SRM for the aircraft. Normally, a similar repair is illustrated, and the types of material, rivets, and rivet spacing and the methods and procedures to be used are listed. Any additional knowledge needed to make a repair is also detailed. If the necessary information is not found in the SRM, attempt to find a similar repair or assembly installed by the manufacturer of the aircraft. 

## Floats 

To maintain the float in an airworthy condition, periodic and frequent inspections should be made because of the rapidity of corrosion on metal parts, particularly when the aircraft is operated in salt water. Inspection of floats and hulls involves examination for damage due to corrosion, collision with other objects, hard landings, and other conditions that may lead to failure. 

NOTE: Blind rivets should not be used on floats or amphibian hulls below the water line. 

Sheet-metal floats should be repaired using approved practices; however, the seams between sections of sheet metal should be waterproofed with suitable fabric and sealing compound. A float that has undergone hull repairs should be tested by filling it with water and allowing it to stand for at least 24 hours to see if any leaks develop. [Figure 4-178] 

## Corrugated Skin Repair 

Some of the flight controls of smaller general aviation aircraft have beads in their skin panels. The beads give some stiffness to the thin skin panels. The beads for the repair patch can be formed with a rotary former or press brake. [Figure 4-179] 

## Replacement of a Panel 

Damage to metal aircraft skin that exceeds repairable limits requires replacement of the entire panel. [Figure 4-180] A panel must also be replaced when there are too many previous repairs in a given section or area. 

In aircraft construction, a panel is any single sheet of metal covering. A panel section is the part of a panel between adjacent stringers and bulk heads. Where a section of skin is damaged to such an extent that it is impossible to install a standard skin repair, a special type of repair is necessary. The particular type of repair required depends on whether the damage is repairable outside the member, inside the member, or to the edges of the panel. 

## Outside the Member 

For damage that, after being trimmed, has 8 1 ⁄ 2 rivet diameters or more of material, extend the patch to include the manufacturer’s row of rivets and add an extra row inside the members. 

## Inside the Member 

For damage that, after being trimmed, has less than 8 1 ⁄ 2 manufacturer’s rivet diameters of material inside the members, use a patch that extends over the members and an extra row of rivets along the outside of the members. 

## Edges of the Panel 

For damage that extends to the edge of a panel, use only one row of rivets along the panel edge, unless the manufacturer used more than one row. The repair procedure for the other edges of the damage follows the previously explained methods. 

The procedures for making all three types of panel repairs are similar. Trim out the damaged portion to the allowances mentioned in the preceding paragraphs. For relief of stresses at the corners of the trim-out, round them to a minimum radius of ½-inch. Lay out the new rivet row with a transverse pitch of approximately five rivet diameters and stagger the rivets with those put in by the manufacturer. Cut the patch plate from material of the same thickness as the original or the next greater thickness, allowing an edge distance of 2 1 ⁄ 2 rivet diameters. At the corners, strike arcs having the radius equal to the edge distance. 

Chamfer the edges of the patch plate for a 45° angle and form the plate to fit the contour of the original structure. Turn the edges downward slightly so that the edges fit closely. Place the patch plate in its correct position, drill one rivet hole, and temporarily fasten the plate in place with a fastener. Using a hole finder, locate the position of a second hole, drill it, and insert a second fastener. Then, from the back side and through the original holes, locate and drill the remaining holes. Remove the burrs from the rivet holes and apply corrosion protective material to the contacting surfaces before riveting the patch into place. 

## Repair of Lightning Holes 

As discussed earlier, lightning holes are cut in rib sections, fuselage frames, and other structural parts to reduce the weight of the part. The holes are flanged to make the web stiffer. Cracks can develop around flanged lightning holes, and these cracks need to be repaired with a repair plate. The damaged area (crack) needs to be stop drilled or the damage must be removed. The repair plate is made of the same material and thickness as the damaged part. Rivets are the same as in surrounding structure and the minimum edge distance is 2 times the diameter and spacing is between four to six times the diameter. Figure 4-181  illustrates a typical lightning hole repair. 

