SS9208 Rev 48 (Production Acceptance Criteria)

Verify current revision of this document in WorldView prior to use.

PREP. E. JARONCZYK

APVD.J. SONICK

GOVT.SUPERSEDES: SHEET ___1___ OF 64___

SS 9208

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CAGE NUMBER

78286

SIKORSKYSPECIFICATION

MATERIAL & PROCESS

J. BONNEY

10/2

7/83

PRODUCT DEFINITIONACCEPTANCE CRITERIA

6900 MAIN ST STRATFORD, CT06497-9129

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5140 R

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/97

WARNING THIS DOCUMENT, OR AN EMBODIMENTOF IT IN ANY MEDIA, DISCLOSES INFORMATIONWHICH IS PROPRIETARY, IS THE PROPERTY OF SI�KORSKY AIRCRAFT CORPORATION, IS AN UNPUB�LISHED WORK PROTECTED UNDER APPLICABLECOPYRIGHT LAWS, AND IS DELIVERED ON THE EX�PRESS CONDITION THAT IT IS NOT TO BE USED,DISCLOSED, OR REPRODUCED, IN WHOLE OR INPART (INCLUDING REPRODUCTION AS A DERIVA�TIVE WORK), OR USED FOR MANUFACTURE FORANYONE OTHER THAN SIKORSKY AIRCRAFT WITH�OUT ITS WRITTEN CONSENT, AND THAT NO RIGHTIS GRANTED TO DISCLOSE OR SO USE ANY IN�FORMATION CONTAINED THEREIN. ALL RIGHTSRESERVED. ANY ACT IN VIOLATION OF APPLICA�BLE LAW MAY RESULT IN CIVIL AND CRIMINAL PEN�ALTIES.

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1/31

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48

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4/02

TABLE OF CONTENTS

SECTION TITLE PAGE

TABLE OF CONTENTS 1

SCOPE 2

APPLICABILITY 2

1.0 ANGULAR TOLERANCE FOR SHEET METAL FLANGES 3

2.0 CHAMFER OR RADIUS OF EXTERNAL CORNERS 3

3.0 ACCEPTANCE OF SURFACE IMPERFECTIONS 4

4.0 REPLACEMENT FASTENERS (SOLIDS, HI–LOKS, 5

5.0 REPLACEMENT FASTENERS (BLIND FASTENERS) 11

6.0 RIVETS FOR NUT PLATE INSTALLATION 14

7.0 EDGE ACCEPTANCE OF ALUMINUM SHEET METAL DETAILS 15

8.0 ACCEPTANCE ASSEMBLY METHODS 15

8.1 SHIMMING METALLIC AIRFRAME COMPONENTS 16

8.2 TRIMMING METALLIC AIRFRAME SKINS 21

8.3 TRIMMING METALLIC AIRFRAME COMPONENTS 23

8.4 PILOT HOLES THAT BREAK INTO FINISHED FASTENER HOLES 34

8.5 DIMENSIONAL TOLERANCES FOR FORMED SHEET METAL FLANGES 35

8.6 ACCEPTANCE CRITERIA TO MEET PROPER GRIP LENGTH OF MECHANICALLY LOCKED FASTENERS. 36

8.7 ACCEPTANCE CRITERIA TO MEET PROPER GRIP LENGTH OF 1/4 TURN CAMLOC FASTENER 39

8.8 ACCEPTANCE CRITERIA FOR PIN HOLE LOCATIONS 40

9.0 INTERCHANGEABLE FASTENERS (STUMP & PULL TYPE LOCKBOLTS) 43

10.0 SAFETY WIRING / SAFETY CABLE 44

11.0 ACCEPTANCE CRITERIA TO MEET THREAD PROTUSION 45

12.0 ACCEPTANCE CRITERIA FOR EDGE AND PITCH DISTANCE 50

13.0 COATINGS AND FINISHES 59

14.0 ACCEPTANCE CRITERIA FOR CASTINGS / FORGINGS 61

15.0 SCREW THREADS 62

15.1 SCREW THREADS ON ELECTRICAL CONNECTORS 62

15.2 THREADED FASTENERS WITH INCONSISTANT FUNCTIONAL ELEMENT/SIZE 62

16.0 CONTROL COMPONENTS 63

16.1 PROOF PRESSURE TESTING OF FLUID COMPONENTS AND PROOFTESTING OF CONTROL CABLE ASSEMBLIES 63

17.0 ELECTRICAL COMPONENTS 64

17.1 GROMMET ALTERNATES 64

17.2 WIRE MARKING CRITERIA FOR ALLSIKORSKY AIRCRAFT WIRING. 64

S21574

WARNING THIS DOCUMENT, OR AN EMBODIMENT OF IT IN ANY MEDIA, DISCLOSES INFORMATION WHICH IS PROPRIETARY, IS THE PROPERTY OF SI� KORSKY AIRCRAFT CORPORATION, IS AN UNPUB� LISHED WORK PROTECTED UNDER APPLICABLE COPYRIGHT LAWS, AND IS DELIVERED ON THE EX� PRESS CONDITION THAT IT IS NOT TO BE USED, DISCLOSED, OR REPRODUCED, IN WHOLE OR IN PART (INCLUDING REPRODUCTION AS A DERIVA� TIVE WORK), OR USED FOR MANUFACTURE FOR ANYONE OTHER THAN SIKORSKY AIRCRAFT WITH� OUT ITS WRITTEN CONSENT, AND THAT NO RIGHT IS GRANTED TO DISCLOSE OR SO USE ANY IN� FORMATION CONTAINED THEREIN. ALL RIGHTS RESERVED. ANY ACT IN VIOLATION OF APPLICA� BLE LAW MAY RESULT IN CIVIL AND CRIMINAL PEN� ALTIES.

S21574


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78286CAGE NUMBER

10/2

7/8

3

SS9208SHEET 2

30 12/15/94

11/27/95

4848

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5139-

1 R

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/97

WARNING THIS DOCUMENT, OR AN EMBODIMENT OF IT IN ANY MEDIA, DISCLOSES INFORMATION WHICH IS PROPRIETARY, IS THE PROPERTY OF SIKORSKY AIRCRAFT CORPORATION,IS AN UNPUBLISHED WORK PROTECTED UNDER APPLICABLE COPYRIGHT LAWS, AND IS DELIVERED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED, DISCLOSED, OR REPRO�DUCED, IN WHOLE OR IN PART (INCLUDING REPRODUCTION AS A DERIVATIVE WORK), OR USED FOR MANUFACTURE FOR ANYONE OTHER THAN SIKORSKY AIRCRAFT CORPORATIONWITHOUT ITS WRITTEN CONSENT, AND THAT NO RIGHT IS GRANTED TO DISCLOSE OR SO USE ANY INFORMATION CONTAINED THEREIN. ALL RIGHTS RESERVED. ANY ACT IN VIOLATIONOF APPLICABLE LAW MAY RESULT IN CIVIL AND CRIMINAL PENALTIES.

STRATFORD, CONNECTICUT 06497-9129

12/0

4/02

48

SCOPE: This specification authorizes product definition/acceptance criteria tobe used in conjunction with Sikorsky Aircraft drawings. This specification will define criteria such as tolerances, process criteria and acceptance criteria that is not defined on the drawing.

Unless otherwise specified, dimensions are in inches.

APPLICABILITY: This specification applies when invoked on the Engineering Parts List.When SS9208 is invoked, the practices and standards described herein may be used in fabrication and inspection of the parts unlessa drawing note appears on the drawing specifically excluding the practice or standard.

INDEX OF SHEETS REVISION DATE

PG# REV# PG# REV# PG# REV# REV DATE REV DATE

1 48 28 48 55 48 1 5/17/84 24 10/3/90

2 48 29 48 56 48 2 8/23/84 25 10/22/90

3 30 30 48 57 48 3 7/19/85 26 2/7/91

4 47 31 48 58 48 4 8/14/85 27 5/15/92

5 47 32 48 59 48 5 6/13/86 28 11/9/92

6 48 33 48 60 48 6 1/27/87 29 12/4/92

7 48 34 48 61 48 7 7/23/87

8 48 35 48 62 48 8 1/13/88 31 9/15/95

9 48 36 48 63 48 9 3/7/88 32

10 48 37 48 64 48 10 4/20/88 33 1/20/96

11 48 38 48 11 6/6/88 34 3/19/96

12 48 39 48 12 8/17/88 35 4/15/96

13 48 40 48 13 8/18/88 36 12/13/96

14 48 41 48 14 VOID 37 2/13/97

15 47 42 48 15 2/9/89 38 7/21/97

16 47 43 48 16 6/26/89 39 10/20/98

17 47 44 48 17 7/21/89 40 1/28/99

18 48 45 48 18 8/29/89 41 7/26/99

19 48 46 48 19 11/16/89 42 9/3/99

20 48 47 48 20 1/4/90 43 10/8/99

21 48 48 48 21 4/23/90 44 11/09/00

22 48 49 48 22 6/29/90 45 1/17/01

23 48 50 48 23 9/10/90 46 1/31/01

24 48 51 48 47 10/23/02

25 48 52 48 48 12/04/02

26 48 53 48

27 48 54 48

S21574

WARNING THIS DOCUMENT, OR AN EMBODIMENT OF IT IN ANY MEDIA, DISCLOSES INFORMATION WHICH IS PROPRIETARY, IS THE PROPERTY OF SIKORSKY AIRCRAFT CORPORATION, IS AN UNPUBLISHED WORK PROTECTED UNDER APPLICABLE COPYRIGHT LAWS, AND IS DELIVERED ON THE EXPRESS CONDITION THAT IT IS NOT TO BE USED, DISCLOSED, OR REPRO� DUCED, IN WHOLE OR IN PART (INCLUDING REPRODUCTION AS A DERIVATIVE WORK), OR USED FOR MANUFACTURE FOR ANYONE OTHER THAN SIKORSKY AIRCRAFT CORPORATION WITHOUT ITS WRITTEN CONSENT, AND THAT NO RIGHT IS GRANTED TO DISCLOSE OR SO USE ANY INFORMATION CONTAINED THEREIN. ALL RIGHTS RESERVED. ANY ACT IN VIOLATION OF APPLICABLE LAW MAY RESULT IN CIVIL AND CRIMINAL PENALTIES.


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1. ANGULAR TOLERANCE FOR SHEET METAL FLANGES .

1.1 The angular tolerance for sheet metal flanges with a flange height greater than .44” but not more than 1.5” shall be ± 2°. The flange angle as producedshall not vary more than 1° over its entire length. Good shop practice shall be followed and kinks or crimps are not acceptable.

1.2 The angular tolerance for sheet metal flanges with a flange height of .44” orless shall be ± 30°. The flange angle as produced shall not vary more than 1° over its entire length. Good shop practice shall be followed and kinks or crimps are not acceptable.

Paragraph 1.1 does not apply when the field of drawing calls out a specified angular tolerancefor sheet metal flanges.

2. CHAMFER OR RADIUS ON EXTERNAL CORNERS .

2.1 Extruded parts with a .25 X 45° chamfer or less, or .25 radius or less, specifiedor drawn on an undimensioned drawing, either a .25 radius or a .25 X 45°chamfer is acceptable and dependent on the process used.

.25R.25 X 45° CHAMFER

Paragraph 2.1 does not apply when the field of drawing calls out a chamfer of .25 X 45° or less,or a .25 radius or less, each having a specified linear tolerance.

.25 ± XX x 15°R

XX

XX

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3. ACCEPTANCE OF SURFACE IMPERFECTIONS

3.1 The visual inspection for nicks, dents, scratches, machining tool marks andscuff marks shall be conducted by Quality Assurance personnel. Theacceptance of these detected irregularities are determined by engineeringdrawing requirements and the following:

3.1.1 Irregularities, such as nicks, dents, scratches, machining tool marks and scuffmarks, on Flight Safety parts with critical characteristics, are acceptable whenthey are .0005 inch deep or less. For all other parts, irregularities, such asnicks, dents, scratches, machining tool marks and scuff marks, are acceptablewhen they fall within drawing specified finish requirements.

3.1.2 Surface irregularities, which have been shot peened over, will be acceptableif they meet the surface requirements of the engineering drawing and under10x magnification, exhibit shotpeen coverage throughout the irregularity.

4. REPLACEMENT FASTENERS (Limited Usage)

NOTE: These allowances are for occasional replacements, repetitive use in any location requires investigation and possible drawing correction. Complete pattern replacement of Lockbolts or rivets with Hi–lock fasteners is acceptable without limitation of 4.1 b,c.

4.1 Solid Rivets, Hi–Loks, Lock Bolts.In cases where non–blind fastener installation is difficult or impossible forreasons of temporary inaccessibility, unavailability of the fastener,unavailability or inference of the tooling Tables I through IV may be used toprovide replacement blind fasteners providing the following are met:(Note: Tables I through IV may also be applied in the reverse condition.)

a) The number of replacement blind fasteners shall not exceed 10% (1 in 10, 10 in 100,etc.) of the total number of solid rivets, Hi–Loks or Lockbolts that are required to joinany one detail part or assembly to any other detail part or assembly. For example,where a stringer joins to a skin, a frame joins to a skin panel assembly or skin panelassemblies are joined together. This applies to Tables I through IV.

b) Hi–Lok fasteners (Table III) may be used to replace steel lockbolts where installedspace does not permit.

c) The number of replacement Hi–Loks (Table IV) for aluminum lockbolts shall notexceed 10 percent (1 in 10,10 in 100, etc ) of the original total number of aluminumlockbolt.

d) All hole sizes for replacement fastener shall conform to SS5100.

e) Blind and non–blind fasteners shall not be mixed together in splice joints.

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f) All blind fasteners shall be wet installed using epoxy primer per Mil–P–23377. Bothends of the rivet must be covered with primer upon completion of the installation.

g) Rivet length shall be determined by Manufacturing Personnel through the use of agrip gage.

h) Minimum sheet thickness must be met where specified.

4.1.1 Aluminum Hiloks can replace Aluminum Lockbolts, Aluminum rivets oraluminum sleeved blind fasteners providing the following is met:

a) A pattern of 1 to 4: Replace 100% of the pattern.

b) A pattern of 5 to 10: Replace 1 fastener or 100% of the pattern.

c) A pattern of 11 or more : Indivual replacement fastener in a line of fasteners areallowed provided that the next replacement fastener is 9 fasteners or more away;or 100% of the pattern.

4.1.2 Steel Hiloks can replace steel rivets or steel sleeved blind fasteners providedthe above are met:

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TABLE 1 (SOLID RIVETS)

NAS523CODE

DRAWING CALLOUT

BLIND REPLACEMENTS

MIN. SHEETTHICKNESS

MS20426AD4 NAS1739B4M7885/7–4

.040 (a)

BB MS20426AD5 NAS1739B5M7885/7–4

.050 (a)

MS20426AD6 NAS1739B6M7885/7–4

.071 (a)

MS20470AD4 NAS1738B4M7885/6–4

.032 (b)

BJ MS20470AD5 NAS1738B5M7885/6–5

.040 (b)

MS20470AD6 NAS1738B6M7885/6–6

.050 (b)

NAS1097AD4 NAS1739B4M7885/7–4

.040 (a)

LZ NAS1097AD5 NAS1739B5M7885/7–4

.050 (a).

NAS1097AD6 NAS1739B6M7885/7–4

.071 (a)

a) Minimum sheet thickness must be met on the sheet that lies against themanufactured countersunk head to avoid knife edge conditions.

b) For solid universal head rivets to be replaced with blind protruding head rivets, eachof the sheets being riveted must meet the minimum sheet thickness requirement.


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TABLE II (HI–LOKS)

NAS523CODE

DRAWINGCALLOUT

BLINDREPLACEMENT

MIN. SHEET-THICKNESS(a)

.AHT

HL20PB–5HL20PB–6HL20PB–8HL20PB–10HL20PB–12HL20PB–14HL20PB–16

MS90354–05MS90354–06MS90354–08MS90354–10MS90354–12MS90354–14MS90354–16

N.A.N.AN.A.N.AN.A.N.A.N.A.

WY

HL19PB–5HL19PB–6HL19PB–8HL19PB–10HL19PB–12

MS90353–05MS90353–06MS90353–08MS90353–10MS90353–12

.080

.090

.125

.160

.190

a) Minimum sheet thickness must be met where specified, on the sheet that liesagainst the manufactured countersunk head to avoid knife edge conditions.


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TABLE III (STEEL LOCK BOLTS)

NAS523CODES

DRAWINGCALLOUT

STANDARDREPLACEMENT

COLLARS MIN. SHEETTHICKNESS(a)

BLINDREPLACEMENT

MIN. SHEETTHICKNESS(a)

NAS1415 HL19PB–5 Note (1) .050 MS90353–05 .080

EA NAS1416 HL19PB–6 Note (1) .063 MS90353–06 .090

JY NAS1418 HL19PB–8 Note (1) .080 MS90353–08 .125

OP NAS1420 HL19PB–10 Note (1) .100 MS90353–10 .160

NAS1422 HL19PB–12 Note (1) .125 MS90353–12 .190

NAS1425 HL20PB–5 Note (2) N.A. MS90354–05 N.A.

DY NAS1426 HL20PB–6 Note (2) N.A. MS90354–06 N.A.

JW NAS1428 HL20PB–8 Note (2) N.A. MS90354–08 N.A.

OS NAS1430 HL20PB–10 Note (2) N.A. MS90354–10 N.A.


DZ NAS1436 HL19PB–6 Note (1) .063 MS90353–06 .090

JX NAS1438 HL19PB–8 Note (1) .080 MS90353–08 .125

OO NAS1440 HL19PB–10 Note (1) .100 MS90353–10 .160

NAS1442 HL19PB–12 Note (1) .125 MS90353–12 .190

DX NAS1446 HL20PB–6 Note (2) N.A. MS90354–06 N.A.

JV NAS1448 HL20PB–8 Note (2) N.A. MS90354–08 N.A.

OR NAS1450 HL20PB–10 Note (2) N.A. MS90354–10 N.A.


DV NAS1456 HL21PB–6 Note (2) .090 MS90353–06 .090

NAS1458 HL21PB–8 Note (2) .125 MS90353–08 .125

DW NAS1460 HL21PB–10 Note (2) .160 MS90353–10 .160

NAS1462 HL21PB–12 Note (2) .190 MS90353–12 .190

Continued on next page.Note (1). Hi–Lok Collars; HL70, HL79, HL82 and HL1094 may be used.Note (2). Hi–Lok Collars; HL75 and HL1087A may be used.

(a) Minimum sheet thickness must be met where specified, on the sheet that liesagainst the manufactured countersunk head to avoid knife edge conditions.


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TABLE III (STEEL LOCK BOLTS) CONTINUED

NAS523CODES

DRAWINGCALLOUT

STANDARDREPLACEMENT


BLINDREPLACEMENT



DS NAS1466 HL20PB–6 Note (2) N.A. MS90354–06 N.A.

DT NAS1468 HL20PB–8 Note (2) N.A. MS90354–08 N.A.



RC NAS1486 HL21PB–6 Note (2) .090 MS90353–06 .090

NAS1488 HL21PB–8 Note (2) .125 MS90353–08 .125

RD NAS1490 HL21PB–10 Note (2) .160 MS90353–10 .160

NAS1492 HL21PB–12 Note (2) .190 MS90353–12 .190


RE NAS1497 HL20PB–5 Note (2) N.A. MS90354–05 N.A.

RF NAS1498 HL20PB–8 Note (2) N.A. MS90354–08 N.A.



Note (1). Hi–Lok Collars; HL70, HL79, HL82 and HL1094 may be used.Note (2). Hi–Lok Collars; HL75 and HL1087A may be used.



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TABLE IV (ALUMINUM LOCK BOLTS)

NAS523CODES

DRAWINGCALLOUT

STANDARDREPLACEMENT


BLINDREPLACEMENT


NAS1516 HL21PB–6 Note (2) .090 MS90353–06 .090

CP NAS1518 HL21PB–8 Note (2) .125 MS90353–08 .125

NAS1520 HL21PB–10 Note (2) .160 MS90353–10 .160

NAS1522 HL21PB–12 Note (2) .190 MS90353–12 .190



CS NAS1528 HL20PB–8 Note (2) N.A. MS90354–08 N.A.



NAS1535 HL19PB–5 Note (1) .050 MS90353–05 .080

NAS1536 HL19PB–6 Note (1) .063 MS90353–06 .090

DJ NAS1538 HL19PB–8 Note (1) .080 MS90353–08 .125

NAS1540 HL19PB–10 Note (1) .100 MS90353–10 .160

NAS1542 HL19PB–12 Note (1) .125 MS90353–12 .190

NAS1546 HL21PB–6 Note (2) .090 MS90353–06 .090

CW NAS1548 HL21PB–8 Note (2) .125 MS90353–08 .125

NAS1550 HL21PB–10 Note (2) .160 MS90353–10 .160

NAS1552 HL21PB–12 Note (2) .190 MS90353–12 .190



CV NAS1558 HL20PB–8 Note (2) N.A. MS90354–08 N.A.



NAS6915 HL19PB–5 Note (1) .050 MS90353–05 .080

NAS6916 HL19PB–6 Note (1) .063 MS90353–06 .090

NAS6918 HL19PB–8 Note (1) .080 MS90353–08 .125

NAS6920 HL19PB–10 Note (1) .100 MS90353–10 .160

NAS6922 HL19PB–12 Note (1) .125 MS90353–12 .190

Note (1). Hi–Lok collars; HL70, HL79, HL82 and HL1094 may be used.Note (2). Hi–Lok collars; HL75 and HL1087A may be used.



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5. REPLACEMENT FASTENERS (LIMITED USAGE)

5.1 Tables V thru VII may be used to provide replacement fasteners for thedrawing callout providing the following criteria are met :

a) All hole sizes for replacement fasteners shall conform to SS5100.

b) Rivet length shall be determined by Manufacturing Personnel through the use of agrip gage.

c) Minimum sheet thickness must be met where specified.


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TABLE V

NAS523 DRAWING REPLACEMENT MIN. SHEET

CODE CALLOUT FASTENER(S) THICKNESS(a)

MS20600AD4 NAS1738B4M7885/6–4

N.A.

AA MS20600AD5 NAS1738B5M7885/6–5

N.A.

MS20600AD6 NAS1738B6M7885/6–6

N.A.

MS20600B4 NAS1738B4M7885/6–4

N.A.

AB MS20600B5 NAS1738B5M7885/6–5

N.A.

MS20600B6 NAS1738B6M7885/6–6

N.A.

MS20600M4 NAS1738MW4 N.A.

JS MS20600M5 NAS1738MW5 N.A.

MS20600M6 NAS1738MW6 N.A.

MS20601AD4 NAS1739B4M7885/7–4

.040

AC MS20601AD5 NAS1739B5M7885/7–5

.050

MS20601AD6 NAS1739B6M7885/7–6

.071

MS20601B4 NAS1739B4M7885/7–4

.040

AE MS20601B5 NAS1739B5M7885/7–5

.050

MS20601B6 NAS1739B6M7885/7–6

.071

MS20601M4 NAS1739MW4 .040

JT MS20601M5 NAS1739MW5 .050

MS20601M6 NAS1739MW6 .071



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TABLE VII (ALUMINUM LOCKBOLTS)

NAS523CODES

DRAWINGCALLOUT

STANDARDREPLACEMENT

COLLARS MIN. SHEETTHICKNESS

CP NAS1516 HL23–6 NOTE (3) 0.07

CSCSCS

NAS1525NAS1526NAS1528

HL22–5HL22–6HL22–8

NOTE (3)NOTE (3)NOTE (3)

N.A.N.A.N.A.

DJDJ

NAS1535NAS1536

HL23–5HL23–6

NOTE (3)NOTE (3)

0.0630.07

CW NAS1546 HL23–6 NOTE (3) 0.07

CVCVCV

NAS1555NAS1556NAS1558

HL22–5HL22–6HL22–8

NOTE (3)NOTE (3)NOTE (3)

N.A.N.A.N.A.

NAS6915NAS6915

HL23–5HL23–6

NOTE (3)NOTE (3)

0.0630.07

NOTE (3) HI–LOK COLLARS ; HL77, HL182, HL277, MAY BE USED.

a) Minimum sheet thickness must be met, where specified, on the sheet that liesagainst the manufactured countersunk head to avoid knife edge conditions


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TABLE VI

NAS523 DRAWING REPLACEMENT MIN. SHEET

CODE CALLOUT FASTENER(S) THICKNESS(a)

NAS1919B04 NAS1738B4M7885/6–4, NAS1919B04S

N.A.

AFJ NAS1919B05 NAS1738B5M7885/6–5, NAS1919B05S

N.A.

NAS1919B06 NAS1738B6M7885/6–6, NAS1919B06S

N.A.

NAS1919C04 NAS1738CW4, NAS1919C04S N.A.

WE NAS1919C05 NAS1738CW5, NAS1919C05S N.A.

NAS1919C06 NAS1738CW6, NAS1919C06S N.A.

NAS1919M04 NAS1738MW4, NAS1919M04S N.A.

WD NAS1919M05 NAS1738MW5, NAS1919M05S N.A.

NAS1919M06 NAS1738MW6, NAS1919M06S N.A.

NAS1921B04 NAS1739B4M7885/7–4, NAS1921B04S

.040

AFH NAS1921B05 NAS1739B5M7885/7–5, NAS1921B05S

.050

NAS1921B06 NAS1739B6M7885/7–6, NAS1921B06S

.071

NAS1921C04 NAS1739CW4, NAS1921C04S .040

WH NAS1921C05 NAS1739CW5, NAS1921C05S .050

NAS1921C06 NAS1739CW6, NAS1921C06S .071

NAS1921M04 NAS1739MW4, NAS1921M04S .040

WF NAS1921M05 NAS1739MW5, NAS1921M05S .050

NAS1921M06 NAS1739MW6, NAS1921M06S .071


6. RIVETS FOR NUT PLATE INSTALLATION

6.1 Cherry Fastener CCR264SS, (steel, blind rivet), shall be considered optionalfor nut plate installation in lieu of MS20426 solid rivet.The CCR264SS fastenershall not be used as a replacement for the MS20426 fastener in exteriorsurfaces.


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6.1.1 Cherry Fastener CR1122 (ALUMINUM blind rivets) shall be consideredoptional for nut plate installation in lieu of MS20426 aluminum solid rivets forexterior and interior installations.

6.2 Cherry Fastener CCR244SS (steel, blind rivet), shall be considered optionalfor nut plate installation in lieu of NAS1097.The CCR244SS fastener shall notbe used as replacement for the NAS1097 fastener in exterior surfaces.

7. EDGE ACCEPTANCE OF ALUMINUM SHEET METAL DETAILS

7.1 The tolerance of .000 –.015 is optional in place of the existing break sharpedge requirement of .005 –.015 (radius or chamfer) provided:

a) The process used is capable of this tolerence without producing a knife edge andall details shall remain free of burrs .

b) This applies only to aluminum sheet .012 –.125 thick.

7.1.1 Paragraph 7.1 shall not apply to:

(1.) Specific Field of Drawing notes pertaining to radius/chamfered edges

(2.) Fastener holes that have been opened to final size

(3.) SS1038 or SS1040 flanged holes.

8. ACCEPTABLE ASSEMBLY METHODS

8.1 Shimming aluminum to other Metallic Airframe Components

8.1.1 Applicability

a. During the assembly of sheet metal or thin walled machined fittingswith forgings, castings, other sheet metal members or thin walled machinefittings, gaps may occur that require shimming for proper fit.

8.1.2 Limitations

a. The elements of this shimming section do not apply to the assembly ofmachined, forged or cast parts in such assemblies as rotor heads,transmissions, etc.

b. Gaps are not allowed for machined fitting components equal to 0.070in.or greater. Sheet metal components of extrusions with thickness greater thanor equal to 0.070 inches are considered to be equivalent to machined fittings.

c. Measured gaps up to the limits listed in Table 8.1(see also Figure 8.1)are closed using the fasteners required by the drawing. Gaps greater thanthose listed in the table, up to a maximum of .063 inches, can be shimmedusing solid shims, or 50% laminated shims, flat or tapered, sized to fit the gapwithout strain or clamp–up.

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8.1.3 Definitions:

a. High Speed Machining(HSM) is defined as a process by which amachined component is cut at high rates of speed and feed such as16,000rpm at 250 in/min. For the purpose of this document, there is nodifference in criteria between conventional machined components and highspeed machined components that are 0.070 in. or greater.

b. Thin Walled Machining (TWM) is defined as a machined component onwhich any feature has a final thickness less that 0.070inches.

c. Gaps are spaces measured between mating parts. Gaps measuredunder the head or tail of a fastener are not addressed herein. ReferenceSS9201

d. In order to determine gap size, finger pressure (thumb and forefinger)is applied to the mating parts during assembly before “take up” of mechanicalfasteners.

e. In cases where it is impractical to use finger pressure to determine gapsize, the spring type CLECO fasteners may be used in order to determine gapsize. Draw type CLECO fasteners shall not be used.

8.1.4 Procedure:

a. Measure gap and determine proper shim size. The length of the shimshall be determined by individual circumstances as shown in the figures. Shimwidth is to approximate the width of the flange or other member to which it willbe attached.

b. Shim shall be made of 7075–T6 unless the same material as thecorresponding metal material, heat treatment and finish is available.

c. Where appropriate, shim shall be installed making sure it does not ridethe radius of the mating part. Chamfer of the shim edge may be necessary toavoid the radius.

d. Shims are to pick up existing fasteners, which shall be increased in griplength as required by the added thickness of the stack up.

e. In addition , added shims (with the exception of floating frame designs)are to be bonded in place to a metal member using SS8622–006 orSS8622–007 adhesive per SS8669 Class II B (clean room requirementswaived). See Figures 8.1–1 through 8.1–5 for shimming examples.

f. Insulate per SS8630

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TABLE 8.1ALLOWABLE GAPS PRIOR TO FASTENER INSTALLATION

JOINT COMBINATIONS

Sheet Metal orExtrusion less

than 0.070” Thk

Sheet Metal orExtrusion 0.070”Thk or Greater

Machined FittingLess Than0.070” Thk

Machined Fitting0.070” Thkor Greater

Sheet Metal orExtrusion less

than 0.070” Thk0.020 in. 0.020 in. 0.020 in. 0.020 in.

Sheet Metal orExtrusion 0.070”Thk or Greater

0.020 in. 0.020 in. 0.010 in. 0.000 in.

Machined FittingLess Than0.070” Thk

0.020 in. 0.010 in 0.010 in 0.010 in

Machined Fitting0.070” Thkor Greater

0.020 in. 0.000 in. 0.010 in 0.000 in.

Example: A joint made up of an 0.094” extruded angle and an 0.050” thick machined fitting can have up to a 0.010” gap prior to fastener instal-lation.

POTENTIAL GAP LOCATIONS

Figure 8.1 GAP LOCATIONS

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Corner must clear radius

Bond

Added shim is to pick upone additional fastener onboth sides of gapped area

Figure 8.1–1


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Added shim to pick up3 additional fastenerson either side of thegapped area.Bond

Corner must clear radius

Figure 8.1–2

Added tapered shim

Bond

Figure 8.1–3

Added shimOuter skin

Figure 8.1–4

8.1 Shimming Metallic Airframe Components (cont)

Structure


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Skin

Frame

Added shim (a single round shim) forfloating frame designs, no bonding orpick–up of additional fastenners required.Change existing fastener to steel or installa Hi–Lok. Insulate dissimilar metals

Figure 8.1–5

8.1 Shimming Metallic Airframe Components (cont)

using epoxy primer per MIL–P–23377or MIL–P–85582


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8.2 Trimming Metallic Airframe Skins

8.2.1 Applicability

a. Trimming metallic skins to eliminate overlap, next assemblyinterference and/or improve cosmetic appearance.

8.2.2 Limitations

a. Metallic skins are defined as:

Aluminum SteelStainless SteelTitanium Up to and including .125 material thickness.

a. No fasteners are to be eliminated or bypassed as the result of trimming.

b. The minimum edge distance between the center of the nearest holeand part edges shall be 2D or greater unless otherwise specified by theengineering drawing. D = maximum diameter of the fastener shank beinginstalled.

c. After all trimming operations, remove all burrs and sharp edges createdby trimming.

d. Areas exposed by trimming are to be touched up locally in accordancewith the table below:

Material Process Specification Aluminum SS8693

Steel MIL–STD–865, Prime, if required per B/PStainless Steel Not requiredTitanium Not required

NOTE: See Figure 8.2–1 for example of skin trimming.


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2D Min.

Skin

Removed material

Figure 8.2–1

8.2 Trimming Metallic Airframe Skins (cont)


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8.3 Trimming Metallic Airframe Components

8.3.1 Applicability

a. End and/or edge of part trim. Trimming of sheet metal and extrudedparts to provide clearance between adjacent parts.

8.3.2 Limitations

a. Extent of trimming should only be to provide minimum (.003 inch)clearance between adjacent structure and the part being trimmed.

b. Metallic components are defined as: Aluminum

SheetExtrusion

SteelStainless SteelTitanium

c. No fasteners are to be eliminated or bypassed as the result of trimming.

d. This does not apply to composite parts, rotor blades, rotor heads,transmissions, forgings, machined or cast parts. Exceptions: Interference that occurs on forged frame splices may be trimmedas shown in Figure 8.3–8.

e. The minimum edge distance between the center of the nearest holeand part edges shall be 2D or greater unless otherwise specified by theengineering drawing. D = maximum diameter of the fastener shank beinginstalled.

f. After trimming operations remove all burrs and sharp edges created bytrimming.

g. See Figures 8.3–1 thru 8.3–10. for trimming examples.


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8.3 Trimming Metallic Airframe Components (cont)

Trim to clear and notviolate edge distance

2D Min.

Conditions: Part touches fastener

Figure 8.3–1


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2D Min

Clearance per partdrawings – Typ

Beam Sheet metalintercostal

(Maintained original radius)

Removedmaterial

D = Max. dia of fastener

Figure 8.3–2



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2D Min.

Extrudedcap angles

Clearance per partdrawings – Typ


BeamRemoved material

(Maintain original radius) Intercostal assembly

D = Max. dia of fastener

Figure 8.3–3


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Figure 8.3–4

2D Min

Trim to clear


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Figure 8.3–5

Caution: Part rides radius

2DMin.

Trim as required to clearradius and not violate edgedistance of fasteners.


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Filler

to obtain condition shown in view below.Trim Drawing Req’t Filler at this end

2D Min

Filler (after trimming)


Figure 8.3–6

FILLERS & SPACERS


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Spacer OverlapTrim either orboth ends as

needed to permitflush seating.2D

MINWeb


Figure 8.3–7


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2D MIN

Frame

Frame

Splice plate

Trim in installationto maintain B/P gapand not violate fastener edge distance requirements

EXCEPTION

Interference that occurson forged frame slices maybe trimmed in accordancewith the procedure outlinedin Section 8.3.3

CABIN FRAME SPLICE


Figure 8.3–8


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Figure 8.3–9

2DMIN

Trim permitted2D Min.

No trimmingpermitted

2DMIN

2DMIN

Material removal permittedto clear adjacent fastener. Must maintain 2D Min.


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Figure 8.3–10

Stringer chafes on frame cutout

OriginalDistance ‘‘D”

Trim to clear. Not toexceed 10% of originaldistance ‘‘D”. Maintainoriginal radius.


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8.4 Pilot Holes that Break into finished fastener holes

8.4.1 Applicability

a. This section applies to mislocated pilot holes that break into finishedfastener holes in aluminum, steel, titanium, stainless steel sheet metal,aluminum extrusions and thin walled machined components under .070 inchthickness.

8.4.2 Limitations

a. This does not apply to composite parts, rotor blades, rotor heads,transmissions, forgings, cast or machined parts .070 inch thick or greater.

b. The minimum edge distance between the center of the nearest holeand part edges shall be 2D or greater unless otherwise specified by theengineering drawing. D = maximum diameter of the fastener shank beinginstalled.

c. Next larger fastener diameter. Hole size shall be per SS5100. Holeshall completely clean up the mislocated pilot hole.

d. Exposed edges shall be cleaned and touched up in accordance withTable 8.4–1 below:

TABLE 8.4–1Material Process SpecificationAluminum SS8693, primer if required by B/PSteel MIL–STD–865, prime, if required per drawingStainless Steel Not requiredTitanium Not required All materials must be deburred and sharp edges removed prior to assembly.

c) Install next larger fastener. The same style and type of fastener must be used.Example: BJ4 rivet must be replaced by a BJ5 rivet.

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8.5 DIMENSIONAL TOLERANCE FOR FORMED SHEET METAL FLANGES

8.5.1 APPLICABILITYThese criteria shall define the acceptable dimensional tolerance on the widthof the formed flanges on sheet metal parts.

8.5.2 CRITERIAThe standard dimensional tolerance on the width of formed sheet metalflanges shall be +/–.030, except, if the following conditions are satisfied, aconditional tolerance of +.060 –.000 shall apply.

8.5.3 CONDITIONS

a) The engineering drawing does not specify a dimensional tolerance for the flangewidth that is tighter than the standard tolerance.

b) The (non–formed) web dimension of the part must satisfy a tolerance of +.000–.030.

c)

.030

.030

.030

.000

.000

.060WEBWEBFORMEDFLANGE

FORMEDFLANGE

STANDARDTOLERANCE

CONDITIONALTOLERANCE


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8.6 ACCEPTANCE CRITERIA TO MEET PROPER GRIP LENGTH OFMECHANICALLY LOCKED FASTENERS

8.6.1 Fastener grip length – The requirement for proper grip length is necessary toensure joint integrity. Improper grip length selection may cause fastenerlooseness or possible head failure. The requirement for proper grip lengthshall apply to all mechanically locked fasteners.

8.6.2 Applicability – in the event of conflict between the contents herein and anyspecifications or standards referenced in the field of drawing, the referenceddocument on the drawing shall take precedence.

8.6.2.1 Section 8.6 is not applicable for the assembly and/or installation of dynamiccomponents such as rotor systems, transmission and drive systems, enginespeed controls or the dynamic portions of flight control systems.

8.6.3 Compensation for assembly tolerance stack–up – Only when the hardwarespecified on the engineering drawing does not meet the installed fastenerrequirements may the following length deviations and use of washers beimplemented.

8.6.3.1 Acceptable fastener length deviations –

8.6.3.1.1 Assemblies using composite materials – When the assembly to be fastenedis comprised of at least one composite member the fastener length may bevaried +/– 2 consecutive length dash numbers from the length noted on theengineering drawing to meet variations in composite material thickness.

8.6.3.1.2 Assemblies using metallic Airframe components – Fastener length may bevaried +/– 1 length dash number from the length noted on the engineeringdrawing to meet variations in total material thickness.

8.6.3.2 Use of washers – washers may be used to adjust grip length only when propergrip cannot be achieved with the fastener alone and only per the following. Thelist of fasteners approved for the use of washers to adjust grip length is shownin table 8.6–l. Washers shall be .016 in., .032 in., or .064 in thickness. Forsingle washer applications the total washer thickness shall not exceed .032in. The total thickness for multiple washer applications shall not exceed .096in.


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Table 8.6–1 Fasteners approved for grip length adjustments by the use of washers.

NASl4l4 thru NAS1422 MS90353

NAS1424 thru NAS1432 MS90354

NAS1436 thru NAS1442 NAS1738

NAS1446 thru NASl452 NAS 1739

NAS1456 thru NAS1462 M7885/6

NASl465 thru NAS1472 M7885/7

NAS1475 thru NAS1482 M7885/8

NAS1486 thru NAS1492 M7885/9

NAS1496 thru NAS1502 All HL Hiloks

NASl5l6 thru NAS1522

NAS1525 thru NAS1532




8.6.3.2.1 Lockbolt and Hilok type fasteners – (NASl4l4–1562, HL)Protruding head – Amaximum of two washers may be used to adjust grip length. The preferredwasher location is under the collar. If insulating washers are used, or if thecollar has an integral washer, only 1 additional washer may be used and thepreferred location is under the collar. Flush head – one washer may be usedunder the collar to adjust grip length.

8.6.3.2.2 Pull through type blind rivets (MS90353, MS90354, NAS1738, NAS1739,M7885/6 thru M7885/9). Protruding head – A single washer may be used toadjust the grip length. On installations where the blind side is inaccessible thewasher shall be located under the manufactured head. On installations wherethe blind side is accessible the washer may be located under the formed heador under the manufactured head unless the application is on an exteriorsurface. On exterior surface applications the washer shall be located underthe formed head. Flush head– Where the blind side of the fastener isaccessible, one washer may be used under the formed head to adjust griplength.


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8.6.3.2.3 Selection of washers – To avoid a dissimilar metal condition the material of thewasher used to correct grip length shall be the material of any additionalwashers defined in the field of the engineering drawing. If the engineeringdrawing does not specify a washer, then the washer material shall be selectedaccording to table 8.6–2 with regards to the material that the washer contacts.

Table 8.6-2 Washer material and callout for grip adjustment

Parent Material Washer Material Callout

Aluminum Aluminum AN960KDx

Steel Steel AN960x

Cres Cres AN960Cx

Titanium Cres AN960Cx

Graphite Cres SS5072CxH

Electrical grounding and bonding per SS7007 shall take precidence over theabove section regarding electrical/electronic assemblies.

8.6.3.3 Limitations of hardware use – When the fastener length is varied as describedin 8.6.3.1 and/or washers are used as described in 8.6.3.2, the assembly shallnot violate any clearance requirements.


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8.7 Acceptance criteria to meet proper grip length of 1/4 turn CAMLOCfastener s.

8.7.1 Purpose – The purpose of this section is to allow grip length adjustment of 1/4turn fasteners from that on the engineering drawing to compensate forassembly tolerance stack–up.

8.7.2 Compensation for assembly tolerance stack–up – Only when the hardwarespecified on the engineering drawing does not meet the installed fastenerrequirements may the following length deviations be implemented.

8.7.3 Acceptable fastener length deviations

8.7.4 Assemblies using composite materials – When the assembly to be fastenedis comprised of conforming parts, with at least one composite member, andis assembled and gauged with the appropriate installation tools, the fastenerlength may be varied 2 grip length dash numbers from the length noted on theengineering drawing to meet variations in composite material thickness.


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8.8 ACCEPTANCE CRITERIA FOR PIN HOLE LOCATIONS (Limited Usage)NOTE: These allowances are only for use when the Engineering Drawingdoes not specify locations. In case of any conflict with this specification, theEngineering Drawing shall govern.

8.8.1 PURPOSE:During the manufacture of sheet metal components, the use of pin holes maybe required for positioning, alignment and/or assembly operations. Thissection provides guidelines for acceptable locations for pin holes.

8.8.2 LIMITATIONS:This section applies to Aluminum, Steel or Titanium sheet metal Airframecomponents. This criteria does not apply to Flight Safety or Flight Essentialcomponents. The criteria specified herein may only be used to defineacceptable locations if not already specified on the Engineering drawing.

8.8.3 DEFINITIONS:

8.8.3.1 Pin Holes are defined as .188” diameter holes which are used during themanufacturing process of sheet metal components. These holes are used tohold a sheet metal part in position during routing, blanking, or cuttingoperations, and to align the part correctly with the forming tool(s) duringforming operation(s). Occasionally, pin holes are also used to locate partsduring assembly and assembly operations.

8.8.3.2 Edge Distance is defined as the distance from the center of the hole to theedge of the part.

8.8.3.3 External Tabs are defined as a detail of the sheet metal part which is trimmedoff as part of the manufacturing operation and does not remain on the finalpart.

8.8.3.4 Web Area is defined as the portion of a part, such as a frame, which maycontain pin holes and/or is not formed (e.g., bent flange) as a step of themanufacturing process.

8.8.4 GUIDELINES FOR ACCEPTABLE PIN HOLE LOCATIONS “GENERAL”(seeFigure 8.8–1 for examples):

8.8.4.1 Pin holes located in external tabs are the preferred method. However, if pinholes must be in the body of the part, they may be located in sheet metal detailsprovided the following guidelines are met.


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8.8.4.2 Pin holes which coincide with fastener locations are acceptable and mayoverride the guidelines within section 8.8.5 below. Pin holes coinciding withfastener locations within a pattern shall utilize the center fastener hole locationor at least the third fastener from the edge of the pattern where practical.

8.8.4.3 Where practical, pin holes in aluminum parts, which do not coincide withfastener locations, shall be subsequently plugged using MS20470AD6bucked rivets. In all parts, pin holes may not be left unplugged if environmentalsealing requirements exist.

8.8.4.4 Pin holes may not be located in any portion of a part which will be subsequentlyformed, such as a bent flange or a beaded panel, unless all other requirementsof this specification are complied with. Example of exception; pin hole locatednear flanged hole in web per para 8.8.5.6

8.8.4.5 Pin holes shall not be located such that they may interfere with subsequentmanufacturing and assembly operations.

8.8.5 GUIDELINES FOR ACCEPTABLE PIN HOLE LOCATIONS “SPECIFIC”(seeFigures 8.8–1 & 8.8–2 for examples)

8.8.5.1 Pin holes at each end of part, for parts that are a minimum of 5” long shall belocated a minimum of 1.25” from edge and approximately at center of edgelength.

8.8.5.2 General pin hole spacing shall be approximately 15” for parts that are greaterthan 18” long.

8.8.5.3 Pin holes in long narrow parts (i.e., less than 3” wide) shall have a minimumspacing of 2”, along the length of the part.

8.8.5.4 Preferred location for pin holes in an unobstructed web area shall beapproximately in the center , unless this is not practical and all otherrequirements are met.

8.8.5.5 Minimum edge distance of .56” shall be maintained from the edge of part orcut edge of detail (e.g., edge of a cutout, bend relief, hole, etc., or final edgelocation of part to be subsequently trimmed or cut) to the center of the pin hole.

8.8.5.6 A minimum distance of .35” shall be maintained from the tangent lines offormed details (e.g., joggles, flanged cutouts, bent flanges, etc.) or finaltangent line location of detail to be subsequently formed, to the center of thepin hole.


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Pin Hole at center offastener pattern

Mininum Edge Distance of .56”

Center Pin Hole along edge of part

Minimum distance of .35” to tangency of formed detail (jogglebend radius)

Center of web area

Minimum distance of .35” to tangency offormed detail (flangedhole)

Minimum distance of .56” to edge of cut or trim

Minimum 2” spacing

Minimum Edge distance of .56”

Figure 8.8–2 Long narrow part example

Figure 8.8–1 Formed frame example


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9. INTERCHANGEABLE FASTENERS (STUMP & PULL TYPE LOCKBOLTS)

9.1 Stump and pull type lockbolts may be used in place of each other providedfinish, grip, size and collar material are the same (see NAS 1080 for propercollar selection). Substitution may be in either direction for each size fastenerin each category in the Table 9.1–1.

TABLE 9.1–1

PULL TYPE PULL TYPE STUMP TYPE& STUMP SIZE LOCKBOLTS LOCKBOLTSSTEEL 3/16 NAS1436 NAS1416100 SHEAR 1/4 NAS1438 NAS1418

5/16 NAS1440 NAS14203/8 NAS1442 NAS1422

STEEL 3/16 NAS1446 NAS1426PROTRUDING HD 1/4 NAS1448 NAS1428SHEAR 5/16 NAS1450 NAS1430

3/8 NAS1452 NAS1432STEEL 3/16 NAS1456 NAS1486100° HD 1/4 NAS1458 NAS1488(MS24694) 5/16 NAS1460 NAS1490TENSION 3/8 NAS1462 NAS1492STEEL 5/32 NAS1465 NAS1497PROTRUDING HD 3/16 NAS1466 NAS1496TENSION 1/4 NAS1468 NAS1498

5/16 NAS1470 NAS15003/8 NAS1472 NAS1502

STEEL 5/32 NAS1475 NAS6925100° HD 3/16 NAS1476 NAS6926(MS20426) 1/4 NAS1478 NAS6928TENSION 5/16 NAS1480 NAS6930

3/8 NAS1482 NAS6932ALUMINUM 3/16 NAS1516 NAS1546100° HD 1/4 NAS1518 NAS1548(MS24694) 5/16 NAS1520 NAS1550TENSION 3/8 NAS1522 NAS1552ALUMINUM 5/32 NAS1525 NAS1555PROTRUDING HD 3/16 NAS1526 NAS1556TENSION 1/4 NAS1528 NAS1558

5/16 NAS1530 NAS15603/8 NAS1532 NAS1562


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15

10. SAFETY WIRING / SAFETY CABLE

10.1 Safety Cable per AS 3509, AS 3510, and AS 3511 when used in accordance withAS 4536, installed with calibrated Safety Cable manufacturer recommended tools,may be used as an approved alternate to Safety Wire per MS 20995 installed inaccordance with MS33540.

10.1.1 The following list indicates the proper alternates:

1. MS20995C alternate is AS3510 of corresponding diameter and length.

2. MS20995N alternate is AS3509 of corresponding diameter and length.

3. MS20995F No alternate is currently available.

4. MS20995NC alternate is AS3510 of corresponding diameter and length .

5. MS20995AB No alternate is currently available.

6. MS20995CY No alternate is currently available.

Safety Cable shall not be used for shear or sealing wire applications or in applications where the ferrule/endfitting could cause an interference.

Safety Cable shall not be used where verification of safety wire application per MS33540 is a CriticalCharacteristic (CC ).

Safety Cable shall not be used on H53 aircraft.


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11. ACCEPTANCE CRITERIA TO MEET THREAD PROTRUSION

11.1 Definitions

11.1.1 Thread Protrusion – is the term defining the requirements for the protrusionof a free running threaded fastener beyond the surface of an engaged nut toensure complete engagement of the mating threads.

11.1.2 Grip Length – is the distance from the under head bearing surface to the startof the thread.

11.2 Justification for Thread Protrusion – The requirement for thread protrusion isnecessary because the first 2 lead threads of the chamfered end of a threadedfastener are not designed to carry loads, but are present to facilitateassembling the nut to the fastener. Also, the 2 lead threads provide inadequatelocking when self–locking nuts are used.

11.3 Applicability – In the event of conflict between the contents herein, and anyspecifications or standards referenced in the field of drawing, the referenceddocuments on the drawing shall be considered a superseding requirement.

11.3.1 Fasteners – The requirement for thread protrusion shall apply to free runningbolts, studs, or screws.

11.3.2 Nuts – The requirement for thread protrusion shall apply to free running andself–locking 6 and 12 point hex nuts, fixed and floating blind nuts, and barrelnuts.

11.4 Limits of protrusion – Unless otherwise specified on the engineering drawing,a bolt, stud, or screw end shall extend beyond the nut at least the lengthequivalent to 2 pitches, including the chamfer. (Figure11.l–1., Table 11.1–I.)Maximum thread protrusion shall be limited by any assembly clearancerequirements.

2 X PITCH, MIN.

FIGURE 11.1–1


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Table 11.1–I. Minimum Acceptable Protrusion

UNC UNF

size min protrusion, in. size min protrusion, in.

4–40 .050 4–48 .042

6–32 .063 6–40 .050

8–32 .063 6—36 .055

10–24 .083 10–32 .063

1/4–20 .100 1/4–28 .071

5/16–18 .111 5/16–24 .083

3/8–16 .125 3/8–24 .083

7/16–14 .143 7/16–20 .100

1/2–13 .154 1/2–20 .100

5/8–1l .182 5/8–18 .111

3/4–10 .200 3/4–16 .125

7/8–9 .222 7/8–14 .143

1–8 .250 1–12 .167

11.5 Compensation for assembly tolerance stack–up – Section 11.5 is notapplicable for the assembly and/or installation of dynamic components suchas rotor systems, transmission and drive systems, engine speed controls, andthe dynamic portions of flight control systems.

NOTE: Only when the hardware specified on the engineering drawing doesnot meet the thread protrusion requirements specified herein may thefollowing length deviations and addition of washers be implemented.

11.5.1 Acceptable bolt, or screw length deviation

11.5.1.1 Assemblies using composite materials. – Due to variations in total compositematerial thickness, and fastener length variations, the bolt, or screw lengthmay be varied +/–2 consecutive length dash numbers from the length notedon the engineering drawing.

11.5.1.2 Assemblies not using composite materials. – Due to variations in total materialthickness, and fastener length variations, the bolt, or screw length may beincreased one consecutive length dash number from the length noted on theengineering drawing. Paragraph 11.5.1.2 shall not apply toelectrical/electronic assemblies. Electrical/electronic assembly requirementsshall be as specified in SS7500.


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11.5.2 Use of washers. – In all cases, except as noted below, a maximum total of 3washers, in any combination of thickness, may be used to insure proper griplength.

11.5.2.1 Assemblies in General. – The number of washers specified on the engineeringdrawing plus any washers added to insure proper grip length shall be a totalof two (2) under the nut, and one (l) under the head. (Figure 11.1–2).

11.5.2.2 Assemblies using nut plates or barrel nuts. – The number of washers specifiedon the engineering drawing plus any washers added to insure proper griplength shall be a total of two (2) under the head. (Figure 11.1–2).

11.5.2.3 Assemblies using studs or fasteners with countersunk heads. – The numberof washers specified on the engineering drawing plus any washers added toinsure proper grip length shall be a total of two (2) under the nut. (Figure 11.1– 2).

11.5.2.4 Protection against electrolytic corrosion. – To avoid a dissimilar metalcondition, the material of any additional washer(s) used under the nut to insureproper grip length shall be the material of the washer defined on theengineering drawing for use under the nut . If the engineering drawing doesnot specify a washer under the nut, then the washer material shall be selectedaccording to MIL – STD – 889 (DISSIMILAR METALS). Similarly, the materialof any additional washer(s) used under the head to insure proper grip lengthshall be the material of the washer defined on the engineering drawing for useunder the head If the engineering drawing does not specify a washer underthe head, then the washer material shall be selected according to MIL – STD– 889 (DISSIMILAR METALS). Paragraph 11.5.2.4 shall not apply toelectrical/electronic assemblies. Protection against electrolytic corrosion forelectrical/electronic assemblies shall be per the requirements of SS7007.

11.5.2.5 Selection of washers

Washers shall be selected from the following standards:

AN960 WASHER, FLAT

MS20002 WASHER, COUNTERSUNK AND PLAIN, HIGH STRENGTH

MS21206 WASHER, COUNTERSUNK AND PLAIN, FOR USE WITHBOLTS AND NUT UP TO AND INCLUDING 220 FTU

SS4409 WASHER–METALLIC, SPECIAL

S5S5072 WASHER (FOR COMPOSITE APPLICATIONS)


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11.5.3 Limitations of hardware variations When the bolt, or screw length is varied asdescribed in 11.5.1, and/or washers are used as described in 11.5.2, theassembly shall not violate any clearance requirements, the nut shall notbottom out on the imperfect threads, and the load transferred by theassembled parts to the bolt, stud, or screw shall not be carried by the threadedportion of the bolt, stud, or screw.

11.5.3.1 Production engineering shall be notified when the bolt, or screw length isvaried as described in 11.5.1 and/or washers are used as described in 11.5.2.Any assembly that requires repetitive corrective action to ensure threadprotrusion as described herein requires investigation and possible drawingcorrection.


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3RD

2 MAX UNDER HEAD(PLAIN OR C’ SUNKWHERE REQUIRED)*

1ST & 2ND2 MAX UNDER NUT

(PLAIN)

HEX BOLT OR SCREWTO HEX NUT

2 MAX UNDER NUT(PLAIN)

1 MAX UNDER HEAD(PLAIN OR C’ SUNKWHERE REQUIRED)*

C’SUNK OR STUD BARREL NUTOR NUT PLATE

* INSURE THAT WASHER UNDER BOLT HEAD IS COMPATIBLE WITH HEAD TO SHANK RADIUS (C’SUNK WHERE REQ’D).

FIGURE 11.1–2


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12. ,ACCEPTANCE CRITERIA FOR EDGE AND PITCH DISTANCE

12.1 PURPOSE

The purpose of this section is to define the minimum acceptable edge andpitch distance requirements for fasteners installed through sheet metalassemblies and thin walled machined components under .070 inch thickness.

12.2 SCOPE

This section provides acceptance criteria for minor product characteristics notdefined on the engineering drawings.

12.3 LIMITATIONS

12.3.1 This section does not apply to fastener through forgings, castings ormachined fittings .070 inch thick or greater. Included tables do not apply tocomposite structure, which shall be reworked to meet dwg. requirements.

12.4 DEFINITIONS

12.4.1 Edge distance (ED) is the distance between a fastener centerline and the edgeof a part (see Figure 12–1).

12.4.2 Pitch distance is the distance between the centerline of adjacent fasteners(see Figure 12–1).

12.4.3 A row of rivets is defined as a line of rivets extending between two frames,stringers, intercostals or other members as shown in Figure 12–1A.

12.4.4 Edge distance shall be acceptable when any one of the following orcombination of the following conditions are met:

a) The edge distance is greater than or equal to two times the nominal shank diameter.(COMANCHE RAH–66 REQUIREMENTS: The edge distance is greater than orequal to 1.5 times the nominal shank diameter except that the edge distance forradius blocks shall be greater than or equal to 1.0 times the nominal shank diameter).

b) The edge distance is defined on the drawing in the form of a note, dimension or scaledfrom the EMD (Engineering Master Drawing).

c) As defined in Tables 12–1 for protruding head fastener in aluminum structure or Table12–2 for countersunk fasteners in aluminum structure.

d) A maximum of three fasteners (in a row of fasteners) with edge distances greaterthan or equal to 1.5 times the fastener shank diameter (limitations defined in Table12–3)( NOT APPLICABLE TO COMANCHE RAH–66).

e) The End Fastener (in a row of five or more fasteners) with edge distance greater thanor equal to 1.5 times the fastener shank diameter, provided all other fastenersconform to Conditions a, b or c above (limitations defined in Table 12–4)( NOTAPPLICABLE TO COMANCHE RAH–66).


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PITCH DISTANCE

FASTENERCENTERLINE

EDGE DISTANCE

EDGE OF PART

SHANK DIAMETER

FIGURE 12–1

FRAMES

STRINGER

STRINGER

ROW OF FASTENERS, TYP.

ROW OF FASTENERS, TYP.

FIGURE 12–1A


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TABLE 12–1MINIMUM ACCEPTANCE EDGE DISTANCES

FOR PROTRUDING HEAD FASTENERS

THESE VALUES APPLICABLE TO FASTENER INSTALLATION INTO2014,2024,2219,AND 7075 ALLOYS IN ANY FULLY HARDENED TEMPER

Thickness A B C D E F G H

.025 .032 .040 .050 .063 .071 .080 .090 .100 .125 .160 .190

. 16 .14 .14 .14 .14 .14 .14 .14 .14 .14 .14 .14

.25

.22

.19

.19

.19

.19

.19

.19

.19

.19

.19

.19

.31

.31

.27

.23

.23

.23

.23

.23

.23

.23

.23

.23

.31

.31

.31

.27

.23

.23

.23

.23

.23

.23

.23

.23

.37

.37

.36

.34

.28

.28

.28

.28

.28

.28

.28

.28

.37

.37

.37

.37

.33

.31

.28 .28 .28 .28 .28 .28

.37

.37

.37

.37

.37

.33

.30

.28

.28

.28

.28

.28

.37

.37

.37

.37

.37

.37

.37

.37

.37

.35

.30

.28

A = MS20470AD3B = MS20470AD4 C = MS20470AD5 D = MS20470DD5E = MS20470AD6 F = MS20470DD6 G = NAS1526 H = NAS1446, NAS1466, NAS1496, NAS1426, NAS2006, NAS2206, NAS2606


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TABLE 12–2MINIMUM ACCEPTANCE EDGE DISTANCES

FOR FLUSH (COUNTERSINK) HEAD FASTENERS

THESE VALUES APPLICABLE TO FASTENER INSTALLATION INTO2014,2024,2219,AND 7075 ALLOYS IN ANY FULLY HARDENED TEMPER

Thickness A B C D E F G H

.025 .032 .040 .050 .063 .071 .080 .090 .100 .125 .160 .190

.19 .17 .16 .16 .16 .15 .15 .15 .14 .14 .14 .14

.25 .25 .22 .21 .21 .21 .20 .20 .19 .19 .19 .19

.31 .31 .27 .26 .26 .25 .25 .25 .25 .24 .23 .23

.31 .31 .31 .30 .26 .25 .25 .25 .25 .24 .23 .23

.37 .37 .37 .37 .33 .32 .32 .31 .31 .30 .30 .28

.37 .37 .37 .37 .37 .36 .32 .31 .31 .30 .30 .28

.37 .37 .37 .37 .37 .37 .34 .31 .31 .30 .30 .28

.37

.37

.37

.37

.37

.37

.37

.37

.37

.37

.32

.28

A = MS20426AD3 or NAS1097AD3 B = MS20426AD4 or NAS1097AD4C = MS20426AD5 or NAS1097AD5 D = MS20426DD5 or NAS1097DD5 E = MS20426AD6 or NAS1097AD6 F = MS20426DD6 or NAS1097DD6 G = NAS1536 H = NAS2506V, NAS2706V, NAS1416, NAS1436


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TABLE 12–3ACCEPTANCE CRITERIA FOR SINGLE AND DOUBLE ROW FASTENERSWITH ED GREATER THAN OR EQUAL TO 1.5 X NOMINAL SHANKDIAMETER

Number of Fas-teners AlongEdge of Part

Single Row of Fas-teners Along Edgeof Part*

Double Row of Fas-teners Along Edgeof Part**

Number of fasteners allowed down to1.5 x nominal shank diameter ED.

1–2 0 0

3–4 0 1

5–9 1 2

10–14 2 3

>14 3 3

This table applies to the following models only:UH–60A BLACK HAWK S–70A–9 RAAF S–70C–2 PRCEH–60A QUICK FIX S–70A–16 WESTLAND S–70C–5 BRUNEI 1SH–60B SEAHAWK S–70A–11 JORDAN S–70A–14 BRUNEI 2SH–60F CV–HELO S–70C–1A TAIWAN S–70B–2 RANHH–60H HCS S–80M CH–53EHH–60J MRR MH–53E

*Example of Single Row Fasteners, see Figure 12–3A.**Example of Double Row Fasteners, see Figure 12–3B.NOTE: This table does not apply to composite structure.


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E.D. GREATER THAN OR EQUALTO 1.5 X NOM. SHANK DIA.

(SEE TABLE 12–3)

FIGURE 12–3A

SINGLE ROW OF FASTENERS


(SEE TABLE 12–3)

FIGURE 12–3B

DOUBLE ROW OF FASTENERS


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TABLE 12–4ACCEPTANCE CRITERIA FOR SINGLE AND DOUBLE ROW FASTENERSWITH ED GREATER THAN OR EQUAL TO 1.5 X NOMINAL SHANKDIAMETER

Number of Fas-teners AlongEdge of Part

Number of Fasten-ers in a row

Number of Fasten-ers allowed down to1.5 x nominal shankdiameter.

11

1–45 or greater

01

This table applies to the following models only:UH–60A BLACK HAWK S–70A–9 RAAF S–70C–2 PRCEH–60A QUICK FIX S–70A–16 WESTLAND S–70C–5 BRUNEI 1SH–60B SEAHAWK S–70A–11 JORDAN S–70A–14 BRUNEI 2SH–60F CV–HELO S–70C–1A TAIWAN S–70B–2 RANHH–60H HCS S–80M CH–53EHH–60J MRR MH–53E

NOTE: This table does not apply to composite structure.For Example of end fasteners, see Figure 12–4A


(SEE TABLE 12–4)

FIGURE 12–4A

TYP. END FASTENER


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12.4.5 Pitch distance shall be acceptable when one of the following or combinationof the following conditions are met:

a) Minimum pitchThis distance shall be as required by engineering drawing, 4 times nominalfastener shank diameter (4D), or as defined in Table 12–5 for protruding headfasteners in aluminum structure, Table 12–6 for countersunk fasteners in aluminumstructure or Table 12–7 for dimpled holed fasteners in aluminum structure.

b) Maximum PitchProtruding Head and Flush Head Fasteners – Maximum allowable pitch is thenominal pitch distance as required on the engineering drawing +1D (nominalfastener shank diameter) .

12.4.5.1 Exceptions to Para. 12.4.5

a) Hard tooled holes must meet drawing tolerances, (spray dot tools are notconsidered hard tools).

TABLE 12–5 MINIMUM ACCEPTABLE PITCH DISTANCE

FOR PROTRUDING HEAD FASTENERS

THESE VALUES APPLICABLE TO FASTENER INSTALLATION INTO2014, 2024,2219, 7075 AND 7079 ALLOYS IN ANY FULLY HARDENED

TEMPER

Fastener Type MS20470 Rivets Three times nominal shank diameter of fastener (3D)All Others Four times nominal shank diameter of fastener (4D)

TABLE 12–6MINIMUM ACCEPTABLE PITCH DISTANCE

FOR COUNTERSUNK FASTENERS


TEMPER

Fastener Type MS20426, NAS 1097 Three times nominal shank diameter of fastener (3D)Rivets All Others Four times nominal shank diameter of fastener (4D)


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TABLE 12–7MINIMUM ACCEPTABLE PITCH DISTANCE

FOR DIMPLE HOLE FASTENERS


TEMPER

Fastener TypeMS20426 Rivets Three times nominal shank diameter of fastener (3D)

12.5 GENERAL NOTES

12.5.1 When determining the minimum edge distance requirements for replacementwith the next larger size fasteners, the diameter of the larger fastener shall beused.

12.5.2 When determining the minimum pitch distance requirements for any twoadjacent fasteners of different diameters, the nominal shank diameter of thelarger fastener shall be used.


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13. COATINGS AND FINISHES

13.1 SHOT PEENED SURFACES

13.1.1 Metal detail parts requiring shot peening may be touch up shot peening perSS8769, as required, to meet engineering drawing requirements.

13.2 PLATED SURFACES

13.2.1 Metal detail parts requiring plating (example: Cadmium plate per QQ–P–416)may be touch–up plated per MIL–STD–865 at assembly, as required, to meetengineering drawing requirements. (See SS 8407 for baking requirementswhich may restrict touch–up of parts on assembly).

NOTE: Not intended to correct misplated parts.

13.2.2 TOUCH–UP FOR ION VAPOR DEPOSITED (IVD) ALUMINUM

13.2.2.1 ALSEAL 505, Coatings for Industry, Inc., Souderton, PA. 18964

13.2.2.1.1 Metal parts coated with IVD Aluminum, that may be exposed to in–servicetemperature of 950�F maximum, requiring touch–up may be repaired byspraying or local brush application of Alseal 505. After application and airdrying for one hour minimum, Alseal 505 can be burnished to match thesurrounding areas.

13.3 TOUCH–UP FOR CADMIUM PLATED ELECTRICAL CONNECTORS ANDCONNECTOR ACCESSORY PLATING ABRASIONS

13.3.1 Cadmium plated Olive drab connectors, backshells and cable clamps whichare determined to be rejectable for scratches which expose or are suspectedof exposing bare metal, during electrical harness fabrication, assembly, orinstallation shall be touched–up as follows.

a) Corrosion protection shall be provided by treatment of a chemical conversioncoating per Mil–C–5541.

b) Top coat sealing of the treated area with flat lacquer, per TT–L–20 olive drabx–34087, or polyurethane per Mil–C–46168, olive drab 34088.

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13.4 PAINTING OF CLOSE TOLERANCE MACHINED SURFACES

13.4.1 Unless otherwise specified, machined surfaces with a total tolerance of lessthan .003 inch, shall not be painted. For example, gears or splined teeth,bearing surfaces, keyways, threads, reamed or honed holes, and superfinished surfaces (16 RMS or better). All other surfaces shall be painted asrequired by the engineering drawing.

13.5 DIMENSIONAL TOLERANCE LIMITS

13.5.1 Unless otherwise specified, dimensional limits and surface roughnessdesignations are prior to shotpeen, plating, painting or other surfacetreatments. Dimensional limits for threads are after plating and/or othersurface treatments.


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14. ACCEPTANCE CRITERIA FOR CASTINGS / FORGINGS

14.1 The following machining operations may be performed by the supplier on castor forged parts:

1. It is allowable to machine any casting/forging tooling points to required drawingdimensions.

2. It is allowable to machine any surface of a casting/forging up to 0.060” to meetdrawing dimensional requirements.

3. The only allowable machining methods for titanium castings/forgings are turningor milling.

14.1.1 The supplier must retain records of machining operations, on internaloperation sheets, by lot number, indicating the castings/forgings that havebeen machined and the amount of stock removed.

14.1.2 Forgings that are subsequenty machined over 90% of their surface areacceptable up to .060” per diameter, .030” per surface, over the drawingmaximum material condition, provided that tooling points are not affected.


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15. SCREW THREADS

15.1 SCREW THREADS ON ELECTRICAL CONNECTORS

15.1.1 The thread gaging note on Spec or Source Control Drawings, does not applyto military, (AN, MS or Mil ), or vendor electrical connectors. (Theseconnectors meet the requirements of their applicable procurementspecifications).

15.2 THREADED FASTENERS WITH INCONSISTENT FUNCTIONAL ELEMENT/SIZE INSPECTIONS

15.2.1 Threaded fasteners, with method “B”, system 22 or “other” inspectionrequirements per Mil–S–8879, ASME B 1.3M or AS8879 respectively, meetingall geometric features but with inconsistent functional element/size indicationsduring inspection, shall be referee inspected for acceptance using theunbiased calibrated ring std. 13000.003–000.


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16. CONTROL COMPONENTS

16.1 Proof pressure testing of fluid components and proof testing of control cableassemblies and push rods.

16.1.1 Unless specifically defined on the engineering drawing, the followingtolerances for proof load/pressure, burst pressure and times apply:

a) A. Control Cable Assemblies;Proof load; + 5 – 0 percentTime at load; From 45 to 75 seconds

b) B. Fluid System Components,Lines, Fittings, and Hoses:Proof pressure; +10 percent / – 0 percentBurst pressure; +10 percent / – 0 percentTime at pressure; +30 / –5 seconds

c) C. Pushrods:Proof Load; +20 / – 0 pounds (lbs.)Ultimate load;* +20 / – 0 pounds (lbs.)Time at load; From 3 to 60 Seconds

*NOTE:Ultimate load test is a one-time test requirement.


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17. Electrical Components

17.1 Grommet AlternatesGrommets per MIL–DTL–22529 may be used as an approved alternate to MS 21266 grommets installed in accordance to SS8640 with exceptions notedherein. The MIL–DTL–22529 grommets do not require adhesive bonding perSS8640.The following table indicates the proper alternates:

Table 17 GROMMET ALTERNATES

MS21266 Dash# Sheet Thickness M22529 Range M22529 Dash #

MS21266–1 .015 / .052 .036 / .063 M22529/2–2C–0085

MS21266–2 .052 / .085 .070 / .093 M22529/2–4C–0085

MS21266–3 .085 / .128 .105 / .134 M22529/2–6C–0085

MS21266–4 .128 / .192 .178 / .198 M22529/2–7C–0085

MS21266–5 .192 / .255 .240 / .260 M22529/2–8C–0085

17.1.1 NOTES / EXCEPTIONS:1. Where clips intrude into the hole, castles on the M22529

grommets shall be trimmed to .03 max height without sharp edges, allowingfit between the clips without damage to the cushion. The first two castles oneach end of the grommet shall not be removed. The gap/seam (.08 max) shallbe at the top of the hole or orientated to remove minimal castles around clips.The castles shall be trimmed only as necessary to prevent interference.

2. M22529 grommets may be used on 7/8 (.875) inch diameterholes and larger and shall not be used on lightening holes.

3. M22529 grommet material shall only be used on flanges orstraight edges where the minimum flat edge distance exceeds .18 inches,allowing the edge to fully bottom into the grommet.

17.2 WIRE MARKING CRITERIA FOR ALL SIKORSKY AIRCRAFT WIRING(including electro/mechanical components).

17.2.1 Wiring shall be marked in accordance with SS7333 or SS7334. SS 7333marking processes are preferred.

17.2.2 Wiring may be marked per SS7334 using Hot Impression Stamping providedall initial qualification and continual acceptance testing is performed.

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SS9208 Rev 48 (Production Acceptance Criteria)

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