SHEET METAL STRUCTURES

INTRODUCTION
Materials used in aircraft construction have changed significantly since the Wright brothers built the first practical airplane. The Wright Flyer was constructed from wood and fabric, as were most early aircraft. Later, to increase
strength and durability, manufacturers replaced wood substructures with welded steel tubing. However, metallic
materials such as aluminum and stainless steel were eventually used not only in the substructure, but also as the
outer covering. Today, most aircraft are primarily fabricated from metallic components, although advanced composite materials are being widely used mostly on control surfaces and nonstructural components. In the future,
composite materials will constitute a greater percentage of an aircraft's structure, but metallic materials will certainly continue to be used for many years. This chapter serves as an introduction to the design, construction,
inspection, and repair of basic airframe structures made from sheet metal. For detailed instructions regarding
maintenance practices for specific airframe components, refer to the manufacturer's publications such as the
maintenance manual (MM) or structural repair manual (SRM).

METALLIC AIRCRAFT CONSTRUCTION

During their career, nearly all aviation maintenance

technicians are involved to some degree in the fabrication or repair of sheet metal aircraft structures.
To fully understand the theories and procedures
used in sheet metal work, a technician must recognize the construction techniques incorporated into
the design of an airframe that allow it to handle different types of structural loads and stresses. In addition, a technician must also be aware of how different physical properties of sheet metal materials
increase the durability and strength of an aircraft.
With an understanding of these items, a technician
can maintain an aircraft to its original condition, or
properly alter its design to improve aircraft performance or safety.

STRESSES AND STRUCTURES

Aircraft structures must be strong, lightweight,
streamlined, and durable. However, in most cases,
all these requirements are unobtainable without
compromise. Truss-type structures can be made
both lightweight and strong; but with a resulting
angular form, require a superstructure to make them
streamlined. A wooden monocoque design does
provide a streamlined form with high strength, but
with compromises due to the limited useful life of
wood, as well as the high cost involved with fabricating a laminated wood structure.
Today, the high volume of aircraft production has
caused riveted or bonded sheet metal designs to
become the most common method of construction.
This is because sheet metal fabrication has been
simplified over the years by developing and standardizing the tooling and equipment necessary for
assembling most structures. Consequently, sheet
metal aircraft are relatively easy to fabricate in a
production facility as well as to repair in the field.
[Figure 2-1]
The type of metal most widely used for aircraft
structures comes from aluminum alloys, which
account for as much as 90% of the metals used for

Figure 2-1. Modern sheet metal construction techniques

produce airplanes that are strong, streamlined, and economical to assemble or repair.

civil aircraft. Heat-treated aluminum alloys have the

advantage of being lightweight with the ability to
carry high structural loads, while being comparably
inexpensive with regard to other similar strength
metals. These assets make aluminum alloy an excellent choice to use for the construction of most modern civil aircraft. The remaining 10% of metals used
include titanium, stainless steel, and assorted exotic
metals that are predominantly used on military or
large transport category aircraft.
TYPES OF SHEET METAL STRUCTURES
There are two basic types of sheet metal structures
used for aircraft; monocoque and semimonocoque.
Both of these are forms of stressed skin structures,
meaning that the greatest part of the load is carried
in the external skin. However, these structures differ in the amount of internal components that they
use. While both designs typically incorporate formers and bulkheads, a semimonocoque airframe also
utilizes stringers and longerons to add rigidity and
strength to the structure.
A thin metal beverage can is an excellent example of
monocoque construction. The can has two
thin

Sheet Metal Structures

metal ends attached to an even thinner body, but as

an assembly, can support a large load if a force is
applied evenly across the ends of the container.
However, a problem with a monocoque structure is
that just a small dent or crease in a side wall can
destroy its ability to support a load.
Semimonocoque structures minimize the problem
of failures caused by dents and creases by supporting the external skin on a framework of formers,
stringers, and longerons. The internal structure stiffens the skin so it is far less susceptible to failure
caused by deformation. Because of its increased
strength, a semimonocoque design is used in the
construction of most modern aircraft.
Even the skin of an aircraft may be made more rigid
across any large unsupported panels by riveting
stiffeners or by laminating honeycomb material to
the panels. Some modern high-speed jet aircraft
have skins that are milled for increased rigidity.
With these skins, stiffeners are formed on the inner
surface by either conventional machining with a
computer-controlled mill or by chemical or electrochemical milling.
STRUCTURAL LOADS
An airplane manufacturer must consider all of the
loads to which the structure will be subjected in
order to design each component properly. A safety
factor is then built in to provide for any unusual or
unanticipated loads that may conceivably be
encountered. In addition to meeting all of the
strength requirements, the structure must be as lightweight as possible and reasonably easy to construct.
As a maintenance technician it is your responsibility to be sure that any repair you make to an aircraft
restores both the original strength and stiffness to
the structure, while maintaining the original shape
of the part. These considerations must be met while
keeping the weight of the repair to an absolute minimum. In most cases of major structural damage, to
guarantee that a repair meets minimum standards
for strength, an aeronautical or structural engineer
must develop and approve the design of the repair.
These engineers have the credentials and experience to analyze the structural loads on the damaged
area. From their analysis, these engineers can produce drawings and instructions that the technician
must follow closely to accomplish a satisfactory
repair. However, for some repairs, an aircraft technician can refer to the manufacturer's Structural
Repair Manual or Maintenance Manual to determine if preapproved information is already avail-

2-3

able to meet FAA requirements. Even in cases

where the damage is slight, it is permissible for a
technician to use reference materials such as the
Advisory Circular AC 43.13-lB, Acceptable
Methods, Techniques and Practices/Aircraft
Inspection, Repair, and Alterations. With this publication, acceptable procedures for performing some
relatively common sheet metal repairs can be found.
Although the advisory circular information is not
FAA-approved data in itself, it can be used to substantiate an approved repair technique.
STRESSES
In order to determine that a repair will restore full
strength to a damaged sheet metal structure, you
should understand how various stresses act on an
airframe. Five types of stress are of major concern.
Two of these are primary, and the other three, for all
practical purposes, can be expressed in terms of the
first two. Tension and compression are the two basic
stresses, and the other three, bending, torsion, and
shear, are essentially different arrangements of tension and compression working on a body at the
same time.
TENSION

Tension is a primary stress that tries to pull a body

apart. When a weight is supported by a cable, the
cable is subjected to tension or, as it is often
expressed, to a tensile stress. The weight attempts to
pull the cable apart. [Figure 2-2]

Figure 2-2. A tensile stress exerted on a cable tends to pull

the cable apart.

COMPRESSION

Compression, another primary stress, tries to

squeeze a part together. For example, a weight supported on a post exerts a force that tries to squeeze

Sheet Metal Structures

2-4

the ends of the post together, or to collapse it. This

is called a compressive stress. [Figure 2-3]

Figure 2-3. An example of a compressive stress is realized

by analyzing the effect of a column that is supporting a
weight. The weight tends to squeeze the ends of the column
together.

Figure 2-5. Wing struts are predominantly under tension in

flight, but under compression when an airplane is on the
ground. Outboard of a wing strut, the remaining portion of a
wing is subjected to bending stresses.

BENDING

A bending force tries to pull one side of a body apart

while at the same time squeezing the other side
together. When a person stands on a diving board,
the top of the board is under a tensile stress while
the bottom is under compression. The wing spars of
a cantilever wing or the section of a wing spar outboard of a strut is subjected to bending stresses. In
flight, the top of a spar is being compressed while
the bottom is under tension, but on the ground, the
top is pulled and the bottom is compressed.
Therefore, the major stresses imposed on wing
struts reverse in flight as compared to on the
ground. For this reason, it is important that spars be
able to withstand both compressive and tensile
stresses. [Figures 2-4 and 2-5

TORSION

Torsion is a twisting force. When a structural member is twisted or placed under torsion, a tensile
stress acts diagonally across the member and a compressive stress acts at right angles to the tension. For
example, the crankshaft of an aircraft engine is
under a torsional load when the engine rotates the
propeller. [Figure 2-6]

Figure 2-6. A torsional stress consists of tension and compression acting perpendicular to each other, with both acting diagonally across the body.
SHEAR

Figure 2-4. When a diving board is under a bending stress,

tension stresses occur on the top of the board, while the
bottom is under compression.

Shear loads are created when opposing forces are

applied on opposite sides of a body. For example, a
rivet is primarily designed to withstand shear loads
from overlapping sheets of metal that are subjected
to being pulled in opposite directions. Rivets hold

2-5

Sheet Metal Structures

pieces of aircraft skin together, and in a properly

designed joint, the rivets support more bearing or
tensile load than shear load. [Figure 2-7]

the sheet metal (the amount of force that will cause

the rivet to tear out from the metal). In a properly
designed joint, the bearing strength and shear
strength should be as near the same as possible,
with the shear strength being slightly less. When
this is provided, the joint will support the maximum load, but if it does fail, the rivet will shear. It
is much less costly to replace a rivet than it is to
repair a hole torn in the metal. [Figure 2-8]

Figure 2-7. A shear stress on a rivet attempts to slide

through the rivet shank.

RIVET JOINT CONSIDERATIONS

The design of an aircraft repair is complicated by
the requirement that it be as lightweight as possible.
If weight were not critical, all repairs could be made
with a large margin of safety so there would never
be a concern about the strength of the repair.
However, in actual practice, repairs must be strong
enough to carry all of the loads with the required
safety factor, but also as lightweight as possible. On
the other hand, a joint must also be manufactured in
a way that if it is subjected to extreme loads, the fasteners will fail instead of the base metal. For these
reasons, a joint that is too weak cannot be tolerated,
but neither can one that is too strong.

Figure 2-8. Rivet selection

skin thickness.

must

be

matched

to

TRANSFER OF STRESSES WITHIN A STRUCTURE

BEARING STRENGTH

Bearing strength can be characterized by a sheet of

metal being able to withstand being torn away from
the rivets in a joint. The bearing strength of a material is affected by both its thickness and by the size
of the rivet in the sheet. A joint is said to bear up
when, for example, the landing gear makes contact
with the runway upon landing and the wings droop
downward (with the skins pulling against the rivets), and then springs back into normal position.
The spring-back recovery results from the tensile
stress produced by the bearing strength of the metal
against the shear strength of the rivets. In other
words, the joint is manufactured to have a certain
amount of elasticity.

An aircraft structure must be designed in such a

way that it will accept all of the stresses imposed on
it by flight or ground loads without any deformation. When repairs are made to the structure, they
must be made to accept the stresses, carry them
across the repair, and then transfer them back into
the original structure. In this manner, the original
integrity of the part is restored. [Figure 2-9]

SHEAR VERSUS BEARING STRENGTH

Most aircraft structures are held together by the

clamping action of either rivets or bolts. When fabricating a riveted joint, consider both the shear
strength of the rivet (the amount of force that is
needed to cut it in two) and the bearing strength of

Figure 2-9. Any repair to an aircraft structure must accept all

of the loads, support the loads, and then transfer them back
into the structure.

Sheet Metal Structures

2-6

Stresses can be thought of as flowing through a

structure, so there must be a complete path for them
to travel with no abrupt changes in the cross-sectional area along the way. Abrupt changes in area
will cause the stresses to concentrate, and it is at
such a point that failures occur. A scratch or gouge
in the surface of a highly stressed piece of metal will
obstruct the flow of stresses and concentrate them to
the point that the metal will fail at the defect.
[Figure 2-10]

Area subjected to tensile stress = .000032 sq. inches

Ultimate tensile strength of metal = 64,000 psi
Stress needed to cause the crack to extend = 2.048
pounds.
A standard fix for a crack developing in sheet metal
is to stop-drill the end of the crack and rivet a patch
over the entire damaged area. By drilling a hole with
a number 30 bit at the end of the crack, the area on
which the stresses concentrate increases from
the .000032 sq. inches to .0129 sq. inches. This
causes the stress needed to extend the crack to
increase to about 819.2 pounds.
Diameter of number 30 drill = .128 inch
Circumference of number 30 drill = .402 inch Area
subjected to tensile stress = .0129 sq. inches Stress
needed to extend crack = 819.2 pounds.
To complete the repair, a small patch can be riveted
over the crack to stiffen the edge of the material so the
crack will not be subject to vibration. [Figure 2-11]

MATERIALS FOR SHEET METAL

AIRCRAFT CONSTRUCTION
Figure 2-10. Abrupt changes in the cross-sectional area of a
part must be avoided. An abrupt area change will concentrate the stresses and could cause the part to fail. To prevent gouges and scratches from becoming stress concentration points, burnishing is often accomplished.
Burnishing involves using special tools called burnishing
knives or spoons to taper and smooth the edges of
the defect.

The thin metal that most aircraft structures are

made of is subject to vibration and stresses, which
in time, can cause cracks to form. These cracks may
start out to be reasonably small, but if they form in
the edge of a sheet that is being subjected to a tensile stress, the stresses will concentrate at the end of
the crack. Eventually, the crack will propagate,
causing the sheet to tear completely through. For
example, if a small crack starts in the edge of a piece
of 0.032 inch sheet aluminum alloy which has a tensile strength of 64,000 pounds per square inch (psi),
it will take a stress of just over two pounds to extend
the crack. Normal vibrations can produce stresses
that far exceed this amount.
Metal thickness = .032 inch Width
at end of crack = .001 inch

In Chapter Seven of the A&P Technician General

Textbook, aircraft metal classifications and designations were discussed in detail. In this section, those
metals used in the repair of aircraft structures are
covered, including a brief review of the physical
characteristics of these materials. By recognizing
these characteristics, you will better understand
how to select the ideal materials for a specific repair.
ALUMINUM ALLOYS
Pure aluminum lacks sufficient strength to be used
for aircraft construction. However, its strength
increases considerably when it is alloyed or mixed
with other compatible metals. For example, when
mixed with copper or zinc, the resultant aluminum
alloy is as strong as steel, with only one-third the
weight. Furthermore, the corrosion resistance possessed by the aluminum carries over to the newly
formed alloy.
ALLOYING AGENTS

Aluminum alloys are classified by their major alloying ingredient. The elements most commonly used
for aluminum alloying are copper, magnesium,
manganese, and zinc. Wrought aluminum and
wrought aluminum alloys are identified by a
four-digit index system. The first digit of a
designation

2-7

Sheet Metal Structures

Figure 2-11. A crack in the edge of a sheet metal panel must be repaired to prevent the crack from expanding. However, cracks can
also develop in the middle of a sheet due to large vibrations. For example, a common location for cracks to develop is ahead of
control surfaces that are improperly balanced or that have extreme wear in the hinges. The air loads imposed on the control surface can cause it to aerodynamically flutter, generating extreme vibrations and stresses that are carried through the airframe structure.
Eventually, the vibrations can cause cracks to form, which then expand at an accelerated rate.

identifies the major alloying element used in the

formation of the alloy. The most common alloying
elements used are as follows:
"Ixxx
2xxx
3xxx
4xxx
5xxx
6xxx
7xxx
8xxx

last two digits are 75, the alloy contains 99.75%

pure aluminum. However, in the 2xxx through 8xxx
groups, the last two digits identify the different
alloys in the group. [Figure 2-12]

aluminum
copper
manganese
silicon
magnesium
magnesium and silicon
zinc
other elements

The Ixxx series of aluminum alloys represents commercially pure aluminum, of 99% or higher purity.
Pure aluminum offers high corrosion resistance,
excellent thermal and electrical properties, and is
easily worked. However, pure aluminum is very low
in strength.
Alloys within the 2xxx series utilize copper as the
principle alloying agent. When aluminum is mixed
with copper, certain metallic changes take place in
the resultant alloys grain structure. For the most
part, these changes are beneficial and produce
greater strength. However, a major drawback to aluminum-copper alloys is their susceptibility to
inter-granular
corrosion
when
improperly
heat-treated. Most aluminum alloy used in aircraft
structures is an aluminum-copper alloy. Two of
the most com-

The second number represents a specific alloy modification. For example, if this digit is zero, it indicates there were no special controls over individual
impurities. However, a digit of 1 through 9 indicates
the number of controls over impurities in the metal.
The last two numbers of the Ixxx group of alloys are
used to indicate the hundredths of 1% above the
original 99% pure aluminum. For example, if the

PERCENT OF ALLOYING ELEMENTS ALUMINUM AND NORMAL

IMPURITIES CONSTITUTE REMAINDER
ALLOY

COPPER SILICON

MANGANESE

MAGNESIUM

ZINC

CHROMIUM

1100

Seldom used in aircraft

3003

1.2

2017

4.0

2117

2.5

2024

4.5

5052
7075

0.5

0.6

Cowling and non-structural parts

0.5

Obsolete

0.3

Most aircraft rivets

1.5

Majority of structure

2.5
1.6

2.5

5.6

Figure 2-12. A variety of elements are used to produce aluminum alloys.

superseded by 2024

0.25

Gas tanks and fuel lines

0.3

High strength requirements

Sheet Metal Structures

2-8

monly used in the construction of skins and rivets

are 2017 and 2024.
The 3xxx series alloys have manganese as the principle alloying element, and are generally considered
nonheat treatable. The most common variation is
3003, which offers moderate strength and has good
working characteristics.
The 4xxx series aluminum is alloyed with silicon,
which lowers a metal's melting temperature. This
results in an alloy that works well for welding and
brazing.
Magnesium is used to produce the 5xxx series alloys.
These alloys possess good welding and
corrosion-resistance characteristics. However, if the
metal is exposed to high temperatures or excessive
cold-working, its susceptibility to corrosion
increases.
If silicon and magnesium are added to aluminum, the
resultant alloy carries a 6xxx series designation. In
these alloys, the silicon and magnesium form magnesium silicide, which makes the alloy heat treatable.
Furthermore, the 6xxx series has medium strength
with good forming and corrosion-resistance properties.
When parts require more strength and little forming,
harder aluminum alloys are employed. The 7xxx
series aluminum alloys are made harder and
stronger by the addition of zinc. Some widely used
forms of zinc-aluminum alloys are 7075 and 7178.
The aluminum-zinc alloy 7075 has a tensile
strength of 77 thousand pounds per square inch
(KSI) and a bearing strength of 139 KSI. However,
the alloy is very hard and is difficult to bend. An
even stronger zinc alloy is 7178, which has a tensile
strength of 84 KSI and a bearing strength of 151 KSI.
CLAD ALUMINUM ALLOY

Most external aircraft surfaces are made of clad aluminum. Alclad consists of a pure aluminum coating
rolled onto the surface of heat-treated aluminum
alloy. The thickness of this coating is approximately
5% of the alloy's thickness on each side. For example, if an alclad sheet of aluminum is .040 inch
thick, then 5%, or .002 inches of pure aluminum, is
applied to each side. This results in an alloy thickness of .036 inch.
This clad surface greatly increases the corrosion
resistance of an aluminum alloy. However, if it is
penetrated, corrosive agents can attack the alloy
within. For this reason, sheet metal should be pro-

tected from scratches and abrasions. In addition to

providing a starting point for corrosion, abrasions
create potential stress points.
HEAT TREATMENT

Heat treatment is a series of operations involving

the heating and cooling of metals in their solid
state. Its purpose is to make the metal more useful,
serviceable, and safe for a definite purpose. By
heat-treating, a metal can be made harder, stronger,
and more resistant to impact. Heat-treating can
also make a metal softer and more ductile.
However, one heat-treating operation cannot produce all these characteristics. In fact, some properties are often improved at the expense of others. In
being hardened, for example, a metal may become
brittle.
All heat-treating processes are similar in that they
involve the heating and cooling of metals. They differ, however, in the temperatures to which the metal
is heated and the rate at which it is cooled.
There are two types of heat-treatments used on aluminum alloys. One is called solution heat-treatment, and the other is known as precipitation
heat-treatment. Some alloys, such as 2017 and
2024, develop their full properties as a result of
solution heat-treatment, followed by about four
days of cooling, or aging, at room temperature.
However, other alloys, such as 2014 and 7075,
require both heat-treatments.
Solution Heat Treatment

When aluminum is alloyed with materials such as

copper, magnesium, or zinc, the resultant alloys are
much stronger than aluminum. To understand why
this happens, it is necessary to examine the microscopic structure of aluminum. Pure aluminum has
a molecular structure that is composed of weakly
bonded aluminum atoms and, therefore, is
extremely soft. Aluminum alloys, on the other
hand, consist of a base metal of aluminum and an
alloying element that is dispersed throughout the
structure. In this configuration, when the aluminum alloy is subjected to stress, these alloying
particles adhere to the aluminum molecules and
resist deformation. However, special processes
must be used to allow the base metal and alloy to
mix properly. For example, when aluminum is
alloyed with copper through conventional
processes, approximately .5% of the copper dissolves, or mixes, with the aluminum. The remaining copper takes the form of the compound CuAl2.
However, when the aluminum alloy is heated suffi-

Sheet Metal Structures

ciently, the remaining copper enters the base metal

and hardens the alloy.
The process of heating certain aluminum to allow
the alloying element to mix with the base metal is
called solution heat-treating. In this procedure,
metal is heated in either a molten sodium or potassium nitrate bath or in a hot-air furnace to a temperature just below its melting point. The temperature is then held to within about plus or minus
10 of this temperature and the base metal is
soaked until the alloying element is uniform
throughout. Once the metal has sufficiently
soaked, it is removed from the furnace and cooled,
or quenched. It is extremely important that no
more than about 10 seconds elapse between
removal of an alloy from the furnace and the
quench. The reason for this is that when metal
leaves the furnace and starts to cool, its alloying
metals begin to precipitate out of the base metal. If
this process is not stopped, large grains of alloy
become suspended in the aluminum and weaken
the alloy. Excessive precipitation also increases the
likelihood of intergranular corrosion.
To help minimize the amount of alloying element
that precipitates out of a base metal, a quenching
medium is selected to ensure the proper cooling
rate. For example, a water spray or bath provides the
appropriate cooling rate for aluminum alloys.
However, large forgings are typically quenched in
hot water to minimize thermal shock that could
cause cracking. Thin sheet metal normally warps
and distorts when it is quenched, so it must be
straightened immediately after it is removed from
the quench. After the quench, all metals must be
rinsed thoroughly, since the salt residue from the
sodium or potassium nitrate bath can lead to corrosion if left on the alloy.
Precipitation Heat Treatment

Heat-treatable aluminum alloys are comparatively

soft when first removed from a quench. With time,
however, the metal becomes hard and gains
strength. When an alloy is allowed to cool at room
temperature, it is referred to as natural aging and
can take several hours or several weeks. For example, aluminum alloyed with copper gains about
90% of its strength in the first half-hour after it is
removed from the quench, and becomes fully hard
in about four or five days.
Alloy aging times can be lengthened, or shortened.
For example, the aging process can be slowed by
storing a metal at a subfreezing temperature imme-

2-9

diately after it is removed from the quench. On the

other hand, reheating a metal and allowing it to soak
for a specified period can accelerate the aging
process. This type of aging is referred to as artificial
aging, or precipitation heat treatment, and develops
hardness, strength, and corrosion resistance by
locking a metal's grain structure together.
Naturally aged alloys, such as the copper-zinc-magnesium alloys, derive their full strength at room
temperature in a relatively short period and require
no further heat-treatment. However, other alloys,
particularly those with a high zinc content, need
thermal treatment to develop full strength. These
alloys are called artificially aged alloys.
Annealing

Annealing is a process that softens a metal and

decreases internal stress. In general, annealing is the
opposite of hardening. To anneal an aluminum
alloy, the metal temperature is raised to an annealing point and held there until the metal becomes
thoroughly heat soaked. It is then cooled to 500at
a rate of about 50 per hour. Below 500, the rate
of cooling is not important.
When annealing clad aluminum metals, they
should be heated as quickly and as carefully as possible. The reason for this is that if clad aluminum is
exposed to excessive heat, some of the core material
tends to mix with the cladding. This reduces the
corrosion resistance of the metal. [Figure 2-13]
Heat-Treatment Identification

Heat-treatable alloys have their hardness condition

designated by the letter "T", followed by one or more
ANNEALING TREATMENT
METAL
ALLOY

APPROX.TIME

TEMPERATURE OF HEATING

HOURS

1100

550

2017
2024
2117
3003
5052
6061
7075

775
775
775
775
650
775
775

TEMPER
DESIGNATION
-0

2-3
2-3
2-3

2-3
2-3

-0
-0
-0
-0
-0
-0
-0

Figure 2-13. Aluminum alloys are heat-treated to increase

their strength and improve their working characteristics.
Heat-treatment temperatures and soak times are critical to
disperse the alloying elements.

Sheet Metal Structures

2-70

numbers. A listing of the more popular temper designation codes includes the following: [Figure 2-14]
HEAT -TREATABLE ALLOYS
TEMPER
DESIGNATION
-0

DEFINITION
Annealed recrystallized (wrought
products only) applies to softest
temper of wrought products.

-T3

Solution heat-treated and cold-worked

by the flattening or straightening
operation.

-T36

Solution heat-treated and cold-worked

by reduction of 6 percent.

-T4

Solution heat-treated.

-T42

Solution heat-treated and aged by user

regardless of prior temper (applicable
only to 2014 and 2024 alloys).

-T5

Artificially aged only (castings only).

-T6

Solution heat-treated and artificially

aged.

-T62

Solution heat-treated and aged by user

regardless of prior temper (applicable
only to 2014 and 2024 alloys).

-T351.-T451
-T3510,-T3511
-T4510,-T4511
-T651.-T851
-T6510.-T8510
-T6511,-T8511
-T652

-T81

Solution heat-treated and stress

relieved by stretching to produce a
permanent set 1 to 3 percent, and
depending on product.
Solution heat-treated and stress
relieved by stretching to produce a
permanent set 1 to 3 percent, and
artificially aged.
Solution heat-treated, compressed to
produce a permanent set and then
artificially aged.
Solution heat-treated, cold-worked
by the flattening or straightening
operation, and then artificially aged.

-T86

NONHEAT-TREATABLE ALLOYS

Commercially pure aluminum does not benefit from

heat treatment since there are no alloying materials
in its structure. By the same token, 3003 is an
almost identical metal and, except for a small
amount of manganese, does not benefit from being
heat treated. Both of these metals are lightweight
and somewhat corrosion resistant. However, neither
has a great deal of strength and, therefore, their use
in aircraft is limited to nonstructural components
such as fairings and streamlined enclosures that
carry little or no load.
Alloy 5052 is perhaps the most important of the
nonheat-treatable aluminum alloys. It contains
about 2.5% magnesium and a small amount of
chromium. It is used for welded parts such as gasoline or oil tanks, and for rigid fluid lines. Cold working increases its strength.
STRAIN-HARDENING AND
HARDNESS DESIGNATIONS

Both heat-treatable and non-heat-treatable aluminum

alloys can be strengthened and hardened through
strain hardening, also referred to as cold working or
work hardening. This process requires mechanically
working a metal at a temperature below its critical
range. Strain hardening alters the grain structure and
hardens the metal. The mechanical working can consist of rolling, drawing, or pressing.

Solution heat-treated, cold-worked by

reduction of 6 percent, and then
artificially aged.

-F

extremely hard and typically receive several

reheat-treatments to make them soft enough to
drive. However, the number of solution
heat-treatments allowed for clad materials is
limited due to the increased diffusion of core
material into the cladding. This diffusion results
in decreased corrosion resistance. As a result, clad
material is generally limited to no more than three
reheat-treatments.

For wrought alloys, as fabricated. No

mechanical properties limits. For cast
alloys, as cast.

Figure 2-14. All heat treatment processes are identified from

the manufacturer by the use of a standardized temper designation number.

Reheat-Treatment

Material which has been previously heat treated can

generally be reheat-treated any number of times. As
an
example, rivets made
of 2017
or
2024 are

Heat-treatable alloys have their strength increased

by rolling after they have been solution heat treated.
On the other hand, non-heat-treatable alloys are
hardened in the manufacturing process when they
are rolled to their desired dimensions. However, at
times these alloys are hardened too much, and must
be partially annealed.
Where appropriate, the metal hardness, or temper,
is indicated by a letter designation that is separated
from the alloy designation by a dash. When the
basic temper designation must be more specifically
defined one or more numbers follow the letter designation. These designations are as follows:

2-11

Sheet Metal Structures

-F For wrought alloys; As fabricated. No mechanical property limits. For cast alloys; As cast.

ALLOYING ELEMENTS

TEMPER CONDITION

A-ALUMINUM

F-

-O Annealed, recrystallized (wrought materials

only); Applies to softest temper of wrought
products.

E - RARE EARTH
H-THORIUM

O- ANNEALED
H2 - STRAIN HARDENED AND
4
PARTIALLY ANNEALED

-Ff

K-ZIRCONIUM
M - MANGANESE
Z-ZINC

T4- - SOLUTION HEAT-TREATED

Strain hardened.

-Hi Strain hardened only. Applies to products

which are strain hardened to obtain the
desired strength without supplementary thermal treatment.
-H2

Strain hardened and partially annealed.

-H3

Strain hardened and stabilized.

When a digit follows the designations HI, H2, or

H3, the second number indicates the degree of
strain hardening. For example, the number 8 in the
designation H18 represents the maximum tensile
strength, while in H10, the 0 indicates an annealed
state. The most common designations include:
-Hx2
-Hx4
-Hx6
-Hx8

Quarter-hard
Half-hard
Three-quarter hard
Full-hard

AS FABRICATED

T5- - ARTIFICALLY AGED ONLY

T6- - SOLUTION HEAT-TREATED

AND ARTIFICIALLY AGED

Figure 2-15. Magnesium alloys use a different designation
system than aluminum. For example, the designation
AZ31A-T4 identifies an alloy containing 3% aluminum and
1% zinc that has been solution heat-treated.

tributes to its difficulty in forming and limits its use

for thin sheet metal parts. However, this tendency is
largely overcome by forming parts while the metal
is hot. Treating the surface with chemicals that form
an oxide film to prevent oxygen from reaching the
metal minimizes the corrosion problem. When oxygen is excluded from the surface, no corrosion can
form. Another important step in minimizing corrosion is to always use hardware such as rivets, nuts,
bolts, and screws that are made of a compatible
material.

MAGNESIUM AND ITS ALLOYS

Magnesium alloys are used for castings, and in their

wrought form, are available in sheets, bars, tubing,
and extrusions. Magnesium is one of the lightest
metals having sufficient strength and suitable working characteristics for use in aircraft structures. It
has a density of 1.74, compared with 2.69 for aluminum. In other words, it weighs only about 2/3 as
much as aluminum.

In addition to cracking and corroding easily, magnesium burns readily in a dust or small-particle form.
For this reason, caution must be exercised when
grinding and machining magnesium. If a fire should
occur, extinguish it by smothering it with dry sand
or some other dry material that excludes air from
the metal and cools its surface. If water is used, it
will only intensify the fire.

Magnesium is obtained primarily from electrolysis

of sea water or brine from deep wells, and lacks sufficient strength in its pure state for use as a structural metal. However, when alloyed with zinc, aluminum, thorium, zirconium, or manganese, it
develops strength characteristics that make it quite
useful.

Solution heat-treatment of magnesium alloys

increases tensile strength, ductility, and resistance
to shock. After a piece of magnesium alloy has been
solution heat-treated, it can be precipitation
heat-treated by heating it to a temperature lower
than that used for solution heat-treatment, and
holding it at this temperature for a period of
several hours. This increases the metal hardness
and yield strength.

The American Society for Testing Materials (ASTM)

has developed a classification system for magnesium alloys that consists of a series of letters and
numbers to indicate alloying agents and temper
condition. [Figure 2-15]
Magnesium has some rather serious drawbacks that
have to be overcome before it can be used
success-hilly. For example, magnesium is highly
susceptible to corrosion, and tends to crack. The
cracking con-

TITANIUM AND ITS ALLOYS

Titanium and its alloys are lightweight metals with
very high strength. Pure titanium weighs .163
pounds per cubic inch, which is about 50% lighter
than stainless steel, yet it is approximately equal in
strength to iron. Furthermore, pure titanium is soft
and ductile with a density between that of aluminum and iron.

2-72

Titanium is a metallic element which, when first

discovered, was classified as a rare metal. However,
in 1947 its status was changed due to its importance
as a structural metal. In the area of structural metallurgy, it is said that no other structural metal has
been studied so extensively or has advanced aircraft
structures so rapidly.
In addition to their light weight and high strength,
titanium and its alloys have excellent corrosion
resistance characteristics, particularly to the corrosive effects of salt water. However, since the metal is
sensitive to both nitrogen and oxygen, it must be
converted to titanium dioxide with chlorine gas and
a reducing agent before it can be used.
Titanium is classified as alpha, alpha-beta, or beta
alloys. These classifications are based on specific
chemical bonding within the alloy itself. The
specifics of the chemical composition are not critical to working with the alloy, but certain details
should be known about each classification.
Alpha alloys have medium strengths of 120 KSI to 150
KSI and good elevated-temperature strength. Because
of this, alpha alloys can be welded and used in
forg-ings. The standard identification number for
alpha titanium is 8Al-lMo-lV-Ti, which is also
referred to as Ti-8-1-1. This series of numbers
indicates that the alloying elements and their
percentages are 8% aluminum, 1% molybdenum,
and 1% vanadium.
Alpha-beta alloys are the most versatile of the titanium alloys. They have medium strength in the
annealed condition and much higher strength when
heat-treated. While this form of titanium is generally
not weldable, it has good forming characteristics.
Beta alloys have medium strength, excellent forming characteristics, and contain large quantities of
high-density alloying elements.
Because of
this,

Sheet Metal Structures

beta titanium can be heat-treated to a very high

strength.
The grain size of titanium is refined when aluminum is added to the alloy mixture. However,
when copper is added to titanium, a
precipitation-hardening alloy is produced.
Titanium
added
to
high
temperature
nickel-cobalt-chromium
alloy
produces
a
precipitation-hardening reaction, which provides
strength at temperatures up to l,500. [Figure 2-16]
Because of its high strength-to-weight ratio, titanium
is now used extensively in the civilian aerospace
industry. Although once rare on commercial aircraft,
alloys containing 10 to 15 percent titanium in structural areas are utilized on modern jet transports.
STAINLESS STEEL
Stainless steel is a classification of corrosion-resistant steels that contain large amounts of chromium
and nickel. Their strength and resistance to corrosion make them well suited for high-temperature
applications such as firewalls and exhaust system
components. These steels can be divided into three
general groups based on the chemical structure:
austenitic, ferritic, and matensitic.
Austenitic steels, also referred to as 200 and 300
series stainless steels, contain a large percentage of
chromium and nickel, and in the case of the 200
series, some manganese. When these steels are
heated to a temperature above the critical range and
held there, a structure known as austenite forms.
Austenite is a solid solution of pearlite, an alloy of
iron and carbon, and gamma iron, which is a nonmagnetic form of iron. Only cold-working can
harden austenitic stainless steels, while heat treatment serves only to anneal them.
Ferritic steels are primarily alloyed with chromium,

Figure 2-16. This table illustrates the composition, tensile strength, and elongation of titanium alloys. The degree of strength is
denoted by the smaller hole elongation percentage shown in the last column.The titanium alloy most commonly used by the aerospace industry is an alpha-beta heat-treated alloy called 6AI-4V.This alloy has a tensile strength of 180 KSI, or 180,000 pounds per
square inch. It is frequently used for special fasteners.

Sheet Metal Structures

2-13

but many also contain small amounts of aluminum.

However, they contain no carbon and, therefore, do
not respond to heat-treatment.
The 400 series of stainless steel is a martensitic
steel. These steels are alloyed with chromium only
and therefore are magnetic. Martensitic steels
become extremely hard if allowed to cool rapidly by
quenching from an elevated temperature.
The corrosion-resistant steel most often used in aircraft construction is known as 18-8 steel because it
contains 18% chromium and 8% nickel. One of the
distinctive features of 18-8 steel is that cold-working may increase its strength.
ALUMINUM ALLOY-FACED HONEYCOMB
Very thin sheets of aluminum alloy may meet all of
the strength requirements for an aircraft structure,
but they may not provide enough rigidity or stiffness to withstand the rough handling to which the
structure is subjected. To provide this rigidity, some
wing skins, fuselage panels, and floorboards are
made of aluminum alloy-faced honeycomb.
With aluminum alloy-faced honeycomb, a core
material is made up of aluminum foil formed into a
cellular structure similar in shape to that used by
the honey bee. This form gives a maximum amount
of strength for its weight, but it is strong only
against loads that act in line with the cells. The core
material is cut into slabs of the proper thickness,
and face sheets of thin aluminum alloy are bonded
to both sides of the core. This stabilizes the core and
produces a panel whose strength is greater than
both of the face sheets. It has the rigidity of a thick
panel, but its weight is far less than that of a solid
panel of similar dimensions, or of a panel built up
by any other method. [Figure 2-17]
Repair of a simple puncture of an aluminum
alloy-faced honeycomb panel can be accomplished
by covering with a doubler plate. The plate should
be cut from a piece of aluminum the same or up to
one and one-half times the thickness of the original
skin thickness. Additionally, the doubler should
be tapered at a ratio of about 100:1. The repair of
honeycomb panels is covered in the section on
Aircraft Wood and Composite Structural Repair in
Chapter Three, Wood and Composite Structures, in
this text.

CORROSION PREVENTION OF
SHEET METAL MATERIALS
As previously mentioned, the susceptibility of aluminum alloys to corrosion is one of the limiting factors as to its use as a structural material. In many

Figure 2-17. Aluminum alloy-faced honeycomb panels are

used in aircraft where high strength, light weight, and stiffness are required. Bonded honeycomb is not restricted to
straight panels, but may also be used to form
complex-shaped control surfaces and is even used for
the rotor blades of some helicopters.

cases, this problem has been largely minimized by

three methods of protection. These methods are;
cladding the alloy with pure aluminum, covering
the surface with an impenetrable oxide film, and
covering the surface with an organic coating such as
primer and paint.
Before looking at each of these methods, a review of
how corrosion forms will help you to understand
what causes it and what can be done to prevent it.
For a more thorough review, this information is covered in much more detail in Chapter Twelve of the
ASrP Technician General Textbook.
Corrosion is an electrochemical action in which an
element in the metal is changed into a porous salt of
the metal. This salt is the white or gray powder that
can be seen on a piece of corroded aluminum. In
order for the corrosion to form, three elements must
be met. First, there must be an area of electrode
potential difference within the metal; second, there
must be a conductive path within the metal between
these areas; and third, some form of electrolyte must
cover the surface between these areas to complete
an electrical circuit.
Look at an example of dissimilar metal corrosion to
see the way it works. When a steel bolt holds two
pieces of aluminum alloy together, there is an
opportunity for galvanic, or dissimilar metal, corrosion to form. Aluminum is more anodic, or more
active, than steel and will furnish electrons for the
electrical action that occurs when the surface is
covered with an electrolyte such as water. When

2-14

electrons flow from the aluminum to the steel, they

leave positive aluminum ions that attract negative
hydroxide ions from the water. This results in the
formation of aluminum hydroxide, or corrosion, as
the aluminum is eaten away.
There are several things that can be done to prevent
corrosion. You may have noticed that almost all
steel aircraft hardware is plated with a thin coating
of cadmium, which has an electrical potential
almost the same as aluminum. As long as the cadmium is not scratched through, there will be no contact between the steel and the aluminum and therefore almost no electrode potential difference. To further protect the aluminum from damage, aluminum
washers may be placed under both the head of the
bolt and the nut, and as even further protection, if
the joint is in a corrosive environment, the bolt can
be dipped in primer before it is installed. This will
exclude water and air from the joint, which will
help prevent corrosion from forming. [Figure 2-18]

Sheet Metal Structures

metal and the alloy, provide a strong and

corrosion-resistant material. For this process, called
cladding, there is a penalty by a loss of only about
5% of the strength of the alloy. To help determine if
a metal sheet is clad or bare, aluminum alloy can be
differentiated from pure aluminum by placing a
drop of 10% solution, caustic soda (sodium
hydroxide) on the surface. If it is an alloy, it will
form a spot.
While pure aluminum does not corrode, it does oxidize; that is, it readily unites with oxygen in the air
to form a dull-looking film on its surface. This film
is extremely tight and prevents any more oxygen
from reaching the metal, so the oxidizing action
stops as soon as the film is completely formed on
the surface. Clad aluminum may be used as the outside skin for airplanes since it gives a nice silvery
appearance without being painted. Care must be
taken, however, to prevent any scratches from penetrating through the thin cladding, as the alloy
would then be exposed and would corrode.
However, it is not unusual for corrosion to form
along the edges where the alloy is exposed and
between overlapping sheets. These joints are often
referred to as fayed edges, and require additional
protection. In many cases, fayed edges are sealed
with a primer or epoxy filler to exclude moisture.
OXIDE FILM
An oxide film can protect aluminum alloy in the
same way it protects pure aluminum; by excluding
air and moisture from the metal. Since an aluminum
alloy cannot corrode unless an electrolyte is in contact with the metal, the oxide film insulates the surface from the electrolyte, and corrosion cannot
form. This protective oxide film may be formed
either electrolytically or chemically. Both methods
produce a film that not only excludes air from the
surface, but also roughens it enough for paint to
bond tightly.

Figure 2-18. Corrosion may be prevented by excluding

moisture from the metal and by preventing contact between
dissimilar metals.

CLADDING
Pure aluminum will not corrode since there is no
electrode potential difference within the metal, but
it is too weak for use as an aircraft structural material. However, as previously mentioned, if a thin coating of pure aluminum is rolled onto the surface of
the strong aluminum alloy, features of both, the pure

PAINT FINISHES
When all-metal airplanes first became popular, they
were seldom painted. Instead, the skin was usually
of clad aluminum alloy, which had a shiny silver
appearance. However, in order to keep the skin
shiny, the dull oxide film had to continually be
rubbed off, and since this type of surface requires so
much care, the modern trend has become to paint
the entire aircraft.
With a painted finish, the majority of modern
high-volume production aircraft is primed with a
two-part wash primer that etches the surface of the
metal so paint will adhere. Then, when the
primer is

Sheet Metal Structures __________________________________________________________________________ 2-75

completely cured, the entire airplane is sprayed

with acrylic lacquer. However, when the cost of the
finish allows it and when there is sufficient time in
the production schedule, the surface may be primed

with epoxy primer and the aircraft finished with

polyurethane enamel. These finishes are far more
durable than acrylic lacquer and yield a much more
attractive finish.

SHEET METAL TOOLS AND FASTENERS

Aircraft constructed from sheet metal require many

specialized tools for fabricating the metal and for
installing special fasteners. Due to the number of
manufacturers of sheet metal equipment and fastener hardware, only a select few items are covered
in this section. Continuous work as an aircraft technician, requires learning how to operate additional
tools and how to install more types of fasteners. In
all cases, refer and adhere to the appropriate manufacturer's instructions regarding the proper use of
equipment and hardware that is used for aircraft
maintenance.

64ths of an inch on one side, and increments of

5Oths and lOOths of an inch on the other, are most
useful. For the greatest accuracy when using a scale,
do not measure from its end. Instead, start with one
of the inch marks. This is recommended because it
is quite possible for a scale-end to have been damaged, resulting in an inaccurate measurement.
[Figure 2-19]

Figure 2-19. Do not make measurements from the end of a

steel scale; rather, start with one of its inch marks.

FABRICATION TOOLS FOR

SHEET METAL STRUCTURES

COMBINATION SQUARE

In Chapter 9 of the A&P Technician General

Textbook, hand tools and measuring devices were
discussed in detail. In this section, a review of some
of the tools especially designed for sheet metal construction and repair is presented. First, a discussion
regarding basic tool selection and operation for
sheet metal construction will be covered, followed
by an introduction to the use of specialized tools for
specific sheet metal fabrications.

A combination square is another extremely useful

tool for sheet metal layout. The blade in this square
is removable and is available with many different
types of graduations. The blade with graduations of
50ths and lOOths of an inch is the most useful for
aircraft layout work. The head of the square has a 45
degree bevel on one side and a 90 degree face on the
other, with a spirit level and a steel scribe in the
head. [Figure 2-20]

LAYOUT TOOLS
When a sheet metal repair is to be made, or a part is
to be fabricated, a detailed drawing of the repair or
part is sometimes available. For example, a drawing
might be available from a structural repair manual.
Other times, the technician must draw the repair
from scratch, using guidance from a manual or from
the FAA Advisory Circular, AC 43.13-lB,
Acceptable
Methods,
Techniques
and
Practices/Aircraft Inspection, Repair, and
Alterations. Whether the technician prepares a new
drawing or transfers dimensions from a drawing for
a pattern, layout tools are necessary to accurately
determine dimensions.
SCALES

One of the most commonly used measuring devices

for sheet metal layout is a flexible steel scale. These
handy tools usually have four sets of graduations on
them. For aircraft work, a scale with 32nds and

Figure 2-20. A combination square is one of the most useful

measuring tools for sheet metal construction and repair.
Aside from the stock head, which is commonly found on a
combination set, a protractor and center head may be
included.

2-17

Sheet Metal Structures

DIVIDERS

A pair of good quality 6 inch spring dividers is

essential for layout work. These tools are handy for
spacing rivets in a row and for transferring distances
when duplicating parts. They may also be used to
transfer measurements from a full-scale drawing to a
layout on an actual metal part. For example, if an
inspection or a lightning hole is needed, dividers are
used to scribe the outline of the hole onto the surface
of the metal. Dividers are also used to make circles,
arcs, and measurement transfers. [Figure 2-21]

Figure 2-22. Steel scribes should be used only to mark the

cut-off lines on sheet metal. As a result of scratches in soft
sheet metal, stresses can concentrate from vibrations at the
scratch, eventually causing the metal to crack. To prevent
this from occurring, lines that will remain on the metal
should be made with a soft felt tip marker, or soft pencil.

PENCILS

Most of the layout marks made on sheet metal can

be made with a sharp, soft lead pencil. These marks
can be more easily seen if the metal is wiped clean
with lacquer thinner or toluol and then sprayed
with a light coat of zinc chromate primer. The
primer takes pencil marks very well, which show
up without eyestrain. Since the film of the primer is
generally so thin, it is not likely to interfere with
accurate layout measurements and marks.

Figure 2-21. Dividers may be set from a steel scale and used
to transfer measurements to the sheet metal.

When using a lead pencil, use caution to avoid making any mark on the hot section of a turbine engine,
or on the exhaust system of a reciprocating engine.
When heated, these marks can cause the carbon
from the pencil to infuse the metal, eventually causing the part to weaken and crack.

SCRIBES

Common lead pencils can cause scratching while

also inducing graphite into the material. To prevent
this from occurring, use only pencils that are
acceptable for sheet metal layout marking. Three
examples of acceptable commercial pencils are
Stabilo "8008," Dixon "Phano," and Blaisdell.
These pencils are made of soft wax-charcoal,
instead of graphite.

In sheet metal fabrications, most work is done with

soft metal so a carbide-tipped scribe is almost never
needed. In many cases, the handiest scribe is made
of plain steel and has a removable point that can be
reversed in the handle so it will not be dulled by
contacting other tools while stored in a toolbox.
When using a scribe for marking sheet metal, a colored dye is usually applied to the metal beforehand,
and the scribe is then used to scratch through
the dye.

Felt marking pens are becoming widely used by

sheet metal technicians because their marks are
more visible than those of other marking tools. To
obtain sharp and clear lines, it is best to use a felt
marking pen with a fresh, sharp tip. Once a part is
fabricated, the lines made by the pen can be easily
removed by wiping them with a rag soaked in
alcohol.

MARKING TOOLS
Once a drawing has been selected, dimensions must
be transferred to the surface of the metal for cutting,
drilling, shaping, and forming. The marking device
will vary according to the surface being marked and
the operation to be performed on the sheet metal.

Scribes should be used in sheet metal work only for

marking the cut-off lines of a part. They should
never be used for marking dimension lines for bending metal. Any mark on a piece of sheet aluminum
or magnesium that is scratched into the metal with
a scribe can cause the part to crack when it is bent.
[Figure 2-22]

FELT MARKING PENS

PUNCHES
The lines drawn on sheet metal indicate where different operations such as bending and drilling are to
be performed. This is not always sufficient for some
operations. Drilling, for instance, requires some
physical indentation on the surface in order to keep
the drill from wandering when first starting.
To

Sheet Metal Structures

2-18

make indentations in metal, different types of

punches are available for accurately transferring
marks. Other types of punches are designed to
impose forces on the metal without damaging adjacent areas.
PRICK PUNCH

Once layout marks have been made with a soft pencil, permanent marks can be made in locations for
holes with a sharp prick punch. It takes only a light
tap with a small hammer to mark these locations,
which can be enlarged later with a center punch.
CENTER PUNCH

Enlarging a prick punch mark with a center punch

allows a drill to be centered so that it will start cutting the metal in the proper location. The center
punch has a blunt point, ground to an angle of about
60 degrees, which approximates the tip angle of a
twist drill. The marks should be deep enough for the
drill to start cutting, but the blow used on the punch
must not be hard enough to distort the metal.
An automatic center punch is one of the handiest
tools a sheet metal technician can have, allowing
punch marks to be made quickly and uniformly.
This punch is spring-loaded; all that is needed is to
center it in the prick punch mark, and depress the
punch. When the punch is pressed hard enough, a
spring-loaded plunger inside the handle is released
and hits the point with a solid blow. [Figure 2-23]

Figure 2-24. A transfer punch is primarily used to mark the

center of rivet holes when using an old skin as a pattern.

PIN PUNCH

One of the most useful punches for a sheet metal

worker is the pin punch because it is ideal for
removing rivets. To do this, begin by drilling
through the rivet head down to the base. Then, by
using a pin punch of the same diameter as the rivet
shank, snap the head off by prying sideways. Once
the rivet head is removed, the rivet shank is then
punched out of its hole with the pin punch, leaving
the original-size rivet hole. When punching the
rivet shanks out of thin materials, back up the metal
before tapping the pin punch to help prevent distorting the metal. [Figure 2-25]

Figure 2-23. An automatic center punch makes uniform

indentations for aligning tools such as drills and hole
cutters.

TRANSFER PUNCH

Much sheet metal repair work consists of replacing

damaged skin with new skins. If the old metal is in
sufficient condition, layout marks can be transferred directly to the new material by the use of a
transfer punch. A transfer punch is used to locate
the exact center of drilled holes, such as those used
for rivets. This punch has a shank the diameter of
the hardware that will be installed in the hole, and
has a sharp point in its exact center. The point will
make a mark similar to a prick punch mark in the
center of the hole. These punches are made as both
solid steel, and automatic punches. [Figure 2-24]

Figure 2-25. A pin punch has a flat tip and a uniform shank
that is available in several different sizes.

Pin punches are available in sizes which correspond to standard rivet diameters. They range in
sizes from 1/16 inch to 1/4 inch. The drill holes are

Sheet Metal Structures

2-19

.002 inch to .004 inch larger than the pin punches.

For example, a 1/8 inch (.125 inch) diameter rivet
uses a No. 30 (.1285 inch) drill. The pin punch used
would be the 1/8 inch size, easily fitting into the
rivet hole with over a .003 inch clearance.
CUTTING TOOLS
Metal cutting tools can be divided into hand-operated or floor-mounted types. The list of these tools
is rather lengthy. However, in this text, the ones
most commonly used in the maintenance of aircraft
will be covered. Again, when using any fabrication
equipment, always consult the tool manufacturer's
information for use and care instructions.
METAL-CUTTING POWER TOOLS

Many of the cutting operations done on sheet metal

require the use of hand tools because the repair is
done on the aircraft rather than being done on a
workbench. Though most operations can be performed with non-powered hand tools, powered
tools make the repair task go much faster and often
much smoother.
Ketts Saw

The electrically operated portable circular-cutting

Ketts saw uses blades of various diameters. The
head of this saw can be turned to any desired angle,
which makes it very useful for removing damaged
sections on stringers and other intricately designed
parts. Advantages of a Ketts saw include:
The ability to cut metal up to 3/16 inch thick.
A starting hole is not required.
A cut can be started anywhere on a sheet of
metal.
The saw provides the capability to cut an inside
or outside radius.
Although the tool is fairly easy to operate, some basic
operating precautions are required. To prevent the
blade from grabbing and kicking back, keep a firm
grip on the saw handle at all times. In addition,
before installing any cutting blade on the tool, the
blade should be checked carefully for cracks. A crack
could cause the blade to fail during operation,
thereby causing parts to fly out, possibly causing serious injury to the operator or bystanders. [Figure 2-26]

Figure 2-26. A Ketts saw uses various circular metal-cutting

blades to easily remove damaged sections of sheet metal.

primarily made of good quality steel and are available with different numbers of teeth per inch of
blade. For metal .250 inch or thicker, use a coarse
cutting blade. However, if a coarse blade is used on
thin metal, the blade can hang up, dull rapidly, or
break. [Figure 2-27]
The saber saw is another tool that is commonly
used for sheet metal repair work. These tools are
electrically powered and similar in operation to the
reciprocating saw. Often, the saber saw is used to
cut holes in flat sheets of metal such as on wings or
control surfaces, or for rough cutting the edges of
sheet metal parts. One advantage of using the saber
saw is that its shoe plate can be tilted, allowing for
bevel-edged cuts. Like the reciprocating saw, saber
saws can be adapted to cut materials other than
metal by using different styles of cutting blades.

Reciprocating Saws

A reciprocating saw is an electrically powered tool

used for rough cutting of large damaged sections
such as portions of spars or stringers. With these
saws, a variety of cutting blades is available to be
used on different types and thickness of materials.
The cutting blades used to cut through metal are

Figure 2-27. When using a reciprocating saw for metal cutting, make certain to use a blade with the proper number of
teeth for the particular operation. In all cases, the manufacturer's information regarding the correct blades to use, and
proper tool operation, should be consulted and followed.

2-20

Sheet Metal Structures

Nibblers

Sheet Metal Shears

A nibbler is a tool used for rough cutting small- to

medium-size holes in skins, radio chassis, and
instrument panels. These tools may be electrically
or pneumatically powered, but are also available in
a non-powered hand version. Regardless of the
operating power, each tool produces a similar style
cut.

One of the most common hand cutting tools used by

sheet metal technicians is a pair of tin snip cutters.
These cutters are considered useful for cutting
metal to a rough shape, but for more accurate and
detailed cuts, aviation snips are used. [Figure 2-29]

The main advantage of a nibbler, aside from its simplicity of operation, is the ability to use the tool for
making detailed inside cuts. To make a cut, the edge
of the sheet metal is placed in a slot in the face of
the tool. By pulling a trigger, a cutting blade moves
down to shear out a small rectangular section of
metal about 1/8 inch deep by 3/16 inch wide. As the
metal is fed into the tool, the action repeats until the
opening is made to the desired size. One disadvantage of the nibbler however, is that it tends to leave
a rough edge requiring the use of a file to smooth the
metal once the cut is complete. For this reason, the
initial cut should be made leaving excess material,
permitting filing to be used to achieve the exact finished dimension. [Figure 2-28]

Figure 2-29. Hand shears and aviation snips are used for
cutting thin sheet metal.

Aviation Snips

Aviation snips are compound action shears which

have a serrated cutting edge that holds the metal
that is being cut. Aviation snips come in sets of
three and are manufactured to perform different
cuts as indicated by a color-code on the handles.
Snips with yellow handles cut straight, those with
green handles cut to the right, and snips with red
handles cut to the left.

Figure 2-28. Manual and powered nibblers are used to cut

out rough-open cutouts in sheet metal. To make inside cuts,
it is necessary to drill a pilot hole in the metal large enough
to allow the nose of the tool to pass through the hole.

NON-POWERED HAND CUTTING TOOLS

Non-powered hand cutting tools are useful since no

outside power is required for their operation, making them ideal for field repairs. These tools also
offer control over the amount of cut, which is often
lacking when using power tools. Since there are so
many types of non-powered cutting tools available,
only a few of the most common types will be discussed in this section.

Files
When aircraft sheet metal skins or other parts with
close tolerances need to fit together, a file is often
used to provide a finished edge or surface. A
detailed description of the file is given in Chapter 9,
Hand Tools and Measuring Devices of the ASrP
Technician General Textbook, but is briefly discussed here as a review of basic file use and care as
it pertains to sheet metal work.
Due to the tolerances and detailed shapes sometimes required when fabricating sheet metal parts, a
wide variety of files may be required to complete a
sheet metal repair or alteration. For most sheet
metal work, the common files include the standard
rectangular, half round, three-square, round or
rat-tail, and knife-edge shapes. With most of these
shapes, the file is available in either a single- or
double-cut variety.

2-21

Sheet Metal Structures

Figure 2-30. Files are available in all sorts of shapes, sizes, and styles. The most common file shapes are shown here.

Keep in mind that single-cut files are primarily used

to provide a smooth finish by removing a small
amount of material with each draw, while
double-cut files provide faster cutting action but
leave a rougher finish. Each of these files is also
usually available in a variety of coarseness of cuts
including coarse cut, bastard cut, second cut,
smooth cut and dead smooth cut. As with any hand
tool, it is important to select the tool that is
designed for the specific task. [Figure 2-30]
File use is also an important consideration.
Improper use not only can cause damage to the aircraft part or the file, but also can cause excessive
time to be spent on accomplishing a fabrication. To
obtain the best results, observe the basic rules of
proper file use.
First, remember that a file is a cutting tool with
sharp edges in one direction. Generally, when filing metal, do not drag the file backward across the
metal with any downward force. Drawing the file
backward while pushing down can dull the teeth.
However, to help remove soft metal from the teeth,
it is acceptable to draw the file backward without
any significant downward force to dislodge metal
particles. Secondly, before and after using a file,
make certain that no metal fragments remain in the
teeth by using a file card to brush the teeth out
before and after use. It is also advisable to coat a
file with light oil before storing the tool for long
periods.

Deburring Tools

Once a hole is drilled in sheet metal, it is not uncommon to find that a sharp edge or burrs, is left around
the circumference of the hole. A drill several sizes
larger than the drilled hole, or a standard countersink
cutter held in a file handle, makes a good tool for
removing the burrs from the edges of holes. However,
a common mistake made by inexperienced technicians is to remove too much material. Remember, a
deburring tool should be used to remove burrs and to
smooth edges. If too much pressure is applied while
deburring, it is possible the hole will become undesirably countersunk. [Figure 2-31]

Figure 2-31. When removing the burrs from the edges of a

drilled hole, do not cut too deeply. If too much material is
removed, the metal will be weakened and any hardware
installed in the hole will not have the same shear area to act
against.

2-22

Sheet Metal Structures

In addition to sharp edges around holes, when sheet

metal is cut, the edge is also left sharp, and with
burrs. A file can be used to remove the burrs from
the edges of a sheet, but grinding a sharp V-shaped
notch in the end of a small file can create a tool that
quickens the job. To use the tool, just pull it along
the edge of the sheet, and the sharp edges of the "V"
will cut the burrs from both sides of the metal at the
same time.
SHOPTOOLS
Shop tools, both powered and non-powered, make
large-scale and repetitive metal cutting and shaping
operations more convenient. Some operations, such
as bends in long sheets of metal, can be accomplished only with larger shop equipment. Although
most shop tools operate in a similar fashion, consult
the tool manufacturer's care and use instructions
before using any new equipment.
SQUARING SHEAR

Of all shop tools, a squaring shear is one of the most

commonly used tools for sheet metal work. A typical size shear will accept a full 4 foot-wide sheet
with the capacity to handle up to a 14-gauge soft
metal, but capacity varies widely depending on
manufacturer. Most shops use foot-operated shears,
but when thick metal must be cut, the shears are
operated by electric motors. [Figure 2-32]
Squaring shears have a guide edge that is adjustable
to keep the material exactly perpendicular to the
blade. Since the guide is adjustable, it is important
to periodically check the alignment by making a
sample cut, and checking the finished edge with a
combination square. This is especially important to
check before making cuts in wide sheets.
In addition to the alignment guide, squaring shears
also have an adjustable stop fence for setting the
depth of a cut, as well as a clamp for holding the
metal tight against the table. The clamp allows fingers to be kept away from the blade during operation. When the metal is in place, stepping on a treadle, or foot pedal, causes the clamp to drop down on
the metal to hold it firmly as the blade shears across
the material. When properly used and maintained,
squaring shears will cut metal smoothly, and leave a
minimum of burrs on the edges of the material.
However, it should be remembered that a squaring
shear can be
a dangerous
piece
of
equipment.

Figure 2-32. A squaring shear is used to make straight cuts

across sheet metal.

Exercise care whenever using a squaring shear to

verify that all fingers are clear before depressing the
treadle. This is especially true when working with
another person who may be helping with positioning large metal sheets.
THROATLESS SHEARS

Throatless shears are best used to cut 10-gauge mild

carbon sheet metal, or up to 12-gauge stainless steel.
The shear gets its name from its construction
because it actually has no throat in the frame of the
tool. Without this throat, there are no obstructions
during cutting, which allows for more mobility in
making detailed cuts. In effect, a sheet of any length
can be cut, and the metal can be turned in any

Sheet Metal Structures

Figure 2-33. The action of throatless shears resembles a

large pair of scissors. A hand lever that causes it to shear
across a fixed lower blade operates the cutting blade
(top blade).

direction to allow for cutting irregular shapes.

[Figure 2-33]
ROTARY PUNCH PRESS

A rotary punch press is used in an airframe repair

shop to punch holes in metal parts, for cutting radii
in corners and for many other jobs where circular
cuts are required. The machine is composed of two
cylindrical turrets, one mounted over the other and
supported by the frame. Both turrets are synchronized so that they rotate together, with index pins
ensuring correct alignment at all times. The index
pins may be released from their locking position by
rotating a lever on the right side of the machine.
This action withdraws the index pins from the
tapered alignment holes and allows an operator to
run the turrets to any size punch desired.
[Figure 2-34]

2-23

Figure 2-34. The hand-operated rotary punch press is used

to punch holes or make radius cuts in metal parts.

that allows the correct cutting speed to be adjusted

for any metal. In addition, the table can be tilted so
bevels and tapers can be cut on thick metal.
However, one of the most useful features of this saw
is a blade cutter and welding machine. If a large
opening or inside hole needs to be cut, a starting
hole can be drilled, the saw blade cut in two, and
then inserted through the hole. Then, with a resistance 'welder that is built into the saw, the blade can
be welded back together. With just a few minutes of
effort, the saw is ready to cut the inside of the hole.
[Figure 2-35]

To operate the machine, select the desired punch by

looking at the stamped size on the front of the die
holder. Then place the metal to be worked between
the die and punch by positioning the desired center
of the hole over a raised teat on the turret. Pulling
the lever on the top side of the machine toward you
actuates a pinion shaft, gear segment, toggle link
and ram, forcing the punch through the metal.
When the lever is returned to its original position,
the metal is released from the punch.
BAND SAW

When sheet metal must be cut along curved lines, or

when the metal is too thick to shear, a band saw can
be used to cut the metal. One of the most versatile
band saws found in aircraft sheet metal shops is a
"Do-all" saw. This saw has a variable speed drive

Figure 2-35. A "Do-all" band saw is useful for cutting curved

lines in metal, wood, or plastic because the blade speed is
adjustable to vary for different types of materials.

Sheet Metal Structures

2-24

DISC SANDER

Wood, plastic materials, and sheet metal can be cut

by the band saw to almost the correct size and then
finished very accurately with a heavy-duty disc
sander. With this tool, the material can be milled
right up to a scribed line. [Figure 2-36]

with specific operating instructions, before using

any equipment for the first time.
DRILL MOTORS

The vast majority of holes drilled in aircraft sheet

metal structure is small and drilled in relatively soft
metal. For this reason, there is seldom a need for a
drill motor larger than one with a 1/4 inch chuck.
Recall that the chuck is the part of the motor that
holds the cutting drill in place, and comes in a variety of sizes depending on the power of the drill motor.
Electric Drill Motors

Figure 2-36. A disc sander is used to trim curved cuts in

sheet metal, wood, or plastic after they have been
rough-cut by a band saw.

SCROLL SHEARS

The convenience of electric outlets in the shop and

the relatively low cost of electric drill motors, as
compared with air drills, make them useful tools. In
addition, a variable speed control makes these tools
even more useful. However, an electric drill motor is
larger and heavier than an air drill and has the potential for producing an electric spark or shock when
being used on an aircraft structure. For these reasons,
air drills, rather than electric drills, are generally
more accepted for sheet metal work. [Figure 2-38]

Scroll shears are used for cutting irregular lines on

the inside of a sheet without cutting through from the
edge. With this tool, the upper cutting blade is stationary while the lower blade is movable. By moving
a handle connected to the lower blade, the shear can
pierce the center of a piece of sheet metal, and cut in
a similar fashion as a can opener. [Figure 2-37]

Figure 2-38. An electric drill motor is often used for sheet

metal repair work when a supply of compressed air is not
readily available. Rechargeable battery-powered drills are
also commonly used for small sheet metal repairs because
of the convenience of use, but should not be used around
compartments containing flammable fluids such as
fuel cells.
Figure 2-37. Scroll shears are used to make irregular cuts on
the inside of a sheet without cutting through to the edge.
Pneumatic Drill Motors

DRILLS
Aviation maintenance technicians use drills and
associated attachments almost more than any other
tool when fabricating sheet metal components.
Drills can be either hand-operated or shop mounted.
Again, always become familiar with the tool manufacturer's operating and safety instructions,
and

The availability of compressed air to operate rivet

guns makes pneumatic, or air drill motors, a logical
choice for aircraft structural repair. These drills are
lightweight, have good speed control, do not overheat regardless of use-frequency, and are available
in a number of shapes that allows them to be used
in difficult locations. [Figure 2-39]

2-25

Sheet Metal Structures

possible to obtain holes that are round, straight, and

free from cracks. This is especially true when the
metal is thick where holes drilled freehand have a
tendency to be made crooked. Drill jigs are most
commonly used during the assembly process while
an aircraft is being built. For example, drill jigs are
very useful for installing anchor nuts or anything
else that requires holes to be made with a high
degree of repetitive dimensional accuracy.

Figure 2-39. A pneumatic, or air drill motor, is the most

widely used drilling tool for aircraft sheet metal repair
work.

The most popular air drill motor is the pistol grip

model with a 1/4 inch chuck. The speed of these
drills is controlled hy the amount of pull on the trigger, hut if it is necessary to limit the maximum
speed, a regulator may he installed at the air hose
where it attaches to the drill. The regulator can then
be adjusted for the maximum amount of air entering
the drill to limit the maximum speed, even with the
trigger fully depressed.
For drilling holes where the structure interferes, a
right-angle drill attachment is available. In addition,
if the chuck and the length of the twist drill prevent
getting the drill motor in where it is needed, a
right-angle drill motor equipped to use
short-threaded twist drills can be used. [Figure
2-40]
DRILL ATTACHMENTS AND SPECIAL DRILLS

Drill jigs are used to assist in drilling accurate holes

in skins and structural subassemblies. These are
held in place by drilling one hole and anchoring the
jig so it can be used as a template to drill numerous
additional holes. The alignment of the jig makes it

Figure 2-40. Threaded shank twist drills are used in drill

motors for a number of reasons. One of the primary reasons
is that the twist drill will not slip in the chuck when subjected to an excessive amount of torque.

A drill attachment used a great deal by sheet metal

technicians during the disassembly of a damaged
aircraft, is a rivet removal tool. A rivet removal tool
is available with interchangeable twist drills that
correspond to standard rivet sizes. Drilling out rivets
is made easier because the tool can be adjusted to cut
only to the depth of the manufactured rivet head.
The procedure is then the same as for the freehand
rivet removal technique. Once the head is drilled,
simply tap or snap off the drilled head, and tap out
the rivet shank with a hammer and pin punch.
Again, the material should be backed up with a
bucking bar or other similar device to prevent damaging the base metal while the shank is driven out.
Right-Angle Drills And Attachments

Angled drill motors are designed for operation in

tight locations where there is limited access to the
structure being drilled. Angled drill motors are
available in two standard head angles of 45 degrees
and 90 degrees. However, for access into even
tighter locations, angled drill motor attachments are
also available. [Figure 2-41]
A right-angled drill motor attachment is primarily
used to open holes in close quarters where even an
angled drill motor cannot work. The attachment is
chucked into a straight pistol-type motor. The twist
drill used on a right angle attachment is installed in
a collet, which can hold a standard twist drill.
When the twist drill becomes too short in the collet,

Figure 2-41. The right-angle attachment allows access into locations that are inaccessible with a standard drill motor.

Sheet Metal Structures

2-26

it can be replaced with a broken straight drill with a

newly sharpened tip. The twist drill is pressed into
the collet and held in place by pressure exerted by
the compressed wall of the collet when it is tightened in the attachment's holder.
Snake Attachments

A flexible snake attachment may be used in limited

access areas where an angle drill motor or angle
attachment cannot be used. The snake attachment
basically performs the same function that a
right-angle attachment does, except it can be snaked
in to drill a hole much farther away than can a
right-angle drill. These are excellent tools for getting
into locations that a regular motor can't, because the
handle will not permit a straight entry on the part
being drilled. One use for a snake attachment is for
back-drilling through holes in original members,
into new, undrilled skins. Back-drilling is done to
open holes in new skins through preexisting holes
drilled in ribs, stringers, or spars, which were
previously made during the original installation of
sheet metal parts. [Figure 2-42]

Figure 2-43. With thin shank extension drills, when pressure

is applied during the drilling operation, the twist drill can
bend and cause whipping. To prevent whipping, the twist
drill is placed in a hollow tube to provide support for the
drill.

SPRING DRILL STOPS

Although it is not uncommon to need a drill that is

reasonably long, it is also important to be conscientious of the fact that a twist drill may be too long for
a given application. In fact, it is often necessary to
limit the amount that a twist drill can penetrate
through a part to prevent damaging components on
the other side of the drilled structure. A device that
is often used to limit twist drill penetration is a
spring drill stop. These stops come in assorted sizes
and use a set screw to anchor the stop to the twist
drill at any desired position. In this fashion, the
exposed length of the twist drill end can be adequately controlled to prevent the drill from penetrating too far through the structure. [Figure 2-44]

Figure 2-42. A snake attachment with its right angle and

threaded twist drill permits access through lightening holes
to back-drill skin repairs.

Extension Drills

There are applications in aircraft maintenance

where it is necessary to reach through a part of the
structure to drill a hole that is beyond the reach of
an ordinary twist drill. When this type problem
occurs, there are two types of extension drills available to use. One is simply a long drill that must have
a piece of aluminum tubing slipped over the shank
to prevent it from whipping during use. The other
has a heavy shank with a small drill fixed into its
end and needs no protective cover, as it is too rigid
to whip. [Figure 2-43]

Figure 2-44. Drill stops are typically color coded to match

the drill size. Silver stops are used with No. 40 drills; copper
stops are used with No. 30 drills; and black stops are used
with No. 21 drills.

DRILL PRESSES

Drill presses are available in a variety of styles with

the most common being the upright variety. When
the upright drill press is in use, the height of the
drill table is adjusted to accommodate the height of
the part to be drilled. When the height of the part is
greater than the distance between the drill and the
table, the table is lowered. When the height of the
part is less than the distance between the table and

2-27

Sheet Metal Structures

the drill chuck, when it is at its full extension, the

table is raised to permit the drill to penetrate completely through the part.
Once the table is properly adjusted, the part is
placed on the table, and the drill is brought down to
aid in positioning the part so that the hole to be
drilled is directly beneath the drill point. The part is
then clamped to the table to prevent it from slipping
during the drilling operation. Parts not properly
clamped may bind on the drill and start spinning,
causing the operator to suffer serious cuts or the loss
of fingers. To prevent injuries, always make sure the
part is properly clamped before starting the drilling
operation. Never attempt to hold a part by hand.
Another consideration when using a drill press is to
make certain to never leave a chuck key in the drill
chuck. Failure to remove the key before turning the
drill press on will cause the key to fly out, possibly
causing serious injury to the operator or bystanders.
[Figure 2-45].

TWIST DRILLS

Twist drills are used for opening holes in metal,

wood, and other materials. A twist drill has three
main parts consisting of the tip, body, and shank.
The tip includes two cutting lips that are normally
sharpened to a 59 degree angle from the center-line.
This produces an included angle of 118 degrees
while the heel of the tip is normally ground to an
angle of about 12 to 15 degrees. However, depending on the type material being cut, twist drills can
have different angles to provide optimum
performance.
The shank of a drill is the portion that is chucked
into the drill motor, whereas the body of the drill
includes hollow flutes and reamer lands. The flutes
aid in carrying material out of the hole while also
providing a method for cooling-oil to be delivered to
the cutting surface. The reamer lands, which are
also part of the body, serve to provide a finished
dimension to the hole. [Figure 2-46]

Figure 2-46. On a typical metal drill, the cutting edges on

the point perform the actual cutting. The lands and flutes
remove the cut material and carry lubricant to the cutting
edges as well as provide a finished cut for proper dimensions.

Figure 2-45. To increase the accuracy and straightness of a

drill press when using a twist drill, it is recommended to
tighten the chuck by using each of the key holes in unison
around the chuck. This tends to provide an even tension on
the shank of the twist drill and helps to ensure straightness.

Some materials require different included and heel

angles to be ground on the tip, while motor speeds
and pressures may also need to be varied. To cut
holes in aircraft aluminum, an included angle of
118 degrees should be used with a high tip speed
and steady pressure on the drill. For soft materials
such as plastics, an included angle of 90 degrees
should be used with drill motor speeds and pressures being adjusted for the particular density.
Stainless steels, on the other hand, require an
included angle of 140 degrees with a slow tip speed
and reasonably heavy drill motor pressure.

2-28
Drill diameters are distinguished in one of four
ways by either a number, fraction, letter, or decimal.
For sheet metal work, number and letter drills are
the types most widely used. Numbered and letter
drills are identified in place of fractional drills in
order to provide a clearance to accept fractional
sized rivets and other hardware. For example, a No.
30 drill has a diameter of .1285 inches whereas a -4

Sheet Metal Structures

rivet has a diameter of 1/8 or .125 inches. Since the

No. 30 drill is .0035 inches larger, the rivet will easily fit into the hole without an excessive clearance.
Although fractional drills come in 1/64 inch increments in sizes less than one inch in diameter, if a
fractional drill is used, the clearances will either be
too close, or too extreme to permit proper hardware
clearance. [Figure 2-47]

Figure 2-47. Fractional twist drills come in 1/64 inch increments in sizes less than 1 inch and can be compared with equivalent decimal and metric measurements by the use of this chart. In addition, the actual decimal equivalent sizes of numbered and lettered
drills can be determined from the chart. This can be useful when selecting drills for the installation of rivets where it is common
to use a numbered drill that is approximately .003 inch larger than the shank diameter of the rivet.

Sheet Metal Structures

2-29

FORMING TOOLS
Very few sheet metal skins are perfectly flat. In fact,
nearly all require bends or curves that must be
shaped in some manner. Forming tools include
tools that create straight bends as well as those that
create compound curves. Some of these tools are
manually powered while others are electrically,
pneumatically or hydraulically powered.
PRESS BRAKES

The secret of economical mass production of airplanes lies in the ability of the designer's skill in
specifying fabrication methods that require only
skilled workers to set up machines, and then having
workers of far less skill produce the parts. The press
brake needs only die installation and adjustment,
and the stops properly set by a skilled worker; then
any number of pieces can be formed with relatively
unskilled labor. [Figure 2-48]

Figure 2-48. The press brake is used for production work

where many similar bends must be made in sheet metal.

Figure 2-49. The cornice brake, or leaf brake, as it is sometimes called, is one of the most commonly used bend fabricating tools found in many aircraft maintenance shops.

nose bar, around which bars of any desired milled

radius may be placed. The bend radius blocks may
be moved back away from the edge of the bending
leaf to accurately adjust the setback or the distance
of the radius from the bending leaf. This is necessary to take into account the thickness of the metal
so the metal will hold a tight contour around the
radius blocks. [Figure 2-49]
When the correct radius block is in place, the metal
to be bent is slipped in the brake and positioned so
the bend line is exactly below the beginning of the
radius in the radius block. However, since the bend
begins under the radius block, it is not possible to see
where the bend line begins. To facilitate placing the
metal in the correct position, a sight line is marked
forward from the bend line approximately at the
same distance as the size of the radius. [Figure 2-50]

With press brakes, a female die is fixed and a male

die is driven by energy stored in a heavy flywheel
by an electric motor. The material is moved over the
female die until it rests against the stop and the
male die is lowered into it. As the dies come
together, they form an accurate bend that can be
duplicated many times.
The number and types of dies available for press
brakes allow them to be used to make almost any
kind of bend in sheet metal. For example, dies are
available that bead the edges so wire can be
installed to make hinges, or they can also be used to
form lock-seams in thin sheet steel, or to form channels and boxes.
CORNICE BRAKES

The cornice brake is one type of widely used bending brake found in most maintenance shops because
it will accommodate a wide range of metal thickness. These brakes normally have a rather sharp

Figure 2-50. By marking a sight line forward of the desired

bend line, a technician will be able to align the metal in the
nose of the brake so that the bend begins at the correct
location. For example, when bending a piece of metal using
a 1/8 inch radius in the brake, mark the sight line 1/8 or .125
inches ahead of the desired bend line.Then, when positioning the metal in the brake, look straight down on the nose of
the radius block to place the sight line at the front of the bar.
A more thorough discussion regarding the setup of bending
brakes is covered in the sheet metal bending section later
in this chapter.

Sheet Metal Structures

2-30

Once the metal is positioned properly in the brake,

a handle is pulled to lower the nosepiece onto the
metal. This action holds the metal securely in place
while being bent. Bending is accomplished by lifting up on a counterweighted bending leaf, which
causes a plate to pivot to force the metal to bend.
Raising the leaf higher causes the angle of the bend
to increase. When making bends to a specified number of degrees, it is generally necessary to bend past
the desired angle. This is because the metal tends to
spring back toward a smaller bend angle once the
bending leaf is returned to the idle position.
Experience facilitates familiarity with how much
additional bending is necessary to achieve a finished angle with various metals.
The manufacturer determines the bending capacity
of a cornice brake. Standard capacities of this
machine are from 12- to 22-gauge sheet metal, and
lengths are from 3 to 12 feet. The maximum bending
angle of the brake is determined by the bending edge
thickness of the radius bars. To provide an increased
bending angle, most radius bars are tapered toward
their front edge to allow the metal to be bent a maximum amount over the bar. [Figure 2-51]

Figure 2-52. The bar folding machine is used to bend the

edges of relatively light stock.

Before using the bar folder, several adjustments

must be made for thickness of material, as well as
the width, sharpness, and angle of fold. Adjusting
the screws at each end of the folder makes the
adjustment for thickness of material. As this modification is made, place a piece of metal of the
desired thickness in the folder and raise the operating handle until a small roller rests on a cam follower. Hold the folding blade in this position and
adjust the setscrews so that the metal is clamped
securely and evenly through the full length of the
folding blade. After the folder has been adjusted,
test for uniformity by actually folding small pieces
of metal at each end of the machine and comparing
the folds.
To make the fold once the machine is adjusted,
insert the metal between the folding blade and jaw.
Hold the metal firmly against the gauge and pull the
operating handle toward you. As the handle is
brought forward, the jaw automatically raises and
holds the metal until the desired fold is made.
When the handle is moved back to its original position, the jaw and blade will return to their original
positions and release the metal.
BOX BRAKE

Figure 2-51. To increase the degree of bend that can be

achieved with a cornice brake, the radius bars are tapered
to allow the bending leaf to have a greater amount of
travel.

BAR FOLDING MACHINE

The bar folder is designed for use in making bends

or folds along edges of sheets. This machine is best
suited for folding small hems, flanges, seams, and
edges to be wired. Most bar folders have a capacity
for metal up to 22-gauge in thickness and 42 inches
in length. [Figure 2-52]

The box brake, sometimes referred to as a pan or

finger brake, is probably one of the most widely
used forming tools. This extremely handy brake is
very similar to the cornice brake except that its top
leaf is fitted 'with a number of radius bars, or fingers.
These bars of varying widths can be selected to the
dimensions of a box interior in which four sides are
bent. Two opposite sides of a box may be formed on
a leaf brake, but the last two sides must be formed
with a box brake. The fingers are selected to fit just
between the two sides that have been formed, and
when the box is clamped in place and the leaf is
raised, the sides of the box will slip between the

2-31

Sheet Metal Structures

Figure 2-53. The box, or finger brake, is similar to a cornice

brake, except that it has split leaves to allow bending of the
multiple sides of four-sided box objects.

fingers. This allows the last two sides of the box to

be formed. [Figure 2-53]
SLIP ROLL FORMER

All of the machines discussed to this point are used

to make rather sharp bends in sheet metal, but
sometimes a gentle curve in a part is needed to form
a metal tube, or to form a skin for a fuselage. To
make these curves, a slip roll former can be used.
A slip roll former is a simple machine consisting of
three hard steel rollers in a framework. A drive
roller is turned with a hand crank, while a clamp
roller is adjustable up or down to provide a tight
clamping action to aid in pulling the metal through
the machine. In addition to the drive and clamp
rollers, a radius roller can be adjusted in or out to
increase or decrease the radius being formed in the
metal as it passes through the rollers. [Figure 2-54]

To use the slip roll former, the metal is placed

between the drive and clamp rollers, and the hand
crank is turned to pull the metal through the
machine. As the metal passes through, it moves over
the radius roller. On the first pass, the radius roller
should be adjusted to just touch the metal to form a
very slight curve. By subsequently passing the metal
through the machine with the radius roller adjusted
to a tighter fit, the metal will take on a greater
curved surface. Each time the metal is rolled
through the machine, the radius roller is moved up
a bit so it will decrease the radius of the curve in the
metal. The metal is passed through the former several times with the radius roller being progressively
adjusted to obtain the desired radius.
COMPOUND CURVE TOOLS

In the modern aircraft factory, large compound

curved skins are produced on stretch presses where
the sheet of metal is grasped in two large sets of
jaws, and the sheet is pulled across a male die until
it stretches to the desired shape. Once formed, the
metal is then trimmed to the proper size.
Stretch Press

Stretch presses are usually found in an aircraft factory. However, variations of this tool can be rented
for use in small repair shops or by aircraft
home-builders. These tools are used to form
compound curved parts by pulling the sheet across
a male die. When formed in this manner, the metal
obtains a certain amount of strength and rigidity by
being left in a cold-worked condition.
Drop Hammer

A process that has been used longer than the stretch

press is drop hammer forming. In this process, large
matching metal male and female dies are used. By
placing sheet metal over the female die and dropping or slamming the male die onto the female die,
the metal will be forged into the contoured shape.
This method of forming tends to make a uniform
grain pattern in the metal, causing the strength of
the material to increase.
Hydropress

Figure 2-54. A slip roll former is used to make gentle bends

to fabricate parts such as tubing or contoured fuselage skins

Smaller components such as fuselage formers, wing

ribs, and all types of compound curved brackets are
formed in a hydropress. With a hydropress, a blank
for the part is punched out of sheet metal on a
punch press. The blank is then placed over a metal
male die and held in place with tooling pins sticking through holes in the blank. The die is placed on
the bed of a hydropress; then a ram, which carries a
thick rubber blanket, is lowered over the die. A

Sheet Metal Structures

2-32

Figure 2-55. A hydropress uses water pressure to force a

piece of sheet metal to assume the shape of the die.

pressure of several thousand tons is applied to press

the rubber down over the metal, making it conform
to the shape of the die. [Figure 2-55]
Shrinkers And Stretchers

Shrinking and stretching tools are used to form contours in parts by expanding or compressing metal to
make it form a curved surface. For example, when
the edge of sheet metal is worked in a stretcher, the
edge will expand, causing it to form an outside
curve. Conversely, a shrinker causes the metal to
contract, which causes the metal to form an inside
curve. Each tool is constructed in a similar fashion
in that they both consist of two pairs of heavy jaws
that are operated by a hand lever or foot pedal. In
each tool, gripping jaws are opened and the edge of
the material is placed between them.
With a shrinker, pulling down on a lever or
hydraulically operating the tool by a foot pedal
causes the jaws to grip the metal and then move
inward to compress a small portion of the edge.
With a stretcher, the opposite is true in that the jaws
grip the metal and then spread apart. By progressively working the metal over a certain distance
along its edge, the metal will eventually begin to
take on a contoured radius. The jaws do not move
enough to buckle or tear the metal, but just enough

Figure 2-56. Sheet metal shrinkers and stretchers work on

the principle of clamping the sheet metal between two jaws
while moving the jaws together or apart slightly, to compress or expand the material, respectively.

to compress or stretch it somewhat. The material is

worked back and forth across the full width of the
curve, shrinking or stretching it just a little with
each movement of the jaws. [Figure 2-56]
Sandbags

When only one part is to be formed, a heavy canvas

bag filled with a good grade of washed sand can
serve as a mold. An impression is made in the sand
that approximates the desired shape, and the metal
is carefully formed into the depression with a
round-face plastic mallet. This is strictly a trial and
error method of forming, and its results depend
upon the skill of the worker and the care that is
taken. [Figure 2-57]

Figure 2-57. A sandbag can be used to form a one-of-a-kind

compound curved part.

2-33

Sheet Metal Structures

SPECIAL ASSEMBLY TOOLS

The job of fabricating sheet metal assemblies is
made much easier by the use of tools that have been
created specifically for working with sheet metal.
Since there are so many specialty tools available for
sheet metal work, only a select few of the most common types are discussed in this text. However, these
tools are representative of those most likely to be
encountered when the technician begins performing
basic sheet metal repairs to aircraft.
CLAMPS AND SHEET FASTENERS

There are many devices used by technicians to

assist them when fabricating sheet metal aircraft
components and structures. Some of the most
important tools are those used to verify that parts
remain in proper alignment during the assembly
process. Three of the most common holding tools
include Cleco fasteners, C-clamps, and wingnut
clamps.
Cleco Fasteners

Before an aircraft sheet metal structure is riveted, it

should be temporarily assembled to be sure that all
of the parts fit together properly. To provide the
closest tolerance fit for rivets, it is standard practice
in many operations to drill all of the rivet holes in
the individual parts with a pilot drill. The pilot drill
is typically smaller than the nominal size of the
rivet shank. Eventually, when the parts are mated
together, another drill is passed through the pilot
holes to open them up to the proper dimensions of
the rivet shank. To help prevent the parts from shifting during the final drilling and assembly process, it

is common to use clamping fasteners to hold the

parts together until the rivets are installed. This
helps ensure alignment of the holes so the rivets
seat properly.
One of the most widely used clamping devices is
the Cleco fastener, a patented product developed by
the Cleveland Pneumatic Tool Company. Although
there are other manufacturers of similarly designed
clamping devices, the name Cleco is generally associated with these types of tools.
Cleco fasteners consist of a steel body, a spring
loaded plunger, two step-cut locking jaws, and a
spreader bar. To install or remove a Cleco requires
the use of a specially designed pair of pliers. With
these pliers, the fastener body is held while pressure is applied to the spring loaded plunger on the
top of the Cleco. This fo rces the pair of
locking jaws away from the body and past the
spreader bar.
As the jaws pass beyond the bar, they come together,
decreasing in diameter. This allows the jaws to be
inserted into a rivet hole and then when the pliers
are released, the jaws draw back in toward the body
past the spreader bar. When the jaws spread apart,
the diameter increases, causing the steps in the jaws
to grab the underside of the metal. When the jaws
retract as far as they can into the body, they apply
spring pressure between the locking jaws and the
sheet metal, as well as filling the hole diameter with
the jaws. Once the pliers are removed from the fastener, a tight grip is formed to help prevent slippage
of the material. [Figure 2-58]

Figure 2-58. Cleco fasteners are used to temporarily hold sheet metal parts together until they are riveted.

2-34

Sheet Metal Structures

Clecos are available in sizes for all the commonly

used rivets and even in one larger size. To help
identify the designed hole size of Clecos, the body is
color coded in one of the
Silver
3/32 inch following colors:
1/8 inch (-3 diameter rivet) (-4 Copper
5/32 inch diameter rivet) (-5 diameter Black
Brass
3/16 inch rivet) (-6 diameter rivet)
Copper
1/4 inch Wing Nut Fasteners
Wing nut fasteners are used prior to final assembly
of aircraft parts that need to be held extra tight
before riveting is started. For example, sheet metal
parts under tension around a bend tend to spring
apart and may need more pressure to hold the metal
together than a Cleco can provide. The wing nut fastener, when hand tightened, will clamp the metal
together with more pressure than the spring tension
of a Cleco, thus ensuring against any possible slippage. However, a major drawback to using wing nut
fasteners is the amount of time required to install
and remove them. [Figure 2-59]
C-Clamps

The C-clamp is a tool primarily used by machinists,

but has been adapted by technicians working with
sheet metal for holding work together on aircraft. It
is useful for holding sheet metal in place before
beginning the drilling operation. C-clamps are available in many sizes. However, smaller sizes are generally preferred for sheet metal applications to prevent damage to the metal.

Figure 2-59. Wing nut fasteners are used for temporarily

holding sheet metal parts together with more pressure than
a Cleco fastener can provide. These fasteners also have the
same color coded bodies as Clecos to identify the diameter
hole they are designed for.

The C-clamp looks like the letter "C"; hence, its

name. The C-frame has a fixed rest on its lower end
and a threaded end at the top. The threaded end has
a shaft that runs through it with a tee handle running
through the shaft, and a floating pad on the end.
Before using one of these clamps on sheet metal, it is
advisable to place masking tape over each of the
pads to help prevent marring of the sheet metal's finish. In addition, before using these clamps, check to
make certain the floating pad on the threaded shaft
is free to swivel and turn to help prevent marring as
the clamp is tightened. [Figure 2-60]

Figure 2-60. C-clamps are useful for holding sheet metal parts together to drill the initial rivet holes as shown on the left. Another
device similar to a C-clamp is a side grip clamp, resembling the one shown here on the right. These clamps are spring loaded in
the same fashion as a Cleco fastener and are installed and removed using Cleco pliers. Because these clamps are small, they are
ideal in tight fitting locations.

Sheet Metal Structures

2-35

HOLE FINDERS

Hole finders are used for locating rivet holes in

undrilled skins where a pre-existing hole is hidden
by the metal sheet. For example, when an aircraft
sheet metal structure is disassembled for a repair,
damaged skins may be removed and replaced with
new skins while some pre-drilled parts remain on
the aircraft. When the new skin is positioned, it may
not be possible to see where the holes are located to
drill to match the new skin to the pre-drilled parts.
A hole finder consists of two metal straps that are
brazed or riveted together at one end. At the opposite end, a pin or pilot extends out from one of the
straps while the other strap either has a drill bushing or a center punch type plunger. To use the hole
finder, separate the straps and slide the one with the
pilot in between the undrilled and drilled parts.
When the pilot drops into a rivet hole the second
strap with the drill bushing or center punch plunger
will be in alignment with the center of the hole. If a
drill bushing is used, drill straight through the hole
finder to make the new hole in the skin.
On the other hand, if a center punch plunger is used
on the hole finder, tap the plunger lightly with a
mallet to mark the center of the hole. Once marked,
remove the hole finder and drill the part in the normal fashion using the center punch mark as a guide.
[Figure 2-61]

Figure 2-61. A hole finder is used to match holes in an

undrilled sheet of metal with existing holes in a hidden
part. These tools come equipped with different sized pilots
for various rivet diameters. Make sure you do not use a
hole finder with too small a pilot, or the drilling accuracy
will be diminished and could cause elongation of the preexisting hole.

CHIP CHASERS

It is sometimes impossible to disassemble skins

after drilling a hole, and as a result, there are metal
chips that can lodge between the skins that will prevent them from fitting tightly together when a rivet
is installed. A tool used to remove these metal chips
is commonly called a chip chaser and can be purchased or made from a strip of feeler gauge stock.
When making a chip chaser, use a piece of stock that
is thin enough to get between the parts and yet stiff
enough to pull out the chips. A strip of .010 inch
thick stock is generally considered adequate. Cut a
notch near the end of the strip and fasten some sort
of handle to the opposite end to make it easy to
hold. To use it, just reach in between the skins with
the chaser and rake the chips out from between the
metal. However, try to pull the parts back so that the
chips or the tool does not scratch the finish of the
metal. [Figure 2-62]

STRUCTURAL FASTENERS
The integrity of an aircraft joint depends upon the
fasteners selected and used to secure its parts
together. However, not all aircraft joints are made

Figure 2-62. A chip chaser can be fashioned to remove drill

chips from between sheet metal skins. Another resource for
a longer chip chaser is to take an old band saw blade and
shear the cutting teeth off its edge. Once cut and shaped,
file the edges of the band smooth so that it does not
scratch or damage the surface of the metal when used.

using fasteners. Some joints on newer aircraft are

made with composite materials that are held
together by adhesives. Although this construction
technique is gaining popularity, this method of construction will probably never completely take the
place of using fasteners in aircraft assemblies. It is

2-36

therefore important for an aircraft technician to be

thoroughly familiar with the different types of fasteners that are encountered in industry. Although
this section provides general guidelines in the selection and installation of various types of hardware
and fasteners, it is always advisable to get
acquainted with the fastener manufacturer's technical information before using its product on an
aircraft.
SOLID SHANK RIVETS
The solid shank rivet has been used since sheet
metal was first utilized in aircraft, and remains the
single most commonly used aircraft fastener today.
Unlike other types of fasteners, rivets change in
dimension to fit the size of a hole during installation. [Figure 2-63]

Figure 2-63. Before a rivet is driven, it should extend

beyond the base material at least one and a half times the
rivet's diameter. Once driven, the rivet shank expands to fill
the hole, and the bucktail expands to one and a half times
its original diameter. Once the bucktail expands to the
appropriate diameter, it should extend beyond the base
material by at least one-half the original rivet diameter.

When a rivet is driven, its cross sectional area

increases along with its bearing and shearing
strengths. Solid shank rivets are available in a variety of materials, head designs, and sizes to accommodate different applications.

Sheet Metal Structures

is a three-digit number that describes the style of

rivet head. The two most common rivet head styles
are the universal head, which is represented by the
code 470, and the countersunk head, which is represented by the code 426. Following the head designation is a one- or two-digit letter code representing
the alloy material used in the rivet. These codes will
be discussed in detail later.
After the alloy code, the shank diameter is indicated
in 1/32 inch increments, and the length in increments of 1/16 inch. Therefore, in this example, the
rivet has a diameter of 4/32 inch and is 5/16 of an
inch long. [Figure 2-64]

Figure 2-64. Rivet identification

head style, material, and size.

numbers

indicate

The length of a universal head (AN470) rivet is measured from the bottom of the manufactured head to
the end of the shank. However, the length of a countersunk rivet (AN426) is measured from the top of
the manufactured head to the end of the shank.
[Figure 2-65]

RIVET CODES

Rivets are given part codes that indicate their size,

head style, and alloy material. Two systems are in
use today: the Air Force - Navy, or AN system; and
the Military Standards 20 system, or MS20. While

there are minor differences between the two systems, both use the same method for describing rivets. As an example, consider the rivet designation,
AN470AD4-5.
The first component of a rivet part number denotes
the numbering system used. As discussed, this can
either be AN or MS20. The second part of the code

Figure 2-65. Universal and countersunk rivet diameters are

measured in the same way, but their length measurements
correspond to their grip length.

Sheet Metal Structures

RIVET HEAD DESIGN

As mentioned, solid shank rivets are available in

two standard head styles, universal and countersunk, or flush. The AN470 universal head rivet now
replaces all previous protruding head styles such as
AN430 round, AN442 flat, AN455 brazier, and
AN456 modified brazier. [Figure 2-66]

2-37

head if the rivet hole was not countersunk or dimpled correctly, resulting in the rivet not expanding
to fill the entire hole.
To ensure head-to-gun set contact, it is recommended that countersunk heads be installed with
the manufactured head protruding above the skin's
surface about .005 to .007 inch. This ensures that
the gun set makes direct contact with the rivet head.
To provide a smooth finish after the rivet is driven,
the protruding rivet head is removed using a
microshaver. This rotary cutter shaves the rivet
head flush with the skin, leaving an
aerodynami-cally clean surface. [Figure 2-67]

Figure 2-66. The AN470 rivet now replaces almost all other
protruding head designs. The round head rivet (AIM430) was
used extensively on aircraft built before 1955, while the flat
head rivet (AN442) was widely used on internal structures.
Flat head rivets are still used for applications requiring
higher head strength.

AN426 countersunk rivets were developed to

streamline airfoils and permit a smooth flow over
an aircraft's wings or control surfaces. However,
before a countersunk rivet can be installed, the
metal must be countersunk or dimpled.
Countersinking is a process in which the metal in
the top sheet is cut away in the shape of the rivet
head. On the other hand, dimpling is a process that
mechanically "dents" the sheets being joined to
accommodate the rivet head. Sheet thickness and
rivet size determine which method is best suited
for a particular application.
Joints utilizing countersunk rivets generally lack
the strength of protruding head rivet joints. One
reason is that a portion of the material being riveted is cut away to allow for the countersunk
head. Another reason is that, when riveted, the
gun set may not make direct contact with the rivet

Figure 2-67. (A) If a countersunk rivet is set with the rivet

head flush with the metal's surface, some of the gun set's
driving energy is lost. (B) However, if the rivet head is
allowed to protrude above the metal all of the gun set's
energy hits the head, resulting in a stronger joint.

An alternative to leaving the rivet head sticking up

slightly is to use the Alcoa crown flush rivet. These
rivets have a slightly crowned head to allow full
contact with the gun set. To drive these rivets, a
mushroom-type rivet set is placed directly on the
crown flush head. When the rivet is driven, the gun
drives the countersunk head into the countersink,
while simultaneously completing rivet expansion.

Sheet Metal Structures

2-38

1100 Aluminum (A)

Rivets made of pure aluminum have no identifying

marks on their manufactured head, and are designated by the letter A in the rivet code. Since this
type of rivet is made out of commercially pure aluminum, the rivet lacks sufficient strength for structural applications. Instead, 1100 rivets are restricted
to nonstructural assemblies such as fairings, engine
baffles, and furnishings. The 1100 rivet is driven
cold, and therefore, its shear strength increases
slightly as a result of cold-working.
2117 Aluminum Alloy (AD)

The rivet alloy 2117-T3 is the most widely used for

manufacturing and maintenance of modern aircraft.
Rivets made of this alloy have a dimple in the center of the head and are represented by the letters AD
in rivet part codes. Because AD rivets are so common and require no heat treatment, they are often
referred to as "field rivets."

Figure 2-68. The raised head of a crown flush rivet allows

greater contact area with a rivet set. This results in a
stronger countersunk joint.

The main advantage for using 2117-T3 for rivets is

its high strength and shock resistance characteristics. The alloy 2117-T3 is classified as a heat-treated
aluminum alloy, but does not require
reheat-treat-ment before driving.
5056 Aluminum Alloy (B)

This results in a fully cold-worked rivet that needs

no microshaving. [Figure 2-68]
RIVET ALLOYS

Most aircraft rivets are made of aluminum alloy. The

type of alloy is identified by a letter in the rivet code,
and by a mark on the rivet head itself. [Figure 2-69]

Some aircraft parts are made of magnesium. If aluminum rivets were used on these parts, dissimilar
metal corrosion could result. For this reason, magnesium structures are riveted with 5056 rivets,
which contain about 5% magnesium. These rivets
are identified by a raised cross on their heads and
the letter B in a rivet code. The maximum shear
strength of an installed 5056-H32 rivet is 28,000
pounds per square inch.
2017 Aluminum Alloy (D)

2017 aluminum alloy is extremely hard. Rivets

made of this alloy are often referred to as D rivets,
and have been widely used for aircraft construction
for many years. However, the introduction of jet
engines placed greater demands for structural
strength on aircraft materials and fasteners. In
response to this, the aluminum industry modified
2017 alloy to produce a new version of 2017 aluminum called the "crack free rivet alloy." The minimum shear strength of the older 2017-T31 rivet
alloy is 30 KSI, while that of the new 2017-T3 alloy
is 34 KSI.
Figure 2-69. Head markings indicate the alloy used in common aircraft rivets.

D-rivets are identified by a raised dot in the center

of their head and the letter D in rivet codes. Because

2-39

Sheet Metal Structures

Figure 2-70. Different rivet alloys produce different shear strengths in their driven condition.

D-rivets are so hard, they must be heat-treated

before they can be used. [Figure 2-70]
Recall from the study of heat treatments, that when
aluminum alloy is quenched after heat treatment, it
does not harden immediately. Instead, it remains
soft for several hours and gradually becomes hard
and gains full strength. Rivets made of 2017 can be
kept in this annealed condition by removing them
from a quench bath and immediately storing them
in a freezer. Because of this, D-rivets are often
referred to as icebox rivets. These rivets become
hard when they warm up to room temperature, and
may be reheat-treated as many times as necessary
without impairing their strength.
2024 Aluminum Alloy (DD)

DD-rivets are identified by two raised dashes on

their head. Like D-rivets, DD-rivets are also called
icebox rivets and must be stored at cool temperatures until they are ready to be driven. The storage
temperature determines the length of time the rivets
remain soft enough to drive. For example, if the
storage temperature is -30, the rivets will remain
soft enough to drive for two weeks. When DD-rivets
are driven, their alloy designation becomes
2024-T31 because of the work hardening achieved
during installation.
7050-T73 Aluminum Alloy (E)

A new and stronger rivet alloy was developed in

1979 called 7050-T73. The letter E is used to designate this alloy, and the rivet head is marked with a
raised circle. 7050 alloy contains zinc as the major
alloying
ingredient,
and
is
precipitation
heat-

treated. This alloy is used by the Boeing Company

as a replacement for 2024-T31 rivets in the manufacture of the 767 wide-body aircraft.
Corrosion-Resistant Steel (F)

Stainless steel rivets are used for fastening corrosion-resistant steel sheets in applications such as
firewalls and exhaust shrouds. They have no marking on their heads.
Monel (M)

Monel rivets are identified with two recessed dimples in their heads. They are used in place of corrosion-resistant steel rivets when their somewhat
lower shear strength is not a detriment.
SPECIAL RIVETS
A rivet is any type of fastener that obtains its clamping action by having one of its ends mechanically
upset. Conventional solid shank rivets require
access to both ends to be driven. However, special
rivets, often called blind rivets, are installed with
access to only one end of the rivet. While considerably more expensive than solid shank rivets, blind
rivets find many applications in today's aircraft
industry.
POP RIVETS

Pop rivets have limited use on aircraft and are

never used for structural repairs. However, they
are useful for temporarily lining up holes. In addition, some "home built" aircraft utilize Pop rivets.
They are available in flat head, countersunk head,
and modified flush heads with standard diameters
of 1/8, 5/32, and 3/16 inch. Pop rivets are made

Sheet Metal Structures

2-40
RIVET
PULLING
SHELL
STEM

STEM
BREAK POINT

HEADER
UNISINK HEAD
FLATHEAD
Figure 2-71. Pop rivets are frequently used for assembly and
non-structural applications. They must not be used in areas
that are subject to moderate or heavy loads.

from soft aluminum alloy, steel, copper, and

Monel. [Figure 2-71]
FRICTION-LOCK RIVETS

One early form of blind rivet that was the first to be

widely used for aircraft construction and repair was
the Cherry friction-lock rivet. Originally, Cherry

friction-locks were available in two styles: hollow

shank pull-through, and self-plugging types. The
pull-through type is no longer common. However,
the self-plugging Cherry friction-lock rivet is still
used for repairing light aircraft.

Figure 2-72. The friction-lock rivet assembly consists of a

shell and mandrel, or pulling stem. The stem is pulled until
the header forms a buck-tail on the blind side of the shell.
At this point, a weak point built into the stem shears and
the stem breaks off. After the stem fractures, part of it projects upward. The projecting stem is cut close to the rivet
head, and the small residual portion remaining in the head
is filed smooth.

shank rivets. However, because of the expensive

tooling required for their installation, Huck-Loks
are generally limited to aircraft manufacturers and
some large repair facilities.
Huck-Loks are available in four standard diameters:
1/8, 5/32, 3/16, and 1/4 inch, and come in three different alloy combinations: a 5056 sleeve with a 2024
pin, an A-286 sleeve with an A-286 pin, and a
Monel 400 sleeve with an A-286 pin. [Figure 2-73]

Cherry friction-lock rivets are available in two head

styles: universal and 100 degree countersunk.
Furthermore, they are usually supplied in three
standard diameters: 1/8, 5/32, and 3/16 inch.
However, larger sizes can be specially ordered in
sizes up to 5/16 inch. [Figure 2-72]
A friction-lock rivet cannot replace a solid shank
rivet, size for size. When a friction-lock is used to
replace a solid shank rivet, it must be at least one
size (1/32 inch) larger in diameter. This is because a
friction-lock rivet loses considerable strength if its
center stem falls out due to damage or vibration.
MECHANICAL-LOCK RIVETS

Mechanical-lock rivets were designed to prevent the

center stem of a rivet from falling out as a result of
the vibration encountered during aircraft operation.
Unlike the center stem of a friction-lock rivet, a
mechanical-lock rivet permanently locks the stem
into place, and vibration cannot shake it loose.
HUCK-LOKS

Huck-Lok rivets were the first mechanical-lock rivets and are used as structural replacements for solid

Figure 2-73. Unlike friction-lock rivets, Huck-Loks utilize a

lock ring that mechanically locks the center stem in place.

2-41

Sheet Metal Structures

CHERRYLOCKS

The Cherry mechanical-lock rivet, often called the

bulbed CherryLOCK, was developed shortly after
the Huck-Lok. Like the Huck-Lok, the CherryLOCK
rivet is an improvement over the friction-lock rivet
because its center stem is locked into place with a
lock ring. This results in shear and bearing strengths
that are high enough to allow CherryLOCKS to be
used as replacements for solid shank rivets.
[Figure 2-74]
CherryLOCK rivets are available with two head
styles: 100 degree countersunk, and universal. Like
most blind rivets, CherryLOCKs are available with
diameters of 1/8, 5/32, and 3/16 inch, with an oversize of 1/64 inch for each standard size. The rivet, or
shell, portion of a CherryLOCK may be constructed
of 2017 aluminum alloy, 5056 aluminum alloy,
Monel,
or
stainless
steel.
Installation
of

CherryLOCK rivets requires a special pulling tool

for each different size and head shape. However, the
same size tool can be used for an oversize rivet in
the same diameter group.
One disadvantage of a CherryLOCK is that if a rivet
is too short for an application, the lock ring sets
prematurely, resulting in a malformed shank header.
This fails to compress the joint, leaving it in a weakened condition. To avoid this, always use the proper
rivet length selection gauge and follow the manufacturer's installation recommendations.
OLYMPIC-LOKS

Olympic-lok blind fasteners are lightweight,

mechanically-locking, spindle-type blind rivets.
Olympic-loks come with a lock ring stowed on the
head. As an Olympic-lok is installed, the ring slips
down the stem and locks the center stem to the

Figure 2-74. (1)

As the stem is pulled into the rivet sleeve, a bulb forms on the rivet's blind side that begins to clamp the two
pieces of metal together and fill the hole. (2) Once the pieces are clamped tightly together, the bulb continues to form until the
shear ring shears and allows the stem to pull further into the rivet. (3) With the shear ring gone, the stem is pulled upward until
the pulling head automatically stops at the stem break notch, and the locking collar is ready to be inserted. (4) When completely
installed, the locking collar is inserted and the stem is fractured flush with the rivet head.

2-42
outer shell. These blind fasteners require a specially
designed set of installation tools. [Figure 2-75]

Sheet Metal Structures

CHERRYMAX

Olympic-lok rivets are made with three head styles:

universal, 100 degree flush, and 100 degree flush
shear. Rivet diameters of 1/8, 5/32, and 3/16 inch
are available in eight different alloy combinations of
2017-T4, A-286, 5056, and Monel.

The CherryMAX rivet is economical to use and strong

enough to replace solid shank rivets, size for size. The
economic advantage of the CherryMAX system is that
one size puller can be used for the installation of all
sizes of CherryMAX rivets. A CherryMAX rivet is
composed of five main parts: a pulling stem, a driving
anvil, a safe-lock locking collar, a rivet sleeve, and a
bulbed blind head. [Figure 2-76]

When Olympic-loks were first introduced, they

were advertised as an inexpensive blind fastening
system. The price of each rivet is less than the other
types of mechanical locking blind rivets, and only
three installation tools are required. The installation
tools fit both countersunk and universal heads in
the same size range.

Available in both universal and countersunk head

styles, the rivet sleeve is made from 5056, monel,
and inco 600. The stems are made from alloy steel,
CRES, and inco X-750. The ultimate shear strength
of CherryMAX rivets ranges from 50KSI to 75KSI.
Furthermore, CherryMAX rivets can be used at temperatures from 250to l,400. They are available

Figure 2-75. (1) Once an Olympic-Lok rivet is inserted into a prepared hole, the stem is pulled into the sleeve, closing any gap
between the materials being riveted: filling the hole, and forming a bearing area. (2) When the stem travel is stopped by the
sleeve's internal step, the locking collar shears free and is forced into the locking groove. (3) Continued pulling breaks the stem
flush with the rivet head.
'

Sheet Metal Structures

2-43

Figure 2-76. (1) s the stem pulls into the rivet sleeve, it forms a large bulb that seats the rivet head, and clamps the two sheets
tightly together. (2) As the blind head is completed, the safe-locking collar moves into the rivet sleeve recess. (3) As the stem continues to be pulled, the safe-lock collar is formed into the head recess by the driving anvil, locking the stem and sleeve securely
together. Further pulling fractures the stem, providing a flush, burr-free installation.

in diameters of 1/8, 5/32, 3/16 and 1/4 inches, and

are also made with an oversize diameter for each
standard diameter listed.
Removal Of Mechanical-Lock Rivets

To remove mechanical-lock rivets, first file a flat spot

on the rivet's center stem. Once this is done, a center
punch is used to punch out the stem so the lock ring
can be drilled out. With the lock ring removed, tap
out the remaining stem, drill to the depth of the manufactured head, and tap out the remaining shank. All
brands of mechanical-lock blind rivets are removed
using the same basic technique.
HI-SHEAR RIVETS

One of the first special fasteners used by the aerospace industry was the Hi-Shear rivet. Hi-Shear riv-

ets were developed in the 1940s to meet the demand

for fasteners that could carry greater shear loads.
The Hi-Shear rivet has the same strength characteristics as a standard AN bolt. In fact, the only difference between the two is that a bolt is secured by a
nut and a Hi-Shear rivet is secured by a crushed collar. The Hi-Shear rivet is installed with an interference fit, where the side wall clearance is reamed to
a tolerance determined by the aircraft builder. When
properly installed, a Hi-Shear rivet has to be tapped
into its hole before the locking collar is swaged on.
Hi-Shear rivets are made in two head styles: flat and
countersunk. As the name implies, the Hi-Shear
rivet is designed especially to absorb high shear
loads. The Hi-Shear rivet is made from steel alloy

2-44

Sheet Metal Structures

Figure 2-77. (A) A bucking bar and rivet gun are used to install Hi-Shear rivets. (B) A collar is placed over the pin's small end.
(C) The rivet gun forces the collar over the pin. (D) The gun set drives the collar onto the rivet pin and cuts off excess
material. (E) When the collar is fully driven, excess collar material is ejected from the gun set.

having the same tensile strength as an equal size AN

bolt. The lower portion of its shank has a specially
milled groove with a sharp edge that retains and finishes the collar as it is swaged into the locked position. [Figure 2-77]

als. They are lightweight, and as strong as standard

bolts.

LOCK BOLTS

There are three types of lock bolts used in aviation:

the pull-type lock bolt, the blind-type lock bolt, and
the stump-type lock bolt. The pull-type lock bolt
has a pulling stem on which a pneumatic installation gun fits. The gun pulls the materials together
and then drives a locking collar into the grooves of
the lock bolt. Once secure, the gun fractures the
pulling pin at its break point. The blind-type lock
bolt is similar to most other types of blind fasteners.
To install a blind-type lock bolt, it is placed into a
blind hole and an installation gun is placed over the
pulling stem. As the gun pulls the stem, a blind
head forms and pulls the materials together. Once
the materials are pulled tightly together, a locking
collar locks the bolt in place and the pulling stem is
broken off. Unlike other blind fasteners that typically break off flush with the surface, blind lock
bolts protrude above the surface.

Lock bolts are manufactured by several companies

and conform to Military Standards. These standards
describe the size of a lock bolt's head in relation to
its shank diameter, as well as the alloy used. Lock
bolts are used to permanently assemble two materi-

The third type of lock bolt is the stump-type lock

bolt, and is installed in places where there is not
enough room to use the standard pulling tool.
Instead, the stump-type lock bolt is installed using

SPECIAL FASTENERS
Many special fasteners have the advantage of producing high strength with light weight and can be
used in place of conventional AN bolts and nuts.
When a standard AN nut and bolt assembly is tightened, the bolt stretches and its shank diameter
decreases, causing the bolt to increase its clearance
in the hole. Special fasteners eliminate this change
in dimension because they are held in place by a
collar that is squeezed into position instead of being
screwed on like a nut. As a result, these fasteners
are not under the same tensile loads that are
imposed on a bolt during installation.

2-45

Sheet Metal Structures

an installation tool similar to that used to install

Hi-Shear rivets. [Figure 2-78]
Lock bolts are available for both shear and tension
applications. With shear lock bolts, the head is
kept thin and there are only two grooves provided
for the locking collar. However, with tension lock
bolts, the head is thicker and four or five grooves
are provided to allow for higher tension values.
The locking collars used on both shear and tension
lock bolts are color coded for easy identification.
[Figure 2-79]
HI-LOKS

Hi-Lok bolts are manufactured in several different

alloys such as titanium, stainless steel, steel, and
aluminum. They possess sufficient strength to withstand bearing and shearing loads, and are available
with flat and countersunk heads.
A conventional Hi-Lok has a straight shank with
standard threads. Although wrenching lock nuts are
usually used, the threads are compatible with standard AN bolts and nuts. To install a Hi-Lok, the hole
is first drilled with an interference fit. The Hi-Lok is
then tapped into the hole and a shear collar is
installed. A Hi-Lok retaining collar is installed
using either specially prepared tools or a simple
Allen and box end wrench. Once the collar is tightened to the appropriate torque value, the wrenching

Figure 2-78. Lock bolts are classified as pull type, stump

type, and blind type. The bolt used for a particular application depends primarily on access to the work area.

Figure 2-79. As shown here, both the shear and tension type lock bolts come in a variety of sizes with multiple head styles.

Sheet Metal Structures

2-46

Figure 2-81. CherryBUCK fasteners combine two titanium

alloys to produce a one-piece fastener with 95 KSI shear
strength.

Ti-Cb alloy is used in the lower shank. When driven, the lower part of the shank forms a buck-tail.

Figure 2-80. (A) An Allen wrench holds a Hi-Lok bolt in

place while a combination wrench is used to tighten the
shear nut. (B) Once a Hi-Lok is installed, the collar is
installed and tightened. When the appropriate torque value
is obtained, the wrenching device shears off, leaving the
collar.

An important advantage of the CherryBUCK is that

it is a one piece fastener. Since there is only one
piece, CherryBUCKs can safely be installed in jet
engine intakes with no danger of foreign object damage. This type of damage often occurs when multiple piece fasteners lose their retaining collars and
are ingested into a compressor inlet. [Figure 2-81]
TAPER-LOK FASTENER

device shears off leaving only the locking collar.

[Figure 2-80]
HI-LITE FASTENERS

The Hi-Lite fastener is similar to the Hi-Lok except

that it is made from lighter materials and has a
shorter transition from the threaded section to the
shank. Furthermore, the elimination of material
between the threads and shank yields an additional
weight saving, with no loss of strength. The
Hi-Lite's main advantage is its excellent strength to
weight ratio.
Hi-Lites are available in an assortment of diameters
ranging from 3/16 to 3/8 inch. They are installed
either with a Hi-Lok locking collar, or by a swaged
collar such as the lock bolt. In either case, the shank
diameter is not reduced by stretch torquing.
CHERRYBUCK RIVETS

The CherryBUCK is a one-piece special fastener

that combines two titanium alloys which are
bonded together to form a strong structural fastener.
The head and upper part of the shank of a
CherryBUCK is composed of 6AL-4V alloy, while

Taper-Loks are the strongest special fasteners used

in aircraft construction. Because of its tapered
shape, the Taper-Lok exerts a force on the conical
walls of a hole, much like a cork in a wine bottle. To
a certain extent, a Taper-Lok mimics the action of a
driven solid shank rivet, in that it completely fills
the hole. However, a Taper-Lok does this without
the shank swelling.
When a washer nut draws the Taper-Lok into its
hole, the fastener pushes outward and creates a
tremendous force against the tapered walls of the
hole. This creates radial compression around the
shank and vertical compression lines as the metals
are squeezed together. The combination of these
forces generates strength unequaled by any other
type of fastener. [Figure 2-82]
HI-TIGUE FASTENERS

The Hi-Tigue fastener has a bead that encircles the

bottom of its shank and is a further advancement in
special fastener design. This bead preloads the hole
it fills, resulting in increased joint strength. During
installation, the bead presses against the side wall of
the hole, exerting a radial force, which strengthens
the surrounding area. Since it is preloaded, the joint

2-47

Sheet Metal Structures

The hole for a Jo-Bolt is drilled, reamed, and countersunk before the Jo-Bolt is inserted, and held
tightly in place by a nose adapter of either a hand
tool or power tool. A wrench adapter then grips the
bolt's driving flat and screws it up through the nut.
As the bolt pulls up, it forces a sleeve up over the
tapered outside of the nut and forms a blind head on
the inside of the work. When driving is complete,
the driving flat of the bolt breaks off. [Figure 2-84]
Removal Of Special Fasteners

Figure 2-82. The hole for a Taper-Lok is made with a special

tapered drill. Once a Taper-Lok is installed and a washer nut
is tightened, radial compression forces and vertical compression forces combine to create an extremely strong
joint.

Special fasteners that are locked into place with a

crushable collar are easily removed by splitting the
collar with a small cape chisel. After the collar is
split, knock away the two halves and tap the fastener from the hole. Fasteners that are not damaged
during removal can be reused using new locking

is not subjected to the constant cyclic action that

normally causes a joint to become cold-worked and
eventually fail.
Hi-Tigue fasteners are produced in aluminum, titanium, and stainless steel alloys. The collars are also
composed of compatible metal alloys and are available in two types: sealing and non-sealing. As with
Hi-Loks, Hi-Tigues can be installed using an Allen
and combination wrench. [Figure 2-83]
JO-BOLTS

Jo-Bolts are patented high-strength structural fasteners that are used in close-tolerance holes where
strength requirements are high, but physical clearance precludes the use of standard AN, MS, or NAS
bolts.

Figure 2-83. A Hi-Tigue fastener features a subtly shaped

bead at the threaded end of the shank. This bead preloads
the hole it is inserted into, thereby strengthening the joint.

Figure 2-84. Once a Jo-Bolt is inserted into a hole, the bolt

is rotated, causing the nut to pull up to the metal. As the nut
moves upward, a sleeve is forced over the tapered end of
the bolt. This creates a blind head that holds the joint
together.

Sheet Metal Structures

2-48

THREADED RIVETS/RIVNUTS

Figure 2-85. Remove flush-type Jo-Bolts by first drilling a

pilot hole into the bolt slightly deeper than the inside of the
head of the nut. Then, using a twist drill of the same size,
drill to the depth of the pilot hole. Drive the shank and blind
head from the hole using a pin punch of the proper size.

collars. The removal techniques of certain special

fasteners are basically the same as those used for
solid shank rivets. However, in some cases, the
manufacturer may recommend that a special tool be
used.
Removal of Taper-Loks, Hi-Loks, Hi-Tigues, and
Hi-Lites requires the removal of the washer-nut or
locking collar. Both are removed by turning them
with the proper size box end wrench or a pair of
vise-grips. After removal, a mallet is used to tap the
remaining fastener out of its hole.
To remove a Jo-Bolt, begin by drilling through the
nut head with a pilot bit, followed by a bit the same
size as the bolt shank. Once the nut head is
removed, a punch is used to punch out the remaining portion of the nut and bolt. [Figure 2-85]

Goodrich Rivnuts were developed by the B.F.

Goodrich Company to attach rubber deicer boots to
aircraft wing and tail surfaces. To install a Rivnut, a
hole is drilled in the skin to accommodate the body
of the Rivnut, and a special cutter is used to cut a
small notch in the circumference of the hole. This
notch locks the Rivnut into the skin to prevent it
from turning when it is used as a nut. A Rivnut of
the proper grip length is then screwed onto a special
puller and inserted into the hole with a key, or protrusion, aligned "with the key-way cut in the hole.
When the handle of the puller is squeezed, the hollow shank of the Rivnut upsets and grips the skin.
The tool is then unscrewed from the Rivnut, leaving
a threaded hole that accepts machine screws for
attaching a de-icer boot. [Figure 2-86]
ACCESS PANEL AND
COWLING FASTENERS
Turn-lock fasteners are used to secure inspection
plates, doors, cowlings, and other removable panels
on aircraft. The most desirable feature of these fasteners is that they permit quick and easy removal or
opening of access panels for inspection and servicing purposes. Turn-lock fasteners are produced and
supplied by a number of manufacturers under various trade names. Some of the most commonly used
are the Dzus, Airloc, and Camlock.
DZUS FASTENERS

Cowling and other inspection access doors, that

must be opened or removed frequently, can be
secured with Dzus fasteners that require only a
quarter of a turn to lock or unlock. With a Dzus fastener, a hard spring-steel wire is riveted across an
opening on a fixed part of the fuselage, while a stud

Figure 2-86. Rivnuts are commonly available with flat heads and with 100 degree countersunk heads. Countersunk head Rivnuts
are made with both .048 inch and .063 inch head thickness, with the thinner head used when it is necessary to install a Rivnut in
a machine countersunk hole in thin material. Closed-end Rivnuts are available for installation in a pressurized structure or sealed
compartment, such as a fuel tank.

Sheet Metal Structures

2-49

Figure 2-87. With a standard Dzus fastener, a slotted stud

engages a spring mounted to the fuselage. As the stud is
turned one quarter turn, the fastener locks into place by
straddling and securing to the spring.

Figure 2-88. The receptacle of a receptacle-type Dzus fastener guides the stud to the exact location it needs to be
prior to engaging the spring.

is mounted on the access panel and secured by a

metal grommet. Turning the stud one-quarter pulls
the stud down by straddling the spring into a
beveled slot cut into the stud. As the stud reaches a
locked position, the spring drops into a recess in the
slot. [Figure 2-87]

locked position. To aid in ensuring that no stud

misses the spring. Special receptacle-type Dzus fasteners are available that guide the stud over the
spring. [Figure 2-88]

When something is fastened with Dzus fasteners,

care must be taken that the stud in every fastener
straddles each of the springs rather than passing
beside them. To ensure that all of the fasteners are
properly locked, the heads of the fasteners should
all line up once secured. Furthermore, when a Dzus
fastener is fastened, a distinct click is heard when
the spring drops into the recess of the slot in the

To aid in identifying the size and head style of a

Dzus fastener, the manufacturer provides a cast letter and number in the head of each stud. The letters
designate the head style as being a raised oval head,
flush head, or winged head. The winged head style
allows for turning the fastener without the use of
hand tools. On the other hand, the raised oval and
flush head styles, usually require a slotted or
Phillips style screwdriver to be used to turn the fastener. The numbers following the head style letter

Sheet Metal Structures

2-50

AIRLOC FASTENER

An Airloc fastener consists of a steel stud and

cross-pin in a removable cowling or door and a
sheet spring-steel receptacle in the stationary
member. To lock this type of fastener, the stud slips
into the receptacle and is rotated one-quarter. The
pin drops into an indentation in the receptacle
spring and holds the fastener locked. [Figure 2-90]
Figure 2-89. Stud lengths of raised oval head and winged
Dzus fasteners are measured from the bottom of the head
to the bottom of the locking slot, whereas flush head styles
are measured from the top of the head to the bottom of the
locking slot.

designate the diameter and length of the stud. The

first number indicates the diameter of the stud body
measured in 1/16 inch increments, while the second number designates the length of the stud measured in hundredths of an inch. [Figure 2-89]

Figure 2-90. Airloc cowling fasteners are similar to Dzus fasteners and are used in many of the same applications.

CAMLOCK FASTENER

The stud assembly of a Camlock fastener consists of

a housing containing a spring and a stud with a steel
pin. This assembly is held onto the removable portion of the cowling or access door with a metal
grommet. The stud fits into a pressed steel receptacle, and a one-quarter turn locks the steel pin in a
groove in the bottom of the receptacle. [Figure 2-91]

Figure 2-91. With a Camlock cowling fastener, the stud

assembly can be inserted when the pin is aligned with the
slot in the receptacle.

SHEET METAL FABRICATION

The selection of sheet metal materials, and proper
fabrication techniques is crucial during initial construction of a sheet metal structure, or for its
restoration of strength during a repair. In most
cases, selection of materials and fabrication
processes can be determined by consulting the
manufacturer's publications, such as the structural
repair or maintenance manuals. However, if the
manufacturer does not identify specific materials
and fabrication procedures, the technician must
use standard industry acceptable techniques to perform sheet metal work.
To aid the technician, many of these standard material identification and fabrication processes are
addressed in Advisory Circular 43.13-lB,
Acceptable Methods, Techniques and Practices. By
learning and applying standard practices, the technician can perform satisfactory work to many types
of sheet metal structures, even when the manufacturer's information is not available to directly cover
the task to be performed.

INSTALLATION OF SOLID RIVETS

A primary task performed by any aircraft maintenance technician working with sheet metal is to
install solid shank rivets in structures or components. This involves selecting the proper rivets and
installing them in such a way that the maximum
structural integrity of the product is attained, as
determined by engineering experience with properly
installed rivets. Although the concept of installing
rivets is a straightforward process, there are a number of aspects that the technician must understand
and observe to achieve the optimum performance
from the structure or component design.
RIVET SELECTION
When initially fabricating or making a repair to an
aircraft structure or component, the technician's primary objective is to obtain the maximum structural
integrity and aerodynamic shape. When an aircraft is
originally certificated, the acceptance of the design
is based on each subsequent aircraft being manufactured to the original design specifications. If an air-

craft is damaged while in service, it is the technician's responsibility to verify that the aircraft is
repaired to those original specifications and certification criteria. With any sheet metal structure, the
proper preparation and installation of solid shank
rivets is paramount in achieving these goals. One of
the most critical aspects of sheet metal work is to be
able to select the proper rivet for a given application.
As previously discussed in the beginning of this
chapter, when a rivet is used for a particular installation, the shear strength of the rivet, as compared to
its bearing strength, must be considered. This is
especially important when replacing rivets of different types of alloys. For example, if replacing a 2024
rivet with a 2117 rivet, the relative bearing and
shear strengths of each rivet should be considered.
These strengths can be found in rivet charts. In this
case, due to the varying strength characteristics of
the two different types of alloys used in the rivets,
the smaller 2024 rivet must be replaced with one
size larger 2117 rivet to produce the same strength
qualities. In many cases, the only course is to use
the same type and size rivet originally specified.
Bearing and shear strength should usually be nearly
the same. However, the bearing strength should be
slightly higher to enable the part to fail by shearing
the rivets rather than tearing out sections of sheet
metal. [Figures 2-92 and 2-93]
The single-shear strength of aluminum alloy rivets
is shown in Figure 2-92. From this figure it can be
determined that a 1/8 inch diameter AD rivet will
support a load of 331 pounds, and a 1/8 inch DD
rivet will support a load of 429 pounds before shearing. For double-shear loads, that is, a joint in which
three pieces of material are being held together, the
values in the chart are doubled. On the other hand,
Figure 2-93 shows the bearing strength of 2024-T3
clad aluminum alloy sheets. From the chart, you
can determine what the bearing strength of the aluminum sheet will be, given different sheet thickness
and rivet diameters. For example, a .040 inch thick
2024-T3 clad sheet will provide 410 pounds bearing
strength using a 1/8 inch diameter rivet. If an AD

Sheet Metal Structures

2-52

Figure 2-92. The shear strength of a rivet is dependent on its alloy and the diameter of the rivet.

rivet is used, the shear strength of the rivet will be

331 pounds, which is less than the 410 pounds of
bearing strength. In this example, the rivet and
metal combination would provide a satisfactory
joint, in that the rivet would shear in two before
damaging the sheet metal.
When charts are not readily available for determining the shear strength of rivets and bearing strength
of sheet metal, a general formula can be used to
determine the proper diameter rivet for single lap
joints. In this formula, the proper diameter rivet is
equal to three times the thickness of the thickest

sheet of metal in the joint. For example, if a joint

consists of one sheet of aluminum .032 inch thick
and another .040 inch thick, the rivet diameter
would be equal to 3 x .040 or .120 inch. The closest
rivet diameter to this dimension is a -4-diameter
rivet, which is .125 inch. Once the proper diameter
rivet has been determined, the correct rivet length
can be calculated.
To fabricate a properly driven rivet, the width of the
bucked head must be equal to one and a half times
the rivet's original shank diameter and the height
must be one half the original shank diameter. In

Figure 2-93. The bearing strength of sheet metal is dependent on the alloy, thickness of the sheet, and the size of the
installed rivet.

2-53

Sheet Metal Structures

order for the bucked head to develop these finished

dimensions, the rivet needs to protrude through the
metal approximately one and a half times the shank
diameter before being driven.
To calculate the proper length, it is necessary to
multiply one and a half times the diameter of the
rivet and then add the grip length of the material.
For the proper dimension rivet in the previous
example, the rivet length is determined by multiplying the diameter of the rivet (.125) by one and a
half, or 1.5. This provides an answer of .1855. To
this number, add the grip length of the metal (.032
+ .040) to obtain an overall length of .2575 inches.
Once this number is determined, convert the
answer into the closest 1/16 inch increment, which
in this case, is equal to 1/4 inch for a -4 length rivet.
If the rivets in this sample project had universal
head styles, the final rivet identification would be
MS20470AD4-4. [Figure 2-94]

Figure 2-94. A properly formed shop or bucked rivet head

will have a diameter of one and a half times the original
shank diameter wide, by one half the shank diameter high,
as shown in this sketch.

Figure 2-95. Rivet cutters have holes to cut common-sized

rivet diameters, and a series of leaves that are rotated into
position to shim under the rivet head to vary the shank
length.

cific amounts of tensile stress depending on the

type and thickness material. In aircraft construction, it is important that sheet metals be able to
withstand the minimum tensile stresses when the
sheets are used in stressed skin structures. For
example, semimonocoque designs rely heavily on
the ability of sheet metal skins to carry stresses into
a substructure. When an aircraft is designed, engineers determine the amount of load that the sheet
metal must carry to provide the desired strength
from a structure. If sheet metal skins or components
have riveted joints or seams, there must be an adequate number of rivets to carry the load. To determine the proper number of rivets, charts are available to determine the quantity of rivets that must be
used for various types and thickness of alloy sheets.
[Figure 2-96]

RIVET CUTTERS

To avoid carrying a large assortment of rivet lengths,

many shops only purchase longer rivets. For shorter
sizes, a rivet cutter can be used to trim the rivets to
the desired length. [Figure 2-95]
RIVET LAYOUT PATTERNS
It is important when making a riveted repair that the
rivets be installed in such a way that they will
develop the maximum strength from the sheet
metal. To obtain this strength, not only the rivet and
sheet strength must be determined, but the rivet pattern is also a critical factor so the drilled holes do
not weaken the joint. This means the spacing
between rivets and the distance they remain from
the edge of the material cannot be closer than minimum specifications.
RIVETED SHEET METAL STRENGTH

From the previous discussion of sheet metal alloys,

it was presented that sheet metal can withstand spe-

For example, when fabricating a seam in 2024-T3

alclad aluminum that is .040 inch thick, it is necessary to use a minimum of 6.2 1/8 inch diameter rivets per inch of seam width. If the seam is 8 inches
wide, it will require 49.6 or 50 rivets to fabricate the
seam to withstand the same tensile stresses as the
original sheet metal. Additional information regarding the use of these types of charts is covered in the
sheet metal repair section of this chapter.
EDGE DISTANCE

It is important when installing rivets that they be

placed a certain distance from the edge of the material. If rivets are installed too close to the edge, the
sheet metal will tear out instead of shearing the
rivet when extreme loads are encountered.
Conversely, if the rivets are placed too far away
from the edge, the metal sheets can separate, allowing foreign contaminates to enter the joint, ultimately causing corrosion.

Sheet Metal Structures

2-54

NO. OF2117-T4(AD) PROTRUDING HEAD RIVETS REQUIRED

PER INCH OF WIDTH "W"

THICKNESS
"T" IN
INCHES

NUMBER
OF BOLTS

Rivet size
3/32

1/8

5/32

3/16

1/4

AN-3

.016

6.5

4.9

--

--

--

--

.020

6.5

4.9

3.9

--

--

--

.025

6.9

4.9

3.9

--

--

--

.032

8.9

4.9

3.9

3.3

.036

10.0

5.6

3.9

3.3

2.4

__

.040

11.1

6.2

4.0

3JL

2.4

__

.051

--

7.9

5.1

3.6

2.4

3.3

.064

9.9

6.5

4.5

2.5

3.3

.081

12.5

8.1

5.7

3.1

3.3

.091

__

__

9.1

6.3

3.5

3.3

.102

__

__

10.3

7.1

3.9

3,3

.128

__

__

12.9

8.9

4.9

3.3

NOTES:
a. For stringers in the upper surface of a wing, or in a fuselage, 80 percent of the number of rivets shown in the table may be used, b.
For intermediate frames, 60 percent if the number shown may be used, c. For single lap sheet joints, 75 percent of the number
shown may be used.
ENGINEERING NOTES: a. The load per inch of width of material was calculated by assuming a strip 1 inch wide in tension.
b. Number of rivets required was calculated for 2117-T4 (AD) rivets, based on a rivet allowable shear stress equal to 50 percent of the
sheet allowable tensile stress, and a sheet allowable bearing stress equal to 160 percent of the sheet allowable tensile stress, using
nominal hole diameters for rivets.
c. Combinations of sheet thickness and rivet size above the underlined numbers are critical in (i.e., will fail by) bearing on the sheet;
those below are critical in shearing of the rivets.
d. The number of AN-3 bolts required below the underlined number was calculated based on a sheet allowable tensile stress of
55,000 psi and a bolt allowable single shear load of 2,126 pounds.

Figure 2-96. Charts are available to provide information regarding the number of rivets required in a joint or seam to endure the
same amount of tensile strength as sheet metal. The chart in this figure provides information regarding the minimum number of
rivets required per inch of width of a joint or seam to restore the strength of stressed sheet metal structures.

An accepted practice is to place the center of a rivet

hole no closer than two rivet shank diameters from
the edge and no further back than four diameters.
With this in mind, it is common to place the center
of the rivet hole about two and a half shank diameters away from the edge of the sheet. However, if
possible, the rivet edge distance should be the same
as the original by matching the previous pattern, or
by consulting the manufacturer's design specifications.
PITCH

The distance between adjacent rivets in a row is

called the pitch. To prevent the joint from being

weakened by too many holes in a row, the adjacent
rivets should be no closer than three diameters to
one another. In contrast, to prevent the sheets from
separating between rivets, the rivet holes should be
no further apart than ten to twelve times the rivet
shank diameter. [Figure 2-97]
RIVET GAUGE OR TRANSVERSE PITCH

The distance between rows of rivets in a multi-row

layout should be about 75% of the pitch, provided
that the rivets in adjacent rows are staggered. If the
rivets are not staggered, then the pitch will be the

2-55

Sheet Metal Structures

within the allowable spacing of between 3 and 12

times the rivet shank diameter (3D to 12D).
The gauge, or distance, between the rows should be
about 75% of the pitch and, in this case, will be
0.468 inch. For practical purposes, 1/2 inch (.5) is
adequate. Mark a row across the strap 1/2 inch from
the first row of rivets and locate the five holes
needed on this line. These holes should be centered
between the rivets in the first row. Again, mark the
rivet locations with a center punch. [Figure 2-98]

Figure 2-97. Edge distance and rivet pitch are critical to

obtaining maximum strength from a riveted repair.

same between rows as it is between rivets in a single row. For most layout patterns, it is most practical to stagger the placement of rivets to reduce the
amount of sheet metal that has to be overlapped. In
addition, multiple rivet rows are often used to prevent rivets in a single row from becoming too close
together, or to improve the cosmetics of a repair.
SAMPLE LAYOUT PATTERN

For a sample layout pattern, assume that you want

to join two 3-3/4 inch straps of .040 inch 2024-T3
clad
aluminum
alloy
sheets
with
11
MS20470AD4-4 rivets. To install 11 rivets, more
than one row will be required, because a single row
would cause the rivets to be so close that the joint
would be weakened. For this example, assume two
rows are used with six rivets in the first row and
five in the second. To make a layout pattern, first
make two lines to mark off the edge distance of two
and a half rivet shank diameters. Since the rivets
are 1/8 inch (4/32), the distance will be 5/16 inch
from the edge of the sheets. Mark these lines with a
soft pencil or felt tip marker so the marks will not
scratch the metal. Measure another 5/16 inch up
from the ends of these lines to locate the position of
the end rivets so they will have the proper edge
distance from both the end and the sides of the sheet.
Mark these locations with a center punch to enable
starting a twist drill in the correct position. Then,
with a pair of dividers, separate the distance
between the two end rivets into five equal spaces to
find the location of the six rivets for the first row.
These rivets will be 5/8 inch apart, or five
diameters, which is well

Figure 2-98. When multiple rows of rivets are used in a layout, the transverse pitch should be approximately 75% of
the rivet pitch, and the rivets should be staggered.

HOLE PREPARATION FOR RIVETS

The hole in which a rivet is installed is critical to
the strength of the finished repair. The hole must be
slightly larger, but not so large that the expanded
rivet does not fill the hole. Sizes of holes for all conventional rivets can be found in charts included in
most aircraft technician handbooks. It is important
that the hole be properly drilled and finished prior
to a rivet being driven.
DRILL SIZE

The twist drills used for aircraft sheet metal work

are most generally of the number and letter sizes,
rather than the fractional sizes commonly used in
other forms of mechanical work. Most of the rivets
used in sheet metal work are between 3-3/32 inch,

2-56

which is the smallest rivet generally allowed in aircraft structure, and 3/8 inch diameter. Rather than
using rivets larger than 3/8 inch, some other form of
fastener is normally used. [Figure 2-99]

Sheet Metal Structures

amount the trigger is depressed. This is very handy

as it allows the hole to be started with a slow speed,
which provides better drill control. As the hole
begins to form, a faster speed can then be used to
permit production that is more efficient.
When selecting a twist drill for rivet hole preparation, examine the point to be sure that it is properly
ground and sharp. To prevent the twist drill from
wobbling during drilling, the point of the tip should
be in the exact center of the drill. To help ensure
uniform tension on the shank of the twist drill, it is
recommended that the chuck of the drill motor be
tightened using each of the chuck key holes with the
proper size chuck key.

Figure 2-99. The final hole for a particular rivet size can be
prepared by drilling a hole the size of the rivet and then
reaming the hole to the final dimension. Where less critical
applications are allowed, the final dimensions can be drilled
using a number or letter twist drill.

The number drill size for each diameter rivet is

slightly larger than the rivet diameter. As previously
mentioned, the holes made by these drills are usually three- or four-thousandths of an inch larger than
the diameter of the rivet. This allows the rivet to be
slipped in place without forcing it and scraping any
protective oxide coating off the rivet shank. The
clearance is small enough that, during driving, the
shank will swell to take up any excess clearance.
[Figure 2-100]

Proper drill motor use is an important consideration

for preparing acceptable rivet holes as well as for
safety. When using a drill motor, hold the tool in a
manner similar to that shown in Figure 2-101. This
allows for maximum tool control and aids in preventing the drill from pushing through the metal so
far as to possibly cause damage to structures behind
the drilled surface.

Figure 2-101. When using a drill motor, hold the drill as

shown in this figure. Pointing the index finger parallel to
the drill chuck will aid in aligning the twist drill with a 90
degree angle to the drilled surface.
Figure 2-100. Too small a hole will destroy the protective
oxide coating on a rivet shank and may also cause the sheet
metal to buckle once the rivet is driven.
RIVET HOLE PREPARATION

Since rivet holes drilled in sheet metal are usually

small and the metal is soft, lightweight drill motors
can be used to produce rivet holes. For safety, most
sheet metal drilling is accomplished using pneumatic drills, so the chances of electric shock and
arcing are reduced. In addition, pneumatic drill
motors are usually equipped with triggers that permit controlling the motor speed by varying
the

To prevent injuries and damage to aircraft structures

when using a drill motor, observe the following
safety considerations:
1. Be sure there are no burrs on the twist drill
shank that could prevent it from fitting properly
in the chuck.
2. When changing twist drills, it is advisable to
disconnect the air source before tightening the
chuck with a chuck key. If the air source is left
connected, injuries may occur if the trigger is
inadvertently activated. Also, never attempt to

Sheet Metal Structures

tighten a drill chuck by holding the chuck stationary by hand and operating the drill motor.
Before drilling a hole, run the drill motor and
watch the end of the drill. It should not appear
to wobble. If it does, remove it from the chuck
and check to see if it is bent, by rolling the twist
drill over a flat surface. Also, check the twist
drill shank for burrs that would prevent it from
centering in the chuck. Bent drills and worn
chucks will cause oversize holes that can ruin a
repair.
Be sure to wear eye protection when drilling.
Fine chips of metal are propelled from the
rapidly spinning twist drill and by the air
exhaust from pneumatic drill motors.
[Figure 2-102]

2-57

begins to cut the metal with the full face of the tip.
Once the tip makes full contact, increase the speed
of the drill to a faster speed, but not so fast as to
cause loss of control. Use enough force to keep the
drill cutting smoothly, but as soon as the tip begins
emerging through the metal, relax the pressure on
the drill motor. Allow the tip and a portion of the
twist drill body to go through the metal, but do not
allow the chuck to touch the work. If the chuck contacts the surface, it will cause scratches, damaging
the finish of the metal. This is especially critical if
the metal is clad with a protective finish.
When two or more sheets of metal are being drilled
together, once the first hole is drilled, use a Cleco or
similar temporary fastener to secure the metal
together. Failure to use a temporary fastener may
cause the metal to slip during subsequent drilling,
causing misalignment of holes when the drilling is
complete.
DEBURRING

When aluminum alloys are drilled sharp burrs can

remain on the edge of the hole. If these burrs are not
removed before riveting, the sheets of metal will not
fit tightly together. This not only causes cosmetic
flaws, but also prevents the rivets from providing
maximum shear strength. In addition, when sheet
metal is cut, burrs can also form along the edges of
the metal. To remove these sharp edges and burrs, a
process referred to as deburring is accomplished.

Figure 2-102. Be sure to wear adequate eye protection

when drilling sheet metal. Impact resistant safety glasses
with side shields should be worn at all times while working
around sheet metal fabrication areas in the shop or on an
aircraft.

When the drill and drill motor are ready, prepare

the metal. Mark the location for drilled holes with a
center punch and make the indentation just large
enough for the twist drill to start cutting. Too small
a mark will allow the drill to walk, while too heavy
a blow with the center punch may distort the metal.
Also, to prevent distorting the metal, it is advisable
to use a scrap piece of wood to backup the material
to oppose the force of the drill motor.
For right handed individuals, hold the handle and
the trigger with the right hand while using the left
hand to rest on the work. Push back against the drill
motor with the left hand to provide a balance to the
pressure applied in the drilling operation. Center
the point of the drill in the center punch mark and
start the drill motor slowly until the twist drill

Deburring consists of using tools to remove excess

material from around the edges of the sheet metal.
As previously discussed, examples of tools that can
be used for hole deburring include fabricating a
handle made from wood and installing a twist drill
or countersink cutter that is larger than the drilled
hole. Lightly turning the twist drill or cutter in a
hole tends to remove the excess material from
around the edges. However, when using these tools,
make certain to apply only a light pressure to avoid
countersinking the hole. Deburring should remove
only the material that is above the surface of the
sheet metal.
Specialty tools are also available and may be used to
increase the speed and accuracy of deburring. For
hole deburring, a tool is available that has a cutter
that can be rotated by a handle, wherein the handle
is swiveled to cause the cutter to rapidly remove
sharp edges and burrs without countersinking. For
edge deburring of sheet metal, tools are available
that have a notch cut in them so the tool can be
pulled across the edge to deburr both sides of the
metal in a single operation. Make certain all holes

2-58

and edges are deburred before installing any rivets.

When two or more sheets have been drilled
together, separate the sheets and deburr the holes on
each side of the metal. [Figure 2-103]

Sheet Metal Structures

can be countersunk to produce a smooth riveted

surface. If the sheet is too thin, the rivet head will
protrude past the surface of the metal and cause the
shearing zone of the joint to be applied to the rivet
head rather than across the shank. This not only
reduces the effectiveness of the rivet, but also weakens the skin by removing too much material.
[Figure 2-105]

Figure 2-105. The depth of the rivet head limits countersinking a recess in sheet metal. If the metal is too thin, the
countersink will enlarge the hole and cause the metal to
shear across the head instead of the shank.
Figure 2-103. Specialty deburring tools are available
commercially and come in a variety of styles and sizes.

HOLE PREPARATION FOR FLUSH RIVETS

It is extremely important that the skin on highspeed aircraft be as smooth as possible. On many of
these aircraft, airfoils are assembled using flush
head rivets to increase the laminar flow of air over
the surface of the skin. In order for the rivets to seat
as flush as possible, the skin must be contoured or
machined to accept the head of the rivet to a depth
that places the rivet head flush with the surface. To
produce a countersunk hole, a number of processes
may be used. In some situations, the surface material is machined away by a countersink cutter while
in others the rivet head is pressed or dimpled into
the skin. In either case, modern countersinking for
rivets involves forming a recess with a 100 degree
taper. [Figure 2-104]

Milling a countersunk hole is accomplished by using

a countersink or micro-stop cutter after a hole has
been drilled to the desired shank diameter. A standard countersink for aircraft rivets has a cutting
angle, which matches the 100 degrees of the countersunk rivet head. A standard countersink can be used
in a drill motor, but the difficulty in cutting the hole
to the correct depth makes this tool impractical when
you have multiple holes to countersink.
A micro-stop, or stop countersink, as it is sometimes
called, uses a cage that can be adjusted to limit the
depth that the cutter penetrates into the sheet metal.
With this tool, the depth of the cutter is adjusted in
increments of .001 inch to obtain a uniform countersunk depth in multiple holes. Sample countersinking tools are shown in Figure 2-106.

COUNTERSINKING

When the top sheet of metal being joined is thicker

than the tapered portion of the rivet head, the sheet

Figure 2-104. Flush rivets used on modern aircraft include

the AN426 or MS20426 rivet. These rivets have a head angle
of 100 degrees and are measured as shown here.

Figure 2-106. Countersink cutters and the cutters used in

micro-stops are manufactured with a 100 degree cutting
angle. With some cutters, a pilot is milled onto the end
while others have interchangeable pilots. Pilots are available in various sizes to match the diameter of the rivet
shank and help position the cutter in the center of the hole.

2-59

Sheet Metal Structures

A micro-stop countersink is used far more often than

a standard countersink cutter. When using a
micro-stop, the cage portion of the tool is held
stationary against the metal, and the countersink is
pushed into the hole until the cutter reaches a stop,
limiting the depth of the countersink. With a
micro-stop, a shaft fits into the chuck of a 1/4 inch
air or electric drill motor, and the cutter screws onto
this shaft.
When adjusting the stop, set the countersink depth
to cut the proper amount by using a piece of scrap
metal the thickness of the top sheet being riveted.
Drill some holes the size used for the rivet, and
adjust the stop by screwing the cage up or down on
the body and locking it into position with the
lock-nut. Hold the stop with one hand and position
the cage collar tightly against the sheet metal.
Then, press the trigger on the drill motor and push
the cutter into the metal until the stop is reached.
Once milled, slip the countersunk rivet into the
hole and check the flushness of the head across the
surface of the sheet. Depending on the operation, the
rivet may be raised a few thousandths of an inch
above the surface, to be milled smooth with a
microshaver.

pling dies. There are two methods of dimpling sheet

metal: coin dimpling, which forges, or coins, the
metal into the dies, and radius dimpling, which
folds the material down to form the dimple.
Although both techniques are commonly used, coin
dimpling generally provides a slightly tighter fit but
tends to leave a sharper bend around the rivet head.
Radius dimpling may not produce as tight a fit, but
has the advantage of leaving a more gradual radius
bend around the rivet head, helping to prevent
cracking during service.
Coin Dimpling

In coin dimpling, a male die fits through the rivet

hole, and a coining ram in a female die exerts pressure on the underside of the hole. By forcing the
male die into the female die, the metal contours to
the shape of the coin. The pressure on the dies
forges the edges of the hole to exactly fit the shape
of the dies. Coin dimpling gives the hole sharply
defined edges that almost resemble machine countersinking. Both the top and the bottom of the dimple are formed to a 100 degree angle, so multiple
sheets can be dimpled and stacked, or nested.
[Figure 2-108]

A microshaver is a pneumatic tool that turns a

flat-faced milling cutter at high speed. The tool is
equipped with a stop that is adjustable to limit the
amount the cutter extends out from a guard. By regulating the depth of the cutter, the rivet head can be
milled perfectly flush with the metal. [Figure 2-107]

Figure 2-108. Coin dimpling is performed by a special pneumatic machine or press, which has, in addition to the usual
dies, a "coining ram." The ram applies an opposing pressure to the edges of the hole so the metal is made to flow
into all the sharp contours of the die, giving the dimple
greater accuracy and improving the fit.

Figure 2-107. A microshaver is a high-speed milling tool

that is useful in shaving the heads of rivets, to obtain an
accurate flush fit to the surface of the sheet metal.
DIMPLING

When the top sheet of metal is too thin to countersink, the edges of the hole may be formed to accommodate the head of the rivet by using a set of dim-

Radius Dimpling

Radius dimpling is a form of cold dimpling in thin

sheet metal in which a cone-shaped male die is
forced into the recess of a female die, with either a
hammer blow or a pneumatic rivet gun. In some
instances, a flush rivet is used as the male die. The

2-60

male die is forced into the female die. In this form

of dimpling, a rivet gun is fitted with a special
female dimpling die, and the rivet head is set into
the sheet metal by rapid impact blows of the rivet
gun. The dimple formed in this way does not have
parallel sides, as the lower side has an angle greater
than 100 degrees. For this reason, radius dimpling is
not usually considered acceptable to stack or nest
multiple sheets. [Figure 2-109]

Sheet Metal Structures

the technician presses a pedal, the dies are pneumatically pressed together until they both just make
contact with the metal. Once the dies make contact,
a dwell time allows sufficient heat to soften the
metal before the dies are fully squeezed together to
form the dimple. The dwell time for heating is automatically controlled by a timer to prevent destroying the temper condition of the metal. The operator
of the machine must be familiar with how to adjust
the machine for the various time limits and temperatures for the types of metal being formed.
MULTIPLE SHEET FLUSH RIVETING

The proper preparation of holes for flush riveting

depends upon the thickness of the sheets being
joined. If the top sheet is thick enough to be countersunk, the substructure, or lower skins, need nothing more than to have the holes drilled for the rivet.
But if the top skin is too thin to be countersunk, it
must be dimpled and the bottom skin either countersunk or dimpled. In this situation, the top skin
must be coin dimpled so the bottom of the dimple
will fit into the 100 degree inside angle of the dimple or countersink in the lower skin. [Figure 2-110]

Figure 2-109. Radius dimpling does not allow the sheets to

be nested unless the bottom sheet is radius dimpled.
Radius dimpling is done because its equipment is smaller
than that needed for coin dimpling, and can be used in locations where access with coin dimpling tools is not practical.

Hot Dimpling

Magnesium and some of the harder aluminum

alloys, such as 7075, cannot be successfully cold
dimpled, because the material is so brittle it will
crack when the dimple is formed. To prevent cracking, these materials are heated before dimpling is
accomplished. The equipment for hot dimpling is
similar to that used for coin dimpling, except that
an electrical current heats the dies.
To perform hot dimpling, the dies are preheated and
then the metal is positioned between the dies. When

Figure 2-110. Care must be taken to ensure compatibility of

countersunk, coin dimpled, and radius dimpled skins.

RIVET INSTALLATION
Because of the many thousands of rivets used to
hold an aircraft structure together, it is easy to get
complacent with the riveting process and not be
concerned about less than perfect riveting techniques. However, each rivet must carry its share of
the total load in an aircraft structure. If a rivet is not
properly installed, it can force the adjacent rivets to

Sheet Metal Structures

2-61

carry more load than they are designed to take, ultimately causing a structure to fail.
In addition to the proper preparation of a hole for a
rivet, the strength of a riveted joint is determined
by the way the rivets are driven. When installing
rivets, it is important to install the rivet with as few
impacts as possible so the materials will not
work-harden and crack. The shop head of the
rivet should be concentric with the shank and flush
with the surface without tipping. In addition,
the formed, or bucked head, should be fabricated
to proper dimensions.
HAND RIVETING

Almost all rivets are driven with either a rivet gun or

squeeze riveter, but there are times when building
small components, or when working in areas without air or electricity, that it is necessary to drive a
rivet by hand. The process used for hand driving aircraft rivets is not the same as that used by some other
commercial sheet metal processes. Aircraft rivets
driven in flat sheets are never peened over. Instead,
the shank is collapsed with a hand set in much the
same manner as other aircraft riveting techniques.
To drive a rivet by hand, the material to be joined is
prepared by drilling and deburring a hole, and a
rivet is inserted to extend one and a half shank
diameters through the metal. A special metal bar
that has a recessed contour approximately the shape
of the rivet head is then mounted in a vise with the
recess facing upward. The rivet is placed through
the hole in the metal and the rivet head is put in the
recess of the metal bar. A draw set is slipped over
the rivet shank and tapped lightly with a hammer to
draw the sheets of metal tightly together. A hand-set
is then placed on top of the rivet shank and struck
with a hammer to force the rivet to compress to the
proper dimensions. It is important to strike the set
hard enough that the rivet compresses with only
three or four strikes of the hammer to prevent
work-hardening the rivet. Be sure to use the
hand-set rather than striking the rivet directly with
the hammer, as the hand-set is machined to
provide a smooth surface to the formed head.
[Figure 2-111]

Figure 2-111. Hand riveting is performed where it is inconvenient to use conventional riveting equipment. However,
the standards for acceptable hand driven rivets are the
same as for all other riveting methods.

cylinder. A dolly, milled with a recess similar to the

shape of the rivet head, is put into the stationary jaw,
and a flat dolly is placed in the movable jaw. When a
handle or trigger is depressed, air flows into the cylinder and squeezes the jaws together to compress the
shank of the rivet in a uniform motion. [Figure 2-112]

COMPRESSION RIVETING

When there are a large number of easily accessible

rivets to be installed, a compression, or squeeze riveter, can be used instead of hand or gun riveting.
These riveting tools reduce the time required to
install the rivets and produce a far more uniform
shape than can be driven by hand or with a rivet gun.
A squeeze riveter consists of a pair of jaws; one stationary and the other moved by a piston in an air

Figure 2-112. Squeeze riveter jaws or yokes are available in

different lengths and configurations. Although these tools
are extremely useful, the yoke length limits the use of the
squeezer to rivets that are located reasonably close to the
edges of sheet metal structures. For this reason, these tools
are used primarily in production rather than repair
processes.

2-62
Shims placed between the jaws and the dollies control the separation of the dollies at the end of the
piston stroke, and this determines the height of the
shop head formed on the rivet. The number of shims
needed is determined by trial and error, using scrap
material of the same thickness as that to be riveted.
Once the dollies are adjusted, all of the compressed
rivets will have exactly the same height and diameter. In addition, the smooth compressive pressure
used to upset the rivet will have a minimum
strain-hardening effect on the rivet shank. [Figure
2-113]

Sheet Metal Structures

from aluminum alloy castings so they are light

enough that the user will not be fatigued after using
the gun for a prolonged period. The long-stroke gun
may be either a slow-hitting reciprocating type, or a
one-shot gun that drives the rivet set only one blow
each time the trigger is pulled. These guns are used
to drive the larger rivets and are much heavier than
fast-hitting guns.
Handle styles also vary with different types of guns.
The pistol grip and offset handle are the most popular styles, with a push-button type available for
special applications where neither of the other
styles of guns will fit because of clearance problems.
[Figure 2-114]

Figure 2-113. To adjust the height of the shop head formed

by a squeeze riveter, add or remove washers between the
dollies and the jaws.

GUN RIVETING

Hand riveting and compression riveting are used for

special conditions, but a rivet gun drives most rivets used in aircraft construction. These tools look
and operate in a similar fashion to a reciprocating
air hammer, but the number of strokes and force of
the impact are considerably different. As such, only
guns designed for riveting should be used on aircraft structures.
Rivet Gun Types

There are a number of different types of rivet guns

used for aircraft fabrication and repair, but these can
be divided into two basic categories: fast-hitting,
short-stroke guns, which produce light blows, and
guns with long strokes that produce heavy blows.
The fast-hitting guns are usually used for 3/32 inch
or 1/8 inch rivets. These guns have bodies made

Figure 2-114. Different handle styles are available on rivet

guns to fit various locations and operator preferences.

When the trigger, or throttle, as it is sometimes

called, is pulled, air enters a sliding valve and drives a piston forward against the stem of a rivet set.
When the piston reaches the end of its stroke, a port
is uncovered by the valve that directs air to the forward end of the piston, and moves it back so it can
get air for another driving stroke. As long as the trigger is held down, the gun will reciprocate, or hammer, on the rivet set. A regulator, built into the handle of the gun or attached to the air hose, restricts
the flow of air into the gun. If the regulator is wide

Sheet Metal Structures

2-63

Figure 2-115. An air regulator, in combination with the gun trigger, allows the operator to vary the impact speed and intensity for
various sizes and alloy rivets.

open, the gun will hit hard and fast, or the regulator
can be adjusted to restrict the air flow to cause the
gun to hit slower and softer. [Figure 2-115]
The gun has a provision whereby different sets can
be installed for different sizes and head styles of rivets. If the gun is operated without a set being
installed, the piston can be severely damaged if the
trigger is pulled, or if the set is not pressed tightly
against either a rivet or piece of scrap wood. The
rivet set is held in place by a retaining spring, sometimes called a beehive because of its appearance.
Without the retaining spring, the set can fly out
from the gun if the trigger is pulled without the set
being against an object. As a safety precaution, the
gun should never be pointed at a person and the
trigger pulled, even with a retaining spring
installed. If the spring were to break, the set could
fly out and cause injury to the person.
Rivet Sets

Rivet sets are manufactured differently for various

head styles and sizes of rivets. In the past, the
numerous styles of raised-head rivets required a set
that was designed for each of the styles, causing a
technician to acquire a large assortment of sets.
Fortunately, with newer sheet metal fabrications,
universal head rivets can be used to replace almost
any protruding head rivet. This means that a tech-

nician rarely needs more rivet sets than those that fit
the various sizes of universal head rivets. Flush
head rivets also require a special set, but generally,
any flush head rivet can be driven with a flush head
set.
It is important when selecting a universal rivet set
for a particular job that its size and shape be correct
for the type rivet being driven. When selecting rivet
sets, the radius of the depression in the set must be
larger than that of the rivet, but not so large that the
set contacts the sheet metal during driving. In addition, damage on the recess face of the set may cause
it to slip off the rivet during driving, or the set may
leave unacceptable marks on the rivet head.
The recess in a universal style rivet set is machined
with a slightly larger radius than the rivet head. By
having a greater radius, the set concentrates more of
the rivet gun's driving energy to the center of the
rivet head. However, if the set is too large, it will produce small indentations in the sheet metal around
the rivet head. These indentations are commonly
referred to as smiles because of the shape they leave
in the metal. In most cases, these indentations are
unacceptable because they damage the protective
coatings of the metal, or create stress concentration
points that can cause the metal to fail around the
rivet. On the other hand, if the set is too small, it will

2-64

produce a similar type mark on the rivet

head, which is also unacceptable. [Figure 2-116]

Figure 2-116. The radius of the cup of the rivet set must be
slightly larger than the radius of the rivet head, but not so
large that the edges of the set contact the surface of the
metal.

Not only must the rivet set have the correct size and
shape of depression, but it must also fit squarely on
the rivet head. Because the structure inside an aircraft
sometimes makes it difficult to align the gun exactly
with the rivet, rivet sets are made in many lengths and
shapes. Some sets are manufactured with a straight
shank while others have one or even two offsets.
When selecting a rivet set, make certain that its shape
concentrates the blows of the rivet gun as close to inline with the rivet as possible. [Figure 2-117]

Sheet Metal Structures

Bucking Bars

When a rivet is driven, the actual compression of

the rivet is not performed by the action of the rivet
gun. Instead, the rivet is backed up by a metal bar
that reciprocates in response to the beats of the rivet
gun. This reciprocating action causes the rivet to be
compressed in successive actions. These metal bars
are referred to as bucking bars because of the
method in which the bar bucks, or vibrates, on the
shank of the rivet.
The driving face of a bucking bar is machined
smooth and polished so that no marks are left on the
rivet shank during driving. This hardened and polished steel surface is held against the end of the
rivet shank, and pressure is applied as the gun
vibrates the rivet against the bar. The position of the
bucking bar is critical in the formation of the shop,
or bucked head. If the bar is tipped slightly, the rivet
will dump over and not form a concentric head. If
too much pressure is held on the bar, or if the bar is
too large, the shop head will be driven too thin, or
the manufactured head may be forced up from the
surface of the metal. On the other hand, if the bar is
too small or is not held tight enough, the hammering of the rivet gun may distort the skin.
There are many sizes and shapes of bucking bars
used in aircraft maintenance. One of the challenging
tasks of performing structural fabrications by riveting
is being able to select a bucking bar that will clear the
structure and fit squarely on the end of the rivet
shank. In the same fashion as a rivet set, when a
bucking bar is selected, its mass should be as close to
being in-line with the rivet as possible. In addition,
the weight of the bar should be heavy enough to
allow driving the rivet in a few short beats of the rivet
gun, yet not so heavy that the operator has difficulty
holding the bar in the correct position. Before using
any bucking bar, inspect the face of the bar to make
certain no damage is present that will leave an indentation on the formed head of the rivet. [Figure 2-118]
Rivet Gun Set-Up and Adjustment

Figure 2-117. Rivet sets are available with different offsets

to allow the blows from the gun to be directed straight inline with the rivet. These sets are useful in locations where
structures interfere with a straight shank set.

One of the most difficult tasks for an aircraft technician to learn is how to properly and efficiently
install rivets using a rivet gun. The skills necessary
to perform gun riveting are acquired over time and
must be practiced on a regular basis in order to
remain proficient. One task that must be learned
before trying to install rivets is setting up and
adjusting a rivet gun for a particular operation.
Since improper riveting can cause irreparable damage to an aircraft structure, experience should first
be gained by developing riveting techniques on
practice projects.

Sheet Metal Structures

2-65

Figure 2-118. Bucking bars are available in different weights and shapes to allow riveting of solid rivets in almost any location.

Begin a practice project by trimming two sheets of

aluminum to a manageable dimension. Sheets
trimmed to six inches square are often used because
of the ease in clamping the material in a vise. Align
the edges of the material and drill a number of holes
for the correct diameter rivet, deburr the edges, and
clamp the material in a padded-jaw vise.

set against the manufactured head of the rivet. The

set must be directly in line with the rivet, and not

Select a rivet set that is appropriate for the head

style and size rivet to be installed and insert it in the
rivet gun. Once the set is in place, install a retaining
spring to keep the set from being propelled out of
the gun during operation. Once the set has been
installed, connect an air hose to the gun and place
the set against a soft piece of wood to perform an
initial adjustment of the air regulator.
With the set in place against the wood, depress
the trigger to cause the gun to pound against the
wood. If the gun is set properly, the wood will be
left with an indentation approximately the depth
of the recess in the set, with only a few gun raps.
If the gun strikes the wood too hard, adjust the air
regulator for a lower pressure, or limit the amount
that the trigger is depressed. This is usually a
good starting adjustment, but will probably have
to be adjusted further when driving a rivet.
[Figure 2-119]
Rivet Installation

Once the metal has been drilled, put a rivet of the

correct length through a hole and hold the rivet gun

Figure 2-119. Adjust the airflow to the gun so it will indent

a scrap of wood but will not shatter it.

Sheet Metal Structures

2-66

tipped or it will contact the sheet metal during driving. [Figure 2-120]

Hold a bucking bar flat against the end of the rivet

shank and develop a good feel of the balance
between the gun and the bucking bar. A proper balance is obtained by applying just enough extra force
on the gun to hold the rivet head firmly against the
skin. Once the gun is in position, pull the trigger to
provide a short burst of raps on the rivet head. The
rivet should be driven with the fewest blows possible so it will not work-harden the rivet, which can
cause cracks to form. It may be necessary to further
adjust the rivet gun airflow to fine-tune it for the
installation of subsequent rivets.
Evaluating Driven Rivets

Figure 2-120. Hold the rivet set square with the rivet head
and support the gun so the set will not slip off during driving.

In the process of developing riveting skills, it is

inevitable that some rivets will be driven improperly. One of the requirements of a technician is to be
able to quickly identify rivets with unacceptable
characteristics. In addition, the technician must be
able to remove damaged or improperly installed
rivets without adversely affecting the base sheet
metal, and then be able to correct the problem with
the installation of replacement rivets. [Figure 2-121]

Figure 2-121. A technician must be able to identify properly driven rivets. Until the technician has gained enough experience to
evaluate driven head dimensions, special gauges may be fabricated to check shop head shapes and sizes.

2-67

Sheet Metal Structures

As previously mentioned, a properly formed shop

head will be one-half the shank diameter in height
with a diameter that is one and a half times that of
the shank diameter. In addition, the rivet should be
uniform with adjacent rivets and each rivet should
be driven concentric with the hole. Placing a
straightedge on top of shop heads that have been
driven in a row can check the uniformity of rivet
heights. Each surface of the shop heads should
touch the straightedge without gaps.
The rivet shank should also be checked for concentricity. Concentricity is achieved when the shop
head of the rivet compresses in an even fashion
around the shank. It is detected by looking closely
for a circular mark left on the driven head. A rivet
that has been properly driven will have an even margin between the circular pattern and the edge of the
shop head. If the margin is uneven, it usually indicates the bucking bar slipped across the rivet during
driving, causing the shop head to form an oval shape
or to be off center with the shank of the rivet.
The manufactured head of the rivet must also be
perfectly flat against the metal. If a thin feeler gauge

blade can be slipped between the manufactured

head and the skin, the rivet must be removed and
the cause of the improper fit determined. The rivet
may be tipped in the hole by a small burr, or the
hole may have been drilled at an angle. If the hole
was improperly drilled, the only satisfactory repair
is to re-drill the metal to accept the next larger
diameter rivet.
Rivet Removal

When it has been determined that a rivet has been

improperly installed, the rivet must be removed and
replaced without damaging the base metal. To
remove a rivet, lightly indent the center of the manufactured head with a center punch. Be sure to
back-up the shop head with a bucking bar when
center punching so as not to distort the skin. Use a
drill the same diameter as the hole or one that is one
number size smaller to drill down to the base of the
rivet head. Once drilled, use a pin punch with a
diameter the same size as the rivet shank diameter
to pry the head off, or tap the head lightly with a
cape chisel to break it off from the shank. If a chisel
is used, be sure that it does not scratch the skin
around the rivet head. [Figure 2-122]

Figure 2-122. When removing a solid rivet, it is important to avoid damaging the sheet metal. Although a cape chisel may be used,
removing the rivet head with a pin punch is preferred to help avoid damaging the base metal.

2-68

Sheet Metal Structures

After the rivet head has been removed, back-up the

underside of the skin with a bucking bar or piece of
wood, and use a pin punch to gently drive the rivet
shank from the sheet metal. When the rivet is out,
examine the hole, and if it is not elongated, another
rivet of the same size may be used as a replacement.
If the hole is damaged, use a twist drill for the next
larger diameter rivet to re-drill the hole. When using
a larger diameter rivet, be sure that the pitch, gauge,
and edge distance values are all satisfactory for the
pattern.
NACA Flush Riveting

It is possible to drive a rivet in such a way that the

shop head will be flush with the outside skin and
the protruding manufactured head will be on the
inside of the structure. This technique is necessary
when a shop head would extend too far beyond a
surface and interfere with an adjacent part or cause
an unacceptable effect on the aerodynamic characteristics of the structure. To aid manufacturers in
standardizing riveting techniques, the National
Advisory Committee for Aeronautics, or NACA,

established a set of standards for riveting aircraft

and aerospace vehicles. When riveting is conducted
to these standards, the process is referred to as
NACA riveting. [Figure 2-123]

Figure 2-123. The NACA method of riveting produces the

smoothest surface possible on a riveted structure.

To perform NACA riveting, a hole is drilled and

countersunk as it would be for the installation of
any flush rivet; however, the rivet is installed from
the inside of the structure so its shank sticks out
through the countersunk side. When the rivet is driven, the shank is upset to fill the countersunk hole
and is allowed to stick up a few thousandths of an
inch above the surface. When all the rivets have
been driven, a microshaver is adjusted to mill the
excess material from the shank to obtain a flush surface. [Figure 2-124]

Figure 2-124. A microshaver is used to smooth the upset

ends of rivets driven using NACA techniques.

the rivet gun from the opposite side. This operation

is called team riveting and requires a great deal of
coordination between the technicians. Since there
are often many teams working on the same structure, the noise produced in the shop may make it
impossible for team members to verbally communicate with one another. To improve communications
between the riveter and the bucker, a method of
standardized tapping codes has been developed,
whereby the person holding the bucking bar can
advise the gun operator as to the condition of a driven rivet.
The gun operator, or driver, is responsible for
putting the rivets into the holes and driving each of
them the same amount. Once a rivet is placed in a
hole, the gun is positioned on the rivet head to prevent it from falling out. The bucker then taps the
shank one time as the bucking bar is brought into
contact with the rivet. After the driver feels or hears
the tap, the gun is operated for a short period to
upset the rivet shank. As soon as the driver stops
the gun, the bucker removes the bucking bar and
examines the rivet. If the rivet is sufficiently driven,
the bucker taps on the rivet twice with the bucking
bar, and the driver goes on to the next rivet.
However, if the rivet needs to be driven more, the
bucker will tap only one time and immediately
place the bucking bar back on the rivet for subsequent driving. If the rivet is dumped over, or for any
other reason is not satisfactory, the bucker taps the
rivet three times and the driver circles the rivet head
with a grease pencil so it can be identified for later
replacement.

Team Riveting

When sheet metal parts are riveted onto a complete

airframe or a large component, it is often necessary
for a person to be on one side of the structure to
hold the bucking bar while another person operates

In the high-speed production needed to build modern aircraft, good, well-coordinated teams of riveters can keep a production line moving effectively. [Figure 2-125]

2-69

Sheet Metal Structures

ONE TAP

START RIVETING

TWO TAPS

THREE TAPS

RIVET OK

BAD RIVET

Figure 2-125. A tapping code allows the riveter on one side

of the skin to communicate with the bucker on the other
side of the structure.

FABRICATION TERMINOLOGY
Fabrication processes require an understanding of
the wrought physical characteristics of metals as
well as the characteristics of metals when they are
shaped or bent. For example, when sheet metal is
bent, it must be formed around a radius to allow the
metal to gradually change direction. If sheet metal is
bent around a sharp corner, the stresses developed
will cause fractures during fabrication or while the
part is in service. However, when metal is formed
around a radius, the amount of material required in
the bend will be less than the amount required to
form around a sharp corner. Also, since a bend
begins and ends at different locations depending on
the radius size, it is necessary to compute and layout the location of the bend's starting and ending
points to properly position the metal in the forming
machine. To understand the methods used in developing sheet metal layouts, it is necessary to consider
the physical characteristics of the metal as well as
knowing the meaning of various terms used in the
fabrication process. [Figure 2-126]

LAYOUT AND FORMING

The fabrication of sheet metal parts for an aircraft
requires the technician to have a fundamental
knowledge of the physical characteristics of the
metal being used, and a working knowledge of
applied geometry. In many cases, parts are fabricated from blueprint drawings or are constructed
from templates created from pre-existing components. In other cases, the technician must use industry acceptable practices and information from publications such as Advisory Circular 43.13-lB and
2A, Acceptable Methods and Techniques for
Aircraft Alterations and Repairs, for conducting
minor repairs to sheet metal structures. In these situations, the technician must consider the physical
characteristics of the metal and perform computations to fabricate parts to the desired dimensions.
When an aircraft is manufactured, fabrication engineers compute all of the bends and cutting dimensions and create dies that can be used in forming
machines to speed the manufacturing process. The
objective is to allow the metal to be cut to size in
one department and formed in another, and yet
when the parts are assembled, they all fit properly.
However, in field repairs and alterations, it is the
technician's responsibility to perform the computations to produce a layout on the sheet metal. A layout is simply the process of placing lines on the
metal to distinguish the locations of cuts and bends.

Figure 2-126. When bending sheet metal, a number of factors must be considered. For example, depending on the
radius size, the point where the bend begins and ends will
vary and must be determined to obtain a desired overall
dimension on the flats of the metal.
SHEET METAL GRAIN

Sheet metal used for aircraft construction and repair

is formed from ingots of aluminum alloy that are
passed through a series of rollers until the metal is
reduced to a desired thickness. In the rolling process,
the molecules in the metal are elongated in the direction that the metal is passed through the roll. This
elongation causes the metal to develop a grain pattern that presents certain physical characteristics that
should be considered before forming sheet metal.
Looking closely for small lines that run in one direction through the material distinguishes the grain
direction. When bending sheet metal, the strength
of the material varies depending on the direction of
the bend in relation to the grain. When laying out a
pattern, it is better to orient bends to run across, or

Sheet Metal Structures

2-70
perpendicular, to the grain of the metal. If the bend
is formed parallel to the grain, the grain boundaries
tend to separate and cause cracks. In some cases, the
metal will initially fabricate without showing signs
of fatigue, but the part may prematurely develop
cracks while in service.

the outside of the bend, which is stretched, will pull

the grain boundaries apart, causing the metal to
crack. On the other hand, if the metal is bent around
a radius that is larger than the minimum size, the
area of the bend may be too large to fit in conjunction with adjacent parts.

BEND RADIUS

NEUTRAL AXIS

Non-aviation sheet metal construction does not

require the high strength and light weight that is
necessary for aircraft, and so for economy of construction, many metal fabrications have sharp
bends. In thin sheet steel, this usually gives no problem, but when working with hard aluminum alloy
sheets for aircraft parts, sharp bends must be
avoided to prevent cracking. To prevent cracks, a
minimum bend radius is recommended for different
types of alloys and metal thickness. A radius is measured on the inside of a bend and is generally measured in fractions of an inch. For instance, a common radius for aircraft sheet metal bends is 1/8
inch. This is the distance from the external edge to
the center of the radius. [Figure 2-127]

When bending a piece of metal around a radius, the

metal on the outside of the bend stretches, while the
metal toward the inside tends to compress or
shrink. Within the metal, a portion neither shrinks
nor stretches, but retains its original dimension. The
line along which this occurs is called the neutral
axis of the metal. This line is not located exactly in
the center of the sheet, but is actually about 44.53%
of the sheet thickness from the inside of the bend.

As an example, notice that in the -O, or annealed

temper, the metal can be bent over a very small
radius, but as the metal's hardness and thickness
increases, so does the minimum allowable bend
radius. If the metal is bent with too small a radius,

Occasionally it is necessary to know the exact

length of the neutral axis, but for most practical purposes, you can assume the neutral axis is located in
the center of the metal. The slight error from this
approximation is usually too small for consideration when constructing a layout pattern.
MOLD LINE

Mold lines are used to designate the dimensions of

a piece of metal on a drawing or layout pattern.
These are formed by extending a line from the exter-

Figure 2-127. The type of alloy, temper, and thickness of sheet metal determines the minimum bend radius.

Sheet Metal Structures

2-71

nal side of the metal, out beyond the radius of a

bend. Although the mold lines themselves do not
include dimensions, they are used as reference
points from where dimensions can be established.
MOLD POINT

The point where two mold lines intersect in a bend

is referred to as a mold point. When a piece of sheet
metal is laid out, all of the measurements are made
from one mold point to the next. However, the
actual corner of the formed metal does not reach the
mold point because of the bend radius. On the other
hand, by measuring from the mold point, the position where the bend should start can be located.
BEND TANGENT LINE

Bend tangent lines are generally shown on blueprints and drawings to designate the location where
the sheet metal begins to form around the bend
radius. When positioning metal into a forming brake,
the metal is inserted so that the bend tangent line is
located under the back edge of the bend radius.
Since the line is positioned under the radius, it is
difficult to see the tangent line's location.
To enable more accurate positioning, a sight line is
marked off from the bend tangent line. The distance
of the sight line from the bend tangent is the same
dimension as the radius. For example, if a 1/8 inch
radius is used, the sight line is marked 1/8 inch
or .125 inch ahead of the bend tangent line. When
the metal is placed in the brake, the sight line is
positioned directly under the nose of the radius
forming block. This will cause the bend tangent line
to be located at the approximate position of the
beginning of the radius curvature.

Figure 2-128. The setback for a 90 degree bend is equal to

the dimension of the radius plus the metal thickness
(Setback = BR + MT).

formula, which is commonly referred to as a K-value.

The K-value takes into account that when the metal
is bent to an angle 90 degrees, the mold point of
the bend will move a certain distance. The direction
the mold point moves is dependent on whether the
bend has an open or closed angle. [Figure 2-129]

SETBACK

The distance between the mold line and the bend

tangent line inside the bend area is referred to as the
setback dimension. When determining where a
bend will begin, it is necessary to subtract the setback amount from the desired dimension of the flat.
For a 90 degree bend, the setback is found by adding
the dimension of the bend radius to the thickness of
the metal. For example, the setback for a 90-degree
bend in .040 inch thick material with a 1/8 inch
radius would be equal to .165 inches (.125 +.040). If
a flat with a developed width of 3 inches were
desired with one end bent, the bend tangent line
would be located at 2.835 inches. However, where
two bends are formed on each end of a flat, it is necessary to subtract the setback twice from the desired
developed width of the flat. [Figure 2-128]
On the other hand, for bends greater or less than 90
degrees, it is necessary to compensate the setback
amount by applying an additional multiplier to the

Figure 2-129. As shown in these diagrams, a closed angle

bend requires the metal to be bent more than 90 degrees,
whereas bending the metal less than 90 degrees develops
an open angle.

2-72

Sheet Metal Structures

Figure 2-130. A K-chart is used to simplify the problem of determining the setback value for bends other than 90 degrees. To determine the setback with a K-chart, use the number of degrees the metal is bent from the flat layout position.

Sheet Metal Structures

K-values for determining the setback of bends are

usually available on charts. These charts make the
computations of setbacks for other than 90 degrees
rather simple. Once the K-value for the bend is
known, the setback is easily found by adding the
radius plus the metal thickness and then multiplying by the K-value (S.B. = K x (R + T)). However, if
a chart is not available, the K-value can be determined mathematically with most calculators that
are capable of performing trigonometric functions,
or by using a trigonometric table. To determine the
K-value with a calculator or table, find the tangent
of one-half the degrees of bend. [Figure 2-130]
For example, to determine the K-value for a closed
angle bend of 50 degrees in .040 inch thick material
using a 1/8 inch radius, use the following procedures. First, determine the number of degrees the
metal will actually be bent from the flat layout position. In this situation, the metal will be bent a total
of 130 degrees (180 degrees - 50 degrees = 130
degrees). Next, find the K-value for the degrees of
bend. In this example, the K factor is equal to the
tangent of one half the bend angle (65 degrees),
which is equal to 2.144 inches.
Keep in mind that if a K-chart is used, merely refer
to the K-value for the number of bend angle degrees.
To complete the setback problem, add the radius
(.125 inch) to the metal thickness (.040 inch) and
multiply that value by the K factor (2.144 inch
x .165 inch = .35376 inch).

2-73
bend radius, plus the thickness of the metal. Since
the circumference of a circle is equal to n (3.1415)
times diameter (reD), begin by finding the diameter
by doubling the radius and then add the thickness
of the metal. For example, for a 1/8 inch radius
and .040 inch thick metal, the diameter of the
circle would be .25 inch (.125 x 2) plus .040 inch
for a total diameter of .290 inch.
Next, find the circumference by multiplying the
diameter by n (.290 x 3.1415), which for this purpose can be rounded to .911 inch. This would be the
amount of metal necessary to make a bend to form
an entire circle. To determine the bend allowance
for the desired bend angle, it is necessary to divide
the circumference by 360 degrees to find the
amount of material required for each degree of bend.
The amount of material in the example would be
found by dividing .911 inches by 360 degrees,
which is equal to .0025 inches/degree. This answer
multiplied by the number of degrees of the desired
bend will be the total bend allowance. For instance,
for a 45 degree bend, the bend allowance will be
equal to .0025 inches times 45 degrees, which is
equal to .1125 inches. This is the approximate
amount of material used in the bend. [Figure 2-131]
Another method of finding the bend allowance,
which produces accurate results, is found by using
an empirical formula. This formula provides for the
bend allowance to be located in the actual position

FLATS

The distance between inside bend tangent lines

from one bend to another, or from the end of a piece
of metal to the first bend tangent line is called a flat.
This is the amount of metal that is not bent. The
length of the flats will always be less than the
desired developed width because the bend is setback into the flat.
BEND ALLOWANCE

Bend allowance is the amount of material that is

actually involved in the bend and is equal to the
length of the neutral axis. When determining the
total developed length of a layout pattern, the bend
allowance values are added to the lengths of the
flats. One method of computing a bend allowance
assumes the neutral axis to be located in the exact
center of the metal. While this may not be the most
accurate method, the final computation is reasonably close and works well for most applications.
To compute a bend allowance, begin by finding the
circumference of a circle with a radius equal to the

Figure 2-131. One method of finding the bend allowance

assumes the neutral axis to be in the center of the metal.

Sheet Metal Structures

2-74

of the neutral axis. The formula for determining the

bend allowance for one degree of bend is:
Bend Allowance = (.0078T + .01743R)
The bend allowance for the previous example by the
use of this formula is:
B.A.

= (.0078 x .040 + .01743 x .125) x

45 = (.000312 + .00218) x 45 = .002492
X45 = .11214

The empirical formula has been used to compile a

table that is found in many aircraft technician and
sheet metal fabrication handbooks. With most of
these charts, the bend allowance for a 90 degree
bend is shown along with the amount of bend
allowance for each degree of bend. [Figure 2-132]

Notice that the computation using the first formula

versus using a bend allowance chart is within a few
ten thousandths inch of each other. For practical
purposes, this degree of accuracy is acceptable for
most sheet metal fabrications, so either method may
be used.
COMPUTATIONS FOR LAYOUTS
To fabricate a sheet metal part with bends, a pattern
is first drawn on flat metal to determine the locations of the bend tangent and sight lines, as well as
the locations for cutting the metal to the proper
length and width. To begin the process, computations are made to determine the dimensions of the
flats and locations of the bend tangent lines. For
example, to form 2024-T3 aluminum that is 0.032
inch thick into a 4 inch long by 2 inch deep and 2
inch wide U-shaped channel, a layout pattern is cal-

Figure 2-132. A bend allowance chart provides the bend allowance for a 90-degree bend and for individual degrees of bend for various thickness metal and bend radii. The bend allowance for 90 degree bends is shown on top while the bend allowance for each
degree of bend is shown in the bottom of each box.

2-75

Sheet Metal Structures

Figure 2-133. The flat pattern layout includes bend tangent lines and sight lines, which are used for bending the metal in a sheet
metal brake.

culated and marked

manner. [Figure 2-133]

in the

following

First, begin by finding the minimum radius that will

be used to fabricate the bends. In many applica-

tions, blueprints or other manufacturing information will specify the radius to use. However, if it is
not given, the minimum radius can be determined
by referring to a chart similar to the one previously
shown in Figure 2-127. For this example, it is found

2-76

that the minimum radius for 2024-T3 aluminum

that is .032 inch thick is between 2 to 4 times the
metal thickness, or .064 inch to .128 inch.
Converted to the nearest fractional equivalent, the
minimum radius would need to be at least 3/32
inch, but 1/8 inch provides for a larger radius to
help prevent cracking. For this example, 1/8 inch
will be used for fabricating the bends.
Once the minimum bend radius has been determined, it is necessary to find the setback value for
the bends. This value is used numerous times in
establishing the dimensions in the layout pattern
since both bends for the U-shaped channel will be
fabricated to 90 degrees. For 90-degree bends, the
setback is equal to the bend radius (.125) plus the
metal thickness (.032), which equals .157 inch. By
subtracting the setback value from each of the mold
line dimensions, the lengths of the flats and locations for the bend tangent lines can be determined.
To layout the pattern, begin from one end of the
metal and progressively mark the bend tangent lines
as each location is calculated. For most layout patterns, computations carried out to the nearest hundredth inch are adequate. Mark the metal with a fine
tipped marker, orienting it, if practical, so the bends
will be made across the grain of the metal.
The first bend tangent line is marked at a distance
from the end of the metal that is equal to the mold
line dimension, minus the setback. For this example, the mold line dimension for flat A is 2 inches,
which will mean the first bend tangent line will be
marked at 1.843 inches or 1.84 inches from the end.
Next, a second bend tangent line is marked off from
the first line, at a distance equal to the bend
allowance.

Sheet Metal Structures

line is then marked 1.686 inches from the second

bend tangent line.
The final bend tangent line is located at a distance
that is equal to the bend allowance away from the
third bend tangent line. Since both bends are the
same, the bend allowances are also the same. This
means the final bend tangent line is marked .218
inch from the third line.
To complete the layout, it is necessary to locate
where the metal needs to be cut for length, and then
sight lines must be established if a bending brake
will be used to fabricate the channel. Since the
length of flat C is the same as flat A, the cutting line
should be marked 1.84 inches from the fourth bend
tangent line. Once the metal is cut on a squaring
shear, deburr the edges before bending the metal. As
a last step, sight lines are marked depending on how
the metal will be positioned in the brake for bending. The sight lines are marked off from the bend
tangent line that will be placed under the nose of
the brake, at a distance equal to the bend radius
used. For this example, the sight lines are
marked .125 inch from the bend tangent line.
FORMING BENDS
To form bends using a Cornice or finger brake, begin
by verifying that the proper size radius blocks are
installed in the upper jaw. For most brakes, the
blocks are stamped with the size. However, if the
block is not marked, it may be necessary to use a
radius gauge to determine the size.

By referring to the chart shown in Figure 2-132, the

bend allowance for .032 inch thick aluminum using
a 1/8 inch radius is found to equal .218 inch for 90
degree bends. Mark the second bend tangent line on
the layout pattern approximately .218 inch away
from the first bend tangent line on the side toward
the next flat.

Once the radius has been verified, adjust the nose of

the blocks so they are back from the edge of the
bending leaf by a distance equal to the thickness of
the metal. Once adjusted, open the jaws of the brake
and slip the metal in place, lining it up so that looking straight down reveals that the sight line is even
with the nose of the radius block. Clamp the jaws of
the brake and raise the leaf to the desired angle.
Since all sheet metal has some spring-back, the leaf
will need to be brought through the desired angle by
a few degrees to achieve the properly finished
dimension. [Figure 2-134]

From the second bend tangent line, it is necessary to

determine the length of flat B to locate the position
of the third bend tangent line. The length of flat B is
found by subtracting the setback amount twice from
the desired developed width of flat B. The two setback values are subtracted to account for the bends
at each end of the flat. In this example, the developed width of flat B is 2 inches, so the length of flat
B would be 1.686 inches. The third bend tangent

When making more than one bend, consider the

possibility of the upper jaw of the brake interfering
with flats that have already been made. In some
cases, the radius blocks may need to be spaced apart
so that bent flats can come up along the sides of the
blocks. However, if the bend cannot be completely
formed because of interference, bumping the metal
down with a plastic or rubber mallet over a hardwood block can do the finished shaping.

2-77

Sheet Metal Structures

FOLDING A BOX
One of the most common sheet metal parts that a
technician is required to fabricate is a four walled
box. Although bending these boxes is similar to
forming a U-channel, a few additional processes
must be performed. As a project, examine the procedure needed to lay out and form a box of .051 inch
2024-T3 clad aluminum alloy. The box is to be 4
inches square and have sides that are 1 inch high.
All of the dimensions are mold line dimensions, and
the bend radius will be 5/32 inch. [Figure 2-136]

Figure 2-134. The sheet metal being bent should be placed

in the brake so that the sight line, which is one radius from
the bend tangent line in the brake, is directly beneath the
nose of the bend radius blocks.

To perform shaping in this manner, clamp the metal

in a vise between a hardwood block that has a
radius formed on one edge, and a second hardwood
block to prevent damage to the metal from the
clamp. Once secured, bump the metal down over
the radius block by using a mallet and a piece of
hardwood. Use as few blows as possible and spread
the force out over as large a distance as possible
with the wood block. [Figure 2-135]

Figure 2-136. The flat pattern layout for a box is similar to a

U-channel except that relief holes must be drilled at the
inner bend tangent lines to prevent the metal from cracking
at the intersection of the bends. In addition, cutting lines
must also be marked for material to be removed so the corners can be fabricated.

Determining setback

All of the bends used in this box are 90 degrees, so

the setback will be the sum of the bend radius and
the metal thickness, or:

Figure 2-135. When it is not possible to complete a bend in

a brake, blocks of wood and a mallet are used to finish the
bend.

Setback = Bend Radius + Metal

Thickness = .156 inch + .051 inch
= .207 inch
Round this off to .21 inch.

Sheet Metal Structures

2-78
Find the length of the flats for the sides
The mold line lengths for the sides are all 1 inch, so
the flats of the sides will be this amount less one
setback:

Find the length of the flat for the bottom

The mold line length for the bottom is 4 inches, and
since there is a setback dimension at each end of
this, the flat for the bottom will be:
Bottom = 4.00 inches - .42 inches x2 =
3.58 inches
Find the bend allowance
Use the chart of Figure 2-132 on page 2-74 and follow the 5/32 inch bend radius column down to
the .051 inch thickness line. For a 90 degree
bend, .280 inch of material is needed.
Find the length of the developed width for the
material
Since the box is to be square, a square piece of metal
equal to the sum of the three flats and two bend
allowances is needed. For this example, the developed width is found as follows:
Developed Width = .79 inch + .28 inch + 3.58 inches
+ .28 inch + .79 inch
= 5.72 inches.
Lay out the box
Cut a square 5.72 inches on each side, remove all of
the burrs, and mark the bend tangent lines in from
the edges, equal to the flat dimensions for the walls
of the box, or at .79 inch. Make these marks with a
fine tipped marker, being careful not to scratch the
metal. From these marks, make a second line inside
each at a distance equal to the bend radius, or at .28
inch. These lines form the inside and outside locations where the bends begin and end.
Since the bends intersect in the corners, the metal
will tend to crack if relief holes are not drilled. A
good rule of thumb for relief holes is to use a diameter of twice the bend radius, with the holes centered at the intersection of the inner bend tangent
lines. The sight line and the ends of each of the
sides will be tangent to these holes.
Cut the material
Drill the relief holes and then use a deburring tool
to smooth the edges of the holes. Then cut out the

material at each of the corners. Once the metal has

been cut to shape, smooth all the edges and corner
cuts using a fine toothed file.
Bend the box
A box, or pan brake, should be used to bend the
sides. These brakes resemble a leaf brake except that
the upper jaw is made up of a series of segmented
blocks. These blocks vary in width and can be positioned to accommodate the bent walls of the box as
previously mentioned. Once two opposite sides of
the box are bent, position the upper jaw of the brake
to fit between the formed sides. When the leaf is
raised, the two sides will ride up in the slots
between the fingers. When using a conventional leaf
brake, form two opposite sides on the brake and
then bend the remaining sides over a forming block,
using a block of hardwood and mallet as previously
described in the procedure for forming a channel.
COMPOUND CURVES AND CONTOURS
A part made of thin sheet metal can be considerably
stiffened without any increase in its weight by
designing it to have compound curves. In addition,
sheet metal parts can be made into shapes that allow
a part to be used for aerodynamic streamlining.
These curves can be fabricated by a number of different methods including hand or machine forming.
With hand forming, considerable experience is necessary to make some of the more complex parts that
have unique shapes. However, for simple forming,
patterns can be used to fabricate contours and
curves.
When a repair must be made that requires a compound curved part, it is more economical to buy the
part from the factory than it is to fabricate it in the
shop. But sometimes parts are not available and the
technician must resort to hand forming a replacement.
When a straight bend is made in a piece of sheet
metal, the inside of the bend is shrunk and the outside is stretched, but no metal is actually moved, or
displaced. When a compound curve is formed, however, metal must be displaced, and the shrinking
and stretching take place in more than one plane.
An example of a part that is occasionally hand
formed, is an extruded bulb angle stringer. These
stringers are used in semimonocoque structures
because of the resistance of the metal to distortion.
In Figure 2-137, if a load is placed on a bulb angle,
it is opposed by the entire width of flat A, which is
stiffened by flat B and the bulb. In order to bend, the

Sheet Metal Structures

2-79

top side of flat A will have to stretch while flat B

and the bulb will have to shrink.

Figure 2-138. A concave curve can be formed in a bulb angle

by shrinking the flange over a V-block made of hardwood.

channel. Forming these channels requires considerable stretching on one side of the part and shrinking
on the other.

Figure 2-137. Extruded bulb angles are used for stringers in

many aircraft. To form a convex curve in a stringer of this
type, the metal on the flat with the bulb angle must be
stretched. This can be accomplished by bumping the metal
with a mallet against a round hardwood block.

To shape a bulb angle to fit the contour of a skin, the

thickness of flat A must be reduced by hammering
it. Although no metal is removed by hammering, the
material that is moved when the thickness is
reduced goes to increasing the length of the part.
When the outside of flat A is lengthened, flat B, and
the bulb, will bend. This method of forming can be
used only for very gentle bends, but stringers seldom require more than a slight curvature.

To form a compound curved channel, begin by making a hardwood forming block. Cut the block to the
exact shape and size of the inside of the desired
channel dimension. Then round the edges with a
radius that is greater than the minimum radius
allowed for the material that will be used for the
part. Taper the edges of the block back about three
degrees to allow for spring-back, so the final bend
will be a true right angle. Once the first block is
made, cut a second block of the proper size and
shape so it comes just to the beginning of the bend
radius. Drill three holes through both pieces to be
used for bolts or other devices to keep the forming
blocks and the material from shifting during forming. [Figure 2-139]

It is more likely required to form a bulb angle into a

convex curve than into a concave shape. To do this,
the edge of flat A must be shrunk. This can be done,
but requires more care than stretching the metal. To
form a concave shape, use a V-block made of wood,
and hammer on the edge of the flat. Do not hit it
hard enough to buckle it. Move the angle back and
forth over the V-block as the metal is hit so it will
shrink uniformly over the entire bend. Only through
practice will the skill be developed to use blows
hard enough to minimize work-hardening and yet
not too hard to buckle the flat. [Figure 2-138]
One of the best projects that can be performed to
develop the skills needed in hand forming aluminum is
done by forming a compound
curved

Figure 2-139. A compound curved channel can be formed

using two hardwood blocks clamped in a vise.

2-80

Sheet Metal Structures

Lay out the flat pattern for the metal to be bent.

Consider the bend allowance when laying out the
material, but leave it slightly larger than needed so it
can be trimmed to the final size after forming.
However, do not allow too much extra material as
this will also have to be shrunk and stretched, and
too much material can make the project far more difficult. Drill the tooling holes in the metal to match
those in the forming blocks. Once drilled, put the
metal between the blocks, securing them with the
proper size pins or bolts, and clamp the assembly in
a vise with the concave side up.Start near the ends of
the curve and back the metal with a piece of tapered
hardwood. Strike the metal with a plastic mallet as
near the bend tangent line as possible. Work from
each end toward the middle, folding the metal over
just a little each time it is hit. Some buckling will
occur, but it can be worked out as the bend progresses across the entire concave side. [Figure 2-140]

Figure 2-141. Many types of components and aircraft structures can be formed using hand-shrinking and stretching.
For example, several different versions of nose ribs can be
reproduced using hand-shrinking and stretching, as shown
here.

Figure 2-140. When forming a compound curve, the metal

should be backed up with a hardwood forming bar for better control of the bend.

Skill in making this kind of bend comes only from

practice. A technician must develop a feel for the
material so it can be formed with as few blows as
possible, to prevent work-hardening the metal,
while not creating any big buckles that cannot be
worked out.
Once the flats have been formed, turn the assembly
over and form the convex side. Back up the material
with the tapered block and strike the metal near the
bend, but this time start at the center and work outward toward each end. When stretching, as when
shrinking, use as few blows as possible so the material will not crack or create wrinkles that cannot be
worked out. [Figure 2-141]

BUMPING
It may sometimes be necessary to form a streamline
cover for some component that must protrude into
the air stream. These parts are usually nonstructural
and are much more easily made of fiberglass reinforced resins, but occasionally they are made from
aluminum alloy sheet metal.
An example of a part that can be formed by bumping is used to cover bellcrank parts that protrude
through an aircraft structure and into the airstream.
To form one of these parts, make a forming block of
hardwood, hollowed out to the shape of the finished
cover. The inside of the depression should be
exactly the size and shape as the outside of the
cover. Make a hold-down plate of metal or heavy
plywood that will hold the edges of the metal, yet
allow a mallet to be used to bump the metal on the
inside of the form. [Figure 2-142]
Cut a sheet of annealed material, usually 3003-O or
5052-O aluminum, large enough to form the part.
Clamp the metal between the forming block and the
hold-down plate tight enough to prevent it from
wrinkling, yet loose enough that it can slip as the

2-81

Sheet Metal Structures

Figure 2-142. A female forming block allows compound curved parts to be made by bumping.

material is forced down into the depression. Begin

forming by striking around the edges of the depression with a wedge-shaped plastic mallet. Stretch the
material slowly and evenly as it goes into the
depression.
In the process of forming deep parts, the material
usually work-hardens and becomes difficult to
form. When this happens, remove the material and
anneal it. It should be annealed in a furnace, but if
one is not available, and if the part is strictly
non-structural, a rather rough procedure can he
followed that will soften the material enough to
finish bumping it to shape.
To perform this annealing process, remove the material from the forming block, and use a welding torch
to coat it with a thin layer of carbon by using an
extremely rich acetylene flame from a large tip.
Then, using a large but very soft neutral flame, carefully heat the metal just enough to burn the carbon
off. When the part cools, put it back between the
forming block and the hold-down plate and finish
bumping it into shape.
FLANGING LIGHTENING HOLES
The thin metal from which aircraft are made usually
has ample strength, but its basic structural limitation

lies in its lack of stiffness and rigidity. Two benefits

can be gained, when making pieces such as fuselage
bulkheads and wing ribs, by removing some of the
metal to decrease weight and flanging the edge of the
cutout to increase the rigidity of the part. These
flanged cutouts are called lightening holes.
When a large number of lightening holes are to be
cut, it is economical to make or purchase a
two-piece flanging die made of steel. These dies are
usually made in various sizes ranging from 1/2
inch to 6 inch diameters. [Figure 2-143]

Figure 2-143.
Using male and female flanging dies can
stiffen the edges of a lightening hole.

To use lightening hole flanging dies, cut the proper

size hole in the component 'with a punch press, hole
saw, or fly cutter. Deburr the edges to be sure there
are no rough spots that could cause the material to
tear when it is stretched. Slip the male die through

2-82

Sheet Metal Structures

the hole in the metal and position it over the female

die. Once the dies arc secured, put the assembly in
an arbor press and press the male die into the
female die. This forms the metal smoothly and uniformly without work-hardening. When the part is
removed, very little finishing is required, making
the process fairly quick and easy.
JOGGLING
When a sheet metal structure is built up, there are
often locations where the metal is stacked into multiple layers where the parts are joined together. In
order for the sheet metal pieces to be flat against the
skin and yet have one on top of the other at the joining intersection, a process known as joggling is
used. In joggling, the end of one of the pieces is bent
up just enough to clear the other, and then it is bent
back so it will be parallel to the original piece. Parts
should be joggled to fit, rather than attempting to
pull them into position with rivets. These joggles
may be fabricated by pounding with a soft hammer
against a block of wood, or they may be formed in a
hydraulic press or with joggling dies. [Figure 2-144]
Joggling dies are often used when many parts are to
be joggled with the same dimensions. If dies are not
available, joggles may also be formed by stacking
sheet metal in a similar fashion to that shown in
Figure 2-145, and forming the joggle in a hydraulic
or arbor press. [Figure 2-145]

Figure 2-144. Joggles are used primarily to place parts on

the same plane so there are no contours in the metal where
the parts overlap. One example is where a doubler must fit
over a bulb angle. Rather than attempting to pull the doubler against the skin with rivets, a joggle should be formed
to allow the two metal pieces to be on the same plane.

Figure 2-145. Clamping the metal between joggle dies or by

placing metal sheets in position and applying force with a
press can form joggles. When positioning the metal to form
a joggle in this manner, it is important to leave enough distance between the sheets to prevent the bends from
exceeding the minimum bend radius of the material being
joggled.

INSPECTION AND REPAIR OF

METALLIC AIRCRAFT STRUCTURES
Whenever sheet metal repairs become necessary, it
is important to do a thorough inspection for damage
that is not immediately apparent. For example,
damage that is initially thought to be just a skin
repair can have further damage to the underlying
structure. Although a visual inspection can usually
disclose damaged parts, distortion is occasionally
difficult to detect by merely looking at the parts. In
these situations, it is advisable for the technician to
feel for deformation, such as wrinkles and buckling,
by running a hand across the material. In other
cases, it may be necessary to make measurements of
the aircraft structure to assure symmetry between
components when the damage is gradual over a
large area. In addition, although inspecting for corrosion should be an on-going process, a more thorough inspection for corrosion can be accomplished
whenever skins are removed for repairs.

REPAIR OF SHEET METAL

STRUCTURES
The most important part of any repair to a sheet
metal structure is to restore the integrity and
strength of the component. If a repair procedure is
not covered in a structural repair manual, the technician must use various tables to determine the
number and sizes of rivets, as well as the best
method for restoring the original quality of the
structure.
REPAIRABILITY OF
SHEET METAL STRUCTURES
Not too many years ago, major sheet metal repairs
were done in most aircraft maintenance shops.
However, today, with the high cost of labor, most
repairs consist of removing the damaged component
and replacing it with a new part from the factory.
The complex construction and design of many
newer sheet metal parts require forming methods
beyond the economical capability of most smaller
shops.
Major repairs to stressed skin aircraft should never
be attempted unless the proper jigs are available to
hold the structure in place when the
skins
are

removed. The manufacturer of the aircraft can normally furnish drawings that locate the critical jig
points so the jigs can be made accurately. Also, in
some cases, prefabricated jigs may be available from
the manufacturer for lease. Examples of components that may need to be assembled in jigs include
the fuselage, wings, doors, control surfaces, and
flaps.
One of the big advantages of sheet metal construction over the formerly used welded steel structures
is the ease with which it can be repaired. If, for
example, there is major damage to the aft section of
a fuselage, the rivets that hold the damaged area can
be drilled out and the entire section removed. A
new section can then be mated to the undamaged
portion in a jig, and with a minimum of man-hours,
the aircraft can be restored to its original condition
and structural integrity.
ASSESSMENT OF DAMAGE
The difference between making a profit and losing
money on a repair job is largely in the assessment of
the damage. An intelligent bid must be made, one
that includes the repair of every bit of the damage,
yet one that is not so large that it disqualifies the
bid. Damage that is visible from the surface is usually easy to evaluate, but it is the damage that is not
readily apparent that can make the difference
between profit and loss.
When examining a damaged structure, use the illustrated parts catalog to determine what types of components are not visible. Consider every piece of
skin, rib, former, stringer, and fitting. Some of these
parts which have only superficial damage may be
quickly repaired, but once the labor of a repair is
considered, it may be more economical to use new
parts on larger or severely damaged components.
It may also be more economical to exchange a damaged component such as a wing or fuselage from a
repair station that specializes in rebuilding these
components. A repair station's specialized skills
and equipment will allow it to make the repair with

2-84

Sheet Metal Structures

a far smaller labor cost than a shop that does the

work only occasionally. By exchanging for a component that has already been repaired, the damaged
aircraft can be returned to service in far less time
than if the work is done in a smaller, less specialized facility.

surface. However, fillers should not be used on control surfaces, because if the filler becomes dislodged, a severe imbalance could cause aerodynamic fluttering of the control. In fact, most repairs
to control surfaces are classified as major because of
the critical balance considerations.

INSPECTION OF RIVETED JOINTS

Hidden damage may extend beyond the area of visible deformation, and any riveted joint that shows
an indication of damage should be inspected well
beyond the last deformed rivet. When inspecting
the rivets, check both the manufactured heads and
the shop heads.

Other forms of damage that may be considered negligible include scratches in aluminum alloy skins.
However, scratches may harbor corrosion and concentrate stresses enough that they may cause the
part to crack. If the scratch is not too deep, it can be
burnished with a smooth, rounded piece of steel to
force the metal back into the scratch. Work the metal
back in smoothly and evenly, but do not allow it to
lap or fold over and form an inclusion that will trap
moisture and cause corrosion. [Figure 2-146]

One method of determining if the rivet has been

tipped from excessive loads is to try slipping
a .020-inch feeler gauge under the rivet head. If it
goes under, the rivet may have been stretched.
When rivet damage is suspected, drill out the rivet
and examine the hole for any indication of
elongation or tearing. If the structure has been
damaged, the skin will shift when the rivet is taken
out. All of the stresses caused by the stretching
will have to be removed by drilling out rivets in
the seam until there is no more shifting. If the holes
are sufficiently out of alignment to require the next
size larger rivet, be sure that the edge distance and
rivet spacing will allow the use of the larger rivet.
Otherwise, the skin will have to be replaced.
INSPECTION FOR CORROSION
Many times, aircraft structures that are enclosed
will develop corrosion that will not be detected
unless the structure is opened for repair. Also, if a
damaged component is improperly stored for a long
period of time, corrosion may develop. One of the
most important aspects of sheet metal repair is to
detect, remove, and treat corroded structural components before the corrosion has a chance to
progress too far. If corrosion is found, every trace
must be removed and the metal treated to prevent
its recurrence. After the treatment, the part should
be primed with either epoxy or zinc chromate
primer. A more complete coverage of the removal
and control of corrosion is found in Chapter Twelve
of the AfrP Technician General Textbook.
REPAIR OF NEGLIGIBLE DAMAGE
Smooth dents in a structure, free from cracks and
sharp corners that do not interfere with any structure or mechanism, are considered negligible damage. These may be left as they are, or, if the structure
is painted, they may be filled with a resin-type filler,
filed smooth, and refinished to match the rest of the

1111111111111111111111\

Figure 2-146. A scratch in a piece of aluminum may be burnished. The displaced metal is moved back into the scratch
to prevent corrosion from forming. In addition, the blending
of the metal reduces the possibility of cracks forming at the
bottom of a scratch.

SPECIFIC SHEET METAL REPAIRS

Before discussing any type of specific repairs that
could be made on an aircraft, remember that the
methods, procedures, and materials mentioned in
the following pages are only typical and should not
be used as the authority for the repair. When repairing a damaged component or part, consult the
applicable section of the manufacturer's Structural
Repair Manual (SRM) for the aircraft. These manuals may also be referred to by some manufacturers as
Structural Inspection and Repair Manuals (SIRM),
and essentially contain the same type of information as an SRM.
An SRM differs from the manufacturer's service or
repair manual in that it is devoted entirely to the
inspection and repair of the aircraft structure. On
some smaller aircraft, the manufacturer will include
a chapter on structural repair in the service manual
rather than in a separate, dedicated SRM. Some of
the areas covered in a structural repair manual (or a
single chapter) will include the criteria
that all

2-85

Sheet Metal Structures

repairs must restore a damaged aircraft to its original design strength, shape and alignment.
Specific areas of repair and adjustment will usually
include the equipment and tools necessary for
repair, control balancing, and setting of the angle of
incidence of the wings or stabilizers. Also included
will be specifications for materials to be used and
the procedures to follow in the repair of the fuselage, wings, ailerons, fin, stabilizer, elevator, rudder,
engine mounts, baffling, and cowling. Instructions
for all types of materials used in the structure will
be included. Normally, a similar repair will be illustrated, and the types of material, rivets and rivet
spacing, and the methods and procedures to be
used, will be listed. Any special additional information needed to make a repair will also be
detailed. If in doubt about any part of a repair
detailed in the SRM, the aircraft manufacturer
should be consulted.
REPAIR OF STRESSED SKIN STRUCTURE
When repairing damage to a stressed skin structure,
it is important to make a repair which fully restores
the original strength of the panel. The repair will be
required to assume any loads transferred to it and
pass them through to the rest of the structure.
APPROVAL OF REPAIRS

For an aircraft to remain legally airworthy, it must

continue to meet all of the requirements for its original certification. This means that any repair must
retain all of the strength, rigidity, and airflow characteristics of the original structure, and it must be
protected against damage from the environment in
the same way as the original, or better. Any repair
that affects any of these factors must be approved by
the FAA. The easiest way of assuring that the repair
will meet the required standards is to verify that all
data used is FAA approved.
Approved data may be in the form of the repairs
that are described by the aircraft manufacturer's service manuals or structural repair manuals, which
are usually FAA approved. Before using the manufacturer's repair information, check to see that there
is a statement in the manual that designates the
manual is FAA approved. Approved data can also
be in the form of an Airworthiness Directive, or a
Supplemental Type Certificate. If the repair is
unusual, the aircraft manufacturer's engineering
department may need to be consulted to obtain the
instructions on how to perform the repair.
When a repair is made according to approved data,
the aircraft can be approved for return to service by

an A&P technician holding an Inspection

Authorization (IA). An IA must examine the repair
to make certain it conforms to the approved data
and then sign a statement of conformity on an FAA
Form 337. Once the IA signs the 337 Form and other
appropriate maintenance record entries are made,
the aircraft can be returned to service.
If the repair cannot be made in accordance with
approved data, a technician can detail the methods
that will be used to conduct the repair on a 337
Form and submit the information for approval from
the FAA. It is important that the repair procedure
receive approval prior to any work being accomplished on the aircraft. In most cases, the 337 Form
can be submitted to the local Flight Standards
District Office for approval. However, if the repair is
extensive, the local office submits the information
to the engineers in the aircraft certification department for approval.
When detailing the methods that will be used to
conduct a repair, information to substantiate that
the procedure meets FAA criteria can come from a
number of sources. One source that is commonly
used is to reference procedures outlined in
Advisory Circular AC 43.13-lB, Acceptable
Methods, Techniques, and Practices. However, the
information contained in this circular is not FAA
approved, but is considered acceptable to be used to
meet airworthiness standards. Once the AC is used
as a reference, the FAA must verify that the information meets approved criteria.
Upon completion of the repair, in most cases, an IA
can perform an inspection to verify that the work
has been done in accordance with the approved procedures, and then permit the aircraft to be returned
to service.
If a similar repair has been made on another aircraft
and written up on a 337 Form and approved, that
337 Form may not be used as approved data because
its approval is for a one-time-only specific repair. A
similar repair can be made, but the repaired aircraft
will have to be approved for return to service hy the
FAA via another 337 Form.
CRITERIA OF A REPAIR

Any repair made on an aircraft structure must allow

all of the stresses to enter, must sustain these
stresses, and must then allow them to return into
the structure. The repair must be as strong as the
original structure, but not different enough in
strength or stiffness to cause stress concentrations
or alter the resonant frequency of the structure.

2-86

Sheet Metal Structures

All-metal aircraft are made of very thin sheet metal,

and it is possible to restore the strength of a repair
without restoring its rigidity. All repairs should be
made using the same type and thickness of material
that was used in the original structure. If the original skin had corrugations or flanges for rigidity,
these must be preserved and strengthened. If a
flange or corrugation is dented or cracked, the material loses much of its rigidity and must be repaired
in such a way that will restore its rigidity and stiffness as well as its strength.
There also must be no abrupt changes in the
cross-sectional area of a repair. If a crack is
reinforced in a stressed skin, it should not be made
with a rectangular patch that causes an abrupt
change in the strength of the skin, as the stresses
enter, and then another abrupt change as they leave.
Rather, use an octagonal patch that gives a more
gradual change as the stresses enter and leave
the repair area. [Figure 2-147]
Think ahead when considering a repair. Remember
that every rivet that is removed must be reinstalled,
and to drive a solid rivet, access must be made to
both the manufactured head and the shop head. If
there are areas that cannot be reached to buck a
solid rivet, it may be necessary to use blind rivets. A
friction-lock Cherry rivet usually requires one size
larger diameter than a solid rivet it replaces, and if
one is used, be sure to verify that sufficient edge distance exists. On the other hand, a mechanical-lock
Cherry rivet normally allows the use of the same
size diameter as the solid rivet it replaces and also
may be available in slightly oversized diameters.
Both Hi-Shear rivets and Huck Lockbolts are types
of high-strength pin rivets that are used in aircraft
factories for applications where high strength is
needed, but where light weight and ease of installation make them a preferred choice over bolts and
nuts. If one of these special fasteners need to be
replaced in a repair and the proper tooling is not
available, bolts and self-locking nuts are generally
allowed as replacement hardware. However, it is
still necessary to verify that the aircraft manufacturer allows the substitution.
REPLACEMENT OF A PANEL

In accordance with FAR Part 43, Appendix A, if

additional seams are cut in a stressed skin panel,
these types of repairs constitute a major repair, and
must have FAA approval before the aircraft can be
approved for return to service. In addition, repairs
to stressed skin panels that exceed 6 inches in any
direction also constitute a major repair, and also

Figure 2-147. A repair should be constructed to allow the

stresses to be imparted on the repair area in a gradual manner. Increasing the cross section of a repair over a wider
area helps reduce the stress concentrations caused by an
abrupt change.

must have FAA approval. On the other hand, if a

skin on a wing or tail surface has been extensively
damaged, it may be more economical to replace an
entire panel rather than making a repair within the
panel.
To perform these repairs, remove the damaged panel
from one structural member to the next, cutting a
generous radius in all of the corners. Usually a
radius of 1/2 inch is considered to be the minimum
size. Remove all of the rivets immediately
sur-

2-87

Sheet Metal Structures

Figure 2-148. It is often advisable to replace an entire panel rather than making a patch within the panel.

rounding the cutout. When installing the new

panel, use the same rivet size and spacing as was
used on the original structure, unless there is different rivet spacing along a sheet splice for the panel
being repaired. If different rivet spacing is used,
apply the same spacing as was used on the splice
inboard or ahead of the panel being replaced. Be
sure when cutting the new panel that sufficient edge
distance exists for all of the rivets to be installed.
[Figure 2-148]
Cut the panel to size and drill one of the corner rivet
holes. Fasten the panel to the structure with a Cleco
fastener, aligning the panel with the structure. Now,
using a hole finder, locate and drill the other corner
holes and temporarily fasten these holes with Cleco
fasteners. If possible, back-drill the rest of the holes
through the structure or, if not possible, use the hole

finder to locate the remaining holes. Then remove

the panel and deburr all of the holes and the corners
of the panel. Finish the panel by gently crimping the
edges so it will fit tightly against the skin, and spray
the inside with a light coat of zinc chromate primer.
Once the panel is prepared, fasten it back in position with Cleco fasteners, and begin riveting the
panel in place.
DESIGN OF PATCHES FOR STRESSED SKIN

When there is damage to a stressed skin, first determine the amount of strength that has been lost, and
then design a patch that will restore the strength. A
typical example of this kind of repair restores the
original strength by placing an octagonal patch over
a crack. For example, assume a repair is needed to
a .040-inch aluminum alloy skin with a 2-inch
crack across the material.

2-88
To begin the process of repairing the panel, begin by
finding out how much strength the damaged section
needs to provide. To determine this value, tables are
available that specify the number of rivets that are
necessary to impart the same strength through the
repair as through an undamaged sheet of aluminum.
These tables specify a particular type and size of
rivet in various thickness aluminum alloy sheets.
Using one such table for 1/8-inch diameter, 2117 AD
rivets in .040 inch 2024-T3 skin, 7.7 rivets per inch
of crack width are called for on each side of the
damaged area. This falls below the line in this column, which means that the joint is critical in shear,
or that it will fail by the rivets shearing rather than
by the sheet tearing at the holes. [Figure 2-149]

Sheet Metal Structures

Begin the repair by drilling a number 30 stop-drill

hole in each end of the crack. Clean a piece
of .040-inch aluminum alloy with lacquer
thinner and spray it with a light coat of zinc
chromate primer so the layout lines will show up.
Start the layout with the locations of the stop-drill
holes, and draw a line between them. Now, draw a
parallel line on each side of this line, two and
one-half rivet diameters from it. This is the edge
distance between the center of the rivet hole and the
edge of the crack.
Since the damage to the skin is 2 inches, there will
need to be a minimum of 16 rivets on each side of
the repair. However, 16 rivets on either side of the
crack will not allow a symmetrical patch. On the
other hand, if 18 rivets are used on each side, a pat-

Figure 2-149. Tables are available that specify the number of rivets required for each side of a single lap joint repair to restore the
original strength to sheet aluminum.

2-89

Sheet Metal Structures

Figure 2-150. This layout of an octagonal patch shows the pattern and number of required rivets to repair a 2-inch crack in
stressed .040-inch thick 2024-T3 aluminum alloy skin.

tern can be formed consisting of seven rivets in the

first row, six in the second, and five in a third row.
Although the pattern will use more than the minimum number of rivets, this is allowed. The determining factor for the maximum number of rivets is
that the rivets cannot be spaced closer together than
minimums allow, while also maintaining edge distances. By using four rivet diameters for the pitch, a
rivet spacing of 1/2-inch can be used and the correct
distance between the rows will be 3/8-inch. [Figure
2-150]

amount of tension on the metal will cause it to slip.

When the rivets are installed, the metal will shift,
causing the drilled holes to misalign. The patch
must fit smooth and tightly before riveting. Also,
slightly crimping the perimeter of the patch prevents the edges from lifting. [Figure 2-151]

Use a fine tipped marker to lay out all the lines and
mark the 36 rivet holes. Draw a line, two and
one-half diameters from the center of the rivets in
the outside rows. Cut the patch along this outside
line, deburr all of the edges, and cut a radius in all
of the corners. Center punch each rivet location,
and drill a number 30 hole for each rivet. Once
drilled, deburr each of the holes.
After the patch has been prepared, center it over the
stop-drilled crack and drill two holes through the
skin to match the holes in diagonal corners of the
patch. If the damage is on a curved portion of the
skin, the patch will first need to be run through a
slip roll former to form its contour to match the
skin. Do not try to form the metal by holding the
patch by hand while drilling. In most cases, the

Figure 2-151. A simple tool for beveling the edges of a patch

can be fabricated from a phenolic block. Using a band saw,
notch the end of the block to the desired depth of the bevel.

Sheet Metal Structures

2-90

Fasten the patch in place with Cleco fasteners and

drill all of the remaining rivet holes. After drilling,
remove the patch, deburr the holes in the skin, and
remove any metal chips. Once deburred and
cleaned, verify that the protective coating is in good
condition and rivet the patch in place.
FLUSH PATCH STRESSED SKIN REPAIRS

Small damage in a stressed skin may be repaired by

making a circular patch that has uniform strength in
all directions. For maximum streamlining, a flush
patch may be installed on the inside of the skin,
using flush rivets, and a plug of the same thickness
as the skin. The plug is riveted in the hole where the
damaged skin is removed, and contours the surface
to the original shape.
Designing a flush patch repair is similar to any other
type of patch repair. For example, if there is damage
to a .025-inch aluminum alloy stressed skin made
from 2024-T3 material, a flush patch can be fabricated in the following fashion.
Before installing a patch, it is necessary to remove
any damaged material. For this example, assume
that a 2-inch hole has been cut to remove the damaged material. Begin designing the patch by deter-

DAMAGE
DIAMETER
SKIN =
ALLOY
RIVET =
RIVETS
18 RIVETS
Figure 2-152. A layout of a flush
circular rows on a doubler plate,
patch riveted to fill the hole

mining the minimum number of rivets required to

restore the strength of the sheet metal. By referring
to the chart in figure 2-149, it is found that the
repair requires 8.6 3/32-inch diameter rivets per
inch on each side of the damage in a doubler plate.
Although the material will be removed in a circular
pattern, the damage still has a 2-inch diameter. This
means that the repair must have at least 18 rivets on
each side of the damage. [Figure 2-152]
Lay out the pattern on a piece of .025-inch material,
making a circle with a linch radius, representing
the removed damage in the skin. Then draw a circle
with a radius of 1.23 inches to locate the first row of
rivet holes, which is approximately two and
one-half rivet diameters from the edge of the
removed damage. A second circle with a radius of
1.61 inches will locate the second row of rivets,
approximately four diameters from the circle on
which the first row is located. Finally, a third
circle with a radius of 1.84 inches is marked to
locate the outside perimeter of the doubler. This
will provide the minimum edge distance from the
outside row of rivets to the edge of the doubler.
Using a protractor, mark off 20 degree increments on
the first circle to locate 9 rivets on each half of the

OUTSIDE OF
PATCH
CLEANED OUT TO 2.0 INCH
HOLE
0.025 CLAD ALUMINUM
CLEANED-OUT
DAMAGE
MS20426AD3
REQUIRED = 8.6 PER INCH OR
ON EACH SIDE OF DAMAGE
patch shows the rivets in
and a non-structural flush
created by the removed skin.

2-91

Sheet Metal Structures

circle. Now, mark between the center of each of

these rivets on the second circle to locate the center
of the rivets in the second row. Mark all of these
locations, and then center punch them for drilling.
Use a number 40 drill to make the rivet holes at each
of the locations.
Once the doubler is fabricated, position it on the
inside surface of the skin and center it under the
cleaned-out damage. Drill one hole, and fasten the
doubler in place with a Cleco fastener. Once one
hole is fastened, continue to drill for the remaining
rivets, securing the doubler with a sufficient number of Cleco fasteners as the drilling progresses.
Once the drilling is complete, remove the doubler,
deburr all holes, and clean out any metal chips.
Because the repair is to be flush, instead of using
universal head rivets, flush head rivets will be
installed. Since the skin has insufficient thickness
to allow counter-sinking, the rivet holes must be
dimpled to accept MS20426AD3 rivets. Once the
doubler plate has been dimpled, spray the surface
with zinc chromate primer and rivet it in place.
The final step in completing the repair involves cutting a circular patch of .025-inch material that will fill
in the removed skin. Once fabricated, place the patch
in the hole and drill for rivets through the patch and
doubler. Since the patch does not offer any strength to
the stressed skin, only enough rivets are required to
hold the patch securely in place to prevent the edges
from lifting. After the patch is prepared, dimple the
metal, and finish installing the rivets.

STRINGER REPAIRS

The most critically loaded stringers in an aircraft

structure are those found in the lower surface of a
cantilever wing. They are under a tensile load in
flight and under a compressive load upon landing.
Stringers must receive the greatest amount of care
when being repaired to enable them to withstand
high stress loads.
When a bulbed stringer must be spliced, first determine the amount of material in the cross-section,
and use material having the same or greater area to
attach a doubler with the number of rivets specified
in figure 2-149. For example, assume a stringer has
a 1 inch wide flange on one side, and a 1/2-inch
wide flange on the other, and is made of .040-inch
2024T-3 aluminum alloy. In this example, the
stringer would have a total cross section of 1.5
inches. According to figure 2-149, there will need to
be 7.7 rivets per inch of width, or 12-1/8-inch diameter rivets on each side of the splice (7.7 x 1.5).
Putting an extra 3/32-inch diameter rivet at each
end will help avoid an abrupt cross-sectional area
change. Allowing for an edge distance of two and
one-half rivet diameters, and a spacing of three
diameters, the splice will have to extend 5.05 inches
on either side of the joint. [Figure 2-153]
For splice material, use a piece of the same type of
bulb angle. Taper the ends of the top flange back to
provide a gradual change in the cross-sectional area
and rivet the two pieces together. For formed
stringers and extrusions other than bulb angles, the
repair is similar. Form a reinforcement piece with

Figure 2-153. This layout shows the required number of rivets spaced out on each side of a stringer splice.

2-92

Sheet Metal Structures

REPAIR MATERIAL IS SHADED

Figure 2-154. The cross-sectional area of the repair material must be greater than the damaged area. On a typical stringer repair,
this requires reinforcing more than one angle of the stringer.

more cross-sectional area than the damaged stringer,

and rivet it in place with the number of rivets specified in figure 2-149. Remember, the function of a
stringer is to provide stiffness as well as strength.
[Figure 2-154]
REPAIRS FOR WATERCRAFT

In addition to providing adequate strength with the

proper streamlining, any repair to a float or boat
hull must be waterproof, and adequately protected
from corrosion. The strength requirements and layout procedures are similar to other repairs previously discussed, but when a patch is prepared, coat
it with a rubber-like sealant, and then put in place.
Also, dip all rivets in the sealant and install them
while the sealant is wet.
TRAILING EDGE REPAIRS

The trailing edge of a truss-type wing is usually

made of aluminum alloy formed into a V-section.
When these areas are distorted or cracked, they
should be straightened out as much as possible and
an insert formed of the same thickness material,
slipped inside and riveted in place. These rivets
will be difficult to install, and will have to be put in
with the manufactured head on the inside, and
bucked with a bar ground to fit in the confines of the

Figure 2-155. A typical trailing edge repair shows the repair

material inserted into the inside of the angle and riveted in
place.

V. The rivet shank can then be upset with a flush

rivet set. [Figure 2-155]
CORRUGATED SKIN REPAIRS

The control surfaces on most light, all-metal airplanes are made from thin sheet metal, which is corrugated to give additional stiffness. When a corrugation is dented or cracked, it can no longer withstand the loads imposed on it, and must be repaired.
To perform repairs to corrugated surfaces, remove
the damaged area and rivet a new piece of skin in

2-93

Sheet Metal Structures

Figure 2-156. The most common repair to light aircraft control surfaces involves replacing a portion of the corrugated skin.

place. Corrugated skins are available from the aircraft manufacturer, or can be fabricated by forming
in a press. [Figure 2-156]
It is extremely important when making any repair
to a control surface that the repair does not add

weight behind the hinge line. In the SRM, the aircraft manufacturer generally specifies the balance
conditions for the surfaces. After repairs have been
made to a control surface, it must be checked to
determine that its balance falls within specifications.
In
addition,
any repair to
monocoque or

2-94

semimonocoque
control
surfaces
constitutes a major repair. [Figure 2-157]

Sheet Metal Structures

SPECIALIZED REPAIRS
The high stresses encountered by modern aircraft
require that every repair to a structure be carefully
considered and made only in accordance with data
that is furnished by the manufacturer, or that is
specifically approved by the FAA. This is especially
true for major load carrying members such as bulkheads, formers, and spars. In addition, special considerations must be used when repairing pressurized
aircraft because of the high stress loads encountered
in the pressurized sections of the airframe.
FORMER AND BULKHEAD REPAIRS

Figure 2-157. The static balance of control surfaces must be

checked after a repair has been made to be sure that it is
within the tolerances allowed by the manufacturer.
INSPECTION OPENINGS

Many times, a repair must be made to a metal structure that requires access to the inside where the
manufacturer has provided no openings. In these
situations, inspection hole kits are often available so
holes can be cut wherever access is needed. These
kits usually include doublers and plates for reinforcing and covering the access opening. Generally,
the doubler is riveted to the inside of the structure,
and screws are used to secure the cover. Be sure,
before cutting a hole in the structure, that it is not
located in a highly stressed area. If there is any
doubt about the location of the hole, check with the
manufacturer or obtain approval from the FAA
before cutting a hole. [Figure 2-158]

Figure 2-158. Inspection holes may be cut in an aircraft skin

to allow access to an area that must be repaired. Be sure
that the location for such a hole is approved before cutting
the opening.

Bulkheads are primary load carrying members of a

fuselage. However, they are also found in wing construction. Bulkheads are usually perpendicular to
the longerons, keel beams, or stringers. Some bulkheads also run fore and aft in the fuselage, especially around passenger and cargo doors. On the
other hand, formers are often called forming rings,
body frames, circumferential rings, or belt frames,
because of the manner in which they provide the
shape to a fuselage structure. Formers are usually
riveted to longerons and stringers in order to carry
primary structural loads. Since formers and bulkheads may be subject to high loads, repairs to these
components should be conducted in strict accordance with the aircraft manufacturer's repair
instructions. [Figure 2-159]

Figure 2-159. A wing rib or fuselage former must be reinforced with a doubler over the damaged area.

2-95

Sheet Metal Structures

Figure 2-160. A spar web butt splice requires adding an insert to replace the cutout damaged area. Any material used for a splice
should be of the same type and thickness as the original spar, and reinforced with doubler plates.
SPAR REPAIRS

The spar, being a primary load carrying member of

the wings, usually requires repairs to be made
according to the aircraft manufacturer's instructions. However, spar repairs of a general nature are
also covered in AC43.13-1B, Acceptable Methods,
Techniques and Practices. Again, these repairs are
not approved for any specific aircraft, but the procedures may be used to obtain FAA approval.
Some spar repairs involve placing an insert in place
of a damaged section. Before riveting the insert in

place, give all contacting surfaces a coat of zinc

chromate primer. The rivets used for attaching the
insert section to the spar flange are in addition to
those calculated for attaching the splice plates. One
typical spar repair is shown in Figure 2-160.
LEADING EDGE REPAIRS

A damaged leading edge usually involves nose ribs,

skins and the spar. Repairs made to these components are usually outlined in the manufacturer's
SRM or maintenance manual. Since the leading
edges are laid out in sections from the wing butt to

2-96

Sheet Metal Structures

the tip, the manufacturer often recommends that an

entire leading edge section be replaced during the
repair procedure.
One difficulty encountered when replacing a leading edge is trying to maintain the contour of the
structure during installation. In many cases, it is
advisable to use cargo straps or other similar
devices to hold the leading edge in position before
drilling any holes. Once the leading edge has been
initially contoured and positioned, wrap the straps
around the wing and tighten them to pull the leading edge into position. Once secured, it is less likely
to have problems with the leading edge shifting,
which causes misaligned rivet holes. [Figure 2-161]

Figure 2-162. A typical repair of a pressurized structure

requires that sealant be used to restore air tightness to the
pressure vessel of the structure.
Figure 2-161. Cargo straps are useful for pulling a leading
edge section into position before drilling and riveting.

PRESSURIZED STRUCTURE REPAIRS

High performance aircraft with pressurized cabins

are becoming more common in aviation, and repairs
to this type of structure must take into account the
need for additional strength. The increased strength
is especially critical due to the flexing of the structure during pressurization and depressurization
cycles. When repairs are necessary on these aircraft,
it is especially critical to follow the aircraft manufacturer's procedures. In many cases, the manufacturer's engineering department must design and
issue specific instructions to be followed when conducting repairs to pressurized airframe structural
components. [Figure 2-162]

skin as well as substructure components. An example of a typical repair for this type damage is shown
in figure 2-163.

MISCELLANEOUS REPAIRS

In many situations, it is possible that more than a

single sheet metal component will suffer damage,
making it necessary to use a combination of repair
techniques. One such repair involves damage to the

Figure 2-163. If the substructure and skin have been damaged, the substructure must first be repaired and then the
skin patched.

Sheet Metal Structures __________________________________________________________________ 2-97

Although many repair procedures have been discussed in this chapter, there are countless sheet
metal structures in an aircraft. In some cases, damage to these components is minor, and only requires
general practices to construct an acceptable repair.

However, it is important to use good judgement in

determining if a repair may affect the integrity of the
aircraft. Always remember to consult the aircraft
manufacturer, or a local FAA inspector before proceeding with any questionable procedures.