STRUCTURAL REPAIR MANUAL

INVESTIGATION - CLEANUP AND AERODYNAMIC SMOOTHNESS

1. General
A. For a high aircraft performance it is necessary that the aircraft has an
aerodynamically clean shape and a smooth external surface. Damage not re-
paired, dents not filled and repairs which change the contour or roughÈ
ens the surface can reduce the performance.
B. The aerodynamic smoothness of the external surface is divided into three
tolerance areas. You can find these tolerance areas under the heading
'Degree of Smoothness'.
- Refer to Figure 2 and Figure 3 and Tables 1 thru 15
(1) Description of the tolerance areas (Refer to Figure 2 and 3):
(a) Area 'A': Surface areas with very good aerodynamic qualities and
requiring close tolerances.
(b) Area 'A1': Surface areas which are parts of area 'A'. They are
subject to further detailed improvements concerning fastener stanÈ
dards.
(c) Area 'B': Surface areas with tolerances usually larger than area
'A'.
(2) You must take precautions to protect the surface from damage when
you work on it. You must wear soft-soled shoes and cover the area
with rubber mats.
2. Aerodynamic Smoothness Requirements
A. Fuselage
(1) Refer to :
- Figure 1, Figure 2, Figure 4, Figure 5, Figure 6, Figure 7 and
Figure 8 and also to Tables 1, 5 and 6
for details of fuselage smoothness requirements.
NOTE: For aerodynamic requirements in the region of static ports,
angle of attack sensors, pitot probes and total air temperature
probes refer to Chapter 53-00-11, Page Block 101, in which
specific aerodynamic tolerances are included.
B. Belly Fairing
(1) Refer to :
- Figure 1, Figure 2, Figure 4, Figure 5, Figure 6, Figure 7 and
Figure 9 and also to Tables 1, 7 and 8.
for details of belly fairing smoothness requirements.

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C. Wing
(1) Refer to :
- Figure 1, Figure 3, Figure 4, Figure 5, Figure 6, Figure 10 and
Figure 11 and also to Tables 2, 3, 4, 9 and 10.
for details of wing smoothness requirements.
D. Stabilizers
(1) Refer to :
- Figure 1, Figure 4, Figure 5, Figure 6, Figure 7, Figure 11 and
Figure 12 and also to Tables 1, 11, 12 and 13.
for details of stabilizer smoothness requirements.
E. Pylon and nacelle
(1) Refer to :
- Figure 1, Figure 4, Figure 5, Figure 6, Figure 7 and Figure 13
and also to Tables 2, 3, 4, 14 and 15.
for details of pylon and nacelle smoothness requirements.
3. Aerodynamic Smoothness - Fasteners
A. All fasteners on external surfaces must be flush. This does not include
section 19-Tail Cone lower shell and end cover.
(1) Sign convention:
+ = protruding above surface
- = recessed below surface

RIVET TYPE DEGREE OF SMOOTHNESS

CRITICAL AREA NORMAL TOLERANCE PERMISSIBLE TOLERANCE
ON 10%
mm in. mm in.
COUNTERSUNK STABILIZER +0.10 to +0.004 to +0.15 to +0.006 to
SOLID RIVETS 0 0 0 0
A
FUSELAGE +0.15 to +0.006 to +0.20 to +0.008 to
0 0 0 0
STABILIZER +0.10 to +0.004 to
A 1 --- ---
0 0
+0.20 to +0.008 to +0.20 to +0.008 to
B
0 0 0 0

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RIVET TYPE DEGREE OF SMOOTHNESS

CRITICAL AREA NORMAL TOLERANCE PERMISSIBLE TOLERANCE
ON 10%
mm in. mm in.
COUNTERSUNK +0.13 to +0.005 to +0.20 to +0.008 to
BLIND RIVETS A -0.10 -0.004 -0.10 -0.004 <1>
AND BOLTS <1>
(FOR EXAMPLE
HI-LOK, TAPER- STABILIZER +0.13 to +0.005 to
A 1 -0.10 -0.004 --- ---
LOK, BOLTS,
LOCKBOLT
LOCKBOLT,
CHERRYMAX, +0.13 to +0.005 to +0.20 to +0.008 to
B -0.30 -0.012 -0.30 -0.012
COMPOSI-LOK)
Flushness of Fasteners - Fuselage, Stabilizer and Pylons
Table 1
<1> On pylon primary structure 0.3 mm (0.012 in.)
NOTE: On angled surfaces the 'Normal' tolerances apply at the lowest intersecÈ
tion (Refer to Figure 1).

RIVET TYPE DEGREE OF SMOOTHNESS

CRITICAL AREA NORMAL TOLERANCE PERMISSIBLE TOLERANCE
ON 10%
mm in. mm in.
COUNTERSUNK SOLÈ +0.08 to +0.003 to +0.12 to +0.005 to
A
ID RIVETS 0 0 0 0
+0.08 to +0.003 to
A 1 --- ---
0 0
+0.15 to +0.006 to +0.20 to +0.008 to
B
0 0 0 0
Flushness of Fasteners - Wing and Nacelle
Table 2
NOTE: On angled surfaces the 'Normal' tolerances apply at the lowest intersecÈ
tion (Refer to Figure 1)

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RIVET TYPE DEGREE OF SMOOTHNESS

CRITICAL AREA NORMAL TOLERANCE PERMISSIBLE TOLERANCE
ON 10%
mm in. mm in.
COUNTERSUNK +0.08 to +0.003 to +0.15 to +0.006 to
BLIND RIVETS AND A -0.08 -0.003 -0.08 -0.003
EXAMÈ
BOLTS (FOR EXAM
PLE HI-LOK, TAÈ +0.08 to +0.003 to
A 1 -0.08 -0.003 ---- ----
PER-LOK, LOCKÈ
BOLT BOLTS,
BOLT, BOLTS
CHERRYMAX, COMÈ +0.08 to +0.003 to +0.18 to +0.007 to
B -0.20 -0.008 -0.20 -0.008
POSI-LOK) <1>
Flushness of Fasteners - Wing and Nacelle
Table 3
<1> Applicable up to aircraft (MSN) 11.
NOTE: On angled surfaces the 'Normal' tolerances apply at the lowest intersecÈ
tion (Refer to Figure 1).
NOTE: The fastener flushness requirements for the pylon pickup fitting to wing
top skin bolting is +0.1 mm (0.004 in.) to -0.6 mm (0.024 in.).

RIVET TYPE DEGREE OF SMOOTHNESS

CRITICAL AREA NORMAL TOLERANCE PERMISSIBLE TOLERANCE
ON 5%
mm in. mm in.
COUNTERSUNK +0.05 to +0.002 to +0.13 to +0.005 to
BLIND RIVETS AND A -0.18 -0.007 -0.18 -0.007
EXAMÈ
BOLTS (FOR EXAM
PLE HI-LOK, TAÈ +0.05 to +0.002 to
A 1 -0.18 -0.007 ---- ----
PER-LOK, LOCKÈ
BOLT BOLTS,
BOLT, BOLTS
CHERRYMAX, COMÈ +0.05 to +0.002 to +0.13 to +0.005 to
B -0.18 -0.007 -0.18 -0.007
POSI-LOK) <1>
Flushness of Fasteners - Wing and Nacelle
Table 4
<1> Applicable to aircraft (MSN) 12 onward.
NOTE: On angled surfaces the 'Normal' tolerances apply at the lowest intersecÈ
tion (Refer to Figure 1).
NOTE: The fastener flushness requirements for the pylon pickup fitting to wing
top skin bolting is +0.1 mm (0.004 in.) to -0.6 mm (0.024 in.).

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Flushness of Fasteners / Special Washers

Figure 1

B. Angled surfaces
(1) On angled surfaces the 'Normal' tolerances apply at the lowest inter-
section (Refer to Figure 1).
C. Special Washers
(1) For the tolerances applicable in particular to washers under bolts on
composite surfaces refer to Figure 1.
4. Abbreviations
A. The following special abbreviations are used in this Chapter:
- IN LOF = in line of flight
- A LOF = across line of flight

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Aerodynamic Smoothness - Tolerance Areas

Figure 2

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Aerodynamic Smoothness - Tolerance Areas

Figure 3

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Definitions and Sign Conventions

Figure 4 (sheet 1)

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Definitions and Sign Conventions

Figure 4 (sheet 2)

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General Measures − Fixed Structure

Figure 5

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General Measures − Hinged Doors etc.

Figure 6

Aerodynamic Smoothness − Filling of Gaps

Figure 7

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Skin Waviness - Fuselage General Surface

Figure 8

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CRITICAL AREA DEGREE OF SMOOTHNESS

IN LOF (excluding seam joints) A LOF
POSITIVE STEP NEGATIVE STEP POSITIVE STEP NEGATIVE STEP
mm in. mm in. mm in. mm in.
AREA A +0.8 +0.031 -0.8 -0.031 +0.5 +0.020 -0.5 -0.020
AREA A (FOR
10% REÈ --- --- --- --- +0.7 +0.028 -0.7 -0.028
LAXATION)
AREA B +1.0 +0.039 -1.0 -0.039 +0.7 +0.028 -0.7 -0.028
Permissible Mismatch - Fuselage (Fixed Structure)
Table 5
NOTE: For definition and general measures refer to Figure 4 and Figure
5.
NOTE: All fixed structural gaps to be filled. Refer to Figure 7 for
filler smoothness tolerances.

CRITICAL AREA DEGREE OF SMOOTHNESS GAPS

IN LOF and A LOF IN LOF and A LOF
POSITIVE STEP NEGATIVE STEP MAX. MIN.
mm in. mm in. mm in. mm in.
AREA A +0.8 +0.031 -0.8 -0.031 3.0 0.118 1.0 0.039
AREA B +1.0 +0.039 -1.0 -0.039 5.0 0.197 1.0 0.039
Permissible Mismatch - Fuselage (Access Panels, surface installed Equipment,
Rapid Access Doors)
Table 6
NOTE: For definition and general measures refer to Figure 4 and Figure
6.

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Skin Waviness - Belly Fairing General Surfaces

Figure 9

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CRITICAL AREA DEGREE OF SMOOTHNESS

IN LOF A LOF
POSITIVE STEP NEGATIVE STEP POSITIVE STEP NEGATIVE STEP
mm in. mm in. mm in. mm in.
AREA A and B +1.5 +0.059 -1.5 -0.059 +1.0 +0.039 -1.0 -0.039
Permissible Mismatch/Gaps - Belly Fairing - Removable Parts (Access panels,
rapid access doors, surface installed Equipment)
Table 7
NOTE: For definition and general measures refer to Figure 4 and Figure
5.

CRITICAL AREA PERIPHERAL GAPS PERMISSABLE TOLERANCE ON 10%

OF LENGTH
IN LOF AND A LOF IN LOF AND A LOF
MAX. MIN. MAX. MIN.
mm in. mm in. mm in. mm in.
AREA A 3.0 0.118 1.0 0.039
AREA B 5.0 0.2 1.0 0.039 6.5 0.256 1.5 0.059
Permissible Mismatch/Gaps - Belly Fairing - Removable Parts (Access panels,
rapid access doors, surface installed Equipment)
Table 8
NOTE: For general surface smoothness requirements refer to Figure 8.

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Skin Waviness - Wing General Surfaces

Figure 10

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CRITICAL AREA DEGREE OF SMOOTHNESS

IN LOF A LOF
POSITIVE STEP NEGATIVE STEP POSITIVE STEP NEGATIVE STEP
mm in. mm in. mm in. mm in.
AREA A +0.6 +0.024 -0.6 -0.024 +0.3 +0.012 -0.3 -0.012
AREA B +1.0 +0.039 -1.0 -0.039 +0.5 +0.020 -0.5 -0.020
Permissible Mismatch - Wing (Fixed Structure)
Table 9
NOTE: For definition and general measures refer to Figure 4 and Figure
5.
NOTE: All fixed structural gaps to be filled. Refer to Figure 7 for
filler smoothness tolerances.

CRITICAL AREA DEGREE OF SMOOTHNESS

IN LOF A LOF
POSITIVE STEP NEGATIVE STEP POSITIVE STEP NEGATIVE STEP
mm in. mm in. mm in. mm in.
AREA A +0.6 +0.024 -0.6 -0.024 +0.3 +0.012 -0.3 -0.012
AREA B +1.0 +0.039 -1.0 -0.039 +0.8 +0.031 -0.8 -0.031
Permissible Mismatch/Gaps - Wing Access Panels and Surface installed Equipment
Table 10
NOTE: For definition and general measures refer to Figure 4 and Figure
5.

CRITICAL AREA PERIPHERAL GAPS

IN LOF and A LOF
MAX. MIN.
mm in. mm in.
AREA A 1.5 0.059 0.5 0.020
AREA B 3.0 0.118 1.0 0.039
Permissible Mismatch/Gaps - Wing Access Panels and
Surface installed Equipment

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Aerodynamic Smoothness - Stabilizers General Surfaces

Figure 11

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Aerodynamic Smoothness - Stabilizers

Figure 12

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CRITICAL AREA DEGREE OF SMOOTHNESS

IN LOF A LOF
POSITIVE STEP NEGATIVE STEP POSITIVE STEP NEGATIVE STEP
mm in. mm in. mm in. mm in.
AREA A +0.6 +0.024 -0.6 -0.024 +0.4 +0.016 -0.4 -0.016
AREA B +1.0 +0.039 -1.0 -0.039 +0.8 +0.031 -0.8 -0.031
Permissible Mismatch - Stabilizers (Fixed Structure)
Table 11
NOTE: For definition and general measures refer to Figure 4 and Figure
5.
NOTE: All fixed structural gaps to be filled. Refer to Figure 7 for
filler smoothness tolerances.

CRITICAL AREA DEGREE OF SMOOTHNESS

IN LOF A LOF
POSITIVE STEP NEGATIVE STEP POSITIVE STEP NEGATIVE STEP
mm in. mm in. mm in. mm in.
AREA A +0.8 +0.031 -0.8 -0.031 +0.5 +0.020 -0.5 -0.020
AREA B +1.0 +0.039 -1.0 -0.039 +0.8 +0.031 -0.8 -0.031
Permissible Mismatch - Stabilizer Access Panel Edges
Table 12
NOTE: For definition and general measures refer to Figure 4 and Figure
5.

CRITICAL AREA PERIPHERAL GAPS

IN LOF and A LOF
MAX. MIN.
mm in. mm in.
AREA A 1.5 0.059 0.5 0.020
AREA B 3.0 0.118 1.0 0.039
Permissible Gaps - Stabilizer Access Panel Edges
Table 13

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Aerodynamic Smoothness - Pylon and Nacelle

Figure 13

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CRITICAL AREA DEGREE OF SMOOTHNESS

IN LOF A LOF
POSITIVE STEP NEGATIVE STEP POSITIVE STEP NEGATIVE STEP
mm in. mm in. mm in. mm in.
AREA A +0.6 +0.024 -0.6 -0.024 +0.25 +0.010 -0.40 -0.016
AREA B +1.0 +0.039 -2.0 -0.079 +1.0 +0.039 -2.0 -0.079
Permissible Mismatch - Nacelle and Pylon (Fixed Structure)
Table 14
NOTE: For definition and general measures refer to Figure 4 and Figure
5.
NOTE: All fixed structural gaps to be filled. Refer to Figure 7 for
filler smoothness tolerances.

CRITICAL AREA GAPS (AT BUTT JOINTS)

IN LOF (MAX.) A LOF (MAX.)
mm in. mm in.
AREA A 1.0 0.039 0.5 0.019
AREA B 1.5 0.059 1.0 0.039
Permissible Mismatch - Nacelle and Pylon (Fixed Structure)
Table 15
NOTE: For definition and general measures refer to Figure 4 and Figure
5.
NOTE: All fixed structural gaps to be filled. Refer to Figure 7 for
filler smoothness tolerances.

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