ASSEMBLY PROCESS SHEETS

Name of AFT FUSELAGE (Stage 1)

Assembly:
Drawing No. RD-02-03-02-02-1-02-18-01-000
Tools Reqd: Aft fselage str!tral assembly "ig #stage-1$ % standard assembly &and tools % 'ortable 'ower
tools
(ig )n!tion: Assembly of aft fselage str!tre* establis&ing 'rin!i'al dimensions and +,- lo!ations.

,om'onents ).. Ring #stn/$ - 01001/0-2ingle ,N, ma!&ined item- 3ood atta!&ment #fwd.$-
Reqd: +nterfa!e wit& nose !one.
4l5&ead 8 - 01/0100- only bottom segment.
4l5&ead 6 - 01/0100-7nly bottom segment- 2tra5e rib atta!&ment.
4l5&ead 10 - 01/01/0-To' and bottom segments- 3ood atta!&ment #aft$-2tra5e rib atta!&ment.
4l5 &ead 11 - 011001100-4ottom and to' segments- 8ing atta!&ments #fwd.$-+,-.
4l5 &ead 12 - 01001/0-4ottom and to' segments.
4l5 &ead 13 - 011001100-4ottom and to' segments-8ing atta!&ments #aft$-+,--
)in atta!&ment #fwd.$ 9 +,-.
4l5 &ead 1: - 01001/0- 4ottom and to' segments- )in atta!&ment #aft$ -+,- -
2''orts !-longeron

A.. Ring #stn 10$ -01801100;0110011:0- 2ingle ,N, ma!&ined item- 4ooster atta!&ment-
4ody fla' atta!&ments-+,--+ntegrated to bl5&ead1: t&rog& ,-longerons.
<-longerons - 0110011001:160 - 4ottom-2no.
T-longerons - 01100100;=3;/0;1001 3/80->iddle -2no.
,-longerons - 01/311001:/0- To'-2no
,-longerons - 01/0 to /011001:/0- >iddle-2no.
,-longerons - 01/0;13811001:/0- 4ottom- 2no.

4l5&ead bra!5ets 9 = ty'es.
Operation sheet
00. +ns'e!t "ig.
10. <o!ate )...ring wit& 8mm t&i!5 >2 drill tem'late at 3 no.10
3/
s&ear &oles. ,&e!5 for 'ro'er alignment
between tem'late and )... ring. Drill 20no. / &oles in stages. Remo?e )...ring and tem'late. Re-install only
)...ring wit& lo!ators trned to t&e t&i!5er side.
10. <o!ate A.. ring at : 'oints sing bs&es #7D 32*+D 10$ and lo!5 wit& 10 'ins.
20. +nsert ,-longerons into A.. ring 'o!5ets meant for t&em. 2tart wit& bottom ,-longerons* t&en middle %
to' ,-longerons. Transfer drill and lo!5.

20. @osition bl5&ead1: bottom and to' segments* simltaneosly inserting t&e ,-longerons. Atta!& t&e
bl5&ead to lo!ators. Transfer drill and lo!5 t&e bottom % middle ,-longerons. T&e to' ,-longeron will be
finaliAed in 2tage-2 "ig after BT s''ort bra!5et is installed.
30. @osition <- longerons #<.3 % R.3$ sing 3 no of lo!ators on ea!& side. Transfer drill and lo!5 t&e
longerons to A.. % ).. rings % bl5&ead1:.
30. @osition bl5&ead 11 and 13 and !lam' to t&e +,- lo!ators for wing atta!&ment. ,lam' to' ends of
bl5&eads to t&e ''er lo!ators.
:0. @osition remaining :no. bottom bl5&ead segments and !lam' to t&e lo!ators. Transfer drill and lo!5 <-
longerons to bl5&ead segments.
:0. +ns'e!t.
00. @osition T-longerons wit& 3 no. lo!ators on ea!& side.#T&is stret!&es from stn1: to )...ring.$
00. @osition t&e remaining = to' bl5&eads and !lam' to lo!ators.
=0. Transfer drill and lo!5 bottom % to' bl5&eads to T-longeron sing bl5&ead bra!5ets as s&own in t&e
drawing.
=0. +ns'e!t.
/0. 2tage- drill all &oles. Disassemble and debrr. A''ly sealant to inter-faying srfa!es.
/0. Reassemble* w&en sealant is ta!5y sing t&e same lo!5 'ins. 7'en ot : to :.1 and ri?et. Remo?e lo!5
'ins* enlarge &oles to : and debrr in sit. 7'en ot : to :.1 and ri?et.

80. )inal +ns'e!tion.
80. Dis!onne!t only t&e lo!ators obstr!ting trolley mo?ement. Rest t&e str!tre on two "ig trolley saddles
at stn6 % stn1:. ,onne!t trolleys wit& tie-rods. Dis!onne!t remaining lo!ators. Roll ot str!tre on to trans'ort
trolley #Crond eqi'ment$ for frt&er o'erations.
!otes
"ig T&e "ig str!tre is rigid as &ea?y se!tions &a?e been !&osen for its fabri!ation and t&e str!tre is well
s''orted and gsseted. +t is modlar in !onstr!tion. A!!essibility for wor5ing is good* as !are &as been ta5en
not to &a?e t&e middle rnner on to' of t&e base str!tre. <o!ators are generally of two- 'ie!e design 9 a base
frame atta!&ed to t&e "ig str!tre and a stri' of >2 'late !onne!ting t&e base frame to t&e !om'onent. 3en!e
t&e lo!ators are easy to install or remo?e. T&e "ig !an be loaded wit& ease and t&e !om'leted assembly nloaded
Dsing s'e!ially designed trolleys.
#ri$$ing ter%ino$og&
Transfer drill means transferring from t&e 're-drilled srfa!es t&e 'ilot &oles #1.0 or 2$ to blan5 srfa!es e.g.
s5in 'anels to longerons or bl5&eads* and enlarging it to lo!5 'in diameter* say 2.8.
2tage- drill means o'ening ot a 'ilot &ole of 1.0 to say 0.2 in stages of 2.8* :.0 and 0.2.
<o!5* in t&is !onte1t* means gri''ing t&e sta!5 !onsisting of s5in* longeron* bl5&ead et!. tig&tly wit& 2.8
ser?i!e bolts or A?del ;,le!o lo!5 'ins.

ASSEMBLY PROCESS SHEETS
Name of AFT FUSELAGE (Stage ')
Assembly:
Drawing No. RD-02-03-02-02-1-02-18-00-000
Tools Reqd: Aft fselage str!tral assembly "ig #stage-2$ % standard assembly &and tools % 'ortable 'ower
tools
(ig )n!tions:
)itting fin bra!5ets #2 nos$
)inaliAing to' ,- longerons #2 nos$
)itting to' ,- longeron bra!5ets #2 nos$
<o!ating body fla's #2no$
25inning #: 25in @anels$.
+nstalling 3ood #1no$
,om'onents to be assembled:
1. Aft fselage str!tre 1no.
2. BT bra!5ets 2no.
3. 3ood 1no.
:. To' s5in 'anel 2no.
0. <3 % R3 s5in 'anels 2 no.
=. 4ottom s5in 'anel 1 no.
/. 4ody fla' &inges 2no.
8. 4l5&ead bra!5ets 2nos.
6.,li's <ot
>aster 'ro!ess s&eet:
00. +ns'e!t "ig.
10. Raise to' !ontor 'lates % lo!5. Remo?e 4ottom <3 % R3 !ontor 'lates.
10. >o?e aft fselage str!tre on trolleys to stage2 (ig.
20. <o!5 bl5&ead 11 % 13 to +,- lo!ators.
20 Atta!& BT bra!5et lo!ators to t&e !ontor 'late at stn.1:. +nsert BT s''ort bra!5ets and !lam' to t&e
lo!ators. Transfer drill and lo!5.
30 @s& t&e to' ,-longerons to btt against t&e BT bra!5ets. Transfer drill and lo!5.
30 )it to' ,-longeron bra!5et btting on t&e inner side of t&e longerons. Transfer drill and lo!5.
:0 Remo?e t&e BT bra!5et lo!ators.
:0 +ns'e!t.
00 @osition to' s5in 'anel. <ower to' !ontor 'lates* w&ere reqired and lo!5. A''ly 'ressre on t&e 'anel
t&rog& t&rst 'ads. ,&e!5 for 2mm niform !learan!e wit& feeler gage. Transfer drill and lo!5.
00 +ns'e!t.
=0 2tage- drill all &oles. Raise !ontor 'lates. Disassemble t&e 'anel and debrr. A''ly sealant to t&e inter-
faying srfa!es.
=0 @osition bottom s5in 'anel* install <3 % R3 !ontor 'lates* and a''ly 'ressre on t&e 'anel t&rog&
t&rst 'ads. ,&e!5 for 2mm niform !learan!e wit& feeler gage. Remo?e !ontor 'lates. Transfer drill and
lo!5.
/0 +ns'e!t.
2tage- drill all &oles. Remo?e !ontor 'lates. Disassemble t&e 'anel and debrr. A''ly sealant to t&e
inter-faying srfa!es.
:0. @osition <3 s5in 'anel* install <3 !ontor 'late* and a''ly on t&e 'anel t&rog& t&rst 'ads. ,&e!5 for
2mm niform !learan!e wit& feeler gage. Remo?e !ontor 'late. Transfer drill and lo!5
:1. +ns'e!t
:2. 2tage- drill all &oles. Remo?e !ontor 'late. Disassemble t&e 'anel and debrr. A''ly sealant to t&e
inter-faying srfa!es.
:0. @osition R3 s5in 'anel* install R3 !ontor 'late* and a''ly 'ressre on t&e 'anel .t&rog& t&rst 'ads.
,&e!5 for 2mm niform !learan!e wit& feeler gage. Remo?e !ontor 'late. Transfer drill and lo!5.
:=. +ns'e!t.
:/. 2tage- drill all &oles. Remo?e !ontor 'late. Disassemble t&e 'anel and debrr. A''ly sealant to t&e
inter-faying srfa!es.
Reassemble* in t&e following seqen!e* w&en sealant is ta!5y sing t&e same lo!5 'ins. 7'en ot : to
:.1 and ri?et. Remo?e lo!5 'ins* enlarge &oles to : and debrr in sit. 7'en ot : to :.1 and se
t&rst 'ads and ri?et.

To' 'anel.
4ottom 'anel.
<3 'anel.
R3 'anel.
00. +ns'e!t
=0. <o!ate body fla' bra!5ets. 3old wit& ,-!lam'. Drill. Disassemble* debrr* a''ly sealant* reassemble and
bolt.
=1. )inal ins'e!tion

=0. 3olding t&e str!tre on ). ring and wing lo!ators* remo?e all !ontor 'lates* bring t&e trolleys from
t&e aft end and rest t&e str!tre on t&e saddles at stn6 % stn1:. ,onne!t trolleys wit& tie-rods.
Dis!onne!t lo!ators on t&e ).. ring. Roll ot t&e aft fselage assembly on to trans'ort trolley for frt&er
o'erations.

!otes
Conto(r P$ates)
,ontor 'lates are aligned to t&e fwd fa!e of t&e bl5&ead. 2tation line is not !onsidered. )... and A... rings are
not 'ro?ided wit& !ontor 'lates* as t&ey are single 'ie!e ma!&ined 'arts. T&e total t&i!5ness of t&e !ontor
'late is 1=mm e1!e't in t&e !ase of bl5&ead 1:* w&ere 20mm !ontor 'late is 'ro?ided in order to !arry t&e BT
bra!5et lo!ators. T&e !&e!5ing edge of t&e !ontor 'late is 0mm t&i!5 and maintains a ga' of :mm from t&e to'
srfa!e of t&e bl5&ead and 2mm from t&e to' srfa!e of t&e s5in 'anel. T&e rest of t&e !ontor 'late is relie?ed
by 0mm.