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 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 approved technical 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 or cannot 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 , 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 A
“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 A or A (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?