GORE SKYFLEX

™ ™
aerospace materials

F-16 Application Guide

Increased Aircraft
Availability with
No-Cure Materials
 GORE SKYFLEX ™ ™
aerospace materials

Proven by more than 20 years of successful applications,

GORE™ SKYFLEX™ Aerospace Materials are lightweight materials
that provide a no-cure seal for panels, fairings, and floorboards
and surface protection against vibration damage. They remain
flexible and compliant over multiple open/close cycles, providing
durable protection against corrosion and the ingress of water,
fuels, and oils. GORE™ SKYFLEX™ Aerospace Materials are
available in a form-in-place tape or die-cut gasket.

GORE™ SKYFLEX™ Aerospace Materials, 720 Series include a

proprietary material used in their construction — expanded
Polytetrafluoroethylene (ePTFE) specifically designed for use
as a fuel sealant. They are resistant to fuels, oils, and hydraulic
fluids while still providing the same benefits as the 100 and
110 Series.

See Figure 1 for suggested areas for application. For more

information or assistance in selecting the right materials for
your application, contact a Gore representative.
Benefits
• Easy installation from single-component material
• Reduced manufacturing cycles and maintenance downtime
with materials that require no curing
• Less replacement and re-work of seals by maintaining
performance over multiple open/close cycles
• Improved sealing of irregular surfaces with highly
conformable materials
• Durable protection against mechanical forces, extreme
temperatures, fluids, and other environmental hazards
• Low environmental impact from non-hazardous waste
Technical Order Approvals
GORE™ SKYFLEX™ Aerospace Materials are approved for use
in the following F-16 Technical Orders:
• TO 1-1-691: Aircraft Weapons System Cleaning and
Corrosion Control
• 1F-16C-2-00GV-00-1: General Vehicle Organizational
Maintenance
• 6J14-2-39-2: 370-Gallon External Fuel Tank
The examples presented in this document were applied using
Gore’s best practices for installing GORE™ SKYFLEX™ Aerospace
Materials. In addition, instructional videos are available at
www.gore.com/skyflex.
Note: This document is only a guide, and procedures in the
current version of the technical orders supersede examples
presented in this document.
 F-16 Application Guide

Extract from T.O. 1F-16C-2-00GV-00-1 for Reduce Application Cure Time

GORE™ SKYFLEX™ Aerospace Tapes, 100 Using GORE™ SKYFLEX™ Aerospace Materials completely
and 110 Series eliminates cure time for sealing and protective materials,
SKYFLEX Sealant Environmental Tape (Non-Fuel, significantly reducing installation time (Table 1). Once the
Non-Hydraulic Areas). This material may be used as sealant is applied and the panels are fitted, the aircraft is ready
an alternate to AMS-3276 or AMS-3277 (formerly for flight.
MIL-S-83430) when installing new access door or panel
sealing. SKYFLEX materials give the advantages of easy Table 1: Installation Time
installation without cure time and cleanup problems.
GORE™ SKYFLEX™ Approximate
SKYFLEX materials should only be used on access doors Aerospace Materials
and panels that are retained with threaded fasteners. Panel Number (100, 110 and 720
Installation Time
Series) (Minutes)
SKYFLEX materials are not authorized on access doors
and panels retained with push button latches. SKYFLEX 2406 and 2408 GSC-21-95241-011 10
environmental tape is non-curing and self-adhering with 2407, 2409 and
a peel and stick adhesive. Use on panels and doors not GSC-21-95241-011 20
2411
containing fuel or hydraulic residue.1 4115 GSC-21-96057-04 45
4216 GSC-21-96057-04 45
4401 GSC-21-96057-027 5
Extract from T.O. 1F-16C-2-00GV-00-1 for 4402 GSC-21-96057-027 5
GORE™ SKYFLEX™ Aerospace Tapes, 720 Series
4405 GSC-21-96057-04 20
SKYFLEX “OP” Environmental Sealant Tape (Fuel/Hydraulic Total number of panels = 9 150
Areas) is a non-hazardous and reusable alternative to
form-in-place Polysulfide sealant. Material consists of
a layer of Polytetrafluoroethylene (ePTFE) sealant tape
placed between the mating surfaces of an access cover
and aircraft sill structure. “OP” sealant tape is designed
for use in applications exposed to fuel and hydraulic fluid.
The tape is bonded to the sill or access cover surface and
is of sufficient thickness to provide a positive seal.
SKYFLEX “OP” sealant tape requires no cure time.2

Note: Since the publication of this T.O., “OP” environmental

sealant tape has been supplanted by GORE™ SKYFLEX™
Aerospace Tapes, 720 Series available under part numbers
as presented.

1
Air Force, Technical Order, 1F-16C-2-00GV-00-1, 2006, s. 2.10.2, p. 2-42
2
Air Force, Technical Order, 1F-16C-2-00GV-00-1, s. 2.10.3, p. 2-44
 GORE SKYFLEX ™ ™
aerospace materials

Panel Identification for GORE™ SKYFLEX™ Aerospace Materials

GORE™ SKYFLEX™ Aerospace Tapes, 100 and 110 Series should be used for panels that require environmental sealing. The 720 Series
of gaskets should be should be used for fuel system panels. Due to exposure to hydraulic fluid from control surface actuators, the 720
Series of tapes is also recommended for non-fuel system panels.

720 Series
100 and 110 Series

*Block 30 Only

6412
6416
6422*
6404 4436

1202 1204 3442

3410 3414
4402
3408 34123416
2404 2406 2408 4404 4406
4406 4420
3402

3401
2413 4407 4419
2409 2411 4403 4405
3409

2407 3415
4401
3431 3413

4435
1101 1103 24053403 3441
5403
5421*
5415
5411

3312 2310 2202

3308

4216 2206 2204

1204 1202
1305

1103 1101

4115

JFS EXHAUST
JFS INLET

Figure 1: Panel Identification for GORE™ SKYFLEX™ Aerospace Materials


Examples: 100 and 110 Series
GORE™ SKYFLEX™ Aerospace Tapes, Part Number GSC-21-95241-
011 (NSN 8030-01-368-7208) installed on aircraft panels 2406
and 2408 (Figures 2 and 3). The fastener holes were pre-punched,
and the installation was completed. Approximate installation
time is 20 minutes. Multiple open/close cycles are possible after
installation.
Figure 2: Airframe installation for panel 2406
Figure 3: Airframe installation for panel 2408
F-16 Application Guide
Panels 2407, 2409 and 2411 were cleaned prior to installation.
GORE™ SKYFLEX™ Aerospace Tapes, Part Number GSC-21-95241-
011 (NSN 8030-01-368-7208) was used to seal the panels
(Figure 4). Approximate cleaning and installation time is 20
minutes for all the panels.
Figure 4: Airframe installation for panels 2407, 2409 and 2411
 GORE SKYFLEX ™ ™
aerospace materials
Examples: 720 Series
Note: Refer to the Technical Orders for installing GORE™ SKYFLEX™
Aerospace Gaskets, 720 Series on fuel cell systems.
GORE™ SKYFLEX™ Aerospace Gaskets, Part Number GSC-21-96527-04
(NSN 5330-01-532-2239) are a replacement for rubber gaskets
on the 370-gallon external tank. The fuel sealants are white
gaskets that protect against harsh environmental conditions,
and eliminate aging and embrittlement (Figures 5 and 6).
Figure 5: Airframe installation for external tank
Figure 6: GORE™ SKYFLEX™ Aerospace Materials, Part Number GSC-21-
96552-04 (NSN 5330-01-631-3573) for wing access panel.
GORE™ SKYFLEX™ Aerospace Tapes, Part Number GSC-21-96057-027
(NSN 5330-01-557-4114) installed on aircraft panels 4115 and
4216 (Figure 7). Although these are not fuel panels, fuel sealants
were used due to the extensive hydraulic fluid exposure in these
areas. Approximate installation time is 45 minutes per panel.
Although not a fuel panel, the presence of hydraulic fluid from
the actuator on panel 4402 required GORE™ SKYFLEX™ Aerospace
Tapes, Part Number GSC-21-96057-027 (NSN 5330-01-557-4114)
(Figure 8). Approximate installation time is 10 minutes.
Figure 7: Airframe installation for Panel 4115
Figure 8: Airframe installation for Panel 4402
 F-16 Application Guide

Inspection of Previously Installed Sealant

The sealant must be inspected whenever the panel is removed. If
the sealant has been damaged, sealing ability may be degraded.
To prevent this, GORE™ SKYFLEX™ Aerospace Materials must
be inspected for large nicks, cuts, gouges and delamination/
separation prior to reuse. The structure should also be inspected
for corrosion before the panel is reinstalled.

Prior to reuse, gently wipe the surface of GORE™ SKYFLEX™

Aerospace Materials with a clean cloth or rag to remove any dust,
dirt, or other foreign matter. While wiping, inspect the sealant for
mechanical damage, such as large nicks, cuts or gouges. Also
check for delamination/ separation from the sealing surface.

For best results, GORE™ SKYFLEX™ Aerospace Gaskets, 720 Series

in fuel cell applications should be replaced in their entirety
if damaged. In the event of any damage to GORE™ SKYFLEX™
Aerospace Tapes, 720 Series in non-fuel cell applications, the
same inspection/repair criteria apply as presented below.
Figure 9: Incorrect sealant installed that pulled away at the corner
(no overlap) leaving the structure exposed at faying surface. GORE™
SKYFLEX™ Aerospace Tapes, 720 Series is recommended for areas
with hydraulic fluid and fuel.

See Table 2 if problems or irregularities are detected to determine

the appropriate action.

When inspecting previously installed GORE™ SKYFLEX™ Aerospace

Tapes, pay close attention to the quality of the installation.
Gaps between materials, poor or incomplete overlap of corners,
or excessive missing material around fastener holes should be
corrected with a reapplication of GORE™ SKYFLEX™ Aerospace
Tapes (Figure 9). Refer to the appropriate technical manual and
Gore’s installation guides and videos for examples of proper
installation.

Table 2: Inspection Criteria

Damage Sealant repair required Sealant repair NOT required

Nicks, cuts gouges
Delamination/Separation
Discoloration
6.4mm (0.25) in size or larger OR any damage at a
fastener hole
Sealant tape does not stay aligned on sealing
surface or corrosion is observed
Sealant is saturated with fuel/hydraulic oil and
will not stay in place
Less than 6.4mm (0.25) in size
Adhesive near delamination area still holds
sealant over required surface
Sealant is discolored due to compression stress
around fasteners or other areas
 GORE SKYFLEX ™ ™
aerospace materials
Table 3: Product Reference
National NATO Stock Current
Stock Number Number Part Number
5330-01-532-1885 N/A GSC-21-96526-04
5330-01-532-2239 N/A GSC-21-96527-04
5330-01-532-2248 N/A GSC-21-96529-04
5330-01-532-3612 N/A GSC-21-96528-04
5330-01-533-7547 N/A GSC-21-96513-00
5330-01-579-0629 N/A GSC-21-96514-00
5330-01-631-3573 N/A GSC-21-96552-04
5330-01-631-3584 N/A GSC-21-96551-04
5330-01-631-3585 N/A GSC-21-96550-04
5330-01-631-3600 N/A GSC-21-96555-04
5330-01-631-3604 N/A GSC-21-96554-04
7510-01-552-9072 N/A GSC-95269-024
8030-01-367-7356 N/A GSC-21-95070-011
5330-01-557-4114 N/A GSC-21-96057-027
5330-01-557-4118 N/A GSC-21-96059-027
8030-01-367-7357 N/A GSC-21-95201-0111
8030-01-368-7207 N/A GSC-21-95158-011
8030-01-368-7208 N/A GSC-21-95241-011
8030-01-475-1368 N/A GSC-21-95201-011
8030-01-618-9582 N/A GSC-21-96059-04
8030-01-618-9583 N/A GSC-21-96062-04
W. L. Gore & Associates
gore.com
Old Description
Part Number (width x thickness) Example of Use
N/A F-16 370-gallon ground cap die-cut gasket F-16 external fuel tank
N/A F-16 370-gallon aft filler cap die-cut gasket F-16 external fuel tank
N/A F-16 370-gallon filler die-cut gasket F-16 external fuel tank
N/A F-16 370-gallon filler die-cut gasket F-16 external fuel tank
N/A F-16 gasket panel 2413 F-16 fuel
N/A F-16D F-1 fuel cell door gasket F-16 fuel
N/A F-16 wing access panel gasket F-16 wing
N/A F-16 wing access panel gasket F-16 wing
N/A F-16 wing access panel gasket F-16 wing
N/A F-16 wing access panel gasket F-16 wing
N/A F-16 wing access panel gasket F-16 wing
N/A 27.4mm x 1.5mm (1.08" x 0.06") Body fairings
4-ribbed tape, no large bulb with adhesive
Color: White
GO-AS-0002/1 7mm x 0.5mm (0.28" x 0.02") Compensation tape used as
GUA 1002-1 Flat tape with adhesive required to fill gaps/ crevices
Color: Grey to create a flat sealing surface
N/A 25.4mm x 0.81mm (1" x 0.032") Hatches and floor panels,
Flat fuel tape with adhesive and hydraulic fluid areas
Color: White
N/A 38.1mm x 0.8mm (1.5" x 0.031") Access doors and panels
Flat fuel tape with adhesive in areas exposed to fuel/
Color: White hydraulic fluids
GO-AS-0053 41mm x 0.5mm (1.61" x 0.02") Access panels
GUA 1001-1 5-ribbed tape with adhesive Seal faying surfaces >33mm
Adhesive width: 25mm (1.0") (1.3") wide
Color: Grey
GUA 1003-1 6mm x 2mm (0.25" x 0.08") Compensation tape used as
Flat tape with adhesive required to fill gaps/ crevices
Color: Grey to create a flat sealing surface
GO-AS-0017 28mm x 0.5mm (1.1" x 0.02") Access panels and windows.
GSC-21-81183-00 5-ribbed tape with adhesive Seal faying surfaces <33mm
GUA 1017-1 Color: Grey (1.3") wide
GUA 1001-2 41mm x 0.5mm (1.61" x 0.02") Access panels for sealing
GO-AS-0053/1 5-ribbed tape with adhesive surfaces 28mm (1.1") to 41mm
GSC-21-81181-00 Adhesive width: 38mm (1.5") (1.61") wide
Color: Grey
N/A 38.1mm x 0.8mm (1.5" x 0.031") Access doors and panels
Flat fuel tape with no adhesive in areas exposed to fuel/
Color: White hydraulic fluids
N/A 50.8mm x 0.8mm (2.0" x 0.031") Access doors and panels
Flat fuel tape with no adhesive in areas exposed to fuel/
Color: White hydraulic fluids
GORE, SKYFLEX and designs are trademarks of W. L. Gore & Associates.   © 2015 W. L. Gore & Associates, Inc.  SKY-0141-R1-REF-US-SEP15