A Captain and Maintenance Technician report about extensive corrosion damage found in the Aft Cargo Compartment; Aft Equipment Bay of a B757-200 aircraft. Pilot also notes immediate inspections and maintenance need to be accomplished on B757/767 aft fuselage sections to prevent a hull lost from similar excessive corrosion.
Synopsis
A Captain and Maintenance Technician report about extensive corrosion damage found in the Aft Cargo Compartment; Aft Equipment Bay of a B757-200 aircraft. Pilot also notes immediate inspections and maintenance need to be accomplished on B757/767 aft fuselage sections to prevent a hull lost from similar excessive corrosion.
Narrative
I was reassigned to fly a ferry flight for what I thought was to move a flight into position for a revenue trip. Instead it was a maintenance reposition; one time ferry flight; for a fuselage repair. This aircraft had extensive corrosion damage in the aft baggage [cargo] compartment that was discovered on a filter replacement the day before. The extensive damage had been there for quite some time.The photos shown to me by Company Air Carrier Maintenance Technician; were eye opening. There was extensive damage to the stringers; and there was a wire bundle that could be seen hanging loose; no longer secured in place. When I asked the Technician about the damage; he said he had seen worse. The photo looked like something you would see on a visit to the Titanic. For the safety of crews and passengers alike; I feel that an inspection on all Boeing B757/767 needs to be accomplished before a hull lost happens due to improper Inspection/Maintenance. This problem can have the same consequences as the MD-80 jack-screw problem. We need to get these aircraft inspected and repaired system wide immediately.
Second reporter narrative
I was helping a new Mechanic just back from furlough; [just] aft of the rear bulkhead in the aft pit. While helping him; I noticed this corrosion. The B757 was ferried to company Maintenance Base to repair the Fuselage Frame. The aircraft is still being worked. No other factors involved.
NASA callback
Reporter stated not only was the extensive corrosion an issue; but the loose; hanging; unsecured electrical wiring was chafing and could have shorted out; or caused a fire in the Aft Equipment area. The amount of corrosion must have taken some time to develop. That's why he feels inspections of that area on B757/767 aircraft should be accomplished immediately.
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Source: NASA Aviation Safety Reporting System (public domain). Reports are voluntary submissions and are not verified by NASA.