Engineering Handout

Split Sleeve Coldworking—

Holes (Aluminum, Steel & Titanium)
WCI-EH-9201-4.1

Seattle, Washington

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 Engineering Handout
WCI—EH-9201-4.1

Split Sleeve Coldworking —

Holes (Aluminum, Steel & Titanium)

Table of Contents
1 Scope

2 Definitions

3 Tooling Descriptions

4 Split Sleeve Coldworking of

Fastener Holes—Procedures

5 CA Tooling–Titanium and High Strength

Steel Alloys

6 CB Tooling–Aluminum, High Interference

7 CW Tooling–Aluminum, Low Interference

8 Metric Tables – High Interference, CA and

CB Tooling

9 CRACKARRESTOR–Stop Drill Procedures

10 Maintenance & Repair Tool Kits

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Split Sleeve Coldworking WCI-EH-9201-4.1 1

1 Scope

1.1 This engineering handout is a reference document describing the split sleeve coldworking process. This
document describes the implementation procedures in detail and is recommended for use in conjunction with
our customers' specified Engineering drawings or other Engineering authority.
1.2 Split sleeve coldworking is performed on holes in highly stressed areas to increase the fatigue life of structural
members. Coldworking expands the hole diameter, thereby creating a radial plastic flow of material which
produces high residual compressive stresses around the hole. The residual compressive zone, depending
upon variables such as material and applied expansion levels, will usually extend out from approximately one
radius to one diameter from the hole.
1.2.1 The expansion process is accomplished by inserting a tapered mandrel into a hole lined with a
longitudinally split, disposable, stainless steel sleeve. The sleeve has a coating of dry film lubricant
on the internal surface to lower the applied load (pull-force) required to draw the mandrel through
the hole. As the mandrel is pulled back through the sleeve, the hole is expanded.
1.3 This engineering handout will support and in some cases enhance customer supplied documents.

1.4 Aluminum (80 ksi Max.) - Differing applied expansion levels (see paragraph 2.4 for a definition of Applied
Expansion) are required for the various aluminum alloy coldworking processes supported by this document.
1.5 Titanium and Steel Alloys (250 ksi Max.) - These metal alloys require applied expansion levels between 4.5
and 6.7 percent (5.5 percent nominal) using the mandrels and sleeve thicknesses defined in Section 5 for
CA Tooling. See paragraph 2.4, for the definition of Applied Expansion.
1.6 Dissimilar Materials - Aluminum alloys in multi-material stackups with titanium and steel alloys should be
expanded to the range specified for the fatigue critical material.
1.7 Special Applications - Some applications require the use of tooling not found in this specification. Tooling
to support these special applications fall into the following categories:
1.7.1 Any application where a material different from those specified in paragraphs 1.4 and 1.5 is used.
1.7.2 Any application requiring the use of an applied expansion level different from that specified in the
appropriate tooling tables referred to in paragraph 1.4, e.g., lug configurations which require a lower
applied expansion level due to short edge-margin. See paragraph 2.3, for the definition of edge-
margin.
1.7.3 Any application requiring special tooling or procedures not described in this document, e.g., special
access restriction requirements. See paragraph 2.12, for the definition of access restriction.

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2 Definitions

2.1 Material Stackup - The combined thickness of a structure through which a hole is located, or the total length
of a bore. Material stackup is important when determining the correct tooling required for a task, ie. mandrel
length, puller unit stroke length, sleeve length, and nosecap length. A stackup of material shall have complete
faying surface contact during start hole preparation, coldworking, and final hole sizing operations. For
minimum stackup requirements, see paragraph 3.7, Backup Block.
2.2 Puller Stroke - The total movement required to pull a mandrel, including the tapered portion and major
diameter, through a given material stackup. Ref. Table 2-01.
2.3 Edge Margin - Edge margin (e/D) is the ratio of the shortest distance between the center of the hole and the
edge of the part. Reworking of fastener holes tends to reduce the edge margin. Fatigue testing has shown
edge margins of 1.75 or greater are preferred. Use of an interference fit fastener is recommended for edge
margins between 1.25 and 1.75. Ref. Fig. 2-01.
edge margin=e e = distance from edge of part to center of hole
D D = final hole diameter

e D

Figure 2-01 — Edge Margin Spacing

2.4 Applied Expansion - CWAE , is the total amount of expansion a hole experiences during coldworking,
expressed as a percentage of the start hole diameter. The required expansion level is a function of hole
diameter and may decrease for hole diameters up to 3¾". See paragraphs 1.4 and 1.5 for standard applied
expansion values.

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CWAE = A-B x 100 CW=Coldworking

B AE=Applied Expansion B=Start Hole Diameter
A=Mandrel Major Diameter + (2 x Sleeve Thickness)

2.5 Retained Expansion - CWRE, is the ratio of total increase in hole size after coldworking, expressed as a
percentage of the start hole diameter. This value is variable and proportional to the yield strength of the
material being coldworked. Generally, greater life improvement is observed with higher retained expansion
values.
CWRE = A-B x 100 CW=Coldworking
B A=Measured Hole Diameter after coldworking
RE=Retained Expansion B=Start Hole Diameter

2.6 Major Mandrel Diameter - The largest mandrel diameter which, in conjunction with the sleeve thickness,
provides the proper amount of applied expansion to coldwork a hole. This dimension is critical to the process.
Ref. Fig. 2-02.
2.7 Minor Mandrel Diameter - The mandrel dimension which, when combined with the split sleeve thickness,
allows insertion into the start hole. Ref. Fig. 2-02.
2.8 Taper - Taper is the section of mandrel on either side of the major diameter which enhances the coldwork
process. The taper on the frontside of the major diameter aides the installation of the split sleeve and insertion
into the hole to be coldworked. The taper on the backside of the major diameter controls the pull-force
required to coldwork the hole. Ref. Fig. 2-02.

Major Diameter Frontside Taper

Minor Diameter Backside Taper

Figure 2-02 — Mandrel

2.9 Pull Force - The amount of force required to pull a mandrel through a particular material is dependant upon
the hole diameter, material stackup and material properties. Ref. Table 2-02.
2.10 Start Hole Diameter - The measured size of the hole prior to coldworking. Important for ensuring the proper
coldworking of the hole. Hole must be measured dimensionally throughout the hole bore and checked for
concentricity or roundness. Holes not meeting the dimensional specifications stated in the particular table,
will not provide the desired fatigue enhancement. Start holes must also be within 2° of normal to the surface,
and have a surface roughness of 125 rms or smoother.
2.11 Existing Hole Diameter - The measured hole diameter determines which coldworking toolset is utilized for
a hole. Proper examination of the hole is important in order to ensure the maximum benefit from coldworking.
Important factors to look for are fatigue indicators such as cracks, out of roundness, and a tapered bore. Holes
slightly oval in shape or with a tapered bore, may be coldworked if dimensions are within start hole tolerances.
2.12 Access Restriction - A term used to refer to areas which contain obstructions that prevent the coldworking
of holes utilizing standard tooling. These obstructions may be backside to the hole, frontside to the hole, or
laterally to the hole. For these types of restrictions, utilize either an Hydraulic Offset or Puller Gun/Offset
Adapter. Ref. Fig. 2-03.
2.12.1 Restricted Backside Clearance - Obstructions on the backside of the hole which prevent the full
insertion of the mandrel and sleeve into the hole prior to coldworking.

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WCI-1700-20

Standard Nosecap

N o R e s tr ic te d A c c e s s

P r o b le m S o lu tio n

WCI-1
700-20

WCI-1700-OA-20
WCI-1700-20

O ffs e t A d a p te r

R e s tr ic te d F r o n ts id e C le a r a n c e

WCI-1700-20

WCI-1700-OA-20

WCI-1700-20

O ffs e t A d a p te r

R e s tr ic te d L a te r a l C le a r a n c e

WCI-1700-20 WCI-1700-20

E x te n s io n N o s e c a p

R e s tr ic te d L a te r a l C le a r a n c e

Figure 2-03 — Restricted Access Problems and Solutions

2.12.2 Restricted Frontside Clearance - Obstructions on the frontside of the hole prevent the insertion of
standard coldwork tooling into the hole.
2.12.3 Restricted Lateral Clearance - Obstructions located laterally to the hole which prevent the utilization
of standard coldwork tooling.
2.13 Fatigue - A phenomenon in which materials crack and fracture, when subjected to cyclic stresses well below
their maximum static strength.
2.14 CRACKARRESTOR - A toolset designed to be utilized in conjunction with stop drill structural repairs. Stop drilling
is an operation performed to prevent further growth of fatigue cracks. Incorporating coldworking with stop
drill repairs, enhances the repair by adding the benefits of coldworking to the repair. See Section 9.
2.15 Satellite Holes - A satellite hole is the smaller of two holes which has less than 0.40 inch distance between
the edges of the holes. The smaller holes should be filled with a steel pin prior to coldworking the larger hole.
The steel pin shall have a diameter less than the start hole diameter, but not greater than 0.002" under the
start hole size. The purpose of these pins is to prevent the collapse of these holes during the coldworking
of the larger hole. Ref Fig. 2-04.

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Satellite Holes

Figure 2-04 — Satellite Holes

2.16 Axial Ridge - An axial ridge on the bore of the hole is formed by plastic flow of material into the logitudinal
split of the sleeve during coldworking. As an indicator of coldworking, it is normally removed by post-size
reaming. However, the ridge is an acceptable condition, and may be left intact if post sizing of the hole is not
required for fastener installation. If necessary, the axial ridge height may be reduced by coldworking the hole
a second time using the same mandrel and new sleeve. The sleeve split shall be rotated 90° from the axial
ridge location. Additionally, holes subject to low cycle fatigue may require that the sleeve split be positioned
away from the area of highest stress levels. Ref. Fig. 4-07.
2.17 Hole Spacing Requirement - Hole spacing may be determined by measuring the distance between the
centerlines of adjacent holes. Hole spacing less than 3 diameters, should be examined, considering material
movement, prior to coldworking. See paragraph 2.15, for the definition of Satellite Holes. Ref. Fig. 2-05.

³ 3D

D=Final Hole Diameter

Figure 2-05 — Hole Spacing Requirements

2.18 Countersunk Holes - It is recommended that start holes not be countersunk or spot faced prior to coldworking.
If a countersunk hole is to be coldworked, the hole should be processed using the next larger toolset if
possible. The hole can then be processed to engineering requirements after coldworking. Contact West
Coast Engineering if hole cannot be processed per this specification.

TABLE 2-01 Puller Dimensions

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Puller Model No Stackup A B
(inches) (inches) (inches)

WCI-1700 1.0 9.7 3.0

For Mandrel Sizes 1.5 10.7 3.5
4-0-N thru 16-3-N 2.0 11.7 4.0
2.5 12.7 4.5 A
Pull Force - 9,200 lbs.
with 10,000 psi 3.0 13.7 5.0
hydraulic pressure
3.5 14.7 5.5
WCI-1800 1.0 12.6 5.2
WCI-1700-20
For Mandrel Sizes 1.5 13.6 5.7
14-0-N thru 30-3-N 2.0 14.6 6.2
Pull Force - 27,600 lbs. 2.5 15.6 6.7
with 10,000 psi 3.0 16.6 7.2
hydraulic pressure
7.0 24.6 11.2
B
WCI-1900 1.0 13.6 5.8
For Mandrel Sizes 1.5 14.6 6.3
32-0-N thru 56-3-N 2.0 15.6 6.8
Pull Force - 38,000 lbs. 2.5 16.6 7.3
with 10,000 psi 3.0 17.6 7.8
hydraulic pressure
7.0 25.6 11.8

TABLE 2-02 Approximate Pull Force Requirements

Nominal Hole Diameter Approximate Puller Unit

(inches) Pull Force Requirements
In Aluminum Alloys

1/8 to 3/16 1,500

13/64 to 1/4 2,500
17/64 to 5/16 3,000
21/64 to 3/8 4,000
25/64 to 3/4 10,000
49/64 to 1 14,000

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3 Tooling Description

3.1 Hydraulic Powerpak - An air actuated powerpak supplies up to 10,000 psi of hydraulic pressure to the puller
gun during the coldwork process.
3.2 Puller Unit - West Coast Industries provides hydraulically actuated units in several sizes which pull the
mandrel through the hole. The different sizes provide for different pull force requirements and stackup lengths
to fit specific requirements. Ref. Table 2-01 & 2-02. A complete line of Hydraulic Offset Pullers are
manufactured to facilitate the coldworking of special access restriction areas. The WCI-HP is a mechanical
puller unit which utilizes a standard shop wrench to provide the pull force required to coldwork holes as a part
of the standard stop drill repair, or special access restricted areas.
3.3 Offset Adapter - The offset adapter is a unit which attaches to the front of the puller, allowing the coldworking
of holes which have an access restriction.
3.4 Nosecap - An assembly composed of a body, a jaw set, and a retainer. The nosecap retains the split sleeve
in the hole as the mandrel is drawn through the sleeve. Extension nosecaps, whether standard or offset
adapter, may be utilized in either restricted or unrestricted access areas. Ref. Fig. 3-01.

B o d y R e ta in e r

N o s e E x te n s io n

B o d y R e ta in e r

J a w s e t

Figure 3-01—Extension and Flush Nosecaps

3.5 Mandrel - A mandrel is a tool manufactured from high strength steel with a tapered end. V1 mandrels are
utilized in aluminum and mild steel applications, while V2 are used on titanium or high stength steel

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applications. Most mandrels are one piece, but some larger mandrels above 1" in diameter are two pieces.
These are ground as a set and may not be mixed.
3.6 Split Sleeve - A rolled piece of stainless steel, with a longitudinal split. The internally prelubricated sleeve is
used in conjunction with the mandrel to expand the hole. In all cases, total sleeve length must exceed the
material stackup by 1/32 inch minimum. When using multi-sleeve stackups, junctures between separate
sleeves shall be a minimum of 1/16 inch from any faying surface. Additionally, there shall be no sleeve juncture
less than one start hole diameter from the back surface of the hole. Ref. Fig. 3-02.
3.6.1 Flared Sleeves - Flared sleeves are to be used with standard nosecaps, extension nosecaps, and
offset adapter nosecaps.
3.6.2 Straight Sleeves - Straight sleeves are to be used in conjunction with flared sleeves in applications
which require multiple sleeve stackups. The sleeve gaps should be arranged in such a manner that
the splits are aligned, in order to facilitate sleeve removal after coldworking.
3.6.3 Do not reuse split sleeves, as they become distorted and lose lubrication during the coldwork
process.

Flared Material Thickness

Length Acceptable
Gage Pin
Gap Width
Diameter
Straight

Unacceptable
Length

Gap between sleeves shown for illustration purposes only

Figure 3-02 — Sleeve Geometry (Left) and Proper Sleeve Orientation (Right)

3.7 Backup Blocks - Aluminum backup blocks are used to increase the stackup thickness, preventing material
buckle in thin materials. These blocks are commonly required for the coldworking of thin material stackups
and shall be used when material stackup is less than one hole diameter in thickness. They are not required
to be of the same alloy or temper as the part. Backup blocks shall have a hole meeting the same dimensional
and finish requirements as the workpiece start hole, and are discarded after use (blocks may be reused if
reamed to the next start hole size). Ref. Fig. 3-03.

Acceptable Unacceptable Acceptable

S >= D S<D S+B >= D

D D D

S S
S
B

S=Stackup Length Backup Block

D=Hole Diameter
B=Backup Block Thickness

Figure 3-03 — Acceptable Stackup Thicknesses

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3.8 Mandrel Wear Gage - The mandrel wear gage is used to check the mandrel major diameter for excessive
wear prior to the coldworking operation. Failure to check the mandrel could result in holes not being
coldworked to the correct expansion level. Ref. Fig. 3-04.
3.9 Gages - The aerospace industry utilizes four types of gages to verify hole sizes during the coldworking
process. Ref. Fig. 3-05.

NO-GO

Mandrel Wear Gage Acceptable Unacceptable

Figure 3-04 — Checking a Mandrel with the Mandrel Wear Gage

3.9.1 Start Hole Gage — The start hole gage is used to verify that the start hole is within tolerance.
3.9.2 Verification Gage — The verification gage is used to verify that the hole has been coldworked.
3.9.3 Combination Gage — The combination gage combines the above two gages into one unit. One end
of the gage checks the pre-coldworked start hole while the other end verifies that the hole has been
coldworked. Ref. Fig. 3-05

Coldwork Verification No-Go Go No-Go Go

WCI-CBG-16-0-N WCI-FHG-16-0-N

Start Hole

COMBINATION GAGE FINAL HOLE GAGE

Figure 3-05 — Combination and Final Hole Gages

3.9.4 Final Hole Gage — The final hole gage is used to verify that the final hole diameter is within the
specified tolerance. Ref. Figure 3-05
3.10 Start Drill — A conventional twist drill is used to produce a pilot hole compatible with the non-cutting pilot of
the start reamer.
3.11 Start Reamer — The start reamer is used to properly size the pilot hole prior to the coldworking operation.
Ref. Fig. 3-06.

Pilot Hole Verification Coldworked Hole Verification

Non-cutting, Go-No Go Pilot Non-Cutting, Go-No Go Pilot

WCI-SR-12-0-N WCI-FR-16-3-N-5463

START REAMER FINAL REAMER

Figure 3-06 — Start and Final Reamers

3.12 Final Reamer — The final reamer is used to properly size the post coldworked hole. The non-cutting pilot
of a final reamer is the same diameter as the verification gage. If the hole has not been properly coldworked,
the reamer pilot will not enter the post coldworked hole. Ref. Fig. 3-06.

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4 Split Sleeve Coldworking of Fastener Holes-

Procedures

4.1 Split sleeve coldworking shall be performed after all material processing operations have been accom-
plished, ie. all forms of heat treating, localized hit forming operations (dimpling), and coining operations.
4.2 Determine the finished hole diameter as indicated by Engineering documents.
4.3 Using the final required hole size, determine the tool code from the applicable tooling table.
4.4 Using the tool code chosen above, select the proper toolset.
4.5 Select the appropriate restricted access tooling (if applicable) to complete the task (extension nosecap, offset
adapter, hydraulic offset, and/or mandrel).
4.6 Assemble Tooling
4.6.1 Procedures for assembling standard system. Ref. Fig. 4-01.

WARNING
Insure puller is disconnected from powerpak and/or shop air
prior to assembling/disassembling tooling

Set Screws
Mandrel Threaded
Adapter

WCI-1700-20

Nosecap Ass'y Barrel

Piston Rod

Figure 4-01 — Exploded View of Standard Puller Gun

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4.6.1.1 Select the proper puller unit for the task.

4.6.1.2 Thread the mandrel completely into the threaded adapter of the puller unit. Note, when
coldworking numerous holes, the set screw on the mandrel side of the threaded adapter
must be tightened.
4.6.1.3 Slide the nosecap onto the mandrel, then thread the nosecap onto the barrel of the puller
unit. Connect the puller hose fittings to the power unit and supply air line.
4.6.2 Procedures for assembling offset adapter coldworking system.

WARNING
Insure puller is disconnected from powerpak and/or shop air
prior to assembling/disassembling tooling

4.6.2.1 Select the proper puller unit and offset adapter for the task.
4.6.2.2 Remove the threaded barrel from the puller unit. Remove the threaded adapter from the
piston rod of the puller unit. Ref. Fig. 4-01.
4.6.2.3 Remove offset adapter cover for ease of installation.
4.6.2.4 Thread the offset adapter moveable arm onto the puller unit piston rod. Ref. Fig. 4-02.
4.6.2.5 After ensuring that the moveable arm is properly installed onto the piston rod, thread the
offset adapter housing into the puller unit and lock in place with the jam nut. Ref. Fig. 4-02.

Stationary Arm
Moveable Arm

WCI-1700-OA-20 WCI-1700-OA-20
WCI-1700-20 WCI-1700-20

Jam Nut Lock Nut

Figure 4-02 — Installing Offset Adapter on Puller Gun

4.6.2.6 Remove or loosen the two screws holding the nosecap backup plate onto the offset
adapter. Ref. Fig. 4-03.

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Jawset

Spring Pin
Jawset

SECTION A-A
Flush Jaw Set

Backup
Plate

See A-A
Stationary Arm
Moveable Arm

Mandrel
Jawset

Screw

Backup Plate

Figure 4-03 — Offset Adapter Jawset (guard not shown)

4.6.2.7 Select proper tooling.

4.6.2.8 Thread the mandrel completely into the offset adapter.
4.6.2.9 Ensure the spring is in place between the jawset halves before installation.
4.6.2.10 Slide the jawset, pin side first, onto the mandrel until flush against the offset adapter.
Ensure the pins slide into the matching holes in the offset adapter housing.
4.6.2.11 Install cover on offset adapter.
4.6.2.12 Install the backup plate using the two screws previously removed.
4.6.2.11 Connect puller to the power unit.

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4.7 Coldworking Procedures Ref. Figure 4-04

1. Drill Start hole 6. Insert mandrel/

sleeve combination

2. Ream hole to 7. Actuate puller,

proper start size drawing mandrel
thru sleeve

3. Check hole with 8. Remove sleeve.

combination gage Hole is coldworked

4. Check 9. Verify coldworking

mandrel with with combination gage
mandrel wear gage

5. Slide sleeve onto 10. Ream to final hole

mandrel diameter

Figurre 4-04 — Split Sleeve Coldworking Process (One Piece Mandrel)

4.7.1 Split sleeve coldworking is a tooling-critical process. The use of nonconforming or worn tooling will
reduce fatigue life improvement or possibly result in extensive rework.
4.7.2 Drill, and/or ream existing hole to the start hole dimensions described for the particular toolset. After
all drilling and reaming operations have been completed, clean the hole, removing all cutting fluid
residue. The presence of any lubrication or cutting fluid may allow the split sleeve to slip during the
coldworking operation. The pre-coldworked hole shall be free of all foreign materials present
including, paint, sealant and metal particles.
4.7.3 Verify the start hole diameter using the correct start hole gage, or combination gage, supplied with
each toolset. If the combination gage is not available, measure the hole using a telescoping ball gage
and micrometer.
4.7.4 Using the mandrel wear gage, check mandrel wear by attempting to insert the mandrel into the wear
gage. If the mandrel will insert into the gage, it is worn beyond limits. Verify that the mandrel and wear
gage part numbers are correct.
4.7.5 Cycle the puller unit, drawing the mandrel completely into the nosecap. A mandrel not drawing into
the nosecap sufficiently may be caused by a failure to thread the mandrel completely into the puller
unit, or selection of incorrect mandrel length.

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4.7.6 Select the proper split sleeve for the task, ie. flared, straight, or a combination of the two. Ensure that
the sleeve length is a minimum of 1/32" longer than the material stackup. Stacked sleeves shall not
have a separation within 1/16 inch of any faying surface. When stacking sleeves, the flared sleeve
is installed first on the mandrel, and it is recommended that sleeve splits be aligned to facilitate their
removal after coldworking. Ref. Fig. 3-02.
4.7.7 Slide the split sleeve onto the mandrel, until flush against the nosecap. Ref. Fig. 4-05.

Sleeve

WCI-CBM-14-0-N-1-20

Minor Diameter

Major Diameter
Figure 4-05 — Positioning Sleeve on Mandrel (dimensions exaggerated for clarity)

WARNING
Failure to meet this requirement may cause the tooling to
experience a catastrophic failure, resulting in possible
operator injury.

4.7.9 Insert the assembled tooling completely into the hole. Ensure that the nosecap is flush against the
material to be coldworked. Nosecap shall be normal to the material surface. For surface to hole
angles greater than 2°, beveled spacers may be used. Follow engineering directions for correct
orientation of beveled spacers.
4.7.10 The hydraulic powerpak is preset to either 7,000 or 10,000 psi at the factory. It is strongly
recommended that this setting not be adjusted lower. The powerpak will only provide the amount
of pressure required to coldwork the hole. Insufficient hydraulic pressure may prevent mandrel from
pulling completely through the material.
4.7.11 Coldwork the hole by actuating the puller unit.
4.7.12 Remove sleeve from hole and discard.
4.7.13 Many mandrels above 1" diameter are of two piece construction due to required mandrel geometry.
Follow the instructions in figure 4-06 for using these mandrels.

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Nosecap Mandrel Nose Mandrel Shaft Threaded Adapter

Thread mandrel shaft into threaded adapter of puller gun

Sleeve

Slide sleeve over assembled mandrel shaft

Unscrew mandrel nose. Insert mandrel Screw mandrel nose into mandrel
shaft and sleeve combination into hole shaft and actuate puller gun

Figure 4-06 – Two Piece Mandrel

4.7.14 Verify coldworking operation utilizing the proper verification gage. If the verification gage is not
available, the hole may be measured using a ball gage and micrometer. The measured values shall
compare to the appropriate tables. When measuring the post-coldworked hole, measure away from
the axial ridge. Ref Fig. 4-07.

Figure 4-07 — Axial Ridge. Note: measure hole away from ridge.

4.7.15 For holes requiring postsizing, the non-cutting finish reamer pilot can function as a verification gage.
4.7.16 Ream to final hole size.
4.7.17 Countersink, if required.

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Seattle, Washington 98133 Fax: (206) 365-7483 1097
Split Sleeve Coldworking WCI-EH-9201-4.1 16

5 CA Tooling—
Titanium and High Strength Steel

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Split Sleeve Coldworking WCI-EH-9201-4.1 17

TABLE 5.01 CA Tooling

Titanium and High Strength Steel

STD TOOL FASTENER DIAMETER (1) STARTING HOLE MAX FINAL VERIFICATION
CODE Fraction Decimal Min Max HOLE (2) GAGE

20 1/8 0.125 0.110 0.112 0.1331 0.1125

21 9/64 0.141 0.125 0.127 0.1513 0.1275
22 5/32 0.156 0.140 0.142 0.1694 0.1425
23 11/64 0.172 0.156 0.158 0.1888 0.1585
30 3/16 0.190 0.170 0.172 0.2040 0.1725
31 13/64 0.203 0.185 0.187 0.2220 0.1875
32 7/32 0.219 0.200 0.202 0.2400 0.2025
33 15/64 0.234 0.216 0.218 0.2592 0.2185
40 1/4 0.250 0.231 0.234 0.2726 0.2350
41 17/64 0.266 0.246 0.249 0.2903 0.2500
42 9/32 0.281 0.261 0.264 0.3080 0.2650
43 19/64 0.297 0.277 0.280 0.3269 0.2810
50 5/16 0.312 0.287 0.290 0.3358 0.2920
51 21/64 0.328 0.302 0.305 0.3533 0.3070
52 11/32 0.344 0.318 0.321 0.3721 0.3230
53 23/64 0.359 0.333 0.336 0.3896 0.3380
60 3/8 0.375 0.348 0.351 0.4037 0.3530
61 25/64 0.391 0.363 0.366 0.4211 0.3680
62 13/32 0.406 0.379 0.382 0.4396 0.3840
63 27/64 0.422 0.394 0.397 0.4570 0.3990
70 7/16 0.438 0.409 0.412 0.4740 0.4160
71 29/64 0.453 0.424 0.427 0.4890 0.4310
72 15/32 0.469 0.440 0.443 0.5050 0.4480
73 31/64 0.484 0.455 0.458 0.5200 0.4630
80 1/2 0.500 0.470 0.473 0.5350 0.4780
81 33/64 0.516 0.486 0.489 0.5510 0.4940
82 17/32 0.531 0.501 0.504 0.5660 0.5090
83 35/64 0.547 0.516 0.519 0.5810 0.5240

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Split Sleeve Coldworking WCI-EH-9201-4.1 18

TABLE 5.01 (cont.) CA Tooling

Titanium and High Strength Steel

STD TOOL FASTENER DIAMETER (1) STARTING HOLE MAX FINAL VERIFICATION
CODE Fraction Decimal Min Max HOLE (2) GAGE

90 9/16 0.563 0.531 0.534 0.5960 0.5390

91 37/64 0.578 0.547 0.550 0.6120 0.5550
92 19/32 0.594 0.562 0.565 0.6270 0.5710
93 39/64 0.609 0.577 0.580 0.6420 0.5860
100 5/8 0.625 0.592 0.595 0.6570 0.6020
101 41/64 0.641 0.608 0.611 0.6730 0.6180
102 21/32 0.656 0.623 0.626 0.6880 0.6330
103 43/64 0.672 0.638 0.641 0.7030 0.6490
110 11/16 0.688 0.653 0.656 0.7180 0.6630
111 45/64 0.703 0.669 0.672 0.7340 0.6800

1) For reference only. Actual hole diameters may vary due to engineering requirements

2) This is the maximum diameter hole that may be reamed, while retaining desired coldworking
properties

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6 CB Tooling—
Aluminum, High Interference

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Split Sleeve Coldworking WCI-EH-9201-4.1 20

TABLE 6.01 CB Tooling

Aluminum and Mild Steel–High Interference

Boeing
STD Starting Hole Diameter Final Hole Decimal Range (1) Max. Allow. Max. Alow.
Tool Code Min Max Min Max Hole Size (2) Hole Size (3)

4-0-N 0.113 0.115 0.1245 0.1399 0.1409 N/A

4-1-N 0.128 0.130 0.1400 0.1554 0.1560 N/A
4-2-N (5-0-N) (4) 0.144 0.146 0.1555 0.1709 0.1760 0.1720
4-3-N (5-1-N) (4) 0.160 0.162 0.1710 0.1864 0.1920 0.1880
4-4-N 0.169 0.171 0.1890 0.1905 0.2026 N/A

6-0-N 0.177 0.180 0.1865 0.1994 0.2130 0.2060

6-1-N 0.192 0.195 0.1995 0.2149 0.2300 0.2220
6-2-N 0.209 0.212 0.2150 0.2304 0.2490 0.2390
6-3-N 0.225 0.228 0.2305 0.2464 0.2650 0.2550

8-0-N 0.235 0.238 0.2465 0.2619 0.2790 0.2655

8-1-N 0.251 0.254 0.2620 0.2774 0.2950 0.2815
8-2-N 0.266 0.269 0.2775 0.2929 0.3128 0.2970
8-3-N 0.283 0.286 0.2930 0.3089 0.3306 0.3140

10-0-N 0.297 0.300 0.3090 0.3244 0.3490 0.3290

10-1-N 0.313 0.316 0.3245 0.3399 0.3650 0.3450
10-2-N 0.328 0.331 0.3400 0.3554 0.3852 0.3605
10-3-N 0.344 0.347 0.3555 0.3714 0.3996 0.3765

12-0-N 0.359 0.362 0.3715 0.3869 0.4190 0.3920

12-1-N 0.375 0.378 0.3870 0.4024 0.4350 0.4080
12-2-N 0.391 0.394 0.4025 0.4179 0.4538 0.4245
12-3-N 0.406 0.409 0.4180 0.4339 0.4710 0.4400

14-0-N 0.421 0.424 0.4340 0.4490 0.4860 0.4555

14-1-N 0.437 0.440 0.4495 0.4699 0.5020 0.4715
14-2-N 0.450 0.453 0.4650 0.4804 0.5150 0.4855
14-3-N 0.465 0.468 0.4805 0.4959 0.5300 0.5005

16-0-N 0.474 0.477 0.4960 0.5119 0.5390 0.5280

16-1-N 0.490 0.493 0.5120 0.5274 0.5550 0.5440
16-2-N 0.505 0.508 0.5275 0.5429 0.5700 0.5595
16-3-N 0.521 0.524 0.5430 0.5579 0.5860 0.5755

18-0-N 0.537 0.540 0.5580 0.5739 0.6020 0.5920

18-1-N 0.553 0.556 0.5740 0.5894 0.6180 0.6080
18-2-N 0.568 0.571 0.5895 0.6049 0.6330 0.6235
18-3-N 0.583 0.586 0.6050 0.6209 0.6480 0.6390

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Split Sleeve Coldworking WCI-EH-9201-4.1 21

TABLE 6.01 (cont.) CB Tooling

Aluminum and Mild Steel–High Interference

Boeing
STD Starting Hole Diameter Final Hole Decimal Range (1) Max. Allow. Max. Allow.
Tool Code Min Max Min Max Hole Size (2) Hole Size (3)

20-0-N 0.597 0.600 0.6210 0.6364 0.6620 0.6562

20-1-N 0.613 0.616 0.6365 0.6519 0.6780 0.6719

20-2-N 0.631 0.634 0.6520 0.6674 0.6960 0.6875
20-3-N 0.646 0.649 0.6675 0.6844 0.7110 0.7040

22-0-N 0.659 0.662 0.6845 0.6999 0.7240 0.7188

22-1-N 0.675 0.678 0.7000 0.7154 0.7400 0.7344

22-2-N 0.690 0.693 0.7155 0.7309 0.7550 0.7500
22-3-N 0.706 0.709 0.7310 0.7459 0.7710 0.7657

24-0-N 0.718 0.721 0.7460 0.7614 0.7830 0.7812

24-1-N 0.734 0.737 0.7615 0.7769 0.7990 0.7968
24-2-N 0.749 0.752 0.7770 0.7929 0.8140 0.8125
24-3-N 0.765 0.768 0.7925 0.8094 0.8300 0.8281

26-0-N 0.782 0.785 0.8095 0.8249 0.8470 0.8437

26-1-N 0.798 0.801 0.8250 0.8404 0.8630 0.8594
26-2-N 0.811 0.814 0.8405 0.8559 0.8760 0.8750
26-3-N 0.826 0.829 0.8560 0.8709 0.8910 0.8906

28-0-N 0.841 0.844 0.8710 0.8864 0.9060 0.9062

28-1-N 0.857 0.860 0.8865 0.9019 0.9220 0.9218
28-2-N 0.879 0.882 0.9020 0.9174 0.9440 0.9420
28-3-N 0.894 0.897 0.9175 0.9344 0.9590 0.9575

30-0-N 0.901 0.904 0.9345 0.9499 0.9660 0.9910

30-1-N 0.917 0.920 0.9500 0.9654 0.9820 1.0067
30-2-N 0.933 0.936 0.9655 0.9809 0.9980 1.0230
30-3-N 0.949 0.952 0.9810 0.9959 1.0140 1.0390

The following mandrels are all two piece, resulting in a two sided operation (5)

32-0-N 0.965 0.968 0.9960 1.0114 1.0468 1.0468

32-1-N 0.981 0.984 1.0115 1.0269 1.0650 1.0650
32-2-N 0.997 1.000 1.0270 1.0424 1.0780 1.0780
32-3-N 1.013 1.016 1.0425 1.0579 1.1050 1.1050

36-0-N 1.075 1.078 1.1210 1.1364 1.1700 1.1700

36-1-N 1.091 1.094 1.1365 1.1519 1.1860 1.1860
36-2-N 1.107 1.110 1.1520 1.1684 1.2020 1.2020
36-3-N 1.123 1.126 1.1685 1.1844 1.2180 1.2180

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Split Sleeve Coldworking WCI-EH-9201-4.1 22

TABLE 6.01 (cont.) CB Tooling

Aluminum & Mild Steel–High Interference

Boeing
STD Starting Hole Diameter Final Hole Decimal Range (1) Max. Allow. Max. Allow.
Tool Code Min Max Min Max Hole Size (2) Hole Size (3)

38-0-N 1.136 1.140 1.1845 1.1999 1.2320 1.2320

38-1-N 1.152 1.156 1.2000 1.2154 1.2480 1.2480
38-2-N 1.168 1.172 1.2155 1.2309 1.2640 1.2640
38-3-N 1.184 1.188 1.2310 1.2459 1.2800 1.2800

40-0-N 1.199 1.203 1.2460 1.2614 1.2970 1.2970

40-1-N 1.215 1.219 1.2615 1.2769 1.3130 1.3130
40-2-N 1.231 1.235 1.2770 1.2934 1.3290 1.3290
40-3-N 1.247 1.251 1.2935 1.3089 1.3450 1.3450

44-0-N 1.316 1.320 1.3710 1.3864 1.4218 1.4218

44-1-N 1.336 1.340 1.3865 1.4019 1.4375 1.4375
44-2-N 1.352 1.356 1.4020 1.4184 1.4531 1.4531
44-3-N 1.368 1.372 1.4185 1.4339 1.4687 1.4687

48-0-N 1.427 1.431 1.4960 1.5114 1.5468 1.5468

48-1-N 1.443 1.447 1.5515 1.5269 1.5625 1.5625
48-2-N 1.459 1.463 1.5270 1.5434 1.5781 1.5781
48-3-N 1.475 1.479 1.5435 1.5589 1.5937 1.5937

52-0-N 1.559 1.563 1.6220 1.6374 1.6718 1.6718

52-1-N 1.575 1.579 1.6375 1.6529 1.6875 1.6875
52-2-N 1.591 1.595 1.6530 1.6684 1.7031 1.7031
52-3-N 1.607 1.611 1.6685 1.6839 1.7187 1.7187

56-0-N 1.696 1.700 1.7460 1.7614 1.8110 1.8110

56-1-N 1.711 1.715 1.7615 1.7769 1.8260 1.8260
56-2-N 1.726 1.730 1.7770 1.7934 1.8420 1.8420
56-3-N 1.742 1.746 1.7935 1.8089 1.8575 1.8575

1) Select mandrel sizes for finished hole diameters in listed range. Under certain cicumstances, such as insufficient room for
clean-up of coldworked hole, it is permissable to coldwork the hole as if the finished hole diameter was 1/64" smaller (i.e.,
smaller starting hole size, mandrel, etc.) and ream to the actual final hole size, provided the maximum allowable hole size
is not exceeded.

2) These figures meet and/or in some cases enhance most industry standard process specifications. It is permissable to
ream the coldworked hole to the diameters listed, without re-coldworking.

3) When working to Boeing BAC 5973, it is permissable to ream the coldworked hole to the diameters listed, without re-
coldworking.

4) Under Boeing 5973, a 5-0-N tool code is equivalent to a 4-2-N, while the 5-1-N is equivalent to a 4-3-N.

5) Tooling configuration and process parameters may vary due to OEM requirements.

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Split Sleeve Coldworking WCI-EH-9201-4.1 23

7 CW Tooling—
Aluminum, Low Interference
TABLE 7.01 CW Tooling—Bolts and Open Holes

TABLE 7.02 CW Tooling—Hex Drive Bolts, Lockbolts and

Rivet Holes

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Split Sleeve Coldworking WCI-EH-9201-4.1 24

TABLE 7.01 CW Tooling—

Aluminum, Low Interference
Bolts and Open Holes

MANDREL NOMINAL HOLE VERIFICATION

START HOLE RANGE FINISHED HOLE DIAMETER
TOOL CODE SIZE GAGE

B1267 1/8 0.1225 0.1255 0.1267 0.1295 0.1265

B1423 9/64 0.1381 0.1411 0.1423 0.1451 0.1421
B1580 5/32 0.1537 0.1567 0.1580 0.1608 0.1577
B1737 11/64 0.1694 0.1724 0.1737 0.1765 0.1734
B1894 3/16 0.1850 0.1880 0.1894 0.1922 0.1890
B2050 13/64 0.2006 0.2036 0.2050 0.2078 0.2046
B2206 7/32 0.2162 0.2192 0.2206 0.2234 0.2202
B2364 15/64 0.2319 0.2349 0.2364 0.2392 0.2359
B2520 1/4 0.2475 0.2505 0.2520 0.2548 0.2515
B2676 17/64 0.2631 0.2661 0.2676 0.2704 0.2671
B2833 9/32 0.2787 0.2817 0.2833 0.2861 0.2827
B2990 19/64 0.2944 0.2974 0.2990 0.3018 0.2984
B3145 5/16 0.3100 0.3130 0.3145 0.3175 0.3140
B3301 21/64 0.3256 0.3286 0.3301 0.3331 0.3296
B3458 11/32 0.3412 0.3442 0.3458 0.3488 0.3452
B3615 23/64 0.3569 0.3599 0.3615 0.3647 0.3609
B3771 3/8 0.3725 0.3755 0.3771 0.3803 0.3765
B3928 25/64 0.3881 0.3911 0.3928 0.3960 0.3921
B4083 13/32 0.4037 0.4067 0.4083 0.4117 0.4077
B4241 27/64 0.4194 0.4224 0.4241 0.4275 0.4234
B4396 7/16 0.4350 0.4380 0.4396 0.4432 0.4390
B4551 29/64 0.4506 0.4536 0.4551 0.4589 0.4546
B4708 15/32 0.4662 0.4692 0.4708 0.4746 0.4702
B4865 31/64 0.4819 0.4849 0.4865 0.4905 0.4859
B5020 1/2 0.4975 0.5005 0.5020 0.5064 0.5015
B5176 33/64 0.5131 0.5161 0.5176 0.5220 0.5171
B5332 17/32 0.5287 0.5317 0.5332 0.5376 0.5327
B5489 35/64 0.5444 0.5474 0.5489 0.5533 0.5484

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Split Sleeve Coldworking WCI-EH-9201-4.1 25

TABLE 7.01 (cont.) CW Tooling—

Aluminum, Low Interference
Bolts and Open Holes

MANDREL NOMINAL HOLE VERIFICATION

START HOLE RANGE FINISHED HOLE DIAMETER
TOOL CODE SIZE GAGE

B5647 9/16 0.5660 0.5630 0.5647 0.5691 0.5640

B5803 37/64 0.5756 0.5786 0.5803 0.5847 0.5796
B5959 19/32 0.5912 0.5942 0.5959 0.6003 0.5952
B6116 39/64 0.6069 0.6099 0.6116 0.6160 0.6109
B6272 5/8 0.6225 0.6255 0.6272 0.6316 0.6265
B6429 41/64 0.6381 0.6411 0.6429 0.6473 0.6421
B6585 21/32 0.6537 0.6567 0.6585 0.6629 0.6577
B6742 43/64 0.6694 0.6724 0.6742 0.6786 0.6734
B6899 11/16 0.6850 0.6880 0.6899 0.6943 0.6890
B7055 45/64 0.7006 0.7036 0.7055 0.7099 0.7046
B7212 23/32 0.7162 0.7192 0.7212 0.7256 0.7202
B7369 47/64 0.7319 0.7349 0.7369 0.7413 0.7359
B7525 3/4 0.7475 0.7505 0.7525 0.7571 0.7515
B7681 49/64 0.7631 0.7661 0.7681 0.7727 0.7671
B7837 25/32 0.7787 0.7817 0.7837 0.7883 0.7827
B7995 51/64 0.7944 0.7974 0.7995 0.8041 0.7984
B8151 13/16 0.8100 0.8130 0.8151 0.8197 0.8140
B8307 53/64 0.8256 0.8286 0.8307 0.8353 0.8296
B8464 27/32 0.8412 0.8442 0.8464 0.8510 0.8452
B8621 55/64 0.8569 0.8599 0.8621 0.8667 0.8609
B8778 7/8 0.8725 0.8755 0.8778 0.8824 0.8765
B8934 57/64 0.8881 0.8911 0.8934 0.8980 0.8921
B9091 29/32 0.9037 0.9067 0.9091 0.9137 0.9077
B9248 59/64 0.9194 0.9224 0.9248 0.9294 0.9234
B9404 15/16 0.9350 0.9380 0.9404 0.9452 0.9390
B9560 61/64 0.9506 0.9536 0.9560 0.9608 0.9546
B9716 31/32 0.9662 0.9692 0.9716 0.9764 0.9702
B9874 63/64 0.9819 0.9849 0.9874 0.9922 0.9859
B10030 1.0 0.9975 1.0005 1.0030 1.0078 1.0015
B10187 1 1/64 1.0131 1.0161 1.0187 1.0235 1.0171
B10343 1 1/32 1.0287 1.0317 1.0343 1.0391 1.0327

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Split Sleeve Coldworking WCI-EH-9201-4.1 26

TABLE 7.02 CW Tooling—

Aluminum, Low Interference
Hex Drive Bolts, Lockbolts and Rivets

MANDREL NOMINAL HOLE VERIFICATION

START HOLE RANGE FINISHED HOLE DIAMETER
TOOL CODE SIZE GAGE

Hex Drive Bolts & Lockbolts

H1870 3/16 0.1830 0.1860 0.187 0.190 0.1870
H2000 13/64 0.1960 0.1990 0.200 0.203 0.2000
H2160 7/32 0.2105 0.2135 0.216 0.219 0.2145
H2470 1/4 0.2430 0.2460 0.247 0.250 0.2470
H2630 17/64 0.2590 0.2620 0.263 0.266 0.2630
H2780 9/32 0.2725 0.2755 0.278 0.281 0.2765
H3090 5/16 0.3055 0.3085 0.309 0.313 0.3095
H3250 21/64 0.3205 0.3235 0.325 0.328 0.3245
H3410 11/32 0.3355 0.3385 0.341 0.344 0.3395
H3710 3/8 0.3670 0.3700 0.371 0.375 0.3710
H3880 25/64 0.3840 0.3870 0.388 0.391 0.3880
H4030 13/32 0.3990 0.4020 0.403 0.406 0.4030
H4340 7/16 0.4285 0.4315 0.434 0.438 0.4325
H4500 29/64 0.4435 0.4465 0.450 0.453 0.4475
H4660 15/32 0.4600 0.4630 0.466 0.469 0.4640

Rivets
R1280 1/8 0.1245 0.1275 0.128 0.131 0.1285
R1590 5/32 0.1555 0.1585 0.159 0.162 0.1595
R1900 3/16 0.1865 0.1895 0.190 0.195 0.1905
R2200 7/32 0.2160 0.2190 0.220 0.2245 0.2200
R2530 1/4 0.2495 0.2525 0.253 0.257 0.2535
R2830 9/32 0.2785 0.2815 0.283 0.286 0.2825
R3170 5/16 0.3115 0.3145 0.317 0.3205 0.3155
R3450 11/32 0.3410 0.3440 0.345 0.348 0.3450
R3780 3/8 0.3725 0.3755 0.378 0.382 0.3765
R4080 13/32 0.4035 0.4065 0.408 0.412 0.4075
R4410 7/16 0.4340 0.4370 0.441 0.444 0.4380

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Split Sleeve Coldworking WCI-EH-9201-4.1 27

8 Metric Tables–High Interference

Table 8.01–CA Tooling
Table 8.02–CB Tooling

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Split Sleeve Coldworking WCI-EH-9201-4.1 28

TABLE 8.01 CB Tooling

Aluminum and Mild Steel–High Interference
Metric Units

Boeing
STD Starting Hole Diameter Final Hole Decimal Range (1) Max. Allow. Max. Alow.
Tool Code Min Max Min Max Hole Size (2) Hole Size (3)

4-0-N 2.87 2.92 3.16 3.55 3.58 N/A

4-1-N 3.25 3.30 3.56 3.95 3.96 N/A
4-2-N (5-0-N) (4) 3.66 3.71 3.95 4.34 4.47 4.37
4-3-N (5-1-N) (4) 4.06 4.11 4.34 4.73 4.88 4.78
4-4-N 4.29 4.34 4.80 4.84 5.15 N/A

6-0-N 4.50 4.57 4.74 5.06 5.41 5.23

6-1-N 4.88 4.95 5.07 5.46 5.84 5.64
6-2-N 5.31 5.38 5.46 5.85 6.32 6.07
6-3-N 5.72 5.79 5.85 6.26 6.73 6.48

8-0-N 5.97 6.05 6.26 6.65 7.09 6.74

8-1-N 6.38 6.45 6.65 7.05 7.49 7.15
8-2-N 6.76 6.83 7.05 7.44 7.95 7.54
8-3-N 7.19 7.26 7.44 7.85 8.40 7.98

10-0-N 7.54 7.62 7.85 8.24 8.86 8.36

10-1-N 7.95 8.03 8.24 8.63 9.27 8.76
10-2-N 8.33 8.41 8.64 9.03 9.78 9.16
10-3-N 8.74 8.81 9.03 9.43 10.15 9.56

12-0-N 9.12 9.19 9.44 9.83 10.64 9.96

12-1-N 9.53 9.60 9.83 10.22 11.05 10.36
12-2-N 9.93 10.01 10.22 10.61 11.53 10.78
12-3-N 10.31 10.39 10.62 11.02 11.96 11.18

14-0-N 10.69 10.77 11.02 11.40 12.34 11.57

14-1-N 11.10 11.18 11.42 11.94 12.75 11.98
14-2-N 11.43 11.51 11.81 12.20 13.08 12.33
14-3-N 11.81 11.89 12.20 12.60 13.46 12.71

16-0-N 12.04 12.12 12.60 13.00 13.69 13.41

16-1-N 12.45 12.52 13.00 13.40 14.10 13.82
16-2-N 12.83 12.90 13.40 13.79 14.48 14.21
16-3-N 13.23 13.31 13.79 14.17 14.88 14.62

18-0-N 13.64 13.72 14.17 14.58 15.29 15.04

18-1-N 14.05 14.12 14.58 14.97 15.70 15.44
18-2-N 14.43 14.50 14.97 15.36 16.08 15.84
18-3-N 14.81 14.88 15.37 15.77 16.46 16.23

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Split Sleeve Coldworking WCI-EH-9201-4.1 29

TABLE 8.01 (cont.) CB Tooling

Aluminum and Mild Steel–High Interference
Metric Units

Boeing
STD Starting Hole Diameter Final Hole Decimal Range (1) Max. Allow. Max. Allow.
Tool Code Min Max Min Max Hole Size (2) Hole Size (3)

20-0-N 15.16 15.24 15.77 16.16 16.81 16.67

20-1-N 15.57 15.65 16.17 16.56 17.22 17.07
20-2-N 16.03 16.10 16.56 16.95 17.68 17.46
20-3-N 16.41 16.48 16.95 17.38 18.06 17.88

22-0-N 16.74 16.81 17.39 17.78 18.39 18.26

22-1-N 17.15 17.22 17.78 18.17 18.80 18.65
22-2-N 17.53 17.60 18.17 18.56 19.18 19.05
22-3-N 17.93 18.01 18.57 18.95 19.58 19.45

24-0-N 18.24 18.31 18.95 19.34 19.89 19.84

24-1-N 18.64 18.72 19.34 19.73 20.29 20.24
24-2-N 19.02 19.10 19.74 20.14 20.68 20.64
24-3-N 19.43 19.51 20.13 20.56 21.08 21.03

26-0-N 19.86 19.94 20.56 20.95 21.51 21.43

26-1-N 20.27 20.35 20.96 21.35 21.92 21.83
26-2-N 20.60 20.68 21.35 21.74 22.25 22.23
26-3-N 20.98 21.06 21.74 22.12 22.63 22.62

28-0-N 21.36 21.44 22.12 22.51 23.01 23.02

28-1-N 21.77 21.84 22.52 22.91 23.42 23.41
28-2-N 22.33 22.40 22.91 23.30 23.98 23.93
28-3-N 22.71 22.78 23.30 23.73 24.36 24.32

30-0-N 22.89 22.96 23.74 24.13 24.54 25.17

30-1-N 23.29 23.37 24.13 24.52 24.94 25.57
30-2-N 23.70 23.77 24.52 24.91 25.35 25.98
30-3-N 24.10 24.18 24.92 25.30 25.76 26.39

The following mandrels are all two piece, resulting in a two sided operation (5)

32-0-N 24.51 24.59 25.30 25.69 26.59 26.59

32-1-N 24.92 24.99 25.69 26.08 27.05 27.05
32-2-N 25.32 25.40 26.09 26.48 27.38 27.38
32-3-N 25.73 25.81 26.48 26.87 28.07 28.07

36-0-N 27.31 27.38 28.47 28.86 29.72 29.72

36-1-N 27.71 27.79 28.87 29.26 30.12 30.12
36-2-N 28.12 28.19 29.26 29.68 30.53 30.53
36-3-N 28.52 28.60 29.68 30.08 30.94 30.94

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Split Sleeve Coldworking WCI-EH-9201-4.1 30

TABLE 8.01 (cont.) CB Tooling

Aluminum and Mild Steel–High Interference
Metric Units

Boeing
STD Starting Hole Diameter Final Hole Decimal Range (1) Max. Allow. Max. Allow.
Tool Code Min Max Min Max Hole Size (2) Hole Size (3)

38-0-N 28.85 28.96 30.09 30.48 31.29 31.29

38-1-N 29.26 29.36 30.48 30.87 31.70 31.70
38-2-N 29.67 29.77 30.87 31.26 32.11 32.11

38-3-N 30.07 30.18 31.27 31.65 32.51 32.51

40-0-N 30.45 30.56 31.65 32.04 32.94 32.94

40-1-N 30.86 30.96 32.04 32.43 33.35 33.35
40-2-N 31.27 31.37 32.44 32.85 33.76 33.76
40-3-N 31.67 31.78 32.85 33.25 34.16 34.16

44-0-N 33.43 33.53 34.82 35.21 36.11 36.11

44-1-N 33.93 34.04 35.22 35.61 36.51 36.51
44-2-N 34.34 34.44 35.61 36.03 36.91 36.91

44-3-N 34.75 34.85 36.03 36.42 37.30 37.30

48-0-N 36.25 36.35 38.00 38.39 39.29 39.29

48-1-N 36.65 36.75 39.41 38.78 39.69 39.69
48-2-N 37.06 37.16 38.79 39.20 40.08 40.08
48-3-N 37.47 37.57 39.20 39.60 40.48 40.48

52-0-N 39.60 39.70 41.20 41.59 42.46 42.46

52-1-N 40.01 40.11 41.59 41.98 42.86 42.86
52-2-N 40.41 40.51 41.99 42.38 43.26 43.26
52-3-N 40.82 40.92 42.38 42.77 43.65 43.65

56-0-N 43.08 43.18 44.35 44.74 46.00 46.00

56-1-N 43.46 43.56 44.74 45.13 46.38 46.38
56-2-N 43.84 43.94 45.14 45.55 46.79 46.79
56-3-N 44.25 44.35 45.55 45.95 47.18 47.18

1) Select mandrel sizes for finished hole diameters in listed range. Under certain cicumstances, such as insufficient room for
clean-up of coldworked hole, it is permissable to coldwork the hole as if the finished hole diameter was .4 mm (1/64 inch)
smaller (i.e., smaller starting hole size, mandrel, etc.) and ream to the actual final hole size, provided the maximum
allowable hole size is not exceeded.

2) These figures meet and/or in some cases enhance most industry standard process specifications. It is permissable to
ream the coldworked hole to the diameters listed, without re-coldworking.

3) When working to Boeing BAC 5973, it is permissable to ream the coldworked hole to the diameters listed, without re-
coldworking.

4) Under Boeing 5973, a 5-0-N tool code is equivalent to a 4-2-N, while the 5-1-N is equivalent to a 4-3-N.

5) Tooling configuration and process parameters may vary due to OEM requirements.

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TABLE 8.02 CA Tooling

Titanium and High Strength Steel
Metric Units

STD TOOL Nominal STARTING HOLE MAX FINAL VERIFICATION

CODE Fastener Min Max HOLE (2) GAGE

20 3.0 2.79 2.84 3.38 2.86

21 4.0 3.18 3.23 3.84 3.24
22 4.0 3.56 3.61 4.30 3.62
23 4.0 3.96 4.01 4.80 4.03
30 5.0 4.32 4.37 5.18 4.38
31 5.0 4.70 4.75 5.64 4.76
32 5.5 5.08 5.13 6.10 5.14
33 6.0 5.49 5.54 6.58 5.55
40 6.5 5.87 5.94 6.92 5.97
41 7.0 6.25 6.32 7.37 6.35
42 7.0 6.63 6.71 7.82 6.73
43 7.5 7.04 7.11 8.30 7.14
50 8.0 7.29 7.37 8.53 7.42
51 8.5 7.67 7.75 8.97 7.80
52 9.0 8.08 8.15 9.45 8.20
53 9.0 8.46 8.53 9.90 8.59
60 9.5 8.84 8.92 10.25 8.97
61 10.0 9.22 9.30 10.70 9.35
62 10.5 9.63 9.70 11.17 9.75
63 11.0 10.01 10.08 11.61 10.13
70 11.0 10.39 10.46 12.04 10.57
71 11.5 10.77 10.85 12.42 10.95
72 12.0 11.18 11.25 12.83 11.38
73 12.5 11.56 11.63 13.21 11.76
80 12.5 11.94 12.01 13.59 12.14
81 13.0 12.34 12.42 14.00 12.55
82 13.5 12.73 12.80 14.38 12.93
83 14.0 13.11 13.18 14.76 13.31

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Split Sleeve Coldworking WCI-EH-9201-4.1 32

TABLE 8.02 (cont.) CA Tooling

Titanium and High Strength Steel
Metric Units

STD TOOL Nominal STARTING HOLE MAX FINAL VERIFICATION

CODE Fastener Min Max HOLE (2) GAGE

90 14.5 13.49 13.56 15.14 13.69

91 14.5 13.89 13.97 15.54 14.10
92 15.0 14.27 14.35 15.93 14.50
93 15.5 14.66 14.73 16.31 14.88
100 16.0 15.04 15.11 16.69 15.29
101 16.5 15.44 15.52 17.09 15.70
102 16.5 15.82 15.90 17.48 16.08
103 17.0 16.21 16.28 17.86 16.48
110 17.5 16.59 16.66 18.24 16.84
111 18.0 16.99 17.07 18.64 17.27

1) For reference only. Actual hole diameters may vary due to engineering requirements

2) This is the maximum diameter hole that may be reamed, while retaining desired coldworking
properties

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Split Sleeve Coldworking WCI-EH-9201-4.1 33

9 CRACKARRESTOR—Stop Drill Repair Procedures

9.1 It is not uncommon for fatigue cracks to develop in airframes. A traditional interim repair has been to stop
drill the crack, which involves drilling a hole at the tip of the crack to reduce the concentration of stress at the
crack tip. Cracks often reinitiate at the stop drilled site due to missing the tip of the crack with the stop drilled
hole.
9.1.1 The CRACKARRESTOR system significantly enhances the stop drill process by cold expanding the stop
drilled hole. Coldworking the stop drilled hole greatly enhances the chances that the very tip of the
crack becomes protected in the zone of compressive residual stress induced around the stop drilled
hole.
9.2 Process the Hole
9.2.1 Determine the desired final hole diameter.
9.2.1.1 Use a 3/16 inch final hole diameter for material thicknesses of 3/16 inch or less.
9.2.1.2 For material thickness greater than 3/16, utilize a 1/4 inch final hole diameter.
9.2.2 Using table 9-01, select the tooling needed to process the hole diameter.
9.2.3 Utilizing approved Non-Destructive Inspection (NDI) methods, determine the location of the end of
the crack. Drill the pilot hole, utilizing the tooling provided in the tool set.

Drill Pilot Hole Drill Pilot Hole

0.100 or Material Thickness 0.300

(Whichever is Greater)
Crack
Crack

Figure 9-01 — Crack Length > 0.200" Figure 9-02 — Crack Length < 0.200"

9.2.3.1 For crack lengths greater than 0.200 inch, the center of the pilot hole shall be located
either 0.100 inch, or one material thickness, ahead of the observed crack tip, whichever
is greater. Ensure hole is within 2° of normal to the surface. See Fig. 9-01.

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9.2.3.2 For crack lengths less than 0.200 inch, the center of the pilot hole shall be located 0.300
inch from the point of crack origin. See Fig. 9-02.
9.2.4 Ream the pilot hole to the start hole diameter utilizing the starting reamer included with the tool set.
9.2.5 Verify starting hole using combination go-no go gage.

NOTE
An oversize start hole is cause for rejection. Process the hole
using the next larger tool set.

9.2.6 Inspect hole, using appropriate NDI procedures, to verify there is no cracking in the hole on the
opposite side from the initial crack indication. If a crack exists, reject the hole. Ream oversize and
repeat the procedure.
9.2.7 Clean the hole, removing all cutting fluid residue. The pre-coldworked hole should be free of any
foreign material or residue.

9.3 Assemble Tooling

9.3.1 Unscrew the nosecap assembly from the puller body. Ref. Fig 9-03.
9.3.2 Extend the internal piston to the end of the unit by turning the end nut counterclockwise with the
provided 5/8" ratchet wrench.
9.3.3 Screw the proper mandrel into the threaded adapter finger tight.
9.3.4 Slide the proper nosecap assembly over the mandrel and screw onto the puller body.
9.3.5 Select the proper sleeve, and slide it onto the mandrel, flared end first. It must fit snug against the
nosecap assembly. Ref. Fig 9-03
9.4 Coldwork the Hole
9.4.1 Insert the assembled tooling completely into the hole.
9.4.2 Ensure that the nosecap is flush against the material to be coldworked. The nosecap must be normal
to the material surface. For surface angle greater than 2°, beveled spacers may be used. Contact
Engineering for proper beveled spacer orientation.
9.4.3 Orient the sleeve/puller so that the sleeve split is toward the crack origin.
9.4.4 Coldwork the hole by turning the end nut in a clockwise direction with the ratchet wrench. This will
draw the mandrel through the sleeve, thereby expanding the hole.
9.4.5 Ensure that the mandrel is completely through the sleeve and remove the puller unit.
9.4.6 Remove the sleeve from the hole and discard.
9.4.7 Using the final hole reamer from the appropriate tool set, ream the hole. Note that there are separate
reamers provided for rivet and interference fit bolt applications.
9.4.8 Install appropriate fastener

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Split Sleeve Coldworking WCI-EH-9201-4.1 35

Nosecap Retainer

Nose Extension

Mandrel

Nosecap Assembly Puller Body

Threaded
Adapter

5/8" Wrench

Assembled WCI-HP-20 shown with mandrel and sleeve installed

Figure 9-03 — Assembling the WCI-HP-20 Hand Puller

Table 9-01 CRACKARRESTOR Start and Final Hole Diameters

Desired Start Hole Diameter

Tool Finish Reamer
Final Hole Fastener Type
Code Min Max Diameter
Size
3/16 A30 0.170 0.172 0.1875 Rivet

0.1845 Interference Fit Bolt (1)

1/4 A40 0.231 0.234 0.2500 Rivet

0.2470 Interference Fit Bolt (1)

17/64 A41 0.246 0.249 0.2656 Rivet

0.2626 Interference Fit Bolt (1)

(1) Hi-Lok or Equivalent

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Table 9-02 CRACKARRESTOR Tooling

QTY PART NUMBER DESCRIPTION

3/16" Nominal Tooling Set

4 WCI-SD-A30 Start Drill
2 WCI-SR-A30 Start Reamer
1 WCI-CBG-A30 Combination Gage
1 WCI-CAM-A30-1-35-V2 Mandrel
50 WCI-CAS-A30-16F Split Sleeves, Flared
1 WCIS-WG-A30 Mandrel Wear Gage
2 WCI-FR-A30-1875 Final Reamer (for 3/16" Aluminum Rivet)
2 WCI-FR-A30-1845 Final Reamer (for 3/16" Interference Fit Bolt)

1/4" Nominal Tooling Set

4 WCI-SD-A40 Start Drill
2 WCI-SR-A40 Start Reamer
1 WCI-CBG-A40 Combination Gage
1 WCI-CAM-A40-1-35-V2 Mandrel
50 WCI-CAS-A40-16F Split Sleeves, Flared
1 WCIS-WG-A40 Mandrel Wear Gage
2 WCI-FR-A40-2500 Final Reamer (for 1/4" Aluminum Rivet)
2 WCI-FR-A40-2470 Final Reamer (for 1/4" Interference Fit Bolt)

17/64" Oversize Tooling Set

2 WCI-SR-A41 Start Reamer
1 WCI-CBG-A41 Combination Gage
1 WCI-CAM-A41-1-35-V2 Mandrel
50 WCI-CAS-A41-16F Split Sleeves, Flared
1 WCIS-WG-A41 Mandrel Wear Gage
2 WCI-FR-A41-2656 Final Reamer (for 17/64"" Aluminum Rivet)
2 WCI-FR-A41-2626 Final Reamer (for 17/64" Interference Fit Bolt)

Capital Tooling
1 WCI-HP-20 Hand Puller
1 WCI-1700NE-A3031-20F 3/16" Extension Nosecap Assembly
1 WCI-1700NE-A4041-20F 1/4" and 17/64" Extension Nosecap Assembly

Documentation
2 WCI-CA-RP Repair Procedures
2 WCI-CA-ROF Reorder Forms

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Split Sleeve Coldworking WCI-EH-9201-4.1 37

10 Maintenance & Repair Toolkits

CR Tooling
CB Tooling

10.1 CR TOOLING
10.1.1 CR Tooling is used to enhance structural repairs performed at the repair facility. This tooling must
be assembled and used in accordance to procedures outlined in section 4.
10.1.2 Instructions for using the tables found in Section 10.
10.1.2.1 Compare the measured existing hole diameter with the values found in Table 10-01. If the
measured value is less than the maximum shown in the table, follow the chart to the far
right which will indicate the correct tool code (tool set) for use.

NOTE
It will be necessary to ream a 17/64 inch existing hole to 9/32 inch
required pilot diameter prior to beginning the coldwork proce-
dure.

10.1.2.2 Table 10-02 provides the hole/fastener diameters for each tool set. The post coldworked
hole may be reamed to the diameter reflected in the “Final Hole Dia. – Max Allowable”
column of the table, without re-expansion of the hole.

NOTE
Do not exceed the maximum hole diameter value when reaming
the coldworked hole. Exceeding this value will remove the
beneficial zone of compression negating any fatigue enhance-
ments.

10.1.2.3 Table 10-03 provides a detail listing of tooling provided in each tool set. After determining
the correct tool code from Table 10-01, refer to Table 10-03 for a listing of tools needed
to perform the coldworking task.

NOTE
The coldworking task will require the use of either standard, or
offset tooling, depending upon the geometry of the application.
For additional information, see paragraph 2.12 for access
restriction.

10.1.2.4 Assemble the tooling and coldwork the hole per section 4.

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10.2 CB TOOLING
10.2.1 CB tooling kits are used to enhance structural repairs performed during a depot level modification.
This tooling must be assembled and used in accordance to procedures outlined in Section 4. Two
standard CB kits are provided, the CWORK-1 for existing hole sizes from 5/32" to 3/8", and the
CWORK-3 for exisiting holes between 13/32" and 7/8".
10.2.2 Instructions for using the tables found in Section 10.
10.2.2.1 Compare the measured existing hole diameter with the values found in Tables 10-04 or
10-05 (CWORK-1 and CWORK-3 respectively). If the measured value is less than the
maximum shown in the table, follow the chart to the left which will indicate the correct tool
code (tool set) for use.

NOTE
Using the 14-0-N tooling for a 7/16 inch diameter hole involves a
minimal (0.004 inch) ream alowance between the coldworked
hole and the final hole diameter. Exercise extreme care when
reaming the final hole.

10.2.2.2 The post coldworked hole may be reamed to the maximum diameter reflected in the far
right of the table, without re-expansion of the hole.

NOTE
Do not exceed the maximum hole diameter value when reaming
the coldworked hole. Exceeding this value will remove the
beneficial zone of compression negating any fatigue enhance-
ments.

10.2.2.3 After determining the correct tool code from Tables 10-04 and 10-05, refer to Tables 10-06
and 10-07 for a listing of tools needed to perform the coldworking task.

NOTE
The coldworking task will require the use of either standard, or
offset tooling, depending upon the geometry of the application.
For additional information, see paragraph 2.12 for access
restriction.

10.2.2.4 Assemble the tooling and coldwork the hole per section 4.

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TABLE 10.01 CR TOOL CODE SELECTION

EXISTING HOLE DIAMETER (1) (2) REQUIRED PILOT FINAL FASTENER

TOOL CODE (2)
Fraction Maximum HOLE DIA (3) HOLE DIA

5/32 0.164 0.157 0.187 R30

3/16 0.194 0.187 0.219 R32

13/64, 7/32 0.224 0.219 0.250 R40

1/4 0.255 0.250 0.281 R42

17/64, 9/32 0.285(4) 0.281 0.312 R50

5/16 0.317 0.312 0.344 R52

21/64, 11/32 0.347 0.344 0.375 R60

3/8 0.378 0.375 0.406 R62

1) If hole is countersunk, and countersink nosecap is unavailable, process the hole using the next
larger tool code

2) Selected tool code may be used for any existing hole diameter which is less than the specified
maximum

3) -0.000 / +0.005 inch.

4) It will be necessary to ream 17/64" existing hole diameter to 9/32" required pilot hole diameter
before performing coldwork procedure

TABLE 10.02 CR HOLE/FASTENER DIAMETERS

APPROX.
START HOLE DIA HOLE DIA FINAL HOLE DIA (3) RECOMMEND RECOMMENDED
TOOL PILOT HOLE FINAL HOLE DIA
AFTER FASTENER
CODE DIA (1)
EXPANSION (HI-LOK)
Min Max (2) Min Allowable Max Allowable Min Max

R30 0.157 0.169 0.171 0.173 0.178 0.207 0.1890 0.186 0.189

R32 0.187 0.199 0.202 0.205 0.210 0.239 0.2177 0.215 0.218

R40 0.219 0.229 0.232 0.236 0.241 0.270 0.2490 0.246 0.249

R42 0.250 0.260 0.263 0.268 0.273 0.301 0.2802 0.277 0.280

R50 0.281 0.290 0.293 0.299 0.304 0.348 0.3115 0.308 0.311

R52 0.312 0.322 0.325 0.332 0.337 0.380 0.3427 0.340 0.343

R60 0.344 0.352 0.355 0.363 0.368 0.411 0.3740 0.371 0.374

R62 0.375 0.383 0.386 0.394 0.399 0.442 0.4052 0.402 0.405

1) -0.000/+0.005

2) ±0.002", dependent upon hole diameter, alloy and heat treatment

3) Expanded hole may be enlarged to maximum allowable diameter without re-expansion of hole

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 TABLE 10.03 CWORK-2B KIT CONTENTS (CR TOOLING)
TOOL CODE/TOOL SET NUMBER

EXPENDABLE TOOLING QTY R30 R-32 R40 R42

SET (1) (2) CWRK-R30 CWRK-R32 CWRK-R40 CWRK-R42

START DRILL (3) 2 WCI-SD-R30 WCI-SD-R32 WCI-SD-R40 WCI-SD-R42

START REAMER 2 WCI-SR-R30 WCI-SR-R32 WCI-SR-R40 WCI-SR-R42

COMBINATION GAGE 1 WCI-CBG-R30 WCI-CBG-R32 WCI-CBG-R40 WCI-CBG-R42

MANDREL GAGE 1 WCIS-WG-R30 WCIS-WG-R32 WCIS-WG-R40 WCIS-WG-R42

FINAL HOLE GAGE 1 WCI-FHG-1860-1890 WCI-FHG-2150-2180 WCI-FHG-2460-2490 WCI-FHG-2770-2800

MANDRELS
EXTENSION 2 WCI-CRM-R30-1-35 WCI-CRM-R32-1-35 WCI-CRM-R40-1-35 WCI-CRM-R42-1-35
OFFSET 1 WCI-CRM-R30-1-20 WCI-CRM-R32-1-20 WCI-CRM-R40-1-20 WCI-CRM-R42-1-20
SLEEVES, FLARED 100 CRS-R30-16F CRS-R32-16F CRS-R40-16F CRS-R42-16F

FINISH REAMER 2 WCI-FR-R30-1860 WCI-FR-R32-2150 WCI-FR-R40-2460 WCI-FR-R42-2770

NOSECAPS
EXTENSION 1 WCI-1700NE-R30-20F WCI-1700NE-R32-20F WCI-1700NE-R40-20F WCI-1700NE-R42-20F
OFFSET 1 WCI-1700-OAJ-R30 WCI-1700-OAJ-R32 WCI-1700-OAJ-R40 WCI-1700-OAJ-R42

R50 R-52 R60 R62

CWRK-R50 CWRK-R52 CWRK-R60 CWRK-R62

START DRILL (3) 2 WCI-SD-R50 WCI-SD-R52 WCI-SD-R60 WCI-SD-R62

START REAMER 2 WCI-SR-R50 WCI-SR-R52 WCI-SR-R60 WCI-SR-R62

COMBINATION GAGE 1 WCI-CBG-R50 WCI-CBG-R52 WCI-CBG-R60 WCI-CBG-R62

MANDREL GAGE 1 WCIS-WG-R50 WCIS-WG-R52 WCIS-WG-R60 WCIS-WG-R62

FINAL HOLE GAGE 1 WCI-FHG-3080-3110 WCI-FHG-3400-3430 WCI-FHG-3710-3740 WCI-FHG-4020-4050

MANDRELS
EXTENSION 2 WCI-CRM-R50-1-35 WCI-CRM-R52-1-35 WCI-CRM-R60-1-35 WCI-CRM-R62-1-35
OFFSET 1 WCI-CRM-R50-1-20 WCI-CRM-R52-1-20 WCI-CRM-R60-1-20 WCI-CRM-R62-1-20
SLEEVES, FLARED 100 CRS-R50-16F CRS-R52-16F CRS-R60-16F CRS-R62-16F

FINISH REAMER 2 WCI-FR-R50-3080 WCI-FR-R52-3400 WCI-FR-R60-3710 WCI-FR-R62-4020

NOSECAPS
EXTENSION 1 WCI-1700NE-R50-20F WCI-1700NE-R52-20F WCI-1700NE-R60-20F WCI-1700NE-R62-20F
OFFSET 1 WCI-1700-OAJ-R50 WCI-1700-OAJ-R52 WCI-1700-OAJ-R60 WCI-1700-OAJ-R62

1) For restricted access situations, the kit includes the Offset Adapter, Offset Mandrels and Offset Nosecaps
2) Indicates the quantity of tooling in each expendable tooling set. If more than 100 holes of any one size need to be
processed, it will be necessary to order additional split sleeves.
3) Starting Drill is required for new holes only.

Each CWORK-2B Eight Tooling Sets Above

Kit Contains: Puller Unit - WCI-1700-20
Offset Adapter - WCI-1700-OA-20
Power Pak - WCI-20
Stop Drill Kit - CrackArrestor WCI-CAK-1A
Four Drawer Mobile Cabinet
 TABLE 10.04 HOLE SPECIFICATIONS—CWORK-1 TOOLKIT

EXISTING HOLE START HOLE FINAL FASTENER / MAX. ALLOW HOLE

TOOL CODE
DIA. (1) (2) DIAMETER HOLE DIAMETER DIAMETER (3)

Fraction Min Max Minimum Maximum

4-4-N 5/32 0.169 0.171 0.18900 0.1905 0.2026

6-2-N 3/16 0.209 0.212 0.2150 0.2304 0.2390

8-0-N 7/32 0.235 0.238 0.2465 0.2619 0.2655

8-2-N 1/4 0.266 0.269 0.2775 0.2929 0.2970

10-0-N 9/32 0.297 0.300 0.3090 0.3244 0.3290

10-2-N 5/16 0.328 0.331 0.3400 0.3554 0.3605

12-0-N 5/8 0.359 0.362 0.3715 0.3869 0.3920

12-2-N 3/8 0.391 0.394 0.4025 0.4179 0.4555

1) Contact West Coast Industries if existing hole is countersunk.

2) Selected tool code may be used for any existing hole diameter which is less than specified maximum

3) Expanded hole may be enlarged to the maximum allowable diameter without coldworking

TABLE 10.05 HOLE SPECIFICATIONS—CWORK-3 TOOLKIT

EXPANDED MAXIMUM
TOOL EXISTING HOLE START HOLE FINAL FASTENER /
HOLE ALLOWABLE
CODE DIAMETER (1) (2) DIAMETER HOLE DIAMETER
DIAMETER (4) HOLE DIA (5)

Fraction Maximum Min Max Nominal Maximum

14-0-N 13/32 13/32 (0.410) 0.421 0.424 7/16 (3) 1/2 0.431 0.505

16-0-N 7/16 15/32 (0.469) 0.474 0.477 1/2 9/16 0.486 0.567

18-0-N 1/2 17/32 (0.531) 0.537 0.540 9/16 5/8 0.550 0.630

20-0-N 9/16 37/64 (0.587) 0.597 0.600 5/8 11/16 0.612 0.692

24-0-N 5/8 45/64 (0.708) 0.718 0.721 3/4 13/16 0.736 0.817

28-0-N 3/4 13/16 (0.831) 0.841 0.844 7/8 15/16 0.862 0.942

30-0-N 7/8 (6) 57/64 (0.891) 0.901 0.904 15/16 1 0.923 1.005

1) Contact West Coast Industries if existing hole is countersunk.

2) Selected tool code may be used for any existing hole diameter which is less than specified maximum

3) Using 14-0-N tooling for 7/16" hole diameter involves a minimal (0.004") ream allowance between the coldworked hole and the final hole diameter.
Exercise care when final reaming the hole.

4) Approximately ±0.003.

5) Expanded hole may be enlarged to maximum allowable diameter without re-expansion of hole.

6) Contact WCI for further information regarding holes greater than 7/8".
 TABLE 10.06 CWORK-1 KIT CONTENTS (CB TOOLING)

TOOL CODE/TOOL SET NUMBER

EXPENDABLE TOOLING 4-4-N 6-2-N 8-0-N 8-2-N

QTY
SET CBMK-4-4-N CBMK-6-2-N CBMK-8-0-N CBMK-8-2-N

START DRILL 2 WCI-SD-4-4-N WCI-SD-6-2-N WCI-SD-8-0-N WCI-SD-8-2-N

START REAMER 2 WCI-SR-4-4-N WCI-SR-6-2-N WCI-SR-8-0-N WCI-SR-8-2-N
COMBINATION GAGE 1 WCI-CBG-4-4-N WCI-CBG-6-2-N WCI-CBG-8-0-N WCI-CBG-8-2-N
MANDREL GAGE 1 WCIS-WG-4-4-N WCIS-WG-6-2-N WCIS-WG-8-0-N WCIS-WG-8-2-N
MANDREL 1 WCI-CBM-4-4-N-1-20 WCI-CBM-6-2-N-1-20 WCI-CBM-8-0-N-1-20 WCI-CBM-8-2-N-1-20
MANDREL 2 WCI-CBM-4-4-N-1-35 WCI-CBM-6-2-N-1-35 WCI-CBM-8-0-N-1-35 WCI-CBM-8-2-N-1-35
SLEEVES, FLARED 100 CBS-4-4-N-16F CBS-6-2-N-16F CBS-8-0-N-16F CBS-8-2-N-16F
EXTENSION NOSECAP 1 WCI-1700NE-0601-20F WCI-1700NE-0623-20F WCI-1700NE-0801-20F WCI-1700NE-0823-20F
O.A. NOSECAP 1 WCI-1700OAJ-0601F WCI-1700OAJ-0623F WCI-1700OAJ-0801F WCI-1700OAJ-0823F
FINISH REAMER 2 WCI-FR-4-4-N-1860 WCI-FR-6-2-N-2150 WCI-FR-8-0-N-2460 WCI-FR-8-2-N-2770
FINAL HOLE GAGE 1 WCI-FHG-1860-1890 WCI-FHG-2150-2180 WCI-FHG-2460-2490 WCI-FHG-2770-2800

TOOL CODE/TOOL SET NUMBER

EXPENDABLE TOOLING 10-0-N 10-2-N 12-0-N 12-2-N

QTY
SET CBMK-10-0-N CBMK-10-2-N CBMK-12-0-N CBMK-12-2-N

START DRILL 2 WCI-SD-10-0-N WCI-SD-10-2-N WCI-SD-12-0-N WCI-SD-12-2-N

START REAMER 2 WCI-SR-10-0-N WCI-SR-10-2-N WCI-SR-12-0-N WCI-SR-12-2-N
COMBINATION GAGE 1 WCI-CBG-10-0-N WCI-CBG-10-2-N WCI-CBG-12-0-N WCI-CBG-12-2-N
MANDREL GAGE 1 WCIS-WG-10-0-N WCIS-WG-10-2-N WCIS-WG-12-0-N WCIS-WG-12-2-N
MANDREL 1 WCI-CBM-10-0-N-1-20 WCI-CBM-10-2-N-1-20 WCI-CBM-12-0-N-1-20 WCI-CBM-12-2-N-1-20
MANDREL 2 WCI-CBM-10-0-N-1-35 WCI-CBM-10-2-N-1-35 WCI-CBM-12-0-N-1-35 WCI-CBM-12-2-N-1-35
SLEEVES, FLARED 100 CBS-10-0-N-16F CBS-10-2-N-16F CBS-12-0-N-16F CBS-12-2-N-16F
EXTENSION NOSECAP 1 WCI-1700NE-1001-20F WCI-1700NE-1023-20F WCI-1700NE-1201-20F WCI-1700NE-1223-20F
O.A. NOSECAP 1 WCI-1700OAJ-1001F WCI-1700OAJ-1023F WCI-1700OAJ-1201F WCI-1700OAJ-1223F
FINISH REAMER 2 WCI-FR-10-0-N-3080 WCI-FR-10-2-N-3400 WCI-FR-12-0-N-3710 WCI-FR-12-2-N-4020
FINAL HOLE GAGE 1 WCI-FHG-3080-3110 WCI-FHG-3400-3430 WCI-FHG-3710-3740 WCI-FHG-4020-4050

Each CWORK-1 Eight Tooling Sets Above

Kit Contains: Puller Unit - WCI-1700-20
Power Pak - WCI-20 (Optional: WCIS-10000)
Offset Adpapter - WCI-1700-OA-20
Four Drawer Mobile Cabinet
 TABLE 10.06 CWORK-3 KIT CONTENTS (CB TOOLING)

TOOL CODE/TOOL SET NUMBER

EXPENDABLE TOOLING QTY 14-0-N 16-0-N 18-0-N 20-0-N

SET (1) (2) CBMK-14-0-N CBMK-16-0-N CBMK-18-0-N CBMK-20-0-N

START DRILL (3) 2 WCI-SD-14-0-N WCI-SD-16-0-N WCI-SD-18-0-N WCI-SD-20-0-N

START REAMER 2 WCI-SR-14-0-N WCI-SR-16-0-N WCI-SR-18-0 WCI-SR-20-0-N
COMBINATION GAGE (4) 1 WCI-CBG-14-0-N WCI-CBG-16-0-N WCI-CBG-18-0-N WCI-CBG-20-0-N
MANDREL GAGE 1 WCIS-WG-14-0-N WCIS-WG-16-0-N WCIS-WG-18-0-N WCIS-WG-20-0-N
MANDREL 2 WCI-CBM-14-0-N-2-30 WCI-CBM-16-0-N-2-30 WCI-CBM-18-0-N-2-30 WCI-CBM-20-0-N-2-30
SLEEVES, STRAIGHT 50 CBS-14-0-N-16S CBS-16-0-N-16S CBS-18-0-N-16S CBS-20-0-N-16S
FLUSH NOSECAP 1 WCI-1800N-14S WCI-1800N-16S WCI-1800N-18S WCI-1800N-20S

24-0-N 28-0-N 30-0-N

CBMK-24-0-N CBMK-28-0-N CBMK-30-0-N

START DRILL (3) 2 WCI-SD-24-0-N WCI-SD-28-0-N WCI-SD-30-0-N

START REAMER 2 WCI-SR-24-0-N WCI-SR-28-0-N WCI-SR-30-0-N

COMBINATION GAGE (4) 1 WCI-CBG-24-0-N WCI-CBG-28-0-N WCI-CBG-30-0-N

MANDREL GAGE 1 WCIS-WG-24-0-N WCIS-WG-28-0-N WCIS-WG-30-0-N

MANDREL 2 WCI-CBM-24-0-N-2-30 WCI-CBM-28-0-N-2-30 WCI-CBM-30-0-N-2-30

SLEEVES, STRAIGHT 50 CBS-24-0-N-16S CBS-28-0-N-16S CBS-30-0-N-16S

FLUSH NOSECAP 1 WCI-1800N-24S WCI-1800N-28S WCI-1800N-30S

1) The CWORK-3 tooling kit which augments the CWORK-2B repair kit, includes the seven expendable
tooling sets given in this table, as well as a WCI-1800 puller unit, and the WCI-20 powerpak

2) Indicates the quantity of tooling included in each expendable tooling set. If more than 50 holes of any
one size are to be processed, it will be necessary to order additional split sleeves

3) Starting drill is required for new holes only

4) Combination Gage checks start hole diameter and verifies coldworking

Each CWORK-3 Seven Tooling Sets Above

Kit Contains: Puller Unit - WCI-1800-30
Power Pak - WCI-20 (Optional: WCIS-10000)
Four Drawer Mobile Cabinet