STRUCTURAL REPAIR MANUAL

G. Removal of Bull Nose Fasteners

(1) There are two methods that you can use to remove a Bull Nose fasĆ
tener, these are:
(a) If you have good access to the threaded end of the fastener use
a TAPER-LOK Knockout Tool.
(b) If you do not have good access use an extractor tool.
(2) Both of these methods are given in Paragraph 9 of this Chapter.
NOTE: The removed Bull Nose pin and nut or collar must be discarded.
You are not permitted to re-use them.
H. Further Information
When a Bull Nose fastener is removed further action to the hole is necĆ
essary as follows:
(1) Interference Fit Hole. Prepare the hole for an oversize fastener
(Refer to Chapter 51-44-00). Two stages of oversize fastener are
available (Refer to Chapter 51-43-00).
(2) Transition Fit Hole. Measure the hole diameter. If the diameter is
within the permitted tolerances (Refer to Chapter 51-44-00) and in
good condition, a replacement standard fastener can be used. If the
diameter is outside the permitted tolerances, the hole must be preĆ
pared for an oversize fastener (Refer to Chapter 51-43-00).
(3) Clearance Fit Hole. If the hole condition is good no further action
is necessary. If the hole condition is not acceptable it must be
prepared for an oversize fastener (Refer to Chapter 51-43-00).
9. TAPER-LOK Fasteners
A. General
(1) A TAPER-LOK fastener is a tapered bolt with a threaded end and a
selflocking nut. The nut is also threaded and includes its own washĆ
er. The use of this fastener is almost the same as that of a stanĆ
dard nut and bolt (Refer to Figure 22).
(2) The TAPER-LOK fasteners are used in those areas of the structure
where a high fatigue performance is required. The TAPER-LOK fastener
helps to achieve this performance because it has a constant interĆ
ference-fit in the tapered hole in the structure. This causes a good
compression of the structure material around the fastener hole, and a
balanced stress pattern (Refer to Figure 23).
(3) An additional feature of the TAPER-LOK fastener is the good sealing
effect that is given by the tapered interference fit.

Printed in Germany
51-42-11 FebPage01/02
54
 STRUCTURAL REPAIR MANUAL

(4) The taper of the bolt and the hole to which it is fitted, is small.
It is only 6.35 mm (0.250 in.) for each linear 300 mm (11.811 in.),
a ratio of 1 in 48.
(5) The TAPER-LOK bolt is a light bolt with a good strength property.
Bolts are available for tension or shear uses.
(6) TAPER-LOK bolts are usually supplied with a special lubricant on
them. The special lubricant must not be removed before the bolt is
installed.
(7) Before the TAPER-LOK bolts are installed in a repair, make sure
that:
- they are made of the correct material,
- they have the correct type of head,
- they are of the correc diameter,
- they are of the correct grip length,
- the nuts are of the correct type (Refer to Paragraph 9.A.(22)).

Example of a TAPER-LOK Bolt

Figure 22

Printed in Germany
51-42-11 Page 55
Feb 01/02
 STRUCTURAL REPAIR MANUAL

Example of a Stress Patterns

Figure 23

(8) It is very important to tightly clamp the parts together when they
are prepared for the installation of TAPER-LOK bolts.
(9) TAPER-LOK bolts can be installed with hand or power tools.
(10) It is very important to prepare the hole for a TAPER-LOK bolt to
the highest possible precision. If this is not done, it could have a
bad effect on the fatigue of the structure.
(11) It is recommended that only trained and approved personnel install
TAPER-LOK bolts.
(12) Special tools, for example, drill-reamers, hole/countersink gages and
head protrusion gages, are available. Only these tools should be used
to ensure the necessary precision. These tools must be kept in a
satisfactory condition. Drill reamers must not be re-sharpened by the
operator; they must be returned to the manufacturer for re-sharpenĆ
ing.
(13) Before you install TAPER-LOK bolts, makes sure that all the holes
are:
- clean,
- smooth,
- fully deburred at the nut end.

Printed in Germany
51-42-11 FebPage01/02
56
 STRUCTURAL REPAIR MANUAL

The holes for protruding head bolts must have a relief radius at the
head end of the hole (Refer to Figure 24).
NOTE: If a hole, that has been used before, is found damaged or
oversize, it must be repaired to use the correct oversize bolt
(Refer to Chapter 51-43-00).
(14) The information on the available types of TAPER-LOK bolts is given
in Chapter 51-40-00.
(15) The data given in Figure 25 will help the operator to identify the
correct bolt to fit in a hole of specified dimensions (nominal diamĆ
eter and grip length).
(16) The TAPER-LOK bolts of different nominal diameters are divided into
grip length groups. Thus bolts of the same nominal diameter can be
found for use on materials of different thicknesses. The part numĆ
bers, that are on the head and the end of the bolt, are used to
identify a bolt Figure 25 shows this in detail).
(17) TAPER-LOK drill reamers are available to prepare a hole for a TAPER-
LOK bolt (countersunk or protruding head). The drill reamers are
identified by a part number. This part number gives the grip length
and nominal diameter of the bolt to which the drill reamer is appliĆ
cable (Refer to Figure 26).

Printed in Germany
51-42-11 Page 57
Feb 01/02
 STRUCTURAL REPAIR MANUAL

Relief Radius Data for Protruding Head - TAPER-LOK Bolts

Figure 24

Printed in Germany
51-42-11 FebPage01/02
58
 STRUCTURAL REPAIR MANUAL

TAPER-LOK Bolt Identification Coding

Figure 25

Printed in Germany
51-42-11 Page 59
Feb 01/02
STRUCTURAL REPAIR MANUAL

TAPER-LOK Drill Reamer Data

Figure 26

Printed in Germany
51-42-11 FebPage01/02
60
 STRUCTURAL REPAIR MANUAL

Example of the Use of a Dished Washer

Figure 27

(18) TAPER-LOK drill reamers that have the part number TLD 2040AR (counĆ
tersunk head bolts) cut the material in three continuous steps. These
are:
- the pilot hole,
- the tapered hole of the correct taper and grip length,
- the correct countersink.
Drill reamers that have the part number TLD 2040BR (protruding head
bolts) only make the pilot hole and the tapered hole of the correct
grip length (Refer to Figure 26).
(19) There are two different types of nuts available for use on TAPER-LOK
bolts. They are:
(a) Nuts with an attached washer. These are for use where the surĆ
faces of the materials, that must be fastened, are out of paralĆ
lel up to 2 ° .
(b) Nuts with a spherically dished washer that is not attached. These
must be used where the material surfaces are out of parallel up
to 7 ° (Refer to Figure 27).
NOTE: On wing structure this limit is 3 ° .

Printed in Germany
51-42-11 Page 61
Feb 01/02
 STRUCTURAL REPAIR MANUAL

(20) These nuts do not have their part number engraved on them, thus they
must be kept in different containers. The containers must be marked
with the applicable number.
(21) The self-locking property of these nuts is caused by a small ellipĆ
tical deformation of the nut/body thread. When the nut is installed
on a bolt, the threaded part of the bolt causes the deformation to
change shape. This causes the nut to tightly hold the bolt.
NOTE: These nuts must only be used once.
(22) The subsequent table shows the nuts that are available for use with
TAPER-LOK bolts on this aircraft.

PART NUMBER NAME NUT/WASHER MAĆ SURFACE PROTECĆ

TERIAL TION
NSA 1726-( ) Nut, Self-LockĆ Stainless Steel Cadmium Plating
(NSA5050) ing with washer or Steel on steel parts,
included Silver Plating
on stainless
steel parts
NSA5057 Nut, Self-LockĆ Stainless Steel Cadmium Plating
NSA5472 ing with washer or Steel on steel parts,
included Silver Plating
on stainless
steel parts
NSA5094 Nut, Self-LockĆ Steel Cadmium Plated
ing
with separate
spherically
dished washer
NSA5151 Nut, Self-LockĆ Steel Cadmium Plated
ing
with separate
spherically
dished washer
Nuts for Use with TAPER-LOK Bolts
Table 14
B. Hole Preparation
(1) Make a mark at the correct positions for the bolts.
(2) Accurately make a mark with a center punch at the positions identiĆ
fied in step 9.B.(1).

Printed in Germany
51-42-11 FebPage01/02
62
 STRUCTURAL REPAIR MANUAL

CAUTION: THE HOLE AXIS MUST BE WITHIN 2 ° OF THE PERPENDICULAR WHEN

YOU DO THE NEXT STEP. USE A DRILL JIG TO ACHIEVE THIS PRECIĆ
SION.
(3) Carefully drill a pilot hole at each of the positions identified in
step 9.B.(1).
NOTE: The correct twist-drill size for this step is 0.4 mm (0.016
in.) smaller than the nominal diameter of the bolt to be
installed.
NOTE: The correct drill speed for this step is approximately 600
revolutions per minute (rpm).
(4) Put the correct drill reamer in an adjustable TAPER-LOK arbor (Refer
to Figure 28). Adjust the arbor to the necessary drill depth. Put
the arbor in a pneumatic drill machine.
NOTE: The drill machine must be a machine on which the speed can be
adjusted from 200 thru 400 rpm. For example, the hole for a
bolt of 1/4 in. (6.4 mm) nominal diameter, must be drilled at
a speed of approximately 300 rpm.
(5) Do a test drill on a piece of material that is of the same type and
thickness as the material to be fastened. Repeat this step until you
have found:
- the necessary drill speed (rpm),
- the necessary drill depth.
NOTE: This information helps to make sure that the hole is to a good
finish.
(6) Put the drill reamer/arbor accurately over the hole drilled in step
9.B.(3). Make sure:
- that the pilot-hole end of the drill reamer is in the center of
the hole,
- that the drill reamer is in line with the vertical axis of the
hole.
(7) Start the drill machine and drill the hole. Use the cutting lubriĆ
cant FREON TB-1, or ICI ARCTON 113, during this step. Make sure that
the drill reamer moves through the material slowly, but with a
constant hand pressure on it.

Printed in Germany
51-42-11 Page 63
Feb 01/02
STRUCTURAL REPAIR MANUAL

TAPER-LOK Arbor Data

Figure 28

Printed in Germany
51-42-11 FebPage01/02
64
 STRUCTURAL REPAIR MANUAL

(8) Stop the drill machine when the drill reamer has reached the depth
set on the adjustable arbor. Carefully remove the drill reamer from
the hole.
NOTE: Because of the taper of the hole and the drill reamer, the
drill reamer will move apart from the hole easily.
(9) If the hole is for a countersunk bolt, make sure that the hole
countersink is correct. Do this with the applicable TAPER-LOK gage
(Refer to Figure 29).
(10) If the hole is for a protruding head bolt, make sure that the top
edge of the hole has the correct radius (Refer to Figure 24).
(11) Deburr all the edges of the holes.
(12) Do the steps that follow on all the prepared holes to make sure
that they have the correct interference fit.
(a) Apply a layer of engineers blue dye (Prussian Blue) to the face
of the applicable plug gage (Refer to Figure 30).
(b) Put the plug gage into the hole and lightly hit it (use a comĆ
posite head mallet to do this). Do this until only 25 % of the
length of the shank is visible (measured from the bottom face of
the plug gage head to the top face of the material).
(c) Carefully hit the end of the plug gage to free the plug gage
from the hole.
NOTE: Take care not to change the marks in the engineers blue on
the plug gage when you do this step.
(d) Look at the marks in the engineers blue on the shank of the
plug gage. If the marks show:
1 That 60 % or more of the plug gage shank touched the face of
the hole (Refer to Figure 31), the hole is satisfactory.
2 That less than 60 % of the plug gage shank touched the face
of the hole, refer to Paragraph 9.E..

Printed in Germany
51-42-11 Page 65
Feb 01/02
 STRUCTURAL REPAIR MANUAL

Data for Countersink Check Gage

Figure 29

Printed in Germany
51-42-11 FebPage01/02
66
STRUCTURAL REPAIR MANUAL

Plug Gage Data

Figure 30

Printed in Germany
51-42-11 Page 67
Feb 01/02
STRUCTURAL REPAIR MANUAL

Use of a Plug Gage

Figure 31

Printed in Germany
51-42-11 FebPage01/02
68
 STRUCTURAL REPAIR MANUAL

C. Installation of TAPER-LOK bolts

(1) Insert the correct TAPER-LOK bolt into the prepared hole. Only use a
light hand pressure on the bolt head.
(2) Check the measurement between the material surface and the bolt head.
NOTE: The data and procedure necessary to do this is given in Figure
32.
CAUTION: ONLY PULL THE BOLT INTO THE HOLE BY THE EFFECT OF THE NUT BEĆ
ING FULLY TORQUED. DO NOT HIT IT IN.
CAUTION: ONLY USE THE SOCKET THAT IS CORRECT FOR THE TYPE OF NUT TO BE
INSTALLED. FOR EXAMPLE, HEXAGONAL SOCKETS MUST ONLY BE USED ON
HEXAGONAL NUTS.
(3) Put the applicable nuts (Refer to Paragraphs 9.A.(19) and 9.A.(22))
on the threaded ends of the bolts. Make sure that the nuts engage
the bolt threads correctly. Torque the nuts to the correct value
(Refer to Chapter 51-49-00).
(4) Make sure that the bolt has been fully pulled into the hole. Do the
subsequent steps if it has not.
(a) Remove and discard the nut.
(b) Put a washer onto the bolt thread.
NOTE: The washer must have an inner diameter that is sufficient
to go over the plain part of the bolt shank.
(c) Do step 9.C.(3) again.

Printed in Germany
51-42-11 Page 69
Feb 01/02
 STRUCTURAL REPAIR MANUAL

TAPER-LOK Bolt Protrusion Data

Figure 32

Printed in Germany
51-42-11 FebPage01/02
70
 STRUCTURAL REPAIR MANUAL

D. Inspection after Installation

(1) After TAPER-LOK bolts have been installed, an inspection of them must
be done. This inspection must look for the subsequent bad conditions
that can occur.
(a) A clearance between the bolt head and the material. The permitted
limits for this condition are:
- A clearance that is not more than 0.04 mm (0.002 in.) (Refer
to Figure 33.
- 60 % or more of the bolt head must fully touch the material
face (Refer to Figure 33).
- Only 10 % of the bolts in a row of bolts can have this condiĆ
tion.
- Two bolts that are adjacent to each other must not have this
condition.
(b) One full thread of the bolt must show out of the end of the
nut.
(c) Damage to the bolt head or nut, and the material around the bolt
head. For example:
- scoring,
- impact damage,
- dishing of the bolt head,
- cracks at the edge of the bolt head,
- surface protection damaged.
(2) The steps that follow give the procedures to repair any of the
conditions referred to in Paragraph 9.D.(1).
(a) If there is a clearance between the bolt head and the material
more than the permitted limits:
1 Remove and discard the nut and the bolt (Refer to Paragraph
9.F.).
2 Install a new bolt and nut (Refer to Paragraph 9.C. for the
procedure).
(b) If one full thread of the bolt does not show out of the end of
the nut:
1 Remove and discard the nut and the bolt (Refer to Paragraph
9.F.).
2 Install a longer bolt (Refer to Paragraph 9.C. for this proceĆ
dure).
(c) Scoring and impact damage is permitted if there are no sharp
edges or corners. The depth of the damage must not be larger
than 0.1 mm (0.004 in.). Do the applicable repair procedure if
necessary.

Printed in Germany
51-42-11 Page 71
Feb 01/02
 STRUCTURAL REPAIR MANUAL

(d) Figure 34 gives the permitted limit for the dishing of the bolt
head. If the dishing is more than this limit, the bolt and the
nut must be replaced. Use the procedure given in Paragraph 9.C.
to do this.

Bolt Head Separation Data

Figure 33

Printed in Germany
51-42-11 FebPage01/02
72
 STRUCTURAL REPAIR MANUAL

Bolt Head Dishing Data

Figure 34

(e) Cracks in the bolt head are not permitted. If there are cracks,
the bolt and the nut must be replaced. Use the procedure given
in Paragraph 9.C. to do this.
(f) If the surface protection is cadmium plating (golden color), and
damaged, replace the bolt and the nut, or the nut only if necesĆ
sary. Use the procedure given in Paragraph 9.C. to do this.
E. Use of Hand Reamers
(1) The use of a hand reamer, refer to Figure 35, is permitted if it is
necessary to improve the face of a hole.
(2) When it is necessary to use a hand reamer, the subsequent steps must
be done after each use:
(a) Deburr the edges of the hole.
(b) If it is applicable, make sure that the countersink is correct
(Refer to Paragraph 9.B.(9)).
(c) If it is applicable, make sure that the radius around the top
edge of the hole is correct (Refer to Paragraph 9.B.(10)).

Printed in Germany
51-42-11 Page 73
Feb 01/02
 STRUCTURAL REPAIR MANUAL

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

TAPER-LOK Hand Reamer

Figure 35

F. TAPER-LOK Fastener - Removal Procedures

One of two procedures can be used to remove TAPER-LOK fasteners; these
procedures are given below. Where possible, use procedure 1.
(1) Procedure 1
(a) Remove and discard the nut. Do this with the correct socket
tool.
(b) Put the correct TAPER-LOK knock-out tool (Refer to Figure 36) on
the thread of the bolt. Make sure that the tool correctly enĆ
gages the bolt thread and is fully turned onto the bolt.
(c) Hit out the bolt. To do this, hit the end of the knock-out tool
with a hammer, this will cause the bolt to move apart from the
hole.

Printed in Germany
51-42-11 FebPage01/02
74
 STRUCTURAL REPAIR MANUAL

CAUTION: TAKE CARE NOT TO DAMAGE THE BOLT HEAD WHEN YOU DO THIS
STEP.
(d) Hold the bolt head (if necessary, pliers can be used, but obey
the caution given above), remove the knock-out tool from the
bolt.
(e) Carefully remove the bolt from the hole.
(f) Examine the bolt. If its condition is satisfactory, it can be
used again.
NOTE: Bolts which are to be used again must be relubricated, reĆ
fer to Paragraph 4.B. for this procedure.

Printed in Germany
51-42-11 Page 75
Feb 01/02
 STRUCTURAL REPAIR MANUAL

TAPER-LOK Bolt Knock-out Tool Data

Figure 36

Printed in Germany
51-42-11 FebPage01/02
76
 STRUCTURAL REPAIR MANUAL

Extraction Tool Data

Figure 37

(2) Procedure 2
In this procedure a locally made extraction tool is used. Figure 37
shows this tool. This tool uses a standard bolt. The standard bolt
must be correct for the dimensions of the TAPER-LOK bolt that is to
be removed.
(a) Drill a hole of the correct dimensions into the shank of the
TAPERLOK bolt. Do this from the head end of the bolt.
(b) Cut a thread into the inner surface of the hole made in step
9.F.(2)(a).
(c) Put the extraction tool in its correct position above the TAPER-
LOK bolt. Engage the standard bolt with the thread in the TAPER-
LOK bolt (Refer to Figure 37).
(d) Remove and discard the nut from the end of the TAPER-LOK bolt.
Do this with the correct socket tool.
CAUTION: MAKE SURE THAT THE BRIDGE OF THE EXTRACTION TOOL DOES NOT
DAMAGE THE STRUCTURE SURFACE.
(e) Turn the nut on the standard bolt to remove the TAPER-LOK bolt
from the structure.

Printed in Germany
51-42-11 Page 77
Feb 01/02