Title Page Prev Page Next Page TOC

STRUCTURAL REPAIR MANUAL

FASTENER PREPARATION AND INSTALLATION — REPAIRS

NOTICE: THIS REPAIR PAGEBLOCK (PAGES 201-2XX) IS FAA APPROVED AND IS INTENDED FOR
OPERATOR USE IN ACHIEVING REPAIR INSTALLATIONS ACCEPTABLE TO THEIR LOCAL
APPROVAL AUTHORITY.
SPECIFIC REPAIR INSTALLATION CLASSIFICATION (MAJOR OR MINOR) AND SPECIFIC
REQUIREMENTS FOR DATA FROM THIS PAGEBLOCK (PAGES 201-2XX) WILL BE
DICTATED BY THE NATURE OF THE STRUCTURE BEING REPAIRED.
IT IS THE RESPONSIBILITY OF THE OPERATOR TO ENSURE THAT THE REPAIR
INSTALLATION, DOCUMENTATION AND ANY REQUIRED ENGINEERING ACTION
(EVALUATION, DESIGN, ANALYSIS, ETC.) MEET THE REGULATIONS OF THE FAA OR
OTHER GOVERNING REGULATORY AGENCY, AS APPLICABLE, BEFORE RETURNING
THE AIRCRAFT TO SERVICE.

1. Composite Fasteners and Fastener Hole — Treatment

A. Preparation
CONSUMABLES
Sealant ........................................................................................................................... MIL-S-81733
Primer, 2012 or 3012 ....................................................................... Courtaulds 515X333 / 910X350
Primer .................................................................................................... Deft 44-GN-11 or 44-GN-57
NOTE: Primers 2012 or 3012 are equivalent.
B. Procedure
(1) Graphite panel installed on graphite panel or graphite structural component.
(a) Remove fasteners, if loose.
(b) On countersinks and in holes, apply primer and let dry.
(c) On countersinks and in holes, apply primer and let dry. See Original Finishes, 51-20-00,
General.
(d) Install removable steel or titanium fasteners dry.
(e) Install permanent fasteners with wet primer or sealant.
NOTE: Finish 3012 primer may be used if water reduction of primer is omitted.
(2) Graphite panel installed on aluminum structure or aluminum repair plates on graphite panels
(a) Remove fasteners, if loose.
(b) On countersinks and in holes, apply primer and allow to dry.
(c) Apply faying surface sealant on mating surfaces.
(d) Install fasteners wet with sealant.
(e) Fillet seal protruding fastener heads and nuts / washers.
(3) Aramid, fiberglass or graphite panels, installed in any combination.
(a) Remove fasteners, if loose.

51-42-00
Page 201
September 30/02
Title Page Prev Page Next Page TOC

STRUCTURAL REPAIR MANUAL

(b) On countersinks and in holes in graphite, apply primer and allow to dry.
(c) Install removable fasteners wet with primer.
NOTE: Finish 3012 primer may be used if water reduction of primer is omitted.
(d) Install permanent fasteners wet with 2012 primer.
2. Hole Preparation Specification — Metallic and Composite Structure Fasteners
A. Drilling and Fastener Installation Requirements for Metallic Structure
(1) Code N in approved number code below shall be specified for holes used with protruding head
fasteners in sheet thickness less than 0.050 (all materials). For steel and titanium structure in
this category where other than solid rivets are used, flat washer ( AN960 or MS15795 ) shall be
specified to provide the required clearance for fastener fillet radii.
(2) All high strength 12 point bolts, and internal wrenching bolts (MS20004 and MS20024), require
the specification of flat countersink washer under bolt head in lieu of edge break, (code N in
approved number code shall be specified in such cases).
(3) Figure 201, the following applies to the diameter code:
(a) The letter following the minimum hole diameter denotes the hole tolerance and maximum
hole surface roughness.

DIAMETER CODE
A C E G J
LETTER
Hole Tolerance 0.002 0.003 0.004 0.005 0.006
Maximum Surface
125
Roughness -(RMS)

NOTE: Axial grooves (less than 45° with respect to axis of hole ) are not acceptable in
hole surface visible to the unaided eye on material over 200 ksi tensile strength.
(4) Approved Number Code:
1 2
(a) Example number - 51-30-22
• 1
- Denotes hole minimum diameter, hole tolerance, and surface roughness. Obtain
diameter code from Figure 201
• 2 - Denotes edge break requirement
• E - Edge Break
• N - No Edge Break
(b) When table indicates ″_____″.
(c) When a washer under the protruding head of a bolt is specified in a repair.
(d) When hole is in structure underneath a removable panel or cover.
(e) Example callouts:
1 51-30-22-070GN
– 0.070 - 0.075 hole for flush head or protruding head 1/16 diameter solid rivet,
surface roughness 125 RMS, no edge break.
2 51-30-22-129CE

51-42-00
Page 202
September 30/02
Title Page Prev Page Next Page TOC

STRUCTURAL REPAIR MANUAL

– 0.129-0.132 hole for flush head or protruding head 1/8 diameter blind rivet.
Surface roughness 125 RMS. Hole edge break.
3 51-30-22-193GN
– 0.1935 - 0.1985 hole for flush head or protruding head 3/16 diameter. Solid
rivet, surface roughness 125 RMS, no edge break.
4 51-30-22-250CE
– 0.250 - 0.253 for flush or protruding head 1/4 diameter hi-lok, bolt, screw and
lockbolt, surface roughness 125 RMS max, hole edge break.
(5) Carbide or diamond coated twist drills and countersinking cutters are the preferred tools for
machining composites. Tools made of high speed steel are acceptable, however the tools must
be inspected for sharpness and damage after each operation. See Table 201 for ranking tooling
material in order of application (abrasive resistance) and cost.
(6) Drills having a point angle of 135° are preferred, however the standard 118° point angle is
acceptable. See Figure 204 for graphic definition of point angle.
(7) Depending on the fastener used, countersinks will either be 100° or 130°. See Table 202 for
countersink angle for various flush head fasteners used in Gulfstream composite structures.
(8) All drilling and reaming shall be performed dry. A vacuum system is required to remove dust and
chips.
(9) When graphite or graphite / fiberglass is joined with a metallic material, drilling shall start from
the graphite side unless otherwise directed by Gulfstream Technical Operations.
(10) The maximum recommended speed, surface feet per minute (SFPM) and feed, Inch Per
Revolution (IPR) for automatic controlled equipment shall be as specified in Table 203.
(a) Convert SFPM to RPM with following formula:
SFPM / 0.262 x diameter = RPM
(11) For hand feed drilling and reaming operations the following guidelines in Table 204 are
maximum recommend values.
(12) Cadmium plated fasteners are not acceptable for use with graphite materials nor are they to be
used in fuel cells unless overcoated with sealant.
(13) Titanium fasteners are to be used in removable graphite panels.
(14) Titanium is the recommended fastener material. Materials such as Monel, A-286, 15-5PH and
17- 7PH steels can be used providing fastener is installed wet with Pro seal 890, equivalent
sealer or primer. See Sealing of Surfaces for Aerodynamic Smoothness, 51-14-00, Repair,
Epoxy Primer Coating - Preparation and Application (Including Finish 2012), 51-07-10, Repair
or Aerodynamic Sealant Compound, 51-21-00, Repair.
(15) CRES “C” material washers applied wet with either approved primer, Pro seal 890 or equivalent
sealer when a washer is required to be in direct contact with graphite material. See Epoxy
Primer Coating - Preparation and Application (Including Finish 2012), 51-07-10, Repair,
Aerodynamic Sealant Compound, 51-21-00, Repairor Sealing of Surfaces for Aerodynamic
Smoothness, 51-14-00, Repair.
B. Acceptable Limits for Drilled Holes in Composite Material
(1) A drilled (nonreamed) hole is acceptable providing it meets the following requirements:
(a) Hole has smooth finish with no visible burned areas and meets the specified diameter.

51-42-00
Page 203
September 30/02
Title Page Prev Page Next Page TOC

STRUCTURAL REPAIR MANUAL

(b) Hole shall be within ±2 degrees and countersink within ±1 degree of being perpendicular
with surface.
(c) Any exit delaminations shall be removed by lightly abrading surface with 180 or finer grit
silicon carbide or emery paper. Abrasion shall not penetrate the top ply.
(d) Frayed and chip areas shall not exceed the limits. See Table 205 and Figure 206.
(e) Chamfer or relief radius for protruding or flush head fasteners shall conform to Table 206
and Figure 205.
(2) Hand reaming a hole is permissible providing the finished hole meets the requirements for
accepting nonreamed holes. See Step 2.B.(1). A maximum of 0.005 inch on the diameter shall
be removed on one reamer pass.
(3) Hole Diameters for Approved Blind and Solid Rivets Used in Composite Materials:
(a) Hole diameters to be per Table 207.
(b) Blind rivets that penetrate and terminate in a honeycomb bonded assembly shall be
installed as follows:
1 Drill through discrepant facesheet and core only to a depth that will allow fastener
head to seat prior to pulling fastener.
2 Fill hole with either edge filling adhesive Type 1 or 2 prior to installing fastener.
3 Install fastener prior to adhesive cure.
(c) Solid rivets shall be installed by squeezing only.
NOTE: Bucking is prohibited.
(4) Hole Diameters for Hi-Loks and Lockbolts in Composite Material:
(a) Hole diameters are to be per Table 208.
(5) Installation Limits for Permanent Fasteners:
(a) A 0.004 inch gap under one side of a protruding head fastener or swage collar and a 0.002
inch gap under one side of a flush head and countersink on internal surfaces will be
acceptable providing the following limits are not exceeded.
1 Gap must involve less than 1/3 of fastener head.
2 Less than 10% of fastener head or collars in fastener pattern are involved.
3 No two fasteners are together.
4 No exposed shank under the fastener head or collar.
(b) No gap shall be allowed between flush head fastener and the countersink on air passage
surface.
(c) Flush head fasteners shall be flush within +0.005 / -0.002 of air passage.
(d) Unless otherwise specified, washers of appropriate material shall be used under all nuts
and torque off collars.
(6) Installation Limits for Removable Fasteners
(a) Except where nutplates are used, the head of a fastener shall be seated prior to
installation of nut.

51-42-00
Page 204
September 30/02
Title Page Prev Page Next Page TOC

STRUCTURAL REPAIR MANUAL

(b) A 0.004 inch gap under one side of a protruding head fastener and a 0.002 inch gap under
one side of a flush head and countersink on internal surfaces will be acceptable providing
the follow limits are not exceeded.
1 Gap must involve less than 1/3 of fastener head.
2 The shank will not be exposed under the fastener head or nut.
3 Less than 10% of fastener head or collars in fastener pattern are involved.
4 No two fasteners are together.
NOTE: No gap shall be allowed between flush head fastener and the countersink
on the air passage surface.
(c) Flush head fasteners shall be flush within +0.005 / -0.002 of air passage.
(d) Unless nutplates are used or it is otherwise specified, washers of appropriate material
shall be used under all nuts.
(7) Repair of Oversized Holes and Fastener Substitutions:
(a) See appropriate repair section for repair guidelines, limitations and torque values. See
Alkaline Cleaning of Ferrous and Nonferrous Alloys, 51-21-00, Repair and Cleaning and
Descaling of Titanium and Titanium Alloys, 51-21-00, Repair.
Table 201: Drill Bits

MATERIAL TYPE APPLICATION COST

Limited / Light
H.S.S. Low
Duty
General - Medium
Cobalt Moderate
Duty
Limited - Heavy
Carbide Moderate
Duty
Diamond Extra Heavy Duty High

Table 202: Composite Structures Fasteners

COUNTERSINK
FASTENER FASTENER
ANGLE
TYPE DESIGNATION
(DEGREES)
Blind and Solid NAS 1921M
100
Rivets NAS 1200U
Hi-Loks and
All HL series 100
Lockbolts
Comp-Tite,
CT420
Composilok Blind 130
MBF2113
Bolts
82563T3
Thread Bolts 130
SC5006

51-42-00
Page 205
September 30/02
Title Page Prev Page Next Page TOC

STRUCTURAL REPAIR MANUAL

COUNTERSINK
FASTENER FASTENER
ANGLE
TYPE DESIGNATION
(DEGREES)
Lightweight
HLGPL9SC 130
Lockbolts

Table 203: Automatic Controlled Equipment Drill Speeds

DRILL SPEED
MATERIAL FEED (IPR)
DIAMETER (SFPM)
Graphite 1/8 - 3/16 300 0.003
Fiberglass 1/8 - 3/16 400 0.003
Graphite /
7/32 - 1/4 400 0.003
Fiberglass

Table 204: Hand Feed Drill Speeds

DRILL SPEED SPECIAL

MATERIAL FEED
DIAMETER (SFPM) NOTES
Graphite 1/8 - 3/16 2000
(1) (2)(3)
Fiberglass 1/8 - 3/16 2000
Graphite /
7/32 - 1/4 500
Fiberglass
(1)
When hand drilling the feed rate should be light; the weight of the air motor plus a light hand force
shall be sufficient. Upon exit of drill, relax feed rate to prevent pull through.
(2)
Backup material is required on the exit side of each hole, unless access is not available.
(3)
Hand feed drilling and reaming of unidirectional tape material is prohibited.

Table 205: Fray and Chip Limits

CONDITION INDIVIDUAL LIMITS MAXIMUM ALLOWED AREA

Chipped or frayed 0.010 inch
beyond hole and / or Total frayed and chipped
Chipped or countersink surface wall or areas shall not exceed 25
Frayed extend more than 0.070 inch percent of the hole or
beyond the hole or countersink countersink surface.
periphery on adjoining surface.

Table 206: Chamfer or Relief Radius Limits

FASTENER TYPE AND

CHAMFER OR RELIEF
DIAMETER RANGE
RADIUS (INCH)
(INCH)
1/8 Rivet 0.020 - 0.030

51-42-00
Page 206
September 30/02
Title Page Prev Page Next Page TOC

STRUCTURAL REPAIR MANUAL

FASTENER TYPE AND

CHAMFER OR RELIEF
DIAMETER RANGE
RADIUS (INCH)
(INCH)
5/32 - 3/16 Blind Bolt 0.015 - 0.025
5/32 - 3/16 Hi-Lok and
0.030 - 0.040
Treaded Bolt
5/32 - 3/16 Lockbolt,
0.030 - 0.040
Comp-Tite, Composilok

Table 207: Drill Size / Hole Diameter

FASTENER
HOLE DIAMETER DRILL SIZE
DIAMETER
1/8 0.132 - 0.136 No. 29
5/32 0.164 - 0.167 No. 19
3/16 0.196 - 0.199 No. 9

Table 208: Hole Diameters for Hi-Loks and Lockbolts

FASTENER
HOLE DIAMETER
DIAMETER
5/32 0.164 - 0.167
3/16 0.190 - 0.193
1/4 0.250 - 0.253

51-42-00
Page 207
September 30/02
Title Page Prev Page Next Page TOC

STRUCTURAL REPAIR MANUAL

Hole Preparation Specification - Fastener; Metallic Structure

Figure 201 (Sheet 1 of 5)

51-42-00
Page 208
September 30/02
Title Page Prev Page Next Page TOC

STRUCTURAL REPAIR MANUAL

Hole Preparation Specification - Fastener; Metallic Structure

Figure 201 (Sheet 2 of 5)

51-42-00
Page 209
September 30/02
Title Page Prev Page Next Page TOC

STRUCTURAL REPAIR MANUAL

Hole Preparation Specification - Fastener; Metallic Structure

Figure 201 (Sheet 3 of 5)

51-42-00
Page 210
September 30/02
Title Page Prev Page Next Page TOC

STRUCTURAL REPAIR MANUAL

Hole Preparation Specification - Fastener; Metallic Structure

Figure 201 (Sheet 4 of 5)

51-42-00
Page 211
September 30/02
Title Page Prev Page Next Page TOC

STRUCTURAL REPAIR MANUAL

Hole Preparation Specification - Fastener; Metallic Structure

Figure 201 (Sheet 5 of 5)

51-42-00
Page 212
September 30/02
Title Page Prev Page Next Page TOC

STRUCTURAL REPAIR MANUAL

Fastener Types
Figure 202

51-42-00
Page 213
September 30/02
Title Page Prev Page Next Page TOC

STRUCTURAL REPAIR MANUAL

Edge Break Configurations

Figure 203

51-42-00
Page 214
September 30/02
Title Page Prev Page Next Page TOC

STRUCTURAL REPAIR MANUAL

Drill Point Angle

Figure 204

Hole Prep Chamfer / Radius

Figure 205 (Sheet 1 of 2)

51-42-00
Page 215
September 30/02
Title Page Prev Page Next Page TOC

STRUCTURAL REPAIR MANUAL

Hole Prep Chamfer / Radius

Figure 205 (Sheet 2 of 2)

51-42-00
Page 216
September 30/02
Title Page Prev Page Next Page TOC

STRUCTURAL REPAIR MANUAL

Hole Prep
Figure 206

51-42-00
Page 217
September 30/02
Title Page Prev Page Next Page TOC

STRUCTURAL REPAIR MANUAL

THIS PAGE IS INTENTIONALLY LEFT BLANK

51-42-00
Page 218
September 30/02