On February 1, 2021, Textron Aviation issued a temporary revision to the Cessna 441/Conquest Maintenance Manual.  This revision included a new Phase Inspection, Phase 58.  The Phase 58 inspection deals with the inspection of the emergency exit door bond.  This inspection needs to be completed every 2000 hours or 4 years.

Inspection of this previously overlooked area can reveal the need for repair.  Needed repairs can range from full skin replacement to new button head rivets installed through the skin.  The West Star Conquest specialists report that of 22 emergency exit door inspections performed, 8 required repair.

Average cost to repair the emergency exit door is approximately $4,310.00, but can vary depending on the specific repair needed.

Downtime can vary from one day to two weeks, depending on the condition of the emergency exit door.  

West Star’s dedicated Cessna 441/Conquest teams have established one of the most respected reputations in the industry when it comes to the maintenance, repair, and overhaul on this airframe.  West Star utilizes a Structures DER for these emergency exit door repairs as the repair is not detailed in the airframe maintenance manual.  

Further, West Star utilizes the deep capability of our affiliate sister company, Dallas Aeronautical Services (DAS) that specializes in structural, composite and assembly repair.  As new skins are not available from the manufacturer, DAS has the tooling, equipment, and necessary expertise to repair the entire bonded skin of the emergency exit door assembly.