STRUCTURAL REPAIR MANUAL

INVESTIGATION - CLEANUP AND AERODYNAMIC SMOOTHNESS

1. General
A. For a high aircraft performance it is necessary that the aircraft has an
aerodynamically clean shape and a smooth external surface. Damage not re-
paired, dents not filled and repairs which change the contour or rough
ens the surface can reduce the performance.
B. The aerodynamic smoothness of the external surface is divided into three
tolerance areas. You can find these tolerance areas under the heading
'Degree of Smoothness'.
- Refer to Figure 2 and Figure 3 and Tables 1 thru 21
(1) Description of the tolerance areas (Refer to Figure 2 and 3):
(a) Area 'A': Surface areas with very good aerodynamic qualities and
requiring close tolerances.
(b) Area 'A1': Surface areas which are parts of area 'A'. They are
subject to further detailed improvements concerning fastener stan
dards.
(c) Area 'B': Surface areas with tolerances usually larger than area
'A'.
(2) You must take precautions to protect the surface from damage when
you work on it. You must wear soft-soled shoes and cover the area
with rubber mats.
2. Aerodynamic Smoothness Requirements
A. Fuselage
(1) Refer to :
- Figure 1, Figure 2, Figure 4, Figure 5, Figure 6, Figure 7 and
Figure 8 and also to Tables 1, 4 and 5
for details of fuselage smoothness requirements.
NOTE: For aerodynamic requirements in the region of static ports,
angle of attack sensors, pitot probes and total air temperature
probes refer to Chapter 53-00-11, Page Block 101, in which
specific aerodynamic tolerances are included.
B. Belly Fairing
(1) Refer to :
- Figure 1, Figure 2, Figure 4, Figure 5, Figure 6, Figure 7 and
Figure 9 and also to Tables 1, 6, 7, 8, 9.
for details of belly fairing smoothness requirements.

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C. Wing
(1) Refer to :
- Figure 1, Figure 3, Figure 4, Figure 5, Figure 6, Figure 10 and
Figure 11 and also to Tables 2, 3, 10, 11, 12 and 12.
for details of wing smoothness requirements.
D. Stabilizers
(1) Refer to :
- Figure 1, Figure 4, Figure 5, Figure 6, Figure 7, Figure 12 and
Figure 13 and also to Tables 1, 14, 15 and 16.
for details of stabilizer smoothness requirements.
E. Pylon and nacelle
(1) Refer to :
- Figure 1, Figure 4, Figure 5, Figure 6, Figure 7 and Figure 14
and also to Tables 2, 3, 17, 18, 19, 20 and 21.
for details of pylon and nacelle smoothness requirements.
3. Aerodynamic Smoothness - Fasteners
A. All fasteners on external surfaces must be flush. This does not include
section 19-Tail Cone lower shell and end cover.
(1) Sign convention:
+ = protruding above surface
- = recessed below surface

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RIVET TYPE DEGREE OF SMOOTHNESS

CRITICAL AREA NORMAL TOLERANCE PERMISSIBLE TOLER
ANCE ON 10%
mm in. mm in.
COUNTERSUNK STABILIZER +0.08 to +0.003 to +0.12 to +0.005 to
SOLID RIVETS 0 0 0 0
FUSELAGE FWD +0.15 to +0.006 to +0.20 to +0.008 to
A
FR 18 0 0 0 0
FUSELAGE AFT +0.20 to +0.008 to +0.20 to +0.008 to
FR 18 0 0 0 0
STABILIZER +0.08 to +0.003 to
A 1 --- ---
0 0
+0.20 to +0.008 to +0.20 to +0.008 to
B
0 0 0 0
COUNTERSUNK +0.13 to +0.005 to +0.20 to +0.008 to
BLIND RIVETS A -0.10 -0.004 -0.10 -0.004
AND BOLTS
(FOR EXAMPLE STABILIZER +0.13 to +0.005 to
HI-LOK, TAPER- A 1 -0.10 -0.004 --- ---
LOK, BOLTS,
LOCKBOLT,
+0.13 to +0.005 to +0.20 to +0.008 to
CHERRYMAX, B -0.30 -0.012 -0.30 -0.012
COMPOSI-LOK)
Flushness of Fasteners - Fuselage and Stabilizer
Table 1
NOTE: On angled surfaces the 'Normal' tolerances apply at the lowest
intersection (Refer to Figure 1).

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RIVET TYPE DEGREE OF SMOOTHNESS

CRITICAL AREA NORMAL TOLERANCE PERMISSIBLE TOLERANCE
ON 10%
mm in. mm in.
COUNTERSUNK SOLID +0.08 to +0.003 to +0.12 to +0.005 to
A
RIVETS 0 0 0 0
+0.08 to +0.003 to
A 1 --- ---
0 0
+0.15 to +0.006 to +0.20 to +0.008 to
B
0 0 0 0
Flushness of Fasteners - Wing/Nacelle
Table 2
NOTE: On angled surfaces the 'Normal' tolerances apply at the lowest
intersection (Refer to Figure 1)

RIVET TYPE DEGREE OF SMOOTHNESS

CRITICAL AREA NORMAL TOLERANCE PERMISSIBLE TOLERANCE
ON 5%
mm in. mm in.
COUNTERSUNK BLIND +0.05 to +0.002 to +0.13 to +0.005 to
A
RIVETS AND BOLTS -0.18 -0.007 -0.18 -0.007
(FOR EXAMPLE HI
HI-
LOK, TAPER-LOK, +0.05 to +0.002 to
A 1 ---- ----
, BOLTS,
LOCKBOLT, , -0.18 -0.007
CHERRYMAX, COM +0.05 to +0.002 to +0.13 to +0.005 to
POSI-LOK) B
-0.18 <1> -0.007<1> -0.18 -0.007
Flushness of Fasteners - Wing/Nacelle
Table 3
<1> For the Plastron the applicable tolerance is + 0.13 mm (0.005 in.) to -
0.18 mm (0.007 in.).
NOTE: On angled surfaces the 'Normal' tolerances apply at the lowest intersec
tion (Refer to Figure 1).

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Flushness of Fasteners/Special Washers

Figure 1

B. Angled surfaces
(1) On angled surfaces the 'Normal' tolerances apply at the lowest inter-
section (Refer to Figure 1).
C. Special Washers
(1) For the tolerances applicable in particular to washers under bolts on
composite surfaces refer to Figure 1.
4. Abbreviations
A. The following special abbreviations are used in this Chapter:
- IN LOF = in line of flight
- A LOF = across line of flight

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Aerodynamic Smoothness - Critical Areas

Figure 2

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Aerodynamic Smoothness - Critical Areas

Figure 3

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Definitions and Sign Conventions

Figure 4 (sheet 1)

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Definitions and Sign Conventions

Figure 4 (sheet 2)

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General Measures - Fixed Structure

Figure 5

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General Measures - Hinged Doors etc.

Figure 6

Aerodynamic Smoothness - Filling of Gaps

Figure 7

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Skin Waviness - Fuselage General Surfaces

Figure 8

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CRITICAL AREA DEGREE OF SMOOTHNESS

IN LOF (excluding seam joints) A LOF
POSITIVE STEP NEGATIVE STEP POSITIVE STEP NEGATIVE STEP
mm in. mm in. mm in. mm in.
AREA A +0.8 +0.031 -0.8 -0.031 +0.5 +0.020 -0.5 -0.020
AREA A (FOR
10% RE --- --- --- --- +0.7 +0.028 -0.7 -0.028
LAXATION)
AREA B +1.0 +0.039 -1.0 -0.039 +0.7 +0.028 -0.7 -0.028
Permissible Mismatch - Fuselage (Fixed Structure)
Table 4
NOTE: For definition and general measures refer to Figure 4 and Figure
5.
NOTE: All fixed structural gaps to be filled. Refer to Figure 7 for
filler smoothness tolerances.

CRITICAL AREA DEGREE OF SMOOTHNESS GAPS

IN LOF and A LOF IN LOF and A LOF
POSITIVE STEP NEGATIVE STEP MAX. MIN.
mm in. mm in. mm in. mm in.
AREA A +0.8 +0.031 -0.8 -0.031 3.0 0.118 1.0 0.039
AREA B +1.0 +0.039 -1.0 -0.039 5.0 0.197 1.0 0.039
Permissible Mismatch - Fuselage (Access Panels, surface installed Equipment,
Rapid Access Doors)
Table 5
NOTE: For definition and general measures refer to Figure 4 and Figure
5.

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Skin Waviness - Belly Fairing General Surfaces

Figure 9

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CRITICAL AREA DEGREE OF SMOOTHNESS

IN LOF A LOF
POSITIVE STEP NEGATIVE STEP POSITIVE STEP NEGATIVE STEP
mm in. mm in. mm in. mm in.
AREA B +1.5 +0.059 -1.5 -0.059 +1.0 +0.039 -1.0 -0.039
Permissible Mismatch - Belly Fairing
Table 6
NOTE: For definition and general measures refer to Figure 4 and Figure
5.

CRITICAL AREA GAPS

IN LOF and A LOF
MAX. MIN.
mm in. mm in.
AREA B 4.0 0.157 1.0 0.039
Permissible Gaps - Belly Fairing
Table 7
NOTE: All gaps must be treated to get no risk of leakage.

CRITICAL AREA DEGREE OF SMOOTHNESS

IN LOF A LOF
POSITIVE STEP NEGATIVE STEP POSITIVE STEP NEGATIVE STEP
mm in. mm in. mm in. mm in.
AREA B +1.5 +0.059 -1.5 -0.059 +1.0 +0.039 -1.0 -0.039
Permissible Mismatch - Belly Fairing - Removable Parts (Access panels, rapid
access doors, surface installed Equipment)
Table 8
NOTE: For definition and general measures refer to Figure 4 and Figure
5.

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CRITICAL AREA PERIPHERAL GAPS

IN LOF and A LOF
MAX. MIN.
mm in. mm in.
AREA B 5.0 0.197 1.0 0.039
Permissible Gaps - Belly Fairing - Removable Parts
(Access panels, rapid access doors, surface installed
Equipment)
Table 9

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Skin Waviness - Wing General Surfaces

Figure 10

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CRITICAL AREA DEGREE OF SMOOTHNESS

IN LOF A LOF
POSITIVE STEP NEGATIVE STEP POSITIVE STEP NEGATIVE STEP
mm in. mm in. mm in. mm in.
AREA A +0.6 +0.024 -0.6 -0.024 +0.3 +0.012 -0.3 -0.012
AREA B +1.0 +0.039 -1.0 -0.039 +0.5 +0.020 -0.5 -0.020
Permissible Mismatch - Wing (Fixed Structure)
Table 10
NOTE: For definition and general measures refer to Figure 4 and Figure
5.
NOTE: All fixed structural gaps to be filled. Refer to Figure 7 for
filler smoothness tolerances.

CRITICAL AREA DEGREE OF SMOOTHNESS

IN LOF A LOF
POSITIVE STEP NEGATIVE STEP POSITIVE STEP NEGATIVE STEP
mm in. mm in. mm in. mm in.
AREA A +0.6 +0.024 -0.6 -0.024 +0.3 +0.012 -0.3 -0.012
AREA B +1.0 +0.039 -1.0 -0.039 +0.8 +0.031 -0.8 -0.031
Permissible Mismatch - Wing Access Panels and Surface installed Equipment
Table 11
NOTE: For definition and general measures refer to Figure 4 and Figure
5.

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CRITICAL AREA PERIPHERAL GAPS

IN LOF and A LOF
MAX. MIN.
mm in. mm in.
AREA A 1.5 0.059 0.5 0.020
AREA B 3.0 0.118 1.0 0.039
Permissible Gaps - Wing Access Panels and Surface
installed Equipment
Table 12
NOTE: For Leading Edge Lower Access Panels (Blowdown) refer to Table 13.

GAP BETWEEN GAP BETWEEN

D-NOSE SKIN AND GAP BETWEEN PAN WINGBOX SKIN AND
PANEL AT EL AND PANEL PANEL AT FRONT
CRITICAL AREA SUB/SPAR (CHORDWISE GAPS) SPAR
(L/E OF PANELS) (T/E OF PANELS)
mm in. mm in. mm in.
LEADING EDGE LOWER AC 2.0 0.079 2.5 0.098 2.5 0.098
CESS PANEL (BLOWDOWN)
RIBS 1-5 1.3 0.051 2.0 0.079 2.0 0.079
LEADING EDGE LOWER AC 2.0 0.079 2.5 0.098 2.5 0.098
CESS PANEL (BLOWDOWN)
RIBS 6-11 1.3 0.051 2.0 0.079 2.0 0.079
Tolerances for Wing Access Panels - Peripheral Gaps
Table 13

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Aerodynamic Smoothness - Wing, Plastron

Figure 11 (sheet 1)

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Skin Waviness - Wing, Plastron

Figure 11 (sheet 2)

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JOINT DEGREE OF SMOOTHNESS

IN LOF
POSITIVE STEP NEGATIVE STEP
mm in. mm in.
A +0.3 +0.012 -0.3 -0.012
B +0.6 +0.024 -0.6 -0.024
C +1.0 +0.039 -1.0 -0.039
Key to Figure 11
NOTE: For definition and sign convention refer to Figure 5.

PERIPHERAL AREA DEGREE OF SMOOTHNESS

MAX.
mm in.
NOSE TO JOINT 'B' (ALONG +0.5 +0.020
'D')
JOINT 'B' TO PLASTRON +1.5 +0.059
TRAILING EDGE (ALONG 'E')
Key to Figure 11
NOTE: For definition and sign convention refer to Figure 5.

GAP AT JOINT GAPS

MAX
mm in.
'A' <1> 2.0 0.079
'B' AND 'C' 3.0 0.118
Key to Figure 11
<1> Not filled but must be internally sealed against air entry into Plastron.
NOTE: All other gaps should be filled except those required for ventilation or
drainage. Refer to Figure 7 for filler smoothness tolerances.

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Aerodynamic Smoothness - Stabilizers General Surfaces

Figure 12

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CRITICAL AREA DEGREE OF SMOOTHNESS

IN LOF A LOF
POSITIVE STEP NEGATIVE STEP POSITIVE STEP NEGATIVE STEP
mm in. mm in. mm in. mm in.
AREA A +0.6 +0.024 -0.6 -0.024 +0.4 +0.016 -0.4 -0.016
AREA B +1.0 +0.039 -1.0 -0.039 +0.8 +0.031 -0.8 -0.031
Permissible Mismatch - Stabilizers (Fixed Structure)
Table 14
NOTE: For definition and general measures refer to Figure 4 and Figure 5.
NOTE: All fixed structural gaps to be filled. Refer to Figure 7 for filler
smoothness tolerances.

CRITICAL AREA DEGREE OF SMOOTHNESS

IN LOF A LOF
POSITIVE STEP NEGATIVE STEP POSITIVE STEP NEGATIVE STEP
mm in. mm in. mm in. mm in.
AREA A +0.8 +0.031 -0.8 -0.031 +0.5 +0.020 -0.5 -0.020
AREA B +1.0 +0.039 -1.0 -0.039 +0.8 +0.031 -0.8 -0.031
Permissible Mismatch - Stabilizer Access Panel Edges
Table 15
NOTE: For definition and general measures refer to Figure 4 and Figure 5.

CRITICAL AREA PERIPHERAL GAPS

IN LOF and A LOF
MAX. MIN.
mm in. mm in.
AREA A 1.5 0.059 0.5 0.020
AREA B 3.0 0.118 1.0 0.039
Permissible Gaps - Stabilizer Access Panel Edges
Table 16

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Aerodynamic Smoothness - Stabilizers

Figure 13

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Aerodynamic Smoothness - Pylon and Nacelle

Figure 14

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CRITICALAREA DEGREE OF SMOOTHNESS

IN LOF A LOF
POSITIVE STEP NEGATIVE STEP POSITIVE STEP NEGATIVE STEP
mm in. mm in. mm in. mm in.
AREA A +0.6 +0.024 -0.6 -0.024 +0.25 +0.010 -0.40 -0.016
AREA B +1.0 +0.039 -1.0 -0.039 +1.0 +0.039 -1.0 -0.039
Permissible Mismatch - Nacelle and Pylon (Fixed Structure)
Table 17
NOTE: For definition and general measures refer to Figure 4 and Figure 5.
NOTE: All fixed structural gaps to be filled. Refer to Figure 7 for filler
smoothness tolerances.

CRITICAL AREA DEGREE OF SMOOTHNESS

IN LOF A LOF
POSITIVE STEP NEGATIVE STEP POSITIVE STEP NEGATIVE STEP
mm in. mm in. mm in. mm in.
AREA A +0.75 +0.029 -0.75 -0.029 +0.75 +0.029 -0.75 -0.029
AREA B +1.50 +0.059 -1.50 -0.059 +1.50 +0.059 -1.50 -0.059
Permissible Mismatch - Nacelle and Pylon, Hinged Access Panels and Latches
Table 18

CRITICAL AREA PERIPHERAL GAPS

IN LOF and A LOF
MAX. MIN.
mm in. mm in.
AREA A 3.0 0.118 1.0 0.039
AREA B 5.0 0.197 1.0 0.039
Permissible Gaps - Nacelle and Pylon, Hinged Access
Panels and Latches
Table 19

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DEGREE OF SMOOTHNESS
POSITIVE STEP NEGATIVE STEP
mm in. mm in.
+ 3.0 + 0.118 - 3.0 - 0.118
+ 2.0 + 0.079 - 2.0 - 0.079
Permissible Mismatch - Nacelle and
Pylon Cowl Door Edges
Table 20
NOTE: Applicable to all cowl door edges.

GAP <1> SPLIT LINE LOF <2>

GAP SPLIT LINE LOF <2>
MAX. MIN. MAX. MIN.
mm in. mm in. mm in. mm in.
5.0 0.197 1.0 0.039 13.5 0.531 10.5 0.413
4.5 0.177 0.5 0.020 11.5 0.453 8.5 0.335
Permissible Gaps - Nacelle and Pylon Cowl Door Edges
Table 21
<1> Except for cowl edge to cascade type thrust reversor edge gap, 8.4 mm
(0.331 in.) " 1.6 mm (0.063 in.).
<2> Gap required for cowl door at pylon junction.
NOTE: Applicable to all cowl door edges.

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