SD3-60 STRUCTURAL REPAIR MANUAL - STRUCTURAL IDENTIFICATION

Transcription

1 SD3-60 STRUCTURAL REPAIR MANUAL z SRM FUSELAGE - STRUCTURAL IDENTIFICATION 1. Introduction This chapter indicates the location of the strcu tural members of the fuselage and shows methods for repairing minor damage to these members by either patching, fitting an insertion or replacing a member. If the repair is of a major nature Bombardier Aerospace (Belfast) will advise on method and procedure to carry out the repair and information can be obtained from Aerospace Customer Support on request from the operator. For procedure and application form refer to the INTRODUCTION to this manual. Refer to INTRODUCTION, pb1. 2. General The fuselage comprises a nose fuselage (-80 inches to 74 inches), main fuselage (74 inches to inches) and a rear fuselage (472.5 inches to 741 inches) joined together with a fully manufactured rivetted joint. The main structural aperatures are for nose baggage compartment door (forward left), freight door (forward left), emergency exit (forward right), passenger door (rear left), emergency exit (rear right), rear baggage compartment door (rear left) and crew ditching hatch (forward top). Frames are located from a datum which is 3 inches forward of the bulkhead at the rear of the nose baggage compartment. Horizontal positions (H) are measured from the inside of the bottom skins on the parallel portion of the fuselage. Vertical positions (V) are measured from the centreline of the fuselage. 3. Nose Fuselage The nose fuselage contains the flight deck compartment, the nose landing gear bay and the forward baggage compartment. The construction is semi-monocoque of conventional skin and lipped angle stringers carried on channel and lipped frames. Materials used are L72 and L73. Forward of frame 3 inches, the nose profile is basically conical with the frames having a deep bottom member to support the baggage compartment floor at 8.2 inches H between frames -60 inches and 3 inches. Aft of frame 3 inches the profile expands to a rectangular shape with frames having top, side and bottom members. The bottom members are increased in depth to support the pilots floor at inches H and end at the keel walls at inches V each side of the fuselage centreline. The keel walls and pilots floor form the nose landing gear bay between frames 3 inches and 74 inches. Page 1

2 z SD3-60 STRUCTURAL REPAIR MANUAL Frame 3 inches has a top, bottom and side member. The bottom member being a continuous web which forms the forward wall of the landing gear bay and supports both the pilots floor and the baggage compartment floor. The frame is converted into a bird strike bulkhead by closing off the area above the pilots floor with a bonded sandwich construction of L72 sheet/aluminium foil honeycomb bolted to the frame. The stringers, which are located by a numbering system, run in cutouts in the frames and are attached with cleats and brackets to the frames and at their terminations. The upper and lower coupe rails are 7075-T6 material and the brackets for supporting the windshield pillars are L65 material. The windshield pillars are each constructed from two channel extrusions which are assembled and installed with bolts. These pillars are continued into the canopy with intercostal members of L72 material. 4. Main Fuselage The main fuselage extends over the length of the passenger seating area. It consists of a parallel rectangular box between frames 74 inches and inches and a constant width section with a curved underside extending aft to frame inches. frames, except the front and rear spar frames, have top, bottom and side members of L73 or 7075-T62 channel section reinforced as necessary with bonded doublers and additional boom angles. The frames are joined at the corners with L73 finger plates and the bottom members have increased depth to support the floor at 8.2 inches H. Outer flanges of frames are stabilised by rivetting through the crown of each corrugation and inner flanges are supported by light gauge L72 tension straps running fore and aft. Shear cleats attach the frames to the skin between each skin corrugation. The front and rear spar frames, at stations inches and inches respectively are fabricated from two flat web plates with separate boom angles. The top and side members are of L73 material and are joined at each corner with 7075-T351 fail-safe wing attachment brackets. Both spar bottom members extend beyond the side of the fuselage as part of a box structure to pick-up the main landing gear ribs. Each of these members consist of two flat 2024-T351 web plates sandwiched between two L73 finger plates, which extend over the entire length of the web and also form the joint with the side members. Double L65 angles form the inner and outer booms. The main landing gear and wing strut loads are carried on two 7075-T7351 ribs which are connected with L93 vertical web plates and attached to the ends of the spar frames at inches V and inches V. Heavy gauge L73 shear decks are attached to the upper and lower booms of the spar frames and extend from the outer rib to the fuselage side. The wing strut attachment brackets are L93 material. Page 2

3 SD3-60 STRUCTURAL REPAIR MANUAL z Generally the skin consists of double skin panels in which a smooth outer skin is bonded to corrugated inner sheet, both of which are L72 material. Vertical joints are closed with flat external and corrugated internal buttstraps attached with a double row of rivets at each side of joint. Inner skin corrugations have a.75 inch radius from the mating face and pitched at 3 inch intervals. The only areas in which conventional skin and stringer configuration is employed are at the window planks along each side of the fuselage, where L72 skins and angle stringers are used, and the curved underside of the fuselage aft of frame inches, which uses L72 skins and top-hat stringers. The bottom corners of the fuselage are formed by mainly single curvature skins of heavier gauge L72 without internal stiffners. The floor seat rails run between frames 74 inches and 458 inches at 20.6 inches V left side and 8.4 inches V right side and are supported on diaphragms of L73 between frames. The side seat rail run inches H between frames inches and 428 inches left side and frames 89 inches and 428 inches right side of fuselage and are supported on 7075-T6 diaphragms intercostal with the frames. The wing fairings and fuel tanks form the upper profile of the aircraft. Forward and aft fuel tanks extend from stations 176 inches to inches and from stations inches to inches respectively and are constructed from conventional skin, stringers and diaphragms of L72 material. Wing fairings are of L72 skin, stringer and frame manufacture and the forward fairing houses the airconditioning system. The main landing gear fairings are of moulded Kevlar reinforced plastic honeycomb construction. 5. Rear Fuselage The rear fuselage comprises the fuselage aft of frame inches. It contains the toilet, attendant's station, galley, aft baggage compartment and support structure for the vertical and horizontal stabilisers and the fuselage tail fairing. The vertical frames have top and side members of flat webs and inner and outer boom angles of 2024-T42 material. The bottom members have been deepened to support the floors and consist of 2024-T3 or T42 webs with upper and lower boom angles. These frame members are lap joined at top and bottom corners. The skins are 2024-T3 throughout and are stiffened by 2024-T42 stringers. Except for the bottom skins forward of frame inches, which have top-hat section, the stringers are of a Z section. stringers are attached by cleats to the frames. Page 3

4 z SD3-60 STRUCTURAL REPAIR MANUAL The top and bottom corners of the fuselage are formed by curved skins with no internal stiffeners. The floors are stepped to cater for the rise in bottom profile and are positioned at 13.8 inches H between frames 458 inches and frame 508 inches 24 inches H between frames 508 inches and frame inches, 30 inches H between frames inches and frame and 34.7 inches H between frame inches and frame 595 inches. The vertical and horizontal stabilisers support structure basically comprises three sloping bulkheads, the forward and rear of which are angled to suit the front and rear spars of the vertical stabilisers, and a horizontal shear deck which runs aft from the rear bulkhead at 80 inches H. These members consist of 2024-T3 webs with boom angles and main structural fittings of T3511. The support fittings for the horizontal stabiliser forward pick-up is located on the forward face of the rear bulkhead and is of 7075-T73510 material. Flanged stabilising diaphragms of 2024-T42 material are attached to stringers 57.5 inches H and 69.5 inches H between frame 620 inches and the centre sloping bulkheads on both sides of fuselage. The closing fairing at the stabilisers and fuselage intersection consists of a top Kevlar reinforced plastic fairing and side fairings of a sandwich construction of Kevlar reinforced plastic/nomex honeycomb with 2024-T62 stiffeners. 6. Structure Identification The following pages contain diagrams and text to define the components, skin materials and thicknesses that comprise the fuselage structure (including top fairings, stub wings, seat rails, and seat rail structure, and fuel tanks). Page 4

5 SD3-60 STRUCTURAL REPAIR MANUAL z Structural G.A. of fuselage Figure 1 Page 5

6 SD3-60 STRUCTURAL REPAIR MANUAL z Nose fuselage structure fwd of frame Elevation Figure 2 (Sheet 1) Page 7

7 z SD3-60 STRUCTURAL REPAIR MANUAL Nose fuselage structure fwd of frame 9 - front view Figure 2 (Sheet 2) Page 8

8 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD Assy of frame 9 2 SD Assy of frame SD Assy of frame SD Assy of frame SD Assy of radome mtg ring 6 SD Assy of radar mtg structure 7 SD Assy of baggage floor structure 8 SD Assy of hinge structure 9 SD Inst of baggage door 10 L72.032" Floor angle 11 L72.048" Tie angle 12 L72.036" Channel 13 L72.022" Seal member 14 L72.036" Reinforcing angle 15 L65 BAR Channel stiffener 16 Refer to Figure 6. Stringer 17 Refer to Figure 6. Stringer 18 L72.028" Stringer Key to Figure 2 Page 9

9 z SD3-60 STRUCTURAL REPAIR MANUAL Nose fuselage structure fwd of frame 9 - front view Figure 3 Page 10

10 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD GA of nose structure 2 SD GA of nose fwd. of Stn. 3 3 L72 SD Assy of frame 3 4 L73 SD Assy of sloped frame 5 L72 SD Assy of frame 22 L.H. 6 L72 SD Assy of frame 22 R.H. 7 L73 SD Frame top 8 L73 SD Frame side L.H. 9 L73 SD Frame side R.H. 10 L72 SD Frame bottom L.H. 11 L72 SD Frame bottom R.H. 12 L72 SD Frame bottom L.H. 13 L72 SD Frame bottom R.H. 14 L73 SD Frame top L.H. 15 L73 SD Frame top R.H. 16 L72 SD Frame top 17 L72 SD Assy of Frame L72 SD Sub-frame 64.0 L.H. 19 L72 SD Sub-frame 64.0 R.H. 20 SD Inst. of upper coupe rail 21 SD Inst. of lwr. coupe rail 22 SD Inst. of windscreen pillar L.H. 23 SD Inst. of windscreen pillar R.H. 24 SD Inst. of ctre. w/screen pillar 25 L72.036" Zed mbr. Fr. 54 to Fr. 74 L.H. 26 L72.036" Zed mbr. Fr. 54 to Fr. 74 R.H. 27 SD Intercstl. Fr to Fr. 74 L.H. 28 SD Intercstl. Fr to Fr. 54 R.H. 29 SD Intercstl coupe rail to Fr L.H. 30 SD Intercstl coupe rail to Fr R.H. 31 L73.064" Inst. of stringer 7 L.H. 32 L73.064" Inst. of stringer 7 R.H. Key to Figure 3 Page 11

11 z SD3-60 STRUCTURAL REPAIR MANUAL ITEM NO. MATERIAL 33 L72.028" Skin reinf. angle L.H. 34 L72.028" Skin reinf. angle R.H. 35 L72.048" Skin reinf. angle L.H. 36 L72.048" Skin reinf. angle R.H. 37 L72.036" Diaphragm Stn L.H. 38 L72.036" Diaphragm Stn R.H. 39 SD Mtg. struct.-dashboard L.H. 40 SD Mtg. struct.-dashboard R.H. 41 L72.036" Diaphragm Stn L.H. 42 L72.036" Diaphragm Stn R.H. 43 L72.036" Diaphragm Stn L.H. 44 L72.036" Diaphragm Stn R.H. 45 L72.040" Reinforcing angle 46 SD Ditching hatch structure 47 SD Inst. of Ditching hatch 48 SD GA of pilots flr. structure. 49 L73.048" Stringer (pilots floor) L.H. 50 L73.048" Stringer (pilots floor) R.H. 51 L73.056" Stringer 15 L.H. 52 L73.056" Stringer 15 R.H. 53 SD Assy of keel wall L.H. 54 SD Assy of keel wall R.H. 55 SD Struct. for grd. supp. plug 56 SD Struct. for grd. supp. i/comm 57 SD Inst. of equipt. bay door L.H. 58 SD Inst. of equipt. bay door R.H. 59 SD Inst. of radio bay door L.H. 60 SD Inst. of radio bay door R.H. Items 2, 4, 7, 8, 9, 20, 22, 23, 24, 29, 30, 39, 40 & 48 have no structural classification. Item 57, 58, 59 and 60 are Class 3. other items are Class 2. THICKNESS/ GAUGE PART NO. Key to Figure 3 DESCRIPTION Page 12

12 SD3-60 STRUCTURAL REPAIR MANUAL z Nose fuselage skinning fwd of fr. 3 Figure 4 (Sheet 1) Page 13

13 z SD3-60 STRUCTURAL REPAIR MANUAL Nose fuselage baggage floor Figure 4 (Sheet 2) Page 14

14 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL Item 4 which is class 1. other items are class 2. THICKNESS/ GAUGE PART NO. DESCRIPTION 1 L72.022" TOP SKIN PANEL 2 L72.032" BOTTOM SKIN PANEL 3 L72.028" SIDE SKIN PANEL 4 L73.072" BOTTOM AFT SKIN (STN-9 TO 3) 5 L72.028" FLOOR SHEET 6 L72.018" FLOOR DOUBLER SHEET Key to Figure 4 Page 15

15 z SD3-60 STRUCTURAL REPAIR MANUAL Nose fuselage skinning aft of frame 3 Figure 5 Page 16

16 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. * Denotes items comprising redux bonded assys DESCRIPTION 1 L72.040" Lower side skin stn 3 to 74 2 L72.028" Upper side skin stn 3 to 74 3 L72.022" Apron skin stn 3 to L72.040" Canopy skin 5 L72.028" Canopy skin stn 54 to 74 6 L72.048" Canopy corner skin stn 54 to 74 7 L72.048" Bottom corner skin stn 3 to L72.048" Bottom corner skin stn 37.5 to 74 9 L72.028" Bottom skin stn 3 to L72.032" Bottom skin stn 37.5 to L72.028" Skin pilots floor stn 3 to 74 centre 12 L72.040" *Skin pilots floor stn 3 to 74 out/bd 13 L72.028" *Doubler 14 L72.022" *Doubler 15 L72.032" Skin panel keel wall stn 37.5 to L72.040" *Skin panel keel wall stn 3 to L72.012" *Doubler 18 L72.012" *Doubler Key to Figure 5 Page 17

17 z SD3-60 STRUCTURAL REPAIR MANUAL Nose fuselage stringer sections Figure 6 Page 18

18 z SD3-60 STRUCTURAL REPAIR MANUAL Main fuselage structure left side Figure 7 Page 20

19 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Diaphragm Assy Stn SD Diaphragm Assy Stn SD Diaphragm Assy Stn SD Diaphragm Assy Stn SD Diaphragm Assy Stn SD Diaphragm Assy Stn SD Diaphragm Assy Stn SD Diaphragm Assy Stn SD Diaphragm Assy Stn SD Diaphragm Assy Stn SD Diaphragm Assy Stn SD Side Sub Frame Stn SD Side Sub Frame Stn SD Side Sub Frame Stn Key to Figure 7 Page 21

20 z SD3-60 STRUCTURAL REPAIR MANUAL Main fuselage structure right side Figure 8 Page 22

21 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Frame Sector (Side) Stn SD Diaphragm Assy Stn SD Diaphragm Assy Stn SD Diaphragm Assy Stn SD Diaphragm Assy Stn SD Diaphragm Assy Stn SD Diaphragm Assy Stn SD Diaphragm Assy Stn SD Diaphragm Assy Stn SD Diaphragm Assy Stn SD Diaphragm Assy Stn SD Diaphragm Assy Stn SD Diaphragm Assy Stn SD Diaphragm Assy Stn SD Upper Door Beam 28 SD Lower Door Beam 29 SD Side Sub Frame Stn SD Side Sub Frame Stn SD Side Sub Frame Stn Key to Figure 8 Page 23

22 z SD3-60 STRUCTURAL REPAIR MANUAL Main fuselage structure top Figure 9 Page 24

23 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD Top Sector Assy Fr SD Top Sector Assy Fr SD Top Sector Assy Fr SD Top Sector Assy Fr SD Top Sector Assy Fr SD Top Sector Assy Fr SD Top Sector Assy Fr SD Top Sector Assy Fr SD Top Sector Assy Fr SD Top Sector Assy Fr SD Top Sector Assy Fr SD Top Sector Assy Fr SD Top Sector Assy Fr SD Top Sector Assy Sub Fr SD Frame Stablizing Structure Key to Figure 9 Page 25

24 z SD3-60 STRUCTURAL REPAIR MANUAL Main fuselage structure bottom Figure 10 Page 26

25 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD Frame Sector (Bottom) Stn SD Frame Sector (Bottom) Stn SD Frame Sector (Bottom) Stn SD Frame Sector (Bottom) Stn SD Frame Sector (Bottom) Stn SD Frame Sector (Bottom) Stn SD Frame Sector (Bottom) Stn SD Frame Sector (Bottom) Stn SD Frame Sector (Bottom) Stn SD Frame Sector (Bottom) Stn SD Frame Sector (Bottom) Stn SD Frame Sector (Bottom) Stn SD Frame Sector (Bottom) Stn SD Assy of Front Spar 15 SD Assy of Rear Spar 16 SD Left Seat Rail Web Sub Assy Stn SD Right Seat Rail Web Sub Assy Stn SD Left Seat Rail Web Sub Assy Stn SD Right Seat Rail Web Sub Assy Stn SD Left Seat Rail Web Sub Assy Stn SD Right Seat Rail Web Sub Assy Stn SD Left Seat Rail Web Sub Assy Stn SD Right Stn Seat Rail Web Sub Assy 24 SD Left Seat Rail Web Sub Assy Stn Key to Figure 10 Page 27

26 z SD3-60 STRUCTURAL REPAIR MANUAL ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. 25 SD Right Seat Rail Web Sub Assy Stn SD Left Seat Rail Web Sub Assy Stn SD Right Seat Rail Web Sub Assy Stn SD Left Seat Rail Web Sub Assy Stn SD Right Seat Rail Web Sub Assy Stn SD Left Seat Rail Web Sub Assy Stn SD Right Seat Rail Web Sub Assy Stn SD Left Seat Rail Web Sub Assy Stn SD Right Seat Rail Web Sub Assy Stn SD Left Seat Rail Web Sub Assy Stn SD Right Seat Rail Web Sub Assy Stn SD Left Seat Rail Web Sub Assy Stn SD Right Seat Rail Web Sub Assy Stn SD Left Seat Rail Web Sub Assy Stn SD Right Seat Rail Web Sub Assy Stn SD Left Seat Rail Web Sub Assy Stn SD Right Seat Rail Web Sub Assy Stn SD Left Seat Rail Web Sub Assy Stn Key to Figure 10 DESCRIPTION Page 28

27 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. 43 SD Right Seat Rail Web Sub Assy Stn SD Left Intercostal Assy Stn SD Right Intercostal Assy Stn SD Inst. Sub Frame Stn SD CentreSub Frame Stn SD Left Sub Frame Stn SD Right Sub Frame Stn SD Left Sub Frame Stn SD Right Sub Frame Stn SD Centre Sub Frame Stn Key to Figure 10 DESCRIPTION Page 29

28 z SD3-60 STRUCTURAL REPAIR MANUAL Main fuselage skinning left side Figure 11 Page 30

29 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD ASSY OF SIDE PANEL 2 L Skin Panel 3 L Skin Panel 4 L Skin Panel 5 L Skin Panel 6 L Skin Panel 7 L Skin Panel 8 L Skin Panel 9 L Skin Panel 10 L Skin Panel 11 QQA-250/5.108 Skin Panel 2024-T3 12 L72 QQA-250/ T CORRUGATION 13 L CORRUGATION 14 L CORRUGATION 15 L CORRUGATION Key to Figure 11 Page 31

30 z SD3-60 STRUCTURAL REPAIR MANUAL Main fuselage skinning right side Figure 12 Page 32

31 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD ASSY OF SIDE PANEL L72 SKIN PANEL L72 SKIN PANEL L72 SKIN PANEL L72 SKIN PANEL L72 SKIN PANEL L72 SKIN PANEL L72 SKIN PANEL L72 SKIN PANEL L72 SKIN PANEL L72 SKIN PANEL T3 SKIN PANEL T42/L72 CORRUGATION L72 CORRUGATION L72 CORRUGATION L72 CORRUGATION L72 CORRUGATION L72 DOUBLER L73 DOUBLER T3 DOUBLER T3 PRE MOD 7230 DOUBLER T3 POST MOD 7230 DOUBLER T3 CORNER SKIN PANEL L72 CORNER SKIN PANEL L72 CORNER SKIN PANEL L72 CORNER SKIN PANEL Key to Figure 12 Page 33

32 z SD3-60 STRUCTURAL REPAIR MANUAL Main fuselage skinning top Figure 13 Page 34

33 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD REDUX ASSY. (L.H.) FR SD REDUX ASSY. (R.H.) FR " L72 OUTSIDE SKIN PANEL " L72 OUTSIDE SKIN PANEL 5.018" L72 OUTSIDE SKIN PANEL 6.022" L72 OUTSIDE SKIN PANEL 7.036" L72 OUTSIDE SKIN PANEL 8.048" L72 OUTSIDE SKIN PANEL " L72 CORRUGATION " L72 CORRUGATION Key to Figure 13 Page 35

34 z SD3-60 STRUCTURAL REPAIR MANUAL Main fuselage skinning bottom Figure 14 Page 36

35 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD REDUX ASSY LH SD REDUX ASSY R.H SD G.A.LOWER SKIN PANEL L72 SKIN PANEL L72 SKIN PANEL L72 SKIN PANEL L72 CORRUGATION L72 CORRUGATION L72 CORRUGATION Key to Figure 14 Page 37

36 z SD3-60 STRUCTURAL REPAIR MANUAL Main fuselage corrugation section Figure 15 Page 38

37 SD3-60 STRUCTURAL REPAIR MANUAL z Main fuselage stub wing structure Figure 16 (Sheet 1) Page 39

38 z SD3-60 STRUCTURAL REPAIR MANUAL Main fuselage stub wing Figure 16 (Sheet 2) Page 40

39 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. 1 SD SD SD SD SD SD SD SD SD SD DESCRIPTION INSTL OF TOP SHEAR DECK BETWEEN U/C RIBS INSTL OF BOTTOM SHEAR DECK BETWEEN U/C RIBS INSTL OF TOP INBOARD SHEAR DECK INSTL OF WING STRUT PICK - UP S/ASSY CLOSING SKIN TO TOP HAT LONGERONS AT F&R SPAR FRAMES 7 SD G.A.OF TENSION STRAP F/SPAR 8 SD G.A.OF TENSION STRAP R/SPAR 9 SD S/ASSY OUTER U/C RIB SD SD SD S/ASSY INNER U/C RIB 11 SD SD SD SD SD SD SD SD SD SD INSTL OF F&R SPARS TO INNER & OUTER U/C RIBS G.A.WING STRUCTURE INSTL FAIRING ATTACHMENT BKT. SUB FRAME STN SUB FRAME STN " L72 ACCESS PANEL " L72 ACCESS PANEL " L72 ACCESS PANEL " L72 BOTTOM SKIN " L72 TOP SKIN " L72 CHANNEL " L72 BUTTSTRAP Key to Figure 16 Page 41

40 z SD3-60 STRUCTURAL REPAIR MANUAL Rear fuselage structure & skinning left side Figure 17 Page 42

41 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD ASSY FRAME 2 SD FRAME 3 SD FRAME 4 SD SUB FRAME 5 SD FRAME 6 SD SUB FRAME 7 SD FRAME 8 SD FRAME 9 SD FRAME 10 SD SUB FRAME 11 SD FRONT SPAR FRAME 12 SD CENTRE CANT FRAME 13 SD REAR SPAR FRAME 14 SD FRAME 15 SD FRAME 16 SD FRAME 17 SD ASSY FRAME " QQ-A-250/5 STRINGER 2024-T " QQ-A-250/5 STRINGER 2024-T " QQ-A-250/5 STRINGER 2024-T " QQ-A-250/5 STRINGER 2024-T " QQ-A-250/5 ANGLE 2024-T " QQ-A-250/5 LONGERON 2024-T42 24 QQ-A-200/11 LONGERON 7075-T QQ-A-200/ T3511 DOOR LONGERON Key to Figure 17 Page 43

42 z SD3-60 STRUCTURAL REPAIR MANUAL ITEM NO. MATERIAL THICKNESS/ GAUGE " QQ-A-250/ T42 27 QQ-A-200/ T QQ-A-200/ T " QQ-A-250/ T " QQ-A-250/ T " QQ-A-250/ T " QQ-A-250/ T " QQ-A-250/ T " QQ-A-250/ T " QQ-A-250/ T3 PART NO. DESCRIPTION CORNER LONGERON CORNER LONGERON MACHINING LONGERON DIAPHRAGM SUPPORT CHANNEL SKIN PANEL SKIN PANEL SKIN DOUBLER (BOTTOM) SKIN DOUBLER (TOP) SKIN DOUBLER Key to Figure 17 Page 44

43 z SD3-60 STRUCTURAL REPAIR MANUAL Rear fuselage struture & skinning (right side) Figure 18 Page 46

44 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD ASSY FRAME 2 SD ASSY FRAME 3 SD ASSY FRAME 4 SD ASSY FRAME 5 SD ASSY FRAME 6 SD ASSY FRAME 7 SD ASSY FRAME 8 ASSY SUB FRAME 9 QQ-A-250/5.025" STRINGER 2024-T " STRINGER " STRINGER " SUPPORT CHANNEL 13 QQ-A-250/5.080" LONGERON 2024-T42 14 QQ-A-200/11 LONGERON 7075-T QQ-A-250/5.025" SKIN PANEL 2024-T3 16 QQ-A-250/5.032" SKIN PANEL 2024-T3 17 QQ-A-250/ T3.050" SKIN DOUBLER Key to Figure 18 Page 47

45 z SD3-60 STRUCTURAL REPAIR MANUAL Rear fuselage structure & skinning (top) Figure 19 Page 48

46 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD FRAME ASSEMBLY 2 SD FRAME ASSEMBLY 3 SD FRAME ASSEMBLY 4 SD FRAME ASSEMBLY 5 SD FRAME ASSEMBLY 6 SD FRAME ASSEMBLY 7 SD FRAME ASSEMBLY 8 SD FRAME ASSEMBLY 9 QQ-A-250/5.025" STRINGER 2024-T42 10 QQ-A-250/5.032" STRINGER 2024-T42 11 QQ-A-250/5.040" STRINGER 2024-T42 12 QQ-A-250/5.050" STRINGER 2024-T42 13 QQ-A-250/5.025" STRINGER C/L AIRCRAFT 2024-T42 14 QQ-A-250/5.025" DORSAL SUPPORT STRINGER 2024-T42 15 QQ-A-250/5.050" ZED MEMBER 2024-T42 16 QQ -A - 200/3 TEE PIECE 2024-T QQ-A-250/5.025" SKIN PANEL 2024-T3 18 QQ-A-250/5.032" SKIN PANEL 2024-T3 19 QQ-A-250/5.040" SKIN PANEL 2024-T3 20 QQ-A-250/5.040" 2024-T3 SKIN DOUBLER 21 QQ-A-250/ T42.025" CORNER SKIN Key to Figure 19 Page 49

47 z ITEM NO. MATERIAL 22 QQ-A-250/ T42 23 QQ-A-250/ T42 24 QQ-A-250/ T42 THICKNESS/ GAUGE SD3-60 STRUCTURAL REPAIR MANUAL PART NO..032" CORNER SKIN.040" CORNER SKIN.050" CORNER SKIN DESCRIPTION Key to Figure 19 Page 50

48 z SD3-60 STRUCTURAL REPAIR MANUAL Rear fuselage structure & skinning (bottom) Figure 20 Page 52

49 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD FRAME ASSEMBLY 2 SD FRAME ASSEMBLY(LEFT) 3 SD FRAME ASSEMBLY(CENTRE) 4 SD FRAME ASSEMBLY(RIGHT) 5 SD FRAME ASSEMBLY 6 SD FRAME ASSEMBLY 7 SD FRAME ASSEMBLY 8 SD FRAME ASSEMBLY 9 SD FRAME ASSEMBLY 10 QQ-A-250/5.025" TOP HAT STRINGER 2024-T42 11 QQ-A-250/5.025" STRINGER 2024-T42 12 QQ-A-250/5.032" STRINGER 2024-T42 13 QQ-A-250/5.040" STRINGER 2024-T42 14 QQ-A-250/5.071 LOWER ANGLE 2024-T42 15 QQ-A-200/11 ANGLE MEMBER 7075-T73 16 QQ-A-250/5.025" SKIN PANEL 2024-T3 17 QQ-A-250/5.032" CORNER SKIN PANEL 2024-T3 18 QQ-A-250/ T3.040" CORNER SKIN PANEL Key to Figure 20 Page 53

50 z SD3-60 STRUCTURAL REPAIR MANUAL Rear fusealge fairing Figure 21 Page 54

51 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD SIDE FAIRING PANEL SD SD TOP FAIRING PANEL 3 SD S/A WATER DEFLECTOR 4 SD TAILPLANE SEAL ASSY. SD SD TAILPLANE SEAL ASSY. SD SD SD INST. OF ELEVATOR TORQUE TUBE SEALS 7 SD RUDDER ACCESS PANEL 8 SD ELEVATOR SHAFT SEAL-UPPER 9 SD ELEVATOR SEAL CLAMP-UPPER 10 QQ-A-250/5 FAIRING SUPPORT BEAMS 2024-T42.040" " ACCESS COVER " TOP HATS 13 QQ-A-250/5 CHANNELS 2024-T42.050" Key to Figure 21 Page 55

52 z SD3-60 STRUCTURAL REPAIR MANUAL GA of wing fairing Figure 22 Page 56

53 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD G.A. OF FAIRINGS 2 SD FORWARD FAIRING 3 SD TOP FAIRING 4 SD TOP FAIRING 5 SD SIDE FAIRING SD SD SIDE FAIRING SD SD REAR FAIRING 8 SD FAIRING-FWD TANK-FRONT SPAR 9 SD FAIRING-AFT TANK-REAR SPAR 10 SD WING ROOT FAIRING SD SD UNDER WING FAIRING 12 SD UNDER WING FAIRING Key to Figure 22 Page 57

54 z SD3-60 STRUCTURAL REPAIR MANUAL GA forward wing fairing & skinning (stn 74 to stn ) Figure 23 Page 58

55 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD G.A. FORWARD FAIRING 2 SD ASSY OF FIXED STRUCTURE 3 SD ASSY OF REMOVABLE PANEL (FWD) 4 SD ASSY OF REMOVABLE PANEL(AFT) 5 SD ASSY OF REMOVABLE PANEL(AFT) 6 SD ASSY OF REMOVABLE PANEL(CENTRE) 7 SD ASSY OF REMOVABLE PANEL (FWD) 8 SD ASSY OF REMOVABLE SERVICING PANEL 9 L REMOVABLE PANEL SKINS 10 L REMOVABLE PANEL SKINS 11 L REMOVABLE SERVICING PANEL SKIN 12 L SKIN PANELS Key to Figure 23 Page 59

56 SD3-60 STRUCTURAL REPAIR MANUAL z Forward wing fairing structure Figure 24 (Sheet 1) Page 61

57 z SD3-60 STRUCTURAL REPAIR MANUAL Forward wing fairing sections Figure 24 (Sheet 2) Page 62

58 SD3-60 STRUCTURAL REPAIR MANUAL z Forward wing fairing structural attachments Figure 24 (Sheet 3) Page 63

59 z SD3-60 STRUCTURAL REPAIR MANUAL Forward wing fairing structure attachment details Figure 24 (Sheet 4) Page 64

60 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD FIXED STRUCTURE ASSY-FWD FAIRING 2 L SD FRAME ASSY. 3 L SD FRAME ASSY. 4 S SD A.C.M.1NTAKE & GROUND FLAP DUCT ASSY 5 S SD INTAKE EMERGENCY FAN DUCT ASSY 6 L SD BEAM ASSY. 7 L SD BEAM ASSY. 8 L SD BEAM ASSY. 9 L SD BEAM ASSY. 10 L SD BEAM ASSY. 11 L SD BEAM ASSY. 12 L SD BEAM ASSY. 13 L SD BEAM ASSY. 14 L SD BEAM ASSY. 15 L SD BEAM ASSY 16 S SD HEAT EXCHANGER GRILL (OUTLET) ASSY. 17 L65 SD MOUNTING BRACKET ASSY. 18 L65 SD MOUNTING BRACKET ASSY. 19 L SD SD MOUNTING BRACKET ASSY. 20 L65 SD MOUNTING BRACKET ASSY. 21 L SD MOUNTING BRACKET ASSY SD L BEAM 23 L BEAM 24 L ZED MEMBER 25 L ZED MEMBER 26 L STIFFENER 27 L STIFFENERS 28 L65 MOUNTING BRACKET 29 L65 MOUNTING BRACKET 30 L65 MOUNTING BRACKET Key to Figure 24 Page 65

61 z SD3-60 STRUCTURAL REPAIR MANUAL Wing fairings (stn to stn ) Figure 25 Page 66

62 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. 1 SD G.A.TOP FAIRING 2 L SKIN PANELS 3 L SKIN PANELS Key to Figure 25 DESCRIPTION Page 67

63 z SD3-60 STRUCTURAL REPAIR MANUAL Wing fairings (Stn to Stn ) Figure 26 Page 68

64 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD G.A. FAIRING-REAR SPAR-AFT TANK 2 SD G.A. TOP FAIRING 3 L72.022" TOP SKIN PANELS 4 L72.022" SIDE SIDE PANELS Key to Figure 26 Page 69

65 SD3-60 STRUCTURAL REPAIR MANUAL z Rear wing fairing (Stn to Stn 475.0) Figure 27 (Sheet 1) Page 71

66 z SD3-60 STRUCTURAL REPAIR MANUAL Rear wing fairing structural attachment Figure 27 (Sheet 2) Page 72

67 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD G.A. OF REAR FIXED FAIRING 2 L SKINS SKIN DIAPHRAGMS STRINGERS STRINGER CENTRE LINE OF AIRCRAFT ACCESS COVER 8 L BRACKET ASSY (FAIRING SUPPORT) Key to Figure 27 Page 73

68 z SD3-60 STRUCTURAL REPAIR MANUAL Forward fuel tank Figure 28 Page 74

69 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD G.A.FWD. TANK 2 SD PYLON ASSY. SD SD BAFFLE ASSY. SD SD BAFFLE ASSY. SD SD CENTRE BAFFLE ASSY-FWD 6 SD CENTRE BAFFLE ASSY-CENTRE 7 SD CENTRE BAFFLE ASSY-AFT 8 SD BULKHEAD ASSY 9 SD BULKHEAD ASSY 10 SD BULKHEAD ASSY 11 SD BULKHEAD ASSY 12 SD SIDEWALL ASSY-FWD SD SD SIDEWALL ASSY-CENTRE SD SD SIDEWALL ASSY-APT SD T3 QQ-A-250/5.0124" SD TOP SKIN ASSY-CENTRE T3 QQ-A-250/5.040" SD SD TOP SKIN ASSY-LEFT 17 L73.028" STRINGERS-TOP SKIN-CENTRE 18 L73 STRINGERS-TOP SKIN-AFT 19 L73 STRINGERS-TOP SKIN-FWD 20 L72 STRINGERS-LOWER SKIN-FWD 21 L73 STRINGERS-LOWER SKIN-CENTRE 22 L72.028" STRINGERS-LOWER SKIN-AFT 23 L72.024" LOWER SKINS 24 L72.028" LOWER SKINS 25 L72.028" ANGLE STIFFENERS Key to Figure 28 Page 75

70 z SD3-60 STRUCTURAL REPAIR MANUAL ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. 26 L72.036" TOP BOOM 27 L72.036" SKIN FORMERS 28 L99 CASTING SD FOOT MACHINING-FWD 29 L168 CASTING SD FOOT MACHINING-FWD 30 4L35 CASTING SD FOOT MACHINING-AFT SD L72.036" FAIRING ATTACH STRIPS 32 L72 FAIRING ATTACH CHANNEL 33 L73 SIDEWALL CHANNELS 34 L72 SEALING ANGLES 35 L72.036" EXTERNAL SEALING ANGLES " INTERNAL SEALING ANGLES " END RIBS " TOP BOOM ANGLES " ANGLE LOWER SKIN " ANGLES " LOWER BOOM ANGLE " LOWER BOOM ANGLE " JOINT ANGLE 44 L72.036" STIFFENERS 45 L73.104" ACCESS DOOR-TANK 3 46 L73.104" ACCESS DOOR-TANKS 1 & 2 47 L72.048" BUTTSTRAP - TOP SKIN 48 L72.048" BUTTSTRAP - LOWER SKIN 49 L73.048" REINFORCING STRAPS Key to Figure 28 DESCRIPTION Page 76

71 z SD3-60 STRUCTURAL REPAIR MANUAL Rear fuel tank Figure 29 Page 78

72 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD INSTL OF FUEL TANKS 2 SD G.A.REAR FUEL TANK 3 L72.024" SD SIDEWALL ASSY. SD L72.028" SD BAFFLE ASSY. SD L72.028" SD BAFFLE ASSY. 6 L72.028" SD BAFFLE ASSY. 7 L72.036" SD BAFFLE ASSY-CENTRE 8 L72.028" SD BULKHEAD ASSY. 9 L72.028" SD BULKHEAD ASSY. 10 L72.028" SD STIFFENER ASSY-TOP 11 L72.028" SD STIFFENER ASSY-TOP SD L72.028" SD STIFFENER ASSY-TOP SD L72.028" SD STIFFENER ASSY-TOP SD L72.028" SD STIFFENER ASSY- BOTTOM SD L72.028" SD STIFFENER ASSY-BOTTOM SD L72.028" SD STRINGER ASSY SD L72.028" SD STRINGER ASSY SD T3 SKIN PANELS-TOP QQ-A-250/5.0124" T3 SKIN PANELS-TOP CENTRE QQ-A-250/B.0124" 20 L72.028" SKIN PANEL-BOTTOM 21 L72.028" STRINGERS-TOP 22 L72.036" END RIBS 23 L72.036" STIFFENERS 24 L72.036" BOOM ANGLES 25 L72.036" REINFORCING STRAP Key to Figure 29 Page 79

73 z SD3-60 STRUCTURAL REPAIR MANUAL ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. 26 L72.040" BOOMS-TOP 27 L72.048" INNER ANGLES 28 L72.048" SEAL ANGLES-BOTTOM 29 L72.048" SEAL ANGLES 30 L72.048" OUTER SEALS 31 L72.064" ATTACHMENT ANGLES 32 L35 CASTING CORNER FITTING BOTTOM 33 L ACCESS DOORS Key to Figure 29 DESCRIPTION Page 80

74 SD3-60 STRUCTURAL REPAIR MANUAL z Installation of side seat rails Figure 30 (Sheet 1) Page 81

75 z SD3-60 STRUCTURAL REPAIR MANUAL Installation of side seat rails (Side seal rail joint) Figure 30 (Sheet 2) Page 82

76 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. DESCRIPTION 1 SD INST L OF SIDE SEAT RAIL 2 SD INST L OF SIDE SEAT RAIL 3 SD DIAPHRAGM ASSY 4 SD DIAPHRAGM ASSY 5 SD DIAPHRAGM ASSY SD SD DIAPHRAGM ASSY 7 SD DIAPHRAGM ASSY 8 SD DIAPHRAGM ASSY SD SD DIAPHRAGM ASSY SD SD DIAPHRAGM ASSY SD SD DIAPHRAGM ASSY SD SD DIAPHRAGM ASSY 13 SD DIAPHRAGM ASSY 14 SD DIAPHRAGM ASSY SD SD DIAPHRAGM ASSY 16 SD DIAPHRAGM ASSY 17 SD DIAPHRAGM ASSY SD SD DIAPHRAGM ASSY SD SD VERTICAL BEAMS ASSY SD EXTRUSION 7075-T6511 SD SIDE SEAT RAILS 20 TO DS508 QQ-A-200/11 SD " L73 JOINT STRAPS " L73 JOINT STRAPS " 7075-T6 QQ-A-250/13 Key to Figure 30 DIAPHRAGMS Page 83

77 z SD3-60 STRUCTURAL REPAIR MANUAL ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO " L73 REINFORCING STRIPS " L73 END REINFORCING PLATES " L73 END REINFORCING PLATES " L73 REINFORCING RINGS Key to Figure 30 DESCRIPTION Page 84

78 SD3-60 STRUCTURAL REPAIR MANUAL z Installation of floor seat rails Figure 31 (Sheet 1) Page 85

79 z SD3-60 STRUCTURAL REPAIR MANUAL Floor seat rail joint Figure 31 (Sheet 2) Page 86

80 SD3-60 STRUCTURAL REPAIR MANUAL z ITEM NO. MATERIAL THICKNESS/ GAUGE PART NO. 1 SD SD SD SD DESCRIPTION INSTL OF FLOOR SEAT RAIL & STRUCTURE ASSY SEAT RAIL JOINT EXTRUSION 7075/T6511 SD SEAT RAILS 3 TO U.S. 507 QQ-A-200/ " L73 JOINT ANGLES Key to Figure 31 Page 87