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March maintainers complete first full KC-135 refurbishment

  • Published
  • By Megan Just
  • 452 AMW Public Affairs
MARCH AIR RESERVE BASE, Calif. --  KC-135 Stratotanker #3533 may be 49 years old, but after July 28, its impeccable interior didn't look a day older than it did when it came off the production line in 1962.

While 452nd Air Mobility Wing maintainers have done partial renovations on KC-135s in the past, Stratotanker 3533 was the first of wing's 13 Stratotankers to undergo a full refurbishment. While the job took the maintainers just 23 working days, the initiation of the refurbishment program at March has been three years in the making.

"We're doing this to make our airplanes last longer and look better," said Master Sgt. Bryan Shifflett, refurbishment supervisor. "When visitors and aircrew come aboard one of our planes, they'll know it's a March jet because it reflects the quality of everything we do here."

Before reporting to March in 2005, Col. Cam LeBlanc was stationed at Grissom Air Force Base, which operates a robust KC-135 refurbishment program. He saw the benefits of refurbishment and suggested initiating a refurbishment program here. When Col. Robert Stormes took over as 452nd Maintenance Group commander, he took the refurbishment program from a concept to a reality.

"The 452nd Air Mobility Wing is emerging as the premier wing in Air Force Reserve Command, and developing a strong refurbishment program that shows pride in our aircraft is just one more piece to that end," he said.

Building a refurbishment program from the ground up was no small task, considering the tools, equipment, facilities, personnel and supplies necessary to make it happen. Shifflett was hired in December of 2007 to help get the program off the ground. He and his crew started work on the first aircraft at the end of June and were able to finish seven working days ahead of the allotment for a unit's first refurbishment.

"It was painstaking, but the finished work speaks for itself," he said.

From squadron commanders to production supervisions, Shifflett credits strong support across the wing with the success of the first KC-135 refurbishment. He is especially appreciative of the continued interest and support from Stormes and 452nd Air Mobility Wing Commander, Col. Karl McGregor.

"If we need things or run into any roadblocks, I know they have my back," Shifflett said.

This spring, Shifflett and his team evaluated all 13 KC-135s and gave them a priority number based on their condition.

"The higher the score, the worse shape the plane was in," he said.

Dedicated crew chief Staff Sgt. Jonathan Flynn, 912th Air Refueling Squadron, would agree with the selection of Stratotanker 3533 to be refurbished first. Although he is used to working with aircraft that are as old as his parents, when he reported for duty in February and first viewed the Stratotanker he would be working with, he was disappointed to discover an interior with dents, tears, rips, chipped paint and stains covering almost all surfaces.

"It had seen better days," he said.

As a dedicated crew chief, Flynn is responsible for all aspects of a particular aircraft's maintenance. When Stratotanker 3533 leaves home station for more than a day, Flynn, or up to three crew chiefs, accompany the plane.

"When you work on a jet that's been refurbished, everything seems to be in better working order. It looks better," he said. "It gives you a better sense of pride in the jet you maintain and it gives you an incentive to keep it looking good."

During the 23-day refurbishment, crew chiefs were an integral part of the work. Flynn oversaw a group of three crew chiefs who were responsible for everything on the flight deck.

"They went the extra mile throughout this whole project," he said. "Their efforts and positive attitudes show in the quality of the finished product."

Flynn said the refurbishment allowed him to complete the long list of additional work he wishes they could do on the aircraft, but never seem to have time for.

Tech. Sgt. Brad Rosario, 452nd Maintenance Squadron Sheet Metal Shop, was the lead painter for the refurbishment. He painted all components that couldn't be easily removed from the aircraft.

"It was very overwhelming at first. So much needed to be done," he said. "When everything was gutted, it was hard to visualize how it would look when it was finished."
Despite the work, Rosario is proud of the final product.

"I think the pilots will see the pride in what the maintenance group does and the products we put out," he said. "I think it will instill a sense of confidence in the equipment they are using."

Rosario said he enjoyed the change of pace during the refurbishment, as well as the opportunity to work alongside maintenance Airmen who hold different Air Force Specialty Codes.

"It helped me understand where they're coming from on their side of aircraft maintenance," he said.

During the refurbishment, 12-15 Airmen worked on the aircraft each day. The Airmen represented the 452nd Maintenance Squadron's Sheet Metal Shop, Electro/Environmental Shop, Periodic Inspection Dock and Aero Repair Shop, as well as the 752nd Aircraft Maintenance Squadron's crew chiefs and Flightline Avionics Shop. Airmen from the 912th Air Refueling Squadron were integrated into several of the shops to work alongside 452nd Air Mobility Wing reservists.

"I could not be more proud of how the team came together to make this event happen," said Col. Stormes. "They exceeded all my expectations, finishing seven days ahead of schedule while delivering an exceptional product. This almost 50-year-old aircraft has never looked any better. Our maintenance team has set the bar very high."

The rest of the aircraft in March's KC-135 fleet are scheduled for refurbishment around operational and inspection schedules, as well as the availability of maintenance group Airmen to be detailed to the project.