B757-200 Cargo Conversion

STRUCTURAL REPAIR MANUAL
SUPPLEMENT FOR B757-200 CARGO

CONVERSION
PC-0118-11
PRECISION CONVERSIONS CONFIDENTIAL, AND/OR TRADE SECRET

Copyright © 2005 Precision Conversions
Unpublished Work – All Rights Reserved
THIS INFORMATION CONTAINED HEREIN IS PROPRIETARY TO PRECISION CONVERSIONS LLC

AND SHALL NOT BE REPRODUCED OR DISCLOSED IN WHOLE OR IN PART OR USED FOR ANY
DESIGN OR MANUFACTURE EXCEPT WHEN SUCH USER POSSESSES DIRECT, WRITTEN
AUTHORIZATION FROM PRECISION CONVERSIONS LLC.
ORIGINAL ISSUE DATE: J ANUARY 10, 2005
REVISION DATE: SEPTEMBER 20, 2018
COMPILED AND PUBLISHED BY:
PRECISION CONVERSIONS
4900 SW GRIFFITH DRIVE, SUITE 133
BEAVERTON, OREGON 97005
USA
PREC ISION B757-200PCF
Structural Repair Manual Supplement
CONVERSIONS LLC
PC-0118-11
LIST OF REVISIONS
REV DESCRIPTION BY APVD DATE
IR Initial Release MV WJW 01/10/05
A Text Clarification MV WJW 02/10/05
B Clarifications DFD WJW 06/17/09
c Clarifications DH DH 11/20/14
D Clarifications JMD DD 12/16/15
Brought current with Boeing 757-200 Structural Repair

E JMD DD 04/15/16
Manual D634N201 Jan 20/2016 Revision
F See Revision Highlights RMJG DD 04/14/17
G See Revision Highlights 5L ~~ </f J.o/ 1?
REVISIONS
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PREC ISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMEN T.
B757-200PCF
PC-0118-11
REVISION HIGHLIGHTS
Revised and/or clarified sections are marked with right margin revision bars:
1. Brought current with Boeing 757-200 Structural Repair Manual D634N201.

2. Incorporated Temporary Revisions 25, 26, 27, adding aircraft 085 to 106 to the List of Effective
Airplanes.
3. Added aircraft 107 to 109 to the List of Effective Airplanes.
4. Updated aircraft registration numbers on the List of Effective Airplanes.
HIGHLIGHTS
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PRECISION CONVERSIONS LLC PROPRIETARY INFORMATION. SEE FRONT SHEET FOR FULL DISCLOSURE STATEMENT.
B757-200PCF
PC-0118-11
Page Date Page Date Page Date
TITLE PAGE 52-30-03 53-30-01
1 Sep 2018 101 Nov 2014 1 Nov 2014
LIST OF REVISIONS 201 Nov 2014 2 Nov 2014
1 Sep 2018 CHAPTER 53 FUSELAGE 3 Nov 2014
HIGHLIGHTS 53-CONTENTS 4 Nov 2014
1 Sep 2018 1 Dec 2015 201 Nov 2014
LIST OF EFFECTIVE PAGES 2 Dec 2015 53-30-03
1 Sep 2018 53-00-00 1 Nov 2014
RECORD OF TEMP. REVISIONS 1 Nov 2014 2 Nov 2014
1 Sep 2018 53-00-01 53-30-04
LIST OF EFFECTIVE AIRPLANES 101 Nov 2014 1 Nov 2014
1 Sep 2018 201 Nov 2014 53-30-07
2 Sep 2018 53-00-03 1 Nov 2014
INTRODUCTION 101 Nov 2014 2 Nov 2014
1 Nov 2014 201 Nov 2014 3 Nov 2014
2 Sep 2018 202 Nov 2014 53-30-15
3 Nov 2014 53-00-04 1 Nov 2014
4 Nov 2014 101 Nov 2014 2 Nov 2014
CONTENTS 201 Nov 2014 3 Nov 2014
1 Jun 2009 53-00-07 4 Nov 2014
CHAPTER 51 STRUCTURES 101 Nov 2014 101 Nov 2014
GENERAL 102 Nov 2014 53-30-52
51-CONTENTS 201 Nov 2014 1 Jun 2009
1 Nov 2014 53-00-13 2 Jun 2009
51-00-00 101 Dec 2015 53-40-52
1 Nov 2014 53-00-51 1 Jun 2009
51-00-04 101 Nov 2014 2 Jun 2009
1 Nov 2014 102 Nov 2014 53-60-01
2 Nov 2014 201 Nov 2014 1 Nov 2014
3 Nov 2014 53-00-52 2 Nov 2014
4 Nov 2014 101 Nov 2014 53-60-03
51-10-00 201 Nov 2014 1 Nov 2014
1 Apr 2017 53-10-01 53-60-07
51-10-02 1 Nov 2014 1 Nov 2014
101 Nov 2014 2 Nov 2014 53-60-51
51-70-00 3 Nov 2014 1 Dec 2015
1 Apr 2017 4 Nov 2014 53-60-52
51-70-11 5 Nov 2014 1 Nov 2014
1 Nov 2014 6 Nov 2014 2 Nov 2014
51-70-12 53-10-03 CHAPTER 54
1 Nov 2014 1 Nov 2014 NACELLES/PYLONS
51-70-13 2 Nov 2014 54-CONTENTS
1 Nov 2014 3 Nov 2014 1 Nov 2014
CHAPTER 52 DOORS 4 Nov 2014 54-00-00
52-CONTENTS 53-10-07 1 Nov 2014
1 Nov 2014 1 Nov 2014 CHAPTER 55
52-00-00 2 Nov 2014 STABILIZERS
1 Nov 2014 3 Nov 2014 55-CONTENTS
52-10-01 4 Nov 2014 1 Nov 2014
1 Nov 2014 53-10-08 55-00-00
2 Nov 2014 1 Nov 2014 1 Nov 2014
3 Nov 2014 2 Nov 2014 CHAPTER 56
52-10-02 101 Nov 2014 WINDOWS
2 Nov 2014 53-10-13 1 Nov 2014
201 Nov 2014 1 Nov 2014 56-00-00
52-10-03 101 Nov 2014 1 Nov 2014
101 Nov 2014 201 Nov 2014 CHAPTER 57
201 Nov 2014 53-10-15 WINGS
52-30-01 2 Nov 2014 57-00-00
1 Jun 2009 101 Nov 2014 1 Nov 2014
2 Jun 2009 53-10-52
3 Jun 2009 1 Nov 2014
52-30-02 2 Nov 2014
1 Nov 2014
2 Nov 2014 LIST OF EFFECTIVE PAGES
EFFECTIVE PAGES
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RECORD OF TEMPORARY REVISIONS
REVISION INSERTED REMOVED REVISION INSERTED REMOVED

TR TR TR B TR
DATE BY DATE DATE DATED DATE DATE
NO. NO. NO. Y NO.
1 06/20/08 DD 06/17/09
2 08/19/10 DD 11/19/14
3 05/10/11 DD 11/19/14
4 06/08/11 TF 11/19/14
5 Cancelled
6 10/21/11 SL 11/19/14
7 07/31/12 DH 11/19/14
8 11/30/12 DH 11/19/14
9 12/21/12 DH 11/19/14
10 08/29/13 DH 11/19/14
11 12/09/13 DH 11/19/14
12 12/26/13 DH 11/19/14
13 05/12/14 SL 11/19/14
14 08/15/14 SL 11/19/14
15 09/23/14 SL 11/19/14
16 10/15/14 SL 11/19/14
17 04/13/15 SL 12/16/15
18 05/12/15 SL 12/16/15
19 07/23/15 SL 12/16/15
20 09/04/15 SL 12/16/15
21 11/30/15 SL 12/16/15
22 07/26/16 RG 04/14/17
23 12/10/16 RG 04/14/17
24 03/14/17 RG 04/14/17
25 10/24/17 SL 09/20/18
26 03/23/18 SL 09/20/18
27 07/20/18 SL 09/20/18
TEMPORARY REVISIONS
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LIST OF EFFECTIVE AIRPLANES
The following list provides a cross reference table of the airplanes that are applicable to the information
contained in this manual. Registration numbers are for reference only.
Cargo Conversion Variable Manufacturing Current Registration
Model No. Line No.
Number No. Serial No. No.
001 757-204 440 NB421 26962 VT-BDO
002 757-23A 257 NB139 24567 C-FLAJ
003 757-23A 255 NB138 24566 C-FKAJ
004 757-26DER 231 NE001 24471 HP-2110DAE
005 757-26DER 235 NE002 24472 9M-RYA
006 757-208ER 273 ND201 24739 TF-FIH
007 757-260ER 348 NE201 25014 ET-AJX
008 757-256ER 553 ND241 26239 EC-FTR
009 757-28A 127 NA441 23767 C-GIAJ
010 757-225 74 NA022 22211 N314ST
011 757-225 75 NA023 22611 VH-PQA
012 757-225 42 NA021 22210 A9C-DHE
013 757-225 117 NA026 22689 N689GX
014 757-225 115 NA025 22688 N688GX
015 757-23N 692 NC059 27598 VT-BDM
016 757-232 111 NA520 22910 N620DL
017 757-236 183 NA395 24121 EC-KLD
018 757-28A 130 NA442 23822 N822PB
019 757-236 279 NA343 24792 C-FKCJ
020 757-25C 475 ND221 25898 VT-BDN
021 757-232 46 NA505 22812 N605DL
022 757-236 441 NA348 25597 VQ-BPY
023 757-21B 232 NB066 24401 B-2899
024 757-27A 910 NT885 29611 HP-1810DAE
025 757-27A 832 NT881 29607 HP-1910DAE
026 757-27A 904 NT884 29610 HP-2010DAE
027 757-2Z0 554 NB293 25887 B-2832
028 757-2Z0 615 NB297 27269 B-2839
029 757-236 449 NA350 25620 VH-TCA
030 757-25CER 565 ND222 25899 B-2828
031 757-21B 389 NB262 25258 B-2817
032 757-222ER 361 NE041 25042 N531UA
033 757-25CER 574 ND223 25900 B-2829
034 757-2B6 106 NC042 23687 N557CM
035 757-2Q8 597 NC071 26273 N751CX
036 757-2Z0 674 NB302 27512 B-2845
037 757-2Z0 622 NB298 27270 B-2840
038 757-28A 704 NB224 26276 VT-BDQ
039 757-2Z0 833 NT202 29793 B-2856
040 757-223 433 ND180 25298 C-FGKJ
041 757-2Z0 624 NB299 27367 B-2841
042 757-2Z0 595 NB294 27258 B-2836
043 757-2Z0 822 NT201 29792 B-2855
044 757-25F 752 NB230 28718 VT-BDA
045 757-2Z0 669 NB301 27511 B-2844
046 757-29JER 588 NE301 27203 N757QM
047 757-2Z0 480 NB292 25886 B-2821
048 757-2Q8 836 NT378 29380 D-ALEN
049 757-230ER 446 NE172 25441 N888LT
050 757-2Q8 821 NT377 29443 D-ALEO
051 757-2Q8 1006 NT346 30046 D-ALEP
052 757-25F 928 NT237 30757 B-6150
053 757-222ER 421 NE147 25397 OO-TFC
054 757-2G5 671 NB446 26278 B-7342
EFFECTIVE AIRPLANES
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Cargo Conversion Variable Manufacturing Current Registration

Model No. Line No.
Number No. Serial No. No.
055 757-25F 932 NT238 30758 B-7082
056 757-23N 737 NC062 27974 VT-BDB
057 757-2Q8 688 NC073 26332 D-ALEQ
058 757-23N 843 NT283 29330 G-DHKA
059 757-28A 738 NB226 27621 B-7689
060 757-2Q8 819 NT376 29442 D-ALES
061 757-2Q8 639 NC072 27351 D-ALER
062 757-23N 814 NT282 27976 G-DHKE
063 757-256ER 943 NT915 29312 G-DHKB
064 757-236 873 NT408 29945 G-DHKF
065 757-23N 779 NT281 27975 G-DHKD
066 757-25CER 685 ND224 27513 B-2848
067 757-222 414 NE145 25368 N547UA
068 757-256 948 NT916 30052 G-DHKC
069 757-236 445 NA349 25598 B-2835
070 757-236 877 NT409 29946 G-DHKG
071 757-2Y0 503 NB328 26156 B-2827
072 757-28A 672 NB222 26275 G-DHKH
073 757-25CER 698 ND225 27517 B-2849
074 757-21B 583 NB266 25889 B-2824
075 757-21K 746 NB571 28674 B-1432
076 757-21B 575 NB265 25888 B-2823
077 757-28A 974 NT248 32449 G-DHKK
078 757-223ER 378 ND163 24605 C-GCJT
079 757-2Y0 482 NB325 26153 B-2831
080 757-28A 865 NT239 28174 G-DHKJ
081 757-28A 723 NB225 28161 G-DHKI
082 757-223ER 847 NT738 29590 G-DHKM
083 757-204 528 NB428 25623 B-1578
084 757-21B 585 NB267 25890 B-2825
085 757-2Z0 613 NB296 27260 B-1463
086 757-28S 966 NT385 32342 B-2813
087 757-223ER 812 NT731 29423 B-1378
088 757-223ER 998 NT981 31308 G-DHKN
089 757-28S 868 NT383 29217 B-2859
090 757-223ER 817 NT733 29425 B-1231
091 757-223ER 1000 NT982 32397 G-DHKO
092 757-28S 961 NT384 32341 B-2812
093 757-223 548 ND182 25730 C-GTCJ
094 757-223ER 816 NT732 29424 B-1252
095 757-223ER 562 ND183 25731 VQ-BKK
096 757-223ER 1002 NT983 32398 G-DHKP
097 757-223ER 828 NT735 29427 G-DHKS
098 757-28S 1015 NT386 32343 B-2830
099 757-223ER 827 NT734 29426 N676AN
100 757-223ER 842 NT737 29589 N679AN
101 757-2B7 655 NB517 27805 B-1145
102 757-223ER 383 ND165 24607 C-GVAJ
103 757-28S 811 NT382 29216 B-2853
104 757-223ER 566 ND184 25696 N690AA
105 757-223ER 837 NT736 29428 N678AN
106 757-2B7 605 NB512 27201 B-1173
107 757-28S 797 NT381 29215 B-2851
108 757-223ER 417 ND175 24617 N659AA
109 757-223ER 661 ND194 27052 B-1177
EFFECTIVE AIRPLANES
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INTRODUCTION
1. General
A. The “Structural Repair Manual (SRM) Supplement for B757-200 Cargo Conversion” is a
supplement to the “Boeing 757-200 Structural Repair Manual” document and is applicable to
Boeing 757-200 airplanes converted from a passenger to a Precision Conversions Freighter
(PCF) configuration in accordance with FAA STC No. ST01529SE. The information contained in
this supplemental SRM only applies to structure that has been added or affected and is not
intended to duplicate data that is presented in the Boeing document. This SRM Supplement is in
compliance with Part 26 Section 26.47.
The added and affected structure is divided into three types:
1) Precision Conversions Freighter Principal Structural Element (PCF PSE) as detailed in Figure
2 of Section 51-00-04. This type of structure is addressed within this SRM Supplement.
(PCF PSE)
2) OEM Principal Structural Element (OEM PSE) affected by the PCF STC as detailed in Figure
3 of Section 51-00-04. This type of structure is addressed within this SRM Supplement.
3) Fatigue Critical Structure (FCS) is structure that is affected by the PCF STC but that does not
result in changes in allowable damage, repairs or inspection thresholds. It is recommended
that this type of structure be reviewed by Precision Conversions if damage or repairs exceed
requirements detailed in the Boeing 757-200 SRM. Precision Conversions considers all
structure within the fuselage pressurized area as FCS.
FCS
INTRODUCTION
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1) General (Cont’d)
A. The conversion of a B757-200 passenger airplane to an all-cargo airplane includes the following
structural modifications:
1) Installation of a main deck cargo door on the left side of the forward fuselage. (See 52-30)
2) Deletion of the No. 1 entry doors, left and right. (See 53-10)
3) Deletion of the No. 4 entry doors, left and right. (See 53-60)
4) Deactivation of the remaining doors and emergency exits in the passenger cabin.
5) Installation of a crew entry door on the left side of the fuselage, forward of the 9G barrier. (See
52-10)
6) Removal of all passenger windows and installation of window plugs.
7) Installation of a rigid 9g cargo barrier behind the flight deck. (See 53-10-08)
8) Reinforce floor beams.
9) Installation of additional seat tracks. (See 53-10-52, 53-30-52, 53-40-52, and 53-60-52)
10) Replacement or modification of floor panels.
11) Modification of frames at aft pallet location.
B. This Supplemental SRM is to be used in conjunction with Boeing 757-200 SRM, D634N201,
dated May 20, 2018. Please contact Precision Conversions Customer Support if the Boeing
SRM revision used differs from the above noted revision.
INTRODUCTION
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1. General (Cont’d)
INTRODUCTION
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2) Manual Arrangement and Numbering System
No change to this section. See original Boeing Structural Repair Manual.
3) How to Use This Manual
4) How to Use This Manual for Spare Parts Identification
5) Airplane Effectivity Designations
6) Publication Change Request
7) Service Bulletin
8) Revision Service
9) Standard Tools
10) Significant Rework Log
A. No change to this section. See original Boeing Structural Repair Manual.
B. If it is necessary to obtain rework data, please contact:
Precision Conversions, LLC

4900 SW Griffith Drive, Suite 133
Beaverton, Oregon 97005
USA
INTRODUCTION
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LIST OF CHAPTERS
SUBJECT CHAPTER
STRUCTURES ................................................................................................................................. 51
DOORS ............................................................................................................................................ 52
FUSELAGE ...................................................................................................................................... 53
NACELLES/PYLONS ....................................................................................................................... 54
STABILIZERS .................................................................................................................................. 55
WINDOWS ....................................................................................................................................... 56
WINGS ............................................................................................................................................ 57
CONTENTS
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CHAPTER 51
STRUCTURES
TABLE OF CONTENTS
SUBJECT CHAPTER SECTION
STRUCTURE .............................................................................................................................. 51-00-00

STRUCTURAL CLASSIFICATION ....................................................................................... 51-00-04
Figure 1 – Structural Classification Diagram
Figure 2 – Principal Structural Elements of PCF STC
Figure 3 – OEM Principal Structural Elements (PSEs) Affected By PCF STC
ALLOWABLE DAMAGE REMOVAL – TYPICAL ................................................................. 51-10-00
Typical Blending ............................................................................................................. 51-10-02
Figure 101 – Allowable Blending
REPAIRS – TYPICAL ........................................................................................................... 51-70-00
Typical Formed Section Repair ...................................................................................... 51-70-11
Typical Extruded Section Repair .................................................................................... 51-70-12
Typical Web Repair ........................................................................................................ 51-70-13
51-CONTENTS
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CHAPTER 51 STRUCTURES
1. General
A. All information contained in the Boeing 757-200 SRM, D634N201, Chapter 51, is applicable to
aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification,
except for any limitations listed in this chapter.
1. STC Structure: No structural reinforcing repairs are applicable to the STC related structure.
This includes but is not limited to repairs noted in the Boeing 757-200 SRM, D634N201,
Chapters 51-70-11, 51-70-12 and 51-70-13.
2. OEM Structure: No repairs are allowed on OEM PSE Structure as detailed in Section 51-
00-04 Figure 3 of this SRM supplement. If damage is common to the noted OEM PSE,
communicate with Precision Conversions Customer Support for assistance.
Note:
It is recommended that any damage exceeding the requirements of the Boeing 757-200 SRM D634N201
or this SRM supplement, on any fuselage structure, be communicated to Precision Conversions
customer service for further review prior to next flight.
51-00-00
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STRUCTURAL CLASSIFICATION
Section 51-00-04
Note: Figure 1 displays a diagram of the areas with new or modified structure due to the passenger to
freighter conversion. Figure 2 provides a list of principal structure elements (PSE) specified by the
Maintenance Planning Data Document (MPD) supplement, PC-0118-05. Figure 3 provides a list of OEM
PSE affected by the passenger to freighter conversion.
Structural Classification Diagram

Figure 1 (Sheet 1)
Section 51-00-04 Structural Classification
51-00-04
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PC SRM
TITLE LOCATION REFERENCE
SECTION
Outer Skin, Crew Entry Door BS 302 to 333, Upper Sill to Lower Sill 52-10-01 007F8348
Crew Entry Door BS 302 to 333, Upper Sill to Lower Sill 52-10-02 007F8349
Outer Skin, Cargo Door BS 480 to 620, S-4L to 17L 52-30-01 007F3125
Inner Skin, Cargo Door BS 480 to 620, S-4L to 17L 52-30-01 007F3105
Intercostals, Cargo Door BS 480 to 620, I-1 to I-9 52-30-02 007F3140
007F3102
Frames, Cargo Door BS 480 to 620, S-4L to 17L 52-30-02
007F3128
Frames, Lower Cargo Door BS 490 to 610, I-7 to S-17L 52-30-02 007F3126
Upper Sill, Cargo Door BS 480 to 620, S-4L 52-30-02 007F3129
Lower Sill, Cargo Door BS 480 to 620, S-17L 52-30-02 007F3130
Latch BS 490 to 610, S-17L 52-30-02 007F3413
BS 489 to 500, S-4L to 6L
Door Support Fittings 52-30-02 007F3123
BS 600 to 611, S-4L to 6L
Skin, Door L1 BS 297 to 378, S-4L to S-20L 53-10-01 007F8061
Skin, Door R1 BS 324 to 365, Upper Sill to Lower Sill 53-10-01 007F8022
OEM Skin – Strap, Upper Attachment BS 340 to 375, LBL and RBL 45, 30, 12 53-10-01 OEM Part
Stringer, Door R1 BS 324 to 365, DS-1R to DS-7R 53-10-03 007F8152
Fitting, Stringer - Door R1 BS 324 and 365, DS-1R to DS-7R 53-10-03 007F8153
Stringer, Door L1 BS 333 to 376, DS-1L to DS-6L 53-10-03 007F8068
Fitting, Stringer - Door L1 BS 376, DS-1L to DS-6L 53-10-03 007F8069
007F8356
Aft Intercostal, Crew Entry Door BS 333 to 345, S-8L to 16L 53-10-15
007F8380
Fwd Intercostal, Crew Entry Door BS 297 to 333, DS-1L to DS-6L 53-10-15 007F8359
Frame, Station 345 - Door R1 BS 345, S-6L to 17L 53-10-03 007F8151
Splice, Lower Frame - Station 345 Door R1 BS 345, S-17R 53-10-07 007F8151
Frame, Station 345 - Door L1 BS 345, S-6L to 17L 53-10-07 007F8066
Splice, Lower Frame - Station 345 Door L1 BS 345, S-17L 53-10-07 007F8066
Frame, Station 365 - Door L1 BS 365, S-6L to 17L 53-10-07 007F8067
Splice, Lower Frame - Station 365 Door L1 BS 365, S-17L 53-10-07 007F8067
Frame, Station 302 BS 302, S-6L to 17L 53-10-15 007F8017
Frame, Station 333 BS 333, S-6L to 17L 53-10-15 007F8365
Lower Sill - Crew Entry Door BS 302 to 333, S-16L 53-10-15 007F8364
Upper Sill - Crew Entry Door BS 302 to 333, S-8L 53-10-15 007F8016
Splice, Upper Frame - Station 333 BS 333, Upper Sill 53-10-15 007F8366
Splice, Lower Frame - Station 333 BS 333, Lower Sill 53-10-15 007F8366
Principal Structural Elements of PCF STC

Figure 2 (Sheet 1)
51-00-04
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PC SRM
TITLE LOCATION REFERENCE
SECTION
007F2208
Outer Skin BS 440-660, S-4R to 26L 53-30-01 007F2309
007F2405
Longitudinal Splice, Outer Skin BS 440 and 660, S-4R to 26L 53-30-01 See Outer Skin
Circumferential Splice, Outer Skin BS 440 to 660, S-4R, 6L, 14L, 19L, 26L 53-30-01 See Outer Skin
Inner Skin BS 460 to 640, S-3L to 4L 53-30-15 007F2204
Stringers BS 440 to 660, S-3R to 24L 53-30-03 007F2503
Splice, Stringers BS 440 and 660, S-3R to 24L 53-30-03 007F2216
Intercostal, Upper Sill BS 460 to 640, S-3L 53-30-15 007F2211
Intercostal, Lower Sill BS 480 to 500, S-20L 53-30-15 007F2313
Frame, Jamb - Fore/Aft (BS 480 and 620) BS 480 and 620, S-4L to 17L 53-30-15 007F2406
Frame, Jamb - Fore/Aft (BS 460 and 640) BS 460 and 640, S-4L to 17L 53-30-15 007F2404
007F2404
Fitting, Fore/Aft Jambs BS 460, 480, 620, 640, S-4L and 17L 53-30-15
007F2406
Frames, Lower Sill BS 460 to 640, S-17L to 25L 53-30-07 007F2302
Inner Flange, Frame - Lower Sill BS 480 to 580, S-20L to 22L 53-30-07 007F2302
Splice, Frames - Lower Sill BS 460 to 640, S-25L 53-30-07 OEM Part
Frames, Upper Sill BS 460 to 640, S-2R to 2L 53-30-07 007F2202
Splice, Frames - Upper Sill BS 460 to 640, S-3R 53-30-07 007F2206
Beam, Lower Sill BS 440 to 660, S-17L 53-30-15 007F2317
Beam, Upper Sill BS 440 to 660, S-4L 53-30-15 007F2205
Hinge BS 480 to 620, S-4L 53-30-15 007F2905
Fitting Splice, Upper Sill BS 440 and 660, S-4L 53-30-15 007F2408
Latch Fitting BS 490 to 610, Lower Sill 53-30-15 007F2308
Floor Beam Splice BS 460 to 640, S-17L 53-30-15 007F2312
Frame middle Splice BS1661 53-60-07 007F6085
Skin, Door 4 BS 1640 to 1682, Upper Sill to Lower Sill 53-60-01 007F8092
Stringer, Door 4 BS 1640 to 1682, DS-1 to DS-6 53-60-03 007F8086
Fitting, Stringer - Door 4 BS 1640 to 1682, DS-1 to DS-6 53-60-07 007F8087
Frame, Station 1620 BS 1620, S-17 53-60-07 007F8093
Frame, Station 1640 BS 1640, S-16 to 19 53-60-07 007F8094
Frame, Station 1661 BS 1661, S-6 to 17 53-60-07 007F8085
Splice, Upper Frame - Station 1661 BS 1661, S-6 53-60-07 007F8100
Splice, Lower Frame - Station 1661 BS 1661, S-17 53-60-07 007F8099
Principal Structural Elements of PCF STC

Figure 2 (Sheet 2)
51-00-04
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TITLE PC MPD ITEM
No. 1 Cargo Door Cutout, PC-53-30-11

BS 560 Edge Frame – Inner Chord, Upper Sill to S-24 Line No. 1-57

BS 560 Edge Frame – Inner Chord, Upper Sill to S-24 Line No. 58 and on
No. 1 Cargo Door Cutout, Edge Frame – Outer Chord, PC-53-30-11

BS 560 Upper Sill to Lower Sill Line No. 1-57
No. 1 Cargo Door Cutout, Edge Frame – Outer Chord, PC-53-30-11

BS 560 Upper Sill to Lower Sill Line No. 58 and on

BS 620 Edge Frame – Inner Chord, S-20 to Lower Sill Line No. 1-57

BS 620 Edge Frame – Inner Chord, S-20 to Lower Sill Line No. 58 and on
No. 1 Cargo Door Cutout, Edge Frame – Inner Chord, PC-53-30-11

BS 620 – Upper Sill to Lower Sill Line No. 1-57
No. 1 Cargo Door Cutout, Edge Frame – Inner Chord, PC-53-30-11

BS 620 – Upper Sill to Lower Sill Line No. 58 and on
No. 1 Cargo Door Cutout,

PC-53-30-12
Door Stop Intercostals, Door Stop No. 1 & 6 (Forward & Aft)
BS1040 Rear Spar Bulkhead, Lower Side Fitting, Inboard Leg at WL 187.70,
PC-53-40-20
(Left & Right)
Rear Spar Bulkhead, Inner Chord, BS1040 S14 –S17, (Left & Right) PC-53-40-20
Overwing Stub Frames, Inner Chord, BS 1000 & 1020,

PC-53-40-25
WL 208.1, Left & Right, Area Hidden by Crease Beam Clip
OEM Principal Structural Elements (PSEs) Affected By PCF STC

Figure 3 (Sheet 1)
51-00-04
200PCF Page 4
Nov 2014
B757-200PCF
PC-0118-11
ALLOWABLE DAMAGE REMOVAL – TYPICAL

Section 51-10-00
1. All information contained in the Boeing 757-200 SRM, Chapter 51-10, is applicable to aircraft
modified in accordance with Precision Conversions 757-200PCF freighter modification.
51-10-00
200PCF Page 1
Apr 2017
B757-200PCF
PC-0118-11
ALLOWABLE DAMAGE REMOVAL – TYPICAL

Section 51-10-02
TYPICAL BLENDING
NOTES:
• Length of Cleanout Boundary (L) is not to exceed 6 inches total length.
• The edge of the blend out should not be within 2 x dia of a fastener location.
• “D” is as noted in the appropriate chapter.
• No other damage or blend out is permitted in the same cross section as the free flange trim out
noted in DETAIL C.
• Perform blend out as given in procedures in Boeing 757-200 SRM 51-10-02.
• Finish blended area per Boeing 757-200 SRM 51-20.
• After blend out is complete per above details, ensure surface is smooth with a 63 RA surface
finish or better and perform a 10X close visual inspection to ensure all damage has been
removed per Boeing 757-200 NDT Manual Part 10.
• Perform an HFEC inspection on the blended surface per 757-200 NDT manual Part 6 to ensure
no crack indications exist.
• The inspections given in the Precision Conversions Maintenance Planning Data Document (MPD)
supplement are sufficient to maintain the Damage Tolerance of the structure with this allowable
damage. See specific chapters for inspections on blended areas beyond MPD requirements.
• No Damage is permitted within 1.0 in. from any lap edge.
Allowable Blending
Figure 101 (Sheet 1)
51-10-02
200PCF Page 101
Nov 2014
B757-200PCF
PC-0118-11
REPAIRS - TYPICAL
Section 51-70-00
1. All information contained in the Boeing 757-200 SRM, Chapter 51-70, is applicable to aircraft
51-70-00
200PCF Page 1
Apr 2017
B757-200PCF
PC-0118-11
REPAIRS – TYPICAL
Section 51-70-11
1. Typical Formed Section Repair
A. The typical formed section repair defined in Boeing 757 SRM, D634N201, 51-70-11, Figure 1 is
applicable to aircraft modified by the passenger to freighter modification, except for the following:
1) STC Structure: This repair is not effective on any Precision Conversions STC structure. If
damage is common to the noted structure, communicate with Precision Conversions
Customer Support for assistance.
2) OEM Structure: Refer to Section 51-00-04, Figure 3 to determine if this repair is common to
an OEM affected PSE. If the repair does affect a PSE item, contact Precision Conversions
for further review.
Note:
It is recommended that any damage or repair exceeding the requirements of the Boeing 757-200 SRM
D634N201 or this SRM supplement, on any affected structure within the pressurized fuselage, be
communicated to Precision Conversions Customer Support for further review prior to next flight.
51-70-11
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11
REPAIRS – TYPICAL
Section 51-70-12
1. Typical Extruded Section Repair
A. The typical extruded section repairs defined in Boeing 757 SRM, D634N201, 51-70-12, Figure 1
and 2 are applicable to aircraft modified by the passenger to freighter modification, except for the
following:
for further review.
Note:
51-70-12
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11
REPAIRS – TYPICAL
Section 51-70-13
1. Typical Web Repair
A. The typical web repair defined in Boeing 757 SRM, D634N201, 51-70-13, Figure 1 is applicable
to aircraft modified by the passenger to freighter modification, except for the following:
for further review.
Note:
51-70-13
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11
CHAPTER 52
DOORS
TABLE OF CONTENTS
DOORS ....................................................................................................................................... 52-00-00

PASSENGER/CREW ENTRY DOOR
PASSENGER/CREW ENTRY DOOR SKIN ......................................................................... 52-10-01
Figure 1 – Crew Entry Door Skin Identification
Figure 2 – R1 Door Skin Plug Identification
Figure 3 – L4/R4 Door Skin Plug Identification
PASSENGER CREW ENTRY DOOR STRUCTURE ........................................................... 52-10-02
Figure 1 – Crew Entry Door Structure Identification
REPAIRS - Passenger/Crew Entry Door Structure
PASSENGER/CREW ENTRY DOOR .................................................................................. 52-10-03
ALLOWABLE DAMAGE – Passenger Crew Entry Door
REPAIRS - Passenger/Crew Entry Door
Figure 201 Repair – Crew Entry Door
MAIN CARGO DOOR
MAIN CARGO DOOR SKIN ................................................................................................. 52-30-01
Figure 1 – Main Cargo Door Skin Identification
MAIN CARGO DOOR STRUCTURE ................................................................................... 52-30-02
Figure 1 – Main Cargo Door Structure Identification
ALLOWABLE DAMAGE - Main Cargo Door Structure .................................................. 52-30-03
REPAIRS - Main Cargo Door Structure
52-CONTENTS
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11
CHAPTER 52 DOORS
1. All information contained in the Boeing 757-200 SRM, Chapter 52, is applicable to aircraft modified in
accordance with Precision Conversions 757-200PCF freighter modification, except as follows:
A. OEM Structure:
1) No damage is allowed on OEM PSE Structure as detailed in Section 51-00-04 Figure 3 of this
supplement SRM. If damage is common to the noted OEM PSE, communicate with Precision
Conversions Customer Support for assistance.
B. Skins at Deleted Door 1 R – L Hand and Door 4 R – L Hand Locations:
1) Refer to Section 53-00-01 for identification, allowable damage and repair instructions.
C. Stringers at Deleted Door 1 R – L Hand and Door 4 R – L Hand Locations:
D. Frames at Deleted Door 1 R – L Hand and Door 4 R – L Hand Locations:
Note:
52-00-00
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11
PASSENGER/CREW ENTRY DOOR SKIN

Section 52-10-01
DETAIL I
ITEM DESCRIPTION GAGE MATERIAL EFFECTIVITY
1 OUTER SKIN 0.063 CLAD 2024-T3 All
Crew Entry Door Skin Identification

Figure 1 (Sheet 1)
52-10-01
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11
DOOR SKIN
SEE DETAIL I
IN SECTION 53-10-01
R1 Door Skin Plug Identification

Figure 2 (Sheet 1)
52-10-01
200PCF Page 2
Nov 2014
B757-200PCF
PC-0118-11
DOOR SKIN
SEE DETAIL I
IN SECTION
53-60-01
L4/R4 Door Skin Plug Identification

Figure 3 (Sheet 1)
52-10-01
200PCF Page 3
Nov 2014
B757-200PCF
PC-0118-11
PASSENGER/CREW ENTRY DOOR STRUCTURE

Section 52-10-02
Crew Entry Door Structure Identification

Figure 1 (Sheet 1)
52-10-02
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11
PASSENGER/CREW ENTRY DOOR STRUCTURE

1 DOOR FRAME FITTING 7050-T7451 PLATE All
2 FITTING, DOOR STOP, AFT 7050-T7451 PLATE All
3 FITTING, DOOR STOP, FWD 7050-T7451 PLATE All
4 FITTING, SWING 7050-T7451 PLATE All
5 FITTING 7050-T7451 PLATE All
Crew Entry Door Structure Identification

Figure 1 (Sheet 2)
52-10-02
200PCF Page 2
Nov 2014
B757-200PCF
PC-0118-11
REPAIRS - PASSENGER/CREW ENTRY DOOR STRUCTURE

Section 52-10-02
1. All information contained in the Boeing 757-200 SRM, Chapter 52-10-02, is applicable to aircraft
modified in accordance with Precision Conversions 757-200PCF freighter modification, except as
follows:
A. Repair 1-FORWARD FRAME OF THE NUMBER 2 LEFT AND RIGHT SIDE PASSENGER
DOORS does not apply to airplanes modified by the Precision Conversions STC.
52-10-02
200PCF Page 201
Nov 2014
B757-200PCF
PC-0118-11
ALLOWABLE DAMAGE - PASSENGER/CREW ENTRY DOOR

Section 52-10-03
1. Allowable damage defined in the Boeing 757-200 SRM D634N201, Section 52-10-01, Figure 101 is
applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter
modification except the following limitations:
A. Crew Entry Door Skin:
1) 10% blend out is permitted on the crew entry door skin. Ensure that damage does not exist
common to attach fasteners. See Section 51-10-02 Figure 101 for blending details.
B. Crew Entry Door Structure:
1) 10% blend out is permitted on the crew entry door structure. Ensure that damage does not
exist common to attach fasteners. See Section 51-10-02 Figure 101 for blending details.
2) No damage is permitted on fittings or mechanism common to the crew entry door.
.
Note:
52-10-03
200PCF Page 101
Nov 2014
B757-200PCF
PC-0118-11
REPAIRS - PASSENGER/CREW ENTRY DOOR

Section 52-10-03
1. Repairs defined in the Boeing 757-200 SRM, D634N201, Section 52-10-01, Repair 1 is applicable to
aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification with
the following limitations:
A. Crew Entry Door Skin:
1) The crew entry door as shown in Detail 1 of this section is limited to Repair 1 of the Boeing
757-200 SRM, D634N201, Section 52-10-01. This repair is an interim Category B repair, with
repeat inspections as detailed in Table 201, Page 202. See Detail 1 below for Stay Out
Zone. Repairs in this Zone are not permitted.
2) Any other damage related to the crew entry door skin must be communicated to Precision
B. Crew Entry Door Structure:
1) No other repairs detailed in the Boeing 757-200 SRM, D634N201, Section 52-10 are effective
for the crew entry door STC structure.
Detail 1
Repair – Crew Entry Door
52-10-03
200PCF Page 201
Nov 2014
B757-200PCF
PC-0118-11
ZONE A – CATEGORY B REPAIR INSPECTION REQUIREMENTS

INSPECTION THRESHOLD METHOD INTERVAL REFERENCE
NDT Part 6
20,000 Flight cycles External High Frequency Eddy 6,500 flight 51-00-01
(Note 1) Current (HFEC) cycles Or
51-00-19
Table 201
Note:
1. The Inspection threshold of this repair is limited to 20,000 total flight cycles from the time of
freighter modification.
2. If this repair deviates from SRM requirements, a Damage Tolerance Evaluation (DTE) is required
within 12 months of its initial installation.
Note:
52-10-03
200PCF Page 202
Nov 2014
B757-200PCF
PC-0118-11
MAIN CARGO DOOR SKIN

Section 52-30-01
Main Cargo Door Skin Identification

Figure 1 (Sheet 1)
52-30-01
200PCF Page 1
June 2009
B757-200PCF
PC-0118-11

1 SKIN 0.080 CLAD 2024-T3 All

Figure 1 (Sheet 2)
52-30-01
200PCF Page 2
June 2009
B757-200PCF
PC-0118-11


Figure 1 (Sheet 3)
52-30-01
200PCF Page 3
June 2009
B757-200PCF
PC-0118-11
MAIN CARGO DOOR STRUCTURE

Section 52-30-02
Main Cargo Door Structure Identification

Figure 1 (Sheet 1)
52-30-02
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11
MAIN CARGO DOOR STRUCTURE

1 FRAME 0.090 CLAD 2024-T42 All
2 SUPPORT ASSEMBLY All
SUPPORT 7050-T7451 AMS4050 All
3 FRAME, LOWER 7050-T7451 AMS4050 All
4 FRAME, SIDE 0.090 CLAD 2024-T42 All
5 BEAM, UPPER 0.090 CLAD 2024-T42 All
6 BEAM, LOWER 0.090 CLAD 2024-T42 All
7 SUPPORT, CORNER UPPER 0.090 6061-T6 All
8 SUPPORT, CORNER LOWER 0.090 6061-T6 All
9 FRAME, STUB 0.090 CLAD 2024-T42 All
10 INTERCOSTAL ASSEMBLY All
INTERCOSTAL 0.050 CLAD 2024-T42 All
11 INTERCOSTAL ASSEMBLY All
INTERCOSTAL 0.071 CLAD 2024-T42 All
12 DOUBLER, VENT DOOR 7050-T7451 PLATE All
Main Cargo Door Structure Identification
Figure 1 (Sheet 2)
52-30-02
200PCF Page 2
Nov 2014
B757-200PCF
PC-0118-11
ALLOWABLE DAMAGE - MAIN CARGO DOOR STRUCTURE

Section 52-30-03
1. Allowable Damage 1 defined in the Boeing 757-200 SRM, D634N201, Section 52-30-01, Figure 101
is applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter
modification except for the following limitations:
A. Main Cargo Door Inner and Outer Skins:
1) 10% blend out is permitted on the main cargo door inner and outer skins. See Section 51-10-
02 Figure 101 for blending details.
B. Main Cargo Door Structure:
1) 10% blend out is permitted on the main cargo door general structure. See Section 51-10-02
Figure 101 for blending details, except for the following areas:
a) All fittings and machined parts common to door assembly.
b) No blending is permitted on the upper beam (Item 5 in Detail 1) of the main cargo door.
Note:
52-30-03
200PCF Page 101
Nov 2014
B757-200PCF
PC-0118-11
REPAIRS - MAIN CARGO DOOR STRUCTURE

Section 52-30-03
1. Repairs defined in the Boeing 757-200 SRM D634N201, 52-30-01, Figure 201 are applicable to
aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification with
the following limitations:
A. Main Cargo Door Inner Skin:
1) The main cargo door inner skin as shown in Detail II of section 52-30 is limited to Repair 2 of
the Boeing 757-200 SRM, D634N201, Section 52-30-01. This repair is a Category A repair
Inspections listed in the Precision Conversions MPD supplement are sufficient to maintain the
damage tolerance capability of the initial structure.
2) Any other damage related to the main cargo door inner skin must be communicated to
Precision Conversions Customer Support for assistance.
B. Main Cargo Door Structure:
1) No repairs, other than noted above detailed in the Boeing 757-200 SRM, D634N201, Section
52-30 are effective on the main cargo door STC structure.
Note:
52-30-03
200PCF Page 201
Nov 2014
B757-200PCF
PC-0118-11
CHAPTER 53
FUSELAGE
TABLE OF CONTENTS
FUSELAGE ................................................................................................................................. 53-00-00
FUSELAGE SKIN ................................................................................................................. 53-00-01
ALLOWABLE DAMAGE - Fuselage Skin
REPAIRS - Fuselage Skin
FUSELAGE STRINGERS .................................................................................................... 53-00-03
ALLOWABLE DAMAGE - Fuselage Stringers
REPAIRS - Fuselage Stringers
FUSELAGE INTERCOSTALS .............................................................................................. 53-00-04
ALLOWABLE DAMAGE - Fuselage Intercostals
REPAIRS - Fuselage Intercostals
FUSELAGE FRAMES .......................................................................................................... 53-00-07
ALLOWABLE DAMAGE - Fuselage Frames
REPAIRS - Fuselage Frames
FUSELAGE BEAMS………………………………………………………………………………53-00-13
REPAIRS – Fuselage Beams
FUSELAGE FLOOR STRUCTURE ...................................................................................... 53-00-51
ALLOWABLE DAMAGE - Fuselage Floor Structure
REPAIRS - Fuselage Floor Structure
FUSELAGE SEAT TRACKS ................................................................................................ 53-00-52
ALLOWABLE DAMAGE - Fuselage Seat Tracks
REPAIRS - Fuselage Seat Tracks
FUSELAGE SKIN – SECTION 41
FUSELAGE SKIN – SECTION 41 ........................................................................................ 53-10-01
Figure 1 – Section 41 Skin Identification
Figure 2 – R1 Door Skin Plug Identification
Figure 3 – Rain Gutter Identification
FUSELAGE STRINGER – SECTION 41 .............................................................................. 53-10-03
Figure 1 – Section 41 Stringer Identification
Figure 2 – R1 Door Skin Plug Stringer Identification
FUSELAGE FRAMES – SECTION 41 ................................................................................. 53-10-07
Figure 1 – Section 41 Frame Identification
Figure 2 – R1 Door Plug Frame Identification
BULKHEADS – SECTION 41 ............................................................................................... 53-10-08
Figure 1 – Section 41 Bulkhead Identification
ALLOWABLE DAMAGE - Bulkhead Section 41
REPAIRS - Bulkhead Section 41
CREASE BEAM AND 9G SHEAR FLOOR – SECTION 41 ................................................. 53-10-13
Figure 1 – Section 41: Crease Beam and 9G Shear Floor
ALLOWABLE DAMAGE - Crease Beam and 9g Shear Floor
53-CONTENTS
200PCF Page 1
Dec 2015
B757-200PCF
PC-0118-11
CHAPTER 53
FUSELAGE
TABLE OF CONTENTS
CREASE BEAM AND 9G SHEAR FLOOR – SECTION 41 (cont’d) .................................... 53-10-13
REPAIRS - Crease Beam and 9g Shear Floor
DOOR SURROUND STRUCTURE – SECTION 41 ................................................................... 53-10-15

Figure 1 – Section 41 Door Surround Structure Identification
ALLOWABLE DAMAGE - Door Surround Structure
SEAT TRACKS – SECTION 41 .................................................................................................. 53-10-52
Figure 1 – Section 41 Seat Track Identification

Figure 1 – Section 43 Skin Identification
Figure 2 – Section 43 Rain Gutter Identification
REPAIRS - Section 43 Fuselage Skin
FUSELAGE STRINGERS – SECTION 43 ........................................................................... 53-30-03
Figure 1 – Section 43 Stringer Identification
FUSELAGE INTERCOSTALS – SECTION 43 ..................................................................... 53-30-04
Figure 1 – Section 43 Intercostal Identification
Figure 1 – Section 43 Frame Identification
DOOR SURROUND STRUCTURE – SECTION 43............................................................. 53-30-15
Figure 1 – Section 43 Door Surround Structure Identification
ALLOWABLE DAMAGE - Door Surround Structure
SEAT TRACKS - SECTION 43 ............................................................................................ 53-30-52
FUSELAGE – SECTION 44
SEAT TRACKS – SECTION 44............................................................................................ 53-40-52
Figure 1 – L4/R4 Door Skin Plug Identification
FUSELAGE STRINGER – SECTION 46 .............................................................................. 53-60-03
Figure 1 – L4/R4 Door Skin Plug Stringer Identification
Figure 1 – L4/R4 Door Skin Plug Frame Identification
FLOOR STRUCTURE – SECTION 46…………………………………………………………..53-60-51
REPAIRS – Floor Structure
SEAT TRACKS – SECTION 46............................................................................................ 53-60-52
53-CONTENTS
200PCF Page 2
Dec 2015
B757-200PCF
PC-0118-11
CHAPTER 53 FUSELAGE
1. All information contained in the Boeing 757-200 SRM, D634N201, Chapter 53, is applicable to aircraft
modified in accordance with Precision Conversions 757-200PCF freighter modification, except as
noted in this chapter.
A. No damage is permitted on OEM PSE Structure as detailed in Section 51-00-04 Figure 3 of this
SRM supplement. If damage is common to the noted OEM PSE structure, contact Precision
53-00-00
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11
ALLOWABLE DAMAGE - FUSELAGE SKIN

Section 53-00-01
1. Allowable damage defined in the Boeing 757-200 SRM D634N201, 53-00-01, Figure 101 is
modification except for the following limitations:
A. STC Fuselage Outer Skin:

The following allowable damage criteria is based on blending that meets requirements detailed in
Section 51-10-02 Figure 101 of this SRM supplement only.
1) ONLY up to 8% blend out is permitted on the 0.190 in. thick skin around the main cargo door
between BS610 and BS630 and between Stringers 3L and 4L.
2) Blend out is NOT permitted on the chem-milled 0.056 in. thick skin around the main cargo
door. The 0.056 in. thick skin is located from BS450 to BS650 between Stringers 2R and 4R
(upper lobe) and between Stringers 22L and 26L (lower lobe).
3) In all other areas, the allowable damage blend out is limited to 10% of the nominal thickness
of the STC skin. See Section 51-10-02 Figure 101 for blending details. Note that this is
categorized as Chart Area A in Figure 101 of the OEM Allowable Damage 2 in Section 53-00-
01.
4) Contact Precision Conversions Customer Support for any damage exceeding the above
requirements.
B. STC Fuselage Rain Gutter:
1) 10% blend out is permitted on the rain gutter. Ensure that damage does not exist common to
attach fasteners. See Section 51-10-02 Figure 101 for blending details.
C. OEM Structure:
1) No Damage is permitted common to lap joints S-4R and 26L
2) No damage is permitted common to butt joints, at skins and straps locations common to
BS440 and BS660 from Stringer 4R to 26L.
53-00-01
200PCF Page 101
Nov 2014
B757-200PCF
PC-0118-11
REPAIRS - FUSELAGE SKIN

Section 53-00-01
Fuselage skin repairs defined in the Boeing 757-200 SRM D634N201, 53-00-01 are applicable to aircraft
modified in accordance with Precision Conversions 757-200PCF freighter modification with the following
exceptions:
1. Fuselage Skin Repair and Inspections
A. STC Fuselage Outer Skin Main Cargo Door Surround (Section 43):
1) The main cargo door surround skins are limited to Repairs 1, 2, 3, 5, and 7, Zones A and B of
the Boeing 757-200 SRM, D634N201, Section 53-00-01. These repairs are determined to be
Category B repairs with inspections as listed in Table 101 below. In addition to the
requirements listed in the Boeing SRM, ensure to maintain a minimum distance of 10 in.
between the edge of the repair and the edge of a lap or butt joint.
2) No repairs are applicable to the crown section of the main cargo door surround skin between
BS 600 and BS 660 from Stringer 6R to 6L, identified as Zone C in the Boeing 757-200 SRM,
D634N201, Section 53-00-01 Repair General, Figure 202. If damage exceeds allowable
damage noted in Chapter 51-10-02 Figure 101, Page 101 of this SRM supplement, contact
Precision Conversions Customer Support for further review.
B. STC Fuselage R1, R4 and L4 Door Plug Skins:
1) The door plug skins are limited to Repairs 2, 3, 4, 5, and 7, Zone A, detailed in the Boeing
757-200 SRM, D634N201, Section 53-00-01 These repairs are determined to be Category B
repairs with inspections as listed in Table 101 below.
ZONE A - CATEGORY B REPAIR INSPECTION REQUIREMENTS

INSPECTION
METHOD INTERVAL REFERENCE
THRESHOLD
NDT Part 6
15,000 Flight Cycles High Frequency Eddy Current 3,000 Flight 51-00-01
Note 1 (HFEC) Cycles or
51-00-19
ZONE B – CATEGORY B REPAIR INSPECTION REQUIREMENTS

INSPECTION
METHOD INTERVAL REFERENCE
THRESHOLD
NDT Part 6
15,000 Flight cycles High Frequency Eddy Current 2,500 Flight 51-00-01
Note 1 (HFEC) Cycles or
51-00-19
Table 101
Note:
1. If this repair deviates from the SRM requirements, a Damage Tolerance Evaluation (DTE) is
required within 12 months of its initial installation.
Note:
53-00-01
200PCF Page 201
Nov 2014
B757-200PCF
PC-0118-11
ALLOWABLE DAMAGE - FUSELAGE STRINGERS

Section 53-00-03
modification except the following limitations detailed in this section:
A. Fuselage Stringers
1) Damage is NOT permitted on the STC stringers from BS 640 to 660 from Stringer 3R to 3L.
and stringers related to the R1, L4 and R4 door plugs.
2) All other STC stringers are limited to a maximum of 10% blend out from the nominal
thickness. See Section 51-10-02, Figure 101 of this SRM supplement for allowable damage
details.
L4 and R4 Door Plug

Stringers. SRM 53-60-03
Main Cargo Door

Surround Structure
Stringers.
SRM 53-30-03
R1 Door Plug
Stringers.
SRM 53-10-03
Crew entry Door

Surround Structure
Stringers.
SRM 53-10-03
Allowable Damage – Fuselage Stringers

53-00-03
200PCF Page 101
Nov 2014
B757-200PCF
PC-0118-11
REPAIRS - FUSELAGE STRINGERS

Section 53-00-03
1. Fuselage stringer repairs defined in the Boeing 757-200 SRM, D634N201, Section 53-00-03 are
modification with the following exceptions:
A. STC Fuselage Stringers common to Main Cargo Door Surround Structure:
1) The stringers common to the main cargo door surround structure are limited to Repair 1 for
Item 1, type 1 stringers, as detailed in the Boeing 757-200 SRM, D634N201, Section 53-00-
03. This repair is determined to be a Category B repair with inspections as listed in Table 1.
2) The stringers common to the main cargo door surround structure are limited to repairs as
previously detailed to only 1 repair in the upper lobe and 1 repair in the lower lobe. Contact
Precision Conversions Customer Support for any damage exceeding the above requirements.
B. STC Fuselage Crew Entry Door Surround Structure, R1, L1, R4 and L4 Door Plug Stringers:
1) The door plug stringers and related structure at Doors R1, L1, R4, L4 and the CED surround
structure have no applicable repairs detailed in the Boeing 757-200 SRM. Contact Precision
Conversions Customer Support for any damage exceeding the allowable damage requirements
detailed in Figure 101.
53-00-03
200PCF Page 201
Nov 2014
B757-200PCF
PC-0118-11
STRINGER REPAIR INSPECTION REQUIREMENTS

INSPECTION
ITEM METHOD INTERVAL REFERENCE
THRESHOLD
NDT Part 6
Internal High Frequency Eddy 4,500 flight 51-00-01
1 10,000 Flight cycles
Current (HFEC) on stringer cycles or
51-00-19
Internal or External NDT Part 6
2,400 flight
2 9,500 Flight cycles Low Frequency Eddy Current 51-00-07
cycles
(LFEC) on stringer. 51-00-08
Table 1
Notes:
1) HFEC to be performed around fasteners and along flanges of the stringer common to the
stringer splice.
2) LFEC to be performed around fasteners on the stringer where concealed by splice and skin
(hatched area).
3) Inspections are not interchangeable and both inspections must be performed.
4) If this repair is installed on non-applicable structure, a Damage Tolerance Evaluation (DTE) is
required within 12 months of its initial installation.
Repair – Fuselage Stringers

Note:
53-00-03
200PCF Page 202
Nov 2014
B757-200PCF
PC-0118-11
ALLOWABLE DAMAGE - FUSELAGE INTERCOSTALS

Section 53-00-04
1. Allowable Damage 1 defined in the Boeing 757-200 SRM, D634N201, Section 53-00-04, Figure 101
is applicable to aircraft modified in accordance with Precision Conversions 757-200PCF freighter
modification except the following limitations detailed in this section:
A. Fuselage STC Intercostals:
1) STC Intercostals are limited to a maximum of 10% blend out from the nominal thickness
except for the following locations: See Section 51-10-02, Figure 101 of this SRM supplement
for allowable damage details.
a) No damage is allowed between BS570 and BS610 of the upper sill intercostals noted in
Section 53-30-04.
b) BL0 intercostals are addressed in Section 53-00-51.
53-00-04
200PCF Page 101
Nov 2014
B757-200PCF
PC-0118-11
REPAIRS - FUSELAGE INTERCOSTALS

Section 53-00-04
1. Fuselage intercostal repairs defined in the Boeing 757-200 SRM, D634N201, Section 53-00-04 are
A. All STC Fuselage Intercostals:
1) There is no applicable repair to STC intercostals.
Note:
53-00-04
200PCF Page 201
Nov 2014
B757-200PCF
PC-0118-11
ALLOWABLE DAMAGE - FUSELAGE FRAMES

Section 53-00-07
A. STC Structure:
1) STC Frames are limited to a maximum of 10% blend out from the nominal thickness, except
for the following listed below. See Section 51-10-02, Figure 101 of this SRM supplement for
allowable damage details.
a) Door sills and jams are not considered frames and should not be repaired under this
section.
b) No damage is permitted on frames from BS480 to BS580, between stringer 20L to 22L.
c) All STC frame splices that attach to OEM frames have no applicable repairs. Contact
d) No damage is permitted on frames at BS345, between stringer 7L to 8L.
B. OEM Structure:
1) No damage is permitted on frames common to floor beam attachments.
2) All OEM frame splices that are attached to STC frames have no applicable repairs. Contact
3) No damage is permitted on the No.1 Fwd and Aft Cargo Door frames as noted in the PSE list
affected by the PCF STC.
C. Allowable damage defined in the Boeing 757-200 SRM D634N201, 53-00-07, Figure 102 is NOT
modification.
53-00-07
200PCF Page 101
Nov 2014
B757-200PCF
PC-0118-11
ALLOWABLE DAMAGE - FUSELAGE FRAMES
L4 and R4 Door Plug

Frames. SRM 53-60-07
Main Cargo Door

Surround Structure
Frames.
SRM 53-30-07
R1 Door Plug Frame.

SRM 53-10-07
Crew entry Door

Surround Structure
Frames.
SRM 53-10-07
Allowable Damage – Fuselage Frames

53-00-07
200PCF Page 102
Nov 2014
B757-200PCF
PC-0118-11
REPAIRS - FUSELAGE FRAMES

Section 53-00-07
1. Fuselage Frame repairs defined in the Boeing 757-200 SRM, D634N201, Section 53-00-07 are
A. STC Frames:
1) All frame sections and related structure common to the cargo conversion STC have no
applicable repairs. Contact Precision Conversions Customer Support for assistance.
2) All STC frame splices that attach to OEM frames have no applicable repairs. Contact
B. OEM Frames:
1) No repair is permitted on OEM frames from BS480 to BS580, between stringer 20L to 22L.
2) No repair is permitted on OEM frames at BS345, between stringer 7L to 8L.
3) No repair is permitted on OEM frames common to floor beam attachments.
4) All OEM frame splices that are attached to STC frames have no applicable repairs. Contact
5) No repair is permitted on the No.1 Fwd and Aft Cargo Door frames as noted in the PSE list
affected by the PCF STC.
Note:
53-00-07
200PCF Page 201
Nov 2014
B757-200PCF
PC-0118-11
REPAIRS – FUSELAGE BEAMS

Section 53-00-13
1. Fuselage beams repairs defined in the Boeing 757-200 SRM, D634N201, Section 53-00-13 are
A. Fuselage beams between STA 297 and STA 460:
1) No repairs in the Boeing 757-200 SRM are applicable to the cargo conversion STC crease
beam structure between STA 297 and STA 460. It is recommended to contact Precision
Conversion Customer Support for any damage found in this area.
53-00-13
200PCF Page 101
Dec 2015
B757-200PCF
PC-0118-11
ALLOWABLE DAMAGE - FUSELAGE FLOOR STRUCTURE

Section 53-00-51
1. Allowable Damage 1 defined in the Boeing 757-200, SRM D634N201, Section 53-00-51, Figure 101 is
modification, except as follows:
A. OEM Floor Beams:
1) Section 41 – Floor Beams: Blend out is NOT permitted on the floor beam web where
cutouts exist in the web at the following locations:
BS 395 outboard of LBL 45.5 and RBL 45.5

BS 440 outboard of RBL 45.5

BS 720 outboard of LBL 45.5

BS 1320 between BL 0 and RBL 24.75
53-00-51
200PCF Page 101
Nov 2014
B757-200PCF
PC-0118-11
4) Section 41 through 46 – Blend out is NOT permitted on the floor beam webs
Floor Beams Webs: common to the frame attachment locations at the
outboard extremities of the floor beams.
B. STC Intercostals at BL0:
1) No damage is permitted to the BL0 intercostals from BS345 to BS1682. If damage is found in
this area, contact Precision Conversions Customer Support for further review.
Sec
46
Sec
44
Sec
43
Sec STC Intercostals
41 at BL0
(007F9208)
(007F9210)
OEM Floor Beams
Allowable Damage – Floor Structure

53-00-51
200PCF Page 102
Nov 2014
B757-200PCF
PC-0118-11
REPAIRS - FUSELAGE FLOOR STRUCTURE

Section 53-00-51
1. Repairs defined in the Boeing 757-200 SRM D634N201, 53-00-51, Figure 201 are applicable to aircraft
modified in accordance with Precision Conversions 757-200PCF freighter modification, except as follows.
A. OEM Floor Beam
1) Section 41 – Floor Beams: Repairs are NOT permitted to end at the following locations:



B. BL0 Intercostals
1. No repairs are applicable to the BL0 intercostals detailed in Figure 101 Sheet 1 of this
section. If damage is found in this area, Contact Precision Conversions Customer Support for
further review.
53-00-51
200PCF Page 201
Nov 2014
B757-200PCF
PC-0118-11
ALLOWABLE DAMAGE - FUSELAGE SEAT TRACKS

Section 53-00-52
1. Allowable Damage 1 defined in the Boeing 757-200 SRM, D634N201, Section 53-00-52, Figure 101 is
modification, except as follows:
A. Seat Tracks
1) All blending related to seat tracks in the cargo compartment is limited to Detail I, Detail VII, Detail IX
and Detail X, Where the “x” dimension shown in these details cannot exceed 10% blend out from
nominal thickness.
2) No blending is permitted in the flange where the seat track is attached to structure, such as the floor
beam or other sub-structure.
3) No blending is permitted within 1.0 in. from the edge of any cargo system attachment.
53-00-52
200PCF Page 101
Nov 2014
B757-200PCF
PC-0118-11
REPAIRS - FUSELAGE SEAT TRACKS

Section 53-00-52
1. Repairs defined in the Boeing 757-200 SRM, D634N201, Section 53-00-52, Figure 201 are applicable to
aircraft modified in accordance with Precision Conversions 757-200PCF freighter modification, except as
follows:
A. STC Seat Tracks
1) Repairs are NOT permitted at BL 0 and BL 62.225 locations.
Note:
53-00-52
200PCF Page 201
Nov 2014
B757-200PCF
PC-0118-11
FUSELAGE SKIN - SECTION 41

Section 53-10-01
Section 41 Skin Identification

Figure 1 (Sheet 1)
53-10-01
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11

1 SKIN 0.080 2024-T3 (CHEM-MILLED TO .080" MIN) All
2 SCUFF PLATE 0.050 CRES 17-7PH CONDITION TH1050 All

Figure 1 (Sheet 2)
53-10-01
200PCF Page 2
Nov 2014
B757-200PCF
PC-0118-11

Figure 2 (Sheet 1)
53-10-01
200PCF Page 3
Nov 2014
B757-200PCF
PC-0118-11
DOOR PLUG STRUCTURE

SEE SECTIONS 53-10-03 AND
53-10-07


Figure 2 (Sheet 2)
53-10-01
200PCF Page 4
Nov 2014
B757-200PCF
PC-0118-11
Rain Gutter Identification

Figure 3 (Sheet 1)
53-10-01
200PCF Page 5
Nov 2014
B757-200PCF
PC-0118-11

1 GUTTER, RAIN 0.032 TIERNAY 60-31545 CLAD 2024-T3 All
Rain Gutter Identification

Figure 3 (Sheet 2)
53-10-01
200PCF Page 6
Nov 2014
B757-200PCF
PC-0118-11
FUSELAGE STRINGER – SECTION 41

Section 53-10-03
Section 41 Stringer Identification

Figure 1 (Sheet 1)
53-10-03
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11
ITEM DESCRIPTION GAGE MATERIAL STRINGER TYPE REF DWG

1 STRINGER 0.070 7050-T7451 PLATE 007F8068

Figure 1 (Sheet 2)
53-10-03
200PCF Page 2
Nov 2014
B757-200PCF
PC-0118-11
(Door 1 Right Plug)

ITEM NO. P/N DESCRIPTION GAGE MATERIAL EFFECTIVITY
1 007F8153 FITTING 7050-T7451 PLATE 001 - 014, 016
2 007F8152 STRINGER 7050-T7451 PLATE 001 - 014, 016
3 007F8154 CLIP 0.063 2024-T42 001 - 014, 016
R1 Door Skin Plug Stringer Identification

Figure 2 (Sheet 1)
53-10-03
200PCF Page 3
Nov 2014
B757-200PCF
PC-0118-11
STA
345 FWD
1
Typ
2
Typ.
3
Typ.
Detail II
(Door 1 Right Plug)

1 007F8087 FITTING 7075-T6511 015, 017 And on
2 007F8086 STRINGER 0.063 2024-T42 015, 017 And on
3 007F8089 CLIP 0.063 2024-T42 015, 017 And on
R1 Door Skin Plug Stringer Identification

Figure 2 (Sheet 2)
53-10-03
200PCF Page 4
Nov 2014
B757-200PCF
PC-0118-11
FUSELAGE FRAMES – SECTION 41

Section 53-10-07
Section 41 Frame Identification

Figure 1 (Sheet 1)
53-10-07
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11
(Crew Entry)

1 007F8067 FRAME 7050-T7451 PLATE 001 – 014, 016
007F6066 FRAME 2024-T42 Al Clad 015, 017 And On
2 007F8066 FRAME 7050-T7451 PLATE 001 – 014, 016
007F6066 FRAME 2024-T42 Al Clad 015, 017 And On
3 007F8067 FRAME, SPLICE 7050-T7451 PLATE 001 – 014, 016
4 007F8066 FRAME, SPLICE 7050-T7451 PLATE 001 – 014, 016

Figure 1 (Sheet 2)
53-10-07
200PCF Page 2
Nov 2014
B757-200PCF
PC-0118-11
S17R
(Door 1 Right Plug)

1 007F8151 FRAME 7050-T7451 PLATE 001 – 014, 016
2 007F8156 CLIP 0.063 2024-T42 All
3 007F8151 FRAME, SPLICE 7050-T7451 PLATE All
R1 Door Plug Frame Identification

Figure 2 (Sheet 1)
53-10-07
200PCF Page 3
Nov 2014
B757-200PCF
PC-0118-11
FWD
STA
345
2
S17R
(Door 1 Right
` Plug)

1 007F6066 FRAME 2024-T42 015, 017 And On
2 007F8156 CLIP 0.063 2024-T42 All
3 007F8151 FRAME, SPLICE 7050-T7451 PLATE All
R1 Door Plug Frame Identification

Figure 2 (Sheet 2)
53-10-07
200PCF Page 4
Nov 2014
B757-200PCF
PC-0118-11
BULKHEADS – SECTION 41
Section 53-10-08
Section 41 Bulkhead Identification

Figure 1 (Sheet 1)
53-10-08
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11
BULKHEADS – SECTION 41
(9G Barrier)

1 PLATE, FWD, 9g BARRIER 0.071 7075-T6 All
2 PLATE, AFT, 9g BARRIER 7075-T6 PLATE All
Section 41 Bulkhead Identification

Figure 1 (Sheet 2)
53-10-08
200PCF Page 2
Nov 2014
B757-200PCF
PC-0118-11
ALLOWABLE DAMAGE - BULKHEADS SECTION 41

Section 53-10-08
modification with the following limitations:
A. Cargo Barrier:
1) Blend out is limited to 10% of nominal thickness of fwd and aft plates. See blending detail in
Section 51-10-02 Figure 101. Note that blend out is NOT permitted on the fwd faceplate and
aft faceplate at the same waterline and butt line. Blend out is ONLY permitted on the fwd or
aft faceplate at a given cross-section.
2) There is no allowable blending on any other STC structure related to the cargo barrier. Any
damage found in this area must be communicated to Precision Conversions Customer
Support for assistance.
53-10-08
200PCF Page 101
Nov 2014
B757-200PCF
PC-0118-11
REPAIRS - BULKHEADS SECTION 41

Section 53-10-08
1. Repairs defined in the Boeing 757-200 SRM, D634N201, 53-10-08, Figures 101, 201 and 202 are
A. Cargo Barrier:
1) No repairs in the Boeing 757-200 SRM are applicable to the cargo conversion STC cargo
barrier related structure. It is recommended to contact Precision Conversions Customer
Support for any damage exceeding the allowable damage requirements detailed in Figure
101, Page 101.
Note:
53-10-08
200PCF Page 201
Nov 2014
B757-200PCF
PC-0118-11
CREASE BEAM AND 9G SHEAR FLOOR – SECTION 41

Section 53-10-13
Sta
460
007F9521 (1)
Sta
297
(2) 007F9401

1 CREASE BEAM 7075-T6 PLATE All
2 9G SHEAR FLOOR 7075-T6 PLATE All
Section 41: Crease Beam and 9G Shear Floor

Figure 1 (Sheet 1)
53-10-13
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11
ALLOWABLE DAMAGE – CREASE BEAMS AND 9G SHEAR FLOOR

Section 53-10-13
A. Crease Beam:
1) There is no allowable blending on any STC structure related to the crease beams. Any
B. 9G Shear Floor:
1) There is no allowable blending on any STC structure related to the 9G shear floor. Any
53-10-13
200PCF Page 101
Nov 2014
B757-200PCF
PC-0118-11
REPAIRS - CREASE BEAMS AND 9G SHEAR FLOOR

Section 53-10-13
1. Repairs defined in the Boeing 757-200 SRM, D634N201, 53-00-51, are applicable to aircraft
modified in accordance with Precision Conversions 757-200PCF freighter modification except the
following limitations:
A. 9G Structure:
1) No repairs in the Boeing 757-200 SRM are applicable to the cargo conversion STC 9G
related structure. It is recommended to contact Precision Conversions Customer Support
for assistance.
Note:
53-10-13
200PCF Page 201
Nov 2014
B757-200PCF
PC-0118-11
DOOR SURROUND STRUCTURE – SECTION 41

Section 53-10-15
Section 41 – Door Surround Structure Identification

Figure 1 (Sheet 1)
53-10-15
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11

1 SILL, UPPER 7050-T7451 All
2 SILL, LOWER 7050-T7451 All
3 FRAME, FWD JAMB 7050-T7451 All
4 FRAME, AFT JAMB 7050-T7451 All
5 INTERCOSTAL 0.063 2024-T42 All
6 INTERCOSTAL 0.090 2024-T42 All
7 INTERCOSTAL, FWD JAMB 7050-T7451 All
8 INTERCOSTAL, AFT JAMB 7050-T7451 All
Section 41 – Door Surround Structure Identification

Figure 1 (Sheet 2)
53-10-15
200PCF Page 2
Nov 2014
B757-200PCF
PC-0118-11
ALLOWABLE DAMAGE – DOOR SURROUND STRUCTURE

Section 53-10-15
1. Allowable damage defined in the Boeing 757-200 SRM, D634N201, Sections 53-10-15, Figure 101 is
A. Crew Entry Door Surround Structure:
1) A maximum of 10% blend out is acceptable on the fwd and aft jambs per Section 51-10-02
Figure 101 of this SRM.
2) A maximum of 10% blend out is acceptable on the upper and lower sills per Section 51-10-02
Figure 101 of this SRM.
3) There is no allowable blending on any STC fittings or machined parts related to the crew
entry door surround structure. Any damage found in these areas must be communicated to
Note:
53-10-15
200PCF Page 101
Nov 2014
B757-200PCF
PC-0118-11
SEAT TRACKS – SECTION 41

Section 53-10-52
Section 41 Seat Track Identification

Figure 1 (Sheet 1)
53-10-52
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11

1 SEAT TRACK BAC 1520-2934 7075-T6511 All
2 SEAT TRACK TIERNAY 60-6549 7075-T6511 All

Figure 1 (Sheet 2)
53-10-52
200PCF Page 2
Nov 2014
B757-200PCF
PC-0118-11

Section 53-30-01

Figure 1 (Sheet 1)
53-30-01
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11

1 SKIN 0.190 CLAD 2024-T3 (CHEM-MILLED TO .056" MIN) All

Figure 1 (Sheet 2)
53-30-01
200PCF Page 2
Nov 2014
B757-200PCF
PC-0118-11
Section 43 – Rain Gutter Identification

Figure 2 (Sheet 1)
53-30-01
200PCF Page 3
Nov 2014
B757-200PCF
PC-0118-11

1 GUTTER, RAIN 0.032 BAC1496-356 CLAD 2024-T3 All
Section 43 – Rain Gutter Identification

Figure 2 (Sheet 2)
53-30-01
200PCF Page 4
Nov 2014
B757-200PCF
PC-0118-11
REPAIRS - SECTION 43 FUSELAGE SKIN

Section 53-30-01
1. Repairs defined in the Boeing 757-200 SRM, D634N201, 53-30-01, are applicable to aircraft
modified in accordance with Precision Conversions 757-200PCF freighter modification except the
following limitations:
A. Repair 2 - PARTIAL SKIN PANEL REPLACEMENT BETWEEN BS 540 TO 640 AND

STRINGERS 14L TO 19L does not apply to airplanes modified by the Precision Conversions
STC.
53-30-01
200PCF Page 201
Nov 2014
B757-200PCF
PC-0118-11
FUSELAGE STRINGERS – SECTION 43

Section 53-30-03

Figure 1 (Sheet 1)
53-30-03
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11
FUSELAGE STRINGERS – SECTION 43
ITEM DESCRIPTION GAGE MATERIAL STRINGER TYPE REF DWG

1 STRINGER 0.063 CLAD 7075-T6 007F2503
2 STRINGER 7050-T7451 PLATE 007F2403

Figure 1 (Sheet 2)
53-30-03
200PCF Page 2
Nov 2014
B757-200PCF
PC-0118-11
FUSELAGE INTERCOSTALS – SECTION 43

Section 53-30-04
Section 43 Intercostal Identification

Figure 1 (Sheet 1)
53-30-04
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11

Section 53-30-07

Figure 1 (Sheet 1)
53-30-07
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11

2 FAILSAFE 0.080 CLAD 2024-T42 All

Figure 1 (Sheet 2)
53-30-07
200PCF Page 2
Nov 2014
B757-200PCF
PC-0118-11

2 FAILSAFE 0.090 CLAD 2024-T42 All

Figure 1 (Sheet 3)
53-30-07
200PCF Page 3
Nov 2014
B757-200PCF
PC-0118-11

Section 53-30-15
Section 43 Door Surround Structure Identification

Figure 1 (Sheet 1)
53-30-15
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11

1 FRAME, JAMB - FORE/AFT JAMB 7050-T7451 PLATE All
2 FRAME, OUTER JAMB - FORE/AFT JAMB 7050-T7451 PLATE All
3 INTERCOSTAL 0.080 CLAD 2024-T42 All
4 SPACER, DOOR GUIDE - FORE/AFT JAMB 2024-T351 PLATE All

Figure 1 (Sheet 2)
53-30-15
200PCF Page 2
Nov 2014
B757-200PCF
PC-0118-11

1 BEAM - UPPER SILL 7050-T7451 PLATE All
2 FITTING, SPLICE, STRINGER-UPPER 7050-T7451 PLATE All
3 SKIN, INNER - UPPER SILL 0.080 CLAD 2024-T3 All
4 SUPPORT ASSEMBLY - UPPER SILL 7050-T7451 PLATE All

Figure 1 (Sheet 3)
53-30-15
200PCF Page 3
Nov 2014
B757-200PCF
PC-0118-11

1 BEAM - LOWER SILL 0.125 CLAD 2024-T42 All
2 ANGLE, COVER - LOWER SILL 0.063 CLAD 2024-T3 All
3 LATCH - FITTING CRES 17-4 PH BAR All
4 SPOOL, LATCH - LOWER SILL PH 13-8Mo CONDITION H 950 BAR All
5 FITTING 7050-T7451 PLATE All

Figure 1 (Sheet 4)
53-30-15
200PCF Page 4
Nov 2014
B757-200PCF
PC-0118-11
ALLOWABLE DAMAGE - DOOR SURROUND STRUCTURE

Section 53-30-15
1. Allowable damage defined in the Boeing 757-200 SRM, D634N201, Section 53-30-15, Figure 101 is
A. Upper Sill Intercostals:

1) See Section 53-00-04, Figure 101 for allowable damage.
B. Upper Sill Inner Skin:

1) The inner skin of the sill is limited to a maximum of 10% blend out from the nominal
thickness. See Section 51-10-02, Figure 101 of this SRM supplement for allowable damage
details.
C. Upper Sill Support Assembly Fittings:

1) Damage is NOT permitted.
D. Upper Sill Stringer 4 Splice:

1) Damage is NOT permitted.
E. Fuselage Lower Sill:

1) No damage is permitted on the STC lower sill between BS620 and BS640. All other areas of
the sill is limited to a maximum of 10% blend out from the nominal thickness. See Section 51-
10-02, Figure 101 of this SRM supplement for allowable damage details
F. Fuselage Upper Sill:

1) No damage is permitted on the STC Upper Sill between BS620 and BS630. All other areas of
the sill are limited to a maximum of 10% blend out from the nominal thickness. See Section
51-10-02, Figure 101 of this SRM supplement for allowable damage details.
G. Longitudinal Splices:
1) Damage is NOT permitted between BS440 and BS660.
H. Circumferential Splices:
1) Blend out is NOT permitted at BS440 and BS660 between Stringer 4R and 26L.
I. Latch Fitting:
1) Girt fittings 007F2312 are limited to 10% blend out from the nominal thickness. See Section
51-10-02, Figure 101 of this SRM supplement for allowable damage details.
J. Fittings:
1) No damage is permitted on all other fittings not listed above.
Note:
53-30-15
200PCF Page 101
Nov 2014
B757-200PCF
PC-0118-11

Section 53-30-52

Figure 1 (Sheet 1)
53-30-52
200PCF Page 1
June 2009
B757-200PCF
PC-0118-11


Figure 1 (Sheet 2)
53-30-52
200PCF Page 2
June 2009
B757-200PCF
PC-0118-11

Section 53-40-52

Figure 1 (Sheet 1)
53-40-52
200PCF Page 1
June 2009
B757-200PCF
PC-0118-11


Figure 1 (Sheet 2)
53-40-52
200PCF Page 2
June 2009
B757-200PCF
PC-0118-11

Section 53-60-01

Figure 1 (Sheet 1)
53-60-01
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11
DOOR PLUG STRUCTURE

SEE SECTIONS 53-60-03
AND 53-00-07
DESCRIPTION GAGE MATERIAL EFFECTIVITY

SKIN 0.063 CLAD 2024-T3 All

Figure 1 (Sheet 2)
53-60-01
200PCF Page 2
Nov 2014
B757-200PCF
PC-0118-11

Section 53-60-03

1 007F8086 STRINGER 0.063 CLAD 2024-T42 All
2 007F8087 CLIP TIERNAY 60-15738 7075-T651 All
3 007F8089 CLIP 0.063 7050-T7451 PLATE All
L4/R4 Door Skin Plug Stringer Identification

Figure 1 (Sheet 1)
53-60-03
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11

Section 53-60-07

1 007F8085 FRAME 7050-T7451 PLATE 001 – 015
007F6085 FRAME 2024-T42 016 And On
2 007F8099 SPLICE 7050-T7451 PLATE All
3 007F8100 PLATE, SPLICE 7075-T6 PLATE All
4 007F8094 FITTING 7050-T7451 PLATE All
5 007F8096 CLIP 0.063 CLAD 2024-T42 All
6 007F8095 STRAP 0.1 CLAD 2024-T3 All
7 007F8089 CLIP 0.063 CLAD 2024-T3 All
8 007F8093 FITTING 7050-T7451 PLATE All
L4/R4 Door Skin Plug Frame Identification

Figure 1 (Sheet 1)
53-60-07
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11
REPAIRS – FLOOR STRUCTURE

Section 53-60-51
1. Floor structure repairs defined in the Boeing 757-200 SRM, D634N201, Section 53-60-51 are
A. Repairs 14 through 18:
1) Repairs 14, 15, 16, 17, and 18 in the Boeing 757-200 SRM Section 53-60-51 are not
applicable to the cargo conversion STC. It is recommended to contact Precision Conversion
Customer Support for any damage found in this area.
53-60-51
200PCF Page 1
Dec 2015
B757-200PCF
PC-0118-11

Section 53-60-52

Figure 1 (Sheet 1)
53-60-52
200PCF Page 1
Nov 2014
B757-200PCF
PC-0118-11


Figure 1 (Sheet 2)
53-60-52
200PCF Page 2
Nov 2014
B757-200PCF
PC-0118-11
CHAPTER 54
NACELLES AND PYLONS
TABLE OF CONTENTS
NACELLES/PYLONS .................................................................................................................. 54-00-00
54-CONTENTS
200PCF Page 1
Nov 2014
B757-200PCF
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CHAPTER 54 NACELLES/PYLONS
54-00-00
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CHAPTER 55
STABILIZERS
TABLE OF CONTENTS
STABILIZERS ............................................................................................................................. 55-00-00
55-CONTENTS
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CHAPTER 55 STABILIZERS
1. All information contained in the Boeing 757-200 SRM, Chapter 55, is applicable to aircraft modified in
accordance with Precision Conversions 757-200PCF freighter modification.
55-00-00
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CHAPTER 56
WINDOWS
TABLE OF CONTENTS
WINDOWS .................................................................................................................................. 56-00-00
56-CONTENTS
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CHAPTER 56 WINDOWS
56-00-00
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CHAPTER 57
WINGS
TABLE OF CONTENTS
WINGS ........................................................................................................................................ 57-00-00
57-CONTENTS
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CHAPTER 57 WINGS
57-00-00
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B757-200 Cargo Conversion

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STRUCTURAL REPAIR MANUAL

SUPPLEMENT FOR B757-200 CARGO

PRECISION CONVERSIONS CONFIDENTIAL, AND/OR TRADE SECRET

THIS INFORMATION CONTAINED HEREIN IS PROPRIETARY TO PRECISION CONVERSIONS LLC

ORIGINAL ISSUE DATE: J ANUARY 10, 2005

REVISION DATE: SEPTEMBER 20, 2018

COMPILED AND PUBLISHED BY:

REV DESCRIPTION BY APVD DATE

IR Initial Release MV WJW 01/10/05

A Text Clarification MV WJW 02/10/05

B Clarifications DFD WJW 06/17/09

D Clarifications JMD DD 12/16/15

Brought current with Boeing 757-200 Structural Repair

F See Revision Highlights RMJG DD 04/14/17

G See Revision Highlights 5L ~~ </f J.o/ 1?

1. Brought current with Boeing 757-200 Structural Repair Manual D634N201.

RECORD OF TEMPORARY REVISIONS

REVISION INSERTED REMOVED REVISION INSERTED REMOVED

LIST OF EFFECTIVE AIRPLANES

Cargo Conversion Variable Manufacturing Current Registration

The added and affected structure is divided into three types:

2) Manual Arrangement and Numbering System

No change to this section. See original Boeing Structural Repair Manual.

3) How to Use This Manual

No change to this section. See original Boeing Structural Repair Manual.

4) How to Use This Manual for Spare Parts Identification

No change to this section. See original Boeing Structural Repair Manual.

5) Airplane Effectivity Designations

No change to this section. See original Boeing Structural Repair Manual.

6) Publication Change Request

No change to this section. See original Boeing Structural Repair Manual.

No change to this section. See original Boeing Structural Repair Manual.

No change to this section. See original Boeing Structural Repair Manual.

No change to this section. See original Boeing Structural Repair Manual.

10) Significant Rework Log

A. No change to this section. See original Boeing Structural Repair Manual.

B. If it is necessary to obtain rework data, please contact:

Precision Conversions, LLC

SUBJECT CHAPTER SECTION

STRUCTURE .............................................................................................................................. 51-00-00

Structural Classification Diagram

Section 51-00-04 Structural Classification

Principal Structural Elements of PCF STC

Principal Structural Elements of PCF STC

TITLE PC MPD ITEM

No. 1 Cargo Door Cutout, PC-53-30-11

No. 1 Cargo Door Cutout, PC-53-30-11

No. 1 Cargo Door Cutout, Edge Frame – Outer Chord, PC-53-30-11

No. 1 Cargo Door Cutout, Edge Frame – Outer Chord, PC-53-30-11

No. 1 Cargo Door Cutout, PC-53-30-11

No. 1 Cargo Door Cutout, PC-53-30-11

No. 1 Cargo Door Cutout, Edge Frame – Inner Chord, PC-53-30-11

No. 1 Cargo Door Cutout, Edge Frame – Inner Chord, PC-53-30-11

No. 1 Cargo Door Cutout,

Overwing Stub Frames, Inner Chord, BS 1000 & 1020,

OEM Principal Structural Elements (PSEs) Affected By PCF STC

ALLOWABLE DAMAGE REMOVAL – TYPICAL

ALLOWABLE DAMAGE REMOVAL – TYPICAL

1. Typical Formed Section Repair

1. Typical Extruded Section Repair