MIL-DTL-9854D
3.2.5.2.5 Control surface rebalancing. Information for mass rebalancing of all hinged control surfaces
by calculated and improvised methods with allowable ield tolerances; and instructions covering dynamic
rebalancing.
3.2.5.2.6 General shop practices. Information on sheet metal forming; working titanium alloys; installation,
removal, and substitution of fasteners equal to or better than those removed; illing dimpled holes; coin
dimpling and special tools. Information relative to weld repair that may be accomplished on assemblies
which are of welded fabrication. Information on minor unstressed ittings and on castings which are
manufactured from weldable materials. Substitute parts and locally manufactured parts shall be identiied.
3.2.5.2.7 Crash handling and shipping. Information relative to safety precautions, such as removal of
batteries, fuel, oil, liquid oxygen, and explosive activated escape devices (prior to crash handling). Information
relative to the equipment, methods, and procedures for lifting and moving damaged aircraft from the crash site.
Information about corrosion prevention (see 3.2.1.7) and, where applicable, crating and shipping instructions,
which would include crates, cradles, support points, weight, and center of gravity, of each component.
3.2.5.2.7.1 Small, short range, or specialized aircraft. For small, short range, or specialized aircraft, complete
aircraft shipping information shall be provided covering disassembly, crating, shipment (mooring), and
reassembly with appropriate references to related manuals. Electronic media only: References shall be
linked to the data to which they apply.
3.2.5.2.8 Damage evaluation. Criteria so that the following inspections may be accomplished:
a. Preliminary external inspection for skin buckles, deformation, etc.
b. Detailed visual inspection information for obvious damaged areas and adjacent areas, including
information about critical points and access. Inspection methods and techniques, such as: ire
damage inspection using portable testers and primer discoloration; alignment check of the aircraft
and of its major assemblies; over "G" and hard landing inspection; corrosion damage (see
3.2.1.7); severe engine stalls; pitch-up or use of drag chute as a spin chute and abnormal
drag chute deployment; external pressure testing of items for strength as well as leaks; heat
damaged or delaminated honeycomb structure.
c. Identiication of those areas requiring structural engineering to develop an acceptable repair.
d. Identiication of the nondestructive inspection method to be used to determine the extent of
damage, or reference to the applicable nondestructive inspection manual.
3.2.5.2.9 Support of structure. Required locations for supporting the structure during repair and details
for the fabrication and use of supports. All stress plates or stress panels of the aircraft which require
shoring or structural supporting prior to removal, shall be identiied.
3.2.5.2.10 In-service use criteria. Permissible wear and deviation over and above original manufacturing
tolerances, critical eternal surface contour tolerances, reaming and bushing, allowable clearances, and
replacement items.
3.2.5.3 Section(s), "Repair Sections". Each repair section (chapter) shall describe the construction of the
major assemblies and structural group involved. Wear tolerance charts shall be provided, when applicable,
and the negligible damage limits shall be given for each component in the group. One-time light (ferry)
repairs, temporary repairs, and permanent repairs shall also be shown for each component, as applicable.
Contour data and dimensions necessary for the construction of templates and repair jigs for use in repairing
the principal components shall be provided at the end of each section. Peculiar fuel tank sealing and
peculiar radome repairs shall be in separate sections (chapters).
3.2.5.4 Section/Chapter, Damage Due To Landing Gear Failure. This section shall cover the type of damage
resulting from landing gear failure, such as auxiliary gear up, main gear up, all gear up, auxiliary gear tire
blowout, main gear tire blowout, and explain the inspections and repair thereof.
3.2.5.5 Section/Chapter, Typical Repairs, and Application. This section shall cover typical repairs which are
considered applicable to more than one section of the manual, i.e., skin patches, extrusion repairs, honeycomb
type structures, formed structure repairs, transparent panel repairs, thermal buckling, deformation due to
pressurization, trim strip manufacture, and installation requirements for removable panels/doors/hatches/etc.
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