g. Blind Rivet Installation.
Prior to installing blind rivets, the hole must be prepared, and
the parts aligned and damped firmly in place. These steps are
the same as for solid riveting operations (refer to para 22-5.d).
Proper drill sizes for standard and oversized blind rivets are
given in table 22-2. Countersinking dimensions and minimum
sheet gauge for countersunk blind rivets are shown in tables 22-
3 and 2-24.
It is very important that the proper length rivet is selected for
each application. Rivet lengths are sized by the range of
material thickness that the rivet will grip. Selecting the proper
rivet length is critical because rivets can tolerate only 1/16-inch
variation in material thickness for each particular rivet length.
Rivet grip lengths are called out as a "dash number" at the end
of the manufacturer's part number. Grip lengths are determined
For double-dimpled sheets, add countersunk head height to
Use rivet installation tool kit, D-100-MIL1, and puller head
adapters, if required, for all blind rivets.
Insert rivet stem into pulling head of rivet gun or adapter.
Hold rivet gun in line with axis of rivet as accurately as possible.
Apply a steady, firm pressure against rivet head.
Squeeze handles of manual gun. The rivet clamping action will pull sheets together, seat rivet head,
and break stem flush with head of rivet.
Repairs should not be made on the body using welding or heat
for forming. Heat will only weaken material and cause further
a. Material. Aluminum material used for repair should be of the same alloy and temper as original, if
possible. In general, 6061-T6 aluminum alloy should be used. Material thickness must be the same or thicker.
This alloy will work well for flat repairs, but is not well suited to bending because it is quite hard and cracks
easily when bent sharply. When bends must be made, use softer 6061-T4 aluminum alloy and increase
material thickness by at least 50 percent. As a general rule of thumb, 6061-T4 alloy should be bent with a
minimum bend radius of one to two times material thickness, whereas 6061-T6 alloy requires at least three
times material thickness radius for bends. In all cases, bends should be closely inspected for cracks. A suitable
method for avoiding cracks during bending is to obtain angles that are extruded from 6061-T6 alloy or use
b. Epoxy Adhesive. Where it is necessary to remove parts, note that epoxy adhesive is used in joints. Use
care in parts removal to avoid unnecessary distortion. Parts should be separated by peeling them apart using a
knife or chisel to start the peeling action. Before parts are reassembled, it will be necessary to remove any
remaining cured epoxy from joints so parts will fit together with good, even contact. Use of epoxy requires
special storage and application procedures which do not lend themselves to field repairs. For this reason, epoxy
will not be used for repair. To compensate for the lack of epoxy, additional rivets should be used when making
repairs to existing joints.