CONFIDENTIALITY NOTICE: The information contained in this document and any attachments are the property of Quest Aircraft Design, LLC and/or Quest Aircraft Company, LLC. and may be used only by the intended 

recipient. In the event that this document has been transmitted or forwarded to you in error, please notify the sender immediately by calling 208-263-1111. No person other than the intended recipient is authorized to 

read, print, retain, copy, and/or disseminate this document or any part of it. After notifying the sender of receipt, please destroy the document and any attachments. This document may contain information that is 

proprietary, privileged, confidential, and/or otherwise legally exempt from disclosure. Any erroneous transmission and/or receipt of this document shall not constitute waiver of any applicable protections against 

unauthorized use or disclosure of the information. QUEST®, KODIAK®, and logos are registered trademarks of Quest Aircraft Design, LLC.

 FIELD SERVICE INSTRUCTION - PAGE: 1 of 18

TITLE: Elevator Doubler Installation REPORT NO.: FSI-106

SERIAL RANGE: Elevator Serial Numbers 0001 thru 0149 JASC CODE: 5522 REVISION: 02

SUBJECT

NNOOTTEE

The serial range provided above is the elevator serial number, not the airplane serial number. The information can 

be found on the placard on the elevator itself. The placard is located on the front face of the spar at the trim actuator 

pass through hole.

This Field Service Instruction provides procedures for installation of a doubler at the inboard forward corner of each

elevator trailing edge skin, top and bottom.

AFFECTED MANUALS AND PUBLICATIONS

None.

INDUSTRY REFERENCES

None.

WEIGHT AND BALANCE

The weight and balance changes to the elevator have been evaluated and found to be negligible; the elevator does not 

need to be weighed and balanced after complying with this Field Service Instruction. If the mechanic chooses to perform 

work outside of the scope and instructions provided within this document, the mechanic must reference the current 

revision of the AM902.0 KODIAK®100 Airplane Maintenance Manual, for instructions on weighing and balancing the 

elevator control surface.

MANPOWER

The estimated man-hours and minimum number of persons required to perform this Field Service Instruction are listed 

below. The “Minimum Persons” refers only to maintenance personnel or installers, and unless otherwise specified 

within this instruction does not include additional personnel that may be needed solely to comply with safety 

requirements (for example, safety observers that are not performing tasks within this instruction). It is the responsibility 

of maintenance personnel to comply with safety requirements, including having a safety observer available as needed.

Estimated Man-hours: 1 to 4 hours

Minimum Persons: 1 person

If more than the minimum personnel perform this instruction, the actual man-hours required may be reduced due to 

increased efficiencies. As appropriate, Quest encourages the use of additional personnel; man-hour estimates are based 

on the minimum personnel required.

RECORD OF COMPLETION

• Update the appropriate maintenance log books

• Ensure the KODIAK®100 Pilot’s Operating Handbook / Aircraft Flight Manual is up-to-date with the current 

revision 

• Ensure the KODIAK®100 Aircraft Maintenance Manual is up-to-date with the current revision (Rev 16 or later)

Quest Aircraft Company, LLC

1200 Turbine Drive

Sandpoint, ID 83864

DDIISSCCLLAAIIMMEERR The instructions / procedures presented herein are based upon the systems and components of the aircraft when it was delivered from the factory, or as modified by Quest Service Bulletins. Thirdparty modifications that have affected any component, system, or operating characteristic discussed by this document may invalidate the instructions / procedures provided. Before performing the

instructions / procedures herein, examine all Supplemental Type Certificate (STC), Supplemental Type Authority (STA), or equivalently authorized modifications to verify that the 

instructions/procedures presented in this document can be properly completed. If an aircraft has an STC, STA, or equivalently authorized modification that affects any component, system, or 

operating characteristic also affected by this document, the operator is responsible for obtaining appropriate regulatory approval before performing the instructions / procedures herein. Quest

Aircraft Company cannot be responsible for the quality of work performed in accomplishing the requirements of this document.

If you have any questions as to the applicability of this document to your specific aircraft, contact Quest Customer Service by 

telephone at (208) 263-1111, toll-free at (866) 263-1112, or via email at CustomerService@QuestAircraft.com
 FIELD SERVICE INSTRUCTION - PAGE: 2 of 18

TITLE: Elevator Doubler Installation REPORT NO.: FSI-106

SERIAL RANGE: Elevator Serial Numbers 0001 thru 0149 JASC CODE: 5522 REVISION: 02

CONFIDENTIALITY NOTICE: The information contained in this document and any attachments are the property of Quest Aircraft Design, LLC and/or Quest Aircraft Company, LLC. and may be used only by the intended 

recipient. In the event that this document has been transmitted or forwarded to you in error, please notify the sender immediately by calling 208-263-1111. No person other than the intended recipient is authorized to 

read, print, retain, copy, and/or disseminate this document or any part of it. After notifying the sender of receipt, please destroy the document and any attachments. This document may contain information that is 

proprietary, privileged, confidential, and/or otherwise legally exempt from disclosure. Any erroneous transmission and/or receipt of this document shall not constitute waiver of any applicable protections against 

unauthorized use or disclosure of the information. QUEST®, KODIAK®, and logos are registered trademarks of Quest Aircraft Design, LLC.

REVISION RECORD

REV PAGE CHANGE DESCRIPTION

00 All Initial Release

REV PAGE CHANGE DESCRIPTION

01

1 Updated note to describe location of placard.

1 Weight and Balance Section has been reworded and clarifying details added

4 Table 2-1: Remove * and * text referring to attached print. (Print removed from FSI)

5

Note Box added in general section regarding standard tolerance on dimensions within 

document

5-6 Added procedure for inspecting for cracks. 

10

Table 5-1: Column 1 Header, Was: Typical Rivet Callout. Column 2 Header, Was: 

Nominal Size

Updated photo in figure 5-4

12-13 Step 3: Added procedure for inspecting for cracks. Remaining pages are renumbered by 1 

page.

14 Filler in image 5-7 text callout updated “Drill Size” and “To existing holes” text is added.

16 Table 5-2: Column 1 Header, Was: Typical Rivet Callout. Column 2 Header, Was: 

Nominal Size

17 Section 5.3, Step 2. Step re-worded to clarify the use of the tygon tubing

Section 5.3, Step 3 added. “Use a borescope...” The following steps renumbered.

A1 Attachment A1 is removed.

REV PAGE CHANGE DESCRIPTION

02

4 Table 2-1 is updated to include MS20470AD5-5.5, MS20470AD5-4 and MS20470AD5-5 rivets

10 Step 7 is updated to clarify that the mechanic must choose the correct length rivet and

optional rivet lengths are provided

10 Figure 5-4 is updated to agree with step 7, same page.

16

Step 13 is updated to clarify that the mechanic must choose the correct length rivet and 

optional rivet lengths are provided

17 Figure 5-9 is updated to agree with step 13, previous page.
 FIELD SERVICE INSTRUCTION - PAGE: 3 of 18

TITLE: Elevator Doubler Installation REPORT NO.: FSI-106

SERIAL RANGE: Elevator Serial Numbers 0001 thru 0149 JASC CODE: 5522 REVISION: 02

CONFIDENTIALITY NOTICE: The information contained in this document and any attachments are the property of Quest Aircraft Design, LLC and/or Quest Aircraft Company, LLC. and may be used only by the intended 

recipient. In the event that this document has been transmitted or forwarded to you in error, please notify the sender immediately by calling 208-263-1111. No person other than the intended recipient is authorized to 

read, print, retain, copy, and/or disseminate this document or any part of it. After notifying the sender of receipt, please destroy the document and any attachments. This document may contain information that is 

proprietary, privileged, confidential, and/or otherwise legally exempt from disclosure. Any erroneous transmission and/or receipt of this document shall not constitute waiver of any applicable protections against 

unauthorized use or disclosure of the information. QUEST®, KODIAK®, and logos are registered trademarks of Quest Aircraft Design, LLC.

TABLE OF CONTENTS

REVISION RECORD............................................................................................................................2

TABLE OF CONTENTS.......................................................................................................................3

1. Special Safety Instructions...............................................................................................................4

1.1 Warnings..............................................................................................................................4

1.2 Cautions ...............................................................................................................................4

1.3 Notes....................................................................................................................................4

2. Parts, Tools, and Equipment ............................................................................................................4

Table 2-1: Parts and Tools Included in the Service Kit................................................................................... 4

Table 2-2: Consumables Included in the Service Kit...................................................................................... 4

Table 2-3: Serial-Number-Specific Parts Included in the Service Kit ............................................................ 4

Table 2-4: Parts and Tools NOT Included in the Service Kit ......................................................................... 4

3. General.............................................................................................................................................5

Figure 3-1: Overview...................................................................................................................................... 5

4. Preparation .......................................................................................................................................5

Figure 4-1: Example of Cracking.................................................................................................................... 6

5. Instructions.......................................................................................................................................7

5.1 Uncracked Elevator Skins ─ Install Doubler.......................................................................7

Figure 5-1: Drill Out Eight Rivets .................................................................................................................. 7

Figure 5-2: Fit Doubler to Corner and Match Drill......................................................................................... 8

Figure 5-3: Slide Doubler Under Skin ............................................................................................................ 9

Table 5-1: Rivet Specifications..................................................................................................................... 10

Figure 5-4: Install Ten Rivets ....................................................................................................................... 10

5.2 Cracked Elevator Skins ─ Repair Cracking and Install Doubler.......................................11

Figure 5-5: Drill Out Eight Rivets ................................................................................................................ 11

Figure 5-6: Trim Away Cracked Skin........................................................................................................... 12

Figure 5-7: Manufacture a Filler................................................................................................................... 14

Figure 5-8: Fit Doubler to Corner and Match Drill....................................................................................... 15

Table 5-2: Rivet Specifications..................................................................................................................... 16

Figure 5-9: Install Ten Rivets ....................................................................................................................... 17

5.3 Repeat and Clean Up .........................................................................................................17

Figure 5-10: Remove Debris......................................................................................................................... 18

6. Completion.....................................................................................................................................18
 FIELD SERVICE INSTRUCTION - PAGE: 4 of 18

TITLE: Elevator Doubler Installation REPORT NO.: FSI-106

SERIAL RANGE: Elevator Serial Numbers 0001 thru 0149 JASC CODE: 5522 REVISION: 02

CONFIDENTIALITY NOTICE: The information contained in this document and any attachments are the property of Quest Aircraft Design, LLC and/or Quest Aircraft Company, LLC. and may be used only by the intended 

recipient. In the event that this document has been transmitted or forwarded to you in error, please notify the sender immediately by calling 208-263-1111. No person other than the intended recipient is authorized to 

read, print, retain, copy, and/or disseminate this document or any part of it. After notifying the sender of receipt, please destroy the document and any attachments. This document may contain information that is 

proprietary, privileged, confidential, and/or otherwise legally exempt from disclosure. Any erroneous transmission and/or receipt of this document shall not constitute waiver of any applicable protections against 

unauthorized use or disclosure of the information. QUEST®, KODIAK®, and logos are registered trademarks of Quest Aircraft Design, LLC.

1. Special Safety Instructions

1.1 Warnings

Failure to comply with “Warnings” contained in this instruction may result in financial 

loss, significant delay in the completion time, and/or serious injury to personnel.

1.2 Cautions

Failure to comply with “Cautions” contained in this instruction may result in the 

destruction of components, unnecessary complications, the need to reverse completed 

work, and/or delays in the completion time.

1.3 Notes

“Notes” are provided when additional information may lead to an increase in efficiency.

2. Parts, Tools, and Equipment

The following tables describe the parts, tools, and equipment necessary to successfully complete

this instruction. Where applicable, reference to drawings provided with this instruction is 

provided.

Table 2-1: Parts and Tools Included in the Service Kit

Item # Part No. Qty Description Drawing No. Dwg Item #

2-1-1 100-534-2102 4 Elevator Doubler N/A N/A

2-1-2 CR3213-4-01 12 Rivet, Cherry N/A N/A

2-1-3 CR3213-4-02 30 Rivet, Cherry N/A N/A

2-1-4 CR3243-4-02 30 Rivet, Cherry, Oversized N/A N/A

2-1-5 MS20470AD5-5.5 10 Rivet, Universal N/A N/A

2-1-6 NAS1242AD5-5.5 4 Rivet, Universal, Oversized N/A N/A

2-1-7 AAG00017 1 ft Tygon Tubing N/A N/A

2-1-8 MS20470AD5-4 10 Rivet, Universal N/A N/A

2-1-9 MS20470AD5-5 10 Rivet, Universal N/A N/A

Table 2-2: Consumables Included in the Service Kit

Item # Part No. Qty Description Drawing No. Dwg Item #

2-2-1 N/A -- N/A N/A N/A

Table 2-3: Serial-Number-Specific Parts Included in the Service Kit

Item # Part No. Qty Description Drawing No. Dwg Item #

2-3-1 N/A -- N/A N/A N/A

Table 2-4: Parts and Tools NOT Included in the Service Kit

Item # Part No. Qty Description Drawing No. Dwg Item #

2-4-1 N/A AR Drill Bits #16, #21, #27, #30, #31, #40 N/A N/A

2-4-2 N/A AR Drill Stop N/A N/A

2-4-3 N/A AR Airplane Touch-up Paint N/A N/A
 FIELD SERVICE INSTRUCTION - PAGE: 5 of 18

TITLE: Elevator Doubler Installation REPORT NO.: FSI-106

SERIAL RANGE: Elevator Serial Numbers 0001 thru 0149 JASC CODE: 5522 REVISION: 02

CONFIDENTIALITY NOTICE: The information contained in this document and any attachments are the property of Quest Aircraft Design, LLC and/or Quest Aircraft Company, LLC. and may be used only by the intended 

recipient. In the event that this document has been transmitted or forwarded to you in error, please notify the sender immediately by calling 208-263-1111. No person other than the intended recipient is authorized to 

read, print, retain, copy, and/or disseminate this document or any part of it. After notifying the sender of receipt, please destroy the document and any attachments. This document may contain information that is 

proprietary, privileged, confidential, and/or otherwise legally exempt from disclosure. Any erroneous transmission and/or receipt of this document shall not constitute waiver of any applicable protections against 

unauthorized use or disclosure of the information. QUEST®, KODIAK®, and logos are registered trademarks of Quest Aircraft Design, LLC.

3. General

This Field Service Instruction provides procedures for inspecting for cracking of the inboard

upper and lower skins of the elevator and installation of doublers to repair existing cracking or 

prevent cracks from occurring.

NNOOTTEE

Inspect a total of four locations on the airplane and perform repairs/install doublers at each in accordance with the 

instructions in Section 4.0 and Section 5.0.

Figure 3-1: Overview

NNOOTTEE

All dimensions throughout this document are in inches. Unless otherwise noted, dimensions with one decimal 

place, X.X, are ±0.100 and those with two decimal places, X.XX, are ±0.030.

4. Preparation

1. Remove the tailcone in accordance with AM902.0, KODIAK 100 Airplane Maintenance 

Manual, Chapter 53, Fuselage.

NNOOTTEE

The elevator may be removed to provide better access to the inspection and repair area.

2. Inspect the elevator, both top and bottom, for signs of cracking in the forward inboard 

end of the trailing edge skin, aft of the spar (Figure 4-1) by using the following 

procedure based on AC43.13-1B, Section 2:

a. Provide adequate lighting to illuminate the edges of the elevator trailing edge skin.

b. Clean the areas to be inspected. Remove any contaminants that might hinder the 

discovery of existing surface indications. Do not remove the protective finish from 

the part or area prior to inspection.

Two locations Two locations
 FIELD SERVICE INSTRUCTION - PAGE: 6 of 18

TITLE: Elevator Doubler Installation REPORT NO.: FSI-106

SERIAL RANGE: Elevator Serial Numbers 0001 thru 0149 JASC CODE: 5522 REVISION: 02

CONFIDENTIALITY NOTICE: The information contained in this document and any attachments are the property of Quest Aircraft Design, LLC and/or Quest Aircraft Company, LLC. and may be used only by the intended 

recipient. In the event that this document has been transmitted or forwarded to you in error, please notify the sender immediately by calling 208-263-1111. No person other than the intended recipient is authorized to 

read, print, retain, copy, and/or disseminate this document or any part of it. After notifying the sender of receipt, please destroy the document and any attachments. This document may contain information that is 

proprietary, privileged, confidential, and/or otherwise legally exempt from disclosure. Any erroneous transmission and/or receipt of this document shall not constitute waiver of any applicable protections against 

unauthorized use or disclosure of the information. QUEST®, KODIAK®, and logos are registered trademarks of Quest Aircraft Design, LLC.

c. Carefully inspect the area for discontinuities, using optical aids as required. An 

inspector should have available, at minimum, a flashlight and a mirror.

d. Determine the extent of any cracks found by directing the light beam at right angles 

to the crack and tracing its length. Use a 10-power magnifying glass to confirm the 

existence of a suspected crack.

3. For locations where no cracking is found: proceed to Section 5.1, Uncracked Elevator 

Skins ─ Install Doubler.

4. For locations where cracking is found: proceed to Section 5.2, Cracked Elevator Skins 

─ Repair Cracking and Install Doubler.

Bottom side of right elevator shown

Figure 4-1: Example of Cracking

OUTBD

FWD
 FIELD SERVICE INSTRUCTION - PAGE: 7 of 18

TITLE: Elevator Doubler Installation REPORT NO.: FSI-106

SERIAL RANGE: Elevator Serial Numbers 0001 thru 0149 JASC CODE: 5522 REVISION: 02

CONFIDENTIALITY NOTICE: The information contained in this document and any attachments are the property of Quest Aircraft Design, LLC and/or Quest Aircraft Company, LLC. and may be used only by the intended 

recipient. In the event that this document has been transmitted or forwarded to you in error, please notify the sender immediately by calling 208-263-1111. No person other than the intended recipient is authorized to 

read, print, retain, copy, and/or disseminate this document or any part of it. After notifying the sender of receipt, please destroy the document and any attachments. This document may contain information that is 

proprietary, privileged, confidential, and/or otherwise legally exempt from disclosure. Any erroneous transmission and/or receipt of this document shall not constitute waiver of any applicable protections against 

unauthorized use or disclosure of the information. QUEST®, KODIAK®, and logos are registered trademarks of Quest Aircraft Design, LLC.

5. Instructions

5.1 Uncracked Elevator Skins ─ Install Doubler

1. Remove eight (8) rivets from the locations shown in Figure 5-1.

CCAAUUTTIIOONN

Use a drill stop to prevent damage to the elevator torque tube while drilling.

Figure 5-1: Drill Out Eight Rivets
 FIELD SERVICE INSTRUCTION - PAGE: 8 of 18

TITLE: Elevator Doubler Installation REPORT NO.: FSI-106

SERIAL RANGE: Elevator Serial Numbers 0001 thru 0149 JASC CODE: 5522 REVISION: 02

CONFIDENTIALITY NOTICE: The information contained in this document and any attachments are the property of Quest Aircraft Design, LLC and/or Quest Aircraft Company, LLC. and may be used only by the intended 

recipient. In the event that this document has been transmitted or forwarded to you in error, please notify the sender immediately by calling 208-263-1111. No person other than the intended recipient is authorized to 

read, print, retain, copy, and/or disseminate this document or any part of it. After notifying the sender of receipt, please destroy the document and any attachments. This document may contain information that is 

proprietary, privileged, confidential, and/or otherwise legally exempt from disclosure. Any erroneous transmission and/or receipt of this document shall not constitute waiver of any applicable protections against 

unauthorized use or disclosure of the information. QUEST®, KODIAK®, and logos are registered trademarks of Quest Aircraft Design, LLC.

2. Line up the doubler in the corner and cleco in place using the forward, inboard pilot 

hole (Figure 5-2).

Figure 5-2: Fit Doubler to Corner and Match Drill

3. Match-drill the two (2) pre-drilled holes into the airplane skin using a #40 drill bit.

Match Drill

(#40 bit)

Align Edges

Cleco
 FIELD SERVICE INSTRUCTION - PAGE: 9 of 18

TITLE: Elevator Doubler Installation REPORT NO.: FSI-106

SERIAL RANGE: Elevator Serial Numbers 0001 thru 0149 JASC CODE: 5522 REVISION: 02

CONFIDENTIALITY NOTICE: The information contained in this document and any attachments are the property of Quest Aircraft Design, LLC and/or Quest Aircraft Company, LLC. and may be used only by the intended 

recipient. In the event that this document has been transmitted or forwarded to you in error, please notify the sender immediately by calling 208-263-1111. No person other than the intended recipient is authorized to 

read, print, retain, copy, and/or disseminate this document or any part of it. After notifying the sender of receipt, please destroy the document and any attachments. This document may contain information that is 

proprietary, privileged, confidential, and/or otherwise legally exempt from disclosure. Any erroneous transmission and/or receipt of this document shall not constitute waiver of any applicable protections against 

unauthorized use or disclosure of the information. QUEST®, KODIAK®, and logos are registered trademarks of Quest Aircraft Design, LLC.

4. Slide the doubler under the skin, matching up the holes. Cleco in place.

Figure 5-3: Slide Doubler Under Skin

5. Match drill the remaining six (6) holes for the doubler with a #30 drill bit, inserting 

clecos as appropriate.

CCAAUUTTIIOONN

Use a drill stop to prevent damage to the elevator torque tube while drilling.

6. Upsize the two (2) holes from Step 3 with a #30 drill bit. Deburr as needed.

NNOOTTEE

Standard sized rivets and hole dimensions are used throughout this document. It is permissible to use the standard 

oversized fastener in all locations where fasteners are replaced in this document. All fasteners shall be installed in 

accordance with Table 5-1; refer to Table 5-1 for edge distance, fastener part numbers, and other pertinent 

information. Solid fasteners may not be replaced with pulled fasteners. Pulled fasteners may always be replaced with 

solid fasteners if desired.

Doubler

Skin
 FIELD SERVICE INSTRUCTION - PAGE: 10 of 18

TITLE: Elevator Doubler Installation REPORT NO.: FSI-106

SERIAL RANGE: Elevator Serial Numbers 0001 thru 0149 JASC CODE: 5522 REVISION: 02

CONFIDENTIALITY NOTICE: The information contained in this document and any attachments are the property of Quest Aircraft Design, LLC and/or Quest Aircraft Company, LLC. and may be used only by the intended 

recipient. In the event that this document has been transmitted or forwarded to you in error, please notify the sender immediately by calling 208-263-1111. No person other than the intended recipient is authorized to 

read, print, retain, copy, and/or disseminate this document or any part of it. After notifying the sender of receipt, please destroy the document and any attachments. This document may contain information that is 

proprietary, privileged, confidential, and/or otherwise legally exempt from disclosure. Any erroneous transmission and/or receipt of this document shall not constitute waiver of any applicable protections against 

unauthorized use or disclosure of the information. QUEST®, KODIAK®, and logos are registered trademarks of Quest Aircraft Design, LLC.

Table 5-1: Rivet Specifications

RIVET 

CALLOUT SIZE

PREPARED HOLE DIAMETER 

(in) STANDARD 

DRILL

MINIMUM 

EDGE 

Min Max DISTANCE (in)

MS20470AD4 4 0.128 0.134 30 0.25

NAS1242AD4 4 oversized 0.143 0.149 27 0.27

CR3213-4 4 0.129 0.132 30 0.25

CR3243-4 4 oversized 0.143 0.146 27 0.27

MS20470AD5 5 0.159 0.164 21 0.31

NAS1242AD5 5 oversized 0.175 0.180 16 0.34

7. Install ten (10) rivets at the location shown in Figure 5-4. The rivet lengths shown 

are provided in the service kit, but the mechanic may adjust the length as necessary 

to ensure a properly installed fastener in accordance with AC-43.13-1B 

Section 4-57.

 Two (2) cherry rivets (P/N CR3213-4-01)

 Six (6) cherry rivets (P/N CR3213-4-02)

 Two (2) fastener (MS20470AD5-*).

Figure 5-4: Install Ten Rivets

8. Proceed to Section 5.3, Repeat and Clean Up.

CR3213-4-01

CR3213-4-02

CR3213-4-02

MS20470AD5-*

*MS20470AD5-4, MS20470AD5-5, and MS20470AD5-5.5 are provided in the 

kit. Select the appropriate length as needed.
 FIELD SERVICE INSTRUCTION - PAGE: 11 of 18

TITLE: Elevator Doubler Installation REPORT NO.: FSI-106

SERIAL RANGE: Elevator Serial Numbers 0001 thru 0149 JASC CODE: 5522 REVISION: 02

CONFIDENTIALITY NOTICE: The information contained in this document and any attachments are the property of Quest Aircraft Design, LLC and/or Quest Aircraft Company, LLC. and may be used only by the intended 

recipient. In the event that this document has been transmitted or forwarded to you in error, please notify the sender immediately by calling 208-263-1111. No person other than the intended recipient is authorized to 

read, print, retain, copy, and/or disseminate this document or any part of it. After notifying the sender of receipt, please destroy the document and any attachments. This document may contain information that is 

proprietary, privileged, confidential, and/or otherwise legally exempt from disclosure. Any erroneous transmission and/or receipt of this document shall not constitute waiver of any applicable protections against 

unauthorized use or disclosure of the information. QUEST®, KODIAK®, and logos are registered trademarks of Quest Aircraft Design, LLC.

5.2 Cracked Elevator Skins ─ Repair Cracking and Install Doubler

1. Remove eight (8) rivets from the locations shown in Figure 5-5.

CCAAUUTTIIOONN

Use a drill stop to prevent damage to the elevator torque tube while drilling.

Figure 5-5: Drill Out Eight Rivets
 FIELD SERVICE INSTRUCTION - PAGE: 12 of 18

TITLE: Elevator Doubler Installation REPORT NO.: FSI-106

SERIAL RANGE: Elevator Serial Numbers 0001 thru 0149 JASC CODE: 5522 REVISION: 02

CONFIDENTIALITY NOTICE: The information contained in this document and any attachments are the property of Quest Aircraft Design, LLC and/or Quest Aircraft Company, LLC. and may be used only by the intended 

recipient. In the event that this document has been transmitted or forwarded to you in error, please notify the sender immediately by calling 208-263-1111. No person other than the intended recipient is authorized to 

read, print, retain, copy, and/or disseminate this document or any part of it. After notifying the sender of receipt, please destroy the document and any attachments. This document may contain information that is 

proprietary, privileged, confidential, and/or otherwise legally exempt from disclosure. Any erroneous transmission and/or receipt of this document shall not constitute waiver of any applicable protections against 

unauthorized use or disclosure of the information. QUEST®, KODIAK®, and logos are registered trademarks of Quest Aircraft Design, LLC.

2. Fully remove the cracked skin by trimming away the trailing edge skin to the 

dimensions shown in Figure 5-6. Remove additional fasteners in the leading edge skin 

as necessary to access the area.

Figure 5-6: Trim Away Cracked Skin

3. Inspect and verify that all of the cracked material has been removed by using the 

following procedure based on AC43.13-1B, Section 2:

a. Provide adequate lighting to illuminate the edges of the trimmed skin.

b. Clean the areas to be inspected. Remove any contaminants that might hinder the 

discovery of existing surface indications. Do not remove the protective finish from 

the part or area prior to inspection.

c. Carefully inspect the area for discontinuities, using optical aids as required. An 

inspector should have available, at minimum, a flashlight and a mirror.

Cracked Skin
 FIELD SERVICE INSTRUCTION - PAGE: 13 of 18

TITLE: Elevator Doubler Installation REPORT NO.: FSI-106

SERIAL RANGE: Elevator Serial Numbers 0001 thru 0149 JASC CODE: 5522 REVISION: 02

CONFIDENTIALITY NOTICE: The information contained in this document and any attachments are the property of Quest Aircraft Design, LLC and/or Quest Aircraft Company, LLC. and may be used only by the intended 

recipient. In the event that this document has been transmitted or forwarded to you in error, please notify the sender immediately by calling 208-263-1111. No person other than the intended recipient is authorized to 

read, print, retain, copy, and/or disseminate this document or any part of it. After notifying the sender of receipt, please destroy the document and any attachments. This document may contain information that is 

proprietary, privileged, confidential, and/or otherwise legally exempt from disclosure. Any erroneous transmission and/or receipt of this document shall not constitute waiver of any applicable protections against 

unauthorized use or disclosure of the information. QUEST®, KODIAK®, and logos are registered trademarks of Quest Aircraft Design, LLC.

d. Determine the extent of any cracks found by directing the light beam at right angles 

to the crack and tracing its length. Use a 10-power magnifying glass to confirm the 

existence of a suspected crack.

e. If unable to remove all of the cracked material while maintaining the 0.27 inch 

minimum and other dimensions shown in Figure 5-6, contact Quest Aircraft.

f. If it is verified that all the cracked material has been removed, proceed to the next 

step in this procedure.
 FIELD SERVICE INSTRUCTION - PAGE: 14 of 18

TITLE: Elevator Doubler Installation REPORT NO.: FSI-106

SERIAL RANGE: Elevator Serial Numbers 0001 thru 0149 JASC CODE: 5522 REVISION: 02

CONFIDENTIALITY NOTICE: The information contained in this document and any attachments are the property of Quest Aircraft Design, LLC and/or Quest Aircraft Company, LLC. and may be used only by the intended 

recipient. In the event that this document has been transmitted or forwarded to you in error, please notify the sender immediately by calling 208-263-1111. No person other than the intended recipient is authorized to 

read, print, retain, copy, and/or disseminate this document or any part of it. After notifying the sender of receipt, please destroy the document and any attachments. This document may contain information that is 

proprietary, privileged, confidential, and/or otherwise legally exempt from disclosure. Any erroneous transmission and/or receipt of this document shall not constitute waiver of any applicable protections against 

unauthorized use or disclosure of the information. QUEST®, KODIAK®, and logos are registered trademarks of Quest Aircraft Design, LLC.

4. Manufacture a filler (from the removed piece or other 2024-T3 clad sheet measuring 

0.020 inch thick) as shown in Figure 5-7.

NNOOTTEE

If the filler is manufactured from clad sheet, etch, alodine, and prime.

Figure 5-7: Manufacture a Filler

Filler
 FIELD SERVICE INSTRUCTION - PAGE: 15 of 18

TITLE: Elevator Doubler Installation REPORT NO.: FSI-106

SERIAL RANGE: Elevator Serial Numbers 0001 thru 0149 JASC CODE: 5522 REVISION: 02

CONFIDENTIALITY NOTICE: The information contained in this document and any attachments are the property of Quest Aircraft Design, LLC and/or Quest Aircraft Company, LLC. and may be used only by the intended 

recipient. In the event that this document has been transmitted or forwarded to you in error, please notify the sender immediately by calling 208-263-1111. No person other than the intended recipient is authorized to 

read, print, retain, copy, and/or disseminate this document or any part of it. After notifying the sender of receipt, please destroy the document and any attachments. This document may contain information that is 

proprietary, privileged, confidential, and/or otherwise legally exempt from disclosure. Any erroneous transmission and/or receipt of this document shall not constitute waiver of any applicable protections against 

unauthorized use or disclosure of the information. QUEST®, KODIAK®, and logos are registered trademarks of Quest Aircraft Design, LLC.

5. On top of the elevator skin, line up the doubler and the filler in the corner, with the 

filler beneath the doubler, and cleco in place (Figure 5-8).

Figure 5-8: Fit Doubler to Corner and Match Drill

6. Match-drill the two (2) pre-drilled holes into the airplane skin using a #40 drill bit.

7. Slide the doubler under the skin, matching up the holes and aligning the filler. Cleco in 

place.

8. Match drill all eight (8) holes in the doubler with a #30 drill bit, inserting clecos as 

appropriate. 

CCAAUUTTIIOONN

Use a drill stop to prevent damage to the elevator torque tube while drilling.

Match Drill

Align Edges

Cleco
 FIELD SERVICE INSTRUCTION - PAGE: 16 of 18

TITLE: Elevator Doubler Installation REPORT NO.: FSI-106

SERIAL RANGE: Elevator Serial Numbers 0001 thru 0149 JASC CODE: 5522 REVISION: 02

CONFIDENTIALITY NOTICE: The information contained in this document and any attachments are the property of Quest Aircraft Design, LLC and/or Quest Aircraft Company, LLC. and may be used only by the intended 

recipient. In the event that this document has been transmitted or forwarded to you in error, please notify the sender immediately by calling 208-263-1111. No person other than the intended recipient is authorized to 

read, print, retain, copy, and/or disseminate this document or any part of it. After notifying the sender of receipt, please destroy the document and any attachments. This document may contain information that is 

proprietary, privileged, confidential, and/or otherwise legally exempt from disclosure. Any erroneous transmission and/or receipt of this document shall not constitute waiver of any applicable protections against 

unauthorized use or disclosure of the information. QUEST®, KODIAK®, and logos are registered trademarks of Quest Aircraft Design, LLC.

9. Remove the clecos, and remove the doubler from under the skin.

10. Deburr as needed.

11. On top of the elevator skin, line up the doubler and the filler in the corner, with the 

filler beneath the doubler, and cleco in place.

12. If needed, upsize rivet holes in accordance with Table 5-2.

CCAAUUTTIIOONN

Use a drill stop to prevent damage to the elevator torque tube while drilling.

NNOOTTEE

Standard sized rivets and hole dimensions are used throughout this document. It is permissible to use the standard 

oversized fastener in all locations where fasteners are replaced in this document. All fasteners shall be installed in 

accordance with Table 5-2; refer to Table 5-2 for edge distance, fastener part numbers, and other pertinent 

information. Solid fasteners may not be replaced with pulled fasteners. Pulled fasteners may always be replaced with 

solid fasteners if desired.

Table 5-2: Rivet Specifications

RIVET 

CALLOUT SIZE

PREPARED HOLE DIAMETER 

(in) STANDARD 

DRILL

MINIMUM 

EDGE 

Min Max DISTANCE (in)

MS20470AD4 4 0.128 0.134 30 0.25

NAS1242AD4 4 oversized 0.143 0.149 27 0.27

CR3213-4 4 0.129 0.132 30 0.25

CR3243-4 4 oversized 0.143 0.146 27 0.27

MS20470AD5 5 0.159 0.164 21 0.31

NAS1242AD5 5 oversized 0.175 0.180 16 0.34

13. Install ten (10) rivets at the locations shown in Figure 5-9. The rivet lengths shown are 

provided in the service kit, but the mechanic may adjust the length as necessary to 

ensure a properly installed fastener in accordance with AC-43.13-1B Section 4-57.

 Two (2) cherry rivets (P/N CR3213-4-01)

 Six (6) cherry rivets (P/N CR3213-4-02)

 Two (2) rivet (MS20470AD5-*).

14. Replace any rivets that were removed to access the inspection and work area.
 FIELD SERVICE INSTRUCTION - PAGE: 17 of 18

TITLE: Elevator Doubler Installation REPORT NO.: FSI-106

SERIAL RANGE: Elevator Serial Numbers 0001 thru 0149 JASC CODE: 5522 REVISION: 02

CONFIDENTIALITY NOTICE: The information contained in this document and any attachments are the property of Quest Aircraft Design, LLC and/or Quest Aircraft Company, LLC. and may be used only by the intended 

recipient. In the event that this document has been transmitted or forwarded to you in error, please notify the sender immediately by calling 208-263-1111. No person other than the intended recipient is authorized to 

read, print, retain, copy, and/or disseminate this document or any part of it. After notifying the sender of receipt, please destroy the document and any attachments. This document may contain information that is 

proprietary, privileged, confidential, and/or otherwise legally exempt from disclosure. Any erroneous transmission and/or receipt of this document shall not constitute waiver of any applicable protections against 

unauthorized use or disclosure of the information. QUEST®, KODIAK®, and logos are registered trademarks of Quest Aircraft Design, LLC.

Figure 5-9: Install Ten Rivets

5.3 Repeat and Clean Up

1. Repeat Section 5.1 or Section 5.2 as appropriate to install a total of 4 doublers (one on 

top, one on bottom, on both the left and right elevators).

2. Remove rivet tails and foreign object debris from inside the elevator using a vacuum 

system. If the elevator was removed from the airplane, connect the included piece of 

Tygon tubing to the vacuum system and insert between the trailing edge skin and the 

inside rib to aid in removing foreign object debris. See Figure 5-10.

3. Use a borescope (if available) to verify all foreign object debris has been removed.

MS20470AD5-*

Filler

Doubler

CR3213-4-02

CR3213-4-01

CR3213-4-02

*MS20470AD5-4, MS20470AD5-5, and MS20470AD5-5.5 are provided in the kit. Select the appropriate 

length as needed.
 FIELD SERVICE INSTRUCTION - PAGE: 18 of 18

TITLE: Elevator Doubler Installation REPORT NO.: FSI-106

SERIAL RANGE: Elevator Serial Numbers 0001 thru 0149 JASC CODE: 5522 REVISION: 02

CONFIDENTIALITY NOTICE: The information contained in this document and any attachments are the property of Quest Aircraft Design, LLC and/or Quest Aircraft Company, LLC. and may be used only by the intended 

recipient. In the event that this document has been transmitted or forwarded to you in error, please notify the sender immediately by calling 208-263-1111. No person other than the intended recipient is authorized to 

read, print, retain, copy, and/or disseminate this document or any part of it. After notifying the sender of receipt, please destroy the document and any attachments. This document may contain information that is 

proprietary, privileged, confidential, and/or otherwise legally exempt from disclosure. Any erroneous transmission and/or receipt of this document shall not constitute waiver of any applicable protections against 

unauthorized use or disclosure of the information. QUEST®, KODIAK®, and logos are registered trademarks of Quest Aircraft Design, LLC.

Figure 5-10: Remove Debris

4. If doubler(s) were installed on the outside of the elevator (in accordance with Section 

5.2), paint the doubler(s) and exposed rivet heads to match in accordance with 

AM902.0, KODIAK®100 Airplane Maintenance Manual, Chapter 6, Standard 

Practices. If the doublers were installed on the inside of the elevator (in accordance 

with Section 5.1), touch up the paint on the exposed rivet heads to match.

6. Completion

1. If the elevator was removed from the airplane, reinstall in accordance with AM902.0, 

KODIAK®100 Airplane Maintenance Manual, Chapter 53, Fuselage.

2. Reinstall the tailcone in accordance with AM902.0, KODIAK®100 Airplane 

Maintenance Manual, Chapter 53, Fuselage.

3. Record the work performed in the appropriate maintenance records.

---END---

Tygon tubing