Corocion Control Manual

ATP
INDEX
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2002
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ATP Grid Index to Manufacturers Publications:
Sabreliner
Corp.
NA-265 SERIES
Corrosion Control Manual
Section
General
T_opic
Information
Title
Page
List of Chapters (Table of Contents)
Manufacturers Introduction
Record of Revisions
Record of
Temporary
Revisions
Letter of Transmittal
(Highlights of Changes)
List of Effective Pages
Airframe Systems
20.00.00
Standard Practices
20.00.00
List of Effective
20.00.00
Airframe
Pages
General
20.00.10
Corrosion
on
Airframe
20.00.20
Corrosion
on
Electrical
20.00.90
Sources of Commercial Proucts
20.10.00
Cleaning
20.10.05
Magnesium Alloys Cleaning and Protective Treatments

Cleaning Iron and Steel
Cleaning Aluminium and Aluminium Alloys
Cleaning Corrosion and Heat Resistant Alloys
20.10.10
20.10.15
20.10.20
20.10.25
20.10.30
20.10.35
20.10.40
20.10.45
20.10.50
20.10.55
03/03/2001
Equipment
Cleaning Copper and Copper Alloys

Cleaning Titanium and Titanium Alloys
Cleaning Plastic and Glass
Polishing Sheet Acrylic Plastic
Stripping Organic Finishes
Stripping Organic Coatings from Metals
Solvent Vapor Degreasing
Copyright
Aircraft Technical
SE
0001
CV)
Publishers
Page
of
Section
Topic
20.10.60
Abrasive
20.20.00
Sealing
Sealing Methods
20.20.02
20.20.02
20.20.04
20.20.06
20.20.06
20.20.08
20.20.08
20.20.10
20.20.10
20.20.12
20.20.12
20.20.14
20.20.14
20.20.16
20.20.16
20.20.18
20.20.18
20.20.20
20.20.20
20.20.22
20.20.22
20.20.24
20.20.24
20.20.26
20.20.26
20.20.28
20.20.28
20.20.30
20.20.30
20.20.32
20.20.32
20.20.34
20.20.36
20.20.38
20.20.40
20.20.40
20.20.44
20.20.44
20.20,46
03/03/2001
Cleaning
Service Information Letter No. 57
Sealing Integral Wing Fuel Tanks

Fuel Tight Faying Surface Sealing for Areas/Normal
Operating Temperatures from -65 to +200F
Liquid Tight Sealing of Areas/Normal Operating
Temperatures from -65 to 225F
Pressure Tight Sealing for Areas/Normal Operating
Temperatures from -65 to +225F
Temperatures from -65 to +225F (Alternate Procedures)
Fume Tight Sealing for Areas/Normal Operating
Application of Self-Contouring Sealing Pads for Areas
Where Normal Operating Temperatures Do Not Exceed 225F
Exterior Watertight Sealing for Areas/Normal Operating
Faying Surfaces Sealing for Areas/Normal Operating
Liquid Tight Sealing for Areas/Normal Operating
Temperatures from 225 to 400F
Fume Tight Sealing for Areas/Normal Operating
Application of Self-Contouring Sealing Pads for Areasl
Normal Operating Temperatures from 225 to 550F
Flame Resistant and Liquid tight Sealing for Areas/
Normal Operating Temperatures From 225 to 400F
Faying Surface Sealing for Areas/Normal Operating
Temperatures From -100 to +550F
Installation of O-rings for Fuel System
Installation of O-Rings for Fuel Sys
Bolted Assy
Instl Procedures for O-Rings Sealing of Bolted Assy
Application of Tape or Sealant Corrosion Barriers
between Magnesium and Other Metals
Electrical Systems Room Temperature Curing Silicone
Rubber Potting
Potting Bendix Connector for Use to 300F
Copyright

SE
0001
CV)
Page
of
Section
20.20.48
20.20.50
Topic
Sealing Electric Terminations with Overcoating

Sealing Neoprene Jacketed Multiconductor and Coaxial
20.20.50
Cable and Kel-f Jacketed Coaxial Cable Terminations
20.20.52
Proofing flee Components/Strippable Sealant

Sealing Electrical Wire Bundles Passing thru Bulkheads
Sealing Electric Terminations Subject to Temp Up to 300F
Sealing Electrical Terminations Subject to a Maximum
Temperature between 300 and 400F
Application of Sealant Electrical Wire Bundles Passing
through Bulkheads for Max Serv Temp from 350 to 500F
Organic Base and Finish Coating
Cati-Coat Primer Application
Wash Prime Application
Moisture and Fungus Resistant Coating Application
Painting Metal Surfaces/Epoxy Poly a Mide Primer or
20.20.54
20.20.56
20.20.58
20.20.58
20.20.60
20.20.60
20.30.00
20.30.05
20.30.10
20.30.15
20.30.20
20.30.20
20.30.25
20.30,30
20.30.35
20.30.40
20.30.45
20.30.50
20.30.55
20.30.60
20.30.65
20.30.70
20.30.75
20.30.80
20.30.85
20.30.90
20.40.05
20.40.10
20.40.15
20.40.20
20.40.25
20.40.30
20.40.35
20.40.40
20.40.45
20.40.50
20.40.55
03/03/2001
Moisture
Zinc Chromate Primer

Conversion
Type Coatings Application

Polyurethane Finish Sys for Sabreliner A/C Ext Surface
Mil-C-83286 Polyurethane Enamel Application
High Impact Polyurethane Coating Application
Urethane Finish Sys for Sabreliner A/C Ext Surfaces
Wrinkle Finish Application
Laminated and Molded Plastic Parts Finishing
Abrasion Resistant Coating Application
Rain Erosion Resistant Coating Application
Spray Painting Methods
Techniques
Radome Coating Material Application
Polyurethane Integral Fuel Tank Coating Application
Organic Integral Fuel Tank Coating Application
Protection of A/C In Out-Of-Doors Temporary Storage
Anodizing and Coloring of Aluminium Alloys
Chromic Acid and Sulfuric Acid Anodizing
Dow No. 17 Anodize Process for Magnesium Alloys
Application of TFE Infused Coating on Aluminum
Application of Scale Inhibiting Compound
Phosphate Treatment
Application of Chemical Films to Aluminium Alloys
Chemical Film Treatment for Titanium and Titanium Alloys
Electrodeposited Hard Nickel Plating
General Procedure for Brush Type Electroplating
Tin Plating by Electrodeposition or Hot Dipping
Copyright

SE
0001
CV
Page
of
Section
Topic
20.40.60
Hard Chromium
20.40.65
Copper Plating
20.40.70
Brush Cadmium
20.40.75
20.40.80
Nickel-Zinc Alloy Plating

Electroless Nickel Plating
20.40.85
Repair and Refinishing
20.40.85
or
Electrical Power
24.00.00
List of Effective
24.70.00
Landing Gear
32.00.00
List of Effective
32.80.00
of Abraded, Scratched, Reworked,
Pages
Accesory Compartment
Battery Compartment
32.00.00
32.00.00
Plating
Corroded Metal Surfaces
24.00.00
24.70.00
Plating
Pages
General
Wheel Wells
Structures
52.00.00
Doors
52.00.00
List of Effective
52.10.00
52.10.00
52.20.00
52.20.00
Passenger/Crew
Main Entrance Door Corrosion
Inflight Escape Hatch Removal, Inspection

Fuselage
53.00.00
List of Effective
53.10.00
53.20.00
53.30.00
Pages
Forward
Fuselage
Center Fuselage
AFT Fuselage
Nacelles/Pylons
54.00.00
List of Effective
54.00.00
General
55.00.00
Stabilizers
55.00.00
List of Effective
03/03/2001
Installation
General
54.00.00
55.00.00
Inspection
Emergency Exit
53.00.00
53.00.00
Pages
Pages
Pages
General
Copyright

SE
0001
CV)
Page
of
Section
Topic
57.00.00
Wings
57.00.00
57.00.00
General
57.10.00
Center Wing
57.10.00
Wing Structure
End of Index
03/03/2001
Copyright

SE
0001
CV)
Page
of
IVI FGI
INTRO
Report No. 8B-76-023
Sabreliner
Corrosion
Control
Manual
ALL MODELS NA 265 AIRCRAFT
ORIGINAL ISSUE: 31 OCT 1976

REVISION NO. 9
REVISED: 6 SEP 1991
Sabrelin~r,
COPYRIGHT, 1991 BV SABRELINER CORPORATION
RECORD OF REVISIONS
MFG REV
NO
DESCRIPTION
ISSUEDATE
ATPREVDATE
INSERTEDBY
8B-76-023
CORROSION CONTROL MANUAL
REVISION LOG
AoolBood To:
Mlnud Control Ile

Blonool Loootod At:
Brlc/
Bov. Doto
0
Oct 31/76
Nov 01/76
Jan 06/78
Oct 06/78
Feb 01/80
May 15/81
Aug 17/84
Aug 31/&1
Jan 16/87
Sep 6/91
Inr~la
Boto
Inur~l
(lnltlol)
BY
Rlmrlo
Basic Issue
Complete Reissue
10-23-91
GM
Ch. 20 and 52
REVISION LOG
Page 1/2 Blank
o3
COPYRIGHT, 1991 BY SABRELINER CORPORATION
Sep 6/91
RECORD OF TEMPORARY REVISIONS
TEMP
REV NO
9/29/00
DESCRIPTION
20-20-02:3
(SIL57)
ATP REV
INSERT
DATE
REV
REMOVE
ISSUE DATE
DATE
BY
REMOVED
INCOR
BY
9/29100
3115101
ATPIIB
SR-76-23
TR 89-1
TEMPORARY REVISION LOG
Atti(lned To:
MlnuJ Control Wo:

Mlnual Loccted At:
Interllon
Oets
Temporsry
Rev. No.
Inrerted By
Remtrke
(Inltitl)
TR 89-1
AUG.15
sn,
29/00
89
03/15/01
IQ
TEMPORARY REVISION LOG

0
Page 1/2 Blank

Aug T5/89
8B-76-023
IMPORTANT
READ THIS NOTICE i i i
REVISION N~TICE
6 SEPTEMBER 1991
SABRELINER
CONTROL
MANUAL
ALL MODELS NE 265 AIRCRAFT
REVISION INSTRUCTIONS
This is the latest revision dated 6 September 1991, Revision No. 9 to your Sabreliner Corrosion Control Manual, Report No.
SR-76-023.
a general revision to the manual, affecting chapters 20 and 52, in chapter 20 a change was made to the Aircraft
Sealing Methods Chart and in chapter 62 Inflight Escape Hatch Removal, Inspections and Installation was added, also all
yellow TR 89-1 pages were deleted and replaced with white pages.
This is
Insert the latest
new or
pages. This ensures that
revised pages in accordance with the List of Effective Pages,

only the latest material remains in the manual.
Sabre~iner,
COI1POIIATION
remove
and destroy superseded
5B-76-023
CORROBION CONTROL MANUAL
FRONTAL
LIST OF EFFECTIVE PAGES
Chapter/
Section
Page
Date
Sep 6/91
TITLE
REVISION LOG
1/2
Sep 6/91
TEMPORARY
REVISION LOG
1/2
Aug 15/89
FRONTAGL.E.P.
1/2"
Sep 6/91
CH.-LIST.
1/2+
Sep 6/91
The asterisk indicates pages revised, added,
or
deleted by the current revision.
FRONTAL-L.E.P.
Page 1/2 Blank

Sep 6/91
CORROSION CONTROL ~HANUAL
CHAPTER LISTING
Chapter
Title
No.
20
24
32
52
53
64
65
57
Introduction
Standard Practices Airframe
Electrical Power
Landing Gear
Doors
.Fuselage 1
Nacelles and Psrlonn
Stabilizers
Wings
Latest
Revision
Date
16/87
Sep 6/91
Aug 17/84
Jan 16/87
Sep 6/91
Aug 17/&1
Aus:17/&l
Aug 17/&1
Aug 17/84
Jan
1B02
1C02
3B02
3C02
3D02
3E02
3G02
3H02
3502
The asterisk indicates chapters revised by the current revision.
CH. LIST
a
COPVRIOHT, 1991 BY SABRELINER CORPORATION
Page 1/2 Blank

Sep 6/91
SR-76-023
CORROSION CONTROL
MANUAL
INTRODUCTION
TABLE OF CONTENTS
Subject
General
Chapter/Section/Subject
Page
Intro.
1
Subject Matter Identification

Page Numbering
Figure Identification
Chapter Table of Contents
Part Numbering
Revisions
1
1
INTRO.-CONTEMTS
0
Page 1/2 Blank

Aug 17/84
SR-76-023
INTRODUCTION
Chapter/
Date
Page
Section
INTRO.-LEP
1/2
Aug 15/89
INTRO.-CONTENTS
1/2
Aug 17/84
1
2"
INTRO.
Added
3/4
Aug17/84
Aug 15/89
Aug 15/89
INTRO.-L.E.P.
a
Page 1/2 Blank

Aug 15/89
8B-76-023
INTRODUCTION
GENERAL
PAGE NUMBERING
This manual contains maintenance oriented information

to guide owners/operators of Sabreliner airplanes in
setting up a good preventive maintenance program for
Pages
corrosion control.
manual is applicable to all Sabreliner series
airplanes. The Structural Repair Manual, Illustrated
Parts Catalog, and Maintenance Manual for a particular
Sabreliner airplane are to be used in conjunction with this
This
manual,
are
numbered within each subject
General Coverage and Description:

Trouble Shooting.:
Maintenance Practices,
If all subtopics are brief,
they are combined into one topic:
as
to
agree
with the
100.
SUBJECT MATTER IDENTIFICATION

follows:
Figures (illustrations)
within each topic
-XX-XX
Chapter Number
~f
Section Number
Subject Number
Pages
201-300
1-100
301-400
401-500
501-600
601-700
701-800
801-900
FIGURE IDENTIFICATION
Subject matter is identified by a three element number as
----I
101-200
Pages
Pages
Pages
Pages
Pages
Pages
Removal/Installation:
Adjustment/Test:
Inspection/Check:
Cleaning/Painting:
Approved Repairs:
functional breakdown utilized in Maintenance Manuals

prepared in accordance with Air Transport Association
(ATA) specification No.
Pages
Pages
follows:
Servicing:
FORMAT
prepared
follows:
If individual subtopics are so lengthy that a combination

would require many pages, each subtopic is covered
individually
This manual has been
as
as
are
When subdivided:
Servicing:
RemovallInstal lation:
Adjustment/Test:
Inspection/Check:
Cleaning/Painting:
Approved Repairs:
20-10-30
t
A "00" section identifies material of a general nature
applicable to the entire chapter. A "00" subject number
identifies material applicable to an entire section.
consecutively
Figure 1, 2, 3, 4, 5, etc.
Figures in Description:
Figures in Trouble Shooting: Figure 101, 102, 103, etc.
Figures in Maintenance Practices, When not subdivided: Figure 201, 202, 203, etc.
EXAMPLE:
Subject 30 Cleaning Titanium and Titanium

Alloys
numbered
follows:
Figure301, 302,303,etc.
Figure 401, 402,
Figure ~01, 502,
Figure 601, 602,
Figure 701, 702,
Figure 801, 802,
403,
etc.
503,
603,
703,
etc.
etc.
etc.
803, etc.

A list of effective pages is the first sheet in each chapter
and will be revised whenever the affected chapter is
revised. The list should be used as a cross reference when
inserting revised pages. This ensures that all obsolete
material is removed and the manual is kept current.
EXAMPLE:
20-00
CHAPTER TABLE OF CONTENTS

Each chapter is
Chapter 20 Standard
00 Information pertinent
to all sections of
prefaced
with
table of contents
noitceSsecitcarP
Chapter
with the following headings:
20.
20-10-00
Proceduresf
DESCRIPTION
TROUBLE SHOOTING
MAINTENANCE PRACTICES
noitceCleaning
SStandard
secitcarP
Chapter
Subject
20
10
00
Information pertinent to
all subjects in Section 10
INTRO.
Page 1
0
Aug 17/84
SR-76-023
INTRODUCTION
2.
PART NUMBER
Part numbers
are
(Continued)
used in this manual only
as means
not
of
identification when nomenclature alone is inadequate.

Consult the applicable Sabreliner Illustrated Parts
Catalog for exact identification of spare parts by number.
EXAMPLE:
III!UIIII1ZI
Do not operate engines with
REVISONS
The LIST OF EFFECTIVE PAGES with each chapter
OF
serves as a tool for maintaining the manual. The LIST
EFFECTIVE PAGES will be revised whenever the
material in the affected chapter is revised. When revision
used as a cross
pages are received, the list should be
reference for inserting the new/revised material and
deleting obsolete material. This ensures that all obsolete
material is destroyed and the manual is kept current.
Revisions to text are indicated by change bars (vertical

lines) in the margin adjacent to the revised material.
Revisions to illustrations may be indicated by change
on electrical schebars, zip-a-tone shading
(CSP
matics, and pointing fingers
hydraulic, and pneumatic diagrams.
on
more
pagination.
When a new page is being added to an existing manual or
section that has all new information included, a new
is used.
I Is m-change symbol
A REVISION LOG page is provided for recording revisions by revision date and the dates they were inserted in
the manual.,
provided for
recording Temporary Revisions (yellow sheets) by revision number, issue date, and the dates they were inserted
A TEMPORARY REVISION LOG page is
in the manual.
WARNINGS, CAUTIONS, AND NOTES

Warnings, cautions and notes are used to set off instructions that require other than ordinary precautions,
Definition and examples of each of the three types of
precautionary notices follow:
An essential clarification of a following
1. Note
operating procedure or condition.
EXAMPLE:
NOTE
One complete turm ofthe acljuetment eerew
will r&iee or lower the preeslcre a2ywozi-
mutely
eowling
or
eowl
pccllele removed.
3.
Warning-- Operatingprocedures orconditionsthat

if not strictly observed will result in
loss of life.
personal injury
or
EXAMPLE:
UlkB1BnBB
I~cgition ewitch must be in the OFFposition when

rototiny the propellers by ~a?uE.
NON-SABRELINER APPROVED PARTS
mechanical,
than 50 percent of a page is changed, a major

is placed in the
Ia
change symbol(
the top line of
above
of
the
1/4"
outside
lower
corner
page
When
Operating procedures or practices that if

strictly observed will result in damage to the
equipment.
Caution
Only Sabreliner parts or Sabreliner approved parts

obtained from approved sources are to be used in conne,tion with the maintenance and repair of Sabreliner
airplanes.
Genuine Sabreliner parts are manufactured and inspected under rigorous procedures in accordance with a
Production Certificate (PC) to insure airworthiness and
suitability for use in Sabreliner aircraft application.
Parts purchased from sources other than Sabreliner, or
its approved vendors, may not have the required tests and
inspections performed and may be different in fabrication techniques and materials. A non-approved part may
seriously compromise the safety of the aircraft.
Government surplus parts, salvaged airplane parts,
reworked parts obtained from non-Sabreliner approved
sources, or parts, components or structural assemblies
which do not have proper documentation may have a
service history which is unknown or cannot be authenticated. These parts may have been subjected to unacceptable stresses or temperatures or have hidden damage
which is not discernible through routine visual or usual
non-destructive teeting techniques. This may render the
part, component or structural assembly unsuitable and
unsafe for aircraft use, even if such part, component or
structural assembly were originally manufactured by
Sabreliner or an approved source.
Sabreliner Corporation expressly disclaims any responsibility for malfunctions, failures, damage or injury
caused by the use of non-Sabreliner approved parts.
poi.
INTRO.
PageZ
Aug 15/89
8B-76-023
INTRODUCTION (Continued)
NON-SABRELINER APPROVED PARTS (Contd)
NOTE
Sabreliner Corporation espressly reservee
the right to suloereede, cancel and/or deprior notice, any
clare obsolete,
part, part number, hit or publication rc5ferenced in Uuis manual.
IlrrmRI
INTRO.
Page 3/4 Blank
Aug 15/89
CHAPTER
STANDARD
PRACTICES
(AIRFRAME)
SR-76-023
CHAPTER 20
STANDARD PRACTICES
AIRFRAME
TABLE OF CONTENTS
Subject
(;eneral
20-00-00
Page
Causes and Nature of Corrosion

2
TypesofCorrosion
Cathodic Metals
CorrosiononAirframe
20-00-10
Corrosion Prone Areas

Location of Magnesium Parts
Cleaning Airframe
701
Cleaning Materials, Methods, and Applications

Corrosion On Electrical Equipment
20-00-20
Cleaning Electrical/Electronic Equipment Components

SourcesotCommercial Products
20-00-90
Cleaning Compounds
Compounds
SealingCompounds
Epoxy-Polyamide Primers
Polyurethane Top Coat

Paint/Primer Remover
Chemical ConversionCoatings
(;orrosion Preventing
Aircraft
Cleaning
5
5
20-10-00
1
Scope
Preliminary Cleaning
Detail Requirements
1
1
Magnesium Alloys Cleaning and Protective

Treatments
20-10-05
1
General
Pre-treatment Cleaning
Protective Treatment Touchup
Protective Treatment Application
CleaningIronand Steel
20-10-10
1
General
Cleaning Methods
Cleaning Aluminum and

Aluminum Alloys
20-10-15
General
Notes and Precautions
Cleaning Procedures
PO-CONTENTS
0
COPYRIGHT, f 984 BY SABRELINER CORPORATION
Page 1
Aug 17/84
SR-76-023
(oHR()SI()N CONTROL MANIIAI,
TABLE OF CONTENTS
(Continued)
C h apte r/Section/ S ubject
Suhject
Cleaning Corrosion and Heat Resistant Alloys
Page
20-10-20
(;eneial
Cleaning
C:ltaningCopperand CopperAlloys
20-10-25
General
1
Cleaning Methods
Cleaning Titanium and Titanium Alloys
20-10-30
1
General
Process I,imitation
Processing Requirements
Processing Solutions
Cleaning Plastic and Glass
20-10-35
1
(;encral
Materials
I
1
Cleaning Procedures
Polishing Sheet Acrylic Plastic
20-10-40
C;eneral
~laterials
EquipmentjTools
1.
Removing Scratches
StrippingOrganic
Finishes
20-10-45
1
General
Materials
Stripping Methods
Stripping Organic Coatings From,Metals
20-10-50
1
(;eneral
Materials
1
1
Stripping Methods
Solvent
Vapor Degreasing
20-10-55
1
General
Materials
Degreasing Techniyues
AbrasiveCleaning
20-10-60
General
Sulface Preparation
Ab~nsive Blasting
Miscellaneous Methods
~Ieparation of Aluminum and Magnesium for Bonding
P1ocessina after Abrasive Cleaning
1
1
or
Encapsulation
PO-CONTENTS
Page 2
Aug ~1/84
SR-76-023
CORROSI<)N CONTROL MANUAL
TABLE OF CONTENTS
(Continued)
Suhject
Chspter/Section/Subject
Sealing
20-20-00
Page
(;eneral
Types and Application of Sealants

1
1
3
4
5
Surface Preparation
Pressuretight and Liquidtight Sealing
Fu metight Sealing
Flame Resistant and Liquldtight Sealing
Sealing Removable Doorsand Covers
Exterior WatertightSealing
Faying Surface Sealing
Groove Injection Sealing
Fueltight SealingS6 to2000F
20-20-02
SealingMethods
General
Materials
I
1
Equipment
Application Notes
Mixing and Handling Sealing Compounds
s\ircraft Sealing
Sealing Integral Fuel Tanks
20-20-04
General
Materials
Equipment
Cleaning and Priming
Mixing and Handling Sealing Compounds
Sealing Procedure
Overcoating
Sealing Fasteners
Resealing Integral Tank Components
1
1
.......................................i........................................
Fuel Tight Faying Surface Sealing for Areas with Normal

20-20-06
Operation From-65to+2000F
General
Materials
Equipment
Installation Notes
Sealing Procedures
I,iquid Tight Sealing of Areas with Normal Operating

Temperatures From -65 to +2250F.......... 20-20-08
General
Materials
1
1
Equipment
Installation Notes
Sealing Procedures
PO-CONTENTS
0
Page
Aug 17/84
SR-76-023
(()HROSION CONTROL MANUAL
TABLE OF CONTENTS
Subject
(Continued)
Pressure Tight Sealing For Areas with Normal

Temperatures From -65 to +2250F
Page
Operating
20-20-10
General
Materials
Equipment
Installation Notes
Sealing Sequence
Tight Sealing For Areas with Normal

Operating Temperatures From -65 to +2250F
20-20-12
(Alternate Procedures)
Pressure
1
1
1
General
Materials
Equipment
Installation Notes
Sealing Procedures
Sealing Rubber Parts
Tight Sealing For Areas with Normal Operating

20-20-14
TemperaturesFrom -65to+2500F
Iume
General
Materials
Equipment
Installation Notes
Sealing Procedures
Application of Self-Contouring Sealing Pads for Areas

Where Normal Temperatures Do Not
Exceed 2259F
20-20-16
General
Materials
Equipment
Installation Notes
Sealing Procedures
Watertight Sealing for Areas With Normal
Operating Temperatures From -65
Exterior
to +2250F
20-20-18
1
General
Materials
1
1
Equipment
Application Notes
Sealing Procedures
Faying Surface Sealing for Areas with Normal Operating

20-20-20
TemperaturesFrom -60to+225"F
1
1
1
General
Materials
E:quipment
Installation Notes
Sealing Procedures
PO-CONTENTS
PaRel
Aug 17/84
SR-76-023
CORROSION CONTROL MANUAI,
TABLE OF (I1:ONTENTS
Subject
(Continued)
C h a r~t.t! r, Sec tio n/Su bject
Page
Liquid Tight Sealing for Areas With Norn\at c)l,clrnting

~C)-XO-22
TemperaturesFrom 225to400"F
General
Materials
Equipment
Sealing Procedures
1
1
Tight Sealing for Areas With Normal Operating

20-20-24
Temperatures From 225 to 3500F
Pressure
General
Materials
Equipment
Installation Notes
Sealing Sequence
Tight Sealing for Areas With Normal Operating

Temperatures From 250 to 4000F ...........2()-20-26
Fume
General
Materials
Equipment
Installation Notes
Application of Self-Contouring Sealing Pads for Areas With

Normal Operating Temperatures From
225to5500F
20-20-28
General
Materials
Equipment
Installation Notes
2
SealingProcedure
Flame Resistant and Liquid Tight Sealing for Areas With
Normal Operating Temperatures From
225 to 4000F
General
Materials
Equipment
1
1
Installation Notes
Sealing Procedures
Faying Surface Sealing for Areas With Normal Operating

Temperatures From -100 to +550oF .........20-20-32
1
General
Materials
1
1
Equipment
Installation Notes
Sealing Procedures
Installation of O-Ring for Fuel System
20-20-34
General
Materials
Installation Notes
PO-CONTENTS
0
Page 5
Aug 31/84
SK-7Ci-023
TABLE OF CONTENTS
Subject
Installation of O-Rings
Bolted Assemblies
(Continued)
for Fuel
Systems
Page
and
......20-20-36
1
(;eneral
Materials
Installation Notes
1
1
Installation Procedures for O-Ring Sealing of Bolted

20-20-38
Assemblies
1
General
hlaterials
Installation Notes
Se;llina Procedure
1
1
A Pplication of Tape or Sealant Corrosion Barriers Between

20-20-40
Magnesium andOtherMetals
1
General
Materials
Installation Notes
Sealing Procedures
1
1
1
F:lectrical Systems Room Temperature Curing

Silicone Rubber Potting
.20-20-44
1
General
Materials
Installation Notes
Sealing Procedures
Potting Bendix Connector for Use

To 3000F
20-20-46
1
General
Materials
Equipment Notes
Installation Notes
Sealing Electric Terminations
With Overcoating
......20-20-48
1
C;eneral
Materials
Installation Notes
Sealing Neoprene Jacketed Multiconductor and Coaxial

Cable and Kel-F Jacketed Coaxial
Cable Terminations
(;eneral
Materials
Installation Notes
.....20-20-50
1
1
1
IIL~
20-CONTENTS
IaRr
Aua ~1/X4
SR-76-023
C()KHOSION (:ONIKOI,
TABLE OF CONTENTS
(Continued)
Cha~ter/Section/Subject
Suhject
Proofing Electrical Components With

Strippable Sealant
IaRt
Moisture
20-20-52
I
General
Materials
Installation Notes
1
1
Sealing Sequence
Sealing Electrical Wire Bundles Passing
Through Bulkheads
..~.20-20-54
General
Materials
Equipment
Installation Notes
Mold Preparation
MoldInstallation
Sealing Electric Terminations Subject

Up to 3000F
to
Temperatures
20-20-56
(;eneral
Materials
Equipment
installation Notes
Sealing Procedure
Sealing Electrical Terminations Subject
to
Maximum
20-20-58
Between 300 and 4000F

(;eneral
Materials
Equipment
Installation Notes
Sealing Procedures
Application of Sealant to Electrical
Wire Bundles
Through Bulkheads for Maximum Service

Temperatures From 350 to 500"F
Passing
20-20-60
1
General
Material
Installation Notes
1
Sealing Procedures
()rganic Base and Finish Coating
20-30-00
of Polyurethane Integral Fuel Tank Coating

of Epoxy-Polyamide Primer
of Polyurethane Top Coat
of Impact Resistant Polyurethane Top-Coat
HemavinR FaintjPrimer Finishes
Corrosion Removal/Paint Touch-Up Kit
Application
Application
Application
Application
201
203
205
206
PO-CONTENTS
0
Page 7
Aug.31/84
SK-76-023
(()R K()SI()N C()NI~ROI, MANUA I,
TABLE OF CONTENTS
(Continued)
Subject
Cati-Coat Primer
20-30-05
Application
C;c!neral
~vIaterials
Installation Notes
Wash P~imer
Page
20-30-10
Application
(;ener~l
;L1Hterials
F:cluipment
Iiistallation Notes
Moisture and
Fungus Resistant Coating

20-30-15
Application
(;eneral
Materials
Installation Notes
Painting Metal Surfaces With Epoxy Polyamide

Primer
or
Zinc Chromate Primer ...........20-30-20
General
Materials
1
1
Equipment
Installation Notes
Conversion Type Coatings
Application ..........20-30-25
1
General
Materials
Application Notes
1
In8tallation Notes
Polyurethane Finish System For

Sabreliner Aircraft Exterior Surfaces
......20-30-30
(;eneral
Materials
F,quipnient
Installation Notes
Polyurethane Enamel
Application
MIL-C-83286
20-30-35
1
General
Materials
1
1
Equipment
Installation Notes
rol:urethane System
f,
Application
IQ
IP
PO-CONTENTS
Page 8
AuR:31/84
SR-76-023
COHROSION CONTROL MAIVL:AI,
TABLE OF CONTENTS
(Continued)
Page
Subject
High Impact Polyurethane
Coating Application
....20-30-40
General
Materials
Equipment
Application Notes
Application of Coating
Urethane Finish System For Sabreliner

Aircraft Exterior Surfaces
20-30-45
1
General
Materials
installation Notes
Surface Preparation
Mixingand Handling
Primer Application
Application of Urethane Top Coat
Clean-Up
2
AdhesionandFinish
Wrinkle Finish
Application
.20-30-50
1
General
Materials
Laminated and Molded Plastic

Parts Finishing
........20-30-55
General
Materials
Installation
Mixing and Handling
Surface Finish
FillerApplication
Ahrasion Resistant Coating Application
20-30-60
I
General
Materials
Installation Notes
Rain Erosion Resistant
Coatings Application .....20-30-65
General
Materials
Installation Notes
1
1
Coating Application
Spray Painting Methods and Techniques

(Instruction and Information Guide) ........20-30-70
C;eneral
Equipment
Cleaning
SprayCunTechnjqua-- AirType
Spray Painting Problems

Facilities
18
IQ
20-CONTENTS
0
Page 9
Aug ~1/84
SR-76-023
c()KH()SION CONTROI, MANIIAI,
TABLE OF CONTENTS
Su~,.iect
Kadome
(Continued)
Coating
Material
Application
Page
..........20-30-75
1
1
1
(;ent1al
Materials
Installation Notes
Polyurethane Integral Fuel Tank

Coating Application
General
Matelials
1
1
Equipment
Installation Notes
()rganic Integral Fuel Tank

Coatings Application
1
General
Materials
Installation Notes
Irotrction of Aircraft in Out-of-Doors
Temporary Storage
1
(;eneral
Materials
Equipment
Installation Notes
Anodizing and Coloring of Aluminum

..........,20-40-05
Alloys
General
Materials
Preparation
Appiication Notes
Finish
Ch,amic Acid and Sulfuric Acid
Anodizing
1
General
I,imitations.......................................................................................
Application Notes
Finish
I)ow No. 17 Anodize Process For
Magnesium Alloys
(;eneral
Materials
...1................................................................................
1
1
Ecluipment
I,imitations
SafetS
c\pplication Notes
.L\nodizinR P,ocedure
of Dow No. 17(oatinRs
Ke\\~ollr ;tndior Re~ail of I)ow No. 17 C:oatings
~tl.il-,VinR
Coating
(ILTllr~ll
20-CONTENTS
Ia8e 10
AuR ~1/84
SR-76-023
C~OKH()SLON CONTKOL MAKUAI,
TABLE OF CONTENTS
(Continued)
Subject
Application of TFE Infused Coating
Page
on
20-40-20
Aluminum
General
Equipment
Coating Quality
Tests
Application of Scale Inhibiting

Compound
20-40-25
General
Materials
Application
Notes
......20-40-30
Phosphate Treatment
General
Materials
Safety
Surface
Finish
1
1
Preparation
Application of Chemical Films

Aluminum Alloys
to
.......20-40-35
1
General
Materials
Properties of Class 1A Coating
Application
Notes
Chemical Film Treatment for Titanium

and Titanium Alloys
....20-40-40
1
General
Materials
Application
1
1
Notes
Finish
Electrodeposited Hard Nickle

Plating
20-40-45
General
Application Notes
Finish
(;eneral Procedure For Brush Type!
Electroplating
20-40-50
General
Materials
F,quipment
Application Notes
Application of Tin
to C;lass-Fiber
Reinforced Plastic Surface
Plating Treatment
Plate Ii~equirements
Posl
9
9
tt
PO-CONTENTS
0
Page ii
Aug 31:81
SR-7fi-023
(c,K K()SI()N CONTHOI. M AN t:Al.
TABLE OF CONTENTS
C h apte r/Sectio n/S u bj ect
Su I,ject
~latinR By Elettrodeposition
Iin
Hot
(Continued)
Page
or
.20-40-55
Dipping
(;eneral
4laterials
pplication
(I:o:ltinB
A
Notes
liard Chlamium
Plating
....20-40-60
1
1
1
(;eneral
~I-,plication
Notes
Finisll
Tests
..20-40-65
(ol,l,er Plating
(;eneial
1
1
Xpplication Notes
Preparation
(oppet Plating Procedures
Surface
~31ush Cadmium
Plating
....20-40-70
i;eneral
Desciiption
Materials
Equipment
Installation Notes
Plating Finish
Nickel-Zinc
Alloy Plating
...20-40-75
I
General
Mateiials
Requirements
Sulface Preparation
Nickel-%ine Plating Prottetlules

of Defective Com posit Coatings
Stril,l,i na
~lectroless Nickel Plating
...20-40-80
1
(;eneral
AI,plication
I
1
Notes
Finish
Kepail and Refinishing of Abraded, Scratched,

Reworked, or Corroded Metal
Surfaces
......................20-40-85
General
Rewo,k PIocedures for Aluminum
K~\\olk Procedures for IJnplRtedCopper and Ferrous Alloys
I,occdules fol M~anesium F,xtrusions, Castings, or Forgings
of Ilaled Surfaces.
1
1
2
2
ICT
lam~
20-CONTENTS
Page 12
Aug 31/84
COPYRIGMT, 1984 BY SABRELINER CORPORATION
SR-76-0~3
CORHOSION CO~THOI, MAh~UAI,
CHAPTER 20
AIRFRAME
STANDARD PRACTICES
LIST OF TABLES
Chapter/
~ection/
Subject
Table No.
60-00-00
20-00-10
1
701
Page!
Title
Metals in C;alvanic Series

Periodic Corrosion Inspection
Cleaning Procedures and Agents
......................................7
707
1
Applications
Solvents and
Acid Descaling and Passivating Solutions

Cleaning Inconel, Inconel X, and Inconel 718
:3
2
20-10-45
Finishes, Strippers, and Thinners
20-10-50
Chemical Strippers
20-10-60
-1
Processing After Abrasive Cleaning
20-20-02
1
2
Aircraft Sealing Methods, Compounds, and Areas

Spacing of Clamp-Up Devices
0-Ring Installation Dimensions
20-10-00
20-10-20
20-20-38
20-5
20-30-20
20-30-30
201
20-30-70
20-.30-80
20-40-05
20-40-20
Spray Guns and Accessories

Pressure Settings

Pressure Settings

Pressure Settings
1
2
3
Air Pressure Drop In Hoses

Faulty Patterns and Suggested Corrections
Spray Painting Problems. Possible Causes, and Possible Remedies
Coating Cure Schedule
3
4
5
Chromic Acid Anodize and Dye Process

Sulfuric Acid Anodize and Dye Process
Sulfuric Acid Anodize and Pigment Precipitation Process
Sulfuric Acid Process Variables
Stripping Procedure
1
2
DC Dow No. 17 Anodize Process

Anodizing Time in Minutes
Near Life Test Specimens

Abrasion Test Specimens
20-40-15
203
1
2
20-30-35
2
9
14
3
6
fi
Sequence for Magnesium Alloys
1
2
PO-TABLES
o
Page I
Aug 31/84
SR-i6-023
COKROSION CONTROL MANUAL
LIST OF TABLES (Continued)
Chapter/
Section/
Subject
20-40-30
1
2
3A
3B
3C
4
20-40-35
2
3
20-40-40
1
2
20-40-50
1
2
3
4
5
6
20-40-55
Cross Reference Chart

Type I Phosphating Procedure
Procedure for
Type II Phosphating Procedures
PhosphatinR with Parco 1A
Procedure for
Type II Phosphating Procedures
Phosphating with Cryscote HC
Procedure for
Type Il Phosphating Procedures
PhosphatinR with Turco 4432
Type III Phosphating Procedures
Page
3
4
5
6
7
8
Chemical Film Immersion Procedure

Chemical Film Spray Procedure
Chemical Film Brush-On Procedure
Immersion Chem Film Process for Titanium

Brush Chem Film Process for Titanium
2
3
Processing with Non-Proprietary Solutions

Processing with Proprietary Solutions
Plating Processes with Proprietary Solutions
Cold Plating of Contacts of Modules with Assembled Contacts
Post-Plating Treatment
Plating Quaiity Requirements
3
6
8
9
10
10
4
Type I Tin Plating By Stannate Process

Type I Tin Plating By Fluoborate Process
Type I TinPlating By Sulfate (Kenvert) Process
Type I Tin Plating By Sulfate (Lea-Ronal) Process
Type II Tin Plating
1
2
Procedure for Copper Plating Carbon and Low Alloy Steels

Copper Plating of CRES and Heat-Resistant Alloys,
Series 400 Stainless Steels

Procedure for Stripping Copper Plating
2
3
4
20-40-65
Title
Table No.
6
7
8
20-40-70
Characteristics of Dalic Plating Solutions

Characteristics of Selectron Plating Solutions
Characteristics of Brooktronics Plating Solutions
3
4
20-40-75
Carbon and Low Alloy Steels

CRES and 400 Series Stainless Steels
Copper and Copper Base Alloys
Stripping Defective Composite Coatings
3
4
5
6
2
3
4
Ia
PO-TABLES
Page
Aug 31/84
8&-76-023
CORROSION CONTROL NIANUAL
CHAPTER 20
AIRFRAME
STANDARD PRACTICES
LIST OF ILLUSTRATIONS
Cbapter/
Section/
Subject
20-00-00
20-00-10
Figure
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
9
10
701
702
Page
Title
No.
2
2
Simplified Corrosion Cell for Electro Corrosion

Corrosion Prevention Using an Organic Film
Effects of Corrosion Removal Solutions on Fitted Aluminum
Extreme Fitting Corrosion of Steel Parts
Extreme Fitting Corrosion of Aluminum Parts
Intergranular Corrosion
Extreme Exfoliation Corrosion at Nutplates
Extreme Exfoliation Corrosion
Extreme Case of Surface Corrosion and Dissimilar Metal Corrosion
Galvanic Corrosion of Magnesium Adjacent to Steel Fastener
Area Relationship in Dissimilar Metal Contact
Concentration Cell Corrosion
Filiform Corrosion at Lap Joint
Filiform Corrosion at Fastener Head
Exterior
Exterior
Exterior
Exterior
Exterior
Surface
Surface
Surface
Surface
Surface
Materials
Materials
Materials
Materials
Materials

NA
NA
NA
NA
NA
265-40
265-60
265-65
265-70
265-80
NA 265-40
NA 265-60
NA 266-70
NA 265-80
Parts
I~Jocation of Magnesium
Protective Covers Installed During Cleaning and Paint Stripping
Cleaning Sequence
Sealant Dimensions
20-20-02
1
2
Applying Sealant to Faying Surface

Prepacking a Void
Prepack Groove Sealing
Sealing of Separable Surfaces
SealingFixedWindows
Sealing Pilots Sliding Window
Sealing Windshields
Injection Groove Sealing
Basic Dimensions of a Sealing Groove
Counterbore Dimensions for installing Rivets in a Sealing Groove
Counterbore Dimensions for Sealing Groove at a Bolt I~ocstion
Groove Configuration for a Double Row of Fasteners
Nozzle Tip Position
Application of Fillets
Lapping Structure .250 In. Max Thickness
Lapping Structure Over 0.250 In. Thickness
Unacceptable Fillets
4
6
6
7
8
9
10
11
12
13
14
15
16
17
2
3
4
5
6
9
10
11
12
13
706
706
2
20-20-00
3
4
4
5
5
6
7
7
8
9
11
11
2
5
6
7
9
10
11
13
13
14
14
15
16
16
16
17
17
20-1 LLUS
(D
Page 1
Sep 6/91
8B-76-023
(Continued)
Chapter/
Section/
Subject
Figure No,
Title
Page
20-20-02
Contd
18
19
20
21
22
23
24
25
20-20-08
1
2
Sealing Holes and Slots

Sealing Holes 1/8 To 1/4 In, Diameter
2
2
20-20-10
1
2

Sealing Seams and Joints
2
Z
20-20-12
1
2
Sealing Joggles
Sealing Holes and Slots Up to 1/8 In, Wide
Sealing 1/8 to 1/4 In, Holes and Slots
2
2
2
2
Sealing 1/8 In. Max Holes

Sealing 1/8 to 1/4 In. Holes
Gap Sealing
Hole and Slot Sealing
3
3
20-20-16
1
2
3
Typical Sealant and Mold Release Application

Typical Excess Sealant Trimming
Typical Tooling Hole and Gap Sealing
2
2
3
20-20-22
1
2
3
Sealing Holes
Sealing Stiffened Seam
1
Z
2
20-20-24
1
2
3
4
SealingJoggles
Sealing Holes
Sealing Beads and Fillets
Sealing But Joints
2
2
3
3
20-20-28
1
2
3
4
Typical
Typical
Typical
Typical
2
2
3
3
20-20-30
1
2
3
Typical Hole Sealing

Typical Seam, Joint, and Rivet Seals
Typical Joffgle and Stiffener Sealing
Sealing Compound Pot Life
3
4
20-20-14
20-20-32
1
2
3
Butt Gaps
Seam Edge Facing High Leg of Flange
Sealing Holes and Slots up To 0.125 In.
Fastener Leak Path Seals
Rivet and Bolt Leak Path Seals
Dome Nut Leak Path Seals
Sealant Bridge
Wing Anti-Icing Duct Sealing
or
18
18
19
20
21
22
23
24
Angle
3
3
Primer Application
Sealant Application
Assembly During Cure
Tooling Hole Back-Up
2
I
3
3
Z
Itlrli~
20-lllUS
Page 2
Aug 31/84
SR-76-023
Chapte r/
Section/
Subject
(Continued)
1
2
3
Typical Counterbore 0-Ring SealinR

Typical Sleeved Joint O-Ring Sealing
Typical Non-Sleeved O-Ring Sealing
1
3
4
Typical
Typical
Typical
Typical
20-20-46
1
2
Connector Preparation
Injection of Potting Compound Into Connector
20-20-50
1
2
3
4
Potting Using Temporary Molds

Potting Using Stacked Permanent Molds
Potting 900 Entry Multiconductor Cable
Potting Coaxial Cables
Typical Sealing
Passing Wire Bundles Thru Connector Shells

Passing Wire Bundles Thru Bulkhead Holes
Passing Wire Bundles Thru Doubler
20-20-38
20-20-40
20-20-52
20-20-54
3
4
5
6
7
8
9
1
2
3
:3
4
5
2
2
3
3
4
5
6
6
7
8
20-30-70
1
2
Principal
Cleaning Cup Type Gun

t~ieaning Tank Type Gun 11..1
Cleaning Gun Nozzle and Fluid Connections
Coating Laminate Edges
5
6
7
8
9
10
11
12
13
Assembling Connector
Connector Potting
Sealant Injection
20-30-65
Molds For Connector Shells

Seal Dimensional Requirements
Standard Cup Molds
Cup Mold Preparation
Sealing Between Wires
Typical Mold Installations
20-30-75
Applications of Tape As ACorrosion Barrier

Application of Tape And Sealing Compound Combined
Application of Sealant As A Corrosion Barrier
Application of Aerodynamic Smoother to Mold Line Joints
Booted Sealing Feedthroughs

Sealing Split-Fitting Bulkhead Feedthroughs
20-20-60
Areas of a Quick-Disconnect
Connector and Lead-in Wires
20-20-58
Page
Title
Figure No.
Parts of
Pressure Tank
1
2
2
1
Spray Gun
4
5
Gun To Part Distance

Some Problems Caused By Tilted Gun
Spray Gun Motions
Spraying Corners
Correct Spray Patterns
Relationship of Aircap Position to Spray Pattern
Spray Gun Adjustment

Causes of Jerky or Fluttenng
7
9
11
12
L3
Spray
Edffe Treatment
111~
20-ILLUS
0
Page 3/4 Blank

Aug 31/84
8B-76-023
CHAPTER 20
STANDARD PRACTICES
AIRFRA1ME

Chapter/
Chapter/
Section
20-L.E.P.
Page
1*
2
3+
4*
80-CONTENTS
20-ILLUS
1
2
3
4
5
6
7
8
9
10
11
12
1*
20-00-00
1
2
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8
9
10
20-00-10
Aug 17/&1
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1
2
3
4
6
6
Section
or
Page
12
Sep 6/91
Sep 6/91
Sep 6/91
Sep 6/91
Sep 6/91
Aug 31/84
Aug 31/84
20-TABLES
Date
13/14
701
702
703
704
705
706
707
708
709
710
20-00-20
Date
Aug 17/84
Aug 17/84
Aug 17/84
Aug 17/84
711/712
Aug 17/84
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2
3
4
6
6
Sep 6/91
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1/2
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1
2
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1/2
Aug 17/84
20-10-15
Aug 17/84
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CORROBION CONTROL biANUAL

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or
PO-L.E.P.
Pagea
Sep 8/91
SR-76-023
CHAPTER 20
STANDARD PRACTICES
AIRFRAME
CAUSES AND NATURE OF CORROSION
GENERAL
Corrosion is caused by direct chemical attack, as in the

of contact with acids, or by electrochemical attack,
which is similar to action on the plates in a storage
battery. All corrosion is electrical in nature; involving the
flow of electrons and ions between two points through a
conductive medium. The conductive medium may be
moisture or gas containing corrosive agents such as salt,
chlorides, or sulphuric acid; or may be a direct metal-tometal contact or connection.
Corrosion is the destruction of metals by chemical or

electrochemical action. This destroys the integrity of
affected areas by converting the metal into a powdery or
flaky metallic oxide, hydroxide, or sulphate compound,
case
Corrosion of metal surfaces begins the instant the

fabrication process is completed and, left unchecked,
continues until the material is exhausted. The rate of
deterioration, or lack of it, depends on corrosion
preventative measures taken and on the environment to
which the part is subjected.
accomplished in two phases:

(1) preventive maintenance, and (2) corrective
maintenance. Preventive maintenance includes frequent
inspections and cleaning. Corrective maintenance
includes the complete removal of corrosion products and
renewal of protective coatings. Both phases are of equal
importance in any successful program of corrosion
control. Where corrosion has progressed unchecked,
the resulting damage may require replacement of parts or
assemblies. Inspections,
ma;or components
conscielltiousiy performed, reveal scratches in protective
coatings or plated surfaces which could result in
The two points of difference of electrical potential will

involve
E ffective corrosion control is
corrosion, result in the detection of areas requiring touchup of the finish coatings, and also provide an indication as
to when the airplane should.be cleaned. Frequent
cleaning will retard the corrosion process.
Corrosion of airplane surfaces and parts has always been
a problem, and can have a very serious effect upon the
performance of modern high speed airplanes. This is
especially true of airplanes which are based in areas
where corrosive elements are present in the atmosphere.
Airplanes which are inaitive for extended periods alz
also susceptible to corrosion. Corrosion control measures
should not he relaxed because an airplane is inactive.
Airplane parts are constructed of many different metals,

and have various shapes, sizes and heat treatments. These
surfaces and parts are constantly exposed to a corrosive
environment such as combustion gases from engines,
atmospheric moisture, condensation, salt spray,
chemicals, dirt, dust, waste water, and fluid spillage.
Also, metal fillings, tools, parts, or other metal objects left
on the interior or exterior surfaces of the airplane will
cs~lse corrosion by dissimilar metal contact. Thus, all of
the necessary factors are present throughout the life of
the airplane to initiate corrosive attack on any metal part
at any time. All types of metal used in the airplane are
subject to corrosion of some kind, but aluminum,
magnesium, and steels not fully protected by adequate
surface treatment are ready prey to corrosion.
one
of the
following conditions:
Dissimilar metals
Differential between grain boundary and grain
center
Different metallic crystaline compositions within

the same metal
Between corrosive elements
metal Itself
on
surface of metal and
In each case, an electrolyte of some kind is present,

creating an electrical cell similar to a storage battery.
One point or area becomes the anode (negative pole) and
the other the cathode (positive pole). The anode is the
portion of the metal which has greater electrical activity
and is the portion which will disintegrate or corrode.
Four conditions must exist before electrochemical
corrosion can proceed: (1) there must be something that
corrodes (the metal anode), (2) there must be a cathode tit
may be either a more noble metal adjacent to the anode or
the same metal which differs in
an
area
on
microstructure, oxygen or metal ion concentration, or
surface condition from the anode), ~3) there must be a
continuous liquid path (electrolyte, usually condensate.
and salt or other contamination), and (4) there must be a
conductor to carry the flow of electrons from the anode to
the cathode ~this conductor is usually in the form of metaito-metal contact such as rivets, bolts, and welds). The four
conditions which are required before electrochemical
corrosion can proceed are illustrated in figure i.
20-00-00
0
1984 BY SABRELINER CORPORATION
Page 1
Aug 17/84
SR 76-023
STANDARD PRACTICES
CAUSES AND NATURE OF CORROSION (Contd)
AIRFRAME
(Continued)
corrosion is first seen as a general dulling of the surface

and if the attack is allowed to continue, the surface
becomes rough and possibly frosted in appearance.
Discoloration or general dulling of metal created by
exposure to heat is not to be considered as uniform etch
corrosion.
Elimination of any one of the four conditions will stop

corrosion, e.g., an organic film on the surface of the metal
will prevent the electrolyte from connecting the cathode
and anode, and the current cannot flow, therefore, no
corrosion. (See figure 2.)
Fitting Corrosion
TYPES OF CORROSION
Fitting
is the most
corrosion
aluminum and
white or gray
powdery deposit similar to dust which blotches the
surface. When the deposit is cleaned away, tiny pits or
holes can be seen in the surface. Fitting corrosion may
also occur in other types of metal alloys. (See figures 3, 4,
and 5.)
Corrosion has been catalogued and typed in many ways.

For descriptive purposes, the following types of corrosion
discussed under what is considered the most
are
commonly accepted titles.
common
magnesium alloys. It is first noticeable
Uniform Etch Corrosion
on
as a
The surface effect produced by most direct chemical

attack (e.g., as by an acid) is a uniform etching of the
metal. (See figure 3.) On a polished surface, this type of
LlaUlD
CURRENT FLOW
PATH
(ELECTROLYTE)
ANODIC
CATHOD1C
AREA
AREA
ELECTRON FLOW
ELECTRON CONDUCTOR
METAL
S265-23-20-9
Simplified Corrosion Ceil for Electro Corrosion

Figure L
NO CONTACT BETWEEN
ELECTROLYTE AND ANODE

AND CATHODE BECAUSE OF
,UNBROKEN ORGANIC
FILM
ORGANIC FILM
CONTINIIOUS LIQUID
PATH
(ELECTROLYTE)
ANODIC
CATHODIC
AREA
AREA
ELECTRON
CONDUCTOR METAL
Corrosion Prevention Using
5265-23-20-10
an
Organic Film
Figure 2
20-00-00
Page
Aug 17/84
COPYRIGHT, 1984 a~ SABRELINER CUHPORATION
SR-76-023
PITTINO CORROSION ON ALUMINUM SURFACE
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20-00-00
Page
COPYRIGHT, 1984 BY SABRELINER 2C~nPORATION
Aug 17/84
SR-76-023
~p;
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Extreme
Fitting Corrosion of Steel Parts

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Figure 5
ORIGINAL
As Received
By
ATP
20-00-00
Page 4
Aug 17/84
SR-76-023
STANDARD PRACTICES
AIRFRAME
(Continued)
Intergranular Corrosion
Exfoliation Corrosion
Intergranular corrosion is an attack on the grain

boundaries of a material. A highly magnified cross
section of any commercial alloy will show the granular
structure of the metal. This consists of quantities of
individual grains, each of which has a clearly defined
boundary that differs chemically from metal in the grain
center. Frequently the grain boundaries are anodic to the
main body of the grain. When in contact with an
electrolyte, rapid selective corrosion of these anodic grain
boundaries can occur. (See figure 6.)
Exfoliation is a form of intergranular corrosion. It lifts up

the surface grains of a metal by the force of expanding
corrosion products occurring at the grain boundariesjust
below the surface. (See figures 7 and 8.) Lifting up or
swelling is visible evidence of intergranular corrosion. It
is most often seen on extruded sections where grain
thickness is usually less than in rolled forms.
ELECTROLYTE ENTERS
,PAINT
THROUGH CRACKS IN
FILM
PAINT FILM
CLADDING
INTERGRANULAR
(CATnODE)
(ANODE)
1075 T6
FASTENER
ALUMINUM
CORROSION
Interffranular Corrosion
Figure 6
se
9265-23-20-21j
ORIGIFIAL
As Received Sy
Extreme Exfoliation Corrosion at

Figure 7
ATP
Nutplates
20-00-00
Page 5
Aug 17/64
SR-76-023
STANDARD PRACTICES
AIRFRAME (Continued)
Galvanic Corrosion
Metals grouped together in table 1 have little tendency to

produce galvanic corrosion and are relatively safe to use
in contact with each other. Coupling of metals from
Galvanic corrosion occurs when dissimilar metals are in

and an external circuit is provided by the
presence of moisture. It is usually recognizable by the
presence of a build-up of corrosion at the joint between the
metals. For example, aluminum and magnesium skins
riveted together form a galvanic couple if moisture and
contamination are present. When magnesium is attached
with steel fasteners, galvanic corrosion can occur. (See
figures ff and 10.)
contact
different groups and distant from each other in the table

will usually result in galvanic or accelerated corrosion of
the metal higher on the list. The farther apart the metals
are in table i, the greater the galvanic tendency will be
because of the greater electrical potential difference
between them.
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Figure
ORIGINAL
As Received
BY
ATP
20-00-00
Page 6
Aug 17/84
COPYRIGHT, 1984 BY SABkeLINER CORPORATION
SR-76-023
ORIGINAL
As Received Dy
ATP
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Extreme Case of Surface Corrosion and Dissimilar Metal Corrosion

Figure 9
ELECTROLYTE
CORROSION
PRODUCTS
(ANODE)
(CATHODE)
STEEL
FASTENER
MAGNESIUM
ALLOY
S265-23-20-15
Galvanic Corrosion of ~Iagnesium Adjacent to Steel Fastener

Figure 10
20-00-00
0
Page 7
Aug 17/84
SR-76-023
CORKOSION CONTROL MANUAL
STANDARD PRACTICES
Galvanic Corrosion (Contd)
severe and extensive

when insulation breaks down. If the cathode or less active
member is small compared with the anode, anodic attack
will be superficial or general. An aluminum fastener in
contact with a relatively inert Monel structure may
corrode severely, while a Monel bracket secured to a large
aluminum member would result in a relatively
superficial attack on the aluminum sheet. (See figure 11.)
All commonly used metals will cause corrosion of
magnesium in a strong salt environment. Cadmium or
zinc plating on the more cathodic metals such as iron and
steel will greatly reduce galvanic corrosion. It has been
found that tin plated metal, when connected to
magnesium, causes less corrosion than cadmium or zinc
plated metal. This happens because, in this unusual
circumstance, the tin polarizes and acts as an insulator.
This is a contradiction of table i. (The galvanic series of
metals and alloys is to be used for general information and
exceptions do exist.) Aluminum alloys containing
magnesium such as 5052 and 50fj~ reduce galvanic
corrosion of magnesium alloys and also reduce
simultaneous corrosion of the aluminum. Under severe
exposure, when the contact of magnesium alloys and
plated steel bolts is necessary, the use of 6052 aluminum
~ulshers may prevent seiere gnlvznic attack. Continuity
of the liquid path may also be broken by the use of vinyl or
polyester tapes. When conditions favorable to galvanic
corrosion are u navoidable, always p rotect both Dortio ns of
a couple. A break in the protective coating on the anodic
ANODIC METALS
Magnesium 6i Magnesium Alloys

Aluminum Alloys 5052, 5056, 5356, 6061
6063
(;loul, 11
Aluminum
Aluminum Alloys
Carlmium
Nickel Zinc Alloy
Zinc B Zinc Alloy
~roup ill
Except Stainless Yteels
(;roup IV
Uhromium
Cobalt
(.opl~er
(;old
Gi.aphiir
Nickel
Silvel
Platinum
Rhodium
surface will
cause severe pitting if the cathodic ~iurface is

protected. This is because of the concentration of
current upon the relatively jmall area e~posed. When
practical, rivets. bolts, and other fasteners should be che
same material as the main structure. When not practical,
they should be selected from materials nearei the
~tainless Steel c~ Stainless Steel Allovs

Titanium c~ Titanium hllovs
not
CXTHODIC ~VIET.-\LS
Ithen
~Continued)
small(more active) member will be
Table i, Metals in Galvanic Series
Iron
Leatl
Tin
Anrl Their Alloys
AIRFRAME
dissimilar metals are used where contact may

develop. if the more active member of the pair is small
compared with the less active member, attack on the
tuc,
cathodic end of table 1 in order
to
distribute the anodic
MONEL RIVET
(SMALL CATHODE)
HEAVY
CORROSIVE
ATTACK
ALUMINUM RIVET
(SMALL ANODE)
RELATIVELY
LITTLE
CORROSIVE
ATtACK
ALUMINUM SIIIET
MONEL SHEET
tLARGE ANODE)
(LARGE CATnODE)
5265-?3-a0-16
Area
Relatinship
in Dissimilar Metal Contact
Figure
11
20-00-00
Page 8
Aug r 1/84
SR-76-023
STANDARD PRACTICES
AIRFRAME (Continued)
Galvanic Corrosion (Contd)
Oxygen Concentration Cells
over the larger of the two coupled metals. This is

particularly important where the fasteners are subjected
to high stress and when the safety factor is low. The
structural strength of the aircraft must not be
endangered by substituting incorrect parts,
A solution in contact with a metal surface will normally

contain dissolved oxygen. An oxygen cell can develop at
any point where the oxygen in the air is not allowed to
diffuse into the solution, thereby creating a difference in
attack
concentration between two points. Typical

locations of oxygen concentration cells are under either
metallic or non-metallic deposits (dirt) an the metal
surface and under faying surfaces such as riveted lap
joints. Oxygen cells can also develop unde r gas kets, wood.
rubber, plastic tape, and other materials in contact with
the metal surface. Corrosion will occur at the area of low
oxygen concentration (anode) as illustrated in figure 12.
view B.
oxygen

Concentration cell corrosion occurs when two or more
of a metal surface are in contact with different
concentrations of the same solution. There are three
general types of concentration cell corrosion:
areas
i.
Metal ion concentration cells
2.
Oxygen concentrationceils
8.
Active-passive cells
Active-Passive Cells
Metals which depend on a tightly adhering passive film

an oxide, for corrosion protection, e.g., austenitic
corrosion resistant steel, are prone to rapid corrosive
attack by active-passive cells. The corrosive action
usually starts as an oxygen concentration cell, e.g., salt
deposits on the metal surface in the presence of water
con tai n i n g oxygen can create the oxygen cell. The passive
film will be broken beneath the dirt particle. Once the
passive film is broken the active metal beneath the film.
will be exposed to corrosive attack. An electrical potential
will develop between the large area of the cathode
(passive film) and the small area of the anode tactive
metal). Rapid pitting of the active metal will result as
illustrated in figure 12, view C.
usually
Metal ion Concentration Cells

The solution may consist of water and ions of the metal in
contact with the water. A high concentration of metal ions
will normally exist under faying surfaces where the
solution is stagnant, and a low concentration of metal ions
will exist adjacent to the crevice which is created by the
faying surface. An electrical potential will exist between
the iwo points; the area of metal in contact with the low
concentration of metal ions will be cathodic and be
protected; the area in contact with the high metal ion
concentration will be anodic and will be corroded. Figure
12. view A illustrates metal ion concentration cell
corrosion.
HIGH OXYGEN
LOW METAL ION CONCENTRATION
CONCENTRATION
HIGH METAL ION
CONCENTRATION
A.
LOW OXYGEN CONCENTRATION
METAL 10N CONCENTRATIO~ CELL

RIVETED LAP JOINT
B.
OXYGEN CONCENTRATION CELL

FOREIGN MATERIAL CREATES
LOW OXYGEN REGION WnlCH
PREVENTS THE RE-FORMAtlON

OF PASSIVE FILM
ACTIVE
PASSIVE FILM
METAL
PROTECTS EXPOSED
SURFACE
C.
ACTIVE
PASSIVE CELL
Figure 12
20-00-00
0
COPYRIGHT, l"nr BY SABRELINER CORPORATION
Page 9
Aug 17/84
SR-76-023
STANDARD PRACTICES
AIRFRAME
(Continued)
Stress Corrosion Cracking

Stress corrosion cracking is caused by the simultaneous
effects of constant tensile stress and corrosion. Stressmay
be internal or applied. Internal stresses are produced by
non-uniform deformation during cold working, by unequal
cooling from high temperatures, and by internal structu ral rearrangements involving volume changes. Stresses
induced when a piece is deformed, those induced by press
and shrink fits, and those in rivets and bolts are internal
stresses. Concealed stress is more important than design
stress, especially because stress corrosion is difficult to
recognize before it has overcome the design safety factor.
The magnitude of the stress varies from point to point
within the metal. Stresses in the neighborhood of the yield
strength are generally necessary to promote stress corrosion cracking, but failures may occur at lower stresses.
Specific environments have been identified which will
cause stress corrosion cracking of certain alloys. Salt soluti o ns and seawater may cause stress corros ion cracking of
heat treatable aluminum alloys. Methyl alcohol-hydrochloric acid solutions will cause stress corrosion cracking
of some titanium alloys. Magnesium alloys may stress
corrode in moist air. Stress corrosion may be prevented by
removing the corrosive environment. This may be done by
applying protective coatings, using corrosion inhibitors,
or controlling the environment. Stress relieving treatment can also be effectively used.
Filiform Corrosion
5letals with organic coatings tend to undergo a type of
cotrosion resulting in numerous threadlike filaments of
corrosion products under the coating. (See figures 1S
and 14).
Filiform corrosion is caused by the diffusion of oxygen
and water through the coating and is considered a special
type of oxygen concentration cell corrosion. This type of
corrosion can be prevented by storing the aircraft
ecluipment in a low humidity environment (below 65%
relxtive humidity). The progress can be markedly
decreasetl by the use of coatings which have a high
resistance to diffusion by water.
20-00-00
Page 10
Aug 17/84
COPYRIGHT, 1984 BY
CORPORATION
SR-76-023
:"-~-i
B
S265-23-20-19
Filiform Corrosion at Lap Joint
Figure
L3
S265-23-20-25
Filliform Corrosion at Fastener Head
Figure
14
ORIGINAL
As Received
By
ATP
COPYRIGHT, 1984 BY SABRELINER CORPORA
10N
20-00-00
Page 11/12 Blank
Aug 17/84
SR-76-023
CORROSION ON AIRFRAME
CORROSION PRONEAREAS
To
prevent corrosion on the aircraft, appropriate

inspection and maintenance of corrosion prone areas
must be performed at scheduled intervals, The aircraft
must be carefully inspected for signs of corrosion at each
scheduled inspectibn. Under certain atmospheric
conditions, such as high humidity, high temperature, and
salt water, it may be necessary to increase the frequency
ofcorrosion inspections.
Principal metals used

airplane are on figures
on
the exterior surface of the
1 thru i. Areas of the
airplane
which should be examined periodically for corrosion are

shown in table I. Specific corrosion prone areas as
applicable to each series of airplanes are shown in figures
tj thru 9.
Corrosion
are
on
unpainted surfaces
painted areas that have peeled
or chipped), skin seams, lap joints, and areas where dirt
anti ~rime collect. Other areas, such as rub strips, access
prone
areas
(actuating mechanisms
or
doors, and crevices are corrosion prone because of the

accumulation of salt water and cleaning compounds.
Moisture in these locations does not evaporate as rapidly
as in other locations more direcfly exposed to sun and air,
such as the upper wing and Fuselage surfaces, Areas
subjected to frequent contact of fluids, such as hydraulic
drains, fuel drains, water drain holes, and ahy other
overboard drain, will require closer attention. There will
be less corrosion on painted, aluminum-coated, or
aluminum-plated surfaces; however, corrosion will

att:lck protected metal, as moisture may penetrate the
prc,tectecl surface. Palticular attention must be given to
where drain holes may become clogged and
areas
moisture may accumulate. Areas where dissimilar
rnetal~ are in contact must be closely inspected. When
appreciable moisture is present between dissimilar

metals, corrosion is accelerated. Leather, neoprene,
soundproofing, and insulating materials

hold moisture, thus c~using corrosion.
can
pick
up and
LOC:I-\TION OF IMACNESIUAI PARTS

Tile location of all maffnesium components is shown in
figure 1U. These components are highly durable and
cor~rosion resistant when the protective finishes are
intact. IMagnesium parts are considered corrosion prone
si nce a slight break or scratch through the primary finish
tesult in corrosion which could penetrate and
ma\l
dearade a mar5nesium part in a relatively short time.
20-00-10
0
Page 1
Aug 17/84
SR-76-023
ALUMNUM ALLOYS
t~j
LAMINATED FIBREGLASS
~i_i ij.il:l::/q
HONEYCOMB
88111711111111mn
GLASSOR PLASTIC
CORROSION RESISTANTSTEEL
OP
g d~rj00
Vt~
o
SIDE
20-00-10
Pa)Se
Au~S 1T/X4
S265-23-20-25
Exterior Surface Materials
Fiffure
o
Model NA 265-40
1
SR-76-023
ALUMINUM ALLOYS
LAMINATED FIBREOLASS
ii -;ii
:-I
HONEYCOMB
mmmmmmm
tJ~l
CORROSION RESISTANT STEEL
773M
~a
i-
ci
SIDE
9265-23-20-6
EKteliol Sulface Materials
erugModel
iF06-~ruAif2
2
S3PYRIGHT, 1984 BY SABRELINER CORPORATION
20-00-10
Page 8
Aug 17/84
SR-76-023
~LUMINUMPILLOYS
LelMINITEDFIBREOLISs
I::.:::::::i:l:l ::::::I:::~
HONEYCOMB
GLASS OR PLASTIC
~j
CORROSION RESISTLNTSTEEL
TOP
ii
I-T-
~i -e=iL~L!
~a\
ro
~a
~sl
a~
BOTTOM
SIDE
20-00-10
Page 4
Aug 17/84
Model NA
erugiF56-Si(2
3
8B-76-023
F~
ALUMINUM ALLOYS
nolcrcama
mmmmmmR
GLASS OR PLASTIC
~I
BOTTOM
SIDE
S265-23-20-7
Model NA
erugiF07-562
4
20-00-10
Page 5
Aug 17/84
SR-76-023
ALUMINUM ALLOYS
HONEYCOMB
mmmmmmn
GLASS OR PLASTIC
CORROSION RESISTANTSTEEL
TOP
/d
BOTTOM
mni
an
mn
;_=
5265-23-20-8
SIDE
20-00-10
Page ti
Aua 17/84
E?rterior Surface Materials
Model NA
erugiF08-5.62
5
SR-76-023
CORROSIONON
Table 1.
Periodic Corrosion
AIRFRAME
(Continued)
Inspection
AREA
i.
ACTION
Fuselage
Access doors
Areas where
panels
Check mating edges for chafing, paint, and sealing.

Check for corrosion in areas surrounding fasteners.
paint has been chipped
or
Check for traces of surface corrosion.
damaged
Bolt and fastener heads
Check for
exfoliation-type
corrosion and rust.
Countersinks in exterior skins
Check for
exfoliation-type
corrosion and damaged
Drain holes
Check for cleanness and for corrosion and paint.
Entry door
Check for sealing, painting, and corrosion.
Ground escape hatch
In-flight
escape hatch-duter door
(inactive)
~IaKnesium control support castings
paint.
Check for galvanic action.
Nose wheel well
Check for corroded tubing and debris.
Nose gear strut
Check for corroded bolts, tubing, and rusted parts.
Nose geal actuating cylinders
Check for
Screw-attacheci dears
Check for painting,

fastener heads.
Speed brake, speed brake well, and

actuating cylinders
Check far painting and corrosion.

Check for rusted or corroded components.
Wintlshieltl retaining
Check sealing, and for corrosion anti aaivanice action

on all edges.
strips
~leas along fuselage lower centerline where

moisture collects and tioes not evaporate tapidly
Battery bay
rust or corrosion on
all components.
sealing, and corrosion around
Check for evidence of interaranular corrosion.
Check for corrosion and that acid-resistant paint

is intact.
Control cables
Check for damageu protective film and corrosion.
Dissimilar metal contacts
Check for galvanic-tyDp corrosion.
,-\nv
where paint has been
chipped
Check fol
traces
Access doors
Check for
painting, sealing, and corrosion.
Xilelon balance weight attachment fasteners
Check for
signs of galvanic corrosion.
Aileron
Check hinge pins and bearings for corrosion.
area
i~f surface corrosion.
ol~
WingGroup~
hinge and
actuator
fittings
Check for galvanic and exfoliation-type corrosion.
Dissimilar metal
iStainless-steel
surrounding compass in left wing tip)
contact
Check for exfoliation-type corrosion and damaged paint.

screws
Check for galvanic-type corrosion.
20-00-10
0
Page 7
Aug 17/84
SR-76-OL3
C()RR()SION CONTROL MANUAL
CORROSION ON AIRFRAME ~Continued)

Table i.
Periodic Corrosion
Inspection (Continued)
AREA
2.
ACTION
Wing Group(Contd)
fittings
Flap
actuator
Flap
tracks and
Check pins and bearings for corrosion.
flap track fittings and rollers
Check flap tracks for flaking of chrome plating

and corrosion.
Check flap fittin)gs and rollers for corrosion and
Exposed
areas
of wing
rear
spar
Main landing gear door actuating cylinders
Check for intergranular corrosion
on
exterior surfaces.
Main landing gear st~ut and actuators
Check for corroded
Main gear wheel well
Check for corroded tubing and Fittings.

Check for cleanness.
Slat tracks and slat track
fittings and rollers
or
rusted
areas,
bolts, and tubing.
Check slat tracks for flaking of chrome plating

and corrosion.
Check slat track fittings and rollers for corrosion
and rust.
Machined land on wing upper and lower skins

wing tip attach area,
Check for intergranular types of corrosion

machined area.
Close
Check for intergranular and galvanic corrosion
at
Aft
out
doors
on
wing leading edge skins
portion of wing leading edge skins adjacent
to front spar
rust.
Check for damaged paint films and evidence of corrosion.
on
Check for damaged paint films and/or evidence

of corrosion.
where slats rub
Empennage
Balance weight attachment fasteners
Check for galvanic corrosion.
Check for galvanic and exfoliation-type corrosion.
Check For
Dissimilar metal
Check for signs of galvanic-type corrosion.
contact
corrosion and
damaged paint.
Dt:lin holes in lowel sutfaceu
Check for e?tfoliation-type corrosion and that all cirain

holes are open.
Hinge and
Check hinge pins and bearings for corrosion.
actuator
fittings
Horizontal and vertical stabii;zer attach fittings

4.
exfoliation-type
Check for all types of corrosion.
Pylonsand EngineNn~zlles
~il. intake ctuct
Checl< interior c,f duct fot surface corrosion.
Bolt anct Fastener heads
Check for galvanic and exfoliation-type colrosion.
Dissimilar metal
Check for. galvanic-type corrosion.
Engine attach
contact
Check for corrosion and rusted
mounts
areas.
Engine nacelle door hooks and latches
Check for corrosion and rust.

Check for damaged paint.
Steel lines and
Check for signs of rust and corrosion.
Pylon firewall
Pvion and
f;ttings
FS 5.57 to 384.5
Check for signs of rust and/or corrosion and also for

indications of excessive heat.
engine air intake duct leading edge skins
Close-out doors and
covers
and related attach
angles in pylon lower skin
20-00-10
Page 8
Aug 17/84
COPYRIGHT,
SR-76-O2.3
CORROSION CONTROL 1MANUAL
r,
10
26
--:=1
11
12
13
14
18
21
20
17
16
19
15
22
23
24
25
1.
GALLEYAREA
2.
ENGINE AIR INTAKE
3.
BATTERYAREA
4.
HORIZONTAL STABILIZER TO FUSELAGE RUB AREA
5.
RUDDER HINGES
5.
TAIL CONE INTERIOR
7.
RUDDER POSTFITTING
8.
HORIZONTAL STABILIZER HINGES
9.
AFTFUSELAGEDRAIN HOLES
10.
FUSELAGE SKINS
11.
CENTER SECTION UPPER SKINS
12.
FLAPTRACKS
THRUST REVERSER IMPINGEMENT AREA
13.
AILERONTRIMTAB MINCES
14.
AILERON HINGES
15.
LOWER SURFACE SKINS
16.
MAIN LANDING GEAR CHASSIS ASSEMBLY
17.
WING ATTACH FITTINGS
18.
WING LEADING EDGE TO FUSELAGE RUB AREA
19.
INFLIGHtESCAPE HATCH
20.
MAIN ENTRYDOOR
21.
SPEED BRAKEWELL
22.
FLOOR AREA INBOARD OF MAIN ENTRY DOOR
23.
INTERIOR AREA BELOW PILOTS SLIDING WINDOW

NOSE GEAR CHASSIS ASSEMBLY
24.
25.
BULKHEADATFS13
26.
PYLON FIREWALL
FS 357 TO 384.5
Figure
Model NA 265-40
6
5285-23-20-1
20-00-10
Paffe
COPYRIGHT, 1984 BY SA=DTTLINER CORPORATION
Aug 17/84
SR-7(i-02:3
C()KK()SI()N CONTROL MANUAL
,li
/13
15
32
17
Is
J
25
24
26
23
22
21
20
27
28
29
30
31
2.
WINDSHIELD RETAINING STRIPS
17.
FLAP TRACKS 8 FLAP TRACK ROLLERS
GALLEY
18.
AILERON TRIM TAB HINGES
i.
SL~T TRACKS 5 SLAT TRACK ROLLERS
19.
L\ILERON HINGES
J~
ADF L\NTENNAMOUNT
20.
LOWER SURFACE SKINS
5.
WINOOWPANS
21.
6.
ENGINEAIR INTAKE
22.
MAIN LANDING GEAR WHEEL WELLS
7.
LAVATORY
23.
WING ATTACH FITTINGS
3.
SATTERYAREA
24.
9.
25.
SPEED BRAKEWELL
lO.
RUDDER HINGES
26.
MAIN ENTRY DOOR FLOOR STRUCTURE AREA
11.
RUDDER POSTFITTING
27.
INTERIOR AREA BELOW PILOTS SLIDING WINDOW
12.
TAIL CONE INTERIOR
28.
NOSE GEARWHEEL
13.
29.
NOSE GEAR CHASSIS ASSEM 8 WHEELS
14.
AFTFUSELAGEDRAIN HOLES
30.
ELECTRONIC COMPARTMENT
15.
FUSELAGE SKINS
31.
BULKHEAD ASSY AT FS 13
16.
CENTER SECTION UPPER SKINS
32.
PYLON FIREWALL
THRUST REVERSER IMPINGEMENT AREAS
FS 357 TO 384.5
5265-23-20-2
20-00-10
Paae 10
Aug 17/84
Colrosion Prune Areas
erModel
ugiF06-568
NA
SR-76-02Y
4~6
1
19
Il
11
23
,13
14
15
21
;o
19
22
17
1.
WINDSHIELD RETAININGSTRIPS
2.
GALLEY
3.
SLAT TRACKS 8 SLAT TRACK ROLLERS
j~
ENGINEAIR INTAKE
5.
LAVATORY
6.
BATTERYAREA
7.
HORIZONTAL STABILIZER TO FUSELAGE RIJB AREA
5.
RUDDER HINGES
9.
10.
AFTFUSELAGEDRP~IN HOLES
!1
FUSELAGE SKINS
12.
MAIN LANDING GEAR WHEEL WELLS
THRUST RE\/ERSER IMPINGEMENT ~REA
13.
14.
15.
AILERON TRIM TAB HINGES
16.
AILERON HINGES
17.
LOWER SURFACESKINS
18.
WING LEADING EDGE TO FUSii~GE RUB AREA
19.
MAIN ENTRY DOOR FLOOR Si r;UCTURE AREA
20.
SPEED BRAKEWELL
21.
NOSE GEAR WELL
22.
23.
PYLON FIREWALL
FS 357 TO 384.5
5265-23-20-3
Colrosion Prone Areas
Figure
o
Model NA 865-70
8
20-00-10
Page 11
Aug 17/84
SR-7fi-02~
C()KH()SI()N CONTROL IMANUAL
1!
3~
ii
.J
10
23
X?
12
13
22
21
20
19
18
17
15
16
i.
WINDSHIELD RETAINING STRIPS
2.
GALLEY
3.
SLAT TRACKS 8 SLAT TRACK ROLLERS
4.
ENGINEAIR INTAKE
5.
LAVATORY
8.

RUDDER HINGES
7.
8.
9.
dFT FUSELAGE DRAIN HOLES
10.
FUSELAGE SKINS
11.
MAIN GEAR WHEEL WELLS
THRUST REVERSER IMPINGMENT AREA
12.
MAINLANDINGGEAR CHASSISASSEMBLY
13.
14.
AILERONTRIMTAB HINGES
15.
L\ILEAON MINCES
16.
LOWER SURFACESKINS
17.
18.

MAIN ENTRY DOOR FLOOR STRUCTURE AREA
19.
SPEED BRAKEWELL
20.
NOSE GEAR WELL
21.
22.
BATTERYBAY
23.
PYLON FIREWALL
IrS 357 TO 384.5

S265-23-20-J
20-00-10
Pane 1~
Aug 17/e
Corrosion Prone Ateas
eruModel
giF08-562
ruA
COPYRIGHT,
SR-76-023
13
5
2
10
19
12
4
11
14
15
17
20
i.
265-430003
SUPPORT--ENGINE THROTTLE QUADRANT AND AILERON BELLCRANK ASSEMBLY
2.
265-524079
PCDAL--PILOTS BRAKE AND DIF\ECTIONAL CONTROL ASSEMBLY
3.
265-334007
SUPPORT--LEFT BRAKE BELLCRANK, FS 76
J.
265-334022
HOUSING--PRESSURE BOX SEALING--PILOTS BRAKE CONTROL SYSTEM
5.
265-437028-1. -2. -11. -12
SUPPORT--TORQUE TUBE--THROTTLE CONTROL SYSTEM. FS 79.5
i.
:65-524031
KNOB--PEDAL ADJUSTMENT-CONTROL COLUMN ASSEMBLY
7.
265-521017-1 &2
PEDESTAL--RUDDER PEDAL AND CONTROL COLUMN
3.
265-522020
SUPPORT--TORQUE TUBE--LONGITUDINAL CONTROL SYSTEM, FS 104.844
265-522023
265-524057
SUPPORT--RUDDER TORQUE TUBE--CONTROL COLUMN ASSEMBLY
10.
246-52231-i 8 9
SUPPORT-LONGITUDINAL CONTROL SYSTEM BELLCRANK, FS 176.5
11.
265-522037
BELLCLlANK-BOBWEIGHT BALANCE BUNGEE--LONGITUDINAL CONTROL SYSTEM
12.
265-334006
SUPPORT-BELLCRANK RIGHT-HAND BRAKE, FS 76
13.
265-524032
LINK--IDLER--RUDDER CONTROL PEDAL FWD AND APT-CONTROL COLUMN ASSEMBLY
9.
265-524033
14.
265-300242-1
HANDLE--FUSELAGE ENTRY DOOR-INSIDE
15.
246-52418
16.
246-52218-11 &12
SUPPORT--DIRECTIONAL CONTROL SYSTEM, FS 116.5 (BELLCRANK)

SUPPORT-LONGITUDINAL CONTROL SYSTEM BELLCRANK. FS 176.5 (UPPER)
ti.
246-33731
SUPPORT-LANDING GEAR EMERGENCY AFT CONTROL
18.
265-522026
SUPPORT-LONGITUDINAL CONTROL SYSTEM BELLCRANK, FS 363
19.
265-524004
SUPPORT--DIRECTIONAL CONTROL BELLCRANK SYSTEM, FS 457.875
20.
265-523048
BELLCRANK--LATERAL CONTROL SYSTEM TRIM ACTUATOR

S265-23-20-(2
Location of
Magnesium
Figure 10
Parts
20-00-10
Page in/14 Blank
Aug 17/84
SR-76-023
CLEANING AIRFRAME
CLEANING MATERIALS, METHODS, AND
APPLICATIONS
Toiuene
Toluene is flammable. Keep away from heat and open
flame. Vapors are harmful. Use only with adequate
ventilation or respirator. Avoid prolonged or repeated
breathing of vapor. Avoid contact with skin and eyes. Do
not take internally, Comply with air pollution control
rules concerning photochemically reactive solvents.
Table 701 provides a listing of the areas and types of soils

which may be encountered during the preventive
maintenance phase of a corrosion control inspection
program and of the materials and methods necessary to
adequately remove any accumulated soils.
Conditions Requiring Immediate
Sealants
Cleaning
Sealants are irritating to the skin and eyes upon contact,

and may emit harmful vapors. Use only with adequate
ventilation. Avoid all skin and eye contact, Use protective
clothing such as rubber gloves, apron and eye protection.
Wash off immediately any accidentally contaminated
skin area. Do not take internally.
Under certain conditions, the need for the immediate

an area
may arise. When any of these
conditions do arise, cleaning of the affected areas should
not be delayed any longer than is absolutely necessary,
The longer the cleaning process is delayed, the greater the
chance of serious damage being caused by the corrosioninducing condition.
cleaning of
Epoxy Polyamide Primer
Immediate cleaning should be accomplished any time the

airplane has been subjected to any of the following
conditions:
deposits in vicinity of
i.
Spi lied electrolyte or corrosive

batteries.
2.
Exposure to fire extinguishing agents other than

carbon dioxide (CO~).
3.
Operation in low-level
4.
saltwater spray during adverse

weather conditions.
Exposure
ocean
Epoxy polyamide primer emits harmful vapors, which

flammable, especially during mixing, curing, and
spray application. Perform these operations only with
adequate ventilation or respirator protection. Epoxy
resins, especially the uncured resins and curing agents
are irritating to the skin and eyes. Avoid all skin and eye
contact. Use protective clothing such as rubber gloves,
apron, and eye protection. Wash off immediately any
may be
flight.
accidentally contaminated skin area. Do not take

internally. Comply with air pollution control rules
concerning photochemically reactive solvents.
to
Hazardous Materials
Polyurethane Paint
~lethvl ethyl ketone(MEK). nliphatic naphtha, toluene,

sealants, epoxy polyttmide primer. polyurethane paint,
anti eposy filler are materials which could be injurious to
the health of persons using them unless the applicable
safety precautions are observed,
Polyurethane paint contains flammable solvents and

toxic diisocyantes. Keep away from heat and open flame.
Vapors or mists are harmful! Complete body protection.
including entire head, is required, to prevent skin or eye
irritation from contact with the paint or its vapors or
mists. Respirator protection is required, usually an airsupplied hood, during mixing, curing and application.
Suitable facilities should be provided for immediate
clean water flushing of any accidental skin or eye contact.
Do not take internally.
Methyl Ethyl Ketone (IMEK)

MEK is flammable. Keep away from heat and open flame.
Vapors may be harmful. Use with adequate ventilation.
~void ptolon~ged or repeated breathing of vapor. Avoid
contact ~ith skin and e~es. Do not take internally.
;\liphatic Naphtha
Naphtha, aliphatic is flammable. Keep away from heat
flame. Vapors may be harmful. Use with
adequate ventilation. Avoid prolonged or repeated
breathing of vapor. Avoid contact with skin and eyes. Do
not take internally. Comply with air pollution control
rules concerning photochemically reactive solvents,
and open
Epoxy Filler
Epoxy emits harmful vapors, especially during mixing
and curing. Use only with adequate ventilation or
respirator. Epoxy resins, especially the uncured resins
and curing agents, are irritating to the skin and eyes.
Avoid all skin and eye contact. Use protective clothing
such as rubber gloves, apron and eye protection. Wash off
immediately any accidentally contaminated skin area.
Do not take internally.
20-00-10
0
Page 701
Aug 17/84
SR-76-023
CLEANING AIRFRAME (Continued)

Cleaning Airplane Surfaces Using Alkaline
Waterbase Cleaner
Alkaline waterbase cleaning compound is a biodegradable
com pound which, when m ixed with water, forms a solution
of silicates, phosphates, and wetting agents, and is particularly adaptable to hard water use because it does not
leave deposits or hard water salts on the surface being
cleaned. Alkaline waterbase cleaner is an excellent
cleaner of both oily and traffic films and is also effective in
removing exhaust soils.
To guard against the dangers of static

electricity, the airplane must be effectively
grounded during all cleaning operations.
Apply alkaline waterbase cleaner, using either a brush,

mop or spray equipment, until selected area to be cleaned
is completely covered. Begin cleaning at the lowest
surface on the airplane. (See figure 70:! far cleaning
sequences.)
NOTE
Prepare the airplane for cleaning by inspecting the

airplane surfaces to be cleaned to determine if more
than one ratio of the cleaner will be required.
The mixing ratio of alkaline waterbase cleaner and water
may vary due to the differences in products from different
manufacturers, the differences in water composition, or
changes in temperature. Several ratios should be tried to
determine the best mixture for the application; however,
the ratio should be maintained somewhere between 5:1
and IU:l
When
Do not mit alkaline waterbase cleaner

with any solvent (naphtha, dy/ cleaning
solvent, IMEK, etc.). The added solvents will
create afire hazard and cause damage to
non-metallic materials.
luorlci~ng loith allcaline umterbase
cleaner, precautions Yh.OZLld be taken for
adequate personnel proteetion; wear elJe,

face, hody, and hand protection equipment.
Seal all openings lair intake ducts, scoops, touvers, drain
holes, etc.) where, the cleaning solutions could possibly
enter. Use either water tight covers or boots, or masking
tape and barrier paper. Also lubricated parts such as
control actuators, bearings, wheels and brakes and
natural entrapments must be protected from cleaning
solutions by masking tape and barrier paper. Pitot static
potts .ihould be protected by sealing with a non-adhesive
barrier paper secured in place with masking tape. (See
figule 701 for protective covers.)
IVOTE
Do not allow alkaline waterbase cleaner to

dry on the airplane surface; this will cause
streaking of the surfaces.
Agitate the applied cleaner by scrubbing with a nonmetallic brush. Extremely soiled areas such as exhaust
impingement areas, wheel wells, etc.. will require
vigorous agitation. Allow the compound to dwell on the
surface for a minimum of at least 10 minutes or longer
(depending on the type of soil present) and then agitate
again prior to rilla ing. The surfaces to be cleaned inust be
kept "wetted" with the cleaner during the complete
agitation, dwell, agitation, and rinse cycles. Thoroughly
rinse the cleaner from the area being cleaned by using
copious amounts of clean potable water. Make certain that
all seams and laps are thoroughly rinsed. Water heated to
about 140"F will give the best results.
if streaking appears, reapplication of the cleaner will
usually reduce, or el i mi nate th is condition. Check to make
certain the surfaces are clean by wiping with a clean
paper towel. If the towel shows indications of soils, the
surface is not clean and the cleaning procedure should be
repeated.
When surfaces are satisfactorily c:eaned, remove all
barrier paper and mask i ng taps cove ri ng areas w here the
cleaner was not to enter or come in contact with. Make
certain all drain holes are open. If any of the cleaner has
entered the protected areas, carefully remove all
cleaneriwater from the area. Areas/component requiring
lubrication shall be inspected and lubricated in
accordance with the applicable maintenance manual.
should be performed
in shaded areas whenever the temperature
ezceed~ 800F,
Cleaning operations
20-00-10
Page 702
Aug 17/84
SR-76-023

Aircraft Surface
Cleaning Compound
cleaning solution with a stiff bristle brush to loosen all

soils. Wipe the cleaning solution from the airplane
surface with clean rags, Repeat the cleaning procedure to
the adjacent areas until the complete surface has been
A i rcraft surface c leaning compound is a general purpose

cleaner primarily used for light to heavy soils an the
surface of the airplane. Aircraft Surface Cleaning
Compound, Type i, is available in 5 gallon containers and
16 and 55 gallon drums. Aircraft Surface Cleaning
Compound, Type 1A, is available in 16 oz. aerosol spray
cleaned,
Waterless Cleaning
When water is at a minimum, the following cleaning

procedure should be used. Spray the area to be cleaned
with Aircraft Surface Cleaning Compound. Type 1A
cans.
(aerosol container). Allow the foam cleaner to remain on

the surface until the foam starts to break, then wipe the
To
guard against the dangers of static

electricity the airplane must be effectively
grounded during all cleaning operations.
cleaner and the soils from the surface using clean cloths.
Solvent Cleaning
Do
Solvent cleaning is used primarily to clean excessively

or greasy areas in the wheel wells, landing gears or
nacelles or engine exhaust deposits, prior to the
app lication of al kal ine water base c leaners. Use any of the
commercially available solvents such as: Stoddards
solvent, naphtha, dry cleaning solvent. etc.
aircraft surface cleaning

co~pound, Type i, full strength as it will
da7nage airplanefinishes.
not
oily
use
Prepare the area to be cleaned by masking all openings to

prevent the cleaning compound from entering into the
structure. Ussnfg masking tape or barrier paper, seal all
lubricated parts such as central actuators, bearings,
hinges, etc. Wheels and brakes and areas of moisture
entrapment should also be protected from the cleaning
compound
as
Do not use solvent cleaning

in
the areas of oxygen storage containers or
on ozl/gen lines, Solvent cleaners are not
compatible with ozlJgen and will cause
ezplosion and fire, Solvent cleaners are
flammable and all potential ignition
sources shall be Icept at least .50 St
frorrL solvent: cleaning opelatio~ns.
applicable,
NOTE
C~lu,cnirLy c,~e.ratiorcR should
be
iR shaded ureas
e~ceed 800F.
tem,peratu~res
To prepare the airplane for solvent cleaning, make sure

that the airplane is properly grounded and that adequate
fire extinguishing equipment is available. iLIake certain
that all rubber, plastic and electronic equipment in the
vicinity of the area to be cleaned is protecLi~d from the
solvent, and that all openings where solvent could enter or
be difficult to remove, are r~.operly sealed.
Slis the aircraft surface
cleaning compound in approximately the following proportions for the applicable

yulface soils:
Light soils
I ~art
Medium soils
He;l\ soils
~olmal
cleaning compound
1 part
1 part
to 16
c;raning compound
cleaning compound
parts
to 9
to
water
parts
parts
water
water
Cleaning
the
Personnel ~uorking auith solvent should

solvent resistant clothin~g and face
shields or goggles. Also the use of a
resp~mtor is recommended Luhen worlcirLg
?vith solvent in a closed or restricted area.
ixed Type 1 cleaning compound to the surface

to be cleaned usingeither a scrub brush, sponge. rag, or a
cleaninff and polishing pad, iSee figure i02 for, cleaning
pply
wear
sell ue nces.
Agitate the ap~!ied solution with
a stiff bristle brush to

all loosened soils then rinse the cleaning
compound from the airplane surfaces with clean water,
remove
Limited Water
Cleaning
Apply the mixed Type I cleaning compound to

area of the surface t~ be cleaned. Scrub the
small
Apply solvent to arc~cs

brush,
sponge
or
to be cleaned using a non-metallic

clean cloth. Allow the solvent to remain
the area for a short period of time (10-15 minutes) then

agitate the solvent using a brush. sponge or cloth. Wipe
the surfaces thoroughly with clean dry cloths. Blowers or
loW pressure air (10-15 psi) may be used to spedd the
on
applied
20-00-10
0
COPYRIGHT, Ibo~ BY SABRELINER CORPORATION
Page 703
Aug 17/84
SR-76-023
C()KROSION CONTROL MANUAL

Solvent Cleaning (Contd)
evaporation of the solvent. All
waste solvent, wiping rags,

disposed of when cleaning
operation has been completed. Inspect the cleaned areas
to determine that there is no trapped solvent within the
etc., should be collected and
structure
Post
or
that solvent has entered into sealed
areas.
Cleaning Procedures
immediately following the completion of a cleaning

operation on the exterior surfaces of an airplane, the
following tasks should be performed in the sequence that
thev
i.
are
listed.
Remove all
protective covers and masking tape from
pitot-tubes.
2.
air intakes, exhausts, etc.
Ensure that all drain holes are clear by inserting a

as a pipe cleaner through each drain hole.
probe such
Examine exterior surfaces of airplane for evidence

of colrosion and/or tleterioration of exterior fi nishes.
1.
Relubricate all points that are equipped with

lubrication fittings to force out any
entrapped cleaning solutions or moisture.
pressure
5.
Remove all deteriorated or damaged sealant and

reapply fresh sealant. incllldincr formed in place
removable
access
door ~eals.
20-00-10
Page 704
Aug 17/84
SR-76-023
COCKPIT COVER
(265-810101-21)
ENGINE AIR INTAKE
DUCT COVER
/q
(265-810102)
ENGINE TAIL PIPE
COVER(285-810103)
PITOT TUBE COVER
(265-810100-3)
MODEL NA 265-40 AND -60
COCKPIT COVER
ENGINE INTAKE DUCT
ENGINE TAIL PIPE
(265-810101-31)
COVER (265-310102)
COVER
(265-810103)
PITOT TUBE COVER
(370-810100-11)
MODEL NA 265-70
COCKPIT COVER
ENGINE INTAKE
ENGINE TAIL
(265-810101-31)
DUCT COVER
PIPE COVER
c~
1~
NOTE
j~
COVER RUBBER TIRES. WINDOWS. AND WINDSHIELD

WHEN WORKING
PITOTTUBECOVER
(370-810100-11)
PAINT STRIPPERS OR CAUSTIC
MODEL t;~ 265-80
Protective Covers
WliH
CLEANERS.
5265-23-20-L8
and Paint
Stripping
20-00-1 O
Page 705
Aug r7/84
SR-76-023
CORROSION CONTROL IMANUAL
WASH UNDERSIDE OF WINGS

STARTING AT WING CENTER
SECTION AND WORKING OUTED
CI
TO WING TIPS.
oQ
WASH UNDER SURFACES OF
FUSELAGE, ENGINE NACELLES ANDHORIZONTAL STABILIZERS.
:i
~j
WASH UPPER SURFACES OF WING

AND CENTER SECTION OF
FUSELAGE. DIRECT RINSING

INWARD WHILE WORKING
OUTED TO WING TIPS.
U_-i4i_~
D WASH
REMAINING PORTIONS OF
::::-:::ic;r:::::::.
UPPER FUSELAGE, ENGINE
NACELLES, HORIZONTAL
STABILIZER, AND BOTH SIDES OF
::::::::::::::::1:::::::
VERTICAL STABILIZER.
[iijiiili-i:i:i:iii-iii 1
AREAS TO BE CLEANED
DIRECTION OF MOVEMENT
20-00-10
Page 706
Aug 17/by
5265-23-20-17
Cleaning
SequnceFigure
702
COPYRIGHT, 1984 BY SABhZLiNER CORPORATION
SR-76-023

Table 701.
Cleaning Procedures
and
AREA OR COMPONENT
TYPE OF SOIL
1.
Agents
CLEANING AGENT
PROCEDURE
ExteriorPainted Surfaces
Light soil
or
dirt
Fresh water
or
aircraft surface
Remove oil stains with dry cleaning

solvent prior to washdown
with water.
cleaning compound in 16 parts water

or alkaline water base cleaning
compound in 9 parts water
Apply with
sponge, soft brush
or
cloth
(avoid direct sunlight). Scrub and

then rinse with fresh water and dry.
Shoe scuff marks and stains
Solution of
one
part aircraft surface
Wet area with fresh water. Apply

solution with sponge or cloth and rub
gently in a circular motion (avoid
scrubbing action). Rinse with fresh
water and dry.
cleaning compound thoroughly

mixed with 4 parts water
Scouring pad
Use scouring pad if cleaner

adequate alone.
Surface grime, oil, exhaust
Solution of one part aircraft surface
Apply with
smudge
spray, soft brush, or cloth.

Scrub or mop surfaces to loosen soil,
Rinse thoroughly with fresh water.
Do not allow solution to dry on
surface, as this will cause streaking.
Rinse thoroughly, then dry.
mixed in 9 parts fresh water
Heavy concentrations of grime,

oil,
Solution of
grease, exhaust stains
one
Wet surface with fresh water. Apply

solution with spray, soft brush or
cloth. Allow to remain on surface,
then scrub with brush. Rinse surface
thoroughly with fresh water and dry.
Repeat procedure for heavily contaminated areas using scouring pad.

Scouring pad
2.
is not
ExteriorUnpainted Surfaces
A z,oid contact of plastic panels with cleaning solution. Do not scrub non-specularfinishes
because this will destroy glare-suppressing characteristics. Scrub only small areas at one
time and only enough to remove residue.
Exhaust residue
Solution of
one
Wet surfa~e with fresh water. Apply

solution and scrub briskly with
abrasive mat or scouring pad. Rinse
with fresh water and dry.

Abrasive mat
3.
or
scouring pad
Interior Areas
Lavatory
Urine residue
One part ammonium hydroxide in

20 parts water or dilute solution of
sodium bicarbonate
Sponge with a solution of ammonium

hydroxide. Flush with fresh water or
I
wetsurfacewithsodium bicarbonate
to dry, rinse with
fresh watel-, Sry with a clean cloth.
solution, allow
20-00-10
0
Page 707
Aug 17/84
SR-76-023

Table 701.
Cleaning Procedures and Agents (Contd)
AREAORCOMPONENT
CLEANING AGENT
TYPE OF SOIL
3.
PROCEDURE
Interior Areas(Contd)
Floor and Deck
Dirt, debris
Wipe with cleaning compounds,
rinse
with fresh water. Use germicidal
tablets as toilet and urinal deodorants.
Alkaline water base cleaning

compound or aircraft surface cleaning compound thoroughly mixed
with 9 parts water
Germicidal tablets, USDA

Reg. 100-12-1.
Radome Interior and Interior
Erluipment Compartment
Do not use synthetic wiping cloths with highlyflammable solvents defined as those having a
flash point of IOo"F or less, such as aliphatic naphtha,
Dust, dirt, oil, and debris
Remove loose dirt with vacuum

cleaner. Wipe glass fiber with damp
cloth wet with cleaning solvent. Wipe
excess solvent with clean cloth.
Water
Cleaning solvent
Cheesecloth bleached
unbleached
or
Cockpit Interior
D~st. dirt, mud,
and light debris
Vacuum cleaner
Loosen any accumulations of mud on

control pedals, floor or other cockpit
equipment with brush and remove
with vacuum cleaner.
Indicator Glass Cover

Dirt and smudge
Cleaning and polishing compound.
Apply compound
flannel cloth
soft, clean cloth. Rub gently in
to
glass
covers
with
circular motion until clean. Polish

with another soft, clean cloth.
hcrylic Plastic
Light soil and smudges
5.
Aliphatic naphtha, flannel cloth
Apply solution with a flannel cloth

and rub gently. Solution will
evaporate and not leave a film,
Interior Plastic and

Cllass Panels
Smudjies
vV3ter. ~lannel cloth
Vacuum and then dust with joft.
clean, damp cloth. Keep cloth free of
grit by rinsing frequently.

6.
Elastomeric Seals and Parts
~o aot u~e .p?lnthetic .10ipilLg cloths with highlllflammable solvents defined as those having a
flash point of loo"F or less, such as aliphatie naphtha.
Dust. dirt. grime, oil
Wipe with fresh water dampened

cloth cloth and dry. Wipe oil spots
with naphtha.
Water
Aliphatic naphtha
Cheesecloth bleached
unbleac;ied
or
20-00-10
Page 708
Aug 17/84
SR-76-023

Table 701,
Cleaning Procedures
and
AREAORCOMPONENT
TYPE OF SOIL
7,
Fabric, Soundproofing, and

Upholstery
Light soil and oil spots
Agents (Contd)
CLEANING AGENT
PROCEDURE
Alkaline water base cleaning compound thoroughly mixed with

9 parts of water
Scouring pad
Remove loose dirt with
vacuum
cleaner. Apply soap solution

with sponge.
Rinse with clean, dampened rag

using clean fresh water.
or
sponge
Aircraft surface cleaning compound

thoroughly mixed with 16 parts
of water
Apply foam, wipe with cloth, rinse

with dampened cloth and dry.
Vacuum cleaner
8.
Plastic and Glass Panels
IWilrllll]B
Remove rings, watches, or other hard objects from hands and wrists before washing
transparent plastics. Personnel must also take precautions to prevent buttons, badges, or
other hard objects from scratching surfaces. Do not use hard, dirty or gritty cloths in
cleaning and polishing transparent plastics, Wiping with such cloths can mar and scratch
plastic surfaces. Do not use any chemical compounds unless speci~fically authorixed for
cleaning plastics.
NOTE
Do not rub dry plastic panels with dry cloth which
electrostatic charge that attracts particles.
might scratch surface
Light dirt, or particles, soil,

grime, salt spray
Fresh water, flannel cloth
Oil,
Aliphatic naphtha
Cleaning and polishing compound
grease
or
create
Flush with fresh water to remove

loose dirt. Rub gently with bare
hands while applying fresh water.
Dry with clean, soft cloth or tissue.
Follow by applying polishing
compound with a soft, clean cloth or
tissue in a circular motion until clean.
Polish with another soft, clean cloth.
Flannel cloth
Apply with a soft, clean cloth. Blot

gently, solution will evaporate and
not leave a film. Apply p:i;hing
compound. Rub in circular motion
until clean and polish with another
soft, clean cloth.
9.
Control Cables
Do not
Dust, dirt, oil,
grease
use
ezeessive
cleaning solvent, Solvent will
remove
Cleaning solvent, corrosion

preventive compound water
displacing, corrosion preventive
compound Grade 1, corrosion
preventive compound Grade 4
internal lubricant.
Wipe with clean cloth dampened with

solvent. Apply corrosion preventive
compound water displacing. Recoat
cables with thin coat of corrosion
preventive compound Grade 1 for
exterior installations and/or corrosion
preventive compound Grade 4 for
interior installations.
20-00-10
Page 709
0
COPYRIGHT, 1984 BY SABhZLiNER CORPORATION
Aug 17/84
SR-76-023

Table 701,
AREA OR COMPONENT
TYPE OF SOIL
10,
CLEANING AGENT
PROCEDURE
LandingGear
m!nllma
Wipe away from seal areas to preclude collection of soil at seal junction areas. Make sure
piston surface is clean and completely lubricated but not dripping. Telescoping action of
strut willforce gritty particles (i~ piston is dry) into cylinder causing leaks and eventual
failure. Do not use aerosol dispensed fluid on hydraulic pressure systems when fluid is
mixed withfluorinated and chlorinated propellants. ESuorinated and chlorinated propellants
will cause severe corrosion in some hydraulic systems.
Sand, dirt, salt deposits, and
other
11.
foreign particles
Hydraulic fluid used in the specific

aircraft system
Clean exposed surfaces with clean

cloth dampened with hydraulic fluid.
Take care not to scratch the surface.
Doors, Linkages,
Cylinder Housings
IW!1I111I1T1
Do not use corrosion preventive compound
Grade 4
on
microswitches or ezposed piston rod
surfaces.
Dust, dirt, oil,
grease
Cleaning solvent, corrosion

preventive compound Grade
or brush surfaces as necessary

with solvent. Coat rod ends and
springs with corrosion preventive
compound Grade 4. Lubricate as
Spray
necessary.
1~.
Wheeisand Brakes
Oil. dirt, sand, and other
Solution of
foreign
matter
one

13,
Clean exposed areas with the solution

by brushing. Rinse thoroughly with
fresh water. Relubricate as required.
Electrical
gg!IlII[lIIg
ituoid direct
impingement of air
forced into components and

Dust, dirt, lint, and other
loose foreign matter, grease,
oil, and smudge
cause
pressure in electronic
compartment since dust
Cleaning compound solvent trichlorotrifluoroethane, corrosion preventive

compound water displacing,
corrosion preventive compound
Grade 4
14.
can
be
damage.
Loosen contaminants by brushing
cleaning solvent. Remove foreign
with
matter with a soft brush. Preserve

with a light coat of water-displacing
corrosion preventive compound.
Follow with light coating of corrosion
preventive compound Graae 4.
Avionics Components
Light tarnish
or
corrosion
Magic rub plastic
eraser
Use eraser to remove light tarnish or

corrosion only if part is sufficiently
rigid to resist rubbing motion.
20-00-10
Page 710
Aug 17/84
COPYRIGHT, 19E
SABRELINER CORPORATION
SR-76-023
Table 701.
AREA OR COMPONENT
TYPE OF SOIL
rFj.
CLEANING AGENT
PROCEDURE
Oxygen Lines(Exterior
Surface Only)
Lre only listed materialsfor cleaning oil

or
or grease
in presence of olcygen can
cause
e~plosion
fire.
Prolonged
or
skin. Use in
Oil, grease
repeated use of trichloroethane liguid and vapor can be injurious

well-ventilated area and wear protective clothing.
to
lungs and
Cleaning solvents: trichloroethane

trichlorotrifluorethane
or
Apply compound to exterior surfaces

of lines only with clean cloth and wipe
lines until dry.
20-00-10
0
Page 711/712 Blank

Aug 17/84
SR-76-023
CORROSION ON ELECTRICAL EQUIPMENT

CLEANING ELECTRICAL/ELECTRONIC
EQUIPMENT COMPONENTS
Sabreliner airplanes contain many electrically operated
controlled power units or controls, including circuit
breaker panels, consoles, motors, lighting fixtures, etc.
Cleaning and proper care of these components, as well
the communications and navigational equipment,
as
requires constant surveillance to preclude any chance of
these units becoming inoperative due to corrosion. All
exposed electrical connectors, terminal strips, bearings,
junction boxes, microswitches, and electronic gear must
be kept clean and dry:
or
Corrosion removal on electrical and electronic components should be accomplished

only b2J personnel ulho are familiar with
the operation and function of the units
involved. Corrosion removal, on some of
these units, is highlll complez and sound
judgment must be ezercised in removing
corrosiolzfrom the mechanical components
of electronic eguipment. The primary consideration is corrosion removal is complete
and that it is accomplished by the mildest
method possible. E~treme care
should be ezercised at all times to prevent
contamination and/or damage ofadjacent
components.
To remove dirt, dust and other foreign materials from
consoles and other accessible areas, use a dry, softbristled brush to clean areas around switches and dials.
Corrosion and/or tarnish may be removed from noncritical interior surfaces with an abrasive mat or metal
polish. Remove polish powder with clean dry compressed
air or a soft bristled brush, followed by wiping with a
clean, lint-free cloth.
The use of solvents on electrical/electronic equipment
~ihould be avoided whenever possible; however, solvents
necessary to remove hard dirt, grease, oils, and
carbon deposits. Apply solvent with a soft-bristled brush
to loosen contaminants then brush dry with another softbristled brush. After corrosion removal and cleaning
have been completed, protect bright surfaces with a light
film coating of water displacing corrosion preventive
compound. (Refer to Sources of Commercial Products,
20-00-9U.) Avoid excessive amounts of the corrosion preventive compound; wipe off with a clean dry lint-free cloth.
are
20-00-20
0
Pak, ~2 Blank
Aug 17/84
5R-76-023
CORROSION CONTROL ~ANUAL
SOURCES OF COM~MERCIAL PIP-ODUCTS

CLEANING COMPOUNDS
Alkaline Waterbase Cleaning
Compound
Air Tec 19
Turco Products
Div. of Purer Corp., LM.
24600 S. Main Street
Carson, CA 90745
Clarco 124P
Clarkson Laboratories, Inc.
1450 Ferry Avenue
Camden, NJ 08104
B and B 713 G
B and B Chemical Co., Inc.
P.O. Box 796
Miami, FL 33166
Fleetline 214
Oakite Products, Inc.
60 Valley Road
Berkeley Heights, NJ 07922
Cee Bee A-69P

Cee Bee Chemical Co.
9520 E. Cee Bee Drive
Downey, CA 90241
Magnus Magnusol 728

Magnus Division
Economics laboratories, Inc.
Osborn Bldg.
St. Paul, MN 55102
ED-S00
El Dorado Chemical Co.
6700 Lookout Road
P.O. Box 32101
San Antonio, TX 78216
Safety Solvent 715N

Brulin L Company,
Inc.
P.O. Box 270-B
Indianapolis, IN 46206
Formula Y-1537
West Chemical Products, Inc.
4426 Bandini Blvd.
Los Angeles, CA 90023
Inter 8758
Inter Products, Inc.
P.O. Box 6648
Greenville, SC 29602
Turco 5767, 5975 and T-4215

Turco Products
Div. of Purer Corp., Ltd.
Carson, CA 90745
Corrosion Removing Compound
M34H (Type I, Class 1)
B
B Chemical Company, Inc.
Miami, FL 33166
Oakite Fleetline JC-S

60 Valley Road
Octagon 3726D
Octagon Process,
Inc.
696 River Road
Edgewater, NJ 07020
Cee Bee B-l (Type II, Class 3)

Downey, CA 90241
Clarco 2100-B1 (Type I, Class 1)

The Clarkson Laboratories, Inc.
1450 Ferry Ave.
Pennwalt 79111
Pennwalt Corp.
Chemical Specialties Div.
Three Parkway
Philadelphia, PA 19102
Aircraft Surface Cleaning
Cee Bee R-677

Downey, CA 90241
Camden, NJ 08104
(Type I)
Pennwalt, Corp.
Chemical Specialties Div.
Three Parkway
715-K
Compound
B and B 2020 Plus

B and B Chemical Co.
876 West 20th Street
Hialeah, FL
Metal-Glo #6 (Type I, Class 1)

Turco 5361
Turco Products
Div. of Purer Corp., Ltd.
Carson, CA 90745
20-00-90
~P
Pagel
Sep 6/91
8~3-76-023
SOURCES OF COMMERCIAL PRODUCTS (Continued)

No-Rust, 21B
Corrosion Removing Compound (Contd)
Stevens Industries, Inc.

39 Avenue C
Bayonne, NJ 07002
AC-12 (Type I, Class 1)

El Dorado Chemical Co., Inc.
6700 Lookout Road
P.O. Box 32101
San Antonio, TX 78216
Visconorust,
1601 Black
Viscosity Oil Co.
Inter 8019 (Type I, Class 1)

Inter Products, Inc.
P.O. Box 6648
Greenville, SC 29606
3200 S. Western Ave.

Chicago, IL 60608
Solvent Cutback
Valvoline TECTYL 502C

Ashland Petroleum Co.
P.O. Box 391
Ashland, KY 41101
CORROSION PREVENTIVE COMPOUND

Solvent Cutback
Grade 1 (Hard Film)
Valvoline TECTYL 890

P.O. Box 391
Ashland, KY 41101
Braycote 137
Bray Oil Co.
1925 Marianna Ave.
Braycote 103
Bray Oil Co.
Rust Preventive 1612A

Franklin Oil Corp.
Box 46030 Franklin Park
Cleveland, OH 44146
1925 N. Marianna Ave.

Los Angeles, CA190032
Nox-Rust201B
Daubert Chemical Ca.
4700 S. Central Ave.
Veedol Anorustol 280

Getty Oil GMBH, Jungfernstieg 51
2000 Hamburg 36, West Germany
Chicago, IL 60638
COSMOLINE 1102
Rust-Foil 161-1
Franklin Oil Corp.
Co.
E. F. Houghton
303 W. Lehigh Ave.
FranklinPark
Cleveland, OH 44146
Box 46030
Steelgard MS10
Harry Miller Corp.

Getty Oil GMBH, Jungfernstieg 51,
4th and Bristol Streets

NOKORODE 731
Lion Oil
Nor-Rust 207
Nor-Rust Division
Daubert Chemical Co.
4700 So. Central Ave.
Chicago, IL 60638
Lion Building
Fl Dorado, AZ 71730
Casmoline 1058
Co.
E. F. Houghton
303 W. Lehigh Ave.
Philadelphia,
PETROTECT 2
PENRECO
P.O. Box 671
PA 19133
Jesco 707
Jesco Lubricant Co., Inc.
P.O. Box 12337
N. Kansas City, MO 64116
Butler, PA 16001
Royco 137R
Royal Lubricants Co.
River Road
Hanover, NJ 07936
Steelgard MS1
Harry Miller Corp.
4th
Grade 2 (Soft Film)
ST 1502 and No-Rust 27

Stevens Industries. Inc.
39 Avenue C
Bayonne, NJ 07002
Bristol Streets
Philadelphia, PA
19140
PETROTEX IX
PENRECO
P.O. Box 671
Butler, PA 16001
20-00-90
Page 2
Aug 17/84
SR-76-023

Solvent Cutback
Grade 2 (Soft Film) (Contd)
Visconorust No. 1602

Viscosity Oil Ca.
3200 Western Ave.
Chicago, IL 60608
Solvent Cutback
Grade 3 (Soft Film-Water
Displacing)
Valvoline TECTYL 894
P.O. Box 391
ashland, KY 41101
Clarco 4000
The Clarkson Lab., Inc.
14.50 Ferry Ave.
Camden, NJ 08104
Solvent Cutback
Grade 4 (Transparent Film)
Valvoline TECHTYL 846

P.O. Box 391
Ashland, KY 41101
Braycote 194
Bray Oil Co.
1925 N. Marianna Ave.
Rust-Ban 397
ESSO A G, Kapstadtring 2,
Rust-Foil 161-4
Franklin Oil Corp.
Cleveland, OH 44146
Rust-Foil 161-3
Franklin Oil Corp.
Cleveland, OH 44146
Veedol, Anorostol 275

Getty Oil GMBH, Jungfernstieg.jl,

Getty Oil GMBH Jungferstieg 51
Cosmoline 1112
E. F. Houghton
Co.
303 W. Lehigh Ave.
Philadelphia, PA 191.33
Steelyard MS-12
Harry Miller Corp.
Philadelphia, PA ~9140
Nox-RustBO8
Nor-Rust Division,
4700 S. Central Ave.
Chicago, IL 60638
Oakite Special Protective Oil
50 Valley Road
Petrotect 3
PENRECO
P.O. Box 671
butler, PA 16001
Ferrocote 367-BL
&uaker Chemical Corp.

Elm and Shady Streets
Conshohocken, PA 19428
Royco 153 R

River Road
Hanover, NJ 07936
St 1894 and No-Rust 28
39 Avenue C
Bayonne, NJ 07002
Steelgard MS-31
Harry Miller Co.
Nor-Rust X-110
Nor-Rust Division, D
709 Enterprise Dr.
Oak Brook, IL 60.521
Protect Amber
PENRECO
P.O. Box 671
Butler, PA 16001
Poly Oleum 5000

Poly Oleum Corp.
13531 Greenfield Rd.
Detroit, MI 48227
Royco 194R
River Road
Hanover, NJ 07936
ST 1846 and No-Rust X-10

39 avenue C
Bayonne, NJ 07002
VICONORUST 1601 Amber
Viscosity Oil Co.
Chicago, IL 60608
Visconoru_, "!o. 1603

v;3cosity Oil Co.
Ch icago, IL 60608
COPYRIGHT, l~a4 BY SABRELINER CORPORATION
20-00-90
Page 3
Aug 17/84
SR-76-023

Water
Flame Resistant
Displacing
Liquidtiffht Sealants
PR-810
Products Research Co.
5426 San Fernando Road
Glendale, CA 91203
Alox 2028CM, Alox 2028DM, and Alox 2030FM

Alox Corporation
P.O, Box 517
Niagara Falls, NY 14302
22028 CM-:3
Fumetight
StevensIndustries, Inc.
Liquidtight Sealant
-65 to 2250F
PR1422G
PR1422GA Accelerator
Glendale, CA 91203
39 Avenue C
Bayonne, NJ 07002
Care No i, Care No 2, and Care No 3

Care Laboratories, Inc.
P.O. Box F
3474 Germantown Pike
Colleffeville. PA 19426
PR703
5426 San Fernando Rd.
Glendale, CA 91203
Conquer
Transportation Chemicals Div.
Chemtrust Industries Corp.
Proseal 707
Proseal 707 Accelerator
Coast Proseal
Mfg. Co.
194.51 Susana Road
Compton. CA 90221
1~2Fi0 W. Addison St.

Franklin Park, IL 60131
D-FiO~G and D-5037
%ip Aerosol Products
A Division of hiIitann. Inc.
21320 Deering Court
Fumetight
Liquidtight Sealant-~EiO
to 4000F
Pr-(310
Glendale, CA 91203
Canoga Park, CA 91:304

A I RC RAFT SEALING COMPOUNDS
Pressuretight
Elterior Waterti~ht Sealants
Liquidtight Sealant
EC-776 or EC-776R
Minnesota Mining
2501 Hudson Road
St. Paul, MN.5Ei119
ECl.i47 QL EC1547 Accelerator

Minnesota Mining
Mfg. Co.
2Fj01 Hudson Road
St. Paul, MN 55119
Mfg. Co.
PR1223CA Accelerator
PR122:3G
Products Research Co,
PR~41
PRY$1 Accelerator
Glendale. CA 91203
Glendale, CA 9120:3
Proseal 707
Coast Proseal
Mfg. Co.
19451 Susana Road
Compton, CA 90221

Proseal 730
Coast Proseal
Mfg. Co.
19451 Susana Road
Compton, CA 90221
Removable Doors
Faying Surface Sealants
Covers Sealant
EC1547 6t EC1547 Accelerator

Minnesota Mining
Mfg. Co.
2501 Hudson Road
St. Paul, MN 55119
PR13~1G cY~ PR1321GA Accelerator

Glendale, CA 91203
PR1223G
PR1223GA Accelerator
Glendale, CA 91203

PIoseal 707
Coast Proseal
Mfg. Co.
19451 Susana Road
Compton, CA 902"1
20-00-90
Page 4
Aug 17/84
SR-76-023
SOURCES OF CO~MMERCIAL PRODUCTS

Removable Doors
Cover Sealant (Contd)
Sterling Thinner U-138Ei

Sterling Lacquer Mfg.

Proseal 7:~0
Coast Proseal
Mfg. Co.
19451 Susana Road
Compton,
Groove
AA92 Base
AA92-C Catalyst
T7,32 Thinner
U.S. Paint, Lacquer
St. Louis, MO
Ident. Code .516690
Injection Sealing Compound
PR 70~
Glendale, CA 9220~
Chemical Co.
PAINT/PR~MER REMOVER
Fueltiaht Faying Surface Sealant
PIt1422. Class B4 ~i PR1428 Accelerator

PIoduct~ Research Co.
5420 San Fernando Roatl
Glendale. CA 91208
B 1567C
B&B Chemical Co.. Inc.
87.5 W. 20th Street
Hialeah. FL ~:3010
Penstrip-Y-tfi69
Chemical Specialties
Division of Amerace
74 Hudson Ave.
Tenafly. N.I 07fi70
Mfa. Co.
St. Paul. MN.i5119
Esna
Corp.
Turco 5409 and 5~Fjl

Turco Products
Division of Purer Corp., Ltd.
24600 So. Main Street
Wilmington, CA 90744
EP()XY-P()LYAMIDE PRIMERS
DeSot~, Primer
DeSoto Catalyst 910X462
DeSoto Reducter 020X:129
DeSoto Incorporated
Belkelev. CA
Ident. Code 159772
Deft
Deft
Deft
Deft
Co.
St. Louis, MO
Ident. Code 572578
CA 90221
F(S7(i or FC770R
Minnesota Mining KL
25()1 Hudson Road
~Continued)
CHEMICAL CONVERSION COATINGS

The chemical conversion coating materials are available
in three different categories:
Form, (2) Class, and
Method of Application. The following table is a key to the
three categories:
Primer 02-Y-1~
Catalyst ()2-Y-l:,
Reducer MIL-T-11T,e~8
Recriucel
Deft Clhemical Coatings
I1~ine. CA
Ident. (ode Ifie7.i~
(1)Form I
Folm II
FormIII
Sterling primer U-1201A

Sterling Catalyst U-1202A
Stelling Reducer MIL-T-19588
Stelling Lacquer Mfg. Co.
(2)ClasslA
Class
St. Louis. MO
Ident. Code 572578
P()LYURETHANE TOP COAT
Concentrated liquid
Powder
Pre-mixed liyuitl
Maximum protection
Protection where low electrical resistance
is required
(3)Method A
Spray application
Method B
Method C
Brush application
Immersion
The following is a partial listing of

conversion coating materials.
DeSoto Base 82
DeS~,to Catalyst 910.Ti:-:ifi
Dt~Soto Retlucer
DeSoto Incolporated
Berkeley. CA
currently available
Iridite 14-2 (Form II. Class 1A. Method A. B. C)

Iridite 14-2 Clear (Form II. Class S, Method C)
Iridite 14 (Form II. Class
Method C)
Allied Research Products. Inc.
4006-06 E. Monument St.
Baltimore. MD 21205
Ident. Code 159772

Deft Base 13
Deft Catnlvst 1:3
Deft Thinner
Deft Chemical Coatings
Irvine, CA
Ident. Code "r,i.i2
Sterl i nR Base U-10()()
20-00-90
Sterling Catalyst C-11)01
COPYRIGHT, 1984 BY SABRELINER CORPORA
I~N
Page 5
Aug 17/84
SR-76-023
C()KK()SION C()NTROL MANUAL

Chemical Conversion
Alodine
Alodine
Alodine
Alodine
Alodine
Coatings (Contd)
1200 (Form II. Class 1A, Method A, B. C)
1200R (Form I, Class 1A, Method C)

12008 (Form II, Class 1A, Method A, B, C)
1200T (Form II. Class 1A, Method A, C)
1201(Form I, Class 1A, Method B)
(Brush on)
Alodine 1200 (Form III, Class tA, Method B)
(Touch up)
Alodine 1201(Form III. Class 1A, Method B)
(Brush on)
Alodine 8:3(Form I. Class 1A. Method A)
Alodine 89 (Form I. Class 1A, Method A)
Alocline AOO (Form II. Class 1A, Method A)
Alotline 600 (Form 11, Class :3, Method A. B. C:)
Alotline 1000(Form II. Class :3. Method A, C)
Alocline Ic)Ol(Form I. (:lass :3, Method A. C)
A lotline 12()0 (Form II. Class :3. Method C)
Alocline 1200S (Form II. Class:3. Method C)
Alotline t;iOO(Form I. (:lass:i, Method A. C)
Amchem Products. Inc.
Ambler. PA 1901)2
(esco Sure Pond A-l~l). (Form
Cesco Products. Inc.
2X2O Oakland Ave.
(;arlantl. TS
Leeders 178H (Form II. Class 1A. Method C)

Leeders 17111 (Form II, Class 3. Method C)
Leeder Chemical, Inc.
16220 Illinois Ave.
Paramount, CA 9072:3
Gil-Chrome 1(Form II, Class

Method C)
The Man-Oil Chemical Co.
23000 St. Clair Ave.
Cleveland, OH 44117
MACro Alum 6 (Form II, Class 1A. Method C)
MACro Alum 7 (Form II. Class 1A, Method C)
MACro Alum 2 (Form II. Class
Method C)
Mac Dermid, Inc.
Fj2tj Huntington Ave.
Waterbury, CT 06720
Mi-Chrome A1(Form n. Class 1A. Method C)

Mitchell-Bradforcl Chemical Co.
Wampus
Lane
Milford. CT 064fi1
Chem-Rite A22 (Form I, Class 1A.:2. Method C,

McYIT Chemical. Inc.
Cllass 1A.:J,. Method C)
Church Street
Matawan, NJ 07747
Alt,al(Form II. Class 1A. Method C:

Albar n (Form 11. Class 1A, Method C)
Centro Form II. Class 1A. Method C)
Centro l~fj Form II. Class 1A, Method C)
Clorcoat (Form II. Class tA, Method C)
Coral Chemical Co.
Wnukeaan. IL B()()8~
(leanite 1()(Form II. Class X. Method A. R)
Clleanite Products, Inc.
I:(l,(, Schwab Road
Hatfielcl. PA 19410
Divercoat 7T (Form II. Class li-\. Method C)
Diversey Corporation
212 W. Monroe Street
Chicago. IL 60606
Shieltl II(Form n. (lass 1.1\. Method C)

Du Bois Chemicals
:36:31) E. E;emper Roaci
Sharonvi.lle. OH
Enthos AL-99() Form I.Class 1A.,Method C)
Enthone. Inc.
P.(). Box 1Y00
Ne~v Haven. CT
Oakite Chromicoat 20:3(Form I. Class 1Al

Oakite Chromicoat L~5 (Form I. Class 1A)
Chrc?micoat ~85 (Fcrm i,
Oakite Products. Inc.
Berkeley Heights. NJ
()7922
Bonderite 721(Form I. Class 1A. Method A)

Bonderite 721SH (Form I. Class 1A. Method A. C)
Bonclerite 722 (Form I. Class 1A. Method A. (1)
Bonclerite $88 (Form I, Class 1A. Method A, 8.
Hooker Chemical Coip.
2177 E. Milwaukee Ave
Detloit. MI48~11
Specialty Chemicals 241 Form [I. Class 1A, Methotl

Specialty Chemicals 231) (Form n, Class :3. Method (I)
Specialty Chemicals and SeiJices, Inc.
P.O. Box :32;36
Atlanta, (;A ~0:302

Turcoat Liquid Accela (;oltl (Form III. (Ilass l.L\.
Method B)
Turcoat hlumigold dl7X-H Foim II. Class 1A. Method
A. E, C)
Turcoat 4:3Fj4 (Form II. Class
~tlethorlC)
Turco Products
Div. of Purer Corp. Lttl.
Carson. C:X 90$4.,
~lchrome b~(Form II. Class 1A. ~Iethod X. C)

Heattsath Colp.
I()";i S. princeton A\e.
Chicapo. II,
20-80-90
Page
E;COPYRIGHT, 1984 BY SABRELINER CORPORATION
SR-76-023
CORROSION CONTROL MANUAL.
CLEANING
DETAIL REQUIREMENTS
SC()PE
This section covers materials and processes for general
purpose solvent cleaning. General purpose solvent
cleaning may be performed as a preliminary operation
prior to subsequent additional cleaning or processing, or
as a final general cleaning process when further cleaning
or
processing
is not
Solvent
required.
PKELIMINARY CLEANING
PIeliminary cleaning may be required to remove gross

contamination such as heavy greases, oil, metal chips,
inks, etc., prior to further cleaning or processing as
specified herein. When required, such preliminary
cleaning should be accomplished by-manual or
immersion solvent cleaning. by vapor degreasing or per
an applicable procedure in this chapter as required,
Manual Methods
Apply solvents to a clean cloth, polyurethane sponge or

scrub brush. Rub or scrub to dislodge the soil. For spot
cleaning, work around the spot and towards its center to
avoid spreading back on clean surface.
Parts requiring general solvent cleaning are either

manually cleaned or immersion cleaned using solvents
selected from table 1. Surfaces which require cleaning or
Use clean cloths
to the presence of contaminants not

removable with solvent are processed per the applicable
in this chapter. When required to remove
easily removable particulate matter, all items should be
off with clean, dry air prior to further cleaning
Air-dry
Fa!ing surfaces,
~erlloLe
etc.
~c,lvent by
or
are
as
required.
clean.
wipe dry with clean cloth.
Immerse part in soak tank. Scrub, slosh and

soil.
seams,
Remove part from solvent and allow
to
to
Immerse part in clean rinse tank,
or
tirain.
flush-rinse part.
using clean solvent.

Remove part from rinse and allow to air-tlrv,
with clean cloths.
Table i. Solvents and
agitate
remove
clevices, between
If such entrapment does occur,
with clean, dry air.
in
sponges,
Immersion Methods
Non-metallic and painted surfaces should be cleaned

usinl( ,M B1121n-01)R solvent only.
entrapping solvents
or
Repeat until surfaces
plucessing due
Avoiti
Cleaning
Use solvent selected from table i. All items solvent

cleaned should be free from dirt, grease, oil, gum, and
other soils, as determined by visual examination. When
required, visual aids such as low power magnification
may be used to assist with visual examination. Solvent
cleaned items should also be wiped with clean cloth.
which should show no indication of residual soils, stains,
or other contaminants.
or
wipe dry
Appiications.
SOLVENT
MB0210-00~
FLAMMABLE
No
APPLICATION
All metals and their
alloys,
except titanium
No
All metals and their alloys.

painted surfaces and all
non-metals except rubber
ABOLIO-()UC3
No
All metals and their

except titanium
TT-,M-"61 ~Methvl eth~l

ketone (~IIEE;)
Ees
All metals and their alloys,

except magnesium
alloys,
20-1 0-00
Page 1/2 Blank

Aug 17/8n
SR-76-023
MAGNESIUM ALLOYS CLEANING AND PROTECTIVE TREATMENTS

Consumables
GENERAL
Naphtha,TT-N-95
The following surface protective treatments may be
applied
to
magnesium alloys:
TREATMENT
Sodium Dichromate, Technical

MIL-M-S171 TYPE
Chrome Pickle
Dichromate
Brush-On Chromic Acid
Nitric Acid,
Type I
Type III
Type VI
Technical(Sp
G. 1.42)
Methyl Ethyl Ketone (MEK), Commercial

Water,Running
Clean, Dry Air Source
PRE-TREATMENT CLEANING
Remove grease and oil by vapor
solvent cleaning method,
degreasing method
Procedure
or
Surfaces to receive dichromate surf ace treatment must be

by alkaline cleaning method.
A ~,Ias i ve clean i ng m ust be followed by al kal i ne clean i ng
anti then pickling in sulfuric acid solution
to 7 fluid
ounces of sulfuric acid. 66" Baume, in sufficient water to
make 1 gallon of solution) at 70 to 900F until 0.002 in. of
surface is removed (10-15 seconds). Abrasive cleaning is
solution of sodium dichromate at 180 to 2129F then rinsed

in cold running water.
O Id
ical fi n ishes are removed by alternately i mmersat 195 to 2050F for 3-10
minutes (followed by a 2-:3 minute cold water rinse) then
in chromic acid pickle at 190 to 2020F for 2-20 minutes
(followed by a 2-8 minute cold water rinse). Repeat as
neetlecl to remove all olrl chemical finish. Alkaline solution
consists of 6 to 10 ounces/gallon (pH 11 min.) of Electrolytic Alkaline Cleaner (LB0210-109) OR 7 to 9
ounces/gallon (pH 12 min.)of Alkaline Cleaner for Magnesium (ST0210HB0001).
Clean part to be treated by wiping with naphtha

MEK.
2.
Brush on chrome pickle solution (1.5 pound sodium

dichromate and 1.5 pint nitric acid in 1 gallon
or
water). Keep surface wet by repeated application for

1.5 minutes.
3
Rinse all chrome pickle solution from part in cold

water. Do not rub. Be especially careful to
rinse all solution from cracks and recesses.
running
limited to sand castings and other parts that remain

within dimensional tolerance with 0.002 in. surface depth
removed during pickling.
Weltling flux is removed by scrubbing with a hard-bristle

b rush and hot water (above lfj00F). A reas i naccessible for
scrubbing are washed with a high-pressure stream of hot
water. When flux is removed, parts are immersed in 2-5%
i.
4.
Blow dry using dry, clean air.
5.
Apply primer
for finish coat
as soon as
practicable.
Dichromate Treatment
Equipment/Tools
FaceShield
Gloves
c hem
inp part in alkaline solution
Apron
Consumables
Chromic .i\cid,Technical
Ammonium Bifluoride. Technical
Sodium Dichromate, Technical
Magnesium Fluoride(Or Calcium Fluoride). Technical

Water, Running(Cold And Hot)
PR()TECTIVE TREATMENT TOUCHUP
Clean, Dry AirSource
Chrome Pickle Treatment (Type I) may be used to

touchup previously treated parts except on assemblies
nhere solution may be trapped in joints or recesses.
Chromic Acid T1eatment (Type VI) may be used to
ton chu p any previously treated part, regardless o f origi nal
protective treatment type, even where solution may be
trapped in joints or recesses.
PROTECTIVE TREATMENT APPLICATION

Chrome Pickle Treatment
EcluipmentfTools
Brush
FaceShield
(;loves
Ap~on
20-1 0-05
Page
Aug 17/84
SR-76-023
MAGNESIUM ALLOYS CLEANING AND

PROTECTIVE TREATMENTS (Continued)
Procedure
Touchup Treatment
i,

MEK.
Chro7nicacidpickle bathmallbeatroom
but part must be kept
immer.sed longer to completely remove
surface oxide or corrosion,
2,
Brush on or dip part in chromic acid treatment

solution (1.33 ounces chromic acid and 1 ounce
calcium sulfate per gallon of water) at room temperature for 1-3 minutes.
I~no surface oxide or corrosion is present,

the chromic oxide pickle and rinse (steps 1
and
may be skipped and the part wiped
clean ulith naphtha or MEK.
3,
Rinse all chromic acid treatment from part in cold

wet rag. If using
clean, wet rag, rinse rag in fresh water frequently.
Do not rub touched up surface.
NOTES
temperature,
1.
2.
running water or wipe with clean,
Immerse part in chromic acid pickle solution (24

ounces chromic acid per gallon of water) at 190 to
2020F for 2-20 minutes as required to remove surface
oxide and corrosion.
4.
Blowdry usingdry, cleanair.
5.
Apply primer for finish
5.
water
Rinse all tlichromate treatment solution from part in

cold running water (L-:~ minutes).
i.
solution at 1.95 to ~OSOFSor ~1-10 minutes

followed by a ~-S minute cold water rinse.
A Ilca~ne cleaning solution consists of s-l o
ounces of electrolytic alkali~ne cleaner (for
pii ii liL.ih.) OR r to .9 ounces of aikaiine
cleaner for maynesizinz (fo, pH i;? milz.)
luater.
per gallon o~t
1,
2.
Blow
9.
dry using dry, clean air.

coat
as soon as
or
Immerse part in chromic acid treatment solution

ounces of chromic acid and 1 ounce calcium
sulfate per,aallon of water) at room temperature for
0,25-2 minutes.
(1.33
clryin,v~
8.

MEK.
Hot ri nse in IfiO to lSOOF water until part is hot to aid

in
practicable.
An alternate to cleaning Luith naphtha or

MEK is to clip part in allcaliae cleaning
(2-3 minutes).
immerse Fart in~bol!ing dichrorr.ate treatment

solution (1.0 to 1.5 pound sodium dichromate and
().33 ounces magnesium fluoride OR calcium fluoride
per gallon of water) for :30 minutes. Maintain pH
between 4.1 and 5.5
as soon as
NOTE
Rinse all acid fluoride etch solution from part in cold
running
coat
Initial Surface Treatment
Rinse all chromic acid pickle solution from part in

cold running water (2-3 minutes).
Immerse part in acid fluoride etch solution (7 ounces

ammonium biofluoride per gallon of water) at room
temperature for 5 minutes.
-t.
or
NOTES
practicable.
Ensure pH remains in I.1 to 1.6 range.

Adjust by slowly stirring in ,5% solution
Chromic Acid Treatment
by Loeight of sodium
E~luipment/Tools
For a rrLore "Brass7J" color chemical co,lcentrations can be reduced jOO/o and the
part left immersedfor 1-3 mi~zuteu.
Face Shield
!;loves
Apron
3.
Rinse all chromic acid treatment solution from part

in cold,
Consumables
running
water
(2-:-: minutes).
Naphtha, TT-N-95
4.
Blow
5,
dry using dry, clean
air.
coat as
soon as
practicable.
Chromic Acid, Technical

Calcium Sulfate.Technical
Sodium Hydroxide. Technical
Water,Running
Clean,DryAirSource
20-1 0-05
Page 2
Aug 17/84
~OPYRIGHT, 1984 BY SABRELINER CORPORATION
SR-76-023
CLEANING IRON AND STEEL

Consumables
GENERAL
This section includes
cleaning procedures for iron, low

alloy steels, maraging steels, tool steels, nickel-iron alloys
(Invar, Ni-Span-C) and silicon-iron alloys.
Alkaline Cleaning Compound (MBO 210-011)

Procedure
1.
CLEANING METHODS
2.
Degreasing
Heavy
rust or scale should be
as
much rust
Immerse part in alkaline cleaning solution (10 to 14

MB0210-011 per gallon of water) at 180 to
2120F for up to 15 minutes as needed until part is
free of rust and scale.
ounces
Whenever possible, grease, oil, and inspection marks

should be removed by wiping with Stoddard Solvent or
equivalent. Vapor degreasing may be used.
Heavy Rust Scale Removal
Degrease and mechanically remove

and other contamination as possible.
3.
Rinsepartin runningwater.
4.
coat as soon as
practicable.
mechanically removed from
all accessible surfaces. Use various methods described in

ABRASIVE CLEANING as required.
Acid Immersion for Scale Removal
on
Mild Steel
Paint Removal
Cse appropriate STRIPPING
Do not use th~is procedzcre to remove scale

from high strength steel or h?/drogen
procedures,
emhrittlement will result.

Alkaline Immersion for
Light Rust Removal

Equipment/Tools
Equipment/Tools
Brush
FLlceShield
FaceShield
Apron
Gloves
Gloves
Apron
Consumables
Consumables
Alkaline Rust Remover: Ender No. 114: Oakite Rust
Stripper: Or Turco No. 4181.
Water, Running, Cold Or Hot As

Rust Remover Manufacturer.
Phosphoric Acid Cleaner: Turco W.O.

Procel K; Or Dolchem Process 200RR.
Specified By Alkaiine
i:
Kenlite
Inhibiting Rinse: Oakite Rinsite Or Wyandotte Ro.

Proecdure
Procedure
i.

and other contamination as possible,
much rust

and other contamination as possible.
8.
immerse part in alkaline rust remover solution 2 to 4

Ib per gallon of water) at 180 to 2120F for up to 15
minutes as needed until part is free of rust and scale.
2.
Brush on phosphoric acid solution (concentrated

1:1 with water) at room temperature as needed
remove scale.
Rinse
3.
Rinse part in
FO parts not receiving immediate subsequent processing, brush on an inhibiting rinse (0.13 to 0.2FjSb
by volume Oakite Rinsite in waterer 1.5 to 2.5 ounces
Wyandotte Ro per gallon of water) at room tempera-
i.
as
partinrunningwater.
Apply primer fol finish
Alkaline Immersion for
coat as
soon as
practicable.
Heavy Rust Removal
much rust
or
to
water.
ture for 2-3 minutes.
Equipment/Tools
FaceShield
running
as
5.
Rinsepartin runningwater.
Apron
(;loves
20-1 0-10
0
Page 1/2 Blank

Aug 17/84
SR-76-023
CLEANING ALUMINUM AND ALUMINUM ALLOYS

4.
GENERAL
This section covers general cleaning of aluminum and
aluminum alloy parts, oxide and corrosion removal,
stripping chemical films, cleaning before and after
welding, etch cleaning of parts, removal of smut, and
general brightening.
NOTES AND PRECAUTIONS
Cleaned parts should be handled with clean gloves and

should be protected against contamination during transfer
and storage.
Abrasive cleaning should not be used on parts that will be
deformed or lose dimensional tolerances by such cleaning.
Abrasive cleaning of castings and forgings, when required,
should be in accordance with 20-10-60. Sheet should not be
abrasively cleaned except for salvage of damaged surfaces.
A cleaning procedure should not be started unless all
steps of the process can be completed without interruption.
Avoid entrapping cleaning solutions in recesses, seams, or

within items being processed. Items with complex con-
figuration
may
require special handling.
Procedures requiring the manual use of chemicals should

be performed only by approved operators.
Cadmium or zinc plated parts such as nut-plates or helical
coil inserts should be either removed or adequately
masked to prevent the various cleaning solutions from
stripping the plating.
Cleaning compounds, obtained from suppliers, should be

controlled within the limits set forth on the suppliers data
sheets.
Demineralized water is preferred to tap or softened water
for all cleaning operations, especially in the final rinse
before drying.
Preliminary cleaning should be performed in accordance

with either step 1, 2, 3, or 4 as follows on parts heavily
contaminated with grease, oil, and forming lubricants, to
prevent excessive contamination of cleaning baths and
shortening of their useful life:
1.
Vapor degrease.
2.
series of cloths dampened with

cleaning solvent until gross contamination is no
longer visible.
3.
Solvent
wipe with
Degrease using 1 part MIL-C-25769 cleaning

compound mixed with 3 parts kerosene or cleaning
solvent. After the solution has remained in contact
with the part for 5-10 minutes, rinse thoroughly with
water.
Mill markings may be removed by solvent wiping with

methyl ethyl ketone(MEK) or toluene. Layout inks with a
shellac base may be removed by solvent wiping with
isopropyl alcohol.
Solvent wiping with naphtha, toluene, isopropyl alcohol,
MEK or l,l,l-trichloroethane
may be difficult,
particularly in hot weather, since these solvents evaporate
rapidly.
Naphtha, toluene, isopropyl alcohol, and MEK constitute
fire hazard since all have flash points below room
temperature and
are
very flammable.
When heat treatment procedures specify cleaning and do

not call out a definite procedure, cleaning should be
performed as specified in this paragraph. Parts, except
those treated with water-soluble forming lubricants or
formed on Kirksite dies or by striking with a lead or
Kirksite hammer, should be cleaned before heat treatment
by one or any combination of the following methods:
i.
Vapor degrease.
2.
Solvent
3.
Alkaline clean, deoxidize, and dry.
wipe.
Cleaned parts should be free from grease, oil, paint, heat

scale, marking ink or dye, and such residues as smut and
powder. The parts should have a uniform appearance free
from stains or racking marks. A slight iridescence or
textural change is permissable, provided the external
surface appearance is not objectionable.
Parts should show no change in dimension

cl"dding removal after cleaning.
or
evidence of
CLEANING PROCEDURES
Mild Alkaline Cleaning for Cadmium-Plated,
Zinc-Plated, Anodized, or Bare Aluminum
Equipment/Tools
Degrease using Turco 3878 emulsion cleaner.
FaceShield
Gloves
Apron
20-1 0-15
0
Page 1
Aug 17/84
SR-76-023
CLEANING ALU1MINU1M AND ALUMINUM ALLOYS (Continued)

3.
Mild Alkaline Cleaning for Cadmium-Plated,

Zinc-Plated, Anodized, or Bare Aluminum (Contd)
4.
room
Immersepartin aluminum deoxidizer solution(mix

per manufacturers instructions) at 60 to 960F for
5-15 minutes.
T-4215
running water.
Water, Running
5.
Rinse in cold
Clean,DryAirSource
6.
Blowdryusingdry, cleanair.
Chemical Cleaning Aiuminnm for Fusion Welding
Procedure
Equipment/Tools
1.
Precleanbywipingwith MEK.
FaceShield
2.
Immerse part in mild alkaline cleaner solution (4 to6

ounces mild alkaline cleaner per gallon of water) at
135 to 1SSOF for 5-10 minutes or until part is clean.
Apron
3.
Rinse in cold running water.
4.
Blow
Gloves
Consumables
dry using dry, clean air.
Mild Alkaline Cleaning
Deoxidizer,TurcoWO No.2
for Chemically Filmed
Water, Running, Hot and Cold
or
Bare Aluminum Parts
Clean, DryAirSource
Equipment/Tools
Procedure
Faceshield
1.
Vapor degrease part to be welded.
Apron
2.
Immerse part in deoxidizer solution (45 to 65% by

volume deoxidizer in water) st room temperature
for 5-10 minutes.
3.
Rinse in cold runningwatertoremoveall

solution.
4.
Rinse in hot(1500 max) water to warm part to lieeiet

in drying.
5.
Blow dry using dry, clean air.
Gloves
Consumables
Mild Alkaline Cleaner, RB0210-005
or
MB0210-003
AluminumDeoxidizer, ST0210GB0001
e
Water,Running
Clean,DryAirSource
temperature with 1500F (max)
running water.
Consumables
Mild Alkaline Cleaner(Non-Silicated),
Rinse in
deoxidizer
Cleaning Oxides and Surface Discoloration from

Aluminum Assemblies
Procedure
EquipmenyTools
IRillZmm
Do not use
Brush
to clean ea&miu~sor anodized parts or to
plated, zinc-plated
clean aeee~nebled, spot we~sd,
or
FaceShield
riveted
parts.
1.
2.
Gloves
Apron
Precleanbywipingwith
HeatGun
MEK.
Immerse part in mild alkaline cleaner solution (6 to 8

of mild alkaline cleaner per gallon of water)
at 135 to 1SSOF for 6-10 minutes.
ounces
1111111111
Consumables
Non-Flame Sustaining Aluminum Surface Cleaning
Compound; MI1-C-5B10, Type II
MethylEthylKetone(MEK),
Do not rinse clremicallyfilmed parts above
Commercial
Water, Running
laoOF.
20-10-15
Page 2
8ep 8/91
SR-76-02,3
CLEANING ALUMINUM AND ALUMINUM ALLOYS (Continued)

Procedure
Consumables
i.
Preclean part
by wiping with MEK.
2.
Brush on or dip part in aluminum surface cleaning

solution (EjO~l solution aluminum surface cleaning
compound in water) at room temperature for
r,-12 minutes,
Sulfuric Acid. Commercial (66" Baume
Water, Running Hot

Procedure
1.
Rinse in cold, running water for 2-4 minutes,

4.
Blow
dry using heat
gun at
2000F
Using stiff scrub brush, scrub weldment

to
2.
max.
2120F)
water to
Immerse weldment in sulfuric acid solution

6.lh solution sulfuric acid in ~vater) at
Cleaning Oxides and Surface Discolorations from

Aluminum Castings
in hot (1130
initiate flux removal.
room
to
tem-
perature for tO-1Fj minutes.
Ecluil,mentlTools
Face Shieltl
(;loves
3.
Repeat steps
4.
Rinse in hot, running water for
6~
Plow
1 and 2 until weldment free of flux.
dry using. heat
Manual Etch
Cleaning
minutes.
gun at Z0O"F
ma~.
of Aluminum Weldments
Alnon
Equipment/Tools
Heat(;un
FaceShield
(c,nsumables
Nitric
Acitl.
(;loves
Commercial
(42"
Baume)
For
Die
Apron
Castings
Hvtlrofluotic Acitl. Commercial (:SO" Eaume) (For
Sand Castings)
Consumables
MethylEthylKetone (MF,K). Commercial
Water, Running
Paste,
Methyl Ethyl Ketone (MEK). Commercial
Aluminum
procetlure
i.
Thickener, Cab-()-Sil
Iieclean aluminum casting
by wiping with ;MEK.
Rinse in cold, running

Elo\\
tlry using heat
water
gun
Soft.
M-;S
Clean
Cloths
pH Test Papel. Hydrion. Range
To 10
Procedure
for 8-Y minutes.
pt B00"F
STOL1I)(;R(IO()1
Masking Tape
B1ush on or dip casting in acid solution (7.5 to 90":1

nitlic acid in water die castings; tO to 251~ for
hyc-lrofluoric acid in water for sand castings) at room
tempelature for 0.85-0.5 minutes(nitric acid)or O.Fi1.~ minutes (hydrofluoric acid).
-I.
Deoxidizer.
i.
Pre-clean by ~ipiny with MEK.
2.
Airdry.
Y.
Mask
4.
Spread Turco:jgfjl etch paste over weld area to be

cleaned. Agitate paste continuously and add flesh
ma~.
Cleaning Welding/BrazinR Flux from Aluminum

Weltfments
aleas
adjacent
to
~veltl
using masking tape.
paste every 8-X minutes. Continue for 1,i-2Fj minutes

until weldment clean.
F,lluipmentiTools
Stiff bristlescrub brush
5.
FaceShield
Rinse etch paste from weldment using running

wiping with clean, soft cl~ths. Remove
masking tape and rinse again.
water
(;loves
6.
Xl,ron
Neutralize by
Heat(;un
wiping
aluminum deoxidizer
on
aluminum deoxidizer per gallon of
water). (Aluminum deoxidizer may be thickened to
paste consistency by adding Cab-O-Sil M-Fj.) Agitate
and wipe aluminum deoxidizer for 10 minutes.
(12
to 20
ounces
20-1 0-15
2
CO py R IGHT, 1984 BY SABR ELI N ER COR PO"

i..
..~v
Page 3
Aug 17/84
SR-76-023
CLEANING ALUMINUM AND ALUMINUM ALLOYS Continued)

Aluminum
Procedures (Contd)
Rinse and wipe using running water and soft, clean
cloths for a minimum of 1 minute to remove alumideoxodizer.
num
7.
8.
Rinse and wipe using deionized distilled water and

clean cloths.
9.
Test
Equipment/Tools
FaceShield
Gloves
Apron
pH of still wet etched area using hydrion

papel. Repeat steps 7 and 8 until pH is between .5.0
and
8.0,
Air
dry
10.
HeatGun
Consumables
or
wipe dry
with
clean cloths.
Nitric Acid, Commerical(42" Baume)
Water, Running
Cleaning of Non-Welded Aluminum Parts
Etch
Brightening and Smut Removal
MethylEthylKetone (MEK), Commercial

Cinpainted clad alunuinulls
yurSaces nzzlst not he cleaned using this
p~rocedu7e.
Procedure
i.
Pre-clean
2,
Immerse part in nitric acid solution (Fjg(~ by volume

nitric acid in water) at room temperature for 1-2
minutes.
Equipment/Tools
FaceShielcl
by wiping
(;loves
MEK,
NOTE
hptan
with
Discard solution when time to

smut exceeds 2 minutes.
Clonsumables
Etchant, Oakite 160 OR Pennsalt AE17
3,
Rinse in cold running water for 2-3 minutes.
Deositlizel. ST0210~B0001
4.
Dry using heat
~vIethylEthylKetone (MEK), Commercial
Equipment/Tools
Preclean
Air
(2000F max).
Manual Stripping of Anodized Aluminum Surfaces
Procedures
i.
gun
by wiping with MEK.
FaceShield
dry.
Gloves
NOTE
Apron
Oakite 1 60 etchant removes approzimately

rL, per rninute. Pennsalt AElr
re,#.o,lr.r 0.0000~3 to 0.00007 in, per minute,
Consumables
0.00010
Etching Paste, Turco Paste
Immerse part in etching solution (0.5 ounce Oakite

IfiO per gallon of water OR 3 to 6 ounces Pennsalt
AEli per gallon of water) at 135 to 1450F (for Oakite
160) or 100 to 1200F (for Pennsalt AE17) for 1-6
minutes (Oakite 160) or for 1-15 minutes (Pennsalt
AE17) to achieve 0.0004 to 0.0006 metal removal.
in cold
-I.
Rinse
.i.
6.
Immerse part in Deoxidizer solution (12 to 20 ounces

ST0210GB0001 per gallon of water) at room
temperature for 5-15 minutes.
Rinse in cold running water for 2-5 minutes.
7.
Ail
dry
or
running
oven
water
for 2-5 minutes.
No.
Deoxidizer, Jellied, Turco No. 2271
Clean, SoftCloths
Deionized/Distilled Watel
W"ter, Running

ScotchBrite
Masking Tape, Aluminum

SwaborNylon
or
Mylar
Brush
dry (2000F max).
20-1 0-15
Page
Aug
1~/8s
SR-76-023
CORROSION CONTROL blANUAL
CLEANING ALUMINUM AND ALUMINUM ALLOYS (Continued)

Procedure
no not use this procedure in

suspected of containing cracks.
any
area
Do not allow stripping chemicals

7esirlues to penetrate faying surfaces
seams or
i.
to contact
or
of
plated surfaces.
Mask surfaces adjacent to

aluminum or mylar tape.
area
to
be
stripped using.
Remove all loose paint particles using Scotch Erite
dampened with
water.
:3.
Pre-clean surface by wiping with MEK.
4.
Air
6.
Apply and constantly agitate etching paste for fi0-90

seconds using swab or nylon brush.
6.
Wipe
dry.
and rinse
using tap
water
and clean cloths.
7.
Neutralize using Jellied Deoxidizer for ~.5 minutes.
13.
Wipe and tinse using deionized/distilled water and

clean cloths. After deoxidizer removed, remove
masking tape and rinse again.
9.
With stripped area still wet, apply hydrion paper

and observe pH. Repeat wipe/rinse until pH is
between 5 and 8.
1().
~ir clrv
or
~vipe with clean tlry cloth.
20-1 0-15
0
Page 5/6 Blank

Aug 17/84
SR-76-023
CLEANING CORROSION AND HEAT RESISTANT ALLOYS

GENERAL
Finished Parts
This
section prdvides cleaning and passivating

procedures for the following corrosion/heat resistant
alloys:
AISI .700 Series stainless steels:
AISI302
AISI30.7
PIISI 304
AISI 321
AISI 347
In general, parts should meet this definition of

cleanliness: When the presence of foreign matter might
impair the proper functioning of the part.
Parts in contact with a specific liquid corrosive medium
should be free of.all surface contamination. Final cleaning
should be an acid treatment.
AISI 400 Series stainless steels:

AISI 410
AISI 416
Parts subjected to tem peratures of 700"F or higher which

have been formed in Kirksite dies or otherwise contacted
zinc should be acid cleaned to remove the zinc from the
surface.
AISl430
AISI431
AISI440C
Removal
Precipitation hardened steels:
Cleaning Prior
to
fluxes
and
scale
should
be
possible after welding. Inert gasshielded are welded parts do not require chemical or
abrasive cleaning after welding providing weld is free of
flux and scale. Weld scale removal by abrasive or stainless
wire brushing should be followed by passivation
treatment whenever possible.
as soon as
All finished parts should have surfaces free of scale, iron

salts, and foreign metals. Zinc, lead, ferritic iron, and
alloys:
Welding
of welding
accomplished
PH ~r,-7MO
17-1PH
17-7PH
.4-286
:),60
Nickel-base and other

Rene 31
Inconel
Inconel 718
Inconel X
19-9DL
1C3-9D?C
N-15;5
Parts in contact with liquids or pressurized gases, or that

critical in aPpeasance should have surfaces free from
flux, scale, iron salts, foreign metals and other
contaminants,
are
other contaminants have a deleterious effect on corrosionresistance and strength properties. Thin tightly adherent
oxides or discoloration need not be completely removed
unless specifically required.
AISI 400
Series steel
reasonably bright
or
Brazing
C lean i ng requirements vary depend ing on the material to

be welded/brazed and the welding/brazing process to be
used.
Nickel-base alloys (Irn~nel, Inconel 718, Inconel X, and
Rene -C1) should be acid descaled.
~iaterial To Be Heat-Treated
parts should
completion
of
rubber, dirt, lead, zinc, aluminum, magnesium, welding

Flux, pencil marks, etc. Before heat treatment, parts
should be given a "Preiiminary Cleaning" followed by the
proper 1Passivation" treatment. Parts requiring pretreat
coating should ~e cleaned and passivated before application of the coating.
When necessary to avoid stress cracking, formed parts of

PH15-7Mo, 17-4PH, 17-7PH, Y50, and 355 CRES Yteeis
may omit passivation prior to stress relieve. These parts,
however, should be cleaned by either Preliminary or
Delchem 2368A Immersion Alkaline Precleaning methods
below prior to stress relieve.
be smooth
and
passivation.
CLEANING
Preliminary Cleaning
Solvent cleaning or vapor degreasing is used Vvhen visible
oils,
greases, forming lubricants or waxes are present.

Alkaline cleaning is used to remove finger prints, light oil
films. mill markings, layout inks, etc.
Delchem 2368A Immersion Alkaline
Parts to be heat-treated should be free of all grease, oil,
Handle cleaned parts only with clean
upon
Precleaning
Concentration: 8 to i:! ounces/,aallon Delchem

in
tap or soft water. T~vo percent volume of Turco No. 1215
atlditive may be added to extend working life of solution.
Temperature: 180
to 2000F
Time: 15-20 minutes

Rinse: Tap or Demineralized Water, 70 to 1150F, 2-5
minutes or until free rinsing.
gloves.
20-1 0-20
0
COPYRIGHT, Ibu~ BY SABRELINER CORPORATION
Page 1
Aug 17/84
SR-76-023
CLEANING CORROSION AND HEAT RESISTANT ALLOYS (Continued)

Abrasive Cleaning
Acid Descaling
Abrasive cleaning is followed by passivation in an acid

bath. Parts should be free of loose abrasive prior to
passivation. Abrasive cleaning should not be used on parts
which are deformed by such cleaning.
The solutions listed in table 1 are used for acid pickling

and passivation in accordance with the instructions given.
In general, the nitric-hydrofluoric acid descaling baths
are used only for removal of heavy oxides or scale.
Essentially scale free parts are acid pickled to remove
tarnish, light oxidation, or stain. Scale free parts are
treated in the applicable bath designated "Passivate
only." Prior to acid passivation parts should be cleaned.
Parts to be "acid descaled" which are free of oil or grease
may omit "preliminary cleaning." Parts that are to be
cleaned prior to "passivation only" need not be vapor
degreased prior to alkaline cleaning if no oil or grease is
visible.
Sodium Hydride Descaling
The sodium hydride molten salt process may be used by

qualified facilities for removal of heat treat scale. This
process should not be used after process annealing of
PH 15-7 Mo, 17-7 PH, 350 and 355 C RE S steel. These alloys
should be in the fully annealed, equalized, sub-zero
transformed or heat aged condition at any time they are
su bjected to the sodium hydride bath. Parts too large to be
immersed in the sodium hydride bath should not be
descaled by this method as some attack occurs at the
solution level. Parts descaled in the sodium hydride bath
normally require an immersion in the applicable acid
pickle
to
remove
conditioned scale.
Turco 4008 Process

The Turco $008 Process may be used for conditioning of
heat treat and welding scale on all alloys and should be
a,, q~E;
followed hv at? acid
rRPS:~
or
4008-8
~11 PH15-TMa. 17-7PH, 17-aPH and 850 materials, in a11

heat treat conditions except following process anneal
prior to transformation, may be cleaned by the Turco 400t3
process and should be followed by an inhibited acid pickle.
(a)
as
follows:
Turce 12008 Bath: Use concentrated at 260 to 2750F,

add water if temperature rises over 2750F and add
Turco 4008 fresh solution if boiling point falls below
"fiO"F. Immerse parts in solution for 15-90 minutes.
rinse
completely
blasting with
water pressure spray
or
by scrubbing
It is mandatory to descale 17-4PH. PH15-7Mo. 360 and

CRES between full anneal and process anneal.
PH15-7Mo may not be heated above room temperature
after process anneal prior to sub-zero cool. Rene ~lshould
be descaled between the 1Y50"F and 14000F heat treatments. Descaling is accomplished as outlined in table 1, by
abrasive methods, or by the sodium hydride or Turco 4008
Process.
355
Special Methods
Silver brazed assemblies do not normally reyuire
cleaning other than flux removal which can be
accomplished with hot water. Since silver brazing alloy is
rapidly attacked by acid, acid-cleaning of brazed parts
should only be attempted when some loss of brazing alloy
would not be objectionable, as in the case of lap joints
where the majority of the brazing alloy is protected by the
joined sheet.
parts may be immersed a maximum of
five minutes in a solution appropriate to the parent alloy.
(See table i.)
in water.
~rurco ~:-:::8 O~idizing Bath: Use
at ~.siO.:Ii Ibs per

~emperature of 175 to ~OO"F.
Immerse parts 15-~0 minutes. Rinse in water and
!,roceed to acid pickling per table i.
#tlllun of
After immersion in acid, parts are rinsed thoroughly in

tap water. Loosely adherent smut or flux is removed by
stainless steel of hemp brush. Parts are dried

thoroughly using an air blast or oven to remove water
from all laps and joints. Final rinsing in hot water
facilitates drying.
NOTE
operated
To prevent entrapment of nitric-hydrofluoric acid, parts

with lap joints are immersed in water for 2-6 minutes
immediately before processing in the acid descaling
solution.
with
T2LTCO Processes
should not be used,
The Turco 4008 Process is
To prevent excessive metal loss, suitable means should be

used to electrically insulate both baskets and parts being
processed from each other during acid pickling operations.
water at a
NOTE
Ttc~rco 4008 Process malJ be repeated if
required for removal of ezces~ive
o:~idatiolz.
Alloys 355, 303 S. 303 SE, and AISI 400 series are
descaied by mechanical methods only (machining
abrasive tumbling, or abrasive blasting). Parts cleaned
by the mechanical methods are passivated per table i.
20-1 0-20
Page 2
Aug 17/84
COPYRIGHT,
1984 BY YABRELINER CORPORATION
SR-76-023
CLEANING, CORROSION AND HEAT RESISTANT ALLOYS (Continued)

Table t,
Acid Descaling and Passivating Solutions

ALLOY
A.
MAXIMUM IMMERSION
TIME (MINUTES)O
TEMP"F
ACID DESCALING USING NITRIC-HYDROFLUORIC PICKLE
NOTE
Nitric-hydrofluoric pickle solution is 15 to ROO/o Izitric acid, 3 to Ei%

r,5 to 82~0 tap water Percent is by weight.
hydrofluoric acid, and
Roo m
120 to 140
tig
30
Except
12() to 140
30
Room
120 to 140
30
30
12() to 14()
:30
rnconel X and Inconelil8

Heat Aged Condition O
1:0 to 14()
Rene 41 Annealed or Ist Stage

Hardening, 1950"F (1/2 hr)
135 +5
30
135 +5
10
ly~gDX
or
DL Annealed
A286. AISl 300 Series

:30.3 S and 303 SE
17-4PH, 17-7PH, PH15-7Mo,

350 after Full anneal
Inconel and ~ncanelX (5~ lnconel

718 Annealed or Stress
N-l.iS .4nnealed j3
Rene 31 Weldments
B.
Relieved,
INHIBITED PICKLE FOR LIGHT SCALE/OXIDATION REMOVAL OR SUBSEQUENT TO

TURCO 4008 PROCESS. II1
ATOTE
IrLh.ibited pickle Yolut~ion is r to 99/0 nitr~ic acid, 6 to 80/0 TI~RCO 4104, and 88 to NrO/o tap
Loater. Percent is by ~uolume.
PH15-7Mo, 17-7PH, 17-4PH and

850 in all heat treat conditions,
except as noted below
Room
10 Max per cycle.

Cycles may be
repeated providing
total time does not

exceed "0 minutes.
Fusion Weldments of 350. PH15-7Nlo
and 1$-7PH Q
Room
5 Max per
cycle.
Cycles may be
repeated providing
total time does not
exceed 10 minutes.
PH15-7Mo Honeycomb
core
in the
;nnealed, 1/2 C, and transformed

conditions. Rene 41 sheet, and
350
Tubing in
any condition.
Room
5 Max per cycle.

Cycles may be
repeated providing
total time does not

exceed 10 minutes.
20-1 0-20
Page
0
Aug ~7/84
SR-76-023
C()RROSION CONTROL MANUAL
CLEANING, CORROSION AND HEAT RESISTANT ALLOYS ~Continued)

Acid Descaling and
Table 1,
Passivating Solutions (Contd)
ALLOY
PASSIVATING SOLUTIONS
c.
TEMP "F
MAXIMUM IMMERSION
TIME (MINUTES)O
O II
NOTE
Passivation solutionfor below listed alloys is 85 to 45% nitric acid and 55 to 6.5% tap water,
Percent is by weight.
:355 CRES and all other
and 19-9DX or DL
alloy except
400 Series
Room
60
(Minimum)
NOTE
Passivation solutionfor below listed alloys is 85 to 35% nitric acid and 66 to ~5% tap water.
Percent is by weight,
AISI 400 series, except 440 C
120 to 140
15-:30
NOTE
Pa.rsivation solutionfor below listed alloys is ~35 to 45% nitric acid, Yj% sodiUm dichromate,
and 52 to 6~0/0 tap water Percent is by weight,
ATSI 400 series, particulariy 440 C
120
to
140
60-120
NOTE
~-iisJiiiuticis Yullltiunfor below listed alloys is 3,0 to R5% nitric acid and 9r,5 to 99.0% tap
water. Percent is by weight.
19-9DX
or
19 DL
Room
60-120
NOTES:
"~ilaximum" times given may be exceeded providing drawing dimensions are maintained and no
attack (i.e. etching or pitting) is incurred.
13
Acid descaling of Iconel, Iconel X and Iconel 718

parts is permitted only under conditions given in
table 2.
II]
bifluoride may be substituted for

on equivalent fluoride
content, except where the inhibited pickle bath is
used.
Fusion weldments made from anneals PH15-7Mo.

17-7PH, and 350 shall not be pickled in the nitrichydrofluoric acid bath until after the weldments
have been annealed; however, the inhibited pickle
may be used as outlined in table i. Fusion weld
ments of Rene 41 in all conditions elcept the
hardened condition may be pickled as outlined in
table i..
Ammonium
hydrofuuoric acid based
I~
P,lundum ~rit blesti ng may be used as an alternate

descaling method if sections are heavy enough to
prevent
warpage,
O Alloys to
be used on contact with hydrogen peroxide shall be passicated in a solution which does not
contain sodium dichromate.
~cid descaling of fusion welded 19-9DX or DL

is permitted only in the annealed condition.
The "as welded" and welded plus stress-relieved
asse m blies should be ab rasive c leaned followed by
passivation in 1 to 2f/z% vol. nitric acid solution.
alloys
Parts being descaled in an acid pickling solution

si mu Itaneously passivated. Descal i ng solutions
remove metal whereas the passivating solutions
produce little or no dimensional change.
are
When passivating baths are used for clearing

only, as when used for cleaning prior to
heat treatment and prior to pretreat coating, 15-20
minutes immersion is sufficient for removal of zinc,
iron and other foreign metals and contaminants.
purposes
20-1 0-20
Page 4
Aug 17/84
COPYRIGHT, 1984 BY SABRELINFR CORPORATION
SR-76-023
CLEANING, CORROSION AND HEAT RESISTANT ALLOYS (Continued)

Table 2.
Cleaning Inconel, ~nconel X, and Inconel 718,

Condition Of Part
Prior to any of the
Cleaning Method
following operations
Descale per table 1 when "pickle" is

indicated. Otherwise passivate only per
table i.
As welded
Parts heated at 16000F or more in an
atmosphere without pretreat coating
Parts heated
at
1600"F
or more
Parts heated above 1600"F in
atmosphere.
or
Wet or dry blast and

passivate per table i.
oxidizing
(SeeO).
with pretreat coating
Wet
or dry blast and

passivate per table 1 (SeeO).
inert
atmosphere reducing to iron.
a vacuum.
OR
Acid descaie per table i.
Parts heat-treated below 1600aF regardless of
atmosphere.
r\s formed
When acid cleaning is required,

passivate in :35 to 450~ nitric acid
per table i.
NOTE
Small
areas
may be abrasive cleaned with
abrasive;paper, cloth,
07
compo~und.
20-1 0-20
0
COPYRIGHT, 1984 BY SABRELINER CORPORATI~::
Page 5/6 Blank

Aug 17/84
SR-76-023
CLEANING COPPER AND COPPER ALLOYS

GENERAL
Bright Dip Acid Pickling for Copper and Copper

Alloys Except Beryllium Copper
This Yection contains procedures for cleaning copper and

copper alloys. These procedures may be used alone, as
preparation for further processing, or as finish processes
for preceeding operations (such as brazing),
solution,
CLEANING METHODS
Equipment/Tools
Remove light scale from copper/copper alloys (except

beryllium copper) by "bright dipping" in acid pickle
FaceShield
Degreasing
Remove heavy oil and grease by vapor degreasing
solvent methyl ethyl lietone (MEK) wiping.
Abrasive
or
Gloves
by
Cleaning
Apron
Consumables
Heavily scaled parts or parts that cannot be satisfactorily

cleaned by alkaline cleaning or acid pickling should be
cleaned by abrasive blasting.
SulfuricAcid, Commercial
Nitric Acid, Commercial
MethylEthylKetone (MEK), Commercial

Rrazing Flux Removal
Water,Running
Xs soon as possible after brazing, remove uncharred flux

by immersing part in hot(l60 to 2100F) water and scrub,
Remove charred flux by immersing part in sulfuric acid
solution(tO to 15% sulfuric acid in waterj

for 1() minutes.
at 135 to
145"F
Alkaline Cleaning
prior
pickling, remove ordinary contaminants from

parts by alkaline cleaning,
to
Air, Dry, Filtered(5 Micron)

Pocedure
1.
Preclean by wiping with MEK.
2,
kirdry,
3.
Dip part in bright dip acid pickle solution (58 to 62?/0

sulfuric acid, 6 to 8~0 nitric acid, 30 to:36% water
all percent by weight) at room temperature for 15-30
seconds.
Ecluipment/Tools
FaceShield
(;loves
Xpron
Rinse in cold,
5.
Blow dry using
running
water
dry, filtered
for 1 minute.
air.
Descaling Acid Pickling for Copper and

Copper Alloys
Consumables
Alkaline
4.
CleaningCompound, LB0210-~09
"I~thyl Ethyl Ketone (MEK), Commercial
Remove scale from any copper/copper alloy parts by

3291 descalig acid pickle.
using Truce
Equipment/Tools
Water. Running
FaceShield
r~ir. Dry, Filtered(5 Micron)
C;loves
Apron
Procedure
i.
Preclean
2.
Air dry.
Descaler,TurcoNo. 3291
8.
Immerse part in alkaline cleaning solution (5 to 8

ounces alkaline cleaning compound per gallon of
water) at 185 to 2100F for 5-15 minutes as needed to
clean part.
BattelleChemical Polish
by wiping with .MEK.
4.
Rinse in cold running
5.
Blow dry
Consumables
Water,Running
Air, Dry, Filtered (5 Micron)
water for 2-3 minutes.
using dry, filtered air.
20-1 0-25
0
Page 1
Aug 17/84
SR-76-023
CLEANING COPPER AND
doPPER
ALLOYS (Continued)
Procedure
I.
Preclean
2.
Air
3.
by wiping with MEK.
dry.
Immerse part in descaling acid pickle solution (8

Turco No. 3291 in a gallon of water) at 135 to
1450 F for 2 minutes.
ounces
4.
Rinse in cold,
5.
Blow dry using dry, filtered air.
ti.
Brighten surface by dipping in Battelle Chemical

Polish at 130 to 1500F for 1-2 minutes.
7.
Rinse in hot, running water

seconds minimum.
8.
Blow
water 5 seconds minimum.
running
(140
to
1800F) for
10
dry using dry. filtered air.
Descnling Acid Pickling For Beryllium Copper

Only
Removt~ ~icale from beryl I iurn copper al loy using descaling
anti bliahtt clip pickling solutions.
Equipment/Tools
FaceShield
(;loves
Apron
Consumables
~uifuric Acid, Commercial
Nitric Acid.Commercial
~Iethyl Ethyl Ketone IMEK). Commercial

Water. Running
Air, Dry, Filtered (5 Micron)

Procedure
I.
Preclean by wiping with MEK.
X.
immerse part in descaling acid pickle solution (400~,

sulfuric acid, 60% water by weight) at 140 to 1450F
for up to 40 minutes ma.u. as needed to remove scale.
i.
Rinse in cold,
running
water
for 15-45 seconds.
Immerse part in bright dip acid pickle solution (58 to

6%,L sulfuric acid, 8 to 110/o nitric acid, 27 to 40%
water
by weight)
at
room
temperature for 10-30
seconds.
K~
RinYe in cold. running
7.
Blow
water
for 1 minute.
dry using dry, filtered air.
20-1 0-25
Page 2
Aug 17/84
COPYRIGHT,
SR-76-023
CLEANING TITANIUM AND TITANIUM ALLOYS

GENERAL
removed
This section covers mechanical and chemical

processes for titanium and titanium alloys.
limitations,
are
process
cleaning
Various
requirements, and chemical solutions
included.
of the following
dry blasting, motor driven low
alloy steel brushes (not stainless), or hand abrasion with
180 grit or finer silicon carbide cloth or paper or steel wool
(not stainless steel), Follow abrasive cleaning with mild
acid
PROCESS LIMITATION
The
following limitations should be observed when

cleaning or descaling titanium and titanium alloys by
eithel mechanical
or
chemical methods.
Chlorinated solvents and other halogenated solvents

including freons should not be used.
Assemblies with areas difficult to rinse or that contain
d issim i lar metals should not be processed th rough an acid
bath.
Abrasive cleaning must not cause the part dimensions,
rface rough ness, or contour to deviate from the drawing
callout. Abrasives used for either wet or dry blasting of
scale from titanium and titanium alloys should be
nonmetallic.
by machining
abrasive methods: Wet
or one or more
or
cleaning.
Surfaces examined without magnification shall be free of

all mill marks, grease, finger prints, scale and foreign
metal contamination. Blue discoloration resulting from
thermal processing is acceptable as a final surface finish
provided that the part will either be painted or located in
an area which will not normally be visible.
Local pitting
or
"islands" indicate excessive pickling.
A"y gbrasive method selected for removing patches of

tenacious scale from appearance-critical parts should
take into consideration the need to produce a uniform
appearing surface.
su
C;rinding
or
machining
may be used to
remove
scale
or
contaminated metal,
Commercial emulsion cleaners, alkaline cleaners, and

other non-etching aqueous alkaline baths not formulated
with chlorides or chlorinated solvents may be used.
PROCESSING REQUIREMENTS
W~-ien parts have a bright, metallic appearing surface
Free of all scale, foreign metal. and visible contamination
inclutlina blue surface discoloration resulting from
thermal processing, further cleaning is not required.
Clean pal~ts to a water break free surface before immersion

in either the nitric-hydrofluoric acid descaling solution or
mild acid cleaning solution,
Process scaled parts through the alkaline scale
conditioning bath before processing through the nitrich!:rlrofl uo ric
ac id
Parts.ihouid
not
PROCESSING SOLUTIONS
Titanium Pickle Solution
Use the following solution for acid descaling, brightening,
etching, and metal removal.
INGREDIENT OR
PROPERTY
Nitric Acirl
(Cc,mmercial.
6:~ to 70~0 (vol)
Bau~ne,
Ammonium Bifluoride
(Commercial)
From 4.~ to Il.loz/~al

necessary to maintain
etch rate.
W"ter (j0,000 ohm/cm
Balance
as
specific resistance,
minimum)
Etch Rate
0.002Fj to O.OCT,
in.~surface/hr.
descal i n~ bath.
touch other metals
CONTROL RANGE
or
each other except
Tt~"l)elature
7;3
to
1000F
edges during descaling. Spacing should be such that

flow of descaling and rinse solution is not restricted.
at
Immersion for scale removal only is limited to the time

to remove 0.001 in./surface. Scale not removed
within this time limitation should be removed
required
mechanically.
Patches of tenacious scale remaining after two complete
cycles through the alkaline scale conditioning bath and
nitric-hydrofluoric acid descaling bath shall either be
20-1 0-30
0
COPVRIGHT, 1984 BY SABRELINER CORPORATION
Pagt
Aug 17/84
SR-76-023
CORR()SION CONTROL MANUAL
CLEANING TITANIUM AND TITANIUM hLLO;YS (Continued)

Titanium Scale Conditioning Solution
following solution or Turco 4316 for scale conditioning prior to acid descaling.
Use the
INGREDIENT OR
PROPERTY
CONTROL RANGE
Sodium Hydroxide
1.5.1 to 6.7
Sodium Dichromate
1.3 to 2.7
Water (50.000 ohm/cm

specific resistance.
Balance
Ib/gal
oz/gal
minimum)
Tempelature
Mild Acid
265 to 2900F
Cleaning Solution
U~e the following solution for mild acid cleaning to

remove iron and other foreign metal contamination from
tormed and machined parts and to remove smut remaining
aftel acid descaling.
INGREDIENT OR
PROPERTY
Nitric Acid
CONTROL RANGE
45 to 60%
(vol)
ICommercial. 12.Baume)
1Vatel (50.0()0 ohm/cm
Balance
.ipecific resistance.
m~nimnm)
Temperature
Ambient
20-1 0-30
Page 2
Aug 17/84
COPYRIGI :T, 198~ Rv SABRELINER CORPORATION
SR-76-023
CLEANING PLASTIC AND GLASS

GENERAL
This section covers materials and procedures to be used
for cleaning plastic materials, glass, and other plastic
sheet, laminated, or molded materials. These procedures
may be ~sed for removing grease and dirt acquired
during normal use or for general airplane cleanup.
the surface. This creates non-parallel surfaces causing

distortion of vision which in most cases is worse than the
impairment caused by the scratches.
Procedure for Cleaning Transparent

Plastic Materials
MATERIALS
Flush the canopy with an ample supply of water, using the

hands to loosen any dust, dirt, or caked mud.
Cleaning Materials For Transparent Plastics
Any thin film of grime, grease, or residue may be removed

by washing with a 10X castile soap solution, Dry with
and Glass
Nu-Wipe tissue,
Castile Soap
(10!il Solution)
Hockwald Chemical Co.

Los Angeles 22, CA
Cleaning Solvent
LB0210-102
Glnsticote 18,
Cleaning and
R, Killion, Industrial
and Domestic Silicone
Polishing Compound
Distributors,
Los
Angeles 22, CA
~iu-Wipe Paper Tissue
Lacquerwax Co.,
Toweling
Hartford
CT
Cleaning Materials For Teflon And Kel-F

Tr?luer?e
TT-T-548
~iylene
TT-X-916
Oaklite No, 61
MIL-W-cj1G0
Cleaning Solvent
LB0210-102
Cleaning ~Iaterials For Phenolics

Sulvent. Dry-Cleaning
cst,,ltiald Solvent)
P-S-~iG1
Cleaning
LB0210-102
Solvent
Any residual film may be removed by cleaning with

Glasticote 18 soaked in Nu-Wipe tissue. ~his will also add
a final polish and luster to the canopy.
Procedure for
Cleaning Laminated Glass
Laminated glass is composed of non-organic materials

and is not attacked in any way by the solvents commonly
in use. Paint overspray, smears, etc., may therefore be
removed by any com mon ly used solvent, such as Stoddard
solvent, but care must be taken that other solvents do not
come in contact with adjacent transparent plastics.
Laminated glass can be broken, chipped. or scratched
easily. It is fagile and should be handled with a maximum
of care.
To
CLEANING PROCEDURES
Carbon tetrachloride, iso-propyl alcohol, thinners, strippers,

and
materials, (most organic solvents) s:lc~uld not
be I.ised on transparent acrylics. These materials will
;o Fren the plastic or cause crazing. resulting in scrapping
~he part,
Do not rub plastic with a dry cloth or tissue since this is not
only likely to cause scratches, but it also builds up an
electrostatic charge which attracts dust particles to the
surface.
Keep cloths and
If a considerable amount of greasy deposits adhere to the

surface of transparent plastic material, it must first be
removed with cleaning solvent LB0210-102. This is done
by soaking Nu-Wipe tissue with the cleaner and wiping
lightly over the surface to be cleaned. All heavy grease
will be removed, leaving only a, thin film of residue.
sponges free of dirt,

water.
remove sulface smears and films, laminated glass

should be cleaned by rubbing the surface with a soft, clean
cloth or tissue wet with Clasticote 18. This will also add a
final polish and luster to the glass.
Procedures for Cleaning Teflon and Kel-F Sheet

Materials
Teflon and Kel-F mal be cleaned ~vith ~olvenU either by
immersion in the solution or by wiping with a rag wetted
with the solvent.
These materials can also be cleaned by immersing them in
a 10~ solution of caustic soda or a solution of
to 8 ounces
of Oakite No, 61 (or equivalent) per gallon of water, at a
temperature of 120 to 1800F.
dllst, and,orit by
rinsing frequently in clean
Procedures for
Exchange soiled cloths or tissues for clean ones, rather

sclatching the plastic. Scratches cannot be
polished out without removing materials from
Phenolic laminated, cast, or molded surfaces may be

washed with a 100/o solution of castile soap or may be
cleaned by wiping with a rag wetted with Stoddard
solvent,
than risk
buffed or
Cleaning Phenalic: Surfaces
20-1 0-35
0
COPYRIGHT, 1984 BY SABRELINER CZ~PORATION
Page 1/2 Blank

Aug 17/84
SR-76-023
POLISHING SHEET ACRYLIC PLASTIC

GENERAL
2.
This section covers

blemished surfaces
repelishing of scratched, abraded,

on acrylic plastic parts,
or
Sheet acrylic (methylmethacrylate plastic) is relatively

soft compared to glass. Furthermore, it is thermoplastic
and softens under the influence of heat developed during
santlingor buffingoperations. Repolishing usually results
in a finish of poorer optical quality than that of the
untouched sheeting,
sand the surf ace in a circular cloverleaf pattern with

a minimum diameter of 6 in. A power sander may be
used on Plexiglas 55,
3.
After deep scratches have been removed, rinse the

surface thoroughly with clean water, rubbing with
the hands to loosen any abrasive or foreign matter.
4,
Dry the panel with

with wati!r,
5.
The remaining scratches in the sanded area should

be approximately 0.00:3 in. in depth when
In canopy
panels or surfaces having a critical area, the

max depth of scratches permissible for rework is 0.015 in.
In I,anels having a noncriticai area, the max depth of
scratches permissible for rework is 0.025 in.
Using No, 400A sandpaper (preferably wet)

wrapped around a wood or rubber block or shot bag,
clean, damp, flannel cloth,
wet
of Macs Super Gloss Polish to a damp

flannel cloth (wet with water) which is wrapped
around a wood or rubber block or shot bag and polish
the entire area in a circular cloverleaf pattern, as
with the sandpaper.
amount
MATERIALS
The following materials
are needed to repolish acrylic

plastic parts. They may be replaced by materials
i necl to be equal c,r better.
Santl~,aper.
wet
grits from :~2()A
or
to
Minnesota
dry,
HO()A
If
Mining
Mfg, Co.,
Los Angeles, CA
Fine At,rasive.
soft flannel
power buffer
is used
for final
polishing, the procedure shall be identical with hand

polishing except for the substitution of the power
machine. Apply one coat of Indosil 27A Compound or
Tyl,e A:5i7.:,
Linde Co., Div. of

Union Carbide Corp.,
Los Angeles, CA
Hantl rubl,ing compound,

M:lcs Supel (;loss
Macs Super Closs Co.,

Los Angeles. CA
(;lasticote 1X
P. Killion
Los Angeles, CA
I n( lox i I ;A Com pou ntl
Indosil Co.,
Resetla, CA
Glasticote 18 to the polished

cloth and then wipe dry.
6.
area
with
clean flan nel
After the scratches have been removed, rinse the

water., rubbing with the
hands to loosen any abrasive or foreign matter, anti
wipe dry with a clean, damp, flannel cloth wet with
water. Remove any residual grease or heavy
contamination with LB021O-I02 cleaning solvent.
panel thoroughly with clean
EQU IPMENT/TOOLS
National Air Sander,
No. 10()
Zonne Electrical Tool Co..

Los Angeles, California
Soft flannel power

bu ffel
Commercial
Shot baK.
Commercial
approsimatelv
-I sls:!inc.. 3.~#
The po"e, sander should

The power buffer should
only be used
not
on
Plexiglas
55.
be used in critical optical
are:ls.
REMOVING SCRAT~HES
To remove scratches in
fo Ilowing procedure:
i.
(lean and nash
acrylic plastic surfaces,
use
the
aiea.
20-1 0-40
Page 1/2 Blank
0
COPYRIGHT, 1984 BY
CORPORATION
Aug 17/84
SR-76-023
STRIPPING ORGANIC FINISHES

GENERAL
This section
covers the materials and procedures needed

strip organic finishes from metal surfaces, plastic
sheet, laminates, and molded materials,
Parts containing plastic, mLbber, or other

nonmetallic components should not be
immersed.
MATERIALS
Dissimilar metals should not be placed in
to
the hot alkaline
Nitrocellulose Lacquer Thinner,

MIL-T-19fj44
Alkaline Rust Remover (Oakite Rust Stripper),
Butyl Alcohol, TT-B-846
Butyl Acetate, TT-B-8:36
Cellulose Nitrate Dope and Lacquer Thinner,
TT-T-266
Cloths, Mill-End, Lint Free, Commercial
Cold Immersion Paint Stripper, (Kelite 1006, or
equivalent), NA3-Fj17Fj
Compound, PR1:301 HT. Products Research Co.
MIL-A-6091
Ethyl Alcohol,
Ethyl Acetate, TT-E-7.il
Isopropyl Alcohol, 99"/n, MIL-F-5566
Methyl Ethyl Ketone (MEK), TT-M-261
M i neral Petroleum) Spirits, TT-T-291
Acrylic
Naphtha, Petroleum, Aromatic (For use in organic

coatings); TT-N-97
Paint and Lacquer Remover, Solvent Type,
iMIL-R-2rj134
Pressure Sensitive Adhesive Tape No, 354 (red
preferred. other colors acceptable, or equivalent),
Dutch Brand Division, Johns-Manville Co.
Sandpaper. No. ~20. No. 400, Commercial
Stripper, Paint, Hot Immersion Liquid. NonAqueous, RB0210-007
Stripper. Chem-iMill, NA~-S188. Type II
Stripper, Turco No. 4737. No. 5059 and No. j06~,
Turco Products, Inc.
Synthetic Enamel Thinner, TT-T-306
Toluene (For use in organic coatings),
Xylene (For use in organic coatings), TT-X-916
STRIPPING METHODS
Organic finishes
metal surfaces should be stripped in

accordance with table 1 when rework, refinishing, or
inspection requires removal of the finish.
on
When primer. lacquer, enamel, or synthetic rubber

coatings are to be removed from plastic sheet and laminated or molded plastics. only methyl ethyl ketone(ME K),
nal,htha, toluene, or,uylene should be used,
Immersion
Stripping
To remove organic finishes from metal surfaces, immerse

the work in the proper stripper indicated in table i. The
entire part should be totally immersed.
stripper
at the
same
time.
Assemblies haviny voids where harmful

residues may become entrapped should not
be immersed.
Immerse the work only long enough to loosen finish.
Usually 15-20 minutes is sufficient.
Remove work from tank and blast off loosened finish with
high-pressure water sprays or steam. Fiber-brush areas

of incompletely removed finish, repeating immersion and
water blast
as
necessary.
Thoroughly rinse with high-pressure
water.
preferably
hot.
Dry the part using compressed air blast, wiping with

clean, dry cloths, or allowing to remain racked until
air-dried.
Eruah-Or;
Stripping
To remove organic finishes from metallic surfaces by the

brush-on procedure, the following sequence should be
followed:
Masking
Prior to stripping
indicated:
Plastic, rubber,
by this method, mask the following
as
other nonmetallic surfaces including

or sealed joints: Use No. 9Tj~
pressure sensitive adhesive tape.
or
aerodynamically smoothed
Access door joi nts and ho res:
App ly PR1301 HT com pou nd.
Apply No. 354 tape over the PR1301 HT compound,

overlPyping the adjacent surfaces.
Lubricated bearings: Use No. Xri4 pressule sensitive
adhesive tape.
Electrical equipment and wiring: Use either No. 13Fj4 tape.

apply PR1301 HT compound with a knife, as applicable.
or
Application of Stripper
Brush or spray (nonatomizing) liberal amounts of the well
mixed stripper indicated in table 1 on surface to be
stripped. applying to an area no larger than that which
can reasonably be worked. When using brush. apply in
Surface must remain moist with
one direction only.
stripper.
20-1 0-45
0
Page 1
A~g 17/84
SR-76-023
STRIPPING ORGANIC FINISHES

Brush-On
Stripping (Contd)
Refinishing Metallic Surfaces

Surface Treatment Undamaged
Application of Stripper (Contd)

Allow stripper to remain undisturbed until finish is
completely loosened, as indicated by wrinkling or
discoloration. This may require 15 minutes to 2 hours
depending on the type of finish being stripped.
If stri ppi ng is incomplete,
fresh stripper.
remove
old stripper and
stripped surface should be refinished
by scrubbing with
fiber
is
required.
If, after stripping organ ic coatings, the underlying surface

are found to be damaged, the surface should
be repaired or reworked, with the following exceptions:
Exception No. 1- Damaged Chemical Films (Colorless):

Strip the entire coating and refinish.
care
to
Exception No. 2 Damaged Phosphate Coatings: Strip the

coating and refinish.
entire
Exception No. 3
Magnesium Alloy
Drying
Dry the surface completely using compressed
clean, dry, lint-free cloths.
air blast
toluene should be used to
Damaged Dichromate Treated

Strip the entire coating and
Parts:
etreat.
or
Damaged Surface Finishes Adjacent

To
Stripping Coatings from Plastic Materials

or
required without
treatments
Pressure water rinse the cleaned surface, taking

direct water stream into all seams and joints.
MEI(, naphtha,
as
further treatment, unless an alternative surface treatment
Surface Treatment Damaged
Rinsing
remove
primer, lacquer, or enamel from polyester, epoxy, or

phenolic resin bonded materials. Any of these solvents
may also be used to remove paint over-spray from Teflon
or
If, after stripping organic coatings, the underlyingsurface

treatments are found to be undamaged, the dry, clean,
reapply
Removal Of Loosened Finish

The loosened finish is removed
brush, squeegee, or cloth.
~Continwed)
Stripped
Areas
Finished surfaces, adjacent to stripped area; which have

been spotted by spilled stripper, shall be thoroughly
washed with water, dried completely, scuff sanded and
touched up with the required finish.
Kel-F.
Allow part to dry, then lightly sand with No. 320 or No.
400 sandpaper. Wipe with clean dry, lint-free cloths.
Cured synthetic
polyester,
rubber
epoxy, and
coatings are removed from

phenolic resin bonded materials as
follows:
Cover the rubber coating with a blanket of cheesecloth
thoroughly saturated with toluent. The cloth is kept wet
with toluene for 3-5 minutes,
The softened rubber coating is removed using
knife and
putty
fingers.
NOTE
In addition to toluene, it is
pelr~zissible to
~naphtha ~individually
or in combination) to soften the coating or
to remove coating residue.
use
MEK, zylene,
or
Allow part to
400
dry, then lightly sand with No. 320 or No.

sandpaper. Wipe with a clean, dry, lint-free cloth.
20-1 0-45
Page 2
Aug 17/84
COPYRlGHl, 1984 BY SABRELINER CORF~?D.9TION
SR-76-023
STRIPPING ORGANIC FINISHES (Continued)

Table 1.
Finishes, Strippers, and Thinners

TYPE OR STRIPPER
FINISH
Enamels
MIL-E-7729
Type I
Type
IMMERSION
NA3-5175,
BRUSH-ON
MIL-R-25134
or
THINNERS
TT-N-97, Type I, Grade B
MIL-R-25134
Naphtha,or
TT-T-291 Mineral
Spirits
II
Type III
MIL-R-25334
MIL-R-25134
TT-X-916 Xylene
NA3-5175
MI~L-R-2Fj134
TT-T-306 Synthetic Enamel

Thinner
Class B
MIL-R-25134
MIL-R-25134
TT-X-916 Xylene
Lacquers
MIL-R-25134,
MI1-R-25134
TT-T-266 Dope
Thinner
TY-E-Fj29
Class A
MIL-R-2~134,
or
or
MIL-L-7178
(Cellulose Nitrate)
Lacquer
NA3-rj17Fj
MIL-L-19Fi:37
(Acrylic-Nitrocellulose)
RS0210-007
MIL-T-19fj44 Lacquer Thinner
Wash Primer
MII,-C-8Fj14
MIL-R-25134
MIL-R-25134
Epoxy Base Paint
NA3-517Fj
Turco No. 47.77
Turco No..5063
Turco No. 5050
TT-B-846 Butyl Alcohol plus

MIL-F-Fifj66 Isopropyl Alcohol
plus MIL-ABOS1 Ethyl Alcohol
Polyurethane Coating
MIL-C-~7227
MB012Fj-002, AB0130-007
TT-M-261(MEK)
AB0130-022, MB0120-02L
Urelane 241
Primers
TT-T-.548 Toluene plus
;MIL-P-85(3Fj
(Zinc Chromate)
MIL-R-25134
MIL-P-26915
II
Types I
(Zine Dust Primer)
NA3-.517rj
TT-X-916 Xylene
or
MIL-R-25 134
TT-T-;291 Mineral Spirits,

TT-T-548 Toluene
or
RB0210-007
TT-T-306 Syntktic Enamel
Thinner,
Varnishes
MIL-V-liY
MIL-R-25134
AB0125-008
M~L-R-25134
MIL-R-25134,
or
TT-T-548 Toluene,
TT-X-916 Xylene
or
or
TT-M-261 (MEK)
Aluminum Colored
EC843Fj
NA3-5188,
(Corogard 14)
Type
TT-M-261
II
(MEK)
(for small areas)
TT-E-751 Ethyl Acetate

(3 parts by vol.) plus
TT-B-838 Butyl Acetate
(1 part by vol.), or
TT-M-261(MEK)
(1 part by vol.) plus
TT-T-548 Toluene (1 part by vol.)
20-1 0-45
0
Page 3/4 Blank

Aug 17/84
SR-76-023
STRIPPING ORGANIC COATINGS FROM METALS

GENERAL
This section
STRIPPING METHODS
materials and procedures required to

strip organic coatings from metals. This section does not
cover stripping inorganic coatings, nor does it cover
stripping coatings from non-metallic surfaces.
covers
MATERIALS
Lead Backed Pressure
Sensitive Tape No. 420,
or
Minnestoa Mining and

Manufacturing Co.
equivalent
Stripper, Turco
5061
Turco Products, Division

of Purer Corporation
Stripper, Turco
5092

Stripper, Turco 5238

Stripper, Cee Bee A-29S
MIL-R-25134
Paint and
Stripper, Kelite 1006
Kelite Products Co.
Nitric
Cee-Bee Chemical Co.
or
Stripper MX-7,
equivalent
Lacquer Remover
MIL-D-6998
Dichloromethane, Technical
0-N-350
Ni-tric Acid
(70 percent concentrated)

MB0225-001, Type
Cab-O-Sil M5,
Coating, Vinyl, Strippable

G.L. Cabot Corp.,
or
equivalent
Boston, MA
TT-M-261
Methyl Ethyl Ketone
Compound PR1301 HT,
or
equivalent
Organic coatings are removed by chemical strippers, by

abrasive blasting, or by hand sanding.
All materials or surfaces subject to damage by the
stripper should be masked. Outline the area to be stripped
with masking to prevent damage to adjacent areas.
Surfaces that require masking include crevices, holes,
joints, seams, aerodynamically smoothed surfaces and
lubricated areas. Materials that require masking include
non-metals and metals subject to attack by the stripper.
Use Compound PR1301HT to putty irregular steps or
holes, etc. in the surrounding area to which tape will not
conform.
Use polyethylene sheets or equivalent to cover large areas

wrap protruding hardware adjacent to the stripping
or
area.
Use lead backed tape No. 420 to outline stripping area and
tape down polyethylene sheets and wraps. Lead backed
tape No. 420 is used because of its compatibility with the
strippers of table 1 and its lack of adhesive transfer

base metal or primer.
to the
General purpose tape may be used where it will not be in

contact with a stripper and there is no concern with
adhesive transfer (e.g., not on a surface which will be
subsequently bonded or processed). General purpose tape
may also be used for abrasive blasting masking where
adhesive transfer is not a problem.
Chemical paint strippers contain chlorinated
hydrocarbons. When stripping with these materials, they
must be used in areas with adequate ventilation such as
out-of-doors, under a fume hood, or in front of a spray
booth.
The
area
to be
stripped should be dry prior
to
applying
stripper.
Polyethylene sheet,
equivalent
Commercially Available
pH Indicating Paper
Abrasive Alumina
Silica, 220 grit
Commercially
or
Once
chemical stripping operation has been started, it

uninterrupted until completion.
must continue
or
General Purpose
Available
When stripping is completed, the stripped area should be

cleaned, dried, and protected. Adjacent coatings
damaged by the stripper shall be refinished.
Masking Tape
Turcoform 622A
Demask
Scotch Brite Abrasive,

Type A, Coarse Grit
3M
Company
20-10-50
oCOPYRIGHT, 1984 BY SABRELINER CORPQRATION
Page 1
Aug 17/84
8B-76-023
STRIPPING ORGANIC COATINGS FROM METALS (Continued)
Immerse work in the

table 1.
IIWIIIIUI~
Except MB0120-032
Immersion Stripping
Primer on Aluminum
applicable stripper indicated
Complete the rinsing operation as quickly

possible. Following rinsing, wipe all
surfaces where water has collected with
clean cheeeeeeoth or rage until tLey are
visibly dry.
in
as
I1BR1Ii~
Do NOTintncerse parts containing plastic,
rubber or Otter non-metallic components
DoNOTintmerse
8armful
entrapped.
inwhich
residues
might
become
racked until air-dried.
Allow work to remain immersed only long enough to

loosen the coating. Usually 15-20 minutes is sufficient.
Remove work from tankand blast off loosened coating
with high pressure water spray or steam. Brush off
loosely attached coating with a brush compatible with the
stripper, such as nylon or soft wire. Repeat immersion and
water/steam blast
as
Final drying should be started within one hour after

stripping by oven drying for one hour minimum at 230
f150F (except chemical filmed parts should not be heated
above 1350F), by blow drying using clean, compressed air,
by wiping with clean, dry cloths, or by allowing to remain
necessary to
remove
coating.
Thoroughly rinse with high pressure hot water until part

is the same pH as the rinse water when checked with pH
indicator paper.
Final drying should be started within
one
hour after
stripping by oven drying for one hour minimum at 230

~150F (except chemical filmed parts should not be heated
above 1350F), by blow drying using clean, compressed air,
by wiping with clean, dry cloths, or by allowingto remain
Brush
or
Spray Stripping
spray (non-atomized) liberal amounts of wellstripper indicated in table 1 on surface to be

stripped, applying to an area no larger than can ressonably be worked. If using brush, apply in one direction only.
Surface must remain moist with stripper.
Brush
mixed
or
stripper to remain undisturbed until coating apcompletely loosened, indicated by wrinkling and
discoloration. This may require two minutes to two hours
depending on the type of coating being stripped.
Allow
pears
Remove loosened coating by scrubbing with

squeegee, cloths, fine aluminum
water spray.
MB0120-032 Primer
If
Immerse part or assembly in concentrated nitric acid

(0-N-350). Allow the stripper to remain undisturbed
until the coating appears completely loosened as indicated
by wrinkling and/or discoloration.
Remove the part from the stripping tank and pressureremove the primer with tap water. Residual primer, if
present, shall be removed by scouring with fine aluminum wool or by repeating immersion and water blast.
is
completed, thoroughly
brush,
pressure
stripper to remain in contact

with surface any longer than is necessary
to
Aluminum surfaces eh~ould not be ezposed

to the stripperfor MBOlgO-05~ primer in
excess offour hours total.
stripping
high
Do not allow
on
In!lRllllal
When all
or
NOTE
racked until air-dried.

Immersion Stripping
Aluminum
wool,
remove
the
coating.
stripping is incomplete, reapply stripper and

as above. Repeat as required to
loosened coating
all coating.
remove
remove
Pressure-rinse the cleaned surface using hot water, taking care to direct the water stream into all areas that
could possibly entrap the stripper until surface is the
same pH as the rinse water when checked with pH
indicator paper.
Dry the surface completely using dry, compressed air

clean, dry cloths.
Manual Stripping
Aluminum
MB0120-032 Primer
or
on
rinse with
pressure hot water until part is the same pH as the

rinse water when checked with pH indicator paper.
IglBgBlPI
high
Use this stripper under ambient conditions oldy.

Use MX-7
or
nitric acid stripper mixed
as
follows for this
operation.
20-1 0-50
Page 2
Sep 6/91
8B-76-023
STRIPPING ORGANIC COATINGS FROM 1VIETALS (Continued)

Manual Stripping
Aluminum (Contd)
MB0120-032 Primer
on
Place in a polyethylene or other suitable material container the amount of concentrated nitric acid (0-N-3S0)
expected to be used. Add to this just enough Cab-O-Sil MS
to thicken the nitric acid so that it adheres to a vertical
surface such as the stainless steel, or equivalent, tool used
to mix the "jelly". Unused "jelly" will be discarded.
Areas to be maskedand
with clean cloths.
stripped
must be
dry. Wipe dry
Apply stripper with a stainless steel spatula or equivalent. Allow stripper to remain undisturbed until coating
appears completely loosened as indicated by wrinkling
and discoloration.
Remove primer with high pressure water spray and/or
fine aluminum wool.
If surface is not free of residues, repeat stripper application and removal as above.
When all stripping is completed, thoroughly rinse with

high pressure hot water until part is the same pH as the
rinse water when checked with pH indicator paper.
Dry surface completely using dry, compressed air

clean, dry cloths.
or
Abrasive Blast Stripping

Abrasive blasting is
when the
an
acceptable method of stripping
following conditions
Use 220 grit aluminum oxide
are
met:
(alumina) or silica (sand).
Nozzle pressure should be between 30 and 50 psi.

Do not dwell in one spot; keep the blasting nozzle moving.
On skins less than 0.020 in. thick a test skin should be
processed to determine that warpage will not occur from
the peening effect.
Hand Sanding
Hand sanding with 180 grit or finer abrasive paper is an

acceptable method of stripping small areas.
Power Abrading
Hand operated power tools fitted with Scotch Brite abrasive brushes are acceptable for stripping small areas.
Abrasive brushes can be fabricated from circular sections
of Type A, coarse grit Scotch Brite mounted on a threaded
mandrel. Each section of Scotch Brite shall be separated
with spacers approximately 3/32 in. thick.
20-1 0-50
Page3
Sep 6/91
SR-76-023
STRIPPING ORGANIC COATINGS FROM METALS (Continued)

Table 1.
(=hemicaiStrippers
A,
fi
L~
oi;u?
METHOD/PSTRIPPER
i~
,t;
g
Cj
e,
ul:
NOTES
G1P-3
t~
III
Cone. Nitric Acid
Turcoform 622A
111
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
t3
c;
~C);/
Immersion
Cee-Bee A-29S
Turco
Kelite 1006
Turco 5092
Demask
Brush-On
Cee-Bee A-29S
Kelite 1006
Turco .5288
Cee-Bee M.X-7
Turco Ti092
MII,-R-2rj134
Vapor Deffrease
NOTES
O
O
O
Forexpoxy coatings
For MB0120-032
primer
ForTurcoform522 Maskant
Concentrated nitric acid thickened with Cab-O-Sil MFj is
O
t~
an
equivalent
to Cee-Bee MX-7
For Organocerams 1-2020 Maskant
Strippers recommended for use on specific metals, but not recommended for removal of a specific coating are
effective in removing all types of coatings on this metal; however, they are usually very slow acting on expoxy
coatings.
20.1 0-50
Page 4
Aug 17/84
oCOPYRIGHT, 1984 BY SABRELINER CORPORATION
SR-76-023
SOLVENT VAPOR DEGREASING

GENERAL
This section covers removal of oil and grease contaminants from metal parts (except titanium) by the following
solvent vapor degreasing methods:
i.
Vapor only
2.
Vapor-spray-vapor
3.
Immersion-vapor
4.
Immersion-spray-vapor
Asse m b I ies contai n ing parts havi ng nonmetallic portions,

such as oil-impregnated sintered bearings, etc., which
might be damaged by vapor degreasing should not be
degreased.
Titanium alloys should not be cleaned using the solvents
specified herein.
All holding fixtures in contact with solvent, such as racks
and baskets and their associated parts such as chains and
hooks, be of corrosion resistant metal. Baskets should be
constructed of expanded or perforated corrosion resistant
metal or mesh. If required to protect parts, baskets should
be lined or coated with Teflon or other solvent resistant
Degreasing Solvent
Degreasing solvents are perchloroethylene conforming to
0-T-236; l,l,l-trichloroethane
conforming to
ST0210GB0002; or trichloroethylene conforming to MILT-27602 or 0-T-634, Type II. (Trichloroethylene and 1,1,1trichloroethane may be used in all applications described
herein, but perchloroethylene is intended specifically for
use in the "vapor only" type of degreaser.)
The
pH of a water extract of trichloroethylene or

perchloroethylene should not be lower than 7.0. The acid
acceptance value of l,l.l-trichloroethane
should not be
less than 0.050/0.
Solvents must be maintained at a temperature sufficient

to maintain a vapor phase, but the temperature should not
exceed the following values:
Trichloroethylene:
19.5"F
17FjOF
25fjoF
l,l.l-Trichloroethane:
Perchloroethylene:
DEGREASING TECHNIQUES
Vapor Only Degreasing
coating.
1.
Lower the part into the
Hang or rack parts or load parts in a basket in a manner to
2~
Allow the part to hang in the vapor zone until the

vapor ceases to condense on the work.
Raise the part from the degreaser.
allow easy access of solvent or solvent vapor to every area

and to permit free drainage of the liquid solvent from all
surfaces. Work wet with water should not be introduced

into the degreaser. (Water reacts with chlorinated
solvents and releases free acid which can cause severe
corrosion of parts and degreaser components.) Complex
parts which may have entrapped water in areas that are
inaccessible for visual inspection should be oven dried
before vapor degreasing,
degreaser.
Vapor-Spray-Vapor Degreasing
1~
Intraduce part into the
2.
Allow the part to hang in the vapor

vapor ceases to condense.
degreaser.
zone
Spray the internal
A part, which because of its mass acts as a large heat sink,

may be removed from the degreaser when clean without
waiting for condensation to stop.
3.
After cooling, parts should be visually examined for

complete removal of oils, greases, and associated loose
debris. If not clean, reclean as necessary.
4.
Allow the part to remain in the vapor

vapor ceases to condense.
5.
Withdraw the part from the
After degreasing, protect parts against contamination

and physical damage.
with
clean
and external surfaces of the part

redistilled solvent to remove any
adhering particles.
7nne
until
degreaser.
Immersion-Vapor Degreasing
1.
MATERIALS
Purging and Drying Gases

When a part is to be purged with nitrogen or blown dry
with nitrogen or air, nitrogen should be in accordance
with MIL-P-27401, Type I, or BB-N-I11. Type I, Class i,
Grade B, and air should be clean, dry, and filtered.
until the
Immerse the part directly into the liquid solvent

without pausing in the vapor zone. Raise and lower
the work in the solvent, making sure that the parts
being c~eaned are immersed at all times, This
technique effects a flushing acii,n by promoting
circulation of the
2.
liquid throughout the
load.
Withdraw part from the solvent and allow to drain.
20-1 0-55
o
Page 1
-~L 17/84
SR-76-023
SOLVENT VAPOR DEGREASING (Continued)

Immersion-Vapor Degreasing (Contd)
3.
Withdraw part from degreaser completely and allow

to cool for about 5 minutes,
4.
Reintroduce part into the degreaser vapor
5.
Allow the part to remain in the vapor zone until

vapor ceases to condense on the part and drainage
zone.
Certain alloys, especially 7039 aluminum and possibly a

few others in the 7000 aluminum series, age at
temperatures recommended for oven drying. 7039
aluminum should not be oven dried.
A vacuum oven is preferred for drying
with entrapments or faying surfaces.
complex parts
stops.
6.
Withdraw part from the degreaser.
I m me rsion-Spray-Vapor
Degreasing
1.
Introduce the part directly into the liquid solvent

without pausing in the vapor zone. Raise and lower
the work in the solvent, making sure that the parts
being cleaned are immersed at all times.
2.
Raise part into the vapor
X.
Spray internal and external surfaces of part with

clean redistilled solvent to remove any adhering
particles and to cool the part.
4.
zone
and allow to drain.
Allow the part to remain in the vapor zone until

ceases to condense on the part and drainage
vapor
stops.
5.
Withdraw part from the degreaser.
Degreasing of Tubing
Tubing should be degreased by immersion-spray-vapor.
When this method is not practical, vapor only or spray
techniques are permissible. In addition, the following
requirements shall be met:
During immersion, the tubing should be racked in
i.
such
way
as
to
promote movement of liquid
through the tubes.

2.
After the exterior has been cleaned, the interior of
tubing should be flushed with clean solvent and

blown dry with air or nitrogen. Take care to avoid
blowi~e solvent into the room during drying.
I)lyinR ()f Parts
I.
Xirtlrv.
2.
Blow
dry with air
:3.
Oven
dry
4.
at 150 to 200"F until part

temperature, then apply 15 to 30 in, of
mercury vacuum for 1 hour. Complex parts may
at 220 to
Heat part in
reaches
or
nitrogen.
250"F.
a vacuum oven
oven
require longer heating with alternate

ambient pressure cycles.
vacuum
and
20-1 0-55
Page
Aug 17/84
L~jrYRIGHT, 1984 BY SABRELINER CORPORATION
SR-76-023
ABRASIVE CLEANING
(;E:NERAL
MATERIAL
Abrasive cleaning is used to remove tightly adhering

contamination from parts not easily cleaned by chemical
methods. Such contamination includes heat-treat gcale,
rust, welding flux, and other corrosion products.
Abrasive cleaning methods include grit blast (dry). slurry
blasting (wet). wire brushing, barrel tumbling, abrasive
paper or cloth, and glass bead blasting.
Magnesium parts
ground, honed,
or
Carbon and alloy steel
Inconel/InconelX parts
the material being

cleaned should be applied at 10 to 100 Dsi as required to
maximize cleaning action without distorting the part.
The blast should be kept in smooth continuous motion to
avoid uneven erosion. Blast only long enough to clean part.
to
being blasted)
t
ci
220-525
80-150
~0-280
625-1250
40-60
220
or
finer
220-325
220
finer
or
on
that have
not
been
other alloys
Do not wet blast carbon and alloy steel parts. Any

abrasive may be used.
O Only
Alundum abrasive not

other material
Wet Abrasive
Alundun Abrasive
Garnet Abrasive
(;lass Beads (lead free)
Silicon Carbitle
Novaculite Abrasive
Steel Grit
finer
any abrasive except steel grit may be

used, silicon carb.de is preferred
abrasives with appropriate grit range are listed

below. item number is used in subsequent list to identify
proper abrasive for specific materials.
Abrasive Compound
Metal chips (same as material
or
~jj Although
Specific
80
NOTES
DIy Abrasive Blasting
MESH
finer
80
O Ail abrasives except steel grit

IS1 Only non-metallic abrasives
NAME
or
Ultra-high-strength steels
those that have been plated.

lapped must be masked. Holes must be
previously used
ITEM
Re"e 41 parts
as
type appropriate
partsl
Titanium alloy parts
ABRASIVE BLASTING
O
O
O
O
O
CRES alloy parts
I,lupaetl.
Dr!: ablasive of
80
Copper alloy parts
Solvent vapor degreasing is normally accomplished prior

to abrasive cleaning except on titanium and titanium
allovs. Titanium is wiped down using acetone or methyl
ethvl ketone(MEK). No chlorinated or fluorinated solvents
a~e usetl on titanium.
Finished ~urfaces such
O
O
Aluminum parts
SURFACE PREPARATION
MESH
ABRASIVE
previously used
on
Blasting
Wet abrasive slurry is blasted onto a surface to be cleaned

to 110 psi air pressure. Blast only long enough to
clean surface as wet abrasive blasting may remove base
metal. Rinse wet blasted item with high pressure water
stream. Blow dry using clean, dry compressed air (or oven
dry at 180 to 200PF maximum).
using 70
Wet abrasive blasting is ;,urmally done in a cabinet

apparatus that recycles she slurry. This slurry should be
replaced at not more than 70 hours use.
The slurry consists of one part d ry abrasive (volume) to
parts water (volume).
Recommended abrasive and
the next page.
applications
are
listed
two
on
20-1 0-60
0
Page 1
Aug 17/84
SR-76-023
C()RK()SION CONTROL MANUAL
ABRASIVE CLEANING
Wet Abrasive
MISCELLANEOUS METHODS
Blasting (Contd)
When
DeburrinR
80
80
625
(leanina
Fast
Fast
Fair
I
40-50
40-.50
220
32F,
1250
Poor
8-15
220
Alundum
Aluntlum
220
A corrosion inhibitor, such as Hydro 12X or an equivalent

inh ibitor. should be adtled to the slurry in the proportion
of i: tc, 1i2 pound of inhibitor per 50 pounds of abrasive.
Disl,ersing or wetting agents may be added if desired.
When wet MastinRR aluminum, the pH of the slurry should
be maintained below
by adding chromic acid to the
slrllry.
Wet (;lass Bead
Blasting
Wet glass bead blasting uses a slurry of solid glass beads

iii watei- blasted ititli 70 to Ilv ysi ail pressure. This wet
glass beatl blast is used for cleaning and surface peening.
Blast only long enough to clean the surface or until the

complete surface is uniformly peened. Rinse glass-bead
cleanetl parts with water by sloshing or spraying. Blow
d r!, using clean, oil free. compressed air, or dry in an oven
at a tem perature that does not exceed 200"C. Do not oventfr~ carbon and allov steels,
~lurry contains glass beads within one of the size

shown below. The slurry should not contain more
than 10":1 (by vol) of cracked glass and other abrasive
contamination. Wetting agents and corrosion inhibitors
Thr
ranges
may be
used if desirt;i.
SI%E N().
1
5
6
7
8
9
10
11
1"
DIA.
0.021
0.016
0.01Y
0.010
0.008
0.007
0.006
0.004
0.003
0.00;!
0.0015
0.001
one
Tumbling
or
Wire
40-50
25-:30
HoninlS
Novaculite
described,
of the methods below may be used.

Barrel
Finishing
When applicable, tumbling or barrel finishing may be

used for descaling or deburring. The abrasive should be
selected on the basis of the nature of the job and the
material being processed. Metallic abrasives shall not be
used.
50-60
50-60
16-20
Fast
Fast
Fast
Fair
(;arnet
Silicon Carbide
impossible or impractical because of size, shape, or

assembly of the part to clean by blasting methods
state of
MICRO-INC
FINISH
CUTTING
APPLICATION/
SPEED
GRIT
ABRASIVE
(;arnet
Silicon Carbide
Novaculite
(Continued)
U.S. BUREAU
OF STANDARDS
SIEVE NO. RANGE
Brushing
All ferrous alloys shall be wire brushed either by hand or

by power-driven machine, using stainless steel wire
brushes. Non-ferrous alloys may be brushed with
nonmetallic, synthetic bristle brushes or metallic brushes
of the same or similar alloy that is being cleaned. A brush
that has been used previously on some other alloy should
,,t
b, used.
Abrasive Cloth
Small
either
or
Paper
shall be cleaned with abrasive paper or cloth

by hand or power buffing. (The latter method is
preferred.) Use abrasive grit size between XO and 60(1
mesh depending upon material being cleaned and the
surface finish requirement of the part.
areas
Polishing Aluminum
When applicable, aluminum and aluminum alloy sheets
cleaned with MIL-P-6888 polish applied with a soft
cloth using only back and forth motion. Rub until all
discoloration, stains, etc., are removed and the part
acquires a "skin-yuality" appearance. When polishing
clad aluminum, take care not to polish through the
cladding. After polish has tlried. wipe the part with a
clean, dry cloth. Remove all traces of polish with MIL-C25769 cleaner diluted 1 part to 3 to 7 parts of water. BIush
diluted cleaner on the part and reapply as necessary to
keep all areas wet. Allow s~lution to remain for i-lrj
minutes, vigorously agitating areas ~Nhere soil is heavy.
Rins with water to remove solution from all joints,
are
recesses, etc.
Cleaning with Pumice
Prepare surface before plating operations by hand

scrubbing with pumice (technical grade) or levigated
20-45
30-50
35-70
40-80
50-100
60-120
70-140
100-200
140-270
alumina (600 mesh
or
finer).
PREPARATION OF ALUMINUM AND

MAGNESIUM FOR BONijING OR
ENCAPSULATION
When
required by applicable bonding ol encapsulation

specifications, surfaces of aluminum and magnesium
parts, including those fabricated from sheet stock, that
are to be bonded or encapsulated may be roughened by
using silicon carbide abrasive cloth ~r paper.
170-8~.i
32.5-400
400
20-1 0-60
Page
Aug 17i84
COPYRIGHT, 1984 BY SABRELII;~.P. CORPORATION
SR-76-023
ABRASIVE CLEANING
(Continued)
PROCESSING AFTER ABRASIVE CLEANING
Remove abrasive particles from part immediately after

abrasive cleaning. Keep handling of cleaned parts to a
minimum until protective coatings have been applied.
Blow loose abrasives from parts that have been dry
abrasive blasted using clean, dry, oil-free compressed air.
Corrosion Resistant Steel and Nickel Base Alloys
Corrosion resistant steel and nickel base alloys should
be aikaline cleaned and passivated in accordance with
table i. The following should not be passivated:
Partsthathavebeen brazed.
Parts that have been
prepared for plating.
Palts fabricated from alloys containing less than 7"/0

chromium, i.e., Hastelloy B, nickel, Monel 400, Monel
K-500.
Aluminum
Alloys
Aluminum alloys that have been abrasive cleaned should

be alkaline cleaned in accordance with table i.
Maffnesium Alloys
Magnesium alloys should be cleaned in accordance with
table i.
Carbon and Alloy Steels
When parts are to be stored for any length of time
ablasive dust should be removed and the parts protected
nith corrosion inhibitors per MIL-P-8420 (Type I). MILor MIL-C-1617:3 (Grade 3).
Titanium and Titanium Alloys

After abrasive cleaning, titanium and titanium alloys
should be further processed in accordance with table 1.
20-1 0-60
o
COPYRIGHT,:3SJ BY SABRELINER CORPORATION
Page 3
Aug 17/84
SR-76-02,3
C()KK()SION CONTROL MANUAL
ABRASIVE CLEANING (Continued)

Table 1.
Processing After Abrasive Cleaning
ALLOY
Corrosion resistant steels.
nickel base alloys
Alkaline, clean
Titanium
10-20
120 to 180
2-5
Nitric acid (42 Be), 20 to Tj0~

(by vol)-- Balance watet
Room
50 (ma?()
Rinse
Water
Room
2-~
Room
Until dry
Room
60 Imin)
dry
Nitric acid (42 Be),
(by vol)-- Balance
1 to
2:/,h
water
Water
Room
dry
Alkaline, clean
MBOZ10-0()8
6 to t3
Titanium
allovs
170 to 200
water
Water
Air
Magnesium alloys
oz/gal,
TIME
MINUTES
Passivate
Rinse
alloys
6 to 8
TEMP
"F
Rinse
Passivate
.i\luminum
MB0210-011,
Balance
Air
SOLUTION
CONCENTRATION
OPERATION
ol,
oz/gal
RB0~10-00.5
Balance water
Room
Until dry
l.iO to 171)
,5 to 1()
Rinse
Water, running
Neutralize
ST0210GE0001. 12
Balance- water
Rinse
Water, running
Dry
Clean. oil-free air
Rinse
Water. running
Room
Pickle
Chromic acid 24f2 oziRal

sodium nitrate 4-0.0.5 oz/gal
Balance- water
Room
2-5
to ~O
Room
oz/gal.
II) Ima.u)
Room
2-:5
2()1) (max)
Until dry
Rinse
Water. running
Dry
Clean, oil-free ail
200 (ma?()
Until cl,\i
Alkaline, clean
MBOB10-011
170 to 200
10-20
Room
1-2
Rinse
Water, Immersion,
Room
constant
overflow
Xcitl cleaner (use
Nitric acid
plastic coated
blankets)
hydrofluoric acid
Rinse
Water, spray or immersion.

(distilled, deionized wlLtel)
Dry (handle with
Air
Room
:3
mas)
Balance- water
or
circulating hot
air
Room
200 (max)
Until tlry
clean gloves
when dry)
NOTE
~lust be alkaline cleaned

resistant steels
and
Iinsed
prior
to
passiviltion in the
same
manner
as
the
other colrosion
20-1 0-60
Page 4
Aug 17/84
SR-76-023
SEALING
GENERAL
Non-Hardening Sealants
The conti nued su rveillance and re-application of damaged

seals and sealant is vitally important in the prevention of
corrosion. Damaged or deteriorated seals or sealant left
unlepaired will allow moisture to penetrate into areas
that are intended to be sealed; thereby providing all of the
ingredients for a corrosive attack.
The
ability of groove injection sealant to seal depends

upon its adhesion to metal. Oils, greases or any other
contaminants in the sealant grooves or sealant injection
holes could cause a defective seal. If the sealant grooves
accessible, wipe the grooves with a clean cloth
are
moistened with cleaning solvent then dry the surfaces
with another clean dry cloth. If the sealant grooves are not
accessible. make certain that the area surrounding the
sealant injection holes are clean and that when the sealant
iniection hole screw is removed, contaminants do not
enter the injection hOle.
TYPES AND APPLICATION OF SEALANTS
Fuselage and nacelle sealing is accomplished with

hardeninff sealing compounds, pressure sensitive tapes,
anti inflatable and non-inflatable rubber seals. The fuel
cell aleas of the wings are sealed by the groove injection
method: using a non-hardening, fuel resistant sealant.
r\ ~eas of the wing other than the fuel cell areas requiring
sealing are sealed with various types of hardening sealing
com pound. Application of the hardening types of sealing
compounds may be accomplished by spreading with a
spatula or knife, or by a pneumatic or hand operated
sealant gun. The non-hardening sealant used in the
xealinQ of the wing fuel cells is applied using a
pneumatically operated groove injection sealant gun. A
hand operated groove injection sealant gun is also
available for the injection of sealant into small areas.
PRESSURETIGHT AND LIQUIDTIGHT

SEALING
The fuselage
area
repairs
or
resealing procedures
pressurized
are
necessary.
Cleaning
Clean surfaces to be sealed
as
instructed in iSurface
Preparation"
Sealant Preparation
;Mix base compound and acceleracor together. in the
proportions recommended by the manufncture t.. The two
Harrlenina Type Sealants

satisfactory seal, the
and all seals in the
to withstand a maximum pressure
The following procedure provides the materials and

processes for the airtight seal ing of all joggles, seams, butt
and Iapjoints. holes, slots, and fasteners in the pressurized
area where the normal
operating temperatures are
between fi5 and 225"F. Refer to "Sources of Commercial
Products" for applicable jealaiit.
SCRF~CE PREPARXTION
be sealed must be
tholoughly cleaned before the application of the sealiny
compound. With a vacuum cleaner or by wiping with a
clean, dry cloth, remove all dust and foreign matter from
the area to be sealed. With a clean cloth saturated with
na~,htha or its equivalent. wipe the area to be sealed.
Eefore the naphtha has evaporated completely, dry the
~vith 3 clean cloth. Repeat this cleaning procedure
I.lntii it is certain that no oil, grease, or other conta m i na t i n g su bstances are left on the surf ace to be sealed.
it is important that only clean cloths be used. When a cloth
becomes .ioiled. it should be discarded. To avoid conlaminating the solvent, the solvent should always be
poured from the container onto the cloth: never dip the
cloth into the container of solvent.
a
structure
designed
differential of 18.4 psi. A maximum allowable leakage of

144 cubic feet per minute at 8.131 psi may esist before
Intiividually (O-ring)sealed fastener installations involve

flush-head fasteners only. The O-ringr is installed on the
fastener adjacent to the head. A receptacle for the O-ring
is formed by a shallow counterbore in the base of the
countelsink. On installation, the ring is compressed by the
sclewhead against the sides and bottom of the counterbored receptacle, forming the seal.
To obtain
are
area
components must be blended until the mixture is uniform.

A bead of fillet from sealant that has been improperly
mixed will have areas where the cure is incomplete. At
room temperature (approximately 770F), the sealing
~ompound must be used within 3 hours after being mixed
with the accelerator or after removal from cold storage.
to
If the surface to be sealed is painted or primed, check for

paint adhesion by scratching the surface with the thumbnail. If paint can be readily removed by scratching, the
paint adhesion is not satisfactory and the painted surface
must be stripped down to the bare surface and then
recleaned.
NOTE
;Ilfter the add7:tion of the aeceberntor, the

Yealiny compozlncl rr~azJ he stored at r) to
-100Ffor a rrLaz. of 72 hours.
Application of Sealing Compound
All joggles should be sealed before any joints or seams are
sealed. Seal the joggles by completely filling them with
sealant. Wherever possible seal the joggles by forcing
sealant under the joggle from either or both sides of the
joggle. If the joggle cannot be filled by forcing sealant
from the side of the joggle. a small hole (No. 40 0.098)
may be drilled in the center of the joggle run out; then
sealant may be injected through the hole to seal the joggle.
(See figure 1,)
20-20-00
0
Page 1
Aug 17/84
SR-76-02:J
COftROSION CONTROL IMANUAL
114
i I-1-
IC
(TYPICIL)~
I
1/16
r118
1--I I
/e
IIB(TYPICPIL)1
i/a
1~1/16
MAX.i I-
jt
(TYP)
r1/16
PRESSURE-SENSITIVE TAPE
1/8 MIN.
1/4
1/4ci
Ie 1/2 MIN.
1/8 TO 1/4
1/8
NO. 40 HOLE
1/8
FUME TIGHT 225 TO 4000 F

FLAME RESISTANT
/,b
MATING SURFACE
N~TE
!F JOGGLE CANNOT BE SEALED FROM
SIDES. DRILL
1/8
STRUCTURE
NO 40 HOLE AND INJECT SEALANT
PRESSURE
LIQUID TIGHT
REMOVABLE PANEL
FUME TIGHT -65 TO 225"F

REMOVABLE DOORS
COVERS
1:8
(+1/18. -0)
1/8
SEALING COMPOUND
OVERCOC\T
GROOVE INJECTION
SEALING COMPOUND
1/8
3/4 MAX.
1/16
1/8
1/16
(+1/16, -0)
Mnr
1MAX.
PRESSURE 5 LIQUID TIGHT
1/4 MAX.
1MAX.
FUME TIGHT -65 TO 225"F
FUME TIGHT, 225 TO 400"F
20-20-00
Page 2
Aug 17/84
Sealant
DimensionsFigure
SR-76-023
SEALING (Continued)
Application of Sealing Compound (Contd)
Sealant Preparation
Holes and gaps up to 1/8 in. in width may be sealed by first

filling the hole or slot with sealant and then building up a
bead to a minimum thickness of 1/16 in. and a width or
diameter of 3/8 in.
Mix the base compound and accelerator together in the

proportions recommended by the manufacturer, The two
Holes 1/8 to 1/4 in, Diameter

Holes having a diameter
of between 1/8 and 1/4 in, can be sealed by first applying a
layer of pressure sensitive tape over the hole. The tape
should extend at least 1/2 in. beyond the hole in all
d i rections. Cover the tape with a layer of sealant at least
1/8 in. thick and extending at least 1/8 in, beyond the
edges of the tape. (See figure 1.)
Holes (;reater Than 1/4 In. Diameter
Holes having a
diameter greater than 1/4 in, must be filled or plugged
with a rivet or balsa wood, and sealed with a layer of
sealing compound, a minimum of 1/16 in. thick. The
sealing compound should extend at least 1/8 in, beyond
the edges of the hole, Before sealing, oversized slots or
joggles should be closed out with material of the same type
as the existing structure. Secure filler in position, using
existing fasteners. Do not drill holes in Chem-Milled areas
to fasten fillers in place.
Riveted Butt and Lap Seams

Seams and riveted Soints
sealed by the use of a pressure gun. Continuous beads
of sealing compound must be applied on all seams and
joints. A bead of sealing compound containing gaps or
bridges cannot be considered a satisfactory seal. (See
figure 1.) Rivets and bolts may be sealed, when
necessary, by brushing a coat of EC776R sealing
compound on all rivets and bolts in the pressurized area.
Sealing equipment should be cleaned up and excess
seal ing compound should be removed within:3 hours after
e?e posu re to room te m peratu re, Nap htha, toluol, o r methy I
ethyl ketone (MEK) should be used as a cleaning
are
components must be thoroughly blended until there is

uniform
mixture.
the accelerator
If the mixture is not thoroughly blended, there will be

where the cure will be incomplete. At room temperature (approximately 770F) the mixed sealant must be
used within 3 hours, or be discarded. After addition of the
accelerator, the sealant may be stored at 6 to -100F for a
period not to exceed 72 hours.
Application
of
Sealing Compound
NOTE
Sealant may be applied to either bale
painted .surfaces
as
or
applicable.
Holes, slots andjoggles up to 1/8 in, in width can be sealed

with general purpose sealing compound. Build up an area
or bead of sealant at least 1/16 in, thick on the
pressure
Side of the area being sealed, (See figure 1.)
Holes, slots, and joggles between 1/8 in, and 1/4 in. in
width can be sealed by using pressure sensitive tape and
general purpose sealing compound, or by using groove
injection sealing compound coated with general purpose
sealing compound, Select applicable method and proceed
as
follows:
Pressure Sensitive Tape and General Purpose
Sealing Compound:
1.
2.
The
application of fumetirght sealing compounds are

dependent upon the operating temperatures of the area
being sealed. Select the applicable sealing compound
Apply a layer of pressure sensitive tape over the hole

being sealed to extend a minimum of 1/2 in. beyond
the edge of the opening on all sides.
Apply
layer of general purpose sealing cur,ipound

1/16 in, thick over tape. Extend sealing
compound at least 1/8 in, beyond edges of tape. (See
figure i.)
a
at least
listed i n Sou rces of C om mere ial Products; maki ng ce rtai n

that the sealant is applicable to intended heat range.
Fumetight Sealing
Areas
Operating Between
-65 and 225"F
The following procedure is applicable to the sealing of

joggles, cutouts, holes, slots and hat sections in areas
where excessive leakage of air, fumes, and smoke could
prove dangerous.
Cleaning
as
instructed in "Surface
Preparation"
20-20-00
0
throughout the
areas
material.
FUMETIGHT SEALING
dispersion of
Page 3
Aug 17/84
SR-76-023
SEALING
Cleaning
Areas Operating Between

Fumetight Sealing
(Contd)
-65 and 225"F
Clean
This method should be used only when the

tape method cannot be
used.
pressure sensitive
On the pressure side of the area, fill the hole or slot

with goove injection sealing compound and form a
fillet or bead extending at least 1/4 in. beyond edges
of hole or slot.
The groove injection sealing compound

may be softened for easier application by
luarming or working with the hands, Make

certain hands arefree of grease and oil.
Apply a 1/8 in. thick coating of General Purpose
Sealing Compound over the Groove Injertion
Sealing Compound. (See figure 1.)
Holes having a diameter greater than 1/4 in, must be

filled or plugged with a rivet or balsa wood, and sealed
with a layer of sealing compound, a minimum of 1/16 in,
thick. The sealing compound should extend at least 1/8 in,
beyond the edges of the hole. Before sealing, oversized
slots or joggles should be closed out with material of the
same type as the existing structure. Secure filler in
position, using existing fasteners. Do not drill holes in
Chem-Milled areas to fasten fillers in place.
sealed by the use of a
pressure gun. Continuous beads of sealing compound
mu;t be applied on all seams and joints, A bead of sealing
compound that contains gaps or bridges cannot be
considered a satisfactory seal. (See figure 1.)
joints
are

seal i ng compound should be removed within 3 hours after
exposure to room temperature. MEK should be used as a
cleaning material.
Fumetight Sealing
Areas
be sealed
as
instructed
in "Surface
The sealant is ready for use as it comes from the container

and no mixing is required. Application of sealant may be
by sealant gun or by a spatula. Do not allow the sealant
container to remain open any longer than necessary
because the solvent contained in the sealant evaporates
very rapidly. If the sealant becomes too thick for easy
application, the sealant may be thinned with MEK. Do not
thin the sealant beyond its original consistency.

Apply sealant only in well ventilated areas or use air
supplied respirators. The sealant should be applied with a
sealant gun (except far minor spot sealing). Locate areas
to be sealed by shining a light on one side of the surf ace to
be sealed and inspecting the opposite side for the passage
of light.
NOTE
Seams and riveted
to
Sealant Preparation
NOTE
2.
areas
Preparation"
Groove Injection Sealing Compound Coated with

General Purpose Sealing Compound:
i.
(Continued)
Operating Between
250 and 400"F
The following procedure is applicable to the sealing of

joggles, cutouts, holes. slots, and hat sections where
excessive leakage of air or fumes must be avoided, where
pressure differentials do not exceed 5 psi and where the
operating temperatures extend from 250 to 4000F and
where peak temperatures do not exceed 500"F.
Holes, slots, cutouts, and joggles less than 1/8 in, width
shall be filled by building up fillet or bead about 1/8 in.
thickness on the pressure side of the area being sealed.
Fillet or bead should extend a minimum of 1/8 in. beyond
edge of hole being sealed. (See figure i.)
Holes, greater than 1/8 in. width must be filled with a

rivet, or cap to reduce the opening size to less than 1/8 in.
before sealing. Slots, joggles or cutouts having a minor
dimension greater than 1/8 in. shall be closed with sheet
metal of the same type as used in fabrication prior to
sealing. Sealant should be a minimum of 1/8 in. thick and
extend at least 1/4 in. beyond the edges of hole being
sealed.

sealing compound should be removed within 3 hours after
exposure to
room
temperature. MEK should be used
as a
cleaning materit~:.
FLAME RESISTANT AND LIQUIDTIGHT
SEALING
This procedure outlines the procedures and materials
used to seal joggles, holes, cut-outs, etc, in areas where
leakage of fluids must be avoided and where a flame tight
seal is necessary in case of fire. The sealing methods
provided are applicable to areas where the temperature
may be z high as 400"F during normal operation and
with occasional short temperature increases to 5000F for
short periods of time. The cured sealant will become soft
and plastic at high temperatures and, therefore, should
not be used as a pressure seal.
20-20-00
Page 4
Aug 17/84
COPYRIGHT, 1~84 BY SABRELINER CORPORATION
SR-76-023
SEALING
(Continwed)
Cleaning
Sealant Preparation
as
Preparation".
Sealant Preparation
Flame resistant and liquidtight sealant (PR-810) is ready
for use as packaged. Application may be by either spatula
or sealant gun. Do not allow sealant container to remain
open any longer than necessary as the solvent contained in
the sealant evaporates rapidly.

Seal all holes, slots and gaps less than 1/8 in. diameter or
width by filling them with applicable sealing compound
from both sides of the bulkhead, web, or firewall; obtaining a bead or button of sealant as indicated on figure i. If
only one side of the area to be sealed is accessible, seal the
hole or gap by forcing an excessive amount of sealant
th rough the hole to form a button or grommet of sealant on
the inaccessible side of the area being sealed.
Holes
slots greater than 1/8 in. diameter, or width,

be plugged or filled with metal clips or snap in
plugs, then sealed by applying sealant at least 1/8 in. thick
over the plugged hole or gap and extending at least 1/4 in.
beyond the edge of the plug. Make certain that there are
no gaps or bridges in the sealant.
or
must first
Seams and riveted joints are sealed using a sealant gun

and high temperature sealing compound. Apply a bead of
sealant at least 1/8 in. thick and minimum of 1/4 in, on
each side of the seam being sealed. (See figure i.) When a
fillet of sealing compound is required, the fillet legs must
be at least 1/4 in, length. If a stiffener crosses the seam
being sealed, the joggle or gap must be injected with
sealant, then both sides of the stiffener must be sealed for
a minimum distance of 6 in. from the seam, or the entire
length of the stiffener, whichever is shorter. Seal rivets
securing seam by applying a coating of sealant over the
rivet with a spatula. Sealant should extend at least 1/8 in.
beyond edge of rivet.
SEALING REMOVABLE DOORS AND COVERS
The following procedures are used to provide synthetic
rubber self-contouring sealing pads to the stationary
stlucture located under removable doors or panels, and
between normally separable sections of the structure
where the operating temperatures range from -65 to
22Ei"F. Refer to "Sources of Commercial Products" for
applicable sealant.
Cleaning
as
Mix base compound and accelerator together, in proportions recommended by manufacturer. The two
components must be mixed to a uniform blend. Sealing
compound that is not thoroughly mixed will have areas
where the cure will be incomplete. The accelerated
sealing compound must be used within 3 hours after
mixing or removal from cold storage.
NOTE
qfter the addition of the accelerator, the

sealing compound may be stored at O to
-100Ffor 7~ hours.
Using a sealant gu n or wooden spatula apply sealant to the

door land areas of the stationary structure. If a sealant
gun is used to apply the sealant, it is recommended that
the sealant beads be smoothed out, using a wooden
spatula, to an even uniform thickness of approximately
1/8 in. This will ensure that sufficient sealant has been
applied to fill all gaps and voids. (See figure i.)
Apply petrolatum to all portions of removable part of
assembly that will come in contact with sealing
compound, to prevent seal i ng com pound from adheri ng to
removable part. Sufficient petrolatum should be applied
to SCews and quick-disconnect fasteners, on the
removable part, to prevent the attachments from being
Se"led into the receptacles.
Assemble parts being sealed, and allow them to remain in
position for approximately 8 hours or until compound has
completely cured. After sealant has cured, disassemble
parts and trim off excess sealing compound with a sharp
knife. The petrolatum must be wiped from the surfaces
with a clean, dry cloth. Attachments must be washed with
naphtha or equivalent to remove all traces of the
petrolatum.
EXTERIOR WATERTIGHT SEALING
The following procedure is applicable to the seal ing of the
exterior surfaces of the airplane where normal temperatures do not exceed 225". Refer to "Sources of Commercial Products" for applicable sealant.
Cleaning
Using a stiff bristle brush and MEK solvent, remove all
paint and primer (except epoxy polyamide primer) from
the surface to be sealed, for a distance of 1/2 in, each side of
the gap being sealed. (Sealants may be applied to a clean
epoxy polyamide primed surface without adverse effects.)
Preparation".
20-20-00
0
Page 5
Aug 17/84
SR-76-023
SEALING (Continued)
Cleaning (Contd)
To obtain
satisf actory seal, the area to be sealed must be
thoroughly cleaned before the application of the sealing

compound. With a vacuum cleaner or by wiping with a
clean, dry cloth, remove all dust and foreign matter from
sealed. With a clean cloth saturated with
its equivalent, wipe the area to be sealed.
naphtha
Before the naphtha has evaporated completely, dry the
surface with a clean cloth. Repeat this cleaning procedure
until it is certain that no oil, grease, or other conlam inating substances are left on the surface to be sealed.
It is imporatant that only clean cloths be used. When a
cloth becomes soiled, it should be discarded. To avoid
contaminating the solvent, the solvent should always be
poured from the container onto the cloth; never dip the
cloth into the container of solvent.
the
area
Immediately after removing the tape, fair out the edges of

compound. This may be done by drawing one finger
along the edge. Moistening the finger with water will
minimize sticking of the compound to the finger.
the
NOTE
to be
Do not
or
use soap on the fingers as this may

impair adhesion of the compound to the
structure.
After the compound has been smoothed, allow the compound to cure a minimum time of 24 hours at room
temperature before covering or disturbing the surface.
Clean up
excess
using MEK
or
sealing compound and the sealant
gun
toluene.
FAYING SURFACE SEALING
Sealant Preparation
Mix the base compound and the accelerator together in
the proportions recommended by the manufacturers. The
two components must be thoroughly mixed to completely
disperse the accelerator throughout the base compound,
If the mixture is not thoroughly blended there will be
areas where the cure will be incomplete. At room temper~ture :ap-,;vximately ""OFj the blended seaialli will
The
following procedure should be used
to
provide
satisfactory faying surface seal between mating surfaces

of the airplane structure. This procedure is applicable to
areas of the airplane which operate in the temperature
range of -65 to 2250F.
Products" for
Refer to "Sources of Commercial
applicable
sealant.
pot life of 3 hours. Any sealant that has been

to the atmosphere for a period of over 3 hours
must be discarded. The blended sealant may be stored at 6
to -100F for a period not to exceed 72 hours providing the
sealant is refrigerated immediately after blending.
Cleaning
The base compound and accelerator shall be mixed together in the proportions recommended by the manufacturer. The two components must be blended until there
is a uniform dispersion of accelerator through the mixture.
A fillet made from sealant that has been improperly
mixed will have areas where the cure is incomplete.
have
exposed
a 3/4 to 1 in, wide strip of masking tape to the skin

each side of the skin gap being sealed, leaving 1/16
(~1/32) in, of skin exposed on each side of the skin gap.
Press the masking tape down on the skin; using a clean,
dry cloth. T)o not use fingers to press the masking tape in
place or allow fingers to touch the cleaned surface. Oil
from the fingers will contaminate the cleaned surface and
necessitate that the surface be re-cleaned.
4pply
on
Apply the sealant by using either the sealant gun or a

clean wooden spatula. If the sealant gun is used, place the
opening of the tip flat against the seam and apply a slight
excess of compound. moving the gun as the joint fills up. If
a spatula is used, apply an excess of sealant at one point of
the seam and work the sealant into and along the seam.
After the
Clean all surfaces to be sealed
as
Preparation"
Sealant Preparation
At
POOm
temperature (approximately 770F) the sealing
compound must be usee:

with the accelerator
or
*r ithin 3 hours after being mixed

after removal from cold storage.
NOTE
After addition of the accelerator the

sealing compound may be stored at O to
-100FSor r~ hours.
compound has been applied using the sealant

gun, use a spatula and press the compounr into the seam:
removing the excess from the sealed area. If a spatula was
used to apply the sealant, remove the excess compound
with the spatula.
a smooth even coat of sealant approximately 1/32

in. thick to both faying surfaces. If a r,ealant gun is used to
apply sealant, smooth out sealant beads with a spatula,
filling all voids in the faying surface.
After the seam has been sealed and the excess compound
removed, the tape shall be removed from the skin. It is
essential that this be done before the compound starts to
As soon as possible after applying the sealing compound to

the faying surfaces, join the faying surfaces together and
secure in place using Lt,~licable fasteners.
Apply
set up.
20-20-00
Page
Aug 17/84
COPYRIGHT, 1984 BY
CORPORATION
8B-76-023
CORROSION CONTROL ~IANUAL
SEALING (Continued)
Application
of
NOTE
Sealing Compound (Contd)
The regular injection gun tip 7nny be u.red,

except when injecting through the ruing
Clean up all excess sealant squeezed out from between

faying surfaces within :Z hours after joining; using MEK
and clean cloths.
GROOVE INJECTION SEALING
This
procedure outlines the necessary procedures and

techniques used in the groove injection sealing of the wing
upper and lower skins.
The groove seal method used for fastener and faying

su rface sealingconsists ofa machined groove in the faying
surface of the under or second member that is continuous
along the fastener row. Continuity of the groove around
each fastener is achieved by spot-facing the holes to the
depth of the groove. Small countersunk holes through the
outer or first member, at approximately 3 in. spacing, are
provided for sealant injection. Sealant injection holes are
in line with, and midway between, structural fasteners.
Flush self-tapping screws are used to plug the injection
holes when the sealing has been accomplished.
joint splice plates,

Place nozzle tip of gun squarely in countersink. Hold gun
firmly in position and depress trigger lair-operated gun)
for about 30 seconds. Release trigger and allow piston to
return. Continue sequence until compound flows out of
adjacent injection hole for a minimum distance of li8 in.
Move the gun tip to one of the adjoining injection holes.
Hold the gun firmly in place and depress the trigger until
the sealant flows out of the hole previously injected.
NOTES
When
injecting sealant into the tank

injection holes to either side of
the gun tip shall be unplugged.
grooves, the
Todecreasethetirne recluiredforin~jectiorL,
it is permissible to heat the guns to a
ability of groove injection sealant to seal depends

upon its adhesion to metal. Oils, greases or any other
The
contaminants in the sealant grooves or sealant injection

holes coultl cause a defective seal. If the sealant grooves
are accessible, wipe the grooves with a clean cloth.
moistened with cleaning solvent; then dry the surfaces

nith another clean dry cloth. if the sealant grooves are not
acuessible. make certain that the area surrounding the
eealant i njection holes are clean and that when the sealant
injection hole screw is removed, contaminants do not
ente~ into the injection hole.
Sealant
Ir~az.
oflIOOF.
Cleaning
iMove grin to adjacent. hole and repeat ope ration. Continue

foregoing procedure until sealant has been forced out of
all injection holes in affected areas.
Repl"ce all self-tapping screws in sealant injection holes.

Remove extruded sealant by carefully scraping with a
non-metallic scraper and wiping with cleaning solvent.
FUELTIGHT SEALING -65 to ~()OOF
Thr
~oilowinR I~n,cetiulee is used to I,ro~juce a fuej

tivht tayinff aurface seal, in the temperature range of -ii~
to ~()I)OF.
Preparation
Groove injection sealing compound is ready for use as it

from the container and no mixing is required.
comes
Cleaning
Clean
areas
to
be sealed
as
instructed
in
"Surface
Preparation"
;\pplication of Sealing Compound
Sealant
IVOTE
In~jectiolz of sealant into groove-sealed

areas should not be attempted when the
of the luiny.strrLcture itself is
belozu 4"C(40"F), Whenever possible, it is
~ecornnzendecl that the temperature of the
strrLcture be at least 850C (rrOF).
Remove self-tapping screws from injection holes in
to be Ieseaied. One hole imin.) each side of the hole
injected must be unplugged.
areas
being
Preparation
Mix the base compound and the accelerator together in

the proportions recommended by the manufacturer. The
two components must be thoroughly mixed to completely
disperse the accelerator throughout the base compound.
If the mixture is not thoroughly blended there will be
areas where the cure will be incomplete. At room temperature (approximately 770F) the blended sealant has a
pot life of 3 hours, and must be discarded when the pot life
has expired. The blended sealant may be stored at 0 to
-10"F for a period of 72 hours providing the sealant is
refrigerated immediately after blending.
20-20-00
0
Page 7
Aug 17/84
SR-76-023
C()KH()SI()N CONTROL MANUAL
SEALING (Continued)
Apply sealant in well ventilated areas or use airsu,plied
respirators. iUsina a spatula or sealant gun apply
su fficient sealant to both faying surfaces of components to
be sealed. Make certain that all voids and surface irregularities are filled Drier to the mating of the two faying
surfaces. The faying surfaces should be joined as soon as
possible after the application of the sealant. Excess
~eal;int forced from between the faying surfaces may be
removed or formed into a fillet or bead; using a spatula.
When the sealant has cured. all exposed sealant shall
Ieceive two brush coats of fuel resistant top coating:
allowing about 20 minutes between each coat. Clean up
sealing equipment and areas adjacent to sealed
coml,onents within the pot life of the sealant (about 3
hours~. Use toluene to clean painted surfaces and IMEK
clean ~,are surfaces.
20-2000
Page 8
Aug 17/84
SR-76-023
SEALING METHODS
GENERAL
Use
This section covers the methods to be used in

of the Sabreliner aircraft.
sealing areas
MATERIALS
Table 1 is a matrix showing sealing applications in
various areas of the airplane and sealing methods and
materials to be used.
Two solvents
are
required during sealant
TYPE
application:
CATALOG NO.
Solvent Blend No. 1

Solvent Blend No. 2
6000-1567888
6000-1531409
Unless otherwise specified, "cleaning solvent" refers to

Solvent Blend No. 1 (Methyl ethyl ketone (MEK) is an
approved substitute).
EC/UIPMENT
The
following equipment,
Commercial
or
equivalent,
is
required:
Equipment:
Roller Paint, Short

Sealant Brush
Nap
Sealant Gun
Sealant Gun
Spray Gun, Paint
Spreader, Toothed
Commercial
Brush Mfg. Co. P/N 960
Delta Size 3
SEMCO Model 250
Grover Model 223
DeVilbiss M,B.C.
SEMCO P/N 22939.5
APPLICATION NOTES
No special facilities are required. Normally clean shop

facilities are adequate. Only use dry air free of moisture
and lubricants to avoid contamination during processing
operations.
Some solvents used in sealing compounds and for cleaning
purposes are highly volatile and toxic. Safety precautions
must be observed during their use to avoid fire. Also, if
solvents are used in a closed area, forced ventilation must
be provided to prevent harm to pesonnel. When compressed air is used, goggles must be worn for eye
protection.
Determine that all surfaces to be sealed have proper
surface treatment before sealing.
All
internat aluminum surfaces of
must have been coated with
fuel tanks
Cati-Coat primer,
Areas to be sealed must be cleaned before application of

the sealing compound. Observe the following general
cleaning practices:
a vacuum
cleaner
or
clean dry cloth to remove

to which the sealing
dust, chips, etc., from the surface
compound is
to be
applied.
Wipe all surfaces to be sealed with a clean cloth

saturated with a cleaning solvent. Before the solvent
has had a chance to dry, wipe the surface completely
dry with a clean cloth.
Only clean, lint-free cloths, should be used in cleaning.
When a cloth becomes dirty, it should be discarded.
To avoid contamination of the solvent, it should always
be poured from the container onto the cloth. Cloths
used for cleaning should never be dipped into the
solvent.
If surfaces to be cleaned are visibly oily or greasy, the
cleaning procedure outlined above should be repeated
until
no
contaminates remain.
Clean all fasteners with solvent to remove grease, oil,

and other contaminants which will reduce the
adhesion of the sealing compound. Keep the fasteners
clean and dry until used.
Before cleaning primed or coated areas, check primer or
coating adhesion. If the primer or coating can be readily
reiiioveci by scraping with the thumb nail, adhesion is
unsatisfactory and it must be removed. Remove the
primer or coating only from areas where sealing
compound is to be applied. If the primer or coating cannot
be readily removed by scraping with the thumb nail, it
should not be removed. Areas from which the primer or
coating have been removed should be reprimed or
recoated before sealant is applied.
Where lubricant is required to insure proper fastener
installation, inspect the fasteners to determine that they
are free of contaminants prior to installation. After
installation clean all exposed portions of the fasteners that
must be sealed by solvent wiping prior to application of
sealant.
Prior to the assembly of integral fuel tank components for
groove-sealing, deburr holes and clean all foreign
materials out of grooved areas. Carefully inspect fastener
holes for evidence of oil or other contaminants by spotchecking at intervals with a clean white rag. If any oil or
wax is present as indicated by a discoloration of the rags,
clean the holes carefully with cleaning solvent.
Immediately before assembling clean all grooved areas
and mating surfaces by wiping with cleaning solvent. In
each case use a clean cloth to apply the solvent and
another clean cloth to wipe the surface dry. To prevent
foreign materials from contaminating the integral
sealing grooves, all injection holes, or holes in which bolts
have not been installed, shall be covered with masking
tape until the sealing operation is performed.
20-20-02
COPYR IGHT, f 984 BY SABRELINER
Page 1
Aug 17/84
SR-76-023
SEALING METHODS
MIXING AND HANDLING SEALING
the temporary fasteners at five minute intervals

until it is no longer possible to tighten the fasteners
and all possible sealant has been squeezed from the
structural joint. Replace the temporary fasteners
with permanent rivets or fasteners and complete
assembly, following normal procedures. Sufficient
sealing compound must be placed in the holes and
around the rivet or fastener before installation to
ensure that the hole is sealed after the rivet is driven
or the fasteners are tightened to the required torque.
All riveting must be completed before the work life
of the sealing compound has expired.
COMPOUNDS
The base compound and accelerator, if purchased as a two
component mixture, should be mixed together in the
proportions prescribed by the manufacturer of the
compound so that there is uniform dispersion of
accelerator throughout the mixture,
Sealing compound must be used within its work life after

being mixed with the accelerator or after reaching room
temperature when removed from cold storage.
After addition of the accelerator, sealing compound may
be stored under conditions of time and temperature such
that after storage the material meets work life
requirements prior to use. Sealing compounds removed

from cold storage and thawed must be used or discarded.
Refreezing of thawed sealants is prohibited.
Carefully conduct mixing, cartridge loading, and other

handling operations to minimize air entrapment in
sealant. Grease, oil, or other contaminants shall not be
allowed to contact the sealant during these operations.
Occasionally parts have to be assembled with sealant

without fasteners installed. When this occurs, clamp
the parts together using "C" clamps and some means
of assuring proper alignment. (Springloaded clamps
should not be used.) Maximum clamp spacing is
shown in table 2. Retighten the clamps at five minute
intervals until it is no longer possible to tighten the
clamps and all possible sealant has been squeezed
from the joint. Allow the sealant to partially cure
before drilling any fastener holes and completing
Faying surface sealing consists of application of sealing

compound between contacting surfaces of a structural
joint then clamping or fastening the surfaces so that
mating surfaces of the structural joint are in physical
contact and all excess sealant is squeezed out. Sealing
compound to be used for Type I sealing is specified in
table i. The steps involved in sealing a faying surface are
as
5.
the assembly.
AIRCRAFT SEALING
i~ype i
(Continued)
Id ~cM
follows:
oA
i.
Apply sealing compound as shown in figure 1 with a

sealant gun or a spatula to one of the faying surfaces,
Spread sealant with a toothed spreader to a thickness
o
o
o
Clamp riveted or fastened together assemblies

initially with temporary fasteners such as wing nut
Clecos or set-up bolts using the maximum spacingof
temporary fasteners shown in: table 2. Retighten
/~--APPLYING
a\/
SEALANT
SPREADING
SEALANT
,"P
LAPPLY AND
Place the uncoated faying surface on the coated

faying surface. Avoid "wiping" one part against the
other as the parts are joined. Wiping can result in
insufficient sealing compound in the wiped area.
4.
10
/.I
of 0.010 to 0.020 in. over the entire surface to be

sealed. Another acceptable method is to apply and
spread the sealant with a short nap paint roller.
Protect the sealant from contamination by dirt,
metal chips, airborn solvents, or other foreign
materials until parts are assembled.
SPREAD SEALANT
wlTn A ROLLER
Applying Sealant
to
Figure
Faying Surface
1
20-20-02
Page
1!
~ug 17/84
COPYRIGHT, 1984
BY SABRELINER CORPORATION
S~LBRLLINER
CORPORATION
SIL
SERVICE INFORMATION LETTER
SIL: 57
REV: Basic
DATE: 9-29-00
PAGE: 1 of~
APPLICABLE:
Model NA265 Series
Ali Models
SUBJECT:
Sealant
DISCUSSION:
Due to sealant
manufacturing environmental restrictions,

most sealants specified in the Sabreliner Corrosion
Control and Structural Repair Manual are obsolete.
Replacement sealants have been developed.
INSTRUCTIONS:
Attached
are
applicable
two
copies
of the current sealant list
to all models of the Sabreliner Aircraft
NA265 Series. Please attach
one copy to SR-76-023,

3
chapter 20-20-02, page (Corrosion Control Manual)
and the other copy to NA-66-1032, chapter 51-30-00,
(Structural Repair Manual) as a

temporary revision until the next manual revision.
page 6A
SEALANTS
Applicable to Aircraft
Application
Sealing Exterior
Skin Seams 8
Antennas
Cabin Pressure
and Liquid Tight
Sealing
MltS81733
1 Mll-S-38228
MIL-S-38228
I MlL-S-38228
I P/S 8708
PIS 8908
CS 32048
AC-632
1 MllS-81733
I Mll-S-8802
1 MlL-S-8802
I MILS-38228
PIS 890C
PIS 670C
IAC236C
Condition
Availability
Specification
PIS 8708
1 P/S 8958
I CS 24108
AC-632
Fay Surface
Sealing: Aircraft
StructureLAux
Fuel Tank Cmpt
All Models
Available Class
Reference
Approved
Materials
NA265 Series
B~, 8-2, B4
B-%, 8-2
82
B-~I, &2
B%, 8-2, 84
8-/1, 82, 84
8-%, B-h 8-2, &4
B-3/t, 8-2
C-20, C-80
C-i2, C-24, C48
C-20, C-80
MIlS-8802
Mil-5-81733
I MllS-8802
2-Part
2-Part
1 2-Part
a-Part
Can a Kit
I Can 8 Kit
Can 8 Kit
Can a Kit
P-Part
Can a Kit
2-Part
2-Part
2-Part
I Can 8 Kit
I Can 8 Kit
2-Part
1 Can a Kit
Can 8 Kit
Can 8 Kit
P-Part
P-Part
Can 8 Kit
SA0106-106
Fuel
Bay Bead
Sealing: Wing 8
Aux Fuel Tank
Structure
Fuel
PIS 8908
PR-1422B
I CS 32048
AC-275B
AC-236B
I MllS-8802
I MlL-S-6802
Mll-S-8802
P/S 690A
PR-1422A
CS 3204A
AC-275A
Bay Sealing
Wing Injection
Sealant
DC94-011
I DC94-031
qlon a Firewall
High Temp.
MllS-8802
I MllS-8802
1 MIL-S8802
I AMS 3276
B-%, 8-2, &4

~t, B-i, B2
B-%, &W, 8-2, B~
B%, 8-2, 8-6
I B-~1, B-i, 8-2, &4, B6
I A-%, A-2
I A-/t, A-2
A-%, A-i, A-2, A-4
A-%, A-2
P-Part
5-Part
Can 8 Kit
I Can 8 Kit
I Can
Kit
I Can 8 Kit
I
I
I
I
I Pre-Mb
I Pre-Mix
I Can 8 Kit
Can 8 Kit
I 2-Part
i 5-Part
Can 8 Kit
Can 8 Kit
1 2-Part
Can 8 Kit
Can 8 Kit
I AMS 3276
I Mll-SS802
CS 1900
PR-812
MILS-38249
(MIL-S-38249
PR-19948
CS 55008
I
I Mll-S-83430
1 8-2
PR-1428B
Mll-S-8784
CS 33308
AC-215B
MlL-S-8784
P-Part
2-Part
P-Part
P-Part
2-Part
S-Part
2-Part
Can 8 Kit
Can 8 Kit
Can 8 Kit
I Can a Kit
Can 8 Kit
Sealant
Wing Leading
Edge Anti-ice
B-2, 8-6
2-Part
g
Cabin 8
W~ndow
Cockpit
Faying
Surface, Access
MIL-S-8784
B-%, 8-2
8-%, 8-2
B-%, 8-2
2-Part
P-Part
P-Part
i Can 8 Kit
Can a Kit
Can 8 Kit
Panel a
Removable Door
Sealant
Cockeit 8 Cabin
Acrylic 8 W~ndow
Installation
Aerodynamic
Smoothing
Sealant
Quick Repair of
Integral Fuel
Tanks
I B-W.
PR-14258
1 8-2
I B-W,
P/S 8958
1 MILS-38228
I B% &X &1, &2

B~1, 8-2
CS 24108
AC632
I MllS-38228
CS 32048
AC250A
&2
PR-17258
CS 32478
AC-2518
AC240B
MltS-38228
1 MllS-8802
I MllS-83318
MllS-8802
a-Part
B-2
1 82
BW. 8-2
I 8%
I A-116, 8-1/6
I B~ 8-2
Reference Sabreliner information Letter 57
5-Part
2-Part
2-Part
2-Part
1 P-Part
2-Part
I P-Part
2-Part
P-Part
Can a
I Can 8
I Can 8
Can 8
Kit
Kit
Kit
Kit
Can 8 Kit
I Can 8 Kit
I Can 8 Kit
I Can a Kit
I Cana Kit
Can 8 Kit
SR-76-023
CORROSION CONTROL NIANUAL
Table 1.
Aircraft Sealing Methods, Compounds, and Areas

SEALING METHODS
TYPE
SEALING COMPOUNDS
METHOD
CLASS I, LOW TEMP.

-65 TO +275"F
Type I
Faying
Brush
III
IV
Fillet
Cabin Pres
Interior
Surfaces
PR-1422G
PR-1225
PR1436G
Gun
Brush
Gun
Or
Or
Or
Or
Roller
Roller
Spatula
Spatula
Class
Type
Fillet
Surface
PR-1431
CLASS II, HIGH TEMP.

-65 TO +450"F
Type
Type II
Class
Class
AIRCRAFT SEALING AREAS
Class
Spray
Gun
Class
T3TPe
I
450"F
PR-810
Gun
Type
II
.760"F
PR-1750B
Gun
INTERIOR
Self
Contouring
PR-1403G
Gun
Exterior
Surface
PR-341
Gun
Fuel Tank
Groove
Or
Or
or
or
Spatula
Spatula
Spatula
Spatula
Spatula
Class
Class
Class
Fuselage
E
L;3
bC
~bL
~be
-a~
~c
W~4
,g
c
I
A-2
B-1/2
B-2
B-2
C-l
B-2
B-2
B-2
B-2
rd
E~
bO"
E
~j
~j
c~
3~4
s,
3
r.E
I;-
E
E
F4
Class
B
3~
0,
(3
C--
E3cl
~4
it
~d
T~i
aO
-65 TO +275"F
-65 TO +450"F
Pre Pack
~1
A-1/2
"1
A-48
Nacelle
~C1
Or
Class
Wing
PR-705
Gun
EXTERIOR
IIA
Sealing
Structural Intersections
1
-65 TO +275"F
-65 TO +450"F
IIB
Integral
III
Self Contouring
818
Fuel Tank Grooves
Separable
Sealing
Surfaces
IIIB
Windous
IIIC
Windshields
Injection Sealing-integral
Fuel Tank Grooves

XI
Fillet
XIA
Seams
c
m
Joints
-65 TO +275"F
-65 TO +450"F
XIB
Holes
1
Slots
-65 TO +275"F
I 8
-65 TO +450"F
E
m
Sealing
XIC
Fasteners
1
-65 TO +2750F
-65 TO +450"F
88888
888
Sealing
XII
Exterior Surface
XIII
Spray Sealing-Interior
8)
Surfaces
XIV
Anti-Icing Duct Sealing
NOTE
As
8elbacilppa
NOTEr Please
see
the
TEMPORARY
REVISION
~that revises this page.
20-20-02
page 3
Sep 6/91
SR-76-023
SEALING METHODS (Continued)

Table 2.
Spacingof Clamp-up
5.
Devices
MAX. SPACING OF
CLECOS, SET-UP
ASSEMBLY MEMBER BOLTS, OR "C" CLAMPS
THICKNESS
OF THINNEST
0.050
0.070
0.090
0.125
6.
1.5
2.0
3.0
4.0
to 0.069 In.
to 0.089 In.
to 0.124 In.
In. and up
the temporary fasteners at five minute intervals

until it is no longer possible to tighten the fasteners
and all possible sealant has been squeezed from the
structural joint. Replace the temporary fasteners
with the permanent rivets or fasteners and complete
the assembly, following normal procedures. Place
sufficent sealing compound in holes and around the
rivets or fasteners before installation to ensure that
the hole is sealed after the rivet is driven or the
fasteners are tightened to required torque. The
operation must be completed before the
In.
In.
In.
In.
When either step 4 or 5 is completed, the squeezed

out sealant. Use clean cloths dampened with a
cleaning solvent and wipe dry with a clean dry cloth.

Apply a fillet seal to seams, joint holes, slots, and
assembly
work life of the sealing
fasteners.
7.
6.
when it is impractical to apply a fillet

be
it
necessary to work the squeezed out
seal,
may
sealant into a fillet seal. To ensure that the squeezed
out sealant will be sufficient to provide the fillet seal,
additional sealant may be required to build up the
In
some
cases,

shown in table 2. Retighten clamps at 5 minute
from the joint. Allow sealant to partially cure before
drilling fastener holes and com pleting assembly.
Prepack Sealing
to fill voids created at structural

intersections and to fill wing leading edge intRgral fuel
tank groove seals when injection groove sealing after
Prepack sealing is used
Type IIB
Type IIA
The sealing compound used for Type IIB sealing is shown

in table 1. Steps involved in this type of sealing, shown in
figure 3, are as follows:
structure is assembled.
Prepack Sealing of Structural
Intersections
1.
The sealing compound used for Type IIA sealing is shown

in table 1. Steps involved in this type of sealing, shown in
the example in figure 2, are as follows:
1.
filled without air entrapped. As the third

final bead on top of the sealant in the
step, lay
surface.
groove. projecting above the faying
a
Applysealing compound to all surfaces enclosing the

2.
material on
a spatula, pack sufficient excess
of the surfaces to ensure filling the void.
Eliminate any entrapped air. If prepacks sealing is
being done in conjunction with faying surface
sealing, pre-pack sealing must be accomplished
before the faying surface sealing.
Using
one
3.
3.
Protect sealant from contamination by dirt, metal

or other foreign material
4.
are
Apply sealing compound as shown in figure 1 with a

sealant gun or spatula to one of the faying surfaces.
Spread sealant with a toothed spreader to a thickness
of 0.010 to 0.020 in. over the entire surface to be

sealed. Another acceptable method is to apply and
spread the sealant with a short nap paint roller.
chips, airborne, solvents,

until the parts
Using a sealant gun, fill sealing groove with the

sealing compound in two steps to ensure that the
corners are
void at the structural intersection.

2.
Prepack Sealing of Integral Fuel
Tank Grooves
practical. Prepack sealing is
assembly is not
accomplished before the
compound expires.
Occasionally, parts have to be assembled with sealant

together using "C" clamps and some means of
parts
assuring proper alignment. (Springloaded clamps
fillet seal.
Type II
Clamp riveted or fastened assemblies together

initially with temporary fasteners such as wing nut
Clecos or set-up bolts using the maximum spacingof
the temporary fasteners shown in table 2. Retighten
Protect sealant from contamination by dirt, metal

chips, airborne solvents, or other foreign materials
until the parts are assembled.
assembled.
Assemble parts, avoiding air entrappment during
assembly. Press parts firmly together.
20-20-02
Page 4
Aug 17/84
(B
SR-76-023

Type IIB
Prepack Sealing of Integral Fuel
5.
Tank Grooves (Contd)

4.
Place the uncoated part
on
the coated part. Press
firmly together. Clamp riveted or fastened assemblies together initially with temporary fasteners
such as wing-nut clecos or set-up bolts using the
maximum spacing shown in table 2. Retighten temporary fasteners at five minute intervals until it is no
longer possible to tighten the fasteners and ail possi-
ble sealant has been squeezed from the faying joint

and extended out of the groove injection holes. Plug
the groove injection holes and replace the temporary
fasteners with the permanent rivets or fasteners and
complete the assembly follow i ng no rmal procedures,
Place sufficient sealing compound on the holes and
around the rivets or fasteners, before installation, to
ensure that the holes are sealed after the rivets are
driven or the fasteners are tightened to the required
Occasionally parts have to be assembled with sealant

the parts together using "C" clamps and some means
of assuring proper alignment. (Springload clamps
shown in table 2. Retighten the clamps at 5 minute
from the joint. Allow the sealant to partially cure
before drilling any fastener holes and completing
the assembly.
6.
When either step 4 or 5 is completed, remove the

squeezed out sealant. Use clean cloths dampened
with a cleaning solvent and wipe dry with a clean dry
cloth. Apply a fillet seal to seams, joint holes, slots,
and fasteners.
torclue.
PREPACK VOID
BEFORE FITTING
ISINSTALLED
:j,
i
/Iv
~v,
~3
8 ~zirl
8
+I
_
Prepacking a Void
Figure 2
20-20-02
a
Page 5
Aug 17/84
SR-76-023
STANDARD PRACTICES
Type III
AIRFRAME
Self-Contouring Sealing
spreader over the entire surface to be sealed to a
Type III sealing is used to apply a rubber self-contouring

sealing pad to the stationary structure under removable
doors and normallp separable sections of structure. Type
IIT sealing is also used to seal transparent areas such as
windows and windshields.
Type IIIA
Self-Contouring Sealing of Separable
3,
and smoothness of the seal.
~below.
t~pply sealing compound to rubber seal base as

sh=wn in figures 1 and 4 with a sealant gun or a
spatula. Spread the sealant with a toothed
short nap
in.
Another
Protect the sealant from contamination by dirt,

metal chips, airborn solvents, or other foreign
materials until the parts are assembled.
c,
Place coated rubber seal surface on the

uncoated stationary surface. Avoid "wiping"
one part against the other as the parts are
joined. Wiping can result in insufficient sealing
compound in the wiped area.
Apply a non-silicone releasing agent, such as mold

release, to the stationary part of the assembly being
sealed to prevent the sealing compound from
adhering to the stationary part. apply the releasing
agent to rubberseals, screws and fasteners that may
be on the laying surface of the stationary part to
prevent these items from being sealed into the
sealing compound. Sprayable mold release agent
shall not be used.
Install rubber seal in the stationary part. Seal the

faying surface between the rubber seal and the
stationary part in accordance with steps a, b and c
a.
0.020
apply and spread the

painting roller.
b.
The sealing compound to be used for Type IIIA sealing is

shown i n table i. The steps involved in this kind of sealing,
shown in figure 4, are as follows:
Apply sealing compound to the removable part of

assembly to be sealed using a sealant gun or a
spatula. If a sealant gun is used, spread the sealant
beads with a spatula to ensure adequate thickness
to
to
sealant with
Surfaces
1.
thickness of 0.010
acceptable method is
4.
Assemble the parts being sealed and allow the

sealant to reach a fully cured status.
FAVING SURFACE SEAL
~t
i: L
.125
Prepack Groove Sealing

Fig-ure:~
20-20-02
Page 6
Aug 17/84
SR-76-023
g FASTENERS
REMOVABLE PART
APPLY SEALANT
STATIONARY PART
APPLY RELEASING AGENT TO ALL
POSSIBLE SEALANT FAYING

SURFACES
FAYING
SURFACE SEALANT
CLEAN RELEASING AGENT

FROM ALL SURFACES
WHERE APPLIED
PRIOR TO ASSEMBLY
~C3
ASSEMBLED DURING SEALANT CURE
CLEAN RELEASING AGENT

FROM ALL SURFACES
WHERE APPLIED
Sealing of Separable Surfs~es

Figure 4
20-20-02
0
COPYRIGHT,
Page 7
Aug 17/84
SR-76-023

NOTE
Self-Contouring Sealing of Separable
Type IIZA
Surfaces (Contd)
OnlZl but splices are permissable in the

application of the double coated tape and
Remove the removable part and remove any excess

sealant, Clean the releasing agent from the
stationary part using MEK or equivalent.
the rubber shim,

2,
In
some cases
applied
the sealing
to the
compound luill be
stationay/ part and the
rubber seal will

~remouable part.
be
attached
to
Seal outer window surface and outer skin joint as

part of Type XLII Exterior Surface Sealing, Allow
exterior surface sealant to cure.
4.
Disassemble the window retainer and the sliding

window assembly. Remove the rubber shim and
double coated tape from the window retainer. Clean
the window retainer surface using MEK or
the
Self-contouring sealing compound used for Type IIIB

window sealing is listed in table 1, The steps involved in
sealing fixed windows and the pilots sliding window are
as
3.
Self-Contouring Sealing of Windows
Type IIIB
equivalent.
5~
follows:
Fixed Windows
The steps involved in sealing
figure 5, are as follows:
Assemble window retainer and sliding window

to cure for 24 hours.
assembly. Allow sealant
NOTE
fixed window,
as
shown in
Prepare the rubber extrusion seal for installation by

roughing the faying surface with a wire brush or
sandpaper. Coat the window retainer and the
extrusion seal with a coat of Minnesota Mining and
Manufacturing Company EC 13.57 adhesive, Let the
first coat of adhesive dry for 60 minutes, then apply a
second coat.
i.
Apply self-contouring sealing material to the

phenolic doubler on the outer side of the outer
window and to the support pan in the area where the

support panattaches to the outer skin. Install
support pan and the outer row of fasteners.
When the adhesive becomes tacky, install extrusion

by starting at the top of the window retainer and
firmly pressing extrusion in place all around the
retainer, Maintain position of the extrusion relative
to the inner perimeter of the window retainer as
shown in figure 6.
7.

phenolic doubler on the outer side of the inner
Assemble window retainer and sliding window

assembly, Leave window closed for a 24 hour period.
Type III C
window and install the window,

L.

phenolic doubler on the inner side of the outer
window and install the window,

4.
Apply inner sealant material to the phenolic doubler

on
5,
the inner side of the inner window,
In,tall the inner retainer and fasteners and allow

a iully cured status.
sealant to reach
Ci.
Seal outer windowiouter skin joint

,YII Exterior Surface Sealing.
Pilots
as
part of
Sliding Window
Attach
0.062
i.
Cover surfacp of structure that mates with the

windshield with acetate fiber tape. Install corkrubber shims, approximately li2 in, wide and spaced
6 in, apart, to the taped sur~aces.
2.
Apply self contouring sealing compound in a

sufficient amount to ensure a smooth pad between
the cork-rubber shims.
Apply adhesive teflon tape
to windshield edges and

inner surfaces that will contact the sealant material.
Install windshield.
4~
Coat outer retainer with self contouring sealant.

Install outer retainer.
as
synthetic rubber shim

single layer of Polyken No. 105
0.75 in.
(AMS 3240) with
The sealing compound used for Type IIIC sealing, is listed

in~table i, The steps involved in this kind of sen ling, shown
in figure 7, are as follows:
Type
The steps involved in sealing the pilots sliding window,

shown in Figure 6, are as follows:
i.
Self-Contouring Sealing
of Windshields.
double coated tape to the window retainer with the

edge of the shim flush with the inside perimeter of
the window retainer as shown in figure 6,
5,
Seal windshield and outer retainer joint

XII Exterior Surface Sealing,
as
part of
Type
20-20-02
Page 8
Aug 17/84
COPYRIGHT, 198$
sV
SR-76-023
SUPPORT
PAN
INNER
00
RETAINER
o/o
o
o
O
O/
\o\
I01
0/0/
wlo
/O/
lo101
lolo
~o
O
O
000
O
VIEW LOOKING OUTBOARD
INNER RETAINER
INNER WINDOW
WITH PHENOLIC
SELF CONTOURING SEALING MATERIAL
DOUBLERS
SUPPORT PAN
OUTER WINDOW
f
WITH PHENOLIC
OUTER SKIN
DOUBLERS
~L
EXTERIOR SURFACE SEALANT
SELF CONTOURING
SEALING MATERIAL
SECTION A-A
Sealing Fixed Windows

Figure 5
20-20-02
0
Page 9
Aug 17/84
SR-76-023
SLIDING WINDOW ASSEMBLY
STRUCTURE
SELF CONTOURING SEALANT
jl
SYNTHETIC RUBBER SHIM

ATTACHED WITH DOUBLE COATED TAPE
WINDOW RETAINER
PRIOR TO ASSEMBLY
2
ASSEMBLED DURING SEALANT CURE
REMOVE RUBBER
J
f
SHIM AND TAPE.

1,. 1/32- 1/32
-3
ATTACH RUBBER
EXTRUSION SEAL
WITH ADHESIVE.
DISASSEMBLED AFTER SEALANT CURE
Sealing Pilots Sliding Window

Figure 6
20-20-02
Page 10
Aug 17/84
C;OPYRIGHT, 1984
SR-76-023
WINDSHIELD
OUTER RETAINER
ACETATE FIBER TAPE
i lr
CORK-RUBBER SHIM
STRUCTURE
VIEW LOOKING INBOARD
OUTER RETAINER
WINDSHIELD
SELF CONTOURING
SEALANT
STRUCTURE
TEFLON TAPE
CORK-RUBBER SHIM
ACETATE FIBER TAPE
SECTION A-A
Sealing Windshields
Figure 7
20-20-02
o
COPYRIGHT, 1984 BY SABRELINER
Page 11
Aug 17/84
SR-76-023
C()RKOSION CONTROL MANUAL

Type
--Injection Sealing of Integral Fuel
Type
Tank Grooves
The sealing compound used for Type X sealing is listed in
table 1. The steps involved in this type of sealing, shown in
figure 8,
i.
Z.
are as
follows:
1.
After all other sealing in the integral fuel tank area

has been accomplished (Type I, Type II A, Types XI
A, XI B and XI C as required), accomplish final
assembly by installing the outer skin. All rivets and
fasteners shall be coated with sealant before they are
installed.
Insert lip of the Gruver sealant gu n into the injection
port. Force sealant into the groove until it extrudes
from the unplugged ports on either side of the port
1.
t2epeat step as required

injected.
to ensure
2,
Use nozzle tips with openings of sufficient size so

that the desired convex shaped fillet, shown in figure
13, can be applied with one pass of the sealant gun. If
more than one pass is required, keep the nozzle tip
buried in the applied sealant to avoid trapping air in
the fillet.
3.
If the fillet contains folds, flaps, ol entrapped air, the

fillet should be worked with a spatula or fairing tool
to remove these undesirable conditions and to retain
the desired convex fillet shape.
that all grooved
areas are
Install
closing
B.
injection hole screws in the injection ports,

off the injected grooves.
Fastener holes may be used as injection ports.

9 shows basic dimensions for a sealing
groove. Figures 10 and 11 present counterbore
dimensions for installing rivets or bolts in sealing
~n,c,ve. F i Rule 12 shows the configu ration io r seal i ng
grooves with a double row of fasteners.
Whc~ applying fillets on vertical or iiicl;iied

surfaces, a small undersized fillet should be applied
first and allowed to partially cure, then a full sized
fillet applied over it. Fillets applied in this manner
Figure
will have less
tendency
to
slump.
5.
As shown in figure 14. all fillets should be continuous

along the length of a jeam and shouitl constitute a
closed loop. Any intersecting fillets jhould also be
continuous and form a jecondarv loop.
6.
Fillets along seams and joints should have the

dimensions shown in figures 16 through 19. Spray
gun or brush applied sealant overlay shown in
figures 1Ei, 18 and 19 should not be used in areas
where Type VII
Spray C,ealing of Interior
Surfaces, will be applied later.
IVOTE
Injsction sealing ofzloids created at structu~ral intersections after assembl~y is ~not an

approved seaCi:tg method. Such, sealing
should be accomplished 5y prepack sealing
before assembl21.
Apply fillet bead to seam or joint using a sealant gun.

Point nozzle tip into the cornet being sealed so that
the sealing compound is forced into the corner as
shown in figure 18. The tip should be in contact with
the surfaces so that the sealant does not "drop" on to
the surfaces but is forced into the corner. Fillets
on" rather than "forced into" the corner
te"d to have voids and air entrapped in the sealant.
Move gun tip to the next adjacent injection part.

Force sealant into the groove until it extrudes from
the unplugged ports on either side of the port being
injected.
Fillet Sealing of Seams and Joints
"dropped
being injected.
Y.
XI A
The sealing compound used for Type XI A sealing is listed

in table i. The steps involved in this type of sealing are as
follows:
Do nzot allozu other sealants to enter the

i~njection sealing grooves as the sealing
groove may be bloclced reszclting in the
i.lLCLb~lit7J to ilzject sealant into the groo~ue.
Type XI
Fillet Sealing
Fillet sealing is the application of a constant bead of

sealing compound at the corner junction formed by two
adjacent parts.
20-20-02
Page 12
Aug 17/84
SR-76-023
INJECTION
PORT
SEALANT
SEALING GROOVE
Injection C;roove Sealing

EiaLIIe
0.03
_L
0.188-0.01
0.050r3.J05R
1
0.050-0.010
0.156 ALUMINUM
Bauic Dimensions of
Figure
Sealing
C;roove
20-20-02
0
COPYRIGHT, 1~03 BY SABRELINER CORPORATION
Page 13
Aug 17/84
SR-76-023
RIVET
11
SIZE
(+0.010)
(+0.010)
(+0.010)
3/32
0.375
0.031
0.050
1/8
.437
.031
.050
5/32
.500
.082
.050
3/16
.562
.062
.050
--1
I
f
Counterbore Dimensions for Installing

Rivets in a Sealing (;roove
Figure
10
1
BOLTHOLE DIAMETER
3tl
AND
D,
COUNTERBORE DIAMETER.
D,,
i=--
SHALL BE CONCENTRIC WITHIN

0.030 TlA
D,
BOLTHOLE
COUNTERBORE DIMENSIONS
DIMENSIONS
TOLERANCE
FASTENER
ALUMINUM
D,
SIZE
Db
STRUCTURE
(+0.010)
(+0.010)
3i16
0.189
+0.003. -0.000
.250
+0.002. -0.001
liJ
5/16
.3125
D,O
RO
(+0.010)
(+0.010)
0.375
0.050
0.438
.137
.050
500
.500
062
562
3/8
.375
.562
7/16
.4375
.625
1/2
.500
625
9/16
0.5625
687
0.002, -0.001
0.750
0.125
(+0.01~:
0.050
687
750
0.062
0.812
0.125
0.050
IVOTE
TO BE USED WHERE STRESS LIMITATIONS REQUIRE

MORE GENEROUS RADII FOR REDUCTION OF NOTCH
EFFECT FROM COUNTERBORES AROUND BOLTHOLES

THROUGH GROOVES
Counterbore Dimensions for Sealing Groove at
Figure
Bolt Location
II
20-20-02
Page
14
Aug 17/84
COPYRIGHT, 1984
BY SABRELINER CORPORAT:CyN
SR-76-023
CORROSION CONTROL blANUAL
C;1oove ConfiRulation fot
Dout,le Ro~ of Fastene~s
FiRule
L"
NOZZLE TIP
45"
Tip Position
Fiaule 1~
Nozzle
20-20-02
Page 15
Aug 17/84
SR-76-023
START
CLOSE
PRIMARY LOOP
START
CLOSE---/
SECONDARY
LOOP
Appiication of Fillets
Figure 1-I
.50 MIN
SPRAY GUN OR BRUSn

APPLIED SEALANT OVERLAY
If-
.250 MAX
:50.IN-L~ II
.008 MIN
-I-
.50 MIN
SEALANT GUN OR SPATULA

APPLIED SEALANT
20-20-02
Page 16
Aug 17/84
Lapping Structure .250 In. Max Thickness

Figure 15
COPYRIGHT,
SR-76-023

Type XIB
Fillet
Sealing of Holes
and Slots
Sealant Gun Application
Sealing compound used for Type XIB sealing is listed in

table I. The steps involved in this type of sealing are as
follows:
Holes or slots that penetrate a sealed
the pressure or wetted side.
area
A sealant gun with a nozzle large enough to fit over the

fastner can be used to coat the upset ends of solid rivets
and both ends of smaller threaded fasteners (5/16 in.
diameter or less). The open end of an extension nozzle can
also be used for the manufactured head of rivets. Place the
nozzle over the fastener and against the fastened structure. Apply sealant until it extrudes from under the edge
of the nozzle. Stop application of the sealant and withdraw
the nozzle with a spiraling motion.
must be sealed
on
Holes (,r slots up to (3.12.5 in, diameter or width shall

be ~ealecl by applying sealing compound as shown in
fi~rule 20.
Type ~IC
Fillet
Sealing
of Fasteners
Brush Application
Sealing compound used for Type XIC sealing is listed in
table i. Three basic methods, sealant gun, brush, or spray

gun, may be used to apply sealing compound over
fasteners, as shown in figures 21, 22, 29. and 24.
to coat all fastenel,s with sealant. Load the brush with
P/N 960 sealant brush
or a
1/8 artist brush
can
be used
sealant and apply the sealant first to the fastener at the

leak path edge. Rotate the brush around the fastener
making sure the leak path edges are covered and then
withdraw the brush from the fastener with a spiraling
motion.
MATERIAL THICKNESS
OR.375 MIN
t-t
Lapping Structure ()ver ().~50
Figure 16
inch I~hickness
CONCAVE
SHAPE
REENTRANT
EDGE
S NOT
ACCEPTABLE
DESIRED
OVEALAP
CONVEX
SHAPE
Lnacceptable Fillets
Figule li~
20-20-02
0
COPYRIGHT, 1984
Page 17
Aug 17/84
SR-76-023
.50
MINt? IJ I;L.50
MAX
.50 MIN
7
.000 MIN
.250 MAX
SELANT GUN OR SPATULA

APPLIED SEALANT
MORE THAN .50
1-
TREAT AS
SEPARATE FILLET SEALS
Hutt (;aps
FiRure
1X
ADD A SPRAY GUN OR BRUSH

APPLIED SEALANT OVERLAY
IF DEPTH OF GAP IS LESS
THAN .150.
.008 MIN
FILL WITH SELANT UNTIL LEVEL.

IF CAP IS LESS THAN .50 WIDE.
Yeam Edge Facing High Leg of FlanRe
Fi~ule
or
;\ngIe
19
20-20-02
Page 18
Aug 17/84
COPYRIGHT,
SR-7fi-023

Fillet Sealing of Fasteners (Contd)
Type XIC
Sprav (;un Application

Use! a paint spray gun to coat all fasteners with sealant
0.008 in, thickness.
Some fasteners have recesses on the nut or collar end. Do
not t,riclae over these recesses and trap air when coating
these Fasts ne rs. F i II them fi rst by extrud i na sealant usi ng
r;mall tip nozzle. Care should be taken to avoid
a
entrapment of air while coating othei parts of the
Fasteners.
two basic
Fastener seals,
fo I ]ORS:
I~he
i.
Xpplv
over
r.
the
fillet dimensional requirements for

shown in figures 21 and 22. are as
as
Extreme care should be taken when applying any fillet to

prevent the creation of bridges, as shown in figure 24
between closely positioned fasteners and structure. Leak
paths can be created that are almost impossible to find
and plug.
Type XTI Exterior Surface Sealing

External skin gaps, laps, and depressions must be sealed
to preclude leakage of water into the aircraft and for
aerodynamic smoothing purposes. The sealing compound
used for the Type XII exterior surf ace sealing is listed in
table i.
Seal skin gaps

i.
~ihown in
figure 2:,.
dome nuts shall t,e sealed
on
as
cleaning procedure.
fo Ilows:
i.
Installed dome nuts with a faying surface seal

i~e twee! n the att~ c h i ng fl a nges and the su hstru~t,u re,
lJse only the required amount of sealant to avoid
2.
estr.utling excess sealant into the dome thereby

immobilizing the nut.
2.
Apply a fillet seal around the dome. Do
cover
the
being careful
not
not
tlome \vith sealant.

ci,vcl the
to
follows:
Apply 3/4 to in. wide masking tape to the skin on

each side of skin gap leaving 1/16tU32 in, of skin
exposed on each side of gap. Before applying tape,
clean the skin by wiping down with solvent and
drying with a clean cloth. Ensure that oil from
fingers does not contaminate the cleaned surface. If
fingers contact the area to be sealed, repeat the
minimum of 0.O60 in. thickness of sealant

leak path edge,
The ~enlant shall cover a minimum of 0.12.5 in,

either ~icle of the leak path edge.
as
cntlap
flange til,s
anY
with ~eaiant,
Apply sealant using either a, sealant gun or a clean

wooden spatula. If the sealant gun is used, place the
opening of the tip flat against the seam and apply a
slight excess of compound. moving the gun as the
joint fills up. If a spatula is used, apply an excess of
sealant at one point on the seam and work the sealant
into and along the seam.
air.
.25 TO .35
PRESSURE SIDE
.25 TO .35
.125 MAX
Sealing Holes and Slots up

Figure 20
to 0.125 In.
20-20-02
Pscre 19
0
Aug 17/84
SR-761023
SEE DETAIL "A"
LEAK PATH EDGE
SEALANT
DIMENSIOPIS FOR ALL LEAK

PATH EDGE SEALS
DETAIL "A"
NT)TE
:25MIN
Fastener Leak Path Seals
Figure
21
20-20-02
Page 20
Aug 17/84
COPYRIGHT,
1984 Br JABRELINER CORPORATION
SR-76-023
SEALING METHODS
Type XIII
:i.
After
Exterior Surface
compound
has been
Sealing (Contd)
applied using
the sealant
spatula and press compound into the

seam, removing the excess from the sealed are. If a
spatula was used to apply the sealant, only remove
excess compound using the spatula.
use
gun,
4.
Xfter the seam has been sealed and excess compound

removed, the tape should be removed. It is essential
that this be done before the compound starts to set
up.
5.
Immediately after removing the tape, fair out the

edges of the compound. This may be done by
drawing one finger along the edge. Moistening the
finger with water or Solvent Blend No. 6 will
minimize
sticking of the compound to the finger. Do

on the fingers as this may impair
adhesion of the compound to the structure,
not
ii.
use
soap
~ftel the
com
compound has been smoothed, allow the
pou ntl to
room
cure for a minimum ti me of 24 hours at

temperature before coveringor disturbing the
Jurface.
Bonding shall be accomplished by either (a) weighted

bags placed over the :airing, 20 Ibsjbsg, or (b) vacuum
bag method, apply a minimum of 7.5 psi pressure.
Cure
Bonding method (a), weighted bag method. Bags

on fairing for 48 hours at 75f50F
at Fjg% relative humidity ~10%. Cure may vary with temperature and humidity.
must be secured and left
Cure
Bonding method (b). vacuum bag. Xpplv 7.5 psi

for 20 hours. Temperature anti humidity
requirements not applicable.
pressure
Type XIII
to
Overwing Fairing
one coat SnD0120-%j0, Type iI, Class A-2 to the

metal ~urfaoe, and one coat SB0120-e50, Type II, Class
B-" to the internal surface of the fairing. Entire surfaces
m 11SL have 1()OX, sealant coverage.
Ajipl!i
80LT
Spray Sealing of Interior Surfaces
Spray sealing is used to coat all interior structural

surfaces within a structural cavity whele bladder type
fuel cells will be installed. It is also used to coat all interior
structural surfaces whele protection from exposure to
detrimental liquids is desired. These areas include the
galley and areas adjacent to crew and passenae, seats.
The sealing compound used for type ~T(III sealing is listed
in table i. The steps involved in this type of sealing are as
follows:
i.
;\I,plication of Sealant
(Continued)
Determine that all other seaiing in the area to be

sealed has been accomplished (Tvpe I, Type IIA.
Types XIP,, XIE and ,YIC a; required;, that the
surfaces to be sealed have been coated with Cati-Coat
primer, and that all surfaces have been juitabiy
cleaned.
NUT OR COLLAR END
COAT THE ENTIRE END
MFG. HEAO MAY OR MAY NOT
RIVETS
BE COATED ON TOP
BOLT HEAD
UPSET END MAY OR MAY NOT

BE COP~TED ON TOP
Rivet and Bolt Leak Path Seals

Figure 22
20-20-02
0
CO~I;1IGHT, 1984 BY SABPFI !NER CORPORAIION
Page 21
Aug 17/84
SR-76-023
ALUMINUM DISH
DOME NUT
ai
FAY SEAL
SCOTCHBRITE PAD SATURATED

WITH FAYING SURFACE SEALANT
WITH 2000 BY VOLUME MEK ADDED
BEFORE INSTALLATION
APPLY FAYING SURFACE SEALANT
FILLET SEAL
ALL AROUND
AFTER INSTALLATION
APPLY FILLET SEALANT
Dome Nut Leak Path Seals
Figure
83
20-20-02
Page 22
Aug 17/84
SR-76-023

Type XIII
Spray Sealing of Interior
Surfaces (Contd)
2.
Type XIV
High temperature sealing compound used for Type XIV

sealing is listed in table 1. The steps involved in sealing
splices in the inbd and outbd heat shield assemblies (wing
leading edge anti-icing hot air duct), shown in figure 25,
Mask off areas that may be exposed to the sealant

spray but should not be coated. Temporarily plug
any openings, such as drainage holes, that should not
be sealed.
8.
Spray a coating of sealant with a maximum

thickness of 0.008 in, an all surfaces. including rivets
and bolts, to be sealed. Where spray sealing is not
practical or for touch up purposes the spray type
sealant may be applied with a brush.
4.
Allow the sealant to cure tack-free and remove all

masking tape and temporary opening plugs.
r).
In fuel ceil cavities. cover all plojectiny surfaces

such as structural corners and fasteners that might
a~,rade or puncture the fuel cell with LB()19()-008
anti-chaffing fuel resistant tape.
Anti-Icing Duct Sealing
are as
1.
follows:
Prior to installation of upper and lower splice angles.

lay a bead of high temperature sealing compound
along the edge of the heat shield cutout and on the
insulation material adjacent to the edge. Lay the
bead along the inbd, outbd, fwd, and aft edges of the
top and bottom cutout in the inbd and the outbd heat
shield assemblies.
2.
Install upper and lower
3.
bead of high temperature sealant over the gap

in the fwd and aft surfaces of the inbd and outbd
head shield assemblies.
Lay
splice angles and fasteners.
FROM ABOVE
LEAK PATHS APPEAR
TO BE COVERED
FROM THE SIDE
A BRIDGE OF SEALANT HIDES

AN UNSEALED LEAK PATH
SEALANT BRIDGE
LEAK PATH
Sealant
Bridge
Figure
24
20-20-02
0
COPYRIGHT, 1984 BY SABRELINE~
Page 23
Aug 17/84
SR-76-()23
CORK()SION CONTROL MANUAL
OUTED HEAT SHIELD ASSY.

INBD HEAT SHlt,D ASSY
HIGH TEMP. SEALANT
HIGH TEMP. SEALANT
i
II
HIGH TEMP. SEALANT
II
HIGH TEMP.
SEALANT
x41.3
159.08
INED
OUTED
UPPER SPLICE
ANGLE
INSULATION
FWD
LOWER
SPLICE
ANGLE
HIGH TEMP.
SEALANT
SECTION A-A
Wing Anti-Icing Duct Sealing

Figure 25
20-20-02
Page
"1
Aug 17/84
COPYRIGHT, 1984 BY SABRELINER COAPORATION
SR-76-023
SEALING INTEGRAL WING FUEL TANKS
GENERAL
This section covers procedures and materials needed to
seal integral wing fuel tanks.
MATERIALS
Sealant, non-hardening
putty
Sealant, Accelerator
LB0120-003
Overcoating, Integral
MIL-S-4383
two components are blended until a complete dispersion

of the acceleration is obtained. (A fillet made from improperly mixed sealant will contain areas of incomplete cure.)
At room temperature (approximately 770F) the MIL-S8802/MIL-S-81733 sealing compound must be used within
three hours after mixing with accelerator or removal
from cold storage. This sealing compound, after addition
of accelerator, may be stored at 0 to -100F for 15 days.
MIL-S-8802/MIL-S-81733
SEALING PROCEDURE
Tank Sealer
Sealing fuel tanks
EQUIPMENT
Groove Sealant Injection gun, four in. drive, 70:1
Head; Grover Smith Pump Co., P/H 223
Rib/spar intersections must be injected with groove

sealant (LB0120-003) prior to installation of leading
edge or outer panel skins.
2.
After leading edge or outer panel skins have been

installed and all fasteners have been torqued, inject
sealant into all of the integral sealing grooves.
3.
Fillet sealing as required is accomplished with

sealing compound (MIL-S-8802/MIL-S-8 1733).
Fillet sealing required at upper skin intersections
should be accomplished prior to final installation of
CLEANING AND PRIMING

or
Deburr holes and clean all foreign materials out of

areas before final assembly of tank components.
Carefully inspect fastener holes for oil or other contaminants. If slny oil or dirt is present, clean the holes with
cleaning solvent. Immediately before assembly, clean all
grooved
lower skins.
4.
grooved areas and mating surfaces by solvent: wiping

with cleaning solvent. Use a clean rag to apply the solvent,
anti another clean cloth to wipe the surface dry.
During assembly of the integral fu~l leading edge and
outer panels, observe the following:
All final machining and blending at step intersections of
spare and ribs must be completed and all faying surfaces
must be free of foreign material prior to fitting leading
edffe or wing skins.
Deburr all
holes, clean structure, and touch-up the
stlucture
required
as
with chemical film.
All fasteners to be sealed with groove sealant must be
vapor-degreased.
All installation fasteners must be
values.
torqued
to proper
follows:
1.
Injection
Integral fuel tank parts must be cleaned, anodized

chemical film treated, and coated before sealing.
as
Fasteners individually sealed with C~rings may be

installed at any convenient time in the assembly
sequence.
Se"ling the Tank Grooves

Inject with LB0120-00S sealant using Grover Smith
Pump Company Groove Sealant Injection Gun or
equivalent. Sealant injection is accomplished as follows:
Place the nozzle tip of the injection gun into the countersink of an injection hole. Hold the gun firmly in place and
depress the trigger until the sealant is injected about half
the distances to the adjacent injection holes. (The
preceding will be accomplished when the plunger travel
indicator has traveled approximately half of the stroke
whe" using the Grover Gun.!
integral sealing grooves, all

injection holes and empty bolt holes must be covered with
masking tape until sealant installed.
To prevent contamination of
MIXING AND HANDLING SEALING

COMPOUND
MIL-S-88C2/MIL-S-8 1733 sealing compound is prepared

by mixing the base compound and accelerator in the
proportions recommended by the manufacturer. The
20-20-04
0
Page 1
Aug 17/84
SR-76-023
SEALING INTEGRAL WING FUEL TANKS

Sealing the Tank Grooves (Contd)
Roll or slide an O-ring over the threaded end of screw until

it rests against the screw head. Care should be taken not to
damage thel0-rinff. Install the O-ring and screw
NOTE
assembly.
It is not
required that any one area be

completely injection-sealed before sealing
ad3acent areas. However, when two
separately injection-sealed areas are
joined, the sealing procedure must be
continued for a minimum of one injeetion
If a sealed fastener is removed after final installation,

reseal as follows:
Fasteners Sealed
hole.
Move the gun tip to one of the adjoining injection holes.
Hold the gu n fi rm ly i n place and depress the trigger until
the sealant flows out of the hole previously injected.
injccti~g sealant into the tank

the in~jection holes to either side of
the gzLn tip shall be ~ltplugged.
tlecrease
to
the time required for injection,

heat the guns to a max of t100F.
screws
in sealed
areas
it
is
After disassembling the structure, completely remove the

or fillet sealant from all surfaces by scraping with
a nonmetallic blade followed by wiping with cleaning
solvent or MEK.
groove
after sealant
Touch up all surfaces where corrosion-resistant coatings

have been removed or damaged by reapplying chemical
film and surface coat.
Reassemble and seal components
A fter final installation of
injection hole
RESEALING INTEGRAL TANK COMPONENTS
Move the gun tip to the next injection hole and continue
iqjectlng around the tar,l: until all of the grooved areas
have been injected.
Install injection
injection.
Remove fastener and replace with a clean (vapordegreased) fastener. Torque fastener as required.
Remove the two injection screws adjacent to the fastener
on either side and reinject groove sealant. Reinstall
injection hole screws.
After removing the fastener, replace O-Ring seal with

new O-ring and reinstall. Torque as required.
When
permissible
by Groove-Injection
Fasteners Sealed with O-Rings
NOTE
To
(Continued)
as
previously outlined.
clean all
excess groove sealant. The sealant may be removed by
sc rap i n IS with a wood o r plastic b lade followed by a methyl
ethyl ketone (MEK) or cleaning solvent wipe. MEK
should not be used on any surface coated with corrosion
resistant finish.
screws,
Fillet Sealing
sealant gun may be used to apply fillets of
sealar.l as required. TJse sufficient sealant to fill holes, gaps, etc. Smooth sealant and
allow to cure approximately 8 hours before applying fuel
A
spatula
or
MIL-S-8802/MIL-S-8173.3
resistant
coating.
OVERCOATING
All exposed MIL-S-8802/MIL-S-81733
sealant is protecteci w ith two coats of M IL-S-4383 Integral Tan k Sealer
Overcoating. Brush an, allowing a minimum of 20
minutes between coats.
SEALING FASTENERS
Clean all fasteners and mating countersinks
contamination from
chips, dirt,
to
ensure no
etc.
20-20-04
Page 2
Aug 17/84
SR-76-023
FUEL TIGHT FAYING SURFACE SEALING FOR AREAS WITH NORMAL

OPERATING TEMPERATURES FROM -65 TO +200"F
GENERAL
Clean sealing equipment and
This section covers procedures and materials to produce a

fuel tight faying surface seal in the operating temperature range -6Fj to ~000F.
areas
adjacent
to
the sealed
components within the work life of the compound
(approximately
3 hours), Use toluene to clean painted

surfaces and MEK to clean bare surfaces,
SEALING PROCEDURES
MATERIALS
Solvent. methyl ethyl
ketone (MEK),
Specifications
TT-M-261
Cleaning
Areas to be sealed must be free of all contaminants and
matter before applying sealing compound.
Sealing Compound, Integral Fuel Tanks and Fuel Cell

Cavities, High Adhesion, Accelerator Required, Speci-
foreign
fication MIL-S-8802
Use
a vacuum
remove
EQUIPMENT
Sealant Gun, Model No. 250, Manufactured
Research, Inc.
by Semco
cleaner, air hose,
chips, dust.
etc. from
or
clean, lint-free cloth
to
faying sealing surfaces.
Wipe all surfaces to be sealed with a clean cloth saturated

with MEK. Before the solvent evaporates, dry with a
clean dry cloth. If the solvent is permitted to evaporate.
dissolved contaminants will be left on the surface.
INSTALLATION NOTES
NOTE
Fit the structural components to be sealed and drill holes

for attaching fasteners as required.
Do not use soiled cleaning cloths. When a

cloth becomes contarninated, discard it.
The cloth usedfor cleaning should never be
dipped into the solvent. A2tozd co~2taminating solvent by
from the
container onto cloth.
Disassemble the components and check the area to be

sealed for cleanliness. Extraneous material such as oil,
chins, lint., etc., must De removed.
Sealing compound
primered surfaces.
may
be
applied
to
bare
or
Cati-Coat
Prior to applyi ng seal i ng com pou nd to pri mered su rfaces,

check adhesion by scratching with the thumbnail. If the
primer is readily removed in this manner, its adhesion is
Repeat cleaning procedures until there are

t"minating materials on the sealing surfaces.
no
con-
inadequate.
Application of Sealant To Faying Surfaces
Mis
Using a spatula or sealant gun, apply a smooth even coat

Of Sealant to the faying surface of each component. Use
Sufficient sealant to fill all voids and surface
base
compound and accelerator together in the

proportions recommended by the manufacturer. The two
components must be blended until a complete dispersion
of the accelerator is obtained. A film or fillet made from
improperly mixed sealant will contain areas of
incomplete
cure.
room
Mating of faying surfaces must be accomplished as soon

practicable but within 3 hours after application of the
sealing compound. Excess compound forced from the
faying surfaces during installation may be smoothed with
a spatula to form an even fillet.
as
NOTE
At
irregularities.
temperatu~re (approzimately
r70F) MIL-S-8802 sealing co~mpound
must
be used urithin 3 hours after miting with

the accelerator or removal from cold
storage. ilfter addition of accelerator the
iMIL-S-C3802 sealing compound may be
stored at O to -100Ffor r~ hours.
20-20-06
o
COPYRIGHI, 1984 BY SABRELINER CORPORATION
Page 1/2 Blank

Plug 17/ar
SR-76-023
LIQUID TIGHT SEALING OF AREAS WITH NORMAL

OPERATING TEMPERATURES FROM -65 TO +2250F
GENERAL
SEALING PROCEDURES
This section covers materials and ptocedures used to seal

areas where fluid leaks (hydraulic oil, fuel, water, etc.)
must be avoided or whre controlled drainage is desired. In
areas where fluid tight sealing is required. all faying
su Iface seams. butt joi nts, angles. sti tfeners, rivets, holes,
slots, ~joggles. etc., are completely sealed.
This section does not cover primary sealing of integral
fuel tanks or other vessels used for liyuid stotage.
Cleaning
Use a vacuum cleaner or clean dry cloth to remove dust
and chips from surfaces to which sealing compound is to
be applied,
Wipe surface
to be sealed with a clean cloth dampened

with naphtha or equivalent solvent. Dry surface with a
clean, dry cloth before solvent has evaporated.
MATERIALS
Methyl
NOTE
Ethyl Ketone(MEK)
Toluol
Compound, General
Pulpose,Sealing
Tape. (;eneral Purpose
Pressule Sensitive
Iliash Thinner
Strit,pina Compound
PR-:1
Hantf Cream
Inhibisol !H!
TT-M-261
TT-T-.i48
SB0120-002
PP-T-fiO
TT-T-BfiG
Cee Bee
Chemical Company
Pro-Tek (E.I. DuPont de
Nemours
Co.)
Pentone Company
Sealant (;un, Model 250
equivalent
Semco Sales
Service Co., Inc.
INSTXLL~TION NOTES
Tht~ iolvent used in the sealant is volatile and Elammable.
grecautions should be observed to prevent tire or
esplosion.
C:ltan-up
cators
escess
sealing compound anti the sealant appli-
within 4 hours after exposure to
room
temperature.
using IMEI<.
Sealant thicltened from standing in open cans may
bt~ thinned to c,riginal package consistency bv additi~n
4Ii~
Repeat cleaning procedure until no oil, grease. or other

contaminating material is left on the surface to be sealed.
Prior to applying sealing compound to any painted
surface, check paint adhesion. If the paint can be readilv
removed, adhesion is Inn9ic!erPrl Llnse~isfactory.
Sealing doggies
EUUIPMENT
or
Use clean clothsfor cleaning. When a cloth

beomes soiled, discard it. To avoid contaminati7Lg solvent, alwalls pourfronz the
container onto the cloth. Never dip cloth
used for cleaning into the solvent,
base
compound and acceletator together in the

proportions recommended by the manufacturer until
there is uniform dispersion of accelerator through the
niistu2e.
sealant fillet that has been improperly mi?ted
\~ill have areas where cure is incomplete,
Seal joggles prior to sealing holes. gaps. and tivets.
Joggles are sealed by completely filling them with sealing

compound. The sealant is injected usin~ a pressure
applicator with a special nozzle that forces the compound
u"der the joggle.
IVOTE
The special n,oxxle mccy be! rrLcccle h~ flaftening the standarcl noxxle, The colzstmccted no~cxle opening mzcat be L3/.3,o ilz.
min width.
Sealing Holes
and Slots
Seal holes anti slots up
to
1;
in. witie
seal ing compound and building up

high as shown in figure i.
by fillina
fiilet
a,
them with
min of
1/16 in.
P P lication of seal i ny com pound shou Id be i imited to bare

metal. chemical film treated aluminum, anodized
aluminum, or SB0125-024 primed surfaces, Adhesion of
com pound to other surfaces (e.g., laccluer) is marginal.
20-20-08
0
Page 1
Aug 17/84
SR-76-023
C()KKOSION CONTROL IMANUAL
LIQUID TIGHT SEALING OF AREAS WITH NORMAL

OPERATING TEMPERATURES FROM -65 TO +225"F (Continued)
Sealing Holes and Slots (Contd)
Ensure that all joggles and holes have been sealed before
Cover holes 1113 to 1/4 in, wide with a layer of pressure

sensitive tape over the hole and extending a min of 1/2 in,
beyond the edge of the opening in all directions. A layer of
sealing compound is then applied over the tape and at
least l/t) in, beyond the edge of the tape, as shown in figure
sealing
seams,
Using a pressure applicator. lay

pound along all seams and joints,
bead of
sealing
com-
Lay beads of sealing material so there are no gaps or

bridges along seam. A cross section of the head is shown in
figure 2.
Fill holes greater than li4 in, diameter with a rivet, bolt,
cap to reduce the opening below 1/X in. max. Seal with a
laler oI sealing compund extending a min of 1/8 in. from
the edge of the filler, Before sealing oversize slots or
joagles, they must be closed with sheet metal similar to
or
A Ilow sealed parts to ai r dry

8 hours before handling.
at roo m tem peratu re a m i n
of
Sealing Rivets
that used in the structure.
Seal all rivets by applying
Xt assembly. seal hat sections with a fajriny surface seal.

To ~eai hat sections after assembly, lay a bead of sealant
3long the outside seams. Close the ends with an approI,i.iate I,lug anct seal tvith a bead of sealant,
heavy brush
c,r
spray coat of
sealant.
Allow sealed areas to air dry until the sealant is tack free
before working in or water testing sealed areas. (This
should require from ~-A hours depending on the temperature and air circculation.)
]i;a
i-r
~7Y_j
1/16

Figure 1
PRESSURE
SENSITIVE TAPE
S80190-002
SEALING COMPOUND
58(1121002
--i
~--I
118 TO 1/4
Sealing Holes 1/8 To 1/4 In, Diameter

Figure 2
20-20-08
Page 2
Aug 17/84
COPYRIGHT, 1984 BY SAB?E,1NEk CORPORATION
SR-76-023
PRESSURE TIGHT SEALING FOR AREAS WITH NORMAL

OPERATING TEMPERATURES FROM -65 TO +2250F
(;ENERAL
Using
the materials and procedures used in

seams, butt and lap joints,
holes, slots, rivets, etc., in pressurized sections with
normal operating temperatures of -6Tj to 22FjOF.
This section
covers
compound is
airtight sealing of all joggles,
TT-M-261
SB0120-002
Use lint-free cloths for cleaning. When

soiled, discard it.
MIL-S-4~88
Topcoat. Fuel Tank,

Runa-N-Type
equivalent
The sealing compounds used in this section may be

applied to bare surfaces or primed surfaces if the
adhesion is considered satisfactory. If the primer can be
readily removed by scratching with the thumbnail, its
adhesion is considered unsatisfactory. Remove unsatisfactory primer and all other paint, lacquer, and
Semco Sales
Service, Inc.
INSTALLATION NOTES
MEE; and the solvent used in MIL-S-4383 are highly
riammabie and toxic. Safety precautions must be
observed during their use to prevent fire. If they are used
in ~1, closed area, forced ventilation must be provided to
prevent harm to the personnel using these materials.
strippable coatings.
Sealing Joggles
Seal joggles before sealing seams, gaps, rivets, etc.
Jogales are sealed by com pletely fi Iii ng them wi th seal in g
compound. The compound is applied using a pressure
applicator, forcing compound under the joggle from
The base compound and accelerator are mixed together in

the proportions recommended by the manufacturer. The
t\vo components must be blended until there is a uniform
dispersion of accelerator through the mixture. A fillet
made from sealant that has been improperly mixed will
have areas where the cure is incomplete.
either side.
Sealing Holes
Seal 1/8
temperature (approximately 770F), the sealing

com pound must be used within 2 hours after being mixed
with the accelerator or after removal from cold sl~rage,
room
SEALING
fillets
extending a
1/4 in. wide holes by applying a layer of

LB0190-00:3, over the hole and
min of 1/2 in. beyond the edge of the opening
in all directions. Apply a layer of sealing

compound over the tape and at least 1i8 in. beyond the
edge of the tape as shown in figure i.
or
Fill holes greater than 1/4 in. diameter with a rivet, balsa
wood plug, or cap to reduce the opening below the 1/8 in.
Seal with a layer of sealing compound
max.
extending a min of 1/8 in. beyond the edge of the hole.
Before sealing oversize slots or joggles, they must be
closed with sheet metal similar to that used in the
SEQUENCE
Cleaning and Surface Preparation

When areas to be sealed are dirty or contaminated with
oil, grease, or any other foreign matter, they must be
cleaned before application of the sealing compound.
to
And Slots
pressure sensitive tape,
beads of sealing
compound for rework or repairs, scrape the compound off
nith wood or plexiglass scrapers. Remove only the major
portion of fillets and beads. After rework, reseal the areas.
remove
cloth becomes
Repeat this cleaning procedure until no oil, grease, or

other contaminating material is left on the surface to be
sealed.
EQUIPMENT
Sealant (;un, Model #2.50
To avoid contaminating the solvent, always pour from the

container onto the cloth. Cloths used for cleaning should
never be dipped into the solvent.
LB0190-003
Fuel Resistant
Sealing Compound.
When necessary to
applied.
free cloth.
Methyl Ethyl Ketone,(MEK)

Sealing Compound,
General Purpose
Tape. Anti-chafing,
At
to be
Wipe all surfaces to be sealed with a clean, lint-free cloth

dampened with MEK, or equivalent. Before the solvent
has evaporated, dry surface completely with a clean, lint-
MATERIALS
or
vacuum cleaner or clean, dry lint-free cloth,

dust, chips, etc., from surface to which the sealing
remove
structure.
20-20-10
0
COPYRIGHT, 1984 BY S.~RSELINER CORPORATION
Page 1
Aug 17/84
SR-76-02~

Sealing Seams And Joints
Sealing Rivets And Pelts
Inspect the area to be sealed to insure that all joggles are

sealed before applying sealing compound to the seams.
After all of the seams, jog.gles, holes, etc., have been

sealed, seal rivets and bolts by brushing a coat of MIIL-S-
Using a pressure applicator, apply

com pound to all seams and joints.
bead of sealing
En~ure there are no gaps or bridges along the seam

The final dimensions of a cross section of the beads
conform to those shown in figure 2.
joint.
must
8173.7 or SB0120-002 Sealing compound on all bolts and

rivets in the pressurized area. Sealing compound may be
thinned to brush-on consistency by adding approsimatelv
1 part by volume of MEK TT-M-fil to 2 parts by volume
of sealing compound.
SEALING
COMPOUND
PRESSURE
880120-002
SENSITIVE TAPE
LB1~XI-POJ
1IBMIN
-I
1/8 TO
1/4I-;i1/2
MIN
le"
1
f

Figure 1
1/8
1/8
ii:
r
1/8
-1/16
1/8
1/8
L~OTE
TOLERANCE ON ALL DIMENSIONS IS +1/16, -0.
20-20-10
Page 2
Aug 17/84

Figure 2
COPYRIGHT,
SR-76-023

OPERATING TEMPERATURES FROM -65 TO +225"F. (Alternate Procedures)
NOTE
(;ENERAL
~f circumstances preclude the use of either

of these methodsfor dust and chip removal,
use an air hose and clean, dy/ air,
the materials and procedures for

seams, butt and lap joints,
holes, slots, rivets, etc., in pressurized areas with normal
operating temperatures between -65 and +225"F.
This section
covers
airtight sealing of all joggles,
Wipe all surfaces to be sealed with a clean cloth dampened

with naphtha, or equivalent, Before the solvent has
evaporated, dry the surface completely with a clean cloth.
MATERIALS
Solvent, Toluol
Solvent. Naphtha
Sealing Compound,
(;enelal Purpose
Low Density
Tal,e, (;eneral Purpose,
TT-T-,548
MIL-N-15178
HB0120-002
i.
It is essential that clean cloths be used for cleaning.

When a cloth becomes soiled, it shall be discarded,
2.
To avoid contamination of the solvent, it must always

be poured from the container onto the cloth. The
cloth used for cleaning should never be dipped into
the solvent.
LB0190-002
Pressure Sensitive
Sealing Compound,
Topcoat. Fuel Tank,
Buna-N Tvpe
C:ee Pee PR:ii Stripping
Com pound
~:c,atinK. Vulcabond
C-:it;
Coating, A56B
MIL-S-4~8:3
Repeat
or
equivalent
Cee Pee Chemical Co.
on
no
the
The sealing compound may be applied to base surfaces or

surfaces primed with M!L-P-6889 primer without
further surface preparation other than cleaning providing the primer adhesion is considered satisfactory.
Check the primer for lack of adhesion by scratching with
the thumbnail. If the primer can be readily removed, its
adhesion is considered unsatisfactory. Remove any
Semco Sales
Service. Inc.
unsatisfactory primer.
Sealing Compound LB0120-00L may be applied over
lacquer only if the surface has been previously brush
coated with MIL-S-438~ Sealing Compound. kllow a
min of 15 minutes drying time after application of the
brush coat before sealing with the LB0120-002 compound,
Safety Precautions
Toluol anti the solvent used in Pro-Seal No. 414 are highly
flammable and toxic. Safety precautions must be
observed during their use to prevent fire. If they are used
in a closed area. forced ventilation must be provided to
prevent harm to Fe~sonnel using these materials,
NOTE
If the use of a brush coat ~MIL-SJBXS is

required, it should eztend a min of 1/8 in,
beyond the outer edge of the sealirLg corrLpound, HB0180-008, to~facilitate iaspection
for sealing integrity,
Sealing Sequence
satisfactory sealing results, the following
must
left
Surface Preparation
American Latex
Products Corporation
B. F. Goodrich Co.
INSTALLATION NOTES
To ot,tain
cleaning procedure until it is certain that
grease, or other contaminating material is

surface to be sealed.
EI~UIPMENT
Sealant (;un, Model 250
this
oil,
be followed.
Cleaning
aleas to be sealed have become dirty through
hanclling or are contaminated with oil, grease, or any
other foreign matter, they must be cleaned before
application of the sealing compound.
Sealing
When
Use a vacuum cleaner or clean dry cloth to remove dust,

ch i ps, etc.. from the su rface to wh ich the seal ing compound
is to be applied.
After the paint primer has been repaired, if necessary, the

cleaned, and coated with MIL-S-4383 where
required, the joggles, holc~ and cut-outs shall be sealed.
area
After
sealing the joggles, holes and cutouts, seal the

remaining seams with beads of sealant.
Seal rivets,bolts,etc.
20-20-12
Page
o
Aug 17/84
SR-76-023
PRESSURE TIGHT SEALING FOR AREAS WITH NORMAL OPERATING

TEMPERATURES FROM -65 TO +2250F. (Alternate Procedures) (Continued)
Mixing and Handling of Sealing Compound
SEALING PROCEDURES
compound and accelerator should be mixed

together in the proportions recommended by the
Sealing Jogffles
The base
manufacturer. The two components must be blended until

there is a uniform dispersion of accelerator through the
mixture. A fillet made from sealant that has been
improperly mixed will have areas where the cure is
incomplete,
At
room
com
pou nd
ust
be used w ith in 3 hou rs after bei ng m ixed

or after removal from cold storage.
Seal joggles prior to sealing seams, holes, gaps, rivets,
etc.
sealed by completely filling them with sealing

Joggles
compound, The compound is applied by the use of a
pressure applicator, forcing the compound under the
joggle from either side. If the joggle is too small to seal
from the sides, it may be sealed by drilling a No. 40 hole in
the joggled angle as shown in figure i.
are

NOTE
Seal holes and slots up to l/t3 in. wide by filling them with
up a bead with a min
thickness of 1/16 in, as shown in figure 2.
sealing compound and building
Aftur the addition of t~Le accele~rator the

to
sualiny co~mpoulzd ma~y be stored at
-100Ffor r~ hollrs.
(lean up of equipment or excess sealing compound must
be accomplished within:J,hours after exposure to room
temperature. Naphtha, toluol, or PR-~1 stripping compound shall be used as the cleaning materials.
To remove fi Ilets or beads of seal ing com pou nd because of
rrwori< or repai~s, scrape the compound off with wood or
plexiglass scrapers. It is necessary to remove only the
major poltion of the fillets and beads. After rework, the
areas should be resealed.
Seal holes 1/8 to 1/4 in. wide by applying a layer of

over the hole and
extending a min of 1/2 in. beyond the edge of the opening
i, all directions. If the surface adjacent to the hole is
coated with paint, varnish, or lacquer, apply a brush coat
of M IL-S-4383 over the tape and the adjace nt su rface for a
min of 1/4 in. beyond th eedge in all directions. A layer of
sealing compound HBi)120-()~2, is then applied over the
tape and at least 1/8 in, beyond the edge of the tape as
shown in figure 3.
pressure sensitive tape, LB0190-002.
NOTE
When drilling the joyyles, all nece.rscL77I
precautions nsust 64 taken to p7ez,ent
damage to the u7lderlyzng $tl%LCtU.rY.
JOGGLE
ao
oo
DRILL NO. 40 HOLE

APPLY SEALAND BEAD
THROUGH JOGOLE ANGLE
/O
ALONG SEAM AFTER
(F JOGGLE IS tOO
FILLING JOGOLE WITH
SEALANT.
SMALL TO FILL FROM
II/
ONE END OR END IS

NOT ACCESSIBLE,
Sealing Joggles
Figure 1
TYP.(a)1/8+1/16,
-o
r1/16+1/16,
.o
--~f ~118 MAX

Sealing Holes and Slots Up
Figure 2
to
1/8 In, Wide
20-20-12
Page 2
Aug 17/84
SR-76-023
PRESSURE TIGHT SEALING FOR AREAS WITH NORMAL OPERATING

TEMPERATURES FROM -65 TO +225"F, (Alternate Procedures) (Continued)
Sealing Holes and Slots (Contd)
Sealing Rivets and Bolts
Holes greater than 1/4 in, diameter must be filled with a

rivet, balsa wood plug, or cap so as to reduce the opening
below the 1/8 in, max and then sealed with a layer of
seal i ng com pou nd.e xtend i ng a m i n of 1/8 i n. from the edge
of the hole. Before seal ing slots or joggles which are over
size, they must be closed with sheet metal similar to that
used in the structure.
After all of the seams, joggles, holes, etc. have been sealed.
brush a coat of MIL-S-4383 on all bolts and rivets in the
pressurized
SEALING RUBBER PARTS
NOTE
The cleaniny procPdure will remove B. F.
Goodrich s A56B coatilzy. If this coating is
reguired, cLpply tzuo h~rush coats of this
coating to the ezposed rzcbher.
Inspect the area to be sealed to ensure that all joggles and

holes have been sealed befole applying sealing compound
to the seams.
UsinB
corn
pressure applicator,
t,ountl to all the seams and
a
apply
joints.
beatl of sealing
Eeatls c,f sealing compound must be applied with care so

there ale no gaps or loridges along the seam joint. The
final dimensions of a cross section of the beads must
con Folm to those shonn in figure 4.
area.
Rubber that will come in contact with the sealing

compound shall be thoroughly cleaned with toluol and
then coated with Vulcabond V-~6. Sealant may be applied
after the Vuicabond V-:3fj has dried tack tack free.
PRESSURE SENS!TI~E
TLPE
SEALING
SEALING COMPOUND
COMPOUND
MIL-S-4383
(IF REQUIRED)
1/8 MIN
1/8
1/8 MIN
to 1/4
Sealing 1/8
-I-1~11/2
to
MIN
le
1/16+ 1/16,
-0
1/4 In. Holes and Slots

Figure 3
NOTE
1/8
II~
r
118
I/ r~
TOLERANCES ON ALL DIMENSIONS ARE -:;16. -0
1/16
1/8
1/16
1L,
-i
NOTE
MIL-S-4383
BRUSH
COATING
EXTENDS
1/8
IN.
MIN BEYOND EDGEOF HB0120-002 SEALING COM-
POUND.
USE
WHEN
SURFACE
HAS
BEEN
LACOUERED PRIOR TO SEALING.

Figure
20-20-12
o
Page 3/4 Blank

Aug 17/84
SR-76-023
FUME TIGHT SEALING FOR AREAS WITH NORMAL OPERATING

TEMPERATURES FROM -65 TO +250"F
GENERAL
5,
This section covers the materials and procedures to be

used in sealing joggles, cutouts, holes, slots, and hat
sections in areas where excessive leakage of air, fumes,
and smoke may prove dangerous. Small leaks, such as
rivets, riveted joints, and seams, do not require sealing.

The sealing compounds may be applied to painted or bare
rfaces.
su
MATERIALS
Solvent. Stoddard
Solvent, Toluene
Solvent, Naphtha
Settling Compound,
General Purpose
Tape, General Purpose
Pressure Sensitive
C::re Bee PR:3t Stripping
Compound
injection Sealing
(.;~oove
When
areas to be sealed have become dirty through

handling, or are contaminated with oil, grease, or any
foreign matter, they must be cleaned before application of
the sealing compound.
NOTE
If circumstances preclude the use of either

of the methods for dust and chip rernoclal,
LB0190-002
Use on
It is essential that clean cloths be used for cleaning. When

cloth becomes soiled, it shall be discarded.
Semco Sales and

Service. Inc.
To avoid contamination of the solvent, it must always be

poured from the container onto the cloth. The cloths used
for cleaning should never be dipped into the solvent.
INSTALLATION NOTES
Repeat the cleaning procedure until it is
Sealing Sequence
obtain satisfactory sealing results,
be followed.
air hose,
Wi pe all su rfaces to be sealed w ith a c lean cloth dam pened

with naphtha. Before the solvent has evaporated, dry the
surface completely with a clean dry cloth.
LB0120-O()~
E:QUIPI\IIENrl~
To
Cleaning

chips, etc., from the surface to which the sealing
compound is to be applied.
P-S-661
TT-T-548
MIL-N-15178
LB0120-002
Compound
Sealant Clun. Model 250
Clean up equipment and excess sealing compound

within three hours after exposure to room temperature, Use toluene or PR-31.
the
following
certain that
oil, grease or other contaminating material is left

on
no
the
;eclnence must
i.
2.
Locate all
IMixing and Handling Sealing Compound
shining
The base compound and accelerator shall be mixed

together in the proportions recommended by the manufacturer, The two components must be blended until there
iS
U"iform dispersion of accelerator through the
"ixtue. A fillet made From sealant that has been
improperly mi?tecl will have areas where the cure is
areas to be sealed. This may be done by

bright light on the unsealed side of the
bulkhead and inspecting the side requiring sealing
for any passage of light,
a
Inspect the
estraneous
to be sealed for cleanliness. Any

material, such as oil, dirt, chips, etc.,
areas
be removed.
Prio~
applying the sealing compound to any

surface, check the paint adhesion by
scratching using the thumbnail. If the paint can be
Ieadilv removed by scratching its adhesion is considerej unsatisfactory. Remove unsatisfactory paint;
using thinner.
4.
incomplete.
to
After the surface preparation has been

apply the sealing compound.
completed,
IVOTE
~fter addition of the accelelator, the

sealing compound mny be .storsd at O to
-100Ffor r~ hours.
At
room
must be used within 3 hours after being mixed

with the accelerator, or after removal from cold storage.
compound
20-28-14
0
Page 1
AUL5 i1/84
SR-76-023

TEMPERATURES FROM -65 TO +250"F (Continued)
SEALING PROCEDURES
2.
Seal holes, joggles, and slots up to 1/8 in. max width by

filling them with accelerated sealing compound LB0120002. Build up a bead of sealant approximately 1/10 in.
thick on the pressure side of the bulkhead, as shown in
figure i.
Seal holes, joggles, and slots from 1/8 to 1/4 in. width.
using either tape or groove injection sealing compound
coateti with LB0120-002 sealing compound.
i.
Useof Groove Injection SealingCompound, LB0120003: This method is to be used only when the tape
cannot be used. Fill the gap completely with
LB0120-003 compound and form a fillet on the
pressure side, asshown in figures 3 and 4. Compound
may be softened for easier application by warming
or working with the hand. Be sure hands are clean
and free from grease and oil. Coat over the
compound fillet with a laye of LB0120-002 sealing
compound, as shown in figures 3 and 4.
Use of Tape: Apply a layer of pressure sensitive tape,

L B0190-002. over the hole, extend i ng a m i n of 1/2 i n.
beyond the edge of the opening in all directions. A
layer of sealing compound is then applied over the
tape and at least 1/8 in. beyond the edge of the tape,
as shown in figure 2.
1/8 1/16,
-o
1/16+ 1/16.
.o
~--y-=rft~)-
1/66644
Sealing L/8 In. Ma?r

Figure Z
Holes
PRESSURE SENSITIVE
TAPE L80190-002
SEALING COMPOUND
L80120-002
CIN(M 1/4~1
1!16-1!16.
~1/2
-O
1/8 to
Sealing 1/8
to 1/4 Inch Holes

Figure J
20-20-14
Page 2
Aug 17/84
COPYRIGHT,
1984 BY S;.SRELINER CORPORATION
SR-76-023

TEMPERATURES FROM -65 TO +2500F (Continued)
Sealing Procedures (Contd)
Holes greater than 1/4 in. diameter must be filled with a
rivet, balsa wood plug, or a cap so as to reduce the opening
below the 1/8 in. max and then sealed with a layer of
sealing compound LB0120-002, extending a min of 1/8 in.
from the edge of the hole. Before sealing slots, joggles, or
hat sections which are oversize, they must be closed with
sheet metal similar to that used in the structure.
SEALING
COMPOUND
L80120-002
1/8 MAX
GROOVE INJECTION
SEALING COMPOUND
~II
L80120-003
3/4MAX
1/4 MAX
1MAX
Gap Sealing
Figure :3
SEALING COMPOUND
L80120-002
GROOVE INJECTION SEALING
COMPOUND
LB0120-003
-O
1MAX
Hole and Slot
Figure
Sealing
4
20-20-14
0
COPYRIGHT, 1Y84 BY SABRELINER
Page 3/4 Blank

Aug 17/84
SR-76-023
APPLICATION OF SELF-CONTOURING SEALING PADS FOR AREAS

WHERE NORMAL OPERATING TEMPERATURES DO NOT EXCEED 225"F
(;ENERAL
used i n applyi ng synthetic rubbe r sel f-contouri ng seal i ng
pads to the stationary structure under removable doors or
between normally separable sections of a structure where
normal operating temperatures range from -65 to 2250F,
LB0120-004
Exterior Surface
Immediately prior to application
Tape: Anti-chafing
of seal i ng com pound or

mold release, remove dust and chips from the surface to
which either is to be applied by using a vacuum cleaner or
clean dry cloth.
LB0190-00S
Fuel Resistant
Solvent, Toluene
Solvent. Methyl
ethyl ketone (MEK)
Solvent. Naptha
TT-T-Tj48
TT-M-26~
Immediately prior
EQUIPMENT
Semco Sales and
Service, Inc.
equivalent
to
application
of
sealing compound
clean the surface to which the compound is to be applied

by wiping witth a clean cloth dampened with naphtha, or
eq u i valen t sol ven t. Before the so Ivent has evaporated, dry
the surface completely with a clean dry cloth.
MIL-N-t5178
Sealant (;un, Model 2.50

or
polyamide.
The non-silicone mold release may be applied over any
painted surface since adhesion of sealing compound to
such surfaces is not desired.
MATERIALS
Compound: Sealing,
Check the primer for lack of adhesion by scratching with

the thumbnail, If the primer can be readily removed, its
adhesion is considered unsatisfactory. Remove unsatisfactory primer and all other paint, lacquer, varnish, and
strippable coatings. Re-apply zinc chromate or exopy

cloth becomes soiled. it shall be discarded.
INSTALLATION NOTES

poured from the container onto the cloth. The cloth used
Sealing Sequence
To obtain
Following
i.
satisfactory adhesion of the compound, the

sequence of
operations
must be
followed:
Check any paint primer for lack of adhesion. If the

surface to which compound is to be applied is coated
with a paint, varnish, or lacquer other than zinc
chromate primer, TT-P-175i or epoxy polyamide
primer. MIL-P-23377, the coating shall be removed,
Clean the
area
to
which the compound is to be
applied.
3.
Clean the
area
to
which mold release is to be applied.
non-silicone mold release to removable part.
4.
Apply
.i.
Appl.vcompound tothestructure.
(i.
r\ssemble the parts and allow the
i.
compound
The cleaning procedure described above shall be repeated

until it is certain that no oil, grease, or other contaminating materials remain on the surface to be sealed,
Mixing and Handling of the Sealing Compound

together in the proportions recommended by the manufacturer. The two components must be blended until there
is a uniform dispersion of accelerator through the
mixture. Compound that is insufficiently mixed will have
areas where the cure is incomplete.
At
room
compound
must be used within three hours after being

mixed with the accelerator or after removal from cold
to cure,
Disassemble the parts, remove excess compound as

figure 2 and wipe mold release from
shown in
surfaces.
storage.
After addition of the accelerator, the
C lean
Cleaning
seal i ng co mpou nd and sealant app i ication

a period of 4 hours after exposure to
temperature by using MEK or toluene.
u p excess
equipment within
room
The compound may be applied over TT-P-1757 or MIL-P25Xii primer if the adhesion is considered satisfactory.
sealing compound
may be stored at 0 to -100F for 72 hours.
20-20-16
Page
0
COPYRIGHT, 1984 BY SABRELINER CQRPORH I ION
Aug 17/84
SR-76-023
C()KR()SION CONTROL MANUAL
APPLICATION OF SELF-CONTOURING SEALING PADS FOR AREAS WHERE
NORMAL OPE RATING TE MPERATURES DO NOT EXCEED 225"F (Continwed)

SEALING PROCEDURES
the cleaned
Apply accelerated sealing compound
stationary part of the assembly to be sealed. This may be
accomplished by using the Sealant gun, Model 250, or a
clean wooden spatula. If the sealant gun is used, it is
recommended that the sealant beads be spread out with a
spatula. This will aid in estimating if sufficient sealant
has been applied in cases where the gap being sealed is
larRe. as shown in figure i.
to
Apl,ly non-silicone mold release to the removable part of

the assembly being sealed, as shown in figure I, to prevent
the sealing compound from adhering to the removable
par.t. Apply sufficient mold release to screws and quick
disconnect fasteners on the removable part to prevent the
attachments from being sealed into the receptacles,
Assemble the parts being sealed and allow them to remain

in that position from approximately 8 hours or until the
compound has beeil cured.
After the sealant has cured, the parts shall be disassembled and the excess compound trimmed off with a
sharp knife. (See figure 2.) The mold release shall be
wiped from the surfaces with a clean dry rag.
Attachments shall be washed with naphtha, or equivalent
solvent, to remove all traces of mold release.
Tooling holes and

008 tape
after the
gaps may be backed up using LB0190shown in figure 3. The tape shall be removed
compound has cured.
as
STATIONARY PART
REMOVABLE PART
CLEAN THIS SURFACE

AND APPLY SEALANT
CLEAN THIS SURFACE AND
APPLY MOLD RELEASS
Typical Sealant and Mold Release Application

Figure
TRIM OFF EXCESS
SEALANT AFTER CURING
20-20-16
Page 2
Aug 17/84
Typical Excess Sealant Trimming

Figure 2
SR-76-023
1/41N.
DIA MAX
TAPE
1T
STATIONARY
1/81N
PART
MAX
REMOVABLE PART
SEALANT
Tyl>ical Toolin~ Hole and (;Ltp Seaiing

Figure
20-20-16
0
COPYRIGHT. 1984 BY SABRELINER CORPORATION
Page 3/4 Plank

Aug 17/84
SR-76-023
EXTERIOR WATERTIGHT SEALING FOR AREAS WITH

NORMAL OPERATING TEMPERATURES FROM -65 TO +2250F
GENERAL
SEALING PROCEDURES
This section covers a watertight seal applied to exterior

surfaces of aircraft structures where normal~operating
temperatures do not exceed 225"F.
MATERIALS
Solvent, Stoddard
Solvent, Toluene
Solvent, Methyl ethyl
P-S-fjG 1
TT-T-M8
TT-M-261
(MF,K)
Solvent, Naphtha
MIL-N-15178
Ensure strippable protective coatings are removed from

the sides and base of the gaps since adhesion of the sealant
on these surfaces is of primary importance,
R)
or
Pentone Company,
Tenafly, N.J
LB0120-004
"Inhibisol"(H)
Compound; Sealing,
Areas dirty
Turco Products Co.
LAR-16~4
Cee Pee PR-31
or
contaminated with oil, grease,
or
any other
foreign matter must be cleaned before application of

sealing compound.
Exterior Surface
Cleaning Compound,
Stripping
Remove all paint and primer from the surface to be sealed

unless the surface has been primed with SB0125-024
(Epoxy Primer), Sealants may be applied directly to
cleaned primed surface. Remove paint and primer
coatings from the area to which sealing compound is to be
applied by brushing with a stiff bristle brush using MEK
solvent, Remove paint for a min distance of 1/2 in, on each
side of the skin gap.
ketone
(A, L, M, N,
Cleaning
Use a vacuum cleaner or clean, dry cloth to remove dust

and chips from the surface to which the sealing compound
is to be applied.
Compound
NOTE
EQUIPMENT
i/se cliiin cloths.
Sealant Gun. Model 250,

or
Semco Sales and

Service, Inc.
equivalent
APPLICATION NOTES
At
room
will have
areas
where
cure
is in-
compound
must be used within 3 hours after
or
being mijcc~
after removal from cold storage.
After mixing, the sealing

-IOOF for 72 hours.
compour.~
may be stored at 0 to
Clean up excess sealing compound and the sealant gun

within 1 hours after exposure to room temperature using
M E K or toluene. If clean up should occur after a period of
1 hours, use L~R-1634 or PR-Si stripping compound.
Clean-up of workers hands

Pro-Tek hand
cream on
cloth becomes
this contaminates the solvent.
Mix base compound and accelerator together in proportions recommended by the manufacturer. Blend the
two components until there is uniform dispersion of
accelerator through the mixture. Improperly mixed
sealing compound
complete.
~ViLese
soiled, discard it. Pour solvent from the

container onto the cloth. Never dip cloth
used for cleaning into the container since
will be facilitated by the use of

the hands prior to handling the
Immediately prior to applying the masking tape, clean

surface to which sealing compound is to be applied by
wiping with a clean cloth moistened with naphtha,
Stoddard solvent, or equivalent. Wipe dry with a clean
dry cloth before solvent evaporates.
Repeat cleaning procedure until no oil, grease, paint, or

other contaminating materials remain on the surface to
be sealed. A bright, silver surface with no white film is
usually evidence of a clean surface.
Masking
Using 3/4 to 1 in. wide masking tape, mask the skin on
each side of the skin gap, leaving 1/16 +1/32 in, of skin
exposed on each side of the gap, Wipe down skin with a
clean cloth so that oil from the fingers does not contaminate the cleaned surface. If the fingers contact the
area to be sealed, repeat the cleaning procedure,
sealing compound.
20-20-18
COPYRIGHI, 1984 BY SABRELINER CORPORATION
Page 1
Aug 17/84
SR-76-023
COKK()SION CONTROL MANUAL
EXTERIOR WATERTIGHT SEALING FOR AREAS WITH

NORMAL OPERATING TEMPERATURES FROM -65 TO +225"F (Continued)
Sealing
Apply sealant: using either
a, sealant gun or a clean

If the sealant gun is used, place the
opening tip flat against the seam and apply a slight excess of
compound; moving the gun as the joint fills up. If a spatula
is used, apply an excess of sealant at one point on the seam
and work the sealant into and along the seam.
wooden
spatula.
compound has been applied using the sealant

spatula to press the compound into the seam
anc.l remove the excess from the sealed alea. if a spatula.
~vas used to;LPP]Y the sealant, it is necessary only to
remove the excess compound: using the spatula,
After the
gun,
use a
:-\fter
seam
removed,
com
pound
has
remove
been sealed and excess compound

tape. This must be done before the
starts to set up
immediately after removing the tape, fail edges of the

coml,ound. This may be clone by drawing one finger along
the edge. Moistening the Finger with water will minimize
stickin~ of the compound to the finger.
Xfter
the
coml,c,und
compound
to
cure
a,
has
min
been
smoothed, allow the
time of 24
temperature before covering
or
hours at
room
disturbing the surfacpi
20-20-18
Page 2
Aug 17/84
5B-76-023
FAYING SURFACE SEALING FOR AREAS WITH NORMAL

GENERAL
Cleaning
This section covers the materials and procedures to seal

between faying surfaces of aircraft parts,
When
MATERIALS
the sealing compound.
Sealing Compound,
General Purpose
Naphtha, Solvent

chips, etc. from the surface to which the sealing compound
is to be applied.
LB0120-002
TT-N-9,5
Inhibisol
Wyandotte Chemical Co.
Pro-Tek hand cream

SBS-40 hand cream
PRC 1~21
PR(: 14~1C;
DuPont Co.
Sugar Beet Products Co.
Semco Products
Semco Products
Safety Solvent
Compound, or
equivalent
EqUIPMENT
Sealant Gun. Model ZFjO
or
equivalent
areas to be sealed have become dirty through

handling, or are contaminated with oil, grease, or any
foreign matter, they must be cleaned before application of
Semco Sales
Service, Inc.
Pyles Industries, Inc.

with solvent. Before the solvent has evaporated, dry the
surface completely with a clean cloth.
Repeat the above cleaning procedure until it is certain

that no oil, grease, or other contaminatinff material is left
on the surface to be sealed.
Surface Preparation
The sealing compounds may be applied to painted or bare

surfaces. Prior toapplying sealing compound to any
painted surfaces, check the paint adhesion hv scratching
using the thumbnail. If the paint can be rea;lily removed
INSTALLATION NOTES
Safety Precautions
Solvents shall not be used in confined areas since the
fumes of most solvents are toxic, flammable and
by scratching, its adhesion is considered unsatisfactory.

Remove unsatisfactory paint.
explosive.
Solvents used For cleaning sealing compounds from the
hands and equipment may cause dermatitis. This danger
can be minimized by using Pro-Tek barrier cream prior
to exposure and the use of SBS-40 hand cream after
cleaning the hands.
Sealing Sequence
To obtain satisfactory sealing results, the
sequence must be followed:
i.
remove

together in the proportions recommended by the manufacturer. The two components must be blended until
there is a uniform dispersion of accelerator through the
mixture. A fillet made from sealant that has been
improperly mixed will have areas where the cure is
incomplete.
following
Fit components of the structure to be sealed together

and drill rivet, bolt holes, etc., as required.
Disassemble the components,

drilled holes and clean.
Mixing and Handlinff of Sealing Compound
At
room
must be used within 3 hours after being mixed

with the accelerator, or after removal from cold storage.
compound
burrs around
5.
After the area has been thoroughly cleaned, check

the paint far lack of adhesion,
4.
After this preparation has been completed, apply the

sealing compound and reassemble the components.
NOTE
of the accelerator the

After
seal~ing compound may be stored at O to
-10oFfor 7;2 hours.
addition
Clean up of equipment or excess sealing compound must

be accomplished within 3 hours after exposure to room
temperature. Solvent or Wyandotte No. 2789 stripping
compound may be used as the cleaning materials.
20-20-20
0
CCO\rRIGHT, 1984 BY SABRELINER CORPORATION
Page 1
Aug 17/84
SR-76-023

SEALING PROCEDURES
A p p iv a 5 mooth, even coat of seal i ng compou nd, approx imately 1/~2 in. thick to the faying surface area of one
component using either a spatula or a sealant gun.
as possible after application of the sealing
pound, rivet or bolt the components of the structure
to~ether. squeezing out the excess compound.
As
soon
corn
20-20-20
Page 2
Aug 17/84
SR-76-023
LIQUID TIGHT SEALING FOR AREAS WITH NORMAL

OPERATING TEMPERATURES FROM 225 TO 400"F
GENERAL
This section
materials and procedures to seal

etc., in areas where fluid leakage
must be avoided and where temperatures may be as high
as 4000F in normal operation with occasional short
duration exposures to temperatures as high as EiOO"F.
covers
cutouts, holes,
seams,
surface completely with a clean dry cloth, discarding

cloths as they become soiled. Repeat cleaning procedure
until no oil, grease, or any other contaminating material is
left on the surface to be sealed.
To avoid contaminating the solvent, always pour solvent
from container to cloth; never dip cloth in solvent
container.
MATERIALS
Sealing Holes
Sealing Compound PR-810 Products Research

Chemical Corp.
Seal holes, joggles, slots, cutouts, etc.. up to 1/8 in, max

width by filling with sealant. Build up a fillet
approximately 1/8 in. thickness on one side of the opening.
Burbank, CA 91504
Stoddard Solvent, P-D-680
(See figure i.)
EQUIPMENT
Air-actuated sealant
dispensing
Sealing Oversize Holes

guns:
Holes greater than 1/8 in, diameter must be filled with

rivets, bolts, or caps to reduce the opening below 1/5 in.
before sealing. Slots. cutouts. etc., with minor
max
dimension greater than 118 in. must be clo~ed with sheet
Model 9Fj0, C;rantner and Associates,

(;arclen (;rove. CA
Motlel 250, Semco. Inc., Los Angeles. CA
metal prior to sealing. (Stiffening

positive slot closure is advisable.)
SEALING PROCEDURES
Cleaning
cleaner or clean dry cloth to remove dust,
compound is to be applied. Wipe all surfaces to be sealed
with n clean cloth dampened with Stoddard Solvent. Dry
Use
a vacuum
at the
joint
to ensure
Seal seams, joints, etc, by applying a sealant bead with

dimensions shown in figure 2. Use the pressure
applicators listed or an equivalent. Apply bead of sealing
compound so that there are no gaps or bridges along seam
joint.
"1 -i i-~
t~-I
Sealing Holes
Figure 1
20-20-22
0
COPYRIGHT,
t 984 BY SABRELINER =SRPORATION
Page 1
Aug 17/84
SR-76-023
COKKOSION CONTROL MANUAL
LI&UID TIGHT SEALING FOR AREAS WITH NORMAL

OPERATING TEMPERATURES FROM 225 TO 4000F (Continued)
Sealing Stiffened Seams
When sealed
joints
covered in places by
or gap and
seal both sides of the stiffener a min of 6 in. from the seam
(01 the enti re length of the stiffener, whichever is shorter).
seams or
are
stiffeners, etc., inject sealant into the joggle
(See fiaure:~.)
1/4
_L
1/4

Figure 2
SEAM TO BE SEALED
INJECT JOGGLE
INJECT JOGGLE
SEAL BOTn SIDES OF STIFFENER
6 IN. FROM SEAL OR ENTIRE

STIFFENER IF STIFFENER IS
LESS THAN 6 IN.
20-20-22
Sealing Stiffened Seam

Figure 3
Pane 2
~ug
~7j84
COPYRIGHT, 1984 BY SABRELINER CCP"ORATION
SR-76-023

OPERATING TEMPERATURES FROM 225 TO 350"F
GENERAL
This section covers the materials and procedures used to
seal holes, slots, gaps, seams, joints, etc., in aircraft
structures
normally exposed
to
operating temperatures
from 225 to 3500F.

These
procedures are for air-tight sealing of anti-icing air

ducts, but they may be used for sealing other areas.
Two methods are used to seal seams and joints: (1) post
assembly, seal by application of sealing compound to the
seam and (2) during assembly, seal faying surfaces of the
component parts of the seam. From a sealing and
structural aspect, post assembly sealing is considered
superior to sealing of faying surfaces.
MATERIALS
P-S-661
Solvent: Dry Cleaning
(Stoddard Solvent)
TT-M-261
Solvent: Cleaning
Methyl ethyl ketone

(MEK)
Wash Thinner
Nh3-5056
LB0120-001
Sealant; Duct, High
Temperature Resistant
Stabond C-136 Fuel and
Oil Resistant Material
Using a vacuum cleaner or clean dry cloth, remove dust,

chips, etc., from the surface to which the sealing compound is to be applied.
with solvent. Before the solvent has evaporated, dry
surface
Semco Sales
equivalent
Service, Inc.
INSTALLATION NOTES
Sealing compound
tion
precautions
as
be used with proper fire preventhe solvents are highly flammable.
must
clean cloth.
Use clean cloths for cleaning. When
cloth becomes
To avoid contaminating the solvent, always pour from the

container onto the cloth. Cloths used for cleaning should
Repeat this cleaning procedure until no oil, grease, or

other contaminating material is left on the surface to be
sealed.
Sealing compounds may be applied to painted or bare
surfaces. Prior to applying sealing compound to any
painted surface, check the paint adhesion by scratching,
using the thumbnail. If paint can be readily removed by
scratching, ~its adhesion is considered unsatisfactoy.
Remove unsatisfactory paint; using wash thinner.
Sealing Jo~gles, Holes,
and Cutouts
NOTE
When drilling thejoggle, all 72ecessary precautions must be taken to preverLt damage
to the underlying structure.
EQUIPMENT
or
soiled, discard it.
American Latex
Products Corp.
Hawthorne. CA
Sealant Gun, iModel 250
completely with
Seal
joggles prior to sealing seams, hole and cutouts.

Using sealant gun, completely fill joggle with High
Temperature Resistant Sealing Compound. Apply compound from either side of the joggle until it extrudes out
the other side. Ifjoggle is too small to seal from the sides,
drill a No, 40 hole ill the joggle as shown in figure 1, and
force corry4und into the joggle through this hole.
SealinR compound loses solvent from the open container

IjlliClil!.. The cans should not be allowed to jtand open
ionyer than necessary. If the sealing compound oecomes
too thick ~or easy application becasue of solvent losses, it
may be thinned with MEK. The compound
~houlcl
nut
be thinned
Equipment
beyond
may be cleaned
its
original consistency.
using MEK.
SEALING SEQUENCE
Cleaning and Surface Preparation

When areas to be sealed are dirty or contaminated with
oil. Xrease, or any other foreign matter, they must be
20-20-24
0
Page 1
Aug 17/84
SR-76-023
C()RROSION CONTROL IMANUAL

OPERATING TEMPERATURES FROM 225 TO 350"F (Continued)
Sealing Joggles, Holes, and Cutouts (Contd)
Seal holes and cutouts up to 1/8 in. diameter or width by

filling them with High Temperature Resistant Sealing
Compound and building up a fillet as shown in figure 2, If
possible, the sealing compound should be applied to the
pressure side of the hole being sealed.
Using
sealant gun, apply a fillet of High Temperature

Resistant Sealing compound to all seams, joints, etc., in
the area requiring sealing. If possible, the sealing compound should be applied to the pressure side of the seam.
Final dimensions of the fillet should correspond to those
shown in figures 3 and 4 with no gaps or bridges along the
Holes or cutouts over 1/8 in, diameter are plugged or

closetl with snap-in plugs, (United Carr Com pany) metal
caps, or plugs made from thin (0.001) aluminum foil. The
t~oil should be packed tightly into a compact plug and
applied from the pressure side of thh opening. The plug
m ust be used on the pressure side to prevent plug blow out
under pressure. Bridge sealing compound over plug and
on the metal frame for a min distance of 1/4 in.
Se"m.
gy/ T/
/O
\OR:LLN0.40nOLE
THROUGH JOGGLED
ANGLE
Sealing Joagles
Figure
LB0120-001
SEALING COMPOUND
1/B(MAX)
Sealing Holes
Fig~--2
20-20-24
Page 2
Aug 17/84
Cn"YRIGHT, 1984 BY SABRELINER CORPORATION
SR-76-023

OPERATING TEMPERATURES FROM 225 TO 350"F (Continued)
NOTE
Sealing Faying Surfaces
This procedure does not apply to any

sealed by the faying surface method
anti-icing air ducts.
NOTE
This method of sealing is not to be used
unless post-assembly procedure outlined
above is impractical.
together and
Fit components of the structure to be sealed

drill rivet and bolt holes, as required.
Disassemble the structure and

Clean
areas
remove
to
Permit fillets, beads, etc., of the High Temperature

Resistant Sealing Compound to dry at room temperature
for at least two hours before the Stabond C-136 material is
applied.
Brush two coats of Stabond C-136 material
all chips.
over
all
exposed surfaces of the High Temperature Resistant

Sealing Compound, allowing a min of 1 hour drying time
to be sealed.
Using a, sealant gun, apply a smooth even coat of High

Temperature Resistant Sealing Compound to one component of the seam or joint. Applied sealing compound
should be 1/64 to 3/64 in. thickness and 1/4 to 5/8 in. width
ancl ~ihould be applied along the centerline of the rivet or
I,olt holes.
possible (within 2 hours) after applying the

sealing compound, rivet or bolt components of the
structure together, squeezing out excess compound.
As
area
or
soon as
Applying Fuel and Oil Resistant Coating

To provide fuel and oil resistance to High Temperature
Resistant Sealing Compound, coat exposed surfaces of
beads, fillets, etc., of the compound with Stabond C-136
Fuel and Oil Resistant Material.
between coats.
Curing
High Temperature Resistant Sealing Compound porosity and bubbling in beads and fillets. a min of
2 weeks curing at room temperature is required before
Subje"ting sealed structure to elevated temperatures.
T, prevent
If.sealed structure will be subjected to elevated temperatures before the above curing cy~le is complete, cure
the sealing compoulid fol at least 24 hours oi room
temperature followed by heating at 110 to 1300F for at
least 24 hours.
When necessary to coat the sealing compound for fuel and
oil resistance, measure the curing time after application
of the Stabond C-136.
LB0120-001
SEP~LING COhllPOUND
-L,
T
1/8
Sealing Beads and Fillets

Figure 3
LB0120-001
SEILINGCdMPOUNO
1/8
Sealing Butt Joints

Figure 4
20-20-24
0
Page 3/4 Bla-1

Aug 17/84
SR-76-023

TEMPERATURES FROM 250 TO 400"F
Except for
~ENERAL
This section covers the sealing of jogffles, cutouts, holes,
slots, etc., in areas where excessive leakage of air or fumes
must be avoided, where pressure differentials do not
exceed 5 psi, and where operating temperatures extend
from 250 to 4000F and peak temperatures do not exceed
5000F.
MATERIALS
High-temperature sealing compound Proseal 714 with

catalyst, manufactured by Coast Proseal and Mfg. Co.
Stoddard Solvent P-D-680
one
areas
requiring spot sealing. dispense using
of the sealant guns listed.
Sealing Procedures
All holes, slots, joggles, etc., through the surfaces of
compartments which must be isolated shall be sealed.
Rivets, riveted joints, seams, etc., do not require sealing.
Holes, slots, joggles, etc., may be found by shining a
bright light on one side of the surface to be sealed, and
inspecting the reverse side for passage of light. Holes.
joggles, slots, cutouts, etc., up to 1/8 in. max width must
be sealed by filling with catalyzed sealant. Build up a
fillet approximately 1/8 in, thick on one side of the
opening. Where possible, this fillet should be on the
opening.
EQUIPMENT
pressure side of the
Sealant Gun Na. 250, Semco, Inc., Los Angeles, CA
Holes greater than 1/8 in. diameter must be filled with a

rivet, bolt, or cap so as to reduce the opening below the 1/8
or
Sealant Gun No. 950, Brantner and Associates, Garden

Grove, CA
in. max before sealing. Slots, joggles, or cutouts having a

minor dimension greater than 1/8 in, must be closed with
sheet metal before sealing. Stiffening at the opening to
INSTALLATION NOTES
insure positive slot closure is advisable.
Cleaning
on
Visually inspect sealed openings by shining a bright light
Remove dust, chips, etc., from the surface to which the

sealing compound is to be applied with a clean dry cloth or
with a
a vacuum cleaner. Wipe all surfaces to be sealed
clean cloth dampened with Stoddard Solvent. Before the
solvent has evaporated, dry the surface completely with a
clean dry cloth, discarding cloths as they become soiled.
Repeat the cleaning procedure until it is certain that no
oil, grease, or any other contaminating material is left
on
one
reverse
side of the sealed surface and inspecting the

side for passage of light. Reseal voided areas.
the surface to be sealed.
NOTE
To avoid contamination of the eolvent, it
should alwalle be pouredfrom the container
onto the cloth. Cloth ueedfor cleaning must
Mixing and Handling Sealant

Mix I can of sealant with the small container of catalyst
provided. If smaller quantities are required, the mixture
shall contain 1-1/2 parts of catalyst by weight to each 100
parts of sealant.
The catalyzed high-temperature sealant can be stored
at 5 +50F for 2 weeks or for 24 hours at room
temperature in a tightly closed container. At room
temperature the sealant has a working life of from 1-2
hours after removal from the closed container. Full cure
is obtained after 72 hours at 75 rt5"F.
20-20-26
0
Page 1/2 Blank

Aug 31/84
SR-76-023
APPLICATION OF SELF-CONTOURING SEALING PADS FOR AREAS WITH

NORMAL OPERATING TEMPERATURES FROM 225 TO 550"F
GENERAL
Cleaning

used in application of elastomeric self-contouring sealing
pads between normally separable sections of structure
When areas to which compound is to be applied have

become dirty through handling or are contaminated with
oil, grease, or any other foreign matter, they must be
ce.a..
access
ranae
doors) where normal operati ng temperatures
fromL25
to
ij~OOF.
Use
MATERIALS
RTV-90 Silicone Rubber Sealing
tured by (;eneral Electric Co..
Compound
.YS-~004 Primer manufactured
cleaner
or
clean
dry cloth
to
remove
dust,
etc. from the surface.
manufac-
NOTE
~f circumstances preclude the use of either

of these methodsfor dust and chip removal,
Silicure L-24 accelerator manufactured by Nuodex

Products Co.
use an
air hose.
by (;eneral Electric Co.
Solvent. Naphtha. Specification MTL-N-1Fj178.

Sierra Supreme Talc manufactured by R. D. Abbot Co., or
ecluivalent.

Surface completely with a clean cloth.
EQUIPMENT
Sealant Gun, Model 250, manufactured by Semco Sales
Services, Inc.
Duck Bill Nozzle, Part No. 8043, manufactured
Sales
Services, Inc.
S-1~50
a vacuum
chips,
~Iixer manufactured
by Semco
by Semco Sales
To avoid contaminaticjii of the

ii; must always be
poured from the container o;lto the cloth. The cloth used
Repeat this cleaning procedure until

oil,
and
grease,
or
it is certain that no
other contaminating material is left on the
surface.
Services, Inc.
Surface Preparation
INSTALLAT~ON NOTES
The materials described in this specification shall be

applied to bare metal surfaces, only.
Sealing Sequence
Remove all organic type finishes (e.g., paint, varnish, etc.)
from metal that P~ill come in contact with the sealing
compound. Adhesion of the compound to various
inconsistent.
sisehsinif
Ulean the area to which adhesion of the

is tiesired.
Apply one thin brush coat of XS-4004 primer to the metal

surface to which adhesion of the sealing compound is
desired, (this should be to the uneven surface, as shown in
figure 1) and allow to air dry for a min period of 30
minutes before application of sealing compound.
sealing compound
Imtnediately after cleaning, apply primer and allow to

temperature for a min period of 30 minutes
before application of sealing compound. Protect the
primed surface from contaminants during cure and do
not use heat to accelerate the cure of the primer.
cure at room
Xpply sealing compound
to the structure.
~ssemble the parts and allow to
cure.
Disassemble
the parts and dust the surface that is

rerluired to part from the sealing compound with Sierra
Supreme talc or equivalent. This may be accomplished at
any time prior to exposure of the assembly to heat.
20-20-28
0
Page 1
Aug 17/84
SR-7Ci-023

NORMAL OPERATING TEMPERATURES FROM 225 TO 5500F (Continued)
Since adhesion of the sealing compound to surfaces that

are not primed is poor, equipment cleanup is easily
accomplished after the compound has been allowed to
cure on the equip ment by mere ly p u Iii ng the cu red rubber
away from the equipment.
Mixing and Handling of the Sealing Compound

The two components of the sealing compound shall be
mixed together in the following proportion: 1 part by
weight of Silicure L-24 accelerator to 100 parts by weight
of RTV-90 sealing compound. The two components must
be blended until there is a uniform dispersion of curing
agent through the mixture; and also so that there is a min
inclusion of air. Compound that is insufficiently mixed
~vill have areas where cure is incomplete: and the
presence of air bubbles in the cured gasket will cause
sponging when the material is exposed to high
temperatures. It is suggested that mixing and loading of
sealant gun tubes be accomplished with an S-1360 mixer.
SEALING PROCEDURE
Apply mixed sealing compound as shown in figure B to the

mating part that has been primed. This may be accomplished by using a sealant gun equipped with a duck bill
nozzle. This nozzle applies a ribbon-like layer of sealing
compound, and the thickness of the ribbon may be
controlled by the rate of travel of the gun. Apply enough
compound in one pass to completely bridge any gap
between the mating surfaces, since any attempt to build
At room temperature (approximately 770F) the sealing

compound must be used within 1 hour after being mixed
u ith the curing agent or after removal from cold storage.
up
the thickness with another ribbon laid over the first

result in entrapped air in the gasket and cause
may
su
NOTE
bsecl uen t
s pon
ISi ng.
the mating parts as shown in figure

immediately and allow them to remain in the assembled
position until the compound has cured.
Assemble
ilcg, th.e secL1ina

sto~prl at _.~+gOF Sor
dal/s. Do rLot stole in dry
ciio;riaie rctmosphsre.
-Ir~ccy he
7
,-1Ste r
ice
or
any carbolz
COVER
(NOT PRIMED)
PRIME SURFACES
WHERE SEALANT
TO BE APPLIED
JOOGLE
Typical Primer Application

Figure 1
SEALING COMPOUND
RIBBON
Typical Sealant Application

Figure 2
20-20-28
Page 2
Aug 17/84
COPYRIGHT, 1984 BY SABRELINER COh;SRATION
SR-76-023

NORMAL OPERATING TEMPERATURES FROM 225 TO 550"F (Continued)
SEALING PROCEDURE (Contd)
After the compound has cured, the parts shall be disassembled and all excess compound removed with a sharp
knife. Dust the clean surface with Sierra Supreme talc,
or
equivalent.
Tooling Holes
up to 1/4 in. diameter and gaps up to 1/8 in.

wide may be backed up using NA2-X711 tape as shown in
figu re 1. After the corn pound has cured, remove the tape.
(;aps larger than 1/8 in, or holes larger than 1/4 in. must
be backed up with permanently attached doublers of
similar metal.
COVER
SEALANT PAD
PRIMED
SURFACE
Typical Assembly During Cure

Figure :3
TAPE
r---1
L,,,~
HOLE
r---11_
L,,
f
1/8 MAX
GAP WIDTH
Typical Tooling Hole Back-Up

Figure 4
20-20-28
a
COPYRIGHT, 1984 BY SP SRFLINER CORPORATION
Page 3/4 Blank

Aug 17/84
SR-76-023
FLAME RESISTANT AND LIQUID TIGHT SEALING FOR AREAS WITH

NORMAL OPERATING TEMPERATURES FROM 225 TO 400"F
It is essential that clean cloths are used in cleaning. When

a cloth becomes dirty, it should be discarded.
GENERAL
This section covers materials and procedures to be used in
seal i nR joggles, cut-outs, holes, seams, slots, etc., in areas
where leakage of fluids must be avoided and where a
flame tight seal is required in case of fire. The sealing
methods set forth in this section may be used in areas
where temperatures may be as high as 4000F in normal
opelation with occasional short duration exposure to as
high as ~O()"F.
To avoid contamination of the solvent, it should always be

poured from the container onto the cloth. Cloths used for
cleaning should never be dipped into the solvent.
If surfaces to be cleaned are visibly oily or greasy, the

cleaning procedure outlined above should be repeated
several times
MATERIALS
Compound PRT-810
Hiah Temperature SealinR
Compound, EC-1548
Solvent. Naphtha
Solvent
Products Research
Chemical Corp.
Burbank, CA 91504
Minnesota MininR
and NIfg. Ca,
MIL-N-151$8
LB0210-102
equivalent
Semco Sales
Service, Inc.
If the sealing compound becomes too thick for easy

application because of solvent losses, it should be dis-
AIl holes. slots, stringer cutouts. and joggles through

~,ulltheacls must be sealed for flame resistance. Holes.
slots, cutouts, etc., may be found by shining a bright light
on one side of the bulkhead and inspecting the other side
fol~ I,assaae of light.
carded: since addition of more solvent will have a

detrimental effect of both the adhesive and cohesive
properties of the compound.

Extreme
In the event of a fire, the sealing compounds will char or

be tlearaded. All fire-damaged sealant must be replaced.
care
should be taken to protect the sealing
compound from temperatures lower than 820F. Once the

compound is frozen, it is no longer usable, even after
thawing.
Cleaning
be sealed must be cleaned before
Equipment
application of
compound.
may be
cleaned: using hot water.
SEALING PROCEDURES
cleaner or clean dry cloth to remove dust

chil,s, etc., from the surface to which the sealing
com pound is to be applied.
Cse
oil remains.
The sealing compound loses solvent from the opened

container quickly. The container should not be allowed to
stand open longer than necessary.
INSTALLATION NOTES
the sealing
no
Handling of EC-1548 High Temperature Sealing

Compound
Sealant C;un, Modei iuo.250
to
until it is certain
re-primed.
EBUIPMENT
or
or
In cleaning primed areas, the primer adhesion should be

checked first. If the primer can be readily removed by
scraping with the thumb nail, its adhesion is unsatisfactory, and it must be stripped. It is necessary to remove
the Dri mer on iy from areas where the seal ing com pound is
to be applied. If the primer cannot be readily removed by
scraping with the thumb nail, it should not be removed,
Areas from which primer has been stripped should be
vacuum
NOTE
Sealing Holes. Slots,

Seal holes, slots,
Gaps
gaps up to
1/8 in, diameter or width by
filling them with EC-1548 High Temperature Sealing

Compound from both sides of the bulkhead as shown in
If cilc2L,rLsta7Lces preclude the use of either

of these ~1Lethoclsfo+ dUYt and chip removal,
.1LSP nn
or
and
figure
1.
nir h~se
Wil,e all surfaces to be sealed with diluent naphtha or

cleaning solvent, LB0210-102. Before the solvent has had
a chance to dly. wipe the surface completely dry with a
clean cloth.
20-20-30
c
Page 1
Aug 17/84
SR-76-023
FLAME RESISTANT AND LIQUID TIGHT SEALING FOR AREAS WITH

NORMAL OPERATING TEMPERATURES FROM 225 TO 4000F ~Continued)
Sealing Holes, Slots, and Gaps (Contd)
Beads of sealing compound should be applied with
there are no gaps or bridges along seam joint.
Holes and slots that are greater than 1/8 in, width must
first be plugged or closed with metal clips or United Car
Snap-in Plugs. Completion of the sealing is then accom-
plished
per
figure
care so
Rivets shall t,e sealed b applvinp a coating of PR-~10

the rivet. A sl,atula mav be used for spreatlinp the
coml,ounti over the t.ivet. The sealant should extend
apl,rosimatel~ 1;X in. t,e~ond the edge of the rivet as
i.
over.,
NOTES
shown in figure 2.
if one side of the hole heilzgsealed is inacces~ihle, the hole ma~ be sealed from one
When seams ol joints tc, l,e ~ealetl ape ot,scured by a

stiffener., etc., the jo#ale oI. gal, shall be injectetl with
sealant. The stiffener shall the~1 be sealed on both sides of
the seam for a min distance of (j in. from the seam or the
entire length of the stiffener. whichever is shorter. (See
side.
When the hole is Realedfrom one side, an
of the sealing compound should be
forced through the hole tofomz, as nearly as
possible, a button or grommet of the compound which will be Inechanically held in
ezcess
figure
place.
Seams anct riveted joints shall be sealed by applying a
beatl of PR-tilt) Sealing Compound whose final dimensions shall be approximateiv those shown in figure 2.
A l,ressure applicator should be used for this operation.
EC01548 HIGH TEMPERATURE SEALING COMPOUND
-I
1IIIMIX
iC tllBUIN
Typical Hole Sealing

Figure 1
1/4
1/8
1/4
;3~TL
t
1/4
NOTE
TOLERANCES ARE +1/8-0 UNLESS OTHERWISE NOTED.
Typical Seam, Joint, and Rivet Seals

Figure 2
20-20-30
Page 2
411i~ 17/8
SR-76-023
FLAME RESISTANT AND LI&UID TIGHT SEALING FOR AREAS WITH

NORMAL OPERATTNG TEMPERATURES FROM 225 TO 4000F
Application of Fuel and Oil Resistant Coating

EC-1548 Hifgh Temperature
Apply a heavy coat of PR-810 Sealing Compound over all

exposed surfaces of the EC-1548 High Temperature
Sealine Compound. Spread the sealing compound with a
spatula to form an even coating extending approximately
1/8 in. in all directions beyond the edge of the EC-1548
High Temperature Sealing Compound.
to
Sealing Compound
In order to
provide fuel and oil resistance to the EC-1548

High Temperature Sealing Compound, it is necessary to
overcoat the exposed surfaces of the compound with PR810 Sealing Compound.
Allow the PR-810 Sealing Compound to cure

hours at room temperature before exposing
min of 24
elevated
to
temperatures.
The EC-1548 High Temperature Sealing Compound

shall, after appiication, be permitted to dry at room
temperature for at least 24 hours before the PR-810
Sealing Compound is applied. A longer time of cure before

application is recommended whenever possible.
this
SEALBOTH
I
SIDES OF
Y
STIFFENER
o
O
8 IN.
INJECT
In
JOGGLE
110\
o\o
SEAL BOTH
I
Cc SIDESOF
\o
SEAM tO BE SEALED
~/O
STIFFENER
"N.
Typical Jog~le and Stiffener Sealing

Figure 3
20-20-30
0
Page 3/4 Blank

Aug r7/84
SR-76-023

GENERAL
at room temperature for a minimum period of thirty

mi"utes before sealing compound is applied.
cure

used in sealing between faying surfaces of aircraft parts
where operating temperatures range from -100 to 5Fj00F.
The materials and process in this section may be used for
pressure tight sealing and for liquid drainage control of
aircraft compartments where fillet type sealing cannot be
employed. This section is not intended for primary sealing
of integral fuel tanks and other vessels to be used for
liquid storage,
After this preparation has been completed, apply

sealing compound and reassemble the components.
the
Cleaning
When areas to be sealed have become dirty through
handling or are contaminated with oil, grease, or any
other foreign matter they must be cleaned before application of the sealing compound.
MATERIALS
Use
Sealing Compound RTV-90 manufactured by General

Electric Company.

compound is to be applied. If circumstances preclude the
use of either of these methods for dust and chip removal,
Sealing compound RTV-60 manufactured by General
use an
Electric
Company.
Silicure L-24 Accelerator manufactured

Products Company.
by Nuodex
SS-4004 Primer manufactured by General Electric
Company.
a vacuum
cleaner
or
clean dry cloth to
remove
dust,
air hose.

surface completely with a dry cloth.
It is essential that clean cloths be used for cleaning, When
Solvent, Naphtha, Specification NIIL-N-15178.
EQUIPMENT
To avoid contamination of the solvent it must always be

Sealant Gun, Model 2rj0, Manufactured by Semco Sales

and Services, Inc., or equivalent
oil,
5-1S5O Mixer manufactured

Services, inc.
by Semco Sales and
Surface Preparation
INSTALLATION NOTES
The materials described in this section shall be

bare metal surfaces, only.
Sealing Sequence
applied
to
Apply one thin brush
To obtain satisfactory sealing results the f~l!owing

jequence must be followed.
Fit components of the structure to be sealed
cirill rivet, bolt holes, etc., as required,
Repeat this cleaning procedure until it is certain that no

grease, or other contaminating material is left on the
together and
Disassemble the components and remove all organic type

finishes (e.g., paint, varnish, etc.) from metal that will
dome in contact with the sealing compound. Confine finish
removal as closely as possible to the actual area to be
sealed,
The area to which sealant is to be applied must be checked
for cleanliness. Any extraneous material such as oil, dirt,
chips, etc., must be removed.
su rfaces
coat of SS-4004 Primer to the metal

and allow to ai r dry for a m i n period of 30 m i nutes.
Mixing and Handling of Sealing Compound

RTV-90 and RTV-60 base compound may be combined in
to obtain optimum viscosity and
extend the pot life. When the optimum ratio has been
determined by shop trial, add one part by weight of
Silicure L-24 Accelerator to 100 parts by weight of the
base compound mixture (RTV-60 and RTV-90). These
components must then be mixed so as to obtain a
min inclusion of air. The presencz of air bubbles in the
cured sealant can cause sponging when exposed to
elevated temperatures and low ambient pressures.
varying proportions
Immediately after cleaning, all areas to which sealing

compound is to be applied shall be primed and allowed to
20-20-32
0
COPYRIGHT, 1984 BY SABRELINER t3riPORATION
Page 1
Aug 17/84
SR-76-023
PAYING SURFACE SEALING FOR AREAS WITH NORMAL,

Mixing and Handling of Sealing Compound (Contd)
SEALING PROCEDURES
iMising and sealant gun loading can be accomplished with
Apply a smooth, even coat of Sealing compound to the

faying surface area of one component; using either a.
spatula or a sealant gun. Use sufficient sealant to ensure a
continuous exudation of sealant along the length of the
assembled faying surfaces. This will facilitate inspection
for sealing integrity.
an
S-13Fj0 Mixer.
Shelf life of the unaccelerated RTV compound and of the

primer is 4 months. The primer must be kept in tightly
seaietl containers.
Rivet or bolt the components of the structure together,

squeezing out the excess compound. Application of the
sealing compound and assembly of the structure must be
accomplished within the time specified in figure 1 for the
specific mixture of base compounds used in sealing.
NOTE
A ccelerated conzpound nra~y buSlash cooled
i~L rl?y ice for a period no longer than XO
lrLinutes. Do not store in dry ice or an~y
carbon d~iozide atmouphere for longer
periods. Carbon diozide absorbed by the
corrrposlnd will cause sponging when the
material is ezposed to elevated tern-
After assembly of the faying surface, the sealing

compound must be permitted to cure at room temperature
(770F) for a min of 12 hours before pressurization.
Exposed
bare metal areas from which the protective

finish has been removed shall be touched-up.
peratures.
~ccelelated compound can be stored at -20+-.5"F for
approsimately 7 days. The room temperature pot life of
t he acce re rated co m pound w ill vary accord i ng to the ratio
of the base compounds since each base compound has a
different pot life. PTV-90 compound has a pot life of 1
hour after mixing or removal from cold storage, and
RTV-fiO compound has a pot life of 5 hours. For mixtures
of compounds, consult figure for the max assembly time
after aclclition of accelerator or removal from cold storage.
%RN-50
100
50
"/D RTV-BO
50
100
Compound Retlo
20-20-32
Page
Sealing Compound Pot Life

Figure 1
Xug 17/84
COPYRIGHT, 1984
BY SABRELINER CORP017,^,~10N
SR-76-023
INSTALLATION OF O-RINGS FOR FUEL SYSTEM
GENERAL
O-rings other than M529512 and MS29513: Do
This section covers the procedures to be followed during

the installation of synthetic rubber O-rings in the fuel
lubricate unless necessary. If lubrication is deemed

necessary, lubricate with the fluid which will contact the
O-ring in service.
system.
not
MATERIALS
Installation
Methyl Ethyl Ketone (MEK), Specification TT-M-261

Petrolatum, Technical. Specification VV-P-236
Uncatalyzed Silicone Adhesive A4000, Dow Cornina
Corp., Midland, MI
MS29512 and MS29518 O-rings: Apply enough

Petrolatum so that the O-ring will not fall out of the
groove. Avoid using excessive amounts of Petrolatum.
INSTALLATION NOTES
MS29512 and MS29ril:3 O-rings are normally used to
2500F, and Viton and Silicone O-rings are normally used
above 2500 F.
O-rings other than MS29612 and MS29513: Subsequent to

cleaning, grooved areas shall be prepared with Dow
Coming A4000 uncatalyzed silicone adhesive prior to the
placing of the O-rings. The grooves shall be brushed for a
length of 1/2 in, at intervals of approximately 4 in, with
the A4000 uncatalyzed silicone adhesive.
Age of O-rings is shown by the cure date on the package.

O-tings shall not be removed from their packages until
NOTE
Care shccll be
to Izeep the 8ilicone
Loithan the yroove. Adhesave accidentally brushed outs~icle the moo?,ps whn,ll
be carefully re~Loved b?l Fol;ent
ulitic MEK,
installation. At time of installation, check to make certain

that call-out on the O-ring package agrees with I.P.C.
callout.
The cleaning, lubricating, anci assembly procedures shall
be followed for all O-ring installations, while the O-ring
retention procedure may be waived in simple installation.
installations are defined as those O-ring installations of unlimited visual and manual access that assure
that the O-ring will not twist or fall out of the O-rinR
Simple
Rloove
during assembly,
Cleaning
The con tact surf aces of mati ng flanges and grooved areas
shall be cleaned of all protective films or tapes. The
After
a min drying period of 5 minutes the O-ring,

inspected to be free of all imperfections detrimental to
sealing, shall be placed in the grooved area. A firm
pressure shall be applied to the O-ring to ensure contact
with the adhesive.

Place the part containin~r the O-i.ina flatly in place
against the matingsurface. Install the required fasteners
and torque.
prottct,ive films or tapes shall be removed by peeling, with

residue being scraped with a non-metallic blade.
Finally, all grooved areas and mating surfaces shall be
solvent wiped with MEK. In each case a clean cloth shall
be used to apply the solvent and another clean cloth used to
\\ipe the surface dry.
any
Cleaning of glooved areas and mating surfaces reinstalled in service shall be accomplished by scraping off
ang residues or foreign material with a non-metallic
blatle, followed by a MEK solvent wipe.
Lublication
MS,9.512 and MS29.513 O-rings: Immediately prior to
installing the O-ring, apply Petrolatum sparingly over
the entire surf ace of the O-ring. If thread lubrication is
red u i Ietl by any th readed fi tting used in connection with
the O-ring. use only Petrolatum for this purpose.
20-20-34
0
Page 1/2 Blank

Aug 17/84
SR-76-023
INSTALLATION OF O-RINGS FOR FUEL SYSTEMS

AND BOLTED ASSEMBLIES
GENERAL
This section covers the materials and procedures to
be ~ollowed during the installation of synthetic rubber
O-lings for fuel systems and bolted assemblies.
MATERIALS
Petrolatum, technical Specification VV-P-236

Commercial
DC-200, 100, 000 Centistoke Oil
Dow
Coming Corp.
INSTALLATION NOTES
The contact surfaces of mating flanges and grooved areas
shall be clean and dry and free of dust, chips, oil, grease or
other foreign materials which can affect the installation
of the O-ring.
To facilitate installation of O-rings and to promote proper

the O-rinR or the surfaces against which it will
bear shall be coated prior to installation with a thin film of
compatible lubricant. Silicone rubber O-rings shall be
lubricated with DC-200 oil. All other rubber O-rings shall
be installed with petrolatum (VV-P-23fj).
The
O-ring shall be firmly pressed into place to ensure

seating. If an instrument is used for this purpose, it
shall not damage the O-ring.
proper
Install the
required fasteners when applicable,
to the
requirements specified in ST0101LA0002.
O-rings
on
which are exposed due to removal of a component

which they are installed shall be replaced prior to
reassembly.
20-20-36
0
COPYRIGHT, 1984 BY SABRELINER CORPC? bTION
Page 1/2 BlarG

Aug 17/84
8B-76-023
INSTALLATION PROCEDURES FOR O-RING SEALING

OF BOLTED ASSEMBLIES
GENERAL

used in the installation of O-rings for sealing bolted
assemblies subjected to 2Fj00F max.
MATERIALS
Solvent, Stoddard
Oil: Hydraulic. Aircraft
Petroleum Base
P-S-Gfil
MIL-H-.560(i
Com pound: Seal ing,

(;eneral Purpose
LB0120-002
Washer, Plain
D(1-200: 100.000
Centistoke Oil
2W1
Dow CorninR
Shimming
If gauging indicates that the bore depth is greater than
the "T dimension" limit, shims shall be used to reestablish the required depth.
Corp.
To fac i I i tate i nstallation of O-rings and to promote proper

seating, the O-rinR or the surfaces against which it will
beal shall be coated prior to installation with a thin film of
material in accordance with the following chart:
O-Rinp
or Adhesive
MIL-H-Fj606 or
LB0120-002
MIL-H-5606
DC-200: 100.000
Centistokes
Lubricant
AN(i227
MS2961~
NAZ-40001
O-rinas of a
color other
than black
For sealing at a counterbore (see figure 1. hole countersunk in one surface), sequence of assembly shall be:
O-ring installation shall be cLmpleted and the

assembly bolted together within 3 hours after application
of the adhesive,
be completed within X hours, the 0assembly
rin~s shall be removed and the adhesive shall be cleaned
flom all surfaces to which it was applied.
cannot
The O-rina shall be firmly pressed into place to ensure

proper seating. If an instrument is used for this purpose,
ita surfaces which contact the O-ring shall not permit
bluising or cutting. Excess adhesive material shall be
removed.
O-Iings shall be replaced

reassembly is required.
su
Ifaces in the seal ing
S ize of the shim (ID and OD) shall be as specified in table 1

for the corresponding bolt diameter and bore diameter.
Assembly
The
.?\11
Shimming shall be done with 2W1 washers. Aluminum

washers shall be used for shims contacting aluminum or
cadmium plated assemblies. Brass washers shall be used
for shims contacting stainless steel or titanium assemblies.
Thickness of the shim shall be determined by the differences between the actual gauged bore depth and the
required "T" dimensions.
The LB()1XO-()02 adhesive shall be prepared per instructions on the vendors shipping container. The mixture
stirred foF 5 minutes after formation oi a uniform
If
The depth of the bore to be sealed shall be gauged, and the

reading compared with requirements specified in
table i. Necessity for shimming, and thickness of shim,
shall be determined from this comparison.
gauge
SEALING PROCEDURE
INSTALLATION NOTES
type of
cutting compounds, and other foreign materials, by

wipi"p with Stoddard solvent.
each time that removal
area
or
i.
2.
3~
Shim, if required.
Adhesivefilm, if used.
O-rinp.
For
sealing a joint between two surfaces when a sleeve is

used (see figure 2), the assembly sequence shall be:
i.
2.
Q~
4.
Adhesive film, if used.
O-ring.
Sleeve.
Shim, if required.
For sealing ajoint between two surfaces when no sleeve is

used (see figure 3), the assembly sequence shall be:
1.
Adhesivefilm, ifused.
2.
O-ring.
3.
Shim, if required.
shall be freed from grease.
20-20-38
Page
0
Aus 17/84
C()RI1OSION CONTROL MANUAL
SEALED
SURFACE
O-RING
-I
Typical Counterbore ()-Ring
eruaiFgnilaeS
-1 .C..
SEE TABLE f
FOR DIMENSIONS
SLEEVE
O-RING
C//
8oa~ol.
Typical Sleeved Joint O-Ring Sealing

Figure 2
-r
SEE TABLE 1
SURFACE
FOR DIMENSIONS
SnlM
O-RING
t..
-I C
i
T
Typical Non-Sleeved O-Ring Sealing

Figure 3
SEALED
SEE TABLE 1
FOR DIMENSIONS
20-20-38
Page 2
Aug 17/84
CC"VRIGHT, 1984 BY SABRELINER
SR-76-023
INSTALLATION PROCEDURES FOR O-RING SEALING OF

BOLTED ASSEMBLIES (Continued)
Table 1.
O-Ring Installation Dimensions
ODimensions
O-RING
MS29Fj~3
AN6227
CROSSSECTION
DIA.
-10
-o
0.070
-11
-5
0.070
-110
-8
0.103
-111
-9
0.103
-112
-10
0.103
-113
-11
0.103
-114
-12
0.103
BOLT
DIA.
"D"
BORE
DIA.
BOLT
SMOOTH
BOLT
THREADED
1/4
5/16
3/8
0.3750
0.050
0.437.5
0.050
0.5625
7/16
1/2
9/16
5/8
SHIM
OD
SHIM
ID
0.045
0.344
0.265
0.045
0.406
0.328
0.080
0.070
0.500
0.390
0.6250
0.080
0.070
0.563
0.453
0.6875
0.080
0.070
0.625
0.515
0.7500
0.080
0.070
0.688
0.578
0.8125
0.080
0.070
0.750
0.640
NOTES:
a
D
O
n
X11 dimensions
are
in inches
Tolerance is +0.003 in.

Tolerance is +0.005 in.
Tolerance is t~.OOEi. -0.0()0 in.
20-20-38
0
COPYRIGHT, 1984 BY SAbn~LINER CORPORATION
Page 3/4 Blank

Aug 17/84
SR-76-023
CORROYION CONTROL MANUAL
APPLICATION OF TAPE OR SEALANT CORROSION BARRIERS

BETWEEN MAGNESIUM AND OTHER METALS
GENERAL
SEALING PROCEDURES
This section covers the methods and materials to be used

in applying tape and sealant corrosion protective barriers
between magnesium alloys and dissimilar metals,
Dissimilar metals, with respect to magnesium alloys, are

defined as ail metals or metallic coatings except
aluminum alloys.50Fj2, Fj0,56, 0061, and 006,3.
Surface Preparation
Before application of tape

following shall be checked:
All corners and/or edges of the faying surfaces shall

be examined for sharp corners or edges. Sharp
corners or edges will cut through the tape or sealant
during assembly; thus destroying the corrosion protection afforded by the tape or sealant. Corners and
edges that do nut meet the radii requirements shall
be reworked and touched up.
2.
All metal faying surfaces shall be detailed (i.e.,

drilled, countersunk or dimpled).
MaKnesium and maynesium alloys, when in contact with

rlissimilar metal and in the presence of moisture, are
subject to severe and rapid corrosion. Since paint films
joints, it is
MATERIALS
i\laphtha, tlliphatic TT-N-S6

Vinyl Tape No. 47:i Minnesota Mining cY~ Mfg. Ca.
Teflon Tape, Mystic No.iSO:J Mystic Tape Co., Los Angeles;
All metal faying surfaces shall have received their

chemical treatment and organic finish.
4.
CA
Compound: Sealing, General Purpose- LB0120-~02

Sealing Compound. Silicone Rubber; RTV. Type III
LB0120-022
CASK Paste
Engelhard Industries, Newark, NJ
Compound: Sealing, Exterior Surfaces LE0120-004

DC-3 slllcone Grease Dow Coming Cotp.
Petlolatum, Technical Grade
VV-P-236
NOTES
~eroctnnmic smoothers shall be used to protect butt
m aKnesium and a dissimi lar metal that are on the
moltl line of the aircraft. Exceptions are noted below,
jo i n t~ o t
Corrosion barriers shall be applied in addition to and

after the required chemical and protective organic finishing. Color coats (i.e, decorative finishes), however, may be
applied after tape, sealant, or smoother.
~ealllnt or aerodynamic smoothers shall not be used as a

c!,~1ojion i,arrier on movable control surfaces. Tape shall
i,t~ tsciusivel\r ilsed on YULh .illrf;lCeS.
Taye
1,1
sealant 3hall
not
be used between press fitted
surfaces.
Tape
c,r ~ealant shall not be used as a corrosion barrier

bet~veen magnesium and dissimilar metals on mechanicai, hydraulic, or electrical assemblies, where the
presence of tape or sealant could cause malfunctioning of
sealing compound the
i.
alone do not afford sufficient corrosion protection to these

necessary to supplement them with other types
of corrosion protective barriers.
or
Immediately prior to application of tape or sealing.

compound all faying surfaces shall be carefully
wiped with a clean cloth saturated in naphtha
(TT-N-S6j.
Application
Of
Tape
Tape
Selvice Temperature
Vinyl Tape No, 47:3 Minnesota

Mining
Mfg, Co.
Teflon Tape, Mystic
No. 1~0:-: Mystic Tape Co.
-6.i to 82,5"F
-fi~ to 3~0"F
Although Tellon tape can be used below ~35"F, vinyl tape

is ptefelred in the -6~ to "":J"F Ianae because of its better
adhesive and lower
cost.
The Sabreliner is normally below 2250F except in hot

areas around engine,
Whenever possible, apply tape
Splicing is
more
as one
continuous film. If
lap the ends at ,jst 14 in. and not

in. Avoid lapping ~ape over any attaching
necessary,
than ~/16
hole.
Carefully apply tape, adhesive side down and without

tension, to the magnesium fayiny surface: if this is not
convenient, apply tape to the other metal surface. Unless
otherwise specified, the width and length of the tape shall
be sufficient to extend 1/4 in. beyond all edges of the
magnesium faying surface, (See figure 1 for typical
applications.)
the part.
20-20-40
Page 1
Aug 17/84
SR-76-023
tC--
1/4 IN.
--i I---IVOTE
MAGNESIUM
ALL DIMENSIONS ARE TYPICAL
WWWWWWI
OTHER METAL
TAPE
Typial ilpplications Of Tape As A Corrosion Barrier

Figure 1
20-20-40
Page
Aug 17/84
COPYRIGHT ia84 BY SABRELINER CORPORATION
SR-76-023
CORKOS~ON CONTROL MANUAL

BETWEEN MAGNESIUM AND OTHER METALS ~Continued)
Application of Tape (Contd)
Application of Tape and Sealing Compound
Whenever possible, the portion of unsupported tape

extending beyond the edges of faying surfaces shall be
folded over the edge of the faying surface. (See figure i,)
The edge of the tape extending onto the mold-line shall
always be pointed downstream.
Apply tape as noted except 1/4 in. extension of the tape

does not apply, Seal the periphery of the tape with sealing
compound as shown in figure 2,
Application
On simple arrowhead magnesium extrusions such as used

trai I ing edges on F-Xfi wings and ailerons, the tape shall
be of such width to encompass the entire interior surface
of the extrusion and extend 1/4 in. beyond the faying
surfaces. (See figure i.) On magnesium trailing edges
where the exposed width of magnesium is less than 1/2
in., the tape shall extend beyond the faying surfaces 1/2
the exposed width of the magnesium.
of
Sealing Compound
Sealing Compounds shall be applied

as shown in figure :3.
as
described below
and
as
The sealing compounds listed below are suitable for

within the indicated service temperature range.
Sealant
Service Temperature
Compound: Sealing, General

Purpose (LB0120-002)
Sealing Compound, Silicone
Machined maffnesium extrusions used as trailing ed~ges

(e.a. P~ N 192-2142(), 1B.i-2 t?S6. and 192-~5489) shall have
the tape applied.
use
-R.i to 2250F
-6:5 to.i:300F
Rubber, RTV (LB01~0-()22.

Type III)
Take extreme care to see that all tape covering air vent
and water drain holes is removed. For this purpose, use an
"Esacto" type knife or other suitable cutting tool.
General Purpose Sealant( LB0120-O02) is preferred below

cost and easier application. RTV
Silicone sealant, however, may be used if desired.
225"F because of lower
Before
inserting rivets, bolts, screws or

fasteners, pierce the tape over the attaching holes with a
sharp nwl or similar tool. Be careful to avoid tearing the
tape beyond the limits of the hole.
All
paint finishes which have been applied for corrosion

protection of the contacting surfaces shall be left in place.
~Yhen positioning parts for attachment. be careful to

clama~ing the tape. Positive protection against
coiiosion ix
fi Im.
possible oniJr
~hen tape is in
one
continuous
1/81N.
1;J
II
~O
MAGNESIUM
1.;4
-tlalN
.o
~888888881
F~
UIIEa.ET*L
raPE
SEIL*NT
;V()TE
4LL DIMENSIONS ARE TYPICAL
Typical Application Of Tape And Sealing Compound Combined

Figure 2
20-20-40
0
Page 3
Aug 17/84
SR-76-023
It";"
-L~
_
1/4_ 1/8
,,,,,,_/
rVOTE
l~n
MAGNESIUM
oTnER METAL
SEALANT
ALL DIMENSIONS ARE TYPICAL
Typical Application Of Sealant As A Corrosion Barrier

Figllr~3
20-20-40
Page 4
Aug 17/84
SR-76-023

BETWEEN MAGNESIUM AND OTHER METALS (Continwed)
Application of Sealing Compound (Contd)
Removable parts shall be assembled so that the sealing
compound does not adhere to the part which is removable
or to the fasteners which attach the part. This may be
accomplished by the use of petrolaturm or the omission of
primer.
are to be permanentlyjoined shall be treated so
that sealant adheres to all surfaces. Examples of such
pa~ts a~e Iiveted assemblies and bolt or screw fastened
pa~ts that ate expected to remain joined for the life of the
Parts that
ailclaft.
Cate shall be exercised in the application of sealant so that
knife trimming can be omitted. When knife trimming is
reyuired, it shall be performed without damage to the
underlying paint coatings.
Xpplication
of
If both edges of the butt joint
are
coated with Teflon
enamel, the smoother shall be omitted unless required for
aerodynamic
reasons,
If one member of the
buttjoint requires frequent removal.

the edges of that part shall be treated to prevent adhesion
of the smoother. Petrolatum can be used for this purpose
when applying LB0120-004 sealing compound, and DC-4
silicone grease can be used for application of CASR paste.
The smoothers listed below are suitable for
indicated service temperature range:
use
within the
Smoother
Service Temperatures
Compound: Sealing, Exterior
-6~ to 225"F
Surface (LB0120-004)
CASR Paste
(Engelhard
Industries)
-6.5 to 5000F
I~erodynamic Smoother
4Ii,ltl-iine butt joints containina maRnesium and a

tlis~imilar metal shall be sealed with aerodynamic
~iloothet See FiRure C) Exceptions are as noted below.
MP~GNESIUM
IVOTE
ALL DIIVIENSIONS ARE TYPICAL
OTHER METAL
t88888888ti
TAPE. SEALANT OR SMOOTHER
~VQQQO
SMOOTHING COMPOUND
Typical Application Of Aerodynamic Smoother To iMold Line Joints

Figure 4
20-20-40
Page
0
Aug 17/84
SR-7fi-02Y

BETWEEN MAGNESIUM AND OTHER METALS (Continued)
Application of Aerodynamic Smoother (Contd)
Although CASR Paste can be used where maximum
service temperatures are below 225"F, LB0120-004
sealing compound is preferred because of its lower cost
and easier application.
Care shall be exercised in applying the smoothers so that
sanding or knife trimming can be avoided. When sanding
or trimming must be performed, the adjacent painted
surfaces shall be protected against damage.
After the smoothing compound has cured, the exterior
surfaces of the aircraft may be finished.
20-20-40
Page 6
Aug 17/84
COPYRIGHT,
SR-76-023
ELECTRICAL SYSTEMS ROOM TEMPERATURE CURING

SILICONE RUBBER POTTING
(;ENERAL
This section
systems with
covers
two methods of
a room
temperature
potting electrical
cure
silicone rubber
provide protection against moisture, carrosion, vibration,or other damage. The potting compound is
compound
su
to
i ta~,le for
use ove r a
tem pe ratu re range of -65 to 500"F.
MATERIALS
Primer, SS 4004 (General Electric Co., Downey, CA)

Masking Agent, Stabond W-600 (American Latex Corp.,
Hawthorne, CA or equivalent)
Methyl ethyl ketone (MEK): TT-M-26
Toluol (Toluene): TT-T-548
Laminate, Glass Cloth, Silicone Resin: MIL-P-997
Type GSG
The above listed materials
below are required:
Group
plus either Group
or
Group 2
Metallic or plastic components to be potted should be

brushed/dipped in clean MEK. Avoid removing perma
nent exterior markings or identification by contact with
MEK.
Clean silicone rubber insulated wire or cable to be potted

by wiping or dipping in toluol. Allow 20 nlinutes fol
drying unless the components can be wiped dry with
clean absorbent paper or dried with dry, oil free air, or
nitrogen.
Potting Preparation and Handling
NOTE
1663 and EC 166r
should be used within 1 1/ear ofmanufaeture.
RTV-11, RTV-90, EC
Preparation of RTV
Potting Compounds
To 100 parts of RTV 11 or RTV 90 by weight, add

1.0 f0.25 parts of Thermolite 12 by weight. One
gram of Termolite 12 by weight is approximately
equal to 35 drops by volume.
2.
Mix
Silicone Rubber, RTV 11(General Electric Co., Downey,
(;roup
Iotting Kit, EC 1Ci63 (Similar viscosity

(Minn. Mining and Mfg. Co., St. Paul, MN)
Potting Kit, EC 1667 (Similar viscosity
(Minn. Mining and Mfg. Co., St. Paul, MN)
(Group 1)
1.
CA)
Silicone Rubber, RTV 90 (General Electric Co., Downey,
CA)
Curing Agent, Thermolite 12 (General Electric Co.,
Downey, CA)
11 and RTV 90
curing agent thoroughly into the Iubber stock.

Generally, 3 minutes of mixing is necessary to
thoroughly blend a 1 Ib. batch of material, as
evidenced by a uniform appearance and consistency
of the mix.
to RTV
to
11.)
3.
RTV 90.)
Place activated rubbel- stock in a vacuum chamber

or bell jar, then evacuate to a vacuum of more than
27 in. of mercury. Hold vacuum until ail bubbles no
longer rise and break on the surface of the rubber
stock.
INSTALLATION NOTES
Safety
Solvents used in this process should be handled in a safe
manner. Resin contacting skin or clothing should be
washed off immediately with soap and water.
Preparation of EC 1663
Potting Compound
E;C 1863 (viscosity equivalent of ItTI/11)

and EC 1667 (viseositll eguivalent ofRTF/
90) compounds are available in a pol~ethylelze cartridge containing rubbe, stock
in the cartridge proper and curirtg agen.t
in the center stem.
Metal containers used as permanent molds should be

sandblasted and vapor degreased,
polished
in
Remove sleeving from solder joints and w i re terminations

in previous soldering operations. Avoid tlamaginff the
wire insulation when removing the sleeving.
If shims are used in the potted assembly, use properlysized silicone-glass laminates, 0.008 in. thick per MIL-P997 Type (L~
rL3LT.
(Group 2)
NOTE
Cleaning
Removable molds should be cleaned and

manner suitable for the material.
and EC 1667
i.
Depress center plunger forcibly anti ruptdre burst

diaphragm in stem, causing curing agent (black) to
be pushed into cartridge proper.
2.
Move center plunger up and down in a puml,ing

motion at least 30 times to distribute curing agent
through rubber stock, as evidenced by uniform dark
red color.
3.
Unscrew center plunger and insert cartridge in
manually or pneumatically operating caulking gun.
20-20-44
0
Page 1
Aug 31/84
SR-76-023
ELECTRICAL SYSTEMS ROOM TEMPERATURE CURING

SILICONE RUBBER POTTING (Continued)
Cured
Potting Preparation and Handling (Contd)
PIeparation of F:C 16Ci3 and E(:

Potting Compound (Contd)
1667
potting compound is firm and rubbery to the touch,
and not tacky.
((;roup 2)
Voids or occasional bubbles over 1/8 in, diameter, or any

void which exposes a functional part of the potted unit
should be reworked by Filling the void with fresh potting
All exterior surfaces of permanent containers should be

free of masking agent and potting compound,
compound.
material oldct than one year from the date

on the resin container should not be used.
Potting
stamped
SEALING PROCEDURES
Externally mask connector threads, boltheads and other

points where leakage is liable to occur with Stabond
W-Ii00. Allow masking compound to dry before proceeding further.
If shims
required to prevent shorting out of electrical

they should be positioned in place at this time.
are
contacts,
P1ime components and assemblies to be potted with No.

SS~()04 primer applied by brush in one thin continuous
caating,as evidenced by a medium-red color of the
primer. Allow primer to dry until tack-free

(approximately 20 minutes). Heat should not be applied
to the plimed surfaces to hasten drying. Pot components
nithin 8 hours after being primed. If more than 8 hours
elapse, wash primer off with MEK, dry, and reprime
befa~e potting is performed.
Or inject potting compound into position, as
apl,lopriate. RTV 90 or EC 1667 is used for filleting,
sealing, caulking, or other applications where the use of a
material with a "spreadable" consistency is advantageous.
RTV Ilor EC 1683 is used where a"pourable" material is
more advantageously applied. RTV 11 or EC 1662 may be
applied by pouring from the container or by means of a
Pour, spread,
caulking
gun.
If entrapment of air is liable to
physicallayout of the assemblies
occur
to be
because of the
potted, repeat air
removal.
Cure potted units by mounting in a suitable holding device
for 24 hours at room temperature. The assembly will be
tack-free at that time and may be handled and functionally
checked. The potted units should not be subjected to
elevated temperature (above 160"1") until 1 week after
potting
or. severe
sponging
of the
potting compound
may
result.
Masking agent and potting compound may be stripped

off exterior surfaces, terminals, etc., by hand or with a
rilzc,l I,lade. Avoid scratchinR plated. printed, or coated
sul1Llcles of the assenll,ly.
Remove temporary molds used in the potting procedure
in an appropriate manner without damaging the potted
unit.
20-20-44
Page 2
Aug 81/84
COPYRIGHT, 1984 BY $ABRELINER CORPORATION
SR-76-023
POTTING BENDIX CONNECTOR FOR USE TO 300"F

fitting and discard
C;ENERAL
i,
?his section covers potting a Bendix electrical connector

for use at temperatures up to 3000F.
Remove rubber insert from elbow

insert.
2.
Drill a No. 30 hole on centerline and l/tS in, flom

shoulder of connector. (See figure 1.) Stliny wire
through elbow fitting and solder.
3.
Clean inner wall of elbow fitting and portion of wire

to be potted by flushing with naphtha. Allow cleaned
surfaces to dry completely.
4.
Spray 3C-200 primer on soldered connection and
MATERIAL
HC-200 primer
Churchill Chemical
Corporation,
Las Angeles, CA
TT-N-95
Naphtha
on
back side of fixed insert of connector.
E:QUIPMENT
Pressure gun, sealant,
Model No. 250
Cartridge, No. 258-CP6
Nozzle, No. 250N-4-2
5.
Semco, Inc,
Los Angeles, CA
Semco, Inc.
Los Angeles, CA
Semco, Inc.
Los Angeles, CA
applying potting compound, allow primer

to dry at room temperature for at least 1
or force dried under a heat lamp or in an oven
Before
coating
hour
at
temperature of 160 +10oF for at least 20
minutes.
6.
Reassemble connector, properly clocking

backshell and tightening backshell retaining nut.
INSTALLATION NOTES
Connector
Preparation
Disassemble electrical connector to the extent shown in

figure 1 and perform the following operations:
in f1/32 IN.
DRILL
NO.30
HOLE
CLEAN POTTING
SURFACES WITH
NAPHTHA AND DRY
REMOVE
RUBBER INSERT
SOLDERCONNECTION
SPRAY PRIMER ON
SOLDERED CONNECTION
AND ON BACK OF INSERT
O
DONOT ALLOW PRIMER
TO CONTAMINATE THIS
PARTOFCONNECTOR
Preparation
Figure 1
Connector
20-20-46
Page 1
Aug 31/84
SR-76-023
POTTING BENDIX CONNECTOR FOR USE TO 300oF (Continued)

Mixing and Handling Potting Compound
Mix using an air driven mixing machine. Keep speed of
the m ixiny machine below 50 rpm to prevent overheating
and introduction of air while mixing, After a mixing for
10-15 minutes, the accelerated compound should be
visually inspected to make sure that no particles of
accelerator are left undispersed in the mixture. If hand
mixing by means of a spatula is necessary, make certain
that the accelerator is evenly dispersed throughout the
compound and avoid introduction of air by too rapid
stirring or by folding action. Hand mix at least 15
minutes. Hand mixing should be limited to small
quantities
of material.
NOTE
suggested that workers engaged in

mixing or cleaning operations befurnished
with ~ruhher gloves.
It is
When the compound is supplied premixed and frozen,

allow a room temperature warmup time of 30-50 minutes
before use. After the warmup period and before insertion
in a pressure gun, wipe the outer surface of the potting
compound tube with a clean, dry cloth.
cases where potting compounds are cured at elevated
temperatures, the connector assembly immediately before
potting should be preheated for at least 10 minutes at a
temperature within 100F of the cure temperature.
In
Sealing Procedure
Seal connector
as
follows:
1.
Place connector in a su itable fixture so that connector

opening is positioned up and wire is held in a vertical
position in center of cavity as shown in figure 2.
2.
A Semco gun or equivalent should be used to inject

the potting compound into connector. To provide
max flow, tip of nozzle may require trimming to
remove mold flash.
3.
Potting compound should be injected until sealant

level is 1/8 f1/16 in. from top of connector. Remove
4.
After connectors are potted, they must be maintained

in an upright position as shown in figure 2 to prevent
leakage until compound has cured. Cure potted
connector according to any one of following timetemperature schedules:
any excess
sealant with
Tempelrtture (OF)
clean cloth.
Minimum Time
iO
120
140
24 hours
3 hours
2 hours
160
200
30 minutes
1 hour
20-20-46
Page 2
Aug 31/84
SR-76-023
COKROSION CONTROL MANUAL,
POTTING BENDIX CONNECTOR FOR USE TO 300"F
~Continued)
SealinR Procedure (Contd)

5.
curing, trim sealant so that its

1/8 +1/16 in. from top of connector.
After
upper level is
must adhere firmly to the

completely enclose the wires. The
cured potting compound should be free from cracks and
The cured
potting compound
connector backshell and
have
smooth, clean surface.
The connector should be reworked if sponging of the

compound has occurred, as indicated by the presence of
numerous small holes or a porous texture.
When bubbles or holes larger than 1/32 in. diameter are
present on the surface of the sealant, the top of the bubble
should be removed with a knife or razor blade, taking care
not to cut the wire insulation. The hole or opened bubble
shall be filled with potting compound and cured.
WIRE HOLDING CLAMP
1/8 f1/16 1N.
UPPER LEVEL OF POTTING

COMPOUND
INJECTION GUN TIP
NO. 30 HOLE
Injection of Potting Compound Into Connector

Figure 2
20-20-46
Page 3/4 Blank

Aug 31/84
SR-76-023
COKROSION C:ONTKOL MANUAL
SEALING ELECTRIC TERMINATIONS WITH OVERCOATING

NOTE
GENERAL
Ihis section covers sealing electric terminations such as
those of relays anti switches used in aircraft with an
overcoati ng to protect them from moisture, corrosion, and
othel tiamaae.rhe overcoatinff is suitable for continuous
operation from -65 to 32FjOF.
MATERIALS
Varnish, Moisture and

Fungus Resistant
MIL-V-173
Naphtha, Petroleum
Aliphatic
Methyl Ethyl Ketone
(MF,K)
Oil Base A (Blue)
TT-N-95
Under
no
conditions should ebsetrieal

aho?tc
sllhJectccl to
relaj~s
1250F during pmeess%zsg.
be
4,
a second coat of varnish

and 3 above.
Apply
following steps 1, 2,
The overcoating must be a continuous, unbroken film,

free from cracks and bubbles. Wrinkling of the overcoating is not cause for rejection. When the coating fails to
pass visual examination, additional coats of varnish shall
be applied until this requirement is fulfilled.
TT-M-261
Du Pont
INSTALLATION NOTES
Cleaning
Clean electrical terminations by immersing them in
naphtha for a period of 2 minutes. Agitate the solvent
continuously while the terminations are immersed. The
solvent may be applied with a spray gun as an alternate
cleaning method. The excess naphtha shall be drained
from the terminations and they shall be allowed to dry for
a min of 15 minutes.
Blue Dye
MII,-V-17:3 varnish is applied in the "as received" con
dition. No solvents shall be added to thin the material for
spraying. To facilitate coverage determination, the
varnish may be dyed blue by dissolving 5 grams of
Du Pont oil base A dye in 1 pint of MF,K and thoroughly
stirring 4 fluid ounces of the dye solution into 1 gallon of
varnish.
Sealing Procedures
Apply overcoating
as
follows:
()vercoaling is applied
i.
as
follows:
Apply one liberal coat of varnish to terminations to

provide as thick a film as possible without causing
excessive runoff. Change direction of spray during
application to provide uniform coverage around all
wires, soldered joints, and other electric ternations.
2.
Allow coating to air dry a min of 15 minutes at room

temperature, with drying up to 24 hours being
11.
After
permissible.
oven
room
temperature drying period, coating is
dried at 120 +50F for at least 3 hours.
20-20-48
0
Page 1/2 Blank

Aug 31/84
SR-76-023
C()RROSI()N CONTROL MANUAL
SEALING NEOPRENE JACKETED MULTICONDUCTOR AND COAXIAL

CABLE AND KEL-F JACKETED COAXIAL CABLE TERMINATIONS
(;I~NE:RAI,
This section covers potting neoprene covered multi-conductor cable terminations, neoprene covered coaxial cable
terminations, or Kel-F jacketed coaxial cable
terminations.
Figures 3 and 4 call oLlt. an estim;lted dimension th;tt i~

subjected to revision as exprrience may indicate.rhe
estimates listed below wele arrived at by using ~O-aaRe
wire, allowing 0.038 in. between layers of wire, and 0.062
in, thickness of potting compound over the top of the
bundle.
MATERIALS
Compound; Potting,
Shell Size
LB0120-006
10SL
125
14S
16S
12
14
16
18
20
Electrical, General
Purpose
Naphtha, Aliphatic
Red Primer, Vulcabond
V-102
TT-N-95
Stabond
Corporation
Gardena, CA
INSTALLATION NOTES
Cleaning
Cleaned parts that will be stored for more than 4 hours

should be provided with covers, such as clean polyethylene
film or clean bags, or stored in closed compartments to
prevent dust and other substances from contaminating
the sealing area.
Mold
Preparation
Permanent nylon molds should be used for straight-entry

and right-angle-entry connectors whenever possible.
When permanent nylon molds are not available, use a
temporary mold as shown in figure i. When resilient
inserts are used, apply one coat of primer to the insert only,
where the mold is of insufficient depth, remove
the beveled top section of a standard mold and stack a
second mold on the top of the first mold. Position on the
connector shell as shown in figure 2.
In
cases
2.156
2.125
24
28
32
36
2.687
2.937
Curing
After the connectors are potted, they must be maintained
in a vertical position to prevent leakage until the compound
has cured. Coaxial cables RG-115A/U, RG-62C/U, and
RG-179/U and multiconductor cables jacketed with neoprene, such as WR-Fi/U, WF-114/U, and WM-8.5/U, may
be exposed to temperatures above 1600F during curing.
All other cables must not be exposed to temperatures
above 160"F.
potting compound should be cured by heating the

potted connector according to one of the following time-
The
temperature schedules within the cable temperature

range:
gh t-angle entry con nectors that te rm i n ate neoplene

jacketed multiconductor cable in accordance with figure 3.
I~ol
1.438
1.438
1.438
1.438
1.969
2.063
2.375
2.500
2.687
2.813
22
Clean area of the neoprene covered cable to be encased in

the potting compound with a clean cloth saturated with
naphtha. Air dry the connector and cable for 30 minutes
at room temperature or forced air dry at 1TjO"F for 10
minutes. Avoid handling the cleaned area.
Dimension in
3 and 4 tin.)
Figures
ri
Pot right-angle entry connectors that terminate neoprene or

Kel-F jacketed coaxial cables in accordance with figure 4.
Temperature
(f50F)
70
120
140
160
200
230
Minimum Time
24
8
6
3
1
30
hours
hours
hours
hours
hour
minutes
20-20-50
0
Page 1
Aug 31/84
SR-76-023
C()KK()SI()N CIONTROL MANUAI,
NEOPRENE CABLE COVERING
POTTING COMPOUND
INJECTION HOLE
REMOVABLE
MOLD
7/8 t1/8 IN.
:O
MOUNTING
PLATE
CONNECTOR
NOT~IS
DISTANCE FROM END OF CONDUCTORS TO BEGINNING OF NEOPRENE CABLE COVERING MUST BE 3/4 IN
MAX
I,IICKNESS OF POTTING COMPOUND AROUND OUT~IUE
OF
HACK
SKIRT
MUST
BE
1/81;,e
IN
AND
POTTING COMPOUND MUST EXTEND TO WITHIN 1/8

IN
OF MOUNTING PLATE.
20-20-50
Pattinff Using Temporary
eruf iFsdloM
t
Paffcl
AuK S1:IX4
CDiPYR IGHT, 1984 BY SA~BR ELINER CORPORATI ON
SR-76-02.3
C()RIIOSION (:()NIK()I~ MANUAL,
STACKED
STANDARD
MOLD
7/16 ir1/16 IN.
~hir
SHELL
SIZE
STACKED
HEIGHT
(IN.)
STACKED
8S -16S
HEIGHT
II
1 t1/8
12-18
(AT RIGHT)
20-22
1-1/8+1/8
24-48
1-5/16 i-1/8
STANDARD MOLD WITH

TOP REMOVED
CONNECTOR PLUG
OR RECEPTACLE
Potting Using Stacked Permanent Molds

Figure 2
NEOPRENEJACKETED
MULTICONDUCTOR CABLE
~Tt""""
1/8 IN.
POTTING
COMPOUND
MIN.f-I
HEIGHT
(866 NOTE)
1 IN. MAX.
NOTE
SEE TEXT FOR ESTIMATED FINAL POTTED CONNEC-
TOR HEIGHT FOR VARIOUS SIZE SHELLS.
Potting 900 Entry Multiconductor Cable
Figure
20-20-50
Page
0
:I
AuK:I1/H4
SR-76-023
COKK()SI()N CONTROL MANUAL
CABLE
CABLE
STACKED
STANDARD MOLD
FERRULE
STACKED
1/4
HEIGnT(+1/8)
(REF.)
1116 i1/32 MAX
1/4
(AEF.)
--i
SHELLSIZE
8S-16S
1-1/4
12-18
1-1/8
20-22
1-5/16
24-48
INNER
DIELECTRIC
STANDARD
-I
MOLD WITH TOP REMOVED
NOTES
DISTANCE
OF
THE
OUTER
JACKET
INCLUDED
IN
POTTING COMPOUND IS BETWEEN 1/2 AND 3/4 IN. FOR

NEOPRENE JACKETED CABLE AND BETWEEN 1/4 AND
1!2 IN. FOR KEL-F JACKETED CABLE
SEE TEXT FOR ESTIMATED FINAL POTTED CONNECTOR

HEIGHT FOR VARIOUS SIZE SHELLS
ALL DIMENSIONS GIVEN IN INCHES.
WHEN AN CONNECTORS WITH METAL BACKSHELLS

ARE
USED.
CABLE
OUTER
INSULATING
JACKET
EXTENDS INSIDE POTTED AREA AT LEAST 1/4 IN.
Potting Coaxial Cahles

Fiffure 4
20-20-50
Paffe
Aug ~1/84
SR-76-02.3
MOISTURE PROOFING ELECTRICAL COMPONENTS

WITH STRIPPABLE SEALANT
GENRAL
SEALING SEQUENCE
This section covers materials and pro~edures to seal

electrical components where easy removal of the cured
sealant is required. The sealant material dries rapidly to a
water tight seal and, after curing, is easily stipped from
the component to permit maintenance of the electrical
system,
Surface Preparation
Using fresh naptha, clean outer surfaces and wire leads

1 in.) of component to be sealed, Allow to dry
thoroughly(l5 minutes min).
(at least
Sealing Wiring/Components
MATERIALS
Naphtha, Petroleum
Aliphatic
Sealant: insulating
Electrical, Strippable
Using a medium-stiff brush or by dipping, apply coating

of sealant approximately litfi in. thick to areas to be
sealed. (See figure 1.)
TT-N-95
LB0120-00Fi
Allow first coat to
INSTALLATION NOTES
coat of sealant
dry a min of 2 hours. Apply a second

approximately 1/16 in. thick over the first,
Allow to dry
min of 1 hour before the part is moved.
After 4 hours drying, the sealant forms a tack free

continuous film over all parts of the sealed unit. This film
is free from voids, bubbles, pin holes, and cracks.
The solvents used in this procedure are highly flammable.

Ohserve precautions pertaining to flammable materials,
Solvents in the sealant are very volatile. Stock supply
container should be kept sealed as much as possible to
prevent thickening of the material, The sealant should be
dispensed into one-half pint containers for application.
Sealant left over in the half-pint containers should not be
poured back into the supply container, but should be
tliscarcled.
Before disconnecting sealed components for maintecured sealant with fingernails, or with a
nootle n or p lastic spatu la. Re movi ng cu red sealant wi th a
Itniee oi other hard and sharp instrument may damage
nance, remove
the
or
component.
r
1/PIN.
WIRES~
/I
I\
WIRE
c.l
-I
1/2
IN.
Typical Sealing Areas of
Quick-Disconnect
Connector and Lead- in Wires
Figure
20-20-52
0
COPYRIGHT, ;25~ BY SABRELINER CORPORATION
Page 1/2 Blank

Aug 17/84
SR-76-023
CORROSlOh CONTE1OI,
SEALING ELECTRICAL WIRE BUNDLES PASSING THRU RULKHEADS
(;ENERAL
This section covers the materials and procedures used in
the preparation and application of synthetic rubber
potting compounds for sealing bundles of electrical wires
passing th ru bulkheads and panels. The seal i nff material

is suitable for continuous operation throughout a temperatu
re
range of -65 to
+2750F.
To avoid conlanlination of the solvent, HI~.BI\S 1)0111. fl.Onl

the container onto the cloth. (;lolh used for cleaning
should never be dipped into the solvent.
The seal i ng
operation m ust begi n with i n 6 hou rs af te r the

cleaning operation or necessary precautions, such as
storage in covered aleas or employment of suitable dust
covers, must
be taken to prevent contamination of cleaned
areas.
MATERIALS
Wire Bundle Placement
NA2-03~4
Compound, Sealing
Bulkhead Wire Bundle
NOTE
MIL-S-851Ci
Potting Compound
Do not pass plastic tubing or conduit tRlw

connector shell or bulkhead uliro seals.
Unsealed tubing and conduit provide a
leak path.
NOTE
Alternate material for applications in
cockpit
areas.
Naphtha, Petroleum
Aliphatic
TT-N-95
Cellulose Acetate
Eronel Industries
Butyrate Molding
Compound No. 910
Caterpillar Nylon
Nylon Moulding Corp.
Wire Bundles in Connectol Shells
Slip the connector shell over the end

position in place. (See figure i.)
bundle
NOTE
Ertreme
be taken to prel,ent
oth.emoise damaging u~ire
insulations during this operation. Care
must be taken during installation and positioning of connector shell on wirP bundle to
prevent edges of shell from sclaping or
othcrwisu damaging wire insulation.
(;rommets, No. GFilH
care
scratching
EQUIPMENT
Sealant (;un, Model
No. 250, or ecluivalent
Polyethylene dust caps
of the
and
Semco Sales and Service

Protective Covers
must
or
INSTALLATION NOTES
Wire Bundles in
Safety Requirements
Install a Caterpillar Nylon grommet in holes in single

panel bulkheads, then pass the wire bundle through the
hole. (See figure 2.)
Adequate fi re prevention methods must be provided, and

area must be properly ventilated.
Single Panel
Bulkhead
Openings
the work
It is suggested that workers engaged in the mixing

cleaning operations be furnished with rubber gloves
or
Wire Bundles in Doubler Panels
Pro-Tex Hand Cream. These facilitate easy removal of the

compounds from the hands and prevent the cleaners from
causing dermatitis.
When wire bundles with large connectors ol lalge cross

section areas pass through bulkheads, large cutouts are
required in the bulkhead. A doubler with cutouts sized to
the wire bundle (rather than the connector) is uscd to
reduce the size of the hole through the bulkhead. Install
Cleaning
wire bundles: and doublers
or
as
shown in
figure
3.
Use a.clean dry cloth to remove dust, chips, etc., from the
surface to which sealing compound is to be applied.
connector shell and wiring surfaces to
be sealed with a clean cloth dampened with naphtha.
Before the solvent has evaporated, dry the surfaces
completely with a clean dry cloth, It is essential that clean
cloths be used for cleaning. When a cloth becomes soiled, it
should be discarded.
Wipe all bulkhead,
20-20-54
Page
0
Aug 31/84
SK-76-023
COHK()SI()N CONTROL MANCIAI,
DURING INSTALLATION
WIRE BUNDLE
IS
KEPT
CENTERED IN CONNECTOR SHELL
il.~
1~1
\I(
---c_
1P-=s- s---
L~CIC_
S~Z
S--s~
Passing Wire Bundles Thru Connector Shells

Figure I
BULKHEAD
rCf)f
CATERPILLAR
GROMMET
WIRE
BUNDLE
Passing Wire Bundles Thru Bulkhead Holes

Figure 2
20-20-54
Page
Aua 31/84
SR-76-023
COKKOSION CONIROL MA~I;AI.
lil
PASS WIRE BUNDLE(S) THRU LARGE HOLE

IN BULKHEAD
DOUBLER
POSITION EACH WIRE

BUNDLE IN DOUBLER
CUTOUT
(j
o~
CLOTH OR TAPE
TO PROTECT WIRE
INSULATION DURING
INSTALLAtlON
Il
INSTALL DOUBLER ON BULKHEAD
INSTALL CATERPILLAR
GROMMEIS
4 DOUBLERBULKHEAD
o~o
O
L3
i,P
~J
If
WIRE BUNDLE
(I
Passing Wire Bundles Thru Doubler
Figure
20-20-54
o
IaRe 3
Aug 31/84
SR-76-023
SEALING ELECTRICAL WIRE BUNDLES

PASSING THRU BULKHEADS (Continued)
M()I,I) PREPARATI()N
Preparation of Molds
Shell Applications
For Connector
Select a suitable polyethylene dust cap of proper size to fit

over each end of the connector. (See figure 4.)
tightly
Determine the diameter of the wire bundle, held securely

by cotton cord, taking care not to dent or otherwise
damage the wire insulation.

With
cork borer
or
knife cut
hole in the center of the
polyethyiene dust cap. The diameter of this hole should be
the same as that of the wire bundle. A sealant filler hole or

overflow hole, approximately 3/16 in. diameter, must be
cut in the edge of the cap. Cut a slit from the cap edge
through the filler or overflow hole and to the center hole.
Preparation of Molds
Mold Applications
For
Integral
Molds should be made from cellulose acetate butyrate

or equivalent). This material becomes
sufficiently fluid at a temperature of approximately
:ILFi"F to pour into casti nff containers and patterns or to be
(Eronel No. 910,
used for dip coating of formed molds, All molds regardless

of configuration must produce seals meeting the dimen
sional requirements of figure 5.
Figure 6 contains a list of dimensions for standard cup

molds which may be used for most wire bundle sealing
applications. Other types of seals made from skew molds
or Iight angle molds must meet the dimensional requirements of the table on figure 6.
With a cork borer or similar tool cut a hole in the center of
the mold of the same size as the wire bundle. (See figure 7.)
Cut a sealant filler hole in the edge of the mold approximately 1/4 in. diameter (No. 3 cork borer). If the wires
cannot be passed directly thru the center mold hole as in
the case of wire bundles with connectors attached, cut a
slit from the mold edge, th rough the sealant filler hole to
the center mold hole.The sealant filler holes in the split
molds may also be made by cutting slots with a knife or
razor
blade.
Sealing Between Wires

Sealing between the wires is
most
procedures must be closely followed
critical. The following

to obtai n a satisfactory
seal.
Slide connectolshell 1/2 in. beyond

be finally installed,
position
where it will
Prior to fi nal positioning of molds arou nd the seal i ng area,

a liberal amount of sealant must be injected or spread
between the wires of the bundles. For this application the
wires are held loosely to enable the sealant to flow freely arou nd
each individual wire in the bundle. (See figure 8.) No spot
ties shall be located within 8 in. of the sealing area during

this application. In the case of large size wire bundles, it
between and
may be necessary to work the material
around the wires to obtain complete coverage of every
wire.
After application of the sealant between the wires, spot
ties must be placed as close to the sealing area as possi ble
without interfering with installation and positioning of
molds. The excess sealant between the wires must be
forced out by the spot ties. It may be necessary to aid this
in the
process by applying pressure on the wire bundle
sealed area using a temporary loop of spot tie cord held
firmly with the hands. Center connector shell on area
being sealed. Within 30 minutes after this operation,
before the sealant thickens, the molds must be installetf
and the final sealing
completed.
MOLD INSTAI,LATION
are placed around the wire bundles with
sealant holes positioned upward, These molds are held
securely in place by clamps, jigs, fixtures, tape or other
deviceswhich will prevent sealant leakage and which will
result in satisfactory seal contours. Typical examples are
Show" in fiRure 9.
The molds
The molded seal techn i que is versati le. if adj acent panel s,
stringers or other objects are too close to the sealing hole to
utilize the molds described, the molds can be trimmed or
cut to fit,
Injecting Sealant
Into Mold
Insert sealant gun nozzle into the sealant filler hole of the
mold. Completely fill the mold and allow the sealing
compound to flow around the wire bundles and fill the
mold on the opposite side of the bulkhead. The presence of
sealing compound in the air escape hole indicates completion of this operation. Any leakage of sealant from the
mold area shall be stopped by tightening the molds.
Additional sealant must immediately be injected into the
mold to replace any leakage. Corks must be placed in
sealant filler and air exhaust to prevent sealant leakage.
Adhesive tape may also be utilized for this purpose.
After the sealant has been applied, the wire bundle must
be held centered in the connector shell or bulkhead
aperature until sealant cures.
Itemove spot ties located within 8 in. of each side of the

bulkhead seal. Avoid damaging the wire insulation.
20-20-54
Page
Aug 31/84
o:COPYRIGHT, 1984 BY SABRELINER CORPORATION
SR-76-023
POLYETHYLENE
DUST CAP MOLD
SEALANT
INJECTION HOLE
WIRE BUNDLE HOLE
Molds For Connector Shells

Figure 4
BULKHEAD
.I
HOLE DIAMETER
Is
SEAL OVERLAP
CLEARANCE
DEPTH
BULKHEAD
HOLE
(IN.)
MINIMUM DEPTH
(IN.)
1/2-1
1/2
1-2
5/8
MINIMUM
MINIMUM CLEARANCE
SEAL
FROM GROMMEf TO
OVERLAP
(IN.)
WIRE BUNDLE
3/8
1/8
1/2
1/4
Seal Dimensional Requirements
Figure
(IN.)
20-20-54
Page 5
Aug~1/84
SR-76-023
l<lc
~-Io1-I
MOLD
BULKHEAD HOLE
DIA.
ID
(IN.)
MOLD
MOLD
MOLD
OD
(IN.)
DEPTH
(IN.)
(IN.)
THICKNESS
D
1/2
1/2-3/4
1-3/8
1-3/4
3/8
3/4-1
1-3/4
2-1/4
3/8
1/2
1-1
2-1/2
1/2
3/4
1-1/4-1-112
2-1/2
1/2
3/4
1-1/2-1-3/4
2-314
3-1/4
1/2
3/4
1-3/4-2
3-1/2
1/2
3/4
1/4
(IN.)
ALL DIMENSIONS +1/16 IN.
Standard Cup Molds
Figure
WIRE BUNDLE
HOLE IN CENTER
SEALANT
FILLING HOLE
CUP MOLD
Cup Mold Preparation

Figure 7
20-20-54
Page 6
Aug 31/84
COPYRIGHT, 1984 BY SABR ELINER CORPORATION
SR-76-023
NO SPOT TIES
WITHINBIN.OFTHE
n
I
/U
CONNECTOR
SHELL
tt---
SEALING*REA
Sealinff Between Wires

Fiffure 8
20-20-54
7
Aua ~1/84
SR-7(i-023
SEALANT INJECTION
HOLE
DUST CAP MOLD
6 ii
CONNECTOR SHELL
WIRE BUNDLE
CONNECTOR SHELL MOLDS
HOLE CLAMP
SEALANT
FILLING HOLE
MOLD
HOSE CLAMP
WIRE BUNDLE
MOLD CAVITY
CATERPILLAR
GROMMET
BULKHEAD
BULKHEAD MOLDS
Typical Mold Installations

Figure 9
20-20-54
Page 8
Aug 31/84
COPYRIGHT, 1984 BY SABRELINEA CORPORATION
SR-76-02~
CORROSI()N C()NTHOL MA~iUAL
SEALING ELECTRICAL WIRE BUNDLES

PASSING THRU BULKHEADS (Continued)
Injtctina Sealant
into Mold
(Contd)
(:urinR may be accomplished at room temperature(7Ti to

80"F) for a period of 24 hours or in a circulating air oven
for 1 hour at 130 to 1400F
under heat radiation from

30 minutes at 130 to
140"F. The usable work life of the material after mixing is
1-1/2 hours. The wire bundles must not be disturbed
durinR the curing periotl.
or
carefully regulated heat lamps for
After the sealant has cured,
carefully
remove
molds.
The dimensions of the final seal must conform to
figure
5.
The cured potting compound should be free from cracks

and have a smooth, clean surface. Surface holes or bubbles
smaller than 1/8 in. diameter are acceptable.
When bubbles andlor holes larger than 1/8 in. diameter

present on the surface of the sealant, remove the top of
the bubble with a knife or razor blade taking care not to
cut the wire insulation. Fill the bubble openings and/or
holes with sealing compound. Very large bubbles may be
filled by making two holes in the bubble, injecting sealant
into one hole and allowing the air to escape from the other.
Corks may be necessary to plug the injection holes.
are
The
compound should adhere firmly
to the
connector shell and to all wire insulation
Th e
com
pou nd
com
bulkhead
or
except Teflon.
pletely encases Teflon wi re i nsulation.
When
small
a new wire is installed in a bulkhead seal, use a

Phillips head screw driver of similar blunt tool for
puncturing the seal to provide a hole for the wire. No
atid i tion al seal i nR i s generally req u i red.
NOTE
Luhricants should not be used on new wires
installed in bulkhead seals.
When
a sealed wire bundle leaks inside the bundle or an

added wire fails to seal, it is necessary to reseal using a
small tipped polyethylene nozzle to inject sealing compound between and around the wires where they exit from
the origi nal seal. Spread the wires apart for this operation.
20-20-54
0
Page 9/10 Blank

Aug 31/84
Sft-lfi-Of?3
C()HH()SI()N (:()NIR()I, MAIVIIAI.
SEALING ELECTRIC TERMINATIONS

SUBJECT TO TEMPERATURES UP TO 300"F
(;ENERAI,
Ihis section
Sealant Mixing and Handling
the
I,otti~lff compounds for
From -65 lo:J00011.
covers
preparation and application of

use in electrical terminations
MArERIALS
Nal,htha
Ketf primer. Vulcabond
TT-N-SFi
Stabond Corp.,
GHrdena, CA
vloz
Iro-Tek 1Iand (:ream
nu Pont
(:onlpountl.. Iotting.
11R()120-0()6
~leclrical, (;eneral
Purpose
EC~IIIIMENT
Pressure (;un, No. 250
Cartridge, No. 250-C6
No~zle, No. 250-4-2
Semco Inc,
Los Angeles, CA
Safc!ty
Ol,sclrve safety precautions for the handlingof flammable
anti tiangerous chemicals. Workers engaged i n the mixing
or cleaning operations should be furnished with rubber
gloves or iro-Tek Hand Cream.
A fter the solder I,ots inside the connector shell have been
clhockctl to make certain that the wires arc~ properly
r,lace and th;il no plastic tubing has been

over thcnl (which would rcsr~lt in a I,oor seal),
r(tlnOVc;lll excess rosin from soldei joints with a small,
sliTi brush using na,hthaa as a cleaning agent. Solder
joints showing evidence of corrosion must be cleaned.
soltlcrod irt
Remove antiseize
If the potting compound is to be cured at a temperature

above 90"F, preheat the connectol assembl! immediately
before potting for at least 10 minutes at a tempelature
within 100F of the cure temperature.
Position connector (plug or receptacle) in a suitable
holding device or Jiff-board with the shell backskirt
opening facing upward. Insert injection nozzle of the
pressure gun between the wires near the lower central
area of the wire bundle (just above the open i ng of the ~hell
Ircparation
shell threads with
When tl-ie compound is supplied premixed and flazen,

allow the compound to warm at room temperature for
30-50 minutes before use. After the warmup period and
before the compound is inserted in a pressure gun. \\ipe
the outel surface of the tube of potting compound u.ith a
clean, dry cloth.
SEALING PROCEDURE:
INSTAI,I,ATION NOTES
C:onnec:tor
Use an air-driven mixing machine operated at 60 ~l,nl or

less (to prevent overheating and the introduction of air)
for mixing. After mixing 10-16 minutes, visually inspect
to make sure that no particles of acceleratol are left
undispersed in the mixture. If hand mixing is
make certain that the accelelatol is evenl~
throughout the compound and that air is not introduced
by rapid stirring or by a folding action. Hand mis fo~
15-20 minutes using a spatula. Only sn7all quantities
should be mixed by hand.
backskirt). Fill the plastic mold or backshell slo\vl! nith

potting compound, taking care to avoid the entiap~nent of
air.
compountls or lubricants on the backnaphtha before wires are installed in
the connectors.
min
Temperature (+50F)
70
(:lean assembled connectors by immersion in naphtha for

2 minutes. Agitate solvent during the immersion period,
Drain excess naphtha from the connectors, and allow
them to dry for 1T, minutes. For connectors with back-
shells, allow
A ftel the connectors are potted, they must be mai ntainetl

in a vertical position to prevent leakage until the compound has cured. Cure potting compound by heating the
potted connector at any one of the following temperature
schedules:
drying period of
~O minutes.
Minimum ?ime
24 hrs
120
3 hls
140
2 hrs
Ihr
160
200
30 minutes
270
15 minutes
Yl,ray or brush one coat of Vulcabond V-102 red primer

the back surface of resilient inserts in electrical
on
co n nectors. Allow pri mer to d ry at room tem perature for
at least 30 m i nutes or force dry under a heat lamp or in an
oven at a temperature of 120 to 1400F for at least Fi
minutes.
20-20-56
0
Page 1
Aug 31/84
SR-76-023
SEALING ELECTRIC TERMINATIONS

SUBJECT TO TEMPERATURES UP TO 300"F (Continued)
SE:AIIIN(; PROCE:I)I~KE:
(C:ontd)
The cured potting compound should be free from cracks,

have a smooth clean surface, and adhere to the metal and
plastic porti ons of the connector, backshell, and all wiring
except MIL,-W-713Y wiring. The compound should completely enclose MIL-W-7139 wiring. Integral molds
should have sufficient adhesion to add structural support
to the potting compound. Air bubbles along inner mold
walls that do not project more than 1/16 in. into the
potting compound are acceptable. The exterior surfaces
of the connector shall be free from
If bubbles
or
holes with
potting compound.
diameter of 118 in.
or more are
present on the surfaceofthesealant,removethetopofthe

or hole with a knife or razor blade, taking care not
the wire insulation. Fill openings with potting
compound and cure.
bubble
to cut
or bubbles greater than 1/8 in. diameter are

present in the body of the potting compound, the connector
must be reworked. Holes or bubbles 1/8 in. diameter or
less in the body of the potting compound or large bubbles
or holes in the surface that cannot be filled must also be
If holes
reworked
i.
as
follows:
itemove the mold (by cutting away if necessary)

backshell.
unsatisfactory material, taking

damage the wire insulation.
Cut out the

to
3.
Install
4.
Repotthe
a new
mold
or
care
or
not
backshell.
connector.
20-20-56
Paae
Aug 31/84
SR-76-023
SEALING ELECTRICAL TERMINATIONS SUBJECT TO A

MAXIMUM TEMPERATURE BETWEEN 300 AND 400"F
GENERAL
INSTALLATION NOTES
This section covers materials and procedures used in

preparing and applying potting compound to protect
electrical terminations from moisture, corrosion. and
other damage caused by metal particles or liquids found
in aircraft.
Potting compound LB0120-007 is suitable for continuous

operation throughout a temperature range of -65 to
MATERIALS
Work area
must be properly ventilated with adequate fi re

prevention provisions.
Naphtha. Petroleum Aliphatic

(;Iease. 4ircraft
Instruments
Compound; Potting, Electrical
TT-N-9,5
MIL-C;-X278
Mixing
or cleaning operations require rubber gloves or

Pro-Tek hand cream to facilitate easy removal of compounds from hands and prevent the cleaners from causing
LB0120-007
dermatitis.
High Temperature
Pro-Tek Hand Cream
DuPont Company
This Dotting compound is a one-component material. No

curing agents or accelerators are added and no mixing is
EC~UIPMENT
required.
Sealant (;un. Model No. 250,
Semco Sales ce.

Service, Inc.
Semco Sales Sr,
Service. Inc.
Semco Sales cP~
Service, Inc.
Met-L-Chek
equivalent
Cartricl~e. No. 250-CP6
or
Nozzle No. 420
P1ogellon Sprayer,
+400"F. (FA2-54 and FA2-90 are used where max temperatures do not exceed 225 and ~OO"F respectively.)
or
equivalent
Remove entrapped or, dissolved air and gases by applying

a m in 89 in. of vacuum inegative 14 psi gage) to the potting
co m pou nd for a m i n o f 2 hours. The i n itial vacuum should
be applied slowly so that the compound does not froth over
the edge of the container. The compound has a tendency to
ex pand du ri ng vacuum ap p licatio n so it may be necessary
to use half filled containers to ensure no overflow. At the
entl of the vacuum application, allow atmospheric air to
slowly enter the vacuum chamber to prevent a turbulent
Western Co.
oo NOT
GREASE
INTERNAL
CONNECTOR
THREADS
7\
c
APPLY MIL-G-3278-
DO NOT GREASE
GREASE TO EXTEANAL
"C" RING SEALING
CONNECTORTHREADS
SURFACEOFCONNECTOR
Assembling Connector
Figure 1
20-20-58
0
Page 1
k;, :7/84
SR-76-0
CORKOSION CONTROL IMANUAL

MAXIMUM TEMPERATURE BETWEEN 300 AND 400"F (Continued)
INSTALLATION NOTES (Contd)
grease from coating the

connector. (See figure i.)
mixing of compound and incoming air. Store vacuum

processed potting compound in tightly sealed friction lid
containers prior to use.
O-ring sealing surface of the
Cured potting compound is free from cracks and has a

smooth, clean surface. Surface holes or bubbles smaller
than 1/8 in, diameter are not cause far rejection.
Tht storage I ife of potti ng com pound LB0120-007 at room

temperature is a max of 9 months. The storage life at
+~F;"F is in excess of 1 year. The compound should be
stolecl in a cool place away from direct sunlight, ovens,
and other sources of heat.
The compound should adhere to metal and plastic portions of the connector and backshell and completely
enclose the wires. Lack of adhesion to the outer edges of
the shell back skirt or backshell is not cause for rejection.
The storage I i fe of primer at room tem perature is a max of

4 months. The storage life at +~50F is a max of 8 months.
The primer should be stored in tightly capped containers
at a tempel.ature of O to 400F to obtain max storage life.
SUPPOt
Exterior surfaces of the connector must be free of potting
A fte I the
al,pl!
potti nff o peration has bee n com p leted. carefu lly

thi n coating of
grease to the external
connectol
threads with
Integral molds have sufficient adhesion to add structural

to the potting compound. Air bubbles along inner
mold walls which do not project more than approximately
1/16 in. into the potting compound are not cause for
ejection.
compound.
If holes or bubbles greater than 1/8 in, in diameter
present, reject the connector.
stiff bristle brush. Prevent
are
(5.* t~
C~.L,.
MAXIMUM ALLOWABLE
EXCESSIVE SPONGING
SPONGING
Connector Potting
Figure 2
20-20-58
Page 3
Aug 17/~1
COPYRIGHT, 1984
SR-76-023

MAXIMUM TEMPERATURE BETWEEN 300 AND 400"F (Continued)
INSTALLATION NOTES (Contd)
If excessive
indicated by
sponging of the compound has occurred, as

numerous small holes greater than 1/16 in.
sealant overlflow in figure 2, reject the
Bubbles and/or holes larger than 1/8 in. diameter on the

surface of the sealant may be reworked by removing the
top of the bubble with a knife or razor blade, taking care
not to cut the wire insulation, Fill the bubble openings
and/or holes with sealing compound and cure.
If excessive
opening
sponging
or
large holes
occur, or
if
hole
or
is present which cannot be
filled, the connector

shou Id be reworked accordi ng to the fol low i ng procedure:
Remove the mold or backshell (by cutting away, if
necessary) and cut out the unsatisfactory material, taking
not to clamaae the wire insulation. Install
t,ackshell and repot the connector,
care
or
a new
mold
15 minutes. For connectors with backshells. allow 30
minutes min
drying period.
An alternate method of removing solder resin and of

cleaning the connector is to use a solvent splay gun
adjusted to give a stream of naphtha under a pressure of
40 ~10 psi. After solvent spray cleaning, allow excess
naphtha to dry for 15 minutes. For connectors with
backshells, the minimum drying period is 30 minutes.
Pimer Application
Apply primer with a Propellon or other sprayer which

produces a fine, narrow-spread, mist-type spray. Hold
nozzle of the spray applicator within one and one-half
inches ofthe backshell or wires during primer application
to ensure complete coverage. Apply primer to the shell
back skirt walls, to the solder pots, and to the ends of the
wires for a distance of 1 in. from the solder pots. Take care
to prevent primer from leaking through connector and
coating electrical pins and sockets in the front skirt.
SE~LIN(; PROCEDURES
Connector Preparation
Check connector solder pots inside the shell to make
certain that the wires are properly soldered in place and
that no plastic tubing has been installed over them. An
inferior seal will result if plastic tubing is allowed to
remain over the solder pots. The depth of potting compound over the ends of the wire insulation extends a
minimum of X;~f in.
Remove ull e~cess reuin From solder joints with
~ciff bristle brush and naphtha.
in connector. After connector assembly, clean connector

by immersing in agitated naphtha for two minutes. Drain
excess naphtha from the connectors and allow to
dry for
small,
Se"ling
Connector
Immediately prior
assembly for
min
of "7Fi~lO"F.
to potting, preheat the connector

period of 10 minutes at a temperature
Place connector (plug or receptacle), ~iith shellback skirt

opening positioned up, in a suitable holding device or
jig-board.
Place the injection nozzle of the pressure gun between the

wires near the lower central area of the wire bundle. (See
Clean any solder joints showing evidence of corrosion,

Remove any anti-seize compound or lubricant present on
backshell threads with naphtha prior to installing wires
figure 3.)
PLASTIC MOLD
Sealant Injection
Figure
20-20-58
0
COPYRIGHT, 1984 BY SP SRFLINER CORPORATION
Page 3
Aug 17/84

MAXIMUM TEMPERATURE BETWEEN 300 AND 400"F (Continwed)
Sealing Connector (Contd)
Slowly fill the plastic mold or backshell with potting compound. Avoid air entrapment.
The spot tie nearest the connector should be installed after
potting compound application and before curing occurs.
Sealant Cure
After connector is
to
potted, maintain in
vertical
position
prevent leakage until the compound has cured. Cure
potting compound
at 275 +100F for 1 ~0.1 hours.
20-20-58
Page 4
Aug 17/84
COPYRIGHT, 19a4 BY SABRELINER CORPORATION
SR-76-023
APPLICATION OF SEALANT TO ELECTRICAL WIRE BUNDLES PASSING

THROUGH BULKHEADS FOR MAXIMUM SERVICE TEMPERATURES
FROM 350 TO 500"F
GENERAL
This section covers the materials and process to be used
for application of sealant to bundles of electrical wires
passing through bulkheads and panels. The sealing
m ate ria I is su itable fo r conti n uous operation th roughout a
mas
temperature range of:~50
to
Fj000F.
A minimum Shore A hardness

evidence of cure.
reading
of 85 shall be
If it is necessary to disassemble any component part

which was previously sealed, or for any other reason, to
rework damaged sealant, clean off all sealant, touch up
damaged finishes and coating, reassemble. reprime, and
seal.
MATERIAL
LB()120-0:51
Areas to which sealant has been applied shall be protected

from stress or contamination until sufficiently cured to
resist normal assembly environment.
Elastomeric Fire Wall Sealant
INSTALLATION NOTES
A reas to be sealed shall be clean, dry, and free of foreign
material which can reduce the adhesion of the sealing
compuntl. Immediately before priming, all areas to be
shall be cleaned by wiping with a suitable hydrocutt-,on or halogenated hydrocarbon solvent, which will
not adversely affect tl;e other materials. Solvents
containing halogens shall not be used on titanium
The dimensions of the applied sealant shall conform to

figure 1 or 2 as applicable.
a
A reas to be sealed shall have
thin film
(approximately
().()()I in.) of
primer applied to all surfaces,
T he I, r i me r shall be allowed to air cu re for one hour before
application of the sealing compound.
I~oom
Wire bundles passing through bulkheads shall be protectecl prior to sealant application to prevent damage to
the wire insulation.
The c:ured se;tlA.nt shall be free of cracks and shall have

smooth, clean surface. Surface holes or bubbles greater
than 1/8 in. diameter are not permitted and should be
removed during sealant application.
Ytr~uctures.
.~t
SEALING PROCEDURES
tempernti.ire, the ~ealant shall be
appiiecl
The sealant shall adhere firmly to the bulkhead and

connector shell and to all wire insulation.
~vithin
ir~ \.~ol!e life.
BULKHEAD
NONPRESSURIZEDSIDE --cl
PRESSURIZED BAY
SEALANT
SCALANT
BbOT
(Typlcal)
111
WIRE BUNDLE
DIA0.12
IN. MIN.
1/32 IN. NOMINAL
SEALANT BUILDUP
A0.251N. MIN. TO
0.35 IN. MAX. AVG.
DETAIL B
DETAIL A
Booted Sealing Bulkhead Feedthroughs
Figure
0
20-20-60
Page 1
Aug 17/84
SR-76-023
NON-PRESSURE SIDE ~I
~e EMP SHIELDED PRESSURIZED BAR
SPLIT FITTING ASSY.
60% WIRE BUNDLE
1/2~1/81N.
COVERED WITH
HALAR SLEEVING
TY-WRAP
LB0120-031
SEALANT
I
LB0120-031
SEALANT
FLUOROSILICONE
LB0120-031
SEALANT
POTTING DAMS
SEALANT ENTRV HOLE
0.12 IN. MIN
0.12 IN. MIN
0.25 IN. MIN TO
0.35 IN. MAX AVG
0.35 IN. MAX AVG
DETAIL B
DETAIL A
20-20-60
0.25 IN. MIN TO
Sealing Split-Fit~ing Bulkhead Feedthroughs

Figure 2
Page 2~
Aug 17/84
COPYRIGHT, 1984 Br SABRELINER CORPORATION
SR-76-023
ORGANIC BASE AND FINISH COATING

Non-woven, Non-metallic
Abrasive Mats, Type I,
APPLICATION OF POLYURETHANE
INTEGRAL FUEL TANK COATING
application of pol~urethane integral
The
fuel tank coating involves materials and

operations that are haxardous, Thefollowing ccczltions should be observed:
PolUurethalre components contain flalnmnhle solvents and should 6e mized and

applied only in well ventilated areas where
there
are no
openflames,
Personnel 7nizing or applying polyurethaneshould wear chemical cartridge respiratorv and protective clothing.
ilirplunes recei~uiny yolqlllrethane should

static b.U.ild-1L~
be Qroundecl to
spraying operations,
no
not
allow
polyu~retha7Le
to
come
in
eyes. In, case of skin

contact, wash with soap and U)ater. -Jn case
con.taet witk skin
of
or
irnmediatel~y wash eyes for

then get medical attention.
eye contact,
15
Wusk hands before eating
or
smoking.
Polurethane integral fuel tank coating is a two comI,c,nent catalyzing material that is fuel resistant and
inhibiting.
3M Co.
Class Z or 2, Grade A
or Finer, Scotchbrite
MIL-A-9962
Turco Products
Cleaning Compound,
Aircraft Surface
Alkaline Waterbase
(Air Tech No. 19)
Neutral Paint Remover.
No. Tj,Fj1
Paint Straining Funnels
Cheesecloth
Tack Rags, No. GR-99 or
equivalent
Rubber Cloves
(Rubber Base
Turco Products
Commercial
Commercial
Bostik Div.,
UMX Corp.
Commercial
or
Nylon)
400 Grit
Commercial
Wet-or-Dry
Abrasive Paper
Tape, Masking (:3M No.

or Mystik No, 62:!0
or equivalent,
2Fj0
~M Co.
or
Mystik Co.
Commercial
Chemical Cartridge
Respirator (Wiison Model

No. 1200 with No. R21
Cartridges)
Glasses. Goggles or Face
Shields. Safety
Fiber Brushes or Tampico
Commercial
Commercial
Brushes
SIate,ials
Surface
Pnlvurethane Coatings for

Integral Fuel Tanks,
No. 132i2<376 (Kit)
Trichloroethane, i, i, i,
Technical. Inhibited,
DeSoto Chemical Co.
Commercial
~[tthvl 1~thvl Retone
Commercial
~solve. Etch Solvent.

No. ()20-~38
Naptha. Type II. TT-N-96
Lacclue,. Thinner.
TT-B-266
?-:ler, K1aft. Untreated
Wrapping, UU-P-268
DeSoto Chemical Co.
Preparation
Integral fuel tank coating shall be applied over surfaces

that have been properly surface treated. All surfaces to be
coated shall be free of foreign material. If necessary,
surfaces shall be wiped with a clean cloth dam pened with
MEK. then wiped dry. Surfaces shall be coated within "4
hours and must be suitably protected from dust anti
handling until they can be coated.
Mixing of Polyurethane Integral Fuel Tank Coating
Commercial
Commercial
Commercial
Polvurethane integral fuel tank coating is a

consisting of a base material and
ponent system
two coma
catalyst.
NOTE
Do not intermiz product components of one
manufacturer with product components of
another muanufacturer. Tile components
will stot intermiz.
20-30-00
0
COPVC)JGHT, 1984 BY SABRELINER CORPORATION
Page 201
Aug 17/84
SR-76-023
MAINTENANCE PRACTICES (Continwed)

Mixing of Polyurethane Integral Fuel Tank
Coating (Contd)
Strain material.
Coating
mixture
NOTES
Use ofthinners other than those speci~fied
by manufacturer may result in poor
adhesion qualities.
1.
Temperature of the components

600F(160C) before *rLizing.
Pressure circulating system with material hose not

to
2.
When nzizing, u.re the batch of the base

material and catalyst supplied as a kit,
IVever suhstitzcte the catal7JstSrom another
hatch,
requires continuous agitation to mainThis requirement can be accomplished
exceed 5 ft.
Agitation
pressure pot with material hose not to
exceed 5 ft,
Pressure cup or suction shall be kept under agitation
by hand or mechanical stirrrin~.
must be
NOTE
above
Mix the components as follows: agitate the base component while slowly adding the catalyst. Mix quantities
less than complete kits by weight only. Spray application
mixinK ratios are as follows:
When painting has ceasedfor more than 10

minutes it is mandatory to bleed out the
material in the line. Mat pot li~Lfe of spray
material is 7 hours at temperatures of
7riOF. Discard any unused catal7Jxed
Product
material.
Component
Volume
Weight
Base ~Material No. Y2iX~S6
1 parts
Catalyst No.
Ipart
100.0 parts
22.5 parts
010-702
Allow admix material to
chemically
react
Coating Application
for 30 minutes,
then add:
Thinnet No. 020-707
1 parts
0:3.7 parts
The application of polyuretiLane integral

fuel tank coating involves materials and
operations that are haxardous, Thefolloao-
ing cautions should be obsermed:

NOTES
PolyzLrethane components contain fla~-
;If%P) Chela.jL(Lb IRCLCtjl).n and thinning,

,esti,
mahle solvents and should he mizecl clrcd

in well ventilated alens
where there art! no open~larnes.
applied only
use.
C:YF oS th.i.YL.YLe7R othel than those speci~iacl

bl NLan~uJacturer ma~l/ result in poor
adhesion gualities.
Brush application mixing ratios

Product
Component
are as
Thinnel No. 0$0-7017
follows:
Volume
Base Material No. 82iIi:376
(I:ltal!st No. 911)-702
Personnel mizing 07 appl:l/ing polyurethane should wear chemical cartridge ~respirators and protective clothing,
parts
1 part
1 part
Airplanes receiving polyurethane should

be grounded to prevent static build-up
during sprayiny operations.
Weight
100.0 pal,ts
22.s parts
Iti.l) patts
Do
allobo
polllureth.nnt,
to
come
in
eyes. IrL case of Nki~vL

leash wzth soap and wcctel. In case
or
contact,
eye contact, immediately luauh eyes for
15 minutes then get medical attention.
NOTES
.-lllolo nclmilr: to Fhelnicnll?j react
~rLIrLutes. Stir Nlaterial before
1Lot
contact with Sk.in
of
for
SO
Wash hands befo7e eating
Cse of thilzners other than those

by mnazufacturer may result in poor
adhesion ryualitiea
or
smoking,
Spray apply light wet single coats (1-2) to eChievd an

optimum total dry film thickness of 0.23-1.5 (+0.5, -0.3)
20-30-00
Page 202
Aug 17/84
COPYRIGHT,
1984 BY SABRELINER CORPORATI(J;V
SR-76-023
MAINTENANCE PRACTICES (Continued)

APPLICATION OF EPOXY-POLYAMIDE
PRIMER
Coating Application (Contd)

Mils. Runs, sags. and grit are not acceptable on finished
surface. Drying or curing time at 600F, relative humidity
40-800~ is 20 hours min in a well ventilated room, or air dry
for 20 minutes, then use a hot-air type ground heater and
bake at 120 to 1450F for a min of 1 hour. The ultimate cure
at air dry, relative humidity 50-80% is 14 days. When
touch-up applied by brush, apply one uniform wet coat,
The application of epox1/-polyamide

primer involves materials and operations
which are haxardous. The following precautions sho2Lld be ohselved:
Apply epozy-polyamide primer only vhen

adec)uate clentilation is available.
Adhesion Test
Wet Adhesion
Tape Test
cnmeincontactwith
The applied coating shall be capable of passing the wet

adhesion tape test after ultimate cure or at the timetempelature conditions specified for exposure to fuel or
traffic in table 201. Coating Cure Schedule.
shin and eyes. IrL case of shin contact, wash

with soap and water. In case of eye contact,
immediately wash eyesfor 2 .5 minutes then
get medical attention.
Solvent Wipe Test
Donotingestorinhale vapors, Wash hands

before eating or smolcing.
NOTE
Surface Preparation
Surfaces to be primed must be thoroughly cleaned before
application of primer coat. In instances where primer is
being applied to bare metal (chemical conversion coating
or anodized coating damaged,, the bare metal must be
treated with the applicable chemical conversion coating.
All areas/parts to be primed must be thoroughly dried
after cleaning and/or chemical conversion treatment.
Parts or areas shall be primed within 24 hours and must
be suitably protected from dust and handling until they
can be primecl.
This test rrLall be performed on process

corLtrol panels cleaned and coated in, conwith detailed parts.
An adhesion cure test shall be made using the solvent wipe
test after the applied catalyzed coating has reached
ultimate cure in accordance with table 201. Saturate a
p iece of cheese cloth with ME K. Wipe a selected area with
at least 50 double strokes using moderate hand pressure.
If coati ng material is dissolved or removed from substrate.
coating is considered as failed and unacceptable. A slight
Jtai n evident on cheese cloth will not be cause for rejection.
Table 201.
EXPOSURE
TEMPERATURE
"F
Ultimate
Cure
air Dry
50-80
Force Cule 120-145

plus ~ir Dry
~O-dO
;Days
.50-80
RELATIVE HUMIDITY
Ambient Cure 60 (Min)
Days
Hours
1 Hour
Force Cure 250

Fuel or
Traffic
14
Force Cure I""

~v-;vv
plus Air Dry
TIME MINIMUM
Days
30 Minutes
40-80
20 Hours
Force Cu;e 90-115
6 Hours
Force Cure 120-145
1 Hour
20-30-00
0
Page 203
Aug 17/84
SR-76-023

Mixing Epoxy-Polyamide Primer
The
epoxy-polyamide primer is a two-part system consistiny of a primer base and a catalyst; along with a
specific reducer/thinner which is applicable to a particular manufacturers
product.
the materials to enter into chemical reaction. The epoxypolyamide primer should only be mixed in the amount
that can be used in an 8-hour shift. Discard, regardless of
appearance, all material that is 8 hours old.
Spraying Epoxy-Polyamide Primer
5mBliRB
NOTE
ElanszJ-pol?Jamide primer base material

and/or catalyst from one manufacturer
The temperature of the mixed primer and

the surface of the area/part to he primed
should be between 60 to griOF. (1 6 to 5.50C).
mlust not he 7nized luith the base material
and/or catalyst from another rrLanufacturel. The 7naterials
are
not
compatible.
After the mixed epoxy-polyamicle primer has been

allowed to stand for the reyuired 1 hours, spray a box coat
(spray Run passes at 9()0 to each other) to a dry film
thickness of 0.6-0.9 mils. Allow the primer to airdry for at
least 1 hour before handlingor stacking. If a second coatof
primer is to be applied, allow 1-2 hours between coats. Ifa
top coating is to be applied over the primer coat, allow the
primer to air-dry for a min of 3 hours before application of
the top coat. Primed surfaces requiring touch-up must be
cleaned using MEK prior to the recoatina of the damaged
or bare area.
Established 7~izing ratios must be followed closel~y; otherwise the primer will
ezhihit zcnuatisSactor7J film properties,
such as poor adhesion, poor chemical
resistance,
or
inadeguate drying.
NOTE
Tenr~eruture of components shall be u

IrLb7L~inzuns of 6()"F (16OC7) before mizing.
primer is mized in the
ratio of 1 volume qfprimer base to I volume
ofpmnzer catalyst, then thinned by approzi~rLatel;l! I uolum~e of manuSacturers
Application
.rpuci~ied reducer!thinner.
Thoroughly stir the primer base material until the

piymunts are completely clispersetl. ~Ieasure and pour the
trtl II i retl amount of the stirred primer base material into
a clean container capable of holding at least ii times the
voiume of the primer base material. To the primer base
add an equal amount, by volume, of thoroughly mixed
pri mer catalyst while constantly stirring the primer base
material.
of Zinc Chromate Primer iTT-P-17G7)
Zinc chromate primer is a.singie component, quick drying

primer that can be applied by either spray or brush.
Because the pigment in zinc chromate primer is heavy
and settles rapidly, the primer must be agitated continually during application. The surface to be primed must
be thoroughly cleaned or chemically treated, then
thooughly dried prior to the application of the zinc
chromate primer. Partsisurfaceu which are not to be
primed immediately after cleaning should be protected
from dust or other contaminants.
Prepare zinc chromate primer by thoroughly mixing the

primer in the original container until the pigment is
thoroughly dispersed. For spray application, add 2-2 1/2
parts by volume of toluene (TT-T-EjL8) to i part by volunle
of zinc chromate primer. Spraying viscosity shoultl be
NOTE
Prilr~er catalyst must always he added to
fhr C-~."L". bose nrcterial. TILis plocecl?cre
he! ,everRed.
between 15-"1 seconds ~vhen checlteci with 3 No.

Za.hn
areas or touch-up, zinc chromate primer
can be brushed. Thin zinc chromate primer by adding
1-1 1/2 parts by volume of toluene or xyiene to 1 part by
volume of primer jxylene will provide a better wet edge
cup. For small
To the mi~ted materials, add

volume of the manufacturers
approximately 1 part by
specified reducer~thinner
provide a spraying viscosity of between 113-21 seconds

when checked with a No. 2 Zahn cup. Stir the thinner
primer and strain through two paint straining fi!nnels or
or 3 layers of lint-free cheesecloth. Allow the mixed
primer to stand at room temperature under agitation for a
min of 1 hour before using to allow
to
Pete"tion).
Spray zinc chromate primer on surface to be primed in a

single wet coat followed in about 30-45 minutes by a second
20-30-00
Page 204
Aug 17/84
SR-76-023

Application of Zinc Chromate Primer
(TT-P-1757) (Contd)
"Sources of Commercial
approved polyurethane top
coat which should
bring the total dry film thickness to

between 0.6-1.2 mils, allow second coat to dry for at least
30 minutes before handling, If a top coating is to be
applied over the primer coat, allow the primer to air dry
for2-6 hours before application of the top coat,
Products" for a listing of

finishing materials.
coat
NOTES
Polyurethanetop coatmaterialsfromone
manufacturer must not be mixed with
mater:alsfrom another manufactzcrer; the
materials will not intermix,
APPLICATION OF POLYURETHANE TOP COAT
Polyurethane top coatings aree mixed in

the ratio of i part 62J volume of base material to 1 part of volume of catalyst.
The! application ofpol2luretha7Le top coat
involves materials and operations which
are haxalzlous. The following precautions
should be observed,
Polyurethane top coat components contain

flam7nable solvents and should he mixed
and applied only in well ventilated areas
lohers there are no open flames,
Pel:sonnel mixing or applying pol~yurethane top coat should wear chemical cartridye respirators and protective clothing,
Airplanes receiving polyurethane top

should be ~rounded
up
to
prevent static build-
no ILot allow pol2lurethane top coat to come

in contact with skin or eyes, In case of skin
contact. luash zuith soap and luater. In case
oS e~e contact, immediately u~ash eyes So,
15 ,n~in?Ltes then get medical attention.
hefore eating
or
smolciny.
Surface Preparation
Primer
coating imperfections such as imbedded dirt,

,aised nibs shall be smoothed using No. 400 grit
abrasive paper before applying the polyurethane top coat.
Immediately prior to the application of the top coat,
liwhtlv wipe the area with a tack rag. Do not allow the tack
to lie c,n the sulface to be top coated,
dust,
Thoroughly stir the polyurethane top coat base material

until the pigment is thoroughly dispersed. Pour the
required amount of the stirred top coat base material into
a container capable of holding at least 3 times the volume
of the base material, To base material, add an equal part
by volume of polyurethane top coat catalyst and mi?e
thoroughly.
NOTES
coat
during spraying operations,
~ctsh hands
Temperatureoftop coatmaterials~mustbe
before mixing,
above 60"F (I 60C)
Top
catalyst must always he added to
the top coat base! material; the procedule
shall not be reversed,
coat
Pot life of the mixed polllurethane top coat

is 8 hours. Materials that are over 8 hours
old should be discarded.
The mixed polyurethane top coat materials may be
thinned for spraying by adding the necessary amount of
the manufacturers approved thinnerjreducer to adjust
the viscosity of the top coat to approximately 18-20
Seco"ds when measured with a No. 2 Zahn cup.
ol
~iIixing Polyurethane Top Coat

top coat is a two part system consisting of a
Iriate~iai anci a cRtalvst. along with a.specific thinnei
apl,licabie to the manufacturers product. Refer to
Pol!urethane
hR,c-
20-30-00
0
Page 205
Aug 17/84
SR-76-023

Spraying Polyurethane Top Coat
Preparation." Touch-up of damaged areas or scratches is

restricted to that which can be repaired using a brush.
Overspray from a spray gun cannot be removed from the
top coat. If the damaged area cannot be touched up with a
brush, it will be necessary to mask off the area at skin
breaks or laps and the damaged area stripped and
refinished.
NOTES
The loolllurethane top coat is applied to
surfaces which have previously been coated
with epozy-polllamide primer and allowed
to air dryfor at least 3-4 hours.
APPLICATION OF IMPACT RESISTANT

POLYURETHANE TOP-COAT
If the primer has dried for ~4 hours or

primed surface must be lightly
more, the
sanded and then cleaned as described in

"Surface Preparation." When the surface
is thoroughly cleaned, spray the surface with
a light coat ofepolcy polyamide primer and
allow to air dry for I-d hours before
application of polyurethane top
Impact resistant polyurethane top-coating is a two component system, formulated for areas which are subject to
gravel/debris impingement during take-offs and landings. The impact resistant coating is also extremely
resistant to humidity, fuel, oil, hydraulic fluids, and
extended exposure to the atmosphere.
coat.
Apply a thin coat of polyurethane top coat to primed

surfaces. Allow to air dry for between 15-.10 minutes, then
apply a full wet cross coat on top coat to provide a total top
coat thickness of between 3.0-3.5 mils.
NOTE
Thefirst coat ofpolyurethane top coat will

not dry sufficiently to be touched or
handled. Care must be taken 90 that air
iicij.eu do not touch the top coated surfaces
between
thefirst and second to?,
coats.
Large areas to be top coated such as the top surfaces of

wings or fuselages which must be walked an to properly
apply the top coat, may have. the top coating applied in 1
~et box coat (spray gun passes at 900 to each other) to
achieve the required dry film thickness of 3.0-3.5 mils.
Areas of the top coating which will be overcoated by
another color should have the edges of the second coat
"feathered" to reduce the total film thickness. If the basic
top coat dries for over 24 hours before being overcoated
with another color, the surface must be lightly sanded
with 400 grit abrasive paper, then wiped down with a tack
rag before the color is applied.
Drying
curing time for the polyurethane top coat is a
max of 12 hours to the "dry hard" condition. Spray
equipment and tools should be cleaned using MEK or
equivalent thinner immediately after the application of
the top coat material. Cleanliness must be exercised since
the top coat materials, once cured, are extremely hard to
dissolve. Surfaces requiring touch-up must first be cleaned
using MEK. Contamination of any kind will cause poor
adhesion, cratering, and pl-e;nature film failure. Damaged
areas where the paint has been scratched or abraded to
the bare metal must be treated as described in "Surface
Surface Preparation
Impact resistant polyurethane top-coat may be applied to

freshly primed chem-film treated aluminum alloys, filled
and freshly primed reinforced plastics, or over existing
epoxy polyamide primed surfaces which have been
thoroughly abraded with Scotch bright pads, Type Alter
equivalent), then reprimed with epoxy polyamide primer
(MIL-P-23377C). Immediately prior to the application of
the impact resistant top coat, the areas to be painted
should be wiped with a tack rag.
Mixing Impact Resistant Polyurethane Top-Coat
The impact resistant coating is a two component system
which is purchased as a kit. Mix the two component
(catalyst base material) plus the manufacturers recommended thinner in the following proportions:
2 parts by volume of base material (821)[398) Color 6011
1 part by volume of catalyst (910X152)
1/2 part by volume of thinner (020X722)

NOTES
Use only catalystwhich is indicatedforuse
with base material.
or
Viscositl/ should be 16-18 seconds when

measured with a No. 2 Zahn cup.
After mixing the base material with the catalyst, allow a
5 minute chemical reaction time before spraying the catalyzed material. Pot life of the catalyzed top coat in a closed
container is 4 hours. If the container is allowed to stand
open, the pot life will be shortened considerably.
20-30-00
Page 206
Aug17/84
COPYRIG~T, 1984 BY SABRELINER CORPORATION
SR-76-023

or all of the followign components
there is any possibility of paint remover
contact: Ae~lic windows, rubber hoses,
fiberglass or plastic parts, tires, and wires
or wiring bundles,
Spraying Impact Resistant Polyurethane Top-Coat
any
Impact resistant polyurethane top-coat may be applied

cvith conventional spray equipment using between 55-6.5
psi of regulated air. Agitate catalyzed mixture before and
during use. Spray a fullwet cross coat of top-coat material
to a dry film thickness of approximately 1..5-2..5 mile.
~llow first coat to dry for 1 hour and then apply a second
Mask or protect all sealant in paint

removal area. Paint remover will soften
and destroy the integrity of sealant,
cross coat. Total dry film thickness of top-coat should

be between 5.0-4.5 mile. Allow coating to air dry at
ambient air temperature far a min of 6 hours before
hantlling. Drying time may be expedited by allowing the
top-coat to air dry for 1 hour, then exposing to an elevated
temperature of 170-180"F for 30 minutes.
wet
NOTE
Whenever possible, paint vemovcLI p7ocedures should be accomplished outdoors
and in a shaded area. If indoor paint
removal is absolutely necessary, make
certain that adeguate ventilation is
assured.
REMOVING PAINT/PRIMER FTNISHES

The removal of damaged or deteriorated paint/primer
films from an airplane surface may be accomplished by
either mechanical or chemical methods. The mechanical
method is limited to removing paint/primer films from
small areas using a motor driven abrasive brush or by
hant-l sanding to "feather out" the edges of the damaged
area.ro remove damaged paint/primer films from large
areas of the airplane. the chemical method of paint
Iemoval should be used. Refer to "Sources of Commercial
Products" for an approved paint remover and proceed as
Follows:
Chemical paint remover~ are tozic and

to both sli~n
cn,ltnin ingl.edients
am.cl c~es and should be 1Lsud luith caution.
R,Lhhel gloves, face 8hields and protective
clathlrLy must he luorrL tohile using paint
re~rLo2ler. I~ paint remover gets 071 the skin,
wash luith large cluantities of
Loater. ildd soap to the water
soap is
rinse
available.
aJE~cted
Freely
readily
with a mizture of 1 part isopropyl
a.bcohob mized 2uith 4 parts of zuater. The
speed 4f removal of remover from skin is
c;xtrenLely important. Do not apply salves
or oint~LerLts. If
gets into elle.r,
inarr~edinteby flood eyes utith large q?ca?Ltitles 4f Luater and obtain medical aid as
area
soor~ as
remover to areas where paint is to be

removed. Use spray or brush and apply sufficient
remover to cover surface.
1.
Apply paint
2.
Allow
remover
to remain
on
surface for sufficient
length of time to wrinkle and lift the paint. This may

require from 10 minutes to hours. depending upon
the temperature and type of paint being removed.
:3.
wet paint remover with a fiber brush

saturated with remover to further loosen any paint
that may be still adhering to surface.
ii.
Reapply paint remover and scrub areas where paint

still adheres to surface or whe,e the remover has
dried on the surface.
6.
Remove loosened paint and residual paint 1emover

by washing and scrubbing surface with fresh watel.
If water spray is available, use a stream of high
pressure water applied directly to the surface while
it is being scrubbed with a fiber brush.
6.
Use non-metallic scrapers or abrasive pads to

remove any small spots of paint that the remover did
Agitate
not remove.
Lis i ng c lean water., fl us h all fsyi ng surf aces and gaps

where paint remover could have penetrated until it
is a certainty that all paint remover and paint
residue have been eliminated.
possible.
8.
Dry
area
with clean dry cloths.
1Mask allfalling surface ~joints and edges

that tuill come in contact Luith paint
prevent removerfrom entering

joilzts or crevices; damage to interiol
surfaces and parts could result. Also, mask
remover, to
into
20-30-00
0
COPYRIGHT, 1984 BY SABRELINER CORPOFi.TION
Page 201
Aug 17/84
SR-76-023
C()RROSION CONTROL IMANUAL

CORROSION REMOVAL/PAINT TOUCH-UP KIT
NOTE
A corrosion removal and
paint touch-up kit may be

obtained from most Sabreliner Service Facilities. The kit
con tai ~1R all materials and equipment
necessary to remove
corrosion and apply a protective finish to corrosion
damaged areas of the airplane. The following procedures
should be used in conjunction with the corrosion removal
:Incl paint touch-up kit.
i.
contained in the kit have a pot l~fe of4

hours after being activated and must be
used within this time span or be discarded.
cans
10.
Determine extent and depth of corrosion deposits

and/or damaged finish,
Strip all paint from the corroded or damaged finish

area using a neutral stripper such as Turco 5R51
(or
eyuivalent).
Abrade the entire damaged
pad from touch-up kit.
4.
The contents of both the eloozll poll/anride

primer avid the polyurethane top coat spra?/
area
using
an
abrasive
if corrosion has been detected, continue scrubbing

with the abrasive Dad or use the aluminum brush
from the touch-up kit until all corrosion has been
removetl.
Use an abrasive pad to lightly sand the primed area

and to remove any nubs, dirt, etc. Be careful not to
sand through the primer, If the primer is sanded
through,
11.
a new coat
of primer
must
be applied.
Remove all sanding residue by lightly wiping with

or a clean, dry soft cloth.
12
Activate spray
can
coat and
2 coats to the
apply
containing the polyurethane top

primed area, allowing
15 minutes between coats.
Do not czceed corrosion removal ii;nite

g ;i;rr iiiJCi(l.rLb
~:s mrLrLs~ccl.
U~ t~UCiL upplicab ie ciLapter in
Feather out the edges of the painted

ing the damaged areas.
ii.
tiin~e the abraded
1V i pe the abraded
i~ith ,LIEI(.
8.
area
aiea
~vith clean
~vith
areas
surround-
~vater
and
dry
clean cloth moisteneti
if bare metal has been exposed during the

abrading
apply a thin coating of a chemical convelsion coating (Alodine 1200, or equivalent) to an
all bare metal using a soft bristle brush. Allow
conversion coating to remain c,, the surface for;:
minl.ltes. then rinse the area with clean water. Wipe
111
cle~n soft cloths.
process,
I,.
the
uan
con tents
and
~llan I,timer
apply
to
of the epos~
poiamide primer
the affected
air rlrv for I-~ hou2s.
cross coat
to
area.
20-30-00
Page 2OL)
Aug 17/84
tac-rag
COPYRIGHT,
SR-76-023
CATI-COAT PRIMER APPLICATION

GENERAL
Application
lhis section covers the application of Cati-Coat primer to

the interior surfaces of aluminum integral fuel tanks
Spray a light tack coat to edges in ordel to insure

adhesion of subsequent coats. On relatively flat surfaces,
spray 2 wet box coats of primer. On surfaces with raised
MAIERIAI,S
lands or com pie x

be applied.
Arro (:ati-Coat Primer,

13uff
E42 N P3
Sherwin-Williams
Aero Cati-Coat
VfiG K P46
Serwin-Williams
Company
Catalyst-Reducer
Company
Aero Cati-Coat Reducer
R7 K P36
Sherwin-Williams
Company
Wash Primer
Butyl Alcohol
Toluene
Naphtha, Aliphatic
Cheese Cloth
Masking Tape
Tack Rags
Abrasive Paper (wet or dry)
320-360 grit
Abrasive Pads
MIL-C-8514
TT-B-846
TT-T-548
TT-N-95
Commercial
No. 250
3 M Company
Commercial
Commercial
3M Company
INSTAI,I,ATION NOTES
Dry coated parts by
Prior
parts
ment.
Preparation
to painting, interior aluminum tank surfaces and

must be anodized or given a chemical film treatSurfaces should be free of all foreign material.
with a clean cloth dampened with naphtha, then
Wipe
wipe dry.
During stripping for anodize or chemical film treatment,

areas that require electrical bonding may be stripped to
the bare metal or masked during processing. Touch up
these
areas.
fiau rations, 4
one
of the
wet
I,arallel
coRts
rn
ay
following methods:
approximately
i.
Air dry in well ventilated

70"F for 24 hours.
2.
Air dry for 20 minutes then bake at 140 to 1500F for

3.
Air dry for 20 minutes then bake at 180 to 2000F for

room
at
The dry film finished coating thickness should be 0.0013

in, min and 0.0023 in, max measured by Model E.C.
Permascope
or
equivalent,
The finished coating should be uniform, smooth, and free

from blisters, runs, alligatoring, and other visible defects.
Particles larger than 1/4 in, diameter or 1/32 in, long
must be removed and the surface repaired by touching up.
Touch Up
Injection sealing grooves, spot faces in the seal i ng grooves,

and fastener holes do not require touch up. Repair all
other areas where the coating has been damaged or metal
is
Surface
con
exposed
as
follows:
Sand the area lightly to insure adhesion of the touch up

coating. Clean by wiping with a clean cloth dampened
with naphtha and wipe dry. Except for counter bores cut
during tank assembly, apply Type I chemical film and
wash primer to all exposed metal.
Nutplates and protruding screws should be cleaned and

coated with wash primer prior to close out. Faying
surfaces which are touched up should be air dried for at
least 30 minutes before joining. Wash primer applied for
touch up should be 0.0004 in, min and 0.0007 in, max.
Mixing and Handling

Stir or shake primer until all pigment is dispersed. While
stirring, slowly add an equal amount of Catalyst-Reducer.
If additional thinning is required, add small amounts of
Cati-Coat Reducer. The 1:1 ratio of primer to Catalyst
Reducer must be maintained. Discard unused catalyzed
Cati-Coat.
20-30-05
a
Page 1/2 Blank

Aug 31/84
SR-76-023
CORROSION CONTROL MANI!AI,
WASH PRIMER APPLICATION

Liquid Ounces
GENERAL
Th is section covers the application of wash primer used to
promote adhesion of zinc chromate primer and other
organic finishes to metal surfaces.
MATERIALS
li-linner, Dope and

Ilaccluer, Cellulose
TT-T-266
Nitrate
Thinner, Cellulose-NitrateDope, Plush Retarding

Coating Compound, Metal
MIL-T-6095
MIL-C-8514
Pre-treatment,
Resin-Acid
Parts By
Volume
To Make
Component
Isopropylalcohol
Butyl alcohol
Table
Acid
Quart
While stirring, slowly add the thinned acid to an equal

amount of resin. If necessary, the amount of alcohol may
be varied but the 2:1 ratio of isopropyl to butyl alcohol
shall not be changed unless high relative humidity
conditions exist. The 1:1 ratio of resin to thinned acid shall
not be
changed.
Mixing Kits
Solvent, Dry Cleaning

("Stoddard Solvent")
Butyl Alcohol
P-D-Ci80
IsopropylAlcohol,
CommercialGrade
TT-B-846
99% Grade
One pint of resin is packaged in a quart can, allowing.

ample space for adding the acid-thinner mixture and
achieving the proper 1:1 ratio. Redisperse any settled
pigment by stirring and shaking until all lumps are
dissolved. While stirring add the acid-thinner mix to the
resin.
EQUIPMENT
NOT~
Spray (;un, De Vilbiss

M.R.C. or equivalent
Number 30 or 36 nozzle
and size FJ needle and tip
or
equivalent
INSTALLATION NOTES
Surface Preparation
All surfaces to be wash primed should be clean and
completely free of other finishes.
Never odd the resin to the ac~id-thinner m~x.
Dry Film Finish

The dry wash primer coating is smooth, uniform and free
from runs, sags, blush and other visible defect. Dry film
adhesion is such that it resists removal when scraped with
the thumbnail. Dry film thickness is 0.0002 in. min and
0.0003 in,
max.
local area of wash primer by removing the

defective coating and recoat. No other
treatment is required.
Refinish
damaged
Mixing and Handling
primer issupplied in two forms; as a two-component

product which requires mixing and thinning and as a kit
which requires mixing only.
Wash
Immediately after mixing, all wash primer should be

The time
clearly labeled "Not to be used after
entered shall be 4 hours after mixing. At the end of that
limcl any unused material shall he discarded.
Mixing Two-Component Product
Agitate the resin on a mechanical shaker until the pig

ment is completely dispersed. Shake the acid thoroughly
then mix with isopropyl and butyl alcohols in the following proportions.
or
Clean-Up
Because wash primer con\erts chemically in the absence
of air, all equipment used far its application must be
thoroughly cleaned aftel every 8 hours of use. Cleaning
may be accomplished with either isopropyl alcohol or
methyl ctliyl ketone (MEK).
Installation irocedure
Spray a th i n, single, wet coat of wash pri mer. Viscosity of

wash I,rimer for spraying is between 29 and 34 seconds
Zahn 2 at 770F.
Do not attempt to achieve a thin film by spraying from too
great a distance. Do not attempt to get complete hiding of
the surface. Both will result in poor adhesion. Each
mixture described will usually provide a blush free film.
20-30-10
0
Page 1
Aug ~1/84
SR-76-023
WASH PRIMER APPLICATION
(Continued)
Installation Procedure (Contd)

If blushing
discontinue painting. If the blushing

20 minutes and the film resists
scratching with the thumbnail, top coating may proceed.
If the blushing does not disappear within 20 minutes, the
coating must be stripped. The chart below shows relative
humidit)l values which, if exceeded, may cause blushing.
When blushing occurs the condition can be corrected by
increasing the temperature, dehumidifying the air or by
using a thinning mixture composed of equal amounts of
isoplopql and butyl alcohols. Do not paint at temperatu res
lou~ei than 65"F.
occurs
disappears within
Maximum Relative
Tempelature
OF
65
80
70
75
80
85
7,7
F)O
95
100
Wash
Humidity
primer drying time
75
74
73
72
71
70
is 15 minutes min and 4 hours
ma~.
20-30-10
Page
Aug 31/84
SR-76-023
MOISTURE AND FUNGUS RESISTANT COATING APPLICATION

4.
~:ENERAI,
Ihis section covers the impregnation and coatinK of
materials and electrical parts and assemblies with a
moisture and fungus resistant varnish conforming to
MII,-V-173.
MATERIALS
Varnish Moisture-and-
MIL-V-173
Component parts such as cable with C,lastic insulation where al,plication of coating matelial rrtluccs
insulation resistance below acceptable valut~s:
capacitors (variable. air, ceramic. or mica dielrctricl
types); ceramic insulators subject to 600 volts
operating where danger of flash-over exists; waveguides; and materials when used for their specific
are-resistant properties and classified as "are
resistant."
Fungus-Resistant (for the

treatment of communica-
Cleaning
tions,electronic,and
All parts and assemblies to be coated with varnish should

be thoroughly cleaned as follows:
associated electrical
equipment)
Thinner; Synthetic Besin
TT-T-306
Wipe parts or
2.
Remove rosin flux residues by scraping wherever

feasible or by vigorous brushing with denatured
alcohol, using a natural bristle brush.
3.
Z,ightly scuff sand glossy plastic parts
Cleaning Solvents
cleaning solvent should be

following.
The
i.
Toluene, commercial grade
2.
Approximately
one
or
more
of the
500/0 by volume isopropyl alcohol,

commercial grade, 99.9%, and either naphtha per
TT-N-95 or petroleum solvent
3.
Naphtha,typeI, TT-N-95
4.
Fetroleumsolvent, Stoddardsolventtype
5.
Denatured alcohol, solventgrade
I~nglazed ceramic materials used in electrical applications, unless enclosed in hermetically sealed assemblies
should be coated with varnish after fabrication and any
firing operation. All nonmetallic materials should be
coated with varnish unless enclosed in hermetically
sealed assemblies or specifically excluded. Precautions,
such as masking, must; be taken so that the coating is not
I.
following:
Contact portion of binding posts, connectors, fuses,
jacks, keys, plugs, relays, sockets, switches,

points, and variable capacitors.
2.
Before the varnish is applied, wipe cleaned items with

clean cheesecloth. No indication of residual soils, stains,
or other contaminants should show.
Store varnish in a closed, airtight container when not in

Discard when it becomes thickened, skinned, or
otherwise affected by evaporation, oxidation, or contamination. When thinning is ,equired, use toluene,
cOMMercial grade, or thinner, TT-T-306.
use.
Applications and Limitations
to the
test
Handle parts throughout impregnation and dipping by

of wires, clamps, or other suitable methods to
prevent parts from contacting each other or contacting
possible contaminants. Coated parts shall be protected
against damage or contamination during transfer and
means
storage.
Varnish should not be sprayed when the relative humidity
at a particular ambient air temperature exceeds the
following values:
Surfaces which contact each other for electrical or

magnet contact such as those in bearings, contact
fingers, potentiometers, shafts; shields, variable
autotransformers, and relays.

3.
to be coated.
Mixing and Handling
INSTALLATION NOTES
applied
areas requiring cleaning with a clean

cloth moistened with cleaning solvent. Dry with a
clean, dry cloth. Parts may also be cleaned by
immersion in, rinsing with, or spraying cleaning
solvent.
1.
Enamel
Mechanical parts such as all bearing surfaces, gear

teeth and gear trains or assemblies, screw threads
and screw adjustments; springs except at base of
pileup; surfaces whose operating temperature
exceeds 3020F or will cause carbonization or
smoking; transparent plastic parts, windows, and
Air
Temperature OF
90
85
80
75
70
65
60
Maximum Relative
Humidity
63
67
70
73
77
80
85
lenses.
20-30-15
o
Page 1
Aug 3 1/84
SR-76-023
MOISTI~RE AND FUNGUS RESISTANT %OATING APPLICATION
(Continued)
Mixing and Handling (Contct)
coatings should have a dried film thickness of at least

coatings should be free of bubbles, wrinkles,
filan~ents, sags, runs, and oversplay when dry. Continuity
of the applied varnish coating can be determined by
inspection under ultraviolet light, A similar uncoated
article may be exposed at the same time to the ultraviolet
light for comparison. Fluorescence indicates the presence
All
4.
0.00% in. The
of coating.
Mark each subassembly that has been moisture and
fungus I,rotected "MFI" and the month and year of
treatment.
performed properly.
Vacuum
~arnish is
or
vacuum
applied bg brushing, dipping, spraying,

impregnation. The coating may be applied
parts after assembly.
to
splaying,, the vainish shall have a %ahn No. 2 cup

reading of 22-29 seconds, which may be achieved by
adtling 1 part toluene to 2-3 parts varnish. A spray gun
uith the tip regu lated to give a wet spray is recommended.
For small compact equipment, a pencil spray tip regulated to clive a narrow wet spl.ay is Iecommended. The
part shall be sprayed from as many angles as necessary to
insul~e complete colelage with a wet coat. When the part
configuration permits, 2 box coats of varnish shall be
apl,lied by spraying, nrith a drying time of 15-60 minutes
betnecn coats. Each box coat normally provides 1 mil of
dried film thickness,
3~
Remove part from varnish, drain, remove excless

drops of varnish from bottom edges or part, and
allow part, to dry for 25-30 minutes at room
Fill and Drain
Rigid metal electrical conduit that will be

temperatures of 300"F
provide a dried-film
dip part in varnish
I:sing varnish thinned
to ~,rovide a total dried film

Ih ickncss between 0.002 and 0.00~ in., dip part in the
va!nish and remove immediately.
ice
Plug
2.
Remove stopper and allow varnish to drain into a

suitable container for reuse. Allow coating to tlrain
from conduit for at least 30 minutes while in a
vertical position. Excess varnish may be removed
from the draining end of the conduit by carefully
wiping exterior area with a clean cloth saturated
with toluene,
lower end with any suitable stopper, place

conduit in a vertical position, and completely fill
with as-received varnish.
After drai nincr has been com pleted, direct a flow of

air thru the coated conduit for at least 1 hour.
4.
Bake the coated conduit in a vented, circulating-air

oven at a temperature of 150 to 1800F for at least 2
hours and then cooled to room temperature. (Wilcs
may be coated with talc to facilitate insertion in the
coated conduit.)
5.
Thickness of dry coating applied by using steps 1

thru 4 is normally 3-6 mile. If a thicker coating is
needed, repeat steps 1 thru 4 until the desirctl
coating thickness is obtained.
thickness of less than 0.0015 in.,

and 1emove immediately.
I)1ain part, remove excess drol,s of varnish from

bottom of part. and allow it to air dry at room
tcm I,erature fol 25-30 minutes. W,inklinff in following tlip operation may occur if air dry is more than
:3() minutes.
serv
or
When
dip pl.ocess is usetl, the coating thickness should
~,e i,rt wclcn 0.002 and O.OOX in. The coating is ;tl,plied as
rollo\r~s:
to
used at
less is coated, after bond ing an rl

cleaning, by the following method:
Dil,PinR
3.
at 120 +100F for 2 +0.26 hours and cool to
temperature.
temperature.
For
d.
follows:
Immerse part in diluted varnish at room temperature and subject immersed part to v;lcuum for 5-fi
minutes. (Excessive foaming will occur if the vacuiini
exceeds 2X.6 in, of Hg.)
SP,ayjnK
I!sing \-arnish thinned
Dry part
as
2.
employed.
i.
impregnate
room
RrrlshinR
MThcn brushed on, the varnish normally is applied as
receiveti, thinned if necessary to reduce consistency for
brushing. No more than 10b by volume of thinner shall be
Impregnation
When the vacuum impregnation process is used, the

thickness of the dry coating should be between 0.002 anti
0.00tl in. The varnish is thinned with 1 volume of toluenc
to 2 volumes of varnish.
Vacuum
Application Procedure
detail
Drain the part, remove excess drops of varnish from

bottom edges of part, and allow to air dry for 14-1Ci
hours. In lieu of air drying, part may be oven dried
at 110 to 1300F for 2-2-1/2 hours. Wrinkling at this
stage indicates that previous steps were not
20-30-15
Parrtr 2
Aug 31/(34
SR-76-083
COKROSIO~ CONTROL MAN17AL
PAINTING METAL SURFACES WITH EPOXY POLYAMIDE PRIMER

OR ZINC CHROMATE PRIMER
Foil, Aluminum. 0.005 in, min
(;ENERAL
Ihis section covers the general procedures to be followed
in al,ply i ng two types of primer coatings to metal su rfaces.
MATEKIALS
I~laxy Primer, Filiform
Str.iping- Brushes
Tape, 3M Co., No.
TT-M-261
TT-T-266
Toluene
TT-T-fi48
TT-P-1757
The spray
MIL-T-6095
The spray
Sensitivity
Dope, Blush Retarding

Non-Woven, Non-Metallic
MIL-A-9962
Abrasive Mats iReqnire

Type I, Class I or TI,
C;rade A or Finer, Scotch
nrite (RM (:o.) or equivalent)
Toluene-Methyl Isobutyl
MIIl-r-19fi88
Ketone
Primel, (:oatinff, E:poxy-Poly-
MII,-T-23~77C
amide, Chemical and

Solvent Ilesistant (Class II
Air Non-Polluting)
(:leaning Solvent (Stoddard
Solvent Type)
Primer (MI~1-P-23377C)
Thinner. Non-Photochemically Iteactive and Compatible with Primer
Aluminum Foil Fabric Tape
(:heesecloth
Visqueen Polyethylene Film

No. C;R-99
Tack Ilags
Bostik Div. USM Corp.,
Middleton, MA, or
equivalent
Itubber Cloves (Rubber Base
o~ Nylon)
(;love lowder (Talc)
400 (;rit Wet-ctr-Dry Abrasive
Paper
Tape, Masking (3M Co.,
No. 250 or Mystik No. Ci2XO
or equivalent)
Boots, Treat Cloth
or
Rubber
Coveralls, IJint-Free
C:al,s,
Painter
Type
(:lasses, (;nggles or Face

Shieltfs, Safety
Commelcial
EQUI[PMENT
Corrosion Inhibitor
lhinner, Cellulose-Nitrate-
(CFM)
SH0125-024
Mc!thyl Ethyl Ketone (MEK)

Thinner. Dope and Ilacquer
Primer C:oating, Zinc
Chromate, Low Moisture
670
Fiber Brushes or Tampico

Brushes
Tape. 3M Co., No. 202
Commercial
Commercial
Commercial
Commercial
ST0210GB0003
Commercial
Paint
Spray Room
should be well illuminated (a min of 50
room
ft-candles), using vapor and explosion-proof lights, and

floor lighting equipment. when necessary.
floors should be kept clean. and free of
other debris. Hose floors down at the
and
rags, paper
beginning of each shift. Additional floor wetting may be
required to keep the overspray and other dust contained
on the floor.
room
Tem perature and hum id i tS i ndicators shou Id be instal I etl

and in proper operation durinlS the time of paintinR and
drying. The temperature of the spray room should be in
the range of 60 to 950F Ifi to 450C) during spray painting
these paint systems. The relative humidity should be in
the range of 25-750/0 during this same time period.
Whenever the temperature and humidity cannot be main-
tained within these limits, discontinue painting.
Spray
Guns and Hoses
The spray guns and accessories used should conform nith

table 1 requirements or be equivalent.
Commercial
Commercial
Commercial
Commercial
Commercial
Commercial
Fluid lines should have a min ID of S/8 in. from tank

shall not exceed 75 ft in length.
High pressure air hoses leading to regulator or tank

should have a min ID of 7/16 in., and a mar; length of 150
ft. Air hoses from tank to gun should have a min ID of 6i 16
in., and a max length of 75 ft.
Recommended pressure settings for fluid tank, Iegulator.
and spray guns are given in table 8.
The following
Commercial
(:ommercial
to
gun, and
precautions should
be observed while sl,ray
painting.
Commercial
Dusting
or
rippling
will be caused
by
too
high
an
air
pressure.
sags will result when the air pressure
the fluid pressure is too high. Both the
epoxy primer and the zinc chromate primel build up
in thickness very rapidly.
Orange peel and

is too low
Commercial
Commercial
Commercial
Commercial
or
20-30-20
o
Page 1
Aug 31/84
(:OHROSION (:ONTROI, MANuAL
PAINTING METAL SURFACES WITH EPOXY POLYAMIDE PRIMER
OR ZINC CHROMATE PRIMER
(;uns and Hoses
SpraS
(Contd)
Thoroughly dry all parts after cleaning and/or chemical
surface treatment.
equipment, guns, lines and pressure pots

thoroughly both before and immediately after use
\~ith toluene (zinc chromate primer) or MEK(epoxy).
\~Then MEK is not available use the thinner comm ere ially available from pri mer supplier and compat(lean spray
ible with the epoxy
Parts should be primed within 24 hours after cleaning,

chemical surface treatment, anodizing, or plating, and
should be suitably protected from dust and handling until
they
primer.
air line out at least twice each day or

oftcllcl, if necessary, when painlina details, or
assenlblies, to purge lines of any oil or water. As a
further precaution, all air lines should contain an air
filter and water separator that is cleaned or changed
at least once a month.
nlou
areas
tape, plugs,
or
adequate ventilaingest.
Do not inhale\apors. WASH HANDS REFORE EATING

OK SM()KINc. Contact of liquid or vapor with eyes may
cause sevele irritation. In clase of skin contact, wash with
sclal, and natel. In case of eye contact, immediately wash
eve~ for at least 1.5 minutes; get medical attention.
NOTE
The No.
maskang tapu
acrl/li.e surfaees.
2.
Preparation
Thoroughly clean surfaces prior
to the
The visqueen protective! covering and/or Protex ZOV

die cuts initially installed on window for physical
protection may be used as the first mask with the
addition of an edge seal i ng usi ng 3M No. 670 (C FM
tape.
contact with the skin and eyes. Do not
Surface
not to be primed with masking pal,er,

other suitable masking materials.
All acrylic and glass transparencies must be double

masked prior to solvent cleaning of adjacent surfaces as
fol lows:
Safet~
with
primed.
Protect any
i.
Al,y1! these coating systems only
are
Acrylic and (:lass Transparencies
INSIALI,ATION N()TES
tion.
(Continued)
musl not touch
A second masking is applied using aluminum foil

0.005 in. min thickness and 3M No. 202 masking
tape.
application of
finishing materials.
Alun-l inum, steel, and magnesium surfaces must be given
the I,ropel chemical treatment prior to application of the
finishinR materials.
lahlt i.

TANK GUN
TYPE GUN
FLUIDTIP
De\ilbiss JC;A
or TKA Model 502
Table 8.
FF
02
EX
AIR CAP
NEEDLE
FF
or
FX
FLUID TIP
F,X
705
or
EX
AIR CAP
NEEDLE
EX
or
FX
30
PressureSettings
FINISHING
MATERIAL
FLUID TANK
SETTING
Primer
%ine (rhromate PIimer
CUP GUN
i~tf d I 1 I, of fl u ill I,lessu Ie fol each ft of

a~,ove the fluid tank level. for normal
AIR RE~ULATOR
SETTING
AIR PRE8SUKE
AT SPRAY (;UN
8-12
psi
60
psi
45
psi
8-12
I.,si
56
psi
40
psi
height of the Run

operation.
Frequent checks should be made with

determ ine ai r pressure at the gu n.
t.cst aaugc to
20-30-20
faffe
Aug 31/84
%OPYRIGHT, 1984 BY SABRELINER CORPORATION
SR-7fi-023
(:()RK()SI()N (:()NTK()I, MAN1IAI,
PRIMER
PAINTING METAL SURFACES WITH EPOXY POLYAMIDE
OR ZINC CHROMATE PRIMER (Continued)
~t;poxy-Polyamide
Class 2)
Primer
I until pigments are thoroughly mixed.

Ited I)evil shaker or equivalent method.) Reduction of Com ponent I (pigmented solution) with Component
Il
solution)is 1 volume to 1 volume. Temperature of
(:amponent
Stir
(Nlix
on
(clear
components
is
a day. Where no such agitation
cans, it is
hand
or
in
cans
such
gun
as
spray
provided,
essential that the primer be well mixed to redisperse all
solids before the primer is sprayed.
24 hours
agitated
Mixing and Handling
must be above 600F
(16"C) before mixing,
Component I into an empty container allowing

II
atlequate time for complete drainage. Pour Component
slowly into Component I with constant stirring. Allow
Thin primer by adding 2-8-1/2 volumes of toluene (rl-T548) to 1 volume of the zinc chromate primer. The spraying
viscosity should have the range of 15-21 seconds when
checked with a No. 2 Zahn cup (8-12 seconds with a No. 4
Ford cup). The primer is ready for use when thinned.
Pour
II. Each container of

proper drai nage time for Component
Components I and IT may be rinsed with the non-photo-
chemically reactive solvent type thinner. Component II is

not
always added to Component I,and this procedure must
he reversed.
NOTE
Yellow zinc chromate
priming is required it should be applied as soon as

possible to give protection against corrosion during shop
When
handling
completion of the after mixing waiting period, the

admired and thinned epoxy primer should be sprayed
with one wet cross coat to
preliminary
chemical reaction and is necessary fol the following

reasons:
Iteduces
cratering.
dry film thickness of 0.6-0.9 mil.
NOTE
The
primed
80
to he
betwee~n
hr
should
plimsl
temperature of the surface

and the
and g.5"F.
No. 2 Zahn cup.
The thinned paint should be stirred thoroughly, strained

through 2 paint straining funnels or 2-3 layers of lint-free
cheesecloth, and allowed to stand at room temperature for
1 hour before using. The standing period for primer is a
period for the components to enter into
2.
storage in stock.
or
After
spraying
Shortensdryina time.
Application
Primer
Thin 2 volumes of the Class 2 admired primer for

spraying by adding approximately 1-1/2 volumes of nonphotochemically reactive thinner which is compatible
with alags 2 primer as specified in manufacturers directions.Ihe
viscosity should have a range of from
I.
For
Never mix epoxy primer from one vendor

with primer from another vendor. Com?30nents also are not interchangeable.
18-21 seconds when checked with
primer (TT-P-1757) can be used

primed surfaces.
touch-up of jet skin and epoxy
Epoxy Polyamide
Primer
Drying Time
Allow primer to air dry 2-4 hours at air temperature of

78 +Fi"F prior to top coating.
Allow to air
dry for
at least 1 houl
prior
to
handling
ol
stacking.
Ihe primed surface may be force cured by allowing a
Ir,-minute flash off periotl followed by a i hour hake at
18() -fT,o F.
Allows any bubbles
(formed by mixing)
to escape.
Epoxy primer should be admired only in that amount that

life of the admired epoxy
can be used in one shift. The pot
material must be
8
After
hours,
hours.
is
8
I,rimer
discarded regardless of appearance.
single coat of zinc chromate primer and

for
30-4Fj minutes. Apply a second coat fol
allow to air dry
mils. Allow second coat to
8 d,y film thickness of O.fi-1.2
then
apply top coat.
air dry for 2-6 hours,
Spray
on a
wet
Hollow Members
(TT-F-1757)
This is a single component primer but the paint must be

well mixed in the original container before being thinned.
The pigment is heavy and will settle rapidly in both the
unthinned and thinned state. To prevent this settling, it is
essential that all such paints being used in mixing tanks,
circulating lines, pressure pots, hoses and wherever
mechanical agitation is practicable, be kept constantly
Hollow members (i.e. tubes), ~hich remain open in

service and require pliming by the fill and drain method,
should be accomplished by using zinc chromate primer
(TT-P-1757). Fill and drain with the specified primer
until the entire surface is covered.
20-30-20
o
Page 3
Aug 31/84
SR-76-023
PAINTING METAL SURFACES WTH EPOXY POLYAMIDE PRIMER

OR ZINC CRROMATE PRIMER (Continued)
louclh
lip of Damaged Primer
tions. Such swrfat:es
are not su itable for touch-ul,

subsequent top coats even if solvent wiping is
attempted, because adhesion will not be atlequate.
Where the initially applied primer coat is to be the only

be touched up to eliminate all bare areas
caused bg shop handling, drilling, cutting, filing, or
form i nff operations. Before su rface treatment and touch
up Feather etlges of the primer adjacent to the bare area
using No. 300 abrasive paper to prevent ridges in the
or
coat it must
coating.
Surfaces reyu iring touch-up must be cleaned (using M EK
fo, epoxy or toluene fol~ zinc chromate primer) since
conlamination of any kind will cause poor adhesion,
cratering~, and premature film failure. Any paint areas
scratched or abraded to the bare metal must be t;ouched
up
Primer (oat Preparation For Finish Coat
Finish (olor Coats Over I)rimers

One coat of epoxy
primer or 2 coats of zinc chromate

pri171el alC applied to surfaces to be subsequently paintetl.
lhis I,rimcl coating must not be removed prior to application of additional finish coats unless the primer is in
pool condition and would not provide a suitable base for
su bsequent finishing.
Polyamide Primei
Epoxy
Stripping of
Primers
Mask off all
plastics, rubber, fabric, joints, parts, and

plated areas that might be damaged by paint strippers or
water using tape (aluminum foil or fabric) and polyethylene film.
Apply paint stripper
to
remove
primer
or.
paint.
Remove loosened paint and contaminants with a bristle

brush and water spray or wipe off with water moistened
clean cloths. Dry surface, An alternate method of
removing paint is by lightly scouring the paint area with
abrasive pad (MIT,-A-9962), Gratle A or finer, moistt!nctl
with a 1:1 mixture of MF:K and lacquer thinner. Wipe
stripped area clean with a sufficient number of solvent
moistened clean cloths to assure adhesion of sut,secloent
paint films.
Cure/Baking
In general, primers usetl c~n detai Is and assemblic!s ail, tlry
satisfactorily and do not require baking; however, primels
for certain parts may be baked for increased abrasion anc
chemical resistance. Baking temperatures shall not
exceed 200"F and time shall not exceed 2 hours.
Before
applyingepoxy polyamide finish coats, wipe cured

primel \Iith a MEK moistened, clean cloth to remove soil
and contamination, Lightly abrade with No. 400 abrasive
papel and wipe again with MF,K moistened, clean cloth to
remove
the dust.
Finish
Inspect painted surface for freedom from dust particles,

lint, and any foreign matter. The surface should be free of
surface irregularities such as too much paint, runs, sags,
and overspray,
To
Primer Test
good adhesion, zinc chromate primed surfaces

given a finish coat as the next operation after
priming must be cleaned of oil and other soil before
applying additional paint coats. Any contamination such
as dirt, grease, and oil must be removed by wiping with
Stotldald solventol lacquer thinner prior to application of
assure
to be
an!,
top coat.
Paint,
coatings falling within the classification noted in

I,ar;taral,hs (I) and (2) below must be removed (refer to
StriPPinR ()f Primers below) before application of reqrl i red fi nal primer or pal nt coatings.
(1)
Shop aged primer
coats on exterior skins of

assembled aire raft, and primer on pair;t coats i n an
unsatisfactory condition.
Stl.il, and rcl,rirne ;111 zinc ch romate primed sur

facts which are intentionally oiled, greased, or
othcru~ ise contam i natetl
;Is an
aid to form ing ol,era
Inspect primer coating for adhesion after it has been

allowed to dry for the full curing period. Apply a 1 in. wide
strip of masking tape (No. 250, 3M Co.) pressed down
using 2 passes of a 4-1/2 Ib rubber roller or by firm
pressure with the hand. Remove the tape in one abrupt
motion 90" to surface. F:xamine the tested area for any
paint damage, such as removal of one of thr! layers ol
removal of the entire system from the metallic surface.
Any such removal is unsatisfactory and the primer must.
be stripped, the surface pr.epared again, and reprinletl.
Shelf Life of
Coating Materials
The unmixed primers may be stored unopened for a max

periad of 1 year stored at temperatures within t.he Iangr
of 36 to 950F (2 to ~50C). After th is storage l,erio(-l of 1 yeal,
the coating materials ma!, be tested far anothe, storage
period of 6 months by m i x i ng and apply i ng sam pie coats
to scrap material. Precatltions must be taken during
storage and handli nff of the pal nts antl thinnt!rs lo I,rev~,r,
water contaniination.
20-30-20
Iaae
/1
Aug 31/84
SR-76-023
CONVERSION TYPE COATINGS APPLICATION

(;ENERAI,
After spraying operations are conipleted, equipment such

spray Runs ;Intf pots may l,e cltl;lncld by
thinner, TI-l-B(iti.
as
lhis section covers Ihe application of convelsion type

finishes lo metal surfaces,
INSTALLATI()N PR()CE:DIIRES
M~TEKIALS
P:namel:
Epoxy, Conversion
Iy I,e
Aliphatic Naphtha
Toluene
Thinner
Apply catalyi~etl mixture t,y splaying at a pressu,.c~ or

psi. ()ne full coat will produce a film thickness of
approximately 0.75-1.0 mi I. Parts that have been sprayed
are cured for 16-18 hours at 1400F or for 7 days at 720F in
LB()125-006
25-XO
Commercial Grade
Commercial Grade
TT-T-266
APPLICATION N<)TES
Cleaning
dust-free environment.
Parts on which a conversion film has been applied should

be examined visually. The applied finish should have a
uniform appearance free from pinholes, blistels, 1uns,
alligatoring, or other imperfections such as drying irreffu
larities noted below:
Surfaces must be clean and free from all dirt, grease, rust,
scale, chips, or other contamination before finishes are
1.
Films remain
applied.
2.
Films remain soft

drying for 7 days.
Metallic parts, except titanium, that are to be painted

must be solvent vapor degreased. Titanium parts must be
cleaned in accordance with applicable titanium cleaning
procedures. Parts that are thoroughly clean, such as those
that have just been anodized, chromodized, phosphatetreated, or given a chemical film treatment, will require
further treatment before application of finishes,
no
Finffermarks, smudges, and smears may be removed
from large surfaces by wiping with aliphatic naphtha.
tacky for
to
24 hours
thumbnail
or
longer.
scratching after
ail
If the applied conversion finish shows poor adhesion,

surface irregularities, or drying irregularities, the conversion film must be stripped, the surfaces recleaned, and the
conversion film re-appplied.
Conversion type coatings may be applied to surfaces

primed with zinc chromate if the surfaces are clean and
intact and the primer has dried at least 16 hours. Dirty or
im properly applied zinc chromate primer films must be
stripped and reprimed before applying the conversion
finish coats.
If a conversion type finish will be applied over a wash
primer, I,repare the surface and apply the wash primer
normally, except that the drying period for the wash
primer must be at least 1 hour.
Conversion coating may be applied directly to surfaces

that have been previously coated with conversion coatings,
except that such surfaces must have been cleaned by
wiping with clean, toluene-soaked cloths before the conversion coating is applied.
Mixing and Hannlinng

The conversion finish is supplied in the form of a resi n and
catalyst. Mix the catalyst and resin in the proportions
recom m ended by th e m an u factu re r. The catalyst m ust be
adtled to the resin with constant stirring until a smooth
uniform mix is obtained. The catalyzed mixture must be
used within 24 hours after mixing. Discard mixtures
more than 24 hours old.
20-30-25
0
COPYRIGHT, 1984 BY SABRELINER CORPORAIION
Page 1/2 Blank

Aug 31/84
SR-76-023
POLYURETHANE FINISH SYSTEM FOR

SABRELINER AIRCRAFT EXTERIOR SURFACES
(;ENERAI,
This section covers the materials, procedures, and requirements for the application of an epoxy polyamide primer
and polyurethane topcoat finishing system to the exterior

of aircraft. Procedures are in accordance with the applicable sections of the Military Specifications MIL-F-18264.
All surfaces,
including well areas normally exposed to the
external environment during flight or
on
the ground,
are
MATERIALS
Technical Inhibited
Methyl Ethyl Ketone (MEK)
Naphtha
Lacquer Thinner
Paper, Kraft, Untreated Wrapping
Non-Slip Walkway Compound
Chemical Conversion Coatings on
Aluminum and Aluminum Alloys
Nan-woven, Non-metallic Abrasive
Mats, Require Type I, Class 1 or
2, Grade A or Finer, Scotchbrite
(3M Co.)
or
TT-M-261
TT-N-95 (Type
TT-T-266
UU-P-268
MIL-W-5044
MIL-C-5541
MIL-A-9962
Non-Polluting)
Cleaning Compound, Aircraft
MIL-P-23377C
MIL-C-25769
Surface Alkaline Waterbase
(Turco Air Tech No. 19)

Neutral Paint Remover, Turco
No. 5351
Primer (MIL-P-23377C) Thinner,
Non-Photochemically Reactive
and Compatible with Primer
Aluminum Foil or Fabric Tape
Cheesecloth

No. GR-99 Bostik
Tack Rags
Div., UXM Corp., Middleton,
MA or equivalent
Scotchbrite Pads, Type A (3M Co.)
Thymol Blue Indicator Paper
(Van Waters and Rogers)
Rubber Gloves (Rubber Base or
Commercial
Commercial
Commercial
Commercial
Commercial
Commercial
Commercial
Commercial
Commelcial
(FJ.I. DuPont)
0-T-620
equivalent
Chemical and Solvent Resistant

Air
Coating (Require Class 2
Shields, Safety
Striping Brushes
Fiber Brushes or Tampico Brushes
Pressure Air/Water Guns
Imron Polyurethane Enamel
considered exterior surfaces.
Trichloroethane, I, 1, 1,
Chemical Cartridge Respirator

(Wilson Model No. 1200 with
N,~ R21 Cartridges)
Boots, Treat Cloth or Rubber
Coveralls, Lint-free
Caps, Painter Type
Glasses, Goggles or Face
192 S Activator(E.I. DuPont)

8485 S Reducer (E.I. DuPont)
II)
Commercial
Commercial
EQUIPMENT
Spray Guns and Hoses
The spray guns and accessories used must conform with
table 1 requirements or be equivalent.
Fluid line must have a min ID of 3/8 in, from tank to gun,
and must not exceed 75 ft in length. High pressure air
hoses leading to regulator or tank must have a min ID of
7/16 in., and a max length of 150 ft. Air hoses from tank to
of
gun must have a min ID of 5/16 in., and a max length
75 ft.
Recommended pressure settings for fluid tank, regulator,
and spray gun are given in table 2.
Observe the following precautions while spray painting.
Dusting
Commercial
or
rippling will be caused by
too
high
an
air
pressure.
Commercial
Orange peel and sags will result when the air pressure
is too low or the fluid pressure is too high. Both epoxy
primer and the polyurethane topcoat build up in
thickness very rapidly.
Commercial
Commercial
Commercial
Commercial
Commercial
Clean spray equipment, guns, lines, and pressure pots

thoroughly both before and immediately after use
with MEK.
INSTALLATION NOTES
Commercial
Commercial
Commercial
Nylon)
Glove Powder (Talc)
4()0 Grit Wet-or-Dry Abrasive
Commercial
Commercial
Paper
Tape, Masking(3M Co., No. 250 or
Mystik Na. 6280 or equivalent)
Commercial
Safety Precautions
Polyurethane vehicle, thinner, and primer components
contain flammable solvents so all ordinary precautions
such as adequate ventilation and absence of open flames
should be observed. Ground all aircraft as static charges
can build up, especially when using spray equipment.
20-30-30
0
Page 1
Aug 31/84
SR-76-023
C()KROSION CONTROL MANUAL
POLYURETWANE FINISH SYSTEM FOR

SABRELINER AIRCRAFT EXTERIOR SURFACES (Continued)
Safety Precautions (Contd)
turbulence and excessive air currents and must

at a min of 125 fpm at the exhaust in the
painting area. Room air must be exhausted through an
exhaust system immediately at one end of the aircraft or
part being painted so that overspray does not drift into
other areas of the room.
to
Isolate painting procedure from exposure of nearby

personnel. Only painters must be allowed inthe spraypainting and adjacent areas. Spray painters must be fully
clothed in coveralls and caps with collars buttoned and
sleeves taped at the wrists.
Solvent-resistant gauntlet style gloves (natural rubber or

neoprene) must be worn by personnel engaged in the
mixing and application of polyurethane paint.
Painters and others must wear a chemical cartridge
respirator when mixing and spraying polyurethane paint.
Apply these coating systems only with adequate ventilation. Avoid contact with the skin and eyes. Do not ingest.
Do not inhale vapors. WASH HANDS BEFORE EATING
OR SMOKING. Contact of liquid or vapor with eyes may
cause severe irritation. In case of skin contact, wash with
soap and water. In case of eye contact, immediately wash
eyes for at least 15 minutes; get medical attention,
cause
be maintained
Floors
The spray
floors must be kept clean, and free of rags,

debris. The floors must be hosed down at
the beginning of each shift and in the area of the aircraft
approximately 1 hour before the beginning of the painting
of the aircraft. Additional floor wetting may be required
to keep the overspray and other dust contained on the
floor.
room
paper and other
Doors
Hangar doors (large) must not be opened for an hour

before, during, and for at least 2 hours after the painting
of an aircraft with the basic topcoat system. Personnel
doors (small) shall be restricted,so thatonly 1 door to the
outside shall be available to foot traffic during the same
time period as the hangar doors.
Facility Requirements
Lighting
The spray room must be well illuminated (recommend a
min of 50 ft-candles), using vapor and explosion-proof
lights, and floor lighting equipment, when necessary.
Air
The paint spray room must use filtered air. The amount of
air forced into the spray room must exceed the volume
withdrawn. Air must be introduced in such manner as not
Table 1.
Spray Guns
and Accessories
TANK GUN
TYPE GUN
DeVilbiss JGA
or TEA Model 502
FLUID TIP
FF
Binks Model 7
Table 2.
FX
NEEDLE
FF
33B
or
AIR CAP
FX
FLUID TIP
765
33
EX
or
FX
NEEDLE
EX
or
AIR CAP
FX
30
33 PM
Pressure Settings
FINISHING
MATERIAL
F~posy
or
CUP GUN
FLUID TANK
SETTING
AIR REGULATOR
SETTING
AIR PRESSURE
AT SPRAY GUN
Primer
8-12
psi
60
psi
40-45
psi
Polyurethane Topcoat
8-12
psi
60
psi
50
psi
Add 1 Ib of fluid pressure for each ft of height of the gun

above the fluid tank level, for normal operation.

determine air pressure at the gun.
test gauge to
20-30-30
Page 2
Aug 31/84
SR-76-023
CORROSION CONTROL MANIIAI,

Facility Requirements (Contd)
Thoroughly abrade metal surfaces with

abrasive nylon pads, ensure that the heads
Temperature and Humidity
fasteners have been abraded.
Thoroughly
NOTE
Re-abrade and rinse

break free" surface.
in the top coat. When this condition is

encountered topcoat should be reduced to
Zahn cup
1 r.0 seconds measured with No.
and allow a min dr2ling time of 1 ~Lour
occur
single
and
plated
immediately. While still
wet, determine if a "water-break free" surface has been

achieved. Refer to Water Break Test below.
Hish temperatures and high relative

humidity can cause bubblinglblistering to
between each
spray water rinse
water
of all
as
necessary to
achieve
"water-
Rinse with high pressure water rinse while agitating to

ensure removal of all sanding residues from abraded
surfaces,
spray coat.
gaps, seams, etc.
Temperature and humidity indicators must be installed

and in proper operation during the time of painting and
dry i nff. The temperature of the spray room must be in the
range of 00 to 90"F 1 hour before, during, and for 4 hours
after spray painting this paint system. The relative
humidity must be in the range of 25-75%.
Water-Break Test
Pressurized Air Source
(without
day or oftener, if
when painting an aircraft, to purge lines of any
Distribute a film of water on the bare metal surfaces. If

th,,,t,, film gathers into discreet droplets with 25
seconds after application of water, the surface has
exhibited a "water-break" and has failed the test.
a continuous film of water
sudden flashout or the forming of droplets)
then the surface has passed the "water-break" test.
If the water film stays in

a
nlow out air lines at least twice each

necessary,
oil
or
water. As
precaution, all air lines contain

separator. Change the filter and
further
air filter and water

separator at least once a month and certify
an
Surface
same,
(:leaning and Stripping

Remove strippable protective shop coatings as required.
Mask off all plastics, rubber, fabric, joints, parts, and
plated areas that might be damaged by paint strippers,
chemical solutions or water by using aluminum foil or
fabric tape and visqueen polyethylene film.
to remove any
Aftel final rinse and while still wet, apply alodine by

brush or spray. Refer to 20-40-30.
The alodine surfaces must dry a min of 1 hour or until
moisture free. Ensure removal of moisture from seams,
gaps around fasteners, etc.
Preparation
Chemical Film (MIL-C-5541)
shop
coats of
The primer must be applied within 24 hours aftel aiodining, subject to the following conditions.
Time After Alodining
paint.
Action Before
Priming
preparation \~.hen
dry
1-4 hours
No further
clean and
4-24 hours
Solvent clean
Refer to 20-10-45.
Remove loosened paint and contaminants with aid of a
bristle brush and high pressure water spray, then dry
surface. Refer to 20-10-45. An alternate method of
removing paint is by lightly scouring the paint area with
abrasive pads (Scotchbrite), Grade A or finer, moistened
with MIEK.
Final traces of organic residues must be removed by
sol vent cleaning. Ensure complete removal of all residues
from gaps, seams around fasteners, etc.
Abrading
Unpainted metal surfaces must be abraded and a water
break free surface must be achieved and then alodined.
Mixing and Handling

Epoxy-Polyamide
Primer
(MIL-P-23:377
Class 2)
Stir Component I thoroughly until pigments are mir;ed.

Mix on Red Devil shaker or equivalent. Reduction
of Component I (pigmented solution) with Component II
(clear solution) must be 1 volume to 1 volume. Temperature of components must be no lower than 600F (160C)
before mixing.
Component I into an empty container allowing

adequate time for complete drainage. Slowly pour Component II into Component I while constantly stirring.
Proper drainage time must be allowed for Component II.
Pour
20-30-30
0
Page 3
Aug 31/84
SR-76-023

SABRELINER AIRCRAFT EXTERIOR SURFACES (C/ontinued)
Mixing and Handling (Contd)
Imron Polyurethane Enamel
Each container of Components I and II may be rinsed with

the non-photochemically reactive solvent type thinner,
Component II must always be added to Component I.
Never reverse this procedure.
Stir Component I (Imron pigmented base material) thoroughly until pigments are mixed. Mix on a Red Devil
shaker or equivalent. Add 1 volume of Component II (192
S Activator) to 3 volumes of Component I. Temperature
of components must be a min of 60"F (16"C) before
mixing.
First pour Component I into
Ne?,er mit epozy primer from one vendor

with primer from another vendor. Components also are not interchangeable.
adequate time
for
an empty container with

complete drainage.
NOTE
Thin 2 volumes of the Class 2 admired
primer for
spraying by adding approximately 1 volume of non-photochemically reactive thinner which is compatible with
Class 2 primer as specified in MIL-P-23377 and manufacturers directions. The spraying viscosity must have a
range
of from 17-19 seconds when checked with
No. 2
%a.hn cup.
Stir the thinned primer thoroughly, strain thru 2 paint

strai n i ng fun nels or 2-3 layers of ii nt-free cheesecloth and
allowed to stand at room temperature under agitation for
1 hour before using. The standing period for primer is
necessary for the components to enter into chemical
reaction,
Mix epoxy primer only in that amount that can be used in
8-hour shift. Discard all material that is 8 hours old,
regardless of appearance.
an
Open Component II can carefully. niscard

Component II if material is not clear or has
turned dark.
Pour Component II slowly into Component I with constant
stirring. Allow proper drainage time for Component II.
Each container of Components I and II may be ri nsed with
8485 S Reducer. Always add Component II to Component
I; never the reverse.
Never mix Polyurethane paint from one vendor with
another vendor. Components of different
colors from the same vendor may not be interchangeable.
Check components and batch numbers to assure compatibility for proper curing. Viscosity must be 18-20 seconds
when checked with a No. 2 Zahn cup. Stir the thinned
paint thoroughly and strain through 2 paint straini?g
funnels or 2-3 layers of lint-free cheesecloth before
paint from
Polyurethane Topcoat
spraying.
SB0125-025 Polyurethane Coating (Alumigrip)
Mix only the amount which can be used in one shift. Pbt
life of the admired topcoat in a closed container is 8 hours.
Discard the paint after 8 hours regardless of appearance.
Stir
Mix
Component I thoroughly until pigments are mixed.

Red Devil shaker or equivalent. Add 1 volume of
Component II to 1 volume of Component I. Temperature
of components shall be a min of 60"F (16"C) before
on
mixing.
First pour Component T into an empty container with
adequate time for complete drainage.
NOTE
Open Component II can carefully. Discard

Component mifmaterial is not clear or has
turned dark.
Shelf Life of Coating Materials

Unmixed materials (primer and topcoat) may be stored
a max period of 1 year from date of
acceptance when stored at temperatures within the range
of 35 to 950F (2 to 35"C) and the peak air temperature
must not exceed 115"F (460C). After this storage period of
1 year, the coating materials may be retested for acceptance for another storage period of 6 months. Precautions
must be taken during the storage and handling of the
paints and thinners to prevent water contamination.
unopened for
slowly pour Component II into Component I with

stirring. Allow proper drainage time for Component II. Each container of Components I and II may be
rinsed ~ith the non-photochemically reactive thinner.
Always add Component II to Component I; never the
Then
constant
reverse.
20-30-30
Page 4
Aug 31/84
CO$YRIGHT, 1984 BY SABRELINER CORPORAIION
SR-76-023

Film
Adhesion C:heck
A tl ry adhesion Icst m list be eonductc!d on Ihe 8i Iylane kst.

panel (see below) after the application of the top coat. If
failu ~e occurs, dZuality Engineering shall be immediately
further action may be taken. Basic topcoats
must dry a min of 48 hours before dry tape test and 8 days
for wet test. (Refer to adhesjBn test.)
informed
magnification lens, there must be no evidence of

microcracks, except that after flight tests, slight microcracks around highly stressed fasteners will not be cause
for reject.ion. A slight surface orange peel effect. is not
6X
Adhesion, Thickness, and Finish
f,,
rejection.
Gloss
so
The white topcoat shall have the gloss value measured

with a Gardener 60" gloss meter and the average measurement shall not be lower than 85%.
Test Panels
painting an aircraft use 4 3 x 5 in. aluminum test

panels (positioned vertically and placed in the vicinity of
the aircraft). Finish in the same manner as the aircraft.
Upon completion, measure the panel for primer thickness
Film Thickness Tests
When
and for total system thickness and adhesion test. The

results should then be recorded in the inspection sign-off
record. Record the aircraft number, date painted, and
system applied, including paint batch numbers.
Dry Tape Test
parallel scratches 2 in. long and 1 in. apart down

Apply a strip of masking tape (3M Co.,
No. 250 or equivalent) horizontally across the test area,
pressing down firmly by hand. Grasp the tape by one end
and rapidly remove with one abrupt motion maintaining
an angle of I)O"F. Examine the tested area for any paint
Make 2
to the bare metal.
damage (i.e., removal
or
damage of
any
portion
of the
paint system).
Wet
Tape Test
Place a piece of cheesecloth or filter paper that is 3 in. min

diameter and 1/8 in, thick and saturated with tap water
onto the painted surface. Overlay with a piece of barrier
material such as grease-proof paper with the coated side
of the paper contacting the wet ~ad.
After 24 hours remove pad and wipe surface dry with a
clean, soft cloth. Apply a strip of masking tape (3M Co.,
No. 250) across test surface and press down firmly by
Film thickness tests should be conducted on all painted

surfaces. A random sampling technique should be
employed. The locations measured and the thickness
measured should be recorded and made part of the
inspection sign-off record. The basic gloss white paint
thickness measurements over 70% of the area must be
within 2.3-3.2 mils total dry film thickness. Areas that
have additional overcoats of International orange or flat
black colors or insignia and markings must not exceed 4.5
mils total dry film paint thickness. Film thickness may be
determined by use of a Dermitron or equivalent instrument.
Repairing Damaged Paint Area

Stripping. of the Paint System
polyurethane topcoat and epoxy primer
stripped using neutral paint remover, Turco No.
5351. A small residue of the epoxy primer may be left on
the stripped surface which may be removed by Scotchbrite
pads and MEK.
If necessary, the
may be
Balanced Control Surfaces
NOTE
The paint film thickness is critical
balanced control surfaces.
on
touch-up balanced control surfaces unless damage

repaired is minor and does not exceed approximately
1 square inch in area. If major repairs are required,
completely strip and refinish the entire control surface.
Do not
hand. Grasp tape by one end and rapidly remove with one
abrupt motion maintaining an angle of 90"F to the
surface. Examine test area for paint damage.
to be
Smoothness
Cleaning of Polyurethane Cured Paint Film
Visually inspect the epoxy primer surface for specks and

bumps. There must be no seediness or roughness.
Removal of boot marks, bugs, etc. from cured painted

surfaces can be accomplished by a MEK or watermoistened clean cloth. Do not use Bon Ami or other
cleaners containing abrasives, chlorine or alkali
Appearance
The final coatings must have a smooth, uniform appearance. The finish must be free of dried overspray, runs,
with a
sags, and blisters. In addition, when examined
c0mp0u"ds.
20-30-30
0
Page 5
Aug 31/84
SR-76-023

Repairing Damaged Paint Area (Contd)
Touch-up of Damaged Paint
Topcoat Application
Film
NOTE
Surfaces requiring touch-up must be cleaned, using MEk,

since contamination of any kind will cause poor adhesion,
cratering, and premature film failure. Treat any paint
areas scratched or abraded to the bare metal as outlined
in
The first coat of polyurethane will not dry

sufficiently to be touched or walked on 90
that
Abrading.
San d i ng the cured pal n t fi Im removes th e gloss and causes

coating deterioration. The touch-up of any scratches or
damaged areas is restricted to that which can be accomplished by brush. Overspray cannot be removed from the
topcoat. If the damaged area cannot be touched up by
brush, it is recommended that the surface be masked off
at skin or part breaks and the damaged area stripped for
refinishing
as
specified originally.
Polyurethane System Application

Operations Prior
to
Painting
Before application of epoxy primer, mask off areas not to

be painted, such as radomes, canopies, intake duct leading
edges, etc. Use Mystik No. 6230 masking tape or equivalent. It is mandatory that rubber or nylon gloves be used
when touching the aircraft surfaces until the topcoat has
been applied and dried.
must be taken not to lean
on the
allow the hoses to touch it
between the first and second topcoats.
care
aircraft
or
Apply the polyurethane topcoat by spraying over epoxypalyamide primer, which has been allowed to dry 3-24
hours at 60 to 900F and a relative humidity of 25-75%.
Apply a wet, thin coat of polyurethane, air-dry 30-45
mi"utes, then spray a full wet cross coat to a total dry film
thickness of 1.7-2.3 mils. Large areas requiring the
topcoat, such as the top surface of wings, fuselage, etc.,
which must be walked on to properly apply the topcoat,
may have the topcoat applied by the cross coat technique
to achieve the required dry film thickness in one application instead of the two-coat system above. Large areas of
the aircraft that will be overcoated by colors other than
gloss white, such as stripings, International orange or flat
black, must be painted with only the fi rst coat Of the basic
topcoat and the second coat should be "feathered" irl at the
edges
of these
areas
to reduce the total film thickness. If
the basic topcoat dries over 36 hours before the colors are
applied, sand the surface with 400 grit abrasive paper and
tack off before the colors
Primer
Application
are
applied.
NOTE
NOTE
Spray
The temperature of the surface to be primed

an.d the primer should be between 60 and
800F.
After completion of the waiting period specified, spray
the admired and thinned epoxy primer with 1 wet cross
coat to a dry film thickness of 0.6-0.9 mil. Allow to air dry
for a min of 3 hours before applying topcoat.
Walkway Areas Masking

After application of the epoxy primer and before the
application of the topcoat, mask off areas to be finished
with walkway coating.
and other equi~ment should be

cleaned using IMEK thinner as soon as the
epoxy primer and polllurethane topcoat
have been applied. Cleanliness must be
ezercised sinCe both these materials, once
eured, are most d~fficult to dissolve.
Drying or curing time for the polyurethane topcoat is

specified as "dry hard" within a max time of 12 hours. The
actual drying time depends on the temperature and
humidity of the spray room. The higher either or both are,
tire more rapid the curing of the topcoat.
Smoothing of Epoxy Primer

Santl primel surfaces to
remove nibs, dirt and other

prin~el coating imperfections before applying the polyurcthanr toy,roat. Acclomplish the smoothing by using
Scot.chblite ol No. 400 grit abrasive paper. Immediately
priol to applying the topcoat, air blow and tack off the
airclaft using tack rags. Wipe lightly with tack rags but
do not allow tack rags to lay on the surfaces to be painted.
20-30-30
Page 6
Aug 31/84
1984 BY SA&RELINER CORPORATION
SR-76-023

Polyurethane System Application (Contd)
Z,eading F,dffe Coating
The leading edge of engine ducts and cowling, wings, and
stabilizers, except where in conflict with blueprint
requirements of a different coating, must be primed and
painted in the same manner as the aircraft. After the
topcoat has cured (8 hours) areas adjacent to the leading
edge areas must be masked off and additional coats tallow

at least 30 minutes of drying time between coats) of the
polyurethane topcoat must be applied so that the total dry
film thickness (primer plus topcoats) is built up to 3.5-4.5
mils.
If drying time exceeds 36 hours between applications,
sand surface with 400 grit abrasive paper and tacked off
prior to application of additional coats.
NOTE
Where topcoats have sharp leading edges
exposed to the airstream, the coating should
be feathered to produce aerodylzamically
smooth surface to preclude coating erosion
duringflight.
An alternate method for the
application
of the additional
co;lting thickness on the leading edges is to free spray

(without masking) the additional topcoats required at the
time that the topcoating is being performed. (Refer
Topcoat Application.)
same
to
Insignia and Marking Application

Masking for insignia and marking may be begun after the
coating has dried tack free, a min of 8 hours. If drying
time exceeds 36 hou rs between applications, sand surface
with 400 grit abrasive paper and tack off prior to
application of additional coats.
Walkway Coating Application
Apply MI11-W-5044 Type II walkway coatings as specified

in MIIJ-W-5050 except the walkway coating must be
applied directly to surfaces primed with epoxy primer.
20-30-30
0
Page 7/8 Blank

Aug 31/84
SR-76-023
MIL-C-83286 POLYURETHANE ENAMEL APPLICATION
(;ENERAI,
This section covers materials, procedures, and requirements for the application of an epoxy polyamide primer
and polyurethane topcoat finishing system to the exterior
of aircraft.
to the external environ-
areas normally exposed

during flight or on the ground,
All well
ment
are
considered
exterior surfaces.
MATERIALS
Trichlaroethane, 1, 1, 1,
Technical, Inhibited
Naphtha
Lacquer Thinner
Paper, Kraft, Untreated Wrapping
Non-Slip Walkway Compound
Aluminum and Aluminum Alloys
Non-woven, Non-metallic Abrasive
Mat (Require Type I, Class 1 or
2, Grade A or Finer, Scotchbrite
(3M Co.)
or
0-T-620
TT-M-261
TT-N-95 (Type
TT-T-266
UU-P-268
MIL-W-5044
MIL-C-5541
MIL-A-9962
equivalent)
MIL-P-23377C
Chemical and Solvent Resistant

Eltoxy Polyalnide Primer
Air
(:oating(Require Class 2
(SB0125-024)
Non-Polluting)
MIL-C-25769
Surface Alkaline Waterbase
(Turco Air Tech No. 19)

Aliphatic Polyurethane
Coating Thinner
Coating Urethane, Aliphatic
Isocyanate, for
Aerospace Applications
Primer (MIL-P-23377C) Thinner,
Non-Photochemically Reactive
and Compatible with Primer
Aluminum Foil or Fabric Tape
Cheesecloth

Tack Rags
No. (;R-99 Bostik
MIL-T-81772
MIL-C-83286
Tape, Masking (:SM Co., No. 250 or

Mystik No, 6230 or equivalent)
Chemical Cartridge Respirator
No. R21 Cartridges)
Coveralls, Lint-free
Caps, Painter Type
Glasses, Goggles or Face
Shields, Safety
Striping Brushes
Commercial
Commercial
Commercial
Commercial
Commercial
Commercial
Commercial
Commercial
Commercial
Commercial
Commercial
Commercial
EQUIPMENT
II)
Spray Guns and
Hoses
The spray guns and accessories used must conform with

table 1 requirements or equivalent.
The fluid line must have a min ID of 3/8 in. from tank to
gun, and not exceed 75 ft in length.
High pressure air hoses leading to regulator or tank must

have a min ID of 7/16 in., and a max length of 150 ft. Air
hoses from tank to gun must have a min ID of 5/16 in., and
a max length of 75 ft.
Recom mended pressure settings for flu id tank, re)Su latol.,
and spray gun are given in table 2.
INSTALLATION NOTES
Safety Precautions
This process involves materials and operations which
hazardous.
are
and primer compoall ordinary precautions such as adequate ventilation and absence of open
flames should be observed. All aircraft should be
grounded as static charges can build up, especially ~hen
The
Commercial
Commercial
polyurethane vehicle, thinner,
nents contain flammable solvents
using
spray
so
equipment.
niv., USM Corp., Middleton,

MA
or
equivalent
Blue Indicator Paper

Rubber Gloves (Rubber Base or
Thymol
Commercial
Commercial
Nylon)
Wet-or-Dry Abrasive
Paper (3M Co.)
400 (;Fit
Commercial
20-30-35
0
Page 1
Aug 31/84
SR-76-023
MIL-C-83286 POLYURETHANE
ENAR;ZEL APPLICATION (Continued)
Safety Precautions (Contd)
turbulence and excessive air currents and must be maintained at a min of 125 fpm at the exhaust in the painting
area. Exhaust room air thru an exhaust system immediately at one end of the aircraft or part being painted so
that overspray does not drift into other areas of the room.
isolate the painting
procedure from exposure of nearby

personnel. Only painters must be allau~ed in the spraypain ting and adjacent areas. Spray painters must be fully
clothed in coveralls and caps with collars buttoned and
sleeves taped at the wrists.
Floors
Solvent-resistant gauntlet style gloves (natural rubber or

neoprene) must be worn by personnel engaged in the
mixing and application of polyurethane paint.
room floors must be kept clean, and free of rags,

paper and other debris. Hose floors down at the beginning
Spray
Painters, and others, when mixing and spraying

polurethane paint must wear a chemical cartridge
of each shift and in the area of the aircraft approx imately

1 hour before the beginning of the pal nting of the aircraft.
Additional floor wetting may be required to keep the
respirator,
overspray and other dust contained
Apply these coating systems only with adequate ventilation. Avoid contact with the skin and eyes. Do not ingest.
Do not inhale vapors. WASH HANDS BEFORE EATING
OR SMOKING. Contact of liquid or
with eyes may
cause severe irriation. In case of skin contact, wash with
soap and water. In case of eye contact, immediately wash
eyes for at least 15 minutes: get medical attention.
Doors
on
the floor.
Hangar doors must not be opened for an hour before,

during, and for at least 2 hours after the painting of an
aircraft with the basic topcoat system. Restrict personnel
doors so that only 1 door to the outside is available to foot
traffic
during this time period.
Lighting
The spray room must be well illuminated (recommend a
min of 50 ft-candles), using vapor and explosion-proof
lights, and floor lighting equipment, when necessary.
Air
The paint spray room must use filtered air. The amountof
air forced into the spray room must exceed the volume
withdrawn. Introduce air in such manner as not to cause
Table i.
Spray Guns
and Accessories
TANK GUN
TYPE GUN
FLUID TIP
DeVilbiss JGA
ol TEA Model
Table 2.
or
FX
FF
or
AIR CAP
FX
FLUID TIP
EX
765
or
EX
NEEDLE
EX
or
AIR CAP
EX
30
Pressure Settings
FINISHING
MATERIAL
FF
NEEDLE
CVP GUN
FLUID TANK
SETTING
AIR REGULAZ~OR
SETTING
AIR PRESSUHE
AT SPHAY (;UN m
EpoxJ Primer
8-12 psi
60
psi
45
psi
Polyulethane Topcoat
8-12
65
psi
50
psi
psi
Add 1 Ib of fluid pressu Ie fol each ft of heightof the gun

above the fluid tank level, for normal operation.
G1

determine air pressure at the gun.
test gauge to
20-30-35
Page 2
Aug 31/84
COPYRIGHT, 1984
SR-76-023
COHKOSION CONTROL MANUAL

Re-abrade and rinse
break free" surface.
Facility Requirements (Contd)
lemperature and I-lumidity

dry i ng. The temperature of the spray room must be in the
and
ranae of 60 to 950F (16 to 350C) 1 hour before, during,
for 4 hours after spray painting this paint system. The
relative humidity must be in the range of 25-759/0, during
this
same
time
period.
rressurized Air Source
are
cleaned
Surface
or
changed
at
regular intervals.
Preparation
Cleaning and Stripping
"water-
Rinse with high pressure water rinse while agitating to

removal of all sanding residues from ablacied
surfaces,
gaps, seams, etc.
After final rinsing and while aircraft is still wet, check

several scattered areas of the aircraft for neutrality.
Touch Thymol Blue indicator paper to the wet surface. If
the paper remains yellow in color the surface is neutral; if
the paper turns blue, the surface is alkaline and must be
rinsed again. Repeat rinsing and testing until the surfaces
neutral.
Chemical Film Treatment

While surface is still wet, apply Brush Alodine 1200 treatment (or equal MIL-C-5541 treatment) to all unanodized
exterior surfaces. Thoroughly rinse, removing all traces
of Alodine 1200 and repeat water-break free test. Anodized surfaces may be given 1 treatment of Alodine 1200
where required. Where the anodized surface is scoured.
the brush alodine system is mandatory.
Remove strippable protective shop coatings as required.

Mask off all plastics, rubber, fabric, joints, parts, and
plated areas that might be damaged by paint strippers,
chemical solutions or water by using aluminum foil or
fabric tape and visqueen polyethylene film.
necessary to achieve
ensure
are
Air lines must be blown out at least twice each day

(oftener, if necessary) when painting an aircraft to purge
lines of any oil or water. As a further precaution, all air
lines mustcontain an air filter and water separator which
as
(Continued)
to remove any
shop
coats of
paint.
chemical film
epoxy primer within 24 hours after
treatment. All surfaces must be thoroughly "dry" before
application of the epoxy primer.
Apply
Mixing and Handling
Epoxy-Polyamide
Primer
(MIL-P-23377 Class 2)
Itc~move the loosened paint and contaminants with aid of a

bristle brush and high pressure water spray, then dry
surface. An alternate method of removing paint is by
I iff htly scouring the paint area with abrasive pads Scotchbrile), Grade A or finer, moistened with MEK.
Thoroughly stir Component I until pigments are mixed.

(Use shaker or equivalent method.) Reduction of Component I(pigmented solution) with Component Il(clear
solution) is 1 volume to 1 volume. Temperature of components must be above 600F (160C) before mixing.
Remove final traces of organic residues by solvent cleaning. Ensure complete removal of all residues from gaps,
Component I is first poured into an empty container with

adequate time for complete drainage. Component II then
is slowly poured into Component I with constant stirring.
Proper drainage time must be allowed for Component II.
seams
around fasteners, etc.
Abrading
Unpainted metal surfaces
must be abraded and
water-
break free surface achieved.
Thoroughly abrade metal surfaces with water and

abrasive nylon pads. Ensure that the heads of all plated
fasteners have been abraded. Spray water rinse immediately. While still wet, determine if a "water-break free"
surface has been achieved.
If the water film gathers into discrete droplets within 25
seconds after application of water, the surface has failed
the test. If the water film stays in a continuous film of
water (without a sudden flashout or the forming of droplets) then the surface shall be considered as having
satisfactorily passed the "water-break"
test.
the
non-photochemically
reactive solvent type thinner.
Component II must always be added to Component I. and

this procedure must not be reversed.
Never mix epoxy primer from one vendor with primer
from another vendor. Components are not inter-
changeable.
Two volumes of the Class 2 admired primer are thinned
for sprayng by adding 1 volume of non-photochemically
reactive thinner which is compatible with Class 2 primer.
The spraying viscosity must have a range of from 17-20
seconds when checked with a No. 2 Zahn cup. The thinned
paint must be stirred thoroughly, strained through paint
2-:3 layers of lint-free cheesecloth)

and allowed to stand at room temperature for 1 hour before
straining funnels (or
20-30-35
0
Page 3
Aug 31/84
SR-76-023
MIL-C-8328(i POLYURETHANE ENANEL APPLICATION (Continued)

Mixing
and
Handling (Contd)
Shelf Life of Coating Materials
Epoxy-Polyamide Primer (MIL-P-23377

(Contd)
Class 2)
using. This period shortens drying time, reduces cratering, allows any bubbles (formed by mixing) to escape, and
is a preliminary period for the components to enter into
handling of the paints
and thinners to prevent water
chemical reaction.
ca8tamination.
Epoxy primer should be admired only in that amount that

be used in an 8-hour shift. Discard, regardless of
Film Adhesion, Thickness,
can
appearance, all material that is 8 hours old.
and Finish
Adhesion Check
Pol!-urethane Topcoat
The
Thoroughly
topcoat system has been allowed
Component I until pigments are mixed,

Mix on shaker or equivalent method. One volume of
Component II is added to 1 volume of Component I.
Temperature of components must be above 60"F (16"C)
stir
before mixing,
First poul Component 1 into an empty container with
adequate time for complete drainage.
Open Component II
can
if material is not clear
carefully. Discard Component II
or
has turned dark.
Slowly pour Component II into Component I with constant

stirring. Allow proper drainage time far Component II.
the non-photochemically reactive solvent type thinner,
MIL-T-81772. Component II must always be added to
Component I, and this procedure must not be reversed,
4
The unmixed materials (primer and topcoat) may be

stored unopened for a max period of 1 year when stored at
temperatures within the range of 35 to 950F (2 to 35"C)
and the peak air temperature must not exceed 115"F
(46"C). Precautions must be taken during storage and
Never mix polyurethane paint from one vendor with paint

from another vendor. Components of different colors from
the same vendor may not be interchangeable. Check
components and batch numbers to assure compatibility
for proper curing. For spray application, thin the admixture with solvent conforming to MIL-T-81772 to a viscosity
of approximately 18-20 seconds when checked with a No.
2 Zahn cup. The thinned paint must be stirred thoroughly
and strained thru paint straining funnels (or 2-3 layers of
lint-free cheesecloth) before spraying.
Mix only the amount which can be used immediately The
pot life of the admired topcoat in a closed container is 6
hours.
Clean splay equipment, guns, lines, and pressure pots
tholoughly both before and immediately after use with
MEK. When MEK is not available,

conforms to MI1,-T-81778.
use
the thinner that
following adhesion
test may be conducted after

to air-dry a min of 168
hoUS.
Randomly select areas to be tape tested. If failure occurs,

select, additional areas to determine extent of faulty
adhesion.
To check pal nt adhesion, a piece of cloth or sponge is taputl
the area under test and the cloth or sponge kept soaked
for a min of 24 hours with tap water. Immediately after
removing the wet cloth or sponge and blotting the surface
water, apply a 1 in. wide strip of masking tape (Code No.
250, 3M Co.; only newly manufactured tape shall be used)
adhesive side down. The tape is pressed down using 2
passes of a4-1/2 Ib rubber roller, or by firm pressure with
the hand. Remove the tape in one abrupt upward motion
(900 to surface) and examine the tested area for any paint
damage such as removal of paint at one of the layers of the
finish system or removal of the entire system from metal.
on
Film Thickness
Film thickness tests may be conducted on all painted
surfaces. The basic gloss white paint thickness measurements over 70% of the area shall be within 2.3-3.2 mils total
dry film thickness and the average thickness shall not be
greater than 3.2 mils. Areas that have additional overcoats
of color or markings must not exceed 4.5 mils total dry film
paint thickness. Film thickness may be determihed by use
of a Permascope or equivalent instrument.
Film Finish
Check the epoxy primer surface for specks and bumps by

drawing gloved finger tips across the finish. There must
be no seediness or roughness.
The final coatings must have
a smooth, uniform appearfree of dried overspray, runs, sags, and blisters.

When examined with a 6X magnification lens, there
should be no microcracks. (After flight, slight microcracks around highly stressed fasteners are not cause for
refinishing.) A slight surface orange peel effect is not
cause for refinishing.
ance,
20-30-35
Page 4
Aug 31/84
C~PYRIGHT, 1984
BY
SA~RELINER CORPORATION
SR-76-023

Film Adhesion, Thickness, and Finish
Iilm Finish
(Contd)
of 3 hours and
a max
(Continued)
of 4 hours I,efore applying tol,zoat.
NOTE
(Contd)
The temperature of the surface to be primed

and the primer should be between 60 and
90"F (2 6 a.nd 35"Cj).
NOTE
or rippling is caused by too high
air pressure. Orange peel and sags
result when the air pressure is too low or
the fluid pressure is too high. Both epozy
primer and the polyurethane topcoat build
up in thickness ve~ rapidly.
nustilzg
an
The white topcoat gloss value can be measured with a

Gard ner 600 gloss meter. The average measurement must
not be lower than 80%.
Nibs, dirt, and other primer coating imperfections
must
be smoothed or repaired before applying the polyurethane

topcoat. Smooth using No. 400 grit abrasive paper.
Immediately prior to applying the topcoat, tack off the
aircraft using the GR-99 or equivalent tack rags. Wipe
lightly with tack rags and do not allow tack rags to lay on
the surfaces to be painted.
Topcoat Application
Repairing Damaged Paint Films
Surfaces requiring touch-up must be cleaned, using
ME:K, since contamination of any kind will cause poor
adhesion, cratering and premature film failure. Any
pal nt area scratched or abraded to the bare metal must be
treated with chemical film treatment,
Sand ing the cured paint film removes the gloss and causes
coating deterioration. The touch-up of any scratches or
damaged areas is restricted to that which can be accompfished by brush. Overspray cannot be removed from the
topeout. If the damaged area cannot be touched-up by
brush, mask the surface off at skin or part breaks and
area for refinishing. Epoxy primer
residue left on the stripped surface may be removed by
abrasive pads and MEK.
strip the damaged
Do not touch-up balanced control surfaces unless damage

to be repaired is minor and does not exceed approximately
1 square inch in area. If major repairs are required,
completely strip and refinish the entire control surface,
The paint film thickness is critical on these surfaces.
POI,YURETHANE SYSTEM APPLICATION

Before application of epoxy primer, mask off areas not to
be painted with the basic topcoat, such as, radomes,
canopies, intake duct leading edges, etc. Immediately
prior to painting, wipe the aircraft down with lint-free
cloths moistened with MF,k to remove dust and dirt.
Follow i ng this cleaning operation, rubber or nylon gloves
must be used when touching the aircraft surfaces until the
topcoat has been applied and dried.
Primer
The polyurethane topcoat is sprayed over epoxy-polyamide primer which has been allowed to air-dry 3-4
hours. Apply a wet, thin coat of polyurethane, allou~ to
air-dry for 15-30 minutes, then spray a full wet cross coat
to a total dry film thickness of 1.7-2.3 mils. Large areas
requiring the topcoat, such as the top surface of wings.
must be walked on to properly apply
th, topcoat, may have the topcoat applied by the box coat
technique to achieve the required dry film thickness in
one application instead of the two-coat system above.
Large areas of the aircraft that will be overcoated by
colors other than gloss white must be painted with only
the first coat of the basic topcoat and the second coat
feathered in at the edges of these areas to reduce the total
film thickness. If the basic topcoat dries over 24 hours
before the colors are applied, the surface must be lightly
sanded with 400 grit abrasive paper and tacked off before
fuselage, etc., which
the colors
are
applied.
The first coat of polyurethane will not dry sufficiently to

be touched or walked on between the first and second
topcoats. Do not lean on the aircraft or allow the hoses to
touch it.
Drying or curing time far the polyurethane topcoat is "dry

hard" within a max of 8 hours. Actual drying time
depends on the temperature and humidity of the spray
room. The higher either or both are, the more rapid the
topcoat
cure.
Application
After completion of the waiting period, the admired and

thinned epoxy primer must be sprayed with 1 box coat to a
dry film thickness of 0.6-0.9 mil. Allow to air dry for a min
20-30-35
0
Page 5
Aug 31/84
SR-76-023
C()RROSION CONTROL MANUAI,
(Continued)
Topcoat Application (Contd)

NOTE
Spray and other equipment should be

cleaned using MEK or MIL-T-8lrr~
thinner as soon as the epoxy primer and
pol2lurethane topcoat have been applied.
ClcanbineRs must be ezarc1:ssd since both
these ,rLatc!rials, ortce eu.red, are dZfficult to
dl:SSO11)P.
Prime and paint leading edge of engine ducts, cowling,

wings, and stabi liters in the same manner as the aircraft.
After the topcoat has cured (8 hours), mask off areas
adjacent to the leading edge areas and apply additional
coats tallow at least 30 minutes of drying time between
coats) of polyurethane topcoat so that the total dry film
th ick ness (pri mer plus topcoats) is bu i It-up to 3.5-5.0 m i Is.
tIf drying time exceeds 24 hours between applications,
surf ace must be sanded with 400 grit abrasive paper and
tacked off prior to application of additional coats.)
An alternate method for the application of the additional
coating thickness on the leading edges is to free spray
(~ithout masking) the additional topcoats required at the
same time that the topcoating is being applied.
Insignia and Marking Application

M as k i nR for i nsign ia an d mark i ng m ay be beau n after the
a min of 8 hours. If drying
ti m e ex ceed s 24 hou rs between appl i cations, surface m ust
be lightly sanded with 400 grit abrasive paper and tacked
off prior to application of additional coats.
coating has dried tack free,
20-30-35
Page 6
Aug 31/84
COiPYRIGHT,
SR-76-023
HIGH INIPACT POLYURETHANE COATING APPLICATION

(;ENEKAL
Safety
lhis section covers the materials and procedures for the

application of a high impact polyurethane coating.
Solvents and coating materials are toxic and flammable.

Observe fire, health, and safety precautions to pleclude
injury to personnel or damage to equipment and facilities.
MATERIALS
Mixing and Handling
TT-M-261
Methyl Ethyl Ketone

(MEK)
Topcoat, 821X398, Color
The topcoat is a two-part catalyzing material that is

purchased and stocked as a kit. When mixing, use only the
catalyst indicated for use with the applicable base
Commercial
component.
6011, DeSoto Chemical Co.

Topcoat, Catalyst, 910X152,
Commercial
Mixing Ratios:
DeSoto Chemical Co.
DeSoto Chemical Co.

Scotchbrite Pads, Type A
(~M Co.), Aluminum Oxide
400 Grit,
2.0 parts
1.0 parts
0.5 parts
Commercial

Topcoat Thinner, 020X310,
with
No. 2 Zahn cup.

a
5 minute chemical reaction time before
using the
The usable pot life of the catalyzed topcoat in a closed

container is 4 hours. When left in an open container the
work life will be shortened.
Brothers, I,.A., CA
EQUIPMENT
Pressure
Thinner, 020X,310
catalyzed material.
Commercial
Wipers, Sandler
Allow
Commercial
Paper
Select Cotton
Base Component, 82123398

Catalyst Component. 910?(152
Viscosity should be 16.0-18.0 seconds when measured
Commercial
Commercial
Wet-or-Dry Abrasive
by volume
by volume
by volume
Mix/agitate catalyzed material just before and during use.
Spray Gun
17se a DeVilbiss MBC Spray Gun with a FX needle and

nazzle and a No. 765 air cap. Regulate air pressure as
follows:
6-9
i.
Pressure feed tank air
2.
Atomization air at spray gun
Always strai n the catalyzed mate ri al th ru pal nt strai ni ng

funnels, prior to filling spray gun containers.
prior
to
Air
psi.
.55-65
psi.
coating to d ry per one of the follow ing schedules

handling.
Allow the
Dry:
6 hours min at ambient temperature.
Force Cure: Allow to air dry 1 hour min, at ambient

expose to a temperature of 170
temperature, and then
to 1800F for 30 minutes min.
Siphon Cup (;un

IJ se a I)eVi Ibi ss M BC Spray Gun with an E needle, nozzle
and No.:30 air cap. Regulate air pressure to 55-65 psi.
APPLICATION NOTES
Paint
Surface Preparation
Ensure all surfaces have been properly treated, as required below prior to coating application of high impact
material:
Spray Reem Requirements
Aluminum chemical film treat
I,ighting
The spray room must be well illuminated,
and explosion-proof lights,
Reinforced
using
vapor
Floors
plastic laminates
or
anodize.
clean and fill surfaces.
epoxy primed parts: Thoroughly abrade

primed surfaces using Scotchbrite Pads. Type A, and
wipe with clean cotton wipers dampened with MFJK to
Previously
remove
all sanding residues.
Sl,ray room floors must be clean and free of rags, paper

and other debris.
lemperature and Humidity
The temperature of the spray room must be in the range of
60 to 90"F 1 hour before, during, and for 4 hours after
be
spray painting this system. The relative humidity must
in the range of 25-75Yo.
20-30-40
0
Page 1
Aug 31/84
SR-76-023
HIGH IMPACT POLYURETHANE COATING APPLICATION

Finish
(Continued)
Requirements
The
coating system must be free of defects which affect its

performance such as bubbles, pin holes, craters.
The specular gloss of the
85, when measured with
applied topcoat must be a min of

a 600 gloss meter.
APPLICATION OF COATING
Prime,
ilpply a coat of SB0125-024 epoxy polyamide primer to

the sulfaces which have been cleaned and prepared.
Topcoat
SDray apply a full wet cross coat of material mixed to a

dry film thickness of approximately 1.5-2.5 mils. Allow to
air dry 1 hour. then apply a second wet cross coat. The
total dry film thickness of the topcoat system should be
3.0-4.5 mils.
20-30-40
Page 2
Aug 31/84
COPYRIGHT,
SR-76-023
CORR()SION C()NI~ROL MANIIAI,
URETHANE FINISH SYSTEM FOR

SABRELINER AIRCRAFT EXTERIOR SURFACES
SURFACE PREPAHATION
(;ENI1:RAI,
Il-lis section establishes the recruirements for a paint
finish system for the exterior surfaces of Sabreliner
ai rcraft. This paint system is appl icable to the appropriate
for each ai rcraft or
ex ter ior pal nt and markings d rawings
The follow ing procedu re and precauti ons m u ~t be fc,l low ed

to prel,l-lre the aircraft for final paint applications
motiel.
Before painting, metal surfaces must be properly cleaned

and stripped, otherwise an unacceptable paint job will
materials
occur. Stripping must be accomplished using
and procedures established in 20-30-25.
rho primer to be used is

material,
two-component urethane
7he topcoat is a two-component

urethane enamel.
aliphatic isocyanate
Cleaning and Stripping
Masking
including well areas

external environment during flight or on the
All exterior surfaces of the aircraft,
exl,osed to
ground must be finished.
Masking is required to prevent damage to windows,

windshields, radome, deicer boots, and other exterior
details of the aircraft that
are
not to be
painted.
MAL~ERIALS
Removing Shop Coating
The materials itemized below are required in performing

the process specified herein. Items identified by a specification number or a manufacturers name are known to be
suitable.
In-process protective shop coatings, such as Turco 498~ of

Fabrifilm, applied to the bare portions of subassemblies
Alumiffrip Urethane Primer

Alumiffrip Urethane Enamel
Alum~Rrip (:atalyst;
I~rethane Thinner T-7:32A

Air Iec. No. 19
(:hem ical (:onversion Coating
MHskinRl;lpe No. 250
U.S. Paint AA-92-Y-43

U.S. Paint AA-92
T~.S. Paint AA-92-C-3I3
U.S. Paint
Commercial Grade
Van Waters
Rogers
Los Angeles, CA
MIL-C-T,S/I1
3M Co.
INSTAI,LATION NOTES
priming and finish coating of the aircraft

performed in a facility suitable for the purpose.
The
must be
Air
facility must be provided with a filtered forced air

ventilating system capable of producing a dried paint
film conforming to Adhesion and Finish below.
The
Temperature and Humidity

Painting shall be done only at temperatures between 70
and 80"F and a relative humidity between 40 and 650/0.
must be removed in accordance with
Removing Sealant Residues and Markings

Sealant and/or zinc chromate residues resulting from
fastener applications and surfaces that show grease pencil
marks or other obvious shop soils must be Iemoved using
cleaning solvent
or
MEK.
Cleaning
After completion of the above items, the aircrait must be
cleaned with Air Tec No. 19. The cleaninR solution is
mixed by adding 5 parts by volume of tap watel to 1 palt
by volume of Air Tec No. 19 concentrate.
All exterior surfaces of the aircraft are to be sprayed with

the mixed cleaner and thoroughly scrubbed with tampico
brushes. After rinsing, the surfaces should be abraded
using Scotch-Brite, manually or with air driven ScotchBrite roller
pads.
Rinse the aircraft with tap water under line pressure. The
rinsing shall be sufficient to ensure complete removal of
cleaning solution and soils. Itepeat the wash. rinse. and
abrade operations above to any area when the rinse watel
"breaks" from the surface at a faster rate than the
adjacent areas, indicating that all soils have not been
removed.
Pressurized Air Source

air used for drying and spraying purposes
filtered, dry and free from dirt and oil.
Compressed
must he
suppliers instructions.
After final rinsing and while aircraft is still wet, several

scattered areas of the aircraft must be checked fot
neutrality. Thymol nlue indicator paper must I,e touched
to the wet su rface. If the pape r rem a i n s ye IloM~ th s 1 rf ace
i, neutral; if the paper. tur.ns blue, the surface is alkalinc~
and the area must be rinsed again. Rinsing and testiny
must be repeated until the surfaces are neutral.
20-30-45
0
CQPYRIGHT, 1984 BY SABRELINER CORPORATION
Page 1
Aug 31/84
SR-76-023

Chemical Film Treatment
PotLife
While the aircraft is still wet, apply chem-film solution

(refer to 20-30-30), using a spray or mop, to the exterior
areas of the aircraft. The surfaces shall be maintained wet
with chem-film solution. After application time has
expired, rinse the aircraft, blow excess water from seams
and recesses using filtered, dry air. Move the aircraft to
the spray area and allow to dry prior to paint application.
Both the
primer and topcoat are two component materiais.

Mixing must be accomplished in accordance with manufacturers instructions. The proporation of catalyst to base
material must not be varied or the curing or performance
of the coating will be adversely affected,
2 Parts
1 Part
T-732A
Alumigrip Urethane Enamel

has a
800F.
max
pot life of 8 hours
at
The urethane top coat prepared above must be applied at

dry film thickness of 1.25-2.25 mils for colors and 1.5-2.5
mils for white. Total thickness of system is 1.75-3.20 mils.
Less than this will result in lower gloss.
Maximum protection and film build is achieved by first

a tack coat followed by a wet coat.
spraying
MIXING AND HANDLING
Primer
AA-92
Preparation
AA-92-Y-43 AlumigripUrethane Primer
AA-92-C-33 Alumigrip Urethane Catalyst
Urethane Thinner as needed
Enamel topcoat should be allowed to air dry a min of 12

hours to obtain 70% hardness, or tape dry condition.
Surfaces will normally be dust dry in 4-5 hours.
If finished surface is to be recoated, lettered or a stencil
enamel is used, this must be applied within a 36-hour
period. A longer time will necessitate a light sanding to
remove g.loss before recoating or lettering.
CLEAN-UP
T-732A, MEK or cellulose

cleaning equipment.
Reduced spray viscosity 18-20 seconds, No. 2 Zahn cup.

After mixing, allow mixture to stand ~O minutes before
acetate may be used
for
ADHESION AND FINISH
application.
PotLife
AA-92
Alumigrip Primer has
Film Finish
a max
The topcoatings must have a smooth uniform appearance.
pot life of 8 hours at 800F.

PRIMER APPLICATION
All bare and previously primed surfaces must be primed,
using material prepared above to a dry film thickness of
0.5-0.7 mils.
Primer should be allowed to dry 4 hours before topcoat is
applied,
Primer should be topcoated within 48 hours. Longer
periods will necessitate a light sanding with 320- or 400grit abrasive cloth or paper and an additional light
primer coat. Tack rags must be used as required to
remove dust after sanding: wipe gently, do not apply
heavy pressure,
APPLICATION OF URETHANE TOP COAT
1 Part
T-732A
GIoss
The topcoat must have a min gloss value of 75 when

measured with a Gardner 600 Gloss Meter.
Adhesion
The applied coatings must pass the tape test described
below. The test must be made directly on non-mold line
surfaces of the aircraft. The test must be made on a
sufficient number of areas to assure that adhesion requirements are met. The coatings must be allowed to air dry for
min of 24 hours at room temperature before testing.
Plastic laminates must not be selected for adhesion
testing.
Paint Preparation
1 F:lrt
The finish must be free from dried overspray, runs, sags,

blisters, dirt, dust and lint. A slight orange peel effect is
ch"racteristic of polyurethane coatings and is acceptable.
Alumigrip Urethane Enamel (color

selected)
Alumigrip Urethane Catalyst
UrethaneThinner(as needed)
Adhesion tests (dry tape test) is performed

below.
as
as
described
Scratch thru the coating with a scribe made from 6061-0

aluminum. The scratch should be approximately 3 in. long.
Reduced spray viscosity 18-22 seconds, No. 2 Zahn cup

After mixing, allow mixture
application.
to stand 30
minutes before
20-30-45
Page 2
Aug 31/84
COPYRIGHT,
1984 BY SA&RELINER CORPORATION
SR-76-023

Adhesion (Contd)
a 1 in. wide strip of No. 250 masking tape (3M Co.)
that the scribed area is completely covered. Use only
newly manufactured tape. Press the tape firmly into place
by rubbing with the thumb while exerting max pressure.
Apply
so
Kemove the tape in one abrupt motion while maintaining

such as
an angle of 90" and examine for any paint damage
blistering or removal of one or more layers of paint.
Repair the scribed
area
with
brush
or
spray
coating.
Failure of the finish to meet the above adhesion test will

2 complete retests performed on the suspected
of the retests,
area of the aircraft. If the finish fails either
the suspected area, section, or entire aircraft must be
stripped and repainted. Failure is defined as removal of
25% or more of the -paint film under the tape.
require
NOTE
Bare aluminum 4 by 8 in. %0~4 panels
(anodixed) taped to the cabin window areas
(at least one on, each side of the aircraft)
and processed with the aircraft, mall be
uged~for adhesion testing,
20-30-45
0
Page 3/4 Blank

Aug 31/84
SR-76-023
WRINKLE FINISH APPLICATION

with spray
application.
(;ENERAL
1.
Clean surfaces
Ih is section covers the application ofa baked-on enamel to

mtt;lllic surfaces so as to produce a wrinkled finish,
2.
As appropriate, brush
cleaned metal I,art.
3.
Apply enamel without reduction

brushing or spraying.
4.
Allow enamel to dry, without forcing by heat

sunlight, until the wrinkle pattern forms.
5.
Do not handle finished part until 14 hours have

elapsed. Do not apply an additional Coat within 24
MAIERIAI,S
Enamel; Wrinkle-Finish, for
MIL-E-5558
Aircraft Use
Primer Coating, Zinc
Chromate, Low-Moisture-
MI7,-P-8585
Sensitivity
Xylene (For Use in Organic
Coatings)
TT-X-916
INSTALLATION
Cleaning
same as
or
spray
primer
in
coat
on
viscosity. I,y
ol
hours.
Finish Consistency
The wrinkle pattern, gloss, color, and texture of finished
parts should be consistent over entire surface regardless
of application method.
Clean metal surfaces to be wrinkle finished using methods

(contained in this chapter) appropriate to the metal
surface. Final cleaning of the surface is with xylene TT-X916 and clean rags.
Priming
After being cleaned, the metal surfaces are given 1 coat of
MII1-I-8rj85 primer.
Wrinkle Enamel
Preparation
If the wrinkling agent and the baking enamel are

packaged separately, mix the required quantity of
with the enamel and stir thoroughly. If
wrinkling agent
further thinning is required after mixing the wrinkling
agent with the baking enamel, add xylene gradually
while stirring the mixture until the desired spraying
consistency is attained.
Wrinkle EnamelApplication
Apply baking wrinkle enamel by spraying in one direction

and then in a direction perpendicular to the first. The
enameled parts must have a uniform wet-film thickness of
0.0(15-0.(308 in.
Drying and Baking
After spraying, air dry the enameled parts for 15 minutes
and then bake for 2 hours at a temperature of 200 to 2500F.
Touchup and Non-Bake Application

Inaccessible areas not easily reached by spraying and
the paint is
areas that cannot be cured by heat after
applied may be finished with an air-drying wrinkle
enamel as follows:
20-30-50
0
Page 1/2 Blank

Aug 31/84
SR-76-023
LAMINATED AND MOLDED PLASTIC PARTS FINISHING

(;ENERAI,
Dry Sanding (Alternate)
Ih is section covers the materials and procedures used for

filling minor imperfections antf pinholes in plastic laminalo surfaces Itrior to application of I,rimers and/or paint
Finishes.
After preliminary solvent wash, dry sand using wet or dry

carborundum paper, 240 grit or abrasive nylon ~,ads.
medium grit, as necessary to clean and remove gloss from
laminate surfaces and indentations. When sanding use
circular motion. All areas must present a matte al>pearance. Do not sand thru the outer ply of cloth; hou~tver.
isolated local abrasion of the cloth is acceptable.
MATEKIALS
Ey,ibond 156, Surface Filler
Furane Plastics
Los
Use filtered air blast to
Angeles, CA
U.S. Paint
Surfacer 84-A28
Commercially
Scotch Rrite Pads,

Medium (;rit
~arborundum Paper, wet
dry ((;rit size 180-400)
nenatured Alcohol
available
3M Co.
or
MIXING AND HANDLING
Mixing Surface Filler
3M Co.
Using a clean metal, glass, or polyethylene container,

thoroughly m ix the 2 components of the applicable surf ace
Commercially
filler.
available
Sandler Brothers
Los Angeles, CA
(:lean select cotton wipers
?richloroethane, 0-T-620
i, i, 1, Technical, Inhibited
all sanding residues.
Wash surface with clean cotton wipers saturated with

MEK. Wipe dry.
Lacquer Co.
Methyl Ethyl Ketone

(MF;K)
remove
Measure in the following proportions:
Epibond
Commercially
available
156
100 parts by weight No. 156 surface filler

6 parts by weight No. 956 hardener
INS1ALLATION N~)TES
Surfacer 84-A-28
Preparation
Surface
Prior to manufacture andlor fabrication of plastic parts,

mold release or parting agents are applied to tools to
fac ilitate removal of parts after cure. During this process,
the releasing agent transfers to the contacting surfaces
and may be tyansparent, translucent, or opaque in form.
Thr!se affellts must be completely removed in order to
obtain subsequent adhesion of
applied fillers and/or
paints.
Wet Sanding
(Preferred)
When surfaces
remove
are
severely contaminated,
solvents to
ul, the
wipers and
stiff
reduce
approximately
25% with T816
Work Life of Catalyzed Filler
Epibond 156 exhibits exothelmic reaction (temperature

rise) as it cures. This temperature rise during mixing and
before application reduces work life. To prevent shortening work life due to internal heat build up, the Epibond
156 may be spread in a thin layer on an aluminum sheet.
only the amount of filler that can be used during wolk
life listed below:
30 minutes
4 hours
156:
Surfacer 84-h-28:
residuals with clean wil>ers while surface is
SURFACE FINISH
Water. sand, using wet
or
dry carborundum
paper, 180-
grit.
Thoroughly rinse with clean tap water, observe water

break. (An acceptable part will momentarily support an
unbroken film of water for 30 seconds).
Remove water
spraying
reducer.
F,pibond
still wet.
400
For
Mix
heavy deposits.
Scrub repeatedly with clean cotton

bristle brush, saturated with MEK.
Wil,e
use
9 pal.ts by volume No. 84-A-28 surfacer

1 part by volume No. 84-C-13 catalyst
by wiping dry with clean
cotton
After filler has cured, sand off all excess fillel using No.
240rit carborundum abrasive paper followed by a final
sanding using No. 400 grit carborundum paper. Remove
all sanding residues using clean cotton wipers.
Apply primers and/or top
coats
as
applicable.
wipers.
Wash the surface at least twice with denatured alcohol

and wil,e tlry.
20-30-55
COPYRIGHT,
t 984 BY SABRELINER CORPORATION
Page 1
Auff.31/84
LAMINATED AND MOLDED PLASTIC PARTS FINISHING
(Continued)
FILLER APPLICATION
Apply Epibond lli6 using a plastic squeege os glazing

knife. Force filler well into the minor imperfections and
pinholes.
Remove all excess filler with squeege or knife to prevent
excessive buildup and subsequent unnecessary sanding.
Spray apply uniform wet cross coats of Surfacer 84A-28

required to ensure total coverage.
as
Allow the
applied catalyzed filler
to
cure
per
one
of the
following schedules:
Epibond 156
Air
cure
Surfacer 84-A-28
Air
dry for
for 12 hours at 770F

OR
Force cure for 1-3 hours at 1500F
1 hour at 77"F
20-30-55
Page
Aug ~1/84
CaPvRiaHT, 1984
BY
$ABRELINER CORPORATION
SR-76-023
CORR()SION CONTROL MAN1AL
ABRASION RESISTANT COATING APPLICATION

GENERAL
lh is section
(:oating"
to
covers
the
application of "Abrasion
Resistant
aluminum, aluminum alloys, magnesium
alloys, steel, and corrosion resistant steel.

MATERIALS
Wash Primer
Abrasion Resistant
Coating
MIL-C-8514
LB0125-011
INSTALLATION NOTES
Surface
Preparation
All surfaces to be coated must be free of oxides, scale, oil,

steel surfaces must
grease and other contaminants. CRES
be primed with MIL-C-8514 wash primer.
Mixing and Handling

The coating is mixed in accordance with the manufacturers instructions. Usually the mixed material is of the
correct consistency for spray or brush application. If
additional thinning is necessary, no more than 5% (by
volume) of thinner recommended by the manufacturer.
APPLICATION, CURE, AND FINISH
Coating Application
The coating may be applied by conventional
spraying and
brushing techniques. Apply 2.5-3 mils of the coating

al lowing a min of 10 minutes air dry between coats. If over
3 mils of coating are required, the dry time between coats
is a min of 1/2 hour.
Cure
applied coating must be fully cured using

following methods before placing in service:
The
i.
Air
cure
2.
Air
dry for 1
1/2 hour.
for
at
room
one
of the
temperature for 7 days.
hour followed by baking at 250 ~1O"F
Finish
The cu red coating must be smooth, continuous, and free of
scratches, seeds, and other visible defects.
Cured coating must be of sufficient hardness that no
intlention is visible after scratching with the fingernail.
(~n cured coating, apply a piece of 1 in. masking tape (3M
Co., No. 250). Rub with the thumb to insure good contact.
Remove the tape in one abrupt motion. No coating must be
removed.
Touchup scratched or abraded coating. Coating exhibiting

poor adhesion must be
stripped
and
reapplied.
20-30-60
0
Page 1/2 Blank

Aug 31/84
SR-76-023
RAIN EROSION RESISTANT COATINGS APPLICATION

(;ENEKAL
covers the matelials and procedures for the
of
a rain erosion resistant coating to glass
applicalion
Fa,ric resin laminates,
Ihis sect.ion
Sulfaces to be coated generally consist of glass fabricplastic resin laminates. The coaling, basically neoprene
rub~,er, is intended to protect such parts from rain erosion
during high speed flight and is primarily applicable to
ailcraft leading edges. The coating provides protection
only if it is of adequate thickness, even in thickness, well
bonded, blemish free, and completely supported. Blemishes and areas supported by a pitted surface erode very
rapidly, while poorly bonded areas blister under rain
impact. ()nce the coating has been completely penetrated,

bseq uent water droplets, along with the ai rstream, peel
the coating from the laminate surface. This exposes the
laminate to rapid el-osion by direct impact.
su
MATERIALS
(;aco N-79 Radome Coating Kit
Consisting of:
Gaco N-18 Primer
(;aco N-7()0-9 Top Coat
Top Coat
Accelerator
No. lfi6 Surface Filler and
No. 956 Hardener
Gates Engineering
Co.
New Castle, DE
~actt N-:S00-9
(;aco N-4.50-9 Diluent
Methyl I~thyl Ketone (MEK)

Toluene
Xylone
obtain a shelf storage life of 8 months from date of

manufacture without deteriolation. If the I, ri mcl i s stored
at room temperature the storage life is rtducetl to)
months. Matelial showing evidence of gelation must not
be used.
Catalyze
the N-700-9
hours after catalv7,ation.

Both the Craco N-18 primer and the Gaco top coat material
N-150may be thinned to spraying consistency with Craco
9 diluent or a 50:50 mixture of MEK and toluene or
xylene. For best results thin 1 pint of catalyzed N-700-9 to
1 quart of N-450-9 thinner.
The top coat thickness in the fully cured condition must
be 0.0085 +0.002 in. Obtain this thickness by spraying a
calculated quantity of the material evenly over the surf ace
of the part. This "calcuiated quantity" for each part being
coated is determined as follows:
(Area of Part)X (K)= Wt. of Spray Material As Received

where K is a factor dependent upon the desired coating
thickness, the solids content of the coating material, and
the density of the finished coating.
K is determined
Furane Plastics, Inc.

Los Angeles, CA
Gates Engineering
Co.
New Castle, DE
TT-M-261
TT-T-548
TT-X916
In
The coating must be applied only to sanded surfaces

completely free from pinholes, voids, or other surface
irregularities. Following initial sanding, any pinholes or
slight surface defects must be repaired per "Laminated
and Moltfetl Plastic Parts Finishing" in this chapter.
follows:
as
(Thickness in inches) (density in ozi i n.:l) (10())
Solid content
general, the valiables
are
as
fairly
percent
constant at:
0.009 in.
Thickness
0.69Soz/in.:
Density= 1.20g/cc
Solids= 35%
(0.009)(0.69~)(100)
INSTAI,LATION NI)TES
Surface Preparation
per the manufacnlust be used \Iithill t(
coating being used
turers instructions. All materials
Therefore K
35
Then, the amount of material

part will be:
0.0178
to spray on an~
(Area of Part in inches")(0.0l78)
pal.ticular
of as received
matelial requiretl
ounces
An additional amount will have to be allowed for
over-
spray.
Mixing and HandlinR

A lu II closed contai ner of (;aco N -700-9 Tap Coat material
70
m ay be sto red u nder standard cond itions (temperatu I.e
to SOOF) for 8 months from date of manufacture without
deterioration. Full closed containers of Gaco N-18 primer
must be stored at a temperature between 40-50"F to
Finish
The cured
coating
pinholes, lumps,
completely free of blisters,

and any other surface irregu-
must be
runs, sags,
larities.
Th, total thickness of the coating(primer plus top coat) in
all areas must be between 0.0087-0.0111 in.
fully cured coating mag be cleaned with water and

mild detergent. Other solvents must not be used.
A
20-30-65
0
Page 1
Auff:31/84
SR-76-023

Finish
(Contd)
(Continued)
COATING APPLICATION
Polishing
Remove surface dust by blowing with clean air or by

a clean cloth dampened with toluene dr a
similar solvent.
wiping with
The
coating
was
such
as
may be polished with a carnauba base paste

Simoniz, Macs, or Johnsons. Liquid type oils,
polishes, cleaners,
etc., must not be used.
Touch Up
When coating damage is not localized or if damaged area
exceeds 5ro of coating area, repair by removing the entire
coati ng and applyi ng a complete new coating, The coating
may be removed by placing cloths saturated with toluene,
xylene, or MEK on the surface for 20-30 minutes. Before
the coating is reapplied special attention must be given to
surfacing the area where the defects were noted.
When defects
are
localized and the total of the
Spray
brush the prepared surface with Gaco N-18

a dry film thickness of 0.0002-0.0006 in. ()ne
coat will normally suffice. If the primed surfaces are not
perfectly smooth, remove nibs by lightly sanding with No.
280 sandpaper after primer has been allowed to air dry a
min of 45 minutes.
or
primer
areas
to
When the coating is to extend to any edge of a part, the

coating must extend around the edge of the part as shown
in figure 1.
of the
coating 1equiring replacement does not exceed 5% of the

coated area, the damage may be touched up as follows:
i.
Mask-off
2.
With a sharp knife carefully cut and strip the film

\vithin the masked area. Do not cut into the plastic
laminate. Next. scuff sand the exposed laminate
with sandpaper, taking care not to loosen the edges
of the adjacent coating.
I~lush the preparetl area with (;aco N-lt~ primer.
This p,i mer must be brushed extremely carefully so
that it barely contacts the edge of the adjacent
coating. The presence of more than a slight amount
of primer solvent against the coating will cause
blistering and loss of adhesion, and necessitate
repeating the entire repair procedure. Air dry the
Gaco N-18 primer for at least 1 hour prior to application of the top coat.
4.
Apply sufficient number of coats of catalyzed top

coat to make the repaired area slightly higher than
the masking tape, allowing an air dry of at least 30
minutes between coats. The top coat may be applied
with a brush or spatula, depending upon the size of
a
the
5.
COATING
LAMINATE
Coating Ilaminate EdRes

Pigule
1.
dry the patch for
temperature prior
to
a min of 96 hours at
illstallation of the part.
Spray the
rain erosion coating with a speed and

pattern that will result in an even, uniform, wet,
smooth coat.
2,
Allow each coat to flash off for approximately 10-15

minutes before the next coat is applied.
NOTE
The initial coats should be very light in,
order to prevent thP Gaco N-1(3 primer
being dissolved into the topcoat material.
Allow sufficient dr2ling time between coats
After the last coat of the top coat has dried for 24
hours 1emove the masking tape and cautiously
feather the edges of the repair using a clean cheese
cloth slightly dampened with toluene. Use of an
Ail
After primer has dried at least 60 minutes spray the

surface with the top coat material as follows:
repair.
excessive amountof the solvent in this operation will

c;~use bl istering and loss of adhesion, and necesssitate
Icl,~;ltillR the ent.ire I,rocedu,e.
ti.
rectangle which includes the defective

area plus a perimeter of at least 1/2 in. of non-defective area. The masking should be at least 2 in, wide.
a
to
3~
prevent sagging.
If entrapped bubbles are present in the coati ng, they

should be dispersed by spraying the surface with a.
mist coat of the N-450-I) thinnel.
room
20-30-65
Page 2
Aug 31/84
COPYRIGHT,
1984 BY SABRELINER CDRPORATION
SR-76-023
CORROSION CONTROI, MANUAI,
(Continued)
COATING APPLICATION (Contd)

4.
A min of 9 spray coats normally should be applied to

achieve required film thickness (0.0085 +0.002).
T,.
Tht! following spray combination or its

recommended for best spray results;
equivalent is
DeVilbiss MUC spray gun

TII-AV15EX
Cap 704
Pot Pressure 4-6 psi
Atomizing Iressure
15-25
psi
The finished coating must be air dried for a min of 96

hours at room temperature prior to installation of the
coated part. In an emergency the coated article may be
put into service after farce curing 3 hours at 150"F.
20-30-65
0
Page 3/4 Blank

Aug 31/84
SR-76-023
CORROSION (:ONrR()L MANl.iAI,
SPRAY PAINTING METHODS AND TECHNIQUES

~INSTRUCTION AND INFOR1MATION GUIDE)
(;ENERAL
covers general spray painting techniques,
eclllil,mcnt use and maintenance for air type spray equipnicnt and painting facilities.
This section
~-r --i---i i-
only and does not contain inspection requirements. Specific requirements specified elsewhere must take
+3
precedence.
I..~
EQUIPMENT
IPI
Spray Gun
A spray gun is
tool
using compressed air
to atomize
sprayable material and apply it to the surface. Air and

material enter the gun thru separate passages and are
mixed and ejected at the air cap in a controlled pattern.
A typical spray gun is shown in figure i.
Common
Type Spray (;uns
PressureFeed
i.
AIRCAP
5.
FLUIDADJUSTMENT SCREW
2.
FLUIDTIP
6.
AIRVALVE
3.
FLUIDNEEDLE
7.
SPREADER ADJUSTIENT VALVE
4.
TRIOOER
8.
OUNBODY
A spray gun with an air cap not necessarily designed

create a vacuum, (The fluid tip is generally flush with the
air cap), Material is forced to the gun by air pressure from
of the same
a tank, cup or pump. When large amounts
color material are being used, when the material is too
to
heavy to be siphoned from

when fast
application
is
cupor container
required,
by suction, or
pressure feed gun is
Standard Nozzles
The letter(s) identifies
diameter is in inches.
used.
Suction Feed
A type of spray gun in which
stream of
compressed air
force
a vacuum allowing atmospheric pressure to
material from an attached container to the spray head of
the gun. This gun is usually limited to quart-size containthe fluid tip
ers or smaller and is easily identified by
feed guns
Suction
air
the
cap.
extending slightly beyond
and small
are used where there are many color changes
amounts of material involved.
creates
These two types
Principal Parts of Spray Gun

Figure 1
can
be further divided into bleeder and
non-bleeder, external and internal mix and pressure,

gravity or suction feed guns. Other types include automatic, extension and special spray guns.
0.086
0.078
0.070
0.070
0.070
0.055
0.047
D
DE
E
EE
EX
FF
FZ
the
nozzle, while aperature

FX
F
G
H
AS
AC
CS
0.0425
0.041
0.028
0.018
0.140
0.110
0.110
Pressure Tanks
Pressure feed tanks (pots) are closed, metal containers,
ranging in sizes from 2-120 gallons, that provide a
constant flow of material at a uniform pressure to the
out of the tank by
spray gun.ISee figure 2.) Fluid is forced
To
material.
the
change the rate
to
air
applied
compressed
of flow, air pressure must be increased or reduced.
Pressure tanks are constructed for working pressures as
high
as
110
psi.
20-30-70
o
Page 1
Aug 31/84
SR-76-023
CORHOSION CONTROL MANUAL

(INSTRUCTION AND INFORMATION GUIDE) (Continued)
Pressure Tanks
Air Pressure
(Contd)
Where continuous production is maintained, pressure

feed tanks provide a practical, economical method of
feed ing material to the spray gun. The flow of material is
posjtive and uniform.
When specified, use the air pressure indicated in the

applicable section. The indicated pressure is a recommendation only, unless a close pressure control (psi) is indicated by a section.
Usually production material in constant use may be left in

pressure pots under constant agitation,
When not
6,
12
4\
specified, use the general pressure of 45 psi for

lacquers, primers and 50 psi for enamels, urethanes, etc.
NOTE
Pressures
p9/
measured and maintained
trigger to indieate true air pressure, or

adjust main line air pressure to compensatefor hose length air pressure dropfrom
to
tr~L
11
are
at the spray gun. Insert a temporary air

gage at gun end of air hose and pull gun
~g
64
table i,
i.
SHELL(POT)
2.
CLAMP-ONLID
7.
OUTLEfVALVES,AIR
INLET VALVE
(POT HEAD)
8.
SAFETY RELIEF VALVE
3.
FLUIDTUBE
g~
AGITATORS
4.
FLUIDHEADER
10.
PRESSUREREGULATOR
5.
AIRVALVE
l1.
PRESSURERELEASE
FLUID VALVE
12.
PRESSURE GAUGE
Pressure Tank
Figure
Table 1.
Air Pressure
Drop
In Hoses
AIR PRESSURE DROP AT SPRAY GUN IN PSI

AIR HOSE INSIDE
I)IAMETER ANI)
INI)ICATED LINE PRESSURE
At 40 Ibs
At 50 Ibs
At 60 Ibs
At 70 ibs
At 80 Ibs
At 90 Ibs
5-FT
LENGTH
2-1/4
3
3-3/4
4-1/2
5-1/2
6-1/2
tO-FT
LENGTH
2-3/4
3-1/2
4-1/2
15-FT
LENGTH
20-FT
LENGTH
4-1/2
4
5
6
6-3/4
7-1/4
6-1/4
4
5
6
7
7-1/2
8-1/2
9-1/2
5-1/4
25-FT
I,ENGTH
8-3/4
re-1/2
S0-ET
LEN(;TN
X-1/2
10
11-1/2
13
14-1/2
16
20130-70
Page 2
Aug 31/84
COQYRIGHT, 1984 BY SABRELINER CORPORATION
SR-76-023

Equipment Cleaning
Air Line Filters

Irse an air line filter which is adequate to remove water
and oils, a DeVilbiss No. P-HLG air transformer, or
Insure that equipment, such
equivalent,
are
Drain fluids from air line filters at least
once a
day.
siphon
or
as
spray guns, material hoses,

paint pumps
pressure cups, pressure pots and
clean prior to introducing materials

color.
or
changing
Time of Cleaning
Hoses
Fluid Hose
Use
only solvent resistant hose, Thiokol cored,

a min I.n. of 3/8 in. Length should
ecluivalent. IJse
or
not
exceed 50 ft.
Materials are easily removed while in the wet state and

become harder to remove as they begin to harden. The
most practical method is to clean painting equipment
immediately after use.
Pressure Pot Care
Air Hose
NOTE
Where necessary the lengthfrom main line
regulator or tank may be increased to a
to
of 150 ft provided only high pressure

hose with a min I.n, of rllB in. is used.
mat
Unless otherwise specified by applicable sections production materials in constant use may be left in pressure pots
under constant agitation. At least once a week or when
paints begin to build up and cake on the upper surfaces of
the pot or on the agitator or head, the pot must be cleaned
follows:
as
i.
Dump or drain remaining paint into an auxiliary pot

Or can.
17se a min I.D. of 5/16 in., except an I.D, of 1/4 in, may be
used for small touch-up type spray guns. Length should
not exceed 50 ft.
2.
Clean pot using scrapers, brushes, rags and the

recommended solvent or stripper for the type of
paint.
CI,EANING
rw!nmnzl
The meticulous cleaning and surface treatment of all

metal surfaces prior to all painting operations cannot be
of prime importance
overem phasized, si nce this factor is
i n obtai ni ng a satisfactory pal nt fi n ish. Reclai med thinner
must not he used for cleaning purposes, since these
matelials may leave a grease film which will cause poor
adhesion. (:leaninK shall be accomplished with solvents
which have no damaging effect on the surface and which
produce surfaces that are satisfactory for receiving subsequent finishes. Cleaning materials which may be effective
against one type of contamination may be ineffective
another. Only recommended and approved clean-
When cleaning the pot head, protect the

safety valve, pressure gauge and pressure
reliefualve inletsfrom eontaminants such
solvents or strippers which
as paints,
would damage the ltelms.
3.
relief valve.
4
Replace head gasket or filler cap gasket when

evidence of flaking or cracking is apparent.
Damaged gaskets will cause pressure leaks and/or
of rubber.
gun, or hose plugging from bits
5.
Remove fluid outlet valves and inspect for plugging

condition. Clean as
or otherwise contaminated
necessary and re-assemble.
6.
Insure that
against
ing materials shall be used.
Cleaners and Strippers for Paint Equipment
following equipment cleaners or strippers

degree of hardness of the material.
Choice of the
depends
on
Wet State
Ilse
Semi-cured
(Cured) State
paint stripper, Turco
7.
5351,
agitator and
motor
condition. Request repairs

this condition.
methyl ethyl ketone (MEK).
Hard
I~se
or
a qualified maintenance mechanic may repair

inoperative safety valve, pressure gauge. or pressure
Only
as
are
in
good operating
necessary to maintain
insure
or wipe down with clean solvent to
complete removal of any residues or contaminants.
Rinse
20-30-70
0
Page 3
Aug 31/84
SR-76-023
SPRAY PAINTING METHQBS AND TECHNI&VES

(INSTRUCTION AND INFORMATION GUTDE) (Continued)
Pressure Pot Care
8.
Strain
pressure
9.
(Contd)
all materials
during filling
refilling
or
pat.
Pressure pots containing materials must be kept

under constant slow agitation. Insure that agitator
motors are never turned off.
paint pigments from settling in the fluid hose

during periods of non-use, flow back the fluid to the
use as
follows:
i.
Keleasepressurein paintpressurepot.
2.
Loosen air cap and hold

Pull gun
spray guns clean and in
good operating condition.
rags, and the solvent recommended for

cleaning the particular paint while it is wet or semi-cured.
Use brushes,
To prevent
pot after
~pray Gun Care
~eep
Fluid Hose Care
pressure
At the end of each work shift, or immediately after use,

~hen paint will not be re-used during the work shift, clean
the fluid hoses, using a hose cleaner or pressure pot and
the solvent recommended for cleaning the applicable
material.
trigger
folded rag
full open for
over
Clean immediately after use and during use

and as follows. (See figures 3, 4, and 5.)
Operation has been successfully

plish.ed when fluid hose can be
fluctuate from surge of pressure.
Remove and soak air cap until paint is softened.

Brush away residues. Never use metallic objects to
clean air passages, as these will distort critical soft
brass orifices.
2.
Cieanremainderofgun beingcareful nottobumpor
fluid tip.
otherwise damage fluid tip. Never soak entire gun in

solvent as this will dry out packings.
ascsmseen
necessary
i.
few seconds,
NOTE
as
to
;s
52f
WHEN USED WITH A cue, THINNER OR SUITABLE
SOLVENT MUST BE 81PMONED THRU OUN BY INSERT!NG TUBE IN OPEN CONTAINER OF THAT LIQUID.
MOVE TRIGGER
CONSTANTLY
TO
THOROUGHLY
FLUSH PASSAGEWAY AND TO CLEAN TIP OF NEEDLE.

GU)I( MAY BE BLOWNBACK.
Cleaning Cup Type Gun

Figure 3
20-30-70
Page 4
Aug 31/84
1984 BY: ~RELINER CORPORATION
SR-76-023
CORROSION CONTROL MANI!AI,
:i
WHEN THE GUN IS USED WITH A PRESSURE TANK OR

GRAVITY BUCKET, REMOVE HOSE, TURN THE GUN
UPSIDE DOWN AND POUR THINNER INTO FLUID OPEN)N(3 WHILE MOVING TRIGGER CONSTANTLY. THIS WILL
rr~r
.I::::::;::::::
FLUSH ALL PASSAGEWAYS.
-t-j:-:j:i::::::::
I:I-
i~
i~ir;
::.I::::::::::::
;:::.>::;::::;I
Cleaning Tank Type Gun
Figure
ENTIRE
IS EXTREMELY POOR PRACTICE TO PLACE
GUN IN THINNER. WHEN THIS IS DONE, SOLVENT
DISSOLVES OIL IN LEATHER PACKING AND CAUSES
IT
GUN TO SPIT.
FLUID
IT IS GOOD PRACTICE TO PLACE NOZZLE AND
q:.r
CONNECTION IN THINNER. VESSEL USED MUST BE

SHALLOW ENOUGH TO PREVENT THINNER FRO#
.,q
REACHING PACKING.
;i:
:i:i
Cleaning Gun ~Ellozzle and Fluid Connections

Figure 5
20-30-70
Page 5
Aug 31/84
SR-76-023
SPRAY PAINTING METHOrDS AND TECHNIQUES

(INSTRUCTION AND INFORMGTION GUIDE) (Continued)
Spray Gun Care (Contd)
3.
6.
Lightly oil leather packings and moving parts except

those in contact with paints or air supply.
4.
Re-assembleaircap tospraygun.
5.
See adjusting procedures and fault correcting procedures in figures and in tables. When simple adjustments or cleaning will not correct faulty conditions,
spray gun must be overhauled but only by a qualified
spray gun mechanic.
Once started, do not stop spraying until job is
complete.
7.
Avoid excessive paint feed which would result in

excessive film thickness.
8.
Paintcornersasshown infigure9.
MAINTAIN 8-10 IN. DISTANCE. MAINTAIN OUN PERPENDICULAR.
m~wnazl
Plncu spray gun on a hook ol other safe
place when in non-use. A dropped spray
gun usually results in damage and distortion ofa.ir cap and its critical orifices and
possibly
SPRAY GUN
damugedPuid tip.
TECHNIQUES
AIR TYPE
Spray Gun Use

The following
are
general techniques for
spray gun.
1.
Hold spray gun perpendicular to area being coated.

(See figure 6.) Do not tilt spray gun. (See figure 7.)
2.
Depending
on
spray
width, maintain a 6-10 in.

area being coated.(See
narrow pattern requires the
distance between air cap and
figure 6.) Generally
Gun To Part Distance
greater distance.
Figure
NOTE
Less than B in, will cause poor atomixation.
More than 10 in. will cause dusting of
paint particles with resultant specks and
MORE MATERIAL IS APPLIED HERE
lumps.
3.
Always trigger spray gun to avoid build-up at

beginning and end of each stroke. Triggering is
technique of starting gun moving toward area to be
splayed, before trigger is pulled and, similarly,
moving gun past area which has just been painted
aftel trigger is released. (See figure 8.)
4.
Avoid too much overlapping of strokes which would

result in excessive film thickness. Overlap each
successive stroke approximately 50% into previous
stroke.
i2djust
stroke
STREAKS OCCUR HERE
spttetl
to
lay down
uniform wet coat.

LESS MATERIAL IS
APPLIED HERE
Some Problems Caused Hylilted (:un
Figure
20-30-70
Page 6
AuR.31/84
CQBYRIGHT,
1984 BY S~PiBRELINER CORPORATION
SR-76-023
RIGHT
~i
8-101N.
MOVE GUN
IN STRAIGHT
LINE
RELEASE TRIGGER
BEGIN STROKE
THEN PULL
TRIGGER
411C~
61P~A
I
R
KEEP
WRIST
BEFORE COMPLETING
STROKE
FLEXIBLE
WRONG
ARCING GIVES
UNEVEN
COATING
WRIST
IS TOO
STIFF
Spray Gun Motions

Figure
20-30-70
Page 7
Aug 31/84
SR-76-023
CORRECT
INCORRECT
METHOD
METHOD
OUTSIDE CORNERS
THICK
THIN
INCORRECT
CORRECT
METHOD
METHOD
INSIDE CORNERS
Spraying Corners
Figure
20-30-70
Page 8
Aug 31/84
SR-76-023

(INSTRUCTION AND INFORMATION GUIDE) (Conlinued)
Faulty Spray Patterns
Examples of faulty spray patterns, causes, and corrections

are
shown in table 2.
Table 2,
Faulty Patterns and Suggested Corrections
Dried material in or damage to

side port "A" restricts passage of
air through it. Result: Full
pressure of air from clean side
port forces fan pattern in
direction of clogged side.
,i
ru!X
iS~
Dissolve material in
port with thinner or
air cap. Do not poke
of the openings with
Dried material around outside of

fluid nozzle tip at position "B"
restricts passage of atomizing air
at one point thru center opening
Of air nozzle and results in
pattern shown. This pattern can
also be caused by loose or
damaged air cap or fluid nozzle.
split
spray
material.
~r,
side
replace
in any
metal
instruments.
If dried material is causing

trouble, remove air nozzle
and wipe off fluid tip, using
end of a fan
or one that is heavy on each
caused
by (1)
is
usually
middle
in
weak
pattern and
tao high an atomizing air pressure, or (2) by
attempting to get too wide a spray with thin
A
~c-
CORRECTION
CAUSE
PATTERN
raff wet with thinner.

Tighten air cap or fluid
nozzle.
Reducing air
correct
cause
pressure will
(1). To correct
open material control to

full position by turning to
left. At same time turn
spray width adjustment to
right. This will reduce
width of spray but will
(2),
correct
split
spray
pattern.
r,i?
20-30-70
Page 9
0
Aug31/H4
SR-76-023

Table 2.
Faulty Patterns and Suggested Corrections (Contd)

PATTERN
CAUSE
1.
CORRECTI<)N
Dried out packing around material needle valve

to get; into fluid passageway. This
results in spitting.
permits air
2.
Dirtbetweenfluid nozzleseatandbodyora
loosely installed fluid nozzle will make
a gun spit.
3.
A loose or defective swivel nut on siphon cup

material hose can cause spitting.
or
~I
q:::::
::iz
To correct cause (1), back up

knurled nut C, place 2 drops of
machine oil on packing,
replace nut and tighten tyith
fingers only. In aggravated
cases,
replace packing.
To correct cause (2), remove

fluid nozzle D, clean back of
nozzle Beat in gun body using
rag wet with thinner, replace
nozzle and draw up tightly
against body.
To correct
cause
replace swivel
A fan spray pattern that is heavy in middle, or a

pattern that has an unatomized "salt-and-pepper"
-c""
effect, indicates that atomizing air

high enough.
(3) tighten
or
nut E.
Increase pressure from your

air supply.
pressure is not
20-30-70
Page 10
Aug 31/84
SR-76-023
CORROSION CONTROI~ MANI!AL,
SPRAY PAINTING NLETHODS AND TECHNIQUES

(INSTRUCTION AND TNFORMATION GUIDE) (Continued)
Correct
Spray Patterns
See figure 10 for
example of correct
spray
pattern.
Relation of Air Cap Position to Spray Pattern

to
The flat spray patterns will always be at right angles
11.)
figure
(See
the air cap wings.
tSiiiiiii~ii
SPRAY PATTERN IS VARIABLE FROM ROUND TO FLAT

WITH ALL PATTERNS IN BETWEEN.
~orrect Spray Patterns
Figure
10
HORNS ARE
HORIZONTAL
(i~
ARE
IN HORIZONTAL OPERATION, WINGS ON NOZZLE
HQRIZONTAL. THIS PROVIDES VERTICAL FAN-SHAPED
PATTERN WHICH GIVES MAX COVERAGE AS GUN IS
MOVED BACK AND FORTH PARALLEL TO SURFACE
BEING FINISHED.
Relationship of Aireap Position

Figure 11
to
Spray Pattern
20-30-70
Page 11
0
AuR 31/84
SR-76-023.
SPRAY PAINTING METHODS AND TECHNI&UES

(INSTRUCTION AND TNFORMATION GUIDE) (Continued)
Spray
Gun
Adjustments and Corrections
See figures 12 and 1,3 for examples of spray gun adjustments and corrections. Cheek and maintain the proper
patttln fol adjusting or cleanina the gun frequently.
SPRAY WIDTH ADJUSTMENT TURN RIGHT FOR ROUND,

LEFT FOR FAN. (SOME TOUCHUP GUNS HAVE THIS
ADJUSTMENT ON SIDE)
::1:::
MATERIAL CONTROL SCREW. TURN RIGHT TO

DECREASE FLOW, LEFT TO INCREASE.
ii::::i::::::; ,:::;t
As WIDTH OF SPRAY IS INCREASED, MORE MATERIAL
:,i::
MUST BE ALLOWED TO PASS THRU GUN TO GET SAME

COVERAGE QN INCREASED AREA.
NOTE
NEVER ADJUST WITH PLIERS. IF CONTROL SCREWS
BIND,
HAVE
GUN
REPAIRED
BY
SPRAY
GUN
MECHANIC
spray GunA~ustment
Figure -18
20-3870
Page 12
Aug 31/84
CQPYRIGMT,
1984 BY SA~PELINER CORPORATION
SR-76-023
CORROSI<)N CC)NTHOL MANlrAL
JERKY OR
FLUTTERING
SPRAY
OBSTRUCTED
FLUID PASSAGE
LOOSE TIP OR DAMAGED

LOOSE PACKING NUT OR
SEAT
DRIED OUT PACKING
s,
15L
LOOSE OR DAMAGED
COUPLING NUT
CLOGGED AIR VENT
LOOSE OR
DAMAGED FLVID
TUBE
CUP TIPPED
TOO FAR
LACK OF SUFFICIENT
MATERIAL IN CUP
Causes of Jerky
or
Fluttering Spray
Figure
13
20-30-70
0
Page 13
Aug 31/84
SR-76-023

(INSTRUCTTON AND INFORMATION GUIDE) (Continued)
SPRAY PAINTING PROBLEMS
See table 3 for spray painting troubles,
and possible remedies.
Table 3.
possible
causes,
Spray Painting Problems, Possible Causes, and Possible Remedies
TROUBLE
Sandpaper
finish
POSSIBLE CAUSES
1.
Unsatisfactory
POSSIBLE REMEDIES
surface finish of
previous
I.
Checkapplication proceduresofsll
coatingsinvolved.
2.
Providecleaner
coats
2.
Exclessive dirt contamination from
painting
Slon Drying
Pret2eatment
Coating
paintingarea.
area
3.
Insufficient scuff sanding of previous coats
3.
Scuff sand previouscoats.
4.
Improperly cleaned paintequipment
4.
Flush paint lines and clean equipment.
yj~
Dried overspray
5.
Sand complete finish until smooth

fingertips.
6.
Wrongthinner used
6.
Compare
7.
I~sccssive ait pressure
7.
(:heck for correct air pressure

recom mended at gun.
8.
Dustonparts
8.
Removedust.
1,
Wrongthinner used
1.
Compare
to
on test panel with material using

recommended thinner.
on
test
panel with material using
recommended thinner.
2.
Excessivefilm thickness
2.
Strip and reapply
3.
High humiditycondition
3.
Checkhumiditycontrol equipmentwhere
employed. Suspend painting operation
until humidity drops.
Blushing
1,
Excessive humidity
1.
Checkhumidity control equipmentwhere

employed. Suspend painting operation
until humidity drops. Use slower
Pinhole C:avities
or (1aters
i.
Lack
2.
Entrapped oils, water, and/or solvent.
correct amount.
evaporating solvents.
of/or improper surface
treatment
1.
Apply
2.
Microscopic examination of surface and

paint removed during tape test. Clean
correct surface treatment.
air filter.
3.
Insufficient primerdryingtime
4.
Excessive alcohol additions to pretreatment
5.
3.
4.
coating
Check
drying time requirements.
Compare
on
test
correct amount.
Improper thinner
5.
Compare
on
test
recommended thillner.
6.
Siliconeson surface
7.
Ioo heavy acoat
7.
Apply thinner
X.
Forcedryingbefore allowingsolventsto
8.
Allow
6.
Strip, thoroughly reclean surface and

reapply finish.
coats of material.
enough time for solvent flash-off.
flash-off
20-30-70
Page 14
Aug 31/84
COPYRIGHT, 1984
SR-76-023

Iahle 3.
Spray Painting Problems, Possible Causes, and Possible
TROUBLE
Tape Test Paint

Transfer
Sags
Streaks
POSSIBLE REMEDIES
P<)SSIBLE CAUSES
1.
Checkdryingtime requirements.
2.
Thoroughly clean surface, using clean

damp with solvent.
3.
Apply
4.
Scuff sand, clean with solvent, and apply

light coat of same primer.
i.
nemove air cap and clean tip and air cap

carefully. Replace if necessary.
Gun stroked too close to surface
2.
StrokegunG-lO in.fromsurface.
3.
Trigger not released at end of stroke

(when stroke does not go beyond object)
3.
Releasetrigger atendof
4.
Gun held at
4.
Hold gun at
5.
Painttoocold
5.
Heat paint in an approved paint heater,

keep in warm area.
6,
Paint
6.
Learn to calculate
1.
Insufficient drying time of primer
2.
Improperly cleaned surface,

oils and soil in primer
3.
Impropersurface
4.
Excessively aged primer
i.
Dirty
2.
entrapped
treatment
damaged air cap and

(distorted spray pattern)
or
piled
wrong
too
on
angle
to
fluid
tip
surface
heavy
correct surface treatment.
right angles
every stroke.
to surface.
depth of
wet film
Paint thinned out too much
7.
Add correct amount of solvent by
8.
Excessive potpressure
8.
Reduce potpressure.
9.
Temperature
9.
Increase temperature.
2.
3.
in
paint
area
too low
Dirtyordamaged aircapandfluidtip
(distorted
spray
Insufficient
strokes.
or
of
paint.
7.
1.
rags
or
incorrect
(;un stroked too

the paint)
over-lapping of
Remove air cap and clean
carefully. Replace if
pattern)
2.
Follow
a
rapidly ("dusting"
of
3.
measure.
tip and air
cap
necessary.
previous stroke accurately. Deposit
wet coat.
Avoid"whipping". Takedeliberateeven
stroke.
angles
4.
Gun should be stroked at right

to surface.
5.
Strokefi-lOin. fromsurface.
Too much air pressure
6.
Useleastair pressurenecessarv.
7.
Splitspray
7.
Clean the fluid tip and air cap.
8.
Painttoocold
8.
Heatpaintto getgoodflowout.
9.
Temperaturein paintarea
9.
Increase temperature.
to surface
4.
Gun stroked at wrong
angle
5.
Strokingtoofarfrom
surface
6.
too low
20-30-70
0
Page 15
Aug 31/84
SR-76-023

Table 3.
Spray Painting Problems, Possible Causes, and Possible Remedies (Contd)
TROUBLE
Orange peel
POSSIBLE CAUSES
POSSIBLE REMEDIES
Paintnotthinned outsufficiently
1.
Add correct amount of solvent by
2.
faint toocold
2.
Heat
3.
Not depositing
3.
Chteck solvent. Use correct

overlap of stroke.
4.
Avoid "whipping". Take deliberate slow

strokes.
1.
4.
wet coat
Gun stroked too rapidly ("dusting"
paint)
5.
Insufficientair pressure
5.
measure.
painttogetflowout.
Increase air pressure
or
speed and
reduce fluid
pressure.
air cap
fluid nozzle
6.
Using
7.
Gun stroked too far from

surface
8.
wrong
Overspray striking
or
or
too close to
previously sprayed
6.
Select correct air cap and nozzle for

material and feed.
7.
StrokegunG-10in. fromsurface.
8.
surface
9.
10.
Excessive Paint
I,oss
Temperature
in
paint
room
too low
9.
Excessive air pressure
"triggering"
10.
1.
Not
2.
Stroking
at wrong
3.
Stroking
gun too
4.
Wrongaircaporfluid tip
5.
Depositing
gun at
each stroke
Spray
detail parts first. End with
wet
angle
to surface
far from surface
paint film of irregular
Increase t;emperature.
Reduce
airpressure.
1.
Release trigger after every stroke.
2.
Stroke gun at right angles to surface.
3.
Stroke gun 6-10 in, from surface.
4.
Usecorrectset-up.
5.
Learn to calculate depth of wet film of

Finish.
thickness
Excessive
Spray
coat
6.
Air pressure too high
6.
Useleastamountof air necessary.
7.
Fluid pressuretoohigh
7.
Reducepressure. Ifpressurekeeps
climbing, clean regulator on pressure
8.
Paint too cold
8.
Heat
1.
Air
1.
Use least amount of compressed air
2.
Spraying past surface of product
2.
Release
3.
Wrong air
3.
Use correct set-up.
4.
(;un stroked too far from surface
4.
StrokegunG-10 in.fromsurface.
5.
Material thinnedouttoomuch
5.
Add correct amount of solvent
6.
Stroking
6.
Use correct method.
pressuretoohigh
FoR
paint
tank.
to reduce air pressure.
necessary.
cap
or
fluid
at wrong
tip
angle
to surface
trigger when
gun passes
by
target.
measure.
29-30-70
Page 16
Aug 31/84
~PYRIGHT, 1984 BY $ABRELINER CORPORATION
SR-7fi-083

Table 3.
Spray Painting Problems, Possible Causes, and Possible Remedies (Contd)
~aint will not

come from
Pressure
Sy,ray (;un
Paint will not

come from
Pressure Tank
POSSIBLE REMEDIES
POSSIBLE CAUSES
TROUBLE
i.
Add paint, correctly thinned out and

strained.
tip
2.
Remove obstruction, stil
gun
3.
Clean spray gun thoroughly, and strain

paint. Always strain paint before using it.
4.
Check viscosity.
5.
Checkgun parts.
Lack of proper air pressure in pressure

tank
1.
Check for leaks
Airintakeopening, insideofpressure
2.
Clean
beginstosputter)
i.
Outof paint(gun
2.
Settled, caked pigment blocking
3.
Grit, dirt, paint skins, etc., blocking

tip, fluid valve, or strainer
4.
Painttoo thick
5.
Wrong tip,
i.
2.
cap
gun
and/or needle combination
or
paint thoroughly.
lack of air entry.
opening.
tank lid, clogged by dried-up paint
Iaint will not

come from
Suction C:up
Iaint leaks from

Sl,ray (;un
3.
Leakinggasketson tankcover
3.
Replacewith newgasket.
4.
Painttoo thick
4.
Check viscosity.
Dirtyfluidtipand aircap
i.
2.
Clogged air
2.
Remove obstruction.
3.
Usingwrongaircapor needle
3.
Use correct setup.
4.
Leaky connections
4.
Check for leaks under water, and repail.
5.
Painttoo thick
5.
Check viscosity.
1.
Fluid needle packing nut too tight
i.
Iloosen nut, lubricate
Packingforflnid needledry
2.
T,ubricate this part daily.
Foreign particle blocks fluid tip
3.
Removetipand
L)amaged fluidtiporneedle
4.
Replace both tip and needle.
i.
2.
4.
vent
on
cup
on
cover
fluid tube
Remove air cap and clean tip and air cap
carefully.
or
nozzle
packing.
clean.
20-30-70
0
Page 17
Aug 31/84
81t-76-02S
(()KR()SI()N C()NTROL M~NCIAL

Fluid Pressure
Electrical
When specified, use fluid pressure indicated in the applicable ~ection. The indicated pressure is a tecommendation
only unless a close pressure control of +O.f, psi or less is
indicated.
Prior to spray ing o f paint, the ai rcraft ol major assem bl ies

the reef m ust be su i tably grou nded to prevent ex plos ion o r
fires caused by static discharges during the spraying
Grounding
operation.
When not specified, use the general range of 8-12 psi.

Viscositv of mateial is controlling factor. FIeavier viscosilics rt~ciu i I(l higher prcssures.
NOTE
~essle res are for normal sprray painting
at Sl,r id ta n.k beu!el, using a stand~crd fluid
hosr..iX i~n. r.n. by ~Oft length.
Inc~tase material pressure at the rate of 1 psi for each ft of
elevation when spray painting above the normal fluid
tank level. A proportionate increase of fluid pressure is
requiled for fluid hoses longer than 20 ft.
FACII,ITIES
Ventilation
Ventilation rate must be commensurate with
protective
measures
necessary to
personnel
protect painters and
helpels from health hazards created by cleaning and

painting procedures employed: and must be capable of
preventing build-up of explosive vapors or mists.
Air must be introduced into spray rooms in such a manner
not to cause turbulence or excessive air currents which
\Iould have effect of causing orange peel in applied paint
film.
as
Intluceti ail in spray rooms must be filtered to ensure that

dirt and tlust are kept to a min.
Lighting
Adecluate lighting
must be provided to illuminate all

of surfaces to be painted and to ensure uniform
appliclxtion of coatings. I,ights must be cleaned as
frequently as necessary to maintain this level.
area~
Scaffolding
Suitable scaffolding or staging must be provided to
fac i litate painting from different levels and to enable the
sl"a! paintels to maintain ;1, wet-edge on the coating
beiny applied.
Housekeeping
Clean spray
necessary to
from
room
floors and scaffolding
as
often
as
prevent dirt, dusts and dried paint materials
contaminating the surfaces being painted.
I)o Ilot
lint
bearing
1ags in the
paint
area.
20-30-70
Page 18
Aug 31/84
COPYRIGHT, 1984 BY SRB-RELINER CORPORATION
SR-76-023
RADOME COATING MATERIAL APPLICATION

INSTAI,LATION NOTES
(;ENERAI,
the materials and procedures used to
Safety
abrasion-resistant, chemical-resistant, and

impact-resistant coating to the plastic surfaces. The
MEKP
Ihis section
apply
covers
an
surfaces to be coated are usually glass fabric

forced
rein
plastic resin laminates. The coating material is
material.
a fast curing, air drying polyester
plastic
The coating is available in black, white, and various

colors.
MATERIALS
Acetone, Technical Grade
Methyl Ethyl Ketone(MEK)

Methyl Isobutyl Ketone
Prestec Finish No. 2111
I)ark Blue Color
I,ight Blue Color
Med i nm (;reen (:olor
PIestec Finish No. 2141
I)ark Red Color
Tan Color
Prcstec Finish No. 2192
Medium Gray Color
White Color
Pres;tec Finish No. 21812
()ff-White (~olor
PIestec Finish No. 21(11
lilask Color
Irc!stokleen No. 5411
Methyl Ethyl Ketone

Peroxide Catalyst (MF,KP)
Fed. Spec. 0-A-51

Fed. Spec. TT-M-261
Fed. Spec. TT-M-268
Presto Chemicals, Inc.
Sun Valley, CA
Sun Valley, C:A
Sun Valley, CA
Sun Valley, CA
Sun Valley, CA
Sun Valley, CA
Sun Valley, CA
(or equivalent)
Cat-A-i,ac White Filler
Bostik-Finch Inc.
Putty No. 467-1)

(ol ccluivalent)
Torrance, CA
(:le;ln ()il-Free (:loth

(:hcc!se C:loth
or
Nu-Wipe Absorbent
Ial,er Toweling,
(or
equ
Commercial
skin irritation. It is
Scuff sand surfaces to be coated with Na. 240 grit

sandpaper and wipe clean. The sanding should not extend
into the outer ply of fabric. All wax, grease, dust and dirt
must be cleaned from the sanded surface by wiping with a
clean cloth or Nu-Wipe toweling moistened (not saturated)
with MEK.
Following initial scuff sanding, fill all pinholes, voids and

other slight surface irregularities. Fill with Cat-A-Lac
White Filler Putty No. 467-~ (or equivalent). Mis the
Cat-A-I,ac Filler Putty resin and catalyst I,er the mallufacturers instructions immediately prior to use, mixing
within a 24 hour period.
no more putty than will be used
Discard
catalyzed putty which is unused at the end of
any
24 hours. The filler putty may be
squeegeeing,
or
Mliping with
dry
applied by knifing.
rag.
NOTE
Use only sand
or
galnet
onr
pape~ wken the
lygr of rlpet,~ral
applied filler to dry overnight (a min of Ifi

bake at 2500F for 15 minutes. Remove excess
filler by wet sanding dawn to the laminate with No. 240
grit followed by No. 400 grit sandpaper. The sanding
must not extend into the outer ply of fabric. Wipe sanding
Allow the
hours)
or
dust off with
clean cloth
or
Nu-Wipe toweling.
Mixing and Handling

must be maintained
fol storage periotls
65"F
and
40
between
a temperature
exceeding 7 days.
Uncatalyzed Prestec Finish material
naniel S. Morris Co.

I,os Angeles. CA
ivalent)
Sand or (;arnet Paper

No. 240 (;rit, No. 400 Grit
and No. 600 (;rit
cause
Surface Preparation

Sun Valley, (:A
Sun Valley, (:A

Sun Valley, CA
Ram Chemical Co.
Gardena, CA
liquid will sometimes
recommended that rubber gloves and eye protection be

while handling this material. Do not wash skin with
solvent. MEKP must be kept away from heat, sparks, and
of MEKP with any
open flame. Avoid contamination
readily oxidizable materials.
Commercial
at
Stir thoroughly and catalyze Prestec Finish material

with MEKP catalyst prior to application. Catalyze the
material by adding 2 parts (by weight) of MEKP catalyst
and
to 100 parts (by weight) of Prestec Finish material
blended.
Catalyze
is
thoroughly
mixture
the
until
stirring
used.
only the amount of Prestec Finish material to be
20-30-75
0
Page I
Aug 31/84
SR-76-023
COKROSION CONTROI, MANUAL
RADOME COATING MATERIAL APPLICATION

Although Prestec is often applied without thinning, it
mR) be thinned prior to application by adding up to 30
pal.ts (by weight) of acetone to 70 parts (by weight) of
catalyzed Prestec. The thinned material must be stirred
thoroughly prior to application,
If the catalyzed material is maintained at a temperature
of 77"F or less, it must be applied within 20 minutes after
it has been catalyzed. If maintained at a temperature
between 78 and 87"F, it must be applied within 11
minutes after it has been catalyzed. If these time limits
exceeded, the material may begin to gel in the spray
gun. The catalyzed material must not be heated above
87"F between the time it is catalyzed and the time it is
are
sprayed,
Remove catalyzed Prestec material from the spray equip-
immediately after completion of the spraying operation. Clean spray equipment as soon as possible with
either acetone or methyl isobutyl ketone. Prestokleen No.
5411 may be used to rernove any material which may gel
in the equipment.
ment
(Continued)
For thinned material, a pressure of between 30 and 40 psi

i9 USU"lly satisfactory. During spraying, the gun should
be held at a distance of 12-18 in. from the surface. If a
pressure pot is used, approximately 10 psi air pressure
Should be maintained on the material, and the moisture
trap and pressure tank must be drained frequently.
I" SP"Ying parts which have unusual or complicated
or which have compound curvatures (such as
co"ve"tional radomes), it is important that the path
followed by the spray gun be carefully selected so that the
"Umber of spray passes made over each area of the part
will be approximately the same. Otherwise, the thickness
of the applied coating may not be uniform. Failure to
carefully select the spray path followed in coating a
radome will generally result in excessive coating thickness
over the rounded nose of the radome.
"h"pes
Whe" the coating is to extend to any edge of a part, the

coating must be applied around the edge of the part as
Shown in figure 1.
COATING
Coating Application
Sl,raZ (:oating
All surfaces which
with a clean cloth
to be coated must be wiped clean

Nu-Wipe toweling moistened (not
are
or
PLASTIC
LAMINATE
saturated) with MEK. The surface must be free of all

wate!
moisture.
5116 +1/18 IN.
Mask over any areas not to be coated with any suitable

clean masking paper held in position along the edges of
the masked area with conventional masking tape.
A spray tack coat may be applied, if desired, prior to the
required flow or wet coats. In most cases several spray
coats will be necessary to produce the required coating
thickness.
Edge Treatment
Figure 1
Coating Finish
The cured coating must be smooth and free of defects such
NOTE
as
blisters, pin holes, lumps,
runs, sags, orange
peel, anti
other surface irregularities.
Th.e th~ckness of the applied Prestec coating

~rza.y be determinedfrorn thickness mea.surements made on, a test panel coated at the
sa,ne time alzd in the same manner as the
ploduction part.
The Prestec coating material is applied by spraying using
a suitable spray gun. An example of acceptable
spray
equipment is the ninks Model 18, using a No. 66SD Air
Nozzlc, a No. 66 Fluid Tip and a No. 65 Needle. When
unthinned matelial, an air pressure of between
Il):~lld ~O r,si i~ usually satisfactory.
20-30-75
Page 2
Aug 81/84
GOPYRIGHT,
SR-76-023
RADONLE COATING MATERIAL APPLICATION (Continued)

(;oating Gpplication (Contd)
Coating Finish (Contd)
If the final finish coating has an orange peel surface,
with No. 240
remove the orange peel pattern by sanding
grit sandpaper and recoat the surface. Where additional
coats of Prestec Finish are applied to cover surface
blemishes or surf ace discontinuities las in the local area of
alightning diverter installation), the local surface should
be appropyiate)y sanded to preclude excessive local buildup of the
coating thickness.
NOTE
Thickness of Prestec coatings builds

rapidly during spray application due to
high solids content of material. Material
a good filler coating for smoothing
rough surfaces. When filling is desired,
apply R or 3 coats and sand with either No.
grit or No. 400 grit sandpaper either by
hand or using a power sander. Sand drll
possible, and remove dust by wiping with a
clean, cloth or Nu- Wipe towelingjust prior
to application offinal finish coat.
makes
The coati ng will cure in from 20-60 m i nutes, depending on

the roam temperature. Fully cured coatings may be
cleaned with water and mild detergent solution, but must
not be cleaned with solvents.
A fter the Prestec material has cured, sand (with No. 600
area that has been coated.
Remove
overspray by sanding with No. 600 grit
grit sandpaper) the total

any
sand paper. The recoated surface areas should be polished

to the desired gloss using any rubbing compound suitable
for use on plastic materials.
Touch-Up
Damaged
touched
The
or
worn
areas
up in much the
area or
of the coated surface can be

way as painted surfaces.
same
spot to be recoated should be sanded with No.
grit sandpaper. Sand areas from which the coating

has been chipped to a feather-edge. If the coating continues
to flake during sanding, continue sanding until a well
bonded area of coating is reached. Otherwise the repaired
24()
surface will continue to flake due to lack of a bond. The

surfaces around the spot to be touched up should be
cleaned by sanding with No. 600 grit sandpaper.
Clean the surface to be repaired by wiping with clean
cloth or N u-Wipe toweling moistened (not saturated) with
ME:K. The Prestec Finish material is prepared and
applied to a repair area the same as applying a total
recoat.
20-30-75
COPYRIGHT, 1984 BY SABRELINER C~ORPORATION
Page 3/4 Blank

Aug 31/84
SR-76-023
CORROSION CONTROL MANIIAI,
POLYURETHANE INTEGRAL FUEL TANK

COATING APPLICATION
GENEHAL
Air
Ihis section covers the materials, equipment, and procedures for application of a fuel resistant, corrosion inhibiting coating to specified detail parts for use in integral fuel
The paint spray room must use filtered air. The amount of
air forced into the spray room should exceed the volume
withdrawn. Air must be introduced in such a manner as
not to cause turbulence or excessive air currents and must
be maintained at a min of 125 fpm at the exhaust in the
painting area. Room air must be exhausted thru an
exhaust system so that overspray does not settle an parts
tanks,
MATERIALS
Polyurethane Coatings for Integral

Fuel Tanks No. 827
SB0125-006
376
as kits) DeSoto
Chemical Co. (Tinted)
(Purchased
Floors
Trichloroethane, 1, 1, i, Technical,
0-T-(i20
Inhibited
Methyl F,thyl
Ketone
(MEK)
Oxolvo. I~tch Solvent, No. 020-~38,

DrS(,to Chemical Co.
Naphtha, Type II
Lacquer Thinner
Paper., Kraft, Untreated Wrapping
Non-woven, Non-metallic Abrasive
Mats, Type I, Class 1 or 2, Grade A
or Finer, Scotchbrite (.7M Co.)
Surface Alkaline Waterbase (Air
Tech No. 19, Turco Products)
Neutral Paint Remover, No. 5351,
Turco Products
Cheesecloth
No. GR-99 Bostik Div.,
Tack Rags
Corp.. Middleton, MA, or

eyuivalent
Ru bber Cloves (Rubber Hase or
Nylon)
TT-M-261
Commercial
TT-N-SS
TT-B-266
UU-P-268
MIL-A-9962
The spray room must be kept clean, and free of rags,

the beginning
paper and other debris. Hose down floors at
of each shift to keep the overspray and other dust contained
on the floor
Temperature and Humdity

drying. The temperature of the spray room must be in the
of 60 to 900F and the relative humidity
the range of 25-75~0.
range
MIL-C-25769
Commercial
Commercial
Commercial
Commercial
UXM
4()() (;rit
being painted.
Spray Guns, Hoses, and Brushes

Spray
Guns
The following equipment and adjustments are satisfactory

for use in the application of this material.
i.
Pressure
a.
Commercial
Ial,er
b.
Tape. Masking (3M Co., No. 250

Mystik No. 62~0, or eyuivalent)
(:hemical C:artridge Respirator
or
Commercial
Commercial
No. R21
2.
Commercial
Regulateair pressureasfollows:
6-I) Dsi (Increase
Pressure feed tank air
necessary for elevated painting)
Commercial
b.
Spray Eyuipment
I,i~hting
36-45
psi
as
at the spray gun
Sil-then CupGun
a.
EQUIPMENT
Iaint
SprayCun
Use a DeVilbiss MBC spray gun with a No. E

needle and nozzle and a No. 30 air cap.
Atomization air
Cartridges)
(;lasses, (;oRlr;les or Face Shields,
Safety
I"ibel Brushes or Tampico Brushes
be in
Discontinue application or curing of coating when ambient

air temperature is below 60"F.
Commercial
Wet-or-Dry Abrasive
must
Use a DeVilbiss MB(I spray gun ~ith a No. E

needle and nozzle and a No. ~O ail cap.
Regulate atomization air

psi at the spray gun.
pressure to deliver
35-45
following precautions should be observed while spray

painting the integral fuel tank coating.
Dusting or rippling will be caused by too high an air
The
min of 50
roam should be well illuminated (a
ft-candles), using vapor and explosion-proof lights, and
floor lighting equipment, when necessary.
The spray
pressure.
Orange peel and sags will result when the air pressure
is too low or the fluid pressure is too high.
20-30-80
Page 1
0
AuK:11/~4
SR-7Ci-023

COATING APPLICATION (Continued)
Sl,ray (;uns, Hoses, and Hrushes (Contd)
Painters and others mixing these materials must wear

solvent-resistant gauntlet style gloves, and goggles to
Ail I,ines
protect
131ow out air lines at least twice each day when painting to
purge lines of oil or water. Air lines must contain an air
filtel and water separator. The filter must be changed at
least
once a
month.
Brushes
Ensule that brushes have good quality bristles and are of
of adequate size for optimum application to the area
requiring touchup.
Equipment Cleaning
eyes.
Surface Preparation
integral fuel tank coating is applied to surfaces that

have been properly surface treated.
All surfaces to be coated must be free of foreign material.
If necessary they must be wiped with a clean cloth
dampened with ME:K, then wiped dry.
The integral fuel tank coating must be applied within 2rl
hours after surface treatment subject to the following:
Time after Treatment
Clean equipment immediately after

this purpose,
use.
Use MEK for
If
coating has cured on equipment, MEK will not remove

it. Use Turco stripper No. 5351. When stripper is used it is
important to thoroughly rinse away all residue, using
water followed by repeated rinses of MEK.
Action Before Coating
1-4 hours
No further preparation
when clean and dry.
4-24 hours
Solvent clean.
Mixing and Handling

Procedures
NOTE
Uo not use stripper
medium. Use stripper
as
The fuel tank coating is a two component catalyzing

material that is purchased and stocked as a kit. Do not
intermix product components of one manufacturer with
pump purge
for parts cleaning
product components of another manufacturer.
onlll.
When mixing,
INSTALLATION NOTES
supplied
Solvents and coating materials are toxic and flammable,

Observe fire, health and safety precautions to preelude injury to personnel and damage to equipment and
facilities,
Painters and others when
gral fuel tank coatings
mixing and spraying intewear a chemical cartridge
must
respirator.
Parts to be coated, and the spray equipment must be
grounded prior to air spray application and equipment
purging. This requirement is mandatory to prevent flash
fires or possible explosion resulting from build-up of
staticl electricity.
Apl,ly these coatings
in adequate ventilation. Avoid

i th the sk in and eyes. Do not ingest. i)o not inhale
vapors. WASH HANDS BEFORE EATING OR
SMOKING. In case of contact of the coating material with
skin, wash with soap and water. In case of eye contact,
immediately wash eyes for at least 15 minutes; get
medical attention.
t.act
the batch of base material and catalyst

kit. Never substitute the catalyst from
use
another batch.
Safety
con
as
Mix the material by agitating the base while slowly

add ing the catalyst. M ix quantities less th an complete k its
by weight only.
i.
SprayApplication MixingRatios
Product
Component
Base Material
No. 827 x 376
Catalyst No. 910-702
Volume
Weight
4 parts
100.0 parts
1 part
22.5 parts
Allow mixed material to chemically react for :~O

minutes, then add:
Thinner No. 020-707
4 parts
63.7 parts
NOTE
After chemical reaction

restir before use.
and
thinning,
20-30-80
Page 2
Aug 31/84
COPVRIGHT, 1984 BY SABRELINER CORPORATION
SR-76-023

I)ryin~ rime
IIocc!tfurcs (~:ontd)
I~rush
2.
Application MixingRatios
Product
Component
Weight
Volume
Rase Material
No. 827 x ~76
Catalyst No. 910-702
Thinner No, 020-707
parts
part
part
100.0 parts
22.5 parts
16.0 parts
NOTE
must be cooled to ambient
Slozalll add the catalyst to base material

while stirring, ne?ler the rever~e. Material
m~zacl and thinnedfor brushing must stand
30 miTLutas
after catalyxing prior
Stir material
to
use,
before using,
Strain material. Coating mixture requires continuous

agitation to maintain its stability. This requirement can
bt! accomplished in the following ways.
Iressure circulating system with material hose not to
exceed 5 ft.
Agitation
pressure
pot with material hose
not to
exceed 5 ft,
or
When painting of coating has ceased for

more than 10 minutes it is mandatory to
bleed out the material in the line.
Pressure cup
or
agitation byhand
suction cup shall be kept under

or by mechanical stirring.
Max pot life of spray material is 7 hours at temperatures

of 75"F. After max pot life, discard any unused catalyzed
material.
C:oatinlJ. Application
Spray apply I iRhl wet s i ngle coats to ach ieve the requ i red
film thickness. When touch-up is applied by brush, apply
uniform wet coat.
Coating Repair
Sand and clean the affected area with Oxolve etch solvent
No, 020-338 using clean wipers, and wipe dry immediately.
Repeat this cleaning as often as necessary to ensure
cle""liness.
Coating Finish
Appearance
The dried coating must be uniform, smooth and free of
applied coating
on
capable of passing the
An adhesion cure test must be made

solvent wipe test.
wet
using the follo\\~ing
After the applied catalyzed coating has reached ultimate

of
cure in accordance with table i, saturate a piece
cheesecloth with MEK solvent, then wipe a selected area
with at least 50 double strokes using moderate hand
removed from
pressure. If coati ng m aterial is d issolved or
and is
failed
considered
is
as
substrate, coating
unacceptable. A slight strain evident on cheesecloth will
total dry film thickness of the applied

mils. The absolute min film thickness is
is
0.8-1.5
coating
0.5 mils and the absolute max film thickness for flat areas
is 2.0 mils. Edge, ends and areas adjacent to recessed
the max.
areas due to confiffuration of parts may exceed
acceptable
be
Cure Test
optimum
requirements are not applicable to

grit or roughness. Runs, sags, and grit are not
must
adhesion tape test after ultimate cure or at the timetemperature conditions specified for exposure to fuel or
traffic as specified in table 1.
not be
runs, sags,
grit.
Adhesion Test
The
Film Thickness
The
temperature before handling
traffic.
runs, sags or
NOTE
one
Table I gives min drying times of the coating at va,ious

temperatures and humidities, prior to subsequent exposure
l,o fuel, production, traffic or handling of detail pal.ts.
Where force drying is specified, a period of 15 minutes at
ambient temperature is required to permit solvents to
flash. Time at force cure temperatures means time after
the structure has attained the specified temperature. All
Detail
cure times must be conducted with air circulation.
parts and subassemblies which have been force cured
cause
for rejection.
NOTE
This test may be performed on p,ocess
control panels cleaned and coated in
conjunction with detail parts.
The film thickness
detail parts.
20-30-80
o
Page
Aug 31/X4
SR-76-023
C()KROSION CONTROI, MANUAL

Table i.
CoatinffCureSchedule
EXPOSURE
Fuel
ol
Traffic
HandlinR of Detail P~trts
Immetliate Assembly
Irltimate Cure
TEMPERATURE ("F)
RELATIVE HUMIDITY (96)
TIME MINIMUM
Ambient Cure
Force Cure
Force Cure
90-115
20 Hours
6 Hours
120-14Fj
i-Hour
Ambient Cure
Force Cure
Force (:ure
120-14Fj
170-200
Force Cure
170-190
Air Dry
Force Cure
plus Air Dry
Force Cure
plus Ail Dry
Force Cure
60
(Min.)
GO(Min.)
40-80
40-80
llj Minutes
I Hour
50-80
120-145
50-80
170-200
50-80
2fj0
2 Hours
RO Minutes
14 Days
2 Hours
7 I)ays
1 Hour
7 Days
~O Minutes
20-30-80
Page 4
Aug 31/84
SR-76-023
ORGANIC INTEGRAL FUEL TANK COATINGS APPLICATION

NOTE
(;ENERAL
This section covers the application of a two-part polyulethane coating to be applied to all surfaces within the
inln~Kral fuel tank.
The polyurethanefuel tank coating mu.st be

applied to titanium surfare,s within L4
ol an ot,solcte
Ihis soct(.io~l also covc!ls the
I(u II a- N ~,ased coati nff to litan i um with i n the i ntegral fuel
One c.oal of splay al,l,lic!tf Co;ltinK rnusl h;lvr:~ dry Fillll

thickness of 0.8-1.2 mils.lwo coats must have a dry fil ill
tank.
thickness of 1.6-2.4 mile.
MA1ERIALS
Measure coating thickness by micrometer

method after cure is completed.
Ioiyurethane Coating
integral
ST0125LB0006
for
Fuel Tanks
after chPmiccrlfilm
INSTALLATION NOTES
equivalent
highly flammable ketones
as
cure
Polyurethane Coating:
Cure per
solvents,
Preparation
A min of 14
one
of the follouing
days (450F min; Relative humidity, 200~,,
min).
OR
2~
A min of 30 minutes after part has reached 260"F
(26FjOF max),
Buna-N-Coating: Cure a min of 30 minutes aftel part
reached 250"F (2fi6"F max).
A I I ~u rfaces must be free of d i 1,t, oi I. Kr.case and other shop

soils I,l.ior to applying fuel tank coatinR.
NO TE
I~rocedures employed for the removal of shop soils must be

they do not remove or damage surface treatments. Any bare metal or damaged surface treatment
coating application.
has
The Buna-N coating will change colo~rfrorn

cerise to rPdish brown 07 da.rk tan on
such that
before
coatings in accordance with
Prior to exposure to fuel,

the following:
1.
Polyurethane coatings contain solvents and other comtoxic

ponents such as toluene diisocyanate (TDI) that are
the skin in
an sensitizing if inhaled or absorbed through
excessive quantities. Buna-N based coatings contain
repaired
ol
schedules:
Safety
must l,e
trPatment.
Coating Cure
ST012FiLB007
Coating for Integral Fuel Tank

Titanium Components
Surface
ho~ls
curing,
Appearance and Adhesion

pin holes, blisters, and
Mixing and Handling
The coating must be free of

other defects.
Iolyurtlhane (:oating
Test coating adhesion by applying a 1 in, wide by about 4

in. long strip of masking tape to the coating. Press at least
Z i,~ of the tape tightly to the surface using either a rubber
roller or the palm of the hand. Remove the tape with one
quick motion. Visually examine the coating for evidence
df damage. Evidence of coating removal is cause for
rejection- Discoloration of the tape does not constitute
Combine catalyst and thinner supplied into the base

material in the ratios recommended by the manufacturer,
The material must stand for 1 hour after mixing, No
material may be used longer than 4 hours after the
standing period.
Run;l-N Coating
runs,
failure.
Hetluce cctatina to viscosity suitable for

atl(lition of methyl-isobutyl-ketone.
spraying by
the
NOTE
lhhs u.ur of the Bunu-N coating ix o~solete
and its uxc! is rastrietud to maintenance of
HM.w,tr-N couf.cd
Up
Touch-up is permissable provided it does not damage any
metal pretreatment. Coati ng th ick ness ii m i tations tlo not
Touch
apply when repaired
or
touched up
area
is 4 squwre in.
oi
less.
After touch-up, where curing at ~T,OOF is im~,ractical,

the material for a min of 48 hours :~1 room leln-
cule
Coating Application
perature.
Al,plication Method
Coati nlSs
are
normally applied by spraying. If spraying is
impractical, brushing
may be
used.
20-30-85
0
Page 1/2 Blank

Aug 31/84
SR-76-023
PROTECTION OF AIRCRAFT IN OUT-OF-DOORS

TEMPORARY STORAGE
Rubber Gloves
GENERAL
covers the preparation and application of a
temporary coating system which will provide protection
of aircraft exterior aluminum surfaces when stored in an
This section
out-of-doors condition for
period of up
to 1 year.
MATERIALS
Corrosion Preventative Soft Film

Type III, Class I or II
Non-Flame Sustaining Aluminum

Surface Cleaning Compound
TT-M-261
TT-N-95 (Type II)
TT-T-266
UU-P-268
MIL-C-81309
MIL-C-5410
(Type II)
Paper
Tape, Masking (3M Co., No. 250)

Decal Material (Fascal 500G or
PPP-T60
Commercial
Commercial
Commercial
Commercial
Striping Brushes
Polyethylene Film (0.005 in.)
No. 471 Vinyl Tape (3M Co.)
Commercial
Commercial
Commercial
Commercial
Fabric or Aluminum Foil Tape

Cheesecloth
Tack Rags No. GR-99 Bostik Div.,
or
Commercial
equivalent)
Blackout Tire
Commercial
Coating
room should be well illuminated (a min of 50

ft-candles) using vapor and explosion-proof lights, and
floor lighting equipment, when necessary.
The spray
SB0125-024
MIL-C-25769
Stripper)
Dyed Deep Blue for
Markings (Turco Products) or
equivalent Waterbase, Alkaline
Removable Coating
paint Straining Funnels
Aluminum Foi1(0.00Tj in. min)
equivalent
Corrosion Preventative Soft Film
Paint Spray Room
Commercial
Turco No. 4983
or
EQUIPMENT
Surface Alkaline, Waterbase

Turco AirTech No. 19 or
equivalent)
Epoxy System Paint Remover,
Turco No. 5351 (Neutral
Commercial
Commercial
MIL-A-9962
equivalent)
Epoxy Polyamide Primer, Filiform

Corrosion Inhibiting
Commercial
Commercial

Coveralls, Lint-Free
Caps, Painter Type
Glasses, Goggles or Face Shields,
Safety
(WD-40
TT-P-1757
MIL-C-5541
Commercial
equivalent Decal)
or
Cloth Rack Adhesive Tape

(Waterproof) Class I
Zinc Chromate, Primer
Aluminum and AluminumAlloys
Non-Woven, Nonmetallic Abrasive
Mats (Require Type I, Class I or
II, C;rade A or Finer, Scotchbrite
Commercial
Use filtered air in the paint spray room. The amount of air
forced into the spray room should exceed the volume
withdrawn. Introduced air in such manner as not to cause
turbulence and excessive air currents and maintain a min
of 125 FPM at the exhaust in the painting area. Withdraw
room air thru an exhaust system immediately at one end
of the aircraft or part being painted so overspray does not
drift into other
areas
of the
room.
spray room floors clean, and free of rags, paper,

and other debris. Hose down the floors at the
beginning of each shift, and in the area of the aircraft,
approximately 1 hour prior to the beginning of the
painting of the aircraft. Additional floor wetting may be
required to keep the overspray and other debris on the
Keep the
and
Commercial
Commercial
Commercial
Commercial
Commercial
Commercial
or
eqyivalent
Scotch-Brite (3M Co.)
Base
Glove Powder (Talc)

No. 400 Grit Wet-or-Dry Abrasive
0-T-620
Inhibited

Naphtha
Lacquer Thinner
Paper, Kraft, Untreated, Wrapping
USM Corp., Middleton, MA,
(Rubber
Nylon)
3M Co., No. 4600 Series
Trichlorethane 1, 1, 1, Technical,
or
or
Commercial
Commercial
floor.
Do not open hangar doors (large) for an hour before,
during, and for at least 1 hour after the painting of an
aircraft with the coating system. Personnel doors (small)
must be restricted, so that only one door to the outside is
available to foot traffic during this time period.
20-30-90
Page 1
a
Aug 31/84
SR-76-023
COKROSION C~NTROL MANUAL
TEMPORARY STORAGE (Continued)

Paint
The
Spray Room (Contd)

drying. Keep temperature of the spray room in the range
of 60 to 900F 1 hour before, during, and for 1 hour after
spl.ay painting this paint system. The relative humidity
must be in the range of 25-75% during this same time
period.
Spray Guns and Hoses

Spray gu ns and accessories used must conform with table
I requirements or be equivalent.
Table I.
Paint
Epoxy Primer
Type Gun
DeVilbiss JGA
OR
TEA Model 502
Tank Gun
Fluid Tip
Needle
Air Cap
Cup Gun
Fluid Tip
Needle
Air Cap
FF
FF
765
or
EX
EX
30
or
or
or
must be observed while spray
Dusting
or
rippling will be caused by
too
high
an
air
pressure.
sags will result when air pressure is
too low and fluid pressure too high.
Orange Peel and
The epoxy primer builds up in equi pment very rapidly.

Clean spray guns, lines, and pressure pots thoroughly
before and immediately after use with MEK. When
MEK is not available, use thinner commercially
available from primer supplier and compatible with
the epoxy primer.

Blow air lines out at least twice each day, or oftener if
necessary, when painting an aircraft to purge lines of
oil and water.
INSTALLATION NOTES
Surface Preparation
FX
FX
Mask off all plastics, glass, rubber, fabric or other

surfaces that would be damaged by solvents, chemicals or
water using aluminum foil or fabric tape and Visqueen
paiyethylene film.
FX
FX
Fluid lines must have a min I.D. of

exceed 75 ft in length.
following precautions
painting.
wax deposits, soils, oils or other surface contamination by washing aircraft metal surfaces with clean,
lint-free cloths saturated with MEK or equivalent.
Remove
3/8 in. from tank
to
gun, and not
Areas suspected of corrosion must be repaired.
High pressure air hoses leading to regulator or tank must

have a min I.D. of 7/16 in., and a max length of 150 ft. Air
hoses from tank to gun must have a min I.D. of 5/16 in.,
and a max length of 75 ft.
All abraded areas where surface treatment has been

removed must receive a chemical film touchup prior to
Recommended pressure settings for fluid tank, regulator,

and spray gun are listed below:
Fluid tank setting
Air regulator setting
Air pressure at spray gun
8-12 psi
60 psi
40-45 psi
Add 1 Ib of fluid pressure for each ft of

height of the gun abo~e thefluid tank level,
for nomzal operation.
a
Mixing and Handling

The unmixed epoxy primer components have
limit of 1 year.
shelf life
Stir Component I until pigments are thoroughly mixed.

(Mix on Red Devil shaker or equivalent method.) Reduce
Component I(pigmented solution) with Component II
(clear solution) in a 1 volume to 1 volume ratio. Temperature of components must be above 600F(160C)before
mixing.
NOTES
Frequent cheeks should be made with
applying primer.
Pour Component I into a proper size empty container,

allowing adequate time for complete drainage. Component Il is then slowly poured into Component I with
constant stirring. Allow proper drainage time for Component II. Each container of Components I and II may be
rinsed with the non-photochemically reactive solvent type
thinner. Component II must always be added to Component I; this procedure must not be reversed.
test
gauge to detemnine air pressure at the gun.
20-39-90
Page 2
Aua:11/84
COPYRI~HI, 1984
BY SABRELINER @ORPORATION
SR-76-023
CORROSION CONTROL MANIIAL

TENIPORARY STORAGE (Continued)
Windshields and Windows
or glass surfaces with soft clean

all dirt particles are removed. PIotect
with polyethylene film or aluminum fail (min thickness
0.005 in.). The film or foil is cut to the desired shape and
overlaps the structure 1/2 +1/4 in. Tape and seal all
edges to ai rcraft structure using No. 471 vinyl tape or cloth
back adhesive tape (PPP-TBO).
Clean and
NOTE
Never mit epoall prilnerfrom one supplier
.UYith primerfrom anotlker ctupplier. ~omponents are also not interchangeable.
lhin 2 volumes of the Class 2 admired primer for
spraying by adding approximately I volume of nonphotochemically reactive thinner compatible with Class 2
primer as specified in manufacturers directions. The
spraying viscosity must have a range of 16-20 seconds
when checked with
dry plastic
cloth, making
No. 2 Zahn cup,
Stir the thinned primer thoroughly, strain thru 2 paint

strai ning funnels or 2-3 layers of lint-free cheesecloth, and
allow tocatalyze at room temperature for 1 hour before
sure
Exterior Plated and Hydraulic Surfaces

Coat all plated metal surfaces and hydraulic struts and
piston rods (such as slat-tracks and landing gear shock
struts) with corrosion preventive solvent soft film
c0mp0u"d MIL-C-81309, WD-40, or equivalent.
Exterior Rubber Parts
Coat all exterior rubber parts (except deicer boots)
exposed to weather with a coating of blackout tire coating.
Do not allow oil or grease on tires.
using.
NOTE
Epoxy primer should be admized onB in tile

amount that can be used in I sh~ft. The pot
life of the admized primer is 8 hours.
Application of Protective Coating

Inspect prior to primer application to ensure surfaces are
free from corrosion
or
other surface contamination.
Surface finish
After completion of the catalyzing period, the admired
The pr i med su rfaces must be free of su rface i rregularities

such as excessive or insufficient paint coverage.
and thinned
Film l,hickness can be checked using

Thickness gauge or equivalent,
Boonton Film
Touch Up
Scratched or abraded paint areas must have primer

touched up prior to extended outside storage. Areas may
be touched up with zinc chromate primer TT-P-1757.
Additional Aircraft Preservation
epoxy-polyamide primer is sprayed with 1

to
coat
a
cross
dry film thickness of 0.0005-0.0008 in. The
films of
spray gun must be kept moving to avoid thick
epoxy
run as
coating. (Thick coats of epoxy coating do not sag or

readily as do other types of paint.) Allow to ail dly
for a min of 4 hours prior to subjecting to inclement

weather.
Relative humidity seems to have no significant effect on
the epaxy primer. However, the temperature of the
surface to be painted and the paint should be between 60
and 90"F.
Slight color differences between adjacent

Exterior
Openings
practical, any openings (unsealed access and

inspection doors, vent holes, seams, personnel door, etc.)
Wherever
i nto which moisture can enter the interior of the aircraft is

closed by suitable means. (Aircraft in flight status are
exempt from this requirement providing that the
windows, doors, covers and other closures normally a
part of the aircraft are maintained in a closed position
when there is danger of water entering.)
cause
for
areas
is not
rejection of the primer.
Masking for temporary insignia and markings for flight

tack free; a min
may be begun after the coating has dried
of 2 hours. The temporary insignia and markings are
stenciled or sprayed over the primer. Use either Turco
No. 4983 coating dyed deep blue in color or decal material.
Stripping Protective Coating
Prior to
processing aircraft
remasking all surfaces that

strippers, solvents, water.
by
damage by
for final finish, pl.otect

are
subject
to
20-30-90
0
Page 3
Aug 31/84
9~3-76-023
C()HROSION CONTROL MANUAL

TEMPORARY STORAGE (Continued)
Stripping Protective Coating (Contd)
IIWrlOl[ll~l
Protective clothing, rubber gloves, andface
mask must be worn during stripping
operations.
Remove the temporary protective coating by applying a
paint stripper, Turco No. 5351, full
coating to be stripped. The remover may
be applied by brush, roller or spray. Aircraft surfaces and
stripper must be above 70"F.
unifo,m coat of
strength over the
Allow sufficient dwell time for stripper to thoroughly

loosen the coating. Agitation with a stiff fiber brush will
aid in the removal.
Rinse surface with high pressure, high volume water or
by steam cleaning. Slight brushing during rinsing operation will assist in complete removal of all residue.
20-30-90
Page 4
Aug 31/84
CBPYRIGHT,
1984 By SABRELINER CORPORATION
SR-76-023
ANODIZING AND COLORING OF ALUMINUM ALLOYS

to suspend parts being
processed must be made of suitable aluminum alloys and
capable of withstanding high anodizing currents.
Wires, clamps and racks used
GENERAL
This section includes procedures for forming an anodic
film by either the sulfuric acid process or the chromic acid
process; and the procedures for coloring the anodic film,
either by means of dyes or by precipitation of an organic
pigment.
Aluminum alloys t100, 3003, 5052. 5056, and 606 1 may be

anodized by either the chromic acid process or the sulfuric
acid process before coloring.
Anodize aluminum alloys 2011, 13, A13, 2014, 2024, 7075,
220, 356, 360, and 384 by the sulfuric acid process before
MATERIALS
Nitric Acid, Technical
Grade
0-A-88
Acid, Sulphuric, (For)

Storage Batteries
Chromic Acid, Technical
0-S-801
coloring.
Handle and store processed parts in a manner that will
or contamination of the anodic coating.
prevent damage
0-C-303
APPLICATION NOTES
Grade
Phosphoric Acid, Technical

Grade
Sodium Dichromate,
Technical Grade
Caustic Soda (Lye)
Acid, Hydrofluoric,
Technical
Cleaner: Alkaline, lilild
Metal Black MP
Aluminum Black 3B
Preliminary cleaning may be accomplished

quired. (Refer to Section 20-10-15.)
0-P-313
0-S-595
Anodizing and coloring
operation of the
Corp.
Sandoz Chemical
Neolan Green WA
Nickel Acetate, Technical
Los Angeles, CA
Sandoz Chemical
Works, Inc.
Ciba Company, Inc.
San Francisco, CA
Ciba Company, Inc.
Commercial
Grade
emmonium Hydrosulfide,
Commercial
Neolan Black ALU
Technical Grade
Cobalt Acetate, Technical
Grade
accomplished
in
Tanks, electrical generators and other equipment must be

of such construction and capacity as to provide satisfactory
Works, Inc.
Aluminum Black BK
be
re-
accordance with tables 1 thru 4.
P-S-631
0-H-795
RB0210-005
American Aniline
Chicago, IL
must
when
Commercial
entire process.
Thermostatically controlled heating must be provided in

the cleaning, anodizing, coloring, setting and sealing
tanks.
Air agitation must be
provided
in the
anodizing tanks.
Removal of anodic coatings from parts must be accomplished in accordance with the procedure outlined in table
5. Wires, clamps and other connectors or part holders
must be stripped of any anodic coating on electrical
contact areas before reuse, since the coating prevents
proper electrical contact with the work.
FINISH
Parts or assemblies found to have unsatisfactory film
characteristics must be completely stripped and
reprocessed.
PREPARATION
Hazardous chemicals used in these procedures must be
handled with caution.
Weld parts
or
assemblies before anodizing.
A nodize welded parts and assemblies by the chromic acid

process per table 1.
Do not anodize by the sulfuric acid process parts and

assemblies which contain joints and recesses capable of
retaining the anodizing solution.
Parts and assemblies containing exposed material other
than an aluminum alloy surface may be anodized only if
the non-aluminum surfaces are completely masked, including a safe margin of overlap.
20-40-05
0
COPVRIGHI, 1984 BY SABRELINER CORPORATION
Page 1
Aug 31/84
SR-76-023

Table 1.
Chromic Acid Anodize and Dye Process
Degrease
TEMP
"F
SOLUTION
COMPOSITION
OPERATION
i.
(Continued)
TIME
pH
REMARKS
I (Refer
to
Section 20-10-55.)
2.
(a)
Clean
6 oz mild alkaline
cleaner per gal of
water,
(b)
160-180
I
I
or
5% caustic soda solution
10 minutes
I
I
I
I
Use either the non-etch
I cleaner(a) or the etch

I cleaner(b) as required.
60 seconds
120-150
3.
Rinse
Tap Water (flowing)
Room
20-30 seconds
With agitation
4.
Pickle
10% nitric, 1% hydrofluoric

acid by volume
80-100
5.
Rinse
Tap Water (flowing)
Room
20-30 seconds
With
6.
Rinse
Tap Water (flowing)
140-160
20-30 seconds
With agitation
7.
Anodize
5% chromic acid solution
120-125
60 minutes
Voltage and current

density requirements
vary with each alloy. (6-
5 minutes
agitation
12 amperes per square ft
typical)
8.
Rinse
Tap Water (flowing)
I).
Dye
(a)
2.2~1, Metal Black
Room
MP,
20-30 seconds
150-170
6.4-6.6
10-15 minutes
I 1 140-160
5.5-5.8
10 minutes
With agitation
or
(b)
1.2%Aluminum Black
BK,
(c)
or
1.2%Neolan Black
ALU 0.20m Neolan
Green WA
10.
Rinse
11.
Seal
1% nickel acetate solution in

distilled water.
12.
Rinse
Tap Water (flowing)
13.
Dry
14.
Wipe
Room
I Tap Water (flowing)
200-210
Room
1 20-30 seconds
5.5-5.8
In distilled water
With agitation
1 5 minutes
1 20-30 seconds
With agitation
I Dry
cotton cloth
20-40-05
Page 2
Aug 31/84
COPYRIGHT,
1984 BY ~BRELINER CORPOS1A~ION
SR-76-023
CORROSION CONTROI, MANI~AI,
ANODIZING AND COLORING OF ALUMINUM ALLOYS (Continued)

Table 2.
Sulfuric Acid Anodize and
OPERATION
Degrease
i.
Dye Process
TEMP
"F
SOLUTION
COMPOSITION
REMARKS
TIME
pH
I (Refer
to
Section 20-10-55.)
2. Clean
(a)
oz mild aikaline
cleaner per gal of
water, or
(b)
59bcaustic sodasolution
3. Rinse
Tap
water
4. Pickle
(a)
(flowing)
l0%hydrofluoric acid,
acid, by
90% nitric
volume
I cleaner(b)
Room
I
I
I
I
With
20-30 seconds
(a)
10 seconds
Room
I
I
as
required.
50 seconds
120-150

cleaner(a) or the etch
10 minutes
160-180
1
I
agitation
Shall beusedon
13, 360, 384. Operation 4(a) preferred
for 43, 85 and 356
alloys, but they

be pickled as
per 4(b).
(b)
5. Rinse
35-400/onitric
volume
acidby
I Tap water (flowing)
Fia. Rinse
all other alloys
Room
30 seconds
(b)
Room
20-30 seconds
With agitation
As
Room
Water Jet
may
required
in holes and
recesses
6. Rinse
Tap water (flowinff)

(With agitation)
Required following
20-30 seconds
90-110
I pickling solution (a)
operation
Per
Table 4
7. Anodize
15%by weightsulfuric acid
8. Rinse
Tap
water
(flowing)
Room
(a)
1.2%Aluminum Black
140-160
9.
Dye
3B
5.8-6.2
of
in
50 minutes
Per Table 4
20-30 seconds
With agitation
10 minutes
(a)
Mandatory foralloys
with 9%
(distilled water)
use
or more
Si
(13,360, 380,384);
not to be used
other
(b)
2.2% Metal Black MP
(distilled water)
(c)
(d)
150-170
1.8lhAluminum Black
I 1 140-160
BK
1.2%Nealan Black
I
I
ALU 0.2% Neolan
I
(c)
10 minutes
5.5-5.8
Green WA
(b)
10-15 minutes
6.4-6.6
I
I
on
alloys
Preferred for all

other alloys
or
(d)
are
possible
substitutes which
may be used for
other type aluminum
alloys.
20-40-05
0
C;QPYRIGHT,
Page 3
Aug 31/84
SR-76-023
ANODIZING AND COLORING OF ALUMINUM ALLOYS (Continued)

Table 2.
Sulfuric Acid Anodize and Dye Process

SOLUTION
COMPOSITION
OPERATION
10.
Rinse
Tap Water (flowing)
11.
Set
1% nickel acetate solution
12.
Rinse
Tap
13.
Seal
water
(flowing)
5%, sodium dichromate
(Contd)
TEMP
OF
Room
200-210
20-30 seconds
5,5-5.8
Room
200-210
TIME
pH
With
agitation
5 minutes
20-30 seconds
5.0-0.0
REMARKS
With agitation
15 minutes
solution
14.
Rinse
15.
Dry
16.
Wipe
Tap
water
(flowing)
Room
20-30 seconds
Dry
With agitation
cotton cloth
20-40-05
Page 4
Aug 31/84
COP~RIGHT,
1984 BYSA.BRELINER CORPORATION
8B-76-023
ANODIZING AND COLORING OF ALUNLINUM ALLOYS ~Continued)

Table 3.
Sulfuric Acid Anodize and Pigment
i.
Degrease
2.
Clean
TEMP
"F
SOLUTION
COMPOSITION
OPEE1ATION
Precipitation
Process
pi-I
(Refer
(a)
6 oz mild alkaline
cleaner per gal of
(b)
4. Pickle
160-180
10 minutes
5% caustic soda solution
120-150
60 seconds
I Tap Water (flowing)

l0%hydrofluoric acid,
90% nitric acid by
(a)
Room
20-30 seconds
Room
10 seconds
(b)
5a. Rinse
35-40% nitric acid by

volume
I Tap water (flowing)

Water
Agitate parts
Pickle (a) must be used
13, 360 and 384 alloys,
4(a) preferred for 43, 85
and 356 alloys but they
Room
30 seconds
,~y b, pickled as per

4(b). Pickle (b) must be
used on all other alloys.
Room
20-30 seconds
Agitate parts
As
Room
jet

cleaner (a) or the etch
cleaner (b) as required.
on
volume
5. Rinse
to
Section 20-10-55.)
water
3. Rinse
REMARKS
TTME
required
in holes and
recesses.
6.
Tap water (flowing)

(With agitation)
7. Anodize
15%
by weight sulfuric
8. Rinse
Tap
water.
9. First Color
Cobalt acetate 204b
acid
(flowinff)
90-110
20-30 seconds
Required following use of

pickle operation 4(a).
84-86
50-60 minutes
Current density 16
amps/sq. ft.
Room
20-30 seconds
Agitate parts.
110-120
5.9-6.2
15 minutes
Dip
(flowing)
10. Rinse
Tap
11. Second
Ammonium
water
hydrosulfide
3%
Room
20-30 seconds
Room
5-15 minutes
20-30 seconds
Color Dip
12. Rinse
Tap
water
(flowing)
Room
13. Wash
Tap
water
(flowing)
Room
Wash, using soft

cloths
as
remove
wet
necessary to
any loose
pigment.
14.
Dry
20-40-05
0
Page 5
Aug 31/84
SR-76-023
(:()IIK()SION CONTROL MANUAL

(Continued)
Tablttl.
SulfuricAcid ProcessVariables
ALUMINUM
ALLOY NO.
18
85
360
384
~S
I1S
2ilS
52S
61,,
MAXIMUM
VOLTAGE
MAXIMUM
CURRENT
DENSITY
(AMPERES
(AMPERE:S
PER SQ. FT.)
PER S6t. ET.)
18
15
15
16
18
17
10
10
10
10
10
84-86
70-72
70-72
84-86
84-86
12
12
12
12
12
12
15
Ifi
17
14
14.5
16
12;
12
18
16
Stripping Procedure
OPERATION
2.
MAXIMUM
STARTING
VOLTAGE
10
70-72
84-86
84-86
70-72
356
i.
"F
84-86
84-86
4~
Table 5.
ANODIZING
TEMPERATURE
MAXIMUM
STARTING
CURRENT
DENSITY
SOLUTION
TEMPERATURE "F
Strip
2% chromic acid and 7% phosphoric

acid by weight in tap water
170-190
Rinse
Tap
Room
water
TIME
5-10 minutes
NOTE
Stripping procedurefor 1 3, 3~0, and S8~ aluminumallo?ls must befollowed by a

physical
of cleaning such asfine sandblasting, rubbing with aluminum wool, or
eguivalent.
means
20-40-05
Page 6
Aun aI!H4
CQPYRIGHT, 1984 BY SA&RELINER CORPORATION
SR-76-023
CHROMIC ACID AND SULFURIC ACID ANODIZING
lhis section
covers
the requirements for anodic coatings

alloys by the chronic acid and
to aluminum and aluminum
sulphuric acid
The
Types
II: Anodic
coatings applied by the sulphuric acid
process.
LIMITATIONS
must not be applied to aluminum alloys
with nominal copper content in excess of 5% or when the
total alloying elements exceed 7.5%.
Type I coatings
Type II coatings must not be applied to parts containing

joints or recesses which may entrap the anodizing solution.
APPLICATION NOTES
(12efer
to section
Surfaces to be anodized must be free from oil, scale,

or
Appearance
The anodic coating must be adherent, continuous, smooth.
uniform in appearance and free from powdery areas,
discontinuities such as breaks, scratches and burned
must be held to a
areas. Size and number of contact marks
min consistant with good practice and must be limited to
noncriticai areas.
Coating Continuity
The continuity and presence of an anodic coating ton other
than as cast, or as forged surfaces)must be determined by
using a battery operated ohmmeter or equivalent. A
resistance of less than 200,000 ohms on any anodized
surface is
Preparation
welding flux
film.
20-40-35.)
FINISH
following type designations applies.
process.
Surface
application of colored chemical
processes.
Type I: Anodic coatings applied by the chromic acid
Type
up of contact marks, blemishes. superficial

scratches, and minor rework may be accomplished \,y
Touch
(;ENERAL
other foreign matter.
Maukina
Prior to anodizing, mask exposed surfaces of nonaluminum materials and any exposed surfaces where an
anodic film is not required.
cause
for rejection.
Process Controls
Process control panels should be processed at least monthly
for coating weight and corrosion resistance. The panels
must be 2024-T3 bare (&&-A-250/4) 0.032 x 3 x 3 in. for
coatinff weight determination and 0.032 x 3 x 10 in. for
salt spray testing.
Coating Weight
must meet the following requirements
when tested per ASTM-B-137:
Coating weight
Application
Anodic coatings must be
deposited only after all heat

and perforating
treatment. machining, forming,

operations have been completed.
Type I
200
Milligrams
per so. ft.
Type II
600
Milligrams
per so. ft.
Sealing
Corrosion Resistance
Type I and Type II coatings

meet the corrosion resistance
suitably sealed to
requirements of Corrosion
must be
Resistance below.
Coating Weight
Coating weight
must meet the
requirements of
Process
Controls below.
After sealing, Type I and Type II coatings must be

exposed for 336 hours to the salt spray in accordance with
ASTM-B-117, except the significant surface must be
inclined 6" from the vertical. The specimens must show no
than 1/32
more than 5 isolated spots or pits, none larger
inches in diameter, except within
1/16 in. from edaes,
marks.
corners, identification markings and racking
Corrosion in excess of the foregoing is cause for rejection.
Rework
Stripping
Anodic coatings may be stripped only if dimensional
tolerances can be maintained. The solution must not cause
pitting or other damage to the basic metal,
20-40-10
0
Page 1/2 Blank

Aug 31/84
SR-76-023
CORROSION CONTROI, MANUAL
DOW NO. 17 ANODIZE PROCESS FOR MAGNESIUM ALLOYS

Electrical Installation
(;ENERAL
procedure for. direct current (dc)

anodizing malSnesium alloys by a process called Dow No.
Ihis section
covers
the
17 Anodize.
This
specification
meets the
requirements of MIL-M-
45202, Type I Class C, and Type II Class D. The designations indicate the following characteristics.
The equipment nlust be installed in such a manner as to

meet the electrical safety requirements under SAFEIY
below.
Timers
Suitable timing equipment, either manual
Class C:
Lightcoating
Light yellow-green coating (Dow 17)
TypeII:
Heavycoatinff
Class D:
Dark green coating (I)ow 17)
TypeI:
automatic,
provided.
Electrodes
1Jnless otherwise indicated, the Type I Class C coating

must be
or
It is suggested that the timing equipment be installed in such a manner that the de electrical
power source is shut off upon completion of anodizing.
must be
applied.
When a lined tank is used, the cathode electrode must be

made of steel. When an unlined tank is used, the tank itself
must be the cathode electrode.
MATERIALS
Ammonium Bifluoride (Talc-free
Commercial
preferred)
Sodium Dichromate
(Na2Crz07,2Hz0)
Phosphoric Acid, 850~wt (sp,

1.09-1.70 C.P.
or
0-S-595A
Commercial
gr.
N.F.
0-C-303
Commercial
Chromic Acid
Sodium Rifluoride (Talc-free
LIMITATIONS
Whenever possible, magnesium parts must be anodized
before any inserts are placed. If the foregoing is not
possible the inserts must be carefully insulated from the
anodizi ng bath by either a baked phenolic coating or vinyl
coating (5 or more mils thick). PVC type rack plastic
coatings are not resistant to chemical attack during
anodizing.
preferred)
NA35167
3M Company
Alkaline Cleaner
No. 410 Electroplaters Tape (or
equivalent)
Unless otherwise indicated, the Type II Class D coating

must be applied to all magnesium alloys processed accord
ing to this section.
EQUIPMENT
SAFETY
Anodizing Tank
Electrical
The anodizing tank must be made of unlined steel or steel

tank lined with synthetic rubber or vinyl base materials.
Stainless steel or aluminum tanks are unsuitable and
must not be used. The tank must be of such size that the
parts to be anodized are a minimum of 2 in, from the tank
Unlined steel tanks, used as cathodes during the anod i zing

operation, must be electrically grounded. In addition,
suitable safety devices, such as any physical barrier, to
prevent short-circuits during anodizing must be instal led.
Physical barriers must be installed in such manner as to
and/or heating coil.
shut off the de electrical
Heating and/or Cooling Coils

The heating coil must be made of carbon steel. Stainless,
lead, copper, aluminum or titanium must not be used.
Racks and Clamps

All racks and clamps for holding magnesium articles
immersed in the solution during anodizing must be made
of any suitable aluminum or magnesium alloy. They must
be protected at the electrolyte-air interface with No, 470
F,lectroplaters vinyl tape (or equivalent) to resist the
action of the electrolyte. Steel, CRES, copper or titanium
components must
not be used for racks
source
if they
are
not in proper
place during anodizing.
or
clamps.
Chem ical
The concentration of air-borne fluoride and hexavalent
chromium substances during anodizing operations must
be removed by operation of the exhaust system.
APPLICATION NOTES
Application of Coating
The coating produced by anodizing of the magnesium
surface must be uniformly applied over the enti re su rf ace,
and must be free from scratches or other damage or
irregularities, and from breaks other than at the point of
20-40-15
0
Page 1
Aug 31/114
SI1-7fi-023
COHH()SION CONTROL MANUAL
Dow NO. 17 ANODIZE PROCESS FOR
I~MAGNESIUM
ALLOYS
(Continued)
Application of Coating (Contd)

electrical contact. The color of the anodize coating must be
chalacteristic of good quality of the Type and Class
specified. Contact marks must be touched-up as necessary
using the Dow
19 soution.
Coating Thickness
The coating thickness resulting from anodizing must
comply with the following values.
Type I Class C: 0.0001-0.0004 in./side

Type II Class D: 0.001-0.002 in./side
The coating thickness
coating below.
must be measured
as
stated in
ANODIZING PROCEDURE
All magnesium
with table 1.
alloys
must be anodized in accordance
STRIPPING OF DOW NO. 17 COATINGS

When it is necessary to strip Dow No. 17 anodic coatings
from all areas of a part and/or magnesium assembly or to
rejuvenate magnesium contacts upon racks and/or clamps
a 200/n/wt solution of chromic acid at a temperature of 160
to 2100F must be used.
REWORK AND/OR REPAIR OF

now No. 17 COATINGS
Refinishing of Dow No. 17 anodized magnesium alloy

surfaces which are corroded, abraded or scratched must
be done in accordance with section 20-40-85.
Re-anodizing of maffnesium surfaces due to rework of
maanesium alloy basis metal can be done without removal
of the previous anodize coating. Anodizing takes place
only on the bare areas until the new coating builds up to
the same thickness as the original. Proceed according to
table 1 but omit operation 5.
20140-15
Page 2
Aug ~1/84
1984 BV
~ABRELINER CORP6RATION
tj
Table 1.
DC Dow No. 17 Anodize Process Sequence for Magnesiun Alloys
II
SOLUTION
C,
CONSTITUENTS
I
-f
OPERATION
1.
AND
TEMPERATURE
CONCENTRATIONtjl
"F
Mask
Maskand/or
areas as necessary
before
racking. 10
2.
(n
a
a
Refer to section 20-10-55. Note: Masking

materials must be resistant to degreasing
fluid or vapors.
Vapor
Degrease
~optional)
3.
Alkaline Soak
Clean
Z
O
PROCESS DETAILS
TIME
Rack
Z
O
tj
n
N
NA3-5167 cleaner,
6-8 oz/gal
195-205
Until clean
free-rinsing
steel tank. The pH of this solution

must always be greater than 11.
Use
0
O
~a
surface is
obtained
m
a
O
C3
4.
Rinse
5.
ChromicAcid
Water
I~
Ambient
30-60
Water should be flowing
freely.
seconds
O
a
Pickle
Chromic Acid,
24 ~fi2
130-140
1-15
minutes
Ambient
30-60
seconds
160-180
See table 2.
oz/gal
6.
Rinse
Water
Tank must be either PVC, lead-iined,

stainless steel or 2002 aluminum. Provide
adequate ventilation. Dump when colored
films form on magnesium Surfaces.
Water must be flowing freely.
M
7.
Magnesium
Anodize
Ammonium Bifluoride,
36-40 oz/gal
Sodium Dichromate,
13.3 f2 oz/gal
Phosiilric Acid
11.5 f2 fl. oz per gal
Type I, Class C
5-50 ASF
5-50 ASF
c~
to 100 de
to 72 de
50-60
cl
Current Density
Amp minutes
I\S
Type II, Class D
per sq. ft.
300 min
Dissolve chemicals in order listed using

160"F water. Stir vigomuslyandheatto
1800F. For replenishment see
Agitation must be per O Ventilation and
r
O
cC
M
B
o
o
Z
C
Z
b
g
safety
must be
o
13
adequate and positive.
O
a
c~3 p~
B
eu
C~
z~
e b
~to
r
cs
c~
Os
os,
a
o
-o
Z
O
cn
DC Dow No. 17 Anodize Process
Table 1.
SOLUTION
CONSTITUENTS
AND
CONCENTRATION O
OPERATION
8.
9.
Sequence
Rinse
Water
HotRinse
Water
for
4~
Magnesium Alloys (Contd)
~Z:
TEMPERATURE
"F
a
TIME
PROCESS DETAILS
ct
Ambient
160-120
30-60
seconds
Water should be
30-45
seconds
Use lined steel
flowing freely,
m
Cd
or
stainless steel tank.
O
m
10.
Dry
Air blast
toil
and
water-free)
or
suitable
drying
M
M
oven
NOTES
C>
Concentrations are by weight of softened distilled or

deionized water, or by volume as noted. Maintenance-of-volume water and water used to dissolve
chemicals must be of same quality.
Q
a
t)
Iii
(n
m
r
Z
n
O
O
Ij Replenishment of bath
should be made when about

20 sq. ft. of surface area per gallon of bath have been
treated, or when final volta-ge exceeds v~ues established by 10 volts. Amounts of various ingredients to
be added are determined by chemical analysis. If
operating voltage attained after addition of make-up
chemicals is lower than that specified, add sodium
(not ammonium) acid fluoride until correct voltage
is attained,
It is mandatory that firm contact be made at all

times between the rack contacts and part to be
anodized. If not done, severe pitting and/or etching
will occur at areas of loose contact. It is preferable to
rack parts on non-critical areas, if possible.
Water must be
softened, distilled,
or
deionized.
Due to increasing resistance of anodic coating being

deposited, voltage required to produce a given current density increases during anodizing process.
Voltage must be regulated manually or automatically to maintain desired current density.
El
O
~d
Z
M
When
complex partsare tobe anodized,they mustbe

agitated while totally immersed in order to minimite entrapment of air in pockets or blind holes.
Parts should be repositioned periodically to bring
anodizing solution in contact with uncoated areas
and to prevent attack at solution-air interface at
such pockets.
F
O
cC
C~
o
=f
0
a
-I
3
e
a
v
SR-76-02:3
COHROSIO~i CONTR()L MANUAI,
DOW NO. 17 ANODIZE PROCESS FOR MAGNESIUM ALLOYS
(Continued)
COATING
Thicknctns
The coating thickness must be in compliance with
APIIJICATION N()TES above. Coating thickness must
be measured by nermitron or equivalent.
Appearance
Refer to APPLICATION NOTES above.
Table 2.
Anodizing Time in Minutes

CURRENT DENSITY
AMPERE~1MINUTES/S&.
FT.
5 ASF
10; ASF
20 ASF
30 ASF
50 ASF
TYPE ICLASSC
1
50
10
2.5
1.66
BO
12
112
30
TYPE II CLASS D
300
60
30
15
400
80
40
20
25
L()
500
100
50
16.6
20-40-15
o
Page 5/6 Blank

Aug 31/84
SR-76-023
APPLICATION OF TFE INFUSED COATING ON ALUMINUM

GENERAL
Abrasion Resistance
gives the requirements for the application of

synergistic coating consisting of anodize per MIL-A8625 (aluminum) infused with tetrafluorethylene (TFE).
The weight loss of the coated part must not be greater

than 40 milligrams when tester under Abrasion
Resistance.
This section
a
TFF, infused anodize is intended for metal surfaces that

will be subjected to service conditions that require a
combination of such properties as corrosion resistance
and abrasion resistance.
The coating is TFE infused hard anodize
on
aluminum
Coating Thickness
The coating thickness must be 0.002 ~0.0002 in. unless
otherwise specified on the engineering drawing.
TESTS
parts.
Appearance
EQUIPMENT
Alpha LFW-1 Tester
or equivalent
Faville-Levally Corp.
Bellwood, IL
COATING QUALITY
QUALITY.
Corrosion Protection
Appearance
The coating must have a smooth, uniform appearance and
must be free of burned spots, chips, scratches or other
discontinuities when examined.
Subject the test specimens to salt spray per ASTM B 117

for 1500 hours. After the panels are removed from the salt
spray chamber, they must show no evidence of corrosion.
Wear Life
Coated parts must show no evidence of corrosion after salt
spray
Visual examination shall be used to determine conformof the coating to the requirements of COATING
ance
testing. (Refer to Corrosion Protection below.)
Wear life performance must be tested on an Alpha LFW-1

tester, or equivalent. All test specimens must be the
standard size for the Alpha LFW-1 tester and must
consist of the materials given in table i.
Wear Life
wear life of specimen costing must be at least 200
cycles when tested with the Alpha LEW-I, or equivalent,
The
tester.
Table 1.
Wear Life Test
MATERIALS
2024 Aluminum
4130 Steel Block
Ring
Specimens
TFE COATING
DIMENSIONS AND SURFACE FINISH

BEFORE COATING APPLICATION
a surface finish of 16-32
microin. and O.D. concentricity must be within 0.0004
in. Coating must be applied to the O.D. surface.
Coated
Outside diameter must have
No Coating
Steel must have a hardness of R,57-60. Surface finish

must be 6-12 microin. on contact area. No coating
must be applied to block.
20-40-20
COPYRleHT, 1984 BY SABRELINER CORPORATION
Page 1
Aug 31/84
SR-76-023
APPLICATION OF TFE INFUSED COATING ON ALUMINUM (Continued)

Test Procedure
For this test, the ring is in sliding contact with a
4130 steel block. The ring is mounted on the
test mandrel and rotated at a speed of 72 rpm (26
ft/minute). Within 1 minute of test initiation, a 30 Ib
normal force must be gently applied to the ~tationary
block mounted in the block holder. The test is run at room
temperature using unidirectional motion only. A coefficient of friction of 0.175 must be used as the failure point.
stationary
Abrasion Resistance
Test two test
specimens
as
indicated in table 2.
Test Procedure
Test the specimens in accordance with FED-STD-141,

Method No. 6192, using CS-17 wheels with a 1900 gram
load. The wheels must revolve on the coating at a speed of
70 rpm for 10,000 cycles. Prior to and after abrading, the
specimens must be weighed and the weight loss obtained
to determine compliance with COATING QUALITY
requirements.
Thickness
Make thickness measurements
using any suitable instru-
ment, such as a micrometer or eddy current devices,

where such instrument is capable of determining the
coating thickness to plus or minus 10% of its true thickness.
Table 2.
Abrasion Test Specimens
MATERIAL
2024-13 Aluminum
TFE COATING
DIMENSIONS
Coated
Specimen dimensions
x
0.040 in. All
must be
corners
approximately4.0 x 4.0
must be rounded and a0.25 hole
cut in center.
20-40-20
Page
Aug 31/84
~YRIGHT,
1984 BY
~BRELINER CORPORATION
SR-76-023
APPLICATION OF SCALE INHIBITING COMPOUND

(;ENERAL
Ih is section covers methods and materials for application
of a ctoati ng for i n hibiting scale du ri nrs heat treating. Th is
section should be used in conjunction with other sections
where pretreatment is called out.
I)rying
Applied films of the com pound must be allowed to ail d ry
at i east 15 m inutes at room temperatu re or fo rce dry fo r 5
minutes at 1500F before heat treatment.
Touch-up
MATERIALS
Compound. Scale Inhibiting
ST0225GB0001
APPLICATION NOTES
Surface Preparation
The surfaces to which the scale inhibiting compound is to
be applied must be clean. There must be no foreign
material such as pencil marks, ink stamps, etc., on the
cleaned parts prior to application of the compound. The
compound must be applied as soon as possible after
cleaning, but in no case later than 24 hours after cleaning,
Cleaned surfaces must be handled only with clean fabric
Protection of coated paris during heat treatment is

dependent upon an unbroken film of the required thickfor
ness on all surfaces. Coated parts must be inspected
film defects before heat treatment. Film defects may be
touched up by brushing or spraying, whichever is
convenient.
Handling
Normal precautions must be taken to prevent accumulation of surface contaminants, dirt or physical damage to
the applied film of the coating.
Racking
gloves.
drying, coated parts must be placed in suitable

racks for heat treating. The racks should be made of such
construction that a min area of coated surfaces are in
contact with them, and at least one half in, space is
maintained between coated parts and surrounding
furnace structure.
After
Cuatinff Preparation
(;cnerally the compound in the "as received" condition is
If thinning is necessary, it
app I led by spraying or dipping.
is accomplished by the addition to the material of not more
than
by volume of toluene.
Heat Treatment
NOTE
Material
as
reeeived must be
thoroughly before
agitated
use,
Heat; treat according

being processed.
to methods
applicable
to materials
NOTE
Film Thickness
During heat treatment, visible fumes will

evolve. These fumes are non-tozic, so no
special precautions are necessar2/.
The applied material must form a continuous coating

with a max dry film thickness of 0.0005 in.
Spray Application
compound may be applied by the use of conventional
will generally depositthe
sl,ray ttpplication. One thin coat
material.
of
requirement
optimum
The
Oil, Application
Generally only one dip is required to deposit the optimum
requirement of material. After dipping, all parts must be
allowed to drain at least 5 minutes,
Coating Removal Before
Heat Treatment
When it is necessary to remove the applied coating prior to

heat treatment, solvent wipe with toluene or methyl ethyl
ketone
(MEK).
Coating Removal After Heat Treatment

Removal of the spent coating after heat treatment must be
accomplished according
rials being processed.
to
cleaning applicable
to mate-
NOTE
To p~reoent ious of Yolvent, the dip tank
shozLld be adeguately covered when not in
uue.
20-40-25
0
COPYRIGHT, 1984 BY SABR~LINER CORPORATION
Page 1/2 Blank

Aug 31/84
SR-76-023
PHOSPHATE TREAT~MENT
Classification:
Rodine No. 50
Acid Inhibitor
Rust Inhibitor, Amine Type for
Water Rinse R-2
Oxalic Acid, Technical Grade
Turcoat Activator
Parcolene "Z"
Heavy Manganese
TypeI
TypeTI --HeavyZine
Light Zinc
Type Iii
Iron Powder, 200 Mesh,

Technical Grade
75%,
Phosphoric Acid
(table 1) compares these types

with the Government specifications and lists the usage for
each type of phosphate coating.
TechnicalGrade
Corrosion Preventative, Soft
Film, Cold
Application
Coating, Organic, Corrosion
(;ENEeAI,
This section covers the materials and processes to be used
in the phosphate treatment of bare, cadmium plated, or
xine coated iron and steel.
A cross-reference chart
Amchem, Inc.
Wyandote Chemicals
Commercial
Parker Rust Proof
Co.
Commercial
Commercial
MIL-C-14201
RB0130-006
Protective, for Liquid Oxygen
MATERIALS
and other Service
Phosphating Compounds:
Type I(MIT~-P-16232, Type M)
Parco Lubrite 2
Type II(MIL-0-16232, Type Z)

Farce 1A
Cryscoat HC
Tn
4432
SAFETY
Parker Rust Proof
Co.
Some of the chemicals used in this process

and must be handled with that in mind.
Parker Rust Proof

Co.
SURFACE PREPARATION
Tyr,e iii (l"r-C-490, Type 1)

Bunderite 32
Accelerator 130
Neutralizer 200
Indicator Iaper No. 17
Test Paper)
Parco 1A
(Iron
Cr.vscoat HC
Tulcoat 4432
Parker Rust Proof

Co.
Parker Rust Proof
Co.
Parker Rust Proof
Co.
Parker Rust Proof
Co.
Parker Rust Proof
Co.
are
hazardous
Complete all forming, machining, welding and heat

treatment prior to cleaning operation.
Pictkling must not be used where prohibited by embrittlement relief method used.
to relieve hydrogen embrittlement must be suitable in duration, temperature, and timeliness for the
metal and process in use.
Baking
Phosphating Requirements
Th, processes used
are
listed in tables 2, :3,
or
4,
as
applicable.
All parts to be phosphated must be processed using one of
the compounds listed in MATERIALS.
FINISH
Alkaline Cleaner for Steel:
Oakite 77
Parco 341

Parker Rust Proof
Co.
I,BOB1C)-10~
Cleaner; Electrolytic, Alkaline
Chromic Acid, Technical Grades
Federal Specifica-
Ilubricating Oil, Preservative
tion 0-C-303
MIL-L-3150
The
rust
coatings must be evenly deposited. There

or finger prints.
must be
no
Stains from chromic acid rinse are not cause for rejection.
Nonuniformity of appearance due to heat treatment,

degree of cold work, or composition of base metal are
icceptable.
Medium
Compound, Corrosion Preventative Finger Printing Remover
MIL-C-15074
Stoddard Solvent
Hydrochloric Acid, Technical
P-S-661
Federal Specification 0-A-86
Grade
Appearance
Salt Spray Resistance

The phosphated article must show no signs of corrosion
when tested by standard salt spray (5 or 20% sodium
chloride) method (Federal Test Method Standard No. 151,
Method 181) for periods shown following.
20-40-30
0
COPYRIQHT, 1984 BY SABRELINER CORPORATION
Page 1
Aug 31/84
8~3-76-023
PHOSPHATE TREATMENT
Salt
(Continued)
Partially Phosphated Items
Spray Resistance (Contd)
In phosphating steel parts which have cadmium plated

masking of the;cadmium plated area is not
Phosphated Steels
areas,
HOURS RESISTANCE
necessary.
TYPE
OF
COATING
NO
SUPPLEMENTARYOILING
WITH
SUPPLEMENTARYOILING
1.Tj
24
48
Type I
Type II
Phosphated Cadmium
There must be no observable attack of either nickel or

chromium plated portions of phoshated treated parts.
Rinsing
The water used for make-up of chromic acid rinses must
contain no more than 70 ppm of combined sulphate and
chloride ions.
Plate
THICKNESS OF
OF CADMIUM (IN.)
HOURS TO CORROSION
OF BASIC METAL
0.0005
0.0003
0.0002
240
Stripping
Unless prohibited by embrittiement relief method used,
192
96
phosphate coatings may be stripped by immersion in 1:1

hydrochloric acid containing 1/8-1/40/0 Rodine No. 50
Inhibitor. Use room temperature until stripped; then
rinse with water. If acid pickling is prohibited, strip by
use of abrasive cleaning melhod compatible with object
being stripped.
Minimum Weight
weight for each type of coating formed on bare

(dry ground, not sand blasted) steel must be as given
below. Test panels must be the same alloy, heat treatment,
The min
surface finish, etc.,
as
is the largest part treated.
TYPE OF COATING
MIN. WEIGHT MG
SQ FT
I
II
III
1500
1000
300
Tests
Tests to determine conformance with Salt
ance and Min Weight must be made.
Spray Resist-
For salt spray resistance, 3 specimen items, or standard

panels to simulate these items, must be tested for each of
Type I and Type II coatings, with and without supple-
mentary oiling.
For coating weight determination 3 specimen items, or
standard panels to simulate these items, must be tested
for each of Types I, II and III coatings.
20-40-30
Page 2
Aug 31/(34
~PVRIGHT, 1984 BY $B~RELINER CORPORATION
Table 1,
CrossReferenceChart
MIL
TYPE I
DESCRIPTION
Chemical Description
Zinc
TYPE III
TT-C-490, Grade 1
MIGPP16232, Type Z
MIIrP-162s2,i~pe M
Spec
TYPEII
Light Zinc Phosphate
Phosphate
Heavy Manganese Phosphate
Heavy
i. Used on bare steel

base for solid film
1. When applied as a heavy

coat, it is used to increase
corrosion resistance,
Cd
td
Purpose(s)
of
use
as a
I]
lubricants. (CAUTION: do
not apply oil to phosphated
surface.)
O
2. Used to increase
a
73
2. When applied
coat, it is used
wear
resistance of Sliding
surfaces.
O
II
O
Z
1. Do not oil. See
in temperature, duration,
and timeliness for the metal
2. Oil with MIGL-3150
and process involved,
1.
Dip in MIGG3150
or
MI1-C-15074 and drain.
call-out.
2. Do not oil. Paint
or
as
drawing call-out,
MJL-C-15074 oil and drain

or as
as
base.
drawing
Post-Treatment. Embrittlement relief must be suitable
light
a paint
as a
drawing designates.
bare steel or
cadmium plated steel to
increase paint adhesion.
on cadmium plated
steel as a base for solid
film lubricants.
i. Used
on
2. Used
1. Do not oil. Paint
2. Do not oil.
phosphating materials
Apply
later.
table 3 may be used to form Type III

Times are as follows:
Parco 1A
3-4 minutes
used to
Cryscote HC
solid film
Z
M
2:
c3
C3
O
~f.
listed in
produce! Type III coating. Phosphating solutions
in table 3.
those
from
given
times
coatings by reducing phosphating
may be
per
lubricant as per drawing

call-out. Chromic aCid
rinses cannot be used as a
final rinse of cadmium
plating cycle when solidfilm lubricants are to be
NOTE
II
as
drawing call-out.
applied
O lype
31
a
O
~fl
3-5 minutes
Turcoat 4432
8-14 minutes
IP
OSc~
w
2~
c b
rCs
s a
1\3
Bm
-a
4
Table 2.
Type I Phouphating Procedure
I
OPERATION
I
MATERIAL
CleaningO
Degrease by
grit,
Rinse
Spray
Phosphate
Type I Ihosphating Solution

(Parco Lubrite 2)
Rinse
vapor
blast with 220
I TEMP"F
CONCENTRATION
IMMERSION
TIME
MINUTES
I
REMARKS
degreaser, clean solvent dip, or clead solvent wipe. Remove scale or adherent soils by grit
or equivalent. Vapor blasting does not leave a satisfactory surface. O
Cd
with cold water; then immerse for 2 minutes in clean hot water.
Make up to 10
Maintain at 11.5-12.5
Points are mi N/10 sodium

hydroxide needed to neutralize 2 mi sample; use phenol
points III
phthalein indicator.
100
gals tap
gals
202-208
per
Total Acid, 0.2 max in 25

mi sample. Keep free of
visible contamination.
Tap-water,
overflowing
12-15
water.
Roomto
180
Chromic Acid
Rinse
Chromic Acid
rjIake upto 6
oz/100 gals
140-180
0.8 free acid points.

Refer to Rinsing. O
Clean, oil-free
Dry
1/2-1
(no more)
water.
air
225
Until
max
m
c~
~d
M
C~
Discard when total acid is 6

times-free-acid, or sooner if
otherwise contaminated.
Use 25 mi sample.
mt
c3
dry
(r,
NOTES
Cleaning is very important to promote uniform

penetration of the metal and to avoid excessive
coating build-up. Do not use strong acid or alkaline
cleaners.
Z
a
9
r
td
Direction of flow must keep

main body of rinse from
being contaminated.
~d
O
Cd
r~
Where internal areas of complex configuration, such

as interiors of small fuel tanks, are too small to
permit grit- blasting and are subsequently to be
131
coated, inhibited acid descaling may be used. In this

case, the part should be rinsed and vapor degreased
cp
prior
to
phosphating.
Maintain iron content at 0.2-0.30~
powdered iron
as
by
additions of
necessary.
One-half the weightof chromic acid may be replaced

an equal weight of phosphoric acid.
by
;:z
Table 3A.
~o
C,
I
OPERATION
1
-e
Procedure for Phosphatlug With Parco 1A
Type II Phosphatiag Procedures

1
MATERIAL
i.
Degrease
2.
Descale
2a.
Rinse(if aciddescale isused).
3.
Clean
CONCENTRATION
I
TEMP "F
TIME
Cd
v,
m~
Alkaline Cleaner
REMARKS
MINUTES
5-8
185-210
oz/gal
15
or
~d
until free
running
4.
Rinse
Max 0.2
Tap water
overflowing
carry
Room
points alkalinity
over
1/2-1-1/2
from cleaner
5.
Pretreat
73
i. ParcoleneZor
2. Oxalic acid
8.0-9.01bs/100gal
2.0-3.0 oz/gal
O
n
6.
Rinse
Tap water
overflowing
7.
Phosphate
Parco 1A
Room
10-60 seconds
Room
1/2-1-1/2
Room
1-3
O
Points are mi N/10 sulfuric
acid needed to neutralize a
10 mi sample using phenolphthalein indicator.
Bath should be
Cd
td
c~
M
agitated.
cj
5a
In all water rinses, direction

of flow must keep main body
of rinse from being contaminated.
2-1/2-3-1/2
100
gal
gatl_I~
190-200
water
25-30. See
Remarks for
cadmium
plated parts
8.
Rinse
Tap water
overflowing
9.
Seal
Chromic Acid
I Partly or completely
Make up to 8
100 gal
oz
140-180
per
1:
c~
C:
o
1/2-1
Control to free acid 0.8-1.2

on 25 mi sample.
Discard when total acid
reaches 5 points (25 mi
Dry
Clean, oil-free
225
max
Until dry
a
a
~a
m
air
(U
points
sample).
10.
be phosphated for 12-15

minutes
Room
cadmium plated parts shall
NOTES
ri
b
e~o
0)
Control total acid 28-30 points on 10 mi sample. Titrate with N/10 sodium
hydroxide. Control iron (ferrous) to 0.1-0.45~/0
One-half by weight of chromic acitl may be replaced by phosphoric acid.
Cr3
(P
i~iU1
rm
~I
z
ts
01
X
~t
h)
c~
c
"b
o"
mb
t-
Table 3B.
Type
II
Phosphating Procedures
Procedure for
Phosphating
with
c~
Cryscote HC
OPERATION
MATERIAL
i.
Degrease
2.
Descale if necessary.
2a.
Rinse(if acid descaled).
CONCENTRATION
TEMP "F
TIME
MINUTES
REMARKS
Clean
Oakite No. 77
4.
Rinse
Tap water
overflowing
12-16 oz/gal
Max 0.2
carry
I :Oxalic acid
6.
Rinse
Phosphate
CryscoteHC
-1
8.
Rinse
Tap water
overflowing
9.
Seal
Chromic Acid
10.
Dry
180-212
points alkalinity
over
Room
Up
to 5
1-2
Until clean

10 mi sample using phenol-
from cleaner
oz/gal
Room
Free of visible
contamination
Room
Cd
td
t~
c3
M
c3
56
M
1/2-1-1/4
~P
Tap wat~r
overflowing
2-3
(Conditioning)
Cd
1%2
r)
3.
Pretreat
3-4
ga1/100 gal
water
P 1
Free of visible
contamination
Clean, oil-free air
63
2-3
63
2-3
Make up to 8 oz/100 gal
140-180
225
1/2-1
Control
as
in table 3A.
~f
d
max
Until dry
tl
NOTES
r
Z~I
~a
O)
~d
Control by titration of 10 mi. samae with N/10 sadium hydroxide.

N/10 sodium hydroxide 0.5 gal Cryscote BC per 100 gal water.
Calculate 4.a mi
O Adjust
immersion time for partly or completely cadmium plated

parts to prevent
removal of cadmium plate, generally 3-5 minutes is sufficient.
One-half by weight of chromic acid may be replaced by

phosphoric acid.
Ta~le
3C.
Type
II
Phosphating Procedures
Procedure
for:Phosphating with
C)
Turco 4432
TIME
I
-I
OPERATION
1.
Degrease
I~
2.
Descale if necessary
3.
Rinse if acid
4.
m
r
Clean
TEMP"F i
CONCENTRATION
MATERIAL
REMARKS
MINUTES
descalingused.
~1
5-8
Alkaline Cleaner
15
185-210
ozlgal
or
until free
5.
Rinse
II
Room
Max 0.2 points carry

over from cleaner
Tap water
overflowing
)1/2-1-1/2
Cd
O
6.
Pretreat
Turcoat
Activator
1/2-1 oz/gal
7.
Rinse
Tap water
overflowing
Free of visible
contamination
Turcoat 4432
Make up to 3 ga1/100 gal

water. Maintain at 17-23
points. Maintain ferrous
iron at 0.05-0.40 points.
10 mi sample; N/10
NaOH. Ratio 7:12
O
8.
9.
10.
Phosphate
Rinse
Seal
Tap water
overflowing
ChromicAcideSI
Dry
5-7
Room
3-5
~d
f~
I
Partly or completely plated
parts shall be phosphated
10-30 See
Remarks
M
c3
O
orange
Room
2-3
I
a
MakeuptoSoz/per
100
170 min
1/2-1
225
Until
~FI
water
Clean, oil-free air
max
dry
NOTE
L1
c~
m
10-12 minutes

10 mi sample using phenolphthalein indicator.
170-185
Phenolphthalein: methyl
gal
11.
Room to
125
O
M
rinsing
One-half by weight of chromic acid may be
replaced by phosphoric acid to lessen staining.
z
a
~L
II
~9
;U
~J
~j
db
-1
PCW
:10
r~
P"
~-b
P~
a
Tablel.
TypeIII PhosphatingProcedures
OPERATION
I.
Clean
MATERIAL
Mild alkaline
cleaner (Parco
CONCENTRATION
2-4
TEMP OF
oz/gal
TIME
MINUTES
180-200
1-1/2
341)
2.
Rinse
Must be free of "water

break." Repeat cleaning, if
necessary.
Tap water
overflowing
Max 0.2 points aikaline

over from cleaner
160-180

10 mi sample using phenol-
carry
REMARKS
Cd
3:
~3
Cd
3e
3.
Phosphate
Type
III
Ig
6.4-7.0
Phosphating
water
gals/100 gals tap
165-175
c3
m
1-1/4-1-1/2
solution
c3
(Bonderite 32)
56
M
4.
Rinse
Tap water
overflowing
Keep free of visible

contamination
Room
Direction of flow must keep

main body of rinse from
c3
being eontarninatedl
1]
5.
Chromic
Chromic acid
~1
acid rinse
--I
6.
Dry
Clean,
oz/100 gals (Refer to

Rinsing.) 0.6-0.8 parts
free acid (25 mi sample)
oil-free air
140-180
225
max
1/2-1
Discard when total acid is 6

times free acid or sooner if
otherwise contaminated.
Z
cj
Until dry
O
~t
NOTES
Phosphating solutions listed in table 3 may be used to form Type

phosphating times from those given in table 3. Times are as follows:
Parco 1A
Z
~o
Parker
1-2
(O
3-4 minutes
Cryscote HC
Companys Accelerator
3-5 minutes
III
coatings by reducing
Turcoat 4432
8-14 minutes
130 must be added to this bath to coat bare steel. Maintain from
oz/100 gallons.
One-half the weight of chromic acid may be replaced by phosphoric acid.
t~
SR-76-023
APPLICATION OF CHEMICAL FILMS TO ALUMINUM ALLOYS

GENERAL
Th is section covers the material and process reyuirements
for application of Class 1A (MII-C-5Tj41), chemical,
chromate conversion coatings (chemical films) to the
surfaces of aluminum and aluminum alloys. All coatings
must be visible, naturally colored (iridescent yellow or
1 ght brown)or dyed a specific color. All coatings must be
dniform in appearance; continuous; free from powdery
or
loose film areas; free from breaks, scratches, flaws or

other defects and damages that will reduce the serviceability or be detrimental to appearance.
MATERIALS
Acid, Nitric (61% or 39.30 Bk.,

Min.), Tech.
Acid, Sulfuric (93% or 600 Bk.,
Min.), Tech.
0-S-809
Amchem Products,
Inc. or Van Dusen
Aircraft Supplies
Amchem Products,
Inc. or Van Dusen
Aircraft Supplies
Turco Products
Alodine 1200 Powder
Alodine 1201
0-N-350
Liquid
Accelagold Series
Bifluoyide, Ammonium
Brushes, Soft Bristles
Chromium Trioxide, Tech.
Cleaner, Acid
Commercial
Commercial
0-C-303
MIL-C-5410,
Type II
Cleaner, Mild Alkaline, NonSilicated, Low Foaming
Cleaner, Mild Alkaline
Cleaner, Mild Alkaline,

Turcd 4215 with Turco 4215
MB0210-004
RB0210-005
Turco Products,
Inc.
Additive
ST0210GB0001
Allie~dResearch
Deoxidizer, Aluminum
iridite 14 Powder
Products
PROPERTIES OF CLASS 1A COATING
as
less than 40 milligrams per square ft. of area

determined by MIL-C-5541, Amendment 2,
no
Section 4.5.2.
Appearance
square
within 1/4 in. from the edges, identification markings and holding points during processing or salt spray
shall be inclined
exposure. The significant coated surface
6" from the vertical. A min of 3 coated panels must be
tested. The coated test surfaces/panels must be aged a min
of 24 hours before testing. Corrosion resistance requirements are specified in MIL-C-5541, except as deviation(s)
are given herein.
areas
Paint Adhesion Properties

The paint adhesion properties of conversion coated subject
surfaces must be satisfactory with the specified paint
the paint must neither chip nor peel from the
system
conversion coated surface(s) after application and curing.
If the conversion coated part(s) is not designed to be
this paint adhesion requirement can be
painted,
disregarded.
Limits
must not be heated above

1400F, to protect them from diminution of corrosion
Unpainted subject coatings

resistance
properties.
Chemical film coatings are not a satisfactory general

substitute for anodized aluminum coatings and must not
be substituted automatically for anodized aluminum
coatings.
These coatings must not be applied prior to any aluminum
forming, welding, surface mechanical processing, thermal
processing
etc.
Material and Components

All materials used must comply with MATF,RIALS above.
Water
Weight of Coatings
Must be
1A chemical coatings must ~ithstand

330 hours of direct exposure to 5"/0 salt spray with the
of a max of 15
occurrence on the conversion coated surface
isolated spots or pits, none larger than 1/32 in. diameter in
in. of exposed test area, except those
a total of 30
Unpainted Class
All make-up water must have a chloride level between

20-50 parts per million parts of water.
Material Processing Requirements

of
Coatings
naturally colored (iridescent
dyed a specific color; uniform in
All coatings must be visible;
yellow or light brown) or
or loose film
appearance; continuous; free from powdery
flaws or other defects
areas; free from breaks, scratches,
and damages that will reduce the serviceability of parts or
be detrimental to appearance, protective value and paint
bonding characteristics. Variation in color between parts
or between areas on same part is satisfactory.
Only Class
1A
(MIL-C-5541) coatings
must be
applied.
APPLICATION NOTES
Conversion coatings must be applied according to the
instructions of the specific table. The tables listed below
shows the key to the correct procedures for application of
Class 1A Chromate, Chemical Conversion Coatings
(Chem Film).
20-40-35
0
Page 1
Aug 31/84
SR-76-023
APPLICATION OF CHEMICAL FILMS TO ALUMINUM ALLOYS

APPLICATION NOTES (Contd)
Table No.
NOTE
Procedures
Immersion
Spray
Brush-On
IOrA Etch per table i,

used as an alternate.
Dip
Small
Iridated Parts
a
of sulfuric acid, 66"Bk.

chromic acid
Water to make 1 gallon
ounces
temperature of 170 flO"F, rinse in
perature tap
room
tem-
water.
NOTE
10rA Etch per table i, Operation 3, may be
used as an alternate.
Alodized Parts
Immerse until stripped in
solution consisting of:
1 volume water
1 volume nitric acid
Use at
room
temperature, rinse in
resistance limits
by applicable specifications, small

areas may be abrasively stripped.
set
Re-Processing
in the
applicable chart for
necessary
DO "Ot allow rags, sponges, swabs, etc., used for applying

the Class 1A solutions to dry out. If allowed to dry, they
constitute a fire hazard. Immediately after use, all such

materials must be thoroughly rinsed in clear tap water;
after such rinsing they may be re-used or discarded.
Spray application of the solutions called out in table 3 may

be used for chem film treatment of a limited number of
parts too large to be processed either by the brush-on
procedures of table 3 or in existing conveyorized equipment. If this spray application cannot be carried out in a
paint spray type booth with water scrubbed vents, extreme
caution must be exercised to prevent droplets contaminatinp; adjacent work areas or drifting over parking lots
or buildings where they will cause staining. Protective
clothing to protect eyes, lungs and skin should be worn by
operators spraying the chem film solutions. The spray
solutions called out in table 2 may be used only in the
temperature controlled conveyorized equipment for which
they
room
of
Under no conditions must the solutions be heated above

the temperatures specified. Strictly avoid breathing dust
from the makeup powders, and avoid inhaling vapors or
spray from the solutions as much as possible.
solution consisting of:
av ounces
use
Normally, chemical films do not prevent

adequatd electrical bonding. V electrical
measurements indicate that chemicalfilm
Use the procedures

re-processing.
When it is necessary to strip the chemical film from the

entire surface of a part, the following procedures must be
used,
Use at
may be stripped of chemical film by

No. 320 grit or finer abrasive paper.
must be removed to meet
Stripping of Chemical Films
13 fluid
or
NOTE
surfaces where resistance to
Chemical film brush-on solutions for touch-up must be

stored in proper containers. They must be applied in
accordance with table 3. No solution is to be returned to
the storage container after use.
4.4
areas
Bon Ami
This brush-on procedure may be used to touch-up small

rework or abraded surfaces on assembled parts which
have been anodized (MIL-A-8625) in accordance with
Immerse for 1-5 minutes in
may 6(?
l[n!nll(l]~l
If the Class 1A films are removed by rework or abrasion in

local areas they may be touched up by applying the
appropriate solution by the brush-on method described in
table 3.
on
Operation 3,
Do not usefollowing process on assemblies

with xine or cadmium plated parts.
Touch-Up Requirements
section 20-40-10, except

abrasion is required.
(continLk~)
temperature tap
water.
are
qualified.
Make-up chemicls m~st not be stared near easily oxidizable material such as paints, solvents, lubricants, etc.
20-40-35
Page 2
Aug 31/84
C~PYRIGHT, 1984
BY
SABPELINER CORPORATION
Cd
d
C:
-I
c~
O
r(
ct
Table i.
Chemical Film Immersion Procedure
OPERATION
i. Clean
m
r
r
TEMP"F
MATERIAL
Mildslkaline
cleaner
Mild alkaline
cleaner, non-
TIME
MINUTES
CONCENTRATION
CONSTITUENTS
a
P
RB0210U05
7.0 f1.0
~MB0210-004
5.0 +1.0
av
oJgal
REMARKS
Ail parts must be rinsed to a.wa~er break free.,
5-10
180 r10
surface.
av.
145 f10
oz/gal
C~
silicated
2. Rinse
Spray and air agitation are desirable. An overflow

is mandatory. Direction of flow must aid in keeping
main body of rinse from being contaminated. Drain
parts well before next step.
2-5
145 f10
Tap water
over-flowing
Wa~er
a
73
O
a
3. Deoxidize
NA107A
Etch
O
z
or
Deoxidizer
Nitrie Acid (703h)
16 i2 fl.
av.
oz/gal
Chromic Acid
2.1 t0.6
av.
oz/gal
Ammonium
Bifluoride
2 +1
oz/gal
ST0210GB0001
Per
av.
Mfgrs
80 ~15
2-5
80 f15
3-5
Room
180
2-5
r
c~l
cl
PJ
Data Sheets
4. Rinse
5. Chem-film
Wa~er
Tap water.
over-flowing
See
:1.0 +0.5
Iridite 14
av.
Avoid drag into
Maintain
2-5
85 ~15
oz/gal
or
Alodine 121)0
2.0 f0..50
or
Alodine 1201
100X~
or
Acrela~olti
av.
Maintain
8.5 i15
oz/gal
~.i and
operation.Iil.
pH
Insure free circulation

to all parts of work, but
do not agitate. Area sur
rounding tank must be
lueli v.niila~eii.
between
1.5 and 1.7
Appl ication,
Immersion
next
to
between
i.?m
0.5-1.0
85 +15
pH
I
CI
2:
C?
Ir
r
O
CC
z
c;
2:
CU
O
rm
cc
c=J
~e
cP
cb
r
ew
~a1\3
c~
50
s;
Cb
Cd
r
;F
cl
C3
2:
c3
ct
~3
1:
o
Table i.
Chemical Film Immersion
CONSTITUENTS
<:ONCENTRATION
CI1
MATERIAI,
OPE:KAIION
ProcedureO(Contd)
TEMP"F
TIME
MINUTES
Roomto
2-5
120
7.
Optional
8. I)rv
rinse
Water
max
I
Imax
Until
dry
Used to aid in the
Circulating
air
drying of parts
oven or room
O;i
131
O
c:onstituents and their
use
operation
specifications
are
61 5. 6. 7. 8 sequence. Omit
listed in MATERIALS.
(:oneentrations are of materials in water. Oz per

amounts to be added to water to make 1 gallon.
e:
O:
may
cl
r
rB
(Mandatory)- Om it deoxidizing step on parts with cadmium-plated, zincplate, or-anodized. surfaces.
C3
For other materials which meet requirements, use make-up and mainteinstructions as recommended by manufacturer.
nance
gal (fl and av) indicate
D(mineralized water is preferred to tap or softened water for all operations, especially operations 6 and 7. Overflow water from one rinse tank to
an~,ther should not be used except where counterflow rinse tanks are used.
r
r
temperature air
NOTES
~1
REMARKS
Maintain pH at 5.0-7.0. Carry-over from chemical
film application is usually sufficient: add chemical
film make-up, if necessary.
be used.
For spot welded assemblies

oparatians-l; 2,:3, and: 4.
a.
I
-f
120-160
160
a~r
-<i
13
Clean. Oilfree
cc
Water
6. Rinsr
IEl
When using Etch as a deoxidizer for Chemical Film

i,, Bifluoride concentrations of from 1-2 av oz/gal
Application, Ammonare
preferred.
Controlled b? discrete additions of nitrir acid.

n
L~
1:
ma
z
m
r
t-
O
cC
~3
O
a
-1
=1
O
a
O
z
ra
co
d
Cd
r
O
-O
CI
~D
O
I
-i
C~
~I
O
m
Table 2,
Chemical Film
Spray Procedure
v,
n
m
1. Clean
Mild alkaline
cleaner
Turco 4215
with Turco 4215
additive
m
n
2. Rinse
Water
see
3. Deoxidize
Deoxidizer
ST0210GB0001
TEMP"F
150 +10
1.0-1.5
All parts must rinse to "water break free" surface.
145t55
0.5-1
Constant overflow mandatory.
C~i
80 +15
0.5-1
This
operation must be omitted when processing

assemblies containing zinc-plated, cadmium plated,
or anodized surfaces.
MATERIAL
OPERATION
TIME
MINUTES
CONCENTRATIONI
CONSTITUENTS
0.5-2.0
av.
oz/gal
C11
REMARKS
ed
M
W
Notel~
12-14
av.
o
~a
Room
180
Water
4. Rinse
O
n
Alodine 1201
5. Chem Film
--I
Application,
100%
or
Accelagold
Constant overflow mandatory.
0.5-2
to
r
0.5-1.0
85 f15
spray
6. Rinse
7.
Dry
85 +15
Water
160
Clean, Oil-
max
pH
0.5 to 1
Do not allow
overflow.
Until dry
Circulating air
be used,
free air
to
exceed 6.5. Maintain constant
oven or room
~1
C~
temperature air may
d
NOTES
O
O
Constituents and
their
specifications
are
listd
in
MATERIALS.
Concentrations are of the MATERIALS in water. Oz per

indieillt. amountr, to be added to water ,,,k, 1 gal,
gal (fi
or
av)
Demineralized water is preferred to tap of softened water for all

operations, especially operation 6. Overflow from one rinse tank to
another should not be used except where counterflow rinse tanks are
uad.
Operations 3 (Deoxidize) and

processed parts pass the MIL-C
omitted
surfaces.
must be
on
d
ci
4 (Rinse): May be omitted as lonK as

5541 salt spray requirement(lfi8 hours);
parts with cadmium plated, zinc-plated,
or
anoclizt-d
r
O
cC
1\3
O
~d
~d
O
m
cl
o
s:
~D
,a%
~to
rl
cn
t3
ru
R~O
CD
s;
s
~e
ChemicalFilm Brush-OnProcedure
TableS.
Cd
r
Q,
C1
O~
Z
c3
az
CONCENTRATION
TIME
MII,-C-.5410
II
Deoxidize
Asapplicable
TEMP~P
MINUTES
Room
As needed
REMARKS
Scotchbrite
or
etchings
pad Type
Tap
1. Rinse
Tap
water
1 part
by volume
1 part
by volume
5-100
80 +1T,
Keep surfaces wet. Use soft bristle brush

rags. Wear rubber Rloves. aa
Room
Room
water
Wet abrade until

been obtained
or
r?
3:
Type I
Alodine
brush
or
100%
or
85+15
0.5-1.0
or
until
Accetagold
application.
coating is
spral
~ormed
6.
RinseO
As needed
Room
Water
clean
"water-break-free" surface has
Hand wipe with clean wet rags frequently rinsed in

clean water. (A spray rinse is preferred, if
practical.)
Fj~ (.hem Film
~d
o
Solvent clean per section 20-10-15. Heavily soiled

surfaces may be steam cleaned prior to solvent
Type
Water
:i. (lean
c3
r
CI
General; Coat only small
areas at a time. Use nylon

clean rags. If no color develops,
repeat Operations 2 or 3. Do not allow solution to dry
on surface.
bristle brush
or
Rinse by flushing with water. Avoid hand

the wet film is easily removed.
rubbing
r~
c3
O
as
t)
160
Clean, Oilfree air
I
--I
i. Dry
a
O
Constituents and
133
Deonjdizer t0peration 2)w nor requirrd when surface is abraded uith

Scotchhrite pads (Operation 3,.
Avoid
max
Until dry
Circulating
oven or room
temperature air.
NOTES
m
n
m
r
specifications
are
listd in
Concentrations are of the MATERIALS in water. Oz per

indicate amounts to be added to water to make 1 gal.
prolonged
contact with
zinc
or
cadmium
gal (fl
or
on rinsing,
(Operation 3).
appear
avf
plated components.
d
cc
"water-break-free" surface. If water breaks

re-apply the de-oxidizing solution or re-abrade
Surface must rinse to
MATERIALS.
Scotchbrite pad cleaning or abrading

deoxidizer (Operation 2) is used.
Demineralized water is preferred to tap

operations, especially Operation 6.
(Operation 3)
or
not
Z
C
required if
softened water for all
r
r
O
CC
IO
~3
C~
n
-D
=f
O
n
J
E
(3
O
Z
cleaning.
ct
=z:
CONSTITUENTS
.MATEHLAL
OPEHATION
i. Solventclean
B
i
~P
pj
cc
cn
CC~
z
C
r
SR-76-023
CHEMI~AL FILM TREATMENT FOR TITANIUM AND TITANIUM ALLOYS

Low Temperature Flexibility
GENERAL
chromate conversion coatings applied
to titanium for the purpose of promoting adhesion of
lhis section
covers
organic coatings.
MATERIALS
Iridite 14-2
Potyurethane Coating for

Integral Fuel Tanks
J P-4 Turbine Fuel
6A1-4V Titanium Sheet
Masking Tape, 3M No. 250
Scotch Brite Type S,
Medium
Alodine 1200 Touch-Up
Solution
Nitric Acid, 420B$
Allied Research
Products, Inc.
ST0125LB0006
MIL-T-5624
MIL-T-9046
3M Co.
3M Co.
hmchem Products, Inc.
Commercial
APPLICATION NOTES
Appearance
The chemical film coating formed must be discernible to
the unaided eye. It must be a tightly adherent, nonpowdery coating. It may be non-uniform in appearance
but must be continuous.

Adhesion
The chemical film formed must be such that the coating
system produced by 2 coats of ST0125LB0006 polyurethane fuel tank coating applied over the chem filled
surface must meet the following requirements. (Refer to
section
20-30-85.)
JP-4 Fuel
FINISH
Process Evaluation
When procedures or materials other than those detailed in

table 1 or 2 are used, the following tests must be made.
High Temperature Fuel Immersion Test

Two test panels prepared as described below must be
placed in a test chamber vented thru a water cooled
condenser so arranged that test fluid vapors are condensed and returned to the test chamber. The panels must
be so placed that their painted surfaces do not contact the
test chamber wall or adjacent panels. Sufficient JP-4
from which the light ends boiling below 2750F have been
removed by distillation must be added to immerse the
bottom half of the test panels. The test chamber must be
held at 270 ~5"F for 390 hours. At the conclusion of the
immersion period, the specimens must be removed and
patted dry with soft cloth or paper tissue. The paint film is
then inspected for blisters and other film defects. Immediately after visual inspection, the paint films must be
subjected to the adhesion tape test described in Federal
Test Method Standard No. 141, Method 6301 except that
th, 24 hour distilled water immersion is to be omitted. The
scribe lines required for this adhesion test must be so
placed that they extend into portions of the paint film that
have been exposed both to liquid immersion and vapors
above the liquid level.
(270"F)
The coating system must remain firmly adhered to its

substrate and exhibit no blisters, checking, cracks, or
crazing after 390 hours exposure at 2700F to JP-4 Fuel
from which the light ends have been removed as described
in High Temperature Fuel Immersion Test below.
Fuel and Brine (2009F)

blisters 1/16 in. or
pu hstrate and exhibit no more than 10
less in diameter in the coating when subjected to 390
hours at 200"F in a two layer solution of JP-4 fuel and 3%
brine in accordance with the Fuel and Brine Immersion
Test below.

substrate and exhibit no cracking, checking nor crazing
when bent over a mandrel at -650F after 390 hours
exposure to 2650F in accordance with the Low Temperature Flexibility test below.
Fuel and Brine Immersion Test

This test must be conducted in the same manner as the test
described above with the exception that the test liquid
must consist of 2 layers. The lower strata consists of
30/0 brine and upper liquid JP-4 jet fuel conforming to
MIL-T-5624. Each liquid should cover approximately 1/3
of the test panels and 1/3 of the panel exposed to vapors
above the liquids. The adhesion test must cover all 3 test
areas.
Low
Temperature Flexibility
This test must be conducted as described in MIL-C-27725

with the exception that test strips must be subjected to 390
hours at 2650F +5"F prior to testing.
20-40-40
o
CQPYRIGMT,
Page 1
Aug 31/84
SR-76-023
C(IRROSION CONTROL MANUAL
CHEMICAL FILM TREATMENT FOR TITANIUM AND

TITANIUM ALLOYS (Continued)
Low
Temperature Flexibility (Contd)
except that the 24 hour distilled water immersion

must be conducted
Organic coatings applied to chem filmed titanium surfaces must meet the following adhesion test. Two in. or
more of a 4 in. long strip of 3M No. 250 masking tape must
be pressed tightly to the surface using either a rubber
roller ol the palm of the hand. The tape must be removed
with one quick motion. The coating must be examined
visually for evidence of damage. No separation of the
pal n t syste m from the metal m ust be perm itted. Discoloration of the tape adhesive does not constitute a failure.
Prepare panels of 6A 1-4V titanium alloy. Panel size m ust

x 6 x 0.025 in. for low temperature flexability and 3 x
6 by 0.025 in. (nominal) for all adhesion tests.
be 1
Test panels must be cleaned. (Refer to section 20-10-30.)
Cleaned panels must be chem filmed by process being

evaluated.
(Refer
to Process
Evaluation.)
Two coats of ST0125LB0006 polyurethane fuel tank coating must be applied and cured. (Refer to section 20-30-85.)
Farced cured coatings must be aged a min of 24 hours
parts must meet the wet adhesion tape test described in

Federai Test Method Standard No. 1111. Method 6301
prior
to
testing.
Immersion Chem Film Process For Titanium
OPERATION
MATERIAL
1.
Clean and pickle. (Refer to section 20-10-30.)
2.
ChemFilmp
Alodine 1200
or
CONCENTRATION
Iridite 14-2
3 f0.5
oz/gal
Temperature
Rinse
REMARKS
Must be chem filmed within

1 hour
Adjust pH
pH 1.4-1.6
3.
at 200
Sample Preparation
Two coats of ST0125LB0006 polyurethane fuel tank

coating applied (refer to section 20-30-85) to three chem
film test panels processed concurrently with production
Table 1.
test
f50F. There must be no

separation of the paint-chem film system from the base
metal. Discoloration of the tape adhesive does not consti
tute a failure.
Adhesion
with nitric acid.
I Immerse 3-5 minutes

60 to 900F
Deionized Water
Constant overflow
spray. CAUTION
or
gentle
Wet
film can be damaged easily

by abrasion or water jets.
4.
Dry
140"F
max
NOTE
Brush chemical film per
operation
4 of table 2 may be substituted.
20-40-40
Page 2
Aug 31/84
COPYRIGMT,
1984 BY SAB:RELINER CORPORATION
SR-76-023
CHE1MICAL FILM TREATMENT FOR TITANIUM AND

TITANIUM ALLOYS (Continued)
BrushChemFilm ProcessforTitanium
Table~.
REMARKS
CONCENTRATION
MATERIAL
OPERATION
Solvent wipe, alkaljne
11 FrecleanOl~
clean,
etc.
remove
as
oil,
required
grease and
to
shop
soils,
Abrade
2.
areas to
Abrade until
Scotch Brite Type S,

Medium
be
chem filmed
area
uniformly bright.
Operation 1 and 2
appears
may be
combined.
Rinse
4.
BrushChem
Fj.
Rinse
6,
Dry
Part must be water break

free.
Tap or Deionized Water

(Spray and/or wipe)
3.
FilmD
Alodine 1200
or
Iridite 14-2
Keep area to be chem

filmed wet 1-3 minutes
using clean gauze or soft
bristle brush or spray.
ozlgal
42"F Baume
Nitric Acid
0..5 vol
DeionizedWater
Balance
Wet film
CAUTION
Tap or deionized water

(Spray and/or wipe)
be damaged
abrasion.
140"F
can
easily by
max
NOTES
Part, shall be free of all scale
Do not
use
prior
to start of chem film
operation.
chlorinated solvents.
of formulation
Alodine 1200 touch-up solution may be used without dilution in lieu
specified.
20-40-40
0
COPYRI~HT, 1984 BY SABRELINER CORPORATION
Page V4 Blank
Aug 31/84
SR-76-023
ELECTRODEPOSITED HARD NICKEL PLATING

Scale and Oxide Removal
GENERAL
This section covers the
hartl nickel plating.
requirements for electrodeposited
APPLICATION NOTES
Scale and oxide removal, prior to plating, must be

restricted to abrasive blasting (Refer to section 20-IO-(i0.)
etching). (Refer to section
or anodic pickling (reverse
20- 10-10.)During anodic pickling, the current must be on
prior to immersion and remain on until after removal
from the electrolyte.
Appearance
The nickel plating must be uniform in appearance,
smooth, and free from pits, blisters and other visible
defects. When plating is performed only on a portion of the
surface, the plated areas must be finished in such a
manner that they blend smoothly with the adjacent
unplated areas. Grinding on the basis metal of parts heat
treated to 180,000 psi
or over
is
prohibited.
to relieve embrittlement from
Stripping
Solutions used for stripping of nickel plating must be
subject the part to hydrogen embrittlement
nor cause pitting of the basis metal.
proven not to
FINISH
The following inspection and testing must be conducted to
verify conformance to the requirements of this section.
Hydrogen Embrittlement Relief

Baking
(Over 180,000 psi)
hydrogen
must be
suitable in duration, temperature, and timeliness for the
Appearance
metal and process in
The appearance of the nickel plating

in APPLICATION NOTES above.
use.
must
be
as
required
Hardness
The hardness of nickel plating must be in the range of RC

40-52 (Vickers hardness No. 390-550).
Tests
Hardness
Adhesiaq
The adht?sion of nickel plating must be such that it shows
710 separation from the basis metal when tested as
described under FINISH.
The hardness requirements specified must be verified by

direct measurement, using Diamond Pyramid Hardness
numbers or Knoop Hardness numbers equivalent to RC
40 as a min value.
Thickness
Adhesion
The thickness of nickel plating on finished parts must be

0.0015 in. min and 0.004 in, max unless otherwise specified
on the applicable drawing or controlled by the following
Adhesion tests must be performed using test coupons of

4130 condition A plated concurrently with production
items. The test coupon must be bent thru an angle of
180"F on a diameter equal to the panel thickness, then
examined at 4 diameters magnification for non-adhesion.
Cracks that occur during bending which do not cause
exception.
Holes,
recesses
and other
areas
sphere 3/4 in, diameter

requirement.
are
that cannot be touched by

a thickness
exempted from
flaking
or
peeling
are
not
cause
for rejection.
Thickness
Preparation for Plating

Stress Relief
The thickness requirement of APPLICATTON NOTES

must be determined by one of the following methods.
Ail
i.
Dermitronelectronic measurement
or a
2.
Micrometer measurement
3.
Magnegage
feroes base alloys, having a hardness of RC 40 or above

heat treat range over 180,000 psi must be stress
relieved by a suitable process, after completion of all
gri nd ing operations and prior to shot peening and plating.
measurement
Shot Peening
All ferous base alloys having a hardness of RC 40 or above

heat treat range over 180,000 psi, must be shot peened
by a suitable process.
Corrosion resistance must be determined by salt spray

test in accordance with ASTM-B-117 as follows:
or a
x 3 x 0.040 in., of 4130 heat treated to

125-140 KSI and plated to a thickness of 0.0015 in.
concurrently with production items must be exposed for
48 hours and exhibit no corrosion of the basis metal.
Test panels, 6
20-40-45
0
COPYRIGHV, 1984 BY SABRELINER CORPORATION
Page 1/2 Blank

Aug 31/84
SR-76-023
GENERAL PROCEDURE FOR BRUSH TYPE ELECTROPLATING
GENERAL
This section covers a procedure to be used for the electrodeposit by "brush plating" of nickel, copper, chromium,
tin,silver, gold, rhodium, cadmium and lead upon copper,
brass, bronze, iron, steel, nickel, beryllium, silver and
aluminum alloys.
damaged plating in non-functional
areas.
plating" may be used only when specified on the

applicable drawing, or when allowed by a plating specification applicable to the part being processed. Touch-up
not to
may be applied Only to non-functional surfaces,
interiors of fluid systems, or to bearings, splines, gears, or
Brush
other functional surfaces.
MATERIALS
Paper;
Ltd.
Solution, chromium stripping; Iiddington and Associales.
This process is intended for the plating of small areas of

parts that are either too large for immersion in a plating
tank, that contain components that would be injured by
immersion in plating solutions, or for the "touch-up" of
Abrasive
Solution, cadmium plating (acid); Piddington and Associates, Ltd.

Solution, cadmium plating (alkaline); Piddington and
Associates, Ltd.
Solution, chromium plating; Piddington and Associates.
500
or
600
grit; commercial
Alumina; levigated, powdered, 600 grit

Baatinnf, Cotton; IJSP
Butyl cellosolve acetate; Union Carbide

Cadmium oxide, technical grade
Cellulose wiping tissue; AB0215-001
Cheese cloth, cotton
Cleaner, electrolytic alkaline; LB0210-109

Chromic Acid; O-C-303, Type II
Copper cyanide (cuprous); technical grade, 70-72% copper

netergent; Joy, Proctor and Gamble, Cincinnati, OH; or
equivalent
Epoxy primer; MB0125-006
Gold, Bright gold concentrate No. 1; Wildberg Bros., Los
Angeles, CA or equivalent
Hydrochloric acid; ACS reagent
Iridite No. 8; Allied Research Products, Inc., Baltimore,
MD.; or equivalent
Methyl chloroform; MIL-T-81533
Nickel chloride; 0-N-335, Type III
Nitric acid; 0-N-350
P~per, filter; UU-P-236, Type I, Class 4
Potassium carbonate, anhydrous; technical grade
Potassium cyanide, technical grade, 94-96% granular
Potassium fluoride; reagent grade
Potassium hydroxide, 0-P-566

Pumice; technical grade
Silver conductive compound; AB0120-014, Type IV
Silver cyanide, technical grade
Sleeving, dacron; Piddington and Associates, Ltd.,
Pasadena, CA
Sodium cyanide; teChnical grade, 94-96% granular
Sodium gluconate; technical grade
Sodium hydroxide; O-S-598, Type I
Ltd.
Solution, tin fluoborate, 47% concentrate, Harshaw Chemical Co.
Solution, lead fluoborate, 50% concentrate, Harshaw

Chemical Co.
Fluoboric Acid,
purified,
48-50%
Peptone, Industrial, Cudahy Laboratory, Omaha, NE

Solution, cleaningand deoxidizing; Piddington and Asso,iate,, Ltd.
Solution, copper plating, (acid); Piddington and Associates, Ltd.
Solution, copper plating (special); Piddington and Associates, Ltd.
Solution, etching No. 1; Piddington and Associates, Ltd.
Solution, etching No. 2; Piddington and Associates, Ltd.
Solution, gold plating; Piddington and Associates. l,td.
Solution, Iridite No. 8; Allied Research Products. Inc.,
Baltimore, MD
Solution, lead plating; Piddington and Associates. Ltd.
Solution, nickel plating (epais); Piddington and Associates, Ltd.
Solution, nickel plating (alkaline); Piddington and Associates, Ltd.
Solution, nickel plating (black); Piddington and Associates, Ltd.
Solution, Selectron Electrolytic Cleaner, Seiectrons. Ltd.
Solution, Selectron, Alkaline Copper, Selectrons, I,td.
Solution, Selectron, Acid Copper, Selectrons, Ltd.
Solution, Selectron Tin, Selectrons. Ltd.
Solution, rhodium plating; Piddington and Associates.
Ltd.
Solution, Selectron Activator No. 1: Selectrons, Ltd.. 153

E. 26th St., New York, NY
Solution, Selectron Nickel, Acid; Selectrons. ltd.
Solution, Selectron Nickel, Neutral; Selectrons, Iltd.
Solution, Seleclron Nickel, Special; Selectrons. lid.
Solution, silver plating; Piddington and Associates. Ltd.
Solution, tin plating (alkaline); Piddington and Associates,
Ltd.
Solvent; 50 +5% TT-I-7.75, Grade A, Isopropyl alcohol, 50

f5%, AB0210-008, Type I, Naphtha
Sulfuric acid; ACS reagent
Assoc.
Solution, Selectron, Activator No. 2, Piddington
Ltd.
Toluene; TT-T-548
1,1,1 Trichloroethane (methyl chloroform); O-T-620
Water, purified; deionized or distilled with no less than
50,000 ohm resistance and no more than 10 ppm total
solids
Water, tap; clear with
no
turbidity
20-40-50
0
CaPYRIGHT, 1984 BY SABRELINER CORPORATION
Page 1
Aug 31/84
9B-76-023
C()RKOSION CONTROL MANUAL
GENERAL PROCEDURE FOR BRUSH TYiPE ELECTROPLATING
(Continued)
EQUIPMENT
Cellulose sponge covered carbon anode; NR Industrial
Engineering Drawing 1501-76C, or Carbon Anode;
Dalic, Piddington and Associates, Ltd., or equivalent
Di rect current power source capable of providing a direct
culrent meeting the requirement of the specific application.
Safety
An anode of suitable size and shape for the work to be done

nnsst be firmly secured in its proper stylus.
Sufficient cotton batting must be torn
All chemicals must be handled so as to avoid contact with

eyes, skin or mouth. Vapors or mists are dangerous to
respiratory
minute quantities
eyes,
passages and skin.

must be avoided.
Swallowing
even
Skin. face and respiratory protection may be required

during some phases of the use of the chemicals Iequired
by this process. Protective clothing and other devices
be used.
Cold Worked Basis Metal

All cold worked basis metal must be stress relieved in
accordance with applicable processes.
Surface
Carbon Anodes:
Carbon anodes, whenever possible, must be enveloped

with UU-P-238 Type I, Class 4 filter paper to minimize
carbon particle contamination of the plating solution.
APPLICATION NOTES
must
Anode Preparation
Preparation
Cleaning and activation must be accomplished by methods

which result in no selective etching or measurable loss of
basis metal.
Solution Cleanliness
The activation and plating solutions must be kept clean
and free of grease and insolubles.
to cover anodes with
or
cut from the roll
layer approximately 1/4 in. thick.
Enough cotton must be used to prevent the exposure of the

~bzrre anode. The cotton may be wrapped in cheese cloth.
GFeater thickness is advantageous where flexibility is
"quied for rough or irregular surfaces.
Carbon anodes must be wetted with purified water and
then wrapped with the cotton by rolling them over the
cotton in the direction of the fibers.
A!dacron or cheese cloth tubular sleeve must be used over
t:he cotton batting when rough surfaces are to be plated.
~er the anode has been wrapped with the cotton batting,
and covered with dacron or cheese cloth sleeving, if used,
the covering must be secured to the anode witha rubber
band or other suitable means.
Cellulose Sponge Anodes
The anode must be disassembled and the soution well, the
anode, the contacts, and the brush must be thoroughly
cleaned using alumina and electroytic clenaer (LB0210-
109) prior
to
use.
Processing
Hydrogen embrittlement relief
plating.
Handling
and
must be
Purified water may be used wherever tap water is called
performed after
Packaging
Before plating the parts must be examined for nicks,

dents, scratches or other damage. Parts that have been
damaged to an extent that will prevent them from
meeting drawing requirements after plating must be
rejected. Parts must be so handled as to be kept clean and
free of damage. After plating, parts must be packaged to
protect them from contamination and physical damage.
Deposit Thickness
rlle
deposit thickness
must
conform to the
enai~lrcli,lg drawing.
out.
Cadmium must be electrodeposited upon steel, copper,

and copper alloys in accordance with either Processing
with Non-Proprietary Solutions, or Processing with Proprietary Solutions.
Silver must be electrodeposited upon copper and copper

81:loys in accordance with the respective paragraphs on
Non-Proprietary or Proprietary Solutions.
Gold must be electrodeposited upon circuit boards in
accordance with either the respective paragraphs on NonProprietary or Proprietary Solutions.
Tin must be electrodeposited upon glass-fiber reinforced

plastic surfaces in accordance with Application of Tin to
Class
Fiber Reinforced Ilastic Surface.
20-40-50
Page 2
Aug 31/84
C~RIGMT, 1984 BY ~tilRELINER CORPORATION
SR-76-O23
GENERAL PROCEDURE FOR BRUSH TYPE ELECTROPLATING (Continued)

Processing (Contd)
All other electrodeposits must be made in accordance
with Processing with Proprietary Solutions.
Remove solder
vestiges from circuit board
abrasion with
motor driven
contacts
eraser no coarser
by
than 320
Parts to be cadmium plated must be processed in accordance with table 1 using step 8 instead of steps 9, 10, and 11.
Circuit boards
to be
gold plated
must be
processed
in
accordance with table 1, using step 9 instead of steps 8, 10.

and 11.
Parts to be silver plated must be processed in accordance
with table 1 using steps 10 and 11 instead of steps 8 and 9.
grit.
Processing with Non-Proprietary Solutions
NOTE
A~plolicable to Surfaces Other than 1Modules

With Assembled Comloonents
Table 1.
Processing With Non-Proprietary Solutions

REMARKS
TIME
MATERIAL
STEP
i.
Degrease
Isopropyl alcohol and naphtha

(Ratio 1:1)
2.
Scrub
Pumice and tap water
3.
Rinse
Flowing tap
Until free of visible soil and
water
pumice
4.
Cathodic Clean
7-9 oz/gal LB0210-109 cleaner
5.
Rinse
Purified water
6.
Activate
25 f20/o sulfuric acid
Rinse
7.
30 seconds min
30-60 seconds
(by volume)
30-60 seconds
Purified water
Iq
Keep
water
flowing
over
all
surfaces
Cadmium Plate
8.
(;oldPlate
9.
33
6
14
6
+1
+1
-tl
fl
oz/gal
oz/gal
oz/gal
oz/gal
sodium cyanide
sodium hydroxide
cadmium oxide
sodium gluconate
Until required thickness
Undiluted bright gold
is
deposited
Silver Strike
0.25
1.4
10.0
6.0
f0.02
+0.1
f1.0
+1.0
Process with
Solutions.
Non-Proprietary
2-3 minutes
Plate in accordance with Plating

Process with Non-Proprietary
Solutions

Solutions.
concentrate Na. 1
10.
oz/gal silver cyanide
oz/galcoppercyanide
oz/galsodiumcyanide
oz/galsodium
gluconate
11.
SilverPlate
32 fl
+1
32
3.0 +0.5
6.5 f1.5
oz/galsilvercyanide
oz/gal potassiumcyanide
oz/gal potassium
Until required thickness
is
deposited

Solutions
hydroxide
oz/gal potassium
carbonate
20-40-50
Page
0
Aug 31/84
SR-76-023
COHROSION CONTROL MANUAL

Table I.
(Continued)
Processing with Non-Proprietary Solutions ~Contd)

STEP
MATERIAL
12.
Rinse
1~.
Embrittlement
Relief
14.
Post-treatment
Flowing tap
TIME
water
:30-60 seconds
REMARKS
Dry
upon
When
All cadmium plate unless

otherwise specified
completion.
required
In accordance with Post-Plating

Treatment
NO~ES
O
111
Wipe free of visible oil and

Sc rub as thorough ly
free surface.
O Clean
until
as
grease,
configuration
water break free
cleaning, scrub
with
or
degrease using clean lint-free cloth.

perm its
until part rinses free of visible soi 1 with
water break
surface is obtained. Where area to be plated does not permit cathodic

(by volume) of detergent.
1-2% solution
O Swab to maintain acid on all surfaces to be plated ~br required time interval.
O Apply silver stlike no longer than necessary to obtain min complete coverage.
20-40-50
Page 4
Aug Y1/84
Q~PYRIGHT,
1984 BY
ABRELIHER GORPORATION
SR-76-023
Processing
with
Non-Proprietary Solutions (Contd)
IlstinR Process with Non-Proprietary Solutions

Iill the anode well with the proper
plating solution.
Adjust the output voltage of the ret,tifier
to
compensate
for the anode size and the solution in use. The ploper
voltage and the plating rate may be checked by a preliminary trial upon a steel plate.
meter to read
Adjust the ampere-hour
zero.
ampere-hours using the area to be

plated,the specified thickness, and the factor determined
in accordance with Plating Process with Proprietary
Calculate the necessary
Solutions
Turn the rectifier on. Move the saturated anode over the
surface to be plated in a circular motion either by hand or
by use of a turning head. Move the anode in respect to the
surface being plated at the rate specified in table 3.
The anode must be kept moist while either etching,

cleaning, or plating. The runoff may be collected in a
porcelain dish and the solution absorbed by the cotton
may be recovered by squeezing it into the porcelain dish.
(Continued)
Move the saturated anode over the surface to be plated in a

circular motion either by hand or by use of a turning head.
Move the anode in respect to the surface being plated at
the rate specified in table X.
Calcu late the necessary am pere- hou rs us i n rr the area to I,e

plated, the specified thickness, and the factor listed in
table 3.
Turn the rectifier
on,
and
plate the surface for the time
calculated, moving the anode relative to the surface being

plated at the rate specified in table 3.
kept moist while either etching,

plating. The runoff may be collected in a
dish and the solution absorbed by the cotton
may be recovered by squeezing it into the porcelain dish.
The anode must be
cleaning,
porcelain
or
The used solution may be stored for re-use in a clean,

labeled bottle. It must never be returned to the bottle
containing new solution.
After the specified plate thickness has been deposited,

rinse with flowing tap water. Rinse a second time with
flowing purified water. Dry the part thoroughly.
The used solution may be stored for re-use in a clean,

labeled bottle. It must never be returned to the bottle
containing
new
solution.
After the specified plate thickness has been deposited,

rinse with flowing tap water. Rinse a second time with
flowing purified
water.
Dry the part thoroughly.
Processing with Proprietary Solutions

Parts shall be processed in accordance with table 2 using
the procedure given in Plating Process with Proprietary
Solutions.
Plating Process with Proprietary Solutions
Saturate the anode with the proper solution.
With cellulose sponge covered anodes: Fill the solution
well with the plating solution.
With carbon anodes:
Pour sufficient plating solution into
a.
porcelain container.
b.
glass
or
Saturate the cotton wrapped anode by immersion in the plating solution.
Adjust the output voltage of the rectifier

in Table 2
or
to that
specified
table 3.
Adjust the ampere-hour
meter to read
zero.
Calculate the necessary ampere-hours using the area to be

plated, the specified thickness, and the factor listed in
table 3.
20-40-50
o
Page 5
Aug 31/84
n
093q
"rl
2:
,Q;
Processing
Table
Oo
with
Proprietary Solutions
~d
SURFACE
CJI
HI(:H (:ARHON
ra
1,ESS THAN IS,
Cd
STE~I,(WITH
BRASS:
IH()N:
I,OW (:AHHON
HR()N%~
STI~EI.
C.()IPISK:
i.
PASSIVATEL)
THAN 1W Mo. OK
AI,I;MINUM:
AI.I:MINIIM
QS (:r)
.41.1,OYS
NI(:KEI,
NICKE:I~
PLATE
Omit
Omit
scale is present
I(q
LI1
Il+lvolts
15f5vol
15 +5 volts
15 f5 volts
15+5volts
6.0f0.5
volts
I~
omit
omit
Lfl
s. Elrctroelean
4. Rinse
a
5.
Etch
15 -e5 Volts
voltsl O
ed
13
131
L3
cJ
Omit
Omit
IPI
Omit
Omit
7. Electroclean
Omit
Omit
13
(3
Omit
Omit
13
Li31
d
M
8. Rinse
Omit
Omit
Omit
Omit
Omit
Omit
C~
c3
9.
Bondinglayer
1 10. Rinse
11.
c~
m
rr!
~a
n
stripping
-C
n
ex,
P
t~
C
Omit
73
I
-I
El
10 lt5
Omit
6. Chromium
SII.VEH
BERYl,l,lliM
I~
10
(O
2. Descale when
3
I
L)e~rease
AI,I,OYS:
35 (:r);
Electroplate
Omit
61
IQ
56
metal
required
Cd
r
NOTES
Oil and grease must be removed by vapor degreasing according to section 20-10-55. Where vapor degreasing is
impractical, wipe with clean cellulose wiping tissue soaked in toluene or methyl chloroform. Always pour solvent onto
either tissue or metal surface rather than dip tissue into container to prevent possible contamination of solvent in
container. Use successive squares of clean tissue until tissue surface shows no trace of soil.
O
so
Scour with
73
pumice (320 grit
E lectroclean
or
finer)
or
levigated alumina
until surface
can
be rinsed free of water break.
cathodically using cleaning and deoxidizing solution at specified voltage. Surface must be cleaned to a water
c3
jZ:
C3
h
S;
break free surface.

O
~d
STAINI.ESS
STEEL: HI(;H
(:ARBON STF:EL
(WITH MORE
Mo
HI(;H NICKEI.
ii
Q,
lo
;O
Table 2.
O
=r!
Processing with Proprietary Solutions (Contd)
~Z:
SURFACE
-0
~d
HIGH CARBON
I
-I
LESSTHANI%
STEEL(WITH
Mo
(D
03
OPERATION
STAINLESS
COPPER:
IRON;
BRASS;
LOW CARBON
HIGH NICKEL
ALLOYS:
PASSIVATED
BRONZE
STEEL
NICKEL
STEEL: HIGH
340 Cr);
CARBON STEEL
(WITH MORE
THANI%Mo.OR
3g Cr)
~d
ELECTROLESS
ALUMINUM:
ALUMINUM
ALLOYS
NICKEL
PLATE
O
BERYLLIUM
SILVER
v,
NOTES (Contd)
m
n
10
F
z
O
O
n
n
and 6.0 f0.2 oz/gal sodium

F,lectroclean cathodically for 2 minutes min using a solution of 6.0 -t0.2 oz/gal sodium cyanide
hydroxide in tape water.
Rinse with
tap
13
water.
Repeat
anodically with No. 2 Etching Solution at 8 +2 vde until
Etch anodically
a.
grey matte surface is obtained. Rinse
in
thoroughly in flowing
for 2 minutes min at either:

using a solution of 0.75 +O.lOii~ (by
b.
crrey to black
surface is obtained.
weight) potassium fluoride
in 25 +5%
ed
(by weight) hydrochloric
I Anodienliy ctrip
using Selectron Activator No.
steels containing
more
i.
than 9% chmmium with chmmium
strippin~
solution at 14 -i-6
15 +5
Electroclean cathodically for.5 ~2 seconds with cleaning and deoxidizing solution at
b.
b
1
as
w
ca
31
A solution of ~2 i-2
Selectron Nickel
oz/gal nickel chloride and
tr!
v.
4 +1
c3
O
d
Process with
Proprietary Solutions.
oz/gal hydrochloric acid in purified water,
or
rm
~2!
o
Special Solution
Use Seleetron Nickel Neutral Solution for

del,osits 0.0005 in. thick and over.
~C
v.
9 without rinsing.
O Activate cathodically using No. 1 etching solution at 8 ~2 v. Proceed to Step

O Rinse in flowing purified water.
O F,lectroplate in accordance with Plating Process with Proprietary Solutons.
O E:lectroglate a 0.0001-0.0002 in. thick nickel (Epais) coating ac~cording to Plating
either:
O Nickel strike at 12.0 +0.05 v for 2-3 minutes over all surface areas using
a.
c3
d
m
or
12.0 +0.5
O
~d
W
33
with No. 2 Etching Solution at 1216 vde unt,l
6.0 f0.5
acid,
13
thoroughly
water.
3 Cathodieally activate
Z
purified
m
r
water.
surface is obtained. Rinse

Etch anodically with No. 1 Etching Solution at Is f3 vdc until a grey matte
with levigated alumina.
flowing tap water. Remove smut from high carbon steels abrasively
Etch
flowing tap
rinse with flowing
C
~a
depo8its less
than 0.0005 in
thil:k and Selectran Nickel Acid Solilti~ln ior
o
Z
C,
O=I
Fmo
~f.
ts
C
z~
(1
cb
arul
SR-iCi-023
(()KIZOSI()N CONTROL MANUAI,
GENERAL PROCEDURE FOR BRUSH TYPE ELECTROPLATINCI
Table
(Continued)
Plating Process with Proprietary Solutions

PRETREATMENT
NE(:ESSARY
V()I,TACI~
AMPERE-HOURS
F()RO.QUOI IN.
SZ~RFACES
DIRECT
DEP()SITION IS
POSSIBI,E: ON(3
REI,ATIVE
CATHODEANOI)E SPEED
I-h
~0-120
LII
(Rdniium (Acid)
8-17
Yes
0.008
(Hd ni i u m
8-IT
Yes
0.008
No
0.1:(7 tl()X,
I-ci
5-:~0
5-1$
Yes
0.012
1-7
:10-100
(:ol,l,tl (Sl,ecial)
Yes
0.012
.5.~i
40-(i0
(;ol(l
Yes
t).()08
I-(i
:~O-(iO
S()I,~ITI()IV
(lll.l)llliu~n
Nickcl (I~I,Ris)
ow 1
sc). IN.
20-80
4-12
No
0.000
6.A
:1()-60
8-80
No
0.021
1-7
20-80
1-7
20-80
Fj
20-80
Nickel (Alkaline)
I2-1X
No
Nirkcl (Ilwck)
12-1X
No
O, O
10-11
No
r\jicktl
Rh(ltl ium
4-1()
Sil\c,
4-2()
Iin tAlkaline)
8-2()
0.026
No
0. 1.57 ?r 10X,
r,
.5-10
0.004
20-60
0.007
1-0
20-80
1-7
20-.50
1
Yes
(lcwlling
and I)eositlizin~
I
I
No. 1 I:trhinR
No,
~l:tching
(FT/MINUTES)
I
I
I
I
1
1
20-r,0
0.()()7
4.7
20-60
I-~i
20-50
NOTES
O ()l,erate
Il;lting
small electrodes in lower end of sl,ecified range.

lime may be tlecreased by ol,clating large elec-
trotles at
enouah
I~
higher voltage. Voltage used
t"
to LU""
cause
must not be
8.
9.
10.
high
"li"B thlu ""1Utio" ""I ~U"i"R "f
(:old plate,
Nickel
Silver
Nickel strike
areas
IIiol to
plating ~ith those solutions ~l,ecificd in table

to be plated must be swabbed with a 10
lkl solulion of sulfuric acid. Then rinse with flowinR
tap water,
rinse a second time using flowing purified water. Howe\er, metals subject to hydrogen umbrittlement must be
cleaned anodically with cleaning and deer idizina solution,
I.
2.
:1.
1.
:i.
(i.
i.
Iron and miltl steel

~Iardened and teml,e,ed steel
(ase hardened steel
Stainlesssteel (aftelclchinR)
(ol,perand b1ass
I(,onze
Aluminum alloys (;lftc~l. ctclhina)
at
approximately 0.00001 in, thick
12.()+0..5
for 2-:~ minutes
over
all srlrface
using~eilhcr:
8.
A SO1UtiO" Of 82
Selectron Nickel Special Solution
oz/gal nickel chloride and

hytlrochloric acid in purified water, or
4 fl
oz/Rat
lise Selectron Nickel Neutral Solution for deposits less

than 0.0006 in, thick and Selectron Nickel Acid Solution
for deposits 0.0006 in. thick and over.
I~ead-tin platingsolution is prepared by

by
volu me alkaline tin solution with 27
by volumeoflead
solution. An al tes nate non props i etasy sol u tion is made
by
mixing 60-66Xl by volume tin fluoborate solution, 2()-25k1
lead fluoborate solution. I:i-15X, fluot,oric acid and .5.r, t0.6
am/i r,er,tone.
lhis solutiorl is to ~,e m;ltic Frt!sh c;tclh
day of
Ilso.
20-40-50
P;lac H
AuR:ll/t~4
1984 RY SABRELINER ~QPPORATION
8R-76-023
(Continued)
POST-PLATING TREATMENT
APPLICATION OF TIN TO GLASS-FIBER

REINFORCED PLASTIC SURFACE
Sand the surface to be plated with No. 500 or No. 600 grit
abrasive paper. Swab the surface with 50/50 isopropyl
alcohol/naphtha solvent and wipe dry with clean tissues.
Apply MB0125-006 epoxy primer, insuring that any gaps
are filled and bridged.
Prepare AB0120-014, Type III, silver conductive compound by mixing 40.0 +0.5 parts by weight of Part A with
1.0 +0.1 parts by weight of Part B (catalyst). Mix
thoroughly in a smooth walled container or on a flat plate.
Mix 1.0 f0.1 parts of the mixed silver compound with 1.0
~t0.1 parts of butyl cellosolve acetate. Apply a thin brush
coat over all prepared areas, extending 1/8-1/4 in, beyond
Embrittlement Relief: When

be embrittlement relieved.
required, steel parts
must
All cadmium plate, unless otherwise specified, must be

treated in accordance with table 5 after any necessary
embrittlement relief.
PLATE
REQUIREMENTS
plating must meet the quality requirements of the

appropriate specifiecation listed in table 6.
The
the sanded surface onto any adjacent plated surfaces.

Cure for 2.0 +0.2 hours at 120 f5"F.
Electroclean cathodically for 5 f2 seconds with Selectron
electrolytic cleaner solution at 15 +5 v. Rinse.
0.0005 in. of Selectron alkaline copper using 8.0
for 5 minutes per sq. in. Rinse.
Deposit
f0.2
Deposit 0.0005 in, of Selectron acid

v
copper
using 8.0
+0.2
for 1.5 minutes per sq. in. Rinse.
Deposit 0.0005 in. of Selectron Tin copper using 8.0 +0.2 v

for 6 minutes per so. in. Rinse.
Gold
Plating Contacts
Gold
plate
ponents
as
contacts of modules with assembled

outlined in table 4.
(;old
Table 4.
STEP
i.
2.
com-
Plating of Contacts of Modules with Assembled Components
Degrease
Isopropyl alcohol naphtha (1-1)
Scrub
Pumice and lint free cloth
REMARKS
TIME
MATERIAL
Wipe
free of visible oil
or
grease
using clean, lint-free cloth.

15
seconds, min
Scrub until surface rinses free of

water break.
3.
Itinse
Deionized water
4.
GoldPlate
Per step 9 of table 1
15 seconds, min
Use flowing water source (e.g.

laboratory wash bottle). If water
break occurs, repeat step 2.
20-40-50
0
Page 9
Aug 31/84
SR-76-023
GENERAL PROCEDURE FOR BRUSH TYPE ELECTROPLATING (Continued)

Table 5.
Post-Plating Treatment
STEP
SOLUTION COMPOSITION
TIME
REMARKS
I.
Activate
0.7-1.7ro Nitric Acid (by volume)
5-10 seconds
2.
Rinse
Flowing tap
0.5-2.0 minutes
3.
Chromate Treat
Bath A
1
1.8-2.20/0 Iridite No. 8 (by volume)
20-30 seconds
Bath B
3.5 ~0.536 Chromic Acid
1-2 minutes
10
90-120 seconds
Agitate parts if
water
(by weight)
4.
Rinse
Flowing tap
water
an
immersion
tank is used.
5.
SprayRinse
I Purified
6.
Dry
15-30 seconds
water
Use
Air
or
spray rinse.
air blast. Chromate
treated surfaces must receive a

min of handling until 12 hours
after drying.
NOTES
O May
be omitted when parts have not been embrittlement relieved.
May be omitted when parts have
not been embrittlement relieved.
Use Bath A for all parts that will not be

as
subjected
to
Agitate parts if
an
immersion tank is used.
temperature above 140"F. Drain and rinse
as
rapidly
possible.
Use Bath B for all parts that will be
Table 6.
subjected
to temperature above 140"F.
PlatingQuality Requirements
PLATE
REQUIREMENTS
Cadmium
QQ-P-416, Type II
Chromium
QQ-C-:I20, Class
(ol,per
AMS 241tl
I,eatf
AMS 2414
Nickel
G2Q-N-2t)O, Class~
Rhodium
AMS 2413
Silvel
QQ-s-~sr>
Tin
MIIrT-10727, Type
20-40-50
Page 10
Aug 31/84
CO:~RI@HT, 1984 BY SA-BRELINER CORPORATION
SR-76-023
TIN PLATING BY ELECTRODEPOSITION OR HOT DIPPING
(;ENERAL
This section covers the recluirements fol the application of
lin plating on ferrous and nonferrous metals by electro-
del,osition
or
hot-dipping.
The tin plating applied in conformance with the

ments is classified as follows:
Type I
Type II
Tin
Tin
reyuire-
Plating by Electlodeposition
Plating by Hot-Dipping
Water, deionized: containing no more than 25 ppm total

dissolved and undissolved solids and having a ~pecific
resistance at 250C: (770F) of 50,000 ohm-cm, min
Zinc Chloride, Technical (;radt; C:ommercial
Zinc Chromate Primer; MI1,-I-2:~:177
Tinglo-Culmo Starter; Lea-Konal, Inc., Freeport, N\i
Tinglo-Culmo Rrightner; Lea-Ronal, Inc., Freeport, NY
Neutra-Rinse 40: Lea-Ronal, Inc., Freeport, NY
Air or Nitrogen Gas, Dry, Filtered: AA0115-172. Purity
Level VIII
Sodium Carbonate, 0-S-571
NOTE
Electrodeposition followed by reflowing

(Tl/pe I) m&T/ be used os an alternative to
hot
dipping (Type II).
Where drawings call out "plate tin in accordance with

AMS 2408", this refers to Type I plating applied over low
alloy and carbon steels. The result is to delete the copper
strike as called for in Type I and apply the tin plate
directly to the basis metal.
IMATERIALS
(Infrared-Heat-Iteflective,
Compound; A30125-017,
Organic Coating
Grade A
Ammonium Chloride; 0-A-491, Type II

Anodes, Tin; Commercial
beta-Naphthol, Technical grade; Commercial
Fluoboric Acid, 48-~0% (wt.), Technical (;rade; MS 36040
(;elatin, Technical (;rade; Commercial

Hydrofol Tinfat No. 50; Metal and Thermit Corp.,
Rahway, NJ
Hydrogen Peroxide, 3036, sulfuric acid stabilized, Technical Grade; Commercial Kenvert Tintillate Starter;
Conversion Chemical Corp., 210 E. Main St., Rockville,
CT
Kenvert Tintillate
Brightener (Conversion Chemical
Corp.)
Tintillaffe Connector (Conversion
(:orp.)
Methyl Ethyl Ketone (MEK); TT-M-261
Kenvert
Chemical
Potassium Hydroxide; 0-P-566

Potassium Stannate, Technical Grade; Commercial
Novaculite 625; Chicago Wheel and Mfg. Co., Chicago, IL
Sulfuric Acid, Sp. Gr. 1.84, Technical Grade; 0-S-809,
Type I, Class 1
Iin, liK(for hot dipping); QQ-T-:371
?in (Stannous) Fluoborate, 47% (wt.), Technical Grade;
Harshaw <:hemical Co., Cleveland, OH
lin
In the event of any conflict between the requirements of

this section and drawings, the requirements of the draMing takes precedence.
Safety
All materials and chemicals required by this section must
be handled, used, and stored with due regard to their
hazardous nature.
Immersion Rinses
Acetic acid; 0-A-76
Aluminized
APPLICATION NOTES
(Stannous) Sulfate, Technical (;rade; Commercial
The immersion rinses should be either the single immer

sion or double immersion counterflow type. A double
immersion counterflow rinse can be substituted for a
single immersion rinse.
Rinsing consists of complete immersion

flowing deionized water.
in
tank of
The flow of deionized water into the tank must be at a

sufficient rate to provide adequate rinsing of the part and
skimming of the tank.
Each immersion rinse step listed in the tables must be
discrete except that one rinse tank may serve two solution
tanks which contain the same chemicals.
Each immersion rinse tank must be equipped with a
suitable overflow. The overflow must extend along the
longest dimension (width or length) of the tank.
Water must be flowing in rinse tanks approximately 1(1
minutes prior to rinsing the first part in any continuous
group. Unless otherwise specified, incoming
rinsing and making up processing solutions
must be as given in MATERIALS. Deionized water may
processing
water for
be substituted where tap water is
specified.
Filtration of Tin Plating baths: The tin electroplating

bath must be filtered as necessary to prevent co-deposition of solid particles on surfaces being electroplated.
20-40-55
0
Page 1
Aug 31/84
SR-76-023
TIN PLATING BY ELECTRODEPOSIT~N OR HOT DIPPING
(Continued)
Handling and Storage
Hot Oil Fusion
for those parts on which tin plating is intended to

be used as a solderable coating, both partially and
completely plated parts must be protected against corrosion and damage during handling and storage.
The hot oil fusion or flowing operation, as detailed in

either table 1 (Operation 6), table 2 (Operation 6), or table
5 (Operation 4), is applicable only to tin plating thickness
Except
Type
Type I
between 0.0025 and 0.0075
(0.0001 and
0.0003
in).
Stripping
Plating
tin
mm
No selective etching or less of parent metal may result

from stripping the plated parts. After stripping, the
finish and dimensions of the parts must meet the recluirc!ments of the applicable drawing.
plating must be applied by stannate process, the
the sulfate process below. Tin

requirements of AMS 2408 ton low
alloy and carbon steels) must be similarly processed
except that the copper or nickel strike is not allowed.
Alkaline tin plating (stannate) must not, be used on
aluminum parts. Acid tin plating(sulfate and fluoborate)
must not be used on magnesium. Bright acid tin (table 3 or
4) may be considered to fulfill the requirement for fusion
or fio~linff in hot oil.
fluoborate process,
plating meeting the
or
Tin Plating Rework

Small
areas
of uncoated base metal may be coated to
design thickness with electrolytic tin by the brush tech

nique. (Refer to section 20-40-50.) This may be applied
ody when bare spots have resulted from rework, minor
physical damage, or uncoated areas masked by holding
St;lnnate Process
After the final activation or "strike" and rinsing operation,
the I,arts must be tlansferred immediately, without
drying. to the tin electroplating bath (Operation 1 of table
1) and processed in accordance with the requirements of
ta~,le i.
fi~ctu res. Bare spots resulting from non-ad hesion of the ti n

must not be touched-up by this method but must be
stripped of tin land copper strike if present, and replated
according to original drawing requirements. Touch-up by

brush techniques is applicable only to external nonfunctional surfaces. The duality of the tin coating must
conform to the requirements in COATING.
Fluoborate Process
Paint
A fte r the fi nal activation or "strike" and r i nsing operation,

the part shall be transferred immediately, without drying
Touch-Up
Pits, voids, minor physical damage and uncoated metal in

including surfaces not touchable by a 19.1 mm (3/4 in.) sphere may be
paint-coated as follows:
as-cast and other non-functional surfaces
the activation bath (Operation 1 of table 2) and

processed in accordance with the requirements of table 2.
to
Sulfate Process
Aftel the final activation or "strike" and ri nsing operation,
the parts must be transferred immediately, without
drying, to the activation bath (Operation 1 of table 3 or 4)
and processed in accordance with the requirements of
table 8 or 4. Since a bright-as-plated tin plate is produced
by this method,
final hot oil treatment is not
Cleaning
Scrub
area to be coated with clean, unused MEK wiping

dry with clean tissues. Repeat this cleaning prior to
priming.
area
Priming
required.
Zinc chromate epoxy primer (MTL-P-23377) must be

applied by brush over an area extending a min of 3.2 mm
(1/8 in.) beyond the defect. The edges of the primer must
be th i nned or "feathered Th e primer mu st be cu red for a
min of 1 hour at room temperature (160C L60"F] min)
prior to application of the topcoat. A forced cure at 49 to
66"C (120 to 1500F) for 20-30 minutes may be substituted
for the room temperature cure.
NOTE
T~pe I pluting applied in accordance with

tahle 4 reguires the use ofNeutra-Rinse ~O
to improve solderahility and minimixe
sta~ining ofparts.
Type II Plating
~Ctel the final activation and rinsing operation, the parts
nlust be transferred immediately, without drying, to the
fluxinR bath (Operation 1 of table 5) and processed in
aclcortfance with the Iequiremenls of table 5.
20-40-55
Page 2
Aug 31/84
COP~RIGHT, 1984 BY S~BRELINER CORPORATION
SR-76-023
TIN PLATING BY ELECTRODEPOSITION OR HOT DIPPING
(Continued)
Plating Rework (~ontd)
Tin
Tol, (:oating
AI,I,ly aluminized top coat, AB0185-017, Grade A, by
brllshing so as to cover all of prime-coated area. T)ry at
room
temperature for
of the
one
min of 30 minutes, then
cure
at
following schedules:
177 +6"C (350

121 f60C (2.50
rtlO"F) for
.100F) for
90 f15 minutes,
180 ~t15 minutes.
or
C()ATING
Adhesion
The adhesion of coating must be such as to show no

separation from the basis metal at the common interface
when examined at a magnification of 4 diameters when
suloiected to a bend test. The test specimens must be bent
rel,eated ly thru an angle of 180" on a diameter equal to the
th ickness of the specimen until fracture of the basis metal
occurs.
Solderability
plated parts must not show evidence of outgassing,

blistering or poor adhesion when heated from 180.4"C
to 4000C (7520F) on a hot plate or in a hot oil
The
bath, either fluxed
or
unfluxed.
C:ontinuity
T i n coati ng over copper substrates must exhibit continu ity
when subjected to the continuity test made in accordance
with ASTM B33.
(:orrosion Resistance
Parts
having a plating thickness of 0.001 in. or greater

capable of passing a 24-hour salt spray test in
must be
accordance with Method 6061 of Fed. Test Method Std.

No. 141.
plating applied to low alloy and carbon steels in

accordance with the modified method (see ~.4 for AMS
2408 requirement) for Type I plating must meet the
requirements of AMS 2408.
Tin
Apparent pitting of tin plating on cast metals is not cause

for rejection since the surfaces of the basis metals themselves are inherently pitted.
Where tin plating is adjacent to a surface that is masked
has an anodized finish, a line of copper may be visible. A
line is defined to have a max width of 0.8 mm (1/32 in).i
This condition is not cause for rejection.
or
Unless otherwise specified, the plating thickness must be

a min. of 0.0025 mm (0.0001 in.).
20-40-55
Page 3
a
Aug 31/84
rahle 1.
P F
cp,
~j
Type I Tin Plating By Stannate Iroeess

SOI~IITION
CONCENTRATI()N
C()NSIITUENTS
1~
pt
r:
TEMP,
"e
cj
i.
142.5 f~7.5 g/l

(19 +5 oz/gal)
18.7 i.7.8 g/l
(2.5 +0.5 oz/gal)
Iotassium
Stannate
rotassium
Ilate
oo
Hydroxide
77 ill
As
Current
(170 +20)
to
amp
recluired
specified
2.
3.
50X,
Acetic Acid
Rinse
a
r
Ambient
by volume
~Z:
r:
W
cC
60 -tYO
M
r
m
seconds
4.
5.
Dry
6.
Elow(Ifrequired)
I
Hydrofol
CAUTION
Until dry
I Airblast,
See details
(490 f10)
No. 50
1
254 i6)
Tinfat
Water should be flowing.

Rinse until free of acetic
acid.
See details
I Ambient
c3
33
O
hotairorother
Treat until tin flows;

evident by the brightening
of the tin surface.
M
Cd
O
n
O
6
Water
Rinse
7.
(Magnesium
Castings
only)
cc
Optional Process. Bake out,

if used, must precede any
BakeOut
c3
ct
to
times and temperatures in

Tin Plating Rework.
I
-I
O
~d
NOTES
ex,
O
O
Concentrations
Sodium
are
constituents in water.
compounds in equivalent quantities
may
V,
be substituted for the
potassium compounds.
c3
t~
m!mnlr~l
H,drog,n pem~ide
of bath.
must be added
ct
with vigorozla solution
agitation,
tozc~ard bottom
ct
O
lo
n
O
n
O
h
C3
O
When work has been put in bath, a high current density strike should be
Pure tin anodes, if used, must be polarized
used at 50-100~ above normal plating current density. When voltage suddenly increases a couple of volts and current
decreases accordingly, anodes have been polarized and current can then be adjusted to normal plating range.
if used, do not have to be polarized with
thelefore easier to discern than in case of pure tin anodes.
O
z
A greenish-yellow film must be maintained at all times on anodes during operation of tin plating bath. This film dissolves
into bath when no current is flowing. It also tends to dissolve when current density is either too high or too low. In later
case, adjustment of current density may restore film and improve tin deposit. If deposit remains dark or rough, additions
of hydrogen peroxide (30%) in 0.5 g/l (1/16 oz/gal) increments may be made.
High speed anodes,
-f
Parts must be completely dry before they
are
high
current
immersed into hot oil bath.
~b
cl
ci
for anodes.
Water must be flowing.

Rinse until part is free of
plating solution and
entrapped salts.
See details
Ambient
Water
Rinse
~Z:
hydrogen peroxide 10.

Refer to
Cn
Cn
CI
density: 2r,-10()
per sq ft. Adjust bath
with acetic acid and
thickness
c5a
DE:TAII,S
TIME
("E)
~f.
C
(P
density strike. Polarized film is darker and
56
O
5
z
C
03to
Oo
Table 2.
Type
I Tin
I
~a
OPERATION
SOLUTION
CONSTITUENTS
CONCENTRATION
TEMP,
I~
"C ("F)
C)
1,
I
-1
15 f5%
Fluoboric acid
Activate
t!
Plating By Fluoborate Process
by
Cd
r
90 i-60
seconds
Ambient,
volume
(not to
(48% by wt.)
DETAILS
TIME
c3
exceed
29
P
ct
G1
[851)
(I,
Rinse
Water
3.
PlateO
Stannous
Fluoborate
30
265.2 f15,6 mi/i

(34 -t2 fl oz/gal)
to
per so ft
beta-Naphthol
0.8 +0.2 g/l

(0.10 +0.02 oz/gal)
oz/gal)
See det~ils
Ambien~
Water
5,
6.
-n
M
r
m
C11
Gelatin
Kinse
(80 +20)
cC
thickness
6 +0.2 g/l
(0.80 ~0.02
(48% by wt.)
4.
Current density: 25-100 amp
(20
Fluoboric Acid
m
ra
As
required
specified
flowing.
27 fll
156 +23.4 mi/i

+3 fl oz/gal)
(47% by wt.)
Water must be
15 +5 seconds
Ambient
2,
2:
Water must be flo~rjng.

fluoborate residues.
other
Dry
Until dry
Air blast, hot air
Flow(Ifrequired)
See details
Treat until tin flows;

usually evident by the
brightening of the tin
or
~d
O
tl
O
r/3
c~
c3
c~
Hydrofol
254 +6
Tinfat
(490 10l
No. 50
CAUTION
surfa~es.
7.
process. Bake out,

further processing, see times
and temperatures in Tin
Plating Kework.
Optional
Bakeout
(Magnesium
Casti ngs
only)
NOTES
Concentrations
The
b
0~
wl
;n
r~I
following alternate bath composition
beta-Naphthol
O
Wp,
constituents in water
Stannous Fluoborate
Fluoboric Acid
Gelatin
09Ce~
are
Parts must be
completely dry
may
be used:
mi/i
46.917.8 mi/i
61+0.2 g/l
0.8 +0.2 ~1
265.2 ~15.fi
before they
are
oz/Rall
(54
ozi~al)
(6.4 tl
(0.80 +0.02 oz/gal)
(0.10 +0.02 oz/gal)
tC
O
c3
Ef
;e
z
c:
+2 fl
immersed into hot oil.
clz
Cd
Cd
1~
1
E:
~fl
;~e
cD
Pi
z
C
b
w
Table 3.
3.
(:()N(:ENTRATION
3:
i.
(SP
2.
25 f.5%
Sulful-ic Acid
Activate
gr.
1.84)
Water
Kinse
Cn
:i.
(Sp.
gr.
105.6 +4
(1X..5
1.84)
5.
Dry
6.
BakeOut
(MaRnesium
Castings
only)
15 ~Fj
seconds
As
O
a
a
0
a

plating bath residues.
See details
Until
dfy
Air blast hot air
or
other.
process. Bake out,

further processing, see times
and temperatures in Tin
Optional
Plating Rework
NOTES
(70 ~10"F)
(21"C (700F) preferred)
21 ~6"C
Cathode Current Density:
0.50-29.00 amps/sq ft (still)

15.0-25.0 amps/sq ft (barrel)
Anode Current
15
Density:
amps/sq ft,
152.5 f30.5
Agitation:
or
t~
M
Cd
~f
c3
w
Cd
Cd
n
cm/mm (5 sl ft/min),
equivalent
G)
solution movement
Use for sludge removal
Anode Area
Equal
to or
ct
max
Filtration:
greater than cathode
area
OMaintenance:
Hull Cell Tests.
~a
O
c~
Temperature:
~d
Plating Bath:
Add 74 mi (2.5 fl oz) of Kenvert
~-3
O
33
constituents in water.
-I
M
r
M
Cd
r
C1
~d
cC
thickness,
I Ambient
are
01
Conditions
O Operating
~ia
C~
c3
Concentrations
O, O
required
mi/i
~Z:
specified
mi/i
oz/gal)
m
r
flowing.
to reach
(70 +10)
Water must be
oz/gal)
Water
Ambient
seconds
(100.0 f0.25 fl
Starter
Rinse
t)O t60
+0.5 fl
78 +2
Kenvert
Tintillate
Ambitnt
to 1Fi50E
brightener
per 378.5 ]tr
(100 gal) based
Q,
ct
DETAII,S
TIME:
("F)
21 ~6
30 t3.8 gl/l
(4.0 ~0..5 oz/gal)
Stannous
Sulfate
Plate
Sulfuric Acid
4.
"C
cj
T~MP.
C:()NSTITUENTS
OPEKA1ION
c:
Type I lin IlatinR By Sulfate (Kenvert) Process
a
on
P1
to
co
c3
Table 4.
a
a
Type I Bright Tin Plating By Sulfate
D
i.
I
--I
2.
Rinse
3.
Plate
25 i5om
Sulfuric Acid
(Sp. (;r. 1.84)
Activate
TEMP,
CONCENTRATION
SOLUTION
CONSTITUENTS
OPERATION
cl
"C ("F)
TIME
Ambient
90 ~60
seconds
by volume
1:
eo
B~
mi/i
Sulfuric acid
10.5.5 i5
(400 +2 mi/gal)
a
a
Tringlo-Culmo
Starter
997 f0.5 ml/t

(378 ~2 mi/gal)
M
r
4.
Rinse
Water
Rinse
Neutra-Rinse 40
5.
Sodium
Carbonate
or
a
73
6.
tj
Water must be fiowing.
Neutra-Rinse 40 residues.
See details
Ambient
--i
Dry
8.
BakeOut
Air blast hot air
Until dry
7.
Water
Rinse
seconds
(160 ~20)
Optional
(Maanesium
Castings
only)
or
other,
process. Bake out
constituents in
O
O (fperating Conditions
are
Sulfuric Acid:
Temperature:
(:athodr (:urrent Density:
Kate:
Plating Tank:
Anode (urrent I)cn~ity:
Anodes:
Anode Hooks:
Filtration:
Ktclifirr:
Agitalion:
O
09
C~
r/3
ct
c3
cl
Tin PlatinR Rework.
O
56
3j
water.
O
15 +1.5
d1(2.0
+0.2
oz/gal)
ll).r, +1.5 by volume

21 tl)"(: (7i) +15"F) (1Xo(: (65"F) preferred)
1r,-2r, amps/sq ft (barrel)
O.r, to 40 amps/sq ft track)
:1.5 minutes per 0.1 mil at 15 amps/sq ft
Folyvinyl chloride, polyethylene

25 ampsiscl ft. max
or
t~
(:opper
or
monel
keep hook
Cd
Cd
~e
~p
C~
%i
ecluivalent
out of
c
z
plating bath
(:ontinuous
(:ontinuous voltage control with 5k~,
Al,~,roximately
10
ft/nlin
or
cl
CI
Iure tin
max
ripple
equivalent solutil,n
movement
BI, mi (1.7 n ori af l.inFlil(.ulmo

Kq,icni*hmm~: Main~in bulh i,, Nidin~
Itr. (1()() gal, t,asrd on HIIII (:ell Trst8.
I,er:(7X.T,
~,riyhtenc.t.
Tin)rll,-(.lllmo
lialh
Plating bath:
Tin Metal:
m
Cd

further processing. See
times and temperatures in
NOTES
(:oncentrations
56
O
6i4
?1 ~11
a.5 +7.5 gil

(5 ii oz/gal)
n
C3

plating bath residues.
See details
JAmbient
ma
4~
W
CC
(70 f15)
(Sp. Gr. 1.84)
V)
seconds
21 +9
30 +0.8 g/l
(4.0 t0.1 oz/gal
Stannous sulfate
Water should be flol.ing
15 ,5
IAmbieot
Cd
r
DETAILS
C1
O
1
noll 25 mi lil.Xi ii oil Of
CP
C.
c
z
i
;3
.~d
3-;1
z
c
5~
ey
c~
3tw
Cd
z
r
c3
cn
c~
r,
Table 5.
Type II
Tin
Plating
SOLUTION
OIEKATI<)N
1.
2.
4.
5.
m
Flux
Zinc Chloride
3.60
Ammonium
Chloride
g/l
(48 oz/gal)
36 g/l
(4.8 oz/gal)
Water
Remainder
Dry
"C ("F)
27
(80)
max
Ambient
Hotdip
Tin, per
&&-T-371
Reflow(see
Hydrofol Tinfat
details)
No. 50
BakeOut
(Magnesium
Castings
Only)
302 +22
1 (576.6 i40.j)l
254 ~6
(490 f10)
ta
r
n
TEMP.
CONCENTRATION
CONSTITUENTS
(Partial)
3.
DETAILS
Immerse part in flux bath until surfaces

wet by flux.
are
sufficiently
Allow flux to drain from part and dry until

surfaces of part is "tacky".
Sufficient time to heat surface and allow
3j
O
M
Cd
O
ct
wettingand freeflo~ingof molten tin,

Reflow if necessary to improve appearance.
Sufficient time should be allowed for excess
tin to drain from part surface.
O
~d
Optional process. Bake out, if used, must

precede any further processing. See times
temperatures in Tin Plating Rework.
O
c3
and
td
nCd
m
r
Z
II
O
O
~o
cp
-I
SR-76-023
CORROSION CONTROI, MANIJAI,
HARD CHROMIUM PLATING

8tril,pinlS
(;ENERAI,
This section gives the
chromium plating,
requirements for electrodeposited
Removal of chromium plating from ferrous base allov~

heat treated over 100,000 psi must be accomplished with
reverse current in an alkaline bath.
APPLI%ATION NOTES
FINISH
Appearance

hydrogen must be
in duration, tem peratures, and timeliness for the
Baking
following inspection and testing must be conducted to

verify conformance to the requirements of this
specification
The
The chromium plating must be uniform in appearance

and free from frosty areas, pits or blisters. When plating
is performed on only a portion of the surface of parts, the
plated areas must be finished in such a manner that they
will blend smoothly with the adjacent unplated areas.
Appearance
The appearance of chromium plating must be
in APPLICATION NOTES above.
as
required
TESTS
su i table
Hardness
The hardness of the chromium
R(: 05.
plate
must be
no
less than
Hardness
The hardness requirement give in APPLICATION

NOTES must be verified by direct measurement using
Diamond Pyramid Hardness numbers or Knoop Hardness
numbers equivalent to R~: 65 as a min value.
Adhesion
Adhesion
The adhesion of the chromium plating must be such that it

shows no separation from the basis metal when tested

4130 Condition A plated with 0.0015-0.003 in. chromium
per side concurrently with production items.
according
to TESTS below.
Thickness
The thickness of the chromium plating on finished parts

must be 0.0015 in, min and 0.0030 in. max or all significant
surfaces unless otherwise specified on the drawing.
Preparation
For
The test coupon must be bent thru an angle of 180" on a

diameter equal to the panel thickness, straightened and
examined for non-adhesion. Flaking, except at interface
of chrom ium and basis metal, or formation of cracks i n the
plating, is not cause far rejection.
When parts
Plating
are
chromium
quently ground to dimension,

to verify adhesion.
Stress Relief
All ferrous base ailoys.having a hardness of Re 40 or a heat
over 180,000 psi shall be stress relieved by a
suitable process, as applicable, after completion of all
gri nding operations and prior to shot peening and plating.
treat range
Shot Peening
plated oversize and subsetest coupons
are
not
required
Thickness
The thickness of chromium plating must be determined

by one of the following methods
i.
Micrometer Method
2.
Magne-Gage Measurement
alloys having a hardness of Re 40 or a heat

over 180,000 psi must be shot peened.
All ferrous base

treat range
Scale and Oxide Removal
(Over 180,000 psi)
Scale and oxide removal prior to plating must be restricted to abrasive blasting or anodic pickling (reverse
etching). During anodic pickling, the current must be on
prior to immersion and remain on until after removal
from the
electrolyte.
20-40-60
o
Page 1/~ Blank

Aug 31/84
COKKOSI()N CONTROL MA~IIAI,
COPPER PLATING
NOTE
(;ENEKAL
On parts with recessed ureas, it ma~y be

plate up to 0.004 in. on so~lu
areas in order to th.rou~ the regze irerI thiek-
gives the materials and procedures to be used

i n clectrotlcpositing copper on carbon and low alloy steels,
(:I~ES and heat resistant alloys, or Series 400 stainless
steclls for carburizing andlor nitriding stop-off purposes.
1 h is section
(:arbon and low alloy steels heat treated to ultimate

tcnsi It! strengths of 240 KSI and above must not be copper
I,lated.
bronze deposits of 10-12% tin)
solutions are acceptable if the
recluirements of APPI,ICATION NOTES of this section
art! complied with.
(:opper electrodeposits (or

from
I,.yrophosphate-type
MATERIALS
of these materials are! haxardous

chemicals and must he handled with due
rc?gard for their lethal potential
62Q-A-673
Commercial
Commercial
0-A-86
MacDermid, Inc.
Commercial
(IlxtinR (;rade)
~hosphoric Acid (sp. Ir;r. 1.69)

IJolassium Cyanide (Plating (.:rade)
I>ot.assium Copper Cyanide
Pot;lssium Carbonate
Iotassium Hydroxide
(:yanide (Ilatinff (;rade)

Sulphuric Acid (66" Be~)
Sotlium
ness
into the
recesses.
Nitriding (Malcomizing) Stop-Off

The min copper plating(or bronze) thickness for nitriding
stop-off is 0.0015 in. All surfaces not to be nitrided must be
covered with a copper plating (or bronze) unless Escess
stock of at least the case depth required plus 0.010 in. of
material will be removed by machining aftel the sulface
hardening operation,
Adhesion
Most
Col,pc!r Anodes
(:ol,per Cyanide (Plating Grade)
Epsclm Salts (MgSO4 7Hz0
Hydrochloric Acid (20" Be)
Meter Strip-Aid (or chemical
equivalent
Nickel Chloride Hcxahydrate
necessayl to
0-P-313
Com mercial
Commercial
Commercial
Commercial
Commercial
O-A-SO1
The adhesion of the copper plating must be such that it

does not evidence separation from the basis metal when
applied thereon nor must separation occur betnletn the
~hen
copper plating and any previously applied plating,
tested as in FINISH of this section.
Stripping of Copper Platings

Copper piatings (or bronze) must be stripped in accordance
with STRIPPING PROCEDURE of this section. Acid
stripping solutions are prohibited.
SURFACE PREPARATION
Prior to copper plating(or bronze), all metal surfaces to be
plated must be properly cleaned or prepared in accordance
with the following

1.
procedures.
Carbon and Low Alloy Steels (Kefel
to
section
20-10-10.)
2.
CRE:S and Heat Resistant Alloys, Series 400 Stainless

Steels (Refer to section 20-10-20.)
APPLICATI()N NOTES
COPPER PLATING PROCEDURES
Appearance
The copper plating, procedures for various basis metals

are contained in the following tabulations.
must be adherenl, smooth,

rlatt!d copper (or
uniform in appearance, free from pinholes, blisters,
nodules, pits or other defects, Lack of brightness and/or
luster, or slight staining and discoloration is not cause for
i.
Sleels
Ces and Heat Resistant Alloys,

Series 400 Stainless Steels
table 1
table 2
rejection.
Thickness
~:arburizing Stop-Off
The min copper plating (or bronze) thickness for carburizina stop-off is 0.001Ei in., except parts to be pack
carburized must have a min of 0.0002 in.
20-40-65
0
Page 1
Aug 31/114
x
iv
3C
~p
QI
t3
b
a
Procedure for
Table 1.
:I
()PE:RA1ION
i. Reverse ISlch
Q)
01
~bcs
Copper Plating Carbon and Low Alloy Steels
APPLICAHLE
SOLUTION (:ONSTITIIENTS
TEMP.
PAKTS
1 AND(:ONCENTRATIONSO I
DEF. "F
Sulphuric Acid
(660 Be)
Epsom Salts
Carbon and
Low Alloy
Steels
32-40
RE:MARKS
Make parts anodic at

4()-50 amp/sq ft O
6-7 minutes
40-60
34 +4Wwt.
3
Z
TIMIS
oz/gal
(MgS0,.7H,O)
1.1 Alternate
Reverse
Etch
3.
Carbon and
I~ow Alloy
Steels
Sulphuric
80
25 f2X
Water
"Strike"
Plate
c,,metal
2.0-~.0
"Free" Potassium Cyanide

Potassium
Carbonate
Potassium
1.0-8.0
Make parts anode, enter sol.

current on at 200 +25
80-90 seconds
max
I
I
wt.
All
Copper
Acid
by
All
2. Rinse
Room
~Oseconds min
120-140
1-:i minutes
Overflowingwater
All
4. Rinse
5.
Copper Plate
All
Water
oz/gal
2.0-8.0
metal
Hydroxide
~a
C)
I
--1
O
IO
73
O
n
O
Z
14Fj-160
Until required
deposit thick-
oz/gal
oz/gal
A1I
Forced oil-free air
density mavrange
I from 5-60 amp/sq ft
C~
C~
3
by
vendors1
or oven
60seconds min
Watertobefreeflowing
CP
drr
NOTES
01
Concentrations are by weight or by volume as noted of the constituents in softened. distilled or

deionized water. Maint~nance-ot-volume water and water used to dissolve chemical additions must
be of the same quality.
To avoid smut on the work piece, it is necessary to have the rectifier

before the parts are immersed in the solution.
water must be free
Copper metal may be added as either copper cyanide or

concentrations of copper and "free" potassium cyanide
proper complexinp: factor when copper cyanide is used
complex salt is used.
flowing tap
C1
Room
7. Dr~
OFHC copper anodes

ball
and/or oval may be used.
Use cathode rod and/or air
agitation. Constant solution
filtrati~n preferred. Cathode
(preferred) forged
current
max
d
r
30 seconds min
4.0-6.0
Water
m
n
Room
ness is
obtained.
As recommended
All
oz/gal
Wetting Agent
and/or
Brighteners
(optional)
Cd
Cd
m
~d
0..5-1.0
8.0
VJ
13
5.0-8.0
Potassium
Carbonate
6. Rinse
oz/gal
"Free" Potasslum Cyanide

Potassium
C1
oz/gal
pH 12.5
3
C
p
freely
CP
Make parts cathodic at

4-6 v. Parts should "Ras"
oz/gal
to
5=
I with
lasf
I
I
Hydroxide
on
and its voltage set
at 3-5
water.
potassium
are
copper
cyanide complex salt. The
controlled by making allowance for the
no
factor allowance is necessary when the
O
a
O
I
Table 2.
400 Stainless Steels
Copper Plating of CRES and Heat-Resistant Alloys,Series
(D
TEMP
CURRENT
DENSITY
TIME
OF
Amp/S4Ft
(MINUTES)
03
SOLUTION
CONSTITUENTS
APPLICABLE
PARTS
OPERI\TIO~
cr,
1. Anodic F,tch
CRES and Heat
Phosphoric Acid
Resistant. Series
sp Rr. 1.69
a
a
m
5
I
I
4
o
3D
a
6. Nirkrl Strike
80
If.~columr
li2-1
mau
30 P ozi
1~ iX fl
80
g.al
.5R125
max
Water to be flo~ina
freely
Mab pnrl~ csthodz:
enter
I
solution
with electrical contact. Use lead (Pb)
Rmm
Nickel Chloride
Hydroehlorie Acid
Icathodes.
j0
Water~
All
Room
2"
Make parts anode: enter solution

with electrical contact. Use lead (Pb)
1-1/2
75
I
All
Rin~
max
gulluric *cid
All
R. (:arhalic Etuh
m
so
Water
All
2. Rinse
80
75 i2B: \-ol
ADDITIONAL DETAILS
Janodes.
to be
flowine ireely
l/e mill
Water
1/2
Do not let parw dry upon remavai
liemin
Do
fromrinsewater.lO
ozgal
(20" Be)
a
Water
All
fi. Kinat
Room
not
~d
Cb
M
d
r
let parts dry upon removal
c~
from rinse water.
-I
ct
7.
(.upl"r.Slnkr~
All
S~*taille
Z
r~
iOperafiona
Plate
X.
All
Rinse
All
11.
Rinx
Al
1,1?
All
Water
See table i.
O
()pcration
liemin
Water
or ~lven
to
be flowinp freely
------l
I
Forced oil-frre air
Room
Rx."
L/E
min
laLrr
1
r=
~lr?
in soflenrci.
(.l,llcelltlations :Il.t. by wripht o,. b?. \-ol u me as notfcl l,f tht rl,n~tituent8
Watcl
O I(~irla"it
1,1 Ircr
i,,, nicl\el strikr
cp
water.
Maintrnance-of-volume
water
and water used todissolve
pi
v
C1
same.
tal, aatel.
bPromP~ ~larii snll/ur
be fiuuinp Ireely
NOTES
chrl,lir;ll s~iditions shall I,e of the
~4
Ix,u.~iili.
thP nicktl lSLIikl I*~IUli(ln Jhall br
purifip,l
or
c
z
c:
1\3
C
t~m
sP
C7
34
CP
3;
e~cU1
s
g
9
%Q,
r76
~tU
r 03
SR-7Ci-023
C()KROSI()N CONTROL MANUAL,
COPPER PLATING
(Continued)
STRIPPING PROCEDURE
Adhesion
The
Test for adhesion must be made on 4 x 1 x 0.040 in.

separate specimens(which have been plated concurrently
with the articles being inspected) in the anneaied condition
and must be of 4130 steel (representing carbon and low
alloy steels) or 350 CRES (representing CRE:S and heat
resistant or Series 400 Stainless). The test speci mens must
be ~nt repeatedly thru an angle of 180" on a diameter
equal to the thickness of the specimen and then exam i ned
at 4 diameters magnification for evidence of non-adhesion
of (1) the copper to the basis metal or (2) copper to the
nickel "strike" or (3) nickel strike to the basis metal.
stripping of copper platings land nickel "strike"

platings beneath the copper plating) must be done according
to
table 3.
FINISH
Appearance
The appearance of the copper plating must be smooth,
uniform in appearance, free from pin holes, blisters,
noclu Ics. I,its or other defects. I,ack of bliRhtness or luster,
slight staining or discoloration is not cause for rejection.
Thickness
Th e t h ickness of copper plati ng must be as required i n the
app I icable section of APPLICATION NOT% S. The thickness must be measured by a non-destructive method.
Table 3.
Procedure for
BASIS
METAL
1. Carbon and Low
Alloy Steels, CRES

Heat Resistant,
Stripping Copper Plating
SOLUTION
CONSTITUENTS
Meter Strip-Aid (or
equivalent)
Sodium Cyanide
CONCEN
TRATIONS
8
oz/gal
TEMP OF
Room to 140
OTHER DETAII,S
Immerse until
stripped. Discard
12-16
oz/gal
when exhausted.
RL Series 400
Stainless Steels
2. Rinse
Water
Room
Water to be free
flowing
20-40-65
Page 4
Aug 31/84
CO-PYRIGHT, 1984 BY SABRELINER CORPORATION
SR-76-023
BRUSH CADMIUM PLATING

MATERIAI,S
(;ENERAI,
Ihis section
covers
the process and mstclials for brush
cadmium plating.
lhe selective
plating")
is
plating process (sometimes called "brush

method of depositing metal from concen-
trated electrolyte solutions on selected areas without

immersion tanks. In this process, metal is deposited from
material attached to an
an electrolyte held in an absorbent
int!rl anode. llating contact is made l,y l:,rushing or
the
(cathode) to be plated with the electro-
part
sw;l~,t,ing
lyte-bearing
Selective plating can be used effectively to perform

functions as bath plating, e.g., corrosion protection,
resistance, repair
wear resistance, lower electrical contact
damaged machine parts,
etc,
DESCRIPTION
of this process is determined by the individual
The areas to be repaired will normally be limited to
reasonably small areas, but in some cases it will be
use
case.
practical
to
plate large
areas.
All solutions must be clean and free from contamination,

~;x Ira care should be taken to insure that the solutions are
solunot contaminated by used anodes or other plating
lions, or grease and oil from surrounding areas.
It ru ah
I,I ati ng. solutions
are
not
designed
to remove
large
amollnts c,f scale, oxide, oil or glcasc!. 1Tse mechanical

ch(lmical rnelhotls to renlove large amounts of scale
oxide. I~se solvents to remove large amounts of grease
or
ol
or
oil.
Selective plating solutions are 5-Fj0 times as concentrated

densities used range from
as tank solutions. The current
Fi00-10,000 amps per sq ft. The voltages listed on the
solution containers have been precalculated to give proper
the
current densities. Too high a current density burns
stressed
produces
density
current
low
Too
a
plating.
deposits and low efficiencies. Agitation is provided by
anode to cathode motion. Too slow a motion causes buring.
Too fast a motion results in low efficiencies and stressed
deposits. Too dry a tool results in burned plate, course
grain structure, and unsound deposits. During operation

the solution reaches temperatures of 100 to 1500F.
Matelials that normally have a passive surface (stainless

steel, chromium, nickel, and aluminum) require an
activating operation. The activating operation removes
the passive surface.
E tch i nlS
for
Cylindrical
1
2.
plating inside diameters.
for outsitle di;lmeters.
bloclt
shaped
for flat
shal,es.
3.
Flat
4.
Rulk bloclts of graphite material is available fol
or
manufacturing special shapes.
same
The
of
The removable anodes are available in a wide Ianffe
fol
lows:
as
are
They
basic
th
and
ree
shal,es.
stand ard si zcs
anode.
the
worn or
Anodes
opc!r;ltions someti mes
resu
It i n the formations of
high purity dense graphite,

and
platinum, platnium-plated titanium or 900/0 platinum
10)/o iridium unless otherwise required. Separate anodes
should be kept for use with each plating solution. Anodes
The anodes must be of
that have been used for reverse current cleaning and

etching operations should be marked for identification as
such, and should not be used with forward current.
ToolCovering
The tool covering is used to hold and distribute the
solution uniformly. The tool can be covered by any of the
b.
following; surgical grade USP long fiber sterile cotton;
or e. dacron
d.
Scotch-Briaht;
c.
dacron batting;
pelon;
felt.
Sleeving
lonaer tool-covering lilE is tlesiled, surgical

t,e used.
cotton, dacron, ol cotton/dacIon sleeving can
When
Solutions
The solutions used in selective plating include solutions
for cleaning, etching and activating the surface to be
plated, plating solutions for depositing pure or alloy
metals, stripping solutions, and special purpose solutions
such as anodizing, chromate treatment, etc. Listed below
are some sources.
Brooktronics solutions
Brooktronics Engineering
Corp.
North
Dalic solutions
CA
Hollywood,
SIFCO Metachemical
Cleveland, OH
or
Piddinfflon and Associates.

Ltd.
Selectron solutions
Monrovia, CA
Selectronics, Ltd.
New York, NY
cx;tml,le: carbon on carbon

steels.lhese layers can interfere with adhesion; therefore,
i 1, i s i m po r lan t th at these fi Im s are removetl i n the pi al;i nR
Vanguard Iacific:
~,rocctlurc.
Red~vood (:ity, (A
an
insoluble surface film, for
or
Sant;~ Monica
Inc.
ol
20-40-70
0
Page 1
Aug 31/84
SR-76-023
COHROSION CONTROL MANUAL
(Continued)
Solutions (Contd)
Rotary Power Head
Solutions of any manufacturer may be used provided they

meet the applicable plating specification, and are qualifled by p,ocedure tests. However, plati nff and preparatory
solutions of different manufacturers should not be intermixed or substituted in lo a pl;t~ting procedure.
Rotary power anodes are used to rotate the anode for the
plating of internal diameters or to reduce operator fatigue
on large areas. A stepless speed control from 0-90() rpm
and a reversing switch are recluired.
EC)I~IPMENT
IRTRTAI,LATION NOTES
Power Unit
The t!lectroplated deposits m ust meet the
A suitable powel sourctl is required.I~he unit must be!

capable of producing direct current having smooth charactelistics with controlled ripple (about 38~). The power
Anode Selection
unit must be able to output at least 2Fj amperes at 25 volts.

Min instrumentation includes a voltmeter, ammeter,
ampelehour meter, variable de output, and ac and de
cilcuit breakers.
Plating Tool Handles
Anode Selection for Plating Steps

Metal is deposited essentially only in the area of the tool to
work contact. As a result of this, the following must
considered when selecting an anode.
The anode must have optimum contact
The handles must be able to hold anodes of various sizes

and configurations. The handles must be designed for
rapid cooling, and be insulated for safety reasons.
Containers
The
dishes, beakers and flasks required to hold the

plating solutions and catch the runoff must be inert to the
solutions and of the appropriate shape and size.
Accessory Equipment
I)t~l,cntlinR upon the tyl,e
m;~y I,e n,cluircd.
req u i rements of
specification QG~-P-41A.
of work
being done other items
Ulasting E~luipment and Abrasive
Motorized Turning Head

A m otor i zed turn i ng head is used for rotati ng com ponents
such as shafts, bearings, etc., to assure concentric and
uniform plating. The motorized turning head must have a
speed control from 0-600 rpm, and have an on-off-reverse
conllol in either direction of rotation.
with the
The anode must be selected which most nearly conforms

to the configuration of the part; for example, flat anodes
for flat parts, cylindrical anodes for internal diameters,
and concave configurations for outside diameters, etc.
The anode must cover the full length of a diameter or the
flat area being plated, unless mechanized to insun!
uniform coverage.
When plating large areas the max tool to work conlacl
will depend on the pl;ltinR solution and power pack used.
The max contact area may be computed using the following formula.
The size of the cabinet must be adequate for the part to be

plated. Air lines must be suitably trapped and filtered to
prevent in-process contamination of the parts to be

cleaned. The blast material must be aluminum oxide
(AleOQ) or silica (SiOZ). The material must be of a size or
grit that will not affect the micro finish or dimensions of
the part.
area
workpieace, approximately 1/3-1/2 the total area to be

pioted when used in manual operations. For automated ol
mechanized flow plating, up to 100% contact is allowed.
CA
C:
Where:
CA=
A
max
contact area, sq in.
amperage output or power pack

current density for solution, optimum conditions
After the anode has been selected, it must be fitted to the

ap3~ropriate stylus, wrapped with batting, and sleeved,
w~e" necessary.
20-40-70
Page 2
Aug
L/X4
1984:BY
S~ELINSR CO:RPO:RATION
SR-76-023
(Continued)
BRUSH CAD1MIUM. PLATING

Anode Scleclion (~:ontd)
Ilnr~lelsion
Anode Selection for Plating Steps ((:ontd)
Immersion deposits will form with no current flowing

from certain solutions on certain base materials. Immrrsion deposits have poor adhesion to the base matelial.
NOTE
Sleeves are used to increase wear resistance, and to decrease overplate on the
edges and sides.
Preplates
preplates
Build-up
To insure that thorough and uniform preparatory operations have been carried out, it is desirable to use adequate
size tools for these operations.
,,n
Plating Solution Selection
etc.
Solution Usage
Alkaline and neutral solutions are preferred an porous

base metals, white metals, high strength steel, and for
iml,rovctf throwing ability,

generally used
deposits
thereby improving adhesion. Common
nickel, gold, and palladium.
often used to prevent immersion
are
Selective plating generally is limited in the thickness that

be
deposited
in
one
pass because of stress
cracking
and roughness of the deposit. As a general rule, the

thickness for one pass of cadmium is 0.005 in.
max
Characteristics of Selective Plating Solutions.
Rrush plating solutions can be used to perform the same

functions as bath plating, e,g. corrosion protection, wear
resistance, lower electrical contact resistance, buildup,
are
are
from forming
Anode Selection for Preparatory Steps
Acid solutions
I)el,osils ;Inct Ircl,lulcs
The solution manufacturers have prepared comprehensive literature on their solutions. This information must
be rev iewed when selecti ng a solution and the i nstruc tion s
followed when using the solution. The solution cantainels

fol various anodes and
are labeled as to range of voltage
solution factor. This information should he used during
operating. The brush plating solution chHractrlisti~s
given in tables 1, 2, and 3 are presented as a Kuitle for
solution selection and use.
for rapid build-up and

conjunction with
in
as a laminating structure material
alkaline-type solutions.
Table 1.
Characteristics of Dalic Plating Solutions
ANODE-CATHODE
PLATING SOLUTION
Cadmium
Cadmium
Cadmium
Cadmium
Nickel
Nickel
Nickel
Nickel
Nickel
Code
Code
Code
Code
Code
Code
Code
Code
Code
2020
2021
2022
2023
2080
2085
20116
2087
2088
VOLTAGE
MOVEMENT
(VOLTS)
FT/MINUTE
SOLUTION FACTOR
AMPERE HOURS FOR
0.0001IN. ON
1
SQ IN.
6-20
5-20
10-22
6-20
30-130
20-80
30-100
30-100
0.007
0.007
0.007
0.007
8-25
8-20
8-25
20-100
50-100
20-100
20-100
20-100
0.021
0.015
8-25
8-25
0.085
0.025
0.021
20-40-70
a
Page 3
Aug 31/84
SR-76-023
CI()KR()SION CONTR<)I, MANUAL

Table 2.
(Continued)
Characteristics of Selectron Plating Solutions
ANODE-CATHODE
PLATING SOLUTION
VOLTAGE
MOVEMENT
(VOLTS)
FT/MINUTE
Cadmium Acid (SPS 5050)

Cadmium LHE (SPS 5070)
Cadmium (Alk) (SPS 5100)
Nickel(Acid) H.R. (SPS 5640)
8-20
8-20
8-20
6-18
Nirkcl(Acid)(SPS 56()0)
6-18
Nickel (I-I.T.) (SPS 5610)

Nickel (Low Stress) (SPS 5621)
6-18
6-20
Nickel(Special) (SPS 5630)

Nickel(Semi Brt.) (SPS 5642)
Nickel (H.S.) (SPS 5644)
Nickel (Neutral) (SPS 5650)
Nickel M (SPS 5647)
Table 3.
30-120
30-100
20-80
27-37
2()-50
20-50
20-50
20-50
6-20
6-20
8-20
10-25
10-25
20-50
30-60
20-80
20-40
SOLUTION FACTOR
AMPERE HOURS FOR
0.0001IN. ON
1 sQ IN.
0.006
0.006
0.006
0.045
0.()25,
0.025
0.038
0.021
0.020
0.017
0.025
0.050
Characteristics of Brooktronics Plating Solutions
PLATING SOLUTION
Cadmium (BEC 301)
Cadmium (BEC 302)
Cadmium (BEC 304)
Nickel(BEC: 360)
Nickel(RE:( 361)
VOLTAGE
ANODE-CATHODE
MOVEMENT
(VOLTS)
FT/MINUTE
SOLUTION FACTOR
AMPERE HOURS FOR
0.0001 IN. ON
1 SQ IN.
8-20
8-20
8-20
35-140
20-80
30-100
0.007
0.007
0.007
10-25
10-26
50-100
20-80
0.01/1
0.014
20-4070
PaRe 4
Aug 31/84
COPYR1GHT,
1984 BY ~AsRELINER CORPORATION
SR-76-023

Controlling Thickness of Electrodeposit
Measuring the ampere-hours during plating is the most
the plating thickness
com man method used for controlling
during contact plating. This technique is independent of
contact area and time. However, the computed amperehour figure only measures the amount of metal deposited,
the distribution of which will depend
time on all areas being plated.
on
uniform contact
Calculation of Required Ampere-Hours

i.
Each selective plating solution has a solution factor

which is equal to the ampere-hours required to
deposit 0.0001 in, on 1 sq in. of surface.
2.
Multiply this figure by the number of sq inches

involved. This gives the ampere-hours required to
deposit 0.0001 in. of deposit on the number of sq
inches involved.
Multiply the figure calculated above by the multiples

of 0.0001 in. to be deposited. The result is the
required ampere-hours. Area times thickness times
solution factor equals ampere-hours; i.e., plate two
R.
solution factor of 0.020 to a thickness of

0.001 in. (2 x 10 x 0.020 0.4 ampere-hours).
sq in. with
General Plating Procedure
procedure is given for general discussion. For

specific applications and the solution manufacturers
instructions. Refer to Surfaces Preparation below.
This
Prior
Preparation
are not designed to remove

large amounts of grease, oil, oxides, and scale. Mechanical
methods must be used to remove large amounts of scale or
oxides. Solvents must be used to remove large amounts of
Selective plating solutions
grease or
oil.
Electroclean
Electroclean to remove residual amounts of oil, grease,
and light oxide films. Forward current is normally used
but reverse current can be used to prevent hydrogen
embrittlement. Electroclean an area larger than the area
to be plated.
(Continued)
Etch
Etch the surface as required. Small amounts of oxides
of many materials after
may still remain on the surface
electrocleaning. "Flowed" metal is often present on the
surface from machining, grinding and polishing operations or thru usage of the part. The etching operation is
used with reverse current and is continued until the oxide
films, flowed metal, and contaminated surface material
have been removed and a uniform "grainy" surface
appearance is obtained.
Rinse
Activate
Activate the surface as required far plating on aluminum

aluminum alloys, high alloy steel, stainless steel,
chromium, nickel or nickel alloys. The purpose of the
activation step is to remove the characteristically passive
surface of these metals.
or
Rinse
In the
cases
preplating
or
where the activating and the following

are compatible, this rinse
plating solution
may be eliminated.
Preplate
obtain max
as required. In many cases to
preplates of a suitable metal are deposited prior
to deposition of the metal desired. Usually the preplate
deposit is just a flash.
Preplate
adhesion
Rinse
Electroplate
The final preparatory operation must be followed as soon
in
as possible by the plating operation. Electroplate
accordance with the solution manufacturers instructions.
Rinse
Dry
Dry using a
dry lint-free
warm
air blower, paper towelling,
or
clean
rags.
Rinse
Rinse thoroughly with water. If water breaks on the
and should be repeated.
su rf ace, cleaning was insuff icient
Surface Preparation
The selective plating solution manufacturers have prepared and made available comprehensive literature on
the use of their solutions. This literature must be reviewed
when planning a selective plating repair. The following
selective
procedures for plating on some of the
plating
more common
basis
are
presented
as a
guide.
20-40-70
a
Page 5
4ua 31/84
SR-76-023

Surface Preparation (Contd)
Plating On Aluminum and Aluminum Base Alloys

I.
2.
E lectroclean
using forward
not break
surface.
on
Activate with reverse current until a uniform gray to

black surface is obtained. I)O NOT over activate.
4.
Rinse
2.
Rinse
3.
Reverse current etch with appropriate solution for

base material until uniformly etched surface is
obtained.
4.
Rinse thoroughly in clean tap water.
5.
Activate surface using forward current and appropriate solution for base material.
6.
DONOTRINSE
7.
Immediate nickel flash surface to a thickness of

0.00005-0.0001 in. with one of preplate nickels.
8.
Rinse thoroughly.
9.
Continue plating with cadmium to proper thickness.
current until water does
Rinsethoroughlywith cleantapwater.
thoroughly.
NOTES
Certain Aluminum Alloys will exhibit

improved adhesion iffollowing are added
to
procedure.
19.
Activate withfonoard current until uniform light surface is obtained.

Rinse
5.
water.
Rinseand dry.
These procedures are not applicable to steels heat treated

above 180,000 psi.
to
color
with
preplate
nickel.
6.
Rinse
7.
thoroughly.
1.
Electroclean using forward current until water does

not break on surface.
2.
Rinse thoroughly in cold tap water.
3.
Reverse current etch with appropriate activating

solution until a uniform gray smut is obtained.
4.
Rinsethoroughly.
5.
Reverse current activate with appropriate activati nR

solution until smut is removed.
6.
Rinse thoroughly.
7.
Electroplate part
8.
Rinseand dry.
Rinse and dry.
Plating On Copper and Copper Base Alloys

1.

2.
Rinse
3.
thoroughly in clean tap
Plating On Iron and Carbon Steels
thoroughly.
Immediately electroplate
(Continued)
water.
Electroplate part with cadmium plating solution.
with cadmium.
NOTES
Plating On Ultra High Strength Steels
If adhesion problems develop, following

must be added to procedure.
These procedures are applicable to steels heat treated to

180,000 psi and above.
Etch with reverse current until clean

copper colored surface is obtained.
Rinse thoroughly.
4.
Rinseand dry.
Plating On
300 Series and 400 Series Stainless
Steels,
Nickel Base Alloys, Chromium Base Alloys, High

Nickel Ferrous Alloys, Cobalt Base Alloys, Nickel Plate
and (:hlomium Pliltcl
i.
i.
Electroclean using reverse current until water does

2.
Rinsethoroughlyin cleantapwater.
3.
Electroplate part with cadmium. Plate initially

highest voltage recommended for solution so as
develop an initial barrier layer, then reduce
standard voltage.
at
to
to
E: lectroclean using forward current until watel does

20-40-70
Page 6
Aug 31/84
~YRIGHT, 1984
SR-76-023

Surface
Preparation (Contd)
Plating On Ultra High Strength Steels (Contd)
(Continued)
4.
Rinse thoroughly.
5.
Activate chrome surface using folward current and

appropriate solution.
4.
Rinseand dry.
6.
nonotrinse.
5.
lakettartfor~ hoursat:~75f2ftOFwithin4hoursof
7~
immediate nickel flash surface to a thickness of

0.()0005-(1.0001 in, with one of prepl;lte nickels.
8.
Rinse
9.
plating.
Plating ()n I~ltra Iliffh Strength Steels
These
procedures
are
applicable
to steels heat treated to
180,000 psi and above.

i.
10.
Electroclean using reverse current until water does

water.
2.
Rinse
3.
F,lectroplate part with cadmium. Plate initially

highest voltage recommended for solution so as
develop an initial barrier layer, then reduce
standard voltage,
to
to
Rinse and
5.
Bake part for 4 hours at 375 +25"F within 4 hours of
dry.
plating.
NOTES
plated with DALIC Cadmium
Code
"No
I>ALIC Cadmium Code

Haka" or Seleetron Cadmium LHE SPS
507(3 will not reguire a post plate bake.
Acidetchingshouldbe avoidedifpossible.
Where etching is absolutely necessary it
must be done with
reverse
Rinse and dry.
PLATING FINISH
Appearance
at
4.
1Darts
thoroughly.
current.
Plating On Dissimilar Metals and Changing Base

As a general rule with two dissimilar metals to plate on,
follow plating procedure for one with most steps of
activation. If activating steps have to be mixed, use
reverse current activation steps prior to forward current
activation steps. Example: To touch up a pit in chrome
plating must be smooth, fine grained, adherent, and

of visible blisters, pits, nodules, porosity, excessive
edge build-up and other defects that would affect the
functional use of the plated part.
The
free
Adhesion Test
All contact plated surfaces must be tested for adhesion of
the electrodeposit. The tape test is the genelally accepted
test. Shot peening or machining is a more severe test.
Apply a 1 in. wide strip of masking tape No. 850. or

equivalent, with the adhesive side to the freshly plated
surface. Apply the tape with heavy hand pressure and
remove the tape with one quick motion perpendicular to
the plated surface. Any plating adhering to the tape is
cause for rejection.
Shot Peen Test
Shot peen using Minnesota Mining and Manufacturing
rotary peening tools. These tools consist of a rotary flap

loaded with No. 330 tungsten carbide shot. The flap is
used in a mandrel and rotated by an air or electric motor
between 2000 and 3500 rpm. The intensities obtained by
this method can be correlated to the Almen Standards.
plated aluminum.
i.

2.
Rinse
3.
Activate aluminum surfaces using reverse current

and appropriate solution until uniform gray to black
surface is obtained.
thoroughly with
clean tap water.
20-40-70
0
Page 7/8 Blank

Aug 31/84
SR-76-023
C<)RROSION CONTROL MANI~AI,
NICKEL-ZINC ALLOY PLATING

GENERAL
covers the materials and procedures used in
electrodepositing a nickel-zinc alloy (16-30% nickel and
balance zinc) for corrosion protection of carbon and low
alloy steels, copper and copper-base alloys, and all CRES
alloys whose service temperatures are up to 9000F.
This section
The nickel-zinc alloy deposit is applied over a thin nickel

film (approximately 0.00005 in. thick) which has been
previously deposited on the base metal after all welding,
brazing and machining have been completed.
MATERIALS
Some of these materials are highly toxic or

corrosive and must be handled properlll.
Anodes, Nickel
(75 Zinc-25 Nickel) Alloy Anodes
Acetic Acid, Glacial
Nickel Chloride (Hexahydrate)
Zinc Chloride
Sulphuric Acid (66" Be)
Boric Acid
Hydrochloric Acid (200 Be)
Epsom Salts (MgS04.7H20)

Enstrip "A" (or chem equivalent)
F,nstrip "S" (or chem equivalent)
Sodium Cyanide
ITdylite Non-Fitter No. 22
QQ-A-677
Commercial
Commercial
Harshaw Chem. Co.
Commercial
Commercial
Commercial
Fed. Spec. 0-A-86
Commerciai
No separation of the composite coating from the base

metal must occur when subjected to the bend test of this
section. The formation of cracks occurring as a result of
the bend test shall not be cause for rejection.
Thickness
Auxiliary electrodes must be used as required to provide

sufficient coating to meet the salt spray requirement of
Corrosion Resistance in those areas which would normally
receive less than the min and which
protected by
drawing.
Ihe nickel-zinc alloy plate must be smooth, fine-grained

and free from pits, blisters, nodules, i ndications of burning
and other visual defects when examined according to
Visual Examination of this section. Superficial staining
or discoloration resulting from rinsing or baking are not
cause
for
rejection.
Adherence
The adhesion of nickel-zinc alloy deposits must be such
that no flaking or chipping from the nickel "strike" film
nor composite coating from the base metal must be evident when examined per Adhesion
Testing of this section.
not otherwise
specified by
the
recesses, and internal threads where a controlled deposit thickness cannot be normally obtained
or which cannot be touched by a sphere 3/4 in. in
diameter is not subjected to a thickness requirement.
1.
Holes,
2.
Parts, whose dimensional tolerances do not permit

0.0003 in, composite plating thickness, must be
given the max composite coating thickness

patible with dimensional toleances.
Udylite Corp.,
Appearance
are
alloy plus nickel "strike" film composite

coating thickness must be 0.0003 in. min and 0.0007 in.
max unless otherwise specified on the governing drawing
or controlled by the following exceptions:
Commercial
REQUIREMENTS
as
The nickel-zinc
Enthone, Inc.
Enthone, Inc.
Harshaw Chem. Co.

Harshaw Chem. Co.
Fed. Spec. 0-A-88
organic coating
Prior to the electrodeposition of the nickel-zinc allo~: a

thin film (or "strike") of nickel approximately 0.00005 In.
thick must be electrolytically deposited directly upon the
base metal.
3.
Detroit, MI
Nickel Carbonate (Plating Grade)
Ammonium Bifluoride
Nitric Acid (42" Be)
an
com-
Bolts, studs, washers and articles with externally

threaded portions must have a min total deposit
thickness of 0.0002 in.
No corrosion of the base metal must be evident on parts
plated with a composite nickel-zinc alloy-nickel "strike"
film thickness of 0.0002 in. to 0.0007 in, when subjected to
a 24 hour salt spray test as in the paragraph on Salt Spray
Test. Test panels, plated with the same composite plating
thickness as above, shall show no corrosion of the base
metal when
subjected
to
48 hour salt spray.

The hydrogen embrittlement relief method used must be
Stripping of Composite Electrodeposit

Procedures and chemicals covered in the paragraph on
Stripping of Defective Composite Coating should be used
to chemically strip defective composite nickel-zinc alloy
nickel "strike" film platings to the base metal.
20-40-75
o
Page 1
Aug 31/84
SR-76-023
NICKEL-ZINC ALLOY PLATING (Continued)

SURFACE PREPARATION
P1ior to nickel-zinc plating, all metal surfaces must be
cleaned or preconditioned in accordance with the follow-
ing procedures.
Ultra High Strength Steels (260 KSI And Above
Or R,50 And Above)
Scale or oxide must be removed from the parts prior to

plating by vapor blasting or grit blasting not to exceed
150 grit particle size. Anodic (reverse etch) pickling or
ther suitable non-embrittling methods may be used for
removal of discoloration, light oxidation, etc.
Soak pickling is prohibited. A non-electrolytic acid dip of
greater than 10 seconds constitute a soak pickle. Cathodic
cleaning or cathodic pickling must not be used. Acid
pickling of parts heat treated above 240 RSI is not
permitted for any duration of time.
Parts must be free of grease, oil, scale, or any other foreign
adjudged harmful to the success of the plating
matter
operation.
(:arbon And Low
Alloy Steels (180 KSI To 240 K8I)
Surface
preparation method of steels other than ultra

high strength steels must be suitable for the steel in
question.
Corrosion Resistant And 400 Series Stainless Alloys
Corrosion resistant steels and 400 series stainless must be
cleaned by a suitable method. (Refer to section 20-10-20.)
Copper And Copper Alloys

These metals must be
properly cleaned before plating.

Plating must immediately follow surface preparation,
beginning with table 3.
NICKEL-ZINC PLATING PROCEDURES
Nickel-zinc plating
are listed below.
procedures for various base metals

CRES and Series 400 Steels
(:ol~pcr and Copper Alloys
table 1
table 2
table 3
2640175
Page
Aug 31/84
1064 BY
~B;RELIN.ER CORPORATION
Table i.
D
I
--I
PARTS
i. Reverse Etch
Carbon and
Low Alloy
Steels. Ineluding 11-11
a.
m
r
5. Nickel-Zinc
Alloy Plate
by
Water
Nickel
Chloride
30 f2
Hydrochloric
13 f3
Pre-Dry
water
Make parts cathode;

sol. with current on at
50-125 Amps/Sq
enter
1-1/2-3
125 f10
minutes
oz/gal
CI
oz/gal
All
Nickel
Chloride
Zinc
Chloride
Acetic Acid
C~
i
Dump when solution
5-10
seconds
125 +10
becomes green
r
r
O
Plate at 80-200 Amp/Sq Ft. Use cathode rod

agitation. Filter as necessary. Use bagged
anodes (auxiliary anodes ex~pted). Make
daily acetic acid additions. Q e~
150 +5
32.0-40.0
oz/gal
14.0-16.0
oz/gal
CC
Cd
r
2.0-3.01
by vol
1.00k, by vol
3.0-3.5
Non Fitter
No. 22
7.
C~
Amps/Sq Ft
Overflowing
30 seconds min
Room
Water with 1.5 +0.5% by

volume of acetic acid
80-120
2-4 minutes
wt.
All
6. Rinse
1:
80 f2%
(20"F Be)
Make parts anode, enter sol.
30-90 seconds
max
bywt.
Acid
13
a
80
2512%
4. Rinse
Make parts anodic 8 40-50

Ft O
ct
O
O
5-7 minutes
32-40 oz/gal
Sulphuric Acid
All
3. Nickel
Strike
40-50
Amps/Sq
All
2. Rinse
34 i4Vwt.
Sulphuric Acid
Carbon
b. H-ll
Steels
TIME
(MgSO,.iHPO)
Steela
Cn
Acid
(66" Be)
Epsom Salts
Alloy
Reverse
Etch
Sulphuric
REMARKS
"F
AND CONCENTRATIONS
OPERATION
1.1 Alternate
TEMP.
SOLUTION CONSTITUENTS
APPLICABLE
pH
C3
All
Water
Room
All
Water
1.50-180
Until free of plating solution
Remove and allow to dry
1-2
G~
minutes
in air
C3
8.
Dry
(Alternate)
9. Bake
Forced
warm
air
or oven
dry
1
For part
requirinR hydrogen embrittlement relief.
use
correct temperature and time for metal involved.
~t
1
;c
NOTES
cP
(:oncentrations are by weight or by volume as noted of constituents in softened. distilled or deionized water.
Maintenance-of-volume water and water used to dissolve chemical additions must be of same quality.
To avoid snlut
solution.
Non Fitter No. 29 may be added to 25Uwt, sulphuric acid etch bath at
removal of smut from etched metal surfaces.
O
O
O
Rinse water must be either softened. tiistilled
on
work
piece. it is
necrssary to have rectifier
on
and its voltage set at:1-5
before parts
are
immersed in
a
v
ri
a
concentration
not to
exceed Ih by volume to aid in
Z
i
a-a
b
E
3q
Maintain
pH of nickel
PlatinR baths
must
strike and nickel-zinc
be kept free of
Krmove zinc-nickel an~,des from
cn
particles
or
deionized.
alloy bath with hydrochloric acid and/or nickel carbonate.
or
sludye bg c~ontinuous
I,lating tank durinp I,roll,n~rtl
idle
or
3: ~a
batch filtration.
I,eriods
to
I,rtvent excessi\cl anode cclnsumption.
ZQ,
r:
3P3
r 03
e
r
F~
C~M
C~
O
LY
Table
~b
CKES and 400 Series Stainless Steels
I)PGRATION
1. clean
C:IIHKENT
TEMP
SOLI]IION CONSTITUENTS
4~
~)KCGNTRITIUNSB
C:
REMARKS
TIME
AMPSi~l FTI
2. Anodic etch
(66" Be)
Make part the anode. Do

not rinse prior to operation
3. O
2-3 minutes
40-.50
40-.50
Sulfuric acid 34 +4h by at
3. (athodir
Etch
Room
5. Nickel
Nickel chloride 32 +2 oz/gal

Hydrochloric acid (200 Re)
13 f3 fl oz/gal
Strike
6. Rinse
7. Nickel-Zinc
Alloy Plate
~I
Water
Water with 1.5 f 0.55h/vol of

acetic acid hj
Nickel chloride 32-40 oz/gal

Zinc chloride 14-16 oz/gal
Acetic acid 2-3% by vol
Non-pitter 1% by vol
2.5-:10
40-.50
Epsom Salts (MgS()4.7H1())

:12-4(1 ozig.al
4. Rinse
125 f10
150 f5
80-200
Make part the cathode.
15-30 seconds
Transfer immediately to
nickel strike after rinsing.
Make
1-1/2-3minutes
.50-125
125 +10
30-90 seconds
partcathode.
8. Rinse
Water
C~
jZ:
Plate at 80-200 AmpiSq

Ft. Cse cathode rod
agitation. Filter as
necessary. Use bagged
anodes (auxiliary anodes
Until free of
solution
Room
oroven
10. Bake
For parts
requiring hydrogen embrittlement relief,
use
correct
L1
Concentrations are by weight or by volume as noted of constituents in softened, distilled or deionized water.
Maintenance-of-volume water and water used to dissolve chemical additions must be of same quality.
C3
To avoid smut on work piece, it is necessary to have rectifier on and its voltage set at 3-5
solution.
Rinsewater mustbeeithersoftened. distilledordeionized.
m
r
O
CC
C~
G~
A
C~
NOTES
Il
a
r
r
temperature and timeformetalinvolved.
v,
SD
C~
m
i
plating
Clean, dry compressed air
9. Dry
on.
acetic acid additions.
~b
Immerse part with
I~a
c~
ercepted).
C)
C)
~Z:
current
Transfer immediately to
nickel-zinc alloy bath.
Dump when solution
becomes green.
5-10 seconds
pH 3,0-3.5
9
i
I)
Part must be free of water

breaks
Use correct method for alloy
being cleaned
m
~D
to
Z"
before parts
are
immersed in
O Maintain pH of nickel strike and nickel-zinc alloy bath with hydrochioric acid and/or nickel carbonate.
O Plating baths shall be kept free of particles or sludge by continuous or batch filtration.
a Remove zinc-nickel anodes from plating tank during prolonged idle periods to prevent escessive anode consumption.
(P
O
73
Table 3.
II
Copper and Copper-Base Alloys
APPLICABLE
PARTS
OPERATION
1. Clean
All
2. Rinse
All
Al or silicon
bronze only
3. Etch
V)
4.
Rinse
5. Nickel
Strike
z
m
~D
Water
Nitric Acid
100 fl
(42" Be)
Ammonium
Bifluoride
11
oz/gal
Overflo\ning
Room
All
30 f 2
Hvdrochloric
Acid (200 Be)
1R tX
All
7. Nickel-Zinc
Alloy Plate
1-1:2-~ minutes
125 +10
fl
oz/gal
Water with 1..5
i-10 seconds
125 -t10
of acetic
Make parts cathode: enter

sol. with current on at 50125 Amps/Sq Ft
32.0-40.0
Zinc Chloride
14.0-lfi.0
Plate at 80-200 Amp/Sq Ft. Use cathode rod

agitation. Filter as necessary Use bagged
anodes (auxiliary anodes excepted). Make
daily acetic acid additions. O,I~ I~
1FiO ~i
8. Rinse
C
CC
CII
by vol
1.01;, by vol.
PH X.O-:i.T,
Non Fitter
No. 22
r
r
Cd
Acetic Acid
C:
Dump when solution

becomes green.
NickelChloride
rz:
I
oz/gal
Z
C;
water
ozipal
cc
NickelChloride
All
2:
Water
acid
Room
oz/gal
water
Use a plastic (PVC) lined

tank. Provide adequate
fume ventilation.
2-5 seconds
ozigal
6. RinSe
~D
73
Overflowing
Room
All
REMARKS
TIME
"F
Use correct method for

metal being cleaned.
(NH,F-HF)
m
TEMP.
SOLUTION CONSTITUENTS
AIVD CONCENTRATIONS
C~
All
Water
Room
All
Water
1.50-180
cc
I!ntil free of plating solution

1-2
minutes
Remove and allow to

in air.
dry
Z
O
C:
Forcrcl
10. I)rv
warnl
ait
I,I oven
~lr?
(Aitel-nate)
For ~,art recluirinp
11. Bake
hydrogen emblittlement relief.
use
correct teml,erature and time for metal involved.
NO?ES
C~
b
E
3q
O
O
III
Maintain
Th~
pH
I,latinp
before I,arts
are
immersed in solution.
of nickel strikr and nirkelzine allo?i bath with
baths mt~at ~,t ktl,t fr~.t of
Krmove zinc-nickel anotlcs lrom
I,articles
I,latin)r t;tnk
or
hyclroc~hloric
t,y continuous
I,rolon)red
in softened. distille(l or deionized water.

(:oncent!ations are by weight or t,?~ volume as noted of constituents
must be of the same qualit~.
Maintrnance-of-volume water and water used to dissolve chemical ad(litions
work I,iece. it is necePzar?- to have
eithe, aoft~netl. distilled or deionized. To avoid smut on
Kinse water must be
rectifirl- on and its voltag~f set at :(-6
1
e
idle
C
C?
acitl and/or nicktl ca,l,onate.
or
3,
v
hatch filtrati~,n.
I,~,icltls
to
Ilrevrnt er;ccssive Rn~,de c~onsuml,tion.
T~=d
ZQ,
C
~p:
~B 4)
~b
3t5
SR-76-023
NICKEL-ZINC ALLOY PLATING (Csntinued)

STRIPPING OF DEFECTIVE COMPOSITE
surement, Magne-Gage
COATINGS
Defective nickel-zinc alloy-nickel "strike" film coatings

stripped from the base metal according to the
must be
applicable
section of table 4.
FILM ADHESION
or Permascope. The thickness

measured must meet the thickness requirements of this
Section.
Verification of the nickel "strike" film must be done by the

Koeour electronic instrument method or by other
approved methods. Protect test spot on production parts.
(Refer
The
to section
20-40-85.)
following inspection and testing must be conducted to

assure conformance with the requirements of this section.
SJt Spray Test
Visual Examination
The following test must be conducted to determine conforinance to the requirements of Corrosion Resistance of
Visual examination for conformance to Appearance and

Adherence paragraphs must be performed under 7x to
IOx binocular
microscope magnification with an illumina2000-8000 ft-candles on the part(s) at the time of
tion of
examination.
this section.
The salt spray test must be conducted according to
S?1;D-1~1,
Plated parts must be exposed for 24 hours. Test panels,

ddcribed below must be exposed for 48 hours.
Adhesion Testing
Initial
Plated parts must be visually examined as described

above for adherence. The bend test for adhesion to test
panels (or specimens) must be made in accordance with
the requirements of the following paragraph
plating facilities
The bend test for adhesion must be performed as follows:

One or more separate specimens, 1 in. wide by 4 in. long
and 0.04 in. thick which are in the hardened condition and
which are of a base metal equivalent to that of the articles
represented, must be used. "Equivalent" base metal

includes chemical composition and surface finish prior to
plating. The specimens must be introduced with each
group of parts and I,rocessed simultaneously thru the
cleaning and plating cycle. The plated specimens must be
bent thru an angle until the base metal breaks and the
plating examined for conformance to the adherence
requirements of this section.
FED-
Method 811.1.
qualification
as
and quarterly evaluation of any
to meet the salt spray requirements of

Corrosion resistance must be done in the following manner:
Test panels, of basis metal equivalent to that of production

articles and of a size 3 in, wide by 6 in, long and 0.04 in.
thick and in the hardened condition and with a surface
finish of 125 RHR or better prior to plating with a total
plating thickness (nickel-zinc alloy plus nickel "strike"
film) of 0.0002-0.0007 in., must be exposed to the salt
spray test.
Control of Alloy Deposit Metal Ratio
Close control of the plating solution constituents, pH,

ca;thode current dens ity and pi ati npt solution tem peratu re
aS listed in tables 1, 2, and 3 will be necessary for control
fd
the 16-30% nickel and balance zinc alloy deposit. The
nickel-zinc alloy deposit must be checked quarterly for

the actual metal ratio to determine conformance with
listed controls.
Thickness Measurement
Measurement of the composite nickel-zinc alloy-nickel

"strike" film thickness must be made on plated parts or
test panels using one or more of the following techniques:
Kocour electronic instrument, microscopic section meaTable 4.
Stripping Defective Composite Coatings
APPLICABI,E
PARTS
Carbon and low alloJr
steel or CRF,S alloys
(ol,l,cr and (lol,l,erbasc;llloys
STRIPPING
SOLUTION
Enstrip "S"
TEMP.
"F
REMARKS
oz/gal
sodium cyanide 16-24
oz/gal
140-170
Enstrip "A"
140-170
As above
180-2()()
As;lbove
F,nstlip 165S (IJsr

1-2 Ih/Ral in a
at
Immerse until stripped. Discard stripping

solution when spent. Use tap water for solution
makeup.
100~volume sulfuric
solution)
acid
NOTE
After parts
are
stripped, rinse in
clean tap water and
d~
as
required.
20-40-75
Page
Aug 81/8$
COPYRIGHT,
1984 BY SABRELINER CQRPORATION
SR-76-023
ELECTROLESS NICKEL PLATING

(;ENERAL
lhis section covers the engineering recluirements for
chemical reduction deposition of nickel plating.
Stripping
APPLICATION NOTES
Appearance
Electroless nickel plating must be uniform in appearance
but not in color, free from pits that expose parent material
and free from blisters.
Stripping of electroless nickel plating must not subject

the part to hydrogen embrittlement nor cause pitting of
the basis metal.
FINISH
Appearance

Baking
Copper. copper alloys, and CRFES and heat resistant alloys

must be prepared in accordance with section 20-10-L5 or
20-10-20, as applicable.
hydrogen
must be

metal and process inuse.
Adhesion
The adhesion of electroless nickel plating must be such
that it shows no separation from the base metal, when
tested under the ar,plicable section of FINISH below.
The appearance of electroless nickel plate must be

described under APPLICATION NOTES.
as
Adhesion
4130 condition A, plated concurrently with production
items. The coupons are bent once thru an angle of 180" an a
1/2 in. diameter mandrel. It must then be impossible to
detach any appreciable area of the coatings on the outside
area of the 180" bend.
Thickness
The thickness of electroless nickel plating must be 0.0008
in. min and 0.0012 in. max unless otherwise specified on
the applicable drawing.
Thickness
The thickness of electroless nickel plating must be determined by one of the following methods.
thickness of 0.0010 +0.0002 in.
must withstand a 48-hour salt spray exposure without
evidence of corrosion of the basis metal.
Test
panels plated
to
1.
Micrometer measurement
2.
Microscopic measurement
Permascope NI, Type N2E3
3.
Corrosion resistance to salt spray must be determined in

the following manner.
Preparation for Plating

Stress Relief
Ail ferrous base alloys with a hardness of Re 40 or heat

treat range of 180 KSI must be stress relieved after
completion of all mechanical operations and prior to shot
peening and plating.
Test panels, 6 x 3 x 0.040 in., of 4130 heat treated to

125-140 KSI plated concurrently with production items.
These panels must be exposed to salt spray in accordance
with ASTM-B-117 for 48 hours. Corrosion of the basis
metal is cause for rejection of the parts and requalification
of the process.
Shot Peening
All ferrous base
alloys with
hardness of Rc 40
treat range above 180 KSI must be shot
Scale and Oxide Removed
(Over
180
or
heat
peened.
KSI)
Scale and oxide removal is restricted to abrasive blasting

During anodic
or anodic pickling (reverse etching).
pickling, the current must be on prior to immersion and
remain on until after removal from the electrolyte.
20-40-80
0
Page 1/2 Blank

Aug 31/84
SR-76-023
C()RKOSI()N CONTROL MANLAL
REPAIR AND REFINISHING OF ABRADED, SCRATCHED,

REWORKED, OR CORRODED METAL SURFACES
1 h i s section covers procedu n~s to be followed i n the rel,ai r

I,sinlsd, chcln ic;llly Ireatetl.or
:Intl/ol Iefi,lish ing of
Inanufzlctured palts which have,cceived minor
I,l;lted
corrosion not serious enough to warrant

the part.
of
scrappinff
tlamage
unpainted palts, clean the;trea thoroughly with Mil,

C-5410 cleaner. If all signs of corrosion are removctl, the
p,,t may be used without fu r,ther rc~work. t(owevcr, i i al~y
evidencc (,r corrosion
(I,its, stains, etc.), t.he I,;~rt
On
(;ENE:RAL,
or
Ihe applicable refinishing procedures may also be used

for touch-up on reworked parts,
Whenever practicalbe, refinishing must be in accordance

with the applicable finish requirements or detail drawing.
When this cannot be accomplished, the applicable substitute finish system detailed in this section must be used.
Itecluired organic finishes

practical after rework.
must be
applied
as
soon
as
with any
or
areas
Iw~ louchctl uI,
KEW()KH PR()CEDURES FOR AI,UMINUM

Clad Aluminum, Base Metal Not Exposed
Excelnal sulfaces of bare, chemical film treated or
anodi~ed clatl parts which have been abraded or scratched
must ~,e used without rework. However, when the
evctn
or
function of the part is seriously affected,

may be required
replacement of assemblies
though structurally sound.
rework
or
to
or
NOTE
required for electrical

practicable,
bondina must be provided by masking prior to the
finishing opelation. After bonding, terminal areas shall
al,l,earance
to be painted. (Refer
application of Iridite No. 14
areas
Re-finish painted parts according to detail dlawing.

Parts which originally were not painted must I,eceive one
coat of wash pri m er (Refe r to sect ion 20-RO-10.) one coat of
zinc chromate primer, and two coats of aluminized
lacquer (Refer to section 20-30-20.).
Whenever a previously unpainted left hand

right hand part reguires painting, consideration should be given to painting the
corresponding right or left hand part for
or
hlldrogen perozide.
bare
Whenever
areas
Apply chemical film to

section 20-40-35.) (Brush
Alodine 1200).
Organic finishes must not be applied to

areas that will subsecluentl21 contact liguid
oz~ygen
followina additional treatment ;IlonK

being reworked.
painted
must receive the
iainted sulfaces which have been abraded or scratched

must be touched up, (Refer to section 20-30-20.)
(:olroded areas on either painted or unpainted parts must
be reworked as described below.
Strip off all paint. (Refer to section 20-10-45.) If not

painted, scrub free of any grease, corrosion products of
other foreign matter with a rag wet with stoddard solvent
of the soil. If neither
or water, depending upon the nature
is effective, Bon Ami or fine aluminum wool may be used.
balanced appearance,
The following Spot Test must be used when base metal
exposure is questionable.
rhe area to be tested must be cleaned in accortlnncle with
section 20-10-10.
One drop of caustic soda solution (100 R1ams caustic soda,

P-S-GR1, in 900 milliliters of water) must be applied to the
scratch and allowed to remain 5 minutes. It is advisable to
apply a drop of the caustic solution in an adjacent area
where there are no scratches, using this spot test as a
comparison with the scratched area fol detelmininR
scratch
penetration,
Rinse the area carefully to remove the caustic solution and

observe the scratched area. Black residue at the bottom of
the scratch indicates penetration to the base metal. If the
residue is white, the scratch does not extend thru the
cladding,
The area exposed to the caustic test solution must be
touched up with either 5% chromic acid solution or MILC-5410 cleaner (see below) to insure complete removal of
all caustic residue.
Steel wool must not be used.
20-40-85
0
Page 1
Aug 31/84
SR-76-023
C()KH()SI()N CONTROI, MANUAL
REPAIR AND REFINISHING O% ABRADED, SCRATCHED,

REWORKED, OR CORRODED METAL SURFACES (Continued)
Non-(:lad Aluminum, C:orrosion Resistant (1100,
3003, 5052, 6001)
Corloded parts on which evidence of corrosion cannot be
completely removed by MIL-C-5410 cleaner applied as
detailed below, and scratched parts (except where
sclatches are limited to superficial abrasions which do not
affect the proper function of the part), should not be
reused.
Application Procedure
For MIL-C-5410
I)ilute cleaner 1:1 (by volume) with water and apply to the
corloded surface with a stiff brush or aluminum wool.
Keel, surf ace of palt wet for 5-10 minutes. Repeat once, if
necessary.
Rinse by spl.aying, wiping with a cloth saturated with

clean water, or immersion in running water. Rinsing
should he thorough, especially at faying surfaces or other
points where solution can be trapped.
or
with
an
air
blast.
Non-Clad Aluminum, Anodized
7075, 2024, 2014, 356 etc.
If no pitting is apparent on the cleaned part, refinish per

either the detailed drawingorthe applicable
sub-paragraph under Non-Clad Aluminum, Anodized
and/or Painted above.
R%WORK PROCEDURES FOR UNFLATED

COPPER AND FERROUS ALLOYS
Type II Cleaner
I)iy 1,3 wiping with clean, lint-free cloths
Remove corrosion stains either with M IL-C-4f,lO, Type II

cleaner as detailed above under Non-Clad Aluminum,
Corrosion Resistant, or by rubbing with Bon Ami.
Lightly scratched
or abraded parts where the damage

does not affect the proper function of the part shall be used
without rework other than paint touch-up. (nefer to
section 20-30-20.)
Corroded bare or painted parts, and parts where the

function is affected by scratch or abrasion damage shall
be reworked as described below.
Strip off paint. (Refer
to section
20-10-45.)
S:mooth out all scratches with abrasive cloth o~ paper.

as necessary to meet the surface
using 150 grit or finer

finish requirements.
and/or Painted
eff.
Process and refinish in accordance with requirements.
When scratch damage is limited to minor abrasions

not damaging the aluminum, the following
finish systems may be substituted for these called out on
the detailed drawing,
Oiled
exposing, but
or preservative coated phosphate treated ferrous

alloys with minor isolated mars or scratches must be used
without rewoik unless
Non-functional External Surfaces
proper function of the part is

affected. Phosphate treated parts which have corroded or
have closely grouped scratches or abraded areas shall he
reworked as described below.
Apply chemical film
Degrease. (Refer
treatment (Refer to section 20-40primer (Refer to section 20-30-10.),

one coat of zinc chromate primer and either two coats of
appropr i ately colored lacquer or one coat of appropriately
colored enamel. (Refer to section 20-30-10.)
35.),
one
coat of wash
Non-functional Internal Surfaces

Touch up (Refer to section 20-30-20) when not immersed
in oil. When immersed in oils such paris must either be
c)lrnlical film treated (Kefer to section 20-40-:35) or
anotlixetl. (Refer to secltion 2()-40-10.)
to section
10-20-10.)
Strip off phosphate coating. (Refer

Smooth out all scratches
or
using
20-40-:-30.)
pits with abrasive cloth
150 grit or finer

surface finish requirements.
paper
to section
as
or
necessary to meet the
Phosphate treat (Refer to section 20-40-30.) and reapply

or preservative as applicable.
oil
REWORH PROCEDURES FOR MAGNESIUM

EXTRUSIONS, CASTIN~S OR F<)RGINGS
These procedures al,ply to unassembled detai I parts with
minor scratch, abrasion, or corrosion damage.
Fll~lclion;ll Surfacc!s
I~elinish in accordance with the tietail
drawing for the
I,art.
Mildl~ colroded parts
must be reworked
as
described
bclo\\.
Stlil,
off all
paint. (Refer
to section
20-10-46.)
20-40-85
Iaac 2
Aug 31/84
COPYRIGHT,
SR-76-023
C()HR()SI()N C()NTHOL MANIIAI,

REWORKED, OR CORRODED METAL SURFACES (Continued)
Apply three coats of zinc chromate primer and any
required finish color coats. (Refer to section 20-30-20.)
Having A Smooth Surface

(E.(;. Sheet, Extrusions Etc.) Must Be Reworked
Parts
As I)escribed Below
paint or primer. (Refrr to section 20-10-46.)

MaRnesium protective treatment need not be! removed.
Remove all
Smooth out all scratches

paper (320 grit
or
or
pits with abrasive cloth
Corroded magnesium parts must be removed from

assemblies and either Icworked, or 1eplacrd with ntlM
detail ~alts. Itcasscmbly ~nust l,e with tal,e or 8c~alant
barriers between magnesium and other metals.
or
finer).
REWORK OF PLATED SURFACES
Refinish the entire part with the chemical treatment and

paint system called out on the detail drawing.
Bright Alloy Plating
Having Rough Or Porous Surfaces

(Castings, Forgings, Etc.) Must Be Reworked
Bright alloy plated capper or copper alloy parts damaged

by isolated minor scratches and/or abrasions may be used
without rework even though minor base metal exposure
has occurred in a few of the damaged areas.
Parts
As Described Below
Remove as much paint as possible from the damaged area
either by stripping (Refer to section 20-10-45.) or with
abrasive cloth
or
paper.
corrosion pits with abrasive
Smooth out all scratches or

cloth or paper (320 grit or finer).
chrome
Apply
pickle
treatment.
(Refer
to
section
zo-10-05.)
A pply
one
coat of wash
primer.(Refer to section 20-30-10.)

NOTE
A 1107AI UlcrSh primer to dr:y ons hour p~rior to

appllling xine chroma.te pri~ner.
coats of zinc chromate primer and any
color coats. (Itefer to section 20-30-20.)
finish
Ieclu i red
Al,[,ly three
Assembled Parts With Minor Scratch Or

Abrasion L)amage May Be Reworked As Described
Below
Smooth scratches with abrasive cloth or paper (320 grit or

finer) keel,ing the reworked area as small as possible.
Cadmium Plating
Cadmium plated parts damaged by isolated minor
scratches and/or abrasions may be used without rework
has occurred in a
even though minor base metal exposure
few of the
damaged
Whenever practicable, parts showing any signs of corrosion must be stripped and replated. (Refer to section 2040-70.) This includes superficial corrosion of the plating
Corrosion of the base
as well as corrosion of the base metal.
metal is evidenced by discoloration on the plate (brown
red for steel, bluish-green for copper alloys).
no not destro21 tape or sealing compound

barrier required between dissimilar metal
faying surfacQ.
procedure.
Remove corrosion products by first washing with
(damp cloth), then rubbing with abrasive paper (:$20 grit
or
finer).
Treat with MIL-C-MIO Type II cleaner (diluted with an

equal volume of water) for 2-3 minutes; then wipe dry.
coat of wash primer (Refer to section
one coat of zinc chromate primer
and two coats of MIL-L-7178 aluminized lacquer(Refer to
pickle touch-up (Refer to section 20-30-20.)

getting solution between faying
solution cannot be
su rfaces or into pockets where excess
and
drying.
water
rinsing
removed by thorough
A I,l,ly
care
one
to avoid
coat of wash
one
20-30-10.) followed by
section 20-30-20.)
Chromium Plating
A r,r,ly chrome
taking
or
Where it is not practicable to replate superficially

corroded parts (i.e., white corrosion products only), the
part may be reworked in place using the following
Finish with
IW!nlan~
areas.
pri mer. (Refer to section 20-30-10.)
Chromium plating is applied chiefly to provide a hard,

smooth bearing surface. Its corrosion properties are
generally of a secondary nature. Consequently, parts from
which the plating has been removed, or which have
corroded due to cracking, scratching or peeling of the
ch ram i u m pi ati ng are not acceptable and m ust be str i pped
(12efer
to section
20-40-60.) and replated.
20-40-85
0
Page 3
Aug 31/84
SR-76-023

REWORK%D, OR CORRODED METAL SURFACES (Continued)
Chromium Plating (Continued)
Sclatch or abrasion damage which does not expose the
base metal may be removed by buffing, providedthat the
required smoothness can be obtained without taking the
plating below the min thickness specified on the drawing.
Parts which cannot be reworked in this manner must be
stripped and replated per drawing requirements.
Nickel
Plating
After the second coat is dry to the touch (about 10 minutes)

bake the painted area for 15 minutes with infra-red lamps
placed 2 in, from the painted surface.
NOTE
Where nickel plating is used to prollide a
smooth bearing surface, the above paint
system is not applicable.
Nickel plating is primarily used to provide corrosion

to temperatures above the
upper limit far cadmium. Protection is obtained only as
long as the plating is free from cracks, pinholes, or other
discontinuities. Whenever practicable, parts on which the
base metal has beerl exposed by corrosion, physical
damage or rework shall be stripped (Refer to section 20-
protection for parts exposed
40-45.) and replated

When it is
procedure
per
impractical
drawing requirements.
to
may be used to
replete the part, the following

salvage the part in place.
NOTE
Heat discoloration (tl/pically blue-grey to
blade) of nickel plating should not be considered as corrosion and will not normally
u,arrant refirLishing of such parts.
Remove any foreign matter (grease, metal chips, corrosion products, etc.) from the affected area by wiping with
cle;tning solvent (NA~-Ii062) or water depending on the

nat.ure of the spoil, If neither is effective, fine abrasive
paper (No. 320 or finer)or wire brushing may be used to
expose the bright lustre of the base metal.
Wipe the exposed area with undiluted MIL-C-5410 Type

II phosphoric acid cleaner until the surface is water
break-free. Rinse thoroughly with water (spray or wet
cloth) and dry immediately.
NOTE
Care should be taken to remove all MIL-C5410 cleaner from seams, lapped joints,
etc.
Immediately after cleaning, apply two coats of Glidden

Angeles, CA) 43~-740 high heat aluminum paint
~,3 I,1ushing or spraying. Feathel the paint so as to
ovrllap into the nickel plated portion. Allbw 20 minutes
dl.vinR time between coats.
(:O. (IuS
20-40-85
PalSc4
Aug 31/84
COP~IC3MT,
C H A PT E R
ELECTRICAL
POVVER
SR-76-023
COKROSION CONTROL IMANUAL
CHAPTER 24
ELECTRICAL POWER
TABLE OF CONTENTS
Chapte r/Sectio n/Subject
Su hiect
Hattt,rv
Compartment
Page
LOC
;!4-70-00
Inspect ~attery Compartment
~01
24-CONTENTS
o
COPYRIGHT, 1984 BY SAt;r7=LINER CORPORATION
GRID
Page 1/2 Blank

Aug 17/84
3B06
SR-76-023
CORROSI()N CONTROL IMANUAL
CHAPTER 24
ELECTRICAL POWER
THIS ENTIRE CHAPTER HAS BEEN~ REVISED.
Chupteri
Section
Page
Date
Chnl,ter d4-L.E.P.
1/2 Blank
Aug 17jX4
Chapter ~1-T.O.C.
t/2 Blank
Aua 17/84
201 and 20;!
Aug 17/84
24-L.E.P.
0
C.OPYRIGHT, 1984 BY SABRELINER CORPORATION
Page 1/2 Blank

Aug 17/84
SR-76-023
BATTERY COMPARTMENT
C.
INSPECT BATTERY COMPARTMENT

On ~Iodel NA 2(iTj-40 and -60, the batteries are located in
the aft fuselage on the lower centerline between FS 369
to the batteries is throu gh the aft fuselage
and :itfO.
between FS
access tlools located on the lower centerline
anti 1 12.
D,
5.
B.
C,
2.
to
battery
area
Remove masking paper and tape,
F.
Reinstall batteries. (Refer to applicable maintenance
6,
If corrosion is detected, determine the extent and
depth of corrosion damage. If damage exceeds

acceptable damage limits, a structural repair of the
damaged area must be accomplished. If corrosion
damage is within acceptable limits, proceed as
follows:
Clean corroded area with alkaline waterbase

cleaner. (Refer to Chapter 20,)
inspection aids,
D.
~F3emove corrosion
E.
Sponge area ~vith a mi~uture of ~j ounces of

sodium bicarbonate mixed with 1 gallon of
water. Keep applying solution until bubbling
stops, Allow solution to remain on corroded
area for Fi-fi minutes after bubbling has jtopped.
F.
Flush
area
Brush
or
to
T!sina
flashlight and mirror
are
indications of
Sponge the
spillage
spilled electrolyte:
area
with clean water.
mixture of ~i
ounces of
area with
sodium bicarbonate mixed with 1 gallon of
water.
Apply generously until
bubbling stops, Allow solution to remain
S1~onRe
on area
for .5-6 minutes after
manual.)
C,
(Refer
B.
E.
Remove
batteries from battery retaining trays

applicable maintenance manual.i
If there
Brush or spray two coats of Everlube No, 1:3~Fill Special on damaged area allowing 10 minutes between coats,
B,
inspect the battery area for evidence of corrosio~,

tlanlaKerl or deteriorated paint, or spilled electlolvte.
-I.
Wipe the entire surface with methyl ethyl

ketone (MEK), or equivalent, and dry
Mask off all componentsiareas that could be

affected bv corrosion removal chemicals or corrosion residue.
by opening applicable
as
Lightly abrade the damaged or deteriorated

with 320 grit emery cloth.
i~.
door.
Remove
Mask all componentslareas adjacent to damarea which could be affected by paint

removal solutions or paint residue,
D.
Loo172.
access
access
deteriorated:
thoroughly.
in
C;ain
or
area
Visually inspect the battery compartment/area (See

fiKure ~01) for corrosion as follows:
i.
applicable main-
aged
On ~Iodel NA 26Ti-6.i and -80, the batteries are located in

the nose of the airplane forward of the bulkhead at FS FjO.
Access to the batteries is thru access doors on each side of
the fuselage nose section between FS 1:2 and 50.
S/1.~.ILld he
to
manual.)
If paint film is damaged

A,
On ~loclel NA dfi.i-70, the batteries are mounted in a

Ietlactuble shelf which is located on the lower centerline
aft f F S ~Oti. Access to the batter ies is th rough the! access
dool on the lower centerline between FS ,()6 and 201i+lS.
cold wnter or a weale solution ofborie acid,

If the eyes are involved leash with a stream
of luater and consult a physician immediatulU. When ha7tdling potassiurr~
gloves and np7ons
idr, f~Lce shields,
Reinstall batteries, (Refer

tenance
Access
a
The potassill~rrL hydrozide electrolyte
rLic/cel cacllnizcm battenJ is uerzJ corrosive.
electrolyte is spilled on the hands,
the affeceed
elothi~iy, ol other
area should be flooded immediately loZtte
Sponge area again with clean water, then dry

surfaces with clean cloths.
bubbling stops,
G,
paint from corroded
area.
using chemical and/or

mechanical methods, I Refer to Chaptel 21).)
511
with clean
water
and dry thoroughly.
spray two coats of Everlube No, 13on damaged area allowing 10 min-
Special
utes between coats.
H,
I.
Remove masking paper and tape,
Reinstallbatteries, (Refertoapplicable mainte,ance
manual.)
24-70-00
0
COPYRIGHT, 1984 BY SABRELINER CORPORAT!~N
Page 201
Aug 17/84
SR-76-023
08
-C
FS 390
Model NA 265-40 AND -60
FS 357
51
Ci3
\I,
FS 206
Model NA 265-70
~T/"
oio o;o
Fl 36.5
Model NA 265-80
926823-57-14
Battery Compartment
Figure 201
24-70-00
Page 202
Aug 17/84
COPYRIGHT,
C H A PT E R
LANDING GEAR
SR-76-023
CHAPTER 32
LANDING GEAR
TABLE OF CONTENTS
Suhjecl
LandingCear
Page
$2-00-00
!;rneral
Wheel Wells ~Maintenance Practices
:32-80-00
In~l,ect ~Iain and Nose(;ear Wheel Wells
201
~P-CONTENTS
0
Page 1/2 Blank

Aug 17/84
SR-76-023
CHAPTER 32
LANDING GEAR
ChaDter/
Section
Date
Page
32-I,.E.P.
1/2"
38-CONTENTS
1/2
32-00-00
1"
2"
3"
4"
32-80-00
201/202
Jan 16/87
Aug 17/84
Jan
Jan
Jan
Jan
16/87
16/87
16/87
16/87
Aug 17/84
32-L.E.P.
0
Page 1/2 Blank

Jan 16/87
SR-76-023
CHAPTER 32
LANDING GEAR
GENERAL
Exterior surface material and corrosion damage limits on
Sabreliner main and nose landing gear are covered in this
chapter.
Figure 1 shows the nose
the main landing gear.
landing gear and Figure 2 shows
Refer to chapter 20 for general cleaning, sealing, and

surface coating procedures.
32-00-00
16/87Psge I
1
Jan
SK-7fi-023
(:()RI1()SI()N C()NIHOII MANI:AI,
rO:
h
5
CHROME PLATE
ITEM
NO.
NOMENCLATURE
MATERIAL
MAXIMUM
ALLOWABLE
CORROSION
DEPTH
NOSE GEAR PISTON
HIGH H.T. STEEL
0.006
NOSE GEAR PISTON

(CHROME PLATED AREA)
HIGH H.T. STEEL
0.003
NOSE GEAR OUTER

CYLINDER
ALUMINUM D.F.
0.015
NOSE GEAR ACTUATING

CYLINDER
ALUMINUM
0.020
NOSE GEAR ACTUATING

CYLINDER PISTON
CHROME PLATED
STEEL
0.003
TRUNNION
HIGH H.T. STEEL
0.008
ALUMINUM
0.020
6
7
8
g
1 STEERING CYLINDER
TOROUE ARMS
NOSE GEAR WHEELS
Nose
ALUM FORGING
0.020
ALUMINUM
0.020
Landing Gear Corrosion Damage Limits

Figure 1
32-00-00
Page
Jan 16/87
COPYRIGHT,
SR-78-023
i\
1
6
i
Ii
ia
d~
ui
ii
CHROIWEPL~TE
MAXIMUM
ITEM
NOMENCLATURE
NO.
MATERIAL
ALLOWABLE
CORROSION
DEPTH
MAIN GEAR WHEELS
ALUMINUM
0.020
TORQUE ARMS
STEEL
0.020
MLO TRUNNION AREA
HIGH H.T. STEEL
0.006
1 MLOACTUATOR CYL.
ALUMINUM
01020
0.003
MLO ACTUATOR PISTON
STEEL
MLO OUTER CYL.
HIGH H.T. STEEL
0.006
MLO PISTON
HIGH H.T. STEEL
0.003
(CHROME PLATED)
NOTES
REFERENCE NUMBERS 2, 3, 6 AND 7 ARE HIGH-HEATTREAT STEEL,
3
280,000 PSI AND ABOVE.
ANY CORROSION DAMAGE ON REFERENCE NUMBERS

5 AND 7 EXCEEDING DEPTH OF THE PLATING SHOULD
BE REMOVED FOR STRIPPING, REPAIR. AND RE-
PLATING.
APPLICABLE TO MODEL NA 265-40, -40A, -60, -60A, -60SC, AND -65

Main
Landing Gear Corrosion Damage Limits

Figure 2 (Sheet 1 of 2)
32-00-00
a
Page 3
16/87
Jan
SK-76-023
C()KK()SI(I~V (ONTROL MANUAL
-eI~
ze
if
C-1
\e
1/i
s~ra
s
3
il
~I
~7
,,-~3C;I
I
11
i
CHROME PLATE
ITEM
~10.
NOMENCLATURE
MATERIAL
MAXIMUM
ALLOWABLE
CORROSION
DEPTH
MAIN GEAR WHEELS
ALUMINUM
0.020
TORQUE ARMS
STEEL
0.020
MLO TRUNNION AREA
HIGH H.T. STEEL
0.008
MLG ACTUATOR CYL
ALUMINUM
0.020
MLO ACTUATOR PISTON
STEEL
0.003
(CHROME PLATED)
6
MLG OUTER CYLINDER
HIGH H.T. 6TE6L
0.008
MLG PISTON
HIGH H.T. STEEL
0.003
NOTES
REFERENCE NUMBERS 2, 3, 6 AND 7 ARE HIGH-HEATTREAT

5
STEEL, 260,000 PSI AND ABOVE.
ANY CORROSION DAMAGE ON REFERENCE NUMBERS

5 AND 7 EXCEEDING DEPTH OF THE PLATING SHOULD
BE REMOVED FOR STRIPPING, REPAIR, AND REPLATING.
APPLICABLE TO MODEL NA 285-70, -80, -80A, AND -80SC

Main
Landing Gear ~orrosion Damage Limits

32-00-00
Page
Jan 16/87
COPYRIGHT,
SR-76-023
WHEEL WELLS
INSPECT MAIN AND NOSE GEAR
WHEEL WELLS
Visually inspect the nose and/or main landing gear wheel

wells for corrosion as follows:
i.
(;ain
2.
Using an inspection mirror and flashlight as inspec

tion aids, visually inspect interiors of landing gear
wheel wells for indications of corrosion and deteriorating or damaged protective finishes. Pay particular attention to areas of moisture entrapment and
areas where mud and other foreign materials have a
tendency to collect.
8.
if corrosion is detected, mask all components/areas

which could be affected by corrosion removal chemicals or corrosion residue.
1.
Sti~ip primer/paint from corroded
access
to
landing
(:leun corloded
area
inn solution. Refer
gear wheel well.
area.
using alkaline waterbase cleanto
Chapter 20.)
R.
Remove corrosion using chemical andior mecht~nical methods. (Refer to Chapter 20.)
7.
Apply chemical conversion coating to areas where

colrosinn has been removed. (ReEer to Chapter 80.i
Y.
ing
applicable primer/paint to
(Refer to Chapter 20.)
match surround-
areas.
Remci\~e maskinR paper and tape.
32-80-00
0
Page 201/202 Blank

Aug 17/84
C H A PT E R
DOORS
SR-76-023
CHAPTER ~2
DOORS
TABI~E OF CONTENTS
Chapter/seetion/subject
Subject
Main Entrance Door Corrosion
Inspection
Innight Escape Hatch Removal, Inspection

andInetsllatian
Page
62-10-00
201
52~20-00..............
2011
SB-CDNTENTS
o
Page 1/2 Blank

9ep g/gl
9B-76-023
CHAPTER 52
DOORS
Chapter/
Page
Section
Date
62-L.E.P.
1/2
Sep 6/91
SE-CONTENTS
1/2
Sep 6/91
52-10-00
201
Sep 6/91
202
Jan 16/87
201
202"
Sep 6/91
Sep 6/91
Sep 6/91
Sep 6/91
62-20-00
Added
203
Added
204*
52-L.E.P.
cc
Page 1/2 Blank

Sep 6/91
SR-76-6Z3
CORROSJON CONTROL MANUAL
MAIN ENTRANCE DOOR

MAIN ENTRANCE DOOR CORROSION
E.
Apply applicable primer/paint finishes to

match surrounding area. (Refer to chapter 20.)
F.
Remove masking paper and tape.
G.
Install batt type insulation per dwg. 282530007.
H.
Reassemble mainentrancedoor.
INSPECTION
NOTE
Under certain geograpi~ical and enuironmental conditions will
~igR-tempemture, salt water or lli0b i~Edustrial conta~ilcation, it may be nectkis
essary to increase tke frelFcency of
be
e~all
determination
TCris
inspection.
made by t~e aircraft Owner and/or
10.
Opemtor.
limits, proceed
Visually inspect the interior of the main

(see Figure 201) for corrosion as follows:
entrance door
Open main
2.
Carefully lift-up and
3.
Remove
access
remove
stair tread coverings.
panels from S/B 86-1 installation
(2 ea.).
Remove screws securing stair treads to structure of
main entrance door, then remove stair treads from
door. Save screws for reinstallation.
Remove all insulation from door
6.
Usingexternal lightsource, inspection mirror, magnifying glass, and any other inspection aids necessary,
visually examine all interior areas of the main
entrance door. Carefully examine the interior side of

the entrance door outer skin for areas of moisture
entrapment and the faying surfaces between the
door structure and the door outer skin for indications

of corrosion between the faying surfaces.
follows:
Mask all components/areas which could be

affected by corrosion removal chemicals or
corrosion residue.
B.
Strip all paint/primer from corroded
C.
Clean corroded areas using alkaline waterbase

cleaner. (Refer to chapter 20.)
D.
Remove corrosion using chemical and/or

chanical methods. (Refer to chapter 20.)
E.
Apply chemical conversion coatings

where corrosion has been removed.
prior to inspection.
5.
as
A.
entrace door.
1.
4.
If corrosion is detected, determine extent and depth

of corrosion damage. If corrosion exceeds damage
limits given in chapter 20, a structural repair must
be accomplished. If damage is within acceptable
area.
to
me-
areas
(Refer
to
chapter 20.)
F.
Apply applicable primer/paint to match

rounding area. (Refer to chapter 20.)
G.
H.
Install batt type insulation per dwg. 282530007.
I.
sur-
Reassemblemain entrancedoor.
entrance door for

deterioration primer/paint and for cracked or
missing sealant between faying surfaces.
7.
Inspect interior finish of main
8.
If no corrosion or damaged paint films are detected,

install bat type insulation per dwg. 282-530007 and
reassemble door.
9.
If damaged paintfilms are found, proceed asfollows:
adjacent to damaged
A.
Mask off
B.
Removeall
paintfromdamagedarea.
C.
Clean
using alkaline waterbase cleaner.
areas
area
area.
(Refer to chapter 20.)

D.
Apply chemical conversion coating

area. (Refer to chapter 20.)
to cleaned
52-1 0-00
Page 201
a
Sep 6/91
8B-76-023
00000
80008800000
c~S)PI
(AEF. 8/8 861)
O
o
NOTE
All doors are ilcs~peeted iderttically, regardless of ai~lane model or door collfiguration.
5265-23-37-11
Main Entrance Door Corrosion Inspection

Figure 201
52-1 0-00
Page 202
Jan 16/87
83~-76-023
EMERGENCY EXIT
INFLIGHT ESCAPE HATCH REMOVAL,
INSPECTION AND INSTALLATION
12.
Removal
13.
sump drain and drain

closeable container.
Open forward fuselage fuel

residual fuel into
Remove
access
doors and speed brake close out
panels. (See Figure 201.)

Do;not allow speed brake panel to swing
free. It can result in daneage to tlcfuselage
skin at tLe speed brake panel kinge poi~ct.
1.
For NA
265-60A/SC, -80A/SC and
port the speed brake panel and
-65 models, supremove
Remove bolts
15.
Support escape hatch and
16.
Before removing escape hatch, open half way and

support fuel bladder.
17.
Remove escape hatch from airplane making

tape does not stick to fuel bladder.
screws,
securing speed brake panel closed; then slowly lower

the panel.
seeuring mounting pins.
14.
remove
pins.
sure
Inspection
inflight escape hatch (see removal).
v114atllll~Ill
1.
Remove
Clear w~eel well area of equipment and

Do not enter speed bmJee area
w~en electrical and Icydr&ulic power is
applied, or ground safety locks not installed. Anyone stncck by a moving c~eed
brake can be serioacsly mfatally injured
2.
Withhatchremoved, carefullyexaminethe infiight

escape hatch opening in the fuselage and the hatch
personnel.
2.
For NA 265-40, -60, -70 and -80 models lower

brake.
3.
Install
4.
On airplanes S/N 306-142, -143, -145, -146, S/N 38070 and all -65 models go to step 11, otherwise
continue with step 5.
5.
Remove floor covering over inflight escape hatch

inner door located on fuselage centerline between
FS 174 and 206.
speed
itself for indications of cracks and corrosion.

3.
If no cracks or corrosion are noted, install escape

hatch per installation instructions.
4.
If cracks and/or corrosion

follows:
are
located repair
as
A.
Remove all primer/paint from cracked and/or

corroded area(s).
B.
Clean
C.
Remove corrosion
chanical methods.
D.
Fabricate
ground safety locks.
area using alkaline waterbsse cleaner.

using chemical and/or

me-
repair parts using approved repair

procedures.
6.
Remove all
hatch area,
soundproofing and/or insulation from
E.
7.
Drill out rivets around periphery of inflight escape

hatch securing pressure seal to hatch.
Apply chemical conversion coatings to repair

parts and to areas of inflight escape hatch
where primer/paint has been removed.
F.
8.
Remove safety wire securing hatch mounting pins

in place,
Prime all repair parts and areas where corrosion has been removed using epoxy polyamide primer. (Refer to chapter 20.)
9.
Remove
G.
Install repairs using

cedures.
mountingpinsfrom receptacles infuselage
structure at FS 174.
approved repair
pro-
10.
Allow forward end of hatch to drop down to clear

fuselage structure, then move hatch forward to remove from airplane,
H.
Apply epoxy polyamide primer followed by a

costing of high impact resistant polyurethane
top coating. (Refer to chapter 20.)
11.
Defuel forward fuselage fuel tank on S/N 306-142,

-143, -145, -146, S/N 380-70 and all -65 models per
applicable Sabreliner Maintenance Manual.
I.
Reinstall inflight escape hatch in airplane per

installation instructions.
ILT
I IQ
52-20-00
a
COPYRIGHT, 1991 t3Y SABRELINER CORPORATION
Page 201
Sep 6/91
8B-76-023
EMERGENCY EXIT
INFLIGHT ESCAPE HATCH REMOVAL,
INSPECTION AND INSTALLATION (Contd)
17.
Apply talc to tack free sealant.
18.
Install secess doors and forward fuselage fuel sump

drain. (899 Figure 201.)
Installation
1.
2.
On airplanes S/N 306-142, -143, -145, -146, S/N ~8070 and all -65 models go to step 11, otherwise
continue with step 2.
Clear
Make
personnel. Do
sure
sl4ru~
drain is clear and assembled properly.
3.
Lubricate mounting pins with Lubri-bond A.
4.
Slide escape hatch aft on to hinge fittings then push

up and install mounting pina, aatety eap~
5.
If any of the
Rubstrips or retainers are in need of

replacement, see figure 201 for part numbers.
wLcel well
area
not enter
and
of
speed bralcc area
udisla sdschical actd

potosr t
aplolied. Anyone 8tmcck by a Ioovng speed
brake panel can be seriously or fatally
(9ee Figure 201.)
6.
(Continued)
injureQ
19.
Remavegroundsafetylocka.
20.
Secure
speed brake.
Seal around pressure seal P/N 282-311214-11 and

using PR1422GB Sealant.
escape hatch
7.
Install
rubstrips and retainers using rivets P/N
MS20600AD4W4
sized
8.
use
or CR3213-4-4. If holes
rivets CR3243-4-4.
Install inaight
covering.
Clear
are over-
escape hatch inner door and floor
well
of eqnipnrent and
speed brake area
when electrical and hydraulic power is
applied Anyone struck by a movilcg speed
wheel
personnel. Do
brake panel
i~tiured.
9.
area
not enter
can
be seriously
or
fatally
Removeground safety locks.
10.
Secure speed brake.
11.
Apply newtapeP/N 427-2"toescapehatch iftape is

worn or
damaged.
12.
Slide escape hatch aft on to hinge fittinffs.
13.
Carefully close
14.
Lubricate mounting pins with Lubri-bond A and

install mounting pine and bolts. (599 Figure 201.)
16.
Support fuel bladder and apply tape around interior

perimeter of escape hatch.
16.
Top
escape hatch making

bladder does not get pinched.
cost
sure
that fuel
taped perimeter with sealant PR1422GB
and allow to
cure
until tack free.
IIBla8ru;wl8E~
52-20-00
Page 202
Sep 6/91
(P
PRESSURE SEAL
P/N 282-31121911
RETAINER,
PACKING
ANOnlOO
IRm
MOUITIIG
fS 114
PIN
(LOWLRI
RUBSTRIP
P/H 202-31121958
RETAINER
P/H 9031121939
MOUNTING PIN
285300084
R~CLPTACLLS
14 PLACESI
50887812
I2PLA0E81
(2
(RL9
PUCES)P/I
12 PUC9
CAP PACKING
INFLIRHT
ESCAPE HATCH
PPLAGESI
INACTIVE ESCAPE
HITCH ON AIRPLANES
IREF)
WITHOUT FORWARD
fUSLLAGE FULL TANK
RUBSTRIP /I 28291141968
RETAINER
P/N 202-81121348
RUBSTRIP
P/H 2112-31121353
RETAINER
P/N 28231121347
RURSTRIP
P/N 20231121957
RETAINLR
P/N 28231121345
PPLACLS)
12 PLACES)
0/
NOTE
\I,RUBSTRIP
P/N 282311213-4~
RETAINER
Inspect all shaded areas

for cracks and corrosion.
P/12~2311P1991
fS 208.25
BOLT (2 PLACESI
WASHER
I INFLIOHT ESCAPE
HATCH
NUT
OUTER DOOR
HINGE FITTIIIOS
FS174
(LOWER)
)I
I,
I,
HATCH ON AIRPLANES
WITH FORWARO
Sj-O-
FUSELAOEFUELTANK
IS/Hs 302142, -143, -145.
MOUNTING
-145. 380-70 AHO ALL

65 MODELS)
blN RECEPTACLES
MOUnTIBrlW
P/N 26&9#1084
I2 PUGBI
Meun
201-
InfllLht Escape Htoh ((lheet
1 oi
2)
Isma
52-20-00
cD
Page 208
Sep 6/91
SR-76-02S
CORROBION CONTROL YANUAL
$i
t::::
ACCESS
DOOR 80RWARD FULL CELL ACCESI
:2:S
FORWIRORSELABI
FUEL SUMP DRAII
SPLEO BAAI(I PAWEL
r 7
II
I
I
IWFLIBHT
IIELPE
HATCH
FWD
SPEEO BRAWE CLOSE OUT PAIELS
(AcCESS
L
SCREWS
IWOT APPLICIBLE
01 S/W 3O8-142.
-143. -145. 146 AHO
S/W 38089 AIR SUBS)
ACCESS ODOR
FORWARD FULL CLLL IITLRIAL
COMPOIERT ACCESSI
IBOTTOM VIEW)
MO DEL NA 265-60; S/N 306-1 42. -143, -145, -146
MODEL NA 265-80; S/N 380-69 AND SUBS
MODEL NA 265-65; S/N 465-1 AND SUBS
IlalA~
Figun 201
Infli~ht E~ape Hatch (8hect 2 of 2)
52-20-00
Page 204
Sep 6/91
CHAPTER
F USE LAG E
SR-76-023
CORR()SION C()NI~ROL MANUAL
CHAPTER 53
FUSE LAGE
TABLE OF CONTENTS
Sut,ject
Chapter/Section/Suhiect
(;enelal
:3~-00-00
Page
Foiwaiti
53-10-00
Fuselage
Insl,ect Dulkhead at FS 13
[n~l,ect Lower Longeron anti c,ckpit Interior Belo~v Pilots Slitling Window
CcnterFuselage
~nspectADF LoopAntennaMount
801
401
In~pectCabin Floor Under Main Entrance Door

ft Fusela~e
Diain Holes In Vertical Hat Section
~iilkheact at FS X:I:i
~01
201
rj3-30-00
on
53-CONTENTS
Page 1/2 Blank
Ai~g 17/84
SR-76-023
CHAPTER 53
FUSELAGE
THIS ENTIRE CHAPTER HAS BEEN REVISED.
Chapter/
Section
Page
Date
!:haptel .S:-i-I,.E.P.
1/2 Blank
Aug 1784
Chal,ter :i:-:-T.O.C.
1/2 Blank
Aug 17/84
1 thru 10
Aug 17/84
201 and 202
Aug 17/84
201 and 202
20~/204 Blank
Aug 17/134
Aug 17/X4
201/202 Blank
AuR 17/84
53-L.E.P.
0
Page ~/2 Blank

Aug ~7/84
SR-76-023
CHAPT7ER 53
FUSELAGE
GENERAL
Materials used on the fuselage external surfaces and the
corrosion damage limits for these surfaces are provided in
this chapter. Also provided in this chapter are instructions far the examination of specific areas of the fuselage
which may be susceptible to corrosion.
Fuselage exterior surface material is shown
on
figure
i.
Corrosion damage limits for the forward fuselage, center

fuselage, and aft fuselage are shown on figures 2, 3, and 4
respectively.
Refer to Chapter 20 for general cleaning, sealing, and
53-00-00
0
Page 1
Aug 17/84
SR-76-023
auSs oR PLnsne
ALUMINUM ALLOYS
FleReoLAas UYINITES
CORROSION RES18TANT8TECL
53-00-00
Page 2
Aug 17/84
Fuselage Exterior Surface Material

SR-76-023
OLAS[I OR PLASTIC
I:
FleREaLASS LAMINATfS
*LUYINUM ALLOYS
CORROSION RESISTI\NT-STEEL
Fuselage Exterior Surface Material

COPYRIGHT,
1984 BY SABRELINER CORPORA.I iuN
53-00-00
age 3
Aug 17/84
SR-76-023
FS
206
FS
118.625
FS
13
MIN
OF
IN.
MUST
SEPARATE
CORROSION
ALONG
SPLICE
DAMAGED AREAS.
CORROSION
2.
1.
50
FS
CORROSION DAMAGE IS LIMITED TO THE FOLLOWING:

5
DAMAGE
OR
FASTENER ROW MUST NOT INCLUDE MORE THAN

3 FASTENERS IN EACH DAMAGED AREA.
i;l:
8
3.
MIN
OF 3 UNDAMAGED
91011
121314
1518
i:--t
17
192021
13
22
MAXIMUM
ITEM
MATERIAL
NOMENCLATUAE
GAGE
NO.
UPPER SKIN
FS 13 TO 50
7178-76 BARE
0.050
UPPER SKIN
FS 50 TO 98
2024-T3 BARE
0.050
UPPER 8K!N
FS l?e.cas To 205
SIDE SKIN
ENTRANCE DOOR SKIN
LOWER SKIN
SIDE SKIN
FS 13 TO 50
7178-T5 BARE
SIDE SKIN
FS 50 TO 76
117~TB BARE
EQUIPMENT ACCESS DOOR
7178-T8 BARE
FS 134 tO 158.5
FS 13 TO 50
BARE
OF
AFFECTED
DEPTH
SURFACE
0.004
0.002
0.092
0.005
2024-T3 BARE
0.050
0.002
7178-T6 BARE
P
0.050 10
0.050 M
0.050 O
0.050 D
0.050 m
0.125 m
0.050 m
0.050 m
0.050 O
0.125 Q
0.050 m
0.050 O
0.05y B
7178-t62 BARE
EOUIPMENTACCESSDOOR
7118-78 BARE
11
ACCESSDOOR
7178nr BARE
12
SIDE SKIN -FS76T0155.25
2024-T3 BARE
2024t3 BARE
0.004
0.004
0.004
0.002
0.002
0.002
0.002
0.002
0.002
SIDESKIN-FS98TO134
7178-T6 BARE
15
ENTRY DOOR CENTER LINK COVER
7075-T8 BARE
16
LOWER SKIN
II
SIDE SKIN
18
LOWER SKIN
19
SPEED BRAKE CLOSE-OUT
7178-T8 BARE
0.032
0.003
20
SPEED BRAKE OUTER SKIN
7178-T6 BARE
0.083
0.004
21
LOWER SKIN
FS 158.25 TO 166.25
7178-t6 BARE
0.032
0.003
22
LOWER SKIN
FS 102.813 TO 151
7178-T8 BARE
0.050
23
NOSE GEAR DOORS
2024-T3 BARE
0.032
24
LOWER SKIN
7178-T6 BARE
0.050
14
FS 164 TO 206
FS 158.5 TO 206
FS 190 TO 208
FS 25.75 TO 50
7075-T8 BARE
2024-T42 BARE
0.005
0.003
0.002
0.003
Lil
ii]
m
P
[il
Lil
O
O
[il
O
m
m
O
[il
O
50
[iJ
Iii
M
O
lil
fiI
10
20
ii)
10
10
10
10
10
50
50
50
10
10
to
lo
10
to
50
co
10
10
to
io
0.003
0.003
PERCENT
CORROSION
0.050
fS 91.44 TO 159.25
0.050
m
m
O
24
ALLOWABLE
2024-73 BARE
10
SIDE SKIN
MUST
FAStENERRoWS.
18
13
FASTENERS
SEPARATE CORROSION DAMAGED AREAS ALONG
0.005
20
NOTES
D
CHEM-MILLED PART
INDIVIDUALCORROSION DAMAGEDAREAS MUST NOT

EXCEED 2 SQUARE IN.
INDIVIDUALCOAROSION DAMAGEDAREAS MUSTNOT

EXCEED 4 SQUARE IN.
53-00-00
Page 4
Aug. t7/84
Forward
Fuselage Corrosion Damage Limits

o
COPYRIGHT,
~B4 BY SABRELINER CORPORATION
SR-76-023

1.
206+17
FS
FS
50
MIN
OF
IN.
MUST
SEPARATE CORROSION
2.
CORROSION DAMAGE ALONG A SPLICE

FASTENER ROW MUST NOT INCLUDEMORCTnAN
3.
A MIN Of 3 UNDAMAGED FASTENERS MUST

FASTENER ROWS.
118.625
FS
DAMAGED AREAS.
FS
OR
or
6 7
8 91011
121314
ITEM
1516
17
Is
NOMENCLATURE
NO.
Is 20
MATERIAL
212223
GAGE
UPPER SKIN
FS 13 TO 50
7175-T8 BARE
0.050
UPPER SKIN
FS 50 TO 98
2024-73 BARE
0.050
UPPER SKIN
FS 118.825 TO 206+17
2024-742 BARE
0.050
2024-T42 BARE
0.050
1 SIDE SKIN- FS134 TO 158.5
24
ENTRANCE DOOR SKIN
1024-T3 BARE
0.050
LOWER SKIN
7178-76 BARE
0.050
SIDE SKIN
FS 13 TO 50
n7e-ra BARE
o.oso
SIDE SKIN
FS 50 TO 76
Tile-re BARE
o.oso
ACCESS DOOR
FS 50 TO 78
7178-Te BARE
0.050
D
m
O
10
ACCESS DOOR
FS 50 TO 78
7178-78 BARE
0.050
I ACCESS DOOR-FS76TO90
7178-Te BARE
0.115
2024-73 BARE
0.050
2024-T3 BARE
0.025
14
1 sIDESKIN-FS91.44TO 159.25
1 SIDE SKIN FS 98 TO 134
7178-T8 BARE
0.050
15
O
O
D
O
D
D
D
D
11
12
13
SIDE SKIN
FS Is TO 155.25
ENTRYDOORCENTER LINKCOVER
2024-742 BARE
0.190
is
LOWER SKIN
2024-73 BARE
0.050
17
SIDE SKIN
2024-T42 BARE
0.050
FS 161 TO 208
FS 158.5 TO 508+17
18
ACCESS DOOR
FS 208
2024-t42 BARE
0.050
19
ACCESS DOOR
FS 190 TO 208
2024-T42 5c~RE
0.050
20
ACCESS DOOR
FS 208+17
2024-742 BARE
o.oJo
21
SPEED BRAKE CLOSEOUTSKIN
7178-76 BARE
0.032
22
SPEED BRAKE
7178-Te BARE
0.064
23
ACCESS DOOR
24
LOWER SKIN
25
7178-Te BARE
0.050
7178-78 BARE
0.050
NOSE GEAR DOOR
2024-T42 CLAD
0.032
26
LANDING LIGHT DOOR
2024-T42 CLAD
0.071
27
ACCESS DOOR
8081-T4 BARE
0.050
FS 150 TO 158.55
FS 102.8 TO 15.1
FS 24.6 TO 35.5
m
P
2627
MAXIMUM
ALLOWABLE
CORROSION
OF
AFFECTED
DEPTH
SURFACE
m
O
m
FS 13 TO 50
25
PERCENT
0.004
so
0.002
[il
10
o.oonm
aocs Cil
o.ooz
D
D
0.004 rs
0.002 O
0.002 O
0.001 O
0.002 O
0.002 m
0.002 [il
0.005 D
0.003 O
0.002 Iii
0.003 O
0.003 1~
0.003 O
0.003 lil
0.004 [jl
0.003 O
0.050 O
0.003 D
o.oos [il
o.oos Iii
to
to
lo
o.oM
50
o.oos
so
so
10
10
10
10
to
10
50
10
10
10
10
10
10
10
20
10
to
20
to
NOTES
O
CnEM-MILLED PART
Iii
INDIVIDUALCORROSION DAMAGEDAREASMUSTNOT
INDIVIDUALCORROSION DAMAGEDAREAS MUSTNOT

EXCEED4SQUAREIN.
EXCEED 2 SQUARE IN.

Forward
COPYRIGHT, 1984

53-00-00
Page 5
Aug 17/84
SR-7fi-02:-3
C()KK()SI()N C()NTROL MANUAL

i.
MIN
MUST
Of 2 1N.
SEPARATE CORROSION
DAMAGED AREAS.
2.
CORROSION DAMAGE ALONG A SPLICE OR

3.
MIN OF 3 UNDAMAGED FASTENERS MUST

A
FASTENER ROWS.
,--7
I
II
3
I
ITEM
NO.
MATERIAL
NOMENCLATURE
2024-T3 BARE
O.oJo
2024-t3 BARE
0.050
DORSAL FIN SKIN
7178-T8 BARE
0.032
LOWER SKIN
2024-T3 BARE
0.050
LOWER SKIN -FS258.4T0308.1
7178-768486
O.oJo
LOWER SKIN FS 308.1 TO 357
2024-T3 BARE
0.050
UPPER SKIN
SIDE SKIN
FS 206 TO 357
GAGE
FS 206 TO 357
FS 206 TO 258.4
MAXIMUM
ALLOWABLE
CORROSION
DEPTH
13
o
0.001
0.002
o.oos
0.003
O
O
0.003
0.003
O
o
O
O
O
O
PERCENT
OF
AFFECTED
SURFACE
10
lo
so
50
10
10
NOTES
O
CHEM-MILLED PART
EXCEEDPSQUAREIN.
EXCEED4SQUAREIN.
APPLICABLE TO MODEL NA 265-40
53-00-00
Page
~ua 17/a4
Center Fuselage Corrosion Damage Limits
Figure
(Sheet 1 of 3)
SR-76-023
CORROSION CONTROL MAWUAL

i.
CORROSION DAMAGE MUST NOT EXCEED 10% OF

AFFECTED SURFACE AREA.
2.
INDIVIDUAL CORROSION-DAMAGED AREAS MUST
3.
NOT EXCEED ?SOUARE IN.

MIN
OF
IN.
MUST
SEPARATE
CORROSION
ALONG
SPLICE
DAMAGED AREAS.
4.
CORROSION
DAMAGE
OR
FASTENER ROW MUST NOT INCLUDEMORETnAN

5.
MIN
OF
UNDAMAGED
FASTENERS
MUST

FASTENER ROWS.
0
3
MAXIMUM
ITEM
NO.
NOMENCLATURE
UPPER SKIN
SIDE SKIN
LOWER SKIN
FS 206 TO 359
MATERIAL
GAGE
O
O
ALLOWABLE
CORROSION
DEPTH
2024-73 BARE
0.050
2024-73 BARE
0.050
FS 298 TO 333
2024-73 BARE
0.050
0.003
LOWER SKIN
FS 333 TO 357
2024-73 BARE
0.050
0.003
LOWER SKIN
FS 257.5 TO 298.5
7178-78 BARE
0.050
0.003
LOWER SKIN
FS 206 TO 257.5
2024-73 BARE
0.050
0.003
LOWER SKIN
FS 206 TO 206+17
7075-78 BARE
0.050
0.003
FS 208 TO 298.5
0.002
0.002
NOTE
D
CHEM-MILLED PART
APPLICABLE TO MODEL NA 265-60, -60A, -60SC, AND -65

Center Fuselage Corrosion Damage Limits
m
COPYslC-HT. 1984 B, "ABRELINER CORPORATION
53-00-00
Page 7
Aug 17/84
SR-76-0~3
C()RK()SI()N C()NTROL MANUAL
CORROSION DAMAGE IS LIMITED TO Tn E FOLLOWIN G:

i.
OF 2
MIN
IN.
MUST SEPARATE
CORROSION
DAMAGED AREAS.
2.
CORROSION
DAMAGE
ALONG
SPLICE
OR

3.
MIN
OF 3
UNDAMAGED
FASTENERS
MUST

FASTENER ROWS.
MAXIMUM
ITEM
MATERIAL
NOMENCLATURE
NO.
GAGE
OF
CORROSION
DEPTH
AFFECTED
2024-73 BARE
0.050
2024-73 BARE
0.050
DORSAL FIN SKIN
7178-78 BARE
0.032
0.005
UPPER SKIN
SIDE SKIN
FS 206+17 TO 357
F.C "06+17 TO 357
n
O
PERCENT
ALLOWABLE
0.002
0.002
LOWER SKIN
FS 298.5+21 TO 333.625
2024-742 BARE
0.050
0.003
LOWER SKIN
FS 298.5 TO 333.825
2024-742 BARE
0.050
0.003
LOWER SKIN
FS 298.5 TO 298.5+21
7178.78 BARE
0.050
0.003
FAIRING SKIN FS 208+17 TO 284.25
2024-73 BARE
0.050
0.003
tit
[il
M
O
(il
m
O
SURFACE
10
10
50
10
10
10
10
NOTES
m
CHEM-MILLED PART
EXCEED 2 SQUARE IN
EXCEED 4 SQUARE IN.
53-00-00
Page
Center

Figure (Sheet 3 of 3)
17;XL
SR-76-023
CORROSION DAMAGE IS LIMITED tO THE FOLLOWING:

1.
MIN
OF 2 IN.
MUST
SEPARATE CORROSION
DAMAGED AREAS.
2.
CORROSION
DAMAGE
ALONG
SPLICE
OR
FASTENER ROW MUST NOT INCLUDEMOAETHAN

4
3.
A MIN OF 3 UNDAMAGED FASTENERS MUST

FASTENER ROWS.
10
11
ITEM
NOMENCLATURE
NO.
MATERIAL
GAGE
MAXIMUM
ALLOWABLE
CORROSION
DEPTH
DORSAL FIN SKIN
T07J-T8 BARE
UPPER SKIN
FS 357 TO CANT STA 457.408
7178-T6 BARE
0.031m
0.040 O
0.003
UPPER SKIN
FS 118.625 TO 206+17
7178-T6 BARE
0.040
0.005
UPPER FAIRING
FWD
7178-78 BARE
0.040
UPPER FAIRING
AFT
7178-To BARE
0.040
UPPER SKIN
AFT SKIN
LOWER SKIN
SIDE SKIN
10
11
FS 485 TO 505
o.oos
so
m
O
I~j
O
O
O
O
0.005
13
PERCENT
OF
AFFECTED
SURFACE
0.005
to
50
so
50
MAGALLOYSHT
0.040
0.005
7178-78 BARE
0.040
0.005
717a-T6 BARE
0.040
CANT STA 451.408 TO FS 505
MAGALLOYSHT
0.050
0.005
50
SIDE SKIN
MAGALLOYSHT
0.050
0.005
50
SIDE SKIN
7178-T8 BARE
0.040
7178-78 BARE
0.040
0.003
iii
ii]
INNER SKIN
2024-T42 CLAD
0.025
0.005
50
OUTER SKIN
2024-T42 CLAD
0.025
0.005
50
FS 504 TO 519
CANT SfA 457.406 TO FS 505
1?
LOWER SKIN
13
AFT FUSELAGE ACCESS DOOR
IP
0.005
0003
50
50
50
10
10
NOTES
CHEM-MILLED PART
INDIVIDUALCORROSION DAMAGEDAREASMUST NOT

EXCEEDPSQUAAEIN.

EXCEED 4 SQUARE IN.
APPLICABLE TO
~ODEL
NA
265-40, -40A, -60, -60A, -60SC, AND
Aft Fuselage Corrosion
Figure
Damage Limits
(Sheet 1 of 2)
5265-23-53-6
-65
53-00-00
Page
CORPORA;Aug 17/84
SR-7fi-02.3
C()KR()SI()N CONTROL MANUAL
a,
~/S
CORROSION DAMAGE IS LIMITED tO THE FOLLOWING:
1.
OF
MIN
IN.
MUST SEPARATE
CORROSION
DAMAGED AREAS.
2.
6
7

3.

A
FASTENER ROWS.
ITEM
MATERIAL
NOMENCLATURE
NO.
DORSAL FIN SKIN
UPPER SKIN
UPPER FAIRING
12
FS 357 tO CANT STA 457.406

FWD
UPPER FAIRING-ACT
FS 485 TO 509
GAGE
MAXIMUM
ALLOWABLE
CORROSION
DEPTH
7075-78 BARE
0.032
o.oos
2024-73 BARE
0.040
0.003
2024-73 BARE
0.040
O
81
2024-742 BARE
0.040
2024-T42 BARE
0.040
2024-742 BARE
0.040
2024-742 BARE
0.040
2024-742 BARE
0.040
o.oos
0.005
0.005
UPPER SKIN
AFT SKIN
LOWER SKIN
SIDE SKIN
ACCESS DOOR
2024-742 BARE
0.040
0.005
1 ACCESSDOOR
FS485
2024-742 BARE
0.040
0.005
2024-T3 BARE
0.040
0.003
7178-T6 BARE
0.040
0.003
INNER SKIN
102eT42CLAD
0.025
0.005
OUTER SKIN
2024-T42CLAD
0.025
0.005
10
FS 509 TO 522.5
11
SIDE SKIN
12
LOWER SKIN
13
0.005
D
D
0.005
PERCENT
OF
AFFECTED
SURFACE
o
O
so
o
O
O
so
O
1~
50
0.005
10
50
50
50
50
O
O
D
O
50
N
O
50
50
to
10
AFT FUSELAGE ACCESS DOOR
50
NOTES
CHEM-MILLED PART
iii

EXCEED 2 SQUARE IN.
[R
EXCEED 4 SQUARE IN.
53-00-00
Page LO
Aug 17/84
Aft Fuselage Corrosion Damage Limits

c
COPYRIGHT. 1984 BY SABRtlil\jER CORPORATION
SR-76-023
FWD FUSELAGE
INSPECT BULKHEAD AT FS 13
4.
corrosion
i.
2.
as
follows:
Remove
access
panels from inboard sides of left and
right hand consoles in cockpit.
Visually inspect the bulkhead at FS 13(see figure 201) for

5.
Remove
access
doors
fuselage between FS
on
left and right sides of
76 and 90.
Gain access to bulkhead at FS 13 by removing

radome on forward side of bulkhead and electrical
bay access doors on both sides of fuselage aft of
bulkhead at FS 13.
6.
Remove reveal below the pilots sliding window.
7.
Using an inspection mirror and flash light as inspection aids, visually inspect both forward and aft sides
of bulkhead paying particular attention to lower
portion of bulkhead.
Using a flashlight and mirror as inspection aids,

inspect the lower longerons between FS 98 and 143,
and the area below the pilots sliding window, for
8.
evidence of corrosion.
Inspect all exposed areas for damaged

primer/paint films.
or
deteri-
orated
NOTE
9.
Remove any componentlequipment interfering with visual inspection of either side

of bulkhead.
If there is no indication of corrosion attack, reinstall
removed components, radome and access doors,
4.
5.
Ifcorrosion isdetected, mask all components/areas

which could be affected by colrosion removal
chemicals or corrosion residue.
Strip primer/paint from corroded
If
no
corrosion is found,
paint films
as
repair damaged primer/
necessary and reinstall
removed
components.
10.
If corrosion is found, determine extent and

depth of
corrosion damage. If corrosion exceeds acceptable
damage limits, a structural repair of the damaged
area must be accomplished. If
damaged is within
acceptable limits, proceed as follows:
A.
Mask off all coitlrJonenis,lareas
damaged by corrosion
or
area.
which could be
removal chemicals
and/
corrosion residue.
B.
Remove all primer/paint from corroded
cleaning solution. (Refer
C.
Clean corroded
7.
Remove corrosion using chemical and/or mechanical methods. (Refer to Chapter 20.)
area using alkaline waterbase

cleaner. (Refer to Chapter 20.)
D.
8.
Apply chemical conversion coating
Remove corrosion using chemical andior

mechanical methods. (Refer to Chapter 20.)
E.
Apply chemical conversion coating to all areas

where corrosion has been removed. (Refer to
F.

coating of high impact resistant polyurethane
top coating. (Refer to Chapter 20.)
G.
6.
Clean corroded
area
using alkaline waterbase

to Chapter 20.)
to areas where
corrosion has been removed.

9.
10.
Apply applicable primer/paint

ing area. (Refer to Chapter 20.)
to match surround-
Remove masking paper and tape; then reinstall

removed components, radome and access doors.
INSPECT LOWER LONGERONS AND COCKPIT

INTERIOR BELOW PILOTS SLIDING WINDOW
Inspect the lower longerons between FS 98 and 143 and

the cockpit interior below the pilots sliding window for
evidence of corrosion
as
follows:
1.
Remove both the pilots and copilots seats.
2.
Remove carpet and pac from cockpit floor.
3.
Remove floor panels from cockpit floor to gain
to lower
area.
Chapter 20.)
H.
Reinstall
access
on left side of cockpit: floor

panels,
panels on inboard sides of consoles; pads
and carpet; seats: and the two

the outside of the airplane.
access
doors
on
access
longerons.
53-10-00
o
COPYRIGHT,
Page 201
Aug 17/84
SR-76-023
C()IIII()SI()N C()NTROL MANUAL
ooo""
FS
~ii8:i fifi
INSPECT SH*DEI)
(BOTH SIDES)
SZ66-2557LO
Bulkhead of FS 13
F;rr~re 201
53-1 0-00
Page 202
Aug 17/84
8B-76-023
CENTER FUSELAGE
INSPECT ADF LOOP ANTENNA MOUNT
1.
Lift-up floor covering to expose area to be inspected.

Start at out-board corner (adjacent to bulkhead at
Examine edges of ADF LOOP ANTENNA bonded

doubler (see figure 201) and areas of fuselage upper skin
adjacent to the bonded doubler on fuselage upper centerline between FS 224.5 and 242 for evidence of corrosion as
fol lows:
2.
Examine exposed
3,
Remove sealant, using a non-metallic scraper, from

periphery of ADF Loop Antenna and doubler
If corrosion is not detected, re-cement floor

in place.
4.
If corrosion is found, determine extent and depth of

damage. If damage is beyond acceptable limits,
install approved structural repair over damaged
1.
FS 143). Use caution to not
installed under antenna,

2.
Inspect edges of antenna doubler and fuselage skins

adjacent to doubler for evidence of corrosion.
A.
If
corrosion is found, reseal using sealant

(PR-341, Pro-Seal-730, EC-1547 or equivalent),
prime and finish using applicable primer and
topcoat. (Refer to Chapter 20 for application
no
5.
If corrosion is within acceptable limits, proceed

follows:
as
Using methyl ethyl ketone (MEK)or any other

acceptable solvent, remove floor covering
cement remaining on cabin floor.
If corrosion is found, remove antenna to determine severity of corrosion damage.
B.
Mask off all areas which could be damaged by

corrosion removal chemicals or corrosion residue.
If corrosion damage is less than 0.010

in. depth, a structural repair will be
required within the next 100 fliyhi ilours,
providing corrosion control measures are
C.
accomplished immediately.
(2)
If damage exceeds 0.010 in.
immediately.
Remove all corrosion, using chemical
mechanical methods, (Refer to Chapter 20.)
D.
Apply chemical
conversion
coating. (Refer
Remove all
damaged
paint/primer from corrosion
area.
D.
Clean corroded area using alkaline waterbase

cleaner. (Refer to Chapter 20.)
E.
Remove corrosion using chemical

mechanical methods. (Refer to Chapter 20.)
F.
Apply chromate conversion coating to areas

where corrosion has been removed. (Refer to
depth, repair
C.
or
or
Chapter 20.)
to
G.
Apply primer applicable to existing paint

Chapter 20.)

coating of high impact resistant polyurethane
top coating. (Refer to Chapter 20.)
H.
Remove masking paper and tape; then cement

floor covering in place.
Chapter 20.)
system. (Refer to
F.
covering
A.
(1)
E.
damage floor covering.
for corrosion.
area.
procedures.)
B.
areas
Apply finish top coat to match surrounding

area.
(Refer
to
Chapter 20.)
INSPECT CABIN FLOOR UNDER MAIN

ENTRANCE DOOR
Cotrosion of the cabin floor inboard of the main entrance
door (see figure 202) may be caused by moisture entering
through an open main entrance door and/or by foot traffic
during wet weather conditions. This could saturate the
floor coverings; thereby providing all the ingredients for
corrosive attack.
To
visually inspect the cabin floor inboard of the main

door between FS 143 and 174, proceed as
entrance
follows:
53-20-00
0
Page 201
Aug 17/84
SR-76-023
INSPECTION FOR CORROSION REOUIRED

AROUND THE AFT LOOP ANTENNA ONLY.
AFT ADF LOOP ANTENNA
FWD ADF LOOP ANTENNA
,FS 242
(008)
AFTADFLOOPANTENNA
FS 224.5
REMOVE SEALANT
FROM THIS AREA.
DO NOT REMOVE THIS SEALANT
USE A NONMETALLIC
SCRAPER.
REMOVE SEALANT
FROM THIS AREA.
USE A NONMETALLIC
SCRAPER.
INSPECT FOR CORROSION

AROUND THE ENTIRE EDGE
OF THE 882-911207-)15 OOUBLER
AND ON THE FUSELAGE SKIN
282-311207-25
DOUBLER (REF)
NEXT TO THE DOUBLER.
FUSELAGE SKIN
FUSELAGE FRAME
(REF)
(REF)
FS 224.50
AFT ADF LOOP ANTENNA
282-311207-25 DOUBLER
INSPECT fOR CORROSION

AROUND THE ENTIRE EDGE
OF 282-311201-25 DOUBLER
AND ON THE FUSELAGE SKIN
NEXT TO THE DOUBLER.
FUSELAGE SKIN
(REF)
S26.59%-57-15
ADF Loop Antenna Mount

Figure 201
53-20-00
Page 202
Aug 17/84
COPYRIGHT, 1984 BY SABHELINER C0;103RATION
SR-76-023
COKROSI()N C()NTROL MANUAL
an~
~1
B
3
FWD
IFWI)
FLOOR LINE
FS
VIEW LOOKING
OUTED At MAIN
143
ENtRYDOOR
FLOOR LINE
FS
174
8266-23-67-11
Cabin Floor
FS 143 to 174
Figure
202
53-20-00
0
COPYRIGh
i,
Page 203/204 Blank

Aug 17/84
SR-76-023
AFT FUSELAGE
DRAIN HOLES IN VERTICAL HAT SECTIONS

ON BULKHEAD AT FS 333
Drain holes through the web below the vertical hat

sections have been provided on Model NA 265-40, S/N 128
a"d SUbs; -60, S/N 126 and subs; -65, all S/Ns; and -80,
S/N 380-55 and subs to eliminate moisture entrapment in
the vertical hat sections. On airplanes which do not have
the drain holes in the lower webs, drain holes
may be
drilled through the lower webs; using the applicable
dimensions shown below to locate the drain holes.
Because of the continuing temperature variations between the cabin and the aft fuel cell area, the vertical hat
sections on the aft side of the bulkhead at FS 338.625 have
a tendency to collect and retain moisture (condensation)
inside the hat.
Use estreme care in locating and drilling

drain holes. Make certain holes enter into
hat section and not into fuel cell area.
BP 19 7/8
BP10
i__L
BP10
90197/9
FS 333.625
__
0.0g2
1.375
0.250 DIA HOLE
(5 PLACES)
VIEW LOOKING DOWN
FS 357
MODELS NA 265-40 AND -60
BP?O
BP10
0.160
2) I
BP 10
0.190
I~e 0.160
~cl
BP 20
0.190
II
ICc0.160
rl
FS333.625
~iZ
0.250 DIA HOLE
VIEW LOOKING DOWN
(5 PLACES)
FS 357
MODELS NA 265-70 AND -80

Vertical Hat Section Drain Holes
Figure
COPYRIGHT,
201
53-30-00
Page 201/202 Blank
Aug 17/84
CHAPTER
NACELLES
PYLONS
SR-76-023
CORRL)SI()N C()NTROL MANUAL
CHAPTER 54
NACELLES AND PYLONS
TABLE OF CONTENTS
Suhject
(;eneral
54-00-00
Page
Rel,air Procedures
54-CONTENTS
C,OPYRIGHT, 1984 BY SABRELINER CORPORATION
Page 1/2 Blank

Aug 17/84
SR-76-023
CHAPTER 54
NACELLES AND PYLONS
Chapter/
Section
Page
Date
Chapter 54-L.E.P.
1/2 Blank
Aug 17/84
Chapter
1/2 Blank
Aug 17/84
li4-00-00
Tj4-T.O.C.
1 thru 6
Aug 17/84
7/8 Blank
Aug 17/84
Aug 17/84
801/802 Blank
54-L.E.P.
0
Page 1/2 Blank

Aug 17/84
SR-76-023
CHAPTER 54
NACELLES AND PYLONS
GENERAL
Specific repair procedures peculiar to nacelle/pylon

components are also included in this chapter.
Exterior surface material and corrosion damage limits

for Sabreliner nacelles and pylons are covered in this
chapter. (See table 1 for figure reference.)
Table

Surface Material and Corrosion Damage Limits Figure References,
MODEL
S/N EFF.
EXTERIOR
CORROSION
SURFACE
DAMAGE
MATERIAL
LIMITS
NA 285-40
All
Figure i
Figure
NA 265-40A
All
Figure
Figure
NA 285-60
All
Figure 1
Figure
NA 265-604\
All
Figure
Figure
NA 265-60SC
All
Figure
Figure
NA 265-65
All
Figure 2
Figure
NA 265-70
370-2 thru -6, -8, and -9
Figure
Figure
NA 285-70
370-7
Figure 3
Figure
NA 265-80
All
Figure
Figure
NA 265-80A
All
Figure
Figure
NA 265-80SC
All
Figure
Figure
54-00-00
o
COPYRIGHT,
Page 1
Aug 17/84
SR-76-023
ALUMINUM ALLOYS
E~
BONEYCOMB
LOWER VIEW
UPPER VIEW
setis-eaj1-a
Pylon and Nacelle Fabrication Material (JT-12 Engines)

Figure 1
54-00-00
Pag,
Aug 17/84
COPYRIGHT,
SR-76-023
LI
ALUMINUM ALLOY
E~l;
"~lon and Nacelle Fabrication Material (TFE 731 Engines)

Figure 2
54-00-00
Page 3
0
COPYRIGHT, 1984 B1
3~BRELINER
CORPORATION
Aug 17/84
SR-76-023
t~l
*LUMINUMALLOYS
CORROSION RESISTANT-BTEEL
I:-
i--:---:-
HoNevcoMe
/////X//////
/i/
:i
z
;/Lr
S285-2S54-~I
Pylon and Nacelle Fabrication Material (TF-700 Engines)

Fiffure 3
54-00-00
Page
Aug 17/84
COP~HIGHT, 1984
BY SABRELINER CORPc/;iATION
SR-76-023

1.
MIN
OF 2 IN. MUST SEPARATE CORROSION
DAMAGED AREAS.
2.
CORROSION
DAMAGE
ALONG
SPLICE
OR
10
FASTENERROWMUSTNOTINCLUDEMORETnAN
3.
MIN
OF 3 UNDAMAGED
/j L57
FASTENERS
O-
MUST

FASTENER ROWS.
3
18
14
14
7
o
~jr$
B
s
15
11
13
MAXIMUM
ITEM
NOiriENCiAViiRe
NO.
MATERIAL
dAOE
ALLOWABLE
CORROSION
DEPTH
PYLON L. E. SKIN
2024-T4 CLAD
0.040
0.008
PVLON UPPER FWD SKIN
7178-T8 EARE
0.050
0.002
PYLON t. E. SKIN
2924-742 CLAD
0.012
0.006
PYLON LOWER FWD SKIN
7178-78 BARE
0.100
0.002
NACELLE SKIN-LOWER FWD
7178-78 BARE
0.040
0.006
NACELLE SKIN
LOWER INtERM.
7178-T6 BARE
0.040
0.008
17-7 PH ORES
0.020
0.002
7
8
NACELLE SKIN
UPPER AFT
NACELLE SKIN LOWER AFT
1 NACELLE INBOARDSKIN
17-7 PH ORES
0.020
17-7 PH ORES
0.040
0.002
0.005
ill
iii
O
O
iii
[11
O
10
1 NACELLE SKIN
7176-76 BARE
0.040
0.006
11
I NACELLE NOSE
FWD OUTED
2024-74 BARE
0.040
0.003
12
NACELLE NOSE
FWD OUTED
6081-T3 BARE
0.040
0.004
13
NACELLE DOOR: FWD OUTED
11-7 PH CRES
0.020
0.002
NACELLE DOOR FWD INBD
17-7 PH CRES
0.020
0.002
lil
Iii
O
17-7 PH CRES
0.050
0.004
17-7 PH CRES
0.050
El
0.004
iii
UPPER
INTERM.
14
15
I ENOINESUPPORTBEAM-
18
1 ENOINESUPPORTBEAM-
OUTER SKIN
INNER SKIN
13
[11
NOTES
m
CHEM-MILLED PART
iii
EXCEED 2
SdUARE
IN.
szes-23-u-1
EXCEED 6 SQUARE IN.
Pylon and Nacelle Corrosion Damage Limits (JT-12 Engines)

Figure 4
54-00-00
Page 5
Aug 17/84
SR-76-023
Is
/6
,7
15
14
13
ri
UPPER SURFACE
S
L
i"
21
I1
/1
PYLON
11:
20
19
9
lo
11
NACELLE
22
12
27
28
?6
24
?5
23
LOWER SURFACE
32
31
30
29
MAXIMUM
ITEM
NOMENCLATURE
NO.
MATERIAL
GAGE
ALLOWABLE
CORROSION
DEPTH
NOSE COWL UPPER SKIN
2024-76 COS
UPPER COWL SKIN
2024-76 COS
AFt COWL UPPER SKIN
2024 OC
THRUST REVERSER UPPER DOOR SKIN
2024-76 COS
THRUST REVERSER LOWER DOOR SKIN
2024-76 COS
0.125
COVER, AFt COWL
2024 OC
0.050
AFT COWL LOWER SKIN
2024 OC
COVER, AFT COWL

COVER, AFt COWL
2024-73 C
0.050
0.063
0.125
0.025
0.050
2024-T3C
0.050
10
1 LOWER COWL DOOR SKIN
2024-76 COS
0.063
11
1 NOSE COWL LOWER SKIN
2024-76 COS
0.050
0.050
12
NOSE COWL L.E. SKIN
302/321 CRES
13
UPPER PVLON T.E. SKIN
2024-T42CLAD
14
UPPER PYLON SKIN
301 CRES
0.050
15
UPPER PVLON SKIN
301 CRES
0.050
16
UPPER PYLON SKIN
301 CRES
0.050
17
UPPER PYLON SKIN
2024-742 CLAD
0.050
18
PYLON L.E. SKIN
2024-742 CLAD
0.040
19
i DOOR ASSEMBLY
2024-742 CLAD
0.040
20
1 UPPER AFT ENGINE SUPPORT ACCESS DOOR
301 CRES
0.050
21
1 UPPER PYLONDOOR
301 CRES
0.050
2024-T42 CLAD
0.040
301 CRES
0.040
22
23
DOOR ASSEMBLY
1 LOWER AFT ENGINE SUPPORT ACCESS DOOR
0.025
0.040
24
LOWER PYLON DOOR
301 CRES
0.050
25
LOWER PYLON SKIN
301 CRES
0.050
28
LOWER PYLON DOOR
2024-742 CLAD
0.050
27
LOWER PYLON SKIN
2024-742 CLAD
0.050
28
LOWER PYLON DOOR
2024-742 CLAD
0.050
29
LOWER PYLON T.E. SKIN
2024-742 CLAD
0.040
30
LOWER PYLON SKIN
301 CRES
0.050
31
LOWER PYLON SKIN
301 CRES
0.050
32
1 LOWER PYLON SKIN
301 CRES
0.050
NOTE
O
CHEM-MILLED PART
Pylon and Nacelle Corrosion Damage Limits (TF

Figure 5
731
Engines)
54-00-00
PaRr
Aug 17/84
COPYRIGHT.
1984 BY SABRELINER CORPORATlOh
SR-76-023
078
1.
A MIN
DAMAGED AREAS.
2.
CORROSION
DAMAGE
ALONG
SPLICE
OR
FASTENER ROW MUST NOT INCLUDEMORETHAN

3.
10
1;

FASTENER ROWS.
11
MAXIMUM
ITEM
NOMENCLATURE
I(O.
MATERIAL
CAGE
ALLOWABLE
CORROSION
DEPTH
88
PYLON UPPER FWD SKIN
5AL-4V Ti
0.032
0.004
PYLON UPPER FWD DOOR
2024-73
0.050
0.005
PYLON UPPER SKIN
8AL-4V T1
0.050
0.005
PYLON UPPER AFT SKIN
2024-73 CLAD
0.050
0.005
PYLON T.E. SKIN
2024-73 CLAD
0.032
0.004
PYLON LOWER AFT SKIN
2024-73 CLAD
0.050
0.005
TRANSLATINGSTRUCTURE
2017-74 CLAD
0.025
0.003
AFT FAIRING SKIN
2017-74 CLAD
0.025
0.003
UPPER DOOR OUTER SKIN
2017-74 CLAD
0.025
0.025
2017-74 CLAD
0.025
0.003
8061-a BARE
0.050
0.005
5AL-4V T1
0.050
(il
lil
0.004 O
CRES STEEL
0.025
0.003
2017-74 CLAD
0.032
0.004 18
201 7-74 CLAD
0.032
0.003 O
OUTER SKIN
10
LOWER INNER DOOR OUTER
11
PYLON LEADING EDGE
12
1 PVLONLOWERFWDSKIN
SKIN
13
TRANSLATINGSTRUCTURE
14
1 LOWEROUTERDOOROUTER
INNER SKIN
SKIN
15
NOSE SECTION OUTER SKIN
Ii]
[il
lil
ill
ill
NOTES
P
CHEM-MILLED PART
INDIVIDUALCORROSION DAMAGEDAAEASMUSTNOT
EXCEEDZSQUAREIN.
EXCEEDGSQUAREIN.
slean3sJ-I
Pylon and Nacelle Corrosion Damage Limits (CF-700 Engines)

Figure 6
54-00-00
0
COPYRIGHT, 1984 t~Y SABRELINER CORPORATION
Page 7/8 Blank

Aug 17/84
SR-76-023
NACELLES AND PYLONS

REPAIR PROCEDURES
REPAIR PROCEDURES
Repair of Cooling Air Inlet Duct Finish

Fibreglass cooling air inlet ducts which exhibit evidence
of erosion, chipping or finish separation may be repaired
using the following procedure:
1.
Remove the existing finish from

damaged areas of the air inlet duct.
the
2.
Fill all
deeply eroded
using a slow
setting
epoxy resin.
:3.
Using fine grit

areas
or
chipped
emery cloth
of the air inlet duct.
or
areas
eroded/
4.
Wipe all surfaces of the air inlet duct with a clean

cloth moistened with methyl ethyl ketone (MEK).
5.
Mask surrounding
6.
Apply two coats of epoxy polyamide primer to

surfaces of air inlet duct. Allow 1-2 hours drying
time between coats.
7.
After final coat of epoxy polyamide primer has dried

for 3 hours, apply a final coating of polyurethane top coating. allow top coating to cure for a
minimum of 12 hours.
areas
not to be refinished.
paper, smooth all
GI
AIR
INLET DUCT
Cooling Air Inlet Duct Location

Figure 801
54-00-00
Page 801/802 Blank
COPYRIGHT, 1984 BY SABRELIN ER CORPORATION
Aug
CHAPTER
STABILIZERS
SR-76-023
COKIIOSI()N CONTROL MANUAL
CHAPTER 55
STABILIZERS
TABLE OF CONTENTS
Su
t,ject
(;eneral
Page
.55-00-00
55-CONTENTS
-~I
COPYRIGHT. 1984 B~ aABRELINER CORPORA;:S;J
Page 1/2 Blank

Aug 17/84
SR-76-023
CHAPTER 55
STABILIZERS
Chapterl
Section
Page
Date
Chapter Fj5-L.E.P.
1/2 Blank
Aug 17/84
Chapter.55-T.O.C.
1/2 Blank
Aug 17/84
1 thru 6
Aug 17/84
5.5-0(3-0(3
55-L.E.P.
e
COPYRIGHT. 1984 BY
SABRELINER
CORPORATION
SR-76-023
CHAPTER 55
STABILIZERS
GENERAL
Exterior surface material and corrosion damage limits
for Sabreliner stabilizers are covered in this chapter.
See figure 1 for exterior surface material.
Corrosion damage limits for horizontal stabilizers,

elevators, vertical stabilizers, and rudders are shown in
figures 2, 3, 4, and 5 respectively.
Refer to Chapter 20 for general
cleaning, sealing,
and
55-00-00
o
COPYRIGHT. 1984 BY SABRELINER CORPORATION
Page
Aug 17/84
SR-76-023
COKHOSION CONTROL MANUAL
HONEYCOMB
FIBREOLASS LAMINATES
ALUMINUM ALLOYS
ELEVATOR TRAILING
EDGE MAY BE HOLLOW
CORE OR HONEYCOMB CORE.
Figure
1
sesj-raas-l
55-00-00
Page
Aug t7/84
SR-76-023
CORROSION DAMAGE 1S LIMITED TO THE FOLLOWING:

1.

2.
3.
A MIN
NOTEXCEEDZSQUAREIN.
OF 2 IN.
MUST
SEPARAiE CORROSION
DAMAGED AREAS.
4.

5.

FASTENER ROWS.
TYPICALSABRELINER
HORIZONTAL STABILIZER
S26F~-e:(-R5-8
MAXIMUM
ITEM
NOMENCLATURE
NO.
MATERIAL
GAGE
ALLOWABLE
CORROSION
DEPTH
HORIZ STAB L.E. SKIN
2024-T3 BARE
0.032
HORIZ STAB UPPER SKIN
2024-T3 BARE
0.050
HORIZ STAB LOWER SKIN
2024-T3 BARE
0.050
2024-T3 BARE
0.050
0.002
2024-T3 BARE
0.050
0.002
(MODEL
THRU
0.002
0.(i02
0.002
NA 285-40, S/N 282-001
-090)
HORIZ STAB LOWER SKIN
(MODEL NA 285-40, S/N 282-091 and

suba, and MODEL NA 265-80 and -70)
HORlt STAB LOWER SKIN
(MODEL
NA 285-65 AND
-80)
NOTE
O
CHEM-MILLED PART
Horizontal Stabilizer Corrosion Damage Limits
Figure
55-00-00
0
COPYRIGHT,
Page 3
Aug 17/84
SR-76-023

1.
CORROSIONDAMAOE MUSTNOTEXCEED1O%OF
2.

NOT EXCEED 2SOUARE IN.
3.
A MIN
DAMAGED AREAS.
4.
CORROSION
DAMAGE
ALONG
SPLICE
OR
FASTENERROWMUSTNOTINCLUDEMORETHAN

5.
MIN
OF
UNDAMAGED
FASTENERS
MUST

FASTENER ROWS.
TYPICAL SABRELINER
ELEVATOR
sa;or::-a~-e
MAXIMUM
ITEM
MATERIAL
NOMENCLATURE
NO.
GAGE
ALLOWABLE
CORROSION
DEPTH
ELEVATOR L.E. SKIN
ELEVATOR SKIN
(UPPER
3
AND
1024-t42 BARE
0.050
2024-T3 BARE
0.032
2024-t3 BARE
0.010
0.002
0.002
LOWER)
ELEVATOR T.E. SKIN
0.002
NOTE
O
CHEM-MILLED PART
Elevator Corrosion Damage Limits

Figure 3
55-00-00
Page
Aug r7/84
COPYRIGHT, 1984 BY SABRELINER C~JnPORATION
SR-76-023
CORROSION DAMAGE IS
LIMITED TO THE FOLLOWING:
1.
A MINIMUM OF 2 INCHES MUST SEPARATE CORROSION-DAMAGED AREAS.
2.

OR FASTENER ROW MUST NOT INCLUDE
MORE THAN THREE FASTENE
DAMAGED AREA.
3.
A MINIMUM
3\
OF THREE UNDAMAGED
FASTENERS MUST SEPARATE CORROSION-DAMAGED AREAS ALONG
FASTENER ROWS.
sr~isrcr,a.:t
ITEM
NO.
NOMENCLATURE
MATERIAL
GAGE
MAXIMUM
ALLOWABLE
CORROSION
DEPTH
VERT STAB FILLET
6061-T4
0.032
VERT STAB SIDE SKINS
2024-T3 CLAD
0.083
VERf STAB L. E. SKIN
2024-T4 BARE
0.032
VERT STAB T. E. SKIN
2024-T3 BARE
0.010
0.010
[il
PERCENT
Op
AFFECTED
SURFACE
25
10
0.002
O
O
0.002
10
0.002
10
NOTES
m
CI-IEM-MILLED PART
EXCEED2SQUAREIN.
EXCEED4SQUAAEIN.
Vertical Stabilizer Corrosion Damage Limits
Figure
55-00-00
0
Page 5
Aug 17/84
SR-76-023
2,
I I
1.

2.
3.
NOT EXCEED 23QUARE IN.

MIN
OF 2 IN.
MUST SEPARATE CORROSION
DAMAGED AREAS.
4.
CORROSION
DAMAGE
ALONG
SPLICE
OR
FASTENER ROW MUST NOT ~NCLUDEMORETHAN

5.
MIN
OF 3 UNDAMAGED
FASTENERS
MUST

FASTENER ROWS.
SZRR-2:(-T,T,-J
MAXIMUM
ITEM
NO.
MATERIAL
NOMENCLATURE
GAGE
ALLOWABLE
CORROSION
DEPTH
0.002
RUDDCR L. E. SKIN
2024-73 CLAD
0.040
RUDDER SIDE SKINS
2024-73 CLAD
0.020
:.~iu2
0.032
0.002
RUDDER T. E. SKIN
2024-73 CLAD
0.010
0.002
RUDDER TRIM TAB SKIN
2024-73 CLAD
0.010
0.002
NOTES
MODEL NA 265-40, -40A, -60, -60A. AND -60SC
ill
MODEL NA 265-65. -70. -80. -80A. AND -80SC
Rudder Corrosion Damage Eimits
Figure
55-00-00
Page 6
Aug r7/84
CHAPTER
VVINGS
SR-76-023
CHAPTER 57
WINGS
TABLE OF CONTENTS
SLlhject
(;eneral
57-00-00
Wing Structure
57-10-00
Page
WingFuelDrainCavity
201
204
Wing Fuel Drain ValveSupports

WinKdoint Rib Assembly
COPYRIGHT, 1984 BY SABRELINER CORPURATION
57-CONTENTS
Page 1/2 Blank
Aug t7/84
SR-76-023
CHAPTER 57
WINGS
Chapter/
Page
Date
Chapter 57-L.E.P.
1/2 Blank
Aug 17/84
Ti7-T.O.C.
1/2 Blank
Aug 17/84
57-0()-00
1 thru 8
9/10 Blank
Aug 17/84
Aug 17/84
Fj7-10-00
201 thru 206
Aug 17/84
Section
Chapter
57-L.E.P.
0
COPYR IGn r, 1984 BY SABRELINER CORPORATION
Page 1/2 Blank

Aug 17/84
SR-76-023
CHAPTER 57
WINGS
GENERAL
This chapter provides exterior surface material, corrosion damage limits, and procedures for inspecting
specific areas of the Sabreliner wing.
Wing exterior surface material is shown
on
figure 1.
Corrosion damage limits for the wing structure, slats,

ailerons, and flaps are shown on figures 2, 3, 4, and 5
respectively.
57-00-00
o
COr,;ilGHT, 1984
Page 1
Aug 17/84
SR-76-023
ALUMINUM ALLOYS
IONEYCOM.
I~J
O
NOTES
s2sa-za-511
.L.PPLICABLE Tu nnODELS NA 265-40, -40A, -60, -70, AND -80
57-00-00
Wing Exterior Surface Material

Page
Aug 17/84
COPYRIGHT, 1984
SR-76-023
:I_-:1
ALUMINUM ALLOYS
HONEYCOMB
APPLICA8LE TO MODEL NA 265-60A, -60SC, -65, -80A, AND -80SC
Wing Exterior Surface Material

Figure 1 ~Sheet 2 of 2)
57-00-00
Page 3
0
Aug 17/84
SR-76-023
7~
Ip

i.
07~
CORROSIONDAMAGE MUSTNOTEXCEED1O%OF

o
2.
3.
A MIN
NOT EXCEED PSQVARE IN.
13
15 (TYP)
14
3
OF 2 IN.
MUST SEPARATE
CORROSION
DAMAGED AREAS.
14
CORROSION
4.
D
DAMAGE
ALONG
SPLICE
OR

5.
~a
ti
16
MIN
OF 3 UNDAMAGED
FASTENERS
MUST
1211
FASTENER ROWS.
OUTED
INED
ITEM
NO.
NOMENCLATURE
MATERIAL
GAGE
MAXIMUM
ALLOWABLE
CORROSION
DEPTH
WING SKIN
LOWER
2024-7531
PLATE
INBD 0;006
OUTED 0.003
WING SKIN
UPPER
7178-t851
PLATE
INBD 0.008
WING SKIN
7075-78 BARE
0.125
WING SKIN
PANEL WING
WING SKIN
INBD T.E. SKIN
8
8
OUTED 0.003
INBD L.E.
INBD T.E.
lD
0.008
7075-78 BARE
PLATE
0.003
7075-78 BARE
0.040
0.002
7075-78 CLAD
0.032
0.003
2024-74 CLAD
0.010
0.002
WING T.E. SKIN
2024-73 CLAD
0.080
0.003
WING T.E.
2024-73 CLAD
0.010
0.002
10
WING SKIN OUTED T.E.
2024-T42CLAD
0.040
11
WING OUTED T.E.
2024-73 CLAD
0.010
0.002
12
2024-T42CLAD
0.040
0.003
13
WING SKIN OUTED L.E.
2024-73 CLAD
0.083
14
WING L.E. SKIN
2024-73 BARE
0.083
15
WING L.E. SKIN DOOR
7075-78 CLAD
0.083
0.002
16
WING SKIN LOWER T.E.
2024-73 CLAD
0.020
0.003
17
WING SKIN
LOWER INBD T.E.
7075-78 CLAD
0.032
18
WING SKIN
LOWER
7075-78 BARE
0.071
INED T.E.
INBD T.E.
0.003
O.OOP
0.002
0.002
0.003
NOTE
P
CHEM-MILLED PART
APPLICABLE TO MODELS NA 265-40, -40A, -60, -70, AND -80

8265-23-572
Wing Structure Corrosion Damage Limits

Figure 2 (Sheetl of 2)
57-00-00
Page 4
Aug 17/84
COPYRIGHT,
SR-76-023
MAXIMUM
ALLOWABLE
ITEM
GAUGE
MATERIAL
NOMENCLATURE
CORROSION
NO.
DEPTH
WING SKIN
INBD
PLATE
2024-7531
LOWER
0.006
OUTED 0.003
WING SKIN
INBD
PLATE
7178-7651
UPPER
0.006
OUTED 0.003
3
WING SKIN
INBD L.E. TOP
7075-76 BARE
0.080
WING SKIN
INED T.E. INED,
7076-78 BARE
PLATE
0.003
FWD UPPER
5
SKIN, INBD, UPPER
2024-73 BARE
0.040
PANEL WING INBD T.E.
7075-76 BARE
0.040
FACE SHEET, UPPER
2024-73 CLAD
0.032
OVERWING FAIRING ASSY
LAMINATED
SPOILER, PANEL ASSY,
2024-7351
0.313
2024-742 CLAD
0.040
SKIN, UPPERSURFACE, EXTENDED
2024-73 CLAD
0.063
0.002
INBD AND OUTED

10
11
I
1
0.003
2024-73 CLAD
0.063
13
ACCESS DOOR
2024-73 CLAD
0.063
14
SKIN, LOWER
2024-73 BARE
0.040
FACESHEET,LOWER
2024-73 CLAD
0.032
SKIN, INBD, LOWER
2024-73 BARE
0.040
SKIN,L.E.LOWER
2024-T42-CLAD
INBD 0.068
SKIN, L.E.
2024-742 CLAD
12
15
SKIN,LOWERSURFACE.
16
17
EXTENDED
OUTED 0.063
18
INBD 0.068
OUTED 0.063
1.
CORROSION
DAMAGE
2
10
INED
MUST NOT EXCEED 10% OF
OUTED
11

2.

NOT EXCEED 2SQUARE IN.
3.
MIN
OF
IN.
MUST SEPARATE
CORROSION
DAMAGED AREAS.
4.
CORROSION
DAMAGE
ALONG
SPLICE
OR
18

5.
MIN
OF 3 UNDAMAGED FASTENERS MUST

CORROSION DAMAGED AREAS ALONG
FASTENER ROWS.
13
12
OUTED
14
IN~D
NOTE
1;
16
15
CHEM-MILLED PART
APPLICABLE TO MODEL NA 265-60A, -60SC, -65, -80A, AND -80SC
Wing Structure Corrosion Damage Limits

57-00-00
a
I"YRIGHT, 1984 BY SABRELINER CORPORATION
Page 5
Aug 17/84
SR-76-023

1.

2.
3.
A MIN
4.

FASTENER ROW MUST NOT INCLUDEMORETHAN
3.
NOTEXCEEDPSQUAREIN.

DAMAGED AREAS.
OR

SEPARATE CORROSION DAMAGED AR EAS ALONG
FASTENER ROWS.
TYPICAL SLAT
ITEM
NO.
NOMENCLATURE
MATERIAL
GAGE
MAXIMUM
ALLOWABLE
CORROSION
DEPTH
SLAT T.E. SKIN
2024-T3 CLAD
0.010
0.002
SLAT UPPER SKIN
2024-73 CLAD
0.040
0.002
SLAT LOWER SKIN
2024-T3 CLAD
0.040
0.002
Slat Corrosion
Damage Limits
Figure 3
526&29573
57-00-00
Page
Aug 17/84
COPYRIGHT.
1984 BY
SR-76-023

i.

2.
3.

MIN
DAMAGED AREAS.
CORROSION
4.
DAMAGE
ALONG
SPLICE
OR
FASTENER ROW MUST NOT INCLUDEMOREtHAN

5.
A MIN
OF 3 UNDAMAGED
FASTENERS
MUST
FAStENERROWS.
MAXIMUM
ITEM
MATERIAL
NOMENCLATURE
NO.
GAGE
ALLOWABLE
CORROSION
DEPTH
AILERON L.E.SKIN-INBD
2024-73CLAD
0.020
AILERON L.E. SKIN
7075-70 CLAD
0.090
0.002
AILERON TRIM TAB SKIN
2024-73 CLAD
0.010
0.002
AILERON SKIN
2024-73 CLAD
0.020
0.002
AILERON T.E. SKIN
2024-73 CLAD
0.010
0.002
AILERON SKIN
2024-73 CLAD
0.020
0.002
UPPER
LOWER
0.002
NOTE
O
CHEM-MILLED PART
AIltron Corrosion Damage Limits
Figure
S?65-2J-67-L
57-00-00
o
Page 7
Aug 17/84
SR-16-023

i.
CORROSION DAMAGE MUST NOt EXCEED 10% OF

2.

3.
MIN
OF 2 IN.
MUST SEPARATE
CORROSION
DAMAGED AREAS.
4.
CORROSION
DAMAGE
ALONG
SPLICE
OR
FASTENER ROW MUST NOT INCLUDEMORETnAN

5.
MIN
OF
3 UNDAMAGED
FASTENERS
MUST

FASTENER ROWS.
MAXIMUM
ITEM
NO.
NOMENCLATURE
MATERIAL
GAGE
ALLOWABLE
CORROSION
DEPTH
FLAP L.E. SKIN
7075-T881 BARE
0.250
FLAP UPPER SKIN
2024-73 CLAD
0.040
0.002
FLAP T.E. SKIN
2024-73 CLAD
0.010
0.002
FLAP LOWER SKIN
2024-T3 CLAD
0.010
11.002
0.002
NOTE
O
CHEM-MILLED PART
APPLICABLE TO MODELS NA 265-40,
-40A, -60, -70,
AND -80
S265-235i-5
Flap Corrosion Damage Limits

Figure 5 (Sheet r of 2)
57-00-00
Page 8
Aug 17/84
COPYRIGHT,
SR-76-023
CORROSION CONTROL MAWUAL
MAXIMUM
ITEM
NOMENCLATURE
NO.
MATERIAL
GAUGE
ALLOWABLE
CORROSION
DEPTH
0.040
FLAP L.E. SKIN
2024-142 CLAD
SKIN UPPER
2024-T3 CLAD
0.040
SKIN LOWER
2024-13 CLAD
0.040
SKIN, UPPER
2024-13 CLAD
0.063
SKIN, LOWER
2024-T3 CLAD
0.063

i.

2.
3.
NOTEXCEEDZSQUAREIN.
MIN
OF
IN.
MUST
SEPARATE
CORROSION
ALONG
SPLICE
DAMAGED AREAS.
4.
CORROSION
DAMAGE
OR

5.
MIN
OF 3
UNDAMAGED
FASTENERS
MUST

FASTENER ROWS.
APPLICABLE TO MODEL NA 265-60A, -60SC, -65, -80A, AND -80SC
Flap Corrosion Damage Limits

57-00-00
o
COPYRIGHT, 19~: SY SABRELINER CORPORATION
Page 9/10 Blank

Aug 17/84
SR-76-023
WING STRUCTURE
WING FUEL DRAIN CAVITIES
9.
The machined surfaces must be polished withabrasive paper, etched with Turco 5361 or equivalent,
and then examined for corrosion.
10.
After inspection is completed, and corrosion

removed, if required, wipe the cavity area with
toluol and remove any trace of primer. Dry with a
clean, dry cloth.
11~
Apply cleaning compound, Turco 4906, Cee Bee,

CBA-301 or equivalent, with a soft bristled brush or
swab, keeping the surface wet for 5 to 10 minutes.
Check the cavities of the fuel drain valves in the lower skin
as follows:
(see figure 201) for corrosion

1.
airplane in accordance with existing

instructions.(Refer to applicable Sabreliner MaintenDefuel the
ance
2.
3.
Manual
Chapter 28.)
Remove access covers necessaryto gain access to fuel

drain valves in LH and RH lower wing skins.
Remove ten fuel drain valves from LH and RH lower
wing surface.
4.
5.
6.
Inspectthe ten cavities for the fuel drain valves for

the presence of Cati-Coat primer (Cati-Coat primer
is "Buff~ in color same as inside of wing tank). If the
cavities are covered with Cati-Coat primer, no
further rework is required. Reinstall fuel drain
valves.
not covered with Cati-Coat
primer, inspect the following areas for corrosion:
Ihe area (land) where the "0" ring seal makes
contact with the wing skin, and the vertical sides of
both inner and outer holes for the fuel drain valves.
If the cavity
areas are
To precent damage to CA TI-COA Tprimer,

do not allow any cleaning materials to
contact the CATI-COATsurface inside the
wing.
12.
droplets) must be obtained. Repeat cleaning process,

if necessary, to obtain this condition.
on the land, remove corrosion

end mill or counterbore (2.125 to 2.188 in.
diameter with a 0.12.5 in. radius). The fuel drain
valve mounting hole in the drain valve support may
be used as a pilot for the cutting tool.
If corrosion exists
using
Wear rmbber gloves when mi~ing and using

solutions. Rags, sponges, swabs, etc., used
for applying chemicalfilm solutions must
not be allowed to dry. If allowed to dry, they
constitute afire hazard. Immediately after
use, they must be thoroughly rinsed in
water, then they may be reused or discarded
an
Cut enough material to entirely remove all corrosion

and leave a clean surface. Do not reduce the wing
skin thickness to less than 0.100 in.
A max of 0.015 in, of material may be removed
without adding a spacer. If the material removed
exceeds 0.015 in. it will be necessary to install a
spacer under the fuel drain fitting to make it flush
with the wing mold line. Remove 0.030 in. min
material if spacer is to be used.
7.
8.
Rinse thoroughly with tap water to completely

remove all cleaner. A water-break-free! surface (no
If corrosion exists on the vertical walls of the inner

hole, it may be removed by using a bearing scraper
or similar tool. It is not necessary to equally remove
material from all sides of the hole; however, the hole
may not be enlarged in any area to a point that would
result in an inadequate land for the drain valve "O"
ring seal.
13~
14.
Use Alodine Kit No. 22 (apply in accordance with

directions contained in kit) or mix 6 ounces by
weight of Iridite 14 and one fluid ounce of ARP No. 2
wetting agent and one gallon of water, or mix 3
ounces by weight of Alodine 1200 and 0.5 fluid
ounces of nitric acid with one gallon of water. Cost
the cleaned surface and keep wet from 3 to 5
minutes, then allow to dry.
Rinse the coated surface with water, but do not rub
brush, as the soft protective film will be damaged.
If there is Do visible film color, repeat step 12. Apply
Cati-Coat primer as indicated in Chapter 20.
or
The diameter of the inner hole may be enlarged

from the original diameter of 1:375 in. to a max of
1.625 in. The diameter of the outer hole may be
enlarged from the original diameter of 2.125 in, to a
max
of 2.188 in.
57-1 0-00
0
Page 201
Aug 17/84
SR-76-023
CORROSION CONTROL MAhrWAL
Wing Fuel Drain Cavities (Contd)

NOTE
All equipment usedfor application of CatiCoat Primer may be cleaned with a 50-50
mQture oftoluol and butyl alcohol.
15.
When Cati-Coat primer is dry and if

required, re-install drain valve.
no
spacer is
If spacer is required under drain valve to make it

flush with the wing mold line skin, proceed with the
following steps.
16.
Fabricate spacer
as
shown, apply Cati-Coat to
spacer.
NOTE
General PurpoSi Sealing Compound
is required to seal spacer.
17.
Applying SealingCompound:
A.
Wipe the surface to be sealed with a clean cloth

dampened with naphtha or equivalent solvent.
Before solvent has evaporated, wipe surface
withacleandrycloth.
B.
Mix the base sealing compond and accelerator

in the proportions recommended by the msnu-
facturer.
N~OTE
The sealing compound must be used within
S;hours after being mized or after removal
from cold storage,
18.
Usings clean wooden spatula or equivalent, apply a

thin coat of sealing compound on the wing skin and
spacer fayjng surface. Install spacer and apply a
srinall bead n the upper surface around the inner
l;oie as shown in figure 201.
19.
Reinstall drain valve while sealing compound is

to provide pressure of the spacer on the wing
skin to insure a fuel tight bond.
pliable
20.;..Air-dry..; sealing compound at room temperature

(approximately 770F) for 24 hours prior to refueling
airplane.
57-1 0-00
Pake
%02
.t~Auff 17/84
COPYRI~HT, 1984 BY SABRELINER CORPORATION
SR-76-023
VIEW LOOKING UP
WING FUEL DRAIN VALVES
LAND(REF)
INNERHOLE(REF)
WING SKIN
WING SKIN
INSPECT THIS AREA FOR CORROSION.
OUTER HOLE (REF)
(ENTIRE CIRCUMFERENCE)
If AREA IS COATED WITH CATI-COAT PRIMER,
NO REWORK RIQUIRED.
WING
SKIN1.825
MAXj/
WING SKIN
1.375REF
1_
.100 MIN
1~-1
2.125
(REF)
-I
2.188 MAX
MATEklALTWICKNESS
AFTER
CORkOS1ON
REMOJAL.
SEAL ENTIRE
CIRCUMFERENCE bF
FAYINO SURFACE USING

PRODUCTS RESEARCH
RADIUS TO MATCH
WING CAVITY.
SPACER
281223
WING SKIN
di~i;t
SEALING.COMPO;U~D,
SPACEROREQUIVALhNi
WING SKIN
SPACER THICKNESS AS REQUIRED

TO MAKE DRAIN VALVE NEAR FLUSH
WITH WING SKIN MOLD LINE
2.082
(.050 MIN)
szes-23-57a
NOTE
MAKE SPACER FROM ALUMINUM ALLOY 2024-T4
Wing Fuel Drain Cavities

Figure 201
57-t 0-00
Page
o
203
Aug 17/84
SR-76-023
C,i)RR()S~)N CONTROL MAN13AL

WING ~EL DBAIN VALVE SUPPORTS
Viaully~
the fuel drain valve supports
202~ :f6xidbrrcigion ~s.follows:
i~l;-.PTsmga $ediiner
2.
Remove
two
securing eac~i fuel drain valve
C.
Apply Cati-Coat primer

support. Refer
to
areas
of the
to fuel drain valve
"Application
of Cati-coat
Primer".
each fuel drain valve support for

of corrosion. If no corrosion is found and
Cati-Coat primer surfaces aielnbt damaged, reinstallfuel drain valve in wing, Torque fuel drain
valve support fasteners to 20-25 in. Ibs, If corrosion
is found and exceeds 0.010 in. depth, the fuel drain
valve support must be replaced.:lf corrosion is
found, and is less than 0.010 in, depth, proceed as
follows:
t~vide;ice
DRRIN
Brush cadmimum plate all bare

fuel drain valve support.
wing lower skin,
3."" 2fisqally examine
i;..7
B.
type wrench, unscre~v;the fuel
screws
to the
Using mechanical methods, remove all corrosion from the fuel drain valve support. Blend
reworked area to create a saucer shaped
depression. The finished blended area must not
exceed O.D10 in, depth.
(see figure
drain valve from the fuel drain val~ve L~pbrt. Refer

:Wing.Skin Drain Vslves" in Chapter 57 of
:;the!applicable maintenance manual.
-;:~;nr*
A.
D.
Reinstall fuel drain valve support fittings in
wings and
screws
E.
secure
in place. Torque
attaching
to 20-25 in.-lbs.
Reinstall fuel drain valves.
V~LVI
117-481005-11
e:
SP
Is^ll
Wing Fuel Drain Valve Support

Figure 202
SZB6-23-67-fi
?r;i
17;1 0-00
^PaE;e 804
Aug 17/84
COPYRIGHT,
1984 BY SABRELINER
CORPOAATION
88-76-023
CORROSION
6.
WING JOINT RIB ASSE~IBLY
Cutenough material tb entirely

a
possible ezplosions during

following procedures, make sure that
To prevent
the
all
airplane switches are at off or normally

maintained safe positions, and that all
sources of electrical power are removed
7.
Repair any wing joint

(See figure 203.)
follows:
Defuei the airplane in accordance with existing

instructions. (Refer to Sabreliner Maintenance
Manual Chapter 28.)
2.
Removeaccesscovers necessarytogain accesstotwo

fuel drain valves in LH and RH lower wing skins,
8.
9.
must be
and
"a.
After inspection is completed, Bnd~:corrosion

removed, if required, wipe the cavitS;1 area..-ith
with a
toluol and remove any trace of
1.:,.1...:
Apply cleaning dompound, Turco 4~306, Cee Pee,

CBA-301 or equivalent, with a soft bristled brush or
swab, keeping the surface wet for 5 to.O minutes.
To prevent damage to Cati-Coat primer, do

not allow any cleaning materials to contact
the cati-coat surface inside the wing.
Remove four fuel drain valves from LH and RH

lower wing surface next to wing joint rib assembly.
10.
nana
cleansur~ac;es
clean, dry cloth.

as
i.
/3.
The
clean surface.
paper, etched with Tu~cb 5361

then examiried for corrosion.
from airplane bus system.

rib assembly corrosion
(Continued):;r~i::.
Comply with necessary safety procedures

workinginsidefuel tanks.
Rinse thoroughly with tap water to completely

remove all cleaner. A water-break-free surface (no
nroplet,9) muat be obtained. Repeat cleaningprocess,
if necessary, to obtain this condition.
when
c~
NOTE
Corrosion
and
Wear rubber gloves when,
solutions. Ra~Fs, sponges swabs etc., used
for applying chemical film solutions must
not be allowed to dry. I;fallowed to dry they
constitute afire hazard. Immediately ~er
use, they must be thoroughly rinsed in
water, ULen theymay be reused or discarded
be detected if paint has

the metal surface is ezposed
can
bubbled up or
through the paint.
If corrosion is detected on the edge of the

flange (seefigure a03), corrosion should be
suspected on the bottom offlange. Wings
then must be separated and bottom wing
skins removed from joint rib assembly to
11.
check for corrosion,

4.
If corrosion
can
be repaired from the drain valve
holes, perform steps 6 through 12.

5.
If corrosion cannot be repaired from the drain valve

holes, the wings have to be separated for access.
Separate at the wing joint rib assembly. Refer to
applicable Sabreliner Maintenance Manual
Chapter 57.
minutes, then allow
(apply
to
or
dry.
NOTE
All equipment used for application of
Cati-Coat primer may be cleaned with a
50-50 mi~ure of toluol and butyl alcohol,
NOTE
Separate the wings on the side of the joint

rib that has to be repairedfm access.
in accordarice with
mix 6 ouncesby
weight of Iridite 14 or one fluid ounce of APR No. 2
wetting agent with one gallori, of water, or mix 3
ounces by weight of Alodinel200 and 0.5 fluid
ounces of nitric acid with, one gallon of water. Coat
the cleaned surface and keep wet from 3 to 5
Use Alodine Kit No.22
directions contained in kit)
12.
Ri nse the coated surface with water, but do not rub or

brush, as the soft protective film will be damaged. If
there is no visible film color, repeat step 10. Apply
Cati-Coat primer as indicated in Chapter 20.
5j-1 OC~c
COPYRIGHT, 1984 BY SABRELINER CORPORA~ION
:Page i05
Aug 17~84
SR76-023.
MANUA~L
SUSPECTED
AREAS FOR
CORROSION
(tVPICAL ON BOTH
SIDES OF RIB)
~TE\
SUSPECTED
CORROSION AREASARE INSPECTED

WITH A SMALL MIRROR-OR BORESCBPE THAU DRAIN:
VALVE HOLES
(4)
,s.151.
DRAIN VALVE
i$
C(10
HOLE (DRAIN
ALVE AND BRACKET
REMOVED).
~n
CORROSION
MUST NOT
EXCEED~/84
IN. DEPTH
01~ TOP OF
FLANaE
~-:IM SIDE OF CENTERLINE JOINT 16

:R:LIN iSHOWN,-RH
SIDEliyPICA~L
la
;r
DRAIN VALVE
HOLE (DRAIN
VALVE AND BRACKET
REMOVED),
IF CORROSION IS;SUSPECTED
ON:BOrrOM OFFLANOE, nr
MUST fjo~EXCGEbS133 IN1 ;:1
iN DEPiH ~/NG SKldS
IVIU9~::
:_
~ORROSION
WING SKIN
MUSTNOT
EXCEED 1/32
IN. DEPTH
ON EDaE OF
FLANtJE
i r
82B5-2-97-7
Win~ Joint Rib Assenbly Corrosion Repair

;203
0-00
P~ge ~(j6
Aug 17/84

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ATP Grid Index to Manufacturers Publications:

Corrosion Control Manual

Sources of Commercial Proucts

Magnesium Alloys Cleaning and Protective Treatments

Cleaning Copper and Copper Alloys

Service Information Letter No. 57

Sealing Integral Wing Fuel Tanks

Aircraft Technical Publishers

Sealing Electric Terminations with Overcoating

Cable and Kel-f Jacketed Coaxial Cable Terminations

Proofing flee Components/Strippable Sealant

Zinc Chromate Primer

Type Coatings Application

Aircraft Technical Publishers

Nickel-Zinc Alloy Plating

Repair and Refinishing

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Inflight Escape Hatch Removal, Inspection

Aircraft Technical Publishers

List of Effective Pages

Aircraft Technical Publishers

Report No. 8B-76-023

ALL MODELS NA 265 AIRCRAFT

ORIGINAL ISSUE: 31 OCT 1976

COPYRIGHT, 1991 BV SABRELINER CORPORATION

Mlnud Control Ile

COPYRIGHT, 1991 BY SABRELINER CORPORATION

RECORD OF TEMPORARY REVISIONS

MlnuJ Control Wo:

TEMPORARY REVISION LOG

COPYRIGHT, 1989 BY SABRELINER CORPORATION

Page 1/2 Blank

Insert the latest

pages. This ensures that

revised pages in accordance with the List of Effective Pages,

and destroy superseded

The asterisk indicates pages revised, added,

deleted by the current revision.

Page 1/2 Blank

CORROSION CONTROL ~HANUAL

The asterisk indicates chapters revised by the current revision.

COPVRIOHT, 1991 BY SABRELINER CORPORATION

Page 1/2 Blank

Subject Matter Identification

COPYRIGHT, 1984 BY SABRELINER CORPORATION

Page 1/2 Blank

COPYRIGHT, 1989 BY SABRELINER CORPORATION

Page 1/2 Blank

This manual contains maintenance oriented information

numbered within each subject

General Coverage and Description:

SUBJECT MATTER IDENTIFICATION

Subject matter is identified by a three element number as

functional breakdown utilized in Maintenance Manuals

(ATA) specification No.

If individual subtopics are so lengthy that a combination

This manual has been

Subject 30 Cleaning Titanium and Titanium