60-08-03: Wing Inspection

60-08-03 DOUGLAS: Amdt. 133 Part 507 Federal Register April 14, 1960. Applies to DC-8 Series Aircraft Serial Numbers 45281 to 45290 Inclusive, 45408 to 45413 Inclusive, 45422, 45423, 45588 to 45594 Inclusive. \n\n\tCompliance required as indicated. \n\n\t(a) Within the next 50 hours' time in service, unless already accomplished, visually inspect the upper and lower wing rib caps, P/N 5615316-1 (left hand) and -2 (right hand) and P/N 5615317-1 (left hand) and -2 (right hand) respectively, at wing station XRS 139.0 for any evidence of cracks. Use at least a 10-power magnifying glass or equivalent. If any doubt exists, utilize dye penetrant or other inspection methods for verification. Aircraft with cracks are not to be returned to service until the damaged parts are repaired in accordance with (c) or (f) or replaced in accordance with (d). \n\n\t(b) Parts which show no evidence of cracks shall be reinspected in accordance with (a) at periods not to exceed 200 hours' time in service until the provisions of (e) are accomplished. \n\n\t(c) Parts which are found to be cracked and which are not replaced per (d) nor permanently repaired per (f) are authorized a reinspection period not to exceed 2,500 hours' time in service, provided: \n\n\t\t(1) The crack in the vertical tang does not exceed a length of ten inches and does not terminate closer than 1/16 inch from the heavy section of the part. \n\n\t\t(2) A stop hole 1/4- to 1/2-inch diameter is drilled in the extreme end of the crack, or the attachment hole in which the crack terminates is enlarged to 1/2-inch diameter. \n\n\t\t(3) A minimum of twenty bulkhead web to cap lock bolts immediately forward of the rear spar are removed, the gap between the web and cap vertical tang is accurately measured, 7075-T6 shims, tapered as necessary in both directions, are installed to fill the gap, and the original type of bulkhead web to cap attachment are reinstalled. \n\n\t\t(4) No fuel or pay load is in the airplane during subsequent jacking operations in which the jack point at the bulkhead in question is utilized. \n\n\t(d) Parts found to be cracked beyond the limits of (c)(1) must be replaced prior to further flight. The replacement parts are subject to the 200 hour time in service inspection limitation of (b) unless, during installation, the gap measurement and shimming provisions of (c)(3) are accomplished. When properly shimmed during installation, the new parts will not be subject to any further special inspections or subsequent airplane jacking weight limitation. \n\n\t(e) Parts inspected and found to have no cracks will no longer be subject to special inspections or airplane jacking weight limitation after gap measurement, shimming and reattachment provisions of (c)(3) have been accomplished. \n\n\t(f) As an alternative to the repair specified in paragraph (c), cracked parts may be repaired per the FAA approved permanent repair recommended by the manufacturer providing crack limitations specified in(c)(1) have not been exceeded and cracks are processed per (c)(2). The special inspections and jacking procedures required by this AD may be discontinued for any part repaired in accordance with this paragraph. \n\n\t(Douglas DC-8 Service Bulletin 57-7 revised June 30 and July 25, 1960, covers this subject.) \n\n\tThis supersedes AD 60-07-04. \n\n\tRevised October 29, 1960.