MAJOR REPAIRS AND ALTERATIONS

1. MAJOR REPAIRS AND ALTERATIONS FLIGHT STANDARDS SERVICE FEDERAL AVIATION ADMINISTRATION

2. Introduction • TO PROVIDE GUIDANCE FOR: • Determining the category of a repair or alteration. • Ensuring that the aircraft can be returned to service in accordance with the approved technical data.

3. AGENDA • Learn of ways to determine major or minor. • Be able to determine what kinds of data are required. • Understand the record keeping requirements for major and minor repairs and alterations.

4. Overview • Will allow for better understanding of: • Airworthiness • Conformity • Types of Data • Regulatory Compliance

5. KEY DEFINITIONS • Airworthiness • Type design • Type Certificate • Conformity • Alteration • Repair

6. AIRWORTHINESS • Conforms to a Type Design!(We will talk about this in more detail later!) • Is in a condition for Safe Flight!(Ask yourself...Will the pilot be able to take-off, conduct the flight and land the aircraft safely?)

7. The Standard Airworthiness Certificate • The FAA Act of 1958...Provides the Authority and basis for issuance: • Establishes: That the aircraft must conform to a Type certificate...AND ...be in a condition for safe flight. • ALSO... Establishes: that it will remain in effect as long as the maintenance, preventive maintenance and alterations are done I/A/W Parts 21, 43 and 91 of the Federal Aviation Regulations

8. Conformity • Are inspections accomplished that are concerned with determining that the materials, parts process, heat treatment, fabrication procedures, and installations involved conform with the approvedtechnical data.

9. Question? • WHAT DOES THE WORD APPROVED MEAN TO YOU?

10. Questions to ask while checking Conformity • Are the materials, parts, etc.... FAA approved? Do they have traceability? • Are the materials used IN CONFORMITY with the Drawings?

11. Questions to ask while checking Conformity(cont...) • Are these materials, parts, etc... approved for installation? • If special processes have been involved during repair or manufacture...was it done I/A/W FAA approved process specifications?

12. Type Design • Drawings and Specifications. • Dimensions, materials, and processes that went into the development of the aircraft, engine or propeller. • Information necessary to define the structural strength of the product. • Airworthiness Limitations. • Special Inspections and maintenance program. • Other data as required.

13. Type Certificate • A document issued by the FAA to the applicant who has proven that his/her aircraft, engine or propeller meets all the requirements of the FAR(s) pertaining to that product. • The issuance of the Type Certificate “Approves” the Type Design.

14. Alteration • A change to the the aviation product FORM or FUNCTION which is not spelled out in the original design standard. • REMEMBER.... “THE DEFINITION OF AIRWORTHINESS?”

15. Repair • A restoration of the aviation product to its original design standard. • REMEMBER... “ CONFORMITY?”

16. LETS REVIEW WHAT WE’VE LEARNED SO FAR TODAY! • What is a Type Design? • What is a Type Certificate? • What is Conformity? • What makes an aircraft airworthy? • Where do we find the definition of airworthiness? • What Part of the FAR(s) describes these issues?

17. ARE YOU CONFUSED ABOUT MAJOR AND MINOR REPAIRS? • There is help out there! • FAR Part 43, Appendix A. • Your local Flight Standards Office. • Designated Engineering Representatives. • FAA Engineering.

18. WHAT IS A MAJOR REPAIR? • ...A repair that, if improperly done, might affect weight, balance, structural strength, performance, powerplant operation, flight characteristics, or other qualities affecting airworthiness...or:A repair, that if not done in accordance with acceptable practices orcannot be done by elementary operations. (FAR PART 1)

19. A MAJOR ALTERATION IS... • ... an alteration not listed in the aircraft, engine, or propeller specifications... (REMEMBER TYPE CERTIFICATES?)...that: • ...might appreciably affect weight, balance, structural strength, performance, powerplant, flight characteristics, or other qualities affecting airworthiness. or:

20. A MAJOR ALTERATION IS (cont..) • ...is not in accordance with acceptable practices or cannot be done by elementary operation. (FAR PART 1)

21. A word about: APPLIANCE MAJOR ALTERATIONS: • An alteration of the basic design which is not made in accordance with the recommendations of the appliance manufacturer or in accordance with an FAA Airworthiness Directive • * instruments *parts * mechanism *equipment

22. SO WHAT ABOUT MINOR REPAIRS AND ALTERATIONS? • If it can not be classified as Major...they are considered Minor. • Must be accomplished using those methods, techniques, and practices acceptable to the Administrator. • Accomplished using elementary operations. • Requires a record entry only!

23. DATA............ • Approved • Accepted

24. “APPROVED DATA” • Type Certificate Data Sheets • Aircraft Specifications • Airworthiness Directives • Manufacturer’s FAA-Approved Data

25. “APPROVED DATA” (cont.) • Designated Engineering (DER) Approved Data with FAA Form 8110-3,Statement of Compliance. • Designated Alteration Station (DAS) Approved Data. • Appliance Manufacturer’s manuals (even though they are not specified as FAA Approved.)

26. “APPROVED DATA” (cont.) • Structural Repair Manuals (SRMs) when specifically approved. • FAA Form 337(s) when the data has been previously approved and will be used for the basis of field approval. • Delegation Option Authorization Data. • Service Bulletins if specifically approved.

27. ALSO: AC 43.13-1A • “Acceptable Methods, Techniques, and Practices-Aircraft Inspection and Repair. • When appropriate to the product being repaired, • Directly applicable to the repair being made. • Not contrary to Manufacturer’s data.

28. “ACCEPTABLE DATA” • Manufacturer’s maintenance manuals. • Manufacturer’s Service Bulletins and technical Info.. • Advisory Circulars 43.13-1A or 43.13-2A (If Applicable). • Far Parts 121 and 135 Operator’s Maintenance Manuals. • FAA Field Approvals.

29. Approval for return to service after Major Repairs/Alterations • Can certificated mechanics approve and return to service after maintenance and alteration?

30. YES!.....................But: • Only for repairs and alterations that are minor in nature. (FAR 65.85[Airframe] & [FAR 65.87[Powerplant]

31. So who can approve for return to service after Major Repairs and Alterations? • Certificated Mechanics with Inspection Authorization. (FAR 65.95) • Certificated and rated Repair Stations. • Air Carriers (PART 135 and 121). • Designated Alteration Stations (DAS) • The manufacturer approve for return to service after alterations only.

32. In addition: • FAA Aviation safety Inspector (Airworthiness) • FAA Designee • Persons approved by Transport Canada Airworthiness Group (AMO).

33. RECORD KEEPING REQUIREMENTS • FAR Part 43, Appendix B will tell you how to record Major Repairs and Alterations.

34. Each Person performing a Major Repair/Alteration SHALL: • Execute FAA Form 337 at least in duplicate. • Provide a signed copy to the owner. • Forward a signed copy to the local FAA office.

35. Repair Station Option for Major Repairs ONLY: • Use the customer work order and record the repair in the aircraft logs. • Give the owner a signed copy of the work order. • Keep a copy of the work order for two years. • In addition: Provide a Maintenance Release.

36. MAINTENANCE RELEASE • Indicate what has been repaired. • That the repair was inspected. • State that it has been approved for return to service. • Identify the work order number on file. • Date and signed by an authorized person. • Certificate number of the Repair Station.

37. Any Questions?