# Boeing Alert Service Bulletin DC8-53A080: U.S. DOT/FAA - SB-DC8-53A080-02

- Rights: © The Boeing Company. Filed by the FAA in regulations.gov docket FAA-2014-0235; AD 2014-22-10 incorporates this document by reference. Not covered by OpenAirDocs’ CC0 dedication.
- Document: [Boeing Alert Service Bulletin DC8-53A080](https://openairdocs.org/service-documents/boeing/dc8-53a080.md)
- Title as filed: U.S. DOT/FAA - SB-DC8-53A080-02
- Pages: 86
- PDF: https://openairdocs.org/files/sha256/a3/76/a3763420a40cc7cb3ff4762b1824a1e545fdda0d472971838c569e764e17428d
- Page: https://openairdocs.org/service-documents/boeing/dc8-53a080/file/a3763420a40c

## Text

Some pages are OCR from a scan. OCR can misread letters and numbers. Each page's text from the PDF; open the PDF at a page with #page=N.

### Page 1

Commercial 
Airplanes
DC8
Service Bulletin
ALERT
Number: DC8-53A080
Original Issue: June 22, 2004
Revision 2: September 18, 2013
ATA System: 5300
SUBJECT: FUSELAGE - Main Frame - Inspect/Repair Fuselage Skin Forward of Flat Aft Pressure
Bulkhead at Longeron 28
Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15
CFR 300-774). An export license may be required before it is used for development, production or use by foreign
persons from specific countries. The controller of this data has the individual responsibility to abide by all export
laws.
9E991ECCN:
BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET
Copyright © 2004 Boeing.
Unpublished Work. All Rights Reserved.
Treatment of this document and its content is governed by contract with Boeing. Rights to use this document
are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The
Boeing Company.
Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner,
BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and
Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in
connection with this document unless provided in writing by Boeing.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
1 of 86
2.0

### Page 2

Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
2 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT
BLANK PAGE

### Page 3

Table of Contents
Revision Transmittal Sheet ............................................ 5
Summary ...................................................... 7
1. PLANNING INFORMATION ........................................ 1 3
A. Effectivity ............................................... 1 3
1. Airplanes ............................................ 1 3
2. Spares Affected ........................................ 1 6
B. Concurrent Requirements ...................................... 1 6
C. Reason ................................................ 1 7
D. Description .............................................. 1 7
E. Compliance .............................................. 2 0
F. Approval ............................................... 6 0
G. Manpower .............................................. 6 0
H. Weight and Balance Changes .................................... 6 1
I. Electrical Load Data ......................................... 6 1
J. References .............................................. 6 1
1. Existing Data: ......................................... 6 1
2. Data Supplied with this Service Bulletin: ........................... 6 2
3. Installation Drawings Used in the Preparation of this Service Bulletin: ........... 6 2
K. Publications Affected ........................................ 6 2
L. Interchangeability and Intermixability of Parts ........................... 6 2
M. Software Accomplishment Summary ................................ 6 2
2. MATERIAL INFORMATION ........................................ 6 3
A. Material - Price and Availability ................................... 6 3
B. Industry Support Information .................................... 6 3
C. Parts Necessary for Each Airplane ................................. 6 3
1. Kits/Parts: ........................................... 6 3
2. Parts and Materials Supplied by the Operator: ........................ 6 3
3. Parts Modified and Reidentified: ............................... 6 5
4. Parts Removed and Not Replaced: .............................. 6 5
D. Parts Necessary to Change Spares ................................. 6 5
E. Special Tooling - Price and Availability ............................... 6 5
F. Special Tooling Necessary to do this Service Bulletin ....................... 6 5
3. ACCOMPLISHMENT INSTRUCTIONS .................................. 6 7
A. GENERAL INFORMATION ..................................... 6 7
B. WORK INSTRUCTIONS ....................................... 6 9
FIGURE 1: METHOD 103 REFLECTANCE TYPE SLIDING PROBE PROCEDURE REFERENCE
STANDARD ........................................... 7 8
FIGURE 2: HIGH FREQUENCY EDDY CURRENT INSPECTION OF SKIN ALONG LONGERON 28 . 80
FIGURE 3: METHOD 103 REFLECTANCE TYPE SLIDING PROBE PROCEDURE .......... 8 1
FIGURE 4: METHOD 103 REFLECTANCE TYPE SLIDING PROBE PROCEDURE .......... 8 2
Appendix A: .................................................. 8 3
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
3 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 4

Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
4 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT
BLANK PAGE

### Page 5

Commercial 
Airplanes
DC8
Service Bulletin
ALERT
Revision Transmittal SheetNumber: DC8-53A080Original Issue: June 22, 2004
Revision 2: September 18, 2013
ATA System: 5300
SUBJECT: FUSELAGE - Main Frame - Inspect/Repair Fuselage Skin Forward of Flat Aft Pressure
Bulkhead at Longeron 28
This revision includes all pages of the service bulletin.
COMPLIANCE INFORMATION RELATED TO THIS REVISION
Federal Aviation Administration (FAA) Airworthiness Directive AD 2008-06-23 is related to this service bulletin.
No more work is necessary on the airplane(s) changed in accordance with Revision 1 of this service bulletin.
REASON FOR REVISION
This revision is sent to add Options 3 and 4 for Group 1, Configuration 2 airplanes that were inadvertently omitted
at the release of Revision 1.
These sections were changed:
1. In Paragraph 1.D., Description, added Options 3 and 4 for Group 1, Configuration 2 airplanes.
2. In Paragraph 3.B., Work Instructions, added Options 3 and 4 for Group 1, Configuration 2 airplanes.
Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes,
to show the location of all content changes.
Pages with no vertical lines have no changes.
REVISION HISTORY
June 22, 2004Original Issue:
May 03, 2013Revision 1:
September 18, 2013Revision 2:
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
5 of 86

### Page 6

Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
6 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT
BLANK PAGE

### Page 7

Commercial 
Airplanes
DC8
Service Bulletin
ALERT
SummaryNumber: DC8-53A080Original Issue: June 22, 2004
Revision 2: September 18, 2013
ATA System: 5300
SUBJECT: FUSELAGE - Main Frame - Inspect/Repair Fuselage Skin Forward of Flat Aft Pressure
Bulkhead at Longeron 28
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OWNER.
CONCURRENT REQUIREMENTS
None.
BACKGROUND
During routine maintenance inspections, three operators reported finding three instances of cracks in the upper
aft skin panel. The cracks were located along the upper row of rivets common to the longeron 28 skin splice,
near the flat aft pressure bulkhead. Cracks were detected on airplanes which had accumulated between 27,072
and 46,176 flight cycles. If not corrected, in-flight fuselage decompression and unscheduled maintenance for
repairs may be required. Inspecting fuselage skin for cracks will determine condition of skin. Inspecting fuselage
skin for cracks, and repairing if necessary, will minimize the possibility of in-flight decompression and unscheduled
maintenance.
The fuselage skin has been determined to be structure that is susceptible to Widespread Fatigue Damage
(WFD).
This table is provided to operators for planning purposes only. Refer to the applicable sections for more
information.
ReferenceAffectedPlanning Data
Paragraph 1.A.2., Spares AffectedNoSpares Affected
Paragraph 1.E., Compliance and Paragraph
1.F., Approval
YesAD Related
Paragraph 1.H., Weight and Balance ChangesNoWeight and Balance Change
Paragraph 1.I., Electrical Load DataNoElectrical Load Changed
Paragraph 1.K., Publications AffectedNoPublications Affected
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
7 of 86

### Page 8

ReferenceAffectedPlanning Data
Paragraph 1.K., Publications AffectedNoAirplane Flight Operations Affected (Flight Crew
Operations Manual and/or FAA Approved Air-
plane Flight Manual)
Paragraph 2.C.1., Kits/PartsNoKits/Parts Required
Paragraph 2.C.2., Parts and Materials Supplied
by the Operator
NoOperator Supplied Parts/Material
Paragraph 2.F., Special Tooling Necessary to
do this Service Bulletin
NoSpecial Tooling Required
ACTION
Group 1, Configuration 1:
1. This service bulletin accomplishes a general visual and a High Frequency Eddy Current inspection of
the fuselage skin for cracks or failed fasteners at longeron 28 forward of flat aft pressure bulkhead, left
and right sides, and accomplishes the following based on condition:
a. Condition 1 (No Crack(s) or Failed Fasteners Found)
Option 1
Does repetitive inspections.
Installs full length improvement modification with finger doubler at a later time.
Option 2
Does repetitive inspections.
Installs full length improvement modification at a later time.
b. Condition 2 (Any Failed Fasteners)
Option 1
Replaces failed fasteners and does repetitive inspections.
Installs full length improvement modification with finger doubler at a later time.
Option 2
Replaces failed fasteners and does repetitive inspections.
Installs full length improvement modification at a later time.
Option 3
Installs full length improvement modification with finger doubler.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
8 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 9

Option 4
Installs full length improvement modification.
c. Condition 3 (Any Crack(s) Found in Skin)
Option 1
Repairs cracked skin locally, and does repetitive inspections.
Installs full length repair with finger doubler at a later time.
Option 2
Repairs cracked skin locally, and does repetitive inspections.
Installs full length repair at a later time.
Option 3
Installs full length repair with finger doubler.
Option 4
Installs full length repair.
Group 1, Configuration 2:
1. This service bulletin accomplishes a general visual and a High Frequency Eddy Current inspection of
the fuselage skin for cracks or failed fasteners at longeron 28 forward of flat aft pressure bulkhead, left
and right sides, and accomplishes the following based on condition:
a. Condition 1 (No Crack(s) or Failed Fasteners Found)
Option 1
Does repetitive inspections of accessible skin.
Replaces previously installed local skin repairs with new local skin repairs defined in this service
bulletin.
Installs full length repair with finger doubler at a later time.
Option 2
Does repetitive inspections of accessible skin.
Replaces previously installed local skin repairs with new local skin repairs defined in this service
bulletin.
Installs full length repair at a later time.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
9 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 10

Option 3
Removes previously installed local skin repairs.
Installs full length repair with finger doubler
Option 4
Removes previously installed local skin repairs.
Installs full length repair.
b. Condition 2 (Any Failed Fasteners)
Option 1
Replaces all failed fasteners.
Does repetitive inspections of accessible skin.
Replaces previously installed local skin repairs with new local skin repairs as defined in this service
bulletin.
Removes previously installed local repairs and installs full length repair with finger doubler at a
later time.
Option 2
Replaces all failed fasteners.
Replaces previously installed local skin repairs with new local skin repairs as defined in this service
bulletin.
Removes previously installed local repairs and does full length repair at a later time.
Option 3
Removes previously installed local repairs and installs full length repair with finger doubler.
Option 4
Removes previously installed local repairs and installs full length repair.
c. Condition 3 (Any Crack(s) Found in Skin)
Option 1
Repairs cracks with local skin repairs as defined in this service bulletin.
Does repetitive inspections of accessible skin.
Replaces previously installed local skin repairs with new local skin repairs as defined in this service
bulletin.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
10 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 11

Removes previously installed local repairs and does full length repair with finger doubler at a later
time.
Option 2
Repairs cracks with local skin repairs as defined in this service bulletin.
Does repetitive inspections of accessible skin.
Replaces previously installed local skin repairs with new local skin repairs as defined in this service
bulletin.
Removes previously installed local repairs and does full length repair at a later time.
Option 3
Removes previously installed local repairs and does full length repair with finger doubler.
Option 4
Removes previously installed local repairs and does full length repair.
EFFECTIVITY
DC-8-55, DC-8-61, DC-8-61F, DC-8-62, DC-8-62F, DC-8-63, DC-8-63F, DC-8-71, DC-8-71F, DC-8-72, DC-8-72F,
DC-8-73, DC-8-73F, DC-8F-54, DC-8F-55 airplanes with flat aft pressure bulkhead. Refer to Paragraph 1.A.1.
for detailed effectivity.
COMPLIANCE
Federal Aviation Administration (FAA) Airworthiness Directive AD 2008-06-23 is related to this service bulletin.
Refer to Paragraph 1.E., Compliance.
INDUSTRY SUPPORT INFORMATION
Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service
bulletin.
MANPOWER
Refer to Paragraph 1.G., Manpower.
MATERIAL INFORMATION
Operator Supplied Parts.
Refer to Paragraph 2.A., Material - Price and Availability.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
11 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 12

Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
12 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT
BLANK PAGE

### Page 13

Commercial 
Airplanes
DC8
Service Bulletin
ALERT
Number: DC8-53A080
Original Issue: June 22, 2004
Revision 2: September 18, 2013
ATA System: 5300
SUBJECT: FUSELAGE - Main Frame - Inspect/Repair Fuselage Skin Forward of Flat Aft Pressure
Bulkhead at Longeron 28
THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH
1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO
THE NEW OWNER.
1.    PLANNING INFORMATION
A. Effectivity
1. Airplanes
This service bulletin is for the airplanes shown below.
DESCRIPTIONCONFIGURATIONGROUP
DC-8 Series 50, 60 and 70 airplanes with flat aft pressure bulkhead-1
Airplanes with no existing repairs in the area of inspection.1
Airplanes that have existing repairs in the area of inspection.2
Airplane Models:
DC-8-55, DC-8-61, DC-8-61F, DC-8-62, DC-8-62F, DC-8-63, DC-8-63F, DC-8-71, DC-8-71F,
DC-8-72, DC-8-72F, DC-8-73, DC-8-73F, DC-8F-54, DC-8F-55
GroupFuselage Num-
ber
1122
1182
1185
1187
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
13 of 86

### Page 14

GroupFuselage Num-
ber
1189
1197
1200
1203
1207 - 208
1218
1223
1234
1241
1246 - 248
1251 - 252
1254 - 255
1259
1261 - 262
1274
1276 - 277
1283 - 284
1286
1288 - 289
1290
1292
1294 - 295
1298
1305
1307
1309
1313
1316 - 319
1320 - 323
1326 - 327
1329
1331
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
14 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 15

GroupFuselage Num-
ber
1333 - 335
1337 - 339
1343 - 344
1347 - 348
1350 - 354
1356
1358
1360 - 361
1363
1365
1368 - 369
1370 - 377
1379
1380 - 382
1385 - 389
1392 - 399
1400 - 401
1403
1405
1407 - 408
1410 - 411
1413
1416 - 419
1420 - 423
1425 - 428
1431 - 432
1434 - 439
1440 - 447
1449
1450 - 451
1453 - 459
1460
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
15 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 16

GroupFuselage Num-
ber
1462 - 469
1471
1475
1477 - 479
1480 - 483
1485 - 488
1490 - 493
1495 - 497
1500 - 504
1507 - 509
1511 - 512
1515 - 516
1519
1520 - 525
1527 - 529
1530 - 531
1534 - 535
1538 - 539
1540
1542
1544
1546 - 549
1551
1554 - 556
2. Spares Affected
None.
B. Concurrent Requirements
None.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
16 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 17

C. Reason
During routine maintenance inspections, three operators reported finding three instances of cracks in
the upper aft skin panel. The cracks were located along the upper row of rivets common to the longeron
28 skin splice, near the flat aft pressure bulkhead. Cracks were detected on airplanes which had
accumulated between 27,072 and 46,176 flight cycles. If not corrected, in-flight fuselage decompression
and unscheduled maintenance for repairs may be required. Inspecting fuselage skin for cracks will
determine condition of skin. Inspecting fuselage skin for cracks, and repairing if necessary, will minimize
the possibility of in-flight decompression and unscheduled maintenance.
The fuselage skin has been determined to be structure that is susceptible to Widespread Fatigue
Damage (WFD).
Revision 1 was sent to add kit configurations for the improvement modification.
Revision 2 is sent to add Options 3 and 4 for Group 1, Configuration 2 airplanes that were inadvertently
omitted at the release of Revision 1..
D. Description
Group 1, Configuration 1:
1. This service bulletin accomplishes a general visual and a High Frequency Eddy Current inspection
of the fuselage skin for cracks or failed fasteners at longeron 28 forward of flat aft pressure bulkhead,
left and right sides, and accomplishes the following based on condition:
a. Condition 1 (No Crack(s) or Failed Fasteners Found)
Option 1
Does repetitive inspections.
Installs full length improvement modification with finger doubler at a later time.
Option 2
Does repetitive inspections.
Installs full length improvement modification at a later time.
b. Condition 2 (Any Failed Fasteners)
Option 1
Replaces failed fasteners and does repetitive inspections.
Installs full length improvement modification with finger doubler at a later time.
Option 2
Replaces failed fasteners and does repetitive inspections.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
17 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 18

Installs full length improvement modification at a later time.
Option 3
Installs full length improvement modification with finger doubler.
Option 4
Installs full length improvement modification.
c. Condition 3 (Any Crack(s) Found in Skin)
Option 1
Repairs cracked skin locally, and does repetitive inspections.
Installs full length repair with finger doubler at a later time.
Option 2
Repairs cracked skin locally, and does repetitive inspections.
Installs full length repair at a later time.
Option 3
Installs full length repair with finger doubler.
Option 4
Installs full length repair.
Group 1, Configuration 2:
1. This service bulletin accomplishes a general visual and a High Frequency Eddy Current inspection
of the fuselage skin for cracks or failed fasteners at longeron 28 forward of flat aft pressure bulkhead,
left and right sides, and accomplishes the following based on condition:
a. Condition 1 (No Crack(s) or Failed Fasteners Found)
Option 1
Does repetitive inspections of accessible skin.
Replaces previously installed local skin repairs with new local skin repairs defined in this
service bulletin.
Installs full length repair with finger doubler at a later time.
Option 2
Does repetitive inspections of accessible skin.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
18 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 19

Replaces previously installed local skin repairs with new local skin repairs defined in this
service bulletin.
Installs full length repair at a later time.
Option 3
Removes previously installed local skin repairs.
Installs full length repair with finger doubler
Option 4
Removes previously installed local skin repairs.
Installs full length repair
b. Condition 2 (Any Failed Fasteners)
Option 1
Replaces all failed fasteners.
Does repetitive inspections of accessible skin.
Replaces previously installed local skin repairs with new local skin repairs as defined in this
service bulletin.
Removes previously installed local repairs and installs full length repair with finger doubler at
a later time.
Option 2
Replaces all failed fasteners.
Replaces previously installed local skin repairs with new local skin repairs as defined in this
service bulletin.
Removes previously installed local repairs and does full length repair at a later time.
Option 3
Removes previously installed local repairs and installs full length repair with finger doubler.
Option 4
Removes previously installed local repairs and installs full length repair.
c. Condition 3 (Any Crack(s) Found in Skin)
Option 1
Repairs cracks with local skin repairs as defined in this service bulletin.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
19 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 20

Does repetitive inspections of accessible skin.
Replaces previously installed local skin repairs with new local skin repairs as defined in this
service bulletin.
Removes previously installed local repairs and does full length repair with finger doubler at a
later time.
Option 2
Repairs cracks with local skin repairs as defined in this service bulletin.
Does repetitive inspections of accessible skin.
Replaces previously installed local skin repairs with new local skin repairs as defined in this
service bulletin.
Removes previously installed local repairs and does full length repair at a later time.
Option 3
Removes previously installed local repairs and does full length repair with finger doubler.
Option 4
Removes previously installed local repairs and does full length repair.
Revision 2 - No more work is necessary on airplanes changed in accordance with Revision 1 of this
service bulletin.
The work in this service bulletin is done in the maintenance zone(s) given below.
Affected Maintenance Zones
ZoneModel
661DC-8-55, DC-8-61, DC-8-61F,
DC-8-62, DC-8-62F, DC-8-63,
DC-8-63F, DC-8-71, DC-8-71F,
DC-8-72, DC-8-72F, DC-8-73,
DC-8-73F, DC-8F-54, DC-8F-55
E. Compliance
Federal Aviation Administration (FAA) Airworthiness Directive AD 2008-06-23 is related to this service
bulletin.
Do the required actions in accordance with Paragraph 3. Accomplishment Instructions.
When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When
more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION
numbers for that CONDITION number or OPTION number.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
20 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 21

Table 1 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the
original issue date of this service bulletin and no skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later )
ActionCondition
.2 years from origi-
nal issue date of
this service bul-
letin
Accumulation of
24,000 total flight
cycles
Do a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the
fuselage skin and fasteners at
longeron 28 forward of flat aft
pressure bulkhead, left and
right sides and do the work
listed based on condition
Airplanes with flat
aft pressure bulk-
head having less
than 24,000 total
flight cycles as of
the original issue
date of this service
bulletin and no
skin repairs in the
area of inspection.
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the
fuselage skin and fasteners at
longeron 28 forward of flat aft
pressure bulkhead, left and
right sides and do the work
listed based on condition
Condition 1
(No Crack(s) or
Failed Fasteners
Found)
Option 1
(a) (b)
AND
.6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Install full length improvement
modification with finger dou-
blers.
AND
5,000 flight cy-
cles
.30,000 flight cycles
from full length im-
provement modifica-
tion with finger dou-
blers installation
Do an external visual inspec-
tions for cracks along all four
edges of the external dou-
blers, left and right sides.
(a) (c)
OR
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
21 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 22

Table 1 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the
original issue date of this service bulletin and no skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later )
ActionCondition
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the
fuselage skin and fasteners at
longeron 28 forward of flat aft
pressure bulkhead, left and
right sides and do the work
listed based on condition
Option 2
(a) (b)
AND
.6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Install full length improvement
modification
AND
10,000 flight cy-
cles
.15,000 flight cycles
from full length
modification installa-
tion
Do a Low Frequency Eddy
Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
22 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 23

Table 1 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the
original issue date of this service bulletin and no skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later )
ActionCondition
..Before further flightReplace all Failed Fasteners.Condition 2
Any Failed Fasten-
er(s) AND
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the
fuselage skin and fasteners at
longeron 28 forward of flat aft
pressure bulkhead, left and
right sides and do the work
listed based on Condition
Option 1
(a) (b)
AND
.6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Install full length improvement
modification with finger dou-
blers.
AND
5,000 flight cy-
cles
.30,000 flight cycles
from full length im-
provement modifica-
tion with finger dou-
blers installation
Do an external visual inspec-
tions for cracks along all four
edges of the external dou-
blers, left and right sides.
(a) (c)
OR
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
23 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 24

Table 1 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the
original issue date of this service bulletin and no skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later )
ActionCondition
..Before further flightReplace all Failed Fasteners.Option 2
AND
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the
fuselage skin and fasteners at
longeron 28 forward of flat aft
pressure bulkhead, left and
right sides and do the work
listed based on Condition
(a) (b)
AND
.6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Install full length improvement
modification.
AND
10,000 flight cy-
cles
.15,000 flight cycles
from full length
modification installa-
tion
Do a Low Frequency Eddy
Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
OR
..Before further flightInstall full length improvement
modification with finger dou-
blers.
Option 3
AND
5,000 flight cy-
cles
.30,000 flight cycles
from full length im-
provement modifica-
tion with finger dou-
blers installation
Do an external visual inspec-
tions for cracks along all four
edges of the external dou-
blers, left and right sides.
(a) (c)
OR
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
24 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 25

Table 1 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the
original issue date of this service bulletin and no skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later )
ActionCondition
..Before further flightInstall full length improvement
modification.
Option 4
AND
10,000 flight cy-
cles
.15,000 flight cycles
from full length
modification installa-
tion
Do a Low Frequency Eddy
Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
25 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 26

Table 1 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the
original issue date of this service bulletin and no skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later )
ActionCondition
..Before further flightDo local skin repair.Condition 3
Any Crack(s)
Found in Skin AND
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the ac-
cessible fuselage skin and
fasteners at longeron 28 for-
ward of flat aft pressure bulk-
head, left and right sides and
do the work listed based on
condition of the unrepaired ar-
eas
Option 1
(a) (b)
AND
5,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For local skin repairs 12 inch-
es or less long, do an external
visual inspections for cracks
along all four edges of the ex-
ternal doublers
(a) (c)
AND/OR
10,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For skin repairs longer than 12
inches, do a Low Frequency
Eddy Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
AND
.6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Install full length repair with
finger doublers.
AND
5,000 flight cy-
cles
.30,000 flight cycles
from full length re-
pair with finger dou-
blers repair installa-
tion
Do an external visual inspec-
tions for cracks along all four
edges of the external dou-
blers, left and right sides.
(a) (c)
OR
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
26 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 27

Table 1 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the
original issue date of this service bulletin and no skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later )
ActionCondition
..Before further flightDo local skin repair.Option 2
AND
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the ac-
cessible fuselage skin and
fasteners at longeron 28 for-
ward of flat aft pressure bulk-
head, left and right sides and
do the work listed based on
condition of the unrepaired ar-
eas
(a) (b)
AND
AND
5,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For local skin repairs 12 inch-
es or less long, do an external
visual inspections for cracks
along all four edges of the ex-
ternal doublers
(a) (c)
AND/OR
10,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For skin repairs longer than 12
inches, do a Low Frequency
Eddy Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
AND
.6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Install full length repair dou-
blers.
AND
10,000 flight cy-
cles
.15,000 flight cycles
from full length re-
pair installation
Do a Low Frequency Eddy
Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
OR
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
27 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 28

Table 1 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the
original issue date of this service bulletin and no skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later )
ActionCondition
..Before further flightInstall full length repair with
finger doublers.
Option 3
AND
5,000 flight cy-
cles
.30,000 flight cycles
from full length re-
pair with finger dou-
blers installation
Do an external visual inspec-
tions for cracks along all four
edges of the external dou-
blers, left and right sides.
(a) (c)
OR
..Before further flightInstall full length repair dou-
blers.
Option 4
AND
10,000 flight cy-
cles
.15,000 flight cycles
from full length re-
pair installation
Do a Low Frequency Eddy
Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
(a) Repeat inspection at noted interval if no discrepancies are found.
(b) If any discrepancy is found, do the work of Condition 2 or 3 as applicable before further flight.
(c) If any discrepancy is found, contact Boeing and do the work required before further flight.
Table 2 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the
original issue date of this service bulletin and no skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later )
ActionCondition
.1 year from original issue date of this
service bulletin
Do a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the
fuselage skin and fasteners at
longeron 28 forward of flat aft
pressure bulkhead, left and
right sides and do the work
listed based on condition
Airplanes with flat
aft pressure bulk-
head having
24,000 or more to-
tal flight cycles as
of the original is-
sue date of this
service bulletin
and no skin re-
pairs in the area of
inspection.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
28 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 29

Table 2 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the
original issue date of this service bulletin and no skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later )
ActionCondition
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the
fuselage skin and fasteners at
longeron 28 forward of flat aft
pressure bulkhead, left and
right sides and do the work
listed based on condition
Condition 1
(No Crack(s) or
Failed Fasteners
Found)
Option 1
(a) (b)
AND
.6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Install full length improvement
modification with finger dou-
blers.
AND
5,000 flight cy-
cles
.30,000 flight cycles
from full length im-
provement modifica-
tion with finger dou-
blers installation
Do an external visual inspec-
tions for cracks along all four
edges of the external dou-
blers, left and right sides.
(a) (c)
OR
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the
fuselage skin and fasteners at
longeron 28 forward of flat aft
pressure bulkhead, left and
right sides and do the work
listed based on condition
Option 2
(a) (b)
AND
.6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Install full length improvement
modification
AND
10,000 flight cy-
cles
.15,000 flight cycles
from full length
modification installa-
tion
Do a Low Frequency Eddy
Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
29 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 30

Table 2 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the
original issue date of this service bulletin and no skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later )
ActionCondition
..Before further flightReplace all Failed Fasteners.Condition 2
Any Failed Fasten-
er(s) AND
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the
fuselage skin and fasteners at
longeron 28 forward of flat aft
pressure bulkhead, left and
right sides and do the work
listed based on Condition
Option 1
(a) (b)
AND
.6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Install full length improvement
modification with finger dou-
blers.
AND
5,000 flight cy-
cles
.30,000 flight cycles
from full length im-
provement modifica-
tion with finger dou-
blers installation
Do an external visual inspec-
tions for cracks along all four
edges of the external dou-
blers, left and right sides.
(a) (c)
OR
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
30 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 31

Table 2 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the
original issue date of this service bulletin and no skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later )
ActionCondition
Before further flightReplace all Failed Fasteners.Option 2
AND
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the
fuselage skin and fasteners at
longeron 28 forward of flat aft
pressure bulkhead, left and
right sides and do the work
listed based on Condition
(a) (b)
AND
.6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Install full length improvement
modification.
AND
10,000 flight cy-
cles
15,000 flight cycles
from full length
modification installa-
tion
Do a Low Frequency Eddy
Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
OR
..Before further flightInstall full length improvement
modification with finger dou-
blers.
Option 3
AND
5,000 flight cy-
cles
.30,000 flight cycles
from full length im-
provement modifica-
tion with finger dou-
blers installation
Do an external visual inspec-
tions for cracks along all four
edges of the external dou-
blers, left and right sides.
(a) (c)
OR
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
31 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 32

Table 2 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the
original issue date of this service bulletin and no skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later )
ActionCondition
..Before further flightInstall full length improvement
modification.
Option 4
AND
10,000 flight cy-
cles
.15,000 flight cycles
from full length
modification installa-
tion
Do a Low Frequency Eddy
Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
32 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 33

Table 2 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the
original issue date of this service bulletin and no skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later )
ActionCondition
..Before further flightDo local skin repair.Condition 3
Any Crack(s)
Found in Skin AND
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the ac-
cessible fuselage skin and
fasteners at longeron 28 for-
ward of flat aft pressure bulk-
head, left and right sides and
do the work listed based on
condition of the unrepaired ar-
eas
Option 1
(a) (b)
AND
5,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For local skin repairs 12 inch-
es or less long, do an external
visual inspections for cracks
along all four edges of the ex-
ternal doublers
(a) (c)
AND/OR
10,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For skin repairs longer than 12
inches, do a Low Frequency
Eddy Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
AND
.6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Install full length repair with
finger doublers.
AND
5,000 flight cy-
cles
.30,000 flight cycles
from full length re-
pair with finger dou-
blers repair installa-
tion
Do an external visual inspec-
tions for cracks along all four
edges of the external dou-
blers, left and right sides.
(a) (c)
OR
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
33 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 34

Table 2 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the
original issue date of this service bulletin and no skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later )
ActionCondition
..Before further flightDo local skin repair.Option 2
AND
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the ac-
cessible fuselage skin and
fasteners at longeron 28 for-
ward of flat aft pressure bulk-
head, left and right sides and
do the work listed based on
condition of the unrepaired ar-
eas
(a) (b)
AND
5,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For local skin repairs 12 inch-
es or less long, do an external
visual inspections for cracks
along all four edges of the ex-
ternal doublers
(a) (c)
AND/OR
10,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For skin repairs longer than 12
inches, do a Low Frequency
Eddy Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
AND
.6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Install full length repair dou-
blers.
AND
10,000 flight cy-
cles
.15,000 flight cycles
from full length re-
pair installation
Do a Low Frequency Eddy
Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
OR
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
34 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 35

Table 2 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the
original issue date of this service bulletin and no skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later )
ActionCondition
.Before further flightInstall full length repair with
finger doublers.
Option 3
AND
5,000 flight cy-
cles
.30,000 flight cycles
from full length re-
pair with finger dou-
blers installation
Do an external visual inspec-
tions for cracks along all four
edges of the external dou-
blers, left and right sides.
(a) (c)
OR
.Before further flightInstall full length repair dou-
blers.
Option 4
AND
10,000 flight cy-
cles
.15,000 flight cycles
from full length re-
pair installation
Do a Low Frequency Eddy
Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
(a) Repeat inspection at noted interval if no discrepancies are found.
(b) If any discrepancy is found, do the work of Condition 2 or 3 as applicable before further flight.
(c) If any discrepancy is found, contact Boeing and do the work required before further flight.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
35 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 36

Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
.2 years from origi-
nal issue date of
this service bul-
letin
Accumulation of
24,000 total flight
cycles
Do a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the ac-
cessible fuselage skin and
fasteners at longeron 28 for-
ward of flat aft pressure bulk-
head, left and right sides and
do the work listed based on
condition.
Airplanes with flat
aft pressure bulk-
head having less
than 24,000 total
flight cycles as of
the original issue
date of this service
bulletin and having
skin repairs in the
area of inspection.
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the ac-
cessible fuselage skin and
fasteners at longeron 28 for-
ward of flat aft pressure bulk-
head, left and right sides
Condition 1
(No Crack(s) or
Failed Fasteners
Found)
Option 1
(a) (b)
AND
.6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Install full length improvement
modification with finger dou-
blers.
AND
.2 years from initial
inspection of ac-
cessible skin
.Remove previously installed
local repairs and replace them
with new local repairs.
AND
5,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For new local skin repairs 12
inches or less long, do an ex-
ternal visual inspections for
cracks along all four edges of
the external doublers
(a) (c)
AND/OR
10,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For new skin repairs longer
than 12 inches, do a Low Fre-
quency Eddy Current inspec-
tion of the fuselage skin along
all four edges of the external
doubler
(a) (c)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
36 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 37

Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
AND
.6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Remove previously installed
local repairs and install full
length repair with finger dou-
blers.
AND
5,000 flight cy-
cles
.30,000 flight cycles
from full length re-
pair with finger dou-
blers installation
Do an external visual inspec-
tions for cracks along all four
edges of the external dou-
blers, left and right sides.
(a) (c)
OR
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
37 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 38

Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the ac-
cessible fuselage skin and
fasteners at longeron 28 for-
ward of flat aft pressure bulk-
head, left and right sides
Option 2
(a) (b)
AND
.2 years from initial
inspection of ac-
cessible skin
.Remove previously installed
local repairs and replace them
with new local repairs.
AND
5,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For new local skin repairs 12
inches or less long, do an ex-
ternal visual inspections for
cracks along all four edges of
the external doublers
(a) (c)
AND/OR
10,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For new skin repairs longer
than 12 inches, do a Low Fre-
quency Eddy Current inspec-
tion of the fuselage skin along
all four edges of the external
doubler
(a) (c)
AND
.6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Remove previously installed
local repairs and install full
length improvement modifica-
tion.
AND
10,000 flight cy-
cles
.15,000 flight cycles
from full length re-
pair installation
Do a Low Frequency Eddy
Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
OR
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
38 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 39

Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
.Before further flightRemove previously installed
local repairs and install full
length repair with finger dou-
blers.
Option 3
AND
5,000 flight cy-
cles
.30,000 flight cycles
from full length re-
pair with finger dou-
blers installation
Do an external visual inspec-
tions for cracks along all four
edges of the external dou-
blers, left and right sides.
(a) (c)
OR
Before further flightRemove previously installed
local repairs and install full
length improvement modifica-
tion.
Option 4
AND
10,000 flight cy-
cles
15,000 flight cycles
from installation of
repair
Do a Low Frequency Eddy
Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
39 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 40

Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
..Before further flightReplace all Failed FastenersCondition 2
Any Failed Fasten-
er(s) AND
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the ac-
cessible fuselage skin and
fasteners at longeron 28 for-
ward of flat aft pressure bulk-
head, left and right sides
Option 1
(a) (b)
AND
..2 years from initial
inspection of acces-
sible skin
Remove previously installed
local repairs and replace them
with new local repairs.
AND
5,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For new local skin repairs 12
inches or less long, do an ex-
ternal visual inspections for
cracks along all four edges of
the external doublers
(a) (c)
AND/OR
10,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For new local skin repairs
longer than 12 inches, do a
Low Frequency Eddy Current
inspection of the fuselage skin
along all four edges of the ex-
ternal doubler
(a) (c)
AND
6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Remove previously installed
local repairs and install full
length repair with finger dou-
blers.
AND
5,000 flight cy-
cles
30,000 flight cycles
from full length re-
pair with finger dou-
blers installation
Do an external visual inspec-
tions for cracks along all four
edges of the external dou-
blers, left and right sides.
(a) (c)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
40 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 41

Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
OR
..Before further flightReplace all Failed FastenersOption 2
AND
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the ac-
cessible fuselage skin and
fasteners at longeron 28 for-
ward of flat aft pressure bulk-
head, left and right sides
(a) (b)
AND
..2 years from initial
inspection of acces-
sible skin
Remove previously installed
local repairs and replace them
with new local repairs.
AND
5,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For new local skin repairs 12
inches or less long, do an ex-
ternal visual inspections for
cracks along all four edges of
the external doublers
(a) (c)
AND/OR
10,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For new local skin repairs
longer than 12 inches, do a
Low Frequency Eddy Current
inspection of the fuselage skin
along all four edges of the ex-
ternal doubler
(a) (c)
AND
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
41 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 42

Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Remove previously installed
local repairs and install full
length repair.
AND
10,000 flight cy-
cles
.15,000 flight cycles
from full length re-
pair installation
Do a Low Frequency Eddy
Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
OR
..Before further flightRemove previously installed
local repairs and install full
length repair with finger dou-
bler
Option 3
AND
5,000 flight cy-
cles
.30,000 flight cycles
from full length re-
pair with finger dou-
blers installation
Do an external visual inspec-
tions for cracks along all four
edges of the external dou-
blers, left and right sides.
(a) (c)
OR
..Before further flightRemove previously installed
local repairs and install full
length repair
Option 4
AND
10,000 flight cy-
cles
.15,000 flight cycles
from full length re-
pair installation
Do a Low Frequency Eddy
Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
42 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 43

Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
..Before further flightDo local skin repair.Condition 3
Any Crack(s)
Found in Skin AND
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the ac-
cessible fuselage skin and
fasteners at longeron 28 for-
ward of flat aft pressure bulk-
head, left and right sides
Option 1
(a) (b)
AND
5,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For local skin repairs 12 inch-
es or less long, do an external
visual inspections for cracks
along all four edges of the ex-
ternal doublers
(a) (c)
AND/OR
10,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For skin repairs longer than 12
inches, do a Low Frequency
Eddy Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
AND
..2 years from initial
inspection of acces-
sible skin
Remove previously installed
local repairs and replace them
with new local repairs
AND
5,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For local skin repairs 12 inch-
es or less long, do an external
visual inspections for cracks
along all four edges of the ex-
ternal doublers
(a) (c)
AND/OR
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
43 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 44

Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
10,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For skin repairs longer than 12
inches, do a Low Frequency
Eddy Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
AND
.6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Remove previously installed
local repairs and install full
length repair with finger dou-
bler
AND
5,000 flight cy-
cles
.30,000 flight cycles
from full length re-
pair with finger dou-
blers installation
Do an external visual inspec-
tions for cracks along all four
edges of the external dou-
blers, left and right sides.
(a) (c)
OR
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
44 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 45

Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
..Before further flightDo local skin repair.Option 2
AND
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the ac-
cessible fuselage skin and
fasteners at longeron 28 for-
ward of flat aft pressure bulk-
head, left and right sides
(a) (b)
AND
5,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For local skin repairs 12 inch-
es or less long, do an external
visual inspections for cracks
along all four edges of the ex-
ternal doublers
(a) (c)
AND/OR
10,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For skin repairs longer than 12
inches, do a Low Frequency
Eddy Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
AND
..2 years from initial
inspection of acces-
sible skin
Remove previously installed
local repairs and replace them
with new local repairs
AND
5,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For local skin repairs 12 inch-
es or less long, do an external
visual inspections for cracks
along all four edges of the ex-
ternal doublers
(a) (c)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
45 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 46

Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
AND/OR
10,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For skin repairs longer than 12
inches, do a Low Frequency
Eddy Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
AND
.6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Remove previously installed
local repairs and install full
length repair
AND
10,000 flight cy-
cles
.15,000 flight cycles
from full length re-
pair installation
Do a Low Frequency Eddy
Current inspection of the
fuselage skin along all four
edges of the external doubler.
(a) (c)
OR
..Before further flightRemove previously installed
local repairs and install full
length repair with finger dou-
bler
Option 3
AND
5,000 flight cy-
cles
.30,000 flight cycles
from full length re-
pair with finger dou-
blers installation
Do an external visual inspec-
tions for cracks along all four
edges of the external dou-
blers, left and right sides.
(a) (c)
OR
..Before further flightRemove previously installed
local repairs and install full
length repair
Option 4
AND
10,000 flight cy-
cles
.15,000 flight cycles
from full length re-
pair installation
Do a Low Frequency Eddy
Current inspection of the
fuselage skin along all four
edges of the external doubler.
(a) (c)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
46 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 47

Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
(a) Repeat inspection at noted interval if no discrepancies are found.
(b) If any discrepancy is found, do the work of Condition 2 or 3 as applicable before further flight.
(c) If any discrepancy is found, contact Boeing and do the work required before further flight.
Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
.1 year from original issue date of this
service bulletin
Do a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the ac-
cessible fuselage skin and
fasteners at longeron 28 for-
ward of flat aft pressure bulk-
head, left and right sides and
do the work listed based on
condition.
Airplanes with flat
aft pressure bulk-
head having
24,000 or more to-
tal flight cycles as
of the original is-
sue date of this
service bulletin
and having skin
repairs in the area
of inspection.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
47 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 48

Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the ac-
cessible fuselage skin and
fasteners at longeron 28 for-
ward of flat aft pressure bulk-
head, left and right sides
Condition 1
(No Crack(s) or
Failed Fasteners
Found)
Option 1
(a) (b)
AND
.6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Install full length improvement
modification with finger dou-
blers.
AND
.2 years from initial
inspection of ac-
cessible skin
.Remove previously installed
local repairs and replace them
with new local repairs.
AND
5,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For new local skin repairs 12
inches or less long, do an ex-
ternal visual inspections for
cracks along all four edges of
the external doublers
(a) (c)
AND/OR
10,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For new skin repairs longer
than 12 inches, do a Low Fre-
quency Eddy Current inspec-
tion of the fuselage skin along
all four edges of the external
doubler
(a) (c)
AND
.6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Remove previously installed
local repairs and install full
length repair with finger dou-
blers.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
48 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 49

Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
AND
5,000 flight cy-
cles
.30,000 flight cycles
from full length re-
pair with finger dou-
blers installation
Do an external visual inspec-
tions for cracks along all four
edges of the external dou-
blers, left and right sides.
(a) (c)
OR
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
49 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 50

Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the ac-
cessible fuselage skin and
fasteners at longeron 28 for-
ward of flat aft pressure bulk-
head, left and right sides
Option 2
(a) (b)
AND
.2 years from initial
inspection of ac-
cessible skin
.Remove previously installed
local repairs and replace them
with new local repairs.
AND
5,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For new local skin repairs 12
inches or less long, do an ex-
ternal visual inspections for
cracks along all four edges of
the external doublers
(a) (c)
AND/OR
10,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For new skin repairs longer
than 12 inches, do a Low Fre-
quency Eddy Current inspec-
tion of the fuselage skin along
all four edges of the external
doubler
(a) (c)
AND
.6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Remove previously installed
local repairs and install full
length improvement modifica-
tion.
AND
10,000 flight cy-
cles
.15,000 flight cycles
from full length re-
pair installation
Do a Low Frequency Eddy
Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
OR
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
50 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 51

Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
.Before further flightRemove previously installed
local repairs and install full
length repair with finger dou-
blers.
Option 3
AND
5,000 flight cy-
cles
.30,000 flight cycles
from full length re-
pair with finger dou-
blers installation
Do an external visual inspec-
tions for cracks along all four
edges of the external dou-
blers, left and right sides.
(a) (c)
OR
Before further flightRemove previously installed
local repairs and install full
length improvement modifica-
tion.
Option 4
AND
10,000 flight cy-
cles
15,000 flight cycles
from installation of
repair
Do a Low Frequency Eddy
Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
51 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 52

Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
..Before further flightReplace all Failed FastenersCondition 2
Any Failed Fasten-
er(s) AND
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the ac-
cessible fuselage skin and
fasteners at longeron 28 for-
ward of flat aft pressure bulk-
head, left and right sides
Option 1
(a) (b)
AND
..2 years from initial
inspection of acces-
sible skin
Remove previously installed
local repairs and replace them
with new local repairs.
AND
5,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For new local skin repairs 12
inches or less long, do an ex-
ternal visual inspections for
cracks along all four edges of
the external doublers
(a) (c)
AND/OR
10,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For new local skin repairs
longer than 12 inches, do a
Low Frequency Eddy Current
inspection of the fuselage skin
along all four edges of the ex-
ternal doubler
(a) (c)
AND
6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Remove previously installed
local repairs and install full
length repair with finger dou-
blers.
AND
5,000 flight cy-
cles
.30,000 flight cycles
from full length re-
pair with finger dou-
blers installation
Do an external visual inspec-
tions for cracks along all four
edges of the external dou-
blers, left and right sides.
(a) (c)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
52 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 53

Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
OR
..Before further flightReplace all Failed FastenersOption 2
AND
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the ac-
cessible fuselage skin and
fasteners at longeron 28 for-
ward of flat aft pressure bulk-
head, left and right sides
(a) (b)
AND
..2 years from initial
inspection of acces-
sible skin
Remove previously installed
local repairs and replace them
with new local repairs.
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
53 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 54

Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
AND
5,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For new local skin repairs 12
inches or less long, do an ex-
ternal visual inspections for
cracks along all four edges of
the external doublers
(a) (c)
AND/OR
10,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For new local skin repairs
longer than 12 inches, do a
Low Frequency Eddy Current
inspection of the fuselage skin
along all four edges of the ex-
ternal doubler
(a) (c)
AND
6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Remove previously installed
local repairs and install full
length repair.
AND
10,000 flight cy-
cles
.15,000 flight cycles
from full length re-
pair installation
Do a Low Frequency Eddy
Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
OR
..Before further flightRemove previously installed
local repairs and install full
length repair with finger dou-
bler
Option 3
AND
5,000 flight cy-
cles
.30,000 flight cycles
from full length re-
pair with finger dou-
blers installation
Do an external visual inspec-
tions for cracks along all four
edges of the external dou-
blers, left and right sides.
(a) (c)
OR
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
54 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 55

Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
..Before further flightRemove previously installed
local repairs and install full
length repair
Option 4
AND
10,000 flight cy-
cles
.15,000 flight cycles
from full length re-
pair installation
Do a Low Frequency Eddy
Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
55 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 56

Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
..Before further flightDo local skin repair.Condition 3
Any Crack(s)
Found in Skin AND
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the ac-
cessible fuselage skin and
fasteners at longeron 28 for-
ward of flat aft pressure bulk-
head, left and right sides
Option 1
(a) (b)
AND
5,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For local skin repairs 12 inch-
es or less long, do an external
visual inspections for cracks
along all four edges of the ex-
ternal doublers
(a) (c)
AND/OR
10,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For skin repairs longer than 12
inches, do a Low Frequency
Eddy Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
AND
..2 years from initial
inspection of acces-
sible skin
Remove previously installed
local repairs and replace them
with new local repairs
AND
5,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For local skin repairs 12 inch-
es or less long, do an external
visual inspections for cracks
along all four edges of the ex-
ternal doublers
(a) (c)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
56 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 57

Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
AND/OR
10,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For skin repairs longer than 12
inches, do a Low Frequency
Eddy Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
AND
.6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Remove previously installed
local repairs and install full
length repair with finger dou-
bler
AND
5,000 flight cy-
cles
.30,000 flight cycles
from full length re-
pair with finger dou-
blers installation
Do an external visual inspec-
tions for cracks along all four
edges of the external dou-
blers, left and right sides.
(a) (c)
OR
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
57 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 58

Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
..Before further flightDo local skin repair.Option 2
AND
2,000 flight cy-
cles
.2,000 flight cyclesDo a general visual and Eddy
Current High Frequency
(ETHF) Inspection of the ac-
cessible fuselage skin and
fasteners at longeron 28 for-
ward of flat aft pressure bulk-
head, left and right sides
(a) (b)
AND
5,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For local skin repairs 12 inch-
es or less long, do an external
visual inspections for cracks
along all four edges of the ex-
ternal doublers
(a) (c)
AND/OR
10,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For skin repairs longer than 12
inches, do a Low Frequency
Eddy Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
AND
..2 years from initial
inspection of acces-
sible skin
Remove previously installed
local repairs and replace them
with new local repairs
AND
5,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For local skin repairs 12 inch-
es or less long, do an external
visual inspections for cracks
along all four edges of the ex-
ternal doublers
(a) (c)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
58 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 59

Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
AND/OR
10,000 flight cy-
cles from initial
inspection
.15,000 flight cycles
from installation of
repair
For skin repairs longer than 12
inches, do a Low Frequency
Eddy Current inspection of the
fuselage skin along all four
edges of the external doubler
(a) (c)
AND
.6 years from the
issue date of Revi-
sion 1 of this ser-
vice bulletin
Accumulation of
45,400 total flight
cycles
Remove previously installed
local repairs and install full
length repair
AND
10,000 flight cy-
cles
.15,000 flight cycles
from full length re-
pair installation
Do a Low Frequency Eddy
Current inspection of the
fuselage skin along all four
edges of the external doubler.
(a) (c)
OR
..Before further flightRemove previously installed
local repairs and install full
length repair with finger dou-
bler
Option 3
AND
5,000 flight cy-
cles
.30,000 flight cycles
from full length re-
pair with finger dou-
blers installation
Do an external visual inspec-
tions for cracks along all four
edges of the external dou-
blers, left and right sides.
(a) (c)
OR
..Before further flightRemove previously installed
local repairs and install full
length repair
Option 4
AND
10,000 flight cy-
cles
.15,000 flight cycles
from full length re-
pair installation
Do a Low Frequency Eddy
Current inspection of the
fuselage skin along all four
edges of the external doubler.
(a) (c)
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
59 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

### Page 60

Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the
original issue date of this service bulletin and having skin repairs in the area of inspection:
Repeat Interval
(Not to Exceed)
Compliance Time (Whichever Occurs
Later)
ActionCondition
(a) Repeat inspection at noted interval if no discrepancies are found.
(b) If any discrepancy is found, do the work of Condition 2 or 3 as applicable before further flight.
(c) If any discrepancy is found, contact Boeing and do the work required before further flight.
F. Approval
This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified
in this service bulletin comply with the applicable regulations and are FAA approved. This service
bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as
modified by other approved Boeing changes.
If an airplane has a non-Boeing modification or repair that affects a component or system also affected
by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval
before incorporating this service bulletin.
In addition, the Manager of the FAA Los Angeles Aircraft Certification Office approves the action (i.e.
inspection or modification) defined in this service bulletin as an alternative method of compliance to
the requirements of paragraphs (f), (g), (h), (i), and (j) of AD 2008-06-23. All provisions of AD 2008-06-23
that are not specifically referenced in the above statement remain fully applicable and must be complied
with.
G. Manpower
The table below shows an estimate of the task hours necessary to do this inspection for each airplane.
This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator
task hour data if necessary. The estimate does not include lost time. These are some examples of lost
time:
 Time to adjust to the workplace
 Time to schedule the work
 Time to inspect the work
 Time to cure the materials
 Time to make the parts
 Time to find the tools.
NOTE: Task hour tables are listed for each inspection method, Operator to determine which inspection
process will be used.
Elapsed HoursTask HoursNumber of PersonsTask
0.50.51Open Access
1.02.02Inspection Method
101
0.50.51Close Access
Export Controlled ECCN: 9E991 - BOEING
PROPRIETARY - Copyright © Unpublished
Work - See page 1 for details.
Original Issue: June 22, 2004
DC8-53A080Revision 2: September 18, 2013
60 of 86
BOEING SERVICE BULLETIN DC8-53A080
ALERTALERT

The text continues at https://openairdocs.org/service-documents/boeing/dc8-53a080/file/a3763420a40c.md?from=61

---
OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain, except the copies of manufacturers’ service documents, which belong to their rights holders.