### 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.9E991 ECCN: 

## 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 Unpublished Work.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.

Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 1 of 86 2.0Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 2 of 86 **BOEING SERVICE BULLETIN DC8-53A080 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 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 3 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 4 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT**

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### 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** June 22, 2004 Original Issue: May 03, 2013 Revision 1: September 18, 2013 Revision 2:

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 5 of 86Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 6 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT**

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### 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.

**Reference Affected**  **Planning Data** Paragraph 1.A.2., Spares Affected No Spares Affected Paragraph 1.E., Compliance and Paragraph 1.F., Approval Yes AD Related Paragraph 1.H., Weight and Balance Changes No Weight and Balance Change Paragraph 1.I., Electrical Load Data No Electrical Load Changed Paragraph 1.K., Publications Affected No Publications Affected

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 7 of 86**Reference Affected**  **Planning Data** Paragraph 1.K., Publications Affected No Airplane Flight Operations Affected (Flight CrewOperations Manual and/or FAA Approved Airplane Flight Manual) Paragraph 2.C.1., Kits/Parts No Kits/Parts Required Paragraph 2.C.2., Parts and Materials Supplied by the Operator No Operator Supplied Parts/Material Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin No Special Tooling Required

**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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 8 of 86 **BOEING SERVICE BULLETIN DC8-53A080 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 9 of 86 **BOEING SERVICE BULLETIN DC8-53A080 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 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 10 of 86 **BOEING SERVICE BULLETIN DC8-53A080 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 11 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT**Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 12 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT**

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### 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.

**DESCRIPTION CONFIGURATION**  **GROUP** DC-8 Series 50, 60 and 70 airplanes with flat aft pressure bulkhead

- 1 Airplanes with no existing repairs in the area of inspection. 1 Airplanes that have existing repairs in the area of inspection. 2

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 **Group Fuselage Num-**  **ber** 1 122 1 182 1 185 1 187

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 13 of 86**Group Fuselage Num-**  **ber** 1 189 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 14 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT Group**  **Fuselage Num- ber**  1 333 - 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 15 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT Group**  **Fuselage Num- ber**  1 462 - 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 2. Spares Affected
None. **B. Concurrent Requirements**
None.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 16 of 86 **BOEING SERVICE BULLETIN DC8-53A080 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 17 of 86 **BOEING SERVICE BULLETIN DC8-53A080 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 PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 18 of 86 **BOEING SERVICE BULLETIN DC8-53A080 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 19 of 86 **BOEING SERVICE BULLETIN DC8-53A080 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 Zone**  **Model** 661 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 **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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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 ) Action**  **Condition**

. 2 years from origi- nal issue date ofthis 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 flataft 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 cycles . 2,000 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 Condition 1 (No Crack(s) or Failed Fasteners Found) Option 1

(a) (b) AND

. 6 years from theissue date of Revision 1 of this service bulletin Accumulation of 45,400 total flight cycles Install full length improvementmodification with finger doublers.

AND 5,000 flight cycles . 30,000 flight cyclesfrom full length improvement modification with finger doublers installationDo an external visual inspections for cracks along all fouredges of the external doublers, left and right sides. (a) (c) OR

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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 ) Action**  **Condition** 2,000 flight cycles . 2,000 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 Option 2

(a) (b) AND

. 6 years from theissue date of Revision 1 of this service bulletin Accumulation of 45,400 total flight cycles Install full length improvement modification

AND 10,000 flight cycles . 15,000 flight cycles from full lengthmodification installation Do a Low Frequency Eddy Current inspection of the fuselage skin along all four edges of the external doubler (a) (c)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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 ) Action**  **Condition**

. . Before further flight Replace all Failed Fasteners. Condition 2Any Failed Fastener(s) AND 2,000 flight cycles . 2,000 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 Option 1

(a) (b) AND

. 6 years from theissue date of Revision 1 of this service bulletin Accumulation of 45,400 total flight cycles Install full length improvementmodification with finger doublers.

AND 5,000 flight cycles . 30,000 flight cyclesfrom full length improvement modification with finger doublers installationDo an external visual inspections for cracks along all fouredges of the external doublers, left and right sides. (a) (c) OR

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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 ) Action**  **Condition**

. . Before further flight Replace all Failed Fasteners. Option 2 AND 2,000 flight cycles . 2,000 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 (a) (b) AND

. 6 years from theissue date of Revision 1 of this service bulletin Accumulation of 45,400 total flight cycles Install full length improvement modification.

AND 10,000 flight cycles . 15,000 flight cycles from full lengthmodification installation Do a Low Frequency Eddy Current inspection of the fuselage skin along all four edges of the external doubler (a) (c) OR

. . Before further flight Install full length improvementmodification with finger doublers. Option 3

AND 5,000 flight cycles . 30,000 flight cyclesfrom full length improvement modification with finger doublers installationDo an external visual inspections for cracks along all fouredges of the external doublers, left and right sides. (a) (c) OR

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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 ) Action**  **Condition**

. . Before further flight Install full length improvement modification. Option 4

AND 10,000 flight cycles . 15,000 flight cycles from full lengthmodification installation Do a Low Frequency Eddy Current inspection of the fuselage skin along all four edges of the external doubler (a) (c)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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 ) Action**  **Condition**

. . Before further flight Do local skin repair. Condition 3 Any Crack(s) Found in Skin AND 2,000 flight cycles . 2,000 flight cycles Do a general visual and Eddy Current High Frequency(ETHF) Inspection of the accessible fuselage skin andfasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides and do the work listed based oncondition of the unrepaired areas Option 1

(a) (b) AND 5,000 flight cycles from initial inspection . 15,000 flight cycles from installation of repairFor local skin repairs 12 inches or less long, do an external visual inspections for cracksalong 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 theissue 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 cycles . 30,000 flight cyclesfrom full length repair with finger doublers repair installationDo an external visual inspections for cracks along all fouredges of the external doublers, left and right sides. (a) (c) OR

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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 ) Action**  **Condition**

. . Before further flight Do local skin repair. Option 2 AND 2,000 flight cycles . 2,000 flight cycles Do a general visual and Eddy Current High Frequency(ETHF) Inspection of the accessible fuselage skin andfasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides and do the work listed based oncondition of the unrepaired areas (a) (b) AND AND 5,000 flight cycles from initial inspection . 15,000 flight cycles from installation of repairFor local skin repairs 12 inches or less long, do an external visual inspections for cracksalong 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 theissue date of Revision 1 of this service bulletin Accumulation of 45,400 total flight cyclesInstall full length repair doublers.

AND 10,000 flight cycles . 15,000 flight cyclesfrom 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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 ) Action**  **Condition**

. . Before further flight Install full length repair with finger doublers. Option 3

AND 5,000 flight cycles . 30,000 flight cyclesfrom full length repair with finger doublers installationDo an external visual inspections for cracks along all fouredges of the external doublers, left and right sides. (a) (c) OR

. . Before further flight Install full length repair dou- blers. Option 4

AND 10,000 flight cycles . 15,000 flight cyclesfrom 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 )**  **Action Condition** 

. 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 flataft pressure bulkhead having24,000 or more total flight cycles asof the original issue date of this service bulletinand no skin repairs in the area of inspection.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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 ) Action**  **Condition** 2,000 flight cycles . 2,000 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 Condition 1 (No Crack(s) or Failed Fasteners Found) Option 1

(a) (b) AND

. 6 years from theissue date of Revision 1 of this service bulletin Accumulation of 45,400 total flight cycles Install full length improvementmodification with finger doublers.

AND 5,000 flight cycles . 30,000 flight cyclesfrom full length improvement modification with finger doublers installationDo an external visual inspections for cracks along all fouredges of the external doublers, left and right sides. (a) (c) OR 2,000 flight cycles . 2,000 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 Option 2

(a) (b) AND

. 6 years from theissue date of Revision 1 of this service bulletin Accumulation of 45,400 total flight cycles Install full length improvement modification

AND 10,000 flight cycles . 15,000 flight cycles from full lengthmodification installation Do a Low Frequency Eddy Current inspection of the fuselage skin along all four edges of the external doubler (a) (c)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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 ) Action**  **Condition**

. . Before further flight Replace all Failed Fasteners. Condition 2Any Failed Fastener(s) AND 2,000 flight cycles . 2,000 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 Option 1

(a) (b) AND

. 6 years from theissue date of Revision 1 of this service bulletin Accumulation of 45,400 total flight cycles Install full length improvementmodification with finger doublers.

AND 5,000 flight cycles . 30,000 flight cyclesfrom full length improvement modification with finger doublers installationDo an external visual inspections for cracks along all fouredges of the external doublers, left and right sides. (a) (c) OR

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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 ) Action**  **Condition** Before further flight Replace all Failed Fasteners. Option 2 AND 2,000 flight cycles . 2,000 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 (a) (b) AND

. 6 years from theissue date of Revision 1 of this service bulletin Accumulation of 45,400 total flight cycles Install full length improvement modification.

AND 10,000 flight cycles 15,000 flight cycles from full lengthmodification installation Do a Low Frequency Eddy Current inspection of the fuselage skin along all four edges of the external doubler (a) (c) OR

. . Before further flight Install full length improvementmodification with finger doublers. Option 3

AND 5,000 flight cycles . 30,000 flight cyclesfrom full length improvement modification with finger doublers installationDo an external visual inspections for cracks along all fouredges of the external doublers, left and right sides. (a) (c) OR

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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 ) Action**  **Condition**

. . Before further flight Install full length improvement modification. Option 4

AND 10,000 flight cycles . 15,000 flight cycles from full lengthmodification installation Do a Low Frequency Eddy Current inspection of the fuselage skin along all four edges of the external doubler (a) (c)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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 ) Action**  **Condition**

. . Before further flight Do local skin repair. Condition 3 Any Crack(s) Found in Skin AND 2,000 flight cycles . 2,000 flight cycles Do a general visual and Eddy Current High Frequency(ETHF) Inspection of the accessible fuselage skin andfasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides and do the work listed based oncondition of the unrepaired areas Option 1

(a) (b) AND 5,000 flight cycles from initial inspection . 15,000 flight cycles from installation of repairFor local skin repairs 12 inches or less long, do an external visual inspections for cracksalong 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 theissue 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 cycles . 30,000 flight cyclesfrom full length repair with finger doublers repair installationDo an external visual inspections for cracks along all fouredges of the external doublers, left and right sides. (a) (c) OR

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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 ) Action**  **Condition**

. . Before further flight Do local skin repair. Option 2 AND 2,000 flight cycles . 2,000 flight cycles Do a general visual and Eddy Current High Frequency(ETHF) Inspection of the accessible fuselage skin andfasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides and do the work listed based oncondition of the unrepaired areas (a) (b) AND 5,000 flight cycles from initial inspection . 15,000 flight cycles from installation of repairFor local skin repairs 12 inches or less long, do an external visual inspections for cracksalong 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 theissue date of Revision 1 of this service bulletin Accumulation of 45,400 total flight cyclesInstall full length repair doublers.

AND 10,000 flight cycles . 15,000 flight cyclesfrom 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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 ) Action**  **Condition**

. Before further flight Install full length repair with finger doublers. Option 3

AND 5,000 flight cycles . 30,000 flight cyclesfrom full length repair with finger doublers installationDo an external visual inspections for cracks along all fouredges of the external doublers, left and right sides. (a) (c) OR

. Before further flight Install full length repair dou- blers. Option 4

AND 10,000 flight cycles . 15,000 flight cyclesfrom 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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) Action**  **Condition**

. 2 years from origi- nal issue date ofthis 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 andfasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides and do the work listed based on condition. Airplanes with flataft 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 . 2,000 flight cycles Do a general visual and Eddy Current High Frequency(ETHF) Inspection of the accessible fuselage skin andfasteners 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 theissue date of Revision 1 of this service bulletin Accumulation of 45,400 total flight cycles Install full length improvementmodification with finger doublers.

AND

. 2 years from initialinspection 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 12inches 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 longerthan 12 inches, do a Low Frequency Eddy Current inspection of the fuselage skin along all four edges of the external doubler (a) (c)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 36 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) Action**  **Condition**

AND

. 6 years from theissue date of Revision 1 of this service bulletin Accumulation of 45,400 total flight cycles Remove previously installed local repairs and install fulllength repair with finger doublers. AND 5,000 flight cycles . 30,000 flight cyclesfrom full length repair with finger doublers installationDo an external visual inspections for cracks along all fouredges of the external doublers, left and right sides. (a) (c) OR

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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) Action**  **Condition** 2,000 flight cycles . 2,000 flight cycles Do a general visual and Eddy Current High Frequency(ETHF) Inspection of the accessible fuselage skin andfasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides Option 2

(a) (b) AND

. 2 years from initialinspection 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 12inches 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 longerthan 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 theissue date of Revision 1 of this service bulletin Accumulation of 45,400 total flight cycles Remove previously installed local repairs and install fulllength improvement modification. AND 10,000 flight cycles . 15,000 flight cyclesfrom 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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) Action**  **Condition**

. Before further flight Remove previously installed local repairs and install fulllength repair with finger doublers. Option 3

AND 5,000 flight cycles . 30,000 flight cyclesfrom full length repair with finger doublers installationDo an external visual inspections for cracks along all fouredges of the external doublers, left and right sides. (a) (c) OR Before further flight Remove previously installed local repairs and install fulllength improvement modification. Option 4

AND 10,000 flight cycles 15,000 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)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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) Action**  **Condition**

. . Before further flight Replace all Failed Fasteners Condition 2Any Failed Fastener(s) AND 2,000 flight cycles . 2,000 flight cycles Do a general visual and Eddy Current High Frequency(ETHF) Inspection of the accessible fuselage skin andfasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides Option 1

(a) (b) AND

. . 2 years from initialinspection 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 12inches 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 skinalong all four edges of the external doubler (a) (c) AND 6 years from theissue date of Revision 1 of this service bulletin Accumulation of 45,400 total flight cycles Remove previously installed local repairs and install fulllength repair with finger doublers. AND 5,000 flight cycles 30,000 flight cyclesfrom full length repair with finger doublers installationDo an external visual inspections for cracks along all fouredges of the external doublers, left and right sides. (a) (c)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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) Action**  **Condition**

OR

. . Before further flight Replace all Failed Fasteners Option 2 AND 2,000 flight cycles . 2,000 flight cycles Do a general visual and Eddy Current High Frequency(ETHF) Inspection of the accessible fuselage skin andfasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides (a) (b) AND

. . 2 years from initialinspection 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 12inches 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 skinalong all four edges of the external doubler (a) (c) AND

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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) Action**  **Condition** 6 years from theissue 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 cycles . 15,000 flight cyclesfrom 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

. . Before further flight Remove previously installed local repairs and install fulllength repair with finger doubler Option 3

AND 5,000 flight cycles . 30,000 flight cyclesfrom full length repair with finger doublers installationDo an external visual inspections for cracks along all fouredges of the external doublers, left and right sides. (a) (c) OR

. . Before further flight Remove previously installed local repairs and install full length repair Option 4

AND 10,000 flight cycles . 15,000 flight cyclesfrom 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)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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) Action**  **Condition**

. . Before further flight Do local skin repair. Condition 3 Any Crack(s) Found in Skin AND 2,000 flight cycles . 2,000 flight cycles Do a general visual and Eddy Current High Frequency(ETHF) Inspection of the accessible fuselage skin andfasteners 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 repairFor local skin repairs 12 inches or less long, do an external visual inspections for cracksalong 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 initialinspection 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 repairFor local skin repairs 12 inches or less long, do an external visual inspections for cracksalong all four edges of the external doublers (a) (c) AND/OR

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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) Action**  **Condition** 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 theissue date of Revision 1 of this service bulletin Accumulation of 45,400 total flight cycles Remove previously installed local repairs and install fulllength repair with finger doubler AND 5,000 flight cycles . 30,000 flight cyclesfrom full length repair with finger doublers installationDo an external visual inspections for cracks along all fouredges of the external doublers, left and right sides. (a) (c) OR

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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) Action**  **Condition**

. . Before further flight Do local skin repair. Option 2 AND 2,000 flight cycles . 2,000 flight cycles Do a general visual and Eddy Current High Frequency(ETHF) Inspection of the accessible fuselage skin andfasteners 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 repairFor local skin repairs 12 inches or less long, do an external visual inspections for cracksalong 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 initialinspection 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 repairFor local skin repairs 12 inches or less long, do an external visual inspections for cracksalong all four edges of the external doublers (a) (c)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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) Action**  **Condition**

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 theissue 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 cycles . 15,000 flight cyclesfrom 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

. . Before further flight Remove previously installed local repairs and install fulllength repair with finger doubler Option 3

AND 5,000 flight cycles . 30,000 flight cyclesfrom full length repair with finger doublers installationDo an external visual inspections for cracks along all fouredges of the external doublers, left and right sides. (a) (c) OR

. . Before further flight Remove previously installed local repairs and install full length repair Option 4

AND 10,000 flight cycles . 15,000 flight cyclesfrom 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)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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) Action**  **Condition** (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)**  **Action Condition** 

. 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 andfasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides and do the work listed based on condition. Airplanes with flataft pressure bulkhead having24,000 or more total flight cycles asof the original issue date of this service bulletin and having skin repairs in the area of inspection.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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) Action**  **Condition** 2,000 flight cycles . 2,000 flight cycles Do a general visual and Eddy Current High Frequency(ETHF) Inspection of the accessible fuselage skin andfasteners 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 theissue date of Revision 1 of this service bulletin Accumulation of 45,400 total flight cycles Install full length improvementmodification with finger doublers.

AND

. 2 years from initialinspection 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 12inches 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 longerthan 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 theissue date of Revision 1 of this service bulletin Accumulation of 45,400 total flight cycles Remove previously installed local repairs and install fulllength repair with finger doublers.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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) Action**  **Condition**

AND 5,000 flight cycles . 30,000 flight cyclesfrom full length repair with finger doublers installationDo an external visual inspections for cracks along all fouredges of the external doublers, left and right sides. (a) (c) OR

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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) Action**  **Condition** 2,000 flight cycles . 2,000 flight cycles Do a general visual and Eddy Current High Frequency(ETHF) Inspection of the accessible fuselage skin andfasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides Option 2

(a) (b) AND

. 2 years from initialinspection 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 12inches 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 longerthan 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 theissue date of Revision 1 of this service bulletin Accumulation of 45,400 total flight cycles Remove previously installed local repairs and install fulllength improvement modification. AND 10,000 flight cycles . 15,000 flight cyclesfrom 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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) Action**  **Condition**

. Before further flight Remove previously installed local repairs and install fulllength repair with finger doublers. Option 3

AND 5,000 flight cycles . 30,000 flight cyclesfrom full length repair with finger doublers installationDo an external visual inspections for cracks along all fouredges of the external doublers, left and right sides. (a) (c) OR Before further flight Remove previously installed local repairs and install fulllength improvement modification. Option 4

AND 10,000 flight cycles 15,000 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)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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) Action**  **Condition**

. . Before further flight Replace all Failed Fasteners Condition 2Any Failed Fastener(s) AND 2,000 flight cycles . 2,000 flight cycles Do a general visual and Eddy Current High Frequency(ETHF) Inspection of the accessible fuselage skin andfasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides Option 1

(a) (b) AND

. . 2 years from initialinspection 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 12inches 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 skinalong all four edges of the external doubler (a) (c) AND 6 years from theissue date of Revision 1 of this service bulletin Accumulation of 45,400 total flight cycles Remove previously installed local repairs and install fulllength repair with finger doublers. AND 5,000 flight cycles . 30,000 flight cyclesfrom full length repair with finger doublers installationDo an external visual inspections for cracks along all fouredges of the external doublers, left and right sides. (a) (c)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 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) Action**  **Condition**

OR

. . Before further flight Replace all Failed Fasteners Option 2 AND 2,000 flight cycles . 2,000 flight cycles Do a general visual and Eddy Current High Frequency(ETHF) Inspection of the accessible fuselage skin andfasteners at longeron 28 forward of flat aft pressure bulkhead, left and right sides (a) (b) AND

. . 2 years from initialinspection 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 DC8-53A080 Revision 2: September 18, 2013 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) Action**  **Condition**

AND 5,000 flight cycles from initial inspection . 15,000 flight cycles from installation of repair For new local skin repairs 12inches 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 skinalong all four edges of the external doubler (a) (c) AND 6 years from theissue 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 cycles . 15,000 flight cyclesfrom 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

. . Before further flight Remove previously installed local repairs and install fulllength repair with finger doubler Option 3

AND 5,000 flight cycles . 30,000 flight cyclesfrom full length repair with finger doublers installationDo an external visual inspections for cracks along all fouredges of the external doublers, left and right sides. (a) (c) OR

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 54 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) Action**  **Condition**

. . Before further flight Remove previously installed local repairs and install full length repair Option 4

AND 10,000 flight cycles . 15,000 flight cyclesfrom 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)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 55 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) Action**  **Condition**

. . Before further flight Do local skin repair. Condition 3 Any Crack(s) Found in Skin AND 2,000 flight cycles . 2,000 flight cycles Do a general visual and Eddy Current High Frequency(ETHF) Inspection of the accessible fuselage skin andfasteners 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 repairFor local skin repairs 12 inches or less long, do an external visual inspections for cracksalong 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 initialinspection 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 repairFor local skin repairs 12 inches or less long, do an external visual inspections for cracksalong all four edges of the external doublers (a) (c)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 56 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) Action**  **Condition**

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 theissue date of Revision 1 of this service bulletin Accumulation of 45,400 total flight cycles Remove previously installed local repairs and install fulllength repair with finger doubler AND 5,000 flight cycles . 30,000 flight cyclesfrom full length repair with finger doublers installationDo an external visual inspections for cracks along all fouredges of the external doublers, left and right sides. (a) (c) OR

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 57 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) Action**  **Condition**

. . Before further flight Do local skin repair. Option 2 AND 2,000 flight cycles . 2,000 flight cycles Do a general visual and Eddy Current High Frequency(ETHF) Inspection of the accessible fuselage skin andfasteners 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 repairFor local skin repairs 12 inches or less long, do an external visual inspections for cracksalong 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 initialinspection 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 repairFor local skin repairs 12 inches or less long, do an external visual inspections for cracksalong all four edges of the external doublers (a) (c)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 58 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) Action**  **Condition**

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 theissue 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 cycles . 15,000 flight cyclesfrom 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

. . Before further flight Remove previously installed local repairs and install fulllength repair with finger doubler Option 3

AND 5,000 flight cycles . 30,000 flight cyclesfrom full length repair with finger doublers installationDo an external visual inspections for cracks along all fouredges of the external doublers, left and right sides. (a) (c) OR

. . Before further flight Remove previously installed local repairs and install full length repair Option 4

AND 10,000 flight cycles . 15,000 flight cyclesfrom 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)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 59 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) Action**  **Condition** (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. **Elapsed Hours Task Hours**  **Number of Persons Task**  0.5 0.5 1 Open Access 1.0 2.0 2 Inspection Method 101 0.5 0.5 1 Close Access

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 60 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT Elapsed Hours**  **Task Hours Number of Persons**  **Task** 2.0 3.0 TOTAL FOR EACH AIRPLANE
**Elapsed Hours Task Hours**  **Number of Persons Task**  0.5 0.5 1 Open Access 4.0 8.0 2 Inspection Method 102 0.5 0.5 1 Close Access 5.0 9.0 TOTAL FOR EACH AIRPLANE
**Elapsed Hours Task Hours**  **Number of Persons Task**  0.5 0.5 1 Open Access 2.0 4.0 2 Inspection Method 103 0.5 0.5 1 Close Access 3.0 5.0 TOTAL FOR EACH AIRPLANE

**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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 61 of 86 **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:

**ADCN DCN/REV**  **Sheet Title**  **Drawing No**

- B AEO SKIN REPAIR - LONG 28 FWD OF AFT PRESSURE BHD, STA 1566.00 SERVICE REWORK DRAWING SR08530032

- A AEO

- - DWG 3. Installation Drawings Used in the Preparation of this Service Bulletin:**Change Title**  **Drawing Number** AC Panel Assembly - L17 to L28 Stations from 1490 to 1690 5649328

V Panel Assembly Bottom, L28 to L28 Stations from 1490 to 1690 5649329

**K. Publications Affected**
None. **L. Interchangeability and Intermixability of Parts** Not affected. **M. Software Accomplishment Summary** Not affected.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 62 of 86 **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:

**Notes Name**  **QTY for Configu- rations 7005 and**  **7007 QTY for Configura**  **tions 7001 and 7003**  **Part Number**

(a) Doubler 1 1 SR08530032-3 (a) Filler 1 1 SR08530032-5 (a) Doubler 1 SR08530032-7 (a) Doubler 1 SR08530032-9 (a) Doubler 1 SR08530032-11 (a) Doubler 1 SR08530032-13 (a) Doubler 1 SR08530032-15 (a) Doubler 1 SR08530032-17 (a) Doubler 1 SR08530032-19 (a) Doubler 1 SR08530032-21 (a) Refer to Service Rework Drawing SR08530032 for fabrication instructions.

Modification Kits:

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 63 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT Notes**  **Name QTY for Configu-**  **rations 7013 and 7015** **QTY for Configura tions 7009 and**  **7011 Part Number** 

(a) Doubler 1 1 SR08530032-3 (a) Doubler 1 SR08530032-7 (a) Doubler 1 SR08530032-9 (a) Doubler 1 SR08530032-11 (a) Doubler 1 SR08530032-13 (a) Doubler 1 SR08530032-15 (a) Doubler 1 SR08530032-17 (a) Doubler 1 SR08530032-19 (a) Doubler 1 SR08530032-21 (a) Refer to Service Rework Drawing SR08530032 for fabrication instructions.

Fastener kits

**Notes Name**  **QTY SR08530032 (Any Configuration)**  **Part Number** (a) Hi-Lok 110 HLT435-6-3 (a) Pin 272 HLT435-6-4 (a) Pin 18 HLT435-6-5 (a) Pin 36 HLT435-6-6 (a) Pin 16 HLT435-6-7 (a) Pin 1 HLT435-6-8 (a) Nut 447 MS21042L3 (a) Rivet 214 NAS1097AD6-6D (a) Rivet 343 NAS1097AD6-7D (a) (b) Washer 420 NAS1149F1165P (a) (b) Washer 18 NAS1252-10L (a) (b) Bolt 12 NAS8803-8 (a) (b) Nut Assy 18 3D0006-3 (a) Maximum quantity listed (b) Refer to AEPL or SRM Chapter 51 for approved substitutes

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 64 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT CAGE**  **Supplier QTY**  **Part Number/Specification** 92108 PRC-DeSoto International, Incorporated 2 Qts PR-1422 B-2 Sealant (DMS 2082 P.O. Box 1800 or Equivalent) Sylmar, California 91342 1 Qt PR-1431G Sealant (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**

**Notes CAGE**  **Supplier Name**  **Tool Number** (a) (b) (c) 29192 Olympus NDT NE, Incorpo-rated NDT NE, Incorporated Flaw Detector (Impedance Plane Display) NORTEC NDT 24

421 North Quay Street Kennewick, Washington 99336-7735 OR (a) (b) (d) 07ZF2 Qi2 Quest CenterMagneto-optic/Eddy Current Imager (MOI) MOI Model 301 or Subsequent 19823 58th Place South - Suite 200 Kent, Washington 98032 OR (a) (b) (e) 29192 Olympus NDT NE, Incorpo-rated NDT NE, Incorporated Reflectance TypeSliding Probe operating at 35 kHz. SPO-2210

421 North Quay Street Kennewick, Washington 99336-7735

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 65 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT Notes**  **CAGE Supplier**  **Name Tool Number**  (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 thisdocument 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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 66 of 86 **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

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 67 of 86 **BOEING SERVICE BULLETIN DC8-53A080 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 68 of 86 **BOEING SERVICE BULLETIN DC8-53A080 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 69 of 86 **BOEING SERVICE BULLETIN DC8-53A080 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)

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 70 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT**(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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 71 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 72 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT**(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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 73 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT 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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 74 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT**(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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 75 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT**(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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 76 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT**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.

Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2: September 18, 2013 77 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT FIGURE 1: METHOD 103 REFLECTANCE TYPE SLIDING PROBE PROCEDURE REFERENCE STANDARD**  **(SHEET 1 OF 2)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2 September 18, 2013 78 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT FIGURE 1: METHOD 103 REFLECTANCE TYPE SLIDING PROBE PROCEDURE REFERENCE STANDARD**  **(SHEET 2 OF 2)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2 September 18, 2013 79 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT FIGURE 2: HIGH FREQUENCY EDDY CURRENT INSPECTION OF SKIN ALONG LONGERON 28**  **(SHEET 1 OF 1)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2 September 18, 2013 80 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT FIGURE 3: METHOD 103 REFLECTANCE TYPE SLIDING PROBE PROCEDURE**  **(SHEET 1 OF 1)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2 September 18, 2013 81 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT FIGURE 4: METHOD 103 REFLECTANCE TYPE SLIDING PROBE PROCEDURE**  **(SHEET 1 OF 1)**
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2 September 18, 2013 82 of 86 **BOEING SERVICE BULLETIN DC8-53A080 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)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2 September 18, 2013 83 of 86 **BOEING SERVICE BULLETIN DC8-53A080 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 AP**  **PLICABILITY DESCRIPTION** 

EDDY CURRENT A 102 103 Olympus NDT NE, Incorpo- rated Flaw Detector (Impedance Plane Display). NORTEC NDT 24 1

101 PRI Instrumentation. Magneto-optic/Eddy Current Imager (MOI).Model 301 2

103 Olympus NDT NE, Incorpo- rated Reflectance Type Sliding Probe operating at 35 kHz.SPO-2210 3

103 Fabrication source optional. High Frequency Reference Standard (sliding probe procedure). See Figure 4 and Figure 5 for fabrication details. See Note 3 below. 4

SURFACE PREPARATION B ALL Source optional. Cleaning Agent in conformance with environmen-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)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2 September 18, 2013 84 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT**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)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2 September 18, 2013 85 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT**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)** 
Export Controlled ECCN: 9E991 - BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. Original Issue: June 22, 2004 DC8-53A080 Revision 2 September 18, 2013 86 of 86 **BOEING SERVICE BULLETIN DC8-53A080 ALERT**  **ALERT**