FOR

'AIRCRAFT

FASTENERS

IIIICDONNELL DOUGLAS

H-I0126

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Copyright, McDonnell Douglas Corp., 1987

UNPUBLISHED

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Written and Compiled by

C. H. Cook, Cl-280
Quality Assurance

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NOTICE
McDonnell Douglas Corporation proprietary rights are included in
the information disclosed herein. Recipient by accepting this document agrees that neither this document nor the information disclosed
herein nor any part thereof shall be reproduced or transferred to
other documents or used or disclosed to others for manufacturing or
for any other purpose except as specifically authorized in writing by
McDonnell Douglas Corporation. Unpublished - created on preparation date of this document. All rights reserved under the copyright
.laws by McDonnell Douglas Corporation.
The information in this document is subject to design and
developmental changes without notice. Since issuance of this document is unofficial and distribution uncontrolled, accuracy, currency,
or completeness of the information is not assured. Reference must be
made to latest revised, officially issued documents for authoritative
information.

iii

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PREFACE
Air transportation is expected to continue to expand in the years
ahead. Douglas aircraft flying the skies of today will serve as springboards to the aircraft of tomorrow, much as the DC-3 and DC-61ed the
way to the DC-8, DC-9, and MD-80, and the DC-IO to the MD-ll. The
technical knowledge acquired from these airplanes will be incorporated into the design and manufacturing processes of the future.
This process of evolution is evident in fasteners and hole preparation.
Today, there are numerous. types of fasteners, made from different
metal alloys; many are more intricate in design than those of the past.
Selection of fasteners is more complex since specific functions often
limit usage. This has created a need for engineers who specialize in
fastener technology. Hole tolerances have become progressively
smaller for a larger percentage of holes. It is futile to purchase expensive fasteners and install them in oversize holes.
Thousands of hours of assembly time are spent each working day in
drilling, reaming, burring, and countersinking thousands and
thousands of holes. A large number of fuel tank and fuselage pressurization leaks have been traced to substandard holes. Hole preparation
that meets all specifications is perhaps the most important function
and responsibility of an aircraft assembler. It is the key to leakproof
fastener installations, strength requirements, and a long useful flying
life.

Aircraft safety, reliability, warranties, and customer satisfaction

require that Quality Assurance and Manufacturing personnel become
more technically oriented. Integrity of tooay's aircraft structure
would be impaired by the hammer-type mechanic of the past. Aircraft
of the immediate future will create the need for structure assemblers
to develop their skill to a degree that is more comparable to the precision, machine-shop type mechanic.
Proficient employees have a background of knowledge and therefore
quickly recognize when the work is not progressing satisfactorily.
Less experienced employees are not cognizant of the discrepancy and
its implications; therefore, the same repetitious errors may occur.
The competitive elemeilt makes it doubtful if .a ny organization could
:l ongsurvive if it ,e ver became satisfied with minimal job 'competence.
An executive of ;a large firm said it less subtly: "We either grow (in
competence) or we go."

If the past is a criterion of the future, it seems reaSonable that we

must be more vigilant ;a nd be more willing to expend 'e ffort,constantlyand persistently, tou;pgrade Q1ll'competence. Personal goals
as well as otg;aniz:ational ,objectives should be unequivocally stated:
"'To become adept ,a nd proficient in ali phases of hole preparation."
The rewards for achieving such a ,goal, both individually and 'collectively, will ensure ' 'success today.and tomorrow."

vi

CONTENTS
Section
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

Introduction ............................... .
Structural Factors .......................... .
Hole Tolerances ........ ... ................. .
Hole-Cutting Tools .......................... .
Edge Distance for Rivets ..................... .
Fastener Spacing ........................... .
Hole Drilling Practices and Techniques .......... .
Checking of Hole Sizes ....................... .
DeburringofHoles .......................... .
Alignment of Parts .......................... .
Drawing Symbols for Fasteners ................ .
Countersinking ............................. .
Dimpling ................. : ................ .
RivetOrientation ........................... .
Method Drawing S5076260 ................... .
BreakingHoleEdges ........................ .
Adjustable Stop Countersink Holders ........... .
Countersink Cutters ................. . ....... .
Stop Countersink Adjustment and Use .......... .
Spot Facing ............ .. ................. .
Coining ............ .. ..................... .
Hole Expansion ............................ .
Glossary .................................. .
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SECTION 1
INTRODUCTION
1-1. SCOPE
This manual has been prepared by Quality Assurance primarily for
the use of inspection personnel, but may be used by other McDonnell
Douglas personnel, as required, for training and indoctrination.
Procedures commonly used to drill, ream, burr, countersink, dimple,
and coin aircraft structures to ensure proper holes for fastener installations are described in this manual. Technical guidelines, shop
practices, and other techniques have been included to aid the user in
producing the finest aircraft in the world.

NOTE
Assembly procedures and specifications contained in this
manual are for reference only and may be changed without
notice. This manual is for advisory purposes and shall not be
cited to accept or reject work nor is it intended to dictate shop
practices.
Some portions of this manual do not relate specifically to detection of
discrepancies, but are presented to gain insight into the parallel prevention function. Proficiency in conducting surveillance audits of
work in progress requires detail knowledge of tool use and assembly
procedures. The manual also supplements the conventional after-the1-1

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work inspection by familiarizing personnel with documented

specifications.

1-2. ARRANGEMENT
The manual is organized so that classroom discussion may be limited
. to specific topics. The text has been arranged in 22 sections, with each

section broken down into various subjects. illustrations and tables

have been provided to help make text material more clear. A table of
contents lists, in sequence, all section titles. An alphabetized glossary
at the back of the manual explains various terms used throughout the
text.

1-3. SPECIFICATIONS AND RELATED DOCUMENTS

The following specifications and documents will assist the reader in
understanding and following the techniques and procedures outlined
in this manual:
Douglas Process Standards
Douglas Drafting Manual
Douglas Quality Specifications
AN, NAS, and MS Standards
Rivet and Screw Hole Preparation, Method Drawing S5076260

1-2

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SECTION 2
STRUCTURAL FACTORS
2-1. GENERAL
Today's aircraft (Figure 1) operate most efficiently at altitudes of
30,000 to 40,000 feet. Man cannot survive in this rarefied air without
supplemental aid. This aid is furnished by maintaining the cabin as
near to sea level pressure as possible at all altitudes.
The limiting factors in cabin pressurization are the structural
strength of the airframe, the leakage rate of the structure, and the
capacity of the pressurization components.
In the MD-ll, a sea level cabin pressure can be maintained up to a
flight altitude of 22,400 feet. A cabin altitude about equal to a
7,600-foot mountain can be maintained at a flight altitude of 43,000
feet. At these altitudes, there is a difference in pressure of 8.6 pounds
per square inch'between the air inside the cabin and the air outside.
Approximately 1,240 pounds of pressure are applied to each square
foot at the boundary of the pressurized area; thus, the application of
force on just one fuselage panel amounts to many tons.
Three air conditioning packs pump air into the pressurized areas of
the fuselage. In the MD-ll, the volume of air flowing into the cabin is
from 2,500 to 5,500 cubic feet per minute, depending upon the cabin
configuration. Therefore, it is mandatory that the tens of thousands
21

MD-11 - A HIGH-TECHNOLOGY TRIJET FOR COMMERCIAL AIRLINE SERVICE, WITH BASIC TWO-CLASS SEATING
WILL CARRY 276 to 405 PASSENGERS UP TO 6,800 NAUTICAL MILES . PROVIDES UNIQUE FLEXIBILITY
IN RECONFIGURING THE INTERIOR CABIN .

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DC-10 - FOUR VERSIONS PROVIDE ECONOMICAL OPERATION ON ROUTE SEGMENTS FROM 300 MILES TO MORE
THAN 6,000 MILES. CAN CARRY 255 TO 380 PASSENGERS. CONVERTIBLE FREIGHTER AND ALLFREIGHTER VERSIONS ALSO AVAILABLE.

KC-10 - AN AERIAL REFUELING TANKER CONVERTIBLE TO ALL CARGO OR TO MIXED PERSONNEL AND CARGO.
RATED " OUTSTANDING " BY THE USAF FOR EXCEEDING RELIABILITY AND MISSION CAPABILTIY GOALS.

MD-80 - FUEL EFFICIENT, QUIET, AND RELIABLE. THE BASIC MODEL CARRIES A MAXIMUM OF 172 PASSENGERS
OVER RANGES UP TO 2,000 MILES. OTHER MODELS OFFER EXTENDED RANGE, SMALLER SIZE FOR
ROUTES WITH LESS TRAFFIC, AND ADVANCED-TECHNOLOGY FLIGHT GUIDANCE.

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CO . . . . . . .

m ...............

C-17

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- THE ONLY MILITARY AIRCRAFT DESIGNED TO TAKE THE ARMY 'S LARGEST TANK AS CARGO. POWERED
LIFT ALLOWS LANDING DISTANCES UNDER 3,000 FEET AT MAXIMUM LANDING WEIGHT. MAXIMUM

TAKEOFF GROSS weIGHT IS 5 7 = J

G~:
T-45

--:- PART OF A U.S. NAVY TRAINING SYSTEM THAT ALSO INCLUDES SIMULATORS AND LOGISTICS SUPPORT.
THE T-45A IS BASED ON THE DESIGN OF THE RAF HAWK, MODIFIED TO NAVY TRAINING NEEDS AND
CARRIER OPERATIONS.

FIGURE 1. MCDONNELL DOUGLAS AIRCRAFT OF TODAY AND TOMORROW

2-2

of fasteners installed at the outward boundary of this pressurized

area be airtight. However, pressurization checks allow for a very
small amount of leakage, since fresh air is continually being pumped
into the cabin interior during flight operations.
Integral wing fuel tanks have requirements similar to those pressurized portions of the fuselage with one major exception: the tank structure must be leakproof instead of airtight. Safety requirements make
it mandatory that there be no fuel leakage whatsoever.
The fuel capacity of the MD-11 is more than 38,000 gallons. The
weight of the fuel ranges up to 259,000 pounds, almost 130 tons.
2-2. GUST LOADS
During flight, gust loads (the result of sudden up and down currents
of air) induce additional stress on the airplane, causing the wings to
flex up or down. The wingtips normally flex up 3.5 feet under normal
flight conditions. Should abnormal maneuver conditions be necessary, the wings are designed to deflect as much as 11 feet.
The extremely heavy stresses on the wing can best be understood if it
is kept in mind that the wings support the entire weight of the airplane. The maximum takeoff weight of the MD-11 is 602,500 pounds, .
and in certain flight attitudes the stress on the underside of the wing
may reach 13,500 pounds per square inch.

2-3

-]
The wing of such an aircraft is an engineering marvel when consideration is given to the weight ratio, aerodynamic functions, and fuel
carrying capacity.

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2-3. FATIGUE LIFE

McDonnell Douglas commercial airplanes are designed for a long and

useful flying life. Long fatigue life Oife expectancy of parts and
assemblies) depends on superior design and quality workmanship.
One without the other means a shorter service life. Generally speaking, fatigue of metal is caused by alternating tension loads, although
there are also many manufacturing processes that may reduce the
fatigue life.

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2-4. ENGINEERING SPECIFICATIONS

Engineering is responsible for providing the specifications that production personnel need to manufacture a quality product and ensure
that it meets contractual obligations.
However, the' 'why" for a certain requirement is seldom explained. It
appears to be unreasonable to expect this type of response.
Engineering has the knowledge, the experience, and the facilities to
conduct thousands of tests. Tests are continually being accomplished
to evaluate strength factors, material requirements, and manufacturing processes.

24

For example, the graph shown in Figure 2 illustrates the conclusion of

a laboratory test for drilling titanium. Improper drilling reduced the
designed fatigue more than 80 percent.

6AI-4V TITANIUM

DRILLED WITH HOT, DULL DRILL

DRILLED PER DPS 3.67-22

,
NUMBER OF CYCLES TO FAILURE

FIGURE 2. IMPROPER DRILLING

2-5. STRUCTURAL INTEGRITY

The adage "Quality cannot be inspected into a product, it must be

built in" is still true. Structural integrity is directly related to each
employee's integrity and willingness to become involved with the
multitude of small but "make or break" details of individual job
. assignments.

2-5

SECTION 3

HOLE TOLERANCES
3-1. GENERAL
Engineering chooses hole diameters with as large a tolerance as
strength, fatigue, and function requirements will permit. The reason
for this is that a considerable cost savings accompanies any increase
in hole tolerance. An aircraft assembler's job, therefore, is to produce
a hole size that is within engineering specifications. Quality is not necessarily a gage of precision; it refers to accuracy that is within
specifications.
Any dimension called out by Engineering is the desired or perfect
size, which may be possible but highly improbable. Therefore, all
dimensions have a permissible variation. One criterion for establishing hole sizes and tolerances is the fastener diameter and its allowable
variation. A hole may be drilled to the minimum size and a fastener
may be of the maximum diameter. On the other hand, a maximum size
hole and a minimum size fastener will provide a fit of greater
clearance. Either fit is of acceptable quality providing the tolerances
of both the hole and the fastener are within the specified tolerances.
Hole tolerances must be maintained to ensure that shear stresses are
distributed evenly; then, each fastener can carry its proportionate
share of the workload. Fasteners installed in oversize or elongated

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holes will transfer shear loads to proper sized holes nearby. In effect,
this reduces the number of fasteners installed. (See Figure 3.)

TENSION STRESS

OVERSIZE HOLE

.SHEAR STRESS
OR WORK LOAD

SHEAR STRESS

J
GAP (EXAGGERATED
FOR CLARITY)

TENSION STRESS

FIGURE 3. SHEAR AND TENSION STRESSES

Fastener hole-filling characteristics are not always the same in oversize and elongated holes, and may cause premature fatigue failures
and leaks of fuel or air in sealed areas.
The most important assembly function is not just the installation of
the fastener - it is the hole preparation as well. It usually requires
more knowledge and skill to produce a quality hole. Great reliance is
placed upon the integrity of the mechanic, since this phase of the
operation cannot be seen or inspected on a completed assembly. Reliability and safety of the airplane are directly related to this operation.

32

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3-2. FITS FOR BOLTED CONNECTIONS

Hole sizes for bolted connections are shown in Table 1, which provides
for six classes of fits. Notice that six different hole sizes are called out
for 1I4-inch bolts or screws. These different classes of fits serve as a
guide for Design Engineering in meeting strength and interchangeability requirements and for facilitating production.
TABLE 1
EXCERPT FROM ENGINEERING DESIGN HANDBOOK: HOLE SIZES FOR
BOLTED CONNECTIONS
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3-3. CLEARANCE FITS

The selection of a clearance fit for a bolted connection is based on the
largest clearance (maximum looseness) between the hole and the bolt
that will meet shear requirements. Clearance fit holes are usually
specified for lockbolts and Hi-Loks when one or more members are
steel, stainless steel, or titanium. The protective coating of noncorrosive cadmium plating on the fastener is softer than any of the
materials listed above. An interference fit hole in steel or titanium
peels the cadmium plating from the fastener. The hole does not
expand, as with aluminum alloys, and the harder metals act as a die
(see Figure 4).
The peeled plating and particles of steel from the fastener are
deposited either between the faying surface or under the fastener
head. This creates a gap and may produce fretting corrosion. In addition to the gap, corrosion of the fastener is accelerated; therefore,
holes through steel or titanium are of close tolerance and are a clearance or net fit. (An exception: See DPS 3.67-20 and -39 for unplated
titanium alloy or unplated corrosion-resistant steellockbolts and HiLoks.) The entire shank (not the threaded end) of some special bolts
installed into interference fit holes may be coated with an approved
lubricant (reference DPS 2.70-2).

34

TITANIUM ALLOY

ALUMINUM ALLOY

1. CAOMIUM PLATING PEELED FROM THE FASTENER

THE ABOVE PHOTO SHOWS THE RESULTS WHEN INTERFERENCE FIT HOLES ARE DRILLED IN
TITANIUM (OR STEEL). THE TWO PLATES ARE SHOWN SEPARATED AFTER PLATED
(CORROSION-PROTECTED) FASTENERS WERE FORCED INTO THE HOLES.

FIGURE4. RESULTS OF INTERFERENCE FIT HOLES

IN HARD METALS - NOT ACCEPTABLE

3-4. INTERFERENCE FITS

Engineering considers the minimum fastener diameter when establishing the maximum hole size for an interference fit. A lockbolt
installed through aluminum parts is a good example. The specified
hole size is from 0.000 to 0.003 inch smaller than the minimum fastener diameter. As the pin is pulled into the hole by the installation
gun, the hole expands to accommodate the lockbolt. The fastener is
designed so that the wall surface of the hole is not damaged or
_broached. In addition to a high-shear joint with a long fatigue life, a
35

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metal-to-metal seal is obtained that is leakproof Without the aid of

cheIllical sealants.
.

Figure 5'shows the results of an engineering laboratory fatigue test

when close"tolerance holes were oversized.

SPECIFIED HOLE TOLERANCE - 0.001

- - HOLE WITHIN JOLERANCE '
........ 0,001 PVERSIZEHOLE
. ..... 0.002 OVERSIZE HOLE .

NUMBER OF CYCLES TO

FAI~URE

. FIGURE 5. PREMATURE FATIGUE FAILURE

3-6

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SECTION 4
HOLE-CUTTING TOOLS
4-1. RUNOUT
Runout of hole-cutting tools refers to the amount of eccentricity (wobble) at the cutting lip of a drill or reamer; the axis of the cutting lip is
off-center to the axis of the drill shank. (See Figure 6.)
Ideally, there should be no runout, but mechanically this is impossible.
The mechanic should be aware of the inherent runout tendencies of
hole-cutting tools and how to minimize the problem.

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FIGURE 6. DRILL RUNOUT

41

Runout is affected by several factors in hole-cutting tools - drill lip

concentricity, lip angle, flute symmetry, and torsional rigidity. Rigidity (stiffness) is lessened as the number of flutes, flute lengths, and
overall lengths are increased or as the size (diameter) is decreased.
The type, balance, and manufactured precision of the motor chuck
also affect runout.
The degree of sharpness and straightness of hole-cutting tools adds to
the problem of runout, as does the trueness of the motor spindle and
the condition of its bearings.
During the drilling operation, runout is affected by motor rigidity, the
rate of feed, and the type of material.
Runout can be lessened through proper storage, use, selection, and
care of tools, and also through the use of drilling aids.

4-2. CARE AND CONDITION

Sharp drills with the proper feed produce large chips of a uniform size
and small burrs on the far side. Dull drills produce powdery chips and
large burrs and increase the possibility of enlarged holes and excessive heat induction into the materials. Dull drills used in automatic feed
equipment, such as the spacematic, can be detected by listening to the
motor. If it slows down and tends to labor, immediately check the condition of the drill and the size of the hole.

4-2

When drilling and reaming clad aluminum alloys, heat tends to fuse
the clad material (nearly pure aluminum) to the margins and lands of
the drilling tool. Inspect core drills and reamers for this "clad
bUildup" since it causes oversize holes and scoring of hole walls.
Crooked or bent drills tend to creep on the material surface, causing
scratches. Motor vibration and the resulting oversize holes are
usually caused by such defects. An extreme safety hazard is also
created by bent (even slightly) extension drills. Therefore, 6- and
12-inch extension drills should be used with a drill guide (see Section 7-6).
Reamers and broaches should never be thrown, dropped, or indiscriminately stored. The tool finish, cutting edges, and trueness may
be adversely affeclefr.--Burrs or scored ridges on the shank end of the
hole cutting tools also adversely affect concentric chucking. Refer to
Paragraph 7-4 "Chuck Runout."
4-3. LENGTH

Twist drills, double margin drills, core drills, and reamers are available in several different lengths. Always use the shortest drill that
allows access with out motor chuck damage to the nearby structure.
The advantages are:
a. When in use, the compression force on the hole-cutting tool
causes it to bow; therefore, short drills improve torsional rigidity
4-3

(longitudinal stiffness) and minimize runout.

b. Tool cost is reduced.
c. The hazard of drill whipping and possible injury to the operator or
other personnel is reduced.

4-4. DRILL SELECTION BY TYPE

There are so many different drilling conditions affecting hole sizes
that only a general guide is practical for the selection of hole cutting
tools. For specific problems related to drilling, consult Perishable
Tool Liaison personnel or the Hole Preparation Manual (Tooling
C652-5076260-PDSI).

4-5. DRILL TYPES

a. Twist Drills (See Figure 7.)
Twist drills are available in three sets:
1. Number drills from 1 (0.2280 inch) to 80 (0.0135 inch)
2. Letter drills from A (0.2340 inch) to Z (0.4130 inch)
3. Fractional drills from 1164 (0.0156) inch increments to
. 1 (1.000) inch

Sizes are stamped on the shank, and drill gages are ~vailable at
f
the tool cribs for verification.

,)

If the tolerance of the final hole size permits selection of optional

sizes, use the smallest size.
44

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DRILL AXIS \

SHAlli<~
JOBBER LENGTH

TWIST DRILL. HIGH-SPEED STEEL. STRAIGHT SHANK

AVAILABLE IN JOBBERS LENGTH - 6 AND 12 INCHES

FIGURE 7. TWIST DRILL

Twist drills are generally used in assembly work for final hole
sizes having an overall tolerance of 0.006 inch or greater. If the
hole tolerance is less than 0.006 inch, carefully evaluate before
using this type of tool.
b. Special Twist Tools
1 . Nitride drills are used to drill thin titanium material.
2. Cobalt drills are used to drill very hard materials such as
stainless steel (180,000 psi) and for deep drilling of titanium.
Cobalt drills retain their sharpness for a longer time, cut
faster, and generate less heat.
3. Split point twist drills, 135-degree angle, should be used for
deep drilling of steel and titanium.
4. Hi-spiral drills may be used for predrilling of thick aluminum
alloys to facilitate chip removal.

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c. Double Margin Drills

The double margin drill (Figure 8) functions as two drills in one.
The piloted end cuts a predrilled hole and the body portion produces the final hole size. It is a fast and efficient tool for drilling
holes having O.003-inch tolerance or greater in thin aluminum
alloys.
These drills are recommended if the total thiclmess of the
material is more than the length of the piloted portion (first step).
They should not be used for drilling titanium or steel parts, since
. more heat is induced than by other drilling procedures. An exception to this is small-diameter holes of 118 inch or less.

.
DASH NO. INmeAnY' OF 00"'

DIAMETER OF 1ST STEP]

s~
.

80. DY DIAMETER
TOLERANCE +.0005

- .0000

IT/'\\~~~-t
CUTTING EDGES

FIGURE 8. DOUBLE MARGIN DRILL

4-6

d. Core Drills, Piloted

Piloted core drills (Figure 9) are recommended for the following
uses:
1. Predrilling for piloted reamer.
2. Holes having a 0.003-inch tolerance in thick aluminum alloy
structure.
3. Step drilling to prevent high heat induction into steel and
titanium materials.
BODY DIAMETER
TOLERANCE + 0.0005
-0.0000

SEE SMALL TOOLS REFERENCE

MANUAL FOR SIZES ~
~

PILOT SIZE

'~~
I ~LOT

"----------""-.::......;=---

- NO CUTIING
EDGE

FIGURE 9. PILOTED CORE DRILL

e. Reamer, Piloted
For holes having a tolerance of 0.002 inch or less, always use a
piloted reamer (Figure 10). The use of a piloted reamer requires a
three-step procedure:
1. Predrill with a twist drill. The hardness and thickness of the

material may require a pilot hole prior to the predrill step. The
47

SODY DIAMETER
TOLE.RANC.E + 0.0002
0.0000

f
~C==-~t~~~~~:2:?
SEE SMALL TOOLS REFERENCE
MANUAL RJR DlAMETERSIZ':

7('"

FIGURE 10. PILOTED REAMER

The size of the predrill must correlate with the pilot of the
core drill used in Step 2.
2. Enlarge the predrilled hole with a core drill. The pilot size
should be 0.001 to 0.0015 inch smaller than the predrilled
hole. The body size must correlate with the pilot size of the
reamer used in Step 3.
3. Ream the core-drilled hole. The pilot size of the reamer should
be about 0.001 inch less than the core-drilled hole. Body size is
determined by the minimum final hole size specified by the
blueprint or applicable fastener DPS.
Hole-cutting tools are also available for oversize salvage fasteners. Pilot sizes are correlated to fit into the original (oversize) hole
(see Section 4-4).

4-8

SECTION 5

EDGE DISTANCE FOR RIVETS

The following information is taken from the Engineering Design
Handbook (DH):
Rivet edge distance (design) for general structural applications is
determined as follows: 2 x diameter + 1116 (0.06) inch

1. This design edge distance should be exceeded where weight or

functional penalty is not incurred.
2. This design edge distance is subject to normal tolerances. Where
conditions permit other than normal tolerances, the acceptable
tolerance shall be noted with the edge distance dimension on the
body of the drawing or in the general notes, as follows:
Rivet edge distance

= 2D + 1116 (0.06) inch for detail parts.

Rivet edge distance

2D minimum acceptable on assembly.

Rivet edge distance

2D from joggles and adjacent structure.

5-1

Use In

~.-

...---.. -....-.-..

Design Edge Distance

Castings

3 times rivet diameter

Nut plates in primary structure

4 times rivet diameter

Riveted plywood joints where full

strength is required

4 times rivet diameter

Nonmetallic moldings

3 times rivet diameter

NOTE
The DR is used only by Engineering and is included here for
reference only.

----~-- - --

I
I

SECTION 6

FASTENER SPACING
6-1. MINIMUM RIVET SPACING
The minimum single-row spacing should be held to four times the
rivet diameter for 5/32-inch diameter and under. A minimum spacing
of about 3-112 times the rivet diameter may be used for 3/16-inch
rivets and larger.
Where closer spacing is required, multiple rows of rivets are used.

6-2. ADJUSTMENT OF RIVET SPACING

(Reference DPS 2.70-2)
During master layout operations (MLO), fastener spacing specified
by the engineering drawing ~ot always be achieved. Method 1 or 2
procedures shall be used as necessary to adjust the spacing when the
distance between the end fasteners is not divisible by the specified
spacing.

Method 1
The spacing of the rivets at the end of the run may be adjusted
between the noted on-center dimensions and four times the rivet
shank diameter (4D). Figure 11 shows a typical example, using a
1/8-inch-diameter rivet on a 5/8-inch on-center spacing.

6-1

MINIMUM DISTANCE = FOUR TIMES

--J ____r-__~I-T-H-E-RIV+I--SH-A-NKbID-IA-M-IT;Er-~--+----r-ffl:r-I

END RIVIT

LIT

IF RIVIT SPACING SPECIFIED ON THE DRAWING " IJWS our AS SHOWN ABOVE,
ADJUST AS SHOWN BELOW.

I
FIGURE 11. RIVET SPACING -

METHOD 1

Method 2
When the spacing specified on the engineering drawmg is equal to
or less than 4D, it will not be possible to adjust in accordance with
Method 1. Under these conditions, make the nominal on-center
spacing 1/32-inch greater or less than that specified on the engineering drawing, except for fuel seal rivet patterns having a rivet
spacing less than 4D. Fuel seal patterns less than 4D may be
spaced 1164 inch to get the required adjustment. The adjustments under this method apply to as many rivets at the end of the
run as necessary.
Rivet spacing adjusted either by Method 1 or Method 2 is acceptable
provided the difference in the number of rivets between the engineering drawing and the MLO is not more than plus or minus one rivet.
Engineering must approve any difference of more than one rivet.
6-2

I
I

NOTE
The above conditions also apply to rivet patterns established
with the aid of tools.

6-3. ADJUSTMENT OF SPACING FOR BOLTS AND

LOCKBOLTS (Reference DPS 2.70-2)
The nominal spacing of bolts and lockbolts can be plus or minus 1/32
inch of that specified on the engineering drawing. This applies to as
many bolts or lockbolts at the end ofthe run as necessary; however, in
no case shall the specified quantity be changed without Engineering
approval.

63

SECTION 7

HOLE DRILLING PRACTICES AND TECHNIQUES

7-1. GENERAL
Most of the fasteners used today are manufactured to close tolerances
and are costly. However, the use of precision fasteners in itself does
not mean that engineering standards of safety, reliability, and long
fatigue life will be met. Fastener strength and hole-filling characteristics are not consistent when fasteners are installed in oversize,
belled, elongated, double, mislocated, undersize, and nonperpendicular holes.
The hole preparation procedure is further complicated by the many
different hole sizes and tolerances. For example, 1/4-inch-diameter
fasteners of various types require about 25 different hole sizes. Hole
tolerances for most steel fasteners range from 0.001 to 0.004 inch;
rivet hole tolerances are usually 0.005 inch.
There is often a tendency on the part of Inspection and Manufacturing personnel, through everyday association, to forget the minuteness of permissible variations in close-tolerance holes. For example,
this piece of paper is approximatley 0.004 inch thick. In order to produce assembly (not machine shop) drilled holes with a maximum variation of only one-fourth this thickness (0.001 inch), the correct tools
and drilling aids must be used,under optimum conditions, by a competent mechanic.
7-1

Because of restricted accessiblity and peculiarities inherent in a particular assembly, it may not always be possible or practicable to use all
of the practices and techniques that are suggested herein. However,
one conclusion appears certain: complete utilization increases the
percentage of quality holes; omission of anyone increases the probability of discrepant holes.

7-2. CORRECT AIR MOTOR SPEED (Reference DPS 3.67-22)

The selection of the correct motor speed is governed by the type of
cutting tool being used, the hardness of materials, hole tolerances,
and the size of the cutting tools.
As the drill or reamer diameter increases, the RPM (revolutions per
minute) requirement decreases. The outside lip of a larger holecutting tool is moving proportionately faster than a small-diameter
drill at the same RPM. Therefore, the speed or RPM must be reduced
as the hole cutting tool increases in size (see Table 2). This not only
prevents tool damage but also improves hole wall finish, enhances
assurance of hole tolerances, and tends to reduce the induction of
excessive heat into the material.
Reaming, countersinking, and counterboring operations also require
slower motors'than the 5,OOO-RPM air motors (see Figure 12).
Usually, but not always, the 2/700-RPM motor may be used. The
recommended RPM is one-third to one-half the drilling speed. The
feed should be two times that used for drilling.
72

TABLE 2
MAXIMUM RATED MOTOR SPINDLE SPEEDS (RPM)
TWIST DRILL DIAMETERS
UPTO UP TO UP TO UPTO

1/2

3/4

1,500

1,200

1,000

750

500

300

250

200

150

100

MATERIAL
ALUMINUM AND MAGNESIUM ALLOYS'
ALL TYPES OF STEEL, TITANIUM, AND
INCONEL. LUBRICANT REQUIRED" 2, 3.

11/2

DATA EXCERPTED FROM DPS 3.6722

NOTES:

1.

2.
3.

USE DRILLING AIDS WHEN HANDMOTORDRILLING HOLES:

LARGER THAN 114-INCH DIAMETER IN ALUMINUM
LARGER THAN 3/16-INCH DIAMETER IN STEEL AND TITANIUM ALLOYS
EXCEPTION: WHEN USING AUTOMATIC FEED AND SPEED DRILLING EQUIPMENT, THE
SPEED MAY BE INCREASED UP TO 7,000 RPM. FOR HIGHER SPEEDS, SEE LIMITATIONS
IN DPS 3.67-22.
OVER 180 KSI, CARBIDE DRILLS ARE RECOMMENDED.
SLOWER RPM MAY BE USED,

WITH CONVENTIONAL CHUCK.

2,700 TO 5,000 rpm.

FIGURE 12. AIR MOTORS

7-3

When drilling a joint containing dissimilar alloys, such as titanium,

Inconel, and aluminum, use the harder alloy in selecting the motor
speed. Do not drill steel, Inconel, and titanium parts with 2,700-RPM
motors. Laboratory tests show that structural fatigue life is severely
reduced.
Using C-clamps on air hoses to restrict the volume of air reduces both
the speed and power of the air motor. The motor stalls under a
workload and close-tolerance holes are belled or oversized. Finger
control (alternately depressing and releasing the motor trigger)
should also be avoided. This causes elongated holes and hardens the
surface of steel, Inconel, and titanium.

7-3. FEED RATE

Feed of a hole-cutting tool depends on the force applied to the drill
motor during the cutting operation. Machine shop feeds are figured in
thousandths of an inch for each revolution of the drill and are commonly referred to as feed per revolution (FPR). Unfortunately, such
measurements cannot be used for hand motors used in assembly
departments. The proper rate of feed is acquired through experience
and by giving close attention to results. Some of the items that affect
feed rate are noted below:
a. Feed rate is limited by the motor speed and power. Motor power
should be sufficient to prevent the rate of feed from stalling the
motor.

7-4

b. Harder alloys require low feeds, while softer alloys may use a
higher rate of feed. Proper feed will produce chips and spirals
rather than powder.
c. Different types of cutting tools require different feeds. The
number and length of flutes affect torsional rigidity (stiffness).
d. Too much feed will bow the cutting tool and cause runout. Long,
small-diameter drills require a slower rate of feed than short,
larger drills.
e. Use fast feed rates (without inducing runout), since fewer revolutions of the motor are needed to penetrate the hole, and holes are
less likely to be enlarged. Longer cutting time increases the probability of a slight tilting of the cutting tool due to hand
unsteadiness.

7-4. CHUCK RUNOUT

The precision and accuracy of a motor chuck may be offset by the
method used in chucking a drill or reamer. Eccentric or off-center
chucking usually happens when only one chuck jaw is tightened. This
tends to move the cutting tool against the other two chuck jaws. This
is only a small amount, but it becomes increasingly more important as
the hole tolerances get smaller. Drill runout induced by chucking can
be minimized by tightening each chuck jaw uniformly until the drill is
completely tight. To make a quick comparison of the two methods,
chuck a 12-inch No. 40 extension drill in a high-speed motor. Use the

75

same drill for both methods and observe the runout. Be sure to take
precautions to control drill whipping. (See Figure 13.)
GRIP LIGHTLY
AND AVOID CONTACT WITH FLUTES

FIGURE 13. FINGER CONTROL OF EXTENSION DRILL

The following are additional suggestions for reducing runout:

a. Never force a tool into an undersize chuck; this is a frequent cause
of damage to keyless or automatic chucks. It also causes scoring
and burring on the shank of the hole cutting tool.
b. Do not bottom the tool in the chuck; this may cause the tool to
bind. Allow about l/16-inch clearance between the shank end of
the tool and the bottom of the chuck.
c. Do not tighten if the drill flutes are within the chuck.
d. Never chuck over burrs on hole-cutting tools used for closetolerance holes since it contributes to drill runout.
7-6

75. DRILL NICKS

Drill nicks (Figure 14) on surrounding structure are caused by

excessive depth penetration of the drill. This can be eliminated by

using drill stops. (Figure 15)

FIGURE 14. DRILL NICKS - NOT ACCEPTABLE

FIGURE 15. USE OF DRILL STOP TO PREVENT DAMAGE

7-7

Always use a drill stop (see Figure 15) when drilling into assemblies
containing electrical or electronic equipment, fluid lines, insulation
bags, or inner structures. Adjust the drill stop to limit penetraton to
1/16 inch beyond the sheet. (Reference DPS 2.70-2).

7-6. DRILL SCRATCHES AND CHUCK MARKS

Drill marks not only detract from appearance, but also act as stress
risers that shorten the fatigue life of skins and structural members. It
is a mistake to believe that primer is the restorative cure-all for surface damage.
Scratches and chuck marks usually occur when jobber length drills
are used and the grip of the hand near the motor chuck is improper.
Notice the proper grip for the left hand as shown in Figure 16. (Also
see Figure 17 for proper grip with the right hand.) Correctly placing
the thumb and forefinger on the skin surface will:
a. Provide stability in overcoming motor torque and preventing the
drill from spinning or walking away from the hole, causing
"pigtails. "
b. Give better control of drill point for accuracy in locating hole.
c. Prevent motor chuck from rotating on skin surface when drill
penetrates material.
When using extension drills, stabilize the drill runout to retain control
and prevent scratches, and to avoid injury to the operator and other
7-8

;':~~'r";'';'~-;:~r.~';~:-~'. PROVIDE

OF DRILL

FIGURE 16. GRIP OF DRILL MOTOR

- - - - - .............+

CORRECT GRIP OF DRILL MOTOR

APPLICATION OF FORCE IS DIRECTLY
BEHIND CENTERLINE OF DRILL.
LESS PREFERABLE GRIP OF DRILL MOTOR
APPLICATION OF FORCE IS BELOW THE
CENTERliNE OF DRILL AND HENCE,
LEVERAGE TILTS THE MOTOR IN AN
UPWARD DIRECTION.

FIGURE 17. GRIP OF DRILL MOTOR

7-9

workers. Twelve-inch drills tend to whip because of excessive runout

and are a hazard if not controlled. Using a drill guide made from
micarta dowel will control the whipping. Another method is to loosely
grasp the extension drill between the forefinger and thumb (see
Figure 13). Do not grip tightly, since the friction can generate sufficient heat to burn the fingers.
7-7. PERPENDICULAR HOLES
Holes must be drilled "normal" to the surface that the fastener head
will seat against, unless specified otherwise. Normal means at 90
112 degrees to the surface, or perpendicular; for contoured surfaces it
means 90 degrees to the point of tangency. Technically, it is impossible to drill a concentric (perfectly round) hole at any angle other than
90 degrees to the surface. This is illustrated in Figure 18. The drilling
angle has been exaggerated to clearly illustrate the hole elongation.
The amount of hole elongation, of course, will vary with malangularity.
The smaller the hole tolerance, the more likely that malangularity will
elongate the hole beyond the maximum hole size. The use of drill
bushings in tooling fixtures, such as drill plates, drill blocks, drill jigs,
and drill tables, not only provides more assurance of perpendicular
holes, but also reduces chatter and the tendency of the drill to wander.
(See Figure 19).

7-10

NOTE: THE HOLE DIAMETER AT THE

PENETRATION AND EXIT SURFACES
(A AND B) IS LARGER THAN THE
DRILL DIAMETER (C).

!
'--+If---A
FIGURE 18. DRILLING NON PERPENDICULAR HOLES

CHECK PAD FOR WEAR

AND IMBEDDED CHIPS
FIGURE 19. DRILL TABLE AND BUSHING

Drill bushings also serve as stabilizers by minimizing the inherent

runout of hole-cutting tools. This dampening effect on tool runout is
an added benefit since it reduces the number of belled and oversized
holes, especially for close-tolerance holes.
711

Always use drill bushings for:

a. Drilling pilot holes and all subsequent steps if the holes are
through thick material.
b. Core-drill step before using a piloted reamer.
c. All final hole sizes, except for rivet holes through thin structure.
Freehand drilling (without the aid of drill bushings) of perpendicular
holes is improved by the proper grip of the right hand on the drill
motor (see Figure 17). Also use the unpainted skin as a mirror to help
align the motor properly; the drill should be in an exact straight line
with the reflected image (see Figure 16).

7-8. DRILL LUBRICANT (Reference DPS 3.67-22)

One drill lubricant authorized for assembly shop use is Mirror Base
Lube, DPM 342. This lube should only be used in cases where parts
can be disassembled and individually cleaned and dried after drilling
operations.
Mirror Base Lube that is available in assembly areas has been diluted
with 10 parts of water to 1 part of lubricant. The primary function of
the diluted solution is as a coolant; undiluted Mirror Base Lube may
be used if better lubrication is needed.
The diluted Mirror Base Lube has a maximum storage life of 3 months
and must not be stored in open or galvanized containers. The lubri7-12

cant drawn from steel drums must be used from standard pressure
pot or plastic containers only. The container must be labeled and the
expiration date noted.
Mirror Base Lube may be used on partially completed and sealed
assemblies provided it is applied very lightly to contain the lubricant
within the hole. Use of lubricant in a sealed area must be as follows:
a. Dip the cutting tool into the lubricant and allow the excess to run
or drip off the end.
b. Remove all residue with a clean water-dampened (not sopping)
cloth and then wipe dry. Since the lubricant is water soluble, use
water for cleanup purposes, not solvent.
To obtain proper sealant adhesive, the surface must be chemically
clean. The use of petroleum-base lubricants or beeswax is prohibited.
Products of this type have a tendency to bleed into the pores of the
metal and cannot be completely removed by the solvent washing
methods used in assembly departments.
Use Metal Working Fluid, DPM 5389 or 6005, for drilling steels,
titanium, Inconel, and aluminum. For aluminum alloys and graphiteepoxy composites, use High-Speed Drilling Fluid, DPM 5172. The
primary functions of a drill lubricant are to cool and to reduce friction.
The advantages of using a lubricant are:
a. Increases tool life.
7-13

b. Improves chip removal.

c. Smoother hole wall finish that enhances fatigue life.
d. Reduces heat expansion of cutting tool, thereby rninirrrizing the
chance of exceeding the hole size limitations.
e. Retards the tendency of clad material (nearly pure aluminum) to
build up on reamer lands.
f.

Reduces heat transfer from the cutting tool to the metal.

7-9. PILOT HOLE SIZES

Pilot holes are normally required prior to using the final drill. The
achievement of quality holes should always be the criterion for selecting the step drill procedure. Therefore, the following information
should not be regarded as mandatory:
a. A No. 40 (0.098-inch) pilot hole is optional for No. 30 (0.1285-inch)
drills, depending onthe thickness and hardness of the material to
be drilled.
b. A general rule is that the pilot hole should be about one-half the
next hole size.
c. A No. 30 (0.1285-inch) drill is recommended for drilling pilot holes
for 5/32-,3/16-, and 1I4-inch holes.
d. For thick material and hard alloys, a No. 40 (0.098-inch) drill may
be practical to use as a pilot drill. However, it should be noted that
the drill bends very easily and may result in additional runout.
7-14

This poor torsional rigidity is typical of all small-diameter holecutting tools and can be minimized by the use of:
1. Drill bushings to make the drill more rigid.

2. Short-length drills, core drills, and reamers.

3. Correct feed rate.
Predrill steps, before the final hole sizing, may vary in size because of
interim assembly processes, such as countersinking, dimpling, and
coining.

710. DISCREPANT HOLES CREATED BY GAPS

Drilling through multiple parts requires correct positioning and use
of clamping devices to eliminate all gaps prior to and during the drilling operation.
Figure 20 shows that a bolt installation would require rereaming and
subsequent oversizing of the hole. A lockbolt pulled into the hole by an
installation gun (3,000 to 5,000 PSn will broach the dotted portion of
the hole.
Figure 21 shows that thin-gauge materials must always be backed up
to prevent sheet separation or distortion during the drilling opera-

tion.

715

no
ill

NOTE: MALANGULARITY OF HOLE

EXCESS~
BURRS ~
-

NECESSARY TO FORCE FASTENER

INTO HOLE

DRILL DIRECTION

DRILLED WITH GAP

HOLE ALIGNMENT AFTER RE-ASSEMBL Y

FIGURE 20. DRILLING OF STRUCTURE WITH GAP

GAP CREATED BY DRILLING PRESSURE

FIGURE 21. DRILLING FLEXIBLE OR THIN MATERIAL WITHOUT BACKUP SUPPORT

716

7-11. DRILLING TECHNIQUES

"Woodpeckering" (removal of drill from hole to facilitate chip
removal) may be required for deep drilling of pilot holes, but should be
avoided during the final sizing step.
"Sawing" (alternate pushing and pulling motion) of the drill after a
breakthrough of the material is usually due to habit and not because it
is necessary. This practice enlarges the hole and is wasted effort and
time. If a fastener fits too tightly, check:
a. The hole-cutting tool for proper size and excessive wear.
b. The fastener diameter to make sure it agrees with the tolerances.
c. Mating parts for accurate hole alignment.

7-12. REAMING TECHNIQUES

Techniques for reaming close tolerance holes are listed in Table 3. The
DON'T column lists common errors that cause oversize holes.
Note that the direction of reamer spirals, relative to the motor chuck
rotation, is such that the reamer will not pull itself into the hole.
Therefore, more force or feed is required than for drilling. Failure to
apply sufficient feed to a reamer will result in belled holes.
A flex drive unit is recommended when hand-reaming close-tolerance
holes. It is an aid in maintaining concentricity and reducing elon-

717

TABLE 3
REAMING TECHNIQUES FOR CLOSETOLERANCE HOLES

1. INSERT PILOT OF
REAMER INTO
CORE-DRILLED
HOLE.

DON'T

DO

STEPS

IF DRILL BUSHING IS NOT USED,

ALIGN CORRECTLY WITH COREDRILLED HOLE BY FEELING AND
OBSERVING MOTOR ANGULARITY_

ALLOW CLEARANCE BETWEEN

CUTTING LIPS OF REAMER AND
SURFACE OF MATERIAL; THEN
START MOTOR.

'I Ir=T

APPROX 1/2 INCH

z:::.;OF ROTATION

APPLY ENOUGH FEED TO QUICKLY

PENETRATE MATERIAL.

STOP ROTATION AND

PENETRATION IMMEDIATELY
UPON BREAKTHROUGH.

~~
FINGER-CONTROL SPEED OF MOTOR.

APPLY FEED LIGHTLY. THERE IS A

TENDENCY TO UNDERFEED FOR ALUMINUM
ALLOYS.
ALLOW REAMER TO PENETRATE THROUGH
HOLE OVER 1 INCH.
PERMIT MOTOR TO TILT AT MOMENT OF
BREAKTHROUGH. FAILURE TO CONTROL
RESULTS IN ELONGATED HOLES.

HOLD MOTOR FIRMLY TO

PREVENT TILTING.
4. REMOVE REAMER
FROM HOLE

PILOT~

ALLOW MOTOR TO STALL.

APPLY CONTINUOUS FEED UNTIL
REAMER BREAKS THROUGH
OPPOSiTE SIDE OF MATERIAL.

3. STOP MOTOR AND

FEED.

CONTACT SURFACE OF MATERIAL WITH

CUTTING LIPS; THEN START MOTOR
ROTATION. THIS CAUSES MOTOR TO LURCH.

INCORRECT METHOD

CORRECT METHOD

2. START MOTOR
BEFORE
APPLYING FEED.

BIND PILOT OF REAMER; INDICATES

MALANGULARITY WITH CORE-DRILLED
HOLE.

LIP CLEARANCE-

~REAMER

JJ

FORCE PILOT INTO HOLE; SHOULD FIT

FREELY (ABOUT 0.002 CLEARANCE)_

AS REAMER IS PULLED FROM

HOLE, ROTATE MOTOR CHUCK BY
HAND IN A CLOCKWISE
DIRECTION (SAME DIRECTION AS
MOTOR ROTATES).

USE AIR POWER OF MOTOR TO REMOVE

REAMER. THE FEWER THE MOTOR
REVOLUTIONS, THE BETTER.
RELAX AND ALLOW MOTOR TO SAG.
ROTATE REAMER COUNTERCLOCKWISE.
CHIPS ARE TRAPPED BETWEEN REAMER
LANDS AND HOLE WALL, RESULTING IN
NICKED HOLE WALL SURFACE.

7-18

gated, oversize holes. Torsional rigidity (stiffness) is improved and

shorter reamers may be used, reducing runout (see Figure 22).
C-652-( )-(GT)

-O~""-------7~~~

C-652-74910-(GT)

REAMER WITH A FLAT GROUND

FLRDR_IV~EU_N.....IT'--_ _ON=S_HANK.
SETSCREW.ALIGN WITH

~PILOTI-

'"-------i

SOCKET SET SCREW TO

RETAIN REAMER SHANK

LENGTHi

(MINIMUM 2 x DIAMETER
OF REAMER BODY)

FIGURE 22. FLEX DRIVE UNIT

The tool is capable of providing a slight flex and thereby creates a

tendency for the reamer pilot to follow the pilot hole. This overcomes
slight movements of the hand while reaming. The key to obtaining a
close-tolerance hole with this tool is a 90-degree pilot hole.
Select the flex drive unit from the data shown below (Reference DPS
3.67-22):
C-652-74910

[BasiC Tool No.

1I
21

GT

General Tool
For reamers with O.188-inch shank

123

For reamers with O.311-inch shank

For reamers with 0.435-inch shank

7-19

7-13. DRILLING OF STEEL, INCONEL, AND TITANIUM

METALS (Reference DPS 3-67-22)
The induction of high heat into metals during the drilling process is
serious, since it causes a loss in mechanical properties and lessens
resistance to corrosion. Stainless steel, Inconel, and titanium alloys
are very hard metals and high temperatures are generated by using
incorrect hole-cutting tools, feeds, and speeds. These materials dissipate heat very slowly, and heat from the drilling operation is
therefore concentrated at the hole wall surface. High temperatures
alter the grain structure and induce residual stresses that cause intergranular cracks.
At the time of drilling, the material (including aluminum) should
never be above touch temperature (approximately 130F). If there is
any indication that the quality of the material has been adversely
affected by drilling, make a hardness test.
Do not depend on discoloration of the metal or primer as evidence of
overheating. It should always be remembered that many discrepancies are not visible to either the mechanic or the inspector. Therefore,
ensuring structural integrity is directly dependent upon the willingness of the assembler to follow the procedures conscientiously.
These procedures are based on laboratory tests that induced the least
amount of heat in the materials and provided the longest fatigue life.
Table 4 is a page excerpted from the noted manual. It is shown here as
an example of hole-cutting tools for O.OOl-inch-tolerance holes for
7-20

TABLE 4
EXCERPT FROM TOOL DESIGN "HOLE PREPARATION MANUAL C6525076260PDSI"
NOMINAL

SIZE

fAITENfI DATA
HOLE
TOLERANCE

.1~909?5

tj4

.2495fS05

5/16

.31~i'313O

y8

.3745/3755

7f6

,437of380

H
A

'"

(i) DRILLS

72157128
=30 (.12851
72157191
=11(.19101
72157250
1/4 (,25001
72157312
5116 (.3125)

"

CUlTlN

3/8 (.3750)

CORE DRillS
.001
.1710 x .1270

.002
.2344 x .1900
.003
.2969 x .2485
.004
.3594 x .3110
.005
.4219 x .3740

REAMERS

PlUC

-070

.1895/.1700

.189S/.190S

2
.2495 x .2330

071
.2495/.2505

-072
.3120/.3130

-4

5
.4370 x .4205

55076260 5 . 7.
8. 20. 21. 22

.3120 x .2950

.3745 x .3580

..

IN IN

METHODi$', OR CPS
TABLE NUMBER.

CYliNDRICAl

S5076260 5.7
8. 20. 21. 22
S5076260 5.7

-073

.s. 20. 21, 22

55076260 5,7

.3745/.3755
-074

.s, 20, 21, 22

S5076260 5, .7,

.4370/ .4380

.s, 20, 21, 22

/
/

/
/
/
STAN

72157375

CO NT

CA

DOUBlE MARGIN

DRillS

._.

/
/

AND EfERENCE

UMENTS

NAS BIB, DAC 3395B, ENGIN.EERING DRAFTING MANUAL

~I1 DOUBlE MARGIN DRilLS MAY BE USED IN liEU Of DRill AND CORE DRilL
SEOUENCEJREFER TO OPS 3.67-22 fOR lIMITATIONS.1

0SEE SHEETS es;v, 8Sv fOR CUTTINC TOOL REfERENCE SKETCHES,CENERAl

TOOL NUMBERS,ANO TOOLING SEQUENCE DATA.
~

FAillNER DESCRIPTION

3116 TO 7116

BOLT AND SCREW HOLE CUTTING TOOL SELECTION

EXTRA CLOSE FIT CLASS A & VI
fOR NOMINA.L SIZE FASTENERS
IN ALUMINUM, STEEL OR ALUMINUM/STEEL COMBINATION
------

FIRST ISSUE
1976
REVISED DATE 1278

---~-~

~--~~--

PAGE NO.
BOLT AND SCA

bolts and screws. It lists the drill, core drill, and reamer to be used for
various diameters. This is typical for other fasteners. Cutting tools
are also given for drilling and/or reaming for oversize fasteners.
The manual also specifies that rivet holes require core drill usage for
drilling steel and titanium parts or in any combination with aluminum
alloys.
The core drill induces less heat into the materials and will cut away
the austenitic material (carbon, etc.) that may be created by the
predrill step (see Figure 23). Coordinate these requirements with the
motor speeds recommended in Table 3, and with the usage of lubricants outlined in Paragraph 7-8, "Drill Lubricants."
When drilling holes through a combination of dissimilar alloys (such
as aluminum and steel), always use the feed and speed for the harder
alloy. Where possible, always drill from the harder alloy into the
softer one.
Upon contact with the material, immediately apply cutting feed to the
drill. Do not permit the drill to dwell on the metal without cutting.
Use enough force to keep the drill cutting continuously.
Cobalt drills are preferred for predrilling and are mandatory if the
material thickness is greater than the fastener diameter.

7-22

17,7 PH STAINLESS STEEL

HOLE WALL

PHOTOMICROGRAPH OF VICINITY AROUND DRILLED HOLE (MAG

350X). THE AUSTENITIC LAYER AT THE HOLE WALL SURFACE
WAS FORMED DURING THE DRILLING OPERATION AS A RESULT
OF OVERHEATING. SINCE THIS LAYER IS MORE DENSE THAN
PARENT MATERIAL, IT IS PUT IN TENSION; THUS RESIDUAL
STRESSES ARE PRODUCED THAT ARE IN EXCESS OF THE YIELD
POINT. RESULTS ARE SHOWN IN THE LOWER PHOTO.

LAYER OF AUSTENITE,
A CONSTITUENT OF STEEL
UNDER CERTAIN CONDITIONS

INTERGRANULAR CRACK
(GRAIN SEPARATION)
PHOTOMICROGRAPH (MAG 300X) OF INTERGRANULAR FAILURE
IN PARENT MATERIAl.

FIGURE 23. EFFECTS OF OVERHEATING METALS

723

7-14. DRILLING OF GRAPIDTE EPOXY-COMPOSITES

(Reference DPS 3.67-22 and -22.1)
Machined and drilled surfaces should show no indications of overheating. Overheating has occurred when the graphite-epoxy surface has
turned a brownish-black.
Drilled or reamed holes should have a maximum surface roughness
ofl~.

Tool life is limited when composites are being drilled. Cutters should
be replaced when there is tool chatter, chipped cutting edges, overheated materials, excessive wear of cutting edges, delamination, or
splintering.

- NOT ACCEPTABLE

ACCEPTABLE

FIGURE 24. HOLE SPLINTER CONDITION

When drilling holes where the drill exit surface is a graphite-epoxy

composite, cover the drill exit surface with a masonite or fiberglass
backup to prevent splintering (see Figure 24). The backup must be
held in close contact with the workpiece by clamping.
7-24

Whenadrilllubricantisrequired(ReferenceDPS3.67-22.1)useDPM
5172. High-speed drilling (20,000 rpm) without lubricant is prohibited.
Graphite dust and drill lube residue should be removed from holes
prior to fastener installation. Use 1, 1, 1 trichloroethane (DPM 5792)
as the cleaning agent. A dampened clean cloth, using the above solvent, may be used.
Graphite-epoxy should be countersunk with a radiused, piloted, carbide cutter rotated at 2,000 rpm maximum speed (Figure 25). The cutter must be rotating before it contacts the graphite to prevent
splintering. Slight splintering around holes to be countersunk is
acceptable if there is no splintering after countersinking.
When required, the edges of holes for protruding head fasteners
should be broken with a diamond-plated countersink cutter (TD
562R2.2).

GRAPHITE-EPOXY COMPOSITE

FIGURE 25. EDGE BREAK

7-25

Graphite-Epoxy Composite Structure Only

When holes are prepared in graphite-epoxy structure only, use the
following procedure:
Step 1: Drill with a carbide-type twist drill or a carbide flat flute
drill (TFIM 25.0253). For 1/8- through 3/8-inch diameter, use 900 to 2,700 rpm drill motors with feed rates of
30 to 45 seconds per inch.
Step 2: If necessary to meet specified hole tolerances, use a carbide reamer.
Back up the drill exit side to prevent splintering and delamination.

Graphite-Epoxy Composite with Aluminum and/or Titanium

Substructure
When drilling holes in a combination of materials, as noted above, use
the following procedure:
Step 1: Drill through the structure with carbide twist drills
using feed and speeds for aluminum or titanium per DPS
3.67-22.
Step 2: If necessary to meet specified hole tolerances, ream
holes to final size using carbide reamers. Use lI64-inch
undersize drill in Step 1 and ream to final size.
Use DPM 5172 dri11lubricant for drilling and/or reaming.
726

Aluminum or Titanium with Graphite-Epoxy Composite

Substructure
When drilling holes in a combination of materials, as noted above, use
the same procedure specified in the previous paragraph.
NOTE: This type of joint requires that the drill exit side of the
graphite be backed up with aluminum or plastic material.

Graphite-Epoxy Composite Joined with Titanium and Aluminum

When drilling holes in a combination of materials, as noted above, use
the following procedure (see Figure 26):

STEP 1

STEP 2 STEP 3

STEP 4

.---....--TITANIUM
ji:':=~=in1::::~~~~_-GRAPHITE
GRAPHITE
1\~~;4--

ALUMINUM

FIGURE 26. COMBINATION GRAPHITE, TITANIUM, GRAPHITE,

AND ALUMINUM SUBSTRUCTURE

Step 1: .Drill graphite-epoxy up to the titanium with carbide

twist drills using feeds and speeds for aluminum drilling
per DPS 3.67-22.
Step 2: Drill titanium up to the graphite-epoxy with twist drills
using feeds and speeds for titanium drilling per DPS
3.67-22.
7-27

Step 3: Drill through the graphite-epoxy with carbide twist

drills using feeds and speeds for aluminum drilling per
DPS 3.67-22.
Step 4: If necessary to meet specified hole tolerances, ream
holes to final size with a carbide reamer using feeds and
speeds for titanium drilling per DPS 3.67-22.
Use drill lubricant (DPM 5172) for drilling and reaming.

Safety
Where no drill lubricant is used, the dust from machining and drilling
graphite-epoxy composites must be collected in a vacuum system and
the operator must wear a respirator.
Comply with Occupational Safety requirements for hole drilling and
trimming of graphite-epoxy composite materials (Reference: DAC
Safety Manual).

7-28

7-15. SUMMARY OF STEPS PRIOR TO DRILLING

Determine the final hole size and limits of tolerance from the
blueprint, method drawing, or fastener DPS. It is also important to
know the approximate thickness of the joint and the types of metal
alloys.
This information is necessary for the proper selection of drill motor
RPM. The speed used may be slower than the recommended RPM,
but not faster.
When selecting cutting tools and drilling steps, check accessibility,
tolerances, hardness, and thickness of materials.
Use a drill lubricant for drilling steel, Inconel, and titanium, and also
for reaming close-tolerance (O.OOl-inch) holes. Use drill bushings to
ensure proper hole angularity, concentricity, and tolerance.
Prior to drilling, check parts for proper clearance, edge distance, and
location against jig stops and pads. Mating parts must fit snugly, free
of distortion, preload, and gaps.
Visually inspect the cutting tool for size, condition, and runout. The
smaller the hole tolerance, the more important it is to use drilling aids
to reduce runout.
The first time a tool is used, check it on a piece of scrap material to
make sure it is accurate. This is not necessary for holes having a
tolerance of 0.006 inch or greater.
7-29

SECTION 8

CHECKING OF HOLE SIZES

81. GENERAL
Attachment holes drilled with conventional air motors have a tendency to be belled or enlarged on the drill entrance side of the material.
The size of the hole gets progressively smaller toward the drill exit
side of the material (see Figure 27).
Belled holes are usually caused by:
a. Vibration and wobble of the cutting tool. This condition lessens
slightly as the drill or reamer cuts deeper into the material.
b. Excessive pressure applied at the time the motor is started. The
outer portion of the drill lips have a small bearing area because of
the pilot hole, and the drill has a tendency to grab.
Lack of motor rigidity and the timing of any hand movement produces holes of many configurations. The cone-shaped hole, shown in C
of Figure 28, is typical of most assembly-drilled holes. The hole
tolerance is the determining factor as to its acceptability.
Lack of motor rigidity may cause tapered holes (see Figure 28).
Detection of discrepant holes is more accurate if checked from the
entrance side. Holes within tolerance near this surface are unlikely to
be oversize in the middle or drill exit side.
8-1

DRILL ENTRANCE SIDE

rBEL~EO PORTIO. OF HOLE

\L----...J1

LHolE IS TIGHTER ON THIS SlOE

FIGURE 27. BELLED HOLE

DO

DO

o o
c

FIGURE 28. TAPERED HOLES

Belled and tapered holes reduce the material bearing area for
fasteners loaded in shear. Therefore, they are undesirable and unacceptable if the discrepancy is more than the maximum tolerance of the
hole.

8-2. GO AND NO-GO PLUG GAGES

These gages (Figure 29) are available in many sizes for different
types offasteners. If used properly, this type of hole gage can quickly
and efficiently detect discrepant holes. The disadvantage of the gage
is the need to use other measuring devices to find the actual dimension of oversize holes for engineering salvage information.
82

REMOVABLE CYLINDRICAL PLUGS

FIGURE 29. GO AND NOGO PLUG GAGE

Before using a plug gage the first time, use a micrometer (Figure 30)
to verify the two sizes stamped on the holder. The "Go" end has a
tolerance of +0.0000, -0.0002-inch. The tolerance of the "No-Go"
end is + 0.0001, - 0.0001-inch.
The "Go" end (colored green) provides assurance that the hole is not
undersize if the gage passes through the hole. The "No-Go" end (colored red) provides assurance that the hole is not over the maximum
size if the red end cannot enter the hole, either totally or partially.

~-~---RATCHET

FIGURE 30. MICROMETER CALIPER

83

STOP

Figure 31 shows a modified type of "No-Go" gage. Rotation of the

gage will allow for a more positive identification of elongated holes.

FIGURE 31. MODIFIED NOGO PLUG GAGE

Personnel can quickly become skilled in using the gages by using sight
and feel. Gages should be used from the final drill or reamer entrance
side. The following sequence is suggested:
a. "Go" end of gage.
1. Gage does not enter the hole; hole is therefore undersize and

not acceptable.
2. Gage passes through the hole and provides assurance that
hole is not undersize.
(a) A tight fit through the entire hole is a good indication that
the hole is within the maximum tolerance.

(b) A loose fit is a caution that the hole may be oversize. The
gage is most likely to be loose at the drill entrance side
and tight near the drill exit side.
3. Observe the gage fit around the edge.
(a) A snug, no-gap fit at the hole edge indicates that the hole
is within tolerance.

(b) Ifthere is a gap, proceed to step b.

8-4

b. "No-Go" end of gage.

1. Gage enters the hole; hole is oversize and not acceptable.

2. Gage does not enter the hole; hole may be acceptable. Proceed
to next step.
3.

~lace gage over the hole and observe around the gage end for

the hole edge.

(a) If no portion of the hole edge is visible, hole is acceptable.
(b) If any part of the hole edge can be seen, hole is rejectable.

8-3. BALL GAGE AND MICROMETER

Ball gages come in various sizes and are used to accurately measure
the diameters of holes. Like most other tools, a ball gage is not infallible; its accuracy depends on the skill, knowledge, and experience of
the user. To properly locate the gage in the hole, perform the followingsteps:
a. Rotate the ball gage inside of the hole and adjust until it touches
the hole wall; drag should be very light.
b. Rotate the gage again; if the drag is not continuous, the hole is
elongated. Readjust the gage to include elongation.
c. Move gage to and fro in a longitudinal direction to detect belled or
tapered holes.

8-5

After the final adjustment has been made on the ball gage, measure it
with a certified micrometer. This is the second time an accurate
measurement depends on a delicate sense of feel, and requires
extreme care.
8-4. INTRIMIKS

To ensure quality holes within engineering tolerances, it is recommended that Intrimiks be used wherever possible (see Figure 32).

FIGURE 32. INTRIMIKS

Selection of gage size is by range. For example, one size gage

(smallest available) is used for measuring any hole size between 0.275
and 0.350 inch (minimum-maximum limitation). This gage can be used
for verifying the size of a hole specified to be 0.312 to 0.313 inch. This
8-6

particular gage, however, cannot be used for a 0.2495- to 0.2505-inch

hole (hole is too small), nor can it be used for a 0.375- to 0.376-inchhole
(gage is too small). Use the next larger size gage. (Micrometers
graduated in metric millimeter increments are also available.)
Prior to using gages, verify the accuracy by using provided check
blocks.
Use the ratchet on the mike for final adjustment to provide consistent
repeat accuracy.
Three contact points, spaced 120 degrees apart, touch the hole wall
surface. Readout is obtained with the attached micrometer.

8-7

BURRS ARE MINIMAL AND EASILY

REMOVED IF SHEETS ARE TIGHT
AND SHARP HOLE DRILLING
TOOLS ARE USED ~

~
DRILL DIRECTION--

BURR ON DRILL EXIT SIDE

EXCESSIVE BURR DUE TO GAP

,/

[]]

~LGAP

FIGURE 33. EXCESSIVE BURRS DUE TO GAP

8-8

SECTION 9
DE BURRING OF HOLES
9-1. GENERAL

Hole burrs, located on the drill exit side, consist of small portions of
material that were pushed out (not cut) because of the force applied to
the drill. The use of dull hole-cutting tools and excessive feed creates
large burrs. Excessive motor speed for drilling and reaming steel,
Inconel, and titanium, or in combination with aluminum, produces
burrs that are larger than normal.
Since the clad on the surface of aluminum alloys is soft, it tends to produce heavier hole burrs than nonclad aluminum alloys. Thick aluminum alloy has thick clad coating; therefore, larger burrs are produced.
Clamp materials together tightly before drilling to minimize burrs
between faying surfaces (see Figure 33).
Hole burrs prevent metal-to-metal contact of the mating surfaces and
can cause fasteners to loosen under repeated surface loads and vibration. '1\1so, fretting corrosion is induced by the wearing action of the
burrs on the mating surfaces. Proper burr removal is essential and
mandatory to ensure structural integrity.

91

CAUTION
In assembly areas, never grind or sand to remove burrs, since
this will adversely affect the material finish and hardness.
Burr removal for fasteners in high-stressed critical fatigue joints shall
be accomplished as specified on the engineering drawing. Check prior
to deburring holes other than for aluminum alloy rivets.

9-2. RIVET HOLES (Reference DPS 3.67-22)

Use a vixen block or channel deburringtool (see Figure 34) to remove
rivet hole burrs on bare, nonclad, aluminum alloy surfaces except on
exterior skin surfaces. Burrs in excess of 0.002 inch high (approximately one-half the thickness of this page) are not acceptable. Use
the following techniques and precautions:
a. The tool should cut clean with one or two strokes. Clean the chips
from the tool after each stroke. If these chips are not cleared
away, they become wedged in the cutting teeth of the tool and will
scratch the surface of the material.
b. If burrs stick to the cutting edges, or if the edges are dull or
chipped, replace the tool.
c. Do not use on exterior skin surfaces.
d. Use only a forward-cutting stroke. Do not scrub.
e. Apply light pressure; too much pressure will cause the tool to dig
and grab.
9-2

ASSURE THAT EDGE RADII PREVENT

CONTACT WITH SKIN SURFACES

VIXEN BLOCK

CUTIING TEETH MUST BE

SURFACE-GROUND, LEAVING
0.005 FLATS

11f2-INCH
VIXEN FILE
SET SCREWS
VIXEN CHANNEL DEBURRING TOOL

FIGURE 34. VIXEN FILE DEBURRING TOOLS

93

On appearance areas, holes may be individually deburred with a

100-to 120-degree countersink cutter in a low~RPM motor. This type
of hole deburring requires caution; remove only the sharp edge.
Removing too much material reduces the bearing area for the
fastener. See Figure 35 for dimensional limitations.
Never use 82-degree countersink cutters for burr removal. A cut

made with this tool, of sufficient width to remove the burr, will result
in a chamfer depth greater than that obtained with a 100-degree
countersink cutter. Figure 36 illustrates the result from using two
different degree cutters.

9-3. DIMPLED HOLES (Reference DPS 3.67-2)

Removal of burrs from holes to be dimpled must be performed per the
applicable DPS by a qualified dimple operator. Before dimpling, use
one of the following methods to remove all sharp and protruding
edges caused by drilling:
a. Vixen deburring block, subject to limitations of the DPS.
b. A 100- to nO-degree countersink cutter driven at low RPM is
mandatory for all screw dimples (see Figure 37). The material
removed by this operation must not exceed 25 percent of the total
sheet thickness.

9-4

olO

D~

MAXIMUM WIDTH OF CUT

FOR BURR REMOVAL

/.005 MAXIMUM WIDTH OF CUT

FOR BURR REMOVAL

-D-

IF MATERIAL IS MINIMUM
MATERIAL THICKNESS FOR
COUNTERSINKING PER

S5076260

IF MATERIAL IS OVER THE

MINIMUM MATERIAL TlHCKNESS
FOR COUNTERSINKING PER

S5076260

FIGURE 35. DEBURRING FOR RIVET HOLES IN APPEARANCE AREAS ONLY

1')

DEPTH IS LESS THAN

"" eHAjFER

100

820 ~EPTH
IS GREATER THAN

Y .'\ /

DO

-1

100" CHAMFER

If

~ ~
~
CORRECT
NOT ACCEPTABLE

NOTE: CHAMFERS ARE

ENLARGED FOR CLARITY

THE OVERALL WIDTHS OF THE TWO CHAMFERS ARE EQUAL; WIDTH

IS THE MINIMAL MATERIAL REQUIRED TO REMOVE BURR.
THE WIDTH OF CHAMFER IS 0.005INCH~MAXIMUM FOR COUNTERSUNK MINIMUM MATERIAL THICKNESS;
OTHERWISE, 0.010 INCH MAXIMUM.

FIGURE 36. BURR REMOVAL

100 TO 110

~--~,~,>~----~
)
DIMPLE DOWN SIDEJ

" '"

>~25% OR LESS

"-"

FIGURE 37. HOLE DEBURRING FOR SCREW DIMPLING

95

NOTE

Deburring both sides of the sheet is permissible, providing total material removed is not more than 25 percent
of the sheet thickness.
When ordinary deburring methods fail to prevent radial cracks,
polish the hole before dimpling.
9-4. STEEL AND TITANIUM MATERIALS (Reference DPS
3.67-22)

To deburr holes on steel and titanium metals, use a fine-tooth, conetype, rotary file, 04522-8Dl-161 (GD-60 degrees), or a 100- to
120-degree countersink cutter in a low-RPM motor. Motor speed for
deburring of holes should be one-third to one-half of the RPM recommended for drilling. Balance the feed and speed to prevent chatter
marks and heat induction.
9-5. RING-COINED HOLES (Reference DPS 3.67-23)

Before ring-coining, deburr holes by using a flat deburring tool, such

as a vixen block. Do not use a countersink cutter.
The engineering drawing may specify the method to use, especially
for high-stressed parts.

96

NOTE
Countersinking and breaking hole edges, if required, shall be
accomplished after the coining operation is complete.

9-6. HOLE EXPANSION (Reference DPS 3.67-25)

Deburr only the ridges protruding above the surface, using No. 240
or finer abrasive paper. Be careful notto chamfer the hole edge.

9-7. PIN STRESS COINING - HOLES AND COUNTERSINKS

(Reference DPS 3.67-56)
The above coining methods require hole edges to be chamfered prior
to coining. These methods eliminate the need for deburring. Refer to
the above DPSs for chamfer dimensions and tolerances.

9-7

c. Distort thin materials.

d. Tear the hole in thin materials.
e. Create gaps and built-in stresses.
f.

Peel the anticorrosion coating from the fastener.

Clearance fit installations may require a slight force to overcome friction between the hole wall and the fastener. Minimum hole sizes and
maximum fastener diameters produce this type of fit. If thumb
pressure is not enough to insert fasteners into clearance fit holes, the
problem is usually hole misalignment, but it may also be:
a. Burrs were not removed, or a chip is trapped between mating surfaces at the hole edge. The hole can be cleared by using an alignment pin or ice pick; use carefully to avoid distortion of the hole.
b. The wrong size cutting tool was used; there is seldom an optional
size that will provide the minimum and maximum hole tolerance.
c. The margins on the cutting tool may be badly worn. An undersize
tool is likely if it has been used to drill hard alloys, such as stainless
steel or titanium.
d. Size of the fastener may be greater than the maximum specification. This seldom happens, but if everything else is satisfactory,
ch~ck the actual size of the fastener with its specification.

10-2

Some causes of misalignment are:

a. The use of clecos to obtain hole alignment is a common practice.
However, a cleco is not a precision tool and is not satisfactory for
accurate alignment of holes. Its one and only function is to hold
parts together temporarily.

NOTE
Clecos will not consistently align holes properly, even for
rivet holes having a 0.005-inch tolerance. Aliowingfor the
permissible variation of the fastener and hole diameter, a
5/32-inch rivet may have a clearance fit of 0.001 to 0.011
inch. If the hole is misaligned only 0.002 inch, there is a
possibility the rivet will not enter the hole freely.
b. A sufficient number of temporary fasteners were not used during
the drilling operation.
c. Failure to spot-rivet allows thin materials (doublers, webs, and
skins) to creep out of alignment during the riveting operation.
d. Failure to eliminate gaps prior to drilling causes hole malangularities, as shown in Figure 38.
Failure to use temporary fasteners creates gaps when close-tolerance
attachments are driven into interference fit holes. Note the sequential steps in Figure 39. Although the parts were drilled correctly, it is
easy to determine that the reassembly step, in this particular case, is
10-3

MARK INDEX HOLES FOR TEMPORARY FASTENER USAGE.

RE-INSTALL TEMPORARY FASTENERS IN SAME HOLES
UPON RE-ASSEMBL Y.

o
o

o
o

FIGURE 40. INDEX HOLES

106

SECTION 11
DRA~GSYMBOLSFORFASTENERS

11-1. GENERAL
The fastener code system applies to all types of fasteners if the installation will cause a permanent deformation of the fastener or if it is
necessary to destroy the fastener to remove it.
The symbol system shown below is explained in Method Drawing
S5076260 and is used to simplify fastener callout and hole preparation. The symbol includes a single cross, with the intersection at the
location of the fastener. Fastener and hole preparation information is
indicated by an alphanumeric code placed within specific quadrants of
the cross. When the symbol is viewed in a position so that the letters
are upright, the upper left-hand quadrant is northwest, etc.

NWINE
SW
SE
11-2. NORTHWEST QUADRANT
Fastener identity is shown by a two-letter basic code. The code is
made up of two letters and defines all features of the fastener except
diameter and grip. Explanation of the fastener identity code will be
found in the "General Notes" on the engineering drawing. All of the

111

two-letter basic codes are identified in NAS 523.

~
11-3. NORTHEAST QUADRANT
The fastener diameter and location of the manufactured head are
defined by a letter-number code. The fastener diameter is shown by a
number that represents the diameter (dash number) in the full part
number; this is usually in 32nds of an inch.
The location of the manufactured head of the fastener is defined by
the letter "F" for far side and "N" for near side. When the location of
the manufactured head is obvious or insignificant, the code letter is
left out.

11-4. SOUTHEAST QUADRANT

The fastener length is shown by a dash number that represents the
length in the full part number.

NOTE
Rivet lengths are not specified unless the requirement is more
than 1 inch.

"2

Lockbolts, Hi-Loks, and most screws are coded by grip length, usually in increments of 1116 inch.

-h11-5. SOUTHWEST QUADRANT

Dimple and countersink information is indicated by a letter-number
code consisting of one, two, or three lines. The following information
is from the method drawing for rivet and screw hole preparation,
S5076260:

D2C
DC
82
D-Dimple
No. - Number of dimpled sheets
C - Countersunk
Blank - Install per methods drawing
82 - Angle of upset end if upset into a cavity

11-6. SPECIAL CONSIDERATIONS

For a full explanation of coding, see specific dash numbers of the
methods drawing. (Refer to Table 5; excerpted from 85076260.)

113

DRAWING NO.

_____...::C:HA:N::G~E~LE:.T~TE~R=6:::Y=====

:5076260

PAGEN~ __~I~.I~____________

.CY'

______________

TABLES
DRAWING SYMBOLS FOR HOLE PREPARATION
The symbol system shown below Is based on NAS 523 which servee to simplify fastener
callout and hole preparat ion with a code in the lower left hand quadrant that defines
the method of hole preparation, in accordance with the methods drawing, 8-5076260.

LETTER 8ASIC

COOE~

DASH NO. THAT REPRESENfS THE

DIAHETER III THE FULL PART KO.
II "" MFO. HEAD NEAR SIDE

--.. .-. . . 88/ IN''':-''--------

F. HFD. HEAD FAR SIDE

02e
DC 2-1' ___________

~~~~T~OiH T~~i ~ijr~E~!~~S H~E

...., 82
COOING WHICH DEFINES A - - / "
SPECIFIC M(THOO TO BE
USED IN PREPARIHG THE
HOLE PER METHODS DRAWING.

o ...

DIMPLE
NO. c: HUMBER OF SHEETS OlMPLED
C :: COUNTERSUNK
BLANK :c INSTALL PER METHODS DRAWIKG
82 :: ANGLE OF UPSET EttO IF UPSET
INTO A CAVITY
FOR EXPLANATIOH OF COOING SEE SPECIFIC DASH NUMBERS OF THE
METHODS DRAWl HG.
EXCEPTIOtt:

Itt DOUBLE FLUSH APPLICATIONS WHERE OIHPLE-<;OUIHERSIICK

OPERATIOttS ARE OPTIONAL. THE COOING WilL BE THUS:

-,aa1_~I

ANGLE OF NfO HEAD

"'NGlE Of UPSET EHO

INDEX OF DIMPLE AND COUNTERSINK

CODES

METHODS DRAWl JIG

DASH JllI(l!If.R

CODE

RIVETS

... ,
0, 02, 0:3. ETC.
02e. D)C. DIlC, ETC

SCREWS

-a

-2,

-5

-3. -) .... -18

DC

COlIIDITIOU

-38. -18

-7. -7A
-78

COUHTERSINK TOP SHEET OR SHEHS

All SIIEETS 01 HPLEO

DIMPLE TOP SHEET; COUlHERSINK
DIMPLE HUMBER Of OUTER SHEETS SPECIfiED;
COUNTERSINK
RIVET IS UPSET nUSH

TWO ANGL(S

xo

MfO IIEAD
UPSET EHO
(UPPER LEFT QUAORANT)

DOU8LE FLUSH ~IYETS WITH OPTIOHAL OIHPLE

COUHTERSIHK OPERATIONS

-<I

10.
-19

DEICER DIMPLE

McDonnell Dougfas Corporation Proprietary Information - Use or d!sclosure of this information is

subject to the restriction o:ljhe title page or on the first page of thiS document.

114

Exception: In double-flush applications, where dimple-countersink

operations are optional, the coding will be as follows:

wo--+.~~~ I

Angle for manufactured head (deg)Angle for upset end (deg)

When it is necessary to indicate the exact installation method, use the

following dimple-countersink coding:
For single-flush rivets, the code consists of only one line, and not more
than three digits.

ct-

mt-

Top and middle

Machine countersink

sheets dimpled;
bottom sheet

regardless of sheet
thickness or number

Inner and outer

sheets dimpled.

countersink.

of sheets affected.

ocst-

For protruding head rivets to be upset flush, the code consists of two
lines.
First line: Indicates the dimple or countersink (or both) operation for the upset end.

115

Second line: Indicates the nominal angle of countersink of the

upset end; 82 degrees is mandatory for upsetting
rivet butts into countersink.

nsc+U;~I

For double-flush rivets, the code consists of three lines:

First line: Indicates the dimple or countersink (or both) operation for the manufactured head.
Second line: Indicates the dimple or countersink (or both) operation for the upset end.
Third line: Indicates the normal angle of dimple or countersink
of the upset end when different from the angle of the
manufactured head; 82 degrees is mandatory.

yt-~Jf8~ I

8~ I

~~ I

Special cases: When a particular method is required, for example

S5076260-14, it will be noted in the drawing symbol thusly:

~
This type of callout is also typical for other methods.
116

No code for dimpling and countersinking is necessary when the

method of installation for flush fasteners (Method Drawing
85076260) is optional. The complete dimpling and countersinking
coding shall be used when it is necessary (1) to restrict the operations
permitted by 85076260 or (2) to authorize deviation from 85076260.
When in doubt, always refer to the general notes on the engineering
drawing.

11-7

1 - -.
1

Il-

...

DIAMETER 0.005 OF
NOMINAL DIMENSION

--r

MINIMUM MATERIAL THICKNESS

PER S5076260

~------I ----.!

KNIFE EDGE - NO RADIUS

AT BOTTOM OF
COUNTERSINK WELL

FIGURE 41. TYPICAL 100DEGREE COUNTERSINK FOR

MANUFACTURED HEADS OF FLUSH RIVETS

118

SECTION 12
COUNTERSINKING
121. GENERAL
Countersinking shall conform to DPS 3.67-3, Countersink for Flush
Attachments, and to Method Drawing S5076260, Rivet and Screw
Hole Preparation. For fasteners other than rivets, refer to the
specific fastener DPS or method drawing. Figure 41 illustrates a typical100-degree countersink for manufactured heads of flush rivets.
The following three rules are excerpts from DPS 3.67-3:
a. All holes must be drilled straight and normal to the surface unless
otherwise specified.
b. Select the tools, speed, and feed that will produce countersinks
that are concentric with the holes and are free from chatter, swirling chip scratches, and other tool marks.
This is especially important on clad exterior skin surfaces. The
clad coating is thin and is almost pure aluminum (soft) and
therefore easily marred by stop countersink holders.
Check these factors on scrap or test material before countersinking production parts.
c. Adjustable stop countersinks are used in portable electric motors,
air-powered motors, or stationary drill presses. The stop countersink must have an accurate and positive locking adjustment for
121

maintaining the proper depth and diameter. The cutters must

also be equipped with a pilot of the proper size to maintain concentricity with the hole and to prevent chatter marks.

12-2. MINIMUM SHEET THICKNESS (Reference DPS 3.67-3)

When countersinking in minimum thickness material, proceed as
follows:
a. Where practicable, countersink on stationary equipment.
b. Where portable equipment must be used, back up the far side of
the material to eliminate enlarged, elongated, or torn countersink
holes.
When countersinking in minimum thickness material or when breaking the edge of the hole at the juncture of the hole and countersink,
the hole diameter may enlarge beyond the maximum hole tolerance.
This condition is acceptable providing the hole tolerance is not
exceeded by 0.005 inch maximum, countersink angle and diameter
are correct, and the oversize hole will not create a leak path.

12-3. BELOW MINIMUM SHEET THICKNESS

When countersinking below the minimum sheet thickness (see
Figure 42), proceed as follows (Note: Must have engineering authorization):
a. The part must be countersunk together with the substructure and
without any chips, burrs, or gaps between the members to
12-2

THE ORIGINAL HOLE IN TOP SHEET

IS ENLARGED BY COUNTERSINKING

1t:

MATERIAL THICKNESS IS LESS

THAN THAT SPECIFIED BY
S5076260

---"""\

KNIFE EDGE - NO
SHOULDER. MOST
STEEL AND TITANIUM
FASTENERS REQUIRE
THIS EDGE TO BE
CHAMFERED OR
RADIUSED

COUNTERSINK EXTENDS
INTO SUBSTRUCTURE
SUBSTRUCTURE PROVIDES
BEARING AREA FOR PILOT
OF COUNTERSINK cunER

FIGURE 42. COUNTERSINKING BELOW MINIMUM SHEET THICKNESS

eliminate a step condition and to prevent torn or folded-over

countersink holes.
b. If the substructure is of light-gauge material, it may be necessary
to back up the far side of the structure to prevent damage to the
countersink or hole.

12-4. MEASURING COUNTERSINK DIAMETERS

Aerodynamics, leak-proof requirements, and flight stresses make it
absolutely necessary that countersinks meet engineering dimensions.
Countersink diameters are specified in thousandths of an inch, usually with a tolerance of 0.005 inch. Exceptions are specific countersink dimensions called out by engineering drawings or by a fastener
DPS. These permissible but small variations make it impractical to
use the head of a fastener as a guide for countersinking.
12-3

On all flat sheets, use a Trulok or Brencor countersink gage to check

countersink diameters. Select the Trulok countersink gage from
Table 6. Refer to Figure 43 for instructions on using the Trulok.
TABLE 6
TRULOK COUNTERSINK GAGES
LIMITS
TRULOK
GAGE

DEGREE OF
ANGLE

MINIMUM

MAXIMUM

1001
100-2
1003
1004
1005

100
100
100
100
100

0.160
0.360
0.560
0.780
1.000

0.360
0.560
0.780
1.000
1.335

821
822
823

82
82
82

0.160
0.360
0.560

0.360
0.560
0.780

Calibrate the Brencor dial indicator gage with the test block. Check
for correct size and degree. Should the gage be dropped or bumped,
recheck calibration.
On assemblies having a 20-inch radius or less, the Trulok gage will not
give accurate readings, and the countersink diameter must be
measured with a scale. Countersinks on curved surfaces are elliptical.
Flush screw heads are always seated "flush" to "low"; rivet heads
are "flush" to "high." Therefore, change the direction of measurement for nomimal countersink dimensions as shown in Figure 44. A
general rule is: for rivets, measure the elliptical countersink in the
widest direction; for screws, in the narrowest direction.
124

1. RESET DIAL BY PULLING UPPER KNURLED

KNOB STRAIGHT OUT TO ITS LIMIT.

BE SURE GAGE IS THE SAME ANGLE AS

COUNTERSINK, AND THAT ITS RANGE INCLUDES
DESIRED COUNTERSINK DIAMETER. DIAMETER
IS READ IN THOUSANDTHS OF AN INCH OPPOSITE
LINE ON THE CENTER SLIDE. EACH SMALL DIVISION
REPRESENTS 0.005 INCH.
3. CHECK COUNTERSINK ANGLE WITH
POINTED BLADE. ANGLE IS STAMPED
ON BLADE.

2. CHECK GAGE ON CHECK BLOCK IN BOX. GAGE

READING SHOULD BE THAT ENGRAVED ON
CHECK BLOCK.

4. PRESS CONICAL HEAD FIRMLY

COUNTERSINK UNTIL BODY OF GAGE
RESTS SOLIDLY ON SURROUNDING
SURFACE.

5. REMOVE GAGE. READ COUNTERSINK

FIGURE 43. INSTRUCTIONS FOR USING THE TRULOK COUNTERSINK GAGE

125

CROSS SECTION VIEW

TUBULAR ANO CONTOURED CONFIGURATIONS,
20-INCH RADIUS OR LESS

INSIDE CONTOUR

STEEL AND TITANIUM FASTENERS - MEASURE CROSSWISE

TUBULAR AND CONTOURED CONFIGURATIONS,

20-INCH RADIUS OR LESS
RIVETS - MEASURE LENGTHWISE

FIGURE 44. MEASURING COUNTERSINK DIAMETERS

(TUBULAR AND CONTOUR SURFACES)

12-6

NOTE
A flexible scale graduated in hundredths of an inch will provide better accuracy than fractional dimensions.
Figure 44 illustrates the method for measuring countersinks for
rivets and screws for tubular and inside contours of 20-inch radius or
less. Reverse the direction of measurement for outside contours.

125. VERIFYING DEGREE OF COUNTERSUNK HOLES

Both the 82-degree and lOO-degree countersink cutters are used in
assembly processes and-it is not uncommon for the wrong degree of
cutter to be used. It is difficult to visually detect this type of
discrepancy without the use of angle blades, shown in Figures 43
and 45.

VERIFICATION OF CORRECT DEGREE OF COUNTERSINK

DETECTING INCORRECT DEGREE OF COUNTERSINK

FIGURE 45. VERIFYING DEGREE OF COUNTERSUNK HOLES
12-7

POINT OF SHEAR - LIMITED BY

SHEAR STRENGTH OF RIVET

NON-DIMPLED JOINT

DIMPLES SUBJECTED
TO SHEAR STRESSES
IN THIS AREA

DIMPLED JOINT
FIGURE 46. DIMPLING

FIGURE 47. DIMPLE DIES

128

SECTION 13
DIMPLING
13-1. GENERAL
A function of a fastener is to transmit loads from one part to another.
In a nondimpled joint, the shear load is limited to the shear value of
the fastener itself (see Figure 46).
A dimpled joint can increase the ability of a flush fastener to transfer
shear loads. The load can even exceed the shear value of the fastener,
since the dimples are interlocked and prevent the transmittal of the
entire shear load to the fastener. It is never permissible to countersink when Engineering specifies dimpling.

13-2. EQillPMENT
Hot-dimpling equipment must be certified. The certification due date
must be stamped on the certification decal that is attached to stationary hot-dimple machines, portable squeezer dimpling equipment,
and control panels. (Reference DQS C5.1-1 AD.)
Dimple dies have a high-grade finish to prevent surface irregularities
in the dimpled material. To protect this finish, dies should be stored
individually to prevent scratches and nicks from other tools, and in
such a way as to prevent corrosive pitting (see Figure 47).

131

Misalignment of dimple dies is frequently the cause of discrepant

dimples. If any misalignment of dies is evident, stop production until
Maintenance has corrected the realignment and Quality Assurance
Certification has verified it.

13-3. HOT DIMPLING

The dimpling of a particular metal is governed by its ductility (the
quality of a metal that determines the ease of forming, without cracking, into various shapes). A somewhat brittle material may be made
more ductile by heating it, thereby allowing dimpling. Dimples must
be formed at higher temperatures for titanium, magnesium, and most
(but not all) aluminum alloys. To determine minimum and maximum
temperature requirements for specific materials, refer to
DPS 3.67-2.
When overheated dimples are evident, it is important to determine
the degree and extent of damage. A comparison of the material hardness at the dimple with the hardness of the surrounding area is an
indicator. The degree of discoloration of scorched paint is meaningless since damage may be considerable even with little or no
darkening. Visual inspection of the finished dimple will not necessarily reveal overheating. For an example of the effects of heat on
materials, see Figure 23.

13-2

13-4. CRACKS
Radial and circumferential cracks are common in dimpling and may
be either internal or external (see Figure 48). Use of a lower die
temperature than referenced can result in internal or nonvisible
cracks. Use of either a higher die temperature or a longer dwell time
will result in low-strength dimples.
Circumferential cracks are less common than radial cracks. Reverse
forming of a dimple, or flattening, is never acceptable since it always
produces circumferential cracks. Never redimple shallow or otherwise unacceptable dimples without documented approval from Process Engineering.
Radial cracks are the result of poorly drilled holes, improper deburring, insufficient heat, or incorrect dwell time.

All cracks, regardless of degree, shall be cause for rejection and must
be referred to Liaison Engineering for disposition.

CIRCUM"'ENTIAL INT;"AL C~
CIRCUMFERENTIAL CRACK
RADIAL CRACK

FIGURE 48. TYPES OF DIMPLE CRACKS

133

13-5. OTHER QUALITY REQUIREMENTS

The protective wash-off coating on exterior skin surfaces must be
removed prior to all hot- and ambient-temperature dimpling.
Hot and cold dimpling is restricted to qualified and certified
operators.
A satisfactory dimple is well defined and the contour is not changed
by the operation. An overformed dimple is caused by excessive
pressure that overstretches the material. An underformed dimple is
due to insufficient pressure. Figure 49 illustrates these variable conditions. Test strips are used for proper adjustment of equipment
pressure. Test specimens shall be of the same material, alloy, temper,
and thickness as the production part.
Analysis of laboratory tests and past experience prove that strict
adherence to Process Engineering procedures produces quality
dimples. This, coupled with the integrity of the dimple operator, is the
best assurance of quality dimples.

PROPERLY FORMED

OVER-FORMED

FIGURE 49. DIMPLE FORMING

13-4

UNDER-FORMED

For more detailed information on dimpling, refer to the following

documents:
DPS 3.67-2, Hot and Cold Dimpling (Stationary Equipment)
DPS 3.67-7, Portable Squeezer Dimpling (Elevated and
Ambient Temperature)
DPS 3.67-8, Portable Vibrator Dimpling (Elevated and Ambient Temperature)
DPS 3.67-37, De-leer Dimpling
S5076260, Method Drawing for Rivet and Screw Hole
Preparation

135

MANUFACTURED RIVET HEAD

{r-----4__
NO LEAKAGE O~GAS
OR lIQUIO AT THE
UPSET END

LMAXIMUM SWELLING AT THE UPSET END

FIGURE 50. LEAKPROOF RIVET HOLES

LEAK STOPPED BY UPSET END

<

THE MILLED HEIGHT IS DETERMINED

BY AERODYNAMIC REQUIREMENTS

.:;VET UPSET INTO CDUNT"SINK

EXTERIOR SKIN

'"d

INNER STRUCTURE
MANUFACTURED RIVET HEADJ

POSSIBLE LEAK

FIGURE 51. NACA RIVET METHOD

13-6

, ...~

PAT~~

For more detailed information on dimpling, refer to the following

documents:
DPS 3.67-2, Hot and Cold Dimpling (Stationary Equipment)
DPS 3.67-7, Portable Squeezer Dimpling (Elevated and
Ambient Temperature)
DPS 3.67-8, Portable Vibrator Dimpling (Elevated and Ambient Temperature)
DPS 3.67-37, De-leer Dimpling
S5076260, Method Drawing for Rivet and Screw Hole
Preparation

13-5

oWr

MANUfACTURED RIVET HEAD

{r-----...,____
NO LEAKAGE

GAS
OR LIQUID AT THE
UPSET END

'-MAXIMUM SWELLING AT THE UPSET END

FIGURE 50. LEAKPROOF RIVET HOLES

LEAK STOPPED BY UPSET END

< :;v,"

THE MILLED HEIGHT IS DETERMINED

BY AERODYNAMIC REQUIREMENTS

UPS," INTO CDUNTER."

EXTERIOR SKIN

MANUFACTURED RIVET HEAD

FIGURE 51. NACA RIVET METHOD

13-6

SECTION 14

RIVET ORIENTATION
Before proceeding into countersinking requirements, an understanding of rivet orientation will provide a better insight into the requirements for using the various methods of rivet installation.
The maximum swelling of the rivet shank is at the upset or butt end of
the rivet (see Figure 50). The grain structure is altered to a great
extent in this area. It is of fine texture and closely packed, because of
the cold working of the rivet during the process of forming the upset
head.
If the hole is of the proper size and the rivet installation is proper,

neither gas nor liquid will be able to escape by the upset end of the
rivet. This is a dry, metal-to-metal seal - the best seal known achieved without the aid of chemical sealants. This is the theory for
rivet orientation in sealed areas and is the basis for the NACA rivet
method (see Figure 51).
Upset all protruding head rivets at sealed boundary areas in such a
way as to locate the maximum swelling in the primary leakage path.
The four views in Figure 52 are typical of laminated joints. Study
each view to get a clear understanding as to how the seal is obtained.
Three fillet seals are necessary to prevent leakage of air or fuel
141

NON-SEALED AREA - THIS SIDE OF WEB

MEMBERS LOCATED OUTSIDE OF SEALED AREA

FILLE~"S~AL~~BE:: ':END ::~SlDE

OF SEALED AREA

SEALED AREA - THIS SIDE OF WEB

ABSENCE OF FILLET WOULD

PERMIT ALEAK PATH AS
INDICATED BY THE DASHED
LINE

FIGURE 52. CORRECT RIVET ORIENTATION

through the joint seam (leakage at the joint seam would bypss the
upset seal and escape at the rivet head). Each view is described in the
following:
View A: To attach one or more members inside the sealed area to the
skin or web (with no seam leading to the outside and no
member outside the sealed area), upset the rivet outside the
sealed area. Note that this is the only time the rivet is upset
outside the sealed area. All other times, the rivet butt is
located on the pressurized, or in-tank, side.
View B: To attach one or more members inside and one or more
members outside the sealed area (with no seam leading to
the outside), upset the rivet inside the sealed area.
View C: To attach one or more members outside the sealed area
(with no seam leading to the outside), upset the rivet inside
the sealed area.
14-2

View D: Where seams lead to the outside, upset the rivet inside the
sealed area.
Where it is impossible to position rivets properly (see Views B, C, and
D in Figure 53), apply sealant over the manufactured rivet heads.
This practice, however, must not be looked on as a simple solution to
sealing all misoriented rivets. It is not only the additional time and
materials that limit this practice, but additional weight is added to the
airplane for its entire lifetime. Aircraft weight is a critical item since
every pound means more fuel consumption and less payload.
Figure 53 is identical to Figure 52 except that all rivets are incorrectly oriented. In this case, notice that in order to make each joint
leakproof it would be necessary to apply two additional fillet seals in
View A, and to apply sealant to the six rivet heads in Views B, C,
andD.
NON-SEALED AREA - THIS SIDE OF WEB

"'7

~. 3]ID; Qffi; ~
0 ..

SEALED AREA-THIS SIDE OF WEB

DOTTED LINES INDICATE POSSIBLE LEAK PATHS

FIGURE 53. INCORRECT RIVET ORIENTATION

143

If
0_

DASH
NO.

~J

MtTHOD-ItIVT II SCRr_ HOLE PREPARATION

~f.

TABlE OF CONTENTS. REviSION LUlU RECORD

TABLE

or

CONTENn .. REVI$ION

l'

TABt.[

or

CONTENTS .. ftEV'S'ON lETT[JII RECORD

g
g

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!I-I

lie::
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::9:
~~

.j,.

PAGE REVISION
NO. U:T. DAft

METHOD

~;
fa:~

i
~.

OIU.llrING S'nUIOLI FOR HOLt: PREPAItATIOH

"11

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COUIINATION "Rt-OIMPLE Il COUNTERSINI( fOR SCREW!

T"11il ' ... VSN '011: II:IVETS-COUNTlRSH'fI( ONt.or

10-15-81

,,PLACO

EIIICO IIIIYUS

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NON-FLAIH RIYITt

10-t-1'

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9-30-'~1
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COVTRSI"IC IHAeA1 "OR IUVETS

COUNTERSINK rOR T!olE 150' ('000801 SHEAR

HEAD seRlE'"

PAGE REVISION
NO. lU. DAn:

1-1-t7

.W 11-12-71

ICIU_S

METHOD
COIJHTEftSIIHC fOIt THE 8R,Il ("$14219) TENSION
HUD R1V!.TS,

10-8-75

"

eCUHTtRSI'UC fOR 'UVTS

Itt.PLACtD tv-3

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COUNTERSINK 'Olt RIVIT HEAD aCIIEWS

-II

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, ... u; ,"vnl CUNCO" . o u n n PRoeUt)

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IJI

SECTION 15
METHOD DRAWING S5076260
15-1. GENERAL
Method Drawing S5076260 (see Figure 54) covers 24 standard
methods for rivet and screw hole preparation. Each of the methods is
identified by a title and dash number. The drawing may be obtained
from Manual Control Files and is subject to revision without notice.

NOTE
It is the responsibility of the user to work to the latest change
letter.
Authorization for the various methods is indicated by the numberletter code in the southwest quadrant of the drawing symbol. Refer to
Section 11 for an explanation of the coding system used in the drawing symbol.

151

ORAWING NO.

G?

_ _ _ _ DOUGLAs

TITLE:

-4

S45794'311

____~C:H~A:N:G:E~L~E:T~T~E~R:::~B:B.::::::

COUNTERSINK FOR RIVETS (MS20426, MS20427,

NAS"99 1 54579429 1

DIHENSIONAL LIMITATIONS:

SOZliZ6Q

PAGE NO.

>

-4

SHEET THICICH(SS

<::-+-"""'"@<"<"~<"<"~~~'""'""1"""""'"
&I""<"'''''~'"'''"''~'''"'''''''
.
t
100

e ?Z 2 Z2 ?2 22 221

ii

DRAWING

SYMBOL

~
CT~

Ie?? ?~2

2 ? S!:A: EDGE .010 MAX RADIUS

FOR COMBINAnoN MACHI NE

D:/COUNTERS'NK OPERATION

C~

~'>~~

.OIOMAX. RAOIllSJ

r----r--~F~~~:~~,~:~~~'---r~--"-T-rn--'c-'-.,-S-S~c-OU-.-T'-'-S'-.-"
*"

RiVET

SIZE

STANDARO

1116

.067
.072

3/)2

.098
.103

.1285

I.

.095

.. 032

.105
.. 160

.0110

.110

.oso

.2'"
.216

.171

.06,3

.261

.1311

5/32

.161
.166

.17"

)/16

"192

1/'
5/16

.317

3/8

.380

.198

.202
.205

~O71

.255
263

.265
.268

.100

.)2)

.)87

THIS MeTHOD SHALL 8E USED

A.

DIAMETER

,.

JACKETED

.!Jla
.111"

118

NOTES:

MINIHUM

./

.217
.,3)"

.3""

.1157
61

.125

.5"5
.555

.160

.675
.685

*NOTE: THE HOLE SIZES

SPECIFIED ARE 111
SUBJECT OF AN INTCR-

COMPANY AGREEMENT
8ETWEEN OAC AND MeA/ii
AND MAY NOTSE CHANGEl

WITHOUT PHIOR INTERCOMPANY COORDINATION.

ANOTE:

WHEN ATTACHING
NUTPLATES AND GANG
CHANNELS ONLY
INCREASE COUNTERSINK
OIAMETER TO .174 .184 IN
.050 AND THICKER
MATERIAL

ONLY IN THE FOLLOWING CONOIT-ION$..

WHERE THE SHEET THICKNESS EXCEEDS THE MAXI MUll THICKNESS FOR
DIMPLE IJETHODS.

OR ..

B.

wHERe DIMPLe MeTHoa OF INSTALLATION IS NOT SPECIFICALLY INDICATEa

C.

SHEET THICKNESS MIN. 032 FOR RIVETS WHEN ATTACHING ANCHOR NUTS.

ON THE ASSFMBL Y DRAW/NG.

<.

COUNTERSINK DIMENSIONS ARE CHOSEN SO THAT MANUFACTURED RIVET HEAD

WILL

BE "FLUSH"

TO "HIGH" AFTER DRIVING.

THIS MAY NCESSI TATE

SHAVING DEPENDING UPON SURFACE REOUIREMENTS

.1.

WHEN

OR ., IS SPECIFIED.

SHEETS 8ELOW JON THICKNESS MUST 8 CSK.

FIGURE 55. COUNTERSINK FOR RIVETS -- 550762604

152

15-2. COUNTERSINK FOR RIVETS, S5076260-4

The -4 method (see Figure 55) is authorized for use when a "c" or a
"-4" appears in the southwest quadrant of the drawing symbol. This
method is used for hole preparation for 100-degree flush-head rivets:
Countersink is 100 1/2 degrees. The chart provides information for
(a 3/16-inch-diameter rivet is used as an example):
Final Hole Size: 0.192 to 0.198 inch for a 3/16-inch standard rivet.
Minimum Sheet Thickness (for countersinking): 0.071. Do not
countersink material thinner than 0.071 inch for a 3/16-inch rivet
unless Note 3 on the -4 drawing is applicable.
Countersink Diameter: 0.334 to 0.344 inch. Note 2 on the -4 drawing specifies that rivet heads will be "flush" to "high" after
driving.

15-3

POSSIBLE LEAKS ARE STOPPED

BY RIVET HEAD

HEAD IS MILLED TO MEET SURFACE

HEIGHT REQUIREMENTS

'--~~-7-=*"t~....,

COUNTERSINK DIAMETERS ARE CALCULATED SO THAT

MANUFACTURED RIVET HEADS WILL BE 'FLUSH'
TO 'HIGH,' NEVER LOW. RIVET GUN VIBRATION PACKS
(CONCENTRATES) THE RIVET HEAD INTO THE COUNTERSINK.

VIEW A
CORRECT INSTALLATION OF FLUSH HEAD RIVET

MILLABLE DEPTH

,..--COUNTERSINK DIAMETER IS LESS THAN THE

MiNIMUM REQUIREMENT

(
HEAD DIAMETER, AFTER MILLING. TO
SURFACE HEIGHT REQUIREMENT,
EXCEEDS THE 5% REDUCTION
LIMITATION

VIEW B
COUNTERSINK IS TOO SMALL

BUCKING BAR PUSHES SUB-SURFACED

RIVET HEAD AGAINST THE RIVET SET
AND FLUSH WITH THE MATERIAL SURFACE

VIEW C
COUNTERSINK IS TOO LARGE

FIGURE 56. COUNTERSINK WIDTH FOR FLUSH HEAD RIVETS

15-4

It is important that countersink dimensions are within the specification. Fuselage skins are usually attached to longerons and station

frames by this method. Since rivet heads are flush on the outside skin
surface, and therefore no option is possible for rivet orientation, the
hole seal must be obtained at and by the manufactured head. View A
of Figure 56 shows how the hole seal is achieved, providing that the
hole and countersink width conform to the method drawing.
If the countersink width is less than the minimum specified (see
View B, Figure 56), too much of the rivet head will be removed by the
milling process. This results in a tension loss that may be prohibitive.
The head diameter of flush rivets must not be reduced over 5 percent
by the milling process (reference DPS 3.621).
If the countersink width is more than the maximum specified (see
View C, Figure 56), the head will not fill the countersink, and leak
paths will be created for fuel or air pressurized areas.
If any portion of the countersink is visible after riveting, it is not
acceptable. The head should not be swelled to hide the countersink,
since a void will exist below the surface of the head.

155

DRAWING NO.-25l!O!...72.62"'6"!O"-_ _ __

______________

TITLE:

-J

DOVO~

PAGE NO._...:4:-_ _ _ _ _ __
CHANGE LETTER

AI!

COMBINATION PRE-DIMPLE AND COUNTERSINK FOR RIVETS

(MS2042G, MS20427, NASI1991

OBtENSIONAL II HIT AT IONS:

S4579429, S45794St)

-3

DRAWINQ
SYHBOL

11==::::::~ IL-e~~~~1

OUTER SHEET

~H

HIDOl( SHEff (OR SIfTS)

(MAY Oil HAY' MOT BE
PREStMT - SEE HOT( ))

f
\
I
Jig

O!~l~~r It===::~

-3

OTH(lhfIS(

SPECIFIED (

.I
ur-

Hilt Sti((T TH'C1.~SS7

f.R <S'"

-34

_)~~~ !

(SEE 'OTE})

J.J

L____

0=,
~I

~ ~-~!~
I

L~~?'D ~~E,~~;::~,.PU"
.IV1:T

Sttl:

1".

-,*

...,

OI~U(lll

.OT2
,0

:t/u

.10S

slu

161
.16(-

.1U!J
U"

"

~,~~

.,,'
.".1

NOT: rHE IIOL SIZeS SPErIFJO AII TH SlIe"Err OF AN

INTERCOMPANY AGREEMENT BETWEEN OAC AND

I.

.117
.U7

..........
0171

0,

.I'U

.lO,

::!,

MC AIR AND MAY NOT 8 CHANGED WITHOI.IT PRIOR

INTERCOMPANY COORDINATION.
NOTES:

...

.o,t'

FOR ATTACHMENT OF ANCHOR NUTS (USE .1/.12 RIVETS ONLY}.

'-. .".........,
. ~4'

.471

.S>

DIMPLE OUTER SHEErS

I.IP TO AND INCLUDING .025 AND COUNTERSINI( OUTER SHEETS .0.32 AND OVER,
2.

IIIDOLE SHEET (OR SHEETS} MAY 8E PR~DIl/PLD PER ~2 IF SHEET DOES NOT ).'CO
MAX THICKNESS FOR DIMPLING.
IIIDDLE SHEET NEXT TO DIMPLE MAY BE CSUNK IF

3,

COUNTERSINKING or MIDDLE SHEET (OR SHEErSI BELOW MIN THICKNt::SS IS NOT PER.
MITTEO UNLESS DC OR w.JA IS SPECIFIED

SHEET IS "'IN THICKNESS FOR

CSK.

UNLESS OTHERWISE SPECIFIED BY OWG SYMBOL.

O~C OR -38 IS SPECIFIED.

MIDDLE SHEET OR SHEETS /JUST 8 OIl/PLED.

4.

WHEN

So

GAP BE TWEEN SHE TS TO BE AS SHOWN FOR Z ME THaD.

FIGURE 57. COMBINATION PREDIMPLE AND COUNTERSINK FOR RIVETS

MeOonneIi Douctas Corpor.tion Proprietary 1nf00000ion - Use or disclosure of 1his information is
subject to the restriction on the title page or on the first page of this document.

15-6

15-3. COMBINATION PRE-DIMPLE AND COUNTERSINK

FOR RIVETS, S5076260-3
The -3 method is used. when the drawing symbol code specifies DC,
D2C, -3, -3A, or -3B. Figure 57 shows various types of joints. The -3
method consists of a dimple nested into a countersink, and is used
when the outer sheet(s) is too thin for countersinking and the inner
structure is too thick for dimpling. Notice that the countersink
diameter for a 3/16-inch rivet is 0.349 to 0.359 inch, while the -4
method specifies 0.334 to 0.344 inch for the same size rivet. The -3
method (larger countersink) would allow a rivet head to seat below
the surface. However, the -3 countersink is not for a rivet, but to
accommodate a dimple. The inner side of a dimple is always wider
than the outer; therefore, the nesting countersink must be larger
than the fastener head to prevent a gap (see Figure 58). Do not use a
fastener head to determine countersink widths; use the micrometertype countersink gages for accuracy. The minimum sheet thickness
for a 3/16-inch rivet is 0.080 inch. Since the countersink for the -3
method is wider than in the -4 method (minimum sheet thickness:
0.071 inch) the material must be thicker.
MAXIMUM MATERIAL
THICKNESS

MINIMU'

I"

'"

q ,

MATERIA~ <1-

THICKNESS

DIMPLE WIDTH ON FLUSH SIDE

(LOWE'!PORTION OF DIMPLE IS WIDER THAN flUSH

SIDE. COUNTERSINK WIDTH TO ACCOMMODATE DIMPLE

~COUNTERSINK PER -3 METHOD

~- HOLE DIAMETER

FIGURE 58. DIMPLE WIDTH DETERMINES COUNTERSINK WIDTH

157

DRAWING NO.

_ _ _ _ DOUGLAS

TITLE:

~.",0C!.7.",t,-,.",0,--_ __

PAGE NO._--'2"'2'-_____

_
__~~:A:N~G:E~L~ET~T~ER::A=C::::::::::=

-23 COUNTERSINK FOR SHEAR HEAD RIVETS (NASI097

54579428, 54579430N,4SI200, RV5928 J

uZZZZZZI

PIZZZZZZ3

23

DRAWING
SYMBOL

-ziRIVET
SIZE

3/32
118

NOTES:

HOLE
DlA*

.098

.103
.1285
.134

....

SHEET THICKNESS

MINIMUM

COUNTERSINK
alA

.032

.135
.140

.040

.175
.185

.0.0

.226
.236

.!3i

.161

3116

.19.

.06'

.283
.293

1/4

.255
.265

.071

.376
.386

.192:

I. COUNTERSINK DIMENSIONS ARE CHOSEN SO THAT MANUFACTURED RIVET

HEAD WILL BE "FLUSH TO HIGH" AFTER DRIVING, THIS MAY NECESSITATE
SHAVING DEPENDING UPON SURFACE REOUIREMENTS.
2. WHE"!n/- OR - 23 IS SPECIFIED. SHEETS 8ELOW MIN. THICKNESS
MUST 8 COUNTERSUNK.

*NOTE: THE HOLE SIZES SPECIFIED ARE THE SUBJECT CF AN INTERCOMPANY

AGREEMENT BETWEEN DAC AND MC AIR AND MAY NOT BE CHANGED
WITHOUT PRIOR INTERCOMPANY COORDINATION.

FIGURE 59. COUNTERSINK FOR SHEAR HEAD RIVETS, S5076360-23

McDonnell Douclas Corporltion Proprietary Information - Use or disclosure of this information is
subject to the restriction on the title page or on the first page of this document.

158

15-4. COUNTERSINK FOR SHEAR-HEAD RIVETS,

S5076260-23

The -23 method is used for countersinking when flush shear-head

rivets (Figure 59) are specified. If the drawing symbol code specifies
"-23," sheets below the minimum thickness must be countersunk.
The countersink diameter for this particular rivet is frequently a
"controlled countersink" (Engineering specifically calls out by
blueprint an exception to the method drawing). This countersink
diameter is less than the dimensional callout on the method drawing
since the material thickness is unusually thin. To prevent chatter and
to maintain concentric countersinks, the substructure must be in
place while the skin is being countersunk (see Figure (2).

NOTE
For inner-member countersink dimensions in a combination
dimple and countersink joint, refer to DPS 3.67-3.

159

DRAwING NO. _ _--=S:;o;,.76::;.~6:;:O:._._

PA"E. NO _ _ _ _~/5~ _ __
CHANGE LETTER AY

-16

T I TL[:

-16

BLIND RIVETS:

DIKUSIOMAL LI"ITATIOM$:

PULL STEil RIVETS:

COUNTERSINK AND HOH-FlUSH
ST.utOARO SHANK RIVETS

RIVEr
SIZE

DIMPLE STANDARD

DIMPlE OVERSIZE
SHAHK flUSH RIVET

SHANK FLUSH RIVET

FINAL
HOLE OIA

~~~!i

RJ~;:

KOlf OIA
aTORE DIMPliNG

)/32

.091
.101

'/8

.Q94

.1285

.100

.1;32

.1'~

.1)7
.141

5/n

20

.160-

.117

.128

.16

.112

,/16

.152

.192
.196

.20,

.205
.209

FlU!.. HOlE
DIAMETER

118

.1285

5/)2

.160

)/16

.192
96

1'2

.164

COUHTEr.,IH. OIA.

COUNTERSINK. OIHFtE & NOH-FLUSH

BUlB SHAHK RIVETS

RIVET SIZE

I"01t

FINAL

IoH="'=I=NA=L=t==A;,;C=TU=A=L=~~H=OL;,;E,,;O;;;'=A'=I

__-j:._...:..:."__7-1

I
~_'_._+-_'_'_'

.159

.11&4

.177

Fl.USH

&tILa RIVETS
(5

HoTE

I)

.22.2

. 232
.213

~_51_)_2-+_ _
.'_7)_ _-j~":'':''.__'-1

.ttS

L-:.:)/.::l,:,,'-L_..:.:.2__.1_5_ _..L-':i.i~~~:.-..J

:.!::

CHEIIICALLY EXPANDED RIVETS:

flUS'H AHO MOH flUSH

RIVET SrzE
ACTUAl
IIOH I IU.l

NOTES:

fiNAl HOLE

DIAMETER

,18

.1:).

.1}S
.139

5/:)2

~171

.172
.176

)/16

.202

.20)
.207

2. ~rJlttf'!r/I/-:'Jfr~.AND GAGE L IMI TATICNS ARE PER ~4 AfETHOO. EXCEPT

3.

DIJJPL DIAMETERS ANO G.46E LlAfI TAT/CNS ARE PER -2 IlElHOO.

4.

IIH&I OII.lPt..S ARE USED. FINAl.. HOLE DIAJlETERS ARE {)fIILL[) AFTER OIJJPL./NG.

5. INSTALL PER CPS J.67.

FIGURE 60. BLIND RIVETS - 5507626016

McDonnell Dougtas Corporation Proprietary Information - Use or disclosure of this information is
. suPiect to the restriction on the titre page or on the first page of this document.

15-10

. Hoi!""'iA
.18'

15-5. BLIND RIVETS, S5076260-16

The -16 method specifies hole sizes, dimpling, and countersinking

requirements for various types of blind rivets (see Figure 60).

15-11

_____________________________

TITLE:

.. /0

pRAWING NO.
PAGE NO.

~UG~

CHANGE lETTER

AT

-/0

COUNTERSINK (NACAJ FOR RIVErs

DIHElISIDHAl LIMIT'TiOKS:

>;SS" 5S5SSS S1

5076260
,

ISS\SSSSSSS\
FLUSH HEAO

PROTRUDIKG HEAD

I<~{@

O"VI'G~
ssi
SYHBOl.

.,"",cru'o

RiVET HEAD (REF)

HOLE 01 AM(TR

RIVET
SIZE

SHEET
COUNTERSINK

STANOARD

*"

THICKNESS
JAClETEO

,061

MINIMUM

OUMETER

.025

.!OO
.100

.0,)2

.136
.1"6

.0110

....

'. 19Z1

.06)

.283

1/16

.ou

3/32

.098

,/8

.1285

SIJ2

.161
.166

.171
.17

)/16

. In

.202
.205

.255

.265
.268

.090

.)95

.100

.1t55
.1165

,I,
5116

.103

.131l

.198
.263

..

.,

.1111

.311
.)23

.1S11

.231
.2/11
.29)

05

NOTCS:
I,

RIvEr IS UPSET INTO THE COUNTERSINK ANO I,/UST 8 SHAVED ':fHR FLUSHNESS

IS REOUIREO.
2.

TI~/S AIETHoa

WHEN SP~CIFIO J,lAY BE USED

IN COUIJlNAT/ON WITH . j . . . 40;1

-15 UTHODS SPEC/FIEO FOR THt. MFO HEAD f..NO OF THE RIVEr.
*Nor: rHE HOLE SIZeS SPECIFIED ARE THE SUBJECT OF AN INTERCOMPANY AGREEMENT BETWEEN
OAe AND "'CAIN AND MAY NOT BE CHANGED w'rHovr PRIOR INTERCOMPANY COORDINATION

FIGURE 61. COUNTERSINK (NACA) FOR RIVETS - S507626()"10

McDonnell DoucIas Corporation PToprietary Information - Use or disclosure of this information is
subjes;t to the restriction on the title page or on the first page of this document.

1512

15-6. COUNTERSINK (NACA) FOR RIVETS, S5076260-10

This NACA (National Advisory Committee for Aeronautics) countersink for rivets method (Figure 61) was developed to obtain a dry,
metal-to-metal seal for rivet holes in integral wing fuel tanks. An additional objective was to maintain the strength of a conventionally
riveted joint.
The angle of countersink for the -10 method is 82 1 degrees. Most
flush-manufactured rivet heads require a 100-degree countersink. It
is advisable to always check the degree of the countersink cutter that
is to be used. Failure to be cautious has often resulted in salvage problems, rework, or scrap.
Protruding rivet-head shanks or flush-head shanks are upset into the
82-degree countersink, as illustrated in Figure 61. If a flush-head
rivet is installed per the NACA method, the exterior side will be an
82-degree countersink, and the manufactured-head side will be a
100-degree countersink. See Figure 61 for the drawing symbol
callout, and Section 11 for an explanation of the code.

15-13

DOUGII;.AS

TITLE:

ORAY!'ING NO. _-,5,-,O"7-,6,-,2,-,6",,O~_ _

PAGE NO. _ _-"'7'-_ _ _ _ __

____:C~H~A~NG~E~L~E~T~T~E:R~:A~&~::::::::

-18

-18 COI.I8INATION PRE .lJIIJPLE IWO COUNTERSINK FOR N~A RIVETS

DIHEMSIOMll lIHlTlTlOMS:
ouT.R' SH.U OR SHU TS

PROTRUDING HEAD

flUSH MEAD

DRAVUG

OR~VI"Q

3YH80L

COOlie FOR MfO

3Y"SOL

H(AO-_Dcl~

COOI:~"~; U~(;(.O.../~~

. ". "

~I

COOIHO rOR UPS(T (WO

flUH8(R OF DUnR SH(.TS TO 8E OIHI'LED HOST

e SP{ClflEI) IF NO OR MORE, I.. D2C,

o,e.

*NOTc'- THE HOLE SIZES

SPECIFIED ARE THE
SI.J/JJcr OF' AN INTERCOMPANY AGREEMENT

RIV(T

Sll.

HOl( SIZE
SEFOR.

OIHf'lIHC

BETWEEN OAC AND

MCAIR AND

MAY NOT

8E CHAHGED WITHOuT
PRIOR INTERCOMPANY
CIXJRDINArtON_

UPPER OIMPU

+.oe)2, -.0011

0 ..

LOWER DIMPLE

0 ..

+.00_. -.002

MAX

)in

.098
.10;1

.1~0

.15S

.025

I/e

.1)"

.128$

.1110
.1114

.19S

.205

.0,32

.161
.166

.171
.174

.2110

.259

.01l0

5/32

NOTES:

fiNAL HOLE

OIAR'~~~~.T~

us

I.

FOR

z.

RIVEr IS UPSET INro DIMPLE ANO MUST 8 SHAVED WHERE FLUSHNESS IS

WHeRE Oll/PLE IS REOUIRED ON UPSET END OF NACA RIVErs.

J.

THIS METHOD WHEN SPECIFIED MAY'BE USED IN COIIBINATION WITH -.).

REOUIRED.

15 ,IIErHOD$ SPECIFIED FOR THE "'FO HEAO END OF THE RIVET.

4.

CAP BETWeeN SHEETS WILL

8 .000S TO .012.

FIGURE 62. COMBINATION DIMPLE AND COUNTERSINK FOR

NACA RIVETS -- 5507626018
McDonnell DoucIa Corporation Proprietary Information - Use or disclosure of this information is
subject to the restriction on the title page or on the first page of this document,

15-14

-4 OR

15-7. NACA COMBINATION PRE-DIMPLE AND

COUNTERSINK FOR NACA RIVETS, S5076260-18
The -18 method (Figure 62) is used when a combination dimple and
countersink is required for the NACA method of rivet installation.
The -18 method provides specifications for the material to be dimpled
(82 degrees) and the -10 method is used for countersinking (82
degrees).
The upset head (butt) is installed in the dimple. The rivet head is
milled (shaved) to aerodynamic tolerances that are applicable to that
particular section of the aircraft.

1515

___________________________

TITLE:

DRAWING NO._-"-50"-7!-'6~2"'6"'O____
PAGE NO. ______.-!1.:::6_____

~UG~

CHANGE LETTER

AV

-17

-17 HAC" SLUG R I VETS

DIHEMSIDIIAl lIHITATIONS:

res'.I.

~
VIEW

A ULARG(O

,-

I
I

UPSET HEAO (REr)

- ' - S L O G RIY(T (REF)

RiVET

STANDARD

1/8

.128
.1)1

51,2

.IS9

'/16
1/_
5/16

NOTES:

HOLE OIAHETR

SllE:

JACItT(O

.111

.162
.191
.190

.11'

..,.111
,,.

.265
.268

.m,
.256

.202

.20'

$tI(Er

COUNTERS I XI(

TKICIUIESS

'1'

.'>0

.16"

M"

.06,
.080

.'2$
.160

.010

.tTt

.020

.111
.221
.263
.273
.J1S

.015

.4J5
.US

.020
.0cO

.}O'

..,0
.020
.040
.020

....

I .

USE HOLES IN STANDARO COLi/MN FOR $-/456832,

Z.

USE HOLES IN "JACKETED" COLUMN FOR $-1.//9869 RIVETS.

$-/458448 ANO

FIGURE 63. NACA SLUG RIVETS -- 55076260-17

McDonnell OoucfIis Corporation Proprieb;ry Inforrrmion - Use or d!sclosure of this information is

subject to the restriction.on the title page or on the first page of thiS document.

15-16

NASIJ2/

158. NACA SLUG RIVETS, S507626017

The -17 method (Figure 63) is used for drivematic-installed slug rivets
and uses the NACA sealing principle. The countersink is 82 degrees,
but the width dimension is slightly smaller than for the -10 method.
The countersink configuration has a radius near the top surface, as
$hown in View A. This improves the seal and reduces chances of
peel-up of the very thin edges of the shaved head due to air velocity
during flight. This occurs if the rivet upset is excessively wide when
bucked into a -10 method countersink.

1517

DRAWING NO.

r/
______________

TITlE:

-8

5076260

PAGE NO. _ _-"-_ _ _ _ __

DOUG~ _ _~C~H~A~N::GE:...:L::E~T~T::ER~:A~Y=====

COUNTERS INK FOR

-8

FLUSH TE:NSION HE:AO SCRE:W

BREAK EDCE SCREw SiZE 110 ANO ABOVE

OtHEHSIOH.ll lIHITATIONS:

:gi~

X 60845[0 0Ii NOH 0'" OR

:g~g

R RASEO OH HOM OIA

>..:'-"...::.....:....::.J-4:-J.:::..:>+>..:::.~...::JiOUTE. SHEET THICKNESS

1\:\\\\$1

NOH

SCREW
SIZE

OIA

1I

HOU:

Q'AH(TER

bSS\\\'I
COUKTER5UIIK OUTER
SHEET TIfICKKESS

MIHIHU,",

.128

.06,)

.2)0

.071

.283

1/.

.250

'"
.250

5/16

.J12

.3IZ"

,I.

.)7:)

4)1

1116

I!>

soo

9/16

.562

51.

625

.O<}O

.125

.2511
.316S
.37~

.)79
.<tJ7S

500

.711

.258

.615

.,

.6,0

.507

.517

.186

.".25

,5675

.)8'

.)96

.6)5
,US

.22_

.505

.)})
.)11.)

.160

.200

.<'l42S

'~2

.025

."~-

.060

,190

--t,~

.220

.1)5

.17,)
.190

o"M(T(R

.159
.166

.166
10

COUltT(RSIHK

....
....

.162

1.01

1.02'
.1.1.115

1.155
1.212

1.281

.".~

.0)0

UJllESS OTK(R'WISE SPECIFIED

0" (/IIG,JI((R,IC DRAWiNG OR
CAllOOT Of It SPEC IFle O.".S

OUVIMa

SY"IOL

+
NO TcS:

I.

COUNTERS/NX DIMENSIONS ARE CHOSEN SO THAT THE SCREW HEAO WILL 8

"FLUSH" TO "LOW"'.
2.

"fHN

c1-

OR -8 IS SPECIFIED.

SHEETS BLOW IJIN THICKNESS MUST BE CSK.

FIGURE 64. COUNTERSINK FOR SCREWS McDonnell ~$ Corporation Propriet.ry InfOflNtion - Use or disclosure of this information is
~bjectJo the restriction on the title page or on the first page of this document.

15-18

S50762608

15-9. COUNTERSINK FOR SCREWS, S5076260-8

The -8 method (Figure 64) is used to countersink for standard screw
heads when "c" or "-8" is specified. Dime:p.sional callouts for hole
sizes, per this method, are used only when not specified by the
engineering drawing or a specific DPS. The countersink dimensions
have an overall tolerance of 0.010 and are chosen so that screw heads
will be flush to low. A screw head fabricated to its maximum tolerance
will seat flush in a minimum-width countersink. This meets strength
and aerodynamic requirements and also lessens moisture entrapment
and resulting corrosion in the moat area (see Figure 65). Stop
countersinks should be adjusted near the minimum rather than the
maximum specified countersink width allowed. It is not acceptable
for screw heads to protrude above the surface of the material, since
this creates parasitic drag during flight and thereby increases fuel
usage.
The bottom edge of the countersink must be broken (see View A,
Figure 64) to permit the screw-head-fillet to nest into the radius or
SCREW HEAD IS FLUSH

MINIMUM TOLERANCE COUNTERSINK

MAXIMUM TOLERANCE COUNTERSINK

FIGURE 65. ACCEPTABLE SCREW HEAD HEIGHTS

15-19

DRAWING NO.
5076260 _ _
PAGE NO. _ _ _ _ _ _'_9 _ _ _

_______________

20

TITLE:

DOUG~

COUNTERSINK FOR RIVET HcAD SCREwS

CHANGE LETTER

(.s~4619:JO.].

4,

S.

6,

7.

AW

8)

-20

DIMENSIONAL lIMITATIOHS:

BREAK EDGE SCRE.W SIZE 110 AHI} ABOvE

:~}~
:gi~

[1/2/7/71

NI'
Oil"

SCREW

SIZE
10

.190

1/'

.312

J/3

.315

7116

.1131

.080

.250

OIAMETER
.3~1

.J61

.112

,1180
.1!.90

,'In

.31.'

.125

.568

315

.160

2~1t

.)19
.4l1~

.1BM

."4~'

.:"00
.50S

.2118

DRAWING
SYH8Dl

:~~:.106

.BI&l
.851
.960
.970

UNLESS OTHERWISE SPECIfiED

*
NOTES:

COUHT(RSIItK

MI"IHUH

.1'.

.500

1/'

SHEET THICKNESS

.190

.250

5/16

PIZZZZZ/ll

COUMHRSUHK ourER

HOll:
OIAMETER

X 60-8A5(0 Oti HOH OIA OR

R BASCO ON NOH OIA

I,

2.

OM HGINEERI"G OitA-WING OR
CALlouT OF It SPECIFIC D.P.S.

f~
,075

'O'O'~

.0)0

COUNTERSINK DIMeNSIONS ARE CHOSeN so THAT THE SCREw HEAD /ifILL 8

"FLUSH" TO *LOw*,

WHEN

----

I --

-~

OR

-20 IS SPECIFIED.

SHEETS BELOW MINIMUM THICKNESS

MUS T BE COUN TERSUNX.

FIGURE 66. COUNTERSINK FOR RIVET HEAD SCREWS

McDonnell Douglas CorporatIOn Proprietary Information - Use or disclosure of this information is
subject to the restriction on the title page or on the first page of thiS document.

15-20

chamfer. This eliminates interference and a resulting gap between

the screw head and the countersink. Refer to 8ection 16 for further
details on breaking hole edges.

15-10. COUNTERSINK FOR RIVET HEAD SCREWS,

S5076260-20
The -20 method (Figure 66) is similar to the -8 method (countersink for
screws); the countersink width is less to compensate for the smaller
flush head on the Douglas special bolt, 84619303 (3/16 inch) through
84619308 (1/2 inch). This bolt has shear values equal to the tensionhead bolt (-8 method) but less tension load capability. Engineering
specifies this weight-saving bolt when load factors permit.

15-21

DOUGLAS

TITLE:

-7

DRAWING NO. ~076260

PAGE NO. _ - ' 7 ' -_ _ _ _ __
_

___:CH~A~N~G:E::L~En<~~R~A~W::::::::::

1=-===::1 ,-f::=~~~l

OIMEHSIOHAl 1IIHTATIOHS:

.
L__
\~~~::,:fT
~l(P'_5

'"

SHUT THICICH[SS

rOR CS 1111(

-7

COMBINATION PRE-OIUPLE AND COUNTERSINK FOR SCREWS

I
t

t====~~

F==.JI g

"'DOLE SHEET (OR StiE(fS)

(HAY OR HAY loT BE
P'R(stttr SH JiIOT( ~)

~)!El

!~

I
MPf $H((T

SCREW

HOLE

rHICkNESS

SIZ(

DI.lMHU

fOj:t COUHTERSll'lk

.128
.lJ~

.1:59
.166

I HOC< I
rOIAI

.166
.17)
10

1/.
5/16

,I.

NOTCS:

.I,.
.250
.'54
.1'0

.11U
.:UCO

.'75

.,79

COUIITRSIU
OIAHT(R

.OJ,O

.06)

.215

.225
.28)
.29)

.n)

080

34)

.09<)

.}86
.)96

.12!J,

.!l1J

.160

.8)9
.6119

.lS8

.767

UNLESS OTH(R_

WiSE SPEC IF' 1(0

OM (ltGIMHRIItG
ORAW'"G 05r
CALLOUT OF A
SPECIFIC O.P.S

.513

.117

I.

COUNTERSINKING 0' IIIDOLE SHEET (OR SHEETS) BELOW /,lIN

PERlilTrED UNLESS DC OR .. 1A IS SPCIFIEO

2.

WHEN Di.2...JlL:MJulC
DIMPLED.

J.

"'.IDDL.. SHEET lOR SHEErS) J/AY 8 PRE-DIMPLED PER -5 IF SHEET OOS NOT EXCEED
"AX THICXNESS FOR OIMPL INt;.
J/IDDLE SHEET NEXT TO DIIIPLE MAY BE COUNTER ..
SUNK IF SHEET IS MIN THICKNESS FOR COUNTERSINK. UNLESS OTHERwISE SPECIFIED
BY DRAWING SYM/JOL.

4.

DIMPLING OF cXTRUSION IS NOT PERMITTED EXCEPT WHERE SPECIFICALLY INOICATEO

ON THE ENGINEERING DRAWING.

S.

GAP BETWEEN SHEErs TO 8 AS SHOWN FOR -5 'uE(HOO.

OR 78 IS SPECIFIED.

rHICI<NESS IS NOT

MIDDLE SHEEr OR SHEETS MUST BE

FIGURE 67. COMBINATION PRE-DIMPLE AND COUNTERSINK FOR SCREWS

McDonnell Douglas Corporation Proprietlry Information - Use or disclosure of this information is
-subject to the restriction on the title page or on the first page of this document.

15-22

15-11. COMBINATION PRE-DIMPLE AND COUNTERSINK

FOR SCREWS, S5076260-7
The -7 method (Figure 67) consists of dimpling the outer sheet(s) and
nesting the dimple(s) into a countersink. It is for standard-tension
screw heads and must be used when the drawing symbol code calls out
a -7, -7A, -7B, or D2C, D3C, etc.
This combination method is used when the flush side material is too
thin to countersink per the -8 method (see Figure 64).
The -7 countersink widths are wider than in the -8 method since they
must accommodate the protrusion side of the dimple. Otherwise, a
gap will occur at the juncture of the countersink and the dimple.

If -7A or DC is specified, countersinking below the minimum sheet

thickness is permitted (see Section 12-3 and DPS 3.67-3).
The callouts for hole sizes are not to be used if specified otherwise on
the engineering drawing or applicable DPS.
After the drilling operation is completed, the material to be dimpled is
removed. However, it is important that the other sheets are held in
accurate alignment with the proper clamping devices. This is an

essential setup, since the countersink cutter will enlarge the hole in
the top material that normally is too thin for countersinking.

15-23

Hole expansion is done only after the final heat treat and the straightening operations have been completed.
Prior to expansion, holes must be prepared as follows (reference
DPS 3.67-25):
a. Ream holes to proper size.
b. Deburr holes, but do not chamfer hole edge. Remove only the
ridges protruding above the surface; use No. 240 or finer
abrasive paper.

NOTE
Do not use a countersink cutter for deburring.
After expansion, if burrs protrude above the surface (see Figure 105),
remove them by hand with No. 240 abrasive paper or finer. A
chamfered hole edge is not acceptable.

NOTE THE HOUR-GLASS

,REMOVE THESE BURRS BUT DO

HO_~A

FIGURE 105. EXPANDED HOLE - CROSSSECTION VIEW

22-2

A water-dampened cloth (not dripping wet) shall be used to wipe off

all lubricant residue adjacent to or inside expanded holes. Wipe dry
with a clean cloth.

22-2. QUALITY REQUIREMENTS

Hole expansion must be performed by certified personnel only.
To obtain the maximum fatigue life improvement, it is important that
the holes meet the diameter requirements, as specified in the DPS,
before and after expansion.
Any holes that have been redrilled and rereamed to achieve the minimum size after the hole has been expanded are not acceptable and
must be submitted to Liaison Engineering.
After expanding, the hole and the adjacent area must be free from
cracks. Detail parts in fabrication departments must be given a fluorescent penetrant inspection for cracks.
Work performed in assembly departments must be visually inspected
with a magnifying glass of five power or better.

22-3

GLOSSARY

BEARING AREA

The contact area between two surfaces

that are forced against each other.

BROACH

A tapered, multitoothed tool used to produce holes of close dimensional tolerances with a fine hole wall finish. The
broach is pulled through a previously
made pilot hole.

BROACHED

A term used to describe a discrepant

condition that occurs when a clearance
fit fastener is forced into an undersize or
misaligned hole. This malpractice tears,
enlarges, elongates, and threads the
hole.

CHAMFER

A slanted or beveled edge.

CHATTER MARKS

Uneven or irregular-shaped cuts on a

surface caused by cutting tool vibration.

G-1

CHUCKING

The process of installing and tightening

a tool in a chuck. (Eccentric chucking is
off-center installation of a cutting tool in
a chuck.)

CHUCK RUNOUT

Runout or wobble induced into a cutting

tool by the chuck. All chucks contribute
to the runout problem; the degree of runout depends on the precision built into
the chuck and wear of the spindle support bearings.

CLEARANCE FIT

A nonforce fit that results when a fastener is inserted in a larger mating hole.

COINING

The process of prestressing holes, slots,

and edges of doublers with highly accurate dies.

COMPRESSION LOAD

External axial forces that are applied on

parts and act toward each other.

CONCENTRIC
COUNTERSINK

A hole and countersink having a commoncenter.

G-2

CORROSION

The process of oxidation or deterioration

of metals, induced by either a direct
chemical attack or by an electrochemical
process.

DUCTILE

Capable of being formed, bent, or

stretched without cracking.

EDGE DISTANCE

The distance measured from the center

of a hole to the edge of the material.

FATIGUE FAILURE

A fracture produced by repeated, alternating tension loads induced during

flight or during aircraft operation.
Damage first occurs on a submicroscopic
scale, the material cracks, and progressively deteriorates until final rupture.

FATIGUE LIFE

The number of cycles of fluctuating

stresses of a specified nature that a
material can sustain before failure
occurs.

G-3

F AYING SURFACE

The surface areas of mating parts that

are in contact with one another. The
area between parts where wet sealant is
applied for sealing purposes.

FEED RATE

The distance that a hole cutting tool

penetrates the material per each revolution of a chuck. Feed per revolution
(FPR) is calculated in thousandths of an
inch. Excessive feed or pressure causes
drill-point deflection and vibration;
insufficient feed tends to let the tool idle
and causes discrepant holes.

FRETTING CORROSION Chips and burrs, between mating surfaces of metal parts, which when subjected to a slight oscillatory motion
cause abrasion of the surfaces. This
wearing action leaves bare metal surfaces, which oxidize rapidly.
GUST LOAD

Additional stresses imposed on an airplane, especially the wings, as a result of

encountering sudden up or down air currents.

G-4

HEAT INDUCTION

Heat that is generated and induced into

materials during the drilling operation.
The heat should not exceed touch temperature for stainless steels, titanium,
and aluminum alloys since it causes a
loss of mechanical properties and corrosion resistance.

HOLE TOLERANCE

The permissible overall variation between the minimum and maximum hole
size as specified by Engineering.

INTEGRAL PILOT

A nonremovable guide that is part of a

countersink cutter. The proper size pilot
provides assurance of concentric
countersinks. Two types are available,
each having a definite and specific purpose: (1) with a built-in radius and
(2) without the built-in radius.

INTERFERENCE FIT

The hole size is smaller than the minimum fastener diameter. The fastener is
forced into the hole, permitting uniform
loading of each fastener for shear
stresses.

G-5

MALANGULARITY

A condition where holes are other than

perpendicular to a surface or other than
90 degrees to the point of tangency on
contoured surfaces.

NOMINAL

Mean; as used in this text designates an

average or intermediate between
minimum and maximum dimensions.

NOTCH PATTERN

Metal surfaces consist of high and low

areas as a result of the tearing and
abrading action of cutting tools. The tool
finish and direction of cutting operation
determines the pattern.

PRELOAD

An external force applied during

assembly by the use of clamping devices
or fasteners to forcibly close a gap between mating surfaces. The result is an
assembly built with detrimental, sustained stresses that were not calculated
in the design and may cause premature
failure of the joint.

REAM

To enlarge a predrilled hole with a

reamer. Reamers are used for holes having a tolerance of 0.002 inch or less.
G6

RESIDUAL STRESS

Internal or locked-in stresses induced

by manufacturing processes such as
machining, fabricating, and heat
treating.

RUNOUT

Inherent wobble at the cutting lip of a

drill or reamer; axis of the cutting lip is
off-center to the axis of the drill shank.

SHEAR STRESS

External loads that tend to slide one

structural part over the surface of
another in opposite directions. This
force tends to cut or shear the fastener.

STRESS

Externally applied loads that are

resisted by the internal strength of a
body. There are many types of stresses,
which are identified by the direction of
the applied loads.

STRESS RISERS

Surface irregularities such as scratches,

nicks, gouges, tool marks, and notch patterns that reduce the fatigue life.

STRIATION

A very small parallel groove.

G-7

TENSION STRESS

External forces or loads that tend to

increase the length of a body.

TORSIONAL RIGIDITY

The degree of resistance of hole-cutting

tools to a twisting load (torque and feed).
For example, short drills with large
diameters have a high resistance to torsional rigidity, while, conversely, long
drills with small diameters have a lower
resistance.

WOODPECKERING

The act of intermittently removing a

drill from the hole to facilitate chip
removal, especially in deep drilling. This
practice is to be avoided during the final
sizing step for holes having a tolerance
of 0.003 inch or less.

G-8