STRUCTURAL REPAIR MANUAL

FASTENERS − HOLE AND DRILL DATA − METALLIC STRUCTURE

CAUTION: REFER TO THE TABLES 3 THRU 9 IN CHAPTER 51−40−00 TO DETERMINE THE

CORRECT DATA TO BE USED IN THIS CHAPTER.

1. General
A. This topic gives the specified hole dimensions referred to the applicable
type of fastener and general drilling information.

B. Table 23 shows a list of the applicable standard twist−drill sizes nec

essary for the fastener holes. These drills are available from general
tool suppliers.
C. Special tools (for example drill reamer, hand reamer, etc.) necessary for
making the special hole for TAPER−LOK fastener are given in Chapter
51−42−11.

2. Hole Data
A. General
(1) The dimensions of a fastener hole have an important relation to the
strength of the fastened joint.

(2) Clearance fit, transition fit or interference fit fasteners are used
depending on the loading.
(3) Deburr the hole using suitable deburring tool.

NOTE: A twist−drill is not permitted for this step.

B. Hole Sizes

(1) The hole dimensions given in this Paragraph are standard to the air

craft structure.

(2) The necessary dimensions for the radius and chamfer of the hole are
given in Figure 1 and Table 2.

(3) Refer to Chapter 51−40−00 to identify the applicable table in this

Topic for the concerned fastener.
(4) The list that follows is an index of fasteners together with their
applicable tables:

Fastener Type and Hole Fit Table

Solid Rivets:
Standard Solid Rivets − Aluminum Alloy 3
Standard Solid Rivets − Monel 3
Fastener Type and Hole Fit
Table 1

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Fastener Type and Hole Fit Table

Standard Solid Rivets − Titanium 3
Standard Solid Rivets − Titanium Bimetal (CHERRY−BUCK) 6
Standard Solid Rivets − Titanium Columbium (E−Z BUCK) 3
Oversize Solid Rivets − Aluminum Alloy 3
Oversize Solid Rivets − Monel 3

Blind Rivets:
Standard Blind Rivets − (HUCK, CHERRY, AVDEL, CHERRYMAX, CHOBERT) 4
Oversize Blind Rivets − (HUCK, CHERRY, AVDEL, CHERRYMAX, CHOBERT) 4
Standard Blind Rivets − (NSA54212, NSA54213) 5
Standard Blind Bolts − (VISU−LOK, JO−LOK) 7
Oversize Blind Bolts − (VISU−LOK, JO−LOK) 7

Standard Pins (Threaded):

− Transition Fit − in Aluminum Alloy, Steel and Titanium 8
− Transition Fit (Close Tolerance) 13
− Clearance Fit − except in Engine Pylon Structure 11
− Clearance Fit − Steel and Titanium Alloy in Engine Pylon 19
Structure
− Interference Fit 15

Oversize Pins (Threaded):

− Transition Fit − 1st Oversize in Aluminum Alloy, Steel and 9
Titanium
− Transition Fit − 2nd Oversize in Aluminum Alloy, Steel and 10
Titanium
− Transition Fit (Close Tolerance) − 1st and 2nd Oversize 14
− Clearance Fit − 1st and 2nd Oversize 12
− Clearance Fit − 1st and 2nd Oversize in Steel and Titanium 20
Alloy in Engine Pylon Structure
− Interference Fit − 1st and 2nd Oversize 16

Standard Bolts:
− Transition Fit − in Aluminum Alloy, Steel and Titanium 8
Fastener Type and Hole Fit
Table 1

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Fastener Type and Hole Fit Table

− Transition Fit (Close Tolerance) 13
− Clearance Fit − except in Engine Pylon Structure 11
− Clearance Fit − in Steel and Titanium Alloy in Engine Pylon 19
Structure
− Special Clearance Fit (for Bolts (tension)) 17

Oversize Bolts:
− Transition Fit − in Aluminum Alloy 9
− Transition Fit − in Steel and Titanium 10
− Transition Fit (Close Tolerance) 14
− Clearance Fit − except in Engine Pylon Structure 12
− Clearance Fit − 1st and 2nd Oversize in Steel and Titanium 20
Alloy in Engine Pylon Structure
− Special Clearance Fit (for Bolts (tension)) 18

Swaged Pins:
Transition Fit − in Aluminum Alloy, Steel and Titanium 8
Transition Fit − 1st Oversize in Aluminum Alloy, Steel and 9
Titanium
Transition Fit − 2nd Oversize in Aluminum Alloy, Steel and 10
Titanium
Fastener Type and Hole Fit
Table 1

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Underhead Radius/Chamfer Limits for Plain Holes and Countersunk Holes

Figure 1 (sheet 1)

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(5) Radius/Chamfer Values and Code Letter application.

STANDARDS AND DIA. CODE RADIUS/CHAMFER CODE LETTER <3>

HL, ABS, THREAD DIA. FASTENER TYPE
HLT,
, ASNA,
,
HST, NAS, PRO
CSK BOLTS: BLIND
DAN, NSA, MS TRUDING HEAD A228
A228, BOLTS
FoN mm in. HEAD MS21250,
ASNA2002
5 2 4.0 5/32 F G − G
6 3 4.8 3/16 F G − G <1>
8 4 6.35 1/4 F G J J
10 5 7.94 5/16 G J J J <2>
12 6 9.5 3/8 G J M J
14 7 11.1 7/16 G L M −
16 8 12.7 1/2 G L M −
18 9 14.29 9/16 J L M −
20 10 15.87 5/8 J L T −
24 12 19.0 3/4 K P T −
28 14 22.2 7/8 L P T −
32 16 25.4 1 P P T −
36 18 28.57 1 1/8 S P − −
Fastener Diameter, Radius/Chamfer Code Letter − Relationship
Table 2
<1> The code letter is also applicable to the Blind Bolt of 5.6 mm (0.220
in.) diameter.

<2> The code letter is also applicable to the Blind Bolt of 7.14 mm (0.281
in.) diameter.

<3> Refer to Figure 1 to obtain the dimensions of the underhead radius/cham

fer (R) from radius/chamfer code letter.
(a) For Solid Rivets (all diameters) the radius/chamfer values (Refer
to Figure 1) are:
− 0.25 mm (0.010 in.) MIN. to 0.51 mm (0.020 in.) MAX.

(b) For all diameters of Blind Rivets the radius/chamfer values (Re

fer to Figure 1) are:
− 0.51 mm (0.020 in.) MIN. to 0.76 mm (0.030 in.) MAX.

(6) Solid Rivets

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NOMINAL RIVET HOLE DIAMETERS <1>

DIAMETER MAX. MIN.
mm in. mm in. mm in.
1.6 1/16 1.75 0.069 1.65 0.065
2.4 3/32 2.57 0.101 2.46 0.097
2.8 7/64 2.95 0.116 2.84 0.112
3.2 1/8 3.35 0.132 3.25 0.128
3.6 9/64 3.76 0.148 3.66 0.144
4.0 5/32 4.17 0.164 4.06 0.160
4.4 11/64 4.57 0.180 4.47 0.176
4.8 3/16 4.95 0.195 4.85 0.191
5.2 13/64 5.36 0.211 5.26 0.207
5.6 7/32 5.77 0.227 5.66 0.223
6.0 15/64 6.17 0.243 6.07 0.239
6.4 1/4 6.55 0.258 6.45 0.254
6.8 17/64 6.96 0.274 6.83 0.269
8.0 5/16 8.15 0.321 8.03 0.316
9.6 3/8 9.75 0.384 9.63 0.379
Standard and Oversize Hole Diameters for Solid Rivets (Aluminum Alloy,
Titanium, Titanium Columbium (E-Z-Buck) and Monel)
Table 3
<1> For the underhead radius/chamfer values refer to Paragraph 2.B.(5)(a)
above.
(7) Blind Rivets (HUCK, CHERRY, CHERRYMAX, AVDEL, CHOBERT)

NOMINAL RIVET HOLE DIAMETERS <1>

DIAMETER MAX. MIN.
mm in. mm in. mm in.
2.4 3/32 2.54 0.101 2.46 0.097
3.2 1/8 3.35 0.132 3.28 0.129
3.6 9/64 3.71 0.146 3.63 0.143
4.0 5/32 4.17 0.164 4.06 0.160
4.4 11/64 4.57 0.180 4.47 0.176
4.8 3/16 4.98 0.196 4.88 0.192
Standard and Oversize Hole Diameters for Blind Rivets (HUCK, CHERRY,
CHERRYMAX, AVDEL, CHOBERT)
Table 4

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NOMINAL RIVET HOLE DIAMETERS <1>

DIAMETER MAX. MIN.
mm in. mm in. mm in.
5.2 13/64 5.31 0.209 5.21 0.205
6.4 1/4 6.62 0.261 6.50 0.256
6.8 17/64 6.98 0.275 6.88 0.271
Standard and Oversize Hole Diameters for Blind Rivets (HUCK, CHERRY,
CHERRYMAX, AVDEL, CHOBERT)
Table 4
<1> For the underhead radius/chamfer values refer to Paragraph 2.B.(5)(b)
above.

BLIND RIVET STANDARDS NSA54212, NSA54213

NOMINAL RIVET DIAMETER HOLE DIAMETERS <1>
MAX. MIN.
mm in. mm in. mm in.
3.2 1/8 3.33 0.131 3.25 0.128
4.0 5/32 4.14 0.163 4.05 0.160
4.8 3/16 4.90 0.193 4.83 0.190
Standard Hole Diameters for Blind Rivets - (NSA54212, NSA54213)
Table 5
<1> For the underhead radius/chamfer values refer to Paragraph 2.B.(5)(b)
above.
(8) Titanium Bimetal Solid Rivets

DIAMETER DASH HOLE DIAMETERS <1>

NUMBER MAX. MIN.
ABS mm in. mm in.
05 4.140 0.1630 4.064 0.1600
06 4.788 0.1885 4.712 0.1855
08 6.312 0.2485 6.236 0.2455
Standard Hole Diameters for Titanium Bimetal Solid Rivets (CHERRY-Buck)
Table 6

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DIAMETER DASH HOLE DIAMETERS <1>

NUMBER MAX. MIN.
ABS mm in. mm in.
10 7.899 0.3110 7.823 0.3080
12 9.487 0.3735 9.411 0.3705
Standard Hole Diameters for Titanium Bimetal Solid Rivets (CHERRY-Buck)
Table 6
<1> For the underhead radius/chamfer values refer to Paragraph 2.B.(5)(a)
above.
(9) Blind Bolts - (VISU-LOK, JO-LOK)

NOMINAL BLIND HOLE DIAMETERS <1>

BOLT DIAMETER MAX. MIN.
mm in. mm in. mm in.
4.17 0.164 4.22 0.166 4.17 0.164
4.57 0.180 4.62 0.182 4.57 0.180
4.83 0.190 4.88 0.192 4.83 0.190
5.05 0.199 5.11 0.201 5.05 0.199
5.46 0.215 5.51 0.217 5.46 0.215
5.79 0.228 5.84 0.230 5.79 0.228
6.32 0.249 6.40 0.252 6.35 0.250
6.60 0.260 6.65 0.262 6.60 0.260
7.01 0.276 7.06 0.278 7.01 0.276
7.32 0.288 7.44 0.292 7.37 0.290
7.92 0.312 7.98 0.314 7.92 0.312
8.31 0.327 8.36 0.329 8.31 0.327
Standard and Oversize Hole Diameters for Blind Bolts
Table 7
<1> For the underhead radius/chamfer values refer to Figure 1 and Table 2.
(10) Pins (threaded) - (HI-LOK, HI-LITE, BULLNOSE), Bolts and Pins
(swaged)

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DIAMETER STANDARD HOLE DIAMETERS − TRANSITION FIT <1>

DASH
ASH NUMBER
NUM IN ALUMINUM ALLOY IN STEEL AND TITANIUM
HL, ASNA, MAX. MIN. MAX. MIN.
DAN,
DAN NAS
NAS,
ABS NSA mm in. mm in. mm in. mm in.
5 2 4.160 0.1638 4.125 0.1624 − − − −
6 3 4.821 0.1898 4.780 0.1882 4.833 0.1903 4.813 0.1895
3A 5.552 0.2183 5.512 0.217 5.5950 0.2202 5.575 0.2195
8 4 6.350 0.2500 6.310 0.2484 6.357 0.2503 6.337 0.2495
10 5 7.940 0.3126 7.900 0.3110 7.950 0.3130 7.925 0.3120
12 6 9.530 0.3752 9.490 0.3736 9.537 0.3755 9.512 0.3745
14 7 11.120 0.4378 11.080 0.4362 11.130 0.4382 11.100 0.4370
16 8 12.710 0.5004 12.670 0.4988 12.717 0.5007 12.687 0.4995
18 9 14.287 0.5625 14.247 0.5609 14.297 0.5629 14.262 0.5615
20 10 15.875 0.6250 15.836 0.6235 15.884 0.6254 15.849 0.6240
24 12 19.052 0.7501 19.013 0.7485 19.064 0.7506 19.024 0.7490
28 14 22.230 0.8752 22.189 0.8736 22.239 0.8756 22.199 0.8740
32 16 25.404 1.0002 25.364 0.9986 − − − −
Standard Hole Diameters − Transition Fit in Aluminum Alloy, Steel and Tita

nium for Pins (threaded), Bolts and Pins (swaged)
Table 8
<1> For the underhead radius/chamfer values refer to Figure 1 and
Table 2.

DIAMETER OVERSIZE HOLE DIAMETERS − TRANSITION FIT <1>

DASH
ASH NUMBER
NUM IN ALUMINUM ALLOY IN STEEL AND TITANIUM
1st OVERSIZE (NOMINAL DIA. 1st OVERSIZE (NOMINAL DIA.
+0.4 mm (1/64 in.)) +0.4 mm (1/64 in.))
HL, ASNA, MAX. MIN. MAX. MIN.
DAN,
DAN NAS
NAS,
ABS NSA mm in. mm in. mm in. mm in.
6 3 5.152 0.2028 5.113 0.2013 5.165 0.2033 5.146 0.2026
3AX 5.949 0.2342 5.909 0.2326 5.959 0.2346 5.939 0.2338
8 4 6.747 0.2656 6.706 0.2640 6.754 0.2659 6.733 0.2651
10 5 8.335 0.3281 8.296 0.3266 8.345 0.3285 8.321 0.3276
1st Oversize Hole Diameters − Transition Fit in Aluminum Alloy, Steel and
Titanium for Pins (threaded), Bolts and Pins (swaged)
Table 9

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DIAMETER OVERSIZE HOLE DIAMETERS − TRANSITION FIT <1>

DASH NUMBER IN ALUMINUM ALLOY IN STEEL AND TITANIUM
1st OVERSIZE (NOMINAL DIA. 1st OVERSIZE (NOMINAL DIA.
+0.4 mm (1/64 in.)) +0.4 mm (1/64 in.))
HL, ASNA, MAX. MIN. MAX. MIN.
DAN, NAS,
ABS NSA mm in. mm in. mm in. mm in.
12 6 9.925 0.3907 9.886 0.3892 9.932 0.3910 9.908 0.3901
14 7 11.515 0.4533 11.476 0.4518 11.525 0.4537 11.496 0.4526
16 8 13.105 0.5159 13.066 0.5144 13.112 0.5162 13.083 0.5151
18 9 14.682 0.5780 14.643 0.5765 14.692 0.5784 14.658 0.5771
20 10 16.272 0.6406 16.232 0.6391 16.280 0.6409 16.245 0.6396
24 12 19.449 0.7657 19.409 0.7641 19.460 0.7661 19.420 0.7646
28 14 22.625 0.8907 22.585 0.8892 22.635 0.8911 22.595 0.8896
32 16 25.800 1.0157 25.760 1.0142 − − − −
1st Oversize Hole Diameters − Transition Fit in Aluminum Alloy, Steel and
Titanium for Pins (threaded), Bolts and Pins (swaged)
Table 9
<1> For the underhead radius/chamfer values refer to Figure 1 and
Table 2.

DIAMETER OVERSIZE HOLE DIAMETERS − TRANSITION FIT <1>

DASH
ASH NUMBER
NUM IN ALUMINUM ALLOY IN STEEL AND TITANIUM
2nd OVERSIZE (NOMINAL DIA. 2nd OVERSIZE (NOMINAL DIA.
+0.8 mm (1/32 in.)) +0.8 mm (1/32 in.))
HL, ASNA, MAX. MIN. MAX. MIN.
DAN,
DAN NAS
NAS,
ABS NSA mm in. mm in. mm in. mm in.
6 3 5.549 0.2185 5.509 0.2169 5.562 0.2190 5.542 0.2182
8 4 7.141 0.2811 7.102 0.2796 7.148 0.2814 7.129 0.2807
10 5 8.732 0.3438 8.692 0.3422 8.742 0.3442 8.717 0.3432
12 6 10.321 0.4063 10.282 0.4048 10.328 0.4066 10.304 0.4057
14 7 11.912 0.4690 11.872 0.4674 11.922 0.4694 11.892 0.4682
16 8 13.501 0.5315 13.462 0.5300 13.508 0.5318 13.479 0.5307
18 9 15.078 0.5936 15.039 0.5921 15.088 0.5940 15.054 0.5927
20 10 16.668 0.6562 16.629 0.6547 16.676 0.6565 16.642 0.6552
2nd Oversize Hole Diameters − Transition Fit in Aluminum Alloy, Steel and
Titanium for Pins (threaded), Bolts and Pins (swaged)
Table 10

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DIAMETER OVERSIZE HOLE DIAMETERS − TRANSITION FIT <1>

DASH NUMBER IN ALUMINUM ALLOY IN STEEL AND TITANIUM
2nd OVERSIZE (NOMINAL DIA. 2nd OVERSIZE (NOMINAL DIA.
+0.8 mm (1/32 in.)) +0.8 mm (1/32 in.))
HL, ASNA, MAX. MIN. MAX. MIN.
DAN, NAS,
ABS NSA mm in. mm in. mm in. mm in.
24 12 19.845 0.7813 19.806 0.7798 19.856 0.7817 19.817 0.7802
28 14 23.021 0.9063 22.982 0.9048 23.031 0.9067 22.992 0.9052
32 16 26.196 1.0313 26.157 1.0298 − − − −
2nd Oversize Hole Diameters − Transition Fit in Aluminum Alloy, Steel and
Titanium for Pins (threaded), Bolts and Pins (swaged)
Table 10
<1> For the underhead radius/chamfer values refer to Figure 1 and
Table 2.

DIAMETER DASH NUMBER STANDARD HOLE DIAMETERS − CLEARANCE FIT <1> <2>
HLT, HST, NAS, MAX. MIN.
HL DAN,
HL, DAN ASNA, NSA
ASNA
ABS mm in. mm in.
6 3 4.877 0.1920 4.826 0.1900
3A 5.584 0.2198 5.544 0.2182
8 4 6.401 0.2520 6.350 0.2500
10 5 7.988 0.3145 7.938 0.3125
12 6 9.576 0.3770 9.525 0.3750
14 7 11.163 0.4395 11.112 0.4375
16 8 12.751 0.5020 12.700 0.5000
18 9 14.338 0.5645 14.288 0.5625
20 10 15.926 0.6270 15.875 0.6250
24 12 19.101 0.7520 19.050 0.7500
28 14 22.276 0.8770 22.225 0.8750
Standard Hole Diameters − Clearance Fit − Pins (threaded) and Bolts
Table 11

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DIAMETER DASH NUMBER STANDARD HOLE DIAMETERS − CLEARANCE FIT <1> <2>
HLT, HST, NAS, MAX. MIN.
HL, DAN, ASNA, NSA
ABS mm in. mm in.
32 16 25.451 1.0020 25.400 1.0000
36 18 28.626 1.1270 28.575 1.1250
Standard Hole Diameters − Clearance Fit − Pins (threaded) and Bolts
Table 11
<1> For the underhead radius/chamfer values refer to Figure 1 and
Table 2.

<2> These values are not applicable for Engine Pylon Structure.

DIAMETER DASH NUM
OVERSIZE HOLE DIAMETERS − CLEARANCE FIT <1> <2>
BER 1st OVERSIZE (NOMINAL DIA. 2nd OVERSIZE (NOMINAL DIA.
+0.4 mm (1/64 in.)) +0.8 mm (1/32 in.))
HL, HLT, ASNA, MAX. MIN. MAX. MIN.
HST ABS
HST,ABS, NSA, NAS
NSA
DAN mm in. mm in. mm in. mm in.
6 3 5.210 0.2051 5.159 0.2031 5.606 0.2207 5.555 0.2187
3AX 5.981 0.2351 5.941 0.2338
8 4 6.797 0.2676 6.746 0.2656 7.193 0.2832 7.142 0.2812
10 5 8.385 0.3301 8.334 0.3281 8.781 0.3457 8.730 0.3437
12 6 9.972 0.3926 9.921 0.3906 10.368 0.4082 10.317 0.4062
14 7 11.560 0.4551 11.509 0.4531 11.956 0.4707 11.905 0.4687
16 8 13.147 0.5176 13.096 0.5156 13.543 0.5332 13.492 0.5312
18 9 14.735 0.5801 14.684 0.5781 15.131 0.5957 15.080 0.5937
20 10 16.322 0.6426 16.271 0.6406 16.718 0.6582 16.667 0.6562
24 12 19.497 0.7676 19.446 0.7656 19.893 0.7832 19.842 0.7812
28 14 22.672 0.8926 22.621 0.8906 23.068 0.9082 23.020 0.9063
32 16 25.847 1.0176 25.796 1.0156 26.246 1.0333 26.195 1.0313
36 18 29.022 1.1426 28.971 1.1406 29.418 1.1582 29.368 1.1562
Oversize Hole Diameters − Clearance Fit for Pins (threaded) and Bolts
Table 12
<1> For the underhead radius/chamfer values refer to Figure 1 and
Table 2.
<2> These values are not applicable for Engine Pylon Structure.

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BOLT DIAMETER NUMBER STANDARD HOLE DIAMETERS − TRANSITION FIT (CLOSE TOLER

ANCE) <1>
HL, DAN, ASNA, MAX. MIN.
AS
ABS NAS NSA
NAS, mm in. mm in.
6 3 4.823 0.1899 4.803 0.1891
8 4 6.347 0.2499 6.327 0.2491
10 5 7.935 0.3124 7.915 0.3116
12 6 9.522 0.3749 9.502 0.3741
14 7 11.110 0.4374 11.090 0.4366
16 8 12.697 0.4999 12.677 0.4991
18 9 14.285 0.5624 14.265 0.5616
20 10 15.872 0.6249 15.852 0.6241
24 12 19.047 0.7499 19.027 0.7491
28 14 22.222 0.8749 22.202 0.8741
32 16 25.397 0.9999 25.377 0.9991
Standard Hole Diameters − Transition Fit (Close Tolerance) − Pins
(threaded) and Bolts
Table 13
<1> For the underhead radius/chamfer values refer to Figure 1 and
Table 2.

BOLT DIAMETER DASH OVERSIZE HOLE DIAMETERS − TRANSITION FIT (CLOSE TOLER

NUMBER ANCE) <1>
1st OVERSIZE (NOMINAL DIA. 2nd OVERSIZE (NOMINAL DIA.
+0.4 mm (1/64 in.)) +0.8 mm (1/32 in.))
HL, DAN, ASNA, MAX. MIN. MAX. MIN.
AS
ABS NAS, NSA
NAS mm in. mm in. mm in. mm in.
6 3 5.179 0.2039 5.159 0.2031 5.602 0.2206 5.582 0.2198
8 4 6.705 0.2640 6.683 0.2631 7.128 0.2806 7.106 0.2798
10 5 8.293 0.3265 8.271 0.3256 8.716 0.3431 8.694 0.3423
12 6 9.880 0.3890 9.858 0.3881 10.301 0.4056 10.281 0.4048
14 7 11.473 0.4517 11.446 0.4506 11.896 0.4683 11.869 0.4673
16 8 13.060 0.5142 13.033 0.5131 13.483 0.5308 13.456 0.5298
18 9 14.648 0.5767 14.621 0.5756 15.071 0.5933 15.044 0.5923
1st and 2nd Oversize Hole Diameters − Transition Fit (Close Tolerance) −
Pins (threaded) and Bolts
Table 14

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BOLT DIAMETER DASH OVERSIZE HOLE DIAMETERS − TRANSITION FIT (CLOSE TOLER

NUMBER ANCE) <1>
1st OVERSIZE (NOMINAL DIA. 2nd OVERSIZE (NOMINAL DIA.
+0.4 mm (1/64 in.)) +0.8 mm (1/32 in.))
HL, DAN, ASNA, MAX. MIN. MAX. MIN.
ABS NAS, NSA mm in. mm in. mm in. mm in.
20 10 16.235 0.6392 16.208 0.6381 16.658 0.6558 16.631 0.6548
24 12 19.416 0.7644 19.383 0.7631 19.839 0.7811 19.806 0.7798
1st and 2nd Oversize Hole Diameters − Transition Fit (Close Tolerance) −
Pins (threaded) and Bolts
Table 14
<1> For the underhead radius/chamfer values refer to Figure 1 and
Table 2.

DIAMETER DASH NUMBER STANDARD HOLE DIAMETER − INTERFERENCE FIT <1>

HLT, HST ASNA, NSA MAX. MIN.
mm in. mm in.
6 3 4.737 0.1865 4.686 0.1845
3A 5.942 0.2339 5.921 0.2331
8 4 6.261 0.2465 6.210 0.2445
10 5 7.849 0.3090 7.798 0.3070
12 6 9.436 0.3715 9.385 0.3695
14 7 11.024 0.4340 10.973 0.4320
16 8 12.611 0.4965 12.560 0.4945
18 9 14.211 0.5595 14.160 0.5575
20 10 15.799 0.6220 15.748 0.6200
24 12 18.974 0.7470 18.923 0.7450
28 14 22.174 0.8730 22.123 0.8710
32 16 25.349 0.9980 25.298 0.9960
Standard Hole Diameter − Interference Fit − Pins (threaded)
Table 15
<1> For the underhead radius/chamfer values refer to Figure 1 and
Table 2.

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DIAMETER DASH NUM
OVERSIZE HOLE DIAMETERS − INTERFERENCE FIT <1>

BER 1st OVERSIZE (NOMINAL DIA. 2nd OVERSIZE (NOMINAL DIA.
+0.4 mm (1/64 in.)) +0.8 mm (1/32 in.))
HLT, HST NSA, ASNA MAX. MIN. MAX. MIN.
mm in. mm in. mm in. mm in.
6 3 5.070 0.1996 5.019 0.1976 5.466 0.2152 5.415 0.2132
3AX 5.499 0.2165 5.448 0.2145
8 4 6.657 0.2621 6.607 0.2601 7.054 0.2777 7.003 0.2757
10 5 8.245 0.3246 8.194 0.3226 8.641 0.3402 8.590 0.3382
12 6 9.832 0.3871 9.782 0.3851 10.229 0.4027 10.178 0.4007
14 7 11.420 0.4496 11.369 0.4476 11.816 0.4652 11.765 0.4632
16 8 13.007 0.5121 12.957 0.5101 13.404 0.5277 13.353 0.5257
18 9 14.608 0.5751 14.557 0.5731 15.004 0.5907 14.953 0.5887
20 10 16.195 0.6376 16.144 0.6356 16.591 0.6532 16.541 0.6512
24 12 19.370 0.7626 19.319 0.7606 19.766 0.7782 19.716 0.7762
28 14 22.570 0.8886 22.520 0.8866 22.967 0.9042 22.916 0.9022
32 16 25.745 1.0136 25.695 1.0116 26.142 1.0292 26.091 1.0272
1st and 2nd Oversize Hole Diameters − Interference Fit − Pins (threaded)
Table 16
<1> For the underhead radius/chamfer values refer to Figure 1 and
Table 2.

BOLT DIAMETER STANDARD HOLE DIAMETERS − SPECIAL CLEARANCE FIT <1>

NUMBER
A, ASNA, MS MAX. MIN.
mm in. mm in.
3 5.287 0.2081 5.012 0.1973
4 6.811 0.2681 6.536 0.2573
5 8.399 0.3307 8.125 0.3199
6 9.986 0.3931 9.711 0.3823
7 11.574 0.4557 11.300 0.4449
8 13.161 0.5181 12.887 0.5074
9 14.736 0.5801 14.461 0.5693
10 16.324 0.6427 16.049 0.6318
12 19.499 0.7677 19.224 0.7568
Standard Hole Diameters − Special Clearance Fit for Bolts (tension)
Table 17

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BOLT DIAMETER STANDARD HOLE DIAMETERS − SPECIAL CLEARANCE FIT <1>

NUMBER
A, ASNA, MS MAX. MIN.
mm in. mm in.
14 22.674 0.8927 22.399 0.8818
16 25.849 1.0177 25.574 1.0068
Standard Hole Diameters − Special Clearance Fit for Bolts (tension)
Table 17
<1> For the underhead radius/chamfer values refer to Figure 1 and
Table 2.

BOLT DIAME
OVERSIZE HOLE DIAMETERS − SPECIAL CLEARANCE FIT <1>

TER NUMBER
NUM 1st OVERSIZE (NOMINAL DIA. 2nd OVERSIZE (NOMINAL DIA.
+0.4mm (1/64 in.)) +0.8mm (1/32 in.))
A, ASNA, MS MAX. MIN. MAX. MIN.
mm in. mm in. mm in. mm in.
4 7.209 0.2838 6.933 0.2729 7.605 0.2994 7.330 0.2886
5 8.795 0.3462 8.522 0.3355 9.192 0.3619 8.918 0.3511
6 10.384 0.4088 10.109 0.3980 10.780 0.4244 10.505 0.4136
7 11.971 0.4713 11.696 0.4605 12.367 0.4869 12.092 0.4761
8 13.558 0.5338 13.283 0.5229 13.954 0.5494 13.680 0.5386
9 15.133 0.5958 14.859 0.5850 15.529 0.6114 15.255 0.6006
10 16.721 0.6583 16.446 0.6475 17.117 0.6739 16.842 0.6631
12 19.896 0.7833 19.621 0.7725 20.292 0.7989 20.017 0.7881
14 23.071 0.9083 22.796 0.8975 23.467 0.9239 23.192 0.9131
1st and 2nd Oversize Hole Diameters − Special Clearance Fit for Bolts
(tension)
Table 18
<1> For the underhead radius/chamfer values refer to Figure 1 and
Table 2.

DIAMETER DASH NUMBER STANDARD HOLE DIAMETERS − CLEARANCE FIT <1> <2>
mm 1/16in. MAX. MIN.
mm in. mm in.
4.17 2 4.208 0.1657 4.163 0.1639
4.80 3 4.868 0.1917 4.823 0.1899
Standard Hole Diameters − Clearance Fit − Pins (threaded) and Bolts − Steel
and Titanium Alloys in Engine Pylon Structure
Table 19

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DIAMETER DASH NUMBER STANDARD HOLE DIAMETERS − CLEARANCE FIT <1> <2>
mm 1/16in. MAX. MIN.
mm in. mm in.
5.60 5.597 0.2204 5.552 0.2186
6.35 4 6.392 0.2517 6.347 0.2499
7.90 5 7.980 0.3142 7.935 0.3124
9.52 6 9.567 0.3767 9.522 0.3749
11.10 7 11.154 0.4393 11.109 0.4374
12.70 8 12.742 0.5016 12.697 0.4999
14.30 9 14.317 0.5637 14.272 0.5619
15.90 10 15.904 0.6261 15.859 0.6244
19.00 12 19.079 0.7511 19.034 0.7494
22.20 14 22.254 0.8761 22.209 0.8744
25.40 16 25.429 1.0011 25.384 0.9994
Standard Hole Diameters − Clearance Fit − Pins (threaded) and Bolts − Steel
and Titanium Alloys in Engine Pylon Structure
Table 19
<1> For the underhead radius/chamfer values refer to Figure 1 and
Table 2.

<2> This table is applicable even if other tolerance values were

used for the original design.

DIAMETER DASH OVERSIZE HOLE DIAMETERS − CLEARANCE FIT <1> <2>

NUMBER
DIAMETER DASH 1st OVERSIZE (NOMINAL DIA. 2nd OVERSIZE (NOMINAL DIA.
NUMBER +0.4 mm (1/64 in.)) +0.8 mm (1/32 in.))
mm 1/16in. MAX. MIN. MAX. MIN.
mm in. mm in. mm in. mm in.
4.17 4.868 0.1916 4.823 0.1899 5.193 0.2044 5.148 0.2027
4.80 3 5.193 0.2044 5.148 0.2027 5.597 0.2203 5.552 0.2186
5.60 3A 5.986 0.2357 5.941 0.2339 6.392 0.2516 6.347 0.2499
6.35 4 6.781 0.2670 6.736 0.2651 7.176 0.2825 7.132 0.2808
7.92 5 8.368 0.3294 8.323 0.3277 8.764 0.3450 8.719 0.3433
9.52 6 9.955 0.3919 9.911 0.3902 10.354 0.4076 10.310 0.4059
11.10 7 11.546 0.4546 11.501 0.4528 11.942 0.4702 11.897 0.4684
12.70 8 13.133 0.5170 13.089 0.5153 13.529 0.5326 13.485 0.5309
14.30 9 14.708 0.5791 14.663 0.5773 15.104 0.5946 15.055 0.5927
1st and 2nd Oversize Hole Diameters − Clearance Fit − Pins (threaded) −
Steel and Titanium Alloys in Engine Pylon Structure
Table 20

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DIAMETER DASH OVERSIZE HOLE DIAMETERS − CLEARANCE FIT <1> <2>

NUMBER
DIAMETER DASH 1st OVERSIZE (NOMINAL DIA. 2nd OVERSIZE (NOMINAL DIA.
NUMBER +0.4 mm (1/64 in.)) +0.8 mm (1/32 in.))
mm 1/16in. MAX. MIN. MAX. MIN.
mm in. mm in. mm in. mm in.
15.90 10 16.295 0.6415 16.251 0.6398 16.692 0.6571 16.647 0.6554
19.00 12 19.481 0.7670 19.429 0.7649 19.877 0.7826 19.825 0.7805
1st and 2nd Oversize Hole Diameters − Clearance Fit − Pins (threaded) −
Steel and Titanium Alloys in Engine Pylon Structure
Table 20
<1> For the underhead radius/chamfer values refer to Figure 1 and
Table 2.

<2> This table is applicable even if other tolerance values were

used for the original design.

3. Drill Data
A. General

(1) The material must be held or clamped in a manner that will prevent
any movement during drilling.

(2) It is important to use a twist−drill that is sharp and accurately

ground. To prevent the twist−drill ’wandering off’, it is advisable
to locate the twist−drill in the required drilling position, and ro

tate the twist−drill by hand, a few revolutions, prior to commencing
the drilling operation.

(3) The twist−drill should run truly and should be held at right angles
to the surface of the material.
(4) To enable accurate and easy production of large holes, it is advis

able to drill pilot holes. The necessity/size of pilot holes shall
be decided according to the material and is left to the discretion
of the operator.

(5) The correct drill speed range (permissible revolution per minute
(rpm)) should be determined according to the size of the twist−drill
and material to be drilled as given in Table 21.

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MATERIAL PERMISSIBLE R.P.M. RANGE (given

range divided by drill diameter)
Aluminum / Al. Alloy 765 to 1145 19450 to 29100
drill DIA in drill DIA in mm
inches
Steel 190 to 305 4850 to 7750
drill DIA in drill DIA in mm
inches
Stainless Steel 115 to 155 2950 to 3950
drill DIA in drill DIA in mm
inches
Titanium Alloy 75 to 230 1950 to 5850
drill DIA in drill DIA in mm
inches
Titanium 190 to 380 4850 to 9650
drill DIA in drill DIA in mm
inches
Drill Speed Range
Table 21
Example of Application:

When drilling a 6.35 mm (0.2500 in.) hole in aluminum alloy use a

drill speed in the range of 3060 to 4580 rpm for example 19450 to
29100 divided by 6.35 mm (0.25 in.) (765 to 1145 divided by 0.25
in. (6.35 mm).
(6) The drilling equipment should be checked for condition, for example,
wear of bearings, spindle concentricity and security of parts.

(7) Drilling holes in structural parts present special problems which

need to be considered before the drilling operation. The primary
problem is drill breakage. This can occur when drilling small holes
in sheet metal or other thin sections. Other problems, their indica

tions and possible causes are given in Table 22.

INDICATIONS POSSIBLE CAUSES

Outer corners of drill 1. Too fast a cutting speed.
b k off
break ff 2. Hard spots in the material.
3. Flutes clogged with swarf.
Parts of the cutting edges 1. Too fast a feed rate.
b k off
break ff 2. Too much drill cutting edge clearance.
Drilling Faults/Causes
Table 22

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INDICATIONS POSSIBLE CAUSES

Cracks in drill 1. Drill overheated or cooled too cutting
edges quickly whilst sharpening or drilling.
Drill breaks 1. Drill point incorrectly ground.
2. Too fast a feed rate.
3. Drill not sharp.
4. Flutes clogged with swarf.
Drill splits up its center 1. Drill cutting edge clearance, not suffi

cient.
2. Too fast a feed rate.
Drill will not feed into 1. Drill not sharp.
material
il 2. Drill cutting edge clearance, not suffi

cient.
3. Drill too large (i.e. pilot hole re

quired).
Hole wall rough 1. Drill point incorrectly ground or not
sharp.
2. Incorrect or not sufficient lubricant.
3. Too fast a feed rate.
4. Material not rigid.
Hole oversize 1. Unequal angle and/or length of cutting
edges.
2. Loose spindle.
Different amounts of swarf 1. One lip does most or all of the cutting.
emerging from flutes.
Drilling Faults/Causes
Table 22

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Twist Drill General Details

Figure 2 (sheet 1)

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B. Drilling Aluminum Alloy

(1) When drilling aluminum alloys use a high speed twist−drill. A cor

rectly ground, sharp twist−drill will drill the hole to the required
dimension or, usually not more than 0.05 mm (0.0020 in.) oversize.

(2) It is not necessary to use a lubricant when drilling aluminum al

loys, but it is recommended that a mineralized soluble oil is used
to help remove swarf and reduce heat build−up.
NOTE: Overheating the material when drilling should be avoided since
it is possible that the hole will decrease minutely when the
material cools.

C. Drilling Steel and Stainless Steel

(1) When drilling steel and stainless steel use a high speed twist−drill.
Use a constant and positive drill feed rate, do not let the twist−
drill turn on the metal, without cutting it. This would harden the
metal and could cause difficulties when starting to drill again.

NOTE: When marking stainless steel use, if possible, a square or

triangular−shaped punch. The use of a round punch will harden
the metal and can cause problems when starting to drill.

(2) When drilling steel and stainless steel use one of these lubricants:
− a sulfurized mineral oil of the chlorinated type for large and/or
deep holes,
− a water soluble oil for small and/or shallow holes.

D. Drilling Titanium and Titanium Alloy

(1) When drilling titanium and titanium alloys use a high speed, cobalt
based, steel twist−drill. Make sure that the twist−drill turns at the
correct speed (Refer to Paragraph 3.A.(5) before it touches the ma

terial. When starting the cutting process keep a constant pressure on
the twist−drill. If the twist−drill turns with only a little or no
pressure when it touches the material:
− the material and the twist−drill becomes too hot,
− the twist−drill will seize.

(2) Drilling titanium material can be difficult due to its hardness. To

assist in this operation the steps that follow are recommended:

(a) Only use sharp twist−drills.

(b) Lift the twist−drill away from the hole frequently, this will
clear the swarf and let you examine the twist−drill to make sure
that it is clean.

(c) Use a good supply of lubricant. A nitrate and halogen free lu

bricant is recommended, a normal drilling emulsion is satisfacto

ry but the twist−drill life will be reduced.

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(d) Where possible, support thin titanium material with a soft ex

pendable material such as wood.
E. Drill Sizes

(1) The hole sizes detailed in Tables 3 thru 20 have tolerances that en

able the use of a standard twist−drill to produce a hole within the
minimum/ maximum dimensions given.

(2) Table 23 that follows, is a list of standard twist−drills from 1.98

mm (0.0780 in.) up to 25.4 mm (1.00 in.).

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Inches Milli− Inches Millimeters

Fractions Decimal meters Fractions Decimal
5/64 0.0781 1.98 7/64 0.1181 3.00
0.0785 0.1200
0.0787 2.00 0.1220 3.10
0.0807 2.05 1/8 0.1250 3.18
0 0810
0.0810
0.1260 3.20
0.0820
0.1279 3.25
0.0827 2.10 0.1285
0.0846 2.15 0.1299 3.30
0.0860 0.1338 3.40
0.0866 2.20 0 1360
0.1360
0.0885 2.25 0.1378 3.50
0.0890 2.26 0 1405
0.1405
0.0905 2.30 9/64 0.1406 3.57
0.0925 2.35 0.1417 3.60
0.0935 2.37 0 1440
0.1440
3/32 0.0937 2.38 0.1457 3.70
0.0945 2.40 0 1470
0.1470
0.0960 2.44 0.1476 3.75
0.0964 2.45 0 1495
0.1495
0.0980 2.49 0.1496 3.80
0.0984 2.50 0 1520
0.1520
0.0995 2.53 0.1535 3.90
0.1015 0.1540
0.1024 2.60 5/32 0.1562 3.97
0.1040 0.1570
0.1063 2.70 0.1575 4.00
0.1065 0.1590
0.1082 2.75 0 1610
0.1610
Drill Sizes
Table 23

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Inches Milli− Inches Millimeters

Fractions Decimal meters Fractions Decimal
7/64 0.1094 2.78 5/32 0.1614 4.10
0 1100
0.1100
0.1654 4.20
0 1660
0.1660
0.1102 2.80
0 1110
0.1110
0.1130 0.1673 4.25

0.1141 2.90 0.1693 4.30

0.1160 0.1695
Drill Sizes
Table 23

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Inches Milli− Inches Millimeters

Fractions Decimal meters Fractions Decimal
11/64 0.1719 4.37 7/32 0.2244 5.70
0 1730
0.1730
0.2263 5.75
0 2280
0.2280
0.1732 4.40
0.1770 0.2283 5.80
0.1771 4.50 0.2323 5.90
0.1800 0.2340
0.1811 4.60 15/64 0.2344 5.95
0 1820
0.1820
0.2362 6.00
0.1850 4.70 0.2380
0.1870 4.75 0.2401 6.10
3/16 0.1875 4.76 0 2420
0.2420
0.1890 4.80 0.2441 6.20
0 1910
0.1910 0.2460 6.25
0.1929 4.90 0.2480 6.30
0 1935
0.1935
0.1960 1/4 0.2500 6.35
0.1968 5.00 0.2520 6.40
0 1990
0.1990
0.2559 6.50
0 2570
0.2570
0.2008 5.10
0 2010
0.2010
0.2598 6.60
0 2610
0.2610
13/64 0.2031 5.16
0.2040 0.2638 6.70
0.2047 5.20 17/64 0.2657 6.75
0.2055 0.2660
0.2067 5.25 0.2677 6.80
0.2086 5.30 0.2716 6.90
0.2090 0.2720
0.2126 5.40 0.2756 7.00
0.2130 0.2770
0.2165 5.50 0.2795 7.10
7/32 0.2187 5.56 0 2811
0.2811
0.2210 5.60 9/32 0.2812 7.14
Drill Sizes
Table 23

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Inches Milli− Inches Millimeters

Fractions Decimal meters Fractions Decimal
9/32 0.2835 7.20 23/64 0.3594 9.13
0.2854 7.25 0.3622 9.20
0.2874 7.30 0.3641 9.25
0.2900 7.36 0.3661 9.30
0.2913 7.40 0.3680 9.35
0 2950
0.2950 0.3701 9.40
0.2953 7.50 0.3740 9.50
19/64 0.2968 7.54 3/8 0.3750 9.53
0 3770
0.3770
0.2992 7,60
0.3020 0.3780 9.60
0.3031 7.70 0.3819 9.70
0.3051 7.75 0.3838 9.75
0.3110 7.90 0.3858 9.80
5/16 0.3125 7.94 0 3860
0.3860
0.3150 8.00 0.3898 9.90
0.3189 8.10 25/64 0.3906 9.92
0.3228 8.20 0.3937 10.00
0 3230
0.3230 0.3970 10.08
0.3248 8.25 0.4040 10.26
0.3268 8.30 13/32 0.4062 10.32
21/64 0.3281 8.33 0 4130
0.4130
0.3307 8.40 0.4134 10.50
0 3320
0.3320 27/64 0.4219 10.72
0.3346 8.50 0.4330 11.00
0.3386 8.60 7/16 0.4375 11.11
0 3390
0.3390 0.4528 11.50
0.3425 8.70 29/64 0.4531 11.51
Drill Sizes
Table 23

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Inches Milli− Inches Millimeters

Fractions Decimal meters Fractions Decimal
11/32 0.3437 8.73 15/32 0.4687 11.91
0.3445 8.75 0.4724 12.00
0.3465 8.80 31/64 0.4843 12.30
0 3480
0.3480 0.4921 12.50
0.3504 8.90 1/2 0.5000 12.70
0.3543 9.00 0.5118 13.00
0 3580
0.3580 33/64 0.5156 13.10
0.3583 9.10 17/32 0.5312 13.49
17/32 0.5315 13.50 25/32 0.7812 19.84
35/64 0.5469 13.89 0.7874 20.00
0.5512 14.00 51/64 0.7969 20.24
9/16 0.5625 14.29 0.8071 20.50
0.5707 14.50 13/16 0.8125 20.64
37/64 0.5781 14.68 0.8265 21.00
0.5906 15.00 53/64 0.8281 21.03
19/32 0.5937 15.08 27/32 0.8437 21.43
39/64 0.6094 15.48 0.8465 21.50
0.6102 15.50 55/64 0.8594 21.83
5/8 0.6250 15.88 0.8661 22.00
0.6299 16.00 7/8 0.8750 22.23
41/64 0.6406 16.27 0.8858 22.50
0.6496 16.50 57/64 0.8906 22.62
21/32 0.6562 16.67 0.9055 23.00
0.6693 17.00 29/32 0.9062 23.02
Drill Sizes
Table 23

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Inches Milli− Inches Millimeters

Fractions Decimal meters Fractions Decimal
43/64 0.6719 17.06 59/64 0.9219 23.42
11/16 0.6875 17.46 0.9252 23.50
0.6890 17.50 15/16 0.9375 23.81
45/64 0.7031 17.86 0.9449 24.00
0.7087 18.00 61/64 0.9531 24.21
23/32 0.7187 18.26 0.9646 24.50
0.7283 18.50 31/32 0.9687 24.61
47/64 0.7344 18.65 0.9843 25.00
0.7480 19.00 63/64 0.9844 25.00
3/4 0.7500 19.05 1 1.0000 25.40
49/64 0.7656 19.45
0.7677 19.50
Drill Sizes
Table 23

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