AIRCRAFT DIVISION Bedek Aviation Group ISRAEL ...70 STRUT INSTL - CFM56-3 ENGINE See document D6-37635 71 POWER PLANT INSTL See document D6-37635 78 FAN DUCT COWL AND THRUST REVERSER

AIRCRAFT DIVISION

B e d e k A v i a t i o n G r o u p

365-53-00-92483

ISRAEL A IRCRAFT IND USTRIES LTD

AIRCRAFT DIVISION Bedek Aviation Group

ISRAEL AIRCRAFT INDUSTRIES LTD

Document 365-53-00-92483 Supplement to Document D6-37635

Structural Repair Manual

CAAI STC SA136

Boeing Model 737-300 Conversion to Special Freighter and Quick Change Freighter

Revision F, OCTOBER 2014

AIRCRAFT DIVISION



365-53-00-92483 Revision Record

Page 1 OCT 14

Revision Status

Revision Level

Date Prepared By

New Sept 03 IAI Engineering

A Oct 03 IAI Engineering

B Dec 03 IAI Engineering

C Feb 04 IAI Engineering

D Oct 06 IAI Engineering

E MAR 07 IAI Engineering

F OCT 14 IAI Engineering

REVISION DESCRIPTION

A: Release B: Updated for QC Configuration C: Changed title to reflect QC applicability, clarified pages noted. D: Added configuration with 9G rigid barrier option, section 53-10-15, revised PSE list section 51-00-04, updated effectivity, added allowable damage and repairs. E: Added identification and allowable damage for rigid barrier, if installed, in section 53-10-15. F. Changed type error "REFER TO SRM 52-00-01" to "REFER TO SRM 53-00-01"

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EFFECTIVE PAGES Page 1 OCT 14

Page Date Page Date Page Date

TITLE PAGE MAR 07 ALLOW DAM 101 OCT 06 4 OCT 06

REV RECORD MAR 07 102 OCT 06 5 MAR 07

1 MAR 07 103 OCT 06 6 OCT 06

EFF PAGES MAR 07 104 OCT 06 7 OCT 06

1 MAR 07 REPAIR 201 OCT 06 8 OCT 06

2 OCT 06 53 FUSELAGE 9 MAR 07

INTRO INTRODUCTION 10 MAR 07

1 OCT 06 1 SEP 03 11 MAR 07

2 OCT 06 CONTENTS SEP 03 12 MAR 07 3 OCT 06 1 SEP 03 ALLOW DAM 101 OCT 06

4 OCT 06 53-00-00 102 OCT 06 5 OCT 06 GENERAL 103 OCT 06

CONTENTS 1 SEP 03 104 OCT 06 1 SEP 03 53-00-01 105 MAR 07 IDENTIFICATION 106 MAR 07

51 CONTENTS 1 SEP 03 REPAIR 201 MAR 07 1 SEP 03 53-10-01 53-10-50

51-00-03 IDENTIFICATION IDENTIFICATION

GENERAL 1 SEP 03 1 OCT 06

1 SEP 03 2 SEP 03 2 SEP 03

2 OCT 03 3 SEP 03 ALLOW DAM 101 OCT 06

51-00-04 4 SEP 03 REPAIR 201 OCT 06

GENERAL ALLOW DAM 101 OCT 06 53-10-51

1 OCT 06 102 OCT 06 IDENTIFICATION

52 DOORS 103 OCT 14 1 SEP 03

1 SEP 03 104 OCT 06 2 OCT 06

52-CONTENTS 105 OCT 06 ALLOW DAM 101 OCT 06

1 OCT 06 106 OCT 06 REPAIR 201 OCT 06

52-00-00 REPAIR 201 OCT 06 53-10-52

GENERAL 202 OCT 06 IDENTIFICATION

1 SEP 03 53-10-03 1 SEP 03

52-30-00 IDENTIFICATION 2 SEP 03

IDENTIFICATION 1 OCT 06 3 OCT 06

1 OCT 06 2 OCT 06 ALLOW DAM 101 OCT 06

52-30-01 ALLOW DAM 101 OCT 06 REPAIR 201 OCT 06

IDENTIFICATION REPAIR 201 OCT 06 53-30-01

1 SEP 03 53-10-07 IDENTIFICATION

2 SEP 03 IDENTIFICATION 1 SEP 03

3 DEC 03 1 OCT 06 2 DEC 03

ALLOW DAM 101 OCT 06 2 SEP 03 3 DEC 03

102 OCT 06 ALLOW DAM 101 OCT 06 ALLOW DAM 101 OCT 06

103 OCT 06 REPAIR 201 OCT 06 102 OCT 06

104 OCT 06 53-10-13 REPAIR 201 OCT 06

105 OCT 06 IDENTIFICATION 202 OCT 06

106 OCT 06 1 SEP 03 53-30-03

REPAIR 201 OCT 06 2 SEP 03 IDENTIFICATION

52-30-02 ALLOW DAM 101 OCT 06 1 SEP 03

IDENTIFICATION REPAIR 201 OCT 06 2 SEP 03

1 SEP 03 53-10-15 3 SEP 03

2 SEP 03 IDENTIFICATION ALLOW DAM 101 OCT 06

3 SEP 03 1 OCT 06 REPAIR 201 OCT 06

4 DEC 03 2 OCT 06

5 DEC 03 3 OCT 06

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365-53-00-92483

EFFECTIVE PAGES Page 2 OCT 06

Page Date Page Date Page Date

53-30-04 53-30-52

IDENTIFICATION IDENTIFICATION

1 OCT 06 1 OCT 06

2 OCT 06 2 OCT 06

3 OCT 06 ALLOW DAM 101 OCT 06

ALLOW DAM 101 OCT 06 REPAIR 201 OCT 06

REPAIR 201 OCT 06 53-60-07

53-30-07 IDENTIFICATION

IDENTIFICATION 1 SEP 03

1 SEP 03 2 SEP 03

2 SEP 03 ALLOW DAM 101 OCT 06

3 SEP 03 REPAIR 201 OCT 06

4 SEP 03 202 OCT 06

5 SEP 03 53-60-50

ALLOW DAM 101 OCT 06 IDENTIFICATION

REPAIR 201 OCT 06 1 SEP 03

202 OCT 06 2 SEP 03

53-30-13 ALLOW DAM 101 OCT 06

IDENTIFICATION REPAIR 201 OCT 06

1 SEP 03 53-60-51

2 SEP 03 IDENTIFICATION

3 SEP 03 1 SEP 03

4 SEP 03 2 SEP 03

5 SEP 03 3 SEP 03

ALLOW DAM 101 OCT 06 4 SEP 03

102 OCT 06 5 DEC 03

103 OCT 06 6 DEC 03

104 OCT 06 7 SEP 03

REPAIR 201 OCT 06 ALLOW DAM 101 OCT 06

53-30-16 102 OCT 06

IDENTIFICATION 103 OCT 06

1 SEP 03 104 OCT 06

2 OCT 06 105 OCT 06


REPAIR 201 OCT 06 53-60-52

53-30-50 IDENTIFICATION

IDENTIFICATION 1 DEC 03

1 DEC 03 2 SEP 03

2 DEC 03 ALLOW DAM 101 OCT 06


REPAIR 201 OCT 06

53-30-51

IDENTIFICATION

1 SEP 03

2 SEP 03

3 SEP 03

ALLOW DAM 101 OCT 06

102 OCT 06

103 OCT 06

104 OCT 06

REPAIR 201 OCT 06

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365-53-00-92483

INTRODUCTION Page 1 OCT 06

Introduction

1. General This manual supplements the data in Document D6-37635, Structural Repair Manual, to include the conversion to a cargo aircraft with a main deck cargo door. See table 1, page 2 for areas of structure which are not affected by the cargo conversion, all areas affected by the conversion are addressed in this supplement. Only aircraft modified in accordance with CAAI STC SA136, are included in this supplement for aircraft which are used as special freighters or quick change aircraft. Allowable damage and standard repairs may be added by revision service when determined required.

2. Manual Arrangement and Numbering System

A. The layout of this manual is similar to Boeing document number D6-37635 and follows the guidelines of Air Transport Association (ATA) Specification 2200, “Information Standards for Aviation Maintenance”.

3. Aircraft Effectivity Designations

All aircraft modified per STC SA-136, Civil Aviation Authority Israel, and ST01566LA, FAA STC.

4. Publications Change Requests

Request should be submitted to: AIRCRAFT DIVISION

Bedek Aviation Group ISRAEL AIRCRAFT INDUSTRIES LTD Ben Gurion International Airport, 70100, Israel

5. Service Bulletins

A. There are no service bulletins for incorporation with this supplement in effect. When a service bulletin is published, it will be listed in this section.

6. Revision Service

This manual will be changed by Revision Service.

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IDENTIFICATION

See figure 1

TITLE

Repairs and Allowable Damage

11 WING CENTER SECTION ASSY See document D6-37635

12 WING ASSY See document D6-37635

14 LEADING EDGE FLAPS AND SLATS INSTL See document D6-37635

18 MAIN LANDING GEAR DOOR INSTL See document D6-37635

19 WING TIP INSTL See document D6-37635

30 OUTBOARD SPOILER See document D6-37635

31 INBOARD TRAILING EDGE FLAP INSTL See document D6-37635

32 OUTBOARD TRAILING EDGE FLAP INSTL See document D6-37635

34 AILERON INSTL See document D6-37635

35 INBOARD SPOILER INSTL See document D6-37635

41 BODY INSTL - SECTION 41 <1>



48 BODY INSTL - SECTION 48 See document D6-37635

52 DOORS <4>

56 WINDOWS <5> 61 MAIN LANDING GEAR INSTL See document D6-37635

62 NOSE LANDING GEAR INSTL See document D6-37635

70 STRUT INSTL - CFM56-3 ENGINE See document D6-37635

71 POWER PLANT INSTL See document D6-37635

78 FAN DUCT COWL AND THRUST REVERSER See document D6-37635

79 TAIL CONE INSTL See document D6-37635

82 HORIZONTAL STABILIZER ASSY See document D6-37635

84 ELEVATOR INSTL See document D6-37635

85 DORSAL FIN ASSY See document D6-37635

86 VERTICAL FIN ASSY See document D6-37635

88 RUDDER INSTL See document D6-37635

89 VERTICAL FIN TIP ASSY See document D6-37635

93 HORIZONTAL STABILIZER TIP INSTL See document D6-37635

41 NOSE LANDING GEAR DOOR INSTL See document D6-37635

43/46 WING/BODY FAIRING INSTL See document D6-37635

71 INLET COWL ASSY See document D6-37635

71 FAN COWL ASSY See document D6-37635

71 PRIMARY EXHAUST INSTL See document D6-37635

48 APU DOOR INSTL See document D6-37635

Table 1: Major Assembly and Installation Breakdown, Repairs and Allowable Damage

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NOTES FOR TABLE 1:

<1> Structure from Sta 328 and Forward is unaffected and document D6-37635 should be

used, with exception of new structure identified in section 53-10 in this supplement.

<2> See document D6-37635 for lower lobe structure between s-26 L and s-26R and lower

cargo floor, see section 53 of this supplement for affected sec 43 body structure.

<3> See document D6-37635 for structure between s-26 L and s-26R and lower cargo

floor, see section 53 of this supplement for affected sec 46 body structure.

<4> See section 52-30 in this supplement for the Main Deck Cargo Door allowable

damage, repairs should be referred to IAI, all other doors are unaffected.

<5> Windows are unaffected except, LH Cockpit Emergency Exit Design is opposite to

RH Cockpit Emergency Exit, all SRM items related to the RH side is applicable to the LH

side. See section 52 and 53 in this supplement for QC windows.

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Not identified: 52 Doors, 56 Windows

Figure 1: Major Assembly and Installation Breakdown, per Table 2

SEE 51-00-03 GENERAL PAGE 2 FIG 1 FOR CARGO DOOR LOCATION

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IDENTIFICATION TITLE

11 WING CENTER SECTION ASSY

12 WING ASSY

14 LEADING EDGE FLAPS AND SLATS INSTL

18 MAIN LANDING GEAR DOOR INSTL

19 WING TIP INSTL

30 OUTBOARD SPOILER

31 INBOARD TRAILING EDGE FLAP INSTL

32 OUTBOARD TRAILING EDGE FLAP INSTL

34 AILERON INSTL

35 INBOARD SPOILER INSTL

41 BODY INSTL - SECTION 41




61 MAIN LANDING GEAR INSTL

62 NOSE LANDING GEAR INSTL

70 STRUT INSTL - CFM56-3 ENGINE

71 POWER PLANT INSTL

78 FAN DUCT COWL AND THRUST REVERSER

79 TAIL CONE INSTL

82 HORIZONTAL STABILIZER ASSY

84 ELEVATOR INSTL

85 DORSAL FIN ASSY

86 VERTICAL FIN ASSY

88 RUDDER INSTL

89 VERTICAL FIN TIP ASSY

93 HORIZONTAL STABILIZER TIP INSTL

41 NOSE LANDING GEAR DOOR INSTL

43/46 WING/BODY FAIRING INSTL

71 INLET COWL ASSY

71 FAN COWL ASSY

71 PRIMARY EXHAUST INSTL

48 APU DOOR INSTL

TABLE 1 (reference document D6-37635)

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365-53-00-92483

CONTENTS Page 1

Sept 03

LIST OF CHAPTERS

SUBJECT CHAPTER INTRODUCTION STRUCTURES - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 DOORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 FUSELAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

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365-53-00-92483 51 CONTENTS

Page 1 Sept 03

Chapter 51 - STRUCTURES – GENERAL

TABLE OF CONTENTS

Subject Chapter Page Effectivity DIMENSIONS 51-00-03 General - Principal 1 All Dimensions STRUCTURAL CLASSIFICATION 51-00-04 General - Structural 1 All

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365-53-00-92483 51-00-03 GENERAL

Page 1 Sept 03

General - Principal Dimensions

1. General

A. This section contains the principal dimensions of the aircraft. The overall aircraft dimensions are shown with main deck cargo door installed. For all other dimensions see D6-37635, Section 51-00-03.

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365-53-00-92483 51-00-03 GENERAL

Page 2 Oct 03

Principal Dimensions and Areas Figure 1 (Sheet 1)

MAIN DECK CARGO DOOR LH

LH COCKPIT EMERGENCY EXIT

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365-53-00-92483 51-00-04 GENERAL

Page 1 OCT 06

1. Principal Structural Elements (PSE’s) PSE’s are identified in 51-00-04 of D6-37635.

PSE’s listed below have been added or revised in inspection requirements due to the conversion to add the main deck cargo door and for freighter loading operation.

PRINCIPAL STRUCTURAL ELEMENT Main Deck Cargo Door Latches, Latch Fittings

Main Deck Cargo Door Skin Splice

Main Deck Cargo Door Frames

Main Deck Cargo Door Hinges

Circumferential Skin Splices

Longitudinal Skin Splices

Frame chord splice, sta 360 to 500

Skin at 9G RH Net Attach Fittings

MDCD Sill Chords

MDCD Edge Frames

MDCD Surround Splice to Floor Beams

Windows in Surround Structure and MDCD

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365-53-00-92483 52-00-00

Page 1 Sept 03

52

DOORS

STRUCTURES SUPPLEMENT

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365-53-00-92483 52-00-00 CONTENTS

Page 1 OCT 06

CHAPTER 52

DOORS

TABLE OF CONTENTS

CHAPTER SECTION

SUBJECT DOORS 52-00-00 General Figure 1 - Door Location Diagram MAIN DECK CARGO DOOR 52-30-00 MAIN DECK CARGO DOOR SKIN 52-30-01 Figure 1 - Cargo Door Skin Identification, Figure 101 - Cargo Door Skin Allowable Damage MAIN DECK CARGO DOOR STRUCTURE 52-30-02 Figure 1 - Cargo Door Structure Identification Figure 101 - Cargo Door Structure Allowable Damage

52-CONTENTS

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365-53-00-92483 52-00-00 GENERAL

Page 1 Sept 03

DOORS 1. General This chapter contains information pertaining to the addition of the main cargo door on the upper deck in section 43.

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365-53-00-92483 52-30-00 IDENTIFICATION

Page 1 OCT 06

Chapter 52-30-00 MAIN DECK CARGO DOOR

Door Location Diagram Figure 1

STA 500

STA 360

SEE SEC 53-00-00 FOR SURROUND STRUCTURE IDENTIFICATION

SEE DTL I 52-30-01

S-3L

S-17L

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365-53-00-92483 52-30-01 IDENTIFICATION

Page 1 Sept 03

View of door outbd skin View looking outbd

MAIN DECK CARGO DOOR

DETAIL I Figure 1 (Sheet 1)

Main Deck Cargo Door Skin Identification

1

2

3

4

5

6

7

STA 500

STA 360

S-3L

S-10L

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365-53-00-92483 52-30-01 IDENTIFICATION

Page 2 Sept 03

View of door inbd skin View looking outbd


DETAIL I Figure 2 (Sheet 2)

Main Deck Cargo Door Skin Identification

10

9

11

12

S-10L

STA 500

STA 360

8

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365-53-00-92483 52-30-01 IDENTIFICATION

Page 3 Dec 03

ITEM DESCRIPTION GAGE MATERIAL

1 OUTER SKIN UPR 0.071 CLAD 2024-T3

2 OUTER SKIN LWR 0.100 CLAD 2024-T3

3 DOUBLER 0.080 CLAD 2024-T3



6 ACCESS COVER 0.071 CLAD 2024-T3

7 ACCESS COVER 0.100 CLAD 2024-T3

8 INNER SKIN UPR 0.071 CLAD 2024-T3

9 INNER SKIN LWR 0.100 CLAD 2024-T3

10 INNER SKIN MID AFT 0.071 CLAD 2024-T3

11 INNER SKIN MID FWD 0.071 CLAD 2024-T3

12 ACCESS PANEL 0.071 CLAD 2024-T3

LIST OF MATERIALS FOR DETAIL I

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365-53-00-92483 52-30-01 ALLOWABLE DAMAGE

Page 101 OCT 06

Fig 101 MAIN DECK CARGO DOOR SKIN ALLOWBLE DAMAGE

STA 500

STA 360

See DTL I for Outer Skin See DTL II for Inner Skin

S-3L

S-17L

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Page 102 OCT 06

View of door outbd skin View looking outbd


Figure 101 DETAIL I Main Deck Cargo Door Skin Allowable Damage

STA 500

STA 360 S-3L

S-10L

INTERNAL DBLR

INTERNAL DBLR

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Page 103 OCT 06

View of door inner skin

View looking outbd

MAIN DECK CARGO DOOR Figure 101 DETAIL II

Main Deck Cargo Door Skin Allowable Damage

S-10L

STA 500 STA

360

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Page 104 OCT 06

DESCRIPTION CRACKS NICKS, GOUGES, SCRATCHES AND CORROSION

DENTS HOLES AND PUNCTURES

OUTER SKIN, OUTER SKIN DOUBLERS AND ACCESS DOORS

NONE ALLOWED

A, E B C

INNER SKINS UPPER AND LOWER ONLY

NONE ALLOWED

A F C

ALLOWABLE DAMAGE FOR FIG 101, DETAILS I AND II

A. REMOVE NICKS, GOUGES, SCRATCHES, OR CORROSION AS SHOWN IN DTLS III, IV, V, AND VI. X

DIMENSION SHOULD NOT EXCEED 10% OF THICKNESS. DAMAGE IS NOT ALLOWED IN MORE THAN 10% OF THE AREA FOR ANY 20 SQUARE INCHES.

B. REFER TO SRM 52-00-01 IN D6-37635, ALLOWBLE DAMAGE 2 FOR DENT ALLOWANCES AND

LIMITATIONS. EXCEPT ADDITIONAL LIMITATIONS ARE:

i. DENTS ARE NOT ALLOWED TO BE ACROSS ATTACHMENTS TO FRAMES, BEAMS AND INTERCOSTALS.

ii. SUBSTRUCTURE SHOULD BE EXAMINED FOR NO DEFORMATIONS AS RESULT OF DENTS.

iii. DENTS ARE NOT ALLOWED TO EXCEED THE LIMITS OF FIGURE SHOWN IN DTL I OF ALLOWABLE DAMAGE 2.

iv. REPAIRS OF DENTS OUTSIDE THE ALLOWABLE LIMITS ARE TO BE PROVIDED BY IAI.

C. HOLES AND PUNCTURES ARE ALLOWED UP TO .25 INCH DIA AFTER CLEANUP PROVIDED

DAMAGE IS 1.00 INCH MINIMUM FROM ANY OTHER HOLE, PART EDGE OR OTHER DAMAGE. CLEAN UP DAMAGE AND FILL WITH A 2117T3 OR 2117-T4 ALUMINUM

PROTRUDING HEAD RIVET INSTALLED WET WITH BMS 5-95 SEALANT. LIMIT ONE HOLE PER 20

INCH SQUARE.

D. RESERVED

E. REMOVAL OF ANY DAMAGE AS SHOWN IN DTL V SHALL NOT EXCEED DAMAGE LIMITS FOR

PRESSURIZED FUSELAGE DOOR SKINS AS SHOWN IN CHART IN SRM 52-00-01 OF D6-37635, ALLOWABLE DAMAGE 1.

F. DENTS ARE ALLOWED AS SHOWN IN DETAIL VII, EXCEPT ARE NOT ALLOWED TO CROSS OVER

ATTACHMENTS TO FRAMES, BEAMS AND INTERCOSTALS. DENTS MUST BE 10 INCHES OR MORE FROM A CUTOUT AND 3 INCHES OR MORE FROM A ROW OF ATTACH FASTENERS AS MEASURED TO

THE EDGE OF THE DENT PERIPHERY.

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Page 105 OCT 06

DAMAGE CLEANUP OF EDGES WHERE DAMAGE CLEAN UP OF EDGES WHERE FASTENER EDGE MARGINS DO NOT OVERLAP FASTERER EDGE MARGINS OVERLAP

DTL III

REMOVAL OF NICK, GOUGE, CORROSION, AND SCTATCH DAMAGE ON A SURFACE

(CLEANUP AT EDGE SHOWN; CLEANUP AWAY FROM EDGE SIMILAR) DTL IV

DAMAGE CLEANUP

DTL V

CARGO SKIN ALLOWABLE DAMAGE

FIGURE 101

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Page 106 OCT 06

REMOVAL OF DAMAGE ON AN EDGE DTL VI

DENT LIMITS ON INNER SKINS

DTL VII

CARGO SKIN ALLOWABLE DAMAGE FIGURE 101

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Page 201 OCT 06

CONTACT IAI BEDEK FOR ALL REPAIRS BEYOND ALLOWABLE DAMAGE LIMITS

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365-53-00-92483 52-30-02 IDENTIFICATION

Page 1 Sept 03

MAIN DECK CARGO DOOR 365-52-30-92202, 365-52-30-92200

DETAIL I

Cargo Door Structure Identification Sheet 1

1 1

2 2

4 4

5

6

9

7

7 8

10 11

STA 500

STA 360

S-17L

S-3L

S-10L

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Page 2 Sept 03


DETAIL I


3 3

3

12 13

14

14

STA 500 STA

360

S-17L

S-10L

S-3L

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Page 3 Sept 03


DETAIL I


15

15

16

16

STA 500

STA 360

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365-53-00-92483 52-30-02 IDENTIFICATION

Page 4 Dec 03

DETAIL I Cargo Door Structure Identification – QC Version

Sheet 4

17

17

18

19

20

20

20

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365-53-00-92483 52-30-02 IDENTIFICATION

Page 5 Dec 03


1 FRAME UPPER 0.063 CLAD 7075-T62

2 FRAME LOWER MACH 7050-T7451

3 HINGE MACH 15-5 PH CRES

4 CORNER 0.063 CLAD 6061-T62

5 BEAM UPPER 0.063 CLAD 7075-T62

6 INTERCOSTAL S-14 0.063 CLAD 7075-T62

7 STRAP 0.100 CLAD 7075-T62

8 FRAME LOWER STUB 0.080 CLAD 7075-T62

9 BEAM LOWER 0.063 CLAD 7075-T62

10 EDGE FRAME AFT 0.063 CLAD 7075-T62

11 EDGE FRAME FWD 0.063 CLAD 7075-T62

12 INTERCOSTAL S-10 0.063 CLAD 7075-T62

13 INTERCOSTAL PRESSURE DOOR .080 CLAD 7075-T62

14 BEARING PLATES MACH 13-8PH CRES

15 RAMP FITTING MACH 7075-T7351

16 STRAPS 0.063 CLAD 7075-T62

17 WINDOW FRAME MACH 7050-T7451

18 WINDOW FRAME FORG 7075-T73 DIE

FORGING

19 WINDOW STRINGERS EXTR 7075-T6511

20 INNER SKIN LOWER .100 2024-T3/T42

Figure 1 and 2 Cargo Door Structure Identification LIST OF MATERIALS FOR DETAIL I

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Page 101 OCT 06

DESCRIPTION CRACKS

NICKS, GOUGES, SCRATCHES AND CORROSION DENTS

HOLES AND PUNCTURES

BEAMS (EXCEPT UPPER AND LOWER BEAM), INTERCOSTALS, WEBS, STIFFENERS AND STRAPS.

NONE ALLOWED A B D

FRAMES, CHORDS AND WEBS

NONE ALLOWED A B D

HINGE SEGMENTS, LIFT ARM, DOOR HOOKS, SNUBBER FITTINGS, SIDE GUIDES AND RAMP FITTINGS

NONE ALLOWED C, E

NOT ALLOWED

NOT ALLOWED

WINDOW FRAME (QC VERSION ONLY)

NONE ALLOWED

SEE 56-20-02 ALLOWABLE DAMAGE 1

NOT ALLOWED

NOT ALLOWED

ALLOWABLE DAMAGE FOR DOOR STRUCTURE

NOTES:

1. REFER TO SRM 51-10-02 FOR INSPECTION AND REMOVAL OF DAMAGE. 2. FOR REWORKED ALUMINUM SURFACES, APPLY A PROTECTIVE ALODINE COATING AS GIVEN IN

51-20-01. 3. FOR REWORKED STEEL SURFACES WHICH HAD CADMIUM PLATING, CADMIUM PLATE AS GIVEN

IN SOPM 20-42-10 OF STANDARD OVERHAUL PRACTICES, DOC D6-51702, AND APPLY TWO COATS OF BMS 10-11, TYPE 1 PRIMER AS

GIVEN IN AMM 5-21.

4. REFER TO IDENTIFICATION SECTION FOR MATERIALS AND STRUCTURE IDENTIFICATION.

A. BLEND OUT DAMAGE AS SHOWN IN DTLS I, II, III, VI AND VIII

B. DENTS ARE ALLOWED AS SHOWN IN DETAIL V.

C. REMOVE NICKS, GOUGES, SCRATCHES, OR CORROSION AS SHOWN IN DTL IV.

D. HOLES AND PUNCTURES ARE AOLLOWED UP TO .25 INCH DIA AFTER CLEANUP PROVIDED

DAMAGE IS 1.00 INCH MINIMUM FROM ANY OTHER HOLE, PART EDGE OR OTHER DAMAGE AND DO NOT EXTEND INTO ANY RADIUS

AFTER CLEAN UP.

CLEAN UP DAMAGE AND FILL WITH A 2117T3 OR 2117-T4 ALUMINUM RIVET MAINTAINING MIN 1.5 EDGE DISTANCE FROM CENTER OF HOLE TO EDGE.

USE PROTRUDING HEAD RIVET INSTALLED WET WITH BMS 5-95 SEALANT.

E. REMOVE LUG DAMAGE AS SHOWN IN DTL VII. DAMAGE NOT ALLOWED WITHIN .02 OF

BUSHING.

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Page 102 OCT 06

DAMAGE CLEANUP OF EDGES WHERE DAMAGE CLEAN UP OF EDGES WHERE

FASTENER EDGE MARGINS DO NOT OVERLAP FASTENER EDGE MARGINS OVERLAP DTL I

REMOVAL OF DAMAGE ON AN EDGE REMOVAL OF DAMAGE ON AN EDGE DTL II DTL III

Cargo Door Structure Allowable Damage

Figure 101 (Sheet 1 of 3)

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Page 103 OCT 06

REMOVAL OF NICK, GOUGE, CORROSION AND SCRATCH DAMAGE ON A SURFACE DTL IV

ALLOWABLE DAMAGE FOR DENT DAMAGE CLEANUP DTL V DTL VI

Cargo Door Structure Allowable Damage

Figure 101 (Sheet 2 of 3)

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Page 104 OCT 06

DAMAGE CLEANUP FOR LUG SURFACES (SAME FOR DOOR LATCH HOOKS)

DTL VII

REMOVAL OF DAMAGE ON AN EDGE DTL VIII

Cargo Door Structure Allowable Damage Figure 101 (Sheet 3 of 3)

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Page 201 OCT 06


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365-53-00-92483 53 INTRODUCTION

Page 1 Sept 03

53

FUSELAGE

STRUCTURES SUPPLEMENT

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53 CONTENTS

Page 1 Sept 03

CHAPTER 53 FUSELAGE

TABLE OF CONTENTS CHAPTER

SECTION SUBJECT FUSELAGE 53-00-00 MAIN DECK CARGO DOOR SURROUND STRUCTURE 53-00-01 FUSELAGE SKIN - SECTION 41 53-10-01 FUSELAGE STRINGERS - SECTION 41 53-10-03 FUSELAGE FRAMES - SECTION 41 53-10-07 BEAMS - SECTION 41 53-10-13 DOOR SURROUND STRUCTURE - SECTION 41 53-10-15 FLOOR PANELS - SECTION 41 53-10-50 FLOOR STRUCTURE - SECTION 41 53-10-51 SEAT TRACKS - SECTION 41 53-10-52 FUSELAGE SKIN - SECTION 43 53-30-01 FUSELAGE STRINGERS - SECTION 43 53-30-03 INTERCOSTALS - SECTION 43 53-30-04 FUSELAGE FRAMES - SECTION 43 53-30-07 BEAMS - SECTION 43 53-30-13 MDCD SURROUND STRUCTURE - SECTION 43 53-30-16 FLOOR PANELS - SECTION 43 53-30-50 FLOOR STRUCTURE - SECTION 43 53-30-51 SEAT TRACKS - SECTION 43 53-30-52 FUSELAGE FRAMES - SECTION 46 53-60-07 FLOOR PANELS - SECTION 46 53-60-50 FLOOR STRUCTURE - SECTION 46 53-60-51 SEAT TRACKS - SECTION 46 53-60-52

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365-53-00-92483 53-00-00 GENERAL

Page 1 Sept 03

FUSELAGE

1. General A. This chapter contains information on identification, allowable damage and repairs to the structural components of the fuselage.

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IDENTIFICATION 1 Page 1

Sept 03

Section 41/43 Main Deck Cargo Door Surround Structure Identification

365-53-00-92301, 365-53-00-92302, 365-53-00-92305

365-53-00-92332 Figure 1 (Sheet 1)

STA 500

STA 360

53-10-01

S-3L

S-17L

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IDENTIFICATION Page1

Sept 03

DETAIL 1 Section 41 Skin Identification, View Looking Outboard 365-53-00-92302, 365-53-00-92305, 365-53-00-92332

Figure 1 (Sheet 1)

1

2

3

FWD

STA 360

STA 328

S-3L

S-17L

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Sept 03

DETAIL 1 Section 41 Skin Identification View Looking Inboard

365-53-00-92302, 365-53-00-92305, 365-53-00-92332 Figure 1Sheet 2

6

5

5

4

FWD

STA 360

STA 328

7

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Sept 03

DETAIL 1 Section 41 Non Airstair Skin Identification View Looking outboard

365-53-00-92302, 365-53-00-92305, 265-53-00-92332 Figure 1Sheet 3

8

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Sept 03


1 LOWER SKIN 0.100 CLAD 2024-T3

2 UPPER EXTERNAL DOUBLER 0.090 CLAD 2024-T3


4 MID SKIN 0.071 CLAD 2024-T3

5 EXTERNAL SPLICE 0.100 CLAD 2024-T3

6 UPPER EXTERNAL DOUBLER 0.063 CLAD 2024-T3

7 LOWER EXTERNAL DOUBLER .100 CLAD 2024-T3

8 LOWER SKIN .0710 CLAD 2024-T3

Figure 1 Section 41 Skin Identification LIST OF MATERIALS FOR DETAIL I

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ALLOWABLE DAMAGE Page101

OCT 14

Section 41 Skin Allowable Damage, Figure 101

See D6-37635, Section 53-00-01

SEE FIGURE 102 FOR ALLOWABLE DAMAGE FOR SKIN AND DOUBLERS THAT ARE PART OF THE SURROUND FOR THE MDCD. FOR ALL OTHER SEC 41 SKIN SEE 53-00-01 OF D6-37635.

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OCT 14

Section 41/43 Surround Skin Allowable Damage,

Figure 102

STA 500

STA 360

SEE SECTION 52-30-00 FOR MDCD ALLOWABLE DAMAGE

S-3L

S-17L

S-4R

S-21L

STA 500B

STA 328

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OCT 14



OUTER SKIN, SKIN DOUBLERS, TRIPLERS AND ACCESS DOORS

NOT PERMITTED

A, D, E B NOT

PERMITTED

LAP SPLICES, RUNOUTS OF DOUBLERS AND TRIPLERS AND BUTT JOINTS

NOT PERMITTED

D, G, H NOT

PERMITTED NOT

PERMITTED

INNER SKINS STA 360 TO STA 344

NOT PERMITTED

A F C

ALLOWABLE DAMAGE FOR FIG 102

A. REMOVE NICKS, GOUGES, SCRATCHES, OR CORROSION AS SHOWN IN DTLS III, IV, V, AND VI. X

DIMENSION SHOULD NOT EXCEED 10% OF THICKNESS. DAMAGE IS NOT ALLOWED IN MORE THAN

10% OF THE AREA FOR ANY 20 SQUARE INCHES.

B. REFER TO SRM 53-00-01 IN D6-37635, ALLOWBLE DAMAGE 2 FOR DENT ALLOWANCES AND LIMITATIONS. EXCEPT ADDITIONAL LIMITATIONS ARE:

v. DENTS ARE NOT ALLOWED TO BE ACROSS ATTACHMENTS TO FRAMES, BEAMS, DOOR

SILLS AND INTERCOSTALS. vi. SUBSTRUCTURE SHOULD BE EXAMINED FOR NO DEFORMATIONS AS RESULT OF

DENTS. vii. DENTS ARE NOT ALLOWED TO EXCEED THE LIMITS OF FIGURE SHOWN IN DTL I OF

ALLOWABLE DAMAGE 2. viii. REPAIRS OF DENTS OUTSIDE THE ALLOWABLE LIMITS ARE TO BE PROVIDED BY IAI.

ix. DENTS IN AREAS OF DOUBLERS, BEAR STRAPS, AND TRIPLERS ARE TO BE APPROVED

BY IAI.

C. HOLES AND PUNCTURES ARE ALLOWED UP TO .25 INCH DIA AFTER CLEANUP PROVIDED DAMAGE IS 1.00 INCH MINIMUM FROM ANY OTHER HOLE, PART EDGE OR OTHER DAMAGE. CLEAN

UP DAMAGE AND FILL WITH A 2117T3 OR 2117-T4 ALUMINUM

PROTRUDING HEAD RIVET INSTALLED WET WITH BMS 5-95 SEALANT. LIMIT ONE HOLE PER 20 INCH SQUARE.

D. DAMAGE REMOVAL IS NOT ALLOWED FROM THE RUNOUTS OF DOUBLERS AND TRIPLERS.

E. REMOVAL OF ANY DAMAGE AS SHOWN IN DTL V SHALL NOT EXCEED DAMAGE LIMITS FOR

PRESSURIZED FUSELAGE DOOR SKINS AS SHOWN IN CHART IN SRM 52-00-01 OF D6-37635,

ALLOWABLE DAMAGE 1.

F. DENTS ARE ALLOWED AS SHOWN IN DETAIL VII, EXCEPT ARE NOT ALLOWED TO CROSS OVER ATTACHMENTS TO FRAMES, BEAMS AND INTERCOSTALS. DENTS MUST BE 10 INCHES OR MORE

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OCT 14

FROM A CUTOUT AND 3 INCHES OR MORE FROM A ROW OF ATTACH FASTENERS AS MEASURED TO THE EDGE OF THE DENT PERIPHERY.

G. NO DAMAGE REMOVAL IS ALLOWED TO THE INSIDE OR OUTSIDE SURFACES OF BUTT JOINT SPLICE STRAPS.

H. DAMAGE REMOVAL IS NOT ALLOWED AT LAP JOINT FASTENER ROWS, AND NOT ALLOWED

WITHIN 1 INCH OF UPPER OR LOWER ROWS OF FASTENERS OF LAP JOINTS.

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DAMAGE CLEANUP OF EDGES WHERE DAMAGE CLEAN UP OF EDGES WHERE FASTENER EDGE MARGINS DO NOT OVERLAP FASTERER EDGE MARGINS OVERLAP

DTL III

REMOVAL OF NICK, GOUGE, CORROSION, AND SCRATCH DAMAGE ON A SURFACE

(CLEANUP AT EDGE SHOWN; CLEANUP AWAY FROM EDGE SIMILAR) DTL IV

DAMAGE CLEANUP

DTL V

B-B

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OCT 14

REMOVAL OF DAMAGE ON AN EDGE DTL VI

DENT LIMITS ON INNER SKINS

DTL VII

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REPAIR Page201

OCT 06

Figure 201

General Fuselage Skin Repairs See page 202 for notes

SEE NOTE 2

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REPAIR Page202

OCT 06

NOTES FOR FIGURE 201

1. SEE SECTION 53-00-01 OF DOCUMENT D6-37635 FOR RESTRICTED AREAS IN SECTION 41 OF SKIN REPAIR.

2. REPAIR IS NOT COVERED BY THIS FIGURE FOR THE AREA BOUNDED BY; STATION 328 TO STA

360, S-4R TO S-21L, MDCD SURROUND SKIN, INCLUDING 5 INCH BAND AROUND SPLICES AT S-21L,

S-4R, AND STA 328. CONTACT IAI FOR DAMAGE IN THIS AREA OUTSIDE THE ALLOWABLE DAMAGE LIMITS.

3. ALL AREAS NOT RESTRICTED HERE FOR REPAIR, SECTION 41, ARE ALLOWED PER DOCUMENT D6-

37635.

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OCT 06

DETAIL 1 Section 41 Stringer Identification

365-53-00-92301

Sheet 1

1

FWD

STA 360

2

S-2L

S-3L

S-4L

S-6L

S-5L

STA 328

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OCT 06


1 STRINGER 0.063 CLAD 7075-T62

2 STRINGER SPLICE 0.063 CLAD 7075-T62

Figure 1 Section 41 Stringer Identification LIST OF MATERIALS FOR DETAIL I

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OCT 06



WEB NOT ALLOWED

A NOT

ALLOWED C, D

SKIN ATTACH FLANGE NOT ALLOWED

A NOT

ALLOWED NOT ALLOWED

FREE FLANGES NOT ALLOWED

A, B NOT

ALLOWED NOT ALLOWED

MDCD SURROUND STRINGERS

ALLOWABLE DAMAGE FOR SECTION 41 STRINGERS AWAY FROM THE MDCD SURROUND SEE SEC 53-00-03 OF DOCUMENT D6-37635.

- REFER TO SRM 51-10-02 FOR INSPECTION AND REMOVAL OF DAMAGE - FOR EWORKED ALUMINUM AREAS APPLY A PROTECTIVE ALODINE COATION AS GIVEN IN SRM 51-20-01. - REFINISH REWORKED AREAS AS GIVEN IN AMM 51-20.

A. NICK, GOUGES AND SCRATCHES THAT DO NOT PENETRATE ALL THE WAY THROUGH THE CLAD SURFACES MAY BE IGNORED. INSPECT PENETRATION DEPTH AS GIVEN IN SRM 51-10-02 B. . EDGE DAMAGE, ON FREE FLANGE ONLY, MUST NOT TO EXCEED 10% OF FREE FLANGE HEIGHT AND BE BLENDED OUT WITH 1.00 R MINIMUM. OTHER DAMAGE MUST BE REMOVED PER DTL II OF SEC 53-00-03 DOCUMENT D6-37635. DAMAGE REMOVED PER DTL II MUST NOT EXCEED 10% OF CROSS SECTIONAL AREA. C. CLEAN OUT DAMAGE UP TO .25 DIA MAX AND NOT CLOSER THAN 1.0 INCH TO FASTENER HOLE OR OTHER DAMAGE. FILL HOLE WITH A 2117-T3 OR T4 RIVET INSTALLED WET WITH BMS 5-95 SEALANT. MAINTAIN 2D MIN EDGE MARGIN. CONTACT IAI FOR ALL OTHER DAMAGE. D. NOT ALLOWED AT STRINGER SPLICES.

MAIN DECK CARGO DOOR SURROUND STRINGERS

ALLOWABLE DAMAGE FIG 101

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REPAIR Page 201

OCT 06

REPAIRS FOR SECTION 41 STRINGERS AWAY FROM THE MDCD SURROUND SEE SEC 53-10-03 OF DOCUMENT D6-37635, CONTACT IAI FOR REPAIR OF STRINGERS IN THE MDCD SURROUND AREA.

AIRCRAFT DIVISION


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365-53-00-92483 53-10-07

IDENTIFICATION Page 1 OCT 06

DETAIL 1 Section 41 Frame Identification, RHS

365-53-00-92429, 365-53-00-92301

Sheet 1

1

2

3

STA 360

FWD

A

A

5

4

VIEW A-A

S-3L

S-2L

S-1

S-2R

S-3R

S-4R

6

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IDENTIFICATION Page 2 Sept 03


1 STA 360 FRAME RH 0.100 CLAD 7075-T62

2 STA 360 FRAME CROWN 0.080 CLAD 7075-T62

3 STA 360 FRAME MACH 7050-T7451

4 REINF STRAP 0.180 CLAD 7075-T62

5 REINF STRAP 0.190 15-5 PH H900

6 SILL CHORD EXTR TMS60-2421 7075-T6511

Figure 1 Section 41 Frame Identification LIST OF MATERIALS FOR DETAIL I

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ALLOWABLE DAMAGE Page 101

OCT 06

FOR SECTION 41 FUSELAGE FRAME ALLOWABLE DAMAGE SEE SECTION 53-00-07 OF

DOCUMENT D6-37635, EXCEPT FRAMES IN MDCD SURROUND SEE SECTION 53-30-07 IN THIS

SUPPLEMENT.

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REPAIR Page 201

OCT 06

FOR SECTION 41 FUSELAGE FRAME REPAIR SEE SECTION 53-00-07 OF DOCUMENT D6-37635,

EXCEPT FRAMES IN MDCD SURROUND SEE SECTION 53-30-07 IN THIS SUPPLEMENT.

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DETAIL 1 Section 41 Crease Beam Instl Identification

Figure 1Sheet 1

1

AFT

2

STA 360

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1 CREASE WEB .071 CLAD 7075-T6

2 INTERCOSTAL .080 CLAD 7075-T6

Figure 1 Section 41 Crease Beam Identification LIST OF MATERIALS FOR DETAIL I

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REPAIR Page 101

OCT 06

SEE SECTION 53-10-15 ALLOWABLE DAMAGE FOR FIGURE 102, BUILT UP INTERCOSTALS DETAILS A, B AND C.

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REPAIR Page 201

OCT 06


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DETAIL 1 (See Dtl 2 for Rigid Barrier Option)

Fwd Entry and Airstairs Doors Surround Structure Identification Inner Skin Not Shown, View Looking Outboard

Figure 1 Sheet 1

FWD

1

2

2

2

2 3

STA 344

STA 360

STA 348

5

AIRCRAFT DIVISION


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DETAIL 1 (See Dtl 2 for Rigid Barrier Option) Fwd Entry and Airstairs Doors Surround Structure Identification

View Looking Outboard Figure 1 Sheet 2

4

Sta 360 Sta 344

LH Fwd Entry Door Cutout

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365-53-00-92483 53-10-15


DETAIL 1 (See Dtl 2 for Rigid Barrier Option) Section 41 Surround Structure Identification

View Looking Outboard, RH Side Figure 1 Sheet 3

6

6

6

Sta 360

Fwd

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1 INTERCOSTAL 0.080 CLAD 7075-T62

2 9G INTERCOSTAL MACH 7050 T7451


4 INNER SKIN 0.071 CLAD 2024-T3

5 9G FITTING MACH 15-5 PH H900

6 9G STRAP ASSY

0.063 MACH

CLAD 2024-T3 7050-T7451

Detail 1, Figure 1 Fwd Entry and Airstair Door Surround Structure Identification LIST OF MATERIALS FOR DETAIL 1 (See Dtl 2 for Rigid Barrier Option)

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IDENTIFICATION Page 5 MAR 07

DETAIL 2

Rigid Barrier Option Structure Identification View Looking Forward at Station 360

Figure 1 Sheet 1

Rigid Barrier, SEE DTL 3

View A, figure 1 sheet 2, for RH Side Identification

View B, figure 1 sheet 3, for LH Side Identification

1

2

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365-53-00-92483 53-10-15


Detail 2, View A, figure 1 sheet 2, for RH Side IdentIfication

3

4

AIRCRAFT DIVISION


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Detail 2, View B, figure 1 sheet 3, for LH Side Identification

6

STA 344

CARGO DOOR LOCATION

s-3L

5

STA 360

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1 ANGLES 0.100 PH 17-7 TH1050

2 SHEAR TIES .080 CLAD 7075-T62

3 9G INTERCOSTAL 0.080 CLAD 7075-T62


5 9G FITTING MACH 7050-T7451

6 DOOR STOP INTERCOSTAL MACH 7050-T7451

Detail 2, Figure 1 Rigid Barrier Option Structure Identification LIST OF MATERIALS FOR DETAIL 2 (See Dtl 1 for Non Rigid Barrier Option)

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DETAIL 3

Rigid Barrier Structure Identification View Looking Forward at Station 348

Figure 1

BL 00.00

LBL 15.75

LBL 50

LBL 70 RBL

30.85 RBL

51.25 RBL 70

LBL 40.75

7

1

2

3

4

5

SEE DTL 3, FIG 2

6

AIRCRAFT DIVISION


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1 LH PANEL ASSY

SKIN .25 7075-T6 SHEET

HONEYCOMB 4 AMS-C-7438 ALUM (5052)C

2 CTR PANEL ASSY



3 RH PANEL ASSY



4 CHANNEL EXTR 7075-T6511

5 VENT FRAME .08 17-7PH TH1050

6 RH CLOSURE

STIFFENERS .040 7075-T6 SHEET

PANEL .063 2024-T3

7 LH CLOSURE

FACE SHEETS .080 7075-T6 SHEET


Detail 3, Figure 1 Rigid Barrier Structure Identification

LIST OF MATERIALS FOR DETAIL 3, FIG 1

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DETAIL 3 Rigid Barrier Structure Identification

Floor Installation Figure 2

STA 344 STA 360

5

4

RIGID BARRIER SEE FIGURE 1

3, 7PL

1

2 6

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1 SPLINE .375 17-7PH

2 BOLT - NAS6206

NUT - MS21042L6

3 HI LOK - HL19PB12

NUT - MS21042L6

4 CHANNEL EXTR 7075-T6511

5 HI LOK - HL20-8

NUT - MS21042-4

6 ANGLE EXTR AND10133-2004, 7075-T6511

Detail 3, Figure 2 Rigid Barrier Structure Identification

LIST OF MATERIALS FOR DETAIL 3, FIG 2

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OCT 06

DETAIL 1

Fwd Entry and Airstairs Doors Surround Structure Allowable Damage Inner Skin Not Shown, View Looking Outboard

Figure 101 Sheet 1

FWD

3

STA 344

STA 360

STA 348

BUILT UP INTERCOSTAL

MACHINED INTERCOSTAL




MACHINED STEEL INTERCOSTAL

AIRCRAFT DIVISION


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OCT 06

DETAIL 1 Fwd Entry and Airstairs Doors Surround Structure Allowable Damage

View Looking Outboard Figure 101 Sheet 2

Sta 360 Sta 344

LH Fwd Entry Door Cutout

SEE SECTION 53-10-01 FOR INNER SKIN ALLOWABLE DAMAGE

AIRCRAFT DIVISION


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OCT 06

DETAIL 1 Section 41 Surround Structure Allowable Damage

View Looking Outboard, RH Side Figure 101 Sheet 3

Sta 360

Fwd

ALUMINUM STRAP ASSYS



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OCT 06

Detail 2 (Rigid Barrier Configuration Intercostals), figure 101 sheet 1, for RH Side Allowable Damage

BUILT UP INTERCOSTALS

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MAR 07



BUILT UP INTERCOSTALS WEB CHORDS

A B

C NOT

PERMITTED

A

MACHINED INTERCOSTALS WEB

A B NOT

PERMITTED A

9G STRAP ASSYS STRAPS FITTING

A A NOT

PERMITTED A

RIGID BARRIER SKINS EXTRUSIONS SPLINE STIFFENERS VENT FRAME

A B

C (SKINS ONLY)

NOT

PERMITTED

A

TABLE 101: ALLOWABLE DAMAGE FOR FIG 101

REFER TO SECTION 53-10-15, DOCUMENT D6-37635, FOR ALLOWABLE DAMAGE AND REPAIR FOR

ALL SECCTION 41 DOOR STRUCTURE NOT AFFECTED BY THIS SECTION.

SEE SECTION T SECTION 53-10-15, DOCUMENT D6-37635, ALLOWABLE DAMAGE 1, PAGE 112 FOR

GENERAL NOTES.

A. CONTACT IAI.

B. REMOVE NICKS, GOUGES, SCRATCHES, OR CORROSION AS SHOWN IN DTLS III AND IV.

C. DENTS ARE ALLOWED AS SHOWN IN DTL V.

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MAR 07

DTL V

DTL IV

DTL III

Y = 0.05 MAX

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REPAIR Page 201

MAR 07

CONTACT IAI FOR REPAIRS TO DOOR SURROUND INTERCOSTALS, NET AND RIGID BARRIER, FITTING AND STRAP ASSYS IDENTIFIED IN SECTION 53-10-15, PAGES 1 – 12 OF THIS SUPPLEMENT.

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DETAIL I Section 41 Main Deck Floor Panel Identification, for continuation of panels into section 43 see

Section 53-30-50 Figure 1, Sheet 1

BL 0.0

1

STA 344

STA 360

RBL 60.7

RBL 45.5

RBL 24.75

LBL 24.75

LBL 45.5

LBL 60.7

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1 FLOOR PANEL TYP 0.40 BMS 4-23 TYPE II

Figure 1 Section 41 Floor Panel Identification


AIRCRAFT DIVISION


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OCT 06

Section 41 Main Deck Floor Panel Allowable Damage

Figure 101

SEE D6-37635, SECTION 53-00-50 FOR ALLOWABLE DAMAGE FOR BMS 4-23 TYPE II FLOOR PANELS

AIRCRAFT DIVISION


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REPAIR Page 201

OCT 06

Section 41 Main Deck Floor Panel Repair

Figure 201

SEE D6-37635, SECTION 53-00-50 FOR REPAIRS FOR BMS 4-23 TYPE II FLOOR PANELS

AIRCRAFT DIVISION


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DETAIL 1 Section 41 Floor Structure Identification

Seat Tracks BL 24.75 and 45.5 not shown Figure 1 Sheet 1

1

1

2

3

3

3

FWD

STA 360

53-10-52

STA 344

STA 360

STA 380

4

BL 0.00

RBL 60.7

LBL 60.7

AIRCRAFT DIVISION


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1 SEAT TRACK FITTINGS MACH 7075-T7351

2 CREASE ANGLE 0.125 CLAD 7075-T62

3 SEAT TRACK FITTINGS MACH 7075-T7351

4 REINF UPPER STRAP REINF LOWER STRAP

0.071 0.080

15-5PH SHEET 15-5PH SHEET

Figure 1 Section 41 Floor Structure Identification LIST OF MATERIALS FOR DETAIL I

AIRCRAFT DIVISION


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OCT 06

SECTION 41 FLOOR ALLOWABLE DAMAGE SEE SECTION 53-10-51 OF DOCUMENT D6-37635 FOR ALLOWABLE DAMAGE OF SECTION 41

FLOOR STRUCTURE

FIGURE 101

SECT 41 FLOOR STRUCTURE

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REPAIR Page 201

OCT 06

SECTION 41 FLOOR STRUCTURE REPAIR

SEE SECTION 53-10-51 OF DOCUMENT D6-37635 FOR REPAIR OF SECTION 41 FLOOR STRUCTURE

FIGURE 201

SECT 41 FLOOR STRUCTURE

AIRCRAFT DIVISION


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DETAIL 1 Section 41 Seat Track Identification

365-53-00-92403 Figure 1 Sheet 1

1

1

1 STA 360

FWD

2

BL 0.00

RBL 60.7

LBL 60.7

2

AIRCRAFT DIVISION


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DETAIL 1 Section 41 Seat Track Identification

365-53-00-92403 Figure 1 Sheet 2

1

Sta 344 Sta 360 Sta 380 Sta 400

BL 0.00

RBL 24.75

RBL 45.5

RBL 60.7

AIRCRAFT DIVISION


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1 SEAT TRACK EXTR TMS60-6549 (BAC 1520-792), 7178-T6511

2 SEAT TRACK FITTINGS EXTR Extruded Bar, 7075-T6511

Figure 1 Section 41 Seat Track Identification LIST OF MATERIALS FOR DETAIL I

AIRCRAFT DIVISION


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OCT 06

Section 41 Seat Track Allowable Damage

Figure 101 See section 53-00-52 of Document D6-37635

AIRCRAFT DIVISION


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REPAIR Page 201

OCT 06

Section 41 Seat Track Repairs Figure 201

CONTACT IAI FOR SEC 41 SEAT TRACK REPAIRS BEYOND ALLOWABLE DAMAGE LIMITS

AIRCRAFT DIVISION


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365-53-00-92483 53-30-01 IDENTIFICATION

Page 1 Sept 03

DETAIL 1 Section 43 Skin Identification

Figure 1 Sheet 1

1 2

3 4

5

6

7 8

9 10

11

12

STA 500

STA 360

STA 500B

FWD

S-4R

S-21L

14

53-10-01

13

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-01 IDENTIFICATION

Page 2 Dec 03

DETAIL 1 Section 43 Quick Change Version, QC, Skin Identification

Figure 1 Sheet 2

15

SEE SECT 56-20-02 FOR SALVAGED WINDOWS (DOC. D6-37635)

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-01 IDENTIFICATION

Page 3 Dec 03


1 UPPER SKIN AFT 0.071 CLAD 2024-T3

2 UPPER SKIN FWD 0.071 CLAD 2024-T3

3 LOWER SKIN AFT 0.071 CLAD 2024-T3

4 LOWER SKIN FWD 0.071 CLAD 2024-T3

5 UPPER DOUBLER AFT 0.100 CLAD 2024-T3

6 UPPER DOUBLER FWD 0.100 CLAD 2024-T3

7 LOWER DOUBLER AFT 0.100 CLAD 2024-T3

8 LOWER DOUBLER FWD 0.100 CLAD 2024-T3

9 UPPER TRIPPLER AFT 0.100 CLAD 2024-T3

10 UPPER TRIPPLER FWD 0.100 CLAD 2024-T3

11 LOWER TRIPPLER AFT 0.100 CLAD 2024-T3

12 LOWER TRPPLER FWD 0.100 CLAD 2024-T3

13 MID FWD SKIN 0.071 CLAD 2024-T3

14 MID FWD DBLR .100 CLAD 2024-T3

15 MID FWD DBLR, QC .100 CLAD 2024-T3

Figure 1 Section 43 Skin Identification LIST OF MATERIALS FOR DETAIL I

AIRCRAFT DIVISION


365-53-00-92483



Page 101 OCT 06

Section 43 Skin Allowable Damage,

Figure 101 See D6-37635, Section 53-00-01

SEE FIGURE 102 FOR ALLOWABLE DAMAGE FOR SKIN AND DOUBLERS THAT ARE PART OF THE SURROUND FOR THE MDCD. FOR ALL OTHER SEC 43 SKIN SEE 53-00-01 OF D6-37635.

AIRCRAFT DIVISION


365-53-00-92483



Page 102 OCT 06

Section 43 Surround Skin Allowable Damage See Section 53-10-01 for Surround Skin Allowable Damage

Figure 102

STA 500

STA 360

STA 500B

FWD

S-4R

S-21L

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-01 REPAIR

Page 201 OCT 06

Section 43 General Fuselage Skin Repair Repair Restriction Areas (see notes page 202)

Figure 201

STA

500B

S-21L

SEE SEC 52-30-01 FOR MDCD

SEE NOTE 2

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-01 REPAIR

Page 202 OCT 06

NOTES FOR FIGURE 201 1. SEE SECTION 53-00-01 OF DOCUMENT D6-37635 FOR RESTRICTED AREAS IN SECTION 43 AND 46 OF SKIN REPAIR. 2. REPAIR IS NOT COVERED BY THIS FIGURE FOR THE AREA BOUNDED BY; STATION 328 TO STA 500B, S-4R TO S-21L, MDCD SURROUND SKIN, INCLUDING 5 INCH BAND AROUND SPLICES AT S-21L, S-4R, STA 500B AND STA 328. CONTACT IAI FOR DAMAGE IN THIS AREA OUTSIDE THE ALLOWABLE DAMAGE LIMITS. 3. ALL AREAS, OF SKIN, NOT RESTRICTED ADDITIONALLY HERE FOR SECTION 43 AND 46, ARE ALLOWED PER DOCUMENT D6-37635.

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-03


DETAIL 1 Section 43 Stringer Identification 365-3-00-92301, 365-53-00-92302, 365-53-00-92305, 365-53-00-92332

Sheet 1

STA 360 STA

500 1

1

1

S-4R

S-3R

S-2R

S-1

S-5L

S-6L

S-7L

S-8L

S-9L

S-10L

S-11L

7

2 5

4

6 6

3

3

8

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-03


DETAIL 1 Section 43 Stringer Identification 365-3-00-92301, 365-53-00-92302, 365-53-00-92305, 365-53-00-92332

Sheet 2

1

1

1

STA 500

STA 360

S-17L

S-20L

FWD

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-03



1 STRINGER 0.063 CLAD 7075-T62

2 LOWER SILL 0.080 CLAD 7075-T6


4 SILL CHORD 0.071 CLAD 7075-T62

5 ANGLE .050 CLAD 7075-T62




Figure 1 Section 43 Stringer Identification LIST OF MATERIALS FOR DETAIL I

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-03


OCT 06



WEB NOT ALLOWED

A NOT

ALLOWED C, D

SKIN ATTACH FLANGE NOT ALLOWED

A NOT

ALLOWED NOT ALLOWED

FREE FLANGES NOT ALLOWED

A, B NOT

ALLOWED NOT ALLOWED

MDCD SURROUND STRINGERS – CONTACT IAI FOR SILL STRUCTURE ALLOWABLE DAMAGE

ALLOWABLE DAMAGE FOR SECTION 43 STRINGERS AWAY FROM THE MDCD SURROUND SEE SEC 53-00-03 OF DOCUMENT D6-37635.

- REFER TO SRM 51-10-02 FOR INSPECTION AND REMOVAL OF DAMAGE - FOR EWORKED ALUMINUM AREAS APPLY A PROTECTIVE ALODINE COATION AS GIVEN IN SRM 51-20-01. - REFINISH REWORKED AREAS AS GIVEN IN AMM 51-20. -

A. NICK, GOUGES AND SCRATCHES THAT DO NOT PENETRATE ALL THE WAY THROUGH THE CLAD SURFACES MAY BE IGNORED. INSPECT PENETRATION DEPTH AS GIVEN IN SRM 51-10-02 B. EDGE DAMAGE, ON FREE FLANGE ONLY, MUST NOT TO EXCEED 10% OF FREE FLANGE HEIGHT AND BE BLENDED OUT WITH 1.00 R MINIMUM. OTHER DAMAGE MUST BE REMOVED PER DTL II OF SEC 53-00-03 DOCUMENT D6-37635. DAMAGE REMOVED PER DTL II MUST NOT EXCEED 10% OF CROSS SECTIONAL AREA. C. CLEAN OUT DAMAGE UP TO .25 DIA MAX AND NOT CLOSER THAN 1.0 INCH TO FASTENER HOLE OR OTHER DAMAGE. FILL HOLE WITH A 2117-T3 OR T4 RIVET INSTALLED WET WITH BMS 5-95 SEALANT. MAINTAIN 2D MIN EDGE MARGIN. CONTACT IAI FOR ALL OTHER DAMAGE. D. NOT ALLOWED AT STRINGER SPLICES.

MAIN DECK CARGO DOOR SURROUND STRINGERS ALLOWABLE DAMAGE

FIG 101

AIRCRAFT DIVISION


365-53-00-92483


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REPAIR Page 201

OCT 06

REPAIRS FOR SECTION 43 STRINGERS AWAY FROM THE MDCD SURROUND SEE SEC 53-30-03 OF DOCUMENT D6-37635, CONTACT IAI FOR REPAIR OF STRINGERS AND SILL STRUCTURE IN THE MDCD SURROUND AREA

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-04


DETAIL 1 Section 43 Intercostal Identification

365-53-00-92302 Figure 1 Sheet 1

1 STA 500

STA 360

S-4R

S-1

S-5L

S-9L

S-11L

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-04


DETAIL 1 Section 43 Intercostal Identification

365-53-00-92332 Figure 1 Sheet 2

2

2

S-17L

S-20L STA 500

STA 360

FWD

3 (SIMILAR AT FWD

LOCATION, STA 360 TO STA 380,, NOT SHOWN)

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-04





3 GUIDE FITTING ICSTL ASSY WEB

CHORDS

0.100 EXTR

CLAD 7075-T6 7075-T6511

Figure 1 Section 43 Intercostal Identification


AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-04


OCT 06

Section 43 Fuselage Intercostals Allowable Damage Figure 101

NOTE: SEE SECTION 53-00-04 OF DOCUMENT D6-37635 FOR ALLOWABLE DAMAGE OF SECTION 43 INTERCOSTALS, EXCEPT MDCD SURROUND INTERCOSTALS ALLOWABLE DAMAGE SEE SECTION 53-10-15 TABLE 101, IDENTIFIED IN THIS SECTION.

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-04

REPAIR Page 201

OCT 06

CONTACT IAI FOR REPAIRS TO DOOR SURROUND INTERCOSTALS FOR ALL OTHER SECTION 43 INTERCOSTAL SEE SECTION 53-30-04 REPAIR 1 OF DOCUMENT

D6-37635

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-07


DETAIL 1 Section 43 Frame Identification

365-53-00-92300, 365-53-00-92301, 365-53-00-92302, 365-53-00-92332 Figure 1 Sheet 1

1

2

3

4 4

STA 360 STA

500 5

6

7

1

FWD

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-07



365-53-00-92300 Figure 1 Sheet 2

8

STA 500

STA 360

10

FWD

8

9

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-07



1 STA 360/500 LOWER FRAME MACH 7050-T7451

2 STA 360 UPPER FRAME MACH 7050-T7451

3 STA 360 CROWN FRAME MACH 7050-T7451

4 FRAME STUB UPPER 0.071 CLAD 7050-T6

5 FRAME 500A UPPER 0.080 CLAD 7050-T6

6 STA 500 UPPER FRAME MACH 7050-T7451

7 FRAME 500A MID 0.080 CLAD 7050-T6

8 LOWER STUB FRAME MACH 7050-T7451

9 STA 500 CROWN FRAME MACH 7050-T7451

10 FRAME 500A LOWER 0.080 CLAD 7050-T6

Figure 1 Section 43 Frame Identification LIST OF MATERIALS FOR DETAIL I

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-07


DETAIL 2

Section 43 Frame Reinforcement 365-53-00-92411 Figure 1 Sheet 1

1

1

1

1

STA 520

STA 500

STA 360

A A

1

FWD

2, see fig 2.

A-A, Failsafe angle not

shown

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-07


DETAIL 2 Figure 2, Sta 500A to Sta 520


1 STRAPS 0.050 CLAD 7075-T6

2 SHEAR TIES 0.063 CLAD 7075-T62

Figure 1 Section 43 Frame Reinforcement Identification LIST OF MATERIALS FOR DETAIL 2

2, s-4r to s-4L

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-07


OCT 06



ZEE FRAMES (FORMED FRAMES) MDCD SURROUND AREA <1>

NOT ALLOWED

A B ALLOWED IN WEB ONLY, E

MACHINED FRAMES, <2> NOT ALLOWED

D NOT

ALLOWED NOT ALLOWED

OTHER SECT 43 FRAMES <3> C C C C

TABLE 101: SECT 43 FRAMES ALLOWABLE DAMAGE LIMITS

<1> INCLUDES FRAMES STATION 367, 380, 400, 420, 440, 460, 480, 493, FROM S-4R TO S-3L; STA 500A FROM S-4R TO S-21L, STA 360 FROM S-4R TO S-14R, <2> MDCD SURROUND, STA 360 AND STA 500 , S-4R TO S-21L AND STA 367 TO STA 493 LWR LATCH FRAMES, FROM MDCD SILL TO S-21L. <3> INCLUDES ALL OTHER SECTION 43 FRAMES NOT LISTED IN NOTES 1 AND 2. A. REMOVE DAMAGE PER DETAIL I AND II, SECTION 53-00-07 DOCUMENT D6-37635, ALLOWABLE DAMAGE 1. B. DENTS ARE ALLOWED IN FRAME WEBS ONLY PER DETAIL IIII OF SECTION 53-00-07 DOCUMENT D6-37635, ALLOWABLE DAMAGE 1. C. SEE SECTION 53-00-07 DOCUMENT D6-37635, ALLOWABLE DAMAGE 1, EXCEPT DTL V IS LIMITED TO .03 MAX DEPTH OF CLEAN UP ON AN EDGE. CONTACT IAI WHERE CLEAN UP IS REQUIRED GREATER THAN .03. D. REMOVE DAMAGE PER DETAIL I, II AND VI, SECTION 53-00-07 DOCUMENT D6-37635, ALLOWABLE DAMAGE 1. E. SEE DTL IV AND VII OF SECTION 53-00-07 DOCUMENT D6-37635, ALLOWABLE DAMAGE 1. CLEAN OUT DAMAGE UP TO 0.18 DIA MAX AND NOT CLSER THAN 3D TO FASTENER HOLE, EDGE OR OTHER DAMAGE WITH A MAXIMUM OF 4 HOLES IN 6 INCHES. FILL HOLE WITH 2117-T3 RIVET INSTALLED WET WITH BMS 5-95 SEALANT. ALL OTHER HOLES TO BE REPAIRED.

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-07

REPAIR Page 201

OCT 06

FIGURE 201 Section 43

DWG 365-53-00-92411 Figure 1 Sheet 1

REINFORCEMENT

STA 520

STA 500

STA 360

A A

FWD

A-A, Failsafe angle not

shown

REINFORCEMENT

REINFORCEMENT TYPICAL

REINFORCEMENT

REINFORCEMENT

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-07

REPAIR Page 202

OCT 06

DESCRIPTION REPAIR

ZEE FRAMES (FORMED FRAMES) MDCD SURROUND AREA <1>

CONTACT IAI

MACHINED FRAMES, <2> CONTACT IAI

OTHER SECT 43 FRAMES <3> A

TABLE 201: SECT 43 FRAMES REPAIR <1> INCLUDES FRAMES STATION 367, 380, 400, 420, 440, 460, 480, 493, FROM S-4R TO S-3L; STA 500A FROM S-4R TO S-21L, STA 360 FROM S-4R TO S-14R, <2> MDCD SURROUND, STA 360 AND STA 500 , S-4R TO S-21L AND STA 367 TO STA 493 LWR LATCH FRAMES, FROM MDCD SILL TO S-21L. <3> INCLUDES ALL OTHER SECTION 43 FRAMES NOT LISTED IN NOTES 1 AND 2. A. SEE SECTION 53-00-07 DOCUMENT D6-37635, SERVICE BULLETIN AND APPLICABLE REPAIRS, EXCEPT IN AREAS OF REINFORCEMENT PER FIGURE 201 CONTACT IAI.

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-13


DETAILS 1 Section 43 RH Crease Beam Identification

365-53-00-92409 Figure 1 Sheet 1

FWD

1

STA 360

2

3

4

5

STA 500

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-13



1 CREASE BEAM 0.080 CLAD 7075-T62

2 CREASE ANGLE 0.050 CLAD 7075-T62

3 STRAP 0.071 CLAD 7075-T62

4 STRAP 0.125 CLAD 7075-T62

5 STRAP 0.100 CLAD 7075-T62

Figure 1 Section 43 RH Crease Beam Identification LIST OF MATERIALS FOR DETAIL

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-13


DETAIL 1 Section 43 LH Crease Beam Identification

365-53-00-92307 Figure 1 Sheet 1

STA 360

STA 500

1

2

3

AFT

7

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-13


DETAIL 1 Section 43 LH Crease Beam Identification

365-53-00-92307 Figure 1 Sheet 2

3

4

5

6

FWD

STA 500C

STA 500B

STA 500A

STA 500

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-13



1 CREASE BEAM 0.080 CLAD 7075-T62

2 PLATE 0.080 CLAD 7075-T62

3 SPLICE ANGLE 0.080 CLAD 7075-T62




7 PLATE 0.200 CLAD 7075-T6

Figure 1 Section 43 Crease Beam Identification LIST OF MATERIALS FOR DETAIL 1

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-13


OCT 06

Section 43 Crease Beam Allowable Damage

Figure 101

DESCRIPTION CRACKS NICKS, GOUGES, SCRATCHES AND

CORROSION DENTS

HOLES AND PUNCTURES

SHEAR WEB NOT

ALLOWED B C E

INBD CHORD DETAILS NOT

ALLOWED A

NOT ALLOWED

NOT ALLOWED

OUTBOARD CHORD DTLS NOT

ALLOWED A

NOT ALLOWED

NOT ALLOWED

CREASE BEAM OTHER <1> NOT

ALLOWED D D D

TABLE 101, ALLOWABLE DAMAGE LIMITS

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-13


OCT 06

NOTES FOR TABLE 101: <1> INCLUDES ALL OTHER CREASE BEAM STRUCTURE IDENTIFIED IN DOCUMENT D6-37635 AND NOT INCLUDED IN FIG 101 SH 2 & 3. A. REMOVE DAMAGE AS SHOWN IN DETAILS II THROUGH VI, SECTION 53-30-13 DOCUMENT D6-37635, ALLOWABLE DAMAGE 1. B. REMOVE DAMAGE AS SHOWN IN DETAILS II, III, V AND VII, SECTION 53-30-13 DOCUMENT D6-37635, ALLOWABLE DAMAGE C. DENTS ARE ALLOWED PER DETAIL VIII OF SECTION 53-30-13 DOCUMENT D6-37635, ALLOWABLE DAMAGE 1. D. SEE SECTION 53-30-13 DOCUMENT D6-37635, ALLOWABLE DAMAGE 1. E. HOLES AND PUNCTURES ARE ALLOWED UP TO .25 DIA MAX AFTER CLEANUP, PROVIDED DAMAGE IS 1.00 MIN FROM ANY OTHER HOLE, PART EDGE OR OTHER DAMAGE. FILL WITH A 2117-T3 OR 2117-T4 PROTRUDING HEAD RIVET INSTALLED WET WITH BMS 5-95 SEALANT.

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-13


OCT 06

DETAIL 1 Section 43 RH Crease Beam

DWG 365-53-00-92409 Figure 101 Sheet 2

FWD

STA 360

STA 500

CREASE BEAM WEB ASSYS ADDED FOR FREIGHTER CONVERSION

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-13


OCT 06

DETAIL 1 Section 43 LH Crease Beam

DWG 365-53-00-92307 Figure 101 Sheet 3

FWD

STA 500C

STA 500B

STA 500A

STA 500

CREASE BEAM WEB ASSYS ADDED FOR FREIGHTER CONVERSION

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-13

REPAIR Page 201

OCT 06

DESCRIPTION REPAIR

SHEAR WEB CONTACT IAI

INBD CHORD DETAILS CONTACT IAI

OUTBOARD CHORD DTLS CONTACT IAI

CREASE BEAM OTHER <1> A

TABLE 201: CREASE BEAM REPAIR

NOTES FOR TABLE 201: <1> INCLUDES ALL OTHER CREASE BEAM STRUCTURE IDENTIFIED IN DOCUMENT D6-37635 AND NOT INCLUDED IN FIG 101 SH 2 & 3. A. SEE SECTION 53-30-13 DOCUMENT D6-37635 REPAIRS.

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-16


DETAIL 1 Section 43 Main Deck Cargo Door Surround Structure Identification 365-53-00-92300, 365-53-00-92301, 365-53-00-92302, 365-53-00-92332

Figure 1 Sheet 1

STA 500

STA 360

3 4 4

1

2

1 1

5

8

6

7

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-16



1 SPLICE 0.071 CLAD 7075-T62



4 FRAME STRAP REINF 0.125 CLAD 2024-T3

5 STRAP 0.200 CLAD 2024-T3

6 SHEAR TIE TYP 0.080 CLAD 7075-T62

7 HINGE SEGMENT, 13 PL MACH 15-5 PH H900

8 SHEAR TIE 0.080 CLAD 7075-T62

Figure 1 Section 43 Surround structure Identification

LIST OF MATERIALS FOR DETAIL 1

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-16


OCT 06

SEE SECTION 52-30-02 FOR HINGE SEGMENTS ALLOWABLE DAMAGE, ALL OTHER STRUCTURE ALLOWABLE DAMAGE IDENTIFIED IN THIS SECTION

CONTACT IAI.

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-16

REPAIR Page 201

OCT 06

CONTACT IAI BEDEK FOR REPAIRS OF CARGO DOOR STRUCTURE

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-50

IDENTIFICATION Page 1 Dec 03

DETAIL 1 Section 43 Main Deck Floor Panel Identification

365-53-00-92407 Figure 1 Sheet 1

1

STA 380 STA

540

LBL 60.7

RBL 60.7

BL 0.00

FWD

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-50



1 FLOOR PANEL 0.400 BMS 4-23 TYPE II

Figure 1 Section 43 Floor Panel Identification LIST OF MATERIALS FOR DETAIL 1

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-50


OCT 06

Section 43 Main Deck Floor Panel Allowable Damage

Figure 101

STA 380 STA

540

LBL 60.7

RBL 60.7

BL 0.00

FWD


AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-50

REPAIR Page 201

OCT 06

Section 43 Main Deck Floor Panel Repair

Figure 201

STA 380 STA

540

LBL 60.7

RBL 60.7

BL 0.00

FWD

SEE D6-37635, SECTION 53-00-50 FOR REPAIRS FOR BMS 4-23 TYPE II FLOOR PANELS

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-51

IDENTIFICATION Page 1

Sept 03

DETAIL 1

Section 43 Floor Structure Identification 365-53-00-92409, 365-52-30-92300

Figure 1 Sheet 1

STA 500

1

2

3

4

5 4

3

7

8

AQW

A

STA 360

9

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-51


Sept 03

VIEW A-A, Typical floor beam splice

365-52-30-92300

DETAIL 1

Section 43 Floor Structure Identification 365-53-00-92409 Figure 1 Sheet 2

FWD

STA 360 6

STA 440

1

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-51


Sept 03


1 FLOOR BEAM SPLICE 0.080 CLAD 7075-T62

2 STAB INTERCOSTALS 0.063 CLAD 7075-T62




6 9G PLATE SPLICE PLATES

0.071 0.071

CLAD 7075-T62 CLAD 7075-T62

7 STABILIZATION TEE EXTR AND10136-1503 7075-T6511

8 REINF STRAPS 0.125 17-7 PH H1050

9 FLOOR BEAM SPLICE MACH 7050-T7451

Figure 1 Section 43 Floor Structure Identification LIST OF MATERIALS FOR DETAIL 1

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-51


OCT 06

Section 43 Floor Structure Allowable Damage Figure 101

SEE TABLE 101

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-51


OCT 06

DETAIL 1

Section 43 Floor Structure ALLOWABLE DAMAGE

Figure 101 Sheet 1

STA 500

SHEAR WEBS

STABILIZATION

STA 360

LBL 45.50

LBL 24.75

BBL 0.0

FLOOR BEAMS STATION 360 TO STA 520

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-51


OCT 06

DETAIL 1

Section 43 Floor Structure DWG 365-53-00-92409

Figure 101 Sheet 2

FWD

STA 360

9g SHEAR PLATES

STA 440

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-51


OCT 06


CORROSION DENTS

HOLES AND PUNCTURES

FLOOR BEAM FLANGES A B NOT ALLOWED NOT ALLOWED

FLOOR BEAM WEB A B NOT

ALLOWED B

SHEAR WEB ASSY ANGLE A B NOT

ALLOWED NOT ALLOWED

SHEAR WEB ASSY WEB A B

B B

STABILIZATION A A B B

9G SHEAR PLATES A A C A

TABLE 101, ALLOWABLE DAMAGE LIMITS

NOTES FOR TABLE 101: A. CONTACT IAI BEDEK. B. SEE SECTION 53-30-51 DOCUMENT D6-37635, ALLOWABLE DAMAGE 1. C. SEE SECTION 53-30-51 DOCUMENT D6-37635, ALLOWABLE DAMAGE 1, DTL IV.

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-51

REPAIR Page 201

OCT 06

CONTACT IAI FOR SEC 43 FLOOR STRUCTURE REPAIRS BEYOND ALLOWABLE DAMAGE LIMITS

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-52


DETAIL 1 Section 43 Seat Track Identification 365-53-00-92403 Figure 1 Sheet 1

STA 360

STA 500

3

4

1

2

1

1

1

3

LBL 60.7

BL 0.00

RBL 60.7

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-52



1 SEAT TRACK EXTR TMS60-6549 7178-T6511

2 SEAT TRACK MACH 15-5PH H1025



Figure 1 Section 43 Seat Track Identification


AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-52


OCT 06

Section 43 Seat Track Allowable Damage

Figure 101 See section 53-00-52 of Document D6-37635

NOTE: CONTACT IAI FOR FINISH REQUIREMENTS OF THE 15-5PH CRES SEAT TRACK SEGMENT IF CLEAN UP OF ALLOWABLE DAMAGE IS ACCOMPLISHED.

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-30-52

REPAIR Page 201

OCT 06

Section 43 Seat Track Repair Figure 201


AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-60-07



365-53-00-92411 Figure 1 Sheet 1

1

1

1

1

1

STA 727B

STA 907

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-60-07



1 REINF STRAP .190 CLAD 7075-T6

Figure 1 Section 46 Frame Identification LIST OF MATERIALS FOR DETAIL 1

1

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-60-07


OCT 06



SECT 46 FRAMES <1> A A A A

TABLE 101: SECT 46 FRAMES ALLOWABLE DAMAGE LIMITS

<1> INCLUDES ALL SECTION 46 FRAMES EXCEPT AREAS OF REINFORCEMENT, SEE IDENTIFICATION DTL 1. A. SEE SECTION 53-00-07 DOCUMENT D6-37635, ALLOWABLE DAMAGE 1, EXCEPT DTL V IS LIMITED TO .03 MAX DEPTH OF CLEAN UP ON AN EDGE. CONTACT IAI WHERE CLEAN UP IS REQUIRED GREATER THAN .03.

AIRCRAFT DIVISION


365-53-00-92483


365-53-00-92483 53-60-07

REPAIR Page 201

OCT 06

DETAIL 1 Section 46 Frame Reinforcement

DWG 365-53-00-92411 Figure 201 Sheet 1

REINFORCEMENT

STA 727B

STA 907

REINFORCEMENT

REINFORCEMENT

REINFORCEMENT

REINFORCEMENT

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REPAIR Page 202

OCT 06

DTL II

Figure 201

DESCRIPTION REPAIR

SECT 46 FRAMES A

TABLE 201: SECT 46 FRAMES REPAIR A. SEE SECTION 53-00-07 DOCUMENT D6-37635, SERVICE BULLETIN AND APPLICABLE REPAIRS, EXCEPT IN AREAS OF REINFORCEMENT PER FIGURE 201 CONTACT IAI.

REINFORCEMENT

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DETAIL 1 Section 46 Main Deck Floor Panel Identification

365-53-00-92407 Figure 1 Sheet 1

AFT

STA 540 STA

1006

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1 FLOOR PANEL TYP 0.400 BMS 4-23 TYPE II

Figure 1 Section 46 Floor Panel Identification


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OCT 06

Section 46 Main Deck Floor Panel Allowable Damage Figure 101

AFT

STA 540 STA

1006


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REPAIR Page 201

OCT 06

Section 46 Main Deck Floor Panel Repair Figure 201

AFT

STA 540 STA

1006 SEE D6-37635, SECTION 53-00-50 FOR ALLOWABLE DAMAGE FOR BMS 4-23 TYPE II FLOOR PANELS

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DETAIL 1 Section 46 FWD Overwing Beam Identification

365-53-00-92565 Figure 1 Sheet 1

1

FWD

STA 727B

STA 540

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DETAIL 1 Section 46 FWD Overwing Beam Identification

365-53-00-92565 Figure 1 Sheet 2

1

1

STA 540

STA 727B

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DETAIL 1 Section 46 FWD Structure Identification

365-53-00-92451 LH Shown, RH opposite

Figure 1 Sheet 3

STA 727B

STA 540

2 2

2 4

4

3

5

5

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1 UPPER CHORD EXTR TMS60-13855 7075-T6511

2 INTERCOSTAL EXTR TMS60-30966 7075-T62

3 SEAT TRACK MACH 15-5 PH H900

4 SHEAR WEB 0.080 CLAD 7075-T62

5 SEAT TRACK CROWN EXTR TMS60-19207 7178-T6511

Figure 1 Section 46 FWD Structure Identification LIST OF MATERIALS FOR DETAIL 1

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DETAIL 2 Section 46 AFT Floor Structure Identification

Figure 2 Sheet 1

2

1

FWD

STA 847

2

2

2

4

4

1

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DETAIL 2 Section 46 AFT Floor Structure Identification

Figure 2 Sheet 2

5

5 FWD

3

3

STA 847

STA 907

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1 LOWER CHORD FITTINGS MACH 7075-T7351

2 FLOOR BEAM DOUBLER FLOOR BEAM STRAP

0.090 0.125

CLAD 7075-T6 CLAD 7075-T6

3 DOUBLER UPPER STRAP LOWER STRAP

0.090 0.125 0.125

CLAD7075-T6 15-5 PH H900 CLAD 7075-T6

4 FLOOR BEAM STRAP 0.100 CLAD 7075-T6

5 STAB INTERCOSTAL 0.050 CLAD 7075-T62

Figure 2 Section 46 Floor Structure Identification


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OCT 06

Section 46 Floor Structure Allowable Damage Figure 101 Sheet 1

SEE DTLS I AND II

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OCT 06

DETAIL 1 Section 46 FWD Structure Allowable Damage

LH Shown, RH opposite Figure 101 Sheet 2

STA 727B

STA 540

SHEAR WEB AT SIDE OF BODY

INTERCOSTAL

BL 0.0 OVER WING BEAM

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OCT 06

DETAIL 2 Section 46 AFT Floor Structure

Figure 101 Sheet 3

FWD

FLOOR BEAM, STATION 727B TO STA 967

STA 847

STA 907

STABILIZATION

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OCT 06


CORROSION DENTS

HOLES AND PUNCTURES

OVER WING FLOOR BEAMS ALL BL CHORDS WEB

A

I J

NOT ALLOWED

C

NOT ALLOWED

D

SHEAR WEB, SIDE OF BODY A G C D

INTERCOSTAL CHD WEB

A

F

G

NOT ALLOWED

C

NOT ALLOWED

D

LATERAL FLOOR BEAMS UPPER AND LOWER FLANGE WEB

A

F

H

NOT ALLOWED

NOT ALLOWED

NOT ALLOWED

E

STABILIZATION STRAP WEB

A

A

G

C

C

NOT ALLOWED

D

OTHER STRUCTURE <1> A B B B

TABLE 101, ALLOWABLE DAMAGE LIMITS FOR DTL I AND II

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NOTES FOR TABLE 101: <1> SECTION 53-60-51 STRUCTURE ADDRESSED IN ALLOWABLE DAMAGE 1, DOCUMENT D6-37635, NOT SHOWN HERE, SHOULD USE THE ALLOWABLE DAMAGE 1 PER DOC. D6-37635. A. CONTACT IAI BEDEK. B. SEE SECTION 53-60-51 DOCUMENT D6-37635, ALLOWABLE DAMAGE 1. C. SEE SECTION 53-60-51 DOCUMENT D6-37635, ALLOWABLE DAMAGE 1, DTL VIII.

D. HOLES AND PUNCTURES ARE ALLOWED UP TO.25 DIA AFTER CLEANUP PROVIDED DAMAGE IS 1.00 MIN FROM ANY OTHER HOLE, EDGE, RADIUS OR OTHER DAMAGE. CILL WITH A 2117-T3 OR 2117-T4 PROTRUDING HEAD RIVET INSTALLED WITH BMS 5-95 SEALANT. E. SEE SECTION 53-60-51 DOCUMENT D6-37635, ALLOWABLE DAMAGE 1, DTL XII. F. REMOVE NICKS, GOUGES, SCRATCHES, OR CORROSION PER DTLS VI, VII, XII, XV, AND XIX OF SECTION 53-60-51 DOCUMENT D6-37635, ALLOWABLE DAMAGE 1. G. REMOVE NICKS, GOUGES, SCRATCHES, OR CORROSION PER DTLS VI, VII, X AND XV OF SECTION 53-60-51 DOCUMENT D6-37635, ALLOWABLE DAMAGE 1. H. REMOVE NICKS, GOUGES, SCRATCHES, OR CORROSION PER DTLS VII AND XII OF SECTION 53-60-51 DOCUMENT D6-37635, ALLOWABLE DAMAGE 1. I. REMOVE NICKS, GOUGES, SCRATCHES, OR CORROSION PER DTLS VI, VII, IX, X, XI AND XIX OF SECTION 53-60-51 DOCUMENT D6-37635, ALLOWABLE DAMAGE 1. J. REMOVE NICKS, GOUGES, SCRATCHES, OR CORROSION PER DTLS VI, VII, X, XV AND XVI OF SECTION 53-60-51 DOCUMENT D6-37635, ALLOWABLE DAMAGE 1.

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REPAIR Page 201

OCT 06

CONTACT IAI FOR SEC 46 FLOOR STRUCTURE REPAIRS BEYOND ALLOWABLE DAMAGE LIMITS, EXCEPT REPAIR GENERAL AND REPAIR 4 ARE NOT AFFECTED BY THIS SUPPLEMENT.

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DETAIL 1 Section 46 AFT Seat Track Identification Figure 1

1

1

1

1

1

STA 847

FWD

1 <SF effectivity only>

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1 SEAT TRACK EXT TMS60-6549 7178-T6511

2 CONTINUOUS FTGS MACH 7075-T7351

Figure 1 Section 46 Seat Track Identification


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Section 46 Seat Track Allowable Damage Figure 101

See section 53-00-52 of Document D6-37635 NOTE: CONTACT IAI FOR FINISH REQUIREMENTS OF THE 15-5PH CRES SEAT TRACK SEGMENT, IN SECTION 46 FWD AT BL 60.6, IF CLEAN UP OF ALLOWABLE DAMAGE IS ACCOMPLISHED.

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OCT 06


Documents

AIRCRAFT DIVISION Bedek Aviation Group ISRAEL ...70 STRUT INSTL - CFM56-3 ENGINE See document D6-37635 71 POWER PLANT INSTL See document D6-37635 78 FAN DUCT COWL AND THRUST REVERSER