A B727-200 DURING A HVY MAINT CHK IT WAS DISCOVERED THE #1 AND #3 ENG FORWARD MOUNTS WERE INSTALLED IMPROPERLY.

Date: 1998-01 · Aircraft: Large Transport; Low Wing; 3 Turbojet Eng

Anomalies: aircraft-equipment-problem-critical|deviation-discrepancy-procedural-far|deviation-discrepancy-procedural-published-material-policy|other-unspecified

Synopsis

A B727-200 DURING A HVY MAINT CHK IT WAS DISCOVERED THE #1 AND #3 ENG FORWARD MOUNTS WERE INSTALLED IMPROPERLY.

Narrative

WHILE PERFORMING BOEING SVC BULLETIN 727-54A0010 ON AN ACR B727 XYZ; FBO REMOVED THE APPLICABLE FASTENERS; ACCOMPLISHED THE EDDY CURRENT INSPECTION (NO CRACKS FOUND); THEN REINSTALLED OVERSIZED FASTENERS TERMINATING THE SVC BULLETIN. REMOVAL OF THE FASTENERS AND THE EDDY CURRENT INSPECTION WERE ROUTINE; HOWEVER UPON REINSTALLATION; THE FOLLOWING OBSERVATIONS WERE NOTED: THE MECHS USED DULL REAMS; NO FIXTURE WAS USED TO INSURE THE HOLES WERE DRILLED STRAIGHT; THE FASTENERS FIT LOOSE IN THE HOLES; AND THE WRONG COUNTERSINKS WERE USED. REGARDING THE LOOSE FIT; ONE MECH NOTED THAT THE PREVIOUS SHIFT HAD INSTALLED ONE FASTENER WITH A PIECE OF A SCOTCH-BRITE PAD IN THE HOLE BECAUSE THE HI-LOCK TURNED WHEN ATTEMPTING TO INSTALL THE COLLAR. I BELIEVE THE PIECE OF SCOTCH BRITE PAD WAS REMOVED; HOWEVER THE FASTENERS ARE STILL UNDERSIZED FOR THE HOLE. MECHS ALSO COMMENTED THAT THEY DIDN'T HAVE THE CORRECT COUNTERSINKS; AND IT IS CLR THE FASTENER HEADS ARE UNDERFLUSH. THESE OBSERVATIONS WERE MADE ON THE #1 ENG PYLON; #2 HAD NOT BEEN COMPLETED DURING MY LAST OBSERVATION. CALLBACK CONVERSATION WITH RPTR REVEALED THE FOLLOWING INFO: THE RPTR STATED IT'S ALMOST CERTAIN THIS WORK WAS NOT CORRECTED AND WAS SIGNED OFF WITH #2 ENG STILL TO BE ACCOMPLISHED. THE RPTR SAID THE SKILL LEVEL WAS NOT UP TO THE STANDARDS REQUIRED TO ACCOMPLISH THIS WORK PER THE MANUFACTURER'S STRUCTURAL REPAIR MANUAL.

Source: NASA Aviation Safety Reporting System (public domain). Reports are voluntary submissions and are not verified by NASA.