STRUCTURAL REPAIR MANUAL

FASTENER INSTALLATION AND REMOVAL − METALLIC STRUCTURE

1. General

A. This topic gives general instructions for the installation and removal of
fasteners. Use the information in this topic together with any specific
instructions that are given in the manual, for example in repairs. If
the instructions in the repairs are different from those contained in
this topic, the instructions in the repairs must take precedence. Refer
to the subsequent list for special details:
− Fastener Selection Paragraph 3.,
− Lubrication of Fastener with Cetyl Alcohol Paragraph 4.,
− Bolts, Screws and Nuts Paragraph 5.,
− Rivets (Solid Rivets) Paragraph 6.,
− Pin (Threaded) Fasteners Paragraph 7.,
− Bull−Nose Fasteners Paragraph 8.,
− Taper−Lok Fasteners Paragraph 9.,
− Rivet−Blind (HUCK Blind Rivets) Paragraph 10.,
− Rivet−Blind (AVDEL Blind Rivets) Paragraph 11.,
− Rivet−Blind (IMEX) Paragraph 12.,
− Rivet−Blind (CHERRYMAX) Paragraph 13.,
− Rivet−Blind (CHERRYLOCK) Paragraph 14.,
− Pin (Swaged) Paragraph 15.,
− Bolt−Blind (Jo−Bolt/AVDEL/VISU/LOK) Paragraph 16.,
− Rivet−Blind (CHERRY Pull−Through) Paragraph 17.,
− Rivet (Solid) (CHERRYBUCK) Paragraph 18.,
− Rivet (Solid) (CHERRY E−Z BUCK Paragraph 19.,
− Drilling of Bolt Threads Paragraph 20,
− Double Countersunk Rivet Paragraph 21..
2. General Instructions

A. Replacement and Additional Fasteners

(1) Replacement fasteners must be of the same type, material and surface
finish as the original fasteners. They must also have the same sur

face lubricant if applicable (for example, lubricant).

(2) For repair work use fasteners that are the same as those in the ad

jacent area unless specified otherwise in the repair procedure. If
these fasteners cannot be identified contact AIRBUS.

(3) After fasteners have been installed their visible surfaces must be
fully cleaned. This is to make sure that the paint finish bonds cor

rectly, refer also to paragraph 2.J..

B. Oversize and Alternative Fasteners

(1) When a fastener hole is damaged or out of tolerance refer to Chapter

51−43−11, Fasteners Oversize − Metallic Structure.

(2) When the correct fastener is not available refer to Chapter 51−43−12,
Fastener Alternative − Metallic Structure.

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CAUTION: DO
NOT
USE
CADMIUM
PLATED
TOOLS
ON
PARTS
MADE
FROM
TITANIUM.
CAD
MIUM
PARTICLES
CAN
CAUSE
BRITTLENESS
AND
CRACKS
IN
TITANIUM.
LEAD,
SILVER,
ZINC
AND
TIN
CAN
CAUSE
THE
SAME
EFFECT
IF
THE
TITANIUM
IS
HEATED
ABOVE
120
°
C
(250
°
F).

C. Special
Tools

Where
special
tools
are
referred
to
in
this
chapter
these
must
be
used
to
install
and
remove
the
applicable
fastener.
These
tools
must
be
kept
in
good
condition,
and
the
fastener
contact
area
of
the
tool
must
be
clean
and
smooth.

D. Loose
Fasteners

(1) The
conditions
that
follow
can
indicate
a
loose
fastener:
− the
fastener
moves
in
relation
to
the
attached
material.
Deflection
of
thin
skins
can
be
seen,
− the
head
of
a
fastener
is
rolled
upwards
at
its
periphery,
− a
black
or
dark
grey
stain
adjacent
to
or
around
the
fastener
head.
The
stain
usually
takes
the
shape
of
a
streak
of
dirt
or
oil
behind
the
loose
fastener,
− broken
or
disrupted
paint
finish
over
fastener
heads.
(2) If
the
indications
do
not
clearly
show
that
a
fastener
is
loose
mark
a
red
line
across
the
head
and
the
adjacent
material.
Check
this
line
at
the
next
inspection.
A
loose
fastener
is
shown
when
the
line
on
the
fastener
head
does
not
agree
with
the
line
on
the
material
(Refer
to
Figure
1).
(3) Loose
fasteners
must
be
replaced,
except
for
some
fasteners
in
the
wingskins,
which
may
be
re−torqued.
Refer
to
paragraph
7.E.
for
de
tails
of
the
fasteners
that
can
be
re−torqued
and
for
the
correct
procedure
to
be
used.

E. Large
Repairs
When
it
is
necessary
to
do
a
large
repair
on
a
riveted
or
bolted
struc
ture,
the
structure
must
be
supported.
This
is
necessary
to
maintain
the
original
size,
contour
and
alignment.

F. It
is
important
that
the
correct
sequence
of
assembly
is
used
when
doing
a
repair,
this
will
make
sure
that
all
parts
are
correctly
aligned.
In
some
cases
it
is
also
necessary
for
accuracy
to
use
jigs
when
drilling
and
reaming
holes.

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Red Line Marking of Fastener Head

Figure 1

G. The Use of Washers under Nuts/Collars.

(1) The use of a washer under a nut/collar is only permitted in the
situations that follow:
(a) When used in the original construction.
(b) When called up in a repair procedure.
(c) When the use of an oversize bolt causes the nut/collar to become
threadbound.
(d) When a bolt of the correct grip-length is not available and an
overlength bolt must be used.
NOTE: The use of a washer under the nut/collar in the situations
given in paragraph 2.G.(1)(c) and 2.G.(1)(d) should be limÈ
ited as far as possible.
(2) One washer 1.6 mm (0.063 in.) thick, or two washers 0.8 mm (0.031
in.) thick, can be used. The use of one washer is preferred.
(3) A suitable standard washer is, e.g. NAS1149 (aluminum and steel maÈ
terial) or NAS1252 (aluminum material only). A washer with an inner
diameter close to the fastener diameter should be selected. For the
correct material refer to the Table 1 that follows:

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STRUCTURE MATERIAL UNDER WASHER WASHER MATERIAL

Aluminum Alloy Aluminum Alloy (Anodised)
Steel Alloy Steel Alloy (Cadmium Plated) (TemperaÈ
ture less than 200
C (392
F) Stainless
Steel (Passivated) (Temperatures above
200
C (392
F)
Stainless Steel, Titanium, Nimonic Stainless Steel (Passivated)
Steel
Washer Material
Table 1
WARNING: SEALANT (MATERIAL NO. 09-001) IS DANGEROUS.
(4) When it is necessary to use a washer, sealant (Material Number
09-001) must be applied to the structure mating surface of the washÈ
er to give a 'wet' assembly. Make sure that the sealant does not
get on the bolt threads or the contacting faces of the washer and
nut/collar, this could cause incorrect pre-tension to be applied to
the fastener.
H. At the appropriate stage of a repair or re-assembly, the correct sealÈ
ing/jointing compound must be applied if it is required (Refer to ChapÈ
ter 51-24-00).
I. Lubricated Fasteners
(1) Fasteners that are supplied lubricated with lubricant (CA) must not
be cleaned before they are installed. The torque values for these
fasteners has been calculated for the lubricated condition. After
installation the visible parts of the fastener must be fully cleaned
to ensure that the paint coating or sealant adheres correctly.
(2) It is a requirement that fasteners to be painted are cleaned with
cleaning agent's 'SOCOMOR DN 108' or industrial alcohol, after they
have been installed.
(3) It is a requirement that within the fuel tanks the visible parts of
these fasteners are cleaned with cleaning agents 'ARDROX PST 108' or
'SOCOSOLVE 446' after they have been installed. This will ensure that
the encapsulating sealant adheres correctly.
J. Chapter 51-42-00 gives a list of other chapters that are related to this
topic.
K. Cleanliness
(1) It is important that all unwanted materials and tools are removed
from the inside of the structure when a repair is completed. When
necessary this must be done before the final repair step.
(2) Failure to remove unwanted materials and tools could cause:

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- physical obstruction of moving parts,

- blocked drain holes, this could cause a build-up of waste fluids
and corrosion,
- corrosion caused by the effect of contact between dissimilar mateÈ
rials, this corrosion cannot always be seen at an early stage.
3. Fastener Selection
A. For the selection of fasteners refer to the type, material, protection,
diameter, length and, if necessary, to the oversize diameter. A specified
selection of the fasteners that are used on this aircraft is given in
this Topic in the fastener type paragraphs. Usually, fasteners are given
an identification number that show its type, material, protection, diameÈ
ter and length. The identification numbers of the different types of
fasteners are given in Chapter 51-40-12, Fasteners - Call-up and DesigÈ
nation.
B. The dash numbering system that is given in Chapter 51-40-12 is not apÈ
plicable to all fasteners. It is sometimes necessary to physically meaÈ
sure the required fastener.
4. Lubrication of Fasteners with lubricant
A. Repair Materials

ITEM NOMENCLATURE QTY MATERIAL/REMARKS

1 Lubricant AR Material Number 06-005 (Refer to
Chapter 51-35-00)
2 Cleaning Agent AR Material Number 11-002 (Refer to
Chapter 51-35-00)
3 Cleaning Agent AR Material Number 11-004 (Refer to
Chapter 51-35-00)
B. Lubrication Instructions
NOTE: The warnings given below apply to all the procedural steps in this
instruction where dangerous materials are in use.
WARNING: OBEY THE MANUFACTURER'S INSTRUCTIONS WHEN YOU USE THE CLEANING
AGENT (MATERIAL NUMBER 11-002). THIS CLEANING AGENT IS DANGERÈ
OUS.
WARNING: OBEY THE MANUFACTURER'S INSTRUCTIONS WHEN YOU USE THE CLEANING
AGENT (MATERIAL NUMBER 11-004). THIS CLEANING AGENT IS DANGERÈ
OUS.
(1) Preparation of the solution

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CAUTION: ONLY USE EQUIPMENT DESIGNED FOR THIS PURPOSE WHEN YOU PREÈ
PARE LUBRICANT SOLUTION (MATERIAL NUMBER 06-005). THIS SOLUÈ
TION IS A FLAMMABLE AND VOLATILE FLUID.
WARNING: CLEANING AGENT (MATERIAL NO. 11-002) IS DANGEROUS.
(a) To prepare the solution, mix 100 to 160 g (3.53 to 5.64 oz.) of
lubricant (Material Number 06-005) per liter (0.26 US gal.) of
cleaning agent (Material Number 11-002).
(b) Increase the temperature of the cleaning agent to between 49 and
54
C (120 and 129
F). This will make sure that the lubriÈ
cant (Material Number 06-005) is fully dissolved.
WARNING: CLEANING AGENT (MATERIAL NO. 11-004) IS DANGEROUS.
(2) Clean the parts with the cleaning agent (Material Number 11-004).
(3) Make sure that the parts are dry for the subsequent work step.
(4) Put the parts into the solution for approximately 2 minutes until
they are fully heated to a temperature of 49
C (120
F).
NOTE: Make sure that the parts are fully immersed in the solution.
NOTE: Keep the temperature of the solution between 49 and 54
C
(120 and 129
F).
(5) Remove the parts from the solution and shake them to remove the exÈ
cess fluid.
(6) Let the parts dry at a room temperature of 18
C (64
F).
NOTE: Do not handle the parts before they are fully dry.
(7) Do a visual check to make sure that the parts have a layer of luÈ
bricant all over them. A white film or a frosty aspect can be a reÈ
sult of the lubrication and is no cause to reject the part.
C. Service Life of the Solution
When a bath of lubricant is in permanent use, it is necessary to reÈ
place the solution after 30 days of continuous use. This is necessary
because of the possible contamination of the bath within this time. ConÈ
tamination can have an adverse effect on the solution. If used intermitÈ
tently, replace the solution after 50 hours or 60 days.
5. Bolts, Screws and Nuts
A. You may use power and/or hand tools to install and remove bolts, screws
and nuts. If a specific type of tool is required this will be given in
this topic where relevant.

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B. Install bolts and screws, where practical, with the head either uppermost
or foremost; as appropriate. In this position there is less risk of the
bolt/screw falling out if it becomes unsecured.
C. If not specified in a repair procedure, or by the original position of
the fastener, install nuts so that not less than 1/32 in. (0.8 mm) of
the bolt or screw extends through the nut. If the bolts or screws are
chamfered, the full chamfer must extend through the nut.
D. The torque values for fasteners are given in Chapter 51-49-00.
6. Rivets (Solid Rivets)
A. General
(1) For the installation of rivets the subsequent methods apply:
- the continuous squeeze riveting process,
- hammering with a pneumatic rivet gun,
- hand hammering.
The continuous squeeze method is recommended, but if this method is
not available then pneumatic hammering is the next recommended methÈ
od. The hand hammering method is used primarily for small repairs
that include very few rivets. It can also be used if other methods
are not available.
(2) A squeeze riveting tool makes the upset head of a rivet in a single
continuous action. For this effect the tools given below are necesÈ
sary:
- a hydraulically operated tool,
- or a pneumatically operated tool.
Static and portable types of tools are available.
(3) The rivet gun, used with a back-up dolly (bucking bar), forms the
upset head. This is known as reaction riveting. A correctly shaped
rivet set (rivet snap) is held in the gun and located on the
manufactured head end of the rivet. At the same time the dolly is
held against the end of the rivet to be upset. When the gun operÈ
ates, the dolly reaction to the pneumatic hammering of the gun forms
the upset head.
(4) Hand hammering is the basic method used to make the upset head of a
rivet. For this method do the subsequent steps:
(a) Support the manufactured head with a correctly shaped rivet set,
(b) Hold a dolly against the end of the rivet and hit it until the
upset head has the correct shape.
NOTE: Make sure that the hammer blows are heavy and as few as
possible because a large number of light blows work-hardens
the rivet. This can result in cracks in the upset head.

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(5) Make
sure
that
the
tools
are
sufficiently
large
to
quickly
form
the
upset
head.
The
subsequent
times
for
the
formation
of
the
upset
head
are
recommended:
− three
or
four
seconds
is
the
optimum
time,
− seven
seconds
is
the
maximum
time.

Hold
the
back−up
dolly
in
position
until
the
rivet
is
fully
installed.

(6) Before
you
install
rivets
in
the
aircraft
structure,
make
some
test
pieces
to
check
the
rivet
and
tool
precision.
These
test−pieces
must
have
the
subsequent
properties:
− for
testpieces,
the
same
type
of
material
and
thickness
as
the
part
to
be
riveted,
− for
rivets,
the
same
type
of
material,
length
and
diameter
as
the
rivets
to
be
used.

(7) Visually
check
rivets
before
they
are
installed.
If
a
rivet
appears
defective,
for
example,
deep
scores
or
indication
of
wire
drawing,
reject
it.
Some
apparent
defects,
for
example,
isolated
nicks,
abra
sions,
die
marks
or
fins,
are
acceptable
up
to
a
maximum
depth
of
0.10
mm
(0.004
in.).

(8) Rivets
made
from
2017A,
3.1324
and
2024
materials
must
be
kept
in
a
refrigerator
after
they
have
been
heat−treated.
Refer
to
Chapter
51−25−00
for
further
information.

(9) For
the
minimum
part
thickness
on
the
upset
head
side
of
7050
rivets
refer
to
Table
2.

Rivet
Diameter Part
Thickness
mm in. mm in.
3.2 1/8 1.2 0.047
4 5/32 1.2 0.047
4.8 3/16 1.8 0.071
5.6 7/32 2 0.079
6.4 1/4 2.2 0.087
Minimum
Part
Thickness
on
the
Upset
Head
of
7050
Rivets
Table
2
B. Installation
(Refer
to
Figure
2
and
Figure
3)
(1) Select
the
required
rivet.
If
for
any
reason
the
dimensions
of
the
required
rivet
are
not
known
proceed
as
follows:

(a) Accurately
measure
the
diameter
of
the
hole.
If
the
diameter
of
the
hole
is
within
the
tolerances
for
a
standard
rivet
(Refer
to
Chapter
51−44−00),
select
a
rivet
of
this
diameter.
If
the
diam
eter
of
the
hole
is
not
within
the
tolerances,
increase
the
di

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ameter
of
the
hole
to
suit
an
oversize
rivet
if
applicable,
or
the
next
standard
size.
(b) To
find
the
required
rivet
length,
accurately
measure
the
total
thickness
of
the
materials
to
be
joined.
Refer
to
Figure
2
to
find
the
correct
length
that
is
relevant
to
the
rivet
diameter
found
above.

NOTE: If
necessary,
the
rivet
can
be
shortened
to
the
required
length.
This
does
not
apply
to
titanium
rivets.

(2) Get
the
correct
rivet
set
and
back−up
dolly
for
the
rivet
type
and
dimensions
(Refer
to
Figure
3).

(3) Make
sure
that
the
hole,
and
if
applicable,
the
countersunk
portion
is
in
a
satisfactory
condition.
This
includes
clean
and
free
from
burrs.

(4) Clean
the
parts
as
necessary.
Apply
sealant
or
jointing
compound
if
it
is
called
for:
− in
the
related
repair
drawing,
− in
the
related
assembly
drawing,

or
is
normally
used
in
the
area
concerned.
NOTE: Install
the
rivets
before
the
work
life
of
the
sealant
or
jointing
compound
ends.

(5) Make
sure
that
the
contact
surfaces
of
the
parts
are
fully
together
and
that
there
are
no
gaps
between
them.
Gaps
will
prevent
the
cor
rect
forming
of
the
rivet
and
reduce
the
joint
strength.
(6) Align
the
holes
as
necessary
and
attach
the
parts
together
tempo
rarily.
Take
care
not
to
cause
damage
to
the
local
area
with
tools.

(7) Put
the
rivet
fully
in
the
hole.
For
this
operation
make
sure
that
the
parts
are
correctly
supported
if
necessary.

(8) Form
the
upset
head.
To
do
this,
use
one
of
the
methods
given
in
paragraph
6.A.
General.
Hold
the
tools
at
right
angles
to
the
sur
faces
do
not
compress
the
rivet
too
much.
If
the
upset
head
is
over
compressed,
it
is
possible
that
the
material
will
crack
(Refer
to
Figure
).
Refer
to
Figure
3
for
the
recommended
back−up
dolly
dimen
sions.
C. Inspection
(Refer
to
Figure
4,
Figure
5,
Figure
6
and
Figure
7)

(1) General

(a) This
section
gives
information
about
the
general
inspection
lim
its
for
solid
rivets.
(b) Make
an
inspection
of
the
rivets
after
they
are
installed.
This
is
necessary
to
make
sure
that
the
joint
is
tight,
and
that
the

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rivets
are
fully
seated
and
correctly
formed.
Make
sure
that
the
adjacent
area
has
no
damage
and
distortions.

Data
to
find
the
necessary
Length
of
Rivets
Figure
2

NOTE: For
additional
data
relating
to
Figure
2
refer
to
Table
3
thru
Table
7
that
follow
below.

Rivet
Nominal
Dia.
(D) Rivet
Protrusion
(C)
mm in. mm in.
2.4 3/32 3.6 0.141
3.2 1/8 4.8 0.189
4.0 5/32 6.0 0.236
4.8 3/16 7.2 0.283
5.6 7/32 7.3 0.287
Data
to
find
the
necessary
Length
of
Rivets
Table
3

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Rivet
Nominal
Dia.
(D) Rivet
Protrusion
(C)
mm in. mm in.
6.4 1/4 8.3 0.327
8.0 5/16 10.4 0.409
Data
to
find
the
necessary
Length
of
Rivets
Table
3
NOTE: The
above
given
table
is
applicable
to
2017A,
2024,
2117,
3.1124
and
3.1324
rivets

Rivet
Nominal
Dia.
(D) Rivet
Protrusion
(C)
mm in. mm in.
2.4 3/32 2.4 0.094
3.2 1/8 3.2 0.126
4.0 5/32 4.0 0.157
4.8 3/16 4.8 0.189
5.6 7/32 5.6 0.220
6.4 1/4 6.4 0.252
8.0 5/16 8.0 0.315
Data
to
find
the
necessary
Length
of
Rivets
Table
4
NOTE: The
above
given
table
is
applicable
to
cold
driven
2017
rivets.

Rivet
Nominal
Dia. Rivet
Protrusion Max.
Rivet
Protrusion

(D) (C) (Cmax)
mm in. mm in. mm in.
3.2 1/8 4.2 0.165 4.8 0.189
4.0 5/32 5.2 0.205 6.0 0.236
4.8 3/16 6.2 0.244 7.2 0.283
5.6 7/32 7.3 0.287 8.4 0.331
6.4 1/4 8.3 0.327 9.6 0.378
Data
to
find
the
necessary
Length
of
Rivets
Table
5
NOTE: The
above
given
table
is
applicable
to
cold
driven
7050
rivets.

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Rivet
Nominal
Dia.
(D) Rivet
Protrusion
(C)
mm in. mm in.
2.4 3/32 2.4 0.094
3.2 1/8 3.2 0.126
3.6 9/64 3.6 0.141
4.0 5/32 4.0 0.157
4.8 3/16 4.8 0.189
5.6 7/32 5.6 0.220
Data
to
find
the
necessary
Length
of
Rivets
Table
6
NOTE: The
above
given
table
is
applicable
to
Monel
or
Titanium
solid
rivets
for
installation
in
aluminum
alloy
structure.

Rivet
Nominal
Dia.
(D) Rivet
Protrusion
(C)
mm in. mm in.
2.4 3/32 1.9 0.070
3.2 1/8 2.6 0.102
3.6 9/64 2.9 0.114
4.0 5/32 3.2 0.126
4.8 3/16 3.8 0.149
5.6 7/32 4.5 0.177
Data
to
find
the
necessary
Length
of
Rivets
Table
7
NOTE: The
above
given
table
is
applicable
to
Monel
or
Titanium
solid
rivets
for
installation
in
steel
or
titanium
struc
ture.

Page
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 STRUCTURAL
REPAIR
MANUAL

General
Details
for
Back−up
Dollies
Figure
3

NOTE: For
additional
data
realating
to
Figure
3
refer
to
Table
8
that
follow
below.

RIVET
NOMINAL
DIAMETER RECOMMENDED
BACK−UP
DOLLY
WEIGHT
mm. in. kilograms pounds
1.6 1/16
(0.062) 0.75
to
1.25 1.5
to
2.0
2.4 3/32
(0.094) 1.0

to
1.5 2.0
to
3.0
3.2 1/8

(0.125) 1.5

to
2.0 3.0
to
4.0
3.6 9/64
(0.140) 1.5

to
2.0 3.0
to
4.0
4.0 5/32
(0.156) 1.5

to
2.0 3.0
to
4.5
4.8 3/16
(0.187) 2.0

to
2.5 4.0
to
5.0
5.6 7/32
(0.219) 2.0

to
2.5 4.5
to
5.5
6.4 1/4

(0.250) 2.25
to
3.0 5.0
to
6.5
8.0 5/16
(0.312) 2.75
to
3.5 6.0
to
8.0
General
Details
for
Back−up
Dollies
Table
8

Page
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51−42−11 Aug
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 STRUCTURAL
REPAIR
MANUAL

Upset
Head
Dimensions
Figure
4

NOTE: For
additional
data
realating
to
Figure
4
refer
to
Table
9
thru
Table
12
that
follow
below.

RIVET
NOMINAL
DIA RIVET
UPSET
DIA. RIVET
UPSET
HEIGHT
(H)

(D) (C)
MINIMUM MAXIMUM MINIMUM
mm in. mm in. mm in. mm in.
2.4 3/32
(0.094) 3.8 0.150 1.6 0.063 1.0 0.039
3.2 1/8

(0.126) 5.0 0.197 2.0 0.079 1.3 0.051
4.0 5/32
(0.157) 6.0 0.236 2.4 0.094 1.6 0.063
4.8 3/16
(0.189) 7.3 0.287 2.9 0.114 1.9 0.075
5.6 7/32
(0.219) 8.4 0.331 3.2 0.126 2.2 0.087
6.4 1/4

(0.252) 9.6 0.378 3.8 0.150 2.6 0.102
8.0 5/16
(0.312) 11.8 0.465 4.6 0.181 3.1 0.122
Upset
Head
Dimensions
Table
9
NOTE: The
above
given
table
is
applicable
to
2017A,
2024,
2117,
7050,
3.1124
and
3.1324
rivets.

Page
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 STRUCTURAL
REPAIR
MANUAL

RIVET
NOMINAL
DIA RIVET
UPSET
DIA. RIVET
UPSET
HEIGHT
(H)

(D) (C)
MINIMUM MAXIMUM MINIMUM
mm in. mm in. mm in. mm in.
2.4 3/32
(0.094) 3.1 0.122 1.3 0.051 1.0 0.039
3.2 1/8

(0.126) 4.2 0.165 1.8 0.070 1.3 0.051
4.0 5/32
(0.157) 5.9 0.232 2.1 0.083 1.6 0.063
4.8 3/16
(0.189) 6.8 0.268 2.7 0.106 1.9 0.075
5.6 7/32
(0.219) 7.3 0.287 3.2 0.126 2.4 0.094
6.4 1/4

(0.252) 8.3 0.327 3.3 0.130 2.5 0.098
8.0 5/16
(0.312) 12.3 0.484 3.8 0.150 3.2 0.126
Upset
Head
Dimensions
Table
10
NOTE: The
above
given
table
is
applicable
to
cold
driven
2017
rivets.

RIVET
NOMINAL
DIA RIVET
UPSET
DIA. RIVET
UPSET
HEIGHT
(H)

(D) (C)
MINIMUM MAXIMUM MINIMUM
mm in. mm in. mm in. mm in.
3.2 1/8

(0.126) 4.0 0.157 2.1 0.082 1.20 0.047
3.6 9/64
(0.140) 4.5 0.177 2.3 0.090 1.35 0.053
4.0 5/32
(0.157) 5.0 0.197 2.5 0.098 1.55 0.061
4.8 3/16
(0.189) 6.0 0.236 3.0 0.118 1.85 0.073
5.6 7/32
(0.219) 7.0 0.276 3.5 0.137 2.10 0.082
Upset
Head
Dimensions
Table
11
NOTE: The
above
given
table
is
applicable
to
Monel
or
Titanium
solid
rivets
installed
in
aluminum
alloy
structure.

RIVET
NOMINAL
DIA RIVET
UPSET
DIA. RIVET
UPSET
HEIGHT
(H)

(D) (C)
MINIMUM MAXIMUM MINIMUM
mm in. mm in. mm in. mm in.
3.2 1/8

(0.126) 4.3 0.169 1.25 0.049 0.85 0.033
3.6 9/64
(0.140) 4.8 0.189 1.5 0.059 0.95 0.037
4.0 5/32
(0.157) 5.3 0.209 1.7 0.067 1.1 0.043
Upset
Head
Dimensions
Table
12

Page
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51−42−11 Aug
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 STRUCTURAL
REPAIR
MANUAL

RIVET
NOMINAL
DIA RIVET
UPSET
DIA. RIVET
UPSET
HEIGHT
(H)

(D) (C)
MINIMUM MAXIMUM MINIMUM
mm in. mm in. mm in. mm in.
4.8 3/16
(0.189) 6.4 0.252 2.0 0.079 1.3 0.051
5.6 7/32
(0.219) 7.4 0.291 2.3 0.091 1.5 0.059
Upset
Head
Dimensions
Table
12
NOTE: The
above
given
table
is
applicable
to
Monel
or
Titanium
solid
rivets
installed
in
steel
or
titanium
structure.

(c) The
acceptance
Limits
given
in
Paragraph
6.C.(2)
are
applicable
to
those
rivets
that
become
part
of
the
structural
strength
after
installation.
For
example,
rivets
that
fasten
the
skin,
formed
and
extruded
sections.
The
acceptance
limits
of
rivets
that
are
not
so
important
shall
be
the
decision
of
the
inspector.
Example
of
such
rivets
are
those
used
to
fasten
identification
tags
and
instruction/information
labels.

(d) A
large
number
of
cracks
found
in
a
high
percentage
of
installed
rivets
indicates
that
the
rivets
have
not
been
correctly
heat
treated.
It
can
also
mean
that
the
installation
time
allowed
for
heat−treated
rivets
has
been
exceeded.
It
is
necessary
to
scrap
and
replace
all
of
these
rivets,
including
those
which
are
not
used,
from
the
batch
concerned,
or
have
them
heat−treated
again
(Refer
to
Chapter
51−25−00).
(e) Deformation
or
buckling
of
the
plating
is
only
permitted
within
the
limits
given
in
Chapter
51−10−00.
This
type
of
damage
is
a
result
of:
− too
much
tool
pressure,
− rivets
expanded
between
the
sheets,
− trapped
foreign
material.
(f) Make
sure
that
the
head
of
a
countersunk
rivet
is
level
with
or
slightly
above
the
surface
of
the
material.
Refer
to
Chapter
51−10−00
for
the
rivet
head
protrusion
limits.

(2) Acceptance
Limits
(a) Ovality
of
the
upset
head
is
permitted
if
the
dimensions
are
within
the
upset
diameter
limits.
These
limits
together
with
the
applicable
rivet
material
are
given
in
Figure
4.

(b) Eccentricity
of
the
upset
head
is
permitted
if
the
rivet
shank
cannot
be
seen
(Refer
to
Figure
5).
(c) Malformation
of
the
upset
head
is
permitted
(Refer
to
Figure
5)
if
the
shape
is
within
the
dimension
limits
given
in
Figure
4.

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51−42−11 Aug
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 STRUCTURAL
REPAIR
MANUAL

(d) Tool
impact
damage
around
the
two
heads
is
permitted
within
the
limits
given
in
Figure
5.
(e) Cracks
in
the
upset
head
of
aluminum
alloy
2017
and
2024
rivets
are
permitted
within
the
limits
given
in
Figure
6.
Cracks
in
the
upset
head
of
other
aluminum
alloy
rivets
are
not
permitted.
Cracks
in
the
structure
material
under
either
head
are
not
per
mitted.
(f) Cracks
in
the
heads
of
titanium
and
monel
rivets
are
not
per
mitted.

(g) Lack
of
head/material
abutment
(seating)
is
permitted
within
the
limits
given
in
Figure
7.

Page
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51−42−11 Aug
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 STRUCTURAL
REPAIR
MANUAL

Riveting
Defect
and
Acceptance
Limits
Figure
5

Page
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51−42−11 Aug
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Printed in Germany
 STRUCTURAL
REPAIR
MANUAL

Acceptable
Limits
for
Cracks
Figure
6

NOTE: Cracks
are
not
permitted
in
the
upset
heads
of
titanium
or
monel
rivets.

NOTE: For
additional
data
realating
to
Figure
6
refer
to
Table
13
that
follow
below.

RIVET
NOMINAL
DIA.
(D) MAXIMUM
WIDTH
OF
CRACK
(W)
mm in. mm in.
1.6 1/16
(0.062) 0.10 0.004
2.4 3/32
(0.094) 0.15 0.006
3.2 1/8

(0.125) 0.20 0.008
3.6 9/64
(0.140) 0.25 0.010
4.0 5/32
(0.156) 0.25 0.010
4.8 3/16
(0.187) 0.30 0.012
5.6 7/32
(0.219) 0.35 0.014
Acceptable
Limits
for
Cracks
Table
13

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51−42−11 Aug
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 STRUCTURAL
REPAIR
MANUAL

RIVET
NOMINAL
DIA.
(D) MAXIMUM
WIDTH
OF
CRACK
(W)
mm in. mm in.
6.4 1/4

(0.250) 0.40 0.016
8.0 5/16
(0.312) 0.50 0.020
Acceptable
Limits
for
Cracks
Table
13

Page
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51−42−11 Aug
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Printed in Germany
 STRUCTURAL
REPAIR
MANUAL

Rivet
Head
Abutment
(Seating)
Check
Figure
7

Page
21




51−42−11 Aug
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Printed in Germany
 STRUCTURAL
REPAIR
MANUAL

D. Removal
(Refer
to
Figure
8)

CAUTION: CAREFULLY
REMOVE
THE
RIVET
TO
PREVENT
DAMAGE
TO
THE
RIVETED
MA
TERIAL.
THIS
IS
SPECIALLY
NECESSARY
IF
IT
IS
THIN
SHEET.
MAKE
SURE
THAT
YOU
APPLY
TOOLS
CORRECTLY
TO
THE
SURFACE
DURING
USE.

(1) To
remove
a
solid
rivet,
first
remove
one
of
its
heads,
then
remove
the
rest
of
the
rivet
out
of
its
hole.

(2) Select
which
rivet
head
must
be
removed.
It
is
better
to
remove
the
manufactured
(set)
head
(this
head
is
on
the
center−line
of
the
riv
et
shank).
Hold
a
dolly
or
equivalent
tool
against
the
upset
head,
and
then
centre−punch
the
rivet
head.
This
will
give
a
location
for
the
twist−drill
tip
(Refer
to
Figure
8).

CAUTION: MAKE
SURE
THAT
THE
RIVET
DOES
NOT
TURN
WHEN
YOU
DO
STEP
6.D.(3),
SPECIALLY
IF
IT
IS
LOOSE.
GRIP
THE
RIVET
UPSET
HEAD
WITH
PLIERS
OR
EQUIVALENT
TOOL
TO
HOLD
IT
IF
NECESSARY.
MAKE
SURE
THAT
YOU
DO
NOT
DAMAGE
THE
MATERIAL
SURFACE.

(3) Use
a
twist−drill
with
a
slightly
smaller
diameter
than
the
rivet
shank.
Put
the
twist−drill
in
the
center
punch
indentation
and
drill
the
head
to
the
depth
as
shown
in
Figure
8.

NOTE: Make
an
estimate
of
the
drilling−depth
and
use,
if
possible,
a
mechanical
stop
to
make
sure
that
the
drilling−depth
is
cor
rect.

NOTE: Titanium
rivets
can
be
drilled
with
a
standard
high−speed
twistdrill
if
the
tip
of
the
twist−drill
is:
− reground
to
an
angle
of
80
°
,
− and
given
a
point
clearance
of
5
°
.

(4) Put
a
tight−fitting
parallel
punch
into
the
drilled
hole
and
move
the
punch
at
an
angle
to
break
off
the
rivet
head.
(5) Support
the
material
around
the
rivet
and
with
a
punch
remove
the
rivet
shank
out
of
its
hole.

NOTE: It
is
permitted
to
drill
a
hole
in
the
rivet
shank
to
make
the
removal
of
a
tight−fitting
rivet
easy.

Page
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51−42−11 Aug
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STRUCTURAL
REPAIR
MANUAL

Removal
of
Solid
Rivets
Figure
8

Page
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51−42−11 Aug
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Printed in Germany
 STRUCTURAL
REPAIR
MANUAL

7. Pin
(Threaded)
Fasteners
(HI−LOK
and
HI−LITE)

A. General
(1) There
are
two
parts
of
the
pin
(Threaded)
fastener:
− a
threaded
pin
with
a
head
(universal
or
countersunk),
− a
collar
with
an
internal
thread
and
an
external
shear
groove.

The
pin
has
an
hexagonal
recess
in
the
threaded
end.
This
recess
permits
the
use
of
an
Allen
wrench
to
hold
the
pin
during
the
installation.
The
hexagonal
drive−end
of
the
collar
breaks
off
at
the
shear
groove
when
the
collar
is
installed
to
its
correct
torque
val
ue
(Refer
to
Figure
9).

(2) In
some
areas
with
a
limited
clearance
self−locking
nuts
and
washers
are
used
instead
of
collars
(Refer
to
Figure
9).
In
this
situation
on
the
wings,
a
washer
is
not
used,
this
reduces
the
risk
of
a
fuel
leak.

(3) When
pin
(Threaded)
fasteners
are
used
to
join
structure
with
outer
surfaces
that
are
not
parallel
(Refer
to
Figure
9),
the
conditions
that
follow
are
applicable:

(a) When
standard
aluminum
alloy
collars
(ASNA2028,
DAN11,
NSA5075
and
NSA5075W)
are
used,
an
out
of
parallel
condition
up
to
3.0
degrees
is
acceptable.

(b) When
standard
CRS
collars
(ABS0258,
ASNA2036,
DAN12,
HL73,
HL86
and
and
HL87)
are
used,
an
out
of
parallel
condition
up
to
0.5
degree
only
is
acceptable.
NOTE: In
conditions
7.A.(3)(a)
and
7.A.(3)(b)
above,
the
axis
of
the
fastener
hole
must
be
perpendicular
to
the
surface
on
which
the
fastener
head
will
seat.

(c) When
the
conditions
in
7.A.(3)(a)
and
7.A.(3)(b)
above
will
be
exceeded,
the
applicable
self−aligning
collar
and
washer
must
be
used.
When
permitted
suitable
self−aligning
standard
nuts
and
washers
can
be
used.

NOTE: Conditions
7.A.(3)(a),
7.A.(3)(b)
and
7.A.(3)(c)
above
are
not
applicable
to
the
wing
structure.
For
the
wing
struc
ture
the

conditions
that
follow
are
applicable:
(d) When
standard
steel
nuts
are
used
spot
facing
(Refer
to
Chapter
51−46−12)
is
necessary
when
the
outer
surfaces
are
more
than
0.5
degree
out
of
parallel.

(e) When
standard
aluminum
alloy
nuts
are
used
spot
facing
(Refer
to
Chapter
51−46−12)
is
necessary
as
follows:
− for
5/16
in.
(8.0
mm)
diameter
pin
(Threaded)
and
the
outer
surfaces
are
more
than
1.5
degrees
out
of
parallel.

Page
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51−42−11 Aug
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 STRUCTURAL
REPAIR
MANUAL

− for
3/8
in.
(9.5
mm)
and
larger
diameter
pin
(Threaded)
and
the
outer
surfaces
are
more
than
1.0
degree
out
of
parallel.
(4) Pins
(Threaded)
and
collars
are
usually
supplied
lubricated
and
this
lubricant
must
not
be
removed.

(5) Pin
(Threaded)
fasteners
are
HI−LOK
(HL)
type
are
used
for
installa
tion
in
clearance
and
transition
fit
holes
unless
otherwise
specified
in
a
repair
procedure.
A
clearance
fit
hole
is
used
(unless
other
wise
specified)
if
one
or
more
of
the
structural
members
to
be
at
tached
are
made
of:
− steel,
− stainless
steel,
− titanium.
For
installation
in
interference
fit
holes
Pin
(Threaded)
HI−LITE
(HST)
and
HI−TIGUE
(HLT)
are
used.

(6) Before
the
installation
of
pin
(Threaded)
fasteners,
make
sure
that:
− all
the
necessary
pins
and
collars
or
nuts
are
of
the
correct
type,
− the
pins
and
collars
or
nuts
are
made
of
the
correct
material,
− the
pins
and
collars
or
nuts
have
the
correct
surface
protection
and/or
lubrication,
− the
pins
have
the
correct
grip
length,
− the
thread
of
the
pin
has
the
same
diameter
as
the
collar
or
nut
applicable
to
the
pin.

(7) Install
the
pin
(Threaded)
fasteners
with
power
or
hand
tools
(Refer
to
Figure
10,
Figure
11
and
Figure
12).

(8) The
correct
hand
tools
are
available
from
the
various
manufacturers
of
pins
(threaded),
an
example
is
shown
in
Figure
11.
But
a
hand
tool
can
be
made
locally
with
a
ratchet
handle
tool
made
of
hardened
steel.
It
is
necessary
to
modify
this
tool
as
follows:
− remove
the
ball
in
the
square
drive,
− drill
a
hole,
necessary
for
the
Allen
wrench,
of
the
correct
size
through
the
ratchet
handle
(Refer
to
Figure
10).

Page
25




51−42−11 Aug
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 STRUCTURAL
REPAIR
MANUAL

Details
of
Pin/Collar
Assemblies
Figure
9

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 STRUCTURAL
REPAIR
MANUAL

Details
for
Modified
Hand
Tool
Figure
10

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 STRUCTURAL
REPAIR
MANUAL

Details
for
HI−Shear
Hand
Tool
Figure
11

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 STRUCTURAL
REPAIR
MANUAL

Installation
of
a
Pin
(threaded)
Fastener
Figure
12

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 STRUCTURAL
REPAIR
MANUAL

B. Installation

(1) General
(a) Before
the
installation
of
pin
(Threaded)
fasteners,
make
sure
that
all
holes
are
clean,
smooth
and
deburred
(Refer
to
Chapter
51−44−00).

NOTE: Use
the
next
oversize
fastener
to
repair
a
damaged
or
over
sized
hole
(Refer
to
Chapters
51−43−00
and
Chapter
51−43−11).

(b) There
are
four
types
of
pin
(Threaded)
fasteners.
These
types
are:
− pin
(Threaded)
with
protruding
head,
for
shear
application
only,
− pin
(Threaded)
with
100
°

countersunk
head,
for
shear
applica
tion
only,
− pin
(Threaded)
with
protruding
head,
for
tension
and
shear
ap
plication,
− pin
(Threaded)
with
100
°

countersunk
head,
for
tension
and
shear
application.
(c) The
part
number
or
the
pin
(Threaded)
is
indented
on
the
head.
Details
of
the
complete
identification
number
are
given
in
Chap
ter
51−40−12.

(d) A
pin
(Threaded)
collar
is
fully
identified
with
the
subsequent
data:
− the
part
number,
− the
material
code,
− the
material
finish
code,
− the
color,
− the
washer
type
(if
applicable),
− the
washer
material
(if
applicable),
− the
washer
material
finish
(if
applicable).
There
are
many
different
types
of
collars
used
with
pins
(Threaded).
There
is
no
part
number
on
these
collars,
thus
they
must
be
kept
in
separate
containers.
The
containers
must
be
marked
with
the
applicable
part
numbers.
NOTE: Some
oversize
collars
are
also
identified
by
a
groove.
This
groove
can
be
around
the
hexagonal
or
near
the
collar
seat.

(2) Installation
with
Hand
Tools
and
Power
Tools
(Clearance
Fit)

(a) Make
sure
that
all
fastener
holes
in
the
repair
are
correctly
prepared
(Refer
to

Chapter
51−44−00,
Chapter
51−46−00,
Chapter
51−48−00).

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(b) Measure
the
total
thickness
of
the
items
to
be
riveted.
This
gives
you
the
correct
grip
length
of
the
pin
(Refer
to
Figure
13).

(c) Install
the
correct
pin/collar
assembly
as
shown
in
Figure
12.
For
a
wet
installation,
refer
to
Chapter
51−76−11.

NOTE: Before
you
use
a
pneumatic
tool
make
sure
that
the
accessi
bility
and
the
position
of
the
pin
(Threaded)
fastener
as
sembly
to
be
installed,
and
the
overall
dimensions
of
the
tool
permits
the
use
of
the
pneumatic
tool.
The
types
of
tools
and
their
different
possibilities
are
shown
in
Figure
14.

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 STRUCTURAL
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MANUAL

Gage
to
find
the
Grip
Length
Figure
13
(sheet
1)

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 STRUCTURAL
REPAIR
MANUAL

Gage
to
find
the
Grip
Length
Figure
13
(sheet
2)

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 STRUCTURAL
REPAIR
MANUAL

Gage
to
find
the
Grip
Lengths
Figure
13
(sheet
3)

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 STRUCTURAL
REPAIR
MANUAL

Examples
of
different
Types
of
Installation
Tools/Drive
Pieces
Figure
14

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 STRUCTURAL
REPAIR
MANUAL

(3) Installation
with
Hand
Tools
and
Power
Tools
(Interference
Fit)

(a) Make
sure
that
all
fastener
holes
in
the
repair
are
correctly
prepared
(Refer
to
Chapter
51−44−00,
Chapter
51−46−00,
Chapter
51−48−00).

(b) Measure
the
total
thickness
of
the
items
to
be
riveted.
This
gives
you
the
correct
grip
length
of
the
pin
(Refer
to
Figure
13).
(c) To
install
pins
in
prepared
interference−fit
holes,
do
the
steps
that
follow:

1 Carefully
put
the
threaded
portion
of
the
pin
in
the
prepared
hole
and
make
sure
that
the
pin
is
aligned
correctly.
CAUTION: MAKE
SURE
THAT
THE
CORRECT
BACK−UP
DOLLY
(IT
MUST
HAVE
THE
NECESSARY
RECESS
TO
ACCEPT
THE
THREADED
PORTION
OF
THE
PIN)
IS
PUT
BEHIND
THE
WORK
AREA
TO
PREVENT
DISTOR
TION
OF
THE
STRUCTURE.

2 Carefully
hit
the
pin
into
the
hole
until
it
is
fully
seated.
Do
this
with
a
pneumatic
hammer
or
composite
head
mallet.

(d) Install
the
correct
collar
as
shown
in
Figure
12.
For
a
wet
installation,
refer
to
Chapter
51−76−11.

NOTE: Before
you
use
a
pneumatic
tool
make
sure
that
the
accessi
bility
and
the
position
of
the
pin
(Threaded)
and
the
over
all
dimensions
of
the
tool
permits
the
use
of
the
pneumatic
tool.
The
types
of
tools
and
their
different
possibilities
are
shown
in
Figure
14.

(4) Where
it
is
necessary
(for
example,
because
of
limited
access)
to
install
a
self−locking
nut
and
a
washer
on
the
pin,
do
the
steps
that
follow:

(a) Put
the
washer
and
the
nut
on
the
pin.

(b) Hold
the
pin
with
an
Allen
wrench
(Refer
to
Figure
10
and
Figure
11).
(c) Tighten
the
nut.
Do
this
until
the
nut
is
fully
seated
and
the
gaps
between
the
parts
are
closed
and
apply
the
correct
torque
value
(Refer
to
Chapter
51−49−00).

C. Inspection
after
Installation
of
Pin
(Threaded)
Fasteners

(1) Visual
Inspection
(a) Examine
the
pin
head
and
the
local
area
surface
around
the
head
for
signs
of
the
subsequent
damage:
− scoring
and
dents,
− damage,
caused
when
the
head
is
hit
(dishing),

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 STRUCTURAL
REPAIR
MANUAL

− peripheral
cracks
and
condition
of
the
cadmium
plating
on
the
head,
where
applicable,
− an
incorrect
seat
of
the
head
and/or
collar.

(b) Scoring
and
dents
are
permitted
if
they
are
within
the
limits
given
below:
− no
sharp
edges
or
corners
are
permitted,
− the
depth
of
damage
must
not
be
more
than
0.1
mm
(0.004
in.).
(c) A
slight
separation
of
the
pin
head
seat
is
permitted,
if
it
is
within
in
the
subsequent
limits:

1 The
maximum
value
of
the
separation
is
not
more
than
0.04
mm
(0.002
in.)
(Refer
to
Figure
15).

2 The
head
is
in
satisfactory
contact
with
at
least
66
%
of
the
seat
area
circumferentially
(Refer
to
Figure
15).

3 Up
to
10
%
of
the
pins
in
a
row
are
permitted
this
condition.

4 Pins
next
to
each
other
are
not
permitted
this
condition.

(d) For
the
limits
on
the
pin
head
dishing,
refer
to
Figure
16.
(e) If
the
pins
are
cadmium−plated
(golden
color)
and
the
cadmium
becomes
damaged
during
the
installation,
replace
the
pin.

(f) Make
sure
that
the
thread
protrusion
through
the
installed
collar
is
correct
(Refer
to
Figure
17)
and
that
the
collar
is
correctly
seated
on
the
structure.

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 STRUCTURAL
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MANUAL

Limits
for
Pin
Head
Seat
Separation
Figure
15

Permitted
Limits
for
Head
Dishing
of
Pins
Installed
in
Interference
Fit
Holes
Figure
16

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 STRUCTURAL
REPAIR
MANUAL

Range
of
Pin/Thread
Protrusion
Limits
for
Protruding
and
100
°

Countersunk
Head
Pins
Figure
17
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 STRUCTURAL REPAIR MANUAL

(g) For the bolt/nut combination to be adjudged to have set correct

ly, the protrusion of the bolt from the face of the joint shall
be within the range tabulated below:

BOLT ASNA2026VHK & VBV ABS0559VHK & VBV

PART ASNA2027VHK & VBV ABS0560VHK & VBV
NO. ASNA2027− ASNA2027−
ASNA2026− ASNA2026−
NUT ABS0117
PART NSA5474 ABS0118 NSA5472
NO. ABS0813
DIA. PROTRUSION
DASH
MAX MIN MAX MIN MAX MIN
NO.
mm in. mm in. mm in. mm in. mm in. mm in.
−3 9.40 0.370 7.62 0.300
−4 10.16 0.400 8.38 0.330 10.16 0.400 8.38 0.330
−5 11.68 0.460 9.91 0.390 11.68 0.460 9.91 0.390
−6 12.70 0.500 10.92 0.430 12.70 0.500 10.92 0.430
−7 14.35 0.565 12.57 0.495
−8 15.37 0.605 13.59 0.535
−9 17.27 0.680 15.59 0.610
−10 18.80 0.740 17.02 0.670
−12 25.76 0.975 22.99 0.905
−14 27.43 1.080 25.65 1.010
−16 31.50 1.240 29.70 1.170
−18 38.18 1.385 33.40 1.315
Bolt Protrusion Tolerances
Table 14
NOTE: The dimensions given in Table 12 can be verified by:
− direct measurement by conventional means,
− use of protrusion gauges.

(h) Gauge Procedure (Refer to Figure 18).

1 Centre gauge over bolt at "TOUCH−NO−GO" end (Refer to Figure
18).

2 If bolt touches top of "TOUCH−NO−GO" gauge−reject.

3 If bolt does not touch, reverse gauge to "TOUCH−GO" end and

check.

4 If bolt touches top of "TOUCH−GO" gauge−accept (Refer to Figure

18).

Printed in Germany
51−42−11 MayPage01/0640
 STRUCTURAL REPAIR MANUAL

5 If bolt does not touch top of "TOUCH−GO" gauge with legs on

structures−reject.
NOTE: It could be possible on a specific joint thickness when a
bolt is on maximum limits that the bolt will be reject

able to the requirements of paragraph 7.C.(1)(h)2 and
substituting with a bolt of the next shorter grip which
is on minimum limits that it will be rejectable to the
requirements of paragraph 7.C.(1)(h)5.

In this situation the shorter bolt is acceptable provided

the gap between the "TOUCH−GO" part of the gauge and the
end of the bolt does not exceed 0.0254mm (0.001in.).
No similar relaxation i.e. the legs of the "TOUCH−NO−GO"
gauge not contacting the structure, is allowable for
bolts rejectable to paragraph 7.C.(1)(h)2 because of the
possibility of bolt thread bonding in the nut counterbore
and consequent loss of clamping.

Gauge Procedure
Figure 18

Printed in Germany
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 STRUCTURAL
REPAIR
MANUAL

Initial
Insertion
of
Bolt
in
Assembly
Figure
19
(sheet
1)

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 STRUCTURAL
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MANUAL

Protrusions
of
Bolt
through
Nut
after
Torque
Tightening
Figure
19
(sheet
2)

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 STRUCTURAL
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MANUAL

D. Pin
(Threaded)
Fastener
−
Removal

CAUTION: TAKE
CARE
NOT
TO
CAUSE
DAMAGE
TO
THE
SURFACE
OF
THE
MATERIAL,
OR
THE
HOLE,
WHEN
YOU
DO
THE
SUBSEQUENT
PROCEDURES.

(1) Removal
from
Clearance
Fit
Holes
(Refer
to
Figure
20)

(a) Only
use
hand
tools
to
remove
these
fasteners
from
clearance
fit
holes.
Use
the
procedure
that
follows
to
remove
the
fasteners:

1 Insert
the
correct
Allen
wrench
into
the
hexagonal
recess
in
the
pin
end.

2 Use
the
Allen
wrench
to
prevent
the
pin
turning,
and
with
pli
ers
(or
similar
gripping
tool),
turn
the
collar
counter−clock
wise
until
it
is
removed.
3 Remove
the
Allen
wrench
and
push
the
pin
out
of
the
hole.

(b) You
can
use
the
pin
again
if:
− the
pin
finish
is
not
damaged,
− the
threads
and
hexagonal
recess
are
in
good
condition.

(2) Removal
from
Interference
Fit
Holes
(Refer
to
Figure
20)
CAUTION: THE
DIAMETER

OF
THE
PIN
PUNCH
MUST
BE
LESS
THAN
THE
FAS
TENER
DIAMETER.

(a) Pin
(Threaded)
fasteners
can
be
removed
from
interference
fit
holes
using
the
procedure
in
Paragraph
7.D.(1)
but
with
this
additional
step:
Support
the
material
around
the
fastener
head
and
hit
the
fastener
out
with
a
parallel
pin
punch
and
hammer.
(b) An
alternative
procedure
is
given
below:

NOTE: You
are
recommended
to
use
the
applicable
power
tools
where
possible
for
this
procedure,
especially
if
many
fasteners
are
to
be
removed.
1 Loosen
the
collar
until
the
fastener
thread
is
in
line
with
end
of
the
collar.

2 Support
the
structure
around
the
fastener
head.

3 Hit
the
end
of
the
collar
with
a
composite
headed
mallet.
This
is
to
break
the
bond
between
the
fastener
and
the
structure.

4 Position
the
removal
tool
over
the
collar.
Apply
a
steady
hand
pressure
and
operate
the
tool
to
remove
the
collar.
Discard
the
collar.

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MANUAL

CAUTION: THE
DIAMETER
OF
PIN
PUNCH
MUST
BE
LESS
THAN
THE
FASTEN
ER
DIAMETER.
5 Support
the
structure
around
the
fastener
head
and
hit
the
fastener
out
with
a
parallel
pin
punch
and
hammer.
Discard
the
fastener.

(3) In
some
cases
(for
example,
limited
access
or
a
damaged
collar),
it
may
be
necessary
to
remove
Pin
(Threaded)
Fasteners
by
drilling
the
head
off
and
removing
the
shank
and
collar.
Use
standard
procedures
to
do
this.
If
the
fastener
is
made
of
titanium
you
will
need
to
make
sure
that:
− you
use
a
slow
drill
speed,
− you
apply
a
constant
steady
hand
pressure
to
the
drill.

This
is
to
prevent
the
twist−drill
tip
overheating.
NOTE: You
can
use
standard
high−speed
twist−drills
to
drill
titanium
fasteners.
But
the
tip
of
the
twist−drill
must
be
re−ground
to
an
angle
of
80
°
,
and
with
a
point
clearance
of
5
°
.

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STRUCTURAL
REPAIR
MANUAL

Details
for
Collar
Removal
Figure
20

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 STRUCTURAL
REPAIR
MANUAL

E. Re−torquing
loose
fasteners

NOTE: This
procedure
is
only
applicable
to
the
wing
fasteners
listed.
(1) ASNA
pins
and
ABS
or
NSA
nuts.

(a) Clearance
fit
fasteners

1 Apply
sealant
around
the
fastener
head.

2 Re−torque
tighten
the
fastener
(for
ABS
nuts
refer
to
Chapter
51−49−00
Table
12
and
for
NSA
nuts
refer
to
Chapter
51−49−00
Table
9).

3 Check
the
bolt
protrusion
to
the
dimensions
in
Table
14.
A
gauge,
obtained
from
the
manufacturer,
may
be
used
in
accor
dance
with
the
procedure
shown
in
Figure
18.
If
the
protrusion
exceeds
the
maximum
limit,
wet
install
an
additional
washer
with
a
new
nut
(Refer
to
Paragraph
2.G.).

NOTE: Do
not
install
more
than
2
washers
per
fastener
assembly.

4 Re−torque
fastener
as
per
step
2.
Overcoat
as
required
(Refer
to
Chapter
51−24−00).
(b) Interference
Fit
Fasteners

1 Apply
sealant
around
the
fastener
head
(Refer
to
Chapter
51−24−00).

2 Re−torque
tighten
the
fastener
(Refer
to
Chapter
51−49−00
Table
9).

3 Check
the
bolt
protrusion
to
the
dimensions
in
Table
14.
A
gauge,
obtained
from
the
manufacturer,
may
be
used
in
accor
dance
with
the
procedure
shown
in
Figure
18.
If
the
protrusion
exceeds
the
maximum
limit,
do
one
of
the
following
steps:
− Install
an
additional
washer
with
a
new
nut
(Refer
to
Para
graph
2.G.).

NOTE: Do
not
install
more
than
2
washers
per
fastener
assembly.
− If
1st
or
2nd
oversize
fasteners
are
available,
remove
the
fastener
and
oversize
the
hole
to
the
next
oversize
fastener
(Refer
to
Chapter
51−43−00).

4 Wet
install
the
correct
grip
length
fastener
and
re−torque
fas
tener
as
per
step
2.
Overcoat
as
required
(Refer
to
Chapter
51−24−00).

(2) HL,
HLT
and
NSA
fasteners.

(a) Clearance
fit
fasteners

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 STRUCTURAL
REPAIR
MANUAL

1 Apply
sealant
around
the
fastener
head.

2 Re−torque
tighten
the
fastener
(for
steel
nuts
refer
to
Chapter
51−49−00
Table
9
and
for
aluminum
alloy
nuts
refer
to
Chapter
51−49−00
Table
10).

3 Check
the
bolt
protrusion
to
the
dimensions
in
Figure
19.
If
the
protrusion
exceeds
to
the
maximum
limit
of
"X",
wet
install
an
additional
washer
with
a
new
nut
(Refer
to
Paragraph
2.G.).
NOTE: Do
not
install
more
than
2
washers
per
fastener
assembly.

4 Re−torque
fastener
as
per
step
2.
Overcoat
as
required
(Refer
to
Chapter
51−24−00).

(b) Interference
Fit
Fasteners
1 Apply
sealant
around
the
fastener
head
(Refer
to
Chapter
51−24−00).

2 Re−torque
tighten
the
fastener
(Refer
to
Chapter
51−49−00
Table
9).
3 Check
the
bolt
protrusion
to
the
dimensions
in
Figure
19.
If
the
protrusion
exceeds
to
the
maximum
limit
of
"X",
do
one
of
the
following
steps:
− Install
an
additional
washer
with
a
new
nut
(Refer
to
Para
graph
2.G.).

NOTE: Do
not
install
more
than
2
washers
per
fastener
assembly.
− If
1st
or
2nd
oversize
fasteners
are
available,
remove
the
fastener
and
oversize
the
hole
to
the
next
oversize
fastener
(Refer
to
Chapter
51−43−00).

4 Wet
install
the
correct
grip
length
fastener
and
re−torque
fas
tener
as
per
step
2.
Overcoat
as
required
(Refer
to
Chapter
51−24−00).
8. Pin
(Threaded)
(Bullnose)

A. General

(1) The
pin
(Threaded)
(Bullnose)
is
a
cylindrical
pin
fastener.
It
is
available
with
a
protruding
or
countersunk
head.

(2) The
fastener
has
an
hexagonal
recess
in
the
threaded
end.
This
is
used
to
assist
you
to
hold
the
fastener
when
you
remove
or
install
the
nut/collar
that
is
used
with
the
fastener.

(3) The
fastener
is
available
in
steel
or
titanium
material.

(4) The
Bull
Nose
feature
of
the
fastener
is
shown
in
Figure
21.

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(5) The
fasteners
are
secured
with
standard
self−locking
nuts
or
collars.

(6) The
fasteners
are
delivered
pre−lubricated.
Do
not
handle
these
fas
teners
more
than
is
necessary.
Do
not
degrease
them.

(7) These
fasteners
are
installed
in
interference,
transition
or
clear
ance
fit
holes.

(8) It
is
recommended
that
only
trained
operators
prepare
the
holes
and
install
these
fasteners.
B. Hole
Preparation

(1) General

(a) The
holes
for
these
fasteners
must
be
prepared
to
give
the
cor
rect
fit
and
to
a
good
standard.
They
are
prepared
in
three
stages,
these
are:
1 Drill
a
pilot−hole
(Refer
to
Chapter
51−44−00).

2 First
stage
boring
by
twist−drill
or
reamer.

3 Final
boring
by
a
reamer.
NOTE: These
stages
only
apply
to
new
holes,
for
example,
when
you
do
a
repair.
For
a
hole
that
already
exists
it
is
only
necessary
to
increase
it
to
the
correct
oversize
di
ameter.

(b) The
Final
Hole
Diameter
tolerances
are
given
in
Chapter
51−44−00.

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Pin
(Threaded)
(Bullnose)
Figure
21

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 STRUCTURAL
REPAIR
MANUAL

(2) When
you
drill
or
ream
the
holes
for
these
fasteners
you
are
recom
mended
to
use
a
drilling
jig
or
an
equivalent
tool.
This
will
help
you
to
make
sure
that
the
hole
is
perpendicular
through
the
materi
al.

(3) Only
use
twist−drills
and
reamers
that
are
sharp
and
in
good
condi
tion.
This
will
make
sure
that
the
holes
are
accurate
and
to
a
good
condition.
C. Hole
Preparation
Procedure

(1) You
are
recommended
to
use
soluble
oil
or
paraffin
to
lubricate
the
twist−drills
and
reamers
when
you
are
preparing
the
holes.

(2) Refer
to
Chapter
51−44−00
(Hole
and
Drill
data),
and
select
the
cor
rect
size
twist−drill
for
the
pilot−hole.
Drill
the
pilot−holes.
NOTE: In
a
repair
procedure
or
other
special
circumstances,
you
can
be
given
a
pilot−hole
diameter
that
does
not
agree
with
the
information
in
Chapter
51−44−00.
In
this
case
use
the
alterna
tive
diameter.

(3) Do
the
first
stage
boring.
You
can
use
one
of
two
methods
to
do
this,
these
are:

(a) With
a
twist−drill
drill
a
hole
that
is
approximately
0.05
mm
(0.002
in.)
smaller
than
the
final
hole.

(b) With
a
reamer
make
a
hole
that
is
approximately
0.3
mm
(0.012
in.)
smaller
than
the
final
hole.
NOTE: After
you
have
done
this
stage
the
entry
to
the
hole
must
permit
the
use
of
the
final
stage
tool.
You
must
be
able
to
enter
the
final
stage
tool
for
at
least
1.0
mm
(0.039
in.).
(4) Carefully
ream
the
holes
to
the
final
diameters
that
are
given
in
Chapter
51−44−00.

NOTE: The
surface
roughness
of
the
inner−face
of
the
holes
must
be
less
than
1.6
micrometers
(63
microinches).

(5) Deburr
and
radius
or
chamfer
the
entry
and
exit
edges
of
the
holes
(Refer
to
Chapter
51−44−00).

(6) Check
the
final
diameter
of
the
holes
with
the
applicable
limit
plug
gage.

D. Selection
of
Fastener
Length

(1) You
can
use
one
of
two
methods
that
follow
to
find
the
correct
length
of
the
fastener
required:

(a) Method
1.
Refer
to
Figure
22
for
the
information
how
to
use
a
griplength
gage
and
the
relevant
fastener
data.

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(b) Method
2.

1 Measure
the
thickness
of
the
materials
that
are
to
be
fastened.
Use
suitable
precision
tools
to
do
this.

2 Refer
to
Figure
22
sheet
3
and
select
a
fastener
of
the
cor
rect
length
to
fit
the
tolerance
given.

E. Fastener
Installation
Procedure
The
procedure
that
follows
is
applicable
to
steel
or
titanium
fasteners.

(1) Put
the
repair
pieces
into
their
correct
position.
Secure
them
with
temporary
bolts
or
grip−pins.

NOTE: Because
the
final
fasteners
will
be
hammered
into
position,
you
are
recommended
to
secure
the
materials
through
at
least
50
%
of
the
holes.
This
is
to
stop
a
gap
forming
between
the
mate
rials.

CAUTION: IT
IS
IMPORTANT
THAT
YOU
MAKE
SURE
THAT
THE
FASTENER
IS
PER
PENDICULAR
TO
THE
HOLE
BEFORE
YOU
HAMMER
IT
IN.

(2) Put
the
fastener
in
the
hole
and
hammer
it
in
until
the
head
is
seated
on
the
material.
To
do
this
you
can
use
a
standard
pneumatic
hammer,
either
single
or
multi−hit.
Use
a
rivet
set
(snap)
of
a
size
that
will
not
damage
the
fastener
head
or
the
material.

NOTE: Install
all
fasteners
"wet"
unless
instructed
differently
in
a
repair
procedure.
Refer
to
Chapter
51−76−11
for
sealing
in
formation.

(3) If
applicable
refer
to
Table
15
and
select
the
correct
washer.
Be
cause
of
the
Bull
Nose
feature
of
this
fastener
it
is
important
that
you
only
use
washers
of
the
correct
thickness
and
internal
diameter.
If
necessary
two
washers
can
be
used
to
get
the
correct
thickness,
but
do
not
use
washers
of
0.4
mm
(0.016
in.)
thickness
or
less.

NOTE: It
is
recommended
that
you
only
use
aluminum
alloy
washers.
But
steel
washers
can
be
used
without
special
authorization
if
alu
minum
alloy
washers
are
not
available.
Do
not
use
a
mixture
of
washer
materials
on
the
same
fastener.
(4) Put
the
applicable
nut/collar
on
to
the
fastener.
Tighten
the
nut
to
the
correct
torque
value
(Refer
to
Chapter
51−49−00).

NOTE: If
the
type
of
nut/collar
is
not
specified
in
the
repair
pro
cedure
select
one
that
is
suitable
from
the
list
that
follows:

ABS
0117
Nut,
self−locking,
counterbored
ABS
0118
Nut,
self−locking,
self−sealing,
counterbored
NSA
5050
Nut,
self−locking
)
NSA
5472
Nut,
self−locking
)
with
captive
washer
NAS
1726
Nut,
self−locking
)
NSA
5474
Nut,
self−locking,
chamfered
end
)
NSA
5151
Nut,
self−locking,
self−aligning
)
for
use
on
non
NAS
1727
Nut,
self−locking,
self−
aligning
)
parallel
surfaces

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MANUAL

F. Inspection
After
Installation
(Refer
to
Figure
23)

(1) After
you
have
installed
Bull
Nose
fasteners
examine
them
for
signs
of
the
conditions
which
follow:

(a) Dishing
of
the
head
(countersunk
fasteners).

(b) Incorrect
seating
of
the
fastener
head
and
nut/collar.

(c) Incorrect
threaded
end
protrusion.
(d) Incorrect
head
alignment
(countersunk
fasteners).

(2) Refer
to
Figure
23
for
the
limits
that
are
applicable
to
conditions
8.F.(1)(a),
8.F.(1)(b)
and
8.F.(1)(c).
The
limits
applicable
to
condition
8.F.(1)(d)
are
given
in
Chapter
51−10−00
(Aerodynamic
Smoothness).

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Gage
to
find
the
Grip
Length
Figure
22
(sheet
1)

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Gage
to
find
the
Grip
Length
Figure
22
(sheet
2)

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MANUAL

How
top
Find
the
Fastener
Grip
Length
Figure
22
(sheet
3)

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FASTENER WASHER
THICKNESS
FOR
USE
WITH
NSA
5050
FIRST
DASH NUTS
NO
NO. FOR
STANDARD FOR
FIRST FOR
SECOND
FASTENER OVERSIZE OVERSIZE
WASHERS WASHERS
NSA WASHERS
NSA
AN960
OR 5368 5368
NSA
5354
NSA HLT mm in. mm in. mm in.
3 6 1.6 0.06 2.4 0.09 2.4 0.09
4 8 2.4 0.09 2.4 0.09 3.2 0.13
5 10 2.4 0.09 3.2 0.13 4.0 0.16
6 12 2.4 0.09 3.2 0.13 4.0 0.16
7 14 3.2 0.13 4.0 0.16 4.8 0.19
8 16 3.2 0.13 4.0 0.16 4.8 0.19
9 18 3.2 0.13 4.0 0.16 4.8 0.19
10 20 3.2 0.13 4.0 0.16 4.8 0.19
Washer
Data
Table
15
FASTENER WASHER
THICKNESS
FOR
USE
WITH
NSA
5151
FIRST NUTS
DASH
NO. FOR
STANDARD FOR
FIRST FOR
SECOND
FASTENER OVERSIZE OVERSIZE
WASHERS

NSA WASHERS WASHERS
NSA
5369 5372
NSA
5372
NSA HLT mm in. mm in. mm in.
3 6 1.6 0.06 2.4 0.09 2.4 0.09
4 8 2.4 0.09 2.4 0.09 3.2 0.13
5 10 2.4 0.09 3.2 0.13 4.0 0.16
6 12 2.4 0.09 2.4 0.09 3.2 0.13
7 14 1.6 0.06 2.4 0.09 3.2 0.13
8 16 1.6 0.06 2.4 0.09 3.2 0.13
9 18 1.6 0.06 2.4 0.09 3.2 0.13
Washer
Data
Table
16

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FASTENER WASHER
THICKNESS
FOR
USE
WITH
NSA
1727
FIRST NUTS
DASH
NO. FOR
STANDARD FOR
FIRST FOR
SECOND
FASTENER OVERSIZE OVERSIZE
WASHERS
NSA WASHERS
NSA WASHERS
NSA
5369 5372 5372
NSA HLT mm in. mm in. mm in.
3 6 1.6 0.06 2.4 0.09 2.4 0.09
4 8 0.8 0.03 0.8 0.03 1.6 0.06
5 10 0.8 0.03 1.6 0.06 2.4 0.09
6 12 0.8 0.03 1.6 0.06 2.4 0.09
7 14
8 16 NONE NONE NONE
9 18
10 20
Washer
Data
Table
17

Permitted
Limit
of
Head
Dishing
Figure
23
(sheet
1)

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MANUAL

Permitted
Limits
of
Head/Set
Separation
Figure
23
(sheet
2)

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MANUAL

Checking
Correct
Fastener
Length
Figure
23
(sheet
3)

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 STRUCTURAL
REPAIR
MANUAL

G. Removal
of
Bull
Nose
Fasteners

(1) There
are
two
methods
that
you
can
use
to
remove
a
Bull
Nose
fas
tener,
these
are:

(a) If
you
have
good
access
to
the
threaded
end
of
the
fastener
use
a
TAPER−LOK
Knockout
Tool.

(b) If
you
do
not
have
good
access
use
an
extractor
tool.
(2) Both
of
these
methods
are
given
in
Paragraph
9
of
this
Chapter.

NOTE: The
removed
Bull
Nose
pin
and
nut
or
collar
must
be
discarded.
You
are
not
permitted
to
re−use
them.

H. Further
Information

When
a
Bull
Nose
fastener
is
removed
further
action
to
the
hole
is
nec
essary
as
follows:

(1) Interference
Fit
Hole.
Prepare
the
hole
for
an
oversize
fastener
(Refer
to
Chapter
51−44−00).
Two
stages
of
oversize
fastener
are
available
(Refer
to
Chapter
51−43−00).

(2) Transition
Fit
Hole.
Measure
the
hole
diameter.
If
the
diameter
is
within
the
permitted
tolerances
(Refer
to
Chapter
51−44−00)
and
in
good
condition,
a
replacement
standard
fastener
can
be
used.
If
the
diameter
is
outside
the
permitted
tolerances,
the
hole
must
be
pre
pared
for
an
oversize
fastener
(Refer
to
Chapter
51−43−00).

(3) Clearance
Fit
Hole.
If
the
hole
condition
is
good
no
further
action
is
necessary.
If
the
hole
condition
is
not
acceptable
it
must
be
prepared
for
an
oversize
fastener
(Refer
to
Chapter
51−43−00).

9. TAPER−LOK
Fasteners

A. General
(1) A
TAPER−LOK
fastener
is
a
tapered
bolt
with
a
threaded
end
and
a
selflocking
nut.
The
nut
is
also
threaded
and
includes
its
own
wash
er.
The
use
of
this
fastener
is
almost
the
same
as
that
of
a
stan
dard
nut
and
bolt
(Refer
to
Figure
24).

(2) The
TAPER−LOK
fasteners
are
used
in
those
areas
of
the
structure
where
a
high
fatigue
performance
is
required.
The
TAPER−LOK
fastener
helps
to
achieve
this
performance
because
it
has
a
constant
inter
ference−fit
in
the
tapered
hole
in
the
structure.
This
causes
a
good
compression
of
the
structure
material
around
the
fastener
hole,
and
a
balanced
stress
pattern
(Refer
to
Figure
25).
(3) An
additional
feature
of
the
TAPER−LOK
fastener
is
the
good
sealing
effect
that
is
given
by
the
tapered
interference
fit.

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(4) The
taper
of
the
bolt
and
the
hole
to
which
it
is
fitted,
is
small.
It
is
only
6.35
mm
(0.250
in.)
for
each
linear
305
mm
(12.008
in.),
a
ratio
of
1
in
48.

(5) The
TAPER−LOK
bolt
is
a
light
bolt
with
a
good
strength
property.
Bolts
are
available
for
tension
or
shear
uses.

(6) TAPER−LOK
bolts
are
usually
supplied
with
a
special
lubricant
on
them.
The
special
lubricant
must
not
be
removed
before
the
bolt
is
installed.

(7) Before
the
TAPER−LOK
bolts
are
installed
in
a
repair,
make
sure
that:
− they
are
made
of
the
correct
material,
− they
have
the
correct
type
of
head,
− they
are
of
the
correc
diameter,
− they
are
of
the
correct
grip
length,
− the
nuts
are
of
the
correct
type
(Refer
to
Paragraph
9.A.(22)).

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TAPER−LOK
Installation
Procedure
Figure
24

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REPAIR
MANUAL

Example
of
a
Stress
Patterns
Figure
25

(8) It
is
very
important
to
tightly
clamp
the
parts
together
when
they
are
prepared
for
the
installation
of
TAPER−LOK
bolts.

(9) TAPER−LOK
bolts
can
be
installed
with
hand
or
power
tools.

(10) It
is
very
important
to
prepare
the
hole
for
a
TAPER−LOK
bolt
to
the
highest
possible
precision.
If
this
is
not
done,
it
could
have
a
bad
effect
on
the
fatigue
of
the
structure.

(11) It
is
recommended
that
only
trained
and
approved
personnel
prepare
the
holes
for
TAPER−LOK
bolts.

(12) Special
tools,
for
example,
drill−reamers,
hole/countersink
gages
and
head
protrusion
gages,
are
available.
Only
these
tools
should
be
used
to
ensure
the
necessary
precision.
These
tools
must
be
kept
in
a
satisfactory
condition.
Drill
reamers
must
not
be
re−sharpened
by
the
operator;
they
must
be
returned
to
the
manufacturer
for
re−sharpen
ing.
(13) Before
you
install
TAPER−LOK
bolts,
makes
sure
that
all
the
holes
are:
− clean,
− smooth,
− fully
deburred
at
the
nut
end.

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Printed in Germany
 STRUCTURAL
REPAIR
MANUAL

The
holes
for
protruding
head
bolts
must
have
a
relief
radius
at
the
head
end
of
the
hole
(Refer
to
Figure
26).
NOTE: If
a
hole,
that
has
been
used
before,
is
found
damaged
or
oversize,
it
must
be
repaired
to
use
the
correct
oversize
bolt
(Refer
to
Chapter
51−43−00).

(14) The
information
on
the
available
types
of
TAPER−LOK
bolts
is
given
in
Chapter
51−40−00.
(15) The
data
given
in
Figure
27
will
help
the
operator
to
identify
the
correct
bolt
to
fit
in
a
hole
of
specified
dimensions
(nominal
diam
eter
and
grip
length).

(16) The
TAPER−LOK
bolts
of
different
nominal
diameters
are
divided
into
grip
length
groups.
Thus
bolts
of
the
same
nominal
diameter
can
be
found
for
use
on
materials
of
different
thicknesses.
The
part
num
bers,
that
are
on
the
head
and
the
end
of
the
bolt,
are
used
to
identify
a
bolt

Figure
27
shows
this
in
detail).

(17) TAPER−LOK
drill
reamers
are
available
to
prepare
a
hole
for
a
TAPER−
LOK
bolt
(countersunk
or
protruding
head).
The
drill
reamers
are
identified
by
a
part
number.
This
part
number
gives
the
grip
length
and
nominal
diameter
of
the
bolt
to
which
the
drill
reamer
is
appli
cable
(Refer
to
Figure
28).

NOTE: A
commercially
available
1:48
hand
taper
pin
reamer
may
be
used
hand
to
finish
or
adjust
a
hole
for
a
TAPER−LOK
bolt
(Refer
to
Figure
37)

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REPAIR
MANUAL

Relief
Radius
Data
for
Protruding
Head
−
TAPER−LOK
Bolts
Figure
26

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 STRUCTURAL
REPAIR
MANUAL

TAPER−LOK
Bolt
Identification
Coding
Figure
27

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STRUCTURAL
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MANUAL

TAPER−LOK
Drill
Reamer
Data
Figure
28

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 STRUCTURAL
REPAIR
MANUAL

Example
of
the
Use
of
a
Dished
Washer
Figure
29

(18) TAPER−LOK
drill
reamers
that
have
the
part
number
TLD
2030AR
or
TLD
2040AR
(countersunk
head
bolts)
cut
the
material
in
three
continuous
steps.
These
are:
− the
pilot
hole,
− the
tapered
hole
of
the
correct
taper
and
grip
length,
− the
correct
countersink.
Drill
reamers
that
have
the
part
number
TLD
2040BR
or
TLD
2040BR
(protruding
head
bolts)
only
make
the
pilot
hole
and
the
tapered
hole
of
the
correct
grip
length
(Refer
to
Figure
28).

(19) There
are
two
different
types
of
nuts
available
for
use
on
TAPER−LOK
bolts.
They
are:

(a) Nuts
with
an
attached
washer.
These
are
for
use
where
the
sur
faces
of
the
materials,
that
must
be
fastened,
are
out
of
paral
lel
up
to
2
°
.

(b) Nuts
with
a
spherically
dished
washer
that
is
not
attached.
These
must
be
used
where
the
material
surfaces
are
out
of
parallel
up
to
7
°

(Refer
to
Figure
29).

NOTE: On
wing
structure
this
limit
is
3
°
.

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 STRUCTURAL
REPAIR
MANUAL

(20) These
nuts
do
not
have
their
part
number
engraved
on
them,
thus
they
must
be
kept
in
different
containers.
The
containers
must
be
marked
with
the
applicable
number.

(21) The
self−locking
property
of
these
nuts
is
caused
by
a
small
ellip
tical
deformation
of
the
nut/body
thread.
When
the
nut
is
installed
on
a
bolt,
the
threaded
part
of
the
bolt
causes
the
deformation
to
change
shape.
This
causes
the
nut
to
tightly
hold
the
bolt.
NOTE: These
nuts
must
only
be
used
once.

(22) The
subsequent
table
shows
the
nuts
that
are
available
for
use
with
TAPER−LOK
bolts
on
this
aircraft.

PART
NUMBER NAME NUT/WASHER
MA SURFACE
PROTEC

TERIAL TION
NSA
1726−(
) Nut,
Self−Lock Stainless
Steel Cadmium
Plating
(NSA5050) ing
with
washer or
Steel on
steel
parts,
included Silver
Plating
on
stainless
steel
parts
NSA5057 Nut,
Self−Lock Stainless
Steel Cadmium
Plating
NSA5472 ing
with
washer or
Steel on
steel
parts,
included Silver
Plating
on
stainless
steel
parts
NSA5094 Nut,
Self−Lock Steel Cadmium
Plated
ing
with
separate
spherically
dished
washer
NSA5151 Nut,
Self−Lock Steel Cadmium
Plated
ing
with
separate
spherically
dished
washer
Nuts
for
Use
with
TAPER−LOK
Bolts
Table
18
B. Hole
Preparation

(1) Make
a
mark
at
the
correct
positions
for
the
bolts.
(2) Accurately
make
a
mark
with
a
center
punch
at
the
positions
identi
fied
in
step
9.B.(1).

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 STRUCTURAL
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MANUAL

CAUTION: THE
HOLE
AXIS
MUST
BE
WITHIN
2°
OF
THE
PERPENDICULAR
WHEN
YOU
DO
THE
NEXT
STEP.
IT
IS
RECOMMENDED
TO
USE
A
DRILL
JIG
TO
ACHIEVE
THIS
PRECISION.

(3) Carefully
drill
a
pilot
hole
at
each
of
the
positions
identified
in
step
9.B.(1).

NOTE: The
correct
twist−drill
size
for
this
step
is
0.4
mm
(0.016
in.)
smaller
than
the
nominal
diameter
of
the
bolt
to
be
installed.

NOTE: The
correct
drill
speed
for
this
step
is
approximately
600
revolutions
per
minute
(rpm).

(4) Put
the
correct
drill
reamer
in
an
adjustable
TAPER−LOK
micro
stop
cage
(Refer
to
Figure
30).
Adjust
the
cage
to
the
necessary
drill
depth.
Put
the
cage
in
a
pneumatic
drill
machine.

NOTE: The
drill
machine
must
be
a
machine
on
which
the
speed
can
be
adjusted
from
200
thru
400
rpm.
For
example,
the
hole
for
a
bolt
of
1/4
in.
(6.4
mm)
nominal
diameter,
must
be
drilled
at
a
speed
of
approximately
300
rpm.
(5) Do
a
test
drill
on
a
piece
of
material
that
is
of
the
same
type
and
thickness
as
the
material
to
be
fastened.
Repeat
this
step
until
you
have
found:
− the
necessary
drill
speed
(rpm),
− the
necessary
drill
depth.

NOTE: This
information
helps
to
make
sure
that
the
hole
is
to
a
good
finish.
(6) Put
the
drill
reamer/micro
stop
cage
accurately
over
the
hole
drilled
in
step
9.B.(3).
Make
sure:
− that
the
pilot−hole
end
of
the
drill
reamer
is
in
the
center
of
the
hole,
− that
the
drill
reamer
is
in
line
with
the
vertical
axis
of
the
hole.
(7) Start
the
drill
machine
and
drill
the
hole.
Use
the
cutting
lubri
cant
FREON
TB−1,
or
ICI
ARCTON
113,
during
this
step.
Make
sure
that
the
drill
reamer
moves
through
the
material
slowly,
but
with
a
constant
hand
pressure
on
it.

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 STRUCTURAL
REPAIR
MANUAL

TAPER−LOK
Micro
Stop
Cage
Data
Figure
30

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 STRUCTURAL
REPAIR
MANUAL

(8) Stop
the
drill
machine
when
the
drill
reamer
has
reached
the
depth
set
on
the
adjustable
micro
stop
cage.
Carefully
remove
the
drill
reamer
from
the
hole.

NOTE: Because
of
the
taper
of
the
hole
and
the
drill
reamer,
the
drill
reamer
will
move
apart
from
the
hole
easily.

(9) If
the
hole
is
for
a
countersunk
bolt,
make
sure
that
the
hole
countersink
is
correct.
Do
this
with
the
applicable
TAPER−LOK
gage
(Refer
to
Figure
29),or
a
TAPER−LOK
fastener
of
proper
dimensions
with
the
shank
reduced
for
a
slip
fit
in
the
mating
TAPER−LOK
hole.

(10) If
the
hole
is
for
a
protruding
head
bolt,
make
sure
that
the
top
edge
of
the
hole
has
the
correct
radius
(Refer
to
Figure
26).

(11) Deburr
all
the
edges
of
the
holes.
(12) Do
the
steps
that
follow
on
all
the
prepared
holes
to
make
sure
that
they
have
the
correct
interference
fit.

NOTE: All
steps
must
be
done
in
conjunction
with
protrusion
check
(Refer
to
paragraph
9.C.(2)).

(a) Apply
a
layer
of
engineers
blue
dye
(Prussian
Blue)
to
the
face
of
the
applicable
plug
gage
(Refer
to
Figure
32)
or
a
TAPER−LOK
fastener
of
proper
dimensions.

(b) Put
the
plug
gage
into
the
hole
and
lightly
hit
it
(use
a
com
posite
head
mallet
to
do
this).
Do
this
until
only
25
%
of
the
length
of
the
shank
is
visible
(measured
from
the
bottom
face
of
the
plug
gage
head
to
the
top
face
of
the
material).

(c) Carefully
hit
the
end
of
the
plug
gage
to
free
the
plug
gage
from
the
hole.

NOTE: Take
care
not
to
change
the
marks
in
the
engineers
blue
on
the
plug
gage
by
rotating
the
gage
when
you
do
this
step.

(d) Look
at
the
marks
in
the
engineers
blue
on
the
shank
of
the
plug
gage.
If
the
marks
show:

1 That
60
%
or
more
of
the
plug
gage
shank
touched
the
face
of
the
hole
(Refer
to
Figure
33),
the
hole
is
satisfactory.
2 That
less
than
60
%
of
the
plug
gage
shank
touched
the
face
of
the
hole,
you
must
hand
ream
the
hole
(Refer
to
Paragraph
9.E.).

NOTE: Take
care
to
ensure
that
the
bolt
protrusion
limits
are
maintained
(Refer
to
Figure
32).

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 STRUCTURAL
REPAIR
MANUAL

Data
for
Countersink
Check
Gage
Figure
31
(sheet
1)

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 STRUCTURAL
REPAIR
MANUAL

Data
for
Countersink
Check
Gage
Figure
31
(sheet
2)

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STRUCTURAL
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MANUAL

Plug
Gage
Data
Figure
32

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STRUCTURAL
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MANUAL

Use
of
a
Plug
Gage
Figure
33

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 STRUCTURAL
REPAIR
MANUAL

C. Installation
of
TAPER−LOK
bolts

(1) Insert
the
correct
TAPER−LOK
bolt
into
the
prepared
hole.
Only
use
a
light
hand
pressure
on
the
bolt
head.

(2) Check
the
measurement
between
the
material
surface
and
the
bolt
head.

NOTE: The
data
and
procedure
necessary
to
do
this
is
given
in
Figure
34.

NOTE: If
the
protrusion
is
greater
than
the
maximum
allowed,
you
must
hand
ream
the
hole
(Refer
to
Paragraph
9.E.).

NOTE: Take
care
to
maintain
the
correct
interference
fit
(Refer
to
Paragraph
9.B.).

CAUTION: ONLY
PULL
THE
BOLT
INTO
THE
HOLE
BY
THE
EFFECT
OF
THE
NUT
BE
ING
FULLY
TORQUED.
DO
NOT
HIT
IT
IN.
CAUTION: ONLY
USE
THE
SOCKET
THAT
IS
CORRECT
FOR
THE
TYPE
OF
NUT
TO
BE
INSTALLED.
FOR
EXAMPLE,
HEXAGONAL
SOCKETS
MUST
ONLY
BE
USED
ON
HEXAGONAL
NUTS.

(3) Put
the
applicable
nuts
(Refer
to
Paragraphs
9.A.(19)
and
9.A.(22))
on
the
threaded
ends
of
the
bolts.
Make
sure
that
the
nuts
engage
the
bolt
threads
correctly.
Torque
the
nuts
to
the
correct
value
(Refer
to
Chapter
51−49−00).

(4) Make
sure
that
the
bolt
has
been
fully
pulled
into
the
hole.
Do
the
subsequent
steps
if
it
has
not.

(a) Remove
and
discard
the
nut.
(b) Put
a
washer
onto
the
bolt
thread.

NOTE: The
washer
must
have
an
inner
diameter
that
is
sufficient
to
go
over
the
plain
part
of
the
bolt
shank.

(c) Do
step
9.C.(3)
again.

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 STRUCTURAL
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MANUAL

TAPER−LOK
Bolt
Protrusion
Data
Figure
34

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 STRUCTURAL
REPAIR
MANUAL

D. Inspection
after
Installation

(1) After
TAPER−LOK
bolts
have
been
installed,
an
inspection
of
them
must
be
done.
This
inspection
must
look
for
the
subsequent
bad
conditions
that
can
occur.

(a) A
clearance
between
the
bolt
head
and
the
material.
The
permitted
limits
for
this
condition
are:
− A
clearance
that
is
not
more
than
0.04
mm
(0.002
in.)
(Refer
to
Figure
35.
− 60
%
or
more
of
the
bolt
head
must
fully
touch
the
material
face
(Refer
to
Figure
35).
− Only
10
%
of
the
bolts
in
a
row
of
bolts
can
have
this
condi
tion.
− Two
bolts
that
are
adjacent
to
each
other
must
not
have
this
condition.
(b) One
full
thread
of
the
bolt
must
show
out
of
the
end
of
the
nut.

(c) Damage
to
the
bolt
head
or
nut,
and
the
material
around
the
bolt
head.
For
example:
− scoring,
− impact
damage,
− dishing
of
the
bolt
head,
− cracks
at
the
edge
of
the
bolt
head,
− surface
protection
damaged.

(2) The
steps
that
follow
give
the
procedures
to
repair
any
of
the
conditions
referred
to
in
Paragraph
9.D.(1).

(a) If
there
is
a
clearance
between
the
bolt
head
and
the
material
more
than
the
permitted
limits:

1 Remove
and
discard
the
nut
and
the
bolt
(Refer
to
Paragraph
9.F.).
2 Install
a
new
bolt
and
nut
(Refer
to
Paragraph
9.C.
for
the
procedure).

(b) If
one
full
thread
of
the
bolt
does
not
show
out
of
the
end
of
the
nut:
1 Remove
and
discard
the
nut
and
the
bolt
(Refer
to
Paragraph
9.F.).

2 Install
a
longer
bolt
(Refer
to
Paragraph
9.C.
for
this
proce
dure).

(c) Scoring
and
impact
damage
is
permitted
if
there
are
no
sharp
edges
or
corners.
The
depth
of
the
damage
must
not
be
larger
than
0.1
mm
(0.004
in.).
Do
the
applicable
repair
procedure
if
necessary.

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 STRUCTURAL
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(d) Figure
36
gives
the
permitted
limit
for
the
dishing
of
the
bolt
head.
If
the
dishing
is
more
than
this
limit,
the
bolt
and
the
nut
must
be
replaced.
Use
the
procedure
given
in
Paragraph
9.C.
to
do
this.

Bolt
Head
Separation
Data
Figure
35

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 STRUCTURAL
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MANUAL

Bolt
Head
Dishing
Data
Figure
36

(e) Cracks
in
the
bolt
head
are
not
permitted.
If
there
are
cracks,
the
bolt
and
the
nut
must
be
replaced.
Use
the
procedure
given
in
Paragraph
9.C.
to
do
this.

(f) If
the
surface
protection
is
cadmium
plating
(golden
color),
and
damaged,
replace
the
bolt
and
the
nut,
or
the
nut
only
if
neces
sary.
Use
the
procedure
given
in
Paragraph
9.C.
to
do
this.

E. Use
of
Hand
Reamers

(1) The
use
of
a
hand
reamer
is
permitted
if
it
is
necessary
to
improve
the
face
of
a
hole
or
to
reduce
the
maximum
protrusion.

NOTE: Hand
reaming
may
be
done
using
a
commercially
available
1:48
hand
taper
pin
reamer
(Refer
to
Figure
35).
For
example,
DORMER
part
number
B301,
available
in
nominal
inch
sizes
1/16
to
7/8.

(2) When
it
is
necessary
to
use
a
hand
reamer,
the
subsequent
steps
must
be
done
after
each
use:

(a) Deburr
the
edges
of
the
hole.

(b) If
it
is
applicable,
make
sure
that
the
countersink
is
correct
(Refer
to
Paragraph
9.B.(9)).
(c) If
it
is
applicable,
make
sure
that
the
radius
around
the
top
edge
of
the
hole
is
correct
(Refer
to
Paragraph
9.B.(10)).

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 STRUCTURAL
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MANUAL

(d) Make
sure
that
the
interference
of
the
hole
is
correct
(Refer
to
Paragraph
9.B.(12)).
NOTE: It
is
very
important
to
make
sure
that
after
a
hole
has
been
hand−reamed,
that
the
bolt
protrusion
is
correct
(Refer
to
Paragraph
9.C.(2)).

Commercially
available
1:48
Hand
Taper
Pin
Reamer
Figure
37

F. TAPER−LOK
Fastener
−
Removal
Procedures
One
of
two
procedures
can
be
used
to
remove
TAPER−LOK
fasteners;
these
procedures
are
given
below.
Where
possible,
use
procedure
1.

(1) Procedure
1

(a) Remove
and
discard
the
nut.
Do
this
with
the
correct
socket
tool.

(b) Put
the
correct
TAPER−LOK
knock−out
tool
(Refer
to
Figure
38)
on
the
thread
of
the
bolt.
Make
sure
that
the
tool
correctly
en
gages
the
bolt
thread
and
is
fully
turned
onto
the
bolt.

(c) Hit
out
the
bolt.
To
do
this,
hit
the
end
of
the
knock−out
tool
with
a
hammer,
this
will
cause
the
bolt
to
move
apart
from
the
hole.

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MANUAL

CAUTION: TAKE
CARE
NOT
TO
DAMAGE
THE
BOLT
HEAD
WHEN
YOU
DO
THIS
STEP.
(d) Hold
the
bolt
head
(if
necessary,
pliers
can
be
used,
but
obey
the
caution
given
above),
remove
the
knock−out
tool
from
the
bolt.

(e) Carefully
remove
the
bolt
from
the
hole.

(f) Examine
the
bolt.
If
its
condition
is
satisfactory,
it
can
be
used
again.

NOTE: Bolts
which
are
to
be
used
again
must
be
relubricated,
re
fer
to
Paragraph
4.B.
for
this
procedure.

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MANUAL

TAPER−LOK
Bolt
Knock−out
Tool
Data
Figure
38

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REPAIR
MANUAL

Extraction
Tool
Data
Figure
39

(2) Procedure
2

In
this
procedure
a
locally
made
extraction
tool
is
used.
Figure
39
shows
this
tool.
This
tool
uses
a
standard
bolt.
The
standard
bolt
must
be
correct
for
the
dimensions
of
the
TAPER−LOK
bolt
that
is
to
be
removed.

(a) Drill
a
hole
of
the
correct
dimensions
into
the
shank
of
the
TAPERLOK
bolt.
Do
this
from
the
head
end
of
the
bolt.

(b) Cut
a
thread
into
the
inner
surface
of
the
hole
made
in
step
9.F.(2)(a).

(c) Put
the
extraction
tool
in
its
correct
position
above
the
TAPER−
LOK
bolt.
Engage
the
standard
bolt
with
the
thread
in
the
TAPER−
LOK
bolt
(Refer
to
Figure
39).

(d) Remove
and
discard
the
nut
from
the
end
of
the
TAPER−LOK
bolt.
Do
this
with
the
correct
socket
tool.

CAUTION: MAKE
SURE
THAT
THE
BRIDGE
OF
THE
EXTRACTION
TOOL
DOES
NOT
DAMAGE
THE
STRUCTURE
SURFACE.

(e) Turn
the
nut
on
the
standard
bolt
to
remove
the
TAPER−LOK
bolt
from
the
structure.

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 STRUCTURAL REPAIR MANUAL

(f) Remove the TAPER−LOK bolt from the extraction bolt. Discard the
TAPER−LOK bolt.
10. Rivet (Blind) (HUCK)

A. General (Refer to Figure 40)

(1) In this paragraph the Rivet (Blind) (HUCK) is referred to as the

HUCK rivet.
(2) The HUCK rivet consists of three parts. These are:

(a) A tubular body that has a protruding or 100 ° countersunk head.

(b) A mandrel (shank) that is retained in the tubular body. When the
HUCK rivet is installed, the mandrel is mechanically secured
within the tubular body and is sheared off level with the rivet
head.

(c) A locking collar that is retained on the mandrel before instal

lation. The installation tool pushes the collar into a locking
groove during installation. This secures the mandrel in the body.

(3) When installed the HUCK rivet is similar to a ’pop’ rivet. But be

cause the mandrel is retained in the tubular body, this rivet has
almost the same properties as a solid rivet. The HUCK rivet can be
installed from one side of a repair or surface.

(4) The HUCK rivet is identified by an identification number. This number

and its specific details are explained in Chapter 51−40−12.
(5) The HUCK rivet can be installed with hand or power operated tools.

(6) HUCK rivets must only be used to replace HUCK rivets, or when called
up in a specific repair procedure or other approved documents.

(7) Before you install HUCK rivets make sure that:

− you have the correct type of rivet,
− the rivets are made of the required material,
− the rivets have the specified surface protection, and that they are
not corroded or scratched,
− the rivets are the correct grip length and diameter,
− the holes for the rivets are correctly prepared (Refer to Chapter
51−44−00).
(8) Before you install HUCK rivets in the structure you are recommended
to make a test piece. This will check the rivet, tool and hole pre

cision. The test materials and rivets must have the same properties
as those required for the repair.

Printed in Germany
51−42−11 MayPage01/0687
 STRUCTURAL
REPAIR
MANUAL

HUCK
Blind
Rivets
−
General
Details
Figure
40

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 STRUCTURAL REPAIR MANUAL

(9) If the correct size for a replacement HUCK rivet is not known, do
the steps that follow:
(a) Accurately measure the diameter of the hole. Refer to Chapter
51−44−00, if the diameter of the hole is within the tolerances
for a standard rivet, use a rivet of this diameter. If the diam

eter of the hole is not within the tolerances, increase the hole
diameter to suit an oversize rivet if applicable, or the next
standard size.
(b) Measure the total thickness of the material at the hole. Refer
to Figure 41 thru Figure 45 as applicable to find the rivet of
the correct grip−length to suit the material thickness.

NOTE: If the typeof HUCK rivet can not be identified, contact

AIRBUS.

Data for Rivet (Blind) (Huck) Type MS 21140

Figure 41

GRIP LENGTH GRIP LENGTH RANGE (T)

CO
CODE FROM (MIN) TO (MAX)
(SECOND DASH
NUMBER) mm in. mm in
02 2.39 0.094 3.99 0.157
03 3.96 0.155 5.99 0.220
Data for Rivet (Blind) (Huck) Type MS 21140

Printed in Germany
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 STRUCTURAL
REPAIR
MANUAL

GRIP
LENGTH GRIP
LENGTH
RANGE
(T)
CODE FROM
(MIN) TO
(MAX)
(SECOND
DASH
NUMBER) mm in. mm in
04 5.56 0.218 7.16 0.281
05 7.14 0.281 8.76 0.344
06 8.74 0.344 10.34 0.407
07 10.31 11.94 0.470
Data
for
Rivet
(Blind)
(Huck)
Type
MS
21140
Table
19
NOTE: Additional
information
about
these
blind
rivets
and
rivets
of
other
diameters
and
grip
lengths
can
be
found
in
the
Standards
Manual.

Data
for
Rivet
(Blind)
(Huck)
Type
MS
90354
Figure
42

GRIP
LENGTH GRIP
LENGTH
RANGE
(T)
CO
CODE FROM
(MIN) TO
(MAX)
(SECOND DASH
(SECOND
DASH
NUMBER) mm in. mm in.
01 0.79 0.031 2.41 0.094
02 2.39 0.094 3.99 0.157

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MANUAL

GRIP
LENGTH GRIP
LENGTH
RANGE
(T)
CODE FROM
(MIN) TO
(MAX)
(SECOND
DASH
NUMBER) mm in. mm in.
03 3.96 0.155 5.59 0.220
04 5.56 0.218 7.16 0.281
05 7.14 0.281 8.76 0.344
06 8.75 0.344 10.34 0.407
07 10.31 0.405 11.94 0.470
Data
for
Rivet
(Blind)
(Huck)
Type
MS
90354
Table
20
NOTE: Additional
information
about
these
blind
rivets
and
rivets
of
other
diameters
and
grip
lengths
can
be
found
in
the
Standards
Manual.

Data
for
Rivet
(Blind)
(HUCK)
Type
NAS
1919
Figure
43

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 STRUCTURAL
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MANUAL

GRIP
LENGTH GRIP
LENGTH
RANGE
(T)
CO
CODE FROM
(MIN) TO
(MAX)
(SECOND DASH
(SECOND
DASH
NUMBER) mm in. mm in.
00 0.508 0.020 0.889 0.035
01 0.635 0.025 1.575 0.062
02 1.600 0.062 3.175 0.125
03 3.200 0.125 4.750 0.187
04 4.775 0.187 6.350 0.250
05 6.375 0.250 7.925 0.312
06 7.950 0.312 9.525 0.375
Data
for
Rivet
(Blind)
(HUCK)
Type
NAS
1919
Table
21
NOTE: This
table
is
applicable
to
blind
rivets
of
diameter
code
−
04
(1/8
in.)
(3.175
mm).

GRIP
LENGTH GRIP
LENGTH
RANGE
(T)
CO
CODE FROM
(MIN) TO
(MAX)
(SECOND DASH
(SECOND
DASH
NUMBER) mm in. mm in.
00 0.635 0.025 1.143 0.045
01 0.787 0.030 1.575 0.062
02 1.600 0.062 3.175 0.125
03 3.200 0.125 4.750 0.187
04 4.775 0.187 6.350 0.250
05 6.375 0.250 7.925 0.312
06 7.950 0.312 9.525 0.375
07 9.550 0.375 11.100 0.437
08 11.125 0.437 12.700 0.500
09 12.725 0.500 14.275 0.562
10 14.300 0.562 15.875 0.625
Data
for
Rivet
(Blind)
(HUCK)
Type
NAS
1919
Table
22
NOTE: This
table
is
applicable
to
blind
rivets
of
diameter
code
−
05
(5/32
in.)
(3.962
mm).

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MANUAL

GRIP
LENGTH GRIP
LENGTH
RANGE
(T)
CO
CODE FROM
(MIN) TO
(MAX)
(SECOND DASH
(SECOND
DASH
NUMBER) mm in. mm in.
01 0.940 0.037 1.575 0.062
02 1.600 0.062 3.175 0.125
03 3.200 0.125 4.750 0.187
04 4.775 0.187 6.350 0.250
05 6.375 0.250 7.925 0.312
06 7.950 0.312 9.525 0.375
07 9.550 0.375 11.100 0.437
08 11.125 0.437 12.700 0.500
09 12.725 0.500 14.275 0.562
10 14.300 0.562 15.875 0.625
11 15.875 0.625 17.450 0.687
12 17.475 0.687 19.050 0.750
Data
for
Rivet
(Blind)
(HUCK)
Type
NAS
1919
Table
23
NOTE: This
table
is
applicable
to
blind
rivets
of
diameter
code
−
06
(3/16
in.)
(4.826
mm).

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Data
for
Rivet
(Blind)
(HUCK)
Type
NAS
1921
Figure
44

GRIP
LENGTH GRIP
LENGTH
RANGE
(T)
CO
CODE FROM
(MIN) TO
(MAX)
(SECOND DASH
(SECOND
DASH
NUMBER) mm in. mm in.
01 1.448 0.057 1.956 0.077
02 1.600 0.062 3.175 0.125
03 3.200 0.125 4.750 0.187
04 4.775 0.187 6.350 0.250
05 6.375 0.250 7.925 0.312
06 7.950 0.312 9.525 0.375
07 9.550 0.375 11.100 0.437
Data
for
Rivet
(Blind)
(HUCK)
Type
NAS
1921
Table
24
NOTE: This
table
is
applicable
to
blind
rivets
of
diameter
code
−
04
(1/8
in.)
(3.175
mm).

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MANUAL

GRIP
LENGTH GRIP
LENGTH
RANGE
(T)
CO
CODE FROM
(MIN) TO
(MAX)
(SECOND DASH
(SECOND
DASH
NUMBER) mm in. mm in.
01 1.905 0.075 2.540 0.100
02 2.032 0.080 3.175 0.125
03 3.200 0.125 4.750 0.187
04 4.775 0.187 6.350 0.250
05 6.375 0.250 7.925 0.312
06 7.950 0.312 9.525 0.375
07 9.550 0.375 11.100 0.437
08 11.125 0.437 12.700 0.500
09 12.725 0.500 14.275 0.562
10 14.300 0.562 15.875 0.625
Data
for
Rivet
(Blind)
(HUCK)
Type
NAS
1921
Table
25
NOTE: This
table
is
applicable
to
blind
rivets
of
diameter
code
−
05
(5/32
in.)
(3.962
mm).

GRIP
LENGTH GRIP
LENGTH
RANGE
(T)
CO
CODE FROM
(MIN) TO
(MAX)
(SECOND DASH
(SECOND
DASH
NUMBER) mm in. mm in.
02 2.540 0.100 3.175 0.125
03 3.200 0.125 4.750 0.187
04 4.775 0.187 6.350 0.250
05 6.375 0.250 7.925 0.312
06 7.950 0.312 9.525 0.375
07 9.550 0.375 11.100 0.437
08 11.125 0.442 12.700 0.500
09 12.725 0.501 14.275 0.562
10 14.300 0.562 15.875 0.625
Data
for
Rivet
(Blind)
(HUCK)
Type
NAS
1921
Table
26

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MANUAL

GRIP
LENGTH GRIP
LENGTH
RANGE
(T)
CODE FROM
(MIN) TO
(MAX)
(SECOND
DASH
NUMBER) mm in. mm in.
11 15.875 0.625 17.450 0.687
12 17.475 0.687 19.050 0.750
Data
for
Rivet
(Blind)
(HUCK)
Type
NAS
1921
Table
26
NOTE: This
table
is
applicable
to
blind
rivets
of
diameter
code
−
06
(3/16
in.)
(4.826
mm).

Data
for
Rivet
(Blind)
(HUCK)
Type
NSA
54217
Figure
45

GRIP
LENGTH GRIP
LENGTH
RANGE
(T)
CO
CODE FROM
(MIN) TO
(MAX)
(SECOND DASH
(SECOND
DASH
NUMBER) mm in. mm in.
01
<1> 0.64 0.025 1.57 0.062
02
<1> 1.58 0.063 3.17 0.125
Data
for
Rivet
(Blind)
(HUCK)
Type
NSA
54217
Table
27

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MANUAL

GRIP
LENGTH GRIP
LENGTH
RANGE
(T)
CODE FROM
(MIN) TO
(MAX)
(SECOND
DASH
NUMBER) mm in. mm in.
03
<1> 3.20 0.126 4.75 0.187
04
<1> 4.78 0.188 6.35 0.250
05
<1> 6.38 0.251 7.92 0.312
06
<1> 7.95 0.313 9.52 0.375
07
<2> 9.55 0.376 11.10 0.437
08
<2> 11.12 0.438 12.70 0.500
Data
for
Rivet
(Blind)
(HUCK)
Type
NSA
54217
Table
27
<1> Blind
rivets
in
these
grip
ranges
area
available
from
stock
in
the
diame
ter
codes:
−4
(1/8
in.)
(3.18
mm),
−5
(5/32
in.)
(3.97
mm)
and
−6
(3/16
in.)
(4.76
mm).

<2> Blind
rivets
in
these
grip
ranges
are
available
from
stock
in
the
diame
ter
code
−6
(3/16
in.)
(4.76
mm).
NOTE: Additional
information
about
these
blind
rivets
and
rivets
of
other
di
ameters
and
grip
lengths
can
be
found
in
the
Standards
Manual.

B. Installation

(1) The
steps
that
follow
give
the
general
sequence
for
the
installation
of
a
HUCK
rivet.
(a) Put
the
rivet
in
its
hole.
Make
sure
that
the
locking
collar
is
in
its
correct
position.

(b) Put
the
applicable
installation
tool
onto
the
rivet
mandrel.
Make
sure
that
the
tool
is
perpendicular
to
the
surface
of
the
mate
rial.
CAUTION: OBEY
THE
MANUFACTURER’S
INSTRUCTIONS
WHEN
USING
A
POWER
OP
ERATED
TOOL.
SOME
DOUBLE
ACTION
TOOLS
HAVE
A
SHIFT
VALVE
CARTRIDGE
THAT
MUST
BE
ADJUSTED
TO
A
SPECIFIC
PRESSURE
BE
FORE
USE.
(c) Operate
the
installation
tool.
This:
− forms
the
upset
head,
− seats
the
locking
collar
into
the
locking
groove,
− shears
the
mandrel
at
the
break−off
groove.

(d) Release
the
tool
trigger
and
remove
the
tool
from
the
rivet
head.
The
broken
off
part
of
the
mandrel
is
automatically
pushed
out
of
the
tool.

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 STRUCTURAL
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MANUAL

(e) If
required,
mill
the
mandrel
at
the
break−off
groove
to
give
a
smooth
finish.
(f) Inspect
the
HUCK
rivet
for
correct
installation
(Refer
to
Para
graph
10.C.).

C. Inspection
after
the
Installation
of
HUCK
Rivets

(1) General
(a) Carefully
examine
the
installed
rivets.

(b) A
visual
inspection
of
the
correct
shape
of
the
formed
(blind)
side
with
a
probe
light
and
a
mirror
is
necessary
when
the
ac
cess
is
possible.

(c) The
installation
of
the
HUCK
rivet
is
correct
when:
− the
pin
is
correctly
locked
by
the
locking
collar,
− the
manufactured
head
is
fully
seated,
− the
blind
head
is
correctly
formed,
− the
adjacent
structure
is
free
from
damage
and
distortion.

(d) Deformation
or
buckling
of
the
outer
skin
is
not
permitted
out
side
the
limits
given
in
Chapter
51−10−00.
(e) Make
sure
that
the
head
of
countersunk
rivet
is
in
the
limits
given
in
Chapter
51−10−00.

(2) Permitted
Limits

(a) For
the
protrusion
and
intrusion
limits
of
the
pin
refer
to
Fig
ure
46.

(b) The
correct
position
of
the
locking
collar
is
given
in
Figure
46.
(c) The
limits
for
the
seat
of
the
head
are
given
in
Figure
47.
(d) Cracks
in
the
material
around
the
fastener
are
not
permitted.

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 STRUCTURAL
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MANUAL

Pin
and
Collar
Prorusion/Depression
Limits
for
Rivets
(Blind)
(HUCK)
Figure
46

THESE
LIMITS
APPLY
TO
PROTRUDING
HEAD
RIVETS
NOM.
RIVET
DIAMETER DIMENSION
A
(MAX) DIMEENSION
B
(MAX)
in. mm in. mm in. mm
5/32 4.0 0.010 0.25 0.010 0.25
3/16 4.8 0.012 0.30 0.012 0.30
1/4 6.4 0.015 0.38 0.015 0.38
5/16 8.0 0.019 0.48 0.019 0.48
3/8 9.6 0.023 0.58 0.023 0.58
7/16 11.2 0.028 0.71 0.028 0.71
1/2 12.8 0.033 0.84 0.033 0.84
Pin
and
Collar
Prorusion/Depression
Limits
for
Rivets
(Blind)
(HUCK)
Table
28

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 STRUCTURAL
REPAIR
MANUAL

THESE
LIMITS
APPLY
TO
countersunk
HEAD
RIVETS
NOM.
RIVET
DIAMETER DIMENSION
A
(MAX) DIMEENSION
B
(MAX)
in. mm in. mm in. mm
1/8 3.2 0.018 0.46 0.008 0.20
5/32 4.0 0.022 0.56 0.010 0.25
3/16 4.8 0.025 0.64 0.012 0.30
Pin
and
Collar
Prorusion/Depression
Limits
for
Rivets
(Blind)
(HUCK)
Table
29

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MANUAL

Rivet
(Blind)
(HUCK)
Abutment
(Seating)
Check
Figure
47

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 STRUCTURAL
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MANUAL

D. Removal
of
HUCK
Rivets
(Refer
to
Figure
48
thru
Figure
51)

(1) General
(a) HUCK
rivets
can
be
removed
with
a
special
tool
kit.
If
this
kit
is
not
available
HUCK
rivets
can
be
carefully
removed
with
con
ventional
twist−drills.
In
this
Paragraph
the
two
procedures
are
given.

(b) The
Figures
referred
to
in
this
Paragraph
show
the
removal
of
a
countersunk
rivet.
The
removal
of
a
protruding
head
rivet
is
the
same.

(2) Removal
with
a
Special
Tool
Kit
(Procedure
1)

(a) For
the
selection
of
the
applicable
tool
kit
use
the
subsequent
Table:

RIVET
NOMINAL
DIAMETER KIT
NUMBER
NECESSARY
5/32
in.
(4.0
mm) 105−50
3/16
in.
(4.8
mm) 105−60
1/4

in.
(6.4
mm) 105−80
5/6

in.
(8.0
mm) 105−100
3/8
in.
(9.6
mm) 105−120

Table
30
(b) Set
the
drill
bushing
vertically
on
the
rivet
mandrel
so
that
it
is
in
full
contact
with
the
locking
collar.
(c) Use
a
power
drill
with
a
maximum
speed
of
1250
revolutions
per
minute
(rpm).
Drill
to
the
locking
collar
depth.
For
the
drill
depth
and
dimensions
refer
to
Figure
48.

(d) Put
the
pin
punch
on
the
rivet
mandrel
and
drive
out
the
mandrel
(Refer
to
Figure
49).

(e) Remove
the
remaining
part
of
the
mandrel
together
with
the
lock
ing
collar
with
a
pointed
tool.

(f) Assemble
the
tool,
to
counterbore
the
rivet
body
as
follows:

1 Install
the
cutter
fully
into
the
holder
and
attach
it
with
the
set
screw.

2 Screw
the
cutter
holder
fully
into
the
micro−limit
tool.
3 Install
the
micro−limit
tool
in
the
anti−rotation
cap
as
far
as
possible
and
secure
it
with
the
set
screws.

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 STRUCTURAL
REPAIR
MANUAL

4 Put
the
assembly
of
the
micro−limit
into
the
chuck
of
the
pow
er
drill
and
secure
it.

HUCK
Rivet
Mandrel
Drilling
Details
Figure
48

RIVET DRIL DRILL DRILL
DEPTH

NOMINAL L
BUSH PART DIAMETER in. mm
DIAMETER ING NUM
PART BER in. NOM. mm MIN MAX MIN MAX
NUM
in. mm BER
5/32 4.0 1036 5029 0.09 7/64 2.5 0.05 0.070 1.3 1.8
15 99 8 0
3/16 4.8 1036 5030 0.12 1/8 3.0 0.07 0.090 1.8 2.3
16 00 0 0
1/4 6.4 1036 5030 0.15 5/32 4.0 0.09 0.110 2.3 2.8
17 01 6 0

HUCK
Rivet
Mandrel
Drilling
Details
Table
31

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 STRUCTURAL
REPAIR
MANUAL

RIVET DRIL DRILL DRILL
DEPTH

NOMINAL L
BUSH PART DIAMETER in. mm
DIAMETER ING NUM
PART BER in. NOM. mm MIN MAX MIN MAX
NUM
in. mm BER
5/16 8.0 1036 5030 0.18 3/16 4.8 0.10 0.125 2.7 3.2
18 03 8 5
3/8 9.5 1036 5030 0.22 15/6 5.8 0.13 0.150 3.3 3.8
19 05 8 4 0

HUCK
Rivet
Mandrel
Drilling
Details
Table
31

HUCK
Rivet
Pin
Removal
Details
Figure
49

RIVET PIN
PUNCH
NOMINAL
PART DIAMETER
DIAMETER NUMBER
in. mm in. mm

HUCK
Rivet
Pin

Removal
Details
Table
32

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REPAIR
MANUAL

5/32 4.0 503010 3/32 2.4

3/16 4.8 503010 3/32 2.4
1/4 6.4 503012 5/32 4.0
5/16 8.0 503013 3/16 4.8
3/8 9.5 503014 7/32 5.6

HUCK
Rivet
Pin

Removal
Details
Table
32

HUCK
Rivet
Body
Counterboring
Details
Figure
50

RIVET ANTI CUTTER CUTTER CUTTER
DEPTH
(INCHES)

NOMINAL ROTA HOLDER
DIAMETER TION PART PART DIAMETER CSK
HEAD PROT.
HEAD
CAP NUMBER NUMBER
PART
in. mm NUMBER in. mm MIN MAX MIN MAX

5/32 4.0 103620 103610 103605 5/32 4.0 0.055 0.065 0.055 0.065
3/16 4.8 103620 103611 103606 3/16 4.8 0.065 0.075 0.120 0.130
1/4 6.4 103621 103611 103607 1/4 6.4 0.090 0.100 0.125 0.135
HUCK
Rivet
Body
Counterboring
Details
Table
33

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 STRUCTURAL
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MANUAL

RIVET ANTI CUTTER CUTTER CUTTER
DEPTH
(INCHES)

NOMINAL ROTA HOLDER
DIAMETER TION PART PART DIAMETER CSK
HEAD PROT.
HEAD
CAP NUMBER NUMBER
PART
in. mm NUMBER in. mm MIN MAX MIN MAX

5/16 8.0 103621 103613 103608 5/16 8.0 0.120 0.130 0.125 0.135
3/8 9.5 103622 103613 103609 3/8 9.5 0.150 0.160 0.190 0.200
HUCK
Rivet
Body
Counterboring
Details
Table
33
(g) Adjust
the
micro−limit
tool
to
the
type
and
size
of
the
rivet.
For
dimensions
refer
to
the
Table
in
Figure
50.

(h) Put
the
cutter
in
the
rivet
body
and
press
the
anti−rotation
cap
tightly
against
the
rivet
head.
Counterbore
to
the
necessary
depth
and
carefully
remove
the
tool
(Refer
to
Figure
50).
CAUTION: BE
CAREFUL
WHEN
YOU
USE
THE
PIN
PUNCH.
DO
NOT
CAUSE
DAMAGE
TO
THE
HOLE
AND,
IF
IT
IS
APPLICABLE,
THE
COUNTERSINK.

(i) Put
the
pin
punch
in
the
rivet
body
and
drive
out
the
lower
part
(Refer
to
Figure
51).
Carefully
remove
the
pin
punch.
(j) If
the
remaining
part
of
the
body,
for
example
the
rivet
head,
is
loose,
lift
it
out
of
the
hole.
If
this
is
not
possible,
put
the
end
of
the
pin
punch
into
the
head.
Move
the
punch
at
an
angle
to
one
side
and
remove
the
rivet
head
(Refer
to
Figure
51).
(3) Removal
with
conventional
twist−drills
(Procedure
2)

NOTE: The
removal
procedure
2
is
not
illustrated
because
it
is
equivalent
to
the
procedure
1.
The
necessary
illustrations
are
given
in
procedure
1.

(a) Use
a
sharp
twist−drill.
The
recommended
diameter
is
given
in
the
subsequent
table
for
the
applicable
rivet
diameter.

RIVET
NOMINAL
DIAMETER RECOMMENDED
DRILL
DIMEN
SION
1/8

in.
(3.2
mm) 5/64
in.
(2.0
mm)
5/32
in.
(4.0
mm) 7/64
in.
(2.5
mm)
3/16
in.
(4.8
mm) 1/8

in.
(3.2
mm)
1/4

in.
(6.4
mm) 5/32
in.
(4.0
mm)
5/16
in.
(8.0
mm) 3/16
in.
(4.8
mm)

Table
34

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 STRUCTURAL
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RIVET
NOMINAL
DIAMETER RECOMMENDED
DRILL
DIMEN
SION
3/8

in.
(9.5
mm) 15/64
in.
(5.8
mm)
7/16
in.
(11.2
mm) 17/64
in.
(6.8
mm)
1/2

in.
(12.8
mm) 5/16
in.
(7.9
mm)

Table
34
(b) Secure
the
twist−drill
in
a
power
tool
and
drill
the
rivet
head
to
the
bottom
of
the
locking
collar.
Make
sure
that
the
twist−
drill
remains
concentric
on
the
rivet.

NOTE: Do
not
use
a
drill
speed
greater
than
1250
rpm.

NOTE: For
the
larger
size
rivet
you
are
recommended
to
drill
a
pilot
hole
first.

(c) Use
a
pin
punch
that
is
the
same
diameter
(or
less)
as
the
twistdrill
used
in
Step
10.D.(3)(b).
Put
the
punch
on
the
rivet
mandrel
and
drive
out
the
mandrel.

(d) Remove
the
remaining
part
of
the
mandrel
together
with
the
lock
ing
collar
with
a
pointed
tool.

HUCK
Rivet
Body
Removal
Details
Figure
51

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 STRUCTURAL
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RIVET PIN
PUNCH
NOMINAL
PART DIAMETER
DIAMETER NUMBER
in. mm in. mm
5/32 4.0 503012 5/32 4.0
3/16 4.8 503013 3/16 4.8
1/4 6.4 503015 1/4 6.4
5/16 8.0 503016 5/16 8.0
3/8 9.5 503017 3/8 9.5
HUCK
Rivet
Body
Removal
Details
Table
35
CAUTION: DAMAGE
MAY
BE
CAUSED
TO
THE
SKIN/COUNTERSINK
IF
THE
RIVET
TURNS
WHEN
YOU
DO
THE
NEXT
STEP.

(e) Use
a
twist−drill
with
the
same
nominal
diameter
as
the
rivet
at
a
drill
speed
of
approximately
250
revolutions
per
minute
(rpm).
Counterbore
the
rivet
head
with
a
light
and
constant
pressure.
For
the
counterbore
depth
of
the
applicable
head
type
and
rivet
dimensions
refer
to
the
table
that
follows:

RIVET
NOMINAL
DIAMETER COUNTERBORE
DEPTH
CSK
HEAD PROTRUDING
HEAD
1/8

in.
(3.2
mm) 1.0
mm
(0.039
in.) 1.2
mm
(0.047
in.)
5/32
in.
(4.0
mm) 1.4
mm
(0.055
in.) 1.5
mm
(0.059
in.)
3/16
in.
(4.8
mm) 1.8
mm
(0.071
in.) 1.9
mm
(0.075
in.)
1/4

in.
(6.4
mm) 2.4
mm
(0.094
in.) 3.3
mm
(0.130
in.)
5/16
in.
(8.0
mm) 3.2
mm
(0.126
in.) 3.3
mm
(0.130
in.)
3/8

in.
(9.5
mm) 3.9
mm
(0.154
in.) 5.0
mm
(0.197
in.)
7/16
in.
(11.2
mm) 4.6
mm
(0.181
in.) 5.0
mm
(0.197
in.)
1/2

in.
(12.8
mm) 5.3
mm
(0.209
in.) 6.6
mm
(0.260
in.)

Table
36
CAUTION: BE
CAREFUL
WHEN
YOU
USE
THE
PIN
PUNCH.
DO
NOT
CAUSE
DAMAGE
TO
THE
HOLE
AND,
IF
IT
IS
APPLICABLE,
THE
COUNTERSINK.

(f) Use
a
pin
punch
that
is
the
same
diameter
(or
less)
as
the
twistdrill
diameter
used
in
step
10.D.(3)(a).
Put
this
punch
in
the
rivet
body
and
drive
out
the
lower
part.
Carefully
remove
the
pin
punch.

(g) If
the
remaining
part
of
the
body,
for
example
the
rivet
head,
is
loose,
lift
it
out
of
the
hole.
If
this
is
not
possible,
put

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 STRUCTURAL
REPAIR
MANUAL

the
end
of
the
pin
punch
into
the
head.
Move
the
punch
at
an
angle
to
one
side
and
remove
the
rivet
head.
11. Rivet
−
Blind
(AVDEL
MBC)

A. General
(Refer
to
Figure
52)

(1) In
this
paragraph
the
Rivet
−
Blind
(AVDEL
MBC)
is
referred
to
as
the
AVDEL
rivet.
(2) The
AVDEL
rivet
consists
of
two
parts.
These
are:

(a) A
tubular
body
that
has
a
protruding
or
100
°

countersunk
head.

(b) A
mandrel
(shank)
that
is
retained
in
the
tubular
body.
When
the
AVDEL
rivet
is
installed
the
mandrel
is
mechanically
secured
within
the
tubular
body
and
is
sheared
off
level
with
rivet
head.

(3) When
installed
the
AVDEL
rivet
is
similar
to
a
’pop’
rivet.
But
be
cause
the
mandrel
is
retained
in
the
tubular
body
this
rivet
has
al
most
the
same
properties
as
a
solid
rivet.
The
AVDEL
rivet
can
be
installed
from
one
side.
(4) The
AVDEL
rivet
is
identified
by
an
identification
number.
This
num
ber
and
its
specific
details
are
explained
in
Chapter
51−40−12.

(5) AVDEL
rivets
can
be
installed
with
standard
’pop’
rivet
tools,
or
with
AVDEL
power
or
hand
operated
tools.

(6) AVDEL
rivets
must
only
be
used
to
replace
AVDEL
rivets,
or
when
they
are
called
up
in
a
specific
repair
procedure
or
other
approved
docu
ments.

(7) AVDEL
rivets
are
supplied
already
lubricated.
Do
not
remove
the
lu
bricant
or
touch
the
rivets
more
than
is
necessary.

(8) Before
you
install
AVDEL
rivets
makes
sure
that:
− you
have
the
correct
type
of
rivet,
− the
rivets
are
made
of
the
required
material,
− the
rivets
have
the
specified
surface
protection
and/or
lubrica
tion,
− and
that
they
are
not
corroded
or
scratched,
− the
rivets
are
the
correct
length
and
diameter,
− the
holes
for
the
rivets
are
correctly
prepared.
(9) Before
you
install
AVDEL
rivets
in
the
structure
you
are
recommended
to
make
a
test−piece.
This
will
check
the
rivet,
tool
and
hole
pre
cision.
The
test
materials
and
rivets
must
have
the
same
properties
as
those
required
for
the
repair.

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General
and
Installation
Features
of
the
Rivet−Blind
(AVDEL
MBC)
Figure
52

B. AVDEL
Rivet
Installation

(1) The
procedure
that
follows
is
applicable
to
installation
with
hand
or
power
operated
tools.
(2) Make
sure
that
the
rivets
are
the
correct
dimensions
(diameter
and
length).
If
these
dimensions
are
not
known
use
the
procedure
that
follows:

(a) Accurately
measure
the
diameter
of
the
hole.
Refer
to
Chapter
51−44−00,
if
the
diameter
of
the
hole
is
within
the
tolerances
for
a
standard
rivet,
use
a
rivet
of
this
diameter.
If
the
diam
eter
of
the
hole
is
not
within
the
tolerances,
increase
the
hole
diameter
to
suit
an
oversize
rivet
if
applicable,
or
the
next
standard
size.

(b) Refer
to
Figure
53
to
find
the
required
length
of
the
rivet.
(3) Make
sure
that
the
installation
tool
is
correct
for
the
rivet
dimen
sions
and
head
shape.

(4) Insert
the
rivet
mandrel
fully
into
the
installation
tool.

(5) Insert
the
rivet
body
fully
into
the
hole.
Make
sure
that
the
installation
tool
nose
is
perpendicular
to
the
material
surface.
(6) Operate
the
tool
to
complete
the
installation
of
the
rivet.

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(7) Remove
the
installation
tool
and
make
sure
that
the
rivet
is
installed
correctly.
NOTE: If
the
mandrel
protrudes
from
the
rivet
head
the
mandrel
can
be
milled
flush.

C. Inspection
after
Installation

(1) General

(a) Carefully
examine
the
installed
rivets
as
far
as
possible.
NOTE: You
are
recommended
to
use
inspection
aids,
for
example,
probe
light
and
mirror,
to
examine
the
’blind’
head.

(b) The
AVDEL
rivet
is
correctly
installed
when:
− the
mandrel
is
correctly
installed,
− the
manufactured
head
is
correctly
seated,
− the
’blind’
head
is
correctly
shaped,
− the
surrounding
structure
is
free
from
damage
and
distortion.

Data
to
find
Second
Dash
Number
for
AVDEL
MBC
Rivets
ASNA
0079
and
ASNA
008
Figure
53

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 STRUCTURAL
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MANUAL

GRIP
LENGTH
(T)
RANGES SECOND
DASH
NUMBER
NECESSARY
FROM
(MIN) TO
(MAX) RIVET/HOLE RIVET/HOLE RIVET/HOLE
DIAMETER
1/8 DIAMETER
1/8 DIAMETER
in. mm in. mm in.
(3.2 in.
(3.2 5/32
in.
mm) mm) (4.0
mm)
0.050 1.27 0.141 3.58 −407 N/A N/A
0.062 1.57 0.141 3.58 N/A −508 N/A
0.077 1.96 0.141 3.58 N/A N/A −609
0.109 2.77 0.203 5.16 −409 −510 −611
0.172 4.37 0.266 6.76 −411 −512 −613
0.234 5.94 0.328 8.33 −413 −514 −615
0.297 7.54 0.391 9.93 −415 −516 −617
0.359 9.12 0.453 11.51 − −518 −619
0.422 10.72 0.516 13.11 − −520 −621
Data
to
find
Second
Dash
Number
for
AVDEL
MBC
Rivets
ASNA
0079
and
ASNA
0080
Table
37
(c) Deformation
or
buckling
of
the
skin
is
not
permitted
outside
the
limits
given
in
Chapter
51−10−00.

(d) The
manufactured
head
of
a
countersunk
rivet
must
be
flush,
or
within
the
limits
given
in
Chapter
51−10−00.

(2) Tests,
Acceptable
Faults
and
Limits
(a) The
security
of
the
mandrel
must
be
tested.
Use
the
AVDEL
pin
tester
(Part
Number
79/95−0700
set
to
35
lbf.
to
do
this.
No
movement
of
the
mandrel
is
permitted.
(b) Refer
to
Figure
54
for
head
seating
limits.
(c) Cracks
are
not
permitted
in
the
material
around
the
rivet.

D. Removal
of
AVDEL
MBC
Rivets
(Refer
to
Figure
55)

(1) General

(a) One
of
two
methods
can
be
used
to
remove
these
rivets.
In
Method
11.D.(1)
the
mandrel
is
removed
by
hitting
it
out
with
a
hammer
and
parallel
pin
punch.
But
the
surrounding
structure
must
be
supported
when
you
do
this.

(b) In
Method
11.D.(2)
the
mandrel
is
removed
by
drilling
it
out
with
a
twistdrill.
A
twist−drill
with
a
diameter
slightly
less
than
the
nominal
diameter
is
used.

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 STRUCTURAL
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MANUAL

(c) After
the
removal
of
rivets
all
unwanted
materials
must
be
re
moved
as
far
as
it
is
possible.
(d) The
removal
methods
are
shown
in
Figure
55
and
are
detailed
be
low.

CAUTION: WHEN
REMOVING
RIVETS
TAKE
CARE
NOT
TO
CAUSE
DAMAGE
TO
THE
STRUCTURE,
ESPECIALLY
WHEN
THE
SKIN
IS
THIN.

CAUTION: IF
THE
RIVET
TURNS
DURING
DRILLING
OPERATIONS
DAMAGE
CAN
BE
CAUSED
TO
THE
SKIN/HOLE.

(2) Removal
Method
1

(a) Hit
out
the
mandrel
from
the
rivet
body.
Do
this
with
a
hammer
and
parallel
pin
punch.
The
pin
punch
diameter
must
be
slightly
less
than
the
inner
diameter
of
the
rivet
body.
Support
the
structure
on
the
underside
during
this
step.

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 STRUCTURAL
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MANUAL

AVDEL
Rivet
Head
Abutment
(Seating)
Check
Figure
54

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STRUCTURAL
REPAIR
MANUAL

Removal
of
AVDEL
MBC
Rivets
Figure
55

Page
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 STRUCTURAL
REPAIR
MANUAL

(b) With
a
twist−drill
of
the
same
nominal
diameter
as
the
rivet
drill
almost
through
the
head.
It
is
recommended
that
a
mechani
cal
stop
is
used
on
the
twist−drill
to
control
the
depth
drilled.

(c) With
a
parallel
pin
punch
remove
the
rivet
head.

(d) With
a
parallel
pin
punch
and
hammer
hit
out
the
remainder
of
the
rivet
body.
The
parallel
pin
punch
diameter
must
be
slightly
less
than
the
nominal
diameter
of
the
rivet,
but
greater
than
the
rivet
inner
diameter.
Support
the
structure
on
the
underside
during
this
step.

(3) Removal
Method
2

(a) Make
a
mark
with
a
centre
punch
in
the
centre
of
the
mandrel.
This
will
help
to
centre
the
twist−drill
in
step
11.D.(3)(b).

(b) Drill
through
the
mandrel
and
part
of
the
rivet
body
wall.
Use
a
twist−drill
with
a
diameter
greater
than
the
mandrel
diameter
but
less
than
the
rivet
nominal
diameter.
(c) Do
steps
11.D.(2)(c)
and
11.D.(2)(d)
of
Method
1
to
complete
the
removal
of
the
rivet.

E. Additional
Information

After
a
rivet
has
been
removed
check
the
hole
for
size
and
damage.
If
the
hole
is
damaged
or
distorted
it
must
be
drilled
for
an
oversize
rivet.

12. Rivet−Blind
(IMEX)

Refer
to
Figure
56
A. General

(1) The
IMEX
blind
rivet
consists
of
two
parts.
These
are:

(a) A
tubular
body
that
has
a
protruding
or
100
°

countersunk
head.

(b) A
mandrel
that
is
retained
in
the
tubular
body.
When
the
rivet
blind
(IMEX)
is
installed
the
mandrel
is
mechanically
secured
within
the
tubular
body
and
is
sheared
off
at
the
break
off
groove
(Refer
to
Figure
56).

(2) The
IMEX
blind
rivet
is
similar
to
a
’pop’
rivet.
The
only
differ
ence
is
that
the
sealed
body
end
completely
encloses
the
head
of
the
mandrel.

(3) Mandrels
are
available
as
short
break
or
long
break
types.
The
long
break
type
breaks
off
above
the
level
of
the
rivet
head
and
must
be

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 STRUCTURAL
REPAIR
MANUAL

milled
flush.
The
short
break
type
breaks
off
internally
in
the

tu
bular
body.
(4) The
IMEX
blind
rivet
has
an
identification
number.
This
number
and
its
specific
details
are
explained
in
Chapter
51−40−12.

(5) IMEX
blind
rivets
can
be
installed
with
standard
’pop’
rivet
tools
using
a
special
nose
piece
and
in
certain
instances,
special
jaws.

(6) IMEX
blind
rivets
must
only
be
used
when
they
are
called
up
in
a
specific
repair
procedure
or
other
A/B
approved
documents.

(7) Before
the
installation
of
IMEX
blind
rivets
make
sure
that:
− the
rivet
type
is
correct,
− the
rivets
are
made
of
the
required
material,
− the
rivets
have
the
specified
surface
protection
and/or
lubrica
tion,
− and
that
they
are
not
corroded
or
scratched,
− the
rivets
are
the
correct
length
and
diameter,
− the
holes
for
the
rivets
are
correctly
prepared.

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 STRUCTURAL
REPAIR
MANUAL

IMEX
Blind
Rivets
−
General
and
Installation
Details
Figure
56

Page
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 STRUCTURAL
REPAIR
MANUAL

B. Installation
Procedure

(1) Make
sure
that
the
rivets
are
the
correct
dimension
(diameter
and
length).
If
the
length
is
not
known
refer
to
Figure
57,
Figure
58
and
Figure
59.

(2) Refer
to
Chapter
51−44−00
to
find
the
correct
dimension
for
the
hole
that
is
applicable
to
the
rivet−blind
(IMEX)
nominal
diameter.

(3) Drill
the
hole
to
the
required
diameter
(Refer
to
51−44−00).
(4) Make
sure
that
the
hole,
including
the
countersunk
and/or
dimpled
portion
if
applicable
is
in
a
satisfactory
condition,
clean
and
free
from
burrs.

(5) Make
sure
that
the
installation
tool
is
correct
for
the
rivet
dimen
sions
and
head
shape.
(6) Insert
the
rivet
mandrel
fully
into
the
installation
tool.

(7) Insert
the
rivet
body
fully
into
the
hole.
Make
sure
that
the
installation
tool
nose
is
perpendicular
to
the
material
surface.

(8) Operate
the
tool
to
complete
the
installation
if
the
rivet.
(9) Remove
the
installation
tool
and
make
sure
that
the
rivet
is
installed
correctly.

NOTE: if
the
mandrel
protrudes
from
the
rivet
head
the
mandrel
can
be
milled
flush.

C. Inspection
after
Installation
(1) General

(a) Carefully
examine
the
installed
rivets
as
far
as
possible.

NOTE: You
are
recommended
to
use
inspection
aids,
for
example,
probe
light
and
mirror,
to
examine
the
’blind’
head.
(b) The
IMEX
rivet
is
correctly
installed
when:
− the
mandrel
is
correctly
installed,
− the
manufactured
head
is
correctly
seated,
− the
’blind’
head
is
correctly
shaped,
− the
surrounding
structure
is
free
from
damage
and
distortion.

(c) Deformation
or
buckling
of
the
skin
is
not
permitted
outside
the
limits
given
in
Chapter
51−10−00.

(d) The
manufactured
head
of
a
countersunk
rivet
must
be
flush,
or
within
the
limits
given
in
Chapter
51−10−00.

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 STRUCTURAL
REPAIR
MANUAL

Determining
Required
Length
(Second
Dash
Number)
of
IMEX
Blind
Rivet
NSA5420
Figure
57

RIVET
NSA5420 RIVET
BODY
LENGTH
(L)
ACCORD
DASH
NUMBER ING
TO
DASH
NO.
in.


0.010 mm



0.25
−42 0.237 6.0
−44 0.300 7.6
−46 0.362 9.2
−48 0.425 10.8
−54 0.315 8.0
−58 0.440 11.2
−510 0.502 12.8
−64 0.330 8.4
−66 0.392 12.4
−68 0.455 11.6
Determining
required
Length
(Second
Dash
Num−
ber)
of
IMEX
Blind
Rivet
NSA5420
Table
38

Page
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51−42−11 Nov
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 STRUCTURAL
REPAIR
MANUAL

RIVET
NSA5420 RIVET
BODY
LENGTH
(L)
ACCORD
DASH
NUMBER ING
TO
DASH
NO.
in.


0.010 mm



0.25
−610 0.517 13.1
−612 0.580 14.7
Determining
required
Length
(Second
Dash
Num−
ber)
of
IMEX
Blind
Rivet
NSA5420
Table
38
GRIP
LENGTH
(T)
RANGES SECOND
DASH
FROM
(MIN) TO
(MAX) NUM
NUMBER
RE
QUIRED
in. mm in. mm
− − 1/16
(0.063) 1.6 2
1/16
(0.063) 1.6 1/8
(0.125) 3.2 4
1/8
(0.125) 3.2 3/16
(0.188) 4.8 6
3/16
(0.188) 4.8 1/4
(0.250) 6.4 8
1/4
(0.250) 6.4 5/16
(0.313) 7.9 10
5/16
(0.313) 7.9 3/8
(0.375) 9.5 12
Determining
Required
Length
(Second
Dash
Number)
of
IMEX
Blind
Rivet
NSA5420
Table
39

Page
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 STRUCTURAL
REPAIR
MANUAL

Determining
Required
Length
(Second
Dash
Number)
of
IMEX
Blind
Rivet
NSA5421
with
Diameter
of
1/8
in.
(3.2
mm)
Figure
58
(sheet
1)

Determining
Required
Length
(Second
Dash
Number)
of
IMEX
Blind
Rivet
NSA5421
with
a
Diameter
of
5/32
in.
(4.0
mm)
Figure
58
(sheet
2)

Page
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 STRUCTURAL
REPAIR
MANUAL

NOTE: Figure
58,
Sheet
1
shows
that
for
IMEX
rivets
of
the
coun
tersunk
type,
the
grip
length
is
measured
outside
a
coun
tersink
but
where
dimpling
is
used,
the
grip
length
is
mea
sured
at
the
hole.
The
second
number
after
the
dash
in
the
part
number
indicates
only
the
parallel
portion
of
the
grip
length
in
1/32nds
of
an
inch,
i.e.
the
head
height
is
not
included.

GRIP
LENGTH
(T)
RANGES NSA5421 RIVET
BODY
LENGTH
(L)
ACCORD

RIVET
DASH ING
TO
DASH
NO.
FROM
(MIN.) TO
(MAX.) NUM
NUMBER
RE in.
±

0.010 mm
±

0.25
QUIRED
in. mm in. mm
0.067 1.7 0.098 2.5 −42 0.242 6.1
0.098 2.5 0.161 4.1 −44 0.305 7.7
0.161 4.1 0.220 5.6 −46 0.367 9.3
0.220 5.6 0.283 7.2 −48 0.430 10.9
0.283 7.2 0.346 8.8 −410 0.492 12.5
Determining
Required
Length
(Second
Dash
Number)
of
IMEX
Blind
Rivet
NSA5421
with
Diameter
of
1/8
in.
(3.2
mm)
Table
40
NOTE: Figure
58,
Sheet
2
shows
that
for
IMEX
rivets
of
the
coun
tersunk
type,
the
grip
length
is
measured
outside
a
coun
tersink
but
where
dimpling
is
used,
the
grip
length
is
mea
sured
at
the
hole.
The
second
number
after
the
dash
in
the
part
number
indicates
only
the
parallel
portion
of
the
grip
length
in
1/32nds
of
an
inch,
i.e.
the
head
height
is
not
included.

GRIP
LENGTH
(T)
RANGES NSA5421 RIVET
BODY
LENGTH
(L)
ACCORD

RIVET
DASH ING
TO
DASH
NO.
FROM
(MIN.) TO
(MAX.) NUM
NUMBER
RE in.
±

0.010 mm
±

0.25
QUIRED
in. mm in. mm
0.110 2.8 0.165 4.2 −54 0.340 8.6
0.165 4.2 0.228 5.8 −56 0.402 10.2
0.228 5.8 0.291 7.4 −58 0.465 11.8
0.291 7.4 0.354 9.0 −510 0.527 13.4
Determining
Required
Length
(Second
Dash
Number)
of
IMEX
Blind
Rivet
NSA5421
with
a
Diameter
of
5/32
in.
(4.0
mm)
Table
41

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 STRUCTURAL
REPAIR
MANUAL

Determining
Required
Length
(Second
Dash
Number)
of
IMEX
Blind
Rivet
NSA5421
with
a
Diameter
of
3/16
in.
(4.8
mm)
Figure
59
NOTE: Figure
59
shows
that
for
IMEX
rivets
of
the
countersunk
type,
the
grip
length
is
measured
outside
a
countersink
but
where
dimpling
is
used,
the
grip
length
is
measured
at
the
hole.
The
second
number
after
the
dash
in
the
part
number
indicates
only
the
parallel
portion
of
the
grip
length
in
1/32nds
of
an
inch,
i.e.
the
head
height
is
not
included.

GRIP
LENGTH
(T)
RANGES NSA5421 RIVET
BODY
LENGTH
(L)
ACCORD

RIVET
DASH ING
TO
DASH
NO.
FROM
(MIN.) TO
(MAX.) NUM
NUMBER
RE in.
±

0.010 mm
±

0.25
QUIRED
in. mm in. mm
0.118 3.0 0.184 4.6 −64 0.342 8.7
0.181 4.6 0.244 6.2 −66 0.404 10.3
0.244 6.2 0.307 7.8 −68 0.467 11.9
Determining
Required
Length
(Second
Dash
Number)
of
IMEX
Blind
Rivet
NSA5421
with
a
Diameter
of
3/16
in.
(4.8
mm)
Table
42

Page
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Printed in Germany
 STRUCTURAL
REPAIR
MANUAL

GRIP
LENGTH
(T)
RANGES NSA5421 RIVET
BODY
LENGTH
(L)
ACCORD

RIVET
DASH ING
TO
DASH
NO.
FROM
(MIN.) TO
(MAX.) NUMBER
RE in.
±

0.010 mm
±

0.25
QUIRED
in. mm in. mm
0.307 7.8 0.366 9.3 −610 0.529 13.4
0.366 9.3 0.425 10.8 −612 0.592 15.0
Determining
Required
Length
(Second
Dash
Number)
of
IMEX
Blind
Rivet
NSA5421
with
a
Diameter
of
3/16
in.
(4.8
mm)
Table
42
(2) Acceptance
Limits

(a) Due
to
the
varying
degrees
of
functional
importance
of
installed
IMEX
blind
rivets,
acceptance
or
rejection
is
mostly
at
the
discretion
of
the
inspector.

(b) As
a
general
guide,
reject
loose
or
cracked
rivets.
D. Removal
of
Rivets−Blind
(IMEX)
(Refer
to
Figure
60)

(1) The
removal
of
IMEX
blind
rivets
is
achieved
by
first
removing
the
manufactured
head
then
driving
the
remainder
of
the
rivet
out
of
its
hole.
(2) If
the
rivet
has
a
long
break
mandrel,
support
the
rivet
with
dolly
or
similar.
Then
accurately
center
punch
the
mandrel
to
provide
location
for
the
twist−drill
tip
(Refer
to
Figure
60).

(3) Rivets
with
short
break
mandrels
have
a
central
cavity
which
can
serve
as
a
pilot
hole
for
the
twist−drill.
CAUTION: WHEN
REMOVING
RIVETS
TAKE
CARE
NOT
TO
CAUSE
DAMAGE
TO
THE
STRUCTURE,
ESPECIALLY
WHEN
THE
SKIN
IS
THIN.

CAUTION: IF
THE
RIVET
TURNS
DURING
DRILLING
OPERATIONS
DAMAGE
CAN
BE
CAUSED
TO
THE
SKIN/HOLE.

(4) With
a
twist−drill
of
the
same
nominal
diameter
as
the
rivet
drill
almost
through
the
head.
It
is
recommended
that
a
mechanical
stop
is
used
on
the
twist−drill
to
control
the
depth
drilled.

(5) With
a
parallel
pin
punch
remove
the
rivet
head.

(6) With
a
parallel
pin
punch
and
hammer
hit
out
the
remainder
of
the
rivet
body.
The
parallel
pin
punch
diameter
must
be
slightly
less
than
the
nominal
diameter
of
the
rivet,
but
greater
than
the
rivet
inner
diameter.
Support
the
structure
on
the
underside
during
this
step.

Page
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 STRUCTURAL
REPAIR
MANUAL

Removal
of
IMEX
Blind
Rivets
Figure
60

Page
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51−42−11 Nov
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Printed in Germany
 STRUCTURAL
REPAIR
MANUAL

13. Rivet−Blind
(CHERRYMAX)

A. General
(Refer
to
Figure
61)
(1) There
are
two
types
of
these
blind
rivets
that
you
can
use
for
re
pair
work
on
the
aircraft.
These
are:
− CHERRYMAX,
− Oversize
CHERRYMAX.

(2) These
blind
rivets
are
supplied
as
one
piece
and
consist
of
three
parts:
(a) A
tubular
body
that
has
a
head
at
one
end.
Two
types
of
head
are
available:
a
100
°

countersunk
head
and
a
protruding
head.

(b) A
pin
that
goes
through
the
body.
The
pin
has
a
head
opposite
the
body
head.
It
also
has
a
lock−groove,
a
break−off
groove
and
pullgrooves.
There
is
also
a
driving
anvil
on
the
pin.
This
makes
sure
that
the
lock−collar
sits
correctly,
and
that
the
pin
always
breaks
off
at
the
break−off
groove.

(c) A
lock−collar
on
the
pin.
When
the
blind−rivet
is
installed,
the
collar
is
swaged
into
the
lock−groove
on
the
pin
and
in
the
head.
This
makes
sure
that
the
pin
is
locked
into
the
body.
(3) To
identify
the
correct
blind−rivet
for
a
repair,
or
a
replacment,
refer
to
Chapter
51−40−12.

(4) These
blind
rivets
are
supplied
with
a
layer
of
lubricant
on
them.
Do
not
clean
them,
or
touch
them
more
than
is
necessary,
before
they
are
installed.

(5) Do
not
install
blind
rivets
that
are
not
in
a
satisfactory
condi
tion.
Discard
any
that
are
not.

(6) You
can
use
hand
or
power
operated
tools
to
install
blind
rivets.
These
tools
must
have
the
correct
heads
attached
to
them.
(7) It
is
recommended
that
you
do
a
test
procedure
on
some
unwanted
ma
terials
before
you
install
blind
rivets.
Do
the
test
on
materials
that
are
the
same
(type
and
thickness)
as
the
repair
materials.
Use
blind
rivets
that
are
the
same
(head
type,
diameter
and
grip−length),
as
those
for
the
repair.
(8) After
you
have
installed
a
blind
rivet,
the
end
of
the
pin
can
be
above
the
rivet
head.
You
can
mill
the
pin
until
it
is
in
line
with
the
top
of
the
rivet
head.

Page
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51−42−11 Nov
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 STRUCTURAL
REPAIR
MANUAL

CHERRYMAX
Blind
Rivets,
General
Data
Figure
61

Page
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51−42−11 Nov
01/05
Printed in Germany
 STRUCTURAL
REPAIR
MANUAL

B. Hole
Preparation

(1) The
holes
for
blind
rivets
are
only
drill−finished.
It
is
not
neces
sary
to
ream
them.

(2) Before
you
install
a
blind
rivet,
you
must
examine
the
hole
to
make
sure
that:
− it
is
clean,
− it
has
no
burrs,
− it
is
not
damaged.
(3) Refer
to
Chapter
51−44−00
to
find
the
correct
dimensions
for
the
hole.

(4) Do
these
steps
if
a
hole
is
damaged,
or
if
a
new
hole
is
necessary.

(a) Use
grip−pins
or
clamps
to
make
sure
that
the
repair
materials
are
correctly
clamped
together.
(b) Drill
a
pilot−hole
in
the
correct
position.

(c) Drill
the
hole
to
the
correct
final
dimension.

(d) Deburr
the
hole.

C. Selection
of
the
Blind
Rivet
(Refer
to
Figure
62).
(1) If
the
correct
size
for
a
replacement
blind
rivet
is
not
known
do
the
steps
that
follow:

(a) Accurately
measure
the
diameter
of
the
hole.
Refer
to
Chapter
51−44−00,
if
the
diameter
of
the
hole
is
within
the
tolerances
for
a
standard
rivet,
use
a
rivet
of
this
diameter.
If
the
diam
eter
if
the
hole
is
not
within
the
tolerances,
increase
the
hole
diameter
to
suit
an
oversize
rivet
if
applicable,
or
the
next
standard
size.
(b) Find
the
grip−length
that
is
necessary
for
the
total
thickness
of
the
materials
to
be
attached.
Use
one
of
the
two
subsequent
pro
cedures
to
do
this:
− Use
standard
equipment
to
measure
the
total
thickness
of
− the
materials.
This
will
give
you
the
second
dash
number
of
the
blind
rivet
part
number
(Refer
to
Figure
62).
− Use
a
CHERRYLOCK
grip−length
gauge.
This
will
give
you
the
se
cond
dash
number.

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51−42−11 Nov
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 STRUCTURAL
REPAIR
MANUAL

Grip−Length
Data
for
CHERRYMAX
Blind
Rivets
Figure
62

Page
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51−42−11 Nov
01/05
Printed in Germany
 STRUCTURAL
REPAIR
MANUAL

D. Installation
Procedure

CAUTION: OBEY
THE
MANUFACTURER’S
INSTRUCTIONS
BEFORE
YOU
USE
THESE
TOOLS.
THE
INSTRUCTIONS
WILL
GIVE
YOU
THE
NECESSARY
PRESSURES.
THEY
WILL
ALSO
GIVE
YOU
THE
CORRECT
DRIVING
ATTACHMENT
TO
USE.

(1) Get
the
correct
installation
tool.
Make
sure
that
the
tool
has
the
correct
driving
attachments
for
the
type
and
diameter
of
the
blind
rivet.
NOTE: A
supply
of
air
under
pressure
is
necessary
for
power
operated
installation
tools.

(2) Clamp
the
repair
materials
so
that
all
the
holes
are
aligned.

(3) Put
the
blind
rivet
in
the
hole.

NOTE: If
a
’wet
assembly’
is
necessary,
or
is
specified,
refer
to
Chapter
51−76−11.

(4) Put
the
installation
tool
on
the
blind
rivet.
Make
sure
that
the
blind
rivet
is
correctly
seated
on
the
material
face.
Operate
the
tool
to
install
the
blind
rivet.

NOTE: The
broken
part
of
the
pin
is
automatically
pushed
out
of
the
tool
when
the
installation
operation
is
completed.

(5) Mill
the
end
of
the
pin
until
it
is
in
line
with
the
body
head,
if
this
is
necessary.

NOTE: Special
tools
are
available
for
this
step.
(6) Do
the
inspection
procedure
that
is
given
in
Paragraph
13.E..

E. Inspection
and
Permitted
Limits

(1) After
you
have
installed
blind
rivets,
make
an
inspection
of
them
to
make
sure
that
they
are
correctly
installed.
This
inspection
must
make
sure:
− that
the
body
head
touches
the
material
correctly.
This
is
done
visually
only,
− that
the
lock−collar
is
correctly
installed
(Refer
to
Figure
63),
− that
the
pin
is
correctly
installed
(Refer
to
Figure
63),
− that
the
’blind’
head
is
correctly
formed.
This
is
a
visual
in
spection
that
you
do
if
you
can
see
the
head,
− that
the
top
of
the
head
of
a
countersunk
blind
rivet
is
in
line
with,
or
only
a
little
above,
the
top
face
of
the
repair
(Refer
to
Chapter
51−10−00).

NOTE: If
it
is
necessary,
use
equipment
(for
example,
probe−light
and
inspection
mirror)
to
do
the
inspection
where
you
cannot
see.

Page
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51−42−11 Nov
01/05
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 STRUCTURAL
REPAIR
MANUAL

Pin
Protrusion/Depression
Limits
for
CHERRYMAX
Rivets
Figure
63

(2) Deformation
of
the
repair
materials
must
not
be
more
than
the
limits
given
in
Chapter
51−10−00.

(3) No
cracks
are
permitted
in
any
part
of
the
blind
rivet,
or
the
ad
jacent
structure.
F. Removal
Procedure
(Refer
to
Figure
64)

CAUTION: TAKE
CARE
NOT
TO
CAUSE
DAMAGE
TO
THE
STRUCTURE
WHEN
YOU
DO
THIS
PROCEDURE.

(1) Make
an
accurate
mark
with
a
centre
punch
in
the
center
of
the
end
of
the
pin.
This
will
give
a
location
for
the
twist−drill
(Refer
to
step
13.F.(2)).

CAUTION: DO
NOT
LET
THE
RIVET
BODY
TURN
WHEN
YOU
DO
THESE
STEPS.

(2) Drill
a
hole
in
the
pin
to
the
bottom
of
the
collar.
Do
this
with
a
twist−drill
that
has
a
diameter
the
same
as
the
pin.
(3) Remove
the
lock−collar
(Refer
to
Figure
64).

(4) Hit
the
remaining
pin
out
of
the
rivet
body.
Do
this
with
a
paral
lel
pin
punch
and
a
hammer.

(5) Get
a
twist−drill
that
has
a
diameter
almost
as
large
as
the
outer
diameter
of
the
rivet
body.
Make
an
estimate
to
find
how
deep
you

Page
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51−42−11 Nov
01/05
Printed in Germany
 STRUCTURAL
REPAIR
MANUAL

will
have
to
drill
the
hole
in
the
river
head.
Put
a
mechanical
stop
on
the
twist−drill
to
give
the
correct
depth
(Refer
to
Figure
64).

(6) Drill
the
hole
in
the
head
of
the
rivet.

(7) Put
a
parallel
pin
punch
in
the
drilled
hole.
The
diameter
of
this
pin
punch
must
agree
with
the
hole
diameter.
Move
the
pin
punch
at
an
angle
to
break
off
the
rivet
head.
(8) Hit
out
the
remaining
shank
of
the
rivet
body.
Do
this
with
the
same
parallel
pin
punch
used
in
step
13.F.(7)
and
a
hammer.

Page
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51−42−11 Nov
01/05
Printed in Germany
 STRUCTURAL
REPAIR
MANUAL

CHERRYMAX
Rivet
Removal
Details
Figure
64

Page
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51−42−11 Nov
01/05
Printed in Germany
 STRUCTURAL
REPAIR
MANUAL

14. Rivet−Blind
(CHERRYLOCK)

A. General
(Refer
to
Figure
65
and
Figure
66)
(1) There
are
three
types
of
these
blind
rivets
that
are
used
for
repair
work
on
the
aircraft.
These
are:
− Standard
CHERRYLOCK
− Bulbed
CHERRYLOCK
− Oversize
CHERRYLOCK

(2) These
blind
rivets
are
supplied
as
one
piece
and
consist
of
three
parts:

(a) A
tubular
body
that
has
a
head
at
one
end.
Two
types
of
head
are
available:
a
100
°

countersunk
head
and
a
protruding
head.

(b) A
pin
that
goes
through
the
body.
The
pin
has
a
head
opposite
the
body
head.
It
also
has
a
lock−groove,
a
break−off
groove
and
pullgrooves.
The
pin
head
of
the
bulbed
type
has
also
a
shear
ring.
This
makes
sure
that
the
pin
breaks
off
at
the
break−off
groove
in
line
with
the
top
of
the
rivet
head
when
the
ring
shears
and
relocates
on
the
pin
head.

(c) A
lock−collar
on
the
pin.
When
the
blind−rivet
is
installed,
the
collar
is
swaged
into
the
lock−groove
on
the
pin
and
in
the
head.
This
makes
sure
that
the
pin
is
locked
into
the
body.

(3) To
identify
the
correct
blind−rivet
for
a
repair,
or
a
replacement,
refer
to
Chapter
51−40−12.
(4) These
blind
rivets
are
supplied
with
a
layer
of
lubricant
on
them.
Do
not
clean
them,
or
touch
them
more
than
is
necessary,
before
they
are
installed.

(5) Do
not
install
blind
rivets
that
are
not
in
a
satisfactory
condi
tion.
Discard
any
that
are
not.
(6) You
can
use
hand
or
power
operated
tools
to
install
blind
rivets.
These
tools
must
have
the
correct
heads
attached
to
them.

(7) It
is
recommended
that
you
do
a
test
procedure
on
some
unwanted
ma
terials
before
you
install
blind
rivets.
Do
the
test
on
materials
that
are
the
same
(type
and
thickness)
as
the
repair
materials.
Use
blind
rivets
that
are
the
same
(head
type,
diameter
and
grip−length),
as
those
for
the
repair.

(8) After
you
have
installed
a
blind
rivet,
the
end
of
the
pin
can
be
above
the
rivet
head.
You
can
mill
the
pin
until
it
is
in
line
with
the
top
of
the
rivet
head.

Page
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51−42−11 Nov
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 STRUCTURAL
REPAIR
MANUAL

Rivet
−
Blind
(CHERRYLOCK)
−
General
Details
Figure
65

Page
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51−42−11 Nov
01/05
Printed in Germany
 STRUCTURAL
REPAIR
MANUAL

Rivet
−
Blind
(Bulbed
CHERRYLOCK)
−
General
Details
Figure
66

Page
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51−42−11 Nov
01/05
Printed in Germany
 STRUCTURAL
REPAIR
MANUAL

B. Hole
Preparation

(1) The
holes
for
blind
rivets
are
only
drill−finished.
It
is
not
neces
sary
to
ream
them.

(2) Before
you
install
a
blind
rivet,
you
must
examine
the
hole,
includ
ing
the
countersunk
or
dimpled
portion
if
applicable,
to
make
sure
that:
− it
is
clean,
− it
has
no
burrs,
− it
is
not
damaged.
(3) Refer
to
Chapter
51−44−00
to
find
the
correct
dimensions
for
the
hole.

(4) Do
these
steps
if
a
hole
is
damaged,
or
if
a
new
hole
is
necessary.

(a) Use
grip−pins
or
clamps
to
make
sure
that
the
repair
materials
are
correctly
clamped
together.

(b) Drill
a
pilot−hole
in
the
correct
position.

(c) Drill
the
hole
to
the
correct
final
dimension.

(d) Deburr
the
hole.
C. Selection
of
the
Blind
Rivet
(Refer
to
Figure
67
and
Figure
68)

(1) If
the
correct
size
for
a
replacement
blind
rivet
is
not
known
do
the
steps
that
follow:

(a) Accurately
measure
the
diameter
of
the
hole.
Refer
to
Chapter
51−44−00
if
the
diameter
of
the
hole
is
within
the
tolerances
for
a
standard
rivet,
use
a
rivet
of
this
diameter.
If
the
diam
eter
of
the
hole
is
not
within
the
tolerances,
increase
the
hole
diameter
to
suit
an
oversize
rivet
if
applicable,
or
the
next
standard
size.
(b) Find
the
grip−length
that
is
necessary
for
the
total
thickness
of
the
materials
to
be
attached.
Use
one
of
the
two
subsequent
pro
cedures
to
do
this:
− Use
standard
equipment
to
measure
the
total
thickness
of
the
materials.
This
will
give
you
the
second
dash
number
of
the
blind
rivet
part
number
(Refer
to
Figure
67
and/or
Figure
68).
− Use
a
CHERRYLOCK
grip−length
gauge.
This
will
give
you
the
se
cond
dash
number.

Page
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51−42−11 Nov
01/05
Printed in Germany
 STRUCTURAL
REPAIR
MANUAL

Grip
−
Length
Data
for
Standard
CHERRYLOCK
Blind
Rivets
Figure
67

Page
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51−42−11 Nov
01/05
Printed in Germany
 STRUCTURAL
REPAIR
MANUAL

Grip
−
Length
Data
for
Bulbed
CHERRYLOCK
Blind
Rivets
Figure
68

Page
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51−42−11 Nov
01/05
Printed in Germany
 STRUCTURAL
REPAIR
MANUAL

D. Installation
Procedure

CAUTION: OBEY
THE
MANUFACTURER’S
INSTRUCTIONS
BEFORE
YOU
USE
THESE
TOOLS.
THE
INSTRUCTIONS
WILL
GIVE
YOU
THE
NECESSARY
PRESSURES.
THEY
WILL
ALSO
GIVE
YOU
THE
CORRECT
DRIVING
ATTACHMENT
TO
USE.

(1) Get
the
correct
installation
tool.
Make
sure
that
the
tool
has
the
correct
driving
attachments
for
the
type
and
diameter
of
the
blind
rivet.
NOTE: A
supply
of
air
under
pressure
is
necessary
for
power
operated
installation
tools.

(2) Clamp
the
repair
materials
so
that
all
the
holes
are
aligned.

(3) Put
the
blind
rivet
in
the
hole.

NOTE: If
a
’wet
assembly’
is
necessary,
or
is
specified,
refer
to
Chapter
51−76−11.

(4) Put
the
installation
tool
on
the
blind
rivet.
Make
sure
that
the
blind
rivet
is
correctly
seated
on
the
material
face.
Operate
the
tool
to
install
the
blind
rivet.

NOTE: The
broken
part
of
the
pin
is
automatically
pushed
out
of
the
tool
when
the
installation
operation
is
completed.

(5) Mill
the
end
of
the
pin
until
it
is
in
line
with
the
body
head,
if
this
is
necessary.

NOTE: Special
tools
are
available
for
this
step.
(6) Do
the
inspection
procedure
that
is
given
in
Paragraph
14.E..

E. Inspection
and
Permitted
Limits

(1) After
you
have
installed
blind
rivets,
make
an
inspection
of
them
to
make
sure
that
they
are
correctly
installed.
This
inspection
must
make
sure:
− that
the
body
head
touches
the
material
correctly.
This
is
done
visually
only,
− that
the
lock−collar
is
correctly
installed
(Refer
to
Figure
69),
− that
the
pin
is
correctly
installed
(Refer
to
Figure
69),
− that
the
’blind’
head
is
correctly
formed.
This
is
a
visual
in
spection
that
you
do
if
you
can
see
the
head,
− that
the
top
of
the
head
of
a
countersunk
blind
rivet
is
in
line
with,
or
only
a
little
above,
the
top
face
of
the
repair
(Refer
to
Chapter
51−10−00).

NOTE: If
it
is
necessary,
use
equipment
(for
example,
probe−light
and
inspection
mirror)
to
do
the
inspection
where
you
cannot
see.

Page
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51−42−11 Nov
01/05
Printed in Germany
 STRUCTURAL
REPAIR
MANUAL

Pin
and
Collar
Protrution/Depression
Limits
for
Standard
and
Bulbed
CHERRYLOCK
Blind
Rivets
Figure
69
Page
A44




51−42−11 Nov
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Printed in Germany
 STRUCTURAL
REPAIR
MANUAL

(2) Deformation
of
the
repair
materials
must
not
be
more
than
the
limits
given
in
Chapter
51−10−00.
(3) No
cracks
are
permitted
in
any
part
of
the
blind
rivet,
or
the
ad
jacent
structure.

F. Removal
Procedure
(Refer
to
Figure
70)

CAUTION: TAKE
CARE
NOT
TO
CAUSE
DAMAGE
TO
THE
STRUCTURE
WHEN
YOU
DO
THIS
PROCEDURE.
(1) Make
an
accurate
mark
with
a
centre
punch
in
the
center
of
the
end
of
the
pin.
This
will
give
a
location
for
the
twist−drill
(Refer
to
step
14.F.(2)).

CAUTION: DO
NOT
LET
THE
RIVET
BODY
TURN
WHEN
YOU
DO
THESE
STEPS.

(2) Drill
a
hole
in
the
pin
to
the
bottom
of
the
collar.
Do
this
with
a
twist−drill
that
has
a
diameter
the
same
as
the
pin.

(3) Remove
the
lock−collar
(Refer
to
Figure
70).

(4) Hit
the
remaining
pin
out
of
the
rivet
body.
Do
this
with
a
paral
lel
pin
punch
and
a
hammer.
(5) Get
a
twist−drill
that
has
a
diameter
almost
as
large
as
the
outer
diameter
of
the
rivet
body.
Make
an
estimate
to
find
how
deep
you
will
have
to
drill
the
hole
in
the
rivet
head.
Put
a
mechanical
stop
on
the
twist−drill
to
give
the
correct
depth
(Refer
to
Figure
70).

(6) Drill
the
hole
in
the
head
of
the
rivet.
(7) Put
a
parallel
pin
punch
in
the
drilled
hole.
The
diameter
of
this
pin
punch
must
agree
with
the
hole
diameter.
Move
the
pin
punch
at
an
angle
to
break
off
the
rivet
head.

(8) Hit
out
the
remaining
shank
of
the
rivet
body.
Do
this
with
the
same
parallel
pin
punch
used
in
step
14.F.(7)
and
a
hammer.

Page
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51−42−11 Nov
01/05
Printed in Germany
 STRUCTURAL
REPAIR
MANUAL

Blind
Rivets
Removal
Details
Figure
70

Page
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51−42−11 Nov
01/05
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 STRUCTURAL
REPAIR
MANUAL

15. Pin
(Swaged)
(LOCKBOLT)

A. General
(1) A
pin
(swaged)
fastener
is
a
two
piece
assembly
consisting
of:

(a) A
pin
with
a
protruding
or
countersunk
head.
The
shank
of
the
pin
includes
grooves
on
to
which
a
collar
is
swaged,
a
tension
break−off
groove
and
pull−grooves.
The
pull−grooves
are
only
used
for
installing
the
pin
(swaged)
(Refer
to
Figure
71).
(b) A
collar
that
is
swaged
on
to
the
locking
grooves
on
the
pin
shank
to
secure
the
pin
(swaged)
when
it
is
installed
(Refer
to
Figure
72)

NOTE: It
is
important
that
the
collars
are
put
on
the
pins
with
the
collar
facing
the
correct
way.

(2) Only
corrosion
resistant
steel
(CRS)
or
titanium
pins
(swaged)
are
used
for
repair
work.

(3) A
correctly
installed
pin
(swaged)
gives
a
strong
but
light
weight
fastener,
and
they
are
available
for
tension
or
shear
requirements
(Refer
to
Figure
71).

(4) Pins
(swaged)
are
installed
in
clearance
and
transition−fit
holes
when
they
are
used
to
repair
steel
or
titanium
structure.

(5) Pins
(swaged)
are
installed
in
clearance−fit
holes
in
structures
that
are
a
combination
of
aluminum
alloy
and
steel
or
titanium,
unless
otherwise
specified
in
a
repair
procedure.

NOTE: If
the
hole
size
is
only
given
for
the
steel
or
titanium
in
the
combination
above,
then
the
hole
in
the
aluminum
alloy
part
is
an
interference−fit.

Page
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51−42−11 Nov
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STRUCTURAL
REPAIR
MANUAL

Examples
of
Pins
(swaged)
Figure
71

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51−42−11 Nov
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 STRUCTURAL REPAIR MANUAL

Typical Pin/Collar Assembly

Figure 72

(6) Pins (swaged) are supplied lubricated. This lubricant must not be
removed before they are intalled unless otherwise specified in an
AIRBUS document.

(7) Repair parts must be temporarily secured with grip−pins or other

suitable tools before pins (swaged) are installed.

(8) When it is not possible to install a pin (swaged) because of limited

space a pin (threaded) (Refer to Paragraph 7.) is an acceptable al

ternative.

(9) Where pins (swaged) are installed in structure with surfaces that are
not parallel, the limits that follow apply:
− for CRS tension type pins (swaged), an angle up to 7 degrees is
acceptable,
− for titanium tension type pins (swaged), an angle up to 5 degrees
is acceptable, except in the wing structure where the limit is 3
degrees,
− for titanium shear type pins (swaged), an angle up to 3 degrees is
acceptable.

(10) All cutting tools (for example, drills, reamers and countersinks)
used to prepare the hole for a pin (swaged) must be in good condi

tion. This is necessary to ensure that the surface of the hole is
smooth.

Page A49
Printed in Germany
51−42−11 Nov 01/06
 STRUCTURAL REPAIR MANUAL

(11) Before installing pins (swaged) make sure that the pins and collars
are as specified in the repair procedure.
NOTE: If it is necessary to replace a pin (swaged) and the pin can

not be identified contact AIRBUS.

(12) The shank of a pin (swaged) does not expand when the pin is
installed, therefore the hole for the pin must be prepared very ac

curately.
(13) The collar for pins (swaged) can only be swaged with a suitable pow

er tool.

(14) The various manufacturer’s of pins (swaged) and collars use different
Part Numbering methods. It is recommended that these items are stored
in containers that show the applicable part number and type of item.
(15) The identification number for pins (swaged) and collars is given in
Chapter 51−40−12.

(16) Unless otherwise specified, pins (swaged) are ’wet installed’ with
sealant (Refer to Chapter 51−76−11).

B. Installation−General
(1) Before you install pins (swaged), make sure that the holes are
clean, smooth and prepared in accordance with Chapter 51−44−00.

(2) When an existing hole is damaged or oversize, install the next over

size pin (Refer to Chapter 51−43−00).

(3) If the grip−length is not specified for a pin (swaged) refer to Fig

ure 73.

Page A50
Printed in Germany
51−42−11 Nov 01/06
 STRUCTURAL
REPAIR
MANUAL

Gage
to
find
the
Grip
Length
Figure
73
(sheet
1)

Page
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51−42−11 Nov
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 STRUCTURAL
REPAIR
MANUAL

Gage
to
find
the
Grip
Length
Figure
73
(sheet
2)

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51−42−11 Nov
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 STRUCTURAL
REPAIR
MANUAL

C. Hole
Preparation

(1) It
is
recommended
that
before
installing
pins
(swaged)
in
the
air
craft
structure
a
test
installation
is
made
on
suitable
test
pieces.
For
this
test
use:
− materials
of
the
same
type
and
thickness
as
the
repair
parts
and/
or
structure,
− pins
(swaged)
and
collars
of
the
same
type
as
those
required
for
the
repair.
This
test
will
help
to
make
sure
that
the
final
fastener,
tool
and
hole
accuracy
is
obtained.

(2) Accurately
mark
the
position
for
the
pin
(swaged)
hole,
make
a
mark
with
a
centre
punch
at
this
position.

NOTE: Only
use
a
soft
pencil
to
mark
the
position
on
aluminum
alloy,
and
an
approved
marker
on
titanium
materials.

(3) Refer
to
Chapter
51−44−00
to
find
the
applicable
final
hole
diameter
and
fit
required
for
the
pin
(swaged).
Use
one
of
the
methods
that
follows
to
cut
the
final
hole.

(a) Method
1.
1 Drill
an
undersize
hole
with
a
suitable
twist−drill.
It
is
recommended
that
this
step
is
done
with
the
drill
machine
mounted
in
a
drilling
jig
or
tripod.
This
is
to
make
sure
that
the
centre−line
of
the
hole
is
within
2
degrees
of
the
perpen
dicular.
2 Ream
the
hole
to
the
required
final
diameter
with
a
reamer/ar
bor
combination
tool
shown
in
Figure
74.

NOTE: If
the
final
hole
is
required
to
be
countersunk,
use
a
countersink
bit
on
the
reamer.
3 Deburr
the
hole
edges,
and
cut
a
relief
radius
or
chamfer
as
specified
in
Chapter
51−44−00.

NOTE: Use
cutting
lubricant
(FREON
TB−1
or
I.C.I.
ARCTON−113)
during
the
drilling/reaming
steps.

(b) Method
2.
1 Cut
the
hole
in
one
step
with
a
special
drill
reamer
tool.
Use
a
drilling
jig
or
tripod
to
make
sure
that
the
centre−line
of
the
hole
is
within
2
degrees
of
the
perpendicular.

2 If
required,
countersink
the
hole
(Refer
to
Chapter
51−46−00).
3 Do
step
15.C.(3)(a)3
of
Method
1.

(4) Clean
the
repair
area
to
remove
unwanted
lubricant
and
swarf.

Page
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51−42−11 Nov
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STRUCTURAL
REPAIR
MANUAL

Tool
Configurations
Figure
74

Page
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51−42−11 Nov
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 STRUCTURAL REPAIR MANUAL

(5) Examine the hole to check that it is clean, smooth and has a good
surface finish.
D. Installation of Pin (Swaged)

CAUTION: REFER TO THE TOOL MANUFACTURER’S INSTRUCTIONS BEFORE USING A

POWER TOOL TO INSTALL/SWAGE THESE PINS AND COLLARS. MAKE SURE
THAT THE TOOL PRESSURE REGULATOR CONTROL IS SET CORRECTLY (HIGH
OR LOW PRESSURE). FAILURE TO DO THIS CAN CAUSE DAMAGE TO THE
PIN AND/OR STRUCTURE.

(1) Three different procedures are used to install pins (swaged). These
procedures are related to the type of fit (interference, transition
or clearance) that is required, and the type of structure (thick or
thin) in which the pins (swaged) will be installed. The procedures
are given in Figure 75, Figure 76 and Figure 77 as follows:

(a) Interference or transition fit in any structure, refer to Figure

75.

(b) Clearance fit in thin structure, refer to Figure 76.

(c) Clearance fit in thick structure, refer to Figure 77.

E. Inspection after Installation of Pin (Swaged) Heads

(1) The limits that follow are applicable to protruding head (also Refer
to Figure 78), and countersunk head (also Refer to Figure 79).

(a) More than 50 % of the pins (swaged) in a row or pattern must

have fully seated heads.

NOTE: Fully seated means full metal−to−metal contact between the

head and the fastened material.

(b) Less than 50 % of the pins (swaged) in a row or pattern can

have a small gap between the head and the fastened material. In
this case there must be a minimum of 25 % of the head circum

ference in full contact, and the gap must be within the limits
given in the applicable figure.

NOTE: This gap is not permitted on any two adjacent pins

(swaged).
(c) It is not permitted to correct the head seating after the collar
has been swaged.

(d) When the head seating is outside these limits, replace the fas

tener. In this case, if it is necessary to install an oversize
fastener refer to Chapter 51−43−00 for the applicable oversize
pin.

Page A55
Printed in Germany
51−42−11 May 01/06
 STRUCTURAL
REPAIR
MANUAL

Installation
of
Pins
(Swaged)
in
any
Structure
Interference
or
Transition
Fit
Figure
75

Page
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51−42−11 Nov
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 STRUCTURAL
REPAIR
MANUAL

Installation
Pins
(Swaged)
in
Thin
Structure,
Clearance
Fit
Figure
76

Page
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51−42−11 Nov
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 STRUCTURAL
REPAIR
MANUAL

Installation
of
Pins
(Swaged)
in
Thick
Structure
Clearance
Fit
Figure
77

Page
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51−42−11 Nov
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 STRUCTURAL
REPAIR
MANUAL

Head−Seating
Allowable
Gap
Data
for
Protruding
Head
Pin
(Swaged)
Figure
78

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 STRUCTURAL
REPAIR
MANUAL

Head−Seating
Allowable
Gap
Data
for
Countersunk
Head
Pin
(Swaged)
Figure
79

Page
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51−42−11 Nov
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 STRUCTURAL
REPAIR
MANUAL

Collar
Inspection
on
a
Surface
with
a
Slope
Figure
80

F. Inspection
of
Pin
Position
and
Swaged
Collar

(1) After
the
installation
of
a
pin
(swaged)
is
completed
it
must
be
in
spected.
This
inspection
is
done
visually
and
with
the
use
of
spe
cial
gages.
Figure
81
shows
examples
of
the
use
of
typical
gages.
The
gage
must
be
held
vertical
to
the
material
surface
and
central
over
the
pin.
Refer
to
Figure
80
if
the
pin
(swaged)
is
installed
through
a
surface
that
slopes.

(2) The
inspection
requires:
(a) A
visual
check
that
the
collar
is
correctly
swaged
(Refer
to
Figure
82).

(b) A
check
(with
the
gages),
that
the
correct
length
pin
(swaged)
has
been
installed,
and
that
the
break
length
protrusion
is
cor
rect.
(3) No
cracks,
scores
or
indentations
caused
by
swaging
are
permitted
in
the
collar.

Page
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51−42−11 Nov
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 STRUCTURAL
REPAIR
MANUAL

Typical
Pin
Position
and
Swage
Gage
Figure
81
(sheet
1)

Page
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51−42−11 Nov
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 STRUCTURAL
REPAIR
MANUAL

Typical
Pin
Position
Only
Gage
Figure
81
(sheet
2)

Page
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51−42−11 Nov
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 STRUCTURAL
REPAIR
MANUAL

Example
of
Pin
(swaged)
Collar
Swaging
Figure
82

NOTE: In
the
above
examples,
details
A,
B
and
C
are
read
as
follows:
− Example
A
This
shows
that
the
collar
has
remained
totally
unswaged
(not
acceptable).
Replace
the
fastener
assembly.
−
Example
B
This
shows
that
the
collar
has
not
been
fully
swaged
(not
acceptable).
Replace
the
fastener
assembly.
− Example
C
This
shows
a
correctly
swaged
collar.
When
you
have
made
the
inspection,
make
a
mark
on
the
fastener
with
inspection
lacquer
if
the
fastener
is
correct.
G. Pin
(Swaged)
Removal
(Refer
to
Figure
83
thru
Figure
86)

(1) General

When
it
is
necessary
to
remove
a
pin
(swaged)
use
one
of
the
meth
ods
that
follow:

NOTE: It
is
recommended
that
Method
1
is
used
for
a
small
number
of
pins,
and
Methods
2
or
3
for
a
large
number
of
pins.
(2) Removal
Method
1
(Manual
Splitter
Tool)

(a) To
remove
the
collars,
use
the
manual
splitter
tool
to
break
them.
This
tool
is
of
the
42−dash
series,
supplied
by
HUCK
Manufacturing
Co.
(Refer
to
Figure
83).

Page
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51−42−11 Nov
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 STRUCTURAL
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MANUAL

(b) Adjust
the
cutting
jaws
of
the
splitter
tool
to
the
applicable
diameter
of
the
pin
(Refer
to
Figure
83).
(c) Cut
the
collar.

(d) Remove
the
cut
collar
from
the
pin.

(e) Examine
the
pin
at
the
locking
grooves
for
metal
projections
that
are
possibly
caused
by
the
collar
splitter
tool.
(f) If
there
are
projections,
remove
them
with
a
file
to
prevent
damage
to
the
structure
when
the
pin
is
removed.

(g) Put
the
correct
back−up
dolly
in
position
to
support
the
struc
ture
around
the
pin
head.

(h) Hit
the
pin
out
of
its
hole
with
a
hammer
and
parallel
punch
of
a
smaller
diameter
than
the
fastener
shank.

(i) Examine
the
hole
for
damage
or
distortion.

NOTE: If
the
hole
condition
is
satisfactory,
you
can
use
another
pin
(swaged)
of
the
same
diameter
as
the
original
pin.
(3) Removal
Method
2
(Power
Splitter
Tool)

(a) To
remove
the
collars,
use
the
power
splitter
tool
to
break
them.
This
tool
is
of
the
20034−dash
series,
supplied
by
BROWN
LINE
Manufacturing
Co.
(Refer
to
Figure
84).

(b) To
complete
the
removal
procedure,
do
the
steps
given
in
para
graph
15.G.(2)(c)
thru
15.G.(2)(i).

(4) Removal
Method
3
(Hollow
Mill
Cutter)

(a) To
remove
the
collar
use
the
hollow
mill
cutter
to
mill
it
care
fully
from
the
pin.
This
tool
is
of
the
1297−dash
series,
installed
in
a
micro−stop
gage
(AVON−1116
series),
fitted
with
a
locator
end−sleeve
(1239−dash
series),
(Refer
to
Figure
85).

(b) Put
the
milling
tool
on
the
collar.
Make
sure
that
the
tool
is
vertical
to
material
face.

(c) Operate
the
tool
and
mill
the
collar
until
all
of
it
is
removed.
(d) To
complete
the
removal
procedure,
do
the
steps
given
in
para
graph
15.G.(2)(e)
thru
15.G.(2)(i).

(5) Removal
Method
4
(Chisel
and
Back−up
Dolly)

(a) Put
a
protective
washer
in
the
position
as
shown
in
Figure
86.
This
washer
is
to
prevent
damage
to
the
material
when
you
do
the
steps
(b)
thru
(e)
below.

(b) Hold
a
back−up
dolly
against
the
collar
(Refer
to
Figure
86).

Page
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 STRUCTURAL
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MANUAL

(c) Put
the
chisel
against
the
collar
(Refer
to
Figure
86).

(d) Hit
the
chisel
with
a
hammer
to
break
the
collar.
(e) Do
the
steps
15.G.(5)(b),
15.G.(5)(c)
and
15.G.(5)(d)
again,
but
on
the
opposite
side
of
the
coller.

(f) Remove
the
protective
washer.

(g) To
complete
the
removal
procedure,
do
the
steps
given
in
para
graph
15.G.(2)(e)
thru
15.G.(2)(i).

Page
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 STRUCTURAL
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MANUAL

Data
for
Manual
Splitter
Tools
Figure
83

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51−42−11 Nov
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 STRUCTURAL
REPAIR
MANUAL

Powered
Collar
Removal
Tool
Data
(Power
Splitter
Tool)
Figure
84

Powered
Collar
Removal
Tool
Data
(Hollow
Mill
Cutter)
Figure
85

Page
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51−42−11 Nov
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 STRUCTURAL
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MANUAL

Chisel/Back−Up
Dolly
Removal
Method
Figure
86

16. Bolt−Blind
(Jo−bolt/AVDEL/VISU−LOK)

A. General
(Refer
to
Figure
87)

(1) The
Bolt−Blind
is
a
three−part
fastener
assembly.
The
parts
are:
(a) A
bolt
with
a

plain
head.
The
bolt
shank
has
a
left−hand
thread
along
all
of
its
length
(the
reason
for
the
left−hand
thread
is
given
in
Paragraph
).
There
are
two
machined
flats
along
the
shank
on
the
end
opposite
the
head.
The
length
of
the
shank
with
the
flats
is
approximately
40
%
of
the
total
length
of
the
shank.
This
part
of
the
shank
is
broken
off
when
the
Bolt−Blind
is
installed.

(b) A
hexagonal
or
countersunk
headed
nut.
The
nut
has
a
shank
that
is
tapered
externally
at
the
end
opposite
the
head.
The
Bolt−
Blind
(VISU−LOK)
includes
a
mechanical
locking
feature
on
the
ta
pered
face
of
the
nut.
There
is
an
internal
left−hand
thread
along
all
the
length
of
the
nut.

(c) A
sleeve
that
is
put
on
the
bolt
between
the
bolt
head
and
the
tapered
end
of
the
nut.

(2) Bolts−Blind
are
high−strength
fasteners.
They
are
used:
− in
locations
that
only
have
access
from
one
side,
− where
space
prevents
the
use
of
a
standard
rivet
or
fastener,

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− when
they
are
specified
in
a
repair
procedure.
(3) The
nut
and
the
bolt
are
made
of
high−tensile
steel,
or
stainless
steel.
The
sleeve
is
made
of
stainless
steel.

(4) Do
not
install
Bolts−Blind
where
the
surfaces
of
the
materials
are
more
than
7
°

out
of
parallel
(3
°

on
the
wing
structure).

(5) Bolts−Blind
are
supplied
with
a
layer
of
lubricant
on
them
(all
parts).
Do
not
clean
or
touch
them
more
than
is
necessary
before
they
are
installed.

(6) Do
not
install
any
parts
of
a
Bolt−Blind
that
are
not
in
a
satis
factory
condition.
Discard
any
parts
that
are
not.

(7) To
identify
the
correct
Bolt−Blind
necessary
for
a
repair,
refer
to
Chapter
51−40−00.

(8) You
can
use
hand
or
power−operated
tools,
to
install
Bolts−Blind.
The
tool
must
have
the
correct
drive
assembly
attached
to
it.

(9) It
is
recommended
that
you
do
a
test
procedure
on
some
unwanted
ma
terial
before
you
install
Bolts−Blind.
Do
the
test
on
materials
that
are
the
same
(type
and
thickness)
as
the
repair
materials.
Use
Bolts−Blind
for
the
test
that
are
the
same
(head
type,
diameter
and
grip−length)
as
those
for
the
repair.

(10) The
installation
procedure
for
the
Bolts−Blind
is
given
in
detail
in
paragraphs
16.B.
thru
16.E.
The
subsequent
steps
give,
in
general,
the
procedure
(Refer
to
Figure
88):
− the
fastener
assembly
is
put
in
the
prepared
hole,
− the
installation
tool
is
put
on
the
bolt
end
and
the
nut,
− the
bolt
is
turned
into
the
nut
(this
is
why
the
bolt
and
the
nut
have
left−hand
threads),
− the
plain
head
of
the
bolt
pushes
the
sleeve
over
the
tapered
end
of
the
nut,
− at
the
correct
torque,
the
part
of
the
bolt
shank
with
the
flats
breaks
off,
− the
installation
tool
is
removed,
− the
broken
part
of
the
bolt
shank
is
pushed
out
of
the
installa
tion
tool
automatically.
NOTE: When
the
sleeve
is
pushed
over
the
tapered
end
of
the
nut,
the
shape
of
the
sleeve
is
changed.
This
causes
two
things:
− the
tapered
end
of
the
nut
is
compressed,
this
causes
a
friction−
lock
between
the
bolt
and
the
nut,
− the
end
of
the
sleeve
that
is
opposite
the
plain
head
of
the
bolt
is
pushed
out.
This
causes
the
sleeve
to
hold
the
fastener
tight
in
the
structure.

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Bolt−Blind
−
General
Details
Figure
87

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MANUAL

Bolts−Blind
Installation
Procedure
in
Steps
Figure
88

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B. Hole
Preparation
(Refer
to
Chapter
51−44−00)

(1) Holes
for
Bolts−Blind
are
drill−finished,
or
ream−finished.
Refer
to
Chapter
51−44−00.

(2) Before
a
Bolt−Blind
is
installed
you
must
examine
the
hole
to
make
sure
that:
− it
is
clean,
− it
has
no
burrs,
− it
is
not
damaged.
(3) Refer
to
Chapter
51−44−00
to
find
the
correct
dimension
for
the
hole
that
is
applicable
to
the
Bolt−Blind
nominal
diameter.

(4) Do
the
subsequent
steps
if
a
hole
is
damaged,
or
if
a
new
hole
is
necessary.

(a) Use
grip−pins
or
clamps
to
make
sure
that
the
repair
materials
are
correctly
held
together.

(b) Drill
a
pilot
hole
in
the
correct
position.

(c) Drill
or
ream
the
hole
to
the
applicable
dimension
(Refer
to
Chapter
51−44−00.
CAUTION: DO
NOT
MAKE
A
CHAMFER
AT
THIS
END
OF
THE
HOLE.
A
CHAMFER
WOULD
DECREASE
THE
AREA
THAT
THE
SLEEVE
TOUCHES.

(d) Deburr
the
hole
carefully
at
the
end
where
the
sleeve
will
touch.

(e) Make
the
relief
radius,
or
the
countersink
and
relief
radius,
as
necessary,
on
the
nut
end
of
the
hole
(Refer
to
Chapter
51−44−00).

C. Selection
of
Bolt−Blind
(1) If
the
Bolt−Blind
is
not
identified
by
a
part
number
in
the
repair
procedure,
do
the
subsequent
steps
to
find
the
correct
Bolt−Blind.

(a) Measure
the
hole
to
find
its
diameter.

(b) Refer
to
the
subsequent
table
and
find
the
first
dash
number
necessary.

Hole
nominal
diameter First
dash
number
applicable
AVDEL ASNA NSA
New Old
0.165
in.
(4.20
mm) 5 −2 −2 −164
0.191
in.
(4.85
mm) 6 −3 −3 −190

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Hole
nominal
diameter First
dash
number
applicable
AVDEL ASNA NSA
New Old
1/4
in.
(6.35
mm) 8 −4 −4 −249
5/16
in.
(7.94
mm) 10 −5 −5 −312

Table
43
NOTE: The
new
and
the
old
first
dash
numbers
are
given
to
help
you
to
make
a
cross−reference
if
it
is
necessary.

(c) Find
the
grip−length
necessary
for
the
total
thickness
of
the
materials
to
be
attached.
Use
one
of
the
two
subsequent
proce
dures
to
do
this:
− use
standard
equipement
to
measure
the
total
thickness
of
the
materials
(Refer
to
Figure
89).
This
will
give
you
the
second
dash
number
of
a
Bolt−Blind
part
number,
− or
use
a
Bolt−Blind
grip−length
gage
(Refer
to
Figure
90).
This
will
give
you
the
second
dash
number.

(d) Refer
to
Chapter
51−40−12
to
find
the
full
data
for
the
Bolt−
Blind
necessary
for
the
repair.

D. Installation
Procedure

(1) Get
the
correct
installation
tool
(hexagonal
or
countersunk
head)
for
the
applicable
Bolt−Blind
(Refer
to
Figure
91).

(2) Assemble
a
Bolt−Blind
that
is
correct
for
the
hole.
Make
sure
that
the
nut
is
turned
on
to
the
bolt
finger
tight
only.

(3) Put
the
Bolt−Blind
into
the
hole.

(4) Use
the
tool
to
hold
the
nut
and
turn
the
bolt.
Do
this
until
the
shank
of
the
bolt
breaks
off
at
the
special
groove
(Refer
to
Figure
92).
(5) Remove
the
installaton
tool.

(6) Make
the
end
of
the
bolt
shank
smooth.

(7) Do
the
inspection
procedure
that
is
given
in
Paragraph
16.E..

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Grip−Length
Data
Figure
89

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Grip−Length
Gage
Data
Figure
90

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Example
of
Installation
Tool
Figure
91

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Bolt−Blind
Installation
Procedure
Figure
92

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E. Inspection
and
Permitted
Limits

(1) General
(a) After
you
have
installed
Bolts−Blind,
make
an
inspection
of
them
to
make
sure
that
they
are
correctly
installed.
This
inspection
must
make
sure:
− that
the
tightness
of
the
bolt
is
correct
(Refer
to
Paragraph
16.E.(2)
− that
the
bolt
shank
has
broken
at
the
correct
position
(Refer
to
Figure
93),
− that
the
nut
head
touches
the
material
correctly
(Refer
to
Figure
94),
− that
the
sleeve
is
correctly
formed
(swaged),
where
it
is
pos
sible
(Refer
to
Figure
95),
− that
the
top
of
the
head
of
a
countersunk
bolt−blind
is
in
line
with,
or
only
a
small
dimension
above,
the
top
face
of
the
repair
(Refer
to
Chapter
51−10−00).

NOTE: If
it
is
necessary,
use
equipment
(for
example,
probe−light
and
inspection
mirror)
to
do
an
inspection
where
you
cannot
see.

Bolt
Shank
Break−Off
Data
Figure
93

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DIAMETER
DASH BOLT−BLIND HEXAGONAL
HEAD COUNTERSUNK
HEAD

NUMBER NOMINAL
NSA ASN AV DIAMETER
AM DIM.
A DIM.
B DIM.
C DIM.
D
A DEL (MIN) (MAX) (MIN) (MAX)
OLD NEW in. mm in. mm in. mm in. mm in. mm
−164 −2 −2 5 0.15 4.0 0.000 0.00 0.089 2.25 0.020 0.50 0.067 1.70
−190 −3 −3 6 0.18 4.8 0.010 0.25 0.104 2.65 0.016 0.40 0.083 2.10
−249 −4 −4 8 0.25 6.4 0.047 1.20 0.136 3.45 0.010 0.25 0.079 2.00
−312 −5 −5 10 0.31 8.0 0.033 0.85 0.146 3.70 0.012 0.30 0.083 2.10

Table
44

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Examples
of
Possible
Bolt−Blind
Installation
Defects
Figure
94

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Examples
of
Good
and
Badly
Installed
Bolts−Blind
Figure
95

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(b) Deformation
of
the
repair
materials
must
not
be
more
than
the
limits
given
in
Chapter
51−10−00.
(c) No
cracks
are
permitted
in
any
part
of
the
bolt−blind,
or
the
adjacent
structure.

(2) Tightness

Do
the
subsequent
test
to
find
if
the
tightness
is
correct.

(a) Get
a
torque
wrench
of
the
correct
torque
value
for
the
bolt−
blind
nominal
diameter.
Refer
to
the
subsequent
table.

Bolt−blind
Nominal
Diameter Applicable
Torque
NSA
ASNA New OLD AVDEL
−2 −164 4
lbf.
in.
(0.05
m.daN)
−3 −190 6
lbf.
in.
(0.07
m.daN)
−4 −249 10
lbf.
in.
(0.11
m.daN)
−5 −372 20
lbf.
in.
(0.22
m.daN)

Table
45
(b) Install
the
correct
nose−piece
(hexagonal
or
countersunk
head)
on
the
torque
spanner.

CAUTION: DO
NOT
USE
MORE
THAN
THE
APPLICABLE
TORQUE
IN
THIS
STEP.
(c) Use
the
torque
wrench
and
try
to
turn
the
bolt−blind
in
a
coun
terclockwise
direction.
If
the
bolt
does
not
turn,
it
is
cor
rectly
installed;
if
it
does
turn,
replace
it.

F. Removal
Procedure
(1) General

(a) To
remove
a
bolt−blind
it
is
necessary
to
drill
the
head.
A
spe
cial
tool
is
available
to
help
you
to
do
this
procedure.
This
tool
is
available
for
each
type
(hexagonal
and
countersunk
head)
and
diameter
of
bolts−blind.
The
tool
has
a
drill
guide
at
each
end.
One
guide
is
for
a
pilot−drill,

the
other
guide
is
for
a
final
dimension
drill.
The
guides
are
made
to
agree
with
the
type
of
bolt−blind
(Refer
to
Figure
96).

(b) It
is
recommended
that
you
use
18
%
tungsten
twist−drill
for
this
procedure.

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Example
of
Removal
Tool
Figure
96

(2) Procedure
(Refer
to
Figure
96).

(a) Put
the
applicable
twist−drill
(in
a
drill−machine)
into
the
hole
in
the
pilot−drill
guide
end
of
the
special
tool.
NOTE: The
applicable
twist−drill
is
that
which
agrees
with
the
internal
diameter
of
the
drill
guide.

(b) Put
the
drill
guide
on
the
nut
head
of
the
bolt−blind.
Drill
a
hole
only
to
the
bottom
of
the
nut
head,
not
the
shank.
Remove
the
twistdrill
and
the
tool
from
the
nut
head.
(c) Do
step
16.F.(2)(b)
again,
but
use
a
final
dimension
twist−drill
in
the
final
dimension
guide
of
the
special
tool.

(d) Put
a
parallel
pin
punch
in
the
drilled
hole
and
hit
the
pin
punch
with
a
hammer.
This
will
cause
the
nut
head
to
break
off.
Hit
out
the
bolt
shank.

17. Rivet−Blind
(CHERRY
PULL−THROUGH)

(Refer
to
Figure
97)

A. General

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(1) In
this
paragraph
the
Rivet
(Blind)
(CHERRY
PULL−THROUGH)
is
referred
to
as
Pull−through
rivet.
(2) The
Pull−through
rivet
consists
of
two
parts.
These
are:

(a) A
tubular
body
that
has
a
protruding
or
100
°

countersunk
head.

(b) A
serrated
mandrel
that
is
retained
in
the
tubular
body.
The
mandrel
has
a
conical
upsetting
head.
As
the
gun
pulls
this
head
into
the
rivet
shank,
a
blind
"tulip−head"
is
formed.
When
this
head
is
tightly
formed
against
the
sheet,
the
upsetting
head
of
the
mandrel
collapses
and
passes
through
the
rivet,
expanding
the
shank
(Refer
to
Figure
97).

(3) The
Pull−through
rivet
has
an
identification
number.
This
number
and
its
specific
details
are
explained
in
Chapter
51−40−12.
(4) Pull−through
rivets
can
be
installed
by
pneumatic−hydraulic
power
or
hand
operated
tools.

(5) Pull−through
rivets
must
only
be
used
when
they
are
called
up
in
a
specific
repair
procedure
or
other
AIB
approved
documents.

(6) Before
the
installation
of
pull−through
rivets
make
sure
that:
− the
rivet
type
is
correct,
− the
rivets
are
made
of
the
required
material,
− the
rivets
have
the
specified
surface
protection
and/or
lubrica
tion,
and
that
they
are
not
corroded
or
scratched,
− the
rivets
are
of
the
correct
length
and
diameter,
− the
hole
for
the
rivets
are
correctly
prepared.

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Pull−Through
Blind
Rivets
−
General
and
Installation
Details
Figure
97

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MANUAL

B. Installation
Procedure

(1) Make
sure
that
the
rivets
are
of
the
correct
dimensions
(diameter
and
length).
If
the
length
is
not
known
refer
to
Figure
98.

(2) Refer
to
Chapter
51−44−00
to
find
the
correct
dimension
for
the
hole
that
is
applicable
to
the
pull−through
rivet
nominal
diameter.

(3) Drill
the
hole
to
the
required
diameter
(Refer
to
51−44−00).

(4) Make
sure
that
the
hole,
including
the
countersunk,
is
in
a
satis
factory
condition,
clean
and
free
from
burrs.

(5) Make
sure
that
the
installation
tool
is
correct
for
the
rivet
dimen
sions
and
head
shape.

(6) Insert
the
rivet
mandrel
fully
into
the
installation
tool.
(7) Insert
the
rivet
body
fully
into
the
hole.
Make
sure
that
the
installation
tool
nose
is
perpendicular
to
the
material
surface.

(8) Operate
the
tool
to
complete
the
installation
of
the
rivet.

(9) Remove
the
installation
tool
and
make
sure
that
the
rivet
is
installed
correctly.
C. Inspection
after
Installation

(1) General

(a) Carefully
examine
the
installed
rivets
as
far
as
possible.

NOTE: You
are
recommended
to
use
inspection
aids,
for
example,
probe
light
and
mirror,
to
examine
the
’blind’
head.

(b) The
pull−through
rivet
is
correctly
installed
when:
− the
manufactured
head
is
correctly
seated,
− the
blind
head
is
correctly
shaped,
− the
surrounding
structure
is
free
from
damage
and
distortion.

(c) Deformation
or
buckling
of
the
skin
is
not
permitted
outside
the
limits
given
in
Chapter
51−10−00.

(d) The
manufactured
head
of
a
countersunk
rivet
must
be
flush,
or
within
the
limits
given
in
Chapter
51−10−00.

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Grip−Length/Length
Data
for
CHERRY
Pull−Through
Blind
Rivets
Figure
98

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NOMINAL GRIP−LENGTH
T
RANGE SE L
±
0.010 F
MAX.

RIVET COND in ( ±
in.
(
±
MIN. MAX. DASH 0.25
mm)
DIA NO
NO.
in. mm in. mm in. mm in. mm
3/32" 0.062 1.57 1 0.130 3.30 0.218 5.54
( 3)
(−3) 0.063 1.60 0.125 3.17 2 0.193 4.90 0.281 7.14
0.126 3.20 0.187 4.75 3 0.255 6.48 0.343 8.71
0.188 4.77 0.250 6.35 4 0.318 8.08 0.405 10.29
0.251 6.37 0.312 7.92 5 0.380 9.65 0.468 11.89
0.313 7.95 0.375 9.52 6 0.443 11.25 0.530 13.46
0.376 9.55 0.437 11.10 7 0.505 12.83 0.593 15.06
0.438 11.21 0.500 12.70 8 0.568 14.43 0.656 16.66
0.501 12.72 0.562 14.27 9 0.630 16.00 0.718 18.24
0.563 14.30 0.625 15.87 10 0.693 17.60 0.781 19.84
0.626 15.90 0.687 17.45 11 0.755 19.18 0.843 21.41
0.688 17.47 0.750 19.05 12 0.818 20.78 0.905 23.00
1/8"
(−4) 0.062 1.57 1 0.160 4.06 0.274 6.96
0.063 1.60 0.125 3.17 2 0.222 5.64 0.336 8.53
0.126 3.20 0.187 4.75 3 0.285 7.24 0.399 10.13
0.188 4.77 0.250 6.35 4 0.347 8.81 0.461 11.71
0.251 6.37 0.312 7.92 5 0.410 10.41 0.524 13.31
0.313 7.95 0.375 9.52 6 0.472 11.99 0.586 14.88
0.376 9.55 0.437 11.10 7 0.535 13.59 0.649 16.48
0.438 11.21 0.500 12.70 8 0.597 15.16 0.711 18.06
0.501 12.72 0.562 14.27 9 0.660 16.76 0.774 19.66
0.563 14.30 0.625 15.87 10 0.722 18.34 0.836 21.23
0.626 15.90 0.687 17.45 11 0.785 19.94 0.899 22.83
0.688 17.47 0.750 19.05 12 0.847 21.51 0.961 24.41
Key
to
Figure
98
NOTE: How
to
use
this
data:
− 1.
Measure
the
material
thickness
(T).
For
example
=
0.315
in.
(8.0
mm).
− 2.
Find
in
the
table
the
grip−length
range
which
includes
this
thickness.
In
this
example
it
is
0.313
in.
(7.95
mm)
to
0.375
in.
(9.52
mm).
− 3.
Thus
the
second
dash
number
necessary,
which
is
related
to
the
grip
range
found
in
step
2
is
6.
(2) Acceptance
Limits

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(a) Due
to
the
varying
degrees
of
functional
importance
of
installed
pull−through
rivets,
acceptance
or
rejection
is
mostly
at
the
discretion
of
the
inspector.

(b) As
general
guide,
reject
loose
or
cracked
rivets.

D. Removal
of
Pull−Through
Rivets

CAUTION: WHEN
REMOVING
RIVETS
TAKE
CARE
NOT
TO
CAUSE
DAMAGE
TO
THE
STRUCTURE,
ESPECIALLY
WHEN
THE
SKIN
IS
THIN.
CAUTION: IF
THE
RIVET
TURNS
DURING
DRILLING
OPERATIONS,
DAMAGE
CAN
BE
CAUSED
TO
THE
SKIN/HOLE.

(1) The
removal
of
pull−through
rivets
is
achieved
by
first
removing
the
manufactured
head
then
driving
the
remainder
of
the
rivet
out
of
its
hole.
With
a
twist−drill
of
the
same
nominal
diameter
as
the
rivet
drill
almost
through
the
head.
It
is
recommended
that
a
mechanical
stop
is
used
on
the
twist−drill
to
control
the
depth
drilled.
With
a
parallel
pin
punch
remove
the
rivet
head.
With
a
parallel
pin
punch
and
hammer
hit
out
the
remainder
of
the
rivet
body.
The
parallel
pin
punch
diameter
must
be
slightly
less
than
the
nominal
diameter
of
the
rivet,
but
greater
than
the
rivet
inner
diameter.
Support
the
structure
on
the
underside
during
this
step.

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 STRUCTURAL
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Removal
of
Pull−Through
Rivets
Figure
99

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18. Rivet
(Solid)
(CHERRYBUCK)

A. General
(1) It
is
recommended
that
only
suitably
trained
and
approved
personnel
do
the
work
necessary
to
install
CHERRYBUCK
rivets.

(2) The
CHERRYBUCK
rivet
is
a
one
piece
bimetallic
solid
rivet.
The
riv
et
is
manufactured
from
two
materials
to
give
a
high
strength
stem
with
an
easily
formable
tail
(Refer
to
Figure
100).
(3) The
CHERRYBUCK
rivet
is
especially
suitable
for
installation
in
com
posite/metallic
or
composite
structure.
In
a
composite/metallic
com
bination
the
upset
head
is
formed
on
the
metallic
material
side.

(4) The
CHERRYBUCK
rivet
can
be
used
when
it
is
necessary
to
form
a
countersunk
upset
head
(Refer
to
Figure
101)
(5) Good
access
and
clearance
is
necessary
to
both
sides
of
the
area
where
CHERRYBUCK
rivets
will
be
installed.
This
will
allow
the
nec
essary
drilling,
installation
and
inspection
procedures
to
be
done.

(6) The
CHERRYBUCK
rivet
can
be
used
where
the
structure
surface
is
at
an
angle
to
the
rivet
axis
up
to
a
maximum
of
105.
This
is
only
permitted
when
the
upset
head
is
a
flat
head
(Refer
to
Figure
102).

CHERRYBUCK
Rivet
−
General
Detail
Figure
100

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CHERRYBUCK
Rivet
used
to
form
a
Countersunk
Head
Figure
101

CHERRYBUCK
Rivet
used
on
an
Angled
Surface
Figure
102

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MANUAL

(7) The
upset
head
of
the
CHERRYBUCK
rivet
can
be
formed
by:

(a) Hand
hammer
(in
metallic
structure
only).
(b) Single
or
multistroke
pneumatic
hammer
(not
on
carbon
fiber
rein
forced
plastic
(CFRP)
structure).

(c) Rivet
squeezer.

(d) Automatic
riveter.
(8) When
a
’wet
installation’
of
CHERRYBUCK
rivets
is
required
refer
to
Chapter
51−76−00.

B. Pretreatment
of
CHERRYBUCK
Rivets

(1) No
pretreatment
is
necessary
for
CHERRYBUCK
rivets
before
they
are
installed.
(2) Any
existing
surface
protection
and
lubrication
on
CHERRYBUCK
rivets
must
be
preserved
until
after
they
are
installed.

C. Hole
Preparation

(1) Holes
must
be
prepared
in
accordance
with
the
information
given
in
Chapter
51−44−11.

(2) If
it
is
required
that
the
holes
be
countersunk
refer
to
Chapter
51−46−11.

D. Rivet
Selection

(1) Grip
length
(a) To
determine
the
correct
grip
length
of
the
rivet
required,
mea
sure
the
thickness
of
the
materials
to
be
joined
using
a
suit
able
tool
(Refer
To
Figure
103).

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Checking
Grip
Length
with
a
Proprietary
Tool
Figure
103

(b) In
an
application
wher
a
countersunk
upset
head
is
to
be
used,
the
measured
sheet
thickness
minus
the
countersunk
depth
for
the
upset
head
gives
the
required
length
of
the
rivet
(Refer
to
Fig
ure
101).
(c) Refer
to
the
relevant
ABS
number
in
the
Standards
Manual
to
find
the
dash
number
for
the
required
length.

(d) The
weld
joining
the
two
materials
of
the
rivet
must
not
be
out
side
the
minimum
grip
(Refer
to
Figure
104).

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Grip Length Detail

Figure 104

(e) If a countersunk upset head is to be formed the weld must be

above the countersunk depth (Refer to Figure 101).

NOTE: CHERRYBUCK rivets must not be shortened.

NOTE: It is not permitted to use a CHERRYBUCK rivet in a materi

al thickness that is less than the minimum allowable value
for the rivet (Refer to paragraph 18.D.(1)(c) above). See
also example 1 below.

Example 1: Material thickness to be joined = 5.537 mm

(0.218 in.). Required grip length dash number = −4. A rivet
with the dash number −4R is not permitted because the grip
range for this rivet is 5.562 mm (0.219 in.) to 6.35 mm
(0.250 in.).

NOTE: The maximum allowable grip length may be exceeded by up to

0.78 mm (0.031 in.). AIRBUS must be contact for this con

cession that is only applicable for −5, −6 and −8 diameter
rivets. See also example 2 below.

Example 2: Material thickness to be joined = 6.32 mm (0.249

in.). Required grip length dash number = −4R. If this grip
length rivet is not available a −4 rivet may be used with
a concession from AIRBUS.

(2) Diameter

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 STRUCTURAL REPAIR MANUAL

(a) To determine the correct diameter rivet, accurately measure the

diameter of the hole. If the hole diameter is within the toler

ances for a standard rivet (Refer to Chapter 51−44−11), select a
rivet of that diameter. If the hole is not within the tolerances
it will be necessary to increase the hole to the next standard
diameter.

(b) If the hole diameter is larger than that required for a −8 rivet
contact AIRBUS for advice.

E. Installation

(1) CHERRYBUCK rivets are initially placed in the hole as follows:

(a) By hand in clearance fit holes.

(b) By using a hammer with a plastic head, or a hammer and aluminum
alloy mandrel in interference fit holes.

NOTE: When placing the rivets in an interference hole, the struc

ture must be supported to prevent damage, for example,
bulging or deformation. Damage to the rivet is not accept

able at this stage.

(2) Use one of the methods that follow to form the upset head. The
method used will depend upon accessibility and the number of rivets
to be installed.

(a) Hand hammer and dolly. With this method the manufactured head is
supported by the dolly and the rivet tail is struck to form the
required type of head.

(b) Pneumatic hammer and dolly. These tools can be used in two ways
as shown in Figures 105 and 106.

NOTE: When using the methods given in paragraphs (a) and (b)
above, the upset head should be formed with a few hammer
blows as necessary.

(c) Automatic riveting tools. These tools are usually only suitable
for production work.
(d) It is a requirement that rivets that are to be painted or
sealed, are cleaned after they have been installed. Cleaning
agents SOCOMOR DN108 or industrical alcohol are recommended for
this task.

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Indirect
Driving
(Reaction)
of
Rivet
Figure
105

Direct
Driving
Figure
106

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F. Inspection

(1) Checking the upset head dimensions.

(a) Refer to Figure 107 for the acceptable dimensions of a flat up

set head.

(b) A countersunk upset head must fill the countersink fully. Unless
specified otherwise in an AIRBUS engineering document the coun

tersink head must be filled flush (Refer to Figure 101).

Upset Head Dimensions for Rivet ABS0213

Figure 107

(2) Manufactured head faults.

(a) A gap of 0.1 mm (0.004 in.) maximum is permitted between the

stucture surface and the manufactured head (Refer to Figure 108).
This fault is permitted on up to 10% of the rivets but not on
two adjacent rivets.

(b) An ’apparent’ circumferential gap at the chamfer around the coun

tersink is permitted (Refer to Figure 108).

Printed in Germany
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 STRUCTURAL
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MANUAL

Manufactured
Head
Faults
Figure
108

(3) Upset
head
faults
(Refer
to
Figure
109).

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Riveting
Faults
Figure
109

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MANUAL

(a) No
cracks
are
permitted
in
the
upset
head.

(b) A
malformed
upset
head
is
permitted
providing
that
the
head
is
within
the
limits
given
in
Figure
107.
In
cases
where
’H’
mini
mum
is
less
than
that
given
in
Figure
107,
it
is
permitted
to
have
up
to
10%
of
the
rivets
with
this
fault
providing:

1 That
the
mean
head
height
is
equal
to
or
greater
than
1/3rd
of
the
rivet
nominal
diameter
(D).
2 Two
adjacent
rivets
are
not
affected.

3 Rivets
at
the
end
of
a
row
are
not
affected.

(c) A
stepped
head
is
permitted
providing
that
after
the
step
has
been
removed
the
head
is
within
the
limits
given
in
Figure
107.
(d) It
is
permitted
for
the
upset
head
to
be
eccentric
to
the
rivet
stem
providing:

1 The
hole
is
not
visible.

2 The
upset
head
does
not
touch
the
circumference
of
the
rivet
stem.

(e) A
bell
shaped
upset
head
is
not
permitted.
This
shape
is
usually
the
result
of
using
a
riveting
dolly
that
is
too
light.

(f) The
upset
head
must
be
formed
at
a
right
angle
to
the
rivet
axis
in
the
case
of
installation
in
an
angled
surface,
not
par
allel
to
the
angled
face.

(4) Buckling
and
distortion
of
the
structure,
and
the
protrusion
of
the
external
rivet
heads
must
be
within
the
limits
given
in
Chapter
51−10−00.
G. Removal
of
CHERRYBUCK
rivets

(1) When
it
is
necessary
to
remove
CHERRYBUCK
rivets
care
must
be
taken
to
avoid
damaging
the
rivet
holes
and
surrounding
structure.
Where
possible
the
rivet
should
be
removed
by
first
removing
the
manufac
tured
head.
During
the
removal
process
take
care
to
ensure
that
de
bris
from
the
rivet
does
not
fall
into
inaccessible
areas.

(2) Three
basic
steps
are
necessary
to
remove
a
rivet,
these
are:

(a) Drill
to
the
depth
of
head
with
a
twist
drill
that
is
0.2
mm
(0.008
in.)
smaller
than
the
nominal
diameter
of
the
rivet,
refer
to
Figure
110,
step
1.
Rivets
that
have
a
long
grip
length
may
be
drilled
deeper.

(b) Break
off
the
drilled
head
with
a
parallel
pin
punch,
refer
to
Figure
110,
step
2.

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(c) Drive
out
the
remaining
rivet
stem
with
a
parallel
pin
punch,
the
diameter
of
the
pin
punch
must
be
slightly
smaller
than
the
rivet
stem
diameter,
refer
to
Figure
110,
step
3.
The
structure
must
be
supported
during
this
step.

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CHERRYBUCK
Rivet
Removal
Procedure
Figure
110

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H. Hole
Inspection

(1) After
removing
a
CHERRYBUCK
rivet,
the
hole
must
be
inspected
for:
− ovality,
− scoring,
− other
damage.

(2) If
the
hole
is
found
to
be
unsatisfactory
it
must
be
enlarged
to
the
next
standard
diameter
rivet,
refer
to
paragraph
18.C.

19. Rivet
(Solid)
(CHERRY
E−Z
BUCK)
A. General

(1) It
is
recommended
that
only
suitably
trained
and
approved
personnel
do
the
work
necessary
to
install
CHERRY
E−Z
BUCK
rivets.

(2) The
CHERRY
E−Z
BUCK
rivet
is
a
solid
rivet
that
is
manufactured
from
a
ductile
titanium/columbium
alloy
which
deforms
the
full
length
of
the
rivet
shank
so
it
fills
the
rivet
hole
when
installed
(Refer
to
Figure
111).

CHERRY
E−Z
BUCK
Rivet
−
General
detail
Figure
111

(3) The
CHERRY
E−Z
BUCK
rivet
is
especially
suitable
for
installation
in
composite/metallic
and
metallic
structure.
The
upset
head
is
formed
on
the
metallic
material
side.

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(4) The
CHERRY
E−Z
BUCK
rivet
can
be
used
when
it
is
necessary
to
form
a
countersunk
upset
head
(Refer
to
Figure
112).

CHERRY
E−Z
BUCK
Rivet
used
to
form
a
Countersunk
Head
Figure
112

(5) Good
access
and
clearance
is
necessary
to
both
sides
of
the
area
where
CHERRY
E−Z
BUCK
rivets
will
be
installed.
This
will
allow
the
necessary
drilling,
installation
and
inspection
procedures
to
be
done.
(6) The
CHERRY
E−Z
BUCK
rivet
can
be
used
where
the
structure
surface
is
at
an
angle
to
the
rivet
axis
up
to
a
maximum
of
10°.
This
is
only
permitted
when
the
upset
head
is
a
flat
head
(Refer
to
Figure
113).

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CHERRY
E−Z
BUCK
Rivet
used
on
an
Angled
Surface
Figure
113

(7) The
upset
head
of
the
CHERRY
E−Z
BUCK
rivet
can
be
formed
by:

(a) Hand
hammer
(in
metallic
structure
only).

(b) Single
or
multistroke
pneumatic
hammer
(not
on
carbon
fiber
rein
forced
plastic
(CFRP)
structure).

(c) Rivet
squeezer.

(d) Automatic
riveter.

(8) When
a
’wet
installation’
of
the
CHERRY
E−Z
BUCK
rivet
is
required
refer
to
Chapter
51−76−00.

B. Pretreatment
of
CHERRY
E−Z
BUCK
rivets

(1) No
pretreatment
is
necessary
for
CHERRY
E−Z
BUCK
rivets
before
they
are
installed.

(2) Any
existing
surface
protection
and
lubrication
on
CHERRY
E−Z
BUCK
rivets
must
be
preserved
until
after
they
are
installed.

C. Hole
Preparation

(1) Holes
must
be
prepared
in
accordance
with
the
information
given
in
Chapter
51−44−11.

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(2) If
it
is
required
that
the
holes
be
countersunk
refer
to
Chapter
51−46−11.
D. Rivet
Selection

(1) Rivet
length

(a) To
determine
the
correct
length
of
the
rivet
required,
measure
the
thickness
of
the
materials
to
be
joined
(grip
length),
using
a
suitable
tool
(Refer
to
Figure
114
and
115)
and
add
the
re
quired
backside
protrusion
(Refer
to
Figure
115).

CheckingGrip
Length
(Material
Thickness)
with
a
Proprietary
Tool
Figure
114

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MANUAL

Grip
Length
and
Length
Detail
Figure
115

(b) In
an
application
where
a
countersunk
upset
head
is
to
be
used,
the
measured
sheet
thickness,
plus
an
additional
length
’X’
to
achieve
optimal
filling
of
the
countersunk
hole
gives
the
re
quired
length
of
the
rivet,
plus
the
required
backside
protrusion
(Refer
to
Figure
116).

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Length Detail for a Rivet with a Countersunk Upset Head

Figure 116

(2) Diameter

(a) To determine the correct diameter rivet, accurately measure the

diameter of the hole. If the hole diameter is within the toler

ances for a standard rivet (Refer toChapter 51−44−11), select a
rivet of that diameter. If the hole is not within the tolerances
it will be necessary to increase the hole to the next standard
diameter.

(b) If the hole diameter is larger than that required for a −6 rivet
contact AIRBUS for advice.
E. Installation

(1) CHERRY E−Z BUCK rivets are initially placed in the clearance fit
hole by hand.

(2) Use one of the methods that follow to form the upset head. The
method used will depend upon accessibility and the number of rivets
to be installed.

(a) Hand hammer and dolly: With this method the manufactured head is
supported by the dolly and the rivet tail is struck to form the
required type of head.

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 STRUCTURAL
REPAIR
MANUAL

(b) Pneumatic
hammer
and
dolly:
These
tools
can
be
used
in
two
ways
as
shown
in
Figures
117
and
118.
NOTE: When
using
the
methods
given
in
paragraphs
(a)
and
(b)
above,
the
upset
head
should
be
formed
with
as
few
hammer
blows
as
necessary.

Indirect
Driving
(Reaction)
of
Rivet
Figure
117

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 STRUCTURAL
REPAIR
MANUAL

Direct
Driving
Figure
118

(c) Automatic
riveting
tools:
These
tools
are
usually
only
suitable
for
production
work.

(d) It
is
a
requirement
that
rivets
that
are
to
be
painted
or
sealed,
are
cleaned
after
they
have
been
installed.
Cleaning
agents
SOCOMOR
DN108
or
industrial
alcohol
are
recommended
for
this
task.

(3) Milling
of
Countersunk
Heads

When
it
is
necessary
to
mill
the
heads
of
the
CHERRY
E−Z
BUCK
coun
tersunk
rivets
care
must
be
taken
to
avoid
damaging
the
structure.
The
heads
of
the
countersunk
rivets
can
be
milled
using
a
plain
cy
lindrical
milling
cutter
with
carbide
cutting
edges.
The
speed
of
the
milling
cutter
should
be
approximately
3000
rpm.
The
equipment
must
have
a
height
adjustment
stop.
NOTE: A
riveted
sample
must
be
used
to
verify
the
adjustment
of
the
milling
cutter
and
to
secure
the
correct
setting.
This
is
nec
essary
to
avoid
damage
to
the
structure
where
the
rivets
to
be
milled
are
installed.

(a) Manufactured
Countersunk
Head
Any
protrusion
of
a
rivet
head
that
is
outside
the
tolerance
can
be
milled
if
the
protrusion
is
not
more
than
10%
of
height
of
the
head
(Refer
to
Figure
119).

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 STRUCTURAL REPAIR MANUAL

Milling Detail − Manufactured Countersunk Head

Figure 119

(b) Countersunk Upset Head

The relevant data for reworking the countersunk upset head will
be given in the specific SRM repair or an AIRBUS engineering
document. Unless specified the countersink head must be milled
flush (Refer to Figure 112).

F. Inspection

(1) Checking the upset head dimensions.

(a) Refer to Figure 120 for the acceptable dimensions of a flat up

set head.

(b) A countersunk upset head must fill the countersink fully. Unless
specified otherwise in an AIRBUS engineering document the coun

tersunk head must be milled flush (Refer to Figure 112).

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 STRUCTURAL
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MANUAL

Upset
Head
Dimensions
for
CHERRY
E−Z
BUCK
Rivets
Figure
120

(2) Manufactured
head
faults.

(a) A
notch
on
the
manufactured
head
is
permitted
within
the
limits
given
in
Figure
121
(sheet
1).
(b) A
gap
of
0.1
mm
(0.004
in.)
maximum
is
permitted
between
the
structure
surface
and
the
manufactured
head
(Refer
to
Figure
121
(sheet
2)).
This
fault
is
permitted
on
up
to
10%
of
the
rivets
but
not
on
two
adjacent
rivets.

(c) An
’apparent’
circumferential
gap
at
the
chamfer
around
the
coun
tersink
is
permitted
(Refer
to
Figure
121
(sheet
2)).

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STRUCTURAL
REPAIR
MANUAL

Manufactured
Head
Faults
Figure
121
(sheet
1)

Manufactured
Head
Faults
Figure
121
(sheet
2)

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 STRUCTURAL
REPAIR
MANUAL

(3) Upset
head
faults
(Refer
to
Figure
122)

(a) No
cracks
are
permitted
in
the
upset
head.
(b) A
malformed
upset
head
is
permitted
providing
that
the
head
is
within
the
limits
given
in
Figure
120.
In
case
where
’H’
minimum
is
less
than
that
given
in
Figure
120,
it
is
permitted
to
have
up
to
10%
0f
the
rivets
with
this
fault
providing:

1 That
the
mean
head
height
is
equal
to
or
greater
than
1/3rd
of
the
nominal
diameter
(D).

2 More
than
two
adjacent
rivets
are
not
affected.

(c) A
stepped
head
is
permitted
providing
that
after
the
step
has
been
removed
the
head
is
within
the
limits
given
in
Figure
120.
(d) It
is
permitted
for
the
upset
head
to
be
eccentric
to
the
rivet
stem
providing:

1 The
hole
is
not
visible.

2 The
upset
head
does
not
touch
the
circumference
of
the
rivet
stem.

(e) A
bell
shaped
upset
head
is
not
permitted.
This
shape
is
usually
the
result
of
using
a
riveting
dolly
that
is
too
light.

(f) The
upset
head
must
be
formed
at
a
right
angle
to
the
rivet
axis
in
the
case
of
installation
in
an
angled
surface,
not
par
allel
to
the
angled
face.

(g) A
measurable
gap
for
a
countersunk
upset
head
is
not
permitted,
but
an
’apparent’
gap
is
permitted
if
it
is
not
circumferential.

(4) Buckling
and
distortion
of
the
structure,
and
the
protrusion
of
ex
ternal
rivet
heads
must
be
within
the
limits
given
in
Chapter
51−10−00.

(5) Gap
between
Components

A
gap
of
0.3
mm
(0.012
in.)
maximum
between
components
is
permitted
between
any
two
rivets.
At
the
rivet
shank
the
gap
must
not
be
more
than
0.05
mm
(0.002
in.)
(Refer
to
Figure
123).

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STRUCTURAL
REPAIR
MANUAL

Riveting
Faults
Figure
122

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 STRUCTURAL
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MANUAL

Gap
between
Components
Figure
123

G. Removal
of
CHERRY
E−Z
BUCK
Rivets

(1) When
it
is
necessary
to
remove
CHERRY
E−Z
BUCK
rivets
care
must
be
taken
to
avoid
damaging
the
rivet
holes
and
surrounding
structure.
Where
possible
the
rivet
should
be
removed
by
first
removing
the
manufactured
head.
During
the
removal
process
take
care
to
ensure
that
debris
from
the
rivet
does
not
fall
into
inaccessible
areas.

(2) Four
basic
steps
are
necessary
to
remove
a
rivet,
these
are:

(a) Center−punch
the
rivet
head.
For
thin−walled
components
use
a
dolly
to
support
the
upset
head.
This
will
give
a
location
for
the
twist
drill
tip,
refer
to
Figure
124,
step
1.

(b) Drill
to
the
depth
of
the
head
with
a
twist
drill
that
is
0.2
mm
(0.008
in.)
smaller
than
the
nominal
diameter
of
the
rivet,
refer
to
Figure
124,
step
2.
Rivets
that
have
a
long
grip
length
may
be
drilled
deeper.

(c) Break
off
the
drilled
head
with
a
parallel
pin
punch,
refer
to
Figure
124,
step
3.

(d) Drive
out
the
remaining
rivet
stem
with
a
parallel
pin
punch,
the
diameter
of
the
pin
punch
must
be
slightly
smaller
than
the
rivet
stem
diameter,
refer
to
Figure
124,
step
4.
The
structure
must
be
supported
during
this
step.

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 STRUCTURAL
REPAIR
MANUAL

CHERRY
E−Z
BUCK
Removal
Procedure
Figure
124

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 STRUCTURAL REPAIR MANUAL

H. Hole Inspection

(1) After removing a CHERRY E−Z BUCK rivet, the hole must be inspected
for:
− ovality,
− scoring,
− other damage.

(2) If the hole is found to be unsatisfactory it must be enlarged to

the next standard diameter rivet, refer to paragraph C..
20. Drilling of Bolt Threads

A. General

(1) Drilling of the bolt on installation is allowed provided all neces

sary precautions are taken to prevent weakening screw strength (in
particular, non off centered drilling, correct perpendicularity, cor

rect bore diameter, slight deburring) and risks of corrosion (instal

lation using grease in the case of steel screws, reprotection if re

quired).

(2) It is recommended to use pre−drilled bolts, suppliers have automatic

machines that guarantee that this procedure will be performed cor

rectly.

(3) Holes for split pins may be drilled in bolts and studs either in−
situ or after disassembly, depending on the accessibility or material
from which the parts are made. The holes are then deburred prior to
fitting the split pins.
B. Limitations

NOTE: It is recommended that only trained and approved personnel perform

shank drilling procedure.
(1) Split Pin Holes
(a) The split pin holes are to be protected by a jointing compound,
that is the same jointing compound as used for the assembly of
the joint, unless stated otherwise in the maintenance procedure.

(b) Thin plain nuts and lightweight self−locking nuts are not to be
locked with split pins, unless stated otherwise in the repair or
maintenance procedure.

(2) Split Pins and Associated Parts

(a) Split pins are to be used once only.

(b) Under no circumstances must split−pin holes be re−drilled to ob

tain alignment or be opened up to accommodate a larger size
split pin.

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 STRUCTURAL REPAIR MANUAL

(c) On assemblies where the bolt/stud has no split pin hole drilled
but the maintenance procedure calls for a split pin to be
fitted, then the bolt/stud must only be drilled in accordance
with the following procedure.

(d) Split pin hole centres must be a distance not less than twice
the nominal diameter of the split pin hole from the end of the
bolt, or in the same position as the hole in the removed bolt.
(e) If not specified, requirements of the bolt standard must be re

spected for split pin hole location and dimensions.

C. Drilling Procedure of Bolt Shank Thread

(1) Install/screw the suitable drill guide on to the bolt/stud thread,

positioning to enable the split pin hole to be drilled to specific
requirements and secure the bolt/stud and guide in a vice, to carry
out the drilling operation (Refer to Figure 125).

(a) Where it is necessary to drill a hole in the bolt thread in−

situ, a locally manufactured drill guide may be used to locate
the hole position.
NOTE: A suitable drill guide can be an home−made guide that allow
to drill a hole to the requirements of the present proce

dure and/or relevant bolt standard.

(b) Where a bolt or stud can be removed, mark the hole location, re

move the bolt/stud from the assembly and install it in a drill
guide. The bolt must preferably not be drilled in−situ. When
possible and especially for titanium bolts, the fastener should
preferably be routed to the machine shop for drilling and debur

ring, otherwise the holes may be drilled using bench or pillar
machines and suitable holding fixture.
(c) Use of slotted nut or slave nut are not recommended because they
offer inadequate location during the drilling procedure.

(2) Set the drilling machine at a recommended cutting speed, ensuring

that the machine and the drill used for general purpose drilling
(Refer to Chapter 51−44−11).

(3) Drill the holes to the procedure requirements or unless otherwise

specified to bolt standard requirements. If anywhere stated, cotter
pin hole centerline must be within 0.25 mm (0.010 in.) within 2° of
bolt centerline.
(4) Deburr the drilled hole.

(5) Check the threads using a suitable nut ensuring that the nut can
move freely on the thread when finger pressure only is applied.

NOTE: If the bolt protective treatment is damaged, the bolt must be

stripped and the protective treatment re−applied.

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 STRUCTURAL REPAIR MANUAL

D. Quality Requirements
− make sure that dimensional requirements are fulfilled for the split pin
hole,
− make sure that at least half the split pin diameter is located in the
slot of the castellated nut,
− make sure that the split pin has no longitudinal play.

E. Examples of Hole Diameter for the majority of bolts

Bolt Diameter Split Pin Hole Diameter

mm in. mm in.
+0.254 +0.010
−0.000 −0.000
4.8 3/16 1.78 0.070
6.4 1/4 1.93 0.076
7.9 5/16
9.5 3/8 2.69 0.106
11.1 7/16
12.7 1/2
14.3 9/16 3.58 0.141
15.9 5/8
19 3/4
22.2 7/8
25.4 1
28.6 1−1/8
31.7 1−1/4
Examples of Hole Diameter
Table 46

Page B24
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51−42−11 May 01/06
 STRUCTURAL REPAIR MANUAL

Suitable Drill Guide

Figure 125

21. Double Countersunk Rivets

A. General

(1) This special procedure is only applicable to aluminum or monel riv

ets.

(2) It is recommended that only suitably trained and approved personnel

do the work necessary to install double countersunk rivets.

(3) Unless stated otherwise, the second countersink (100°) will have same
dimensions as the first one.
(4) The length of rivet to be used must be determined to avoid trimming:
the volume of the protruding metal shall be chosen so that it is
slightly greater than the countersink to be filled.

(5) A countersunk driven head must fill the countersink fully. Unless
otherwise specified in an AIRBUS engineering document, the counter

sunk head must be milled flush (Refer to Figure 126).

Page B25
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51−42−11 Nov 01/06
STRUCTURAL REPAIR MANUAL

Double Countersunk Rivet

Figure 126

Page B26
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51−42−11 Nov 01/06