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Show 22 HILL TOP TIMES Wednesday, November 26, 1 986 Obsolete aircraft parts rolling off program assembly line By Ross Day Kelly AFB, Texas When the family car begins to show its age, things begin to quit working normally right after the warranty runs out. The corner auto parts store usually has the replacement part because manufacturers know they're going to be needed and make plenty. But where does one go to find a replacement part for an aircraft that builders thought would only last for two decades but ends up flyng for 30 years or longer? How do you buy a part that was no longer manufactured after the last plane rolled off the assembly line in 1962? "You don't," said Jerry Turner. "You make it." Mr. Turner is the Directorate of Maintenance Aircraft Division's monitor for Pacer LIGHT at Kelly AFB, Texas. He oversees the program that directs the manufacture of parts for and H models that can no B-52- G longer be economically manufactured by defense contractors. "Let's take, for instance, the engine first wrap cowl for the manufactured in 1962," said Mr. Turner. "We have built 88 of these panels' over the past two years at a unit cost of $19,600. weapon "Figures supplied by Oklahoma at City system managers Air Logistics Center show that one B-52- B-5- manufacturer wanted $91,401 to turn out a similar cowl," he said. And that is the story for numerous other parts that have fallen under Pacer LIGHT one nose cowl, contract estimate $384,563; Pacer LIGHT cost $120,000. Ten have been B-5- ' , . 2 Air Force Photo by Ross Day) hand-hel- d Sandra Trevino of the San Antonio Air Logistics Center uses a pneudraulic vice to put the squeeze on rivets in a upper righthand engine side cowl. B-5- 2H .- -- COUPON- B-52- G manufactured since completion of proeventutotyping in April. Thirty-nin- e ally will be built. side cowls for the Seventy-fiv- e been manufactured H have and to date at Kelly AFB. Civilian industry wanted as much as $454,677 per cowl. Pacer LIGHT did it for $6.4,125 each. "The problem is quantity," Mr. Turner explained. "When orders for hundreds of these parts were rolling in from Boeing, subcontractors costs and recouped their start-u- p made a significant profit. There is no profit, however, in retooling for 20, 50 or even 100. "It was difficult even finding contractors who were willing to bid on these parts even at the higher prices the Air Force was willing to pay," he added. Pacer LIGHT is presently gearing up for its most ambitious and complex manufacturing project yet the buildhas four of these ing of struts. A vital and intricate connectors, each of B-52- G (U.S. . 2 B-5- 2 which joins two engines to the wing and houses iuel and control systems. "We will begin prototyping struts in January," Mr. Turner said. "Sacramento ALC will probably join us in this effort because of their advanced capabilities in 'skin stretching' technology. We'll build the internal portion and put the skin on when we receive it from Sacramento." Aircraft Division officials noted that although they have been repairing products encompassed by Pacer LIGHT for years, the step to complete production is an ambitious one. Overall, the program calls for manufacture of 423 items for the and H. They estimate that at the finish of the program, Pacer LIGHT will have saved the Air Force about $40 million and will ensure that the 2 remains combat ready for years to come. Mr. Turner pointed out that Pacer LIGHT was the brainchild of item and system managers at Oklahoma City ALC. "They had a big problem and came up with a workable solution," he said. "We are happy to be part of that soB-5- B-5- 2 lution." is the first airAlthough the from to benefit this craft program, it probably won't be the last. Lessons learned during Pacer LIGHT may well be applied to other aging aircraft in the Air Force inventory such as the B-5- 2 and Officials agree that if we intend to use aircraft past their originally forecasted life cycle, then we must mainC-1- 30 C-14- 1. tain the capability to manufacture parts when they are no longer available commercially. (AFLC News Service) 1 ) ASmart JE rJL? lube oil filter 10 MINUTE LUBE OIL, FILTER CHANGE Wednesday is... ...LADIES' DAY don't give you time to miss your car!" "V7o VISA 3 OFF J No Appointment Necessary No Waiting! Illllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllg Check & Fill Change Oil (up Transmission (up to I to 5 quarts) pt. or I lb.) Filter Oil Change Check & Fill Battery Check & Fill DifCheck & Clean Air ferential (up to I lb.) 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