470405 RIVETS,
USING 48470000
RIVETS
rj I~
r~rrm
STRINGER SPLICE
(TYP)
s/cnvPI
3/16RITYP)
I
STRINGER MACHINEO
ON REPAIR OOUBLER.
THICKNESS MUST
88470804
RIVETS
INSTALL 2
ADOITIOWAL
RIVETS BETWEEN
MATCH SKIN
STRINGERS
SIRIIIC~R
~I
3!8 [TYPJ
f,
5/8
.I
I
5/321TYPI
Ril Rn111
2-1/2
SKIN REPAIR
B0UBtERIREF)
~..n
SECTION
0.063
IZ
CC
I-f
ONE GAUGE HEAVIER

THAN DAMAGEO SKIN
SECTION
mUIII"---/
G.,Os
IRMIN
~I+
EOUALS SKIN
LANO WIOTH
REPAIR OOUBLER IREFI
E-E
STRINGER SPLICE
1/8 A
3/4
CHAMPER
45" BY
ITYPI
L..-
5/32, BOTH SIOES,

TO ACCOMMODATE
SEALING COMPOUNO
SEALANT LINE
OAMACEO
SKIN
IREF)
SECTION
DD
S265-3-261
57-30-20
Lower Machined Hox Skin

Repair
3)
Page 21fi
Aug 17/X4
NA-66-1032
LOWER SKIN
2 TIMES FASTENER
OIA FOR JOBOLTS.
(SEE OETAIL A FOR
INTEGRAL STRINGER
TRIM OUT OAMAGE

RIVET
I I
RIB LANB
MS20BO1A04
FILLER
SCREWS.I
(MINI
4 TIMES FASTENER
1
TYP ALL
IN.IMAXI
rILlTEnrAa
if*
+I
888
++f
Ar
AC-I
~e 2 Il/,a svpl
I/slMlNl
MS2O601MP5
RIVET
L
EXTEND REPAIR CNANNEL COMPLETELY

ACROSS RIB BAY. INSTALL FIELD
RIVETS IMS20001MP5) AS REOB
FASTENER
IMIN) REOO
EA SIRE
OF BAMAOE. USE 78363 SCREWS

INBB OF WS 159. USE F1O4
JO-BOLTS OUTBB OF WS 159.
BETWEEN SCREWS IOR JO-BOLTSJ
REDO In TAB
EA EnO OR REPAIR
CHAMFER 45" (TYPI
ANR TAB EnO RIVETS.
SKIN IREF)
[TYP)
0.750
IIig
t~ I
o.lsB R
REPAIR CHAnNEL
0.OO17075-0
1/2R[TYP)SMOOTH
EOOES
SEALANT LINE
SECTION
A-A
FILLER
IROTATEOI
REPAIR CHANNEL
RIVET
BY~dVr
MS20420493
,._.c.
DOME NUT
f~
SEALANT
7075-78
FILLER
THICKNESS TO
MATCH SKIN
livPI
1/2
Oye-penefrant~hsct
SEALANT
i
DET*IL
O
O
lil
ITYP ALL PLACES)
extent at cracts.
LBy
Out fastener
pat tern
and dril
h~ies
thmugn
skin.
Srim out damage and smooth
edges.
Install doubler and filler and line-drill fastener
fabricate
O
O
holes.
Measure distance between integral stringers and

repair channel. Channel legs should nest close
.sregnirtsot
Install dome nuts
on
repair
channel
(when
applicable).
Heat-treat
repair channel
to -T6 condition.
Fabricalefiller
NOTES
THIS REPAIR, WITHIN DAMAGE LIMITS SHOWN,
APPLICABLE TO WING MAIN BOX LOWER SKIN.
IS
ACCESS MAY BE GAINED BY REMOVING SLAT TRACK
O
IFD
rm
Countersink skin and filler.
Painlal
interialparts
Prepare sealing compound, Seal
over
dome nut
retaining rivets and around dome nut mount (when

applicable). Seal all faying surfaces on assembly as
instructed in "Sealing Repairs" in this chapter.
CUPS IN FRONT SPAR.

I
A MAX OF TWO REPAIRS MAY BE INSTALLED IN EACH
ale BAY
Refinish exterior
surrounding
(BETWEEN RIB STATIONS).
areas
of
repair
to
match
area.
USE EITHER ESNA A3205-2 OR NUTT-SHEL 14633H-02.

5285-3-265

Figure 210
0
Repair
Blind
57-30-20
Page 217
Aug 17/84
NA-66-10321
REPLACE, USING FASTENER Of SAME TYPE
EXISTING FASTENER LOCATIONS
ANO DIA AS ORIWAL FASTENER, 5/32 IN. LONGER
r_LD_
EXISTING FASTENER LOCATIOIS
JO-BOLTS,EIW
INDIYIDUALLY SEALEO
lo
IC,;Oi
7/8 MAX
L~
OI
D~
AOOED FASTENERS
ANO GROOZIWJECTION:SEALEO
lo)
ITYP)
(F184 JO-BOLTS)
lol
LOWER MLCHIWFO
SKIH:(RE9
t
i,
~i=
~tl
SEALANT INJECTION
Aj
I(-j~
a
GROOVE
I/P(TYP)
GRILL 1/8 IN. OIA SEALANT INJECTIOW:HOLES. DISTANCE BETWEEN INJECTION

HOLES NOT TO EXCEED 3 11. MAX.
lo;
I:ol
3116171)1
3/8 011
~I
0.050 OEPTH ITYP

ALL SEALANT
0.050
D~EPSPOTFACEITYPI
11
~f CROOYES
OAOOVES1
CHAMFER 30" BY 1/4 11.
LOWER MACHINED
SKIN (REF)
O-RINGIREF)
FILLER
2 TIMES FASTENER
011 ITYPI
S/IIITYPJ
z z _~
SEALANT
REPAIR OOUBLER
REPAIR
(AEF)
SECTIONA~A
0;382
lt0.0005)
0.1885
SECTIONC~C
OET*ILB
/e
[+0.00051
PIII1IRE(I
O
elgrind
iF.dsurrounding
egamUsing
ad
O
Smooth
or
trim all
rough sdgaj in damaged area.

dye-penetrant solution,
out all cracks.
or
check whether
Iwllll
FILLEB
O.O1BR
JECTION
D-D
MACHINE FROM
7178-76 AL ALLOY
BAR STOCK
ODUBLER(RF~F)
area
is
Layoul mpsl, douaie aa mat ii rovsrrona.llinger

bay fwd and aft of damaged section, and extends so that it
picks up existing fasteners in adjacent ribs on remaining
two sides.
01
Machine sealant grooves
required. Spot-face
an area
around all fasteners
on
inner surface
on
3/8 in. in dia
by
0.050 in.
as
deep
sealant grooves.
Drill 1/8 in, dia sealant
injection
holes
on
centerline
of machined sealant grooves. Max distance between

injection holes must not exceed 3 in.
01
Fabricate fillers for replacement fasteners. Install
fillers flush with, to 0.010 in, below surface,

sel
LOWER MACHINED SKIN
remaining
in
existing O-ring
place.
lij)
Install repair doubler, using F164 Jo-Bolts Seal all

jo-bolts as instructed in 51-70-30. Reinstall fasteners
through repair doubler and ribs. Use fasteners of same type
and dia as removed fasteners, 5/32 in, longer.
REPAIR OOORLER 0.156 7178-78 AL ALLOY
NOTE
01
IF DAMAGE IS LOCATED INBD OF WS 65.00, REPAIR

DOUBLER MUST BE ONE GAUGE HEAVIER THAN
Inject
sealant into sealant
injection holes, and plug
holes.
GAUGE INDICATED.
s2es-3-2a7
57-30-20
Paffe 218
Auff 17/84
Repair
Class
112erugiFR
NA-66-1032
STRUCTUHAI, KEPAIK MANUAI,
ale
(REFJ
REPAIR DOUBLER
-~--"1 I
RIB
SKIN
Al
Rtp~a
II
jli li i~i
RIVETS IN SHADEB
: i i i :I:i: r~ii i
PATTERN IS AEPEATEO
It
FOR OTHER
It
FOR ONE SIOE.
OOUBLER
5/16 ITYP)
fi
+f-+
)i
+Ii)
:j::
iiiiiii:ii~i
AREA ARE COUNTED
(REFJ
::::i::::
FILLER
ci
\Y+
THREE SIDES.
II
3/4 TO I
L
TO
1
ITYP)OIMPLE
RIVET
ITYP)
II
MS2O426AD4
SKIN AND
jl
REPAIR DOUBLER.
REFER TO NOTE FOR
RIVET
A~J
TO MATCH REMOVEO
A-A
SECTION
FASTENER ITYP ALL PLACES
WHERE FASTENERS ARE
SKIN
l\r
NO. REOO.
SKIN
REPLACEDI
ILOOSENEO
ANO RAISEB FOR

INSTALLATION OF
REPAIRI
FILLER
MATERIAL
ANO GAUGE TO MATCH

SKIN
O
O
O
O
O
Trim out
damage.
Loosen and raiseskin to
Fabricate and install
permit installation of repair
repair
parts./e
Refasten loosened skin.
Refinish
repaired
skin to match
surrounding
area
w
L_,=
RIB
NOTES
THIS REPAIR
TRAILING
IS APPLICABLE TO THE WING
TRAILING EDGE
(CANTED
IREFI
EDGE~IREF)
MATERIAL
REPAIRBOUBLER
TO MATCH SKIN. THICKNESS
INBD
TES 30.079 TO 51.284).
IS ONE GAUGE HEAVIER.
FOR NUMBER OF RIVETS REPUIRED ON EACH OF 4
SIDES OF REPAIR. MULTIPLY 3.25 BY HOLE DIA. DISTRIBUTE FASTENERS AS SHOWN IN SKETCH.
s265-3-253
Wing Inboard Trialing Edge Skin Repairs
Figure 212
o
57-30-20
Page ~19
Aug 17/84
NA-fiCi-l 082
SIIII("I~I!KAI, REIAIR MANlrAL
MAIN BOX SKIN
(REFI
RIVET
EXISTING
MS20426iAD4
EXISTING LOCATIONS
RIVET (REF
IMDO
ITYPI. DIMPLE REPAIR SKIN.
MAIN BOX SKIN
TYP)
IREFI
23/64
ale
o
EXISTING SKIN
1[
\Ij
t/I
Al tr
7/8
OF REPAIR DOUBLER
1/4 MIN
t~----
RIVET
MS2O42OAD4
DIMPLE REPAIR
Is REOO1. 4 EOUAL
ODuBLER
SPACES BEIWEEN
ITYPI
ii
EXISTIHG
ale
~t
3/8
JOGGLE REPAIR
It
-I-b
DOUBLER TO
1-1/8
MATCH JOGGLE
tr~
IN RIB
MS2D428A05
TEVIA.IBIR
BEAM IREF)
[TYP AT EA
5/16
OIMPLE RIPIIR SIIW.
HONEYCOMB TE
BECTION
(REFJ
A-A
REPAIR SKIN
0.032
2024-742 CLAD INBD
OF RSS 113.758: 0.020
RSS
113.758
2024-T42 CLAD OUTED

OF RSS 113.758
Remove inbd skin fasteners and trim off damaged

as
DOUBLER
REPAIRSKIN
REPAIR DOUBLER
A~i
skin
REPAIR
ANOREPAIA 60UBLER.
OAMAGEOI
It
SKIN
DIMENSIONS SHOWN.
DIMPLE REPAIR SKIN
I
1-9/16
TRIM OFF
CHAMFERFWDEOGE
5/16
MAIN BOX SKIN
IREF)
li:i
shown
REPAIR DOUBLER
0.020 301 CRES.
ii.Sli:l;:i~i.L
Fabricate, prime. and install repair doubler between

rib at RSS 113 758 and
El
O
existing
1/2 uRo
skin
EXISIING
SKIN IREFI
Refinish repair to match
surrounding
area
uic~
NO T~
THIS REPAIR IS APPLICABLE, AS
SHOWN, TO CRACKED
(OR OTHERWISE DAMAGED) WING TRAILING EDGE

UPPER SKINS WHEN DAMAGE IS INBD OF RSS 113.758.
IT
MAY
BE ADAPTED TO DAMAGE OUTED OF RSS
113 758 BY ALTERING SKIN TRIM LINE AS REQUIRED.
HONEYCOMB TE
(REFI
57-30-20
Page
s265-3-255
Wing Intermediate Trailing Edge Skin
erugiFriapeR
219
220
Aug lilX4
STKI!(:II!I(~I, K~IAIKM ANI:AI,

RIVET
SCREW
NAS1097AD4. ONE REOO
TRRU SKIN AND SRIM EA

SIDE OF RIB. DIMPLE SKIN. CSK SHIM.
DEVOMRECFASTENER(TYPI
ALPER
NAS1O97A05.
RIVET
THRU SKIN, SHIM, ANO
SPAR. DIMPLE SKIN.

CSK SHIM
ol\il
ol~
I,
nllte
oO
I~ Ia,
RIVET
NAS1O97A04.
THRU SKIN, SHIM, AND
ale ITYP). DIMPLE
SKIN. CSK SHIM.
jiE
I 1
00
Tel ei
/IllI~e
13
j~
!:li
A
C/
I;k
PLANE
REPLACEMENT
:Q
SKIN
VIEW LOOKING DOWN ON UPPER SURFA6E

(LOWEH SUAFACE IS SHOWN ON SHEET 21
I/la IrvP]
FRONT SPAR
SHIM IREFJ
~I
-1-
Iel(
SRIM
8TIFFENER
"fl
SICTION
IREF)
REPAIB SKIN
IREF)
SECTION
B-B
RIB
RIB
SS
8TIFFLYER
A-A
FRONT SPAR
PLANE
TRIM TO CLEAR
JOOGLEIN
REPAIR SKIN
SHIMS
2024-T3
i::_:i:i-:l::i:ii-
0.032
CLAD
JOOGLE 0.063 IN. DEEP

BY 7/8 IN. WIRE AS
RE(IUIREO. TO MATCH
0,023
MATING SKIN
\L~
202413
CLAO
STIFFENER
RIB
Remove
as
slats, slat track ribs, and roller assemblies
IREF
TYP)
(REF
TYPI
necessary.
O
O
O
O
I~
Trim
damage midway L~tlwen
slat trscl nbs.
elign
reps
drilling, dimpling,
Repair
or
Fabiicale
replace damaged
ribs aod.if fenem,
O
II~
repair parts
holes
Primerepairparls
Assemble shims to ribs with two 3/32 in, tack rivets
as
0~1
doubletn inride it
and
sk
PFliurm
countersinking operations.
in
piece
Align repair skin; drill, dimple,

required.
Rivet repair skin in
and countersink
piacs
per shim.
Finish
NOTI~
THIS
REPAIR
IS APPLICABLE TO ALL
repair
to match
surrounding
area
UNDERSLAT
LEADING EDGE AREAS.

SEE SHEET 2 FOR DETAILS OF LOWER SIDE OF REPAIR.
Wing Underslat LeadingEdffe Skin Splice Repair

o
5255-9-?51
57-30-20
Paffe 821
Auy 1T/X4
NA-66-1032
RIVET
4401007404, 2 ROWS REDO EA SIDE OF SPLICE THRU SKIN AID
REPAIR DOUBLER. DIMPLE SKIN. CSK REPAIR DOUBLER,
ITYP)
0401097404. DIMPLE SKII.
CSK RIBS AND STIFFENERS PPI
RIVET
REPAIR OOUBLER ITYP)

FRONT SPAR PLANE
li,
he
+lall
~C,
lle+
+1"!1
OIAFIISTENER
;pl~t
III~ii
SHlM IREFJ
LI
2 TIMES
3/4 MI\X(TYP)
e
739-343, THRU SKIN, REPAIR DOUBLER,

WIND SKIN, ANO SLAT TRACK RIB.
DIMPLE SKIN. CSK SHIM. (TYP]
SCREW
REPAIR DOUBLER
LOWER WING
SKIN (REFJ
SECTION
D-D
NAS1D7OAD5, THRU LE SKIN, SHIM, AND

WING SKIN. DIMPLE SKIN. CSK SHIM.
RIVET
r REPAIR DOUBLER
(REFJ
(REFJ
REPAIR SKIN
IREFI
SECTION
B-B
REPAIR SKIN
(SEE SHEET 1)
REPAIR SKIN IREF)
CHEM-MILLEO TANoENT
LINE on UnoAMAOED
REPAIR DOUBLER
2024-73 CLAD
PART OF LEAOInG EDGE
SKIN
j
i
REPAIR OOUBLER
0.050
CFJ
t/32 (TYP)
i~il
:i:i:"i
_I
DETAIL
C~
:i::
IFASTENER PATTERN
AIO
ADJACENT STRUCTURE
OMITTED FOR CLARITY)
SHlMS
CLAD
0.032 2024-T3
NOTE
REFER TO NOTES AND STEPS ON SHEET i.
57-30-20
Page 222
A-ug 17/84
S285-9-251
Wing Underslat Leading Edge Skin Splice Repair

Figure 214 (Seet 2 of 2)
o
NA-66-1032
STRU~TURAL REPAIR MANUAZ,
FASTENERS TO MATCH THOSE

REMOVED, EXCEPT In BLlnB AREAS.
IN BLINB AREAS, USE MSMOOIAD4 RIVETS
,TI
II
FILLER
B(I~
rr
II
j
o
IaI1
(I
I+
i)
Itpll
II
iCll
re!
-e
t-f-tl"lYo I I
ii
ri
REPAIR DOUBLER
2 ROWS
MSM424AD4
RIVET
REOUIREB THROUGH
OAMAOED SKII. BIMPLE

SKIN AND REPAIR DOUBLER.
if I~il
11-
(TYP)
REPAIR BOUBLER IREFI
t 2TIMES
FASTENER
1/2 M~X
j,[
[TYPI
BIA
SECTION
MS2042OAD4
2 ROWS
THROUGH FILLER ANO

REPAIR DOUBLER.
MS2042OAD4
REOUIRED
THROUGH SI(IN AND

REPAIR DOUBLERS.
DIMPLE FILLER ANO
DIMPLE SKIW AWO

REPAIR DOUBLER.
VIEW LOOKING UP AT LOWER SURFACE

REPAIR DOUBLER
SECTION
FILLER
A-A
iutnlatn
REPAIR
OOURLER
_/+7 1/2 ~3 I
~llnPI
$I-1-++)-L
~loll
REPAIR DOUBLER.
3000LE AS REOUIREO
JOGGLE AS REOUIRED.
(RE9FAST~NER
DlA
RIVETS
(REFI
2 TIMES
(I
I
yli
ilIrI
13
-1-
O1BUIO 8KIU
11)11
iLO-O
T-l
Ic
,,,1,,1
JH
ilitl
IC
CJ
10
L~?
ii
(REFI
BAMAGED SKIN (REF)
ii
l~tl ItalBITYPI
REPAIR DOUBLER
IREFJ
(REF)
(REF)
MATERIAL
AND 61U0E TO MATCH
FILLER
B-B
FRONT SPAR REFERENCE PLANE

8820428404
WHEN ACCESS IS AOEOUATE,
MSMBOI1~04 WHEW NECESSARY.
DIMPLE SKIW AWO REPAIR
MATERIAL
FILLER
DOUBLER.
AWO GAUGE TO MATCH
SKIN
REPAIR OOUBLER
MATERIAL TO MATCH
SKIN. GAUGE SKIN
RIVET
ant
I
DAMAGED SKIN
BAMAGEO SKIN
REPAIR DOUBLER
MATERIAL TO MATCH SKIW.
GAUGE SKIN GAUGE +0.MID
JOGGLE TO MATCH CHEMMILLED LAID ON DAMAOEO

SKIN.
REPAIR BOUBLER
(0.032 MAXI.
Remove slats and slat track ribs and roller
blies, when necessary for
assem-
access.
O Trim~uldamagedares.
O
EI
O
O
O
Fsbricaterepair parts.
NOTE
L.Y
ON THIS ILLUSTRATION MAY BE

USED TO MAKE REPAIRS ON CHEM-MILLED SKINS ON
UNDER-SLAT LEADING EDGE SKINS. AEPAIR
REPAIRS SHOWN
DOUBLER SHOULD BE MADE OF ONE PIECE WHEN

DAMAGED AREA IS ACCESSIBLE THROUGH DOORS
AND REMOVABLE RIBS.
Out laotener
pattern
Asaemble end rivet repair parb in PISCe-
repair
to
Wing Underslat Leading Edge Skin Repair

Figure 215
0
part.
Plimsrapsirparts
Refinish
and dril all
msteh
surrounding
area
5165-3-?50
57-30-20
Page 223
Aug 17/84
NA-66-1032
STRUCTURAL REPAIR MANUAL,
Ar~
SLAT LEAOING
EDGESK~IREFJ
SLAT TRACK
ATTACHING
BOLT IREF)
21I
II
II
~ICj;b
\c\
i
-r-
/i
1-1/2
1_
51
ii,,
/111
II I
I I
111
2-5/8
11
II/
II;
o
OlA
ImlNI
c
I----r
If
1-1/2
ITYPI
ITYP)
2-3/16
SECTION A-A
1/188
II (TYPI
II
:~T"E"nSER
t-
Ilu-~lnI,
i___i
lr
II
-t
2-5/8
ITYP)
r~_____
Il~o
I
Illj
(\O
RIVET
(TYPI
5122484-2
COUNTERSINK REPAIR
OOUOLER 6 PLACES
SLAT INNER
PICK UP EXISTING FASTENER
SKIN
LOCATIONS USING 082249-4-3

FASTENERS. OIMPLE REPAIR
IREFI
OOURLER 3 PLACES
REPAIR OOUBLERS
0.040 2024-342 CLAO
AL ALLOY SHEET
Make cutouts in slat lower skin

to
gain
access to
adjacent
O
O
to slat ribs
slat track attach bolt. Smooth all
edges of
cutout
Install
existing
rivets in each rib
repair doublers using size and type of
fasteners called out.
Tighten,
rework
or
replace slat track
attach bolt
as
required
E)
Drill out three
Fabricate
repair doublers using
Finish
repair
to match
surrounding
area.
materials and dimen-
ions shown.
57-30-20
Page 224
Aug 17/84
S370-3-101
Slat Track Attach Bolt
Access Hole
Figure 216
o
Repair
COP~RIGHT, 19814 BY SABRELINER CORPORATI.ON
NA-66-1032
FLIGHT SURFACES
~ENERAL
This section contains the repair indexes for the slats,
ailerons, and flaps. See figures 1 through 4.
57-50-00
0
Page 1
Aug 17/84
NA-66-1032
46
45
42
44
43
FRAME ASSEMBLY OAAWING HO.
265-170001 INBO ASSY

285-1 10002 INBD INTERMEOIATE ASSY
n/
265-170003 INTERMLDIATE ASSY

265-170004 OUTBO IHTERMEOIATE ASSY
285-170005 OUTBO ASSY
40
~39
33
38
36
Y~
ITEM NUMBERS IN KEY.
35
34
32
55
30
23
56
29
28
27
26
25
53
24
54
22
14
20
19
)7
12
52
49
50
10
9
47
48
9285-3-241
57-50-09
Page 2
AuR 17/84
Wing Slat Repair
Index
M6del NA 265-40, -661, -76), and
erugiF081
NA-66-1032
STRUCTURAL REPAIH MANUAL
GAUGE OR
EXTRUSION
ITEM
NO. DRAWING NO.
1
2
3
265-170001-39
265-179691-13
265-170001-11
4
5
265-170001-25
265-170001-9
265-170030
265-170030-3
265-170030-5
DESCRIPTION
CSS 77.348
Rib
SS 74.140
Rib
SS 74.890
Rib
SS 82.045
Rib
SS 90.375
Rib
Slat Inbd
TE
Skin
Core
NO.
MATERIAL
2024-T42 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
0.632
0.050
0.050
0.020
0.020
2024-T3 Clad
5652-1139
0.010
3/16
0.001
Honeycomb
7
8
9
10
11
12
13
14
Channel
SS 96.900
Rib
SS 97.636
Rib
Rib--SS104.433
SS 105.062
Rib
SS 113.952
Rib
SS 114.702
Rib
SS 121.858
Rib
TE
Slat, Inbd Intermediate
265-170030-7
265-170001-7
265-170001-5
265-170001-37
265-170002-5
265-170002-19
265-170002-17
265-170002-15
265-170043
26.5-170043-3
265-170043-5
Skin
Core
2024-T42
7675-16 Clad
7075-T6 Clad
2024-T42Clad
2024-T42 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
0.020
0.050
0.050
0.032
0.020
0.050
0.050
2024-T3 Clad
5052-H39
0.010
3/16
0.001
Honeycomb
15
16
17
18
19
20
21
22
23
265-170043-7
265-179662-13
266-170002-11
265-170002-9
265-170002-7
265-170002-3
265-170003-8
265-170003-15
265-170003-13
265-170053
265-170053-3
265-170053-5
Channel
SS 129.062
Rib
SS 136.265
Rib
SS 142.797
Rib
SS 143.547
Rib
SS 152.406
Rib
SS 153.030
Rib
SS 161.780
Rib
SS 162.530
Rib
TE
Slat, Intermediate
Skin
Core
2024-T42
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
2024-T42 Clad
2024-T42 Clad
7075-T6 Clad
7675-16 Clad
0.020
0.020
0.020
0.050
0.050
0.020
0.020
0.050
/2024-T3 Clad
5052-H39
0.010
0.050
3/16
0.001
Honeycomb
24
25
26
27
28
29
.70
31
32
33
265-170053-7
265-170003-17
265-170003-11
265-170003-9
265-170003-7
265-170003-5
265-170004-17
265-170004-15
265-170004-13
265-176664-11
265-170063
265-170063-3
265-170063-5
Channel
SS 169.685
SS 179.578
SS 186.109
SS 18.859
SS 194.539
Rib
SS 195.163
Rib
SS 202.874
Rib
SS 203.624
Rib
SS 210.780
Rib
TE
Slat, Outbd Intermediate
Skin
Core
Rib
Rib
Rib
Rib
0.020
2624-142
0.020
7675-16 Clad
0.020
7075-T6 Clad
0.050
7675-16 Clad
0.050
7075-T6 Clad
2024-T42 Clad 0.020
2624-142 Clad 0.020
0.050
7075-T6 Clad
0.050
7075-T6 Clad
0.020
7075-T6 Clad
2024-T3 Clad
5652-1139
0.010
3/16
0.001
Honeycomb
2024-T42~1ad
Channel
265-170063-7
0.020
NOTE
For additional
repairs, refer
to 57-70-00.
5265-3-241
Key
0
to
57-50-00
Page 3
Aug 17/84
NA-66-1032
YTRIICTURGL REPAIR MANWAL
ITEM
NO. DRAWING NO.
34
265-170004-9
35
265-170004-7
265-170004-5
265-170004-3
265-170005-37
265-170005-7
265-170005-9
265-170005-11
265-170072
26Fi-170072-8
265-170072-5
36
.37
38
39
40
41
42
GAUGE OR
EXTRUSION
MATERIAL
NO.
DESCRIPTION
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
TE
SS
SS
SS
SS
SS
SS
SS
SS
228.297
7075-16 Clad
7075-T6 Clad
229.047
236,672
237.296
244.546
245.296
252.451
7075-T6 Clad
2024-142 Clad
2024-T42 Clad
7075-T6 Clad
7075-T6 Clad
7075-16 Clad
221.765
REPAIR
FIGURE
NO.
0.020
01050
0.050
0.020
0.032
0.050
0.050
0.020
Slat, Outbd
Skin
Core
2024-T3 Clad
5052-H39
0.010
3/16
0.001
Honeycomb
43
44
45
46
47
48
49
50
265-170072-7
265-170005-17
265-170005-13
265-170005-15
265-170005-35
265-170055-1
265-170029-1
265-170073-1
265-170042-1
52
53
54
265-170074-1
265-170052-1
265-170075-1
265-170062-1
55
56
265-170076-1
265-170071-1
51
Channel
Rib
SS 262.141
Rib
SS 268.672
Rib
SS 269.422
Rib--SS275.874
Skin
Slat, Inbd
Skin
Shroud, Inbd Slat
Skin
Slat, Inbd Intermediate
Skin
Shroud, Inbd
Intermediate Slat
Skin
Slat, Intermediate
Skin
Shroud, Intermediate Slat
Skin
Slat, Outbd Intermediate
Skin
Shroud, Outbd
Intermediate Slat
Skin
Slat, Outbd
Skin
Shroud, Outbd Slat
2024-T42Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
2024-T42Clad
2024-13 Clad
2024-T42 Bare
2024-T3 Clad
2024-T42 Bare
0.020
0.020
0.020
0.050
0.032
0.040
0.040
0.040
0.040
57-50-20,
57-50-20,
57-50-20,
57-50-20,
Fig
Fiff
Fig
Fig
212
212
212
212
2024-13 Clad
2024-T42 Bare
2024-T3 Clad
2024-T42 Bare
0.040
0.040
0.040
0.040
57-50-20,
57-50-20,
57-50-20,
57-50-20,
Fig
Fig
Fig
Fiff
212
212
212
212
2024-T3 Clad
0.040
2024-T42 Bare 0.040
57-50-20, Fig 212

57-50-20, Fig 212
s2es-s-w~
NOTE
For additional
57-50-00
Page 4
Aug 17/84
repairs, refer
to 51-70-00.
Key
to
Figure
o
(Sheet
2 of
2)
NA-66-1032
STRIICTURAI, KEPAIR MANUAL
29
28
FRAME ASSEMBLY
ORAWINO WO. 285-158001

INBEX NUMBERS CORRESPOWR TO
ITEM NUMBERS IN KEY.
30
32
34
35
v,
33
38
L :~D
a
7
10
08
t~C\
it
II
F-
13
Is
Is
Is
20
23
26
27
24
22
5265-3-242
Repair Index
Figure 2
Aileron
57-50-00
Page 5
Aug 17/84
NA-66-1032
GAUGE OR
EXTRUSION
ITEM
NO. DRAWING NO.
1
246-16003
246-16003-3
246-16003-5
246-16003-13
DESCRIPTION
MATERIAL
TE
Aileron
Skin
Skin
Core
NO.
2024-T3 Clad
2024-T3 Clad
0.010
5952-1139
3/16
0.001
3/16
0.001
REPA1[R
FIGURE
NO
0.010
Honeycomb
246-16003-15
Core
5052-H39
Honeycomb
2
246-16003-9
246-16003-7
265-160068
LH Only
265-160003
LH Only
Channel
Channel
Channel
Tab
265-160003-3
265-160003-5
2024-T3 Clad
2624-13 Clad
2624-14 Clad
0.020
0.020
0.025
2024-T3 Clad
0.010
5952-1139
3/16
Aileron Trim
Skin
Core
0.001
Honeycomb
4
265-160003-17
246-16003
246-16003-5
246-16003-15
Channel
TE
Aileron
Skin
Core
2624-142 Clad
0.025
2024-T3 Clad
5652-1139
0.010
3/16
0.001
Honeycomb
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
246-16003-9
246-16520
265-160037
265-160036
265-160059
265-160035
265-160034
265-160058
265-160067
265-160033
265-160032
265-160031
265-160030
265-160029
265-160028
265-160027
265-160026
265-160025
265-160024
265-160041
265160040
LH Only
265-160023
LH Only
Channel
Rib Assy
CAS 92.802
Rib
AS 86.750
2024-T3 Clad
2124-14 Clad
2024-T42 Clad
0.020
0.020
0.020
Rib
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
0.040
AS 81.500
Intercostal
AS 75 to 81.500
Rib Assy
AS 75.500
Rib Assy
AS 74.500
Intercostal
AS 69 1/4 to 75
Rib
AS 69.250
Rib
AS 64.000
Rib
AS 58.750
Rib
AS 53.500
Rib
AS 48,250
Rib
AS 43.000
Rib
AS 37.750
Rib
Rib
Rib
Rib
Rib
AS 32.500
AS 27.250
AS 22.678
AS 17.500
Assy
AS 13.594
Support
Rib
AS 13.094
CAS 12.625
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
2024-T42 Clad
2624-142 Clad
2624-142 Clad
2024-T42 Clad
2024-T42 Clad
2624-T42 Clad
2024-T42 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
2024-T42 Clad
7178-T6 Al Aly
Bar
7675-16 Clad
57-50-20, Fig 205

57-50-20, Fig 205
57-50-20, Fig 205
0.040
0.040
0.050
0.040
0.063
0.020
0.020
0.020
0.020
0.020
0.020
0.020
0.032
0.025
0.063
0.032
57-50-20,
57-50-20,
57-50-20,
57-50-20,
57-50-20,
57-50-20,
57-50-20,
57-50-20,
57-50-20,
0.050
57-50-20, Fig
57-50-20, Fig 205

57-50-20, Fig 205
57-50-20, Fig
206
57-56-29, Fiff 205

57-59-9, Fig 295
Fig 205
Fig 205
Fig 205
Fig 295
Fig 205
Fig 295
Fig 205
Fig 205
Fig 205
205
NOTE
For additional repairs, refer to 51-70-00.
57-5000
Page 6
Aug 17/84
Key
to
Figure
o
(9h~t
1 of
2)
CUP~IGHT,
1984 BY SkBRELINER
CORPORATION
NA-66-1032
ITEM
NO DRAWINGNO
GAUGE OR
EXTRUSION
REPAIR
FIGURE
NO.
NO.
MATERIAL
DESCRIPTION
26
27
265-160021
265-160022
LH Only
Rib Assy
Rib Assy
CAS 8.500
CAS 1.000
7075-T6 Clad
2024-142 Clad
0.025
0.020
57-50-20, Fig 205

57-50-20, Fig 205
28
265-160002-3
265-160002-9
246-16548
246-16031
2024-T3 Clad
2024-T3 Clad
0.020
0.020
57-50-20, Fig 207
265-16530
Aileron Upper
Skin
Skin
Aileron Outbd Hinge
Pin Assy
Aileron Outbd Hinge Assy
Link
Aileron LE
Skin
Aileron Inbd Hinge
Link
34
265-160002-5
265-160002-7
Skin
Skin
35
265-160073-3
29
30
31
32
33
265-160061
Thru -11 and -15
36
265-160073-13
and -17
265-160073-19
Thru -25
246-16511
37
265-160049
4130SteelBar 1.000
7075-16 Clad
7075-T6 Al Aly
Bar
2024-13 Clad
2024-T3 Clad
0.090
Weight
1018 Stl Bar
1/2
Weight
lolo Stl Sh
1/8
Aileron Lower
Aileron LE
Weight
Stringer
Aileron Outbd
Channel
CAS 0 to 12-5/8
57-50-20, Fig 206
2-3/16
0.020
0.020
57-50-20, Fig 207
0.190
301 CRES Sh
7075-T6 Al Aly 3/8
Plate
2024-142 Clad 0.032
NOTES
For additional
repairs, refer
to 51-70-00.

This is
areas or
Sa65-3-242
Key
0
to
Figure
(Sheet
2 of
2)
57-50-00
Page 7
Aug 17/84
NA-66-1032
FRAME IS8EM8LY
OBAWINO NO. 285-108811
INOEX NVMBERS CORRESPONO TO
ITEM NUMBERS II KEY.
~Y.
50
53
52
13
1B
17
20
22
48
48
21
24
46
47
23
44
28
45
42
25
43
40
27
38
41
31~
37
34
35
32
33
30
29
28
57-5000
PaRe
8285-3-2~3
Flap Repair
Index
Modeli265-40, -60,;70, and
3erugiF08-
Auff L 7/84
COiPPRIGHTI
1 984:BV SABRELINER ,CORPORAJION
NA-66-1 032
STHUCTIIRAI~ REPAIR MANCrAI,
ITEM
NO. DRAWING NO.
1
265-280002-11
265-180001-5
265-180001-7
265-180036
265-180046
26.5-180047
265-180948
265-186949
265-180062
266-1(30053
265-180054
26.5-180055
265-180056
265-180057
265-180059
265-180060
265-180061
265-180062
265-180063
265-180064
265-180065
265-180066
265-180067
265-180034
265-180035
265-180001-3
265-180071
265-180971-3
265-180071-5
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
MATERIAL
DESCRIPTION
Spar, Flap
Stringer
707Fi-T6 Clad
2024-T42 Clad
2024-T42 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
Front
Stringer
Rib
LE, FS 84.769
Rib
TE, FS 73.769
Rib
TE, FS 79.269
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
Rib
FS 84.769
FS 87.393
FS 92.233
FS 97.074
TE, FS 101.914
TEI FS 106.774
TE, FS 111.974
TE, FS 114.344
TE, FS 118.640
TE, FS 123.840
TE1 FS 128.846
TE, FS 133.802
TE, FS 138.757
TE, FS 143.713
TE, FS 148.756
TE1 FS 151.381
TE, FS 156.881
FS 162.381
FS 167.881
TE,
TE1
TE,
TE,
7075-16 Clad
7075-T6 Clad
7075-T6 Clad
7975-16 Clad
7075-T6 Clad
2024-T42 Clad
Stringer
TE
Flap
Skin
2024-T3 Clad
5052-H39
Core
GAUGE OR
EXTRUSION
NO.
0.063
0.025
0.025
0.071
0.020
0.020
0.050
0.071 Ilfl
0.020
0.020
0.020
0.020
9.063
0.068
0.063
0.020
0.020
0.020
0.020
0.020
0.040
0.0710
0.020
0.020
0.020
0.025
REPAIR
FIGURE
NO.
57-50-20, Fig 210
Fig 210
Fig 210
Fig 210
Fig 210
Fig 210
Fig 210
Fig 210
Fig 210
Fig 210
Fig 210
Fig 210
Fig 210
Fig 210
57-50-20, Fig 210
57-50-20, Fig 210
57-59-29, Fig 210
57-50-20, Fig 210
57-50-20, Fig 210
57-50-20, Fig 210
57-50-20,
57-50-20,
57-50-20,
57-50-20,
57-50-29,
57-50-20,
57-50-20,
57-50-20,
57-50-20,
57-50-20,
57-50-20,
57-50-20,
57-50-20,
0.010
3/16
0.001
Honeycomb
28
29
39
31
32
33
34
35
36
87
38
39
265-189971-7
265-180921
265-180933
265-189644
265-1800135
265-180042
265-180032
265-180031
265-180030
265-180029
265-180028
265-180041
265-180089
40
41
42
43
44
45
265-180040
265-180027
265-180026
265-180025
265-180024
265-180038
Channel
Rib
Flap DCS 171.345
Rib
I,E, FS 156.881
Rib Assy
LE, FS 151.381
Roller Assy
Flap Outbd Track
Rib
Rib
Rib
Rib
Rib
Rib
Rib
LE,
LE,
LE,
LE,
LE,
LE,
LE,
Support
Fwd
Rib
LE,
Rib
LE,
Rib
LE,
Rib
LE,
Rib
LE,
Rib Assy
2024-T3 Clad
2024-T42 Clad
707fj-T6 Clad
7975-16 Clad
0.020
Clad
Clad
Clad
Clad
Clad
Clad
7075-16 Clad
2924-142 Al Aly
Bar
7075-16 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-T6 Clad
7075-16 Clad
0.071
0.020
0.020
7075-T6
7075-T6
7075-T6
7075-T6
7075-T6
7075-T6
FS 148.756
FS 143.713
FS 138.757
FS 133.802
FS 128.846
FS 123.840
FS 118.640
Flap Actuator Attach
FS
FS
FS
FS
FS
111.974
106.774
101.914
97.074
92.233
LE, FS 87.393
9.029
0.020
0.071
0.020
0.020
0.020
0.063
2.000
0.063
0.020
0.020
0.020
0.020
0.071
NOTES
For additional
repairs, refer
to 51-70-00.

This is
areas or
S265-3-243
Key
to
Figure
(Sheet
1 of
2)
57-50-00
PageS
Aug 17/84
NA-Ci6-1032
ITEM
NO. DRAWING NO.
46
265-180076
47
48
265-180023
265-180022
265-180020
265-180069
265-180068
265-180070
265-180081
49
50
51
52
53
GAUGE OR
EXTRUSION
MATERIAL
NO.
DESCRIPTION
Roller Assy
Flap Inbd Track
Rib
LE, FS 79.269
Rib
LE, FS 73.769
DCCS 68.336
Rib
Skin
Flap, Lower
Skin
Flap, Upper
Skin
LE Flap
Skin, LE Flap
Support
7075-T6 Clad
0.020
7075-T6 Clad
0.020
2024-142 Clad 0.020
2024-T3 Clad
0.040 O
2024-T3 Clad
0.040
7075-T651 Bare 0.250
7075-T6 Bare
1/4
REPAIR
FIGURE
NO.
51-50-20, Fig 209

51-50-20, Fig 209
NOTES
For additional
O)
This is
repnils, refer
to 51-70-00.

a
areas or
5285-3-243
57-50-00
Page 10
Aug 17/84
Key
to
Figure a(Sheet
o
2 of
2)
QQPYRIGHT, 1984 BY SABAELINER CORPORATIOW
NA-6fi-1032
STRUCTURAL REPAIR MANITAI,
2
2
2\
2
5
4
2
2
2~
2
2
2
5
4
9
2
2
2
2
10
Flap Repair Index

Fiffure 4
c
57-50-00
Paffe 11
Aug 17/84
NA-66-1032
STRLTCTURAL REPAIR MANUAL
STRUCTURAL IDENTIFI%ATION (Continued)
GAUGE OR
EXTRUSION
ITEM
NO. DRAWING NO.
1
2
76-57604-013
76-57604-009
76-57604-079
76-57604-041
76-57604-065
76-57604-003
7
8
9
10
76-57604-063
76-57604-015
76-57604-005
76-57604-007
3
-1
57-50-00
Page 12
Aug 17/84
DESCRIPTION
MATERIAL
NO.
Rib
Rib
Channel
Rib
Rib
LE Skin
Rib
Channel
2024-142 Clad
2024-142 Clad
2024-142 Clad
Skin, Upper
Skin, Lower
2024-T3 Clad
0.032
0.032
0.063
0.063
0.063
0.040
0.032
0.063
0.040
2024-13 Clad
0.040
2024-142 Clad
2024-T42 Clad
2024-142 Clad
2024-T42 Clad
2024-T42 Clad
Key
to
Figure
CIO~RIGHT, 1984
REPAIR
FIGURE
NO.
57-50-20, Fiff 209

57-50-20, Fig 209
BY SABRELINER CORPQRATION
NA-66-1032
STRLICTURAL REPAIR MANUAL,
FLIGHT SURFACES
AI,LOWABLE DAMAGE
GENERAL
flight surfaces.
LEADING
MAXIMUM WEAR ALLOWANCES
MODEL NA 265-40,
EDGE SLAT TRACKS
-60, -70, AND -80
See figure 101 for maximum wear allowances for the
lead i ng edge slat tracks for model NA 265-40, -60, -70, and
-80.
INBOARD
MAXIMUM WEAR ALLOWANCES
MODEL
AND OUTBOARD FLAP TRACKS
NA 265-60A, -60SC, -65, -80A AND -80SC
See figure 102 for maximum wear allowances for the inbd
and outbd flap tracks for model NA 265-60A, -60SC, -65,
-80A, and -80SC.
57-50-10
0
Page 101
Aug 17/84
NA-66-1032
SLAT:TRACK
P/N 285-1.70000, 285110007.
285-10008. 285170009 ANO
2651:7Q10
WING LE
:-C
0.083 IN.
0,110 IN.
i
0;110 IN.
t
TYPICAL TRACK; SECTION
MIN ALLOWABLE DIMENSIONS
NOTE
IF
SLAT TRACK
EXCEEDS MAX WEAR ALLOWANCE
REPLACE OR CONTACT SABRELINER ENGINEERING.
57-50-10
Page

Wing Leading Edge Slat Tracks
Model NA 265-48, $0, -711, and
Igk
eru;piF08-
102
Aug ~7/84
COPYRIGHT, 1984 BY SA;BRELINER CORPORATION
NA-66-1032
ZONEI
TRACK
PIN 78-57612
J(s
ZOnL2
sg
l"rAR
~roU
Rf~_
_L
-f
O.1M1IN.
o.lmill
0.200 IN.
0.l00ln.---( ~t-
i
ZOWEI
0.150 In.
-f
ZOIEP
MIN ALLOWABLE OIMENSIONS

NOTE
IF FLAP TRACKS EXCEED MAX WEAR LIMITS, REPLACE.
OR CONTACT SABRELINER ENGINEERING.

Model NA 265-60A, -60SC, -65, -80A, and
erugiFCSO(I102
57-50-10
Page 103/104 Blank
Aug 17/84
NA-66-1032
FLIGHT -S~RFACES
REPAIRS
GENERAL
This section contains repairs for the slats, ailerons, and
flaps. For applicability of repairs, refer to 57-50-00
STATIC BALANCING AILERONS
Whenever a repair has been performed on an aileron, it is
essential that the repaired surface be static-balancechecked. Rebalance repaired surface if it is not within
specified tolerance. The procedures for checking the
static balance and the addition of weights(if required) are
given in figures 201 through 204.
BALANCE REQUIREMENT
BALANCE
AILERON
0 TO 10 IN.
LBS.
NOSE HEAVY
265-160001
AILERON REPAIRS
Repairs
to
ailerons
are
given in figures
205
through
208.
FLAP REPAIRS
Repairs
to
flaps
are
given in figures 209 through 211.
SLAT REPAIRS
Repairs
to slats
a~e
given in figure
212.
57-50-20
o
Page 201
Aug 17/84
NA66-f032
STKuCTURAI, HEPAIR MANUAI,
SHOULD HAVE 1OLB CAPACITY (MIN)I\NO BE

SCALE
GRIIOUATEO:IN 1/100 LB; (ORABUATIOW IW 1/2 DZ
IsmAxl
STRING
ADHESIVE
KNIFE EDGE
TAPE
SURFACE SUPPORT
STAND 12 REOO)
POINTER~ND
STLIIO:
STEEL TAPE
TEST WEIGHT
CONTAINER
SURFACE
BOLT -;TO MATCH HINGE
BOLTS IH SURFACE BEING

CNECKEO
POINTER,
SUPPORT STANOS
ADJUST POINTER;UERIICALLY TO COINCIDE WITH.OE#TEAOF BOLT; THEN: POSITION IT ADJACENT TO SURFACE

TE.
5285-3-278
57-50-20
Slatid
Balance:Che~lijng
Page:202
Aug 17/84
:o
I G HT, 1984 BY::SPiiBR EL I N ER COR PORAT I ON
NA-Gfi-1032
AILERON BALANCE REOUIREMENTS

Place aileron
on
support stands
on a
level bench.
265
Adjust pointer to height of hinge cente*(ine, Ihen

place it adjacent to aileron TE. TE of aileron should be even
with pointer (O balance) or above pointer (nose heavy).
El
To dnermine
acrua
aileron
unbalance, prowed
BALANCE
AILEROH
160001
51
61
71
81
52
82
72
82
LB NOSE HEAVY
10 IN.
as
follows:
weight
container to TE
edge
shown.
(a)
Tape
(b)
Add
(c)
Measure distance from center of container to aileron
test
as
to container until aileron TE is
weights
opposite pointer.
hinge
directly
line to determine "L" dimension.

(d)
Weigh
(e)
Multiply weight by "L" dimension to determine in.

pounds of unbalance. Unbalance condition must be
within
tolerance
shown
on
"Aileron
Balance
Requirement" chart or weights must be added

bring aileron into a balanced condition. Refer
Adding Rebalancing Weight, figure 204.
to
to
SUPPORT
STAWD
TAPE
STRING
\TAILERON
POINTER
1 IN.
NOTE
RUOOER HINGE
LINE
ABOVE PROCEDURE IS FOR A COMPLETE AILERON

INCLUDING TRIM TAP AND TRIM TAB ACTUATOR (iF
APPLICABLE),
TESTWEIGHT
CONTAINER
AND PAINT.
5265-3-279*
CheckinlS Aileron Static Ralance
FiISule 20~
57-50-20
PaRt! 20X
Aug 17/84
NA-66-1032
STKIT(:TI!RAL REPAIR MANUAL
SURFACE TE
~f-
1
__
a HIW68
W? (_.r~J
WJ
0203
Wt
Net
weight
W2
Wg
weight of repair aft of hinge line. (Net weight of repair

of repair minus weight of any removed material.)
Net
weight of repair fwd
Weight
of
repair
balance
of
hinge
is total
D1
Distance from CG of
W1
to CL of
hinge.
D2
Distance from CG of
Wq
to CL of
hinge.
Wg
to CL of
hinge.
line.
Dg
Distance from CG of
weight.
CALCULATING REBALANCE WEIGHT REQUIREMENTS
ALLOWABLE MOMENT OF INERTIA INCREASE
Moment (In.-pound
effect) of a repair is found by multiplying weight of

repair by moment arm (dlstance from CO of repair to hinge centerline).
Weight of rebalance weight required to counterbalance repair is found by
Allowable moment of Inertia increase (expresaed in Ils in.2) determines

permissible extent of repairs In relation to total weight that must be added
(repair plus rebalance weight).
dividing in.-pound effect at repair by dl~tance(rom CO of rebalance weight

to hinge centerline.
Moment of Inertia increase is
Considering repair
W1
only
in sketch. Formula is
W1
D1
.a
~9Blerrlng
4.
to
sum
of increases from each added
weight.
sketch, formula would be:
(W1
Inarthl ncra.eYomant of
D12)
(W2 x 022)
(Wa
D%)
EXAMPLE
(asslgning possible
numberlcal
Using
values)
W1 0.5 Ib
01=10.510.
03 4.75 in.
values
Moment of
assigned
1
(0.5
In
calculating rebalance weight requirements:
10.51)
(0.4
2.52)
(0.89
4.752)
Ihertia Increa~e= 55.13+ 2.5+ 20.1

77.73 Ib
ln.2
SOLUTION
MOMENT OF INERTIA INCREASE LIMITS
(W1)(D1)
0.5810.5
5.25
285-160001-52 and -62 arleron, RH -89 Ib

285-160001-51 and -81 ailaron, LH -64 Ib
1.1 Ib
4.75
4.75
(Dg)
II
LE
285-186001-72 aileron, RH 71 Ib in.

285-160001-71 sllaron, LH -43 Ib R~2
Wp in skatch,ls Insllled .[multaneou.ly with

repair represented by W1, counterbalancing effect of Wp Is subtracted
from in.-pound enect of W1 before solving for rebalance weight (WQ)
a
r~pair, replssan(sd by
Using values given
in first
example and assigning W
0.4 Ib and D
in.2
ln.2
3.5 In.,
solution Is:
(W,) (D1)
(0.5
(W2) (D2)
10.5)- (0.4
Wa:
2.5)
4.25
10.8916
4.75
4.75
(D3)
NOTE
CALCULATIONS MAY BE MADE USING 0.284 POUND
PER CUBIC IN. FOR STEEL ALLOYS AND 0.1 POUND PER
CUBIC IN. FOR ALUMINUM ALLOYS.
8285-3-280A
57-50-20
PaRe
Aua 17/811
Static Rebalance
208
erugiFsnoitalu~G
204
1984 BY SABRELINER
%ORPORATION
NA-66-1032
AS
43.000
AS
ACS
22.678
AS
.58.150
WEIGHT
WEIGHT
AILERON
ABBREVIATIONS
AS
AILEROW STATIOW
CANTEG
NOTES
FOR REPAIR
INBD OF AS
22.678, ADD REBALANCE
WEIGHT TO INBD RIB (ACS O).

FOR REPAIR OUTED OF AS 22.678, ADD REBALANCE
WEIGHT BETWEEN AS 43.000 AND 58.750, SELECTING
THE BAY NEAREST THE REPAIR.
MAX MOMENT OF INERTIA INCREASE:
265-160001-52 AND -62 AILERON, RH -89 LB IN.

265-160001-51 AND -61 AILERON, LH -64 LB IN.
285-160001-72 AILERON, RH -71 LB IN.
265-160001-71 AILERON, LH -43 LB IN.

265-160001-82 AILERON, RH -71 LB IN.
265-160001-81 AILERON, LH -43 LB IN.
S?65-3-281B

0
57-50-20
Page 205
Aug 17/84
NA-66-1032
STRITCTURAL REPAIH MANUAL
(LENGTH
AS
READ REPAIR DOUBLER
REOD)
18 RE0G1
RIVET
M820801A04-1 110 REOG1.
CSK DOUBLER. RIVET PATTERN TO
CLEAR REBALANCE WEIGHT
FA8fEnIl P~TTIRY.
TO CLEAN BEAD IN RIB
P164 JOBOLTS
I\CS 0.7930
RIB
RIVETS
--------1
EXISTING HOLESTHRU
LIIORIPIIR
REBALANCE
WEIGHT FASTENER
o
_
dUI
ill
IrrQ1
MS2O428804
18 REDO).- PICK UP
oi
RIVETS
MS2OWHIAO41
P
t:II
HEOO)
1/4 EDGE
DISTANCE
0.50620240It1?-I
(TYP
i,
1111
1 111
1\
cce
FOR 1/8
GIA RIVETS)
REPAIR GOUBLER
BARE SHEEP:-3/32 BENORAOIUS
_I
II
ITYP)
ale
REBALANCE WEIGHT
-1~
SECTION
-742 CONOITIGN
JREq
It
11
HEAT-TREAT TO
A-A
REPAIR OOUBLER
INSTALLATION OFRSBALANCE WEIGHT SUPPORT DOUBLER
INSTALLATION OF REDALANCE WEIGHT
ACS 0.7930
REBALANCING RH AILERON:-AT ACS 0.793

I
DRILL ONE 80.12 HOLE
O~
r~
t?
II
BOLT
NASlIOS(LENOTR 88 REOO)
ANOBOPOIO 12 REOei_ONE
WASHER
UNOER NUT AND ONE 8ETWEElli
REBALANCE WEIGHT ANO RIB1:
;t=l"
NUT
ACTUATOR IREF)
Y-
1181281-3
GRILL TWO NO. 12 HOLES IN WEIGHT

BOLT
8831103 ILENGTH AS REQO)
WASHER
AWBIPOIO 1288- REOG1
(3
C)
1
JI
nUT
BRACKETFOR~TRINI
NASl29l.s
I I
12 EA REOD1
PICK UP EXISTING HOLES
011
CI
cJ /L
rC
REBALANGE WEIOS
II~
~fF-
L;
~-L-RIB
ACS 1.000
L--"
REBALANCING LHIAILERON:AT ACS 1.000

RIGHT-HANG AILERGN
Remove AN7510-1
lnslall
plate from
fwd section of
~:lnMall
rib,
relocate it aft of present location, and install with four

MS20600AD4-1 rivets.
Fabricaie
(Old holes need
repairdauDler
doubler to -T42 condition after
not be
plugged.)
asrhown Heat-treat
repair doubleras shown
rebalancs
weighta6
shorm
LEFT-HAND:AILERON
repair
forming.
Remove two fwd
mounting
bolts in trim actuator
~ket.
Prime
repair
doubler with
nc-chromats
primer
IE9
NOTE
In.tsll rebalancs
weight
as shown
INSTRUCTIONS FOR FABRICATION OF REBALANCE

WEIGHTS ARE GIVEN ON SHEET 4.
sles-a-?s?
57-50-20
Page 206
Aug 17/84
Adding Rebalanc~ -Weights

Figure 204 (Sh~et2 of 4)
o
COB~RIGHT, 1984 BY SABRELINER CORPORATION
NA-66-1032
O
O
NA
UaLe cutDut in skin
phovn, to pravids
as
access.
Attach
new
weignt
shown. (Length of
Remove
nswrighl
is determined
by
as
thickness of
weight.)
existing weight.
Drill nolsa In
to LE with ANSOS-1OR screws
screw
to match
O
O
PI
hole. in
exi.ting
LE skin.
Fabricate
Prims
EFB6.
access
doublerand fi Isr
doubler and filler.
Inglallpansasshorm.
PICK VP EXISTING
DIMPLE OOUBLER
FASTEIIERS. DRICL no. 27 11.144) HOLES.
CR22484.
RIVETS
EXISTING FASTEnER
REMOVE IS REOO
TOInSTALLACCESS
DOUBLER
loll
I
INITYP)
T,
rz-/
e,
I djl
A(1
II
II
II/
3/4
II
ACCESSOOUBLER
Id
le
It
tl
II
It
B
II
1/4 R
3/4
(TYP)
~I
~t
II~\
2-1/8
Ce
II\
10
__I
II
25/8
052248-4
111
1
_
le
RIVETS
_
3
DIMPLE FILLER AHO OOVBLER

OHILL no. 27 10.1541 HOLES
+1"II1
L" II
FILLER
CLAD
I$II(
-t
ACCESS DOUBLER
0.025 2024-74
CLAD
0.020 2024-74
I~t
1~-
(I+
3/1817701
j
1 )I
II+
II
II
ITYPJ
]1
It
Ilf~
II
~F
la "a
1 111
t~
II
710(1
1-1/8
LE SHIN
II
_
A~1
DIMPLE SHIN AHO WUBLER

DRILL NO. 2710.144) HOLES
RIVETS
052248-4, 2 STAODEREO
ROWS AROUND CUTOUT
DRILL NO.
2710.144 HOLES
RIVETS
082248-4
RALANCE
SECTION
t-
A-A
BALANCE WEIGHT
SCREWS
WASHERS
(II
10
IIL
7/16
11
II
WEIGHT
81509-105
AnOWI-IO
NUTS
8481291-8
13 EA REOO)
II
AEBALAWCING:LEFT AND RIGHT AILERDNS

BETWEEN -AS 43.000 AND 58.750
NOTE
INSTRUCTIONS FOR FABRICATION OF REBALANCE
S285-3-283
WEIGHTS ARE GIVEN ON SHEET 4.
Gdding Rebalance Weights

0
57-50-20
Page 207
Aug 17/84
MANIIAI,
REBALANCE WEIGHT
RH AeS 0.793
1-5/16
3/8
UNOERCUT
TO CLEAR BEAOIN REPAIR OOUBIER
APPROX 12 Sg IN.
3/4
1-13/32
5/8
7/18~
5/8[TYP)
~--23/8
I/
I-rBICI*IMLI
AEOO TO
I/el%8xl
11
-rr
THICKNESS AS REOO
TO1/2 IMAX)
1-
REBALANCE WEIGHT
LH ACS 1.000
3-3/4
Make
weights from 1010 steel bar
or
plate
as
applicable.
IITYPI
APPROX 8-3/4
10
SO IN.
0.
O
5/161TYP)
1-:
2-518
5/16
Cadmium-plate weights
Prime
weights
after fabyicalion
after fabrication.
3-1/4
/c~----
4-5/16
1/18
3 R
1/8
RI~ROIISOIII
1~
t
PICK UP HOLE LOCATIONS

FROM HOLES IN LEAOINC
1-5/8
7/1BITYP)
j~
THICKNESS AS:REOO
TO 1/211AXI
REBALANCE WEIGHT
AS143.000 T0:58,150
EOGE SKINS
IF HEQUIH1-D THICKNESS OF WEIGHT IS LESS THAN
516 IN
MAKE WEIGHT IN TWO PIECES.
57-50120
Page
szes-3-2a4A
Adding Rehala~s Weights

4 of 4)
Figure 204
208
Au~ 17/84
CSPYRIGHT, 1984 BY 8ABRELINER CORPORATION
NA-fiG-1032
STHII(:rllRAI, KEPAIH MANlrAL
SKIN
TRIM OAMAGE MIDWAY
IREFI
RIVET
BETWEEN EXISTING
FASTENERS
TO MATCH
REMOVED FASTENER
ITYPI
ITYPJ
---l,,rfr~.-.
-il~-..l
$7
cD
3/4 MAX
I:
CE,
__1
RIB
RIVET
MS20470A04
RIVET
SKIN
REOUIREMENTS
3/4 MAX
IRE FI
SEE RIVET
TABLE FOR
FILLER
SKIN (REFI
7/16[TYP)
FILLER
IIPITYPJ
REPAIR
DOUBLER
f
C~
i+
+f
f
f-
--f+
RIB
1-1/8
(TYPJ
1/2 R MIN
DISTRIBUTE RIVETS
FOR EA SIOE OF
SECTION
FILLER
A-A
MATERIAL
ANO GAUGE TO
AIVET TABLE
MATCH RIB
NO. REOD
RIB
RIVET
MITERIAL
EA SIDE OF
ICLAO)
GAUGE
MS20470
2024-73
0.020
404
2024-73
0.025
405
2024-T3
0.032
405
2024-73
0.040
405
2024-T3
0.050
006
2024-73
0.083
006
7075-76
0.020
404
1O
7075-T6
0.025
405
7075-T6
0.032
405
7075-T6
0.040
A05
7075T6
0.050
006
7075-T6
0.083
008
Rls
DAMAGE
REPAIR DOUBLER
MATERIAL TO MATCH RIB.
THICKNESS IS ONE GAUGE

HEAVIER THAN RIB.
Trimauldamage
01
FdbliEdte(epairpar(E
Heat-treat parts made from annealed materials.
NOTES
THIS REPAIR
IS APPLICABLE TO
O
O
FLANGED SHEET-
METAL RIBS WITH FLANGE WIDTH OF 3/4 IN. OR LESS.
Primereparparts
Inotallrgpsirpartp
USE A SPECIFIC REPAIR WHEN INDICATED IN THE

5265-3-270
REPAIR INDEX KEYS.
Aileron Rib
Figure
C~
Repairs
205
57-50-20
Page 209
Aug 17/84
IC A -(iCi-1032
S1Kl~("llrKAI, KI~IAIK MA~lrAI,
Ale
(REF
TYPI
TRIM DAMAGE
MIDWAY BETWEEN
EXISTING FASTENERS
UPPER SKIN
-C
I)
ii
1%
II
tt~
Ji I Ii
~(-t
le
LE
~k
cD
0.090 IREF)
II
~-FASTENER
ITvP1
FZOO JO-BOLT
OR ANSOB-lOdCREW
2 ROWS AEOOiEA SIDE
SKIN
rti
11
IC
(TYPI
OF OAMAGE
BALANCE
WEIGHT
AEPAIR
I(TYPI
DOUBLER
LE SKIN
I-t
In
reT
f,t
it
I-
tt
It
t
ii
li*PI
3/8 MIN
i~
ICPI,
eel
1,3- -L
_____
.UPPtA:SKINIAEF)
lb)
i,
LE REPAIR SKIN
NIBRICATION OETIILS
STATIC
1].063
~P
I+
--L7-I:
1/4 R
r-
"(Ji
I"j
Icl/Z
t
-M ~J /rt lilillTIPI
A
RtPllROOUBLER
Remove TE and loosen portions of upper and lowe~

skins
as
I~
:O
required
Trim off
damaged
LOWER SKIN
skin
IREFJ
Fabricate repair parts Make repair skin from

7075-0 neat-treat affer fabrication Machine and form aft
edges
of
repair
skin
as
shown
SECTION
Contour skin to match
A-A
removed section
Make repair doubler from normalized

material. Heat-treat after forming
UPPER SKIN
Cadmium-plate
Prime
repair parts
Temporarily
balance
IREFJ
repair doubler
TE
IREF)
Install
Alter balance
repair doubler
repair parts and check static
weight
and to achieve
as
necessary to fit inside
balanced condition
Install repair parts. relasten upper and lower skins.

and reinstall TE
LOWERSKIN
assembly
IAEq
Refinish repair In IllillCh SLllrOLlndlnS
illna5
REPAIR-SKIN
0.000:1075-T6
RARE
NOI~S
THIS
REPAIR
IS APPLICABLE TO AILERON
LE
REPAIR OOUBLER
0.050 4130 STEEL

HEATTREATEO TO
160.000 PSI
SKIN
BETWEEN AS 27 5 AND 64 AND OUTED OF AS 81 5

DOUBLER MAY BE MADE. USING THE DATA GIVEN
57-50-29
~ilelon
I,c!adinR 6dffoSkin
S265-3-271
:!cruf iFsria,leK
~O(i
Punc~lO
Auv 17/X4
~RERIGHT,
1984 BY SA8RELINER CORPORATION
NA-66-1032
STRUCTUKAI, RE:IAIR MAPil:AI,
TAIM OAMIGE MIOWRY
TE ASSY
IREF)
BETWEEN EXISTING
FASTENERS
TE BEAM
TE SKIN
r
-t
.I
REPAIR SKIN
I
(SEE
.i
o
++t
-C- c
+e
t -C
-e
SKIN
iI
i,
-t
~I
t- t-- t-
II
t-
--)1
$I
TABLE
3/8
ITYPI
i"
c
c -t
REPAIR STRAP
t C -C
-t -C-
TO
MATCH REMOVEO
1-1/4
FASTENER (TYPI
tolle P
3/8
-e
RIVET
LE SKIN (REFI
~11161
SECTION
LE
SKI~ IREFI
~UBLLA
-C -C -C
t- St
cj II
LRIPIIR
3/41TYP)
ibl
C.,
AIVET
TABLEI
-t
Ilt +t
--i
!Ilia
[REFJ
IREF]
A-A
C-J
SKIN
GAUGE TO MATCH SKIN
O
O
10
(O
II~I
Remove TE
Trimuff
assembly
necessary
damaged skin.
Fabricate and
temporarily
install repair parts
Check static balance and rebalance
as
necessary.
REPAIR STRAP
repair parts
assembiy(ies) as applicable.
as
Secure
in
place
and
replace
LE
TE
SKIN(AEFI
~y
2024-T3
t;03A02
REPAIR $OUBLER
0.032 2024-73 CLIIO
areas.
RIVET TABLE
NOTES
THIS REPAIR IS APPLICABLE TO UPPER AND LOWER
AILERON SKINS.
R1VET
ROWS
MS2O426AO4
082248-5
REPO
SPACING
7/8

PRESENTED IN THIS REPAIR.
S265-3272
Aileron Aft Skin Repairs

Figure 207
57-50-20
Page
211
Auff li/84
1V
S7Hl("llrKAI, KRI~IK MANLAI,
AILERON OUTBO
HINGE FITTING
All STA
IAS) 74.500
AILERON HINGE
TO 75.500
AILERON OUTBO
CLOSE-OUT RIB
i(EEFR
RIB ITYPI
,1
C~7
II
II
!II
ii
-dl
II
II
II
it
r
I
I
I
II
II
~b
---wtt
4~
rr
II
II
II
-U
,_J
ENLARGE HOLE IN GUlOf
DETAIL
TO 0.375 IN. TO PERM(T
PASSAGE OF REAMEA.
0.3:1 ;1:5 i(0.0000.
O.Oos:Ol OIA PLLOT
Rie
AS
AS
746(10
15 600
1.500
1.250
SUPPORT
ITYP)
INIERCOSTAL
ull
Ir(ll
ITYP)
FLUTE
LENGTH
0.375 1 t 0;00051
OIA BEANER
20.509
-11 RLAMER
ill
ISUGGESTEO CONFIGUAATION)
9 REPAIB BUSHING
ON PRESS TOOL NUT
ii
:9 REPAIB BUSHING
SHOWN
-3 PRESS
TOOL BUSHING
INSTALLEO\,Iuj,n
Il
11
Enlarge hole
in
Ream hales
Install -3
guide
on
close-out rib.
hingefilling
bushing
ruith
11
in reamed hole
reomei
on
one
sid~! of
fitting.
Install
Q
5 PRESS TOOL BOLT
1-5 ANB
-7 RETAILS
NAKE UP REPAIR
BUSHING PRESS TOOLI
I/
AND
tool
(detail A).
ign pressfoal in 9 busning nold

pressing repair bushing in place.
5 bolt and lum
WHEN-REPAIR BUSHING IS STARTED INHOLE,:PAINT
OUTER SURFACES OF BUSHING WITH ZINC CHRO:MATE PRIMER. AND INSTALL BUSHING WMILEpHIMER
IS WET
Remove press tool and -3
NOT~F=
TOOL
bushingon press
NOTI~
O
DETAIL
SEE
-9
-7 nut,
7 PRESS TOOL NUT
REPAIR
BUSHING
FABRICATION
tool
DETAIIS ON SHEET 2
bushing.
Repeat step 5 on opposite side of fitting with

aligned in installed repair bushing instead
press
of
-3
bushing.
S370-374A
57-50-20
Pa~e ~1L
Aug li/84
Ailcllotl :(_)utboard
Hin~e ~-n:Bushinff Hel,ail

of 2)
o
IG HT, 1984 BY
E L1N:ER %O RPORAT~I O N
NA-66-1032
0.3125 1~0.00051
l~t0.0051Ifi
0.312
0.035
0.3735
0.50 HEX
(+O.OOOO,
-o.wos) FOR -3
03785 (+O.OOOO,
0.530r0.300
18T09
0.3011 (4.0~0.
-o.ooos) FOR -g
0.0011
0.500
OAILL OWE WO. 310.213)

HOLE THBU
CSK
BREAK 0.005
TO 0.010
MAX ECCEWTBICITY 0.0I13 TIB
O.M)5 TO 0.015 R
0.250 OIA
BOTH EWOS. TAP 1/4-28
UWF 38 THBU, PITCH OIA
0.2288 1+O.O032, -O.OO001.
90"
-9 REPAIR BUSRlNG AND

-3 PRESS TOOL BUSHING
BREAK 0.010 TO 0.020
-7 PRESS TOOL NUT
a
O.lBl 1+O.OOO,
0.010)
0.030 R (2 PLIICESI
0.308 I+O.OOO, -0.001)
1I1
0.250
8.000
I+O.OOOO,
onw~ssl(il
t
0.005 TO 0.015 B
0.190I~I
O.1OO
1-0.125
0.3W
0.750
CHAMFEB 45"
x 0.030
THREAO 1/628 UWF -34, PITCH
OIA 0.22581+00000, -0.0025)
0.840
-5 PRESS TOOL BOLT

(MAY BE WELO ASSYI
BASH
WO.
IOMEICLATURE
-9
REPAIR BUSHIWO
-3
MATERIAL
HEAT-TREAT
3U8FACEFIWISH
(O
4130 STEEL
125 TO 145 KSI PER MIL
TUBE
SPEC MIL-H-OS75
PRESS TOOL BUSHIWB
4130 STEEL
TUBE
cane n
COWB n
-5
PRESS TOOL BOLT
4130 STEEL
BAR
COWB F4
-7
PRESS TOOL WUT
4130 STEEL
BAR
PEXI
125 TO 145 KSI

SPEC MILH-8875
COWO F4
MIL
125
125
1
NOTES
DIMENSIONS APPLY BEFORE PLATING. CADMIUMPLATE ALL SURFACES EXCEPT INSIDEDIA.
MAX ECCENTRICITY 0.003 TIR.
TWOREQUIREDFOREACH FITTINGREPAIR.
8370-3-75
Aileron Outboard Hinge Pushing Repair

0
57-50-20
Page 213
Aug 17/84
NA-66-1032
ale
(BEFI
TRIM DAMAGE MIBWAY BETWEEN EXISTING
FASTENERS. ALTER AS NECESSARY TO MAINTAIN

1/2 EDGE DISTANCE BETWEEN SPAR AND REAA
ASSYTRAILING
UPPER SKIN
EOGE
REAM.
II
SPAR
01
ol o (j o o c o o c, c; c
P_I- ---------------~C
~ltti+ittt++
fD
-t
-t
(D
-t
1,
t~
cR
t~3)
a~l
"I
t
t
FD
~3
(I)
I
c
-t
C-C
4,
c~i
Cf~
FR
C~
1~1)
Ii
REPAIR RIB
t~cf
e
-c
i
iTt
REPAIR RIB
-C
REPAIR
DOUBLER
Ct~t+S
REPAIR
tL+
0.50
SKII
ale
cT~
T~
EDGE
RIVET
TO MATCH
SKIN
REMOVED FASTENER
-II
IPIRIYOTHRU
0.875
SIDE OF SPLICE
SECTION
~S1
SECTION
0.32 ITYP EXCEPT

AS NOTED)
ITYPI
TE BEAM EA
RIVET
B-B
REPAIR SKIN
(MINJ REDO
EA SIDE OF SPLICE.
--------,Y~
rfj\
A-A
MS2O42OAD4
4 ROWS
s-
DIMPLE SKINS AND

REPAIR DOUBLER
0.032 LESS
LANIGRONAHT
BIB
CONSTANT
REAR BEAM
SPAR
L
REPAIR RIB
REPAIR DOUBLER
REPAIR SKIN
1.
RemoveTE assembly.
Trim off
3.
Fabricate repair parts. Repair rib is identical to the

original rib except as noted. Make rib from annealed
material and heat-treat to applicable "T" condition.
5.
Prime
0.020
2024-73 CLAD
2.
14.
IREFJ
$1~/80
~j
-I
LEAOING
IRE9
LII
Je_O.B7SIPIPI
-t
ale
ccoTi~
0.875 ITYPI
/UPPERSKIN
damaged skin.
LEADING EDGE
SKIN
IREFI
rTE
I yREPAIROOUBLEA
0.032
2024-73 CLAD
repair parts with MIL-P-23377C.
Install repair parts and refinish repair to match
surrounding
areas.
NOTES
This repairis applicable toflap upperand
lower skins ezcept in areas between pairs
of hinge and actuator ribs (i.e., between
FS 84. r69 and 873393; 111.9r4 and 118. 640;
and 148. 758 and 151.381).
REPAIR RIB -MATERIAL

ANO GAUGE TO MATCH
RIB BEING REPLACED
Anl smaller repair incorporating a onepiece doubler may be made, using the data
presented.
S265-3-273
Figure
299-
Flap Skin Repairs
57-50-20
Page
214
1Mar 16/90
NA-66-1032
LEGE~D
Eaisting Fasbener
Location
MS20426AD4 Fastener
Location (40 Ea)
CR3212-4 Fastener
Location (40 Ea)
ENO OF REPAIR OOUBLER

TRIM LINE
[TYPI
o.aO ITYP)
SiS
:fF--~-Y.+$
++il+Sj++S++F-+j-t
IT
-r--,---r--41-~-l-k
ii
4
+4
1]
s
5:
+I
1+1
+I
I$
i
I+
+I
r+i
0.47
ITYP]
u+j
fi
iC;
I
ii
-t
1+:
I
~+I
Y+
II
4,1
DOUBLERS)
-C
~I
\t
t
II,,
I,ti
a
II+I
CI
III
,t
:t/
Cc
1+1
C-r
\~f
lt
Ufi
I___+++tS~*_f~
t,
a
a
-23 AND/DR -25
-C
-t
1+1
0.35 ITYPI
+5
;I+
2024T3 CLAO
II~CI
I+/
It
REPAIR OOV5LER -0.MO
14
II$
1+1
,59~
a
,f
IREPLACES 265-180001
ii+I
;-r
f
e
;t_ltSYd;+
tl
(TYP)
a
cc-
i:
O.GM
2024-T3 CLAD
IT:
IITI
-t
0.70
Ilc
It
C+1
I~II
If~
I1C,
ij
1--4
iSJ
Il
r+
t
l(+i
REPAIR SKIN
11
t
t
;r
,t
1:
it
t+++++i+
o.sO [TYPI
FLAP TRAILING EDGE
FLAP STATION
[REF]
en.De ITvPI
DimPLE SKIN
AND AEPAIRf OGUBLER
damaged
NOTES
skin.
i.
Trimoff
2.
Fabricate repair parts and

fastener locations.
pick
up 80 additional
-I.
Use PR1131G Sealant bet~een mating surfaces.

Install
repair parts and refinish repair
surrounding
r4yair is applicable
to LH and RH
and
PS;zss-lsooss.
parts ~-ith
Prime
.5.
This
upy4, and lo~cer skin
3.
repair
to
match
areas.
Figure 209A
Flap Skin Repairs (Sonic Doublers)
JT
57-50-20
Page 214A/214B Blank
a
Mar 16/90
NA-fiG-1052
8I~KU<"IIIKAI, REIAIH MANIIAL
TO MATCH
REMOVEO FASTENER
TRIM OAMACE MIDWAY
(yyp)
FASTENERSITYP)
RIVET
BETWEEN EXISTING
-D-L~
L,-
RIB
SEE SECTION A-R
4~ j~j
FILLER
SKINIREFI
DOUBLER
IlelMiN)
f.c~
tjrl/4R
I
f+
+~t
-C
2 TIMES RIVET
TO SKIN-TO-RIB
SPACING (OR 5 TIMES
RIVET 0IA
MIN)
EOUAL
OIA
IE
RIVET
FOR
AND GAUGE TO MATCH
REOUIREMENTS
MATERIAL
FILLER
RIVET TABLE
REPAIR DOUBLER
MATERIAL TO MATCH
1~
SKIN
RIB.THICKN~SSIS
FILLER
LTIMLSRIVET
I--W
RIVET
If
2024-T4
SHIM
CLAD --THICKNESS
ONE GAUGE HEAVIER
DIA
RIB
RIB
RIB REPAIR
DOUBLER
nscoo
SECTION
RIB
B-B
DETAIL OF
CHEM-MILLED ale (ENLARGEOI
I-w
O
O
O
O
RIVET TABLE
RADIUS
NO. REOO
1-1/2 TIMES
Trimoutdamage
FS
RIVET OIA
RIVET
MS20470
Form flangsd parts fl~m

Fabricate repel, pans
annealed material and heat-treat to applicable~T" condition
after
ENO OF
forming
SECTIONA_A
IENLARGERJ
Primsrepairparlp
lnS18111.pBilp8nZ
N(~1ES
IHIS REPAIR IS APPLICABLE TO FLAP RIBS LISTED IN
RIVET TABLE
WHEN DAMAGE IS TOO CLOSE TO EITHER END OF RIB
TO
INSTALLATION
PERMIT
(EACH
SIDE OF
GATED
MATCH
REQUIRED
RIVETS
A NEW RIB MAY BE FABRI-
MATERIAL AND GAUGE OF NEW R1B MUST

RIB
MATERIAL
MILLED
DAMAGE),
OF
BEING
NEED
NOT
REPLACED
BE
THINNED
EXCEPT
(AS
IN
THAT
CHEM-
RIBS)
EA SIDE OF
DAMAGE
79.269
AD4
)O
s4.w1
~os
to
87.393
AD5
11
92.233
AD4
10
97.074
A04
10
101.914
AD4
10
106.774
A04
10
111.974
006
114.344
006
119.640
006
123.840
AO4
1O
128.846
AD4
10
133.802
AD4
10
139.757
AD4
10
143.713
AD4
10
148.756
405
151.381
006
156.981
AD4
10
162.381
AO4
10
S265-3-274
Flap Kih Itepairs

Fiffure ~10
57-50-20
Page
215
Aua 17/84
NA-6Ci11032
WING INBO TE SEAL ASSY
MS2M70~03
GRILL OUT ANO REPLACE
WITH MS20800AM
RIVET
WING INTERMEOIATE TE
lNRO SEAL ASSY

4 NO1 10 SCHEWS
INBOINTMEO
SEAL ASSY
BNO. )O SCREWS
OUTBOINTMED
SEAL ASSY
6 NO. 10 SCREWS
OUTRO SEAL
SEE VIEW A
rl
SEAL RETAINER
ANGLE
NAS1O97AO8
IOR WASlOglDMI)
BI-t
.C7
Q
RIVET
SEAL SUPPORT
VU
CJ
RIVET
VIEW A
n15108784
RIVET
THRU SEAL RETAINERS
THRU
SEAL RETAINERS,
SEAL. ANO SEAL
(SEE EXCLGOEO
VIEWS)
ANO SEAL
SUPPORT ANGLE.
FLUSH FAR SIRE
(TYP).
SEAL ANO SEAL

RETAINER RIVET
SEAL SUPCORT AWQLL
SEAL RETAIWeff
SEAL ASSY RETAINING

RIVET
SECTION
A-A
SECTION
To
lemave
remove screws or
B-B
seal assemblies fmm either TE
drill out
NOTE=S
attaching
rivets
as
assem
Drill out rivets ettsching seal retainers

assembly (intermediate TE seals).
THIS ILLUSTRATION PROVIDES INSTRUCTIONS FOR

REPLACING ALL FLAP SEAL ASSEMBLIES.
El
ALL FLAP SEAL ASSEMBLIES ON WING INTERMEDIATE

TE EXCEPT OUTED ASSEMBLY, ARE INSTALLED WITH
new
SCREWS. OUTED ASSEMBLY IS RIVETED. RIVETS ARE
EXCEPT FOR MOUNTING FASTENERS.
to
Rebuild all intermediate TE seal assemblies,
sssi
using
rubber/fabric seals.
FLUSHED ON INNER (FWD) SIDE. THIS ASSEMBLY IS

ILLUSTRATED IN DETAIL. OTHERS ARE SIMILAR
bly.
applicable.
Reassemble intermediate TE seal assemblies
as
shown.
FLAP SEALS ON WING INBD TE ARE INSTALLED WITH
3/32 IN
EI
DRIVEN RIVETS.
Rebuild inbd TE seals,
using
new
Reinstall inbd TE seal assemblies
rubber/fabric seals.
as shown
5265-3-275
57-50-20
Page 216
Aua 17/84

Figure 211 (~et 1 of 2)
o
NA-66-1032
STRZICTURAL REPAIR MANUAI,
00 NOT USE THIS HOLE
GRILL FOR 8820470800 RIVET
SEAL SUPPORT
ANGLE
a,
s&)
8820470406
USE IN THIS HOLE ONLY
RIVET
0
O
~h
SEAL RETAINER
QQ
IlmERI
rRlm FneAle ro m~TcH
REMOVED PART (TYP)
~Q
8,
0"
o
O)
QP
(3
09
OP
SEAL RETAINER
louTq
,8
SEAL AWD 8EIL
RETAINER ASSY
--J
DIMPLE INNER
RETAINER FOR 3/18 IW.
COUWTERSINK
OUTER RETAINER.
FLUSH FAR SIDE.
THIS HOLE ONLY.
RIVET
SEAL
WIND INDD TE
8E1L
\3
8EAL SUPPORT
WING INBG TE
SEAL ASSEMBLIES
5285-3-278

0
57-50-20
Page 217
Aug 17/84
NA-66-1032
RIVET
3
OF SPLICE, DIMPLE SKIN

AND REPAIR~OOUBLEA
C~ A
REPAIR SKIN
ti
tl
-I-
t-l-F
It
I,
,L___
I
ii
I-e
c
ILP
gll
ttl
I-C
Ci
-t
~I
lol
I
I
-~1_
lol
Is/lslTn
-tic -C
OOURLER
lol
+I
-t
REFAIA.
lol
t
c
JrRIB(REF)
I~I
I=I-
c+
-e
REPAIR SKIN
SLAT SKIN
-e
I -:t
MS204281~05
ROWS1RE00iEA SIDE
lot
INNER SKIN
IREF)
t
is
I~
le~
I~C
81
i-
It
~-I+-
clC
tl
cl
i-
ct
--jfL
IPJOGBLE~ASREOO
(TYP EA END DF
REPAtRDOURLERI
RIVET EDGE DISTANCE
-I
lonlrcwr.r
OF OUTER SKIN
RIVET
TO
aEVeMERHCTAM
FASTENER
TE
PB:.-:
REPAIR DOUBLER
ITYP EA ENO
OF REPIIIROOUBLER)
IREFJ
TRIM OAMAOE
MIDWAY .DETWEEH i:
EXISTIHO:FASTEWCRS
SECTION
A-A
AEPAIRSKIW0.040 2024-73
CLAD
10
O
O
Remove slat inner skin
Trim off
outer skin.
Fabricate repairparts
Install
Oj
damaged
repair parts
Refinilh
repair
REPAIR:DDWBLEA
0.050.2924.T3
and reinstall inner skin.
to match
sllrroundlng
CLAD
areas
INNER SKIN
IREF)
NOTE
VIEW ROTATED 180"
A COMPLETE SKIN SPLICE IS SHOWN. ANY SMALLER
TE
IREFJ
FOR CLARITY
REPAIR INCORPORATING A ONE-PIECE DOUBLER MAY

BE MADE. USING REPAIR DA1A GIVEN.
57;59-20
Page 218
Aug 17/84
Slat
Fi~ure %;lei(S~ed 1 Of 2)
o
GQ~RIGHT, 1984 BY SABRELINER CORPORATION
NA-66-1032
AC1
OUTER SKIN IREF)
l"i
I
I
I o;
REPAIR OOUBLER
(ol
olO;o
IOi
I++clt++!~-:
!O;
It
t-
+f-t
io
;ol
_t
~tl:
-*I I-
loi
!Oi
I+
o
7ns
le~l
ITyP)
REPAIR SKIN
lol
/10i
io
O
1~1
ti
I~ a/4 (TYP)
I+
or
I~ 13/i6 PYP)
tl
$I
t/
i i4!
JOOGLE AS
REOO
t!
cl+
t
~lf4
RIVET EDGE
DISTANCE TO
MATCH THAT OF
OUTER SKIN
InHrR swlw
SECTION
TO MATCH
RIVET
A-A
TRIM DAMAGE MIDWAY
REMOVEOFASTENER
BETWEEN EXISTING
(TYPI
FASTENERS
032248-5
RIVET
3 ROWS REOO EA SIDE
OF SPLICE; DIMPLE
SKIN AWO REPAIR
DOUBLER.
REPAIR SKIN
J OALC3T-420
0.040
nemove liMI.
holding
outer nbin to inner skin
as
necessary.
O
O
O
O
Trim off
damaged
Fabricate
Install
innerakin
rspaiiparls
repair partaand rot asten loosened outer
Refinish
repair
to
matoh surrounding
skin
areal.
REPAIR DOUBLER
0.050 2024-T3
CLAD
NOTE
OUTER SKIN (REF)
A COMPLETE SKIN SPLICE IS SHOWN. ANY SMALLER

REPAIR INCORPORATING A ONE-PIECE DOUBLER MAY
BE MADE. USING REPAIR DATA GIVEN.
s265-32ee
Slat Skin Repairs

57-50-20
Page ~19/220 Rlank
Aug 17/84
CHAPTER
EXHAUST
NA-66-1032
STRUCTURAL HEPAIR MA~UAL
CHhPTER 78
EXHAUST
TABLE OF CONTENTS
Subject
Exhaust Stuctural Identification
General
Chaptel/Section/Subjeet
Page
78-00-00
1
Structural Identification.,
Thrust Reversel
78-30-00
General
Thrust Reverser Component Locator
Model NA 265-40, -60, -60A, -60SC, and -iO
(S/N 370-2 thru 6, -8 and -9)
Thrust Reverser
Allowable Damage
78-30-10
Genelal
Model NA 265-40, -60, -60A, -60SC, and -70
Wear Allowances
(S/N 1!70-2 thru -6, -X, and -9)
Thrust Reverser
78-30-20
Repairs
(;eneral
Thlust Reverser Deflector or Doors Contact Requirements
Model NA 265-40, -60, -60A, -60SC, and -70 (S/N 370-2 thru -6, -8, and -9)
Model 265-40, -60, -60A, -60SC, and -70 (S/N 370-2 thru -6, -8, and -9)
~icpairs
Thrust Reverser Support Cradle NA 265-70, (S/N 370-1 thru -7), -80, -80A, and -80SC
.........,.,._.,
201
201
201
801
78-COMTEWTS
Parre 1/2 illank

Aua 17,84
NA-66-1032
CHAP~ER 78
EXHA~ST
Section
78-30-00
Page
Title
Figure
Thrust Reverser Component Locator
Model NA 265-40, -60, -60A, -60SC,

2
and -80
78-30-10
101
102
104
105
106
78-30-20
201
202
203
204
205
206
207
208
209
210
211
Thrust Reverser Door Latch Hook and Latch Hook Pivot

Wear Allowances
Pin, Model NA 265-40, -60, -60A, -60SC and -70 (S/N 370-2 thru -6, -8 and -9)
Thrust Reverser Guide Pins and Guide Pin Support
Wear Allowances
Fittings Model NA 265-40, -60, -60A, -60SC and -70 (S/N 370-2 thru -6, -8
and -9)
Thrust Reverser Drive Link Rogie, Bogie Tubes, and
Wear Allowances
Model NA 265-40, -60, -60A, -60SC and -70
Outboard Support FittinRs
(S/N 370-2 thru -6, -8 and -9)
Thrust Reverser Deflector Door Drive Link and Drive
Wear Allowances
Model NA 265-40, -60, -60A, -60SC and -70 (S/N 370-2 thru
Link Bearing
-6, -8 and -9)
Thrust Reverser Upper and Lower Deflector Door
Wear Allowances
Model NA 265-40, -60, -60A, -60SC and -70 (S/N 370-2 thru -6,
Longerans
-8 and -9)
Wear Limits
Thrust Reverser Door Latch Hook Model NA 265-40, -60,

-60A, -60SC and -70 (S/N 370-2 thru -6, -8 and -9)
Thrust Reverser Deflector Door Rework to Provide Proper Contact

Model NA 265-40, -60, -60A, -60SC and -70 (S/N 370-2 thru
Requirements
-6, -8 and -9)

Thrust Reverser Door Latch Hook
Wear Damage Repair

Model NA 265-40, -60, -60A, -60SC and -70 (S/N 370-2 thru -6, -8 and -9)
Thrust Reverser Door Latch Hook Bushing Installation, Model NA 265-40,
102
103
104
105
106
107
201
203
-60, -60A, -60SC and -70 (S/N 370-2 thru -6, -8 and -9)
Model NA 265-40,
Outer Skin Repair
Thrust Reverser Deflector Door
-60, -60A, -60SC and -70 (S/N 370-2 thru -6. -8 and -9)
Model NA 265-40,
Inner Skin Repair
Thrust Reverser Deflector Doot
Model NA 265-40.
Thrust Reverser Deflector Door Forward Frame Repair
Thrust Reverser Deflector Door Forward Frame End Repair Model NA 2S~Fi40, -60, -60A, -60SC and -70 (S/N 370-2 thru -6, -8 and -9)
Motlel NA 265Thrust Reverser Lower Deflector Door Loose Jo-Bolt Repair
204
40, -60, -60A, -60SC and -70 (S/N 370-2 thru -6, -8 and -9)
Thrust Reverser Support Channel Repair (140-54301-35, -37, -47, and -48)
Model NA 265-40, -60, -60A, -60SC and -70 (S/N 370-2 thru -6, -8 and -9)
Model NA
Thrust Reverser Support Channel Repair (140-5401-73 and 75)
265-40, -60, -60A, -60SC and -70 (S/N 370-2 thru -6, -8 and -9)...............
Model NA 265-70, (S/N 370-1 and -7), -80.
Thrust Reverer Support Cradle
209
-80A, and-80SC
205
206
207
208
210
211
212
78-ILLUS
o
Page 1/2 Blank

Aug 17/84
NA-66-1032
CHAPTER 78
EXHAUST
Chapter/
Page
Section
Date
16/90
78-L.FJ.P.
1/2"
Mar
78-CON~ENTS
1/2
Aug 17/84
78-ILLUS.
1/2
Aug 17/84
78-00-00
1/2
Aug 17/84
hug 17/84
Aug 17/84
78-30-00
101
78-30-10
102
103
104
105
106
107/108
78-30-20
201
202
203
204
205
206
207
208
209
210
211
212
213/214
Aug
Aug
Aug
Aug
bug
Aug
Aug
17/84
17/84
17/84
17/84
17/84
17/84
17/84
Aug 17/84
hug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
or
78-L.E.P.
oCOpyRIGHT,19908YSABRELINERCORPORATION
Page 1/2 Blank

Mar16/90
NA-66-1032
CHAPTEIE 78
EXI-IA~ST
(;ENERAI,
This chapter contains information and repairs for

components of the exhaust.
78-00-00
0
Page 1/2 Blank

Aug 17/84
NA-66-1032
THRUST:: RE~ERSER
GENERAL
The engine thrust reverser system is used to decelerate
the airplane during landing roll by diverting the engine
exhaust gases forward, thus creating a breaking effect.
On model NA 265-40, -60, -60A, -60SC and -70 (S/N 370-2
thru -6, -8, and -9) equipped with thrust reversers this is
accomplished by two doors (targets) attached to the rear
of the tail pipe. When the doors are deployed (reverse
thrust position), the exhaust gases are diverted fwd above
and below the engine pod. The doors, when stowed, form
the aft section of the engine cowling. The doors
operated (stowed
or
deployed) by
hydraulic
are
actuator.
The actuator is connected to a main drive link (bogie),

which in turn is connected to each door through driver
links.
On model NA 265-70 (S/N 370-1 and -7), -80, -80A, and
-80SC the reversing elements consist of cascades and
blocker doors which are nested between the exhaust
nozzle and cowling during normal engine operation, but
which are extended to a position aft of the exhaust nozzle
to provide reverse thrust.
THRUST REVERSER COMPONENT LOCATOR

MODEL NA 265-40, -60, -60A, -60SC, AND -70
(S/N 370-2 THRU -6, -8 and -9)
See figure i. The figure identifies the components of the
thrust reverser.
78-30-00
0
Page 1
Aug 17/84
N A-GCi- f 032
STR~(lrlTRA1. ~EPAIR MANUAL
TOP OEFLECTOR: DOOR
ENGINE ACCESS 000R-
EXHAUST
NUZZLE
DRIVER LINK BOLT
0OOR
\Y
j;:
BOGIE GUIDE TUBES
e
a
fsco
ATtABH BOLTS
R0 )TNIDP
IHINGE
s:l
e4"j
~i;! ri
OUTBO WIIRING
ISTANO)
BOO1E
d:
B~TOM OEFLECTOA DOOR
THRWST IEI~R;SER
OUTB;B VIEW
OOOl LATCH AND
,s
INBO FAIRING
(STAIIGI
LATCH INSPECTION
HOLES
SECONDARY LATCH
UNLOCK SOLENOID
BOOR LATCH STRIKER
THRUST REVERSER
IHgD VIEII~\
s?as-3-35o
78-30-00
Paae
.L\u# 17;;84
Thrust Reverser
Model NA 265-40, -60,
(S/W ~70-2 thru~
Eocator
-608C, and -70
-6,-8, and
ssUgiF)9P
gj
1984 BY S~BRELINER GORPORATION
NA-66-1032
BTRUCTURAL, REPAIR MANUAL
THRUST RE-VERSER
ALLOWABLE DAMAGE
(;EN ERA I,
thrust reverser.
MODEL NA 265-40, -60,

WEAR ALLOWANCES
370-2 THRU -6, -8,
-70
AND
(S/N
-60SC,
-60A,
AND -9)
Fiffures 101 thru 106 show specific wear areas of the

thrust reverser components and tables which provide
wear allowance for each area.
78-30-10
0
Page 101
Aug 17/84
NA-66-1032
O
DEFLECTOR DOOR LATCH HOOK
LATCH HOOK PIVOT BOLT
----lm~
I,n--
--._-
1.-
WEAR ALIOWAMCES
OESCRIPTION
OEFLECTOR BOOR
LATCH HOOK
LATCH HOOK
PIVOT BOLT
PART
II11
HOLE
MIN
MAX
ALLOWANCE
140-5442
0.3150
0.3190
0.002
140-5424
0.3110
0.9120
0.003
Paffe lot
Au~ 17/84
MAX WEAR
5285-3-338
Wear Allowances
78-30-1 O
MFG ALLOWANCE
NUMBER
Thrust Reverser Door Latch Hook and

Latch Hook Pivot Pin, Nodal NA 265-40, -66,
ellA, aoSL and
thru 6. Y. and -9)
QQPVRI~HT, 1984 BY 8P89ELINER CORPORATION
NA-66-1032
STRI!CTURAI, KEIAIR MANUAI,
GUIDE PIN
O
00O
GUIDE PIN SUPPORT FITTING
WEAR ALLOWANCES
DESCRIPTION
OUIOE PIN
CUIOE PIN
SUPPORT FITTING
MFO ALLOWANCE
MAX WEAR
PART
NUMBER
OIA
HOLE
MIN
MAX
ALLOWANCE
1405481
0.3740
0.3745
0.014
140-5478
0.3860
0.3900
0.014
8261-3-395
Thrust Reverser Guide Pins and

Wear Allowances
Guide Pin Support Fittings, Model NA 265-40, -60, -60A,
-60SC and -70 (S/N 370-2 thru -6, -8, and -9)
Figure 102
78-30-10
Page 103
Aug 17/84
NA-66-1032
STRITCTURALREPAIR MANUAL
if
a
-8
BGGIEiDBIVE L1NK
t
OIM A
BOGIE TUBES
OUTBOARDSPPORT FITTING:
WEAR:ALLOWIIQES
DESCRIPTION
DOGIE-DRIVE LINK
MFG ALLOWANCE
PART
NUMOEA
:O1A
HOLE
140-5441
0,3174.
140-5484
B
C
0,3144
0.5045
MIN
MAX;
MAX WEAA
ALLOWANCE
0.3164
0.3164
0.002
0.5130
0.010
0;002
ROGIE TVDES
140-54112
9.4978
0.4995
0.002
OUTBO SUPPORT FTG.
140-5407
O.WW
0.5035
0.006
1405439
szes-a-339
Wear Allowanccs
78~30-1:0
t:affcl 114
Aua::17/84
Thrust R~verser.Drlve Link Huffie,

Ro~Sieluhes, and: ()utbo~,rcl;8t4Dport FSl~injis
Model N 72 286-10; -811, ~(3&4,i -86181: Hnd -7()
:(S/I\r:170-2 611 ru -(i;;-H1 ::lntl i!))
C~R!PGHT,:
1984 BY:~;R:EL;INER CORPO.RATION
NA-fiG-1032
STRUCTURAL KEIAIR MANUAI,
DOOR-DRIVE LINK
DRIVE LINK BEARING
WEAR ALLOWANCES
OESCRIPTIBN
0003-53192 LINK
RRIYE LINK BEARING
MFO ALLOWAIQ
PART
NUMBER
OIA
HOLE
MIN
MAX
MIX WEAR
ALLBWANCE
140-5409
0.5935
0.5940
0.0005
140-5410-1
0.3120
0.3125
0.3140
0.3145
0.5920
0.5930
0.5915
0.5920
140-5410-3
140-5410-1
140-5410-3
NOTE
140-5410-3 BEARING MAY BE USED TO REPLACE 1405410-1 BEARING
140-5410-1 BEARING MAY NOT BE USED TO REPLACE
140-5410-3 BEARING
5265-3-338
Wear Allowances
Thrust Reverser Deflector Door Drive Link and
Drive Link Bearing
Model NA 265-40, -60, -60A,
-60SC and -70 (S/N 370-2 thru -6, -8, and -9)
Figure 104
0
78-30-10
Page 105
Aug 17/84
NA-66.1032
R,
fI\II- I
,_.1
cAM
~A
__R_C~L_
r
SECTION B-R
SECTION A-A
WEAR ALLOWANCES
OESCRIPTION
UPPER OEFLECTOR
R00R LONGERON
LOWER OEFLBTOR
000R LONGERON
FIAT
NUMBER
DIA
HOLE
140-5405
140-5437
140-5405
140-5437
MFG ALLOWANCE
MIN
MAX
0.3125
0.3185
0.3154
0.3134
0.3125
0.3134
140-5406
1405438
140-5406
140-5438
0.3125
0.3134
0.3125
0.3134
MAX WEAR
ALLOWANCE
0.002
0.002
0.W)2
0.002
0.3165
0.3154
0.3185
0.002
0.002
0.3154
0.31 85
0.002
0.002
0.3154
NO
I~
MAXIMUMGAMWEARNOTTO EXCEED0.0101NDEPTH.
s2es-3-a37
78-30-10
Page 106
Aug 7.7!84
Wear Allowances
Thrust Reverser Upper and Lower
Deflector Door Longerons
Model NA 265-40, -60, -60A, -60SC and -70
(8/N:370-2 thru -6, -8, and
erugiF)9106
COPYRIGHT, 1984
NA-66-1032
STHUC:IIIKAI, HISPAIK MANUAI,
0.430
MIN
0.005
MAX
WEAR0.005
MAX
0.020MAX
WEAR
WEAR
WEAR
WEAR
In
WEAR
I
0.005
MAX
0.005
MAX
(TYPI
(TYP)
0.520 MIN
WEIIRIREIS
NOTE
IF
WEAR
LIMITS
ARE
EXCEEDED, REMOVE DOOR
LATCH HOOK AND REPAIR AS SHOWN IN FIGURE 202,

78-30-20 OA
REPLACE WITH A NEW DOOR LATCH
HOOK.
5265-3334
Wear Limits
Model NA 265-40, -60, -60A, -60SC and -70
(S/N 370-2 thru -6, -8, and -9)
Figure 106
e
78-30-10
Page 107/108 Blank
Aug 17/84
NA-66-1032
STRUCTURAL REPAIR MANCAL
THRUST REVERSER
REPAIRS
(;ENERAL
?his section contains
repairs
to the thrust
reverser.
THRUST REVERSER DEFLECTOR DOORS

CONTACT REQUIREMENTS
MODEL NA 265-40, -60, -60A, -60SC, AND -70
~70-2 THRU -6, -8, AND -9)
(S/N
See figure 201 for methods of

for proper door contact.
reworking deflector doors
MODEL NA 265-40, -60, -60A, -60SC,

REPAIRS
AWI) -70 (S/N 370-2 THRU -6, -8, AND -9)
See figures 202 thru 210 for

anti components.
repairs to the thrust reverser
THRUS1 REVERSER SUPPORT CRADLE

WA 265-70, (S/N 370-1 THRU -7), -80, -80A,
AND -80SC
See
figure 211.
78-30-20
o
Page 201
17/84
Aug
NA-66-1032
IN. ~e3 1N.
DOORS
(OEPLOYEO)
FORM THIS AREA TO

OBTAIN CORRECT DEFLECTOR
DOOR CONTACT
DEFLECTOR DOOR
AFT CHANNEL
AFT CHANNEL
(REFI
OUTER SKIN
INNER SKIN
IREF)
(REF)
OUTER SKIN
NO. 19
lO.lss) HOLE
12 PLACES EA OOOR)
i~ O
IAEF)
)0
IIW.IMIW)
10
INNER SKIN (REFJ
9.030 TO 0.080
OAF
0EFLECTOR OOOR LONOERON
TO OBTAIN
CORRECT CONTACT REQUIREMENTS

BETWEEN AFT CHANNELS OF UPPER AND LOWER
DEFLECTOR DOORS, FOLLOWING PROCEDURES
SHOULD BE UTILIZED AS APPLICABLE.
(3)
IT ISACCEPTABLETOCOCALLYGRINDAFT
FACE
OF DEFLECTOR DOOR AFT CHANNEL TO OBTAIN
CORRECT CONTACT REQUIREMENTS. DO NOT
REMOVE MORE THAN 0.033 IN. FROM FACE OF

AFT CHANNEL. THICKNESS OF AFT CHANNEL IS
0.063 AND A MIN OF 0.030 MUST REMAIN AFTER

GRINDING.
NO1I~
(b)
0.06 MAX IN.
(DOORS DEPLOYED AND HYDRAULIC

PA ESSU R E ON). PHYSICAL CONTACT M UST OCCUR AT
CL OR SOMEPLACE WITHIN 3 IN OF EITHER SIDE OF
CL MIN GAP OF 0.020 IN. MUST BE MAINTAINED FOR A
ABOVE
ILLUSTRATION.
(SOME DEFLECTOR
DOORS ALREADY HAVE HOLE AND SLOT IN
THEM.)
REFORM AFT CHANNEL TO CLOSE UP

0.030 TO 0.060 WIDE SLOT TO A ZERO IN WIDTH
SLOT.
DISTANCE OF 3 IN. ALONG TRAILING EDGE FROM

OUTER ENDS OF DOORS.
78-30-20
OUTER ENDS OF DEFLEC~OR DOOR AFT

CHANNEL MAY BE REFORMED BY DRILLING A
HOLE AND CUTTING A SLOT AS SHOWN IN
Thrust Reverser Deflector Door Rework to

Provide Proper Contact Requirements
Model NA 265-40) -601 -(iOAi-GOSCi and -70
(S/N 370-2 thru -6,
,and -9)
82653-342
eruf iF,8-
201
Pa#e 202
pua
17/34
COPYR:IGHT,
N~-Ci6-IOf12
REPAIR MANIIAI,
0.230 MIN
O.Oso R
ITYP)
0.020 MAX
0.12 R (TYPI
j
0.82 OIA
SPOTFIICE
O.ss (TYP)
0:
0.030 RAOIUS
ON CUTTER
~ili
0.080 R
0.8
0.500 MAX
ITYP)
I-i
0.170 MIN
0.220 MAX
0.080 MIN
NOTES
LIMITS SHOWN
ARE
MAX ALLOWABLE
MACHINING
DEPTHS. DO NOT MACHINE TO MAX EPTH
IF IT IS
NOT NECESSARY.
ALL MACHINED SURFACES TO BE
125
FINISH OR
BETTER.
IF DAMAGE EXCEEDS MAX ALLOWABLE MACHINING
DEPTH, REPLACE DOOR LATCH HOOK.

MACHINE DOOR LATCH HOOKS TO REMOVE WORN
AREAS.
8285-3-541
Wear Damage Repail

Model NA 265-40, -60, -60A, -60SC, and -70
(S/N 370-2 thru -6, -8, and -9)
i
Figure
0
202
78-30-20
Page 203
Aug 17/84
STKUCTUKAL REPAIR MANUAL
BUSHING TO BE
FLUSH WITH
,BUSHING TO BE
FLUSH WITH
THIS SURFACE
~I
THIS SUBFACE
REAM TO 0.375 TO
0.379 IN. OliR
Ream oversize
hole in door latch hook to 0.375
pivot
toi)379 in. dia
Manufacture repair
Bushing
Coat repair
still
bushing
wet.pres repair bushing
bushing
from
321
CRES.
must have an 0.001 to 0.0015 in, interference fit.
It
with zinc ch romate
into door latch hook
primer, then
while primer is
0.030 MIN
0.315 TO .319
f
Machine
repair bushing flush
with both sides of door
BEPAIR BUSHING
MAKE FROM
latch hook.
-i I
321 CArS.
Ream
repair burhing
I D to
required dimension
W3163
NOTE~S
ALL MAC~IINED SVRFACES ARE TO
BL~OR
BETTER
MACHINE O.D. OF BUSHING TO CREATE AN 0.001 TO

0.0015
IN.
INTERFERENCE
FIT
BETWEEN
BORE OF
HOOK AND BUSHING O.D.

5285;3-3~0
78-30-20
Thrust Reverser I)oor Latch Hook Rushing Installation,

Model NA 265-40, -60, 60A, -60SC, and -70
(S/N -2 thru -6, -8i and
erugiF)9203
PaKc 204
Aug 17/84
COPYRIGHT,
t 984 BY SABRELINERCORPORATION
NA-66-1032
FASTENER SPACIIIC 4 TO 6 TIMES

FASTENER OIA
5/8 MIN
ITYPI
PICK UP EXISTING FASTENERS
EB
FASTENER EOGE
OISTANCE IS 2 TO
2-1/2 TIMES FASTENER
RIA
ITYPI
~e
e~
-t
+t
3/8 R 1
~___-J
082538-4
RIVETS
7~
i-
-t
$ONEL-AMOUNTOF
RIVETS REOR IS
-t
DETERMINED BY
SIZE OF REPAIR
~e
o
ORIVEN RIVETS
Trim out
damage
or
stop
drill cracks
PULLRIVETS
Smooth all
edges and
radius all
corners
of damage
REPAIR OOUBLER
cutout
Make
repair
repair
doubler from 0.040 A286 CRES. Form
doubler to match contour of outer skin at
damaged
Chamfer all edges of repair doubler.
Heat-treat
passivate repair
Layout
Pick up
repair doubler
to a min of 140
REFLECTOR OOOR
OUTER SKIN
KSI, then
doubler.
and drill fastener
existing
pattern in repair doubler.
fastener locations wherever
possible.
at existing fastener locations

repair doubler for 1/8 dia flush fasteners at
Dimple repair doubler
and counter sink
all other fastener locations.
MAKE FROM 0.040

3285 CRES
O
area.
j;
Install repair doubler using CR2538-4 blind monel
pull rivets.
When
CR2538 the
picking up existing fastener locations
same
size
as
use
removed rivet.
NOTE
THIS REPAIR MAY BE ADAPTED TO ANY AREA OF THE
DEFLECTOR DOOR OUTER SKIN.
TRIM OUT OAMAOEO AREA
5265-3-343
Outer Skin Repair-Model NA 265-40, -60, 60G, -60SC, and -70

(S/N 370-2 thru -6, -8, and -9)
Thrust Reverser Defleetor Door
Figure
0
204
78-30-20
Page 205
Aug 17/84
NA66-I032
a>
FAST~NEA EOGE OISTANCE
2 TO 2-1/2 TIMES FASTENER
OIA
ITYP)
4>
i-
Il-t
-t
c~
t II
U~
FnsrEnERs
S+flT
5/11 MIY
tilt
fll I
-t
~V
t
1~+
liB
PICKU~UISTIWO,
ORIVEN RIVETS
PULLRIVETS
I"
I+
+t
I+
Ilt
1-+
Ff;
c~
tllj~itll
t
t
-t~
14
~It
RIVETS
84213980-4 MONEL
AMOUNT OF RIVETS REOO
OETERMIWEO BY SIZE OF
-t
-t
+t--e
.-----.-LL
I-
REPAIR
a~
-t
FASTEN~R:SPACING 4
TO g TIMES
FASTENER:DIA
Trim out
damage and/or stop
Smooth all
edges
drill all cracks.
and radius all
corners
of
damage
cutout
JOOGLE ABAIR OOUBLER

0.032 OEEP BY 5/8 WIOE
TO CLEAR:ANOLE
Make repair doubler from A286 ORES. Form repair

doubler to match contour of deflector door inner skin.
Joggle fwd end of repairdoubler0.032 by 5/8 in. Joggle run
out to be 1/8 in.
Heat repair doubler

passivate repairdouble~
to
min
of
140
KSI, then
Ell
Drill out
existing fasteners
that will be located cinder
0~
repair doubler
r;l
monel
/O
Layout and drill fastener pattern in repair doubler.

Pick up existing fastener locations wherever possible.
Fasten
repair doilbler in place using NAS139864

pull rivets at all new fastener locations Install
NAS1398C-5 monel pull rivets in all
existing fastener
REPAIROOUBLER
locations
MAKE FROM
8.840-1288 ORES
NOTE
TRIM OUT
REFLECTOR
THIS REPAIR MAY BE ADAPTED TO ANY AREA OF THE
OAMAOEO
OOOR INNER
DEFLECTOR DOORS INNER SKIN BY EITHER OMITTING
AREA
SKIN
OR CHANGING JOGGLE LOCATION
S265-3-344
Thrust Reverser Deflectbr Deer

Inner Skin Repair
Model NA 2651-49, -60, -6~W, 60SC, and -29
(S/N R70-2 thru -fi,:-ll, and
i
78-30-20
PaRe
eruaiF)9205
206
Auff 17/84
COP~RIGHT,
NA-66-1032
STRU(:TUKAL HEPAIH MANUAL
BRIVEN RIVETS
PULL RIVETS
t-tt-
-r
~3
PICK UP EXISTING
FASTENEAS
\1Xi
BIB(TrPl~j je
Trim
CID
damage (if praclical midway between

existing fasteners or stop drill all cracks as applicable.
\cB
ouf
Make repair doubler from 0.060 A286 CRES
material.
3
Heat-treat repair doubler to
min of 140 KSI, then
passivate repair doubler.
Layout and drill fastener holes
Chamfer all
edges and
in
radius all
repair doubler.
corners
of repair
doubler.
Install
or
repair doubler Using NAS1198-5 monel rivets

as applicable.
NAS1398C-5 monel pull rivets
REPAIR DOUBLER
MAKE FROM O.OWO

n2eecREs
i.lri
a~8a
6
6
o
o
o
o
I
s265-3-345
Forward Frame Repait

Thrust tleverser Defleetor Door
Model NA 265-40, -60, -60A, -60SC, and -70
(S/N 370-2 thru -6, -8, and -9)
Figure
0
206
78-30-20
Page 207
Aug 17/84
1LA-66-1032
STKUCTURAL REPAIR MAIVUAL
6t
I
DRIVEN RIVETS
PULL RIVETS
~tSS
x
x
gz~
PICK UP,EXISTING
FASTEEEA LOCATIONS
\O
O
Remove three
screws
securing
latch to deflector
door.
REPAIR DOUBLER
MAKE FROM 0.050
AnRO 0000
JOOGLE 0.050
OEEP BY 1 14 IN.
RUNOUT
existing fasteners in damaged area, then

damage midway between existing fasteners and/or
stop drill all cracks as required.
Drill out
trim out
aB
Make
repair doubler
Irom
A286 CRES material
Joggle repairdouble~
O
Hssl-treat
passivate repair
rspai~ doubler
min o( 140 KS) Ihen
O
O
not drill holes for screws
nrepaiidouDlerOo
securing latch to end plate.
~-C
63
E3
Fasten
repair doubler in place using
of fasteners
anrl
doubler.
O
Iii;
to
dr
13
plncss through existing etch
10
attach holes in deflector door structure to drill latch attach

holes
In
~3
size, type
removed.
as
carplul v hack
same
~-fi,
repair doubler.
Install door latch
using removed
hardware.
51653-348
78-30-20
IaRc ~OX
Aug 17/H4
Thlusl Iic~veraer Deflector Door Forward Frame End

Model NA 266-40, -66, -6~A, -fiOfiC, and -70
(S/N 870-2 thru -6, -8, and
%07
Repair
eruypiF)9-
N ,2-6ti- 10:~
LOWER OOOR INNER SKIN
RIVETS
NAS 139895 (REFI
-4.
FWO SLOT FAIRING SKIN
RIVETS
81125-614
ITYPI
OENTEER:LINE
BOX FRAME
LOOSE JO-ROLTS (TYP)
dri I out
so nalfoenlargsf
eight (NAS 1393C5) rivets on lower door inner
contoured surface attaching fwd slot fairing skin.
single
row
O
single
of
Caref ully.
row
of ten
contoured surface
so
oatlo
enlarge fsstenerhole,
dr II out
(BR125-6-4) rivets on lower door

attaching fwd slot fairing skin.
inner
Drill out loose
of four located
O
O
washer
Re-drill JoBoll hale to 199/202
Install
fig
NOTES
a
THIS REPAIR PROCEDURE IS APPLICABLE TO LOOSE
JO-BOLT(S) ON
new
(ANSGOC1OL)
O
Iii
P
Jo-Bolt(s) (P-164A-1)
2.Instal
dia
Jo-Bolt(s) (PP220A-2) using

under Jo-Bolt head for suitable
one
grip
Jo-Bolt in accordance with instructions in
Place fwd slot
fairing
skin in
position.
(NAS 1398C5) rivets in

attaching fwd slot fairing
Install 8
contour surface
in the group
each side of center line box frame
on
lower door inner

skin.
EITHER SIDE OF CENTER LINE BOX
FRAME
Install 10
WASHER MAY BE DRILLED OUT
(13/64
IN. DRILL FOR
(CR2533-4) rivets
in lower door outer
contour surface.
SLIP FIT OVER JO-BOLT SHANK.
S265-3-347
Thrust Reverser Lower Deflector Door Loose Jo-Bolt Repair

Model NA 265-40, -60, -60A, -60SC, and -70
(S/N 370-2 thru -6, -8, and -9)
Figure 208
c,
78-30-20
Page 209
Aug 17/84
NA-66-1032
REPAIR MANI~AL,
WELOEO 88888
WELOEO OOURLER REPAIR
REPAIR
r
r
0.31 MIN ITYPI
0.18
140-5401-35, -37, -47 ANO -48 SUPPORT CHANNELS
WELDEDDOUBLERREPAIR
(3)
Grind out
radius in
(b)
damage maintaining
damage removal area
Fabricate repair doubler from
material, the
0.16 in.
Hasteloy
gauge as damaged
channel. Refer to chart for material gauge.
(C)
same
Weld doubler in
place using Heliarc inert are

Hasteloy "W" rod. Weld should
completely around repair doubler.
process and
extend
I:
WCLDEDCR*CKREPAIR
NOTE
CRACKS MAY BE WELDED TO A MAX LENGTH OF 50%
OF WEB WIDTH OR EXTEND OVER 2 IN. IN LENGTH IN
THE SPANWISE DIRECTION.
(a,
Stop
(bj
Weld crack
drill crack with
Ici
No 40
using Heliarc inert
Hasteloy
in
(0.098)
are
drill.
process and
rod. Weld bead must extend 1/8
beyond stopdrilled hole
Dye! penolranl inspect ~ep;lir
to insure
repair
is
cornpl~!le
N07%1
DAMAGED CHANNELS MAY BE REPAIRED BY EITHER A
WELDLD DOUBLER OR BY WELDING CRACKS
?h rust Kevrlser
78-30-20
PaK(210
AuR 17:84
Support (:hannel Repair (140-5401-35, -37, -47, and -4N)

Motlc!l NA 211,1-411, -fiO, -CiOA, -BOSC, and -70
S165-3-328
(S/N ~70-2 Ihru -6, -8, and
!ciruCliF)9%09
COPYRIGHT,
NA-6Ci-1032
STKIICTIIHAI, KEPAIK MANI~;AI,
140-5401-73 OR -75
SUPPORT CRAHNEL (AEFI
WELDED CRACK
STOP DRILL ANO

GRIHD OUT
NEW CRACK
140-5401-73 OR -75 SUPPORT CHANNELS
PREPARATION
NOTE
IF DAMAGE IS LOCATED ON OUTED CHANNEL
ASSEMBLY, ACCOMPLISH THE PREPARATION PROCEDUHtS IN STEP A. IF DAMAGE IS LOCATED ON INBD
(3)
reverser
IN STEP B.
on
outbd channel
Remove insulation
secl~rlng insulation blanket to channel.
blanket to expose
(b)
It
damage
is
on
damaged
drill
area.
Position
number 40
crack
area
prior
to
thin piece of stainless steel sheet
stock between channel
Inbd channel assembly: remove three
~leegrinooulcrack
Dye penetrant inspect

welding crack
assembly, remove thrust

actllator from channel assembly: then drill out rivets
damage is
Il
Stop drill each end of crach with
(0098)
O
O
CHANNEL ASSEMBLY, ACCOMPLISH PREPARATION
PROCEDURES
assembly
and nuzzle to act
as a
heat
shield to protect nozzle.
clamps
and secure wire

secllrlng wire harness to sllpport charlnel
llnrllc:ss so that It will not illlerft?le witll repair pr~,cedures.
Wed
cracks
oslng
Heliare
ner~ sre
proc.ss
Weld bead should extend at least 1/8 in beyond stop drilled

holes at each end of crack
REPAIR PROCEDURE
NOTE
Dye penetrant inspect completed
weld to
maKe
certain that all cracks have been completely welded
OUTED CHANNELS ARE FORMED FROM 0.063 INCONEL

Reinslalallremavetl components
SHEET. AND INBD REPAIR CHANNELS ARE FORMED

FROM 0.050 INCONEL SHEET.
s265-3-349
Suppor.l Channel Repail 140-5401-7:) and -75)

Modell NA 865-40, -tiO, -60A. -BOS(, and -70
(S/N :~70-2 thru -8, -X, anti -9)
lh rust Rcvcr*el
Eiffure
o
~10
78-30-20
Eaar~ll
AuR 17/X4
NA-66-1032
STRII(TI;RAL REPAIR MANUAL
FWOSAOOLEIHEFI
PLATES [REF)
I/41N.AUBBEH
BAL IHEF)
CHAOLE CUSHION
AFT SAOOLE
IREF)
RIGHT HANG ENGINE

THRUST REVERSER CRADLE
LEGS
HEIGHT AS REOO
ILH OPPOSITE)
To fabricate either LH
cradle, proceed
as
or
RH aft
fairing/thrust
reverser
follows:
P1
LBVOY1 and (abricate cradle base. fwd and atl

cradles, and p~ates using dimensions and materials called
out on;sheet 2.
PI
SBCurelwd and aft cradle base using waad
lag
screws.
Anacn
height.
Secure
El
Cement 1/4 in. thick
or
rubber
on
reverser
Oi
N07~
TO REMOVE AFT FAIRING/THRUST REVERSER FROM
CRADLE. REMOVE TWO li4 IN. DIA BOLTS THROUGH
PLATES
AND
INTO
CATCHES.
att cradles to obtain desired

with bolts
by
or
lag
2 in. wide
screws.
strips
of sheet
cradle surfaces to cushion aft
assembly
lairingilhrusl reverser assembly in

edge of aft fairing is even with fwd edge of
fwd cradle. Place aluminum plates over catches on fwd end
of aft fairing. Secure plates to aft fairing with 1/4 in. bolt
through plates into Catch.
cradle
ALUMINUM
lags t~ fwd and

legs to cradles
screws
THEN
REMOVE ASSEMBLY FROM CRADLE.
Position
so
sil
that fwd
Secure plates to fwd cradle with 1/4 in lag
screws.
5380-3-2
Thrust Reverser
78-3020
Paffe 212
AuR 17/84
Support Cradle
(8/N 870-1 on$-7), -80, -80A, and -808(:

FiRure 211 fSheet 1 of 2)
Model NA 265-70,
NA-6fi-10:~2
SI1ZII(:II]ILAI
KEPAIK
it---r
13/4
13/4
21-3/8
17-13/84 R
13-13/32 8
25-3/18
-2
13
11
26-----+i
I--------"
AFT CRADLE
12 IN. THICK PLYWOOD]
CRADLE BASE
(3/4
IN. PLYW0OD1
13/32
1-1/4 A
5/16
ELOHAI
1-
?i
5/8rl
29-23/64
4-1/2
IY
217YP)
1
1/2
Illov
HOLE
-b
if-- 2-/2
R;Y;.
3-~C3
127/32
14
(4 PLICESI
13/1615-19/64
28-19/32 8
18-1/2
17-11/32
-I
PLATES 12 REOD)
11/8 IN. ALUM PLATE)
INBD
_E~r
le-------~
36
NOTE
FWD CRADLE
ALL DIMENSIONS ARE IN IN.
12
IN. THICK
Thrust Reverser Support Cradle

Model NA 265-70, (S/N 370-1 and -7), -80, -80A, and -80SC
COPYRIGHT, 1984 BY SABRELINER CORPORAT19N
PLYWOOD)
S380-3-3
78-30-20
Page213/214 Hlank
Aug 17/114

Stuctural Repair Manual

Caricato da

Informazioni sul documento

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Stuctural Repair Manual

Caricato da

Copyright:

Formati disponibili

ATP

COPYRIGHT IS NOT CLAIMED AS TO ANY PART OF AN ORIGINAL WORK

Aircraft Technical Publishers

6AM-5PM PST M-F

101 South Hill Drive

ATP Grid Index to Manufacturers Publications:

Dimensions and Areas

List of Effective Pages

Main Gear and Doors

Landing Gear Shock

Aircraft Technical Publishers

Flight Limits with Restricted-Life Repairs

Load and Buckle Patterns

Over-G, Over Pressurization, and Hard Landing Inspection

Structural Joint Wear

Fuselage and Nacelle Sealing

Support of Airplane for Repair/Alignment Check Procedures

Main Entrance Door (Structural

Main Entrance Door

Landing Gear Doors (Structural Identification)

Main Frame (Structural

Plates and Skins

Plates and Skins

Plates and Skins

Horizontal Stabilizers (Structural

Vertical Stabilizer (Structural

Aircraft Technical Publishers

Windshields and Windows

Cabin Windows (Structural

Cabin Windows (Allowable Damage)

Wing Allowable Damage

Main Frame (Structural

Plates and Skins

Trailing Edge and

Trailing Edge Devices

Thrust Reverser (Structural

Thrust Reverser (Allowable Damage)

Aircraft Technical Publishers

ALL MODELS NA 265 AIRCRAFT

ORIGINAL ISSUE: 1 JAN 1967

COPYRIGHT, 1990 BY SABRELINER CORPORATION

Intro., Chaps 51 thru 57

Manual Control No:

Basic Issue Date

COPYRIGHT, 1990 BY SABRELINER CORPORATION

Page 1/2 Blank

RECORD OF TEMPORARY REVISIONS

Manrl Control Wo:

TEMPORARY REVISIO# LOG

Page 1/2 Blank

affecting the following chapters: Intro., and

L.E.P. update (new format).

Revised landing gear shock struts procedure.

Acres Fastener Sleeves

Revised elevator balance procedure.

Revised damage limits for windshields and windows.

Repair Manual, Report No.

main entrance door repair.

Addition of overwing fairing delamination limits.

flaps sonic doublers repair.

When revising your manual, the List of Effective Pages

appearing in the front of the manual should be used as a cross

The asterisk indicates pages revised, added,

deleted by the current revision.