Narrative:

I performed a repair on a md-80 aircraft at the left hand alternate static port area station location 420-465; longeron 28-left to 26-left. The repair was performed per structural repair manual (srm); outlining a flush repair concerning the production skin overlap. This repair is called a 'brick method' pertaining to the thick internal doublers. The srm figure illustrates the 'bricks' terminate; or start and stop at the longerons and shear ties/frames; with continuous finger doublers running under all related structure.this repair also illustrates straps being used in the longerons. The damaged area was removed and all repair materials were verified by our inspectors on duty as per primary structure repair; and clearance to install/begin build-up of repair. After visiting with another mechanic after repairs were completed; we debated over the 'bricks' starting and stopping at the shear ties frames; and installing new shear ties/frames. The mechanic showed me another similar repair being for another area; which had a better/sharper picture outlining the repair.we then looked at srm under closer examination; we discovered the 'bricks' are supposed to pass under the shear ties/frames; with modified/repaired shear ties/frames to allow the doubler to not apply preload or stress to the repair and skin; and causing contour changes in the rvsm [skin] area. The srm figure does not make mention of altering/modifying or performing repairs to the affected shear ties/frames. And the srm figure does not include a view of the shear ties/frames; or a view of modified/repaired shear ties/frames. In the srm figure; near the shear tie/frame area; the dashed/jagged lines; and fastener legend/identifying marking do not accurately represent performing this repair.

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Original NASA ASRS Text

Title: Three mechanics report an MD-80 Structural Repair Manual (SRM) illustration does not accurately represent the requirement to have flush repair internal doublers pass under longerons; modified shear ties and frames for a left alternate static port external fuselage skin repair in an RVSM area.

Narrative: I performed a repair on a MD-80 aircraft at the left hand Alternate Static Port area station location 420-465; longeron 28-left to 26-left. The repair was performed per Structural Repair Manual (SRM); outlining a Flush Repair concerning the production skin overlap. This repair is called a 'brick method' pertaining to the thick internal doublers. The SRM Figure illustrates the 'bricks' terminate; or start and stop at the longerons and shear ties/frames; with continuous finger doublers running under all related structure.This repair also illustrates straps being used in the longerons. The damaged area was removed and all repair materials were verified by our Inspectors on duty as per primary structure repair; and clearance to install/begin build-up of repair. After visiting with another Mechanic after repairs were completed; we debated over the 'bricks' starting and stopping at the shear ties frames; and installing new shear ties/frames. The Mechanic showed me another similar repair being for another area; which had a better/sharper picture outlining the repair.We then looked at SRM under closer examination; we discovered the 'bricks' are supposed to pass under the shear ties/frames; with modified/repaired shear ties/frames to allow the doubler to not apply preload or stress to the repair and skin; and causing contour changes in the RVSM [skin] area. The SRM figure does not make mention of altering/modifying or performing repairs to the affected shear ties/frames. And the SRM figure does not include a view of the shear ties/frames; or a view of modified/repaired shear ties/frames. In the SRM figure; near the shear tie/frame area; the dashed/jagged lines; and fastener legend/identifying marking do not accurately represent performing this repair.

Data retrieved from NASA's ASRS site as of April 2012 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.