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51-42-11 - Description - Fastener Installation and Removal - Metallic
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51-42-11 - Description - Fastener Installation and Removal - Metallic Structure

WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL
MANUFACTURER INSTRUCTIONS AND YOUR LOCAL REGULATIONS.

CAUTION: WHEN IT IS NECESSARY TO DO A LARGER REPAIR ON A RIVETED OR BOLTED

STRUCTURE, THE STRUCTURE MUST BE SUPPORTED. THIS IS NECESSARY TO MAINTAIN
THE ORIGINAL SIZE, CONTOUR AND ALIGNMENT.
1. General

NOTE: For oversize installation, always use a washer under the nut to prevent clashing of the nut with the
shank of the bolt, unless the nut has the capability to be used with oversized bolt.
A. This task gives general instructions for the installation and removal of fasteners. Use the information in
this task together with any specific instructions that are given in the manual, for example in repairs. If
the instructions in the repairs are different from those contained in this task, the instructions in the
repairs must take precedence. Refer to the subsequent list for special details:
- Fastener Selection Paragraph
2.
.
B.
,
- Lubrication of Fastener with Cetyl Alcohol Paragraph
2.
.
C.
,
- Bolts, Screws and Nuts Paragraph
2.
.
D.
,
- Rivets (Solid Rivets) Paragraph
2.
.
E.
,
- Pin (Threaded) (HI-LOK and HI-Lite) Fasteners Paragraph
2.
.
F.
,
- Bull-Nose Fasteners Paragraph
2.
.
G.

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,
- Taper Fasteners Paragraph
2.
.
H.
,
- Rivet-Blind (HUCK Blind Rivets) Paragraph
2.
.
I.
,
- Rivet-Blind (AVDEL Blind Rivets) Paragraph
2.
.
J.
,
- Rivet-Blind (IMEX) Paragraph
2.
.
K.
,
- Rivet-Blind (CHERRYMAX) Paragraph
2.
.
L.
,
- Rivet-Blind (CHERRYLOCK) Paragraph
2.
.
M.
,
- Pin (Swaged) Paragraph
2.
.
N.
,
- Bolt-Blind (Jo-Bolt/AVDEL/VISU/LOK) Paragraph
2.
.
O.
,
- Rivet-Blind (CHERRY Pull-Through) Paragraph
2.
.
P.
,
- Rivet (Solid) (CHERRYBUCK) Paragraph
2.

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.
Q.
,
- Rivet (Solid) (CHERRY E-Z BUCK Paragraph
2.
.
R.
,
- Drilling of Bolt Threads Paragraph
2.
.
S.
,
- Double Countersunk Rivet Paragraph
2.
.
T.
,
- High Interference Fit Fasteners - Removal and Repair Paragraph
2.
.
U.
,
- Pin (Threaded) (Tension) Paragraph
2.
.
V.
.
- Fastener removal (E-drill tooling) Paragraph
2.
.
W.
.
- Structural Blind Bolt ABS2322K (ER755) Paragraph
2.
.
X.
.
2. Procedure
A. General Instructions
(1) Replacement and Additional Fasteners
(a) Replacement fasteners must be of the same type, material and surface finish as the
original fasteners. They must also have the same surface lubricant if applicable (for
example, lubricant).
(b)

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For repair work use fasteners that are the same as those in the adjacent area unless
specified otherwise in the repair procedure. If these fasteners cannot be identified contact
AIRBUS.
(c) After fasteners have been installed their visible surfaces must be fully cleaned. This is to
make sure that the paint finish bonds correctly, refer also to paragraph
2.
.
A.
.
(9)
.
(2) Oversize and Alternative Fasteners
(a) When a fastener hole is damaged or out of tolerance refer to Chapter 51-43-00, Fastener
Oversize and Alternatives.
(b) When the correct fastener is not available refer to Chapter 51-43-00, Fastener Oversize
and Alternatives.

CAUTION: DO NOT USE CADMIUM PLATED TOOLS ON PARTS MADE FROM TITANIUM.
CADMIUM PARTICLES CAN CAUSE BRITTLENESS AND CRACKS IN TITANIUM.
LEAD, SILVER, ZINC AND TIN, CAN CAUSE THE SAME EFFECT IF THE TITANIUM
IS HEATED ABOVE 120 °C (250 °F).
(3) Special Tools
Where special tools are referred to in this chapter these must be used to install and remove the
applicable fastener. These tools must be kept in good condition, and the fastener contact area of
the tool must be clean and smooth.
(4) Loose Fasteners
(a) The conditions that follow can indicate a loose fastener:
- the fastener moves in relation to the attached material. Deflection of thin skins can
be seen,
- the head of a fastener is rolled upwards at its periphery,
- a black or dark grey stain adjacent to or around the fastener head. The stain usually
takes the shape of a streak of dirt or oil behind the loose fastener,
- broken or disrupted paint finish over fastener heads.
(b) If the indications do not clearly show that a fastener is loose mark a red line across the
head and the adjacent material. Check this line at the next inspection. A loose fastener is
shown when the line on the fastener head does not agree with the line on the material
(Refer to Figure 001).
(c) In general loose fasteners must be replaced, except for some fasteners in the wing skins,
which may be re-torqued. Refer to paragraph
2.
.
F.
.
(5)

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. for details of the fasteners types that can be re-torqued and for the correct procedure to
be used. Note that where loose fasteners are found or suspected in the MLG upper or
lower wing skin bolting regions, advise AIRBUS of the findings and any action taken in
accordance with paragraph
2.
.
A.
.
(4)
.
(b)
above and await instructions regarding replacement or re-torquing.
(5) It is important that the correct sequence of assembly is used when doing a repair, this will make
sure that all parts are correctly aligned. In some cases it is also necessary for accuracy to use
jigs when drilling and reaming holes.
(6) The Use of Washers under Nuts/Collars.
(a) The use of a washer under a nut/collar is only permitted in the situations that follow:
1 When used in the original construction.
2 When called up in a repair procedure.
3 When the use of an oversize bolt causes the nut/collar to become threadbound.
4 When a bolt of the correct grip-length is not available and an overlength bolt must
be used.

NOTE: The use of a washer under the nut/collar in the situations given in
paragraph
2.
.
A.
.
(6)
.
(a)
.
3
and
2.
.
A.
.
(6)
.
(a)
.
4
should be limited as far as possible.

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(b) One washer 1.6 mm (0.063 in) thick, or two washers 0.8 mm (0.031 in) thick, can be used.
The use of one washer is preferred.
(c) A suitable standard washer is, e.g. NAS1149 (aluminum and steel material) or NAS1252
(aluminum material only). A washer with an inner diameter close to the fastener diameter
should be selected. For the correct material refer to the Table 1 that follows:

NOTE: For Bullnose Fasteners refer to Table 18 and 19.

STRUCTURE MATERIAL UNDER WASHER WASHER MATERIAL

Aluminum Alloy Aluminum Alloy (Anodised)
Steel Alloy Steel Alloy (Cadmium Plated) (Temperature less th
200°C (392°F) Stainless Steel (Passivated)
(Temperatures above 200°C (392°F)
Stainless Steel, Titanium, Nimonic Steel Stainless Steel (Passivated)

Table 1 - Washer Material

(7) At the appropriate stage of a repair or re-assembly, the correct sealing/jointing compound must
be applied if it is required (Refer to Chapter 51-24-00).
(8) Lubricated Fasteners
(a) Fasteners that are supplied lubricated with lubricant (CA) must not be cleaned before they
are installed. The torque values for these fasteners has been calculated for the lubricated
condition. After installation the visible parts of the fastener must be fully cleaned to ensure
that the paint coating or sealant adheres correctly.
(b) It is a requirement that fasteners to be painted are cleaned with cleaning agent's
'SOCOMOR DN 108' or industrial alcohol, after they have been installed.
(c) It is a requirement that within the fuel tanks the visible parts of these fasteners are
cleaned with cleaning agents 'ARDROX PST 108' or 'SOCOSOLVE 446' after they have
been installed. This will ensure that the encapsulating sealant adheres correctly.
(9) Chapter 51-42-00 gives a list of other chapters that are related to this task.
(10) Cleanliness
(a) It is important that all unwanted materials and tools are removed from the inside of the
structure when a repair is completed. When necessary this must be done before the final
repair step.
(b) Failure to remove unwanted materials and tools could cause:
- physical obstruction of moving parts,
- blocked drain holes, this could cause a build-up of waste fluids and corrosion,
- corrosion caused by the effect of contact between dissimilar materials, this
corrosion cannot always be seen at an early stage.
(11) Fastener grip length definition
(a)

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Where due to the accumulation of tolerances, the required fastener grip length is not
compatible with that given on the drawing, the inspection function may allow substitution
of an alternative grip length subject to the following limitations:
- fastener grip length variations shall not exceed ±1 of that given on the drawing or
AIPC,
- fastener protrusion and geometric installation parameters shall conform to the
requirements of the SRM,
- required clearance allowances shall be maintained to prevent fouling of parts.
B. Fastener Selection
(1) For the selection of fasteners refer to the type, material, protection, diameter, length and, if
necessary, to the oversize diameter. A specified selection of the fasteners that are used on this
aircraft is given in this task in the fastener type paragraphs. Usually, fasteners are given an
identification number that show its type, material, protection, diameter and length. The
identification numbers of the different types of fasteners are given in Chapter 51-40-12,
Fasteners - Call-up and Designation.
(2) The dash numbering system that is given in Chapter 51-40-12 is not applicable to all fasteners. It
is sometimes necessary to physically measure the required fastener.
C. Lubrication of Fasteners with lubricant

NOTE: Both methods in

2.
.
C.
.
(1)
or
2.
.
C.
.
(2)
are alternative.
(1) Lubrication of fasteners with cetyl alcohol base lubricant (Material No. 03RBA1)
(a) Repair Materials

ITEM NOMENCLATURE QTY MATERIAL/REMARKS

Cetyl Alcohol base Material No. 03RBA1
1 AR
Lubricant - Fasteners (Refer to CML)
Non Aqueous Cleaner - Material No. 08BBB1
2 AR
Petroleum Based (Refer to CML)
Non Aqueous Cleaner - Material No. 08BBU9
3 AR
Trichloroethane Legacy (Refer to CML)

Non Aqueous Cleaner -

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3 General AR Material No. 08BAA9

(Refer to CML)

(b) Lubrication Instructions

NOTE: The warnings given below apply to all the procedural steps in this instruction
where dangerous materials are in use.
1 Preparation of the solution

WARNING: ONLY USE EQUIPMENT DESIGNED FOR THIS PURPOSE WHEN

YOU PREPARE LUBRICANT SOLUTION (MATERIAL NO.
03RBA1). THIS SOLUTION IS A FLAMMABLE AND VOLATILE
FLUID.
a To prepare the solution, mix 100 to 160 g (3.53 to 5.64 oz.) of cetyl alcohol
base lubricant (Material No. 03RBA1) per liter (0.26 US gal.) of non aqueous
cleaner (Material No. 08BBB1).
b Increase the temperature of the cleaning agent to between 49 and 54° C
(120 and 129° F). This will make sure that the cetyl alcohol base (Material
No. 03RBA1) is fully dissolved.
2 Clean the parts with the non aqueous cleaner (Material No. 08BBU9 or Material No.
08BAA9).
3 Make sure that the parts are dry for the subsequent work step.
4 Put the parts into the solution for approximately 2 minutes until they are fully heated
to a temperature of 49° C (120° F).

NOTE: Make sure that the parts are fully immersed in the solution.
NOTE: Keep the temperature of the solution between 49 and 54° C (120 and
129° F).
5 Remove the parts from the solution and shake them to remove the excess fluid.
6 Let the parts dry at a room temperature of 18° C (64° F).

NOTE: Do not handle the parts before they are fully dry.
7 Do a visual check to make sure that the parts have a layer of lubricant all over
them. A white film or a frosty aspect can be a result of the lubrication and is no
cause to reject the part.
(2) Lubrication of fasteners with cetyl alcohol base lubricant (Material No. 03RBB1)
(a) Repair Materials

ITEM NOMENCLATURE QTY MATERIAL/REMARKS

Cetyl Alcohol base
Material No. 03RBB1
1 Lubricant - Fasteners AR
(Refer to CML)
Water base -

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2 Demineralized Water AR Or grade A pure water,

refer to PMS 02-05-19
Non Aqueous Cleaner - Material No. 08BBU9
3 AR
Trichloroethane Legacy (Refer to CML)
Non Aqueous Cleaner - Material No. 08BAA9
3 AR
General (Refer to CML)

(b) Lubrication Instructions

NOTE: The warnings given below apply to all the procedural steps in this instruction
where dangerous materials are in use.

WARNING: OBEY THE MANUFACTURER INSTRUCTIONS WHEN YOU USE THE

CLEANING AGENT (MATERIAL NUMBER 08BAA9/08BBU9). THIS
CLEANING AGENT IS DANGEROUS.
1 Preparation of the solution
a To prepare the solution, mix cetyl alcohol base lubricant (Material No.
03RBB1) with demineralized water by stirring to obtain a concentration of 30
to 60 g (1.06 to 2.12 oz.) of cetyl alcohol per liter (0.26 US gal.). Do not
shake, this will cause unwanted bubble formation.

NOTE: For interference bolts a concentration up to 100 g (3.53 oz.) of cetyl

alcohol per liter (0.26 US gal.) is acceptable.
NOTE: Use a plastic or stainless steel container large enough to immerse
completely the parts.
b Increase the temperature of the water to between 65 and 71° C (149 and
160° F). Make sure that the lubricant is fully dissolved.
2 Clean the parts with the non aqueous cleaner (Material No. 08BAA9 or Material No.
08BBU9).
3 Make sure that the parts are dry for the subsequent work step.
4 Put the parts into the solution for approximately 2 minutes until they are fully heated
to a temperature of 65 to 71° C (149 to 160° F).

NOTE: Make sure that the parts are fully immersed in the solution.
NOTE: Keep the temperature of the solution between 65 and 71° C (149 and
160° F).
5 Remove the parts from the solution and shake them to remove the excess fluid.
6 Let the parts dry at a room temperature of 18° C (64° F) or in slow moving heated
air, not to exceed 93° C (200° F). Make sure all part surfaces are completely coated.

NOTE: Do not handle the parts before they are fully dry.
7

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Do a visual check to make sure that the parts have a layer of lubricant all over
them. A white film or a frosty aspect can be a result of the lubrication and is no
cause to reject the part.
(c) Service Life of the Solution
When a bath of lubricant is in permanent use, it is necessary to replace the solution after
30 days of continuous use. This is necessary because of the possible contamination of
the bath within this time. Contamination can have an adverse effect on the solution. If
used intermittently, replace the solution after 50 hours or 60 days.
D. Bolts, Screws and Nuts

NOTE: For oversize installation, always use a washer under the nut to prevent clashing of the nut
with the shank of the bolt, unless the nut has the capability to be used with oversized bolt.
(1) You may use power and/or hand tools to install and remove bolts, screws and nuts. If a specific
type of tool is required this will be given in this task where relevant.
(2) Install bolts and screws, where practical, with the head either uppermost or foremost; as
appropriate. In this position there is less risk of the bolt/screw falling out if it becomes unsecured.
(3) If not specified in a repair procedure, or by the original position of the fastener, install nuts so
that not less than 1/32 in (0.8 mm) of the bolt or screw extends through the nut. If the bolts or
screws are chamfered, the full chamfer must extend through the nut.
(4) The torque values for fasteners are given in Chapter 51-49-00.
(5) Reuse of Fasteners (Nuts, Bolts and Washers)
It is recommended that nuts and bolts that were installed to a specific torque value are not
reused. However, when it is necessary to reuse such nuts and bolts apply the rules that follow:
(a) Do not reuse aluminum alloy nuts.
(b) Nuts and bolts made from metallic materials other than aluminum, can be reused if:
- the surface protection of the nut/bolt is not damaged
- the original lubrication can be renewed
- the applicable torque can be achieved.
(c) A plain washer can be re-used on a permanent basis provided it is not damaged and
relevant protection is applied as required.
(d) A lock nut washer / tab washer has several tabs and only one tab can be used to lock the
nut. The re-use of a lock nut washer / tab washer is acceptable on a permanent basis
provided that:
- Lock washer has not been damaged during removal and relevant protection is
applied as required.
- A previously un-used tab is utilized to secure the lock nut after installation.
E. Rivets (Solid Rivets)
(1) General
(a) For the installation of rivets the subsequent methods apply:
- the continuous squeeze riveting process,
- hammering with a pneumatic rivet gun,

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- hand hammering.
The continuous squeeze method is recommended, but if this method is not available then
pneumatic hammering is the next recommended method. The hand hammering method is
used primarily for small repairs that include very few rivets. It can also be used if other
methods are not available.
(b) A squeeze riveting tool makes the upset head of a rivet in a single continuous action. For
this effect the tools given below are necessary:
- a hydraulically operated tool,
- or a pneumatically operated tool.
Static and portable types of tools are available.
(c) The rivet gun, used with a back-up dolly (bucking bar), forms the upset head. This is
known as reaction riveting. A correctly shaped rivet set (rivet snap) is held in the gun and
located on the manufactured head end of the rivet. At the same time the dolly is held
against the end of the rivet to be upset. When the gun operates, the dolly reaction to the
pneumatic hammering of the gun forms the upset head.
(d) Hand hammering is the basic method used to make the upset head of a rivet. For this
method do the subsequent steps:
1 Support the manufactured head with a correctly shaped rivet set,
2 Hold a dolly against the end of the rivet and hit it until the upset head has the
correct shape.

NOTE: Make sure that the hammer blows are heavy and as few as possible
because a large number of light blows work-hardens the rivet. This can
result in cracks in the upset head.
(e) Make sure that the tools are sufficiently large to quickly form the upset head. The
subsequent times for the formation of the upset head are recommended:
- three or four seconds is the optimum time,
- seven seconds is the maximum time.
Hold the back-up dolly in position until the rivet is fully installed.
(f) Before you install rivets in the aircraft structure, make some testpieces to check the rivet
and tool precision. These test-pieces must have the subsequent properties:
- for testpieces, the same type of material and thickness as the part to be riveted,
- for rivets, the same type of material, length and diameter as the rivets to be used.
(g) Visually check rivets before they are installed. If a rivet appears defective, for example,
deep scores or indication of wire drawing, reject it. Some apparent defects, for example,
isolated nicks, abrasions, die marks or fins, are acceptable up to a maximum depth of
0.10 mm (0.004 in).
(h) Rivets made from 2017A, 3.1324 and 2024 materials must be kept in a refrigerator after
they have been heat-treated. Refer to Chapter 51-25-00 for further information.
(i) For the minimum part thickness on the upset head side of 7050 rivets refer to Table 2.

Rivet Diameter Part Thickness

mm in mm in

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3.2 1/8 1.2 0.047

4 5/32 1.4 0.055
4.8 3/16 1.8 0.071
5.6 7/32 2 0.079
6.4 1/4 2.2 0.087

Table 2 - Minimum Part Thickness on the Upset Head of 7050 Rivets

(2) Installation (Refer to Figure 003 and Figure 004)
(a) Select the required rivet. If for any reason the dimensions of the required rivet are not
known proceed as follows:
1 Accurately measure the diameter of the hole. If the diameter of the hole is within the
tolerances for a standard rivet (Refer to Chapter 51-44-00), select a rivet of this
diameter. If the diameter of the hole is not within the tolerances, increase the
diameter of the hole to suit an oversize rivet if applicable, or the next standard size.
2 To find the required rivet length, accurately measure the total thickness of the
materials to be joined. Refer to Figure 003 to find the correct length that is relevant
to the rivet diameter found above.

NOTE: If necessary, the rivet can be cut by shearing to the required length. This
does not apply to titanium rivets.
(b) Get the correct rivet set and back-up dolly for the rivet type and dimensions (Refer to
Figure 004).
(c) Make sure that the hole, and if applicable, the countersunk portion is in a satisfactory
condition. This includes clean and free from burrs.
(d) Clean the parts as necessary. Apply sealant or jointing compound if it is called for:
- in the related repair drawing,
- in the related assembly drawing,
or is normally used in the area concerned (external surfaces, fuel tank areas), refer to
Chapter 51-76-11 or Chapter 51-76-12 (fuel tank) for wet installation of rivets.

NOTE: Install the rivets before the work life of the sealant or jointing compound ends.
(e) Make sure that the contact surfaces of the parts are fully together and that there are no
gaps between them. Gaps will prevent the correct forming of the rivet and reduce the joint
strength.
(f) Align the holes as necessary and attach the parts together temporarily. Take care not to
cause damage to the local area with tools.
(g) Put the rivet fully in the hole. For this operation make sure that the parts are correctly
supported if necessary.
(h) Form the upset head. To do this, use one of the methods given in paragraph
2.

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.
E.
.
(1)
General. Hold the tools at right angles to the surfaces do not compress the rivet too much.
If the upset head is over compressed, it is possible that the material will crack (Refer to
Figure 007). Refer to Figure 004 for the recommended back-up dolly dimensions.
(3) Inspection (Refer to Figure 005, Figure 006, Figure 007 and Figure 008)
(a) General
1 This section gives information about the general inspection limits for solid rivets.
2 Make an inspection of the rivets after they are installed. This is necessary to make
sure that the joint is tight, and that the rivets are fully seated and correctly formed.
Make sure that the adjacent area has no damage and distortions.

NOTE: For additional data relating to Figure 003, refer to Table 3,Table 4, Table 5
, Table 6, Table 7 and Table 8 that follow below.

Rivet Nominal Dia. (D) Rivet Protrusion (C)

mm in mm in
2.4 3/32 3.6 0.141
3.2 1/8 4.8 0.189
4.0 5/32 6.0 0.236
4.8 3/16 7.2 0.283
5.6 7/32 7.3 0.287
6.4 1/4 8.3 0.327
8.0 5/16 10.4 0.409

Table 3 - Data to find the necessary Length of Rivets

NOTE: The above given table is applicable to 2024, 2117, 3.1124 rivets.

Rivet Nominal Dia. (D) Rivet Protrusion (C)

mm in mm in
2.4 3/32 3.12 0.123
3.2 1/8 4.16 0.164
4.0 5/32 5.2 0.205
4.8 3/16 6.24 0.246
5.6 7/32 7.28 0.287

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6.4 1/4 8.32 0.328

8.0 5/16 10.4 0.409

Table 4 - Data to find the necessary Length of Rivets

NOTE: The above given table is applicable to 2017A and 3.1324 rivets

Rivet Nominal Dia. (D) Rivet Protrusion (C)

mm in mm in
2.4 3/32 2.4 0.094
3.2 1/8 3.2 0.126
4.0 5/32 4.0 0.157
4.8 3/16 4.8 0.189
5.6 7/32 5.6 0.220
6.4 1/4 6.4 0.252
8.0 5/16 8.0 0.315

Table 5 - Data to find the necessary Length of Rivets

NOTE: The above given table is applicable to cold driven 2017 rivets.

Rivet Nominal Dia. (D) Rivet Protrusion (C)

mm in mm in
3.2 1/8 4.16 0.164
4.0 5/32 5.2 0.205
4.8 3/16 6.24 0.246
5.6 7/32 7.28 0.287
6.4 1/4 8.32 0.328
8.0 5/16 10.4 0.409

Table 6 - Data to find the necessary Length of Rivets

NOTE: The above given table is applicable to cold driven 7050 rivets.

Rivet Nominal Dia. (D) Rivet Protrusion (C)

mm in mm in
2.4 3/32 2.4 0.094
3.2 1/8 3.2 0.126

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3.6 9/64 3.6 0.141

4.0 5/32 4.0 0.157
4.8 3/16 4.8 0.189
5.6 7/32 5.6 0.220

Table 7 - Data to find the necessary Length of Rivets

NOTE: The above given table is applicable to Monel or Titanium solid rivets for
installation in aluminum alloy structure.

Rivet Nominal Dia. (D) Rivet Protrusion (C)

mm in mm in
2.4 3/32 1.9 0.070
3.2 1/8 2.6 0.102
3.6 9/64 2.9 0.114
4.0 5/32 3.2 0.126
4.8 3/16 3.8 0.149
5.6 7/32 4.5 0.177

Table 8 - Data to find the necessary Length of Rivets

NOTE: The above given table is applicable to Monel or Titanium solid rivets for
installation in steel or titanium structure.
NOTE: For additional data relating to Figure 004, refer to Table 9 that follow
below.

RECOMMENDED BACK-UP DOLLY

RIVET NOMINAL DIAMETER
WEIGHT
mm. in kilograms pounds
1.6 1/16 (0.062) 0.75 to 1.25 1.5 to 2.0
2.4 3/32 (0.094) 1.0 to 1.5 2.0 to 3.0
3.2 1/8 (0.125) 1.5 to 2.0 3.0 to 4.0
3.6 9/64 (0.140) 1.5 to 2.0 3.0 to 4.0
4.0 5/32 (0.156) 1.5 to 2.0 3.0 to 4.5
4.8 3/16 (0.187) 2.0 to 2.5 4.0 to 5.0
5.6 7/32 (0.219) 2.0 to 2.5 4.5 to 5.5
6.4 1/4 (0.250) 2.25 to 3.0 5.0 to 6.5

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8.0 5/16 (0.312) 2.75 to 3.5 6.0 to 8.0

Table 9 - General Details for Back-up Dollies

NOTE: For additional data relating to Figure 005, refer to Table 10, Table 11,
Table 12, Table 13 and Table 14 that follow below.

RIVET UPSET
RIVET NOMINAL RIVET UPSET HEIGHT (H)
DIA. (C)
DIA (D)
MINIMUM MAXIMUM MINIMUM
mm in mm in mm in mm in
3/32
2.4 3.8 0.150 1.6 0.063 1.0 0.039
(0.094)
1/8
3.2 5.0 0.197 2.0 0.079 1.3 0.051
(0.126)
5/32
4.0 6.0 0.236 2.4 0.094 1.6 0.063
(0.157)
3/16
4.8 7.3 0.287 2.9 0.114 1.9 0.075
(0.189)
7/32
5.6 8.4 0.331 3.2 0.126 2.2 0.087
(0.219)
1/4
6.4 9.6 0.378 3.8 0.150 2.6 0.102
(0.252)
5/16
8.0 11.8 0.465 4.6 0.181 3.1 0.122
(0.312)

Table 10 - Upset Head Dimensions

NOTE: The above given table is applicable to 2024, 2117 and 3.1124 rivets.

RIVET RIVET UPSET DIA. (C) RIVET UPSET HEIGHT (H)

NOMINAL
DIA (D) MAXIMUM MINIMUM MAXIMUM MINIMUM

mm in mm in mm in mm in mm in
3/32 (
2.4 4.8 0.189 3.6 0.141 1.4 0.055 0.8 0.031
0.094)
1/8 (0.
3.2 6 0.236 5 0.197 1.8 0.071 1.1 0.043
126)
5/32 (
4.0 7.5 0.295 6.2 0.244 2.3 0.091 1.3 0.051
0.157)

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4.8 3/16 ( 8.7 0.343 7.3 0.287 2.5 0.098 1.5 0.059
0.189)
7/32 (
5.6 10 0.394 8.5 0.335 3.1 0.122 1.7 0.067
0.219)
1/4 (0.
6.4 11 0.433 9.5 0.374 3.5 0.138 1.9 0.075
252)
5/16 (
8.0 13.5 0.531 11.8 0.465 4.4 0.173 2.6 0.102
0.312)

Table 11 - Upset Head Dimensions

NOTE: The above given table is applicable to cold driven 2017A, 7050 and
3.1324 rivets.

RIVET UPSET
RIVET NOMINAL RIVET UPSET HEIGHT (H)
DIA. (C)
DIA (D)
MINIMUM MAXIMUM MINIMUM
mm in mm in mm in mm in
3/32
2.4 3.1 0.122 1.3 0.051 1.0 0.039
(0.094)
1/8
3.2 4.2 0.165 1.8 0.070 1.3 0.051
(0.126)
5/32
4.0 5.9 0.232 2.1 0.083 1.6 0.063
(0.157)
3/16
4.8 6.8 0.268 2.7 0.106 1.9 0.075
(0.189)
7/32
5.6 7.3 0.287 3.2 0.126 2.4 0.094
(0.219)
1/4
6.4 8.3 0.327 3.3 0.130 2.5 0.098
(0.252)
5/16
8.0 12.3 0.484 3.8 0.150 3.2 0.126
(0.312)

Table 12 - Upset Head Dimensions

NOTE: The above given table is applicable to cold driven 2017 rivets.

RIVET UPSET
RIVET NOMINAL RIVET UPSET HEIGHT (H)
DIA. (C)
DIA (D)
MINIMUM MAXIMUM MINIMUM
mm in mm in mm in mm in

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3/32
2.4 4.0 0.157 2.1 0.082 1.20 0.047
(0.094)
1/8
3.2 4.5 0.177 2.3 0.090 1.35 0.053
(0.126)
5/32
4.0 5.0 0.197 2.5 0.098 1.55 0.061
(0.157)
3/16
4.8 6.0 0.236 3.0 0.118 1.85 0.073
(0.189)
7/32
5.6 7.0 0.276 3.5 0.137 2.10 0.082
(0.219)

Table 13 - Upset Head Dimensions

NOTE: The above given table is applicable to Monel or Titanium solid rivets
installed in aluminum alloy structure.

RIVET UPSET
RIVET NOMINAL RIVET UPSET HEIGHT (H)
DIA. (C)
DIA (D)
MINIMUM MAXIMUM MINIMUM
mm in mm in mm in mm in
3/32
2.4 4.3 0.169 1.25 0.049 0.85 0.033
(0.094)
1/8
3.2 4.8 0.189 1.5 0.059 0.95 0.037
(0.126)
5/32
4.0 5.3 0.209 1.7 0.067 1.1 0.043
(0.157)
3/16
4.8 6.4 0.252 2.0 0.079 1.3 0.051
(0.189)
7/32
5.6 7.4 0.291 2.3 0.091 1.5 0.059
(0.219)

Table 14 - Upset Head Dimensions

NOTE: The above given table is applicable to Monel or Titanium solid rivets
installed in steel or titanium structure.
3 The acceptance Limits given in Paragraph
2.
.
E.
.
(3)
.

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(b)
are applicable to those rivets that become part of the structural strength after
installation. For example, rivets that fasten the skin, formed and extruded sections.
The acceptance limits of rivets that are not so important shall be the decision of the
inspector. Example of such rivets are those used to fasten identification tags and
instruction/information labels.
4 A large number of cracks found in a high percentage of installed rivets indicates
that the rivets have not been correctly heattreated. It can also mean that the
installation time allowed for heat-treated rivets has been exceeded. It is necessary
to scrap and replace all of these rivets, including those which are not used, from the
batch concerned, or have them heat-treated again (Refer to Chapter 51-25-00).
5 Deformation or buckling of the plating is only permitted within the limits given in
Chapter 51-10-00. This type of damage is a result of:
- too much tool pressure,
- rivets expanded between the sheets,
- trapped foreign material.
6 Make sure that the head of a countersunk rivet is level with or slightly above the
surface of the material. Refer to Chapter 51-10-00 for the rivet head protrusion
limits.
(b) Acceptance Limits
1 Ovality of the upset head is permitted if the dimensions are within the upset
diameter limits. These limits together with the applicable rivet material are given in
Figure 005.
2 Eccentricity of the upset head is permitted if the rivet shank cannot be seen (Refer
to Figure 006).
3 Malformation of the upset head is permitted (Refer to Figure 006) if the shape is
within the dimension limits given in Figure 005.
4 Tool impact damage around the two heads is permitted within the limits given in
Figure 006.
5 Cracks in the upset head of aluminum alloy 2017 and 2024 rivets are permitted
within the limits given in Figure 007. Cracks in the upset head of other aluminum
alloy rivets are not permitted. Cracks in the structure material under either head are
not permitted.
6 Cracks in the heads of titanium and monel rivets are not permitted.
7 Lack of head/material abutment (seating) is permitted within the limits given in
Figure 008.

NOTE: Cracks are not permitted in the upset heads of titanium or monel rivets.
NOTE: For additional data relating to Figure 007 refer to Table 15 that follow
below.

RIVET NOMINAL DIA. (D) MAXIMUM WIDTH OF CRACK (W)

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mm in mm in
1.6 1/16 (0.062) 0.10 0.004
2.4 3/32 (0.094) 0.15 0.006
3.2 1/8 (0.125) 0.20 0.008
3.6 9/64 (0.140) 0.25 0.010
4.0 5/32 (0.156) 0.25 0.010
4.8 3/16 (0.187) 0.30 0.012
5.6 7/32 (0.219) 0.35 0.014
6.4 1/4 (0.250) 0.40 0.016
8.0 5/16 (0.312) 0.50 0.020

Table 15 - Acceptable Limits for Cracks

(4) Removal (Refer to Figure 009)

CAUTION: CAREFULLY REMOVE THE RIVET TO PREVENT DAMAGE TO THE RIVETED

MATERIAL. THIS IS SPECIALLY NECESSARY IF IT IS THIN SHEET. MAKE
SURE THAT YOU APPLY THE TOOLS CORRECTLY TO THE SURFACE
DURING USE.
(a) To remove a solid rivet, first remove one of its heads, then remove the rest of the rivet out
of its hole.
(b) Select which rivet head must be removed. It is better to remove the manufactured (set)
head (this head is on the center-line of the rivet shank). Hold a dolly or equivalent tool
against the upset head, and then centre-punch the rivet head. This will give a location for
the twist-drill tip (Refer to Figure 009).

CAUTION: MAKE SURE THAT THE RIVET DOES NOT TURN WHEN YOU DO STEP,
SPECIALLY IF IT IS LOOSE. GRIP THE RIVET UPSET HEAD WITH PLIERS
OR EQUIVALENT TOOL TO HOLD IT IF NECESSARY. MAKE SURE THAT
YOU DO NOT DAMAGE THE MATERIAL.
(c) Use a twist-drill with a slightly smaller diameter than the rivet shank. Put the twist-drill in
the center punch indentation and drill the head to the depth as shown in Figure 009.

NOTE: Make an estimate of the drilling-depth and use, if possible, a mechanical stop to
make sure that the drilling-depth is correct.
NOTE: Titanium rivets can be drilled with a standard high-speed twistdrill if the tip of the
twist-drill is:
- reground to an angle of 80°,
- and given a point clearance of 5°.
(d) Put a tight-fitting parallel punch into the drilled hole and move the punch at an angle to
break off the rivet head.

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(e) Support the material around the rivet and with a punch remove the rivet shank out of its
hole.

NOTE: It is permitted to drill a hole in the rivet shank to make the removal of a tight-
fitting rivet easy.
F. Pin (Threaded) Fasteners (HI-LOK and HI-LITE)

NOTE: For oversize installation, always use a washer under the nut to prevent clashing of the nut
with the shank of the bolt, unless the nut has the capability to be used with oversized bolt.
(1) General
(a) There are two parts of the pin (Threaded) fastener:
- a threaded pin with a head (universal or countersunk),
- a collar with an internal thread and an external shear groove.
The pin has an hexagonal recess in the threaded end. This recess permits the use of an
Allen wrench to hold the pin during the installation. The hexagonal drive-end of the collar
breaks off at the shear groove when the collar is installed to its correct torque value (Refer
to Figure 010).
(b) In some areas with a limited clearance self-locking nuts and washers are used instead of
collars (Refer to Figure 010). In this situation on the wings, a washer is not used, this
reduces the risk of a fuel leak.
(c) When pin (Threaded) fasteners are used to join structure with outer surfaces that are not
parallel (Refer to Figure 010), the conditions that follow are applicable:
1 When standard aluminum alloy collars (ASNA2028, DAN11, NSA5075 and
NSA5075W) are used, an out of parallel condition up to 3.0 degrees is acceptable.
2 When standard CRS collars (ABS0258, ASNA2036, DAN12, HL73, HL86 and and
HL87) are used, an out of parallel condition up to 0.5 degree only is acceptable.

NOTE: In conditions
2.
.
F.
.
(1)
.
(c)
.
1
and
2.
.
F.
.
(1)
.
(c)

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.
2
above, the axis of the fastener hole must be perpendicular to the surface
on which the fastener head will seat.
3 When the conditions in
2.
.
F.
.
(1)
.
(c)
.
1
and
2.
.
F.
.
(1)
.
(c)
.
2
above will be exceeded, the applicable self-aligning collar and washer must be
used. When permitted suitable self-aligning standard nuts and washers can be
used.

NOTE: Conditions
2.
.
F.
.
(1)
.
(c)
.
1
,
2.
.
F.
.
(1)
.
(c)
.
2

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and
2.
.
F.
.
(1)
.
(c)
.
3
above are not applicable to the wing structure. For the wing structure the
conditions that follow are applicable:
4 When standard steel nuts are used spot facing (Refer to Chapter 51-46-12) is
necessary when the outer surfaces are more than 0.5 degree out of parallel.
5 When standard aluminum alloy nuts are used spot facing (Refer to Chapter 51-46-
12) is necessary as follows:
- for 5/16 in (8.0 mm) diameter pin (Threaded) and the outer surfaces are more
than 1.5 degrees out of parallel.
- for 3/8 in (9.5 mm) and larger diameter pin (Threaded) and the outer surfaces
are more than 1.0 degree out of parallel.
(d) Pins (Threaded) and collars are usually supplied lubricated and this lubricant must not be
removed.
(e) Pin (Threaded) fasteners are HI-LOK (HL) type are used for installation in clearance and
transition fit holes unless otherwise specified in a repair procedure. A clearance fit hole is
used (unless otherwise specified) if one or more of the structural members to be attached
are made of:
- steel,
- stainless steel,
- titanium.
For installation in interference fit holes Pin (Threaded) HI-LITE (HST) and HI-TIGUE
(HLT) are used.
(f) Before the installation of pin (Threaded) fasteners, make sure that:
- all the necessary pins and collars or nuts are of the correct type,
- the pins and collars or nuts are made of the correct material,
- the pins and collars or nuts have the correct surface protection and/or lubrication,
- the pins have the correct grip length,
- the thread of the pin has the same diameter as the collar or nut applicable to the pin.
(g) Install the pin (Threaded) fasteners with power or hand tools (Refer to Figure 011, Figure
012 and Figure 013).
(h) The correct hand tools are available from the various manufacturers of pins (threaded), an
example is shown in Figure 012. But a hand tool can be made locally with a ratchet
handle tool made of hardened steel. It is necessary to modify this tool as follows:
- remove the ball in the square drive,
- drill a hole, necessary for the Allen wrench, of the correct size through the ratchet
handle (Refer to Figure 011).

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(2) Installation
(a) General
1 Before the installation of pin (Threaded) fasteners, make sure that all holes are
clean, smooth and deburred (Refer to Chapter 51-44-00).

NOTE: Use the next oversize fastener to repair a damaged or oversized hole
(Refer to Chapters Chapter 51-43-00 and Chapter 51-43-11).
2 There are four types of pin (Threaded) fasteners. These types are:
- pin (Threaded) with protruding head, for shear application only,
- pin (Threaded) with 100 ° countersunk head, for shear application only,
- pin (Threaded) with protruding head, for tension and shear application,
- pin (Threaded) with 100 ° countersunk head, for tension and shear
application.
3 The part number or the pin (Threaded) is indented on the head. Details of the
complete identification number are given in Chapter 51-40-12.
4 A pin (Threaded) collar is fully identified with the subsequent data:
- the part number,
- the material code,
- the material finish code,
- the color,
- the washer type (if applicable),
- the washer material (if applicable),
- the washer material finish (if applicable).
There are many different types of collars used with pins (Threaded). There is no
part number on these collars, thus they must be kept in separate containers. The
containers must be marked with the applicable part numbers.

NOTE: Some oversize collars are also identified by a groove. This groove can be
around the hexagonal or near the collar seat.
(b) Installation with Hand Tools and Power Tools (Clearance Fit)
1 Make sure that all fastener holes in the repair are correctly prepared (Refer to
Chapter 51-44-00, Chapter 51-46-00, Chapter 51-48-00).
2 Measure the total thickness of the items to be riveted. This gives you the correct
grip length of the pin (Refer to Figure 014).
3 Install the correct pin/collar assembly as shown in Figure 013. For a wet installation,
refer to Chapter 51-76-11.

NOTE: Before you use a pneumatic tool make sure that the accessibility and the
position of the pin (Threaded) fastener assembly to be installed, and the
overall dimensions of the tool permits the use of the pneumatic tool. The
types of tools and their different possibilities are shown in Figure 015.
(c) Installation with Hand Tools and Power Tools (Interference Fit)

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1 Make sure that all fastener holes in the repair are correctly prepared (Refer to
Chapter 51-44-00, Chapter 51-46-00, Chapter 51-48-00).
2 Measure the total thickness of the items to be riveted. This gives you the correct
grip length of the pin (Refer to Figure 014).
3 To install pins in prepared interference-fit holes, do the steps that follow:
a Carefully put the threaded portion of the pin in the prepared hole and make
sure that the pin is aligned correctly.

CAUTION: MAKE SURE THAT THE CORRECT BACK-UP DOLLY (IT MUST
HAVE THE NECESSARY RECESS TO ACCEPT THE THREADED
PORTION OF THE PIN) IS PUT BEHIND THE WORK AREA TO
PREVENT DISTORTION OF THE STRUCTURE.
b Carefully hit the pin into the hole until it is fully seated. Do this with a
pneumatic hammer or composite head mallet.
4 Install the correct collar as shown in Figure 013. For a wet installation, refer to
Chapter 51-76-11.

NOTE: Before you use a pneumatic tool make sure that the accessibility and the
position of the pin (Threaded) and the overall dimensions of the tool
permits the use of the pneumatic tool. The types of tools and their
different possibilities are shown in Figure 015.
(d) Where it is necessary (for example, because of limited access) to install a self-locking nut
and a washer on the pin, do the steps that follow:
1 Put the washer and the nut on the pin.
2 Hold the pin with an Allen wrench (Refer to Figure 011 and Figure 012).
3 Tighten the nut. Do this until the nut is fully seated and the gaps between the parts
are closed and apply the correct torque value (Refer to Chapter 51-49-00).
(3) Inspection after Installation of Pin (Threaded) Fasteners
(a) Visual Inspection
1 Examine the pin head and the local area surface around the head for signs of the
subsequent damage:
- scoring and dents,
- damage, caused when the head is hit (dishing),
- peripheral cracks and condition of the cadmium plating on the head, where
applicable,
- an incorrect seat of the head and/or collar.
2 Scoring and dents are permitted if they are within the limits given below:
- no sharp edges or corners are permitted,
- the depth of damage must not be more than 0.1 mm (0.004 in).
3 A slight separation of the pin head seat is permitted, if it is within in the subsequent
limits:

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a The maximum value of the separation is not more than 0.1 mm (0.004 in)
(Refer to Figure 016).
b The head is in satisfactory contact with at least 66 % of the seat area
circumferentially (Refer to Figure 016).
c Up to 10 % of the pins in a row are permitted this condition.
d Pins next to each other are not permitted this condition.
4 For the limits on the pin head dishing, refer to Figure 017.
5 If the pins are cadmium-plated (golden color) and the cadmium becomes damaged
during the installation, replace the pin.
6 Make sure that the thread protrusion through the installed collar is correct (Refer to
Figure 019) and that the collar is correctly seated on the structure.
7 For the bolt/nut combination to be adjudged to have set correctly, the protrusion of
the bolt from the face of the joint shall be within the range tabulated below:

BOL ASNA2026VHK & VBV ABS0559VHK & VBV

TP ASNA2027VHK & VBV ABS0560VHK & VBV
ART ASNA2027- ASNA2027-
NO. ASNA2026- ASNA2026-
NUT
ABS0117
PAR
NSA5474 ABS0118 NSA5472
T
ABS0813
NO.
DIA. PROTRUSION
DAS
MAX MIN MAX MIN MAX MIN
H
NO. mm in mm in mm in mm in mm in mm in
0.37 0.30
-3 9.40 7.62 -
0 0
10.1 0.40 0.33 10.1 0.40 0.33
-4 8.38 8.38
6 0 0 6 0 0
11.6 0.46 0.39 11.6 0.46 0.39
-5 9.91 9.91
8 0 0 8 0 0
12.7 0.50 10.9 0.43 12.7 0.50 10.9 0.43
-6
0 0 2 0 0 0 2 0
14.3 0.56 12.5 0.49
-7
5 5 7 5
15.3 0.60 13.5 0.53
-8
7 5 9 5

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-9 17.2 0.68 15.5 0.61

7 0 9 0
18.8 0.74 17.0 0.67
-10
0 0 2 0
25.7 0.97 22.9 0.90
-12
6 5 9 5
27.4 1.08 25.6 1.01
-14
3 0 5 0
31.5 1.24 29.7 1.17
-16
0 0 0 0
38.1 1.38 33.4 1.31
-18
8 5 0 5

Table 16 - Bolt Protrusion Tolerances

NOTE: The dimensions given in Table 12 can be verified by: - direct

measurement by conventional means, - use of protrusion gauges.
8 Gauge Procedure (Refer to Figure 020).
a Centre gauge over bolt at "TOUCH-NO-GO" end (Refer to Figure 020).
b If bolt touches top of "TOUCH-NO-GO" gauge-reject.
c If bolt does not touch, reverse gauge to "TOUCH-GO" end and check.
d If bolt touches top of "TOUCH-GO" gauge-accept (Refer to Figure 020).
e If bolt does not touch top of "TOUCH-GO" gauge with legs on structures-
reject.

NOTE: It could be possible on a specific joint thickness when a bolt is on

maximum limits that the bolt will be rejectable to the requirements
of paragraph
2.
.
C.
and substituting with a bolt of the next shorter grip which is on
minimum limits that it will be rejectable to the requirements of
paragraph
2.
.
F.
2.
.
F.
.
(3)
.

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(a)
.
8
.
e
. In this situation the shorter bolt is acceptable provided the gap
between the "TOUCH-GO" part of the gauge and the end of the bolt
does not exceed 0.0254 mm (0.001 in). No similar relaxation i.e. the
legs of the "TOUCH-NO-GO" gauge not contacting the structure, is
allowable for bolts rejectable to paragraph
2.
.
C.
because of the possibility of bolt thread bonding in the nut
counterbore and consequent loss of clamping.
(4) Pin (Threaded) Fastener - Removal

CAUTION: TAKE CARE NOT TO CAUSE DAMAGE TO THE SURFACE OF THE

MATERIAL, OR THE HOLE, WHEN YOU DO THE PROCEDURES THAT
FOLLOW.
(a) Removal from Clearance Fit Holes (Refer to Figure 021)
1 Only use hand tools to remove these fasteners from clearance fit holes. Use the
procedure that follows to remove the fasteners:
a Insert the correct Allen wrench into the hexagonal recess in the pin end.
b Use the Allen wrench to prevent the pin turning, and with pliers (or similar
gripping tool), turn the collar counter-clockwise until it is removed.
c Remove the Allen wrench and push the pin out of the hole.
2 You can use the pin again if:
- the pin finish is not damaged,
- the threads and hexagonal recess are in good condition.
(b) Removal from Interference Fit Holes (Refer to Figure 021)

CAUTION: THE DIAMETER OF THE PIN PUNCH MUST BE LESS THAN THE
FASTENER DIAMETER.
1 Pin (Threaded) fasteners can be removed from interference fit holes using the
procedure in Paragraph
2.
.
F.
.
(4)
but with this additional step: Support the material around the fastener head and hit
the fastener out with a parallel pin punch and hammer.

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2 An alternative procedure is given below:

NOTE: You are recommended to use the applicable power tools where possible
for this procedure, especially if many fasteners are to be removed.
a Loosen the collar until the fastener thread is in line with end of the collar.
b Support the structure around the fastener head.
c Hit the end of the collar with a composite headed mallet. This is to break the
bond between the fastener and the structure.
d Position the removal tool over the collar. Apply a steady hand pressure and
operate the tool to remove the collar. Discard the collar.

CAUTION: THE DIAMETER OF THE PIN PUNCH MUST BE LESS THAN THE
FASTENER DIAMETER.
e Support the structure around the fastener head and hit the fastener out with a
parallel pin punch and hammer. Discard the fastener.
(c) In some cases (for example, limited access or a damaged collar), it may be necessary to
remove Pin (Threaded) Fasteners by drilling the head off and removing the shank and
collar. Use standard procedures to do this. If the fastener is made of titanium you will need
to make sure that:
- you use a slow drill speed,
- you apply a constant steady hand pressure to the drill.
This is to prevent the twist-drill tip overheating.

NOTE: You can use standard high-speed twist-drills to drill titanium fasteners. But the
tip of the twist-drill must be re-ground to an angle of 80°, and with a point
clearance of 5°.
(5) Re-torquing loose fasteners

NOTE: This procedure is only applicable to the wing fasteners listed.

(a) ASNA pins and ABS or NSA nuts.
1 Clearance fit fasteners
a Apply sealant around the fastener head.
b Re-torque tighten the fastener (for ABS nuts refer to Chapter 51-49-00 Table
12 and for NSA nuts refer to Chapter 51-49-00 Table 9)
c Check the bolt protrusion to the dimensions in Table 16. A gauge, obtained
from the manufacturer, may be used in accordance with the procedure
shown in Figure 020. If the protrusion exceeds the maximum limit, wet install
an additional washer with a new nut (Refer to
2.
.
B.
).

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NOTE: Do not install more than 2 washers per fastener assembly.

d Re-torque fastener as per step 2. Overcoat as required (Refer to Chapter 51-
24-00).
2 Interference Fit Fasteners
a Apply sealant around the fastener head (Refer to Chapter 51-24-00).
b Re-torque tighten the fastener ( Chapter 51-49-00 Table 9)
c Check the bolt protrusion to the dimensions in Table 16. A gauge, obtained
from the manufacturer, may be used in accordance with the procedure
shown in Figure 020. If the protrusion exceeds the maximum limit, do one of
the following steps:
- Install an additional washer with a new nut (Refer to
2.
.
B.
).

NOTE: Do not install more than 2 washers per fastener assembly.

- If 1st or 2nd oversize fasteners are available, remove the fastener and
oversize the hole to the next oversize fastener (Refer to Chapter 51-43-
00).
d Wet install the correct grip length fastener and re-torque fastener as per step
2. Overcoat as required (Refer to Chapter 51-24-00).
(b) HL, HLT and NSA fasteners.
1 Clearance fit fasteners
a Apply sealant around the fastener head.
b Re-torque tighten the fastener (for steel nuts refer to Chapter 51-49-00 Table
9 and for aluminum alloy nuts refer to Chapter 51-49-00 Table 10).
c Check the bolt protrusion to the dimensions in 018. If the protrusion exceeds
to the maximum limit of "X", wet install an additional washer with a new nut
(Refer to
2.
.
B.
).

NOTE: Do not install more than 2 washers per fastener assembly.

d Re-torque fastener as per step 2. Overcoat as required (Refer to Chapter 51-
24-00).
2 Interference Fit Fasteners
a Apply sealant around the fastener head (Refer to Chapter 51-24-00).
b Re-torque tighten the fastener (Refer to Chapter 51-49-00 Table 9).

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c Check the bolt protrusion to the dimensions in 018. If the protrusion exceeds
to the maximum limit of "X", do one of the following steps:
- Install an additional washer with a new nut (Refer to
2.
.
B.
).

NOTE: Do not install more than 2 washers per fastener assembly.

- If 1st or 2nd oversize fasteners are available, remove the fastener and
oversize the hole to the next oversize fastener (Refer to Chapter 51-43-
00).
d Wet install the correct grip length fastener and re-torque fastener as per step
2. Overcoat as required (Refer to Chapter 51-24-00).
G. Pin (Threaded) (Bullnose)
(1) General
(a) The pin (Threaded) (Bullnose) is a cylindrical pin fastener. It is available with a protruding
or countersunk head.
(b) The fastener has an hexagonal recess in the threaded end. This is used to assist you to
hold the fastener when you remove or install the nut/collar that is used with the fastener.
(c) The fastener is available in steel or titanium material.
(d) The Bull Nose feature of the fastener is shown in Figure 022.
(e) The fasteners are secured with standard self-locking nuts or collars.
(f) The fasteners are delivered pre-lubricated. Do not handle these fasteners more than is
necessary. Do not degrease them.
(g) These fasteners are installed in interference, transition or clearance fit holes.
(h) It is recommended that only trained operators prepare the holes and install these
fasteners.
(2) Hole Preparation
(a) General
1 The holes for these fasteners must be prepared to give the correct fit and to a good
standard. They are prepared in three stages, these are:
a Drill a pilot-hole (Refer to Chapter 51-44-00).
b First stage boring by twist-drill or reamer.
c Final boring by a reamer.

NOTE: These stages only apply to new holes, for example, when you do a
repair. For a hole that already exists it is only necessary to increase
it to the correct oversize diameter.

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2 The Final Hole Diameter tolerances are given in Chapter 51-44-00.

(b) When you drill or ream the holes for these fasteners you are recommended to use a
drilling jig or an equivalent tool. This will help you to make sure that the hole is
perpendicular through the material.
(c) Only use twist-drills and reamers that are sharp and in good condition. This will make sure
that the holes are accurate and to a good condition.
(3) Hole Preparation Procedure
(a) You are recommended to use soluble oil or paraffin to lubricate the twist-drills and
reamers when you are preparing the holes.
(b) Refer to Chapter 51-44-00 (Hole and Drill data), and select the correct size twist-drill for
the pilot-hole. Drill the pilot-holes.

NOTE: In a repair procedure or other special circumstances, you can be given a pilot-
hole diameter that does not agree with the information in Chapter 51-44-00. In
this case use the alternative diameter.
(c) Do the first stage boring. You can use one of two methods to do this, these are:
1 With a twist-drill drill a hole that is approximately 0.05 mm (0.002 in) smaller than
the final hole.
2 With a reamer make a hole that is approximately 0.3 mm (0.012 in) smaller than the
final hole.

NOTE: After you have done this stage the entry to the hole must permit the use of
the final stage tool. You must be able to enter the final stage tool for at
least 1.0 mm (0.039 in).
(d) Carefully ream the holes to the final diameters that are given in Chapter 51-44-00.

NOTE: The surface roughness of the inner-face of the holes must be less than 1.6
micrometers (63 microinches).
(e) Deburr and radius or chamfer the entry and exit edges of the holes (Refer to Chapter 51-
44-00 ).
(f) Check the final diameter of the holes with the applicable limit plug gage.
(4) Selection of Fastener Length
(a) You can use one of two methods that follow to find the correct length of the fastener
required:
1 Method 1. Refer to Figure 023 for the information how to use a griplength gage and
the relevant fastener data.
2 Method 2.
a Measure the thickness of the materials that are to be fastened. Use suitable
precision tools to do this.
b

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Refer to Figure 023 Sheet 3 and select a fastener of the correct length to fit
the tolerance given.
(5) Fastener Installation Procedure
The procedure that follows is applicable to steel or titanium fasteners.
(a) Put the repair pieces into their correct position. Secure them with temporary bolts or grip-
pins.

NOTE: Because the final fasteners will be hammered into position, you are
recommended to secure the materials through at least 50 % of the holes. This is
to stop a gap forming between the materials.

CAUTION: IT IS IMPORTANT THAT YOU MAKE SURE THAT THE FASTENER IS

PERPENDICULAR TO THE HOLE BEFORE YOU HAMMER IT IN.
(b) Put the fastener in the hole and hammer it in until the head is seated on the material. To
do this you can use a standard pneumatic hammer, either single or multi-hit. Use a rivet
set (snap) of a size that will not damage the fastener head or the material.

NOTE: Install all fasteners "wet" unless instructed differently in a repair procedure.
Refer to Chapter 51-76-11 for sealing information.
(c) If applicable refer to Table 17 and select the correct washer. Because of the Bull Nose
feature of this fastener it is important that you only use washers of the correct thickness
and internal diameter. If necessary two washers can be used to get the correct thickness,
but do not use washers of 0.4 mm (0.016 in) thickness or less.

NOTE: It is recommended that you only use aluminum alloy washers. But steel washers
can be used without special authorization if aluminum alloy washers are not
available. Do not use a mixture of washer materials on the same fastener.
(d) Put the applicable nut/collar on to the fastener. Tighten the nut to the correct torque value
(Refer to Chapter 51-49-00).

NOTE: If the type of nut/collar is not specified in the repair procedure select one that is
suitable from the list that follows:
ABS 0117 Nut, self-locking, counterbored ABS 0118 Nut, self-locking, self-sealing,
counterbored NSA 5050 Nut, self-locking) NSA 5472 Nut, self-locking ) with captive
washer NAS 1726 Nut, self-locking ) NSA 5474 Nut, self-locking, chamfered end) NSA
5151 Nut, self-locking, self-aligning) for use on non NAS 1727 Nut, self-locking, self-
aligning) parallel surfaces.
(6) Inspection After Installation (Refer to Figure 024)
(a) After you have installed Bull Nose fasteners examine them for signs of the conditions
which follow:
1 Dishing of the head (countersunk fasteners).
2 Incorrect seating of the fastener head and nut/collar.
3 Incorrect threaded end protrusion.

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4 Incorrect head alignment (countersunk fasteners).

(b) Refer to Figure 024 for the limits that are applicable to conditions
2.
.
G.
.
(6)
.
(a)
.
1
,
2.
.
G.
.
(6)
.
(a)
.
2
and
2.
.
G.
.
(6)
.
(a)
.
3
. The limits applicable to condition
2.
.
G.
.
(6)
.
(a)
.
4
are given in Chapter 51-10-00 (Aerodynamic Smoothness).

WASHER THICKNESS FOR USE WITH NSA 5050 NUTS

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FASTENER FIRST FOR STANDARD FOR FIRST FOR SECOND

DASH NO. FASTENER OVERSIZE OVERSIZE
WASHERS AN960 WASHERS NSA WASHERS NSA
OR NSA 5354 5368 5368
NSA HLT mm in mm in mm in
3 6 1.6 0.06 2.4 0.09 2.4 0.09
4 8 2.4 0.09 2.4 0.09 3.2 0.13
5 10 2.4 0.09 3.2 0.13 4.0 0.16
6 12 2.4 0.09 3.2 0.13 4.0 0.16
7 14 3.2 0.13 4.0 0.16 4.8 0.19
8 16 3.2 0.13 4.0 0.16 4.8 0.19
9 18 3.2 0.13 4.0 0.16 4.8 0.19
10 20 3.2 0.13 4.0 0.16 4.8 0.19

Table 17 - Washer Data

WASHER THICKNESS FOR USE WITH NSA 5151 NUTS

FASTENER FOR STANDARD FOR FIRST FOR SECOND
FIRST FASTENER OVERSIZE OVERSIZE
DASH NO. WASHERS NSA WASHERS WASHERS NSA
5369 NSA 5372 5372
NSA HLT mm in mm in mm in
3 6 1.6 0.06 2.4 0.09 2.4 0.09
4 8 2.4 0.09 2.4 0.09 3.2 0.13
5 10 2.4 0.09 3.2 0.13 4.0 0.16
6 12 2.4 0.09 2.4 0.09 3.2 0.13
7 14 1.6 0.06 2.4 0.09 3.2 0.13
8 16 1.6 0.06 2.4 0.09 3.2 0.13
9 18 1.6 0.06 2.4 0.09 3.2 0.13

Table 18 - Washer Data

WASHER THICKNESS FOR USE WITH NSA 1727 NUTS

FASTENER FOR STANDARD FOR FIRST FOR SECOND
FIRST FASTENER OVERSIZE OVERSIZE
DASH NO. WASHERS NSA WASHERS NSA WASHERS NSA
5369 5372 5372

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NSA HLT mm in mm in mm in
3 6 1.6 0.06 2.4 0.09 2.4 0.09
4 8 0.8 0.03 0.8 0.03 1.6 0.06
5 10 0.8 0.03 1.6 0.06 2.4 0.09
6 12 0.8 0.03 1.6 0.06 2.4 0.09
7 14
8 16 NONE NONE NONE
9 18
10 20

Table 19 - Washer Data

(7) Removal of Bull Nose Fasteners
(a) There are two methods that you can use to remove a Bull Nose fastener, these are:
1 If you have good access to the threaded end of the fastener use a Taper Knockout
Tool.
2 If you do not have good access use an extractor tool.
(b) Both of these methods are given in Paragraph
2.
.
H.
of this Chapter.

NOTE: The removed Bull Nose pin and nut or collar must be discarded. You are not
permitted to re-use them.
(8) Further Information
When a Bull Nose fastener is removed further action to the hole is necessary as follows:
(a) Interference Fit Hole. Prepare the hole for an oversize fastener (Refer to Chapter 51-44-00
). Two stages of oversize fastener are available (Refer to Chapter 51-43-00).
(b) Transition Fit Hole. Measure the hole diameter. If the diameter is within the permitted
tolerances (Refer to Chapter 51-44-00) and in good condition, a replacement standard
fastener can be used. If the diameter is outside the permitted tolerances, the hole must be
prepared for an oversize fastener (Refer to Chapter 51-43-00).
(c) Clearance Fit Hole. If the hole condition is good no further action is necessary. If the hole
condition is not acceptable it must be prepared for an oversize fastener (Refer to Chapter
51-43-00).
H. Taper Fasteners

NOTE: For oversize installation, always use a washer under the nut to prevent clashing of the nut
with the shank of the bolt, unless the nut has the capability to be used with oversized bolt.

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(1) General
(a) A taper fastener is a tapered bolt with a threaded end and a selflocking nut. The nut is
also threaded and includes its own washer. The use of this fastener is almost the same as
that of a standard nut and bolt (Refer to Figure 034).
(b) The taper fasteners are used in those areas of the structure where a high fatigue
performance is required. The taper fastener helps to achieve this performance because it
has a constant interference-fit in the tapered hole in the structure. This causes a good
compression of the structure material around the fastener hole, and a balanced stress
pattern (Refer to Figure 025).
1 When a taper group is changed for a given diameter:
- the height of the head does not change,
- the diameter of the head changes,
- the diameter of the under-head radius changes.
2 Repair sizes of taper are one group higher than the nominal size:
- R1 # Group + 1
- R2 # Group + 2

NOTE: Diameter + measured grip # taper group number. There are five groups of
nominal sizes. Each group corresponds to a different reamer (reamers
can also be designed to cover several groups).
(c) An additional feature of the taper fastener is the good sealing effect that is given by the
tapered interference fit.

REPAIR GROUP
NOMINAL GROUP
GRIP LENGTH (REAMER)
DIAMETER NOMINAL
R1 R2
1 3 to 8 2 3
3 (3/16) 2 9 to 16 3 4
3 17 to 24 4 5
1 3 to 10 2 3
4 (1/4) 2 11 to 20 3 4
3 21 to 30 4 5
1 3 to 11 2 3
5 (5/16) 2 12 to 22 3 4
3 23 to 33 4 5
1 4 to 12 2 3
6 (3/8) 2 13 to 24 3 4
3 25 to 36 4 5
1 4 to 14 2 3
7 (7/16) 2 15 to 28 3 4
3 29 to 42 4 5
1 4 to 16 2 3

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8 (1/2) 2 17 to 32 3 4
3 33 to 48 4 5
1 6 to 24 2 3
9 (9/16) 2 25 to 48 3 4
3 49 to 72 4 5
1 7 to 26 2 3
10 (5/8) 2 27 to 52 3 4
3 53 to 78 4 5
1 to 30 2 3
12 (3/4) 2 31 to 60 3 4
3 61 to 90 4 5
1 to 36 2 3
14 (7/8) 2 37 to 72 3 4
3 73 to 108 4 5
16 (1) 1 to 40 2 3

Table 20 - Relation Grip Length / Group Number for Nominal and Oversize Taper
(d) The taper of the bolt and the hole to which it is fitted, is small. It is only 6.35 mm (0.250 in)
for each linear 305 mm (12.008 in), a ratio of 1 in 48.
(e) The taper bolt is a light bolt with a good strength property. Bolts are available for tension
or shear uses.
(f) Taper bolts are usually supplied with a special lubricant on them. The special lubricant
must not be removed before the bolt is installed.
(g) Before the taper bolts are installed in a repair, make sure that:
- they are made of the correct material,
- they have the correct type of head,
- they are of the correct diameter,
- they are of the correct grip length,
- the nuts are of the correct type (Refer to Paragraph
2.
.
H.
.
(1)
.
(u)
).
(h) It is very important to tightly clamp the parts together when they are prepared for the
installation of taper bolts.
(i) Taper bolts can be installed with hand or power tools.
(j) It is very important to prepare the hole for a taper bolt to the highest possible precision. If
this is not done, it could have a bad effect on the fatigue of the structure.

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(k) It is recommended that only trained and approved personnel prepare the holes for taper
bolts.
(l) Special tools, for example, drill-reamers, hole/countersink gages and head protrusion
gages, are available. Only these tools should be used to ensure the necessary precision.
These tools must be kept in a satisfactory condition. Drill reamers must not be re-
sharpened by the operator; they must be returned to the manufacturer for re-sharpening.
(m) Before you install taper bolts, makes sure that all the holes are:
- clean,
- smooth,
- fully deburred at the nut end.
Protruding hole must have a relief radius where the head of the bolt will seat to prevent
damage to the under head radius of the bolt.

NOTE: If a hole, that has been used before, is found damaged or oversize, it must be
repaired to use the correct oversize bolt (Refer to Chapter 51-43-00).
(n) The information on the available types of taper bolts is given in Chapter 51-40-00.
(o) The data given in Figure 027 will help the operator to identify the correct bolt to fit in a hole
of specified dimensions (nominal diameter and grip length).
(p) The taper bolts of different nominal diameters are divided into grip length groups. Thus
bolts of the same nominal diameter can be found for use on materials of different
thicknesses. The part numbers, that are on the head and the end of the bolt, are used to
identify a bolt Figure 027 shows this in detail).
(q) Taper drill reamers are available to prepare a hole for a taper bolt (countersunk or
protruding head). The drill reamers are identified by a part number. This part number
gives the group number and nominal diameter of the bolt to which the drill reamer is
applicable (Refer to Table 22).

NOTE: A commercially available 1:48 hand taper pin reamer may be used hand to finish
or adjust a hole for a taper bolt (Refer to Figure 037).
(r) There are two different types of nuts available for use on taper bolts. They are:
1 Nuts with an attached washer. These are for use where the surfaces of the
materials, that must be fastened, are out of parallel up to 2°.
2 Nuts with a spherically dished washer that is not attached. These must be used
where the material surfaces are out of parallel up to 5° ( 125).

NOTE: On wing structure this limit is 5°.

(s) These nuts do not have their part number engraved on them, thus they must be kept in
different containers. The containers must be marked with the applicable number.
(t) The self-locking property of these nuts is caused by a small elliptical deformation of the nut
/body thread. When the nut is installed on a bolt, the threaded part of the bolt causes the
deformation to change shape. This causes the nut to tightly hold the bolt.

NOTE: These nuts must only be used once.

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(u) The subsequent table shows the nuts that are available for use with taper bolts on this
aircraft.

NUT/WASHER SURFACE
PART NUMBER NAME
MATERIAL PROTECTION
NSA5057 Nut,Self-Locking with Stainless Steel or Cadmium Plating on
NSA5472 washer included Steel steel parts, Silver
NAS1726-( ) Plating on stainless
(NSA5050) steel parts
ASNA2532 Nut,Self-Locking Steel Cadmium Plated
NAS1727-( ) with separate
NSA5151 spherically
dished washer

Table 21 - Nuts for Use with Taper Bolts

(2) Hole Preparation (Refer to Figure 129 and Figure 130)

NOTE: We recommend using a guide tool to drill and ream taper fastener hole.
(a) Make a mark at the correct positions for the bolts.
(b) Accurately make a mark with a center punch at the positions identified in step
2.
.
H.
.
(2)
.
(a)
.

CAUTION: THE HOLE AXIS MUST BE WITHIN 2 DEGREES OF THE PERPENDICULAR

WHEN YOU DO THE NEXT STEP. IT IS RECOMMENDED TO USE A DRILL
JIG TO ACHIEVE THIS PRECISION.
(c) Carefully drill a pilot hole at each of the positions identified in step
2.
.
H.
.
(2)
.
(a)
.

NOTE: The correct twist-drill size for this step is 0.4 mm (0.016 in) smaller than the
nominal diameter of the bolt to be installed.
NOTE:

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The correct drill speed for this step is approximately 600 revolutions per minute
(rpm).
(d) For taper drill reamers that have the part number TLD 2030AR or TLD 2040AR
(countersunk head bolts) cut the material in three continuous steps. These are:
- the pilot hole,
- the tapered hole of the correct taper and grip length,
- the correct countersink.
Drill reamers that have the part number TLD 2040BR or TLD 2040BR (protruding head
bolts) only make the pilot hole and the tapered hole of the correct grip length (Refer to
Figure 028).
(e) Put the correct drill reamer in an adjustable taper micro stop cage (Refer to Figure 029).
Adjust the cage to the necessary drill depth. Put the cage in a pneumatic drill machine.

NOTE: The drill machine must be a machine on which the speed can be adjusted from
200 thru 400 rpm. For example, the hole for a bolt of 1/4 in (6.4 mm) nominal
diameter, must be drilled at a speed of approximately 300 rpm.
(f) Do a test drill on a piece of material that is of the same type and thickness as the material
to be fastened. Repeat this step until you have found:
- the necessary drill speed (rpm),
- the necessary drill depth.

NOTE: This information helps to make sure that the hole is to a good finish.
(g) Put the drill reamer/micro stop cage accurately over the hole drilled in step
2.
.
H.
.
(2)
.
(c)
. Make sure:
- that the pilot-hole end of the drill reamer is in the center of the hole,
- that the drill reamer is in line with the vertical axis of the hole.
(h) Start the drill machine and drill the hole. Use the cutting lubricant FREON TB-1, or ICI
ARCTON 113, during this step. Make sure that the drill reamer moves through the
material slowly, but with a constant hand pressure on it.
(i) Stop the drill machine when the drill reamer has reached the depth set on the adjustable
micro stop cage. Carefully remove the drill reamer from the hole.

NOTE: Because of the taper of the hole and the drill reamer, the drill reamer will move
apart from the hole easily.
(j) If the hole is for a countersunk bolt:
1

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Select the relevant countersink depth gauge. Put it into countersink hole to assess
the amount of material to be removed to ensure a flush installation. It will be
necessary to remove only a small amount of material for the next oversize.
2 Install the relevant tapered guide into the tapered hole (Refer to Figure 135).
3 Install the 100° countersink cutter in a pneumatic drill machine (Refer to Figure 159
). A low rotation speed for the pneumatic drill machine must be selected for quality
reasons (150-200 rpm).
4 Align the cutter pilot in the tapered guide bushing to control the cutter position.
5 Progressively machine the countersink to the required depth defined by the adapted
countersink depth gauge. Use a cutting lubricant. Machining must be stopped on a
regular basis to check the countersink dimension with the countersink depth gauge
(Refer to Figure 136).

NOTE: This step is essential to guarantee the correct final dimension of the
countersink. Take care not to exceed the required dimension.
(k) Under-Head Chamfer Machining (For Countersunk and Protruding Head Taper).
1 Manually machine the under-head chamfer slightly using the 60° or 90° countersink
cutter keeping a good alignment of the tool and hole axis.
2 Visual confirmation is considered as sufficient for approximate values specified in
Table 20. The objective of the chamfer is to avoid sharp edges and stress
concentration below fastener heads.
(l) Deburr all the edges of the holes.
(m) Do the steps that follow on all the prepared holes to make sure that they have the correct
interference fit.

NOTE: All steps must be done in conjunction with protrusion check (Refer to paragraph
2.
.
H.
.
(5)
.
(d)
).
1 Apply a layer of engineers blue or prussian blue to the face of the applicable plug
gage (Refer to Figure 031) or a taper fastener of proper dimensions.
2 Put the plug gage into the hole and lightly hit it (use a composite head mallet to do
this). Do this until only 25 % of the length of the shank is visible (measured from the
bottom face of the plug gage head to the top face of the material).
3 Carefully hit the end of the plug gage to free the plug gage from the hole.

NOTE:

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Take care not to change the marks in the engineers blue on the plug gage
by rotating the gage when you do this step.
4 Look at the marks in the engineers blue on the shank of the plug gage. If the marks
show:
a That 60 % or more of the plug gage shank touched the face of the hole
(Refer to Figure 032), the hole is satisfactory.
b That less than 60 % of the plug gage shank touched the face of the hole, you
must hand ream the hole (Refer to Paragraph
2.
.
H.
.
(3)
).

NOTE: Take care to ensure that the bolt protrusion limits are maintained
(Refer to Figure 033).
(3) Use of Hand Reamers
(a) The use of a hand reamer is permitted if it is necessary to improve the face of a hole or to
reduce the maximum protrusion.

NOTE: Hand reaming may be done using a commercially available 1:48 hand taper pin
reamer (Refer to Figure 037). For example, DORMER part number B301,
available in nominal inch sizes 1/16 to 7/8.
(b) When it is necessary to use a hand reamer, the subsequent steps must be done after
each use:
1 Deburr the edges of the hole.
2 If it is applicable, make sure that the countersink is correct (Refer to Paragraph
2.
.
H.
.
(2)
.
(j)
).
3 If it is applicable, make sure that the radius around the top edge of the hole is
correct (Refer to Paragraph
2.
.
H.
.
(2)
.

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(k)
).
4 Make sure that the interference of the hole is correct (Refer to Paragraph
2.
.
H.
.
(2)
.
(m)
).

NOTE: It is very important to make sure that after a hole has been hand-reamed,
that the bolt protrusion is correct (Refer to Paragraph
2.
.
H.
.
(5)
.
(d)
).
(4) Oversize Taper Fasteners
(a) This procedure defines general operations to oversize taper to R1 or R2. If it is necessary
to create a tapered hole starting from a hole, then specific adaptations are required.
(b) Tools and Material

NOTE: Re-grinding of tools can only be handled by the tooling manufacturer. Tools
should not be re-ground by operators. Handle the tools carefully to prevent them
from falling.
NOTE: Contact the tooling manufacturer to order tooling with appropriate part numbers
and following data: - Original taper data (head-and bolt end marking), - Repair
taper data (head-and bolt end marking), - Access constrains (could influence
reamer length), - Tools part number last digit figure in tool designation, when
required, corresponds to an attachment code. It will be defined by the
manufacturer itself.
For Tooling Contact refer to: SOA (Sud-Quest Affutage) ZI Galaxy II 2 Rue
Cassiopee 33160 SAINT-MEDARD-EN-JALLES Tel: 05 56 28 70 37 Fax: 05 56
28 95 17 Mail: [Link]@[Link]
(c) Hole Reaming
1 Select the applicable Single Flute Reamer, refer to Figure 137.
2 Perform a reaming test on a piece of material that is of the same type and thickness
as the material to be fastened. Do this step until you have reached the final hole
dimension required for the repair taper.

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NOTE: This step will familiarize the operator with tools and method. A test specimen per
tool drawing 98D571030010000 can be used.
3 Progressive hole reaming with regular protrusion checking using the repair taper:
a Put the final repair taper into the original hole to assess the amount of
material to be reamed.
b Put the reamer accurately over the hole. Make sure that the reamer is in line
with the vertical axis of the hole.
c Progressively ream the hole. Use a cutting lubricant during this step. Make
sure that the drill reamer moves through the material slowly, but with a
constant hand pressure applied in the axis of the hole. Regularly stop
reaming to remove metallic chips and check the repair taper protrusion. To
do this check, install the repair taper in the cleaned hole. The measured
protrusion must be within the range indicated in Figure 133. That defines
when reaming is finished.

NOTE: Keep on rotating the reamer in the same direction when removing
the reamer from the hole for quality reasons.
d Deburr the edges of the hole (entry and exit side) then clean and dry the hole
to remove chips and grease that could affect next measurement.
e Do the steps that follow on all the prepared holes to make sure that they
have the correct interference fit.
- If available, install the plug gauge into the Blueing Gauge Holder BGH-
***.
- Attach the Blueing Gauge Holder BGH-*** to the hammering tool
HAMT-5.
- Apply a layer of engineers blue or prussian blue to the face of the
applicable plug gauge.
- Put the Blueing Gauge into the hole and lightly tap it with the
hammering tool.
- Carefully extract the plug gauge from the hole with the hammering tool.

NOTE: Take care not to change the marks in the engineers blue on the
plug gauge when you perform this step.
- Look at the marks in the engineers blue on the shank of the plug
gauge. If the marks show that:
60% or more of the plug gauge shank touched the face of the hole, the
hole is satisfactory,
less than 60% of the plug gauge shank touched the face of the hole,
slightly manually re-machine the hole to get the correct quality. The
minimum bolt protrusion must be fulfilled (Refer to Figure 032 and 127).
- If reading is difficult (too much Prussian Blue used for example), then
clean the hole and the gauge and perform the verification again.
(d) Countersink Machining (For Countersunk Head Taper only)
1

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Select the relevant countersink depth gauge. Put it into countersink hole to assess
the amount of material to be removed to ensure a flush installation. It will be
necessary to remove only a small amount of material for the next oversize.
2 Install the relevant tapered guide into the tapered hole.
3 Install the 100° Countersink Cutter in a pneumatic drill machine. A low rotation
speed for the pneumatic drill machine must be selected for quality reasons (150-
200rpm).
4 Align the cutter pilot in the tapered guide bushing to control the cutter position.
5 Progressively machine the countersink to the required depth defined by the adapted
countersink depth gauge. Use a cutting lubricant. Machining must be stopped on a
regular basis to check the countersink dimension with the countersink depth gauge.

NOTE: This step is essential to guarantee the correct final dimension of the
countersink. Take care not to exceed the required dimension.
6 Under-Head Chamfer Machining (For Countersunk and Protruding Head Taper).
7 Slightly manually machine the under-head chamfer using the 60° or 90° countersink
cutter keeping a good alignment of the tool and hole axis.
8 Visual confirmation is considered as sufficient for approximate values specified in
Table 20. The objective of the chamfer is to avoid sharp edges and stress
concentration below fastener heads.
9 Deburr the edges of the hole.

DIAMETER COUNTERSUNK HEAD PROTRUDING HEAD

x x
in (1/16) mm
mm in mm in
4 6.35 0.2 0.008 0.5 0.0197
0.1 0.004 0.4 0.0157
5 7.92 0.25 0.010 0.6 0.0236
0.15 0.006 0.5 0.0197
6 9.52 0.25 0.010 0.6 0.0236
0.15 0.006 0.5 0.0197
7 11.1 0.3 0.012 0.6 0.0236
0.2 0.008 0.5 0.0197
8 12.7 0.3 0.012 0.6 0.0236
0.2 0.008 0.5 0.0197
9 14.3 0.45 0.018 0.75 0.0295
0.35 0.014 0.65 0.0256
10 15.9 0.45 0.018 0.75 0.0295
0.35 0.014 0.65 0.0256

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12 19.1 0.6 0.024 1 0.0394

0.5 0.020 0.9 0.0354

Table 22 - Under-Head Chamfer

(5) Installation of taper bolts
(a) Select the required taper fasteners. Measure the total thickness of the stack-up to
determine the required grip length (Refer to Figure 126).

NOTE: For self-aligning nuts, the repair taper grip length is the one obtained by
measurement. It may be shorter than the original fasteners call-up on the
drawing.
(b) Taper bolts must be wet installed. Sealant must be applied under the head of the fastener
prior to installation and residual sealant removed after installation.
1 For wet installation use sealants below:

MATERIAL
ITEM NOMENCLATURE QTY
/REMARKS
Polysulfide Sealant - Material No. 06ABA1
- AR
Fuel Tank Brushable (Refer to CML)
Polysulfide Sealant - Material No. 06ABB1
- AR
Fuel Tank Fillet (Refer to CML)
Polysulfide Sealant -
Material No. 06ABF1
- Fuel Tank Quick AR
(Refer to CML)
Curing
Polysulfide Sealant -
Material No. 06AAA1
- General Purpose AR
(Refer to CML)
Brushable
Polysulfide Sealant - Material No. 06AAB1
- AR
General Purpose Fillet (Refer to CML)

(c) Insert the correct taper bolt into the prepared hole. Only use a light hand pressure on the
bolt head.
(d) Check the measurement between the material surface and the bolt head.

NOTE: The data and procedure necessary to do this is given in Figure 033.
NOTE: If the protrusion is greater than the maximum allowed, you must hand ream the
hole (Refer to Paragraph
2.
.
H.
.
(3)
).

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NOTE: Take care to maintain the correct interference fit (Refer to Paragraph
2.
.
H.
.
(3)
).

CAUTION: ONLY PULL THE BOLT INTO THE HOLE BY THE EFFECT OF THE NUT
BEING FULLY TORQUED. DO NOT HIT IT IN.

CAUTION: ONLY USE THE SOCKET THAT IS CORRECT FOR THE TYPE OF NUT TO BE
INSTALLED . FOR EXAMPLE, HEXAGONAL SOCKETS MUST ONLY BE
USED ON HEXAGONAL NUTS.
(e) Put the applicable nuts (Refer to Paragraphs
2.
.
V.
.
(7)
.
(a)
.
2
and
2.
.
H.
.
(1)
.
(u)
) on the threaded ends of the bolts. Make sure that the nuts engage the bolt threads
correctly. Torque the nuts to the correct value (Refer to Chapter 51-49-00).

NOTE: Ensure that the nut does not interfere with the thread run-out area (threads roots
before shank). Washers may be required under the nut.
(f) Make sure that the bolt has been fully pulled into the hole. Do the subsequent steps if it
has not.
1 Remove and discard the nut.
2 Put a washer onto the bolt thread.

NOTE: The washer must have an inner diameter that is sufficient to go over the
plain part of the bolt shank.
3 Do step
2.

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.
H.
.
(5)
.
(e)
again.
(6) Inspection after Installation
(a) After taper bolts have been installed, an inspection of them must be done. This inspection
must look for the subsequent bad conditions that can occur.
1 A clearance between the bolt head and the material. The permitted limits for this
condition are:
- A clearance that is not more than 0.04 mm (0.002 in) (Refer to Figure 035).
- 60 % or more of the bolt head must fully touch the material face (Refer to
Figure 035).
- Only 10 % of the bolts in a row of bolts can have this condition.
- Two bolts that are adjacent to each other must not have this condition.
2 One full thread of the bolt must show out of the end of the nut.
3 Damage to the bolt head or nut, and the material around the bolt head. For example:
- scoring,
- impact damage,
- dishing of the bolt head,
- cracks at the edge of the bolt head,
- surface protection damaged.
(b) The steps that follow give the procedures to repair any of the conditions referred to in
Paragraph
2.
.
H.
.
(6)
.
(a)
.
1 If there is a clearance between the bolt head and the material more than the
permitted limits:
a Remove and discard the nut and the bolt (Refer to Paragraph
2.
.
H.
.
(7)
).
b Install a new bolt and nut (Refer to Paragraph

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2.
.
H.
.
(5)
for the procedure).
2 If one full thread of the bolt does not show out of the end of the nut:
a Remove and discard the nut and the bolt (Refer to Paragraph
2.
.
H.
.
(7)
).
b Install a longer bolt (Refer to Paragraph
2.
.
H.
.
(5)
for this procedure).
3 Scoring and impact damage is permitted if there are no sharp edges or corners.
The depth of the damage must not be larger than 0.1 mm (0.004 in). Do the
applicable repair procedure if necessary.
4 Figure 036 gives the permitted limit for the dishing of the bolt head. If the dishing is
more than this limit, the bolt and the nut must be replaced. Use the procedure given
in Paragraph
2.
.
H.
.
(5)
to do this.
5 Cracks in the bolt head are not permitted. If there are cracks, the bolt and the nut
must be replaced. Use the procedure given in Paragraph
2.
.
H.
.
(5)
to do this.
6 If the surface protection is cadmium plating (golden color), and damaged, replace
the bolt and the nut, or the nut only if necessary. Use the procedure given in
Paragraph
2.

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.
H.
.
(5)
to do this.
(7) Taper Fastener - Removal Procedures
Before removing any taper, record locations and taper references (head and opposite side
marking) to assist in the selection of the repair taper.
One of two procedures can be used to remove taper fasteners; these procedures are given
below. Where possible, use procedure
2.
.
H.
.
(7)
.
(a)
.
(a) Procedure 1
1 Remove and discard the nut. Do this with the correct socket tool.
2 Put the correct taper knock-out tool (Refer to Figure 038) on the thread of the bolt.
Make sure that the tool correctly engages the bolt thread and is fully turned onto the
bolt.
3 Hit out the bolt. To do this, hit the end of the knock-out tool with a hammer, this will
cause the bolt to move apart from the hole.

CAUTION: TAKE CARE NOT TO DAMAGE THE BOLT HEAD WHEN YOU DO THIS
STEP.
4 Hold the bolt head (if necessary, pliers can be used, but obey the caution given
above), remove the knock-out tool from the bolt.
5 Carefully remove the bolt from the hole.

NOTE: For bolt reuse, refer to Chapter 51-49-00.

(b) Procedure 2
In this procedure a locally made extraction tool is used. Figure 039 shows this tool. This
tool uses a standard bolt. The standard bolt must be correct for the dimensions of the
taper bolt that is to be removed.
1 Drill a hole of the correct dimensions into the shank of the taper bolt. Do this from
the head end of the bolt.
2 Cut a thread into the inner surface of the hole made in step
2.
.
H.

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.
(7)
.
(b)
.
1
.
3 Put the extraction tool in its correct position above the taper bolt. Engage the
standard bolt with the thread in the taper bolt (Refer to Figure 039).
4 Remove and discard the nut from the end of the taper bolt. Do this with the correct
socket tool.

CAUTION: MAKE SURE THAT THE BRIDGE OF THE EXTRACTION TOOL DOES
NOT DAMAGE THE STRUCTURE SURFACE.
5 Turn the nut on the standard bolt to remove the taper bolt from the structure.
6 Remove the taper bolt from the extraction bolt. Discard the taper bolt.
I. Rivet (Blind) (HUCK)
(1) General (Refer to Figure 040)
(a) In this paragraph the Rivet (Blind) (HUCK) is referred to as the HUCK rivet.
(b) The HUCK rivet consists of three parts. These are:
1 A tubular body that has a protruding or 100 ° countersunk head.
2 A mandrel (shank) that is retained in the tubular body. When the HUCK rivet is
installed, the mandrel is mechanically secured within the tubular body and is
sheared off level with the rivet head.
3 A locking collar that is retained on the mandrel before installation. The installation
tool pushes the collar into a locking groove during installation. This secures the
mandrel in the body.
(c) When installed the HUCK rivet is similar to a 'pop' rivet. But because the mandrel is
retained in the tubular body, this rivet has almost the same properties as a solid rivet. The
HUCK rivet can be installed from one side of a repair or surface.
(d) The HUCK rivet is identified by an identification number. This number and its specific
details are explained in Chapter 51-40-12.
(e) The HUCK rivet can be installed with hand or power operated tools.
(f) HUCK rivets must only be used to replace HUCK rivets, or when called up in a specific
repair procedure or other approved documents.
(g) Before you install HUCK rivets make sure that:
- you have the correct type of rivet,
- the rivets are made of the required material,
- the rivets have the specified surface protection, and that they are not corroded or
scratched,

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- the rivets are the correct grip length and diameter,

- the holes for the rivets are correctly prepared (Refer to Chapter 51-44-00).
(h) Before you install HUCK rivets in the structure you are recommended to make a test
piece. This will check the rivet, tool and hole precision. The test materials and rivets must
have the same properties as those required for the repair.
(i) If the correct size for a replacement HUCK rivet is not known, do the steps that follow:
1 Accurately measure the diameter of the hole. Refer to Chapter 51-44-00, if the
diameter of the hole is within the tolerances for a standard rivet, use a rivet of this
diameter. If the diameter of the hole is not within the tolerances, increase the hole
diameter to suit an oversize rivet if applicable, or the next standard size.
2 Measure the total thickness of the material at the hole. Refer to Figure 041, Figure
042, Figure 043, Figure 044 and Figure 045 as applicable to find the rivet of the
correct grip-length to suit the material thickness.

NOTE: If the type of HUCK rivet can not be identified, contact AIRBUS.

GRIP GRIP LENGTH RANGE (T)

LENGTH
FROM (MIN) TO (MAX)
CODE
(SECOND
DASH mm in mm in
NUMBER)
02 2.39 0.094 3.99 0.157
03 3.96 0.155 5.99 0.220
04 5.56 0.218 7.16 0.281
05 7.14 0.281 8.76 0.344
06 8.74 0.344 10.34 0.407
07 10.31 11.94 0.470

Table 23 - Data for Rivet (Blind) (Huck) Type MS 21140

NOTE: Additional information about these blind rivets and rivets of other
diameters and grip lengths can be found in the Standards Manual.

GRIP GRIP LENGTH RANGE (T)

LENGTH
FROM (MIN) TO (MAX)
CODE
(SECOND
DASH mm in mm in
NUMBER)
01 0.79 0.031 2.41 0.094
02 2.39 0.094 3.99 0.157

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03 3.96 0.155 5.59 0.220

04 5.56 0.218 7.16 0.281
05 7.14 0.281 8.76 0.344
06 8.75 0.344 10.34 0.407
07 10.31 0.405 11.94 0.470

Table 24 - Data for Rivet (Blind) (Huck) Type MS 90354

NOTE: Additional information about these blind rivets and rivets of other
diameters and grip lengths can be found in the Standards Manual.

GRIP GRIP LENGTH RANGE (T)

LENGTH
FROM (MIN) TO (MAX)
CODE
(SECOND
DASH mm in mm in
NUMBER)
00 0.508 0.020 0.889 0.035
01 0.635 0.025 1.575 0.062
02 1.600 0.062 3.175 0.125
03 3.200 0.125 4.750 0.187
04 4.775 0.187 6.350 0.250
05 6.375 0.250 7.925 0.312
06 7.950 0.312 9.525 0.375

Table 25 - Data for Rivet (Blind) (HUCK) Type NAS 1919

NOTE: This table is applicable to blind rivets of diameter code - 04 (1/8 in) (3.175
mm).

GRIP GRIP LENGTH RANGE (T)

LENGTH
FROM (MIN) TO (MAX)
CODE
(SECOND
DASH mm in mm in
NUMBER)
00 0.635 0.025 1.143 0.045
01 0.787 0.030 1.575 0.062
02 1.600 0.062 3.175 0.125
03 3.200 0.125 4.750 0.187

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04 4.775 0.187 6.350 0.250

05 6.375 0.250 7.925 0.312
06 7.950 0.312 9.525 0.375
07 9.550 0.375 11.100 0.437
08 11.125 0.437 12.700 0.500
09 12.725 0.500 14.275 0.562
10 14.300 0.562 15.875 0.625

Table 26 - Data for Rivet (Blind) (HUCK) Type NAS 1919

NOTE: This table is applicable to blind rivets of diameter code - 05 (5/32 in)
(3.962 mm).

GRIP GRIP LENGTH RANGE (T)

LENGTH
FROM (MIN) TO (MAX)
CODE
(SECOND
DASH mm in mm in
NUMBER)
01 0.940 0.037 1.575 0.062
02 1.600 0.062 3.175 0.125
03 3.200 0.125 4.750 0.187
04 4.775 0.187 6.350 0.250
05 6.375 0.250 7.925 0.312
06 7.950 0.312 9.525 0.375
07 9.550 0.375 11.100 0.437
08 11.125 0.437 12.700 0.500
09 12.725 0.500 14.275 0.562
10 14.300 0.562 15.875 0.625
11 15.875 0.625 17.450 0.687
12 17.475 0.687 19.050 0.750

Table 27 - Data for Rivet (Blind) (HUCK) Type NAS 1919

NOTE: This table is applicable to blind rivets of diameter code - 06 (3/16 in)
(4.826 mm).

GRIP LENGTH RANGE (T)

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GRIP FROM (MIN) TO (MAX)

LENGTH
CODE
(SECOND mm in mm in
DASH
NUMBER)
01 1.448 0.057 1.956 0.077
02 1.600 0.062 3.175 0.125
03 3.200 0.125 4.750 0.187
04 4.775 0.187 6.350 0.250
05 6.375 0.250 7.925 0.312
06 7.950 0.312 9.525 0.375
07 9.550 0.375 11.100 0.437

Table 28 - Data for Rivet (Blind) (HUCK) Type NAS 1921

NOTE: This table is applicable to blind rivets of diameter code - 04 (1/8 in) (3.175
mm).

GRIP GRIP LENGTH RANGE (T)

LENGTH
FROM (MIN) TO (MAX)
CODE
(SECOND
DASH mm in mm in
NUMBER)
01 1.905 0.075 2.540 0.100
02 2.032 0.080 3.175 0.125
03 3.200 0.125 4.750 0.187
04 4.775 0.187 6.350 0.250
05 6.375 0.250 7.925 0.312
06 7.950 0.312 9.525 0.375
07 9.550 0.375 11.100 0.437
08 11.125 0.437 12.700 0.500
09 12.725 0.500 14.275 0.562
10 14.300 0.562 15.875 0.625

Table 29 - Data for Rivet (Blind) (HUCK) Type NAS 1921

NOTE:

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This table is applicable to blind rivets of diameter code - 05 (5/32 in)

(3.962 mm).

GRIP GRIP LENGTH RANGE (T)

LENGTH
FROM (MIN) TO (MAX)
CODE
(SECOND
DASH mm in mm in
NUMBER)
02 2.540 0.100 3.175 0.125
03 3.200 0.125 4.750 0.187
04 4.775 0.187 6.350 0.250
05 6.375 0.250 7.925 0.312
06 7.950 0.312 9.525 0.375
07 9.550 0.375 11.100 0.437
08 11.125 0.437 12.700 0.500
09 12.725 0.500 14.275 0.562
10 14.300 0.562 15.875 0.625
11 15.875 0.625 17.450 0.687
12 17.475 0.687 19.050 0.750

Table 30 - Data for Rivet (Blind) (HUCK) Type NAS 1921

NOTE: This table is applicable to blind rivets of diameter code - 06 (3/16 in)
(4.826 mm).

GRIP GRIP LENGTH RANGE (T)

LENGTH
FROM (MIN) TO (MAX)
CODE
(SECOND
DASH mm in mm in
NUMBER)
01 <1> 0.64 0.025 1.57 0.062
02 <1> 1.58 0.063 3.17 0.125
03 <1> 3.20 0.126 4.75 0.187
04 <1> 4.78 0.188 6.35 0.250
05 <1> 6.38 0.251 7.92 0.312
06 <1> 7.95 0.313 9.52 0.375

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07 <2> 9.55 0.376 11.10 0.437

08 <2> 11.12 0.438 12.70 0.500

Table 31 - Data for Rivet (Blind) (HUCK) Type NSA 54217

<1> Blind rivets in these grip ranges area available from stock in the diameter
codes: -4 (1/8 in) (3.18 mm), -5 (5/32 in) (3.97 mm) and -6 (3/16 in) (4.76 mm).
<2> Blind rivets in these grip ranges are available from stock in the diameter
code -6 (3/16 in) (4.76 mm).

NOTE: Additional information about these blind rivets and rivets of other
diameters and grip lengths can be found in the Standards Manual.
(2) Installation
(a) The steps that follow give the general sequence for the installation of a HUCK rivet.
1 Put the rivet in its hole. Make sure that the locking collar is in its correct position.
2 Put the applicable installation tool onto the rivet mandrel. Make sure that the tool is
perpendicular to the surface of the material.

CAUTION: OBEY THE MANUFACTURER'S INSTRUCTIONS WHEN USING A

POWER OPERATED TOOL. SOME DOUBLE ACTION TOOLS HAVE A
SHIFT VALVE CARTRIDGE THAT MUST BE ADJUSTED TO A
SPECIFIC PRESSURE BEFORE USE.
3 Operate the installation tool. This:
- forms the upset head,
- seats the locking collar into the locking groove,
- shears the mandrel at the break-off groove.
4 Release the tool trigger and remove the tool from the rivet head. The broken off part
of the mandrel is automatically pushed out of the tool.
5 If required, mill the mandrel at the break-off groove to give a smooth finish.
6 Inspect the HUCK rivet for correct installation (Refer to Paragraph
2.
.
I.
.
(3)
).
(3) Inspection after the Installation of HUCK Rivets
(a) General
1 Carefully examine the installed rivets.
2 A visual inspection of the correct shape of the formed (blind) side with a probe light
and a mirror is necessary when the access is possible.
3 The installation of the HUCK rivet is correct when:

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- the pin is correctly locked by the locking collar,

- the manufactured head is fully seated,
- the blind head is correctly formed,
- the adjacent structure is free from damage and distortion.
4 Deformation or buckling of the outer skin is not permitted outside the limits given in
Chapter 51-10-00.
5 Make sure that the head of countersunk rivet is in the limits given in Chapter 51-10-
00.
(b) Permitted Limits
1 For the protrusion and intrusion limits of the pin refer to Figure 046.
2 The correct position of the locking collar is given in Figure 046.
3 The limits for the seat of the head are given in Figure 047.
4 Cracks in the material around the fastener are not permitted.

THESE LIMITS APPLY TO PROTRUDING HEAD RIVETS

NOM. RIVET DIAMETER DIMENSION A (MAX) DIMEENSION B (MAX)
in mm in mm in mm
5/32 4.0 0.010 0.25 0.010 0.25
3/16 4.8 0.012 0.30 0.012 0.30
1/4 6.4 0.015 0.38 0.015 0.38
5/16 8.0 0.019 0.48 0.019 0.48
3/8 9.6 0.023 0.58 0.023 0.58
7/16 11.2 0.028 0.71 0.028 0.71
1/2 12.8 0.033 0.84 0.033 0.84

Table 32 - Pin and Collar Prorusion/Depression Limits for Rivets (Blind) (HUCK)

THESE LIMITS APPLY TO countersunk HEAD RIVETS

NOM. RIVET DIAMETER DIMENSION A (MAX) DIMEENSION B (MAX)
in mm in mm in mm
1/8 3.2 0.018 0.46 0.008 0.20
5/32 4.0 0.022 0.56 0.010 0.25
3/16 4.8 0.025 0.64 0.012 0.30

Table 33 - Pin and Collar Prorusion/Depression Limits for Rivets (Blind) (HUCK)
(4) Removal of HUCK Rivets (Refer to Figure 048, Figure 049, Figure 050 and Figure 051)

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(a) General
1 HUCK rivets can be removed with a special tool kit. If this kit is not available HUCK
rivets can be carefully removed with conventional twist-drills. In this Paragraph the
two procedures are given.
2 The Figures referred to in this Paragraph show the removal of a countersunk rivet.
The removal of a protruding head rivet is the same.
(b) Removal with a Special Tool Kit (Procedure 1)
1 For the selection of the applicable tool kit use the subsequent Table:

KIT NUMBER
RIVET NOMINAL DIAMETER
NECESSARY
5/32 in (4.0 mm) 105-50
3/16 in (4.8 mm) 105-60
1/4 in (6.4 mm) 105-80
5/6 in (8.0 mm) 105-100
3/8 in (9.6 mm) 105-120

Table 34
2 Set the drill bushing vertically on the rivet mandrel so that it is in full contact with the
locking collar.
3 Use a power drill with a maximum speed of 1250 revolutions per minute (rpm). Drill
to the locking collar depth. For the drill depth and dimensions refer to Figure 048.
4 Put the pin punch on the rivet mandrel and drive out the mandrel (Refer to Figure
049).
5 Remove the remaining part of the mandrel together with the locking collar with a
pointed tool.
6 Assemble the tool, to counterbore the rivet body as follows:
a Install the cutter fully into the holder and attach it with the set screw.
b Screw the cutter holder fully into the micro-limit tool.
c Install the micro-limit tool in the anti-rotation cap as far as possible and
secure it with the set screws.
d Put the assembly of the micro-limit into the chuck of the power drill and
secure it.

RIVET DRILL DRILL

NOMINAL BUSHING
DIAMETER PART DIAMETER
PART
NUMBER NUMBER
in mm in NOM.

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5/32 4.0 103615 502999 0.098 7/64

3/16 4.8 103616 503000 0.120 1/8
1/4 6.4 103617 503001 0.156 5/32
5/16 8.0 103618 503003 0.188 3/16
3/8 9.5 103619 503005 0.228 15/64

Table 35 - HUCK Rivet Mandrel Drilling Details

RIVET PIN PUNCH

NOMINAL
DIAMETER PART DIAMETER
NUMBER
in mm in mm
5/32 4.0 503010 3/32 2.4
3/16 4.8 503010 3/32 2.4
1/4 6.4 503012 5/32 4.0
5/16 8.0 503013 3/16 4.8
3/8 9.5 503014 7/32 5.6

Table 36 - HUCK Rivet Pin Removal Details

ANTI CUTTER DEPTH

RIVET CUT CUTTER
ROT (INCHES)
NOMINAL ATIO TER
DIAMETER HOL PROT.
N DIAMETER CSK HEAD
DER PAR HEAD
CAP
PAR T NU
PAR
T NU MBE
T NU
in mm MBE R in mm MIN MAX MIN MAX
MBE
R
R
1036 1036 1036 0.05 0.06 0.05 0.06
5/32 4.0 5/32 4.0
20 10 05 5 5 5 5
1036 1036 1036 0.06 0.07 0.12 0.13
3/16 4.8 3/16 4.8
20 11 06 5 5 0 0
1036 1036 1036 0.09 0.10 0.12 0.13
1/4 6.4 1/4 6.4
21 11 07 0 0 5 5
1036 1036 1036 0.12 0.13 0.12 0.13
5/16 8.0 5/16 8.0
21 13 08 0 0 5 5
1036 1036 1036 0.15 0.16 0.19 0.20
3/8 9.5 3/8 9.5
22 13 09 0 0 0 0

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Table 37 - HUCK Rivet Body Counterboring Details

7 Adjust the micro-limit tool to the type and size of the rivet. For dimensions refer to
the Table in Figure 050.
8 Put the cutter in the rivet body and press the anti-rotation cap tightly against the
rivet head. Counterbore to the necessary depth and carefully remove the tool (Refer
to Figure 050).

CAUTION: BE CAREFUL WHEN YOU USE THE PIN PUNCH. DO NOT CAUSE
DAMAGE TO THE HOLE AND, IF IT IS APPLICABLE, THE
COUNTERSINK.
9 Put the pin punch in the rivet body and drive out the lower part (Refer to Figure 051
). Carefully remove the pin punch.
10 If the remaining part of the body, for example the rivet head, is loose, lift it out of the
hole. If this is not possible, put the end of the pin punch into the head. Move the
punch at an angle to one side and remove the rivet head (Refer to Figure 051).
(c) Removal with conventional twist-drills (Procedure 2)

NOTE: The removal procedure 2 is not illustrated because it is equivalent to the

procedure 1. The necessary illustrations are given in procedure 1.
1 Use a sharp twist-drill. The recommended diameter is given in the subsequent table
for the applicable rivet diameter.

RECOMMENDED DRILL
RIVET NOMINAL DIAMETER
DIMENSION
1/8 in (3.2 mm) 5/64 in (2.0 mm)
5/32 in (4.0 mm) 7/64 in (2.5 mm)
3/16 in (4.8 mm) 1/8 in (3.2 mm)
1/4 in (6.4 mm) 5/32 in (4.0 mm)
5/16 in (8.0 mm) 3/16 in (4.8 mm)
3/8 in (9.5 mm) 15/64 in (5.8 mm)
7/16 in (11.2 mm) 17/64 in (6.8 mm)
1/2 in (12.8 mm) 5/16 in (7.9 mm)

Table 38
2 Secure the twist-drill in a power tool and drill the rivet head to the bottom of the
locking collar. Make sure that the twist-drill remains concentric on the rivet.

NOTE: Do not use a drill speed greater than 1250 rpm.

NOTE: For the larger size rivet you are recommended to drill a pilot hole first.
3 Use a pin punch that is the same diameter (or less) as the twistdrill used in Step

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2.
.
I.
.
(4)
.
(c)
.
2
. Put the punch on the rivet mandrel and drive out the mandrel.
4 Remove the remaining part of the mandrel together with the locking collar with a
pointed tool.

RIVET PIN PUNCH

NOMINAL
DIAMETER PART DIAMETER
NUMBER
in mm in mm
5/32 4.0 503012 5/32 4.0
3/16 4.8 503013 3/16 4.8
1/4 6.4 503015 1/4 6.4
5/16 8.0 503016 5/16 8.0
3/8 9.5 503017 3/8 9.5

Table 39 - HUCK Rivet Body Removal Details

CAUTION: DAMAGE MAY BE CAUSED TO THE SKIN/COUNTERSINK IF THE

RIVET TURNS WHEN YOU DO THE NEXT STEP.
5 Use a twist-drill with the same nominal diameter as the rivet at a drill speed of
approximately 250 revolutions per minute (rpm). Counterbore the rivet head with a
light and constant pressure. For the counterbore depth of the applicable head type
and rivet dimensions refer to the table that follows:

RIVET NOMINAL COUNTERBORE DEPTH

DIAMETER CSK HEAD PROTRUDING HEAD
1/8 in (3.2 mm) 1.0 mm (0.039 in) 1.2 mm (0.047 in)
5/32 in (4.0 mm) 1.4 mm (0.055 in) 1.5 mm (0.059 in)
3/16 in (4.8 mm) 1.8 mm (0.071 in) 1.9 mm (0.075 in)
1/4 in (6.4 mm) 2.4 mm (0.094 in) 3.3 mm (0.130 in)
5/16 in (8.0 mm) 3.2 mm (0.126 in) 3.3 mm (0.130 in)
3/8 in (9.5 mm) 3.9 mm (0.154 in) 5.0 mm (0.197 in)

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7/16 in (11.2 mm) 4.6 mm (0.181 in) 5.0 mm (0.197 in)

1/2 in (12.8 mm) 5.3 mm (0.209 in) 6.6 mm (0.260 in)

Table 40

CAUTION: BE CAREFUL WHEN YOU USE THE PIN PUNCH. DO NOT CAUSE
DAMAGE TO THE HOLE AND, IF IT IS APPLICABLE, THE
COUNTERSINK.
6 Use a pin punch that is the same diameter (or less) as the twistdrill diameter used
in step
2.
.
I.
.
(4)
.
(c)
.
1
. Put this punch in the rivet body and drive out the lower part. Carefully remove the
pin punch.
7 If the remaining part of the body, for example the rivet head, is loose, lift it out of the
hole. If this is not possible, put the end of the pin punch into the head. Move the
punch at an angle to one side and remove the rivet head.
J. Rivet-Blind (AVDEL MBC)
(1) General (Refer to Figure 052)
(a) In this paragraph the Rivet - Blind (AVDEL MBC) is referred to as the AVDEL rivet.
(b) The AVDEL rivet consists of two parts. These are:
1 A tubular body that has a protruding or 100 ° countersunk head.
2 A mandrel (shank) that is retained in the tubular body. When the AVDEL rivet is
installed the mandrel is mechanically secured within the tubular body and is
sheared off level with rivet head.
(c) When installed the AVDEL rivet is similar to a 'pop' rivet. But because the mandrel is
retained in the tubular body this rivet has almost the same properties as a solid rivet. The
AVDEL rivet can be installed from one side.
(d) The AVDEL rivet is identified by an identification number. This number and its specific
details are explained in Chapter 51-40-12.
(e) AVDEL rivets can be installed with standard 'pop' rivet tools, or with AVDEL power or
hand operated tools.
(f) AVDEL rivets must only be used to replace AVDEL rivets, or when they are called up in a
specific repair procedure or other approved documents.

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(g) AVDEL rivets are supplied already lubricated. Do not remove the lubricant or touch the
rivets more than is necessary.
(h) Before you install AVDEL rivets makes sure that:
- you have the correct type of rivet,
- the rivets are made of the required material,
- the rivets have the specified surface protection and/or lubrication,
- and that they are not corroded or scratched,
- the rivets are the correct length and diameter,
- the holes for the rivets are correctly prepared.
(i) Before you install AVDEL rivets in the structure you are recommended to make a test-
piece. This will check the rivet, tool and hole precision. The test materials and rivets must
have the same properties as those required for the repair.
(2) AVDEL Rivet Installation
(a) The procedure that follows is applicable to installation with hand or power operated tools.
(b) Make sure that the rivets are the correct dimensions (diameter and length). If these
dimensions are not known use the procedure that follows:
1 Accurately measure the diameter of the hole. Refer to Chapter 51-44-00, if the
diameter of the hole is within the tolerances for a standard rivet, use a rivet of this
diameter. If the diameter of the hole is not within the tolerances, increase the hole
diameter to suit an oversize rivet if applicable, or the next standard size.
2 Refer to Figure 053 to find the required length of the rivet.
(c) Make sure that the installation tool is correct for the rivet dimensions and head shape.
(d) Insert the rivet mandrel fully into the installation tool.
(e) Insert the rivet body fully into the hole. Make sure that the installation tool nose is
perpendicular to the material surface.
(f) Operate the tool to complete the installation of the rivet.
(g) Remove the installation tool and make sure that the rivet is installed correctly.

NOTE: If the mandrel protrudes from the rivet head the mandrel can be milled flush.
(3) Inspection after Installation
(a) General
1 Carefully examine the installed rivets as far as possible.

NOTE: You are recommended to use inspection aids, for example, probe light
and mirror, to examine the 'blind' head.
2 The AVDEL rivet is correctly installed when:
- the mandrel is correctly installed,
- the manufactured head is correctly seated,
- the 'blind' head is correctly shaped,
- the surrounding structure is free from damage and distortion.

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GRIP LENGTH (T) RANGES SECOND DASH NUMBER NECESSAR

FROM (MIN) TO (MAX) RIVET/HOLE RIVET/HOLE RIVET/HO
DIAMETER 1/8 DIAMETER 5 DIAMETE
in mm in mm in (3.2 mm) /32 in (4.0 mm) /16 in (4.8
0.050 1.27 0.141 3.58 -407 N/A N/A
0.062 1.57 0.141 3.58 N/A -508 N/A
0.077 1.96 0.141 3.58 N/A N/A -609
0.109 2.77 0.203 5.16 -409 -510 -611
0.172 4.37 0.266 6.76 -411 -512 -613
0.234 5.94 0.328 8.33 -413 -514 -615
0.297 7.54 0.391 9.93 -415 -516 -617
0.359 9.12 0.453 11.51 - -518 -619
0.422 10.72 0.516 13.11 - -520 -621

Table 41 - Data to find Second Dash Number for AVDEL MBC Rivets ASNA 0079
and ASNA 0080
3 Deformation or buckling of the skin is not permitted outside the limits given in
Chapter 51-10-00.
4 The manufactured head of a countersunk rivet must be flush, or within the limits
given in Chapter 51-10-00.
(b) Tests, Acceptable Faults and Limits
1 The security of the mandrel must be tested. Use the AVDEL pin tester (Part
Number 79/95-0700 set to 35 lbf. to do this. No movement of the mandrel is
permitted.
2 Refer to Figure 054 for head seating limits.
3 Cracks are not permitted in the material around the rivet.
(4) Removal of AVDEL MBC Rivets (Refer to Figure 055)
(a) General
1 One of two methods can be used to remove these rivets. In Method
2.
.
J.
.
(4)
.
(b)
the mandrel is removed by hitting it out with a hammer and parallel pin punch. But
the surrounding structure must be supported when you do this.

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2 In Method
2.
.
J.
.
(4)
.
(c)
the mandrel is removed by drilling it out with a twist-drill. A twist-drill with a diameter
slightly less than the nominal diameter is used.
3 After the removal of rivets all unwanted materials must be removed as far as it is
possible.
4 The removal methods are shown in Figure 055 and are detailed below.

CAUTION: WHEN REMOVING RIVETS, TAKE CARE NOT TO CAUSE DAMAGE TO THE
STRUCTURE, ESPECIALLY WHEN THE SKIN IS THIN.

CAUTION: IF THE RIVET TURNS DURING DRILLING OPERATIONS, DAMAGE CAN BE

CAUSED TO THE SKIN/HOLE.
(b) Removal Method 1
1 Hit out the mandrel from the rivet body. Do this with a hammer and parallel pin
punch. The pin punch diameter must be slightly less than the inner diameter of the
rivet body. Support the structure on the underside during this step.
2 With a twist-drill of the same nominal diameter as the rivet drill almost through the
head. It is recommended that a mechanical stop is used on the twist-drill to control
the depth drilled.
3 With a parallel pin punch remove the rivet head.
4 With a parallel pin punch and hammer hit out the remainder of the rivet body. The
parallel pin punch diameter must be slightly less than the nominal diameter of the
rivet, but greater than the rivet inner diameter. Support the structure on the
underside during this step.
(c) Removal Method 2
1 Make a mark with a centre punch in the centre of the mandrel. This will help to
centre the twist-drill in step
2.
.
I.
.
(4)
.
(c)
.
2

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.
2 Drill through the mandrel and part of the rivet body wall. Use a twist-drill with a
diameter greater than the mandrel diameter but less than the rivet nominal diameter.
3 Do steps
2.
.
J.
.
(4)
.
(b)
.
3
and
2.
.
J.
.
(4)
.
(b)
.
4
of Method 1 to complete the removal of the rivet.
(5) Additional Information
After a rivet has been removed check the hole for size and damage. If the hole is damaged or
distorted it must be drilled for an oversize rivet.
K. Rivet-Blind (IMEX)
Refer to Figure 056
(1) General
(a) The IMEX blind rivet consists of two parts. These are:
1 A tubular body that has a protruding or 100 ° countersunk head.
2 A mandrel that is retained in the tubular body. When the rivetblind (IMEX) is
installed the mandrel is mechanically secured within the tubular body and is
sheared off at the break off groove (Refer to Figure 056).
(b) The IMEX blind rivet is similar to a 'pop' rivet. The only difference is that the sealed body
end completely encloses the head of the mandrel.
(c) Mandrels are available as short break or long break types. The long break type breaks off
above the level of the rivet head and must be milled flush. The short break type breaks off
internally in the tubular body.
(d) The IMEX blind rivet has an identification number. This number and its specific details are
explained in Chapter 51-40-12.

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(e) IMEX blind rivets can be installed with standard 'pop' rivet tools using a special nose piece
and in certain instances, special jaws.
(f) IMEX blind rivets must only be used when they are called up in a specific repair procedure
or other A/B approved documents.
(g) Before the installation of IMEX blind rivets make sure that:
- the rivet type is correct,
- the rivets are made of the required material,
- the rivets have the specified surface protection and/or lubrication,
- and that they are not corroded or scratched,
- the rivets are the correct length and diameter,
- the holes for the rivets are correctly prepared.
(2) Installation Procedure
(a) Make sure that the rivets are the correct dimension (diameter and length). If the length is
not known refer to Figure 057, Figure 058 and Figure 059.
(b) Refer to Chapter 51-44-00 to find the correct dimension for the hole that is applicable to
the rivet-blind (IMEX) nominal diameter.
(c) Drill the hole to the required diameter (Refer to Chapter 51-44-00).
(d) Make sure that the hole, including the countersunk and/or dimpled portion if applicable is
in a satisfactory condition, clean and free from burrs.
(e) Make sure that the installation tool is correct for the rivet dimensions and head shape.
(f) Insert the rivet mandrel fully into the installation tool.
(g) Insert the rivet body fully into the hole. Make sure that the installation tool nose is
perpendicular to the material surface.
(h) Operate the tool to complete the installation if the rivet.
(i) Remove the installation tool and make sure that the rivet is installed correctly.

NOTE: if the mandrel protrudes from the rivet head the mandrel can be milled flush.
(3) Inspection after Installation
(a) General
1 Carefully examine the installed rivets as far as possible.

NOTE: You are recommended to use inspection aids, for example, probe light
and mirror, to examine the 'blind' head.
2 The IMEX rivet is correctly installed when:
- the mandrel is correctly installed,
- the manufactured head is correctly seated,
- the 'blind' head is correctly shaped,
- the surrounding structure is free from damage and distortion.
3 Deformation or buckling of the skin is not permitted outside the limits given in
Chapter 51-10-00.

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4 The manufactured head of a countersunk rivet must be flush, or within the limits
given in Chapter 51-10-00.

RIVET BODY LENGTH (L) ACCORDING TO DASH

RIVET NSA5420 DASH NO.
NUMBER
in ± 0.010 mm ± 0.25
-42 0.237 6.0
-44 0.300 7.6
-46 0.362 9.2
-48 0.425 10.8
-54 0.315 8.0
-58 0.440 11.2
-510 0.502 12.8
-64 0.330 8.4
-66 0.392 12.4
-68 0.455 11.6
-610 0.517 13.1
-612 0.580 14.7

Table 42 - Determining required Length (Second Dash Num-ber) of IMEX Blind

Rivet NSA5420

GRIP LENGTH (T) RANGES SECOND

DASH
FROM (MIN) TO (MAX)
NUMBER
in mm in mm REQUIRED
- - 1/16 (0.063) 1.6 2
1/16 (0.063) 1.6 1/8 (0.125) 3.2 4
1/8 (0.125) 3.2 3/16 (0.188) 4.8 6
3/16 (0.188) 4.8 1/4 (0.250) 6.4 8
1/4 (0.250) 6.4 5/16 (0.313) 7.9 10
5/16 (0.313) 7.9 3/8 (0.375) 9.5 12

Table 43 - Determining Required Length (Second Dash Number) of IMEX Blind

Rivet NSA5420

NOTE:

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Figure 058, Sheet 1 shows that for IMEX rivets of the countersunk type,
the grip length is measured outside a countersink but where dimpling is
used, the grip length is measured at the hole. The second number after
the dash in the part number indicates only the parallel portion of the grip
length in 1/32nds of an inch, i.e. the head height is not included.

NSA5421 RIVET BODY LENGTH (L)

GRIP LENGTH (T) RANGES
RIVET ACCORDING TO DASH NO.
DASH
FROM (MIN.) TO (MAX.)
NUMBER in ± 0.010 mm ± 0.25
in mm in mm REQUIRED
0.067 1.7 0.098 2.5 -42 0.242 6.1
0.098 2.5 0.161 4.1 -44 0.305 7.7
0.161 4.1 0.220 5.6 -46 0.367 9.3
0.220 5.6 0.283 7.2 -48 0.430 10.9
0.283 7.2 0.346 8.8 -410 0.492 12.5

Table 44 - Determining Required Length (Second Dash Number) of IMEX Blind

Rivet NSA5421 with Diameter of 1/8 in (3.2 mm)

NOTE: Figure 058, Sheet 2 shows that for IMEX rivets of the countersunk type,
the grip length is measured outside a countersink but where dimpling is
used, the grip length is measured at the hole. The second number after
the dash in the part number indicates only the parallel portion of the grip
length in 1/32nds of an inch, i.e. the head height is not included.

NSA5421 RIVET BODY LENGTH (L)

GRIP LENGTH (T) RANGES
RIVET ACCORDING TO DASH NO.
DASH
FROM (MIN.) TO (MAX.)
NUMBER in ± 0.010 mm ± 0.25
in mm in mm REQUIRED
0.110 2.8 0.165 4.2 -54 0.340 8.6
0.165 4.2 0.228 5.8 -56 0.402 10.2
0.228 5.8 0.291 7.4 -58 0.465 11.8
0.291 7.4 0.354 9.0 -510 0.527 13.4

Table 45 - Determining Required Length (Second Dash Number) of IMEX Blind

Rivet NSA5421 with a Diameter of 5/32 in (4.0 mm)

NOTE: Figure 059 shows that for IMEX rivets of the countersunk type, the grip
length is measured outside a countersink but where dimpling is used, the

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grip length is measured at the hole. The second number after the dash in
the part number indicates only the parallel portion of the grip length in 1
/32nds of an inch, i.e. the head height is not included.

NSA5421 RIVET BODY LENGTH (L)

GRIP LENGTH (T) RANGES
RIVET ACCORDING TO DASH NO.
DASH
FROM (MIN.) TO (MAX.)
NUMBER in ± 0.010 mm ± 0.25
in mm in mm REQUIRED
0.118 3.0 0.184 4.6 -64 0.342 8.7
0.181 4.6 0.244 6.2 -66 0.404 10.3
0.244 6.2 0.307 7.8 -68 0.467 11.9
0.307 7.8 0.366 9.3 -610 0.529 13.4
0.366 9.3 0.425 10.8 -612 0.592 15.0

Table 46 - Determining Required Length (Second Dash Number) of IMEX Blind

Rivet NSA5421 with a Diameter of 3/16 in (4.8 mm)
(b) Acceptance Limits
1 Due to the varying degrees of functional importance of installed IMEX blind rivets,
acceptance or rejection is mostly at the discretion of the inspector.
2 As a general guide, reject loose or cracked rivets.
(4) Removal of Rivets-Blind (IMEX) (Refer to Figure 060)
(a) The removal of IMEX blind rivets is achieved by first removing the manufactured head
then driving the remainder of the rivet out of its hole.
(b) If the rivet has a long break mandrel, support the rivet with dolly or similar. Then
accurately center punch the mandrel to provide location for the twist-drill tip (Refer to
Figure 060).
(c) Rivets with short break mandrels have a central cavity which can serve as a pilot hole for
the twist-drill.

CAUTION: TAKE CARE NOT TO CAUSE DAMAGE TO THE SURFACE OF THE

MATERIAL, OR THE HOLE, WHEN YOU DO THE PROCEDURES THAT
FOLLOW.

CAUTION: IF THE RIVET TURNS DURING DRILLING OPERATIONS, DAMAGE CAN BE

CAUSED TO THE SKIN/HOLE.
(d) With a twist-drill of the same nominal diameter as the rivet drill almost through the head. It
is recommended that a mechanical stop is used on the twist-drill to control the depth
drilled.
(e) With a parallel pin punch remove the rivet head.

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(f) With a parallel pin punch and hammer hit out the remainder of the rivet body. The parallel
pin punch diameter must be slightly less than the nominal diameter of the rivet, but greater
than the rivet inner diameter. Support the structure on the underside during this step.
L. Rivet-Blind (CHERRYMAX)
(1) General (Refer to Figure 061)
(a) There are two types of these blind rivets that you can use for repair work on the aircraft.
These are:
- CHERRYMAX,
- Oversize CHERRYMAX.
(b) These blind rivets are supplied as one piece and consist of three parts:
1 A tubular body that has a head at one end. Two types of head are available: a 100 °
countersunk head and a protruding head.
2 A pin that goes through the body. The pin has a head opposite the body head. It
also has a lock-groove, a break-off groove and pullgrooves. There is also a driving
anvil on the pin. This makes sure that the lock-collar sits correctly, and that the pin
always breaks off at the break-off groove.
3 A lock-collar on the pin. When the blind-rivet is installed, the collar is swaged into
the lock-groove on the pin and in the head. This makes sure that the pin is locked
into the body.
(c) To identify the correct blind-rivet for a repair, or a replacment, refer to Chapter 51-40-12.
(d) These blind rivets are supplied with a layer of lubricant on them. Do not clean them, or
touch them more than is necessary, before they are installed.
(e) Do not install blind rivets that are not in a satisfactory condition. Discard any that are not.
(f) You can use hand or power operated tools to install blind rivets. These tools must have
the correct heads attached to them.
(g) It is recommended that you do a test procedure on some unwanted materials before you
install blind rivets. Do the test on materials that are the same (type and thickness) as the
repair materials. Use blind rivets that are the same (head type, diameter and grip-length),
as those for the repair.
(h) After you have installed a blind rivet, the end of the pin can be above the rivet head. You
can mill the pin until it is in line with the top of the rivet head.
(2) Hole Preparation
(a) The holes for blind rivets are only drill-finished. It is not necessary to ream them.
(b) Before you install a blind rivet, you must examine the hole to make sure that:
- it is clean,
- it has no burrs,
- it is not damaged.
(c) Refer to Chapter 51-44-00 to find the correct dimensions for the hole.
(d) Do these steps if a hole is damaged, or if a new hole is necessary.

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1 Use grip-pins or clamps to make sure that the repair materials are correctly
clamped together.
2 Drill a pilot-hole in the correct position.
3 Drill the hole to the correct final dimension.
4 Deburr the hole.
(3) Selection of the Blind Rivet (Refer to Figure 062).
(a) Accurately measure the diameter of the hole. Refer to Chapter 51-44-00, if the diameter of
the hole is within the tolerances for a standard rivet, use a rivet of this diameter. If the
diameter if the hole is not within the tolerances, increase the hole diameter to suit an
oversize rivet if applicable, or the next standard size.
(b) Find the grip-length that is necessary for the total thickness of the materials to be
attached. Use one of the two subsequent procedures to do this:
- Use standard equipment to measure the total thickness of
- the materials. This will give you the second dash number of the blind rivet part
number (Refer to Figure 062).
- Use a CHERRYLOCK grip-length gauge. This will give you the second dash
number.
(4) Installation Procedure

CAUTION: IF THE RIVET TURNS DURING DRILLING OPERATIONS, DAMAGE CAN BE

CAUSED TO THE SKIN/HOLE.
(a) Get the correct installation tool. Make sure that the tool has the correct driving
attachments for the type and diameter of the blind rivet.

NOTE: A supply of air under pressure is necessary for power operated installation tools.
(b) Clamp the repair materials so that all the holes are aligned.
(c) Put the blind rivet in the hole.

NOTE: If a 'wet assembly' is necessary, or is specified, refer to Chapter 51-76-11.

(d) Put the installation tool on the blind rivet. Make sure that the blind rivet is correctly seated
on the material face. Operate the tool to install the blind rivet.

NOTE: The broken part of the pin is automatically pushed out of the tool when the
installation operation is completed.
(e) Mill the end of the pin until it is in line with the body head, if this is necessary.

NOTE: Special tools are available for this step.

(f) Do the inspection procedure that is given in Paragraph
2.
.
L.
.

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(5)
.
(5) Inspection and Permitted Limits
(a) After you have installed blind rivets, make an inspection of them to make sure that they
are correctly installed. This inspection must make sure:
- that the body head touches the material correctly. This is done visually only,
- that the lock-collar is correctly installed (Refer to Figure 063),
- that the pin is correctly installed (Refer to Figure 063),
- that the 'blind' head is correctly formed. This is a visual inspection that you do if you
can see the head,
- that the top of the head of a countersunk blind rivet is in line with, or only a little
above, the top face of the repair (Refer to Chapter 51-10-00 ).

NOTE: If it is necessary, use equipment (for example, probe-light and inspection mirror)
to do the inspection where you cannot see.
(b) Deformation of the repair materials must not be more than the limits given in Chapter 51-
10-00.
(c) No cracks are permitted in any part of the blind rivet, or the adjacent structure.
(6) Removal Procedure (Refer to Figure 064)

CAUTION: TAKE CARE NOT TO CAUSE DAMAGE TO THE STRUCTURE WHEN YOU
DO THIS PROCEDURE.
(a) Make an accurate mark with a centre punch in the center of the end of the pin. This will
give a location for the twist-drill (Refer to step
2.
.
L.
.
(6)
.
(b)
).

CAUTION: DO NOT LET THE RIVET BODY TURN WHEN YOU DO THESE STEPS.
(b) Drill a hole in the pin to the bottom of the collar. Do this with a twist-drill that has a
diameter the same as the pin.
(c) Remove the lock-collar (Refer to Figure 064).
(d) Hit the remaining pin out of the rivet body. Do this with a parallel pin punch and a hammer.
(e) Get a twist-drill that has a diameter almost as large as the outer diameter of the rivet body.
Make an estimate to find how deep you will have to drill the hole in the river head. Put a
mechanical stop on the twist-drill to give the correct depth (Refer to Figure 064).
(f) Drill the hole in the head of the rivet.

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(g) Put a parallel pin punch in the drilled hole. The diameter of this pin punch must agree with
the hole diameter. Move the pin punch at an angle to break off the rivet head.
(h) Hit out the remaining shank of the rivet body. Do this with the same parallel pin punch
used in step
2.
.
L.
.
(6)
.
(g)
and a hammer.
M. Rivet-Blind (CHERRYLOCK)
(1) General (Refer to Figure 065 and Figure 066)
(a) There are three types of these blind rivets that are used for repair work on the aircraft.
These are:
- Standard CHERRYLOCK
- Bulbed CHERRYLOCK
- Oversize CHERRYLOCK
(b) These blind rivets are supplied as one piece and consist of three parts:
1 A tubular body that has a head at one end. Two types of head are available: a 100 °
countersunk head and a protruding head.
2 A pin that goes through the body. The pin has a head opposite the body head. It
also has a lock-groove, a break-off groove and pullgrooves. The pin head of the
bulbed type has also a shear ring. This makes sure that the pin breaks off at the
break-off groove in line with the top of the rivet head when the ring shears and
relocates on the pin head.
3 A lock-collar on the pin. When the blind-rivet is installed, the collar is swaged into
the lock-groove on the pin and in the head. This makes sure that the pin is locked
into the body.
(c) To identify the correct blind-rivet for a repair, or a replacement, refer to Chapter 51-40-12.
(d) These blind rivets are supplied with a layer of lubricant on them. Do not clean them, or
touch them more than is necessary, before they are installed.
(e) Do not install blind rivets that are not in a satisfactory condition. Discard any that are not.
(f) You can use hand or power operated tools to install blind rivets. These tools must have
the correct heads attached to them.
(g) It is recommended that you do a test procedure on some unwanted materials before you
install blind rivets. Do the test on materials that are the same (type and thickness) as the
repair materials. Use blind rivets that are the same (head type, diameter and grip-length),
as those for the repair.
(h)

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After you have installed a blind rivet, the end of the pin can be above the rivet head. You
can mill the pin until it is in line with the top of the rivet head.
(2) Hole Preparation
(a) The holes for blind rivets are only drill-finished. It is not necessary to ream them.
(b) Before you install a blind rivet, you must examine the hole, including the countersunk or
dimpled portion if applicable, to make sure that:
- it is clean,
- it has no burrs,
- it is not damaged.
(c) Refer to Chapter 51-44-00 to find the correct dimensions for the hole.
(d) Do these steps if a hole is damaged, or if a new hole is necessary.
1 Use grip-pins or clamps to make sure that the repair materials are correctly
clamped together.
2 Drill a pilot-hole in the correct position.
3 Drill the hole to the correct final dimension.
4 Deburr the hole.
(3) Selection of the Blind Rivet (Refer to Figure 067 and Figure 068)
(a) If the correct size for a replacement blind rivet is not known do the steps that follow:
1 Accurately measure the diameter of the hole. Refer to Chapter 51-44-00 if the
diameter of the hole is within the tolerances for a standard rivet, use a rivet of this
diameter. If the diameter of the hole is not within the tolerances, increase the hole
diameter to suit an oversize rivet if applicable, or the next standard size.
2 Find the grip-length that is necessary for the total thickness of the materials to be
attached. Use one of the two subsequent procedures to do this:
- Use standard equipment to measure the total thickness of the materials. This
will give you the second dash number of the blind rivet part number (Refer to
Figure 067 and/or Figure 068).
- Use a CHERRYLOCK grip-length gauge. This will give you the second dash
number.
(4) Installation Procedure

CAUTION: OBEY THE MANUFACTURERS INSTRUCTIONS BEFORE YOU USE THESE

TOOLS. THE INSTRUCTIONS WILL GIVE YOU THE NECESSARY
PRESSURES. THEY WILL ALSO GIVE YOU THE CORRECT DRIVING
ATTACHMENT TO USE.
(a) Get the correct installation tool. Make sure that the tool has the correct driving
attachments for the type and diameter of the blind rivet.

NOTE: A supply of air under pressure is necessary for power operated installation tools.
(b) Clamp the repair materials so that all the holes are aligned.

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(c) Put the blind rivet in the hole.

NOTE: If a 'wet assembly' is necessary, or is specified, refer to Chapter 51-76-11.

(d) Put the installation tool on the blind rivet. Make sure that the blind rivet is correctly seated
on the material face. Operate the tool to install the blind rivet.

NOTE: The broken part of the pin is automatically pushed out of the tool when the
installation operation is completed.
(e) Mill the end of the pin until it is in line with the body head, if this is necessary.

NOTE: Special tools are available for this step.

(f) Do the inspection procedure that is given in Paragraph
2.
.
M.
.
(5)
.
(5) Inspection and Permitted Limits
(a) After you have installed blind rivets, make an inspection of them to make sure that they
are correctly installed. This inspection must make sure:
- that the body head touches the material correctly. This is done visually only,
- that the lock-collar is correctly installed (Refer to Figure 069),
- that the pin is correctly installed (Refer to Figure 069),
- that the 'blind' head is correctly formed. This is a visual inspection that you do if you
can see the head,
- that the top of the head of a countersunk blind rivet is in line with, or only a little
above, the top face of the repair (Refer to Chapter 51-10-00).

NOTE: If it is necessary, use equipment (for example, probe-light and inspection mirror)
to do the inspection where you cannot see.
(b) Deformation of the repair materials must not be more than the limits given in Chapter 51-
10-00.
(c) No cracks are permitted in any part of the blind rivet, or the adjacent structure.
(6) Removal Procedure (Refer to Figure 070)

CAUTION: TAKE CARE NOT TO CAUSE DAMAGE TO THE STRUCTURE WHEN YOU
DO THIS PROCEDURE.
(a) Make an accurate mark with a centre punch in the center of the end of the pin. This will
give a location for the twist-drill (Refer to step
2.
.
M.
.

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(6)
.
(b)
).

CAUTION: DO NOT LET THE RIVET BODY TURN WHEN YOU DO THESE STEPS.
(b) Drill a hole in the pin to the bottom of the collar. Do this with a twist-drill that has a
diameter the same as the pin.
(c) Remove the lock-collar (Refer to Figure 070).
(d) Hit the remaining pin out of the rivet body. Do this with a parallel pin punch and a hammer.
(e) Get a twist-drill that has a diameter almost as large as the outer diameter of the rivet body.
Make an estimate to find how deep you will have to drill the hole in the rivet head. Put a
mechanical stop on the twist-drill to give the correct depth (Refer to Figure 070).
(f) Drill the hole in the head of the rivet.
(g) Put a parallel pin punch in the drilled hole. The diameter of this pin punch must agree with
the hole diameter. Move the pin punch at an angle to break off the rivet head.
(h) Hit out the remaining shank of the rivet body. Do this with the same parallel pin punch
used in step
2.
.
M.
.
(6)
.
(g)
and a hammer.
N. Pin (Swaged) (LOCKBOLT)
(1) General
(a) A pin (swaged) fastener is a two piece assembly consisting of:
1 A pin with a protruding or countersunk head. The shank of the pin includes grooves
on to which a collar is swaged, a tension break-off groove and pull-grooves. The
pull-grooves are only used for installing the pin (swaged) (Refer to Figure 071).
2 A collar that is swaged on to the locking grooves on the pin shank to secure the pin
(swaged) when it is installed (Refer to Figure 072)

NOTE: It is important that the collars are put on the pins with the collar facing the
correct way.
(b) Only corrosion resistant steel (CRS) or titanium pins (swaged) are used for repair work.
(c) A correctly installed pin (swaged) gives a strong but light weight fastener, and they are
available for tension or shear requirements (Refer to Figure 071).
(d)

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Pins (swaged) are installed in clearance and transition-fit holes when they are used to
repair steel or titanium structure.
(e) Pins (swaged) are installed in clearance-fit holes in structures that are a combination of
aluminum alloy and steel or titanium, unless otherwise specified in a repair procedure.

NOTE: If the hole size is only given for the steel or titanium in the combination above,
then the hole in the aluminum alloy part is an interference-fit.
(f) Pins (swaged) are supplied lubricated. This lubricant must not be removed before they are
intalled unless otherwise specified in an AIRBUS document.
(g) Repair parts must be temporarily secured with grip-pins or other suitable tools before pins
(swaged) are installed.
(h) Threaded pin fasteners are generally given as alternatives to swaged pin fasteners for the
reasons that follow:
- for swaged pins, special tooling is necessary for the installation,
- for swaged pins, good access is necessary.
When technically acceptable, the alternative part numbers will be called up in Chapter 51-
43-00, Fasteners Oversize and Alternative.
(i) Where pins (swaged) are installed in structure with surfaces that are not parallel, the limits
that follow apply:
- for CRS tension type pins (swaged), an angle up to 7 degrees is acceptable,
- for titanium tension type pins (swaged), an angle up to 5 degrees is acceptable,
except in the wing structure where the limit is 3 degrees,
- for titanium shear type pins (swaged), an angle up to 3 degrees is acceptable.
(j) All cutting tools (for example, drills, reamers and countersinks) used to prepare the hole
for a pin (swaged) must be in good condition. This is necessary to ensure that the surface
of the hole is smooth.
(k) Before installing pins (swaged) make sure that the pins and collars are as specified in the
repair procedure.

NOTE: If it is necessary to replace a pin (swaged) and the pin cannot be identified
contact AIRBUS.
(l) The shank of a pin (swaged) does not expand when the pin is installed, therefore the hole
for the pin must be prepared very accurately.
(m) The collar for pins (swaged) can only be swaged with a suitable power tool.
(n) The various manufacturer's of pins (swaged) and collars use different Part Numbering
methods. It is recommended that these items are stored in containers that show the
applicable part number and type of item.
(o) The identification number for pins (swaged) and collars is given in Chapter 51-40-12.
(p) Unless otherwise specified, pins (swaged) are 'wet installed' with sealant (Refer to
Chapter 51-76-11).
(2) Installation-General

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(a) Before you install pins (swaged), make sure that the holes are clean, smooth and
prepared in accordance with Chapter 51-44-00.
(b) When an existing hole is damaged or oversize, it is recommended to install the next
oversize threaded pin, if this is given as an alternative in Chapter 51-43-00. If it is
necessary to install a swaged pin, check access and tool requirements.
(c) If the grip-length is not specified for a pin (swaged) refer to Figure 073.
(3) Hole Preparation
(a) It is recommended that before installing pins (swaged) in the aircraft structure a test
installation is made on suitable test pieces. For this test use:
- materials of the same type and thickness as the repair parts and/or structure,
- pins (swaged) and collars of the same type as those required for the repair.
This test will help to make sure that the final fastener, tool and hole accuracy is obtained.
(b) Accurately mark the position for the pin (swaged) hole, make a mark with a centre punch
at this position.

NOTE: Only use a soft pencil to mark the position on aluminum alloy, and an approved
marker on titanium materials.
(c) Refer to Chapter 51-44-00 to find the applicable final hole diameter and fit required for the
pin (swaged). Use one of the methods that follows to cut the final hole.
1 Method 1.
a Drill an undersize hole with a suitable twist-drill. It is recommended that this
step is done with the drill machine mounted in a drilling jig or tripod. This is to
make sure that the centre-line of the hole is within 2 degrees of the
perpendicular.
b Ream the hole to the required final diameter with a reamer/arbor combination
tool shown in Figure 074.

NOTE: If the final hole is required to be countersunk, use a countersink bit

on the reamer.
c Deburr the hole edges, and cut a relief radius or chamfer as specified in
Chapter 51-44-00.

NOTE: Use cutting lubricant (FREON TB-1 or I.C.I. ARCTON-113) during

the drilling/reaming steps.
2 Method 2.
a Cut the hole in one step with a special drill reamer tool. Use a drilling jig or
tripod to make sure that the centre-line of the hole is within 2 degrees of the
perpendicular.
b If required, countersink the hole (Refer to Chapter 51-46-00).
c Do step of Method 1.
(d) Clean the repair area to remove unwanted lubricant and swarf.

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(e) Examine the hole to check that it is clean, smooth and has a good surface finish.
(4) Installation of Pin (Swaged)

CAUTION: REFER TO THE TOOL MANUFACTURERS INSTRUCTIONS BEFORE USING

A POWER TOOL TO INSTALL/SWAGE THESE PINS AND COLLARS. MAKE
SURE THAT THE TOOL PRESSURE REGULATOR CONTROL IS SET
CORRECTLY (HIGH OR LOW PRESSURE). FAILURE TO DO THIS CAN
CAUSE DAMAGE TO THE PIN AND/OR STRUCTURE.
(a) Three different procedures are used to install pins (swaged). These procedures are
related to the type of fit (interference, transition or clearance) that is required, and the type
of structure (thick or thin) in which the pins (swaged) will be installed. The procedures are
given in Figure 075, Figure 076 and Figure 077 as follows:
1 Interference or transition fit in any structure, refer to Figure 075.
2 Clearance fit in thin structure, refer to Figure 076.
3 Clearance fit in thick structure, refer to Figure 077.
(5) Inspection after Installation of Pin (Swaged) Heads
(a) The limits that follow are applicable to protruding head (also Refer to Figure 078), and
countersunk head (also Refer to Figure 079).
1 More than 50 % of the pins (swaged) in a row or pattern must have fully seated
heads.

NOTE: Fully seated means full metal-to-metal contact between the head and the
fastened material.
2 Less than 50 % of the pins (swaged) in a row or pattern can have a small gap
between the head and the fastened material. In this case there must be a minimum
of 25 % of the head circumference in full contact, and the gap must be within the
limits given in the applicable figure.

NOTE: This gap is not permitted on any two adjacent pins (swaged).
3 It is not permitted to correct the head seating after the collar has been swaged.
4 When the head seating is outside these limits, replace the fastener. In this case, if it
is necessary to install an oversize fastener refer to Chapter 51-43-00 for the
applicable oversize pin.
(6) Inspection of Pin Position and Swaged Collar
(a) After the installation of a pin (swaged) is completed it must be inspected. This inspection
is done visually and with the use of special gages. Figure 081 shows examples of the use
of typical gages. The gage must be held vertical to the material surface and central over
the pin. Refer to Figure 080 if the pin (swaged) is installed through a surface that slopes.
(b) The inspection requires:
1 A visual check that the collar is correctly swaged (Refer to Figure 082).

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2 A check (with the gages), that the correct length pin (swaged) has been installed,
and that the break length protrusion is correct.
(c) No cracks, scores or indentations caused by swaging are permitted in the collar.

NOTE: In the above examples, details A, B and C are read as follows:

- Example A This shows that the collar has remained totally unswaged (not
acceptable). Replace the fastener assembly.
- Example B This shows that the collar has not been fully swaged (not acceptable).
Replace the fastener assembly.
- Example C This shows a correctly swaged collar. When you have made the
inspection, make a mark on the fastener with inspection lacquer if the fastener is
correct.
(7) Pin (Swaged) Removal (Refer to Figure 083, Figure 084, Figure 085 and Figure 086)
(a) General
When it is necessary to remove a pin (swaged) use one of the methods that follow:

NOTE: It is recommended that Method 1 is used for a small number of pins, and
Methods 2 or 3 for a large number of pins.
(b) Removal Method 1 (Manual Splitter Tool)
1 To remove the collars, use the manual splitter tool to break them. This tool is of the
42-dash series, supplied by HUCK Manufacturing Co. (Refer to Figure 083).
2 Adjust the cutting jaws of the splitter tool to the applicable diameter of the pin (Refer
to Figure 083).
3 Cut the collar.
4 Remove the cut collar from the pin.
5 Examine the pin at the locking grooves for metal projections that are possibly
caused by the collar splitter tool.
6 If there are projections, remove them with a file to prevent damage to the structure
when the pin is removed.
7 Put the correct back-up dolly in position to support the structure around the pin
head.
8 Hit the pin out of its hole with a hammer and parallel punch of a smaller diameter
than the fastener shank.
9 Examine the hole for damage or distortion.

NOTE: If the hole condition is satisfactory, you can use another pin (swaged) of
the same diameter as the original pin.
(c) Removal Method 2 (Power Splitter Tool)
1 To remove the collars, use the power splitter tool to break them. This tool is of the
20034-dash series, supplied by BROWN LINE Manufacturing Co. (Refer to Figure
084).

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2 To complete the removal procedure, do the steps given in paragraph

2.
.
N.
.
(7)
.
(b)
.
3
thru
2.
.
N.
.
(7)
.
(b)
.
9
.
(d) Removal Method 3 (Hollow Mill Cutter)
1 To remove the collar use the hollow mill cutter to mill it carefully from the pin. This
tool is of the 1297-dash series, installed in a micro-stop gage (AVON-1116 series),
fitted with a locator end-sleeve (1239-dash series), (Refer to Figure 085).
2 Put the milling tool on the collar. Make sure that the tool is vertical to material face.
3 Operate the tool and mill the collar until all of it is removed.
4 To complete the removal procedure, do the steps given in paragraph
2.
.
N.
.
(7)
.
(b)
.
5
thru
2.
.
N.
.
(7)
.
(b)

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.
9
.
(e) Removal Method 4 (Chisel and Back-up Dolly)
1 Put a protective washer in the position as shown in Figure 086. This washer is to
prevent damage to the material when you do the steps
2.
.
N.
.
(7)
.
(e)
.
1
thru
2.
.
N.
.
(7)
.
(e)
.
5
below.
2 Hold a back-up dolly against the collar (Refer to Figure 086).
3 Put the chisel against the collar (Refer to Figure 086).
4 Hit the chisel with a hammer to break the collar.
5 Do the steps
2.
.
N.
.
(7)
.
(e)
.
1
,
2.
.
N.
.
(7)

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.
(e)
.
3
and
2.
.
N.
.
(7)
.
(e)
.
4
again, but on the opposite side of the coller.
6 Remove the protective washer.
7 To complete the removal procedure, do the steps given in paragraph
2.
.
N.
.
(7)
.
(b)
.
5
thru
2.
.
N.
.
(7)
.
(b)
.
9
.
O. Bolt-Blind (Jo-bolt/AVDEL/VISU-LOK)
(1) General (Refer to Figure 087)
(a) The Bolt-Blind is a three-part fastener assembly. The parts are:
1 A bolt with a plain head. The bolt shank has a left-hand thread along all of its length
(the reason for the left-hand thread is given in Paragraph ). There are two machined
flats along the shank on the end opposite the head. The length of the shank with
the flats is approximately 40 % of the total length of the shank. This part of the
shank is broken off when the Bolt-Blind is installed.

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2 A hexagonal or countersunk headed nut. The nut has a shank that is tapered
externally at the end opposite the head. The Bolt-Blind (VISU-LOK) includes a
mechanical locking feature on the tapered face of the nut. There is an internal left-
hand thread along all the length of the nut.
3 A sleeve that is put on the bolt between the bolt head and the tapered end of the
nut.
(b) Bolts-Blind are high-strength fasteners. They are used:
- in locations that only have access from one side,
- where space prevents the use of a standard rivet or fastener,
- when they are specified in a repair procedure.
(c) The nut and the bolt are made of high-tensile steel, or stainless steel. The sleeve is made
of stainless steel.
(d) Do not install Bolts-Blind where the surfaces of the materials are more than 7° out of
parallel (3° on the wing structure).
(e) Bolts-Blind are supplied with a layer of lubricant on them (all parts). Do not clean or touch
them more than is necessary before they are installed.
(f) Do not install any parts of a Bolt-Blind that are not in a satisfactory condition. Discard any
parts that are not.
(g) To identify the correct Bolt-Blind necessary for a repair, refer to Chapter 51-40-00.
(h) You can use hand or power-operated tools, to install Bolts-Blind. The tool must have the
correct drive assembly attached to it.
(i) It is recommended that you do a test procedure on some unwanted material before you
install Bolts-Blind. Do the test on materials that are the same (type and thickness) as the
repair materials. Use Bolts-Blind for the test that are the same (head type, diameter and
grip-length) as those for the repair.
(j) The installation procedure for the Bolts-Blind is given in detail in paragraphs
2.
.
O.
.
(2)
thru
2.
.
O.
.
(5)
.The subsequent steps give, in general, the procedure (Refer to Figure 088):
- the fastener assembly is put in the prepared hole,
- the installation tool is put on the bolt end and the nut,
- the bolt is turned into the nut (this is why the bolt and the nut have left-hand
threads),
- the plain head of the bolt pushes the sleeve over the tapered end of the nut,

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- at the correct torque, the part of the bolt shank with the flats breaks off,
- the installation tool is removed,
- the broken part of the bolt shank is pushed out of the installation tool automatically.

NOTE: When the sleeve is pushed over the tapered end of the nut, the shape of the
sleeve is changed. This causes two things:
- the tapered end of the nut is compressed, this causes a friction-lock between the
bolt and the nut,
- the end of the sleeve that is opposite the plain head of the bolt is pushed out. This
causes the sleeve to hold the fastener tight in the structure.
(2) Hole Preparation (Refer to Chapter 51-44-00)
(a) Holes for Bolts-Blind are drill-finished, or ream-finished. Refer to Chapter 51-44-00.
(b) Before a Bolt-Blind is installed you must examine the hole to make sure that:
- it is clean,
- it has no burrs,
- it is not damaged.
(c) Refer to Chapter 51-44-00 to find the correct dimension for the hole that is applicable to
the Bolt-Blind nominal diameter.
(d) Do the subsequent steps if a hole is damaged, or if a new hole is necessary.
1 Use grip-pins or clamps to make sure that the repair materials are correctly held
together.
2 Drill a pilot hole in the correct position.
3 Drill or ream the hole to the applicable dimension (Refer to Chapter 51-44-00).

CAUTION: DO NOT MAKE A CHAMFER AT THIS END OF THE HOLE. A

CHAMFER WOULD DECREASE THE AREA THAT THE SLEEVE
TOUCHES.
4 Deburr the hole carefully at the end where the sleeve will touch.
5 Make the relief radius, or the countersink and relief radius, as necessary, on the nut
end of the hole (Refer to Chapter 51-44-00).
(3) Selection of Bolt-Blind
(a) If the Bolt-Blind is not identified by a part number in the repair procedure, do the
subsequent steps to find the correct Bolt-Blind.
1 Measure the hole to find its diameter.
2 Refer to the subsequent table and find the first dash number necessary.

First dash number applicable

Hole nominal diameter NSA
AVDEL ASNA
New Old

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0.165 in (4.20 mm) 5 -2 -2 -164

0.191 in (4.85 mm) 6 -3 -3 -190
1/4 in (6.35 mm) 8 -4 -4 -249
5/16 in (7.94 mm) 10 -5 -5 -312

Table 47

NOTE: The new and the old first dash numbers are given to help you to make a
cross-reference if it is necessary.
3 Find the grip-length necessary for the total thickness of the materials to be
attached. Use one of the two subsequent procedures to do this:
- use standard equipement to measure the total thickness of the materials
(Refer to Figure 089). This will give you the second dash number of a Bolt-
Blind part number,
- or use a Bolt-Blind grip-length gage (Refer to Figure 090). This will give you
the second dash number.
4 Refer to Chapter 51-40-12 to find the full data for the Bolt-Blind necessary for the
repair.
(4) Installation Procedure
(a) Get the correct installation tool (hexagonal or countersunk head) for the applicable Bolt-
Blind (Refer to Figure 091).
(b) Assemble a Bolt-Blind that is correct for the hole. Make sure that the nut is turned on to
the bolt finger tight only.
(c) Put the Bolt-Blind into the hole.
(d) Use the tool to hold the nut and turn the bolt. Do this until the shank of the bolt breaks off
at the special groove (Refer to Figure 092).
(e) Remove the installation tool.
(f) Make the end of the bolt shank smooth.
(g) Do the inspection procedure that is given in Paragraph
2.
.
O.
.
(5)
.
(5) Inspection and Permitted Limits
(a) General
1 After you have installed Bolts-Blind, make an inspection of them to make sure that
they are correctly installed. This inspection must make sure:
- that the tightness of the bolt is correct (Refer to Paragraph

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2.
.
O.
.
(5)
.
(b)
)
- that the bolt shank has broken at the correct position (Refer to Figure 093),
- that the nut head touches the material correctly (Refer to Figure 094),
- that the sleeve is correctly formed (swaged), where it is possible (Refer to
Figure 095),
- that the top of the head of a countersunk bolt-blind is in line with, or only a
small dimension above, the top face of the repair (Refer to Chapter 51-10-00).

NOTE: If it is necessary, use equipment (for example, probe-light and inspection

mirror) to do an inspection where you cannot see.

DIAMETER DASH BOLT- COUNTERSUNK

HEXAGONAL HEAD
NUMBER BLIND N HEAD
OMINAL
DIAMETE DIM. A DIM. B DIM. C DIM. D
NSA AV
AS R (MIN) (MAX) (MIN) (MAX)
DE
NA
OL NE L
in mm in mm in mm in mm in mm
D W
-16 0.00 0.08 0.02 0.06
-2 -2 5 0.15 4.0 0.00 2.25 0.50 1.70
4 0 9 0 7
-19 0.01 0.10 0.01 0.08
-3 -3 6 0.18 4.8 0.25 2.65 0.40 2.10
0 0 4 6 3
-24 0.04 0.13 0.01 0.07
-4 -4 8 0.25 6.4 1.20 3.45 0.25 2.00
9 7 6 0 9
-31 0.03 0.14 0.01 0.08
-5 -5 10 0.31 8.0 0.85 3.70 0.30 2.10
2 3 6 2 3

Table 48
2 Deformation of the repair materials must not be more than the limits given in
Chapter 51-10-00.
3 No cracks are permitted in any part of the bolt-blind, or the adjacent structure.
(b) Tightness
Do the subsequent test to find if the tightness is correct.
1 Get a torque wrench of the correct torque value for the bolt-blind nominal diameter.
Refer to the subsequent table.

Bolt-blind Nominal Diameter

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NSA Applicable
Torque
ASNA New OLD AVDEL
4 lbf. in (0.05
-2 -164
[Link])
6 lbf. in (0.07
-3 -190
[Link])
10 lbf. in (0.11
-4 -249
[Link])
20 lbf. in (0.22
-5 -372
[Link])

Table 49
2 Install the correct nose-piece (hexagonal or countersunk head) on the torque
spanner.

CAUTION: DO NOT USE MORE THAN THE APPLICABLE TORQUE IN THIS STEP.
3 Use the torque wrench and try to turn the bolt-blind in a counterclockwise direction.
If the bolt does not turn, it is correctly installed; if it does turn, replace it.
(6) Removal Procedure
(a) General
1 To remove a bolt-blind it is necessary to drill the head. A special tool is available to
help you to do this procedure. This tool is available for each type (hexagonal and
countersunk head) and diameter of bolts-blind. The tool has a drill guide at each
end. One guide is for a pilot-drill, the other guide is for a final dimension drill. The
guides are made to agree with the type of bolt-blind (Refer to Figure 096).
2 It is recommended that you use 18 % tungsten twist-drill for this procedure.
(b) Procedure (Refer to Figure 096).
1 Put the applicable twist-drill (in a drill-machine) into the hole in the pilot-drill guide
end of the special tool.

NOTE: The applicable twist-drill is that which agrees with the internal diameter of
the drill guide.
2 Put the drill guide on the nut head of the bolt-blind. Drill a hole only to the bottom of
the nut head, not the shank. Remove the twistdrill and the tool from the nut head.
3 Do step
2.
.
O.
.
(6)

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.
(b)
.
2
again, but use a final dimension twist-drill in the final dimension guide of the special
tool.
4 Put a parallel pin punch in the drilled hole and hit the pin punch with a hammer.
This will cause the nut head to break off. Hit out the bolt shank.
P. Rivet-Blind (CHERRY PULL-THROUGH)
(Refer to Figure 097)
(1) General
(a) In this paragraph the Rivet (Blind) (CHERRY PULL-THROUGH) is referred to as Pull-
through rivet.
(b) The Pull-through rivet consists of two parts. These are:
1 A tubular body that has a protruding or 100° countersunk head.
2 A serrated mandrel that is retained in the tubular body. The mandrel has a conical
upsetting head. As the gun pulls this head into the rivet shank, a blind "tulip-head"
is formed. When this head is tightly formed against the sheet, the upsetting head of
the mandrel collapses and passes through the rivet, expanding the shank (Refer to
Figure 097).
(c) The Pull-through rivet has an identification number. This number and its specific details
are explained in Chapter 51-40-12.
(d) Pull-through rivets can be installed by pneumatic-hydraulic power or hand operated tools.
(e) Pull-through rivets must only be used when they are called up in a specific repair
procedure or other AIB approved documents.
(f) Before the installation of pull-through rivets make sure that:
- the rivet type is correct,
- the rivets are made of the required material,
- the rivets have the specified surface protection and/or lubrication, and that they are
not corroded or scratched,
- the rivets are of the correct length and diameter,
- the hole for the rivets are correctly prepared.
(2) Installation Procedure
(a) Make sure that the rivets are of the correct dimensions (diameter and length). If the length
is not known refer to Figure 098.
(b) Refer to Chapter 51-44-00 to find the correct dimension for the hole that is applicable to
the pull-through rivet nominal diameter.
(c) Drill the hole to the required diameter (Refer to Chapter 51-44-00 ).
(d) Make sure that the hole, including the countersunk, is in a satisfactory condition, clean
and free from burrs.

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(e) Make sure that the installation tool is correct for the rivet dimensions and head shape.
(f) Insert the rivet mandrel fully into the installation tool.
(g) Insert the rivet body fully into the hole. Make sure that the installation tool nose is
perpendicular to the material surface.
(h) Operate the tool to complete the installation of the rivet.
(i) Remove the installation tool and make sure that the rivet is installed correctly.
(3) Inspection after Installation
(a) General
1 Carefully examine the installed rivets as far as possible.

NOTE: You are recommended to use inspection aids, for example, probe light
and mirror, to examine the 'blind' head.
2 The pull-through rivet is correctly installed when:
- the manufactured head is correctly seated,
- the blind head is correctly shaped,
- the surrounding structure is free from damage and distortion.
3 Deformation or buckling of the skin is not permitted outside the limits given in
Chapter 51-10-00.
4 The manufactured head of a countersunk rivet must be flush, or within the limits
given in Chapter 51-10-00.

NOMI GRIP-LENGTH T RANGE SECO L ± 0.010 in (

NAL ND D F MAX.
MIN. MAX. ± 0.25 mm)
RIVET ASH
DIA in mm in mm NO. in mm in mm
0.062 1.57 1 0.130 3.30 0.218 5.54
0.063 1.60 0.125 3.17 2 0.193 4.90 0.281 7.14
0.126 3.20 0.187 4.75 3 0.255 6.48 0.343 8.71
0.188 4.77 0.250 6.35 4 0.318 8.08 0.405 10.29
0.251 6.37 0.312 7.92 5 0.380 9.65 0.468 11.89
0.313 7.95 0.375 9.52 6 0.443 11.25 0.530 13.46
3/32"
(-3) 0.376 9.55 0.437 11.10 7 0.505 12.83 0.593 15.06
0.438 11.21 0.500 12.70 8 0.568 14.43 0.656 16.66
0.501 12.72 0.562 14.27 9 0.630 16.00 0.718 18.24
0.563 14.30 0.625 15.87 10 0.693 17.60 0.781 19.84
0.626 15.90 0.687 17.45 11 0.755 19.18 0.843 21.41

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0.688 17.47 0.750 19.05 12 0.818 20.78 0.905 23.00

0.062 1.57 1 0.160 4.06 0.274 6.96
0.063 1.60 0.125 3.17 2 0.222 5.64 0.336 8.53
0.126 3.20 0.187 4.75 3 0.285 7.24 0.399 10.13
0.188 4.77 0.250 6.35 4 0.347 8.81 0.461 11.71
0.251 6.37 0.312 7.92 5 0.410 10.41 0.524 13.31

1/8" 0.313 7.95 0.375 9.52 6 0.472 11.99 0.586 14.88

(-4) 0.376 9.55 0.437 11.10 7 0.535 13.59 0.649 16.48
0.438 11.21 0.500 12.70 8 0.597 15.16 0.711 18.06
0.501 12.72 0.562 14.27 9 0.660 16.76 0.774 19.66
0.563 14.30 0.625 15.87 10 0.722 18.34 0.836 21.23
0.626 15.90 0.687 17.45 11 0.785 19.94 0.899 22.83
0.688 17.47 0.750 19.05 12 0.847 21.51 0.961 24.41

Table 50

NOTE: How to use this data:

- 1. Measure the material thickness (T). For example = 0.315 in (8.0 mm).
- 2. Find in the table the grip-length range which includes this thickness. In this
example it is 0.313 in (7.95 mm) to 0.375 in (9.52 mm).
- 3. Thus the second dash number necessary, which is related to the grip
range found in step 2 is 6.
(b) Acceptance Limits
1 Due to the varying degrees of functional importance of installed pull-through rivets,
acceptance or rejection is mostly at the discretion of the inspector.
2 As general guide, reject loose or cracked rivets.
(4) Removal of Pull-Through Rivets

CAUTION: WHEN REMOVING RIVETS, TAKE CARE NOT TO CAUSE DAMAGE TO THE
STRUCTURE, ESPECIALLY WHEN THE SKIN IS THIN.

CAUTION: IF THE RIVET TURNS DURING DRILLING OPERATIONS, DAMAGE CAN BE

CAUSED TO THE SKIN/HOLE.
(a) The removal of pull-through rivets is achieved by first removing the manufactured head
then driving the remainder of the rivet out of its hole. With a twist-drill of the same nominal
diameter as the rivet drill almost through the head. It is recommended that a mechanical
stop is used on the twist-drill to control the depth drilled. With a parallel pin punch remove
the rivet head. With a parallel pin punch and hammer hit out the remainder of the rivet
body. The parallel pin punch diameter must be slightly less than the nominal diameter of

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the rivet, but greater than the rivet inner diameter. Support the structure on the underside
during this step.
Q. Rivet (Solid) (CHERRYBUCK)
(1) General
(a) It is recommended that only suitably trained and approved personnel do the work
necessary to install CHERRYBUCK rivets.
(b) The CHERRYBUCK rivet is a one piece bimetallic solid rivet. The rivet is manufactured
from two materials to give a high strength stem with an easily formable tail (Refer to
Figure 100).
(c) The CHERRYBUCK rivet is especially suitable for installation in composite/metallic or
composite structure. In a composite/metallic combination the upset head is formed on the
metallic material side.
(d) The CHERRYBUCK rivet can be used when it is necessary to form a countersunk upset
head (Refer to Figure 101)
(e) Good access and clearance is necessary to both sides of the area where CHERRYBUCK
rivets will be installed. This will allow the necessary drilling, installation and inspection
procedures to be done.
(f) The CHERRYBUCK rivet can be used where the structure surface is at an angle to the
rivet axis up to a maximum of 105. This is only permitted when the upset head is a flat
head (Refer to Figure 102).
(g) The upset head of the CHERRYBUCK rivet can be formed by:
1 Hand hammer (in metallic structure only).
2 Single or multistroke pneumatic hammer (not on carbon fiber reinforced plastic
(CFRP) structure).
3 Rivet squeezer.
4 Automatic riveter.
(h) When a 'wet installation' of CHERRYBUCK rivets is required refer to Chapter 51-76-00.
(2) Pretreatment of CHERRYBUCK Rivets
(a) No pretreatment is necessary for CHERRYBUCK rivets before they are installed.
(b) Any existing surface protection and lubrication on CHERRYBUCK rivets must be
preserved until after they are installed.
(3) Hole Preparation
(a) Holes must be prepared in accordance with the information given in Chapter 51-44-11.
(b) If it is required that the holes be countersunk refer to Chapter 51-46-11.
(4) Rivet Selection
(a) Grip length

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1 To determine the correct grip length of the rivet required, measure the thickness of
the materials to be joined using a suitable tool (Refer To Figure 103).
2 In an application wher a countersunk upset head is to be used, the measured sheet
thickness minus the countersunk depth for the upset head gives the required length
of the rivet (Refer to Figure 101).
3 Refer to the relevant ABS number in the Standards Manual to find the dash number
for the required length.
4 The weld joining the two materials of the rivet must not be outside the minimum grip
(Refer to Figure 104).
5 If a countersunk upset head is to be formed the weld must be above the
countersunk depth (Refer to Figure 101).

NOTE: CHERRYBUCK rivets must not be shortened.

NOTE: It is not permitted to use a CHERRYBUCK rivet in a material thickness
that is less than the minimum allowable value for the rivet (Refer to
paragraph
2.
.
E.
.
(1)
.
(h)
above). See also example 1 below.
Example 1: Material thickness to be joined = 5.537 mm (0.218 in).
Required grip length dash number = -4. A rivet with the dash number -4R
is not permitted because the grip range for this rivet is 5.562 mm (0.219
in) to 6.35 mm (0.250 in).
NOTE: The maximum allowable grip length may be exceeded by up to 0.78 mm
(0.031 in). AIRBUS must be contact for this concession that is only
applicable for -5, -6 and -8 diameter rivets. See also example 2 below.
Example 2: Material thickness to be joined = 6.32 mm (0.249 in).
Required grip length dash number = -4R. If this grip length rivet is not
available a -4 rivet may be used with a concession from AIRBUS.
(b) Diameter
1 To determine the correct diameter rivet, accurately measure the diameter of the
hole. If the hole diameter is within the tolerances for a standard rivet (Refer to
Chapter 51-44-11), select a rivet of that diameter. If the hole is not within the
tolerances it will be necessary to increase the hole to the next standard diameter.
2 If the hole diameter is larger than that required for a -8 rivet contact AIRBUS for
advice.
(5) Installation
(a) CHERRYBUCK rivets are initially placed in the hole as follows:

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1 By hand in clearance fit holes.

2 By using a hammer with a plastic head, or a hammer and aluminum alloy mandrel
in interference fit holes.

NOTE: When placing the rivets in an interference hole, the structure must be
supported to prevent damage, for example, bulging or deformation.
Damage to the rivet is not acceptable at this stage.
(b) Use one of the methods that follow to form the upset head. The method used will depend
upon accessibility and the number of rivets to be installed.
1 Hand hammer and dolly. With this method the manufactured head is supported by
the dolly and the rivet tail is struck to form the required type of head.
2 Pneumatic hammer and dolly. These tools can be used in two ways as shown in
Figures 105 and 106.

NOTE: When using the methods given in paragraphs

2.
.
Q.
.
(5)
.
(b)
.
1
and
2.
.
Q.
.
(5)
.
(b)
.
2
above, the upset head should be formed with a few hammer blows as
necessary.
3 Automatic riveting tools. These tools are usually only suitable for production work.
4 It is a requirement that rivets that are to be painted or sealed, are cleaned after they
have been installed. Cleaning agents SOCOMOR DN108 or industrical alcohol are
recommended for this task.
(6) Inspection
(a) Checking the upset head dimensions.
1 Refer to Figure 107 for the acceptable dimensions of a flat upset head.

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2 A countersunk upset head must fill the countersink fully. Unless specified otherwise
in an AIRBUS engineering document the countersink head must be filled flush
(Refer to Figure 101).
(b) Manufactured head faults.
1 A gap of 0.1 mm (0.004 in) maximum is permitted between the stucture surface and
the manufactured head (Refer to Figure 108). This fault is permitted on up to 10%
of the rivets but not on two adjacent rivets.
2 An 'apparent' circumferential gap at the chamfer around the countersink is permitted
(Refer to Figure 108).
(c) Upset head faults (Refer to Figure 109).
1 No cracks are permitted in the upset head.
2 A malformed upset head is permitted providing that the head is within the limits
given in Figure 107. In cases where 'H' minimum is less than that given in Figure
107, it is permitted to have up to 10% of the rivets with this fault providing:
a That the mean head height is equal to or greater than 1/3rd of the rivet
nominal diameter (D).
b Two adjacent rivets are not affected.
c Rivets at the end of a row are not affected.
3 A stepped head is permitted providing that after the step has been removed the
head is within the limits given in Figure 107.
4 It is permitted for the upset head to be eccentric to the rivet stem providing:
a The hole is not visible.
b The upset head does not touch the circumference of the rivet stem.
5 A bell shaped upset head is not permitted. This shape is usually the result of using
a riveting dolly that is too light.
6 The upset head must be formed at a right angle to the rivet axis in the case of
installation in an angled surface, not parallel to the angled face.
(d) Buckling and distortion of the structure, and the protrusion of the external rivet heads must
be within the limits given in Chapter 51-10-00.
(7) Removal of CHERRYBUCK rivets
(a) When it is necessary to remove CHERRYBUCK rivets care must be taken to avoid
damaging the rivet holes and surrounding structure. Where possible the rivet should be
removed by first removing the manufactured head. During the removal process take care
to ensure that debris from the rivet does not fall into inaccessible areas.
(b) Three basic steps are necessary to remove a rivet, these are:
1 Drill to the depth of head with a twist drill that is 0.2 mm (0.008 in) smaller than the
nominal diameter of the rivet, refer to Figure 110, step 1. Rivets that have a long
grip length may be drilled deeper.

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2 Break off the drilled head with a parallel pin punch, refer to Figure 110, step 2.
3 Drive out the remaining rivet stem with a parallel pin punch, the diameter of the pin
punch must be slightly smaller than the rivet stem diameter, refer to Figure 110,
step 3. The structure must be supported during this step.
(8) Hole Inspection
(a) After removing a CHERRYBUCK rivet, the hole must be inspected for:
- ovality,
- scoring,
- other damage.
(b) If the hole is found to be unsatisfactory it must be enlarged to the next standard diameter
rivet, refer to paragraph
2.
.
Q.
.
(3)
.
R. Rivet (Solid) (CHERRY E-Z BUCK)
(1) General
(a) It is recommended that only suitably trained and approved personnel do the work
necessary to install CHERRY E-Z BUCK rivets.
(b) The CHERRY E-Z BUCK rivet is a solid rivet that is manufactured from a ductile titanium
/columbium alloy which deforms the full length of the rivet shank so it fills the rivet hole
when installed (Refer to Figure 111).
(c) The CHERRY E-Z BUCK rivet is especially suitable for installation in composite/metallic
and metallic structure. The upset head is formed on the metallic material side.
(d) The CHERRY E-Z BUCK rivet can be used when it is necessary to form a countersunk
upset head (Refer to Figure 112).
(e) Good access and clearance is necessary to both sides of the area where CHERRY E-Z
BUCK rivets will be installed. This will allow the necessary drilling, installation and
inspection procedures to be done.
(f) The CHERRY E-Z BUCK rivet can be used where the structure surface is at an angle to
the rivet axis up to a maximum of 10°. This is only permitted when the upset head is a flat
head (Refer to Figure 113).
(g) The upset head of the CHERRY E-Z BUCK rivet can be formed by:
1 Hand hammer (in metallic structure only).
2 Single or multistroke pneumatic hammer (not on carbon fiber reinforced plastic
(CFRP) structure).
3 Rivet squeezer.

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4 Automatic riveter.
(h) When a 'wet installation' of the CHERRY E-Z BUCK rivet is required refer to Chapter 51-
76-00.
(2) Pretreatment of CHERRY E-Z BUCK rivets
(a) No pretreatment is necessary for CHERRY E-Z BUCK rivets before they are installed.
(b) Any existing surface protection and lubrication on CHERRY E-Z BUCK rivets must be
preserved until after they are installed.
(3) Hole Preparation
(a) Holes must be prepared in accordance with the information given in Chapter 51-44-11.
(b) If it is required that the holes be countersunk refer to Chapter 51-46-11.
(4) Rivet Selection
(a) Rivet length
1 To determine the correct length of the rivet required, measure the thickness of the
materials to be joined (grip length), using a suitable tool (Refer to Figure 114 and
115) and add the required backside protrusion (Refer to Figure 115).
2 In an application where a countersunk upset head is to be used, the measured
sheet thickness, plus an additional length 'X' to achieve optimal filling of the
countersunk hole gives the required length of the rivet, plus the required backside
protrusion (Refer to Figure 116).
(b) Diameter
1 To determine the correct diameter rivet, accurately measure the diameter of the
hole. If the hole diameter is within the tolerances for a standard rivet (Refer to
Chapter 51-44-11), select a rivet of that diameter. If the hole is not within the
tolerances it will be necessary to increase the hole to the next standard diameter.
2 If the hole diameter is larger than that required for a -6 rivet contact AIRBUS for
advice.
(5) Installation
(a) CHERRY E-Z BUCK rivets are initially placed in the clearance fit hole by hand.
(b) Use one of the methods that follow to form the upset head. The method used will depend
upon accessibility and the number of rivets to be installed.
1 Hand hammer and dolly: With this method the manufactured head is supported by
the dolly and the rivet tail is struck to form the required type of head.
2 Pneumatic hammer and dolly: These tools can be used in two ways as shown in
Figures 117 and 118.

NOTE: When using the methods given in paragraphs

2.
.

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R.
.
(5)
.
(b)
.
1
and
2.
.
R.
.
(5)
.
(b)
.
2
above, the upset head should be formed with as few hammer blows as
necessary.
3 Automatic riveting tools: These tools are usually only suitable for production work.
4 It is a requirement that rivets that are to be painted or sealed, are cleaned after they
have been installed. Cleaning agents SOCOMOR DN108 or industrial alcohol are
recommended for this task.
(c) Milling of Countersunk Heads
When it is necessary to mill the heads of the CHERRY E-Z BUCK countersunk rivets care
must be taken to avoid damaging the structure. The heads of the countersunk rivets can
be milled using a plain cylindrical milling cutter with carbide cutting edges. The speed of
the milling cutter should be approximately 3000 rpm. The equipment must have a height
adjustment stop.

NOTE: A riveted sample must be used to verify the adjustment of the milling cutter and
to secure the correct setting. This is necessary to avoid damage to the structure
where the rivets to be milled are installed.
1 Manufactured Countersunk Head
Any protrusion of a rivet head that is outside the tolerance can be milled if the
protrusion is not more than 10% of height of the head (Refer to Figure 119).
2 Countersunk Upset Head
The relevant data for reworking the countersunk upset head will be given in the
specific SRM repair or an AIRBUS engineering document. Unless specified the
countersink head must be milled flush (Refer to Figure 112).
(6) Inspection
(a) Checking the upset head dimensions.
1 Refer to Figure 120 for the acceptable dimensions of a flat upset head.
2

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A countersunk upset head must fill the countersink fully. Unless specified otherwise
in an AIRBUS engineering document the countersunk head must be milled flush
(Refer to Figure 112).
(b) Manufactured head faults.
1 A notch on the manufactured head is permitted within the limits given in Figure 121
(sheet 1).
2 A gap of 0.1 mm (0.004 in) maximum is permitted between the structure surface
and the manufactured head (Refer to Figure 121 (sheet 2)). This fault is permitted
on up to 10% of the rivets but not on two adjacent rivets.
3 An 'apparent' circumferential gap at the chamfer around the countersink is permitted
(Refer to Figure 121 (sheet 2)).
(c) Upset head faults (Refer to Figure 148)
1 No cracks are permitted in the upset head.
2 A malformed upset head is permitted providing that the head is within the limits
given in Figure 120. In case where 'H' minimum is less than that given in Figure 120
, it is permitted to have up to 10% 0f the rivets with this fault providing:
a That the mean head height is equal to or greater than 1/3rd of the nominal
diameter (D).
b More than two adjacent rivets are not affected.
3 A stepped head is permitted providing that after the step has been removed the
head is within the limits given in Figure 120.
4 It is permitted for the upset head to be eccentric to the rivet stem providing:
a The hole is not visible.
b The upset head does not touch the circumference of the rivet stem.
5 A bell shaped upset head is not permitted. This shape is usually the result of using
a riveting dolly that is too light.
6 The upset head must be formed at a right angle to the rivet axis in the case of
installation in an angled surface, not parallel to the angled face.
7 A measurable gap for a countersunk upset head is not permitted, but an 'apparent'
gap is permitted if it is not circumferential.
(d) Buckling and distortion of the structure, and the protrusion of external rivet heads must be
within the limits given in Chapter 51-10-00.
(e) Gap between Components
A gap of 0.3 mm (0.012 in) maximum between components is permitted between any two
rivets. At the rivet shank the gap must not be more than 0.05 mm (0.002 in) (Refer to
Figure 149).
(7) Removal of CHERRY E-Z BUCK Rivets
(a)

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When it is necessary to remove CHERRY E-Z BUCK rivets care must be taken to avoid
damaging the rivet holes and surrounding structure. Where possible the rivet should be
removed by first removing the manufactured head. During the removal process take care
to ensure that debris from the rivet does not fall into inaccessible areas.
(b) Four basic steps are necessary to remove a rivet, these are:
1 Center-punch the rivet head. For thin-walled components use a dolly to support the
upset head. This will give a location for the twist drill tip, refer to Figure 150, step 1.
2 Drill to the depth of the head with a twist drill that is 0.2 mm (0.008 in) smaller than
the nominal diameter of the rivet, refer to Figure 150, step 2. Rivets that have a long
grip length may be drilled deeper.
3 Break off the drilled head with a parallel pin punch, refer to Figure 150, step 3.
4 Drive out the remaining rivet stem with a parallel pin punch, the diameter of the pin
punch must be slightly smaller than the rivet stem diameter, refer to Figure 150,
step 4. The structure must be supported during this step.
(8) Hole Inspection
(a) After removing a CHERRY E-Z BUCK rivet, the hole must be inspected for:
- ovality,
- scoring,
- other damage.
(b) If the hole is found to be unsatisfactory it must be enlarged to the next standard diameter
rivet, refer to paragraph
2.
.
R.
.
(3)
.
S. Drilling of Bolt Threads
(1) General
(a) Drilling of the bolt on installation is allowed provided all necessary precautions are taken
to prevent weakening screw strength (in particular, non off centered drilling, correct
perpendicularity, correct bore diameter, slight deburring) and risks of corrosion
(installation using grease in the case of steel screws, reprotection if required).
(b) It is recommended to use pre-drilled bolts, suppliers have automatic machines that
guarantee that this procedure will be performed correctly.
(c) Holes for split pins may be drilled in bolts and studs either in-situ or after disassembly,
depending on the accessibility or material from which the parts are made. The holes are
then deburred prior to fitting the split pins.
(2) Limitations

NOTE:

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It is recommended that only trained and approved personnel perform shank drilling
procedure.
(a) Split Pin Holes
1 The split pin holes are to be protected by a jointing compound, that is the same
jointing compound as used for the assembly of the joint, unless stated otherwise in
the maintenance procedure.
2 Thin plain nuts and lightweight self-locking nuts are not to be locked with split pins,
unless stated otherwise in the repair or maintenance procedure.
(b) Split Pins and Associated Parts
1 Split pins are to be used once only.
2 Under no circumstances must split-pin holes be re-drilled to obtain alignment or be
opened up to accommodate a larger size split pin.
3 On assemblies where the bolt/stud has no split pin hole drilled but the maintenance
procedure calls for a split pin to be fitted, then the bolt/stud must only be drilled in
accordance with the following procedure.
4 Split pin hole centres must be a distance not less than twice the nominal diameter
of the split pin hole from the end of the bolt, or in the same position as the hole in
the removed bolt.
5 If not specified, requirements of the bolt standard must be respected for split pin
hole location and dimensions.
(3) Drilling Procedure of Bolt Shank Thread
(a) Install/screw the suitable drill guide on to the bolt/stud thread, positioning to enable the
split pin hole to be drilled to specific requirements and secure the bolt/stud and guide in a
vice, to carry out the drilling operation (Refer to Figure 122).
1 Where it is necessary to drill a hole in the bolt thread in-situ, a locally manufactured
drill guide may be used to locate the hole position.

NOTE: A suitable drill guide can be an home-made guide that allow to drill a hole
to the requirements of the present procedure and/or relevant bolt standard.
2 Where a bolt or stud can be removed, mark the hole location, remove the bolt/stud
from the assembly and install it in a drill guide. The bolt must preferably not be
drilled in-situ. When possible and especially for titanium bolts, the fastener should
preferably be routed to the machine shop for drilling and deburring, otherwise the
holes may be drilled using bench or pillar machines and suitable holding fixture.
3 Use of slotted nut or slave nut are not recommended because they offer inadequate
location during the drilling procedure.
(b) Set the drilling machine at a recommended cutting speed, ensuring that the machine and
the drill used for general purpose drilling (Refer to Chapter 51-44-11).
(c)

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Drill the holes to the procedure requirements or unless otherwise specified to bolt
standard requirements. If anywhere stated, cotter pin hole centerline must be within 0.25
mm (0.010 in) within 2° of bolt centerline.
(d) Deburr the drilled hole.
(e) Check the threads using a suitable nut ensuring that the nut can move freely on the thread
when finger pressure only is applied.

NOTE: If the bolt protective treatment is damaged, the bolt must be stripped and the
protective treatment re-applied.
(4) Quality Requirements
- make sure that dimensional requirements are fulfilled for the split pin hole,
- make sure that at least half the split pin diameter is located in the slot of the castellated
nut,
- make sure that the split pin has no longitudinal play.
(5) Examples of Hole Diameter for the majority of bolts

Bolt Diameter Split Pin Hole Diameter

mm in
mm in +0.254 +0.010
-0.000 -0.000
4.8 3/16 1.78 0.070
6.4 1/4
1.93 0.076
7.9 5/16
9.5 3/8
11.1 7/16 2.69 0.106
12.7 1/2
14.3 9/16
15.9 5/8
19 3/4
22.2 7/8 3.58 0.141
25.4 1
28.6 1-1/8
31.7 1-1/4

Table 51 - Examples of Hole Diameter

T. Double Countersunk Rivets
(1) General

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(a) This special procedure is only applicable to aluminum or monel rivets.

(b) It is recommended that only suitably trained and approved personnel do the work
necessary to install double countersunk rivets.
(c) Unless stated otherwise, the second countersink (100°) will have same dimensions as the
first one.
(d) The length of rivet to be used must be determined to avoid trimming: the volume of the
protruding metal shall be chosen so that it is slightly greater than the countersink to be
filled.
(e) A countersunk driven head must fill the countersink fully. Unless otherwise specified in an
AIRBUS engineering document, the countersunk head must be milled flush (Refer to
Figure 123).
U. High Interference Fit Fasteners - Removal and Repair
(1) General
(a) This section describes the removal and repair of the following High Interference Fit
Fasteners:
- Hi-Lite Pull-In (ABS0925, ABS0876 and ABS0997),
- Hi-Lite Pull-Stem (ABS0907),
- Pull-Type Studs (Threaded Pin),
- XPL Pin swaged.
(b) Hi-Lite Pull-In and Hi-Lite Pull-Stem are part of the threaded pin family. This system is
designed to allow good installation for interference fit. As a difference, compared to
normal Hi-Lite, the pin use a stem and specific tooling to pull the fastener into position. Hi-
Lite Pull-In and Hi-Lite Pull-Stem are particular adapted to interference and very high
interference fits.
(c) XPL Pin swaged (or XPL Lockbolt) is part of the pin swaged family. As normal pin
swaged, a stern is used for installation. This design is adapted to interference up to very
high interference fits. There are also applications in composite (clearance fit). This system
has a double grip capability and high mechanical performances due to the fact that
material of the swaged collar is of titanium alloy.
(d) For further information about Hi-Lite Pull-In, Hi-Lite Pull-Stem and XPL Pin swaged refer
to Figure 138.
(2) Fastener Identification - Head Marking
(a) For information about the head marking on Hi-Lite Pull-In, Hi-Lite Pull-Stem and XPL Pin
swaged fasteners, refer to Figure 139.
(3) Fastener Applications and Repairs
(a) Hi-Lite Pull-In, Hi-Lite Pull-Stem and XPL Pin swaged systems are capable for the
installation with a very high interference level (up to 120-200 interference for diameter 1.0
in). This very high interference fit is used in some areas with high fatigue loads. These
areas are:
- Wing to fuselage junction,
- Wing rear spar.

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NOTE: For repairs in the above mentioned areas, please contact AIRBUS.
(b) For very high interference fits (Hi-Lite Pull-In, Hi-Lite Pull-Stem and XPL fasteners) the
removal is manageable up to an average limit of 10/16 in in a maximum thickness of 48
/16 in. If a removal above this limits is necessary, please contact AIRBUS.
(c) Normal interference cases are repairable as for all other Hi-Lites or Bull Nose pins. For
such cases, a repair with Hi-Lite or Bull Nose pins may be applicable, refer to Chapter 51-
43-00.
(d) Please refer to drawing set for interference fit identification in case of doubt.
(e) "Pull-back" removal method from the head side. The removal is done by pulling the
fastener from the head side.
1 Removal by using mechanical extraction tools.
a Removal with mechanical extraction tools. For information about the removal
by drilling and trapping, refer to Figure 140.
b For information about the removal by pulling, refer to Figure 141 and 142.
Simple extraction tools can be home made.
2 Removal by using hydraulic extraction tools.
a Pull-in installation tools can also be used for removal.
b Please contact LISI Aerospace and ALCOA Fastening Systems for details on
applicable tools.
c For information about tooling for the removal procedure and removal data,
refer to Figure 143 and 144.
(f) "Push-out" removal method from the thread side.
1 This method is applicable for common SRM fits. For very high interference, special
assistance from AIRBUS is required.
(4) Installation
(a) Pull-type fasteners are mainly designed for production. But it might occasionally be
necessary to re-install same fastener types, refer to Figure 145.
(b) Installation tooling.

NOTE: Installation tooling are specific. Only experienced personnel can operate them.
1 For information about Hi-Lite Pull-In and Hi-Lite Pull-Stem tooling details, contact
LISI Aerospace.
2 For information about XPL Pin swaged tooling details, contact ALCOA Fastening
Systems.
(c) Break-Stem designs (diameter from 3/16 in to 8/16 in).
1 The installation of XPL Lockbolts is the same as for standard pin swaged.
Associated swaged collars are made from titanium alloy (ABS1505 for metallic
applications and ABS0999 for composite applications).

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2 The installation of Hi-Lite Pull-Stem, compared with normal Hi-Lites, uses and
additional break-stem. After installation with the appropriate tooling, the stem is
broken by bending. Then, as for all standard threaded pins, a nut is installed.
According to cases, ASNA5131 or ASNA2532 is applicable.
3 For information about the installation of swaged and threaded systems, refer to
Figure 146.
(d) Threaded-Stem designs (diameter # 8/16 in).
1 The general principle is the same as for installation. In this case, the stem is
screwed on the pin for installation, then unscrewed after installation.
2 For information about Threaded-Stem design, refer to Figure 147.
(5) Inspection after installation.
(a) For information about inspection after installation for Hi-Lite Pull-In and Hi-Lite Pull-Stem,
refer to Paragraph
2.
.
F.
.
(b) For information about inspection after installation for XPL Pin swaged fasteners, refer to
Paragraph
2.
.
N.
15.
V. Pin (Threaded) (Tension)

NOTE: For oversize installation, always use a washer under the nut to prevent clashing of the nut
with the shank of the bolt, unless the nut has the capability to be used with oversized bolt.

CAUTION: THIS PROCEDURE IS APPLICABLE TO FOLLOWING FASTENERS: A228,

ABS0110, ABS0853, ABS0927, ASNA2002, MS21134, MS21250, NSA5378,
NSA5398 AND NSA5399.
(1) General
(a) The pin (Tension) is a cylindrical pin fastener. It is available with a protruding head.
(b) The fastener has an external wrenching flanged end. This is used to drive or hold the
fastener during removal or installation of the nut and when it is difficult to access the nut.
(c) The fasteners are available in Alloy Steel, Corrosion Resistance Steel or Inconel material.
(d) The fasteners are secured with standard self-locking tension or castellation nuts.
(e) The fasteners are delivered pre-lubricated. Do not handle these fasteners more than is
necessary. Do not degrease them.
(f) These fasteners are installed in clearance fit holes.

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(g) It is recommended that only trained operators prepare the holes and install these
fasteners.
(2) Hole Preparation
(a) The holes for these fasteners must be prepared to give the correct fit and to a good
standard. They are prepared in three stages, these are:
- 1. Drill a pilot-hole (Refer to Chapter 51-44-00),
- 2. First stage boring by twist drill or reamer,
- 3. Final boring by a reamer.

NOTE: These stages only apply to new holes, for example, when you do a repair. For a
hole that already exists, it is only necessary to increase it to the correct oversize
diameter.
(b) The final hole diameter tolerances are given in Chapter 51-44-00.
1 When you drill or ream the holes for these fasteners you are recommended to use a
drilling jig or equivalent tool. This will help you to make sure that the hole is
perpendicular with the material.
2 Only use twist drills and reamers that are sharp and in good condition. This will
make sure that the holes are accurate and to a good condition.
(3) Hole Preparation Procedure
(a) You are recommended to use soluble oil or praffin to lubricate the twist drills and reamers
when you are preparing the holes.
(b) Refer to Chapter 51-44-00 (Hole and Drill Data) and select the correct size twist drill for
the pilot hole. Drill the pilot hole.

NOTE: In a repair procedure or other special circumstances, you can given a pilot hole
diameter that does not agree with the information in Chapter 51-44-00. In this
case use the alternative diameter.
(c) Do the first stage boring. You can use one of two methods to do this, these are:
1 With a twist drill, drill a hole that is approximately 0.05 mm (0.002 in) smaller than
the final hole.
2 With a reamer make a hole that is approximately 0.3 mm (0.012 in) smaller than the
final hole.

NOTE: After you have done this stage the entry to this hole must permit the use
of the final stage tool. You must be able to enter the final stage tool for at
least 1.0 mm (0.039 in).
(d) Carefully ream the holes to the final diameters that are given in Chapter 51-44-00.

NOTE: The surface roughness of the inner face of the holes must be less than 1.6
micrometers (63 micro inches).
(e) Deburr and radius or chamfer the entry and exist edges of the holes (Refer to Chapter 51-
44-00).

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(f) Check the final diameter of the holes with the applicable limit plug gage.
(4) Selection of Fastener Length
(a) You can use one of two methods that follow, to find the correct length of the fastener
required:
- Method 1: Refer to Figure 023 for the information how to use a grip length gage and
the relevant fastener data,
- Method 2: 1. Measure the thickness of the materials that are to be fastened. Use
suitable precision tools to do this. 2. Refer to Figure 023 (sheet 3) and select a
fastener of the correct length to fit the tolerance given.

NOTE: The diagram in Figure 023 (sheet 3) is for information only and is not an exact
feature of a typical Tension Bolt.
(5) Fastener Installation Procedure
The procedure that follows is applicable to steel, corrosion resistance or Inconel fasteners.
(a) Put the repair pieces into their correct position. Secure them with temporary bolts or Grip-
pins.

NOTE: Because the final fasteners will be hammered into position, you are
recommended to secure the materials through at least 50% of the holes. This is
to stop a gap forming between the materials.

CAUTION: IT IS IMPORTANT THAT YOU MAKE SURE THAT THE FASTENER IS

PERPENDICULAR TO THE HOLE BEFORE YOU DRIVE IT IN.
(b) Put the fastener in the hole and drive it in until the head is seated on the material. To do
this you can use a standard pneumatic hammer, either single or multi-hit. Use a rivet set
(snap) of a size that will not damage the fastener head or the material.

NOTE: Install all fasteners "wet" unless instructed differently in a repair procedure.
Refer to (Refer to Chapter 51-76-11) for sealing information.
(c) If applicable refer to Table 15, and and select the correct washer. It is important that you
only use washers of the correct thickness and internal diameter. If necessary two washers
may be used to get the correct thickness, but do not use washers of 0.4 mm (0.016 in)
thickness or less.

NOTE: It is recommended that you only use alloy steel or corrosion resistance washers.
Do not use a mixture of washer materials on the same fastener.
(d) Put the applicable nut on to the fastener. Tighten the nut to the correct torque value (Refer
to Chapter 51-49-00).

NOTE: If the type of nuts is not specified in the repair procedure select one that is
suitable from the list that follows: NSA5057 Nut, Self-locking 12 Point with
captive; NSA5373 Nut, Self-locking 12 Point Double durability; ASNA0094 Nut,
12 Point Self-locking; NSA5060 Nut, Castellated, Hexagon, Self-locking; SL4108
Nut, Castellated, Hexagon.
(6) Inspection After Installation (Refer to Figure 024).

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(a) After you have installed Tension Fasteners examine them for signs of the conditions
which follows:
- incorrect seating of the fastener head nut,
- damage to the structure,
- incorrect head alignment.
(b) Refer to Figure 024 for the limits that are applicable to conditions
2.
.
G.
.
(6)
.
(a)
.
1
,
2.
.
G.
.
(6)
.
(a)
.
2
and
2.
.
G.
.
(6)
.
(a)
.
3
.
To calculate the total protrusion of bolt beyond the part surface, the formula below shall be
used:
B = # T + C + Wt - Tp
For checking the correct fastener length, refer to Figure 152.
(7) Removal of Tension Fasteners
(a) There are 3 methods to remove a Tension Fastener, these are:
1 If you have good access to the threaded end of the fastener, use a Taper Knockout
Tool.
2 An alternative procedure is given below.

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NOTE: You are recommended to use the applicable power tools where possible
for this procedure, especially if many fasteners are to be removed.
a Loosen the nut until the fastener thread is in line with end of the nut.
b Support the structure around the fastener head.
c Drive the end of the nut with a composite headed mallet. This is to break the
bond between the fastener and the structure.
d Position the removal tool over the collar. Apply a steady hand pressure and
operate the tool to remove the collar. Discard the collar.

CAUTION: THE DIAMETER OF THE PIN PUNCH MUST BE LESS THAN THE
FASTENER DIAMETER.
e Support the structure around the fastener head and hit the fastener out with a
parallel pin punch and hammer. Discard the fastener.
3 Extraction tool option may be used if you do not have good access.
(b) Methods (1-) and (3-) are given in Paragraph
2.
.
H.
. of this Chapter.

NOTE: The removed Tension bolt may be reused if:

- the pin finish is not damaged,
The nuts must be discarded. You are not permitted to re-use them.
(8) Further Information
When a Tension Fastener is removed, further action to the hole is necessary as follows:
(a) Transition Fit Hole.
Measure the hole diameter and if the diameter is within the permitted tolerances (Refer to
Chapter 51-44-00) and in good condition, a replacement standard fastener can be used. If
the diameter is outside the permitted tolerances, the hole must be prepared for an
oversize fastener (Refer to Chapter 51-43-00).
(b) Clearance Fit Hole.
If the hole condition is good no further action is necessary. If the hole condition is not
acceptable, it must be prepared for an oversize fastener (Refer to Chapter 51-43-00).
W. Fastener Removal with E-drill Tooling

WARNING: FOR HEALTH, SAFETY AND ENVIRONMENT CONDITIONS, REFER TO THE

MANUFACTURER’S INSTRUCTIONS.
(1) General
(a) It is recommended that only trained personnel remove fasteners by using e-drill tooling.
(b) E-drill tooling can be used only on metallic assemblies to remove fasteners listed in Table
52.

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(c) E-drill tooling can be used to remove any of the fasteners listed in Table 52 and their
alternatives as per Chapter 51-43-00.

NOTE: Application covers all CSK and protruding types.

PART DIAMETER RANGE

NUMBER 3 4 5 6
ASNA2026 /
ASNA2027 /
X X X X
EN6114 /
EN6115
ABS0550 X X
ABS0548 X X X
NAS1790 X
NAS1321 X X

Table 52 - Fastener Types and Sizes

(2) Surface Preparation
Before using the tool to cut fastener head, it is necessary to remove paint (or any other
insulating layer) from the head of the fasteners which are to be removed with this process so
that electrical conductivity through the head of the fastener is ensured. Since the surrounding
surface is also used to seal in the Dielectric Water, rough surfaces around the fastener head
should also be cleaned of any debris or smoothed by covering with tape. Removing any surface
paint must be conducted in accordance with the requirement of the SRM.
(3) Removal Procedure

WARNING: WHEN USING ANY ELECTRIC DEVICE ON THE AIRFRAME, ENSURE THE
AIRFRAME IS GROUNDED. REFER TO SUPPLIER USER MANUAL FOR
DETAILS OF GROUNDING PROCESS.

CAUTION: BEFORE CUTTING, YOU MUST MAKE SURE THAT THE HAND-TOOL IS
CORRECTLY CONFIGURED. FAILURE TO USE THE CORRECT ADAPTOR
AND ELECTRODE CAN RESULT IN DAMAGE TO THE AIRFRAME.
(a) When it is necessary to remove any type of fastener, use one of the methods that follow:
1 Removal Method 1 (Part Number Selector)
a Press Select by part number on the home screen.
b Highlight the part number window and scroll down to the correct part number
and select it by pressing it.
c Hit Save to select that part number and load parameters from the library.
2 Removal Method 2 (Visual Selector)
a Press Select Visual on the home screen.

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b Progressing down the screen from top to bottom and left to right, in order
highlight and select Type, Method, Material, Head (or collar) Diameter range,
and Stem Size.
c Hit Save to accept the selection and load parameters from library.
d The system will select the correct cutting and depth parameters and
download them from the library, as soon as the Save button is pressed.
(b) Cutting Electrode Sizes and Electrode Guide Colour Matching:
1 There are 14 different standard Cutting Electrode sizes available to cover 14
different diameter fasteners between 5/32 inch and 3/8 inch. Electrodes are
designed to remove nominal, ’X’ (1st Oversize) and ’Y’ (2nd Oversize) fasteners
(refer to Table 53). This task is only valid for the sizes given in Table 53.
2 Cutting Electrodes are packaged with colour coded inserts and provided in kits of 5
each to match their sizes.
3 The e-drill Electrode Guides to be used in the e-drill adaptors are color-coded to
match. For convenience, each electrode is engraved with its Electrode Part
Number. For size and colour coding, refer to Table 53.
4 The applicable diameter range is between 3/16 inch and 3/8 inch as shown in the
table below.

ELECTRODE SIZE ADAPTER ELECTRODE ELECTRODE

IN INCHES GUIDE PACKAGING
3/16 Nominal YELLOW Electrode Guide YELLOW Cutout
3/16 1st Oversize (X) WHITE Electrode Guide YELLOW Cutout
3/16 2nd Oversize (Y) TURQUOISE Electrode YELLOW Cutout
Guide
1/4 Nominal BLACK Guide BLACK Cutout
1/4 1st Oversize (X) WHITE Guide BLACK Cutout
1/4 2nd Oversize (Y) TURQUOISE Guide BLACK Cutout
5/16 Nominal RED Guide RED Cutout
5/16 1st Oversize (X) WHITE Guide RED Cutout
5/16 2nd Oversize (Y) No Guide Required at this RED Cutout
size
3/8 Nominal No Guide Required at this GREY Cutout
size
3/8 1st Oversize (X) No Guide Required at this GREY Cutout
size
3/8 2nd Oversize (Y) GREY Cutout

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No Guide Required at this

size

Table 53 - Size and Colour Coding

WARNING: IT IS MANDATORY TO USE THE VACUUM FLUSH-HEAD LOCATOR (VFHL).

(c) Removal of Flush-Head Fasteners

NOTE: This task is only applicable for Countersunk (CSK) fasteners and their
alternatives given in Table 52. The process to remove flush-head fasteners is
different to the method for protruding fasteners.
1 Select the correct fastener type on the Hand Held Terminal. Identify from the screen
which Electrode and Electrode Guide are required and install the electrode, adapter
and guide on the hand tool.
2 Place the VFHL over the fastener head, using the sighting aperture to ensure the
VFHL is concentric. Once the locator is centralised to the fastener head, press the
airline button to secure in position, and re-check the VFHL is still central (Refer to
Figure 153).
3 Remove the sighting aperture and insert the e-drill (Refer to Figure 154).
4 At this point the Adaptor should be located concentrically around and over the
fastener, sealing to the surrounding airframe. If in doubt about e-drill placement and
concentricity go back to step
2.
.
W.
.
(3)
.
(c)
.
1
and try again. If the e-drill is not placed centric over the fastener, the e-drill will cut
out of the pin and damage the airframe.
5 While holding the e-drill firmly but lightly against the fastener (Refer to Figure 151),
wrap fingers around the e-drill grip and squeeze the trigger with your second finger.
The device will then automatically go through the following sequence:
a The Vacuum Pump will turn on to purge the area.
b The cutting electrode will advance until it detects the electrically conductive
head to the fastener, whereupon it will calibrate itself.
c The cutting electrode will retract slightly, the system Water Pump will start
and cutting will be initiated.
d Cutting will proceed until the prescribed depth is achieved (as defined by the
fastener selection in the Hand Held Terminal), at which point the power will

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be shut off, the system Water Pump will stop, and the light on the back of the
hand-tool will illuminate green. The system Vacuum Pump will continue to
operate until the trigger is released.
e Remove the e-drill from the fastener, revealing the circular groove cut in the
fastener head (Refer to Figure 156).
f If the light on the back of the e-drill does not show green at the completion of
the cut, then the cut may not have completed successfully to depth. If the
light is showing a solid red then the likely cause is either bad electrical
continuity resulting from paint or other coating, or the fastener material is not
the same as was selected from the library.
Ensure all paint or other coatings are removed, place the e-drill over the
fastener and try again. A flashing green light indicates the cutting electrode
must be replaced. A flashing red light indicates a system error, refer to
Operator hand Held Terminal for details.
g Upon completion of the cut, select a proper size hand punch and centre the
punch in the fastener head. Sever the fastener head with a sharp blow on the
punch with a hammer.
It may be necessary to strike the punch more than once. If the fastener head
does not separate, the fastener is most likely an oversize stem. Once this is
confirmed, select an oversize cutting electrode and setting. Re-cut the
fastener and attempt to sever the fastener head again with a punch and
hammer. Oversized cutting electrodes must only be subsequently used after
consultation and agreement with local engineering.
(4) Completion
Both a visual and diametric inspection of the holes are required following each fastener removal
as per existing specifications.
Damage or misaligned cuts caused due to electrode contact with the structure must be raised as
a defect report (Refer to Figure 155 and Figure 157)
Any exposed untreated aluminium surface must be thoroughly dried with either a lint-free cloth
or similar approved method as per SRM requirements to prevent corrosion due to exposure with
deionised water. If the surface will be exposed for any period of 24 hours or greater, temporary
protection must be applied as per SRM requirements.
X. Structural Blind Bolt ABS2322K (ER755) (Refer to Figure 160)

DIAMETER AIRBUS PART

AFS PART NUMBER
CODE mm (in) NUMBER

5 4.16 (0.1638) ER( )-5-( )( ) ABS2322K5-( )

4.8 (0.189) ER( )-6-( )( ) ABS2322K6-( )
6
5.2 (0.205) ERXS( )-6-( )( ) ABS2322K6X-( )
8 6.35 (0.25) ER( )-8-( )( ) N/A
10 7.9 (0.311) ER( )-10-( )( ) N/A

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Table 54 - Blind Bolt P/N References

(1) Installation Tooling
(a) Pneumatic (Refer to Figure 161 and Figure 163)

DIAMETER NOSE INSTALLATION

FASTENER
ASSEMBLY TOOL PART
CODE mm (in) PART NUMBER
PART NUMBER NUMBER
5
4.16 (0.1638) ER( )-5-( )( ) ETT2000-05N ETT2000-05
<1>

6 4.8 (0.189) ER( )-6-( )( )

ETT2000-06N ETT2000-06
<1> 5.2 (0.205) ERXS( )-6-( )( )
8
6.35 (0.25) ER( )-8-( )( ) ETT2000-08N ETT2026-08
<2>
10
7.9 (0.311) ER( )-10-( )( ) ETT2000-10N ETT2026-10
<2>

Table 55 - Pneumatic Tool P/N References

<1> ATLAS COPCO LLB16 motor, 300 RPM - Weight about 800 g (28.22 oz).
<2> ATLAS COPCO LBB26 motor, 300 RPM - Weight about 1 kg (2.20 lb).
(b) Electrical (Refer to Figure 162 and Figure 163)

DIAMETER NOSE INSTALLATION

FASTENER
ASSEMBLY TOOL PART
CODE mm (in) PART NUMBER
PART NUMBER NUMBER
5 4.16 (0.1638) ER( )-5-( )( ) ETT2000-05N ETTGELS12-05
4.8 (0.189) ER( )-6-( )( )
6 ETT2000-06N ETTGELS12-06
5.2 (0.205) ERXS( )-6-( )( )
8 6.35 (0.25) ER( )-8-( )( ) ETT2000-08N ETTGELS12-08
10 7.9 (0.311) ER( )-10-( )( ) ETT2000-10N ETTGELS12-10

Table 56 - Electrical Tool P/N References

(2) Nose Assembly Consumable Spares
Anti-rotation inserts and in a lower extent spline driver are recommended to be kept available in
house for smooth maintenance operation. They will be subjected to normal wear and tear.
(3) Tool Cleaning (Refer to Figure 164)
Tool performance and life time can be drastically affected by foreign materials pollutions in the
nose assembly. Nose shall be kept cleaned and in good conditions. A regular cleaning at end of
each shift for example, with solvent or similar and before complete curing of sealant is
recommended.

DIAMETER

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ANTI-ROTATION SPLINE DRIVERS

CODE mm (in) INSERTS PART PART NUMBER
NUMBER
5 4.16 (0.1638) A20770
4.8 (0.189) A20553
6 A20769
5.2 (0.205)
8 6.35 (0.25) A20771 A20552

Table 57 - Nose Assembly P/N References

(4) Pre-installation
(a) Grip Selection (Refer to Figure 165)
1 The specific ABS2322K Structural Blind Bolt gage part number is A22540. In
addition to grip selection it allows diameter and grip code identification of the
ABS2322K Structural Blind Bolt fastener.
2 ABS2322K Structural Blind Bolt has the same grip range as HI-LOK, HI-LITE or
LOCKBOLT fasteners. The Arconic 122666 GP/LGP grip gage will also provide a
direct reading of the ABS2322K Structural Blind Bolt grip code to be installed. It is
widely available and used.
(b) Grip Verification
Use grip scale on side of the gage to verify grip length of the fastener, refer to Figure 166.
(c) Inspection
Gages allows the bulb shape and protrusion to be checked with the part numbers
identified below:

DIAMETER FASTENER PART GAGE PART

CODE mm (in) NUMBER NUMBER

5 4.16 (0.1638) ER( )-5-( )( ) A23213-05

4.8 (0.189) ER( )-6-( )( ) A23213-06
6
5.2 (0.205) ERXS( )-6-( )( ) A23213-XS06
8 6.35 (0.25) ER( )-8-( )( ) A23213-08

Table 58 - Gage P/N References

(5) Installation Process (Refer to Figure 167)

CAUTION: DO NOT USE BLIND BOLT ABS2322K (ER755) IN FUEL BOUNDARY.

(a) Ensure that the blind bolt to be used is free from damage.
(b) Insert the appropriate blind bolt into the pre-prepared hole ensuring that the bolt is free to
move and it seats properly with the hole geometry.

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(c) Use the appropriate installation gun with the required nose insert; ensure that the anti-
rotation feature engages the recess pattern on the sleeve head of the blind bolt by rotating
driver splined pintail.
(d) Rotation of the corebolt starts bulbing of the sleeve.
(e) Continued rotation completes bulb formation.
(f) Pintail is twisted off flush with the sleeve head and discard.
(g) Installation is complete.
(6) Post Installation (Refer to Figure 168)
(a) The breakneck must shear in torsion.
(b) The core bolt surface must be within ± 0.08 mm (0.003 in) of the sleeve and core bolt
reference points.
(c) Use a dial gauge to measure the flushness where required. It is recommended to use 0.8
mm (0.032 in) stylus tip with a tripod or quadpod or magnetic support for measurements.
1 Place the zero gauge against part surface as close as possible to the edge of the
bolt. Ensure that gauge feet/contact points are not touching fastener when zeroing.
2 Check measurement of fastener at least in 3 points (example: points A, B, C) of the
fastener head ensuring no contact with the recess or manufacturer identification
mark. Do not measure the corebolt.
3 The flushness is correct if each point measured in the previous step is inside the
flushness tolerance.
a Ensure the bulb is adequately formed at the back of the plate or structure by
checking for defect as shown in Figure 169.
b If there is no access on the other side, use appropriate NDT process to check
for adequate formation of the bulb.
(7) Removal Process
(a) Drill through the head of the corebolt 3 mm (0.12 in) depth approximately using a cutting
tool with 2.5 mm (0.098 in) diameter, refer to Figure 170 (Sheet 1).
(b) Use an easy-out tool to remove the corebolt by placing the tool into the hole drilled into
the corebolt and rotating in an anti-clockwise direction, refer to Figure 170 (Sheet 2).
(c) Drill in the center of sleeve using a cutting tool with 3.9 mm (0.154 in) diameter. Use a
micro stop tool to control the depth to avoid damaging the hole, refer to Figure 170 (Sheet
3).
(d) Remove the sleeve by using a "pin hunting" tool: place a center punch inside of sleeve
head inner diameter and hammer out the sleeve, refer to Figure 170 (Sheet 4).
(e) Typical bolt removal as shown in Figure 170 (Sheet 5) indicates end of removal process.
Figure 001 / 51-42-11 (sheet 1) Red Line Marking of Fastener Head
Figure 002 / 51-42-11 (sheet 1) Inspection after Installation

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Figure 003 / 51-42-11 (sheet 1) Data to find the necessary Length of Rivets
Figure 004 / 51-42-11 (sheet 1) General Details for Back-up Dollies
Figure 005 / 51-42-11 (sheet 1) Upset Head Dimensions
Figure 006 / 51-42-11 (sheet 1) Riveting Defect and Acceptance Limits
Figure 007 / 51-42-11 (sheet 1) Acceptable Limits for Cracks
Figure 008 / 51-42-11 (sheet 1) Rivet Head Abutment (Seating) Check
Figure 009 / 51-42-11 (sheet 1) Removal of Solid Rivets
Figure 010 / 51-42-11 (sheet 1) Details of Pin/Collar Assemblies
Figure 011 / 51-42-11 (sheet 1) Details for Modified Hand Tool
Figure 012 / 51-42-11 (sheet 1) Details for HI-Shear Hand Tool
Figure 013 / 51-42-11 (sheet 1) Installation of a Pin (threaded) Fastener
Figure 014 / 51-42-11 (sheet 1) Gage to find the Grip Length
Figure 014 / 51-42-11 (sheet 2) Gage to find the Grip Length
Figure 014 / 51-42-11 (sheet 3) Gage to find the Grip Lengths
Figure 015 / 51-42-11 (sheet 1) Examples of different Types of Installation Tools/Drive
Pieces
Figure 016 / 51-42-11 (sheet 1) Limits for Pin Head Seat Separation
Figure 017 / 51-42-11 (sheet 1) Permitted Limits for Head Dishing of Pins Installed in
Interference Fit Holes
Figure 018 / 51-42-11 (sheet 1) Initial Insertion of Bolt in Assembly
Figure 018 / 51-42-11 (sheet 2) Protrusions of Bolt through Nut after Torque Tightening
Figure 019 / 51-42-11 (sheet 1) Range of Pin/Thread Protrusion Limits for Protruding
and 100° Countersunk Head Pins
Figure 020 / 51-42-11 (sheet 1) Gauge Procedure
Figure 021 / 51-42-11 (sheet 1) Details for Collar Removal
Figure 022 / 51-42-11 (sheet 1) Pin (Threaded) (Bullnose)
Figure 023 / 51-42-11 (sheet 1) Gage to find the Grip Length
Figure 023 / 51-42-11 (sheet 2) Gage to find the Grip Length
Figure 023 / 51-42-11 (sheet 3) How top Find the Fastener Grip Length
Figure 024 / 51-42-11 (sheet 1) Permitted Limit of Head Dishing
Figure 024 / 51-42-11 (sheet 2) Permitted Limits of Head/Set Separation
Figure 024 / 51-42-11 (sheet 3) Checking Correct Fastener Length
Figure 025 / 51-42-11 (sheet 1) Example of a Stress Patterns

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Figure 026 / 51-42-11 (sheet 1) Relief Radius Data for Protruding Head - Taper Bolts
Figure 027 / 51-42-11 (sheet 1) Taper Bolt Identification Coding
Figure 028 / 51-42-11 (sheet 1) Taper Drill Reamer Data
Figure 029 / 51-42-11 (sheet 1) Taper Micro Stop Cage Data
Figure 030 / 51-42-11 (sheet 1) Data for Countersink Check Gage
Figure 030 / 51-42-11 (sheet 2) Data for Countersink Check Gage
Figure 031 / 51-42-11 (sheet 1) Plug Gage Data
Figure 032 / 51-42-11 (sheet 1) Use of a Plug Gage
Figure 033 / 51-42-11 (sheet 1) Taper Bolt Protrusion Data
Figure 034 / 51-42-11 (sheet 1) Taper Installation Procedure
Figure 035 / 51-42-11 (sheet 1) Bolt Head Separation Data
Figure 036 / 51-42-11 (sheet 1) Bolt Head Dishing Data
Figure 037 / 51-42-11 (sheet 1) Commercially available 1:48 Hand Taper Pin Reamer
Figure 038 / 51-42-11 (sheet 1) Taper Bolt Knock-out Tool Data
Figure 039 / 51-42-11 (sheet 1) Extraction Tool Data
Figure 040 / 51-42-11 (sheet 1) HUCK Blind Rivets - General Details
Figure 041 / 51-42-11 (sheet 1) Data for Rivet (Blind) (Huck) Type MS 21140
Figure 042 / 51-42-11 (sheet 1) Data for Rivet (Blind) (Huck) Type MS 90354
Figure 043 / 51-42-11 (sheet 1) Data for Rivet (Blind) (HUCK) Type NAS 1919
Figure 044 / 51-42-11 (sheet 1) Data for Rivet (Blind) (HUCK) Type NAS 1921
Figure 045 / 51-42-11 (sheet 1) Data for Rivet (Blind) (HUCK) Type NSA 54217
Figure 046 / 51-42-11 (sheet 1) Pin and Collar Prorusion/Depression Limits for Rivets
(Blind) (HUCK)
Figure 047 / 51-42-11 (sheet 1) Rivet (Blind) (HUCK) Abutment (Seating) Check
Figure 048 / 51-42-11 (sheet 1) HUCK Rivet Mandrel Drilling Details
Figure 049 / 51-42-11 (sheet 1) HUCK Rivet Pin Removal Details
Figure 050 / 51-42-11 (sheet 1) HUCK Rivet Body Counterboring Details
Figure 051 / 51-42-11 (sheet 1) HUCK Rivet Body Removal Details
Figure 052 / 51-42-11 (sheet 1) General and Installation Features of the Rivet-Blind
(AVDEL MBC)
Figure 053 / 51-42-11 (sheet 1) Data to find Second Dash Number for AVDEL MBC
Rivets ASNA 0079 and ASNA 008
Figure 054 / 51-42-11 (sheet 1) AVDEL Rivet Head Abutment (Seating) Check

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Figure 055 / 51-42-11 (sheet 1) Removal of AVDEL MBC Rivets

Figure 056 / 51-42-11 (sheet 1) IMEX Blind Rivets - General and Installation Details
Figure 057 / 51-42-11 (sheet 1) Determining Required Length (Second Dash Number)
of IMEX Blind Rivet NSA5420
Figure 058 / 51-42-11 (sheet 1) Determining Required Length (Second Dash Number)
of IMEX Blind Rivet NSA5421 with Diameter of 1/8 in. (3.2 mm)
Figure 058 / 51-42-11 (sheet 2) Determining Required Length (Second Dash Number)
of IMEX Blind Rivet NSA5421 with a Diameter of 5/32 in. (4.0 mm)
Figure 059 / 51-42-11 (sheet 1) Determining Required Length (Second Dash Number)
of IMEX Blind Rivet NSA5421 with a Diameter of 3/16 in. (4.8 mm)
Figure 060 / 51-42-11 (sheet 1) Removal of IMEX Blind Rivets
Figure 061 / 51-42-11 (sheet 1) CHERRYMAX Blind Rivets, General Data
Figure 062 / 51-42-11 (sheet 1) Grip-Length Data for CHERRYMAX Blind Rivets
Figure 063 / 51-42-11 (sheet 1) Pin Protrusion/Depression Limits for CHERRYMAX
Rivets
Figure 064 / 51-42-11 (sheet 1) CHERRYMAX Rivet Removal Details
Figure 065 / 51-42-11 (sheet 1) Rivet - Blind (CHERRYLOCK) - General Details
Figure 066 / 51-42-11 (sheet 1) Rivet - Blind (Bulbed CHERRYLOCK) - General Details
Figure 067 / 51-42-11 (sheet 1) Grip - Length Data for Standard CHERRYLOCK Blind
Rivets
Figure 068 / 51-42-11 (sheet 1) Grip - Length Data for Bulbed CHERRYLOCK Blind
Rivets
Figure 069 / 51-42-11 (sheet 1) Pin and Collar Protrution/Depression Limits for
Standard and Bulbed CHERRYLOCK Blind Rivets
Figure 070 / 51-42-11 (sheet 1) Blind Rivets Removal Details
Figure 071 / 51-42-11 (sheet 1) Examples of Pins (swaged)
Figure 072 / 51-42-11 (sheet 1) Typical Pin/Collar Assembly
Figure 073 / 51-42-11 (sheet 1) Gage to find the Grip Length
Figure 073 / 51-42-11 (sheet 2) Gage to find the Grip Length
Figure 074 / 51-42-11 (sheet 1) Tool Configurations
Figure 075 / 51-42-11 (sheet 1) Installation of Pins (Swaged) in any Structure
Interference or Transition Fit
Figure 076 / 51-42-11 (sheet 1) Installation Pins (Swaged) in Thin Structure, Clearance
Fit
Figure 077 / 51-42-11 (sheet 1) Installation of Pins (Swaged) in Thick Structure
Clearance Fit

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Figure 078 / 51-42-11 (sheet 1) Head-Seating Allowable Gap Data for Protruding Head
Pin (Swaged)
Figure 079 / 51-42-11 (sheet 1) Head-Seating Allowable Gap Data for Countersunk
Head Pin (Swaged)
Figure 080 / 51-42-11 (sheet 1) Collar Inspection on a Surface with a Slope
Figure 081 / 51-42-11 (sheet 1) Typical Pin Position and Swage Gage
Figure 081 / 51-42-11 (sheet 2) Typical Pin Position Only Gage
Figure 082 / 51-42-11 (sheet 1) Example of Pin (swaged) Collar Swaging
Figure 083 / 51-42-11 (sheet 1) Data for Manual Splitter Tools
Figure 084 / 51-42-11 (sheet 1) Powered Collar Removal Tool Data (Power Splitter
Tool)
Figure 085 / 51-42-11 (sheet 1) Powered Collar Removal Tool Data (Hollow Mill Cutter)
Figure 086 / 51-42-11 (sheet 1) Chisel/Back-Up Dolly Removal Method
Figure 087 / 51-42-11 (sheet 1) Bolt-Blind - General Details
Figure 088 / 51-42-11 (sheet 1) Bolts-Blind Installation Procedure in Steps
Figure 089 / 51-42-11 (sheet 1) Grip-Length Data
Figure 090 / 51-42-11 (sheet 1) Grip-Length Gage Data
Figure 091 / 51-42-11 (sheet 1) Example of Installation Tool
Figure 092 / 51-42-11 (sheet 1) Bolt-Blind Installation Procedure
Figure 093 / 51-42-11 (sheet 1) Bolt Shank Break-Off Data
Figure 094 / 51-42-11 (sheet 1) Examples of Possible Bolt-Blind Installation Defects
Figure 095 / 51-42-11 (sheet 1) Examples of Good and Badly Installed Bolts-Blind
Figure 096 / 51-42-11 (sheet 1) Example of Removal Tool
Figure 097 / 51-42-11 (sheet 1) Pull-Through Blind Rivets - General and Installation
Details
Figure 098 / 51-42-11 (sheet 1) Grip-Length/Length Data for CHERRY Pull-Through
Blind Rivets
Figure 099 / 51-42-11 (sheet 1) Removal of Pull-Through Rivets
Figure 100 / 51-42-11 (sheet 1) CHERRYBUCK Rivet - General Detail
Figure 101 / 51-42-11 (sheet 1) CHERRYBUCK Rivet used to form a Countersunk
Head
Figure 102 / 51-42-11 (sheet 1) CHERRYBUCK Rivet used on an Angled Surface
Figure 103 / 51-42-11 (sheet 1) Checking Grip Length with a Proprietary Tool
Figure 104 / 51-42-11 (sheet 1) Grip Length Detail

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Figure 105 / 51-42-11 (sheet 1) Indirect Driving (Reaction) of Rivet

Figure 106 / 51-42-11 (sheet 1) Direct Driving
Figure 107 / 51-42-11 (sheet 1) Upset Head Dimensions for Rivet ABS0213
Figure 108 / 51-42-11 (sheet 1) Manufactured Head Faults
Figure 109 / 51-42-11 (sheet 1) Riveting Faults
Figure 110 / 51-42-11 (sheet 1) CHERRYBUCK Rivet Removal Procedure
Figure 111 / 51-42-11 (sheet 1) CHERRY E-Z BUCK Rivet - General detail
Figure 112 / 51-42-11 (sheet 1) CHERRY E-Z BUCK Rivet used to form a
Countersunk Head
Figure 113 / 51-42-11 (sheet 1) CHERRY E-Z BUCK Rivet used on an Angled Surface
Figure 114 / 51-42-11 (sheet 1) CheckingGrip Length (Material Thickness) with a
Proprietary Tool
Figure 115 / 51-42-11 (sheet 1) Grip Length and Length Detail
Figure 116 / 51-42-11 (sheet 1) Length Detail for a Rivet with a Countersunk Upset
Head
Figure 117 / 51-42-11 (sheet 1) Indirect Driving (Reaction) of Rivet
Figure 118 / 51-42-11 (sheet 1) Direct Driving
Figure 119 / 51-42-11 (sheet 1) Milling Detail - Manufactured Countersunk Head
Figure 120 / 51-42-11 (sheet 1) Upset Head Dimensions for CHERRY E-Z BUCK
Rivets
Figure 121 / 51-42-11 (sheet 1) Manufactured Head Faults
Figure 121 / 51-42-11 (sheet 2) Manufactured Head Faults
Figure 122 / 51-42-11 (sheet 1) Suitable Drill Guide
Figure 123 / 51-42-11 (sheet 1) Double Countersunk Rivet
Figure 124 / 51-42-11 (sheet 1) Group Definition and Oversizing Principle
Figure 125 / 51-42-11 (sheet 1) Use of Self-Aligning Nuts
Figure 126 / 51-42-11 (sheet 1) Measurement for the required grip length
Figure 127 / 51-42-11 (sheet 1) Acceptance Criteria for Surface Bearing
Figure 128 / 51-42-11 (sheet 1) Taper Installation
Figure 129 / 51-42-11 (sheet 1) Taper Installation
Figure 130 / 51-42-11 (sheet 1) Taper Installation
Figure 131 / 51-42-11 (sheet 1) Manual Reaming
Figure 132 / 51-42-11 (sheet 1) Under-Head Chamfer
Figure 133 / 51-42-11 (sheet 1) Taper Bolt Protrusion Measurement

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Figure 134 / 51-42-11 (sheet 1) Blueing Gauge - Bearing Verification

Figure 135 / 51-42-11 (sheet 1) Tapered Guide and Cutter Pilot Principle
Figure 136 / 51-42-11 (sheet 1) Countersink Depth Gauge Usage
Figure 137 / 51-42-11 (sheet 1) Tooling
Figure 138 / 51-42-11 (sheet 1) Hi-Lite Pull-In, Hi-Lite Pull-Stem and XPL Pin swaged
Figure 139 / 51-42-11 (sheet 1) Fastener Identification - Head Marking
Figure 140 / 51-42-11 (sheet 1) Drilling and Tapping
Figure 141 / 51-42-11 (sheet 1) Extraction Tool
Figure 142 / 51-42-11 (sheet 1) Extraction Tool
Figure 143 / 51-42-11 (sheet 1) Tooling for Removal Procedure
Figure 144 / 51-42-11 (sheet 1) Removal Procedure and Data
Figure 145 / 51-42-11 (sheet 1) Re-Install of Fasteners
Figure 146 / 51-42-11 (sheet 1) Installatin of Swaged and Threaded Systems
Figure 147 / 51-42-11 (sheet 1) Threaded-Stem Design
Figure 148 / 51-42-11 (sheet 1) Riveting Faults
Figure 149 / 51-42-11 (sheet 1) Gap between Components
Figure 150 / 51-42-11 (sheet 1) CHERRY E-Z BUCK Removal Procedure
Figure 151 / 51-42-11 (sheet 1) Correct Grip of E-drill
Figure 152 / 51-42-11 (sheet 1) Correct Handling of Button Locator
Figure 153 / 51-42-11 (sheet 1) Flush Head Locator Alignment
Figure 154 / 51-42-11 (sheet 1) E-drill Engagement into VFHL
Figure 155 / 51-42-11 (sheet 1) Cuts Extended through the Wall of the Fastener
Figure 156 / 51-42-11 (sheet 1) Circular Groove Cut into the Fastener Head
Figure 157 / 51-42-11 (sheet 1) Example of Damage caused by Electrode Clash with
the Structure
Figure 158 / 51-42-11 (sheet 1) Example of Fastener with Removed Head
Figure 159 / 51-42-11 (sheet 1) 100° Countersink Cutter in Machining Position
Figure 160 / 51-42-11 (sheet 1) Blind Bolt ABS2322K (ER755)
Figure 161 / 51-42-11 (sheet 1) Pneumatic Tool
Figure 162 / 51-42-11 (sheet 1) Electrical Tool
Figure 163 / 51-42-11 (sheet 1) Nose Tool
Figure 164 / 51-42-11 (sheet 1) Nose Assembly
Figure 165 / 51-42-11 (sheet 1) Grip Selection

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Figure 166 / 51-42-11 (sheet 1) Grip Verification

Figure 167 / 51-42-11 (sheet 1) Installation Process
Figure 168 / 51-42-11 (sheet 1) Flushness Measurement
Figure 169 / 51-42-11 (sheet 1) Bulb Checking
Figure 170 / 51-42-11 (sheet 1) Removal Process (Step 1)
Figure 170 / 51-42-11 (sheet 2) Removal Process (Step 2)
Figure 170 / 51-42-11 (sheet 3) Removal Process (Step 3)
Figure 170 / 51-42-11 (sheet 4) Removal Process (Step 4)
Figure 170 / 51-42-11 (sheet 5) Removal Process (Step 5)

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Figure 001 / 51-42-11 (SHEET 1) - Red Line Marking of Fastener Head

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Figure 002 / 51-42-11 (SHEET 1) - Inspection after Installation

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Figure 003 / 51-42-11 (SHEET 1) - Data to find the necessary Length of Rivets

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Figure 004 / 51-42-11 (SHEET 1) - General Details for Back-up Dollies

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Figure 005 / 51-42-11 (SHEET 1) - Upset Head Dimensions

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Figure 006 / 51-42-11 (SHEET 1) - Riveting Defect and Acceptance Limits

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Figure 007 / 51-42-11 (SHEET 1) - Acceptable Limits for Cracks

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Figure 008 / 51-42-11 (SHEET 1) - Rivet Head Abutment (Seating) Check

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Figure 009 / 51-42-11 (SHEET 1) - Removal of Solid Rivets

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Figure 010 / 51-42-11 (SHEET 1) - Details of Pin/Collar Assemblies

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Figure 011 / 51-42-11 (SHEET 1) - Details for Modified Hand Tool

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Figure 012 / 51-42-11 (SHEET 1) - Details for HI-Shear Hand Tool

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Figure 013 / 51-42-11 (SHEET 1) - Installation of a Pin (threaded) Fastener

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Figure 014 / 51-42-11 (SHEET 1/3) - Gage to find the Grip Length

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Figure 014 / 51-42-11 (SHEET 2/3) - Gage to find the Grip Length

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Figure 014 / 51-42-11 (SHEET 3/3) - Gage to find the Grip Lengths

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Figure 015 / 51-42-11 (SHEET 1) - Examples of different Types of Installation Tools/Drive Pieces

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Figure 016 / 51-42-11 (SHEET 1) - Limits for Pin Head Seat Separation

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Figure 017 / 51-42-11 (SHEET 1) - Permitted Limits for Head Dishing of Pins Installed in Interference Fit Holes

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Figure 018 / 51-42-11 (SHEET 1/2) - Initial Insertion of Bolt in Assembly

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Figure 018 / 51-42-11 (SHEET 2/2) - Protrusions of Bolt through Nut after Torque Tightening

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Figure 019 / 51-42-11 (SHEET 1) - Range of Pin/Thread Protrusion Limits for Protruding and 100° Countersunk Head
Pins

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Figure 020 / 51-42-11 (SHEET 1) - Gauge Procedure

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Figure 021 / 51-42-11 (SHEET 1) - Details for Collar Removal

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Figure 022 / 51-42-11 (SHEET 1) - Pin (Threaded) (Bullnose)

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Figure 023 / 51-42-11 (SHEET 1/3) - Gage to find the Grip Length

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Figure 023 / 51-42-11 (SHEET 2/3) - Gage to find the Grip Length

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Figure 023 / 51-42-11 (SHEET 3/3) - How top Find the Fastener Grip Length

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Figure 024 / 51-42-11 (SHEET 1/3) - Permitted Limit of Head Dishing

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Figure 024 / 51-42-11 (SHEET 2/3) - Permitted Limits of Head/Set Separation

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Figure 024 / 51-42-11 (SHEET 3/3) - Checking Correct Fastener Length

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Figure 025 / 51-42-11 (SHEET 1) - Example of a Stress Patterns

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Figure 026 / 51-42-11 (SHEET 1) - Relief Radius Data for Protruding Head - Taper Bolts

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Figure 027 / 51-42-11 (SHEET 1) - Taper Bolt Identification Coding

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Figure 028 / 51-42-11 (SHEET 1) - Taper Drill Reamer Data

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Figure 029 / 51-42-11 (SHEET 1) - Taper Micro Stop Cage Data

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Figure 030 / 51-42-11 (SHEET 1/2) - Data for Countersink Check Gage

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Figure 030 / 51-42-11 (SHEET 2/2) - Data for Countersink Check Gage

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Figure 031 / 51-42-11 (SHEET 1) - Plug Gage Data

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Figure 032 / 51-42-11 (SHEET 1) - Use of a Plug Gage

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Figure 033 / 51-42-11 (SHEET 1) - Taper Bolt Protrusion Data

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Figure 034 / 51-42-11 (SHEET 1) - Taper Installation Procedure

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Figure 035 / 51-42-11 (SHEET 1) - Bolt Head Separation Data

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Figure 036 / 51-42-11 (SHEET 1) - Bolt Head Dishing Data

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Figure 037 / 51-42-11 (SHEET 1) - Commercially available 1:48 Hand Taper Pin Reamer

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Figure 038 / 51-42-11 (SHEET 1) - Taper Bolt Knock-out Tool Data

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Figure 039 / 51-42-11 (SHEET 1) - Extraction Tool Data

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Figure 040 / 51-42-11 (SHEET 1) - HUCK Blind Rivets - General Details

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Figure 041 / 51-42-11 (SHEET 1) - Data for Rivet (Blind) (Huck) Type MS 21140

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Figure 042 / 51-42-11 (SHEET 1) - Data for Rivet (Blind) (Huck) Type MS 90354

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Figure 043 / 51-42-11 (SHEET 1) - Data for Rivet (Blind) (HUCK) Type NAS 1919

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Figure 044 / 51-42-11 (SHEET 1) - Data for Rivet (Blind) (HUCK) Type NAS 1921

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Figure 045 / 51-42-11 (SHEET 1) - Data for Rivet (Blind) (HUCK) Type NSA 54217

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Figure 046 / 51-42-11 (SHEET 1) - Pin and Collar Prorusion/Depression Limits for Rivets (Blind) (HUCK)

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Figure 047 / 51-42-11 (SHEET 1) - Rivet (Blind) (HUCK) Abutment (Seating) Check

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Figure 048 / 51-42-11 (SHEET 1) - HUCK Rivet Mandrel Drilling Details

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Figure 049 / 51-42-11 (SHEET 1) - HUCK Rivet Pin Removal Details

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Figure 050 / 51-42-11 (SHEET 1) - HUCK Rivet Body Counterboring Details

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Figure 051 / 51-42-11 (SHEET 1) - HUCK Rivet Body Removal Details

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Figure 052 / 51-42-11 (SHEET 1) - General and Installation Features of the Rivet-Blind (AVDEL MBC)

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Figure 053 / 51-42-11 (SHEET 1) - Data to find Second Dash Number for AVDEL MBC Rivets ASNA 0079 and ASNA 008

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Figure 054 / 51-42-11 (SHEET 1) - AVDEL Rivet Head Abutment (Seating) Check

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Figure 055 / 51-42-11 (SHEET 1) - Removal of AVDEL MBC Rivets

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Figure 056 / 51-42-11 (SHEET 1) - IMEX Blind Rivets - General and Installation Details

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Figure 057 / 51-42-11 (SHEET 1) - Determining Required Length (Second Dash Number) of IMEX Blind Rivet NSA5420

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Figure 058 / 51-42-11 (SHEET 1/2) - Determining Required Length (Second Dash Number) of IMEX Blind Rivet NSA5421
with Diameter of 1/8 in. (3.2 mm)

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Figure 058 / 51-42-11 (SHEET 2/2) - Determining Required Length (Second Dash Number) of IMEX Blind Rivet NSA5421
with a Diameter of 5/32 in. (4.0 mm)

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Figure 059 / 51-42-11 (SHEET 1) - Determining Required Length (Second Dash Number) of IMEX Blind Rivet NSA5421
with a Diameter of 3/16 in. (4.8 mm)

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Figure 060 / 51-42-11 (SHEET 1) - Removal of IMEX Blind Rivets

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Figure 061 / 51-42-11 (SHEET 1) - CHERRYMAX Blind Rivets, General Data

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Figure 062 / 51-42-11 (SHEET 1) - Grip-Length Data for CHERRYMAX Blind Rivets

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Figure 063 / 51-42-11 (SHEET 1) - Pin Protrusion/Depression Limits for CHERRYMAX Rivets

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Figure 064 / 51-42-11 (SHEET 1) - CHERRYMAX Rivet Removal Details

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Figure 065 / 51-42-11 (SHEET 1) - Rivet - Blind (CHERRYLOCK) - General Details

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Figure 066 / 51-42-11 (SHEET 1) - Rivet - Blind (Bulbed CHERRYLOCK) - General Details

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Figure 067 / 51-42-11 (SHEET 1) - Grip - Length Data for Standard CHERRYLOCK Blind Rivets

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Figure 068 / 51-42-11 (SHEET 1) - Grip - Length Data for Bulbed CHERRYLOCK Blind Rivets

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Figure 069 / 51-42-11 (SHEET 1) - Pin and Collar Protrution/Depression Limits for Standard and Bulbed CHERRYLOCK
Blind Rivets

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Figure 070 / 51-42-11 (SHEET 1) - Blind Rivets Removal Details

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Figure 071 / 51-42-11 (SHEET 1) - Examples of Pins (swaged)

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Figure 072 / 51-42-11 (SHEET 1) - Typical Pin/Collar Assembly

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Figure 073 / 51-42-11 (SHEET 1/2) - Gage to find the Grip Length

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Figure 073 / 51-42-11 (SHEET 2/2) - Gage to find the Grip Length

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Figure 074 / 51-42-11 (SHEET 1) - Tool Configurations

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Figure 075 / 51-42-11 (SHEET 1) - Installation of Pins (Swaged) in any Structure Interference or Transition Fit

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Figure 076 / 51-42-11 (SHEET 1) - Installation Pins (Swaged) in Thin Structure, Clearance Fit

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Figure 077 / 51-42-11 (SHEET 1) - Installation of Pins (Swaged) in Thick Structure Clearance Fit

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Figure 078 / 51-42-11 (SHEET 1) - Head-Seating Allowable Gap Data for Protruding Head Pin (Swaged)

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Figure 079 / 51-42-11 (SHEET 1) - Head-Seating Allowable Gap Data for Countersunk Head Pin (Swaged)

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Figure 080 / 51-42-11 (SHEET 1) - Collar Inspection on a Surface with a Slope

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Figure 081 / 51-42-11 (SHEET 1/2) - Typical Pin Position and Swage Gage

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Figure 081 / 51-42-11 (SHEET 2/2) - Typical Pin Position Only Gage

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Figure 082 / 51-42-11 (SHEET 1) - Example of Pin (swaged) Collar Swaging

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Figure 083 / 51-42-11 (SHEET 1) - Data for Manual Splitter Tools

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Figure 084 / 51-42-11 (SHEET 1) - Powered Collar Removal Tool Data (Power Splitter Tool)

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Figure 085 / 51-42-11 (SHEET 1) - Powered Collar Removal Tool Data (Hollow Mill Cutter)

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Figure 086 / 51-42-11 (SHEET 1) - Chisel/Back-Up Dolly Removal Method

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Figure 087 / 51-42-11 (SHEET 1) - Bolt-Blind - General Details

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Figure 088 / 51-42-11 (SHEET 1) - Bolts-Blind Installation Procedure in Steps

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Figure 089 / 51-42-11 (SHEET 1) - Grip-Length Data

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Figure 090 / 51-42-11 (SHEET 1) - Grip-Length Gage Data

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Figure 091 / 51-42-11 (SHEET 1) - Example of Installation Tool

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Figure 092 / 51-42-11 (SHEET 1) - Bolt-Blind Installation Procedure

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Figure 093 / 51-42-11 (SHEET 1) - Bolt Shank Break-Off Data

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Figure 094 / 51-42-11 (SHEET 1) - Examples of Possible Bolt-Blind Installation Defects

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Figure 095 / 51-42-11 (SHEET 1) - Examples of Good and Badly Installed Bolts-Blind

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Figure 096 / 51-42-11 (SHEET 1) - Example of Removal Tool

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Figure 097 / 51-42-11 (SHEET 1) - Pull-Through Blind Rivets - General and Installation Details

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Figure 098 / 51-42-11 (SHEET 1) - Grip-Length/Length Data for CHERRY Pull-Through Blind Rivets

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Figure 099 / 51-42-11 (SHEET 1) - Removal of Pull-Through Rivets

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Figure 100 / 51-42-11 (SHEET 1) - CHERRYBUCK Rivet - General Detail

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Figure 101 / 51-42-11 (SHEET 1) - CHERRYBUCK Rivet used to form a Countersunk Head

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Figure 102 / 51-42-11 (SHEET 1) - CHERRYBUCK Rivet used on an Angled Surface

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Figure 103 / 51-42-11 (SHEET 1) - Checking Grip Length with a Proprietary Tool

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Figure 104 / 51-42-11 (SHEET 1) - Grip Length Detail

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Figure 105 / 51-42-11 (SHEET 1) - Indirect Driving (Reaction) of Rivet

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Figure 106 / 51-42-11 (SHEET 1) - Direct Driving

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Figure 107 / 51-42-11 (SHEET 1) - Upset Head Dimensions for Rivet ABS0213

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Figure 108 / 51-42-11 (SHEET 1) - Manufactured Head Faults

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Figure 109 / 51-42-11 (SHEET 1) - Riveting Faults

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Figure 110 / 51-42-11 (SHEET 1) - CHERRYBUCK Rivet Removal Procedure

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Figure 111 / 51-42-11 (SHEET 1) - CHERRY E-Z BUCK Rivet - General detail

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Figure 112 / 51-42-11 (SHEET 1) - CHERRY E-Z BUCK Rivet used to form a Countersunk Head

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Figure 113 / 51-42-11 (SHEET 1) - CHERRY E-Z BUCK Rivet used on an Angled Surface

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Figure 114 / 51-42-11 (SHEET 1) - CheckingGrip Length (Material Thickness) with a Proprietary Tool

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Figure 115 / 51-42-11 (SHEET 1) - Grip Length and Length Detail

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Figure 116 / 51-42-11 (SHEET 1) - Length Detail for a Rivet with a Countersunk Upset Head

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Figure 117 / 51-42-11 (SHEET 1) - Indirect Driving (Reaction) of Rivet

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Figure 118 / 51-42-11 (SHEET 1) - Direct Driving

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Figure 119 / 51-42-11 (SHEET 1) - Milling Detail - Manufactured Countersunk Head

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Figure 120 / 51-42-11 (SHEET 1) - Upset Head Dimensions for CHERRY E-Z BUCK Rivets

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Figure 121 / 51-42-11 (SHEET 1/2) - Manufactured Head Faults

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Figure 121 / 51-42-11 (SHEET 2/2) - Manufactured Head Faults

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Figure 122 / 51-42-11 (SHEET 1) - Suitable Drill Guide

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Figure 123 / 51-42-11 (SHEET 1) - Double Countersunk Rivet

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Figure 124 / 51-42-11 (SHEET 1) - Group Definition and Oversizing Principle

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Figure 125 / 51-42-11 (SHEET 1) - Use of Self-Aligning Nuts

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Figure 126 / 51-42-11 (SHEET 1) - Measurement for the required grip length

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Figure 127 / 51-42-11 (SHEET 1) - Acceptance Criteria for Surface Bearing

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Figure 128 / 51-42-11 (SHEET 1) - Taper Installation

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Figure 129 / 51-42-11 (SHEET 1) - Taper Installation

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Figure 130 / 51-42-11 (SHEET 1) - Taper Installation

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Figure 131 / 51-42-11 (SHEET 1) - Manual Reaming

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Figure 132 / 51-42-11 (SHEET 1) - Under-Head Chamfer

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Figure 133 / 51-42-11 (SHEET 1) - Taper Bolt Protrusion Measurement

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Figure 134 / 51-42-11 (SHEET 1) - Blueing Gauge - Bearing Verification

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Figure 135 / 51-42-11 (SHEET 1) - Tapered Guide and Cutter Pilot Principle

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Figure 136 / 51-42-11 (SHEET 1) - Countersink Depth Gauge Usage

JCP Title: Thomas © AIRBUS S.A.S. ALL RIGHTS RESERVED. Page 274 of 312
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Figure 137 / 51-42-11 (SHEET 1) - Tooling

JCP Title: Thomas © AIRBUS S.A.S. ALL RIGHTS RESERVED. Page 275 of 312
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Figure 138 / 51-42-11 (SHEET 1) - Hi-Lite Pull-In, Hi-Lite Pull-Stem and XPL Pin swaged

JCP Title: Thomas © AIRBUS S.A.S. ALL RIGHTS RESERVED. Page 276 of 312
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Figure 139 / 51-42-11 (SHEET 1) - Fastener Identification - Head Marking

JCP Title: Thomas © AIRBUS S.A.S. ALL RIGHTS RESERVED. Page 277 of 312
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Figure 140 / 51-42-11 (SHEET 1) - Drilling and Tapping

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Figure 141 / 51-42-11 (SHEET 1) - Extraction Tool

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Figure 142 / 51-42-11 (SHEET 1) - Extraction Tool

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Figure 143 / 51-42-11 (SHEET 1) - Tooling for Removal Procedure

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Figure 144 / 51-42-11 (SHEET 1) - Removal Procedure and Data

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Figure 145 / 51-42-11 (SHEET 1) - Re-Install of Fasteners

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Figure 146 / 51-42-11 (SHEET 1) - Installatin of Swaged and Threaded Systems

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Figure 147 / 51-42-11 (SHEET 1) - Threaded-Stem Design

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Figure 148 / 51-42-11 (SHEET 1) - Riveting Faults

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Figure 149 / 51-42-11 (SHEET 1) - Gap between Components

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Figure 150 / 51-42-11 (SHEET 1) - CHERRY E-Z BUCK Removal Procedure

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Figure 151 / 51-42-11 (SHEET 1) - Correct Grip of E-drill

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Figure 152 / 51-42-11 (SHEET 1) - Correct Handling of Button Locator

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Figure 153 / 51-42-11 (SHEET 1) - Flush Head Locator Alignment

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Figure 154 / 51-42-11 (SHEET 1) - E-drill Engagement into VFHL

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Figure 155 / 51-42-11 (SHEET 1) - Cuts Extended through the Wall of the Fastener

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Figure 156 / 51-42-11 (SHEET 1) - Circular Groove Cut into the Fastener Head

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Figure 157 / 51-42-11 (SHEET 1) - Example of Damage caused by Electrode Clash with the Structure

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Figure 158 / 51-42-11 (SHEET 1) - Example of Fastener with Removed Head

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Figure 159 / 51-42-11 (SHEET 1) - 100° Countersink Cutter in Machining Position

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Figure 160 / 51-42-11 (SHEET 1) - Blind Bolt ABS2322K (ER755)

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Figure 161 / 51-42-11 (SHEET 1) - Pneumatic Tool

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Figure 162 / 51-42-11 (SHEET 1) - Electrical Tool

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Figure 163 / 51-42-11 (SHEET 1) - Nose Tool

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Figure 164 / 51-42-11 (SHEET 1) - Nose Assembly

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Figure 165 / 51-42-11 (SHEET 1) - Grip Selection

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Figure 166 / 51-42-11 (SHEET 1) - Grip Verification

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Figure 167 / 51-42-11 (SHEET 1) - Installation Process

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Figure 168 / 51-42-11 (SHEET 1) - Flushness Measurement

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Figure 169 / 51-42-11 (SHEET 1) - Bulb Checking

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Figure 170 / 51-42-11 (SHEET 1/5) - Removal Process (Step 1)

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Figure 170 / 51-42-11 (SHEET 2/5) - Removal Process (Step 2)

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Figure 170 / 51-42-11 (SHEET 3/5) - Removal Process (Step 3)

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Figure 170 / 51-42-11 (SHEET 4/5) - Removal Process (Step 4)

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Figure 170 / 51-42-11 (SHEET 5/5) - Removal Process (Step 5)

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