CESSCO WICHITA
September 27, 1963
63-40
TO: CESSNA SALES AND SERVICE ORGANIZATION
SUBJECT: FUSELAGE FRONT SPAR MODIFICATION - - - - - (URGENT)
MODELS AFFECTED: 190 AND 195
Service Letter 190/195-1, dated May 18, 1960 and Supplement #1 dated October 11,
1960, called for an immediate inspection of the center section spars on all Model
190 and 195 airplanes, which had 4500 hours or more flight time on the airframe.
This inspection was based on one accident -- an additional accident has recently
been reported; therefore, the following inspection and modification needs to be
accomplished immediately on all 190/195 aircraft.
(1) Front and rear center section spars on all 190/195
aircraft must be inspected in accordance with inspec-
tion procedures set forth in Service Letter 190/195-1
within next 10 hours of flight operation.
NOTE: Aircraft which have been inspected in accord-
ance with Service Letter 190/195-1 within last
100 hours of flight operation need not be re-
inspected.
(2) If cracks are found in either spar, as a result of this
inspection, spar(s) must be replaced. New replacement
spar(s) are to be ordered from the Cessna Parts Depart-
ment.
(3) After inspection (and spar replacement if required)
reinforcement bars are to be added to front center
section spar in accordance with the attached Service
Kit, SK195-3. Please note special tools (Service Kit,
SK195-4 attached) which are required to install bars.
(4) Once Steps 1, 2 and 3 above have been incorporated on
an aircraft, future spar inspections (other than normal
periodic inspections) per Service Letter 190/195-1 and
Supplement #1, dated October 11, 1960, are no longer
required.
(Continued)
Page #2 Service Letter 63-40, dated September 27, 1963
Cessna will pay, through Cessna Distributors - - -
(1) Cost of Service Kit, SK195-3.
This kit should be ordered from the Cessna Parts Department -
Kits will be billed out at $26.00 Net and shipped prepaid to
destination. Full kit credit will be issued upon receipt of
Reporting Form D-102-13 at the Cessna Service Department
verifying kit installation.
(2) Cost of Special Tools, Service Kit, SK195-4.
If special tools are not procured/fabricated locally, this
kit may be ordered from the Cessna Parts Department, priced
$36.00 Net (shipments will be prepaid to destination). After
all installations are made, if no further use is anticipated
for special tools, they may be returned to Cessna Return Goods
Board for credit. Since these tools can be passed around and
reused many times, only fifty (50) kits are being made avail-
able (approximately one kit per Distributor area).
This no charge parts offer will expire September 1, 1964.
(Owner Notification System - No. 2)
**********
ALL PRICES SUBJECT TO CHANGE WITHOUT NOTICE
CESSNA AIRCRAFT COMPANY
ADDRESS C
CESSCO WICHITA
COMMERCIAL DIVISION CESSNA AIRCRAFT COMPANY WICHITA KANSAS
October 25, 1963
63-40
(Supplement #1)
URGENT
TO: CESSNA SALES AND SERVICE ORGANIZATION
SUBJECT: FUSELAGE FRONT SPAR MODIFICATION
MODELS AFFECTED: MODELS 190 AND 195
The following Night Letter was dispatched on October 24, 1963, to all
Distributors and Dealers under jurisdiction of the FAA.
"REALIZING THAT TECHNIQUES AND EQUIPMENT HAVE CHANGED TO
SOME EXTENT SINCE ISSUANCE OF SERVICE LETTER 190/195-1
DATED MAY 18, 1960, AND SUPPLEMENT #1 DATED OCTOBER 11,
1960, FOLLOWING INFORMATION IS BEING SUPPLIED TO HELP
CLARIFY THE INSPECTION REQUIREMENTS ON THE CENTER SECTION
FRONT SPAR. THE X-RAY SETTINGS SET FORTH IN THE ORIGINAL
SERVICE LETTER (ITEM IB1 UNDER INSPECTION PROCEDURES)
WERE PROVIDED AS A GUIDE; THEREFORE, VARIATIONS FROM THESE
SETTINGS ARE ACCEPTABLE. THE BASIC INTENT OF THE INSPECTION
IS FOR A QUALIFIED TECHNICIAN USING A PENETRATING PHOTOGRAPHIC
DEVICE TO DETERMINE THE STRUCTURAL INTEGRITY OF THE FRONT SPAR.
THE X-RAY SETTINGS SHOWN IN THE ORIGINAL SERVICE LETTER WERE
ESTABLISHED WITH THE HI-SHEAR RIVETS INSTALLED IN THE FRONT
SPAR. IT IS PERMISSIBLE TO CONDUCT THIS INSPECTION WITH THE
HI-SHEAR RIVETS REMOVED."
This clarification will assist you in performing the Model 190 and 195
front spar X-ray inspection called out in Service Letter 63-40, dated
September 27, 1963.
(Owner Notification System - No. 2)
CESSNA AIRCRAFT COMPANY
SK 195-3
SEPTEMBER 23, 1963
CENTER SECTION FRONT SPAR FUSELAGE MODIFICATION
MODELS AFFECTED SERIALS AFFECTED
All 190 and 195 Series ALL
PARTS LIST:
QUANTITY PART NUMBER NOMENCLATURE
2 10195-001-1 Bar - Reinforcement
10 NAS464P7A64 Bolt - 7/16" Close Tolerance
10 AN960-760 Washer
10 MS20364-720 Nut
1 (12 oz spray can) CES-1099-I-Cs Zinc Chromate Primer
1 Installation Instructions
ESTIMATED INSTALLATION TIME: 10 to 12 Hours.
CHANGE IN WEIGHT AND BALANCE:
MODEL 190- 195
WEIGHT INCREASE 23 pounds
ARM 48.25 inches
RESULTANT MOMENT 1, 109 pound-inches
INDEX 1. 1
1. DESCRIPTION OF INSTALLATION.
Installation of Service Kit SK195-3 consists of:
a. Removing the 10 inboard, hi-shear rivets from the lower part of the center section front spar,
increasing the 10 holes from 3/8" to . 436" and installing 2 steel reinforcement bars w. :h close
tolerance bolts.
2. MODIFICATION INSTRUCTIONS.
a. Refer to figure 1 and perform the modification as follows:
(1) Remove two front seats and unzip headlining to gain access to the front spar.
(2) Remove sufficient insulation and padding to clear the five inboard hi-shear rivets (position 1)
on each side of the lower spar beam.
(3) Remove the five inboard rivets (1), from each side of the spar.
(4) Using a special 27/64" core drill with a 1" x3/8" pilot carefully drill all ten holes to 27/64".
1 of 3
PROJECT STRUCTURES DMCR
(SK195-3)
(5) Mark a line (do not scribe) 11/16" below the centerline of the ten holes on the front and aft
side spar plates (4).
(6) Position the steel reinforcement bar (2) on the front side of the spar plates (4) so the bottom
edge of the bar is aligned with the 11/16" mark made in step (5), and clamp the bar securely
in place.
NOTE
Be sure to position the bar evenly between the flanges of the bulkhead.
(7) Using a . 420 transfer punch, through each of the ten holes, lightly punch a center mark.
(8) Repeat steps 6 and 7 with the second reinforcement bar (2) on the aft side of the spar.
(9) Using a center punch, carefully increase the size of the center marks to a size sufficient to
keep a No. 2 center drill from creeping.
(10) Using first a No. 2 center drill start each of the ten holes in each reinforcement bar.
NOTE
Use a drill press for steps 10 thru 12.
(11) Increase the hole diameter by next using a No. 4 then a No. 5 center drill until each hole is
approximately 27/64" diameter.
(12) Using a 27/64" drill bit, drill the ten holes in each reinforcement bar.
(13) Reposition bars in aircraft to align all 10 holes.
(14) Using the special . 436 reamer with the 1" x 27/64" pilot ream all holes to .436.
(15) Remove the bars from the aircraft and using a 90 ° rotary file chamfer each side of all holes in the
bars .030" x 45°.
(16) Thoroughly clean all holes of metal chips and foreign matter.
(17) Spray zinc chromate primer on the spar plates (4), covering the entire area that will be in
bearing with the reinforcement bars.
(18) Install the reinforcement bars with bolts (1).
NOTE
Immediately before installing the bolt spray the bolt with zinc chromate and
insert the bolt wet.
(19) Install washers (1) and secure the bolts with nuts (1). Torque nuts to 270 to 300 inch-pounds.
NOTE
Spray zinc chromate under the washer and tighten the nut while the primer is
wet. This will seal the holes against moisture.
(20) Split the rubber spar pad (3) down the middle and install each section over the reinforcement bar.
Secure the rubber pad to the spar with tape through the spar lightening holes.
(21) Replace insulation and padding and zip headlining.
(22) Replace seats.
2 of 3
SK195-3
REMOVE 10 HI-SHEAR RIVETS
NAS464P7A64 BOLT
AN960-760 WASHER
MS20364-720 NUT
10 EA. REQD.
2 REQD
(REF)
3 of 3
SK 195-4
Title SPECIAL TOOLS FOR SK195-3.
PARTS LIST:
QUANTITY PART NUMBER NOMENCLATURE
1 Core Drill 27/64" with
1" x 3/8" Pilot
1 Reamer .436 with
1" x 27/64" Pilot
1 Transfer Punch .420
1 No. 2 Center Drill
1 No. 4 Center Drill
1 No. 5 Center Drill
ADDITIONAL TOOLS REQUIRED.
Tools required but not included in kit:
1 ea. 90 ° Rotary File
1 ea. 27/64" Drill Bit
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