Gonzalo Andres Salas Torres

During my last year of work, I was part of a Boeing 777-300 modification project. I performed various tasks focused on the installation of a new cargo door. The work was divided into three main areas: lower, middle, and upper sections. We began with the installation of the lower sill, where multiple splices were installed around the structure to ensure sufficient reinforcement before proceeding with the upper sections, which followed the same securing process.

Various splices were installed and attached to the existing stringers, along with the installation of new supports to increase structural rigidity. After completing the installation of these components around the existing skin, the work continued with the positioning of different fittings that connected the three phases of the process in the mid-section of the new cargo door. This required drilling multiple holes with diameters ranging from 0.128" to 0.599".

The project also involved reinforcing specific structural areas of the aircraft to improve strength and safety, as well as replacing the crown skin in the forward section of the door. The new skin had a greater thickness than the original. In this area, all beams along both the forward and aft cargo holds were reinforced. Subsequently, new cargo tracks were positioned and installed, reinforced throughout with various intercostals, angles, and clips.

All tasks were performed in accordance with engineering drawings, engineering orders, and maintenance manual procedures.

Conversion of Airbus A330 (P2F) aircraft from passenger to freighter. This work is divided into different maintenance checks, each with specific processes.

The first check focuses on preparing the aircraft for its final position, where all major modification work will be performed. Tasks include installation of external fuselage patches, mainly in the forward door areas, as well as skin replacements in the crown skin area. Frame replacements are also carried out at jack point areas in different aircraft sections to allow subsequent jacking operations. Cross beams in these areas are replaced to bring the aircraft to a zero-stress condition.

The second check begins once the aircraft is positioned. During this phase, multiple frame replacement tasks are performed, particularly in the middle sections of the lower fuselage zones. Once the frames are replaced on both the right-hand (RH) and left-hand (LH) sides, cross beams are installed and aligned according to required measurements. In parallel, reinforcement work is carried out in the fuselage areas designated for the new cargo door, in compliance with all tasks defined in the modification program. This phase also includes cutting operations required for cargo door installation.

All tasks are closely interrelated, and experience across multiple aircraft provides a clearer understanding of the overall process and the purpose of each activity. All work is performed in accordance with maintenance drawings, engineering orders, specific task cards, and maintenance manuals. Additionally, various brackets are installed to accommodate new hydraulic lines, pneumatic lines, ventilation ducts, and electrical wiring throughout the aircraft.

Structures Worker with experience on B767-300, B767-300F, and A320 FAM aircraft.

Performed major structural tasks including replacement of floor beams in seat tracks and cargo tracks in accordance with maintenance manual instructions; removal of critical corrosion; skin replacement due to major damage; component replacement due to cracks; and fabrication or modification of parts in accordance with engineering orders or airworthiness directives.

On A320 FAM aircraft, participated in the LOPA modification project, replacing beams to provide access for new seat and galley installations.

Experienced in aeronautical rivet replacement; structural damage analysis based on various inspections defined by maintenance manuals or maintenance programs; and creation of damage reports for subsequent repair. Proficient in the use of Maintenix systems and standard tools for aircraft structures maintenance.

Performed structural inspections, identified and resolved discrepancies, and evaluated and carried out major repairs in accordance with SRM, AD, SB, and EI. Skilled in precision drilling; installation of solid, blind, and Hi-Lok fasteners; skin rework; replacement and modification of structural members; and fuel tank structural tasks.

Experienced in cargo door maintenance, including routine and scheduled inspections and replacement of depressor seals in common damage areas around cut-outs.

Able to read and interpret manufacturer and airline maintenance manuals, service bulletins, and technical specifications to determine repair or replacement methods and feasibility.

Internship – Surface Treatment Section: Use of technical documentation for chemical application processes, including depainting in repair or inspection areas, application of Alodine treatments, and application of protective coatings prior to decorative paint.

Different paint application tasks were performed, including primer application, painting specific areas using pneumatic tools, and paint removal work.