Tavaero Jet Charter Corporation

Sanction: $1,500 · case closed 2006-04-18

Part: SENSOR — FAULTY (RT ENGINE) · airframe 12,028 hrs · 6,385 cycles

AIRCRAFT DEPARTED, DURING CLIMB OUT THE RIGHT ENGINE 14TH DUCT OVERHEAT MESSAGE ALERTED THE CREW. POWER WAS PULLED BACK TO IDLE AND THE 14TH STAGE BLEED AIR VALVE WAS POSITION TO CLOSE. RIGHT 14TH DUCT MESSAGE REMAINED. RIGHT ENGINE WAS SHUT DOWN AND FLIGHT CREW DIVERTED WITH NO INCIDENTS. 14TH STAGE DUCT MESSAGE REMAINED UNTIL AIRCRAFT SHUTDOWN.

Part: RELIEF VALVE — FAULTY (AC BAY) · airframe 9,715 hrs · 7,089 cycles

AFTER TAKEOFF CREW REPORTED THE ACFT WOULD NOT PRESSURIZE. CREW SWITCHED AIR SOURCE TO EMER AIR AT WHICH TIME THEY NOTICED A HAZE WITH AN EXHAUST ODOR. RETURNED & UPON TAXI TURN OFF THE PILOT THOUGHT A LITTLE SMOKE MIGHT HAVE COME FROM THE OUTSIDE NOSE LT AVIONICS PITOT TUBE AREA. PERFORMED VISUAL & OPERATIONAL CHECK IN LT AVIONICS COMPARTMENT, FOUND NO DISCREPANCIES. PERFORMED INSP CHECK & RIGGING CHECK OF THE LT MLG POSITION SWITCH, NO DISCREPANCIES NOTED. TROUBLESHOOTING OF PRESSURIZATION FOUND THE BLEED PRESS RELIEF VLV PN 227915 TO BE FAULTY & BYPASSING. R & R THE PRESS RELIEF VLV & PERFORMED GND PRESSURIZATION CHECK, NO DISCREPANCIES NOTED. PERFORMED GND CHECK OF ALL AIR SOURCES DURING ENG RUNS, NO DISCREPANCIES NOTED IAW 1124 MM 32-60-00, 21-30-00, 32-60-00, 21-30-06 & 21-00-01. PERFORMED VISUAL & OPERATION INSP OF COCKPIT & CABIN ELEC EQUIP, NO DISCREPANCIES NOTED IAW 1124 MM 5-20-01 & 5-20-02. IT IS BELIEVED THE HAZE IN THE COCKPIT CAME FROM THE INTRODUCTION OF HOT UNCONDITIONED AIR FROM EMER AIR SOURCE FROM THE ENG SOURCE WITH HIGH HUMIDITY IN CABIN AFTER EARLY MORNING DEPARTURE.

Part: LANDING GEAR — MALFUNCTIONED · airframe 4,327 hrs · 2,754 cycles

THE AIRPLANE WAS SCHEDULE FOR A TRIP. WE DEPARTED ON SCHEDULE AND THE OUTBOUND LEG PASSED WITHOUT INCIDENT. UPON OUR DESCENT, BEFORE LANDING PROCEDURES, WHEN WE TRIED TO LOWER THE LANDING GEAR. WE OBSERVED IT WOULD NOT COME DOWN. WE HEARD THE NOISE MADE BY THE OPEN LANDING GEAR DOORS BUT WE NEVER RECEIVED A LANDING GEAR "DOWN AND SAFE" INDICATION, LANDING GEAR GREEN LIGHTS, FOR EITHER OF THE 3 GEARS. ALL WE OBSERVED WERE THE 3 RED LIGHTS INDICATING OUR LANDING GEAR IS NOT DOWN. AT THIS POINT WE ASKED THE TOWER FOR A LOW FLYBY TO VISUALLY CONFIRM OUR LANDING GEAR POSITION, UP OR DOWN AND REQUESTED A PATTERN AROUND THE AIRPORT INTENDING TO SOLVE THE PROBLEM. ASKED MY F/O TO OPEN THE EMERGENCY PROCEDURE MANUAL AND WE BOTH EXECUTED THE PROCEDURE PERTAINING TO THE LANDING GEAR NOT COMING DOWN. AT THIS POINT, DECIDED NOT TO CONTINUE OUR TRIP TO AND TO RETURN TO HOME-BASE. WE HAD AMPLE FUEL ON BOARD, ENOUGH FOR OUR ROUND TRIP AND AMPLE RESERVES. DURING OUR RETURN LEG, WE EXECUTED THE EMERGENCY BLOW DOWN PROCEDURE AND ONCE WE RECEIVED THE “LANDING GEAR DOWN AND SAFE” INDICATION, WE CONTINUED BACK TO HOME BASE LEAVING THE GEAR IN THE DOWN POSITION FOR THE REMAINDER OF THE FLIGHT. UPON ARRIVING, WE REQUESTED A FLYBY WITH THE TOWER AND A VISUAL CONFIRMATION OF THE LANDING GEAR BEING DOWN BEFORE OUR LANDING.

Part: AMPLIFIER — FAULTY (AUTOPILOT SYS) · airframe 10,855 hrs · 8,066 cycles

EXPERIENCED AN UN-COMMANDED 400 DECENT BY THE AUTOPILOT. PILOTS ADI TUMBLED 15 DEGREES WITH HEADING & NAV MODE UNRESPONSIVE. CREW DESCENDED ACFT TO FL020. CONTINUED FLIGHT WITHOUT AUTOPILOT TO HOME BASE. R & R THE AUTOPILOT AMPLIFIER PN 522-2900-028 SN 2617. R & R NR 1 VERTICAL GYRO WITH PN 7000622-901 SN 94067506. WORK PERFORMED IAW MM 22-10-04 & 34-20-07. SYS OPERATIONS CHECKED.

Part: SEAL — WEAK (BLEED AIR SYS) · airframe 5,905 hrs · 4,944 cycles

CREW REPORTED REAR BAY OVERHEAT AT FL 250. TROUBLESHOOTING FOUND BLEED AIR LEAK AT LT BLEED AIR VLV & LT NON-RETURN VLV. REMOVED LT BLEED AIR SOV & LT NON-RETURN VLV. REPLACE DEFECTIVE SEALS WITH NEW PN 20496-200A, 6-464-1PAR & HTE580-3060-112A & REINSTALLED BLEED AIR VLV & NON-RETURN IAW HS125-800 MM 21-10-25. PERFORMED ENGINE OPERATION CHECK & NO LEAKS NOTED.

Part: STARTER GEN — VIBRATION (ZONE 400) · airframe 9,430 hrs · 8,690 cycles

CREW NOTICED A VIBRATION IN FLIGHT ENROUTE. DIVERTED. TROUBLESHOOTING FOUND THE LT STARTER GENERATOR TO BE DEFECTIVE. REMOVED LT STARTER GENERATOR, AND INSTALLED OVERHAULED STARTER GENERATOR. INSTALLATION AND OPS CHECKED GOOD. RAN ENGINE WITH NO VIBRATION NOTED.

Part: PIN — BENT (LT MLG CONNECTOR) · airframe 9,525 hrs · 6,930 cycles

DURING TAKEOFF MAIN LANDING GEAR HANDLE WOULD NOT MOVE TO THE RETRACT POSITION. DURING TROUBLESHOOTING FOUND BENT AND DAMAGED PINS ON LEFT LANDING GEAR CONNECTOR P217. REMOVED LEFT MLG CONNECTORS P 217 AND INSTALLED NEW PLUG P/N MS3126F20-39S AND MS3126F20-39P IAW WW 1124 STANDARD PRACTICES 20-10-05. REMOVED LEFT GROUND CONTACT SWITCH P/N 444E1-12 AND INSTALLED NEW SWITCH P/N 444E1-12 AND ADJUSTED IAW WESTWIND 1124 MM 32-60-00. REMOVED DEFECTIVE LANDING GEAR OVERRIDE SOLENOID P/N SDC-120 AND INSTALLED SERVICEABLE UNIT P/N SCD-120 IAW WW1124 STANDARD PRACTICES 20-10-06. GEAR WARNING HORN FUNCTION CHECK IAW WW 1124 MM 32-60-00. LANDING GEAR RETRACTION AND EXTENSION CHECK IAW WW 1124 MM 32-30-00. LIFT DUMP SYSTEM FUNCTION CHECK IAW WW1124 MM 27-60-00. ANTI SKID SYSTEM OPS CHECK IAW WW 1124 MM 32-44-00. ALL SYSTEMS OPERATED SATISFACTORY.

Part: HINGE FITTING — CRACKED (HORIZ STAB) · airframe 9,518 hrs · 6,930 cycles

C/W AD 89-12-08 STABILIZER AFT SPAR INSPECTION IAW SB 1124-55-020 R2. FOUND CRACK ON LEFT OUTER HINGE LUG UPPER FLANGE ONE INCH FROM TRAILING EDGE TRAVEL THRU TRAILING EDGE.

Part: TEE FITTING — CRACKED (CABIN PRESSURE) · airframe 9,300 hrs · 8,603 cycles

ACFT WILL NOT DEPRESSURIZE UNTIL ACFT HAS LANDED. FOUND TEE FITTING FOR AUX VOLUME TANK CRACKED. REMOVED AND INSTALLED NEW TEE FITTING, FOUND VACUUM SHUTOFF VALVE CRACKED. REMOVED SHUTOFF VALVE, AND INSTALLED NEW VALVE, IAW MM 21-31-02. PERFORMED ENGINE RUNS AND TESTED PRESSURIZATION SYS OPS CHECK IAW MM 21-31-00. SYS OPS CHECK OK. REINSTALLED CABIN INTERIOR REMOVED TO GAIN ACCESS TO SYS.

Part: LATCH — FAILED (MLG DOOR) · airframe 92,106 hrs · 31,462 cycles

AFTER TAKEOFF, THE CREW HEARD A LOUD NOISE FROM NOSE GEAR AREA, THEY RETURNED TO DEPARTURE WITHOUT FURTHER INCIDENT. MX INSPECTED NOSE GEAR AND FOUND RT NOSE GEAR DOOR OPENED. THEY CLOSED AND SECURED DOOR LOCK MECHANISM DOOR. OPS CHECK GOOD IAW MM 32-22-1. ACFT WAS RETURNED TO SERVICE.

Part: FITTING — CRACKED (RT MLG WW)

RIGHT-HAND WHEEL WELL STA 931 FALSE SPAR STA 1.50 FITTING IS CRACKED 1.50 INCH LONG FORWARD TO AFT. DEFERRED IAW GMM 3.5 CAT 1. REF BOEING SERVICE ENGINEERING TECH & FLEET SUPPORT LETTER DHL-CVG-04-00024H 15MAR04. ENTERED AS DMI 16041E. ONLY 2 REVENUE FLIGHTS WITH NOTED DAMAGE. REF. DMI NR 16041E RT WHEEL WELL STA. 931 FALSE SPAR STA. 1.50 FITTING IS CRACKED. REPLACED FITTING AND FABRICATED PER ASTAR EA 5730-012 DATED 03-17-04. INSTALLED IAW SRM 51-10-1 P/N: 4652201-2SP MINOR REPAIR THIS CLEARS DMI 16041E.

Part: SPAR — CRACKED (LT MLG WW)

LT MLG WHEEL WELL FUSELAGE STA 931 FALSE SPAR STA 1.50 THE UPPER END OF CHANNEL HAS A .375 INCH CRACK IN RADIUS OF VERT LONG. DEFERRED IAW GMM 3.5 CAT 1. REF BOEING SERVICE ENGINEERING TECH & FLEET SUPPORT LETTER DHL-CVG-04-00024H 15MAR04. ENTER AS DMI 16042E. ONLY 2 REVENUE FLIGHTS WITH NOTED DAMAGE. COMPLY WITH ASTAR J/C MSI57300035-001-D REF. DMI 16042E LT MLG WHEEL WELL STA. 931 FALSE SPAR STA. 1.50 3.75 CRACK IN RADIUS OF VERT LONG. P/N: 5643117-30. COMPLIED WITH J/C MSI57300035-001-D REPLACED CHANNEL P/N: 5643117-30. THIS CLEARS DMI 16042E.

Part: RIB — CRACKED (TE FLAP)

LEFT-HAND INBOARD FLAP UNDER JOINT PANEL THERE IS A .75 INCH CRACK OUTBOARD RIB LOWER CORD 40 INCHES FROM TRAILING EDGE. DEFERRED IAW GMM 3.5 CAT 1. REF BOEING SERVICE ENGINEERING TECH & FLEET SUPPORT LETTER DHL-CVG-04-00024H 15MAR04. ENTER AS DMI 16040E. ONLY 2 REVENUE FLIGHTS WITH NOTED DAMAGE. REF. DMI 16040E LT INBOARD FLAP UNDER JOINT PANEL THERE IS A .75 CRACK OUTBOARD RIB LOWER CHORD 40 DEGREES FROM TRAILING EDGE (DAILY INSP.) DUE 20 MAR 04. REPLACED LEFT-HAND INBOARD FLAP ASSEMBLY IAW 27-51-1. PERFORMED INSPECT/CHECK IAW 27-51-1. PERFORMED ADJUSTMENT TEST IAW 27-50-0. NO DEFECTS NOTED. THIS CLEARS DMI 16040E. PLACARD REMOVED.

Part: WINDSHIELD — CRACKED (COCKPIT)

F/O'S WINDSHIELD CRACKED. REMOVED AND REPLACED F/O'S FORWARD SIDE WINDOW IAW DC8 M/M 56-10-2, NO LEAKS NOTED.

Part: FAN — NOISY (COCKIT)

ON TAKEOFF AND AT CRUISE ALTITUDE, RECIRCULATION FAN IS LOUD & VIBRATION IS FELT UNDERFLOOR NEAR LAV NOISE DECREASES WITH FAN OFF. DEFERRED RECIRCULATION FAN, PLACARD INSTALLED. AT FL 330, 30 MINUTES INTO FLT, NOTED BURNING ODOR IN FLOOR AREA NEAR LAV MID CABIN TEMP INDICATED 95 DEG ON CABIN TEMP INDICATOR. SMELL WENT AWAY AFTER TURNING RT PACK OFF. CABIN STABILIZED AT 5000 FT. INSPECTED LT & RT PACKS. NO DEFECTS NOTED. OPERATED PACKS IN ALL RANGES & SETTINGS. OPS CHECKED OK. SMELL FROM RECIRCULATION FAN AT LOG ITEM 367524 - 1P. REMOVED AND REPLACED FAN ASSEMBLY, OPS CHECKED OK. DMI CLEARED, STICKER REMOVED.

Part: BATTERY — INOPERATIVE (EMERGENCY LIGHTS)

DURING BISE CHECK - EMERGENCY LIGHT SWITCH MUST BE RECYCLED ONCE BEFORE EMERGENCY LIGHTS FUNCTION NORMALLY. REMOVED AND REPLACED AIRCRAFT BATTERY, OPS CHECKED GOOD PER DC-8 M/M 24-30-1.

Part: BELLCRANK — CRACKED (PAX DOOR)

MAIN ENTRY DOOR IS DIFFICULT TO OPEN AND CLOSE. FOUND BAYONET BELLCRANK CRACKED, ALSO FOUND DAMAGED ROLLER ASSEMBLY ON DOOR SEAL ACTUATING CRANK. REMOVED BAD PARTS.

Part: DOOR — LACK OF LUBE (MAIN PAX)

MAIN CABIN DOOR HARD TO CLOSE. LUBED MAIN CABIN DOOR MECHANISM. OPS CHECKED GOOD PER 52-11-1.

Part: BATTERY — DISCHARGED (FUSELAGE)

EMERGENCY EXIT LIGHT OVER ENTRY DOOR INOPERATIVE. RECHARGED BATTERY AND OPS CHECKED GOOD PER M/M 33-50-0.

Part: DOOR — OUT OF ADJUST (COCKPIT)

COCKPIT DOOR BINDING OUTSIDE KNOB SO SMOOTH YOU CAN NOT PULL DOOR OPEN WHEN UNLOCKED. ADJUSTED DOOR IAW SMM 52-51-01 OPS CHECKED OK.

Part: LATCH — OUT OF ADJUST (PAX DOOR)

FLIGHT DECK DOOR WILL NOT LATCH CLOSED PROPERLY AND JAMS IN CLOSED POSITION. ADJUSTED UPPER LATCH AND OPS CHECKED PER MSI M/M 52-10-0. ALL CHECKS GOOD.

Part: HANDLE — UNSECURE (CARGO DOOR)

AT BEGINNING OF TAKEOFF ROLL BELLY DOOR LIGHT ILLUMINATED. DURING TAXI DOOR LIGHT ILLUMINATED INTERMITTENTLY. FOUND B PIT DOOR HANDLE NOT SECURED. RE-SECURED HANDLE. OPS CHECKED NORMAL IAW M/M 25-51-0. REJECTED T/O RWY 27 AT 271,000 LBS. AT 70 KTS. / ZONE 2. PERFORMED REJECTED T/O CHECK IAW DC-8 SM/M 05-51-0. BRAKE TEMPERATURES CHECKED WITHIN LIMITS. AIRCRAFT OK FOR SERVICE.

Part: DOOR — OUT OF ADJUST (COCKPIT)

COCKPIT ENTRY DOOR JAMS AND IS VERY HARD TO OPEN FROM THE GALLEY SIDE. ADJUSTED DOOR PER SMM AND M/M 51-10-0.

Part: DOOR — OUT OF ADJUST (COCKPIT)

COCKPIT DOOR IS HARD TO OPEN FROM THE OUTSIDE. DOOR JAMMED CLOSED. ADJUSTED COCKPIT DOOR PER M/M 52-10-0. OPS CHECKED GOOD.

Part: MEC — MALFUNCTIONED (NR 3 ENGINE)

NR 3 ENG FAILED 3-5 MIN AFT SETTING CRUISE THRUST (0938Z) ENG LOST POWER SLOWLY. PERFORMED ENG FAILURE CHECKLIST ATTEMP RESTART, NO FUEL FLOW, OR EGT INDICATION, BOOST PUMP 21 PSI. ENG WINDMILL TIME 1 HR 22 MIN. OIL PRESS DROPPED TO 0 AFT APPROX 10-15 MIN AFT ENG FAILURE. FOUND 4 EA BOLTS ON BOOST PUMP FEED LINE LOOSE. PERFORMED PRESSURE CHECK ON FUEL LINE FROM IN TANK BOOST PUMP TO NASH PUMP ON NR 3 ENG. NO DEFECTS FOUND. RETIGHTENED BOLTS ON BOOST PUMP. BOROSCOPE INSPECTION OF NR 3 ENG BOOSTER, HPC 3, 5, & 9, COMBUSTOR HPT & LPT. REINSTALLED ALL REMOVED PLUGS. REMOVED & REPLACED NR 3 ENG MEC, OPS AND LEAK CHECKED. RIGGED NR 3 ENG MEC, VSV AND VBV. NO LEAKS. PARAMETERS WITHIN LIMITS.

Part: BATTERY — DISCHARGED (EMERGENCY LIGHT)

DURING PREFLIGHT EMERGENCY EXIT LIGHTS AND STANDBY ATTITUDE INDICATOR WERE FOUND INOPERATIVE. TROUBLESHOT SYSTEM, FOUND EMERGENCY LIGHTS NOT GETTING ENOUGH POWER FROM AC BATTERY. REPLACED AC BATTERY. SYSTEM OPS CHECKED GOOD IAW 33-50-0.

Part: WARNING SYSTEM — FAULTY (GPWS) · airframe 89,636 hrs · 28,948 cycles

GPWS FAIL LIGHT ILLUMINATED. REPLACED GPWS MK II WITH GPWS/WS MKVII AND OPS CHECKED GOOD IAW J/C EA34450002-001-D.

Part: DOOR FRAME — DAMAGED (CARGO DOOR) · airframe 89,636 hrs · 28,948 cycles

TWO INTERIM REPAIRS ON LT AFT LWR CORNER OF MAIN CARGO DOOR STA 270.000 BETWEEN L-20L AND L-22L. REMOVED FASTENERS AND INTERIM REPAIR. TRIMMED OUT DAMAGED AREA IAW EODHL-030584 ED-3486. PERFORMED EDDY CURRENT INSPECTION IAW DC8 NDT SPM PART 06-10-01-001. FABRICATED (1) DOUBLER (7075-T6 AL0.080) AND (2) FILLERS (7075-T6 AL0.071) AND (2) FINGERS DOUBLERS (7075-T6 AL0.050) IAW EODHL-030584, ED-3486. CLEANED, TREATED AND PRIMED AREA AND DOUBLER AND FILLERS AND FINGER DOUBLERS IAW SRM 51-1-8B. APPLIED PRC SEALANT TO FAYING SURFACES IAW SRM 51-1-11 PG 9. INSTALLED DOUBLER AND FINGER DOUBLERS AND FILLER WITH NEW FASTENERS IAW EODHL-030584, ED-3486, SRM 51-1-20D PG 9, SRM 51-1-21 PG 1.

Part: SPLICE — CRACKED (FUSELAGE) · airframe 89,636 hrs · 28,948 cycles

FWD CARGO COMPT SPLICE FITTING CRACKED 2.000 STA 440.000 - 460.000, L-31L. PERFORMED MAJOR REPAIR IAW SRM 53-1-0 PG 1, SRM 51-1-20D PG 9, 21. REMOVED SPLICE FITTING IAW SRM 51-1-20D PG 21. CLEANED, TREATED AND PRIMED AREA IAW SRM 51-1-8B. INSTALLED NEW FITTING IAW SRM 51-1-20D PG 9.

Part: SKIN — CORRODED (FUSELAGE) · corrosion level 2 · airframe 89,636 hrs · 28,948 cycles

FUSELAGE NOSE SECTION EXTERNAL SKIN CORRODED & DENTED BETWEEN STA 35.000 AND STA 70.000, L-31L TO L-31R. REMOVED FASTENERS & EXISTING EXTERNAL DOUBLER. REMOVED CORROSION, FOUND OUT OF LIMITS. TRIMMED OUT DAMAGED SKIN PANEL SEGMENT. PERFORMED EDDY CURRENT INSPECTION. FABRICATED NEW SKIN PANEL SEGMENT 7075-T6 AL0.050 AND 2 EXTERNAL DOUBLERS 7075-T6 AL0.190, 7075-T6 AL0.063 & 1 FINGER DOUBLER 7075-T6 AL0.032 AND 11 INTERNAL DOUBLER 7075-T6 AL0.050. CLEANED, TREATED, PRIMED AREA, NEW SKIN PANEL SEGMENT, INTERNAL/EXTERNAL DOUBLERS & FINGER DOUBLER. APPLIED PRC SEALANT TO FAYING SURFACES. INSTALLED FINGER DOUBLER, INTERNAL DOUBLERS, NEW SKIN PANEL SEGMENT, EXTERNAL DOUBLERS WITH NEW FASTENERS.

Part: STRINGER — CRACKED (LT WING) · airframe 89,636 hrs · 28,948 cycles

LT WING NR 1 ALT TANK, S-59 CRACKED 1.500 (LOWER), NEAR XRS 463.000 (MAJOR REPAIR). PERFORMED MAJOR REPAIR IAW SRM 57-2-2 FIG 3D, 3E, 3F. REMOVED FASTENERS IAW SRM 51-1-21 PG 1, SRM 51-1-20D PG 21. FABRICATED SPLICES (02 EA), CLIPS (02) AND SPACERS (04 EA) IAW SRM 57-2-2 FIG 3D, 3E, 3F. APPLIED TANK COATING MATERIAL TO AREA AND SPLICES AND CLIPS SPACERS IAW SRM 51-1-12 PG 12. INSTALLED SPLICES, CLIPS, SPACERS WITH NEW FASTENERS IAW SRM 51-1-21 PG 1, SRM 51-1-20D PG 9. FOR LEAK CHECK SEE NR 3824.

Part: FRAME — BROKEN (FUSELAGE) · airframe 89,636 hrs · 28,948 cycles

AFT CARGO COMPT. DOOR NR 4 FRAME ANGLE BROKEN, STA.1440.000. REMOVED BROKEN ANGLE IAW SRM 51-3-0 PG.1. FABRICATED NEW ANGLE (2024-T3 AL0.040) IAW SRM 53-2-0 PG.1-2. CLEANED, TREATED AND PRIMED AREA AND NEW ANGLE IAW SRM 51-1-8B. INSTALLED NEW ANGLE IAW SRM 51-3-0 PG.1

Part: ANGLE — BROKEN (FUSELAGE) · airframe 89,636 hrs · 28,948 cycles

AFT CARGO COMPT DOOR NR 4 FRAME ANGLE BROKEN, STA 1440.000 CORR REMOVED BROKEN ANGLE IAW SRM 51-3-0 PG 1. FABRICATED NEW ANGLE IAW SRM 53-2-0 PG 1-2. CLEANED, TREATED, AND PRIMED AREA AND NEW ANGLE IAW SRM 51-1-8B. INSTALLED NEW ANGLE IAW SRM 51-3-0 PG 1.

Part: ATTACH FITTING — CRACKED (LT WING) · airframe 89,636 hrs · 28,948 cycles

LT WING T/E INNER UPPER FITTING CRACKED 1.000 AT XRS.434.000. REMOVED CRACKED FITTING IAW SRM 51-1-20D PG.21. CLEANED, TREATED AND PRIMED AREA IAW SRM 51-1-8B. INSTALLED NEW FITTING ON LT. WING T/E AT XRS. 434.000 IAW SRM 51-1-20D

Part: SKIN — DENTED (RT ELEVATOR) · airframe 89,636 hrs · 28,948 cycles

RT ELEVATOR UPPER PLATING CTR. SECTION HAS DENTS FROM XE. 132.000 TO XE. 246.000 PERFORMED MAJOR REPAIR IAW EODHL-030525, ED-3276. REMOVED FASTENERS IAW SRM 51-1-21 PG.1. REMOVED DAMAGED SKIN PANEL IAW EODHL-030525, ED-3276. CLEANED, TREATED AND PRIMED AREA IAW SRM 51-1-8B. FABRICATED NEW SKIN PANEL (2024-T3 AL0.032) IAW EODHL-030525, ED-3276. CLEANED, TREATED AND PRIMED NEW SKIN PANEL INTERIOR SURFACE IAW SRM 51-1-8B. APPLIED PRC SEALANT ON FAYING SURFACES IAW SRM 51-1-11 PG.9. INSTALLED NEW SKIN PANEL ON RT ELEVATOR UPPER SURFACE CTR. SECTION (FROM STA. XE.132.000 TO XE.246.000) USING NEW FASTENERS IAW EODHL-030525, ED-3276, SRM 51-1-21 PG.1. SEE N/R 4037 FOR WEIGHT AND BALANCE.

Part: PANEL — CRACKED (L/E SLOT) · airframe 89,636 hrs · 28,948 cycles

RT OUTBOARD SLOT UPPER CENTER DOOR WITH 0.500 CRACK IN IT. REMOVED AND REPLACED RT OUTBOARD SLOT UPPER CENTER DOOR IAW MM 27-80-2 PG 201-204. REFER TO NR 0531 FOR OPS CHECK.

Part: SKIN — DAMAGED (LT AILERON) · airframe 89,636 hrs · 28,948 cycles

LT IB AILERON LWR SURFACE WITH INTERIM REPAIR BETWEEN STA.XA441.000 AND XA.502.000. PERFORMED MAJOR REPAIR IAW EODHL-030569, ED-3399. REMOVED FASTENERS AND DAMAGED SKIN SEGMENT INCLUDING INTERIM REPAIR IAW SRM 51-1-21 PG.1. FABRICATED NEW SKIN SEGMENT (2024-T3 AL0.050) AND SPLICE STRAP (2024-T3 AL0.050) IAW EODHL-030569, ED-3399. CLEANED, TREATED, AND PRIMED AREA AND INNER SIDE OF SKIN SEGMENT AND SPLICE STRAP IAW SRM 51-1-8B. APPLIED (PRC) SEALANT TIO FAYING SURFACES IAW SRM 51-1-11 PG.9. INSTALLED NEW SKIN SEGMENT AND SPLICE STRAP WITH NEW FASTENERS IAW EODHL-030569, ED-3399, SRM 51-1-21 PG.1. REFER TO N/R 2199 FOR WEIGHT AND BALANCE. FOR REMOVAL AND REINSTALLATION SEE J/C 8-27-11-020

Part: SKIN — DENTED (FUSELAGE) · airframe 89,636 hrs · 28,948 cycles

FUSELAGE EXTERIOR SKIN SHOWS DENTS (03 EA), FS 255.000, L-24L TO L-26L (MAJOR REPAIR). PERFORMED MAJOR REPAIR IAW EODHL-030516, ED-3357. REMOVED FASTENERS IAW SRM 51-1-21 PG 1. BLENDED OUT DENTS IAW EODHL-030516, ED-3357. PERFORMED EDDY CURRENT INSPECTION IAW DC8 NDT SPM PART 06-10-01-001. CLEANED, TREATED AND PRIMED AREA IAW SRM 51-1-8B. FABRICTED INTERNAL DOUBLER IAW EODHL-030516, ED-3357. CLEANED, TREATED AND PRIMED REPAIR AREA IAW SRM 51-1-8B. APPLIED PRC SEALANT ON FAYING SURFACES IAW SRM 51-1-11 PG 9. INSTALLED INTERNAL DOUBLER WITH NEW FASTENERS IAW EODHL-030516, ED-33547, SRM 51-1-20D PG 9, SRM 51-1-21 PG 1.

Part: SKIN — CORRODED (RT ELEVATOR) · corrosion level 2 · airframe 89,636 hrs · 28,948 cycles

RT ELEVATOR LOWER OUTER SKIN CORRODED ON SEVERAL SPOTS FROM STA XE 246.000 TO STA XH 285.000 (MAJOR REPAIR). PERFORMED MAJOR REPAIR IAW EO DHL 030574, ED 3411. REMOVED FASTENERS AND DAMAGED SKIN PANEL IAW SRM 51-1-21 PG 1. CLEANED, TREATED AND PRIMED AREA IAW SRM 51-1-8B. FABRICATED A NEW SKIN PANEL IAW EO DHL 030574, ED 3411. CLEANED, TREATED AND PRIMED NEW SKIN PANEL INTERIOR SURFACE IAW SRM 51-1-8B. APPLIED PRC SEALANT ON FAYING SURFACES IAW SRM 51-1-11 PG 9. INSTALLED NEW SKIN PANEL ON RT ELEVATOR LOWER OUTER SURFACE (STA XE 246.000 TO STA XH 285.000) USING NEW FASTENERS IAW EO DHL 030574, ED 3411, SRM 51-1-21 PG 1. SEE NR 4037 FOR WEIGHT AND BALANCE.

Part: SKIN — CORRODED (RT ELEVATOR) · corrosion level 2 · airframe 89,636 hrs · 28,948 cycles

RT ELEVATOR UPPER SKIN INBD SECTION SHOW CORROSION, SEVERAL DENTS AND INTERIM REPAIR FROM STA XAR 0.000 TO XE 132.000. REMOVED FASTENERS AND THE DAMAGED SKIN PANEL IAW SRM 51-1-21 PG 1. CLEANED, TREATED AND PRIMED AREA IAW SRM 51-1-8B. FABRICATED A NEW SKIN PANEL (2024-T3AL 0.032) IAW EO DHL 030573, ED 3410. CLEANED, TREATED AND PRIMED THE NEW SKIN PANEL INTERIOR SURFACE IAW SRM 51-1-8B. APPLIED PRC SEALANT ON FAYING SURFACES IAW SRM 51-1-11 PG 9. INSTALLED THE NEW SKIN PANEL ON RT ELEVATOR UPPER SURFACE INBD SECTION (STA XAR 0.000 TO XE 132.000) USING NEW FASTENERS IAW EO DHL 030573, ED 3410 AND SRM 51-1-21 PG 1. SEE NR 4037 FOR WEIGHT AND BALANCE.

Part: SKIN — CORRODED (RT ELEVATOR) · corrosion level 2 · airframe 89,636 hrs · 28,948 cycles

RT ELEVATOR LOWER PART EXTERNAL SKIN SHOWS DEFLECTION AND CORROSION FROM STA. XAR.0.000 TO XE.132.000. PERFORMED MAJOR REPAIR IAW EODHL-030521, ED-3405. REMOVED FASTENERS AND DAMAGED SKIN PANEL IAW SRM 51-1-21 PG.1, SRM 51-1-21A PG.4. CLEANED, TREATED AND PRIMED AREA IAW SRM 51-1-8B. FABRICATED NEW SKIN PANEL (2024-T3 AL0.032) IAW EODHL-030521, ED-3405. CLEANED, TREATED AND PRIMED AREA IAW SRM 51-1-8B. APPLIED PRC SEALANT ON FAYING SURFACES IAW SRM 51-1-11 PG.9. INSTALLED NEW SKIN PANEL WITH NEW FASTENERS IAW EODHL-030521, ED-3405, SRM 51-1-21 PG.1, SRM 51-1-21A PG.4, FOR WEIGHT AND BALANCE SEE N/R 4037. FOR REMOVAL AND REINSTALLATION SEE J.C 8-27-60-016.

Part: SKIN — DENTED (RT ELEVATOR) · airframe 89,636 hrs · 28,948 cycles

RT ELEVATOR OUTER LOWER SKIN HAS DENTS ON SEVERAL SPOTS FROM STA. XE.132.000 TO XE.246.000. PERFORMED MAJOR REPAIR IAW EODHL-030522, ED-3406. REMOVED FASTENERS AND DAMAGED SKIN PANEL IAW SRM 51-1-21 PG.1, SRM 51-1-21A PG.4. CLEANED, TREATED AND PRIMED AREA IAW SRM 51-1-8B. FABRICATED NEW SKIN PANEL (2024-T3 AL0.032) IAW EODHL-030522, ED-3406. CLEANED, TREATED AND PRIMED INTERIOR SURFACE IAW SRM 51-1-8B. APPLIED PRC SEALANT ON FAYING SURFACE IAW SRM 51-1-11 PG.9. INSTALLED NEW SKIN PANEL WITH NEW FASTENERS IAW EODHL-030522, ED-3406, SRM 51-1-21 PG.1, SRM 51-1-21A PG.3. FOR WIEGHT AND BALANCE SEE N/R 4037. FOR REMOVAL AND REINSTALLATION SEE J/C 8-27-60-016.

Part: SKIN — CORRODED (RT ELEVATOR) · corrosion level 2 · airframe 89,636 hrs · 28,948 cycles

RT ELEVATOR UPPER PLATING OTBD SECTION SHOWS INTERIM REPAIR AND CORROSION FROM STA XE 246.000 TO XH 285.000. REMOVED FASTENERS, REMOVED CORROSION AND FOUND OUT OF LIMITS. REMOVED DAMAGED SKIN PANEL, CLEANED, TREATED AND PRIMED AREA. FABRICATED NEW SKIN PANEL (2024-T3 AL0.032) IAW EODHL-030523, ED-3404. CLEANED, TREATED AND PRIMED NEW SKIN PANEL INTERIOR SURFACE IAW SRM 51-1-8B. APPLIED PRC SEALANT ON FAYING SURFACES IAW SRM 51-1-11 PG 9. INSTALLED NEW SKIN PANEL ON RT ELEVATOR UPPER PLATING OTBD SECTION STA XE 246.000 TO XH 285.000) USING NEW FASTENERS IAW EODHL-030523, ED-3404, SRM 51-1-21 PG 1. SEE N/R 4037 FOR WEIGHT AND BALANCE. FOR REMOVAL AND RE-INSTALLATION SEE J/C 8-27-60-016.

Part: FITTING — CRACKED (FUSELAGE) · airframe 89,636 hrs · 28,948 cycles

MAIN CARGO COMPT DOOR FRAME LOWER INTERNAL SKIN FITTING 2.00 CRACKED AT STA 255.000, L-21L. PERFORMED MAJOR REPAIR IAW SRM 53-1-0 PG 1, SRM 51-3-0 PG 1. REMOVED CRACKED FITTING IAW SRM 51-3-0 PG 1. CLEANED, TREATED AND PRIMED AREA IAW SRM 51-1-8B. INSTALLED NEW FITTING WITH NEW FASTENERS IAW SRM 51-3-0 PG 1.

Part: CARGO TRACK — WORN (FUSELAGE) · airframe 89,636 hrs · 28,948 cycles

MAIN CARGO COMPT NR 2 TRACK LUGS WORN, STA -55.000 - STA 310.000. REMOVED NR 2 TRACK WITH WORN LUGS IAW SRM 51-3-0 PG 1. CLEANED, TREATED AND PRIMED AREA IAW SRM 51-1-8B. INSTALLED NEW NR 2 TRACK ON MAIN CARGO COMPT STA -55.000 - STA 310.000 IAW SRM 51-3-0 PG 1.

Part: FAIRING — DELAMINATED (LT WING) · airframe 89,636 hrs · 28,948 cycles

LT OTBD FAIRING ASSY WITH EXTERNAL SKIN DELAMINATED. REMOVED AND REPLACED OB FAIRING ASSY ON LT WING IAW SRM 51-3-0 PG 1, SRM 51-3-1 PG 2A. FOR OPS CHECK SEE NR 0531.

Part: SKIN — CORRODED (FUSELAGE) · corrosion level 2 · airframe 89,636 hrs · 28,948 cycles

LOWER FUSELAGE PLATING SHOWS 04 SPOTS OF CORROSION BETWEEN STA 743.000 AND STA 767.000, L-35L TO L-35R (MAJOR REPAIR). REMOVED FASTENERS IAW SRM 51-1-21 PG 1. REMOVED CORROSION, FOUND OUT OF LIMITS IAW SRM 53-2-0 PG 2P. BLENDED OUT THE DAMAGED SKIN AREA IAW EODHL-030518, ED-3389. PERFORMED NDT INSPECTION IAW DC8 NDT SPM PART 06-10-01-001. CLEANED, TREATED AND PRIMED AREA IAW SRM 51-1-8B. FABRICATED A REPAIR DOUBLER (7075-T6 AL0.100) IAW EODHL-030518, ED-3389. CLEANED, TREATED AND PRIMED THE REPAIR DOUBLER IAW SRM 51-1-8B. APPLIED PRC SEALANT ON FAYING SURFACES IAW SRM 51-1-11 PG 9. INSTALLED DOUBLER ON LWR FUSELAGE PLATING BETWEEN STA 743.000 - 767.000, L-35L TO L-35R USING NEW FASTENERS.

Part: SKIN — CORRODED (FUSELAGE) · corrosion level 2 · airframe 89,636 hrs · 28,948 cycles

FWD CTR SECTION SHOWS SEVERAL SPOTS OF CORROSION AND DOUBLER REPAIR (03 EA.) BETWEEN STA.660.000 AND STA.725.000, L-34L TO L-34R. PERFORMED MAJOR REPAIR IAW EODHL-030564, ED-3389. REMOVED FASTENERS AND DOUBLER REPAIRS, REMOVED CORROSION. FOUND OUT OF LIMITS. BLENDED OUT CORRODED AREA IAW. PERFORMED EDDY CURRENT INSPECTION IAW DC8 NDT SPM PART 06-10-01-001. CLEANED, TREATED AND PRIMED AREA IAW SRM 51-1-8B. FABRICATED FILLER (7075-T6 AL0.125), DOUBLER (7075-T6 AL0.125) IAW EODHL-030564, ED-3389. CLEANED, TREATED AND PRIMED FILLER AND DOUBLER IAW SRM 51-1-8B. APPLIED PRC SEALANT TO FAYING SURFACES. INSTALLED FILLER AND DOUBLER WITH NEW FASTENERS.

Part: PLATE — DENTED (RT WING FLAP) · airframe 89,636 hrs · 28,948 cycles

RT WING INBD FLAP UPPER PLATING SHOWS DENTS AND WEAR OUT OR LIMITS BETWEEN STA XW 104.000 TO XW 115.000. REMOVED FASTENERS AND DAMAGED SKIN PANEL IAW SRM 51-1-21 PG.1. CLEANED TREATED AND PRIMED AREA IAW SRM 51-1-8B. FABRICATED A NEW SKIN PANEL ( 2024-T3AL 0.063) AND THREE FILLERS AS INDICATED BELOW, TWO FILLERS OF 2024-T3AL 0.025 AND ANOTHER ONE OF 2024-T3AL 0.016 IAW EO DHL 030567, ED 3385. CLEANED TREATED AND PRIMED THE NEW SKIN PANEL INTERIOR SURFACE AND FILLERS. APPLIED PRC SEALANT ON FAYING SURFACES. INSTALLED THE NEW SKIN PANEL AND FILLERS ON RT WING INBD FLAP UPPER PLATING (STA. XW 104.000 - XW 115.000) USING NEW FASTENERS.

Part: FRAME — CRACKED (FUSELAGE) · airframe 89,636 hrs · 28,948 cycles

FWD ACCY COMPT FRAME CRACKED 2.000, STA 55.000, L-24L. TRIMMED OUT DAMAGED FRAME SEGMENT IAW SRM 53-2-0 FIG 2, TR 53-125, TR 53-110. CLEANED, TREATED AND PRIMED AREA IAW SRM 51-1-8B. FABRICATED NEW FRAME SEGMENT (7075-T6 AL0.071) AND SPLICE ANGLE (02 EA) (7075-T6 AL0.071) IAW SRM 53-2-0 FIG 2, TR 53-125, TR 53-110. PERFORMED HEAT TREATMENT TO FRAME SEGMENT AND NEW SPLICE ANGLES IAW SRM 51-1-1, DPS 7.00-1. CLEANED, TREATED AND PRIMED FRAME SEGMENT AND NEW SPLICE ANGLES IAW SRM 51-1-8B. INSTALLED FRAME SEGMENT AND NEW SPLICE ANGLES WITH NEW FASTENERS IAW SRM 53-2-0 FIG 2, TR 53-125, TR 53-110, SRM 51-1-20D PG 9, SRM 51-1-21 PG 1.