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