Nut Bolt Installation Practices

 Examine the markings on the bolt head to determine that each bolt is of the correct
material.
 It is of extreme importance to use like bolts in replacement.
 In every case, refer to the applicable Maintenance Instructions Manual and Illustrated
Parts Breakdown.
 Be sure that washers are used under both the heads of bolts and nuts unless their omission
is specified.
 A washer guards against mechanical damage to the material being bolted and prevents
corrosion of the structural members.
 An aluminium alloy washer should be used under the head and nut of a steel bolt securing
aluminium alloy or magnesium alloy members.
 Any corrosion that occurs then attacks the washer rather than the members.
 Steel washers should be used when joining steel members with steel bolts.
 Whenever possible, place the bolt with the head on top or in the forward position.
 This positioning tends to prevent the bolt from slipping out if the nut is accidentally lost.
 Be certain that the bolt grip length is correct.
 Grip length is the length of the unthreaded portion of the bolt shank.
 Generally speaking, the grip length should equal the thickness of the material being
bolted together.
 However, bolts of slightly greater grip length may be used if washers are placed under the
nut or the bolt head.
 In the case of plate nuts, add shims under the plate.

Safetying of Bolts and Nuts

 It is very important that all bolts or nuts, except the self locking type, be safetied after
installation.
 This prevents them from loosening in flight due to vibration.

Repair of Damaged Internal Threads

 Installation or replacement of bolts is simple when compared to the installation or
replacement of studs.
 Bolt heads and nuts are out in the open, whereas studs are installed into internal threads
in a casting or built up assembly.
 Damaged threads on bolts or nuts can be seen and only require replacement of the
defective part.
 If internal threads are damaged, two alternatives are apparent:
 The part may be replaced or the threads repaired or replaced.
 Correction of the thread problem is usually cheaper and more convenient.
 Two methods of repairing are by replacement bushings or helicoils.
Replacement Bushings
 Bushings are usually special material (for example, steel or brass spark plug bushings
into aluminium cylinder heads).
 A material that will resist wear is used where removal and replacement is frequent.
 The external threads on the bushing are usually coarse.
 The bushing is installed, a thread lock compound may or may not be used, and staked to
prevent loosening.
 Many bushings have left hand threads external and right-hand threads internal.
 With this installation, removal of the bolt or stud (right hand threads) tends to tighten the
bushing.
 Bushings for common installations, such as spark plugs, may be up to 0.040 oversize (in
increments of 0.005).
 Original installation and overhaul shop replacements are shrunk fit: consisting of a
heated cylinder head and a frozen bushing.
Helicoils
 Helicoils are precision formed screw thread coils of 18-8 stainless steel wire having a
diamond shaped cross section. (Figure 5-63)
 They form unified coarse or unified fine thread classes 2-band when assembled into
(helicoil) threaded holes.
 The assembled insert accommodates (controlled radius root) male threaded members.
 Each insert has a driving tang with a notch to facilitate removal of the tang after the
insert is screwed into a helicoil tapped hole.
 They are used as screw thread bushings.
 In addition to being used to restore damaged threads, they are used in the original design
of missiles, aircraft engines, and all types of mechanical equipment and accessories.
 They protect and strengthen tapped threads in light materials, metals, and plastics,
particularly in locations which require frequent assembly and disassembly or where a
screw locking action is desired.
 Helicoil installation is a 5 or 6 step operation, depending upon how the last step is
classed. (Figure 5-64)
 Step 1: Determine what threads are damaged.
 Step 2: (a) New installation of helicoil-
 Drill out damaged threads to minimum depth specified.
 (b) Previously installed helicoil-
 Using proper size extracting tool, place edge of blade in 90° from the edge of the insert.
 Tap with hammer to seat tool.
 Turn to left, applying pressure, until insert backs out.
 Threads are not damaged if insert is properly removed.
 Step 3: Tap-
 Use the tap of required nominal thread size.
 The tapping procedure is the same as standard thread tapping.
 Tap length must be equal to or exceed the requirement.
 Step 4: Gauge-
 Threads may be checked with a helicoil thread gauge.
 Step 5: Insert assembly-
 Using proper tool, install insert to a depth that puts end of top coil ¼ to ½ turn below the
top surface of the tapped hole.
 Step 6: Tang breakoff-
 Select proper breakoff tool.
 Tangs should be removed from all drilled through holes.
 In blind holes, the tangs may be removed when necessary if enough hole depth is
provided below the tang of the installed insert.
 These are not to be considered specific instructions on helicoil installation.
 The manufacturer's instruction must be followed when making an installation.
 Helicoils are available for the following threads:
 Unified coarse, unified fine, metric, spark plug, and national taper pipe threads.
Cotter Pin Hole Line Up
 When tightening castellated nuts on bolts, the cotter pin holes may not line up with the
slots in the nuts for the range of recommended values.
 Except in cases of highly stressed engine parts, the nut may not be over torque.
 Remove hardware and realign the holes.
 The torque loads specified may be used for all unlubricated cadmium-plated steel nuts of
the fine or coarse thread series which have approximately equal number of threads and
equal face bearing areas.
 These values do not apply where special torque requirements are specified in the
maintenance manual.
 If the head end, rather than the nut, must be turned in the tightening operation, maximum
torque values may be increased by an amount equal to shank friction, provided the latter is
first measured by a torque wrench.
Hole Repair and Hole Repair Hardware
 Many of the blind fasteners are manufactured in oversized diameters to accommodate
slightly enlarged holes resulting from drilling out the original fastener.
 When using rivets or even bolts, care must be taken to ensure the hole is not elongated or
slanted.
 To reduce the chances of an incorrectly drilled rivet or bolt hole, use a slightly smaller
drill bit first, then enlarge to the correct diameter.
 The last step to prepare the hole for the fastener is to deburr the hole using either a very
large drill bit or a special deburring tool.
 This practice also works well when drilling out a previously attached fastener.
 If the drill bit does not exactly find the center of the rivet or bolt or screw, the hole can
easily be elongated.
 But when using a smaller drill bit, drill the head only off the fastener, then the ring and
stem that is left can be pushed out with a pin punch of the appropriate diameter.
 If an incorrectly drilled hole is found, the options are to redrill the hole to the next larger
diameter for an acceptable fastener or repair the hole using an Acres fastener sleeve.

Acres Fastener Sleeves

 Acres fastener sleeves are thin-wall tubular elements with a flared end.
 The sleeves are installed in holes to accept standard bolts and rivet-type fasteners.
 The existing fastener holes are drilled 1/64-inch oversize for installation of the sleeves.
 The sleeves are manufactured in 1-inch increments.
 Along their length, grooves provide a place to break or cut off excess length to match
fastener grip range.
 The grooves also provide a place to hold adhesive or sealing agents when bonding the
sleeve into the hole.

Advantages and Limitations

 The sleeves are used in holes which must be drilled 1/64 inch oversize to clean up
corrosion or other damage.
 The oversize hole with the sleeve installed allows the use of the original diameter
fastener in the repaired hole.
 The sleeves can be used in areas of high galvanic corrosion where the corrosion must be
confined to a readily replaceable part.
 Oversizing of holes reduces the net cross-sectional area of a part and should not be done
unless absolutely required.
 Consult the manufacturer of the aircraft, aircraft engine or aircraft component prior to
repair of damaged holes with Acres sleeves.

Identification
 The sleeve is identified by a standard code number which represents the type and style of
sleeve, a material code, the fastener shank diameter, surface finish code letter and grip
tang for the sleeve.
 The type and material of the sleeve is represented by the basic code number.
 The first dash number represents the diameter of the sleeve for the fastener installed and
the second dash represents the grip length of the sleeve.
 The required length of the sleeve is determined on installation and the excess is broken
off of the sleeve.
 A part number e.g. JK5512A-05N-10 is represent as-
 JK5512 –(Basic part Number) 100° low profile head sleeve.
 A- Material code (A,B,C) A-5052 aluminium alloy ½ hard, 6061 aluminium alloy (T6
Condition) and C-A286 Stainless Steel.
 05- Fastener shank diameter in 32nds (5/32 inch)
 N-Surface finish (N,C) N- no surface finish and C- Chemical film per MIL-C-554
  10- Length in sixteenth-inch increments (5/8 inch in length) e.i. required installation
length by breaking of at proper groove.

Hole Preparation
 Refer to table (Hole preparation) for drill number for standard or close fit holes.
 Inspect hole after drilling to assure all corrosion is removed before installing the sleeve.
 The hole must also be the correct shape and free from burrs.
 The countersink must be enlarged to receive the flare of the sleeve so the sleeve is flush with
the surrounding surface.
Hole Preparation for 1/64 Oversize Bolt
Bolt Size Drill No Drill Dia
13/64 7/32 0.2187
17/64 9/32 0.2812
21/64 11/32 0.3437
25/64 13/32 0.4062

Hole Preparation
Bolt Standard Fit Close Fit
Drill Drill Dia Drill Drill Dia
Size No No
1/8 9/64 0.1406 28 0.1405
#6 23 0.1540 24 0.1520
5/32 11/64 0.1719 18 0.1695
#8 15 0.1800 16 0.1770
#10 5 0.2055 6 0.2040
¼ 14 0.2660 17/64 0.2656
5/16 21/64 0.3281
3/8 25/64 0.3908

Installation
 Drill out corrosion or damage to existing hole to 1/64 inch oversize.
 Select proper type and length acres sleeve for existing fastener.
 After selecting the correct type and diameter sleeve, use the 6501 sleeve break off tool
for final installation length.
 Refer to Figure 5-68 for the sleeve break off procedure.
 The sleeve may be installed with or without being bonded in the hole.
 When bonding the sleeve in a hole, use MIL-S-8802A½ sealant.
 Reinstall original size fastener and torque as required.
Sleeve Removal
 Sleeves not bonded in the hole may be removed by either driving them out with a drift
pin of the same diameter as the outside diameter of the sleeve or they may be deformed
and removed with a pointed tool.
 Bonded sleeves may be removed by this method, but care should be used not to damage
the structure hole.
 If this method cannot be used, drill the sleeves out with a drill 0.004 to 0.008 inch
smaller than the installation drill size.
 The remaining portion of the sleeve after drilling can be removed using a pointed tool
and applying an adhesive solvent to the sealant.

Questions

1. A washer guards against mechanical damage to the material being bolted and prevents
corrosion of the structural members.
2. An aluminium alloy washer should be used under the head and nut of a steel bolt
securing aluminium alloy or magnesium alloy members.
3. Steel washers should be used when joining steel members with steel bolts.
4. Grip length is the length of the unthreaded portion of the bolt shank.
5. The grip length should equal the thickness of the material being bolted together.
6. Bolts of slightly greater grip length may be used if washers are placed under the nut or
the bolt head.
7. Safetying of Bolts and Nuts prevents them from loosening in flight due to vibration.
8. Installation or replacement of bolts is simple when compared to the installation or
replacement of studs.
9. If internal threads are damaged, two alternatives are apparent:
10. Many bushings have left hand threads external and right-hand threads internal.
11. Bushings for common installations, such as spark plugs, may be up to 0.040 oversize (in
increments of 0.005).
12. Helicoils are precision formed screw thread coils of 18-8 stainless steel wire having a
diamond shaped cross section.
13. Helicoils form unified coarse or unified fine thread classes 2-band when assembled into
(helicoil) threaded holes.
14. Each insert has a driving tang with a notch to facilitate removal of the tang after the
insert is screwed into a helicoil tapped hole.
15. Helicoils are used as screw thread bushings.
16. Helicoil installation is a 5 or 6 step operation, depending upon how the last step is
classed.
17. Acres fastener sleeves are thin-wall tubular elements with a flared end.
18. Acres fastener sleeves are installed in holes to accept standard bolts and rivet-type
fasteners.
19. The existing fastener holes are drilled 1/64-inch oversize for installation of the sleeves.
20. The sleeves are manufactured in 1-inch increments.
21. Along Acres fastener sleeves length, grooves provide a place to break or cut off excess
length to match fastener grip range.
22. The oversize hole with the sleeve installed allows the use of the original diameter
fastener in the repaired hole.
23. The sleeves can be used in areas of high galvanic corrosion where the corrosion must be
confined to a readily replaceable part.
24. Over sizing of holes reduces the net cross-sectional area of a part and should not be done
unless absolutely required.
25. The first dash number represents the diameter of the sleeve for the fastener installed and
the second dash represents the grip length of the sleeve.
26. In a part number of acres sleeve e.g. JK5512A-05N-10 ; 05 is represent as-Fastener
shank diameter 5/32 inch.
27. In a part number of acres sleeve e.g. JK5512A-05N-10 ; 10 is represent as-Length 5/8
inch.
28. For Installation of acres sleeve drill out corrosion or damage to existing hole to 1/64 inch
oversize.
29. Sleeves not bonded in the hole may be removed by either driving them out with a drift
pin of the same diameter as the outside diameter of the sleeve.
30. Bonded sleeves may be removed by drilling the sleeves out with a drill 0.004 to 0.008
inch smaller than the installation drill size.