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ISSUE 02 , JAN 2018 FOR TRAINING PURPOSES ONLY
CESSNA Model 510 Structural Repair Manual (Rev 2) EXTRACT
•
Chapter 51 Standard Practices – Structures
Cessna 510 Mustang (PW 615)
THIS STRUCTURAL REPAIR TRAINING MANUAL HAS BEEN PRODUCED AS AN INSTRUCTION AID
IN SUPPORT OF TECHNICAL GROUND INSTRUCTION. NO AMENDMENTS ARE PROVIDED AFTER
ISSUE. THEY SHOULD ONLY BE USED AS A STUDY GUIDE. THE NOTES MAY NOT BE USED FOR
THE PURPOSE OF AIRCRAFT MAINTENANCE: PLEASE REFER TO THE MANUFACTURERS OFFICIAL
PUBLICATIONS.
FOR TRAINING USE ONLY
ISSUE 02 , JAN 2018 FOR TRAINING PURPOSES ONLY
•
CONTENT:
51-00-00 - STRUCTURES
51-00-01 - PRINCIPAL STRUCTURAL ELEMENTS
51-00-02 - STRUCTURAL IDENTIFICATION AND DIMENSIONS
51-00-03 - AERODYNAMIC SURFACES
51-01-00 - MAJOR STRUCTURAL DAMAGE REPORT AND REPAIR REQUESTS
51-10-01 - CRACK, SCRATCH, GOUGE AND CORROSION
51-20-01 - PROTECTIVE TREATMENT OF METAL
51-30-01 - SHEET METAL MATERIALS
51-40-03 - FASTENER INSTALLATION AND REMOVAL
51-40-04 - FASTENER SUBSTITUTION
51-40-05 - TORQUE VALUES
51-40-06 - HOLE SIZE AND EDGE DISTANCE
51-40-08 - COUNTERSINKING
51-60-00 - CONTROL SURFACE BALANCING
51-60-01 - AILERON BALANCING
51-60-02 - ELEVATOR BALANCING
51-60-03 - RUDDER BALANCING
51-70-00 - REPAIRS
51-70-01 - TYPICAL REPAIRS FOR MINOR DENTS
51-70-02 - TYPICAL SKIN REPAIRS
51-71-00 - VACUUM BAGGING FOR COMPOSITE REPAIRS
51-71-01 - COIN TAP INSPECTION
51-72-00 - ELECTROMAGNETIC DENT REMOVAL
STRUCTURES
1. General
A. Chapter 51 describes general repair practices, materials and procedures which are applicable throughout the subsequent
chapters.
B. General information included in Chapter 51 will help when doing the repairs.
Model 510 Structural Repair Manual (Rev 2)
51-00-00-0 (Original Issue)
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PRINCIPAL STRUCTURAL ELEMENTS
1. General
A. The Mustang is certified to the Damage Tolerance and Fatigue requirements. PSE's are defined as, “Those elements
which contribute significantly to carrying flight, ground, and pressurization loads, and whose failure could result in
catastrophic failure of the airplane.”
B. Airplane principal structural element (PSE) inspections and safe life limits must be based on an engineering durability and
damage tolerance assessment (i.e., crack growth analysis for the airframe structure, and classical fatigue analysis for the
safe life limited landing gears and landing gear attachment fittings).
C. Repairs to PSE’s must have a durability and damage tolerance assessment before returning the airplane to service.
Additionally, repairs to PSE’s must be approved by the FAA or a DER authorized in damage tolerance.
D. The following structures are PSE’s. They are listed to make sure structural inspections and safe life limits, as defined in the
Maintenance Manual, will remain valid after a field repair to a PSE.
PRINCIPAL STRUCTURAL ELEMENT
(PSE)
DESCRIPTION
Spars Wing
Vertical fin
Horizontal tail
Upper engine beam caps
Stringers Wing, lower
Stabilizer, upper
Pressure vessel
Skins Lower wing
Pressure vessel
Vertical fin (all)
Horizontal stabilizer (upper)
Splices and fittings Horizontal tail centerline splice
Horizontal tail attachment fittings
Wing centerline splice
Wing-to-fuselage links and attachment fittings
Vertical fin attachment fittings
Engine mounts and isolators
Main landing gear trunnion support
Main landing gear side-brace support
Nose gear trunnion support
Nose gear retraction support
Flap hinge
Ribs Wing BL 0.00
Wing side-of-body (near attachment fittings)
Horizontal stabilizer BL 0.0
Fuselage Bulkheads/Frames Pressure bulkheads (forward and aft)
Tailcone forward canted bulkhead
Tailcone aft canted frames (fin attachment)
Fuselage openings Cabin entry door frames
Escape hatch frame
Windshield frames
Cabin Entry Door Latches and pins and supporting structure
Control Surfaces Hinges
Actuators and actuator fittings
Torque tubes
Model 510 Structural Repair Manual (Rev 2)
51-00-01-0 (Original Issue)
Copyright © Textron Aviation Inc. Page 1 of 2
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Landing Gear All structural elements of main gear and nose landing gear
Model 510 Structural Repair Manual (Rev 2)
51-00-01-0 (Original Issue)
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STRUCTURAL IDENTIFICATION AND DIMENSIONS
1. General
A. This section provides identification and locations of major assemblies, station identification and principal dimensions
(Refer to Figure 1, Figure 2, Figure 3, and Figure 4).
2. Abbreviations and Terminology
FS - Fuselage Station is a vertical reference plane measured perpendicular to the airplane longitudinal axis,
starting in front of the airplane's nose.
WL - Water Line is a horizontal reference plane measured parallel to the airplane longitudinal axis, starting below
the airplane.
BL - Buttock Line is a vertical reference plane measured parallel to the airplane longitudinal axis, starting at the
airplane centerline. Right or left is added to indicate the direction from airplane centerline (RBL, LBL).
WS - Wing Station is a horizontal reference plane measured perpendicular to the wing datum plane and parallel to
the longitudinal axis of the airplane, starting at the airplane centerline.
CL - Centerline is a horizontal reference plane which represents the airplane centerline.
SS - Stabilizer Station is a horizontal reference plane measured perpendicular to the stabilizer datum plane and
parallel to the longitudinal axis of the airplane, starting at the airplane centerline.
TCS - Tailcone Station is a vertical reference plane measured perpendicular to the airplane longitudinal axis, starting
92 inches forward of FS321.00.
NAC STA - Nacelle Station is a vertical reference plane measured perpendicular to the nacelle centerline.
NAC WL - Nacelle Waterline.
NAC BL - Nacelle Buttock Line.
DATUM - Datum is a reference plane from which calculations are taken.
Model 510 Structural Repair Manual (Rev 2)
51-00-02-0 (Original Issue)
Copyright © Textron Aviation Inc. Page 1 of 11
Retain printed data for historical reference only. For future maintenance, use only current data.
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ISSUE 02 , JAN 2018
Figure 1 : Sheet 1 : Major Assembly Breakdown
A60933
7010T1002
Radome
Nose
Cabin Entry Door
Speed Brake
Wing Assembly
Emergency Exit
Speed Brake
Flap
Aileron
Nacelle Assembly
Pylon Assembly
Strake
Vertical Stabilizer
Horizontal Stabilizer
Elevator
Elevator
Trim Tab
Aileron
Trim Tab
Flap
Aileron
Elevator
Elevator
Trim Tab
Model 510 Structural Repair Manual (Rev 2)
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Copyright © Textron Aviation Inc. Page 2 of 11
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Figure 1 : Sheet 2 : Major Assembly Breakdown
A60934
7010T1002
Horizontal Stabilizer
Vertical Stabilizer
Pylon
Nacelle
Wing
Strake
Nacelle
Vertical Stabilizer
Rudder
Trim Tab
Rudder
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51-00-02-0 (Original Issue)
Copyright © Textron Aviation Inc. Page 3 of 11
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Figure 2 : Sheet 1 : Major Structural Members Location
A60935
7010T1002
Forward
Pressure
Bulkhead
FS 144.000
Aft
Pressure
Bulkhead
FS 321.000
Forward Engine
Beam Centerline
FS 362.750
Aft Engine
Beam Centerline
FS 380.35
(TCS 151.35)
Engine Forward
Beam Top Edge
WL 112.65
Strut Extended
FS 305.16
Baggage
Compartment
Floor
WL 88.00
Main Spar
Centerline
Strut Extended
FS 132.773
Engine Aft
Beam Top Edge
WL 111.30
Model 510 Structural Repair Manual (Rev 2)
51-00-02-0 (Original Issue)
Copyright © Textron Aviation Inc. Page 4 of 11
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Figure 3 : Sheet 1 : Station Diagram
7010T1002
A60936
WL 121.870
WL 130.078
WL 157.045
WL 177.220
WL 192.71
WL 73.62
WL 77.06
LBL
6.00
LBL
6.00
RBL
6.00
59.97 inches
1.52 meters
WL 115.00
Fuselage Water Lines
Pedestal
Instrument Panel
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51-00-02-0 (Original Issue)
Copyright © Textron Aviation Inc. Page 5 of 11
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ISSUE 02 , JAN 2018
Figure 3 : Sheet 2 : Station Diagram
A60937
7010T1002
Pressure
Bulkhead
FS 144.00
Pressure
Bulkhead
FS 321.00
FS 132.773
FS 276.000
FS 249.50
FS 540.90
FS 276.000
Instrument Panel
Pedestal
FS 144.00
FS 321.00
Fuselage Stations
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51-00-02-0 (Original Issue)
Copyright © Textron Aviation Inc. Page 6 of 11
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Figure 3 : Sheet 3 : Station Diagram
A60938
7010T1003
WL 114.682
5 Degrees
LBL 47.852
Trace of FS 362.750
Cut Through Pylon
Centerline
0.0 Degrees
3.5 Degrees
Side View
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51-00-02-0 (Original Issue)
Copyright © Textron Aviation Inc. Page 7 of 11
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Figure 3 : Sheet 4 : Station Diagram
A60939
7010T1003
Flap Inboard Edge
WS 135.4000
WS 173.500
WS 349.725
WS 273.110
Flap Hinge Centerline
WS 256.610
Flap Hinge Centerline
WS 205.500
Flap Hinge Centerline
WS 146.00
Model 510 Structural Repair Manual (Rev 2)
51-00-02-0 (Original Issue)
Copyright © Textron Aviation Inc. Page 8 of 11
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Figure 3 : Sheet 5 : Station Diagram
A60940
7010T1003
Stabilizer Station
BL 0.00
FS 523.305
BL 26.849
WL 183.965
FS 545.249
BL 96.473
WL 183.965
FS 245.249
BL 96.673
WL 183.965
LBL 98.665
Model 510 Structural Repair Manual (Rev 2)
51-00-02-0 (Original Issue)
Copyright © Textron Aviation Inc. Page 9 of 11
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Figure 4 : Sheet 1 : Principal Dimensions
A60941
7010T1002
17.23 feet
5.25 meters
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51-00-02-0 (Original Issue)
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Figure 4 : Sheet 2 : Principal Dimensions
A60942
7010T1002
11.79 feet
3.59 meters
43.17 feet
13.16 meters
14.36 feet
4.38 meters
13.45 feet
4.10 meters
40.54 feet
12.36 meters
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51-00-02-0 (Original Issue)
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AERODYNAMIC SURFACES
1. Loft Contour
A. The loft contour is the outside surface of the skin for the wings, fairings, nacelles, and pylons.
B. The loft contour is the inside surface of the skin for the nose, cockpit, fuselage, and tailcone.
C. The loft contour is the outside surface of the horizontal stabilizer, vertical fin, elevator, rudder, and flap, except the leading
edge of these components. The inside surface of the leading edge of these components is the loft contour.
2. Local Contour
A. Unless otherwise specified in this manual, the skin should be smooth, without elevations, depressions, or flat spots which
exceed the tolerances in Table 1 over any six-inch (150 mm) length in the zones defined in Figure 1.
Zone 1 +0.040 or -0.040 inch +1.01 or -1.01 mm
Zone 2 +0.060 or -0.060 inch +1.52 or -1.52 mm
Zone 3 +0.100 or -0.100 inch +2.54 or -2.54 mm
Table 1. Local Contour
3. Mismatch and Gap
A. Mismatch and gap as defined by Figure 2 must not be more than the values shown in Table 2.
ZONE 1 inches
(mm)
ZONE 2 inches
(mm)
ZONE 3 inches
(mm)
SKIN
Maximum Gap 0.025 (0.63) 0.040 (1.01) 0.060 (1.52)
Mismatch Perpendicular to Airstream 0.015 (0.38) 0.020 (0.51) 0.030 (0.76)
Mismatch Parallel to Airstream 0.040 (1.01) 0.040 (1.01) 0.040 (1.01)
DOORS AND ACCESS PANELS
Maximum Gap 0.040 (1.01) 0.025 (0.64) 0.040 (1.01)
Mismatch Perpendicular to Airstream 0.040 (1.01) 0.035 (0.89) 0.040 (1.01)
Mismatch Parallel to Airstream 0.040 (1.01) 0.040 (1.01) 0.040 (1.01)
Table 2. Mismatch and Gap
B. Tolerances for fastener flushness are illustrated in Figure 3.
Model 510 Structural Repair Manual (Rev 2)
51-00-03-0 (Original Issue)
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Figure 1 : Sheet 1 : Flushness Requirements and Tolerances
A63612
Zone 3
Zone 2
Zone 1
Model 510 Structural Repair Manual (Rev 2)
51-00-03-0 (Original Issue)
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Figure 1 : Sheet 2 : Flushness Requirements and Tolerances
A60932
6782T1030
Loft Contour (corrected for
norminal skin thickness).
6.00 Inches
(152 mm)
Actual Contour
Maximum +0.05 or −0.05 Inch (+1.3 or −1.3 mm)
from Loft Contour
(adjusted for skin thickness)
Refer to Table 1.
Maximum Local Deviation
(Waviness)
Refer to Sheet 1 for zone locations.
NOTE:
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51-00-03-0 (Original Issue)
Copyright © Textron Aviation Inc. Page 3 of 5
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Figure 2 : Sheet 1 : Mismatch and Gap
Model 510 Structural Repair Manual (Rev 2)
51-00-03-0 (Original Issue)
Copyright © Textron Aviation Inc. Page 4 of 5
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