A B757-200 ENG INLET COWLING SHOP TECHNICIAN ALLEGES IMPROPER REPAIR PROCS BEING PRACTICED WITH UNRELATED ENGINEERING AUTHS.

Narrative

NOSE COWL CAME INTO SHOP BECAUSE OF ACOUSTIC PANEL DAMAGE. DUE TO COWL HISTORY; AN INSPECTION AND REPAIR FORM WAS DEVELOPED TO ENCOMPASS PROB AREAS ON THE COWL. AFTER INSPECTION WAS COMPLETE; ACR CHOSE TO DISREGARD CERTAIN ITEMS BECAUSE THE REPAIR TIME WOULD TAKE TOO LONG. 1) CORROSION FOUND IN COWL MOUNT HOLES. MGMNT SIGNED OFF WRITE-UP EVEN THOUGH CORROSION EXISTED. MAINT INSISTED ON REMOVING CORROSION PER THE MAINT MANUAL. 1 HOLE WAS SO BADLY CORRODED IT WENT FROM .375 TO .500 BEFORE CORROSION WAS REMOVED. EVEN AFTER HOLES WERE REPAIRED; THE ALODINE AND PRIME STEP WAS STILL NOT COMPLETED TO PREVENT FUTURE CORROSION IN A KNOWN CORROSION AREA. 2) THE FAN CASE ABUTMENT GROOVE ON THE AFT EDGE OF THE COWL (ENTIRE CIRCUMFERENCE) AHD 50% OF ITS FLAME SPRAY MISSING AND WEAR INTO THE 'V' GROOVE. AFTER WEAR WAS BLENDED AND READY FOR FLAME SPRAY; THE DECISION WAS MADE TO NOT FLAME SPRAY; BUT TO APPLY MOLY COAT ANTI-ABRASION. THEN MADE THE SIGNOFF USING AN UNRELATED ENGINEERING AUTH. THIS WILL RESULT IN PREMATURE FAILURE OF ABUTMENT FACE. MOLY COAT REQUIRES HEAT TO CURE. NO HEAT WAS USED -- MOLY IS BASICALLY INEFFECTIVE. PROB BROUGHT TO MGMNT -- NO RESULTS. PROB BROUGHT TO MGMNT COMPLETING WORK -- NO RESULTS. PROB BROUGHT TO UNION STANDARDS COMMITTEE -- NO RESULTS. PROB BEING BROUGHT TO FAA.