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Challenger 600 Series Pylon Chafing

Challenger 600 Series Pylon Chafing
Challenger 600 Series Pylon Chafing

West Star Aviation’s Challenger Team is always looking for ways to keep operators informed with useful information, tips, and areas of interest for their specific airframe. One such relevant topic is Pylon Chafing.

96-month inspections on Challenger 604 and 605 aircraft require specific inspection to the right and left side engine pylon areas where they meet the fuselage. This portion of the inspection looks for potential chafing to the fuselage skin from the pylon itself.  

Our Specialists have encountered and helped correct at least 9 occurrences of this problem over the last two years. The key is early detection and correction. If left unchecked, the chafing can cause significant enough damage to the fuselage skin to require skin replacement.

If pylon chafing is detected, it is repaired per a recent addition to the Challenger Structural Repair Manual (SRM) in section 53-32-00. The specified repair does not require engine removal, and effectively repairs and prevents recurrence of the chafing. The process does require some paint work, per the SRM, only in the pylon area.  

The cost of the repair is approximately $15,000 per side, which is significantly less than having to replace damaged fuselage skin completely.  

As mentioned, the Challenger 96-month inspection requires review of this area, and West Star has recently added inspection of the area as an option in their Technical Evaluations (Pre-purchase Inspections). Due to the downtime required for the repair, it is recommended to address any problems in this area during these events. Chafing repair downtime is approximately 13 days when both sides are repaired simultaneously. 

West Star can complete your next Challenger inspection, maintenance, or modification, including this repair, at our East Alton, IL (ALN), Grand Junction, CO (GJT), or Chattanooga, TN (CHA) full-service facilities.

For more information or to schedule your next maintenance event, please contact any of the West Star Aviation Challenger Specialists:

Steve Bates

Steve Bates

Bombardier Technical Sales Manager (ALN)

Donnie Shealy

Donnie Shealy

Technical Sales Manager (CHA)

George Laiten

George Laiten

Program Director Bombardier (ALN)

Jeff Olson

Jeff Olson

Program Manager Challenger (GJT)

Steve Smith

Steve Smith

Challenger/Global Program Manager (CHA)

Randy Miller

Randy Miller

Technical Sales Manager, Challenger & Global (GJT)

Larry Marler

Larry Marler

Technical Sales Manager (CHA)

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Mark White

RSM, California

Dave Godo

RSM, Ohio Valley

Mark Daniels
Tim Cane
Robbie Johnson

RSM, Mid Atlantic

Santiago Carol

RSM, Latin America

Steve Fleeman

RSM, Landing Gear

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WSAA will be piloted at the East Alton, IL facility with the first round of apprentices anticipated to start in August 2024. For more information on West Star Aviation employment or WSAA apprentice selection criteria, please visit or contact Katie Johnson ( or Dave Lagermann (

Application & Selection Process

Before applying, please be aware of the standards of conduct for employment with West Star along with the strict requirements below while attending WSAA.

  • Working in Aviation requires a commit to being drug-free.  Pre-employment drug testing along with random and reasonable suspicion testing is required for all companies employing people working in safety sensitive positions. The position you are considering applying for is safety sensitive.  If hired, you must pass a DOT drug test to start working, if you fail the job offer is rescinded.  If you pass, you must remain drug-free during employment, failing a random or reasonable suspicion test may result in termination of employment.  Please note: marijuana is legal in certain states however the FAA follows Federal law where marijuana is illegal.  This means testing positive for marijuana, or any other illegal drug, will prevent you from working in Aviation. 
  • The first 7.5 months will follow a strict schedule: Monday – Friday 7:00am – 3:30pm (breaks and meal periods provided). 
  • The expectation is to arrive inside the learning center and clocked in at 7:00am.
  • While attending WSAA, no more than 4 hours a week can be missed.  Extenuating medical circumstances will be given full consideration with supporting documentation.
  • WSAA follows an FAA approved curriculum which has certain requirements including attendance. 
  • Testing for the FAA license at the conclusion of WSAA is required, along with passing.  Two opportunities to test will be provided, if needed.  Employment may terminate if the FAA license is not obtained.
  • Candidates will be contacted to complete pre-screening assessments and questionnaires. 
  • Qualified candidates will be contacted in late November and scheduled for a tour and interview with Hiring Managers at West Star Aviation in East Alton, IL.
  • To be qualified, candidates must pass the pre-screening process along with submitting a negative DOT drug test result.
  • Finalists will be selected after onsite interviews. Job offers will be extended in mid-December with a start date of January 9, 2024.
  • Pay while learning in the Academy will be $20 per hour.  Upon successfully graduating and obtaining your FAA license, pay will increase to $27 per hour.