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STRUCTURAL REPAIR MANUAL

CHAPTER 51 − Structures General

TABLE OF CONTENTS

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SECTION
SUBJECT TITLE PAGE
51-00-01 Structural Definition
General 1
General 1

51-00-05 Major Structural Breakdown Diagrams

General 1
Aircraft Description and Dimensions 1

51-03-00 Restricted Areas Diagram

General 1
Definition of Restricted Repair Areas 1

51-06-00 Glossary of Structural Terms

General 1
Glossary of Terms 1

51-07-10 Aircraft Coatings

Repair 201
Epoxy Primer Coating — Preparation and Application (Including Finish
2012) 201
Surface Preparation and Painting Procedure 207
Epoxy Primer Coating — Hydraulic Fluid Resistant (Finish 2012) 217
Waterborne Epoxy Primer — Preparation and Application (Finish 3012) 220
Gloss Epoxy Finish — Application (Includes Finish 2013 and 3013) 235
Epoxy Topcoat — Hydraulic Fluid Resistant Series 2000 239
Application of Epoxy Polyamide Primer Coating 242
Urethane Enamel — Preparation and Application 244
White Primer Coating / Sanding Sealer 250
Antistatic Epoxy Primer 254
Antistatic Epoxy Primer — General Application 260

51-11-00 Damage Classification

Allowable Damage 101
Damage 101

51-13-10 Corrosion Removal and Preventive Procedures

General 1
Corrosion Removal and Preventive Procedures 1
Types of Corrosion 2
Corrosion Inhibitors 9
Corrosion Removal Techniques — Safety Precautions 10
Corrosion Levels and Rework Limits 13
Corrosion Rework Preparations 18
Standard Surface Treatment Methods 20

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51-13-20 Corrosion Removal
Repair 201
Corrosion Removal 201

51-13-21 Aluminum and Aluminum Alloy Corrosion Removal

Repair 201
Aluminum and Aluminum Alloy — Corrosion Removal 201

51-13-22 Magnesium Alloy Corrosion Removal

Repair 201
Magnesium Alloy — Corrosion Removal 201

51-13-23 Alloy Steel Corrosion Removal

Repair 201
Alloy Steel — Corrosion Removal 201

51-13-24 Stainless Steel and Nickel Chromium Alloy Corrosion Removal

Repair 201
Stainless Steel and Nickel Chromium Alloy — Corrosion Removal 201

51-13-25 Titanium Alloy Corrosion Removal

Repair 201
Titanium Alloy — Corrosion Removal 201

51-13-26 Plated or Phosphated Surfaces Corrosion Removal

Repair 201
Plated or Phosphated Surfaces — Corrosion Removal 201

51-13-27 Tungsten Ballast Weights Corrosion Removal

Repair 201
Tungsten Ballast Weights — Corrosion Removal 201

51-14-00 Aerodynamic Smoothness Requirements

Repair 201
Aerodynamic Contour Smoothness 201
Sealing of Surfaces for Aerodynamic Smoothness 211
GIV Finish Specification 216
GIV Sealing Specification 235

51-20-00 Processes
General 1
Individual Process and Finish Codes 1
Finishes, Processes and Nondestructive Test (NDT) Inspection —
Methodology and Equipment 4
Original Finishes 30

51-21-00 Chemical Treatment of Materials

Repair 201

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Chromate Conversion Coating of Aluminum Alloys 201
Cleaning and Chemical Surface Treatment of Aircraft Surfaces 206
Alkaline Cleaning of Ferrous and Nonferrous Alloys 211
Cleaning and Descaling of Titanium and Titanium Alloys 213
Aerodynamic Sealant Compound 220
Fuel Resistant Sealing Compound — Fillet and Faying (−65°F to +360°F
Service) 223

51-21-21 Aluminum and Aluminium Alloy Surface Treatment Method

Repair 201
Aluminum and Aluminum Alloys — Surface Treatment 201

51-21-22 Magnesium Alloy Surface Treatment Method

Repair 201
Magnesium Alloys — Surface Treatment 201

51-21-23 Low Alloy Steel Surface Treatment Method

Repair 201
Low Alloy Steels — Surface Treatment 201

51-21-24 Stainless Steel and Nickel Chromium Alloy Surface Treatment Method
Repair 201
Stainless Steel and Nickel Chromium Alloy — Surface Treatment 201

51-21-25 Titanium Alloy Surface Treatment Method

Repair 201
Titanium Alloy — Surface Treatment 201

51-21-26 Cadmium Plated or Phosphated Metals Surface Treatment Method

Repair 201
Cadmium Plated or Phosphated Metals — Surface Treatment 201

51-22-00 Sealing / Filling Materials Curing

Repair 201
Sealing Pressurized Areas, Skin Joints, Faying Surfaces, Access Closures
and Coating Exterior Surfaces 201
Faying Surface Sealing Compound — Corrosion Inhibitive 208
Integral Fuel Tank Coating — MIL-C-27725 Application 210

51-22-10 Integral Fuel Tank Sealing

General 1
Fuel Access Door Assembly Anti-chafing Gasket 1
Repair 201
Sealing the GIV Wing 201

51-27-00 Permaswage Fittings

Repair 201
Swaging of Tubing to Deutsch PermaswageT Fittings 201

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Installation of Externally Swaged Tube Fittings (PermaswageT Fittings) 219

51-28-10 Preparation of Surfaces by Abrasive Methods

Repair 201
Preparation of Surfaces by Abrasive Methods 201

51-29-00 Ultrasonic Testing

Allowable Damage 101
Ultrasonic Testing of In Service Composite Parts 101
Repair 201
Ultrasonic Quality Requirements for Aluminum Alloy Products 201

51-30-00 Materials
General 1
Approved Materials and Solutions 1

51-34-00 Approved Adhesives

General 1
Mixing and Handling Repair Adhesives - General Requirements 1
Approved Repair Adhesive Charts 2

51-35-00 Formed Repair Materials

General 1
Tolerances — Sheet Metal Forming 1

51-36-00 Materials Cross Reference

General 1
Material Substitution 1

51-41-00 Fastener Types, Materials and Sizes

Structural Identification 1
Clamps 1
Fasteners Bolts / Screws 4
Fasteners — Hi-Lok / Hi-Tigue 14
Fasteners — Rivets 17
Shims 18

51-42-00 Fastener Preparation and Installation

Repair 201
Composite Fasteners and Fastener Hole — Treatment 201
Hole Preparation Specification — Metallic and Composite Structure
Fasteners 202

51-43-00 Fastener Strength Values and Substitution Cross Reference

General 1
Substitution 1
Gulfstream to Vendor Fastener Conversion Table 2

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51-50-00 Support of Aircraft for Repair and Alignment Check Procedures
General 1
Gear Collapse 1

51-51-00 Support Locations

General 1
Shoring of Aircraft 1
Repair 201
General Aligning Procedures 201
Aircraft Shoring Potting Material 212

51-70-00 Repairs (General Aircraft)

General 1
Structural Repairs — General 1
Minimum Fastener Edge and Center-to-Center Distances 1
Repair 201
Shy Edge Distance On Spliced Member — Splice Plate 201
Shy Edge Distance On Spliced Member — Spliced Member 204
Shy Edge Distance — Intersection of Two Flanges 206
Shy Edge Distance — Clip or Gusset 208
Shy Material at Edge — End or Cutout of Sheet Metal Part 210
Shy Edge Distance on Flange End 210
Fastener Hole Breaking Out — Flange End 211
Fastener Head, Tail, Collar or Nut Riding Radius of Flange 212
Excessive Depth of Countersink — Shallow Head / Flush High Strength
Fasteners 215
Shallow Countersink or Dimple — High Rivet Head 217
Deep Countersink or Dimple — Oversize, Oblique or Elongated Hole 218
Incorrect Holes or Countersinks — Shallow Head Rivets 221
Oversize, Elongated or Damaged Holes 224
Extraneous Holes in Aluminum Alloy Parts and Assemblies 226
Minor Scratches, Wrinkles, Dents or Depressions in Pressurized and
Nonpressurized Sheet Metal 230
Rivet Set Cuts 233
Crack in Radius of Flange 234
Cracked Lightening Hole Flange 237
Lateral Crack in Flange or Angle Leg 238
Drill Marks 240
Crack or Puncture in Interior or Exterior Skins 241
Crack or Puncture in Continuous or Spliced Interior or Exterior Skin —
Flanged Side 245
Crack or Puncture in Continuous or Spliced Interior or Exterior Skin —
Opposite Flanged Side 248
Cracks on Edges of Flat or Contoured Skins 251

51-70-56 Window Repairs

Repair 201

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SUBJECT TITLE PAGE
Pits, Nicks, Surface Scratches on Cockpit and Cabin Windows —
Removal Procedures 201

51-75-10 Main Landing Gear Structural Components

General 1
Main Landing Gear — Blend Out Limits 1

51-75-20 Nose Landing Gear Structural Components

General 1
Nose Landing Gear — Blend Out Limits 1

51-77-00 Repairs to Thin Wall Tubes and Ducting

General 1
Thin Wall Tubes and Ducting 1
Supplier Listings 8
Material Listings 23

51-77-01 Duct Inspection

General 1
Applicable GIV Ducts / Tubes 1
Tube Repair — Chapter 21 Air Conditioning Ducts (within Pressure
Vessel) 14
Tube Repair — Chapter 21 Equipment Cooling Ducts 17
Tube Repair — Chapter 21 Air Conditioning Ducts (External to Pressure
Vessel) 19
Tube Repair — Chapter 28 Fuel Lines 22
Tube Repair — Chapter 30 Ice and Rain 25
Tube Repair — Chapter 36 Pneumatic Ducts 28
Tube Repair — ATA Chapter 71: Powerplant Ducts 31
Tube Repair — ATA Chapter 75: Air Ducts 33
Tube Repair — ATA Chapter 80: Starting Ducts 34
Ducts / Tubes — Press Fit Bushing 34
Ducts / Tubes — Slip Fit Bushing 35
Ducts / Tubes — V-Band Splice Sleeve 37
Ducts / Tubes — Splice Sleeve Butt Weld 38
Ducts / Tubes — Splice Sleeve Fillet Weld 39
Duct Repair 41
Allowable Damage 101
Duct Cleaning and Passivation 101
Duct Inspection 111
Alkaline Cleaning 113
Nitric Acid Cleaning 113
Nitric Acid Passivation 113
Aluminum Alloy Acid Cleaning 114

51-77-03 Fusion Welding

Repair 201
Fusion Welding Procedure 201

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51-77-04 Hydrostatic Pressure Testing
Repair 201
Hydrostatic Pressure Test 201

51-77-05 Finish Requirements

Repair 201
Finish Requirements 201

51-77-06 Insulation
Repair 201
Insulation 201

51-77-07 Special Tools and Fixtures

Repair 201
Special Tools and Fixtures 201
Plug And Ball Mandrel Fabrication 238
Female V-Band Test Flange 238
Mating Test Flange For 20075-300FR Flange 238
Male V-Band Test Flange 239
Mating Test Flange For 20074 - 500FI Flange 239
Mating Test Flange For C-2330-400F Flange 239
Mating Test Flange For 20070-0250M Flange 240
Mating Test Flange For GF530A-M300A Flange 240
Mating Test Flange For 20060-300N Flange 241
Mating Test Flange For 20045-300F Flange 241
Mating Test Flange For MFB65202-250 Flange 241
Gammah P/N T2009 Nut — Test Plug 242
Gammah P/N F1042-250 Nut — Test Cap 242
Beaded End Test Plug 243

51-77-10 Corrosion Rework

Repair 201
Corrosion Rework 201
Patch Doubler Repair — Corrosion 223
Reinforcement Strap Repair — Corrosion 223
Reinforcement Strap Repair — Under Support Clamp 224
Reinforcement Strap Repair — Corrosion (Filler Installation) 224

51-77-11 Scratch and Abrasion Rework

Repair 201
Scratch and Abrasion Rework 201

51-77-12 Dent and Puncture Rework

Repair 201
Dent and Puncture Rework 201
Patch Doubler Repair — Dents and Punctures 202
Reinforcement Strap Repair — Dents and Punctures 203
Reinforcement Strap Repair — Dents and Punctures (Filler Installation) 206

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SUBJECT TITLE PAGE
Reinforcement Strap Repair — Under Support Clamp 208

51-77-13 Duct Reinforcement Repair

Repair 201
Duct Reinforcement Repair 201
Duct Reinforcement Welding Requirements 215
Duct Straight Section Reinforcement Patch Repair — General 215
Duct Curved Section Reinforcement Patch Repair — General 216
Duct Straight Section Reinforcement Repair — General 217
Duct Conic Section Reinforcement Repair — General 218

51-77-14 Duct Crack Repair

Repair 201
Duct Crack Repair 201
Crack Repair Welding Instructions 212
Single Crack Patch Doubler Repair 212
Reinforcement Patch Repair — Boss Reinforcement 212
Duct Attachment Doubler Installation 213
Reinforcement Strap Repair — Multiple Cracks 214
Reinforcement Patch / Strap Repair — Multiple Cracks 214
Reinforcement Patch / Strap Repair — Boss Reinforcement 215
Reinforcement Strap Repair — Cracks Under Support Clamp 215

51-77-15 Welded Attachment Crack Repair

Repair 201
Welded Attachment Crack Repair — General 201
Welded Attachment Crack — Repair 208
Welded Attachment Crack Repair — Doubler Installation 208

51-77-16 Gamah Couplings

Repair 201
Gammah Coupling End Flange Replacement 201
Gammah Couplings — Swaged Replacement 202
Gammah Couplings (Swaged) — Duct Section Replacement 205
Gammah Couplings — Butt Welded Replacement 207

51-77-17 Duct Section Replacement

Repair 201
Duct Section Replacement 201
Damaged Duct Section Replacement — Splice Sleeve 207
Damaged Duct Section Replacement 207
Damaged Beaded End Replacement 207
Damaged Beaded End Replacement — Splice Sleeve 208

51-77-18 V-Band Flange Replacement

Repair 201
V-Band Flange Replacement 201

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51-77-19 Duct Component Replacement
Repair 201
Duct Component Replacement 201
Damaged Component Section Replacement — Splice Sleeve 204
Damaged Component Section Replacement 205

51-77-20 Oversize Bushing Repair

Repair 201
Oversize Bushing Repair 201

51-77-21 Electrical Bonding Strap Repair

Repair 201
Electrical Bonding Strap Repair 201

51-77-22 Miscellaneous Repairs

Repair 201
Miscellaneous Repairs 201
Damage To Butt Weld 206

51-77-23 Threaded Boss / Port Repair

Repair 201
Threaded Boss / Port Repair 201
AS3077 Series Lockring Installation 215
AS3077 Series Lockring Removal 216
AS3078 Series Insert Removal Procedure 216

51-78-00 Repairs to Composites

Repair 201
Cuts, Scratches, Pits, Erosion of Outer Fiberglass Ply 201
Missing or Torn Outer Fiberglass Ply — Less Than 1.00 Inch in Length or
Diameter 202
Missing or Torn Outer Fiberglass Ply — Larger Than 1.00 Inch in Length
or Diameter 203
Internal Delamination Around Fastener Hole 204
External Delaminations With No Missing Plies 207
Impact Damage Resulting in External Delaminations on the Edge of Part
With Missing Plies 209
Internal Delamination Not Open to an Edge 212
Internal Delamination Open to an Edge — Injected from Part Edge 214
Internal Delamination Open to Part Edge — Pressure Injection 217
Small Indent / Gouge Less Than 0.25 Inch in Diameter That Does Not
Penetrate Skin 220
Small Puncture Less Than 0.25 Inch Diameter That Penetrates Skin
(Using Fastener Plug) 222
Small Puncture Less Than 0.25 Inch in Diameter That Penetrates Skin
(Using Adhesive Plug) 223
Deep Countersink 226
Elongated / Oversize Drilled Holes With Edge Margin 227

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Torn or Missing Conductive Wire Mesh 230

51-78-10 Composite Repair Techniques

General 1
Composite Components 1
Repair 201
Vacuum Injection of Liquid Repair Adhesive 201
Using Vacuum to Assist Pressure Injection 204
Water Removal From Composite Surfaces 204
Using a Router to Remove Damaged Skin 207
Using a Hole Saw to Remove Damaged Skin 207
Air Flow Test For Verifying an Adhesive Flow Path 209
Saturating Dry Repair Cloth With Repair Adhesive 210
Pressure Application Methods Using Clamps, Weights, and Vacuum Bag 213
Vacuum Bag Installation Working Upside Down or on a Side 215
Cold Weather Curing Operations 215

51-79-00 Repairs to Aluminum Honeycomb

Repair 201
Scratches, Nicks and Dings on Face Sheets of Aluminum Sandwich
Assembly 201
Minor Skin Dents and Depressions in Aluminum Sandwich Assembly 202
Small Puncture on External or Internal Sandwich Assemblies 205
Voids / Unbond Around Fastener Holes on Bonded Metal Panels 207
Skin Puncture Through Both Skins of a Sandwich Assembly 212
Skin Puncture on Both Skins of a Sandwich Assembly 215
Skin Puncture or Crack Through One Skin Only With Core Damage Depth
Being 20% of Depth or Less 221
Unbond Between Skin and Core on One Side Only — Pressure Injection
Method 224
Unbond Between Skin and Core on One Side Only — Vacuum Injection
Method 226
Voids / Unbond Along a Foam Fill Joint 228
Depression in Aluminum Sandwich Assembly with a Diameter Less Than
1.5 Inch — Minor Core Damage 230
Spinning Insert with Access for Removal 232
Skin Crack / Puncture Around Inserts — Honeycomb Board 233
Impact Damage on Extreme Trailing Edge (Dents or Fracture) — External
Surface Patch 236

51-79-10 Aluminum Repair Techniques

General 1
Metal Honeycomb and Metal to Metal Bonded Assemblies 1
Repair 201
Vacuum Injection of Liquid Repair Adhesives 201
Using Vacuum to Assist Pressure Injection 204
Water Removal From Sandwich Assemblies with Known Water Entrapment
or with a Skin Puncture 205

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Removal of a Single Skin 209
Removing and Installing Replacement Core 210
Removal of Two Discrepant Skins and Core 211
Air Flow Test for Verifying an Adhesive Flow Path 213
Pressure Application Examples Using Clamps, Dead Weights and Vacuum
Bag 215
Vacuum Bag Installation Working Upside Down or on a Side 217
Cold Weather Curing Operations 217
Methods for Removing Paint and Primer From Aluminum Surface 217
Cleaning Aluminum for Bonding Using Pasa Jell 105 Acid Paste 218
Recommended Methods for Removing Inserts 219
Construction of Peel Process Control Panel 221
Fly Cutting Honeycomb Core 223

51-80-00 Electrical Bonding

General 1
Bonding Safety and Precautions 1
Repair 201
Electrical Bonding Requirements 201

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