* T.0. 1F-86K-3 HANDBOOK STRUCTURAL REPAIR INSTRUCTIONS USAF SERIES F-86K AIRCRAFT THIS PUBLICATION REPLACES T.O. 1F-86K-3 DATED 22 APRIL 1955 PUBLISHED UNDER AUTHORITY OF THE SECRETARY OF THE AIR FORCE ok: SACTO UTHO 10/4/57 750 16 AUGUST 19571.0, 1F-86K-3 Reproduction for non-military use of the information or illustrations contained in this publi: cation is not permitted without specific approval of the issuing service (BuAer or USAF) The policy for use of Classified Publications is established for the Air Force in AFR 205-1 and for the Navy in Navy Regulations, Article 1509. ‘Te aero iodine pages revit, added or dled by the cutrot revision. "ADDITIONAL COPIES OF THIS PUBLICATION MAY BE OBTAINED AS FOLLOWS: Usar Ip acordance with Techaical Order No. 005-2 Ba SE See eae eee oriole, Var NaS Gan Bigg, Cally NAS: Seat, “Wiahs ASD, or ting faible mail and deal of dveibuio, se Naval Acrostic Publication ladex NavAer 00-500T.0. 1F-86K-3 TECHNICAL MANUAL STRUCTURAL REPAIR USAF SERIES F-86K AIRCRAFT ats LATEST CHANGED PAGES SUPERSEDE THE SAME PAGES OF PREVIOUS DATE BANS PUBLISHED UNDER AUTHORITY OF THE SECRETARY OF THE AIR FORCE ‘AF. SMAMA 6/280-c00 16 AUGUST 1957 CHANGED 20 MARCH 19591.0. 1F-86K-3 Reproduction for nonmilitary use of the information or illustrations contained in this publication is 90¢ per Riked lout speciic approval of the isuing service (BuAcr or USAF). The policy for use of Classined Panta clams established forthe Ait Force in AER 205-1 and for the Navy in Navy Regulations, Ardcle 3509. LIST OF EFFECTIVE PAGES TOTAL NUMBER OF PAGES IN THIS PUBLICATION 15.524 CONSISTING OF THE FOLLOWING: inser LATEST CHANGED PAGES, DESTROY SUPERSEDED PAGES. NOTE: ‘The portion ofthe ex afeced by he changes indicted bp ven Hoe inthe oer magia of the Por. Page tase Page Tasue Page Issue No No No, smite... 20 March 2-344 thru 2-345, . 9 January 1958 SRS UTUTIIIII zo aren 19592935 0.01 9 Jamary 1989 PSII oiantary 198002736 hed 2-40" 222 2 rteinal Wehrw wid 222 Noriginat 2a ATT po ntareh 1959 Bebtnrw 11022025221 Original 2-49 thre 2-46" 277 Original 20 ses ‘0'biareh 1950 2-46A thru 2-408. . 0 January 1059 1-204 thew 9 Jauary 1959 Seal thrw 1-32 02-2 Original #17324 thru 1-328, | 20 ‘March 1980, 1-39 thew 1-50. => seus thru 1-16 Sure + ua 2 ‘ etcatda thew ‘ T-UI8F .... +. 20March 19894 118 III go mares 1959 relao 12LIDIII SS Ortgimat 4 12104 tw’ 4 T-120B +... + 20 March 19590 4-3 2 original stead ee sLL1 01 20 Mareh 1989 4304 thru 4-30B. | 8 Jaiuary 1950 Tela thaw i-t6 2122. Original = 31 9 January 1050 sIU26a thew 32 TQ6B ...... 20March 1959 4 1-32 thre 1-338 Original Zimm23... Original 240 thru 2-11.11 20'Mareh 1050 212 tara 2-13" ¢ ‘Original Die eee... 8 January 1059 21S thea 2-21.02 Original Dan e122 0 March 1959, 120 March 1959, aoa3 2222 origina ce Original 2a ITIL 20 Maren 1950 ‘20 ntarcn 1989 2-25 thw 3-26" 11... «Original eee OFiginal 2°27 thru 2.29221 9 Yanuary 1959 Original 2-0 thru 2-84 221.22. Original Original Th strides pages changed, ded of deleted by the cure cha "ADDITIONAL COPIES OF THIS PUELICATION MAY BE OBTAINED AS FOLLOWS: USAF ACTIVITIES —In accordance with T.0. 005-2. USAF NAVY ACTIVITIES—Sbmis ropes to nearet supply poin lined below, using form NavAer 4a: NASD, Philadelphia, Pa; NAS, Alameda, Calif; NAS, Jacksoaville, Fla; NAS, Norfolk, Va.; NAS, San Diego, Calif. NAS, Seatle, Wash ASD, NSC, Guam, For listing of available material and details of distribution sce Naval Aeronautics Publications Index NavAer 00-500. A Changed 20 March 19595 LATEST CHANGED PAGES SUPERSEDE THE SAME PAGES OF PREVIOUS DATE BANS faire * 1.0. 1F-86K-3 TECHNICAL MANUAL STRUCTURAL REPAIR USAF SERIES F-86K AIRCRAFT PUBLISHED UNDER AUTHORITY OF THE SECRETARY OF THE AIR FORCE A, MAMA 9779900 16 AUGUST 1957 CHANGED 5 JUNE 19597.0. 1F-86K-3 Reproduction for nonmilitary use of the information oF itustations contained in this publiation is not pes. Fite thot specie apprnal of she iain service, Baer or USAF). The pole for use of Chsed Bublicadons is edablished forthe Ais Force in AER 205-4 and forthe Navy ia Navy Regulations, Artie 1309. INSERT LATEST CHANGED PAGES, DESTROY SUPERSEDED PAGES. Sh eeekes eee: 1100. LIST OF EFFECTIVE PAGES TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS NOTE: The portion ofthe text alfeced bythe changes i indeed br ent Hoe i be outer marine the pee 548 CONSISTING OF THE FOULOWING: Page Tssue Page Iasse Page Issue No. No. Ne erie Sse 1989 2-2. AAD vg e es 9 January 1950 * Bune 1989 2-25 thru 2-08 Car thew 50 1 Original ie 271 tora 2-03 42504 thru 4-808 | 30 March 1950 “ 2.30 thra 2-84 HBL eevee ee se 25 dune 1959 £2. 1 20 March 1959 9 damuary 1959 June 1950, Aon eirw't-ids | ‘anuary 1959 1-106 thru Orie! 1-1068 5 June 1989 2-107 tara 1-108... Original 1-100 vara 1108, 20 March 1959 sali... fees Original 112 tire L112... . 20 March 1959, A-13 thru T-iie | ‘Or : ‘2h Rare 1980 ‘rw 3-382 5112 Original ‘Original 1 ab biareh 1059 9 January 1989 20 March 1980 Original 20 March 1959 ‘20 biareh 1059, a Ori 8 sanuary 1959 1 Sisune 1050 woes Ort ‘20 Mares 1959 i Samuary 1080 sees Original 28 dune 1058 0 March 1959 Original 2 thre 2-0 Deh Original 240 thre 2-1 90 March 1988 dada 213.222... Original Ct 5 June 1959 Para : Lies Original 25 9 Sasuary 1959 “218 oie Original 2.17 thre 3-18)! ‘Ori 3 January 1080 210A thru 2-108. | 22 8 June 1088 8 January 10959 eee Original 12 S'sune 1050 £90. 11 8 June 1959 The anise indicates pages changed, ade, oF deleted by the cute change, "ADDITIONAL COPIES OF THIS PUBLICATION MAY BE OBTAINED AS FOLLOWS: USAF ACTIVITIES —ta accordance with T.0. 005-2. NAVY ACTIVITIES. Submit request to nearest supply point lined Below using form NavAer 140; NASD, "Philadelphia, Pa; NAS, Alameda, Cali; NAS, Jacksonville, Fla; NAS, Noefoll Va; NAS, San Diego, Calif: Wash; ASD, NSC, Guam, ‘and details of distribution see Naval Aeronautics Publications Index NavAer 00-500. Changed 5 June 1959 USAF For listing of AeT.0. 1F-86K-3 TECHNICAL MANUAL STRUCTURAL REPAIR USAF SERIES F-86K AIRCRAFT 15 LATEST CHANGED PAGES SUPERSEDE THE SAME PAGES OF PREVIOUS DATE BAM PUBLISHED UNDER AUTHORITY OF THE SECRETARY OF THE AIR FORCE AF SANA NOV 8, 6 16 AUGUST 1957 CHANGED 25 SEPTEMBER 19591.0. 1F-86K-3 eptucn fo moulin ofthe inormation or tao onan in hit publican ot pr sited without speci approval of the iwing service (BuAcr or USAT), The policy for ase of Clos Publications is etablished or : in Navy Reg the Aic Force in AFR 205-1 and for the Navy ia Navy Regulations, Article 1509 INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES. TOTAL NUMBER OF PAGES IN THIS PUBLICATION 15 562,CONSISTING OF THE FOLLOWING: Page Teme Page asue Page Isove Ne. No. No. site .....- 25 September 1959 2-3 thru 2-9 6.0.20. 10F . 6... 5 June 1950 SAC LILI 25 September 1959 3-10 thru 2-111! 2b aren 1059 40g this cil ls. Odamuary 1989 2-12 thra 2-13 ihre wir 0202222" Original 2014 siT'taru 1-26. 25 September 1989 2-15, ce Original 228 amuary 1980 4a Orginal = 12 | "al 19 January 1989 HS thru 1A Original 2086 2222 LLTII I Suma tgso 413 chew ee Ogi $20 wes 5 20 March 19580 2aT thew 218222011." riginal © 46a thru 4-18B. | |S game 1090 120A 222051 o January 1988 218A reeves ccs. Syme 988 TIT dune 1959 +1208 the 2188 220121 “zs'September 1959 files Original 1-20H . 28 September 1959 2-10 thru S21. 4-20 unra 221. 22 b'Yanuary 1058 Lead thru 1-28... Original = 2-22 seve sl2 4-22 tara $230. 22222 Original Sez0 meu 1230. 2222 S'yune 1059 2028 2222222255 ginal 42304 thru 4-903, | 9 January 1089 AeSh oar 2°92 2222 originat 2-24 222DDIIT TT ao aren tose Zain St 8 January 1959 1.324 thre 2:25 thew 3-26.112.. Original 4292 thru 4-36... Original 4-$2B. «4. 20 March 1959 2-27 thru 2-20.11. 9 January 1050 4-37 thru 88D... S june 1059 439 tora i50270 6. Original §— 2-80 thru 2-84. 11ST Original = £89 sees 351 thru 1253.8 January 1050 2-344 thru a0 11 sa So January 1959 2-94B..... 4.9 January 1959 4-al thru 4-47) 1.54 thre cee Original = 238 02111) 8 January 1959, 1-62 thru 1-635. 9 January 1950 2-36 thew 34121112 Original Le sanuary 1950 2742... 212 Bb March 1959 wise Original 2248 thru 3-43. 11) Original ‘September 1959 2-46A thru 1075 thru 1-76. Original 2-485... .. 9 January 1950 sor thee 24 111 T lo January 195940828 thru 48D. Some 1959 1-808... 25September 1959 24d thw 3-491... Original = 483 5 June 1959 $81 thru 1-82. 68 Original «2-50 eee eet 2 2 a Vanuary 1050464 thre 61222222 Originat A163 ores. /OJanuary 1989 2-81 TIIT ao March 19894262 01 0 aren 1089 ree thru 1-99.17" Original 2-53 thee 542211 Original ‘as’ september 1989, A100... 20 March 1050 2-55 ereeve sess @ January 1960 coer es Original $o10) thew T1082." Original 2-56 thew 35022222 “Original 2s'Sepiember 1959 17106 the 260 eee. 2 20 Mare 1999 25 September 1989 1-106B...... 20 March 1969 2-604. 0272111! damuary 1959 “6-2 ihrw 6210 Je Original A107 new T-i08 2. <"Original 2-608 thr 2-805! ."S june 1980 P-L thru 122A | 28'Sepiemnber 1059 35109 thru BOL veveeeeess cle. Original Pees dane 1989 A-110B.... + 20 Maren 1959 2-62.°2222°7 01 Toyanuary 1980 9s s Soll lL1LL Le Original Lue Original 2-88 thru 270. 27200" Original «142222271111 o yanuary 1980 12102 ehrw 2270 thea 2708.27! Sse 1959 5 thew 7 coe Original 1-112D...... 20 March 1960 . Original Tra Tod 227 9 Yanuary 1089 18 thew tie | “Original 2 20 Maren 1980 1 thru 8-28 | 125 September 1959 WAT... 5 20'Maroh 1959 63-1 thru 9-28 «125 September 1950 8-3 thru 8-14 J Original PMB. eee Original 8-9 TT 20 Mazen 1989 “9-1 thru Sed. | -25'Seplember 4050 128A thre 304 tra 3-2! | «Original 9-5 thru 8.26 |... +, Original L-UIGF...... 20 March 1959 3-28A thru 8-288. 20 daren 1959 +101 thru 10-2. 25 Sepiember 1989 AeHI8..6 0007 20 meareh 1959-28 ee! 20 March 1989 “1003 thru 10-4 Wrag0s 222 T Le Originat 390 tar $95 oe origina «_ Deleted. . 25 September 1959 121204 ‘iew! 3-36 thru 3-88. <7 20 Maren 1059 10-8 thru 19-78, .- Original L120D......., SJune 1959 #41... Z8'September 1989 Ari thruA-0.+. Original rt. Cao arch 19800 4-z imac 11S Original oTndexsT thru Yei2 thew 1-136 |. "Original 4-4 thru 4-44 | 138 Septemiver 1989 Tndex-6'. ..28 September 1959 121364 thew AaB ee cree sles 20 March 1989 ° 1-1268 29 March 1989 4-5 thru £6 11 8 January 1959 . srt thru 1-186 ‘Original «= 4-Tanra 4-0-2221 Original *2-1 thru 2-28. 28 September 1959 49 thru 4-108... @ January 1959 {The americas pages changed, ede, of dled by the caren cha ADDITIONAL COPIES OF THIS PUBLICATION MAY BE OBTAINED AS FOLLOWS: USAR ACTIVITIES —In accordance with T.0, 00-52, USAF NAVY. ACTIVITIES.--Submit request to nearest supply point listed below, using form NavAee 140; NASD, Philadelphia, Pa; NAS, Alameda, Calif; NAS, Jacksonville, Fla NAS, Nodfolks Va; NAS. Son Diego, CALE Aviation Supply’ Annex, NSD, Guam. For listing of available material and details of distribution sce Naval Aeronautics Publications Index NavAer 00-500, 4 Changed 25 September 19591.0. 1F-86K-3 TECHNICAL MANUAL STRUCTURAL REPAIR USAF SERIES F-86K AIRCRAFT 5 LATEST CHANGED PAGES SUPERSEDE WN THE SAME PAGES OF PREVIOUS DATE sh potic® PUBLISHED UNDER AUTHORITY OF THE SECRETARY OF THE AIR FORCE A. SMAMA 97279069) 16 AUGUST 1957 CHANGED 9 JANUARY 19591.0. 1F-86K-3 Reproduction for ogmilitary ut of he infomation or ilusrations conics in dis publition i nt ee sited wi roval of the issuing service (BuAer or USAF). The policy for use. of Classlied Publications is elablsal Yor the it Fore ie ABH 205-1 and for the Navy Rad) Regulations, Reticle 1503. INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES. LIST OF EFFECTIVE PAGES TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS ..424 ., CONSISTING OF THE FOLLOWING. NOTE: The ponion ofthe tat alee by the changes i indicted y's were line inthe outer mars ofthe page Page Issue Page Issue No No. 4-52 ‘amuary 1959, 55 thre cee Original S-1eare 5-8 II origina Sct tru 6-10 22222222 Original Ta thre 1-3 Original STA eee 2211 8 Fanuary 1959 8 thr 126 ‘Origizal 262222 9 Satuary 1950, Original IU Original Original SEETITY original shndexs1 ths Thdex-8 «9 January 1950 164 thew ict 222° GFiginat my Dieu eid lL! eae 28 thw 3-253 2-24 : 235 thw 3-26 2-27 tru 2-29 2-30¢thra 2-34 | 234A thrs 2-348. 2-35 : 2°36 thr 2-48"! p24eA thru 2-485. <6 sanuary 1850 aan. 9 Jamary 1959 ‘Original 3 Sauary 1959 el ‘yasuary 1958 aeas tard 210° 2222 Original azo uwrs 4oan 121 ‘January 1990 am tra 230 12 Original 4-304 thru 4-808. - 9 January 1950 MOL eee eae oo 8 January 1958 aoa thre 423711 Original 4-38 thru 4-388". 9 January 1950 4-39 thru 4-40. 9 January 1986 aeaninra 81221. Original 4 The asterisk indicates pages changed, added, or deleted bythe caren change "ADDITIONAL COPIES OF THIS PUBLICATION MAY BE OBTAINED AS FOLLOWS: USAF ACTIVITIES—In accordance with T.O, 00-52 USAF NAVY ACTIVITIES—Submit request to nearest supply point listed below, using form NavAer 140; NASD, ‘Philadephia, Pe: NAS, Alameda, Calif; NAS, Jacesoovlle, Flas NAS, Nosfolie Va NAS, San Dish, Calif ‘Wash; ASD, NSC, Guam, tnd details of distribution see Naval Aeronautics Publications Index NavAer 00-500. A Changed 9 January 1959” T.0. 1F-86K-3 TECHNICAL MANUAL STRUCTURAL REPAIR USAF SERIES F-86K AIRCRAFT 6m LATEST CHANGED PAGES SUPERSEDE THE SAME PAGES OF PREVIOUS DATE PAN, a: 16 AUGUST 1957 AP SMAMA Mar 6, CHANGED 22 JANUARY 19601.0. 1F-86K-3 Reproduction for aoamilitary use of the information or illustrations contained in this publication is not per imited without specie approval of the isving acrvice (BuAer or USAF), ‘The policy for vs of Clesiied Publications is extablished for ‘i § Pin Navy Ree the Air Force ia AFR 205-1 and for the Navy in Navy Regulations, Article 1509. INSERT LATEST CHANGED PAGES. OESTROY SUPERSEDED PAGES. LIST OF EFFECTIVE PAGES NOTE: Tie prion of se wx lcd hy se change faded by TOTAL NUMBER OF PAGES IN THIS PUBLICATIONS 604,CONSISTING OF THE FOLLOWING: Page fasue Page lasse Page Tsou 22 Jan 60 1 22 Jan 60 «Original 20 Mar 59 20 Mar 59 + Original ‘a2 dan 60 «Original 20 Mar 50 26 Sep 58 Original ‘22 Jan 60 28 Sep 50 20 mar 59 Tordan 88 + Original 9'Jan 80 1 5.dun 50 Lo dan 59 "22 an 60, Original oan 89 {Original ‘22 dan 60, 5 Jun 58 8 Jun 59 + Original 1 9'Fan 89 {original "n2"tan 60 BRe8 HES: hon gReareat $106 thew 4-308 ag a i 20 tare 421 || 22 ena £30! C304 thru 4-300. ea Van 58, 32 thes TT onigina 3 thr 4-884. 2222211 8 aun 59 MBB eel 00022 a2 Jan 60 ‘aac thew 4-380. 1 1."§ Jon 89 15 un 89 Logan 58 Original ‘25 Sep 69 «Original 30 mar 50 25 dun 58 9 Jan 50 do tian 59 San 58 8 Jun 59 Original 20 Mar 59 125 Sep 59 Original ‘2 gan 60 TI! a2 3an 60 DIIIIE Zontetaa TILIDID as'sep so nett: 1104 thr 1-105 | 1406 thru 1-1068 1407 thew 1-108 1109 thru 1-108 i i i BEDEIE 113 thru 1-116 2272 tnrw 3-78 | Sdthw 3-28 | a 11244 thr 1-124 aaas. - II oniginal Sanam 60 +3-104 thra 3-101 I agkneo “3antaw 3-18 eéiogesanenenenenn £88 [ADDITIONAL COPIES OF THIS PUBLICATION MAY BE OBTAINED AS FOLLOWS: USAF ACTIVITIES—In accordance with T.0. 0052. USAF NAVY ACTIVITIES. Submit request to nearest supply point listed below, using form NavAer 140; NASD, Philadelphia, Pa NAS, Alameda, Calif; NAS, Jacksoaville, las NAS, Norfolk, Vaz, NAS, San Diego, Cali; Aviation Supply Annex, NSD, Guam. For listing of available material and deuails of distribution see Naval Aeronautics Publications Index NavAer 00-500 Changed 22 January 1960Seepeseee iginal ‘25 ep 50 25 Sep 58 ‘Original "22:Jan 60 Ct balan 60 11 aa an 60 1 aa han 60 . 22 Jan 60 1.0. 1F-86K-3 -————____1IST OF EFFECTIVE PAGES (Continued). Changed 22 January 19601.0, 1F-B6K-3 -———IT OF EFFECTIVE PAGES (Continued) —__—. ‘This page lotentionally let blank © Changed 22 January 19601.0, 1F-86K-3 CONTENTS TABLE OF CONTENTS Page INTRODUCTION. 2 ee HOW TO REVISETHIS HANDBOOK... 2 2 2 wl Section \ GENERAL . c4 eee el Section WING GROUP. 2 2 2 ee . 24 Section w EMPENNAGE GROUP». 2. 2) ee ee ST Section w FUSELAGE GROUP. 2 2 2 2 ee At Section v TANDING GEAR Cet scl Section vi ENGINE. ©... Do OT Section vu PAMRICS AND] FOAGTICS ge tet tar 721 Section vin EXTRUSION CHARTS. ce OT Section GEAR-UP LANDING DAMAGE... 2. 7. OT Section x TYPICAL REPAIRS © 2. 10 Appendix \ REPAIR MATERIALS... ce AT Appendix GLOSSARY OF AIRPLANE AND AIRPLANE REPAIR TERMS... 2A-1 ALPHABETICAL INDEX . bo ee etext Changed 22 January 1960 i1.0. 1F-86K-3 ‘This page intentionally left blankf u 1.0, 1F-86K-3 INTRODUCTION INTRODUCTION ‘The Structural Repair Handbook is designed to guide personnel in handling, evalu- ating, and repairing crash-damaged airplanes. The primary purpose of this handbook is to reduce the time that airplanes remain in the crash-damaged category. This time can only be reduced with the help and cooperation of the personnel who do the work. Evaluation of the damage serves a twofold purpose. First, the mature and extent of ‘damaged will determine the type of facility necessary for its repair. Airplanes damaged beyond the repair capabilities of the base where the damage occurred will have to be transported to a facility capable of making the repairs. Transit time and distances will be cut by scheduling the airplanes to the proper repait bases. Second, by knowing the condition of the airplanes and the parts damaged, the time and effort required to get replacement parts will be reduced to a minimum. Repairs outlined provide structural maintenance coverage for the airplane. The repairs are not based on any certain extent of damage, since the scope of possible damage is s0 broad. It is impractical to outline procedures because, in many cases, it will be nec- essary to alter the repair to suit the specific situation. The material requirements, river specifications, etc, are the minimum allowable. For repairs of important primary struc- ture, when excessive alteration of the repair would be required, the struccural repair officer should be consulted. Repairs for the individual components are grouped together within each section of the handbook (for instance, in the wing group, all repairs for the slat will be found in one group). Each group is preceded by an illustration showing the structural re- pair breakdown of the component and the repairs for that component. The structural repair breakdown is listed in the repair index in the front part of each section. Indi- vidual repairs may also be found by using the alphabetical index in che back of the book. Typical repairs covering all sections of the airplane are in Section X. Personnel using this handbook must bear in mind that there is no substitute for sound judgment. This handbook can be used as an aid and a guide, but putting what is in the handbook into practice is the responsibility of those who are responsible for the status of the airplane.INTRODUCTION TO HANDBOOK 1.0, 1F-86K-3 USE OF HANDBOOK... OSE OF ALPHABETICAL USE OF MASTER REPAIR INDEX {THIS INDEX 1 AW ALPHABETICAL UST OF ITEMS CONTAINED IN THIS BOOK. ‘BOLDFACE TYPE DENOTES PAGES OW WHICH ILUSTRATIONS APPEAR. {THE MASTER REPAIR INDEX SEPARATES THE MAIOR ASSEMBLY INTO COMPONENTS AND REFERS TO SUBINDEXES FOR THESE COMPONENTS. evan sumvaenes ust oiawind numsens, Maer, ano RepAin 7 TYPICAL REPAIRS “HORE MUMBERS FOR COMPONENTS OF MAJOR ASSEMBLES. ga TYPICAL REPAIRS ARE DESIGNED FOR MIDE AND VARIED ‘APPLICATION THROUGHOUT THE AIRPLANE.1.0, 1F-86K-3, INTRODUCTION TO HANDBOOK Let the handbook help you AANDUNG DAMAGED AIRPLANES Sea ame Wa aon se PREM FORA ‘ \ j ° f . INSPECT AND EVALUATE DAMAGE CAREFUL INSPECTION OF THE AIRPLANE. WILL DETERMINE THE EXTENT OF DAMAGE, GEAR-UP LANDING IWS SCION QNCEINS powact 74a Is EXPECTED FROM GEAR-UP LANDINGS.HOW TO REVISE THIS HANDBOOK 1.0. 1F-86K-3 STEP 3. (CONTINUED) The “A” page shows what the revi reissue or basic issue of the book was made. Each revised or deleted page by page number and date. Page Date of Latest Ne. ‘ewe . 30 June 1955 ii chrough vi... 18 March 1955 “ 30 June 1953, 2 18 March 1953 93 dirough § °°... 30 June 1955 “through 16 |. is March 3 date on the lower right- or left-hand corner. vised page carries the revi Replace all eld end like-numbered pages in your book, with the new revised pages. Insert all “AY "pages in alphabetical order following ih same basic page number. Example: Pages 45A, 45B, etc, should follow page 45. Text changes or additions on each new revised page are indicated by a black vertical line placed opposite the text lines changed. Read the lines of text so marked, and compare them with the same lines on the old page. This will give you ind quick method to determine a change in information. The remainder of the new page will be identical to the page it is replacing. bottom spacing of each new pat may be necessary to delete whole pages of Pe replaced with new pages. In this cose, you will find such a notation on the re page which precedes or follows the pages requiring deletion. For exampl fion on page 44 may say that pages 45 through 49 are deleied. If any i ‘appeared on the pages being deleted, the figure numbers of the delete: ‘are also given in the deletion notation. Remove these pages from your handbook, «as they contain obsolete informati When’ @ complete set of pages are issued, this means the entire book has been reissued. A note appears on the new title page to that effect. In this case, remove the old pages from your book and insert the new pages. 1E-86K-2-0-61.0, 1F-86K-3 HOW TO REVISE THIS HANDBOOK [How To (RE The airplanes you are working with do not remain static in design. Improvements and design changes are taking place through the entire life of the airplane. Is ANDBO To reflect these changes, this handbook is constantly being revised. It is either revised or reissued every 90 days. The following steps will make sure you have the latest handbook and the proper method of keeping it revised. STEP 1 Make sure you have the latest issue of the book including all ot 7 To check this, refer to T. 0. 0-1-1, Numerical ublications. Find Model -B6K Series listing of Technical Orders. Here you will find the basic Issue date for this 100k, the date of the lat ind the T. O. number and title of the book. The dates given should be identic 6 appearing on the title page of your book. If they are net, your book is not up-to-date. STEP 2 Notify your Engineering Officer if your book is not up-to-date. He can obtain the latest Issue of your handbook by ordering. STEP 3 ‘When you receive revisions for your handbook, be sure you insert them in your book as soon as possible and properly. Includes the basic pul 1¢ lower right-hand corner, with the latest date immediately below the basic date. 18 MARCH 1955 REVISED 30 JUNE 1955 1 -86K-2-0-6Section 1 1.0, 1F-86K-31.0. 1F-86K-3 Section 1 SECTION I GENERAL Contents TYPE OF CONSTRUCTION ...... GENERAL ARRANGEMENT AND FEATURES: MAJOR ASSEMBLIES .. ACCESS PROVISIONS AIRPLANE DIMENSIONS ....—---~ AIRPLANE STATIONS CATEGORIES OF REPAIR CAPABILITIES . ‘TYPES OF REPAIR AND CLASSIFICATION OF DAMAGE ONE-TIME FLIGHT DAMAGE — —— NEGLIGIBLE DAMAGE .. PERMANENT REPAIRS... ‘TEMPORARY REPAIRS AERODYNAMIC SMOOTHNESS CAUSES AND TYPES OF DAMAGE CRASH HANDLING AND SHIPPING EMERGENCY REMOVAL OF AIRPLANE FROM RUNWAY vol 20 LIFTING AIRPLANE WITH WEB SLING ne) LIFTING AIRPLANE WITH SLING 0.0 : : A2t LIFTING AIRPLANE WITH PNEUMATIC LIFTING BAGS .cc.cc00rncecnenon Bh REMOVING AIRPLANE FROM CRASH SITE soo seed 23, ‘TRANSPORTING AIRPLANE AND COMPONENTS even 23 DAMAGE EVALUATION AND INSPECTION CRITERIA .. AS FORCES ON AIRPLANE IN FLIGHT 1:35 STRESSES AND STRAINS .... = : 1:35 INVESTIGATING DAMAGE .. ~ 1.38 1-39 INSPECTION TECHNIQUES SKIN BUCKLING .. — AIRPLANE ALIGNMENT ‘AIRPLANE REFERENCE DIMENSION CHECK FIRE DAMAGE INSPECTION —— CORROSION . : TYPES OF CORROSION oe vs 7 CORROSION-PREVENTIVE MEASURES ... . AO MATERIALS USED IN REPAIR ..... ~ : ALUMINUM ALLOYS ‘TITANIUM . : . CORROSION-RESISTANT STEEL — : — CHROME MOLYBDENUM STEEL : een HONEYCOMB SANDWICH PANELS ' vo — CONTROL SURFACE STATIC BALANCE see : STATIC BALANCE EQUIPMENT enna BZ STATIC BALANCE CHECK = . _— BALANCING FLIGHT CONTROL SURFACES : od 83 Changed 25 September 1959TO. 1F-86K-3 Contents SEALS AND SEALANTS cocoon TYPES OF SEALANTS 7 SEALING PRESSURIZED AREAS LIQUIDTIGHT SEALING FUMETIGHT SEALING SEALING FAYING SURFACES ..... EXTERIOR WATERTIGHT SEALING ‘SELF-CONTOURING SEALING PADS GENERAL SHOP PRACTICES .. AERODYNAMIC SKIN FILLER SHEET METAL THICKNESS «00.0 RAM-COIN DIMPLING FILLING DIMPLED HOLES ‘STOP-DRILLING ..... = BOLTHEAD IDENTIFICATION BLIND FASTENERS ... THREADED INSERTS LOCATING BLIND HOLES WITH HOLE FINDER LOCATING SKIN TRIM LINES ‘SPECIAL TOOLS ' HAND-FORMING 7 CHARTS AND TABLES SHOP MATHEMATICS TYPE OF CONSTRUCTION. ‘The North American F-86K Airplane is a single-place, swept-wing, all-weather fighter-interceptor, The wing, fuselage, and empennage are of all-metal construction, with the exception of some laminated glass cloth used in wing tips, vertical stabilizer tips, and radome, The fuselage is a semimonocoque structure in two sections, with a break point at fuselage station 279.3 for removal and servicing of the General Electric J47 series turbojet Access doors in the fuselage make most areas accessible for repair and maintenance. The 35-degree swept-back wing is made up of a center-section panel and ‘two outer wing panels. The outer wing panels are tied to the center section through matching bolting bats. Four-point suspension is used to attach the wing to the fuselage. The wing center section and outer panels to wing station 126 contain fuel cells. Most of the box section of the wing from this point outboard is inacces- sible for repair without removing the wing outer panel lower cover. The empennage consists of a 35-degree swept-back all-movable horizontal stabilizer, a 35-degree swept-back fixed vertical stabilizer, and a movable rud- der. Conventional ib-and-skin type structure is used for all parts. The landing gear is a fully retractable cycle type. In retracted position, the gear is completely enclosed inside the fuselage and wing and covered by ing doors. Details of the structure for each part of Changed 22 Jenvary 1960 the airplane are contained in corresponding sections of the handbook, GENERAL ARRANGEMENT AND FEATURES. MAJOR ASSEMBLIES. See figure 1-1, ACCESS PROVISIONS. See figures 1-3 through 1-5, AIRPLANE DIMENSIONS. See figuee 1-2. AIRPLANE STATIONS. LOCATING AIRPLANE STATIONS, In modern day airplanes ic is becoming more and more difficule to locate specific points on the airplane. With milled skin, canted ribs and frames, etc, the counting of ribs and frames to find a particular location is not practical. For this reason, basic reference planes have been set up for the fuselage, wing, and empennage, 121.0. from which all other dimensions are established. (See figure 1-6.) For purposes of explanation, a line repre- senting an edge view of a reference plane is referred to asa plane. All measurements are taken in inches. FUSELAGE STATIONS. The fuselage is divided hori- zontally along the Zf plane by units referred co as water planes, vertically along the Xf plane by buttock planes, and longitudinally along the Yf plane by fuselage sta- tion planes. The ¥F plane is used as a fuselage reference plane. Water plane zero, which falls on the fuselage reference plane, and station zero are arbitrarily defined by design, Buttock plane zero is defined as the vertical plane of symmetry. Water planes below the fuselage reference plane are negative (—); those above it are positive (++). Stations forward of station zero are nega- tive (—); those aft of it are positive (+). Buttock planes Changed 25 September 1959 1F-86K-3 Section t to the left of buttock plane zero are positive (+); those to the right of it are negative (—). Fuselage stations are normal (at right angles) to the fuselage reference plane and (0 the plane of symmetry. They are measured i increments of inches forward and aft of station zero. Fuselage canted stations are diagonal to the fuselage reference plane. They are designated by their point of intersection with the fuselage reference plane. WING STATIONS. Wing stations (Xw planes) are normal to the wing reference plane and che 25-percent plane. Wing station zero is where the 25-percent plane, projected, intersects fuselage buttock plane zero. The 25-percent plane (Yw~0) is vertical and normal to the ‘wing reference plane (Zw = 0). It was originally located by drawing a line through points which represent one quarter of the straight-line distance from -the wing 1-28Section 1 1.0, 1F-86K-3 EXPLODED VIEW OF AIRPLANEREF No. PART NO. 165-4205 165-42141 165.31463 165-3147 16531802 190-53009 207-3181 201-3104 165-31010 165-34011 165-34301 165-10003 165-1004 165-1005 165-13001 165-13039 165-14002 207-3301 165-33011 165-17002 165-1703 165-17004 165-17005 173-14009 165-14003 me Shroud Assy Shroud Assy Eng Med Shroud Assy’ Eng Access Fus Duct Door Canopy Assy Ejection Seat ‘Windshield Radar Access Door Radome Nose Gear Inst! Nose Wheel Door Cer Wing Fairing Ctr Wing Fairing Ctr Wing Fairing Ctr Wing Assy Ateaching Joine ‘Wing Outer Panel ‘Main Wheel Door Main Gear Inst Slat Assy Slac Assy Slat Assy Slat Assy. Leading Edge Assy Front Spar 1. 0, 1F-86K-3 REF NO. 26 27 28 29 30 31 32 33 4 35 36 37 38 39 4 4 a B “4 45 46 4a 48 Key to Figure 1-1 PART No. 165-1405 165-1414 165-16001 177-18001 165-14006 207-3102 207-31401 165-4001 207-31604 165.310124 190-2301 165-2331 157-2401 157-24501 165-25010 1365-25020 1365-25015 165-31609 165-21811 1365-21501 165-21464 165-316126 165-39002 190-39002 Section | me Rear Spar ‘Wing Tip Ailleron Assy Flap Assy ‘Trailing Edge Assy Forward Fuselage Intermediate Fuselage Power Plant Insel Aft Fuselage Door Assy Dorsal Access Vertical Stab Vertical Stab Tip Rudder Assy Rudder Trim Tab Fillet Assy Cone Assy Fillet Asy Aspicator, Horizontal Stab Tip Horizontal Stab Stab Beam Fillet Assy Speed Brake ‘Speed Brake Honeycomb 13Section | 1.0, 1F-86K-3 Figure 1-2. Airplane Dimensions1.0, 1F-86K-3 Section | BLUEPRINT NUMBERING os ‘ll parts within Components of fate uses the civplane will be numbered within the seme series of _— numbered dash number, end right-hond ‘with even-numbored dash numbers. ne ee Silo 31-00 snes. TyS6o sees Wo 00 sens ae Figure 1-24. Structural Drawing Numbering System Changed 22 January 1960Sec 1.0. 1F-86K-3 ‘This page intentionally left blank 1-48 Changed 22 Janvary 19601.0. 1F-86K-3 008 cours on FUSELAGE ACCESS PROVISIONS, ‘it Ben Y Z = Ss1.0, 1F-86K-3, FUSELAGE ACCESS PROVISIONS verat] IN ACCESS DOE amoe vaste) cow Eon CONTE, Section 1 Toeaime ACESS DoOH- ‘seceews inte Aces DOOR iimoe rarer) Aff RADAR ACCESS DOOR Nose oHan MECHANISM Le Fasten Betws S ” LN fastens) tsoano oun acess 0008 ot (sew. cane —S fapan ruesunzATion SIAtiOn i co ZX pment ACES DOOR g c . LQUIBOARD GUN ACCESS PANE, enw). A) rout Reta 4 Sows) E SHOCK STRUT AIRINGS NOSE LANDING GEAR WHEEL WEL AND ACCESS HOLS an eee Inventek CHANGEOVER RELAY ACCESS HOME ‘eto stoves SeconARY vee {ainioc rare Nos oeas ook nme es acess 9008 ss cnt (ON CONTROL EMERGENCY FURL Rieutavor wsctews) cuan Aces (aintoe rs voutace ska Access Door (ARLOC FASTING stanon 2793 sunrace conrton, cABte Sgeakne atts Coon Tex Nook ontrorwer neat netess6008 sae can nora tur acersronerer fhintoe aston) (seeewst seyomauuc onoune Ts, ne acetss Book (Rivoe rasrenens) tate Sten ‘tt (Same tice) fakes Figure 1-3. Forward Fuselage Access Provisions (Sheet 2 of 3)FUSELAGE ACCESS PROVISIONS,Section I 1.0, 1F-86K-3 WING ACCESS PROVISIONS incu ‘atts anaes} ‘won meetal Ba oc = = wey en es (aires aston toto vanes rseo--00-188 Figure 1-4. Wing Accoss Provisions (Sheet 1 of 2)1.0, 1F-86K-3, Section I” WING ACCESS PROVISIONS io LES Figure 1-4. Wing Access Provisions (Sheet 2 of 2)Section | 1.0, 1F-86K-3 AFT FUSELAGE ACCESS PROVISIONS Ee1.0, 1F-86K-3 Section 1 “ACCESS DOORS AND PANELS io =F S ae g@5 4 n we wee se tee? Tt ii = & = e a * wf Bo nw Figure 1-5A. External Removable Doors and Panels (Sheet 1 of 3) Changed 22 January 1960 1-1081.0. 1F-86K-3TO, 1F-86K-3 Section | ACCESS DOORS AND PANELS =o \\ Oo 2 " Figure 1-5A. External Removable Doors and Panels (Sheet 3 of 3) Changed 22 January 1960 1-106Section | 1.0. 1F-86K-3 ro DRAWING. sein NO. No. GAGE MATERIAL 1 190-3104 Radar Equiment Access 0032 7075-76 Clad 2 1265-51091 Hydraulic Fitting Access 0.066 2024-74 Clad 3 16531270 Shock Serut Filler Access 0.066 7075-76 Clad ‘4 20731108 Flectronic Control Amplifier Access 0032, 7075-T4 Clad 5 165.31005 Marker Beacon Receiver Access (LH doot) 0032 7075-16 Clad Radar Equipment Access (RH door) : 6 165.31006 Radio Equipment Access (LH door) 0.032 7075-76 Clad TIFF Radar Access (RIT dooc) U 165.31007 Primary Inverter Access (LH door) oo32 7075-76 Clad ‘Secondary Inverter Acces (RI door) 8 205-31008 Engine Control Theus Selector Unit Access (LH door) 0.032 7075-76 Clad Radio Access (RH door) ° 207-31108, Forward Fuselage Accest 0.060 2024-74 Clad 10 165.51018 [Nose Gear Hydraulic Stering Shutoff Valve Access 0032 7075-76 Clad a 205-31016 Canopy Emergency Release Access 0032 2024-T4 Clad 2 165.73338 Oxygen Filler Access 0.064 — 2024-T4 Clad B 16531017 Engine Electronic Control Access 00% 7075.76 Clad “ 16531062 Radar Test Set Access 00% 7075-76 Clad 15 165.31094 Nose Gear Emergency Hydraulic Accumulator Access 0.032 2024-74 Clad 16 21361040 Inboard Gun Access Panet 0.090 RES ” 207-61041 ‘Outboard Gun Access Panel 0.00 cRES 18 205-31012 Expended Ammunition Door 0.032 2026-74 Clad 9 2085-31013 Expended Ammunition Doot 0.040 2026-74 Clad 20 207-3188 External Canopy Locking Access 0032, 7075.76 Clad a 165-4805 Fuel Filler Access ost — 2024-74 Clad 2 165.48526 Single-point Refueling Nozzle Adapter Access 0032 7075-76 Clad 23 165.31068 Fool Probe Access ore 2024-T4 Clad ™ 17331063 Life Accelerometer Access 00st 7075-76 Clad 2s 165-1070 Taxi Hook Emergency Release Access 0.00 2024-74 Clad 26 165-3103 Hydraulic Tank Filler Access ous 2024-74 Clad 7 165-3104 Engine Control Emergency Fuel Regulator Access 0.040 2024-44 Clad 8 165.31045 Anti-icing Line Access 0040 2026-74 Clad 29 190-3107 Generator Lead Access 0032 7075-76 Clad 0 205:31010, Step Access Door 0032 2024-74 Clad 3 16548405 uel Filler Access 0.06% 2026-74 Clad 3 165-4905 Fuel Tank Filler Access 0.081 2024-T4 Clad 33 165.3100 [Hydraulic Ground Test Connection Access 0.080 2024-74 Clad Pa 165-3103 Foselage Break Hydraulic Disconnect Access 0040 2024-74 Clad 35 16551071 Surface Conteol Cable Disconnect Access of 202474 Clad 36 165.51044 Fuel Probe Access 0072 7075-76 Clad 7 1653141 Engine Forward Steady-support Bolt Access 0.072 2024-74 Clad 38 207-31404 Emergency Fuel Regulator Access 0.090 7075-76 Clad 9 16531069 Spark Plug Access ost 7075-T6 Clad © 16551039 Engine Duct Disconnect Access cost 2024-T4 Clad Inverter External Power Access “a L7731035 Engine LH Access 00% 202674 Clad Engine RH Access a 165-31035 Fact Booster Pump and Drain Access 0032 7075.76 Clad ‘Drawing numbers are for reference only, ond 1-100 Key to Figure 1-54, Changed 22 January 1960 ‘be used for ordering parts.1.0. 1F-B6K-3 tem DRAWING. sxiw No. Noe GACr MATERIAL 6 165-31029 Lower Aft Fuselage Access oot 2024-74 Clad “« 16531072 Variable nozsle Actuator Ait Duct Access 0032 6osi-T6 4“ 213-1000 ‘Wing Center Section Fairing Afe Cover 04 202474 Clad 46 165317114 Antiicing Access oot 2024T4 Clad a 165.31023 Fuel Vent Line Access 0032 2026-74 Clad “ 165-5102 Rear Fuselage Attachment Bolt Access 0032 2024-4 Clad ” 165.31020 ‘Rear Fuselage Auachment Bolt Access 0032 20244 Clad 30 165-5175 Fireighting Access 0.064 2024-74 Clad st 165.31026 ‘Thermocouple Connector Lead Access 04 7075-76 Clad 2 168-31027 Engine Support Trunnion Access ois CRES ‘Dorsal Fis Stabilize Sector Accest 33 165316126 Heat and Vent Empennage Antcicing Line Access 0032 2024-74 Clad 4 191-23428 0.064 707576 Clad 55 16523751 Radder Trim Tab Electrical Disconnect Access oot 20244 Clad 56 165.2514 Drag Chote Door Linkage Adjustment Access 0051 202674 Clad 5 165.31087 avery Access 0032 2026-74 Cad ss 165.31060 Emergency Battery Access 0032 2024-T4 Clad » s4o-1doce Remote Compass Transmitter Access 0.032 2024-14 Clad © 1365-14059 Aileron Mechanism Access 0051 7075.76 Clad 6 rsL141s5 ‘Teannion Pin Access 0.020 CRES e 165.14548 Gun Camera Access 0.066 7075-76 Clad 6 20531011 Fuselage Equipment Access 0032 2026-74 Clad 6 165.14268 Aileron Hydraulic Access 0.040 2024-74 Clad 6 165-4285 Ailecon Hydraulic Access 0.00 2024-74 Clad 6 165.10260 Drop Tank Connection Access 0.00 2024-74 Chad o 165.14609 Aileroa Hydeaulic Line Access 0.040 7075-76 Clad 6s 165-14608 Aileron Seal Access 0.06¢ 7075.76 Cad © 165-1446 Flap Actuator Access 0.032 2024-74 Clad 7 151-18030 Flap Roller Access 002s 2024-74 Clad n Ho-021 Flap Roller Access 002s 2024-74 Clad 2 16514199 Pitot Tube Drain Access 0.020 RES * 16-1002 Booster Pump Drain Access ot 2024-74 Clad Flow Control Valve Drain Access Fuel Tank Sump Desia "4 165.10017, Afterburner Pump Drain Accest 0.060 2026-74 Clad Hydraulic Accumulator Valve Accest 7% 1265-10013 Hydeautic Access 0.000 2026-74 Clad %6 165-1002 Hinge Access 00 202674 Clad ” 16510020 Fairing 0032 202474 Clad 7” 205-10006 ‘Main Fuel Pump Access 0.040 2024-74 Clad ” 165-1000 Right Side Panel 0.000 202474 Clad #0 1773108 Single-point Refueling Equipment Access 00st — 202474 Clad a r7s108, External Power Receptacle Access 0.066 2024-74 Clad 2 16531034 Fuel Tank Sump Desia Access 0032 2024-74 Clad ‘Drawing numbers are for Changed 22 January 1960 Key to Figure 1-5A (Continued) ronce only, ond are net to be ured for ordering -10ESection | 1.0. 1F-86K-3 ‘This page intentionally left blank 1-10F Changed 22 January 19601.0. 1F-86K-3 leading edge to the wing trailing edge. The wing tral- ing edge was relocated in the original design of the F.86 wing, and the 25-percent plane on the present F-6K wing is actually an arbitrary reference plane which can only be located by given distances from the leading or trailing edge of the wing, In figure 1-6, the straight-line distance aft of the leading edge is given at the inboard and outboard tcims. Since wing stations zero is a theoretical plane inside the fuselage, a known location on the wing is necessary 2s, 4 starting point when locating a wing station, In figure 1-6, the intersection of the 25-percent plane with the skin trim line at the wing tip has been selected as a point from which to measure. ‘Wing leading edge stations (Xw planes) are normal co the basic leading edge. Wing leading edge station “o” is in the fuselage, where a line drawn from wing station “0” and normal to the 25-percent plane intersects the leading edge plane. As with the wing stations, an exter- ‘nal known point is needed from which to measure. The skin trim line at the tip leading edge has been selected as this point. (See figure 1-6.) AILERON AND FLAP STATIONS. Because the aileron and flap stations are normal (at tight angles) to their hinge centerlin, they may be measured along their hinge centerline from the inboard skin trim lines. Flap stations are normal (at right angles) to theic hinge centerlines. Station zero is where the flap hinge center- line, projected, would intersect fuselage buttock plane VERTICAL STABILIZER STATIONS. Vertical stabili- zer stations are parallel to fuselage water planes, with stations “0” at water plane 24.75, In general, the ribs are canted stations normal to the hinge line (80-percent plane), and are designated by the station in which they intersect the hinge line. To find a station on the vertical stabilizer, construct a line on the stabilizer, perpendicular to the fuselage reference plane. Stations are normal to this line, In figure 1-6, the skin trim lines where the 80-percent plane crosses the lower edge of the radio antenna cover have been taken as a reference point from which co measure. HORIZONTAL STABILIZER STATIONS. Horizontal stabilizer stations are parallel co fuselage buttock planes. In general, the ribs are canted stations normal to the 72-percent plane, and are designated by the station in which they intersect the 72-percent plane, To construct a line representing the 72-percent plane, take 72 percent of the straight-line distance (parallel to the fuselage buttock planes) of the stabilizer chord at two points. Draw a reference line spanwise chrough these points. Section | To locate stations along the reference line, construct « perpendicular line to fuselage buttock plane “0.” (A straightedge placed along the aft outboard tips of che stabilizer will do.) Stations are normal to this line, and measured at the 72-percent plane. The skin trim line at the stabilizer tip, where crossed by the 72-percent plane, is given in figure 1-6 as a known reference point from which to measure. CATEGORIES OF REPAIR CAPABILITIES. Repairs may be divided into two categories: those which ‘would require extensive disassembly of the sirplane to gain access to the damaged area, and those for which the damage is readily accessible. Also, repairs may be categorized by the extent of damage, and by che mate- rials available for the repair, The ability of an organiza- tion to repair an airplane will depend on the manpower, tools, and materials available. The repairs in this hand. book are divided into the two categories. Category “A” repairs are minor (squadron or base shop) repairs; category “B” repairs are major (depot) repairs. It is assumed that at depot level both category “A” and repairs would be performed. It is also assumed that squadron or base shop, with adequate fa power would perform certain category TYPES OF REPAIR AND CLASSIFICATION OF DAMAGE. ‘The repair and damage in this handbook is broken down into four basic types: one-time flight damage, negligible damage, permanent repairs, and temporary repairs, ONE-TIME FLIGHT DAMAGE. One-time fight damage is damage that can be left as, is or which requires only minor repaits to allow the airplane to be ferried co an overhaul base. Flight restric. tions will be placed on the airplane as follows: Maximum airspeed 300 knots Maximum G-load 36-16 A placard is placed in che cockpit that reads as follows: FLIGHT OF THIS AIRPLANE IS RESTRICTED TO A MAXIMUM AIRSPEED OF 300 KNOTS AND A MAXIMUM G-LOAD OF +3°G" -1°G."7.0, 1F-86K-3 Section 1 MEASURING THE AIRPLANE Figure 1-6, Locating Aicplane Stations Viz1.0, 1F-86K-3, Section NOTE stotions which are referenced tion chart are those which have o por in the descrip ticular function. Figure 1-7. Airplane Stations—Wing (Sheet 1 of 2)Section 1 1.0, 16-86K-3, WING STATIONS om [ceveHune AUERON GE ROAD [ENTERING AIGION INGE AND ACTUATOR] we. aaa BeSEE eee [ABBREVIATIONS NOTE Stations which ore referenced inthe description ‘those which have a particular func tion ¥060-3-0-88 Figure 1-7. Airplane Stations—Wing (Sheet 2 of 2)Section | 1.0, 1F-86K-3 EMPENNAGE STATIONS Figure 1-8. Airplane Stations—Empennage 115Section f 1.0, 1F-86K-3 FUSELAGE STATIONS vf, WANS Stations which are refer ed in the description1.0. 1F-B6K-3 Section 1 REPAIR DRAWING EXPLANATION — A “el teter | +t4 +tollot + 7 cos +t _H10Hloth + = cs wt ~ ExaiehE:t TYPICAL FASTENER SYMBOLS USED ON ALL REPAIR DRAWING. ‘added festener used to accom- fastener through sure rounding skin ond structure esteners required will ISOMETRIC VIEW Figure 1-94. Repair Drawing Explanation (Sheet 1 of 2) Changed 22 January 1960 1-168Section | 1.0. 1F-86K-3 REPAIR DRAWING EXPLANATION ‘The letters next to the section arrows indicate or rel section view details. hidden part or structure rom the side from which the _—--— Phontom lines are used either fe indicate the posi- iow af the repair pert when in pl ide how repair parts are exploded from emetic view. parts on the isometric ISOMETRIC VIEW Figure 1-9A. Repair Drawing Explanation (Sheet 2 of 2) 1.168 Changed 22 January 19601.0, 1F-86K-3 Each section of the handbook contains a one-time fight dliagram which indicates the area of the airplane that may be damaged but that will not prevene the airplane from being flown to a repair base. Repair to these areas is not required for ferry flight. One-time fight repairs are included in the handbook and will be used as indi- cated on the individual repaie. NEGLIGIBLE DAMAGE. Negligible damage is chat damage which can be per- mitted to exist as is, or which may be corrected by simple procedure, without restricting flight. In most cases, a corrective action must be taken to Keep the dam- age from spreading, Frequent inspection of areas with negligible and minor damage is necessary to ensure that the damage does not spread. Some examples of negligible damage are: NEGLIGIBLE DAMAGE—DENTS. Minor dents with no damage to structure which may be left as is, and large dents after being bumped back to ‘mold line dimension, provided there are no sharp dents, or wrinkles. NEGLIGIBLE DAMAGE—SCRATCHES AND DENTS. A damage which does not go through the protective coat- ing of the material, or through the cladding on alclad sheet, is not considered a scratch. To determine whether the damage has gone through the cladding, thoroughly clean the surface with methyl ethyl ketone and apply a 10% solution of sodium hydroxide to the damage area. If the damage has gone through the cladding and into ‘parent material, a black or dark brown discoloration will appear. This solution should not remain on the area for Jonger than two minutes because of its corrosive action, ‘The solution must be thoroughly washed from the area with water, Scratches or nicks are not considered negligible until after they have been reworked by blending or other prescribed methods. Scratches or nicks may reduce the ‘cross sectional area of a material and produce localized stress concentration. This condition can lead to fatigue cracks and possible failure of the component. (See fig- ure 1-10.) Blending of scratches or nicks is the process of smooth- ing out the damage area. To blend properly, a fine grit (400 or finer) abrasive cloth or paper, of aluminum wool should be used. Do not use crocus cloth ot steel ‘wool since it tends to cause corrosion. Scratches or nicks should be smoothed out with the abrasive to remove all damage, The reworked area must be kept as small as possible. (See figure 1-11.) Section | Figure 1-10. Stress Concentrations at Nicks ‘and Scratches In certain highly stressed areas, it is necessary (0 use 12 dye penetrant check after blending to reveal any cracks which may be undetected. (Refer to “Penetrant ‘Method of Inspection.”) After blending, the damage area must be chemical film treated (refer to “Corrosion Rework by Chemical Film Treatments") and painted. Limitations regarding the length and depth of scratches and nicks vary in different locations throughout the limitations are shown on the illustra- NEGLIGIBLE DAMAGE—CORROSION DAMAGE. Corrosion damage which does not exceed the pre- scribed limits for scratches and nicks may be con- sidered negligible if the corrosion is cleaned out and the area chemical film treated (refer to “Corrosion Rework by Chemical Film Treatments") and painted. NEGLIGIBLE DAMAGE—CRACKS. This type of damage usually originates at edges, holes, for points where concentrated loads are applied of abrupt changes occur in the cross-sectional area, Limita- tions regarding length of crack, distances from other damages, specific locations, ete, vary ia different loca tions throughout the airplane. These limitations are shown on the illustrations of negligible damage for the various areas, All cracks will be stop-drilled at each end. NEGLIGIBLE DAMAGE—HOLES. Cleaned-up holes that do not reduce the cro area of a material enough to introduce prohibitive stress, ‘or which do not interfere with the function of a compo- 17Section | NOTE blending scratch of nick in machined bar or extrusion may be accomplished in same Figure 1-11. Blending Scratches neat (including pressurized areas and fueltight areas) may be considered negligible. Limitations regarding size of holes, distances from other damages, etc, vary in different locations throughout the airplane. These limi- tations are shown on the illustrations of negligible damage for the various areas. PERMAMENT REPAIRS. Permanent repairs are those which put the airplane, both structurally and aerodynamically, back to its otig- inal configuration. Permanent repairs may be made by one of the following methods: 1, Patching the damage. Repairing damage by patch- ing is to completely encircle or bridge the damaged area of a component with splice material of the same type as the original. Holes and cracks which exceed the prescribed limitations for negligible damage in a given area may be repaired by this method. Filler plates may be used for bearing surfaces or for returning the part to its original contour when necessary. 2. Repairing damage by insertion. Damage repair- able by insertion is that damage which can be repaired by splicing in a section of matetial to replace the damaged material, The section used for insertion should be identical in shape and type to che damaged part. The inserted material is fastened into place by a splice. The splice connection ¢o the ofiginal structure provides for load transfer between the original structure and the inserted section. 3. Repair of damage by replacement of parts. The part is generally replaced when a repair cannot be made by practical means. When replacing a damaged component or part, care should be taken to avoid damage to adjacent or attaching structure. 1.0, 1F-86K-3, [Te TEMPORARY REPAIRS. ‘Temporary repairs are repairs that retum che airplane to its original configuration structurally, but do not fully restore it aerodynamically. External (scab) patches, protruding head fasteners, etc, are temporary repairs, (Refer to “Aerodynamic Smoothness.”) In spite of the undesirable effects of nonflush (temporary) repairs they are sometimes necessary to make airplanes available for flight in the shortest possible time. They are semporary repairs, however, and they should be replaced with permanent (flush) repairs as soon as possible. ‘When the wings, vertical stabilizer, or control surfaces have been repaired in any manner which could possi- bly affect flight characteristics, a test flight should be made to determine what fight restrictions are necessary. AERODYNAMIC SMOOTHNESS. Modern sisplane specifications require that the airplane exterior surfaces be of extremely smooth construction to obtain design performance. The structural repairman ‘must keep this in mind when making repairs or changes. Figure 1-12 shows the ateas that are most critical aero- dynamically; however, smoothness of the entire airplane surface area is a critical requirement from the perform- ance standpoint. The seriousness of this condition is proportional to the airflow disturbance created. ‘The prime considerations of aerodynamic smoothness are parasite drag (drag caused by skin friction and nonlifting surfaces of an airplane) and the aerodynamic load distsibution on the surface. Any repair or change which increases parasite drag will reduce the top speed of the airplane. Also, combat range will be reduced, since more power, and thus more fuel, is required to maintain cruising speed. ‘Any change which disturbs the smooth flow of sir ‘over a critical susface will change the load on that surface, as well as increase the drag, This effect is greatly increased at transonic and supersonic speeds because of shock wave formation in these speed regions. Since, in most cases, a shock wave results in a radical change of load distribution and increased drag, @ patch that will cause no difficulty (disturbance) at low speed ‘may become critical when a shock wave is produced by this patch in the transonic and supersonic speed regions. If this flow change occurs on the wing, a wing-heavy condition proportional to the amount of disturbance will result. If this condition is on the vertical stabilizer, a