Project Library

BOEING 737-400
REPAIR

CASABLANCA, MOROCCO

A towing incident caused a breech in the pressure boundary, forward fuselage. Project scope included removal of damage, multiple frame replacements, frame and skin installations, final checks and certification. SOAR provided a customized quality solution with a minimum amount of downtime, despite difficult-to-obtain structural parts and jurisdiction certification, all at low AOG costs.

MCDONNELL DOUGLAS MD-83
FIELD RECOVERY

YPSILANTI, MICHIGAN


An MD-83 overran the runway approximately 400 meters during a rejected takeoff. The aircraft overran the runway end by approximately 1,100 feet, coming to rest over a gulley, the aircraft bridging between a public road edge and a field. The nose landing gear drag links had fractured when the aircraft crossed a sharp rise in the ground at the public road, permitting the gear to enter the electronics compartment behind the wheel well. Both main landing gear upper strut bodies had failed at the same rise, folding the gear back and through the inboard flaps. These conditions would prevent moving the aircraft by typical means after the recovery, requiring special equipment to relocate the aircraft to a temporary parking position.

EMBRAER E-190
FIELD RECOVERY

CUENCA, ECUADOR


The aircraft overran the runway by a reported 70 meters from the end of the runway, stopping just short of and above a public street. One main gear folded back into its wheel well and one main gear was partially buried in a ditch. The aircraft came to rest facing in the opposite direction of the line of travel and on an incline.

BOEING 727 E1
EVALUATION & REPAIR

EVERETT, WASHINGTON


SOAR was contacted in early 2015 by Seattle's Museum of Flight to evaluate whether the first 727 could be made airworthy for its last flight to the field where it would be formally displayed as a historic prototype. SOAR provided a customized work scope of extensive restoration services. Laurie Haag Museum Vice President commented, "SOAR's team performed magnificently and the final flight of 727-22 was a grand testament to their work." SOAR's work is recognized on Bob Bogash's website: E1 Support Companies

BOEING 737-400
REPAIR

SUBANG, MALAYSIA


SOAR was called to Subang to perform heavy aircraft structures repair, engineering and Scribe Line AD Inspection. The inspections revealed scribe line damage and other defects that required significant additional engineering repairs. SOAR managed and supervised multiple MRO and NDT partners and engineering firms to conduct a large scope of repair work, including repair designs and additional repair needs.

BOEING 767-300
REPAIR & MODIFICATION

MEDINA, SAUDI ARABIA


The aircraft landed with one main gear retracted. The lack of local infrastructure did not support the heavy structure repair & pylon modification that was required. SOAR was contracted to repair the aircraft to serviceable condition for ferrying. Work scope included fuselage damage repair, engine strut replacement & engine strut wing interface modification.

AIRBUS A320-232
RESTORATION

NEW DELHI, INDIA


The aircraft had been heavily cannibalized by the operator & inactive for years. The lease company requested SOAR to restore the aircraft for ferry flight from India to Mexico for major maintenance. SOAR managed this complex work scope, requiring more than 2,045 line items of parts at a remote location & multi-jurisdictional airworthiness issues. The aircraft was ferried 13,000 miles without incident.

AIRBUS A320-214
COMPLETE TURNKEY LOGISTICS PROVISION

DAVAO CITY, PHILIPPINES


The A320 incurred damage to its nose gear due to a runway excursion rendering it unable to ferry itself to a repair station. SOAR was contacted to provide a temporary hangar for the onsite repair process. SOAR supervised local contracting companies, utility providers and safety officers to complete this large-scale project on time and within budget.

AIRBUS A321-232
RESTORATION

MUMBAI, INDIA


The Aircraft had been cannibalized for parts by the operator and remained inactive for 1.5 years. The leasing company requested SOAR to restore the aircraft for ferry flight from India to England for major maintenance. The complex scope of work, requiring more than 1,300 parts, included flight deck, avionics bay, air-conditioning system restorations, engine, thrust reverser and APU installations. Landing gear component refit, maintenance manual restoration after storage, A4 Check and testing of all systems. Its ferry flight to England was accomplished without incident.

MCDONNELL DOUGLAS MD-82
DAMAGE EVALUATION

AFGHANISTAN


During a landing in windy conditions, the aircraft's right hand wing outboard section made contact with a runway light fixture causing major damage to the outboard section and common structure of the right hand wing. The SOAR team was contacted and the damage evaluation was efficiently and comprehensively completed.

AIRBUS A320-214 HORIZONTAL
STABILIZER REPAIR

HANOI, VIETNAM


SOAR provided a low-cost, turn-key stabilizer replacement, including logistics and charters for large parts and tools, on schedule and below budget.

AIRBUS A340-600
AIRCRAFT RECOVERY

QUITO, ECUADOR


The aircraft overran the runway and came to rest on a slope at the edge of the airport. SOAR recovered the aircraft without causing any secondary damage and worked with the OEM in the performance a detailed damage evaluation. SOAR also provided all site logistics for the aircraft after the recovery.

BAE146 RECOVERY

BUCHAREST, ROMANIA


The aircraft departed the runway after landing, collapsed its right hand main landing gear and came to rest on its tail and right wing. SOAR arrived on-site one day after the initial contact and a comprehensive recovery plan was completed on the same day.
Project scope included lifting the plane using air bags and extending the landing gear in order to tow the aircraft back to the tarmac on its own gear for an extensive damage evaluation.

MCDONNELL DOUGLAS MD-83
FIELD RECOVERY

YOUNGSTOWN, OHIO


The aircraft slid off an icy taxiway after landing and settled in frozen and muddy turf. The SOAR team promptly responded to a call from the airline and recovered the aircraft from field to taxiway within eight hours of arrival on-site.

MCDONNELL DOUGLAS MD-83 RECOVERY & DAMAGE EVALUATION

JUBA, SUDAN


The aircraft overran its runway, passed through a watercourse and came to rest in a minefield. SOAR performed a joint forces recovery that involved saturated sedimentary soil, de-mining, and bridge building under difficult environmental conditions. A detailed evaluation upon completion of the recovery was also performed and used in the eventual aircraft repair.

BOEING 737-800
FUSELAGE REPAIR

MELBOURNE, AUSTRALIA


SOAR provided a low-cost onsite fuselage repair, on schedule and within budget.

MCDONNELL DOUGLAS
MD-83 VERTICAL STABILIZER REPLACEMENT &
EMPENNAGE REPAIR

GOODYEAR, ARIZONA

Damage to the horizontal stabilizer caused a buckle to the vertical stabilizer. A donor MD-80 provided the replacement vertical stabilizer, which was refurbished and re-certified by Aero-Mechanical. SOAR supervised the installations of the stabilizers, the re-wiring of systems, structural assemblies, flight controls, engineering and coordinated certification. SOAR makes it possible for the strategic re-use of out-of-production aircraft as a viable and economic method of operation.

BOEING 707-31B REFUELING TANKER LOWER NOSE RECONSTRUCTION

VICTORVILLE, CALIFORNIA


The client aircraft received damage within the lower bulkhead after a hard landing, due to a poor quality previous repair and substantial accumulation of corrosion. SOAR was contacted by a local MRO to take over the structural reconstruction (the MRO did not have the experience) and responded with a comprehensive quote 24 - 48 hours after initial contact. Qualified personnel with heavy structural experience worked 24-hours a day to reduce the aircraft's down time.

BOEING 737-300
FUSELAGE REPAIR

PALMA DE MALLORCA, SPAIN


The aircraft received damage to its forward right-hand side fuselage skin and support structure. SOAR conducted a turn-key repair on schedule and on budget.

BOEING 737-400 NOSE REPAIR

CASABLANCA, MOROCCO


A towing incident caused a breech in the pressure boundary, forward fuselage. Project scope included removal of damage, multiple frame replacements, frame and skin installations, final checks and certification.
SOAR provided a customized quality solution with a minimum amount of downtime, despite difficult-to-obtain structural parts and multi-jurisdiction certification, all at low AOG costs.

BOEING 737-700 FIELD RECOVERY

CONAKRY, GUINEA


The aircraft overran its runway and landed in a field where it was stranded, unresolved for three months. SOAR was contacted and the recovery was completed in two days without secondary damage.

BOEING 737-800
FUSELAGE REPAIR

MELBOURNE, AUSTRALIA


A service truck struck the aircraft causing damage to its forward right-hand side fuselage. SOAR provided a complete evaluation and repair within budget.

BOEING 747-400F INBOARD RIGHT HAND FUSELAGE
& BODY GEAR REPAIR

LOS ANGELES, CA


The #11 and #12 tires were destroyed on landing, which caused damage to the aircraft’s fuselage body fairings, pressure vessel, external skins, and support structure. The client contacted SOAR, which arrived on-site within 24-hours later. 747 experienced sheet metal mechanics, electricians and a quality assurance inspectors.
The aircraft was re-certified and driven from the hanger to the tarmac 15 days later where it was boarded by its flight crew and loaded with its scheduled cargo--on time.