206-srm-01-s05

BHT-206-SRM-1

TABLE OF CONTENTS

Paragraph Page Number Title Number

SECTION 5 SHEET METAL STRUCTURE REPAIRS

FORWARD FUSELAGE

5-1 Forward Fuselage ............................................................................................... 5-15-1-1 Controls Tunnel Side Web Repair ................................................................. 5-25-1-2 Controls Tunnel Vertical Stiffeners Repair..................................................... 5-115-1-3 Addition of Access Panel to Lower Web of Roof Box Beam.......................... 5-125-1-4 Forward Engine Attachment .......................................................................... 5-15

AFT FUSELAGE

5-2 Aft Fuselage........................................................................................................ 5-15-2-1 Crosstube Support Structure (206A/B Series)............................................... 5-395-2-2 Engine Pan .................................................................................................... 5-505-2-3 Longeron Assembly (206A/B and L Series)................................................... 5-515-2-4 Engine Mount Half-frame Splice/Replacement F.S. 142.0 (206A/B Series).. 5-565-2-5 Typical Splice of Aft Fuselage Skin (206A/B and L Series) ........................... 5-56F

TAILBOOM

5-3 Tailboom ............................................................................................................. 5-15-3-1 Tailboom Skin (206A/B and L Series)............................................................ 5-56J5-3-2 Tailboom Driveshaft Support (206A/B and L Series)..................................... 5-72

FAIRINGS, COWLINGS, AND COWL SUPPORTS

5-4 Fairings, Cowlings, and Cowl Supports .............................................................. Not Assigned

ECCN EAR99 14 DEC 2010 Rev. 2 i/ii

BHT-206-SRM-1

SECTION 5 REPAIRS TO SHEET METAL STRUCTURE

INTRODUCTION

This section covers the repair of sheet metal structures to the helicopter.

5-1. FORWARD FUSELAGEIncludes nose section and instrument console, crew seat bulkhead assembly and vertical controlstunnel, roof beam, passenger seat bulkhead and engine mounts.

5-2. AFT FUSELAGEIncludes aft fuselage skins, aft fuselage bulkheads and frames, firewalls and engine pan, and longeron,stiffeners, and fittings.

5-3. TAILBOOMIncludes tailboom skins and horizontal stabilizers.

5-4. FAIRINGS, COWLINGS, AND COWL SUPPORTSNo assigned at this time.

ECCN EAR99 14 DEC 2010 Rev. 2 5-1

5-1-1. CONTROLS TUNNEL SIDE WEB REPAIR,206A/B SERIES.

APPLICATION A. Repair of side web damaged beyond limits stated in Section 3-6, 206A/BSeries. For repair of 206L series, refer to application B.

RESTRICTIONS.

Any section of web can be replaced; however, web cut line to be located betweenW.L. 37.0 and W.L. 59.3..

2. Repair doubler not to interfere with stiffening beads in web.

3. If accomplished in conjunction with a vertical stiffener angle splice repair, angle andweb cut lines must be separated by 3.0 inches minimum.

4. Damaged parts which serve to locate control system pivot points must be replaced.

5. Only one splice is allowed per side.

1.0 REQUIRED.

1.1 Web, refer to applicable IPC for correct part number.

1.2 Doubler (1) , using material per Bell Standard 150-021-IOB(W)-(L).

1 .3 Fasteners: MS20470AD4 rivets, grip length to suit.

USE OR DISCLOSURE OF DATA CONTAINED ON THIS PAGE IS SUBJECT5-2 TO THE RESTRICTIONS ON THE TITLE PAGE OF THIS DOCUMENT.

BHT-206-SRM-1 FAA APPROVED

NO REPAIR ALLOWEDIN SHADED AREAS.

FAA APPROVED BHT-206-SRM-1

1.4 Adhesive (item S317).1.5 Sealant (item S392).1.6 Epoxy polyamide primer (item S204).1 .7 Process sheets. Cleaning (refer para. 3-2-5)

Bonding (refer para. 3-2-7)

2.0 PROCEDURE

2.1 Gain access to damaged area. Retain items removed for later installation. Recordtype, size and locations of fasteners removed.

NOTESOME CONTROL TUBES MAY HAVE TO BE REMOVED AND RETAINED TOALLOW ACCESS.

2.2. Cut out damaged portion of web as shown on figure 1.

CAUTIONPROTECT STIFFENERS OR OTHER PARTS OF CONTROLS TUNNELFROM DAMAGE WHEN CUTTING WEB.

2.3 Deburr sharp edges, remove debris and loose material.

2.4 Prepare new web section dimensioned as portion of web removed.

2.5. Prepare splice doubler(1), dimensioned as shown on figure 1.2.6. Locate new web, splie doubler(1). Transfer existing rivet pattern and drill new

fastener holes as shown in figure 1. Maintain proper edge distance and spacing.

2.7. Remove parts, deburr all holes and remove debris.

2.8 Secure new web using fasteners specified in 1 .3 and figure 1, grip length to suit.

NOTEDO NOT INSTALL FASTENERS COMMON TO SPLICE DOUBLER

2.9 Clean repair area in preparation for bonding.

2.10 Locate and bond doubler(1) in position using bonding adhesive specified in 1.4.2.11 Secure doubler(1) using fasteners specified in 1.3 and figure 1, grip length to suit.

NOTEINSTALL FASTENERS WHILE ADHESIVE IS WET.

2.12 Remove excess adhesive squeeze-out.

USE OR DISCLOSURE OF DATA CONTAINED ON THIS PAGE IS SUBJECTTO THE RESTRICTIONS ON THE TITLE PAGE OF THIS DOCUMENT. 5-3

2.14

2.15

2.16

2.17



2.13 Allow to cure at room temperature for 24 hours applying a pressure of 0.5 to 1.0 psito doubler (1).Prime all bare metal surfaces using material specified in 1 .6. Allow to dry.

Seal all edges of repair area using material specified in 1 .5.

Inspect for voids and unbonded area(s).Re-finish as required.

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REPAIR 5-1-1 APPLICATION A FLGURE 1SHEET 1 OF 1


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8.0 INCHES

5-1-1. CONTROLS TUNNEL SIDE WEB REPAIR,206L SERIES.

APPLICATION B. Repair of damaged side web beyond limits stated in Section 3-6, 206L Series.

RESTRICTIONS.

1. Any section of web can be replaced. However, web cut line to be located betwenW.L. 37.0 and W.L. 61.0

2. If accomplished in conjunction with a vertical stiffener angle splice repair, angle andweb cut lines must be separated by 3.0 inches minimum.

3. Damaged parts which serve to locate control system pivot points must be replaced.

4. Only one splice is allowed per side.

1.0 REQUIRED.

1 .1 Web, using Al. Alloy, 2024T3, QQ-A-250/5, 0.025 inch thick.

1.2 Splice doubler (1), using material 150-021-1OB(W)-(L).1 .3 Fasteners: M7885/2-4 rivets, grip length to suit.

MS20470 AD4/AD5 rivets, grip length to suit.


1.4 Sealant (item S392).1.5 Epoxy polyamide primer (item S204).1.6 Adhesive (item S31 7).1 .7 Process sheets. Cleaning (para. 3-2-5)

Bonding (para. 3-2-7)2.0 PROCEDURE.

2.1 Gain access to damaged area. Retain items removed for later installation. Recordtype, size and locations of fasteners removed.

NOTESOME CONTROL TUBES MAY HAVE TO BE REMOVED ANDRETAINED TO ALLOW ACCESS.

2.2. Cut out damaged portion of web as shown on figure 1.

CAUTIONPROTECT STIFFENERS OR OTHER PARTS OF CONTROLS TUNNELFROM DAMAGE WHEN CUTTING WEB.

23 Deburr sharp edges, remove debris and loose material.

2.4 Prepare new web section dimensionned as portion of web removed.

2.5. Prepare splice doubler(1), dimensioned as shown on figure 1.2.6. Locate new web, splice doubler(1). Transfer existing rivet pattern and drill new

fastener holes as shown in figure 1. Maintain proper edge distance and spacing.

2.7. Remove parts, deburr all holes and remove debris.

2.8 Secure new web using fasteners specified in 1 .3 and figure 2, grip length to suit.

NOTEDO NOT INSTALL FASTENERS COMMON TO SPLICE DOUBLER


2.10 Locate and bond doubler(1) in position using bonding adhesive specified in 1.6.2.11 Secure doubler(1) using fasteners specified in 1.3 and figure 2, grip length to suit.


2.1 2 Remove excess adhesive squeeze-out.



2.13 Allow to cure at room. temperature for 24 hours applying a pressure of 0.5 to 1.0 psito doubler (1).

2.14 Prime all bare metal surfaces using material specified in 1.5. Allow to dry.

2.1 5 Seal all edges of repair area using material specified in 1 .4.

2.16 Inspect for voids and unbonded area(s).2.17 Re-finish as required.


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REPAIR 5-1-1 APPLICATION B

SECTION

EXISTINGSTRUCTURE REF

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5-10USE OR DISCLOSURE OF DATA CONTAINED ON THIS PAGE IS SUBJECT

TO THE RESTRICTIONS ON THE TITLE PAGE OF THIS DOCUMENT.

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RIVETS

STIFFENER REF


5-1-2.

NO REPAIR ALLOWEDIN SHADED AREAS

CONTROLS TUNNEL VERTICAL STIFFENERS REPAIR,206A/B AND L SERIES.

APPLICATION. Repair of vertical stiffener/stiffener angles.

RESTRICTIONS.

1. Repair may be accomplished on a case by case basis by request to Product SupportEngineering (PSE). FAA DER approval is required to accomplish this repair.

NOTEIN MOST CASES DAMAGE IS LOCATED IN A CURVED SECTIONOFSTIFFENER MAKING REPAIR IMPOSSIBLE. IT IS THENPREFERABLE TO REPLACE THE ENTIRE PART.

2. If accomplished in conjunction with a side web splice repair(or if already exist),stiffener angle and web cut lines must be separated by 3.0 inches minimum.

1.0 REQUIRED.

As provided through Product Support Engineering (PSE).2.0 PROCEDURE.

As provided through Product Support Engineering (PSE).


8.0 INCHES


5-1-3. ADDITION OF ACCESS PANEL TO LOWER WEB OF ROOF BOX BEAM, 206A1BSERIES.

APPLICATION. Provides access to interior of beam for strap or transmission support fittingreplacement.

NOTEFOR INSTRUCTIONS ON STRAP REPLACEMENT, REFER TOALERT SERVICE BULLETIN (ASB) 206-01-74-2 DATED 1974,206A/B SERIES.

RESTRICTIONS.

1. Damage may not be associated with any accident or incident that resulted in roof or

1 .0 REQUIRED

beam damage.

CAUTIONTHE TOTAL MAIN BEAM ASSEMBLY IS UNSERVICEABLE IF ANYPART IS DEFORMED OR DAMAGED IN ACCIDENT. ALL PARTS OFBEAM SHOULD BE SCRAPPED.

1.1 Cover (1), using 2024-T3 Aluminum Alloy, 0.025 inch thick, qty 2.1.2 Fasteners: M7885/2-4 rivets, grip length to suit




1 .3 Epoxy polyamide primer(item S204).1 .4 Sealant (Item S392).

2.0 PROCEDURE.

2.1 Gain access to working area, and remove control tubes from beam.

2.2. Cut out and remove required portions of skin. Shape cutout as shown on figure 1.Deburr edges of cutout.

2.3 Prepare cover(s), qty 2 dimensioned to extend a minimum of 0.60 in. beyond skincutouts and as shown on figure 1.

2.4 Locate covers in position and drill for new fasteners specified in 1 .2 using fastenerspattern shown on figure 1. Maintain proper edge distance and spacing.

2.5 Prime all bare metal surfaces using material specified in 1 .3. Allow to dry.

2.6 Install cover using fasteners specified in 1 .2.

2.7 Seal all edges of repair area using material specified in 1 .4.

2.8 Re-finish as required.


REPAIR

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FAA APPROVED BHT-206-SRM- 1

APPLICATION A. Repair of Channel Cracks in Area of Forward Engine Mount Attachment,206A1B Series.

For repair of cracks in the upper flange bend radius of engine mount support channel 206-03 1-302, 206B Series.

RESTRICTIONS.

1. Maximum of two cracks per channel, limited to one crack at either or both mounthole locations (R & LBL 8.5), refer to table 1 for crack length. No damage allowedto other areas of channel.

2. There must be a minimum of 0.080 inch thick of engine mount shim available oncracked side of bulkhead to accomodate installation of doubler repair.

3. Damage is not as a result of an accident or incident. No otherengine pan allowed.

4. Original drivetrain alignment must be maintained.

damage to roof skin or


5-1-4. FORWARD ENGINE ATTACHMENT, 206A/B SERIES.

BHT-206-SRM-1 REVISION 1 FAA APPROVED

5. When accomplishing repair to only one side, install fitting 206-031-629-103 onopposite side to preclude cracking. Omit doubler repair on good side and adjustlength of shear fasteners to compensate for reduced material thickness.

NOTEIF ANY ONE OF THE CONDITIONS STATED ABOVE IS EXCEEDED,CHANNEL MUST BE REPLACED USING A BELL HELICOPTERAPPROVED FUSELAGE FIXTURE.

1.0 REQUIRED.

1.1 Stiffener, 206-031-201-291, qty 2.

1.2 Fitting, 206-031-629-103, qty 2.

1.3 AngIe, 206-031-302-086(RHS), -085(LHS).1.4 Tube assembly, 206-031-333-139, qty 1.

1.5 Shim, 120-062-1, qty 1.

1.6 Doubler(1), using 301 Corrosion resistant steel (Cres) per MIL-S-5059, 1/2 hard,0.063 inch thick.

1.7 Filler(2) using 7075-T6 Aluminum alloy per QQ-A-250/1 2, .070 inch thick.1.8 Fasteners: MS2061 5-4MP rivet, grip length to suit.

MS2061 5-5MP rivet, grip length to suit.100-048-5-4 pin, qty 6.30-0 1 5-5 collar, qty 6.AN96OC1OL washer, qty 6.

1.9 Hardware: NAS1 44A-() bolt, grip length to suit(refer to table 1), qty 2.MS17825-4 nut, qty 2.MS20002C4 washer, qty 2.MS24665-153 cotter pin, qty 2.

1.10 Adhesive, (item S317)1.11 Sealant, general purpose (item S392).1.12 Epoxy polyamide primer, (item S204).1.13 Sealant, firewall (item S308).1 .14 Process sheets: Cleaning (refer to para. 3-2-5)

Bonding (refer to para. 3-2-7)


FAA APPROVED REVISION 1 BHT-206-SRM-1

2.0 PROCEDURE

2.1 Remove engine assembly. Gain access to damage area recording type, size andlocation of fasteners removed. Remove and discard existing clips, angle and stiffenerincluding bonded radius block. See figures 1 through 6.

2.2 Measure and record shim thicknesses (including taper if applicable). Remove shimsand save for future installation.

2.3 Dye penetrant inspect damage areas to determine extent of cracks.

TABLE 1, (206A1B)MAX. ALLOWABLE CRACK LENGTH (IN.)

LHS RHS

Inboard Outboard Inboard Outboard

1.15 1.20 1.40 1.90

2.4 Cut out and remove damaged portions of channel and frame containing the cracks.Cutouts to be rectangular in shape with 0.38 in. corner radii and cutlines betweenexisting fasteners as shown on figures 2 and 5.

NOTECUT LINE MUST BE AT LEAST 0.10 INCH PAST CRACK END.

2.5 Deburr cutout, remove debris and loose material.

2.6 Dye penetrant inspect area to ensure that cracks have been completely removed.

2.7 Prepare doubler (1) dimensioned as shown on figures 1 and 2 (3 and 4). Ensureminimum edge distance of 0.38 in. with existing rivets.

2.8 Prepare filler (2) dimensioned to match portion removed nested as shown on figures1 and 2 (3 and 4).

2.9 Locate doubler (1), angle and filler (2) in position and drill for existing fasteners,maintaining proper edge distance and spacing.

2.10 Transfer rivet locations from holes left open by removal of angle in existing structureto doubler (1).

2.11 Remove all parts, deburr all sharp edges, remove debris and loose material.

2.12 Remove paint, dirt and primer from repair area and clean in preparation for bonding.

2.13 Locate and bond doubler (1), filler (2), and angle in position using general purposeadhesive.

USE OR DISCLOSURE OF DATA CONTAINED ON THIS PAGE IS SUBJECTTO THE RESTRICTIONS ON THE TITLE PAGE OF THIS DOCUMENT. 517

BHT-206-SRM-1 REVISION I FAA APPROVED

2.14 Secure doubler (1), filler (2) and angle using existing type fasteners as shown onfigures 1 and 2 (3 and 4), grip length to suit.



2.16 Allow to cure at room temperature for 24 hours applying a pressure of 0.5 to 1.0 psito repair area.

2.17 Inspect for voids and unbonded area(s).2.18 Locate stiffeners in position and center to engine mount and fastener holes. Ensure

proper edge distances and transfer existing holes in structure to stiffeners.

2.19 Remove stiffeners, deburr all holes, remove debris and loose material.

2.20 Locate stiffener and engine mount fittings centered to and up against stiffener andfwd face of channel.

2.21 Transfer engine mount attachment holes to fittings.

2.22 Remove fittings, deburr all holes, remove debris and loose material.

2.23 Clamp engine mount fittings to underside of stiffeners using engine mountattachment hardware. Torque bolts to 50 to 70 in. lbs. Drill for new holes in channel,frame and fittings P/N 206-031-629-1 03, dimensioned as shown in figures 5 and 6.


2.25 Secure stiffeners and engine mount fittings using rivets and shear fasteners as shownon figures 1, 2 and 5 (3, 4 and 6), rivet grip length to suit.

NOTEINSTALL STIFFENERS AND FITTINGS WITH FAYING SURFACESWET WITH SEALANT.

GRIP LENGTH OF SHEAR FASTENERS MAY BE ADJUSTED USINGA MAXIMUM OF TWO WASHERS INSTALLED UNDER COLLAR. DONOT FRACTURE COLLAR NUTS AT THIS POINT.

2.26 If required, prepare shims dimensioned to fit between ears of stiffeners and enginemount fittings.

2.27 Apply final torque to Hi-Lok fasteners.

2.28 Seal forward face of bulkhead area.

2.29 Reinstall all remaining parts removed.



2.30 Reduce shims resting on the surface of the doubler by an amount equal to thethickness of the material added by the installation of the doubler.

2.31 Locate and bond shims in position using bonding adhesive specified in 1.10.

2.32 Allow to cure at room temperature for 24 hours applying a pressure of 0.5 to 1.0 psito shims.

2.33 Inspect for unbonded area(s).2.34 Seal surface of doubler in engine pan with firewall sealant specified in 1 .13. Reinstall

engine mount legs using hardware hsted in 16. Torque bolts 50 to 70 inch-pounds.

NOTETHE FOLLOWING ARE RECOMMENDED BOLT GRIP LENGTHSFOR VARIOUS MATERIAL THICKNESS:

NAS144A-13 0.3125-14 0.3750-15 0.4375-16 0.5000-17 0.5625


2.36 Seal all edges of repair. Reprime sealant.



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5-1 -4. FORWARD ENGINE ATTACHMENT, 206L SERIES.

APPLICATION B. Repair of Channel Cracks in Area of Forward Engine Mount Attachment, 206 LSeries.

For repair of cracks in the upper flange bend radius of engine mount support channel 206-033-302, 206L Series.

RESTRICTIONS.

1. Maximum of two cracks per channel, limited to one crack at either or both mount holelocations (R & LBL 8.5), refer to table 2 for crack length. No damage allowed to otherareas of channel.

2. There must be a minimum of 0.080 inch thick of engine mount shim available on crackedside of bulkhead to accomodate installation of doubler repair.

3. Damage is not as a result of an accident or incident. No other damage to roof skin orengine pan allowed.

4. When accomplishing repair to only one side, install fitting 206-031-629-1 03 on oppositeside to preclude cracking. Omit doubler repair on good side and adjust length of shearfasteners to compensate for reduced material thickness.

5. Original drivetrain alignment must be maintained.



IF ANY ONE OF THE CONDITIONS STATED ABOVE IS EXCEEDED,CHANNEL MUST BE REPLACED USING A BELL HELICOPTERAPPROVED FUSELAGE FIXTURE.

1.0 REQUIRED.

1.1 Stiffener, 206-033-201-1 67, qty 2.

1.2 Fitting, 206-031-629-103, qty2.

1.3 Angles, 206-033-302-040(RHS), -039(LHS).1.4 Shim, 120-062-1, qty 1.

1 .5 Doubler(1), using 301 Corrosion resistant steel (Cres) per MIL-S-5059, 1/2 hard, 0.063inch thick.

1 .6 FilIer(2) using 7075-T6 Aluminum alloy per QQ-A-250/1 2, .070 inch thick.1.7 Fasteners: MS2061 5-4MP, MS2061 5-5MP and MS2061 5-6MP rivets, grip

length to suit.HL64PB6-4 pin and HL87-6 collar, qty 2.AN96OC1OL washer, qty 2.100-048-5-4 pin and 30-015-5 collar, qty 6.AN96OCO8L washer, qty 6.

1.8 Hardware: NAS1 44A-() bolt, grip length to suit(refer to table 2), qty 2.MS1 78 25-4 nut, qty 2.MS20002C4 washer, qty 2.MS24665-1 53 cotter pin, qty 2.

1.9 Adhesive, (item S317)1.10 Sealant, general purpose (item S392).1.11 Epoxy polyamide primer, (item S204).1.12 Sealant, firewall (item S308).1 .13 Process sheets: Cleaning (refer to para. 3-2-5)

Bonding (refer to para. 3-2-7)2.0 PROCEDURE

2.1 Remove engine assembly. Gain access to damage area recording type, size andlocation of fasteners removed. Remove and discard existing clips, angle and stiffener.Remove and retain filler block and skin filler. See figures 1 through 6.

2.2 Measure and record shim thicknesses (including taper if applicable). Remove shims andsave for later installation.



2.3 Dye penetrant inspect damage areas to determine extent of cracks.

2.4 Cut out and remove damaged portions of channel and frame containing the cracks.Cutouts to be rectangular in shape with 0.38 in. corner radii and cutlines betweenexisting fasteners as shown on figures 2 and 5.

TABLE 2, (206L series)MAX. ALLOWABLE CRACK LENGTH (IN.)

LHS RHS

Inboard Outboard Inboard Outboard

1.10 1.00 1.90 1.70

2.5 Deburr cutout, remove debris and loose material.

2.6 Dye penetrant inspect area to ensure that cracks have been completely removed.

2.7 Prepare doubler (1) dimensioned as shown on figures 1 and 2 (3 and 4). Ensureminimum edge distance of 0.38 in. with existing rivets.

2.8 Prepare filler (2) dimensioned to match portion removed nested as shown on figures 1and 2 (3 and 4).

2.9 Locate doubler (1), angle, and filler (2) in position and drill for existing fasteners,maintaining proper edge distance and spacing.

2.10 Transfer rivet locations from holes left open by removal of angle in existing structure todoubler (1).

2.11 Remove all parts, deburr all sharp edges, remove debris and loose material.


2.13 Locate and bond doubler (1), filler (2) and clip in position using general purposeadhesive.

2.14 Secure doubler (1), filler (2) and angle using existing type fasteners as shown onfigures 1 and 2 (3 and 4), grip length to suit.



2.16 Allow to cure at room temperature for 24 hours applying a pressure of 0.5 to 1.0 psi torepair area.

2.17 Inspect for voids and unbonded area(s).



2.18 Locate stiffeners and filler block in position and center to engine mount and fastenerholes. Ensure proper edge distances and transfer existing holes in structure tostiff eners.

2.19 Remove stiffeners and filler block, deburr all holes, remove debris and loose material.

2.20 Locate stiffener, filler block and engine mount fittings P/N 206-031-629-103 centeredto and up against stiffener and fwd face of channel.

2.21 Transfer engine mount attachment holes to fittings.


2.23 Clamp engine mount fittings to underside of stiffeners using engine mount attachmenthardware. Torque bolts to 50 to 70 in. lbs. Drill for new holes in channel, frame andfittings P/N 206-031-629-1 03, dimensioned as shown in figures 5 and 6.


2.25 Secure stiffeners, filler block and engine mount fittings using rivets and shear fastenersas shown on figures 1, 2 and 5 (3, 4 and 6), rivet grip length to suit.

NOTEINSTALL STIFFENERS AND FITTINGS WITH FAYING SURFACES WETWITH SEALANT.

GRIP LENGTH OF SHEAR FASTENERS MAY BE ADJUSTED USING AMAXIMUM OF TWO WASHERS INSTALLED UNDER COLLAR. DONOT FRACTURE COLLAR NUTS AT THIS POINT.

2.26 If required, prepare shims dimensioned to fit between ears of stiffeners and enginemount fittings.

2.27 Apply final torque Hi-Lok fasteners.

2.28 Seal forward face of bulkhead. Reprime sealant.

2.29 Reinstall all remaining parts removed.

2.30 Reduce shims resting on the surface of the doubler by an amount equal to thethickness of the material added by the installation of the doubler.

2.31 Locate and bond shims in position using bonding adhesive specified in 1 .9.

2.32 Allow to cure at room temperature for 24 hours applying a pressure of .5 to 1.0 psi toshims.

2.33 Inspect for unbonded area(s).2.34 Seal surface of doubler in engine pan with firewall sealant specified in 1 .12. Reinstall

engine mount legs using hardware listed in 1.8. Torque bolts 50 to 70 inch-pounds.



NOTETHE FOLLOWING ARE RECOMMENDED BOLT GRIP LENGTHSFOR VARIOUS MATERIAL THICKNESS:

NAS144A-13 0.3125-14 0.3750-15 0.4375-16 0.5000-17 0.5625

2.35 Prime all bare metal surfaces and allow to dry.

2.36 Seal all edges of repair. Reprime sealant.




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ui

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RIGHT HAND SIDE

-U I 11 0 C) Cr, -

FASTENERS

EXISTING RIVETS

+

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5-2-1. CROSSTUBE SUPPORT STRUCTURE, 206 A/B SERIES.

APPLICATION A. Repair cracks in, or reinforce aft crosstube support structure, F.S. 125.0,206A1B Series.

RESTRICTIONS.

1. Limited to cracks in flange and web of support at LBL & RBL 13.5, crack to becontained within a 1 .0 inch diameter as shown on figure 1.

2. Fuselage support required (Appendix B).

1.0 REQUIRED.

1.1 Support (1), refer to applicable IPB for correct part number (if required).1.2 Doubler (2) using Bell standard 1 50-021-1OB(W)-(L). As an alternate, cut doubler

section from purchased support frame, refer to applicable IPB for correct part number.

1 .3 Fasteners: M20470AD4 rivets, grip length to suit.

1.4 Bonding adhesives (Item S317).1.5 Epoxy polyamide primer (Item S204).



1.6 Sealant (Item S392).1 .7 Process sheets. Preparation for bonding (refer to para. 3-2-3)

Bonding of flat stock (refer to para. 3-2-7)2.0 PROCEDURE. (Repair accomplished on LH side, RH is mirror image)

2.1 Gain access to damage area. Remove and retain all items in repair area recordingtype, size and location of fasteners removed.

2.2 Remove paint, dirt and primer from repair area.

2.3 Dye penetrant inspect damage area for cracks. Stop drill all cracks using a # 40 drill.Carry out dye penetrant inspection again to ensure proper position of stop drill.

2.4 Dye penetrant inspect existing supports for cracks, if any cracks are found, discardsupport.

2.5 Deburr all holes and edge of crack, remove debris and loose material.

2.6 Prepare doublers (2), dimensioned to pick up a minimum of 2 rows of rivets on eachside of damaged area as shown on figure 1, to be nested inside of existing frame asshown on sections A-A.

2.7 Locate doubters (2) and (if required) supports (1) in position. Drill for new fastenersspecified in 1.3 using fasteners pattern shown on figure 1, maintaining proper edgedistance and spacing Transfer existing fastener holes same size as original

2.8 Remove all part(s), deburr all holes and remove all debris and loosematerial.


2.10 Locate and bond doublers (2) and (if required) supports (1) in position using bondingadhesive specified in 1 .4.

2.11 Secure doublers (2) and (if required) supports (1) using fasteners specified in 1.3 innew rivet locations, grip length to suit and using original type and size fasteners inoriginal locations, grip lenght to suit.



2.13 Allow to cure at room temperature for 24 hours applying a pressure of 0.5 to 1.0 psito all parts.

2.14 Inspect for voids and unbonded area(s).2.15 Prime all bare metal surfaces using material specified in 1.5. Allow to dry.


FAA APPROVED REVISION i BHT-206-SRM-1

2.16 Seal all edges of repair area using material specified in 1 .6.





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5-2-1. CROSSTUBE SUPPORT STRUCTURE, 206 A/B SERIES.

APPLICATION B. Repair cracks in, or reinforce aft crosstube support structure, F.S. 1 30.0,206A/B Series.

RESTRICTIONS.

1. Limited to cracks in flange and web of support at LBL & RBL 1 2.5, crack to becontain in a 1 .0 inch diameter as show.n on figure 1.

2. Fuselage support required(Appendix B).

1 .0 REQUIRED

1.1 Doublers (1) using section of purchased support, refer to applicable IPC for correctpart number.

1.2 Shims (2) using Bell standard 150-021-2A(W)-(L). As an alternate use flat section ofpurchased support in 1 .1.

1 .3 Stiffeners (3), refer to applicable IPC for correct part number.1 .4 Fasteners: MS2O47OAD-4 rivets, grip length to suit.

1.5 Bonding adhesive (Item S317).




1.5 Bonding adhesive (Item S317).1.6 Epoxy polyamide primer (Item S204).1.7 Sealant (Item S308).1 .8 Process sheets. Preparation for bonding (refer para. 3-2-5)

Bonding (refer para. 3-2-7).

2.0 PROCEDURE (Repair accomplished on LH side, RH side is mirror image).2.1 Gain access to damage area recording type, size and location of fasteners removed.

Remove existing support fittings and cracked stiffeners recording type, size andlocation of fasteners removed. Discard damaged stiffeners. See figure 1.

2.2 Remove paint, dirt and primer from repair area.

2.3 Dye penetrant inspect damage areas for cracks. Stop drill all cracks using a #40 drillat both ends. Carry out dye penetrant inspection again to ensure proper position ofstop drill.

2.4 Remove all parts, deburr all sharp edges and edge of crack. Remove debris and loosematerial.

2.5 Prepare doubler (1), dimensioned to be nested outside of existing frame and asshown on figUre 1. Ensure minimum edge distance of 0.38 in. with existing rivets.Break sharp corners.

2.6 Prepare shim (2), dimensioned as shown on figure 1. Break sharp corners.2.7 Locate doubler (1), shim (2) and stiffener (3) in position. Drill for new fasteners

specified in 1 .4 using fasteners pattern shown on figure 1, maintaining proper edgedistance and spacing. Transfer existing rivet holes same size as original.

2.8 Remove all parts, deburr all holes and remove debris and loose material.


NOTEDO NOT USE METHYL-ETHYL-KETONE (MEK) ON FIBERGLASS.

2.10 Locate and bond shim (2), doubler (1), stiffener (3) and support fittings in positionusing bonding adhesive specified in 1 .5.

2.11 Secure using fasteners specified in 1.4 and figure 1, grip length to suit.





2.13 Allow to cure at room temperature for 24 hours applying a pressure of0.5 to 1 .0 psi to all parts.

2.14 Inspect for voids and unbonded areas.


2.16 Seal all edges of repair area using material specified in 1.7.



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5-2-2. ENGINE PAN.

APPLICATION. Repairs to engine pan.

1.0. PROCEDURE. All conditions of repair section 3-7 apply for repair of the engine pan.



206A1BSERIES AND

2061

2061-1 ,L-3,L-4

FAA APPROVED BHT-206-SRM- 1

5-2-3. LONGERON ASSEMBLY, 206A/B AND L SERIES.

APPLICATION. Splice repair of lower attachment fitting/ longeron assembly, 206A/B and Lseries. Tailboom attachment fitting replacement.

RESTRICTIONS.

1. Fitting and Iongeron are a bonded assembly and may not be separated from eachother.

2. Replaced Iongeron assembly fitting face must be in-plane with three other fittingswithin 0.002 inch.

3. Maximum permissible gap between replaced longeron assembly fitting and cantedframe 206-031-308 or 206-032-308 web is 0.003 inch.

4. Only one longeron assembly may be removed and replaced at a time.

5. Splice repairs to different longeron assembly should not be in the bay.

6. Most aft cutline to be located as per figure 1.

1.0 REQUIRED.

1.1 Longeron assembly, refer to applicable IPC for correct part number.


UBHT 206 SRM-1 FAA APPROVED

1 .2 Splice angle, using 7075-T6 aluminum alloy per QQ-A-250/1 2, 0.07 1 inch thick.

1.3 Tailboom drill plate (AppendixB).1.4 Bonding adhesive (item S317)1 .5 Fasteners: MS20470AD4 rivets, grip length to suit.

Hi-Lok pins 1 00-048-6-()Collars 30-01 5-6.

1 .6 Sealant (item S392)1 .7 Epoxy polyamide primer (Item S204).1 .8 Process sheets. Cleaning (refer to para. 3-2-5)

Bonding (refer to para.3-2-7).2.0 PROCEDURE.

2.1 Gain access to damage; Record type, size and location of fasteners removed. Seefigure detail A.

2.2 Cut out longeron as shown on detail A. Remove and discard damaged section oflongeron assembly. Deburr sharp edges from remaining section of longeron.

CAUTIONDO NOT DAMAGE SKIN OR WEB IN CONTACT WITH LONGERON

2.3 Secure tailboom drill plate to three undisturbed tailboom attachment fittings. Tightenbolts 50 to 70 inch pounds.

2.4 Prepare new longeron assembly to match section removed.

2.5 Locate and clamp new longeron assembly against mating structure. Install a 10-32high strength bolt through pilot hole in fitting and secure to drill plate. Tighten nut40 inch pounds. Loosen clamps attaching longeron to structure and tighten nut 50to 70 inch pounds. Tighten clamps.

2.6 Locate spice angle in position, transfer existing rivet pattern on structure to newlongeron assembly and splice angle.

2.7 Remove parts, deburr holes and remove loose material.




2.9 Locate and bond longeron assembly and splice angle in position using bondingadhesive specified in 1 .4.

NOTEINSTALL RIVETS WHILE ADHESIVE IS WET.

Remove excess adhesive squeeze-out.

Allow to cure at room temperature for 24 hours applying a pressure of 0.5 to 1 .0 psito splice angle.

Inspect for voids and unbonded area(s).Prime all bare metal surfaces using material specified in 1 .7. Allow to dry.


With drill plate installed, locate, drill and ream fitting 0.376 to 0.378 inch diameter.Remove drill plate and deburr hole.

Prime all bare metal surfaces using material specified in 1 .7. Allow to dry.


Refinish as required.

2.10

2.11

2.12

2.13

2.14

2.15

2.16

2.17

2.18


BHT-206-SRM-1

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EXISTING

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EXTERIOR SKIN NOT SHOWN FOR CLARITY

TYP FOR A/B AND L

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EXISTING

RIVETS

MS20470AD4 RIVETS AT ORIGINAL LOCATIONS

NOTE: H S

PLICE ANGLE TO EXTEND A MINIMUM OF 4

RIVETS FWD AND AFT OF LONGERON CUTLINE.


BL RBL0.00 10.125

_______

REF MAX

LHSVIEW LKG FWD

MOUNT HALF FRAME REPLACEMENT F.S. 142.0, 206A/B.

Replacement of alignment critical engine mount attachment frame as a spliced sectionto minimize effect on powertrain alignment; F.S. 142, 206 A/B.

1. Accomplished one half frame replacement at a time. Full frame replacement requires use ofa Bell Helicopter approved fuselage fixture.

2. Drivetrain alignment must be maintained.

3. Frame cutline to be located between RBL 10.125 and LBL 10.125 and halfway between anylightening hole(Maintaining proper edge distance) refer to figure 1.

1.0 REQUIRED.

1 .1 Replacement frame, purchased: refer to applicable Illustrated Parts Catalogue for correct partnumber.

1 .2 Doubler (2): using Al Alloy 7075-T6, QQ-A-250/1 2, 0.032 inch thick.1.3 Angles (3,4): using unused portion of frame in 1.1 or removed portion of existing frame.1 .4 Shims (5): using At Alloy 2024-T3, QQ-A-250/4, 0.025 inch thick, qty 2.1 .5 Fasteners: MS20470AD4 rivets, grip length to suit.


LBL10. 125MAX

LIMIT FORFRAME CUTLINE

LIMIT FORFRAME CUTLINE

5.2.4. ENGINE

APPLICATION.

RESTRICTIONS.


1.6 Bonding adhesive (item S317).1.7 Primer, epoxy polyamide (item S204).1 .8 Sealant (item S392)1 .9 Process sheets: Cleaning (refer to para. 3-2-5)

Bonding (refer to para. 3-2-7)

2.0 PROCEDURE. (refer to FIGURE 1)

2.1 Gain access to frame. Record type and size of fasteners removed. Also remove stiffeners (asrequired).

2.2 Cut out frame as shown and retain damaged portion of frame. Deburr.

2.3 Prepare replacement frame, dimensioned to replace portion of frame removed. Ensure minimumedge distance with existing rivets.

NOTE

RETAIN UNUSED PORTION OF PURCHASED FRAME TO FABRICATE ANGLES(3,4).

2.4 Prepare doubler (2) dimensioned as shown. Ensure minimum edge distance of 0.38 in. withexisting rivets.

2.5 Prepare angles (3,4), cut from purchased frame (or section of frame removed in 2.2) and shims(5), dimensioned as shown.

2.6 Locate replacement frame, doubler (2), angles (3,4) and shims (5) in position. Drill for newfasteners specified in 1 .5 to pattern shown. Maintain proper edge distance and spacing.Transfer existing fasteners holes same size as original.

2.7 Remove all parts, deburr all holes, remove debris and loose material.

NOTE

DO NOT BOND FRAME TO EXISTING STRUCTURE.

2.8 Clean repair area, doubler (2), angles (3,4), and shims (5) in preparation for bonding.2.9 Locate and bond new frame, doubler (2), angles (3,4) and shims (5) in position using general

purpose adhesive.

2.10 Secure all parts using fasteners specified in 1.5, grip length to suit.

NOTE

INSTALL FASTENERS WHILE ADHESIVE IS WET.


2.12 Apply a pressure of 0.5 to 1 .0 psi to doubter (2) and angles (3,4). Allow adhesive to cure at

USE OR DISCLOSURE OF DATA CONTAINED ON THIS PAGE IS SUBJECTTO THE RESTRICTIONS ON THE TITLE PAGE OF THIS DOCUMENT. 5-56A


room temperature for 24 hours.

2.13 Inspect for voids and unbonded area(s). Voids shall not exceed 10% of total bonded area. Noone void shall exceed 0.25 square inch.

2.14 Prime all bare metal surfaces and allow to dry. Seal all edges of repair area. Reprime sealant.


NOTEMODEL 206A/B PRIOR TO SIN 2310 MUST ACCOMPLISH ENGINEMOUNT FITTING REPLACEMENT IN ACCORDANCE WITH T.B.206-79-29.

USE OR DISCLOSURE OF DATA CONTAINED ON THIS PAGE IS SUBJECT5-56B TO THE RESTRICTIONS ON THE TITLE PAGE OF THIS DOCUMENT.

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REPAIR 5.2.4ENGINE MOUNT HALF-FRAME REPLACEMENT


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5-3-1 TAILBOOM SKIN, 206A/B AND L SERIES.

APPLICATION A. General repair criteria.

RESTRICTIONS.

1. Scratch, as defined by fluorescent penetrant inspection method, shall not exceed 10percent of skin thickness after cleanup and one sixth circumference of the localtailboom station in length, if angle exceeds 45 degrees angle to the longitudinal axis.If scratch is less than 45 degrees angle to longitudinal axis, Length shall be limited to50 percent of the length between hanger supports.

2. Longitudinal waviness, of skin surface measured with straight edge offset 0.100 inchfrom surface may not exceed the following values.

MODEL.

LONGITUDINAL WAVINESS

0.060 INCH MAXIMUMTOTAL WAVINESS

ALLOWED BETWEENSTATIONS:

0.090 INCH MAXIMUMTOTAL WAVINESS

ALLOWED BETWEENSTATIONS:

206A/B SERIES 42.6 & 80.8 88.4 & 163.6

206L SERIES 42.6 & 79.8 98.9 & 174.1

USE OR DISCLOSURE OF DATA CONTAINED ON THIS PAGE IS SUBJECTTO THE RESTRICTIONS ON THE TITLE PAGE OF THIS DOCUMENT. 5-56J15-56K

______ RESTRICTED AREA2061 SERIES


3. Dents, smooth to a maximumare considered negligible.

diameter of 1 .25 inches and of the following depths

MODEL/BOOM STATION QUADRANT/MAXIMUM DEPTH

206A/B SERIES 206L SERIES LOWER RH LOWER LH TOP TWO

31.92-42.59 31 .92-42.59 0.00542.59-55.00 42.59-61.29 NO DENT ALLOWED 0.005

55.00-80.00 61.29-79.82 NO DENT ALLOWED 0.010

80.00-136.0 79.82-146.1 0.010 0.020

136.0-163.0 146.1-174.1 0.020 0.030

4. Corrosion, to a maximum depth of 10 percent of skin thickness (0.004 inch in thecase of a single skin and 0.008 inch in aft doubler area, 206L series only) aftercleanup for 10 percent cicumference and 4 inches in length. Corrosion areas must beseparated by a minimum of eight inches. No more than two such damages allowedin one boom station. Repair corrosion damage per paragraph 3-8.

5. Total area of all combined damages (1 thru 4) shall not exceed 160.0 square inches.6. Creases, creasing of skin is not allowed Under any circumstances.

ANGLE OF SCRATCH EXCEEDS 45

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A

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EXISTING RIVETS

FWD

5-3-'j TAILBOOM SKIN, 206A/8 ANDAPPLICATION B. Fretting damage to front of tailboomand L series.

RESTRICTIONS

1. Maximum dimensions of damage from BS 31.92 after0.020 inch deep.

clean-up is 3.0 inch long by

Damage may affect One or both sides of tailboom between Stations 31.92 and34.82.

1.1 Doublers (1,2), Using Bell Standard l5O-02118s(w)(L) As an alternate 301 cressteel MIL-S5059 1/2 hard, 0.025 inch thick may be used.

Bonding adhesive (item S31 7).MS20470AD4 rivets, grip length to suit, orMS2O615Mp4 rivets, grip length to suit (for

BHT 206 SRM 1 FAA APPROVED

L SERIES.

caused by T/R driveshaft Cover, 206A/B

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121 3 Fasteners

alternate doubler)1 4 Sealant (Item S392)1 5 Epoxy polyamide primer (item S204)

USE OR DISCLOSURE OF DATA CONTAINED ON THIS PAGE IS SUBJECT5 58 TO THE RESTRICTIONS ON THE TITLE PAGE OF THIS DOCUMENT

2.

1.0 REQUIRED.


1 .6 Process sheets: Cleaning (refer to para 3-2-5)Bonding (refer to para 3-2-7)

2.0 PROCEDURE.

2.1 Remove tailboom and place on a support.

2.2 Gain access to damage area recording type, size and location of fasteners removed.See figure 1.

2.3 Blend damage. Remove minimum amount of material.

2.4 Fill blended area(s) with adhesive and allow to cure for 24 hours at roomtemperature. Sand adhesive to contour of tailboom.

2.5 Prepare doublers (1) and(2) dimensioned to overlap blended out areas a minimum of1 .50 inches as shown on figure 1. Roll doubler to match contour of tailboom.

2.6 Locate d.oubler (1) and(2) in position and drill for new fasteners specified in 1 .3 usingfasteners pattern shown on figure 1. Maintain proper edge distance and spacing.Transfer existing fasteners holes same size as originals.

NOTEDO NOT DRILL INTO INTERCOSTAL SUPPORTS LOCATED BELOW THE SKIN INTHIS AREA.

2.7 Remove doublers, deburr holes, remove debris and loose material.

2.8 Remove paint, dirt and primer and clean repair areas in preparation for bonding.

2.9 Locate and bond doubler (1) and(2) in position using bonding adhesive specified in1.2.

2.10 Secure doubler (1) and(2) using fasteners specified in 1.3 and figure 1, grip length tosuit.


2.1 1 Remove excess adhesive squeeze-out.

2.1 2 Allow to cure at room temperature for 24 hours applying a pressure of 0.5 to 1 .0 psito doublers (1,2).

2.13 Inspect for voids and unbonded area(s).2.14 Prime all bare metal surfaces using material specified in 1.5. Allow to dry.


2.16 Refinish as required.



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SPLICE RIVET PATTERN.

FWD VIEW LKG DOWN


TAILBOOM SKIN, 206A/B SERIES.

APPLICATION D. Tailboom skin splice repair; upper and lower, 206A/B series.

RESTRICTIONS.

1. Not applicable to 206L series tailbooms.

2. Limit of one splice repair per skin.

3. Upper and lower skin splice cut lines must be offset by 6.0 inches mm. Accomplishone skin splice at a time to preclude loss of tailboom alignment.

4. Upper skin cutline must be a minimum of 3.12 inches aft from last driveshaft supportbracket.

5. Most forward skin cut line: boom sta. (BS) 136.9 (lower skin) and 141 .5 (upper skin).Most aft skin cut line: BS 1 55.0 for upper or lower skins.

1.0 REQUIRED.

1.1 Tailboom skin (1,2), purchased; refer to applicable IPC for correct part number.

1 .2 Splice doubler (3,4), using 2024-T3 aluminum sheet per QQ-A-250/4, 0.050 inchthick.



1.3 Fasteners: M7885/2-4 rivets, grip length to suit.

1 .4 Bonding adhesives (Item S31 7)1.5 Epoxy polyamide primer (item S204).1.6 Sealant dhesive (item S392).1 .7 Process sheets. Cleaning (refer to para 3-2-5)

Bonding (refer to para 3-2-7)2.0 PROCEDURE.

2.1 Remove tailboom assembly and place on support.

2.2 Gain access to damage area recording type, size and location of fasteners removed.See figure 1 or 2.

2.3 Cut out tailboom skin to be removed as shown on figures 1 or 2. Deburr edge.Retain damaged skin.

CAUTIONDO NOT DAMAGE OPPOSITE SKIN.

2.4 Prepare new tailboom skin (1 ,2) to match exactly the section of skin removed.2.5 Prepare splice doubler, dimensioned to extend a minimum of 2.25 in. beyond skin

cutout and as shown on figure 1 or 2. Insure minimum edge distance of 0.38 in. withexisting rivets. Provide joggle as required at each end to overlap existing skin. Spliceto be rolled to same contour as internal diameter (l.D.) of tailboom skin.

2.6 Using damaged skin as a locating template. Transfer holes to new skin one edge at atime. Deburr holes.

CAUTIONEXCESSIVE PRESSURE WHEN DRILLING THIN UNSUPPORTEDSKINS MAY RESULT IN UNACCEPTABLE SKIN WAVINESS ATINSTALLATION.

2.7 Locate splice doubler (3,4) in position and drill for new fasteners specified in 1 .3using fasteners pattern forward of cutline as shown on figure 1 or 2. Maintain properedge distance and spacing. Transfer existing fasteners holes same size as originals.




2.9 Locate splice doubler (3,4) and new skin (1 ,2) in position and drill for new fastenersspecified in 1 .3 using fasteners pattern aft of cutline as shown on figure 1 or 2.Maintain proper edge distance and spacing. Transfer existing fasteners holes of aftsupport, same size as originals.


2.1 1 Clean repair area of skin (1 ,2) and doubler (3,4) in preparation for bonding.2.1 2 Locate and bond splice doubler in position using bonding adhesive specified in 1 .4.

Secure doubler to existing skin using fasteners specified in 1 .3 and figures 1 and 2,grip length to suit.

2.13 Locate and bond new skin to doubler only using bonding adhesive specified in 1.4.Secure doubler to new skin using fasteners specified in 1 .3 and figures 1 and 2, griplength to suit.


2.15 Allow to cure at room temperature for 24 hours applying a pressure of 0.5 to 1.0 psito repair area.



2.18 Refinish tailboom as required.

USE OR DISCLOSURE OF DATA CONTAINED ON THIS PAGE IS SUBJECTTO THE RESTRiCTIONS ON THE TITLE PAGE OF THIS DOCUMENT. 5-67

REPAIR 5-3-1 APPLICATION D FIGURE 1SHEET 10F2

USE OR DISCLOSURE OF DATA CONTAINED ON TI-US PAGE IS SUBJECT5-68 TO THE RESTRICTIONS ON THE TITLE PAGE OF THIS DOCUMENT.

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