Subject STRUCTURES - SOLEING FOP INTERCONTINENTAL STRUCTURAL REPAIR CHAPTER 51 STRUCTURES - GENERAL TABLE OF CONTENTS Subject No. ERA ete ee erg Figure 1 - Abbreviations Figure 2 - Principal Dimensions Figure 3 - Major Assembly Breakdown Figure 4 ~ Structural Classification Figure 5 - Principal Structural Elements SHEET METAL MATERIALS ©... Sede General. Aluminum Alloys Figure 1 ~ Most Commonly used Sheet Metal Figure 4 ~ Material Substitution Figure 5 - Minimum Bend Radii Magnesium Alloys Titanium Alloy Corrosion Resistant Steel Flat Patterns Figure 6 - Flat Pattern Layout Figure 7 ~ Flat Pattern Set-Back Graph Figure 8 - Developed Length Graph Shim Rules Figure 9 - Shim Rules Figure 10- Approximately Equivalent Strength Materials ‘SPECIAL MATERIALS SPECIFICATIONS... 2.2... 01. Sieded Special Materiais List SEALANTS, oe ct tt et ee ee eee eee eee Bleleg FASTENERS wee ee ee eee ee ee ee ee Sle SRM 320 Dec 31/88 Genera Application Classes Common Sealants Substitution Data General Figure 1 - Red Lining of Fasteners Page 10 10 Contents 51 Page 1BQEING . FOP INTERCONTINENTAL STRUCTURAL REPAIR Subject Subject No. Subject No. FASTENER IDENTIFICATION. ©. eee ee... ee. Stepan General Figure 1 - Fastener symbols Figure 2 - Fastener Identification - Rivets Figure 3 - Fastener Identification = Lockbolts 4 ~ Fastener Identification - Threaded Fasteners 5 > Fastener Identification - Tapered Shank Bolts Figure 6 - Fastener Veniors gure 7 - Obsolete and Replacement Fasteners FASTENER INSTALLATION AND REMOVAL.» .. 1... . 520202 Fastener Instalistion z Figure 1 - Lockbolt and Hi-Lok Installation = Figure 2 - Hlind Bolt Installation 3 Fastener Removal 4 Special Tools 5 Figure 3 - Grip Range for Fluid Tight Rivets é Figure b - solia shank Rivet Removal 7 Figure 5 - Hi-Shear Rivet Removal 8 Figure 6 = Dimensions for Driving of "D" Rivets n "D" Rivet Instalistion 2 ‘Tapered Shank Bolts “ Figure 7 - Head Protrusion before Driving Taper Shank Bolts 15 Figure 6 - Head Dishing Limits for Installed Taper Shank Bolts is FASTENER SUBSTITUTION... ee. 5ue0g Generel 1 Teper Shank end 70-Degree Radiused Lead Fastener Replacement 2 Figure 1 - Fastener Substitution 3 Figure 2 - Fastener Substitution for MS20470D and BACRISES -D Universal Head Rivet uo Figure 3 - Fastener Substitution for MS20426D and BACRISBA-D Rivet in Countersunk Holes he TORQUE WRENCH VAWES 2 2... oe ee Sleek Generel 2 Figure 1 1 Figure 2 - Torque Wrench Adapters end Extensions 5 FASTENER HOLE SIZES. ©. ee ee ee She General 1 Figure 1 - Fastener Hole Sizes i Figure 2 - Fastener Hole Sizes for Taper Shank Bolts a . ‘SRM 320 Contents 52 Jen 10/60 Page 2BSQENG ~ LaF INTERCONTINENTAL STRUCTURAL REPAIR Subject Subject No. Page FASTENER ED@ MARGIN |. Stead General 1 Figure 1 - Fastener Edge Margins 2 COW DIMFLING. see ste General 1 Figure 1 - Coin Dimpling 2 Figure 2 - Pre-Dimple mle Size 2 Figure 3 - Coin Dimpling Sheet Thickness 3 Figure | - Minimum Allowable Thickness for 100 Degrees Countersinking of Understructures 3 Hot Dimpling : Coin Dimpling Tools 4 Figure § - Hot Dimpling 5 Figure 6 - Portable Coin Dimpling Hquipment é Flow Form Dimpling 7 COUMIERSINING. «ee . 5teae8 Miero-Stop Countersinking L The Pilot Pin a Figure 1 - Micro-Stop Countersink 1 Figure 2 - Maximum Countersink Diameter for Shear Head Rivets (BACRISCE) 4 Figure 3 - Minimm Allowable Sheet Thickness for 100 Degrees Countersinking 5 Figure 4 - countersink Repair Washer é ‘tgure 5 - Average Hole Diameter of Countersunk Holes 9 STRENGTH OF FASTENERS © ee ee. Step Generel 1 Fastener Index 2 Figure 1 = Strength of Solid Rivets 4 Figure 2 - Strength of Blind Fasteners 10 Figure 3 - Strength of Prowruding Head Bolts, Lockbolts end Hex-Drive Bolts ub Figure 4 - Strength of Standard Flush Heed Bolts, Leckbolts and Hex-Drive Bolts B Strength of Shear Flush Head Bolts, Shear Flush end Frotruding Head Lockbolts and Hex-Drive Bolts a Strength of Shear Flush Head Teper Shenk Bolts ae trength of 70-Degree Head Radius Lead-in Bolts 25 1 SRM 320 Jar. 10/80 Contents 52 Page 3SOE ADF INTERCONTINENTAL STRUCTURAL REPAIR Subject Subject No. Page COLD WORKING OF HOLES FOR FATIGUE IMPROVEMENT... . sa-2012 General High Interference Cold Working Process Low Interference Cold Working Process Figure 1 ~ High Interference Cold Working Process Figure 2 - Low Interference Cold Working Process Figure 3 - Tools for Cold Working of Holes EATUSIONS AND FORMED SECTIONS... ee... 2... 5203 Generel Extrusion Index Extrusion Dimensions by Part Number ee CATER General, 1 Figure 1 - Protective Coatings, Sealants, Adhesives end Cleaners Figure 2 - Fiberglass and Plastics AERODYNAMIC SMOOTHNESS. . 2... Fee eee Sunken Generel, Joints = Critical Areas Joints - Non-critical Areas Fastener Aerodynamic Flushness Microshaving of Aluminum Alloy Rivets Figure 1 - Aerodynamic Smoothness Critical Areas. Figure 2 - Microshaving of Alumimm Alloy Rivets TESTING OF METAS... + 515-2 General Figure 1 - Ernst Fortable Metal Hertness Tester Figure 2 - Barcol Fortable Hardness Tester Figure 3 - Hardness Values of Aircraft Materials FIRS DAMAGE BVALWATION. oo Stes General TION. ee AM ERE BB ww mH SRM 320 Jen 10/8SQL AOF INTERCONTINENTAL - STRUCTURAL REPAIR Subject Subject No. Page eeumeitt CUNO EPOCEDES es oe eee General 1 General Requirements 2 Prepare Airplane for Raising 2 Raise Airplane 3 level Airplane 4 Lock ALL Jacks 5 Bleed All Jacks 3 Check Attitude of Airplane 6 Reeleveling of Airplane to Meet Required Tolerance 6 Celculete Hye-Piece Elevation n Place Floor Mark Levels a Place Index Cards Under Body Points M,x,Y snd L, and at Nose Landing Gear Oleo Centerline n Place and Set Up Engineer's Transit 1 Trim Stabilizer pry Take Elevation Resdings 2 Take Body, Wing, Nose Gear Oleo and Stabilizer Azimith Readings Bb Check Main Landing Gear Alignment wh Check Nacelle Alignment ue Check Nose Landing Geer Longitudinal Alignment 1 Set Up Engineer's Transit for Fin ‘Tip Azimith Reading 1s Take Fin Tip Azimth Reading 5 Reassenble Nose Landing Gear Door au Close Nose Landing Gear Doors 16 Open Main Landing Gear L.E. Wheel Well Doors 16 Take Plumb Bob - Leveling Scale Reading 16 Prepare Airplane for Lovering 16 Lover Airplane a7 Remove Plumb Bob ar Remove Jacks and Jack Pads uv Close Mein Landing Gear L.H. Wheel Well Doors Lu Figure 1 - Alignment Check Squipment we > Jacking Diagram 2 ~ Alignment Point and Nose Wheel Well Leveling Pad Location al ~ Measuring Methods and Deteils 28 ~ Plumb Bob Line Holder at liose Landing Gear Oleo Centerline 29 ~ Plumb Bob Line Holder et Mein Lending Gear Tow Ring 29 Figure 7 - Plumb Bob Line Holder for Alignment Points on Contoured Surface x Figure 8 - Trammel Assembly 30 SRM 320 Jan 10/80 7 Contents 51 Page 5SQN a Goes ‘A STRUCTURAL NEPAR Subject Subject No. Page ALIGIMENT CHECK PROCEDURES (CONT). «e.g teben Figure 9 Preparation of Floor Mark Labels and Index cards 2 Figure 10 - Airplane Leveling Using Plumb Bob 32 Figure 11 - Airplane Leveling Using Engineers Transit or Dumpy Level 3 Figure 12 - stabilizer Aligment Check 3 Figure 13 - Landing Gear Alignment Check 35 Figure 1h - Nacelle Aligament Check 37 Figure 15 - Fin Tip Alignment Check 38 Figure 16 - Alignment Date 39 Figure 17 - Post - Repair Alignment Data he SUPPORT OF STRUCTURES FOR REPAIRS... 2... 51-7-0 General 1 SUPPORT OF AIRPLANE IN JIG POSITION... 2... 53 Figure 1 - Support Equipment for Jig Position 2 Figure 2 - Support of Airplane in Jig Position 3 Figure 3 - Support of Airplane for Belly Landing Damage Repair 4 Figure 4 - support Jigs = Fuselage T Figure 5 - Support Cradles - Fuselage 10 Figure 6 - Support Jigs and Cradles - Wing and forizonta) Stabilizer 2 SUPPORT OF AIRPLANE IN WON-JIG POSITION... 2... . siete Figure 1 - Support Equipment for Non-Jig Position 2 Figure 2 - Support of Airplane in Non-Jig Position 3 SUPPOR? OF REMOVABLE STRUCTURAL COMPONENTS. ©... . 51-7. General 1 Figure 1 - Equipment and Removal Procedures Index 2 Figure 2 - Access Door Repair Jig - Air conditioning 3 Figure 3 - Cargo Door Repair Jig = Forvera, ‘ Figure 4 - Cergo Door Repair Jig - Center 3 Figure 5 - Cargo Door Repair Jig - Ate é Figure 6 - Entry Door Repair Jig - Forward 2 Figure 7 - Entry Door Repair Jig - Ate 8 Figure 6 - Gelley Door Repsir Jig - Forvard 9 Figure 9 - Galley Door Repair Jig - APE 0 Figure 10 - Hatch Repeir Jig - Emergency na Eiger: Lt 7 Wheel Welt Door Repair Jig ~ Nose Landing Gear u Figure 12 - Wheel Well Door Repair Jig - Mein Landing Gear 3 35 + Couling Repair Jig'= Engine X SRY 320 Contents 52 Jen 10/80 Page 6Bateme x wt ma TI “ONT INE! STRUCTURAL REPAIR Subject Subject No. Page SUPPORT OF REVOVAELE STRUCTURAL COMPONENTS (CONT)... 51~7-3 Figure 1k - Spoiler Repair Jig - Inboard and Outboard 16 Figure 15 - Flap Repair Jig - Fillet 17 Figure 16 - Flap Repair Jig - Inboard x Figure 17 - Flep Repair Jig - Outboard 19. Figure 18 - Atleron Repair Jig - Inboard 20 Figure 19 - Atleron Repair Jig - Outboard 22 Figure 20 - Elevator Repair Jig 22 Figure 21 - Rudder Repair Jig 23 AUIPLANE RAISING. «oe ke ee Seg Procure Equipment per Figure 1 1 Check Placement of Airplane 1 Prepare Airplane for Raising 1 Raise Airplane 2 Figure 1 - Equiment for Airplane Raising 4 Figure 2 ~ Jacking Diagram for Airplane Reising 5 ATE TANS LEVELING (se Gece ee Plumb Level the Airplane. 1 Level Airplane for Jig Position 2 Figure 1 = Leveling Equipment 5 Figure 2 - Jig Position Dete é AURPLANE LOWERING «ee ee ee Stet Lower Airplene a PROTECTIVE TREATMENT OF METAL REPAIR PARTS. ©... 2. 51000 Generel 5 Aluminum Alloy Brush Alodize Process 1 Magnesium Alloy Brush Alodize Proces: u Steel Cadmium Plating 5 Faying Surfaces 5 Fastener Installation 6 teter Displacing Corrosion Preventive Compound 6 Sefety Precautions 6A Competib-lity of Water Displacing Corrosion Inhibiting Compounds 63 “Leaning Seicre Application of Water Displecing Corrosion Inhibiting Compounds 6B Applicaticn. of Water Displacing Corrosion Sthibiting Compounds 6c Spray Application of Water Displacing Corrosion Inhibiting Compounds 6c Removal of Water Displecing Compounds oO Contents 51SQL&«NG ate Cor RCONTINENTA\ STRUCTURAL REPATR Subject Subject No. Page PROTECTIVE TREATMENT OF METAL REPAIR PARTS (CONT)... .. 51-80 Exterior Discoloration by Corrosion Prevention Compounds 6 Figure 1 - Classification of Dissimiler Metals 7 Pigure 2 - Faying Surfaces - Protective Finishes 8 Figure 3 - Protective Trestuent for Fastener Installation 9 Pigure 4 - application of Water-Displacing Compound to Structure 20 CORROSION REMOVAL, GENERAL REPAIRS, AND SURFACE FINISHING REQUIREMENTS... 1... S1eBeL Generel 1 Safety Procedures 1 Corrosion Damage and Rework Limits 4 Corrosion Removal Techniques 5 ‘Identification of Metals 6 Corrosion Rework Application nu Corrosion Removal Procedures for Alumimm end Aluminum Alloys 12 Corrosion Removal Procedures for Magnesium Alloys 15 Corrosion Removal Procedures for Carbon Steel 16 Corrosion Removal Procedures for Stainless Steel ‘snd Nickel Chromium Alloys 1 Corrosion Removal Procedures for Titanium Alloys 20, Corrosion Removal Procedures for Plated Surfaces 20 Corrosion Removal from Chromium and Nickel Plated Parts 20 Corrosion Removal from Cadmium end Zine Plated Parts aL Cadmium Plating 22 Mechanical Corrosion Removel by Blasting 23 Figure 1 - Corrosion Demege and Rework Measurement Using Depth Dial Gege 25 Figure 2 - Abrasive for Corrosion Removal 26 Figure 3 - Single Depression Fairing 27 Figure 4 - Blend Out of Miltiple Pits in Corroded Area. 26 Figure 5 - Profile of Reworked Corroded Areas in Regions of Limited Access 29 Figure 6 - Corrosion Removal and Control - Equipment end Materials 30 ee Gib) a Procedure to Arply Astrocoat L SRM 320 Jan 10/80Subject BONDED METAL STRUCTURAL REPAIR... eee... eee SOLE BAO INTERCONTINENTAL STRUCTURAL REPAIR General 1 Separation of Resin Bonded Metal Structures 1 Preparation of Faying Surfaces Before Bonding 2 Primer Application 5 Adhesive Application for Structural Repairs 6 Sealing for Structural Repairs 7 Sealing of Fuselage Scin Lap Splices to Prevent Corrosion 8 Figure 1 - Phosphoric Acid Non=Tank snodize (PANTA) Method for Bonding Repairs 10 Figure 2 - Fillet Sealing of Bonded Repairs 12 Figure 3 - Separation of Bonded Joints with Wedges 13 FIBERGLASS CLOTH OVERLAY REPAIRS... . 2.2... . Siege Introduction 2 Preparation of Damage Area 1 Processing of Patches 2 Finishing the Repair 4 Figure 1 - Fiberglass Cloth Overlay Repair 5 Figure 2 - Preparation of Adhesive for Fibergi: é ALUMINUM HONEYCOMB STRUCTURE REPAIRS... 2... 2... Slel0el Introduction a Repair Procedure 1 Preparation of Damage Area 1 Processing of Fiberglass Honeycomb Replacement Core 5] Processing of Patches 3 Sh 320 van 10/81 Hot-Bonded Metal-to-Metal Repair of Aluminum Honeycomb Structure 4A Figure 1 ~ Damage Evaluation and Repair Index - Aluminum Honeycom> Structure 4B Figure 2 - Repair Material and Equipment 6 Figure 3 - Sein Crack Repair - Hneyeomb Structure 8 Figure 4 ~ Potted Repair - Honeycomb Structure 9 Figure 5 - Replacement pre Repair ~ Honeycomb Structure 10 Figure 6 - Tapered Panel Trailing Edge Repair - Honeycom> Structure qi Figure 7 ~ Edge Delamination Repair - Honeycomb Structure az Figure 6 - Skin Delamination Repair - Honeycomb Structure 43 Figure 9 - Router and Template ak Figure 10 ~ Router Support Assembly 15 Figure 11 ~ Router Template Assembly 16 Figure 12 = Hole Saw 18 Figure 13 - Squeegee 18 Figure 14 - Preparation of Adhesive for Fiberglass 185 Figure 15 - Preparation of Potting Compounds 20 Contents 51 Page 9Subject ALUMINUM HONEYCOMB Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure SQEING LOL INTERCONTINENTAI STRUCTURAL REPATR Subject No. STRUCTURE REPAIRS (CONT)... . 2... S1-10-1 16 17 18 19 20 a 22 23 au 25 26 27 28 29 30 2 32 33 3u 35 36 = Skin to Spar Delamination, Bonded - Riveted Repair - Honeycomb Tapered Panel = Mlowable Repairs - Honeycomb Structure - Flap Trailing Edge - Time Limited Repair ~~ Skin Delamination Repair - Honeycomb Tapered Panel. + Honeycomb Structure Repair - Wing Fixed ‘Trailing Edge ~ Honeycomb Structure Repair at Static Dischargers ~ Flap Trailing Edge Spar to Honeycomb Delamination - Potted Bolt Repair + Trailing Bige Flap Spar to Honeycomb Delamination, Potted Bolts and Bonded - Riveted Repair ~ Machining with Valve Stem cutter = Band Sawing Honeycomb Material + Repair Doubler Requirements ~ Doubler Installation + Application of Pressure During Gure for Flat Panels = Application of Pressure During Qure for Ourved Panels ~ Bonded Metal Skin Repair - Typical = Dent Repair with External Doubler + Skin and Core External Repair ~ Scin and Gre Flush Repair ~ Square Edge Panel Repair - Puncture Damage ~ Square Edge Panel Repair - Gorrosion and/or Delamination Damage - Trailing Edge Repair - Honeycomb MOISTURE REMOVAL FROM PERFORATED ALUMINUM HONEYCOMB (ASSEMBLES) | tee reeset ee sys10-7 Introduction Preparing the Assembly Removing the Moasture Water Removal from Control Tabs Repair of ind Seals BMS 5-79 Sealant Gontents 51 Page 10 application BMS 5-28 Sealant Figure 1 - Repair Materials and squipment Figure 2 - Water Removal - Honeycomb Assemblies Figure 3 - Location of tbles in Sein Figure 4 - Water Removal from Tabs - Alternate to Heated Vacuum Platen Figure 5 - Locatfon of Holes for Water Removal from Tabs Page a 23 24 25 27 28 29 30 32 33 35 36 37 38 39 do a 42 43 ui ‘SRM 320 san 107/81Subject S08ING ADE. INTERCONTINENTAL STRUCTURAL REPAIR Subject No. Page CORRODED ALUMINUM HONEYCOMB TAB REPAIR... 2 2... 51-1003, Introduction Prepare Tab for Examination Repair Limits Repair Procedures Figure 1 - Honeycomb Tab Examination Figure 2 - Honeycomb Tap Repair Limits Figure 3 - Honeycomb Tab Repair Figure 4 - Inboard Aileron Honeycomb Tab Repair (COMET UGS AUMGE/EEPATA tee eee ee yy Introduction L Prepare Hinge for Examination i Hinge Examination a Repair Procedures for Unbushed Hinges 1 Repair Procedure for Bushed Hinges 2a Figure 1 - Continuous Hinge Repair 2B Figure 2 - Bushing Fabrication - Continuous Hinge 8 FIBERGLASS CLOTH REINFORCED PLASTICS REPAIR... SiaLiel Introduction 1 How to Use ‘This Section of the Manual 2 Preparation of Damage Area - Radome 2 Honeycomb Core Repair 3 Processing of Patches - Radome Repair 5) Replacement of Erosion Shoe 6 Repair of Radome Damage Caused by Electrical Damage 6 Repair of Antenna Doors 7 Processing of Patches 7 Preparation of Lamage Area 10 Repair of stiffeners 10 Repair of Skin un Sealing 12 Figure 1 - Fiberglass and Cotton Goth Reinforced Plastics Repair Index Figure 2 - Stiffener Repair - Plastic Hat Sections Figure 3 ~ Fiverglass Skin Repair Figure 4 - Cracked Fiberglass Taileone Repair Figure 5 - Preparation of Adhesives Figure 6 ~ Radome Repair igure 7 - External Repair with Accelerated Cure for Glass Faoric Reinforced Honeycomb Components 264 Repair for Doppler Radome Laminated Fiberglass Cloth Wall 27 Figure 8 - Repair of Solid Laminate Doppler Radar Door 32 Quick Repair for Doppler Radome per Kit 65-9946 3u Figure 9 - Skin Patch : 37 Figure 10 - Kit 65-9946 37 Quick Temporary Repair Procedures for Non-electronie Components 38 SRM 320 van 10/8) . contents 51 Page 12Subject BQEING YO INTERCONTINENTAL STRUCTURAL REPAIR FIBERGLASS CLOTH REINFORCED PLASTICS REPAIR (CONT)... . . Figure 11 - Preparation of Adhesive Rapid Permanent Repair Procedures at Room Temperature for Non-electronic Components Figure 12 - Potted Core Repair = Preparation of Potting Compound Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 = Preparation of Resin Mixture = Potting and. Laminating Resin Cure Temperatures Preferred Repair - Nose Radot ~ Repair of Single Stage Epoxy Subject No. Page si-11-1 (CoBand) H/C Sandwich Details Used on Electrical Applications Preferred Repair ~ Nose Radome (C-Band and X-Band) - Fiberglass and cotton Cloth Reinforced Plastic Repair Index "Nose" Radome Procedure for Radome Repair Thickness Measurements Procedure for Radome Repair Thickness Measurenents Repair of Aluminum Flame-Sprayed Coating Pull Obnductivity, Wingtip Leading Edge Repair Repair Procedures - Electrically Noneritical, Wingtip Leading Bdge ALUMINUM-FACED PAPER HONEYCOMB STRUCTURE REPAIR FOR GALLEYS. 2... 1. eae General Removal of Moisture Repair of Dents Repair of Delaminated Areas Repair to Skin and Gore Panel Replacement Sealing nin, a a Adhesive Potting Compound Potting Compound for the Installation of Inserts Equipment and Materials Figure 1 - Allowable Damage and Repair Index ~ Repair of Delaminated Free Bdge of Panel Figure Figure Figure Figure Gontents 51 Page 12 2 3 4 5 Repair to Skin and Core Replacement of -Damaged Panel Typical Sealant Applications SLeL1-2 40 a 45 46 46 47 4B 59 a 7 a a5 85 86 SRM 320 gan 10761BOEING ADP INTERCONTINENTAL STRUCTURAL REPAIR Subject Subject No. Page MAT MOLDED FIBERGLASS REPAIR... 2... 2.2... Sielad Introduction L Evaluate Damage 1 Figure 1 - Damage Evaluation 1 Select Applicable Resin Mixture from Figure 2 a Procure Repair Materials and Equipment per Figure 3 Prepare Damage Area 1 Mix Selected Resin Mixture 2 Repair Damage 2 Figure 2 - Repair Mixtures and Mixing Procedures 3 Figure 3 - Repair Materials and Equipment a Figure 4 - Mat Molded Fiberglass Repair 6 GENERAL REPAIR PROCEDURES». ~~~... . 0.2... 51132 Classification of Damage to Airplane Structural Members 1 Allowable Damage 2 Figure 1 - Gorrosion Removal Tools 3 Repairable Damage 4 Replacement of Part 5 Operations Concerned with Repairs for Damage Beyond Allowable Damage Limits 5 tus bL Tho GoogooondoduggaG Tei) Introduetion Usage 2 TYPICAL REPAIR FOR MINOR DENTS.» 2... 2... S}eluel Introduction 1 Figure 1 = Minor Dent Repair - Wing and Stabilizer Leading Edges 4 Figure 2 - Minor Dent Repair - Nacelle Nose cowl 5 Unfilled Dents 0 WEB REPAIRS © ee ee ShedbeD Figure 1 - Typical Web Repair 1 Figure 2 ~ Cracked Lightening Hole Flange Repair 6 FORMED SECTION REPAIR. ee ee Sed uSS Figure 1 = Typical Formed Section Repair 1 Figure 2 - Tab Flange Repair 7 EXTRUDED SECTION REPAIRS...) 2)... Stadued Figure 1 = Typical Extruded Section Repairs 1 Figure 2 - Typical Repair of Thin Extrusions . Up to 0,08 Gage. 7 Figure 3 - Extruded Section Repair - Machiné Tapered nn Figure 4 - Typical Extruded Section Repair 22 SAM 320 van 10/81 Contents si Page 132o8ne FOP. INTERCONTINEN’ STRUCTURAL REPAIR Subject Subject No. Page CONTROL SURFACE REBALANCING + 11 ee ee ee eeu SdedbHO General 1 Special Tools end Equipment 2 Repair Categori 2 Estimation of Repair Weight of Honeycomb Structures 4 Rebalance Requirements after Repairs 4 Sign Convention 4 Teb Adjust Weight syaten. ha Figure 1 - Control Surface Weight and Moment Requirements 5 Figure 2 - Tab Balancing Requirement é Figure 3 - Special Tools and Equipment for Balancing Control Surfaces 8 Figure 4 - Estimated Weight of Honeycomb Repairs 3 Figure 5 - Estimated Weight of Finish ub INBOARD AILERON BALANCING see eee ee ee ShedSeD Generel 2 Special Tools and Equipment 2 Balancing Procedures with Inboard Atleron Removed from Airplane 1 Sample Calculetion for Balancing an Inboard Atleron Configuration II - With Single Tab Control Rod Removed 2 Adjustment of Balance after Minor Repair vith Inboard Alleron Installed 3 Sample Calculation for Rebalancing after Minor Repair with Aileron Installed 4 Figure 1 - Inboard Atleron ~ Preparation for Belencing 5 Figure 2 - Inboard Aileron Support During Balancing 7 Figure 3 - Inboard Aileron Balance Weight Dimensions and Installation 9 Figure 4 - Inboard A‘leron Balance Weight Dimensions fend Installation 20 Figure 5 - Inboard Aeron Balance Weight Requirenents B Figure 6 - Inboard Aileron Balance Weight Dimensions end Instalistion 6 INBOARD AILERON BALANCE PANELS - REBALANCING... . 51e15<2 General 1 Specific Tools and Zquipment 2 Balancing Procedures 2 Caleulstions for Balencing an Inboard Balence Fenel 2 i Inboard aileron Balance Fanels - Preparation for Belancing 2 - Inboard aileron Balance Panels - Support During Balencing 3 > Inboerd Atleron Balance Panels - Weight Instellation and Requirements 8 Figure 4 - Inboard Aileron Balance Panels - Balance Weight Detail 38 Contents 51 . Jan Xi Page 16Subject SQeINe ~*~ ADF INTERCONTINENTAL STRUCTURAL REPAIR Subject No. INBOARD AILERON TAB REBALANCING... 1... 2. 51625-3 balancing Procedure = Inboard Aileron Tab - Preperation for Weighing ~ Inboard Aileron Tab - Distance "X" Layout ~ Inboard Aileron Teb - Distance "X" Dimension + Inboard Atleron Tab - Balancing Arrangement 7 Inboard Atleron Tab - Rebalance Weight Lengths > Inboard Afleron Tab - Rebalance Weight = Inboard Aileron Tab - Rebalance Weight Installation Figure 6 - Inboard Aileron Tab - Adjust Weight Installation Re} PL ae OUTBOARD AILERON BALANCING. ©... 4. 52e25e8 General Special Tools and Equipment Balancing Procedures with Outboard Atleron ‘Removed from Airplane Semple Calculation for Balancing an Outboard Aileron Adjustment of Balance after e Minor Repair to an Outboard Aileron While Installed Semple Celeulation for Adjustment of Balance Weights efter e Minor Repair of an Installed Outboard Aileron Figure 1 - Outboard Atleron - Preparation for Balancing Figure 2 - Outboard A‘leron Support During Balancing Figure 3 - Qutboard Aileron - Repair Weight and Moment Arm Diagram Figure 4 - Outboard Aileron Balance Weight Requirements Figure 5 - Outboard Aileron Balance Weights - Location and Instelletion Figure 6 - Outboard Aileron Balence Weight - Mounting Diagram Figure 7 - Outboard Aileron Balance Weights - Weight Detail OUTBOARD AILERON BALANCE PANELS - BALANCING PROCEDURES». se... ee. 52etS 5 General SRY 320 Jan 10/80 Special Tools and Squipment Balancing Procedures, Outboard Aileron Balance Panels Sample Calculations for Balancing a Bay 5 Belence Panel Figure 1 - Outboard Aileron Balance Panel Locations Figure 2 - Outboera Aileron Belence Panel Support During ‘Balancing DAML 20 3 me oe Bo our w Contents 51 Page 15Soe INTERCONTINE! NT STRUCTURAL: REPATR Subject Subject No. Page OUTEOARD AILERON BALANCE PANELS = BALANCING PROCEDURES (CONT)... 2.2... 2. FL -15<5, Figure 3 - Outboard Aileron Balance Panel Bay 2 = Balance Weight Requirements and Installation Figure 4 - outboard Aileron Balance Panel Bay 3 - Balance Weight Requirements and Installation 20 Figure 5 - Outboard Aileron Balance Panel Bay 4 = Balance Weight Requirements and Installation or Figure 6 - Outboard Aileron Balance Panel Bay 5 = Preperation for Balancing % Figure 7 - Outboard Aileron Balance Panel Weight Detaiis 16 OUTBOARD AILERON TAB BALANCING... Sieageg Generel Preperation for Balancing Adjustment of Aileron Balance for Change in Tab Weight Outboard Aileron Tab Adjust Weights Installation Figure 1 - Outboard Aileron Tab = Preparation for Balancing Figure 2 - Outboard Atleron Tab Adjust Weight Location Figure 3 - Outboard Aileron Tab Adjust Weight Installetion Figure 4 - Outboard Aileron Tab Adjust Weight Requirements Pega ASSEMBLY SACANCUO oe sa General Special Tools and Equipment Elevator Assembly Balancing Procedure . Adjustment of Balance after Minor Repair vith Elevator Installed Sample Calculation for Rebslancing efter Minor Repair to an Installed Elevator Figure 1 - Elevator Preperetion for Balancing Figure 2 - Elevator Support During Belencing Figure 3 - Elevator Balance Weight Requirements Figure | - Elevator Balance Weight Installation and Dimensions Figure 5 - Elevator Repair Weight and Moment Arm Diagram. @ BS) Ramee) care ELEVATOR BALANCE PANELS © ee steno General Preperation for Belaneing Belancing Procedure Figure 1 - Elevator Balance Panels - Location Figure 2 - Elevator Belence Panels - Balance Weight Installation and Requirement ~ Elevator Balance Panels - weight Detail x Figure . gan 10/60Subject SQGNG HOF INTERCONTINENTAI STRUCTURAL REPAIR Subject No. SLSVATOR STABILIZER ACTUATED TAB REBALANCING... . . 51-35-9 Rebalancing Procedures Elevator Stabilizer Actuated Tab Adjust Weight Installation Figure 1 - Elevator Stabilizer Actuated Tab - Preparation for Weighing Figure 2 - Distance "X" Layout - Elevator Stabilizer Actuated Tab. Figure 3 - Elevator Stabilizer Actuated Tab - Distance "" Dimensions Figure 4 - Elevator Stabilizer Actuated Tab - Rebalancing Arrangement Figure 5 - Elevator Stabilizer Actuated Tab - Rebalance Weight Lengths Figure 6 - Elevator Stabilizer Actuated Tab - Rebalence Weight Figure 7 - Elevator Stabilizer Actuated Tab - Rebelence Weight Installation Figure 6 - Elevator Stabilizer Actuated Tab - Adjust Weight Installation RLEVATOR CONIFOL TAB - BALANCING PROCEDURES ©... . 51-15-10 SRM 320) Jar. 10/80 Rebalancing a Control Tab Elevator Control Tab Adjust Weight Installation Mize 1 7 Elevator Control Tab - Preparstion for Weighing Figure 2 - Distance "x" Layout - Elevator Control Tab Figure 3 - Elevator Control Tab - Distance "X"" Dimensions pibure & ~ Elevator Control Tab - Rebalancing Arrangement Fibaze 2 7 Elevator Control Tab - Rebalance Weight Lengths Figure 6 - Elevator Control Tab - Rebalance Weight Figure T - Elevator control Tab - Rebalance Weight instelletion Figure 6 - Elevator Control Tab - Adjust Weight Installation BALANCING... . Fee ee saeagent General Special Tools end Equipment Procedure for Rudder Removed from Airplane culeticn for Selencing a Rudder of Balance after a Minor Repair with Rudder Rebelancing efter d Rudder E wo a 2 2 3SQLNC ADP INTERCONTINENTAL STRUCTURAL REPATR bject Subject No. Page RUDDER BALANCING (CONT) we . gteagean Figure 2 - Rudder Support During Balancing 7 Figure 3 - Rudder Balance Weight Requirements 2 Figure L - Rudder Balance Weight Dimensions and : Installation n Figure 5 - Rudder Repair Weight and Moment Arm Diagram B RIMDER BALANCE PANELS ~ BALANCING»... steageae General. A Special Tools and Equipment - Platform scale 1 Balance Procedure for Belance Panels L Pelence Procedures for Balance Panels after Minor Repair 2 2 3 4 Iocation Figure 2 Rudder Balance Panels - Weight Installation end Requirenents 5 Figure 3 - Rudder Belence Panel Extension - Weight Installation and Requirement 8 Figure 4 - Rudder Balance Panel - Weight Detat. 12 RUDDER CONTROL TAB REBALANCING. ©... 0... | 52-15-13 Rebelancing Procedures 2 ize } 7 Rudder contre Teb - Preperation for weighing 3 Figure 2 - Distance "X" Layout - Rudder Control Tab: 4 Figure 3 - Rudder Control Tab - Distance "%" Dimensions 4 ide + 7 Rudder Control Tab - Rebalancing Arrangement 5 3 7 Rebelance Weight Lengths - Rudder Conteol Tab é § - Rebelence weights Rudder Control Tab 6 7 - Rudder Control Tb - Rebalance Weight Installation 7 & - Adjust Weight Installation - Rudder Control Tab 8 SRM 320 . Jen 10/80STRUCTURAL 8S Boy STATION. oistaNce MEASURED PARALLEL TO BODY GTO 4 PLANE PERPENDICULAR TO SODY ¢ PRON ‘Pour 130 WCHES FORWARD OF THE NOSE. SL s00¥ BUTTOCK LINE. DISTANCE AWORIZONTAL PLANE MEASURED. Frou BOO" VERTICAL &. MATER LIne. Distance measuRED PERPENDICULAR FROM A HORIZONTAL PLANE LOCATED 136 INCHES BELOW ‘oTTOu oF Boy FS FRONT spa station RSs REAR SpaR STATION SWING STATION. 4 PLANE PERPEN. DICULAR TO WING CHORD PLANE MEASUNED FROM INTERSECTION OF LEADING EDGE AND Wat WAL win BUTTOCK LINE. A PLANE I [RORUAL TO WING CHORD PLANE ANO PARALLEL TO BODY GIT IS MEASURED FROM INTERSECTION (OF NING CHORD PLANE AND I 81 eas | MAC MLMACELLE WATERLINE. 4 PLANE PARALLEL TO wine CHORD, PLANE MEASURED Fim MACELLE @ iicr i na me 0, We rveicat Te Taluing eoce JM sesome cose Oct 1/68 REPAIR [7400 To INSIDE OF SKIN: sooy stanion as pe ‘3 —— ba Amman c anD aL @ Abbrevations e Figure 1 51-0 Page 1ae PEPAIR STRUCTURAL BODY STATION. DISTANCE MEASURED PARALLEL TO BODY q TO A PLANE PERPENDICULAR TO BODY G. FROM “APOWNT 13D INCHES FORWARD OF THE HOSE, BL BODY BUTTOCK LINE, CISTANCE IN 'AWORIZONTAL PLANE MEASURED FROM BODY VERTICAL @. ML ATER LINE, DISTANCE MEASURED ‘PERPENDICULAR FROM A HORIZONTAL PLANE LOCATED [36 CHES BELOW ‘sorrow oF NOD", FAS FRONT SPAR STATION RSS _-REAR SPAR STATION WING STATION. A PLANE PERPEN- DICULAR TO WING CHORE Yel IED FROM INTERSECTION OF Msasun TEADING €OGE AND WoL 0. FOL WNG BUTTOCK LINE. A PLANE [NORMAL TO WES CHORD PLANE ‘AND PRALLEL TO BODY GIT FSMEASURED FROM INTERSECTION (OF WIKG CHORD PLANE AND BL 7848 NAC WL NACELLE WATERLINE. A PLANE PARALLEL TO VING CHORD. PLANE VEASURED FROM NACELLE tac 1S NAC We 100. we TyPIcaL wax wa natn Wr HEAT TREAT. Te TRAILING EDGE Le Leapnc eoce Oct 3/68 abbrevations Figure 1 (peomr eurroce un au 7400 TO INSIDE OF SKIN He AIRPLANE ct AND H6 © 52-0 Tage 1neta STRUCTURAL REPAIR Principal Dimenatone 51-0 Figure 2 (Sheet 1 of 2) Jon 1/62 Page 2Prinetpal Dimensions Figure 2 (Sheet 2)510 Page 4 INBOARD #ING ASSY OUTBOARD WING ASSY INBOARD WING LE INSTL ‘OUTBOARD WING LE INSTL MORRO MIKO TE INSTL ‘UTBOARO MING TE NSTI No THP Inst WING SPOILER INSTL. INBOARD FLAP INSTL ‘OUTBOARD FLAP INSTI, HeBOARD AILERON INSTL OUTBOARD AILERON STL BODY INSTL SECTION at ‘BOOT INSTL SECTION «2 BOO INSTL SECTION 45 ‘BODY INSTL SECTION 48 VENTRAY. FIM INSTL, MARL LANOING CEAR STL NOSE LANDING GEAR INSTL INBOARO STRUT IMSTL. (OUTBOARD STRUT INSTL. PANT INST. sTAguizer center Echo mst STRUCTURAL REPAIR osto7t sos Bt osteo ssn syaui7 S78 65105828 NOTE FOR AIRPLANES ITH JT ENGINES csvmon| & was es1a7s2m |] POR AlgpsaNes wiTH ROLLS-ROvCE esisas CONWAY ENGINES. e596 coma | 4 soa 610666 65202 eam 65106078 ose 65190872 65105008 sani ¢TuRe03T) IR AIRPLANES WITH TD ENGINES (TURBOFAN) stasiLizer structure st | soa7e2 staaiti IR LEINSTL ELEVATOR & BALANCE ASSY FIN INSTL DORSAL FIN INTERSPAR AND TE ASSY ER EXTENSION INSTL. (KIT) Fin EXTENSION ASST ‘mework) VERTICAL Tal. ASSY FW LE INSTL RUDDER & BALANCE ASSY PIN THP ISTE, sere sores soem 15.0367 estan ssi stam sue mone enn Major Assenbly Breakdown Figure 3 (Bheet 1 of 2) Jan 1/62 RevisedMajor Assembly Breakdown genie Figure 3 (Sheet 2 of 2)INTERCONTINENTAL STRUCTURAL REPAIR Nore ‘© AREAS AS INDICATED ARE CLASSED AS SECONDARY STRUCTURE. (@ THESE COMPONENTS, THOUGH NOT PRIMARY LOAD CARRYING UNITS, ARE ‘SUBJECTED 10 AERODYNAMIC LOADS AND SUBJECT TO COMPLETE PATLURE. ‘SUCH FAILURES, WHICH MAY CACSE POSSIBLE DAMAGE TO PRIMARY STRUCTURE AND ENGINES OR ADVERSELY .FFECT AERODYMAMTC CHARACTERISTICS AND/OR SURFACE STIFFNESs, MUST BE CONSIDEPED. esee notes @ aun W . (© OTHER AREAS ARE CONSIDERED AS PRIMARY STRUCTURE. WITHIN PRIMARY STRUCTURE ARE PRINCIPAL, ‘STRUCTURAL ELEMENTS (SEE FIGURE 5). PRINCIPAL STRUCTURAL BLEMENTS (PSE'S) ARE THOSE WHICH CONTRIBUTE SIONTPICANTLY TO CARRYING FLIGHT, GROUND AND PRESSURIZATION LOADS. @ TRAILING EDGE 1. PRIMARY STRUCTUES IN THIS AREA IS DEFINED AS THAT STRUCTURE WHICH G=VES SUPPORT ‘70 THE FLAPS, AILERC.IS, ‘SPOLLERS AND COVE LIP DOORS. 2. SGCONDARY STRUCTURE IN THIS AREA IS LIMITED TO THE UPPER AND LOWER PANELS, using ence A. PRIMARY STRUCTURE IN THIS AREA 1S LIMITED TO THE LEADING EDGE FLAPS AND SLATS AND TO THE FIXED LEADING EDGE RIBS WHICH SUPPORT THEIR RINGES, 2, SBCONDARY STRUCTURE IN THIS AREA IS LIMITED TO THE FIXED LEADING EDGE STRUCTURE. Structural Classification Diagram 51-0 Figure 4 (Sheet 2) ‘SRM 320 Page 6 Deo 32788Sais PUP INTERCONTINENTAL, STRUCTURAL REPAIR Gil seconoany staucruse MAIN LANDING GEAR ‘STRUT DOOR MAIN LANDING ‘GEAR DOORS Structural Classification Apr 1/69. Figure 4 (Sheet 2 of 2) sy Page 7BOE GaP INTERCONTINENTAL STRUCTURAL RECATR FUSELAGE UPPER LOBE SKIN AND STRINGERS FUSELAGE LOWER LOBE SKIN AND STRINGERS FUSELAGE CIRCUMFERENTIAL SPLICES FUSELAGE LAP SPLICES TYPICAL FRAMES SKIN AT CORNERS OF MISC. ACCESS DOOR CUTOUTS STRINGER / FRAME ATTACHMENTS BULKHEAD BS 178 (FORWARD PRESSURE ) FUSELAGE BS 227.8 BULKHEAD FUSELAGE BS 254.6 BULKHEAD FUSELAGE BS 294.5 BULKHEAD LOWER: LOBE FRAMES BS 360 TO BS 600) FUSELAGE 8S 600K /620 BULKHEAD FUSELAGE 8S 820 BULKHEAD FUSELAGE BS 960 BULKHEAD LOWER LOBE FRAMES 8S 960M TO BS 1420 FUSELAGE 8S 1440 BULKHEAD (AFT PRESSURE ) FUSELAGE BS 1505.87 BULKHEAD FUSELAGE BS 1592 BULKHEAD SECTION 48 SKIN AND §7RINGERS FLOOR BE4M STRUCTURE HORIZONTAL PRESSURE DECK OVERWING STUB FRAMES STRINGER 18A SKIN BS 820 AT STRINGER 18A DELTA BEAM- UNDER WING FUSELAGE FLOOR BEAMS OVER MAIN LANDING GEAR WHEEL WELL FUSELAGE KEEL BEAM (S620 TO SS.960) CREW WINDOW CABIN STRUCTURE WINDOW FORGINGS (PA°SENGER CABIN) SKIN AT CORNERS OF WINDOW FORGINGS FORWARD ENTRY DOOR AFT ENTRY DOOR EMERGENCY EXIT DOORS FORWARD GALLEY DOOR AFT GALLEY DOOR ELECTRONIC BAY ACCESS DOOR FUSELAGE UPPER DECK CARGO DOOR FUSELAGE LOWER LOBE CARGO COMPARTMENT DOORS FUSELAGE STRUCTURE ‘TABLE | Principal Structural Elements Figure 5 (Sheet 1) SRM 320 Deo 31/88SGENB ACF INTERCONTINENTAL, STRUCTURAL REPAIR ELECTRONICS ACCESS DOOR CUTOUT FUSELAGE LOWER LOBE CARGO COMPARTMENT DOOR CUTOUTS FUSELAGE UPPER DECK CARGO DOOR CUTOUT FORWARD ENTRY DOOR CUTOUT FORWARD GALLEY DOOR CUTOUT AFT ENTRY DOOR CUTOUT AFT GALLEY DOOR CUTOUT EMERGENCY EXIT DOOR CUTOUT NOSE LANDING TEAR WHEEL WELL FORWARD ACCESS DOOR AND CUTOUT /DOPPLER ANTENNA WELL FUSELAGE STRUCTURE TABLE | (CONT) FORWARD ENGINE MOUNT FITTING, LINKS AND SUPPORT STRUCTURE. ‘AFT ENGINE MOUNT FITTING, LINKS AND SUPPORT STRUCTURE THRUST LINK . FRONT SPAR FITTING MIDSPAR FITTINGS DIAGONAL. BRACE AND LOWER SPAR ATTACH FITTING POWEH PLANT STRUCTURE TABLE I Prinoipal Structural Elements ‘SAM 320 Figure 5 (Sheet 2) Deo 31/8351-0 Page RGENG POP INTERCONTINENTAL, STRUCTURAL REPAIR CENTER SECT:2N FRONT SPAR CHORDS, WEB, AND SiiFFENERS CENTER SECTION REAR SPAR CHORDS, WEB, AND STIFFENERS CENTER SECTION LOWER PANEL STRINGERS AND SKIN CENTER SECTION UPPER PANEL STRINGERS AND SKIN CENTER SECTION UPPER AND LOWER SKIN SPLICE STRINGERS CENTER SECTION SPANWIST BEAMS OVERWING FLOOR BEAMS LEFT AND RIGHT LOWER BEAM - BL 13.0 AND 420 WING-TO- BODY BREATHER WEB ATTACHMENT FRONT SPAR TERMINAL FITTINGS AND BOTTLE PINS REAR SPAR TERMINAL FITTINGS AND BOTTLE PINS LOWER SURFACE BBL 70.5 SPLICE UPPER SURFACE 8BL70.5 SPLICE LOWER SURFACE WS 360 SPLICE UPPER SURFACE WS 360 SPLICE WS 733 PRODUCTION BREAK JOINT REAR SPAR CHORDS, WEB, ANU STIFFENERS FRONT SPAR CHORDS, WEB, AND STIFFENERS LOWER PANEL STRINGERS ANO SKIN UPPER PANEL STRINGEHS AND SKIN UPPER AND LOWER SKIN SPLICE STRINGERS LOWER PANEL CUTOUTS TYPICAL RIBS SHEAR TIED IBS BS! 705 RIB TRAILING EDGE FLAPS- MAIN BOX TRAILING EDGE FLAP TRACKS AND SUPPORT STRUCTURE TRAILING EDGE FLAP MAIN CARRIAGES AND SEQUENCE CARRIAGES FLOOR BEAMS AND INTERCOSTALS ENGINE SUPPORT STRUCTURE MAIN LANDING GEAR SUPPORT STRUCTURE (INCLUDING BEAVERTAIL) WING STRUCTURE TABLE Ill Principal Structural Elements Figure 5 (Sheet 3) ‘SRM 320 10 Deo 31/38BOETE 20? TNTERCONG INENTAL STRUCTURAL REPAIR FIN FRONT SPAR CHORDS, STIFFENERS, AND WEB REAR SPAR CHORDS, STIFFENERS, AND WEB TERMINAL FITTING TORSION AIG (FIN STA.50.53) ‘SKIN TYPICAL RIBS CLOSURE RIB ‘STABILIZER FRONT SPAR CHORDS, STIFFENERS, AND WEB REAR SPAR CHORDS, STIFFENERS, AN WEB ‘SKIN (EXPOSED PPNELS) FRONT SPAR TERMINAL FITTING REAR SPAR TERMINAL FITTING REAR SPAR TERMINAL SHEAR FITTING CLOSURE RIB TYPICAL INSPAR RIB INSPAR ELEVATOR SUPPORT RIB CENTER SECTION FRONT SPAR CENTER SECTION REAR SPAR CENTER SECTION REAR SPAR AUX. FAILSAFE FITTING CENTER SECTION TRANSVERSE RIB (- 100/- 200; CENTER SECTION BLO RIB CENTER SECTION TORQUE BOX CENTER SECTION CLOSURE RIB STABILIER ACTUATOR FITTING STABILIER ACTUATOR SUPPORT FITTINGS (- 100/- 200) STABILIER ACTUATOR ARMS (- 100/- 200) HINGE HOUSING AND HINGE BEARING CENTER SECTION JACKSCRSW SUPPORT FITTING CENTER SECTION DIAGONAL BRACE ATTACH POINTS FIN TO BODY TERMINAL PINS STABILIZER CENTER SECTION TO BODY HINGE PINS STABILIZER SPAR TO BODY KINGE PINS STABILIZER CENTER SECTION HINGE HOUSING BEARING JACKSCREW SUPPORT FITTING TO JACKSCREW GIMBLE EMPENNAGE STRUCTURE TABLE IV Principal Structural Elements ‘SRM 320 Figure 5 (Sheet 4) 51-0 Deo 31/88 Page 11RSF LLP INTERCONTINENTAL STRUCTURAL REPAIR MAIN LANDING GEAR ‘OUTER CYLINDER INNER CYLINDER, ‘TRUNNION ‘TRUNNION /OLEO PIN DRAG BRACE DRAG BRACE FUSE PIN DRAG BRACE ‘OLEO PIN TORSION LINKS PINS, TORSION LINK SIDE STRUT ASSY. PINS, SIDE STRUT PISTON ROD (ORIFICE SUPPORT TUBE ) ORIFICE PLATE METERING PIN GLAND NUT ‘TRUCK ASSY. PINS, TRUCK ASSY. NOSE LANDING GEAR OUTER CYLINDER INNER CYLINDER, ‘TORSION LINKS PINS, TORSION LINKS ‘TRUNNION PINS TOW COLLAR ASSY. PINS, TOW COLLAR ASSY. STEER KNUCKLE ASSY. PINS, STEER KNUCKLE ASSY. STEERING SUPPORT PLATES PIN, SUPPORT PLATES TOW AND STEERING LINK ASSY. DRAG BRACE A3SY. PINS. DRAG BRACE ‘TUBE, PISTON ORFICE, PISTON TUBE ORIFICE ROD (METERING PIN) ORIFICE ROD BULKHEAD GLAND NUT * LANDING GEAR STRUCTURE TABLE V Principal Struntural Elements Figure 5 (Sheet $) ‘SR 320 Page 12 Deo 31/88IERCONTINENTAL STRUCTURAL REPAIR 204 ouND our To 1.008 win. ai IND'TaPER TO TNS LINE NOTES: ERR RE Maange, von RS EE Aaxinuu DEPTH x OF ScRATCH OR GOUGE 1S x OF eanuix GRRE rckeaiss tek og TATE SCRATCH, GOUGE OR MIST NOT INTERFERE WITH < ATTACHMENT EDGE MAROIN AFTER CLEAN UP SMILAR TO DETAIL! 25 0 DETAIL Il - INTERSPAR WING UPPER STIFFENERS Allowable Damage ~ Interspar Wing Structure Figure 1 (Sheét 1) ‘SRM 320 FaBaL aul 10/78 eeINTERCONTINENTAI STRUCTORAL HEPAT WwW ‘SCRATCH, GOUGE OR NICK Must WOT IWTERFERE WITH /ATTACHMENT EDGE MARGIN ‘AFTER CLEAN UP SHMILAR yo DETAIL seo see onan. en, era seer w son SERS oe ' SX an crore, NOTES: 1.00 iH eaunsngen nan oo pare pains ees Oe SLO Ses ses pe wns or vo oA rR ae OTA ME reiggaron won een : TB maxon anowasee SEE AE novo mee eateaine Gree s ete Resear. peer ae Smear eee Resi Beer cere B35: a t ag 4 5 i is i i STIFFENER NOT TO EXCaED 4, DETAIL HI ~ SPAR Allowable Damage - Inters; jing Structur ST-2-1 Figure 1 oneae 2} ae : ‘SRM 320 Page 2 sur 1078)Nores NO HOLES IN TANK END RIBS up Wess MAXIMUM NUMBER OF HOLES ALLOWED IS 1S htn’any ‘pane us STIFFENERS Staxiuus DEPTH OF SCRATCH On GOUGE 1S (0.08 aur NOT TO EXCEED 20 PERCENT MATERIAL THICKNESS. ARIMUM HUMBER OF WOLES PEN STIFFENER ‘fs cHoRD MAXIMUM DEPTH OF SCRATCH OR GOUGE IS ‘04 BUT NOT TO EXCEED 20 PERCENT MATERIAL THICKNESS. -ROUND OUT SERATCHES AND GOUGES A SHOWN IN 1 Ge counts or 1s ess THAN DIAMETER OF LARGEST €5..-5.4G RIVET OM BOLT HOLE IN DAMAGE AREA OF DAMAGED CHORD, DETAIL IV — INTERSPAR RIBS Allowable Damage = Interepar Wing Structure SRM 320 Figure 1 (Bheet 3) gul 10/82LDP STRUCHRNL REPAIR Z LOWER EXTERNAL FB CHORD, WAL 68.34 {UPPER CHORD SIMILAR ‘300 MAX (INBOARD AND OUTBOARD}: 200 MAX {INBOARD AND OUTBOARD}: UPPER EXTERNAL mB CHORD, WOL 60.26 (Cowen CHORD SIMILAR ores. fon Goucel witw a MAXIMUM LENGTH OF 200 {1 ‘Twe INOOARD ‘AND A Maximum REWORKED DEPTH OF O18 Itz CRACK "29 REWORK] OR Z5X OF THE MATERIAL ‘The Gotwe COMPANY. : ‘21007 OUT DAMAGED AREA Wir A 1.9 Muna RADIUS AB INDICATED. EXTEND THE CLEANUP [BEYOND THE END OF THE DAMAGE. es TE RENO a Bat 39 ARWURE COMPLETE RONOVAL OF SECTION THROUGH GOUGE DETAIL V = BEAVERTAIL ALLOWABLE DAMAGE ‘Allovable Danage - Interepar Wing Btructure 51-22 Figure 1 (Sheet 4) SRM 320 Page 23 Jan 10/81fire TINENTAL, RUCTURAL REPAIR 202 s rs ' ZA “ \ 31 \ won ‘APPROX 117 INCHES aad “s Ey es So | a “5 ms so ~rmmverion aneak pe Sc revere 1 UPPER SKIN svrox 90 nents “ bo sean sean —™ va yg Mtg 17 ces oO, oo ts 4 A wo Clean uP oan 10 / (over Sxan'nu0 Bete. / ‘LOWER SKIN AtLowable Danage ~ Wing Skin Outboard of BBL 70.5 Figure 1A (Sheet 1) sr 320 Jan 10/81INTERCONTINENTAL STRUCURNL Wee! ROUND OUT TO 1.008 AI. AND TAPER TO THIS LINE SECTION THROUGH CLEANED UP DAMAGE DETAIL 1 BOUNDARY OF CLEANED UP AREA 1 Ts oINENSION 15 LESS TH 1.50 "ED torn ets base ME CNet {o"ae ‘ov sea hossateion eee TO REAR SPAR ADDITIVE DAMAGE DETAIL 11 Allowable Damage - Wing Skin Outboard of BBL 70.5 Figure 1A (Sheet 2) ‘SRM 320 ST-2-1 Jan 10/81 Page 20SEINE LOL van TO aNY STLerENeR aN THE HARE ARTA. INTERCONTINENTAL, STRUCTURAL REPAIR D uss or cosss-secrsomn. aut Prapcaoico.as To Tae atin MULTIPLE ASEAS OF samsée ant To oC COUStOCHED o€ THE SARE Lint 17 LENS THAN 1.50 Peon race oTuen measutee Paws Ge eran 1D. eares sue sutereaen ansacent 10 4 san Foans a tareees pamel utth Tee 1) ‘THE ALLOWABLE BaMAGE LIMITATION Yo THE AREA ETeErE TaE span ane tHE ‘ecomn STivvenee, ouLess Tar oisrance ETVEEN tae sran‘aue apuaceny strrrrets 4H LQGLVALENT TO LOCAL STIFFEMER,BPACI a Lae IEGARD STIVFENERE 54, 64, AND 7A, EEN VE 94B AND WE 960 IF THETALiED. nov oF 5 THe AFT x0 ™ HN mess mk ge ~ Wing Skin Outboard of BBL 70.5 Figure 1A (Sheet 3) GD stuowsce oanase crmrvarsons anew APPLICAMLE IW THE FOLLovING AtEas CONSULT THE BOEING: COMEREIAL AT 0, F00 SPECLFLE EHETAUCTIONS 4. WENA 1.30 OF any cnons-atae rasreneni 2. roRWARD OF A LINE 1.50 477 fov OF FASTENERS ATTACKING THE To'THE HORT Pane 3 A Lime 4.50 romvany oF tov oF fasreneas AT¥A0 THE SKE 'TO THE REAR PAR. 4. vrtarn 1.30 oF rastemens TH SPANVISE’BKIN SPLICE. 5. WERE THE aenAtaias sxtm tateC Woute oe cess Taw 0.000 Incw FUEL TAME AREA, Allowable SRM 320 Apr 28/95, TR Page 2 of 2 a Ape 28/95| 5724 57-11STRUCTURAL REPAIR ALLOWABLE DAMAGE {3} ALLOWABLE DAMAGE UPPER SKIN TABLE ALLOWABLE DAMAGE TOTAL Max cr ‘WAX POSSIBLE OUE TO LIMITATIONS ON LOSS OF GASE-BECTIONAL AREA ALLOWABLE DAMAGE TABLE I LOWER SKIN Allowable Damage - Wing Skin Outboard of BBL 70.5 Figure 1A (Sheet 4) SRM 320 S122 Jon 10/82ENTERCONT INENT STRUCTURAL NEPAL carcusaTion [ASSUME THE DAMAGE 18 TWO ABAASIONS LOCATED AS ‘Shown of THE LOWER Ox: SECTION THROUGH DAMAGE AFTER CLEAN-UP PERPENDICULAR TO REAR SPAR TES CEH oF Danae BETWEEN TOREAK ta Oe, STEP2 - CHECK LOMB IN AREA geTWcEN STIFF ENERE, SSE Age Roar SAMAgE CewENOICULAR LOS IN AREA OF AFT DAMAGE = 3 x 0022 = 0400 80. ‘THESE ARE BOTH WITHIN THE 0.000 LIMITATION OF TABLE 1! ore) ~ cH THE TOTAL Lome. AREA gETALIN FT AND FEAR Bran Se DAMAGE ARE ie TWO A ‘iy ArAnT pEPENOICULAR TO Ro) ‘a BAMAoe Weeumutarive, geo * 0038 = BGNerne roe 08F CITATION OF TAD (AS. ALL OF THE CRITERIA ARE WITHIN TADLE 11 LIMITATIONS ‘The DAMAGE SHOWN WOULD BE ACCEPTABLE ‘Allovable Damage - Wing Skin Outboard of BBL 70.5 SRM 320 Figure 1A (Sheet 5) 51-221 Jan 10/81 Page 20(TERCONT INENTAL RUCTURAL REPAIR NOTE zi ocern oF soncren on gouee Fea pu RET TS gSEs S08 SONS Saas SECTION THROUGH GOUGE DETAIL! SEE FIG. 28 FOR eR SKIN ts ZB Beameneno: ‘SEE DETAIL WE ‘SPARS AND SPANWISE BEAM SEE DETAIL STIFFENERS Bsee veran ‘SoRaTCH on coUGE MUST NOTINTERFERE WITH ATTACHMENT EDGE MARGIN SE DETAIL! 02501AMN INTERSPAR WING UPPER STIFFENERS Lit Allowable Damage ~ Wing Center Section , Figure 2 (sheet 1) 5T-2a1 ‘SRM 320 Page 2H Jen 10/79> hawt one oo SLENDOUT INSTRUCTIONS... —_ eae ‘EXTERMAL SURFACE OF THE WINE. HUTTON: 90 wor eat fake the Blendout fncher Ry oF Exeaine the tng damage Anapection to Reaove the densge atin, LOP INTERCONTINENTAL STRUCTURAL REPAIR APPLICABILITY PROCEDURE 1 1. Shot poem the danige ar UY FASTENER WOLE. ARE 2 Apply Alodine 600. Refer te 38m 51-8-0, 8 10-79, Type 11 fer to $OPR 20-64-04. yaynante svetic = FALL the aren ten ons 5-1 7 Lat the seatant cure F of ORE 10-70, Type LLL priaer ever the sealant. te! S0PH 20-46-04" = Anoty ane Layer of ans 40-100 to the oper atin. Apely ORE 5-95, class sealant plce ant 10-40 protective enamel tothe Lover akin. ER TO SEN S7-2-1, 4 FIG. $A GIVES THE ALLOWABLE BARAAE ‘THE WING TasPaR SciN eUTDOAND Se PROCEDURE 11 bs REROVE THE FUEL FRO THE TaxS. SUPPLY THE TANK WITH A 6000 FLOW 1 for the anxious depth of tte te 1h for the Unite of the inapar akin. fee oetatl I. sure th aueoth to 125 aterem danaze 12 wore than the Listts of $n URN STOEL, Hig. Thy ae If the dosage t not sore then y AN ST=2-1, Fig. Thy” blend the fer to bataii 1. Rake the st aaooth to. 125 aleroined 4, oa penetrant inspection to make sui al reneved tran the fastener damage than the depth ta IT Part 6, 37-30-07. ‘ef a crack in the hale, ‘inatructionss 8 poen the dansped 7. WALL and countersink the 4 oo TF there te the ‘Apply Alodine 600 to the blendout ane countersink. Refer te ERR S1-8-2. Wing Inspar Skin ~ Renoval of Damage at a Fastener Figure 18 (Sheet 1) a 7-1 0 Moe THs 320 SRR apr 7/95INTERCONTINENTAL STRUCTURAL REPAIR BLENDOUT INSTRUCTIONS (CONT) - erates ee PROCEDURE 11 (CONT) INSPECTION ProceoutEs FER 10 $0PM 20-64-06 FOR THE APPLECATION CONROSION RESTSTANT PRIMER © REFER vo sum 1-2-2 rou Fastener ARENOVAL AND THSTALLATI REFER Yo Sun 51-2-5 ron rasrenER svastitorion mR TO SRR 51-205 FOR FASTENER WOLE 2 Uh tack or 413 ine a hex drive bett. We = REERR 10 ARR S1-2-11 FOR COLE voRKING ‘ote that hes the MOLES FOR FATIGUE IRPROVERENT. ieleste REFER To SEN 51-41 FoR atno seradymante surtes ‘snootaness FALL the area with ORB 5-95 seatant o RErER 10 g0n Bi-8-0 4 TA = Let the seatent cure meTAL nePAt “tn aver ae afm, PEN Ta aun std ron rteze ris 7211 priser ever the seatents” Refer ee torn acaeeee REFER To ON 51-91 ron nePAre senLtNs Ly one Layer of aR& 10-100 te the 4 REYEN To. gen S1-13-1 ron exMERAL tePatE upbat shin, "Apoty aa 543, Class ? eee raoceoun ‘Ont 10-40 protective ensact to THAT ATTACH THE sate, ‘SEIN TOA STRUCTURE, 90 As FOL 9 or atnavt wont aan 738 oF Ht ‘WOTES: ‘CASTENERS AT ONE TIRE oe = HU” a aun or one rastenen, 14 200 = TEE quamern or vases on Sr emn"rarenes, Th acon - see tame ar oe tants 2 08 rat truce. te ste att ones Tie eemaree’ ate Nicentse suite Sane re arcana? cttan, WEN rae Peart OU Rinin fermess anne anne ‘eae eeecenmes axl evctetce 16 as fod Met ane ut re cnreasae ts cit OF ana LE Tr OR BLE, LE, €0 TO THE BOEING CORPARY OR ‘NORE OURABLE THAN SEX MOE OF CADRIUN PLATED STEEL. THUS HEX DRIVE cone! ‘BOLTS RADE OF ALURIWUR COATED TETARIUR ARE GZ) cove vone at moves rm we Lover urae sx1 Pnevennei OSE THE ALON IHTENFERENCE COLD WORE RETHO © ALL DIMENSIONS ARE aM tucueS, UNLESS a1vEE eee atest DuFreneerty. COLD voRe Hors Tm Tat uPPE © AEPER 10 nn 20-0 F008 otrvtuies & Imvoand oP vaL 343, a8 411 2-11, an ru. tan REED EDGE MARGINS To A AININUN OF 1.730. © REFER To AMM 31-2-0 fom raTent0R AND GTEC Tf an Ataruane 14 covenee im exrenron FLNLGKES senvice auitern © REFER TO ANN 31-2012 ron conto! . Oy AARUAL, Pa 4 7-307 10 Ao 9040-06, Stent Casey eu muST nC INSPECTION PaO rr Areuova. vuon Tat apeLicanu . 30-07 AEGULATORY AvTaoRtTY ro. REVOKE T 70 my AMAL TT a re teas ream tt aay anaaenaee «tren ro sau s-t-08 ron sor pee Proceounes, 320 SRN TR 5 7-1 0 ‘Apr 7/95 Ape 7/95ayy INTERCONTINENTAL ‘STRUCTURAL REPAIR NOTES (CONTINUED) cuino tnr0 tee auap oF 4 rasreate ‘REPLACERENT GIVER TH TWAT OES WOT WAVE! aE It. 18 wor Listen, 60 10 Tm THE QOEIH6’cOMPARY WILL FANTERER Te Use, UNE Tae THe 0 as Fauuonts > FOR AN MMTTEAL ALUMINUM exvED autB A 30° THAN 1/32. 14cx anoune UY HOT WORE THAN Te a2* COUNTEAGIOG, Ste TABLE LIT 0.35 ENN FROM Tad CENTERLINE OF THE KOLE = fon Tae race eastenees arven tH Tae = TERE 13.4 aruznom oF 50 peacent oF tut TARLE, 00 wore [H) 8 Gtr TuSTENCTIONS AMEVEAL MATERIAL GERALHING BETWEEE aon Tae petine . gece ravens.” rat eatin GO 1 van sexu varceneas av rae rastenee arren papas eecrereraepamer males ome CLEANUP GILL OE LESS TiN Tur REGIONS RATER to SUR S1-8-4 ro A nem REPAIR, KEEP EDGE RAREIE. 7 SIVE THE ottNG company oerazes oF THE clear, oe wore. WAXIRUR DEPTH OF MATERIAL REMOVAL FROM A FASTENER HEAD CINCH) (3) INITIAL FASTENER 3/16 DIA 16 DIA 5/16 O18 3/8 OIA ‘ALatwun aver oa TABLE I Wing Inspar Skin - Removal of Danage at 0 Fastener Figure 1B (Sheet 3) TR 57-10 320. sen Apr 7/95 572-4 Page 2Lean ALT INTERCONTINENTAL, STRUCTURAL REPAIR wma [aged mananon rmzeeness | ser aceneut FASTENE! cane) SKIN FASTENER [E) + eae e ae bed GACESONNEKOY BOLT WITH A nae SEBS pur TT eo Ser Se ee sang ee Soe a a Spe wT TT wae Sa [, SapRTOT SS ae 4 Bear scr AT Seanad bod a ‘GACRSONNSZEOY BOLT WITH A] Soar Po ees 2] STABLE 11 antian rastEnea) wintnun rarceutss PLACERENT OIA OF THE RERAINING Fastener [ canem |" 'senw anch FasTenee (8 08 ‘ACeRONNGKOY BOLT viTH A Acez0R6 COLLAR s.omiwn ervey “ 0.09 ewemCcY weer vine ae a a2°130" coomrensron | 5746 010 eacesoMTORCOY veLT vITH A feaceaoeto coLian SACASDRNI2EOT BOLT wie A] TABLE 111 Skin = Removal of Damage at a Fastener Figure 18 (Sheet 6) Sot 6 i = TR 57-10 * Apr 7/95ee > INTERCONTINENTAL ‘STRUCTURAL REPAIR 10x mIMIRUN urPeR seus. 20x ALNINUN LovER SKIN L A CSEE TABLET FoR Tue axtnum (OEPTW OF MATERIAL AEROVAL PERLITE REMOVAL OF DAMAGE BY THE FASTENER-GRIMD METHOD TAIL 1 contoston vasrenre +t sm sae sae EES 2 EEE te react eat daw rt sams U ] Ct fe $e} rar anea ron rie MACEMENT FASTENER REMOVAL OF DAMAGE AT A FASTENER DETAIL 11 Wing Inspar Skin ~ Removal of dan Figure 1B (Sheet 5) at a Fastener S7-2-4 TR 57-10 ir s§ 320_ SRK Apr 7/95 ge 2HINTERCONTINENTAL STRUCTURAL REPAIR MAX. auicces. PER STIFFENER DETAIL IT SPARS AND SPANWISE BEAMS Bisee vera EE DETAIL! OETAILIV ‘SPAR CHORD AND SPANWISE BEAM CHORD °OIAMIN Allowable Denage ~ Wing Center Section Figure 2 (Sheet 2) SRM 320 STa201 Jul 10/78 Poge 3Se) = INTERCONTINENTAL STRUCTURAL REPAIR APPROX 11, INCHES 4 XS NO UP OAMAGE OS ‘UPPER SKIN ‘AMD REFER TO TABLE 1 FRONT SPAR UPPER SKIN CLEAN UP DARAGE To LOWER SKIN ‘AND REFER TO TABLE 11 FRONT SPAR LOWER SKIN Allowable Danage - Wing Center Section Skin Figure 2A (Sheet 1) SRM 320 SP-2-1 Jul 10/78 Page 4ee > LE acon ONTINENTAL STRUCTURAL REPAIR {AND TAPER TO THIS LINE SECTION THROUGH CLEANED UP DAMAGE DETAIL I [BOUOARY OF CLEANED UP AREA AF THIS DIMENSION 18 LESS THAN 1.30 GOTH AREAS OF DAMAGE ARE CONSIDERED TO BE ON THE SAME CROSS-SECTION ADDITIVE DAMAGE DETAIL 11 Allowable Damage - Wing Center Section skin Figure 2A (Sheet 2) 2SAR-57-2-1" FLGZALT SRM 320 sul 10/78 ROUND OUT TO 1.00R MIN. 51-2-1 Bene §BONG 7D ae INTERCONTINENTAL STRUCTURAL REPAIR NOTES DAMAGE TO CENPER WING SKINS BY NICKS, SCRATCHES GOUGES, CRACKS, ABRASIONS AND CORROSION’ 18, ALLOWABLE FROVIDED THAT ALL OF THE LIMITAIONS IN TABLE T OR TABLE IT ARE NOP EXCEEDED, DAKAGE DEPTH AND LOSS OF GROSS- SECTIONAL AREA ARE 10 BE DSTERMINED AFTER CLEAN-UP (SEE DETAIL I ) THESE ALLOWABLE DAMAGR LaMrTS ARE NOT APPLICABLE IF THERE 18 WIREPAIRED DAMAGE T0 ANY STIP- FENER IN THE SAME AREA, SEE FIG. 1A FOR TYPICAL SAMPLE CALCULATION, ALLOWABLE DAMAGE LIMPTATIONS ARE NOP APPLICABLE Di THE FOLLOWING AREAS (CONSULT THE BOEING COMMERCIAL ALAPLANE CO, FOR SPECIFIC INSTRUCPIONS) 1. WITHIN 1,50 OF ANY CHORD- WISE ROW OF FASTENERS 2, FORWARD OF A LINE 1,50 AFT OP THE AFT ROW OF FASTENERS ATTACHING TSE SKIN TO THE FROND SPAR 3. AFT OP A LIME 1,50 FORWARD OF THE FORWARD ROW OP FASTENERS ATTACH- ING THE SKIN 10 THE REAR SPAR, 4, WITHIN 1.50 OF FASTENERS IN THE SPANWISE SKIN SPLIOES EXCEPT AS SHOWN IN SECTIONS A-A, B-B AND C=C, LOSS OF CROSS~SE: SIONAL AREA ON ‘A LINE PERPENDICULAR 10 THE REAR SPAR, MULPIPLE AREAS OF DAMAGE ARE TO BE CONSIDERED ON ‘THE SAME LINE IF LESS TAN 1,50 FROM EACH OTHER MEASURED SPANWISE (SEE DETAIL II) REPAIRS ARE REQUIRED WHERE CLEANUP IS BEYOND LIC IS Allowable Damage - Wing Center Section Skin Figure 2A (Sheet 3) SRM ZO van 10/79oown rv, couaxl ! 1 £ f 1 4 BRM 320 dul 10/78 pwnd bl Lome SECTION A~A, sue SECTION B-B eae | aseun penn] SECTION C-C Allovable Damage - Wing Center Section Skin Figure 2a (Sheet 4) ST-201 Page 6AINTERCONTINENTAL STRUCTURAL REPAIR ALLOWABLE DAMAGE Max oerTH IAPTER CLEANUP Rs To $106 8-100 To s-126 170 To 6-186 ‘s-100 10 $280 snctTossic | aoe 0086 sate 10 #8. oor 0.054 ALLOWABLE DAMAGE UPPER SKIN TABLE | ‘ALLOWABLE DAMAGE (4) Max DERTH. Max. Loss OF APTER ectanur | GAGSS-SECTIONAL ‘Pea SETWEEN ‘Abaacent Stirrenens on SETween gear aoa RETO EE s-4c To $06 2c To He ste To e216 ene To s-28c 280 TO FS. ‘TOTAL Max ey + MAX POSSIBLE DUE TO LIMITATIONS ON LOSS OF (GAOSS-SECTIONAL AREA ALLOWABLE DAMAGE - LOWER SKIN ‘TABLE II Allowable Danage = Wing Center Section Skin Figure 2a (sheet 5) RH 320 Jul 10/79STRUCTURAL REPAIR DETAIL! ‘Reuv our To .a0R AND'TAPER TO TH Line NOTE [MAINTAIN FDGE MARGIN ON ALL. FASTENERS BY resncer THickMEss. WO OPEN HOLES IN BALANCE PANEL AREAS Bi suxsmun oer oF sceaten on couse wot To EXCEED 20 PERCENT MATERIAL THICKNESS Bi Harun aLLowante wes cRoss SECTIONAL AREA [REMOVED INCLUDING ALL. EXISTING HOLES SHALL HOT EXCEED 20 PERCENT, IN SOLID WEB Gy FoR Honevcous ALLOWASLE DAMAGE ANO REPAIR SEE S104 Gh cLeAn uP nicas ro 1.00 wnt RADIUS ‘ss Wow IM DETAIL | Allowable Demage-Wing Trasl.ing Bdge Figure 3STRUCTURAL R& NO HOLES IN PANELS~ NOTE OR AERODYNAMIC SMOOTHNESS REGURENENTS see steer Hh wixmun verre oF scraTcH of couce WoT To EXCEED 20 PERCENT MATERIAL THICKNESS Ecc aLLowace aia wen cross secriowat, ‘AREA REMOVED INCLUDING. EXISTING HOLES MALL WOT EXCEED 20 PERCENT. DETAIL! Barm SECTION THROUGH GOUGE sera BDuurration wore 1s ror op rum [PERFORMANCE 1CKS TO 1.00 MIM RADIUS AS SHOWN AM Bh wanrai cove manom on ALL FasTencnsSTRUCTURAL REPAIR NOTE MAINTAIN EDGE MAROIN OM ALL FASTENERS, FOR AERODYNAMIC SMOOTHNESS REQUIREMENTS. seeset ‘THERE ARE WO STRUCTURAL L [BE REMOVED AY THE EARLIEST OPPORTUNITY. MAXIMUM ALLOWABLE SPAR WH CROSS SECTION: ‘AL AREA REMOVED INCLUDING EXISTING HOLES SHALL NOT EXCEED 25 PERCENT Gi resneer tuicxness B sau cere oF sexarcn ot aouse not To ExCEED 25 PERCENT MATERIAL THICRNGSS. Ou OUT ANO TREAT ALL SCRATCHES AcD ‘couces PER DETAIL | BE cLean ve wicns 10 appRoxMaTEL 100 tn sa.STRUCTURAL REPAIR NOTE MAXIMUM ALLOWABLE CROSS SECTIONAL EXISTING HOLES, SERATCHES AND GOUGES, MAINTAIN EDGE MARGIN ON ALL FASTENERS Bi ror wonevcos ALLOWABLE OMAGE AND REPAIR ‘SEE S1-10-1 va (MAXIMUM DLP IH OF SCRATCH OR GOUCE KOT TO. T Bo ene ATE On cover no se ey Bie vr wices ro .09 wnwun enous Stoner v wo cmkexs On WoUEE M sx 0c stRUCTURE —, “ LO ron covoes ato scasrewes AO ‘SEE DeralL 1 -ROUND OUT TO 1 BRD TAPER TO: DETAIL | SECTION THROUGH GOUGE 51-24 ieee Page 10 IR 18 UNE au 1/59stifle STRUCTURAL REPA MAINTAIN EDGE MARGIN OW ALL FASTENERS MAXIMUM DEPTH OF SCRATCH OR GOUCE NOT TO EX. ‘CEED 20 PERCENT MATERIAL THICKNESS MAXIMUM ALLOWABLE AREA REMOVED PROM WEB IN- {CLUDING MOLES AND SCRATCHES SHALL HOT EXCEED ‘29 PERCENT Biron HOneYcous ALLOWABLE DAMAGE AND REPAIR SEE St-10-1 BB cLean ur wicxs 10 1.00 mn RADIUS AS SHOWN IH OE ‘ale By ovrooaRo AILERON TAB. THE ALLOGABLE WARPAGE DETAIL OF a staucruRaLuy Z2UMD TAB 1s 5 FOLLOWS seliies ‘the DISTANCE OF Any POINT OF THE TAB TRAILING SECTION THROUGH GOUGE {ASURED FROM ASTRAIGHT EDGE LALO ALONG EDGE MUST H EXCEED O.01N THE LENGTH MUST BE EGUAL To OR GREATER THAN TAB LENGTH. see pevatLt ‘Aowable Danage-AtLeron ‘Apr 1/63 Pigure 7 5T-2-1 Rovised FageSTRUCTURAL REPAIR NOTE MAINTAIN EDGE MARGIN OM ALL FASTENERS Bl cuean ue mice ro 1.00 ummm eadius B texmun verte oF scrarcn on couce nor To EXCEED 20 PERCENT MATERIAL THICKNESS i uaxwun atcowsste AREA Reuoven Frou wee INCLUDING HOLES AND SCRATCHES SHALL NOT EXCSED mrercent DETAIL} SECTION THROUGH GOUGE Allovable Damage-Spotlers 51-21, Figure 8 Page 12tliat STRUCTURAL REPAIR NOTE: .100 INCH AIMIMUM STOP ORILL HOLE. SEE DETAIL 1 FoR TABULATION ‘OF DAMAGE CRITERIA, Allowable Damage - Fillet Flap Casting oct 1/61 Figure 9 (Sheet 1 of 21 ST-Be2, Revieed Page 13struct 1 ORIND OR FILE To A tuooTH FAIR SORFACE WITH RO SHARP CORNERS Om EDGES RUSH ALODIZE PER s14-2, URAL aii REPAIR CLEANUP PROCEDURE FOR OnE PLIGHT To WEAREST MaDe BASE 'POR REPAIR OR REPLACEMENT DETERMINE END OF CRACK AFTER STOP DRILLING AND OYE| ‘heck PROCEDURES, MAKE A FAIR SHAPED CUTOUT ‘TO REMOVE MATERIAL IN CRAC REGION ‘ORIND OR FILE TOA SwOOTH FAIR SURFACE WITH NO SHARP ‘CORNERS OF EDGES, 4 BRUSH ALODIZE PER S12, ORILL OUT AND PLUG RIVET FLL OW SKIN SURFACE BY INSTALLING ‘S036 ALUM ALLOY BY SQUEEZE METHOD OR TIOOF RIVETS BY ie PACT ORIVING. USE 1/8, 5/32 OR 2/76 SIZES WITH MINIMUM SPACING OF'.00 OLE lOREATER Tuan ta8 bu 57-28-12 Page 14 ‘DETERMINE END OF CRACK [AFTER STOP DRILLING AND OYE| ‘CHECK PROCEOURES, MAKE A Falk sHapeD CUTOUT ‘TO REMOVE MATERIAL IN CRACK REAION. ‘GRIND OR FILE TO. SMOOTH PAIR SURFACE WITH HO SHARP (CORNERS OR EDGES, (ORUSH ALODIZE PER $1.82 DETAIL! Allowable Damage - Fillet Flap Casting Figure 9 (sheet 2 of 2)Le a SRM 320 Figure 10 (She General A. Maintain records of all material removed by rework to wing structures, Jnclude all revork of spar chords, webs, stringers and skin panels. The cumulative effect of such revork, at a particular wing station, could have a significant bearing on structural integrity. B. Extensive rework to the upper and lover skin panels and spar chords at any wing cross-section may produce a significant chango in the wing properties at that cross section. Consult Te Boeing Company when extensive revork is required. Rework danaged and corroded chords as shown in 51-8: wprizontal legs Refer to Detail ZIT, Fig. 1 for revork Limits on horizontal legs. Vertical lags A. Wing spar chord vertical legs may be reworked within limits defined by the accompanying graphs for the removal of damage and corrosion products. B. Where the thickness Liaits defined in these graphs are exceeded consult ‘The Boeing Company or wake a repair in accordance with SB 324C. Ce The curves on these graphs are based on static strength criteria Fatigue life of the component may be affected by rework. Allowable Rework Limits - Gutboard Wing Spar chords 2 ST=2-1 van 10/81 Page 15nape STRUCTURAL REPAIR 0.3 7 a g 8 & ceca] g UPPER CHORD 8 seer # § 3 - E oa 7 aie fat E a a. g = a i a g Lover con g 02 - Ad ! [ § 3 | fw Ee 5 8 a i a0 I a a a a ) FRONT SPAR STATION ROUT SPAR LOMER CHORD VERTICAL LE) Allowable Rework Limits - Outboard Wing Spar Chords Figure 10 (Sheet 2) sin 320 st-2-1 Jon 10/77 Page 16— aH STRUCTURAL REPAIR ‘UPPER CHORD 0.6 os 02 ot WINIIWUH VERTICAL LEG THICKNESS CINCHS) 0.0 WING STATION REAR SPAR UPPER CHORD (VERTICAL LEG) 4. i ct Bos L o 100 200 ~«300~—A00 S007 OOD WANG STATION REAR SPAR LOVER CHORD CVERTICAL LES) Allowable Rework Limits - Outboard Wing Sper Chords Figure 10 (Sheet 3) SRM 320 dan 10/77 STo204INTERCONTINENTAL, STRUCTURAL REPAIR ‘BOEING 707 INTERCONTINENDAL ‘STRUCTURAL REPAIR NoTEs © ‘THE REWORK LIMITS SHOWN WITHIN INDICATE THE MAXIMUM REWORK PERMITTED AT ONE (1) CARRTAGE AND THE ACTUATOR ATTACH FITTING CAVITIES. SHOULD LIMITS BE EX. CEEDED IN ONE (1) PARTICULAR ARKA WITH LESS CORROSION IN OTHER AREAS, CONTACT THE BOEING COMPANY TO DETERMINE IF THE SLAT CAN BE REWORKED MAXIMUM DEPTH OF SCRATCH OR GOUGE NOT TO EXCEED 20 PERCENT OF MATERIAL THICKNESS @ wacoum Very OF DENT MUST NOT EXCEED Y=0,05, MAXIMUM ¥/A RATIO MUST NOT EXCEED 0.03 INCHES PER INCH OF WIDTH (A MINDMUM OF ONE (1) FASTENER PER SIDE MUST NOP ‘BE CRACKED FROM HOLE 10 FREE EDGE. AT HOLES THAT ARB CRACKED 10 FREE EDGE, EDDY CURRENT FOR ADDITIONAL CRACKS IN HOLE, IF NO ADDITIONAL CRACKS, OVERSIZE BOLE 1/16 INCH IN DIAMETER AND INSTALL OVERSIZE FASTENER LOCAL CORROSION SPOTS IN THE ‘LOWER HORIZONTAL FLANGE ARE ALLOWABLE IF DEPTH OF CORROSION 18 LBSS THAN OR EQUAL TO ONE-HALF OF MATERIAL ‘THICKNESS AND THERE 18 A MIWIMUM OF 0,32, INCHES BETWE2N CORROSION AND NEAREST FASTENER, 0,38 MAXIMUM REMOVABLE OVER ENTIRE SURFACE 18 ALLOWABLE ‘A MINIMUM OF ONE-HALF OF ‘THE ORIGINAL MATERIAL THICKNESS 0 REMAIN OVER THE ENTIRE SURFACE A MAXIMUM OF 0,05 REMOVABLE lls MAXIMUM HOLE HEIGHT THRU WEB OR REMOVE AVERAGE DEPTH OF 0,10 OVER ‘TOTAL HEIGHT OF WEB LOCAL CORROSION SPOTS IN LOVER SKIN, NON-PADDED AREA, ARE ALLOWABLE IF DEPTH OF’ CORROSION IS L858 THAN OR EQUAL TO ONE. HALF OF THE MATERIAL ‘THICKNESS AND THERE IS A MINIMIM OF 0.25 INCHES BRIVEEN CORROSION AND NEAREST FASTENER ‘SHOULD MATERIAL BE REMOVED FROM RAISED BOSSES /T FASTENER HOLES, SHIMS WILL HAVE 10 BE USED WHEN REINSTAL- KINO ACTUATOR FITTING ‘A MAXIMUM OF 0,07 REMOVABLE Allowable Damage - leading Edge Slats, Outboard Wing Figure 11 (Sheet 1) ‘SRM 320 Jan 10/19DONE INTERCONTINENTAL ‘STRUCTURAL REPAIR Adlowable Danage ~ Leading Edge Slate, Outboard Wing Figure 11 (Sheet 2) a SRM 320 Jan 10/19 Page 19an ROUND OUT TO 1.00 Mm va ‘TAPER TO THIS LINE Y= DEPTH OF DENT ‘A= MINOR AXIS OF DENT [SECTION THROUGH DENT {5} DETAIL 1 Allowable Damage ~ Leading Edge Slats, Outboard Wing Figure 11 (sheet 3) 51-201 ‘SRM 320 Page 20 Jan 10/79INTERCONTINENTAL STRUCTURAL REPAI PWS eran ewe) DETAIL IV iwaol Allovible Damage - Lesding Bige Slats, Outboard Wing Figure 11 (Sheet 4) SRM 320 Steed Jan 20/19 Page 21SOEING Ss INTERCONTINENTAL, STRUCTURAL REPAIR 512-2 Page 22 SECTION A-A ‘Alovatle Dmage ~ Leading Fige Slate, Outboard Wing Figure 11 (Sheet 5) ‘SRM 320 Jan 10/79Gog, *S> INTERCONTI! STRUCTURAL, DETAIL VI SECTION 8-B 5T-201 Page 23 Sheet 6) ng Bage Slate, Ovtboard Wing Figure 11 Allowable Damage - Lewd Jan 10/79 ‘SRM 320Bae INTERCONTINENTAL STRUCTURAL REPAIR eR, eran wi woot? Sis Ic SECTION C~C Allowable Danage - Leading Edge Slats, Outboard Wing Figure 11 (Sheet 7) ST-2ed 8RM_320 Page 2 Jen 20/59INTERCONTINENTAL STRUCTURAL REPAIR eet Allowable Danage - leasing age Geto, °.:tonrd Wing Figure 11 (sheet 8) SRM 320 S122 Jan 10/79 Page 25,R Bu 3s 2 BS ze ‘ Se N WwW I DETAIL 1x C SECTION 0-D ‘SRM 320 Jan 10/79 Allovable Damage ~ Leading Bdge Sata, Outboard Wing Figure 11 (sheet 9) ge tS21 Page 27 ® trv, SECTION F-F DETAIL x HOP => INTERCONTINENTAL STRUCTURAL REPAIR =~ SECTION €-E Allovable Damage ~ Leading Rige Slats, Outboard Wing Figure 11 (sheet 10) SRM 320 Jan 10/79STRUCTURAL REPAIR ®|@|® ov 91-1909 910° whew Tenaiww SaxoH> | = [o[ele[e[o/e/e/elo Wing Leading Bdge Structure Identification Figure 1 (Sheet 1 of 14) Jan 1/63a REPAIR STRUCTURAL oreee acnivany | @ srsiar ronvseint anv | © “oscar vor-seibt ane A0uiv mnisanovn iveoe seristove lela|e [ele fole 051-9610) ONY 1-00 rocoousast 3ve Wing Leading Edge Structure Identification EB } @® ® ® ® ® @ ® ® ® © © ® 2 eI re Lee] Jan 5/70 Figure 1 (Sheet 2 of 14)STRUCTURAL REPAIR Der ov oot eves avs ore per avin oro" @/@|@|@| © ® susuoe avo er asta avn ont vis0 avid oe o| © lol © Dern avid one Giaaam 913002 POre-TeLat GN oxscoe ov oe wove ‘wamon pLsioc Pooe-se10t ON i wagan suse Gv Dee" waeaww SaHoH? Wing Leading Sige Structure Identification Figure 1 (sheet 3 of 14) wh Jan 1/63 RevisedREPAIR STRUCTURAL [ole Mae o Taare s aaa] © ® | ®|® ®| ® |@| © wreww Twi SawoH> Wing Leading Bage Structure Identification Figure 1 (Sheet 4 of 14) gan 1/63 57-43 Page i,STRUCTURAL REPAIR ‘ousmmoa aay GL6tnt 30 $40015 OMLLSIXa NAHM GBGKENNOISY UY gontewod EL1-sioe ‘woLLanGoud MI CLLacol JQ SONTOUOS Re aaovusu Nase SAWH Wwivaivm O1eco 20 SoNIDuOS “aaLVuOUNOONI OBE “8S HAVA SaNWTUIY NWsOoUNA TIY NO [} wane anviwang AML 40 TECHS 335 ONISVD SIH JO UIvEaY ONITTEM UOS [) INO SaNVTauIY UBLWT AMOS NO a38n SES $S4 LY w. OB's0E s$4 2V TH HA TIvI30 -Atwaaa Wing Leading Edge Structure Identification Figure 1 (sheet 5 of 14) uh 15/73ilu, STRUCTURAL REPAIR Re | ri WEE Tea wees wea | Ta | waa ware waa] war—|-* § 5 5 g a g 3 5 3 Z i 5 5 wae ® ©. CMs eT Wing Leading Edge Structure Identification STalin3 Figure 1. (Sheet 6 of 14) Jan 5/70 geee STRUCTURAL REPAIR 3 5 t 2 2 2 i ® Wing Leading Edge Structure Identification dan 1/63 Figure 1 (Sheet 7 of 1h) 5T-hn3 Revised Page 7STRUCTURAL REPAIR van 1/63 Revised Wing Lending Bdge Structure Identification Figure 1 (sheet 6 of 1h)STRUCTURAL REPAIR Rage Structure Identifi zation Jax 1/63 Figure 1 (sheet 9 of 1h) 5T=he3 Rerised Page 9Taliee STRUCTURAL REPAIR ELAP CROSS SECTION DETAILIV OPTIONAL OUTBOARD see DeTANL . Wing Leading Rage structure Identification S1nb=3 Figure 1 (Sheet 10 of 14) van 1/63 Page 10 RevisedSTRUCTURAL REPAIR Wing Leading Bdge Structure Identification Figure 1 (sheet 11 of 14)STRUCTURAL REPAIR # : 3 Wing Leading Edge Structure Identification 57h} Figure 1 (Sheet 12 of 1h) Oct 1/64 Page 12 Rovinod,STRUCTURAL ZEPAIR ALL TURBOFAN AIRPLANES Wing Leading Edge structure Identification Sul 15/73 ‘Figure 1 (sheet 13 of 14) ST abe}STRUCTURAL REPAIR 3 g 3 & 2 3 i 2 4 a Wing Leading Bdge Structure Identification ry eek gure 1 (Sheet 1 of 1/4) Sul 15/73 +REPAIR INSTRUCTIONS ‘The following procedure is epplicable only if damage is eetablislied as a crack radiating from the drain hole. 1, Remove the slat fron the in accordance with Chapter 27-16 of ‘the 707 Maintenance Manual. 2, Renove actuator fitting. NOU: ‘he actuator ritting my be difficult to remove, A simple puller my be fabricated thet picks up the actuator attach lugs and applies a light steady pull through tvo ‘thuxbscrews that react on the slat itself, With a steady pull exerted, apply modersie heat (200*F max) to fitting and slat, 3. Rady current inspect the drain hole per D6~7170, Nondestructive Test Manual, to identity and locate cracke enanating fron the @rain hole, 4, Mark a 11/16=inch diameter efrele around the drain hole and encompassing cracks, 5. If crack 4s not detected outside of the 11/i6-inch diaueter cirele proceed to Method I repair. If crack extends beyond the 11/16-inch diameter circle Proceed to Method II, III or IV repair, Refer to note for general description, tl STRUCTURAL REPA Method I 1. Oversize Grain hole to 8 final Atameter thet will remove 1/32 inch of materiel beyond end 0° crack. If crack can be detected runing out of only one side of @rein hole, assume thet none detectable crack progresses out of the other eide, and renove 1/32 inch of material from tnat side of the hole, alec, The waximin allovable hole diameter shall not exceed 3/l-inch Glaneter. ‘This hole limit can be moved to encompass both the end of the crack and the ¢rein hole plus 1/32 inch beyond the end of ‘the crack and outer edge of drain hole, . Febricate 20cK~73 aluminun alloy plug having 0,00015/0.00020-tnch interference fit with the hole. 3. Inotall plug with vet zine chromate priner. 4, Prine the surfaces of the part in ‘the repair area with BNS 10-11, After curing a? the priner, coat ‘the primed areas with polyure- ‘thane enamel, BMS 10-60, 6. Respply potting compound, if required, and reinstall actuator fitting, 7. Restore original finish in accordance vith 51-20 of the 707 Yaintenance Manual, |. Reinstall slat according to Chapter 27-16 of the 707 Maintenance Manual, Leading Bage Slats = Repair at Drain Hole ‘ARM 320 Jul 10/75 Figure 1 (Sheet 1)STRUCTURAL REPAIR REPAIR INSTRUCTIONS (CONT) Method Li, Method T11 enc Method IV ‘HQUE: Damage repeir my be accom plished by proceeding with efther Method IL, III or IV repair procedure, Method II requires full penetration velding under stringent high temperature preheat with subsequent, stress relieving and heat treating, Wethod IIT requires full Penetration welding under less stringent and lover temperature Preheat vith no stress Telfeving or heat-treating required, A doubler, however, is fastened over the damge area. Method IV requires no welding but requires @ doubler end a ‘tripler fastened over the damage area, Methoa 1, Drill a 0,167 diameter stop hole at the extrene end of the crack, 2, Rady current inspect the creck area per D6-7170, Nondestructive ‘Test Manual, to ensure that cracking does not exist beyond ‘the hole, If no cracking exists, enlarge stop hole to 0.25 atemeter, 3. Remove fasteners from rib chords as required, 4 o a Prepare the slat for welding and ‘weld the crack in accordance with 57-50-32 of the 707 Overhaul Mamal. Also f111 the drain hole vith veld, Prime the surfaces in the repair area with BMS 10-11, Reinstall fasteners wet with BY 10-11 priner, After curing of the primer, coat ‘the primed areas vith polyure= ‘thane enamel, BMS 10-60. Reapply potting compound, if required and reinstall actuator ritting, Restare origins! finish tn accordance vith 51-2-0 of the 707 Maintenance Manual, Reinstall slat according to Chapter 27-16 of the 707 Maintenance Manual, Eady current inspect the crack area per 15-7170, Nondestructive ‘Test Manual, to ensure that cracking does not exist beyond the hole, If no cracking exists enlarge hole to 0,25 diameter. Remove fasteners from rib chords as required, ‘Leading Edge Slate « Repair At Drain Hole Figure 1 (feet 2) RM, STs Page 2REPAIR INSTRUCTIONS (CONT) Method III (Cont) 4, Prepare the slat for welding ani weld the crack in accordance with 57-50-32 of the 707 Overhaul Manuel except as follove: a. Preheating and etress relieving shall be lintted to 35¢°F maximum and shall be accomplished by furnace methed only. bd, Re-heat treat of the casting is not required. c. Radiographic inspect and penetrant inspect per MIL- C-6021F only the veld area end 2 1.0-tnch wide zene cn doth sides and both ends of ‘the weld areas, 3+ Fabricate part , lay out and drill fastener holes to match existing holes in the rib chords, See Repair I or II for part configuration. Ley out and drill repair fastener holes in repair part and slet surface and countersink to suit fasteners, Drill completely through nose of casting for for~ ward row of blind fasteners. Holes will be filled vith resin after fastener installation. 7. Brush alodize the repair part and prime the surfaces of the repsir part ani the original with BMS 10-11, Tgehtpe dp STRUCTURAL REPAIR 8. a 10. a. After curing of the priner, coat the primed areas with’ polyurethane enamel BYS 10-60. Install countersunk repair washers in rib chord fastener holes. Refer to 51-2-8, Fig. & of the Structural Repair Manual. ‘ply corrosion preventive faying surface seal PRLAI3G or PRIU36G between plate ami slat surface. Install “astener wet, with BMS. 10-11 priner. Reapply potting compound, if required and reinstall actuator fitting. Restore original finish in oc~ cordance with 51-2-0 of the 707 Maintenance Namal, Reinstall slat according to 27-16 of the 707 Maintenance Manual. Method 1 lL 2. Drill a 0.187 diameter stop hole at the extreme end of the crack. Bady current inspect the crack area per D6-7170, Nondestructive Test Manual, to ensure that crack= ing does not exist beyond the hole. If no cracking exists en- large hole to 0.25 dieneter. Remove fasteners from rib chords as required. Fabricate parte [) and @ , lay out and drill fastener holes to match exiating holes in the rib chords, Leading Hige Slats ~ Repair at Drain Hole SRM 320 van 10/76 Figure 1 (Sheet 3) STok5 Page 3STRUCTURAL REPAIR INSTRUCTIONS (CONT) Method IV (Cont) 5. Lay out and drill fastener repair fastener holes in repair parts and slat surface and countersink or dimple to suit fastener call- outs and on illustration. HOPE: Drill completely through nose of casting for for~ ward row of blind fasteners. Holes will be filled vith resin after fastener installation. 6. Brush alodize the repair parts and prime the surfaces of the repair parts and the slat surface with BYS 10-11. 7. After curing of the primer, coat the primed areas vith polytre- ‘thane enamel, BMS 10-60, 8. Apply corrosion preventive fay- ing surface seal, PRIMIG or PRL436G between repair plates and slot surface prior to in- stallation. 9. Install fastener wet, with BMS 10-11 priner. 10, Reapply potting compound, if required and reinstall actuator fitting. LL, Fat heads of WASL3966 fasteners ani 0.72 diancter holes through parts (3) and @ with serodynamic filler. 12, Restore original finish in accordance with 51-2-0 of the 707 Maintenance Manual. 43, Reinstall slat according to instructions in 27-16 of the Maintenance Manual. Leading Bdge Slate - Repair at Drain Hole Figure 1 (Sheet 4) SRM 320nip iflet STRUCTURAL REPAIR OnES sueo1s © VISUALLY INSPECT FOR PROPAGATION A OF CRACK AT EACH "C" INSPECTION q ORIGINAL FASTENER LOCATIONS © THIS REPAIR 15 FOR USE GN cur + BOARD LEADING EDGE SLATS WHERE ‘A CRACK HAS OCCURRED DN ‘THE | repare FASTENER Locentoss VICINETY GF A WATER DRAIN HOLE eR PANS 1o sits vm ccs EXTENDING BEYOND THE LENGTHS SHOWN, CONTACT THE BORTNG COMPANY, FISLD SERVICE DEPART= vent © USE WHICHEVER REPAIR 1S APPLICABLE, (@ BREAK SHARP EDGES OF GRIGINAL AND REPAIR PARTS 0.015 TO 0,030 ‘AUD CORNERS FROM ORIGINAL AND REPAIR PARTS © REFER TO THE FOLLOWDIG WHEN USING EITHER OF THESE REPAIRS: 51-8-0 FOR PROTECTIVE TREATMENT OF METAL. 51-2-0 FOR FASTENER CODE, REMOVAL, INSTALLATION, HOLE SIZES AND EDGE MARGINS 5U-9-L FOR STRUCTURAL BONDING 5i-4el FOR AERODYNAMIC SMOOTHNESS ‘REQUIREMENTS 51-2-6 FOR COUNTERSINK REPAIR WASHERS 51-2-0 OF THE 707 MAIVTENANCE BACRL5CB6B, CSK NANUAL FOR DNTERIGR AND EXTERIOR FLUSH YOTH SIDES FDIISHES Leading Edge Slate - Repair at Drain Hole ‘SRK 320 Figure 1 (Sheet 5) Jan 10/76 oar Page 5STRUCTURAL REPAIR “Weiga uasnVvHO turvesy mt GOMLaN oe {S3LON 3HL NI Oa1sI0ads Sv SLIWTT 3HL NOLIN Broo “TIOH NIVHG WOUS L4V ONY 3U03 SNINNNY XOVED HOS UIva3y SIML wow NoNDas Suanaisya annie vod s0NvERIOL 2ZIS FIOM Bnd Say. Saunom woe swoon" SiS Men Aces G scram sum yuas Sat |$) i sion nie tain Se __i, +e + Yeading Edge Slate - Repair at Drain Hole ‘Figure 1 (Sheet 6)Cagle STRUCTURAL REPAIR € i gs] 8 ; a889 i 4 Lis a 3 eit Be ES gee Tl | ae 22 ll peut i iT iJ 1 a REPAIR HL USE THIS REPAIR FOR SHORT CRACKS RUNNING FORE AND AFT OF ORAIN HOLE AND TERMINAT! 1G 0.50 INCH FROM WEB RADII. METHOD HH Leading Bage Slate + Repair at Drain Hole ‘Figure 1 (Sheet 7) sul 10/75 Page 7 sR 320 STale5LZ. STRUCTURAL Werk i 2 ; : i : i 4H § : : i j § i : iSeEme _ SOMMERLIAL SET OVERHAUL MANUAL ‘ALL HOLDERS OF WING LEADING EDGE SLAT ASSEMBLY OVERHAUL MANUAL, 57-50-32 REVISION NO, 1, DATED MAR 5/78 ‘WiGHLIGHTS: To: TOPICS AFFECTED i DESCRIPTION OF CHANGE 't/Shocting Stools ‘Storage PL T/Overhaal (Cleaning i é D/Assy ° 2 a Clarified bracket and bushing installation in Fig. 1108 Mar 5/78 HIGHLIGHTS Page 1 of 1tts OVERHAUL MANUAL WING LEADING EDGE SLAT ASSEMBLY 57-50-31 , BOEING P/N 65-18763-1, -2, -5 thru -12 65-18704-1 thru -6, ~9 thru -32 65-18705-1, -2, «5 thm -12 AIRLINE P/N. ‘THE FOLLOWING DIRECTIVES APPLY TO THIS SUBLET; BOEING BOEING am DATE DIRECTIVE SERVICE TEMPORARY ee INCORPORATED BUWLETIN REVISION INTO TEXT PRR 16778R oct 1/68 1748, Rev 2 RR 15183 Jan ifm Boe BRR 16770 Jan 10/70 FRR 1573201 oct 10/71, FRR 159k Oct 10/71 2962, Rev 2 BR ETT Oct 10, PRR 16778-2 Oct 10/7 2956 FRR 17686 Oct lo/m PR 17688-R oct 10/72 2206 PRR 15904 dul 10/72 PRR 1766-4 dal 15/73 Jul 15/73 57-50-31 Page a1womme _, COMMEMCIAL SET OVERHAUL MANUAL [— LIST OF EFFECTIVE PAGES + Indicates pages revised, added or deleted in ltert revision F lndictes foldout pages print one side only PAGE DATE PAGE DATE PAGE DATE 57-50-32 509 a 15/73, 123 gu 10/72 Bel gud 15/73 510 dul 15/73 nab Jen 5/Th ‘BLANK su Jul 15/73 21125 Oct 10/71 a Mar 5/78 512 Sul 15/73 1126 Oct 10/71 Is Nar 5/78 53 oul 15/73 l2T oe: 10/71 Jen 10/70 ul dul 15/73 11268 Sul 15/73 BLANK 515 Tul 15/73 129 0 Jen 5s Tul 15/73 516 Sul 15/73 1230 Jan 5/74 Jul 15/73 601 Jul 10/72 131 gul 15/73 dul 15, 602 dul 10/72 132 Jan 5/7 Oct 1/68 603 Jan 10/70 1133. Ost 10/7 Oct 1/68 604 Jan 10/70 1134 et 10/72 oul 15/73 605 Jan 10/70 1135 Oct 10/72 Oct 1/68 606 Jan 10/70 1236 oct 10/71 Oct 1/68 6o7 Jan 10/70 137 oct: 10/71 Oct 1/68 608 Sul 10/72 1238 oct: 10/71 108 gut 15/73 goL oct 1/58 139 Jen 5/74 109 oct 1/68 902 BLANK ako Jon 5/7 0 Oct 1/68 ho Jan 5/74 aa dul 10/72 m Oct 1/68 30a st 10/71. ke oct. 10/71 ne BLANK 1103 Oct 10/72 akea BLANK 20 Oct: 1/68 ok ot oy aiken Jan 5/7h 202 BLANK 105 Jan 5/74 13 oct 10/71 30 Jen 10/70 1106 Jan 5/74 ab, Oct 10/71 302 ‘apr 5/16 no; Jan 5/7 1N5 et 10/71 303 108 BLANK KG oct 10/71 nu 09 Jan 5/7 by oct 10/72 306 DELETED 10 Oct 10/72 148 Jan 5/74 hon Jul 15/73 Ul oet 40/72 BA et 10/72 hoe Jul 15/73 m2 oct 10/71 31463 gu 10/72 403 Apr 5/76 1113 Oct 10/71, ng BLANK hol Apr 5/76 ak et: 10/71 1150 Jen 5/7 405, Apr 5/76 5 Jan 5/74 1151 Oct 10/71 06 dul 15/73 ug gan 5/7 1152 cet 10/71 50L Oct 1/68 UGA Jan 5/74 153. oct. 10/71 502 oot 3/68 16B oct 10/72 54 oct 10/71 503 sul 15/73, ur gan 5/74 155 Jan 5, 508 qu 5/73 18 oot 10/7 156 gan 5/74 1 505 Jul 15/73 119 et: 0/71 11564 Jon 5/7 506 dul 15, 1220 Oct 10/71 21568 Jan 5/74 507 Oct 1/68 Mal ost: 10/71 157 BLANK’ 508 Oct 1/68 122 San 5/74 Mar 5/18@ernve _. COMMENGIAL SET OVERHAUL MANUAL LIST OF EFFECTIVE PAGES * Indicates pages revised, edded or deleted in ltest revision E Indicates foldout pops - print one side only PAGE Dare [PAGE DATE PAGE , DATE 1158 Jen 5/7 * 159 Mar 5/78. 1160 Oct. 10/7. U6 Oct 10/71. 1é2 oct. 10/7. 2163 Oct. 10/71: 16h et 10/72. * 165 Mar 5/78 66 Jan 5/7 166A Jen 5/74 1668 Jan 5/74 167 et 10/7. 168 Jan 5/74 269 Oct 10/7. LTO Oct 10/7. LT Oct 10/71. Le et 10/72. 13 Oct 10/72 ath Jan 5/74 15 Jen 5/74 17% = dul 10/72 176A Oct 10/72. 11763 Jul 15/73 177 Oct 10/71 178 Jen 5/7 179 Jen 10/70 180 Jen 10/70 1281 Jan 10/70 3262 et 10/72. 12828 Oct 10/72. 11628- oct 10/71 283 Jan 5, 118i Jan 5/7 2185 Jen 5/7 1286 Jan 5/74 met San 5/Th 188 BLANK 51-50-31, Mar 5/78 Page LEP-2OVERHAUL MANUAL TABLE OF commen Perngreph Title Pus Desortption and Operations se see e ec eee eee eens le Dinasoembly oo eee nee eee eneeeaees aa Cleaning, . TnepoctionfOhack. 66. ee eee eee tee teens son Retr ee a ee 60000500q0000G000500 202. Assembly, 66. ee See ee ee ee 501 | Fite and Clearances... eee ee eee eee eee 61 Reet ee one ‘Trouble Shooting... 4... 4 Stomge Instructions, 6... 6. os Be None en ou Special Tools, Fixtures, and Equipment, go None Illustrated Parts List. 6... ee ee eee oe a0 Mumerical Parts List Index, 6. ee ee eee eee eee ee un Jan 10/70 57-50-31 + Page T/C-1 (Page T/0-2 BLANK)| 2B weet OVERHAUL MANUAL 1 Wing Lending Bdge Slat Asceably Figure 1 DESCRIPTION AND OPERATION 1, Deseription A, Hach slat assenbly consiste of machined magnesium casting, hinge fitting assemblies, a link assembly plus associated yarts. dul 15/73 57-50-31 Page 22; / 65-18763 aya 65-1878 65~-18785 OVERHAUL MANUAL operation The lift capability of the 707-320B/3200 airplane is supplemented by a set of three slat assemblies, vhich are installed between the engine nacelles on each ving, ‘They are attached’ to the underside of the Leading edge with steel, gooseneck hinge fittings. These lightweight Lesding edge devices work together, in coordimtion with the trailing edge flap assemblies, to improve operation of the atrplane ari emble takeoff in minimm distance. B. Each slat is operated by a two-position, cylinder type, hydraulic actuator. An integral part of each actuator ie a locking mechanism which locks the slat in either the fully extented, or the fully retracted position, This action precludes the possibility of the slat being blown ‘open or closed if hydraulic pover fails. Each slat contains e linkage system which operates a hinged fairing assembly mounted on the trailing edge. Leading Particulars Width -- 21.0 inches approximately, P/fi'a 65-18763, 65-16764, 65-10705 Length -- 51,0 inches approximately, P/N's 65-18783, 65-1878), 65-18705 Height -- 6.0 inches epproximately, P/fi'e 65-18763, 65-6704, 65-16705 Weight -- 34.3 pounds approximately, P/N 65-18783 == 36.1 pounis approximtely, P/N 65-1876h = 29.5 pounds approximately, P/il 65-18765 31-50-31 sud 15/73 ge65=18783 6518784 neg —— oe = ee ’ OVERHAUL MANUAL DISASSEMBLY 1a. Pisnoposbly of Leading Bage Slat, F/M! 6518783-7 through 2 (see figure no, A. Place slat assenbly ine suitable holding fixture and dleassexble as follows: (2) Remove mut (1), doit (2), and washer (3), Renove link assembly (4), (2) Remove fork assembly (5) and checknut (8) from rod end (9). NOME: Do not disessenble rest of 1ink assembly (4). (3) Remove nuts (17), bolts (18), washers (19), and spacers (20), Remove pea (16), (4) Remove bonding Jumpers (21) by renoving volte (22 and 23), nuts (2k), and washers (25 end 26), (5) Remove nuts (27), bolts (28), washers (29), and laminated vashers (30). Remove fairing (31) from slat, (6) Remove nuts (35), bolts (37), screws (38), and washers (36), iecove fitting assembly (32) from fairing. Remove helical coils (7) Remove seal (40) from fairing (31), (8) Renove nuts (45), volts (46), and vashers (47), Renove hinge fitting assemblies (42) and shims (¥8), Measure end record tidekness of shims for fabrication of nev shims if replacenent 16 necessary. (9) Remove nute (55), bolts (53 and 5), and vashers (56), Remove hinge fitting essenblies (49) and shims (57 and 58), Measure and record thickness of shins for fabrication of new shine if replacenent 1s necessary, (10) Remove striker (59) from hinge fitting (50) by removing rivet (60), nut (61), bolt (62), and veshers (63). (11) Renove its (66), borts ($6 and veshers (67), Renove hinge supporta (64) and shims (68), Measure and record thicknese of shite 4 replecenent is necesoary. sul 15/73 3150-31 PagePcie 65-18785 OVERHAUL MANUAL (12) Remove seal assembly (69) and retainer (70) by removing nute (72) and bolts (71). NOTE: Do not remove bushings (1) from fairing (31), or rub strips (73) From slat (75) wnlews rence ta necessary. 2, Disassenbly of Leading Bdge Slat, P/N 65-18783-5 or -6 (See figure 1102.) A, Place slat assembly in a suitable holding fixture and disassemble as follows: (1) Renove cotter pine (2), mute’ (2), volta (3 ent 4), and vashers (5). Remove Link essenbly (2) Renove clevis assenbly (8) and checknut (11) fran rod end (12), NOTE: Do not disassenble reat of Link assenbly (6). (3) Remove nuts (8. ‘olts (15), wehers (17), and spacers (16). Renove pads (1 (4) Remove screw (2h), washers (25), and vasher (26) trom stop (19). (5) Remove stop (19) by removing nute (21), bolts (20), washers (22), ‘and shim (23). (6) Remove cotter pin oo at (32), bot (33), end washer (311). Remove Link assenbly (1 (7) Remove bracket assenblies (35 end 36) by renoving mute (l2), ete (41), and washera (13). Remove shins (lth end 45), Measure record thickness of shins for fabrication of new shins if replecenent 1s necessary. (8) Renove bonding jumpers (46) by renoving volte (47 and 48), nuto (49), and washers (50 and 51). (9) Remove cotter pins (52), washers (53), end pins (54). Renove fairing (55) from slat, (10) Remove fitting assembly (56) from fairing by removing nuts (61), volte (59 and 60), and washers (62), (11) Remove seal (64) trom fairing, (ae) aa nuts (69), bolts (68), and washers (70), Remove hinge tting assemblies (65) and shims (71). Measure and record Ehtcintoo of thine Sez fabrication of new shins 1f replacement 18 necessary. 57-50032 oct 1/68 Page 102 ieae 5-1 65.18785 rata OVERHAUL MANUAL (23) Remove nute (78), bolts (76 and 77), and vashers (79). Remove hinge fitting essenblies (72) end shina (80 end 61). Measure and record thickness of shins for fabrication of nev shims 4f replacement 18 necessary. (1h) Remove striker (82) from 2 rite (73) by removing rivet (63), ee Cie hole (B53, can make ESR (73) by semortng toe ( (25) Remove hinge supports (87) by removing nuts (89), bolts (88), and washers (90), Remove shims (91). Measure and record thickness of shins for fabrication of nev shins if replacement 16 necessary. (16) Remove stud (92) by removing nuts (94), bolts (93), and washers (95). (17) Remove seal assembly (96) and etther retainer (98) or chim (97) by renoving bolts (99), nuts (100), and washers (101), ee epplicable, NOTE: Do not remove bushings (63) from fairing (55) unless replacement 4s necessary. Do not renove rub stripe (102) from slat (104) unless replacement is necessary. 3, Disassenbly of Leading Bage Slat, P/N 65-18783-1 or -2 (See figure 1103.) A. Place slat assembly ina suitable holding fixture and disassenble as follows: (1) Remove cotter pins (1), nuts (2), bolts (3 and 4), and washers (5). Remove link assembly (6), (2) Remove clevie (9) from link assembly (6). NOTE: Do not disssseuble rest of Link assenbly. @) peaove nuts (14), volte (13), washers (15), epacers (16), end pads (4) Remove nuts (21), volte (19 and 20), and washers (22). Remove Plates (17) and spacer (18). (5) Remove cotter pin (27), nut (28), bolt (29), and washer (30), Remove link assenbly (23). (6) Remove nuts (33), bolts (32), and washers (34). Remove bracketa (31). (1) Remove mits (38), bette (36 and 37), and veshers (39 and 0). Remove donding Jumers (35), Oct 1/68 57-50-31 + Page 10365«18783 CET Sere OVERHAUL MANUAL solid (8) Remove cotter pins (4), wahers (2), end pins (43), Remove fairing (Ils) from slat, (9) Remove nuts (50), bolts (46 and 49), and washers (51), Renove fitting assenbly (U5) fron fatring, , (10) Remove seal (53) from fetring, (a) Remove nuts (58), baits G7), oma and washers (59). Remove hinge fitting assemblies (54) end shims (60), Measure and record. ‘thickness of shims for alr ‘of new shims if replacement is necessary. Remove mits (67), bolts (65 and 6), ond vashere (68), Renove hinge fitting assemblies (61) ani shims (69 ani 70), Measure and record thickness of shims for fabrication of new shims if replacement 1s necessary. (13) Remove nut (73), bolt (74), washers (Te end rivet (72), Remove striker (71) from hinge fitting (62) qe (2h) Remove mits (78), bolts (77), and washers (79), Remove hinge support (76) and shins (80), Measure and record thickness of shins for febricetion of nev shims if replacenent is necessary. (25) Remove stud (81) by removing nuts (63), bolte (82), end vashers (84). (16) Remove bolts (86), mits (87), and washers (88), Remove seal assembly (85) and stim (895, ORE: Do not remove bushings (52) from fairing (4), or rub strips (90) from elet (92) unless replacement is necessary, pa Disnogonbly of Leading Bigs Slat, P/M 65-18705~7 through -12 (See figure 2104, A, Place slat assembly in a suitable holding fixture and disassemble as follows: (2) Remove nut (1), bolt (2), and washer (3), Remove Link assembly (14). (2) Remove fork essembly (5) end checknut (8) from link assembly (4), WOME: Do not disassenble rect of Link assembly, (3) Remove mute (17), bolts (18), vashers (19), end spacers (20), Remove pad (16). 51-50-32 Jud 15/73 Page 104 ots65-18785 Srrimanata OVERHAUL MANUAL 4) Remove ¢ 21 and 22) by 25), bolts (23 (a) Ba Ba ek a mmere 622 ae 52) Y removing nuts (25), 8 ( (5) Remove nuts (28), bolts (29), washers (30), and laminated vashers (31). Remove fairing (32) from ela’ (6) Remove fitting aasexbly (33) from fairing by removing muta (36), bolts (36), screws (39), and veshers (37). (7) Remove helical cotis (40) from fairing. (8) Remove seal (41) from fairing. (9) Remove nute (46), vorts (7), and washers (48), Remove hinge fitting assemblies (43) and shins (49). Measure ani record thickness of shins for fabrication of new shims if replacement 18 necessary. (10) Remove nuts (57), bolts (55 and 56), end yashers (58), Remove hinge fitting assemblies (50 end 51) and ahims (59), Measure and record ‘thickness of shins for febrication of new shims if replacement 12 necessary. (11) Remove nuts. (64), bolts (62 and 63), end washers (65). Remove hinge supports (60 and 61) and shims (66). Measure and record thickness of shims for fabrication of new shine if replacement 1s necessary. (22) Remove striker (67) by removing bolts (68). (13) Remove retainer (69) and geal (70) by removing bolts (71), nuts (72), and washers (73). NOME: Do not remove bushings (42) trom fatring (32), or rub strips (7h) from slat (76) unless replacement ie necessary. 5+ Disassembly of Leading Bdge Slat, P/N 65-16785-5 or -6 (See figure 1105.) A. Place slat assembly ina suitable holding fixture end disassemble as follova: (1) Remove cotter pina (1), nuts (2), volte (3 and 4), and washers (5). Remove link assembly (6). (2), Remove clevie asseubly (8) andichecknut (11) trom roi end (12), NOTE: Do not disassemole rest of link assembly (6), Oct 1/68 57-80-31 + Page 105(3) a (3) (6) mM (8) (9) (10) (11) (12) (33) (aay (as) (26) 57-50-32 Page 106 7 65=18763 ape? Sa. 65-1878 ormmanala oH 18785 OVERHAUL MANUAL Remove auts (16), bolts (15), washers (17) and spacers (18), Remove pads (1h), Remove screw (24), washers (25), and washer (26) from stop (19). Remove stop.(19) ty removing mits (21), washers (22), and bolts (20). ‘Remove shim (23). Renove cotter pin (31), nut (32), bolt (33), and vasher (34). ‘Remove link assenbly (27). Remove nuts (40), bolts (39), and washers (1). Remove bracket sssemblies (35 and 36) and shims (l2 end 43). Measure and record ‘thickness of shims for fabrication of new shims if replacement 1s necessary. Remove bonding jumpers (44 and 45) by removing nutes (48), bolts (6 and 47), and washers (49 and 50), Remove cotter pine (51), washers (52), and pins (53). Remove fairing (54) from slat. Remove bolte (58 and 59), nuts (60), and washers (61). Remove fitting assembly (55) from fairing. Remove seal (63) from fairing. Remove hinge fitting assemblies (6h) and shims (70) by removing mute (68), bolts (67), and washers (69). Measure and record thickness of shins for fabrication of new shims if replacement 1s necessary. Remove nuts (78), bolts (76 and 77), and washers (79). Remove hinge fitting assemblies (71 and 72) and shims (80). Measure and record thickness of shins for fabrication of new ahime if replacement 1s necessary. Remove hinge supports (81 and 82) by removing nuta (85), bolts (83 end 84), and washers (86), Remove shims (87). Measure and record ‘thickness of shims for fabrication of new shims if replacement 16 necessary. Remove stut (68) by removing nuts (90), bolts (89), and vashers (91). Remove striker assembly (92) and shim (96) by removing bolts (93), nuts (9h), and washere (95). NOTE: Nuts (94). washers (95), and shim (96) are used only with striker assembly (92), P/M 69-15399-1 or -2. Oct 1/68 5CE etad Le OVERHAUL MANUAL (17) Remove retainer (97) and seal (98) by removing nuts (100), bolts (99), vend washers (101), HOTE: Do not remove bushings (62) from fatring (51), or rub stripe (102) from slat (104) unless replacenent is necessary. 6. Disassenbly of Leading Bdge Slat, P/N 65-18705-1 or -2 (See figure 1106.) A. Place slat assembly ina suiteble holding fixture end disassemble as follows: (2) Remove cotter pins (1), nuts'(2), bolts (3 and 4), and washers (5). Remove link assembly (6), (2) Remove levis (9) from rod end (8). NOTE: Do not disassemble rest of link asseubly (6). (3) Remove pads (12) by renoring bolts (13), nuts (14), washere (15), and spscers (16). (4) Remove plates (17) and spacer (18) ty removing bolts (19 end 20), nuts (21), and washers (22). (5) Remove cotter pin (27), mut (28), bolt (29), and washer (30), Remove Link eseembly (23), (6) Remove nuts (33), bolts (32), and vashers (34). Remove brackets (32), (7) Remove bonding Jumpers (35 end 36) by removing nuts (39), bolts (37 and 38), and washers (40 and hi). (8) Remove cotter pins (42), vashers (3), and pina (lil), Remove fairing (45) from slat. (9) Renove fitting assenbly (46) from fairing by removing nute (51), bolts (49 end 50), end washers (52), (10) Remove seal (54) from fairing. (12) Remove nute (59), bolts (58), and washers (60). Remove hinge fitting assemblies (55) and shims (62). Measure and record thickness of shims for fabrication of new shims if replacement is necessary. (12) Remove nuts (69), torts (67 and 68), and yeshers (70). Remove hinge fitting assenbiies (62 ond 63) and china (71). Meaoure and record thickness of ehims for fabrication of new shims if replacement is necessary. Oct 1/68 57-50-31 + Page 107. 65-18783 py sera OVERHAUL MANUAL (23) Remove nuts (76), bolts (7 and 75), and washers (77). Remove hinge supports (72 and 73) end shims (78). Measure and record thickness of shims for fabrication of new shins if replacetent 1s necessary. (2K) Renove stua.(79) ty renoving mits (81), botts (60), and vashers (82). (15) Remove nuts (85), bolts (84), end washers (85). Renove striker assembly (63) and shim (87). (16) Remove retainer (88) end seal (89) by removing nuts (91), bolts (90), ‘and washers (92), NOTE: Do not remove bushings (53) from fairing (45), or rub strips (93) from slat (95) unless replacement is necessary. 7. Ptoascenbly of Leading Bdge Slat, P/N 65-16784-15 through -32 (See figure nor. A. Place slat assembly ina suitable holding fixture and disassemble as follows: (1) Remove nut (1), bolt (2), and vasher (3), Remove Link assembly (11), (2) Remove fork assenbly (5) and checknut (8) from roa end (9). HOM: Do not dtsassenble rest of Link assembly (4), (3) Remove nuts (17), volts (18), washers (19), and spacers (20). Remove pad (16). (4) Remove bonding jumpers (21) by removing bolts (22 and 23), nuts (2h), and washers (25 and 26), (5) Remove nuts (27), bolte (28), weshers (29), and leminatea vashers (30), Remove fairing (31) from elet. (6) Remove nuts (35), washers (36), bolts (37), and screws (38). Remove fitting assembly (32) from fatring, (7) Remove helical cotis (39) from fairing. (8) Remove eeal (40) from fairing. (9) Remove nuts (45), boits (46), and vashors (47), Remove hinge fitting assemblies (42) and shims (N68). Measure and record thickneas of shims for fabrication of new shims if replacenent 1e necessary. 0.3 : Jul 15/7365-18783 65-1876 naps? a / 5 ~18785 ommenatal OVERHAUL MANUAL (10) Renove nuts (56), washers (57), and bolts (5h end 55). Remove hinge fitting assemblies (49 end 50) end shins (58). Measure and record thickness of shins for fabrication of nev shins if replacement 1s necessary. (11) Remove nuts (63), washers (64), and bolts (61 and 62). Remove hinge supports (59 and 60) and shims (65). Measure and record thickne of shims for febrication of new shine if replacement 19 necessary. (12) tare seal (66) and retainer (67) by removing nute (69) and bolts (13) Remove striker assembly (70) by removing bolts (71). OTE: Do not remove bushings (1) from fairing (31), or rub etrips (72) from elat (7h) uiless replacement ie necessary. 8, Pisgasenbly of Leading Bago Slat, F/M 65-18701-9 through -1h (See fleure 1108, A, Place slat assembly in e suitable holding fixture and disassemble as follows: (1) Remove cotter pins (1), nuts (2), bolts (3 and 4), and washers (5). Remove link assenbly (6). (2) Remove levis assembly (8) and checknut (11) from rod end (12). NOT: Do not disassemble rest of Link assenbly (6). (3) Renove nuts (16), bolts (15), washers (17), end spacers (18). Remove pads (1h). (4) Remove screw (24), washers (25), and vasher (26) from stop (19). (5) Remove nuts (21), bolts (20), and washers (22), Remove atop (19) and shim (23). (6) Renove cotter pin (31), nut (32), bolt (33), and washer (3h). Remove link assembly (27). (7) Remove nuts (40), bolts (39), and washers (41). Remove bracket assemblies (35 and 36) and shims (42 end 43). Measure end record thickness of shims for fabrication of new shine if replacement 10 neceseary. (8) Remove bonding jumpers (4h) by removing nuts (47), bolts (45 and 46), ed washers (18 end U9), Oct 1/68 57-50-31 + Page 10965~18783 Cot Gara, OVERHAUL MANUAL - (9) Remove cotter pine (50), washers (51), and pins (52). Remove fairing (53) fron slat. (20) Renove nute (59), volts (57 end 58), and veshers (60). Remove fitting assembly (54) from fairing, (11) Remove seal (62) from fairing. (12) Renove nuts (67), bolts (66), and vashers (68), Renove hinge fitting assemblies (63) and shims (69). Measure and record ficlmese of shins for fabrication of new shins 1 replacement 12 necessary. (13) Reaove nuts (77), bolts (75 and 76), end yashers (78), Remove hinge fitting assemblies (70 and 71) and shims (79). Measure and record Bticlmess of shims for fabrication of new shine if replacement te necessary. (1h) Remove nuts (8), volts (8 and 93), and washers (85). Remove hinge supports (80 and 61) and shins (85). Measure ant record thickness of shine for fabrication of nev shins if replacement 1a necessary, (15) Remove stud (87) by removing nuts (89), volts (68), and washers (90). (26) Remove seat assembly (91), shin (92), and/or retainer (93) vy, renoving bolts (94), nute (95), and washers (96), ee eppiiceble, (17) Renove striker assembly (gn) by removing bolts (98), nuta (99), washers (100), and shim (101), as applicable. NOTE: Do not remove bushings (61) from fairing (53), or rub strips (102) from slat (104) unless replacement 1s necessary. % TOD gTMBDY of Lending Bdge Slat, P/N 65.18781.1 through -6 (See figure 1209, A; Place slat assenbly in a suitable holding fixture and dtsascenble as follows: (2) Remove cotter pine (1), nuts (2), bolts (3 and 4), and washers (5). Remove link assembly (6). (2) Remove clevis (9) from end of Link assexbly (6), NOTE: Do not disassenble rest of Link assenbly, (3) Remove nuts (1h), bolts (13), washers (15), and spacers (16), Remove pads (12), 57-50-31 Oct 1/68 Page +33, 65-1878 eae ep OVERHAUL MANUAL (4) Remove plates (17) and spacer (18) by removing nute (21), bolts (19 and 20), and washers (22), (5) Remove cotter pin (21), nut (28), bolt (29), and washer (30). Remove link assenbly (23). (6) Remove nuts (33), bolts (32), and washers (34). Remove brackets (31). « (1) Remove bonding soma (35) by removing nuts (38), bolts (36 and 37), and vashers (39 and 40). (8) Remove cotter pins (ii), washers (42), end pins (43), Remove fairing (4h) from slat. (9) Remove nuts (50), bolts (48 and 49), and washers (51). Remove fitting assenbly (45) from fatring. (10) Remove seal (53) from fairing. (11) Remove nuts (58), bolts (57), and washers (59). Remove hinge fitting assenblies (54) and shims (60), Measure and record ‘thickness of shims for fabrication of new shins if replacement 1s necessary. (22) Remove nuts (66), washers (69), and bolts (66 and 67). Remove hinge ‘fitting assemblies (61 and 62) and shims (70). Measure and record ‘thickness of shims for febrication of new shine 1f replacement 1s necessary. (13) Remove nuts (75), washers (76), and bolts (73 end 7h), Remove hinge supports (71 and 72) and shims (7). Measure and record thickness of shims for fabrication of nev shins if replacement 1s necessary. (214) Remove stud (78) by removing nuts (60), bolts (79), end washers (81). (25) Panowe mute (64), boxte (83), ent vashere (85). Remove sea assenbly (Bey cot ants (08). (16) Rewove bolts (88), nuts 9). ‘end washers (90). Remove striker assenbly (87) and shim ( NOTE: Do not remove bushings (52) from fairing (4l), or rub stripe (92) from slat (94) unless replacement 1s necessary. oct 1/68 51-50-31 + Page (Page 132 BLANK)a co 6518765 ara OVERHAUL MANUAL CLEANING 1. Generel ‘A, Wash ond rinse 11 metal parts, except bearings, in drycleening solvent, ‘Specification P-D-680, or equivalent. B, Remove stubborn accumulations of dirt or grease with @ stiff-bristle brush. Do not use @ metallic brush. ©, Drain, end dry ell parts thoroughly with clean, lint-free cloth, or with clean, dry air. D. For further cleaning information, refer to Subject 20-30-03, "General Cleaning Procedures. 2. Bearings ‘A, Clean all bearings as directed in Subject 20-30-01, "Cleaning and Relubricating Antifriction Bearings." oct 1/68 57-50-32 + Page 201 (Page 202 BLANK)Ll Visual Check =~ A 65-18783 Sack eee, Cred OVERHAUL MANUAL ‘INSPECTION, Bmmine ell metal parts for pits, scratches, cracks, corrosion, and Gamge. Use e strong light and a minimum of 10-power magnification, Emumine entire basic assembly for loose fasteners, corrosion, damge, and general condition of paint end finish, Eymine all bearings for excessive radial end axiel play. omine ali beering, bushing, and bolt holes for excessive or eccentric Check parte listed in figure 601, “Fits and Clearances" for vear beyond allowble limite, Special Check A If visual examination discloses evidence of defects in any of listed yerts, perform following checks: (1) Magnetic Particle Part igure and Item Nusber Clevis no1-12 Hinge Fitting 101-50 Hinge Support no1-64 Hinge Fitting 2102-73 Hinge Support, 1102-87 Hinge Fitting 1103-62 Hinge Support 1103-76 Chevis nok.12 ‘Hinge Fitting 10k-52, Hinge Support 04-60 Hinge Support 2204-61 Hinge Fitting 2005-73, Hinge Suprort 1005-81, Hinge Support 105-62 Hinge Fitting 106-64, Hinge Support 1206-72 Jan 10/70 57-50-32 + Page 301eons. Se / 65~18783 Commercial ele 65-1878 OVERHAUL MANUAL 65-18785 Part Figure and Item Taber Hinge Support 06-73 Clevis uo7-12 ' Hinge Fitting ao7-52 Hinge Support 107-59 Hinge Support u07-60 Hinge Fitting n108-72 Hinge Support 308-80 Hinge Support 308-81 Hinge Fitting 1109-63 Hinge Support uo097i Hinge Support n09-72 (2) Penetrant Part Figure and Item Nusber slat 01-75 slat 1202-104 Slat 3403-92 Sat m0ln76 Slat 1205-10 Slat 106-95 sine u07-74 Stat 1108-104 ‘Slat o9-94 B. Deleted 31-50-31 Apr §/76 Page 302 nee’6-10783 gage BE, 8105 OVERHAUL MANUAL REPAIR 1. Repair + , A, Remove corrosion ani minor defects from metal parts by polishing lightly with abrasive cloth, 200-grit or finer, Do not exceed limits given in Fig. 601. Refinish polished area as necessary for protection against corrosion. B. Repair damage as follows: Optional: Cracks propagating from érein holes my be repaired as outlined in 57-45, 707 Structural Repair Mamal, D6~2962, (1) Installation of Rivets (a) If demge does not exceed 0.25-inch diameter, drill out to fit 1/B- to L/inizch Glaneter rivet. () countersink exterior surface ai install BACRLSEA/ /B-series rivet by squeeze method, Installation by impact driving my be ‘wed, hovever, minimum of 0.03-inch head thickness for shaving mist be alloved, CAUTION: MAINTAIN RIVET EDGE MARGINS PER D6~-2692, 707 STRUCTURAL REPAIR MANUAL, 51-2-6, DO NOT SPACE REPAIR RIVETS LESS ‘HAN 1,00 INCH BETWEEN RIVETS AND LESS THAN 1.00 INCH FROM ANY ASSEMBLY FASTENER . (2) Gas Tungsten Arc Fusion Welding (a) Remove protective finish per 20-30-02, Stripping of Protective Finishes. (b) Stop @riii crack with 0.18-tnch dieneter hole. Eddy current check to ensure crack does not extend beyond stop hole. Oversize atop hole to 0.25 inch dleneter. (c) Groove cracked area (both sides if possible) to assure 100% Joint penetration. Crack my be slotted to maximum width of 0,040 inch in order to clean abutting surfaces. (a) Welding and inspection should be completed so that protective finish can be applied as soon as possible but no leter than 1 ‘week from time of cleaning. Jun 15, 57-50-31 ie Page 4OL97-50-32 Page hoz (e) (ft) (e) (4) (3) (x) 6518783 “Leis Babi OVERHAUL MANUAL 2 Preheat slat to 650-725°F before welding. WARNING: TO PREVENT POSSIBLE FIR HAZARD, DO NOT USE OXACETYLENE OR SIMILAR INTENSE FLAME, WOW: Preheating ina furmce is desirable, hovever @ gentle sootfree gas fleme my be used, if necessary, Welding Jigs, clamping tars, and backup plates shall be used here meessary during preheating, welding, or stress relieving operations. Weld crack using gas tungsten arc welding process using argon or helium a8 inert gas shield and AZ92A rod (Dov C) filler material per MIL-R-67l, Fill stop holes vith filler material. If required, countersink holes to assure 100} penetration, CAUTION: MATWIAIN PREHEAT TEMPERATURE OF 650 10 725°F DURING ENQIRE WELDING OPERATION TO PREVENT DAMAGE. YOTE; Measure temperature vith a surface pyrometer or other suitable temperature indicating device with an accurecy of # 25°F, Stress relieve after veléing by placing slat in a furmace ant ralsing temperature to 4g0-500°F, Maintain thie temperature for 60 mimtes, CAUTION: TO FREVENT POSSIBLE FIRE HAZARD, STRESS RELIEF BY GAS TORCH IS PROHIBITED, Reheat treat to T-6 condition. Material for casting is magnesium alloy, AZIIC~I6, QQ-M-56, composition AZ91. Remove slat from furmice ani allow to cool in still air to rom ‘temperature. Remove emit from weld bead and surrouniing area by wire ‘rushing with stainless steel brush, burnishing with stainless steel wool, or pickling. Retove weld bead on aerodynamic surface from flush to 0.003~inch protrusion. Remove weld bead on interior surface as required. CAUTION: 0 PREVENT PART DAMAGE, NO UNDERCUTTING 18 PERMISSIBLE, Place velders "otomp" and inspectors "bug" near weld by means of Lectroetch Formula Number 2, Jul 15/1365-18783 9 —— L 65-18784 era he 65-16785 OVERHAUL MANUAL (2) check for contour defects by laying straightedge across slat surface, (um) Radtogrenie check and peretrent check per 20-20-02, Penetrant Methods of Inspection, entire alet vith particular emmirstion of repair eres, and as follow: 1) Internal quality of veld shall meet requirenents for class ITA castings including critically-stressed ares. 2) Weld shall have 100% penetration and fusion and be free from cracks, craters, undercut, underfill, concavity, and (n) Refinten per mar, 2. Ce Repair of Loose bearing in fitting assembly (32, Pig. 1101; 33, Fis. iol; 32, Fig. 1207). (2) Solvent clean fitting per 20-30-03, General Cleaning Procedures. (2) Install bearing in housing per 20-50-03, Bearing Installation and Retention, using adhesive, EPON 933. (3) Cure adhesive, without movement of parts, at 70 to 60°F for 72 hours to obtain maximm bond strength. 2, Refinishing WOTE: Refer to 20-30-02 for stripping of protective fintehes, and to 20-H1- 01 for explanation of F and SRF finish codes. A. Fork (6, Figs. 1101, 1104, and 1107) -- Aoply Fe1,1913 all over. Hold ID of holes to between 0.3748 and 0.3754 inch after plating. Material: 4340 steel, 125-145 kei. B. Fairing (31, Fig. 1101; 32, Fig. 110%; 31, Fig. 1107) -~ Apply SRF-2.30 all over, followed by SRP=12,63 all over, except in bushing holes. Woterfal! Alum alloy. C, Fitting (33, Fig. 1101; 34, Pig. 1104; 33, Fig. 1107) -- Apply SRF~2.30 folloved by SRF-12.63, all over except in bearing holes. Materiel: Alun alloy. D. Hinge fitting (43, Fig. Mol; WM, Fig. lok; 43, Fig. 1107) =~ Apply SRF=2.30 followed by SRF-12.63 all over, except’ in bearing holes. Material: Alum alloy. ape 5/16 57-50 ge PagerR L a kK Le 65-18783 CE ater Ll 65-1878h OVERHAUL MANUAL 65-18785 Hinge fitting (50, Fig, 1101; 73, Fig. 1102; 62, Fig. 1103; 52, Me. 0b; 73, Fig. 1105; 64, Fig. 1106; 51, Fig. 1167; 72, Fig. 1108; 63, Fig. 1109) ~~ Apply SRF-1,28 followed by one coat of BMS 10-11, type’ 2 enamel, color BACTS1 gray semiglocs all over, except in bushing and bearing holes, Material: 4340 steel, 160-200 kei. : Hinge support (64, Fig. 1101; 87, Fig. 1102; 76, Fig. 1103; 60, 61, Figs 104; 61, 62, Fig. 1105; 72, 73, Fig. 1106; 59, 60, Fig. 11073 60, @, Fig. 1108; 71, 72, Figs 1109} -~"apnly F-14191 Followed by SRP-12.206 all over, except in 1/e-inch diameter hole. Material: 430 steel, 150-170 kat. Slat (15, P/N 65-1696L-5, -6, Fig. 1101; lok, Fig. 1102; 92, Fig. 1103; 16, P/M 65-18963-5, =6, Fig. 11043 104, Fig. 1105; 95, Fig. 1106; 74, P/M 65~16962-15 thru -26, Fig, 1107; 104, Fig. 1108; 94, Fig. 1109) —~ Apply SRP-3.30 plus SRF-14.96 on all accessible surfaces. Apply SRF-12,206 over entire interior surface of tubular area, Rubber stamp letters "MAG" 0.5 inch high over protective finish at point approximately 365 inches forward and approximately 16.5 inches measured from lower right-hand edge of slat. Use number 73K-I¥ Black Opaque Ink or equivalent: and allow to dry at least 10 mmtes, Brush on overcoat of Finch 683-3-2 clear system, Material: Magnesium alloy, Slat (75, P/M 65-10961-7, -8, Fig. 1101; 76, P/N 65-18963~7, -8, Fig. Lol; and 74, PAT 65~18962-19 thra =2, Fig. 1107) -- Apply SRF23.30 all surfaces plus apply two coats enamel, SRF-14,9816-707 to all accessible surfaces. Rubber stamp letters "WAG" 0,5 inch high over protective finish at point approximately 3.5 inches forward and approximately 16.5 inches mesured frou lover right-hand edge of slat. Use mimber 73K-If Hack Opaque Ink or equivalent and allow to dry at least 10 mimtes, Brush an overcoat of Finch 663-3-2 clear system, Material: Magnesium alloy. Link (28, Figs. 1102, 1105, 1108) ~~ Apply SRF-2.30 followed by one coat of BMS 10-11, type 2 enamel, color BACTS1 gray, semtgloss, all over except in holes. Material: Alun alloy. Bracket (37, Figs. 1102, 1105, 1108) -= Apply SRP-2.30 followed by one coat of BMS 10-11, type 2 enamel, color BACT51 grey, semigloss, all over except in bushing holes, Material: Alum alloy. Fairing (55, Fig. 1102; 4h, Fig. 1103; 5k, Fig. 11055 45, Fig. 1106; 53, Fig. 1108; 4%, Fig. 1209) ~ Apsly Si-2.50 all over, followed by ove coat of BMS 10-11, type 2 enamel, color BACT51 gray, semigloss, all over except in bushing holes, Material: Alum alloy. Fitting (57, Fig. 1108; 56, Fig. 1105; 55, Fig. 1108) -= Apply F-1,1913 all over except in bearing holes, Material: 13h0 steel, 125-145 kel. 57-50~31 Amr 5/76 Page tok65-18783 gape BEL 6518785 Lt OVERHAUL MANUAL Hinge Fitting (66, Fig, 1102; 95, Fig. 1103; 65, Fig. 1105; 56, Fig. 1106; 64, Fig, 1108; 55, Fig. 1109) ='Apnly SRF-2.30 all over except in ‘bushing holes, “Material: Alum alloy, MN, Link (24, Figs. 1103, 1106, 1109) -~ Apply SRF-2.115 all. over except in holes. Material: Alum alloy. 0 Fitting (46, Fig. 1103; 47, Fig. 1106; 46, Fig. 1109) -- Apply SRF-2.30 all over except in 3/8-inch diameter hole. Material: Alum alloy. P, Coat all miscellaneous metal parts with primer, BMS 10-11, type 1. 3- Replacement A. Replace all defective antifriction bearings as follows: (1) Apply primer, BMS 10-11, type 1, on faying surfaces of bearing and housing. Install bearing in housing, and ball stake in six places as directed in 20-50-03, Bearing Installation and Retention. B, Replace vorn bushings as follows: (1) Press ola bushing out of housing. (2) Coat surface of housing with primer, EMS 10-11, type 1. (3) Cost faying surface of bushing with grease, MIL-G-23627 (no substitute). (4) Shrine bushing vith éry ice anf alcohol, or liquid nitrogen, and press bushing into housing per 20-50-03. C. Replace all damaged laminated shins ae follows: (1) Delaminate basic chim to adjust thickness to dimension recorded when ehim was renoved during disassembly. (2) Drill or punch hole pattern in shim to match hole pattern of old shim, Deburr. (3) Coat shim with primer, BMS 1011, type 1. D. Replace all parts that are vorn beyond allowable Linite given in Fig. Apr 5; 51-50-32 he Page 405ornare e : OVERHAUL MANUAL ae Materials A, Welding Rod -- AZQ2A, Dow Chemical Company, Abbott Road, Midlen, Michigan 48640 B, Marking Yaterial -- Lectroctch Formle 2, Liepaner ani Co. Inc., 1513 Oak Street, Kaneas City, Missouri 64108 or Marking Methods, Inc., 363 8. Date Averme, Alhanbra, California 91802 C. Ink, Black Opaque -- Number 73X-I, Independent Ink Inc., 14705 $. Avalon Biva., Gerdem, California 90247 Resin - Finch 663-32 Clear System, Finch Paint ami Chemical Co., 20846 8. Normandie Aveme, Torrance, California 90502 E, Adhesive -- Epon 933, Shell Chemical Co., Willow Pass Road, P.O. Box 831, Pitteburgh, California 9565 age Jub 15/73 e65-18783 * 65-1878 mong, 65-18785 Commaenrat. OVERHAUL MANUAL ASSEMBLY 1. Buildup of Slat, P/M 65-18784-1 through -6 (See figure 1109.) ' A, Place basic slat assenbly ine suitable holding fixture and build up as follows: (1) Locate striker assembly (87). Fit shin (91) to eliminate exp Setveey sriier and eat. Thatatl bette (68), vesers (50), and ute (89). NOTE: Remove 0,003-inch laminations from shim to adjust thickness. Coat shim with priner after delaminstion. (2) Locate seal assembly (€2). Fit shim (86) to eliminate gap between seal and slat. Install bolts (63), washers (85), and nuts (84). NOTE: Remove 0.003-inch laminations from shim to adjust thickness. Coat shim with primer after delamination. (3) Inetal2 stua (78) with bolts (79), washers (61), and nuts (80). (¥) Locate hinge supports (‘1 and 72) end shins (777). Attach vith bolts (73 and 74), washers (76), and nuts (75). NOTE: Install bolts with vet primer. (5) Tighten bolta (73 and 7h) within torque range of 100 to 10 pound- inches. (6) Install hinge fitting assemblies (61 and 62) and shims (70). Attach with bolts (66 and 67), washers (69), and nuts (68). HOTE: Install bolts with wet primer. (7) Tighten bolts (66 and 67) within torque range of 100 to 140 pound. inches. (8) Install hinge fitting assemblies (54) and shins (60), Attach with ‘volts (57), washers (59), and nuta (58). NOTE: Install bolts with vet primer. (9) Install seal (53) in fetring (4h). Drill two holes through each end of seal with No. 50 drill, using existing holes in fairing es pilots, Install lockwire through each set of holes. (10) Install fitting assembly (45) on fairing with bolts (48 and 49), washers (51), and nute (50). oct 1/68 51-5063 + Page 501: gare tLe Sa8t0s OVERHAUL MANUAL 1 (11) Attach fairing (44) to slat in three places with pins (43), washers (12), and cotter pins (42). (12) Install bonding Jumpers (35) with bolts (36 and 37), washers (39 and 40), and nuts (38), ca (13) Install brackets (31). Attach with bolts (32), washers (34), and ute (33). HO: Install bolts vith vet primer, (14) Install Link assembly (23) with bolt (29), washer (30), and nut (28). ‘Tighten nut finger-tight only (torque of 0 to 5 pound-inches), and Anetall cotter pin (27). (15) Install plates (17) with bolts (19), washers (22), and nuts (21). CAUPION: INSTALL BOLTS WITH HEADS TOWARD LINKAGE. (16) Install spacer (18) between plates (17) with bolt (20), washer (22), and nut (21). (17) Insta pads (12) vith spacers (16), bolts (13), washers (15), and nuts (14). (18) Install clevis (9) on end of link assembly (6). Adjust length of Link aseenbly to 7.33 inches between centerlines of clevis attaching holes. (19) Inetall link assembly (6) in slat with bolte (3 and 44), washers (5), and nute (2), ‘Tighten nuts finger-tight only (torque of 0 to 5 pound-inches), and install cotter pins (1). B. Touch up finish on assenbly as necessary efter coupletion of buildup. 2, Bulldup of Slat, P/t! 65-18784-9 through -1h (See figure 1108.) A, Place basic slat assenbly in a suitable holding fixture and build up as follows: (1) Tnotall striker assenbly (97), If P/N 69-15399-1 or -2 10 wed, install shim (101) aleo, and fit to eliminate gap between striker and slat, NOTE: Remove 0.003-inch laminations from shim to adjust thickness. Coat shin with primer after delamination. (2) Attach striker assembly with bolts (98). If P/M 69-15399-1 or -2 18 used, install washers (100) and nuts (99) also. 57-50-31 oct 1/68 +(4) (5) (6) (1) (8) (9) (20) (a) (aa) (13) i) (45) Sub 15/73 Catal OVERHAUL MANUAL Install seal assembly (91), Tf P/N 6934883-1 is used, ‘install retainer (93) ele. If P/l 69-15309-1, 2, 1, or =I 1s used, install shim (92) instead of retainer, ani fit to eliminste gap Detween seal and slat. Renove 0,003~inch laminations fron shin to adjust thickness, Coat shin with primer after delamization, - Install bolts (9h), washers (96), as applicable; and mts (95), ‘Install stud (87) with bolts (88), washers (90), ana mite (89). Locate shims (86) ani hinge supports (60 and &.). Attach vith bolte (82 and 63), washers (85), and mts (64), Install bolts with vet primer, ‘Tighten bolts (62 and 63) within torque range of 100 to 140 pouni- inches. Locate shims (79) and hinge fitting asseablies (70 ani TL). Attach ‘with bolts (75 ant 76), washers (76), ani mts (77). Install bolts with wet primer, ‘Tighten bolts (75 ani 76) within torque range of 100 to 140 pound~ inehes. Locate shims (69) and hinge fitting assemblies (63). Attach with ‘bolts (66), vashers (68), and mts (67). Install seal (62) in fairing (53). Dril1 two holes through each ent Of seal vith lio. 50 drill, using existing holes in feiring as pilote. Install lockvire through each set of holes. Install fitting assembly (54) on fairing with bolts (57 and 58), washers (60), and mts (59). Attach fairing to slat in three places with pins (52), vashers (51), and cotter pins (50). Install bonding jumpers (44) with bolts (45 and 46), washers (48 end 4g), and nits (\s7), Install washer on esch eide of each bonding Jumper termiml, vith washers (19) against slet (104). Install bolts with wet primer under heads. Install shins i and 43) and bracket assemblies (35 ani 36), Attach with bolts (39), washers (11), and muta (40), Install bolte with wet primer, 57-50-31 Page 50365-18783 “CimatLe Bi OVERHAUL MANUAL (16) Install link essenbly (27), Attach with bolt (33), washer (34), and mit (32). Tighten mt finger-tight only (torque of 0 to 5 pouni- inches), and install cotter pin (31). (17) Locate stop (19). Fit shim (23) to eliminate gap between stop and | brackets. Remove 0,003=inch lemimtions from shim to adjust thickness. Coat chim with primer after delamination. (18) Install bolts (20), washers (22), and mits (21), CAUTION: INSTALL BOLTS WITH HEADS TOWARD LINKAGE 10 PREVENY OO TRPERFERENCE « (19) Cost washer (26), washers (25), ani ecrey (24) with primer, ant Anstall on stop (19), (20) Install pads (14) with eyaeers (18), bolts (15), vashers (17), and mute (16). (21) Tnetald checkmt (11) ant clevis assesbly (8) on end of Link assanbly (6), Adjust length of link assembly to 7.22 inches between centerlines of bushings (10), Tighten checkaut against clevis (9). (22) Install Link assembly (6) in slat with bolts (3 and 4), vashere (5), and mits (2). Tighten mits finger-tight only (torque of 0 to 5 Pound-inches), and install cotter pins (1). B. Touch up finish on assembly as necessary after completion of bulldup, 3. Bulldup of Slat, P/N 65-18764-15 thru -32 (Fig. 1107) nor! 3 For ascenbly F/# 65-16704-15 thru -26, install all steel fasteners through slat (7h) with IMS 10-11, type 1 primer applied to all areas of hole including countersink, counterbore, or other recess, ani imediately install fastener. For assenbly P/il 65-16784-27 tru -32, apply one coat IMS 5-79 or ‘BMS 5-95 sealant to faying surfaces of metal Parts contacting slat (74). ‘optioml: Apply one brush coat of HIS 10-11, type 1 primer to faying surfaces, allowing approximately 1/2 inch of primer beyond edge of mating part. Fastener through slat (7h) are to be installed vith FR 14366 sealant. Optional: Install fasteners with vet EMS 10-11, type 1 primer applied to all areas of tole including any countersink, counterbore, or other recess, and immediately install fastener, 2503, sul 15/7365-18783 L 187 TT Sab rth OVERHAUL MANUAL A, Place basic slat assembly ina cuitable holding fixture and build up as follows: Q) (2) (3) (4) (6) mM (8) (9) (10) (1) (12) (13) au 15/13, Install striker assembly (70) with bolts (71). Install seal assembly (66) ani retainer (67) with bolts (68) and mts (69). Locate shims (65) end hinge supports (59 and 60). Attach with bolts (G1 and @), weshers (64), and mts (63). Tighten bolts (61 end 62) vithin torque range of 100 to 140 pounl- inches, Locate shims (58) and hinge fitting assemblies (49 and 50). Attach with bolts (54 and 55), washers (57), and mite (56). ‘Tighten bolts (54 and 55) within torque range of 100 to 140 pound- inches. Install hinge fitting assemblies (42) and shims (48) with bolts (46), washers (47), ant mite (85). Install seal (M0) in fairing (1). Drill two holes with No. 50 @rill in each end of seal, using exteting holes in fairing es pLlote, Install lockvire through each set of hole Cont tvo helical coile (39) vith primer and install in fairing vhile primer is wet. Install vith end one-quarter turn belov surface, Renove tang. Install fitting assenbly (32) on fetring (31) with screve (38), bolts (31), washers (36), and mts (35). Attach fairing (31) to slat with bolts (28), washers (29), lamimtea washers (30), end mts (27). Adjust thickness of lemimted vashers to elimimate gap between lugs of hinge fittings (3) and fairing. Remove 0,003-inch laminations from washer to adjust thickness, Coat washer vith primer after delemiration. Install bonding jumpers (21) with bolts (22 end 23), washers (25 and 26), and mite (2l), Install washer on each side of each bonding jumper terminal, with vashers (26) against slat (74), Install ped (16) vith spacers (20), bolts (18), washers (19), and mute (17),65-18763 racers td Loca Se OVERHAUL MANUAL (4) Instell fork essembly (5) and checlamt (8) on end of link essenbly (4). Adjust length of Link assenbly to 17.60 inches between centerlines of bushings (7 and 13). Make measurement on 8 plane parallel to centerline of tube (10), Tighten checkmt against fork, (15) Install link essembly (/4) in slat vith bolt (2), washer (3), amd mt (1). (16) Secure loose end of Link assembly (1h) to prevent damge to slet assembly. B, Touch up finish on essenbly as necessary after completion of buildup, 4, Butldup of Slat, P W 65-18705-1 or -2 (Fig. 1106) A, Place basic slat assesbly ina sulteble holding fixture and build up as follows: (1) Locate seal (89) end retainer (68). Attach vith bolts (90), washers (92), amd mits (91). (2) Locate striker assembly (63), Fit shim (87) to eliminate gap between striker and slat, Install bolts (Bi), washers (86), and mute (65), Remove 0,003-inch leminations from shim to adjust ‘thickness, Coat shim vith primer after delamiration, (3) Install stud (79) with bolts (60), washers (82), end mts (81). (4) Locate shins (76) and hinge supports (72 and 73), Attach with bolts (7h ard 75), washers (77), and mite (76). Install bolts with wet primer. (5) Tighten bolts (7h and 75) within torque range of 100 to 140 pound~ inches, (6) Locate shims (71) and hinge fitting assemblies (62 and 63). Attach with bolte (67 end 68), washers (70), and mits (69). Install bolts with vet primer, (7) Tighten bolts (67 and 68) within torque range of 100 to 140 pound~ inches, (8) install hinge fitting assemblies (55) and ohims (61) with bolte (58), washers (60), ent mits (59), (9) Inste1l seal (54) in fairing (U5). Drill two holes through each ent of seal with No, 50 drill, using existing holes in fairing as pilots. Install lockwire through each set of holes. 51-50-31 dul 15/7365-1873 : ; 65-1878 gas NPL OVERHAUL MANUAL (20) Install £itting asseubly (46) on fairing (45) with bolte (49 and 50), washers (52), and nuts (51). (11) Attach fetring (45) to slat with pins (lit), washers (43), and cotter "pins (12), ’ ‘ (22) Install bonding jumpers (35 and 36) with bolts (37 and 38), washers (40 end 41), end nuts (39). NOTE: Place washer on each side of each bonding Jumper terminal, with washers (11) next to slat (95). (13) Install brackets (31) with bolte (32), washers (34), and nuts (33). NOTE: Install bolts with vet priner. (1s) Install link assembly (23) with bolt (29), washer (30), and nut (26). Tighten nut finger-tight only (torque of 0 to 5 pound-inches), and Anetall cotter pin (27). (45) Install plates (17) with bolts (19), washers (22), and nute (21). CAUNION: INSTALL BOLTS WITH HEADS TOWARD LINKAGE. (26) Instali spacer (18) between plates (17) with bolt (20), washer (22), and nut (21). (17) Install pads (12) with spacers (16), bolts (13), washers (15), and ute (14), (18) Install clevis (9) on end of link assembly (6). Adjust length of Link assembly to 7.33 inches between centerlines of clevis attaching holes. (19) Insta2l1 link assembly (6) in slat with bolts (3 and 4), washers (5), and nuts (2). Tighten nuts finger-tight only (torque of 0 to 5 pound-inches), and install cotter pins (1). B, Touch up finish on assembly as necessary after completion of butldup. 5. Buildup of Slat, P/N 65-18785-5 or -6 (See figure 1105.) ‘A. Place basic olat assembly ina suitable holding fixture and build up as follows: ' (1) Locate seal (98) and retainer (97). Attach with bolts (99), washers (201), and nuts (100). oct 1/68 51-50-31 + Page 507(2) (3) (4) (5) (6) (1) (8) (9) (10) (1) (22) (13) (14) 57-50-31 Page 508 65-18783 65-1876 Commenratat 65-18785 OVERHAUL MANUAL Locate striker essenbly (92), If P/N 65-15399-1 or -2 18 used, install shim (96) also, and fit to eliminate gp between striker and slat. Remove 0.003~inch laminations from shim to adjust thickness. Coat shim vith primer after delamination. Attach striker assembly with bolts (93), If P/t! 69-15399-1 or -2 18 used, install washers (95) and nute (94) witn dorts (93). Install stud (88) with bolts (89), washers (91), and nuts (90). Locate shims (87) and hinge supports (81 and &). Attach vith bolte (83 ena 84), washers (86), ond nuta (85). NOME: Install bolts with wet primer. Tighten bolts (63 and Gl) within torque range of 100 to 140 pound- inches. Locate shims (80) and hinge fitting assenblies (71 ani 72). Attach with bolts (76 and 77), washers (79), and nuts (76). NOTE: Install bolts with vet primer, ‘Tighten bolts (76 ant 77) within torque range of 100 to 1h0 pound. inches. Install hinge fitting assenblies (6) and shims (70) with bolts (67), washers (69), and nuts (68), Install seal (63) in fairing (54). Drill two holes through each end of seal vith No. 50 drill, using existing holes in fairing as pilots. Install lockwire through each set of holes. Install fitting assembly (55) on fairing vith bolte (58 and 59), washers (61), and nuta (60), Attach fairing to slat in three places with pins (53), washers (52), and cotter pine (51). Tnotall bonding jumera (lsh and 45) with bolts (46 and 47), washers (hg end 50), and mite (48). NOTE: Place washer on each side of each bonding jumper terminal, with washers (50) against elet (104). Locate shima (42 ond 43) and bracket assenblies (35 and 36). Attach with bolts (39), washers (41), and nuta (40), NOTE: Install bolts vith vet primer. oct 1/68 +65-18783 Se omega ee 65-18785 + OVERHAUL MANUAL (15) Locate stop (19). Fit chim (23) to eliminate gap between stop and I! brackets, Remove 0.003-inch laminations fron shim to adjust thickness, Coat shim with primer after delamination. (26) Instell bolts (20), washers (22), and nuts (21). ‘ | CAUTION: INSTALL BOLTS WITH HEADS TOWARD LINKAGE TO PREVENT ‘INTERFERENCE. (17) Coat washer (26), washers (25), and screw (2l) with primer, and install on stop (19). (18) install link assexbly (27) with bolt (33), washer (34), and mut (32). Tighten nut finger-tight anly (torque of 0 to 5 pound-inches), and install cotter pin (31). (19) Install geds (114) with spacers (16), bolts (15), washers (17), and mits (16). (20) Instail clevis assembly (6) and checknut (11) on end of Link asseubly (6), Adjust length of Link assembly to 7.22 inches Tetween cexterLinse of buskines (10). Tighten checkmut against clevis (9). (21) Install Link assenbly (6) in slat with bolts (3 and 4), washers (5), and mits (2). Tighten nute finger-tight only (torque of 0 to 5 pound-inches), and install cotter pins (1). B, Touch up finish on assembly as necessary after completion of buildup, 16. Butidup of Slat, P/l 65-16765~7 thru -12 (Fig. 1104) NOTE: For assembly P/M 65-18705-7 thru -10, install ell steel fustenere ‘through slat (76) with BMS 10-11, type 1 primer applied to all areas of hole including countersink, counterbore, or other recess, and inmediately instell fastener. For assenbly P/jl 65-18705-11 and -12, apply one cout BAS 5-79 or BMS 5-95 sealant to faying surfaces of metal parts contacting slat (76). Optional: Apply one brush coat of BMS 10-11, type 1 primer to faying surfaces, ellowing approximately 1/2 inch of primer beyond edge of mating part. Fasteners through slat (76) are to be installed with PR 18360 sealant. Optional: Install fasteners vith vet BMS 10-11, type 1 primer applied ‘to all areas of hole including eny countersink, countertore, or other recess, and imedistely install fastener. gud 15/73 91-90-31 Page 50965-18783 tft oases rane 65-18785 OVERHAUL MANUAL - ‘A. Place basic slet assembly in 9 suitable holding fixture and build up as follows: (1) Locate seal (70) and retainer (69). Attach with bolts (71), washers (73), and nuts (72). (2) Install striker assembly (67) with bolts (68). (3) Locate hinge supports (60 and 61) end shims (66). Attach with bolts (62 end 63), vashers (65), and mits (64). (4) Tighten bolts (62 and 63) within torque range of 100 to 140 pound- inches. (5) Locate hinge fitting assonblies (50 and 51) and shims (59). Attach with bolts (55 and 56), washers (58), and nuts (57). (6) Tighten bolts (55 and 56) within torque range of 100 to 140 pound= inches. (7) Install hinge fitting assesblics (43) ond shina (49) with bolts (47), washers (48), and nuts (46). ° (8) Goat two helical coils (40) with primer end instell in fairing (32) while priner is wet. Install eotls one-quarter turn below surface. Remove tang. (9) Install seat (41) in fairing. Drill two holes through each end of seal vith No. 50 drill, using existing holes in fairing as pilots. Install lockwire through each set of holes. (10) Install fitting assembly (33) on fairing with screvs (39), bolte (38), washers (37), and mts (36). (11) Attach fairing to slat with bolts (29), washers (30), laminated veshers (31), and nuts (26). Adjust thickness of laminated washers to eliminate gap between lugs of hinge fittings (Wl) and fairing. Remove 0.003-inch laminations from vashers to adjust thickness. Coat washers with primer efter delamination. (12) IngtelL bonding Jumpers (21 and 22) with bolts (23 and 24), washers (26 ond 27), and nuts (25). Place washer on each side of éach Donding jumper terminal, with washers (27) egainst slat (76). (23) Instal1 pad (16) with spacers (20), bolts (18), washers (19), and mute (17). 51-50-31 Jud 15/73 Page 51065=18763 See ees 6518785 rere OVERHAUL MANUAL (14) Instat fork assenbly (5) and checkmut (8) on end of Link assembly (4). Adjust Length of Link assembly to 17.80 inches between centerlines of bushings (7 and 13). Make measurement on plane Parallel with centerline of tube (10). Tighten checknut against Fees ’ (15) Install Link assembly in slat with bolt (2), washer (3), and mt (1). (16) Secure loose end of link asseabiy (4) to prevent damge to slat assembly. B, ‘Touch up finish on assenbly as necessary after completion of buildup. 7. Buildup of Slat, P/M 65-18783-1 or -2 (Fig.1103) A. Place basic slat asseubly in a suitable holding fixture and build up as follows: (2) Locate seal assenbly (85). Fit shim (89) to eliminate gap between seal and clet. Install bolts (86), washers (88), end mite (67). NOTE: Remove 0.003-inch leminations from shim to adjust thickness. Cost shins with primer efter delamination. (2) Instell stud (61) with bolts (82), washers (84), and mts (83). (3) Locate shims (60) and hinge supports (76). Attach with bolts (77), washers (79), and mits (78). x (4) ‘Tighten tolte (7) within torque range of 100 to 140 pound-inches. Install bolts with wet primer. (5) Install striter (71) on hinge fitting (62) with rivet (72), bolt (74), washers (75), and mut (73). (6) Locate shine (69 end 70) end hinge fitting assemblies (61). Attach with bolts (65 and 66), washers (68), and nuta (67). NOTE: Install bolts with vet primer. (7) Tighten torts (65 and 66) within torque range of 100 to 140 pounde inches. (8) Install hinge fitting assemblies (54) and shins (60) with bolts (57), washers (59), and mts (58). Sul 15/73 Bee @(9) (ao) (a) (a2) (23) (aay (as) (26) 7) (28) (ag) 65-18783, mee 65-1878 oorrurrua redex cht 65-10785 OVERHAUL MANUAL Instell seal (53) in feiring (144). Drill two holes through each end of seal with No. 50 drill, using existing holes in fairing as pilots. Instell lockvire through each set of holes. Install fitting asceubly (1:5) on fatring vith bolts (48 ena 49), washers (51), and mits (50). Attach fatring to slat in three places with pins (3), washers (12), and cotter pins (41). Install bonding jumpers (35) with bolts (36 and 37), washers (39 and 40), and nuts (38). NOIE: Place vasher on each side of each bonding Jumper terminal, with washers (0) against slat (92). Install bolts with vet primer under heads. Install brackets (31) with bolte (32), washers (34), and mts (33). HOME: Install bolts with vet priner. Instell link assenbly (23) with volt (29), washer (30), and nut (28). ‘Tighten nut finger-tight only (torque of to 5 pound-inches), and install cotter pin (27). Install plates (17) with bolts (19), vashers (22), ana mts (21). CAUETGH: INSTALL BOLTS WITH HEADS TOWARD LINKAGE, Install spacer (18) between plates (17) with bolt (20), wacher (22), and nut (21), Install pads (12) with bolts (13), spacers (16), washers (15), and mute (1s). Install. clevis (9) on end of Link assembly (6). Adjust length of ‘ink assembly to’ 7.33 inches between conterlines of clevis attaching holes. Tnotall Link assembly (6) in alet vith bolts (3 and 4), vashers (5), and nute (2). Tighten nuts finger~tight only (torque of 0 to 5 pound-inches), and install cotter pins (1). B, ‘Touch up finish on assembly as necessary after coupletion of butldup. 97-50-32. Page 512 Sul 15/7365-16783 ak mera est me OVERHAUL MANUAL 8. Buildup of Slat, P/N 65-18783-5 or ~6 (Fig. 1102) A. Place basic slat assembly in e suiteble holding fixture and build up ae follows: (1) Locate seal assembly (96). If P/N 69-34883-1 1s used, locate retainer (98) also. If P/M 69-15389-1, -2, -11, or -12 is used, locate shim (97) instead of retainer. “Fit shim to eliminate gap detween seal and alet. NOTE: Remove 0,003-inch laminations from shim to adjust thickness, Coat shim with primer after delamination. (2) Install, bolts (99); washers (101), as applicable; end mts (100). (3) Install stud (92) wita bolts (93), washers (95), and nuts (9I). (4) Install hinge supports (87) end shims (91) with bolts (86), washers (0), and mts (69). Install bolts with wet primer, (5) Mghten bolts (68) within torque range of 100 to 140 pomnd-inches, (6) Install striker (62) on hinge fitting (73) with rivet (63), dolt (85), washers (86), and nut (84). (7) Locate shims (80 and 81) end hinge fitting assenblies (72). Attach with bolts (76 and 77), washers (79), and nuts (76). Install bolts vith wet primer. (8) Tighten bolts (76 and 7) within torque range of 100 to 140 pound~ ‘inches. (9) Install hinge fitting assemblies (65) and shims (71) with bolts (68), washers (70), and nute (69). (10) Intel seal (64) in fatring (55). Drill two holes through each end of seal with No. 0 drill, using existing holes in fairing as pilots. Instell Lockwire through ach set of holes. (21) Install fitting assembly (56) on fairing with bolts (59 and 60), washers (62), end nuts (61). (12) Attach fairing to slat in three places with pina (54), vashers (53), and cotter pine (52). (23) tated be jumpers (46) with bolts (47 and 48}, washers (50 and 51), end nuts (49). Place vasher on each aide of each bonding Jumper torminal, with washers (51) next to elat (104). Install bolts vith wet primer under heads. Jul 15/73 grea age: : 65216783 te Sasres OVERHAUL MANUAL (as) Locate bracket assenblies (35 and 36) and shims (Wt and 45). Attach vith bolte (I), washers (43), and mts (42). Install bolts with wet primer. (15) Install Link agseubly (27) vith bolt (33), washer (34), and mut (32). ‘Tighten mt finger-tight only.(torque of 0 to 5 pound~inches), end install cotter pin (31). (16) Locate stop (19). Fit shim (23) to eliminate gap between stop and rackets, Instell bolts (20), washers (22), and mts (21). Remove 0.003+inch laminations from shim to adjust thicmess. Coat shim with primer after delemination. CAUETON: INSTALL BOLTS WITH HEADS TOWARD LINKAGE TO PREVENT [ONTERFERBICE. . (27) coat vasher (26), washers (25), and screw (2h) vith primer, end install on stop (19)+ (18) Install pads (24) with spacers (18), bolts (15), washers (17), end mute (16). (19) Install clevis assexbly (8) ond checknut (11) on end of Link assenbly (6). Adjust length of Link assembly to 7.22 inches between centerlines of bushings (10). Tighten checkmut against clevie (9). (20) Install link assembly (6) in slat with bolte (3 and 4), washers (5), ‘and mute (2), Tighten mts finger-tight only (torque of 0 to 5 pound-inches), and install cotter pins (1). 3B. ‘Touch up finish on assembly as necessary after completion of buildup. [.9- puttdup of sist, Pt 65-18703-7 thru -12 (Fig. 1102) NOTE: For assenbly F/M 65-18763-7 tra -10, install ell steel fasteners ‘through slat (75) with EMS 10-11, type 1 primer applied to all sreas of hole including counteraink counterbore, or other recess, and immediately install fastener. For assesbly P/N 65-1676312 and -12, apply one coat BS 5~79 or BMS 5-95 sealant to feying surfaces of metal perts contacting slat (15)+ Optional: Apely one brush coxt of BMS 10-11, type 1 primer to faying surfaces, allowing epproximately 1/2 inch of primer beyond edge of ! mating part. Fasteners through slat (75) are to be installed with PR 1436¢ sealant. Optionel: Install fasteners with wet BMS 10-11, type 1 primer applied to all areas of hole including eny countersink, counterbore, or other recess, and immediately install fastener. a cee bul .65-18763 65-1878 pe £ Onieres raha OVERHAUL MANUAL A. Place basic slat assenbly in a suitable holding fixture and bulla up os follows: (1) Install. seal asseably (69) and retainer (70) with bolts (72) and . nute (72). * (2) Install hinge supports (64) end chims (68) with volte (65), washers (67), and mits (66). (3) Tighten bolte (65) within torque range of 100 to 140 pound~inches. (4) Install striker (59) on hinge fitting (50) with rivet (60), bolt (62), washers (63), and mt (61). (5) Locate shims (57 and 56) and hinge fitting assemblies (49). attach with bolte (53 and 5i), washers (56), and nuts (55). (6) Tighten bolts (53 and 5!) within torque range of 100 to 140 pound= inches. (7) Inotalt hinge fitting assenblies (42) and chine (48). Attach vith dolts (46), vashers (47), and nuts (45), (8) Install seal (io) on fairing (31). Drill two holes through each end of seal with No. 50 drill, using existing holes in fairing as pilots. Install lockvire through each set of holes. (9) Coat two helical coils (39) vith primer and install in fairing while Friner 1s wet. Insert coils one-quarter turn below surface. Remove teng. (20) Install fitting assembly (32) on fairing with bolts (37), screws (38), washers (36), and mits (35). (11) Attach fatring to slat with bolts (28), washers (29), laminated washers (30), and mts (27). Adjust thickness of laminated vashers to eliminate gap between luge of fittings (3) and fairing, 0.003~inch laminations from washers (30) to adjust thicknes: washers with BMS 10-11, type 1 primer after delamination, (12) Install bonding jumpers (21) vith bolts (22 end 23), washers (25 and 26), and nuts (24), Place washer on each side of each ‘bonding dumper terminal, with vashera (26) againet elat (75). (13) tstata poa (26) with epacers (20), bolte (16), washers (29), and nuts (17). dul 15/73 51-90-31 Page 515. 65-18763 eee 65-18764 emma ea 65-18785 OVERHAUL MANUAL (14) Install fork assenbly (5) and checknut (8) on end of link assembly (4). Adjust length of link assembly to 17.80 inches between centerlines of bushings (7 and 13). Make measurement ona Plane Parellel with centerline of tube (10). (as) Tstall Lok asombly (4) dn slat with bolt (2), washer (3), end aut a). (26) Secure 1oose end of link assembly (4) to prevent damage to clat assembly. B. ‘ouch up finieh on asseubly as necessary after completion of butldup. 10. Materials A. Primer -- HS 10-11, type 1 B. Sealant -- BE 5-79, BMS 5-95, P.R. 14366, Products Research and Chemical Corp., 410 Jersey Aveme, Gloucester City, New Jersey 08030 57-50-31 Jul 15/73 Page 516 fe6518783 meena? SL ou Commercts Bue OVERHAUL MANUAL PITS AND CLEARANCES 1. ‘the fite and cleararices table lists design dimensions and service wear limite for cloae tolerance parts of the assembly that are subject to wear or corrosion. Unless otherwise specified, parts should be returned to the @esign dimensions whenever rework is accomplished. 2, Clearances are given to ald assembly of the components. ‘The values given in the Macimm Allowable Clearance colum are the maximum penaitted to ensure proper fimctioning of the unit, If asseubled parts fail to meet this Tequirement, one or more of the parte must be rejected. Parte that are Fejected ahould be reworked if within the rework Limits given in the Repair procedure; if not within revork Limits, the parte should be screpped. It 1c Tecoumended thet the design clearances be used os the guiding assembly criteria when newly reworked parts are assenbled, Fite and Clearences sua 10/72 Figure 601 (Sheet 1) 57-5003. + Page 60165-18783 OTe 65-16764 OVERHAUL MANUAL one Leo, Lk ineTACATiON SECTION c-c a sft oO Hs VCH. o Ey—o to o secvion FAIRING HINGE Original Design Limite Bervice Wear Linite Mating Ret. | Index ster | “To. 'ig.601| Fig.( ) 10] 29,1102 A oD > - 1n|29, 1205 A op} xo]29, 1208 A op] Fito and Clearances 57-50-31 Figure 601 (Sheet 2) Page 602 Jul 10/7265-18783 gue OP, cous OVERHAUL MANUAL Original Design Limtta Service Wear Limits | D A 0.0005] 0.0030 0.0085 oD] B> | o.2k85] 0.2h95 02461 1D]25, 1109 | 0.2500 | 0.2515 0.2530 A 0.0005 | 0.0030 0.0045 L op] B> | 0.2165] 0.2895 0.2861 ‘D}30, 2102 | 0.3765 | 0.375 [0.3195 B 0.0020 | 0.0080 0.0050 | 375 0.3732 D 3115 0.3795 B 0.0020} 0.0040 0,0050 00] 33,1105 | 0.3735 | 0.3745 0.3732 ‘1D]30, 1108 | 0,3765 | 0.375 9.3795 B 0.0020} 0.0080 0.0050 11208 | 0, . 0. 0b} 33,1108 | 0.3735 | 0.3745 3731 10]26, 1103 | 0.2500 | 0.2515 0.2530 B 9.0005] 0.0030 0.0045 00} 29,1203 | 0.2485 | 0,295 0.2481 ID] 26,1106 | 0.2500 | 0.2515 0.2530 3B 0.0005 | 0.0030 0.0045, 0} 29,1106 | 0.2485 | 0.295 0.24681, Fite and Clearances Jan 10/70 Figure 601 (Sheet. 3) 51-50-31 a Page 603: 65=18783 Lorre rete he 65-18784 OVERHAUL MANUAL ae Original Design Limtts Service Weer Limits Assembly ‘Dimension Mating Dimension Clearance Tanita | Nexium Ref, | Index (4nches) (1nches) (inches) | Allowable etter | Nos Clearance Fig.601] Figeil0l | Min, | Max, | Min, | Max. | Min, | Max. | (inch) o]e6, 1109 | 0.2500 | 0.2515 0.2530 B ' 0.0005 | 0.0030 0.0045 co|eg, 109 | 0.2485 | 0.2495 o.2heL ‘D]39,1102 | 0.3765 | 0.3775 0.3795 c 0.0020 | 0.0040 0.0050 op |33,a102 | 0.3735 | 0.3785 0.3731 ‘D]39,1105 | 0.3765 | 0.3775 0.3795 c 0.0020 | 0.0040 0.0050, co] 33,1205 | 0.3735] 06375 0.37 ‘TD]39,1108 | 0.3765 | 0.3775 ‘[o.st85 c 0.0020 | 0.0040 }40050 (0D}33,1106 | 0.3735 | 0.3745 0.3731 ‘TD]31,1103 | 0.2500 | 0.2540 0.2550 c 0.0005 | 0.0055 0.0060 op |29,1103 | 0.2485 | 0.2895 o.2k81 1031, 1106 0.2500 | 0.2540 0.2550 c 0.0005 | 0.0055, 0.0080, oo}29,1106 | 0.2485 | 0.2495 0,2K61 ]31, 2109 | 0.2500 | 0.2540 0.2550 c 0.0005 | 0.0055, 0.0080, nag, 1209 | 0.2485 | 0.2495 0,246, 97-50-31, Flew 3 (aint 8) 1/70 I~ ‘igure 601 (Shaet. Jan 10, Page Gok +65~18763 a : cs EL sarah mre OVERHAUL MANUAL Clearance Pige601 | Fige( ) | Min, | Max, | Min, | mex, | min, | Mex. (ren) | ]4o,1102| 0.2515] 0.2585 0.250 D 0.0020 | 0.0040 0.0045 0} 33,2102] 0.2485 | 0.2495 0.2461, ID} 40, 1105] 0.2515 | 0.2505 0.2540 D 0.0020 | 0.0040 0.0045 (] 33,1205] 0.2485} 0.2h95 0.2h61 ]40,1108] 0.2515] 0.2585 042540 D 0.0020 | 0.0040 0.0085 0} 33,1108! 0.2485 | 0.2495 0.2461 | [29,an0e) ovens | 0.2505 0.2540 8 0.0015 | 0.0030 0.0085 @®] 3,102] 0.2495 | 0.2500 0.2491 a 1]29,1105] 0.2515 | 0.2525 0.2540 z 0.0025 | 0.0030 0.0085 ©} 3,1205] 0.2495 | 0.2500 0.240 B|29,1208] 0.2515 | 0.2525 042540 zB 0.0025 | 0.0030 0.0045 @|_3,1208] 0.2495 | 0.2500 0.2hon + 1/25, 1203] 0.2500 | 0.2515 042530 zg 10.0005 | 0.0030 0.0085 GD} 3,103] 0.2485 | 0.295 0.2481, 10] 25,1106] 0.2500 | 0.2535 0.2530 B 0.0005 | 0.0030 0.0085 ©] 3,2206| 0.2485 | 0.2495 0.2462 Fite and Clearances Jan 10/70 Figure 601 (Sheet 5) 51-5031 + Page 65‘ 65~18763 ” 518704 pt Ls Spas OVERHAUL MANUAL Griginal Design Limits Service Weer Limite Aasenbly imension Mating Clearance Limits Moxtmm Ref. Index (inches) (inches) | ALlowsble Letter | No. Clearance Pig.6or} Fig.() | Min. | Mex. | min. | Mex. | Min. | Max. | (inch) p}es,1109| 0.2500 | 0.2515 El [ 0.2530 E 0.0005 | 0.0030 0.0085 I op] 3,109] 0.2485 | 0.295 | oveken | I}20, 1102] 0.2515 | 0.2525 0.2540 r 0.0025 | 0.0030 0.0085 op] 3,202] 0.295 | 0.2500 ovation | ]20, 1205] 0.2515 | 0.2505 T (0.250 F 0.0015 | 0.0030 0.0045 OD} 3,105] 0.2495 | 0.2500 o.2hon ro)20, 1208] 0.2515 | 0.2505 0.2540 | r 0.0015 | 0.0030 0.0045, op} 3,2108] 0.2495 | 0.2500 0.249. 1p]20, 1203] 0.2500 | 0.2510 0.2530 7 0.0005 | 0.0025 0.00h5, OD} 3,1103] 0.2485 | o.2ho5 0.248. ID]10,1106| 0.2500 | 0.2520 [0.2530 | F 0.0005 | 0.0025 0.0045, OD} 3,1106} 0.285 | 0.2495 0.2481 1D}10,1109] 0.2500 | 0.2510 0.2530 F 0.0005 | 0.0025 0.0045 OD] 3,1109] 0.2485 | 0.2495 0.2481. TD} 47,1203] 0.2500 | 0.2515 0.2530 @ 0.0005 | 0.0030 0.0045, L op} 4,2203] 0.2485 | 0.2495 0.2481 3/48, 1206] 0.2500 | 0.255 0.2530 @ ‘0.0005 } 0.0030 0.0045 0p} 4,1106] 0.2485 | o.2b95 0.2461. Fite and Clearances 57-50-31 Figure 601 (Sheet 6) Jen 10/70 Page 606 +