Re-sealed fuel tanks have been reinstalled and cleared for close. Wings are back on the ship, repaired ailerons have been reinstalled, rigged and undergoing safeties. Polish on the last few areas continues. The battery upgrade has received a new mounting installation that has been designed in house and CNC cut for a precise and clean install. Final engine components are being installed before pre-flight engine runs. Interior discrepancies have been addressed and are awaiting reinstallation after a final clear-to-close has been completed.
Aileron repair, Fuel tank leak repair, wing pull inspection and reassembly of aircraft. – March, 2023
The ailerons have bee thoroughly inspected and the fabric repairs have been completed awaiting topcoat. All four fuel tanks have been removed, inspected, cleaned and are undergoing a re-seal. Fuel tank cradles have been stripped of their old padding and repainted and new pads installed. Both engines have had all discrepancies addressed and are awaiting post maintenance engine runs. Landing gear is back together and preparations have been made for final gear swings. Wing inspection is nearly complete, wings should be well on their way to reinstallation in the coming days.
Technical team has been cruising along addressing all the minor engine discrepancies and various other maintenance items. Structures continues on the wing attach, creating shim packs for all the inspected and measured components. Avionics discrepancies are being diagnosed and addressed. Polish has started on the wings to continue onto the rest of the aircraft.
With the aircraft moved into its temporary stall, engine inspections have begun along with routine inspections of systems components. A discrepancy list is populating with repairs and maintenance items being addressed. With the wings off and inspections completed, the center section receives the same procedures to ensure the fitment and tolerance of the wings.
Wing Attach cleaning and inspection, various maintenance items in work. – february, 2023
Wing attach angles on the wings and center section have been thoroughly cleaned. An inspection of all the bolt holes has been completed on the wing attach angles. The precise inspection and measurement at the attach angles per the Douglas specification has begun. After the receiving inspection of the aircraft, a few maintenance items have gone into work including a leaking hydraulic compensator on the R/H main landing gear.
Wing Pull. – February, 2023
R/H wing removed from aircraft without a hitch. Attach angle inspections to proceed on both right and left wings.
wING pULL – fEBRUARY, 2023
L/H wing has been pulled and ready to start the inspection. R/H wing is prepped and ready to be removed from the aircraft.
Wing pull. – february, 2023
Technical and structures teams have joined forces to get the wing pull underway. All preparations have been made and hardware/components are being removed before wings are pulled.
updated galley, avionics upgrade
Left Hand Galley – 4/14/2021
Galley Test FitGalley Upper Cabinet Test FitDecanter Storage TestIce BinHigh Pressure Laminate CuttingGalley Closeout with False FacesDrawer Cabinet Test Fit
Right Hand Galley – 4/14/2021
Coffee Dispenser Right Hand Cabinets Being InstalledRight Hand Cabinets Being InstalledCoffee Dispenser Valves
Electrical – 4/14/2021
Passenger Cabin USBPassenger Cabin USBGalley Control Panel
GAlley Cabinetry – 4/8/2021
Large Storage DrawerSilverware DrawersOven CabinetR/H Cabinet Interior LaminatedEdge-Fill of Cabinet ComponentsLarge Storage Drawer CabinetCNC Cutting of Sandwich Panels
Wash lights and electrical – 4/8/2021
Cut for Passenger Cabin USB ChargerNew Circuit Breaker Final ConnectionsAll Valances Ready for Installation
Thermos solution – 4/1/2021
Thermos SolutionNew & OldMoved Hydraulic Accumulator to Accommodate Thermos
RIGHT HAND GALLEY MODIFICATION – 4/1/2021
Galley Veneer in Stainless SteelGalley Veneer in Stainless SteelLatch Installed in New VeneerDoor Opening in New VeneerNew Trash Can InsertAdjusting Door Size For New Veneer
DRINKWEAR – 4/1/2021
LED and Electrical – 4/1/2021
Co-Pilots USB Charger LocationOne of Four New LED Controllers Being InstalledCircuit Breaker Bussing CompleteCB ready for Install with Pilots USB installedValances Removed for LED WorkValances Removed for LED WorkContinuing Work on LED Installation
Left-hand galley modifications – 3/25/2021
Finalized L/H Galley Construction, Honeycomb for R/H Cabinet is Being Cut Today and Tomorrow.
Complete ReorganizationComplete ReorganizationMocking Up Reorganization Mocking Up ReorganizationMocking Up ReorganizationMocking Up ReorganizationIn Work of ReorganizationIn Work of ReorganizationBlue Tooth Receiver Installation
Avionics upgrade – 1/27/2021
Pilot Side “alive” Co-Pilot Side “alive”GTN750sNe Co-Pilot Overhead OverlayNew Pilot Overhead OverlayCompleted Wire Routing and Pitot/Static SystemMain Trunk Wire RoutingBluetooth Audion Module LocationFlight Level for ADAHRS Calibration Flight Level for ADAHRS CalibrationFlight Level for ADAHRS CalibrationFlight Level for ADAHRS CalibrationFAA Approval Installation
Loading Setting Loading SettingsInstalling Pitot Static SystemCompleted HarnessCompleted HarnessPitot Static PlumbingPrepping for Cabin Audio Blue Tooth InstallationPrepping to Level Aircraft for CalibrationPrepping to Level Aircraft for Calibration
Avionics upgrade – 1/6/2021
Panel Physical InstallationPanel Physical InstallationPanel Physical InstallationPanel Physical InstallationPanel Physical InstallationPilots Sub-PanelPilots Sub-PanelWiring ConnectionsWiring ConnectionsWiring ConnectionsWiring ConnectionThe Few Remaining Connections to Make
polish PROGRESS – 1/6/2021
Polish ProgressPolish ProgressPolish Progress
Avionics Installation – 12/22/2020
Making ConnectionsRe-Placarding overhead panelHarnessing ConnectionMaking ConnectionsFlux ValveFlux Valve InstallationMaking ConnectionsContinuing to Merge Old and NewNew Circuit Breaker LocationsFlux Valve Harness Location (Outboard Wing, Both Sides)
Polish – 12/22/2020
Polish ProgressPolish Progress
INSTRUMENT Panel – 12/9/2020
Merging New and Old HarnessesMerging New and Old HarnessesMerging New and Old Harnesses
polish 12/9/2020
Polish In WorkPolish In WorkPolish In WorkPolish In Work
avionics installation 12/2/2020
Wiring Harness 70% CompleteBacking Panel Ready for CoatingFace Panels Ready for CoatingsFace Panels Ready for CoatingsFace Panels Ready for CoatingsBacking Panel Structural MountingBacking Panel Structural MountingStructures Work On Instrument Panel ComponentsStack Mounting of GTN and GTXStack Mounting of GTN and GTXReworking Overhead in Preparation for EL Panel OverlayEmptied Avionics Rack SpaceEmptied Avionics Rack SpaceReady For New Harnesses
Final Panel Template Test FitFinal Panel Template Test FitFinal Panel Template Test FitOld Wiring RemovedWire Harnesses OpenedOld Avionics To Be Removed
Inspection / Corrective Actions – 11/12/2020
Correcting An Oil Leak On the Right Engine At a Rocker Cover and Push Rod TubeCorrecting An Oil Leak On the Left Engine At a Rocker CoverRight Engine with Propeller in Feathered PositionRight Engine Rocker CoverInspection of Under Floor Area in Baggage Compartment
Gear SwingsGear SwingsInspecting BreaksFlight Deck Interior Removed For InspectionFlight Deck Interior Removed For InspectionGalley Interior Removed For InspectionGalley Interior Removed For InspectionGalley Interior Removed For Inspection
Avionics Upgrade – 10/28/2020
1:1 Print of New Panel to Verify FitmentInterior With Protection InstalledInterior With Protection InstalledInterior With Protection InstalledInside of Nose, Prepping for Avionics WorkAvionics Cabinet With Door Removed (Under Galley)Terminal Strips Inside Avionics CabinetFlux Valves RemovedWiring Trunk Panel Open
Inspection Cycle – 10/28/2020
Left Engine In InspectionRight Engine In InspectionCowlings Removed and Stored On RacksL/H Wing Root Fairing RemovedInspection Panels OpenWing Attach Angle Covers Removed