STRUCTURAL REPAIR MANUAL

COUNTERSINKING - METALLIC STRUCTURE

1. General
A. The use of a countersunk fastener requires a countersunk recess in the
surface of the material. The countersunk recess receives the head of the
fastener and therefore gives a smooth surface.
B. The tools, used to produce the countersunk recess, are of various types
(Refer to Figure 1). These types are:
- a countersink bit with an integral pilot pin, a cutting edge to proÈ
duce the required internal corner radius and an adapter for use with a
drilling machine,
- a countersink bit with a replaceable pilot pin and an adapter for use
with a drilling machine,
- an adjustable countersink tool with an integral pilot pin and a cutÈ
ting edge to produce the required internal corner radius,
- an adjustable countersink tool with a replaceable pilot pin.
NOTE: The diameter of the pilot pin must fit the diameter of the fastenÈ
er hole. The diameter of the countersink bit must be larger than
the maximum diameter of the required countersunk recess.
C. Before countersinking, it is necessary to observe the minimum part
thickness given in Table 1 and Figure 2.
D. Recommended Procedure
The use of an adjustable countersink tool is recommended (Refer to FigÈ
ure 1).
CAUTION: CARE SHOULD BE TAKEN THROUGHOUT THIS PROCEDURE TO ENSURE THAT
THE COUNTERSINK PRODUCED IS NOT TO DEEP.
(1) Obtain a piece of scrap metal to use as a test piece, this should
be similar in type and thickness as the material that is to be used
for the repair. Obtain also a fastener of the same type and diameter
as the ones to be installed.
(2) Drill several holes to the required diameter in the test piece.
(3) Adjust the micro stop on the countersinking tool to give a minimum
countersink. Make a countersink on the test piece. Gradually increase
the amount of countersink by adjusting the micro stop until the reÈ
quired depth is obtained. Check the depth with the correct fastener.
Refer to Chapter 51-10-00 for the required Aerodynamic Smoothness for
the type of fastener.
(4) When the required depth of countersink has been obtained, check that
the remaining parallel portion (excluding the deburred area) of the
hole is at least 0.2 mm (0.008 in.) long.
(5) Complete the test by fully installing a fastener in the test piece
and check for correctness.

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Countersinking Tools
Figure 1 (sheet 1)

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MINIMUM PART THICKNESS FOR COUNTERSINKING <1>

FASTENER NOMINAL APPLICABLE FASTENER TYPE
DIAMETER
AM SOLID RIVETS STANDARD SOLID BLIND BOLTS HI−LOK (SHEAR) HI−LOK (SPECIAL HI−LOK (TENSION) PIN (SWAGED) PIN (SWAGED) BOLTS
(SHEAR) + BLIND RIVETS SHEAR) (TENSION) (SHEAR)
mm in. mm in. mm in. mm in. mm in. mm in. mm in. mm in. mm in. mm in.
3.2 1/8 0.940 0.037 1.295 0.051 − − − − − − − − − − − − − −
4.0 5/32 1.143 0.045 1.600 0.063 2.083 0.082 1.245 0.049 1.448 0.057 1.981 0.078 2.057 0.081 1.295 0.051 − −
4.8 3/16 1.397 0.055 1.981 0.078 2.286 0.090 1.397 0.055 1.626 0.064 2.286 0.090 2.286 0.090 1.422 0.056 2.286 0.090
6.4 1/4 1.727 0.068 2.591 0.102 2.972 O.117 1.753 0.069 2.083 0.082 2.972 0.117 2.972 0.117 1.803 0.071 2.972 0.117
8.0 5/16 − − − − 4.064 0.160 2.235 0.088 2.845 0.112 3.973 0.155 4.039 0.159 2.032 0.080 3.937 0.155
9.6 3/8 − − − − 4.775 0.188 2.489 0.098 3.302 0.130 4.623 0.182 4.750 0.187 2.565 0.101 4.623 0.183
11.2 7/16 − − − − − − 2.972 0.117 3.708 0.146 5.309 0.209 − − − − 5.309 0.209
12.7 1/2 − − − − − − 3.226 0.127 4.115 0.162 5.994 0.236 − − − − 5.994 0.236
14.3 9/16 − − − − − − − − 4.394 0.173 6.680 0.263 − − − − 6.680 0.263
15.9 5/8 − − − − − − − − 4.928 0.194 7.417 0.292 − − − − 7.417 0.292
Minimum Part Thickness for 100 ° Countersinking
Table 1

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<1> Only measure the single thickness of the material/part that is to be

countersunk.
NOTE: Minimum thickness is given assuming fastener heads are flush (i.e. level
with the skin surface). Where it is permitted to install fasteners with
negative flushness, the minimum thickness values in the table should be
increased by the same value as the negative flushness.

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Example of machined Countersunk Fastener Holes

Figure 2 (sheet 1)

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E. Countersinking when called for by a repair must be done with tools shown
in Figure 1, or equivalent. Where possible, it is recommended that an
adjustable tool should be used to make the countersink recess. This is
particularly necessary when a large number of countersinks are to be
made.

NOTE: When using an adjustable tool, make sure that the stop on the tool
does not rotate when countersinking. Rotation of the stop can cause
damage to the surface of the material around the countersink.

NOTE: If a large number of countersinks are to be made, the adjustment

of the tool must be checked from time to time.

F. To achieve adequate seating of the fastener, the edge of the countersink

recess/hole must be chamfered as shown in Chapter 51−44−11, Figure 1 and
2.

G. Some countersinking tools produce a chamfer (Radius) in a one−step op

eration with the countersinking (Refer to Figure 1). If the pro− duced
radius has the correct dimension for the required fastener (Refer to
Chapter 51−44−11), no further chamfering is necessary.
H. Examples of countersinking possibilities for the different surfaces are
given in Figure 3.

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Examples of Countersinking
Figure 3 (sheet 1)

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