[ABN T3204026204 HISTORIC AIRCRAFT PROJECTS PTY. LTD. PO Box 1071 Albion Perk Rail NSW 2527 Australia Tel: 61 24257 4333 © Fax: 61 2.4247 4388 Cc AIRCRAFT RESTORATION SPECIALISTS ENGINEERING ORDER Number: EO 023 ITitte: Fuselage Stringer Repair AIRCRAFT PROJECT: C47 VH-EAE issue | Date Prepared Approved Description 1 ‘wo2z0I7 | G Lawrence Original Issue Latest amendments highlighted grey een + Weight and Balance Update Required - No Authorised Representative’s + Electrical Load Analysis Update Required - No Name and Delegation: ‘+ Flight Manual Supplement Required - No (AWAL or CASA) + Testing Required - No ‘© Continuing Airworthiness Changes Required- No C '* CASA Action Required - No l + IFRVFR NA "The master oF his document is archived in HARS files, No changes are penned without farther approval 1. APPLICABILITY: Aircraft: Model: Regn.No: Serial No.: Douglas ca7B VH-EAE 16348 2. REASON FOR ENGINEERING ORDER: This engineering order approves the stringer repairs and replacement due to corrosion on the fuselage on the above mentioned aircraft. The replacement stringer differs from the SRM callout due to obsolescence, and this EO identifies the repairs necessary to accommodate the change in stringer section and subsequent splicing. rietouss Fuselage stringer Repair Sheet | of 8HISTORIC AIRCRAFT PROJECTS PTY. LTD. 09/02/17 ENGINEERING ORDER EO 023 ISSUE 01 TITLE Fuselage Stringer Corrosion Repair 3. PLANNING INFORMATION: 3.1. SUMMARY: This engineering order details the repairs made to fuselage structure between Stns. 260 and 400 because of corrosion found in one of the stringers in the upper fuselage. The replaced stringer section differs from the original aircraft due to obsolescence and the replacement stringer complies with the SRM requirements for repair and replacement. 3.2. COMPLIANCE: Before further flight. 3.3. SPECIAL TOOLING: Not required. 3.4. WEIGHT & BALANCE: (REFER CAO 100.7) Weight and balance change is negligible. No further action required. Reweigh the aircraft on completion of the complete aircraft maintenance check. 3.5. ELECTRICAL LOAD DATA: Not applicable. “3.6, FLIGHT MANUAL SUPPLEMENT: Not required. 3.7. CONTINUING AIRWORTHINESS: No changes to the aircraft's system of maintenance are required as a result of this repair. 3.8. REFERENCE INFORMATION: Aircraft Maintenance Manual Technical Manual- Structural Repair Instructions T.O. 1C-47-3. FAA AC.43-13-1B or -2A, 3.9. DOCUMENTS APPROVED: THIS EO 3.10. PUBLICATIONS AFFECTED: NIL ACCOMPLISHMENT INSTRUCTIONS: Note: The compatibility of this design approval with the affected aircratt/component has been based on information available at the time of design approval. It is the installer's responsibility to report back on conflict with any existing repairs and/or modifications, riczooss Fuselage stringer Repair Sheet 2 of 8HISTORIC AIRCRAFT PROJECTS PTY. LTD 9/02/17 ENGINEERING ORDER EO 023 ISSUE 01 TITLE Fuselage Stringer Corrosion Repair = This repair/modification may affect future repairs in accordance with the Structural (©) Repair Manual (or Maintenance Manual), Contact Preparer of this EO if clarification is required. 4.1. PRELIMINARIES: 4.1.1 Gain access to the fuselage structure by removal of insulation material etc. in accordance with the aircraft maintenance manual. 4.4.2 \nspect areas for corrosion 4.2. INSTALLATION / REPAIR: 4.2.4 Stringer Repairs Corrosion has been identified in the top RH stringer between Stns 260 and 400. See Fig 1. 4.2.1.1 Remove affected stringer by cutting at Stn 260 and removal of the existing stringer splice at Stn 400. 4.2.1.2 Remove any skin panels adjacent to the stringer which are affected by corrosion. Remove surface corrosion as necessary and determine if corrosion depth exceeds SRM limits. Treat affected areas within SRM limits with Alodine 1200S and BMS 10-79 epoxy primer. 4.2.1.3 Manufacture replacement stringer section as depicted in Fig 2, from 1”x1" x.063" 2024- 73511 extrusion and L$220 Extrusion section (2024-T3511) modified with bottom flange removed. 4.2.1.4 Install replacement stringer section and in order to aid installation, reduce replacement stringer attachment flange locally by 0.25” at each frame location. 4.2.1.8 Manufacture and install stringer splice plates similar to those shown in Fig 2 ensuring 2D edge distance is maintained. If edge distance Is insufficient for AD6 rivets, then either 11off ‘AD4 rivets or 8 off ADS rivets can be used either side of spliced joint. Length of splice plate is to be increased accordingly. 4.2.1.6 Replace treated skin panels with PR1422 sealant around periphery. Wet install skin to stringer attachment rivets. 4.2.4.7 Mark the area adjacent to the replaced stringer with this engineering order number in indelible ink in a location visible to persons performing maintenance. 4.3. TESTING: 4.3.1No testing is required as a result of this repair. 4.4. TRIAL FIT: (4.4.1 No formal trial installation is required to be conducted prior to the completion of this repair riceoons: Fuselage stringer Repair Sheet 3 of 8HISTORIC AIRCRAFT PROJECTS PTY. LTD 09/02/17 ENGINEERING ORDER EO 023 ISSUE 01 TITLE Fuselage Stringer Corrosion Repair 4.5. MATERIALS INFORMATION: 4.5.1___ Required Materials: fem] Part No. Description ‘Gty_| Material/ Specification 1 | AND 10133- Extruded angle 1 2024-T3511 to QQA 250/ 1001-2 4°x1"x,083" 2 [ts220 Extruded bulbed angle 7_|2024-T3511 to GGA. 3 4 4.5.2 Parts Removed: Ifem| Part No. Description ‘Gty_| Materiall Specification 1 | 103893 Stringer 1 _|248 2 3 4 5. LOGBOOK ENTRY: 5.1.1Annotate the aircraft's logbook to state that corroded fuselage stringer replacement between Stn 260 and 400 has been carried out in accordance with this issue of HAP engineering order EO 023 issue 1. 6. STANDARD NOTES: 6.1, REGISTERED OPERATOR'S RESPONSIBILITIES: 6.1.1 Any flight manual supplements associated with this engineering order are to be inserted into the aircraft flight manual. 6.1.2If applicable, amend the MEL to reflect the changed configuration of the aircraft. 6.1.3Implement any IPC or maintenance manual changes, or maintenance manual supplements associated with this engineering order. 6.1.4Ensure weight and balance actions have been carried out. 6.1.5If applicable, it is the certificate of registration holders’ responsibility to advise CASA of the make and description of the ELT installed within 28 days of installation in accordance with CAO 100.37 Para 7.3. ELTs transmitting on 406MHz are also required to be registered with the Australian Maritime Safety Authority (AMSA). 6.2, MAINTENANCE ORGANISATION RESPONSIBILITIES: 6.2.1 All work to be conducted by an approved facility by persons approved for the appropriate C processes. 6.2.2Carry out the accomplishment instructions of this engineering order with reference to applicable information in the standard notes section. vaceouss Fuselage stringer Repair Sheet 4 of 8HISTORIC AIRCRAFT PROJECTS PTY. LTD 09/02/17 ENGINEERING ORDER EO 023 ISSUE 01 TITLE Fuselage Stringer Corrosion Repair _6.2.3If the maintenance organisation is the applicant/holder of this engineering order then a Ga copy of the engineering order is to be provided to the operator. 6.2.4Provide the certification in the aircraft log book in accordance with section 5 of this engineering order. 6.3. ACCOMPLISHMENT NOTES: 6.3.1 This engineering order may not be construed as changing the applicability of any related airworthiness directives. 6.3.2 This design is copyright to HAP Fasteners: 6.3.3 Fasteners used in avionics installations must be metal or nylon thread locked fasteners unless noted otherwise. Alternatively, Loctite 222 or 242 may be used on threads. Sheetmetal: 6.3.4Unless otherwise noted, observe standard sheetmetal practices in accordance with Manufacturer's SRM or AC43.13-1B Chapter 4, Section 4. Maintain a minimum fastener edge distance of 2D (2.5D for Countersunk) and a minimum fastener pitch of 4D. Material specifications as detailed below: 2024-0 Alclad QQ-A-250/5 2024-T3 Alcla QQ-A-250/5 2024-T42 Alok QQ-A-250/5 7075-T6 Alclat QQ-A-250/13 7075-0 Alclad QQ-A-250/13 7075-T6 Bare QQ-A-250/12 6061-T6 Bare QQ-A-250/11 4130N Sheet MIL-S-18729 (AI 4130N Tube MIL-T-6736 4130 Rod = MIL-S-6758 Electrical 6.3.5 All new unshielded wire to meet M22759/16 specifications. All new shielded wiring to meet MIL-C-27500. Wire gauge as indicated in the wiring diagram. All wiring to be in accordance with AC21.99. (i ‘6.3.6 Alll circuit breakers are to be placarded with their function and rating. Text to be similar in a size and font to other circuit breakers on panel. 6.3.7 Cap and stow all unused wiring in accordance with standard aircraft practices. Pull and ty-rap circuit breaker. Placard circuit breaker “U/S". If any other systems are affected by ric eo00.1 Fuselage stringer Repair Sheet 5 of 809/02/17 HISTORIC AIRCRAFT PROJECTS PTY. LTD ISSUE 01 ENGINEERING ORDER EO 023 TITLE Fuselage Stringer Corrosion Repair - this procedure then HAP General Manager Maintenance is to be advised for a revision € Ef to this process. 6.3.8 All grounds are to be made fo a suitable lug bonded with self-locking nut and screw or earthing blocks. Refer to CASA AC21.99 Chapter 13 "Bonding and grounding”. Bonding to be better than 0.00250 for RF components and 0.10 for all other components. oO iceoos Fuselage stringer Repair Sheet 6 of 809/02/17 ISSUE 01 7.0, 1047-8 Section 1 FOR STRINGER REPAIR & CODING SEE FIG, 17-15, FOR FLOOR BEAM REPAIR SEE FIG, 7-4 REFERENCE: DOUGLAS DRAWINGS 5110524, 5111164, 5110594, 5110591 FOR FRAME REPAIR SEE FIG, 7-5 AND 5110533 AFteetey oreincen Te eat TITLE Fuselage Stringer Corrosion Repair Cc HISTORIC AIRCRAFT PROJECTS PTY. LTD ENGINEERING ORDER EO 023 Sheet 7 of 8 Figure 1 — Fuselage stations and stringer location ricso02 Fuselage stringer RepairHISTORIC AIRCRAFT PROJECTS PTY. LTD Rie ENGINEERING ORDER EO 023 TITLE Fuselage Stringer Corrosion Repair eee aie UGS AL ~ ADE RIVETS. (see wore) HN ws Ainap Ad Zz EGF Osta Oe Rs — 0 nor Paws ao cove CT snuice marenan [i Jortainsat. structure @ New ewer ea ZZ rerrncemeas srmserye eruey VIEW AVA 4m en * Hace of oF tx i"c.ctet” gute T FeAMES WKH BotCon franine aT Noakes Ls. Fores Foo ues 220 Wousges Ade “ Frsteats Coven we Ron dated ENGL et 3 Zee Ss" Arte Notes, ee Construct splice trom QEPLACEMENT to . splice two 130893 bulb angles. This applies also to 103893 stringars of center wing. 2, ADE rivets each side of splice when both spliced are Douglas 130893 bulb angles. Figure 2 Replacement structure and splicing details vieeooiss Fuselage stringer Repair Sheet 8 of 8