Story/photo by Elizabeth Poe

Naval Air Depot Cherry Point has a new repair capability in the AV-8 program, which should help to ensure the continuance of pilot training in the Harrier. NADEP artisans can now install main landing gear drag brace beams on AV-8 Harrier trainers or TAV-8s.

A major structural component, the drag beam attaches the landing gear to the aircraft. Unfortunately, this beam is beginning to crack on nearly a third of the early “T-birds.”

“We need to replace those beams with strengthened beams,” said engineer Steve Barnette, who provided on-site engineering support during the repair.

TAV-8s are critical to the Marines; these aircraft support ground forces and the Corps’ capability as a “Force in Readiness.”

Depot artisans do not ordinarily replace major structural components on aircraft. NADEP sheet metal mechanics Gary Sanders, William Ruth, Joe Baker and Larry Styron performed this unusual repair.

The beams are major load-carrying items on the aircraft, so the first task for the artisans was to support the aircraft properly and ensure that the fuselage was stable. Special tooling was required to cradle the aircraft during the repair.

The artisans could then begin to remove the old beam and replace it with beams supplied by British Aerospace Engineering.

“You can’t take the old beam out in one piece because it’s wedged in,” said Baker. “We had to cut it out.”

To make the repair, the AV-8 team adapted some replacement structures developed by the British and modified them for the TAV-8, said industrial specialist Jeff Jaskolka.

The original beam was one piece; depot artisans spliced together two beams with doublers, or supporting plates, for each beam.

“Then we had to sandwich the beam together,” Ruth said.

Accurate measurements were critical to the process. After ensuring proper spacing between the two beams, they were drilled to the aircraft in the holes that matched between the fuselage and the new beams.

“The ones we couldn’t match we had to route to the machine shop and specially drill them,” Jaskolka said. The team used the old beam as a reference and was pleased when the new beam fit.
The replacement of the main landing gear drag beam was completed in three weeks requiring less than 400 man-hours.

“It took place quickly because everyone communicated and worked well together,” Barnette said.
The Defense Aircraft Repair Agency and BAE assisted the depot in securing the kitting and adapters required for the repair.

AV-8 engineer Fritz Seaman and machinist David Knox also participated in the repair effort and were instrumental to its success.

The aircraft will be returned to Cherry Point-based VMAT-203 after other repairs are completed on the TAV-8 within the depot.

Only five of the 17 TAV-8s in service require this repair. Stronger beams were installed on the aircraft after determining that the beams on the original six aircraft were not sufficient.

The AV-8 team expects to perform this repair on two more such aircraft over the next several months.

“Without TAV-8 aircraft, the Harrier pilot training program would cease to exist,” said Gunnery Sgt. Marco Argento, assistant AV-8 program officer.

Cutline: AV-8 personnel responsible for the successful repair of a major structural component to the TAV-8 are (front row from l-r) machinists David Knox and Fred Land; (back row from l-r) structural engineers Steve Barnette and Frederick “Fritz” Seamon; sheet metal mechanics Joe Baker and William Ruth; and sheet metal worker Gary Sanders.