Work Progress Log
this report up to date is a chore, so I am behind! I plan to add
material as time permits. The below details some of the work done
through the end of 2004. There has been a lot of activity.
Progress Report 28 October 2004
A critical event occurred yesterday, 27 October, when a 7 man Boeing
AOG Team surveyed the airplane for structural and airworthiness issues
that might stand between us and a successful ferry flight.
Most of the team,
which included AOG Planning, AOG Quality, and Service Engineering, had,
for example, participated in the 'second' restoration of the B-307
Stratoliner after its water landing in Elliott Bay. Areas of
known concern to us were examined, as well as areas they were
knowledgeable about. The entire fuselage crown was examined, as
the S-Duct, the keel beam, wheel wells, wing spars and skins, and main
landing gear support structure. A fuel tank entry was made and an
extensive examination of the RH inboard tank structure was made.
A written report will be prepared and
forwarded to me within about a
week. At a verbal de-brief after the survey, certain issues were
discussed along with some recommendations for additional
They agreed to do some NDT testing and evaluation of certain key
components at no cost to the museum. But, the Bottom Line was: They
felt the airplane was in excellent condition, given its length of
storage (better than some in-service airplanes, was the comment
and saw no major structural or airworthiness obstacles to perfoming the
sought after ferry flight. They
helped us especially with advice
on some critical question areas we had - such as flap track integrity -
that will significantly speed our work.
Boeing AOG Survey Team with T.C.
Really getting into things!
A good-looking wing tank structure -- 42 years old!
Here's what it looked like 42 years ago.......
Progress Report August - September 2004
While Steve has been way-laid
by some home and medical problems, T.C. has gained valuable support
from Boeing, Goodrich, and a number of parts suppliers and vendors.
A number of needed components
(like hydraulic filters), have been located and obtained, along with
lengths of bulb seals, which he has been installing in Kreuger flap
leading edge areas.
Progress Report 28 Jul 2004
We got some good P.R.
today in an article in the Seattle Post-Intelligencer. T.C. got
his mug in the paper in a nice color picture. You can find it
Steve is on a temporary stand-down
due to a plumbing crisis in his house. We know what those are
Another reminder as to why we're doing all this!
Progress Report 26 Jul 2004
All Jackscrews have now been
removed from FedEx (E371) as well as many of the transmissions.
Flap drive torque tubes are also being removed.
Removed torque tubes tagged and stored on E371.
Terry has obtained a good supply of donated metal-cal (foil) marker ID
tags for use on our removals, many of which had no ID markings.
They came from:
Progress Report 8 Jul 2004
2040 15th AVE W
Seattle, WA 98119
Many thanks to Jeff and GM Nameplate!
The four flap jackscrews have
been removed from the LH flaps.
Most flight and engine instruments have been removed from the forward
Progress Report 1 Jul 2004
A progress evaluation was held Thursday Jul 1, to review work
activities and decide on trailing edge flap issues.
A new work table and book case was built and installed by Bruce
Sutherland on Tuesday 29 Jun in the fwd RH cabin.
The airplane RH side (E1) - very green from moss and mildew, was
pressure washed by Museum volunteer Barry Horner,
and looks better than it has looked in several years. Thanks,
Damage to FedEx N124FE was found after the county mowed the grass
around the airplane on Saturday. The LH slat fence was severely
damaged and the RH inbd aft flap was also struck. We can operate
around that damage. Airport officials came and observed the
damage and action was promised.
Enough serviceable bearings have been recovered from both airplanes'
Kreuger flaps to make a complete shipset. They will be point
staked onto the E371 Kreuger flap hinge arms.
The corrosion on the LH aft body of E1 will be repaired in a manner
similar to the RH side - rivets drilled out, lap joint corrosion
cleaned up, and replacement fasteners - either nuts and bolts, or
We obtained an IPC (Illustrated Parts Catalog) from FedEx and added it
our document library.
We have been given access to Boeing drawings and engineering support
through Boeing My Fleet by Alan Mulally.
All the FedEx flap track fairings and canoes have been removed, and
work has started on removing the jackscrews and gearboxes.
Landing gear doors, fore flaps, flap track fairings removed
I have begun disassembling the cockpit and removing instruments and
panels. Removed parts will be kept as spares for E1 or cycled
into the Museum's education and exhibits program.
After close examination of the flaps, tracks, and carriages on both
airplanes, it was decided that:
1- The Numbers 4 and 5 flap tracks on E1 will be retained without
replacement. Track 5 will be properly installed - it currently
only has minimal fasteners.
2- The flaps from FedEx (E371) will be removed and installed on E1,
with the exception of the RH outbd foreflap, which is missing from
FedEx, and possibly the RH inbd aft flap, which was damaged by an
airport mower. The carriages from E371 will be moved to E1 - E1's
carriages and rollers are badly corroded and will no longer accept
3- E1's flap tracks will be cleaned of rust and lubricated or protected
from further corrosion.
Progress Report 24 Jun 2004
Main Landing Gear Hockey Stick
Doors have been removed from FedEx.
Door before Removal....and, after its removal
Work on removing the fore-flaps has begun.
Steve Huemoeller - Chief Mechanic
Terry Howard ("T.C.") - Chief
Progress Report 15 Jun 2004
Steve and T.C. Howard have
been working steadily on replacing E1's Kreuger flaps. All flaps
have now been removed from both airplanes. Installation of the
FedEx flaps on E1 is beginning.
Kreuger flaps removed from E1
Donor flaps from N124FE -
removed subsequent to these pictures.
Last Meeting Minutes
Meeting was held Weds,
May 19, 2004 at PAE.
Huemoeller, Howard, Dale Ranz, Bogash
We reviewed our plans, work
accomplished to date, possible help from Boeing, and a configuration
for a ferry flight.
Dale has volunteered to be the pilot.
He is currently qualified on the airplane.
We then inspected the airplanes and discussed problems
encountered with removing the badly corroded Kreuger flaps from E1.
A structural survey is needed fairly urgently to direct the path we
intend to follow, i.e. fly the airplane or restore to non-airworthy
display condition. T.C. Howard is working this issue.
Steve has been working on the airplane steadily. All the
Kreugers have now been extended and several have been removed.
Badly corroded Kreuger Flaps
E1 Kreuger flaps - to be replaced.
morning, March 20, 2004, a meeting was held at the Museum of Flight
Paine Field at 0900 hours (9:00 AM.)
discussed the plans for transferring parts from our FedEx donor
airplane to our Prototype airplane, followed by a tour of both
Attendees: Sutherland, Muscat, Cawvey, Cole, Howard,
Graham, Huemoeller, Sandvig, Nord, Bogash
It was decided to conduct a structural survey of N7001U to determine
whether it could be made airworthy for a ferry flight. Certain
structural issues involving corrosion are known. A group of
retired Boeing Quality Assurance and Liason Engineering personnel will
be assembled to examine and assess the airplane. ACTION: T.C. Howard
A FedEx Maintenance Manual is available on CD and will be provided by
An A.D. Compliance Run and a Component Time Change Log will be obtained
from Dave Sutton of FedEx.
ACTION: Bob Bogash
Saw-horse and plywood work tables will be built and installed in the
aft right main cabin of the FedEx 727. ACTION: Bruce Sutherland
COMPLETE: 3 Apr 2004
We will use the United Air Lines Maintenance Record System to write up
discrepancies and maintenance actions. Huemoeller and Bogash have
supplies of the forms.
A search will be undertaken for an I.E. to help create planning
paperwork and perhaps construct bar charts.
Consideration will be given to swapping certain components
between airplanes, over and above just replacing missing
hardware. In particular, items which may be replaced on N7001U
include: Flap tracks, trailing edge flaps, Kreuger flaps, wheels and
tires, main gear hockey stick doors, and tail skid. Replacing the
entire horizontal stabilizer and elevators (which are currently AD
compliant on FedEx N124FE) was also discussed.
Paint will be scraped or removed from a half dozen windows on
N124FE to allow light into the cabin.
COMPLETED by Steve
H. 12 Apr 2004
Re-activation of the aft airstairs on N7001U will be researched to
allow the airplane to be locked.
FedEx gave permission to discard a lot of unwanted items, e.g.
cabin liners and insulation blankets.
Insulation Blankets discarded.
Steve H. 12 Apr 2004.
Previous actions on N124FE: Cabin clean-up; sealing of holes in
fuselage and windshields; and padlocking the aft airstair and E/E hatch.
Airplane cabin as received.
Airplane cabin after cleanup
with Bruce Sutherland's work tables
Cabin after cleanup
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Copyright 2004-2007 by Robert A. Bogash. All Rights Reserved.
Last revised 28 Oct 2004
25 Aug 2007