Narrative:

Aircraft was being ferried to ZZZ1 for inoperative slide at door 2L. Amt's mr X; mr Y; and mr Z were asked to accomplish visual inspection for ferry permit. After inspection found on aft cargo door approximately 3.5 inches long by .75 inches wide; and .5 inches high mound of sealant at sta 798. This repair was previously accepted at ZZZ2 repair station by contract maintenance. Amt's questioned validity of this repair in accordance with approved manuals (srm). Major repair accomplished not following boeing structural repair manual as permanent repair. Major repair accomplished per an engineering authority as permanent. Callback conversation with reporter revealed the following information: when the sealant was peeled back to examine the repair it was discovered several hi-lok fasteners were used in the repair. But what was odd was the shear head nuts were on the outside of the door skin protruding into the airstream. It was evident the repair was not per the structural repair manual or accomplished by a skilled sheet metal technician. This repair was not accomplished per the structural repair manual and was cleared at the contract maintenance facility by a structures engineer as a permanent repair.

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Original NASA ASRS Text

Title: A B737-300; DURING AN INSPECTION PRIOR TO A MAINT FERRY; TECHNICIANS DISCOVERED AN AFT CARGO DOOR REPAIR NOT IN ACCORDANCE WITH THE STRUCTURAL REPAIR MANUAL.

Narrative: ACFT WAS BEING FERRIED TO ZZZ1 FOR INOP SLIDE AT DOOR 2L. AMT'S MR X; MR Y; AND MR Z WERE ASKED TO ACCOMPLISH VISUAL INSPECTION FOR FERRY PERMIT. AFTER INSPECTION FOUND ON AFT CARGO DOOR APPROX 3.5 INCHES LONG BY .75 INCHES WIDE; AND .5 INCHES HIGH MOUND OF SEALANT AT STA 798. THIS REPAIR WAS PREVIOUSLY ACCEPTED AT ZZZ2 REPAIR STATION BY CONTRACT MAINT. AMT'S QUESTIONED VALIDITY OF THIS REPAIR IN ACCORDANCE WITH APPROVED MANUALS (SRM). MAJOR REPAIR ACCOMPLISHED NOT FOLLOWING BOEING STRUCTURAL REPAIR MANUAL AS PERMANENT REPAIR. MAJOR REPAIR ACCOMPLISHED PER AN ENGINEERING AUTHORITY AS PERMANENT. CALLBACK CONVERSATION WITH RPTR REVEALED THE FOLLOWING INFO: WHEN THE SEALANT WAS PEELED BACK TO EXAMINE THE REPAIR IT WAS DISCOVERED SEVERAL HI-LOK FASTENERS WERE USED IN THE REPAIR. BUT WHAT WAS ODD WAS THE SHEAR HEAD NUTS WERE ON THE OUTSIDE OF THE DOOR SKIN PROTRUDING INTO THE AIRSTREAM. IT WAS EVIDENT THE REPAIR WAS NOT PER THE STRUCTURAL REPAIR MANUAL OR ACCOMPLISHED BY A SKILLED SHEET METAL TECHNICIAN. THIS REPAIR WAS NOT ACCOMPLISHED PER THE STRUCTURAL REPAIR MANUAL AND WAS CLEARED AT THE CONTRACT MAINT FACILITY BY A STRUCTURES ENGINEER AS A PERMANENT REPAIR.

Data retrieved from NASA's ASRS site as of January 2009 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.