Aarap 001

Transport
Airplane
Directorate
U.S.Department LosAngeles
Aircraft
ofTransportation Certification
Ofliee
Federal
Aviation 3960Paramount
Boulevard
Administration Lakewood,
California
90712-4137
FEB 5 200I
LongBeachDivision
McDonnell
DouglasCorporation
A wholly
ownedsubsidiary
of
TheBoeingCompany
Attention:
Mr.KevinHull,
Sr.Manager,
Airworthiness
Boeing
AirplaneServices
MailCode:801-0023
3855LakewoodBoulevard
LongBeach,California
90846-0001
Reference:
Boeing
letter
C I-IAL-00-2184,
datedNovember
30,2000
DearMr.Hull:
Approval
of DC-9/MD-80
Repair
Assessment
Program
Document
Report
No.MDC-91KO263,
Revision
1, Dated
October
2000
A final
ruletomandatea repairassessmentprogram
forpres~ fuselagesofcertain
model
transportairplanes
(14CFRparts 91,121,125and129)waspublished intheFederal
Register
onApril25,2000withaneffectivedateofMay25,2000. Thefinalrulelang-~ge
wasnotsubstantially
changed
fromthatoftheNotice of ProposedRulemaking
(NPRM)
(Docket
97-16).
TheFAAfindsthat therepairassessment
guidelinescontained
inthe
D C-9/MD-80
Repair AssessmentProgram DocumentReportNo.MDC-91K0263, Revision
1,datedOctober
2000,
fulfill
theintentofthefinalrule.Revision
1 ofthedocument
is
hereby
approvedcontingent
uponRevision1 ofthedocumentbeingutilized
exclusive
ofthe
original
issueofthedocument.Theuseoftheoriginal issueofMDC-91K0263cannot
be
combined
withuseofRevision1.
Inaddition,
repairs
andinspection/replacement
programs
accomplished
inaccordance
with
DC-9/MD-80
Repair
Assessment
Program
DocumentReportNo.MDC-91K0263,
Revision
1,dated
October
2000,
areapproved
asAlternative
Methods
ofCompliance
fortherepair
andinspection/replacement
program
requirements
ofparagraph
(c)ofAirworthiness
Directive
(AD)93-01-15
in accordance
withparagraph
(d)ofAD 96-13-03.
Purpose
- Aviation
Safety
Professionalism
- Technical
Excellence
Pride
-Highest
Quality
Ifthere
areanyquestions
regarding
thisapproval,
please
contact
Mr.Mike
Leeat
(562)
627-5325.
Sincerely,
Gilbert
L. Thompson
Manager,
LosAngeles
Aircraft
Certification
Office
ReportNo. MDC 91K0263
Revision
1 October2000
DC-9/MD-80
AGING AIRCRAFT
REPAIR ASSESSMENT
PROGRAM DOCUMENT
MCDONNELLDOUGLASCORPORATIONPROPRIETARYRIGHTSARE INCLUDEDIN THE INFORMATIONDISCLOSEDHEREIN RECIPIENTBY ACCEPTINGTHIS

DOCUMENT AGREESTHAT NEITHERTHIS DOCUMENTNOR THE INFORMATIONDISCLOSEDHEREIN NOR ANY PART THEREOFSHALL BE REPRODUCEDOR
TRANSFERREDTO OTHER DOCUMENTSOR USED OR DISCLOSEDTO OTHERS FOR MANUFACTURINGOR FOR ANY OTHER PURPOSE EXCEPT AS SPECIFICALLY
AUTHORIZEDIN WRITINGBY MCDONNELLDOUGLASCORPORATION UNPUBLISHED- CREATEDON PREPARATIONDATE OF THIS DOCUMENTALL RIGHTS
RESERVED UNDER COPYRIGHTLAWS BY MCDONNELL DOUGLAS CORPORATION
MDC 91K0263
RECORD OF REVISIONS
REV. ISSUE DATE DATE BY REV. ISSUE DATE BY

NO INSERTED NO DATE INSERTED
ORIG. July1997 July1997 DAC
1 October2000 October2000 BA
RETAIN THIS RECORD IN THE FRONT OF THIS REPORT. UPON RECEIPT OF REVISIONS, INSERT
~REVISED PAGES IN THE DOCUMENT AND ENTER REVISION NUMBER, DATE INSERTED AND INITIAL.
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THESE DATA SUBJECTTO RESTRICTIVELEGEND ON TITLE PAGE. October2000
MDC 91K0263
REVISION NO. 1 SUMMARY

PageNo. Change
viii Newpageadded foradditional of effectivepage.

xi Pagenumber forsection 8 haschanged.
TitleforAppendix D haschanged.
xiii Namefortable6-2haschanged.
Figure9.1wasinserted inthepage.
8 Modifiedthe paragraph explaining thedatacollectionwindow
to include6
yearshmit.
13 Modified theparagraph to notethenamechange of appendix
D to Damage
Tolerance Exclusion Area(DTEA).
14 Modifiedtheparagraph addressingRepairsto Principal
Structural
Elements.
20 Namefortable6-2haschanged.
31 Shiftedthesection explaining theFastener Spacing
fromthispageto page35.
32 - 34 Newpagesaddedto setallowance for1.7,and1.5EdgeDistance.
35 - 52 Pagesshifted duetoaddition ofthreenewpages32,33,and34.
47 QualificationsandMaintenance requirementsin exampleguideline
changed.
48 Item5 changed fromsteel to steel doublers.
A.3 Appendix D changed to Appendix C.
A.8,A.7 Add pagenumber.
B.4 Addeddiagrams to showFuselage Zones.
B.8 Removed a paragraph explaining JointTypeNumber.
B.11 Add pagenumber.
B.13 QualificationsandMaintenance requirementsin guideline
changed.
B.14 Modifiedthefirst paragraph toexcluderepairjointnumberandqualifications
and
maintenance requirements in guidelinechanged.
B.15-B.17 Qualifications andMaintenance requirementsin guideline
changed.
B.19,B.37 Qualifications inguideline changed.
B.20- B.27 QualificationsandMaintenance requirementsin guideline
changed.
B.28,B.31 Qualifications inguideline changed.
B.29,B.30 Qualifications andMaintenance requirementsin guideline
changed.
changed.
changed.
B.46,B.49 Qualificationsin guideline changed.
B.47,B.48 Qualifications andMaintenance requirementsin guideline
changed.
B.50- B.53 Qualifications andMaintenance requirementsin guideline
changed.
B.69,B.77 Qualifications in guideline changed.
changed.
changed.
B.93- B.99 Newguideline addedforGeneral DoorJambEdgeRepair.
B.100- B.102Newguideline addedforGeneral Pressure BulkheadWebRepair.
B.103- B.110Newguideline addedforGeneral UpperCargoDoorRepair.
D.1 NameforAppendix D changed to DamageTolerance ExclusionAreas(DTEA).
D.3-D.5 Addeddiagram to showDTEAandincluded additional itemsto DTEA.
D.6-D.11 Newpagesforaddeddiagram to showDTEAandincluded additionalitemsto
DTEA(suchas service door,access door,airstairdooretc.)
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2000
MDC 91K0263
LIST OF EFFECTIVEPAGES
Section Page Issue Date
TITLE PAGE Oct 2000
RECORD OF REVISIONS Oct 2000
REVISION SUMMARY ii-R1 Oct 2000
LIST OF EFFECTIVEPAGES iii Oct 2000

IV Oct 2000
V Oct 2000
vi Oct 2000
vii Oct 2000
viii Oct2000
PREFACE ix OriginalJuly1997
x 1 Oct2000
TABLE OF CONTENTS xi 1 Oct2000

xii OriginalJuly1997
TABLE OF FIGURES xiii Oct2000
INTRODUCTION OriginalJuly1997
OriginalJuly1997
BACKGROUND OriginalJuly1997
OriginalJuly1997
PROGRAM OBJECTIVES 5 OriginalJuly1997

6 OriginalOct 2000
IMPLEMENTATION 7 OriginalJuly1997
8 1 Oct2000
9 OriginalJuly1997
10 OriginalJuly1997
11 OriginalJuly1997
12 OriginalJuly1997
APPROACH 13 1 Oct 2000

14 1 Oct 2000
15 Onginal July1997
16 OriginalJuly1997
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MDC 91 K0263
BASELINE ZONAL INSPECTION 17 OriginalJuly1997

18 OriginalJuly1997
19 OriginalJuly1997
20 1 Oct 2000
21 OriginalJuly1997
22 OriginalJuly1997
DATA REQUIREMENTS 23 OriginalJuly1997

24 OriginalJuly1997
25 OriginalJuly1997
26 OriginalJuly1997
27 OriginalJuly1997
28 OriginalJuly1997
29 OriginalJuly1997
30 OriginalJuly1997
31 1 Oct 2000
32 New Oct 2000
33 New Oct2000
34 New Oct2000
35 1 Oct2000
36 1 Oct 2000
37 1 Oct 2000
38 1 Oct 2000
39 1 Oct 2000
40 1 Oct 2000
41 1 Oct 2000
42 1 Oct 2000
43 1 Oct 2000
44 1 Oct 2000
REPAIR ASSESSMENT GUIDELINE PROCESS 45 1 Oct 2000

46 1 Oct 2000
47 1 Oct 2000
48 1 Oct2000
MAINTENANCE REQUIREMENTS 49 1 Oct 2000

50 1 Oct2000
51 1 Oct2000
52 1 Oct2000
OPTIONAL QUESTIONNAIRE AND EXPLANATION A.1 OriginalJuly1997

A.2 OriginalJuly1997
A.3 1 Oct 2000
A.7 1 Oct 2000
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MDC 91K0263
OPTIONAL QUESTIONNAIRE AND EXPLANATION A.8 Oct2000

(CONTINUE)
REPAIR ASSESSMENT GUIDELINE B.1 Original July1997

B.2 1 Oct2000
B.3 Original July1997
B.4 1 Oct2000
B.8 1 Oct2000
B.11 1 Oct2000
B.13 1 Oct 2000
B.14 1 Oct 2000
B.15 1 Oct 2000
B.16 1 O~ 2000
B.17 1 O~ 2000
B.18 1 Oct2000
B.19 1 Oct2000
B.20 1 Oct2000
B.21 1 Oct2000
B.22 1 Oct2000
B.23 1 Oct2000
B.24 1 Oct2000
B.25 1 Oct2000
B.26 1 Oct2000
B.27 1 Oct2000
B.28 1 Oct2000
B.29 1 Oct2000
B.30 1 Oct2000
B.31 1 Oct2000
B.32 1 Oct2000
B.33 1 Oct2000
B.34 1 Oct2000
B.35 1 Oct2000
B.36 1 Oct2000
B.37 1 O~ 2000
B.38 1 Oct2000
B.39 1 Oct2000
B.40 1 Oct2000
B.41 1 Oct2000
B.42 1 O~ 2000
B.43 1 O~ 2000
B.44 1 Oct2000
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MDC 91K0263
REPAIR ASSESSMENTGUIDELINE (CONTINUE) B.45 1 Oct 2000

B.46 1 Oct 2000
B.47 1 Oct 2000
B.48 1 Oct 2000
B.49 1 Oct 2000
B.50 1 Oct 2000
B.51 1 Oct 2000
B.52 1 Oct 2000
B.53 1 Oct 2000
B.54 1 Oct 2000
B.55 OriginalJuly1997
B.68 1 Oct 2000
B.69 1 Oct 2000
B.70 1 Oct 2000
B.71 1 Oct 2000
B.72 1 Oct 2000
B.73 1 Oct 2000
B.74 1 Oct 2000
B.75 1 Oct 2000
B.76 1 Oct 2000
B.77 1 Oct 2000
B.78 1 Oct 2000
B.79 1 Oct 2000
B.80 1 Oct 2000
B.81 1 Oct 2000
B.82 1 Oct 2000
B.83 1 Oct 2000
B.84 1 Oct 2000
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MDC 91 K0263
REPAIR ASSESSMENT GUIDELINE (CONTINUE) B.92 New Oct 2000

B.93 New Oct 2000
B.94 New Oct 2000
B.95 New Oct 2000
B.96 New Oct 2000
B.97 New Oct 2000
B.98 New Oct 2000
B.99 New Oct 2000
B 100 New Oct 2000
B.101 New Oct 2000
B.102 New Oct 2000
B.103 New Oct 2000
B.104 New Oct 2000
B.105 New Oct 2000
B.106 New Oct 2000
B.107 New Oct 2000
B.108 New Oct 2000
B.109 New Oct 2000
B.110 New Oct 2000
ZONING GUIDANCE FOR RECORD KEEPING C.1 Original July1997

C.2 Original July1997
C.3 Original July1997
DAMAGE TOLERANCE EXCLUSION AREAS D.1 1 Oct 2000

D.2 1 Oct 2000
D.3 1 Oct 2OOO
D.4 1 Oct 2000
D.5 1 Oct 2OOO
D.6 New Oct 2OO0
D.7 New Oct 2OOO
D.8 New Oct 2000
D.9 New Oct 2000
D.10 New Oct 2000
D.11 New Oct 2000
SERVICE BULLETINS E.1 Original July1997

E.2 Original July1997
PROGRAM EXAMPLE F.1 Original July1997

F.2 Original July1997
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PROGRAM EXAMPLE (CONTINUE) F.3 Original July1997

F.4 Original July1997
GLOSSARY G.1 Original July1997

G.2 Original July1997
G.3 Original July1997
ACRONYMS H.1 Original July1997

H.2 Original July1997
H.3 Original July1997
REFERENCES I.1 Original July1997

1.2 Original July1997
1.3 Original July1997
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MDC 91 K0263
PREFACE
Thisdocument
outlinesa programto review
repairs currently
installedon DC-9/ MD-80model
aircraft
utilizing
damage toleranceprinciples.
TheSupplementalInspectionDocument(SID)
Program
assuresthatairplanescertified
priorto theimplementation
of damagetolerance
requirements
arereassessedfordamage tolerance
of designfeatures.Thisdocument is the
result
ofan Airworthiness
Assurance
TaskForce(AATF)taskinitiated
toreview aircraft
structural
repairs
whicharenotoriginally approvedfordamage tolerance
to determinewhatmaintenance
requirements
areneeded on eachindividual
repair to satisfy
damagetolerancerequirements.
It is important
to notethattheguidelines
in thisdocument
havebeendeveloped
as a means
to
evaluateexisting
repairson aircraft.
These
guidelines
aremeantto beusedinconjunction
with
theStructural
RepairManual,Service
Rework
drawings
or anyotherrepair
design
instructions
for
futuredesign
ofrepairs.
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Douglas
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MDC 91 K0263
Intentionally
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MDC 91K0263
TABLE OF CONTENTS
SECTION TITLE PAGE

RECORD OF REVISIONS i
LIST OF EFFECTIVEPAGES iii
PREFACE ix
TABLE OF CONTENTS xi
TABLE OF FIGURES xiii
1 INTRODUCTION 1
......................................................
2 BACKGROUND 3
.......................................................
3 PROGRAM
OBJECTIVES 5
..................................................
4 IMPLEMENTATION 7
.....................................................
CreditforInspection Accomplished
DuringDataCollection 11
ExtensionforDatacollection 11
Stored Airplane Requirements 11
Transferred Airplane Requirements 12
Compliance / Documentation 12
Implementation Considerations 12
5 APPROACH 13
.........................................................
STC/ Modifications/ MajorAlterationEffect 13
Repairsto Principal Structural
Elements 14
Identificationofrepairsthatrequireimmediate
action 14
Stage1 Screening of Repairs 14
Repairs to be Assessed 15
6 BASELINE
ZONALINSPECTION 17
..............................................
Effectofrepair installation
uponinspection 18
Optionalmethod to screen
repairs 20
Maintenance CheckInterval Change 21
Additional OptionusingNon-destructive methods 22
Inspection
7 DATA
REQUIREMENTS 23
...................................................
8 REPAIRASSESSMENT GUIDELINEPROCESS 45
................................
Repair Assessment GuidelineDescription 46
9 MAINTENANCE
REQUIREMENTS 49
..............................................
Repair inspection requirements 50
APPENDIX A OPTIONALQUESTIONNAIRE ANDEXPLANATION A.1
...........................
APPENDIX B REPAIR
ASSESSMENTGUIDELINE B.3
............................................
RepairAssessment B.5
Minimum RepairRequirements B.5
STAGE1 Screening SheetExplanation B.5
Optional Worksheet / SummaryFormExplanation 10
Repair Assessment Guideline 3
APPENDIX C ZONINGGUIDANCE FORRECORD KEEPING C.1
..................................
APPENDIX D DAMAGETOLERANCE EXCLUSIONAREAS D.1
.....................................
APPENDIX E SERVICE
BULLETINS
...................................................
E.1
Modification andRepairLists E.3
Modifications / RepairsMandated Directive E.5
by Airworthiness
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2000
MDC 91 K0263
Modifications/RepairsNotMandatedbyAi~o~hinessDirective
E.7
APPENDIX F PROGRAM
EXAMPLE F.1
.........................................................
APPENDIX G GLOSSARY G.1
.............................................................
APPENDIX H ACRONYMS H.1
.............................................................
APPENDIXI REFERENCES 1.1
............................................................
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MDC 91K0263
TABLE OF FIGURES
Figure
4.1
Example
ofextension 11
..........................................................
Figure
5.1
Approach
flowchart 16
...........................................................
Table
6-1Basehne
ZonalInspection 18
........................................................
Figure
6.1External
RepairDoublerVisualInspectability 18
...........................................
Figure
6.2Internal
RepairDoubler
Inspectability 19
................................................
Table
6-2Example
operatorsinspection
interval
data 20
.............................................
Table
6-3
Example
repairintervals 20
........................................................
Table
6-4Example
Summary.............................................................21
Figure
7.1Repair
Installation
Surface 24
......................................................
Figure
7.2
Repair
Doubler
Size 25
...........................................................
Figure
7.3
ShimConfiguration 26
...........................................................
Figure
7.4
Doubler
Stagger
.............................................................26
Figure
7.5Example
1 ofDoublerContinuity 27
...................................................
Figure
7.6Example
2 ofDoublerContinuity 27
...................................................
Figure
7.7Example
ofa continuous
doubler 28
...................................................
Table
7-1
Repair
Proximity
.............................................................30
Figure
7.8Proximity
measurement
example 30
....................................................
Figure
7.9Edgedistance
illustration 31
......................................................
Figure7.10
Fastener
spacing
illustration 35
....................................................
Figure7.11Example
ofblind fastener
criteria
beingsatisfied 36
.......................................
Figure7.12Example
ofblind fastener
criteria
notbeing
satisfied 37
....................................
Figure7.13UsingFigure7.11 andFigure7.12
ina repair
example 38
...................................
Figure7.14
Example
sketchofarepair 42
.....................................................
Figure8.1
RepairGuideline
example 46
.......................................................
Figure9.1
Repairswithout
finger
doublers 50
...................................................
Figure9.2
Repairs
withfingerdoublers 50
.....................................................
Figure9.3Repair
overproduction
doublers 51
..................................................
Figure9.4
Repairs
atdoor openings 52
.......................................................
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MDC 91K0263
1 INTRODUCTION
TheRepairAssessment
Program
addresses
thecontinued
airworthiness
of therepairs
installed
on thefuselage
pressureshell.
Continued
airworthiness
of these
repairswereidentified
asa
concernduring
an Airworthiness
Assurance
TaskForce(AATF)
review andevaluation
structural
repairs.
Thecontinued
airworthiness
ofthese
repairs
~s addressed
similar
tothe
original
structure.
Theoriginal
structure
hasa Supplemental
Inspection
Document(SID)program
thataddresses
continued
airworthiness.
TheSIDprogram
introduced
damagetolerancephilosophy
to
pre-amendment
Federal
Aviation
Regulation
(FAR)25-45airplanes.
TheRepair
Assessment
Program
evaluates
repairs
installed
on thefuselage
pressure
shell
using
damage
tolerance
philosophy.
Theneedfora damage
tolerance
evaluation
withthedetermination
of maintenance
requirements
resulted
in thedevelopment
of an operator
useablesystem.
Thisreport
documents
a repair
assessment
program
thatreviewsexisting
aircraft
repairs
which
determine
proper
maintenance
requirements
withrespectto damage
tolerance
requirements.
Theenormous
scope
ofthiseffort
requires
guidance
material
thatcovers
a majority
ofexisting
aircraft
repairs.
Thisrepairassessment
guidelinedeveloped
fortheDC-9/ MD-80modelairplanes
provide
the
operator
a meansto reviewexisting
repairs
anddetermine
theappropriate
maintenance
action
whichmustbeemployedto ensure
thecontinued
airworthiness
of a particular
airplane
with
respect
toeachrepaironthatairplane.
Theintegrity
ofa specific
repair
duringtheoperational
lifeofanairplane
maydeteriorate
asthe
airplane
issubjectedtoroutine
loadingconditions.
Inorderto assure
theairworthiness
ofthe
airplane
at alltimes,
eachrepairmustbeassessed
fordamage
tolerant
characteristics
and
maintained
in accordance
withitsspecific
requirements.
Foradditional
background
information
concerning
Damage
Tolerance,
ContinuedAirworthiness
andSID,FAApublications
Advisory
Circular
(AC)25.1529,
AC 25.571
andAC 91.56should
consulted.
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MDC 91K0263
2 BACKGROUND
Recentevents in thefieldof commercialaviation

havereemphasized
a requirement
forthe
continual
assessmentofthestructural integrity
andrelated
safetyof commercial
transports
as
theycontinuein servicebeyondtheir
originaldesign
lives.InresponsetothistheFederal
Aviation
Administration (FAA)sponsored
theInternational
Conference
onAgingAircraftinJune
of 1988.
As a result of thisconference
theAerospaceIndustries
Association
of America
(AIA)
initiateda comprehensiveprogramto defineandrecommendactions
requiredto assurethe
structural
integrityofaircraftthroughout
theireconomic
lifetimes.
In orderto implement
theprogram,
theAirTransportAssociation
of America
(ATA)andAIA
established
an Airworthiness
AssuranceTaskForce(AATF)
withrepresentatives
fromaircraft
operators,
manufacturers,
regulators
andotheraviationauthorities(NASA,
PAMA,USAF).The
AATFidentified
three
major
areastobe investigated
in order
to quantify
therequirements
forthe
continued
structural
integrity
ofaircraft
throughout
theireconomic
lifetimes:
1. Product
specific
service
actions
andrecommendations
2. Research
and development
requirements
3. Humanfactors
issues
associated
withagingaircraft
maintenance
TheAATFappointed
appropriate
experts
to working
groupsin eachof thetaskareas,
except
the
first.
Because
of thespecific
nature
of thattask,threeProduct
WorkingGroups
(PWG)were
established,
oneeachforMcDonnell
Douglas,Boeing,andothermanufacturers
(Airbus,
British
Aerospace,
Lockheed,
etc.).
EachPWGwastasked withfivebasicissues:
o "Review
of Service
Actionswhich
relyonspecial
repetitive
inspections
to maintain
structural
integrity
of theaircraft
anddetermine
which
Service
Actions
torecommend
for
incorporation."
2. "Review
andrecommend
improvements
to thecorrosion
preventative
programs."
"Review
andrecommend
meansof improving
thequality
of structural
repairs
currently
on
.
aircraft."
4. "Review
and recommend
improvements
to the routine
maintenance
programs."
5. "Review
theSupplemental
Inspection
Documents
(SIDs)
foreffectiveness."
To support
the PWGfor McDonnell
DouglasequipmentthreeModelTaskGroups(MTGs)were
formed;
onefortheDC-8fleet,onefortheDC-9/ MD-80
fleet,andonefortheDC-10fleet.Each
MTGwaschartered
to evaluate
thefiveissuesandrecommend
actions
to be initiated
on the
respective
fleet.TheDC-9/ MD-80MTGwascomprisedof theDC-9! MD-80operators,
Douglas
AircraftCommercial
Product
SupportandEngineering
personnel
andvariousregulatory
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MDC 91K0263
authorities.
Industry
subcommittees
to theAATFwerealsoformed
to promote
common
approaches
forallmodels
ofairplane.
TheAATFchangedintotheAirworthiness
Assurance
WorkingGroup(AAWG)
to better
alignthe
functions
andtasksoriginally
assigned
to theAATF.TheAAWGcurrently
oversees
thefive
issues
taskedto thePWGs.
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MDC 91 K0263
3 PROGRAM OBJECTIVES
Thematerial
compiled
herecontains
theresults of theMTGandAATF/AAWG
review of Issue3
anditsapplication
totheDC-9/MD-80
modelaircraft.Theprimary
objective
of thisprogram
is to
address
theresults
fromthereview
of Issue3 by theAATF/AAWG.
Thisguidance
material
fortheAgingAircraft
Repair
Assessment
Programwasdeveloped
as part
oftheoverall
effort
to support
thecontinuing
airworthiness
oftheDC-9/MD-80
fleet
ofairplanes.
Theprimary
objectives
of theRepair
Assessment
Program
outlined
in thisdocument
are:
A) To provide
a practical
methodology
in theformof guidance
material
(based
on damage
tolerance
principles)
thatwillallow
a majority
ofexisting
repairs
tobeevaluated
byoperators
without
complex
analysis.
B) To direct
therepair
evaluation
process
towards
showing
thataninstalled
repair
which
replaces
thestrength
anddurability
oftheoriginal
structure
isdamage
tolerant
provided
the
existing
inspection
levels
areadequate.
C) To develop
a repair
evaluation
process
suchthatitwillidentify
therequirements
for
inspection
(threshold,
method,
interval)
andreplacement.
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4 IMPLEMENTATION
Theimplementation
of theRepair
Assessment
Program
includes
threemainparts:
1) A revision
to theoperatorsmaintenance
program
to include
therequtrement
fora repair
assessment
thatis to be accomphshed
on eachairplane.
Therevision
to theoperators
maintenance
program
is accomplished
prior
tothefirst
repair
assessment
intheoperators
fleet.
Therevision
to theoperators
maintenance
program
includes
thescheduleforaccomplishing
theassessment.
2) Theaccomplishment
of therepair
assessment.
Theageoftheairplane
isdetermined
asof1 yearafter
theoriginal
issue
dateofthts
document
or perregulatory
requirements.
Theassessment
of eachrepairincludes
twosteps;
StepA: Datacollection
StepB: Categorization
and determination
of maintenance
requirements
StepA
Datacollection
fortheassessment
is completed
according
to thefollowing
schedule:
Airplanes
ator below
60,000
total
landings
havesix(6)years
after
theaccumulation
60,000
total
landings
or115,000
total
landings
whichever
comes
first.
6 years DATA
COLLECTION
WINDOW
AIRPLANE I
60,000 100,000
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DATA
S COLLECTION
WINDOW
AIRPLANE
60,000 100,000 115,000
Airplanes
between
60,000
and100,000
totallandings
havesix(6)yearsor 115,000
total
landings
whichever
comesfirst.
6 years DATA
COLLECTION
.~-i WINDOW
}
"1
AIRPLANE
60,000 100,000 115,000
DATA
COLLECTION
WINDOW
AIRPLANE
60,000 100,00
l
I
115,000
Airplanes
above100,000
totallandings
havetwo(2)yearsor 115,000
totallandings
which
everislater,
butnottoexceed6 years.
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DATA
COLLECTION
WINDOW
2 years
AIRPLANE
100,000 115,000
DATA
COLLECTION
WINDOW
\ 2years i~
AIRPLANE
100,000 115,000
StepB
Thecategorization
of eachrepairandthedetermination
of additional
maintenance
requirements
occur
within24 months
of thecompletion
of thedatacollection.
NOTE: The24months
listed
in part2 stepB is thesame24 months
in part3 ofthe
implementation
forcaseswhena thresholdfora givenrepairis exceeded.
24 Monthsto
determine
maintenance
requirements
J
" 7
StartData Finish
Data
Collection
fora Collection
fora
Repair Repair
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MDC 91 K0263
3) Accomplishment
of anyadditional
maintenance
requirements.
Thesemaintenance
requirementsareto be accomplished
by thethresholds
determined
by theassessment,
or 24 months
fromdatacollection,
whichever
islater.
Whentheageof therepair
exceeds
thethresholds
thefollowing
schedule
is followed.
Forrepairsthathaveexceeded
theReplacement
/ Rework
Threshold
(RRT):
Replace
/ reworktherepair
within
24months
fromdatacollection.
24 MONTHS
I I
DATA REWORK OR
COLLECTION REPLACEMENT
Forrepairs
thathaveexceeded
theRepetitive
Inspection
Threshold
(RIT):
Accomplish
initial
inspection
within
24 months
fromdatacollection.
24 MONTHS
DATA INITIAL
COLLECTION INSPECTION
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Creditfor Inspection
Accomplished
DuringData Collection
Whenan inspection
is accomplished
during
thedatacollection
thenextinspectionis
accomplished
by theInspection
Repetitive
Interval
(IRI)basedon themethod
usedforthat
inspection.
INITIAL INSPECTION REPETITIVE
INSPECTION INTERVAL
I /
DATA REPEAT
COLLECTION INSPECTION
Extension
for Datacollection
An extension
of 3 months
maybe usedforextending thedatacollectiontimeframeif an operator
notifies
theirlocalregulatory
authority.
Thisextension
is forthosesituations
wheretheschedule
of theairplaneis changed.
The 3 monthsaredeductedfromthe24 monthtimeframethatis
usedforthecategorization,determinationof maintenance
requirements
and accomplishment
of
thosemaintenancerequirements,
if the24 monthtimeframeis applicable.Theoperatorwould
have21 months(ifan extension
of 3 months
is used)insteadof theoriginal
24 months.
24 Months
3 Months
I
I. J. 21 Months
r 7 &&
IF
Original Revised
Schedule Schedule
Figure4.1 Exampleof extension
Stored AirplaneRequirements
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MDC 91 K0263
A stored
airplane
thathasexceeded
theimplementation
requirements
stated
in thissection
must
be assessed
prior
toreturning
to service.
Transferred
AirplaneRequirements
An airplanethathasnotbeenassessed
andis transferred
aftertheimplementation
requirements
statedin thissection
havebeenexceeded
mustbe assessed
prior
to introduction
intoservice
for
thatoperator.
Compliance
/ Documentation
Theoperator
coordinates
withtheir
local
regulatory
authority
therequirements
for
compliance
withthisprogram. Appendix
APPENDIX
C providessomeguidanceon howan
airplane
maybe zonedandcompliance
be demonstrated
in phases
as eachzoneis
reviewed.
There
areno reporting
requirements
to Douglas
Aircraft
Company
forthisprogram.
Implementation
Considerations
Theoperatorshould
be awarethattheminimum thresholdfortheaccomplishmentof the
maintenance
requirements
is also24 months
fromdatacollection.
It isbeneficial
tothe
operator
to accomplish
theassessment earlyin the24 monthtimeframesincethe
assessment
mayshowthatsomerepairs require
replacement
or inspection
at theendof the
same24 months.
Thefollowing
topics
areadvisory
innature
andcompliance
isnotrequired
aspartof this
program.
Scheduling
Repairs
maybeinstalled
atanytimeduringthelifeof theairplane.
Thetrend,however
would
befortheoldest
airplanes
to havetheoldest
repairs;
thus,
thereview
of repairs
on
older
airplanes
before
thoseonnewerairplanes
is preferable.
Thedetermination
of therepair
categoryandmaintenancerequirements
is recommended
to
be accomplished
duringthesamemaintenance
checkas thedatacollection.
Thiswill
enabletheoperator
tohaveaccesstotherepairintheeventadditional
information
is
required.
Compliance
/ Documentation
Newmaintenance
requirements
fora specific
repair
as a result
ofthisprogram
canbe included
in
theexisting
maintenance
programfortheaffected
airplane
in thesamemanner
as anynew
repair
withspecial
inspection
/ replacement
requirements.
Page 12 McDonnell
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5 APPROACH
Therepair
assessment
is conducted
in stages.
Thestages
areidentified
belowandare
illustrated
intheflow
chartinFigure
5.1.
STAGE 1 Area/component
screening
STAGE 2 Repair
categorization
STAGE 3 Specific
maintenance
requirements
STAGE 1
Stage
1 oftherepairassessment
istheidentification
anddocumentation
ofallrepairs tothe
fuselage
pressure
shell.
Station
diagrams,
platingdiagrams,etc.canbe usedto document
repair
locations.
TheStructural
RepairManual
containsdiagramswhichtheoperatormayuseforthis
purpose.
Therepairshould
havesufficient
documentation
to showthatit hasbeenassessedfor
damage
tolerance.
Thefuselage
pressure
shellis identifiedasthefuselagepressurized
skin,
pressurepanelwebsandpressure
bulkheadwebs.
A visual
identification
ofeachrepair
isrequired
toverify
repairconfigurations.
A visual
inspection
of eachrepair
isnecessary
to collect
theminimum
datato accomplish
therepairassessment.
As
an option
theoperator
mayalsoconducta maintenance
recordssearchforanyadditional
information.
Repairs
thatareaddressed
bythisprogram
arethoserepairs
thatreinforcetheoriginal
structure.
Changes
totheoriginalstructure
thatdo notaddreinforcement
suchasblendouts,
plugrivets,
minor
trimouts,etc.arenotaddressed
by thisprogram.
Thesesituations
donotrequirea
damagetoleranceassessment.
I
Repairs
Areas
in lowstress
(DTEA),
areas,
arenotcritical
identified
in Appendix
fordamage
tolerance.
APPENDIX
D as Damage
Theserepairs
ToleranceExclusion
do notneedto be reviewed
further
as normalmaintenanceprovides
adequateassurance
of structural
integrity.Normal
maintenance
is considered
to include
thereplacement
of substandard
repairsin theseareas.
Inspectors
arenormallyresponsible
forfindinga repairthathasbeendamagedor corroded
in
service.
TheBaseline ZonalInspection
accountsfornormal maintenance
by theoperator.
This
concept
isexplainedin Section6.
STC/ Modifications
/ MajorAlteration
Effect
DuringStage1 repairs,
whicharenotcovered
by therepairassessment
guidelinessupplied
in
thisdocument,
areidentified
bytheoperator.
Thisincludes
repairs
toor adjacent
to
Supplemental
TypeCertificate
(STC)modifications
andMajorAlterations
whicharenotapproved
by DAC.Thesemodifications
mayinvalidate
theseguidelines
andtherepairsmustbe
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2000
MDC 91K0263
addressed
by theoperator
andappropriate
regulatory
agencywithrespect
to proper
evaluation.
Repairs
willbeconsidered
"adjacent
to"STCmodifications
if theyarecloser
thanthespecified
limits
documented
in Section
7 listed
underthequalifications
forusingtherepair
assessment
guidelines.
REPAIRS TO STC MODIFICATIONSAND REPAIRS TO MAJOR ALTERATIONSARE NOT

COVERED BY THIS DOCUMENT. IF EVALUATIONIS REQUIRED IT MUST BE ADDRESSED
BY THE OPERATOR AND THE APPROPRIATE REGULATORY AGENCY.
STC MODIFICATIONS AND MAJOR ALTERATIONS ARE NOT REQUIRED TO BE ASSESSED

BY THIS PROGRAM.
Preventative
modifications
or repairs
installed
perDouglasService
Bulletins
areto beevaluated
as anyotherrepair.
A listofServiceBulletins
withtheappropriate
maintenance
requirements
is
containedin Appendix
APPENDIXE. Additional
explanationconcerning
howService Bulletins
areto be evaluated
is includedin Appendix
APPENDIXE.
Repairs
to Principal
Structural
Elements
A repairto a Principal
Structural
Element(PSE), seeSupplementalInspection
Document
(SlD)
reportnumber L26-008forareasdefinedas PSEs,is evaluated by theRepairAssessment
Programfordamage tolerance
as anyother
repair to thefuselagepressureshell.
Theinspection
requirementsdetermined
fromtheassessment of therepair to thePSEwouldthenbe
consideredas an Altemate
Meansof Compliance(AMOC) to theSIDAirworthinessDirective
(AD)inspectionrequirements.
ThisAMOCis onlyapplicableto therepairedarea,andnotthe
wholePSE.Thisinspection requirements
mustbe documented in theships records
as an
AMOCto the properAD.
Identification
of repairs
thatrequire
immediate
action
Should
a repair
notmeetminimum
requirements
basedon itscondition
(cracking,
corrosion,
dents,
etc.)or inadequate
design,
a procedurein AppendixAPPENDIX
B provides
theimmediate
identification
ofsubstandard
repairs
in order
toupgradesuchrepairs
priortofurther
flight.
The
minimum
repairrequirements
supplied
in Appendix
APPENDIX B enable
theoperatorto identify
substandard
repairs
immediately
after
datacollection.
Stage1 Screening
of Repairs
A Stage1 ScreeningSheetis provided

in Appendix
APPENDIXB. Repairs
may be screened
as
Category
A repairs
if theoperator
satisfies
therequirements
of theBaseline
Zonal
Inspection
(BZI),Section
6, andtheStage1 ScreeningSheet.
TheStage1 Screening
Sheetprovides
the
repairs
thathavetheirmaintenance
requirements
satisfied
bytheBZI.
Page14 McDonnell
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Repairsto be Assessed
Repairs
thatpassthescreening
processareassessedusingtheAgingAircraftRepair
Assessment
Guidelineand arealsosupplied in AppendixAPPENDIXB. Thisassessment
is
completed
aftertheaircraft
hasbeenreturned
toserviceif therepair
satisfies
theminimum
requirements.
If theminimumrequirements(seeAppendix APPENDIXB pageB.5)arenot
used,
theRepairAssessment
Guideline
should
be employed
priorto furtherflight
inorder
to
determine
thecategory
oftherepair.
STAGE 2
Stage2 oftherepair
assessment
isthecategorization
of therepair.
Thecategory
of a particular
repairindicates
theneedforsupplemental
maintenance
actions
ortheacceptability
ofcontinuing
withtheexistingmaintenance
program.
To definestructural
maintenance
requirementsfor
existingrepairs,
threecategories
ofrepairsareprovided.
These
categories
aredefinedas
follows:
CATEGORY A
A permanent
repair
in whichtheBaseline
ZonalInspection*
is adequate
to ensure
continued
airworthiness
equaltotheunrepaired
surrounding
structure.
*Baseline
ZonalInspection
(BZI)reflects
typical
maintenance
inspections
assumed
to
performed
by theoperator.
TheBZIis explained
anddefined
inSection
6.
CATEGORY B
A permanent
repair
whichrequires
supplemental
inspections
to ensure
continued
airworthiness.
CATEGORY C
A temporary
repair
whichneeds
to be reworked
or replaced
priorto an established
time
limit.Supplemental
inspections
maybe necessary
to ensure
continuedairworthiness
prior
tothis
limit.
Therepairassessment
guidelines
provided
in Appendix
APPENDIX
B areusedduring
Stage2 of
the RepairAssessment
Program
STAGE 3
Thespecific
maintenance
actionrequired
foranindividual
repair
uponcategorization
is
determined
in Stage3. Theseactions
aredetermined
through
theuseof therepair
assessment
guidelines
providedin Appendix
APPENDIX
B.
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MDC 91K0263
STAGE 1 AREA / COMPONENT SCREENING
/
// \
ARE SPECIAL""
I CONTINUEWITH NORMAL " INSPECTIONS ",
REQUIREDFOR THIS
MAINTENANCE "., REPAIRAT THIS "
"-,LOCATION~ / /
/
Yes
\\
STAGE 2 REPAIR CATEGORIZATION
\
I
/
.,/CANTHE REPAIRBE
\ CONTACT MANUFACTURER
CATEGORIZEDBY No OFREGULATORYAGENCY
"\ THE GUIDELINES/ FOR RECOMMENDATIONS
\ i
\ /,
\ /
/
Yes
/ -~.
x~x
//DETERMINE "~
--CATEGORY A ~ CATEGORY OF THE CATEGORY C-
""x .. REPAIR J
CATEGORY B
STAGE 3 MAINTENANCE REQUIREMENTS
APPLY GUIDELINES APPLY GUIDELINES TO

TO DETERMINE DETERMINE INSPECTION
INSPECTION INTERVAL, THRESHOLD AND
L INTERVAL AND
THRESHOLD
REMOVAL TIME LIMIT
Figure
5.1 Approach
flowchart
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MDC 91K0263
6 BASELINE ZONAL INSPECTION
Oneoftheobjectivesofthisprogramistoshowthata repair
thatsatisfies
thestatic
strengthand
durability
oftheoriginalstructure
isdamagetolerant
iftheexisting
inspections
areadequate.
Everyrepairrequires
somelevel ofinspection
tomaintain
itsairworthiness.
Thatlevelof
inspection
is dependent
upontheoriginaldesign
of thestructure,
thedesignof therepairandthe
maintenance
schedule of theoperator.Thoseinspections
include
an inspection
methodor type
anda repetitiveinspection
interval.
Thetypeofinspection
canvaryfromanexternal
visual
inspection
to a lowfrequencyeddycurrent
inspection.
Therepetitive
interval
canvaryfroma
weekto years.TheBaselineZonalInspection
(BZI)enables
theoperatortoutilizetheir"Normal
Maintenance"
todetermine which
repairsaredamage
tolerantfortheirfleet.
TheBZIis an industry
termusedto define "NormalMaintenance"
fortheRepair
Assessment
Program.
Thedefinitionof "Normal Maintenance"
is necessary
sincethemaintenance
requirements
fora CategoryA repairis "Normal
Maintenance"and"Normal
Maintenance"
is
defined
differently
bydifferent operators.
TheBZIconceptallows
DACtogrouptogether
repair
types
thathavetheirinspectionrequirements
satisfiedbytheBZI.
NOTE:TheBZIis nota newmaintenance

schedule
or program
fortheoperator.
Alloperators
havea maintenance
programthatinspects
theairplane.Thismaintenance
program
visually
inspects
theexternal
and/ orinternal
surfaces
atregularintervals.
Theseinspections
typically
checkforgeneral
condition
andstructural
distress
suchascorrosion,
cracking,
dents,
scratches,
etc.Anyrepairs
in theinspection
areareceive
thesameattention
as theother
structural
components.Theoperatormayhavetheairplanebrokendownintozonesto
accomplish
the"Normal Maintenance"
inspections.
Thesezonesmayhavedifferentinspection
intervals
and/ or theinspections
maybe staggered.
TheBZIconcept
takesadvantage
of theoperators
"Normal
Maintenance"
to satisfy
a repairs
inspection
requirements.
These"Normal
Maintenance"
inspectionsmustmeetcertain
requirements
inorder
to satisfy
theinspections
requirements
of a repair.
External
inspections
.
a) Therepair
and/ or basestructure
mustbe inspected
withinarmslength.
b) Thelighting
mustbesufficient
tofinddistress
intherepair
andthebasestructure.
c) Fairingsmustbe displaced.
d) Paintandcorrosioninhibiting
compound
removalarenotrequired.
Internal
inspections
.
a) Therepair
and/ or basestructure
mustbeinspected
within
armslength.
b) Thelighting
mustbesufficient
tofinddistress
intherepair
andthebasestructure.
c) Interior
furnishings
mustbedisplaced
(interior
panels,
insulation,
liners,
etc.).
d) Paintandcorrosioninhibiting
compound
removal
arenotrequired.
A comparison
to theBZIis usedto determine
whichrepairsarescreened
outin Stage1 as a
Category
A repair.
Theoperatordetermines
whichzoneson thefuselage
pressureshellare
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MDC 91K0263
visually
inspected
by theirmaintenance
programmorefrequently
thanor equalto theappropriate
visual
repetitive
inspection
intervals
oftheBZI.
Fuselage
External FuselageInternal
Inspection
Interval Inspection
Interval
DC-9 6,000Landings 30,000Landings
MD-80 6,000Landings 30,000Landings
Table6-1 Baseline
ZonalInspection
Effect
of repair
installation
uponinspection
External
andinternalinspections
arebothusedto maximize
thebenefitfromtheBZI.The
significance
of thesetwovisualinspections
is demonstrated
wheneachareevaluated
withan
external
repair
doublerandan internal
repair
doubler.
Thesurfaceonwhichtherepair
is installed
on impacts
theeffectiveness
ofa visual
inspection
to
finda smallcrack
intheskin.Theimpact
ofan external
doubler
onvisual
inspections
is
illustrated
inFigure6.1
External
RepairDoubler SkinCrack1
/
/ , ---------~_--
....-~
~Skin Crack :2 Internal Inspection
Figure
6.1 External
Repair
Doubler
Visual
Inspectability
An external
repair
doubler
would
hidea crackfromanexternal
visual
inspection
until
thatcrack
is
longerthantherepair
doubler.
SkinCrack
1 inFigure6.1illustrates
thehidden
crackwhile
Skin
Crack2 depicts
thecrack
thatislongerthantherepairdoubler.
Aninternal
visual
inspection
wouldfinda smaller
crack
intheskinthantheexternalvisual
inspection.
Aninternal
repair
doubler
creates
a similar
situation
withtheexternal
andinternal
inspections.
Theimpact
ofaninternal
doubler
onvisual
inspections
isillustrated
inFigure
6.2.
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MDC 91K0263
SkinCrack1 IntemalRepairDoubler
Skin
i
~i~a~p!iln \Skin Crack
Internal
Inspection
Figure
6.2Internal
Repair
Doubler
Inspectability
Aninternal
repair
doubler
wouldhidea crackfromaninternal
visual
inspection
until
thatcrack
is
longer
thantherepair
doubler.
SkinCrack1 inFigure
6.2illustrates
thehidden
crack
while
Skin
Crack
2 depicts
thecrack
thatis longer
thantherepairdoubler.
An external
visual
inspection
would
finda smaller
crack
intheskinthantheinternalvisual
inspection.
Theimportance
of finding
smaller
cracks
is evident
in inspection
intervals.
Thesmaller
thecrack
thatcanbefound,
thelonger
theinspection
interval.
Theinspection
interval
fora repair
isfixed
uponthetypeofinspection
procedure.
Theseinspection
intervals
fortherepairarecompared
withtheoperators
"NormalMaintenance"
intervals.
NOTE: Theoperators
maintenance
program
doesriotrequire
adjustment
to reflect
theBZI
inspection
intervals.
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Optional
methodto screenrepairs
An optional
methodof screening
repairsmaybe usedby theoperator.
Thismethodinvolves
additional
workby theoperator
in documenting
theirmaintenance
schedules
andin
understanding
therepair assessment
guidelines
in Appendix
APPENDIX
B.
Theoperator
determines
whichzoneson thefuselage
pressureshellarevisually
inspected
by
theirmaintenance
program
morefrequently
thantherequiredvisual
repetitive
inspection
intervals
of thedifferent
repair
typeslistedin theguidelines
in Appendix
APPENDIX
B. Thiscomparison
includes
theexternal
visualinspections
andtheinternal
visualinspections
foreachzone.
Foreachzonelistedbytheoperator,
theoperators
external
visualinspection
interval
and
internal
inspection
interval
iscompared
toeachrepair
types
requiredexternalandinternal
visual
inspection
interval.
Iftheoperators
external
orinternal
visualinspection
interval
isshorter
than
or equal
totherepairs,thenthatrepair
canbescreened
outin Stage1 of theprocess.
An
I exampleusingTable6-2exampleoperatorsinspection dataand example
interval repair
data
fromTable6-3is provided
inTable6-4.
ZoneDescription External
Inspection Internal
Inspection
Operator
A ForwardCargo 1,000Landings 8,000Landings
Compartment
MainCabinbetween
Floor 1,500Landings 15,000
Landings
and Window
Operator
B ForwardCargo 1,500Landings 10,000Landings
Compartment
MainCabinbetween
Floor 2,500Landings 17,000Landings
and Window
Table6-2 Example
operators
inspection
interval
data
External
Visual
Inspection Internal
VisualInspection
Interval Interval
Repair
I 500 Landings 10000Landings
Repair
2 1000Landings 5000Landings
Repair
3 10000Landings 500 Landings
Repair
4 5000Landings 15000 Landings
Table6-3 Example
repair
intervals
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OperatorA Operator
B
ForwardCargo MainCabin ForwardCargo MainCabin
Compartment between
Floor Compartment between Floor
and Window and Window
Repair
1 500<1000 500<1500 500<1500 500<2500
10000>8000 10000<15000 10000=10000 10000<17000
Yes-Internal No Maybe No
inspection
Repair
2 1000=1000 1000<1500 1000<1500 1000<2500
5000<8000 5000<15000 5000<10000 5000<17000
Maybe No No No
Repair
3 10000>1000 10000>1500 10000>1500 10000>2500
500<8000 500<15000 500<10000 500<17000
Yes- External Yes- External Yes- External Yes- External
inspection Inspection Inspection Inspection
Repair
4 5000>1000 5000>1500 5000>1500 5000>2500
15000>8000 15000=15000 15000>10000 15000<17000
Yes- Both Yes- External Yes- Both Yes- External
inspections Inspection Inspections Inspection
Table6-4 ExampleSummary
Table6-4summarizestheexample usingtwo(2)imaginary operatorsandfour(4)imaginary

repairtypes.Thetableshowsthatwhentheoperatorsinterval
is smaller
thantherepairs
intervalthenthatrepaircanbecategodzedas a Category
B repair
in Stage1 withtheoperators
"NormalMaintenance"
satisfyingtherepairsmaintenancerequirements.
Thetypeof inspection
thatsatisfiestherepairs
requirements
islisted aswell.There
arealso"Maybe" results.
These
occurbecausetheoperators
intervals
arethesameas therepairs intervals
andthisis impacted
by maintenance
checkintervalchange.
It istheoperators decision
whetherto include
these
repairstobe screened
out.The"No"results occurwhentherepairsinspectionintervals
are
smallerthantheoperators
inspection
intervals,external
orinternal
inspection.
Maintenance CheckIntervalChange
A change
of maintenance
checkintervalsby an operator
requirestheoperatorto assessthat
changewithrespectto theRepairAssessment Program.If theoperatordecreasesa
maintenance
checkintervalthentheoperator maywantto reevaluatewhichrepairs
havetheir
maintenance
requirements
satisfied
by theoperators revisedmaintenance
interval.An
escalation
orincreaseofa maintenance
checkintervalrequiresa reevaluation
of whichrepairs
havetheirmaintenance
requirements
satisfiedby theoperatorsrevised
maintenanceinterval.
Theoperatorcanreducetheimpactof a maintenancecheckintervalincrease
by selectingthose
repairs
thathavea larger
repetitive
intervalthanthecurrentmaintenance
interval.
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Additional
OptionusingNon-destructive
Inspection
methods
Theoperator
maywishto usea non-destructive
inspectton
(NDI)methodin placeof thevisual
inspection
described.
Theoperator mayinspect
everyrepairin a given
zoneof theairplane
with
a NDImethod
ataninterval
lessthanorequalto therepairs
inspection
interval
fortheapplicable
NDImethod.TheNDI procedurewouldin effectbecome"Normal Maintenance"
forthosetypes
of repairs
andtherefore
wouldbe screened
outin Stage1.
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MDC 91K0263
7 DATA REQUIREMENTS
Thedatarequired
to categorize
eachrepair
is collected
during
Stage1. Thedatarequirements
arelisted
below.
Dateof datacollection
,
2. Modeland Series
3. Landings
4. Location
5. Proximity
to otherrepairsorSTCs
6. Satisfactory
repair
condition
7. RepairData
a) Doubler data
i) Material
ii) Thickness
iii) Size
iv) Geometry
v) Orientation
vi) Number of repair
doublers
vii) Staggering ofrepair
doublers,
if multiple
doublers
arepresent
viii) Internalorexternal
repair
doublers
b) Fastener Data
i) Edgedistance
ii) Spacing
iii) Fastener diameter
iv) Fastener type
v) Fastenermaterial
vi) Fastener
location
vii) Fastener arrangement
Dateofdatacollection
Datewhentheairplane
returns
toservice
after
completion
of thedatacollection.
Modelandseries
Modelandseriesoftheairplane
thatis repaired.
Forexample
themodelwould
be DC-8,
DC-9,MD-88or DC-10.
Theseries
wouldbe 15,20,30,33,81,61 etc.
Landings
Numberof landings
theairplane
acquired
whentherepairwasinstalled
andnumberof
landings
whenthedatais collected.
In thecasewhenthenumber
of landings
is notknown,
thentherepairisassumed
tobe installed
whentheairplane
hadzero(0)landings.
Location
Theapproximate
locationofthecenter
of therepair
(+ 2 inches).
Thisinformation
important
inidentifying
thezoneorzonesthattherepair
is~nstalled
in.Frame
station
location
andleftandright
Iongeron
location
isrequired.
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Satisfactory
repaircondition
exists
Therepairsatisfies
theoperatorsrequirements
forrepair
conditionto continue
in service.
Itemsthatwouldindicatethatan unsatisfactory
condition
mayexistinclude, butarenot
limitedto,corrosion,
cracking,
dents, dings,
gouges,looseor workingfasteners.
Unsatisfactory
conditionsareto be addressed
in accordance
withtheoperators standard
maintenancepractices.
Repairdoublerdata
Thereplacementof production
partsis considered
a repairforthoseareasthathavenew
fastener
holes. Replacing
theproductionskinfromproduction
spliceto production
splice
is
nota repair.A newsplicein themiddleof theskinpanelwouldbe considered
a newrepair.
Therepair
doublerdatais to be collected
foreachsideof therepair.
Thefollowing
information
is required
to use theguidelines
in AppendixAPPENDIX
B.
Thesurface
on whicheachrepair
doubler
is installed
External
or internal
surface.
External
doubler
j
I I I
I I I
/7
Skin
Internal
doubler
Figure
7.1 RepairInstallation
Surface
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MDC 91K0263
Length
of eachlayerof therepair
(+ 0.5inches)
EXTERNAL
DOUBLER LENGTH
THIS SIDE
EXTERNAL
DOUBLER LENGTH
>
INTERNAL
DOUBLER LENGTH
Figure 7.2 Repair DoublerSize
Repairdoublergeometry
Thegeneralshapeof therepair doubler,
specifically
whentherepairdoubleris a
fingerdoubler.The repairassessment guidelines
providedin AppendixAPPENDIXB
whichillustrate
fingerdoublers assume
thatthefingerdoublersareof Douglas
Aircraft
Company(DAC)design. If thefingerdoublersare notof DACdesignthenthefigures
withoutfinger
doublers areto be usedforthoserepairs.Circular
shapedrepair
doublersareconsidered to haveonesideandareto be evaluatedas such.
Thegeometryis alsousedto determine

whattypeof shimor filler
is used.Theshim
canbe a workingor notworking
shim.Bothshimtypesareillustrated
in Figure
7.3.
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MDC 91 K0263
I I III I II
,I I, I i I Ill,
IIIIIII
III I
III I
Figure7.3 ShimConfiguration
Repair
Doubler
Orientation
Theorientation
of eachforeachsideoftherepair
isrequired.Longitudinal
versus
Circumferential
orientation
versusatan angle
otherthan90 or 180degrees.
Repair
doubler
staggering
Thestaggering
or offset
of repair
doublers
is required
information
toaccomplish
the
assessment
usingtheguidelinesin Appendix
APPENDIXB. Thisinformation
is used
whentherearemultipledoubler
layerspresent.
Theguidelines
represent
thestagger
bya numberoffastener
rowsthattherepair
doublers
areoffset.
+ .........
+i i+ ..........
+
......
;t
....
/ ~-+I, I+ .........+~
/ +~ ---: = --- = --+-
Figure7.4 DoublerStagger
Figure
7.4shows
thattherepair
doublers
areoffset
by 1.5rowsof fasteners.
A rowof
fasteners
inthefinger
rowisconsidered
0.5rowsandnota fullrow.
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Continuity
andextentsof eachlayer
Existingstructure
mayrequiretheuseof internal
doublers
thatarenotcontinuous.
A
frame,Iongeron,
damagecutout
or otherstructure
mayinterferewiththeinstallation
of
a continuous
doubler(seeFigure7.5).
Longeron
Internal
Doubler
Frame
Figure7.5 Example1 of DoublerContinuity
Theprevious
illustration
(Figure 7.5)showshowa repair doubler
maynot
continuous
dueto existingstructure.
TheframeandIongeron aretheextentsof the
repair
doubleron twosides.Thisinformation
is usedto determine
therepairjoint
geometry
whichin turn,determinesthecategory of therepair.Thedamagecutout
mayalsodefinetheextentof therepairdoubler.
.....i-- I:------=-=------~T~---~-~-----"I
"-- -/ Longeron
f I 1,1 ~I I
I it I iI " " J I
kk, _,-,_,-,_,-,_,.,_,
,_, "i
,_,,
..... l
\ t _
i
..<.:,::.,-,.,-,.i\
_<,.," _ .
Internal
-- Doubler
Frame
Figure7.6 Example2 of DoublerContinuity
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MDC 91K0263
Theaboveexample (Figure7.6)showstheextentof an internaldoubleras the

damagecutoutand theframe.Theexternal repairdoublerin the twoprevious
examplesare continuousdoublers.
An exampleof a continuous
internaldoubleris
thesituationwherea section
of skinis removed
anda newskinsectionis installed
(Figure
7.7).
Internal
Finger
Production .,..~~-~.~3
j iF ~ Doubler
SkinPanel~~ ,__, ,,, I;Ii;

/ i -,
~ip/a
~H~ Y
Pcen~/at r
toer~a
~, _ I lil i,- ("
~~~
Figure 7.7 Exampleof a continuousdoubler
Skinspliceoverlap
Therelativelocation
of therepair
to skinsplices
willbe usedto determine
whichrepair
jointgeometryin the guidelines
in AppendixAPPENDIXB is themostappropriate
to
use.Therepair
canendat different
locationsrelative
to theendof theskinpanels.
Thefollowing
examplesillustrate
differentgeometry.
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/
iz
.....
il t
~I +:I+-
+: ~I t
I,
iIE
Ii
i iIEI
i i I ...... I
I
i
iii
Ii
ill+
i
i,
/
+
i-i
i......
t ]
I
,
n
Iill
,I,I
I
unEI
n
ILl
II
Li
I,,
i+ 1 + II++ - +i
I
,
i

"-- ....-~
t
I
Thickness
of eachlayerof therepair
andskinthickness.
Thethicknessforeachlayercanfallwithin a rangeof values.
Whenthemeasured
thickness
is betweentwo(2)standard
thicknessesthenthethinnerstandard
gage
tobe used.Whentheproduction
materialis nota standardmaterial
gage,the
measured
ortheblueprint material
gageis to beused.
Material
ofeachrepairdoubler
andskin
Thematerial
of therepairdoubler(s)
anddamagedskinisrequiredinformation.
The
material
oftherepairlayerisaluminum,
steel
ortitanium.
Theheattreatortemperis
assumed
to be correct.
Theskinmatedalmustbe specified
as to whether
it is 2014
aluminum,
2024or 7075aluminumor titanium.
Theheattreator temperis assumed
tobecorrect.
Typically,STEEL IS MAGNETICand ALUMINUMAND TITANIUMARE NON-

MAGNETIC.
Somestainless
steelsareeither
non-magnetic
or slightly
magnetic.The
material
mayalsobeidentified
byaccomplishing
a conductivity
testwithsample
material
typesforcalibration
andcomparison.
Hardness
testmayalsobe usedafter
paintremoval,
butsometitanium
andaluminum
hardness
rangesoverlapin thehigh
Rockwell
"B"scalerange.
Proximity
oftherepair
tootherstructure
Thisistheshortest
verticalandhorizontal
distancefromtherepair
toanadjacentrepair,
STCor Major
Alterations
installed
onthepressureshell.Theproximity
condition
doesnot
applywhentherepairs
areon separate
structuralcomponents.
Forexample
if a repair
is
installed
onthedoorskinandanother
repairis installed
atthedoorjambcornerthen
thesetworepairs
wouldnotbeconsidered
inproximityto eachother.
Tworepairs installed
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on twodifferent
skinpanels
butwithin
thedistance
specified
wouldbe considered
in
proximity
to eachother.
If thevertical
andhorizontal
distances
arebothlessthanthoselisted
belowthentherepair
is considered
adjacent
to theotherstructure.
Fuselage
Skin
Otherrepair 20 + 0.5inches
STCor MajorAlteration 20 + 0.5inches
Table7-1 RepairProximity
-2-_-22--_ ----------
I....................
....................
I I I
I I I
"7 r
I I VERTICAL
I, I DISTANCE
..... J L .....
-
-
- -"-
- -
-
-
-
-
- ...... m
HORIZONTAL .~
Figure 7.8 Proximitymeasurementexample
FastenerData
Thisdatais required
foreachsideof therepair.
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MDC 91K0263
Edgedistance
Thevisible
edgedistanceis required.
Thisistheedgedistancethatmeasured
without
removingfastenersandstructure.
Theminimumedgedistanceandthe
average
edgedistanceis evaluated.
Edgedistance
is thedistance
fromthecenter
of
theholetotheedgeof thepartdivided
bytheholediameter.
Theguidelines
in
Appendix
APPENDIXB expressedgedistance
in termsof "D",diameters.
Length Length
Diameter Edge Distance-
Diameter
Edge
ofpart
Figure
7.9Edgedistance
illustration
Excessive
edgedistance
wouldindicate
thattoomuchmaterial
wasusedtorepairthe
damage.
A concernwithtoomuchedgedistanceis theimpact
thatwouldhaveon
somenon-destructive
inspection
procedures.
Insufficient
edgedistance
mayreduce
thefatigue
lifeofthestructure
repaired
orthe
repair.
Theedgedistance
ofallpartsrepaired
andallrepairpartsshall
be reviewed.
Thiswillrequire
aninternal
inspection
ofthestructure.
Thisdoesnotrequire
disassembly
oftherepair.
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MDC 91 K0263
Thefollowing
criteria
providethe2D edgedistance
requirement
fora repair
doubler.
Wheneither
of thecriteria
hasbeenmet,therepairdoubler
canbeconsidered
satisfying
the2D edge
distancerequirement.
Criteria
h
Theedgedistance
mustbe equalto 1.7Dor greater.
There
isnolimit
onthenumber
offastenerswiththiscriteria.
Criteria
2:
Theedgedistancemustbe equalto 1.5Dor greater.

Thenumberof fasteners
thathavean edgedistanceequalto 1.5Dmustbe 25%or feweron
thefirst
row(row1 ).
A couple
of examples
areshownhowto qualify
the2D edgedistance
requirement.
oooo
go000 0 >- 2D
ooooot >__ 1.7D
O000
O000
0000
O000 Criteria
Test:
O000
Allfasteners
onthefirst
rowhavetheedgedistance
O0000 1.7Dorgreater.
000 Thecriteria
1ismet;therefore,
theedgedistance
is2D.
000
OO0
Row 1
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~ 000 Q Q 0000000000~ Row 1

0000000000000000
0000000000000000
0000000000000000
0000 0000
0 > 1.7D
__ 1.59
Criteria
Test:
Allfasteners
onthefirst
1.5Dorgreater.
Among
16fasteners
on thefirst row(row1),4 fasteners
arewith1.5Dedge
distance,
andtheyare25 % of the16.
Thecriteria
2 ismet;therefore,
theedgedistance
is2D.
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fOOOOQOtOOOQQO00~ Row 1
0000000000000000
0000000000000000
0000000000000000
0000 0000
O >_ 1.7D
_> 1.5D
Criteria
Test:
Allfasteners
on thefirst
1.5Dorgreater.
Among
16 fasteners
on thefirstrow(row1),5 fasteners
arewith1.5Dedge
distance,
andtheyare31.25% of the16.
Thecriteria
2 isnotmet;therefore,
theedgedistance
is1 .SD.
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Spacing
Thespacingbetweenfastenersis required.Thisis thedistancebetween
thecenters
of twoadjacent
fastenersdivided by thediameter
of thefastener.Theminimum,
averageandmaximumspacingis to be collected.
Thespacingis collected
withina
row andbetweenrowsof fasteners, seebelow.The guidelines
in Appendix
APPENDIXB expressspacingin termsof"D",diameters. Productionfastener
locations
arenotrequiredto havefastenerspacing
collected.
I. .I Spacing
within
arw
Fooooo I 1 oooooooo&
0000000000000000
000000000000000
0000000000000000 Spacing
0000 0000 between
rows
/-
Figure7.10 Fastener
spacing
illustration
Fastener
diameter
Theaveragediameter
of thefasteners
is evaluated
in theguidelines.
Thisis the
diameter
of themajority
of fasteners
on thesideof therepairbeingevaluated.
Oversize
fastenersareconsidered
thestandarddiameterforthisevaluation.
Fastener
type
Thetypesof fasteners
thatareacceptable
include
solidrivets,
solidpinsand
interference
fitbolts(Hi-loks)
andblindfasteners.
Fullthreaded
screws
arenot
acceptable
fasteners.Whenthereis a mixture
of fastener
typesthenthefastener
typesandmaterialsarerequired.
There
arecaseswhenit isdifficult
toinstall solidfasteners
inalllocations.
Forthose
casesthefollowing
criteria
canbe usedto alleviate
therequirements
forblind
fasteners
in existing
repairs.
Theuse of blindfastenersis a commonpracticewhenrepairing an airplane.The

blindfastenersareusedin locations
whereaccessis restricted
to onesideor timeis a
constraintforaccomplishing
therepair. A statically
adequaterepair canbe designed
usingblindfasteners.
Theconcern withblindfastenersis thelifeof therepair maynot
be adequate.Theuseof blindfastenersresultm an interimrepairthatmustbe
reworkedto a permanent
repairat somethreshold.Limited applicationor useof blind
fastenersmay be acceptable
in someapplications.
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Therearesituations
whenit is impossibleto install
a solidfastenerat eachfastener
location.
Thisis typicallydueto permanently attached
structure whichcreatesan
inaccessible
area.In allcasestheuseof solidfasteners should
be attemptedfirst.
Thefollowing
criteriaisto be usedin thedisposition
of a repair
thathasa mixture of
solidandblindfasteners.
If thefollowing
criteriaissatisfiedthentheblindfasteners
installed
in therepaircanbe consideredsolidfasteners.
1. When20%or fewerfastenerspersideof therepairareblind.

2. If no morethan2 fasteners
areblindin a rowof 10 consecutive Ifless
fasteners.
than10 fastenersperrowthen1 blindfastener
perrowis allowed.
Thefollowing
figures
provide
examples
of thecriteria
forblindfasteners.
~,, 000000000000000
fO Row1
00000000 Q 000000"- Row 2
0000000000000000" Row 3
0 t 000000000000 Q 0 Row 4
0000 0000 0 Sohd
~ J Blind
First
criteria.
There
are4 rowsof16fasteners
onthiss~deoftherepair
fora total
of64fasteners.
20%of64 is12.8.
There
are12blind fasteners
onthissideoftherepair
which
islessthan12.8
First
criteria
satisfied
Secondcriteria.
Row1 has4 blindfasteners,
butonly2 areina consecutive
rowof 10.Thereare8 solid
fastenersbetween
2 groupsof 2. Thecombinations
thatwould be of concern
are,2 bhnd
then8 solid,
1 blind
then8 solidthen1 blind
and8 sohdthen2 blind.
Row2 androw3 onlyhave2 blind fasteners
in eachrow.
Row4 hasthe2 groupsof fasteners
fartherapartthanrow1.
Therearemorethan10 fasteners perrow.
Second
cnteriasatisfied
Allthese
fasteners
canbeconsidered
solid
forthissideof therepair
forthis
program.
Figure7.11Example
of blindfastener
criteria
beingsatisfied
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October2000
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0 Solid
~00000
Blind
00000
FirstCriteria
0000 4 rowsof12 fasteners
provides48fasteners.
QO00 20%of 48is 9.6fasteners.
8 blind
fasteners
islessthan9 6 fasteners.
0000 First
criteria
satisfied.
0000 SecondCriteria
0000 Row1 onlyhas1 blindfastener.
Row2 has3 blindfasteners
in a rowof 10 consecutive
0000 fasteners.
1 blind,
2 solids,
1 blind,
4 solids,
1 blind
and
1 solid.
Atthispointthesecondcriteria
isnotmetand
0000 theblindfasteners
onthissideoftherepair cannot
be
000 considered
assolidfasteners.
SecondCriteria
notsatisfied.
0000
\0000
LLL Row
Row
Row 2
3 4
Row 1
Figure
7.12 Example
ofblind
fastener
criteria
notbeing
satisfied
Thetwoprevious
figures,
Figure
7.11andFigure7.12,illustrate
thesignificance
ofthe
blind
fastener
criteria.
Figure
7.11illustrates
a repair
sidethat
satisfies
thecriteria
for
blindfasteners
treated
assolidfasteners.
Figure7.12illustrates
a repair
sidethat
doesnotsatisfy
thearrangement
andquantity
criteriaforblindfasteners
treated
as
solidfasteners.
If bothfigures
werefromthesamerepairthenthatrepairwould
have
onesidewithblindfastener
requirements,
seeFigure7.13.
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f
OO0000000QO000
OOOO0000O00000 O Solid
Blind
00000000000000
QQO00000000000
0000 0000
0000 0000
0000 0000
0000 0000
0 , 00000000000000
0000000000000000
0000000000000000
0000000000000000
J
Figure
7.13UsingFigure
7.11andFigure
7.12in a repair
example
Fastener
material
Thefastenermaterial
is required
to accomplishtheevaluation.
Thematerialchoices
forsolidarealuminum,
steelortitanium.Aluminumfasteners
aretypically
rivets
with
theheadofthefastenerheadmilledor shavedafterinstallation.
Steelandtitanium
fasteners
aretypically
pinsofinterferencefitbolts(Hi-loks)
andtheheadsofthese
fasteners
aretypically
leftalone.Blindfastenershavethebrokenendof thestemin
thecenterofthefastener.Blind
fasteners areassembledfromdifferent
materials
and
therefore
cannotbea singlematerial,
forblindfasteners
listthematerial
asblind
fastener.
Fastenerrows
Thenumberof rowsin eachlayerof therepairandtheproduction
structure
is
necessaryto evaluatetherepairpertheguidelines in Appendix
APPENDIX
B..A row
of fasteners
inthefinger rowisconsidered
0.5rowsandnota fullrow.Thereare
caseswhenthenumber of rowsof fastenerscannotbe collected,
whenthedamage
cannotbelocated
(cutout,blendout,
etc.)orthefastener
pattern
isirregular.
Whenthedamage
cannotbe located
usinga visual
inspection
thentheoperator
must
determine
thedamage
usinganothermethod.Thismayrequirenon-destructive
inspection
techniques,
displacement
ofinteriorfurnishings
orremoval
ofallorpartof
therepair.
iPage 38
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An irregular
fastener
patternmaycomplicate
collecting
thenumberof fastener
rows.
Forthesecasesthefollowing methodology
maybe usedto determinetheequivalent
numberof fasteners
rows.
Thenumberof fastenersarecountedandtheaveragefastenerdiameterIs
determined
persideof therepair.
//O 0 00 000 00 000 00

0 0 00
O0 0 0 0
0000 0 O0 0 00
0 0 0 0 O0 0 00 000 O0
0
000000000 00000 0 0
/ \
~
Thisrepair
has64fasteners
onthisside
oftherepairwithanaverage
diameter
of
3/16inches
Thelengthof thedoubler
andthedistance
fromthedamageto theedgeof the
doublermeasured.
14mches
0 O0 0 00 0 0 00
0 O0 0 0 O0 0 0
0 000 0 000 o 0 o 0 3inches
0 0 0 0 O0 0 00 O0000 0
0 000000000 00000 0
/ k
t 1

Usinga fastener
spacing
of 4D,5D and6D,thenumberof fasteners
perrowis
determined.
1 fastener
14 inches x = 18.667fastenersat 4D
0.75 inches
1 fastener
14 inches x = 14.933fastenersat 5D
0.9375 inches
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MDC 91 K0263
1 fastener
14 inchesx = 12.444fasteners
at 6D
1.125inches
Determine
thenumber
of rowsbaseduponthenumber
of fasteners
andthefasteners
perrow.
64 fasteners
= 3.4286rows
18.667fasteners
/ row
64 fasteners
= 4.2687rows
14.993fasteners
/ row
64 fasteners
= 5.1430rows
12.444fasteners
/ row
Basedon thedistance measured

fromthedamage
to theedgeof thedoubler,
fastenerspacingof 4D,5D and6D andthenumber
of rowsfromabovedetermine
the
numberof rowsof fasteners.
1 fastener
row
3 inchesx = 4 fastener
rowsat 4D
0.75inches
1 fastener
row
3inchesx = 3.2 fastener
rowsat 5D
0.9375inches
1 fastener
row
3inches x = 2.67fastener
rowsat 6D
1.125inches
A comparison
of thetwofastener
rowcalculations
is usedto determine
howmany
equivalent
rowsarepresent.
Thewholenumber
thatthetwocalculations
overlap
is 4
rows,therefore
theequivalent
numberoffastener
rowsis 4 rows.
64 fasteners
= 16 fasteners
/ row
4 rows
14inches
= 0.875inches
per fastener
16 fasteners
0.875inches
= 4.667Dfastenerspacing
0.1875inches
Production
fastener
locations
Theproduction
fastener
locations
fromIongerons,
intercostals,
framesanddoublers
mustbe noted.
Theguidelines
in Appendix
APPENDIX
B utilize
thisinformation
to
assess
therepair.
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MDC 91 K0263
Otherissues
Production
structure
mayinterfere
withtheinstallation
oftherepair.Theproduction
structure
mayrequire
deviation
fromstandard
practices
foritemssuchas edgedistance,
spacing,
shimsandfillers.
Although
itisnotrequired
itmaybe totheoperators
benefit
tosecure
a sketch,
photograph
or
drawing
oftherepair
forwhich
thedataisbeingcollected
forfuture
reference.
A sketch
is onemethod
of documenting
information
required
to accomplish
theassessmentof a
repair,
seeFigure7.14.
Textsupplements
thesketch
inproviding
information
thatis noteasily
documented
withanillustration.
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MDC 91 K0263
January
21,2001
DC-9-15
T~meofinstallation
unknown
therefore
~nstalled
at0 landings
Goodrepair
condition
2014-T6
0 050in.THICK DAC DESIGN FINGER
SKIN F.S.332 DOUBLER
0.025in THICK ALUMINUM
TYPICAL
Long2 L
fSr
_4"
_"[-,
"T"
_+
_"T"1 r +
~~
....
+~-"TI
I+ .......... +1 [+ " +1
i
L/~+.......... +1 I+ ....... I
Long3 L r+ .......... + I I+ ..........
L ........... +
....
~.-__ ......... :J j
;---;--
;-- +-+-+

I,,, i,llt 15inches
II ~111 I
, , ,~ I,,,,
Ill, ,llll
Long4 L - ++++
++ ....................
._. f+ ..........
I
+---- i+--- +
I
Long5 L I+_
,-,+_
,-,+_
,",+_
,-,+,
-,_+,
JL+,_,+ ,+1
EXTERNAL REPAIR
DOUBLER0.063IN.
THICK ALUMINUM
20inches
Fasteners
infingerare5/32aluminum
rivets
Fasteners
through
existing
locations
are3/16steel
H~-Ioks
Fasteners
throughotherlocations
are3/16aluminumrivets
Edgedistancesare2D average,2D minand2.3Dmax
Spacingis between
4Dand6D except
forexisting
locations
Norepairsarewithin20inches
No STCsarewithin20 inches
Figure7.14Example
sketchof a repair
An optionalrepairassessment
questionnairehas beendeveloped whichmay be usedby the
operatorwhencollecting
datato be usedwiththerepairassessment guidelines.The
questionnaire
andadditional
guidancematerial
on howto fillit outis supplied
in Appendix
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MDC 91K0263
APPENDIX
A. Although
theuseof thequestionnaire
is optional,
theoperator
mustcollect
sufficient
dataabout
therepair
toevaluate
it fordamagetolerance.
Theinformation
required to complete
therepairassessment
maybe obtained
by non-destructive
inspection
(NDI)methodsorvisuallywithminimal
interference
withthestructure.
Thisprogram
requires
an on-aircraft
visual inspection
to collect
theminimum
dataneeded
toconductthe
assessment.
Theuseof NDIisat theoperatorsdiscretion.
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8 REPAIR ASSESSMENT GUIDELINE PROCESS
Therepairassessment
process
utilizesthedatacollected
pertherequirements
of
Section7 - DATAREQUIREMENTS.
The repairassessmentprocess
usesthisdatato
determine
themaintenance
requirements
andcategory
of eachrepair
through
theapplication
of
the guidelinesin AppendixAPPENDIXB - REPAIRASSESSMENT GUIDELINE.
Theoperator
compares
thedatacollectedwiththerepairjoint
geometryillustrated
oneachofthe
guideline
pages.
Thiscomparison
is accomplished
on eachsideof therepair.
Therepair
joint
geometry
illustrations
showthefollowing
information.
Orientation
andlocation
ofrepair doublers
Presence,
orientation
andlocationof finger
doublers
Location
of framesandIongerons
Minimumnumberof fastenersrows
Theminimumstaggering
of repairdoublers
Repairlayerstack-up
arrangement
Showsthedifferentacronyms
Lists
materials
thatapplies
tothatparticular
illustration
Lists
theapplicable
typefastener
Liststheapplicable
ModelandSeries
Oncetherepairjointgeometry
ismatched
withtherepair data,determinetheapplicability
of the
repairtoa zoneontheairplane.
A repairina givenzoneon theairplaneisonlybe acceptable
as
a temporary
repair.Theoperator
searchesdownthefirstcolumn labeled"Category"
until the
zoneinwhichthatrepair
isinstalled
isfound.
Theprocessthencontinues
with"Qualifications"
inthesecond columnmustsatisfyallthe
qualifications
oftherepairlisted.
Iftherepair
doesnotsatisfyallthequalifications
then
the
qualifications
onthenextrowdownis used.Iftherepairdoesnotsatisfy thequalifications
on
anyrowthentherepair mustbeupgradedwithinthetimeframe allowed
forthose repairsthat
haveexceeded theRework/ Replacementthreshold(seeSection 4 - IMPLEMENTATION).If all
thequalifications
aresatisfied
thentherepairsmaintenance
requirementsarelisted
onthatrow
in thethirdcolumn.Thefinalmaintenance
requirements
of therepair aretheminimumvalues
fromeachofthesides oftherepair.
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MDC 91K0263
DC-9/MD-80
Skin
Matl A
2024-T3 Skin
Repair
Matl ~ ~ t~
I Finger _ . : __
2024-T3
2014-T6 , ~ Dblr -- --
7075-T6 i+- +-+++++++-+-+++-+ -- " ~ Finger
...- : ...... Dblr
~ ~____~ExtOblr ~ :-G
Forward
Aft
Qualificabons Maintenance
Requirements
PermanentRepair No existingfastenerlocationsin shaded
area Inspection
IntervalandMethod
exceptforframeIocat=ons Inspection
Threshold
Zone1 and 2 1 11< td/ts-<
1 27 30,000
landings
0025-<tf-<0 032 Inspection
IntervalandMethod
5/32<- Fastener Diameter
-< 114 ExtVtsual= 4,000
4D < Average Spacing -< 6D Ext HFEC =
M,mmumSpecmg > 3 5D
MaximumSpacing-< 6 5D
AverageE D = 2D + 1/16inches
MinimumE D -> 2D
Fastenersthrough Iongeronareinterference
fitpm
(Fsu> 95 ks0
Proximity> 3 inches
TemporaryRepair Anyexisting fastenerlocationsin shaded
area Inspection
Threshold
except forframeIocabons 20,000
landings
Zone1 and 2 1 00-<td/t,-<1 50 Inspection
IntervalandMethod
tf-->0032 external
LFEC= 6,000
h--<0 025 external
US = 6,000
FastenerD=ameter -> 5/32 Replacement/rework
Threshold
3 5D < Average Spacing-< 7D 40,000Landings
Max=mumSpacing<- 7 5D
Average E D -> 1 7D
Mm=mumE D >-- 1 5D
fitpm
(Fsu>- 95ks=)
Figure
8.1 Repair
Guideline
example
Thenumberoflandings
atthetimeofrepair installation
isrequired.
Whenthisinformation
is not
knownthentherepairis assumed
to be installed
whentheairplane hadzerolandings.
The
numberof landings
whentherepairwasinstalledis addedto theRework
\ Replacement
ThresholdandtheRepetitive
InspectionThreshold.
RepairAssessment
Guideline
Description
TheRepair
Assessment
Guideline
addresses
thedamagetolerance
capability
of repairs
to the
pressurized
fuselage
shell.
Issues
thattheguideline
address
include,
butarenotlimited
to,the
iPage 46
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MDC 91K0263
general
condition,
size,
location,
design
details,
aswellastherepairs
proximity
toother
repairs,
modifications
or STCs.
Theguideline
is developed
usingstatic
analysis,
fatigue
analysis,
fracture
mechanics
analysis
andnon-destructive
inspection
techniques.
Repair
categorization
(Stage
2) andthedetermination
of replacement
/ rework
timelimit,
inspection
thresholds
andrepeatinspection
intervals
(Stage
3) arecombined
in theRepair
Assessment
Guideline.
Theguidehne
is a collection
of pagesthatareusedtogetherto assessa repair.
Eachpage
illustrates
a typeofrepairjoint,theorientation
oftherepairjointandcontains
thenecessary
information
toassessthatrepair joint.
Theassessment
of a repairrequires
theuseofmultiple
pages,
eachonedepictinga repairjointtypeandorientation.
Anexplanation
of theguideline
and
itsuseareprovided in AppendixAPPENDIXB. An exampleof a repairandtheassessment
process
is providedin Appendix APPENDIXF.
TheRepair
Assessment
Guideline
utilizes
thedatacollected
in Stage1 to determine
thecategory
oftherepair
andspecific
maintenance
requirements.
TheRepair
Assessment
Guidelineprovided
in thisdocument
provides
theoperator
withthe
maintenance
requirements
to satisfy
damagetolerance
requirements,
assuming
thefollowing
conditions
aremet:
1. Theairplane
hasan approved
maintenance
program.
2. Thedamage
wastreated
(blended,
cutout, ) before
etc..... therepair
wasapplied.
3. Therepair
wasinstalled
in accordance
withstandard
DACSRMpractices.
4. Thematerial
oftherepair
isoftheproper
heattreat.
Steel
doublers
areat least
140KSlultimate
tension
strength.
I 5.
6. The fasteners
wereDACSRMapproved
or equivalent.
It isrecommended
thatrepairs
notmeeting
these
conditions
bereferred
to Douglas
Aircraft
Company.
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i
MDC 91K0263
9 MAINTENANCE REQUIREMENTS
Themaintenance
requirements
of a repair
canhaveup to four(4)parts.
Thesepartsinclude
repetitive
inspection
threshold,
repetitive
inspection
interval,inspection
method
and
rework
/ replacement
requirements.
Therepetitive
inspection
threshold
isthetimebywhich
theinitial
inspection
mustbeperformed.
Thisthreshold
is measured
fromthetimetherepair
isinstalled
on theairplane.
Whenthetimeof
installation
isunknown
thentherepair
isassumed
tobe installed
atzero(0)landings.
See
Section
4, IMPLEMENTATION
foradditional
information
concerning
theinspection
threshold.
Therepetitive
inspection
interval
provides
thewindow in which
thenextinspection
mustbe
accomplished.
Thewindow
forthenextinspection
is measuredfromthepriorinspection.
The
repetitive
inspection
interval
isbasedupontheinspectionmethod
used,
notthemethod
thatwill
beusedat thenextinspection.
Themostcommoninspection
methodforeachoftherepairjoints
is listedwiththatrepairjoint.
Theoperator
determines
which method
andassociated
repetitive
inspectioninterval
fitsthebest
intotheirmaintenanceprogram.Eachof themethodshaveadvantages anddisadvantages.
Somerequireinternal
accesswhileothers
requireexternal
access.Bothshortandlongrepetitive
inspection
intervals
arepossible.Someinspection
methodsrequireadditional
equipmentwhile
others
willnotrequireanyadditional
equipment.
Theoperator
isto decidewhichoneof thelisted
inspections
methodsto usewhenthereis morethanonechoice. Onlyoneinspcetionmethod~s
required
to beused.
Therework
/ replacement
of a repair
isrequired bya specifiedthreshold
whenthatrepairis
assessed
tohavelimitedlife. Therework / replacement
of therepair
couldbe thereplacement
of
somefasteners
or thereplacementof therepair.Therearealternatives
to rework/ replacement
ofrepairswhich
includeaninspection to determine
thefastenersize,
material
thicknessoreven
thetypeof material
usedin therepair. Notallcasesrequiretheremoval
andreplacementof the
repair.
Theoperatorshouldcheckto seewhere thedesignoftherepairfallsshort
of a
permanent
repairandcorrect thatsituationwhenappropriate.
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Repairinspection
requirements
Theinspection
oftherepair
isto beaccomplished
in theareasshown
oftherepair
perthe
intervals
listed
intheguidelines.
Unless
otherwise
statedtheinspection
oftherepair
istobe
accomplished
per theNondestructive
Testing
StandardPracticeManual(NDTSPM)
Skin __ Skin
,,..,,/.,/--
Inspection Inspection
Area Area
Repair ,-,~Repair
Repair ~ ,, .,._
Doubler Doubler Doubler
/--._
Figure
9.1 Repairs
without
finger
doublers
Skin
Inspection
Area Finger
" Doubler

Repair
Repair / " Doubler
Doubler /"-
Figure9.2Repairs
withfingerdoublers
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of
MDC 91K0263
Skin
Skin
Inspection
Repair Inspection Repair 41 -...__
Area
Doubler Area -~
Doubler _~
Repair
Doubler
J
f
Repair/~"
Doubler--
Skin
Skin
Inspection
Repair Inspection Repair I
Doubler -" Area ~

Doubler_--C
I .... I
I .... I
I .... I
m Repair
% #" Doubler
,,4
t /
Repair ?
Doubler-
Skin "1"1 Skin _

Repair m 1-1 Inspection Repair
I
Doubler
----~_ .~-~
. Area Doubler
--~ Inspection
m Area
. m - i
-
. m - |
Repair Repair
Doubler-----* .
Doubler~
Figure9.3 Repairover production

doublers
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MDC 91K0263
Skin . Inspection Skin -:3",

Area Inspection
Area
I I ---- I
= I .... I
i
n. - -I,~
- I I
Repair Repair 7 Repair

Doubler Doubler " Doubler
J
t,--...
Internal
production
doublers
omitted
forclarity
Figure9.4 Repairsat dooropenings
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MDC 91K0263
APPENDIX A OPTIONAL QUESTIONNAIRE AND EXPLANATION
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MDC 91 K0263
Repair
Assessment
Optional
Questionnaire
Explanation
Thefollowing
explanations
of specific
questions
ontherepair
assessment
questionnaire
will
provide
someguidance
forindividuals
conducting
thedatacollection
segmentof theprogram
and
utilizing
theoptional
questionnaire.
It istotheoperators
advantage
to provide
asmuch
information
aspossible.
DATE:
Record
thedatethattheairplane
returns
toservice
after
completion
ofthedatacollection.
Thisdateis NOTthedatetherepair
wasinstalled.
OPERATOR:
Identify
atleast
thetwoletter
identifier
oftheoperator.
A/C NUMBER:
Identify
aircraft
byfactory
serial
number,
especially
ifthereport
istobesubmitted
to
Douglas.
Thisnumber
mustbe obtained
through
records.
Fuselage
number
can alsobe
used.
MODEL / SERIES:
Recordthemanufacturer
model;
DC-8,DC-9,MD-88,
DC-10andseries
- 15,20 etc.
CURRENT LANDINGS
Thisisnumber
of landings
whenthedatais collected
LANDINGSAT REPAIR:
Record
number
ofcycles
atthetimeofrepair
installation,
orifunknown,
use0 (zero)
landings.
Thisassumes
therepair
wasinstalled
ontheaircraft
atdelivery.
REPAIR REFERENCE NO:

Inorder
tomaintain
records
fortherepair
review,
itwould
behelpful
toestablish
a
reference
numbering
system,
andlogthenumberofa particular
repair
onthisform.
Appendix
C provides
an optional
method
fornumbering
repairs
if theoperator
doesnot
haveonealready.
1) ATTACH SKETCH, PHOTOGRAPH OR DRAWING OF REPAIR (OPTIONAL).

A rubtracing
canalsobe used.
A sketch
or drawingof a repair
withIongeron
and
station
references
provides
valuable
information
on thesize, location
andexact
fastener
locations.
These
arefactorsusedtodeterminetherepaircategory.
2) LOCATION
Thisis theapproximate
center
oftherepair.Obtainstation
information
from
diagramsor drawings.
Longerons
canbe counted,
starting
fromcenterline
top,or by
reference
todrawing
orStation
LinesGuides.
Also,noteiftherepair
isontheleft
sideorrightside
oftheairplane.
3) SATISFACTORYREPAIR CONDITION
Items
thatwould
indicate
anunsatisfactory
condition
include,
butarenotlimited
to,
corrosion,
cracking,
dents,
dings,
gouges,
loose
orworking
fasteners.
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MDC 91K0263
4) REPAIR DOUBLER DATA

Thedatarequired
foreachsideoftherepairincludes
length,
proximity,
material,
thickness,
overlapping
ofskinsplices,
continuity,
andifthedoubler
isa finger
doubler.
Theorientation
ofthedoublerforeachsideistobe noted
inthequestion
withthelength.
If therepairis circular
andsymmetric
thenonlyside1 needs
tobe
filled
out.Theinformation
needed isthesameforexternal
andinternalrepair
doublers.
Length:
Thisisthelength
andortentatlon
oftherepair
doubler
forthesideoftherepair
thatis being
assessed.
Thickness:
Measure
therepair
doublerfromthethickest
location
- notfroma tapered
edge.
A straight
edgecanbe extended
fromthetopof repairdoubler
pasttheedgeof
repair.
Measure
vertical
distance
fromthestraight
edgeto fuselage
skin.
Thickness
mayalsobe collected
after
paintremoval
insmalllocalareaswith
ultrasonic
methods
similar
tothoseintheSRMifrepair material
isknown.
Material:
Thisisthematerial
oftherepair.
Aluminum,
steelortitanium
aretypical
materials.Typically, ALLOYSTEELIS MAGNETICand ALUMINUMAND
TITANIUMARE NON-MAGNETIC.Somestainlesssteelsare eithernon-
magnetic
orslightlymagnetic.
Thematerial
mayalsobe identified
byusinghigh-
frequency
eddycurrentwithsample
material
typesforcalibration
andcomparison
similar
to thefasteneridentification
method.
Hardness
testmayalsobeused
afterpaintremoval,butsomeTitanium
andAluminum
hardnessrangesoverlap
in
thehighRockwell
"B"scale range.
Continuous:
Theassessment
of therepair
willrequireinformation
whetherornota repair
doubleris continuous
across
thedamage thatis beingrepaired.
A YESor NO
answeris needed.
Skinsplice
overlap:
Whenthesideof a repair
overlaps
a skinsplice
thedesignoftherepairneedsto
account
forthatoverlap.Howtherepair overlaps
theskinsplice
is needed?
Fingerdoubler:
Theuseof a finger
doublerwillenhance
thedesign
of therepair.
Therequired
information
is whether
or nottherepair
doubler
isa DACdesign
finger
doubler.
Thisis a YESor NO requirement.
Proximity:
Thisis theshortest
distance
fromtherepair
doubler
toanSTCoranother
repair.
5) FASTENER DATA
Thedatarequired
foreachsideoftherepairincludes
spacing,
edgedistance,
number
of rowsoffasteners,
theaverage
diameterandmaterials
of thefasteners.
therepair
iscircular
andsymmetric
thenonlyside1 needs
tobefilled
out.
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MIN/ AVGvisibleedgedistance:
Thisis minimum
andaverage
edgedistance
thatisvisible
without
theremoval
of
therepair
forthat
sideoftherepair.
MIN/ AVG/ MAXspacing:
Thisis theminimum,
average
andmaximum
fastener
spacing
forthatsideof the
repair.
Fastener
rows- internal
doubler:
Thisisthenumberofrowsoffastenersintheinternal
doubler
ordoublers
(if
present).
A fingerdoubler
wouldbe noted
witha halfrowoffasteners
andthe
number
offullrowsoffasteners.
Ifmorethan1 internal
repair
doubler
ispresent
thenusea slashto separate
thenumberofrowsof fasteners
in eachrepair
doubler,
thefirstnumber
shouldbeforthedoublerclosest
totheskin.
Fastener
rows- externaldoubler:
Thisisthenumberofrowsoffasteners
intheexternaldoubler
or doublers
(if
present).
A fingerdoubler
wouldbenoted
witha halfrowof fasteners
andthe
number
offullrowsoffasteners.
Ifmorethan1 external
repair
doubler
ispresent
thenumber
of rowsof fasteners
ineachrepair
doubler,
thefirstnumbershould
beforthedoubler
closesttotheskin.
Repair
doubler
stagger- ext.toext.:
Whenmultiple
externaldoublers arepresent additional
information
is needed
to
accomplish
theassessment. Thenumber of rowsof fasteners
thatthedoublers
arestaggered
byis needed. If morethan2 external repair
doublers
arepresent
thenusea slashtoseparate thenumber of rowsof fasteners
thateachdoubler
is
staggered
fromtherepair doubler nexttoit,thefirst number
should
beforthe
doubler
closest
totheskin
Repair
doubler
stagger
- ext.toint.:
Whenexternal
andinternalrepair
doublers
arepresent
additional
information
is
neededto accomplish
theassessment.Thenumber
of rowsof fasteners
thatthe
doublers
arestaggeredby is needed.
Thenumber
of rowslistedshould
be for
thedifference
oftheexternal
andinternal
doubler
nearesttheskin.
Repair
doubler
stagger
- int.
toint.:
Whenmultiple
internaldoublers
arepresent additional
information
is needed
to
accomplish
theassessment.Thenumber of rowsof fasteners
thatthedoublers
arestaggered
byis needed.If morethan2 internal
repair
doublersarepresent
thenumberofrowsoffastenersthateachdoubler
is
staggered
fromtherepairdoubler
nexttoit,thefirst number
should
beforthe
doubler
closesttotheskin
Averagediameter:
Thisistheaverage
diameter
ofallthesolid
fasteners
ontheparticular
sideofthe
repairthatisbeingassessed.
Thenumber
should
be tothenearest
1/16ofan
inch.
Material:
McDonnell
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MDC 91 K0263
Thematerials
of thesohdfasteners
arenecessaryfortheassessment.
The
material
typecanbe determined
witha magnet
or an eddycurrent
inspection.
Typically:
ALLOY STEEL IS MAGNETIC
ALUMINUM IS NON-MAGNETIC
TITANIUM IS NON-MAGNETIC
A286 IS SLIGHTLYMAGNETIC
Blindfasteners
present:
Arethereanyblindfasteners
present?
SeeSection
7 forinformation
concerning
blind
fasteners.
PageA.6 McDonnell
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MDC 91K0263
OPTIONAL QUESTIONNAIRE DATE
OPER: A/C NO: MODEL - SERIES:

CURRENT LANDINGS: LANDINGS AT REPAIR"
REPAIR REF NO:
1) SKETCH, PHOTOGRAPH OR DRAWING OF REPAIR (OPTIONAL)
THIS CAN BE USED TO DEPICT THE NECESSARY INFORMATION OF THE REPAIR.
2) LOCATION (APPROXIMATE CENTER OF THE REPAIR)
STATION NO: LONGERON:
3) SATISFACTORY REPAIR CONDITION: YES NO
4) REPAIR DOUBLER DATA
EXT DBLR SIDE 1 SIDE 2 SIDE 3 SIDE 4

LENGTH
THICKNESS
MATERIAL
CONTINUOUS
SKIN SPLICE
OVERLAP
FINGER
DOUBLER
PROXIMITY
INT DBLR SIDE 1 SIDE 2 SIDE 3 SIDE 4

LENGTH
THICKNESS
MATERIAL
CONTINUOUS
SKIN SPLICE
OVERLAP
FINGER
DOUBLER
PROXIMITY
Ifmorethan1 layer
is present
fortheinternal
or external
doubler
thenlistthedataforeachlayer
separated
by"\"withthedataforthedoubler
closesttotheskinlisted
first.
Anillustration
showing
therelativeposition
of therepair
doublers
foreachsidewillhelp
accomplish
theassessment.Spaceis provided
on thefollowingpage.
Page A.7
October2000
THIS PAGE MAY BE REPRODUCED
MDC 91K0263
5) FASTENER DATA
SIDE 1 SIDE 2 SIDE 3 SIDE 4
MIN / AVG VISIBLE
EDGE DISTANCE
MIN / AVG / MAX
SPACING
FASTENER ROWS -
INTERNAL DOUBLER
FASTENER ROWS -
EXTERNAL DOUBLER
REPAIR DOUBLER
STAGGER - EXT TO
FXT
REPAIR DOUBLER
STAGGER - EXT TO
!NT
REPAIR DOUBLER
STAGGER - INT TO
INT
AVERAGE DIAMETER
MATERIAL
BLIND FASTENERS
PRESENT
SKETCH
IPage A.8
October2000 THIS PAGE MAY BE REPRODUCED
MDC 91 K0263
APPENDIX B REPAIR ASSESSMENT GUIDELINE
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MDC 91K0263
Intentionally
LeftBlank
PageB.2 McDonnell
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Corporabon
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Informabon
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of
October2000 THESE DATA SUBJECTTO RESTRICTIVELEGEND ON TITLE PAGE,
MDC 91K0263
RepairAssessment
Inthisappendix
thefollowing
items
areincluded:
Minimumrepair
requirements
Stage1 Screening
Sheet
ZoneFactorChart
Visual
Inspection
Interval
Chart
OptionalWorksheet
/ Summary
Page
RepairAssessment
Guidelines
MinimumRepairRequirements
Theminimum
repairrequirements
areto be usedas thedatais collected.
Thiswdlallowa
determination
if anyrepairsrequireimmediateattention.
The~mmedlate
attention
maybe the
assessment
of therepairusingtheguidelines,as theminimumrepair
requirements
aremeantas
a screening
of extreme
cases,or areto be addressed
in accordance
withtheoperators
standard
maintenance
practices.Theminimumrequirementsarebasedon static
considerations
only.
1. Repair
doublerisatleastasthick
asbasestructure.
2. Minimum
of 3 rowsof fasteners.
3. Allfasteners
present
4. Repair
isinsatisfactory
condition.
TheStage
1 screening
sheet is usedat theairplane
to determine
if there
areCategory
A repairs
installed
ontheairplane. Thoserepairsthataredetermined
nottobe Category
A arerequired
to
continue
withStage2 of therepair assessment
process.
TheStage1 screening
sheetandan
explanation
ofhowtouseitislocated inthisappendix.
STAGE1 ScreeningSheetExplanation
TheStage1 screening
sheetis usedduring Stage1 toscreenoutrepairs
fromcontinuing
with
Stage2 of theassessment.
Repairsthatarescreened outusing
theStage1 screening
sheetstill
requiredocumentation
to showthattheyhavebeenassessed by thisprogram.
TheStage1
screening
sheetislimitedto those
operators thatsatisfytherequirements
fortheBaseline
Zonal
Inspection
(BZI)asoutlinedin Section6. TheStage 1 screening
sheet
isa toolthatshould
reducetheamountof workrequiredby theoperator instages2 and3.
TheStage
1 screening
sheetdepicts
whichrepair
typescanbe screened
outforthedifferent
locations
on theairplane.
TheStage1 screening
sheet
containsqualifications
fortherepair,
an
illustration
oftherepair
anda side
viewoftheairplane.
Theoperator
determines
thelocation
oftherepair
thatis tobe assessed
andthe
geometry/design
details
oftherepair.
Thelocation
of therepairwilldetermine
whattypes
of
McDonnell
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MDC 91 K0263
repairs
couldbescreened
out.Thegeometry/design
details
areusedto matchtheillustration
andsatisfy
thequalifications
listed.
An example
on the use of the Stage1 screening
sheetis in Appendix
APPENDIX
F, PROGRAM
EXAMPLE.
ZoneFactorSheet
TheDC-9/ MD-80is divided

into2 (two)mainzones.Thefirstzoneor Zone1 is belowthe
window
beltnoseto AftPressure Bulkhead
andabovethewindow beltforwardof station389.
Thesecondzoneor Zone2 is abovethewindowbeltfromStation389to theAftPressure
Bulkhead.
DC-9 MODEL
/ /f
ZONE 1
ZONE 2
MD--80MODEL
0000000~ 000000000 OO0000000000000~O~O000000000DO00000
/ /
L11~Loo~oooo,~6noooboooooobboodoob~oo~bDoOoooOo6,
~ JOoboO
L18 "-~[ ~~t - -
[] ZONE 1
~. ZONE 2
PageB.4 McDonnell
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October
2000 THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE.
MDC 91K0263
Stage1 Screening
SheetforExternal
Inspections
AllFlush
Repairs
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MDC 91K0263
Stage
1 Screening
SheetforInternal
Inspections
Contact
DACforRepairs
to be screened
in Stage1
PageB.6 McDonnell
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MDC 91K0263
TheVisualInspection
Interval
Chart
is usedtodetermine
thevisual
Inspection
Repetitive
Interval
basedon various
surface
configurations
andconditions.
Contact
DACforVisual
Inspection
Chart.
McDonnell
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Informabon
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MDC 91K0263
OptionalWorksheet/ SummaryForm Explanation
TheOptional
Worksheet/ Summarypagecanbe usedto document
intermediate
valuesthatare
usedwithin
theassessmentguideline,
preliminary
values
of themaintenance
requirements
from
theguideline
andthefinalmaintenance
requirements
fortherepair.
Thisformcanbe usedin
conjunction
withtheoptional questionnaire
to document
thedamagetolerance
assessmentof a
repair.
Thisformhas3 majorsections/areas.
Thefirst
section
isthetopareaoftheform.
Thissection
isforrecord
keeping
and
.
tracking
purposes.
"DATE"
is thedatethisformis completed.
"MODEL"
isthemodel
oftheairplane
thattherepair
isinstalled
on.
"AIRPLANE
ID"istheidentification
theoperator
willusetotrack
whatairplane
this
repair
isinstalled
on.
"REPAIR
ID"istheidentification
thattheoperator
usestoidentify
therepair.
2. Thesecond
section
is comprised
of six(6)columns.
Thefirstcolumnlistsitems
thatareneeded
to accomplish
therepairassessment.
Someof theseitemsaredetermined
fromthedatacollected
in Stage1 andothers
arefromtheguidancematerial.
Thisinformation
isneeded
foreachsideof the
repair.
Theseconditemis "SPACING"of thefasteners.

The minimum,
average
andmaximumspacingis needed.
Fastenerspacingis expressed
in terms
of fastener
diameters.
Additional
guidance
/ information
concerning
spacingis in Section7 DATAREQUIREMENTS.
Thethirditemis "E.D."
of thefasteners.
Theminimumandaverage edge
distance
is needed.
Fasteneredgedistance
is expressed
in termsof
fastener
diameters.Additional
guidance
/ information
concerning
E.D.is
locatedin Section7 DATAREQUIREMENTS.
Thefourthitemis the"THICKNESS
RATIOS"
of therepair.
Therepair
mayhavemultiple
layersandtherefore
thenumber
of thickness
ratios
required
to accomplish
theassessment
willdepend
on theguidelines.
The
guidelines
determinewhatthickness
ratios
arerequired.
Thefifth,
sixthandseventh
itemsrelate
totherework
/ replacement
threshold.
"RRI"istherework
/ replacement
threshold
forthattypeof
repair
jointas determined
fromtheguidance
material
underthecolumn
labeled"Maintenance
Requirements".
"ZONEFACTOR"adjuststhe "RRT
PageB.8 McDonnell
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Corporation
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Information
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of
MDC 91 K0263
toreflect
thezoneoftheairplane
thattherepair
isinstalled
in."RRT
RESULTis "RRTmultiplied
by "ZONEFACTOR".
Theeighth,ninth
andtenthitems
relatetotherepetitive
inspection
threshold.
"RITistherepetitive
inspection
threshold
forthattypeofrepair
jointas determined
fromtheguidance
material
underthecolumnlabeled
"MaintenanceRequirements".
"ZONEFACTOR"adjuststhe"RIT"to
reflect
thezoneoftheairplanethattherepair
isinstalled
in."RITRESULT"
is "RITmultipliedby "ZONEFACTOR".
Theeleventh,
twelfth
andthirteenth
itemsrelate
totherepetitive
inspection
interval.
"IRI"istherepetitive
inspection
interval
forthat
typeofrepair
joint
andinspectionmethodas determinedfromtheguidancematerial
under
the columnlabeled "MaintenanceRequirements"."ZONEFACTOR"
adjusts
the"IRI"toreflect
thezoneoftheairplane
thattherepair
is
installed
in."IRIRESULT is "lRrmultiplied
by "ZONEFACTOR".
Thesecond
through
fifth
columns
arethesides
of therepair.
Thelastorsixthcolumnis thelowest
valueforthe"RRTRESULT,,
"RITRESULT,
andthe"IRIRESULT,
as determined
bycomparison
ofallthesides
of therepair.
Thethirdandlastsection
of theformis usedto adjust
thelowest"RRTRESULT"
.
and"RITRESULT,.Thiscanbe accomplishedwhenthenumberof landingsat
thetimeofrepairinstallation
is known.
Whenthenumberoflandings
is known
thatnumbercan be addedto the lowest"RRTRESULTand "RITRESULT" to
determine
theappropriate
thresholdsforthatrepair
onthatrepair.
Ifthenumber
oflandings
is notknownthenzero(0)mustbeusedforthenumberoflandings.
Thelowest
"IRIRESULT
is alsorecorded
in thissection
withthecorresponding
inspection
method.
Thesameinspection
methodshould
be usedforallsides
of
therepair
toprovide
theappropriate
inspection
interval.
McDonnell
Douglas
Corporabon
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Information
- UseorD~sclosure
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THESE DATA SUBJECTTO RESTRICTIVELEGENDON TITLE PAGE. July1997
MDC 91K0263
Intentionally
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PageB. 10 McDonnell
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InformaUon
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MDC 91K0263
REPAIR ASSESSMENT PROGRAM OPTIONAL WORKSHEET / SUMMARY

MODEL: AIRPLANE ID DATE
REPAIR REF NO:
SIDE 1 SIDE 2 SIDE 3 SIDE 4
SPACING
E.D.
THICKNESS
RATIOS
RRT
ZONE LOWEST RRT
FACTOR RESULT
RRTRESULT
RFF
ZONE LOWEST RIT
FACTOR RESULT
RIT RESULT
IRI
ZONE LOWESTIRI
FACTOR RESULT
IRIRESULT
LANDINGSAT INSTALLATION
0f unknownuse zero):
REWORK / REPLACEMENT THRESHOLD FOR THE REPAIR:

LOWEST RRT RESULT + LANDINGS AT INSTALLATION
+ =
REPETITIVE INSPECTION THRESHOLD hUH THE REPAIR:
LOWEST RIT RESULT + LANDINGS AT INSTALLATION
+ =
INSPECTION R/=PETITIVE INTERVAL AND METHOD:
LOWEST IRI RESULT:
INSPECTION METHOD:
Page B.11
THISPAGE MAY BE REPRODUCED October 2000
MDC 91K0263
Intentionally
LeftBlank
PageB. 12 McDonnell
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of
MDC 91K0263
RepairAssessment
Guideline
TheRepair
Assessment
Guideline
is usedto assess
a repairfordamagetolerance
requirements.
Thenumber
ofpossible
repair
configurations
islarge.
In aneffort
to assessasmanyrepair
configurations
aspossible
theguideline
issetupasa collection
ofindividual
repair
doubler
joints
(repair
joints).
Thecollection
ofrepair
doubler
jointsarefirst
broken
downintolongitudinal
joints
or
circumferential
joints.
Thenextbreakdownisintotheactual
geometry
oftherepair
joint.
At this
leveltheguideline
pagehasallthepertinentinformation
toaccomplish
theassessment
of that
particular
repair
joint.
Following
is anexample
ofoneofthese pages.
DC-9/MD-80
SkmMatl A.,,il--
2024-T3
Skin
ts ~
Repatr
Matl ~ ~ tf
I Finger
2024-T3 -- --
+ ++ +++-~ L1/Dblr
2014-T6
7075-T6 ~ + ++ +++-I +++++++~ -- --
~.~ Ext Dblr ~ Dblr
~ .,ql-
td
Fasteners ~~"
Solid A-A
Forward
Aft
Qualifications Maintenance
Requirements
area Inspection
Threshold
except forframelocations 60,000Landings
Zone1 and2 1 15< t~/t~
-<125 Inspection
IntervalandMethod
0 025-<tf< 0 032 ExtVisual= 8,000Landings
5/32-< FastenerD=ameter-< 1/4
4D -< Average Spacing < 6D
MmtmumSpacing-> 3 5D
MaximumSpacing< 6 5D
Mmtmum E D > 2D
FastenersthroughIongeron areinterference
fitpm
(Fsu->95kst)
Proxlmtty> 3 inches
area Inspection
Threshold
except forframelocations 20,000landmgs
Zone1 and 2 1 00 <tjts
-< 1 50 Inspection
IntervalandMethod
tf->0 032 external
LFEC= 6,000
tf< 0 025 external
US = 6,000
Replacement/rework
Threshold
Fastener D=ameter > 5/32
40,000Landmgs
3 5D < AverageSpecmg-< 7D
MaximumSpacing< 7.5D
MimmumE D >- 1 5D
fitpm
Eachpageof theguideline
is separated
intofour(4)areas.
Thefourareasarethetopboxwith
anillustration
oftherepair
geometry
(A),thefirst
column
ontheleft(B),themiddle
column
andthecolumnon theright(D).
McDonnell
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Informabon
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THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE October
2000
MDC 91 K0263
Thefirst
area(A)contains
informationaboutthegeneral
geometry
of therepair
joint.
The
information
inthisareaincludesthemodelandseries
theguideline
pageisacceptable
for,the
skinmaterial,
therepair
doubleror doublers
material,
thefastenertypeandmaybe
material,the
orientation
of therepair
joint,thenumberof repair
doublerlayers,
theminimum
numberof rows
offasteners
thatarerequired,
thelengthorwidthdimension
oftherepair,
thelocation
where
repair
doublersterminate
withrespecttoeachotherorto thedamage,
thedifferent
thicknesscall
outsanddepictswhich
wayis forwardandaft.
DC-9/MD-80
Skin
Matl A
Repair
Matl ~
2024-T3 Finger _--~-"
2014-T6 + +++*= ~~~t~Dblr -- _ __
7075-T6 ~l---------
Dblr Ext Dblr
-- -~~-~
~ t
F,nger
~
++++++~-+-T-+~+.+.!
j~
Fasteners A~LR --~,

Sohd
LENGTH A-A
Forward
Aft
Requirements
PermanentRepair No existingfastener
locations in shaded
area Inspection
Threshold
exceptforframelocations 60,000Landings
Zone1 and 2 111-<~t, -<127 Inspecbon
IntervalandMethod
0 025---tf< 0032 ExtVisual= 8,000Landmgs
5/32-<Fastener Diameter
-< 1/4
4D <- Average Spaang-< 6D
MmimumSpaong-> 3 5D
Minimum E.D.>--2D
FastenersthroughIongeronareinterferencefitpm
Proximity > 3 mches
TemporaryRepair Anyexisting fastener
locations in shaded
area Inspection
Threshold:
exceptforframe locations. 20,000
landings
Zone1 and 2 100 ~;t~ < 150 Inspection
IntervalandMethod
k ->0.032 external
LFEC= 6,000
5<0025 external
US = 6,000
Fastener Diameter
-> 5/32 Replacement/rework
Threshold
3 5D -< AverageSpacing-< 7D 40,000Landings
MaxtmumSpaong< 7 5D
MimmumE.D -> 1 5D
Fasteners through
Iongeronareinterferencefitpm
(Fsu->95ksl)
PageB. 14 McDonnell
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Information
- Use or Disclosure
of
Oct 2000 THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE.
MDC 91K0263
Thesecondarea(B)informs
theoperatorwhich zoneon theairplane
thisrepair
jointgeometry
canbea permanent
repair
or isa temporary
repair.Thecategory
oftherepair
jointis
determined
usingdatagathered
in Stage1 in themiddlecolumn
(C).Area(B)onlyinforms
operator
ofthepossible
categories
therepatrjointcouldbe.
DC-9/MD-80
Skin
Matl
2024-T3 Skin
Sktn
Repair
Marl
2024-T3
2014-T6
7075-T6
-N-
-- [~...Finger
, - ." ExtDblr ~ tdDblr
:+~. ~++++1++++++ I~
Fasteners ""A~: .....
Sohd
LENGTH I
h A A
i-
Forward
9 II
Aft
Quahficatlons Maintenance
Requtrements
Permanent
Repair No existing fastenerlocationsin shaded
area Inspection
Threshold
exceptforframe Iocat=ons 60,000Landmgs
Zone1 and 2 1 15-<tJts < 1 25 Inspecbon
IntervalandMethod
0 025-<tf-<0 032 ExtVtsual=8,000Landings
5/32-<Fastener Dtameter-<1/4
4D -< Average Spacing -< 6D
Minimum Spacing -> 3 5D
MaxCmumSpacing-< 6.5D
MinimumE D -> 2D
Fasteners through Iongeronareinterference
fitpm
(Fsu->95 ks0
Proxtmtty> 3 inches
Temporary
Repair Anyexisting fastenerlocationsin shaded
area Inspection
Threshold
exceptforframeIocabons 20,000
landings
Zone1 and 2 1 00< tJt, -<1 50 Inspection
IntervalandMethod
tf->0 032 external
LFEC= 6,000
tf-<0 025 external
US = 6,000
Fastener D=ameter -> 5/32 Replacement/rework
Threshold
3 5D <- Average Spacing-< 7D 40,000Landmgs
MaxtmumSpacing-< 7 5D
MinimumE D -> 1 5D
Fasteners through Iongeronareinterference
fitpm
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THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE October
2000
MDC 91K0263
Oncethedetermination
is madewhichcategory
is possible
theoperatorshouldcontinuewiththe
assessment
witharea(C).Thethird
area(C)listthequalifications
therepairjointbeing
assessed
mustsatisfy,inaddition
tothegeneralinformation
inarea(A).Ifmorethanone
category
ispossibletheoperator
should
startwiththequalifications
fora permanent
repair,if
possible,
thencontinue
downthesheetuntil
therepairsatisfies
thequalifications
in thesecond
column.
Note: interference
fitpinmusthaveminimum Fsu= 95ksistrength.
DC-9/MD-80
Skin
Matl A~
2024-T3 Skin-- t
Skin
"---~
L] ~ .... ts ~
7075-T6 ~r-~..
Finger
J ..._._-.--
ExtDblr~ Dblr
~.~-- t~
Fasteners
Solid
~ A-A
r
Forward
Aft
i Qualifications Maintenance
Requirements
area Inspection
Threshold
except forframeIocabons 60,000Landings
Zone1 and 2 1 11 -<~t~-<1 27 Inspection
Interval
andMethod
0 025-<tf-<0 032 ExtVisual
= 8,000
Land=rigs
5/32-< FastenerDiameter-< 1/4
4D -< Average Spaang-< 6D
Minimum Spacing -> 3 5D
MaximumSpacing-< 6 5D
MinimumE D -> 2D
FastenersthroughIongeronareinterference
fitp=n
Prox=m~y > 3 inches
area Inspection
Threshold
except forframelocations 20,000landings
Zone1 and 2 1 00-<td/t~<1 50 Inspection
IntervalandMethod
t~->0 032 external
LFEC= 6,000
t~-<0 025 external
US = 6,000
FastenerD,ameter >- 5/32 Replacement/rework
Threshold
40,000Landings
3 5D < AverageSpacing < 7D
MaxEmumSpa~ng< 7 5D
MinimumE D -> 1 5D
fitpm
Iftherepair
joint
doesnotsatisfy
thelasttemporary
repair
qualifications
thentheoperator
should
contact
Douglas
Aircraft
Company
or replace/rework
therepair.
Oncethecategory
of therepair
is determined
themaintenance
requirements
arealso
determined.
Themaintenance
requirements
arelocated
in thefourth
area(D).
PageB. 16 McDonnell
DouglasCorporation
propnetary
Information
- Use or D~sclosure
of
October2000 THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE.
MDC 91K0263
Thefourth
area(D)liststhemaintenance
requirements
forthatrepair
joint.Thesemaintenance
requirements
couldbe recorded
on theoptional
worksheet
/ summary
pagein column(5).
DC-9/MD-80
Skin
Matl A ~ Skm --
2024-T3
Skin ~ r ..<
Repair Mall
I
F,er _ : __
~ .1~ tf
2014-T6 ~ +---~-$-~~++-%"~-~-~-~
~/Dblr -- - --
7075-T6 -- -J --
:+ + + + + + + +" "+"+++ +"L~ qr--.......
Finger
Dblr
- "" "" ~ ~ Ext Dblr -------I=.
FastenerSSohd
~ A~-----[_R .._.~,
.~--
t~
LENGTH ~ A-A
I~
Forward
q
Aft
Quahficat=ons Maintenance
RequKrements
PermanentRepair No existing fastenerlocationsin shaded
area Inspection
Threshold
except forframeIocabons 60,000Landings
Zone1 and 2 1 11< tdt~-<1 27 Inspection
IntervalandMethod
0 025-<tf-<0 032 ExtVisual= 8,000Landings
5/32-< Fastener D=ameter<- 1/4
4D -< Average Spacing -< 6D
MimmumSpa~ng>- 3 5D
Max=mumSpaong-< 6 5D
MinimumE D > 2D
Fasteners throughIongeron areinterference
fitpm
Prox=mlty > 3 inches
area Inspection
Threshold
except forframeIocabons 20,000landings
Zone1 and 2 1 00 < tJt~-<1 50 Inspecbon
Interval and Method
tf->0032 externalLFEC= 6,000
tf-<0 025 external
US = 6,000
Replacement/rework
Threshold
Fastener Dzameter -> 5/32
40,000Landings
3 5D -< Average Spacing-< 7D
Max=mumSpacing-< 7 5D
MinimumE D >- 1 5D
Fasteners throughIongeron areinterference
fitpin
McDonnell
DouglasCorporabon
propnetary
Informabon
- Use or Disclosure
of PageB. 17
THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE. October
2000
MDC 91K0263
Intentionally
LeftBlank
PageB. 18 McDonnell
DouglasCorporabon
proprietary
Informabon
- Use or Disclosure
of
October2000 THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE
MDC 91 K0263
DC-9/MD-80
SkinMatl Skm
Skm
2014-T6
Repatr
Matl
2024-T3
2014-T6
7075-T6
Fasteners
Solid td
LENGTH ~
Forward ExtDblr A-A
Aft
Quahfications MamtenanceRequirements
Permanent
Repair Noexisting fastener locationsm shaded
areaexcept
for Inspecbon
Threshold:
frame locations. 20,000landings
Zone1 1.11_<t~/t
s _<1.27 Inspection
Interval andMethod
5/32< Fastener Diameter < 1/4 external
visual =
4D _< Average Spacing < 6D externalLFEC= 6,000
Minimum Spacmg>_ 3.5D externalUS = 6,000
Maximum Spacing _< 6.5D
Mmtmum E.D.>__2D
Proximity> 3 inches
Temporary
Repair Noexisting fastener locationsinshaded
areaexcept
for Inspection
Threshold:
frame Iocattons. 20,000landings
Zone2 1.11 _<~t~_< 1.27 Inspection
IntervalandMethod
5/32_<Fastener Diameter < 1/4 extemalvisual=
4D < Average Spacing _<6D extemal LFEC= 6,000
MimmumSpacing> 3.5D externalUS= 6,000
MaximumSpacmg_< 6.5D internal
visual=
Minimum E.D_> 2D internalHFEC= 6,000
Proximity > 3 inches Replacement/rework
Threshold
40,000Landings
Temporary
Repair 1.00
_<tJt~_<1.50 Inspection
Threshold:
Fastener
Diameter
_>5/32 5,000landings
Zone1 and2 3.5D< AverageSpacing
< 7D Inspection
Interval andMethod
MaximumSpacmg< 7.5D external LFEC= 3,000
MinimumE.D.>_1.5D externalUS = 3,000
Replacement/reworkThreshold
10,000Landings
McDonnell
Douglas
Corporabon
propnetary
Informahon
- UseorD~sclosure
of Page B. 19
THESEDATASUBJECTTO RESTRICTIVE
LEGENDON TITLEPAGE Oct 2000
rap1
MDC 91K0263
DC-9/MD-80
SkinMatl Finger Skin
Skin Finger
2014-T6 Dblr
t Dblr
Repair
Matl
2024-T3
2014-T6 ,i _-, _-, _ _ - _ - _--- :
7075-T6 # ..... =1
:++++++++++++++:
:++++++++++++++:
h ..........................
Fasteners
Solid .j ........~
.,~._.
td
,4- LENGTH D,
Forward ExtDblr A-A
Aft
Requirements
PermanentRepair Noexist fastener locationsinshadedareaexcept
for Inspection
Threshold
Zone1 and2 frame locations 60,000Landings
1.11< t~/4< 1.27 Inspection
IntervalandMethod
0.025_<tf_<0.032 ExtVisual= 8,000Landings
5/32_<Fastener Diameter< 1/4
4D < Average Spacing < 6D
Average E.D.= 2D+ 1/16inches
Minimum E.D.>_2D
Fastener rowthrough theIongeronisinterference
fitpin
(Fsu_>95ksi)
Proximity > 20inches
PermanentRepair Noexist fastenerIocabonsin shadedareaexcept
for Inspection
Threshold
Zone1 and 2 frame locations. 10,000Landmgs
1.11_<~ts< 1.27 Inspection
Interval
andMethod
0.025 < t~< 0.032 ExtVisual
= 4,000Landings
Mmimum E.D.>__2D
Fastener rowthrough theIongerontsinterference
fitpm
(Fsu_>95ksi)
3 < Proximity < 20inches
Temporary
Repair 1.00<_td/t s-<1.50 Inspection
Threshold:
Fastener Diameter> 5/32 20,000landings
Zone1 and 2 3.5D_<Average Spacing _<7D Inspection
IntervalandMethod
Maximum Spacing _< 7.5D externalLFEC= 6,000
Minimum E.D.>_ 1.5D external
US = 6,000
Replacement/rework
Threshold
Fastener rowthroughtheIongeronisinterference
fitpin
(Fsu>_.95ksi) 40,000Landings
Page B.20 McDonnell

Douglas
Corporabon
propnetary
Informabon
- UseorD~sclosure
of
Oct 2000 THESEDATASUBJECTTO RESTRICTIVE
LEGENDON TITLEPAGE.
rap1
MDC 91K0263
Sk,n
Skin Finger
Finger
Dblr Dblr
1
-3-,
+-T-,
,.:,
~g,V,-T-,
,g--~ -- -
f I ",+++
Longeron-/ +++ + + + + + + +," ~
i+++++++++++++i
( ....
I ,++++++++++++++" ~ -- " --
:::::::::::::::::::::::::::::
f
_.,,
.._
t,
LENGTH ~ ~ A-A
Forward ExtDblr
Aft
Quahficabons Maintenance
Requirements
Permanent
Repair 1.11<_tJt~_ 1.27 Inspection
Threshold
0.025_<tf< 0.032 60,000Landings
Zone1 and 2 5/32< Fastener Diameter
_<1/4 Inspection
Interval
andMethod
4D _<Average Spacing < 6D ExtVisual= 8,000Landings
AverageE.D.= 2D+ 1/16inches
M,mmumE.D.> 2D
Proximity> 20inches
Permanent
Repa=r 1.11_<~t~< 1.27 Inspection
Threshold
0.025_<t~< 0.032 10,000Landings
Zone1 and2 5/32_<Fastener Diameter_<1/4 Inspection
IntervalandMethod
4D_< Average Spacing< 6D ExtVisual= 4,000Landings
AverageE.D.= 2D+ 1/16inches
MinimumE.D.>_.2D
3 < Proximity< 20inches
Temporary
Repair 1.00_<tJt~_<1.50 Inspection
Threshold:
Zone1 and2 3.5D< Average Spacing < 7D Inspection
IntervalandMethod
Minimum E.D.> 1.5D external
US = 6,000
Replacement/rework
Threshold
40,000Landings
McDonnell
Douglas
Corporation
propnetary
Informabon
- UseorD=sclosure
of Page B.21
rap1
MDC 91 K0263
DC-9/MD-80
Skin Finger
2014-T6 Dblr
Dblr
Repair
Matl ts ~
2024-T3
I.
2014-T6
7075-T6 "- ...... : ........
~", _
+..
Fasteners
Solid
R
L- LENGTH
Forward
/
ExtDblr A-A
Aft
Requirements
PermanentRepair Noexist fastener locationsinshadedareaexcept
for Inspection
Threshold
Zone1 and2 framelocations. 60,000Landings
1.11_<~ts_< 1.27 Inspection
Interval
andMethod
5/32_<Fastener Diameter_<1/4
4D _<Average Spacing _< 6D
Average E.D.= 2D_ 1/16inches
Minimum E.D._> 2D
Fastenerrowthrough theIongeron isinterference
fitpin
(Fsu_>95ksi)
Proximity > 20 mches
PermanentRepair Noexistfastener locations m shaded
areaexcept
for Inspection
Threshold
Zone1 and2 frame locations. 10,000Landings
1.11_<~t~_< 1.27 Inspection
IntervalandMethod
4D_< Average Spacing _< 6D
Average E.D.= 2D +_1/16inches
Minimum E.D.>_ 2D
Fastener rowthrough theIongeron isinterference
fitpin
(Fsu_>95ksi)
Tempora~Repair 1.00< t~ < 1.50 Inspection
Threshold:
Fastener Diameter >_5/32 20,000landings
Zone1 and2 3.5D_< Average Spacing < 7D Inspection
IntervalandMethod
MaximumSpacing< 7.5D externalLFEC= 6,000
Minimum E.D.> 1.5D external
US = 6,000
fitpin Replacement/rework
Threshold
(Fsu> 95ksi) 40,000Landings
Page B.22 McDonnell

Douglas
Corporabon
proprietary
Informabon
- UseorDisclosure
of
Oct 200O THESEDATASUBJECTTO RESTRICTIVE
LEGENDON TITLEPAGE.
rap1
MDC 91K0263
DC-9/MD-80
Skin Finger
2014-T6 Dblr
l " Dblr
RepairMatl / ts -
2024-T3 .+,.~,:-T-,
". -- -
~
2014-T6 .... .~~
,-L,~4..+_.p,,
F ~+.~.+.~.
+,.p
+~..
~_. !
Longeron "j ++++++++++++++ r- I -- --
I~.+.++++.+.+..+.+..+..+.+.+.+~_~;-.~_ tf
Fasteners .~~ -
Solid p~.
---ID-, ~ td
i~_~
A.~-..- i LR ..~"
- 91---- LENGTH D.
Forward Ext Dblr A-A
d
Aft
Quahficattons MaintenanceRequtrements
PermanentRepatr 1 11_<tJt,_.<_
1.27 InspecttonThreshold
0.025< tf < 0.032 60,000Landings
Zone 1 and 2 5/32_< Fastener Diameter< 1/4 InspectionInterval
andMethod
4D < AverageSpacing< 6D Ext Visual= 8,000Landmgs
Average E.D. = 2D + 1/16inches
MinimumE.D._> 2D
Proximity > 20 inches
PermanentRepair 1.11 <~ts<_1.27 InspectionThreshold
0.025< tf< 0 032 10,000Landings
Zone 1 and 2 5/32_< Fastener Dtameter< 1/4 InspectionInterval
andMethod
4D < AverageSpacing_< 6D Ext Visual= 4,000Landings
AverageE.D.= 2D + 1/16inches
Mmtmum E.D. > 2D
3 < Proximity< 20 inches
TemporaryRepair 1.00_<tJt~< 1 50 Inspection
Threshold:
Fastener Dtameter_> 5/32 20,000 landmgs
Zone 1 and 2 3 5D < AverageSpacing_< 7D Inspection
Interval andMethod
Max,mumSpacing_< 7.5D externalLFEC= 6,000
MinimumE.D.>_ 1.5D externalUS = 6,000
Replacement/rework Threshold
40,000Landings
McDonnell
Douglas
Corporahon
propnetary
Informat=on
- UseorD=sclosure
of Page B.23
THESE DATA SUBJECTTO RESTRICTIVELEGEND ON TITLE PAGE Oct2000
rap1
MDC 91K0263
DC-9/MD-80 Finger Skin

SkinMatl Skin Dblr Finger
2014-T6
~~@~~A~/ Frame
Repair
Matl _ ~ ts
~
Dblr
2014-T6
7075-T6 ~ ~ t,
4- D
:++++++++._
i
;+.
.+.
.+.
.+.+..+.
.+.
.+.
i :+++++++~i+++++++:=
i i
:l.+..+..+..+.+..+..+..+..+..+.+..+..+..+.:
I........1. ....... .......=.... b
-
Fasteners J
Solid
R_J
~
LENGTH
Forward ExtDblr A-A
Aft
Requirements
PermanentRepair Noexist fastener locationsinshaded areaexcept
for Inspection
Threshold
Zone1 and2 frameIocahons. 60,000Landings
1.11_<tJt~ < 1.27 Inspection
IntervalandMethod
0.025< tf< 0.032 ExtVisual= 8,000Landings
5/32_<Fastener Diameter < 1/4
4D _< Average Spacing < 6D
Average E.D.= 2D + 1/16inches
MinimumE.D.> 2D
fitpin
(Fsu> 95ksi)
PermanentRepair Noexist fastener locations inshadedareaexcept
for Inspection
Threshold
1.11< tJts< 1.27 Inspection
Interval
andMethod
0.025< tf_<0.032 ExtVisual= 4,000Landings
5/32< Fastener Diameter _< 1/4
4D < Average Spacing _< 6D
Average E.D.= 2D_+ 1/16inches
MinimumE.D.> 2D
fitpin
(Fsu_>95ksi)
Temporary
Repair 1.00< tJts< 1.50 Inspection
Threshold:
Fastener Diameter_> 5/32 20,000landings
Zone1 and2 3.5D_<Average Spacing _<7D Inspection
IntervalandMethod
MinimumE.D._> 1.5D external
US = 6,000
Replacement/rework
Threshold
fitpm
40,000Landings
(Fsu_>95ksi)
Page B.24 McDonnell

Douglas
Corporation
propnetary
Information
- UseorDisclosure
of
LEGENDON TITLEPAGE.
rap1
MDC 91K0263
DC-9/MD-80 Skin
SkinMatl Skin Finger
2014-T6 Finger Dblr
Frame Dblr /- Longeron
\
~ ~ ~ A~~ r
Repair
Matl
0,4-TO !
C:. "--
7075-T6 ~ -:++++++++:,ri _, :++++++++++++++:
:++++++++,, I :++++++++++++++i (
:++++++++: ; :++++++++++++++: ..~ \
t...... ..... ....i I ,........................,,
FastenersSolid
r
- RJ ~--"~x
.~_~
LENGTH A-A
Forward ExtDblr
4
Aft
RequIrements
Permanent
RepaIr 1.11_<tJt~_< 1.27 Inspectton
Threshold
0 025_<tf< 0.032 60,000Landings
Zone1 and2 5/32_<Fastener Diameter< 1/4 Inspection
Interval
andMethod
4D <_ Average Spacing < 6D ExtVisual= 8,000Landings
Average E.D= 2D + 1/16inches
Minimum E.D.>_ 2D
Permanent
Repair 1.11<_tJts < 1.27 Inspection
Threshold
0.025< tf< 0 032 10,000Landings
Zone1 and2 5/32< Fastener Diameter < 1/4 Inspecbon
IntervalandMethod
4D < Average Spacing _< 6D ExtV~sual= 4,000Landings
MmtmumE.D.> 2D
Temporary
Repatr 1.00< tJt~< 1 50 Inspecbon
Threshold.
Fastener Dtameter _> 5/32 20,000
landings
Zone1 and2 3.5D< Average Spacing _< 7D Inspecbon
Interval andMethod
MaxtmumSpacing< 7.5D external
LFEC= 6,000
Minimum E.D._> 1.5D external
US = 6,000
ReplacementJrework
Threshold
40,000Landings
McDonnell
Douglas
Corporabon
propnetary
Information
- UseorD~sclosure
of Page B.25
rap1
MDC 91K0263
DC-9/MD-80
SkinMatl Skin Finger Skin
Dblr Finger
2014-T6 Frame
,.
Repair
Matl ts _~.~r
2024-T3
p ,
2014-T6 " -........"
- " ,i . :-
_" -".....
,-~r , :!
...... . ~
7075-T6 ~ __~ .......~" .
+++1-++++ ~++++++ "1"
"1"++"1"
++
+++
i!++++
..L. . m
Fasteners I b-lo
Solid
R
L
r" LENGTH
Forward ExtDblr A-A
Aft
Qualifications Manntenance
Requnrements
PermanentRepair Noexist fastener locations
=nshaded
areaexcept
for Inspection
Threshold
Zone1 and 2 frameIocatnons. 60,000Landings
1.11< tJt,_<1.27 Inspection
IntervalandMethod
0.025_<tf< 0.032 ExtVisual= 8,000Landings
5/32< Fastener Diameter< 1/4
4D < Average Spacing< 6D
MaxnmumSpacing< 6.5D
MinimumE.D.> 2D
Fastenerrowthrough theIongeron
isinterference
fitpin
(Fsu> 95ksi)
Proximity> 20inches
PermanentRepair Noexist fastener locations
inshaded
areaexcept
for Inspection
Threshold
1.11<~ts_< 1.27 Inspectnon
Interval
andMethod
0.025< t~<_0.032 ExtVisual= 4,000Landings
5/32_<Fastener Diameter
< 1/4
MaxnmumSpac0ng< 6.5D
Minimum E.D._> 2D
is0nterference
fitpin
(Fsu> 95ksi)
3 < Proximity< 20inches
Temporary
Repair 1.00_<t~/t,< 1.50 Inspectnon
Threshold"
Fastener Diameter > 5/32 20,000
landings
Zone1 and2 3.5D_< Average Spacing< 7D Inspecbon
Interval
andMethod
MaximumSpacing< 7.5D extemalLFEC= 6,000
US= 6,000
isinterference
fitpin Replacement/rework
Threshold
Page B.26 McDonnell

Douglas
Corporat0on
propnetary
Informaluon
- UseorDnsclosure
of
LEGENDON TITLEPAGE.
rap1
MDC 91K0263
DC-9/MD-80 Skin
2014-T6 Finger
Dblr
Frame Dblr /--Longeron
\
RepairMatl r _ ts
2024-T3
;-T-,"~,;-T-,
"~-,
. -T-,
"4:,
", -~
2014-T6 -t- -~
$ ~ ++++++++
-+-~+-+--H-.-
t-:-~-
+-F+ ++-++-++-++q:,/
+++++++++++++ .-~~)-
-- --
7075-T6
++++++++:l i+++++++++++++ !(
r,~_ ++++++++: :+++++++++++++ -;,:, \
, .......................................... :-:LL~/
Fasteners ~-"" R~R~ ~
Solid - - f td
A..I---
LENGTH _-- A-A
~ V
Forward Dblr
Aft
Quahfications MaintenanceRequtrements
PermanentRepair 1.11_<tJt~< 1 27 Inspection
Threshold
0 025<_tf_<0.032 60,000Landings
Zone 1 and 2 5/32_<Fastener Diameter_<1/4 Inspection
Interval
andMethod
4D _< AverageSpacing< 6D ExtVisual= 8,000Landings
MaximumSpacing_< 6.5D
MinimumE.D > 2D
Proximity> 20 inches
PermanentRepair 1.11_<tJt~_<1.27 Inspection
Threshold
0.025_<tf_<0.032 10,000Land,rigs
Zone 1 and 2 5/32_< Fastener Diameter< 1/4 Inspection
IntervalandMethod
4D < AverageSpacing_< 6D ExtVisual= 4,000Landings
AverageE.D = 2D + 1/16 inches
MinimumE.D._> 2D
TemporaryRepair 1 00< tJt,_<1.50 Inspecbon
Threshold:
FastenerDiameter _> 5/32 20,000landings
Zone 1 and 2 3.5D < AverageSpacing< 7D Inspecbon
Intervaland Method
MaximumSpacing_< 7.5D externalLFEC= 6,000
MinimumE.D._> 1 5D external
US = 6,000
Replacement/rework
Threshold
40,000Landings
McDonnell
Douglas
Corporahon
propnetary
Information
- UseorD~sclosureof Page B27
rap1
MDC 91 K0263
DC-9/MD-80 Skin
SkinMatl Skin
Repair
Matl "ce
L ~ ~ ts ~
2024-T3
2014-T6
7075-T6 ~ _ ". --
~ ~: ++i++: ...........
++++++++++,.++:+++++1"+++++ "~ .....
+ + +++ + ++ ++:+
~ +: :+++ ++++ +++ + ) .....
Fasteners ;~ " ,- ----.
..,,~.
i
Solid ~~
R]
J-- LENGTH ~, ..--.
Forward ExtDblr A-A
Aft
Requirements
Permanent
Repair No existing fastener locations
m shadedareaexceptfor Inspection
Threshold:
framelocations. 20,000landings
Zone1 1.11<~t~<1.27 Inspect,on
IntervalandMethod
5/32< Fastener Diameter < 1/4 external
visual=
4D < Average Spacing < 6D extemal
LFEC= 6,000
Minimum Spacing _> 3.5D extemal
US = 6,000
Maximum Spacing _< 6.5D internal
HFEC= 6,000
Minimum E.D._> 2D
Fastener rowthrough theIongeronandproduction
splicefastener locationsareinterference
fitpin(Fsu>
95ksi)
Temporary
Repair Noexisting fastenerlocationsin shaded
areaexceptfor Inspection
Threshold:
frameIocat=ons 20,000landings
Zone2 1.11_<~ts-<1.27 Inspection
Interval andMethod
5132<_Fastener D=ameter_<1/4 external
v=sual =
4D__.Average Spacing _<6D extemalLFEC= 6,000
Minimum Spacing _> 3.5D externalUS = 6,000
visual =
internalHFEC=6,000
Minimum E.D._> 2D
Fastener rowthrough theIongeron andproduction
40,000Landings
splicefastenerlocationsareinterference
fitpin(Fsu_>
95ksi)
Temporary
Repair 1.00< ~t,__<1.50 Inspection
Threshold:
Fastener Diameter >_5/32 5,000
landings
Zone1 and2 3.5D_< Average Spacing _<7D Inspection
IntervalandMethod
MaximumSpacing< 7.5D external
LFEC= 3,000
US = 3,000
Fastener rowthrough theIongeron andproduction Replacement/rework
Threshold
10,000Landings
fitpm(Fsu>
95ksi)
Page B.28 McDonnell

Douglas
Corporation
propnetary
Information
- UseorD,sclosure
of
LEGENDON TITLEPAGE.
rap1
MDC 91K0263
DC-9/MD-80
Skin Splice Finger
2014-T6 Dblr
Repair
Matl
2024-T3 : "
2014-T6
7075-T6 , ; !! i
., , , , , ...... ~ ~ . . .:. . . ~ ; ,
,++++++++::++:++ ++ +++++++:
:++++++++. ++:++ m ++ +++++++:
...
--:;-
Fasteners
Solid
LENGTH
Forward ExtDblr A-A
w
Aft
Qualifications MaintenanceRequirements
PermanentRepair No extstfastener locations m shadedareaexceptfor Inspection
Threshold
Zone 1 and 2 frameIocat=ons. 60,000Landings
1.11< tJt
s _<1.27 Inspection
IntervalandMethod
5/32< Fastener Diameter < 1/4
4D < AverageSpacing< 6D
MinimumE.D. _> 2D
Fastener row throughtheIongeron and production
splicefastenerlocations areinterference
fitpin(Fsu>_
95ksi)
PermanentRepair No existfastener locations in shaded
areaexceptfor InspectionThreshold
Zone 1 and 2 framelocations. 10,000Landings
1.11_<~ts_< 1.27 InspectionIntervalandMethod
0,025_<tf_<0.032 Ext Visual= 4,000Landings
5/32_< Fastener D~ameter <_ 1/4
4D _< AverageSpacing _< 6D
Max=mumSpacing_< 6.5D
MinimumE.D. >_ 2D
Fastener row through the Iongeron and production
splicefastener locationsareinterferencefitpin(Fsu>_
95 ksi)
3 < Proximity < 20 inches
TemporaryRepair 1.00
_<tJt~ _<1.50 Inspection
Threshold.
FastenerDiameter > 5/32 20,000landings
Zone 1 and 2 3.5D< AverageSpacing_< 7D Inspection
IntervalandMethod
MaximumSpacing_< 7.5D externalLFEC = 6,000
MinimumE.D.>_ 1.5D external
US = 6,000
Fastenerrowthroughthe Iongeron and production Replacement/reworkThreshold
splicefastenerlocations areinterferencefitpin(Fsu> 40,000Landings
95ksi)
McDonnell
Douglas
Corporabon
proprietary
Informat=on
- UseorDisclosure
of Page B.29
THESE DATA SUBJECTTO RESTRICTIVELEGEND ON TITLE PAGE. Oct 2000
rap1
MDC 91K0263
DC-9/MD-80
Skin Splice Finger
2014-T6 Dblr
Repair
Matl
2024-T3
2014-T6
7075-T6
Fasteners
Solid
R
LENGTH
\ =i ~
Forward ExtDblr A-A
Aft
Requirements
PermanentRepair No exist fastenerlocations inshaded
Threshold
1.11_<tJts < 1.27 Inspection
IntervalandMethod
MaximumSpacing _< 6.5D
Minimum E.D.> 2D
fitpin(Fsu>
95ksi)
PermanentRepair Noexist fastenerlocations inshaded
Threshold
1.11_<tJts_< 1.27 Inspection
Interval
andMethod
0.025<_t~_<0.032 ExtVisual
= 4,000Landings
5/32_<Fastener Diameter _<1/4
4D _< Average Spacing _< 6D
Minimum E.Do>_ 2D
fitpin(Fsu>_
95ksi)
Temporary
Repair 1.00< tJts< 1.50 Inspection
Threshold:
Fastener Diameter _> 5/32 20,000landings
Zone1 and2 3.5D< Average Spacing _< 7D Inspection
Interval andMethod
Minimum E.D.> 1.5D externalUS = 6,000
Fastener rowthrough theIongeronandproduction Replacement/rework
Threshold
fitpin(Fsu_> 40,000Landings
95ksi)
Page B.30 McDonnell

Douglas
Corporation
proprietary
information
- UseorDisclosure
of
LEGENDON TITLEPAGE
rap1
MDC 91K0263
Skin
SkinSplice._
i
t
: !
.
i , , , ,
:++++++++++++++++++
, ,
/
, ...........
ts -.-~ ~
: ++ +++ + ++++ ++.+.T +++ + \

J
~ .,9-- ta
A..9----[~R
LENGTH ~
Forward ExtDblr A-A
Aft
Quahficat~ons MaintenanceRequirements
Permanent
Repair Noexisting fastener locations
m shaded
Threshold"
framelocations 20,000landings
Zone1 1 11_<tits_<1 27 Inspecbon
Interval andMethod
5/32_ Fastener Diameter < 1/4 extemalvisual=
4D _< Average Spacing < 6D external LFEC= 6,000
Minimum Spacing _> 3.5D external US= 6,000
Maximum Spacing< 6.5D internal HFEC=6,000
Minimum E.D.> 2D
Proximity> 3 inches
Fastener rowthrough theIongeron
andproduction
sphcefastenerlocationsareinterference
fitpin(Fsu_>
95ksl)
Temporary
Repair Noexistingfastenerlocations
inshaded
Threshold:
frame
locations. 20,000landings
Zone2 1.11
_<tit,< 1.27 Inspection
Interval andMethod
5/32< FastenerDaameter< 1/4 extemalvisual=
4D_<Average Spacing_<6D externalLFEC= 6,000
MinimumSpacing _> 3.5D externalUS = 6,000
MaximumSpacing< 6.5D internalHFEC= 6,000
MmtmumE.D.>_ 2D Replacement/reworkThreshold
andproduction 40,000Landings
sphce
fastenerlocations
areinterference
fitpin(Fsu_>
95ksi)
Proximity
> 3 inches
Temporary
Repair 1.00
< tJt~< 1.50 Inspection
Threshold
Fastener
Diameter _>5/32 5,000landings
Zone1 and2 3.5D< Average Spacing< 7D Inspection
IntervalandMethod
MaximumSpacing _< 7.5D externalLFEC= 3,000
MimmumE.D._> 1.5D extemalUS = 3,000
andproduction Replacement/rework
Threshold
sphce
fastenerlocations
areinterference
95ksi)
McDonnell
Douglas
Corporabon
propnetary
Informatton-
UseorD=sclosure
of Page B.31
rap1
MDC 91K0263
DC-9/MD-80
SkinMatl Skin Skin Finger
2014-T6
Repair
Matl
2024-T3
2014-T6
7075-T6
FasteneB
Solid
ExtDblr A-A
Requirements
PermanentRepair No exist fastener Iocabons in shaded
Threshold
1.11_<tJt, ___1.27 Inspection
IntervalandMethod
4D <_ Average Spacing < 6D
Minimum E.D.> 2D
splice fastener Iocabons areinterferencefitpin(Fsu>
95ksi)
for Inspection
Threshold
1.11_<~ts_< 1.27 Inspection
IntervalandMethod
4D_<Average Spacing _<6D
Average E.D.= 2D :1:1/16 inches
Minimum E.D._> 2D
splice fastener locations areinterference
fitpin(Fsu>_
95ksi)
Temporary
Repair 1.00_<tJt, _<1.50 Inspection
Threshold:
Zone1 and 2 3.5D_<Average Spacing _<7D Inspection
IntervalandMethod
US = 6,000
Fastener rowthrough theIongeron andproduction ReplacementJrework
Threshold
fitpin(Fsu>_ 40,000Landings
95ksi)
Page B.32 McDonnell

Douglas
Corporation
propnetary
Information
- UseorDisclosure
of
LEGENDON TITLEPAGE.
rap1
MDC 91K0263
O4TO
DC-9/MD-80
Dblr
Skm
Finger
2024-T3 I
2014-T6 -----t
~tf - -,ql
7075-T6
. ::++++++++++,+++++++
i ::++ ++++++++~i+++++++
~,(
~ ~~~ ~~.--- -" -------
-----"-~."
".: ~~
Fasteners 1 i ..... "
: ., t
Sohd
~ td
k,
LENGTH fl
Forward ExtDblr A-A
4
Aft
Requirements
PermanentRepatr Noexist fastener locationsinshaded
areaexceptfor Inspectnon
Threshold
Zone1 and2 framelocations 60,000Landings
1 11< ~ts_< 1.27 Inspection
IntervalandMethod
5/32_<Fastener Dtameter_<1/4
4D _<Average Spacmg _<6D
MaximumSpacmg< 6.5D
MmtmumE.D >_ 2D
andproductuon
sphcefastener Iocattons
areinterference
fitpm(Fsu_>
95ksi)
Proximity > 20 mches
PermanentRepatr Noextst fastener locationsinshaded
areaexceptfor Inspectnon
Threshold
1.11<_tJt, < 1.27 Inspection
Interval
andMethod
0.025< t~< 0.032 ExtVtsual= 4,000Landings
5/32< Fastener Dtameter_<1/4
4D < Average Spacmg< 6D
Average E.D.= 2D + 1/16mches
Mimmum E.D.>__2D
andproduction
splicefastenerlocationsareinterference
fitpin(Fsu_>
95ksi)
3 < Proximity < 20mches
Temporary
Repanr 1 00< tJt~_<1.50 Inspection
Threshold:
Fastener Diameter _>5/32 20,000landings
Zone1 and2 3.5D_<Average Spacing
___7D Inspection
IntervalandMethod
Maxtmum Spacing _< 7.5D externalLFEC= 6,000
Minimum E.D_> 1 5D external
US = 6,000
andproductton Replacement/rework
Threshold
splicefastener locations
areinterference
fitpm(Fsu_> 40,000Landings
95kst)
McDonnell
Douglas
Corporabon
propnetary
Informabon
- UseorDtsclosure
of Page B.33
LEGENDON TITLEPAGE. Oct 2000
rap1
MDC 91K0263
DC-9/MD-80 Skin A-.~-- Finger Skin

Skin201Matl
4-T6 Finger
Dblr
Repair
Matl
2024-T3 ~ ~Dbl~ -
2014-T6 :+ ++ +++ 4 +++ +++ +:
7075-T6 ~.+..+.
t.t.~
+..+.
~.
~.t.~
.+.! ZiZ
+
- -" - - ~- - ",,-...........
i,r .....
__.1~
l..=
_,,td
FastenersSolid
~"---~ ~ ~
ExtDblr
A~
LENGTH
Forward A-A
Aft
PermanentRepair Noexist fastener locations inshaded
Threshold
1.11_<tJ4< 1.27 Inspection
Interval
andMethod
4D _< Average Spacing< 6D
MinimumE.D.> 2D
Fastener rowthrough theIongeron andproductton
splicefastenerlocations
areinterference
fitpin(Fsu>__
95ksi)
PermanentRepair Noexist fastenerIocattons inshaded
Threshold
Zone1 and2 flame locations. 10,000Landings
1.11<_~ts_< 1.27 Inspection
Interval
andMethod
5/32_<Fastener Diameter<_1/4
4D_< Average Spacing _<6D
Minimum E.D._> 2D
splicefastener Iocat=ons
areinterference
fitpin(Fsu_>
95ksi)
Temporary
Repair 1.00-<t~/t~ < 1.50 Inspection
Threshold:
Zone1 and2 3.5D_<Average Spacing _<7D Inspection
IntervalandMethod
MimmumE.D._> 1.5D external
US = 6,000
Fastener rowthrough theIongeronandproduction Replacement/rework
Threshold
splice fastenerIocattons
areinterference
95ksi)
Page B.34 McDonnell

Douglas
Corporation
propnetary
InformatJon
- UseorD~sclosure
of
LEGENDON TITLEPAGE.
rap1
MDC 91 K0263
DC-9/MD-80 Skin Skin

SkinMatl "~k Finger
2014-T6 A-~DblrFinger Dblr
-
ts
i jl~ T
1 .I
Repair
Matl -- -- tf
2024-T3 I
,++_L - - .
2014-T6 ,+ ++ ++ + 4 +++++++,
7075-T6 ~t.
t.+.
.+.
.+.
t.-t
.+..+..+.~-.t.f..+.!
+~++"d" J
~ +~-:~-i-~:
+
+ + +::++++ + +p-+:.,:+
+ + h/ d
Fasteners
Solid
ExtDblr
Forward A-A
Aft
Requtrements
PermanentRepair Noextst fastener Iocattons m shaded
areaexceptfor Inspectton
Threshold
1 11_<tJts < 127 Inspectton
IntervalandMethod
0.025_<tf_ 0.032 ExtV~sual= 8,000Landings
Average E.D.= 2D_+1/16inches
MinimumE.D.z 2D
areinterference
fitpm(Fsu>_
95ksi)
Proximtty> 20 inches
PermanentRepair No exist fastener locationsm shaded
Threshold
1 11_<tJts <_1.27 Inspection
Interval
andMethod
0.025< tf___0.032 ExtVtsual=
4,000Landings
5/32< Fastener Diameter_<1/4
Minimum E.D >_ 2D
splice fastener locations
areinterference
fitpin(Fsu>
95ksi)
Temporary
Repair 1.00< tJt s < 1.50 Inspection
Threshold
Zone1 and2 3.5D_<Average Spacing _<7D Inspectton
IntervalandMethod
MmtmumE.D._> 1.5D external
US = 6,000
Fastener rowthrough theIongeron andproduction Replacement/rework
Threshold
areinterference
95ksi)
McDonnell
Douglas
Corporatton
propnetary
Information
- UseorD=sclosure
of Page B.35
rap1
MDC 91K0263
Intentionally
LeftBlank
Page B.36 McDonnell

DouglasCorporation
propnetary
Information
- Use or D=sclosure
of
Oct2000 THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE
rap1
MDC 91K0263
DC-9/MD-80
SkinMatl Skin
Skin
Repatr
Matl ts .~
2024-T3
2014-T6
7075-T6
I - ----
Fasteners
Solid
. i.....
..... .,/
i LENGTH =..~ ~ ~. tdl

Forward ExtDblr A-A
Aft
Qualifications MamtenanceRequirements
Permanent
Repair Noextstmgfastener locations
in shaded
areaexcept
for Inspection
Threshold:
Zone1 1.11
_<~ts<-1.27 Inspection
Interval andMethod
5/32_<FastenerDiameter_<1/4 external
visual=
4D_< Average Spacing < 6D externalLFEC= 15,000
MinimumSpacing >_ 3.5D externalUS = 15,000
MaximumSpacmg_< 6.5D
MinimumE.D._> 2D
Proximity
> 3 inches
Temporary
Repair Noexistingfastener locations
m shaded
areaexcept
for Inspection
Threshold:
Zone2 1.11_<tJt,< 1.27 Inspection
Interval andMethod
5/32_<Fastener Diameter_<1/4 external
visual =
4D_< Average Spacing<_ 6D extemalLFEC= 15,000
MinimumSpacing _> 3.5D externalUS = 15,000
MaximumSpacing _< 6.5D intemal
visual =
MinimumE.D.>_ 2D internalHFEC= 15,000
Proximity
3 inches
40,000Landings
Temporary
Repair 1.00_ ~t~_ 1.50 Inspection
Threshold:
FastenerDiameter
_> 5/32 5,000landings
Zone1 and2 3.5D_< Average
Spacing_<7D Inspection
Interval andMethod
Maximum Spacing_< 7.5D externalLFEC= 3,000
MinimumE.D._> 1.5D externalUS= 3,000
10,000Landings
McDonnell
Douglas
Corporation
proprietary
Informatton-
UseorD=sclosure
of Page B.37
rap
I
MDC 91K0263
DC-9/MD-80
SkinMatl
A ~ Skin
2024-T3
Skin ~ ,_(--*~~--~
~---,~ ts ~
o~,~,~,~va,r
Marl ---=. tf
, Fmger .....
2024-T3 r ..... : : : : : : : : :-
2014-T6 :+ +++++++++++++:.~,L-1~Dblr ....
7075-T6 :++++++++++++++."1 -- -- --
........................... ~ ~.~..Fmger
" Dblr
, ..-" ~f,......
,----", ExtDblr
Fasteners I A-.~ .__~.,..~_

t~
Solid
J~ LENGTH ~ A-A
Forward
Aft
Qualiflcahons MaintenanceRequirements
PermanentRepair No exlstmg fastener locationsin shadedareaexceptfor InspectionThreshold
framelocations. 60,000Landings
Zone 1 and 2 1.11< tJts-<1.27 InspectionInterval
and Method
0.025< tf < 0.032 Ext Visual= 8,000Landmgs
5/32< Fastener Diameter_< 1/4
4D _< AverageSpacmg_< 6D
MaximumSpacing<_ 6.5D
MinimumE.D. > 2D
Fastenerrowthrough theIongeron is interference
fitpin
(Fsu_>95ksi)
Proximity 20 inches
PermanentRepair No existing fastener locationsm shadedareaexceptfor Inspection
Threshold
Zone 1 and 2 1.11-<~ts-< 1.27 Inspection
Interval
andMethod
5/32_< Fastener Diameter _< 1/4
MinimumE.D. _> 2D
fitpin
(Fsu_>95ksi)
TemporaryRepair Anyexisting fastener Iocattonsin shadedareaexcept Inspection
Threshold:
forframelocations. 20,000landings
Zone 1 and 2 1.00_<tJts _<1.50 Inspection
Interval andMethod
tf_>0.032 extemalLFEC = 6,000
t~< 0.025 externalUS = 6,000
Fastener Diameter >_ 5/32 Replacement/rework Threshold
3.5D<_ AverageSpacing< 7D 40,000Landings
MaximumSpacing<_ 7.5D
MinimumE.Do>_ 1.5D
Fastenerrowthrough theIongeronis interference
fitpin
(Fsu>__95ksi)
PageB.38 McDonnell
Douglas
Corporal]on
propnetary
Information
- UseorDisclosure
of
Oct 2000 THESE DATA SUBJECTTO RESTRICTIVELEGEND ON TITLE PAGE
rap1
MDC 91 K0263
DC-9/MD-80
Skin
2024-T3 Finger
Dblr Dblr
t
Repair
Matl 1
A-q~-- / ts ----~
2024-T3 ,f
. ~ ~ .~ ~ /
2014-T6 ~ -T-,
"-T-,
:~-,
,-,
:-I-,]"+,
"+i~ -- "
7075-T6
__.
_~._i.+_~.+..1:
":+++++++..i.-+
,t.-+
++++ .p-+
+++ +.+~ :~~.--
+."
Longeron
:++++++++++++++i ( ....
~
Fasteners :+++++++++++++_+i
.......................... ~--I "-
~ tf
Solid - ~.~
i-ql~ tdl
LENGTH ~ A-A
Forward ExtDblr
Aft
Quahfications Maintenance
Requirements
PermanentRepair 1 11_<tit s < 1.27 Inspection
Threshold
Zone1 and2 0 025< t~_<0.032 60,000Landings
5/32_<Fastener Diameter< 1/4 Inspecbon
IntervalandMethod
4D _< Average Spacing < 6D ExtVIsual= 8,000
Landings
Minimum E.D.>_ 2D
PermanentRepair 1 11< tJt~< 1.27 Inspecbon
Threshold
Zone1 and2 0 025_<tf< 0.032 30,000Landings
5/32< Fastener Diameter < 1/4 Inspection
Interval
andMethod
4D _<Average Spacing _< 6D ExtVisual= 4,000Landings
Average E D. = 2D + 1/16inches
Minimum E.D.>_ 2D
TemporaryRepair 1.00_<tJt~ _<1.50 Inspection
Threshold.
Zone1 and2 0.032< t( 20,000landings
0.025> tf Inspection
IntervalandMethod
Fastener Diameter >_5/32 externalLFEC= 6,000
3 5D <_Average Spacing _<7D externalUS= 6,000
Maximum Spacing _< 7.5D Replacement/rework
Threshold
1 7D<_Average E.D. 40,000Landings
1.5D< Minimum E.D.
McDonnell
Douglas
Corporabon
propnetary
InformaBon
- UseorD~sclosure
of Page B.39
rapl
MDC 91K0263
DC-9/MDo80
Finger Skm
SkinMatl Skm Finger
2024-T3 Dblr
Repair
Matl
2024-T3
2014-T6 ,, -, _ , -! _ ,
-- ~~ tf
7075-T6 -J ....... -:"_
+++ ++++++++-+-++ {-
++++++++++++++ ~-i
~.. .... " ".....,." ";-,..... ,-

.".,."
Fasteners i_.-;
..... ,4,-.-
Solid dl
LENGTH
Forward ExtDblr
.dl A-A
Aft
areaexcept for Inspection
Threshold
1.11< tJt~_< 1.27 Inspection
IntervalandMethod
0.025 _<tf_<0.032 ExtVisual= 8,000Landings
Minimum E.D.> 2D
fitpin
(Fsu _>95ksi)
Proximity 20 inches
PermanentRepair Noexist fastener locationsinshadedareaexceptfor Inspection
Threshold
ZoneI and2 frame locations. 30,000Landings
1.11_<~t~_< 1.27 Inspection
IntervalandMethod
0.025 _<tf_<0.032 ExtVisual= 4,000Landings
4D _< Average Spacmg_< 6D
Minimum E.D.>_ 2D
fitpin
(Fsu> 95ksi)
Tempora~Repair Anyexisting fastener locations
in shadedareaexcept Inspection
Threshold:
Zone1 and2 forframe locations. 20,000landings
1.00_<td/ts--<1.50 Inspection
IntervalandMethod
0.032-<tf extemalLFEC= 6,000
0.025>-tf external
US = 6,000
Fastener Diameter >_ 5/32 Replacement/rework
Threshold
3.5D< Average Spacing < 7D 40,000Landings
1.7D_<Average E.D.
1.5D_< Minimum E.D.
Fastener rowthrough theIongeronismterference
fitpin
(Fsu >_95kst)
Page B.40 McDonnell

Douglas
Corporation
proprietary
Information
- UseorDisclosure
of
LEGENDON TITLEPAGE.
rap1
MDC 91K0263
DC-9/MD-80
SkinMatl
2024-T3
Repair
Matl
2024-T3
2014-T6
7075-T6
Fasteners
Sohd
Requirements
PermanentRepair 1 11< tJt~ < 1.27 Inspection
Threshold
Zone1 and2 0.025 < t~< 0.032 60,000Landings
5/32_<Fastener Diameter< 1/4 Inspection
IntervalandMethod
4D < Average Spacing _< 6D ExtVisual= 8,000Landings
Minimum E.D.>__2D
PermanentRepair 1.11_<tJt~ _<1.27 Inspection
Threshold
Zone1 and2 0.025 _<tf< 0.032 30,000Landings
5/32< Fastener Diameter_<1/4 Inspection
Interval
andMethod
4D < Average Spacing _< 6D ExtVisual
= 4,000Landings
MimmumE.D >_ 2D
TemporaryRepair 1.00 _<~t~_<1.50 Inspection
Threshold:
Zone1 and2 0.032 < tf 20,000landings
0.025 > tf Inspection
IntervalandMethod
Fastener Diameter _>5/32 externalLFEC= 6,000
3.5D< Average Spacing _< 7D external
US = 6,000
MaximumSpacing< 7.5D Replacement/rework
Threshold
1.7D< Average ED 40,000Landings
1.5D< Minimum E.D.
McDonnell
Douglas
Corporation
propnetary
Informabon
- UseorD~sclosure
of PageB.41
LEGENDON TITLEPAGE Oct2000
rapl
MDC 91K0263
DC-9/MD-80 Finger Skin

Frame Dblr
2024-T3 Dblr
~,
Repair
Matl ts
2024-T3
2014-T6
7075-T6 I
lllmm/
I +-t-+++++t-,
,+-I--l--I-++-t
-I-+-I-+-I-+-1-~
:++++++.~ +++++++:
=
~ tf
r ,,++++++++, I ...........................
................
.......... i. .................... F
Fasteners i ......,~ I ",....
"--J
Solid
~ tdl
~~~,.
LENGTH ~ J
j
Forward ExtDblr A-A
Aft
Requirements
PermanentRepair Noexistfastener locationsm shadedareaexcept for Inspection
Threshold
1.11_<tJt~ < 1.27 Inspection
IntervalandMethod
5/32< Fastener Diameter_< 1/4
MinimumE.D.> 2D
fitpin
(Fsu_>95ksi)
PermanentRepair Noexistfastener locationsinshaded areaexceptfor Inspectoon
Threshold
Zone1 and2 frame Iocatuons. 30,000Landings
1.11_<tJt~ _<1.27 Inspection
Interval
andMethod
0.025<_tf_<0.032 ExtVisual= 4,000Landings
4D _<Average Spacing_< 6D
Minimum E.D._> 2D
fitpm
(Fsu>_95ksi)
TemporaryRepair Anyexisting fastener locationsin shadedareaexcept Inspection
Threshold:
Zone1 and2 forframe locations. 20,000landmgs
1.00<_tJt s < 1.50 Inspection
Interval
andMethod
0.032_<tf external
LFEC= 6,000
0.025->t~ external
US= 6,000
Fastener Diameter _>5/32 Replacement/rework
Threshold
3.5D< Average Spacing < 7D 40,000Landings
1.7D_<Average E.D.
1.5D_< MimmumE.D.
fitpm
(Fsu_>95ksi)
Page B.42 McDonnell

Douglas
Corporatmn
propnetary
Information
- UseorDisclosure
of
LEGENDON TITLEPAGE
rap1
MDC 91K0263
DC-9/MD-80 Skin
Skm Matl Skm Finger
2024-T3 Finger Dblr
Frame Dblr /-Longeron
\
1
Repa,r Marl r ~ / iL~"~ A~I~ ~ ~ tS "~il~D ~ /
2024-T3 ~g,
"-T-,
"-T-,
";,! -T-,
2O14-T6 _. _ i,~~.~-,,i. ri~.,. ~..~,~.~,._~ .....
7075-T6 r.++++++++ , .++++++++++++++.. i~
~ ....
i+++++++: l i+++i (
[ ++++++++
i
, _ __;;;;;
,_......
,+++++++++++++,
:1, +++_+++--___
................ : _. t,
FastenersSolid .....
~ ";R~ i~--~~ ~ ~"
k~
LENGTH D, ~ f A-A
Forward ExtDblr
Aft
PermanentRepair 1 11< tJts-<1.27 InspectionThreshold
Zone 1 and 2 0.025< tr _<0.032 60,000Landings
5/32_<Fastener Diameter_< 1/4 InspectionInterval
and Method
4D < AverageSpacmg < 6D Ext Visual= 8,000Landings
AverageE.D. = 2D + 1/16 mches
Mmimum E.D _> 2D
Proxlmaty > 20 mches
PermanentRepair 1.11~ tJt,< 1.27 InspectionThreshold
Zone 1 and 2 0.025< tf< 0.032 30,000Landings
5/32_< Fastener Diameter< 1/4 Inspection
Intervaland Method
4D <_ Average Spacing _< 6D Ext Visual= 4,000Landmgs
AverageE.D.= 2D + 1/16 inches
MmlmumE D. _> 2D
3 < Proximity < 20 mches
TemporaryRepair 1.00_<tJt~ _<1 50 Inspection
Threshold:
Zone 1 and 2 0.032< tf 20,000landings
0.025_>tf Inspection
IntervalandMethod
Fastener Diameter > 5/32 externalLFEC = 6,000
3.5D< AverageSpacing_< 7D external
US = 6,000
Maximum Spacmg < 7.5D Replacement/reworkThreshold
1.7D_< Average E.D. 40,000Landings
1.5D _< MmlmumE.D
McDonnell
Douglas
Corporatzon
proprietary
Information
- UseorDisclosure
of Page B.43
rap1
MDC 91K0263
DC-9/MD-80
SkinMatl Skm Finger Skin
Dblr Finger
2024-T3 Frame
Dblr
RepairMatl
2024-T3
! ,~_. ,~_. ~Z_. ,7 .~ - -- -
2014-T6
7075-T6 .... ~ ........ . ~; ~" ~ .~.~ .~ .~ .~ .~ .~ .~:-: ~;:=
+-F "t+ + + ++ + +l" "f" +++ +F-I- +
++++++4"+: +++++t+
o, ...... i L ;++++++
..............
. = ... _ ........ =. .............
Fasteners
Sohd
R LENGTH
~,~
IX J
Forward ExtDblr
A-A
Aft
PermanentRepair No existfastenerlocations in shadedareaexceptfor InspectionThreshold
1.11< tJt,< 1.27 Inspect=onIntervalandMethod
0.025_<tf< 0.032 Ext Visual= 8,000Landings
5/32_< FastenerDiameter_< 1/4
MJmmum E.D. > 2D
fitpm
(Fsu> 95 ksi)
PermanentRepair No existfastenerIocabons in shadedareaexceptfor Inspect,onThreshold
Zone 1 and 2 frameIocabons. 30,000Landings
1.11 <~t~_<1.27 InspectionInterval
and Method
0.025< t~< 0.032 Ext Visual= 4,000Landings
4D _< AverageSpacing< 6D
MinimumE.D._> 2D
fitpin
(Fsu_>95 ks0
TemporaryRepair Anyexisting fastener locationsin shadedareaexcept Inspection
Threshold:
Zone 1 and 2 forframelocations. 20,000landings
1.00_<~L,- 1.50 Inspection
IntervalandMethod
0.032__tf externalLFEC= 6,000
0.025_>tf external
US = 6,000
FastenerD=ameter _> 5/32 Replacement/reworkThreshold
3.5D_< Average Spacing _< 7D 40,000Landings
1.7D_< Average E.D.
1.5D < Mimmum E.D.
fitpin
(Fsu> 95 ks0
Page B.44 McDonnell

Douglas
Corporabon
proprietary
Informabon
- UseorDisclosure
of
Oct 2000 THESE DATA SUBJECTTO RESTRICTIVELEGEND ON TITLE PAGE.
rap1
MDC 91K0263
DC-9/MD-80 Skin
2024-T3 Finger \
_Longeron Dblr
\ Frame Dblr
Repair
Mat12024-T3 L-- A-.,--/ t ts ---i,.

C -~_ ~
2014-T6 _t~.--
.~.+;-~."
+-"+-~+~
~_.~+~.~.:~
"+ -.-:-
-:----:-
----:--":-:--
- " ~ --
To ------
++++++++,
,--+
;..
++++++++++++4-+
I ,+++++++4-4-+4-4-4-+
-.-
~j .
--
4-+++++++ -I
;~ ++++++++ :++++++++++++++ +j ~. "~,
,j~::::::::::::::::::::::::::::::::::::::::::::::::::::::
Fasteners
Solid r
~~. ~ td
LENGTH . ~ / A-A
Forward ExtDblr
...,
Aft
Requirements
PermanentRepair 1.11<td/t~ _<1 27 Inspection
Threshold
Zone1 and2 0 025_<tf_<0.032 60,000Landings
5/32_<Fastener Diameter_<1/4 Inspection
IntervalandMethod
4D < Average Spacing < 6D ExtVisual= 8,000Landings
MaximumSpacing < 6.5D
Minimum E.D_> 2D
PermanentRepair 1.11_<tJt, <_1 27 Inspection
Threshold
Zone1 and2 0.025_<tf_<0.032 30,000Landings
5/32_<Fastener Diameter< 1/4 Inspecbon
Interval
andMethod
4D< Average Spacing _<6D ExtVisual
= 4,000Landings
Average E.D= 2D + 1/16inches
Mimmum E.D.>__2D
TemporaryRepair 1 00_ Vt~< 1.50 Inspection
Threshold:
Zone1 and2 0.032< t~ 20,000landings
0.025> t~ Inspection
IntervalandMethod
Fastener D~ameter > 5/32 externalLFEC= 6,000
3 5D < Average Spacing < 7D external
US = 6,000
Threshold
40,000Landings
1.7D<_Average E.D.
1.5D_< Minimum E.D.
McDonnell
Douglas
Corporabon
propnetary
Informabon
- UseorD~sclosure
of Page B.45
rap1
MDC 91 K0263
2024-T3
~,/ \~Ktn
bp,ceA.,l__. ~,]~
Repair
Matl ,- ~ ~ ts ~
2024-T3 i ~ ~ -- ---"-"~~
~
2014-T6 : : ~.
7075-T6 , ~i++:++!+++ ~--++++++? / -- :" --
++++++++,++:++;++++++++++1" -- "" --
/
I +++++++++++
++++++++i++i++i \ -- "r --
Fasteners """"
.,~................
" .............
"~-..-- _~ "
Sohd ~ \ . _i ~ ~ td~
R _] TH A4-- r
LENG -- -- .~
Forward ExtDblr A A
-~ Aft
Permanent
Repair Noex=sting fastener Iocat=onsinshadedareaexceptfor Inspection
Threshold:
Zone1 1.11<~t,<1.27 Inspection
Interval andMethod
5/32_<Fastener D=ameter <_1/4 extemalvisual =
4D _< Average Spacing < 6D external LFEC= 15,000
MmtmumSpacing _> 3.5D external US = 15,000
MinimumE.D.> 2D
Proximity 3 inches
splicefastener locations areinterference
fitpin(Fsu>
95ksi)
Temporary
Repair Noexisting fastener locationsinshaded
Threshold:
Zone2 1.11< tJts< 1.27 Inspection
IntervalandMethod
5/32_<Fastener Diameter _<1/4 external
visual
=
4D < Average Spacing < 6D externalLFEC= 15,000
Minimum Spacing >_ 3.5D externalUS= 15,000
visual
=
internal
HFEC= 15,000
Minimum E.D._> 2D
Replacement/rework
Threshold
Proximity 3 inches
40,000Landings
splicefastener locations areinterference
fitpin(Fsu_>
95ksi)
Temporary
Repair 1.00_<~t~_<1.50 Inspection
Threshold:
Fastener Diameter _>5/32 5,000landings
Zone1 and2 3.5D_< Average Spacing < 7D Inspection
Interval andMethod
Max=mum Spacing _< 7.5D externalLFEC= 3,000
MinimumE.D.>_ 1.5D externalUS = 3,000
Fastenerrowthrough theIongeronandproduction Replacement/reworkThreshold
splice fastener locationsareinterference
fitpm(Fsu>_ 10,000Landings
95ksi)
PageB.46 McDonnell
Douglas
Corporabon
propnetary
Informabon
- UseorD=sclosure
of
Oct2oo0 THESEDATASUBJECTTO RESTRICTIVE
LEGENDON TITLEPAGE.
rap1
MDC 91K0263
DC-9/MD-80
Skin Splice Finger
2024-T3 Dblr
Repair
Matl
r
2024-T3
2014-T6 --. --. --. :Z.. -- .... Z ..... n --
tf
7075oT6 i: ........ ,., :: I ....... L
:++++++++ ++ :+ -t- :. + + +++++++:
:++ ++++++
.++i++::
............... ++
- +++++++,
. . ....-- ; ...........
Fasteners
Sohd
R
LENGTH
Forward ExtDblr
q
A-A
Aft
Requirements
PermanentRepair Noexist fastener Iocahons ~nshadedareaexceptfor Inspection
Threshold
Zone1 and2 frame locations. 60,000Landmgs
1.11< t#t,< 1.27 Inspechon
IntervalandMethod
Minimum E.D._> 2D
splice fastener IocaUons areinterference
fitpin(Fsu>
95ksi)
for Inspection
Threshold
1.11 _<tJt, < 1.27 Inspection
Interval
andMethod
0.025 < tf_<0.032 ExtVisual= 4,000Landings
Average E.D.= 2D _+1/16inches
Minimum E.D.>_ 2D
Fastener rowthrough theIongeronandproduct=on
fitpin(Fsu>
95ksi)
3 < Prox=mity < 20inches
Tempom~Repair Anyexisting fastener Iocahons inshadedareaexcept Inspechon
Threshold.
1.00< ~t~< 1.50 Inspection
IntervalandMethod
0.032 < t~ extemalLFEC= 6,000
0.025 > tf external
US = 6,000
Fastener Diameter _>5/32 Replacement/rework
Threshold
3.5D_<Average Spacing _<7D 40,000Landings
1.7D< Average E.D
1.5D_< Minimum E.D.
fitpin(Fsu>
95ksi)
McDonnell
Douglas
CorporatJon
propnetary
Informat=on
- UseorDmclosure
of Page B.47
rap1
MDC 91K0263
DC-9/MD-80
Sphce Dblr Finger
2024-T3 \ Dblr
Repair
Matl ts
2024-T3
2014-T6
7075-T6
-I-++-I-++-I--I-:++:+- +-F-t-++++
I-
+ -I-+ +-I-+ ++,+ + :+ + ::+++++++-F++
Fasteners
Sohd
IR
14 LENGTH
Forward ExtDblr A-A
Requirements
PermanentRepair Noexistfastener locationsm shaded
Threshold
1.11<tJ4_<1.27 Inspecbon
IntervalandMethod
Minimum E.D.>_ 2D
areinterference
fitpin(Fsu>
95ksi)
areaexceptfor Inspechon
Threshold
Zone1 and2 flame Iocat=ons. 30,000Landings
1.11<_tJt, <__1.27 Inspection
Interval
andMethod
0.025 < tf< 0.032 ExtVisual= 4,000Landings
4D_<Average Spacing_.<6D
Minimum E.D._> 2D
fitpin(Fsu_>
95ksi)
TemporaryRepair Anyexisting fastenerlocationsinshadedareaexcept Inspection
Threshold:
1.00< tJt~< 1.50 Inspection
IntervalandMethod
0.032_<tf externalLFEC= 6,000
0.025_>tf external
US = 6,000
Fastener Diameter >_ 5/32 Replacement/rework
Threshold
3.5D_<Average Spacing _< 7D 40,000Landings
1.7D_< Average E.D.
1.5D_< Minimum E.D.
areinterference
fitpm(Fsu_>
95ksi
Page B.48 McDonnell

Douglas
Corporabon
propnetary
Information
- UseorDmsclosure
of
LEGENDON TITLEPAGE.
rap1
MDC 91K0263
DC-9/MD-80
Skin Skin
SkinMatl
Repair
Matl ts ~ -4~
2024-T3
2014-T6
7075-T6 -- -. __
~~
:+++++++++++~-.) .....
: ++ + ++ + +++ + ++.+.+.+ ++ +" \ .....
Fasteners
L .......... ! ..................
,~ ""- /
LENGTH ~ ~ ~I
Forward ExtDblr
A-A
Aft
PermanentRepair No extstrngfastenerlocationsin shadedareaexceptfor Inspection
Threshold
Zone 1 1 11_<tJts< 1.27 Inspection
Interval andMethod
5/32< Fastener Diameter_<1/4 extemalvisual=
4D < AverageSpacing<_ 6D externalLFEC = 15,000
MinimumSpacing>_ 3.5D externalUS = 15,000
MinimumE.D. >_ 2D
Proximity> 3 inches
Fastener rowthroughtheIongeron and production
areinterference
fitp~n(Fsu_>
95ksi)
TemporaryRepair No existing fastener
locationsin shadedareaexceptfor Inspection
Threshold.
Zone 2 1.11< tJt
s _<1.27 Inspection
Interval andMethod
5/32< Fastener Diameter_< 1/4 external
visual =
4D _< Average Spacing_< 6D externalLFEC = 15,000
Minimum Spacing>__3.5D externalUS = 15,000
MaximumSpacing< 6 5D internal
visual=
MinimumE.D >_ 2D internalHFEC = 15,000
40,000Landings
Fastener rowthroughtheIongeron and production
areinterferencefitpin(Fsu_>
95ksi)
TemporaryRepair 1.oo
_<tJt,
_<15o Inspection
Threshold:
FastenerDiameter>_ 5/32 5,000landings
Zone 1 and 2 3.5D < AverageSpacing< 7D Inspection
IntervalandMethod
MaximumSpacing_< 7.5D externalLFEC= 3,000
MinimumE.D _> 1.5D external
US = 3,000
Fastenerrow throughthe Iongeron
andproduction
splicefastener
locations
areinterference
95ksi)
McDonnell
Douglas
Corporation
proprietary
Information
- UseorD0sclosure
of Page B.49
rapl
MDC 91 K0263
DC-9/MD-80
Skin Finger Skin
SkinMatl Finger
Skin Dblr
2024-T3
Repair
Matl
2024-T3
2014-T6
7075-T6
Fasteners
Solid
R
LENGTH
Forward ExtDblr A-A
Aft
Qualifications Mamtenance
Requirements
PermanentRepatr Noexist fastener locationsinshadedareaexceptfor Inspection
Threshold
1.11_<tJt, _<1.27 Inspection
Interval
andMethod
4D _< Average Spacing _< 6D
Maximum Spacing_< 6.5D
Average E.D.= 2D _+ 1/16inches
Minimum E.D._> 2D
fitpin(Fsu>__
95ksi)
PermanentRepair Noexist fastener locationsinshaded
Threshold
1.11< tJts_< 1.27 Inspection
Interval
andMethod
0.025 < tf_<0.032 ExtVisual= 4,000Landings
MaxtmumSpacing< 6.5D
Minimum E.D.>__2D
splice fastener locationsaremterference
fitpm(Fsu_>
95ksi)
Tempora~Repair Anyexisting fastenerlocationsinshadedareaexcept Inspection
Threshold:
Zone1 and2 forframe Iocattons. 20,000landings
1.00_< ~4< 1.50 Inspection
IntervalandMethod
0.032_<tfand/or 0.025>_tf externalLFEC= 6,000
Fastener Diameter >__5/32 extemalUS = 6,000
3.5D_<Average Spacing _<7D Replacement/rework
Threshold
Maximum Spacing_< 7.5D 40,000Landings
1.7D_< Average E.D.
1.5D_< Minimum E.D.
fitp=n(Fsu
95ksi)
Page B.50 McDonnell

Douglas
Corporatton
proprietary
Information
- UseorDtsclosure
of
LEGENDON TITLEPAGE
rap1
MDC 91K0263
DC-9/MD-80
Skin Finger
2024-T3 SkinS Dblr
RepairMatl
2024-T3
2014-T6
7075-T6
Fasteners
Solid
LENGTH
I-
Forward ExtDblr
el .~-
A-A
Aft
Quahfications MaintenanceRequirements
PermanentRepair No existfastener Iocattons in shadedareaexceptfor Inspect0on
Threshold
s_<1.27
111_<tJt Inspecbon
Intervaland Method
0.025< t~ < 0.032 ExtVisual= 8,000Landings
5/32< Fastener Diameter _< 1/4
4D _< Average Spacing_< 6D
MaximumSpac,ng< 6.5D
Mimmum E.D > 2D
Fastenerrow throughthe Iongeronand producbon
splicefastener locationsareinterferencefitpm (Fsu_>
95ksi)
PermanentRepair No existfastener iocattons m shadedareaexceptfor InspectionThreshold
1.11< tJt~_< 1.27 Inspection
IntervalandMethod
0.025_<tf_<0.032 Ext V~sual= 4,000Landings
5/32_< Fastener Diameter < 1/4
4D _< AverageSpacing< 6D
AverageE D. = 2D + 1/16inches
MinimumE.D. > 2D
Fastener row throughtheIongeron and product0on
sphcefastener locations areinterferencefitpm (Fsu>_
95ksi)
Tempom~ Repatr Anyexistmgfastener locations m shadedareaexcept Inspecbon
Threshold.
Zone 1 and 2 forframelocations. 20,000landings
1.00_<tJts < 1.50 InspectIon
Intervaland Method
0.032<_tfand/or 0.025> tf externalLFEC= 6,000
Fastener Diameter _> 5/32 external
US = 6,000
3.5D<_ AverageSpacing< 7D Replacement/reworkThreshold
MaximumSpacing_< 7.5D 40,000Landings
1.7D < AverageE.D.
1.5D < MinimumE.D
Fastener row through the Iongeron andproduction
sphcefastener locationsareinterferencefitp~n(Fsu>__
95 ks0
McDonnell
Douglas
Corporabon
proprietary
Informatton
- UseorD~sclosure
of Page B.51
rap1
MDC 91 K0263
DC-9/MD-80
DblrFInger Skin
SkinMatl Skin
I A~ Finger
2024-T3 Dblr
ts
Repair
Matl -- -- tf
2024-T3
i-I-++ -F+ + -~ + + + + + + -I-,
2014-T6
7075-T6 :.t.t.+..+.
-J-.t.f
.+..+.~-. -J-.t.~
.+-:
-- ~ .=:::.i ......
,+,+,+,~";..... ~.:~,+:#,
Fasteners
Solid
ExtDblr1
Forward A-A
A~
Requirements
PermanentRepair Noexist fastener locations inshadedareaexceptfor Inspection
Threshold
1.11< tJts< 1.27 Inspectaon
Interval
andMethod
0.025 < tf< 0.032 ExtVisual= 8,000Landings
MinimumE.D _> 2D
fitpm(Fsu_>
95ksi)
PermanentRepair Noexist fastener locations inshadedareaexceptfor Inspection
Threshold
Interval
andMethod
0.025_<tf< 0.032 ExtVisual= 4,000
Landings
5/32_<Fastener D~ameter _<1/4
Minimum E.D.>_ 2D
fitpin(Fsu>_
95ksi)
TemporaryRepair Anyexisting fastener locations =nshadedareaexcept Inspection
Threshold:
1.00 ___~t~_ 1.50 Inspection
IntervalandMethod
0.032_<tfand/or 0.025 _>t~ externalLFEC= 6,000
Fastener Diameter _>5/32 external
US = 6,000
3.5D_<Average Spacing ___7D Replacement/rework
Threshold
Maximum Spacing _< 7.5D 40,000Landings
1.7D_< Average E.D.
1.5D_< Minimum E.D.
sphce fastener locations areinterference
fitpin(Fsu_>
95 ks0
Page B.52 McDonnell

Douglas
Corporat=on
propnetary
Information
- UseorD=sclosure
of
LEGENDON TITLEPAGE
rap1
MDC 91K0263
DC-9/MD-80 Skm A~ Finger

SkinMatl
2024-T3
/~ ~.] ~/blr
ts Skin
"~j r
r,~Finger
! ! _jj
Repair
Matl
2024-T3
2014-T6
7075-T6 {_
L+ + +::,~-+++1+ +~-+:,,+
~ + +J ~
Fasteners
Sohd
~ Forward
Ext Dblr 1 /
A-A
Aft
Quahficat~ons MaintenanceRequirements
Threshold
Zone1 and2 frame locations. 60,000Landmgs
1 11< tJt~< 1.27 Inspectton
IntervalandMethod
0 025_<tf< 0.032 ExtVisual= 8,000Landings
MaximumSpacmg_< 6.5D
Mintmum E.D.>__2D
sphce fastenerIocatmonsareinterference
fitpin(Fsu_>
95ksl)
Proxtmity> 20 mches
Threshold
1.11< tJt~< 1.27 Inspectton
Interval
andMethod
0.025 _<tf< 0.032 ExtVisual= 4,000Landings
MaximumSpac,ng< 6.5D
Minimum E.D._> 2D
sphce fastener locationsaremterference
fitpm(Fsu>_
95 ks0
3 < Proximity < 20 mches
TemporaryRepair Anyexisting fastener locations
inshadedareaexcept Inspectton
Threshold.
1.00 < tJt~_<1.50 Inspection
IntervalandMethod
0.032_<tfand/or 0.025
>_tf externalLFEC= 6,000
Fastener Diameter >_5/32 externalUS= 6,000
3.5D< Average Spacing < 7D Replacement/reworkThreshold
Maximum Spacing _< 7.5D 40,000Landings
1.7D_<Average E.D.
1.5D_< Minimum E.D.
andproductton
sphce fastenerlocationsareinterference
fitpin(Fsu>_
95ksl)
McDonnell
Douglas
Corporatton
propnetary
Information
- UseorDisclosure
of Page B.53
rap1
MDC 91 K0263
Intentionally
LeftBlank
Page B.54 McDonnell

Douglas
Corporat=on
proprietary
Information
- UseorD~sclosure
of
Oct2000 THESE DATA SUBJECTTO RESTRICTIVELEGEND ON TITLE PAGE.
rap1
MDC 91 K0263
DC-9/MD-80
SkinMatl Skin
Skin
Aluminum
~,
Repair
Matl ts ~ ,~
2024-T3 ~~
2014-T6 !
7075-T6 _ . m
Fasteners
Blind
~ ..9--- td
Fomrard ExtDblr
_~ ~ A-A
Aft
Requirements
Permanent
Repair
Notavailable
forthis
configuration
Temporary
Repair 1.00
_<Vt,_<1.50 Inspection
Threshold:
FastenerDiameter> 5/32 3,000landings
Zone1 and2 3D< Spacing_<6D Inspection
Interval
andMethod
E.D.= 1.5D+ 1/16inches external
visual
= 3,000
Replacement/rework
Threshold
8,000Landings
Page B.55
McDonnell
Douglas
Corporabon
propnetary
Informabon
- UseorDisclosure
of
LEGENDON TITLEPAGE July 1997
rap1
MDC 91 K0263
DC-9/MD-80
Skin \ Finger
Aluminum
Dblr
RepairMatl 1 ~--~
ts
2024-T3
2014-T6 ~r"T,
~ , I-T-,
, ~
tf
Dbl~
:+ ++-P-I-++ +++ +++ +:
!
:+ +++++++++++++: i I
.........................
Fasteners i . ...;" ~ ....

.-i.,
LENGTH
Forward ExtDbl
~A-A
Aft
Quahficabons MaintenanceRequirements
PermanentRepair
Notavailable
forthis
configuration
TemporaryRepair 1.00< tJt,_<1.50 Inspection

Threshold"
FastenerDiameter_> 5/32 3,000landings
Zone 1 and 2 3D < Spacing< 6D Inspection
Interval
and Method
visual= 3,000
Replacement/rework
Threshold
8,000Landings
PageB.56 VlcDonnell
Douglas
Corporabon
propnetary
Informabon
- UseorD~sclosure
of
MDC 91 K0263
DC-9/MD-80
Skin Finger
Aluminum Dblr
t
~
Repair
Matl ~ ts
2024-T3
2014-T6 .~=. ~t~
i ~l_lf t_l-~_ s. .....
7075-T6
I -j ++++++++++++++c~"++++++++++++++"
c t ~ I....
.....
++++++,+++++++ _( ....
Fasteners
Blind
L" ~_~
~ ~ td
LENGTH ~ l-
Forward ExtDblr
~ A-A
Aft
Requirements
Permanent
Repair
Notavailable
forthis
configuration
Temporary
Repair 1.00< tJts
-<1.50 Inspection
Threshold
FastenerDiameter
>__5/32 3,000landings
Zone1 and2 3D < Spacing< 6D Inspection
Interval
andMethod
visual
= 3,000
Replacement/rework
Threshold
8,000Landings
McDonnell
Douglas
Corporabon
proprietary
Informabon
- UseorD=sclosure
of Page B.57
LEGENDON TITLEPAGE. July 1997
rap1
MDC 91K0263
DC-9/MD-80 Finger Skin ..

SkinMatl S..
Frame Dblr Dblr
Ilnger
Aluminum
in
Repair
Matl ~I~F
ts
2024-T3
/~,E-,,~ ,-T-,i r~ I-T-,I-T-,,::=J-~-T-,
~I ~.
2014-T6 - - t,
7075-1"6 It!++++++++!
!*+++++++++++++!
t
I i++++++++:l:+++++++-i-+++~-+i
)
:!i*...........+.~.~.*,
iii.+.-t-..*..........~.
~.*.
...
...
...
~...
...
iI
Fasteners
Blind
"4-"
!4 LENGTH ~ ~
FonNard ExtDblr~AA
Aft
Requirements
Permanent
Repair
Notavailable
forthis
configuration
Temporary
Repair 1.00< tJt~
_<1.50 Inspection
Threshold:
Zone1 and2 3D _< Spacing
< 6D Inspection
Interval
andMethod
E.D.= 1.5D 1/16inches external
visual
= 3,000
Replacement/rework
Threshold
8,000Landings
Page B.58 McDonnell

Douglas
Corporat=on
propnetary
InformatJon
- UseorD=sclosure
of
July 1997 THESEDATASUBJECTTO RESTRICTIVE
LEGENDON TITLEPAGE
-r
MDC 91K0263
DC-9/MD-80
Dblr Finger
Aluminum I Frame
Dblr
RepairMatl ts~
2024-T3
2014-T6
7075-T6 ++++++++ .
~, H-i i+, i+l i+~, I c+t ~+, i+~ i.., ~+, I+L H-~ . .,4.--
tf
-,i++++*+++:
! :********++*+++
,~_)
_,..........
,...................
~-i++++++++:
..............
, :++++++-t
...............
:::::-_:..-.
4-++++++ ~J(~
I"
Fasteners
Blind
\
LENGTH ~ -- ~. J
Forward ExtDblr
.., v A-A
Aft
QualificatJons MaintenanceRequirements
PermanentRepair
Notavailable
forthis
configuration
TemporaryRepair 1.00< tJt~< 1 50 Inspection

Threshold
FastenerDIameter _> 5/32 3,000landings
Zone 1 and 2 3D < Spacing_< 6D Inspection
Interval
andMethod
E.D = 1.5D+ 1/16 inches external
visual
= 3,000
Replacement/rework
Threshold
8,000Landings
McDonnell
Douglas
Corporation
propnetary
Informatmon
- UseorDisclosure
of Page B.59
THESE DATA SUBJECTTO RESTRICTIVELEGEND ON TITLE PAGE. July 1997
rap1
MDC 91K0263
DC-9/MD-80
SkinAluminumMatl
l SkinSplice S~n
Sin
Repair
Matl ts
2024-T3
2014-T6
7075-T6
~r-
l ~~
-++ +++ + ++ : ++:++ :++++
Fasteners
) ++++++++i++i++i++++
r
~
........
...
-."
-.-....,.L=
..o-.O..
......
Blind "-- ~ _ "" -~ td

R-J A
LENGTH
--
~
\
-- ~"
Forward ExtObl
Aft
Requirements
Permanent
Repair
Notavadable
forthis
configuration
Temporary
Repair 1.00< ~ts _<1.50 Inspect=on
Threshold:
Zone1 and2 3D < Spacing < 6D Inspect=on
Interval
andMethod
visual
= 3,000
Replacement/rework
Threshold
8,000Landings
Page B.60 VlcDonnell

Douglas
Corporabon
propnetary
Information
- UseorD~sclosure
of
LEGENDON TITLEPAGE
MDC 91 K0263
DC-9/MD-80
Skin Finger
Aluminum Dblr
Dblr
/ Skin Splice
RepairMatl
2024-T3
2014-T6 --.~. ~ ~ h
7075-T6 i++++++++::
++:++::++4
+++++++:"
(
:++++++++~++:++:
++4+++++++:)
:+++++
+++~++:++i:
++4+++++++,
Fasteners
Blind
A~-"
LENGTH /
Forward ExtDblr
D. A-A
Aft
PermanentRepair
Notavadable
forth=s
configuration
TemporaryRepair 1.oo
_<tjt,
_<1.5o Inspection
Threshold:
Interval
andMethod
E.D = 1.5D + 1/16inches external
wsual= 3,000
Replacement/rework
Threshold
8,000Landings
McDonnell
Douglas
Corporation
proprietary
Information
- UseorDisclosure
of Page B.61
rap1
MDC 91K0263
DC-9/MD-80
Aluminum \
l SkinSplice Dblr ~1~ Finger
Repair
Matl F ts
2024-T3
2014-T6 :,~0_ -- .
,-; . ~ ~ t!
7075-T6 __ .:. n
I c~- 2+++++++: ++:++ ~+++ 4-+++++-I: ~j(
-j ++++++++i++:++::+++~+++++++ r~ ....
- -
Fasteners -
Blind
RJ ~
i
A-4---
< LENGTH ---~.~- t~
Fo "~ Ext Dblr A-A
i
Requirements
Permanent
Repair
Notavailable
forthis
configuration
Temporary
Repair 1.00
_<tJts _<1.50 Inspection
Threshold:
FastenerDiameter>_5/32 3,000landings
Zone1 and2 3D_<Spacing _< 6D Inspecbon
Interval
andMethod
E.D.= 1.5D_+1/16inches external
visual
= 3,000
Replacement/rework
Threshold
8,000Landings
PageB.62 McDonnell
Douglas
Corporation
propnetary
Information
- UseorDisclosure
of
July1997 THESEDATASUBJECTTO RESTRICTIVE
LEGENDON TITLEPAGE.
MDC 91K0263
DC-9/MD-80
SkinMatl Skin Skin
Aluminum
\ Skin Splice
3
RepairMatl ts ~
2024-T3
2014-T6 : :
7oTs-T61:: ~--"--
.
: : ++ ++++++++ .f -p++ +++ + }f
! :+++++-i-++++-~++++++ -- --
, ~
Fasteners
;...i. .: : ""
Blind ~ td
/ ~
R
LENGTH ~ i
i=
Forward ExtDblr
4 A-A
Aft
PermanentRepair
Notavailable
forthis
configuration
TemporaryRepair 1.00-<tJts
< 1.50 Inspection
Threshold:
Interval
andMethod
E.D.= 1.5D+ 1/16inches extemal
visual= 3,000
Replacement/rework
Threshold
8,000Landings
McDonnell
Douglas
Corporation
proprietary
Information
- UseorD~sclosure
of Page B.63
rap1
MDC 91 K0263
DC-9/MD-80
Dblr S~in Finger
Aluminum SkinSplice--~
RepairMatl
2024-T3
2014-1"6
7075-T6
~ :
~
i;
. r~-,
e-T,
~,_l-T-,j:
::++ +++ + ++++-I- +++ +++ +:
~ ~ tf
:
i ::++++++++++*++++++
::
++
+*+*
* +i )\
~..+....+...+...+..+.+..+
Fasteners
~:.:::::::::.-......:---
j i .... ........
Blind
Forward ExtDblr
AoA
Aft
Requirements
PermanentRepair
Notavailable
forthis
configuration
TemporaryRepair 1.00< t~/4< 1.50 Inspection

Threshold.
Interval
and Method
E.D.= 1.5D+ 1/16inches extemal
visual= 3,000
Replacement/rework
Threshold
8,000Landings
Page B.64 VIcDonnell

Douglas
Corporation
propnetary
Information
- UseorDisclosure
of
MDC 91K0263
DC-9/MD-80
Aluminum Skin Spliceq Dblr
1
[~blr
Repair
Matl
2024-T3
ts.~~ 2_
~
Fin;er-
2014-T6 ~..,~--- tf
7075-T6 ;",-T-,_,~-,
~-,_J~-,
J.
: ::++++++++++t+++++++ ~ r
: ::++++++++++-t+++++++ r._)
: ::++**+**+++~
+;+;;+;,+-[
I
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....
.....................
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.............
. :,
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.,d,., /
Blind
LENGTH J
i"
Forward ExtDblr A_A
Al~--Il
Aft
Qualificabons MaintenanceRequirements
PermanentRepair
Notavailable
forthis
configurabon
TemporaryRepair 1.00-<td/~< 1.50 Inspect0on

Threshold:
FastenerDtameter_> 5/32 3,000landings
Interval
andMethod
EoD.= 1.5D+ 1/16inches external
v=sual= 3,000
Replacement/rework
Threshold
8,000Landings
McDonnell
Douglas
Corporation
propnetary
Information
- UseorD=sclosure
of Page B.65
rap1
MDC 91 K0263
DC-9/MD-80 Skin A-~--- Finger

SkinMatl Skin ~ 1" Finger
Aluminum
ts ~ ~r
RepairMatl :~"~-~-~;]1 ~ 41.~-- t,

2024-T3 .4--t-+++-1-4
2014-T6 :+ +++++4 4-++++++:
7075-T6 ..1-.
"].+..+.
~.l-.-t
".,;-:,:
".-+
+++
Fasteners
Blind
ExtDblr
LENGTH
Fon#ard
A-A
Aft
Quahficat~ons MaintenanceRequ=rements
PermanentRepair
Notavailable
forthis
configuration
TemporaryRepair 1 00___tJt,
___1.50 Inspection
Threshold.
FastenerDiameter>_ 5/32 3,000landings
Interval
and Method
wsual= 3,000
Replacement/rework
Threshold
8,000Landings
Page B.66 McDonnell

Douglas
Corporation
propnetary
Informahon
- UseorDtsclosure
of
MDC 91 K0263
DC-9/MD-80 Skin Aql"~ Finger Skin

Aluminum er
rRng
ts
Repair
Matl
2024-T3
2014-T6
7075-T6
.-~j-T-,_s-T-,_~::,
,.1".
+:1::
.+.
H:,j-T-,
:++++++++++++++!
:++++++++++++++i
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"::"~.~.H;.~.I
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Blind
A--F--
ExtDblrJ
LENGTH -~
Font/ard A-A
Aft
PermanentRepatr
Notavailable
forthis
configurabon
TemporaryRepair 1.00_<~t~_<1.50 Inspection

Threshold:
Zone 1 and 2 3D < Spacing
_< 6D Inspection
Interval
and Method
visual= 3,000
Replacement/rework
Threshold
8,000Landings
McDonnell
Douglas
Corporation
propnetary
Informahon
- UseorD~sclosure
of Page B.67
MDC 91K0263
Intentionally
LeftBlank
Page B.68 McDonnell

DouglasCorporabon
propnetary
Informatzon
- Use or D=sclosure
of
Oct2000 THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE
rap1
MDC 91K0263
DC-9/MD-80
SkinMatl Skin Ext Dblr
2014-T6 ~. I __
ExtDblr
Repair
Matl ~. I~+ + : \
~ ~+ + .j t Skin
2024-T3
2014-T6 Longeron ........... :--- III
:. A EN ,II I
A
Fasteners Longeron t._ Bi

++
++
+ i
~---R
TG
H
, ts J 1 I
III
"
t,,
Solid + + i
+ ,t
A~
Requirements
Permanent
Repair Noexisting fastenerlocations inshadedareaexcept
for Inspection
Threshold:
framelocations 20,000landings
Zone1 s_<127
111_<tJt Inspection
Interval andMethod
5/32_<Fastener Diameter _<1/4 external
visual =
4D_<Average Spacing _<6D externalLFEC= 6,000
Minimum Spacing >_ 3.5D externalUS = 6,000
Maximum Spacing< 6.5D
MinimumE.D.>_ 2D
fitpin
(Fsu> 95ksi)
Fastenersinbetween Iongerons areinterference
fitpin
Proximity> 3 inches
Temporary
Repair Noexisting fastenerlocations inshadedareaexcept
for Inspection
Threshold.
frameiocat=ons. 20,000landings
Zone2 1 11_<tJt, < 1.27 Inspection
Interval andMethod
5/32_<Fastener Diameter < 1/4 extemalvisual=
4D < Average Spacing < 6D externalLFEC= 6,000
Minimum Spacing >_ 3.5D externalUS = 6,000
MaximumSpacing< 6.5D intemal
visual =
MinimumE.D.>__2D internalHFEC= 6,000
AverageE.D.= 2D+ 1/16inches Replacement/reworkThreshold
fitpin 40,000Landings
(Fsu> 95ksi)
Fasteners inbetween Iongerons areinterference
fitpm
Temporary
Repatr 1.00< ~ts < 1.50 Inspection
Threshold
Fastener D=ameter >_5/32 5,000landings
Zone1 and2 3 5D < Average Spacing < 7D Inspection
Interval andMethod
Maxtmum Spacing _< 7.5D externalLFEC= 3,000
Minimum E.D_> 1.5D externalUS = 3,000
fitpin Replacement/reworkThreshold
Fasteners inbetween Iongerons areinterference
fitpm
(Fsu_>95ksi)
McDonnell
Douglas
Corporabon
propnetary
Informabon
- UseorD~sclosure
of Page B.69
rap1
MDC 91K0263
DC-9/MD-80
SkinMatl Skin ExtDblr
2014-T6 j,.~Frame
Repair
Matl
~ ExtDblr
2024-T3
2014-1"6 L
t Skin I
7075-T6 E
iii
N
G
T
L,
Fasteners Longeron -" H
Solid
~;ger ~-~Frame
A-A
Foreward
Aft
Requirements
Permanent
Repatr 1.11_<tJt, _<1.27 Inspection
Threshold
0.025_<tf< 0.032 60,000Landings
Zone1 and 2 5/32< Fastener Diameter < 1/4 Inspecbon
IntervalandMethod
4D_< Average Spacing _<6D ExtVmsual= 8,000Landings
AverageE.D.= 2D_+1/16inches
Minimum E.D._> 2D
Fasteners through theIongeron andin shaded
areaare
interference
fitpin(Fsu >_95ksi)
Permanent
Repair 1 11< tJt,_<1.27 Inspection
Threshold
0.025-<tf<_0.032 10,000Landings
Zone1 and2 5/32< Fastener Diameter < 1/4 Inspection
Interval
andMethod
4D_< Average Spacing _<6D ExtVisual
= 4,000Landings
Minimum E.D.> 2D
areaare
interferencefitpros (Fsu>_95ksi)
3 < Proxmmity < 20inches
Temporary
Repair 1.00_<tJts -<1.50 Inspection
Threshold"
0.032_<tf 20,000landings
Zone1 and2 0.025_>tf Inspect=on
Interval andMethod
Fastener Diameter > 5/32 externalLFEC= 6,000
3.5D< Average Spacing < 7D externalUS = 6,000
Maximum Spacing __47.5D Replacement/reworkThreshold
40,000Landings
1.7D< Average E.D.
1.5D< MimmumE.D.
Fasteners through theIongeron andm shaded
areaare
interferencefitpins(Fsu > 95ksi)
Page B.70 McDonnell

Douglas
Corporal]on
propnetary
Informahon
- UseorD=sclosure
of
LEGENDON TITLEPAGE.
rap1
MDC 91K0263
ExtDblr
Finger ~---"~" ~~"~

ExtDblr
Dblr~ i ~r
~-f-+ , Skin
~lilllJ-..1_ --
L tll
7075-T6
Longeron--- ~--~.-.-" ....
A J~
";" +" ~
\
A ,
N : - J
,-
T ts
Fasteners
Solid
i++
....
H
S
Finger
tf
Dblr A-A
Foreward
Aft
Qualificattons Maintenance
Requirements
PermanentRepair Noextstmg fastenerlocation in shaded
Threshold
Zone1 and2 Iongeronlocations. 60,000Landings
1.11< tJts < 1.27 Inspection
Interval
andMethod
0.025< t~< 0.032 ExtVisual
= 8,000Landmgs
MtmmumE.D.>_ 2D
Fasteners throughIongeron andbetween Iongeron
are
interferencefitpms(Fsu> 95ksi) exceptforfinger
row
PermanentRepair Noexisting fastenerlocation inshadedareaexcept
for Inspectton
Threshold
Zone1 and2 Iongeron locations. 10,000Landings
1.11_<t~/t~_<1.27 Inspection
Interval
andMethod
Minimum E.D.>_ 2D
Fasteners throughIongeron andbetween Iongeron
are
interferencefitpins(Fsu >_95ksi) except
forfinger
row
TemporaryRepair 1.00_<~t~_<1.50 Inspection
Threshold:
Zone1 and 2 0.032_<t~ 20,000landings
IntervalandMethod
Fastener Diameter> 5/32 externalLFEC= 6,000
3.5D_<Average Spacing_<7D extemalUS = 6,000
Threshold
1.7D< Average E.D. 40,000Landings
1.5D< Minimum E.D.
Fasteners throughIongeron andbetween iongeron
are
interferencefitpins(Fsu> 95ksi)
McDonnell
Douglas
Corporation
propnetary
Information
- UseorDtsclosure
of Page B.71
rap1
MDC 91 K0263
DC-9/MD-80
ExtDblr_
RepairMarl
2024-T3 ~~ ::~. t
Longeron......+ + .P, _
~ .
7075-T62014"T6
A.1,-T--
"--"-:B
~/""1--/LE
-
t/,,, !; t
, Ski~
Longeron--
FastenerSSolid
~-----~
~-.+.:~-
-..--~-.
i+++~;
i( .... Jit,
ts
ii"tL.,
t, IXFinger
HI
:+1-,+1" t A-A Dblr
Foreward
An
Requirements
PermanentRepair 1.11_<~ts< 1.27 Inspection
Threshold
5/32_<Fastener Diameter _<1/4 Inspect=on
IntervalandMethod
4D_< Average Spacing _< 6D ExtVisual= 8,000Landings
Average E.D.= 2D 1/16inches
Minimum E.D.>_ 2D
Fasteners through theIongeron andin shadedareaare
interferencefitpins (Fsu_>95ks=)
PermanentRepair 1.11_<t~/t s <1.27 Inspection
Threshold
Zone1 and2 0.025 < tf< 0.032 10,000Landings
5/32_<Fastener Diameter _<1/4 Inspection
Interval
andMethod
4D <_ Average Spacing _<6D ExtVisual= 4,000Landings
Minimum E.D.>_ 2D
Fasteners through theIongeronandinshaded areaare
interferencefitpins (Fsu>_95ksi)
TemporaryRepair 1.00_<~t,_ 1.50 Inspect=on
Threshold:
Zone1 and2 0.032_<t~ 20,000landings
0.025>_tf Inspection
Interval andMethod
3.5D_< Average Spacing _<7D externalUS = 6,000
Maximum Spacing _< 7.5D ReplacemenUreworkThreshold
1.7D_<Average E.D. 40,000Landings
1.5D_< Minimum E.D.
areaare
interference fitpins(Fsu_ 95ksi)
Page B.72 McDonnell

Douglas
Corporation
proprietary
Information
- UseorDmclosure
of
LEGENDON TITLEPAGE
rap1
MDC 91K0263
DC-9/MD-80
. n
2014-T6 \ I
Finger
OUr~ ,%-;.?.~:.,
Repair
Matl
2024-T3 "~i~.T.,
- +++, :
[+ . .p. ~ l ExtDblr
2014-T6 Longeron "~l+ + ~, " I Skin

....---~-t -/.... L
i--".-~-----
,A-,Ira) A.
1+ ,.
:
,II I,-
I
. 1
Longeron
!L.(
------;.-]:.-."
".L.--:
. I-....
G
) TH t,Jitlii" t.L~,
Fasteners ~-I++~" :
Solid =+1+++: ,,,/
I,+L+**: iq " A-A-Finoor
) Dblr
Foreward
Aft r
Qualificatoons Mamtenance
Requirements
PermanentRepanr 1.11_<tJts -<1.27 Inspecbon
Threshold
Zone1 and2 0.025_<tf< 0.032 60,000Landings
5/32< Fastener Diameter _<1/4 Inspection
IntervalandMethod
4D _<Average Spacing _<6D ExtVisual= 8,000Landings
MinimumE.D.> 2D
Fasteners through theIongeron andinshaded areaare
nnterferencefitpins (Fsu>_95ksi)
PermanentRepair 1.11< Vt~< 1.27 Inspection
Threshold
Zone1 and2 0.025< tf< 0.032 10,000Landings
5/32< Fastener Diameter _<1/4 Inspection
Interval
andMethod
4D _< Average Spacing < 6D ExtVisual
= 4,000Landings
Minimum E.D._> 2D
Fasteners through theIongeron andon shadedareaare
interferencefitpins(Fsu> 95ksi)
3 < Proximuty < 20 inches
TemporaryRepair 1.00< tJt, _<1.50 Inspection
Threshold:
Zone1 and2 0.032< tf 20,000landings
IntervalandMethod
Fastener Diameter >_ 5/32 externalLFEC= 6,000
3.5D<_Average Spacing _< 7D external
US = 6,000
Threshold
1.7D<__Average E.D. 40,000Landings
1.5D_< Minimum E.D.
areaare
interferencefitpins (Fsu> 95ksi)
McDonnell
Douglas
Corporabon
propnetary
Informabon
- UseorDKsclosure
of PageB.73
rap1
MDC 91K0263
ExtDblr
Finger ~.~.~ Frame

ExtDblr
Dblr ~ / .~+h~l+L" j
--~ i++li t Skin

.~
E I
II! ,J
N
A 1.,: I ,
~.-t,
" I
GT t, "j~ J~l"~
H j tt
Finger
Dblr
A-A
Foreward
Aft
Requirements
PermanentRepair 1.11< tJt,_< 1.27 Inspection
Threshold
Zone1 and2 0.025_<tf< 0.032 60,000Landings
IntervalandMethod
4D < Average Spacing< 6D ExtVisual= 8,000Landings
MinimumE.D.> 2D
Fasteners throughIongeron andbetween Iongeronare
interferencefitpins(Fsu> 95ksi) except
forfinger
row
PermanentRepair 1.11_<t~/t~ < 1.27 Inspection
Threshold
Zone1 and2 0.025< tf< 0.032 10,000Landings
Interval
andMethod
MinimumE.D.> 2D
Fasteners through Iongeron andbetweenIongeronare
interferencefitpins(Fsu _>95ksi)except
forfinger
row
in shadedareaexcept Inspection
Threshold:
Zone1 and2 forframeIocabons. 20,000landings
Interval andMethod
0.032_<tf externalLFEC= 6,000
0.025>-tf externalUS = 6,000
Fastener Diameter > 5/32 Replacement/reworkThreshold
3.5D_< Average Spacing < 7D 40,000Landings
1.7D_< Average E.D.
1.5D< Minimum E.D.
Fasteners through Iongeron andbetweenIongeronare
interferencefitpins(Fsu> 95ksi) except
forfingerrow
Page B.74 McDonnell

Douglas
Corporabon
propnetary
Information
- UseorDisclosure
of
LEGENDON TITLEPAGE.
rap1
MDC 91K0263
DC-9/MD-80
Frame
2014-T6
Finger ExtDblr
~ , _
Dblr ~ /i:l-~"i+~..]
RepairMatl 1
~k~-" - " ~\
4 + 4-: , t Skin
2014-T6
7075-T6 gongeron
-.- .I-~~:- .-."
~,-~-
--~....
L II
A E .I ,, ,
A /, ~!!~,
Fasteners , [--.--~-~,-r.--
_ .... H
Longeron--.1---
/ - .....
~-"+"1-~
,I tt
Solid /
~-+ + +T: Finger e
~KX__Fram
=~.~,++ --: ,;L ~ Dblr
" "H-I-L+|"I
~,~- ~ _1 A-A
Foreward
Aft
Permanent Repaw 1.11_<tJt~ _<1.27 InspectionThreshold
Zone 1 and 2 0.025< tf < 0.032 60,000Landings
5/32_< Fastener Diameter< 1/4 Inspection
Interval andMethod
4D < AverageSpacing< 6D Ext Visual= 8,000Landings
MinimumE.D. _> 2D
Fasteners through the Iongeron andin shadedareaare
interferencefitpros(Fsu_>95ksl)
PermanentRepair 1.11< tJt~_<1.27 InspectionThreshold
Zone 1 and 2 0.025-<tf< 0.032 10,000Landings
5/32_<Fastener Diameter_< 1/4 InspectionIntervalandMethod
4D < AverageSpacing_< 6D ExtVisual= 4,000Landings
MimmumE D. >__ 2D
Fasteners throughtheIongeron and in shadedareaare
interference fitpros(Fsu> 95 ks0
TemporaryRepair 1.00-<t~/t~_<1.50 InspechonThreshold:
Zone 1 and 2 0.032_<t~ 20,000land=ngs
0.025->tf Inspecboninterval and Method
Fastener D~ameter _> 5/32 extemal LFEC = 6,000
3.5D_< Average Spacing _< 7D externalUS = 6,000
MaximumSpacing< 7.5D Replacement/rework Threshold
1.7D_< Average E.D 40,000 Landings
1.5D _< MinimumE.D.
Fasteners through the Iongeren and in shadedareaare
interferencefitpros(Fsu> 95ksi)
McDonnell
Douglas
Corporabon
propnetary
Informat=on
- UseorD~sclosure
of Page B.75
rap1
MDC 91K0263
Intentionally
LeftBlank
Page B.76 McDonnell

Douglas
Corporation
proprietary
Informabon
- Useor D=sclosure
of
Oct2000 THESE DATA SUBJECTTO RESTRICTIVELEGEND ON TITLE PAGE
rap1
MDC 91K0263
DC-9/MD-80
ExtDblr
Repair Matl + + ~~ il
2024-T3 Longeron I "~" l~ l Skin
2014-T6 L III l
7075-T6 -A-";5; .... A N
++ i ) vII J L
Fasteners
i~ "f T ts "J ll
Longeron-- "-,_
I H
Solid 4--I- ~ -"
+
~t A-A
Forewarcl
Aft
PermanentRepair No existing fastenerlocations =n shadedareaexceptfor Inspection
Threshold:
frameIocattons. 20,000landings
Zone 1 1.11< tJt
s _<1.27 Inspection
Intervaland Method
5/32_< Fastener Diameter_< 1/4 external
visual=
4D <_ AverageSpacing _< 6D extemalLFEC = 15,000
MmtmumSpacing_> 3.5D externalUS = 15,000
MinimumE.D._> 2D
Fastenerrowthrough theIongeron areinterference
fit
pins(Fsu_> 95ks0
Fasteners m betweenIongerons areinterference
fitpros
(Fsu_>95kst)
TemporaryRepair No exisbng fastenerlocations in shadedareaexceptfor Inspection
Threshold.
frameIocabons 20,000landings
Zone 2 1.11_<t~t~_< 1.27 Inspechon
Interval and Method
5/32< Fastener D~ameter < 1/4 external
visual=
4D _< Average Spacing _< 6D externalLFEC= 15,000
MinimumSpacing_> 3.5D externalUS = 15,000
MaximumSpacing_< 6.5D internal
wsual=
MinimumE.D. > 2D internalHFEC= 15,000
40,000Landings
Fastener rowthrough theIongeron areinterference
fit
pros(Fsu_>95ksi)
Fasteners in betweenIongerons areinterferencefitpros
(Fsu_>95ksi)
TemporaryRepair 1 00 < ~t~_<1.50 Inspection
Threshold:
Fastener Diameter >_ 5/32 5,000landings
Zone 1 and 2 3.5D_< Average Spacing _< 7D Inspecbon
Intervaland Method
MaximumSpacing_< 7 5D external
LFEC = 3,000
MinimumE.D.>_ 1.5D external
US = 3,000
Fastener rowthrough theIongeron areinterference
fit Replacement/rework
Threshold
pins(Fsu_>95ksi) 10,000Landings
Fasteners in betweenIongerons areinterference
fitpins
(Fsu_>95ksl)
McDonnell
Douglas
Corporahon
proprietary
Informatton-
UseorDtsclosureof Page B.77
THESE DATA SUBJECTTO RESTRICTIVELEGEND ON TITLE PAGE Oct 2000
rap1
MDC 91K0263
ExtDblr
X~~-- Frame ExtDblr
t Skin

E i
,11 I
= = =
N = =
T ts
-"--
H tf
DblrFinger ~Frame
I J A-A
Forewarcl
q
Aft
Requirements
Permanent
Repair 1.11< ~t,___1.27 Inspection
Threshold
0.025< tr< 0.032 60,000Landings
Zone1 and2 5/32< Fastener Diameter_<1/4 Inspection
Interval
andMethod
Minimum E.D._> 2D
Fasteners through theIongeronandin shadedareaare
interference fitpins (Fsu
>_95ksi)
Permanent
Repair 1.11_<tJt~ _<1.27 Inspection
Threshold
0.025< tf_<0.032 30,000Landings
Zone1 and2 5/32_<Fastener Diameter< 1/4 Inspection
Interval
andMethod
4D _<Average Spacing _< 6D ExtVisual
= 4,000
Landings
MinimumE.D.> 2D
areaare
interference fitpins(Fsu > 95ksi)
Temporary
Repair 1.00_ ~t~__.1.50 Inspection
Threshold:
0.032 < tf 20,000landings
Zone1 and2 0.025>_tf Inspection
IntervalandMethod
Fastener Diameter _> 5/32 externalLFEC= 6,000
3.5D_<Average Spacing_<7D extemalUS = 6,000
Maximum Spacing_< 7.5D Replacement/rework
Threshold
40,000Landings
1.7D_< Average E.D.
1.5D_< Minimum E.D.
areaare
interference fitpins (Fsu
>__95ksi)
PageB.78 McDonnell
Douglas
Corporation
propnetary
InformatJon
- UseorDisclosure
of
LEGENDON TITLEPAGE.
rap1
MDC 91K0263
DC-9/MD-80
2024-T3
Finger ExtDblr
Repair
Matl Dblr"~,=i
2024-T3 f Skin
2014-T6 Longeron....1
7075-T6
.--:..-.-.
_ .,__.
A
E
N
\, =1 I I
| ! | ! =
l
Fasteners Longeron H
,,Jifil
~
A.t ~ tf
Solid ~+ +: !
Finger
Dblr A-A
Foreward
Aft
Quahficattons Maintenance
Requtrements
PermanentRepair Noexisting fastener location inshaded
areaexcept
for Inspection
Threshold
Zone1 and2 IongeronIocattons. 60,000Landings
Interval
andMethod
0.025< tf< 0.032 ExtVisual= 8,000
Land,ngs
5/32_<Fastener D0ameter < 1/4
4D_< Average Spacing _< 6D
Minimum E.D._>2D
Fasteners through Iongeron andbetweenIongeron
are
interferencefitpins(Fsu >_95ksi)except
forfinger
row
Proximtty> 20 inches
PermanentRepair Noexisting fastener Iocabon inshaded
areaexcept
for Inspectton
Threshold
Zone1 and2 IongeronIocattons. 30,000Landings
1.11< tJt, < 1.27 Inspection
Interval
andMethod
0.025_<tf_<0.032 ExtVisual
= 4,000Landings
MmimumE.D.> 2D
are
interferencefitpins(Fsu> 95kst) except
forfinger
row
TemporaryRepair 1.00-<tJt, _<1.50 Inspectton
Threshold:
Zone1 and2 0.032<_tf 20,000landings
0.025_>tf Inspection
IntervalandMethod
Fastener Diameter _> 5/32 externalLFEC= 6,000
3.5D_< Average Spacing _<7D external
US = 6,000
Maxtmum Spacing _< 7.5D Replacement/rework
Threshold
40,000Landings
1 7D _<Average E.D.
1.5D_<Minimum E.D.
are
interferencefitpins (Fsu>_95ksi)
McDonnell
Douglas
Corporabon
propnetary
Informabon
- UseorD~sclosure
of Page B.79
rap1
MDC 91K0263
DC-9/MD-80
2024-T3 ~ ~ Frame
!n
or
UOlr ~ F "j""~: t,
ExtDblr
Repair
Matl ~ ~ : ~ + -I-: , \
2024-T3 ~ i+ +4-i ,I 1~ Skin
,++ ~.: : I
,0,,T
2014-T6 Longeron....~---
"--.-.~:
i+ + +:
---~-;,-:
A
N
-.
E I III
.,,.

!i . ~"
A (,~"-i-+:+
-~ ++.
,,__
R
\I I/T
I ).:.+~l~:l: ,, I ts
z " "I H
Longeron ..... tf
FastenerSSolid t !+~!"
]"~-3-"
"-:~-
t-",, .i
Finger
\ Frame
i~++.Li;q Dblr
A-A
Foreward
Aft
Requirements
PermanentRepair 1.11<_tJts _<1.27 Inspection
Threshold
Zone1 and2 0 025< tf< 0.032 60,000Landings
5/32___Fastener Diameter< 1/4 Inspectton
Interval
andMethod
4D < Average Spacrng _< 6D ExtVisual= 8,000Landings
Minimum E.D._> 2D
are
interference fitpins(Fsu_>95ksl) except
forfinger
row
Proxtmtty 20 inches
PermanentRepair 1.11_<t~/t~ _<1.27 Inspection
Threshold
Zone1 and2 0.025-<tf_<0.032 30,000Landings
5/32< Fastener Diameter< 1/4 Inspection
IntervalandMethod
4D _< Average Spacing< 6D ExtVisual= 4,000Landings
Average E.D.= 2D+_1/16inches
Minimum E.D.> 2D
are
interference fitpros(Fsu_ 95ksi) except
forfinger
row
Temporary
Repair 1.00<__t~/t~ <1.50 Inspection
Threshold:
Zone1 and2 0.032< tf 20,000landings
IntervalandMethod
3.5D< Average Spacing < 7D external
US = 6,000
Threshold
1.7D< Average E.D. 40,000Landings
1.5D_< Minimum E.D.
are
interference fitpins(Fsu> 95ksi) except
forfinger
row
PageB.80 McDonnell
Douglas
Corporat=on
propnetary
Information
- UseorDisclosure
of
Oct2000 THESEDATASUBJECTTO RESTRICTIVE
LEGENDON TITLEPAGE
rap1
MDC 91K0263
ExtDblr
Frame
Finger ~ly--C-_
_~P~ ExtDblr
Dblr
"- /--J+llrl+t.
"- -+ ~+4-:!
"n%~.++-I-i-. I Skin
-- - L,
++.t-: : -I
r ....
Longeron .~--::~. ~:~
E N
A
l!,l
Il
,-; ; ~,---
T J,:,(
13
T t ts
I ta
Longeron F .... H
--t.-----,:-~:-!~/.- tl
~
Finger ~Ik~ Frame
,~.~++.Li
-
iL Dblr
A-A
Foreward
Aft
Requirements
PermanentRepair 1 11_<tJl~ < 1.27 Inspection
Threshold
Zone1 and2 0.025< t~_<0 032 60,000Landings
Interval
andMethod
Maximum Spacing <_ 6.5D
Minimum E.D_> 2D
Fasteners through theIongeron andinshadedareaare
interferencefitpros(Fsu > 95ksi)
Proxtmity> 20inches
PermanentRepair 1.11_<tJt, _<1.27 Inspection
Threshold
Zone1 and2 0.025< tf_<0.032 30,000Landings
5/32_<Fastener DCameter< 1/4 Inspectton
Interval
andMethod
Minimum E.D._> 2D
interferencefitpros (Fsu
> 95ksi)
3 < Proxlmtty < 20inches
TemporaryRepaw 1.00< ~ts _<1.50 Inspection
Threshold:
Zone1 and2 0.032 < tf 20,000landings
0.025_>Lr Inspect0on
IntervalandMethod
3.5D_<Average Spacing _<7D extemalUS = 6,000
Maximum Spacing <_ 7.5D Replacement/rework
Threshold
1.7D< Average E.D 40,000Landings
1.5D< Minimum E.D.
Fasteners through theIongeronandin shaded
areaare
interference fitpins(Fsu > 95ksl)
McDonnell
Douglas
Corporation
propnetary
Information
- UseorD~sclosure
of Page B.83
rap1
MDC 91K0263
Intentionally
LeftBlank
Page B.84 McDonnell

Douglas
Corporation
propnetary
Informatton-
UseorDisclosureof
rap1
MDC 91K0263
DC-9/MD-80
2024-T3
Fingerk~~..~,

,"
Dblr~ 7 !..t~[,+,,)
RepairMatl
2024-T3
~
--,. !:t-++" : \
+++: ..j l ExtDblr
2014-T6 Longeron......."":-:,-
:+ + 4" I
....._. L Skin
A -J,-;"
~ : X IL
7075-T6
.,it
f -~ E~ : :
~"""~~"""" ~- ....
IG
Fasteners Longeron
Solid : ~-~" : /
/ :+++:;I
L.!i,-,t,
t A-A Dblr
Fomward
Aft
Quahficatlons Maintenance
Requirements
PermanentRepair 1.11< ~t,_<1.27 Inspection
Threshold
Zone1 and2 0.025_<tf_<0 032 60,000Landings
Interval
andMethod
4D_<Average Spacing _< 6D ExtVisual= 8,000Landings
MaxImumSpacing< 6.5D
Minimum E.D._> 2D
areaare
interferencefitpins (Fsu> 95ksi)
Proximity 20inches
PermanentRepair 1.11_<Vt~_< 1.27 Inspection
Threshold
Zone1 and2 0.025_ tf<__0.032 30,000Landings
IntervalandMethod
4D_<Average Spacing _< 6D ExtVisual= 4,000Landings
Minimum E.D.>_ 2D
Fasteners through theIongeren andin shaded
areaare
interferencefitpins (Fsu_>95ksi)
Temporary
Threshold:
Zone1 and2 0.032_<tf 20,000landings
0.025
___t~ Inspection
IntervalandMethod
Fastener Diameter > 5/32 extemalLFEC= 6,000
3.5D< Average Spacing < 7D extemalUS = 6,000
Threshold
40,000Landings
1.7D_<Average E.D.
1.5D_<Minimum E.D.
interferencefitpros(Fsu > 95ksi)
McDonnell
Douglas
Corporation
proprietary
Informat=on
- UseorD=sclosure
of Page B.81
rap1
MDC 91 K0263
DC-9/MD-80 =
2024-T3
FingerX.,---C-
-,1+}+
2014-T6 Longeron .... _...., .-t.
:i .... L Skin
:_::--._
A + ......"
..,..]
E
\ ~ ,-
JI I~
H ts
FastenersLongeron
-- 1""- :.,:---:-~- ". "~ .... /
~ ,~, i+ ~ ~ ,, I t,
Solid
I,~-i+ + +: ~ I ~ ~Finger
} A-ADb,r
Fomward
Aft
Requirements
PermanentRepair 1.11_<~t~_< 1.27 Inspection
Threshold
5/32_<Fastener Diameter _<1/4 InspectJon
Interval
andMethod
4D _<Average Spacing _< 6D ExtVisual= 8,000Landings
Max=mum Spacing _< 6.5D
Average E.D.= 2D+_ 1/16inches
Minimum E.D._> 2D
interference fitpins (Fsu>_95ksi)
PermanentRepair 1.11_<tJts < 1.27 Inspection
Threshold
Zone1 and2 0.025< tf_<0.032 30,000Landings
IntervalandMethod
4D<_ Average Spacing _<6D ExtVisual= 4,000Landings
Average E.D.= 2D_+1/16inches
Minimum E.D.>_2D
areaare
interference fitpins (Fsu_>95ksi)
inshadedareaexcept Inspection
Threshold:
1.00< ~ts -<1.50 Inspection
IntervalandMethod
0.032 < tf extemalLFEC= 6,000
0.025_>tf extemalUS = 6,000
Fastener Diameter __.5/32 Replacement/rework
Threshold
3.5D_<Average Spacing <_7D 40,000Landings
Maximum Spacing <__7.5D
1.7D_<Average E.D.
1.5D_<Minimum E.D.
Fasteners through theIongeron andin shadedareaare
interference fitpins (Fsu_>95ksi)
Page B.82 McDonnell

Douglas
Corporabon
proprietary
Informabon
- UseorDisclosure
of
LEGENDON TITLEPAGE.
rap1
MDC 91K0263
DC-9/MD-80
, Frame
2024-T3
Finger ~ ExtDblr
Repair
Matl
2024-T3 I++ +i. Skin
2014-T6 Longeron
~-"j+"
+.tJ
: I .... A j/,t
t
7075-T6
-i v :T!I! ,
Fasteners Longeron--
Solid ;-.".7--;-
Finger N Frame
Dblr
A-A
Foreward
Aft
Quahficattons Maintenance
Requtrements
PermanentRepa0r 1 11_<tJt~ _<1.27 Inspect=on
Threshold
Zone1 and2 0 025< 4 < 0.032 60,000Landings
IntervalandMethod
4D< Average Spacing _<6D ExtVisual= 8,000Landings
Maxtmum Spacing _< 6.5D
Average E D = 2D + 1/16inches
Mm0mumE D. _> 2D
areaare
interferencefitpins(Fsu _>95ks0
Prox0mity > 20inches
PermanentRepatr 1.11< ~/t~ < 1 27 Inspectton
Threshold
Zone1 and2 0.025-<tf_<0 032 30,000Landings
5/32_<Fastener Dtameter<_1/4 Inspechon
IntervalandMethod
4D<_ Average Spacing _<6D ExtVusual= 4,000Landmgs
Maxtmum Spacing _< 6.5D
Average E.D.= 2D4- 1/16inches
Minimum E.D_> 2D
interferencefitpms(Fsu >_95ksl)
3 <Proximtty < 20 inches
TemporaryRepair 100< tJts<--1.50 Inspection
Threshold:
Zone1 and2 0 032< tf 20,000landmgs
0 025_>tr Inspection
IntervalandMethod
3 5D_< Average Spacing _< 7D extemalUS = 6,000
Maxtmum Spacing< 7.5D ReplacementJrework
Threshold
1.7D_<Average ED 40,000Landings
1.5D_<_Minimum E.D.
areaare
mterferencefitpins (Fsu>__95kst)
McDonnell
Douglas
Corporabon
propnetary
Informabon
- UseorDisclosure
of Page B.83
rap1
MDC 91 K0263
Intentionally
LeftBlank
Page B.84 McDonnell

Douglas
Corporation
proprietary
Informat=on
- Useor Disclosure
of
Oct2000 THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE.
rap1
MDC 91K0263
DC-9/MD-80
Aluminum
~ t-"~ ExtDblr
RepairMatl ~++i

, + + + " ~ I Skin
2014-T6 Longeron L
..............
---- Ill ~r
.)-
"
.7 r
A( +++
+++
+++ !5
.\
"
= N
G ""
; ,
III E_ta

// ;I ~ T
Fasteners /onneron -- -+-- ..........:I .... H
Blind + + + ..
++ + i A-A
Foreward
q
All
PermanentRepair
Notavailable
forthis
configuration
TemporaryRepair 1.00_<~t,_<1.50 Inspection

Threshold:
Interval
andMethod
E.D = 1.5D + 1/16 inches external
visual= 3,000
Replacement/rework
Threshold
8,000Landings
McDonnell
Douglas
Corporat}on
proprietary
Information
- UseorDisclosure
of Page B.85
THESE DATA SUBJECTTO RESTRICTIVELEGEND ON TITLE PAGE July 1997
rap1
MDC 91 K0263
ExtDblr
Finger ~ -"-~ ExtDblr

Dblr- / ,~ .~I )
+++ :\
--~ +++ . J I~ Skin
+++ ;I
Longeron --- ~ .......... .~ .... I Ill ,
A f~" "4" ~? ~L
J +++. ,\1 AEN "
A, 1,-i-
+++: :--I
/,J.~+~:~i --
. .- j ~.
_. H
+++ i Finge~
tf
+++ i, Dblr
A-A
+++ i
Foreward
Aft
Quahficabons MaintenanceRequirements
PermanentRepair
Notavailable
forthis
configuration
TemporaryRepair 1.00< tJts-<1.50 Inspection

Threshold:
Zone 1 and 2 3D _< Spacing< 6D Inspection
IntervalandMethod
visual= 3,000
Replacement/rework
Threshold
8,000Landings
Page B.86 McDonnell

Douglas
Corporabon
propnetary
Informabon
- UseorDisclosure
of
July 1997 THESE DATA SUBJECTTO RESTRICTIVELEGEND ON TITLE PAGE.
rdpI
MDC 91K0263
DC-9/MD-80
Frame
Aluminum I,~"
ExtDblr
/ ~,I j
RepairMatl
I ++~-. j s :
2024-T3
2014-T6 Longeron \ ++P:!
-. - --..-: -- . --; ....... i1111 ,r
7075-T6 A-77~:
~:+:T:~, L .,,, , I
A
,I,: liar
Fasteners
/ ) ;"1titi~--"
/
Longeron
Blind t"--"
it ~+~ ":,~
~
A
~F A
rame
Foreward
Aft
Requirements
PermanentRepair
Notavailable
forthis
configuration
TemporaryRepair 1.00___~t,_<1 50 InspecbonThreshold.

FastenerDiameter _> 5/32 3,000landings
IntervalandMethod
E.D.= 1.5D_+ 1/16inches extemalvisual= 3,000
8,000Landings
McDonnell
Douglas
Corporation
propnetary
Informabon
- UseorDisclosure
of Page B.87
rap1
MDC 91 K0263
DC-9/MD-80
Aluminum
Finger
Dblr ~ ~7 !;,~ ExtDblr
Repair2024_T3Ma,l
"~" : ++ +;+:. :~, .~ t
2014-T6 Longeron-.-.~--.""
+ -I-+.,
":--"...... .I- L Skin
/
- +++: N I
Fasteners
~
/i :, .+++:
-L
a
,
G ,,,...
jitlii
,
H ts
Blind Longeron-l""" ,:~
~" -,--
""
:++-14 . r..... t,
L,,,,,,
Finger
i~++ +: ~ I ~
~..;+r-,+t ) A-A Dblr
Foreward
Aft
Requirements
Permanent
Repair
Notavailable
forthis
configuration
Temporary
Threshold:
FastenerDiameter
>_5/32 3,000landings
Zone1 and2 3D_<Spacing _<6D Inspection
Interval
andMethod
E.D.= 1.5D_+1/16inches extemal
visual
= 3,000
Replacement/rework
Threshold
8,000Landings
Page B.88 McDonnell

Douglas
Corporabon
propnetary
Information
- UseorDisclosure
of
LEGENDON TITLEPAGE
-r
MDC 91K0263
DC-9/MD-80
Aluminum Lit Frame
Finger ~ ExtDblr
Dblr~ / +~ll+a"
Repair
Matl :%+ +: : \
2024-T3 "~, il++i . Skin
2014-T6 Longeron.... ,~++ ~ :/ L
~.."
.-r.".-.-
:-;
:-"
-";-~
-"
7075-T6 ,~ E
A./~_+~+ +4-
f~,!++:4- :~1 N
(,~++! :~,_ G
/ )_~
++:1:it T
Fasteners Longeron
-"~"--"
~4-":-::/.
_.._"
:,_:._..: H
Blind / t, i
++ i Finger ~,~Frame
I
:,++-:
~+j-,+j
Dblr
A-A
Foreward
Aft
Requnrements
Permanent
Repa0r
Notavailable
forthis
configuration
Temporary
Repair 1.00
_<~t~_<.1.50 Inspection
Threshold:
Fastener
Diameter_>5/32 3,000landings
Zone1 and2 3D_<Spacing_<6D Inspection
Interval
andMethod
visual
= 3,000
Replacement/rework
Threshold
8,000Landings
Page B.89
McDonnell
Douglas
Corporation
propnetary
Information
- UseorDtsclosure
of
LEGENDON TITLEPAGE July 1997
rap1
MDC 91K0263
DC-9/MD-80
SldnMatl Skin Ext Dblr
Aluminum
Finger - -
Dblr ~~
Repair
Matl ExtDblr
2024-T3 7~c-T- +++: , J /
2014-T6 Longeron~~" ...---:,-.].... L Skin
7075-T6 ,-T"+"~--:~,1
A. l-I A
E
+++: \ N
41 ,~" +++ : "~ ,-
//.--.,
+~~+.+i t
i(-"
ii"
,Jif,
| n u I n
Longer=
-- ~---~-..
~--:"
---~ -~-.... H
-:.,-
Fasteners
Blind (z ++% ~ te
~N,,Finger
A-A Dblr
Aft
Requirements
Permanent
Repair
Notavailable
forthis
configuration
Temporary
Repair 1.00
_<toJt~
-<1.50 Inspection
Threshold:
FastenerDmmeter_> 5/32 3,000landings
Zone1 and2 3D_<Spacing_<6D Inspection
Interval
andMethod
v0sual
= 3,000
Replacement/rework
Threshold
8,000Landings
Page B.90 McDonnell

Douglas
Corporation
propnetary
Information
- UseorDisclosure
of
LEGENDON TITLEPAGE.
MDC 91K0263
DC-9/MD-80
SkinMatl Skin Ext Dblr Frame
Aluminum
Finger ~"- -~
ExtDblr
Dblr
"~ ,/.i.~
,lrHt
i
Repair
Matl
~h" 1,+
+ +4": . Skin
2024-T3 ++t.~ : I
2014-T6 Longeron....~--~
.--...:.:.
~.",-~.
-,.....
7075-T6
A f-i-l-+ 4-:-(-
~ A NE II
, o
T ts
j
--t .z.-.-:._1.
Fasteners kongeron -:,_~..... N tf
Blind -::
f
c~-j ++ : ,j
,+,++~-i
;L
Finger
Dblr
""H-I-t-F-I
"* )
A-A
Foreward
Aft
Requtrements
Permanent
Repair
Notavailable
forthts
configuration
Temporary
Repair 1 00_<toJt
s_<1.50 Inspection
Threshold:
FastenerDmmeter> 5/32 3,000landings
Zone1 and2 3D_< Spacing< 6D Inspection
Interval
andMethod
E.D.= 1.5D+ 1/16inches externalwsual= 3,000
Replacement/rework
Threshold
8,000Landings
McDonnell
Douglas
Corporation
propnetary
Informatton
- UseorDtsclosure
of PageB.91
LEGENDON TITLEPAGE. July1997
rap1
MDC 91K0263
Intentionally
LeftBlank
PageB.92 McDonnell
Douglas
Corporation
proprietary
Information
- UseorDisclosure
of
rap1
MDC 91K0263
Repair at the corners of all the door jamb
Reference
SRMandServiceReworkdrawings
of the repairat the corners
of allthedoor-jamb
fordamage
tolerancerequirements.
Requirements
Reference
SRMfigurein chapter
53andService Reference
SRMfigurein chapter
53
Rework
drawmg
forthequalifications
oftherepair. andService
Rework
drawingforthe
maintenance
requirements.
McDonnell
Douglas
Corporatton
propnetary
Informatton
- UseorDisclosure
of Page B.93
rap1
MDC 91K0263
DC-9/MD-80 Skinrepair
fortheDoorJambedges(awayfromthecomers)
SkinMatl
2024-T3
2014-T6
DOOR JAMB FRAME ..... I
Repair
Matl ~~
2024-T3 I R 50

I /
4- 41~-4- 4-
0 06 GAPTYP ,l + 4 4
Fasteners
~
Solid ---"
14"-r4
-F-3;21 EXTDOUBLER t
tdISext.doubler
thickness FILLER///++ I,,+
+ *+
-~ (
R10 -~4
tsisskinthickness
/ "4"-I1-1-
-#"1"
,-4-
.~l + +
REWORK TRIM ON /
DAMAGED SKIN I
I
DOOR JAMB TRIM ~ j

I
I I
/
!
Qualifications Maintenance Requirements

1.0"radius minimum
forcut-out crack
area. InspectionThreshold
PermanentRepair Crack< 2 inch 28,000Landings
Zone1 and 2 1.11_<t~/t~_<1.27 Inspection
interval:
Onlyskinrequirescutout. 20,000Landings
Repairmaynotextend beyondthetangent
pointofthe Inspectionmethod:
doorcomer. Per SRM 51-10-5C
Largest repairdoubler mayextendfromonecomer
tangentto nextcomertangent.
Doubler mustextend threerowsminimum beyondthe
cutout ofdamage.
Use2024-T3 withthicknessasrequired
forfiller
Minimum E.D._> 2D
6/32< Fastener Diameter< 8/32
Fastenerthroughframe
orintercostal
isinterference
fit
pin(Fsu _>95ksi)
Proximity> 20inches
Page B.94 McDonnell

Douglas
Corporation
pmpnetary
Information
- UseorD~sclosure
of
LEGENDON TITLEPAGE.
rap1
MDC 91 K0263
SkinMatl
2024-T3
2014-T6
Repair
Matl
2024-T3 DOOR JAMB FRAME -..... t "~3
Fasteners ~Ti+
Sohd
006 GAPTYP ~ +~,~ ~ ~
tdisext.doubler
thickness --~---~ ;~ +:~
FILLER-.
---
+,,__~_=~,,
+++++
EXTDOUBLER
tsisskinthickness
Rio-17;4+ * *
/-
REWORK TRIM ON
DAMAGED SKIN
DOOR JAMB TRIM ~

F

1.0"radius mintmumforcut-out crack
area. InspectionThreshold
PermanentRepair Crack_<2 inch 14,000Landings
Zone1 and 2 1.11<td/ ts<__
1.27 Inspection
interval.
Onlyskinrequtres cutout. 8,000Landings
Repairmaynotextend beyond thetangent
pomtof the Inspectionmethod:
doorcomer. Per SRM 51-10-5C
Largest repair doubler mayextend fromonecomer
tangenttonextcomer tangent.
Doubler mustextendthreerowsmmtmumbeyondthe
cutoutof damage.
Use2024-T3 withthickness asrequired
forfiller
Minimum E.D_> 2D
Fastenerthroughframe ortntercostal
tsinterference
fit
pin(Fsu_>95ksi)
3 <Proximtty< 20inches
McDonnell
Douglas
Corporation
propnetary
Information
- UseorDisclosure
of Page B.95
rap1
MDC 91 K0263
SkinMatl
2024-T3
2014-1"6
Repair
Matl
2024-T3 DOOR JAMB FRAME ~ ~ =
/ SKIN
,,
Fasteners
Blind -~.i-~
-~
0 06 GAPTYP 4-+14--I.
"~ -_ I
tdisext.doubler
thickness ~ ;=2~ i -F .
tsisskinthickness
FILLER
R10
f
+ .~,+ *
Tr=~ i + 4
++l.~.~
4. 4-t-I--I.
+ .~z,.,
%
l
I
REWORKTRIM
DAMAGED SKIN
ON
DOOR JAMB TRIM 3 , /

I
I
I
I
I
I
Requirements
1.0"radiusminimumforcut-out crack
area. Inspection
Threshold
TemporaryRepair Crack_<2 inch 3,000Landings
Zone1 and2 1.11
_<td/ ts_<1.27 Inspection
intervalandmethod
Onlyskinrequirescutout. External
visual
= 3,000
Repairmaynotextend beyondthetangentpointofthe Replacement/reworkThreshold
doorcomer. 8,000landings
Largestrepair doublermayextend fromonecomer
tangentto nextcomertangent
Doubler mustextendthreerowsminimum beyondthe
cutoutof damage.
Use2024-T3withthickness asrequired
forfiller
3.5D<__Average Spacing_<7D
MinimumE.D.>__1.5D
UseNAS21141-6 orequivalent protruding
highstrength
blinddvets.Donotcountersink holes.
Page B.96 McDonnell

Douglas
Corporabon
propnetary
Information
- UseorDisclosure
of
LEGENDON TITLEPAGE
rap1
MDC 91K0263
SkinMatl
2024-T3
2014-T6
__J__
Repair
Matl DOOR JAMB FRAME..... I
2024-T3 ~ "~ 1" SKIN
, R 5TYP
Fasteners 0 O6 GAPTYP .@
+~-@14
4 -@4 :+
,+
Solid
~:-~I*-@" + *-- EXT DOUBLER \
tdisext.doubler
thickness ~J/4-I=+-@"~ *
t,isext.
tnpler
thickness FILLERj /1 .~ ,+ -@ +
,l,;
R 1 0 MIN.___/~=~l* .@ .@ + .......... \
t~r.bdouWertS
ISskin
thlckneSSis
production
internal %- r^ i i ~rLEr~
.-/+ -@114 .@ /
/I 4 +l + + 4 4 ~
aluminumdoubler
REWORK TRIM ON/i ~ :
DAMAGED SKIN ~ /~
DOORJAMB TRIM-----,
Qualifications Mamtenance Requirements

1.0"radius minimum forcut-out
crackarea. InspectionThreshold
PermanentRepair Crack_<2 inch 28.000Landings
Zone1 and2 1.11
_<t~/ t~< 1.27 Inspection
interval:
1.11
_<t~/tjambdoubler --<1.27 20,000Landings
Skinandjambdoubler requtres
cutout. Inspectionmethod:
Repairmaynotextend beyond
thetangent pomtofthe Per SRM 51-10-5C
doorcomer.
Largest repair doubler mayextendfromonecomer
tangentto nextcomertangent.
Tnpler mustextend threerowsminimum beyondthe
cutout of damage.
Doubler mustextend a mmtmumof onefastener row
beyondthetripler.
Use2024-1-3withthickness asrequired
forfillers.
MaxtmumSpacmg< 6.5D
Minimum E.D.>_ 2D
Fastenerthrough frame orintercostal
tsinterference
fit
pm(Fsu> 95ksi)
Proximity> 20inches
McDonnell
Douglas
Corporation
propnetary
Information
- UseorD=sclosure
of Page B.97
rap1
MDC 91K0263
SkinMatl
2024-T3
2014-T6
..---L__
DOOR JAMB FRAME ~ ,
Repair
Matl ~ SKIN
2024-T3 ~
, R 5 TYP ~..~
/
@@1@4-@
806 GAPTYP
Fasteners ~-=~l (T DOUBLER \
Solid =-= + + + + *" EXTDOUBLER
//4-it+ 4 4 4.
t~isext.doubler
thickness +-r,11+ 4 .~ +
FILLER//
R1 0 MIN ~/~+~ : : : ~ EXT~TRIPLER /
tstt
ISis
ext.skintdplerthicknessthickness
J +,+ -~+
tjambdoubler
isproduction
intemal
REYM:)RKTRIM ON / ~ + /
aluminumdoubler
DAMAGED SKIN
~
DOOR JAMB TRIM ~ L
1.0"radius minimumforcut-out crack
area. Inspection
Threshold
PermanentRepair Crack_<2 inch 14,000Landings
Zone1 and2 1.11_<t~/t~_< 1.27 Inspecbon
interval:
1.11_<tt/ tj=,
baou~-<1.27 8,000Landings
Skinandjambdoubler requirescutout. Inspectionmethod:
Repair maynotextend beyondthetangentpoint
of the Per SRM 51-10-5C
doorcomer.
Largest repair doublermayextend fromonecomer
tangent to nextcomertangent
Tripler mustextend threerowsminimum beyondthe
cutout of damage.
Doubler mustextend a mimmumof onefastenerrow
beyond thetdpler.
Use2024-T3 withthicknessasrequired
forfillers.
Minimum E.D._> 2D
_<7/32
Fastenerthroughframeorintercostal
isinterference
fit
pin(Fsu> 95ksi)
3 <Proximity< 20 inches
PageB.98 McDonnell
Douglas
Corporation
propnetary
Information
- UseorDisclosure
of
Oct2000 THESEDATASUBJECTTO RESTRICTIVE
LEGENDON TITLEPAGE.
rap1
MDC 91K0263
SkinMatl
2024-T3
2014-T6
Repatr
Matl DOOR JAMB FRAME ~ ~
2024-T3 ~.~ ~-~/ SKIN
, R 5 TYP
Fasteners O06GAPTYP : :1: : : :

Bhnd ~:~l +4 + *"- EXT DOUBLER \
t~lsext
doubler thickness FILLER-//
+T,ll~+4~ +
ttisext.
tripler
thickness R 1 O MIN ~-=J +
tsisskinthickness .1"7++l + + , ~ EXT TRIPLER /
tjambdouble
r ISproduction
internal ~ +~"4 ~
aluminum doubler REVVORKTRIMON j ~ +.
/
!
t
Requirements
1.0"radiusminimumforcut-out crackarea. Inspection
Threshold
TemporaryRepair Crack< 2 inch 3,000Landings
Zone1 and2 1.11
_<td/t,_< 1.27 Inspection
intervalandmethod
1.11
_<t~/t~amb
double
,--<1.27 External
visual= 3,000
Skinandjambdoubler requires
cutout. Replacement/rework
Threshold
Repairmaynotextend beyondthetangentpointof the 8,000landings
doorcomer.
Largestrepair doublermayextend fromonecorner
tangenttonextcomertangent.
Tdplermustextend threerowsminimum beyondthe
cutoutof damage.
Doubler mustextend a minimumof onefastenerrow
beyondthetnppler
Use2024-T3w~ththicknessasrequiredforfillers.
3.5D< Average Spacing< 7D
MinimumE.D.> 2D
UseNAS21141-6 orequivalentprotrudingheadhigh
strengthblindnvets. Donotcountersink
holes.
McDonnell
Douglas
Corporation
propnetary
Information
- UseorDisclosure
of Page B.99
rap1
MDC 91 K0263
DC-9/MD-80 PressureBulkhead
WebRepair
WebMatl
2024-T3 Web
2014-T6 Web /
A-- Finger
Dblr
\ /
Repair
Marl f
/" ~J~~S \
2024-T3 4 / -
(+ ++*-~ + +1. +++"
2014-T6 ++P+++++ "f- "1" -f
~, ~++~ ~_~_1 + ~.~.~C. =
<=JtOb,
r_
7075-T6 ] ~. +++,~----.~+++ E /~ .
+++~ I I;+++ L .//
~-"}""{-
+I d""}"
+ -i-~ f ""
~,"PIII
~ lltl"
/~
Fasteners ~ ++++++++ +++j + - -
Solid "
ktf-
-~ +k~p
+ktj~
~k~j^
+kj-~f
t~isdoublerthickness \
t~iswebthickness SECTIONA-A
G is fingerdoubler
thickness A~

Repairis minimum 10"awayfromPSEor AD areaand InspectionThreshold
Permanent
Repair doorjambor system cutout. 60,000Landings
Onlywebrequires cutout. Inspection
interval:
1.11< td/ t,< 1.27 Visual: 8,000
0.25_<tf< 0.032" Ifweb=snotvisible,
use
4D _< AverageSpacing _< 6D LFEC= 15,000
MaximumSpacing< 6.5D US = 15,000
MinimumE.D.> 2D
5/32< Fastener Diameter_<114
Proximity> 20inches
Repairis minimum 10"awayfromPSEor AD areaand InspectionThreshold:

Permanent
Repair doorjamborsystem cutout. 10,000 Landings
(2014-T6web)
Onlywebrequires cutout. 30,000Landings (2024-T3web)
1.11<t~It,~ 1.27 Inspection
interval:
0.25< tf< 0.032" Visual: 4,000(2014-T6
web)
4D _< AverageSpacing_<6D Visual: 4,000(2024-T3
web)
MaximumSpacing _< 6.5D Ifwebisnotvisible,
use
Minimum E.D.>_ 2D LFEC= 6,000(2014-T6 web)
5/32~ Fastener Diameter
~ 1/4 US = 6,000(2014-T6web)
3 <Proximity< 20inches LFEC= 15,000(2024-T3 web)
US = 15,000(2024-T3web)
Repairis minimum 10"awayfromPSEor AD areaand Inspection

Threshold
Temporary
Onlywebrequires cutout. Inspecbon
interval:
1.00 _<td
/ tw_<
1.50 LFEC= 6,000
tt_<0.025" US = 6,000
tt > 0.032" Replacement/rework
Threshold
3.5D_< Average Spacing< 7D 40,000 landings.
Minimum E.D.> 1.5D
Fastener Diameter> 5/32
Page B. 100 McDonnell

Douglas
Corporation
propnetary
Information
- UseorD=sclosure
of
LEGENDON TITLEPAGE.
rap1
MDC 91K0263
DC-9/MD-80 PressureBulkheadWeb Repair
Web Matl
2024-1"3
2014-T6 Web
Web
A FingerDblr .,-
Stiffener ",~
Repair2024_T3Matl ~~/" f$~#~~/~.//".,J~,~ \ "\,~-t

2014-T6 /""--/+
(
+ + +++1-~
+ .., 1
.i"--+++-
++"-~, // --~--~,
-~.
7075-T6 j ~ t-h++++++ +++ --
+ + + + + + I_+ -t- + + ~+. I\ Ex/t Obir _.,.
~ ~----1+++
+++l Y 7""-
I +++1
+++ I ~ //~ "
\ i~~i+++1 -~ i+++ /~ / " ,

"~- ~
td--i-t J + "t"+
Fasteners c-~~ * + ~+++
=-+-+- J ---f
+ ~"
++++ +
I .~1~+++ + ~+
c--" t
Solid (+ L+++++++ +++> +~, ---~"
-~--+ ~ ++++~+++ +-"-- t - F--
t , -.
tdis doublerthickness \ ,,
t~ is webthickness \./
tfisfingerthickness ,~
SECTION A-A
Stiffener
Repairis minimum10" away from PSE or AD area and InspectionThreshold
PermanentRepair doorjambor systemcutout. 60,000Landings
1.11< td/ tw< 1.27 Inspection
interval
0.25_<t~_<0.032" Visual. 8,000
4D < AverageSpacing< 6D Ifwebisnotvisible,
use
MaximumSpacing_< 6 5D LFEC = 15,000
MinimumE.D _> 2D US = 15,000
5/32_< FastenerDiameter
< 1/4
Fastenerrowthroughstiffener
isinterference-fit
pin
(Fsu> 95 ksl)
Repairis minimum10" away from PSE orAD area and Inspection

Threshold:
PermanentRepair doorjambor systemcutout. 10,000Landings(2014-T6web)
1.11_<td/ t~<__1.27 30,000Landings(2024-T3web)
0.25_<tr< 0.032" InspectJon
interval
4D _< AverageSpacing< 6D Visual: 4,000(2014-T6
web)
MaximumSpacing<_ 6.5D Visual" 4,000(2024oT3
web)
MinimumE.D. > 2D Ifwebisnotvisible,use
5/32_< Fastener D=ameter< 1/4 LFEC = 6,000(2014-T6web)
Fastenerrowthrough stiffener
Jsinterference-fit
pin US = 6,000(2014-T6web)
(Fsu_>95ksl) LFEC = 15,000(2024-T3web)
3 <Proximity < 20 inches US = 15,000(2024-T3web)
Repairis minimum10" away from PSE orAD area and InspectionThreshold

TemporaryRepair doorjambor systemcutout. 20,000Landings
1.00
_<t~/ t~_<1.50 Inspection
interval
tt-<0.025" LFEC = 6,000
t~_>0 032" US = 6,000
3.5D _< AverageSpacing< 7D Replacement/rework
Threshold
MaximumSpacing< 7.5D 40,000landings.
MinimumE.D.>_ 1 5D
Fastener Diameter
_> 5/32
Fastenerrowthroughstiffener
is interference-fit
pin
(Fsu> 95 ksi)
McDonnell
Douglas
Corporation
propnetary
Information
- UseorDisclosure
of Page B.101
THESE DATA SUBJECTTO RESTRICTIVELEGEND ON TITLE PAGE. Oct2000
rap1
MDC 91K0263
DC-9/MD-80 Pressure
Bulkhead
WebRepair
WebMatl
2024-T3 ~Veb
2014-T6 Web
\ A-,~~
Repair
Matl ~ \\
2024-T3 / "+~ + -~ + + + +++" /
2014-T6 -= ++"~++ +++++ ~ iExt
7075-T6 , -"- ~ .....
~+ ++ "Oblr
.-J \.
1 +-+ +++ J// i ~"
--~+1 ~P = "i-+ "f-~ \:i
"~" "~ -- V_ .....f +-f
/ -P--- +-~ + + + +-f-j-
; +~-m+ +-t-+ + +++ /
Fasteners i + ~ + + + + + * +++~ I
Solid / i
\ l
t~isdoubler
thickness "\ /
t~iswebthickness ~ -~-~" SECTION A-A
A~
Repairis m,mmum10" awayfromPSEorADareaand Inspection
Threshold
Permanent
Fastenersof theouterrowmustbeinnewholes. Inspection
Lntcrval:
1.11< t~/t,< 1.27 LFEC= 6,000(2014-T6web)
4D _< Average Spacing
< 6D US = 6,000(2014-T6
web)
MaximumSpacing< 6.5D LFEC= 15,000(2024-T3web)
MmtmumE.D._> 2D US = 15,000(2024-T3
web)
< 1/4
Fastenerrowthrough
stiffener
isinterference-fit
pin
(Fsu_>95ksi)
Proximity> 3 inches
Repairis minimum 10"awayfromPSEorADareaand InspectionThreshold

Temporary
Repa=r doorjambor system cutout. 20,000Landings
1.00
<t~/ t~< 1.50 Inspection
interval
3.5D< Average Spacing_< 7D LFEC= 6,000
Maximum Spacing _< 7.5D US = 6,000
Minimum E.D >_ 1.5D Replacement/rework
Threshold
5/32_< FastenerDiameter 40,000 landings.
Fastener
rowthroughstiffener
isinterference-fit
pin
(Fsu
>_95ksi)

Douglas
Corporation
propnetary
Informat=on
- UseorDisclosure
of
LEGENDON TITLEPAGE.
rap1
MDC 91K0263
DC-9/MD-80 UpperCargoDoor
Skin
SkmMatl Skin
2014-T6
2024-T3
Repatr
Matl
2024-T3
2014-T6
7075-T6
~~ ++ +++++
+ +++++++++++++ t __ -..__
~ "
Fasteners
Solid
~A ~ ~
LENGTH D,-
Forward ExtDblr A-A
Aft
Quahficattons MaintenanceRequirements
Permanent
Repair No existingfastenerIocattons
m shaded
areaexcept
for Inspection
Threshold"
frameIocabons. 60,000landmgs
1.11_<td/ts_<127 Inspection
Interval
andMethod
5/32"< Fastener Dtameter<8/32" external
visual=
4D < Average Spacmg_< 6D extLFEC= 6,000(2014-T6 skin)
MaximumSpacing< 6.5D extUS = 6,000(2014-T6
skin)
MmtmumE.D.>_ 2D ext.LFEC= 15,000(2024-T3skin)
Proxlmtty> 20 inches extUS = 15,000(2024-T3skm)
FastenerrowthroughIongeronisinterference-fit
pm
(Fsu> 95ksi)
PermanentRepaw No existingfastenerIocattons
m shaded
Threshold:
frameiocabons. 20,000 landings
1.11_<t~/t~< 127 Inspection
Interval
andMethod
5/32"_<FastenerD~ameter_<8/32" externalwsual=
4D _< AverageSpacmg_< 6D ext.LFEC= 6,000(2014-T6
skin)
MaximumSpacmg_< 6.5D ext.US = 6,000(2014-T6
skin)
Minimum E.D.>_ 2D ext.LFEC= 15,000 (2024-T3
skm)
3 <Proxlmtty< 20inches extUS = 15,000(2024-T3skm)
FastenerrowthroughIongerontsinterference-fit
pin
(Fsu>_95ksi)
Temporary
Repatr 1.00
_<tJt,_<1.50 Inspecbon
Threshold.
Fastener
Dtameter>__5/32 20,000landings
3.5D_< Spacing < 6D Inspection
IntervalandMethod
MinimumE.D.> 1.5D external
US = 6,000
Replacement/rework
Threshold
Fastener
rowthroughIongeron~sinterference-fit
pin
40,000Landmgs
(Fsu
>_95kst)
McDonnell
Douglas
Corporation
proprietary
Information
- Use or D0sclosure
of Page B. 103
rap1
MDC 91 K0263
DC-9/MD-80 Upper Cargo Door

SkinMat"l
2014-T6 Ext
2024-T3
~, ~. Ex
RepairMatl
Jt
~" -t"
i I t Db
2024-T3 -I-
+
2014-T6 +
L II Sk,
,tl.
7075-T6 ++
~ ~E
I
II ~
J
Fastener ++~ +
Solid +~+ ~t
Ski L__ ,6,-
Forwa

PermanentRepair No existing fastenerlocations in shadedareaexceptfor Inspect]onThreshold:
1.11_<td/ts < 1.27 InspectionIntervaland Method
5/32"_<Fastener Diameter_<8/32" externalvisual=
4D _< Average Spacing_< 6D ext. LFEC = 6,000(2014-T6skin)
MaximumSpacing_< 6.5D ext.US = 6,000(2014-T6 skin)
MinimumE.D.>__2D ext. LFEC = 15,000(2024-T3skm)
Proximity > 20 inches ext.US = 15,000(2024-T3 skin)
Fastenerrowthrough Iongeronisinterference-fit
pin
(Fsu>__95ksi)
PermanentRepair No existing fastenerlocations in shadedareaexceptfor InspectionThreshold:
framelocations. 20,000 landmgs
1.11_<t~/ ts_< 1.27 Inspect]onInterval andMethod
5/32"_< Fastener Diameter<_ 8/32" externalvisual=
4D < AverageSpacing< 6D ext.LFEC= 6,000(2014-T6 skin)
MaximumSpacing_< 6.5D ext.US = 6,000(2014-T6 skin)
MinimumE.D._> 2D ext.LFEC= 15,000(2024-T3 skin)
3 <Proximity < 20 inches ext.US = 15,000(2024-T3 skin)
Fastenerrowthrough Iongeronis interference-fit
pin
(Fsu_>95ksi)
TemporaryRepair 1.00< ~t~< 1.50 InspectionThreshold:
Fastener Diameter > 5/32" 20,000landings
3.5D < Spacing< 7D InspectionInterval and Method
MaximumSpacing< 7.5D extemalLFEC = 6,000
MinimumE.D. >_ 1.5D external US = 6,000
Fastenerrowthrough Iongeronis interference-fit
pm ReplacementJrework Threshold
(Fsu>_95ksi) 40,000 Landings

Douglas
Corporation
proprietary
Informabon
- UseorDtsclosure
of
Oct 2000 THESE DATA SUBJECTTO RESTRICTIVELEGEND ON TITLE PAGE.
rap1
MDC 91K0263
SkinMatl A-~--
2024-T3 Skin,,,,,
"~
Skin ,~
2014-T6
Repair
Matl
i Finger --1-
=~"~=~+-=-=~
=+
2024-T3
2014-T6 + ++++++ +++++++ ~ Dblr I i.=
7075-T6 i~.....
FingerDblr
A-~=---
~ .~_._.----
Ex~Dblr
~ .~._ ta
Fasteners LENGTH ~ A-A

Solid Forward
Requirements
Permanent
Repair Noexisting fastenerlocations
inshaded
areaexcept
for Inspection
Threshold
0.025"
_<tf_<0 032" Inspection
Interval
andMethod
1.11_<tdIt,_< 1.27 ExtVisual= 8,000Landings
5/32"_<Fastener Diameter
_<8/32"
4D_< Average Spacing_<6D
Minimum E.D.>_ 2D
Fastener rowthrough Iongeron
isinterference-fit
pin
(Fsu_>95ksi)
Permanent
Repair Noexisting fastenerlocations
inshaded
areaexcept
for Inspection
Threshold
(2014-T6
skin)
0.025"< tf_<0.032" 30,000Landings
(2024-T3
skin)
1.11_<td/ts < 1.27 Inspection
interval
andMethod
5/32"_<Fastener Diameter
_<8/32" Ext.Visual
= 4,000
(2014-T6
skin)
4D_< Average Spacing_<6D Ext.Visual
= 4,000
(2024-T3
skin)
Minimum E.D.>_ 2D
3 <Proximity < 20inches
Fastener rowthrough Iongeron
isinterference-fit
pin
(Fsu>_95ksi)
Temporary
Repair Anyexisting fastenerlocations
inshaded
areaexcept Inspection
Threshold:
forframe locations. 20,000landings
1.00<_tJt~ _<1.50 Inspection
IntervalandMethod
t~_>0.032" externalLFEC= 6,000
tf<_0.025" external
US= 6,000
Fastener Diameter> 5/32" Replacement/rework
Threshold
3.5D< Spacing _<7D 40,000Landings
MimmumE.D._> 1.5D
McDonnell
Douglas
CorporatJon
pmpnetary
Information
- UseorD=sclosure
of Page B. 105
rap1
MDC 91K0263
SkinMarl
2014-T6
Ext.
2024-T3 Finger Ext.
Dblr Skin Di,Ir
Repair
Mat12014.T6
I ":%:~
~~ ~+
. kk~ I I
I
,o,5-T6 ~-N +++
~-~+ + I J I ,I
c,=+++
...+ + pR I I I I
.--"
- +++
% ~--++. ( ~ LENGTH
FlngerDblr
Fasteners -~-+ +
~+-~ ,-
Solid "%* +++
.~FI-~, ~;~ + ,) I
Sk~
Forward
I -=
Aft
Qualifications Mamtenance
Requtrements
Permanent
Repair Noexisting fastenerlocations Jnshadedareaexceptfor Inspection
Threshold
0.025"
< t~_<0.032" Inspectton
Interval
andMethod
1.11<td/ t~< 1.27 ExtVtsual=8,000Landmgs
5/32"_<Fastener Diameter< 8/32"
4D _< AverageSpacing _ 6D
MaximumSpacmg< 6.5D
Minimum E.D.> 2D
Proximity> 20inches
Fastenerrowthrough Iongeron ismterference-fit
pm
Permanent
Repair Noexisting fastenerlocations inshadedareaexceptfor Inspection
Threshold
framelocations. 10,000Landmgs(2014-T6
skin)
0.025"
_<tf_<0.032" 30,000Landings(2024-T3
skin)
1.11_<td/t~_<1.27 Inspection
Interval
andMethod
5/32"< Fastener Diameter_<8/32" Ext.Vtsual
= 4,000(2014-T6
skin)
4D _<Average Spacing < 6D Ext.Visual
= 4,000(2024-T3
skin)
Minimum E.D._> 2D
3 <Proximity< 20 inches
Fastenerrowthrough Iongeron tsinterference-fit
pin
Temporary
Repair Anyexisting fastener Iocattons m shaded
areaexcept Inspection
Threshold:
forframe Iocabons. 20,000landings
1.00<_~t~_<1.50 Inspection
IntervalandMethod
tf> 0.032" externalLFEC= 6,000
tf< 0.025" external
US = 6,000
Fastener
Dtameter _>5/32 Replacement/rework
Threshold
3.5D_< Spacmg _<7D 40,000Landings
Minimum E.D.>_ 1.5D
PageB. 106 McDonnell

Douglas
Corporat=on
propnetary
Informatton-
UseorD~sclosure
of
LEGENDON TITLEPAGE.
rap1
MDC 91K0263
SkinMatl Skin
Skin
2014-T6
2024-T3
Repair
Matl
2024-T3
2014-T6
7075-T6 + +++++ + +++++++
+++++++ +++++++
Fastenem
Blind t~
/
Forward ExtDblr A-A
Aft
Requirements
Permanent
Repair
Notavadable
forthis
configuration
Temporary
Repair 1.00
_<~t,_<1.50 Inspection
Threshold:
FastenerDiameter
> 5/32" 3,000landings
3.5D< Spacing< 7D Inspecbon
Interval
andMethod
MaximumSpacing< 7.5D External
visual
= 3,000
MinimumE.D.>_1.5D Replacement/rework
Threshold
8,000Landings
McDonnell
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Information
- Useor D~sclosure
of Page B. 107
THESE DATA SUBJECT TO RESTRICTIVE LEGEND ON TITLE PAGE. Oct 2000
rap1
MDC 91K0263
SkinMat"l
2014-T6 ExtDblr
2024-T3
--- ~i Ext
RepairMatl
2024-T3
ir ~
+
.+
,
l Dbl
r
2014-T6
7075-T6

+ ,__1L III skin

~
III
" 8
Fastener ~+~ +
Blind +~+ I
skin ~ A-A
FWD
PermanentRepair
Notavailable
forthis
configuration
TemporaryRepair 1.00
_<tJt~_<1.50 Inspection
Threshold"
FastenerDiameter
_> 5/32" 3,000landings
3.5D_< Spacing
<_ 7D Inspection
Interval
and Method
MaximumSpacing_< 7.5D External
visual= 3,000
MinimumE.D. > 1 5D Replacement/rework
Threshold
8,000Landings

Douglas
Corporabon
propnetary
Informal]on
- UseorDisclosureof
rap1
MDC 91K0263
SkinMatl A..~-.
2024-T3 Skin
2014-T6 Skin ~
tf
RepairMatl
2024-T3 T4-++4-4--~ ~ ~ ~ ~ ~. L..--""
Dblr
2014-T6 j 4-+-I- 4-4--~++4-++++
-I-
~. Finger
7075-T6
] Dblr
A-~--
Fasteners LENGTH ~ A-A
Blind Forward
PermanentRepair
Notavailable
forthis
configuration
TemporaryRepair 1.00< tJt,_<1.50 Inspection

Threshold:
FastenerDiameter> 5/32" 3,000landings
3.5D< Spacing< 7D Inspection
Interval
andMethod
visual= 3,000
MinimumE.D._> 1.5D Replacement/rework
Threshold
8,000Landings
McDonnell
Douglas
Corporahon
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Informahon
- Useor Disclosure
of PageB. 109
THESE DATA SUBJECTTO RESTRICTIVELEGEND ON TITLE PAGE. Oct2000
rap1
MDC 91K0263
DC-9/MD-80 Upper CargoDoor

Skin Marl
2014-T6
Finger Ext. Ext.
2024-T3
Dblr Skin
Dhlr
Repair2024_T3Matl ~ /,
J~
2014-T6 I -~ + + ]
707
-T6 I~
++t+
++++ R
I I ,
~ +.F-I-
~1
~i
411, <% + "I- + i ~ LENGTH
. ~T +
:.+.+++ A F,ngerDblr
--+t-+
Fasteners y.~ + + +
Blind -~ + ~- +
.~-,c++ + I lr
Sk~
Forward
I D--
Aft
PermanentRepair
Notavailable
forthis
configuration
TemporaryRepair 1.00_<tJt,< 1.50 Inspection

Threshold:
FastenerDiameter_> 5/32" 3,000landings
3.5D < Spacing< 7D Inspection
Interval
andMethod
wsual= 3,000
MinimumE.D. >_ 1.5D Replacement/rework
Threshold
8,000Landings

Douglas
Corporation
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Informabon
- UseorD~sclosure
of
rapl
MDC 91K0263
APPENDIX C ZONING GUIDANCE FOR RECORD KEEPING
McDonnell
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MDC 91K0263
Intentionally
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PageC.2 McDonnell
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Information
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MDC 91K0263
Therepairassessmenton theairplaneis scheduled

according
to therequirements
of the
operator,exceptforthetimeframes describedin Section
4 IMPLEMENTATION.
Theoperator
mayelectto accomplish
theassessmentduringthemaintenance
visitthata particularzoneis
beingdoneandnotaccomplish theassessment on theentireairplaneat once.Therearemany
waysto dividetheairplaneintozones. TheOn AircraftMaintenance
Planning
document is one
exampleas to howan airplaneis brokendownintozones. Anymethodmaybe usedto planthe
assessment
foran airplane.
A unique
numbering
systemmaybe advantageous
foran operatorto number andrecord the
repairs
thatarebeingassessed.Thenumberingsystem mayinclude ATAChapternumbers,
manufacturer
fuselage
number,manufacturer
factory
serial number,
airlineairplane
number, a
zonenumber
anda sequential
number.
Thisnumbering
of repairs
~s at thediscretion
of the
operator.
Theoperator
stillisrequired
tobe abletoshowcompliancewiththisprogram.
McDonnell
Douglas
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Information
- UseorDisclosure
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MDC 91K0263
APPENDIX D DAMAGE TOLERANCE EXCLUSION AREAS
McDonnell
Douglas
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Information
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2000
MDC 91K0263
Intentionally
LeftBlank
PageD.2 McDonnell
Douglas
Corporation
proprietary
Information
- UseorDisclosure
of
MDC 91K0263
Repairs
installed
in theDamageTolerance
ExclusionAreas(DTEA)
do notrequire
categorization.
Theseareasareshownbelowandon thefollowing
pages.
DC-9/MD-80
Low StressAreas
Series
11,14 and15 (RC,MC)
Station Longeron
566to604 18 to20(LeftandRight)
604to 642 17 to20(LeftandRight)
642to670 18 to26(LeftandRight)
642to689 26to30 (LeftandRight)
Servicedoor,fwdentrancedoor,over-wing
emergency
doors,lowercargodoors,
airstair
door,windshield
wiper
door,accessdoor,aftpressurebulkhead
emergencyexit
door,gyros door,passenger
aftentrancedoor,sta.110
bulkhead,slant
pressure
panel,andportion
ofsta.37 to
110horizontal
pressure
panel
(seedetailindiagram).
DC-9,SERIES11, 14, AND 15
Lll --
L18--
L26--
I
STA STA
566 STA 689
642
STA STA
604 670
DAMAGE TOLERANCE EXCLUSION AREA
McDonnell
Douglas
Corporat=on
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Information
- UseorD=sclosure
of PageD.3
LEGENDON TITLEPAGE October
2000
MDC 91K0263
Series20
Station Longeron
474to 484 17 to 19 (LeftandRight)
525 to 544 15 to 16 (LeftandRight)
Servicedoor,fwdentrance door,over-wing emergency
doors,lowercargodoors,airstairdoor,windshield wiper
door,accessdoor,aftpressure bulkhead emergencyexit
door,gyrosdoor,passengeraftentrance door,sta.110
bulkhead,slantpressure
panel,andportion of sta.37 to
110horizontalpressure
panel(seedetail in diagram).
DC-9,SERIES20
Lll
L18~
L26
STA
474
STA STA STA

484 544 670
Page D.4 McDonnell

Douglas
Corporation
propnetary
Informabon
- UseorDisclosure
of
MDC 91K0263
Series
31,32 (F,CF),34 (CF)
Station Longeron
588to598 17 to 19 (LeftandRight)
617 ~ 756 16 to 20 (LeftandRight)
Servicedoor,fwd entrancedoor,over-wing emergency
doors,lowercargodoors,airstair
door,windshield wiper
door,gyrosdoor,passenger
aftentrance door,sta.110
110horizontal
pressure
DC-9,SERIES
31,32 (F,CF),34 (CF)
L1
Lll
L18
L26~
STA
588
STA STA STA

598 699 784
McDonnell
Douglas
Corporation
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Informat=on
- UseorD=sclosure
of Page D.5
THESE DATA SUBJECTTO RESTRICTIVELEGENDON TITLE PAGE. October2000
MDC 91K0263
Series33 (F,CF,RC)
Station Longeron
756to 841 26 Leftto bottom centerline
to 26 Right
doors,lowercargodoors,airstairdoor,windshieldwiper
door,accessdoor,aft pressurebulkhead emergencyexit
110horizontal
pressure
DC-9,SERIES
33 (F,CF,RC)
Lll
L18
L26~
I
STA
588
STA
658
TIA
STA 841
756
Page D.6 McDonnell

Douglas
Corporation
propnetary
Informal]on
- UseorDisclosure
of
MDC 91K0263
Series
41
Station Longeron
626to 696 15 to19 (Left andRi,qht)
696to 794 15 to 20 (LeftandRiaht~
794to 841 18 to26 (Left andRi.qht)
doors,lowercargodoors,airstairdoor,windshieldwiper
110horizontal
pressure
panel(seedetail in dia.qram).
DC-9,SERIES40
L1
Lll
L18--
L26--
I
STA
626
STA
696
sl"
STA
841
McDonnell
Douglas
Corporation
propnetary
Informal]on
- UseorD=sclosure
of Page D.7
MDC 91 K0263
Series
51
Station Longeron
753to 851 15 to 20 (LeftandRiaht)
851 to 936 18 to26 (left andRight)
851 to 974 26 Leftto bottom centerline
to 26 Riqht
doors,lowercargodoors,
airstair door,windshield wiper
bulkhead,
andportion
of sta.37 to 110horizontal
pressure
DC-9,SERIES51
m
L1
Lll
L18~
L26--
I
STA
683
STA
753
Is
01s!
s;,;
STA
936
DAMAGE TOLEP, ANCE EXCLUSION AREA
Page D.8 McDonnell

Douglas
Corporabon
propnetary
Informal]on
- UseorDtsclosure
of
MDC 91K0263
Series
81,82,83,88
Station Longeron
798to 835 18to19(LeftandRight)
835to 1003 15to20(LeftandRight)
1003to 1117 18to26(LeftandRiaht)
1003to 1183.5 26Lefttobottom centerline
to 26Right
Servicedoor,fwdentrancedoor,over-wingemergency
doors,lower
cargodoors,
airstair
door,windshield
wiper
door,access
aftentrance
door,sta.110bulkhead,
andportionofsta.37 to110
horizontal
pressure
panel(seedetailindiagram).
MD--80,
SERIES
81,82,83,88
OO000000000DOOODODODOOOOOOOOOOOOOOJLO~O000000000000000[
L1
Lll --
L18
L26~
I
STA
798
STA STA 1183.5
835 1003 STA
1117
McDonnell
Douglas
Corporation
propnetary
Informabon
- UseorDisclosure
of PageD.9
MDC 91K0263
Series87
Station Longeron
684to 721 18 to 19 (LeftandRiaht)
721 to 889 15 to 20 (LeftandRiaht)
889 to 974.5 21 to 26 (LeftandRiaht)
889 to 974.5 26 Leftto bottom centerline
to 26 Right
doors,
lowercargodoors,airstairdoor,windshield wiper
door,accessdoor,gyrosdoor,passenger aftentrance
door,sta.110bulkhead,
andportion of sta.37 to 110
horizontal
pressure
MD--87WITHAFTSERVICE
DOOR
Lll
L18
L26~
STA
I
684
STA STA
721 889
STA
9745
II DAMAGE TOLERANCE EXCLUSION AREA
PageD. 10 McDonnell
Douglas
Corporation
propnetary
Information
- UseorDisclosure
of
MDC 91K0263
Station
37 to station
110horizontal
pressure
panel
I i
STA ! STA
X=25 X=-25
VIEW LOOKING DOWN
~ DAMAGE TOLERANCE EXCLUSION AREA
McDonnell
Douglas
Corporation
propnetary
Information
- Useor Disclosure
of PageD. 11
MDC 91K0263
APPENDIX E SERVICE BULLETINS
McDonnell
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MDC 91K0263
Intentionally
LeftBlank
PageE.2 McDonnell
Douglas
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Information
- UseorDisclosure
of
MDC 91K0263
Modification
andRepair
Lists
Theservice
bulletins,
KitChange Numbers(KCNs) andService
ReworkDrawingslistedin the
tables
in thissectionhavebeenreviewedfordamage tolerance.
Themaintenancerequirements
listed
areforthoserepairsontheairplane
thatareinstalledpertheseitems.Themaintenance
requirements
listedarenecessaryto completetheassessment
on thefuselagepressure
boundary.
Twotableareusedto listthese
items. Thefirsttable
liststhose
modifications
or
repairs
thatareaffected
byFederalAviationAdministration
(FAA)Airworthiness
Directives
(ADs).
Thesecond
tablelistthosemodifications
or repairsthatarenotaffected
by FAAADs.
McDonnell
Douglas
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Informabon
- UseorD=sclosure
of PageE.3
MDC 91 K0263
Intentionally
LeftBlank
PageE.4 McDonnell
Douglas
Corporabon
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Informabon
- Useor Disclosure
of
MDC 91K0263
Modifications
/ RepairsMandatedby Airworthiness
Directive
Service
Bulletin
ReferenceInspection Inspecbon Inspection Airworthiness
Threshold Method Interval Directive
Reference
McDonnell
Douglas
Corporabon
propnetary
Inforrnabon
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of Page E.5
MDC 91K0263
Intentionally
LeftBlank
PageE.6 McDonnell
Douglas
Corporation
propnetary
Informabon
- UseorDisclosure
of
MDC 91 K0263
Modifications
/ Repairs
Not Mandated
by Airworthiness
Directive
Service ReferenceInspectionInspection
Bulletin Inspection
Threshold Method Interval
McDonnell
Douglas
Corporabon
propnetary
Informabon
- UseorD=sclosureof PageE.7
MDC 91 K0263
APPENDIX F PROGRAM EXAMPLE
McDonnell
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Information
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MDC 91 K0263
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Page F.2 McDonnell

Douglas
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Informabon
- UseorDisclosure
of
MDC 91 K0263
Theoperator
willneedto decide
howtheRepair
Assessment
Program
is to be implemented
into
theirmaintenance
program.
Operator
Program
Implementation
Operators Repair
Maintenance Assessment
Schedule Document
Operatordecideshow
J
bestto implement
program.
Eachof theseitemscanaffect
howan operator
implements
theprogram.
1. Age ofairplanes
a) Theageof theairplanes
impact
whento implement
theprogram.
b) Onesituation
iswherealltheairplanes
arebelow
theimplementation
threshold.
Theoperator
canwaituntiltheleadairplane
reaches
theimplementation
threshold
before
implementing
theprogram.
c) Another
situation
is where
thatoperatorhasairplanes
overandbelowthe
implementation
threshold.
In thiscasetheprogram
is to be implemented
according
to the requirements
of Section4 IMPLEMENTATION.
Number
of airplanes
.
a) Thenumberof airplanes
canaffectthemethods
whichan operator
decides
to use
in therepairassessment
andproofof compliance
methods.
Fleet
plans
.
a) Thedecision
to continue
usingan airplane
or tostopusing
an airplane
mayaffect
therequirements
forthisprogram
forthatoperator.
Expected
typesof repairs
.
a) Ifanoperator
knowswhattypeofrepair
isinstalled
ontheairplanes
thenthe
operator
canplanaccordingly.
Expected
number
of repairs
perairplane
.
a) If theoperator
knowsapproximately
howmanyrepairs
areinstalled
on the
airplane
thentheoperator
canplanaccordingly
Maintenance
schedule
.
a) Theoperators
maintenance
schedule
notonlysetswhento accomplish
the
assessment
butalsodetermines
maintenance
requirements
fortherepairs.
McDonnell
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MDC 91 K0263
Maintenance
system
.
a) An operators
maintenance
systemmaydetermine
thebestwayto implement
tracking
andproof
of compliance
forthisprogram.
Changes
of maintenance
intervals
.
a) Theseshould
be accounted
forwhena an airplane
is to be assessed.
These
changes
canalsoaffect
themaintenance
requirements
of repairs.
g. Documentation
choices
a) Thiscanrangefromcomplete
documentation
of therepair
to minimal
documentation.
Theoperator
decides
thebestmethod
forthemselves.
10. NDIcapability
a) TheNDIcapability
oftheoperator
mayaffect
theinspection
decisions
forthe
maintenance
requirements
of therepair.
PageF.4 McDonnell
Douglas
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Informabon
- UseorD=sclosure
of
MDC 91 K0263
APPENDIX G GLOSSARY
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THESE DATA SUBJECT TO RESTRICTIVELEGEND ON TITLE PAGE July1997
MDC 91K0263
Intentionally
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Information
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MDC 91K0263
EvaluationTimeFrame
Thetimeframe
to do therepair
evaluation/audit/assessment.
Thisincludes
thetimetolocate,
classify
anddetermine
action
fora repair.
Inspection
Repetitive
Interval
Themaximum
interval
allowed
between
required
repetitive
inspections.
Inspection
Threshold
Thenumber
of cycles
bywhichrepetitive
inspections
mustbegin
forCategory
B or C repairs.
Replacement/Rework
Threshold
Thetimeby whichreplacement/rework
of a Category
C repair
mustoccur.
Inspection
Threshold
Allowance
A grace
period
orallowance
timefora repair
alreadybeyondtheinspection
threshold.
(Thisis to
allow
theoperator
a reasonable
periodof timetoincorporate
inspection
requirements
intotheairplanes
maintenanceprogram
without
grounding
the
aircraft
fora repair
evaluated
bythisprogramwhich
iseither
pastofverynearits
inspection
threshold
atthetimeofitsevaluation.)
Replacement/ReworkThreshold Allowance
A graceperiod
or allowancetimefora repair
alreadybeyondthereplacement/rework
threshold.
(Thisis toallowtheoperator
a reasonable
period
oftimeto develop
and
incorporate
a repair
fora Category
C repair
beforehaving
to ground
theaircraft
because
theexistingrepairiseitherpastorverynearitsreplacement/rework
thresholdwhenevaluated
fortherepairprogram.)
Repair
A repair
isdefined
astheelimination
ofstructuraldamage
and/or
therestoration
of
structure
toanairworthy
condition.
If a structure
isrestored
byreplacement,
the
interface
ofthereplaced
structure
andtheexistingstructure
maybe considered
therepair.
Temporary
Repair
(Interim Repair)
A repair
thathasa fatigue
lifethatislessthana permanent
repair.
PermanentRepair
A repair
that
hasa fatigue
lifeatleast
asgreat
astheoriginal
airframes
life.
Fuselagepressure
shell
Thefuselagepressurized
skin,pressure
panelwebsandpressure
bulkhead
webs.
Local
Regulatory
Authority
Thedesignated
regulatory
authority
thatprovides
oversight
foranoperator.
Substandard
repairs
Repairs
which
do notsatisfy
theminimum
requirements
forreturn
to service.
Supplemental
TypeCertificate
SeeFederal
Aviation
Regulation
Part1 andPart21.
McDonnell
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MDC 91K0263
APPENDIX H ACRONYMS
McDonnell
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Information
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of PageH. 1
THESE DATA SUBJECTTO RESTRICTIVELEGENDON TITLE PAGE, July1997
MDC 91 K0263
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Information
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of
May 1997 THESE DATA SUBJECTTO RESTRICTIVELEGEND ON TITLE PAGE.
MDC 91K0263
AATF Airworthiness Assurance TaskForce

AATF-SC AATFSteering Committee
AAWG Airworthiness Assurance Working
Group
AC AdvisoryCircular
AD AirworthinessDirective
AIA Aerospace Industries Association
ATA AirTransport Association
BZI BaselineZonalInspection
CPCP Corrosion Prevention andControlProgram
DTA DamageTolerance Analysis
DAC Douglas Aircraft Company
ED or E.D. EdgeDistance
FAA Federal Aviation Administration
FAR Federal Aviation Regulation
HFEC H~ghFrequency EddyCurrent
IATA InternationalAirTransport Association
IRI Inspection
Repetitive Interval
KCN Kitcharge Number
LFEC Low Frequency EddyCurrent
MED Multiple Element Damage
MSD Multiple SiteDamage
MD McDonnell Douglas
MTG ModelTask Group
NASA National Aeronautics andSpaceAdministration
NDE Nondestructive Engineering
NDE Nondestructive Evaluation
NDI Nondestructive Inspection
NDT Nondestructive Testing
NDTSPM Nondestructive Testing Standard
Practice
Manual
OAMP On Aircraft Maintenance Planning
OEM Original Equipment Manufacturer
PAMA Professional Aircraft Mechanics
Association
PI Principal
Inspector
PMI Principal Maintenance Inspector
(FAA)
PSE Principal Structural Element
RAP RepairAssessment Program
RIT Repetitive Inspection Threshold
RRT Replacement / ReworkThreshold
SAR Service Action Requirement
SB ServiceBulletin
SDR Service Difficulty Report
SFAR Special Federal AviationRegulation
SID Supplemental Inspection Document
SRM Structural Repair Manual
STC Supplemental TypeCertificate
USAF United States AirForce
WFD Widespread FatigueDamage
McDonnell
Douglas
Corporal]on
propnetary
Information
- UseorDisclosure
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MDC 91K0263
APPENDIX I REFERENCES
McDonnell
Douglas
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Informabon
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MDC 91 K0263
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LeftBlank
Page1.2 McDonnell
Douglas
Corporabon
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Informabon
- UseorDisclosureof
MDC 91 K0263
FAAAdvisory
Circulars
AC 91-56 Supplemental
Structural
Inspection
ProgramForTransport
Category
Airplanes
AC 25.571-1B Damage-Tolerance
AndFatigue
Evaluation
Of Structure
AC 25.1529-1 Instructions
ForContinued
Airworthiness
Of Structural
Repairs
On Transport
Airplanes
FAAFederal
AviationRegulations
FAR 25.571 Damage
Tolerance
AndFatigue
Evaluation
Douglas
Aircraft
Documents
MDC-K1579 ServiceActionRequirements
Document
L26-011 DC-8SupplementalInspection
Document
Structural
RepairManual
MDC-K4608 Corrosion
Prevention
And ControlProgramDocument
MDC 93K0393 Nondestructive
Testing
Standard
Practice
Manual
McDonnell
Douglas
Corporabon
propnetary
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of Page1.3

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MCDONNELLDOUGLASCORPORATIONPROPRIETARYRIGHTSARE INCLUDEDIN THE INFORMATIONDISCLOSEDHEREIN RECIPIENTBY ACCEPTINGTHIS

REV. ISSUE DATE DATE BY REV. ISSUE DATE BY

ORIG. July1997 July1997 DAC

REVISION NO. 1 SUMMARY

viii Newpageadded foradditional of effectivepage.

Section Page Issue Date

TITLE PAGE Oct 2000

RECORD OF REVISIONS Oct 2000

REVISION SUMMARY ii-R1 Oct 2000

LIST OF EFFECTIVEPAGES iii Oct 2000

TABLE OF CONTENTS xi 1 Oct2000

TABLE OF FIGURES xiii Oct2000

PROGRAM OBJECTIVES 5 OriginalJuly1997

APPROACH 13 1 Oct 2000

Section Page Issue Date

BASELINE ZONAL INSPECTION 17 OriginalJuly1997

DATA REQUIREMENTS 23 OriginalJuly1997

REPAIR ASSESSMENT GUIDELINE PROCESS 45 1 Oct 2000

MAINTENANCE REQUIREMENTS 49 1 Oct 2000

OPTIONAL QUESTIONNAIRE AND EXPLANATION A.1 OriginalJuly1997

Section Page Issue Date

OPTIONAL QUESTIONNAIRE AND EXPLANATION A.8 Oct2000

REPAIR ASSESSMENT GUIDELINE B.1 Original July1997

Section Page Issue Date

REPAIR ASSESSMENTGUIDELINE (CONTINUE) B.45 1 Oct 2000

Section Page Issue Date

REPAIR ASSESSMENT GUIDELINE (CONTINUE) B.92 New Oct 2000

ZONING GUIDANCE FOR RECORD KEEPING C.1 Original July1997

DAMAGE TOLERANCE EXCLUSION AREAS D.1 1 Oct 2000

SERVICE BULLETINS E.1 Original July1997

PROGRAM EXAMPLE F.1 Original July1997

Section Page Issue Date

PROGRAM EXAMPLE (CONTINUE) F.3 Original July1997

GLOSSARY G.1 Original July1997

ACRONYMS H.1 Original July1997

REFERENCES I.1 Original July1997

SECTION TITLE PAGE

Recentevents in thefieldof commercialaviation

Figure4.1 Exampleof extension

REPAIRS TO STC MODIFICATIONSAND REPAIRS TO MAJOR ALTERATIONSARE NOT

STC MODIFICATIONS AND MAJOR ALTERATIONS ARE NOT REQUIRED TO BE ASSESSED

A Stage1 ScreeningSheetis provided

STAGE 1 AREA / COMPONENT SCREENING

STAGE 3 MAINTENANCE REQUIREMENTS

APPLY GUIDELINES APPLY GUIDELINES TO

6 BASELINE ZONAL INSPECTION

NOTE:TheBZIis nota newmaintenance

~Skin Crack :2 Internal Inspection

Table6-4summarizestheexample usingtwo(2)imaginary operatorsandfour(4)imaginary

Figure 7.2 Repair DoublerSize

Thegeometryis alsousedto determine

Figure7.5 Example1 of DoublerContinuity

Figure7.6 Example2 of DoublerContinuity

Theaboveexample (Figure7.6)showstheextentof an internaldoubleras the

SkinPanel~~ ,__, ,,, I;Ii;

Figure 7.7 Exampleof a continuousdoubler

Typically,STEEL IS MAGNETICand ALUMINUMAND TITANIUMARE NON-

Figure 7.8 Proximitymeasurementexample

Theedgedistancemustbe equalto 1.5Dor greater.

~ 000 Q Q 0000000000~ Row 1

Theuse of blindfastenersis a commonpracticewhenrepairing an airplane.The

1. When20%or fewerfastenerspersideof therepairareblind.