Sheet Metal Materials - Cessna 510 Mustang Structural Repair Manual

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Maintenance manual (11 pages)

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General

Most of the sheet metal stock used in the structure of the airplane is aluminum alloy. In addition, significant amounts of

sheet stock corrosion resistant steel alloys and steel alloys are used.

Table 1 lists standard sheet metal gages and stop drill hole sizes.

C. When doing repairs to the airplane structure, all bare metal parts, including surfaces exposed by cutting or drilling, must be

coated using protective treatment described in Protective Treatment of Metal.

Aluminum Alloys

Aluminum alloys are designated by symbols of the Aluminum Association standard four-digit index system.

The heat-treat condition of the material is indicated by a "T" number that follows the alloy designation. The "0" that follows

the alloy designation indicates that the material is in the annealed condition.

C. The word "clad" preceding the material designation indicates that a protective coating of pure aluminum has been applied

prior to completion of the final rolling process of the material. Clad aluminum is not normally used in bonded assemblies.

D. The most commonly used aluminum alloy sheet materials are 2024-T3/T42. 2024/T3 is generally formed in the heat

treated condition.

When making structural repairs, Cessna Engineering approval of substitute materials must be obtained prior to

proceeding, if parts identical to the factory installed parts are not available.

Corrosion Resistant Steel

Corrosion resistant steel plate or sheet stock is used in some areas of the airplane structure where high strength or fire

resistance is required.

Steel is cathodic to aluminum and must be insulated from it when you make repairs. Refer to Protective Treatment of Metal

for protection from dissimilar metals contact.

Flat Patterns

A flat pattern is the outline of the flat blank sheet required to make a bent up or formed part. To make a flat pattern, take the

dimensions and contours from the damaged or opposite-hand part. This may be accomplished by the following methods:

Shaping a piece of soldering wire around the part, or cutting a cardboard template to fit the part, or scaling the part and

making a sketch as illustrated in the following paragraph. The latter method is the most accurate. Derive the developed

length and lay out the flat pattern.

(1) Make a sketch of the section to be formed ( Figure 1) showing the following dimensions: A = Flange Length; B = Set-

Back (Figure 2); C = Web Length; D = Set-Back (Figure 2); E = Flange Length; BR = Bend Radius; F = Flange

Angle; G = Flange Angle; T = Gage

(2) Derive the developed length by the following formula: Developed Length = A - X+C -X + E

CAUTION: Do not use a metal scriber when making layouts. The scratches on the metal may cause cracks.

(3) Lay out flat pattern on the flat blank sheet of repair material (Figure 1, Figure 2 and Figure 3) with a pencil or sharp

crayon.

Table 1. Sheet Metal Standard Gages and Minimum Stop Drill Hole Sizes

Sheet Metal Standard Gage (Inches)

0.006

0.010

0.012

0.016

0.020

0.025

0.032

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