Uploaded April 2018 | Updated September 2026, 1 hour ago
This skill video will show you how to use a hydraulic spreader and cutter in tandem to open a hole in the side of an aircraft.
Three-sided Method
1. Select appropriate cut-in area. Some aircraft may have cut-in marks on the aircraft fuselage.
2. Create an access hole near the upper corner of the rectangle with either a pick-head axe or the point of a Halligan tool.
3. Insert the hydraulic cutter blade into the hole and make multiple horizontal cuts across the upper side of the rectangle.
4. Make vertical cuts from the ends of the horizontal cut down to the lower edge of the cut-in area.
5. Use a hydraulic spreader or a prying tool to begin to fold the flap of aircraft skin downward toward the ground.
6. Pad jagged edges if time allows.
Four-sided Method
NOTE: This method must be used on composite materials.
NOTE: This method requires students to work in groups of two or more: one to make the cuts, and one or more to catch the removed piece.
1. Select appropriate cut-in area. Some aircraft may have cut-in marks on the aircraft fuselage.
2. Create an access hole in each corner of the rectangle with either a pick-head axe or the point of a Halligan tool.
3. Insert the hydraulic cutter blade into the hole and make multiple horizontal cuts across the lower side of the rectangle.
NOTE: When completely cutting an access/egress panel, the bottom cut should be your first cut to avoid the saw blade or rescue tool from binding (caused by the weight of the cutaway panel).
4. Make vertical cuts from the upper access holes downward to the lower edge of the cut-in area.
5. Make a horizontal cut across the upper side of the rectangle.
6. Remove the rectangle of aircraft skin.
7. Pad jagged edges if time allows.
This skill video will show you how to use a hydraulic spreader and cutter in tandem to open a hole in the side of an aircraft.
Three-sided Method
1. Select appropriate cut-in area. Some aircraft may have cut-in marks on the aircraft fuselage.
2. Create an access hole near the upper corner of the rectangle with either a pick-head axe or the point of a Halligan tool.
3. Insert the hydraulic cutter blade into the hole and make multiple horizontal cuts across the upper side of the rectangle.
4. Make vertical cuts from the ends of the horizontal cut down to the lower edge of the cut-in area.
5. Use a hydraulic spreader or a prying tool to begin to fold the flap of aircraft skin downward toward the ground.
6. Pad jagged edges if time allows.
Four-sided Method
NOTE: This method must be used on composite materials.
NOTE: This method requires students to work in groups of two or more: one to make the cuts, and one or more to catch the removed piece.
1. Select appropriate cut-in area. Some aircraft may have cut-in marks on the aircraft fuselage.
2. Create an access hole in each corner of the rectangle with either a pick-head axe or the point of a Halligan tool.
3. Insert the hydraulic cutter blade into the hole and make multiple horizontal cuts across the lower side of the rectangle.
NOTE: When completely cutting an access/egress panel, the bottom cut should be your first cut to avoid the saw blade or rescue tool from binding (caused by the weight of the cutaway panel).
4. Make vertical cuts from the upper access holes downward to the lower edge of the cut-in area.
5. Make a horizontal cut across the upper side of the rectangle.
6. Remove the rectangle of aircraft skin.
7. Pad jagged edges if time allows.
