Timeline

October 7th 2019

Day 1.

Our aim is to take this helicopter back to its former glory days, and eventually return it to its playground in the air, so that it can be used for historical and airshows around the country.

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October 29th 2019

New Beginnings

Our XZ179 has seen it’s first steps in its regeneration process.

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December 2nd 2019

Progress in November

We are delighted with the progress in 2019, and we are hugely excited by the prospects of 2020. You are invited to join us on our journey, and hope you enjoy the ride.

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January 24th 2020

Let There Be Light!

In December and early January there has been continued work on the helicopters electrical parts and wiring. We have now connected power to the aircraft. And are in the process of working through the electrical systems checking the AC and DC power after re wiring some systems.

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February 19th 2020

Testing and Inspections

Our team at Weald Aviation have been working very hard on our Lynx in recent weeks.
There has been a lot of work going on behind the scenes, as testing and inspections are on-going on the installed systems of the helicopter. Testing is an essential part of the re-development of the Lynx, and we are grateful of the expertise of Weald Aviations team.

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March 24th 2020

A Gear Box Day!

Our Lynx has had plenty of attention recently, with lots of work undertaken recently by Weald Aviation.
This week she has had a new hydraulic return pipe fitted to her tail boom, had her No.1 hydraulic system cleaned, the main rotor gear box removed and area cleaned, her tail rotor gearbox removed and had all of her NDT zones marked up.
A pretty significant piece of work, which takes time and expertise, and we are greatful we have a team with such knowledge looking after her.

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April 9th 2020

Tail Rotor Gearbox Fit

• MOD 0821 fuel pipe fit completed

• Tail rotor gearbox fit started

• Intermediate tail rotor gearbox fitted

• Intermediate gearbox cooling fan installed

• Torque adaptor for IGB fan made

• Pilots seats inspected for serviceability and missing parts

• Hydraulic reservoirs refitted – pipe work refit started

• MRGB oil coolers removed and packed up to be sent away for overhaul.

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April 24th 2020

ADC Filter Fitted

• ADC filter fitted

• Starter generator cabling inspected and continuity checks carried out

• Rotor head packed for transport

• New rotor head removed from aircraft and delivered to north weald

• No.5 driveshaft MOD states research carried out and AGS required

• Tooling required for rotor head overhaul located

• ECU inspections completed

• ECU MOD state research carried out

• MRGB oil cooler test box switch repaired

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May 1st 2020

Engine Bay Work

• No.1 engine bay stripped and cleaned, inspections started
• No.2 engine bay stripped and cleaned, new speed tape fitted and inspections started
• ECU and ECU bay MOD states researched to bring to correct level
• Fire extinguisher pipes removed, flushed and refitted
• No.5 tail rotor drive shaft trial fitted
• Extensive research into how to refit all drive shafts carried out and plan changed – MRGB will now be fitted first and adjustments to shims on all drive shafts made
• MRGB started to be dressed with all required components

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May 7th 2020

ECU and ECU Bay Inspections

• No.1 engine bay fitted with new aluminium tape and sealed with RTV – components have begun to be refitted, still on going

• No.2 engine fitted with new aluminium tape and all available components have been refitted – waiting on a bracket to support a cabin hot air take off valve – still on going

• ECU and ECU bay inspections have been carried out, the MOD state has been determined and the missing component required has been ordered.

• Forward fuel tank pump has been wired up correctly and repaired after being found damaged during checks for continuity

• All fuel tanks have been cleaned and hovered again after previous work to ensure no FOD.

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May 15th 2020

MOD0821 Manufactured

• Both collector and forward fuel tanks have been tested for leaks.

• Several leaks have been fixed in various tanks – one drain replaced, one fuel pump replaced – awaiting another fuel pump to make one complete pump.

• Cut wires within fuel pump have been repaired

• X3 tanks approx. 1/3 full – more leaks may present themselves as the tanks swell due to the fuel and more fuel is added.

• Bracket for MOD0821 manufactured and fitted to fuel pipe – awaiting Pclip.

• MRGB continued to be dressed – x2 servos now fitted and x2 control lay shafts slaved into place – awaiting O-rings to fit hydraulic pipes.

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May 22nd 2020

Leaky Weekend

• Fuel leak started over the weekend, has been traced to the forward bag tank.

• Collector tanks have been filled completely and sealed. Waiting to see if any leaks occur over the weekend

• P-clip fitted to MOD fuel pipe and bracket from last week.

• Sump panel from forward fuel tank removed for seals to be checked to try and locate leak

• Cabin hot air valve fitted to port ECU bay and secured. Once fireproof P seal arrives and is fitted ECU bays will be ready to receive engines.

• MRGB continued to be dressed – All servos fitted to new MRGB. Serviceability inspections have been started. Light corrosion found on No.1 engine drive coupling, corrosion removed and treated.

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May 29th 2020

Forward Tank Defuled

• Forward tank defueled and sump panel removed to inspect seal for damage, none found so panel refitted and tank filled with fuel.
• Forward tank still leaking so defueled and tank removed from aircraft.
• Tank inflated with low-pressure air and x3 leaks found.
• Collector tanks completely filled and main tanks filled a few inches.
• Another leak has appeared but unclear if it is residue from previous leak or new leak from collector tanks.
• Ground handling wheels have started being serviced in regards to moving aircraft to the front of the hangar to use with AC generator.

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June 5th 2020

Further Leak Testing

• Ground handling wheels bay serviced and tested on aircraft ready for
moving to front of hangar.
• Fuel leak investigation continued – coupling at bottom of starboard main tank found leaking and seal replaced.
• Nose bay rebuild continued.
• Transportation joint completed.
• Tail rotor PFCU started to be refit.
• MRGB hydraulic adaptor began to be fit with new O-rings – one adaptor
found to have been previously cross-threaded.
• MOD 0527 cover plate fitted and PRC’d.v

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June 12th 2020

Hydraulic Adaptor Threads Cut

• Hydraulic adaptor threads recut to allow hydraulic pipes to be fitted to new MRGB.

• Hydraulic adaptors fitted to new servos along with new O-rings.

• Paperwork and duplicate inspections carried out of MRGB and servos with hydraulic pipes started – awaiting signatures for input lay shafts after gearbox fit to aircraft.

• Paperwork and duplicate inspections of transportation joint completed.

• New forward fuel tank inspected inside and out for potential damage.

• Leak checks carried out of new tank.

• Tank bay removed of old and loose anti-chafe tape.

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June 19th 2020

RE-FAMILIARISATION WITH CONTROL SYSTEM

• Fuel system inspected for leaks – no evidence of leaks found.

• Ferry tank connection valve dismantled to investigate overflow – seal found perished, investigation into finding new seal carried out.

• Re-familiarisation with control system and finding AGS to fit components.

• Fore and aft position transmitter fitted under P1 seat.

• Rebuild of ECU throttle box continued.

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June 19th 2020

CENTRE CONSOLE REBUILD BEGUN

• Fuel system inspected for leaks – no evidence of leaks found.
• Ferry tank connection valve dismantled to investigate overflow – seal
found perished, investigation into finding new seal carried out.
• Re-familiarisation with control system and finding AGS to fit components.
• Fore and aft position transmitter fitted under P1 seat.
• Rebuild of ECU throttle box continued.
• No.5 Drive shaft fitted with new bolts and paperwork completed.
• Centre console rebuild begun buy starting to determine the missing
components and looking for loose cables before applying power.
• Bonding leads fitted to sump panels and pipes in the under floor fuel
system

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June 26th 2020

FILLING GAPS

• Fore and aft and lateral artificial feel spring units slaved into place – filling gaps making it easier to determine what parts are missing/still required.
• Lateral trim servo slaved into place awaiting correct bolts and rigging.
• Centre console build completed – all components fitted in correct locations are plugged in awaiting electrical test.
• Serviceable battery picked up from overhaul.

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CENTRE CONSOLE BUILD COMPLETED

• Fore and aft and lateral artificial feel spring units slaved into place – filling
gaps making it easier to determine what parts are missing/still required.
• Lateral trim servo slaved into place awaiting correct bolts and rigging.
• Centre console build completed – all components fitted in correct
locations are plugged in awaiting electrical test.
• Serviceable battery picked up from overhaul.
• Auxiliary fuel tank self sealing coupling fitted with new hand made seal –
awaiting leak tests next week.

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July 3rd 2020

MAIN TANKS COVER PANELS FITTED

• Filling fuel system and curing leaks to the venting system as required
• Main tanks cover panels fitted and main tanks filled to approx. half capacity.
• Research into missing avionics in rear avionics cupboard.
• Collective trim servo slaved into place
• Yaw control trim servo slaved into place
• Fuel indication system fault investigated and rectified – further calibration required when aircraft is jacked
• Cut rate gyro cables investigated and con checked to find other ends

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July 3rd 2020

FILLING FUEL SYSTEM

• Filling fuel system and curing leaks to the venting system as required
• Main tanks cover panels fitted and main tanks filled to approx. half
capacity.
• Research into missing avionics in rear avionics cupboard.
• Collective trim servo slaved into place
• Yaw control trim servo slaved into place
• Fuel indication system fault investigated and rectified – further
calibration required when aircraft is jacked

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July 5th 2020

TRANSPORTATION JOINT COMPLETED

• Ground handling wheels bay serviced and tested on aircraft ready for moving to front of hangar.

• Fuel leak investigation continued – coupling at bottom of starboard main tank found leaking and seal replaced.

• Nose bay rebuild continued.

• Transportation joint completed.

• Tail rotor PFCU started to be refit.

• MRGB hydraulic adaptor began to be fit with new O-rings – one adaptor found to have been previously cross-threaded.

• MOD 0527 cover plate fitted and PRC’d.

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July 10th 2020

NEW BLADES

• Fitted new seals to the fuel vent system.

• Completely filled the fuel tanks via the gravity fill system.

• New leaks traced – list of required components made and requests for quotes made.

• AGS fitted to control system and lateral trim servo wire locked.

• Lateral spring unit fitted – awaiting rigging.

• Locking wire holes drilled in bolts for collective trim servo.

• AC power fault finding carried out to get power on aircraft.

• Attitude indicators tested – 1 new gyro and 1 new indicator fitted and tested.

• Static inverter system (back up instruments) fault finding started.

• New blades unloaded and visually inspected.

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July 17th 2020

STANDBY AI SYSTEM TESTED

• Most components for fuel system ordered – chasing lead on last few components

• Gyro compass system has been tested and gyro unit found U/S – new gyro fitted and system test nearly completed

• Standby AI system tested – new static inverter required

• AFCS system rewire progressing – awaiting pin extraction tools

• All trim servos fitted, paperwork completed and awaiting rigging

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July 31st 2020

NO LEAKS EVIDENT

• Defueled aircraft completely.

• Fitted new components and seals to fuel system

• Refuelled aircraft and left to check for leaks (none currently evident)

• Research into already embodied MODs

• New rotor brake selector valve started to be fitted to complete a MOD.

• Started preparing engine bay fire wall MOD

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September 25th 2020

TAIL-ROTOR RIGGING STARTED.

• AFCS rewiring continued.
• Aircraft defueled and defuel valve removed.
• Defuel valve with new seals fitted to aircraft and all components refitted.
• Aircraft filled with fuel for leak checks – no leaks evident at the moment.
• Tail-rotor rigging process researched and prepped for start of rigging.
• Tail-rotor hub fitted.
• Research into life details of tail-rotor pitch change assembly carried out.
• Tail-rotor pitch change beam fitted. New pitch change rods and bolts required – order placed.
• Tail-rotor rigging started.
• Seized bolts in control system removed, old JC5A removed and bolt refitted.

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November 13th 2020

NO.2 ENGINE

• Engine serviceability checks carried out on No.2 engine

• ECU prepped for fit – engine stay and various pipes moved to correct side, winch pump removed and blanked off.

• ECU filters inspected and replaced as required.

• Engine bay inspected and prepped for installation.

• ECU fitted.

• Exhaust and cowling fitted.

• Exhaust vent pipe ordered.

• ECU control rigging started

• Gimbal ring and drive shaft connected and torqued

• Lower intakes MODed to same state as aircraft with IR station keeping lights.

• Test fit of lower intake.

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November 20th 2020

NO.1 ECU FITTED

• ECU Pre-installation checks carried out.
• ECU bay cleaned and pre-installation checks carried out
• No.1 ECU fitted to aircraft.
• Exhaust assembly fitted to No.1 engine
• Panels for rear of aircraft around exhausts refitted
• Port and starboard upper intakes rubbed down and prepped for painting
• Port lower intake prepped and fitted to aircraft
• Gearbox dish mounts fitted
• Paperwork brought up to date and independent checks carried out

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November 26th 2020

ANOTHER MILESTONE

Fitting both engines is a huge milestone for the team

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January 15th 2020

TRANSPONDER CODING REWIRE

• Transponder coding rewire continued.

• Flex Ops written out and organised for inclusion in 700 forecast sheets.

• SEM’s investigation into which are applicable started.

• Rigging of cyclic controls continued – control rods and parallel actuators adjusted.

• Paperwork brought up to date and duplicate inspections started for control system.

• Screws and panels for cabin researched and ordered in preparation for rigging completion.

• Grease/oil guns for driveshaft and tail rotor hub ordered and filled ready for use.

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January 22nd 2021

AFCS SYSTEM BITE CHECKS STARTED

• AFCS system BITE checks started.

• Rigging of position indicators for fore and aft and lateral controls started.

• Split pinning of control system finished.

• Duplicate inspections of flying controls carried out.

• Research into operation of ASE and AFCS systems carried out after ASE failed BITE checks.

• ASE and AFCS systems switched on for position indicator rigging and setup.

• Pilots seats inspected and serviced. Service bulletin IGQSB033 carried out.

• MOD’s research continued.

• Intercom and radio systems tested – fault found with P1 intercom system. Research and fault finding started.

• Cockpit panels fitted.

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March 10th 2021

MAIN ROTOR HEAD RIGGING

• Main rotor head rigging carried out. Adjustment of the pitch links, fore and aft and lateral control rods.

• Control system position indicators set up.

• Cockpit voice recorder fitted.

• P1 and P2 seats refitted.

• AFCS and ASE testing and fault finding started.

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March 16th 2021

MAIN ROTOR BLADE

• Windscreen washing system adjusted and both sides functioned.

• Annual service paperwork brought up to date.

• Blade anti-node weights removed, inspected and refitted.

• MODs research and paperwork continued.

• Pitot static instrument research into calibration carried out and spares sourced.

• Carrying out BITE tests of AFCS and ASE systems (on going).

• Investigated blade tracking procedure and equipment.

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March 22nd 2021

AFCS AND ASE SYSTEM TESTING

• AFCS and ASE system testing, BITE tests started and fault finding problems.

• Replacement hydraulic pipe in No.1 system fitted – leak solved.

• Wire locking and testing of hydraulic system.

• Dish fairing drain for starboard side fitted.

• Testing of RNS252 – fault finding required.

• Testing ADU – more tests required.

• Static inverter replaced and standby horizon tested.

• Confidence duplicate check of main rotor head rigging carried out.

• Fault finding rate gyro system.

• First batch of pitot static instruments send away for calibration.

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March 30th 2021

SLIDING FAIRING REFITTED

• Sliding fairing refitted.

• Duplicate inspections and paperwork brought up to date.

• Major service continued (tail rotor inspections carried out).

• Sorting and batching of new parts.

• ASE and rate gyros testing and fault finding continued.

• Tail rotor gearbox and servo inspections carried out.

• Torque systems tested to ensure correct engine torque codes.

• Tail panels refitted.

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May 4th 2021

AC GENERATORS FITTED AND WIRED UP

• MOD’s research continued.

• Both AC generators fitted and wired up.

• Accessory drive actuator functional tested.

• No.1 engine prepped for ground running.

• Sorting of spare components continued.

• Aircraft and bay moved to front of the hangar to facilitate fuel flow checks etc.

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May 11th 2021

PREPARATION FOR GROUND RUNS

• Preparation for ground runs.

• Instruments refitted.

• Loose components bolted down.

• ADU tests started.

• De-inhibiting and bleeding No.1 fuel system.

• 3 successful ground runs of No.1 engine.

• Minor defect rectification post ECU start.

• Big ‘BZ’ to maintenance team.

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May 18th 2021

FUEL LEAK FROM NO.1 ECU TRACED

• Fuel leak from No.1 ECU traced

• Engine removed for access

• Oil scavenge pump gasket changed

• Engine refitted

• Starter generator replaced

• Wet and dry runs carried out to bleed fuel system

• Minor instrument snags rectified

• Torque meter test procedure researched and gauges tested

• Rad alt system tested and new gauges fitted

• Engine and airframe prepped for ground run

• No.1 engine run up to 95% power successfully with no problems

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May 24th 2021

ENGINE AND AIRFRAME PREPPED FOR GROUND RUN

• Engine and airframe prepped for ground run

• No.1 engine run up to 95% power successfully – AC power snag found

• No.1 AC system Control and Protection Unit replaced

• AC power generation functional tests carried out and found satis

• No.1 DC generator tuned to give correct output under load

• 1 hour total further ground running carried out on engine

• Standby Horizon found inop on ground run, snag investigation on-going

• Various magnetic indicators found sricky/inop, being replaced

• Serial numbers of major components found and listed for paperwork

• Lynx spares packed into container

• Investigation of method required to modify audion system for acceptance of 8.33 radios

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June 1st 2021

8.33KHZ RADIO INSTALL STARTED

• USB charging socket install started

• 8.33kHz radio install started

• Inventory of new serviceable ADU’s and AFCS computers taken after unpacking

• New ADU fitted for transponder tests

• New transponder control unit fitted and transponder tests carried out,
all modes functioning Satis.

• AFCS system testing continued – replacement CAC required.

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June 7th 2021

RADIO REMOTE HEAD METAL WORK COMPLETED

• Radio remote head metal work completed

• Wiring and circuit breakers for remote head and USB run through centre console

• Replacement starter motor fitted to No.2 engine

• Fuel flow light panel repaired with new filaments soldered in

• No.1 ECU L.P cock magnetic indicator replaced

• Replacement CAC fitted and tested – satis

• AFCS system functional tests continued

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June 15th 2021

NO.1 ECU GROUND RUNS CARRIED OUT SUCCESSFULLY

• Wiring for USB and radio remote head unit continued.

• Aircraft prepped for ground runs.

• No.1 ECU ground runs carried out successfully.

• Research and testing of BAR ALT hold system.

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June 21st 2021

XZ179 ENGINE TEST

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June 29th 2021

ANNUAL INSPECTIONS CONTINUED

• Annual inspections continued

• Ground use only rotor blades test fitted ready for show

• Panels and fairings refitted for show

• Lateral position indicator wire locked and repanelled

• Rotor brake control wire locked and repanelled

• Wiring for radio and USB continued

• Radio mounting tray installed

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August 16th 2021

NO.1 AND 2 ECU’S REFITTED

• No.1 and 2 ECU’s removed.

• 2x stub shafts changed for serviceable components with life details

• No.1 and 2 ECU’s refitted

• Calibrated pitot static instruments retrieved and batched in ready for fitting

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August 23rd 2021

PORT AND STARBOARD CABIN DOORS REFITTED

• No.1 and No.2 ECU refit finished

• No.1 and No.2 Air Intake assemblies refitted and oil cooler fairings refitted.

• Port and starboard cabin door rail and carrier assemblies lubricated and refitted.

• Port and starboard cabin doors refitted.

• Pitot/static instruments removed from instrument panels and serviceable items fitted.

• Fire bottle system tested for serviceability and found satis.

• GPMG mount test fitted to starboard door.

• Footstep and night-sun test fitted to starboard skid.

• Footstep test fitted to port skid.

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September 20th 2021

WIRING INSPECTIONS COMPLETED

• Nose bay door seals replaced

• Wiring inspections completed

• RTI inspections carried out

• Rotor head damper bolts replaced IAW RTI

• Aircraft alignment checks carried out

• Environmental control system Teleflex locked and split pinned

• No.2 ECL range adjusted and locked

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September 27th 2021

AIRCRAFT DE-JACKED AFTER ALIGNMENT CHECKS

• Aircraft de-jacked after alignment checks

• Aircraft prepared for ground running

• AFCS system fault finding/testing

• Ground run carried out

• Replacement controller engaging ordered

• MRH spider arm wear check carried out

• Crash switches test looms started to be made

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October 19th 2021

AIRCRAFT BONDING CHECKS COMPLETED

• Aircraft bonding checks completed

• Fault finding of aircraft crash switches carried out – new fire bottle cross feed switch ordered

• Unloaded XZ678 after arrival

• XZ678 cabin unloaded and sound proofing removed along with interior and cleaning started

• Serial numbers for engine and driveshafts collected for checking life details

• Sorting and batching of new spares

• Fault finding of No.1 torque indicating system started

• RTI’s investigated

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November 2nd 2021

VISUALLY INSPECT NO.2 ECU FOR CORRECT ASSEMBLY AND CONDITION

XZ179:

  • Visually inspect No.2 ECU for correct assembly and condition in preparation for ground run.
  • Visually inspect No.2 ECU bay for presence of FOD and cleanliness in preparation for ground run, any debris cleaned/removed as required.
  • Inspect No.2 ECU/ECU bay for any static leaks that may have developed – nil found.
  • Ensure No.2 ECU oil level is correct in preparation for ground run.
  • Lubricate tail rotor hub in preparation for No.2 ECU ground runs.
  • Lubricate tail rotor driveshaft bearings in preparation for No.2 ECU ground runs.
  • Carry out an inventory/assessment of blade folding kit in our possession, make up a complete kit and trial fold blades to right hand side of aircraft.
  • Manufacture torquemeter system test cables.
  • Continue testing/fault finding of torquemeter system.
  • Fire bottle system crossfeed system switch arrived.

XZ678: 

  • Airframe and cabin cleared as far as possible of debris.
  • Begun inventory of any components removed to allow access.
  • Begun inventory of rotable components for life span and condition assessment.
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November 15th 2021

PAPERWORK GONE THROUGH PRIOR TO CAA VISIT

XZ179:

• Doppler radar removed, inspected, resealed, refitted and tested

• Paperwork gone through prior to CAA visit

• Airworthy blades cleaned and inspected

• Airworthy main rotor blades fitted in preparation for ground runs

XZ678:

• Airframe survey completed

• Forward and starboard collector tank sumps removed, stripped and cleaned – collector tank sump still to be rebuilt and fitted.

• Transfer pumps removed from donor sump and fitted to forward tank sump

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November 30th 2021

NO.1 VOLTAGE REGULATOR REPLACED

XZ179:

• Fault finding vertical gryo problem ground run

• No.1 voltage regulator replaced

• Main rotor blade sleeves oil replenished

• Sound proofing fitted to aircraft

• Post ground run inspections carried out

• Preparation for ground run carried out

• Rotors turning ground run carried out

• Cabin environmental control system tested

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December 7th 2021

AIRCRAFT WEIGHED

XZ179: 

  • No.2 AC control and protection unit replaced after fault found on ground run.
  • Aircraft prepped for weighing. Basic fit determined and role equipment gathered to be weighed for fit as required.
  • Aircraft defueled to minimum fuel status.
  • Aircraft weighed.
  • Tracking requirements discussed and initial tracking arranged with Heli-Tune representative.
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To be continued...