Commercial 

Airplanes DC8

Service Bulletin

ALERT

Number: DC8-53A080

Original Issue: June 22, 2004

Revision 2: September 18, 2013

ATA System: 5300

SUBJECT: FUSELAGE - Main Frame - Inspect/Repair Fuselage Skin Forward of Flat Aft Pressure

Bulkhead at Longeron 28

Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15

CFR 300-774). An export license may be required before it is used for development, production or use by foreign

persons from specific countries. The controller of this data has the individual responsibility to abide by all export

laws.

ECCN: 9E991

BOEING PROPRIETARY, CONFIDENTIAL AND/OR TRADE SECRET

Copyright © 2004 Boeing.

Unpublished Work. All Rights Reserved.

Treatment of this document and its content is governed by contract with Boeing. Rights to use this document

are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The

Boeing Company.

Boeing, the Boeing signature, the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner,

BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and

Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in

connection with this document unless provided in writing by Boeing.

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Revision 2: September 18, 2013 DC8-53A080

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2.0
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ALERT ALERT

BLANK PAGE
Table of Contents

Revision Transmittal Sheet ............................................ 5

Summary ...................................................... 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

2. Data Supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 62

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

M. Software Accomplishment Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

C. Parts Necessary for Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 63

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 65

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

FIGURE 1: METHOD 103 REFLECTANCE TYPE SLIDING PROBE PROCEDURE REFERENCE

STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

FIGURE 2: HIGH FREQUENCY EDDY CURRENT INSPECTION OF SKIN ALONG LONGERON 28 . 80

FIGURE 3: METHOD 103 REFLECTANCE TYPE SLIDING PROBE PROCEDURE . . . . . . . . . . 81

FIGURE 4: METHOD 103 REFLECTANCE TYPE SLIDING PROBE PROCEDURE . . . . . . . . . . 82

Appendix A: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Export Controlled ECCN: 9E991 - BOEING

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ALERT ALERT
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ALERT ALERT

BLANK PAGE
Commercial 

Airplanes DC8

Service Bulletin

ALERT

Revision Transmittal Sheet Number: DC8-53A080

Original Issue: June 22, 2004

Revision 2: September 18, 2013

ATA System: 5300

SUBJECT: FUSELAGE - Main Frame - Inspect/Repair Fuselage Skin Forward of Flat Aft Pressure

Bulkhead at Longeron 28

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

Federal Aviation Administration (FAA) Airworthiness Directive AD 2008-06-23 is related to this service bulletin.

No more work is necessary on the airplane(s) changed in accordance with Revision 1 of this service bulletin.

REASON FOR REVISION

This revision is sent to add Options 3 and 4 for Group 1, Configuration 2 airplanes that were inadvertently omitted

at the release of Revision 1.

These sections were changed:

1. In Paragraph 1.D., Description, added Options 3 and 4 for Group 1, Configuration 2 airplanes.

2. In Paragraph 3.B., Work Instructions, added Options 3 and 4 for Group 1, Configuration 2 airplanes.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes,

to show the location of all content changes.

Pages with no vertical lines have no changes.

REVISION HISTORY

Original Issue: June 22, 2004

Revision 1: May 03, 2013

Revision 2: September 18, 2013

Export Controlled ECCN: 9E991 - BOEING

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ALERT ALERT

BLANK PAGE
Commercial 

Airplanes DC8

Service Bulletin

ALERT

Summary Number: DC8-53A080

Original Issue: June 22, 2004

Revision 2: September 18, 2013

ATA System: 5300

SUBJECT: FUSELAGE - Main Frame - Inspect/Repair Fuselage Skin Forward of Flat Aft Pressure

Bulkhead at Longeron 28

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

CONCURRENT REQUIREMENTS

None.

BACKGROUND

During routine maintenance inspections, three operators reported finding three instances of cracks in the upper

aft skin panel. The cracks were located along the upper row of rivets common to the longeron 28 skin splice,

near the flat aft pressure bulkhead. Cracks were detected on airplanes which had accumulated between 27,072

and 46,176 flight cycles. If not corrected, in-flight fuselage decompression and unscheduled maintenance for

repairs may be required. Inspecting fuselage skin for cracks will determine condition of skin. Inspecting fuselage

skin for cracks, and repairing if necessary, will minimize the possibility of in-flight decompression and unscheduled

maintenance.

The fuselage skin has been determined to be structure that is susceptible to Widespread Fatigue Damage

(WFD).

This table is provided to operators for planning purposes only. Refer to the applicable sections for more

information.

Planning Data Affected Reference

Spares Affected No Paragraph 1.A.2., Spares Affected

Paragraph 1.E., Compliance and Paragraph

1.F., Approval

AD Related Yes

Weight and Balance Change No Paragraph 1.H., Weight and Balance Changes

Electrical Load Changed No Paragraph 1.I., Electrical Load Data

Publications Affected No Paragraph 1.K., Publications Affected

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Planning Data Affected Reference

Airplane Flight Operations Affected (Flight Crew No Paragraph 1.K., Publications Affected

Operations Manual and/or FAA Approved Airplane Flight Manual)

Kits/Parts Required No Paragraph 2.C.1., Kits/Parts

Paragraph 2.C.2., Parts and Materials Supplied

by the Operator

Operator Supplied Parts/Material No

Paragraph 2.F., Special Tooling Necessary to

do this Service Bulletin

Special Tooling Required No

ACTION

Group 1, Configuration 1:

1. This service bulletin accomplishes a general visual and a High Frequency Eddy Current inspection of

the fuselage skin for cracks or failed fasteners at longeron 28 forward of flat aft pressure bulkhead, left

and right sides, and accomplishes the following based on condition:

a. Condition 1 (No Crack(s) or Failed Fasteners Found)

Option 1

Does repetitive inspections.

Installs full length improvement modification with finger doubler at a later time.

Option 2

Does repetitive inspections.

Installs full length improvement modification at a later time.

b. Condition 2 (Any Failed Fasteners)

Option 1

Replaces failed fasteners and does repetitive inspections.

Installs full length improvement modification with finger doubler at a later time.

Option 2

Replaces failed fasteners and does repetitive inspections.

Installs full length improvement modification at a later time.

Option 3

Installs full length improvement modification with finger doubler.

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ALERT ALERT
Option 4

Installs full length improvement modification.

c. Condition 3 (Any Crack(s) Found in Skin)

Option 1

Repairs cracked skin locally, and does repetitive inspections.

Installs full length repair with finger doubler at a later time.

Option 2

Repairs cracked skin locally, and does repetitive inspections.

Installs full length repair at a later time.

Option 3

Installs full length repair with finger doubler.

Option 4

Installs full length repair.

Group 1, Configuration 2:

1. This service bulletin accomplishes a general visual and a High Frequency Eddy Current inspection of

the fuselage skin for cracks or failed fasteners at longeron 28 forward of flat aft pressure bulkhead, left

and right sides, and accomplishes the following based on condition:

a. Condition 1 (No Crack(s) or Failed Fasteners Found)

Option 1

Does repetitive inspections of accessible skin.

Replaces previously installed local skin repairs with new local skin repairs defined in this service

bulletin.

Installs full length repair with finger doubler at a later time.

Option 2

Does repetitive inspections of accessible skin.

Replaces previously installed local skin repairs with new local skin repairs defined in this service

bulletin.

Installs full length repair at a later time.

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ALERT ALERT
Option 3

Removes previously installed local skin repairs.

Installs full length repair with finger doubler

Option 4

Removes previously installed local skin repairs.

Installs full length repair.

b. Condition 2 (Any Failed Fasteners)

Option 1

Replaces all failed fasteners.

Does repetitive inspections of accessible skin.

Replaces previously installed local skin repairs with new local skin repairs as defined in this service

bulletin.

Removes previously installed local repairs and installs full length repair with finger doubler at a

later time.

Option 2

Replaces all failed fasteners.

Replaces previously installed local skin repairs with new local skin repairs as defined in this service

bulletin.

Removes previously installed local repairs and does full length repair at a later time.

Option 3

Removes previously installed local repairs and installs full length repair with finger doubler.

Option 4

Removes previously installed local repairs and installs full length repair.

c. Condition 3 (Any Crack(s) Found in Skin)

Option 1

Repairs cracks with local skin repairs as defined in this service bulletin.

Does repetitive inspections of accessible skin.

Replaces previously installed local skin repairs with new local skin repairs as defined in this service

bulletin.

Export Controlled ECCN: 9E991 - BOEING

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ALERT ALERT
Removes previously installed local repairs and does full length repair with finger doubler at a later

time.

Option 2

Repairs cracks with local skin repairs as defined in this service bulletin.

Does repetitive inspections of accessible skin.

Replaces previously installed local skin repairs with new local skin repairs as defined in this service

bulletin.

Removes previously installed local repairs and does full length repair at a later time.

Option 3

Removes previously installed local repairs and does full length repair with finger doubler.

Option 4

Removes previously installed local repairs and does full length repair.

EFFECTIVITY

DC-8-55, DC-8-61, DC-8-61F, DC-8-62, DC-8-62F, DC-8-63, DC-8-63F, DC-8-71, DC-8-71F, DC-8-72, DC-8-72F,

DC-8-73, DC-8-73F, DC-8F-54, DC-8F-55 airplanes with flat aft pressure bulkhead. Refer to Paragraph 1.A.1.

for detailed effectivity.

COMPLIANCE

Federal Aviation Administration (FAA) Airworthiness Directive AD 2008-06-23 is related to this service bulletin.

Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the inspection and/or repair procedures given in this service

bulletin.

MANPOWER

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

Operator Supplied Parts.

Refer to Paragraph 2.A., Material - Price and Availability.

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ALERT ALERT

BLANK PAGE
Commercial 

Airplanes DC8

Service Bulletin

ALERT

Number: DC8-53A080

Original Issue: June 22, 2004

Revision 2: September 18, 2013

ATA System: 5300

SUBJECT: FUSELAGE - Main Frame - Inspect/Repair Fuselage Skin Forward of Flat Aft Pressure

Bulkhead at Longeron 28

THIS BULLETIN IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH

1.A., EFFECTIVITY. IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OPERATOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS SERVICE BULLETIN TO

THE NEW OWNER.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

This service bulletin is for the airplanes shown below.

GROUP CONFIGURATION DESCRIPTION

1 - DC-8 Series 50, 60 and 70 airplanes with flat aft pressure bulkhead

1 Airplanes with no existing repairs in the area of inspection.

2 Airplanes that have existing repairs in the area of inspection.

Airplane Models:

DC-8-55, DC-8-61, DC-8-61F, DC-8-62, DC-8-62F, DC-8-63, DC-8-63F, DC-8-71, DC-8-71F,

DC-8-72, DC-8-72F, DC-8-73, DC-8-73F, DC-8F-54, DC-8F-55

Fuselage Num- Group

ber

122 1

182 1

185 1

187 1

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Fuselage Num- Group

ber

189 1

197 1

200 1

203 1

207 - 208 1

218 1

223 1

234 1

241 1

246 - 248 1

251 - 252 1

254 - 255 1

259 1

261 - 262 1

274 1

276 - 277 1

283 - 284 1

286 1

288 - 289 1

290 1

292 1

294 - 295 1

298 1

305 1

307 1

309 1

313 1

316 - 319 1

320 - 323 1

326 - 327 1

329 1

331 1

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Fuselage Num- Group

ber

333 - 335 1

337 - 339 1

343 - 344 1

347 - 348 1

350 - 354 1

356 1

358 1

360 - 361 1

363 1

365 1

368 - 369 1

370 - 377 1

379 1

380 - 382 1

385 - 389 1

392 - 399 1

400 - 401 1

403 1

405 1

407 - 408 1

410 - 411 1

413 1

416 - 419 1

420 - 423 1

425 - 428 1

431 - 432 1

434 - 439 1

440 - 447 1

449 1

450 - 451 1

453 - 459 1

460 1

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ALERT ALERT
Fuselage Num- Group

ber

462 - 469 1

471 1

475 1

477 - 479 1

480 - 483 1

485 - 488 1

490 - 493 1

495 - 497 1

500 - 504 1

507 - 509 1

511 - 512 1

515 - 516 1

519 1

520 - 525 1

527 - 529 1

530 - 531 1

534 - 535 1

538 - 539 1

540 1

542 1

544 1

546 - 549 1

551 1

554 - 556 1

2. Spares Affected

None.

B. Concurrent Requirements

None.

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ALERT ALERT
C. Reason

During routine maintenance inspections, three operators reported finding three instances of cracks in

the upper aft skin panel. The cracks were located along the upper row of rivets common to the longeron

28 skin splice, near the flat aft pressure bulkhead. Cracks were detected on airplanes which had

accumulated between 27,072 and 46,176 flight cycles. If not corrected, in-flight fuselage decompression

and unscheduled maintenance for repairs may be required. Inspecting fuselage skin for cracks will

determine condition of skin. Inspecting fuselage skin for cracks, and repairing if necessary, will minimize

the possibility of in-flight decompression and unscheduled maintenance.

The fuselage skin has been determined to be structure that is susceptible to Widespread Fatigue

Damage (WFD).

Revision 1 was sent to add kit configurations for the improvement modification.

Revision 2 is sent to add Options 3 and 4 for Group 1, Configuration 2 airplanes that were inadvertently

omitted at the release of Revision 1..

D. Description

Group 1, Configuration 1:

1. This service bulletin accomplishes a general visual and a High Frequency Eddy Current inspection

of the fuselage skin for cracks or failed fasteners at longeron 28 forward of flat aft pressure bulkhead,

left and right sides, and accomplishes the following based on condition:

a. Condition 1 (No Crack(s) or Failed Fasteners Found)

Option 1

Does repetitive inspections.

Installs full length improvement modification with finger doubler at a later time.

Option 2

Does repetitive inspections.

Installs full length improvement modification at a later time.

b. Condition 2 (Any Failed Fasteners)

Option 1

Replaces failed fasteners and does repetitive inspections.

Installs full length improvement modification with finger doubler at a later time.

Option 2

Replaces failed fasteners and does repetitive inspections.

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ALERT ALERT
Installs full length improvement modification at a later time.

Option 3

Installs full length improvement modification with finger doubler.

Option 4

Installs full length improvement modification.

c. Condition 3 (Any Crack(s) Found in Skin)

Option 1

Repairs cracked skin locally, and does repetitive inspections.

Installs full length repair with finger doubler at a later time.

Option 2

Repairs cracked skin locally, and does repetitive inspections.

Installs full length repair at a later time.

Option 3

Installs full length repair with finger doubler.

Option 4

Installs full length repair.

Group 1, Configuration 2:

1. This service bulletin accomplishes a general visual and a High Frequency Eddy Current inspection

of the fuselage skin for cracks or failed fasteners at longeron 28 forward of flat aft pressure bulkhead,

left and right sides, and accomplishes the following based on condition:

a. Condition 1 (No Crack(s) or Failed Fasteners Found)

Option 1

Does repetitive inspections of accessible skin.

Replaces previously installed local skin repairs with new local skin repairs defined in this

service bulletin.

Installs full length repair with finger doubler at a later time.

Option 2

Does repetitive inspections of accessible skin.

Export Controlled ECCN: 9E991 - BOEING

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ALERT ALERT
Replaces previously installed local skin repairs with new local skin repairs defined in this

service bulletin.

Installs full length repair at a later time.

Option 3

Removes previously installed local skin repairs.

Installs full length repair with finger doubler

Option 4

Removes previously installed local skin repairs.

Installs full length repair

b. Condition 2 (Any Failed Fasteners)

Option 1

Replaces all failed fasteners.

Does repetitive inspections of accessible skin.

Replaces previously installed local skin repairs with new local skin repairs as defined in this

service bulletin.

Removes previously installed local repairs and installs full length repair with finger doubler at

a later time.

Option 2

Replaces all failed fasteners.

Replaces previously installed local skin repairs with new local skin repairs as defined in this

service bulletin.

Removes previously installed local repairs and does full length repair at a later time.

Option 3

Removes previously installed local repairs and installs full length repair with finger doubler.

Option 4

Removes previously installed local repairs and installs full length repair.

c. Condition 3 (Any Crack(s) Found in Skin)

Option 1

Repairs cracks with local skin repairs as defined in this service bulletin.

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ALERT ALERT
Does repetitive inspections of accessible skin.

Replaces previously installed local skin repairs with new local skin repairs as defined in this

service bulletin.

Removes previously installed local repairs and does full length repair with finger doubler at a

later time.

Option 2

Repairs cracks with local skin repairs as defined in this service bulletin.

Does repetitive inspections of accessible skin.

Replaces previously installed local skin repairs with new local skin repairs as defined in this

service bulletin.

Removes previously installed local repairs and does full length repair at a later time.

Option 3

Removes previously installed local repairs and does full length repair with finger doubler.

Option 4

Removes previously installed local repairs and does full length repair.

Revision 2 - No more work is necessary on airplanes changed in accordance with Revision 1 of this

service bulletin.

The work in this service bulletin is done in the maintenance zone(s) given below.

Affected Maintenance Zones

Model Zone

DC-8-55, DC-8-61, DC-8-61F, 661

DC-8-62, DC-8-62F, DC-8-63,

DC-8-63F, DC-8-71, DC-8-71F,

DC-8-72, DC-8-72F, DC-8-73,

DC-8-73F, DC-8F-54, DC-8F-55

E. Compliance

Federal Aviation Administration (FAA) Airworthiness Directive AD 2008-06-23 is related to this service

bulletin.

Do the required actions in accordance with Paragraph 3. Accomplishment Instructions.

When more than one OPTION is given for a CONDITION, do only one of the OPTION numbers. When

more than one ACTION is given for a CONDITION number or an OPTION number, do all of the ACTION

numbers for that CONDITION number or OPTION number.

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20 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 1 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the

original issue date of this service bulletin and no skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later )

Condition Action

2 years from origi- .

nal issue date of

this service bulletin

Accumulation of

24,000 total flight

cycles

Do a general visual and Eddy

Current High Frequency

(ETHF) Inspection of the

fuselage skin and fasteners at

longeron 28 forward of flat aft

pressure bulkhead, left and

right sides and do the work

listed based on condition

Airplanes with flat

aft pressure bulkhead having less

than 24,000 total

flight cycles as of

the original issue

date of this service

bulletin and no

skin repairs in the

area of inspection.

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the

fuselage skin and fasteners at

longeron 28 forward of flat aft

pressure bulkhead, left and

right sides and do the work

listed based on condition

Condition 1

(No Crack(s) or

Failed Fasteners

Found)

Option 1

(a) (b)

AND

6 years from the .

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Install full length improvement

modification with finger doublers.

AND

5,000 flight cycles30,000 flight cycles .

from full length improvement modification with finger doublers installation

Do an external visual inspections for cracks along all four

edges of the external doublers, left and right sides.

(a) (c)

OR

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21 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 1 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the

original issue date of this service bulletin and no skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later )

Condition Action

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the

fuselage skin and fasteners at

longeron 28 forward of flat aft

pressure bulkhead, left and

right sides and do the work

listed based on condition

Option 2

(a) (b)

AND

6 years from the .

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Install full length improvement

modification

AND

10,000 flight cycles15,000 flight cycles .

from full length

modification installation

Do a Low Frequency Eddy

Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

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22 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 1 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the

original issue date of this service bulletin and no skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later )

Condition Action

Condition 2 Replace all Failed Fasteners. Before further flight . .

Any Failed Fastener(s) AND

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the

fuselage skin and fasteners at

longeron 28 forward of flat aft

pressure bulkhead, left and

right sides and do the work

listed based on Condition

Option 1

(a) (b)

AND

6 years from the .

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Install full length improvement

modification with finger doublers.

AND

5,000 flight cycles30,000 flight cycles .

from full length improvement modification with finger doublers installation

Do an external visual inspections for cracks along all four

edges of the external doublers, left and right sides.

(a) (c)

OR

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23 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 1 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the

original issue date of this service bulletin and no skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later )

Condition Action

Option 2 Replace all Failed Fasteners. Before further flight . .

AND

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the

fuselage skin and fasteners at

longeron 28 forward of flat aft

pressure bulkhead, left and

right sides and do the work

listed based on Condition

(a) (b)

AND

6 years from the .

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Install full length improvement

modification.

AND

10,000 flight cycles15,000 flight cycles .

from full length

modification installation

Do a Low Frequency Eddy

Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

OR

Install full length improvement Before further flight . .

modification with finger doublers.

Option 3

AND

5,000 flight cycles30,000 flight cycles .

from full length improvement modification with finger doublers installation

Do an external visual inspections for cracks along all four

edges of the external doublers, left and right sides.

(a) (c)

OR

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24 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 1 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the

original issue date of this service bulletin and no skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later )

Condition Action

Install full length improvement Before further flight . .

modification.

Option 4

AND

10,000 flight cycles15,000 flight cycles .

from full length

modification installation

Do a Low Frequency Eddy

Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

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25 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 1 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the

original issue date of this service bulletin and no skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later )

Condition Action

Condition 3 Do local skin repair. Before further flight . .

Any Crack(s)

Found in Skin AND

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the accessible fuselage skin and

fasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides and

do the work listed based on

condition of the unrepaired areas

Option 1

(a) (b)

AND

5,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For local skin repairs 12 inches or less long, do an external

visual inspections for cracks

along all four edges of the external doublers

(a) (c)

AND/OR

10,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For skin repairs longer than 12

inches, do a Low Frequency

Eddy Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

AND

6 years from the .

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Install full length repair with

finger doublers.

AND

5,000 flight cycles30,000 flight cycles .

from full length repair with finger doublers repair installation

Do an external visual inspections for cracks along all four

edges of the external doublers, left and right sides.

(a) (c)

OR

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26 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 1 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the

original issue date of this service bulletin and no skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later )

Condition Action

Option 2 Do local skin repair. Before further flight . .

AND

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the accessible fuselage skin and

fasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides and

do the work listed based on

condition of the unrepaired areas

(a) (b)

AND

AND

5,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For local skin repairs 12 inches or less long, do an external

visual inspections for cracks

along all four edges of the external doublers

(a) (c)

AND/OR

10,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For skin repairs longer than 12

inches, do a Low Frequency

Eddy Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

AND

6 years from the .

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Install full length repair doublers.

AND

10,000 flight cycles15,000 flight cycles .

from full length repair installation

Do a Low Frequency Eddy

Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

OR

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27 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 1 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the

original issue date of this service bulletin and no skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later )

Condition Action

Install full length repair with Before further flight . .

finger doublers.

Option 3

AND

5,000 flight cycles30,000 flight cycles .

from full length repair with finger doublers installation

Do an external visual inspections for cracks along all four

edges of the external doublers, left and right sides.

(a) (c)

OR

Install full length repair dou- Before further flight . .

blers.

Option 4

AND

10,000 flight cycles15,000 flight cycles .

from full length repair installation

Do a Low Frequency Eddy

Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

(a) Repeat inspection at noted interval if no discrepancies are found.

(b) If any discrepancy is found, do the work of Condition 2 or 3 as applicable before further flight.

(c) If any discrepancy is found, contact Boeing and do the work required before further flight.

Table 2 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the

original issue date of this service bulletin and no skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later )

Condition Action

1 year from original issue date of this .

service bulletin

Do a general visual and Eddy

Current High Frequency

(ETHF) Inspection of the

fuselage skin and fasteners at

longeron 28 forward of flat aft

pressure bulkhead, left and

right sides and do the work

listed based on condition

Airplanes with flat

aft pressure bulkhead having

24,000 or more total flight cycles as

of the original issue date of this

service bulletin

and no skin repairs in the area of

inspection.

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28 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 2 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the

original issue date of this service bulletin and no skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later )

Condition Action

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the

fuselage skin and fasteners at

longeron 28 forward of flat aft

pressure bulkhead, left and

right sides and do the work

listed based on condition

Condition 1

(No Crack(s) or

Failed Fasteners

Found)

Option 1

(a) (b)

AND

6 years from the .

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Install full length improvement

modification with finger doublers.

AND

5,000 flight cycles30,000 flight cycles .

from full length improvement modification with finger doublers installation

Do an external visual inspections for cracks along all four

edges of the external doublers, left and right sides.

(a) (c)

OR

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the

fuselage skin and fasteners at

longeron 28 forward of flat aft

pressure bulkhead, left and

right sides and do the work

listed based on condition

Option 2

(a) (b)

AND

6 years from the .

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Install full length improvement

modification

AND

10,000 flight cycles15,000 flight cycles .

from full length

modification installation

Do a Low Frequency Eddy

Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

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29 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 2 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the

original issue date of this service bulletin and no skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later )

Condition Action

Condition 2 Replace all Failed Fasteners. Before further flight . .

Any Failed Fastener(s) AND

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the

fuselage skin and fasteners at

longeron 28 forward of flat aft

pressure bulkhead, left and

right sides and do the work

listed based on Condition

Option 1

(a) (b)

AND

6 years from the .

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Install full length improvement

modification with finger doublers.

AND

5,000 flight cycles30,000 flight cycles .

from full length improvement modification with finger doublers installation

Do an external visual inspections for cracks along all four

edges of the external doublers, left and right sides.

(a) (c)

OR

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30 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 2 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the

original issue date of this service bulletin and no skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later )

Condition Action

Option 2 Replace all Failed Fasteners. Before further flight

AND

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the

fuselage skin and fasteners at

longeron 28 forward of flat aft

pressure bulkhead, left and

right sides and do the work

listed based on Condition

(a) (b)

AND

6 years from the .

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Install full length improvement

modification.

AND

10,000 flight cycles15,000 flight cycles

from full length

modification installation

Do a Low Frequency Eddy

Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

OR

Install full length improvement Before further flight . .

modification with finger doublers.

Option 3

AND

5,000 flight cycles30,000 flight cycles .

from full length improvement modification with finger doublers installation

Do an external visual inspections for cracks along all four

edges of the external doublers, left and right sides.

(a) (c)

OR

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31 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 2 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the

original issue date of this service bulletin and no skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later )

Condition Action

Install full length improvement Before further flight . .

modification.

Option 4

AND

10,000 flight cycles15,000 flight cycles .

from full length

modification installation

Do a Low Frequency Eddy

Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

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32 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 2 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the

original issue date of this service bulletin and no skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later )

Condition Action

Condition 3 Do local skin repair. Before further flight . .

Any Crack(s)

Found in Skin AND

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the accessible fuselage skin and

fasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides and

do the work listed based on

condition of the unrepaired areas

Option 1

(a) (b)

AND

5,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For local skin repairs 12 inches or less long, do an external

visual inspections for cracks

along all four edges of the external doublers

(a) (c)

AND/OR

10,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For skin repairs longer than 12

inches, do a Low Frequency

Eddy Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

AND

6 years from the .

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Install full length repair with

finger doublers.

AND

5,000 flight cycles30,000 flight cycles .

from full length repair with finger doublers repair installation

Do an external visual inspections for cracks along all four

edges of the external doublers, left and right sides.

(a) (c)

OR

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33 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 2 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the

original issue date of this service bulletin and no skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later )

Condition Action

Option 2 Do local skin repair. Before further flight . .

AND

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the accessible fuselage skin and

fasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides and

do the work listed based on

condition of the unrepaired areas

(a) (b)

AND

5,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For local skin repairs 12 inches or less long, do an external

visual inspections for cracks

along all four edges of the external doublers

(a) (c)

AND/OR

10,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For skin repairs longer than 12

inches, do a Low Frequency

Eddy Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

AND

6 years from the .

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Install full length repair doublers.

AND

10,000 flight cycles15,000 flight cycles .

from full length repair installation

Do a Low Frequency Eddy

Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

OR

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34 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 2 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the

original issue date of this service bulletin and no skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later )

Condition Action

Install full length repair with Before further flight .

finger doublers.

Option 3

AND

5,000 flight cycles30,000 flight cycles .

from full length repair with finger doublers installation

Do an external visual inspections for cracks along all four

edges of the external doublers, left and right sides.

(a) (c)

OR

Install full length repair dou- Before further flight .

blers.

Option 4

AND

10,000 flight cycles15,000 flight cycles .

from full length repair installation

Do a Low Frequency Eddy

Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

(a) Repeat inspection at noted interval if no discrepancies are found.

(b) If any discrepancy is found, do the work of Condition 2 or 3 as applicable before further flight.

(c) If any discrepancy is found, contact Boeing and do the work required before further flight.

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35 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

2 years from origi- .

nal issue date of

this service bulletin

Accumulation of

24,000 total flight

cycles

Do a general visual and Eddy

Current High Frequency

(ETHF) Inspection of the accessible fuselage skin and

fasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides and

do the work listed based on

condition.

Airplanes with flat

aft pressure bulkhead having less

than 24,000 total

flight cycles as of

the original issue

date of this service

bulletin and having

skin repairs in the

area of inspection.

2,000 flight cycles

Do a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the accessible fuselage skin and

fasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides

Condition 1

(No Crack(s) or

Failed Fasteners

Found)

Option 1

(a) (b)

AND

6 years from the .

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Install full length improvement

modification with finger doublers.

AND

2 years from initial .

inspection of accessible skin

Remove previously installed .

local repairs and replace them

with new local repairs.

AND

5,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For new local skin repairs 12

inches or less long, do an external visual inspections for

cracks along all four edges of

the external doublers

(a) (c)

AND/OR

10,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For new skin repairs longer

than 12 inches, do a Low Frequency Eddy Current inspection of the fuselage skin along

all four edges of the external

doubler

(a) (c)

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BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

AND

6 years from the .

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Remove previously installed

local repairs and install full

length repair with finger doublers.

AND

5,000 flight cycles30,000 flight cycles .

from full length repair with finger doublers installation

Do an external visual inspections for cracks along all four

edges of the external doublers, left and right sides.

(a) (c)

OR

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37 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the accessible fuselage skin and

fasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides

Option 2

(a) (b)

AND

2 years from initial .

inspection of accessible skin

Remove previously installed .

local repairs and replace them

with new local repairs.

AND

5,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For new local skin repairs 12

inches or less long, do an external visual inspections for

cracks along all four edges of

the external doublers

(a) (c)

AND/OR

10,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For new skin repairs longer

than 12 inches, do a Low Frequency Eddy Current inspection of the fuselage skin along

all four edges of the external

doubler

(a) (c)

AND

6 years from the .

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Remove previously installed

local repairs and install full

length improvement modification.

AND

10,000 flight cycles15,000 flight cycles .

from full length repair installation

Do a Low Frequency Eddy

Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

OR

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38 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

Remove previously installed Before further flight .

local repairs and install full

length repair with finger doublers.

Option 3

AND

5,000 flight cycles30,000 flight cycles .

from full length repair with finger doublers installation

Do an external visual inspections for cracks along all four

edges of the external doublers, left and right sides.

(a) (c)

OR

Remove previously installed Before further flight

local repairs and install full

length improvement modification.

Option 4

AND

10,000 flight cycles15,000 flight cycles

from installation of

repair

Do a Low Frequency Eddy

Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

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39 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

Condition 2 Replace all Failed Fasteners Before further flight . .

Any Failed Fastener(s) AND

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the accessible fuselage skin and

fasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides

Option 1

(a) (b)

AND

2 years from initial . .

inspection of accessible skin

Remove previously installed

local repairs and replace them

with new local repairs.

AND

5,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For new local skin repairs 12

inches or less long, do an external visual inspections for

cracks along all four edges of

the external doublers

(a) (c)

AND/OR

10,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For new local skin repairs

longer than 12 inches, do a

Low Frequency Eddy Current

inspection of the fuselage skin

along all four edges of the external doubler

(a) (c)

AND

6 years from the

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Remove previously installed

local repairs and install full

length repair with finger doublers.

AND

5,000 flight cycles30,000 flight cycles

from full length repair with finger doublers installation

Do an external visual inspections for cracks along all four

edges of the external doublers, left and right sides.

(a) (c)

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40 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

OR

Option 2 Replace all Failed Fasteners Before further flight . .

AND

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the accessible fuselage skin and

fasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides

(a) (b)

AND

2 years from initial . .

inspection of accessible skin

Remove previously installed

local repairs and replace them

with new local repairs.

AND

5,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For new local skin repairs 12

inches or less long, do an external visual inspections for

cracks along all four edges of

the external doublers

(a) (c)

AND/OR

10,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For new local skin repairs

longer than 12 inches, do a

Low Frequency Eddy Current

inspection of the fuselage skin

along all four edges of the external doubler

(a) (c)

AND

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41 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

6 years from the

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Remove previously installed

local repairs and install full

length repair.

AND

10,000 flight cycles15,000 flight cycles .

from full length repair installation

Do a Low Frequency Eddy

Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

OR

Remove previously installed Before further flight . .

local repairs and install full

length repair with finger doubler

Option 3

AND

5,000 flight cycles30,000 flight cycles .

from full length repair with finger doublers installation

Do an external visual inspections for cracks along all four

edges of the external doublers, left and right sides.

(a) (c)

OR

Remove previously installed Before further flight . .

local repairs and install full

length repair

Option 4

AND

10,000 flight cycles15,000 flight cycles .

from full length repair installation

Do a Low Frequency Eddy

Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

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42 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

Condition 3 Do local skin repair. Before further flight . .

Any Crack(s)

Found in Skin AND

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the accessible fuselage skin and

fasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides

Option 1

(a) (b)

AND

5,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For local skin repairs 12 inches or less long, do an external

visual inspections for cracks

along all four edges of the external doublers

(a) (c)

AND/OR

10,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For skin repairs longer than 12

inches, do a Low Frequency

Eddy Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

AND

2 years from initial . .

inspection of accessible skin

Remove previously installed

local repairs and replace them

with new local repairs

AND

5,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For local skin repairs 12 inches or less long, do an external

visual inspections for cracks

along all four edges of the external doublers

(a) (c)

AND/OR

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43 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

10,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For skin repairs longer than 12

inches, do a Low Frequency

Eddy Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

AND

6 years from the .

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Remove previously installed

local repairs and install full

length repair with finger doubler

AND

5,000 flight cycles30,000 flight cycles .

from full length repair with finger doublers installation

Do an external visual inspections for cracks along all four

edges of the external doublers, left and right sides.

(a) (c)

OR

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44 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

Option 2 Do local skin repair. Before further flight . .

AND

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the accessible fuselage skin and

fasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides

(a) (b)

AND

5,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For local skin repairs 12 inches or less long, do an external

visual inspections for cracks

along all four edges of the external doublers

(a) (c)

AND/OR

10,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For skin repairs longer than 12

inches, do a Low Frequency

Eddy Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

AND

2 years from initial . .

inspection of accessible skin

Remove previously installed

local repairs and replace them

with new local repairs

AND

5,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For local skin repairs 12 inches or less long, do an external

visual inspections for cracks

along all four edges of the external doublers

(a) (c)

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45 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

AND/OR

10,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For skin repairs longer than 12

inches, do a Low Frequency

Eddy Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

AND

6 years from the .

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Remove previously installed

local repairs and install full

length repair

AND

10,000 flight cycles15,000 flight cycles .

from full length repair installation

Do a Low Frequency Eddy

Current inspection of the

fuselage skin along all four

edges of the external doubler.

(a) (c)

OR

Remove previously installed Before further flight . .

local repairs and install full

length repair with finger doubler

Option 3

AND

5,000 flight cycles30,000 flight cycles .

from full length repair with finger doublers installation

Do an external visual inspections for cracks along all four

edges of the external doublers, left and right sides.

(a) (c)

OR

Remove previously installed Before further flight . .

local repairs and install full

length repair

Option 4

AND

10,000 flight cycles15,000 flight cycles .

from full length repair installation

Do a Low Frequency Eddy

Current inspection of the

fuselage skin along all four

edges of the external doubler.

(a) (c)

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46 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 3 Airplanes with flat aft pressure bulkhead having less than 24,000 total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

(a) Repeat inspection at noted interval if no discrepancies are found.

(b) If any discrepancy is found, do the work of Condition 2 or 3 as applicable before further flight.

(c) If any discrepancy is found, contact Boeing and do the work required before further flight.

Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

1 year from original issue date of this .

service bulletin

Do a general visual and Eddy

Current High Frequency

(ETHF) Inspection of the accessible fuselage skin and

fasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides and

do the work listed based on

condition.

Airplanes with flat

aft pressure bulkhead having

24,000 or more total flight cycles as

of the original issue date of this

service bulletin

and having skin

repairs in the area

of inspection.

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47 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the accessible fuselage skin and

fasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides

Condition 1

(No Crack(s) or

Failed Fasteners

Found)

Option 1

(a) (b)

AND

6 years from the .

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Install full length improvement

modification with finger doublers.

AND

2 years from initial .

inspection of accessible skin

Remove previously installed .

local repairs and replace them

with new local repairs.

AND

5,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For new local skin repairs 12

inches or less long, do an external visual inspections for

cracks along all four edges of

the external doublers

(a) (c)

AND/OR

10,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For new skin repairs longer

than 12 inches, do a Low Frequency Eddy Current inspection of the fuselage skin along

all four edges of the external

doubler

(a) (c)

AND

6 years from the .

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Remove previously installed

local repairs and install full

length repair with finger doublers.

Export Controlled ECCN: 9E991 - BOEING

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Revision 2: September 18, 2013 DC8-53A080

48 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

AND

5,000 flight cycles30,000 flight cycles .

from full length repair with finger doublers installation

Do an external visual inspections for cracks along all four

edges of the external doublers, left and right sides.

(a) (c)

OR

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49 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the accessible fuselage skin and

fasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides

Option 2

(a) (b)

AND

2 years from initial .

inspection of accessible skin

Remove previously installed .

local repairs and replace them

with new local repairs.

AND

5,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For new local skin repairs 12

inches or less long, do an external visual inspections for

cracks along all four edges of

the external doublers

(a) (c)

AND/OR

10,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For new skin repairs longer

than 12 inches, do a Low Frequency Eddy Current inspection of the fuselage skin along

all four edges of the external

doubler

(a) (c)

AND

6 years from the .

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Remove previously installed

local repairs and install full

length improvement modification.

AND

10,000 flight cycles15,000 flight cycles .

from full length repair installation

Do a Low Frequency Eddy

Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

OR

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50 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

Remove previously installed Before further flight .

local repairs and install full

length repair with finger doublers.

Option 3

AND

5,000 flight cycles30,000 flight cycles .

from full length repair with finger doublers installation

Do an external visual inspections for cracks along all four

edges of the external doublers, left and right sides.

(a) (c)

OR

Remove previously installed Before further flight

local repairs and install full

length improvement modification.

Option 4

AND

10,000 flight cycles15,000 flight cycles

from installation of

repair

Do a Low Frequency Eddy

Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

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51 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

Condition 2 Replace all Failed Fasteners Before further flight . .

Any Failed Fastener(s) AND

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the accessible fuselage skin and

fasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides

Option 1

(a) (b)

AND

2 years from initial . .

inspection of accessible skin

Remove previously installed

local repairs and replace them

with new local repairs.

AND

5,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For new local skin repairs 12

inches or less long, do an external visual inspections for

cracks along all four edges of

the external doublers

(a) (c)

AND/OR

10,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For new local skin repairs

longer than 12 inches, do a

Low Frequency Eddy Current

inspection of the fuselage skin

along all four edges of the external doubler

(a) (c)

AND

6 years from the

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Remove previously installed

local repairs and install full

length repair with finger doublers.

AND

5,000 flight cycles30,000 flight cycles .

from full length repair with finger doublers installation

Do an external visual inspections for cracks along all four

edges of the external doublers, left and right sides.

(a) (c)

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52 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

OR

Option 2 Replace all Failed Fasteners Before further flight . .

AND

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the accessible fuselage skin and

fasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides

(a) (b)

AND

2 years from initial . .

inspection of accessible skin

Remove previously installed

local repairs and replace them

with new local repairs.

Export Controlled ECCN: 9E991 - BOEING

PROPRIETARY - Copyright © Unpublished

Work - See page 1 for details.

Original Issue: June 22, 2004

Revision 2: September 18, 2013 DC8-53A080

53 of 86

BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

AND

5,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For new local skin repairs 12

inches or less long, do an external visual inspections for

cracks along all four edges of

the external doublers

(a) (c)

AND/OR

10,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For new local skin repairs

longer than 12 inches, do a

Low Frequency Eddy Current

inspection of the fuselage skin

along all four edges of the external doubler

(a) (c)

AND

6 years from the

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Remove previously installed

local repairs and install full

length repair.

AND

10,000 flight cycles15,000 flight cycles .

from full length repair installation

Do a Low Frequency Eddy

Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

OR

Remove previously installed Before further flight . .

local repairs and install full

length repair with finger doubler

Option 3

AND

5,000 flight cycles30,000 flight cycles .

from full length repair with finger doublers installation

Do an external visual inspections for cracks along all four

edges of the external doublers, left and right sides.

(a) (c)

OR

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BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

Remove previously installed Before further flight . .

local repairs and install full

length repair

Option 4

AND

10,000 flight cycles15,000 flight cycles .

from full length repair installation

Do a Low Frequency Eddy

Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

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BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

Condition 3 Do local skin repair. Before further flight . .

Any Crack(s)

Found in Skin AND

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the accessible fuselage skin and

fasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides

Option 1

(a) (b)

AND

5,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For local skin repairs 12 inches or less long, do an external

visual inspections for cracks

along all four edges of the external doublers

(a) (c)

AND/OR

10,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For skin repairs longer than 12

inches, do a Low Frequency

Eddy Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

AND

2 years from initial . .

inspection of accessible skin

Remove previously installed

local repairs and replace them

with new local repairs

AND

5,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For local skin repairs 12 inches or less long, do an external

visual inspections for cracks

along all four edges of the external doublers

(a) (c)

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BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

AND/OR

10,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For skin repairs longer than 12

inches, do a Low Frequency

Eddy Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

AND

6 years from the .

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Remove previously installed

local repairs and install full

length repair with finger doubler

AND

5,000 flight cycles30,000 flight cycles .

from full length repair with finger doublers installation

Do an external visual inspections for cracks along all four

edges of the external doublers, left and right sides.

(a) (c)

OR

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BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

Option 2 Do local skin repair. Before further flight . .

AND

2,000 flight cyclesDo a general visual and Eddy 2,000 flight cycles .

Current High Frequency

(ETHF) Inspection of the accessible fuselage skin and

fasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides

(a) (b)

AND

5,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For local skin repairs 12 inches or less long, do an external

visual inspections for cracks

along all four edges of the external doublers

(a) (c)

AND/OR

10,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For skin repairs longer than 12

inches, do a Low Frequency

Eddy Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

AND

2 years from initial . .

inspection of accessible skin

Remove previously installed

local repairs and replace them

with new local repairs

AND

5,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For local skin repairs 12 inches or less long, do an external

visual inspections for cracks

along all four edges of the external doublers

(a) (c)

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BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

AND/OR

10,000 flight cycles from initial

inspection

15,000 flight cycles .

from installation of

repair

For skin repairs longer than 12

inches, do a Low Frequency

Eddy Current inspection of the

fuselage skin along all four

edges of the external doubler

(a) (c)

AND

6 years from the .

issue date of Revision 1 of this service bulletin

Accumulation of

45,400 total flight

cycles

Remove previously installed

local repairs and install full

length repair

AND

10,000 flight cycles15,000 flight cycles .

from full length repair installation

Do a Low Frequency Eddy

Current inspection of the

fuselage skin along all four

edges of the external doubler.

(a) (c)

OR

Remove previously installed Before further flight . .

local repairs and install full

length repair with finger doubler

Option 3

AND

5,000 flight cycles30,000 flight cycles .

from full length repair with finger doublers installation

Do an external visual inspections for cracks along all four

edges of the external doublers, left and right sides.

(a) (c)

OR

Remove previously installed Before further flight . .

local repairs and install full

length repair

Option 4

AND

10,000 flight cycles15,000 flight cycles .

from full length repair installation

Do a Low Frequency Eddy

Current inspection of the

fuselage skin along all four

edges of the external doubler.

(a) (c)

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BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Table 4 Airplanes with flat aft pressure bulkhead having 24,000 or more total flight cycles as of the

original issue date of this service bulletin and having skin repairs in the area of inspection:

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs

Later)

Condition Action

(a) Repeat inspection at noted interval if no discrepancies are found.

(b) If any discrepancy is found, do the work of Condition 2 or 3 as applicable before further flight.

(c) If any discrepancy is found, contact Boeing and do the work required before further flight.

F. Approval

This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified

in this service bulletin comply with the applicable regulations and are FAA approved. This service

bulletin and its approval were based on the airplane in its original Boeing delivery configuration or as

modified by other approved Boeing changes.

If an airplane has a non-Boeing modification or repair that affects a component or system also affected

by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval

before incorporating this service bulletin.

In addition, the Manager of the FAA Los Angeles Aircraft Certification Office approves the action (i.e.

inspection or modification) defined in this service bulletin as an alternative method of compliance to

the requirements of paragraphs (f), (g), (h), (i), and (j) of AD 2008-06-23. All provisions of AD 2008-06-23

that are not specifically referenced in the above statement remain fully applicable and must be complied

with.

G. Manpower

The table below shows an estimate of the task hours necessary to do this inspection for each airplane.

This estimate is for direct labor only, done by an experienced crew. Adjust the estimate with operator

task hour data if necessary. The estimate does not include lost time. These are some examples of lost

time:

• Time to adjust to the workplace

• Time to schedule the work

• Time to inspect the work

• Time to cure the materials

• Time to make the parts

• Time to find the tools.

NOTE: Task hour tables are listed for each inspection method, Operator to determine which inspection

process will be used.

Task Number of Persons Task Hours Elapsed Hours

Open Access 1 0.5 0.5

Inspection Method 2 2.0 1.0

101

Close Access 1 0.5 0.5

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BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
Task Number of Persons Task Hours Elapsed Hours

TOTAL FOR EACH AIRPLANE 3.0 2.0

Task Number of Persons Task Hours Elapsed Hours

Open Access 1 0.5 0.5

Inspection Method 2 8.0 4.0

102

Close Access 1 0.5 0.5

TOTAL FOR EACH AIRPLANE 9.0 5.0

Task Number of Persons Task Hours Elapsed Hours

Open Access 1 0.5 0.5

Inspection Method 2 4.0 2.0

103

Close Access 1 0.5 0.5

TOTAL FOR EACH AIRPLANE 5.0 3.0

NOTE: Actual task hour and elapsed hours for repair modification are contingent upon inspection

findings and are to be estimated by the operator.

H. Weight and Balance Changes

Weight and balance changes affected by incorporation of this service bulletin are contingent upon the

changes to each particular airplane. Weight data is to be computed by the operator by weighing parts

removed and parts installed during this change. Necessary revisions should be made to the appropriate

airplane weight and balance report.

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. Federal Aviation Administration (FAA) Airworthiness Directive (AD) 2008-06-23

b. DC8 Aircraft Maintenance Manual (AMM) 7-20-1.

c. DC-8 Structural Repair Manual (SRM) 51.

d. DC8 Structural Repair Manual (SRM) 51-1-11, 51-1-20D, 51-1-21.

e. DC-8 Widespread Fatigue Damage Summary Document, Report Number MDC 12K9001,

dated July 11, 2012.

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BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
2. Data Supplied with this Service Bulletin:

No data is supplied with this service bulletin. To obtain the data necessary to support this service

bulletin submit a data request to:

Data and Services Management

MS D800-0019

3855 Lakewood Boulevard

Long Beach, California 90846

Phone: (562) 593-6996

Fax: (562) 593-2001

E-mail: dse.boecom@boeing.com

a. Drawings:

Drawing No Title Sheet DCN/REV ADCN

SKIN REPAIR - LONG 28 FWD OF AFT AEO B -

PRESSURE BHD, STA 1566.00 SERVICE

REWORK DRAWING

SR08530032

AEO A -

DWG - -

3. Installation Drawings Used in the Preparation of this Service Bulletin:

Drawing Number Title Change

Panel Assembly - L17 to L28 Stations from AC

1490 to 1690

5649328

Panel Assembly Bottom, L28 to L28 Stations V

from 1490 to 1690

5649329

K. Publications Affected

None.

L. Interchangeability and Intermixability of Parts

Not affected.

M. Software Accomplishment Summary

Not affected.

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BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
2. MATERIAL INFORMATION

A. Material - Price and Availability

The operator can supply the parts and materials shown in Paragraph 2.C., Parts Necessary for Each

Airplane. As an alternative, operators can purchase the parts from Boeing Spares. This service bulletin

does not show the Boeing price and supply data.

B. Industry Support Information

Boeing warranty remedies are not available for the configuration changes given in this service bulletin.

C. Parts Necessary for Each Airplane

1. Kits/Parts:

None.

2. Parts and Materials Supplied by the Operator:

NOTE: Maximum quantity of parts is shown, actual quantity is to be determined based upon

inspection findings.

Repair Kits:

QTY for Configu- Name Notes

rations 7005 and

7007

QTY for Configurations 7001 and

7003

Part Number

SR08530032-3 1 1 Doubler (a)

SR08530032-5 1 1 Filler (a)

SR08530032-7 1 Doubler (a)

SR08530032-9 1 Doubler (a)

SR08530032-11 1 Doubler (a)

SR08530032-13 1 Doubler (a)

SR08530032-15 1 Doubler (a)

SR08530032-17 1 Doubler (a)

SR08530032-19 1 Doubler (a)

SR08530032-21 1 Doubler (a)

(a) Refer to Service Rework Drawing SR08530032 for fabrication instructions.

Modification Kits:

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BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
QTY for Configu- Name Notes

rations 7013 and

7015

QTY for Configurations 7009 and

7011

Part Number

SR08530032-3 1 1 Doubler (a)

SR08530032-7 1 Doubler (a)

SR08530032-9 1 Doubler (a)

SR08530032-11 1 Doubler (a)

SR08530032-13 1 Doubler (a)

SR08530032-15 1 Doubler (a)

SR08530032-17 1 Doubler (a)

SR08530032-19 1 Doubler (a)

SR08530032-21 1 Doubler (a)

(a) Refer to Service Rework Drawing SR08530032 for fabrication instructions.

Fastener kits

QTY SR08530032 Name Notes

(Any Configuration)

Part Number

HLT435-6-3 110 Hi-Lok (a)

HLT435-6-4 272 Pin (a)

HLT435-6-5 18 Pin (a)

HLT435-6-6 36 Pin (a)

HLT435-6-7 16 Pin (a)

HLT435-6-8 1 Pin (a)

MS21042L3 447 Nut (a)

NAS1097AD6-6D 214 Rivet (a)

NAS1097AD6-7D 343 Rivet (a)

NAS1149F1165P 420 Washer (a) (b)

NAS1252-10L 18 Washer (a) (b)

NAS8803-8 12 Bolt (a) (b)

3D0006-3 18 Nut Assy (a) (b)

(a) Maximum quantity listed

(b) Refer to AEPL or SRM Chapter 51 for approved substitutes

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ALERT ALERT
Part Number/Specification QTY Supplier CAGE

PRC-DeSoto International, 92108

Incorporated

PR-1422 B-2 Sealant 2 Qts

(DMS 2082

or Equivalent) P.O. Box 1800

Sylmar, California 91342 PR-1431G Sealant 1 Qt

(DMS 2013

or

or Equivalent)

3. Parts Modified and Reidentified:

None.

4. Parts Removed and Not Replaced:

None.

D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

The operator can supply the tools shown in Paragraph 2.F., Special Tooling Necessary to do this

Service Bulletin. Tool price and supply data are not given.

F. Special Tooling Necessary to do this Service Bulletin

Tool Number Name Supplier CAGE Notes

(a) (b)

(c)

Olympus NDT NE, Incorpo- 29192

rated NDT NE, Incorporated

Flaw Detector

(Impedance Plane

Display)

NORTEC NDT 24

421 North Quay Street

Kennewick, Washington

99336-7735

OR

(a) (b)

(d)

Qi2 07ZF2

Quest Center

Magneto-optic/Eddy Current Imager

(MOI)

MOI Model 301

or

Subsequent 19823 58th Place South -

Suite 200

Kent, Washington 98032

OR

(a) (b)

(e)

Olympus NDT NE, Incorpo- 29192

rated NDT NE, Incorporated

Reflectance Type

Sliding Probe operating at 35 kHz.

SPO-2210

421 North Quay Street

Kennewick, Washington

99336-7735

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ALERT ALERT
Tool Number Name Supplier CAGE Notes

(a) The equipment/materials listed above were used to develop this procedure. Refer to

Nondestructive Testing Standard Practice Manual (NDTSPM) Part 06-00-04 for Supplier/Vendor

information.

(b) Equipment/material substitutions producing results equivalent to those defined by this

document may also be used. Refer to NDTSPM Parts 01-00-03 and 06-00-03 for equipment/material information.

(c) Used in Inspection Sequence 102 and 103

(d) Used in Inspection Sequence 101

(e) Used in Inspection Sequence 103

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BOEING SERVICE BULLETIN DC8-53A080

ALERT ALERT
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

WARNING: IF ELECTRICAL POWER IS APPLIED TO THE AIRPLANE, MAKE SURE YOU OBEY

ALL PRECAUTIONS WHILE YOU DO WORK. IF YOU DO NOT OBEY THE

PRECAUTIONS, DEATH OR INJURY TO PERSONS, AND DAMAGE TO THE AIRPLANE

CAN OCCUR.

CAUTION: ELECTRICALLY GROUND THE AIRPLANE. THIS WILL HELP TO PREVENT DAMAGE

TO THE AIRPLANE OR EQUIPMENT.

CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR

OTHER ELECTRICAL DAMAGE.

CAUTION: ELECTRICALLY GROUND THE AIRPLANE. THIS WILL HELP TO PREVENT DAMAGE

TO THE AIRPLANE OR EQUIPMENT.

NOTE: 1. Visually inspect periphery of fasteners adjacent to detected skin cracks for cracking.

If cracks exist at these fasteners, skin removal must encompass these areas to insure

all cracks are removed.

2. When using HI-LOK pins as alternate fastener for rivets, check for grip length required.

Do not use grip length called out for the rivets.

1. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for

definition of the acronyms.

2. Equivalent parts are listed in the AEPL, Drawing 7595071.

3. Use the approved fastener and process material substitutions, in accordance with

DC-8 SRM 51.

4. If the length of any fastener specified in this service bulletin does not meet installation

standards given in Structural Repair Manual (SRM) Chapter 51, then a fastener of

the same specification, or an approved substitute, with a length which meets the

installation standards given in SRM Chapter 51 may be used. In addition, washers

may be installed for fastener grip length in accordance with SRM Chapter 51.

5. A 1/8-inch thick stack of the same type washers called for in this service bulletin is

the maximum thickness which may be used under fastener head or nut to counteract

accumulation of tolerances.

EXCEPTION: When the available fastener length increments are greater than

1/16-inch, a 3/16-inch thick stack of the same type washers may be used.

6. Unless shown differently, these dimensions and tolerances are used:

– Linear dimensions are in inches

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ALERT ALERT
– Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus

or minus 0.03 inch.

– Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch

– Angular tolerance is plus or minus 2 degrees

– Hole dimensions for standard solid rivets are in DC-8 SRM 51.

– Torque limits to tighten nuts and bolts are in DC-8 SRM 51.

7. Refer to these SRM chapters for applicable operations, as accepted procedures:

– DC8 SRM 51-1-11 Sealant Application

– DC8 SRM 51-1-11 Drilling and Countersinking

– DC8 SRM 51-1-21 Removing and Installing Rivets

– DC8 SRM 51-1-20D Removing and Installing Hi-Loks

– DC8 SRM 51-1-20D Substitution and Interchangeability

8. Obey all of the warnings and cautions given in the specified manual sections.

9. A Detailed Inspection is defined as: An intensive examination of a specific item,

installation, or assembly to detect damage, failure, or irregularity. Available lighting

is normally supplemented with a direct source of good lighting at an intensity deemed

appropriate. Inspection aids such as mirrors, magnifying lenses, etc. may be

necessary. Surface cleaning and elaborate procedures may be required.

10. A General Visual Inspection is defined as: A visual examination of an interior or

exterior area, installation or assembly to detect obvious damage, failure or irregularity.

This level of inspection is made from within touching distance unless otherwise

specified. A mirror may be necessary to enhance visual access to all exposed surfaces

in the inspection area. This level of inspection is made under normally available

lighting conditions such as daylight, hangar lighting, flashlight or drop-light and may

require removal or opening of access panels or doors. Stands, ladders or platforms

may be required to gain proximity to the area being checked.

11. These work instructions refer to procedures included in other Boeing documents.

When the words "refer to" are used and the operator has an accepted alternative

procedure, the accepted alternative procedure can be used. When the words "in

accordance with" are included in the instruction, the procedure in the Boeing document

must be used.

12. If it is necessary to remove more parts for access, you can remove those parts. If

you can get access without removing identified parts, it is not necessary to remove

all of the identified parts. Jacking and shoring limitations must be observed.

13. Shaded areas in Figures are reference only. Shaded areas in Figures may look

different than your airplane.

14. When more than one OPTION is given for a CONDITION, do only one of the OPTION

numbers. When more than one ACTION is given for a CONDITION number or an

OPTION number, do all of the ACTION numbers for that CONDITION number or

OPTION number.

15. The compliance times for the actions in Paragraph 3.B., WORK INSTRUCTIONS

are in Paragraph 1.E., Compliance.

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ALERT ALERT
16. The CONDITIONS, ACTIONS and OPTIONS shown apply to each side of the airplane

independently.

17. Accomplishment of full length modification/repair with finger doubler per Service

Rework Drawing SR08530032-7001, -7003, -7009, or -7011 and full length

modification/repair per Service Rework Drawing SR08530032-7005, -7007, -7013

or -7015 will require shoring of airplane. Refer to DC8 AMM 7-20-1.

18. Repair parts added per this rework must be clearly identified for traceability to this

repair per operators standard procedures.

B. WORK INSTRUCTIONS

Group 1, Configuration 1:

1. If using the Sliding Probe inspection method (Method 103), fabricate reference standard as shown

on Figure 1.

2. Gain access to tail skid, tail cone section door number 60. Refer to DC-8 access door diagram

and data sheets.

3. Accomplish general visual and High Frequency Eddy Current inspections of the fuselage skin for

cracks and/or loose fasteners using one of the methods and techniques listed in Appendix A.

Inspect at longeron 28 between the tail section bolted connection to forward of flat aft pressure

bulkhead. Inspect both left and right sides as shown on Figure 2, and accomplish the following

based on condition:

a. Condition 1 (No Crack(s) or Failed Fasteners Found))

Option 1

(1) Continue repetitive inspections in accordance with Paragraph 1.E., Compliance.

(2) Do full length improvement modification with finger doublers in accordance with Service

Rework Drawing SR08530032-7009 (left side) or SR08530032-7011 (right side) in

accordance with Paragraph 1.E., Compliance.

(3) Do an external visual inspection for cracks along all four edges of the external doublers,

left and right sides in accordance with Paragraph 1.E., Compliance.

Option 2

(1) Continue repetitive inspections in accordance with Paragraph 1.E., Compliance.

(2) Do full length improvement modification in accordance with Service Rework Drawing

SR08530032-7013 (left side) or SR08530032-7015 (right side) in accordance with

Paragraph 1.E., Compliance.

(3) Do an external Low Frequency Eddy Current inspection for cracks along all four edges

of the external doublers, left and right sides in accordance with Paragraph 1.E.,

Compliance.

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ALERT ALERT
b. Condition 2 (Any Failed Fastener(s))

Option 1

(1) Replace all failed fasteners

(2) Continue repetitive inspections in accordance with Paragraph 1.E., Compliance.

(3) Do full length improvement modification with finger doublers in accordance with Service

Rework Drawing SR08530032-7009 (left side) or SR08530032-7011 (right side) in

accordance with Paragraph 1.E., Compliance.

(4) Do an external visual inspection for cracks along all four edges of the external doublers,

left and right sides in accordance with Paragraph 1.E., Compliance.

Option 2

(1) Replace all failed fasteners

(2) Continue repetitive inspections in accordance with Paragraph 1.E., Compliance.

(3) Do full length improvement modification in accordance with Service Rework Drawing

SR08530032-7013 (left side) or SR08530032-7015 (right side) in accordance with

Paragraph 1.E., Compliance.

(4) Do an external Low Frequency Eddy Current inspection for cracks along all four edges

of the external doublers, left and right sides in accordance with Paragraph 1.E.,

Compliance.

Option 3

(1) Do full length improvement modification with finger doublers in accordance with Service

Rework Drawing SR08530032-7009 (left side) or SR08530032-7011 (right side).

(2) Do an external visual inspection for cracks along all four edges of the external doublers,

left and right sides in accordance with Paragraph 1.E., Compliance.

Option 4

(1) Do full length improvement modification in accordance with Service Rework Drawing

SR08530032-7013 (left side) or SR08530032-7015 (right side).

(2) Do an external Low Frequency Eddy Current inspection for cracks along all four edges

of the external doublers, left and right sides in accordance with Paragraph 1.E.,

Compliance.

c. Condition 3 (Any Crack(s) Found in Skin)

Option 1

(1) Repair cracked skin locally in accordance with Service Rework Drawing SR08530032-7005

(left side) or SR08530032-7007 (right side)

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(2) For repairs 12 inches or shorter, do an external visual inspection for cracks along all four

edges of the external doublers, left and right sides in accordance with Paragraph 1.E.,

Compliance.

(3) For repairs longer than 12 inches, do an external Low Frequency Eddy Current inspection

for cracks along all four edges of the external doublers, left and right sides in accordance

with Paragraph 1.E., Compliance.

(4) Do repetitive inspections of accessible skin in accordance with Paragraph 1.E.,

Compliance.

(5) Do full length repair with finger doublers in accordance with Service Rework Drawing

SR08530032-7001 (left side) or SR08530032-7003 (right side) in accordance with

Paragraph 1.E., Compliance.

(6) Do an external visual inspection for cracks along all four edges of the external doublers,

left and right sides in accordance with Paragraph 1.E., Compliance.

Option 2

(1) Repair cracked skin locally in accordance with Service Rework Drawing SR08530032-7005

(left side) or SR08530032-7007 (right side)

(2) For repairs 12 inches or shorter, do an external visual inspection for cracks along all four

edges of the external doublers, left and right sides in accordance with Paragraph 1.E.,

Compliance.

(3) For repairs longer than 12 inches, do an external Low Frequency Eddy Current inspection

for cracks along all four edges of the external doublers, left and right sides in accordance

with Paragraph 1.E., Compliance.

(4) Do repetitive inspections of accessible skin in accordance with Paragraph 1.E.,

Compliance.

(5) Do full length repair in accordance with Service Rework Drawing SR08530032-7005 (left

side) or SR08530032-7007 (right side) in accordance with Paragraph 1.E., Compliance.

(6) Do an external Low Frequency Eddy Current inspection for cracks along all four edges

of the external doublers, left and right sides in accordance with Paragraph 1.E.,

Compliance.

Option 3

(1) Do full length repair with finger doublers in accordance with Service Rework Drawing

SR08530032-7001 (left side) or SR08530032-7003 (right side) in accordance with

Paragraph 1.E., Compliance.

(2) Do an external visual inspection for cracks along all four edges of the external doublers,

left and right sides in accordance with Paragraph 1.E., Compliance.

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Option 4

(1) Do full length repair in accordance with Service Rework Drawing SR08530032-7005 (left

side) or SR08530032-7007 (right side).

(2) Do an external Low Frequency Eddy Current inspection for cracks along all four edges

of the external doublers, left and right sides in accordance with Paragraph 1.E.,

Compliance.

4. Record results of inspection, include the factory serial number of affected aircraft, flight hours, and

accumulated landings. Forward results to:

Boeing Commercial Airplanes

Manager

Structures/Payloads

Technical and Fleet Support

Service Engineering/Commercial Aviation Services

3855 Lakewood Boulevard

Long Beach, California 90846

5. Lower airplane and remove shoring equipment if applicable.

6. Close access doors.

7. Put the airplane back in serviceable condition.

Group 1, Configuration 2:

1. If using the Sliding Probe inspection method (Method 103), fabricate reference standard as shown

on Figure 1.

2. Gain access to tail skid, tail cone section door number 60. Refer to DC-8 access door diagram

and data sheets.

3. Accomplish general visual and High Frequency Eddy Current inspections of the accessible fuselage

skin for cracks and/or loose fasteners using one of the methods and techniques listed in Appendix

A. Inspect at longeron 28 between the tail section bolted connection to forward of flat aft pressure

bulkhead. Inspect both left and right sides as shown on Figure 2, and accomplish the following

based on condition:

a. Condition 1 (No Crack(s) or Failed Fasteners Found))

Option 1

(1) Do repetitive inspections of accessible skin in accordance with Paragraph 1.E.,

Compliance.

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(2) Replace existing local repairs with new local repairs in accordance with Service Rework

Drawing SR08530032-7005 (left side) or SR08530032-7007 (right side) in accordance

with Paragraph 1.E., Compliance.

(3) For repairs 12 inches or shorter, do an external visual inspection for cracks along all four

edges of the external doublers, left and right sides in accordance with Paragraph 1.E.,

Compliance.

(4) For repairs longer than 12 inches, do an external Low Frequency Eddy Current inspection

for cracks along all four edges of the external doublers, left and right sides in accordance

with Paragraph 1.E., Compliance.

(5) Do full length repair with finger doublers in accordance with Service Rework Drawing

SR08530032-7001 (left side) or SR08530032-7003 (right side) in accordance with

Paragraph 1.E., Compliance.

(6) Do an external visual inspection for cracks along all four edges of the external doublers,

left and right sides in accordance with Paragraph 1.E., Compliance.

Option 2

(1) Do repetitive inspections of accessible skin in accordance with Paragraph 1.E.,

Compliance.

(2) Replace existing local repairs with new local repairs in accordance with Service Rework

Drawing SR08530032-7005 (left side) or SR08530032-7007 (right side) in accordance

with Paragraph 1.E., Compliance.

(3) For repairs 12 inches or shorter, do an external visual inspection for cracks along all four

edges of the external doublers, left and right sides in accordance with Paragraph 1.E.,

Compliance.

(4) For repairs longer than 12 inches, do an external Low Frequency Eddy Current inspection

for cracks along all four edges of the external doublers, left and right sides in accordance

with Paragraph 1.E., Compliance.

(5) Do full length repair in accordance with Service Rework Drawing SR08530032-7005 (left

side) or SR08530032-7007 (right side) in accordance with Paragraph 1.E., Compliance.

(6) Do an external Low Frequency Eddy Current inspection for cracks along all four edges

of the external doublers, left and right sides in accordance with Paragraph 1.E.,

Compliance.

Option 3

(1) Replace existing local repairs with full length repair with finger doublers in accordance

with Service Rework Drawing SR08530032-7001 (left side) or SR08530032-7003 (right

side) in accordance with Paragraph 1.E., Compliance.

(2) Do an external visual inspection for cracks along all four edges of the external doublers,

left and right sides in accordance with Paragraph 1.E., Compliance.

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Option 4

(1) Replace existing local repairs with full length repair in accordance with Service Rework

Drawing SR08530032-7005 (left side) or SR08530032-7007 (right side) in accordance

with Paragraph 1.E., Compliance.

(2) Do an external Low Frequency Eddy Current inspection for cracks along all four edges

of the external doublers, left and right sides in accordance with Paragraph 1.E.,

Compliance.

b. Condition 2 (Any Failed Fastener(s))

Option 1

(1) Replace failed fasteners.

(2) Do repetitive inspections of accessible skin in accordance with Paragraph 1.E.,

Compliance.

(3) Replace existing local repairs with new local repairs in accordance with Service Rework

Drawing SR08530032-7005 (left side) or SR08530032-7007 (right side) in accordance

with Paragraph 1.E., Compliance.

(4) For repairs 12 inches or shorter, do an external visual inspection for cracks along all four

edges of the external doublers, left and right sides in accordance with Paragraph 1.E.,

Compliance.

(5) For repairs longer than 12 inches, do an external Low Frequency Eddy Current inspection

for cracks along all four edges of the external doublers, left and right sides in accordance

with Paragraph 1.E., Compliance.

(6) Do full length repair with finger doublers in accordance with Service Rework Drawing

SR08530032-7001 (left side) or SR08530032-7003 (right side) in accordance with

Paragraph 1.E., Compliance.

(7) Do an external visual inspection for cracks along all four edges of the external doublers,

left and right sides in accordance with Paragraph 1.E., Compliance.

Option 2

(1) Replace failed fasteners.

(2) Do repetitive inspections of accessible skin in accordance with Paragraph 1.E.,

Compliance.

(3) Replace existing local repairs with new local repairs in accordance with Service Rework

Drawing SR08530032-7005 (left side) or SR08530032-7007 (right side) in accordance

with Paragraph 1.E., Compliance.

(4) For repairs 12 inches or shorter, do an external visual inspection for cracks along all four

edges of the external doublers, left and right sides in accordance with Paragraph 1.E.,

Compliance.

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(5) For repairs longer than 12 inches, do an external Low Frequency Eddy Current inspection

for cracks along all four edges of the external doublers, left and right sides in accordance

with Paragraph 1.E., Compliance.

(6) Replace existing local repairs with full length repair in accordance with Service Rework

Drawing SR08530032-7005 (left side) or SR08530032-7007 (right side) in accordance

with Paragraph 1.E., Compliance.

(7) Do an external visual inspection for cracks along all four edges of the external doublers,

left and right sides in accordance with Paragraph 1.E., Compliance.

Option 3

(1) Replace existing local repairs with full length repair with finger doublers in accordance

with Service Rework Drawing SR08530032-7001 (left side) or SR08530032-7003 (right

side) in accordance with Paragraph 1.E., Compliance.

(2) Do an external visual inspection for cracks along all four edges of the external doublers,

left and right sides in accordance with Paragraph 1.E., Compliance.

Option 4

(1) Replace existing local repairs with full length repair in accordance with Service Rework

Drawing SR08530032-7005 (left side) or SR08530032-7007 (right side) in accordance

with Paragraph 1.E., Compliance.

(2) Do an external Low Frequency Eddy Current inspection for cracks along all four edges

of the external doublers, left and right sides in accordance with Paragraph 1.E.,

Compliance.

c. Condition 3 (Any Crack(s) Found in Skin)

Option 1

(1) Repair cracked skin locally in accordance with Service Rework Drawing SR08530032-7005

(left side) or SR08530032-7007 (right side)

(2) Do repetitive inspections of accessible skin in accordance with Paragraph 1.E.,

Compliance.

(3) Replace existing local repairs with new local repairs in accordance with Service Rework

Drawing SR08530032-7005 (left side) or SR08530032-7007 (right side) in accordance

with Paragraph 1.E., Compliance.

(4) For repairs 12 inches or shorter, do an external visual inspection for cracks along all four

edges of the external doublers, left and right sides in accordance with Paragraph 1.E.,

Compliance.

(5) For repairs longer than 12 inches, do an external Low Frequency Eddy Current inspection

for cracks along all four edges of the external doublers, left and right sides in accordance

with Paragraph 1.E., Compliance.

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(6) Replace existing local repairs with full length repair with finger doublers in accordance

with Service Rework Drawing SR08530032-7001 (left side) or SR08530032-7003 (right

side) in accordance with Paragraph 1.E., Compliance.

(7) Do an external visual inspection for cracks along all four edges of the external doublers,

left and right sides in accordance with Paragraph 1.E., Compliance.

Option 2

(1) Repair cracked skin locally in accordance with Service Rework Drawing SR08530032-7005

(left side) or SR08530032-7007 (right side)

(2) Do repetitive inspections of accessible skin in accordance with Paragraph 1.E.,

Compliance.

(3) Replace existing local repairs with new local repairs in accordance with Service Rework

Drawing SR08530032-7005 (left side) or SR08530032-7007 (right side) in accordance

with Paragraph 1.E., Compliance.

(4) For repairs 12 inches or shorter, do an external visual inspection for cracks along all four

edges of the external doublers, left and right sides in accordance with Paragraph 1.E.,

Compliance.

(5) For repairs longer than 12 inches, do an external Low Frequency Eddy Current inspection

for cracks along all four edges of the external doublers, left and right sides in accordance

with Paragraph 1.E., Compliance.

(6) Replace existing local repairs with full length repair in accordance with Service Rework

Drawing SR08530032-7005 (left side) or SR08530032-7007 (right side) in accordance

with Paragraph 1.E., Compliance.

(7) Do an external visual inspection for cracks along all four edges of the external doublers,

left and right sides in accordance with Paragraph 1.E., Compliance.

Option 3

(1) Repair cracked skin and replace existing local repairs with full length repair with finger

doublers in accordance with Service Rework Drawing SR08530032-7001 (left side) or

SR08530032-7003 (right side) in accordance with Paragraph 1.E., Compliance.

(2) Do an external visual inspection for cracks along all four edges of the external doublers,

left and right sides in accordance with Paragraph 1.E., Compliance.

Option 4

(1) Repair cracked skin and replace existing local repairs with full length repair in accordance

with Service Rework Drawing SR08530032-7005 (left side) or SR08530032-7007 (right

side) in accordance with Paragraph 1.E., Compliance.

(2) Do an external Low Frequency Eddy Current inspection for cracks along all four edges

of the external doublers, left and right sides in accordance with Paragraph 1.E.,

Compliance.

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4. Record results of inspection, include the factory serial number of affected aircraft, flight hours, and

accumulated landings. Forward results to:

Boeing Commercial Airplanes

Manager

Structures/Payloads

Technical and Fleet Support

Service Engineering/Commercial Aviation Services

3855 Lakewood Boulevard

Long Beach, California 90846

5. Lower airplane and remove shoring equipment if applicable.

6. Close access doors.

7. Put the airplane back in serviceable condition.

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FIGURE 1: METHOD 103 REFLECTANCE TYPE SLIDING PROBE PROCEDURE REFERENCE STANDARD

(SHEET 1 OF 2)

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FIGURE 1: METHOD 103 REFLECTANCE TYPE SLIDING PROBE PROCEDURE REFERENCE STANDARD

(SHEET 2 OF 2)

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FIGURE 2: HIGH FREQUENCY EDDY CURRENT INSPECTION OF SKIN ALONG LONGERON 28

(SHEET 1 OF 1)

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FIGURE 3: METHOD 103 REFLECTANCE TYPE SLIDING PROBE PROCEDURE

(SHEET 1 OF 1)

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FIGURE 4: METHOD 103 REFLECTANCE TYPE SLIDING PROBE PROCEDURE

(SHEET 1 OF 1)

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ALERT ALERT
Model Affected: DC-8

Drawing Reference: 5649328, 5649329

Requirement:

TO COMPLETE THE REQUIREMENTS OF THIS INSPECTION,THE PRIMARY INSPECTION (01), OF EACH

INSPECTION SEQUENCE, OR ITS ALTERNATE SUBSTITUTE(S) MUST BE ACCOMPLISHED.

NOTE:

1. ALTERNATE INSPECTIONS WILL BE IDENTIFIED BY NUMERALS OTHER THAN 01.

2. MULTIPLE ALTERNATE INSPECTIONS WHICH MUST BE PERFORMED TO ADEQUATELY REPLACE

A PRIMARY INSPECTION WILL BE IDENTIFIED BY AN ALPHA CHARACTER FOLLOWING THE

ALTERNATE DESIGNATOR, i.e., 02a AND 02b, ETC.

3. INSPECTIONS ARE TYPICALLY IDENTIFIED WITH THE FIRST DIGIT REPRESENTING THE

INSPECTION SEQUENCE NUMBER. THE FOLLOWING DIGITS REPRESENT THE INSPECTION

METHOD.

Inspection Sequence 1:

01. Eddy Current, High Frequency - Magneto-Optic/Eddy Current Imager

02. Eddy Current, High Frequency - Surface Probe

03. Eddy Current, High Frequency - Sliding Probe

Description:

The inspection area consists of the fuselage skin panels 5649328 (upper panels, left and right sides) and 5649329

(lower panel) at the longitudinal skin splice along Longeron 28 from Fuselage Stations 1490 to 1566 (for basic

model, see Figure 1 for other models). Inspect the upper panels at the two fastener rows common with Longeron

28. Inspect the lower panel at the fastener row in common with Longeron 28 and -11 doubler (upper row) and

the lower row in common with the -11 doubler only. The purpose of these inspections is to detect fatigue cracks

initiating at the fastener hole and propagating in the forward/aft direction. See Figure 1.

Access:

FOLLOW APPLICABLE SAFETY INSTRUCTIONS AND PRECAUTIONS PER THE NONDESTRUCTIVE

TESTING STANDARD PRACTICE MANUAL (NDTSPM) PARTS 01-00-01 AND 06-00-01 AS WELL AS ALL

LOCAL AND COMPANY REQUIREMENTS.

Preparation for Inspection:

A. Remove all dirt, grease, and loose paint from the inspection area.

B. Thoroughly clean the inspection area with an approved cleaning agent.

Appendix A:

(SHEET 1 OF 4)

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ALERT ALERT
General Visual Inspection:A. Perform a preliminary check of the general inspection area for cleanliness, presence

of foreign objects, distortion, damage, cracks, corrosion, security of parts and evidence of loose attachments.

B. If additional information regarding visual inspection is desired, See Part 09 of the Nondestructive Testing

Standard Practice Manual (NDTSPM.)

Equipment/Materials

SEQUENCE APPLICABILITYDESCRIPTION

A EDDY CURRENT

Olympus NDT NE, Incorpo- 102 103

rated

Flaw Detector (Impedance Plane Display).

NORTEC NDT 24

1

Magneto-optic/Eddy Current Imager (MOI).Model PRI Instrumentation. 101

301

2

Olympus NDT NE, Incorpo- 103

rated

Reflectance Type Sliding Probe operating at 35

kHz.SPO-2210

3

High Frequency Reference Standard (sliding Fabrication source optional. 103

probe procedure). See Figure 4 and Figure 5 for

fabrication details. See Note 3 below.

4

B SURFACE PREPARATION

Cleaning Agent in conformance with environmen- Source optional. ALL

tal regulations and harmless to surfaces contacted.

1

NOTE: The equipment/materials listed above were used to develop this procedure. See NDTSPM

Part 06-00-04 for supplier/ vendor information

1.

2. Equipment/material substitutions producing results equivalent to those defined by this document

may also be used. See NDTSPM Parts 01-00-03 and 06-00-03 for equipment/material

information.

3. The High Frequency Reference Standard for sliding probe procedure is the same as the DC-9

Supplemental Inspection Document (SID) 9RS11 standard. Reference DC-9 SID, Volume II,

Reference Standard Supplement, Pages 36 and 37 for fabrication. MD-80 SID, Volume II,

Section 2-1, Figure 15 may also be referenced for fabrication of the 9RS11. The 9RS11

standard may be substituted for the sliding probe procedure standard.

Inspection Procedure

A. Inspection Sequence 1:

1. Inspection Method 01 (Eddy Current, High Frequency, MOI)

Appendix A:

(SHEET 2 OF 4)

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a. Perform a High Frequency Eddy Current surface inspection at the fuselage skin panels 5649328

(upper panels, left and right sides) and 5649329 (lower panel) at the longitudinal skin splice along

Longeron 28 from Fuselage Stations 1490 to 1566 (basic model, see Figure 2 for other models).

Inspect the upper panels at the two fastener rows common with Longeron 28. Inspect the lower

panels at the fastener row in common with Longeron 28 and -11 doubler (upper row) and the lower

row in common with the -11 doubler only. Scan the full length of the fastener rows looking for

cracks propagating in the forward and aft direction following the instructions found in the

Nondestructive Testing Standard Practice Manual (NDTSPM) 06-10-03.001 (M.O.I. - Procedure

1). See Figure 2.

2. Inspection Method 02 (Eddy Current, High Frequency, Pencil Probe)

a. Perform a High Frequency Eddy Current surface inspection at the fuselage skin panels 5649328

(upper panels, left and right sides) and 5649329 (lower panel) at the longitudinal skin splice along

Longeron 28 from Fuselage Stations 1490 to 1566 (basic model, see Figure 2 for other models).

Inspect the upper panels at the two fastener rows common with Longeron 28. Inspect the lower

panel at the fastener row in common with Longeron 28 and -11 doubler (upper row) and the lower

row in common with the -11 doubler only. Scan the forward and aft side of the fasteners in the

above stated fastener rows looking for cracks propagating in the forward/aft direction. Follow the

instructions found in the Nondestructive Testing Standard Practice Manual (NDTSPM) 06-10-01.001

(ETHF - Procedure 1). Use Calibration Method "N" and Scan Method "46." See Figure 2.

3. Inspection Method 03 (Eddy Current, High Frequency, Sliding Probe)

a. Attach probe to eddy current instrument and set operating frequency to a 35 KHz.

b. Place the eddy current probe on the sliding probe procedure reference standard in an area free

of defects and edge effects with the probe centered over the fastener row centerline as shown in

Figure 3. Null/balance the instrument.

c. Using the nonconductive straightedge as a guide, scan the probe along the fastener row. Scan

across the reference EDM notch area and adjust the instrument display settings to obtain a display

pattern similar to that shown in Figure 3.

NOTE: Reference standard for sliding probe procedure contains 5/32 inch rivets. The inspection

area has primarily 3/16 inch rivets in addition to some 5/32 inch rivets. The impedance

plane display will change slightly when scanning over the 3/16 inch rivets in the inspection

area after calibrating on the 5/32 inch rivets as shown on Figure 3. All other indications

will remain the same.

d. Gain access to the fuselage skin panels 5649328 (upper panels, left and right sides) and 5649329

(lower panel) at the longitudinal skin splice along Longeron 28 from Fuselage Stations 1490 to

1566 (basic model, see Figure 2 for other models). Inspect the upper panels at the two fastener

rows common with Longeron 28. Inspect the lower panel at the fastener row in common with

Longeron 28 and -11 doubler (upper row) and the lower row in common with the -11 doubler only.

Use the nonconductive straightedge as a guide to center the probe on the centerline of the fastener

row. Null/balance the instrument. Scan all fastener rows on both sides of aircraft looking for cracks

propagating in the forward/aft direction. See Figures 2 and 4.

Inspection Results:

Appendix A:

(SHEET 3 OF 4)

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A. Any indication is considered a crack which exhibits the same relative phase angle and an amplitude of 50

percent or greater than the indication obtained from the calibration notch in the reference standard.

Appendix A:

(SHEET 4 OF 4)

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ALERT ALERT