N830BX

Part: STEERING SYS — INOPERATIVE (NLG) · airframe 83,929 hrs · 33,933 cycles

DURING TAKEOFF, F/O HAD NO RESISTANCE IN RUDDER PEDAL AND NO NOSE WHEEL STEERING. THE CREW ABORTED TAKEOFF AND RETURNED TO BLOCKS WITHOUT FURTHER INCIDENT. MX INSPECTED THE F/O RUDDER PEDAL ASSY, OPS CHECK GOOD IAW MM 27-23-28, 27-20-03 AND 27-23-29. ACFT WAS RETURNED TO SERVICE.

Part: CONNECTOR — DIRTY (RT A/C PACK) · airframe 82,945 hrs · 33,371 cycles

DURING CRUISE, THE RT BLEED VALVE'S DO NOT SHUT OFF INDIVIDUALLY, BUT WHEN THEY ARE SHUT OFF PRESSURE DROP'S TO 10 PSI, MANIFOLD TEMP IS 10 TO 20 DEGREE CELSIUS, RT PACK SEEMS TO BE INOPERATIVE. THE CREW RETURNED TO DEPARTURE WITHOUT FURTHER INCIDENT. MX CLEANED CONNECTOR AT RT PACK. OPS CHECK GOOD IAW MM 21-55-0. ACFT WAS RETURNED TO SERVICE.

Part: FUEL FILTER — CLOGGED (ZONE 400) · airframe 82,932 hrs · 33,361 cycles

DURING CLIMB OUT NR 1 ENGINE FLAMED OUT. THE CREW ACCOMPLISHED FLAME OUT IN FLIGHT START CHECKLIST. THE NR 1 ENGINE STARTED ALL PARAMETER NORMAL. CREW LANDED WITHOUT FURTHER INCIDENT. MX PERFORMED TROUBLESHOOTING FAULT 51 AND REPLACED ENGINE FUEL FILTER. OPS CHECK GOOD IAW MM 71-00-00, 73-11-10, ERH 70.01, 91.01. ACFT WAS RETURNED TO SERVICE.

Part: MECHANISM — DIRTY (MLG DOOR) · airframe 82,324 hrs · 32,985 cycles

AFTER TAKEOFF AND GEAR RETRACTION FROM KDFW, A SEVERE VIBRATION WAS FELT IN THE NOSE GEAR AREA. THE CREW RECYCLED THE LANDING GEAR AND THE CONDITION PERSISTED. THE CREW RETURNED TO KDFW AND LANDED WITHOUT INCIDENT. MAINTENANCE OBSERVED THE LEFT NOSE GEAR DOOR OPEN WHEN THE AIRCRAFT ARRIVED IN THE BLOCKS. MAINTENANCE INSPECTED NOSE GEAR DOORS AND RETRACT MECHANISM, AND NO DEFECTS WERE FOUND. MAINTENANCE CLEANED AND LUBRICATED THE TRIGGERS. THE OPERATIONAL CHECK WAS GOOD AND THE AIRCRAFT WAS RETURNED TO SERVICE IAW DC-8 MM 32-20-0.

Part: DETECTOR — MALFUNCTIONED (ZONE 400) · airframe 82,120 hrs · 32,902 cycles

DURING CRUISE FROM KLAX, NR 4 ENGINE FIRE WARNING ILLUMINATED. THE CREW PERFORMED COM EMERGENCY PROCEDURES, THE CREW DISCHARGED NUMBER ONE FIRE BOTTLE, AFTER TWO MINUTES FIRE WARNING ILLUMINATED AGAIN AND DISCHARGED NR 2 FIRE BOTTLE. THE CREW SHUT NR 4 ENGINE DOWN. THE CREW LANDED IN KICT WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED LEFT AND RIGHT FAN DETECTOR, LEFT AND RIGHT CORE, AND FIRE DETECTOR CONTROL UNIT. REPLACED BOTH FIRE BOTTLES. OPERATIONAL CHECK GOOD IAW MM 26-10-2, MM 26-11-16, 20-50-0, FCD 7-18-08, ERH 70.01, MM 26-11-07, AND GMM 3.124. AIRCRAFT WAS RETURNED TO SERVICE.

Part: CONNECTOR — CONTAMINATED (NR 4 NACELLE) · airframe 82,075 hrs · 32,879 cycles

DURING CRUISE FROM KTOL NR 4 ENGINE FIRE WARNING INTERMITTENTLY GOING OFF, THEN CAME ON STEADY. THE CREW SHUTDOWN NUMBER FOUR ENGINE, LIGHT IN HANDLE REMAINED ON UNTIL FL 18,000 ON DESCENT. THE CREW DISCHARGED BOTH FIRE BOTTLES. THE CREW LANDED IN KDEN WITHOUT FURTHER INCIDENT. MAINTENANCE INSPECTED AND FOUND LEFT FAN LOOP CONNECTOR CONTAMINATED WITH OIL. MAINTENANCE CLEANED CONNECTOR. REPLACED BOTH FIRE BOTTLES. OPERATIONAL CHECK GOOD IAW GMM 3.124 AND FCD 7/18/08. AIRCRAFT WAS RETURNED TO SERVICE.

Part: COMPUTER — DEFECTIVE (AUTO PILOT) · airframe 81,950 hrs · 32,736 cycles

DURING CLIMB-OUT OF KTOL WITH RUDDER POWER ON, YAW DAMPER ON AND AUTO PILOT ON THE RUDDER HAD A LEFT RUDDER INPUT. THE CREW TURNED THE AUTO PILOT OFF AND THE CONDITION REMAINED, TURNED THE YAW DAMPER OFF AND NO CHANGE. THE LEFT INPUT WENT AWAY ONLY WHEN RUDDER POWER WAS TURNED OFF. THE CREW RETURNED TO KTOL AND LANDED WITHOUT INCIDENT. MAINTENANCE TROUBLESHOT THE SYSTEM AND FOUND A DEFECTIVE YAW CHANNEL COMPUTER. THE YAW CHANNEL COMPUTER WAS DEFERRED AND THE ACFT WAS RETURNED TO SERVICE.

Part: SKIN — MISREPAIRED (FUSELAGE)

DURING ROUTINE C-CHECK INSPECTION, FOUND LOWER AFT FUSELAGE BELLY FWD OF AFT BASKET DOOR HAS IMPROPER REPAIR AT STA FS1142 LONGERON 35.5 RT. REMOVED FASTENERS AS NEEDED TO PERFORM REPAIR. REMOVED EXISTING REPAIR. REMOVED DAMAGED AREA. PERFORMED NDT INSPECTION. NO CRACK, NO CORROSION FOUND. FABRICATED EXTERNAL DOUBLER, EXTERNAL TRIPLER, FILLER AND FINGER DOUBLER. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. INSTALLED NEW FASTENERS AND REPAIR PARTS IAW SRM. (K)

Part: SKIN — CORRODED (HORIZ STAB)

DURING ROUTINE C-CHECK INSP, FOUND RT HORIZ STABILIZER AFT PANEL CORRODED AT STA XF 195.963. REMOVED CORROSION. FOUND OUT OF LIMITS. REMOVED FASTNERS AS NEEDED TO PERFORM REPAIR. REMOVED CORRODED SKIN. FABRICATED NEW SKIN, AND DOUBLER. BONDED PART AS NEEDED WITH HYSOL. CLEANED, TREATED, PRIMED AREA AND REPAIR PARTS. INSTALLED NEW FASTNERS AND REPAIR PARTS IAW SRM. (K)

Part: SKIN — MISREPAIRED (TE FLAP)

DURING ROUTINE C-CHECK INSPECTION, FOUND RT OTBD FLAP EXHAUST GATE LOWER SKIN HAS IMPROPER REPAIR. REMOVED FASTENERS AS NEEDED TO PERFORM REPAIR. REMOVED EXISTING REPAIR. FABRICATED NEW SKIN. CLEANED TREATED AND PRIMED AREA AND REPAIR PART. INSTALLED NEW FASTENERS AND REPAIR PARTS IAW SRM. (K)

Part: SKIN — MISREPAIRED (TE FLAP)

DURING ROUTINE C-CHECK INSP, FOUND RT OTBD FLAP LOWER SKIN HAS IMPROPER REPAIR AT STA XF 238.000. REMOVED FASTENERS AS NEEDED TO PERFORM REPAIR. REMOVED EXISTING REPAIR. FABRICATED NEW SKIN. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. INSTALLED NEW FASTENERS AND REPAIR PARTS IAW SRM. (K)

Part: SKIN — MISREPAIRED (FUSELAGE)

DURING ROUTINE C-CHECK INSP, FOUND LT AFT CORNER OF A PIT DOOR OPENING HAS IMPROPER REPAIR AT STA FS340, LONGERON 31 LT. REMOVED FASTENERS AS NEEDED TO PERFORM REPAIR. REMOVED EXISTING REPAIR. FABRICATED NEW SKIN. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. INSTALLED NEW FASTENERS AND REPAIR PARTS IAW FORM 8100-9. (K)

Part: SKIN — MISREPAIRED (FUSELAGE)

DURING ROUTINE C-CHECK, FOUND DOUBLER FWD OF A-PIT DOOR ON LWR CENTERLINE, HAS IMPROPER REPAIR AT FS220, LONGERON 36. REMOVED FASTNERS AS NEEDED TO PERFORM REPAIR. REMOVED EXISTING REPAIR. REMOVED DAMAGED AREA. PERFORMED NDT INSP, NO CRACK, NO CORROSION FOUND. FABRICATED NEW SKIN, DOUBLER REPAIR, FILLER, INTERNAL FINGER DOUBLERS, CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. INSTALLED NEW FASTENERS AND REPAIR PARTS IAW SRM. (K)

Part: SKIN — MISREPAIRED (FUSELAGE)

DURING ROUTINE C-CHECK INSP, FOUND FWD LWR FUSELAGE AFT OF AFT ADF ANTENNA HAS IMPROPER REPAIR AT STA FS 172 LONGERON 35.5 RT. REMOVED FASTENERS AS NEEDED TO PERFORM REPAIR. REMOVED EXISTING REPAIR. REMOVED DAMAGED AREA. PERFORMED NDT INSP. NO CRACK AND NO CORROSION FOUND. FABRICATED REPAIR DOUBLER, FILLER, INTERNAL FINGER DOUBLERS. CLEANED, TREATED, AND PRIMED AREA AND REPAIR PARTS. INSTALLED NEW FASTENERS AND REPAIR PARTS.

Part: SKIN — MISREPAIRED (FUSELAGE)

DURING ROUTINE C-CHECK INSP, FOUND AFT LOWER FUSELAGE AFT OF OUTFLOW VALVE HAS IMPROPER REPAIR AT STA FS1688, LONGERON 35.75 RT. REMOVED FASTENERS AS NEEDED TO PERFORM REPAIR. REMOVED EXISTING REPAIR. REMOVED DAMAGED AREA. PERFORMED NDT INSP. NO CRACK, NO CORROSION FOUND. FABRICATED REPAIR DOUBLER, TRIPLER, FILLER, INTERNAL DOUBLER. CLEANED TREATED, AND PRIMED AREA AND REPAIR PARTS. INSTALLED NEW FASTENERS AND REPAIR PARTS IAW SRM.

Part: SKIN — MISREPAIRED (FUSELAGE)

DURING ROUTINE C-CHECK INSPECTION, FOUND LT FWD FUSELAGE AFT AND BELOW EMERGENCY EXIT DOOR HAS IMPROPER REPAIR AT FS 447 LOGN 25.5 LT. REMOVED FASTENERS AS NEEDED TO PERFORM REPAIR. REMOVED EXISTING REPAIR. REMOVED DAMAGED AREA. FABRICATED NEW SKIN, EXTERNAL DOUBLER, INTERNAL FINGER DOUBLERS AND FILLER. CLEANED TREATED AND PRIMED AREA AND REPAIR PARTS. INSTALLED NEW FASTENERS AND REPAIR PARTS IAW SRM 51-1-11, SRM 51-1-21, SRM 51-1-20D, SRM 51-3-1, SRM 53-2-1, SRM 51-1-21, SRM 53-4-1 & SRM 51-1-8B. (K)

Part: SKIN — MISREPAIRED (FUSELAGE)

DURING ROUTINE C-CHECK INSPECTION, FOUND AFT LOWER FUSELAGE AFT AND BELOW L-2 AND R-2 DOORS HAS IMPROPER REPAIR AT STA FS 1695, LONGERON 36. REMOVED FASTENERS AS NEEDED TO PERFORM REPAIR. REMOVED EXISTING REPAIR. REMOVED DAMAGED AREA. FABRICATED NEW SKIN. REPAIR DOUBLER, INTERNAL FINGER DOUBLER, AND FILLER. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. INSTALLED NEW FASTENERS AND REPAIR PARTS IAW SRM 51-1-11, SRM 51-1-21, SRM 51-1-20D, SRM 51-2-1, FIGURE 7 SHEETS 1 AND 4, SRM 53-5-1, FIG 1 ITEM "E", AND DC8 SRM 51-1-8B. (K)

Part: FITTING — CRACKED (CARGO BAY)

DURING ROUTINE C-CHECK INSPECTION, FOUND AFT CARGO COMPARTMENT SPLICE FITTING CRACKED AT STA 1040.000-1060.000 LONGERON 31 LT. REMOVED CRACKED SPLICE FITTING. FABRICATED SPLICE FITTING. PERFORMED NDT INSP. NO CRACK, NO CORROSION FOUND. CLEANED, TREATED, AND PRIMED AREA AND SPLICE FITTING. INSTALLED NEW SPLICE FITTING SRM. (K)

Part: SKIN — DENTED (RT WING)

DURING ROUTINE C-CHECK INSP, FOUND RT WING INBD L/E UPPER SKIN DENTED AT STA SFS 120.000. REMOVED FASTENERS AS NEEDED TO PERFORM REPAIR. REMOVED DAMAGED AREA. FABRICATED NEW SKIN, DOUBLER, ANGLES, FILLER, AND FAIRING. PERFORMED HEAT TREATMENT TO REPAIR ANGLES. CLEANED, TREATED, PRIMED AREA AND REPAIR PARTS. INSTALLED NEW FASTENERS AND REPAIR PARTS IAW SRM. (K)

Part: SKIN — MISREPAIRED (TE FLAP)

DURING ROUTINE C-CHECK INSP, FOUND LT OTBD FLAP UPPER SKIN HAS IMPROPER REPAIR AND AT STA XF420.000. REMOVED FASTENERS AS NEEDED TO PERFORM REPAIR, REMOVED DAMAGED SKIN. FABRICATED NEW SKIN, DOUBLER. BONDED PARTS AS NEEDED WITH HYSOL. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. INSTALLED NEW FASTENERS AND REPAIR PARTS IAW SRM. (K)

Part: SKIN — MISREPAIRED (FUSELAGE)

DURING ROUTINE C-CHECK, FOUND LWR FWD FUSELAGE BELLY AFT OF FWD BASKET DOOR HAS IMPROPER REPAIR AT STA FS403, LONGERON 35.5 LT. REMOVED FASTNERS AS NEEDED TO PERFORM REPAIR. REMOVED EXISTING REPAIR DOUBLER. REMOVED DAMAGED AREA. FABRICATED NEW SKIN, REPAIR DOUBLER, INTERNAL FINGER DOUBLERS, AND FILLER. CLEANED, TREATED, PRIMED AREA AND REPAIR PARTS. INSTALLED NEW FASTNERS AND REPAIR PARTS IAW SRM. (K)

Part: SKIN — CRACKED (RT WING)

DURING ROUTINE C-CHECK INSPECTION, FOUND RT WING UPPER SKIN CRACKED AT STRINGER 8 STA XW 408.00. REMOVED FASTENERS AS NEEDED TO PERFORM REPAIR. REMOVED DAMAGED AREA. PERFOMRED NDT INSP. NO CRACK AND NO CORROSION FOUND. FABRICATED REPAIR DOUBLER, AND FILLER PLUG. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. INSTALLED NEW FASTENERS AND REPAIR PARTS IAW SRM. (K)

Part: FITTING — CRACKED (CARGO BAY)

DURING ROUTINE C-CHECK INSP, FOUND AFT CARGO COMPARTMENT SPLICE FITTING CRACKED AT STA 1040.00-1060.000 LONGERON 31 RIGHT. REMOVED CRACKED SPLICE FITTING. FABRICATED SPLICE FITTING. PERFORMED NDT INSP. NO CRACK, NO CORROSION FOUND. CLEANED, TREATED AND PRIMED AREA AND SPLICE FITTING. INSTALLED NEW SPLICE FITTING IAW SRM. (K)

Part: SEAT TRACK — DAMAGED (FUSELAGE)

DURING ROUTINE C-CHECK INSPECTION, FOUND P-1-5 SEAT TRACK DAMAGED. REMOVED DAMAGED TRACK SEGMENT. FABRICATED SPLICES. CLEANED, TREATED, AND PRIMED AREA AND SPLICES. INSTALLED NEW TRACK SEGMENT AND SPLICES IAW SRM 53-7-1, FIG 4, SHEET 1 ITEM C, SRM 51-2-0, FIG 50 SHEET 73. (K)

Part: SKIN — MISREPAIRED (FUSELAGE)

DURING ROUTINE C-CHECK, FOUND FWD OF FLAT AFT PRESSURE BULKHEAD HAS IMPROPER REAPIR AT LONGERON 28. REMOVED FASTENERS AS NEEDED TO PERFORM REPAIR. REMOVED EXISTING REPAIR DOUBLERS. REMOVED DAMAGED AREA. PERFORMED NDT INSPECTION. NO CRACK, NO CORROSION. FABRICATED NEW SKIN, INTERNAL AND EXTERNAL DOUBLERS. CLEANED, TREATED, AND PRIMED AEA AND REPAIR PARTS. INSTALLED NEW FASTENERS AND REPAIR PARTS IAW SB. (K)

Part: CONNECTOR — MALFUNCTIONED (FIRE DETECTION)

FLT NR: ATN 801 / KLAX TO KTOL / TAT 81755.9 / TAC 32719. DURING CRUISE FROM KLAX NR 2 ENGINE FIRE WARNING LIGHT CAME ON. THE CREW ACCOMPLISHED EMERGENCY CHECKLIST AND SHUTDOWN NR 2 ENGINE. FIRE WARNING LIGHT EXTINGUISHED SHORTLY AFTER ENGINE SHUTDOWN, THE CREW DID NOT DISCHARGE FIRE BOTTLES. THE CREW LANDED IN KTOL WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED LT CORE ELEMENT, AND RT CORE FORWARD CONNECTOR. OPERATIONAL CHECK GOOD IAW MM 26-10-1, 20-50-1 AND 26-10-0. AIRCRAFT WAS RETURNED TO SERVICE. (A)

Part: CONNECTOR — DAMAGED (FIRE DETECTOR) · airframe 817,463 hrs · 32,717 cycles

FLT NR: ATN 229/PKMJ TO KHNL. DURING CRUISE FROM PKMJ NR 4 FIRE WARNING CAME ON, THE CREW SHUTDOWN NUMBER FOUR ENGINE AND DISCHARGED BOTH BOTTLES. THE CREW LANDED IN KHNL WITHOUT FURTHER INCIDENT. MAINTENANCE INSPECTED NR 4 FIRE WARNING SYSTEM AND FOUND LOW RESISTANCE. MAINTENANCE REPLACED P1-7037 CONNECTOR, AND BOTH FIRE BOTTLES. OPERATIONAL CHECK GOOD IAW MM 26-10-0, 26-21-09. AIRCRAFT WAS RETURNED TO SERVICE. (A)

Part: FIRE WARNING — ACTIVATED (NR 4 NACELLE)

FLT NR: ATN 229/PKMJ TO KHNL/TAT 81746.9/TAC 32717. DURING CRUISE FROM PKMJ NR 4 FIRE WARNING CAME ON THE CREW SHUTDOWN THE NR 4 ENGINE AND FIRE BOTH BOTTLES. THE CREW LANDED IN KHNL WITHOUT FURTHER INCIDENT. (A)

Part: FIRE WARNING — ACTIVATED (NR 4 NACELLE)

FLT NR: ATN 229/PKMJ TO KHNL/TAT 81746.9/TAC 32717. DURING CRUISE FROM PKMJ NR 4 FIRE WARNING CAME ON THE CREW SHUTDOWN THE NR 4 ENGINE AND FIRED BOTH BOTTLES. THE CREW LANDED KHNL WITHOUT FURTHER INCIDENT. CORRECTIVE ACTION IN WORK. (A)

Part: FIRE WARNING — FALSE ACTIVATION (NR 4 NACELLE)

FLIGHT NR: ATN 229/ TAT 81724.7/ TAC 32713 - DURING CRUISE, NR 4 ENGINE FIRE WARNING CAME ON, THE CREW ACCOMPISHED CHECK LIST AND RETURNED TO DEPARTURE AND LANDED WITHOUT INCIDENT. CORRECTIVE ACTION IN WORK. (K)

Part: CONNECTOR — DAMAGED (FIRE WARNING)

DURING CRUISE, NR 4 ENGINE FIRE WARNING LIGHT AND BELL CAME ON, THE CREW SHUTDOWN NR 4 ENGINE AND AS SOON AS T-HANDLE WAS PULLED THE BELL STOPPED AND LIGHT WENT OUT. THE CREW RETURNED TO DEPARTURE AND LANDED WITHOUT FURTHER INCIDENT. MAINTENANCE REPLACED LT AND RT CORE SENSING ELEMENT, LT FAN SENSING ELEMENT, CONNECTOR P1-7072 AND CONNECTOR P1-7087. OPERATIONAL CHECK GOOD IAW MM 26-10-0 AND 25-50-1. AIRCRAFT WAS RETURNED TO SERVICE. (K)

Part: SKIN — BROKEN (TE FLAP)

DURING ROUTINE C-CHECK INSPECTION, FOUND LT WING OTBD FLAP UPPER SKIN BROKEN AT STA XF 169.000-213.000. REMOVED FASTENERS AS NEEDED TO PERFORM REPAIR. REMOVED DAMAGED SKIN. FABRICATED NEW SKIN. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. INSTALLED NEW FASTENERS AND REPAIR PARTS IAW SRM 57-7-1, FIG 4 TR 57-94 DATED 10/01/02, SRM. (K)

Part: CONNECTOR — DIRTY (FIRE DETECTION) · airframe 81,687 hrs · 32,695 cycles

FLT NR: ATN 808, DURING CRUISE NR 2 ENGINE FIRE WARNING & BELL CAME ON INTERMITTENT FOR 1-2 SECONDS. CREW ACCOMPLISHED CHECK LIST AND SHUT DOWN NR 2 ENGINE. THE FIRE BELL STOPPED AFTER FIRE HANDLE WAS MOVED TO FULL FORWARD POSITION. THE FIRE BOTTLES WERE NOT DISCHARGED. THE CREW LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTED NR 2 FIRE WARNING SYSTEM AND FOUND LT FAN ELEMENT CONNECTOR WET, RT FIRE DETECTOR ELEMENT CONNECTOR DIRTY. MAINTENANCE CLEANED BOTH CONNECTORS, AND REPLACED LT AND RT FAN ELEMENT, AND LT AND RT FIRE DETECTOR ELEMENT. OPERATIONAL CHECK GOOD IAW MM 26-10-1, ERH 70-1-01. AIRCRAFT WAS RETURNED TO SERVICE. (A)

Part: FIRE WARNING — INTERMITTENT (NR 2 ENGINE)

DURING CRUISE, NR 2 ENGINE FIRE WARNING AND BELL INTERMITTENT FOR 1-2 SECONDS. THE CREW RAN CHECK LIST AND SHUT DOWN NR (2) ENGINE. THE FIRE BELL STOPPED AFTER FIRE HANDLE WAS MOVED TO FULL FWD POSITION. THE FIRE BOTTLES WERE NOT DISCHARGED. THE CREW LANDED WITHOUT INCIDENT. C/A: IN WORK. (K)

Part: CONNECTOR — DIRTY (NR 2 ENGINE)

DURING CRUISE, NR 2 ENGINE FIRE WARNING AND BELL CAME ON INTERMITTEN FOR 1-2 SECONDS. THE CREW ACCOMPLISHED, RAN CHECK LIST AND SHUTDOWN NR (2) ENGINE. THE FIRE BELL STOPPED AFTER FIRE HANDLE WAS MOVED TO FULL FWD POSITION. THE FIRE BOTTLES WERE NOT DISCHARGED. THE CREW LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTED NR 2 FIRE WARNING SYS AND FOUND LT FAN ELEMENT CONNECTOR WET, RT FIRE DETECTOR ELEMENT CONNECTOR PLUG, DIRTY. MAINTENANCE CLEANED BOTH CONNECTOR PLUG, AND REPLACED LT AND RT FAN ELEMENT, AND LT AND RT FIRE DETECTOR ELEMENT, OPS CHECK GOOD IAW MM 26-10-1, ERH 70-1-01. AC WAS RETURNED TO SERVICE. (K)

Part: CONTROL UNIT — DEFECTIVE (FIRE DETECTION)

DURING CRUISE FROM KRFD NUMBER ONE ENGINE FIRE BELL AND LIGHT CAME ON, THE CREW ACCOMPLISHED RUN ENGINE FIRE CHECK LIST, THE CREW DISCHARGED ONE AGENT, AND DISCHARGED THE SECOND AGENT AND THE SECOND AGENT WOULD NOT DISCHARGE, THE CREW LANDED IN KTOL WITHOUT INCIDENT. MAINTENANCE INSPECTED THE NUMBER ONE ENGINE FIRE EXTINGUISHING SYSTEM AND FOUND BROKEN GROUND WIRE ON STUD, MAINTENANCE CONFIRMED SECOND AGENT DID DISCHARGED. MAINTENANCE ALSO REPLACED FIRE DETECTOR CONTROL UNIT, PYLON FIRE LOOP, CORE FIRE LOOP, LT FIRE ELEMENT, RT FIRE ELEMENT, RT FAN FIRE ELEMENT, AND LT FAN FIRE ELEMENT. OPERATIONAL CHECK GOOD IAW DC8 MAINTENANCE MANUAL 26-10-4, DC8 MAINTENANCE MANUAL 20-50-1. AIRCRAFT WAS RETURNED TO SERVICE. (A)

Part: CYLINDER — BYPASSING (ZONE 700) · airframe 78,978 hrs · 31,458 cycles

DURING CLIMB FROM KSEA, AFTER LANDING GEAR RETRACTION, THE GEAR AND DOOR UNSAFE LIGHT REMAINED ON. THE CREW COMPLIED WITH THE APPLICABLE CHECK LIST, DURING THE UP-LATCH CHECK THE GEAR FAILED TO UP-LATCH. THE CREW DIVERTED TO KPDX. MAINTENANCE INSPECTED THE GEAR AND FOUND THE RIGHT MAIN GEAR RETRACT CYLINDER BYPASSING. THE RIGHT MAIN GEAR RETRACT CYLINDER WAS REPLACED, ALL OPERATIONAL CHECKS WERE COMPLIED WITH, AND THE AIRCRAFT WAS RETURNED TO SERVICE PER DACO MM 32-32-2.

Part: DOUBLER — IMPROPER (LT WING) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION FOUND LEFT HAND OUTER WING INBOARD EXTENDED LEADING EDGE OUTER SKIN EXISTING REPAIR DOUBLER WITH DISSIMILAR MATERIAL BETWEEN STATION 585.000 AND STATION 591.250. PERFORMED MAJOR REPAIR IAW FAA FORM 8110-3 NUMBER 06260 DATED 05-29-06, SEMAN DRAWING NUMBER ED 4233 DATED 05-22-06. REMOVED EXISTING REPAIR DOUBLER IAW DC-8 SRM 51-1-21. REMOVED DAMAGED AREA IAW SEMAN DWG NUMBER ED 4233. PERFORMED NDT INSPECTION IAW DC-8 NDT SPM PART 06-10-01-001. NO CRACKS, OR CORROSION FOUND. FABRICATED REPAIR DOUBLER, AND FILLER IAW SEMAN DRAWING ED 4233. CLEANED, TREATED AND PRIMED AREA, FILLER, AND REPAIR DOUBLER IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC8 SRM 51-1-11. INST

Part: SKIN — CRACKED (TL AILERON) · airframe 78,898 hrs · 31,422 cycles

DURING C CHECK, FOUND LEFT WING L/E SKIN CRACKED ON INBOARD AILERON, AT STATION XA 480.000. PERFORMED MAJOR REPAIR IAW DC-8 SRM 57-8-1 FIG 1. REMOVED DAMAGED SKIN IAW DC-8 SRM 57-1-0 PAGE 1, DC-8 SRM 51-1-21. FAB`D NEW SKIN IAW DC-8 SRM 57-8-1 FIG 1 ITEM E. CLEANED, TREATED AND PRIMED AREA AND NEW SKIN INTERNAL SURFACE IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11. INSTALLED NEW SKIN IAW DC-8 SRM 51-1-21. PERFORMED BALANCE IAW DC-8 SRM 51-4-1 PAGES 1, 2. FOUND WITHIN TOLERANCE MOMENT 3328.3 IN LBS.

Part: FITTING — CRACKED (FUSELAGE) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND MAIN CARGO COMPARTMENT AFT BATHTUB FITTING CRACKED STATION 902.100 LONGERON 9 LEFT. REPLACED AFT BATHTUB FITTING ON MAIN CARGO COMPARTMENT AT STATION 902.100 LONGERON 9 LEFT IAW DC-8 SRM 51-1-20D, DC-8 SRM 51-1-23, DC-8 SRM 51-3-1.

Part: SKIN — WORN (CARGO DOOR) · airframe 78,898 hrs · 31,422 cycles

DURING INSPECTION, FOUND EXT FUSELAGE C PIT BELLY DOOR EXTERNAL SKIN WORN. PERFORMED MAJOR REPAIR IAW DC-8 SRM 52-2-0 FIG 4 (SHEET 3). REMOVED FASTENERS IAW DC-8 SRM 51-1-2. REMOVED DAMAGED AREA IAW DC-8 SRM 52-2-0 FIG 4 (SHEET 3). PERFORMED DETAILED VISUAL INSPECTION. NO CRACKS OR CORROSION FOUND. FAB`D REPAIR DOUBLER, AND FILLER IAW DC-8 SRM 52-2-0 FIG 4 (SHEET 3), DC-8 SRM 57-4-1 FIG 1 ITEM Q, DC-8 SRM 51-9-0 FIG 68A. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11. INSTALLED REPAIR PARTS IAW DC-8 SRM 51-2-0 FIG 4 (SHEET 3), DC-8 SRM 51-1-21.

Part: SKIN — MISREPAIRED (ZONE 600) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND RIGHT WING CENTER LEADING EDGE LOWER SKIN WITH NON STANDARD REPAIR AT STATION XFS 341.500. PERFORMED MAJOR REPAIR IAW FAA FORM 8110-3 NUMBER 06237 DATE 05-15-06, SEMAN DRAWING NUMBER ED 4217 DATE 05-10-06. REMOVED EXISTING REPAIR DOUBLERS IAW DC-8 SRM 51-1-21, DC8 SRM 51-1-20D. REMOVED DAMAGED AREA IAW SEMAN DRAWING NUMBER ED 4217. PERFORMED NDT INSPECTION IAW DC-8 NDT SPM PART 06-10-01-001. NO CRACKS OR CORROSION FOUND. FABRICATED REPAIR DOUBLER AND FILLERS IAW SEMAN DRAWING ED 4217. CLEANED, TREATED AND PRIMED AREA, FILLERS, AND REPAIR DOUBLER IAW DC-8 SRM 51-1-8B. INSTALLED REPAIR PARTS IAW SEMAN DRAWING NUMBER ED 4217, DC-8 SRM 51-1-21, DC8 SRM 51-3-0, DC-8

Part: FINGER DOUBLER — CORRODED (HORIZ STAB) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION FOUND RIGHT HAND HORIZONTAL STABILIZER RIGHT HAND ELEVATOR CENTER LOWER PANEL FINGER DOUBLER WITH SPOTS OF CORROSION, FROM STATION XE 132.750 TO STATION XE 251.562. PERFORMED MAJOR REPAIR IAW DC-8 SRM 55-4-1 FIGURE 1 SHEET 1, AND 2. REMOVED CORROSION IAW DC8 SRM 51-1-8 PAGES 17, AND 18. FOUND OUT OF LIMITS IAW DC8 SRM 55-2-0 PAGE 12. REMOVED DAMAGED PANEL SKIN IAW DC-8 SRM 55-1-0, DC-8 SRM 51-1-21. FABRICATED NEW PANEL SKIN, AND FINGER DOUBLER IAW DC8 SRM 55-4-1 FIGURE 1, SHEET 1, AND 2, ITEM E, AND F. BONDED BOTH PARTS WITH HYSOL IAW DC8 SRM 51-1-9. CLEANED, TREATED AND PRIMED AREA AND NEW PANEL SKIN IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-1

Part: SKIN — CRACKED (PAX DOOR) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, FORWARD PASSENGER DOOR SKIN WITH 03 CRACKS APPROXIMATELY ¾ INCH LONG. PERFORMED MAJOR REPAIR IAW FAA FORM 8110-3 NUMBER 06282 DATE 06-06-06, SEMAN DRAWING NUMBER ED 4238 DATED 06-03-06. REMOVED FASTENERS AS NEEDED TO REMOVE DAMAGE IAW DC-8 SRM 51-1-21. REMOVED DAMAGED AREA IAW SEMAN DRAWING ED 4238. PERFORMED NDT INSPECTION IAW DC-8 NDT SPM PART 06-10-01-001. NO CRACKS, OR CORROSION FOUND AFTER DAMAGED WAS REMOVED. FABRICATED NEW SKIN SEGMENT, INTERNAL STRAP DOUBLER, AND INTERNAL SPLICES DOUBLERS IAW SEMAN DRAWING ED 4238. CLEANED, TREATED AND PRIMED AREA AND REQUIRED REPAIR PARTS IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC8 SRM 51-1-11. INSTALLED REPAIR P

Part: SKIN — DENTED (T/E FLAP) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION FOUND RIGHT HAND OUTBOARD FLAP LOWER SKIN DENTED AT STATION XF 440.000. PERFORMED MAJOR REPAIR IAW DC-8 SRM 57-7-1 FIG 4 TEMPORARY REVISION NUMBER 57-94 DATED 10-01-02. REMOVED DAMAGE IAW DC-8 SRM 57-1-0 PAGE 1, DC-8 SRM 51-1-21. FABRICATED NEW SKIN AND DOUBLER IAW DC-8 SRM 57-7-1 FIG 4 ITEM U AND Q BONDED BOTH PARTS WITH HYSOL IAW DC-8 SRM 51-1-9. CLEANED, TREATED AND PRIMED AREA AND NEW PANEL PLATING INTERNAL PART IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11. INSTALLED NEW SKIN AND DOUBLER IAW DC-8 SRM 51-1-21.

Part: FITTING — CRACKED (ZONE 100) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND MAIN CARGO COMPARTMENT FITTING CHANNEL CRACKED AT STATION 680.000 LBL 45. REMOVED CRACKED FITTING IAW DC-8 SRM 53--1-0 PAGE 1, DC-8 SRM 51-1-20D. FABRICATED NEW FITTING IAW ATI REPAIR SPECIFICATION NUMBER 2003-05. DWG DOUGLAS NR 4645517. PERFORMED HEAT TREATMENT 7075 “O” TO 7075 T6 IAW DC-8 SRM 51-1-1 PAGES 1, 13, 17. CLEANED, TREATED AND PRIMED AREA AND NEW FITTING IAW DC-8 SRM 51-1-8B. INSTALLED NEW FITTING IAW DC-8 SRM 51.1.20D, DC-8 SRM 51-3-1.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND AFT PASSENGER DOOR JAMB FORWARD UPPER CORNER CRACKED 1 INCH. PERFORMED MAJOR REPAIR IAW AD 2000-20-08, SB 53-075, DOUGLAS DRAWING SR 08530021, 5750776. REMOVED DAMAGED AREA IAW DOUGLAS DRAWING SR 08530021. PERFORMED NDT INSPECTION IAW NDT SPM PART 06-10-01-001. NO CRACKS, OR CORROSION FOUND AFTER DAMAGE WAS REMOVED. FABRICATED REPAIR DOUBLER (AL 7075T6 0.090”), REPAIR TRIPLER (AL 7075T6 0.125”), AND FILLER IAW DOUGLAS DRAWING SR 08530021. CLEANED, TREATED AND PRIMED AREA, AND REPAIR PARTS IAW SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW SRM 51-1-11. INSTALLED REPAIR PARTS IAW DOUGLAS DRAWING SR 08530021, SRM 51-1-21, DC8 SRM 51-3-0, SRM 51-1-20D, SRM 51-3-1 (TO

Part: DOUBLER — MISREPAIRED (ZONE 100) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND EXTERNAL FUSELAGE REPAIR DOUBLER IMPROPER, FROM STATION 1540.000 TO STATION 1560.000 BETWEEN LONGERONS 35 RIGHT TO LONGERON 35 LEFT. PERFORMED MAJOR REPAIR IAW DC8 SRM 53-2-1 FIG 7. REMOVED EXISTING REPAIR DOUBLER IAW DC-8 SRM 51-1-21, DC8 SRM 51-1-20D. FABRICATED NEW REPAIR DOUBLER AND FILLERS IAW DC8 SRM 53-2-1 FIG 7 (SHEET 1, 3) IAW DC8 SRM 53-4-1 FIG 16 (SHEET 2) ITEM B DC8 SRM 51-9-0 FIG 68A. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11. INSTALLED REPAIR PARTS IAW DC8 SRM 53-2-1 FIG 7 (SHEET 1, 3) DC8 SRM 51-1-21, DC8 SRM 51-1-20D, DC8 SRM 51-3-1.

Part: SKIN — MISREPAIRED (RT WING) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION FOUND RIGHT HAND WING CENTER LEADING EDGE LOWER SKIN WITH NON STANDARD REPAIR AT STATION XOLDI 6.225. PERFORMED MAJOR REPAIR IAW FAA FORM 8110-3 NR 06242 DATE 05-18-06, SEMAN DRAWING NR ED 4224 DATE 05-10-06. REMOVED NON STANDARD REPAIR IAW DC-8 SRM 51-1-21, DC8 SRM 51-1-20D, DC8 SRM 51-3-0. REMOVED DAMAGED AREA IAW SEMAN DRAWING NR ED 4224. PERFORMED NDT INSPECTION IAW DC-8 NDT SPM PART 06-10-01-001. NO CRACKS OR CORROSION FOUND. FABRICATED REPAIR DOUBLER AND FILLERS IAW SEMAN DRAWING ED 4224. CLEANED, TREATED AND PRIMED AREA, FILLER, AND REPAIR DOUBLER IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC8 SRM 51-1-11. INSTALLED REPAIR PARTS IAW SEMAN DRAWING NUMB

Part: SKIN — CANNING (RT ELEVATOR) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, RT ELEVATOR UPPER SKIN OIL CANNED, BETWEEN STATIONS XE 139.000 AND XE 252.000. PERFORMED MAJOR REPAIR IAW SRM 55-4-1 FIGURE 1 SHEET 1, AND 2. REMOVED DAMAGED SKIN, AND FINGER DOUBLER IAW SRM 51-1-21, SRM 55-1-0 PAGE 1. FABRICATED NEW SKIN. AND FINGER DOUBLER BOTH AL 2024T3 0.016” IAW SRM 55-4-1 FIGURE 1 SHEET 1, AND 2, ITEM E, AND F. BONDED BOTH PARTS WITH HYSOL IAW SRM 51-1-9. CLEANED, TREATED AND PRIMED AREA AND NEW REPAIR PARTS IAW SRM 51-1-8B. INSTALLED NEW REPAIR PARTS FROM STATION XE 132 TO STATION XE 246. IAW SRM 51.1.21.

Part: REPAIR — IMPROPER (RUDDER) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION FOUND RUDDER LEADING EDGE LT SKIN WITH IMPROPER REPAIR AT STATION ZR 159.094. PERFORMED MAJOR REPAIR IAW SRM 55-6-1 FIGURE 1. REMOVED SKIN WITH NON STANDARD REPAIR IAW SRM 51-1-21, DC-8 SRM 55-1-0 PAGE 1. FABRICATED NEW SKIN (AL2024T3 0.050”) IAW SRM 55-6-1 FIGURE 1 ITEM G CLEANED, TREATED AND PRIMED AREA AND NEW SKIN IAW SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACE IAW SRM 51-1-11. INSTALLED NEW SKIN IAW SRM 51-1-21.

Part: SKIN — DENTED (ZONE 600) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND RIGHT WING INBOARD AILERON LEADING EDGE SKIN DENTED, AND CRACKED AT STATION XA 475.000. PERFORMED MAJOR REPAIR IAW DC-8 SRM 57-8-1 FIG 1. REMOVED DAMAGED SKIN IAW DC-8 SRM 57-1-0 PAGE 1, DC-8 SRM 51-1-21. FABRICATED NEW SKIN IAW DC-8 SRM 57-8-1 FIG 1 ITEM E. CLEANED, TREATED AND PRIMED AREA AND NEW SKIN IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11. INSTALLED NEW SKIN IAW DC-8 SRM 51.1.21. PERFORMED BALANCE IAW DC-8 SRM 51-4-1 PAGES 1, 2. FOUND WITHIN TOLERANCE MOMENT 3334.99 IN. LBS.

Part: REPAIR — IMPROPER (FUSELAGE) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, UPGRADE REPAIR OF DENT ON FORWARD LOWER FUSELAGE PLATING AFT OF NLG WW RT AFT CORNERS AT STA 16, L35R IAW EO 53-DC8-2428. MAJOR REPAIR. COMPLETED FAA FORM 8110-3 NUMBER 06260 DATED 05-29-06, SEMAN DRAWING NUMBER ED 4231 DATED 05-27-06. REMOVED EXISTING FASTENERS AS NEEDED TO REMOVE EXISTING REPAIR DOUBLER IAW DC-8 SRM 51-1-21, DC8 SRM 51-3-0. REMOVED DAMAGED AREA IAW SEMAN DRAWING NUMBER ED 4231. PERFORMED NDT INSPECTION IAW DC-8 NDT SPM PART 06-10-01-001. NO CRACKS, OR CORROSION FOUND. FABRICATED REPAIR DOUBLER, SKIN FILLER, AND FINGER DOUBLER IAW SEMAN DRAWING NUMBER 4231. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURF

Part: REPAIR — IMPROPER (RUDDER) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION FOUND RUDDER LEADING EDGE LEFT HAND SKIN WITH NON STANDARD REPAIR AT STATION ZR 96.000. PERFORMED MAJOR REPAIR IAW DC-8 SRM 55-6-1 FIGURE 1. REMOVED EXISTING SKIN WITH NON STANDARD REPAIR IAW DC-8 SRM 51-1-21, DC-8 SRM 55-1-0 PAGE 1. FABRICATED NEW SKIN WITH AL2024T3 0.050 IAW DC-8 SRM 55-6-1 FIGURE 1 ITEM G. CLEANED, TREATED AND PRIMED AREA, AND NEW SKIN IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACE IAW DC8 SRM 51-1-11. INSTALLED NEW SKIN IAW DC-8 SRM 51-1-12.

Part: VANE — ELONGATED (ZONE 500) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND LEFT WING INBOARD SLOT VANE HOLES ELONGATED AT STATION XS 240.000. PERFORMED MAJOR REPAIR IAW FAA FORM 8110-3 NUMBER 06237 DATE 05-15-06, SEMAN DRAWING NUMBER ED 4211 DATE 05-10-06. REMOVED EXISTING REPAIR DOUBLER IAW DC-8 SRM 51-1-21. REMOVED DAMAGED AREA IAW SEMAN DRAWING ED 4211. PERFORMED NDT INSPECTION IAW DC8 NDT SPM ÁRT 06-10-01-001. NO CRACKS OR CORROSION FOUND. FABRICATED REPAIR DOUBLER, FILLER AND INTERNAL DOUBLER IAW DWG ED 4211. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11. INSTALLED REPAIR PARTS IAW SEMAN DRAWING NUMBER ED 4211, DC8 SRM 51-1-21, DC8 SRM 51-1-20D, DC8

Part: SKIN — MISREPAIRED (L/E SLOT) · airframe 78,898 hrs · 31,422 cycles

DURING INSPECT, FOUND LT INNER WING EXTENDED L/E SLOT OUTER SKIN EXISTING REPAIR IMPROPER AT STA XFS 310.000. PERFORMED MAJOR REPAIR. REMOVED EXISTING REPAIR DOUBLER IAW DC-8 SRM 51-1-21. REMOVED DAMAGED AREA IAW SEMAN DWG NR ED 4233. PERFORMED NDT INSPECTION IAW DC-8 NDT SPM PART 06-10-01-001. NO CRACKS OR CORROSION FOUND. FAB`D REPAIR DOUBLER AND FILLER IAW SEMAN DRAWING ED 4233. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS. PRIMED INTERNAL AREA IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC8 SRM 51-1-11. INSTALLED REPAIR PARTS IAW SEMAN DRAWING NUMBER ED 4233, DC-8 SRM 51-1-21, DC8 SRM 51-3-0, DC-8 SRM 51-1-20D, DC-8 SRM 51-3-1

Part: FITTING — CRACKED (ZONE 100) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND AFT LOWER CARGO COMPARTMENT FITTING CRACKED BETWEEN STATION 1160.000 AND STATION 1170.000 LONGERON 35 RIGHT. REMOVED CRACKED FITTING IAW DC8 SRM 51-1-20D. FABRICATED NEW FITTING IAW ATI REPAIR SPECIFICATION NUMBER 2003-05 AND DOUGLAS DRAWING 4706211. PERFORMED HEAT TREATMENT FROM 7075T6 51 TO 7075T6 IAW DC8 SRM 51-1-1 PAGES 1, 13, 17. PERFORMED NDT INSPECTION IAW DC8 NDT SPM PART 08-00-02 TO 07. CLEANED, TREATED AND PRIMED AREA AND NEW FITTING IAW DC8 SRM 51-1-8B. INSTALLED NEW FITTING IAW DC8 SRM 51-1-20D, DC8 SRM 51-3-1.

Part: SKIN — DAMAGED (L/E SLAT) · airframe 78,898 hrs · 31,422 cycles

DURING C CHECK, FOUND RT OUTER WING INBD EXTENDED L/E OUTER SKIN LWR SIDE, 3 EXISTING DOUBLER REPAIRS BETWEEN XW 485.000 AND XFS 591.250. REMOVED EXISTING REPAIR DOUBLERS IAW DC-8 SRM 51-1-21. REMOVED DAMAGED AREA IAW SEMAN DRAWING NUMBER ED 4228. PERFORMED NDT INSPECTION IAW DC-8 NDT SPM PART 06-10-01-001. NO CRACKS OR CORROSION FOUND. FAB`D REPAIR DOUBLERS AND (03EA) FILLERS IAW SEMAN DRAWING ED 4228. CLEANED, TREATED AND PRIMED AREA, FILLER, REPAIR DOUBLER, AND INTERNAL PARTS IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC8 SRM 51-1-11. INSTALLED REPAIR PARTS IAW SEMAN DRAWING NUMBER ED 4228, DC-8 SRM 51-1-21, DC8 SRM 51-3-0, DC-8 SRM 51-1-20D, DC-8 SRM 51-3-1.

Part: SKIN — DAMAGED (T/E FLAP) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION FOUND RIGHT HAND INBOARD FLAP DENTED AT SEVERAL SPOTS AND NON STANDARD REPAIR ON LOWER. SKIN BETWEEN STATIONS XW 2.000 AND XW 104.000. PERFORMED MAJOR REPAIR IAW DC-8 SRM 57-7-1 FIG 1. REMOVED DAMAGED SKIN IAW DC-8 SRM 57-1-21. FABRICATED NEW SKIN AND BONDED DOUBLER IAW DC-8 SRM 57-7-1 FIG 1 ITEM B, I BONDED BOTH PARTS WITH HYSOL IAW DC-8 SRM 51-1-9. CLEANED, TREATED AND PRIMED AREA AND NEW PARTS IAW DC-8 SRM 51-1-8B. INSTALLED NEW PARTS IAW DC-8 SRM 51-1-21.

Part: REPAIR — IMPROPER (RT WING) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION FOUND RIGHT HAND WING CENTER LEADING EDGE EXTERNAL HAS NON STANDARD REPAIR AT STATION XFS 297.750. REMOVED FASTENERS AS NEEDED TO REMOVE IMPROPER REPAIR. FABRICATED NEW REPAIR PARTS, LOCATED, DRILLED, TRIMMED, TREATED, PRIMED, AND INSTALLED NEW REPAIR PARTS. PER ALL APPLICABLE DATA.

Part: SKIN — MISREPAIRED (ZONE 500) · airframe 78,898 hrs · 31,422 cycles

DURING C CHECK, FOUND LT WING CENTER LEADING LWR SKIN HAS NON STANDARD REPAIR AT STA XOLDL 6.225. PERFORMED MAJOR REPAIR IAW FAA FORM 8110-3 NUMBER 06237 DATE 05-15-06, SEMAN DRAWING NUMBER ED 4210 DATE 05-12-06. REMOVED EXISTING REPAIR DOUBLER IAW DC-8 SRM 51-1-21, DC8 SRM 51-1-20D. REMOVED DAMAGED AREA IAW SEMAN DRAWING ED 4210. PERFORMED NDT INSPECTION IAW DC8 NDT SPM PART 06-10-01-001. NO CRACKS OR CORROSION FOUND. FAB`D REPAIR DOUBLER AND FILLER IAW SEMAN DRAWING ED 4210. CLEANED, TREATED AND PRIMED AREA, FILLER, AND REPAIR DOUBLER IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11. INSTALLED REPAIR PARTS IAW SEMAN DRAWING NUMBER ED 4210, DC8 SRM 51-1-21, DC8 SRM 51-1-20D,

Part: SKIN — CRACKED (RT WING) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, RIGHT HAND WING CENTER LEADING EDGE EXTERNAL SKIN CRACKED AT STATION XF 283.000. PERFORMED MAJOR REPAIR IAW DC-8 SRM 55-6-1 FIGURE 2 SHEET 1, AND 3, DOUGLAS DRAWING NUMBER 5655068. REMOVED DAMAGE IAW DC8 SRM 51-1-8 PAGES 17, AND 18. FABRICATED REPAIR PARTS. CLEANED, TREATED AND PRIMED AREA, AND REPAIR PARTS IAW DC-8 SRM 51-1-8B. INSTALLED REPAIR PARTS. APPLIED SEALANT TO FAYING SURFACES IAW DC8 SRM 51-1-11. IAW DC8 SRM 51-1-21, DC8 SRM 51-3-0, DC8 SRM 51-1-20D, DC8 SRM 51-3-1.

Part: SKIN — DENTED (T/E FLAP) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND RIGHT OUTBOARD FLAP LOWER SKIN DENTED AT STATION XF 360.000. PERFORMED MAJOR REPAIR IAW DC-8 SRM 57-7-1 FIG 4 TR NR 57-94 DATE 10-01-02. REMOVED DAMAGED SKIN IAW DC-8 SRM 57-1-0 PAGE 1, DC-8 SRM 51-1-21. FABRICATED NEW SKIN IAW DC-8 SRM 57-7-1 FIG. 4 ITEM “A”. CLEANED, TREATED AND PRIMED AREA AND NEW SKIN INTERNAL PART IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11. INSTALLED NEW SKIN IAW DC-8 SRM 51.1.21.

Part: SPAR CAP — CORRODED (RUDDER) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, RUDDER LEFT HAND CAP CORRODED AT HINGE SUPPORT AT STATION ZR 103.000. PERFORMED MAJOR REPAIR IAW DC-8 SRM 55-6-1 FIGURE 2, SHEET 1, AND 3, DOUGLAS DRAWING 5655068. REMOVED CORROSION IAW DC8 SRM 51-1-8 PAGES 17, 18. FOUND OUT OF LIMITS IAW DC8 SRM 55-2-0 PAGE 12. REMOVED CORRODED SPAR CAP IAW DC-8 SRM 51-1-21, DC-8 SRM 55-1-0, DC8 SRM 51-3-0, DC8 SRM 51-1-20D. CLEANED, TREATED AND PRIMED AREA IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC8 SRM 51-1-11. INSTALLED NEW SPAR CAP, IAW DC8 SRM 51-1-2L, DC8 SRM 51-3-0, DC8 SRM 51-1-20D, DC8 SRM 51-3-1. PERFORMED REBALANCE TO RUDDER IAW DC8 SRM 51-4-6. FOUND WITHIN TOLERANCE LIMITS. MOMENT 2540 14 IN LBS.

Part: SKIN — MISREPAIRED (ZONE 200) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND FUSELAGE EXT SKIN HAS A NON STANDARD REPAIR AT STATION 55.000, LONGERON 9 LEFT. PERFORMED MAJOR REPAIR IAW FAA FORM 8110-3 NUMBER 06245 DATED 05-22-06, SEMAN DRAWING NUMBER ED 4225 DATED 05-18-06. REMOVED NON STANDARD REPAIR IAW DC-8 SRM 51-1-21, DC8 SRM 51-1-20D. REMOVED DAMAGED AREA IAW SEMAN DRAWING ED 4225. PERFORMED NDT INSPECTION IAW DC8 NDT SPM ÁRT 06-10-01-001. NO CRACK, CORROSION FOUND. FABRICATED REPAIR DOUBLER AND FILLER IAW SEMAN DRAWING ED 4225. CLEANED, TREATED AND PRIMED AREA, AND REPAIR PARTS IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING IAW DC-8 SRM 51-1-11. INSTALLED REPAIR PARTS IAW SEMAN DWG NR ED 4225, DC8 SRM 51-1-20D, DC8 SRM 51-3-1.

Part: REPAIR — IMPROPER (RT WING) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION FOUND RIGHT HAND WING CENTER LEADING EDGE HAS NON STANDARD REPAIR FROM STATION XFS 310.250 TO STATION XFS 316.000. PERFORMED MAJOR REPAIR REMOVED IMPROPER REPAIR. FABRICATED REPAIR PARTS, LOCATED, DRILLED, TRIMMED, TREATED, AND PRIMED. APPLIED SEALANT TO FAYING SURFACES. INSTALLED REPAIR PARTS. IAW DC8 SRM 55-6-1 FIGURE 2, SHEETS, 1 AND 3, DC8 SRM 51-1-8, AND 18, DC8 SRM 55-2-0 PAGE 12, DC8 SRM 51-1-21, DC8 SRM 55-1-0, DC8 SRM 51-3-0, DC8 SRM 55-1-0, DC8SRM 51-3-0, DC8 SRM 51-1-11, AND DC8 SRM 51-3-0.

Part: REPAIR — IMPROPER (L/E SLOT) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, LEFT HAND INNER WING EXTENDED LEADING EDGE SLOT OUTER PLATING LOWER SIDE EXISTING REPAIR IMPROPER AT STATION XFS 341.500. PERFORMED MAJOR REPAIR IAW FAA FORM 8110-3 NUMBER 06245 DATE 05-22-06, SEMAN DRAWING NUMBER ED 4220 DATED 05-19-06. REMOVED EXISTING FASTENERS AS NEEDED TO REMOVE EXISTING REPAIR DOUBLER IAW DC-8 SRM 51-1-21, DC8 SRM 51-3-0. REMOVED DAMAGED AREA IAW SEMAN DRAWING NUMBER ED 4226. PERFORMED NDT INSPECTION IAW DC-8 NDT SPM PART 06-10-01-001. NO CRACKS, OR CORROSION FOUND. FABRICATED REPAIR DOUBLER, AND SKIN FILLERS IAW SEMAN DWG ED 4226. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC8 SRM 51-1

Part: SPAR CAP — CORRODED (RUDDER) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, RUDDER RIGHT HAND CAP CORRODED NEXT TO SUPPORT HINGE HOUSING AT STATION ZR 103.000. PERFORMED MAJOR REPAIR IAW DC-8 SRM 55-6-1 FIG. 2, DOUGLAS DRAWING NUMBER 5655068. REMOVED CORROSION IAW DC8 SRM 51-1-8 PAGES 17, 18. FOUND OUT OF LIMITS IAW DC8 SRM 55-2-0 PAGE 12. REMOVED CORRODED SPAR CAP IAW DC-8 SRM 51-1-21, DC-8 SRM 55-1-0, DC8 SRM 51-3-0, DC8 SRM 51-1-20D. CLEANED, TREATED AND PRIMED AREA IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC8 SRM 51-1-11. INSTALLED NEW SPAR CAP IAW DC8 SRM 51-1-21, DC8 SRM 51-3-0, DC8 SRM 51-1-20D, DC8 SRM 51-3-1. PERFORMED BALANCE CHECKED RUDDER IAW DC8 SRM 51-4-6. FOUND WITHIN TOLERANCE LIMITS. MOMENT 2540 14 IN LBS.

Part: DOUBLER — CRACKED (ZONE 500) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND LEFT WING CENTER LEADING EDGE INTERNAL SPLICE DOUBLER CRACKED AT STATION XOLDI 6.225. PERFORMED MAJOR REPAIR IAW BOEING MESSAGE NR 1-190592 951-3 DATE 05-12-06. REMOVED DAMAGED INTERNAL SPLICE DOUBLER IAW DC-8 SRM 57-1-0 PAGE 1, DC-8 SRM 51-1-21. FABRICATED INTERNAL SPLICE DOUBLER IAW BOEING MESSAGE NUMBER 1-1905929 51-3. CLEANED, TREATED AND PRIMED AREA AND NEW INTERNAL DOUBLER IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11. INSTALLED NEW INTERNAL SPLICE DOUBLER IAW DC-8 SRM 51.1.21, DC-8 SRM 51-1-20D, DC8 SRM 51-3-1.

Part: PANEL — DEFORMED (LT ELEVATOR) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION FOUND RIGHT HAND ELEVATOR LT UPPER PANEL DEFORMED, TRAILING EDGE BROKEN 2 INCHES AND DELAMINATED AT STATION 28.843. PERFORMED MAJOR REPAIR IAW DC-8 SRM 55-4-1 SHEET 1, AND 2. REMOVED DAMAGED PANEL IAW DC-8 SRM 55-1-0, DC-8 SRM 51-1-21. FABRICATED NEW PANEL. CLEANED, TREATED AND PRIMED AREA, AND NEW PANEL IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11. INSTALLED NEW PANEL FROM STATION XAR 0.000 TO STATION XE 132.000 IAW DC-8 SRM 55-4-1 FIG 1 SHEET 1, AND 2, DC8 SRM 51-1-21. PERFORMED BALANCE TO RIGHT HAND ELEVATOR IAW DC-8 SRM 51-4-4 PAGES 1-4. FOUND WITHIN TOLERANCE MOMENT 1477.44 LBS.

Part: SKIN — MISREPAIRED (T/E FLAP) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK, FOUND LEFT WING INBOARD FLAP UPPER PANEL HAS NON STANDARD REPAIR BETWEEN STATIONS XW 104.000 AND XW 115.000. PERFORMED MAJOR REPAIR IAW DC-8 SRM 57-7-1 FIG 1. REMOVED PANEL PLATING WITH NON STANDARD REPAIR IAW DC-8 SRM 57-1-0 PAGE 1, DC-8 SRM 51-1-21. FABRICATED NEW PANEL PLATING AND BONDED DOUBLER IAW DC-8 SRM 57-7-1 FIG 1 ITEM “A”, “L” BONDED BOTH PARTS WITH HYSOL IAW DC-8 SRM 51-1-9. CLEANED, TREATED AND PRIMED AREA AND NEW PANEL PLATING INTERNAL PART IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11. INSTALLED NEW PANEL PLATING IAW DC-8 SRM 51.1.21.

Part: FRAME — CRACKED (ZONE 100) · airframe 78,898 hrs · 31,422 cycles

C CHECK, FOUND RT AFT LWR CARGO COMPART FRAME CRACKED 1" AT STA 1520.000 BETWEEN LONGERON 21 LT AND LONGERON 22 LT. PERFORMED MAJOR REPAIR IAW DC8 SRM 53-2-0 FIG 2 SHEET 5 TR 53-125 DATE 08-31-01. REMOVED FASTENERS IAW DC8 SRM 51-1-21, DC8 SRM 51-1-20D. TRIMMED OUT DAMAGED FRAME SEGMENT IAW DC8 SRM 53-2-0 FIG 2 SHEET 5 TR 53-125. FAB`D NEW FRAME SEGMENT IAW DC-8 SRM 53-4-1 FIG 5 (SHEET 19), DC8 SRM 51-2-0 FIG 52 (SHEET 1) DC8 SRM 53-2-0 FIG 2 (SHEET 1) DC8 SRM 53-2-0 FIG 2 (SHEET 8) TR 53-110 DATE 11-10-00 AND ANGLES IAW DC8 SRM 53-2-0 FIG 2 (SHEET 5) TR 53-125 DC8 SRM 53-2-0 FIG 2 (SHEET 6) DC8 SRM 53-2-0 FIG 2 (SHEET 7) TR 53-110. PERFORMED HEAT TREATMENT TO FRAME SEGMENT AND ANGLES 7075 “O” TO 7075T6 IA

Part: FITTING — CRACKED (ZONE 200) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK, FOUND MAIN CARGO COMPARTMENT AFT FITTING CRACKED 2", STATION 760.000 LONGERON 19 RIGHT. REPLACED CRACKED AFT END FITTING IAW DC8 SRM 53-1-0, DC8 SRM 51-1-20D. FABRICATED NEW END FITTING IAW ATI REPAIR SPECIFICATION NUMBER 2003-05, DOUGLAS DRAWING NUMBER 3779978. PERFORMED NDT INSPECTION IAW DC8 NDT SPM PART 08-00-02 TO 07. CLEANED, TREATED AND PRIMED AREA AND NEW FITTING IAW DC8 SRM 51-1-8B. INSTALLED NEW END FITTING IAW DC8 SRM 51-1-20D, DC8 SRM 51-3-1.

Part: REPAIR — IMPROPER (DOOR FRAME) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, EXTERNAL FUSELAGE LEFT HAND FORWARD PASSENGER DOOR LOWER AFT JAMB CORNER HAS NON STANDARD REPAIR AT STATION 55.000 FROM LONGERON-20 LEFT TO LONGERON 22 LEFT. PERFORMED MAJOR REPAIR IAW AD 2000-20-08, SB DC8 53-075, DOUGLAS DRAWING SR 08530021, 5750776. REMOVED EXISTING FASTENERS AS NEEDED TO REMOVE NON STANDARD REPAIR IAW DC8 SRM 51-1-21. REMOVED DAMAGED AREA IAW DOUGLAS DRAWING SR 08530021. PERFORMED NDT INSPECTION IAW DC-8 NDT SPM PART 06-10-01-001. NO CRACKS, OR CORROSION FOUND. FABRICATED REPAIR DOUBLER, REPAIR TRIPLER, AND FILLER IAW DWG DOUGLAS SR 08530021. CLEANED, TREATED AND PRIMED AREA , AND REPAIR PARTS IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW

Part: FITTING — CRACKED (ZONE 200) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK, FOUND MAIN CARGO COMPARTMENT AFT BATHTUB FITTING CRACKED 2" AT STATION 680.000. REMOVED CRACKED FITTING IAW DC8 SRM 51-1-20D. CLEANED, TREATED AND PRIMED AREA IAW DC8 SRM 51-1-8B. INSTALLED NEW FITTING IAW DC8 SRM 51-1-20D, IAW DC8 SRM 51-3-1.

Part: FITTING — CRACKED (FUSELAGE) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK FOUND FORWARD LOWER CARGO COMPARTMENT SPLICE FITTING CRACKED 3 INCHES FROM STATION 440.000 TO STATION 460.000, LONGERON 3 LEFT. REMOVED CRACKED SPLICE FITTING IAW DC8 SRM 51-1-20D. CLEANED, TREATED AND PRIMED AREA IAW DC8 SRM 51-1-8B. INSTALLED NEW SPLICE FITTING AND TORQUED NUTS IAW DC8 SRM 51-1-20D, DC8 SRM 51-1-21, DC8SRM 51-3-1.

Part: FITTING — CRACKED (FUSELAGE) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION FOUND MAIN CARGO COMPARTMENT FITTING CRACKED 1INCH FROM STATION 1100.000 TO STATION 1110.000 AT LONGERON 16 RIGHT. REMOVED CRACKED FITTING IAW DC8 SRM 51-1-20D. FABRICATED NEW FITTING IAW ATI REPAIR SPECIFICATION NUMBER 2003-05, DOUGLAS DRAWING 5755936. PERFORMED HEAT TREATMENT IAW DC8 SRM 51-1-1 PAGES 1, 13, AND 17. PERFORMED NDT INSPECTION IAW DC8 NDT SPM PART 08-00-02 TO 07. CLEANED, TREATED AND PRIMED AREA, AND NEW FITTING IAW DC8 SRM 51-1-8B. INSTALLED NEW SUPPORT IAW DC8 SRM 51-1-20D, DC8 SRM 51-3-1.

Part: FITTING — CRACKED (ZONE100) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND AFT CARGO COMPARTMENT BILGE INTERIOR SPLICE FITTING CRACKED FROM STATION 1040.000 STATION 1060.000 LONGERON 31 LEFT. REPLACED BILGE INTERIOR SPLICE FITTING FROM STATION 1040.000 TO STATION 1060.000 LONGERON 31 RIGHT IAW DC8 SRM 51-1-20D, SRM 51-3-1.

Part: SKIN — MISREPAIRED (T/E FLAP) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK FOUND LEFT HAND WING INBOARD FLAP PLATING HAS NON STANDARD REPAIR FROM STATIONS XW 122.000 TO XW 125.000. PERFORMED MAJOR REPAIR IAW DC-8 SRM 57-7-1 FIG 1. REMOVED EXISTING PLATING WITH NON-STANDARD REPAIR IAW DC-8 SRM 57-1-0 PAGE 1, DC-8 SRM 51-1-21. FABRICATED NEW PLATING IAW DC-8 SRM 57-7-1 FIG 1 ITEM F. CLEANED, TREATED AND PRIMED AREA AND NEW PLATING INTERNAL PART IAW DC-8 SRM 51-1-8B. APPLIED NEW SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11. INSTALLED NEW PLATING IAW DC-8 SRM 51-1-21

Part: SPLICE — CRACKED (FUSELAGE) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION FOUND AFT CARGO COMPARTMENT BILGE INTERIOR SPLICE FITTING CRACKED FROM STATION 1040.000 TO STATION 1060.000 LONGERON 31 RIGHT. REPLACED BILGE INTERIOR SPLICE FITTING FROM STATION 1040.000 TO STATION 1060.000 LONGERON 31 LEFT IAW DC8 SRM 51-1-20D.

Part: FITTING — CRACKED (ZONE 200) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND MAIN CARGO COMPARTMENT, FORWARD BATHTUB FITTING CRACKED 3", AT STATION 857.000 LONGERON 9 LEFT. REMOVED AND REPLACED FWD BATHTUB FITTING ON MAIN CARGO COMPARTMENT, STATION 857.000 LONGERON 9 LEFT IAW DC-8 SRM 51-1-20D, DC-8 SRM 51-1-23, AND DC-8 SRM 51-3-1.

Part: SKIN — MISREPAIRED (T/E FLAP) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK FOUND LEFT HAND WING INBOARD FLAP PLATING HAS NON STANDARD REPAIR BETWEEN STATIONS XW 104.000 AND XW 122.000. PERFORMED MAJOR REPAIR IAW DC-8 SRM 57-7-1 FIG 1. REMOVED EXISTING PLATING WITH NON-STANDARD REPAIR IAW DC-8 SRM 57-1-0 PAGE 1, DC-8 SRM 51-1-21. FABRICATED NEW PLATING IAW DC-8 SRM 57-7-1 FIG 1 ITEM D. CLEANED, TREATED AND PRIMED AREA AND NEW PLATING INTERNAL PART IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11. INSTALLED NEW PLATING IAW DC-8 SRM 51-1-21.

Part: FITTING — CRACKED (FUSELAGE) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, MAIN CARGO COMPARTMENT- AFT FITTING CRACKED 3",AT STATION 680.000, LONGERON 11 RIGHT. REMOVED CRACKED FITTING IAW DC-8 SRM 51-1-20D. FABRICATED NEW FITTING IAW ATI REPAIR SPECIFICATION NR 2003-05, DOUGLAS DRAWING NR 4751625. PERFORMED NDT INSPECTION IAW DC8 NDT SPM PART 08-00-02 TO 07. CLEANED, TREATED, AND PRIMED AREA AND, NEW FITTING IAW DC8 SRM 51-1-8B. INSTALLED NEW FITTING IAW DC8 SRM 51-1-20D, DC8 SRM 51-1-23 (PLI-WASHER), DC8 SRM 51-3-1.

Part: FITTING — CRACKED (FUSELAGE) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION FOUND FITTING CRACKED AT STATION 1766.000 LONGERON 17 RIGHT. REPLACED FITTING AT STATION 1766.000 LONGERON 17 RIGHT IAW DC8 SRM 51-1-21.

Part: FITTING — CRACKED (ZONE 200) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK, FOUND MAIN CARGO COMPARTMENT FORWARD BATHTUB FITTING CRACKED 2", STATION 857.100 LONGERON 11 LEFT. REPLACED CRACKED FITTING STATION 857.000 LONGERON 11 LEFT IAW DC-8 SRM 51-1-20D, DC-8 SRM 51-3-1.

Part: FITTING — CRACKED (ZONE 200) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK, FOUND MAIN CARGO COMPARTMENT FORWARD BATHTUB FITTING CRACKED 2" AT STATION 857.100, LONGERON 9 RIGHT. REPLACED CRACKED FITTING IAW DC-8 SRM 51-1-20D, DC-8 SRM 51-1-23, DC-8 SRM 51-3-1.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION FOUND MAIN CARGO COMPARTMENT FORWARD INTERCOSTAL CRACKED 3 INCHES AT STATION 902.000 LONGERON 19 RIGHT. REMOVED CRACKED INTERCOSTAL IAW DC8 SRM 51-1-20D. FABRICATED NEW INTERCOSTAL IAW ATI REPAIR SPECIFICATION NUMBER 2003-05 AND DOUGLAS DRAWING NUMBER 3779498. PERFORMED NDT INSPECTION IAW DC8 NDT SPM PART 08-00-02 TO 07. CLEANED, TREATED AND PRIMED AREA AND NEW INTERCOSTAL IAW DC8 SRM 51-1-8B. INSTALLED NEW INTERCOSTAL SUPPORT IAW DC8 SRM 51-1-20D, DC8 SRM 51-3-1.

Part: SKIN — DAMAGED (LT WING) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK FOUND LEFT HAND WING CENTER LEADING EDGE EXTERNAL SKIN HOLES ELONGATED AT STATION XOLDO 67. PERFORMED MAJOR REPAIR IAW FAA FORM 8110-3 NR 06237 DATE 05-15-06, SEMAN DRAWING NR ED 4212 DATED 05-06-06, SEMAN EO NUMBER 2006322 DATE 05-15-06. REMOVED EXISTING REPAIR DOUBLER IAW DC8 IAW DC-8 SRM 51-1-2L, DC8 SRM 51-1-20D, DC8 SRM 51-3-0. REMOVED DAMAGED AREA IAW SEMAN DWG NR ED 4212. PERFORMED NDT INSPECTION IAW DC8 NDT SPM PART 06-10-01-001. NO CRACK OR CORROSION FOUND. FABRICATED EXTERNAL REPAIR DOUBLER, FILLER, AND INTERNAL DOUBLER, IAW SEMAN DRAWING NUMBER ED 4212. CLEANED, TREATED AND PRIMED AREA, FILLER, INTERNAL AND EXTERNAL REPAIR DOUBLER. APPLIED SEALANT TO FAYING SURFACES IAW DC-8

Part: LONGERON — MISREPAIRED (FUSELAGE) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK FOUND RIGHT HAND MAIN LANDING GEAR LONGERON 24 HAS NON STANDARD REPAIR FROM STATION 940.000 TO STATION 960.000. PERFORMED MAJOR REPAIR IAW DC-8 SRM 53-2-2 FIG 5 TEMPORARY REVISION 53-123 DATE 05-15-01. REMOVED REPAIR IAW DC-8 SRM 51-1-21. PERFORMED NDT INSPECTION IAW DC-8 NDT SPM PART 06-10-01-001. NO CRACKS OR CORROSION FOUND. FABRICATED REPAIR ANGLES IAW DC-8 SRM 53-2-2 FIG 5 (SHEET 1, 2, 20, 21, 22, 23, 27). CLEANED, TREATED AND PRIMED AREA AND REPAIR ANGLES IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11. INSTALLED REPAIR ANGLES IAW DC-8 SRM 53-2-2 FIG 5 (SHEET 2, 20, 21, 22, 23, 25, 27).

Part: SKIN — DELAMINATED (AILERON TRIM TAB) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, RIGHT HAND WING- INBOARD AILERON TRIM TAB UPPER AND LOWER SKIN DELAMINATED. CLEANED AND BONDED RIGHT HAND INBOARD AILERON TRIM TAB UPPER AND LOWER SKIN EDGE WITH HYSOL IAW DC8 SRM 51-1-9.

Part: FITTING — CRACKED (FUSELAGE) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK FOUND MAIN CARGO COMPARTMENT AFT FITTING CRACKED 1 INCH, STATION 780 LONGERON 13 RIGHT. REMOVED AFT END FITTING IAW DC-8 SRM 53-1-0, DC-8 SRM 51-1-20D. FABRICATED NEW END FITTING IAW ATI REPAIR SPECIFICATION NR 2003-05 DOUGLAS DRAWING NUMBER 3779970. PERFORMED NDT INSPECTION IAW DC-8 NDT SPM PART 08.00.02 TO 07. CLEANED, TREATED AND PRIMED AREA AND END FITTING IAW DC-8 SRM 51-1-8B. INSTALLED NEW END FITTING IAW DC-8 SRM 51-1-20D, DC-8 SRM 51-3-1.

Part: INTERCOSTAL — CRACKED (FUSELAGE) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION FOUND MAIN CARGO COMPARTMENT INTERCOSTAL CRACKED 1 INCH AT STATION 857.000, LONGERON 19 LEFT. REMOVED CRACKED INTERCOSTAL IAW DC8 SRM 51-1-20D. FABRICATED NEW INTERCOSTAL IAW ATI REPAIR SPECIFICATION NUMBER 2003-05 AND DOUGLAS DRAWING NUMBER 47 50420. PERFORMED NDT INSPECTION IAW DC8 NDT SPM PART 08-00-02 TO 07. CLEANED, TREATED AND PRIMED AREA AND NEW INTERCOSTAL IAW DC8 SRM 51-1-8B. INSTALLED NEW INTERCOSTAL SUPPORT IAW DC8 SRM 51-1-20D, DC8 SRM 51-3-1.

Part: FITTING — CORRODED (ZONE 200) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, MAIN CARGO COMPARTMENT FORWARD FITTING CORRODED, STATION 742.000 LONGERON 19 RIGHT. REMOVED CORROSION IAW DC-8 SRM 51-1-8 PAGES 17, 18. FOUND OUT OF LIMITS IAW DC8 SRM 53-2-0 PAGE 2P. REMOVED CORRODED BATHTUB FITTING IAW DC8 SRM 51-1-20D. FABRICATED NEW BATHTUB FITTING (AL7075T6 51) IAW ATI SPECIFICATION NR 2003-05, DOUGLAS DRAWING NR 4751511. PERFORMED NDT INSPECTION IAW DC8 NDT SPM PART 08-00-02 TO 07. NO CRACK FOUND. CLEANED, TREATED AND PRIMED AREA AND BATHTUB FITTING IAW DC8 SRM 51-1-8B. INSTALLED NEW BATHTUB FITTING IAW DC8 SRM 51-1-20D, DC8 SRM 51-3-1.

Part: FITTING — CORRODED (ZONE 200) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, MAIN CARGO COMPT AFT FITTING CORRODED, STATION 717.000 L-13L. REMOVED CORROSION IAW DC-8 SRM 51-1-8 PAGES 17, 18. FOUND OUT OF LIMITS IAW DC8 SRM 53-2-0 PAGE 1P. REMOVED CORRODED BATHTUB FITTING IAW DC8 SRM 51-1-20D. FABRICATED NEW BATHTUB FITTING (AL7075T6 SI) IAW ATI SPECIFICATION NUMBER 2003-05, DOUGLAS DRAWING NUMBER 4751511. PERFORMED NDT INSPECTION IAW DC8 NDT SPM PART 08-00-02 TO 07. NO CRACK FOUND. CLEANED, TREATED AND PRIMED AREA AND BATHTUB FITTING IAW DC8 SRM 51-1-8B. INSTALLED NEW BATHTUB FITTING IAW DC8 SRM 51-1-20D, DC8 SRM 51-3-1.

Part: FRAME — MISDRILLED (ZONE 200) · airframe 78,898 hrs · 31,422 cycles

DURING C CHECK, FOUND MAIN CARGO COMPT FRAME FLANGE HOLE MISDRILLED AT STA 200.000 BETWEEN LONGERONS 14 RT AND LONGERON 15 RT. PERFORMED MAJOR REPAIR IAW FAA FORM 8110-3 NR 06242 DATE 05-18-06, SEMAN DRAWING NR ED 4220 DATE 05-12-06. REMOVED DAMAGED CLIP, DC-8 SRM 51-1-21. PERFORMED BLEND OUT TO DAMAGED AREA IAW DWG ED 4220. PERFORMED NDT INSPECTION IAW DC8 NDT SPM ART 06-10-01-001. NO CRACK, CORROSION FOUND. FAB`D ANGLE DOUBLER, ANGLE TRIPLER AND FILLER IAW SEMAN DRAWING ED 4220. PERFORMED HEAT TREATMENT ON ANGLE DOUBLER AND TRIPLER FROM 7075 “O” TO 7075T6 IAW DC8 SRM 51-1-11 PAGES 13, 17. CLEANED, TREATED AND PRIMED AREA AND REPAIR PARTS IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC

Part: FITTING — CRACKED (FUSELAGE) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK, FOUND MAIN CARGO COMPARTMENT FORWARD FITTING CRACKED 1" AT STATION 920.000, LONGERON 18.5 RIGHT HAND. REMOVED CRACKED FITTING IAW DC8 SRM 51-1-20D. FABRICATED NEW FITTING IAW ATI REPAIR SPECIFICATION NUMBER 2003-05. PERFORMED HEAT TREATMENT FROM 7075T6 51 TO 7075T6 IAW DC8 SRM 51-1-1 PAGES 1, 13, 17. PERFORMED NDT INSPECTION IAW DC8 NDT SPM PART 08-00-02 TO 07. CLEANED, TREATED AND PRIMED AREA AND NEW CLIP IAW DC8 SRM 51-1-8B. INSTALLED NEW FITTING IAW DC8 SRM 51-1-20D, DC8 SRM 51-3-1.

Part: SKIN — MISREPAIRED (T/E FLAP) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK FOUND LEFT HAND WING INBOARD FLAP HAS NON STANDARD REPAIR AND DENTS FROM STATIONS XW 3.000 TO XW 92.000. PERFORMED MAJOR REPAIR IAW DC-8 SRM 57-7-1 FIG 1. REMOVED DAMAGED PANEL PLATING IAW DC-8 SRM 57-1-0, DC-8 SRM 51-1-21. FABRICATED NEW PANEL PLATING WITH PLATING AND BONDED DOUBLER IAW DC-8 SRM 57-7-1 FIG 1 ITEM A, L. BONDED BOTH PARTS WITH HILOKS IAW DC8 SRM 51-1-11. CLEANED, TREATED AND PRIMED AREA AND NEW PANEL PLATING INTERNAL PART IAW DC-8 SRM 51-1-8B. APPLIED NEW SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11. INSTALLED NEW PLATING IAW DC-8 SRM 51-1-21.

Part: SKIN — CRACKED (RT WING) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK FOUND RIGHT HAND WING UPPER SKIN CRACKED AT STATION XRS 74.000 - 9.000. PERFORMED MAJOR REPAIR IAW DC-8 SRM 57-2-1 FIG 17. REMOVED FASTENERS IAW DC-8 SRM 51-1-20D. REMOVED DAMAGED AREA IAW DC-8 SRM 57-2-1 FIG 17. PERFORMED NDT INSPECTION IAW DC-8 NDT SPM PART 06-10-01-001. NO CRACK, OR CORROSION FOUND AFTER TRIM OUT. FABRICATED EXTERNAL REPAIR DOUBLER AND FILLER IAW DC-8 SRM 57-2-1 FIG 17, DC-8 SRM 57-3-1 FIG 10. TAPERED EXTERNAL REPAIR DOUBLER 0.160 TO 0.080 IAW DC-8 SRM 51-10-0 FIG 1 (SHEET 6). CLEANED, TREATED, AND PRIMED AREA AND EXTERNAL REPAIR DOUBLER IAW DC-8 SRM 51-1-12 PAGES 7-25. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11. INSTALLED REPAIR PARTS IAW DC-8 SRM

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, EXTERNAL FUSELAGE AFT PASSENGER DOOR LEFT HAND LOWER CORNER CRACKED 2". PERFORMED MAJOR REPAIR IAW AD 2000-20-08, SB DC8 53-075, DOUGLAS DRAWING SR 08530021, S750776. REMOVED EXISTING FASTENERS IAW DC8 SRM 51-1-2L, DC-8 SRM 51-1-20D. REMOVED DAMAGED AREA IAW DOUGLAS DRAWING SR 08530021. PERFORMED NDT INSPECTION IAW DC-8 NDT SPM PART 06-10-01-001. NO CRACK, OR CORROSION FOUND. FABRICATED REPAIR DOUBLER, REPAIR TRIPLER AND FILLER IAW DOUGLAS DRAWING SR 08530021. CLEANED, TREATED, PRIMED AREA AND REPAIR PARTS IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11. INSTALLED REPAIR PARTS IAW DOUGLAS DRAWING SR 08530021, DC8 SRM 51-1-21, DC-8 SRM 51-1-20D, D

Part: REPAIR — IMPROPER (DOOR FRAME) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, EXTERNAL FUSELAGE LEFT HAND FORWARD PASSENGER DOOR UPPER AFT JAMB CORNER HAS NON STANDARD REPAIR AT STATION 55.000, FROM LONGERON-9 LEFT, TO LONGERON-11LEFT. PERFORMED MAJOR REPAIR IAW AD 2000-20-08, SB DC8 53-075, DOUGLAS DRAWING SR 08530021, 5750776. REMOVED EXISTING REPAIR DOUBLER IAW DC8 SRM 51-1-20D, DC8 SRM 51-1-21, DC8 SRM 51-3-0. PERFORMED NDT INSPECTION IAW DC-8 NDT PART 06-10-01-001. NO CRACK, OR CORROSION FOUND. FABRICATED REPAIR DOUBLER AND REPAIR TRIPLER IAW DOUGLAS DRAWING SR 08530021. CLEANED, TREATED, PRIMED AREA, AND REPAIR PARTS IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11. INSTALLED REPAIR PARTS IAW DOUGLAS DRAWING SR 08530

Part: REPAIR — IMPROPER (DOOR FRAME) · airframe 78,898 hrs · 31,422 cycles

DURING ROUTINE C CHECK INSPECTION, EXTERNAL FUSELAGE LEFT HAND FORWARD PASSENGER DOOR UPPER FORWARD JAMB CORNER HAS NON STANDARD REPAIR AT STATION 25.000, FROM LONGERON-9 LEFT TO LONGERON 11 LEFT. PERFORMED MAJOR REPAIR IAW AD 2000-20-08, SB DC8 53-075, DOUGLAS DRAWING SR 08530021, 5750776. REMOVED EXISTING FASTENERS AS NEEDED TO REMOVE EXISTING REPAIR DOUBLER IAW DC8 SRM 51-1-21 DC-8 SRM 51-1-20D. PERFORMED NDT INSPECTION IAW DC-8 NDT SPM PART 06-10-01-001. NO CRACK, OR CORROSION FOUND. FABRICATED REPAIR DOUBLER, AND REPAIR TRIPLER IAW DWG DOUGLAS SR 08530021. CLEANED, TREATED AND PRIMED AREA, AND REPAIR PARTS IAW DC-8 SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW DC-8 SRM 51-1-11. INSTALLED REPAIR PART

Part: STRIKER — BROKEN (MLG DOOR) · airframe 78,828 hrs · 31,394 cycles

AFTER DEPARTURE FROM MMMX THE GEAR DOORS LIGHT REMAINED ILLUMINATED. CREW RECYCLED GEAR PER COM PROCEDURES AND IT HAD NO EFFECT. CREW LANDED WITHOUT INCIDENT. MAINTENANCE FOUND BROKEN RIGHT DOOR STRIKER. REMOVED AND REPLACED THE STRIKER AND THE OPERATIONAL CHECK WAS GOOD PER ALL APPLICABLE MANUALS. AIRCRAFT WAS RETURNED TO SERVICE.

Part: LINK ASSY — BINDING (NLG) · airframe 76,567 hrs · 30,389 cycles

WHEN THE GEAR UPLATCH CHECK WAS ACCOMP WITH THE HANDLE IN THE UPLATCH CHECK POSITION. AT THE SAME TIME THE NOSE GEAR SEEMED TO FALL HARD ONTO THE NOSE DOORS CAUSING INCREASED NOISE. THE GEAR WAS CYCLED DOWN AND UP. THE UPLATCH CHECK REPEATED AND THE NOISE FROM THE NOSE GEAR WAS LOUDER AND THE "GEAR UNSAFE" LIGHT CAME BACK ON. NO LIGHTS ARE ON WITH THE GEAR HANDLE UP. AN INVESTIGATION IS ON GOING. WHEN MORE INFORMATION BECOMES AVAILABLE IT WILL BE PROVIDED. MX FOUND RIGHT UPPER UPATCH LINK BINDING. REMOVED AND REPLACED LINK ASSEMBLY AND THE OPS CHECK WAS GOOD PER ALL APPLICABLE MANUALS. THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: SMOKE DETECTOR — BROKEN (CARGO BAY) · airframe 75,963 hrs · 30,171 cycles

DURING ROUTINE TAKEOFF FROM MIAMI LOWER CARGO COMPT FIRE LIGHT ILLUMINATED. AFTER SHUTDOWN, MECHANIC DISPLAY SHOWED FALSE ALARM. FIRE DEPARTMENT VERIFIED NO HEAT IN (D) PIT. DOOR OPENED AND NOTHING FOUND. OVERWEIGHT INSPECTION REQUIRED. T/S SMOKE SYSTEM AND REPLACED 2EA SDU'S IN (D) PIT AND 1 EA IN (B) PIT. RECHARACTERIZED SYSTEM AND COMPLETE INOP. ACFT RETURNED TO SERVICE.

Part: WIRE — BROKEN (RADAR) · airframe 75,934 hrs · 30,159 cycles

DURING CRUISE FROM KTOL, RADAR HAD A TENUATION NOISE BAND AT 20 MILE MARKER RUNNING COMPLETELY ACROSS DISPLAY IN ANY RANGE SELECTED. CREW RETURNED AIRCRAFT TO KTOL AND LANDED WITHOUT INCIDENT. MAINTENANCE REPAIRED DEFECTIVE SPLICES BEHIND PLUG D10-61 IN RADIO RACK AND RADAR OPERATIONAL CHECK WAS GOOD PER ALL APPLICABLE MANUALS. AIRCRAFT WAS RETURNED TO SERVICE.

Part: PLATE — CRACKED (ZONE 100) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE C CHECK INSPECTION, FOUND FUSELAGE AFT CENTER SECTION LWR PLATING CRACKED 1 INCH BETWEEN STA 1555.00 AND SB 1560.00. REPAIRS WERE ACCOMPLISHED BY PERFORMING MAJOR REPAIR IAW DC8-53-2-1 FIG 7. REMOVED FASTENERS IAW DC8 SRM 51-1-21, PAGE 1. REMOVED DAMAGED AREA AND FABRICATED DOUBLER FINGER DOUBLER & FILLER, IAW DC8 SRM 53-2-1 FIG 2. CLEANED, TREATED AND PRIMED AREA, FILLER AND FINGER DOUBLER IAW DC8 SRM 51-1-8B. APPLIED PRC SEALANT ON FAYING SURFACES IAW DC8 SRM 51-1-11 PAGE 9. INSTALLED DOUBLER, FILLER AND FINGER.

Part: FITTING — CRACKED (FUSELAGE) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE A-CHECK INSPECTION, FOUND ALT. CARGO COMPT FITTING CRACKED AT STA 1260.000. REPAIRS WERE ACCOMPLISHED BY PERFORMING MAJOR REPAIRS IAW SRM 53-1-0 PAGE, PAIR SPECIFICATION NR 2003-05M DWG NR 3350223, REMOVED FASTENERS IAW SRM 51-1-21 PAGE 1, TRIMMED FOR CRACKED FITTING REMOVAL IAW SRM 53-2-2 FIG 10, REMOVED CRACKED FITTING IAW SRM 51-1-20D PAGE 21, CLEANED, TREATED AND PRIMED AREA IAW SRM 51-1-8B, FABRICATED STANDARD LONGERON SPLICE, (TR NR 53-193 MARCH 15/04) DWG SR08530009, FABRICATED FITTING, IAW SRM REPAIR SPECIFICATION PART 08-00-02102, SRM 53-2-2 FIG 10M CLEANED, TREATED AND PRIMED STANDARD LONGERON SPLICES & FITTING WITH FASTENERS IAW DC8 SRM 51-1-20D PAGE 9.

Part: SKIN — DAMAGED (ZONE 500) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE C CHECK INSPECTION, FOUND LT WING OTBD FLAP LWR PART SKIN HAS INTERIM REPAIR AT XF 320.00. REPAIRS WERE ACCOMPLISHED BY PERFORMING THE FOLLOWING REPAIRS IAW DC8 SRM 57-1-0 PAGE 1, DC8 SRM 57-7-1 FIG 4 PAGE 2 OF 2. REMOVED LOWER PLATING WITH INTERIM REPAIR IAW DC8 SRM 51-1-21 PAGE 1. FABRICATED NEW PLATING IAW DC8 SRM 57-7-1 PAGE 2 OF 2 FIG 4. CLEANED, TREATED AND PRIMED NEW PLATING AND AREA IAW DC8 SRM 51-1-8B. INSTALLED NEW PLATING IAW DC8 SRM 51-1-21 PAGE 1.

Part: SKIN — DENTED (CARGO DOOR) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE A-CHECK INSPECTION FOUND B-CARGO DOOR HAS REPAIRS & DENTS ON EXTERIOR SKIN AND .2500 INCH BROKEN AT RT SIDE EDGE. REPAIRS WERE ACCOMPLISHED BY PERFORMING REPAIR IAW SRM 52-10 PG. 1, SRM 52-4-1 PG. 2 FIG. 1, REMOVED DAMAGED EXTERIOR SKIN IAW SRM 51-1-21 PG. 1-2, FABRICATED NEW EXTERIOR SKIN, DOUBLER PLATE & EXTERNAL DOUBLERS, IAW SRM 52-4-1 PG. 2 FIG. 1 CLEANED, TREATED AND PRIMED AREA OF EXTERIOR SKIN, DOUBLER PLATE & EXTERNAL DOUBLERS IAW SRM 51-1-11 PG. 9 INSTALLED DOUBLER PLATE, EXTERIOR SKIN & EXTERNAL DOUBLER IAW SRM 51-1-21 PG. 1-2.

Part: DOOR FRAME — CRACKED (FUSELAGE) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE C CHECK INSPECTION, FOUND FWD ACCY COMPT FRAME CRACKED 1" AT STA 55.000, 1-24R. REPAIRS WERE ACCOMPLISHED BY PERFORMING MAJOR REPAIRS IAW DC8 SRM 53-2-0 FIG 2. REMOVED FASTENERS IAW DC8 SRM 51-1-21 PAGES 1, 2. REMOVED DAMAGED FRAME IAW DC8 SRM AND ANGLE DOUBLERS IAW DC8 SRM 53-2-0 FIG 2 PAGE 1 OF 3. PERFORMED HEAT TREATMENT IAW DC8 SRM 51-1-1 PAGES 1-13-17. CLEANED, TREATED AND PRIMED AREA AND FRAME SEGMENT AND ANGLES IAW DC9 SRM 51-1-8B. APPLIED PRC SEALANT TO FAYING SURFACES AND INSTALLED FRAME SEGMENT AND ANGLE DOUBLERS WITH NEW FASTENERS IAW DC9 SRM 53-2-0 FIG 2, DC8 SRM 51-1-21 PAGE 1, DC8 SRM 51-1-20D, PAGE 9 DC8 SRM 51-1-15 PAGE 1.

Part: SKIN PANEL — DAMAGED (TE FLAP) · airframe 75,918 hrs · 30,152 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND LT INBD FLAP HAS INTERIM REPAIR ON UPPER PLATING, STA XW 89.000. REPAIRS WERE ACCOMPLISHED BY PERFORMING THE FOLLOWING REPAIRS IAW DC8 SRM 57-1-0 PG 1, DC8 SRM 57-7-1 PG 2 FIG 1. REMOVED UPPER PLATING IAW DC8 SRM 51-1-21 PG 1. FABRICATED NEW PLATING IAW DC8 SRM 57-1-0 PG 1, DC8 SRM 57-7-1 PG 2 FIG 1. CLEANED, TREATED AND PRIMED INNER FACE OF NEW PLATING IAW DC8 SRM 51-1-8B. INSTALLED NEW PLATING IAW DC8 SRM 51-1-21 PG 1.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE C CHECK INSPECTION, FOUND LT FUSELAGE FORWARD CENTER SECTION INTERIM REPAIR AROUND STA FS 356.00, L-25L. REPAIR WAS ACCOMPLISHED. REMOVED EXTERNAL CIRCULAR DOUBLER IAW DC8 SRM 51-1-20D PG 21. FABRICATED NEW DOUBLER AND FINGER DOUBLER IAW DC8 SRM 53-2-1 FIG 7. CLEANED, TREATED AND PRIMED AREA. APPLIED SEALANT TO FAYING SURFACES IAW DC8 SRM 51-1-11 PG 9. INSTALLED DOUBLER AND FINGER DOUBLER WITH NEW FASTENERS IAW ALL APPLICABLE MANUALS.

Part: SKIN — DAMAGED (TE FLAP) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE C CHECK INSPECTION, FOUND LT WING OTBD FLAP L/E UPPER PART HAS INTERIM REPAIR AT XE 415.000. REPAIRS WERE ACCOMPLISHED BY PERFORMING MAJOR REPAIRS IAW DC8 SRM 57-1-0 PAGE 1, DC8 SRM 57-7-1 FIG 4. REMOVED PLATING WITH INTERIM REPAIR IAW DC8 SRM 51-1-21 PAGE 1. FABRICATED NEW PLATING IAW DC8 SRM 57-7-4 FIG 4. CLEANED, TREATED AND PRIMED AREA AND PLAYING INTERNAL PART IAW DC8 SRM 51-1-8B. INSTALLED NEW PLATING IAW DC8 SRM 51-1-21 PAGE 1.

Part: SKIN — DAMAGED (FUSELAGE) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE C CHECK INSPECTION, FOUND FWD FUSELAGE EXTERNAL AC POWER RECEPTACLE EXTERNAL SKIN HAS INTERIM REPAIR AT FS 32.000, L-31R TO L-32R. REPAIRS WERE ACCOMPLISHED BY PERFORMING THE FOLLOWING REPAIR IAW DC8 SRM 51-1-21 PAGES 1, 2. REMOVED DAMAGED AREA IAW DC8 SRM 53-2-0 PAGES 2K FIG 10. FABRICATED FILLER AND DOUBLER IAW DC8 SRM 53-2-0 PAGE 2K FIG 10. CLEANED, TREATED AND PRIMED FILLER AND DOUBLER IAW DC8 SRM 51-1-8B. INSTALLED FILLER AND DOUBLER IAW DC8 SRM 51-1-20D PAGE 9, SRM 51-1-21 PAGE 1.

Part: SKIN — DAMAGED (SERVICE DOOR) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE A-CHECK INSPECTION, FOUND AFT SERVICE DOOR HAS INTERIM REPAIR ON UPPER AFT CORNER, STA 1660.000 L-11R TD L-98. REPAIRS WERE ACCOMPLISHED BY PERFORMING MAJOR REPAIR IAW SRM 53-2-0, FIG 76, TR NR 53-197 MAR 26/04 REMOVED INTERIM REPAIR IAW SRM 51-1-21 PG. 1, REMOVED DAMAGED SECTION IAW SRM 53-2-0, FIG. 16 PG. 109-110 FABRICATED FILLER & DOUBLER TREATED AND PRIMED AREA, FILLER, DOUBLER & TRIPLER IAW SRM 51-1-8B INSTALLED CONICAL WASHER IAW DC8 SRM 51-1-26 PG. 1 APPLIED (PRC) SEALANT TO FAYING SURFACES IAW SRM 51-1-11 PG. 9 INSTALLED FILLER DOUBLER & TRIPLER IAW SRM 53-2-0 PG. 108-110, SRM 51-1-21 PG. SRM 51-1-20D PG. 9 ALL ENTERED ON LP NR 094771 ITEM 5M.

Part: ACCESS DOOR — DAMAGED (ZONE 100) · airframe 75,918 hrs · 30,152 cycles

DURING ROUTINE C CHECK INSPECTION, FOUND FWD FUSELAGE (02 EA) INTERIM REPAIRS ON EXHAUST DOOR SYSTEM CORNERS AT STA 40,000 L-31L. REPAIRS WERE ACCOMPLISHED BY PERFORMING THE FOLLOWING REPAIRS IAW DC8 SRM 53-2-0 FIG 13. REMOVED INTERIM REPAIR IAW DC8 SRM 51-1-20D PAGE 21. FABRICATED DOUBLER IAW DC8 SRM 53-2-0 PAGES 69 AND 70 FIG 13. CLEANED, TREATED AND PRIMED AREA AND DOUBLER IAW DC8 SRM 51-1-8B. APPLIED PRC SEALANT ON FAYING SURFACES IAW DC8 SRM 51-1-15 PAGE 1. INSTALLED DOUBLER WITH NEW FASTENERS IAW DC8 SRM 53-2-0 PAGES 69 AND 70, DC8 SRM 51-1-20D PAGE 9.

Part: PLATE — WORN (ZONE 600) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE C CHECK INSPECTION, FOUND RT OUTBD FLAP L/E UPPER PLATING WEAR AT STA XF 211.000. REPAIRS WERE ACCOMPLISHED BY PERFORMING MAJOR REPAIR IAW DC8 SRM 57-1-0 PG 1, DC8 SRM 57-7-1 PG 2 FIG 4. REMOVED WORN PLATING IAW DC8 SRM 51-1-21 PG 1 FABRICATED NEW PLATING IAW DC8 SRM 57-7-1PG 2. CLEANED, TREATED AND PRIMED AREA AND INNER FACE OF NEW PLATING IAW DC8 SRM 51-1-8B. INSTALLED NEW PLATING IAW DC8 SRM 51-1-21 PG 1, DC8 SRM 51-1-15 PG 1.

Part: SKIN — WORN (ZONE 600) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE C CHECK INSPECTION, FOUND RT OUTBD FLAP UPPER SKIN HAS INTERIM REPAIR AT STA XF 282.000. REPAIRS WERE ACCOMPLISHED BY PERFORMING MAJOR REPAIRS IAW DC8 SRM 51-1-0 PG 1 DC8 SRM 57-7-1 PG 2 FIG 4. REMOVED RT OUTBD FLAP FWD UPPER PLATING WITH INTERIM REPAIR ON IT IAW DC8 SRM 51-121 PG 1. FABRICATED NEW UPPER PLATING IAW DC8 SRM 57-7-1 PG 2. CLEANED, TREATED AND PRIMED AREA AND PLATING INTERIOR IAW DC8 SRM 51-1-8B. INSTALLED NEW UPPER PLATING IAW DC8 SRM 51-1-21 PG 1.

Part: SKIN — CORRODED (FUSELAGE) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE C CHECK INSPECTION, FOUND FUSELAGE EXTERIOR SKIN BELOW ADF LOOP ANTENNA CORRODED, STA 115.000 TO 160.000, L-35R TO L-35L. REPAIR WAS ACCOMPLISHED. REMOVED THE CORROSION AND FOUND OUT OF LIMITS IAW 51-1-8 PG 17-18, AND 53-20 PG 24. REMOVED CORRODED SKIN AND INTERNAL DOUBLER IAW DC8 SRM 51-1-21 PG 1. CLEANED, TREATED AND PRIMED AREA. APPLIED SEALANT TO FAYING SURFACES AND INSTALLED DOUBLER AND SKIN PER ALL APPLICABLE MANUALS.

Part: VANE — DAMAGED (RT WING) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE C-CHECK INSPECTION FOUND RT WING VANE SLOT HOLES ELONGNATED AT SX 515.720. REPAIR WAS ACCOMPLISHED. REMOVED ALL FASTENERS WITH THE REPAIR AREA AND REMOVED DAMAGED AREA PER APPLICABLE MANUALS, PERFORMED NDT INSPECTION PER NDT SPM PART 06-10-01-001. CLEANED, TREATED AND PRIMED IAW EC8 SRM 51-1-8R. FABRICATED ON EXTERNAL DOUBLER, A FILLER & INTERNAL DOUBLER IAW DWG V82-R04. CLEANED, TREATED AND PRIMED THE REPAIR DOUBLER (EXTERNAL) INTERIOR SURFACE, FILLER & INTERNAL DOUBLER, APPLIED PRC SEALANT ON FAYING SURFACES PER ALL APPLICABLE MANUALS. INSTALLED EXTERNAL DOUBLER, FILLER & INTERNAL DOUBLER ON RT WING SLOT VANE IAW DWG V82-R04, DC8SRM 51-1-21 PG 1.

Part: VANE — ELONGATED (RT WING FLAP) · airframe 75,918 hrs · 30,152 cycles

ROUTINE C-CHECK INSP FOUND RT IB VANE SLOT ELONGATED HOLES AT STA XS. 250.089. REPAIR WAS ACCOMPLISHED. REMOVED ALL FASTENERS WITHIN REPAIR AREAS IAW SRM 51-1-21 PG 1, SRM 51-1-20D PG 21. REMOVED DAMAGED AREA IAW DWG V82-R07. PERFORMED NDT INSP IAW NDT SPM PART 06-10-01-001. CLEANED, TREATED AND PRIMED AREA IAW SRM 51-1-8B. FABRICATED AN EXTERNAL DOUBLER AND FILLER AND INTERNAL DOUBLER IAW DWG VR2-R07. CLEANED, TREATED AND PRIMED REPAIR DOUBLER INTERIOR SURFACE, FILLER AND INTERNAL DOUBLER IAW SRM 51-1-8B. APPLIED SEALANT ON FAYING SURFACES IAW SRM 51-1-11 PG1. INSTALLED EXTERNAL DOUBLER, FILLER AND INTERNAL DOUBLER ON RT IB VANE SLOT USING NEW FASTENERS IAW DWG V82-R07, SRM 51-1-21 PG.1, SRM 51-1-20D PG7.

Part: SKIN PANEL — DAMAGED (HORIZONTAL STAB) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE C-CHECK INSPECTION FOUND RT HORIZONTAL STABILIZER LE HAS AND INTERIM REPAIR. STA XFS 210.000. REPAIR WAS ACCOMPLISHED. REMOVED INTERIM REPAIR IAW SRM 51-1-21 PG 1. FABRICATED DOUBLER AND FILLER IAW SRM 55-2-1 PG 17 FIG 4. CLEANED, TREATED AND PRIMED AREA AND FILLER AND DOUBLER INTERIOR IAW SRM 51-1-8B. APPLIED PRC SEALANT ON FAYING SURFACES IAW SRM 51-1-11 PG 9. INSTALLED DOUBLER AND FILLER WITH NEW FASTENERS IAW SRM 51-1-21 PG 1.

Part: SKIN — DAMAGED (VERTICAL STAB) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE C-CHECK INSPECTION, FOUND VERTICAL STAB LE HAS AN INTERM REPAIR STA ZFS 179.750. REPAIR ACCOMPLISHED. REMOVED INTERIM REPAIR IAW SRM 51-1-21 PG 1, FABRICATED FILLER AND DOUBLER IAW SRM 55-2-1 PG 17 FIG 4. CLEANED, TREATED AND PRIMED AREA AND INNER FACE OF FILLER & DOUBLER IAW SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW SRM 51-1-15 PG 1. INSTALLED FILLER & DOUBLER IAW SRM 55-2-1 PG 17 FIG.4 SRM 51-1-21 PG 1.

Part: SKIN — CRACKED (FUSELAGE) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE C-CHECK INSP CRACK WAS FOUND IN LT FUSE NOSE SECTION HOLD OPEN HOOK COMPT BETWN STA FS 8.00 TO FS 17.0, L-15L TO L-16L. REPAIR WAS ACCOMPLISHED. FASTENERS WITHIN REPAIR AREA, INCLUDING DAMAGED SKIN WERE REMOVED. PERFORMED A NDT INSPECTION. CLEANED, TREATED AND PRIMED AREA. FABRICATED A REPAIR DOUBLER, TWO FINGER DOUBLERS AND A FILLER IAW DRAWING V82-R03. CLEANED, TREATED AND PRIMED THE REPAIR DOUBLER, FILLER AND FINGER DOUBLERS IAW DC8 SRM 51-1-8B. APPLIED PRC SEALANT ON FAYING SURFACES IAW DC8 SRM 51-1-11 PG 1. INSTALLED THE REPAIR DOUBLER, FINGER DOUBLERS AND FILLERS ON FWD PASSENGER DOOR BUMPER SKIN AREA USING NEW FASTENERS IAW DWG V82-R03, DC8 SRM 51-1-21 AND 51-3-0 PG 1.

Part: SKIN — DAMAGED (HORIZONTAL STAB) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE C-CHECK INSPECTION, FOUND RT HORIZONTAL STAB LE HAS AN INTERIM REPAIR. STA XFS. 109.750. REPAIR WAS ACCOMPLISHED. REMOVED INTERIM REPAIR IAW SRM 51-1-21 PG1. FABRICATED DOUBLER. CLEANED, TREATED AND PRIMED AREA AND DOUBLER INTERNAL PART IAW SRM 51-1-8B. APPLIED PRC SEALANT ON FAYING SURFACES IAW SRM 51-1-15 PAGE 1. INSTALLED DOUBLER WITH NEW FASTENERS IAW SRM 55-2-1 PG 17. FIG 4, SRM 51-1-21 PG1, SRM 51-1-21A PAGES 1-4.

Part: SKIN — CRACKED (ZONE 500) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE C-CHECK INSPECTION, FOUND LT WING OB LE LOWER SKIN CRACKED .5000 INCH. REPAIR ACCOMPLISHED. REMOVED FASTENERS WITHIN REPAIR AREA IAW SRM 51-1-21 AND 51-1-20D PG1. REMOVED DAMAGED AREA IAW DWG V82-R01. PERFORMED NDT INSPECTION IAW NDT SPM PART 06-10-01.001. CLEANED, TREATED AND PRIMED AREA. FABRICATED A REPAIR DOUBLER AND A FILLER IAW DWGV82-R01. CLEANED, TREATED AND PRIMED THE REPAIR DOUBLERS INTERIOR SURFACE AND FILLER IAW SRM 51-1-8B. APPLIED PAC SEALANT ON FAYING SURFACES IAW SRM 51-1-11 PG1. INSTALLED THE REPAIR DOUBLER AND FILLER ONLY WING OB LE LOWER SKIN USING NEW FASTENER IAW DWG V82-R01, SRM 51-1-21 AND 51-1-20D PAGES 1 AND 9.

Part: SKIN — CORRODED (LT WING) · airframe 75,918 hrs · 2,677 cycles

DURING A ROUTINE C-CHECK INSPECTION, FOUND LT OB WING LE OB SECTION CORRODED AT STA XFS 710.000. THIS REPAIR WAS ACCOMPLISHED IAW DWG V82-R02 AND N/R 0652. REMOVED FASTENERS IAW SRM 51-1-21 PG1. REMOVED CORROSION IAW SRM 51-1-8 PGS. 17-18. FOUND OUT OF LIMITS. REMOVED THE DAMAGED AREA AND PERFORMED NDT INSPECTION IAW NDT SPH 06-10-01-001. CLEANED, TREATED AND PRIMED AREA. FABRICATED A REPAIR DOUBLER AND FILLER IAW SRM 51-1-8B. APPLIED SEALANT ON FAYING SURFACES. INSTALLED REPAIR DOUBLER AND FILLER ON LT OB WING LE OB SECTION USING NEW FASTNERS IAW DWG V82-R02 AND SRM 51-1-21 PG. 1 SRM 51-1-20D PG 9.

Part: DOOR — DAMAGED (PAX) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE C-CHECK INSPECTION FOUND AN INTERIM REPAIR ON THE UPPER AFT CORNER OF AFT PASSENGER DOOR STA 1660.000 L-9L TO L-11L. REPAIR WAS ACCOMPLISHED. THE INTERIM REPAIR WAS REMOVED IAW DC8 SRM 51-1-21 PG 1, FABRICATED A NEW DOUBLER, TRIPLER AND FILLER IAW DC8 SRM 53-2-0 FIG 18. CLEANED, TREATED AND PRIMED IAW DC8 SRM 51-1-8B. APPLIED PRC SEALANT TO FAYING SURFACES IAW DC8 SRM 51-1-15 PG 1. INSTALLED FILLER, DOUBELR AND TRIPLER IAW DC8 SRM 53-2-0 FIG 18, DC8 SRM 51-1-21 PG 1 DC8 SRM 51-1-20D PG 9.

Part: SKIN — CRACKED (FUSELAGE) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE C-CHECK INSPECTION A CRACK (1 INCH) WAS FOUND ON FUSELAGE EXTERIOR STA 174.000-1745.000, L-16R TO L-17R. REPAIR WAS ACCOMPLISHED. FASTENERS AND EXISTING EXTERNAL DOUBLER WERE REMOVED IAW DC8 SRM 51-1-21 PG 1. REMOVED DAMAGED SKIN IAW DC8 SRM 53-2-1 PG 105-106 FIG 7 VIEW 6. FABRICATED DOUBLER, FILLERS AND FINGER DOUBLER IAW DC8 SRM 53-2-1 PG 99-100 FIG 7 SHEET 1. CLEANED, TREATED AND PRIMED IAW 51-1-8B AND INSTALLED FILLERS, DOUBLER AND FINGER DOUBLER IAW DC8 SRM 53-2-1 PG 99-100 FIG 7 SHEET 1, DC8 SRM 51-1-21 PG 1 AND DC8 SRM 51-1-15 PG 1.

Part: SKIN PANEL — CORRODED (LT WING) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE C-CHECK INSPECTION, FOUND LT WING CTR LE UPPER SURFACE CORRODED AT STA XFS 341.500. REPAIR WAS ACCOMPLISHED, REMOVED CORROSION AND FOUND OUT OF LIMITS IAW SRM 51-1-8 PG 17-18 AND 57-2-1 PG 11. TOOK OUT DAMAGED SECTION IAW SRM 57-2-1 FIG. 38, TR NR 57-85 NOV 22/00. FABRICATED DOUBLER AND FILLER IAW SRM 57-2-1 FIG 38 TR NR 57-85 NOV 22/00. CLEANED, TREATED AND PRIMED AREA & INNER FACE OF FILLER AND DOUBLER IAW SRM 51-1-8B. INSTALLED FILLER AND DOUBLER IAW SRM 57-2-1 FIG. 38 TR NR 57-85 NOV 22/00, SRM 51-1-21 PG 1, SRM 51-1-20D PG 9, SRM 51-1-15. PG 1.

Part: PANEL — CORRODED (LT WING) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE C-CHECK INSPECTION, FOUND LT WIND IB LE SLANT PANEL UPPER CAP CORRODED AT SEVERAL AREAS. STA XW.0 - XFS 164.000. REPAIR WAS ACCOMPLISHED. PERFORMED MAJOR REPAIR IAW SRM 57-1-0 PG 1. REMOVED CORROSION IAW SRM 51-1-8 PG 17-18. FOUND OUT OF LIMITS IAW SRM 57-2-1 PG 135-136. REMOVED CORRODED SLANT PANEL UPPER CAP IAW SRM 51-1-21 PG 1. CLEANED, TREATED AND PRIMED AREA IAW SRM 51-1-8B INSTALLED NEW SLANT PANEL UPPER CAP IAW SRM 51-1-21 PG. 1

Part: SKIN — DAMAGED (LT WING) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE C-CHECK INSPECTION, FOUND LT WING CENTER LE HAS REPAIR ON UPPER SURFACE, STATION XFS 304.000. THIS REPAIR WAS ACCOMPLISHED IAW SRM 57-2-1 FIG 38 TR NR 57-85, 51-1-21, 51-1-20D. REMOVED DOUBLER AND FABRICATED FILLER AND DOUBLER. CLEANED TREATED AND PRIMED AREA PLUS FILLER AND DOUBLER INNER FACE IAW SRM 51-1-8B. APPLIED SEALANT TO FAYING SURFACES IAW SRM 51-1-11 FG. 9, INSTALLED FILLER AND DOUBLER IAW SRM 57-2-1 FG. 38, TR 57-85 NOV 22100, SRM 51-1-21 PG. 1, SRM 51-1-20D PG 9.

Part: SPAR — CRACKED (LT WING) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE C CHECK INSPECTION, FOUND LT WING REAR SPAR DOUBLER UPPER SIDE HAS CRACK DAMAGE AT STA XCW 69.500. REPAIR WAS ACCOMPLISHED. REMOVED FASTENERS, ALONG WITH THE DAMAGED AREA IAW DC8 SRM 51-1-20D PG 21 AND DC8 SRM 57-2-6 FIG 15. FABRICATED FILLER AND DOUBLER IAW DC8 SRM 57-2-6 FIG 15 PAGES 67 AND 68. CLEANED, TREATED AND PRIMED FILLER AND DOUBLER AREA. APPLIED SEALANT ON FAYING SURFACES, INSTALLED DOUBLER AND FILLER WITH NEW FASTENERS PER ALL APPLICABLE MANUALS.

Part: SKIN — DENTED (RT WING) · airframe 75,918 hrs · 30,152 cycles

DURING A ROUTINE C-CHECK INSPECTION, FOUND DENTS ON RT WING STATION 660. REPAIR WAS ACCOMPLISHED. REMOVED FASTENERS IAW SRM 51-1-21 PG. 1 ALSO REMOVED DAMAGED AREA AND FABRICATED REPAIR DOUBLER 57-2-1 FIG 24 PG 15. CLEANED, TREATED AND PRIMED AREA IAW SRM 51-1-8B. APPLIED SEALANT ON FAYING SURFACES IAW DC8 SRM 51-1-15 PG. 1. INSTALLED DOUBLER WITH NEW FASTENERS IAW SRM 51-1-21.

Part: HINGE — LOOSE (MLG DOOR) · airframe 75,318 hrs · 29,910 cycles

DURING TAKEOFF FROM GEAR DOOR LIGHT REMAINS ON WITH GEAR HANDLE IN UP POSITION. ABNORMAL CHECKLIST COMPLIED WITH LIGHT REMAINED ON. CREW DUMPED FUEL & RETURNED KTOL. UPON INSPECTION MAINTENANCE NOTED L/H MAIN GEAR DOOR HINGE ATTACH POINT AT KEEL & ADJACENT AREA HAD LOOSE FASTNERS. ALL FASTNERS WERE REPLACED PER APPLICABLE MANUALS.MAINTENANCE INSPECTED MLG DOOR POSITION WARNING SYSTEM AND NO DEFECTS NOTED. JACKED AIRCRAFT, SWUNG GEAR MULTIPILE TIMES GEAR & INDICATION OPS CHECK NORMAL. UPLATCH CHECK NORMAL WITH AND WITHOUT HYDS, GEAR FREEFALL CHECK NORMAL. NO DEFECTS NOTED ON ALL GEAR AND OPERATIONAL CHECKED GOOD PER APPLICABLE MANUALS. AIRCRAFT WAS RETURNED TO SERVICE.

Part: WARNING SYSTEM — CORRODED (MLG DOOR) · airframe 75,317 hrs · 29,909 cycles

AFTER TAKEOFF FROM KTOL LANDING GEAR DOORS LIGHT REMAINED ILLUMINATED AFTER GEAR RETRACTION. THE ABNORMAL CHECK LIST COMPLIED WITH AND DOORS LIGHT REMAINED ON. CREW RETURNED TO KTOL AND LANDED WITHOUT INCIDENT. MAINTENANCE INSPECTED GEAR DOOR WARNING LIGHT SYSTEM AND FOUND CORROSION. MAINTENANCE CLEANED, RESECURED AND TESTED GEAR DOOR WARNING SYSTEM ON GROUND. OPERATIONAL CHECK GOOD ON GROUND PER ALL APPLICABLE MANUALS. AIRCRAFT WAS RETURNED TO SERVICE.

Part: SWITCH — SHORTED (MLG DOOR) · airframe 75,317 hrs · 29,910 cycles

AFTER TAKEOFF FROM KTOL GEAR DOORS LIGHT REMAINED ILLUMINATED AFTER GEAR RETRACTION. CREW RETURNED TO KTOL AND LANDED WITHOUT INCIDENT. MAINTENANCE R / R LT GEAR DOOR SWITCH AND CONNECTOR. AN INSPECTION OF THE KEELBEAM LOWER BRACKETS WAS ACCOMPLISHED WITH NO DEFECT FOUND. JACKED AIRCRAFT, LANDING GEAR AND DOOR INDICATION OPERATIONAL CHECK GOOD ON SEVERAL EXTENSIONS AND RETRACTIONS PER ALL APPLICABLE MANUALS. AIRCRAFT WAS RETURNED TO SERVICE.

Part: ENGINE — FLAMED OUT (NR 3) · airframe 75,196 hrs · 29,835 cycles

IN CRUISE FROM KTOL TO KLAX NR 3 ENGINE FLAMED OUT. ALL TANK SELECTORS AND CROSSFEEDS CLOSED (FULL UP POSITION) CREW RAN CFM-56 FLAME OUT/ INFLIGHT CHECK LIST. OIL PRESSURE NOTED AT ZERO. DISCONTINUED CHECK LIST AND SHUTDOWN ENGINE. CREW RETURNED TO KTOL AND LANDED WITHOUT INCIDENT. MAINTENANCE TROUBLESHOT ENGINE PER ALL APPLICABLE MANUALS AND NO DEFECTS WERE NOTED. ENGINE IS FULLY OPERATIONAL AND AIRCRAFT WAS RETURNED TO SERVICE.

Part: FITTING — DAMAGED (TE FLAP) · airframe 74,494 hrs · 29,408 cycles

ON APPROACH TO BFI CREW RECEIVED A FLAP SPLIT INDICATION ALONG WITH A AIRCRAFT ROLL TO THE LT. CREW RAISED FLAPS AND DIVERTED TO PDX. MAINTENANCE INSPECTION AND REPAIR IS IN PROGRESS. ADDITIONAL INFORMATION WILL BE PROVIDED AS IT BECOMES AVAILABLE. MAINTENANCE FOUND A BROKEN EYE LOBE AND NUT BOLT TO ACTUATOR FLAP LINK MISSING. THE FLAP LINK RT AT STATION 98 WAS BROKEN. MAINTENANCE REPLACED FLAP LINK AND REMOVED AND REPLACED ACUATOR AT STATION 98 IN ACCORDANCE WITH DOUGLAS AIRCRAFT MAINTENANCE MANUAL. OPERATIONAL CHECK GOOD AND AIRCRAFT WAS RETURNED TO SERVICE.

Part: CYLINDER — LEAKING (AILERON) · airframe 74,206 hrs · 29,276 cycles

AFTER TAKEOFF FROM DEN, THE FLIGHT CREW NOTICED A DROP IN THE HYDRAULIC SYSTEM QUANTITY. THE FLIGHT CREW RETURNED TO DEN FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT WHICH REVEALED A LEAK AROUND THE LEFT AILERON PACK. MAINTENANCE REPLACED THE LEFT HAND AILERON POWER CYLINDER PER THE AIRCRAFT MAINTENANCE MANUAL AND RETURNED AIRCRAFT TO SERVICE.

Part: STRUCTURE — CRACKED (FUSELAGE) · airframe 73,236 hrs · 28,832 cycles

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS DETECTED ON THE LOWER SECTION AFT OF THE NOSE WHEEL WELL STATION 16 AND LONGERON 35R. REPAIR ACCOMPLISHED REMOVAL OF DAMAGED AREA, FABRICATION AND INSTALLATION OF EXTERNAL DOUBLER IN ACCORDANCE WITH DOUGLAS STRUCTURAL REPAIR MANUAL AND ENGINEERING DIRECTIVE EDQ27-1.

Part: DOOR — MISDRILLED (AFT SERVICE) · airframe 73,236 hrs · 28,832 cycles

DURING ROUTINE C-CHECK INSPECTION, MISDRILLED HOLES WERE DETECTED IN THE RIGHT HAND AFT SERVICE DOOR JAMB LOWER EDGE EXTERNAL SKIN FROM FUSELAGE STATION 1636 TO STATION 1648. REPAIR ACCOMPLISHED REMOVAL OF DEFECTIVE DOUBLER, FABRICATION AND INSTALLATION OF NEW REPAIR DOUBLER AND TRIPLER IN ACCORDANCE WITH DOUGLAS STRUCTURAL REPAIR MANUAL AND BOEINGS FAX #TIN-MIA-02-003F.

Part: DOOR — CRACKED (L/H PASSENGER) · airframe 73,236 hrs · 28,832 cycles

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS DISCOVERED ON THE LEFT HAND PASSENGER DOOR CUT OUT LOWER CORNER. REPAIR ACCOMPLISHED DAMAGED AREA CUT OUT, FABRICATION AND INSTALLATION OF FILLER AND REPAIR DOUBLER IN ACCORDANCE WITH THE DOUGLAS STRUCTURAL REPAIR MANUAL AND DRAWING SR08530021.

Part: COWLING — DEPARTED (NR 2 ENGINE) · airframe 73,103 hrs · 28,721 cycles

EN ROUTE, SHORTLY AFTER TAKEOFF THE FLIGHT CREW HEARD AN ABNORMAL NOISE IN THE COCKPIT. THE FLIGHT CREW CYCLED THE LANDING GEAR BUT THE NOISE WAS STILL PRESENT. THE FLIGHT RETURNED TO MCO FOR AN UNEVENTFUL LANDING. MAINTENANCE INSPECTED THE AIRCRAFT WHICH REVEALED THE NUMBER TWO ENGINE FAN COWLINGS HAD DEPARTED THE AIRCRAFT. THE ENGINE FAN COWLS WERE REPLACED AND THE AIRCRAFT WAS RETURNED TO SERVICE.

Part: TRU — DEFECTIVE (COCKPIT)

EN ROUTE, THE FLIGHT CREW SENSED A SMOKE ODOR IN THE COCKPIT. THE FLIGHT ENGINEER NOTICED THE NUMBER THREE DC LOAD MONITOR WAS READING AN EXCESSIVE LOAD. THE NUMBER THREE TRANSFORMER RECTIFIER CIRCUIT BREAKER WAS OPENED AND THE ODOR SUBSIDED. MAINTENANCE INVESTIGATED AND FOUND THE TRANSFORMER RECTIFIER DEFECTIVE. MAINTENANCE DEFERRED THE NUMBER THREE TRANSFORMER RECTIFIER.

Part: SWITCH — DEFECTIVE (RT MLG DOOR)

DURING CLIMBOUT, THE GEAR DOOR WARNING LIGHT WAS INTERMITTENTLY FLASHING. THE CREW CYCLED THE LANDING GEAR AND PERFORMED A GEAR UPLATCH CHECK, ALL INDICATIONS WERE NORMAL. MAINTENANCE INSPECTED THE GEAR DOOR WARNING SYSTEM AND TRACED THE DISCREPANCY TO THE RIGHT MAIN GEAR DOOR SWITCH. THE SWITCH WAS REPLACED AND A SUCCESSFUL OPERATIONAL CHECK WHICH RETURNED THE AIRCRAFT TO SERVICE.

Part: FRAME — CORRODED (BS 70)

DURING ROUTINE C-CHECK INSPECTION, CORROSION WAS FOUND ON FUSELAGE FRAME AT FUSELAGE STATION 70 BETWEEN LONGERONS 32 AND 33 RIGHT. REPAIR WAS ACCOMPLISHED BY CORROSION REMOVAL, FABRICATION AND INSTALLATION OF A NESTED ANGLE REPAIR DOUBLER IN ACCORDANCE WITH FAA DER APPROVED DRAWING E27-R04 AND ENGINEERING ORDER 53-DC8-820.

Part: PLATING — CORRODED (BS 30)

DURING ROUTINE C-CHECK INSPECTION, CORROSION WAS DETECTED ON FUSELAGE EXTERNAL PLATING BETWEEN FUSELAGE STATIONS 30 AND 61 LONGERON 34 RIGHT. REPAIR ACCOMPLISHED BY REMOVAL OF DAMAGED AREA, FABRICATION AND INSTALLATION OF A REPAIR FILLER AND REPAIR DOUBLERS IN ACCORDANCE WITH FAA DER APPROVED DRAWING E27-R03 AND ENGINEERING ORDER 53-DC8-825.

Part: PLATING — CRACKED (BS 418)

DURING ROUTINE C-CHECK INSPECTION, A CRACK WAS DETECTED AT THE LEFT FORWARD EMERGENCY EXIT DOOR LOWER AFT JAMB CORNER AT FUSELAGE STATION 418. REPAIR WAS ACCOMPLISHED BY REMOVAL OF DAMAGED AREA, FABRICATION AND INSTALLATION OF AN EXTERNAL REPAIR DOUBLER AND A TRIPLER IN ACCORDANCE WITH DOUGLAS FAX FILE ACTION 362047, FILE 98-03-05-005 AND ENGINEERING ORDER 53-DC8-822.

Part: PLATING — CORRODED (BS 340)

DURING ROUTINE C-CHECK INSPECTION, CORROSION WAS FOUND ON THE FUSELAGE EXTERNAL PLATING AT FUSELAGE STATION 340 LONGERON 31 LEFT. REPAIR WAS ACCOMPLISHED BY CORROSION REMOVAL, FABRICATION AND INSTALLATION OF AN EXTERNAL REPAIR DOUBLER IN ACCORDANCE WITH FAA DER APPROVED DRAWING E27-R05 AND ENGINEERING ORDER 53-DC8-821.

Part: ELEVATOR — JAMMED (ELEVATOR CONTROL)

DURING TAXI CHECK OF THE ELEVATORS AND POSITION INDICATION SYSTEM, ALL INDICATIONS WERE NORMAL. DURING TAKEOFF ROLL AT 80 KNOTS, THE ELEVATOR CHECK WAS ABNORMAL AND ELEVATOR JAMMED. THE TAKEOFF WAS REJECTED AND THE AIRCRAFT RETURNED TO THE BLOCKS. THE LOCAL NTSB AND FAA WERE NOTIFIED. MAINTENANCE INSPECTED THE CONTROL SYSTEMS OF THE ELEVATOR FOR DEFECTS. DURING THE INSPECTION OF THE RIGHT ELEVATOR TAB DRIVE TUBE ASSEMBLY, WASHERS WERE FOUND INSTALLED BENEATH THE ATTACHING BOLT HEADS. THE INSTALLATION WAS CORRECTED USING THE DOUGLAS ILLUSTRATED PARTS CATALOG, 27-30-0 FIGURE 53. THE AIRCRAFT THEN COMPLETED A HIGH SPEED TAXI CHECK AND TEST FLIGHT TO VERIFY NORMAL ELEVATOR CONDITIONS.