When Replacement Isn’t Practical

For many aging aircraft, maintaining airworthiness is less about replacement and more about repair. As parts availability declines, operators increasingly rely on experienced maintenance teams to extend the life of existing structures through disciplined, engineering-driven solutions. A recent Falcon 20 outboard flap repair at DAS Aviation demonstrates this approach in action.

The component arrived with multiple areas of structural damage, including dented spars, damaged ribs, and compromised skin. Replacement was not a practical option—an increasingly common reality for legacy platforms—so the focus shifted to restoring structural integrity while preserving the surrounding, undamaged material.

The repair began with careful access. Rivets were removed methodically to lift the skin without disturbing the underlying structure, as additional damage during access can quickly escalate repair scope and cost. During skin removal, technicians used temporary protective backing material beneath the cut area to shield critical structure below. This backing absorbs incidental contact from cutting tools, preventing unintended damage to spars and ribs while allowing precise removal of the affected skin section.

Once access was established, damaged skin sections were removed and replaced with a chem-milled filler designed to match the original material thickness exactly. Maintaining precise thickness was essential to preserve proper load paths and aerodynamic integrity once the repair was complete.

New ribs were fabricated, relocated, drilled, and installed in accordance with engineering specifications. A custom-fit doubler was then designed to tie the repair together, restoring strength across the affected area and distributing loads as intended. Temporary fasteners were used throughout the process to ensure proper alignment before final drilling and installation of permanent hardware.

All work was completed in accordance with an engineering order defining materials, hardware, and installation sequence. Following inspection to verify conformity, the component moved on to paint and final preparation for return to service.

For legacy aircraft like the Falcon 20, repairs like this go beyond component restoration. They preserve safety, reliability, and operational viability in an environment where replacement is often unrealistic. Through skilled craftsmanship and engineering discipline, DAS Aviation continues to help operators extend the service life of critical structures while meeting the highest airworthiness standards.

Learn more about DAS Aviation’s capabilities, including component repair and overhaul, parts support, and engineering solutions, at dasaviation.com.