Vai R1854e

VENTURA AEROSPACE
MAINTENANCE & INSPECTION REQUIREMENTS 727-100 & -200 9G RIGID BARRIER INSTALLATION
VENTURA AEROSPACE
9G CARGO BARRIER INSTALLATION
BOEING 727-100/200
MAINTENANCE & INSPECTION REQUIREMENTS

REPORT NO. VAI-1854 REV E
THE DATA CONTAINED IN THIS DOCUMENT IS VENTURA AEROSPACE, INC (VAI) PROPRIETARY DATA AND CAN NOT BE DIVULGED, COPIED OR OTHERWISE USED IN ANY MANNER WITHOUT THE EXPRESS WRITTEN PERMISSION OF VAI. THIS DATA IS NOT TO BE
DIVULGED BY A FREEDOM OF INFORMATION ACT (FOIA) REQUEST. THIS DATA MEETS THE REQUIREMENTS OF FOIA EXEMPTION 4 BECAUSE IT CONTAINS COMPANY PROPRIETARY DATA THAT HAS ECONOMIC VALUE TO VAI.
Ventura Aerospace, P.O. Box 2968 Thousand Oaks, CA 91358, http://www.VenturaAerospace.com, engineering@VenturaAerospace.com
VENTURA AEROSPACE
TABLE OF CONTENTS
REVISIONS & ADDITIONS .................................................................................................................................................. i

TABLE OF CONTENTS ........................................................................................................................................................ ii
REFERENCES ........................................................................................................................................................................ ii
1.0 INTRODUCTION ................................................................................................................................................... 1
2.0 AIRCRAFT MODIFICATION DESCRIPTION ................................................................................................. 2
3.0 INSPECTION REQUIREMENTS ........................................................................................................................ 3
4.0 SUPPLEMENTAL STRUCTURAL INSPECTION REQUIREMENTS .......................................................... 4
4.1 Inspection Instructions Fuselage Skin and External Doubler ............................................................................... 4
4.2 Inspection Instructions, Fuselage Stringers .......................................................................................................... 5
5.0 REPAIRS AND MAINTENANCE REQUIREMENTS....................................................................................... 6
5.1 Repairs.................................................................................................................................................................. 6
5.2 Maintenance ......................................................................................................................................................... 6
6.0 PERMISSIBLE ATTACHMENTS TO THE BARRIER .................................................................................... 7
REFERENCES
1. Federal Aviation Regulations, CAR 4b, 1953 - Airworthiness Standards: Transport Category
Airplanes, Including Amendments 4b-1 thru 4b-11.
2. Type Certificate Data Sheet, A3WE, Rev 17.
3. Boeing Structural Repair Manual (SRM) D6-4062
4. Master Drawing List 2919 Rev F or later approved revision
5. Advisory Circular (AC) 43.13
6. ATS Report No. 1855 Supplemental Structural Inspection Requirements
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VENTURA AEROSPACE
1.0 INTRODUCTION
This manual is in support of the modification to Boeing 727-200 aircraft modified by STC
ST00848LA and Ventura Aerospace (VAI) Master Drawing List No. 2919 Rev F or later approved
revision. This manual is intended to provide supplemental inspection and maintenance
requirements for the continued airworthiness of the 9g crash barrier only.
For all maintenance and inspection requirements other than the 9g barrier installation refer to the
standard aircraft maintenance and inspection manuals. The 9g barrier must be maintained in an
airworthy condition to ensure continued airworthiness and reliable operation.
The 9g Barrier is intended to restrain the entire cargo compartment load in the event of a 9g forward
crash load. The barrier is also a smoke barrier to prevent smoke migration from the cargo
compartment to the cockpit.
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VENTURA AEROSPACE
2.0 AIRCRAFT MODIFICATION DESCRIPTION
2.1 The 9g crash barrier is installed to prevent cargo from impacting the cockpit during an
emergency landing. A door is provided on the left-hand side of the barrier for access into
the aft cabin (cargo compartment). This door must seal off the cargo compartment when
closed to prevent smoke from moving forward into the cockpit area in the event of a fire.
2.2 The barrier attaches to the aircraft fuselage structure around the perimeter with flexible
attachments. The door hinges aft for access through the barrier. The door also acts as an
emergency rapid decompression panel in the event of a rapid loss of pressurization.
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VENTURA AEROSPACE
3.0 INSPECTION REQUIREMENTS
The following list of inspections is a supplement to the FAA approved maintenance plan. These
inspections are for the unique features of the 9g barrier only. These inspection requirements should be
incorporated into the FAA approved aircraft maintenance program
3.1 250 Flight hour inspection requirements (inspection intervals not to exceed 250 flight
hours)
3.1.1 Visually inspect the crash barrier for cracks, loose or missing fasteners, proper fit
and condition of the barrier door. The door seal must also be inspected to verify that
the door is sealed in the closed position.
3.1.2 For aircraft with sliding doors, inspect door for smooth operation. Clean tracks as
required. Adjust door guides and pin brackets for proper door sealing.
3.2 3,000 hour inspection requirements
3.2.1 After removal of the cargo liner around the crash barrier, visually inspect The
bulkhead attachment and adjacent fuselage structure for cracks, loose fasteners,
wrinkling, etc.
3.2.2 Particular attention must be paid to the fasteners between the barrier flexures and the
fuselage stringers. Visually inspect for cracks in the stringers. Reinstall removed
components after inspection and any required repairs.
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VENTURA AEROSPACE
4.0 SUPPLEMENTAL STRUCTURAL INSPECTION REQUIREMENTS
The following inspection requirements are in addition to the inspection requirements defined in
Boeing CPCP and SSID documents.
No. Location of Detail Inspection Action Figure
1 Skin, external skin doubler & internal skin High Frequency Eddy Current
near the beam fitting at sta. 335 to 355, (HFEC) inspection at regular 4.1
upper cabin skin. intervals of 10,000 flight or
less.
Note: Inspection requires removal of IAW Boeing 727 NDT Manual
external doubler D6-48875 part 6, 51-00-00
2 Stringers at Barrier Flexure fitting High Frequency Eddy Current

attachment to stringers between Sta. 344 (HFEC) inspection at regular 4.2
and 360 stringers S-4L to S-16R. intervals of 10,000 flight or
less.
Note: Inspection requires removal of IAW Boeing 727 NDT Manual
the barrier flexure fitting D6-48875 part 6, 51-00-00
4.1 Inspection Instructions Fuselage Skin and External Doubler
Using a High Frequency Eddy Current (HFEC) probe, inspect the skin/doubler for typical
cracks as shown, from outside the aircraft. From inside the aircraft, inspect the fuselage skin
and beam fitting.
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VENTURA AEROSPACE
4.2 Inspection Instructions, Fuselage Stringers
Using a High frequency Eddy Current (HFEC) probe, inspect the fuselage stringers between
station 344 and 360 at stringer locations S-4L through S-16R for typical cracks as shown, from
the inside of the aircraft. (requires removal of cargo liner).
Figure 4.2
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VENTURA AEROSPACE
5.0 REPAIRS AND MAINTENANCE REQUIREMENTS
5.1 Repairs
5.1.1 Repairs of structural discrepancies should be accomplished in accordance FAA approved

data only. If there is a repair scheme provided by the Boeing SRM and it does not conflict
with the VAI modifications it may be used. Where no applicable repair scheme is found,
or it is unclear if a conflict exists, the following procedure must be followed.
5.1.2 Replace loose, missing or broken fasteners with like kind. Next oversize fastener may be
used to maintain fit.
5.1.3 Repair of cracked or otherwise damaged structure must be performed in accordance with a
specifically designed and FAA approved repair scheme. Consult Ventura Aerospace
(VAI) or other FAA approval authority for guidance and FAA approval of repairs.
5.1.4 Damage to the barrier face sheet or door may be repaired by application of a local doubler,
contact VAI for instructions and FAA approval.
NOTE: It is always permissible to replace damaged parts in their entirety as long as the
replacement part meets all of the approved data requirements.
5.2 Maintenance
5.2.1 The 9g crash barrier door must be maintained so that it seals against the barrier. The door
seal must be maintained to ensure a good seal. Replacement seal must be of the same
material as the original approved material.
5.2.2 The rubber pad at the bottom of the aft face of the barrier is intended to absorb pallet
impacts during normal pallet loading. Replace torn or missing rubber pad as necessary.
5.2.3 Any areas of the barrier that have been bared by wear, scratch or impact must be touched
up in accordance with Mil-C-5541 Class 1A and Mil-P-23377, type I, class 1 or 2
applied IAW Mil-T-704, Type A-1
5.2.4 The barrier door seal must be maintained in good working order to maintain the smoke
seal. If the seal becomes damaged it must be repaired or replaced. Repairs can be made
by splicing in new sections of seal and joining the ends with RTV adhesive.
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VENTURA AEROSPACE
6.0 PERMISSIBLE ATTACHMENTS TO THE BARRIER
6.1 All installations must be FAA approved.
6.2 A maximum of 50 pounds may be attached to the forward face of the 9g barrier without
reducing the main deck cargo load limit. If more than 50 pounds is attached to the barrier the
60,000 cargo limit must be reduced on a one for one pound basis and the attachment must be
approved by Ventura Aerospace.
6.3 All attachments to the barrier for equipment must be through bolts using 3/16 or ¼ inch
diameter fasteners. No bushing around the bolt is required nor are large area washers.
Maximum fastener torque is 40 in-lbs. Fasteners must be at least 1.0 inch spacing and no more
that 4 fasteners may be installed within a 4 square inch area.
6.4 Acceptable areas for installation of equipment are as follows:

a) Within 30 inches of the bottom of the barrier,
b) Within 30 inches of the top of the barrier.
c) No fasteners are permitted within 10 inches vertically of the horizontal barrier panel
skin splice line.
d) No attachment is permitted to the barrier door.
6.5 All installations must be structurally analyzed and FAA approved (8110-3 is acceptable).
6.6 A lavatory partition may be attached to the barrier using blind fasteners such as Cherry Max
rivets. Maximum fastener diameter is 3/16 inch. Minimum fastener spacing is 4.0 inches. No
fasteners are permitted within 10 inches of the barrier panel splice line.
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VENTURA AEROSPACE

MAINTENANCE & INSPECTION REQUIREMENTS

REVISIONS & ADDITIONS .................................................................................................................................................. i

2. Type Certificate Data Sheet, A3WE, Rev 17.

3. Boeing Structural Repair Manual (SRM) D6-4062

4. Master Drawing List 2919 Rev F or later approved revision

5. Advisory Circular (AC) 43.13

6. ATS Report No. 1855 Supplemental Structural Inspection Requirements

2.0 AIRCRAFT MODIFICATION DESCRIPTION

3.0 INSPECTION REQUIREMENTS

3.2 3,000 hour inspection requirements

4.0 SUPPLEMENTAL STRUCTURAL INSPECTION REQUIREMENTS

No. Location of Detail Inspection Action Figure

2 Stringers at Barrier Flexure fitting High Frequency Eddy Current

4.1 Inspection Instructions Fuselage Skin and External Doubler

4.2 Inspection Instructions, Fuselage Stringers

5.0 REPAIRS AND MAINTENANCE REQUIREMENTS

5.1.1 Repairs of structural discrepancies should be accomplished in accordance FAA approved

6.0 PERMISSIBLE ATTACHMENTS TO THE BARRIER

6.1 All installations must be FAA approved.

6.4 Acceptable areas for installation of equipment are as follows:

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