T.O 1T-38C-2-2.pdf
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- T-38 Wing & Stabilizer Covers
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- FA309925Q0010
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The document is a Technical Manual (TO 1T-38C-2-2) for Organizational Maintenance of the T-38C Aircraft, specifically providing detailed instructions and specifications for ground handling, servicing, and airframe maintenance. The manual includes comprehensive technical details about special tools and test equipment for ground handling, with a focused section on manufacturing hail covers for aircraft wings and stabilizers. The technical specifications include precise measurements, material requirements, and assembly instructions for creating protective covers, with specific guidance on using materials like Velcro, nylon webbing, and various attachment methods to protect aircraft surfaces during potential hail events.
The manual provides a detailed material listing for local manufacture of hail covers, including specific measurements for wing and stabilizer covers, recommended materials such as Facilon fabric, nylon webbing, elastic cord, and hardware like snaps and D-rings. An alternative technique using Velcro is recommended as safer and less damaging to the aircraft. The document is marked as Controlled Unclassified Information (CUI) and includes a distribution statement limiting access to DoD components, with a publication date of 8 April 2025 and a warning about export control restrictions on the technical data.
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TO 1T-38C-2-2
TECHNICAL MANUAL
ORGANIZATIONAL MAINTENANCE
GROUND HANDLING, SERVICING, AND AIRFRAME MAINTENANCE
USAF SERIES
T-38C AIRCRAFT
(ATOS-HILL)
This manual supersedes TO 1T-38C-2-2 dated 17 December 2024.
DISCLOSURE NOTICE - This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Depart-ment of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.
DISTRIBUTION STATEMENT E - Distribution authorized to DoD Components only (Direct Military Support, Export Controlled) (8 April 2025). Other requests for this document must be referred to AFLCMC/WNDT, Hill AFB, Utah 84056-5811.
WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Section 2751 of Title 22, United States Code) or the Export Control Reform Act of 2018 (Chapter 58 Sections 4801-4852 of Title 50, United States Code). Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25 and DoD Instruction 2040.02.
HANDLING AND DESTRUCTION NOTICE - Comply with distribution statement and destroy by any method that will prevent disclosure of contents or reconstruc-tion of the document.
Published Under Authority of the Secretary of the Air Force
8 APRIL 2025
Controlled by: Air Force Controlled by: AFLCMC/WNDT CUI Category: Controlled Technical Information Distribution Statement: E POC: Corwyn Goodman, AFLCMC/WNDT, corwyn.goodman@us.af.mil, 801-586-2675
CUI
CUI
1247033129C Merged Stamp
Table 2-1. Special Tools and Test Equipment for Ground Handling
Name Part Number Alternate Use and Application Kit, Aircraft Mooring AN8015-2 Used for mooring aircraft in bad weather.
SEMITRAILER, Low Bed Specification MIL-S-45152, Type
1, Class A, Size 20, Style 4 Used to transport disabled aircraft.
ADAPTER, Mooring Aircraft 2-76074-1 Installed on aircraft, provides tiedown for mooring lines.
ADAPTER, Mooring Jacking, Hoisting, or Shipping Tiedown
2-76077-1, 2-76077-501 Installed on aircraft, provides attach points for jacking, hoisting, and so forth.
COVER, Inlet, Engine Air 2-76118-1 Used to cover engine air inlet.
COVER, Inlet, Engine Air (Airframe) PM-1038P Used to prevent foreign material from entering air inlet duct.
COVER, Canopy 2-76130-1 Used to protect canopy against weather.
COVER, Multifunction Display (MFD) Locally Manufacture Refer to
Figure 2-123 Used to protect MFD glass from damage.
ADAPTER, Installation and Removal, Accessory Power Assembly
2-76550-505 Use to remove and install accessory power assembly.
PIN, Quick-release, Ground Safety, Main Landing Gear (MLG)
2-76771-1, 6-76007-1 Use to protect main landing gear from accidental retraction.
PIN, Quick-release, Ground Safety, Nose Gear
2-76772-501 Use to protect nose gear from accidental retraction.
PIN, Quick-release, Nose Gear Steering Retention
2-76773-1, 6-76060-1 Used to prevent nose gear steering actuation.
STAND, Maintenance, Engine, Universal 21C539G5 Used to support engine during maintenance.
COVER, Pitot Tube 3-76050-1 Used to protect pitot head.
COVER, Antenna, UHF Radio Blade 3-76068-1 Used during maintenance to protect person-nel.
CASTER ASSEMBLY, Transportation Dolly, Engine Installation and Removal Adapter
3-76097-1 Used to remove engine in limited space areas.
COVER, Aft Fuselage 3-76115-1 Used to prevent engine tailpipes from extraneous material.
HAIL COVER, Protective Local Manufacture, refer to Table 2-2.
Used when hail is forecasted ½ inch or larger and hangar space is not available.
SLING, Ejection Seat MBEU200895 Used to remove ejection seats.
ADAPTER, Maintenance, Ejection Seat MBEU200897 Used to mount ejection seat to maintenance stand.
STAND, Maintenance, Ejection Seat MBEU205120 Used to support ejection seat during off aircraft maintenance.
COVER, Duct Protective 3-76116-1 Used to cover hydraulic heat exchanger outlet duct opening while aircraft is parked.
COVER, Equipment Cooling Duct (Interchangeable with 3-76032-1)
3-76201-1 Used to prevent extraneous material from entering duct.
COVER, Protective Duct 3-76204-1 Used to cover hydraulic heat exchanger outlet duct opening while aircraft is parked.
COVER, Protective Duct 3-76204-2 Used to cover hydraulic heat exchanger outlet duct opening while aircraft is parked.
PLUG, Ram Air Inlet 3-76205-1 Used to prevent extraneous material from entering duct.
ADAPTER, Component Trailer Engine Installation and Removal
3-76501-1 Used to support engine during removal and installation.
COVER, Engine Bay Cooling Inlet Upper 3-76689-1 Used to prevent extraneous material from entering duct.
CUI
TO 1T-38C-2-2
CUI
2-28
1239583225C Highlight
1239583225C Highlight
1239583225C Highlight
1239583225C Highlight
Table 2-2. Hail Covers (Wing and Stabilizer)
Noun NSN/Part Number Unit of Issue
MATERIAL LISTING FOR LOCAL MANUFACTURE OF HAIL COVERS
Facilon 8305-00-926-1585 Yards Webbing, Nylon OD 2 Inches 8305-00-261-8585 Yards Cord, Elastic 1/2 Inch Dia 8305-00-267-3115 Feet Snap, Hook/Swivel 5340-01-046-4076 Each Snap, Hook/Nonswivel 3906 T16 McMaster Carr 50/Box Tubing 4710-00-278-7959 Feet D-Ring 2 Inch, Zinc Plated 3648T87 McMaster Carr Each Rebonded Dacron Padding 2 Inch Local Purchase Roll Mesh Fabric (Optional) Local Purchase (Oklahoma Upholstery Supply, S/N 1972
ME)
Yards
ALTERNATE TECHNIQUE
Velcro may be used in place of elastic cords. Velcro will not damage the plane and is much safer. It is the preferred securing technique.
Hook, Velcro 8515-00-926-4931 Yards Pile, Velcro 8515-00-926-4930 Yards The following patterns (Figure 2-92 through Figure 2-99) include all seam allowances. All hardware, straps and pockets shall be sewn to their respective sides before to the three layers being sewn together. Sew the three layers together with the cover inside out. Three sides shall be sewn and then the cover righted and the last side sewn closed, in a manner that will not leave any raw edges exposed.
NOTE
• All three layers must be caught by the stitching in order to keep the padding from shifting.
• Deviations from design are allowed as long as padding requirements are maintained.
CUI
TO 1T-38C-2-2
CUI
2-113
1239583225C Cross-Out
1239583225C Cross-Out
P0900297
1 FINISHED LENGTH:
A. 63 INCHES
B. 64 INCHES
C. 67 INCHES
D. 53 INCHES
E. 42 INCHES
F. 20 INCHES
STRAP
5 IN
D-RING
1/4 IN
2-IN FOLD UNDER
4 IN
3 IN
3 IN
BUNGEE CLAMP (CRIMP AFTER FOLDING)
BUNGEE CLAMP
(CRIMP AFTER FOLDING)
ATTACH TO D-RINGATTACH SNAP
NOTE
STAB COVERS REQUIRE DOUBLE D-RING.
STRAP TO BE CUT 14 INCHES BEFORE SEWING TOGETHER.
ALL RINGS AND STRAP ARE SEWN TO COVER TOP USING
A 4 X 1.5-INCH BOX WITH WEBBING REINFORCEMENT
UNDERNEATH. THE THREE COVER LAYERS ARE ASSEMBLED
AFTER ALL POCKETS AND HARDWARE ARE ATTACHED.
ATTACH TO SNAP BEFORE FOLDING AND CRIMPING.
ATTACH TO D-RING BEFORE FOLDING AND CRIMPING.
Figure 2-92. Hail Covers Bungee Cord Strap
CUI
TO 1T-38C-2-2
CUI
2-114
P0900299
IN
F
T
IN
F
T
IN
IN
14 IN
F
T
IN
20 IN
IN
W
IN
G T
IP
P
O C
K E
T
IN
F
R O
M T
O P
A N
D C
E N
T E
R E
D
F
T
IN
C E
N T
E R
L
IN
E
IN
IN
F
T
IN
IN
NOTE
WING COVER
WING TIP POCKET
ATTACHED TO
BOTTOM SIDE
(SEE SHEET 2)
WING COVER PATTERN FOR TOP AND BOTTOM (RIGHT SIDE SHOWN,
INVERT FOR LEFT SIDE). ALL MEASUREMENTS INCLUDE SEAM
ALLOWANCE. SHADED AREAS ARE TO BE CUT OFF BEFORE SEWING.
Figure 2-94. Hail Covers (Sheet 1 of 4)
CUI
TO 1T-38C-2-2
2-116
P0900300
30 IN
90˚
24 IN
2 IN TURN UNDER
90˚
44 IN
19 IN
WING POCKET PATTERN
(RIGHT WING SHOWN, INVERT FOR LEFT WING,
POCKET IS MADE OF DOUBLED MATERIAL.)
Figure 2-94. Hail Covers (Sheet 2)
CUI
TO 1T-38C-2-2
2-117
P0900303
34-INCH STRAP-SEW IN WHEN
STITCHING TOP AND BOTTOM
HALF TOGETHER
22 1/2 IN
2 POCKETS
ONE ON EACH SIDE
34 IN
12 IN
P I
L E
VELCRO PILE 12 INCHES
LONG ON BOTH SIDES
OF STRAP
VIEW A 75 3/4 IN
FRONT 7 IN
VELCRO HOOK
SEW HERE
9 IN
64 1/4 IN
7 IN
71 3/4 IN
SEE VIEW A
2 INCH X 34 INCH
STRAP SEWED
WITH 12 INCH
VELCRO PILE ON
END OF STRAP
Figure 2-95. Hail Cover (Right Side Stabilizer)
CUI
TO 1T-38C-2-2
2-120
P0900304
34 IN 12 IN
P
I
E L
VELCRO PILE 12 INCHES
LONG ON BOTH SIDES
OF STRAP
75 3/4 IN
VIEW A
FRONT
7 IN
VELCRO HOOK
SEW HERE
2 POCKETS
ONE ON EACH SIDE
22 IN
71 3/4 IN
SEE VIEW A
2 INCH X 34 INCH
STRAP SEWED
WITH 12 INCH
VELCRO PILE ON
END OF STRAP
7 IN
9 IN
64 1/4 IN
34-INCH STRAP - SEW IN WHEN
STITCHING TOP AND BOTTOM
HALF TOGETHER
Figure 2-96. Hail Cover (Left Side Stabilizer)
CUI
TO 1T-38C-2-2
2-121
P0900305
3 3 3
12 FT 10 3/4 IN
35 IN
11 IN
64 IN10 IN
7 IN
34 IN19 1/2
IN
36 3/4
IN
21 IN
27 1/4
IN
8 3/4
IN
54 1/4 IN
11 FT 3 IN
23 1/2 IN
45˚
17 IN
CENTER LINE 12 FT 1/4 IN
TOP STITCH
10 FT
NOTE
12-INCH LENGTH OF NYLON WEBBING FOLDED IN HALF TO FORM A LOOP.
LENGTH OF NYLON WEBBING SHOULD BE ENOUGH TO GO UNDERNEATH BELLY
OF PLANE AND MEET STRAP FROM OTHER COVER. ONE STRAP WILL HAVE THE
PILE SIDE OF THE VELCRO AND THE OTHER STRAP WILL HAVE LOOP SIDE OF THE
VELCRO. 18 TO 24 INCHES OF CONNECTED VELCRO IS REQUIRED TO SECURE
BOTH COVERS TOGETHER.
LENGTH OF NYLON WEBBING SHOULD BE ENOUGH TO GO UNDERNEATH WING,
THROUGH THE LOOP FORMED BY , THEN FOLD VELCRO BACK ON TO ITSELF.
THE LOOP SIDE OF THE VELCRO WILL BE SEWN TO THE WEBBING SECTION
BETWEEN THE LEADING AND TRAILING EDGES OF THE WING. THE PILE OF THE
VELCRO WILL BE SEWN TO WEBBING SECTION THAT GOES THROUGH THE LOOP.
18 TO 24 INCHES OF CONNECTED VELCRO IS REQUIRED TO SECURE COVER.
Figure 2-97. Hail Cover Wing - Left and Right Wing Top Side
CUI
TO 1T-38C-2-2
2-122
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