300/300LW Maintenance Manual (Rev A38)

51-00-00-001 (Rev Feb 1/09)

STRUCTURES - DESCRIPTION AND OPERATION

Being of semionocoque construction, the Super King Air Model 300 fuselage is pressurized to the skin between bulkheads at stations 84.0
and 347.75. All skin, bulkheads and structure points, plumbing and wiring connections passing through a pressure wall, access doors,
windows, control cables and torque shafts are sealed to minimize air leakage. Although the wing center section is an integral part of the
fuselage, the wing panels outboard of the nacelles are removable. To provide a convenient stairway for boarding the airplane, the cabin
entrance door on the left side of the fuselage swings down. Emergency exits are installed on both sides of the fuselage just aft of the crew
compartment partition. Individual passenger seats are provided, and the front seats may be installed facing either forward or aft.

PRIMARY STRUCTURAL COMPONENTS

The following primary structural components are essential to the proper function of the airplane. Failure occurring to any of the
components would seriously endanger the safety of the airplane and/or the passengers.
a. Control systems.
b. Engine mounts.
c. Fittings.
d. Coverings of the fuselage, wings, tail surfaces and control surfaces.
e. Wing, tail surface and control surface spars.
f. Landing gears and support structure.
g. Auxiliary members used to straighten or support other members carrying direct loads.
h. Seat and seat support structure.

SECONDARY STRUCTURAL COMPONENTS

The following secondary structural components in the event of failure would require immediate attention, but would not necessarily
endanger the safety of the airplane and/or passengers.
a. Wing tips.
b. Fairings.
c. Nose cone.
d. Non structural doors and covers.
Note: See Figure 1 for locations of structural doors and fairings.
e. Furnishings and upholstery (excluding seats).

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 300/300LW Maintenance Manual (Rev A38)
51-00-00-001 (Rev Feb 1/09)

Figure 001 : Sheet 1 : Fig 1 - Doors, Plates, Covers and Fairings

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 300/300LW Maintenance Manual (Rev A38)
51-00-00-001 (Rev Feb 1/09)

Figure 001 : Sheet 1 : Fig 1 - Doors, Plates, Covers and Fairings

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 300/300LW Maintenance Manual (Rev A38)
51-00-00-201 (Rev Feb 1/09)

STRUCTURES - MAINTENANCE PRACTICES

STRUCTURAL REPAIR
Warning: Drilling, modification or any type of work which creates a break in the pressure vessel is considered the responsibility
of the owner or facility performing the work. Obtaining approval of the work is, therefore, their responsibility.
Minor repair to chem-milled skins may be accomplished, provided proper edge distances (twice the rivet diameter plus 0.06 inch) are
maintained between repair rivets and all points of change in skin thickness at points of transition between the original skin thickness and
the etched portions of the skin.
In general, structural repair methods used on the Super King Air 300 may be used in accordance with AC 43.13-1A: AIRCRAFT
INSPECTION AND REPAIR MANUAL and AC 43.13-2: AIRCRAFT ALTERATIONS MANUAL. Never make a skin replacement or patch from
a materials thinner than the original skin. The following considerations are recommended in addition to AC 43.13-1A: AIRCRAFT
INSPECTION AND REPAIR MANUAL and AC 43.13-2: AIRCRAFT ALTERATIONS MANUAL for repair of the pressure vessel of the Super
King Air 300.
Caution: In the pressurized area, all skins, formers, stringers, etc. are structural members and should be treated as such.
a. All lap joints, including patches, must have at least two staggered rows of rivets.
b. All repair material must be free of any defects such as nicks, scratches, etc. which can cause stress rises.
c. Never dimple a structural member by driving the rivet head into the part.
d. Do not countersink deeper than 75% of the material thickness.
e. Scratches in the outer windows of acrylic plastic may be removed with 400 to 600 grit sandpaper, providing that not more than 0.003
inch of material is removed. Polish the repaired area smooth with buffing compound. The minimum thickness of the crew compartment
side windows is 9/32 inch and for the cabin and baggage compartment windows, 7/32 inch. No crazing or cracks are permitted in the
pressure windows.
Note: The window repair above is for localized repair of individual scratches only and should not be performed over the
entire window.

METAL SKIN REPAIR IN PRIMARY STRUCTURE

Isolated dents to a depth of 0.250 inch are permissible on wing upper skins, providing all requirements except for the 10% of the area
rule of SKIN DENT LIMITATIONS - BOTH SIDEDS ACCESSIBLE are met. Fill the dents with aerodynamic smoother per REPAIR WHEN
ONE SIDE IS ACCESSIBLE.

METAL SKIN DENT REPAIR IN SECONDARY STRUCTURE

The following dent repairs can be made only to secondary structural skins specified under SECONDARY STRUCTURAL COMPONENTS,
51-00-00.

SKIN DENT LIMITATIONS - BOTH SIDES ACCESSIBLE

These limitations apply only to aluminum skins.
a. Dents do not exceed 0.125 inch in depth (Ref. Figure 201, Detail A).
b. Dents do not exceed 10% of total surface area in one square foot.
c. Dents are no closer than 0.50 inch to any rivet or structural area.
d. Sharp dents or penetration of skin is not permitted.

REPAIR - BOTH SIDES ACCESSIBLE

These repairs apply only to aluminum skins.
a. Remove finish from damaged area (Ref. Chapter 20-08-00).
b. Use a solid backup support and form-out dents to skin contour.
c. Inspect for cracks and uneven surfaces.
d. Dye penetrant inspect for cracks.
e. When a smoother surface is desired, apply a filler per SKIN DENT FILLER REPAIR.

SKIN DENT LIMITATIONS - ONE SIDE ACCESSIBLE

These limitations apply to aluminum skins that are accessible from one side.
a. Dents do not exceed 0.125 inch in depth (Ref. Figure 201, Detail A).

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 300/300LW Maintenance Manual (Rev A38)
51-00-00-201 (Rev Feb 1/09)

b. Dents do not exceed 10% of total surface area in one square foot.
c. Sharp dents or penetration of skin is not permitted.

REPAIR - ONE SIDE ACCESSIBLE

This procedure is applicable to aluminum skins when only one side is accessible.
a. Prepare and fill dent with aerodynamic smoother per SKIN DENT FILLER REPAIR.
b. After dent has been filled, inspect for smoothness.

SKIN DENT FILLER REPAIR

a. Sand area lightly with 400 grit sandpaper.
b. Clean area with methyl propyl ketone ( Item No. 38, Chart 1, 91-00-00) and dry completely.
c. Apply primer ( Item No. 182, Chart 1, 91-00-00) and dry for a minimum of five minutes. Wipe area clean with a dry cheesecloth.
d. Fill dented area with aerodynamic smoother ( Item No. 162, Chart 1, 91-00-00) per manufacturer's instructions.
e. After four hours at room temperature, sand area smooth.
f. Apply finish as required.

REPAIR OF FIBERGLASS COMPONENTS

Field repair of fiberglass should be limited to those areas where there will not be an excessive amount of heat. In areas where fiberglass
is used, with heat reaching a temperature near 300°F (149°C) or above, a special phenolic resin impregnated fiberglass is used. It is
recommended that these parts not be repaired unless there is a shop available which is equipped for this type of fiberglass work.
a. Large holes and cracks require that the damaged area be cut out and trimmed just beyond the area of damage (Ref. Figure 202). If the
parts are painted, remove the paint and sand that portion of the part extending at least 2 inches beyond the cutout.
b. On small holes or cracks, sand lightly using 400 grit sandpaper to remove any raised or rough surface.
c. Clean with methyl propyl ketone ( Item No 38, Chart 1, 91-00-00) and wipe dry.
d. Cut fiberglass plies equal to, or greater than, the number of damaged plies. The first ply should be one inch (1.0") wider and on inch
(1.0") longer than the damaged area. Each succeeding ply should be one inch (1.0") longer then the preceding ply and should overlap
the preceding glass cloth ply by 1/2 inch step on all sides.
e. Prepare the resin (Laminac 4116, Glidpol 1001, or their equivalent) for the patch in accordance with the manufacturer's instructions.
Make sure the your hands are free of oil, grease and dirt when handling the resin.
f. Apply an even coat of resin to the sanded area. Impregnate all three laminated glass cloth patches by laying the patches on clean
waxed paper and working the resin through the fabric with a 2 inch brush.
g. Place the large patch over the cutout area, working out all air bubbles and wrinkles. If the patch starts to sag, place a support behind
the repair area. Coat the support with automobile wax or cover with waxed paper to prevent the resin from adhering to the support.
Work out all air bubbles and wrinkles while installing the second patch over the first. Install the third patch over the second in the same
manner.
h. Brush the repaired area with an even coat of resin. After the patches have cured for the 24 hours at temperatures between 23°C
(75°F) and 66°C (150°F), blend the patch into the contour of the part with fine sandpaper. Prime and paint the repair to match the rest
of the part.

SEALING
The Super King Air 300 airplane is pressurized and sealing the skin, bulkhead seams, windows, doors, etc., is of prime importance.
Control cables and torque shafts have removable rubber seals. When making a structural repair or modification which creates a break in
the pressure vessel, the mating surfaces must be sealed with the proper sealer. All other components piercing the pressure vessel or
attached to it must be sealed with the proper sealers (Ref. Chapter 91-00-00). For effective bonding of the sealers, be sure to clean all
mating surfaces, mating parts and rubber seals thoroughly.

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 300/300LW Maintenance Manual (Rev A38)
51-00-00-201 (Rev Feb 1/09)

Figure 201 : Sheet 1 : Fig 201 - Skin Dent Limitations

FA51B
085472AA.AI

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 300/300LW Maintenance Manual (Rev A38)
51-00-00-201 (Rev Feb 1/09)

Figure 202 : Sheet 1 : Fig 202 - Fiberglass Repair

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 300/300LW Maintenance Manual (Rev A38)
51-00-00-201 (Rev Feb 1/09)

Figure 201 : Sheet 1 : Fig 201 - Skin Dent Limitations

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 300/300LW Maintenance Manual (Rev A38)
51-00-00-201 (Rev Feb 1/09)

Figure 202 : Sheet 1 : Fig 202 - Fiberglass Repair

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