Just a bit about Aircraft Maintenance

[737tdi]

Well, I just got off of my regular shift and a holiday shift at my favorite place to work (SWA). I am now watching the movie Memphis Belle for the 100th time.

You know there is not much that exceeds the pride you have when you see the aircraft you work on, loaded with passengers, leaving for the ultimate destination of Montego Bay. I worked for 9 hours to get that aircraft ready for it's flight. What I love is that you see the fruits of your pain, working on an engine that is hotter then anything you have ever touched. I have blisters on my arms from touching things that should not have been touched, cuts in my hands from sharp objects that shouldn't have been rubbed against. These are impossible to avoid. Internal engine temp is around 800 degrees Celsius and this propagates to all of the metal surrounding the core.

I am tired and going to bed, but I know that I did everything right, per the Maintenance Manual, and know the aircraft is safe. How many people take 150 peoples lives in their own hands and know that their own knowledge and expertise keeps them safe? I do everyday.

Just a day in the life of us slugs. We keep them flying but if you were to read a comment made by AA's CEO we really don't have much to do with the airline making money or deserve the money we make. An unbelievable statement from an ignorant man.

I know there are a fair amount of people here who do the same. I am just tired of the lack of respect for what we contribute to "Keeping them flying".

I am on my 36th year of "Keeping them flying" and I would think that should get some recognition from the powers that be. Not. We are 4 years without an amendable contract or pay raise. Don't get me wrong, I love where I work but it is starting to get depressing.

Sorry for the dirty laundry but I'm tired and very disappointed that we are doing our jobs but the uppity ups are dragging their feet. By the way if you saw the big article about profit sharing, realize that is not money in our pockets. It is available only as a retirement benefit. No cash what so ever.

Still, I love what I do and wouldn't want to do anything else. To see the aircraft that you just did major maintenance on take off to Montego Bay is a hoot. I wish I was on it.


Get yourself in vacation mode. We are flying a lot of flights to the islands and Mexico.


Semper Fi:

Karl

 

[mohavesam]

I understand your points. Built inspected and certified turbine propulsion engines for years, then went to Repair & Overhaul... I believe the concept of "Bigger plane, bigger (maintenance) budget". There are certain (major US) airlines that I still won't put my family on. I've faced down the #2 man from XXX airlines over destroyed landing gear (destroyed on takeoff roll) and was able to quickly determine the parts had been run to 350% PLUS of their service life... yeah, that happened.

Maintenance pros get no respect. They see the crap that gets bolted on to aircraft and they have to sleep at night knowing. When the breaking story was the Valuejet LOP (leftover plane) hit the swamp I was sipping my morning coffee wondering if one of my Inspectors' stamps were on that craft. We live with that.
Carry on Karl.

 

[stevemb]

Keep up the good work guys ! I'm also on the list of few remaining well paid blue collar jobs left. The slots are dwindling daily..the desk weasels don't understand why we make more than enty level engineers..and their nephews..Stay the course.

 

[Colonialgirl]

Hope you get your raise Karl. I've always loved flying SWA and never experienced a problem on their flights.

I've never really decided whether its Better to sit in the very last row of seats and be the last person to hit the ground, sit in the Front row and get it over all at once, or sit over the wings and make sure the engines keep running. I've had pilots tell me the "safest" seats are in the rear row because the fuselage is stronger there. I guess if you fall from 30,000 feet it doesn't matter too much WHERE you sit.
Keep'm Flying.

 

[Kevin]

Well, I can say thank you. We have started to use SWA more and more. My folks came in on SWA back in January and for spring break we are headed to Las Vegas! I like the terminal at Love Field, it's pretty nice. And it seems loading and unloading (is passengers) from the plane is pretty smooth.

Now if you could get the stewardesses to raise the hem line of their skirts a few inches...

 

[Bob Wright]

I'm not a veteran of aircraft work, but do understand the pride of seeing the fruits of your labor. I was in construction and designed many grain elevators and barge loading facilities. Always took pride in my drawings, their presentations, and then seeing thousands of bushels of corn or soybeans flowing along those belt conveyors!

Bob Wright

 

[Fox Mike]

Having spent 20+ years of my life in aircraft maintenance I totally understand what you are saying. The pilots and crews understood what went into making their jobs a safe place. I think many others just thought that it was something that just magically happened, that you could safely go from point A to B without anything falling off or quit working. In all those years we, the maintenance crews, never lost a aircraft due to a maintenance error.

 

[737tdi]

All of the responses are much appreciated. Again, I can't sleep. I have had this problem for the last 10 years or so. Nothing to do with aircraft maintenance. I just can't sleep sometimes.

Kevin: We, as mechs., try to keep our aircraft at tip top shape. Yes, your reading light might malfunction or your seat back recline feature may not work. I will fix that but the priority is the really important stuff. Engines and flight controls, we have a very limited time to return aircraft to service.

My airplane got into KDAL at 0015, it was scheduled out at 0630. There was no way in hades to get that aircraft to make a 0630 departure. I apologize to the passengers but I won't short cut the procedure. I will work my butt off to get it done. We were about 30 minutes late. Yes, OSHA would have had a fit because we could have hurt ourselves due to the heat and we did. Oh well. I guess it is all about what you are willing to do with a loss of skin.

What is kinda funny? The airplane flying to Montego Bay had to have rafts.. Guess what, that was my aircraft. Not very many of ours carry life rafts. All in all a good night. I will say that I was on triple time just so you don't feel sorry for me. Holiday pay plus regular wages.


Thanks for the inputs:


Karl

 

[pyth0n]

I hear ya. Thirty five years as a mech. and QC, military & commercial. Did many twenty hour days & holidays to ensure an aircraft met the schedule. Worked in temps from -75* wind chill to +115*, neither of which you'd want to touch exposed metal with bare hands. And most times you couldn't work with gloves on. But we always managed to do it. I look back and wonder how.

 

[opos]

In 1974 I was onboard TWA flight 88 from LAX to Boston's Logan..we took off over the ocean and immediately made a severe left bank onto a "downwind" to the runway we had just left...the pilot came on and indicated we had an engine fire which could not be extinguished and we did not have time to go over the ocean to dump fuel...we were going to make a "fast and hard" landing and the crew prepared everyone for the "position", etc. The serious nature of this whole thing was that with a full plane and a full fuel load onboard with no chance to dump fuel..the plane was way over landing gross weight...it was going to be a real test to get on the ground safely...the equipment was lined up when we came in..there was a serious engine and nacelle fire but the fire trucks and crews were on it like a hawk..most folks deplaned down the chutes ok...I was in first class and when I went to hop into the slide the male steward pushed me and caused me to "topple"...my back was broken. The fire was serious but confined to the wing and engine area and did not explode or get into the passenger cabin....Thank God for the guys in the aluminum suits with the foam trucks.

This is all just "history" for what my feelings are. There was a period during the '70's as it came out at the hearing when the 747 was equipping their 747's with a particular engine that had a real propensity to catch fire...I think it was Pratt and Whitney engines but I may be wrong there....During the hearing several maintenance supervisors were called to testify and the problem seemed to be the amount of air intake space around the engine or something of the sort. It also was discussed that maintenance personnel could predict when the engines were suspect by discoloration and other factors but had been overridden by the superiors when it was pointed out that extra maintenance hours would be needed and the plane needed to come out of service....As memory serves me it was not long after all that when Boeing began to replace the existing "problem" engines with engines that did not have the fire issues..My feeling is that if a maintenance person notices something and it needs attention...the damn airplane should be red tagged until the situation is resolved...either by repair or by at least notification. The TWA I was on was full so I'd guess 300 people taking off on a plane that was suspect for engine fires....My case was settled and the settlement was not a small one...that tells me that they "agreed" that there was a defect in the acknowledgement of a problem.

I flew many thousands of hours during my career...had 3 "mishaps" but the first 2 were very minor and just a good 'scare"...the TWA situation happened over 40 years ago and I still fight the back every day.

My vote goes with the guy or gal on the line and not in the suit with the "budget line item" to meet...I flew a private aircraft for part of my career and there was absolutly no skimping on maintenance..when maintenance time came around it got done...I had (operative word was "had") a friend with a Bonanza similar to mine that is now a spot on a mountain in Alaska...he pushed the hours between maintenance based on "how it felt when he flew it"....I don't know what happened..nobody does but we do know he was way overdue for work which he just kept putting off...he always wondered why we didn't want to hop over to Vegas for the afternoon...there was a reason.

 

[Number9]

Long.. long.. hours.. and not a dime of overtime pay did I see.. to go with my already low pay.

"How many people take 150 peoples lives in their own hands and know that their own knowledge and expertise keeps them safe?"

How many people serve over 200 million people to maintain their freedom?

 

[Heliman]

I am now 2 years removed from my 25 year career as a turbine engine repairer/over hauler/and tester. I sleep much better nowadays. I feel no pressure. I don't miss the commute. I don't miss the management bean counters trying to cut corners.

I do miss the satisfaction of doing a job that requires attention to detail, seeing an airworthy product leave the hangar and knowing I was an integral part of assuring it was safe to operate. I miss working with a team of like minded individuals who are always thinking safety and always using certified parts and procedures to meet the airworthy goals.

Going back to my Navy days, I always knew that my pilots trusted us lowly mechanics to put a safe and reliable aircraft in their hands.

No editorial here, but in my 25 years we never had a layoff, or missed a scheduled pay raise. I said good morning to the Prez of the company every day. We were a team from top to bottom with a common goal. Oh.....and by the way we did all this without being unionized. Don't get me wrong, unions have their place, but advisarial attitudes can get out of hand.

Best of luck Karl, and keep 'em flying!

Dave

 

[willk]

As a pilot (or used to be cause I cannot honestly get a current medical, like I could afford to fly in these days and times) I DO APPRECIATE YOU AND EVERY OTHER A&P.

My life was in your hands every time I pushed the throttle forward or even moved the control yoke and you never ever failed me. Every flight I ever made, the aircraft I flew operated perfectly. Thank you, thank you, Thank you so Very Much!

 

[737tdi]

I love this website. So many guys and gals who have a link to aviation.

A little more background, as a "rifleman" in the USMC I also worked as an aircraft mechanic (10 years). As such I ended up being in a squadron that was the "protector of the world". A NATO attached squadron, we did cold weather training and training in only what I can call as heat from hell. I really don't know which was worse?? They were both very trying.

As far as management pushing to get an aircraft back into service, I think that things have changed for the positive. If I ground an aircraft due to maintenance it is not so easily put back into service. Yes, our engineering dept. can override my decisions but that is rare and has never happened to me. Once a write-up has been put in the logbook it is almost golden.

opos: Your story is very interesting, I will have to do a little research to find some data on that problem. I had never heard of a problem with the Pratts on the 747. I only worked on them for a few months back in the early 90's. I was basically stuck on the Douglas lines for maintenance. Want to learn how to rig flight controls just spend a week working McD. I spent almost 10 years.

Dave, my friend, I am looking forward to the day that I can follow you into retirement. I fear that is a long ways off. I am 53 and feel like 83 with all of the bumps, bruises, cuts, scrapes, burns. I do have to say though that my good buddy Blaze is 77 and can keep up with a 30 year old fellow. He works right along side me and never whimpers, may the good Lord take me before I am working at that age. He is close to an original employee at SWA. We still have a few that are day one employees (1973)! WOW.

Keep the stories coming, this is awesome.

Semper Fi:

Karl

Oh, and Willk, we do what we do because it is fun. Repairing an aircraft is not really a job, it is a joy. The only problem with it is that you have to "report" to work. Judy (wife) always comments on why I overhaul old tractors and implements, my response?, it is fun, it is my television. Get some AC/DC or Eagles rocking and I can fix anything. I used to fly as well but my hearing has gotten so bad that I can't pass the physical either.

 

[RSIno1]

......My feeling is that if a maintenance person notices something and it needs attention...the damn airplane should be red tagged until the situation is resolved.......... a friend with a Bonanza similar to mine that is now a spot on a mountain in Alaska...he pushed the hours between maintenance

Problem is the bean counters won't let someone pull an aircraft out of service for something the manufacturer hasn't listed/recognized as a problem. Sure the mechanic knows that the engine is showing signs it may fail but it's not in the Boeing book so it's not a problem to the front office. If it does fail all they have to do is show maintenance by the book and the manufacturer is on the hook for the lawsuits.
A friend runs into guys like your friend all the time. He's got an FBO and 80% of the people that come in want to just get it patched up enough to pass the annual. He sends them down the road.

 

[737tdi]

......My feeling is that if a maintenance person notices something and it needs attention...the damn airplane should be red tagged until the situation is resolved.......... a friend with a Bonanza similar to mine that is now a spot on a mountain in Alaska...he pushed the hours between maintenance

Problem is the bean counters won't let someone pull an aircraft out of service for something the manufacturer hasn't listed/recognized as a problem. Sure the mechanic knows that the engine is showing signs it may fail but it's not in the Boeing book so it's not a problem to the front office. If it does fail all they have to do is show maintenance by the book and the manufacturer is on the hook for the lawsuits.
A friend runs into guys like your friend all the time. He's got an FBO and 80% of the people that come in want to just get it patched up enough to pass the annual. He sends them down the road.

It is not a conspiracy! Please don't make it seem like one. Boeing is no different then Ford or Chevrolet. They want to sell you parts. If they/you/SWA/me finds a problem then that problem gets fixed/repaired. It is no more no less. Yes, Boeing wants their airplanes to be reliable but they jump on the chance to sell parts. That is their bread and butter, just like automobile companies.

If you have ever been involved in an aircraft accident investigation you would know that all of the records are locked. There is no way out if a maintenance or airworthiness procedure was not followed. There is a saying we all keep in the back of our minds. Cradle to the grave. If you did a repair, you are responsible for it from the day you did it until the next guy alters or repairs it or until the aircraft is retired. Most folks don't realize this.


Karl

 

[coach]

As a semi-frequent traveler I thank you for your professionalism and diligence in maintaining the aircraft I fly on. Flying to Nashville tomorrow on SW.
BTW- Let a few AA planes go down and see how that affects his profits. What a moron.

 

[737tdi]

As a semi-frequent traveler I thank you for your professionalism and diligence in maintaining the aircraft I fly on. Flying to Nashville tomorrow on SW.
BTW- Let a few AA planes go down and see how that affects his profits. What a moron.

Coach, thank you for your business and I hope you have a great flight. Tell the FA that clock no. 57234 asks that you get a free beer on me. Happy flying.


Karl
Dal2mx

 

[Scout943]

Not surprised to hear that not much has changed since i retired from TWA in 2001 after 35 years ,don't let it get to you !

 

[GunnyGene]

I have a couple books from my time with Boeing ('85 - 2000 ) that might be of interest to y'all. Both are available on Amazon for about $5 each.

"Vision, The Original "Story of Boeing" by Harold Mansfield"

and

"Legend and Legacy", by Robert J. Serling

And also have an older book, not about Boeing or Commercial aircraft tho.

"Victory through Air Power" by Maj Alexander P. De Seversky, Pub. 1942 , Dedicated to Gen. William Mitchell. Also on Amazon for a couple dollars used, or New Original Edition for around $230. (The one I have is a family heirloom in perfect condition, so don't ask me to loan it out. :wink: )

 

[mohavesam]

Different times, different men.

 

[737tdi]

Gunny, I am kinda of a aviation geek so I look for and read all things aviation, especially older books on aircraft maintenance. Here are just two of the many books I own on the subject. If I am lucky I will get what is called the Charles Taylor award when I turn 68. If some don't know who he was, he was the first officially licensed aircraft mechanic plus he was the designer and mechanic on the Wright Flyer.











Both of these books are from the early 40s and are a great look into the techniques used at the time.


Semper Fi:

Karl

 

[737tdi]

Long.. long.. hours.. and not a dime of overtime pay did I see.. to go with my already low pay.

"How many people take 150 peoples lives in their own hands and know that their own knowledge and expertise keeps them safe?"

How many people serve over 200 million people to maintain their freedom?

Well, as a Marine I think I qualify. I spent 10 years doing my duty with many many holidays and birthdays away from family protecting over 200 million people. Is this what you mean? If not I don't understand.


Semper Fi:

Karl

 

[Bull Barrel]

Hmm...Aircraft Maintenance for the Airplane Mechanic.

Are they sure?

 

[737tdi]

Hmm...Aircraft Maintenance for the Airplane Mechanic.

Are they sure?

HaHa, I found that amusing as well. What else would/could it be? Aircraft Maintenance for the TV repairman...


Karl

 

[GunnyGene]

Hmm...Aircraft Maintenance for the Airplane Mechanic.

Are they sure?

HaHa, I found that amusing as well. What else would/could it be? Aircraft Maintenance for the TV repairman...


Karl

Probably to make a distinction between aircraft mechanics and pilots. As all mechanics know, pilots just break stuff. :wink:

 

[Jeepnik]

In 1974 I was onboard TWA flight 88 from LAX to Boston's Logan..we took off over the ocean and immediately made a severe left bank onto a "downwind" to the runway we had just left...the pilot came on and indicated we had an engine fire which could not be extinguished and we did not have time to go over the ocean to dump fuel...we were going to make a "fast and hard" landing and the crew prepared everyone for the "position", etc. The serious nature of this whole thing was that with a full plane and a full fuel load onboard with no chance to dump fuel..the plane was way over landing gross weight...it was going to be a real test to get on the ground safely...the equipment was lined up when we came in..there was a serious engine and nacelle fire but the fire trucks and crews were on it like a hawk..most folks deplaned down the chutes ok...I was in first class and when I went to hop into the slide the male steward pushed me and caused me to "topple"...my back was broken. The fire was serious but confined to the wing and engine area and did not explode or get into the passenger cabin....Thank God for the guys in the aluminum suits with the foam trucks.

This is all just "history" for what my feelings are. There was a period during the '70's as it came out at the hearing when the 747 was equipping their 747's with a particular engine that had a real propensity to catch fire...I think it was Pratt and Whitney engines but I may be wrong there....During the hearing several maintenance supervisors were called to testify and the problem seemed to be the amount of air intake space around the engine or something of the sort. It also was discussed that maintenance personnel could predict when the engines were suspect by discoloration and other factors but had been overridden by the superiors when it was pointed out that extra maintenance hours would be needed and the plane needed to come out of service....As memory serves me it was not long after all that when Boeing began to replace the existing "problem" engines with engines that did not have the fire issues..My feeling is that if a maintenance person notices something and it needs attention...the damn airplane should be red tagged until the situation is resolved...either by repair or by at least notification. The TWA I was on was full so I'd guess 300 people taking off on a plane that was suspect for engine fires....My case was settled and the settlement was not a small one...that tells me that they "agreed" that there was a defect in the acknowledgement of a problem.

I flew many thousands of hours during my career...had 3 "mishaps" but the first 2 were very minor and just a good 'scare"...the TWA situation happened over 40 years ago and I still fight the back every day.

My vote goes with the guy or gal on the line and not in the suit with the "budget line item" to meet...I flew a private aircraft for part of my career and there was absolutly no skimping on maintenance..when maintenance time came around it got done...I had (operative word was "had") a friend with a Bonanza similar to mine that is now a spot on a mountain in Alaska...he pushed the hours between maintenance based on "how it felt when he flew it"....I don't know what happened..nobody does but we do know he was way overdue for work which he just kept putting off...he always wondered why we didn't want to hop over to Vegas for the afternoon...there was a reason.

As an old "aluminum suiter" I can say that most aircraft fires don't result in an explosion. Oh they can burn really fast, but the only time I saw an aircraft explode was when the ordnance under the wing went up. Still it does get exciting.

Oh, and if you really want to know who to thank, thank 3M. They made the first AFFF (aqueous film forming foam). The difference between it and the older "protein" foam was night and day.

 

[Don Lovel]

Just knowing that a guy of your caliber and integrity works on 737's for SWA is the main reason that I only fly SWA whenever possible.
One time when I worked on KCI, I watched two US Air mechanics beat a flap into submission with a big steel sledge hammer where it goes into the guide rail on the fuselage, just maybe 30 seconds before the plane backed out of the loading ramp.
Big ole NOPE flying US Air after that

 

[bogus bill]

I spent 35 years as a Lockheed security guard first in Burbank until 1969 and then Palmdale 1965 to 2000. Knew all that worked there back then. Everyone from Kelly Johnson and all the test pilots to the janitors. It was a good place to work. Never was laid off.
Yesterday I was at our airport and met a couple of government hunters that just landed from shooting coyotes out of their Cub. Interesting! I then went home and googled story's about it. Very interesting. I went to their hanger and visited. One of the planes they use is also a Citabria. I have one too.

 

[graygun]

Thanks and good work Karl and others in the field! I worked on USAF sims for 21.5 years and always enjoyed saving a mission or repairing a component.