Narrative:

While performing boeing service bulletin 727-54a0010 on an air carrier B727 xyz, FBO removed the applicable fasteners, accomplished the eddy current inspection (no cracks found), then reinstalled oversized fasteners terminating the service bulletin. Removal of the fasteners and the eddy current inspection were routine, however upon reinstallation, the following observations were noted: the mechanics used dull reams, no fixture was used to insure the holes were drilled straight, the fasteners fit loose in the holes, and the wrong countersinks were used. Regarding the loose fit, one mechanic noted that the previous shift had installed one fastener with a piece of a scotch-BRITE pad in the hole because the hi-lock turned when attempting to install the collar. I believe the piece of scotch BRITE pad was removed, however the fasteners are still undersized for the hole. Mechanics also commented that they didn't have the correct countersinks, and it is clear the fastener heads are underflush. These observations were made on the #1 engine pylon, #2 had not been completed during my last observation. Callback conversation with reporter revealed the following information: the reporter stated it's almost certain this work was not corrected and was signed off with #2 engine still to be accomplished. The reporter said the skill level was not up to the standards required to accomplish this work per the manufacturer's structural repair manual.

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Original NASA ASRS Text

Title: A B727-200 DURING A HVY MAINT CHK IT WAS DISCOVERED THE #1 AND #3 ENG FORWARD MOUNTS WERE INSTALLED IMPROPERLY.

Narrative: WHILE PERFORMING BOEING SVC BULLETIN 727-54A0010 ON AN ACR B727 XYZ, FBO REMOVED THE APPLICABLE FASTENERS, ACCOMPLISHED THE EDDY CURRENT INSPECTION (NO CRACKS FOUND), THEN REINSTALLED OVERSIZED FASTENERS TERMINATING THE SVC BULLETIN. REMOVAL OF THE FASTENERS AND THE EDDY CURRENT INSPECTION WERE ROUTINE, HOWEVER UPON REINSTALLATION, THE FOLLOWING OBSERVATIONS WERE NOTED: THE MECHS USED DULL REAMS, NO FIXTURE WAS USED TO INSURE THE HOLES WERE DRILLED STRAIGHT, THE FASTENERS FIT LOOSE IN THE HOLES, AND THE WRONG COUNTERSINKS WERE USED. REGARDING THE LOOSE FIT, ONE MECH NOTED THAT THE PREVIOUS SHIFT HAD INSTALLED ONE FASTENER WITH A PIECE OF A SCOTCH-BRITE PAD IN THE HOLE BECAUSE THE HI-LOCK TURNED WHEN ATTEMPTING TO INSTALL THE COLLAR. I BELIEVE THE PIECE OF SCOTCH BRITE PAD WAS REMOVED, HOWEVER THE FASTENERS ARE STILL UNDERSIZED FOR THE HOLE. MECHS ALSO COMMENTED THAT THEY DIDN'T HAVE THE CORRECT COUNTERSINKS, AND IT IS CLR THE FASTENER HEADS ARE UNDERFLUSH. THESE OBSERVATIONS WERE MADE ON THE #1 ENG PYLON, #2 HAD NOT BEEN COMPLETED DURING MY LAST OBSERVATION. CALLBACK CONVERSATION WITH RPTR REVEALED THE FOLLOWING INFO: THE RPTR STATED IT'S ALMOST CERTAIN THIS WORK WAS NOT CORRECTED AND WAS SIGNED OFF WITH #2 ENG STILL TO BE ACCOMPLISHED. THE RPTR SAID THE SKILL LEVEL WAS NOT UP TO THE STANDARDS REQUIRED TO ACCOMPLISH THIS WORK PER THE MANUFACTURER'S STRUCTURAL REPAIR MANUAL.

Data retrieved from NASA's ASRS site as of July 2007 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.