TECHNICAL BULLETIN NO.

212-86-92

DATE
Bell Helicopter DATE 2-12-86
Division of Textron Inc

REV. Post Office Box 482 · Fort Worth. Texas 76101 PAGE NO. 1 of 11

MODEL AFFECTED: 212

SUBJECT: FIN SPAR CAP P/N 212-030-447-101
INSTALLATION OF

HELICOPTERS AFFECTED: All helicopters that have tailbooms

P/N 212-030-100-(All) installed.
COMPLIANCE: Whenever events require replacement
of Spar Cap P/N 212-030-447-001

DESCRIPTION:

Two fatigue crack/breaks have occurred in spar cap P/N

212-030-447-001. These cracks originated from top c'sunk rivet
hole in spar to canted bulkhead attach fasteners. Two fatigue
cracks have occurred in the vertical leg of spar cap at the top
rivet hole for hinge that secure drive shaft cover. Three spar
caps have been found with exfoliation corrosion.
Spar cap P/N 212-030-447-101 has been created to resolve these
problems. This spar incorporates a cres steel reinforcement
and special heat treat processing. The spar will be installed
using hi-lok pin in place of c'sunk rivet. This bulletin
provides the instructions for the installation of this spar
cap.
FAA APPROVAL:

The engineering changes of this bulletin are FAA approved.

MANPOWER:

It is estimated approximately 50 manhours will be required to

accomplish this bulletin. Manhours are based on "hands-on"
time and may vary with personnel and facilities available to
operator.

MATERIAL:

The following materials are available through normal authorized

Bell Helicopter Textron supply outlets. Fasteners may be
procured locally.
Part Number Nomenclature Quantity
212-030-447-101 Reinforced Spar Cap 1
412-030-117-107 Doubler 1
412-030-117-109 Doubler 1
412-030-118-101 Support 1
412-030-118-103 Filler (may not be required) 1
AN APPROPRIATE ENTRY SHOULD BE MADE IN THE AIRCRAFT LOG BOOK UPON ACCOMPLISHMENT
IF OWNERSHIP OF AIRCRAFT HAS CHANGED PLEASE FORWARD TO NEW OWNER
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Part Number Nomenclature uantitv

209-031-863-001 Shim 2
100-048-6-6 Hi-lok Pin 2
100-048-6-8 Hi-lok Pin 1
100-048-5-5 Hi-lok Pin 5
100-048-5-7 Hi-lok Pin 1
30-015-6 Collar 4
30-015-5 Collar 6
HL64PB6-9 Hi-lok Pin 3
HL64PB6-8 Hi-lok Pin 4
HL64PB6-6 Hi-lok Pin 1
HL93-6 Collar 14
HL220-8-13 Hi-lok Pin 2
HL220-8-12 Hi-lok Pin 2
AN960JD416 Washer 4
MS21042L4 Nut 4
110-175-6-13 Rivet 3
110-175-6-12 Rivet 5
110-175-6-11 Rivet 2
110-175-6-10 Rivet 1
110-175-5-10 Rivet 1
110-175-5-9 Rivet 4
110-175-5-8 Rivet 3
MS20470AD5-12 Rivet 1
MS20470AD5-11 Rivet 10
MS20470AD5-10 Rivet 16
MS20470AD5-9 Rivet 9
MS20470AD5-8 Rivet 8
MS20470AD5-7 Rivet 24
MS20470AD5-6.5 Rivet 1
MS20470AD4-9.5 Rivet 12
MS20470AD4-9 Rivet 11
MS20470AD4-8 Rivet 11
MS20470AD4-7 Rivet 10
MS20470AD4-6 Rivet 32
MS20426AD6-4 Rivet 1
MS20426AD4-10 Rivet 4
MS20426AD4-4 Rivet 17
MS20426AD3-8 Rivet 8
MS20426AD3-4 Rivet 40
M7885/6-5-09 Blind Rivet 4
M7885/6-5-08 Blind Rivet 4
M7885/6-5-05 Blind Rivet 52
M7885/6-5-04 Blind Rivet 33
M7885/6-5-03 Blind Rivet 33
M7885/6-4-04 Blind Rivet 14
M7885/6-4-03 Blind Rivet 58
M7885/6-4-02 Blind Rivet 156
299-947-100 TY2 CL2 50gm Adhesive 2
299-947-107 TY3 CL7 3 oz. Sealant 1
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The following tools must also be ordered in addition to the

parts listed.

APT 12850 .1895 Reamer with .1820 Pilot 1

APT 12851 .2026 Reamer with .1985 Pilot 1
APT 12852 .2807 Reamer with .2770 Pilot 1
WEIGHT AND BALANCE:

Weight (Lbs.) Moment Arm (Inches) Moment (Inch-Pounds)

0.91 449.9 407.4
ELECTRICAL LOAD DATA:

Not affected.

SPECIAL TOOLS:

.1895 inch Reamer with .1820 Pilot 3.5 inch long with square
shank for "T" (Tap) Handle (BHTI Tool P/N APT 12850)
.2026 inch Reamer with .1985 Pilot 3.5 inch long with square
shank for "T" Handle (BHTI Tool P/N APT 12851)
.2807 inch Reamer with .2770 Pilot 3.5 inch long with square
shank for "T" Handle (BHTI Tool P/N APT 12852)
Tail Boom Driveshaft Alignment Tools

REFERENCES:

Model 212 Maintenance Manual Sections 66-82 and 66-83

PUBLICATIONS AFFECTED:
None

ACCOMPLISHMENT INSTRUCTIONS:

1. Remove tailboom from helicopter and support with stand at

forward end and strap cradle under Boom Station 185.

2. Remove drive shaft sections, 42 degree gearbox, 90 degree

gearbox, aft section and fin drive shaft covers, anti
torque control tubes in fin and center section of tailboom,
control bellcrank support fitting on aft face of canted
bulkhead and tail skid. Store for future use.

PROCEDURE NOTE
Caution must be exercised to insure parts
are not damaged during fastener removal.
The following procedure should be
followed.
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a. Drill off head of rivet.

b. Punch out body. Back up thin parts
to prevent deformation.
c. Remove any burrs.
Parts will be required for reassembly of
fin-splice assembly. Any parts that are
damaged must be replaced.

3. Remove clips, P/N 212-030-099-091 and -093. See Figure 2.

Remove support, P/N 212-030-446-001, filler, P/N 212-030-

099-085, and filler, P/N 212-030-100-035.

5. Remove rivets aft of tailboom station 185 that secure drive

shaft cover angles, P/N 212-030-137-101 and -103 to top
surface of fin splice.

6. Remove doubler, P/N 212-030-099-089, and skin, P/N 212-030-

099-087, by removing fasteners securing parts to tailboom.
Slide skin and doubler assy. aft up face of spar until
clear of bulkhead and tailboom skin. Slide assembly
forward then slide parts from under angles, P/N
212-030-137-101 and -103. Clean proseal from parts using
plastic scraper and Scotch Brite and M.E.K.
NOTE

Deflect angles to provide access to 8

MS20426AD3 rivets that attach 42 degree
gearbox attach nut plates to supports and
skins. Save nutplates.

7. Remove rivet attaching stiffener (tie angle) P/N

205-030-801-007 to left support, P/N 205-030-832-004.

8. Remove nutplates used for securing two left and two right
anti-torque support fitting attach bolts. Ream holes to
.2510/.2515. Remove hi-lok's or rivets from between .251
holes (one each side).

9. Remove rivets securing spar cap, P/N 212-030-447-001, to

canted bulkhead assy., P/N 205-030-817-037, and spar
assembly, P/N 212-030-121.

10. Remove eight rivets securing left 42 degree gearbox

support, P/N 205-030-832-004 from spar cap, P/N
212-030-447-001. Save support.

11. Fabricate spar cap drill templet.

a. Rivet .125 x 20 x 20 inch aluminum angle 90.0 inches

long to .188 x 4.0 x 90.0 inch aluminum strap to form a
"T" shape.
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b. Two inches from one end, rivet a .125 inch thick stop to
strap.
c. Place top end of spar cap on strap against stop with
other leg against angle. Clamp in place.

d. Using #10 drill for 3/16 fasteners, #20 drill for 5/32
fasteners and #30 drill for 1/8 fasteners, back drill
templet to match spar cap.

e. At location of two .250 inch holes in lower end of cap

use #E drill to back drill templet.

NOTE

Extreme care must be used to ensure no

side load or twist is applied to drill
while back drilling templet.

f. Deburr holes.

12. Clamp new modified spar P/N 212-030-447-101 cap in place in

templet.

NOTE

Spar cap must be in templet in same

position original cap was when drilling
templet.

13. Drill new spar cap following procedure and safeguards used
in fabricating templet. Deburr all holes.

14. Secure doubler, P/N 412-030-117-109, adhesive side up to

drill templet strap. Align two .250 inch holes in doubler
with two #E drill holes in strap and the long end of
doubler to lower end of templet. Drill doubler to match
templet. Deburr holes.
15. Cleco support P/N 205-031-832-004 to outboard side of spar
cap, P/N 212-030-447-101. With heads of rivets on inboard
side, rivet support to cap with 110-175-6-13 (3 required)
and 110-175-6-12 (5 required).

16. Place new spar cap in fin and cleco in place for full
length.

17. Through holes in fin and 90 degree gearbox support fitting,

ream hi-lok holes to .1635/.1640 in new spar cap. Install
100-048-5-( ) hi-lok pin in each hole as reamed and secure
with 30-015-5 collar.
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NOTE

Increase hole size with No. 10 Drill and ream

to .1895 to .1905 and use 100-048-6-( ) pin
and 30-015-6 collar if good holes are not
obtained when reamed to .1635/.1640.
18. Install MS20470AD5 rivets through leg against web and
MS20470AD4 rivets through leg against skin, grip lengths as
required to attach spar from top of spar to canted
bulkhead.

NOTE
With proper size and shape bucking bars,
rivets can be installed by inserting bucking
bar through lightening holes in spar web. If
necessary to accomplish rivet installation in
spar, blind rivets securing fin left skin may
be removed as required to gain access to aft
face of spar to buck rivets. Do not remove
rivets securing skin to tip rib or aft spar.
19. Install 110-175-6-10 rivet at first hole below lower end of
angle assembly and two 110-175-6-11 rivets through next two
holes.
20. Install M7885/6-5-4 rivets through three lowest holes in
spar/bulkhead assembly.

21. Install 110-175-5-8 or -9 rivets in seven (7) remaining

spar/bulkhead attachments.
22. Cleco doubler, P/N 412-030-117-109, adhesive side up to
back face of canted bulkhead and spar assembly. Mark
doubler location on bulkhead.

23. With number 8 drill, increase size of seven (7) #10

(HL64PB6 hi-lok) holes to 0.1990 inch. With piloted .1016
reamer and "T" (Tap) handle ream holes to .2026 to .2031.
Deburr all holes.

NOTE
All holes must be hand reamed using "T"
(Tap) handle. Temporarily insert hi-lok
pins through holes as reamed to insure
holes in doubler match fin spar and canted
bulkhead assembly.
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24. Remove peel ply from doubler, P/N 412-030-117-109. Remove

finish from faying surface of canted bulkhead. Prepare
surfaces for bonding. Bond doubler in place with adhesive,
P/N 299-947-100 TY2 CL2. Install two each vasoline coated
AN4-6 or -7 bolts, AN960-416 washers and AN315-4 nuts.
Torque to 70 to 75 inch-pounds.

25. Install HL64PB6-9 hi-lok pin (head down) and HL93-6 collar
in hole between 1/4 inch bolt holes.

26. Install, head up, HL64PB6-9 hi-lok pin using HL93-6 collar
through hole immediately above top .250 inch hole in spar
cap.

27. Install one HL64PB6-9 and four HL64PB6-8 hi-lok pins using
five HL93-6 collars (starting at hole below AN4-7 bolt and
working to lower end) through angle assembly spar cap and
web, and canted bulkhead.

28. Retorque AN4-7 bolts to 70 to 75 inch-pounds. Remove

excess adhesive and allow adhesive to cure.

29. Remove two (2) each AN4-6 or 7 bolts, AN960-416 washers

and AN315-4 nuts, installed in step 24.

30. Remove hi-lok pin, P/N 100-048-6-6 from between .250 inch
holes on right spar cap. Secure doubler, P/N
412-030-117-107, adhesive side up to aft face of canted
bulkhead. Drill, ream to match hi-lok hole and deburr.
31. Install doubler, P/N 412-030-117-107, on aft face right
side of canted bulkhead, following procedure in step 24.
32. Install 100-048-6-6 hi-lok pin, head down, with 30-015-6
collar in hole from which it was removed. Remove excess
adhesive and allow adhesive to cure. Remove AN4-6 bolts.
33. Install control bellcrank and support fitting removed in
step 2, using original fasteners, AN4-12A bolts. Use
AN960-416 washer and AN315-4 nuts on bolts. Torque to
50-70 in-lbs.
34. Remove lower left side bolt just installed. Increase .250
inch hole to .261 inch with number "G" drill and then to
.277 inch with number "J" drill. Finally ream to
.2807/.2817 using piloted reamer and "T" (Tap) handle.
Deburr hole.
35. Install HL220-8-13 hi-lok pin head up using AN960JD416L
washer and MS21042L4 nut. Torque to 50 to 70 inch-pounds.
36. Repeat steps 34 and 35 with upper left side bolt.
T.B. 212-86-92
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37. Repeat steps 34, 35, and 36 except use HL220-8-12 hi-lok
pins on right two holes.

38. Align support,412-030-118-101,with forward face of support,

212-030-446-001, (removed in step 4) as shown in figure 2.
Using support,212-030-446-001,as drill guide and number 16
drill, drill six holes through 412-030-118-101 support and
increase hole diameter through 412-030-446-001 support to
.176/.180 inch. Increase diameter of all holes through
filler,P/N 212-030-099-087,and filler,P/N 212-030-100-035
to .176/.180 inch.
39. Cleco filler, P/N 212-030-099-085,to back face of support,
P/N 212-030-446-001, (parts removed in step 4). With ink
flow pen, mark support along left end of filler and extend
line around bend in support. Draw line along lower
tangency line of support from left edge to line drawn
above. Refer to Figure 2.
40. Drill .375 hole through upper left corner of support with
edges tangent to lines drawn above. Cut support along lines
to hole. Smooth edges and remove any burrs.
41. Align rivet hole in support (tie angle), P/N
205-030-801-007, and left 42 degree gearbox support, P/N
205-030-832-004. Clamp if necessary to maintain alignment.
Install MS20470AD5-6.5 rivet.

42. Install nutplates on 42 degree gearbox supports. C'sink

eight attaching rivet holes in top of support. Attach
nutplates removed in step 7 with MS20426AD3-8 rivets.

43. Prime any bare metal with MIL-P-23377 epoxy polyamide

primer.
44. Slip skin and doubler removed in step 6 under angles, P/N
212-030-137. Reverse removal procedure. Cleco skin in
place.

NOTE
The use of MS20470AD rivets is
recommended for the assembly of skins on
fin and tailboom at locations where
rivets can be bucked and rivet holes have
not been enlarged.
45. Locate modified support, P/N 212-030-446-001, support, P/N
412-030-118-101, fillers, P/N 212-030-099-087,
212-030-100-035, and P/N 412-030-118-103 if required in
place on skin and doubler and against face of spar as shown
in Figure 2, View A-A. Cleco in place.
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46. Install MS20470AD5 and MS20470AD4 rivets, proper grip

length in all locations where hole have not been enlarged
and access for bucking is available for remaining holes.
Skin and doubler will be attached using cherry max or
cherry bulb-lock rivets. Using Figure 2 as guide, verify
all number 4 rivet holes are .143 to .146 inch and number 5
rivet holes are .176 to .180 inch. A number 27 and number
16 drill, respectively, should be used to size any
undersized holes. Be certain all parts are pulled
together.

47. If side skin was opened to buck spar rivets, the following
rivets may be used. Cleco skin in place prior to starting
riveting.
M7885/6-4-2 for attaching skin to ribs and stiffeners.
MS20426AD3-4 rivets to secure nutplates around access
door openings.
MS20426AD4-4 rivets between nutplates.

48. Inject a 1/8 inch bead of MIL-S-8802 sealant under edge of

all unriveted skins. Lay a 1/8 inch bead of sealant along
skin, fin skin line and around edge of clip/skin faying
surface. Cleco clips, P/N 212-030-099-091 and -093 in
place. Be certain holes are in line.
49. Install fasteners as shown in Figure 2.

50. Using alignment procedure in 212 Maintenance Manual,

Section 66-82 and 66-83 determine thickness and install two
P/N 209-031-863-001 shims.

51. Prime modification area with MIL-P-23377 epoxy polyamide

primer and paint with Dupont Imron Enamel to match
helicopter.

52. Install parts removed in steps 2, following Maintenance

Manual instructions.

53. Enter spar cap replacement, including part numbers, in

aircraft log.

54. Recheck torque on bellcrank attachment nuts after 50 hours

of flight operations.
 T.B. 212-86-92
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212-030-137-103 212-030-446-001
ANGLE SUPPORT

212-030-099-085
FILLER

212-030-100-035
FILLER
M7885/6-5-8 RIVET

4 PLACES

-212-030-137-101 SUPPORT(TIEANGLE)
TRIMUNEFOR
DRIVESHAFTCOVERANGLE FLANGETO FIT IN 212-030-446-001
ANGLE ASSY
VIEW A-A

CLIP R.H.
212-030-099-093
212-030-099-091 /
CLIPL.H.

212-030-099-087

4 4
M7885/6- -
M7885/6.4-4 212-030-099-089 SKIN.
M7885/6-4-4 REMOVE AS AN ASSEMBLY
3
M7885/6-5-
5 -4
M7885/6-
M7885/6-5-5 SEEFIGURE
3 ASB412-13-1

FIGURE 1
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