John Millar, left, and Dennis Locke, both Code 6.2.1.7, install a rivet that secures the spar cap and doubler to the tail boom. Photo by ADC (AW) James Bennett

Raul Ramirez, Code 6.2.1.7, shows the length of a spar cap. Photo by ADC (AW) James Bennett

Pendleton team steps it up a notch

By ADC (AW) James Bennett
NADEP North Island

If you felt the heartbeat of Naval Air Depot North Island raise and lower recently, it was because the Field Service In-Service Repair team stepped it up a notch for NAVAIR. On Feb. 14, we lost an aircraft that subsequently downed every H-1N helicopter. The concern was with a tail boom spar cap, which is a single, thick forged aluminum support beam (designated Air Force spar cap) that runs the length of the tail boom and is a structure critical component. The Air Force spar cap is being replaced with a single forged aluminum spar (designated Navy/Marine) plus a “doubler” (an additional piece of 90-degree angle bracket made of aluminum).
Marines at Camp Pendleton identified 12 aircraft that needed to have the spar cap replaced. The average turnaround time to replace a spar cap is eight days; however, this would not meet the operational commitments of Marine Air Wing 39.
The NADEP North Island’s Camp Pendleton ISR team committed themselves to reducing the turnaround time by 50 percent by increasing the work schedule to 12-hour days, seven days a week. Russell Moore, Code 6.2.1, lead on-site planner and estimator, devised the working plan. The MAW-39 commanding officer and the wing’s maintenance officer fully supported Moore’s plan.
Before starting the 12/7 working schedule, two of the on-site sheet metal mechanics, Dennis Locke and John Millar, both Code 6.2.1.7, said that they were ready to step up to the plate when they were asked if they were up for the challenge.
All the spar caps were replaced in 20 days, three days ahead of schedule.