Cessna 510 Mustang Structural Repair Manual

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)

Retain printed data for historical reference only. For future maintenance, use only current data.

Print Date: Wed Mar 21 05:09:43 CDT 2018

FOR TRAINING PURPOSES ONLY

ISSUE 02 , JAN 2018

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)

Retain printed data for historical reference only. For future maintenance, use only current data.

Print Date: Wed Mar 21 05:09:44 CDT 2018

FOR TRAINING PURPOSES ONLY

ISSUE 02 , JAN 2018

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)

Retain printed data for historical reference only. For future maintenance, use only current data.

Print Date: Wed Mar 21 05:09:44 CDT 2018

FOR TRAINING PURPOSES ONLY

ISSUE 02 , JAN 2018

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)

Retain printed data for historical reference only. For future maintenance, use only current data.

Print Date: Wed Mar 21 05:09:46 CDT 2018

FOR TRAINING PURPOSES ONLY

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

Trim Tab

Aileron

Trim Tab

Flap

Aileron

Elevator

Trim Tab

Model 510 Structural Repair Manual (Rev 2)

51-00-02-0 (Original Issue)

Retain printed data for historical reference only. For future maintenance, use only current data.

Print Date: Wed Mar 21 05:09:46 CDT 2018

FOR TRAINING PURPOSES ONLY

ISSUE 02 , JAN 2018

Figure 1 : Sheet 2 : Major Assembly Breakdown

A60934

7010T1002

Horizontal Stabilizer

Vertical Stabilizer

Pylon

Nacelle

Wing

Strake

Nacelle

Vertical Stabilizer

Rudder

Trim Tab

Rudder

Model 510 Structural Repair Manual (Rev 2)

51-00-02-0 (Original Issue)

Retain printed data for historical reference only. For future maintenance, use only current data.

Print Date: Wed Mar 21 05:09:46 CDT 2018

FOR TRAINING PURPOSES ONLY

ISSUE 02 , JAN 2018

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)

Retain printed data for historical reference only. For future maintenance, use only current data.

Print Date: Wed Mar 21 05:09:46 CDT 2018

FOR TRAINING PURPOSES ONLY

ISSUE 02 , JAN 2018

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

Model 510 Structural Repair Manual (Rev 2)

51-00-02-0 (Original Issue)

Retain printed data for historical reference only. For future maintenance, use only current data.

Print Date: Wed Mar 21 05:09:46 CDT 2018

FOR TRAINING PURPOSES ONLY

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

Model 510 Structural Repair Manual (Rev 2)

51-00-02-0 (Original Issue)

Retain printed data for historical reference only. For future maintenance, use only current data.

Print Date: Wed Mar 21 05:09:46 CDT 2018

FOR TRAINING PURPOSES ONLY

ISSUE 02 , JAN 2018

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

Model 510 Structural Repair Manual (Rev 2)

51-00-02-0 (Original Issue)

Retain printed data for historical reference only. For future maintenance, use only current data.

Print Date: Wed Mar 21 05:09:46 CDT 2018

FOR TRAINING PURPOSES ONLY

ISSUE 02 , JAN 2018

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)

Retain printed data for historical reference only. For future maintenance, use only current data.

Print Date: Wed Mar 21 05:09:46 CDT 2018

FOR TRAINING PURPOSES ONLY

ISSUE 02 , JAN 2018

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)

Retain printed data for historical reference only. For future maintenance, use only current data.

Print Date: Wed Mar 21 05:09:46 CDT 2018

FOR TRAINING PURPOSES ONLY

ISSUE 02 , JAN 2018

Figure 4 : Sheet 1 : Principal Dimensions

A60941

7010T1002

17.23 feet

5.25 meters

Model 510 Structural Repair Manual (Rev 2)

51-00-02-0 (Original Issue)

Retain printed data for historical reference only. For future maintenance, use only current data.

Print Date: Wed Mar 21 05:09:46 CDT 2018

FOR TRAINING PURPOSES ONLY

ISSUE 02 , JAN 2018

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

Model 510 Structural Repair Manual (Rev 2)

51-00-02-0 (Original Issue)

Retain printed data for historical reference only. For future maintenance, use only current data.

Print Date: Wed Mar 21 05:09:46 CDT 2018

FOR TRAINING PURPOSES ONLY

ISSUE 02 , JAN 2018

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)

Retain printed data for historical reference only. For future maintenance, use only current data.

Print Date: Wed Mar 21 05:09:51 CDT 2018

FOR TRAINING PURPOSES ONLY

ISSUE 02 , JAN 2018

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)

Retain printed data for historical reference only. For future maintenance, use only current data.

Print Date: Wed Mar 21 05:09:51 CDT 2018

FOR TRAINING PURPOSES ONLY

ISSUE 02 , JAN 2018

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:

Model 510 Structural Repair Manual (Rev 2)

51-00-03-0 (Original Issue)

Retain printed data for historical reference only. For future maintenance, use only current data.

Print Date: Wed Mar 21 05:09:51 CDT 2018

FOR TRAINING PURPOSES ONLY

ISSUE 02 , JAN 2018

Figure 2 : Sheet 1 : Mismatch and Gap

Model 510 Structural Repair Manual (Rev 2)

51-00-03-0 (Original Issue)

Retain printed data for historical reference only. For future maintenance, use only current data.

Print Date: Wed Mar 21 05:09:51 CDT 2018

FOR TRAINING PURPOSES ONLY

ISSUE 02 , JAN 2018

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Cessna 510 Mustang Structural Repair Manual

Cessna 510 Mustang Structural Repair Manual

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