STRUCTURAL REPAIR MANUAL
CHAPTER 51
TABLE OF CONTENTS
SUBJECT CH/SE/SU C PAGE EFFECTIVITY
STRUCTURES − GENERAL 51−00−00
General 1
Miscellaneous Aircraft Data 1
Abbreviations 2
Special Terms 5
Major Aircraft Dimensions 5
Figures applicable to the previous 6
text
INVESTIGATION − CLEANUP AND 51−10−00
AERODYNAMIC SMOOTHNESS
General 1
Aerodynamic Smoothness Requirements 1
Aerodynamic Smoothness − Fasteners 2
Abbreviations 5
DAMAGE CLASSIFICATION 51−11−00
General 1
Examination of Damage 1
Damage Categories 2
Procedure of Skin Waviness Measurement 7
Measurement of Remaining Thickness in 17
Small Blended Out Areas
Procedure 17
ALLOWABLE DAMAGE 51−11−11
General 1
STRUCTURE CLASSIFICATION 51−11−12
General 1
Approval of Repairs 2
Primary/Secondary Structural Items 3
Principle Structural Elements (PSE), 29
Safe Life Items and Fatigue Critical
Structure (FCS) − Identification
DAMAGE/DEFECT REPORTING 51−11−13
General 1
Reporting Methods 3
Illustrations 3
Follow−Up 8
Reporting Requirements 8
CLASSIFICATION − REPAIR APPROVAL 51−11−14
General 1
Repair Design Approval Procedure 2
Repair Categories: 4
RDAS Description 5
Concepts Definitions 11
Printed in Germany
51 CONTENTS AugPage 1
01/13
STRUCTURAL REPAIR MANUAL
SUBJECT CH/SE/SU C PAGE EFFECTIVITY
DATA RECORDING OF ALLOWABLE DAMAGE 51−11−15
AND REPAIRS
General 1
PROCESSES 51−20−00
General 1
Processes and Information for the 1
Aircraft Protection
Processes and Information to 1
manufacture Metal Repair Parts
Processes and Information after Heat 1
Damage of the Structure
PROTECTIVE TREATMENT 51−21−00
General 1
Protective Treatment Areas 1
Types of Surface Protection 2
APPLICATION OF PROTECTIVE TREATMENT 51−21−11
TO METAL PARTS
General 1
Aluminum 3
Steel Alloys 9
Titanium 31
Copper Alloys 32
CORROSION PREVENTION 51−22−00
General 1
Causes of Corrosion 1
Types of Corrosion 3
Locations for Corrosion 10
Inspection for Corrosion 10
Removal of Corrosion 11
Types and Functions of Corrosion 11
Protection Procedures
COATINGS APPLICATION − GENERAL 51−23−00
General 1
PAINT COATINGS 51−23−11
General 1
Paint Scheme 1
Paint Coatings 20
Printed in Germany
51 CONTENTS AugPage 2
01/13
STRUCTURAL REPAIR MANUAL
SUBJECT CH/SE/SU C PAGE EFFECTIVITY
SPECIAL COATINGS 51−23−12
General 1
Special Coatings for Corrosion 2
Prevention
Special Coating for Abrasion 4
Protection
Special Coatings with Antistatic 4
Properties
Special Coating for Surface 4
Preparation of Composite Components
Special Coating for Protection of 5
Sealant Beads
Special Coatings for Erosion 5
protection
Special Primer for Composite Materials 5
Special Antislip Paint 6
Special Primer for Corrosion 6
Inhibition and Adhesive Films
Ultra Violet Resistant Varnish − 6
U.V.R. Clear Coat
SEALING − GENERAL 51−24−00
General 1
Safety Precautions 1
Areas of the Aircraft and the 1
Applicable Sealing
HEAT TREATMENT 51−25−00
General 1
Heat Treatment of Aluminum Alloy 1
Solid Rivets
Heat Treatment of Aluminum Alloy 6
Products
FORMING 51−26−00
General 1
BENDING 51−26−11
General 1
Bending Process 1
JOGGLING 51−26−12
General 1
Joggling Data 1
CUTTING 51−27−00
General 1
Printed in Germany
51 CONTENTS AugPage 3
01/13
STRUCTURAL REPAIR MANUAL
SUBJECT CH/SE/SU C PAGE EFFECTIVITY
CUTTING AND MACHINING OF METALLIC 51−27−11
STRUCTURES
General 1
Safety Precautions 1
Removal of Sheet Metal 1
Cutting Bonded or Fixed Sealed 2
Doublers/Parts
CUTTING AND MACHINING OF GLARE 51−27−12
STRUCTURES
General 1
Safety Precautions 1
Machining of GLARE structures 1
Pre−cutting by sawing 2
CUTTING AND MACHINING OF COMPOSITE 51−27−21
STRUCTURES
General 1
Safety Precautions 1
Machining Of Composite Structures 1
HEAT DAMAGE EVALUATION 51−28−00
General 1
Visual Examination of Heat Damage 1
Detailed Evaluation 2
Repair 2
HARDNESS TESTING AND CONDUCTIVITY 51−28−11
VALUES
General 1
Procedure for Hardness Testing 1
Hardness and Conductivity Values 3
PRESTRESSING OF COMPONENTS 51−29−00
General 1
Procedures 1
FLAP PEENING 51−29−11
General 1
Safety Precautions 2
Equipment and Materials 3
Preparation
Peening Procedure
Additional Information
MATERIALS 51−30−00
General 1
METALLIC MATERIALS 51−31−00
General 1
Validity 2
Material Selection 2
Use of General Tables 3
Printed in Germany
51 CONTENTS AugPage 4
01/13
STRUCTURAL REPAIR MANUAL
SUBJECT CH/SE/SU C PAGE EFFECTIVITY
MISCELLANEOUS METALLIC MATERIALS FOR 51−31−11
REPAIR
General 1
Miscellaneous Metallic Materials 1
EXTRUDED AND FORMED SECTIONS 51−31−12
General 1
Cross−Reference List 1
GLARE MATERIALS 51−32−00
General 1
NONMETALLIC MATERIALS 51−33−00
General 1
List of Nonmetallic Materials 6
List of Manufacturers 33
CONSUMABLE MATERIALS 51−35−00
General 1
HAZARDOUS MATERIALS 51−37−00
General 1
FASTENERS 51−40−00
General 1
Rivets (Solid) 2
Special Fasteners 2
Blind Fasteners 4
Description of the Leader Partnumber 6
(LPN)
Explanation of Diamonds and 6
Abbreviations in Tables 3 thru 9
Cross−Reference List 9
FASTENERS − CALL−UP AND DESIGNATION 51−40−12
General 1
Additional Information 1
Fastener Illustrations 1
FASTENER SYMBOLS 51−41−00
General 1
Production Drawing Fastener Symbols 1
FASTENER INSTALLATION AND REMOVAL 51−42−00
General 1
Printed in Germany
51 CONTENTS AugPage 5
01/13
STRUCTURAL REPAIR MANUAL
SUBJECT CH/SE/SU C PAGE EFFECTIVITY
FASTENER INSTALLATION AND REMOVAL − 51−42−11
METALLIC STRUCTURE
General 1
General Instructions 1
Fastener Selection 5
Lubrication of Fasteners with 5
lubricant
Bolts, Screws and Nuts 7
Rivets (Solid Rivets) 7
Pin (Threaded) Fasteners (HI−LOK and 25
HI−LITE)
Pin (Threaded) (Bullnose) 50
TAPER−LOK Fasteners 63
Rivet (Blind) (HUCK) A12
Rivet − Blind (AVDEL MBC) A34
Rivet−Blind (IMEX) A41
Rivet−Blind (CHERRYMAX) A52
Rivet−Blind (CHERRYLOCK) A60
Pin (Swaged) (LOCKBOLT) A70
Bolt−Blind (Jo−bolt/AVDEL/VISU−LOK) A92
Rivet−Blind (CHERRY PULL−THROUGH) B9
Rivet (Solid) (CHERRYBUCK) B17
Rivet (Solid) (CHERRY E−Z BUCK) B30
Drilling of Bolt Threads B45
Double Countersunk Rivets B48
High Interference Fit Fasteners − B49
Removal and Repair
Pin (Threaded) (Tension) B60
FASTENER INSTALLATION AND REMOVAL − 51−42−12
GLARE STRUCTURE
General 1
Safety Precautions 1
General Instructions 1
FASTENER INSTALLATION AND REMOVAL − 51−42−21
COMPOSITE STRUCTURE
General 1
General Instructions 1
Fastener Selection 4
Rivet (Blind) (HUCK) 5
Pin (Threaded) Fasteners (HI−LOK and 20
HI−LITE)
Bolt−Blind (COMPOSI−LOK) 35
Rivet (Blind) (CHOBERT) 51
Rivet (Solid) (CHERRY E−Z BUCK) 56
Rivet (Hollow End) (CHERRY E−Z BUCK) 71
Tubular Rivet 77
Printed in Germany
51 CONTENTS AugPage 6
01/13
STRUCTURAL REPAIR MANUAL
SUBJECT CH/SE/SU C PAGE EFFECTIVITY
FASTENER OVERSIZE AND ALTERNATIVES 51−43−00
General 1
Solid Rivets for Oversize − Metallic 3
Structure
Blind Rivets for Oversize − Metallic 3
Structure
Explanation of Diamonds in Tables 3 3
thru 9
Cross−Reference List 4
FASTENER OVERSIZE − METALLIC STRUCTURE 51−43−11
General 1
FASTENER ALTERNATIVE − METALLIC 51−43−12
STRUCTURE
General 1
FASTENER OVERSIZE − COMPOSITE 51−43−21
STRUCTURE
General 1
FASTENER ALTERNATIVE − COMPOSITE 51−43−22
STRUCTURE
General 1
FASTENERS − HOLE AND DRILL DATA 51−44−00
General 1
Procedures and Information for the 1
Fastener Hole Preparation
FASTENERS − HOLE AND DRILL DATA − 51−44−11
METALLIC STRUCTURE
General 1
Hole Data 1
Drill Data 18
FASTENER HOLE AND DRILL DATA − GLARE 51−44−12
STRUCTURE
General 1
Safety Precautions 1
Hole Data 1
General Drilling Requirements 2
Preparation of Holes 3
Drilling−Tools and Drilling Parameters 3
Countersinking and Under−Head 4
Radius/Chamfer Machining
Cooling Lubricants 4
Deburring 5
Chip Removal 5
Drill Kit Availability 5
Tooling for Drilling Holes for Bush 6
Repairs
Printed in Germany
51 CONTENTS AugPage 7
01/13
STRUCTURAL REPAIR MANUAL
SUBJECT CH/SE/SU C PAGE EFFECTIVITY
FASTENERS − HOLE AND DRILL DATA − 51−44−21
COMPOSITE STRUCTURE
General 1
Hole Data 1
Drill Data and Drilling Requirements 10
COUNTERSINKING 51−46−00
General 1
COUNTERSINKING − METALLIC STRUCTURE 51−46−11
General 1
SPOT FACING PROCEDURE 51−46−12
General 1
COUNTERSINKING − GLARE STRUCTURE 51−46−13
General 1
Tools and Parameters 6
COUNTERSINKING − COMPOSITE STRUCTURE 51−46−21
General 1
FASTENER SPACING AND MARGIN DATA 51−47−00
General 1
Fastener Hole Pitch and Edge Distance 2
− Metallic Structure
Fastener Hole Pitch and Edge Distance 10
− Composite Structure
Fastener Hole and Edge Distance − 11
GLARE Structure
COLD EXPANSION OF FASTENER HOLES 51−48−00
General 1
Cold Expansion Process 2
Hole Inspection Requirements 34
Tooling 34
Tooling Source and Information 36
COLD EXPANSION OF CRACK STOP HOLES 51−48−11
General 1
Tooling Source and Information 12
Printed in Germany
51 CONTENTS AugPage 8
01/13
STRUCTURAL REPAIR MANUAL
SUBJECT CH/SE/SU C PAGE EFFECTIVITY
BUSHLOC INSTALLATION PROCEDURE 51−48−12
General 1
Safety Precautions 3
Bush Design Requirements 3
Parent Structural Requirements 11
Application Requirements 14
Accessibility 15
Repair of Damaged Holes in Aluminum 16
Alloy Structure
Procedures 19
Manufactured Bush Installation 32
Procedure
Quality Assurance Considerations 36
Tools and Equipment 40
Tooling Source and Information 53
STANDARD TORQUE VALUES 51−49−00
General 1
Safety Precautions 1
Use of Castellated Nuts 1
Re−Use of Nuts and Bolts 2
Lubricants and Correction Coefficients 2
Use of an Adaptor 2
Explanation of Terms 3
SUPPORT OF AIRPLANE FOR REPAIR AND 51−50−00
ALIGNMENT CHECK PROCEDURES
General 1
SUPPORT OF AIRPLANE FOR REPAIR 51−51−00
General 1
Repair Site Situation 1
Request for Specific Jacking 2
Instruction
General Jacking/Monitoring/Dejacking 2
Method
A/C Configuration Sheet 17
CONTROL SURFACE BALANCING 51−60−00
General 1
REPAIRS 51−70−00
General 1
Shimming 2
Printed in Germany
51 CONTENTS AugPage 9
01/13
STRUCTURAL REPAIR MANUAL
SUBJECT CH/SE/SU C PAGE EFFECTIVITY
REPAIR DESIGN GUIDELINE 51−70−10
General 1
Calculation 7
Example 1 − Riveted Flange Cutout 12
Example 2 − Extrusion Cutout 18
Example 3 − Complete Extrusion Cutout 24
Example 4 − Profile Cutout 30
Example 5 − Profile Cutout 40
Example 6 − Typical T−Profile Cutout 54
Example 7 − Typical C−Type Beam upper 61
flange Cutout
Example 8 − Typical Formed Section 77
Cutout
Example 9 − Typical Formed Section 84
Cutout
Example 10 − I−Type Beam upper flange 93
Cutout
Example 11 − Web Repair (Limited A6
Cutout Height)
Example 11 − Plate Repair (Unlimited A14
Cutout Size)
TECHNICAL DATA FOR THE REVERSE 51−70−11
ENGINEERING METHOD
Material Allowable Values 1
TECHNICAL DATA FOR REVERSE 51−70−12
ENGINEERING METHOD
Material Substitution Factors 1
TECHNICAL DATA FOR REVERSE 51−70−13
ENGINEERING METHOD
Fasteners − Strength of Mechanical 1
Joints
TECHNICAL DATA FOR REVERSE 51−70−14
ENGINEERING METHOD
Allowable Local Buckling Loads for 1
Standard sections
GENERAL REPAIR REQUIREMENTS 51−70−20
General 1
FILLING OF EXISTING COUNTERSINKS 51−71−15
General 1
Safety Precautions 1
Local Manufacture of Filler Washers 1
Local Manufacture of Filler Washer 3
for Special Countersinks
Filler Washer available from MSC 3
Printed in Germany
51 CONTENTS AugPage01/13
10
STRUCTURAL REPAIR MANUAL
SUBJECT CH/SE/SU C PAGE EFFECTIVITY
REPLACEMENT OF COMPONENTS 51−72−00
General 1
Procedures 1
REPLACEMENT OF STRUCTURAL COMPONENTS 51−72−11
General 1
Safety Precautions 1
Instructions for Replacement 1
Parts to be Replaced 1
Replacement 1
Installation 2
REPLACEMENT OF BUSHES IN SITU 51−72−12
General 1
Permissible Increase of the Inner 1
Diameter of Bushes
Replacement of Standard Bushes 2
Installation of Oversize Bushes 7
REPAIR OF MINOR DAMAGE 51−73−00
General 1
Safety Precautions 1
Repair of Small Dents 1
Removal of Scratches 3
Blending and Rework 7
Stop−Drilling of Cracks 11
Dress−out of Dents 12
NEGLIGIBLE DAMAGE 51−73−11
General 1
Dents 2
Impressions (GLARE Panels only) 6
Blending 7
Rivet Pull−In 12
REPAIR BY INSTALLATION OF A FREEZE 51−73−12
PLUG
General 1
Safety Precautions 3
Materials/Equipment 4
Installation Procedure 4
Printed in Germany
51 CONTENTS AugPage01/13
11
STRUCTURAL REPAIR MANUAL
SUBJECT CH/SE/SU C PAGE EFFECTIVITY
REPAIR OF CORRODED AREAS 51−74−00
General 1
Safety Precautions 2
Materials 3
Corrosion Rework Preparation 4
Corrosion Removal Techniques − General 4
Corrosion Removal for Aluminum Alloys 8
Corrosion Removal Procedure for 11
Carbon Steel
Corrosion Removal Procedure for 12
Stainless−Steel and Nickel−Chromium
Alloys
Corrosion Removal for Titanium Alloys 12
Removal of Corrosion from 13
Cadmium−Plated Parts
PAINT REPAIR 51−75−00
General 1
Procedures 1
STRIPPING/PAINT REMOVAL 51−75−11
General 1
Chemical Paint Stripping Procedure − 4
Metallic Structure Only − Methylene
Chloride Based Paint Stripper
Paint Removal by Abrasion 8
One−Time Full Chemical Paint 9
Stripping Procedure − External
Fuselage Metallic Structure Only −
Acid Activated Paint Stripper
Chemical Paint Stripping Procedure − 14
External Fuselage Metallic Structure
Only − Hydrogen Peroxide based Paint
Stripper
Chemical Paint Stripping Procedure − 18
External Metallic Structure Only −
Alkaline Benzyl Alcohol based Paint
Stripper − Intermediate Coat Paint
System
Chemical Paint Stripping Procedure − 23
Fuselage and Wing Metallic Structure
Only − IMPROVED Hydrogen Peroxide
based Paint Stripper
Printed in Germany
51 CONTENTS AugPage01/13
12
STRUCTURAL REPAIR MANUAL
SUBJECT CH/SE/SU C PAGE EFFECTIVITY
REPAIR OF PAINT COATINGS 51−75−12
General 1
Safety Precautions 1
Repair of damaged top coat for metal, 3
composite and glare parts
Renewal of paint build−up after 3
damage to metal and glare parts or
after paint stripping of metallic and
glare parts
Renewal of paint build−up of 6
composite components that require no
anti−erosion paint
Renewal of paint build−up of 9
composite components that require
anti−erosion paint
Repair of peeled−off paint coatings 11
on fastener heads
Application of anti erosion tape on 12
vertical and horizontal stabilizer
painted leading edge
Renewal of damaged fuel tank top 18
coating on center tank and horizontal
stabilizer center tank
Renewal of external paint build−up 19
with AMS 3095 external paint scheme
SEALING REPAIRS 51−76−00
General 1
Terms and Definitions 1
Sealing Repair Materials 2
REPAIR OF SEALING EXCLUDING FUEL TANK 51−76−11
General 1
Safety Precautions 1
Repair Materials 3
Repair Procedures 4
Printed in Germany
51 CONTENTS AugPage01/13
13
STRUCTURAL REPAIR MANUAL
SUBJECT CH/SE/SU C PAGE EFFECTIVITY
REPAIR OF FUEL TANK SEALING 51−76−12
General 1
Safety Precautions − General 2
Safety Precautions − Specific 3
Other Safety Precautions and 3
References
Repair Materials and General 3
Guidelines for Application
Equipment and Materials 9
The Source of the Fuel Leakage 12
Removal of Damaged Sealant 12
Cleaning the Repair Area 15
Sealant Application 16
Specific Fuel Leak Repairs 39
Helium Detection Procedure 39
Quick Curing Sealant Device 39
Fuel Leak Reporting Form 43
STANDARD COMPOSITE REPAIRS 51−77−00
General 1
COMPOSITE COMPONENTS − ALLOWABLE 51−77−10
DAMAGE AND REPAIR CLASSIFICATION
General 1
Inspection and Types of Damage − 1
Composite Components
Damage Evaluation 5
Repair Classifications 9
Post Repair Inspection/Checks 10
MATERIAL HANDLING AND PREPARATION 51−77−11
General 1
Safety Precautions 1
Material Handling 1
Preparation 19
Material Application 72
Material Data A7
Manufacturing Procedures for Mould A68
Tools
COMPOSITE REPAIRS − SKIN DAMAGE ALL 51−77−12
STRUCTURES
General 1
Repairs 4
Permanent Skin Repairs for non 7
Perforating Damage
Permanent Skin Repairs for 29
Perforating Damage
Printed in Germany
51 CONTENTS AugPage01/13
14
STRUCTURAL REPAIR MANUAL
SUBJECT CH/SE/SU C PAGE EFFECTIVITY
REPAIR OF COMPOSITE AND METALLIC 51−77−13
SANDWICH STRUCTURES
General 1
Repairs 6
RT Repairs to Metal Skinned, A8
Honeycomb Cored Components
Hot Bonding Repairs to Metal Skinned, A39
Honeycomb Cored Components
CLEANING PROCESSES 51−78−00
General 1
SKYDROL SPILLAGE 51−78−11
General 1
Safety Precautions 1
Skydrol Removal in Areas where Access 1
is Possible
Skydrol Removal in Areas where Access 2
is restricted
SMOKE DEPOSITS 51−78−12
General 1
TITANIUM DAMAGE 51−78−13
General 1
Safety Precautions 1
Equipment and Materials 1
Check of Titanium 1
Cleaning/Painting of Titanium 2
Approved Titanium Repairs 3
MERCURY SPILLAGE 51−78−14
General 1
Safety Precautions 2
Inspection Procedure 2
Mercury Spillage Removal 3
ACID AND ALKALI SPILLAGE 51−78−15
General 1
Safety Precautions 1
List of Materials 2
Removal of Acid and Alkali Spillage 2
Inspection and Removal of Corrosion 4
Reprotection of Contaminated Areas 4
CONTAMINATION BY FISH CONTAINER 51−78−16
LEAKAGE
General 1
Safety Precautions 1
Material 1
Procedure 1
Printed in Germany
51 CONTENTS AugPage01/13
15