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- Phase 1 (Inspection and Refurbishment)
- Inspection completed:
- All assemblies except the forward fuselage were found to be in remarkably
good condition.
- Front fuselage is structurally sound but needs significant cockpit refurbishment.
- Refurbishment of items found during the inspection phase is ongoing.
Several key areas have been accomplished:
- Port and starboard wing tanks resealed
- Port & Starboard Wing Trailing Edge damage repaired
- Tailplanes, Airlerons, Flaps and Leading Edges refurbished
- Canopy has been totally refurbished
- Cockpit was totally stripped of all instrument panels, rudder pedals, control columns,
throttle box, etc. and refurbishment of most items has been completed
- Ventral Tank repair and updates to the #1 engine bay door are 90% complete
- Refurbishment of the ejection seats is underway
Wing inner tank resealing complete and cover plate re-installed
- Phase 2 (Airframe reassembly) started in March 2001
and was completed in September 2001
- Wings mated
- Rear fuse mated to wings
- Front fuse mated to rear fuse
- Undercarriage lowered and assembly dollies removed
- Fin, tailplanes, flaps, rudder & ailerons installed
- Aircraft rolled out on 16 September 2001
- 66% of the 20,000 spare parts have been sorted and cataloged
Photo: Rear fuselage
sits on assembly dolly prior to reassembly
Photo: Chief
Mechanic, Michael Shallbetter, next to the wing assembly dolies he fabricated
for wing-to-wing mate
Photo: Early
rollout—front view
Photo: Early
rollout—starboard view
Photo: Bo
identifies some of the starboard cable loom wiring
- Phase 3 (subsystem installations and flight test) started
in August 2001
- Number 1 engine bay subsystems re-installed
- Cable loom wiring identified and splicing started
- UK team has acquired several specialist tools and equipment including
a Didsbury lift and a “fueldraulic” rig
- Avionics configuration assessed & revised panel layouts developed
- Hydraulic system re-activated and tested
Photo: #1 engine rebuild
Photo: Didsbury hoist in use
during flap installation
Photo: Arrival of engines
Landing gear being retracted
Artificial feel unit — new refurbished unit vs the original
Refurbished control column
XS422 in early November 2004 being worked on by both USA and UK team members
John Sherry starts connecting up the fwd and rear fuse wiring. Power up is getting closer.
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