SECTION 3. EXHAUST SYSTEMS8-28
8-45. GENERAL8-28
8-46. MUFFLER/HEAT EXCHANGER FAILURES8-28
8-47. MANIFOLD/STACK FAILURES8-30
8-48. INTERNAL MUFFLER FAILURES8-31
8-49. INSPECTION8-33
8-50. REPAIRS8-35
8-51. TURBOSUPERCHARGER8-36
8-52. AUGMENTER SYSTEMS8-36
8-53.–8-70. [RESERVED.]8-36
SECTION 4. REPAIR OF METAL PROPELLERS8-37
8-71. GENERAL8-37
8-72. STEEL BLADES8-37
8-73. ALUMINUM PROPELLER REPAIRS8-37
8-74. REPAIR LIMITS8-40
8-75. STEEL HUBS AND HUB PARTS8-42
8-76. PROPELLER HUB AND FLANGE REPAIR8-42
8-77. CONTROL SYSTEMS8-43
8-78. DEICING SYSTEMS8-44
8-79.–8-90. [RESERVED.]8-44
SECTION 5. INSPECTION OF PROPELLERS8-45
8-91. GENERAL8-45
8-92. WOOD OR COMPOSITION PROPELLERS AND BLADES8-45
8-93. METAL PROPELLERS AND BLADES8-47
8-94. PROPELLER HUB8-48
8-95. TACHOMETER INSPECTION8-49
8-96.–8-106. [RESERVED.]8-49
SECTION 6. PROPELLER TRACKING AND VIBRATION8-50
8-107. GENERAL8-50
8-108. PROPELLER TRACKING CHECK8-50
8-109. VIBRATION8-51
8-110.–8-129. [RESERVED.]8-51
CHAPTER 9. AIRCRAFT SYSTEMS AND COMPONENTS9-1
SECTION 1. INSPECTION AND MAINTENANCE OF LANDING GEAR9-1
9-1. GENERAL9-1
9-2. GENERAL INSPECTION9-1
9-3. CLEANING AND LUBRICATING9-1
9-4. FIXED-GEAR INSPECTION9-2
9-5. INSPECTION OF RETRACTABLE LANDING GEAR9-3
9-6. EMERGENCY SYSTEMS9-4
9-7. LANDING-GEAR COMPONENTS9-4
9-8. FLOATS AND SKIS9-6
9-9. INSPECTION AND REPAIR OF FLOATS AND SKIS9-8
9-10. TYPES OF LANDING-GEAR PROBLEMS9-9
9-11. SPECIAL INSPECTIONS9-11
9-12. RETRACTION TESTS9-11
9-13. TIRE AND TUBE MAINTENANCE9-11
9-14. TIRE INSPECTION AND REPAIR9-12
9-15. INFLATION OF TIRES9-13
9-16. PERSONAL SAFETY9-14
9-17. DISASSEMBLE THE WHEEL9-14
9-18. REASSEMBLING THE WHEEL9-15
9-19. SLIPPAGE9-15
9-20. WHEEL INSPECTION9-15
9-21. WHEEL INSTALLATION9-15
9-22.–9-24. [RESERVED.]9-16
SECTION 2. HYDRAULIC SYSTEMS9-17
9-25. GENERAL9-17
9-26. PURPOSES OF HYDRAULIC SYSTEMS9-17
9-27. TYPES OF HYDRAULIC FLUID9-17
9-28. HANDLING HYDRAULIC FLUID9-18
9-29. HYDRAULIC SYSTEM MAINTENANCE PRACTICES9-19
9-30. HYDRAULIC LINES AND FITTINGS9-22
9-31.–9-36. [RESERVED.]9-34
SECTION 3. EMERGENCY EQUIPMENT9-35
9-37. LIFE RAFTS9-35
9-38. LIFE RAFT INSPECTIONS9-35
9-39. SURVIVAL KIT INSPECTION9-37
9-40. SPECIAL INSPECTIONS9-41
9-41. INSPECTION RECORD9-41
9-42. RAFT REPAIRS9-41
9-43. LIFE PRESERVERS9-44
9-44. LIFE PRESERVER INSPECTION9-45
9-45. REPAIR OF LIFE PRESERVERS9-46
9-46. MISCELLANEOUS EQUIPMENT9-46
9-47. OXYGEN SYSTEMS9-47
9-48. INSPECTION9-48
9-49. MAINTENANCE9-49
9-50. FUNCTIONAL TESTING AFTER REPAIR9-51
9-51. REQUIREMENTS FOR REQUALIFICATION OF OXYGEN CYLINDERS9-52
9-52.–9-59. [RESERVED.]9-55
SECTION 4. CABIN INTERIOR9-56
9-60. GENERAL9-56
9-61. CAR 3 AIRCRAFT INTERIOR9-56
9-62. PART 23 AIRCRAFT INTERIOR9-56
9-63. SOURCE OF INFORMATION9-57
9-64. UPHOLSTERY AND/OR BELTS9-57
9-65.–9-70. [RESERVED.]9-57
CHAPTER 10. WEIGHT AND BALANCE10-1
SECTION 1. TERMINOLOGY10-1
10-1. GENERAL10-1
10-2. TERMINOLOGY10-1
10-3.–10-13. [RESERVED.]10-9
SECTION 2. WEIGHING PROCEDURES10-10
10-14. GENERAL10-10
10-15. PROCEDURES10-10
10-16. REPAIRS AND ALTERATIONS10-11
10-17. ANNUAL OR 100-HOUR INSPECTION10-11
10-18. W&B COMPUTATIONS10-12
10-19. W&B EXTREME CONDITIONS10-13
10-20. LOADING CONDITIONS AND/OR PLACARDS10-16
10-21. EQUIPMENT LIST10-19
10-22. EQUIPMENT CHANGE10-20
10-23. SAMPLE W&B REPORT10-21
10-24. INSTALLATION OF BALLAST10-24
10-25. LOADING SCHEDULE10-25
10-26.–10-34. [RESERVED.]10-25
CHAPTER 11. AIRCRAFT ELECTRICAL SYSTEMS11-1
SECTION 1. INSPECTION AND CARE OF ELECTRICAL SYSTEMS11-1
11-1. GENERAL11-1
11-2. INSPECTION AND OPERATION CHECKS11-1
11-3. FUNCTIONAL CHECK OF STAND-BY OR EMERGENCY EQUIPMENT11-2
11-4. CLEANING AND PRESERVATION11-2
11-5. BATTERY ELECTROLYTE CORROSION11-2
11-6. ADJUSTMENT AND REPAIR11-2
11-7. INSULATION OF ELECTRICAL EQUIPMENT11-3
11-8. BUS BARS11-3
11-9. ASTM INTERNATIONAL11-3
11-10.–11-14. [RESERVED.]11-4
SECTION 2. STORAGE BATTERIES11-5
11-15. GENERAL11-5
11-16. BATTERY CHARGING11-5
11-17. BATTERY FREEZING11-5
11-18. TEMPERATURE CORRECTION11-6
11-19. BATTERY MAINTENANCE11-7
11-20. ELECTROLYTE SPILLAGE11-10
11-21. NOXIOUS FUMES11-10
11-22. INSTALLATION PRACTICES11-10
11-23.–11-29. [RESERVED.]11-12
SECTION 3. INSPECTION OF EQUIPMENT INSTALLATION11-13
11-30. GENERAL11-13
11-31. INSTALLATION CLEARANCE PROVISIONS11-13
11-32. WIRES, WIRE BUNDLES, AND CIRCUIT PROTECTIVE DEVICES11-13
11-33. ALTERNATOR DIODES11-13
11-34. STATIC ELECTRICAL POWER CONVERTERS11-13
11-35. ACCEPTABLE MEANS OF CONTROLLING OR MONITORING THE
ELECTRICAL LOAD11-14
11-36. ELECTRICAL LOAD DETERMINATION11-14
11-37. JUNCTION BOX CONSTRUCTION11-15
11-38.–11-46. [RESERVED.]11-15
SECTION 4. INSPECTION OF CIRCUIT-PROTECTION DEVICES11-16
11-47. GENERAL11-16
11-48. DETERMINATION OF CIRCUIT BREAKER RATINGS11-16
11-49. DC CIRCUIT PROTECTOR CHART11-16
11-50. RESETTABLE CIRCUIT PROTECTION DEVICES11-17
11-51. CIRCUIT BREAKER USAGE11-17
11-52. CIRCUIT BREAKER MAINTENANCE11-18
11-53. SWITCHES11-18
11-54. RELAYS11-22
11-55. LOAD CONSIDERATIONS11-23
11-56. OPERATING CONDITIONS FOR SWITCHES AND RELAYS11-23
11-57.–11-65. [RESERVED.]11-23
SECTION 5. ELECTRICAL WIRE RATING11-24
11-66. GENERAL11-24
11-67. METHODS FOR DETERMINING CURRENT CARRYING CAPACITY OF
WIRES11-28
11-68. INSTRUCTIONS FOR USE OF ELECTRICAL WIRE CHART11-29
11-69. COMPUTING CURRENT CARRYING CAPACITY11-33
11-70.–11-75. [RESERVED.]11-40
SECTION 6. AIRCRAFT ELECTRICAL WIRE SELECTION11-41
11-76. GENERAL11-41
11-77. AIRCRAFT WIRE MATERIALS11-41
11-78. SUBSTITUTIONS11-43
11-79.–11-84. [RESERVED.]11-43
SECTION 7. TABLE OF ACCEPTABLE WIRES11-44
11-85. AIRCRAFT WIRE TABLE11-44
11-86. OPEN AIRFRAME INTERCONNECTING WIRE11-47
11-87. PROTECTED WIRE11-47
11-88. SEVERE WIND AND MOISTURE PROBLEMS (SWAMP)11-47
11-89. SHIELDED WIRE11-47
11-90.–11-95. [RESERVED.]11-48
SECTION 8. WIRING INSTALLATION INSPECTION REQUIREMENTS11-49
11-96. GENERAL11-49
11-97. WIRING REPLACEMENT11-52
11-98. TERMINALS AND TERMINAL BLOCKS11-53
11-99. FUSES AND FUSE HOLDERS11-53
11-100. CONNECTORS11-54
11-101. JUNCTION BOXES, PANELS, SHIELDS, AND
MICRO-SWITCH HOUSINGS11-55
11-102. RIGID METALLIC, FLEXIBLE METALLIC AND RIGID NONMETALLIC
CONDUIT11-55
11-103. JUNCTIONS11-55
11-104. CIRCUIT BREAKERS11-56
11-105. SYSTEM SEPARATION11-56
11-106. ELECTROMAGNETIC INTERFERENCE (EMI)11-56
11-107. INTERFERENCE TESTS11-56
11-108. IDENTIFICATION STENCILS AND PLACARDS ON ELECTRICAL
EQUIPMENT11-57
11-109.–11-114. [RESERVED.]11-57
SECTION 9. ENVIRONMENTAL PROTECTION AND INSPECTION11-58
11-115. MAINTENANCE AND OPERATIONS11-58
11-116. GROUP AND BUNDLE TIES11-58
11-117. MINIMUM WIRE BEND RADII11-59
11-118. SLACK11-59
11-119. DRIP LOOP IN WIRE BUNDLE11-60
11-120. POWER FEEDERS11-61
11-121. RF CABLE11-61
11-122. PRECAUTIONS11-61
11-123. MOISTURE PROTECTION, WHEEL WELLS, AND
LANDING GEAR AREAS11-62
11-124. PROTECTION AGAINST PERSONNEL AND CARGO11-62
11-125. HEAT PRECAUTIONS11-62
11-126. MOVABLE CONTROLS WIRING PRECAUTIONS11-62
11-127. FLAMMABLE FLUIDS AND GASES11-62
11-128.–11-134. [RESERVED.]11-63
SECTION 10. SERVICE LOOP HARNESSES (PLASTIC TIE STRIPS)11-64
11-135. GENERAL11-64
11-136. SUPPORT11-64
11-137. ANTI-CHAFING MATERIAL11-64
11-138. STRAIN RELIEF11-64
11-139. “SERVICE LOOP”11-64
11-140.–11-145. [RESERVED.]11-65
SECTION 11. CLAMPING11-66
11-146. GENERAL11-66
11-147. WIRE AND CABLE CLAMPS INSPECTION11-66
11-148.–11-154. [RESERVED.]11-69
SECTION 12. WIRE INSULATION AND LACING STRING TIE11-70
11-155. GENERAL11-70
11-156. INSULATION MATERIALS11-70
11-157. STRIPPING INSULATION11-70
11-158. LACING AND TIES11-71
11-159. INSULATION TAPE11-74
11-160.–11-166. [RESERVED.]11-74
SECTION 13. SPLICING11-75
11-167. GENERAL11-75
11-168.–11-173. [RESERVED.]11-75
SECTION 14. TERMINAL REPAIRS11-76
11-174. GENERAL11-76
11-175. ATTACHMENT OF TERMINALS TO STUDS11-77
11-176. STUDS AND INSULATORS11-77
11-177. WIRE TERMINALS AND BINDING POSTS11-78
11-178. CRIMP ON TERMINAL LUGS AND SPLICES (pre-insulated crimp type)11-78
11-179. LOCK WASHERS FOR TERMINALS ON EQUIPMENT11-79
11-180.–11-184. [RESERVED.]11-79
SECTION 15. GROUNDING AND BONDING11-80
11-185. GENERAL11-80
11-186. GROUNDING11-80
11-187. BONDING11-82
11-188. BONDING INSPECTION11-82
11-189. BONDING JUMPER INSTALLATIONS11-84
11-190. CREEPAGE DISTANCE11-89
11-191. FUEL SYSTEMS11-89
11-192. ELECTRIC SHOCK PREVENTION BONDING11-89
11-193. LIGHTNING PROTECTION BONDING11-89
11-194. LIGHTNING PROTECTION FOR ANTENNAS AND AIR DATA PROBES . 11-90
11-195. STATIC-DISCHARGE DEVICE11-90
11-196. CLEANING11-90
11-197. HARDWARE ASSEMBLY11-90
11-198.–11-204. [RESERVED.]11-91
SECTION 16. WIRE MARKING11-92
11-205. GENERAL11-92
11-206. WIRE IDENTIFICATION11-92
11-207. IDENTIFICATION AND INFORMATION RELATED TO THE WIRE AND
WIRING DIAGRAMS11-92
11-208. PLACEMENT OF IDENTIFICATION MARKINGS11-92
11-209. TYPES OF WIRE MARKINGS11-93
11-210. HOT STAMP MARKING11-94
11-211. DOT MATRIX MARKING11-94
11-212. INK JET MARKING11-94
11-213. LASER MARKING11-95
11-214. IDENTIFICATION SLEEVES11-95
11-215. IDENTIFICATION TAPE11-95
11-216. OPERATING CONDITIONS11-96
11-217. INSTALLATION OF PRINTED SLEEVES11-96
11-218. IDENTIFICATION OF WIRE BUNDLES AND HARNESSES11-96
11-219. TERMINAL MARKING SLEEVE AND TAGS11-97
11-220. SLEEVES AND CABLE MARKERS SELECTION11-98
11-221. TEMPORARY WIRE AND CABLE MARKING PROCEDURE11-103
11-222. MARKER SLEEVE INSTALLATION AFTER PRINTING11-103
11-223.–11-229. [RESERVED.]11-104
SECTION 17. CONNECTORS11-105
11-230. GENERAL11-105
11-231. SELECTION11-105
11-232. TYPES OF CONNECTORS11-105
11-233. VOLTAGE AND CURRENT RATING11-111
11-234. SPARE CONTACTS (FUTURE WIRING)11-111
11-235. INSTALLATION11-112
11-236. FEED-THROUGH BULKHEAD WIRE PROTECTION11-113
11-237. SPECIAL PURPOSE CONNECTOR11-113
11-238. POTTING COMPOUNDS11-113
11-239. POTTING CONNECTORS11-113
11-240. THROUGH BOLTS11-114
11-241.–11-247. [RESERVED.]11-114
SECTION 18. CONDUITS11-115
11-248. GENERAL11-115
11-249. SIZE OF CONDUIT11-115
11-250. CONDUIT FITTINGS11-115
11-251. CONDUIT INSTALLATION11-115
11-252. RIGID CONDUIT11-115
11-253. FLEXIBLE CONDUIT11-116
11-254.–11-259. [RESERVED.]11-117
SECTION 19. UNUSED CONNECTORS AND UNUSED WIRES11-118
11-260. GENERAL11-118
11-261. QUICK REFERENCE CHART11-118
11-262. UNPRESSURIZED AREA CONNECTORS11-118
11-263. PRESSURIZED AREAS11-120
11-264.–11-270. [RESERVED.]11-120
SECTION 20. ELECTRICAL AND ELECTRONIC SYMBOLS11-121
11-271. GENERAL11-121
11-272. SYMBOLS11-121
11-273.–11-283. [RESERVED.]11-134
CHAPTER 12. AIRCRAFT AVIONICS SYSTEMS12-1
SECTION 1. AVIONICS EQUIPMENT MAINTENANCE12-1
12-1. GENERAL12-1
12-2. HANDLING OF COMPONENTS12-1
12-3.–12-7. [RESERVED.]12-1
SECTION 2. GROUND OPERATIONAL CHECKS FOR AVIONICS EQUIPMENT
(ELECTRICAL)12-2
12-8. GENERAL12-2
12-9. INSPECTION OF AVIONICS SYSTEMS12-2
12-10. COMMUNICATION SYSTEMS12-4
12-11. VHF OMNI-DIRECTIONAL RANGE (VOR)12-4
12-12. DISTANCE MEASURING EQUIPMENT (DME)12-4
12-13. AUTOMATIC DIRECTION FINDER (ADF)12-5
12-14. INSTRUMENT LANDING SYSTEMS (ILS)12-5
12-15. MARKER BEACON12-6
12-16. LONG RANGE NAVIGATION (LORAN)12-6
12-17. GLOBAL POSITIONING SYSTEM (GPS)12-6
12-18. AUTOPILOT SYSTEMS12-6
12-19. ALTIMETERS12-7
12-20. TRANSPONDERS12-7
12-21. AUTOMATIC DEPENDENT SURVEILLANCE-BROADCAST (ADS-B)12-8
12-22. EMERGENCY LOCATOR TRANSMITTERS (ELT)12-8
12-23. INSPECTION OF ELT12-8
12-24. FLIGHT DATA RECORDER (FDR)12-9
12-25. COCKPIT VOICE RECORDERS (CVR)12-10
12-26. WEATHER RADAR12-11
12-27. RADOME INSPECTION12-11
12-28. DATABUS12-11
12-29. ELECTRIC COMPATIBILITY12-11
12-30.–12-36. [RESERVED.]12-12
SECTION 3. GROUND OPERATIONAL CHECKS FOR AVIONICS EQUIPMENT
(NON-ELECTRICAL)12-13
12-37. COMPASS SWING12-13
12-38. PNEUMATIC GYROS12-15
12-39.–12-50. [RESERVED.]12-18
SECTION 4. PITOT/STATIC SYSTEMS12-19
12-51. GENERAL12-19
12-52. SYSTEM COMPONENTS12-19
12-53. PITOT/STATIC TUBES AND LINES12-19
12-54. STATIC PORTS AND VENTS12-20
12-55. HEATER ELEMENTS12-20
12-56. SYSTEM INSPECTION12-21
12-57. SYSTEM LEAK TEST12-21
12-58. STATIC SYSTEM TESTS12-21
12-59. TEST PITOT SYSTEM12-22
12-60. MAINTENANCE PRECAUTIONS12-22
12-61. REPLACING LINES12-23
12-62. RELOCATION OF PITOT TUBE12-23
12-63. TROUBLESHOOTING THE PITOT/STATIC PRESSURE SYSTEM12-23
12-64.–12-69. [RESERVED.]12-24
SECTION 5. AVIONICS TEST EQUIPMENT12-25
12-70. GENERAL12-25
12-71. TEST EQUIPMENT CALIBRATION STANDARDS12-25
12-72.–12-83. [RESERVED.]12-26
CHAPTER 13. HUMAN FACTORS13-1
13-1. HUMAN FACTORS INFLUENCE ON MECHANIC’S PERFORMANCE13-1
13-2. THE FAA AVIATION SAFETY PROGRAM13-1
APPENDIX 1. GLOSSARY1
APPENDIX 2. ACRONYMS AND ABBREVIATIONS1
APPENDIX 3. METRIC-BASED PREFIXES AND POWERS OF 101
LIST OF FIGURES
Figure 1-1. Relative shrinkage of wood members due to drying1-5
Figure 1-2. Tapering of faceplate1-5
Figure 1-3. Likely areas to incur structural damage1-15
Figure 1-4. Consideration of grain direction when making scarf joints1-17
Figure 1-5. Method of splicing solid or laminated rectangular spars1-18
Figure 1-6. Method of splicing solid “I” spars1-19
Figure 1-7. Repairs to built-up “I” spar1-20
Figure 1-8. Method of splicing box spar flanges (plate method)1-21
Figure 1-9. Method of splicing box spar webs1-22
Figure 1-10. Method of reinforcing a longitudinal crack and/or local damage in
a solid spar1-24
Figure 1-11. Repair of wood ribs1-26
Figure 1-12. Typical wing compression rib repairs1-28
Figure 1-13. Splayed patch1-30
Figure 1-14. Surface patches1-32
Figure 1-15. Scarf patches (back of skin accessible)1-33
Figure 1-16. Scarf patches (back of skin not accessible)1-34
Figure 1-17. Oval plug patch assembly1-36
Figure 1-18. Round plug patch assembly1-37
Figure 2-1. Fabric seams2-7
Figure 2-2. Typical methods of attaching fabric2-8
Figure 2-3. Exploded side view of rib2-11
Figure 2-4. Standard external modified seine knot used for single and
double rib lacing2-12
Figure 2-5. Starting stitch for rib lacing2-13
Figure 2-6. Standard single-loop lacing2-14
Figure 2-7. Standard knot for double-loop lacing2-15
Figure 2-8. Standard double-loop lacing (optional)2-16
Figure 2-9a. Alternate sequence to tie a modified seine knot for rib lacing2-17
Figure 2-9b. Alternate sequence to tie a modified seine knot for rib lacing2-18
Figure 2-9c. Alternate sequence to tie a modified seine knot for rib lacing2-19
Figure 2-10. Splice knot2-20
Figure 2-11. Blindstitch lacing square knot secured with half hitches2-21
Figure 2-12. Fabric attachment spacing2-23
Figure 2-13. Repair of tears in fabric2-39
Figure 2-14. Hand-stitch detail2-40
Figure 3-1. Typical laminate (facing) repair3-2
Figure 3-2. Typical core and facing repair3-3
Figure 3-3. Typical stepped joint repair3-3
Figure 3-4. Preparing the fiberglass sandwich3-5
Figure 3-5. Scarfed repair to a nonstructural laminated fiberglass component3-6
Figure 3-6. Symmetrical layup same as original number of plies, plus one extra ply3-7
Figure 3-7. Typical scarf joint repair3-8
Figure 3-8. Carefully cut through each layer of fiberglass cloth and
remove it from the damaged area3-9
Figure 3-9. Sample bagging layup cross-section3-10
Figure 3-10. Typical types of core replacement3-14
Figure 3-11. Typical undercut core material cavity3-15
Figure 3-12. Cross-section of bonded and bolted overlap repairs3-15
Figure 3-13. Honeycomb core removal3-16
Figure 3-14 Removing honeycomb core from a tapered control surface3-16
Figure 3-15. Removal of core with core knife3-17
Figure 3-16. Details of core repair3-18
Figure 3-17. Hanging of acrylic sheets3-21
Figure 3-18. Drill having an included angle of approximately 150º,
used to drill acrylic plastics3-24
Figure 3-19. Unibit drill for drilling acrylic plastics3-24
Figure 3-20. Applying pressure to acrylic plastics3-25
Figure 3-21. Stop-drilling cracks3-26
Figure 3-22. Surface patches3-27
Figure 3-23. Plug patch repair3-28
Figure 3-24. Temporary repairs to cracked windshields or windows3-31
Figure 4-1. Comparison of indentation made by Knoop and Vickers
indenters in the same work metal and at the same loads4-10
Figure 4-2. Setback for a 90-degree bend4-17
Figure 4-3. Methods of determining setback for bends other than 90 degrees4-19
Figure 4-4. Rivet identification and part number breakdown4-21
Figure 4-5. Rivet hole spacing and edge distance for single-lap sheet splices4-25
Figure 4-6. Riveting practice and rivet imperfections4-26
Figure 4-7. Self-plugging friction-lock cherry rivets4-27
Figure 4-8. Mechanical-lock (Bulbed CherryLOCK) cherry rivet4-29
Figure 4-9. CherryMAX rivet4-30
Figure 4-10. Olympic-Lok rivet4-31
Figure 4-11. Huck rivet4-32
Figure 4-12. Typical repair method for tubular members of aluminum alloy4-34
Figure 4-13. Typical repair for buckled or cracked metal wing rib cap strips4-36
Figure 4-14. Typical metal rib repairs4-37
Figure 4-15. Typical repairs of trailing edges4-38
Figure 4-16. Typical repairs of stressed sheet metal coverings4-39
Figure 4-17. Typical stringer and flange splices4-44
Figure 4-18. Example of stringer splice (material: 2017 alloy)4-45
Figure 4-19. Application of typical flange splices and reinforcement4-46
Figure 4-20. Example of intermediate frame stringer splice
(material: 2017-T3 AL alloy)4-50
Figure 4-21. Typical methods of repairing cracked leading and trailing edges and
rib intersections4-51
Figure 4-22. Typical methods of replacing cracked members at fittings4-52
Figure 4-23. Typical methods of repairing cracked frame and stiffener combination4-53
Figure 4-24. Typical repairs to rudder and to fuselage at tail post4-54
Figure 4-25. Typical methods of repairing elongated or worn bolt holes4-56
Figure 4-26. Common defects to avoid when fitting and welding
aircraft certification cluster4-66
Figure 4-27. Lap weld strength calculation4-67
Figure 4-28. Basic gas-welding flames: each has a distinctive shape, color,
and sound; neutral flame is the most used4-68
Figure 4-29. Set TIG welder to DC current, straight polarity for welding
mild steel, stainless steel, and titanium4-69
Figure 4-30. Set TIG to AC current for welding aluminum and magnesium4-70
Figure 4-31. In spot welding, heat is produced by electrical resistance between copper electrodes; pressure is simultaneously applied to electrode tips to force metal together to complete fusing process;
spot-weld nugget size is directly related to tip size4-71
Figure 4-32. Silver brazing joints4-73
Figure 4-33. Electric soldering iron4-74
Figure 4-34. Finger patch repairs for members dented at a cluster4-77
Figure 4-35. Members dented in a bay (repairs by welded sleeve)4-78
Figure 4-36. Welded-patch repair4-79
Figure 4-37. Splicing by inner-sleeve method4-81
Figure 4-38. Splicing by outer-sleeve method (replacement by welded outside sleeve)4-82
Figure 4-39. Tube replacement at a station by welded outer sleeves4-83
Figure 4-40. Splicing using larger diameter replacement tube4-84
Figure 4-41. Repairs at built-in fuselage fittings4-85
Figure 4-42. Streamline tube splice using round tube (applicable to landing gear)4-87
Figure 4-43. Streamline tube splice using split sleeve (applicable to wing and tail
surface brace struts and other members)4-88
Figure 4-44. Streamline tube splice using split insert (applicable to landing gear)4-89
Figure 4-45. Streamline tube splice using plates (applicable to landing gear)4-90
Figure 4-46. Representative types of repairable axle assemblies4-91
Figure 4-47. Landing gear assemblies that cannot be repaired by welding4-92
Figure 5-1. Typical borescope designs5-11
Figure 5-2. Using a flashlight to inspect for cracks5-13
Figure 5-3. Generating an eddy current5-14
Figure 5-4. Detecting an eddy current5-15
Figure 5-5. Typical instrument displays5-15
Figure 5-6. Typical surface cracks5-16
Figure 5-7. Typical subsurface cracks5-17