Aviation Mechanic Practical Test Guide

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A & P MECHANIC

CTICAL


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AVIATION MECHANICPRACTICAL TEST GUIDE

ACME PUBLICATIONSFORT WORTH, TEXASCopyright 19a91


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FOREWORDThank you for purchasing this ACME publication. We have sought to make it the finesttest preparation material available. The Mechanic Practical Test is one of the many AcmeBlue Books published specifically to help persons obtain FAA certificates and ratings.These books cover the entire range of pilot and mechanic certificates. Of special interestto mechanics is ACME's Mechanic Test Guide series, which are prepared for the General,Airframe, and Powerplant written test. Other ACME books can be found on the specialorder sheet inserted in the back of this book. New books are being added regularly, soif you don't find what you want, please call for updated information.

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WRITTEN EXAMS

Three written exams must be passed to obtain an FAA Mechanic Certificate with both the Airframe andPowerplant ratings, These are the General Mechanic, Airframe Mechanic, and Powerplant Mechanic writtenexams.To obtain an FAA Mechanic Certificate with only one rating (either the Airframe or Powerplant), only twowritten exams must be passed. These are the General Mechanic and either the Airframe or Powerplantwritten exams. Once you have passed the General Mechanic exam and received one rating, you do nothave to retake the General exam when testing for the other mechanic rating.The General Mechanic written exam has one section consisting of 50 multiple choice-type questions. TheAirframe and Powerplant written exams each have two sections as follows: Airframe Structures (25questions) and Airframe Systems and Components (75 question); Powerplant Theory and Maintenance (25questions) and Powerplant Systems and Components (75 question). If you fail any section of the exams,you must retake only the section you failed. 70% Is the passing grade for each section.The FAA has designated certain persons to administer written exams. Your answer sheet must be mailedto the FAA In Oklahoma City, Oklahoma for grading and recording, You can normally expect to receive thetest results in one to two weeks.

DESIGNATED EXAMINERS

The practical examination for a mechanic certificate may be obtained from either the FAA maintenanceInspector at an FAA District Office, or from an Airframe and Powerplant Mechanic who has been designatedby the FAA as a mechanic examiner. Also, this designated examiner probably holds an Inspection Authorization (IA). The great majority of mechanic applicants take their practical examination with a designatedexaminer.When you have your written examination grade slips shOWing a passing grade for each section, make anappointment with a designated Mechanic Examiner to take the practical examinations. YOll do not have tosupply any tools, just your written examination grade slips, the appropriate fee, and the FAA Form 8610-2.The projects and questions that you will be given on the practical exams will depend on the examiner, whatequipment he has, and what he believes to be Important. The various test subjects are grouped as in thefollowing. Each group consists of both practical job projects and oral questions. Genera!!y, the practicalwill consist of projects from about 10% to 50% of the subjects listed. Six hours Is the official time for theoral and practical exams.

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GENERAL TEST SUBJECTS

1. Basic electricity 7. Cleaning and corrosion control2. Aircraft drawings 8. Mathematics3. Weight and balance 9. Maintenance forms and records4. Fluid lines and fittings 10. Physics5. Materials and processes 11. Maintenance publications6. Ground operation and servicing 12. Mechanic privileges and limitations

AIRFRAME TEST SUBJECTSSTRUCTURES

1. Wood structures 5. Welding2. Aircraft covering 6. Assembly and rigging3. Aircraft finishes 7. Airframe inspection4. Sheet metal structures

SYSTEMS AND COMPONENTS

1. Landing gear systems 6. Fuel systems2. Hydraulic and pneumatic power systems 7. Electrical systems3. Cabin atmosphere control systems 8. Position and warning systems4. Instrument systems 9. Ice and rain control systems5. Communication and navigation systems 10. Fire protection systems.

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POWERPLANT TEST SUBJECTS

THEORY AND MAINTENANCE

1, Reciprocating engines maintenance and overhaul 3, Engine inspection2, Turbine engines maintenance and overhaul

SYSTEMS AND COMPONENTS

1, Engine Instrument systems 7, Engine fuel systems2, Engine fire protection systems a. Induction systems3, Engine eiectrical systems 9, Engine cooling systems4. Lubricating systems 10, Engine exhaust systems5, Ignition systems 11, Propellers6. Fuel metering systems

If you already have either an Airframe or Powerplant mechanic certificate you will not be tested on theGeneral oral or practical test subjects.The mechanic examiner will grade you as "satisfactory" or "unsatisfactory" on each test subject given. If youreceive an unsatisfactory on any subject, you fall the pracll cal test and must be retested later on that specificsubject. At the time of retesting, you must present documentary evidence to the examiner that you havereceived at least five hours of additional training or Instruction on the failed subject before you can beretested,Upon successful completion of the practical test, the mechanic examiner will complete the application form,assign a grade of satisfactory, and Issue you a temporary mechanic certificate, He will then mall theapplication to the FAA, Airman Certification Branch, Oklahoma City, Oklahoma Your permanent mechaniccertificate will be sent to you by the FAA within 120 days,

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GENERAL TEST SUBJECTS

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BASIC ELECTRICITY ORAL1. What Is the most Important law applicable to the study of electricity?

Ohm's Law (I = E + A)2. What are the elements of Ohm's Law?

Voltage (E), current (I), and resistance (A).3. What are the sources of electrical power?

Mechanical (generator). chemical (battery), photoelectric (light). and thermal (heat).4. What does an electrical circuit consist ol?

A source of electrical pressure or EMF, resistance in the form of an energy consuming electricaldevice, and conductors, usually in the form of copper or aluminum wires. to provide a path forelectron flow. .5. What represents capacitance in an AC circuit?

A capacitor (condenser).6. What is the function of a capacitor?

To store electricity.7. What Is inductance?

A voltage that is induced in a call In an AC circuit. This voltage is opposite in direction to theapplied voltage, and opposes any change in the alternating current.8. What is impedance?

. It is the combined effect of resistance. inductive reactance. and capacitive reactance in an ACcircuit.9. What Is the unit of measurement of power In a DC circuit?

The wall. Amperes times volts equals walls (P I x E). 746 walls equals one horsepower.10. What Is a kllowall?

It Is 1,000 wailS.11. In a DC circuit, what occurs when voltage is increased while resistance remains constant?

There wn! be an increase In current.12. What are the three types of DC electrical Circuits?

They are series circuits, parallel circuits, and serlesparallel circuits.13. A 24 volt lead-acId ballery has how many cells?

It has 12 cells. Each cell is rated at 2 volts.

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14. What should be the specific gravity of'the electroly1e in a fully charged lead-acid battery?It should be between 1.275 and 1.300.

15. What Instrument Is used to determine the specific gravity of electroly1e in a lead-acid battery?A hydrometer.

16. Why can't a hydrometer be used to determine the charge of a nickel-cadmium battery?The specific gravity of the electroiy1e In a nickel-cadmium battery does not change appreciablyduring charge or discharge of the battery.

17. When USing a hydrometer to check the charge of a lead-acid battery, at what temperatures must acorrection factor be applied to the reading?

Adjustments must be made if temperature of the electroly1e Is above gOF or below 70'F.1B. What Is electromagnetic induction?

It Is the transfer of electrical energy by means of a magnetic field. This Is the prinCiple of transformeroperation.19. How are battery compartments protected against corrosion?

They are coated with special corrosion resistant paints such as bituminous paint.'120. What should be the correct electroly1e level In a properly serviced batter'(

It should be approximately 3/8 Inches above the plates. If the battery has baffle plates above thecell plates, the electroly1e level should be up to the hole in the baffle plate in each cell.

BASIC ELECTRIC1Y PROJECTS

1. Compute voltage in an electrical circuit.2. CompU1e resistance In an electrical circuit.3. Compute current In an electrical circuit.4. Identify aircraft electrical symbols.5. Calculate voltage drop across several resistors In an electrical circulI.6. Use an ohmmeter to check an electrical system for opens and shorts.7. Use a voltmeter to measure voltages in an electrical system.B. Compute the total power requirements lor the operation 01 several components in an electricalsystem .9. Match a list 01 electrical quantity prellxes such as kilo, mllli, micro, etc., with a list of their numericalvalues.10. Use an ohmmeter and measure the resistance of several electrical components.11. Identify electrical system malfunctions by reference to circuit diagrams.

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12. Check the state of charge of a lead-acid battery.13. Correctly connect a lead-acid battery to a constant current battery charger.14. Remove spilled electroly1e and treat all adjacent surfaces to prevent corrosion.15. Install swaged terminal fittings on electric wiring.

AIRCRAFf DRAWINGS ORAL

1. What type of lines are used on aircraft drawings to Indicate hidden views, alternate positions, andcenter lines?A hidden view line Is a medium width line made up of short dashes. It represents an edge thatcannot be seen when looking at the part from a specific position.Alternate position lines are medium width lines composed of one long and two short evenly spaceddashes. They are used to show the alternate position of a part or the relative position of a missingdart.Center lines are composed of alternate long and short dashes, and are used to Indicate the centerof an object or part of an object.

2. Define "tolerance" as used In aircraft drawings.It Is the sum of plus and minus allowance figures when a dimension shows an allowable variation.

3. Define "clearance" as used In aircraft drawings.Clearance Is the dimensions given for fits between moving parts.

4. What Information Is given in the title block of a blueprint?The drawing number, the name of the part or assembly, the scale, the date, the name of the firm,the name of the draftsman, the checker, and the approving official.

5. Why are dimensions used, and how are they shown on an aircraft drawing?Dimensions are solid narrow lines, broken at midpoint for the Insertion of measurements. Theyare used to Indicate the size of an object.

6. How can a change to an aircraft drawing be Identified?They are usually listed In columns, either next to the title block or at one corner of the drawing.

7. What Is a "bill of material" associated with aircraft blueprints?It Is a list of materials and parts necessary for fabrication or assembly of a component or system.

8. Why are symbols used when drawing aircraft blueprints.?Symbols are a type of shorthand used for drawing. They show the characteristics of a componentwith a minimum amount of drawing.

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9. How many views are required to determine the shape of an object?Two views will not always determine the shape of an object. If three views are given, all three mustbe reviewed.

AIRCRAFT DRAWINGS PROJECTS

1. Read, Interpret, and plot data from an engine performance chart.2. Interpret any dimension appearing on a drawing, Including the correct application of limits ortolerances to the dimension.3. Make a sketch of a repair or an alteration, Including the correct position of the views, the dimension,and the material specifications.4. Use an electrical cable and determine the correct cable size for carrying a specified amount ofcurrent for a certain distance.5. Identify lines and symbols on a typical aircraft detail and assembly drawing.6. Name all the major components and their location in an Installation diagram.7. Identify changes that have been made to a blueprint.8. Draw a sketch of an aircraft part to onefourth scale.

WEIGHT AND BALANCE

If an aircraft Is to be safely flown, Its weight and balance must be kept within specified limits. Therefore,calculations are required whenever a repair or alteration is made that affects the aircraft's weight andbalance. Additionally, each time an aircraft Is loaded for flight, Its weight and balance shOUld be checkedto determine If both are within prescribed limits. Knowledge of the following definitions and terms Is essentialto proper weight and balance control.EMPTY WEIGHT - consists of the airframe, englne(s), and all items of operating eqUipment which havefixed locations and are parmanently installed In the aircraft. This Includes optional and special eqUipment,fixed ballast, unusable fuel, and full operating fluids (all, hydraulic fluid, and other fluids that are required fornormal operation of airplane systems, except potable water, lavatory precharge water, and water Intendedfor Injection In the engines). NOTE: The empty weight of some older aircraft may not Include full all butonly the undralnable (residual) oil.USEFUL LOAD -Is the weight of the pilot, copilot, passengers, baggage, and usable fuel. It Is empty weightsubtracted from the maximum allowable takeoff weight.GROSS WEIGHT - is the empty weight plus useful load. When an aircraft Is carrying the maximum loadfor which it Is certificated, takeoff weight Is called the maximum allowable gross weight.BALANCE refers to the location of the CG (center of gravity) of an aircraft. It Is of primary Importance toaircraft stability and safety in flight. The CG Is the point about which an aircraft would balance If It werepossible to suspend it at that point. It Is the mass center of the aircraft, or the theoretical point at whichthe entire weight of the aircraft is assumed to be concentrated. The CG must be within specific limits forsafe flight.

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4. What Is the "arm" of an item, and how Is it obtained?The arm Is the distance (In Inches) an Item Is located either forward or aft of datum. It Is obtainedeither by actual measurement or from the aircraft weight and balance records.

5. What Is "tare" weight, and how Is it handled when making weight and balance calculations?'Tare' Is the weight of the extra equipment used for weighing the aircraft such as chocks, blocks,jacks, and chains. Tare weight must be subtracted from the scale readings in order-to obtain theactual weight of the aircraft.

6. What Is meant by "minimum fuel" and how Is It calculated for weight and balance purposes?Minimum fuel Is the amount of fuel that should be used in weight and balance computations whenthe aircraft Is loaded for an extreme condition check. For a reciprocating engine airplane e r t ~ i c a t e dunder FAR Part 23, this Is the fuel necessary to operate the englne(s) for one-half hour at maximumcontinuous power.

7. What is meant by "residual" fuel?It Is the fuel remaining in the tanks, lines, and engine after draining. Also called "undralnable" or"unusable: It Is part of the aircraft's empty weight.

B. How would you determine the empty weight and empty weight CG of an aircraft which has tricyclelanding gear if all weight and balance records are missing?Use three scales and record the weight under each wheel. Then, measure the distance in inchesfrom the nosewheel to the main gear and multiply this figure by the combined weight of each mainwheel. Into this number, divide the total weight of the aircraft. The answer will be the number ofinches. the CG Is located aft of the nosewheel. NOTE: This can be proved by using the figures inProblem 2 on page 13. You should find a CG 46.75 inches aft of the nosewheel. The nosewheelis B Inches forward of datum.

9. What is "ballast"?Ballast is lead bars, metal plates, shot bags, sand bags, or other items of weight which are placedin an aircraft to attain a desired CG location.

10. What Is the difference between flxedwing aircraft and helicopter CG ranges?The CG location in a helicopter Is much more critical than in fixed-wing aircraft. The CG range Insome helicopters is less than three inches.

11. When weighing an aircraft to determine the empty weight CG, what must you do with regard to theequipment Which is normally carried In the aircraft?All operating eqUipment whether It is required, optional, or special equipment must be included Inthe aircraft's empty weight.

12. Why do some manufacturers specify an empty weight CG even though the aircraft Is not operated atthis empty weight?

When the empty weight CG falls within the empty weight CG range, it is unnecessary to performa forward or aft weight and balance check If standard loading and seating arrangements are used?

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13. Why must the aircraft category be considered when computing weight and balance?Some airplanes are certificated In both normal and utIlity categories. This means a differentmaximum allowable gross weight depending on which category the aircraft will be operated In.The following problems are typical of the different types of weight and balance calculations whichmay be required during the Mechanic Practical Test.

PROBLEM 1You have a 5-pound welghllocated 24 Inches aft of a fulcrum (datum) and a 10-pound weight located 48inches aft of the fulcrum. How far forward of the fulcrum must you place a 20-pound weight In order toestablish a balance?The first step Is 10 find the tolal moment acting aft of Ihe fulcrum. Using the basic weight and balanceformula of WEIGHT times ARM equals MOMENT, find the total moment acllng aft of the fulcrum to be 600pound-Inches.WEIGHT

5lbs. x101bs. x151bs.

ARM24"48"

MOMENT120480600You have now determined that a 600 pound-Inch moment Is acting downward aft of the fulcrum. To be Inbalance, the 20-pound weight must be placed forward of the fulcrum at a distance which will create anequal 600 pound-Inch moment. since WEIGHT x ARM MOMENT, MOMENT + WEIGHT ARM.Therefore, 600 pound-Inches divided by 20 pounds equals 30 Inches.The 20-pound weight placed 30 Inches forward of the fulcrum will exactly balance the 5 and la-poundweights at 24 and 48 Inches respectively aft of the fulcrum.

PROBLEM 2When an empty airplane was weighed, the scale readings were as follows: Nosewheel - 500 pounds; leftmain wheel - 570 pounds; and right main wheel - 530 pounds. The nosewheel arm Is 8 Inches forward ofdatum and the main gear Is located at 60 Inches aft of datum. Find the empty weight CG.

Nosewheel WEIGHT lib)500Right main WheelLeft main wheel 53057016001bs.

ARM (In)- 86060

MOMENT (Ib-in)- 4000318003420062000 Ib-In.The CG Is now obtained by dividing total moment by total weight. Therefore, 62,000 divided 1 600 38. 75inches aft of datum.

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PROBLEM 3Find the location of the new loaded CG for an airplane which was modified Into a cropduster.The original empty weight was 1,BOO pounds with the CG located at 40 Inches aft of datum. Removed a300-pound engine at - 15 Inches and replaced It with a 40o-pound engine at an arm of -25 inches. Removeda 20-pound propeller at -40 Inches and replaced It with a 40-pound propeller at -50 Inches. The fuel tankremains at 50 inches aft of datum (+50) and has capacity of 20 gallons usable fuel. The pilot seat Is at 60Inches aft of datum and the pilot weighs 170 pounds. Removed a 2O-pound passenger seat at an arm of30 inches (+30) and installed a 50-pound hopper at the same point Total capacity of the hopper is 440pounds.

WEIGHTS ARM MOMENTSITEM Plus Minus Positive NegativeEmptyairplane 1 BOO. 40. 72,000,Remove engine -300. -15. 4,500.Add engine 400. -25. -10,000.Remove propeller -20. -40. 800.Add propeller 40. -50. -2,000.Fuel (5 Ib/gal) 120. 50. 6,000.Pilot 170. 60. 10,200.Remove seat -20. 30. -BOO.Add hopper 500. 30. 15,OOg.3,030. -340. 108,600. -12,600.-340. - 12,{lgg.2,690.lbs. 95,900. Ib-In.The loaded airplane CG may now be found by dividing the new total moment by the new total weight.Therefore, 95,900 divided by 2,690 = 35.66 Inches aft of datum.

WEIGHT AND BALANCE PROJECTS

1. Determine the empty weight and empty weight CG of a loaded airplane.2. Determine the CG of a fully loaded airplane.3. Alter making an equipment change, establish new weight and balance data, then determine if thechange has caused either the maximum weight or the CG limits to be exceeded.4. Determine the amount of fuel needed as minimum fuel for weight and balance computations.5. Prepare an aircraft and record the scale readings.6. Weigh an aircraft and record the scale readings.7. Compute weight and balance for a helicopter and determine If it Is within the CG range.S. Using a weight and balance report, list the forward and aft CG limits and determine the total distancebetween them.9. Using the weight and balance information for two aircraft, locate the datum line lo r each aircraftwithout error.10. During the weighing of an aircraft, list all the tare items.

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FLUID UNES AND FITTINGS ORAL

1. What are aircraft plumbing lines usually made of?Metal tubing and fittings, or flexible hose.

2. How Is metal tubing sized?By outside diameter which is measured fractlonally in sixteenths of an inch, and by wallthicknassmeasured In thousandths.

3. What precautions should be taken when routing fluid lines adjacent to electrical wiring?Route the fluid lines below the electrical wiring and maintain a clearance of at least six Incheswhenever possible. In no case should fluid lines and electrical wiring be closer than one-hall inch.Ensure that both the wiring and the fluid lines are fastened to the aircraft structure by clamps orother methods that will maintain the separation.

4. What is the purpose of the Identification stripe running along the length of a flexible hose?The stripe is used to determine H he hose has twisted during Installation. The stripe should notspiral around the hose after installation is completed.

5. How are standard AN-type fluid line fittings identified?AN fluid line fittings are colored either blue or black while AC type fittings are usually gray or yellow.AN fittings have coarser threads than AC fittings, and they also have a small shoulder between thethreads and the flare cone. The AC fittings are completely threaded from the shoulder all the wayto the llare cone.

6. What is the purpose of using quick disconnect couplings In fluid systems?Quick disconnect couplings are Installed at locations where frequent uncoupling of the lines isrequired for Inspection or maintenance. Each half has a valve that is open when coupled togetherand spring loaded closed when disconnected. They provide a means of quickly disconnecting aline without a loss of fluid or air entering the system.

7. How is flexible hose sized?By the Inside diameter in sixteenths of an inch increments.

8. How much slack must be left in a flexible hose during Installation?Five to eight percent of the total hose length must be allowed for freedom of movement underpressure.

9. What are the three parts of a Military Standard (MS) flareless-tube fitting?The body, the sleeve, and a nut.

10. What will be the result of overtightening a f1areless tube fitting?The sleeve's cutting edge will cut too deeply Into the tube and cause the tube to be weakened.

11. What are the two kinds of flares used In aircraft plumbing systems?A single lIare and a double flare.

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12. What is tlie advantage of flexible tellon hose over rubber hose?It can be used in the same manner as rubber hose and it has a better operating strength.

13. What precaution should be taken when deburring the cut end of a tube?Care should be taken that the tubing is not cracked or that the wall thickness Is not reduced bythe deburrlng process.

FLUID LINES AND FlmNGS PROJECTS

1. Make up and Install a complete replacement rigid fluid line that requires cutting, bending, and theinstallation of fittings.2. Repair a metal tube line using a union and connection fittings.3. Make a proper single flare on a piece of tubing.4. Make a proper double flare on a piece of tubing.5. Fabricate and correctly Install a flexible hose.6. Point out defects in metal tubing that are cause for relection.7. Install support clamps on a metal fluid line using the proper spacing.S. POint oULand identify several different fluid and air lines that are Installed in an aircraft

.MATERIALS AND PROCESSES ORAL

1. What is a suitable nondestructive method for detecting surface cracks in aluminum castings andforgings?The dye penetrant inspection method detects surface cracks with equal success on aluminum,magnesium, brass, copper, and titanium. It can also be used on ceramics, plastics, and glass.

2. Briefly describe the steps to be taken when performing a dye penetrant Inspection.Thoroughly clean the metal surface, dry completely, and apply the penetrant. Remove the penetrantfrom the surface, dry the part, and apply the developer. Inspect and interpret the results.

3. Briefly describe the procedure for performing a magnetic particle inspection.Thoroughly clean all grease, oil and dirt from the metal part which must be of magnetic materialsuch as iron or steel. Magnetize the part and then apply the ferromagnetic particles, either heldin liquid suspension or in dry powder form, to the area to be Inspected. If a discontinuity is present,the magnetized particles will form a pattern In the approximate shape of the discontinuity.

4. What Is the general rule for using self-locking nuts?Do not use self-locking nuts at jOints which subject either the nut or bolt to rotation.

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5. What type of cable Is used in primary control systems?EXira flexible 7 x 19 cable.

6. How can the correct "grip length" of a bolt be determined?The grip length Is the unthreaded portion of the bolt shank. Generally speaking, the grip lengthshould equal the total thickness of the material being bolted together.

7. What is the smallest cable that can be used in primary control systems?Federal regulations state that no cable smaller than one-eighth Inch In diameter may be used forthis purpose.

8. What should be the depth of penetration when malting a fillet weld?Penetration should be 25 to 50 percent of the thickness of the base metal.

9. What should be the width of the weld bead and depth of penetration when making a butt weld?The bead width should be 3 to 5 times the thickness of the base metal and there should be 100percent penetration.

10. What system Is used to Identify AN-type aircraft bolts?Aircraft bolts have code markings on the bolt heads for Identification.

11. What are the steps for solution heat treating aluminum alloys?The alloy must be heated to a predetermined temperature, heat soaked for a specified period oftime, and then rapidly quenched to a relatively low temperature.

12. In what state Is aluminum alloy Immediately after solution heat treating and quenching?The alloy Is in a comparatively soft state, so the material must be naturally aged or precipltatlonhardened.

13. What Is done to prevent certain aluminum alloy rivets from becoming hard after heat treating andquenching?The rivets are stored in a refrigerator at a temperature lower than 32'F. The rivets will remain softfor several days.

14. What are the characteristics of a cold weld?A cold weld has improper penetration and cold laps caused by the insufficient heat. It appearsrough and Irregular and Its edges are not feathered into the base metal.

15. What tool is used to measure the outside dimenSions of shafts, thickness of sheet metal stock,diameter of drills, and for many other similar applications?Outside micrometer calipers.

16. What should be used to a Visual inspection of a weld?A magnifying glass of at least ten power.

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MATERIALS AND PROCESSES PROJECTS

1 Perform a dye penetrant Inspection on an aircraft part.2. Perform a magnetic particle Inspection on a steel part.3. Use a micrometer with a vernier scale and make precision measurements.4. Perform a single-wrap and a double-wrap method of safe tying a turnbuckle.5. Identify aircraft hardware such as bolts and rivets by the manufacturer's markings.6. Identify aircraft control cable.7. Install a swagedtype fitting on an aircraft cable.8. Check the alignment of a crankshaft using a dial Indicator and determine If it is within limits.9. Perform a chemical etching test on aluminum alloy and determine if the material Is weldable.10. Make a visual Inspection of several sample welds and point out any undesirable characteristics.

GROUND OPERATIONS AND SERVICING ORAL

1. What Is the procedure for extinguishing an Induction system fire that occurs during starting of areciprocating aircraft engine?A IIreguard who is familiar with the aircraft's Induction system should be standing by with a C02fire elctlngulsher during the engine start. If an engine fire develops, continue cranking to start theengine and blowout the fire. If the engine does not start and the fire continues to burn, discontinuestarting; The flreguard should extinguish the fire using available equipment

2. What Is the purpose of pulling a propeller through by hand for two or three revolutions prior tostarting some reCiprocating engines?The purpose Is to detect a hydraulic lock If one Is present. Any liquid present In the cylinder willbe Indicated by an abnormal effort required to rotate the propeller, or by the propeller stoppingabruptly during rotation.

3. What damage is most likely to occur If force Is exerted on the crankshaft when there Is a liquid lock?The force can bend or break a connecting rod.

4. What information must be located on or near fuel filler openings? Oil filler openings?

For normal category aircraft, the word "fuel" and the minimum fuel grade or designation for theengine. For transport category aircraft, the same Information listed for normal category. 011 filleropenings require the word "011" to be marked at or near the filler cover.

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5. Describe the system used to designate performance rating of aViation gasoline.For fuels below grade 100, octane numbers are used, such as 91/96. The fue! Is compared withmixtures of Iso-octane and normal heptane. Thus, grade 91 fue! has the same knock characteristicsas a blend of 91 percent octane and 9 percent heptane. When two numbers are used, the firstnumber Is the !ean mixture performance rating, while the second number Is the rich mixtureperformance rating.For fuels above grade 100, the numbers represent the performance rating of the fuel compared to100 percent Iso-octane. That Is, its knockfree power available as compared with that available withpure Iso-octane. The first number Is the lean mixture performance rating. The second number Isrich mixture performance rating.

6. What would be the result of operating an aircraft reciprocating engine using a lower grade ofgasoline than that specified for the engine?There would be a loss of engine power, efficiency, and possible detonation.

7. Why should an aviation mechanic know the meaning of the standard light signals which are used bycontrol tower operators?If radio communication Is not possible, the light signals may be used for taxi control whenan aircraft must be taxied to another part of the airport.

S. Which publication lists the standard FAA hand signals a taxi signalman should use?The FAA Airman's Information Manual (AIM).

9. What will be the result of mixing aviation gasoline with Jet fue! In a turbine engine?When aviation gasoline is m!xed with jet fuel, the tetraethyllead In the gasoline will form depositson the turbine blades and vanes. Continued use of mixed fuels may cause a loss In engineefficiency. However, there will be no detrimental effect on the engine if such usage Is on alimited basis.

10. What may result if gasoline that is contaminated with Jet fuel is used in a reciprocating engine?Gasoline which Is contaminated with Jet fuel is unsafe for use In a reciprocating engine and canresult In complete engine failure.

11. When towing an aircraft with a tow tractor, what brakes should be used to slOP the aircraft?The tow tractor brakes and the aircraft brakes should both be used. Use of the brakes should becoordinated by the man In the cockpit.

GROUND OPERATION AND SERVICING PROJECTS

1. Start, runup and shutdown an aircraft reciprocating engine which has a floattype carburetor.2. Identify the different grades of aviation gasoline by color.3. Check an aircraft fuel system for water contamination by draining all sumps and strainers.4. DemonS1rate the hand signals used to direct aircraft movement.5. Demonstrate the procedures to check for and to clear a hydraulic lock In a reCiprocating engine.

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6. Tledown and secure an aircraft that Is to be stored outside. Assume storage will be under normalweather conditions.7. Connect a lowbar to an aircraft and prepare for towing.8. Properly connect an external auxiliary power unit to an aircraft.9. Determine the amount of fuel on board an aircraft.10. Select the proper fuel and refuel an aircraft.11. Perform an engine start on a turbine engine, operate the engine through the normal operating range,and shutdown the engine according to operating Instructions.

CLEANING AND CORROSION CONTROL ORAL

1. What are the five common forms of corrosion?Surface corrosion, dissimilar metal corrosion, Intergranular corrosion, stress corrosion, andfretting corrosion.

2. What is the cause of fretting corrosion?It occurs when two mating surfaces, which are normally at rest with respect to each other, aresubjected to slight relative motion. It is characterized by pitting of the surfaces and the generationof large quantities of fine debris between the surfaces.

3. What are the factors which affect the type (form) of corrosion?Theform of corrosion varies with atmospheric conditions, size and shape of the metal, the type ofmetal, and the corrosion-producing agents present.

4. What methods are used for removing rust from aircraft materials?Except on highly stressed steel surfaces, the use of abrasive papers and compounds, small powerbuffers and buffing compounds. hand wire brushing and steel wool are all acceptable methods ofremoving rust.

5. What specific operations are part of corrosion-preventive maintenance?Adequate cleaning, periodic lubrication, detailed inspection, prompt corrosion treatment, touch upof damaged paint, sealing, use of protective covers, and daily wipe-down of exposed critical areas.

6. Name the steps for corrosion removal.Clean and strip the corroded area, remove as much corrosion as possible, neutralize any residualmaterial remaining In pits and crevices, restore protective sUrface films and paint.

7. What tools are approved for cleaning corroded anodized sUrfaces?Fiber bristle brushes, aluminum wool, and aluminum wire brushes.

B. What products should be used to clean an aircraft engine?A fine spray of kerosene or solvent.

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9. What Is the preferred cleaning agent for plastic suriaces?Soap and water.

10. What areas of an aircraft are more prone to corrosion?Battery compartments, bilge areas, wheel well and landing gear, flap recesses, and other areaswhere water might be entrapped.

11. What is the difference between ''wet wash' and "dry wash" aircraft cleaning?Wet wash cleaning Is used to remove oil, grease, carbon deposits and solis, with the exception ofcorrosion and oxide films. Dry wash cleaning Is used to remove film, dust, and small accumulationsof dirt.

12. What are types of light duty and heavy duty aircraft cleaning agents?Ught duty cleaning agents are soap and synthetic detergent and heavy duty cleaning agents aresolvents and emulsions.

CLEANING AND CORROSION CONTROL PROJECTS

1. Identify the type of corrosion on an aircraft part.2. Remove corrosion products from aluminum and steel engine parts.3. Use paints and other organic coatings for corrosion protection purposes.4. Flush steel structural tubing interior to protect it against corrosion.5. Select correct cleaning materials for aluminum, steel, and magnesium parts.6. Clean rubber parts.7. Strip paint from a corroded part without damaging the part.e. Clean an aircraft exterior without damage to the finish or any components.

MATHEMATICS ORAL

1. What Is the formula for the area of a rectangle?A = LW

2. What is PI (.) ?PI Is a constant (3.1416) and Is the ratio of the circumference to the diameter of any circle.

3. What is the formula for the circumference of a circle?

4. What Is the formula for the area of a circle?

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5. What Is the root of a number?The root of a number Is one of two or more equal numbers that, when multiplied together, '11111produce the number.

6. Give examples of perfect square numbers.4,9,16,64,100,144, etc.

7. How do you express a decimal as a percent?Move the decimal two places to the right and add the percent sign. For example, .75 is 75% or.375 Is 37.5%.

B. Using the powers of ten, how may 1,000,000 be expressed?Ten to the sixth power or 106.

9. What 15 the sum of a large negative number and a small positive number?Subtract the smaller number from the larger number and use the sign of the larger number In theanswer.

10. How Is a ratio expressed?A ratio may be expressed as a fraction or It may be written using the colon (:) as the symbol forexpressing ratio. Thus, the ratio 5/7 may be wrlUen 5:7.

MATHEMATICS PROJECTS1. Convert a list of fractional numbers to decimal equivalents.2. Select the correct formula from a list of formulas and compute the volume of a cylinder.3. Compute the compression ratio of a cylinder.4. Select the correct formula and compute the area of a wing.5. Add, SUbtract, multiply, and divide positive and negative numbers.6. Add, subtract, multiply, and divide common and uncommon fractions.7. Select the correct fonnula and compute the volume of a baggage compartment.8. Square a list of numbers.9. Using reference material, locate the Instructions for determining square root.10. Compute the surface area of a cylinder.11. Using reference material, locate square root charts.

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MAINTENANCE FORMS AND RECORDS ORAL

1. What is the definition of "time In service" with respect to maintenance time records?"Time In service" means the time from the moment an aircraft leaves the surtace of the earth untflit touches it at the next point of landing.

2. What are the record requirements for returning an aircraft to service after a 100 hour Inspection?There must be an entry made In the maintenance records Indica ing the type and date of theinspection, aircraft time In service, a statement to the effect that the aircraft has been inspected Inaccordance with 100 hour Inspection requirements and was determined to be In airworthycondltlon,and the signature and certificate number of the person approving the aircraft for return toservice.

3. What are the record requirements after compliance with an Airworthiness Directive (AD)?No specific format for the record entry is required. However, the record entries must show thespecific number assigned to the AD, the date of compliance, the method of compliance, aircraftlime In service, as well as the signature and certificate number of the person who compiled withthe AD. In addition, the records must show the current status of all applicable AirworthinessDirectives, and must Include the method of compliance.

4. Where should the description of a major repair or major alteration be recorded?On an FAA Form 337, which then becomes part of the maintenance records.

5. What is the disposition of an FAA Form 337 after it is completed?You must give one signed copy to the aircraft owner and one copy to the FAA.

6. Who is required to make the entry in the aircraft records after a 100 hour inspection has beenpertormed? .7. How long must the record of a 100 hour inspection be retained by the owner or operator?

Until the work is repeated or superseded by other work or for one year after the 100 hour Inspectionwas pertormed.8. Where can a mechanic find an example of a 100 hour Inspection maintenance record entry?

FAR 43.11.9. When an aircraft is sold, what is done wllh the aircraft records containing the current status ofAirworthiness Directives?

FAR's require the records to be transferred to the purchaser at the lime of the sale.10. What type of maintenance record entry is required when an inspection under FAR 91.169 Is made toa large airplane or a turbine engine-powered multienglne airplane and defects are found?

The entry must name the kind of inspection (continuous airworthiness inspection program, approvedinspection program, etc.). A signed and dated list of defects found must be given to the owner.

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11. What are the required entries In a new maintenance record for an engine that has been rebuilt andgranted zero time by the manufacturer or by an agency approved by the manulacturer?The manufacturer or agency that grants zero lime to a rebuilt engine must enter Into the recordsa signed statement of the date the engine was rebuilt, each change made as required byAirworthiness Directives, and each change made In compliance with the manufacturer's servicebulletins if an entry is specifically requested In a bulletin.

MAINTENANCE FORMS AND RECORDS PROJECTS

1. Prepare an FAA Form 337, Major Repair and Alteration form, describing either a major repair ormajor alteration. Know the disposition of this form and all copies.2. From samples of completed FAA Form 337, select the ones that have been filled in correctly withall the required Information.3. Make a maintenance record entry for returning an aircraft to service after a 100 hour inspection.4. Make a maintenance record entry to indicate compliance wtth an Airworthiness Directive.5. Enter the required information In the permanent maintenance records when routine maintenance hasbeen pelformed.6. Make a maintenance record entry for the altimeter system test and inspection which is required byFAR Part 91.

BASIC PHYSICS ORAL

1. What is matter?Anything that occupies space and has weight.

2. What are the three states of matter?Solids, liquids, and gases.

3. What is standard atmospheric pressure at sea level?It is considered to be 14.7 psi.

4. What Is the name of the atmospheric phenomenon where cool air Is trapped near the earth by warmair?A temperature inversion.

5. What is the speed of souna through the air under standard sea level conditions?It is 662 knots and 76 i mph.

6. What determines the density of the air (density altitude)?The temperature ana pressure acting upon it.

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7. What are the three basic parts of a lever?The fulcrum, foree or effort, and resistance.

8. What is a first class lever, ami give an example?A first class iever Is when the fulcrum Is located between the effort and the resistance. An exampleof a first class lever Is a seesaw.

9. In what direction is force transmitted In a confined fluid?Force Is transmitted equally in all directions.

10. What Is the formUla for computing force, pressure, and area?Force equals pressure times area or F = P x A.

11. What Is absolute zero?It Is the temperature al which all motion of the molecules will cease entirely In a given sample ofgas. It Is considered to be -273C.

12. What are the two factors Involved In work?Force and movement through a measurable distance.

13. How is pressure expressed In hydraulics and pneumatics?It is expressed In pounds per square Inch (pSI).

14. What are the three methods of heat transfer?Conduction, convection, and radiation.

BASIC PHYSICS PROJECTS1. From a drawing of ten levers, select two each of the three classes of levers.2. From a standard temperature and altitude chart, select the standard temperature at sea level, and at5,000 foot Increments up to 30 thousand feet.3. Label the area of lowest pressure and highest velocity on a drawing of a venturI.4. Correctly compute force, pressure, and area problems using the formula, F = P x A.5. Given the formula, convert Centigrade to Fahrenheit and Fahrenheit to Centigrade.6. Correctly compute an inclined plane problem using the formula: 1. = R

L = Length of the ramp along the slope.1 = Height of the ramp.R = Weight of the object to be raised.E = Force required to raise the object.

1 E

7. Using a single pulley, draw a pulley system that will 11ft a 200 pound load with a 100 pound force.

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MAINTENANCE PUBLICATIONS ORAL

1. What Is the purpose of Airworthiness Directives?They are used to correct unsafe conditions In aircraft, engines, propellers, and appliances.

2. What FAA publication is used to notify aircraft owners of unsafe conditions?Airworthiness Directives.

3. When must an Airworthiness Directive be complied with?The AD will include the time or period necessary for corrective action.

4. Where can you find a list of approved engines for use In a specific model aircraft?On the Type Certificate Data Sheet for the Aircraft.

5. Where can you find Airworthiness Standards for normal, utility, and acrobatic category airplanes?FAR Part 23.

6. Where can you find Airworth:ness Standards for transport category airplanes?FAR Part 25

7. What federal regulation defines the requirements for the Issue of Type Certificates?FAR Part 21.

8. Where would you look to find out if a specific airplane can be certified in more than one category?On the Aircraft Specifications or Type Certificate Data Sheet.

9. What publication is issued by airirame, engine, and component manufacturers to notify aircraftowners of design defects.Service bulletins.

10. What publication contains complete instructions for maintenance of all systems and componentsinstalled In an aircraft?The manufacturer's Aircraft Maintenance Manual.

11. What are FAA Advisory Circulars?They are publications containing non-regulatory material of Interest to the aviation public.

MAINTENANCE PUBLICATIONS PROJECTS

1. Use the Aircraft Specifications or Type Certificate Data Sheets and flnel the CG range of an aircraft.2. Find and list all the AilWorthiness Directives that apply to a specific airplane.3. Inspect an airplane for AD compliance.

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4. Use Technical Standard Orders to find the standards lo r a specific part manufactured under the TSOsystem.5. Read, Interpret, and write a short descrlpllon of the work to be accomplished as set forth In anAirworthiness Directive or a Supplementaf Type Certificate.6. Using a manufacturer's Illustrated Parts Catalog. locate and list the correct part number for a

replacement partMECHANIC PRIVILEGES AND LlMrrATIONS ORAL

1. Which federal regulation prescribes the certificate requirements for a mechanic?FAR Part 65

2. What are the privileges of a certified mechanic In regard to aircraft Instruments?A mechanic may not calibrate or make any repairs or alterations to aircraft instruments.

3. What are the privileges of a certified mechanic In regard to propellers?A powerplant mechanic may make minor repairs and alterations, but may not make majorrepairs or major alterations to propellers.

4. When a mechanic has a permanent change of address, what must be done within 30 days after thechange?He must notify in writing the Administrator of the FAA.

5. What is the duration of a mechanic certificate?It is effective until surrendered, suspended, or revoked.

6. How long is a temporary mechanic certificate in effect?For a period of 120 days.

7. What is used as a guide to determine if a repair is a major or a minor repair?FAR Part 43, Appendix A.

B. What are the recency of experience requirements for a mechanic?A certified mechanic may not exercise the privileges of his certnlcate and rating unless within thepreceding 24 months he has, for at least 6 months, served as a mechanic under his certificate andrating; or supervised other mechanics; or supervised, in a technical capacity, the maintenance oralteration of aircraft; or the administrator has found that he Is able to do the work.

9. What may be used as a guide for 100 hour Inspections?FAR Part 43, Appendix D.

10. What are the privileges of a certificated mechanic in regard to performing a 100 hour inspection andreturning an aircraft to service? An annual Inspection?A certificated A& P mechanic may perform a 100 hour inspection and return an aircraft to serviceby making the proper entries In the maintenance records. An A&P mechanic with an InspectionAuthorization may perform an annual inspection and return an aircraft to service.

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11. Who has final responsibility for maintaining aircraft maintenance records?The owner or operator of the aircraft.

12. Mayan airframe mechanic perform maintenance on engines?Yes, under the supervision of a powerplant mechanic.

MECHANIC PRIVILEGES AND LIMITATIONS PROJECTS

1. Using FAR Part 43, Part 65, and Part 91, list the type of Inspections a certificated mechanic mayperform and the FAR reference for each one.2. Review a list of 10 maintenance functions and determine which an airframe mechanic may perform.3. Review a list of 10 maintenance functions and determine which functions a powerplant mechaniCmay perform.4. Using FAR Part 43, classify a list of 10 repairs as either major or minor repairs.5. Using FAR Part 43, classify a list of 10 alterations as either major or minor alterations,6. Using FAR Part 65, list the procedures required for a permanent change of address.

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AIRFRAME TEST SUBJECTS

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AIRFRAME STRUCTURES

WOOD STRUCTURES ORAL

1. What species of wood Is used as a standard for strength properties of other species of wood used Inaircraft structures?Spruce Is used as a standard.

2. What type of wood quality must be used In the repair of aircraft structures?The wood must be aircraft quality.

3. What is the difference between laminated wood and plywood?Laminated wood consists of two or more layers of wood which have been glued together with thegrain of all layers approximately parallel. .

4. What are the two types of glue used for aircraft wood structure repair?They are casein and synthetic resin glue. The resin glues that are recommended for woodaircraft applications are the resorcinol formaldehyde type glues.

5. What method is used to prepare plywood for bending?The wood Is soaked in hot water. and then placed on a form until completely dry.

6. What are the results of using InSUfficient gluing pressure when making a wood joint?The results will normally be thick glue lines, which Indicate a weak Joint.

7. How long should a wood glue Joint be kept under pressure before removing the clamps?The pressing time will vary depending on the temperature of the curing room. The curingtemperatures are from 70T and up. Higher temperatures will cause the glue to set faster. Tobe certain that a glue joint is satlslactory, it is recommended that It remain under pressure atabout 65'F. for a period of at least seven hours. Full joint strength will develop only afterconditioning for at least two days.

8. What are some of the various methods used to apply pressure to JOints In aircraft gluing operations?Brads, nails, screws, clamps, and hydraulic and electric power presses.

9. Why does the strength of a scarf joint depend upon the accuracy of the two beveled surfaces?Because an Inaccurate bevel will reduce the amount of effective glue area.

10. What type of patch is preferred for repair of stressed plywood skin and why?A properly prepared and Inserted scarf patch Is the best repair for plywood, and Is preferred formost skin repairs. It dil lers from a splayed patch In that the edges are scarfed to a 12 to 1 slopeinstead of a 5 to 1 slope, and it uses reinforcements under the patch where the glue joints occur.

11. Are mineral streaks acceptable In aircraft wood?Yes, providing careful Inspection fails to reveal any decay,

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12. How can the moisture content of wood be determined?One way is to use a moisture meter. However, the most accurate method Is to take a sample ofthe wood, weigh it, dry it in an oven at a temperature of 100C to 105'C, reweigh it, and thencompute the moisture content by using the following formula.

W1 - W2 X100 = Percent moisture contentW2W1 = the weight of the wood sample before drying.W2 = the weight of the wood sample after drying.

13. What area of a wood spar may not be spliced?It may not be spliced under wing attachment fittings, landing gear fittings, engine mount fittings,or lift-and-Interplane strut fittings.

14. What type of joint Is generally used In spliCing structural members in aircraft?A scarf joint.

15. What is compression wood and why is it not acceptable for aircraft structures?Compression wood Is wood that is characterized by high specific gravity and has theappearance of excessive growth of summer wood. This defect Is difficult to recognize and isvery detrimental to strength. Reject all material containing compression wood.

WOOD STRUCTURES PRO.IECTS

1. From reference material, locate the repair procedures for elongated bolt holes in a spar.2. From reference material, locate a wood material substitute chart.3. Identify defects in aircraft wood.4. Identify samples of aircraft wood.5. Determine the moisture content of wood by weighing, heating, reweighing, and making the propercalculations.6. Inspect aircraft solid wood structure and determine if it is airworthy.7. Inspect plywood structure and determine 11 it Is airworthy.8, From reference material, locate the requirements for making scarf splice joints.9. From reference material, locate wood rib structure repair procedures,10. Repair stressed plywood skin damage by Installing a scarf patch.

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AIRCRAFT COVERING ORAL

1. What determines the required quality and strength of fabric that Is to be used for covering aircraft?The required strength and quality of aircraft fabric Is determined by the pounds per square footof wing loading, and the never-exceed airspeed of the aircraft.

2. When are anti-tear strips recommended, and where are they used?Anti-tear strips are used on aircraft with never-exceed speeds In excess of 250 mph, and they areInstalled over the ribs under the reinforcing tape. They are recommended for the complete uppersurface of the wings. and on the bottom surface of that part of the Wing that Is In theslipstream.

3. What is the maximum permissible deterioration of aircraft fabric before It Is considered unworthy?Fabric covering is considered unworthy when it deteriorates more than 30 percent from Its originallyrequired tensile strength.

4. What should be the strength of the fabric used for re-covering an aircraft?All fabrlc, surface tape, reinforcing tape, thread and lacing cord used to re-cover or repair aircraftcover should be of high grade aircraft textile material. The materials must be at least as good aquality and of equivalent strength as those' originally used by the aircraft manufacturer.

5. What is the purpose, location, and the methOd of Installing drain grommets In aircraft fabric?Drain grommets are located on the underside of airfoils at the trailing edge as close to the rib aspractical, and at the lowest point along the center of the underside of each fuselage bay. Theyallow the condensed moisture to leave the aircraft as well as furnish ventilation. Brass grommetsshould be mounted on fabric patches and then doped to the covering. Plastic grommets are dopeddirectly to the covering. Both types are installed with the second coat of dope, and the drain holesopened by cutting out the fabric with a small knife.

6. What is the purpose of reinforcing tape?Reinforcing tape is used over ribs between the fabric covering and the rib stitching to prevent thestitching cord from cutting through the fabric.

7. What type of fabric is not affected by moisture and mildew?Fiberglass fabric Is not affected by moisture, mildew, chemicals, or most acids.

8. What methods are used to check the strength of doped fabric?Fabric punch testers will provide a general Indication of the strength of the labrie, but if a punchtester Indicates that the fabric strength is marginal, a laboratory test should be performed todetermine the actual strength of the fabric.

9. What type of machine-sewed seams are used in aircraft covering?Plain overlap seams, folded-fell seams, and french-fell seams.

10. What should be done with structure that will come in contact with doped fabric?Treat all parts of the structure that will come In contact with doped fabric with a protective coatingsuch as aluminum foil, dope-proof paint, or cellulose tape.

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11. If the original rib stitch spacing cannot be determined when re-covering and aircraft, what rib stitchspacing should be used?Use the rib stitch spacing chart In Advisory Circular 43.13-1A.

12. What Is the standard tie-off knot used during rib stitching?A modified seine knot is used to tie off all stitches except the startlng stitch.

13. What do you call the edge of cloth, tape, or webbing that has been woven to prevent raveling?Selvage edge.

14. The types of fabric used for covering aircraft are organic and synthetic. Name two organic and twosynthetic fibers.The organic fibers are cotton and linen. The synthetic fibers Include fiber glass and heat shrinkablesynthetic fibers such as nylon, orion, and dacron.

15. When covering aircraft, where is surface tape used?Sewed seams, lapped edges, and rib stitching or screws must be covered pinked-edge surfacetape.

AIRCRAF-T COVERING PROJECTS1. Make a small sewed-on patch to a fabric covered structure.2. Make a small doped-on patch to a fabric covered structure.3. Make a strength test on doped aircraft fabric using a punch tester and determine if it Is withinminimum strength requirements or needs furtlher testing.4. Demonstrate how to tie both a splice knot and a modified seine knot.5. Demonstrate installing drain grommets on a small control surface.6. Hand sew a fabric tear using a baseball stitch and correct stitch spacing.7. Sew a french-fell and a folded-fell seam.8. Ust at least three types of material used In aircraft covering.9. Prepare a fabric sample for laboratory testing.

AIRCRAF-T FINISHES ORAL1. Name the safety and health precautions to be observed In operating a dope room, including storage

of male rial.The dope room should be well lighted and ventilated using spark proof motors. lights and switches.All flammable material should be stored In fireproof containers in protected areas. Dope and paintrooms that are not located In a separate building should be Isolated from the rest of the buildingby metal partitions and fireproof doors.

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2. What type of tests can be performed to Identify existing paint finishes?Apply a coat of engine all to a small area. Nitrocellulose will soften In a few minutes, but acrylicand epoxy will show no effects. If not Identified, next wipe down a small area with MEK. MEK willpick up pigment from an acrylic finish, but will not affect an epoxy coating.

S. What causes blushing when applying dope or lacquer, and how can it be prevented?When doping Is accomplished under humid conditions blushing Is common. Rapid evaporationof thinners and solvents lower the temperature of the surface of the wet cope causing condensationof moisture from the air. The moisture causes a milky white appearance known as blush. Thecondition may be eliminated by heating the room to decrease humidity, or by using a blushretardingthinner to increase the drying time. Blushing is also caused by moisture in the air supply, drafts,or changes in temperature.

4. What Is the purpose of using fungicidal dope when finishing aircraft fabric?To prevent mlcroblologlcal deterioration (rotting) of the fabric.

5. What are the Identification marking requirements for United Stales registered fixed wing aircraft?The Roman capital letter "N" followed by the registration number must be displayed on both sidesof the fuselage, or on both sides of the vertical tall sUrfaces. The height of the characters must beequal In sIze and be at least 12 inches, and the characters must be 2/3 as wide as they are high.The exceptions to the width rule are the number "1", which must be 1/6 as wide as it Is high, andthe letters "M" and "W', which may be as wide as they are high. Characters must be formed by solidlines 1/6 as thick as they ate high, and the spacing between each character may not be less than1/4 of the character width.

6. What'are three types of dope used for aircraft finishes?They are clear dope, semi.pigmented dope, and pigmented dope.

7. What would happen if dope was used over paint or enamel?It would have the tendency to lift and remove such materials.

8. What is applied to metallic surfaces as a corrosion resistant covering before the application ofenamel or lacquer?Zinc chromate primer is normally used for this purpose.

9. What are the most common methods of applying aircraft finishes?They are dipping, brushing, or spraying.

10. What type of paint may be used over any paint system that is In good condition?Epoxy topcoats will adhere to all the paint systems that are in good condition and may be usedgeneral touchup, including touchup of defects in baked enamel coatings.

11. What is normally the cause of runs and sags in a spray paint finish?HoldIng the gun too long In one place causing too much paint to be applied.

12, What causes an "orange peel" or "pebble" finish?The spray gun setting, Incorrect air pressure, incorrect paint viscosity, and holding the gun toofar from the work.

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13. What Is used to thin zinc chromate primer?Toluene.

14. Which federal regulation prescribes the size and location requirements for aircraft Identificationnumbers?FAR Pari 45

15. What type of materials should be thoroughly protected when using paint remover?Synthetic rubber surfaces, aircraft tires, fabric, and acrylics must be protected against possiblecontact with paint remover.

AIRCRAFT FINISHES PROJECTS

1. Correctly apply dope by brush to an aircraft fabric structure.2. Correctly apply dope with a spray gun to an aircraft fabric structure.3. Determine the type dope that was used on a fabric covered surface by suitable testing methods.4. Prepare a metal surface for painting, and apply the primer coat.5. Spray a topcoat finish on a metal surface without defects.6. Correctly Identity various paint finish defects from samples.7. Inspect a doped fabric covered structure and identify any defects such as pinholes, blushing,blisters, etc.B. Correctly match a list of finishing materials with the appropriate thinner for each.9. Correctly adjust a spray gun for painting primers or paints.10. On a three view drawing of an aircraft, determine where the registration numbers should be located.11. Using reference material, locate the requirements for aircraft registration numbers.

SHEET METAL STRUCTURES ORAL

1. What Is the grip length of a rivet?The grip length is the combined thickness of the materials to be Joined by the rivet.

2. Where are special rivets, such as Huck or Cherry lock rivets, used?They are used in places where access to both sides of the riveted structure Is Impossible, or wherelimited space will not permit the use of a bucking bar. These rivets require special tools, Installation.and removal procedures. They are commonly called blind rivets.

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3. What is bonded honeycomb (sandwich) construction?It is a laminar construction consisting of a combination of alternating dissimilar materials, assembledand fixed In relation to each other so that the properties of each can be used to attain specificstructural advantages for the whole assembly.

4. What type of materials are used in honeycomb construction?Honeycomb construction may employ stainless steel, titanium, magnesium, plywood, reslnImpregnated paper, glass, nylon, or colton cloth in various combinations.

5. Where are sandwich construction assemblies used?They are used for such areas as bulkheads, control surfaces, fuselage panels, wing panels,radomes, empennage skins, or shear webs.

6. What procedures should be used to prevent damage to the hole when drilling through plexiglas?The plexiglas should be backed with wood and the feed slowed as the drill point breaks throughthe underside of the sheet. A drill that Is to be used for this purpose should be modified to a 60'tip angle, the cutting edge to a zero rake angle, and the back lip clearance angle Increased to 12-15 degrees.

7. What calculation must be made when bending sheet metal?The amount of material required for the bend must be determined to assure that the linal dimensionswill be correct. Bending a strip of metal compresses the material on the inside of the curve, andstretches the material on the outside of the curve. However, In the approximate center betweenthese two extremes Is a space that Is neither stretched nor compressed which is called the neutralexls. When making a bend to exact dimensions the length of the neutral line must be calculatedso enough material can be allowed for the bend. Bend allowance depends on four factors: (1) thedegree of bend, (2) the radius of the bend, (al the thickness of the metal, and (4) the type of metalused. To save time In calculation of bend allowance, formulas and charts for various angles, radiiof bends, material thicknesses and other factors have been established.

8. What factors are used to determine setback?The radius of the bend and the thickness of the material. Setback = Radius + Thickness.

9. What Is a joggle?A joggle is an offset formed on an angle strip to allow clearance for a sheet or extrusion.

10. What are several methods used in forming sheet metal?Folding. bumping, crimping, shrinking, and stretching.

11. What may cause plastic to craze?Subjecting plastic to large stresses, and exposure to harmful solvents will cause crazing.

12. What rules apply for the replacement of 2017-T3 and 2024-T4 rivets with 2117-T3 rivets?You may replace 2017-T3 rivets of 3/16 Inch diameter or less, and 2024-T4 rivets of 5/32 Inchdiameter or less with 21t7-T3 rivets for general repairs. provided the replacement rivets are 1/32Inch greater In diameter than the rivets they replace, and the edge distances and spacing are notless than specified minimums.

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13. Briefly describe the anodizing process and what purpose it serves.Aluminum alloys are placed In an electrolytic bath which causes a thin film of hydroxide to formon the surface of the aluminum. This anodized coating not only provides excellent resistance tocorrosion, but It Is also an excellent bond for paint.

14. What are the acceptable repair methods for bonded honeycomb structure that has been damaged?There are two acceptable methods of repair currently being used on damaged skin and carematerials of bonded honeycomb structures. One Is the paned compound repair method. Theother Is the laminated glass fabric cloth overlay method, which Is applied to honeycomb damagewhich exceeds the repair limitations of the potted compound method.

15. What size drill should be used lor the common shank rivet diameters of 3/32 inch, 1/8 inch, and5/32 Inch?

For a 3/32 rivet, a number 41. For a l /B rivet, a number 30. For a 5/32 rivet, a number 22.16. What Is used for hole filling in a bonded honeycomb repair?

Potting compound.

SHEET METAL STRUCTURES PROJECTS

1. Repair a hole In the sheet metal skin of an aircraft by the riveted flush patch method.2. Remove several rivets by drilling.3. Layout and bend a piece 01 sheet metal to a specified angle.4. Bend a piece 01 metal to the minimum bend radius lor the type and thickness of the material.5. Inspect plastic windshield for cracks, craze, and scratches.6. Repair shallow surface scratches in transparent plastic enclosures.7. Identify window enclosure material samples.8. Select and use twist drills for drilling aluminum and steel.9. Correctly install several special rivets.10. Correctly repair a small damaged area In a bonded honeycomb structure.11. Select rivets of the proper diameter and length for different combinations 01 aluminum sheets withdifferent thicknesses.

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12. Why is it especially desirable to use a soft flame when welding aluminum?To avoid blowing holes In the metal when the puddle Is formed.

13. What Is the purpose of using flux when welding aluminum?Aluminum and Its alloys combine with air and form oxides very rapidly, and oxides form doublyfast if the metal Is hoI. Aluminum welding flux Is designed to remove the aluminum oxide bychemically combining with II. Aluminum fluxes dissolve below the surface of the puddle and floatthe oxides to the surface where they can be removed.

14. What is the maximum safe pressure for acetylene gas when welding?When acetylene gas is compressed In a container to a pressure greater that 15 psi It becomesdangerously unstable. At 29.4 psi acetylene Is self-explosive and only a slight shock can cause Itto explode.

15. How can dents at a steel tube cluster jOint be repaired?Weld a specially formed steel patch plate over the dented area and surrounding tubes.

16. What type of flame should be used when sliver soldering?The lIame should be neutral.

17. What are the procedures for preparing a metal fuel tank for welding?The interior of the tank should be washed thoroughly with hot water and a detergent, and thensteamed for a minimum of thirty minutes. This procedure will vaporize and remove any residualfuel in the tank. Then fill the tank with C02 gas from a fire extinguisher and seal the tank exceptfor a small vent hole.

16. When splicing tubing by the Inner sleeve method, what method can be used to insert a tight fittinginner sleeve into the replacement tube?The sleeve can be chilled with dry Ice or In cold water.

WELDING PROJECTS

1. Inspect different samples of steel welds and point out acceptable and non-acceptable welds.2. Inspect aluminum welds for acceptability.3. Select the proper torch tip for several metal samples to be welded.4. Select the proper size welding rod and alloy for several metal samples to be welded.5. Adjust an oxyacetylene torch to a neutral flame, and oxidizing flame, and a reducing flame.6. Use an oxyacetylene cutting torch to cut a piece of metal In half.7. Form a lap Joint by brazing.8. Using ferrous metal, make an oxyacetylene butt weld, a lap Joint weld, or a tee weld.9. Correctly use electric arc welding equipment to run a bead across a metal sample.10. Solder an electric wire to a connector.

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11. From pictures of tubular structures with damage, select the correct repair procedure from AdvisoryCircular 43.13-1A.12. Demonstrate both forehand and backhand welding procedures.

ASSEMBLY AND RIGGING ORAL

1. What are three types of commonly used flight control systems?They are the cable, the push-pull, and the torque tube systems. The cable system Is the mostwidely used because deHections of tile structure to which it is attached do not affect Its oparaIi::n

2. What Is used in large metal aircraft to keep control cable tension within acceptable limits?Because there Is a considerable difference In temperature expansion between the aluminum aircraftstructure and the steel control cables, some large aircraft incorporate cable tension regulators In thecontrol cable systems. These regulators are designed to maintain a given cable tension. The unitconsists of a compression spring and a locking mechanism which allows the spring to makecorrections in the system only when the cable system Is in neutral.

3. What Is a falrlead?It Is a cable guide used to guide cables in a straight line through or between structural membersof the aircraft. Falrleads shOUld never deflect the alignment of a cable more than 3' from a straightline.

4. Where does breakage of control cables occur most frequently?Breakage of wire strands occurs most frequently where cables pass over pulleys and throughfairleads.

5. Which flight control surfaces are considered the primary group?The elevators, the ailerons, and the rudder.

6. Which flight controls are considered the secondary group?The trim tabs and the spring tabs.

7. Which flight controls are Included in the auxiliary group?This group consists of the wing flaps, speed brakes, spoilers, slats, leading edge flaps and slots.

B. How do wing flaps affect landing speed and approach angle of an aircraft?The use of flaps Increase the camber of a wing and therefore the lift of the wing making it possiblefor the speed of the aircraft to be decreased without stalling. This permits a sleeper gliding angleto be obtained for the landing approach.

9. What Is a balance tab?It is an auxiliary control with fixed linkage that is designed in such a way that when the controlsurface is moved the tab moves In the opposite direction. Aerodynamic forces acting on the tabassists in moving the control surface.

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10, What Is a trim tab?It Is an auxiliary control attached to the trailing edge of a control suriace that is positioned bymovement of a cockpit control to balance the forces acting on the control suriace.

11, What is the purpose of the collective pitch control in a helicopter?It is used to change the lift (pitch) of the main rotor blades.

12, What unit on a helicopter Is used to compensate for torque created by the main rotor?Tlie) tall rotor.

13. What control operates the helicopter tail rotor?The anti-torque pedals.

14. What are the three axes of an aircraft, and which control suriaces cause the aircraft to move abouteach axis?The axis of an aircraft can be considered as an imaginary axle around which the aircraft turns likea wheel. The axis which extends through the fuselage from nose to tall is the longitudinal axis. Theaxis which extends crosswise, from wingtip to wingtip, is the lateral axis. The axis which passesthrough the center from top to bottom, is the vertical axis. Motion about the longitudinal axis iscalled roll and Is controlled by the ailerons. Motion around the lateral axis is called pitch and Isaffected by the elevators. Finally, motion about the vertical axis is called yaw and Is produced bythe rudder of the aircraft.

15. When Installing an aircraft bolt, what precaution would you take regarding the position of the bolt?Where possible, the bolt head should be posltfoned on top when a bolt is Installed vertically, andthe bolt head shoul,d be forward when It is installed horizontally. In these positions the bolt is lesslikely to slide out if the locking device comes off.

16. How is propeller torque corrected for during assembly and rigging In some single engine aircraft?Some aircraft have the leading edge of the vertical fin offset to the longitudinal center line tocounteract engine torque.

17. What reference publications should be used to rig an aircraft, inc!udlng the control system?You should refer to the Aircraft Specifications or Type Certfficate Data Sheets issued by the FAA,and also to the Maintenance Manual issued by the manufacturer.

ASSEMBLY AND RIGGING PROJECTS

1. Remove and reinstall a primary flight control.2. Inspect a flight system for travel and security.3. Check for correct position of flight control surfaces when the cockpit controls are In variouspositions.4. Inspect primary control cables for corrosion and broken strands.5. Adjust cable tension In the flight control system of a small aircraft.6. Install swaged cable terminals.

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7, Adjust a push-pull control system to obtain the correct surface travel.B, Remove and reinstall a primary flight control cable,9. Check a control surface for static balance,10, Locate the jacking points on a specific airplane.11, List the three aircraft axes and name the control surface that provides movement about each of thethree axes,12, Check the alignment of landing gear,13, Identify fixed wing aircraft rigging adjustment locations.14, Locate the information for tracking the main rotor blades on a helicopter.

AIRFRAME INSPECTION ORAL

1. What needs to be done to prepare an aircraft for an annual or 100 hour Inspection?Before starting either Inspection the aircraft the aircraft engine should be thoroughly cleaned.Then you must remove or open all necessary inspection plates, access doors, fairings and cowling,

2. What is the difference between an annual and a 100 hour inspection?Except for the difference in time between inspections there Is no difference between the annualand the 100 hour Inspection. They are identical in scope.

3. Who has the authority to sign off and return to service a 100 hour inspection?A certified Airframe and Powerplant mechanic may return an aircraft to service after a 100 hourInspection,

4, What are the operating conditions which make the 100 hour inspection mandatory?The 100 hour inspection is required for aircraft that carry persons for hire or Is used to give flightinstruction for hire.

5, Where can you find a checklist for the 100 hour inspection?In FAR Part 43, Appendix D,

6, Where would you find the recommended statement for recording the approval or disapproval forreturn to service of an aircraft after a 100 Inspection?In FAR Part 43,

7. Who can approve an aircraft for return to service after an annual inspection?An A & P mechanic who holds an Inspection Authorization (IA},

8. Who can approve an aircraft for return to service after a progressive inspection has been performed?A certified mechanic holding an Inspection Authorization, the aircraft manufacturer, or'acertificated repair station,

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9. Does an aircraft being operated under a progressive inspection program require a 100 hourinspection if It Is used to give flight Instruction for hire?No.

10. What are the privileges of a certificated mechanic with regards to propellers?A certiffcated powerplant mechanic may make minor repairs and alterations to a propeller. He Isnot authorized to make malor repairs or major alterations to propellers.

j j WhAt Is the maximum time that a 100 hour Inspection may be extended?Not more than 10 hours.

AIRFRAME INSPECTION PROJECTS1. Perform a 100 hour Inspection on an aircraft.2. Make all the required entries In the permanent maintenance records for a 100 hour Inspection.3. Inspect an aircraft and the maintenance records to determine if all applicable AirworthinessDirectives have been complied with.4. Determine from the aircraft maintenance records when the next 100 hour inspection is due.5. Determine from the aircraft maintenance records when the next annual Inspection is due.6. Inspect an aircraft after maintenance and determine if the aircraft Is ready for return to service.7. Determine from the aircraft maintenance records if any repetitive Inspections are required byAirworthiness Directives and when they are due

.AIRFRAME SYSTEMS AND COMPONENTSAIRCRAFT LANDING GEAR SYSTEMS ORAL

1. What are two sources of power used to extend and retract landing gear?They are electrical and hyd raullc.

2. When should landing gear retraction checks be accomplished?During annual and other type inspections, after replacing landing gear components, and after anyhard landing.

3. What is used to Inflate an oleo type landing gear shock strut?Inflate the strut with a high pressure source of dry air or nitrogen.

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4. Where would you look to find proper tire Inflation information?When inflating aircraft tires the amount of pressure Is determined by such factors as tire size. outsideair temperature and the gross weight of the aircraft. Specific tire Infiatlon Information may be foundIn the Operators Manual, the Aircraft Maintenance Manual and in special tire Inflation pressure chartsbased on gross weight.

5. What Is the purpose of a hydraulic shimmy damper?It is a unit designed to prevent nose wheel Vibration or shimmy during taxiing, landing, or takeoff.

6. What type care shOUld be given to landing gear shock struts?They shOUld be Inspected regularly for leakage of fluid and for proper extension. The exposedportion of the strut piston should be wiped clean daily and Inspected for scoring or corrosion.

7. What Is the effect of under inflated tires?Under Inflated tires are more likely to creep or slip on the wheel when landing or when brakes areapplied. Under Inflation also causes rapid or uneven wear at or near the edges of the tread.

8. What Is the purpose of the rubber packing mounted on the mating surface of the outer wheel half ofa split type wheel?To prevent air leakage from the tubeless tire used with this wheel.

9. WhaLare three types of aircraft brake systems?The independent, the power boost, and the power control type.

10. What is the purpose of a shuttle valve in a power brake system?Each brake actuating line In a power brake system incorporates a shuttle valve for the purpose ofIsolating the emergency brake system from the normal brake system. When emergency brakeactuating pressure enters the shuttle valve, the shuttle is systematically moved to the opposite endof the valve. This closes off the normal hydraulic brake system actuating line and allow theemergency fluid to actuate the brakes.

11. What component in the landing gear system keeps the landing gear in alignment?The landing gear torque links.

12, What Is used to prevent a nose gear from being retracted with the wheel out of the center position?Centering devices, such as an Internal centering cam or an external track, that straighten the nosewheel before it enters the wheel well.

13. What Is the purpose of the fusible plug In some aircraft wheels?It Is designed to melt at specific elevated temperatures and relieve air pressure to prevent the lirefrom blowing out or breaking of the wheel.

14. What is the purpose of the antis kid system?To bring the airplane to a stop without skidding by providing effective braking under all types ofrunway conditions.

15. What are two methods of bleeding brakes?The gravity method and the pressure method.

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AIRCRAFT LANDING GEAR SYSTEMS PROJECTS

1. Operate and check a retractable landing gear system.2. Remove, Inspect, and reinstall an aircraft wheel assembly.3. Remove and reinstall a wheel brake assembly.4. Service a landing gear oleo shock strut and check for leaks.5. Perform brake system bleeding.6. Remove and replace brake linings in a hydraulically operated single disk brake system.7. Demount, Inspect, and reinstall aircraft tires on wheels.8. Service a nose wheel shimmy damper with hydraulic fluid and air.9. Inspect a landing gear for alignment.10. AqJust nose wheel steering pushpull rods or cables.11. Inspect tires and determine if they are airworthy.12. List the conditions necessary for proper storage of aircraft tires.13. TroubleShoot an aircraft steering system.14. Replace the seals in a master brake cylinder.

HYDRAUUC AND PNEUMATIC POWER SYSTEMS ORAL

1. What are the three types of hydraulic fluid currently being used in civil aircraft?They are vegetable base, minerai base, and phosphate ester base fluids.

2. What Is the color of mineral base hydraulic fluid?It Is red.

3. How do you determine Which type of hydraulic fluid to use In a specific system?The type lIuid is specified In the aircraft maintenance manual, or on the instruction plate attachedto the reservoir or unit being serviced.

4. What will happen to the seals In a vegetable base hydraulic system if It Is serviced with mineral baseor phosphate ester base fluids?The seals will swell. break down. and black the system.

5. When hydraulic lines have been disconnected. what precautions should be taken to preventcontamination of the system?All hydraulic lines and fittings should be capped or plugged immediately after disconnecting.

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6. What happens to the hydraulic fluid flow iF the Filter element becomes clogged with foreign matter?There Is a bypass valve which routes the hydraulic fluid directly form the Inlet port to the outletport.

7. Why are some hydraul ic reservoirs pressurized?To ensure a" positive flow of fluid to the engine driven pump at high altitudes.

8. What methods are used to pressurize hydraulic rese(\/oirs?Some systems use air pressure directly from the aircraft. cabin pressurization system, or from theengine compressor in turbine powerec aircraft.. Another method is an aspirator or venturi-tee.

9_ Name three types of hydraulic accumulators?The diaphragm type, the bladder type, and the piston

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Aviation Mechanic Practical Test Guide

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