June 26, 2003

Revision 1: February 12, 2009 747-53A2484

BOEING PROPRIETARY - Copyright © Unpublished Work - See page 1 for details. 1 of 218

Commercial

Airplane

Group 747

Service Bulletin

Number: 747-53A2484

Date: June 26, 2003

Revision 1: February 12, 2009

ATA System: 5311

SUBJECT: FUSELAGE - Stringer 8 And 10, Body Station 460, 480, And 500 - Inspection, 

Modification And Repair - 747 SUD Airplanes

BOEING PROPRIETARY, CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 2003 The Boeing Company

Unpublished Work - All Rights Reserved

Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable 

subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third 

parties. Treatment of the document and the information it contains is governed by contract with Boeing. For 

more information, contact The Boeing Company, P.O. Box 3707, Seattle, Washington 98124.

Boeing, 707, 717, 727, 737, 747, 757, 767, 777, BBJ, BOEING BUSINESS JET, DC-8, DC-9, DC-10, MD-10, 

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BLANK PAGE
 Table of Contents

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BOEING SERVICE BULLETIN 747-53A2484

Table of Contents

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

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

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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

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

E. Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . 21

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . 22

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . 22

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

A. Material - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . 28

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

E. Special Tooling - Price and Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . 28

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

FIGURE 1: ACCESS AND RESTORATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

FIGURE 2: STRINGER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

FIGURE 3: STRINGER MODIFICATION - STRINGER 8L AT BS 460 . . . . . . . . . . . . . . . . . 39

FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460. . . . . . . . . . . . . . . . . . . . . . 44

FIGURE 5: STRINGER MODIFICATION - STRINGER 8L AT BS 480 . . . . . . . . . . . . . . . . . 54

FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480. . . . . . . . . . . . . . . . . . . . . . 59

FIGURE 7: STRINGER MODIFICATION - STRINGER 8L AT BS 500 . . . . . . . . . . . . . . . . . 69

FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500. . . . . . . . . . . . . . . . . . . . . . 74

FIGURE 9: STRINGER MODIFICATION - STRINGER 8R AT BS 460 . . . . . . . . . . . . . . . . . 84

FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460 . . . . . . . . . . . . . . . . . . . . . 89

FIGURE 11: STRINGER MODIFICATION - STRINGER 8R AT BS 480 . . . . . . . . . . . . . . . . 99
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BOEING SERVICE BULLETIN 747-53A2484

FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480 . . . . . . . . . . . . . . . . . . . . 104

FIGURE 13: STRINGER MODIFICATION - STRINGER 8R AT BS 500 . . . . . . . . . . . . . . . . 114

FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500 . . . . . . . . . . . . . . . . . . . . 119

FIGURE 15: STRINGER MODIFICATION - STRINGER 10L AT BS 460 . . . . . . . . . . . . . . . 129

FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460. . . . . . . . . . . . . . . . . . . . 134

FIGURE 17: STRINGER MODIFICATION - STRINGER 10L AT BS 480 . . . . . . . . . . . . . . . 144

FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480. . . . . . . . . . . . . . . . . . . . 149

FIGURE 19: STRINGER MODIFICATION - STRINGER 10L AT BS 500 . . . . . . . . . . . . . . . 159

FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500. . . . . . . . . . . . . . . . . . . . 164

FIGURE 21: STRINGER MODIFICATION - STRINGER 10R AT BS 460 . . . . . . . . . . . . . . . 174

FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460 . . . . . . . . . . . . . . . . . . . 179

FIGURE 23: STRINGER MODIFICATION - STRINGER 10R AT BS 480 . . . . . . . . . . . . . . . 189

FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480 . . . . . . . . . . . . . . . . . . . 194

FIGURE 25: STRINGER MODIFICATION - STRINGER 10R AT BS 500 . . . . . . . . . . . . . . . 204

FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500 . . . . . . . . . . . . . . . . . . . 209
Original Issue: June 26, 2003

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Commercial

Airplanes 747

Service Bulletin

Number: 747-53A2484 Revision Transmittal Sheet

Original Issue: June 26, 2003

Revision 1: February 12, 2009

ATA System: 5311

SUBJECT: FUSELAGE - Stringer 8 And 10, Body Station 460, 480, And 500 - Inspection, 

Modification And Repair - 747 SUD Airplanes

This Revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

No more work is necessary on airplanes changed as given in the initial release of this service bulletin.

Airplane RS699 was added to Group 1 of the service bulletin effectivity. Airplanes RT631 and RT632, which 

have been converted to the Large Cargo Freighter (LCF) configuration, were moved from Group 3 to new Group 

4.

Federal Aviation Administration (FAA) Airworthiness Directive 2005-15-08 is related to this service bulletin.

REASON FOR REVISION

This revision is sent to:

— In Effectivity, Paragraph 1.A., added airplane RS699 to Group 1. This airplane was omitted from the 

effectivity of the original release of this bulletin.

— Moved airplanes RT631 and RT632, which have been converted to the Large Cargo Freighter (LCF) 

configuration, from Group 3 to new Group 4.

— In WORK INSTRUCTIONS, Paragraph 3.B., revised access instructions due to different interior 

configurations.

— In Compliance, Paragraph 1.E., added reference to AD 2005-15-08. Also, added compliance table and 

revised compliance information to agree with AD 2005-15-08.

— In Material - Price and Availability, Paragraph 2.A., updated kit information to add new repair kits which 

contain repair angles made from improved materials.

— In Industry Support Information, Paragraph 2.B., updated industry support statement.

— In Figures 4, 6, 10, 12, 16, 22, and 26, corrected fastener quantities and fastener locations.

— In Figures 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, and 26, revised views to show new updated repair parts. 

Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity 

paragraph for changes.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location 

of important changes.

Pages with no vertical lines have no important changes.
 

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BOEING SERVICE BULLETIN 747-53A2484

REVISION HISTORY

Original Issue: June 26, 2003

Revision 1: February 12, 2009
June 26, 2003

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Commercial

Airplane

Group 747

Service Bulletin

Number: 747-53A2484 Summary

Date: June 26, 2003

Revision 1: February 12, 2009

ATA System: 5311

SUBJECT: FUSELAGE - Stringer 8 And 10, Body Station 460, 480, And 500 - Inspection, 

Modification And Repair - 747 SUD Airplanes

CONCURRENT REQUIREMENTS

None.

BACKGROUND

Inspection of fuselage stringers adjacent to the window belt on the upper deck on 747 airplanes with Stretched 

Upper Decks (SUD) will make sure that stringer cracks do not grow to include the fuselage skin at the window 

areas of the upper deck. If stringer cracks at these locations are not found and repaired, the cracks can grow 

to include the fuselage skin along the window belt of the upper deck. Such skin cracks can result in extensive 

damage to the skin at the window belt, with related rapid decompression of the fuselage. 

Operators have told Boeing about cracks in the fuselage Stringers 8L, 8R, 10L and 10R at the Body Station 460, 

480 and 500 frame locations. The airplanes in these reports had between 29,873 and 90,333 flight-hours, and 

between 9,691 and 25,513 flight cycles.

Installation of the repair shown in this service bulletin (new frame clips and new, additional stringer splice and 

doublers) will restore the stringers’ strength. For locations where no stringer cracks are found, installation of the 

preventive modification shown in this service bulletin (new frame clips and a new load-spreading doubler) will 

prevent stringer cracks form occurring.

Boeing Service Related Problem (SRP) 747-SRP-53-0174 is related to this service bulletin.

Boeing Structural Item Interim Advisory (SIIA) 747-178 is related to this service bulletin.

ACTION

Get access to Stringers 8 and 10, on the left and right side of the airplane upper deck, between Body Stations 

(BS) 440 and 520. At Stringers 8L, 8R, 10L and 10R, do a detailed inspection of the stringers where the frame 

clips attach to the stringers, at BS 460, BS 480 and BS 500 frame locations. If cracks are found, install repairs 

as given in this service bulletin (if cracks exceed the repairable length as given in this service bulletin, use data 

from the 747 Structural Repair Manual with data given in this service bulletin to make the necessary repairs). 

Do the inspections again at the times given in Paragraph 1.E., "Compliance". To stop the special inspections 

given in this service bulletin, install the preventive modification shown in this service bulletin. 
 

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BOEING SERVICE BULLETIN 747-53A2484

The airplane effectivity is divided into four groups, Group 1 airplanes are also in the effectivity of Service Bulletin 

747-53A2265, and have 100 Degree countersink rivets installed in the fuselage skin. Group 2 airplanes are also 

in the effectivity of Service Bulletin 747-53A2265, and have special 120 Degree countersink rivets installed in 

the fuselage skin. Group 3 airplanes are not in the effectivity of Service Bulletin 747-53A2265, and have special 

120 Degree countersink rivets installed in the fuselage skin. Group 4 airplanes have been modified to the 747-

400 Large cargo Freighter (LCF) configuration.

EFFECTIVITY

747-100B SUD, 747-200B, 747-300, 747-400, and 747-400D airplanes.

Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

COMPLIANCE

See Service Bulletin Paragraph 1.E, Compliance.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the configuration changes, inspection, and/or repair procedures 

given in this service bulletin.

MANPOWER

MATERIAL INFORMATION

Boeing Supplied Kits/Parts.

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

Task Total Task Hours Elapsed Hours

Preventive 

Modification (all 

12 locations)

122 61

Repair (all 12 

locations)

230 115
 

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BOEING SERVICE BULLETIN 747-53A2484

CRACKS.

ARE FOUND.

CRACKS.

ARE FOUND.

S-10

S-8

460

STA

480

STA STA

500

RIGHT SIDE OPPOSITE

STR-10

LEFT SIDE SHOWN,

EDGE OF WINDOW CUTOUT

EDGE OF

WINDOW CUTOUT

CRACKS ARE FOUND.

DO A REPAIR IF

MODIFICATION IF NO CRACKS

INSTALL PREVENTIVE

EXAMINE THE STRINGER FOR

STR-8

CLIP

FRAME

FRAME

CLIP

CRACKS ARE FOUND.

DO A REPAIR IF

MODIFICATION IF NO CRACKS

INSTALL PREVENTIVE

EXAMINE THE STRINGER FOR

FWD

FWD

FWD

SEE B

SEE C

A

B

C

SEE A

N68182
 

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BLANK PAGE
Original Issue: June 26, 2003

Revision 1: February 12, 2009 747-53A2484

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Commercial

Airplanes 747

Service Bulletin

Number: 747-53A2484

Original Issue: June 26, 2003

Revision 1: February 12, 2009

ATA System: 5311

SUBJECT: FUSELAGE - Stringer 8 And 10, Body Station 460, 480, And 500 - Inspection, 

Modification And Repair - 747 SUD Airplanes

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index Document D6-30300 Part 3 for Airplane Variable Number, Line 

Number, and Serial Number data.

This service bulletin is for the airplanes shown below.

Airplane models:

747-100B SUD 747-200B 747-300 747-400

747-400D

IDENTIFICATION BY CUSTOMER, CUSTOMER CODE, GROUP AND VARIABLE NUMBER

GROUP CONFIGURATION DESCRIPTION

1 - 747-300 Airplanes within the effectivity of 

Service Bulletin 747-53A2265 and have 100 

Degree countersink rivets installed in the 

fuselage skin.

2 - 747-200B, 100B SUD and 300 Airplanes within 

the effectivity of Service Bulletin 747-53A2265 

and have special 120 Degree countersink rivets 

installed in the fuselage skin.

3 - 747-300, 747-400, and 747-400D airplanes 

through line number 875, not included in the 

effectivity of Service Bulletin 747-53A2265, with 

special 120 Degree countersink rivets installed 

in the fuselage skin, except 747-400 Large 

Cargo Freighter airplanes.

4 - 747-400 Large Cargo Freighter (LCF) airplanes 

through line number 875,
 

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BOEING SERVICE BULLETIN 747-53A2484

AEROLINEAS ARGENTINAS (ARG)

3 RT701–RT702

AEROSUR (REO)

1 RS235

AIR ATLANTA ICELANDIC (AID)

1 RS211 RS233 RS237

3 RS332–RS333 RT751

AIR CHINA (BEJ)

3 RT031–RT033

AIR CHINA CARGO (CGC)

3 RT101 RT103

AIR FRANCE (AFA)

2 RD721–RD722

3 RT071 RT121 RT591 RT711–RT712

AIR INDIA (AIN)

3 RS781–RS782

AIR NEW ZEALAND (ANZ)

3 RT671–RT672 RT703

AIR PACIFIC (APC)

3 RT502 RT504

AIR PULLMANTUR (PUL)

3 RS331

AIRBRIDGE CARGO (ABM)

3 RS762

ALL NIPPON AIRWAYS (ANA)

3 RT753 RT776–RT777

ATLAS AIR (TLS)

2 RS722

3 RT752

AVION AIRCRAFT TRADING H.F. (VNG)

3 RT633

BRITISH AIRWAYS (BAB)

3 RT471–RT489

CATHAY PACIFIC AIRWAYS (CAT)

3 RT451–RT458 RT508 RT511–RT512 RT781–RT782

CORSAIR (COR)

1 RS239–RS240
 

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BOEING SERVICE BULLETIN 747-53A2484

DRAGONAIR (DRG)

2 RS741 RS771

3 RT510

DUBAI AIR WING (DAW)

3 RT102

EVERGREEN INTERNATIONAL A/L (EVR)

4 RT631–RT632

EXPORT RESTRICTED AIRPLANES (YWV)

2 RS751–RS752

3 RT602 RT606

FINOVA (GRB)

2 RS761

GENERIC CUSTOMER/SUPPLIER (XXX)

2 RD382

GOVERNMENT OF JAPAN (JAG)

3 RT681–RT682

JAL INTERNATIONAL (JAL)

1 RS251–RS252 RS254

2 RS256

3 RS259 RS265–RS267 RT641–RT652 RU801

KALITTA AIR (KAC)

3 RT021–RT022

KLM - ROYAL DUTCH AIRLINES (KLM)

3 RT001–RT007 RT531–RT533

KOREAN AIR (KAL)

3 RT061 RT571–RT576

LUFTHANSA GERMAN AIRLINES (DLH)

3 RT041–RT047 RT431–RT438

MARTINAIR HOLLAND (MTH)

3 RT501 RT506–RT507 RT509

NORTHWEST AIRLINES (NWA)

3 RT401–RT410

OASIS HONG KONG AIRLINES (OHK)

3 RT503

ORIENT THAI AIRLINES (OTH)

1 RS253 RS292 RS712

2 RS001–RS002 RS257
 

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BOEING SERVICE BULLETIN 747-53A2484

PAKISTAN INT'L AIRLINES (PIA)

1 RS301

2 RS302–RS304

3 RS305–RS306

PHUKET AIRLINES (PHK)

1 RS238 RS241 RS711

2 RD381 RD605

QANTAS (QAN)

1 RS272–RS273

2 RS274–RS276

3 RT551–RT563 RT741–RT742

SATAIR (SAI)

2 RD606

SAUDI ARABIAN AIRLINES (SVA)

1 RS311–RS315

2 RS316–RS320

SAUDI ROYAL FLIGHT (SRF)

1 RS699

SOUTH AFRICAN AIRWAYS (SAA)

1 RS212 RS232 RS236

SOUTHERN AIR (SOF)

1 RS721

2 RD383 RD601–RD602 RD607

3 RS786

SURINAM AIRWAYS (SUR)

2 RS713

TAAG (ANGOLA AIRLINES) (ANG)

2 RS742

3 RS703

THAI AIRWAYS INTERNATIONAL (TII)

3 RT691–RT693

TRANSAERO AIRLINES (TRX)

1 RS271

2 RS255 RS258

3 RS263 RS268

UNICAL AVIATION (UNL)

2 RS341

3 RS342

UNITED AIR LINES (UAL)

3 RT601 RT603–RT605 RT607–RT610
 

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BOEING SERVICE BULLETIN 747-53A2484

WELLS FARGO (FSB)

3 RT505

IDENTIFICATION BY VARIABLE NUMBER

Variable Group

RD381–RD383 2

RD601–RD607 2

RD721–RD722 2

RS001–RS002 2

RS201 1

RS211–RS212 1

RS221–RS222 1

RS231–RS241 1

RS251–RS254 1

RS255–RS258 2

RS259 3

RS263 3

RS265–RS268 3

RS271–RS273 1

RS274–RS276 2

RS291–RS292 1

RS301 1

RS302–RS304 2

RS305–RS306 3

RS311–RS315 1

RS316–RS320 2

RS331–RS333 3

RS341 2

RS342 3

RS699 1

RS701–RS702 1

RS703 3

RS711–RS712 1

RS713 2

RS721 1

RS722 2

RS731–RS732 3

RS741–RS743 2

RS751–RS752 2

RS761 2
 

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BOEING SERVICE BULLETIN 747-53A2484

2. Spares Affected

None.

RS762 3

RS771 2

RS781–RS782 3

RS786 3

RT001–RT007 3

RT021–RT022 3

RT031–RT033 3

RT041–RT047 3

RT061 3

RT071 3

RT101–RT103 3

RT121 3

RT401–RT410 3

RT431–RT438 3

RT451–RT458 3

RT471–RT489 3

RT501–RT512 3

RT531–RT533 3

RT551–RT563 3

RT571–RT576 3

RT591 3

RT601–RT610 3

RT631–RT632 4

RT633 3

RT641–RT652 3

RT671–RT672 3

RT681–RT682 3

RT691–RT693 3

RT701–RT703 3

RT711–RT712 3

RT741–RT742 3

RT751–RT753 3

RT776–RT777 3

RT781–RT782 3

RU801 3

Variable Group
 

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BOEING SERVICE BULLETIN 747-53A2484

B. Concurrent Requirements

None.

C. Reason

Inspection of fuselage stringers adjacent to the window belt on the upper deck on 747 airplanes with 

Stretched Upper Decks (SUD) will make sure that stringer cracks do not grow to include the fuselage 

skin at the window areas of the upper deck. If stringer cracks at these locations are not found and 

repaired, the cracks can grow to include the fuselage skin along the window belt of the upper deck. 

Such skin cracks can result in extensive damage to the skin at the window belt, with related rapid 

decompression of the fuselage. 

Operators have told Boeing about cracks in the fuselage Stringers 8L, 8R, 10L and 10R at the Body 

Station 460, 480 and 500 frame locations. The airplanes in these reports had between 29,873 and 

90,333 flight-hours, and between 9,691 and 25,513 flight cycles.

Installation of the repair shown in this service bulletin (new frame clips and new, additional stringer 

splice and doublers) will restore the stringers’ strength. For locations where no stringer cracks are 

found, installation of the preventive modification shown in this service bulletin (new frame clips and a 

new load-spreading doubler) will prevent stringer cracks form occurring.

Boeing Service Related Problem (SRP) 747-SRP-53-0174 is related to this service bulletin.

Boeing Structural Item Interim Advisory (SIIA) 747-178 is related to this service bulletin.

This revision is sent to:

— In Effectivity, Paragraph 1.A., added airplane RS699 to Group 1. This airplane was omitted from 

the effectivity of the original release of this bulletin.

— Moved airplanes RT631 and RT632, which have been converted to the Large Cargo Freighter 

(LCF) configuration, from Group 3 to new Group 4.

— In WORK INSTRUCTIONS, Paragraph 3.B., revised access instructions due to different interior 

configurations.

— In Compliance, Paragraph 1.E., added reference to AD 2005-15-08. Also, added compliance 

table and revised compliance information to agree with AD 2005-15-08.

— In Material - Price and Availability, Paragraph 2.A., updated kit information to add new repair kits 

which contain repair angles made from improved materials.

— In Industry Support Information, Paragraph 2.B., updated industry support statement.

— In Figures 4, 6, 10, 12, 16, 22, and 26, corrected fastener quantities and fastener locations.

— In Figures 4, 6, 8, 10, 12, 14, 16, 18, 20, 22, 24, and 26, revised views to show new updated repair 

parts. 

D. Description

Get access to Stringers 8 and 10, on the left and right side of the airplane upper deck, between Body 

Stations (BS) 440 and 520. At Stringers 8L, 8R, 10L and 10R, do a detailed inspection of the stringers 

where the frame clips attach to the stringers, at BS 460, BS 480 and BS 500 frame locations. If cracks 

are found, install repairs as given in this service bulletin (if cracks exceed the repairable length as 

given in this service bulletin, use data from the 747 Structural Repair Manual with data given in this 

service bulletin to make the necessary repairs). Do the inspections again at the times given in 

Paragraph 1.E., "Compliance". To stop the special inspections given in this service bulletin, install the 

preventive modification shown in this service bulletin. 
 

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The airplane effectivity is divided into four groups, Group 1 airplanes are also in the effectivity of 

Service Bulletin 747-53A2265, and have 100 Degree countersink rivets installed in the fuselage skin. 

Group 2 airplanes are also in the effectivity of Service Bulletin 747-53A2265, and have special 120 

Degree countersink rivets installed in the fuselage skin. Group 3 airplanes are not in the effectivity of 

Service Bulletin 747-53A2265, and have special 120 Degree countersink rivets installed in the 

fuselage skin. Group 4 airplanes have been modified to the 747-400 Large cargo Freighter (LCF) 

configuration.

No more work is necessary on airplanes changed as given in the initial release of this service bulletin.

Accomplishment of the inspections in service bulletin 747-53A2265 concurrent with the inspections in 

this service bulletin on commonly affected airplanes is recommended due to common access.

E. Compliance

Boeing recommends that you do the inspections and related tasks as given below:

Group 1-3: Table 1 - Stringer Inspection Airplanes with 19,000 Total Flight Cycles or less

Condition Action

Compliance Time

(Whichever Occurs Last)

Repeat Interval 

(Not to Exceed)

All Do a detailed inspection 

as given in Paragraph 

3.B., Work Instructions, 

PART 1 - INSPECTION

Before 8,000 

total flight 

cycles

within 2,000 flight 

cycles after August 30, 

2005, not to exceed 

20,000 total flight 

cycles

3,000 flight cycles 

(a)

Cracks Found Repair as given in 

Paragraph 3.B., Work 

Instructions, PART 2 - 

REPAIR

Before further 

flight

- (a)

(a) Installation of a repair as given in PART 2 of the Work Instructions or accomplishment of the preventive 

modification as given in PART 3 of the Work Instructions at all stringer inspection locations, terminates the 

repetitive inspections that are recommended in this service bulletin. Beginning at 22,000 total flight-cycles, 

this area is also inspected as given in Boeing Service Bulletin 747-53A2349 and 747-53A2500.

Group 1-3: Table 2 - Stringer Inspection Airplanes with 19,001 Total Flight Cycles or more

Condition Action

Compliance Time

(Whichever Occurs Last)

Repeat Interval 

(Not to Exceed)

All Do a detailed inspection 

as given in Paragraph 

3.B., Work Instructions, 

PART 1 - INSPECTION

- 1,000 flight 

cycles after 

August 30, 

2005

3,000 Flight 

Cycles (a) 

Cracks Found Repair as given in 

Paragraph 3.B., Work 

Instructions, PART 2 - 

REPAIR

Before Further 

Flight

- (a)

(a) Installation of a repair as given in PART 2 of the Work Instructions or accomplishment of the preventive 

modification as given in PART 3 of the Work Instructions at all stringer inspection locations, terminates the 

repetitive inspections that are recommended in this service bulletin. Beginning at 22,000 total flight-cycles, 

this area is also inspected as given in Boeing Service Bulletin 747-53A2349 and 747-53A2500.
 

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Federal Aviation Administration (FAA) Airworthiness Directive 2005-15-08 is related to this service 

bulletin.

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, as well 

as European Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/

JAA approved airplanes listed in the service bulletin effectivity. 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.

This service bulletin has been approved by the FAA. In addition, the manager of the FAA Seattle ACO 

approves the accomplishment of the applicable inspection, repair, and modification procedures of this 

service bulletin as an alternative method of compliance to the corresponding inspection, repair, and 

modification requirements of paragraphs (f), (g) and (h) of FAA AD 2005-15-08. This AMOC only 

applies to the areas inspected, repaired, or modified as given in this service bulletin. All provisions of 

AD 2005-15-08 that are not specifically referenced above 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, repair and 

preventive modification 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 examine the work

— Time to cure the materials

— Time to make the parts

Group 4: Table 3 - Stringer Inspection

Condition Action Compliance Time

Repeat Interval 

(Not to Exceed)

All Do a detailed inspection as given in 

Paragraph 3.B., Work Instructions, 

PART 1 - INSPECTION

within 1,000 flight cycles 

after the date on 

Revision 1 of this service 

bulletin

1,500 flight cycles (a)

Cracks Found Repair as given in Paragraph 3.B., 

Work Instructions, PART 2 - REPAIR

Before further flight (a)

(a) Installation of a repair as given in PART 2 of the Work Instructions or accomplishment of the preventive 

modification as given in PART 3 of the Work Instructions at all stringer inspection locations, terminates the 

repetitive inspections that are recommended in this service bulletin. Beginning at 22,000 total flight-cycles, 

this area is also inspected as given in Boeing Service Bulletin 747-53A2349 and 747-53A2500.
 

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— Time to find the tools.

NOTE: The manpower estimates for open and close access have been determined assuming

lavatory modules are installed, this is the most labor intensive configuration. All operators that

have other monuments in these locations should require less time to open and close access.

H. Weight and Balance Changes

For all airplanes, use the tables below to find the weight and balance changes. Add the weight 

changes and the moment changes for all of the Preventive Modifications and/or Repairs that you 

make on the airplane to get the total Weight and Moment changes.

Task

Number of 

Persons Task-Hours Elapsed Hours

Open Access 2 37 18.5

Inspect (all 

locations)

2 3 1.5

Install Repair (one 

stringer/frame 

location)

2 12 6

Install Preventive 

Modification (one 

stringer/frame 

location)

2 3 1.5

Close Access 2 59 29.5

TOTAL FOR EACH AIRPLANE 114 57.0

Preventive 

Modification 

(Location)

Change in Weight 

(Pounds)

Change in Moment 

(Pound-Inches)

BS 460, S-8L +0.43 +197.8

BS 480, S-8L +0.43 +206.4

BS 500, S-8L +0.43 +215.0

BS 460, S-8R +0.43 +197.8

BS 480, S-8R +0.43 +206.4

BS 500, S-8R +0.43 +215.0

BS 460, S-10L +0.43 +197.8

BS 480, S-10L +0.43 +206.4

BS 500, S-10L +0.43 +215.0

BS 460, S-10R +0.43 +197.8

BS 480, S-10R +0.43 +206.4

BS 500, S-10R +0.43 +215.0
 

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BOEING SERVICE BULLETIN 747-53A2484

I. Electrical Load Data

Not changed.

J. References

1. Existing Data:

a. Service Related Problem (SRP) 747-SRP-53-0174.

b. 747 Maintenance Manual (AMM) Subject 25-21-02, 25-21-04, 25-22-03, 25-25-01, 25-28-

15, 25-40-03, 25-24-00, 25-19-03 and 25-19-04.

c. 747 Structural Repair Manual (SRM) Subject 53-00-03 or 53-10-03.

d. 747 Nondestructive Test (NDT) Manual Part 6, Subject 51-00-00, Figure 1, Figure 11, or 

Figure 16, and Part 6, Subject 51-00-00, Figure 4 or Figure 23.

e. Boeing Standard Overhaul Practices Manual (BSOPM) 20-43-03.

f. 747 Structural Item Interim Advisory (SIIA) 747-178.

g. Boeing Service Bulletin 747-53A2265, "FUSELAGE - NOSE SECTION 41 - BODY FRAME 

STRUCTURE INSPECTIONS AND CRACK REPAIRS".

h. Boeing Parts Standards Document D-590.

i. Boeing Drawing 012W6100.

j. FAA Airworthiness Directive 2005-15-08.

2. Data supplied with this Service Bulletin:

None.

Repair (Location)

Change in Weight 

(Pounds)

Change in Moment 

(Pound-Inches)

BS 460, S-8L +1.13 +519.8

BS 480, S-8L +1.13 +524.4

BS 500, S-8L +1.13 +565.0

BS 460, S-8R +1.13 +519.8

BS 480, S-8R +1.13 +524.4

BS 500, S-8R +1.13 +565.0

BS 460, S-10L +1.13 +519.8

BS 480, S-10L +1.13 +524.4

BS 500, S-10L +1.13 +565.0

BS 460, S-10R +1.13 +519.8

BS 480, S-10R +1.13 +524.4

BS 500, S-10R +1.13 +565.0
 

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BOEING SERVICE BULLETIN 747-53A2484

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

These drawings were used to prepare this service bulletin. These drawings are not necessary 

to make the specified changes, and are not supplied with this service bulletin. These drawings 

may not be applicable to all airplane configurations or operators.

K. Publications Affected

None

L. Interchangeability and Intermixability of Parts

Accomplishment of this service bulletin does not affect interchangeability or intermixability of parts.

Drawing Number Title

65B07653 SKIN PANEL INSTL - UPR, S-6 TO S-14 STA 340 TO 520

65B01716 FRAME INSTALLATION - BODY STATION 460

65B01717 FRAME INSTALLATION - BODY STATION 480

65B01718 FRAME INSTALLATION - BODY STATION 500

65B27201 BODY SECTION 41 INSTL. -200B SUD MOD
 

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2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary For Each Airplane as shown 

below. If there is a limit to the quantity (QTY) of available kits, a supply sequence is given by Spares. 

More kits become available as shown in the Reorder Lead Time (ROLT). ROLT is calculated from the 

date Boeing gets the purchase order.

The kits are subject to the terms and conditions of the Boeing standard purchase order 

acknowledgment. After the Unit Price date, new price and ROLT data is applicable. Prices are in 

United States dollars. Terms: Net 30 days.

Reference this service bulletin and submit your purchase order by one of the methods that follow: 

1. Order on-line via ATA Spec 2000 or Boeing Part Page

2. Fax to (206) 662-7145

3. Spares Customer Support - MC 36-65

Boeing Spares Department

P.O. Box 3707

Seattle, Washington 98124-2207 USA

B. Industry Support Information

Boeing warranty remedies are not available for the configuration changes, inspection, and/or repair 

procedures given in this service bulletin.

C. Parts Necessary For Each Airplane

1. Kits/Parts:

To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.

Kit Number Name Date

ROLT 

(weeks) QTY

Unit Price thru 

31-Mar-2009

691U1042-1 Top Kit, Repair Instl (a) (a) (a) (a)

691U1042-5 Top Kit, Preventive Instl Available 19 10 $7,290

691U1042-13 Top Kit, Repair Instl Jan 2009 33 30 $25,436

691U1042-15 Subkit, Repair Instl Jan 2009 33 - $12,718

691U1042-16 Subkit, Repair Instl Jan 2009 33 - $12,718

691U1042-17 Subkit, Part Kit - Repair Jan 2009 33 - $12,066

691U1042-18 Subkit, Part Kit - Repair Jan 2009 33 - $12,066

691U1042-19 Supplemental Kit Jan 2009 30 - $4,796

691U1042-21 Supplemental Kit Jan 2009 30 - $2,398

691U1042-22 Supplemental Kit Jan 2009 30 - $2,398

691U1042-2 Subkit, Fastener Kit Jan 2009 33 - $652

(a) 691U1042-1 Top Kit is no longer available.
 

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NOTE: One top kit for the preventive modification and the items shown in Paragraph 2.C.2.,

Parts and Materials Supplied by the Operator, are necessary for the preventive

modification on each airplane. One top kit for the repair and the items shown in

Paragraph 2.C.2., Parts and Materials Supplied by the Operator, are necessary for the

repair on each airplane.

Existing Kit Name Supplemental Kit New Replacing Kit

691U1042-1 (a) Top Kit, Repair Instl 691U1042-19 (f) 691U1042-13 (k)

691U1042-3 (b) Subkit, Repair Instl - LH 691U1042-21 (g) 691U1042-15 (l)

691U1042-4 (c) Subkit, Repair Instl - RH 691U1042-22 (h) 691U1042-16 (m)

691U1042-9 (d) Subkit, Part Kit - Repair - LH 691U1042-21 (g) 691U1042-17 (n)

691U1042-10 (e) Subkit, Part Kit - Repair -RH 691U1042-22 (h) 691U1042-18 (o)

(a) Replaced by 691U1042-13.

(b) Replaced by 691U1042-15.

(c) Replaced by 691U1042-16.

(d) Replaced by 691U1042-17.

(e) Replaced by 691U1042-18.

(f) Supplements 691U1042-1 and is only necessary if 691U1042-1 has shipped. Discard existing 

691U1042-105 through -116 repair angles and BACF3F007D008NN and BACF3F008D018NN fillers 

from existing -1 kit.

(g) Supplements 691U1042-3 or -9 and is only necessary if 691U1042-3 or -9 has shipped. Discard 

existing 691U1042-105, -107, -109, -111, -113, and -115 repair angles and BACF3F007D008NN and 

BACF3F008D018NN fillers from existing -3 or -9 kit.

(h) Supplements 691U1042-4 or -10 and is only necessary if 691U1042-4 or -10 has shipped. Discard 

existing 691U1042-106, -108, -110, -112, -114, and -116 repair angles and BACF3F007D008NN and 

BACF3F008D018NN fillers from existing -4 or -10 kit.

(k) Equivalent to 691U1042-1 plus 691U1042-19 after 691U1042-105 through -116 repair angles and 

BACF3F007D008NN and BACF3F008D018NN fillers are deleted from existing -1 kit.

(l) Equivalent to 691U1042-3 plus 691U1042-21 after 691U1042-105, -107, -109, -111, -113, and -115 

repair angles and BACF3F007D008NN and BACF3F008D018NN fillers are deleted from existing -3 kit.

(m) Equivalent to 691U1042-4 plus 691U1042-22 after 691U1042-106, -108, -110, -112, -114, and -116 

repair angles and BACF3F007D008NN and BACF3F008D018NN fillers are deleted from existing -4 kit.

(n) Equivalent to 691U1042-9 plus 691U1042-21 after 691U1042-105, -107, -109, -111, -113, and -115 

repair angles and BACF3F007D008NN and BACF3F008D018NN fillers are deleted from existing -9 kit.

(o) Equivalent to 691U1042-10 plus 691U1042-22 after 691U1042-106, -108, -110, -112, -114, and -116 

repair angles and BACF3F007D008NN and BACF3F008D018NN fillers are deleted from existing -10 kit.
 

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Kit 691U1042

New Part Number

QTY

-12 -11 -8 -7 -5 Name Notes

691U1042-5 . . . . - TOP KIT, PREVENTATIVE 

INSTL

691U1042-7 . . . - 1 SUBKIT, PREVENTATIVE 

INSTL 

691U1042-8 . . - . 1 SUBKIT, PREVENTATIVE 

INSTL 

691U1042-11 . - 1 1 . SUBKIT, PART KIT 

691U1042-12 - . 1 1 . SUBKIT, FASTENER KIT

691U1042-118 . 6 . . . DOUBLER

691U1042-119 . 3 . . . FRAME CLIP

691U1042-120 . 3 . . . FRAME CLIP

BACB30NX6K3 40 . . . . BOLT (a)

BACB30NX6K3Y 18 . . . . BOLT (a)

BACB30NX6K4Y 5 . . . . BOLT (a)

BACB30NX6K5Y 3 . . . . BOLT (a)

BACB30NX8K4Y 12 . . . . BOLT (a)

BACB30VT6K3 12 . . . . BOLT (a)

BACC30AC6 29 . . . . COLLAR

BACC30AC8 12 . . . . COLLAR

BACC30BH6 40 . . . . COLLAR

BACC30BL6 12 . . . . COLLAR

BACS40R010B040F . 2 . . . SHIM

(a) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length 

longer than indicated. Also, if any fasteners part numbers listed are not available or have been 

superseded, substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 

012W6100 are used to determine the part numbers used as substitutes.

Kit 691U1042 

New Part Number

QTY

-18 -17 -16 -15 -13 -2 Name Notes

691U1042-2 . . 1 1 . - SUBKIT, FASTENER KIT

691U1042-13 . . . . - . TOP KIT, UPPER DECK 

WINDOW BELT REPAIR, STA 

460 - STA 500

691U1042-15 . . . - 1 . SUBKIT, UPPER DECK 

WINDOW BELT REPAIR, LEFT 

SIDE

691U1042-16 . . - . 1 . SUBKIT, UPPER DECK 

WINDOW BELT REPAIR, 

RIGHT SIDE
 

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691U1042-17 . - . 1 . . PART KIT - REPAIR, LEFT 

SIDE

691U1042-18 - . 1 . . . PART KIT - REPAIR, RIGHT 

SIDE

691U1042-100 12 12 . . . . REPAIR STRAP

691U1042-101 3 3 . . . . FRAME CLIP

691U1042-102 3 3 . . . . FRAME CLIP

691U1042-103 6 6 . . . . REPAIR ANGLE

691U1042-117 6 6 . . . . STRINGER SEGMENT

691U1042-133 . 1 . . . . REPAIR ANGLE

691U1042-134 1 . . . . . REPAIR ANGLE

691U1042-135 . 1 . . . . REPAIR ANGLE

691U1042-136 1 . . . . . REPAIR ANGLE

691U1042-137 . 1 . . . . REPAIR ANGLE

691U1042-138 1 . . . . . REPAIR ANGLE

691U1042-139 . 1 . . . . REPAIR ANGLE

691U1042-140 1 . . . . . REPAIR ANGLE

691U1042-143 . 1 . . . . REPAIR ANGLE

691U1042-144 1 . . . . . REPAIR ANGLE

691U1042-145 

(691U1042-141 optional)

. 1 . . . . REPAIR ANGLE

691U1042-146 

(691U1042-142 optional)

1 . . . . . REPAIR ANGLE

BACB30NX6K3 . . . . . 40 BOLT, PROTRUDING HD (a)

BACB30NX6K3Y . . . . . 18 BOLT, PROTRUDING HD (a)

BACB30NX6K4 . . . . . 66 BOLT, PROTRUDING HD (a)

BACB30NX6K4Y . . . . . 6 BOLT, PROTRUDING HD (a)

BACB30NX6K5 . . . . . 66 BOLT (a)

BACB30NX6K5Y . . . . . 2 BOLT, PROTRUDING HD (a)

BACB30NX8K4 . . . . . 12 HI-LOK (a)

BACB30VT6K3 . . . . . 12 BOLT, PROTRUDING HEAD (a)

BACB30VT6K5 . . . . . 12 BOLT (a)

BACC30AC6 . . . . . 29 COLLAR

BACC30BH6 . . . . . 172 COLLAR

BACC30BH8 . . . . . 12 COLLAR

BACC30BL6 . . . . . 24 COLLAR

BACF3F007D019NN 1 1 . . . . FILLER- FLAT

BACF3F008D029NN 1 1 . . . . FILLER, FLAT

Kit 691U1042 

New Part Number

QTY

-18 -17 -16 -15 -13 -2 Name Notes
 

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BACR15FV7KE9 . . . . . 51 RIVET (a)

BACR15GF7D9 . . . . . 51 RIVET, 100 DEG (a)

BACS40R010B048F 2 2 . . . . SHIM, LAMINATED

(a) If grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer 

than indicated. Also, if any fasteners part numbers listed are not available or have been superseded, 

substitute fasteners may be supplied in kits. Boeing Document D-590 and Boeing Drawing 65B88700 are 

used to determine the part numbers used as substitutes.

Kit 691U1042 

New Part Number

QTY

-22 -21 -19 Name Notes

691U1042-19 . . - SUPPLEMENTAL KIT, 

UPPER DECK 

WINDOW BELT 

REPAIR, STA 460 - 

STA 500

691U1042-21 . - 1 SUPPLEMENTAL KIT, 

LEFT SIDE

691U1042-22 - . 1 SUPPLEMENTAL KIT, 

RIGHT SIDE

691U1042-133 . 1 . REPAIR ANGLE

691U1042-134 1 . . REPAIR ANGLE

691U1042-135 . 1 . REPAIR ANGLE

691U1042-136 1 . . REPAIR ANGLE

691U1042-137 . 1 . REPAIR ANGLE

691U1042-138 1 . . REPAIR ANGLE

691U1042-139 . 1 . REPAIR ANGLE

691U1042-140 1 . . REPAIR ANGLE

691U1042-143 . 1 . REPAIR ANGLE

691U1042-144 1 . . REPAIR ANGLE

691U1042-145 

(691U1042-141 optional)

. 1 . REPAIR ANGLE

691U1042-146 

(691U1042-142 optional)

1 . . REPAIR ANGLE

BACF3F007D019NN 1 1 . FILLER- FLAT

BACF3F008D029NN 1 1 . FILLER, FLAT

Kit 691U1042 

New Part Number

QTY

-18 -17 -16 -15 -13 -2 Name Notes
 

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2. Parts and Materials Supplied by the Operator:

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

None.

F. Special Tooling Necessary to do this Service Bulletin

No special tools or equipment are necessary to do the change in this service bulletin. But, 

maintenance and overhaul tools in the manuals given in Paragraph 1.J., References, can be 

necessary. Examine operator tool supply to make sure all necessary tools are available.

Part Number / 

Specification QTY Name Notes

BMS 5-95 1 Pint Sealant (a)

BMS 10-11, Type 1 1 Pint Primer (a)

- - Chemical Conversion coating (b)

BACB30NX6K6Y 6 Bolt (c)

BACR15GF7D( ) - Rivet (d)

BACR15FV7KE( ) - Rivet (e)

(a) refer to the Qualified Products List at the end of the Boeing Material Specification (BMS) for 

supplier data.

(b) Reference: BSOPM 20-43-03

(c) Can be necessary at some frame clip locations when the repair or preventive modification is 

done

(d) For Group 1 airplanes, additional rivets of grip lengths from 7 to 14 can be necessary if 

removal of rivets from fuselage skin is necessary to allow stringer repair.

(e) For Group 2, 3 and 4 airplanes, additional rivets of grip lengths from 7 to 14 can be 

necessary if removal of rivets from fuselage skin is necessary to allow stringer repair.
 

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3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

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.

NOTE:

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

definition of the acronyms.

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

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

— Linear dimensions are in inches.

— Tolerance on linear dimensions, other than rivet and bolt edge distance, is plus or 

minus 0.03 inch.

— Tolerance on rivet and bolt edge distance is plus or minus 0.05 inch unless 

otherwise specified.

— Angular tolerance is plus or minus 2 degrees.

— Hole dimensions for standard solid rivets are given in 747 Structural Repair 

Manual, Chapter 51.

— Torque limits to tighten nuts and bolts are given in 747 Structural Repair Manual, 

Chapter 51.

4. For approved fastener and process material substitutions, refer to 747 Structural Repair 

Manual, Chapter 51, Alternate fasteners are given in 747 Structural Repair Manual 

Chapter 51 and Boeing Drawing 012W6100. 

5. If the length of fasteners specified in this service bulletin do not meet the installation 

standards, fasteners of the same specification, or an approved substitute, one grip 

length longer or shorter may be used.

6. 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.

B. WORK INSTRUCTIONS

PART 1 - INSPECTION

1. Get access to the inspection areas as given in Figure 1. 

2. Do a detailed inspection as given in Figure 2.

3. Actions after you do the inspection:
 

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a. If you do not find any cracks in any of the inspection areas, either:

(1) Install the Preventive Modifications in the areas as given in "PART 3 - PREVENTIVE 

MODIFICATION" of these Accomplishment Instructions.

-OR-

(2) Close access to the inspection areas as given in Figure 1 and do the inspections of the 

un-cracked areas again at the times specified in the Compliance paragraphs of this 

service bulletin.

b. If you find any cracks at any of the inspection areas, do the repair at cracked locations as 

given in "PART 2 - REPAIR" of these Accomplishment Instructions:

And either:

(1) Install the Preventive Modifications in the un-cracked areas as given in "PART 3 - 

PREVENTIVE MODIFICATION" of these Accomplishment Instructions.

-OR-

(2) Close access to the inspection areas as given in Figure 1 and do the inspections of the 

un-cracked areas again at the times specified in the Compliance paragraphs of this 

service bulletin.

PART 2 - REPAIR

1. Group 1: For repairs on Group 1 Airplanes, remove and discard Rivets BACR15FV7KE9 (with 

special "Briles" countersink head) from Fastener Kit 691U1042-2 before you begin a repair at any 

location. These rivets are not used on Group 1 airplanes.

2. Group 2-4: For repairs on Group 2, 3 and 4 Airplanes, remove and discard Rivets 

BACR15GF7D9 (with standard 100 degree countersink head) from Fastener Kit 691U1042-2 

before you begin a repair at any location. These rivets are not used on Group 2, 3 and 4 

airplanes.

3. Repair cracked stringers as given in the table below:.

Stringer Repair Table

Stringer Body Station Figure

8L 460 4

480 6

500 8

8R 460 10

480 12

500 14
 

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NOTE: If you cannot repair a stringer as given in this service bulletin, install a new section of

stringer as given below: 

1. For cracks at Body Station 460, cut the stringer at Body Stations 480 and 440. Use 

the Repair parts shown in this service bulletin at Body Station 480 and the stringer 

splice installation from Chapter 53 of the 747 SRM for Body Station 440 to install a 

new section of stringer between Body Stations 480 and 440. Install the Preventive 

Modification parts at Body Station 460. See Chapter 53 of the 747 Structural 

Repair Manual (SRM) to identify the correct stringer material for the new stringer 

section.

2. For cracks at Body Station 480, cut the stringer at Body Stations 460 and 500. Use 

the Repair parts shown in this service bulletin at Body Stations 460 and 500 to 

install a new section of stringer between Body Stations 460 and 500. Install the 

Preventive Modification parts at Body Station 480. See Chapter 53 of the 747 

Structural Repair Manual (SRM) to identify the correct stringer material for the new 

stringer section.

3. For cracks at Body Station 500, cut the stringer at Body Stations 480, and remove 

the stringer end from the existing stringer splice at Body Station 520. Use the 

Repair parts shown in this service bulletin at Body Station 480 and the stringer 

splice installation from Chapter 53 of the 747 SRM for Body Station 520 to install a 

new section of stringer between Body Stations 460 and 500. Install the Preventive 

Modification parts at Body Station 480. See Chapter 53 of the 747 Structural 

Repair Manual (SRM) to identify the correct stringer material for the new stringer 

section.

4. For cracks at multiple body stations (460 thru 500), use a single stringer splice and 

refer to Notes 1 thru 3 above to determine the splice installation method for the 

ends of the new stringer section. At frame locations where there is no splice repair 

installed, install the Preventive Modification parts as given in this service bulletin.

4. Close access as given in Figure 1.

10L 460 16

480 18

500 20

10R 460 22

480 24

500 26

Stringer Repair Table
 

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PART 3 - PREVENTIVE MODIFICATION

1. Make modifications to stringers as given in the table below:

2. Close access as given in Figure 1.

Stringer Modification Table

Stringer Body Station Figure

8L 460 3

480 5

500 7

8R 460 9

480 11

500 13

10L 460 15

480 17

500 19

10R 460 21

480 23

500 25
 FIGURE 1: ACCESS AND RESTORATION

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FIGURE 1: ACCESS AND RESTORATION

SIDEWALL STOAWAGE

UNIT (TYPICAL)

DOOR

DOOR

LAVATORY U15

PASSENGER COMPARTMENT

TYPICAL UPPER DECK

440

STA 520

STA

LAVATORY U14

2 11

6 7

4 9

3 5 8 10

1 12

N83542

(SHEET 1 OF 3)
 FIGURE 1: ACCESS AND RESTORATION

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The step numbers shown below agree with the numbers shown in the circle symbols in the figure.

ACCESS

STEP TASK NAME AMM SUBJECT NOTES

1

Remove/Keep Passenger Seats 25-25-01 Between Stations 470 and 

520. Operators may have 

any of the equipment 

listed at this location.

Lavatories 25-40-03

Closet 25-24-00

Flight Deck Crew Rest Lining 25-19-04

Flight Deck Crew Rest 

Partitions

25-19-03

2 Remove/Keep Sidewall Stowage Units 25-28-15 Between Stations 440 and 

520, as necessary

3 Remove/Keep Window Reveals 25-21-02 Between Stations 460 and 

520

4 Remove/Keep Ceiling Panel 25-22-03 One panel, forward of 

Station 460, if installed

5 Remove/Keep Sidewall and Ceiling 

Insulation

25-21-04 Between Stations 440 and 

520

6

Remove/Keep Lavatories, U-16, U-18, or U2025-40-03 Operators may have any 

of the equipment listed at 

this location. Closet 25-24-00

Flight Deck Crew Rest Lining 25-19-04

Flight Deck Crew Rest 

Partitions

25-19-03

Passenger Seats 25-25-01

RESTORATION

STEP TASK NAME AMM SUBJECT NOTES

7

Install (Kept) Lavatories, U-16, U-18, or U2025-40-03 Operators may have any 

of the equipment listed at 

this location. Closet 25-24-00

Flight Deck Crew Rest Lining 25-19-04

Flight Deck Crew Rest 

Partitions

25-19-03

Passenger Seats 25-25-01

8 Install (Kept) Sidewall and Ceiling 

Insulation

25-21-04 -

9 Install (Kept) Ceiling Panel 25-22-03 -

10 Install (Kept) Window Reveals 25-21-02 -

11 Install (Kept) Sidewall Stowage Units 25-28-15 -

(SHEET 2 OF 3)
 FIGURE 1: ACCESS AND RESTORATION

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12

Install (Kept) Passenger Seats 25-25-01 Between Stations 470 and 

520. Operators may have 

any of the equipment 

listed at this location.

Lavatories 25-40-03

Closet 25-24-00

Flight Deck Crew Rest Lining 25-19-04

Flight Deck Crew Rest 

Partitions

25-19-03

RESTORATION

STEP TASK NAME AMM SUBJECT NOTES

(SHEET 3 OF 3)
 FIGURE 2: STRINGER INSPECTION

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FIGURE 2: STRINGER INSPECTION

LEFT SIDE SHOWN,

RIGHT SIDE OPPOSITE

S-10

STA

460

STA

500 480

STA

S-8

FWD

SEE B

SEE C

A

SEE A

N68208

(SHEET 1 OF 3)
 FIGURE 2: STRINGER INSPECTION

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STR-10R OPPOSITE

TYPICAL CRACKS

CLIP

STR-10L

FRAME

STR-8R OPPOSITE

TYPICAL CRACKS

STR-8L

EDGE OF WINDOW CUTOUT

CLIP

FRAME

FWD

FWD

1

C

B

1

N68215

(SHEET 2 OF 3)
 FIGURE 2: STRINGER INSPECTION

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The step numbers shown below agree with the numbers shown in the circle symbols in the figure. 

STEP TASK NAME PROCEDURE REFERENCES NOTES

1 Inspect Stringer Detailed 

Inspection

- Look at both sides of 

the stringer. Make a 

note about the 

locations and lengths 

of any cracks found

(SHEET 3 OF 3)
 FIGURE 3: STRINGER MODIFICATION - STRINGER 8L AT BS 460

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FIGURE 3: STRINGER MODIFICATION - STRINGER 8L AT BS 460

S-10L

S-8L

STA

460

STA

500 480

STA

FWD

SEE B AND C

A

SEE A

N68231

(SHEET 1 OF 5)
 FIGURE 3: STRINGER MODIFICATION - STRINGER 8L AT BS 460

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30

CLIP

STR-8L

DOUBLER

CLIP

(3 LOCATIONS)

(4 LOCATIONS)

(3 LOCATIONS)

(WITH FILLER)

(WITHOUT FILLER)

RADIUS FILLER

STR-8L

UP

FWD

UP

FWD

B

C

5

2

1

6 B

D 6

6 B

C 6 3 7 8

4 7 8

3

A

6

6 3

A

4

A

N68293

(SHEET 2 OF 5)
 FIGURE 3: STRINGER MODIFICATION - STRINGER 8L AT BS 460

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The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

(SHEET 3 OF 5)
 FIGURE 3: STRINGER MODIFICATION - STRINGER 8L AT BS 460

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NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— The minimum radius on a cut part is 0.50 inch.

— Remove all burrs and sharp edges from the parts.

— All cut surfaces must be 125 microinches smooth.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance 

from the edge of the part to the center of the hole, and "D" is the final hole diameter.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 

51-00-00, Figure 1, 

Figure 11, or Figure 16 

3 Put / Hold Doubler 691U1042-118 1 -

4 Put / Hold Frame Clip 691U1042-119 1 -

5

Cut Frame Clip 691U1042-119 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length.

6

Drill Holes - - refer to Fastener Codes 

A, B, C and D for 

locations and hole sizes 

7 Remove Frame Clip 691U1042-119 1 Prepare the parts for 

final installation Doubler 691U1042-118 1

8

Install Doubler 691U1042-118 1 refer to Fastener Codes 

A, B, C and D Frame Clip 691U1042-119 1

(a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 4.

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 4 OF 5)
 FIGURE 3: STRINGER MODIFICATION - STRINGER 8L AT BS 460

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The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than 

indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute 

fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used 

to determine the part numbers used as substitutes. 

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

B

Bolt BACB30NX6K3 0.187 - 0.190

Collar BACC30BH6 -

C

Bolt BACB30VT6K3 0.187 - 0.190

Collar BACC30BL6 -

D

Bolt BACB30NX8K4Y 0.278 - 0.281

Collar BACC30AC8 -

(SHEET 5 OF 5)
 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460

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FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460

S-10L

S-8L

STA

460

STA

500 480

STA

FWD

A

SEE B

SEE A

N68325

(SHEET 1 OF 10)
 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460

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BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM

CUT IN STRINGER

CRACK TIP TO

0.44 MIN.

EDGE MARGIN

LOCATION OF CUT

IN STRINGER

CRACK TIP

CRACK

STR-8L

STR-8L

UP

FWD

UP

FWD

SEE C OR D

C SEE E

1

5

2

B

3 3

4

3

2

2

N68333

(SHEET 2 OF 10)
 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460

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0.060 MIN. FROM

OPTIONAL STRINGER CUT FOR SMALL CRACKS

CUT IN STRINGER

CRACK TIP TO

0.25 (MINIMUM)

CRACK

LOCATION OF CUT

IN STRINGER

RADIUS IN STRINGER

(MAXIMUM)

CUT TO TANGENT LINE OF

CRACK TIP

UP

FWD

D

2

4

2

SEE E

W13592

(SHEET 3 OF 10)
 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460

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30

STR-8L

B

A

B

A

UP

FWD

E

9 12 19 21

7

15 19 20

10

6 19 20

19 20

8 19 20

19 20

13

16 17

N68495

(SHEET 4 OF 10)
 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460

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BOEING SERVICE BULLETIN 747-53A2484

STR-8L

RADIUS FILLER

(WITHOUT FILLER)

(WITH FILLER)

(4 LOCATIONS)

STR8L

REPAIR

SEGMENT

STRINGER REPAIR

ANGLE

STRAPS

FILLER

UP

FWD

E

3

4

E

11

11 E

3

11 14

11 14

A

3

FWD

INBD

A

3

A

3

4

4 A

A

4

4 A

A

4

B

5

C

C

3

C

3

5

C

4

4 B

A

4

4 A

A

4

A

A

3

A-A

B-B

3

F

G D D

11

D D D D D D G

G

18

F

4 3

F

4

F

5

F

5

F

5

F

5

F

5

F

5

F

5

F F

5 5

F

5

F

G

G

G

N68588

(SHEET 5 OF 10)
 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460

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The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-2 and 691U1042-17 are used when you do the repair shown in this figure.

(SHEET 6 OF 10)
 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460

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NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— The minimum e/D (edge margin) for existing fastener locations common to the new 691U1042-

143 repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of 

the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener 

locations is 2.0.

— The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the 

fastener diameter).

— Use the pilot hole locations in Repair Angle 691U1042-143 as a guide when you cut the stringer 

(this will help make sure you keep the minimum edge margin for adjacent fasteners).

— The minimum radius is 0.50 inch when you cut the stringer.

— Do not remove the full section of the stringer as shown in View C if you can remove all cracks by 

making the cut in the stringer that is shown in View D.

— The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must 

make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current 

inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed.

— Remove all burrs and sharp edges from the parts.

— All surfaces must be 125 microinches smooth after you cut them.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect Stringer - 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23.

Make sure you can cut 

the stringer at least 

0.060 inch from the 

crack tip and also have 

the minimum 1.7 edge 

margin for adjacent 

fasteners. See View C 

and D for stringer cut 

details.

3

Remove / Discard Fasteners - - at Fastener Code G only 

if you must cut an entire 

section of stringer to 

remove cracks as shown 

in View C. Remove 

enough fasteners to 

allow you to put a thin 

CRES sheet between 

stringer and the skin 

structures.

(SHEET 7 OF 10)
 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460

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4

Cut Stringer - 1 Cut the stringer 0.030 

inch beyond the crack 

tip. Cut the minimum 

amount of stringer 

segment out to remove 

cracks. To protect the 

skin, put a thin CRES 

sheet between the 

stringer and the skin if 

you cut an entire 

segment out.

Inspect Stringer - 1 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23. Make sure 

there are no cracks 

found.

Cut Stringer - 1 Cut an additional 0.030 

inch of stringer to make 

sure all cracked material 

is removed.

5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area 

in the stringer

6 Put / Hold Stringer Segment 691U1042-117 1 -

7 Put / Hold Filler BACF3F008D029NN 1 -

8 Put / Hold Repair Angle 691U1042-143 1 -

9 Put / Hold Frame Clip 691U1042-101 1 -

10

Cut Frame Clip 691U1042-101 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length.

11

Drill Holes - - refer to Fastener Codes 

A, B, C, D and E for 

locations and hole sizes 

12 Install Frame Clip 691U1042-101 1 Use temporary fasteners

13 Put / Hold Repair Angle 691U1042-103 1 -

14

Drill Holes - refer to Fastener Codes 

A, B and C for locations 

and hole sizes

15 Install Repair Angle 691U1042-103 1 Use temporary fasteners

16 Cut Repair Strap 691U1042-100 2 -

17 Put / Hold Repair Strap 691U1042-100 2 -

18

Drill Holes - refer to Fastener Code F 

for locations and hole 

sizes 

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 8 OF 10)
 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than 

shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers 

can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the 

alternative part numbers. 

19

Remove Repair Strap 691U1042-100 2 Prepare the parts for 

final installation Repair Angle 691U1042-103 1

Frame Clip 691U1042-101 1

Repair Angle 691U1042-143 1

Filler BACF3F008D029NN 1

Stringer Segment 691U1042-117 1

20

Install Stringer Segment 691U1042-117 1 refer to Fastener Codes 

A, B, C, D, E and F. Filler BACF3F008D029NN 1

Repair Angle 691U1042-143 1

Repair Angle 691U1042-103 1

Repair Strap 691U1042-100 2

21 Install Frame Clip 691U1042-101 1 refer to Fastener Code E

22

Install Fasteners - if previously removed. 

Refer to Fastener Code 

G

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

STEP TASK NAME PART NUMBER QTY NOTES

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 9 OF 10)
 FIGURE 4: STRINGER REPAIR - STRINGER 8L AT BS 460

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BOEING SERVICE BULLETIN 747-53A2484

B

Bolt BACB30NX8K4 0.247 - 0.250

Collar BACC30BH8 -

C Bolt BACB30VT6K( ) 0.187 - 0.190

Collar BACC30BL6 -

D

Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 

Airplanes only. DO NOT 

make the existing 

special countersink 

deeper in the skin.

E Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

F Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

G

Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 

Airplanes Only. DO NOT 

make the existing 

special countersink 

deeper in the skin.

CODE NAME PART NUMBER HOLE DIA NOTES

(SHEET 10 OF 10)
 FIGURE 5: STRINGER MODIFICATION - STRINGER 8L AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

FIGURE 5: STRINGER MODIFICATION - STRINGER 8L AT BS 480

S-8L

S-10L

STA STA STA

500 480 460

FWD

A

SEE B AND C

SEE A

N68630

(SHEET 1 OF 5)
 FIGURE 5: STRINGER MODIFICATION - STRINGER 8L AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

CLIP

CLIP

STR-8L

30

(3 LOCATIONS)

(WITH FILLER)

(WITHOUT FILLER)

RADIUS FILLER

DOUBLER

(3 LOCATIONS) (3 LOCATIONS)

STR-8L

UP

FWD

UP

FWD

4 7 8

2

1

B

5

C

3

A 6

4

A

6 5

A

6 B

D 6

6 B

C 6 3 7 8

N68631

(SHEET 2 OF 5)
 FIGURE 5: STRINGER MODIFICATION - STRINGER 8L AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

(SHEET 3 OF 5)
 FIGURE 5: STRINGER MODIFICATION - STRINGER 8L AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— The minimum radius on a cut part is 0.50 inch.

— Remove all burrs and sharp edges from the parts.

— All cut surfaces must be 125 microinches smooth.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance 

from the edge of the part to the center of the hole, and "D" is the final hole diameter.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 

51-00-00, Figure 1, 

Figure 11, or Figure 16 

3 Put / Hold Doubler 691U1042-118 1 -

4 Put / Hold Frame Clip 691U1042-119 1 -

5

Cut Frame Clip 691U1042-119 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length and shape

6

Drill Holes - - refer to Fastener Codes 

A, B, C and D for 

locations and hole sizes 

7 Remove Frame Clip 691U1042-119 1 Prepare the parts for 

final installation Doubler 691U1042-118 1

8

Install Doubler 691U1042-118 1 refer to Fastener Codes 

A, B, C and D Frame Clip 691U1042-119 1

(a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 6.

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 4 OF 5)
 FIGURE 5: STRINGER MODIFICATION - STRINGER 8L AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than 

shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers 

can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the 

alternative part numbers. 

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

B

Bolt BACB30NX6K3 0.187 - 0.190

Collar BACC30BH6 -

C

Bolt BACB30VT6K3 0.187 - 0.190

Collar BACC30BL6 -

D

Bolt BACB30NX8K4Y 0.278 - 0.281

Collar BACC30AC8 -

(SHEET 5 OF 5)
 FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480

S-10L

S-8L

500 480 460

STA STA STA

FWD

SEE B

A

SEE A

N68655

(SHEET 1 OF 10)
 FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM

STR-8L

CRACK TIP

STR-8L

CUT IN STRINGER

CRACK TIP TO

0.44 MIN.

EDGE MARGIN

LOCATION OF CUT

IN STRINGER

CRACK

FWD

UP

UP

FWD

1

SEE C OR D

3

3

3

2

5

B

SEE E

2

4

2

C

N68662

(SHEET 2 OF 10)
 FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM

OPTIONAL STRINGER CUT FOR SMALL CRACKS

CUT IN STRINGER

CRACK TIP TO

0.25 (MINIMUM)

CRACK

LOCATION OF CUT

IN STRINGER

RADIUS IN STRINGER

(MAXIMUM)

CUT TO TANGENT LINE OF

CRACK TIP

UP

FWD

D

2

4

2

SEE E

W13613

(SHEET 3 OF 10)
 FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

30

STR-8L

B

A

B

A

UP

FWD

7 18 19

9

8 11 18 20

16 18 19

18 19

6 18 19

E

12 14

15

N68683

(SHEET 4 OF 10)
 FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

STR-8L

STR8L

(WITH FILLER)

(3 LOCATIONS)

(WITHOUT FILLER)

RADIUS FILLER

REPAIR

SEGMENT

STRINGER

REPAIR

ANGLE

STRAPS

0.38 MIN.

UP

FWD

A-A

5

E

10

4

E

10 E

3

10 13

10 13

A

3

FWD

INBD

A

3

A

3

4

4 A

A

4

4 A

A

4

B

5

C

C

3

C

3

5

C

4

4 B

A

4

4 A

A

4

A

A

3

B-B

3

F

G G D

10

D D D D D G G

G

17

F

4 3

F

4

F

5

F

5

F

5

F

5

F

5

F

5

F

5

F F

5 5

F

5

F

G

G

G

10

N69063

(SHEET 5 OF 10)
 FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-2 and 691U1042-17 are used when you do the repair shown in this figure.

(SHEET 6 OF 10)
 FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— Unless otherwise specified, the minimum e/D (edge margin) for existing fastener locations 

common to the new 691U1042-145 (691U1042-141 optional) repair angle is 1.7. "e" is defined 

as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. 

The minimum edge margin for all other fastener locations is 2.0.

— The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the 

fastener diameter).

— Use the pilot hole locations in Repair Angle 691U1042-145 (691U1042-141 optional) as a guide 

when you cut the stringer (this will help make sure you keep the minimum edge margin for adjacent 

fasteners).

— The minimum radius is 0.50 inch when you cut the stringer.

— The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must 

make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current 

inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed.

— Do not remove the full section of the stringer as shown in View C if you can remove all cracks by 

making the cut in the stringer that is shown in View D

— Remove all burrs and sharp edges from the parts.

— All surfaces must be 125 microinches smooth after you cut them.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect Stringer - 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23.

Make sure you can cut 

the stringer at least 

0.060 inch from the 

crack tip and also have 

the minimum 1.7 edge 

margin for adjacent 

fasteners. See View C 

and D for stringer cut 

details.

3

Remove / Discard Fasteners - - at Fastener Code G only 

if you must cut an entire 

section of stringer to 

remove cracks as shown 

in View C. Remove 

enough fasteners to 

allow you to put a thin 

CRES sheet between 

stringer and the skin 

structures.

(SHEET 7 OF 10)
 FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

4

Cut Stringer - 1 Cut the stringer 0.030 

inch beyond the crack 

tip. Cut the minimum 

amount of stringer 

segment out to remove 

cracks. To protect the 

skin, put a thin CRES 

sheet between the 

stringer and the skin if 

you cut an entire 

segment out.

Inspect Stringer - 1 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23. Make sure 

there are no cracks 

found.

Cut Stringer - 1 Cut an additional 0.030 

inch of stringer to make 

sure all cracked material 

is removed.

5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area 

in the stringer

6 Put / Hold Stringer Segment 691U1042-117 1 -

7 Put / Hold Repair Angle 691U1042-145 

(691U1042-141 opt)

1 -

8 Put / Hold Frame Clip 691U1042-101 1 -

9

Cut Frame Clip 691U1042-101 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length and 

shape.

10

Drill Holes - - refer to Fastener Codes 

A, B, C, D and E for 

locations and hole sizes 

11 Install Frame Clip 691U1042-101 1 Use temporary fasteners

12 Put / Hold Repair Angle 691U1042-103 1 -

13

Drill Holes - refer to Fastener Codes 

A, B and C for locations 

and hole sizes

14 Install Repair Angle 691U1042-103 1 Use temporary fasteners

15 Cut Repair Strap 691U1042-100 2 -

16 Put / Hold Repair Strap 691U1042-100 2 -

17

Drill Holes - refer to Fastener Code F 

for locations and hole 

sizes 

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 8 OF 10)
 FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than 

shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers 

can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the 

alternative part numbers. 

18

Remove Repair Strap 691U1042-100 2 Prepare the parts for 

final installation Repair Angle 691U1042-103 1

Frame Clip 691U1042-101 1

Repair Angle 691U1042-145 

(691U1042-141 opt)

1

Stringer Segment 691U1042-117 1

19

Install Stringer Segment 691U1042-117 1 refer to Fastener Codes 

A, B, C, D, E and F. Repair Angle 691U1042-145 

(691U1042-141 opt)

1

Repair Angle 691U1042-103 1

Repair Strap 691U1042-100 2

20 Install Frame Clip 691U1042-101 1 refer to Fastener Code E

21

Install Fasteners - if previously removed. 

Refer to Fastener Code 

G

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

B

Bolt BACB30NX8K4 0.247 - 0.250

Collar BACC30BH8 -

STEP TASK NAME PART NUMBER QTY NOTES

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 9 OF 10)
 FIGURE 6: STRINGER REPAIR - STRINGER 8L AT BS 480

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C Bolt BACB30VT6K( ) 0.187 - 0.190

Collar BACC30BL6 -

D

Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 

Airplanes Only. DO NOT 

make the existing 

special countersink 

deeper in the skin.

E Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

F Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

G

Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 

Airplanes Only. Do 

NOT make the existing 

special countersink 

deeper in the skin.

CODE NAME PART NUMBER HOLE DIA NOTES

(SHEET 10 OF 10)
 FIGURE 7: STRINGER MODIFICATION - STRINGER 8L AT BS 500

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BOEING SERVICE BULLETIN 747-53A2484

FIGURE 7: STRINGER MODIFICATION - STRINGER 8L AT BS 500

S-10L

S-8L

STA STA STA

500 480 460

FWD

SEE B AND C

A

SEE A

N69172

(SHEET 1 OF 5)
 FIGURE 7: STRINGER MODIFICATION - STRINGER 8L AT BS 500

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BOEING SERVICE BULLETIN 747-53A2484

30

(3 LOCATIONS)

(WITHOUT FILLER)

CLIP

(WITH FILLER)

RADIUS FILLER

DOUBLER

(3 LOCATIONS) (3 LOCATIONS)

STR-8L

CLIP

STR-8L

UP

FWD

UP

FWD

5

C

4 7 8

3

A 6

3

A

6 4

A

6 B

D 6

6 B

C 6 3 7 8

B

1

2

N69173

(SHEET 2 OF 5)
 FIGURE 7: STRINGER MODIFICATION - STRINGER 8L AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

(SHEET 3 OF 5)
 FIGURE 7: STRINGER MODIFICATION - STRINGER 8L AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— The minimum radius on a cut part is 0.50 inch.

— Remove all burrs and sharp edges from the parts.

— All cut surfaces must be 125 microinches smooth.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum, except in fastener holes.

— The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance 

from the edge of the part to the center of the hole, and "D" is the final hole diameter.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 

51-00-00, Figure 1, 

Figure 11, or Figure 16 

3 Put / Hold Doubler 691U1042-118 1 -

4 Put / Hold Frame Clip 691U1042-119 1 -

5

Cut Frame Clip 691U1042-119 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length and shape

6

Drill Holes - - refer to Fastener Codes 

A, B, C and D for 

locations and hole sizes 

7 Remove Frame Clip 691U1042-119 1 Prepare the parts for 

final installation Doubler 691U1042-118 1

8

Install Doubler 691U1042-118 1 refer to Fastener Codes 

A, B, C and D Frame Clip 691U1042-119 1

(a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 8.

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 4 OF 5)
 FIGURE 7: STRINGER MODIFICATION - STRINGER 8L AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than 

shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers 

can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the 

alternative part numbers. 

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

B

Bolt BACB30NX6K3 0.187 - 0.190

Collar BACC30BH6 -

C

Bolt BACB30VT6K3 0.187 - 0.190

Collar BACC30BL6 -

D

Bolt BACB30NX8K4Y 0.278 - 0.281

Collar BACC30AC8 -

(SHEET 5 OF 5)
 FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500

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BOEING SERVICE BULLETIN 747-53A2484

FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500

S-10L

S-8L

500 480 460

STA STA STA

FWD

SEE B

A

SEE A

N69177

(SHEET 1 OF 10)
 FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500

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BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM

0.44 MIN.

EDGE MARGIN

CRACK TIP TO

CUT IN STRINGER

STR-8L

TIP

CRACK

CRACK

LOCATION OF CUT

IN STRINGER

STR-8L

FWD

UP

UP

FWD

SEE C OR D

1

SEE E

3

3

B

5

2

3

C

2

2

4

N69179

(SHEET 2 OF 10)
 FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500

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0.060 MIN. FROM

CRACK TIP

CUT TO TANGENT LINE OF

(MAXIMUM)

RADIUS IN STRINGER

IN STRINGER

LOCATION OF CUT

CRACK

0.25 (MINIMUM)

CRACK TIP TO

CUT IN STRINGER

OPTIONAL STRINGER CUT FOR SMALL CRACKS

FWD

UP

SEE E

2

4

2

D

W13688

(SHEET 3 OF 10)
 FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500

June 26, 2003

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30

STR-8L

A

B B

A

UP

FWD

7 18 19

E

9

8 11 18 20

15 16 18 19

12 14 18 19

6 18 19

N69180

(SHEET 4 OF 10)
 FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500

June 26, 2003

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SEGMENT

STRINGER REPAIR

STRAPS

REPAIR

ANGLE

STR-8L

STR-8L

(WITHOUT FILLER)

(WITH FILLER)

(3 LOCATIONS)

RADIUS FILLER

UP

FWD

D

5

F

5

F

D

17

F

3

G

3

F

4

F

4

F

5

F

5

F

5

F

5

F

5

F

5

F F

5 5

F

G D D D D

G

G

D G G

G

10

B-B

10 13

E

3

4

E

10

10 E

3

5

C

5

C

C

3

C

3

A-A

10 13

A

3

FWD

INBD

A

3

A

3

4

4 A

A

4

4 A

A

4

B 4

4 B

A

4

4 A

A

4

A

A

3

N69181

(SHEET 5 OF 10)
 FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-2 and 691U1042-17 are used when you do the repair shown in this figure.

(SHEET 6 OF 10)
 FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500

June 26, 2003

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NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— The minimum e/D (edge margin) for existing fastener locations common to the new 691U1042-

139 repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of 

the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener 

locations is 2.0.

— The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the 

fastener diameter).

— Use the pilot hole locations in Repair Angle 691U1042-139 as a guide when you cut the stringer 

(this will help make sure you keep the minimum edge margin for adjacent fasteners)

— The minimum radius is 0.50 inch when you cut the stringer.

— The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must 

make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current 

inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed.

— Do not remove the full section of the stringer as shown in View C if you can remove all cracks by 

making the cut in the stringer that is shown in View D

— Remove all burrs and sharp edges from the parts.

— All surfaces must be 125 microinches smooth after you cut them.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect Stringer - 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23.

Make sure you can cut 

the stringer at least 

0.060 inch from the 

crack tip and also have 

the minimum 1.7 edge 

margin for adjacent 

fasteners. See View C 

and D for stringer cut 

details.

3

Remove / Discard Fasteners - - at Fastener Code G only 

if you must cut an entire 

section of stringer to 

remove cracks as shown 

in View C. Remove 

enough fasteners to 

allow you to put a thin 

CRES sheet between 

stringer and the skin 

structures.

(SHEET 7 OF 10)
 FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500

June 26, 2003

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4

Cut Stringer - 1 Cut the stringer 0.030 

inch beyond the crack 

tip. Cut the minimum 

amount of stringer 

segment out to remove 

cracks. To protect the 

skin, put a thin CRES 

sheet between the 

stringer and the skin if 

you cut an entire 

segment out.

Inspect Stringer - 1 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23. Make sure 

there are no cracks 

found.

Cut Stringer - 1 Cut an additional 0.030 

inch of stringer to make 

sure all cracked material 

is removed.

5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area 

in the stringer

6 Put / Hold Stringer Segment 691U1042-117 1 -

7 Put / Hold Repair Angle 691U1042-139 1 -

8 Put / Hold Frame Clip 691U1042-101 1 -

9

Cut Frame Clip 691U1042-101 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length and 

shape.

10

Drill Holes - - refer to Fastener Codes 

A, B, C, D and E for 

locations and hole sizes 

11 Install Frame Clip 691U1042-101 1 Use temporary fasteners

12 Put / Hold Repair Angle 691U1042-103 1 -

13

Drill Holes - refer to Fastener Codes 

A, B and C for locations 

and hole sizes

14 Install Repair Angle 691U1042-103 1 Use temporary fasteners

15 Cut Repair Strap 691U1042-100 2 -

16 Put / Hold Repair Strap 691U1042-100 2 -

17

Drill Holes - refer to Fastener Code F 

for locations and hole 

sizes 

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 8 OF 10)
 FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than 

shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers 

can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the 

alternative part numbers. 

18

Remove Repair Strap 691U1042-100 2 Prepare the parts for 

final installation Repair Angle 691U1042-103 1

Frame Clip 691U1042-101 1

Repair Angle 691U1042-139 1

Stringer Segment 691U1042-117 1

19

Install Stringer Segment 691U1042-117 1 refer to Fastener Codes 

A, B, C, D, E and F. Repair Angle 691U1042-139 1

Repair Angle 691U1042-103 1

Repair Strap 691U1042-100 2

20 Install Frame Clip 691U1042-101 1 refer to Fastener Code E

21

Install Fasteners - if previously removed. 

Refer to Fastener Code 

G

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

B

Bolt BACB30NX8K4 0.247 - 0.250

Collar BACC30BH8 -

STEP TASK NAME PART NUMBER QTY NOTES

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 9 OF 10)
 FIGURE 8: STRINGER REPAIR - STRINGER 8L AT BS 500

June 26, 2003

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C Bolt BACB30VT6K( ) 0.187 - 0.190

Collar BACC30BL6 -

D

Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 

Airplanes Only. DO NOT 

make the existing 

special countersink 

deeper in the skin.

E Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

F Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

G

Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 

Airplanes Only. Do 

NOT make the existing 

special countersink 

deeper in the skin.

CODE NAME PART NUMBER HOLE DIA NOTES

(SHEET 10 OF 10)
 FIGURE 9: STRINGER MODIFICATION - STRINGER 8R AT BS 460

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BOEING SERVICE BULLETIN 747-53A2484

FIGURE 9: STRINGER MODIFICATION - STRINGER 8R AT BS 460

S-10R

S-8R

480

STA

460

STA

500

STA

FWD

SEE B AND C

A

SEE A

N69185

(SHEET 1 OF 5)
 FIGURE 9: STRINGER MODIFICATION - STRINGER 8R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

30

CLIP

STR-8R

(WITHOUT FILLER)

(WITH FILLER)

(3 LOCATIONS) (3 LOCATIONS)

CLIP

STR-8R

DOUBLER

(4 LOCATIONS)

RADIUS FILLER

UP

FWD

FWD

UP

B

C

1

2

5

3

A

4

A

B 6

D 6

B 6

4 7 8

C 6

3 7 8

3

A 6

6

N69195

(SHEET 2 OF 5)
 FIGURE 9: STRINGER MODIFICATION - STRINGER 8R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

(SHEET 3 OF 5)
 FIGURE 9: STRINGER MODIFICATION - STRINGER 8R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— The minimum radius on a cut part is 0.50 inch.

— Remove all burrs and sharp edges from the parts.

— All cut surfaces must be 125 microinches smooth.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance 

from the edge of the part to the center of the hole, and "D" is the final hole diameter.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 

51-00-00, Figure 1, 

Figure 11, or Figure 16 

3 Put / Hold Doubler 691U1042-118 1 -

4 Put / Hold Frame Clip 691U1042-120 1 -

5

Cut Frame Clip 691U1042-120 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length.

6

Drill Holes - - refer to Fastener Codes 

A, B, C and D for 

locations and hole sizes 

7 Remove Frame Clip 691U1042-120 1 Prepare the parts for 

final installation Doubler 691U1042-118 1

8

Install Doubler 691U1042-118 1 refer to Fastener Codes 

A, B, C and D Frame Clip 691U1042-120 1

(a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 10.

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 4 OF 5)
 FIGURE 9: STRINGER MODIFICATION - STRINGER 8R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than 

indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute 

fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used 

to determine the part numbers used as substitutes. 

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

B

Bolt BACB30NX6K3 0.187 - 0.190

Collar BACC30BH6 -

C

Bolt BACB30VT6K3 0.187 - 0.190

Collar BACC30BL6 -

D

Bolt BACB30NX8K4Y 0.278 - 0.281

Collar BACC30AC8 -

(SHEET 5 OF 5)
 FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460

S-10R

S-8R

460

STA STA

480 500

STA

FWD

A

SEE B

SEE A

N69210

(SHEET 1 OF 10)
 FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM

STR-8R

CRACK

CRACK TIP

LOCATION OF CUT

IN STRINGER

STR-8R

0.44 MIN.

EDGE MARGIN

CRACK TIP TO

CUT IN STRINGER

FWD

UP

FWD

UP

3

SEE C OR D

2

2

4

1 2

5

3 3

SEE E C

B

N69211

(SHEET 2 OF 10)
 FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM

CUT IN STRINGER

CRACK TIP TO

0.25 (MINIMUM)

CUT TO TANGENT LINE OF

RADIUS IN STRINGER

(MAXIMUM)

CRACK TIP

CRACK

LOCATION OF CUT

IN STRINGER

OPTIONAL STRINGER CUT FOR SMALL CRACKS

2

2

4

SEE E

D

UP

FWD

W13869

(SHEET 3 OF 10)
 FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

30

STR-8R

A

B B

A

FWD

UP

9 12 19 21

8 19 20

E

10

16 17 19 20

13 15 19 20

6 19 20

7 19 20

N69217

(SHEET 4 OF 10)
 FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

STR-8R

STR-8R

FILLER

REPAIR

ANGLE

RADIUS FILLER

(WITHOUT FILLER)

(4 LOCATIONS)

(WITH FILLER)

SEGMENT

STRINGER

REPAIR

STRAPS

FWD

UP

11

11 14

11 14

A

3

A

3

4

4 A

A

4

4 A

A

4

B

5

C

5

C

C

3

C

3

4

4 B

A

4

4 A

A

4

A

A

A 3

3

4

F

3

F

4

F

D D D D D

G

D D D

18

F

5 5

F

5

F

5

F

5

F

5

F

5

F

5

F

5

F

5

F F

3

G G

G

G

G

E

3

4

E

11

E

3 11

INBD

FWD

A-A

B-B

N69363

(SHEET 5 OF 10)
 FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-2 and 691U1042-18 are used when you do the repair shown in this figure.

(SHEET 6 OF 10)
 FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— The minimum e/D (edge margin) for existing fastener locations common to the new 691U1042-

144 repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of 

the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener 

locations is 2.0.

— The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the 

fastener diameter).

— Use the pilot hole locations in Repair Angle 691U1042-144 as a guide when you cut the stringer 

(this will help make sure you keep the minimum edge margin for adjacent fasteners)

— The minimum radius is 0.50 inch when you cut the stringer.

— The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must 

make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current 

inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed.

— Do not remove the full section of the stringer as shown in View C if you can remove all cracks by 

making the cut in the stringer that is shown in View D

— Remove all burrs and sharp edges from the parts.

— All surfaces must be 125 microinches smooth after you cut them.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect Stringer 1 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23.

Make sure you can cut 

the stringer at least 

0.060 inch from the 

crack tip and also have 

the minimum 1.7 edge 

margin for adjacent 

fasteners. See View C 

and D for stringer cut 

details.

3

Remove / Discard Fasteners - - at Fastener Code G only 

if you must cut an entire 

section of stringer to 

remove cracks as shown 

in View C. Remove 

enough fasteners to 

allow you to put a thin 

CRES sheet between 

stringer and the skin 

structures.

(SHEET 7 OF 10)
 FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

4

Cut Stringer - 1 Cut the stringer 0.030 

inch beyond the crack 

tip. Cut the minimum 

amount of stringer 

segment out to remove 

cracks. To protect the 

skin, put a thin CRES 

sheet between the 

stringer and the skin if 

you cut an entire 

segment out.

Inspect Stringer - 1 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23. Make sure 

there are no cracks 

found.

Cut Stringer - 1 Cut an additional 0.030 

inch of stringer to make 

sure all cracked material 

is removed.

5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area 

in the stringer

6 Put / Hold Stringer Segment 691U1042-117 1 -

7 Put / Hold Filler BACF3F008D029NN 1 -

8 Put / Hold Repair Angle 691U1042-144 1 -

9 Put / Hold Frame Clip 691U1042-102 1 -

10

Cut Frame Clip 691U1042-102 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length.

11

Drill Holes - - refer to Fastener Codes 

A, B, C, D and E for 

locations and hole sizes 

12 Install Frame Clip 691U1042-102 1 Use temporary fasteners

13 Put / Hold Repair Angle 691U1042-103 1 -

14

Drill Holes - refer to Fastener Codes 

A, B and C for locations 

and hole sizes

15 Install Repair Angle 691U1042-103 1 Use temporary fasteners

16 Cut Repair Strap 691U1042-100 2 -

17 Put / Hold Repair Strap 691U1042-100 2 -

18

Drill Holes - refer to Fastener Code F 

for locations and hole 

sizes 

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 8 OF 10)
 FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than 

shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers 

can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the 

alternative part numbers. 

19

Remove Repair Strap 691U1042-100 2 Prepare the parts for 

final installation Repair Angle 691U1042-103 1

Frame Clip 691U1042-102 1

Repair Angle 691U1042-144 1

Filler BACF3F008D029NN 1

Stringer Segment 691U1042-117 1

20

Install Stringer Segment 691U1042-117 1 refer to Fastener Codes 

A, B, C, D, E and F. Filler BACF3F008D029NN 1

Repair Angle 691U1042-144 1

Repair Angle 691U1042-103 1

Repair Strap 691U1042-100 2

21 Install Frame Clip 691U1042-102 1 refer to Fastener Code E

22

Install Fasteners - if previously removed. 

Refer to Fastener Code 

G

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

STEP TASK NAME PART NUMBER QTY NOTES

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 9 OF 10)
 FIGURE 10: STRINGER REPAIR - STRINGER 8R AT BS 460

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BOEING SERVICE BULLETIN 747-53A2484

B

Bolt BACB30NX8K4 0.247 - 0.250

Collar BACC30BH8 -

C Bolt BACB30VT6K( ) 0.187 - 0.190

Collar BACC30BL6 -

D

Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 

Airplanes Only. DO NOT 

make the existing 

special countersink 

deeper in the skin.

E Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

F Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

G

Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 

Airplanes Only. Do 

NOT make the existing 

special countersink 

deeper in the skin.

CODE NAME PART NUMBER HOLE DIA NOTES

(SHEET 10 OF 10)
 FIGURE 11: STRINGER MODIFICATION - STRINGER 8R AT BS 480

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FIGURE 11: STRINGER MODIFICATION - STRINGER 8R AT BS 480

S-10R

S-8R

460

STA

480

STA STA

500

FWD

SEE B AND C

A

SEE A

N69460

(SHEET 1 OF 5)
 FIGURE 11: STRINGER MODIFICATION - STRINGER 8R AT BS 480

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30

STR-8R

(3 LOCATIONS)

CLIP

DOUBLER

(WITH FILLER)

(WITHOUT FILLER)

(3 LOCATIONS)

(3 LOCATIONS)

RADIUS FILLER

STR-8R

CLIP

FWD

UP

UP

FWD

4

C

5

B 6

3 7 8

C

5

A

6

4

A

B 6

D 6

7 8

6

A

3 6

B

2

1

N69461

(SHEET 2 OF 5)
 FIGURE 11: STRINGER MODIFICATION - STRINGER 8R AT BS 480

June 26, 2003

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The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

(SHEET 3 OF 5)
 FIGURE 11: STRINGER MODIFICATION - STRINGER 8R AT BS 480

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NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— The minimum radius on a cut part is 0.50 inch.

— Remove all burrs and sharp edges from the parts.

— All cut surfaces must be 125 microinches smooth.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance 

from the edge of the part to the center of the hole, and "D" is the final hole diameter.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 

51-00-00, Figure 1, 

Figure 11, or Figure 16 

3 Put / Hold Doubler 691U1042-118 1 -

4 Put / Hold Frame Clip 691U1042-120 1 -

5

Cut Frame Clip 691U1042-120 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length.

6

Drill Holes - - refer to Fastener Codes 

A, B, C and D for 

locations and hole sizes 

7 Remove Frame Clip 691U1042-120 1 Prepare the parts for 

final installation Doubler 691U1042-118 1

8

Install Doubler 691U1042-118 1 refer to Fastener Codes 

A, B, C and D Frame Clip 691U1042-120 1

(a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 12.

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 4 OF 5)
 FIGURE 11: STRINGER MODIFICATION - STRINGER 8R AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than 

indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute 

fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used 

to determine the part numbers used as substitutes. 

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

B

Bolt BACB30NX6K3 0.187 - 0.190

Collar BACC30BH6 -

C

Bolt BACB30VT6K3 0.187 - 0.190

Collar BACC30BL6 -

D

Bolt BACB30NX8K4Y 0.278 - 0.281

Collar BACC30AC8 -

(SHEET 5 OF 5)
 FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480

S-10R

S-R8

460

STA

480

STA

500

STA

FWD

SEE B

SEE A

A

N69462

(SHEET 1 OF 10)
 FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM STR-8R

STR-8R

CRACK TIP

CRACK

0.44 MIN.

EDGE MARGIN

CRACK TIP TO

CUT IN STRINGER

IN STRINGER

LOCATION OF CUT

FWD

UP

FWD

UP

SEE C D OR

3

1

2

2

SEE E C

4

3

B

5

2

3

N69464

(SHEET 2 OF 10)
 FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

CUT TO TANGENT LINE OF

RADIUS IN STRINGER

(MAXIMUM)

0.060 MIN. FROM

CUT IN STRINGER

CRACK TIP TO

0.25 (MINIMUM)

OPTIONAL STRINGER CUT FOR SMALL CRACKS

CRACK TIP

IN STRINGER

LOCATION OF CUT

CRACK

SEE E

D

FWD

UP

2

4

2

W13870

(SHEET 3 OF 10)
 FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

30

STR-8R

B

A A

B

FWD

UP

8 11 18 20

15 16 18 19

7 18 19

E

9

12 14 18 19

6 18 19

N69468

(SHEET 4 OF 10)
 FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

STR-8R

STR-8R

(WITHOUT FILLER)

(WITH FILLER)

REPAIR

ANGLE

SEGMENT

STRINGER

REPAIR

STRAPS

RADIUS FILLER

(3 LOCATIONS)

0.38 MIN.

FWD

UP

10

17

4

E

E

3

10 13

10 13

10

INBD

FWD

E

3 10

G

G

G

G

G G D D D D D D G G

5

F

5

F F

5 5

F

5

F

5

F

5

F

5

F

5

F

3

F

4

F

5

F F

4 3

F

A

3

A

3

4

4 A

A

4

4 A

A

4

B

5

C

5

C

C

3

C

3

4

4 B

A

4

4 A

A

4

A

A

A 3

3

A-A

B-B

10

N69474

(SHEET 5 OF 10)
 FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-2 and 691U1042-18 are used when you do the repair shown in this figure.

(SHEET 6 OF 10)
 FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— Unless otherwise specified, the minimum e/D (edge margin) for existing fastener locations 

common to the new 691U1042-146 (691U1042-142 optional) repair angle is 1.7. "e" is defined 

as the distance from the edge of the part to the center of the hole, and "D" is the final hole diameter. 

The minimum edge margin for all other fastener locations is 2.0.

— The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the 

fastener diameter).

— Use the pilot hole locations in Repair Angle 691U1042-146 (691U1042-142 optional) as a guide 

when you cut the stringer (this will help make sure you keep the minimum edge margin for adjacent 

fasteners)

— The minimum radius is 0.50 inch when you cut the stringer.

— The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must 

make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current 

inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed.

— Do not remove the full section of the stringer as shown in View C if you can remove all cracks by 

making the cut in the stringer that is shown in View D

— Remove all burrs and sharp edges from the parts.

— All surfaces must be 125 microinches smooth after you cut them.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect Stringer 1 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23.

Make sure you can cut 

the stringer at least 

0.060 inch from the 

crack tip and also have 

the minimum 1.7 edge 

margin for adjacent 

fasteners. See View C 

and D for stringer cut 

details.

3

Remove / Discard Fasteners - - at Fastener Code G only 

if you must cut an entire 

section of stringer to 

remove cracks as shown 

in View C. Remove 

enough fasteners to 

allow you to put a thin 

CRES sheet between 

stringer and the skin 

structures.

(SHEET 7 OF 10)
 FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

4

Cut Stringer - 1 Cut the stringer 0.030 

inch beyond the crack 

tip. Cut the minimum 

amount of stringer 

segment out to remove 

cracks. To protect the 

skin, put a thin CRES 

sheet between the 

stringer and the skin if 

you cut an entire 

segment out.

Inspect Stringer - 1 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23. Make sure 

there are no cracks 

found.

Cut Stringer - 1 Cut an additional 0.030 

inch of stringer to make 

sure all cracked material 

is removed.

5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area 

in the stringer

6 Put / Hold Stringer Segment 691U1042-117 1 -

7 Put / Hold Repair Angle 691U1042-146 

(691U1042-142 opt)

1 -

8 Put / Hold Frame Clip 691U1042-102 1 -

9

Cut Frame Clip 691U1042-102 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length and 

shape.

10

Drill Holes - - refer to Fastener Codes 

A, B, C, D and E for 

locations and hole sizes 

11 Install Frame Clip 691U1042-102 1 Use temporary fasteners

12 Put / Hold Repair Angle 691U1042-103 1 -

13

Drill Holes - refer to Fastener Codes 

A, B and C for locations 

and hole sizes

14 Install Repair Angle 691U1042-103 1 Use temporary fasteners

15 Cut Repair Strap 691U1042-100 2 -

16 Put / Hold Repair Strap 691U1042-100 2 -

17

Drill Holes - refer to Fastener Code F 

for locations and hole 

sizes 

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 8 OF 10)
 FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than 

shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers 

can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the 

alternative part numbers. 

18

Remove Repair Strap 691U1042-100 2 Prepare the parts for 

final installation Repair Angle 691U1042-103 1

Frame Clip 691U1042-102 1

Repair Angle 691U1042-146 

(691U1042-142 opt)

1

Stringer Segment 691U1042-117 1

19

Install Stringer Segment 691U1042-117 1 refer to Fastener Codes 

A, B, C, D, E and F. Repair Angle 691U1042-146 

(691U1042-142 opt)

1

Repair Angle 691U1042-103 1

Repair Strap 691U1042-100 2

20 Install Frame Clip 691U1042-102 1 refer to Fastener Code E

21

Install Fasteners - if previously removed. 

Refer to Fastener Code 

G

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

B

Bolt BACB30NX8K4 0.247 - 0.250

Collar BACC30BH8 -

STEP TASK NAME PART NUMBER QTY NOTES

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 9 OF 10)
 FIGURE 12: STRINGER REPAIR - STRINGER 8R AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

C Bolt BACB30VT6K( ) 0.187 - 0.190

Collar BACC30BL6 -

D

Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 

Airplanes Only. DO NOT 

make the existing 

special countersink 

deeper in the skin.

E Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

F Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

G

Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 

Airplanes Only. Do 

NOT make the existing 

special countersink 

deeper in the skin.

CODE NAME PART NUMBER HOLE DIA NOTES

(SHEET 10 OF 10)
 FIGURE 13: STRINGER MODIFICATION - STRINGER 8R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

FIGURE 13: STRINGER MODIFICATION - STRINGER 8R AT BS 500

S-10R

S-8R

460

STA

480

STA STA

500

FWD

A

SEE B AND C

SEE A

N69533

(SHEET 1 OF 5)
 FIGURE 13: STRINGER MODIFICATION - STRINGER 8R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

CLIP

30

STR-8R

STR-8R

(WITH FILLER)

(WITHOUT FILLER)

(3 LOCATIONS) (3 LOCATIONS)

DOUBLER

(3 LOCATIONS)

RADIUS FILLER

CLIP

FWD

UP

FWD

UP

4 7 8 5

4

A

6

3

A

B 6

B 6

D 6

3 7 8

C 6

2

3

A 6

C

1

B

N69534

(SHEET 2 OF 5)
 FIGURE 13: STRINGER MODIFICATION - STRINGER 8R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

(SHEET 3 OF 5)
 FIGURE 13: STRINGER MODIFICATION - STRINGER 8R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— The minimum radius on a cut part is 0.50 inch.

— Remove all burrs and sharp edges from the parts.

— All cut surfaces must be 125 microinches smooth.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance 

from the edge of the part to the center of the hole, and "D" is the final hole diameter.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 

51-00-00, Figure 1, 

Figure 11, or Figure 16 

3 Put / Hold Doubler 691U1042-118 1 -

4 Put / Hold Frame Clip 691U1042-120 1 -

5

Cut Frame Clip 691U1042-120 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length.

6

Drill Holes - - refer to Fastener Codes 

A, B, C and D for 

locations and hole sizes 

7 Remove Frame Clip 691U1042-120 1 Prepare the parts for 

final installation Doubler 691U1042-118 1

8

Install Doubler 691U1042-118 1 refer to Fastener Codes 

A, B, C and D Frame Clip 691U1042-120 1

(a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 14.

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 4 OF 5)
 FIGURE 13: STRINGER MODIFICATION - STRINGER 8R AT BS 500

June 26, 2003

Revision 1: February 12, 2009 747-53A2484

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than 

indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute 

fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used 

to determine the part numbers used as substitutes. 

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

B

Bolt BACB30NX6K3 0.187 - 0.190

Collar BACC30BH6 -

C

Bolt BACB30VT6K3 0.187 - 0.190

Collar BACC30BL6 -

D

Bolt BACB30NX8K4Y 0.278 - 0.281

Collar BACC30AC8 -

(SHEET 5 OF 5)
 FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500

S-10R

S-8R

460

STA

480

STA

500

STA

FWD

SEE B

SEE A

A

N69536

(SHEET 1 OF 10)
 FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

CRACK TIP

0.060 MIN. FROM

IN STRINGER

LOCATION OF CUT

CRACK CRACK TIP TO

CUT IN STRINGER

0.44 MIN.

EDGE MARGIN

STR-8R

STR-8R

UP

FWD

UP

FWD

2

3

3

1

4

SEE C OR D

5

2

3

2

SEE E

C

B

N69538

(SHEET 2 OF 10)
 FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500

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0.060 MIN. FROM

CUT IN STRINGER

CRACK TIP TO

0.25 (MINIMUM)

CUT TO TANGENT LINE OF

RADIUS IN STRINGER

(MAXIMUM)

OPTIONAL STRINGER CUT FOR SMALL CRACKS

CRACK TIP

IN STRINGER

LOCATION OF CUT

CRACK

SEE E

D

FWD

UP

2

4

2

W13873

(SHEET 3 OF 10)
 FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

30

STR-8R

A

B

A

B

FWD

UP

7 18 19

15 16 18 19

9

12 14 18 19

8 11 18 20

E

6 18 19

N69539

(SHEET 4 OF 10)
 FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

(3 LOCATIONS)

(WITHOUT FILLER)

(WITH FILLER)

RADIUS FILLER

STR-8R

REPAIR

ANGLE

REPAIR

STRAPS SEGMENT

STRINGER

STR-8R

UP

FWD

17

10 13

10 13

10 E

3

10

4

E

10

E

3

FWD

INBD

A

3

A

3

4

4 A

A

4

4 A

A

4

B

5

C

5

C

C

3

C

3 4

4 B

A

4

4 A

A

4

A

A

A 3

3

G G D D D D D D D G

F

4 3

F

5

F

5

F F

5 5

F

5

F

5

F

5

F

5

F

5

F

5

F

4

F

3

F

G

G

G

G

B-B

A-A

N69541

(SHEET 5 OF 10)
 FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-2 and 691U1042-18 are used when you do the repair shown in this figure.

(SHEET 6 OF 10)
 FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— The minimum e/D (edge margin) for existing fastener locations common to the new 691U1042-

140 repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of 

the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener 

locations is 2.0.

— The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the 

fastener diameter).

— Use the pilot hole locations in Repair Angle 691U1042-140 as a guide when you cut the stringer 

(this will help make sure you keep the minimum edge margin for adjacent fasteners)

— The minimum radius is 0.50 inch when you cut the stringer.

— The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must 

make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current 

inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed.

— Do not remove the full section of the stringer as shown in View C if you can remove all cracks by 

making the cut in the stringer that is shown in View D

— Remove all burrs and sharp edges from the parts.

— All surfaces must be 125 microinches smooth after you cut them.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect Stringer 1 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23.

Make sure you can cut 

the stringer at least 

0.060 inch from the 

crack tip and also have 

the minimum 1.7 edge 

margin for adjacent 

fasteners. See View C 

and D for stringer cut 

details.

3

Remove / Discard Fasteners - - at Fastener Code G only 

if you must cut an entire 

section of stringer to 

remove cracks as shown 

in View C. Remove 

enough fasteners to 

allow you to put a thin 

CRES sheet between 

stringer and the skin 

structures.

(SHEET 7 OF 10)
 FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500

June 26, 2003

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4

Cut Stringer - 1 Cut the stringer 0.030 

inch beyond the crack 

tip. Cut the minimum 

amount of stringer 

segment out to remove 

cracks. To protect the 

skin, put a thin CRES 

sheet between the 

stringer and the skin if 

you cut an entire 

segment out.

Inspect Stringer - 1 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23. Make sure 

there are no cracks 

found.

Cut Stringer - 1 Cut an additional 0.030 

inch of stringer to make 

sure all cracked material 

is removed.

5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area 

in the stringer

6 Put / Hold Stringer Segment 691U1042-117 1 -

7 Put / Hold Repair Angle 691U1042-140 1 -

8 Put / Hold Frame Clip 691U1042-102 1 -

9

Cut Frame Clip 691U1042-102 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length and 

shape.

10

Drill Holes - - refer to Fastener Codes 

A, B, C, D and E for 

locations and hole sizes 

11 Install Frame Clip 691U1042-102 1 Use temporary fasteners

12 Put / Hold Repair Angle 691U1042-103 1 -

13

Drill Holes - refer to Fastener Codes 

A, B and C for locations 

and hole sizes

14 Install Repair Angle 691U1042-103 1 Use temporary fasteners

15 Cut Repair Strap 691U1042-100 2 -

16 Put / Hold Repair Strap 691U1042-100 2 -

17

Drill Holes - refer to Fastener Code F 

for locations and hole 

sizes 

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 8 OF 10)
 FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than 

shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers 

can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the 

alternative part numbers. 

18

Remove Repair Strap 691U1042-100 2 Prepare the parts for 

final installation Repair Angle 691U1042-103 1

Frame Clip 691U1042-102 1

Repair Angle 691U1042-140 1

Stringer Segment 691U1042-117 1

19

Install Stringer Segment 691U1042-117 1 refer to Fastener Codes 

A, B, C, D, E and F. Repair Angle 691U1042-140 1

Repair Angle 691U1042-103 1

Repair Strap 691U1042-100 2

20 Install Frame Clip 691U1042-102 1 refer to Fastener Code E

21

Install Fasteners - if previously removed. 

Refer to Fastener Code 

G

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

B

Bolt BACB30NX8K4 0.247 - 0.250

Collar BACC30BH8 -

STEP TASK NAME PART NUMBER QTY NOTES

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 9 OF 10)
 FIGURE 14: STRINGER REPAIR - STRINGER 8R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

C Bolt BACB30VT6K( ) 0.187 - 0.190

Collar BACC30BL6 -

D

Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 

Airplanes Only. DO NOT 

make the existing 

special countersink 

deeper in the skin.

E Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

F Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

G

Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 

Airplanes Only. Do 

NOT make the existing 

special countersink 

deeper in the skin.

CODE NAME PART NUMBER HOLE DIA NOTES

(SHEET 10 OF 10)
 FIGURE 15: STRINGER MODIFICATION - STRINGER 10L AT BS 460

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BOEING SERVICE BULLETIN 747-53A2484

FIGURE 15: STRINGER MODIFICATION - STRINGER 10L AT BS 460

S-10L

S-8L

STA

460

STA

500 480

STA

FWD

SEE B AND C

A

SEE A

N69546

(SHEET 1 OF 5)
 FIGURE 15: STRINGER MODIFICATION - STRINGER 10L AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

CLIP

30

CLIP

STR-10L

DOUBLER

SHIM

(3 LOCATIONS)

(WITH FILLER)

(WITHOUT FILLER)

STR-10L

(4 LOCATIONS)

RADIUS FILLER

(3 LOCATIONS)

UP

FWD

FWD

UP

2

1

B

3 7 8

3 7 8

5

6 B

C 6

4 7 8

6 6

A

5

A

6 3

A

6 B

D 6

C

N69555

(SHEET 2 OF 5)
 FIGURE 15: STRINGER MODIFICATION - STRINGER 10L AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

(SHEET 3 OF 5)
 FIGURE 15: STRINGER MODIFICATION - STRINGER 10L AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— The minimum radius on a cut part is 0.50 inch.

— Remove all burrs and sharp edges from the parts.

— All cut surfaces must be 125 microinches smooth.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance 

from the edge of the part to the center of the hole, and "D" is the final hole diameter.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 

51-00-00, Figure 1, 

Figure 11, or Figure 16 

3

Put / Hold Doubler 691U1042-118 1 -

Shim BACS40R010B040F 1 use if the gap between 

the doubler and the 

stringer is more than 

0.005 inch. Remove 

laminations from shim 

until the gap is 0.005 

inch or less.

4 Put / Hold Frame Clip 691U1042-120 1 -

5

Cut Frame Clip 691U1042-120 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length.

6

Drill Holes - - refer to Fastener Codes 

A, B, C and D for 

locations and hole sizes 

7

Remove Frame Clip 691U1042-120 1 Prepare the parts for 

final installation Doubler 691U1042-118 1

Shim BACS40R010B040F 1

8

Install Doubler 691U1042-118 1 refer to Fastener Codes 

A, B, C and D Frame Clip 691U1042-120 1

Shim BACS40R010B040F 1

(a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 16.

(SHEET 4 OF 5)
 FIGURE 15: STRINGER MODIFICATION - STRINGER 10L AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than 

indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute 

fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used 

to determine the part numbers used as substitutes. 

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

B

Bolt BACB30NX6K3 0.187 - 0.190

Collar BACC30BH6 -

C

Bolt BACB30VT6K3 0.187 - 0.190

Collar BACC30BL6 -

D

Bolt BACB30NX8K4Y 0.278 - 0.281

Collar BACC30AC8 -

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 5 OF 5)
 FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460

S-10L

S-8L

STA

460

STA

500 480

STA

FWD

SEE B

A

SEE A

N69564

(SHEET 1 OF 10)
 FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM

CRACK TIP TO

CUT IN STRINGER

CRACK TIP

EDGE MARGIN

0.44 MIN.

CRACK

STR-10L

STR-10L

LOCATION OF CUT

IN STRINGER

SEE C OR D

2

3

3

SEE E

2

5

UP

FWD

UP

FWD

C

4

3

1 2

B

N69603

(SHEET 2 OF 10)
 FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

CRACK

IN STRINGER

LOCATION OF CUT

0.060 MIN. FROM

CUT TO TANGENT LINE OF

RADIUS IN STRINGER

(MAXIMUM)

CRACK TIP TO

CUT IN STRINGER

0.25 (MINIMUM)

CRACK TIP

OPTIONAL STRINGER CUT FOR SMALL CRACKS

2

4

2

SEE E

D

UP

FWD

W13877

(SHEET 3 OF 10)
 FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

30

STR-10L

B B

A A

16 17 19 20

9 12 19 21

10

E

8

15 19 20

19 20

8 19 20

6 19 20

UP

FWD

7 19 20

13

N69606

(SHEET 4 OF 10)
 FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

FILLER

REPAIR

ANGLE SEGMENT

STRINGER

REPAIR

STRAPS

STR-10L

STR-10L

RADIUS FILLER

(WITHOUT FILLER)

(WITH FILLER)

(4 LOCATIONS)

UP

FWD

5

F

D D D D D D

5

F

5

F

5

F

5

F

4

F

3

F

18

5

F

5

F F

5 5

F F

4 3

F

5

F

11

G

G

G D G

G

G

B-B

11 14

FWD

A

3

11

4

E

5

E

11 E

3

11 14

INBD

A

3

4

A

4

4 A

A

4

4 A

B

5

C

5

C

C

3

C

3

4

B

4

4 A

A

4

4 A

A

A

3

A

3

A-A

D

N69613

(SHEET 5 OF 10)
 FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-2 and 691U1042-17 are used when you do the repair shown in this figure.

(SHEET 6 OF 10)
 FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460

June 26, 2003

Revision 1: February 12, 2009 747-53A2484

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BOEING SERVICE BULLETIN 747-53A2484

NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— The minimum e/D (edge margin) for existing fastener locations common to the new 691U1042-

133 repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of 

the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener 

locations is 2.0.

— The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the 

fastener diameter).

— Use the pilot hole locations in Repair Angle 691U1042-133 as a guide when you cut the stringer 

(this will help make sure you keep the minimum edge margin for adjacent fasteners)

— The minimum radius is 0.50 inch when you cut the stringer.

— The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must 

make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current 

inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed.

— Do not remove the full section of the stringer as shown in View C if you can remove all cracks by 

making the cut in the stringer that is shown in View D

— Remove all burrs and sharp edges from the parts.

— All surfaces must be 125 microinches smooth after you cut them.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect Stringer - 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23.

Make sure you can cut 

the stringer at least 

0.060 inch from the 

crack tip and also have 

the minimum 1.7 edge 

margin for adjacent 

fasteners. See View C 

and D for stringer cut 

details.

3

Remove / Discard Fasteners - - at Fastener Code G only 

if you must cut an entire 

section of stringer to 

remove cracks as shown 

in View C. Remove 

enough fasteners to 

allow you to put a thin 

CRES sheet between 

stringer and the skin 

structures.

(SHEET 7 OF 10)
 FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

4

Cut Stringer - 1 Cut the stringer 0.030 

inch beyond the crack 

tip. Cut the minimum 

amount of stringer 

segment out to remove 

cracks. To protect the 

skin, put a thin CRES 

sheet between the 

stringer and the skin if 

you cut an entire 

segment out.

Inspect Stringer - 1 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23. Make sure 

there are no cracks 

found.

Cut Stringer - 1 Cut an additional 0.030 

inch of stringer to make 

sure all cracked material 

is removed.

5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area 

in the stringer

6 Put / Hold Stringer Segment 691U1042-117 1 -

7 Put / Hold Filler BACF3F007D019NN 1 -

8

Put / Hold Repair Angle 691U1042-133 1 -

Shim BACS40R010B048F 1 use if the gap between 

the repair angle and the 

stringer is more than 

0.005 inch. Remove 

laminations from shim 

until the gap is 0.005 

inch or less.

9 Put / Hold Frame Clip 691U1042-102 1 -

10

Cut Frame Clip 691U1042-102 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length and 

shape.

11

Drill Holes - - refer to Fastener Codes 

A, B, C, D and E for 

locations and hole sizes 

12 Install Frame Clip 691U1042-102 1 Use temporary fasteners

13 Put / Hold Repair Angle 691U1042-103 1 -

14

Drill Holes - refer to Fastener Codes 

A, B and C for locations 

and hole sizes

15 Install Repair Angle 691U1042-103 1 Use temporary fasteners

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 8 OF 10)
 FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

16 Cut Repair Strap 691U1042-100 2 -

17 Put / Hold Repair Strap 691U1042-100 2 -

18

Drill Holes - refer to Fastener Code F 

for locations and hole 

sizes 

19

Remove Repair Strap 691U1042-100 2 Prepare the parts for 

final installation Repair Angle 691U1042-103 1

Frame Clip 691U1042-102 1

Repair Angle 691U1042-133 1

Shim BACS40R010B048F 1

Filler BACF3F007D019NN 1

Stringer Segment 691U1042-117 1

20

Install Stringer Segment 691U1042-117 1 refer to Fastener Codes 

A, B, C, D, E and F. Repair Angle 691U1042-133 1

Shim BACS40R010B048F 1

Filler BACF3F007D019NN 1

Repair Angle 691U1042-103 1

Repair Strap 691U1042-100 2

21 Install Frame Clip 691U1042-102 1 refer to Fastener Code E

22

Install Fasteners - if previously removed. 

Refer to Fastener Code 

G

STEP TASK NAME PART NUMBER QTY NOTES

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 9 OF 10)
 FIGURE 16: STRINGER REPAIR - STRINGER 10L AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than 

shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers 

can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the 

alternative part numbers. 

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

B

Bolt BACB30NX8K4 0.247 - 0.250

Collar BACC30BH8 -

C Bolt BACB30VT6K( ) 0.187 - 0.190

Collar BACC30BL6 -

D

Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 

Airplanes Only. DO NOT 

make the existing 

special countersink 

deeper in the skin.

E Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

F Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

G

Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 

Airplanes Only. Do 

NOT make the existing 

special countersink 

deeper in the skin.

(SHEET 10 OF 10)
 FIGURE 17: STRINGER MODIFICATION - STRINGER 10L AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

FIGURE 17: STRINGER MODIFICATION - STRINGER 10L AT BS 480

S-10L

S-8L

STA STA STA

500 480 460

FWD

SEE B AND C

A

SEE A

N69630

(SHEET 1 OF 5)
 FIGURE 17: STRINGER MODIFICATION - STRINGER 10L AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

30

CLIP

DOUBLER

(WITH FILLER)

(WITHOUT FILLER)

(3 LOCATIONS)

STR-10L

(3 LOCATIONS)

RADIUS FILLER

STR-10L

4

A 6

6 A

5

2

1

C 6

3 7 8

5

C

6

5

A

6

A

4 7 8

D 6

6 B

FWD

UP

6 B

B

FWD

UP

N69635

(SHEET 2 OF 5)
 FIGURE 17: STRINGER MODIFICATION - STRINGER 10L AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

(SHEET 3 OF 5)
 FIGURE 17: STRINGER MODIFICATION - STRINGER 10L AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— The minimum radius on a cut part is 0.50 inch.

— Remove all burrs and sharp edges from the parts.

— All cut surfaces must be 125 microinches smooth.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance 

from the edge of the part to the center of the hole, and "D" is the final hole diameter.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 

51-00-00, Figure 1, 

Figure 11, or Figure 16 

3 Put / Hold Doubler 691U1042-118 1 -

4 Put / Hold Frame Clip 691U1042-120 1 -

5

Cut Frame Clip 691U1042-120 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length.

6

Drill Holes - - refer to Fastener Codes 

A, B, C and D for 

locations and hole sizes 

7 Remove Frame Clip 691U1042-120 1 Prepare the parts for 

final installation Doubler 691U1042-118 1

8

Install Doubler 691U1042-118 1 refer to Fastener Codes 

A, B, C and D Frame Clip 691U1042-120 1

(a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 18.

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 4 OF 5)
 FIGURE 17: STRINGER MODIFICATION - STRINGER 10L AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than 

indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute 

fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used 

to determine the part numbers used as substitutes. 

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

B

Bolt BACB30NX6K3 0.187 - 0.190

Collar BACC30BH6 -

C

Bolt BACB30VT6K3 0.187 - 0.190

Collar BACC30BL6 -

D

Bolt BACB30NX8K4Y 0.278 - 0.281

Collar BACC30AC8 -

(SHEET 5 OF 5)
 FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480

S-8L

S-10L

500 480 460

STA STA STA

FWD

SEE B

A

SEE A

N69638

(SHEET 1 OF 10)
 FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM

CRACK TIP

CRACK TIP TO

CUT IN STRINGER

0.44 MIN.

EDGE MARGIN

IN STRINGER

LOCATION OF CUT

CRACK

STR-10L

STR-10L

SEE C OR D

5

2

3

UP

FWD

UP

FWD

4

2

C

SEE E

3

1

2

3

B

N69643

(SHEET 2 OF 10)
 FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

IN STRINGER

LOCATION OF CUT

0.060 MIN. FROM

CRACK

0.25 (MINIMUM)

CRACK TIP

CUT TO TANGENT LINE OF

(MAXIMUM)

RADIUS IN STRINGER

CRACK TIP TO

CUT IN STRINGER

OPTIONAL STRINGER CUT FOR SMALL CRACKS

4

2

2

SEE E

FWD

UP

D

W13881

(SHEET 3 OF 10)
 FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

30

STR-10L

A

B

A

B

7 18 19

6 18 19

E

8 11 18 20

9

FWD

UP

15 16 18 19

12 14 18 19

N69656

(SHEET 4 OF 10)
 FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

REPAIR

ANGLE SEGMENT

STRINGER

STR-10L

STR-10L

RADIUS FILLER

(WITH FILLER)

(WITHOUT FILLER)

REPAIR

UP STRAPS

FWD

A-A

10 5

E

4

E 10

10

5

E

10 13

5

F

5

F

D

4

A

4

A 4

A

4

4 A

B

5

F

5

F

5

F

5

F F

5 5

F

D D D D D

6

E

10 13

17

10

F

4 3

F

G G G

5

F

G

5

F

4

F

3

F

G

G

G

G

FWD

INBD

B-B

A

A 3

3

C

3

C

3

5

C

5

C

4

B

4

4 A

A

4

4 A

A

A

3

A

3

N69690

(SHEET 5 OF 10)
 FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-2 and 691U1042-17 are used when you do the repair shown in this figure.

(SHEET 6 OF 10)
 FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— The minimum e/D (edge margin) for existing fastener locations common to the new 691U1042-

135 repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of 

the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener 

locations is 2.0.

— The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the 

fastener diameter).

— Use the pilot hole locations in Repair Angle 691U1042-135 as a guide when you cut the stringer 

(this will help make sure you keep the minimum edge margin for adjacent fasteners)

— The minimum radius is 0.50 inch when you cut the stringer.

— The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must 

make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current 

inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed.

— Do not remove the full section of the stringer as shown in View C if you can remove all cracks by 

making the cut in the stringer that is shown in View D

— Remove all burrs and sharp edges from the parts.

— All surfaces must be 125 microinches smooth after you cut them.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect Stringer 1 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23.

Make sure you can cut 

the stringer at least 

0.060 inch from the 

crack tip and also have 

the minimum 1.7 edge 

margin for adjacent 

fasteners. See View C 

and D for stringer cut 

details.

3

Remove / Discard Fasteners - - at Fastener Code G only 

if you must cut an entire 

section of stringer to 

remove cracks as shown 

in View C. Remove 

enough fasteners to 

allow you to put a thin 

CRES sheet between 

stringer and the skin 

structures.

(SHEET 7 OF 10)
 FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

4

Cut Stringer - 1 Cut the stringer 0.030 

inch beyond the crack 

tip. Cut the minimum 

amount of stringer 

segment out to remove 

cracks. To protect the 

skin, put a thin CRES 

sheet between the 

stringer and the skin if 

you cut an entire 

segment out.

Inspect Stringer - 1 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23. Make sure 

there are no cracks 

found.

Cut Stringer - 1 Cut an additional 0.030 

inch of stringer to make 

sure all cracked material 

is removed.

5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area 

in the stringer

6 Put / Hold Stringer Segment 691U1042-117 1 -

7 Put / Hold Repair Angle 691U1042-135 1 -

8 Put / Hold Frame Clip 691U1042-102 1 -

9

Cut Frame Clip 691U1042-102 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length and 

shape.

10

Drill Holes - - refer to Fastener Codes 

A, B, C, D and E for 

locations and hole sizes 

11 Install Frame Clip 691U1042-102 1 Use temporary fasteners

12 Put / Hold Repair Angle 691U1042-103 1 -

13

Drill Holes - refer to Fastener Codes 

A, B and C for locations 

and hole sizes

14 Install Repair Angle 691U1042-103 1 Use temporary fasteners

15 Cut Repair Strap 691U1042-100 2 -

16 Put / Hold Repair Strap 691U1042-100 2 -

17

Drill Holes - refer to Fastener Code F 

for locations and hole 

sizes 

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 8 OF 10)
 FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than 

shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers 

can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the 

alternative part numbers. 

18

Remove Repair Strap 691U1042-100 2 Prepare the parts for 

final installation Repair Angle 691U1042-103 1

Frame Clip 691U1042-102 1

Repair Angle 691U1042-135 1

Stringer Segment 691U1042-117 1

19

Install Stringer Segment 691U1042-117 1 refer to Fastener Codes 

A, B, C, D, E and F. Repair Angle 691U1042-135 1

Repair Angle 691U1042-103 1

Repair Strap 691U1042-100 2

20 Install Frame Clip 691U1042-102 1 refer to Fastener Code E

21

Install Fasteners - if previously removed. 

Refer to Fastener Code 

G

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

B

Bolt BACB30NX8K4 0.247 - 0.250

Collar BACC30BH8 -

STEP TASK NAME PART NUMBER QTY NOTES

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 9 OF 10)
 FIGURE 18: STRINGER REPAIR - STRINGER 10L AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

C Bolt BACB30VT6K( ) 0.187 - 0.190

Collar BACC30BL6 -

D

Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 

Airplanes Only. DO NOT 

make the existing 

special countersink 

deeper in the skin.

E Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

F Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

G

Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 

Airplanes Only. Do 

NOT make the existing 

special countersink 

deeper in the skin.

CODE NAME PART NUMBER HOLE DIA NOTES

(SHEET 10 OF 10)
 FIGURE 19: STRINGER MODIFICATION - STRINGER 10L AT BS 500

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BOEING SERVICE BULLETIN 747-53A2484

FIGURE 19: STRINGER MODIFICATION - STRINGER 10L AT BS 500

S-8L

S-10L

STA STA STA

500 480 460

FWD SEE B AND C

A

SEE A

N69745

(SHEET 1 OF 5)
 FIGURE 19: STRINGER MODIFICATION - STRINGER 10L AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

CLIP

30

(WITH FILLER)

(WITHOUT FILLER)

(3 LOCATIONS)

STR-10L

STR-10L

(3 LOCATIONS)

RADIUS FILLER

DOUBLER

CLIP

C 6

4 7 8

6 3

A

6 4

A

5

6

4

A

5

A

D 6

6 B

2

FWD

UP

FWD

UP

6 B

3 7 8

1

C

B

N69746

(SHEET 2 OF 5)
 FIGURE 19: STRINGER MODIFICATION - STRINGER 10L AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

(SHEET 3 OF 5)
 FIGURE 19: STRINGER MODIFICATION - STRINGER 10L AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— The minimum radius on a cut part is 0.50 inch.

— Remove all burrs and sharp edges from the parts.

— All cut surfaces must be 125 microinches smooth.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance 

from the edge of the part to the center of the hole, and "D" is the final hole diameter.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 

51-00-00, Figure 1, 

Figure 11, or Figure 16 

3 Put / Hold Doubler 691U1042-118 1 -

4 Put / Hold Frame Clip 691U1042-120 1 -

5

Cut Frame Clip 691U1042-120 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length.

6

Drill Holes - - refer to Fastener Codes 

A, B, C and D for 

locations and hole sizes 

7 Remove Frame Clip 691U1042-120 1 Prepare the parts for 

final installation Doubler 691U1042-118 1

8

Install Doubler 691U1042-118 1 refer to Fastener Codes 

A, B, C and D Frame Clip 691U1042-120 1

(a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 20.

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 4 OF 5)
 FIGURE 19: STRINGER MODIFICATION - STRINGER 10L AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than 

indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute 

fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used 

to determine the part numbers used as substitutes. 

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

B

Bolt BACB30NX6K3 0.187 - 0.190

Collar BACC30BH6 -

C

Bolt BACB30VT6K3 0.187 - 0.190

Collar BACC30BL6 -

D

Bolt BACB30NX8K4Y 0.278 - 0.281

Collar BACC30AC8 -

(SHEET 5 OF 5)
 FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500

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BOEING SERVICE BULLETIN 747-53A2484

FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500

S-8L

S-10L

500 480 460

STA STA STA

FWD

SEE B

A

SEE A

N69747

(SHEET 1 OF 10)
 FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM

0.44 MIN.

EDGE MARGIN

STR-10L

IN STRINGER

LOCATION OF CUT

CRACK TIP

CRACK

CUT IN STRINGER

CRACK TIP TO

STR-10L

SEE C OR D

4

2

2

SEE E

C UP

FWD

3

5

2

1

3

3

FWD

UP

B

N69749

(SHEET 2 OF 10)
 FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

LOCATION OF CUT

IN STRINGER

0.060 MIN. FROM

CUT IN STRINGER

CRACK TIP TO

0.25 (MINIMUM)

CRACK

RADIUS IN STRINGER

(MAXIMUM)

CUT TO TANGENT LINE OF

CRACK TIP

OPTIONAL STRINGER CUT FOR SMALL CRACKS

4

2

2

SEE E

D

UP

FWD

W13894

(SHEET 3 OF 10)
 FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

30

STR-10L

A A

B B

6 18 19

9

8 11 18 20

7 18 19

12 14 18 19

UP

E

FWD

15 16 18 19

N69750

(SHEET 4 OF 10)
 FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

(WITHOUT FILLER)

(WITH FILLER)

RADIUS FILLER

SEGMENT

STRINGER

REPAIR

STRAPS

REPAIR

ANGLE

STR-10L

STR-10L

UP

FWD

10 4

E

10 E

3

17

5

F

5

F

4

E

5

E

F

3

10

10

10 13

G

G

G G D D D D

4

F

5

F

5

F F

5 5

F

5

F

5

F

5

F

5

F

4

F

3

F

D D G G

G

G

B-B

10 13

4

B

C

3

C

3

5

C

5

C

FWD A-A

INBD

A

A 3

3

4

A

4

4 A

A

4

4 A

B

4

4 A

A

4

4 A

A

A

3

A

3

N69751

(SHEET 5 OF 10)
 FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-2 and 691U1042-17 are used when you do the repair shown in this figure.

(SHEET 6 OF 10)
 FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— The minimum e/D (edge margin) for existing fastener locations common to the new 691U1042-

137 repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of 

the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener 

locations is 2.0.

— The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the 

fastener diameter).

— Use the pilot hole locations in Repair Angle 691U1042-137 as a guide when you cut the stringer 

(this will help make sure you keep the minimum edge margin for adjacent fasteners)

— The minimum radius is 0.50 inch when you cut the stringer.

— The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must 

make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current 

inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed.

— Do not remove the full section of the stringer as shown in View C if you can remove all cracks by 

making the cut in the stringer that is shown in View D

— Remove all burrs and sharp edges from the parts.

— All surfaces must be 125 microinches smooth after you cut them.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect Stringer 1 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23.

Make sure you can cut 

the stringer at least 

0.060 inch from the 

crack tip and also have 

the minimum 1.7 edge 

margin for adjacent 

fasteners. See View C 

and D for stringer cut 

details.

3

Remove / Discard Fasteners - - at Fastener Code G only 

if you must cut an entire 

section of stringer to 

remove cracks as shown 

in View C. Remove 

enough fasteners to 

allow you to put a thin 

CRES sheet between 

stringer and the skin 

structures.

(SHEET 7 OF 10)
 FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

4

Cut Stringer - 1 Cut the stringer 0.030 

inch beyond the crack 

tip. Cut the minimum 

amount of stringer 

segment out to remove 

cracks. To protect the 

skin, put a thin CRES 

sheet between the 

stringer and the skin if 

you cut an entire 

segment out.

Inspect Stringer - 1 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23. Make sure 

there are no cracks 

found.

Cut Stringer - 1 Cut an additional 0.030 

inch of stringer to make 

sure all cracked material 

is removed.

5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area 

in the stringer

6 Put / Hold Stringer Segment 691U1042-117 1 -

7 Put / Hold Repair Angle 691U1042-137 1 -

8 Put / Hold Frame Clip 691U1042-102 1 -

9

Cut Frame Clip 691U1042-102 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length and 

shape.

10

Drill Holes - - refer to Fastener Codes 

A, B, C, D and E for 

locations and hole sizes 

11 Install Frame Clip 691U1042-102 1 Use temporary fasteners

12 Put / Hold Repair Angle 691U1042-103 1 -

13

Drill Holes - refer to Fastener Codes 

A, B and C for locations 

and hole sizes

14 Install Repair Angle 691U1042-103 1 Use temporary fasteners

15 Cut Repair Strap 691U1042-100 2 -

16 Put / Hold Repair Strap 691U1042-100 2 -

17

Drill Holes - refer to Fastener Code F 

for locations and hole 

sizes 

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 8 OF 10)
 FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than 

shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers 

can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the 

alternative part numbers. 

18

Remove Repair Strap 691U1042-100 2 Prepare the parts for 

final installation Repair Angle 691U1042-103 1

Frame Clip 691U1042-102 1

Repair Angle 691U1042-137 1

Stringer Segment 691U1042-117 1

19

Install Stringer Segment 691U1042-117 1 refer to Fastener Codes 

A, B, C, D, E and F. Repair Angle 691U1042-137 1

Repair Angle 691U1042-103 1

Repair Strap 691U1042-100 2

20 Install Frame Clip 691U1042-102 1 refer to Fastener Code E

21

Install Fasteners - if previously removed. 

Refer to Fastener Code 

G

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

B

Bolt BACB30NX8K4 0.247 - 0.250

Collar BACC30BH8 -

STEP TASK NAME PART NUMBER QTY NOTES

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 9 OF 10)
 FIGURE 20: STRINGER REPAIR - STRINGER 10L AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

C Bolt BACB30VT6K( ) 0.187 - 0.190

Collar BACC30BL6 -

D

Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 

Airplanes Only. DO NOT 

make the existing 

special countersink 

deeper in the skin.

E Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

F Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

G

Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 

Airplanes Only. Do 

NOT make the existing 

special countersink 

deeper in the skin.

CODE NAME PART NUMBER HOLE DIA NOTES

(SHEET 10 OF 10)
 FIGURE 21: STRINGER MODIFICATION - STRINGER 10R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

FIGURE 21: STRINGER MODIFICATION - STRINGER 10R AT BS 460

S-10R

S-8R

STA

460

STA

480 500

STA

FWD

SEE B AND C

A

SEE A

N69754

(SHEET 1 OF 5)
 FIGURE 21: STRINGER MODIFICATION - STRINGER 10R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

CLIP

(4 LOCATIONS)

(WITHOUT FILLER)

(WITH FILLER)

CLIP

SHIM

STR-10R

(3 LOCATIONS) (3 LOCATIONS)

DOUBLER

RADIUS FILLER

30

STR-10R

FWD

UP

FWD

UP

2

1

3

A

5

6 6

A

5

A

4 7 8

3 7 8

3 7 8 C 6

B 6

D 6

B 6

6

C

B

N69758

(SHEET 2 OF 5)
 FIGURE 21: STRINGER MODIFICATION - STRINGER 10R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

(SHEET 3 OF 5)
 FIGURE 21: STRINGER MODIFICATION - STRINGER 10R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— The minimum radius on a cut part is 0.50 inch.

— Remove all burrs and sharp edges from the parts.

— All cut surfaces must be 125 microinches smooth.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance 

from the edge of the part to the center of the hole, and "D" is the final hole diameter.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 

51-00-00, Figure 1, 

Figure 11, or Figure 16 

3

Put / Hold Doubler 691U1042-118 1 -

Shim BACS40R010B040F 1 use if the gap between 

the doubler and the 

stringer is more than 

0.005 inch. Remove 

laminations from shim 

until the gap is 0.005 

inch or less.

4 Put / Hold Frame Clip 691U1042-119 1 -

5

Cut Frame Clip 691U1042-119 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length.

6

Drill Holes - - refer to Fastener Codes 

A, B, C and D for 

locations and hole sizes 

7

Remove Frame Clip 691U1042-119 1 Prepare the parts for 

final installation Doubler 691U1042-118 1

Shim BACS40R010B040F 1

8

Install Doubler 691U1042-118 1 refer to Fastener Codes 

A, B, C and D Frame Clip 691U1042-119 1

Shim BACS40R010B040F 1

(a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 16.

(SHEET 4 OF 5)
 FIGURE 21: STRINGER MODIFICATION - STRINGER 10R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than 

indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute 

fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used 

to determine the part numbers used as substitutes. 

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

B

Bolt BACB30NX6K3 0.187 - 0.190

Collar BACC30BH6 -

C

Bolt BACB30VT6K3 0.187 - 0.190

Collar BACC30BL6 -

D

Bolt BACB30NX8K4Y 0.278 - 0.281

Collar BACC30AC8 -

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 5 OF 5)
 FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460

S-10R

S-8R

460

STA

480

STA

500

STA

FWD

SEE A

SEE B

A

N69772

(SHEET 1 OF 10)
 FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM

CRACK

CRACK TIP

IN STRINGER

LOCATION OF CUT

0.44 MIN.

EDGE MARGIN

CRACK TIP TO

CUT IN STRINGER

STR-10R

STR-10R

SEE C OR D

3

2

5 3

2

4

SEE E

2

UP

FWD

C

3

1

FWD

UP

B

N69794

(SHEET 2 OF 10)
 FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM

CRACK TIP TO

CUT IN STRINGER

0.25 (MINIMUM)

CRACK

IN STRINGER

LOCATION OF CUT

CRACK TIP

(MAXIMUM)

RADIUS IN STRINGER

CUT TO TANGENT LINE OF

OPTIONAL STRINGER CUT FOR SMALL CRACKS

FWD

UP

2

4

2

SEE E

D

W13904

(SHEET 3 OF 10)
 FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

30

STR-10R

A

B B

A

E

9 12 19 21

10

17 19 20

7 19 20

8 19 20

8 19 20

13 15 19 20

16

FWD

UP

6 19 20

N69807

(SHEET 4 OF 10)
 FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

STR-10R

(4 LOCATIONS)

REPAIR

STRAPS

REPAIR

ANGLE

RADIUS FILLER

(WITHOUT FILLER)

(WITH FILLER)

STR-10R

FILLER

SEGMENT

STRINGER

UP

FWD

11

18

B-B

E

3 11

11 14

D D D G

3

F

3

F

4

F

5

F

5

F

5

F

5

F

5

F

5

F F

5 5

F

5

F

5

F

4

F

11 14

G D D D

A-A

5

E

11

4

E

A

3 A

3

4

A

4

A 4

A

4

A 4

B

5

C

5

C

C

3

C

3

4

4 A

A

4

4 A

B

4

A

A

3

A

3

FWD

INBD

G

G

G

G

D D

N69830

(SHEET 5 OF 10)
 FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-2 and 691U1042-18 are used when you do the repair shown in this figure.

(SHEET 6 OF 10)
 FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— The minimum e/D (edge margin) for existing fastener locations common to the new 691U1042-

134 repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of 

the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener 

locations is 2.0.

— The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the 

fastener diameter).

— Use the pilot hole locations in Repair Angle 691U1042-134 as a guide when you cut the stringer 

(this will help make sure you keep the minimum edge margin for adjacent fasteners).

— The minimum radius is 0.50 inch when you cut the stringer.

— The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must 

make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current 

inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed.

— Do not remove the full section of the stringer as shown in View C if you can remove all cracks by 

making the cut in the stringer that is shown in View D

— Remove all burrs and sharp edges from the parts.

— All surfaces must be 125 microinches smooth after you cut them.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect Stringer - 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23.

Make sure you can cut 

the stringer at least 

0.060 inch from the 

crack tip and also have 

the minimum 1.7 edge 

margin for adjacent 

fasteners. See View C 

and D for stringer cut 

details.

3

Remove / Discard Fasteners - - at Fastener Code G only 

if you must cut an entire 

section of stringer to 

remove cracks as shown 

in View C. Remove 

enough fasteners to 

allow you to put a thin 

CRES sheet between 

stringer and the skin 

structures.

(SHEET 7 OF 10)
 FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

4

Cut Stringer - 1 Cut the stringer 0.030 

inch beyond the crack 

tip. Cut the minimum 

amount of stringer 

segment out to remove 

cracks. To protect the 

skin, put a thin CRES 

sheet between the 

stringer and the skin if 

you cut an entire 

segment out.

Inspect Stringer - 1 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23. Make sure 

there are no cracks 

found.

Cut Stringer - 1 Cut an additional 0.030 

inch of stringer to make 

sure all cracked material 

is removed.

5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area 

in the stringer

6 Put / Hold Stringer Segment 691U1042-117 1 -

7 Put / Hold Filler BACF3F007D019NN 1 -

8

Put / Hold Repair Angle 691U1042-134 1 -

Shim BACS40R010B048F 1 use if the gap between 

the repair angle and the 

stringer is more than 

0.005 inch. Remove 

laminations from shim 

until the gap is 0.005 

inch or less.

9 Put / Hold Frame Clip 691U1042-101 1 -

10

Cut Frame Clip 691U1042-101 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length and 

shape.

11

Drill Holes - - refer to Fastener Codes 

A, B, C, D and E for 

locations and hole sizes 

12 Install Frame Clip 691U1042-101 1 Use temporary fasteners

13 Put / Hold Repair Angle 691U1042-103 1 -

14

Drill Holes - refer to Fastener Codes 

A, B and C for locations 

and hole sizes

15 Install Repair Angle 691U1042-103 1 Use temporary fasteners

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 8 OF 10)
 FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

16 Cut Repair Strap 691U1042-100 2 -

17 Put / Hold Repair Strap 691U1042-100 2 -

18

Drill Holes - refer to Fastener Code F 

for locations and hole 

sizes 

19

Remove Repair Strap 691U1042-100 2 Prepare the parts for 

final installation Repair Angle 691U1042-103 1

Frame Clip 691U1042-101 1

Repair Angle 691U1042-134 1

Shim BACS40R010B048F 1

Filler BACF3F007D019NN 1

Stringer Segment 691U1042-117 1

20

Install Stringer Segment 691U1042-117 1 refer to Fastener Codes 

A, B, C, D, E and F. Repair Angle 691U1042-134 1

Shim BACS40R010B048F 1

Filler BACF3F007D019NN 1

Repair Angle 691U1042-103 1

Repair Strap 691U1042-100 2

21 Install Frame Clip 691U1042-101 1 refer to Fastener Code E

22

Install Fasteners - if previously removed. 

Refer to Fastener Code 

G

STEP TASK NAME PART NUMBER QTY NOTES

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 9 OF 10)
 FIGURE 22: STRINGER REPAIR - STRINGER 10R AT BS 460

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than 

shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers 

can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the 

alternative part numbers. 

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

B

Bolt BACB30NX8K4 0.247 - 0.250

Collar BACC30BH8 -

C Bolt BACB30VT6K( ) 0.187 - 0.190

Collar BACC30BL6 -

D

Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 

Airplanes Only. DO NOT 

make the existing 

special countersink 

deeper in the skin.

E Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

F Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

G

Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 

Airplanes Only. Do 

NOT make the existing 

special countersink 

deeper in the skin.

(SHEET 10 OF 10)
 FIGURE 23: STRINGER MODIFICATION - STRINGER 10R AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

FIGURE 23: STRINGER MODIFICATION - STRINGER 10R AT BS 480

S-10R

S-8R

460

STA

480

STA STA

500

FWD

SEE A

A

SEE B AND C

N69833

(SHEET 1 OF 5)
 FIGURE 23: STRINGER MODIFICATION - STRINGER 10R AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

DOUBLER

(WITHOUT FILLER)

(WITH FILLER)

CLIP

30

CLIP

STR-10R

STR-10R

(3 LOCATIONS) (3 LOCATIONS)

6 RADIUS FILLER C

3 7 8

4

A 6

5

A

6

A

5

A 6

4 7 8

2

1

B

5

B

B 6

6 D 6

FWD

UP

6

FWD

UP

C

N69836

(SHEET 2 OF 5)
 FIGURE 23: STRINGER MODIFICATION - STRINGER 10R AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

(SHEET 3 OF 5)
 FIGURE 23: STRINGER MODIFICATION - STRINGER 10R AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— The minimum radius on a cut part is 0.50 inch.

— Remove all burrs and sharp edges from the parts.

— All cut surfaces must be 125 microinches smooth.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance 

from the edge of the part to the center of the hole, and "D" is the final hole diameter.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 

51-00-00, Figure 1, 

Figure 11, or Figure 16 

3 Put / Hold Doubler 691U1042-118 1 -

4 Put / Hold Frame Clip 691U1042-119 1 -

5

Cut Frame Clip 691U1042-119 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length.

6

Drill Holes - - refer to Fastener Codes 

A, B, C and D for 

locations and hole sizes 

7 Remove Frame Clip 691U1042-119 1 Prepare the parts for 

final installation Doubler 691U1042-118 1

8

Install Doubler 691U1042-118 1 refer to Fastener Codes 

A, B, C and D Frame Clip 691U1042-119 1

(a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 24.

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 4 OF 5)
 FIGURE 23: STRINGER MODIFICATION - STRINGER 10R AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than 

indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute 

fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used 

to determine the part numbers used as substitutes. 

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

B

Bolt BACB30NX6K3 0.187 - 0.190

Collar BACC30BH6 -

C

Bolt BACB30VT6K3 0.187 - 0.190

Collar BACC30BL6 -

D

Bolt BACB30NX8K4Y 0.278 - 0.281

Collar BACC30AC8 -

(SHEET 5 OF 5)
 FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480

S-10R

S-8R

460

STA

480

STA

500

STA

FWD

A

SEE A

SEE B

N69842

(SHEET 1 OF 10)
 FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM

CRACK TIP

IN STRINGER

LOCATION OF CUT

CRACK

STR-10R

CRACK TIP TO

CUT IN STRINGER

0.44 MIN.

EDGE MARGIN

STR-10R

FWD

UP

FWD

UP

3

SEE C OR D

2

4

1

5

3

3

2

2

SEE E

B

C

N69858

(SHEET 2 OF 10)
 FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM

CRACK TIP TO

CUT IN STRINGER

0.25 (MINIMUM)

CRACK

LOCATION OF CUT

IN STRINGER

CUT TO TANGENT LINE OF

(MAXIMUM)

RADIUS IN STRINGER

CRACK TIP

OPTIONAL STRINGER CUT FOR SMALL CRACKS

UP

FWD

2

4

2

SEE E

D

W13907

(SHEET 3 OF 10)
 FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

30

STR-10R

A

B B

A

7 18 19

8 11 18 20

9

15 16 18 19

12 14 18 19

6 18 19

FWD

UP

E

N69963

(SHEET 4 OF 10)
 FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480

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BOEING SERVICE BULLETIN 747-53A2484

RADIUS FILLER

STR-10R

(WITH FILLER)

(WITHOUT FILLER)

STR-10R

STRAPS

REPAIR

SEGMENT

STRINGER REPAIR

ANGLE

UP

FWD

10 4

E

10 5

E

5

F

5

F

4

A 4

A

4

A 4

B

6

E

10

5

E

10 13

10 13 INBD

A

3 A

3

4

A

5

C

C

3

C

3

5

C

4

B

4

A 4

A

4

A 4

A

A

3

A

3

FWD

10

D D

3

F F

3

G

G

G G D D D D G G

4

F

5

F

5

F

5

F

5

F

5

F F

5 5

F

5

F

4

F

B-B

17

G

G

A-A

N69967

(SHEET 5 OF 10)
 FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-2 and 691U1042-18 are used when you do the repair shown in this figure.

(SHEET 6 OF 10)
 FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— The minimum e/D (edge margin) for existing fastener locations common to the new 691U1042-

136 repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of 

the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener 

locations is 2.0.

— The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the 

fastener diameter).

— Use the pilot hole locations in Repair Angle 691U1042-136 as a guide when you cut the stringer 

(this will help make sure you keep the minimum edge margin for adjacent fasteners).

— The minimum radius is 0.50 inch when you cut the stringer.

— The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must 

make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current 

inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed.

— Do not remove the full section of the stringer as shown in View C if you can remove all cracks by 

making the cut in the stringer that is shown in View D

— Remove all burrs and sharp edges from the parts.

— All surfaces must be 125 microinches smooth after you cut them.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect Stringer - 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23.

Make sure you can cut 

the stringer at least 

0.060 inch from the 

crack tip and also have 

the minimum 1.7 edge 

margin for adjacent 

fasteners. See View C 

and D for stringer cut 

details.

3

Remove / Discard Fasteners - - at Fastener Code G only 

if you must cut an entire 

section of stringer to 

remove cracks as shown 

in View C. Remove 

enough fasteners to 

allow you to put a thin 

CRES sheet between 

stringer and the skin 

structures.

(SHEET 7 OF 10)
 FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

4

Cut Stringer - 1 Cut the stringer 0.030 

inch beyond the crack 

tip. Cut the minimum 

amount of stringer 

segment out to remove 

cracks. To protect the 

skin, put a thin CRES 

sheet between the 

stringer and the skin if 

you cut an entire 

segment out.

Inspect Stringer - 1 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23. Make sure 

there are no cracks 

found.

Cut Stringer - 1 Cut an additional 0.030 

inch of stringer to make 

sure all cracked material 

is removed.

5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area 

in the stringer

6 Put / Hold Stringer Segment 691U1042-117 1 -

7 Put / Hold Repair Angle 691U1042-136 1 -

8 Put / Hold Frame Clip 691U1042-101 1 -

9

Cut Frame Clip 691U1042-101 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length and 

shape.

10

Drill Holes - - refer to Fastener Codes 

A, B, C, D and E for 

locations and hole sizes 

11 Install Frame Clip 691U1042-101 1 Use temporary fasteners

12 Put / Hold Repair Angle 691U1042-103 1 -

13

Drill Holes - refer to Fastener Codes 

A, B and C for locations 

and hole sizes

14 Install Repair Angle 691U1042-103 1 Use temporary fasteners

15 Cut Repair Strap 691U1042-100 2 -

16 Put / Hold Repair Strap 691U1042-100 2 -

17

Drill Holes - refer to Fastener Code F 

for locations and hole 

sizes 

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 8 OF 10)
 FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than 

shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers 

can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the 

alternative part numbers. 

18

Remove Repair Strap 691U1042-100 2 Prepare the parts for 

final installation Repair Angle 691U1042-103 1

Frame Clip 691U1042-101 1

Repair Angle 691U1042-136 1

Stringer Segment 691U1042-117 1

19

Install Stringer Segment 691U1042-117 1 refer to Fastener Codes 

A, B, C, D, E and F. Repair Angle 691U1042-136 1

Repair Angle 691U1042-103 1

Repair Strap 691U1042-100 2

20 Install Frame Clip 691U1042-101 1 refer to Fastener Code E

21

Install Fasteners - if previously removed. 

Refer to Fastener Code 

G

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

B

Bolt BACB30NX8K4 0.247 - 0.250

Collar BACC30BH8 -

STEP TASK NAME PART NUMBER QTY NOTES

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 9 OF 10)
 FIGURE 24: STRINGER REPAIR - STRINGER 10R AT BS 480

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

C Bolt BACB30VT6K( ) 0.187 - 0.190

Collar BACC30BL6 -

D

Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 

Airplanes Only. DO NOT 

make the existing 

special countersink 

deeper in the skin.

E Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

F Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

G

Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 

Airplanes Only. Do 

NOT make the existing 

special countersink 

deeper in the skin.

CODE NAME PART NUMBER HOLE DIA NOTES

(SHEET 10 OF 10)
 FIGURE 25: STRINGER MODIFICATION - STRINGER 10R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

FIGURE 25: STRINGER MODIFICATION - STRINGER 10R AT BS 500

S-10R

S-8R

460

STA

480

STA STA

500

FWD

A

SEE B AND C

SEE A

N69970

(SHEET 1 OF 5)
 FIGURE 25: STRINGER MODIFICATION - STRINGER 10R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

30

(WITHOUT FILLER)

STR-10R

STR-10R

(WITH FILLER)

(3 LOCATIONS)

CLIP

DOUBLER

(3 LOCATIONS)

RADIUS FILLER

CLIP

C 6

3

A 6

4

A 6

5

B 6

4 7 8

3 7 8

B 6 D 6

FWD

UP

4

A

5

A

6

1

2

FWD

UP

B

C

N69971

(SHEET 2 OF 5)
 FIGURE 25: STRINGER MODIFICATION - STRINGER 10R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-11 and 691U1042-12 are used when you do the modification shown in this figure.

(SHEET 3 OF 5)
 FIGURE 25: STRINGER MODIFICATION - STRINGER 10R AT BS 500

June 26, 2003

Revision 1: February 12, 2009 747-53A2484

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BOEING SERVICE BULLETIN 747-53A2484

NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— The minimum radius on a cut part is 0.50 inch.

— Remove all burrs and sharp edges from the parts.

— All cut surfaces must be 125 microinches smooth.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— The minimum e/D (edge margin) for any fastener location is 2.0. "e" is defined as the distance 

from the edge of the part to the center of the hole, and "D" is the final hole diameter.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect (a) Fastener Hole - 2 747 NDT Part 6, Subject 

51-00-00, Figure 1, 

Figure 11, or Figure 16 

3 Put / Hold Doubler 691U1042-118 1 -

4 Put / Hold Frame Clip 691U1042-119 1 -

5

Cut Frame Clip 691U1042-119 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length.

6

Drill Holes - - refer to Fastener Codes 

A, B, C and D for 

locations and hole sizes 

7 Remove Frame Clip 691U1042-119 1 Prepare the parts for 

final installation Doubler 691U1042-118 1

8

Install Doubler 691U1042-118 1 refer to Fastener Codes 

A, B, C and D Frame Clip 691U1042-119 1

(a) If you find cracks in these holes, you must do the repair to the stringer as given in Figure 26.

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 4 OF 5)
 FIGURE 25: STRINGER MODIFICATION - STRINGER 10R AT BS 500

June 26, 2003

Revision 1: February 12, 2009 747-53A2484

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than 

indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute 

fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 012W6100 are used 

to determine the part numbers used as substitutes. 

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

B

Bolt BACB30NX6K3 0.187 - 0.190

Collar BACC30BH6 -

C

Bolt BACB30VT6K3 0.187 - 0.190

Collar BACC30BL6 -

D

Bolt BACB30NX8K4Y 0.278 - 0.281

Collar BACC30AC8 -

(SHEET 5 OF 5)
 FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500

S-10R

S-8R

460

STA

480

STA

500

STA

FWD

SEE B

A

SEE A

N69972

(SHEET 1 OF 10)
 FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM

0.44 MIN.

EDGE MARGIN

CUT IN STRINGER

CRACK TIP TO CRACK

CRACK TIP

STR-10R

IN STRINGER

LOCATION OF CUT

STR-10R

UP

FWD

FWD

UP

SEE E

SEE C D OR

3

1

3

3

5

2

2

2

C

4

B

N69973

(SHEET 2 OF 10)
 FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

0.060 MIN. FROM

CRACK TIP TO

CUT IN STRINGER

0.25 (MINIMUM)

CRACK

LOCATION OF CUT

IN STRINGER

CUT TO TANGENT LINE OF

(MAXIMUM)

RADIUS IN STRINGER

CRACK TIP

OPTIONAL STRINGER CUT FOR SMALL CRACKS

UP

FWD

2

4

2

SEE E

D

W13914

(SHEET 3 OF 10)
 FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

30

STR-10R

A

B B

A

15 16 18 19

8 11 18 20

6 18 19

7 18 19

12 14 18 19

9

FWD

UP

E

N69974

(SHEET 4 OF 10)
 FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

RADIUS FILLER

(WITH FILLER)

(WITHOUT FILLER)

STR-10R

STR-10R

REPAIR

ANGLE

SEGMENT

REPAIR

STRAPS STRINGER

UP

FWD

4

E 10

E

3 10

10 13

10 13

10 5

E

4

E

4

B

4

A 4

A

4

A 4

A

A

3

A

3

A

3 A

3

4

A

4

A 4

A

4

A 4

B

C

3

C

3

5

C

5

C

INBD

10

D D D G G

G

17

G G D D D

3

F

4

F

5

F

5

F

5

F

5

F

5

F

5

F

5

F F

5 5

F

5

F

4

F F

3

G

G

G

A-A

B-B

FWD

N69975

(SHEET 5 OF 10)
 FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY 

numbers shown below are the number of parts necessary for the location shown in this figure. Parts from Kits 

691U1042-2 and 691U1042-18 are used when you do the repair shown in this figure.

(SHEET 6 OF 10)
 FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

NOTE: Before you do the work given in the Step numbers, refer to the list below for general installation data:

— The minimum e/D (edge margin) for existing fastener locations common to the new 691U1042-

138 repair angle is 1.7. "e" is defined as the distance from the edge of the part to the center of 

the hole, and "D" is the final hole diameter. The minimum edge margin for all other fastener 

locations is 2.0.

— The distance between the centerlines of adjacent fasteners is 4D to 6D (four to six-times the 

fastener diameter).

— Use the pilot hole locations in Repair Angle 691U1042-138 as a guide when you cut the stringer 

(this will help make sure you keep the minimum edge margin for adjacent fasteners).

— The minimum radius is 0.50 inch when you cut the stringer.

— The 0.060 inch dimension from the crack tips to the cut in the stringer is shown because you must 

make a first cut of 0.030 inch to remove the tips of any cracks that you can find with Eddy Current 

inspection, then make a second cut of 0.030 inch to make sure crack tips are completely removed.

— Do not remove the full section of the stringer as shown in View C if you can remove all cracks by 

making the cut in the stringer that is shown in View D

— Remove all burrs and sharp edges from the parts.

— All surfaces must be 125 microinches smooth after you cut them.

— Apply Chemical Conversion Coating (Reference: BSOPM 20-43-03) to all bare aluminum, except 

in fastener holes.

— Apply one layer of Primer BMS 10-11, Type 1 to all bare aluminum.

— Install all parts with Sealant BMS 5-95 on mating surfaces.

STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Frame Clip - 1 -

2

Inspect Stringer - 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23.

Make sure you can cut 

the stringer at least 

0.060 inch from the 

crack tip and also have 

the minimum 1.7 edge 

margin for adjacent 

fasteners. See View C 

and D for stringer cut 

details.

3

Remove / Discard Fasteners - - at Fastener Code G only 

if you must cut an entire 

section of stringer to 

remove cracks as shown 

in View C. Remove 

enough fasteners to 

allow you to put a thin 

CRES sheet between 

stringer and the skin 

structures.

(SHEET 7 OF 10)
 FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

4

Cut Stringer - 1 Cut the stringer 0.030 

inch beyond the crack 

tip. Cut the minimum 

amount of stringer 

segment out to remove 

cracks. To protect the 

skin, put a thin CRES 

sheet between the 

stringer and the skin if 

you cut an entire 

segment out.

Inspect Stringer - 1 747 NDT Part 6, Subject 

51-00-00, Figure 4 or 

Figure 23. Make sure 

there are no cracks 

found.

Cut Stringer - 1 Cut an additional 0.030 

inch of stringer to make 

sure all cracked material 

is removed.

5 Cut / Make Stringer Segment 691U1042-117 1 to fit into the open area 

in the stringer

6 Put / Hold Stringer Segment 691U1042-117 1 -

7 Put / Hold Repair Angle 691U1042-138 1 -

8 Put / Hold Frame Clip 691U1042-101 1 -

9

Cut Frame Clip 691U1042-101 1 cut the inboard end of 

the frame clip as 

necessary to get the 

correct length and 

shape.

10

Drill Holes - - refer to Fastener Codes 

A, B, C, D and E for 

locations and hole sizes 

11 Install Frame Clip 691U1042-101 1 Use temporary fasteners

12 Put / Hold Repair Angle 691U1042-103 1 -

13

Drill Holes - refer to Fastener Codes 

A, B and C for locations 

and hole sizes

14 Install Repair Angle 691U1042-103 1 Use temporary fasteners

15 Cut Repair Strap 691U1042-100 2 -

16 Put / Hold Repair Strap 691U1042-100 2 -

17

Drill Holes - refer to Fastener Code F 

for locations and hole 

sizes 

STEP TASK NAME PART NUMBER QTY NOTES

(SHEET 8 OF 10)
 FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure. 

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, kits can have fasteners that are one grip length longer than 

shown. Also, if any of the fastener part numbers have alternative part numbers, the alternative part numbers 

can be supplied in Boeing kits. Boeing Document D-590 and Boeing drawing 012W6100 are used to find the 

alternative part numbers. 

18

Remove Repair Strap 691U1042-100 2 Prepare the parts for 

final installation Repair Angle 691U1042-103 1

Frame Clip 691U1042-101 1

Repair Angle 691U1042-138 1

Stringer Segment 691U1042-117 1

19

Install Stringer Segment 691U1042-117 1 refer to Fastener Codes 

A, B, C, D, E and F. Repair Angle 691U1042-138 1

Repair Angle 691U1042-103 1

Repair Strap 691U1042-100 2

20 Install Frame Clip 691U1042-101 1 refer to Fastener Code E

21

Install Fasteners - if previously removed. 

Refer to Fastener Code 

G

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

B

Bolt BACB30NX8K4 0.247 - 0.250

Collar BACC30BH8 -

STEP TASK NAME PART NUMBER QTY NOTES

COUNTERSINK FASTENER

C

D

EXAMPLE OF FASTENER SYMBOL

LENGTH/GRIP

FASTENER

6F

7

LETTER CODE

DIAMETER

(OPTIONAL) 

HEAD LOCATION

N = NEAR SIDE

F = FAR SIDE

(OPTIONAL)

(OPTIONAL)

S36173

(SHEET 9 OF 10)
 FIGURE 26: STRINGER REPAIR - STRINGER 10R AT BS 500

June 26, 2003

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BOEING SERVICE BULLETIN 747-53A2484

C Bolt BACB30VT6K( ) 0.187 - 0.190

Collar BACC30BL6 -

D

Rivet BACR15GF7D9 Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE9 Number 2 Drill Group 2, 3 and 4 

Airplanes Only. DO NOT 

make the existing 

special countersink 

deeper in the skin.

E Bolt BACB30NX6K( )Y 0.216 - 0.219

Collar BACC30AC6 -

F Bolt BACB30NX6K( ) 0.187 - 0.190

Collar BACC30BH6 -

G

Rivet BACR15GF7D( ) Number 2 Drill Group 1 Airplanes Only. 

Do NOT make the 

existing countersink 

deeper in the skin.

Rivet BACR15FV7KE( ) Number 2 Drill Group 2, 3 and 4 

Airplanes Only. Do 

NOT make the existing 

special countersink 

deeper in the skin.

CODE NAME PART NUMBER HOLE DIA NOTES

(SHEET 10 OF 10)