Houston, Texas: Challenger 601

Challenger 601
Challenger 601
Challenger 601

A Challenger 601 suffered a bird strike and was grounded at KHOU. Bombardier wanted to bring in a team and perform the permanent repairs on-site. The Customer preferred to pursue a repair at our PCD MRO.

Two West Star Aviation MRT Structure Technicians traveled to the Customer’s base hangar and began an evaluation. After establishing and documenting the extent of the damage, the West Star AOG/MRT Team reached out to an outside DER. Due to the damage location, they were not be able to support a temporary repair to facilitate a ferry.

Instead, West Star’s PCD onsite DER was utilized to provide the required support.  Working closely with our engineering team, we designed a repair that ensured a safe ferry. Materials and equipment that could be sourced locally, were located and procured. All other items were found by the West Star Aviation Parts Team and shipped on-site.

The temporary repair required that we straighten the bent frame so the door would close normally. Then, a combination of existing fasteners was utilized and rows were added that would best secure a doubler for the ferry.

We created a transfer template with plexiglass, and used that to locate our repair doubler to the fuselage. After sealing it down and installing it with blind and solid rivets, the AC was ready to be transported to our Repair Station for permanent repair and Returned to Service.

This was an excellent example of West Star Aviation, as a Team, coming together to provide Engineering solutions, in the field/on-site recovery, material and equipment sourcing/procurement, and the Facilities capable to ensure safe and continuous Airworthiness. 

AOG/MRT Responders:
Chad Head
Patrick Presnell

PCD DER
Don Carter

AOG Van

Trust the West Star Aviation AOG/MRT team when you need expertise the most.  Our team of 43 (and growing) specialists can tackle most any issue when you are away from your home base and AOG.  From common emergency repair issues to more complicated issues with engines, structural repair and avionics, the West Star Aviation AOG/MRT Team is just a simple click or phone call away – anywhere in the world. 

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WSAA will be piloted at the East Alton, IL facility with the first round of apprentices anticipated to start in January 2024. For more information on West Star Aviation employment or WSAA apprentice selection criteria, please visit www.weststaraviation.com/careers or contact Katie Johnson (katiejohnson@wsa.aero) or Dave Lagermann (dlagermann@wsa.aero).

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.