A composite shop Mechanic reports that a time limited repair of a B767 right main landing gear (MLG) strut door for lightning strike damage had exceeded the time allowed when a permanent repair had to be accomplished.
Synopsis
A composite shop Mechanic reports that a time limited repair of a B767 right main landing gear (MLG) strut door for lightning strike damage had exceeded the time allowed when a permanent repair had to be accomplished.
Narrative
Due to unknown factors at this time a permanent repair could not be accomplish; I found lightning strikes as indicated in Aircraft Logbook to be minor and within allowable limits for a time limited repair. After accomplishing limited repair; log sheet was signed-off per the B767-400 (Structural Repair Manual) SRM 52-80-02. Sealed damage with aluminum tape at mid-section outboard (O/B) side of (Right-Hand) R/H main gear strut door. Inspect at each 'A' Check; for tape peeling. Repair no later than next 'C' Check.It was coded [in a way that] would have created an Open Maintenance item file to schedule repetitive inspections and then permanent repair; but -41 was not entered as the ATA sub-code. When it was entered into the computer system by Line Maintenance; it was coded incorrectly. After returning to the Composite Shop in the hangar; I filed an online generic time limited repair information form but was unable to send form so I printed the form and faxed it to the Maintenance desk.Recently it was discovered that the time limited repairs were still installed and had never been replaced with a permanent repair. They were then repaired and the company is seeking a solution.
NASA callback
Reporter stated the right Main Landing Gear (MLG) strut door is made from carbon fiber material. The lightning had burned out the resin; but the fibers were intact. So they were able to seal and tape the damaged areas on the strut door. He also applied tags next to each lightning strike location to help identify each strike when the permanent repair was accomplished. Reporter stated that during a recent main gear change; a Lead Mechanic for that crew noticed the strut door surface did not look right and realized that when the aircraft had been painted some months earlier; the painters had painted right over the sealing tape and the identification tags. The aircraft also had numerous A-Checks accomplished and no one had noticed the paint.Reporter stated a different Lead Mechanic had originally entered an incorrect letter code in their maintenance computer database that contributed to the time limited repair requirements being overlooked.
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Source: NASA Aviation Safety Reporting System (public domain). Reports are voluntary submissions and are not verified by NASA.