Workmanship Standards Manual

Mechanical Fabrication, Fasteners, & Finishes

Prototek Sheetmetal Fabrication, LLC

244 Burnham Intervale Rd
Contoocook, NH 03229

Section V -- Mechanical Fabrication, Fasteners, & Finishes

1.0 Scope
1.1. Purpose -- This standard applies to all Mechanical Fabrication, Finishes, and
Fasteners assembled for use by Hybricon or by contract vendor. If there is a
conflict between the requirements of this standard and the Purchase contract
or Engineering drawing, the precedence shall be:
1.2. This section defines the workmanship practices required in the fabrication of
sheet metal and the use, assembly sequence, and workmanship requirements
associated with mechanical fasteners

2.0 GENERAL
2.1 - Cardcages, mechanical, electro-mechanical subassemblies and panels shall
conform to the requirements specified herein or as required by referenced
paragraph.
Damage - There shall be no damage beyond the limits specified in applicable
sections of this document
2.2 Conflict -- In the event of conflict between this specification and other
applicable or referenced documents, the following order of precedence shall
apply:
FIRST - Engineering Drawing/Specification
SECOND - Purchasing Contract

Approved Manufacturing Processes

FOURTH - This Standard
2.2 Terminology -- The terms referred to in this section are defined throughout this
document and in the Glossary (045-030-07).
2.3 The purpose of this section is to identify minimal acceptable criteria for
manufactured mechanical fabricated finishes and including fastening
methods.
2.4 All tools and equipment used during the fabrication of these
assemblies/methods shall be capable of maintaining total conformance to
Specification No: 045-030-05
REV: D
SHEET 1 OF 26
 these Standards.
2.5 Unless otherwise specified, the end products must be in full compliance with
the criteria noted within this Standard.
3.0 SHEET METAL
3.1 Bend Condition - Bends should show no evidence of fracture. Reduction of
metal section (pinching) may not exceed 10% of the stock thickness.

3.2 Blended Corners - Fillets or radii on machined or grounded surfaces shall be

blended smoothly at tangent points.

3.3 Bend Radii - All bends shown square shall have maximum inside radii of the
stock thickness unless otherwise specified on the drawing.

Figure 3.3

AS MANUFACTURED
3.4 Edge Condition
3.4.1 Burr Removal - A burr is defined as material existing beyond the
intersection of two surfaces. All manufactured parts are to be free
from burrs or loose metal chips which might cause hazardous handling.
3.4.2 If burr removal is not specified on the drawings, burrs which do
not project over .005" on aluminum or .003" on all other metals are

Specification No: 045-030-05

REV: D
SHEET 2 OF 26
 acceptable.

3.4.3 When burr removal is specified on the drawings without further

qualification, all burrs, including those around holes and cut-outs, shall
be broken to .010 maximum. The contour of broken edges may vary
from a square corner to a chamfer to a true radius.
3.4.4 Combined chamfers shall not exceed 30% of the part thickness.
3.5 Edges - Sheared
3.5.1 A sheared edge shall be square within 10o. The extreme edge
shall be used when measuring to or from the edge.
3.6 Punch or Nibbling Marks/Mismatch
3.6.1 Punch or nibbling marks are the normal result of multiple
punching with a sharp punch and die and are not considered burrs.

3.6.2 Nibbling mismatch due to punch clearance or positioning error

shall not exceed .005 and shall not include burrs. Nibbling mismatch
shall not be allowed in critical areas such as mechanism slides, etc.

Specification No: 045-030-05

REV: D
SHEET 3 OF 26
3.7 Corners
3.7.1 Unless otherwise specified, corners shown sharp on the blanked
part may be produced with a radius, chamfer, or break, as indicated
below in the sectioned area.

3.8 Sheet Flatness

3.8.1 Variation from flatness shall not exceed the value in table
below. Measurements shall be made by laying the part on a surface
plate. No clamps or weights shall be used.

Specification No: 045-030-05

REV: D
SHEET 4 OF 26
3.8.2 In any surface, two waves not exceeding the values above are
permissible. Any additional waves shall not exceed half the value
shown.

Specification No: 045-030-05

REV: D
SHEET 5 OF 26
4.0 CABINETRY/CHASSIS METAL WORK
3.9 Weld Slag and Spatter
3.9.1 Weld slag shall be removed before application of finish,
evidence after finishing is cause for rejection.
3.9.2 Weld spatter on a mounting surface is cause for rejection;
permissible on all other surfaces.
3.10 Burrs
3.10.1 If present, burrs shall not exceed the limits of paragraph 3.4.
3.10.2 Removal of burrs shall comply with the requirements of
paragraph 3.4.
3.11 Corners
3.11.1 Corners shown sharp on a blanked part may be produced with a
radius, chamfer, or break complying with paragraph 3.7.
3.12 Sheared Edges
3.12.1 A sheared edge shall be square within 10o (refer to paragraph
3.5).
3.12.2 The extreme edge as illustrated in paragraph 3.5 shall be used
when measuring to or from the edge.
3.13 Squareness - Unless otherwise specified, sheet metal cabinets,
panels, doors, chassis, etc. (over 12" in the smallest dimension) shall be
Specification No: 045-030-05
REV: D
SHEET 6 OF 26
square within .015 in/ft. not to exceed .12 max. Squareness to be within
dimensional limits.

3.13.1 Squareness - Right Angle Bend - Unless otherwise specified, 90o

forms 1 inch or under in length shall be square within the locating
dimension. Forms beyond 1 inch shall be square within .005 in./in. of
bend length. The long leg is considered to be datum.

3.13.2 Squareness of Cabinets and Racks - Cabinets and racks,

fabricated by welding or riveting together sheet metal and/or
structural pieces shall be square and free from twist or lean within the
tolerance of tables and illustrations shown below.

Specification No: 045-030-05

REV: D
SHEET 7 OF 26
3.13.3 "U" Forms - Legs of the "U" form shall be square to the common
axis of the two datum holes within .005 in./in. Squareness is
measured radially from the common axis.

3.13.4 Edge Squareness - Between two sheared edges or two formed

sides, the squareness shall be within .015" per linear foot. Between a
sheared edge and a formed side, the squareness shall be within .020"
per linear foot. Dimensional tolerances shall apply if tighter.

Specification No: 045-030-05

REV: D
SHEET 8 OF 26
 3.13.5 Squareness - Intersecting Surfaces Shown at 90o - Unless
otherwise specified, intersecting surfaces shown at 90o shall be square
within the tolerance on the dimension of the longest surface. The long
surface is used as the datum for checking squareness.

3.14 Parallelism - Surfaces - Unless otherwise specified, the

parallelism of surfaces shall be controlled by the tolerance of dimension
between the two surfaces. The longest surface shall be used as datum. This
is illustrated below.

3.15 Flatness
3.15.1 Stamping Flatness - To be within tolerance expressed below.

Specification No: 045-030-05

REV: D
SHEET 9 OF 26
 3.15.2 Sheet metal cabinets, panels, doors, chassis, etc. (over 12
inches in the smallest dimension) shall be flat within .03 in./ft. not to
exceed .12 max. At any point flatness variation shall not exceed .03
in./ft. applied over a smooth curve. Flatness includes dishing, bow,
and twist.

3.16 Bend Line Straightness - Unless otherwise specified, bend line

shall be straight within .010 in./ft. not to exceed .06 max. At any point the
straightness variation shall not exceed .010 in./ft. applied over a smooth
curve.

Specification No: 045-030-05

REV: D
SHEET 10 OF 26
3.17 Mounting Plane Flatness - All points on members which form a
mounting surface shall form a true plane surface within the limits of figure
4.7a. All points within a 12" x 12" area must form a plane within .016, and
24" x 24" area must from a plane within .031", and the entire surface must
form a plane within .062".
3.18 Grain direction shall be perpendicular to formed bends unless
otherwise
specified. This minimizes crazing or material fracture on bends.

Specification No: 045-030-05

REV: D
SHEET 11 OF 26
4.10 COMPONENT ASSEMBLY
4.10.1 General - Cardcages, doors, panels, sideplates, electro-mechanical
subassemblies, cabling and hinge/latch/locking mechanisms shall conform to
the requirements specified herein or as required by referenced paragraph.
4.10.2 Damage - There shall be no damage beyond the limits specified in
applicable sections of this document.
4.11 Installation
4.11.1 External Doors
4.11.1.1 Vertical requirements shall be cause for rejection.
4.12 Hardware Assembly Sequence
4.12.1 Acceptable - The sequence of mechanical hardware assembly
conforms to specific product documentation. . See 045-030-05 Section
5.2.2
4.12.2 Unacceptable - Any deviation from product documentation.
4.13 Overall Requirements of Cabinets and Enclosures
4.13.1 Cabinets - Installation is not above or below frame top surface by more
than 0.125"; not out of parallel with frame (there shall not be more
than 0.150" difference between top and bottom dimension measured;
measured from edge of frame to edge of door at extreme top and
bottom).
4.13.2 Low Profile Cabinet - Installation is not out of parallel by more than
0.125" (measured gap between door and frame at hinged side; compare
to gap dimension at opposite side).
4.13.3 Foam Tape (non-FCC compliant system) is applied in parallel with
mounting surfaces; ends are cut square, with no gaps or overlaps
between sections.
4.13.4 EMI gasketing (FCC compliant system) is installed in accordance with
applicable engineering drawing requirement, and no discernible damage
is evident. Sections of gasketing can not have less than three (3)
mounting anchors to be acceptable.
4.13.5 Doors hinge smoothly throughout open/closure travel; close or latch
positively. For FCC compliant cabinets, EMI gasketing (either wire mesh
or carbon filled) must make intimate contact with cabinet; this is
measured by inserting dollar bill between door and cabinet; lock door;
gently pull the dollar out. A resistance must be felt, if none is felt,
door/latch mechanism must be adjusted.
4.14 Sideplates
4.14.1 (Vertical Cabinets) - Installation is not above or below frame top surface
by more than 0.100"; not out of parallel with frame (there shall not be
more than 0.125" difference between top and bottom dimension
measured; measure from edge of frame to edge of sideplates at
extreme top and bottom).
4.14.2 (Low Profile Cabinets) - Installation is not out of parallel by more than
0.100" (measure gap between door and frame at hinged side; compare
to gap dimension at opposite side).
4.14.3 Foam Tape (non-FCC compliant system) is applied in parallel with
Specification No: 045-030-05
REV: D
SHEET 12 OF 26
 mounting surfaces; ends are cut square, with no gaps overlaps between
sections.
4.14.4 EMI gasketing (FCC compliant system) is installed in accordance with
applicable engineering drawing requirement, and no discernible damage
is evident. Sections must have at least three (3) mounting anchors to
be acceptable.
4.14.5 For FCC compliant cabinets, EMI gasketing (either wire mesh or carbon
filled) must make intimate contact with cabinet; this is measured by
inserting a dollar bill between sideplate and cabinet; gently pull the
dollar out. A resistance must be felt; if none is felt, adjustments must
be made.

5.0 MECHANICAL FASTENERS

5.1 General - Mechanical parts shall be assembled in accordance with the
requirements described herein unless otherwise specified in the applicable
product documentation.
5.2 Threaded Hardware
5.2.1 Damage - Extreme care shall be exercised during the assembly
of threaded parts to avoid cross-threading or deformation.
5.2.1.1 Cross-Threading - Usually the result of attempted use of
mismatched threaded parts, or improper thread starting
followed by extreme force.

5.2.1.2 Deformation - Usually caused by not using the correct tool to

tighten or through exertion of excessive force.

Specification No: 045-030-05

REV: D
SHEET 13 OF 26
5.2.2 Assembly Sequence - General Application (See 045-030-04
section 3.1)
5.2.2.1 Flat washers shall always be installed between the nut and the
surface of items assembled. A flat washer shall also be installed
between the screwhead and the surface of items assembled
where those surfaces are either non-metallic of compressible
material, painted or in any combination thereof.
5.2.2.2 Lock washers are available as "split lock", "Internal tooth" and
"external tooth" types. Internal tooth washers are used for
small head screws such as Fillister head or Cap screws; external
tooth type is for use under large head screws such as Binder
head screws. Any of the three types are acceptable for use with
Pan head screws. Lock washers shall be used under the heads of
all screws employed in tapped holes, with the exception of
Flathead screws used at countersunk hole applications, or where
self-locking screws are employed.
5.2.2.3 Typical assembly sequences are shown in the following:

Specification No: 045-030-05

REV: D
SHEET 14 OF 26
5.2.3 Assembly Sequence - Special Application
5.2.3.1 Enlarged or Elongated Hole

5.2.3.2 Dissimilar Metals

Specification No: 045-030-05

REV: D
SHEET 15 OF 26
5.2.3.3 Self Locking Hardware - Both screws and nuts are available with
built-in locking features. Use of this type of hardware
eliminates the need for lockwashers or for the liquid staking
compound described in 5.2.3.4 Self-locking nuts and screws
shall not be used together.

Nut - Available in "all metal" or "plastic insert" types. The all

metal types obtain their locking action through screw thread
engagement in a deformed section of the nut. The plastic insert
types (Elastic Stop Nut) exert a friction grip on the screw
threads upon insertion. Neither type is reusable. Screw - As
with the "elastic stop nut", a plastic insert provides the locking
action. Proper usage requires that the mating thread part
include an entrance chamfer to prevent shearing of the insert as
it enters the first thread.

5.2.3.4 Staking Liquid - Liquid staking compounds, which are used to

Specification No: 045-030-05
REV: D
SHEET 16 OF 26
 ensure mechanical fastener reliability, shall be employed only
when use of mechanical locking devices, such as lockwashers,
self-locking nuts, or screws, is not practical. This staking
compound, which is commonly referred to by its "brand name"
(Loctite) is available in several types.
5.2.3.4.1 Type Selection - Per applicable product
documentation.
5.2.3.4.2 Procedure - Zinc and cadmium plated
material and oily or greasy surfaces,
shall be cleaned and thoroughly dry
before application of staking material. Apply the liquid to
the mechanical fastener's threads; mate the fasteners,
tightening to the required degree. Excess staking material
shall be wiped away.
NOTE: Any previous application of staking compound must be removed
prior to re-applying whenever it is necessary to disassemble and
reassemble the mated mechanical fasteners.

5.2.4 Thread Protrusion

5.2.4.1 Screws shall extend beyond nut or threaded surface by a
minimum of 1 1/2 threads unless otherwise specified in
applicable drawing.
5.2.4.2 Screws entering blind holes shall engage threads for a minimum
depth equivalent to 1 1/2 times the screw diameter. This shall
apply to self-tapping screws or screws entering tapped
holes.

Specification No: 045-030-05

REV: D
SHEET 17 OF 26
5.2.5 Tightness/Torque - Threaded products achieve their holding
power from the tension, or twisting force, derived during the mating of
the external and internal threads. Therefore, all screws shall be
tightened to the degree necessary to assure the proper holding power.
This assurance is provided by applying torque in accordance with the
values specified in the table below. The torque limits are expressed in
"inch pounds.

5.2.6 Special Applications

5.2.6.1 Trusshead Screw - This type of screw has a head of much greater
Specification No: 045-030-05
REV: D
SHEET 18 OF 26
 diameter than standard hardware of the same size, making it
ideally suited for use in elongated holes. Unless installed
through a painted surface, trusshead screws will not require use
of a flat washer under the head.
5.2.6.2 Flathead Screw - This type of screw is used where the projection
of standard hardware head would interfere at higher assembly
levels. Criteria for head angle and flushness is as follows:
5.2.6.2.1 Countersink Angles

5.2.6.2.2 Flushness

5.2.6.3 Self-Tapping/Thread Rolling Screws - Application for these types

should be limited to small gauge sheet metal and/or where
frequent disassembly and re-assembly will not be required.
5.2.6.3.1 Chips formed by the thread-cutting
action shall be removed to preclude
their entry into undesirable areas.
5.2.6.3.2 Re-use of holes, once threads have
been formed by screw reinstallation, is
permitted if screw used can be fully tightened within

Specification No: 045-030-05

REV: D
SHEET 19 OF 26
 specification.

5.3 Eyelets & Rivets - Eyelets and rivets are used to fasten two or
more mechanical parts together, often providing an alternative to
screw/washer/nut assembly. Examples of these are shown in the illustration
which follows:

Figure 5.3

5.3.1 Eyelet and Rivet Selection

5.3.1.1 Eyelets - The recommended protrusion length through the
mounting surfaces shown in the table below are provided only as
a guide; sample settings should be made and qualified for each
new application.

5.3.1.2 Rivets - Recommended minimum "clinch allowances" are shown

in the table below. To determine rivet length to be used for a
given application, add combined thicknesses of materials to be
joined and the clinch allowance dimension shown, then use the
next higher applicable increment.

Specification No: 045-030-05

REV: D
SHEET 20 OF 26
5.3.2 Acceptance Criteria
5.3.2.1 Eyelets and rivets shall be formed as shown in paragraph 5.3.1
and shall firmly secure the joined parts. Looseness, which
permits a separation of the joined parts, shall be considered
cause for rejection.

5.3.2.2 Excessively tight installation usually results in damage to either

the fastener or to the surface of the joined parts.
5.3.2.2.1 Up to three splits are permitted at
either end of the fastener unless
extension into the barrel portion is noted.
5.3.2.2.2 No circumferential split or cracks are
permitted.
5.3.2.2.3 Damage, such as evidence of
delamination on epoxy- glass board material
shall not extend more than 0.030" from the rivet or eyelet
periphery.

Specification No: 045-030-05

REV: D
SHEET 21 OF 26
6.0 SURFACE FINISHES
6.1 Standard Finishes
6.1.1 Clear Iridite on aluminum.
6.1.2 Clear Zinc on Steel.
6.2 Custom Finishes
6.2.1 Chemical Film per MIL-C-5541, Class 1A for aluminum parts requiring
corrosion protection. Color: Yellow, unless specified clear.
6.2.2 Chemical Film per MIL-C-5541, Class 3 for aluminum parts requiring low
electrical resistance. Color: yellow, unless specified clear.
6.2.3 Chromeric Anodize per MIL-A-8625, Type I, Class 1* for aluminum parts
that are welded or where extrapment is possible. Color: clear-metallic
gray. *Specify Class 2 for dyed colors.
6.2.4 Sulfuric Anodize per MIL-A-8625, Type II, Class 1* for aluminum parts
where no overlapping surfaces or pockets are present. *Specify Class 2
for dyed colors.
6.2.5 Hard Anodize per MIL-A-8625, Type III, Class 1* for aluminum parts
requiring durable wear surfaces. Thickness is .003 normally. *Specify
Class 2 for dyed colors.
6.2.6 Bright Tin Plate per MIL-T-10727, min thickness of .003 for copper parts
requiring corrosion protection or galvanic compatibility.
6.2.7 Electroless Nickle Plate per MIL-C-26074, Class 1, Grade A for steel and
copper parts requiring corrosion protection.
6.2.8 Zinc Plate per ASTM B633, Type III, Class SC3 for steel parts requiring
corrosion protection. Color is clear and bright in appearance.

6.3 General - The criteria provided in this section relates to visual appearance of
parts which have been plated, painted, or both. Of major importance are those
surfaces that will be highly visible on critical surfaces; somewhat less stringent
requirements are imposed in other areas.

This section is to be used for in-process activities only; assessment

Specification No: 045-030-05

REV: D
SHEET 22 OF 26
 of received materials shall be performed using appropriate Procurement
specifications, and/or detailed Incoming Inspection criteria and techniques.

Major Defect The type of defect that:

• Is clearly visible in an un-highlighted condition
• Exposes bare metals or substrate surface
• Exceeds stated criteria or other specific requirements
• Is easily felt with a fingernail (dents or scratches)
• Would leave a greater flaw if removed or reworked (inclusion)
• Is non-uniform surface finish (shaded appearance)
• Would cause corrosion, rust, peeling, delamination, etc.

Minor defect The type of defect that:

• Is clearly not visible in an un-highlighted condition or when assembled in
an
assembly
• Barely felt with a fingernail
• Tends to fade out or blend in with surrounding surface
• Would be concealed during next process or assembly level (label, paint
or
other finishing process)

Normal Viewing Plane The normal viewing plane is defined as the view
obtained when observing the assembled unit top, front, sides, and back
exterior surfaces in a plane perpendicular to these surfaces. The part will
not be rotated except to eliminate any glare from surrounding light that
tends to produce a “highlighted” condition.

Light condition 75 – 90 foot candles

Viewing distance These are appropriate based on the part in an installed

position.
Surface Class A: 18 inches
Surface Class B: 36 inches
Surface Class C: in excess of 36 inches not to exceed 72 inches

Viewing Time All surfaces 10 seconds maximum

Personnel vision 20/20 vision

6.4 Surface Classification - Surfaces are grouped into three

categories for inspection purposes:
Specification No: 045-030-05
REV: D
SHEET 23 OF 26
Class A User's Primary Product Exterior: Doors, chassis skins, cabinet
tops, rack mount flanges, control panels, exposed areas of
cabinet frames; Any surface that is normally and immediately
visible to the customer or end user while the product is being
used in its normal operating condition and visible to the user
without opening service doors. On card cages the Class A surface
will be flanges and the number strip edge of the card guide rail.

These surfaces will be free of all major defects and reasonably

free of any minor defects.

Defects on these surfaces are likely to be seen and associated

with a perceived reduction in the overall quality or appearance of
the product.

Note: Slight imperfections characteristic of individual process

capabilities may be visible on Class A surfaces. Acceptance of
these slight imperfections shall be judged according to applicable
Hybricon or customer specifications and standards.

Class B User Access Interior: Chassis skins, cabinet and enclosure tops,
internal control panels, interior side of enclosure and card cages,
power distribution, front panels, interior items with user
information / silk-screening; areas which are visible when the
user access doors are open. Expected to appear consistent, of
good integrity, and with limited appearance of flaws.

These surfaces may have some minor defects but will be free of
all major defects.
Minor defects on these surfaces are not likely to be seen or
viewed as a perceived reduction in the overall quality or
appearance of this product.

Any surface that can be seen from the front (but not the front
surface of the unit) with the unit and/or cover plate removed.

Any surface that is visible from the rear after installation, or the
rear surface of the individual removable option card. For
example, rear panels, side panels, top and bottom surfaces are
commonly Class B surfaces

Class C Structural Interior: Areas not visible without disassembly.

Coatings are for corrosion protection only.
Specification No: 045-030-05
REV: D
SHEET 24 OF 26
 Class C surfaces may have any or all minor defects and some
major defects. These major defects may be subject to review by
the MRB Board.

Defects on these surfaces, if seen by the customer, are not likely

to be regarded as detracting from the overall cosmetic or
functional quality of the product.

Interior surfaces, or areas to be covered by labels or other panels

are examples of “C” surfaces.

PROCEDURE

All drawings will incorporate cosmetic surface requirements as specified below.

Designations All part surfaces will be designated as one of three classes (A,B, or C)
according to location and importance in a completely assembled product or system.
6.4Acceptance Criteria - Three acceptance designations are used in the following
table to describe the criteria.

None Allowed - No occurrences of the attribute are permissible. Items with

this designation are typically functional in nature, and will result in product
degradation. These attributes are not subject to the cursory inspection
described below.

Not Apparent - Attribute is not discernible in the final application of the

part. Attributes with this designation are aesthetic in nature. Visual
inspection for aesthetics is to be conducted in a manner which best
duplicates the end use of the part. The preferred viewing angle and distance
being that which would exist if the part was installed in its final location, and
the inspector is standing where the operator would stand while using or
accessing the equipment. Minimum viewing distance should be three feet.
The intention of the aesthetic inspection is to avoid usage of parts which
detract from the appearance of the final product. Inspection time is limited
to that which is necessary to scan (cursory inspection) all areas of the part.

Acceptable - Aesthetic in nature; will have no effect on the function of the

part and will not detract from the appearance of aesthetic viewpoint. Some
flaws may have acceptable as well as not-acceptable attributes, e.g. a
scratch which does not break the surface of the coating may be acceptable
(depending on the class of surface), whereas if the coating is broken, there is
a coverage void (Not Acceptable).

Specification No: 045-030-05

REV: D
SHEET 25 OF 26
 Characteristic Class A Class B Class C
Scratches None Allowed Not Apparent Acceptable*
Tooling Marks None Allowed None Allowed Acceptable
(Uniformed)
Corrosion None Allowed None Allowed None Allowed**

Characteristic Class A Class B Class C

Coverage Voids None Allowed None Allowed None Allowed**
Non-Adhesion None Allowed None Allowed None Allowed
Blisters None Allowed None Allowed None Allowed**
Burns (Plating) None Allowed None Allowed Acceptable
Color Variegation*** None Allowed Acceptable Acceptable
Color Deviation Not Apparent Not Apparent Acceptable
(paint coatings)
Rinse Stains None Allowed Not Apparent Acceptable
Finger Printing None Allowed Not Apparent Acceptable
Orange Peel None Allowed Not Apparent Acceptable
Paint Runs None Allowed Not Apparent Acceptable

*Any apparent scratches after plating will not be allowed. For scratches
that are not apparent there cannot be removed metal and
the scratches may not be detected by feel.
** Acceptable if repaired, providing that corrosion is removed prior to
repair, area void of coating is supplemented
with paint, and that the defect is not merely a symptom of
further problems with the coating.

*** For gold chromate coatings color variegation will be acceptable as long
as it is in conformance to MIL-C-5541E.

6.6 PACKAGING

All suppliers of parts or service per this specification shall use those standard
commercial packaging materials and methods sufficient to protect the
integrity of the highest class of surface called out on the applicable drawing.
An item with both Class A surfaces and Class C surfaces, for example, will be
packaged as though all surfaces are Class A surfaces. Exception: Specific
protective covers, tapes, snap-on protectors, etc. may be approved or
specified by Hybricon to reduce/improve the overall packaging needs. All
packaging materials must be robust enough to protect surface finishes
throughout the handling, vibration, and environmental extremes associated
with normal commercial freight practices.

Specification No: 045-030-05

REV: D
SHEET 26 OF 26
 When required, product designers and/or Prototek Engineering Department
shall specify those materials or practices necessary to insure product
protection.

7.0 Tolerance criteria for non-dimensioned parts.

7.1 Unless otherwise specified on drawing, the following table is to be used

for part fabrication tolerances. Refer to 3D CAD database for all nominal
dimensions.

Unless Otherwise Specified: Soft Tool

Production Run Tolerances

Feature: Units=Inches 0"-24" ANY 24"-UP

Edge/Hole to Edge/Hole +/-.005 +/-.010

Bend/Dimple/Insert to Bend/Dimple/Insert +/-.010 +/-.015

Edge/Hole to Bend/Dimple/Insert +/-.010 +/-.015

Hole Diameter +/-.003

Angular +/-1/2deg

8.0 Tolerance criteria for dimensions locating masked areas on painted parts.
8.1 Unless otherwise specified on drawing, the following table is to be used
for masking tolerances.

Unless otherwise Tolerance Tolerance

specified O”-24” 24”- UP
Feature:
Edge to mask line +/- .03” +/- .06”
Bend to mask line +/- .06” +/- .06”
Mask line to Mask line +/- .03” +/- .06”

Specification No: 045-030-05

REV: D
SHEET 27 OF 26