1. ENJJPT SC #69 T-38 Programs Mr. Ryan Bruce T-38 Programs Chief
MAPA Branch
March 2015

2. T-38 Life Extension Current AETC retirement date 2023-2029
Follow AETC Drawdown plan
Structure is primary concern with T-38 retirement extension
Structural modifications and inspections required
Diminishing Manufacturing Sources and Material Shortages (DMSMS) is a significant concern
Impact unknown today
Retirement extensions can be managed and risks mitigated with proper lead times 2

3. SC69 Funding Timeline (FY) Summary
FY11
FY12
FY13
FY14
FY15
FY16
FY17
FY18
FY19
FY20
FY21
FY22
FY23
SC69
SC68
SC67
Quantities:
PC III Kits 9 12 6 10 66 47
PC III Installs 57
VDTS Installs 8 22 31 40
123
124
ADS-B Kits
ADS-B Installs 41 82
AvCI Parts
HUD 15 62 46
MDP
VOR-ILS-RCVR 18
VHF COMM
Costs:
PCIII
$3.6
$5.1
$12.3
$13.9
$15.0
$14.6
$11.0
$9.9
$99.3
70.8
VDTS
$0.2
$0.7
$0.8
$0.5
$0.3
$2.5
$2.8
3.4
ADS-B
$1.8
$4.2
4.2
AvCI
$8.2
$30.5
$23.2
$64.5
$65.4
Total Costs ($M)
$3.8
$5.8
$12.6
$16.4
$24.0
$45.9
$35.0
$10.7
$170.5
$171.7
$78.4
Cost subject to change
Numbers may not add correctly due to rounding 3

4. Pacer Classic III (PCIII)
Program Objectives
Ensure structural integrity of 150 aircraft at high risk of grounding prior to FY23
Ensure execution of AETC mission through FY29 4

5. PCIII Program Overview
NGTS Parts
- Parts Replaced All The Time (100% Parts)
- Parts Replaced as required, Select Structural Components (SSC)
- Parts Removed for Access and also SSC
- Parts Removed for Access to other parts, but not replaced (RFOM)
DLA Parts 5

6. Pacer Classic III Way Ahead
AETC updated retirement date to
Additional PCIII aircraft (19 Sheppard a/c = $28.5M)
Recommend FY18/19 wedge for kit procurement and FY19/20 for installs
Requirement validation occurs during the first year of PCIII installs
Actual structural health assessment for the high-time airframes
Destructive testing on replaced components
Further assess need for more comprehensive/intrusive inspections
Validate ASIP analysis of structural health and then make informed adjustments 6

7. SC69 Funding Timeline T-38C PC III
FY11
FY12
FY13
FY14
FY15
FY16
FY17
FY18
FY19
FY20
FY21
Total
Quantities:
Kits 9 12 6 10 66
Installs
Costs:
$3.6
$5.1
$2.4
$4.0
$26.7
$9.9
$11.0
$72.6
$12.3
$13.9
$15.0
$14.6
$99.3
Non-US Cost Estimated
$2.7
$1.1
$3.1
$3.5
$3.8
$3.7
$2.8
$2.5
$26.5
Costs will be reconciled with individual country cost at the end of each
modification period
Aircraft quantities and costs subject to change
Numbers may not add correctly due to rounding 7

8. VDTS/SBIS Program Video Data Transfer System (VDTS)
Replaces current obsolete video tape recorder
Used for debriefing both SUPT and IFF students
Especially important on IFF missions for critiquing
energy management and validating weapons employment
Kits already purchased under Avionics Upgrade Program
Depot-level install
Speed Brake Indicator Switch (SBIS)
Inadvertent speed brake actuation common in T-38
Caused Class A mishap resulting in loss of aircraft
SBIS provides a “hands-off” means of confirming safety of the aircraft during a critical phase of flight
Kits already purchased; installed in conjunction with VDTS 8

9. SC69 Funding Timeline T-38C VDTS/SBIS
FY11
FY12
FY13
FY14
FY15
Total
Quantities:
Kits
Installs 8 22 31 40
123
Costs ($M):
$0.2
$0.7
$0.8
$0.5
$0.3
$2.5
Non-US Cost Estimated
$0.04
$0.17
$0.21
$0.13
$0.08
$0.62
Installations began June 2011
Costs paid by US. All costs will be reconciled with individual country cost at the end of the modification
Costs subject to change
Numbers may not add correctly due to rounding 9

10. New T-38 Modification Efforts10

11. T-38C Avionics Component Integration (AvCI)
T-38C requires replacement of key Avionics components due to obsolescence
Primary components affected
Heads-up Display (HUD)
Mission Display Processor (MDP)
VHF Navigation Receiver
VHF Communication Receiver/Transmitter
Notional FY16 – FY23 development and integration schedule
Development begins in FY16
Production and installs begin in FY17 for some components
Source selection in progress
Estimated award in Q4 FY15, RFP released 23 January 2015
Costs and schedule are estimates; will revise figures after contract award 11

12. SC69 Funding Timeline T-38C Avci
FY17
FY18
FY19
FY20
FY21
FY22
FY23
Total
Quantities (Parts):
HUD 15 62 46
123
MDP
VHF Navigation Receiver 18
VHF Communication R/T
Quantities (Installs):
VOR-ILS-RCVR
VHF COMM
Costs:
$4.6
$18.3
$13.8
$36.7
$2.9
$11.5
$8.6
$23.0
$0.3
$2.1
$0.4
$0.5
$2.7
Installs
$0.0
$0.7
$8.2
$30.5
$23.2
$0.8
$64.5
Non-US Cost Estimated
$0.2
$7.6
$5.8
$0.1
$16.1 12
Still in Planning Phase; Costs and year of requirement subject to change

13. Automatic Dependent Surveillance-Broadcast (ADS-B)
FAA is transforming air traffic control to a satellite-based system known as the Next Generation Air Transportation System (NextGen)
Mandatory for all aircraft operating in CONUS by 2020
Increases safety and efficiency
Airspace requiring ADS-B compliance:
Class A, B, and C
Class E above 10,000 ft
Around those airports identified in 14CFR 91, Appendix D
AETC T-38C training syllabi require access to controlled airspace above 10,000 feet
AF 1067 approved to incorporate ADS-B in T-38s Fleet-wide
Solution to be determined as part of AvCI contract effort 13

14. ADS- B Funding Timeline (FY)
FY17
FY18
FY19
FY20
Total
Quantities:
Kits
123
Installs 41
Costs:
$1.8
$0.8
$2.4
$4.2
Non-US Cost Estimated
$0.5
$0.2
$1.1
Still in Planning Phase
Numbers may not add correctly due to rounding 14

15. Fwd Canopy Development
Background : The T-38 has experienced 7 Class A mishaps and 3 pilot fatalities since 1964 due to bird strikes to the front canopy transparency. The current T-38 front canopy has a minimum birdstrike capability of 4 lb. bird at 125 knots. USAF expects to increase the minimum birdstrike capability significantly to be consistent with mission profiles without shattering in order to significantly increase pilot safety. The Program is in the early stages of market research and feasibility testing.
Still in Planning Phase 15

16. Proposal: Extend LOA Period of Performance16

17. Background
AFI , Vol 1, Chapter 5, para states: Multiple-Year Appropriations. For multiple-year appropriations whose periods of availability for obligation overlap, apply new reimbursable orders and related transactions only to the most current account available during the period the orders were accepted.
Problem: 1-year LOAs don’t provide enough flexibility to manage programs efficiently and effectively. 17

18. Issue
Issue: AF Policy does not allow for FY14 funds and FY15 LOAs to be used on the same line. Matching year funds are required. Impact: ENJJPT investment programs will be delayed or not start until matching year funds are available. This will lead to production line shutdowns. Aircraft will not be available to train pilots. Example: PCIII is fully funded across the FYDP; however, each fiscal year when a budget is not signed, the US is under Continuing Resolution Authority (CRA); FY15 funds were not available until 26 Nov 14. PCIII production almost didn’t start on 1 Dec 14. Previously, FY14 funds could be used. 18

19. Proposal Extend LOA Period of Performance
DSCA states that this is allowable
Partner Country money will take on the same characteristics as US money utilized
O&M funded efforts stay 1 year money
Investment funded efforts become 3 year money
Budget for each FY requirement
Only utilize money for each FY’s requirement
Example: Don’t use prior FY funds to cover next FY requirement 19

20. SC68 Funding Timeline T-38C PC III
FY11
FY12
FY13
FY14
FY15
FY16
FY17
FY18
FY19
FY20
FY21
Total
Quantities:
Kits 9 12 6 10 66
Installs
Costs:
$3.6
$5.1
$2.4
$4.0
$26.7
$9.9
$11.0
$72.6
$12.3
$13.9
$15.0
$14.6
$99.3
Non-US Cost Estimated
$2.7
$1.1
$3.1
$3.5
$3.8
$3.7
$2.8
$2.5
$26.5
Costs will be reconciled with individual country cost at the end of each
modification period
Aircraft quantities and costs subject to change
Numbers may not add correctly due to rounding 20

21. Benefits
Provides flexibility to Program Office to adjust to fact of life changes
Allows for countries to obligate funds received without having to return money when schedules slip
Avoids production line shutdowns
Meets mission of ENJJPT and ensures pilots get trained 21

22. Recommendation Extend LOA Period of Performance
If approved, a PO change is required
PO section 7.19, ,and 7.30 22

23. Sustainment Efforts 23

24. Control Rods and Magnesium Parts Replacement
TCTO 1T
Control Rods and Magnesium Parts Replacement
TCTO 837 addresses two issues in the primary flight control system. Inspections showed that magnesium CSIs contained corrosion damage. They also showed that control rods were bent which induces fatigue damage. To correct these issues the control rods will be replaced with new control rods. To correct the corrosion on the magnesium parts, new parts will be built out of aluminum and replaced. This is a one time change out of 39 flight control parts.
Control Rods
Magnesium Parts 24

25. SC69 Funding Timeline Magnesium to Aluminum
FY13
FY14
FY15
FY16
Total
Quantities:
Kits 8 41 44 30
123
Installs
Costs ($M):
Kits*
$0.00
$0.0
$0.20
$1.60
$1.86
$1.38
$5.0
O&A
$0.03
$0.16
$0.17
$0.14
$0.5
$0.23
$1.76
$2.03
$1.52
$5.5
Non-US Cost Estimated
$0.07
$0.53
$0.61
$0.45
$1.7
* Kit cost included in the install rate
Numbers may not add correctly due to rounding 25

26. Engine Bay Asbestos Removal Effort
TCTO 1T
Engine Bay Asbestos Removal Effort
Asbestos originally used in the production of T-38 aircraft in the engine bays and liquid oxygen system areas as an insulator. It is now recognized asbestos poses a major health risk and field units are being tasked to perform increasing inspections in these areas due to aircraft age and usage. Removing the asbestos at depot creates a single controlled environment for asbestos removal allowing the field perform required inspections more efficiently without work-arounds required to mitigate asbestos exposure..
Pre 870
Post 870
Asbestos Removal 26

27. Asbestos Removal
Background: Asbestos is used to isolate the heat shields from the aluminum structure. Asbestos is considered a carcinogenic and requires Hazmat procedures to be in place when performing maintenance in this area. 27

28. SC69 Funding Timeline Asbestos Removal Program
FY14
FY15
FY16
Total
Quantities:
Kits 42 44 37
123
Installs
Costs ($M):
Kits*
$0.00
$0.0
$1.53
$1.68
$1.70
$4.9
O&A
$.38
$0.48
$0.17
$1.0
$1.91
$2.16
$1.87
$5.9
Non-US Cost Estimated
$0.57
$0.65
$0.56
$1.8
* Material/Kit cost included in the install rate
Numbers may not add correctly due to rounding 28

29. Lower Center Longeron
Background : Cracks are being discovered on lower center longerons during phase inspection. The field cannot replace or repair these longerons. The depot is currently replacing them. Both left and right longerons are replaced regardless if only one side is cracked. 29

30. Attach Lower Aft Support
Background: Inspection added to depot workload during asbestos removal as opportunistic maintenance. Cracks were discovered on numerous aircraft in depot. An inspection TCTO will be issued to inspect all aircraft in the field. 30

31. Cost Saving Measures New LED Beacon Light New Radial Tires
Increased visibility
Increased mean time between failure
New Radial Tires
Increased Landings
New Generator Stator Housing
Operates at cooler temperatures
Currently implemented
Improved P-panel Circuit Cards
Testing completed
Technical Review Board (TERB) at Tinker
TERB and Configuration Control Board at T-38 SPM
T-5 Amp Go No Go Tester
Capability to test T-5 Amp before returning to contractor for repair
Approximately 60% returned to supply as serviceable 31

32. LED Beacon Light
Background: Existing electromechanical rotating beacon light is prone to failure due to age and condition. This light has a mean time between failures of <300 hours. The new LED beacon has no moving parts and is expected to have a MTBF of >27,000 hours. 32

33. Bias vs Radial Tires FEATURES BENEFITS Bias Radial 33
Improved FOD Resistance
Mature Technology
Low Heat Generation
Improved Ride Quality (Reduced Vibration/flat spots)
Tire Cooling Time Reduced
Less Rolling Resistance
Increased Overload & Taxi Durability
Marginal Safety Benefit 33

34. Generator Stator Housing
Background: During depot overhaul, stator housings needed to be condemned due to damage to the stator housing. A redesign was initiated and a new stacked housing was approved. Testing proved that a generator operated at cooler temperatures and service life increased. Several test generators are still in service after 1400 hours. 34

35. Protection Panel Circuit Cards
Background: Legacy P-panel circuit cards are 1960s technology. New circuit cards use state of the art technology and are expected to increase service life. Legacy and improved p-panels can be installed on an aircraft with no issues. Operational testing is scheduled soon for final approval. 35

36. Safety Initiatives
Forward Canopy Redesign – Improved bird-strike resistance
Flap Y Rod Replacement – TCTO 1T completed 164 A/C
Rudder Interconnect Crank Replacement – Deliveries Mar 16
Rudder Force Producer Spring Replacement – 6 remaining
Control Stick Bolt Safety Wire – 15 remaining
Brake Quadrant Replacement – Deliveries Feb 15 36

37. Summary
Cost figures presented are subject to change due to program delays, aircraft beddown changes, DoD funding adjustments, efficiencies not determined, contract restructuring and re-pricing, or other unforeseen circumstances.
This info is provided for long range budget planning purposes and should not be interpreted as a final cost estimate.
Goal is to ensure NATO’s future fighter pilot training needs are met and ENJJPT, with new advanced training systems, will continue to produce the world’s best pilots. 37

38. Steering Committee approve proposed funding plan
Recommendation
Steering Committee approve proposed funding plan

39. Backup 39