
INTRODUCTION OF AIRCRAFT STRUCTURAL REPAIR TECHNIQUES FOR MECHANICS BY AN ENGINEER. This Blog’s target audience is A&P sheet metal mechanics and new structural engineers. Feel free to comment or ask questions.
Visit our website at www.Callahan.aero or e-mail us at der@callahan.aero for any questions or special interest.
Posts will be on Mondays containing technical, quotes, and stories. The technical will be excerpts from my book or by request, quotes will be from several humor and historical sources, my personal stories, and some marketing I’m a capitalist).
I’ve decided to present my new book by way of online classes. Each chapter will be a class segment. Each module will be available online for a fee. This seems to be the future but it does allow me to teach a chapter at a time with no travel costs or hassles. There will be interaction by in class work and email. Access to me will also be available. Need feedback, what say you?
“Company versus Consultant DERs“
Company DERS are now called ARs just to add confusion to an already complex situation.
If I have only confused you more about DERs just remember we are the master of change and deviation and are extremely anal. If you think you need four widgets but only have three widgets call us because we may approve only three or even two widgets unless we explain you really need five or no widgets. And we will ask what a widget is and its specification.
But one of the reasons DERs seem to be misunderstood is because we create new data. New data as in original data. The OEM may generate and appear to approve data for the A&P’s use but actually the OEM only generates unapproved data. The FAA approves all data but they may delegate this authority and responsibility to some qualified engineers at the OEM. The OEM does not receive this authority, the individual AR does.
The company DER may only approve data on their own company’s products.
Did you know when you call the OEM for engineering assistance you usually get customer support (a non-engineer) that suggests a known repair or part replacement. When you open up your pocketbook communication with an engineer starts. The keyword is “an” meaning any or any recent new hire to screen the calls. If you PAY for the repair then it will be analyzed by a stress analyst (engineer). Once the repair is shown acceptable it is given to the AR or DAS engineer for FAA approval. Yep, I threw another acronym into the mix so here are they are: AR, DAS, DER, DOA, SFAR 36, and ODA engineering staff members. Did you notice you don’t talk to the approving DER.
Consultant DERs can be hired by an OEM representing OEM’s ARs staff. The Consultant DER approves OEM data for the OEM like a company DER. There are some countries that will not accept a Consultant DER’s approval but if he is sitting at the OEM they will. Canada doesn’t have a choice because of our bilateral agreement with them, they have to accept it.
Consultant DER are not restricted to any companies product or geographical area. A misconception about Consultant DER is their lack of available data may be wrong. DERS have enormous resources and are NOT restricted by office politics, other OEM customer requirements, or most importantly the cosmetic requirements.
Office politics held up the use of a new corrosion inhibiting sealant on new Boeing aircraft because their Wichita plant developed it. It took years for Boeing Seattle to accept it on their aircraft.And you would have thunk that Boeing cares about corrosion protection more than male ego.
The story I like is the “Wichita repair” for the 747 aft pressure bulkhead developed in Wichita by Liaison Engineers (not designers or stress analysts). Everett Division wouldn’t put Wichita developed repairs in the SRM (Everett builds the 747) but when the airlines demanded the repair was inserted into the SRM. All this repair does is to allow access and repair of the lower aft pressure bulkhead when corroded but its’ not like it was more important than Everett elitism (remember Japan Airlines Flight 123).
But the best part of a Consulting DER is he doesn’t need to make it pretty. A dented fender is acceptable but a Ford dealer (OEM) will push a new one or a repair. You don’t have to fix it and you could remove the fender. And if you’re a taxi or bus service a “use as is” approval is worth a lot especially given within minutes in the middle of the night.
Other customer requirements means you accept an exterior doubler with protruding head rivets accepting the drag penalty and cosmetic scar next to the entry door but other airlines or corporate owners say no to “scab” patches. Your DER will approve a scab patch but the OEM DER may not.
I had a sharp deep skin dent just aft of the entry door on a DASH 8 that was scheduled to depart within the hour at 7 AM. What to do? Simple, drill a big hole to remove dent (3/8″‘ diameter), HFEC, then install 3/8″ diameter protruding head bolt (exterior), washer, and nut. Plane was ready and off it went. Oh the OEM did not like that because it was ugly (and it was) and they said, “we would never do that!” So they would never get an aircraft airworthy to make a scheduled revenue flight? Because their solution several hours later was to ground the aircraft and repair it “properly” (skins, door cutout reinforcing doubler, adjacent skin lap, a long down time. My repair was “properly” repaired later at the next C check (planned long down time inspection, maintenance, and repair) within the year. Safe and certified! Right now there are engineers thinking I was wrong to do that!
Before you give me credit for being a genius, this repair is in the 747 SRM. Oh, those poor engineers that were just thinking I was wrong are confused because if it is in a Boeing SRM it must be right. No. it doesn’t. It means it is approved and it may be wrong because there are errors in SRMs. Why do you think there are ADs.
All DERs must comply with the Federal Aviation Regulations and physics don’t change. But it is a given the OEM DER may be more up to date and access to more data leaving the Consulting DER to be more conservative. And don’t forget all DERs are not created equal but we are all Amazing Super Stars (acronym?).
CALLAHAN AIRCRAFT SERVICES, LLC CURRENT PROJECTS:
CONVAIR 440 AIRBORNE PLATFORM ANALYSIS & APPROVAL
SUPER CONSTELLATION REBUILD REPAIRS
GULFSTREAM III AIRBORNE PLATFORM ANALYSIS & APPROVAL
402B UPPER WING WALK REINFORCEMENT REPAIR DESIGN, ANALYSIS & APPROVAL
402C ENGINE MOUNT SHIM REPAIR STC / PMA
E170 & E190 SLAT TOOL JIGS AND CHECK FIXTURES DESIGN, ANALYSIS & APPROVAL
KING AIR “EYEBROW WINDOW” STC / PMA
KING AIR WING ROOT SPAR CAP CRACK AD 89-25-10 AMOC REPAIR DESIGN, ANALYSIS & APPROVAL
KING AIR UPPER AND LOWER EXTERNAL AVIONIC PLATFORMS STC / PMA
ALL COMPOSITE CARGO CONTAINERS STC / PMA
MISCELLANEOUS REPAIRS DESIGN, ANALYSIS & APPROVAL
Next week, “identifying a shear joint” And we haven’t forgotten shimming
Y’all, some DERs do take questions and are on the same team. Most DERs are comfortable in their role and don’t mind giving a few minutes of free advice to other aviation professionals. I did say we wouldn’t be PC so I confess, there are quite a few DERs and engineers that are jerks. They do milk the job for all its worth and complicate the design on purpose. Some even generate designs on purpose that wont fit so they make more money.
I was working AF-1 after it was over due and over budget with poor but acceptable inspected cosmetic quality is the perfect example of unethical engineering. The B747-200 AF-1 project went to a design / build phase because of schedule (meaning the design is late but manufacturing is ready). Contrast that with other design / build projects that design is planned to be concurrent with the build in an overall effort to tighten the schedule. The AF-1 program hired many contract engineers and some were affiliated with their own contract shop so they had an unethical incentive to generate engineering man-hours. A particular contract engineer would make suggestions because noticed the Boeing management team’s lack of the design and manufacturing process knowledge and the overall engineers lack of modification experience and design skill. He made two types of suggestions with one being the placement of avionics and other equipment knowing full well there would be a conflict with other installations down the line. This allowed him to “immediately” know how to remedy the “problem” when it surfaced. This one act generated two very positive results for him. One it generated more engineering man-hours and two his standing among his peers and management soared. The later lent to him being a Czar of the design / build teams. The second type of suggestion were the “improvements” like suggesting an access panel between to wire bundle connections “in case” they ever had to have access between those connections. It was a remote possibility but if maintenance did need access later, couldn’t they do it then. And the delivery slid to the right, costs soared, and he was praised and his wallet grew thicker. Oh, how do I know this? We bumped heads over a disconnect bracket (I won).
My network of DERs and engineers do not do this because they are ethical and some are even moral. “The ethical man knows he shouldn’t cheat on his wife, whereas the moral man actually wouldn’t.” Dr. Donald “Ducky” Mallard (David McCallum) in the CBS television series “NCIS”
O x y m o r o n s
A verbal contract isn’t worth the paper it’s written on. — Samuel Goldwyn
Words of Wisdom and Warning
“Democracy is two wolves and a lamb voting on what to have for lunch. Liberty is a well-armed lamb contesting the vote!”
Benjamin Franklin
Aged to perfection
We do not stop playing because we are old; we grow old because we stop playing.
Sincerely,
James W. Callahan
General Manager / FAA DER
DER@CALLAHAN.AERO
256-891-3677
P.O. BOX 533
Albertville, AL 35950

