SD3-60 STRUCTURAL REPAIR MANUAL. The following pages contain details of approved repairs to the fuselage of the SD360 aircraft.
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1 SRM FUSELAGE - REPAIRS 1. General The following pages contain details of approved repairs to the fuselage of the SD360 aircraft. Reference must also be made to CHAPTER 51, for materials and repair practices of a general nature. CAUTION: THESE REPAIRS MAY AFFECT THE FATIGUE CRITICAL BASELINE STRUCTURE. REFER TO FOR FURTHER INFORMATION ON FCBS AND PROCEDURES TO BE FOLLOWED, PRIOR TO INCORPORATING ANY OF THESE REPAIRS. 2. List of approved repairs to the fuselage structure: - Typical Frame Repair - Nose Fuselage. Refer to Figure Typical Frame Repair, Side & Top Members - Nose Fuselage. Refer to Figure Typical Frame Repair and Reinforcing - Main Fuselage. Refer to Figure Typical Frame Repair in way of Flanged Lightening Holes, Bottom Frames (not spars) - Main Fuselage. Refer to Figure Typical Frame Repair - Rear Fuselage. Refer to Figure External Patch Between Adjacent Stringers. Refer to Figure Skin Repair in Clear Area - Main Fuselage. Refer to Figure Skin Repair at Skin Laps - Main Fuselage. Refer to Figure Skin Repair, Larger than Frame Pitch - Main Fuselage. Refer to Figure Repair to 'Z' Section Stringer - Rear Fuselage. Refer to Figure Repair to Top Hat Section Stringer. Refer to Figure Typical Repairs to Stiffener - Fuel Tanks. Refer to Figure Typical Repair to Stiffener - Fuel Tank Sidewall. Refer to Figure Typical Skin Repairs of Varying Sie - Fuel Tanks. Refer to Figure Floor Skin Repair - Forward Baggage Bay. Refer to Figure Typical Patch for Damaged Honeycomb Bulkhead. Refer to Figure Bottom Corner Skin Repair - STN R.H.S. - Rear Fuselage. Refer to Figure 217 (Sheet 1). - Repair to Fuselage Structure - FR to FR 447 Lower port. Refer to Figure 218 (Sheet 1). - Repair to Corner Skin in Nose Section. Refer to Figure Repair to Skin Panel Corrugations. Refer to Figure 220 (Sheet 1). - Repair to Upper Side Fairing Rear Fuselage. Refer to Figure Repair to Corner Skin. Refer to Figure Repair to MLG Fairings (Corrosion of bonding strips) L.H. & R.H. Refer to Figure 223 (Sheet 1). - Repair to Damaged Front Bulkhead of Fwd Fuel Tank. Refer to Figure 224 (Sheet 1). - Repair to Port Skin Side Panel. Refer to Figure Repair to Stabilising Structure. Refer to Figure 226 (Sheet 1). - Repair to corrosion damage Fr. 392 btm. Refer to Figure 227 (Sheet 1). - Repair to Retaining Pin Hole in Top and Bottom Shear Deck of Stub Wing with in. Dia. Bushes. Refer to Figure 228 (Sheet 1). - Repair to Retaining Pin Hole in Top and Bottom Shear Deck of Stub Wing with in. Dia. Bushes. Refer to Figure 229 (Sheet 1). Page 201 Feb 01/10
2 SD3-60 STRUCTURAL REPAIR MANUAL Typical frame repair - nose fuselage Figure 201 Page 202
3 Typical frame repair - side and top members - main fuselage (nose fuselage similar) Figure 202 Page 203
4 SD3-60 STRUCTURAL REPAIR MANUAL Typical frame repair & reinforcing - main fuselage Figure 203 Page 204
5 Typical major frame repair in way of flanged L' holes bottom frames (not spars)- main fuselage Figure 204 Page 205
6 SD3-60 STRUCTURAL REPAIR MANUAL Typical frame repair - rear fuselage Figure 205 Page 206
7 External patch between adjacent stringers Figure 206 Page 207
8 SD3-60 STRUCTURAL REPAIR MANUAL Skin repair in clear area - main fuselage Figure 207 Page 208
9 Skin repair at skin laps - main fuselage Figure 208 Page 209
10 SD3-60 STRUCTURAL REPAIR MANUAL Typical skin repair - larger than frame pitch - main fuselage Figure 209 Page 210
11 Repair to 'Z' section stringer - rear fuselage Figure 210 Page 211
12 SD3-60 STRUCTURAL REPAIR MANUAL Repair to top hat section stringer Figure 211 Page 212
13 Typical repairs to stiffener - fuel tanks Figure 212 Page 213
14 SD3-60 STRUCTURAL REPAIR MANUAL Typical repairs to stiffener - fuel tanks side wall Figure 213 Page 214
15 Typical skin repairs of varying sie - fuel tanks Figure 214 Page 215
16 SD3-60 STRUCTURAL REPAIR MANUAL Floor skin repair - fwd baggage bay Figure 215 Page 216
17 Typical patch for damaged honeycomb bulkhead Figure 216 Page 217
18 SD3-60 STRUCTURAL REPAIR MANUAL Bottom corner skin repair - stn R.H. side rear fuselage Figure 217 (Sheet 1) Page 218
19 Bottom corner skin repair - rear fuselage Figure 217 (Sheet 2) Page 219
20 SD3-60 STRUCTURAL REPAIR MANUAL Bottom corner skin repair - rear fuselage Figure 217 (Sheet 3) Page 220
21 Repair to fuselage structure Fr Fr. 447 lower port Figure 218 (Sheet 1) Page 221
22 SD3-60 STRUCTURAL REPAIR MANUAL Repair to fuselage structure Fr Fr. 447 lower port Figure 218 (Sheet 2) Page 222
23 Repair to corner skin in nose section Figure 219 Page 223
24 SD3-60 STRUCTURAL REPAIR MANUAL Repair to skin panel corrugations Figure 220 (Sheet 1) Page 224
25 Repair to skin panel corrugations Figure 220 (Sheet 2) Page 225
26 SD3-60 STRUCTURAL REPAIR MANUAL Repair to upper side fairing - rear fuselage Figure 221 Page 226
27 Repair to corner skin Figure 222 Page 227
28 SD3-60 STRUCTURAL REPAIR MANUAL Repair to M.L.G. fairings (corrosion of bonding strips) L.H.S. & R.H.S. Figure 223 (Sheet 1) Page 228
29 Figure 223 (Sheet 2) Page 229
30 SD3-60 STRUCTURAL REPAIR MANUAL Figure 223 (Sheet 3) Page 230
31 Repair to damaged front bulkhead of fwd fuel tank Figure 224 (Sheet 1) Page 231
32 SD3-60 STRUCTURAL REPAIR MANUAL Repair to front bulkhead of fwd fuel tank (damaged by lip of fuel retention dam) Figure 224 (Sheet 2) Page 232
33 Repair to port side skin panel Figure 225 Page 233
34 SD3-60 STRUCTURAL REPAIR MANUAL Repair to stabilising structure Figure 226 (Sheet 1) Page 234
35 Repair to stabilising structure Figure 226 (Sheet 2) Page 235
36 SD3-60 STRUCTURAL REPAIR MANUAL Repair to corrosion damage fr. 392 btm. Figure 227 (Sheet 1) Page 236
37 Repair to corrosion damage Fr. 392 btm. Figure 227 (Sheet 2) Page 237
38 SD3-60 STRUCTURAL REPAIR MANUAL Repair to corrosion damage Fr. 392 btm. Figure 227 (Sheet 3) Page 238
39 Repair to Retaining Pin Hole in Top and Bottom Shear Deck of Stub Wing with in. Dia. Bushes Figure 228 (Sheet 1) Page 239
40 SD3-60 STRUCTURAL REPAIR MANUAL Repair to Retaining Pin Hole in Top and Bottom Shear Deck of Stub Wing with in. Dia. Bushes Figure 228 (Sheet 2) Page 240
41 REPAIR PROCEDURE IN. DIAMETER BUSHES: (1) OPEN UP THE EXISTING IN. DIAMETER RETAINING PIN HOLE IN THE TO AND BOTTOM SHEAR DECK TO IN. ( IN.) DIAMETER (H8) (2) COUNTERBORE THE HOLES TO IN. ( IN.) DIAMETER AND IN. (±0.005 IN.) DEPTH. (3) MAKE A IN. (±0.020 IN.) X 45 CHAMFER ON THE IN. DIAMETER HOLES TO MATE WITH THE REPAIR BUSHES. (4) AFTER COUNTERBORE, IF CORROSION REMAINS OUTSIDE THE DIAMETER O THE COUNTERBORE IT IS ACCEPTABLE TO BLEND CORROSION OUT TO A MAXIMUM DEPTH OF IN. ENSURING A SMOOTH REGULAR PROFILE. (5) PROTECTIVE TREAT THE COUNTERBORED/BLENDED AREAS WITH ALODINE1200. (6) MANUFACTURE REPAIR BUSHES FROM S154 MATERIAL AS DETAILED IN SHEET 1, OBEYING ALL INSTRUCTIONS. (7) MAGNETIC FLAW DETECT THE BUSHES TO P.SPEC (8) FREEZE FIT THE BUSHES IN ACCORDANCE WITH P.SPEC (9) MAKE SURE THERE IS A FLUSH EXTERNAL SURFACE OF 63. (10) PROTECTIVE TREAT TO D.S. 445 F+B. (11) IDENT TO D.S. 518/4. (12) OMIT THE CAD PLATING FROM THE BORE OF THE BUSHES. (13) IT IS ACCEPTABLE TO BLEND OUT THE MLG FAIRING LIP (TOP SHEAR DECK) AND THE TENSION STRAP (BOTTOM SHEAR DECK) AS SHOWN IN SHEET 2, WITH A MINIMUM RADIUS OF IN., ENSURING A SMOOTH PROFILE. (14) RESTORE PROTECTIVE TREATMENTS TO D.S. 445 F1+L+C5 (OR ALODINE 120 IN LIEU OF L). (15) PAINT A WITNESS MARK BETWEEN THE SHEAR DECKS AND BUSHES. Repair to Retaining Pin Hole in Top and Bottom Shear Deck of Stub Wing with in. Dia. Bushes Figure 228 (Sheet 3) Page 241
42 SD3-60 STRUCTURAL REPAIR MANUAL Repair to Retaining Pin Hole in Top and Bottom Shear Deck of Stub Wing with in. Dia. Bushes Figure 229 (Sheet 1) Page 242
43 REPAIR PROCEDURE IN. DIAMETER BUSHES: (1) OPEN UP THE EXISTING IN. DIAMETER HOLE TO IN. ( IN.) DIAMETER (H8). (2) MANUFACTURE THE REPAIR BUSHES FROM S154 MATERIAL AS DETAILED IN SHEET 1, OBEYING ALL INSTRUCTIONS. (3) MAGNETIC FLAW DETECT THE BUSHES TO P.SPEC (4) FREEZE FIT THE BUSHES IN ACCORDANCE WITH P.SPEC (5) MAKE SURE THERE IS A FLUSH EXTERNAL SURFACE OF 63. (6) PROTECTIVE TREAT TO D.S. 445 F+B. (7) IDENT TO D.S. 518/4. (8) OMIT THE CAD PLATING FROM THE BORE OF THE BUSHES. (9) PAINT A WITNESS MARK BETWEEN THE SHEAR DECKS AND BUSHES. Repair to Retaining Pin Hole in Top and Bottom Shear Deck of Stub Wing with in. Dia. Bushes Figure 229 (Sheet 2) Page 243
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