How to Repair Minor Aircraft Skin Damage

Step-by-Step Guide

1. 1

   Step 1: Draw a circle around the damaged area.

   Debur the newly cut hole. , The diameter will depend on the number of rows of rivets you’re planning on installing.
   
   Debur the outer edge of the patch. ,, The edge distance for riveting will be ¼”.
   
   The patch cut for this repair is big enough in diameter for 2 rows of rivets, so I will draw a line 1/4” from the small hole and ¼’’ inward from the outline of the patch I drew. , The rule for rivet spacing is a minimum of 4 times the diameter of the rivet and a maximum of 12 times the diameter of the rivet.
   
   You’ll also want to keep the spacing between each rivet the same.
   
   Just make sure you’re within those limits. ,, Use the holes previously drilled in the skin as a guide. , Use clecos to make sure the patch does not move while drilling. ,,,
2. 2

   Step 2: Drill a pilot hole in the circle so a bigger Unibit can easily drill into the aluminum.

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   Step 3: Using a preferred method cut out the aluminum within the circle drawn around the damage.

4. 4

   Step 4: Cut out a circular patch from a sheet of aluminum that is the same thickness and the original aircraft skin.

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   Step 5: Center the patch over the hole in the aircraft skin and mark its outline.

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   Step 6: Since the aluminum being used here is 0.040” thick

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   Step 7: and the rivets are 4/32" in diameter.

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   Step 8: Once the edge distance lines are drawn

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   Step 9: it’s time to mark the location of each rivet.

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    Step 10: drill pilot holes where the rivet makings are located with a small drill bit so it is possible to drill the holes to full size

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    Step 11: without deformation of the aluminum sheet.

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    Step 12: Secure the patch on the aircraft skin and drill pilot holes in the patch.

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    Step 13: With the patch still secured to the aircraft skin

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    Step 14: expand the holes to the proper diameter.

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    Step 15: Remove the patch from the aircraft skin and deburr all the holes both on the patch and on the aircraft skin.

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    Step 16: Once deburred

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    Step 17: re-secure the patch on the skin using clecos.

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    Step 18: Using the proper rivets

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    Step 19: secure the patch to the aircraft skin.

Detailed Guide

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