Hilok pins http://www.mlevel3.com/BCIT/hilok2.

htm

HiLok Aviation Fasteners

HiLoks aircraft fasteners are a two-part device capable of high shear or tensile strength. The main
part of a hilok installation is the pin which is threaded at one end, and features several types of head
at the other. The second part is a female threaded collar which winds onto the exposed pin threads
from the backside of the material.

Hilok Pin
At the threaded end of the pin is a hexagonal recess capable of accepting an allen key. This
receptacle is made available for the purposes of maintaining rotational stability during installation,
and to aid in removal of the pin. HiLok pins are driven into holes which are slightly undersized to
permit an interference fit. HiLok holes are traditionally .002 - .004" undersized compared to the
diamter of the pin shank.
HiLoks are available in countersunk, shear or tension head pins. Countersunk pins are
manufactured with 100° heads similar to other aviation fasteners. Pin construction materials vary
from 7075-T6 aluminum, steel, titanium, and chrome steel. Collars may be manufactured from
2024 aluminum, steel and inconel. Pins and collars are dry lubricated during manufacture, so no
further lubricant is required during installation.

HiLok collar
HiLok pins feature four common head styles, as follows;

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Protruding Shear type

Protruding Tension type

Flush Shear type

Flush Tension type

The unique aspect of HiLok installations is the ability of the collar to shear off a portion of its body
and leaving behind a swedged portion which grips the pin threads. There is a particular area of the
collar which is "necked" down in material thickness to allow this shearing action to take place at a
certain rotational torque.

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In the image above, the main body of the collar stays installed on the pin, while the hexagonal
wrenching flats shear at the thinnest portion of the material. Inside the collar body is a female
thread, compatible with the pin, but slightly elongated to produce friction to prevent accidental
removal.

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Pins and collars are selected by part number, and must be related to each other according to the
manufacturer's charts. Certain collars are available which allow a slight deviation in angle, up to a
maximum of 7°. Other than this special collar, HiLoks are to be installed straight (that is, at less
than 3° deviation) through the material. Other varieties of collars are available for high temperature
use such as engine exhaust components. Pins and collars are designed to be stored in clean dry
containers, and not exposed to solvents or cleaning agents. Most HiLok pins, once used, are
considered unserviceable for any further aviation purposes as cadmium coatings are displaced
during installation. HiLok pins rely on the contact between the skin and the pin head, and also the
hole and the shank, to provide anti-rotational friction.
HiLok pins are available in 1/32" diameters, and in grip lengths incrementing in 1/16". For some
common sizes of pins, certain oversize diameters are available, but their use is permitted only by
advice of the aircraft structural repair manual. HiLok pin basic part numbers are printed on the
fastener heads.
A common HiLok pin part number breaks down as follows:

HL20PB 6 - 8

HL20 Basic Part Number of the pin

PB Pin Material
6 Diameter in 1/32"
8 Grip Length in 1/16" **

**certain part numbers vary the incrementation of the grip length. 1/16" is the most common.
Grip lengths are best ascertained by use of grip gauges ("hook" gauges), also commonly used for
Cherry and other types of blind fasteners. After proper installation, there will be 1 - 3 threads
showing above the sheared neck of the collar.
Installation tools are minimal. Check the material thickness with a grip gauge. A hammer and
backup tool is used to install the pin in the interference hole. Check the amount of pin protruding

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from the far side of the hole.A washer may be added under the collar if required to comply with
standard 1 -3 thread exposures. Start the collar threading onto the pin threads by hand, then
continue with a wrench or ratchet. Do not allow the pin to rotate during this phase of collar
installation. If necessary, use an allen key to maintain pin position during torquing. When the collar
reaches its torque value, the hex portion of the collar will shear. Check that the collar body is flush
with the metal surface, and any washers under the collar have not interfered with installation.
(*Note: do not use a collar to help pull the pin into the hole.)
HiLok pins and collars are not designed to be shaved or altered after installation.
Removals are equally simple. Use lobster pliers (or mechanically locking pliers) to grip and untwist
the collar from the pin. Use the allen key to prevent pin rotation. Tap the pin out once the collar is
removed. There are special collar removal tools which fit on standard ratchets to speed removals.

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