31 MXS clips a Falcon's wing

  • Published
  • By Senior Airman Austin Harvill
  • 31st Fighter Wing Public Affairs
AVIANO AIR BASE, ITALY --  Turn the wrench, take off the panel and fix the problem. Repeat. For the "Witless Wyvern," this process describes the jobs of avionics, fuels, crew chiefs and any other U.S. Air Force Airmen known as "maintainers" perform.

However, while routine maintenance comprises the majority of their work, they occasionally have to take off their gloves. Well, the wing of an F-16 Fighting Falcon, in this case.

With nearly three decades of service, it is up to maintainers to keep the 31st Fighter Wing Falcons flying. After a while, sheet metal patches and sealant are not enough. At that point, these Airmen kick into overdrive and do more than simply spruce up the old birds.

"With the extensive training and maintenance we do on the aircraft, it's no wonder these guys know the ins-and-outs of the jet," said Master Sgt. Thomas Hale, 31st Maintenance Squadron accessories flight chief. "Wing replacements are a rare relative to our day-to-day operations, but we have the capability, equipment and understanding necessary to make it happen."

Falcons are made to be taken apart and put back together so Airmen can perform swift maintenance, even if it means taking off a whole wing. This accessibility is necessary to maintain the well-used aircraft.  

"With up to 9,000 pounds [loaded] on each wing, it seems pretty obvious different components will break down over time, so we need the ability to quickly access and fix these problems in order for the jet to fly as soon as possible," said Staff Sgt. Dale Marsh, 31 MXS fuel systems craftsman.

After receiving word of the removal, every maintenance career field has a hand in taking apart the complex flight surfaces, avionics, wire harnesses and more.

"With all the steps we go through taking apart the wing, we are basically doing all of the maintenance we might do throughout the jet's life all at once," said Tech. Sgt. Donald Hannant, 31 MXS fuel systems assistant flight chief. "Taking off the wing is really the most difficult part."

With a few thousand pounds coming off the side of an aircraft, even the smallest bump from the now-floating wing could damage the attachment points or worse, the internal aspects of the aircraft body.

"There are 16 giant bolts holding the wing to the [Falcon's] frame," explained Hannant. "As they come off, the wing will shift slightly and we have to ensure it stays as still as possible. It can get nerve wracking at times."

Once the wing is fully removed, the maintainers team up again to perform multiple inspections before installing the new wing in the reverse order. Then the Falcon goes through the truest test of all - flight tests.

"Signing the 'X' stating the plane is ready to fly is personally a big step," laughed Marsh. "That signature means everyone from beginning to end has done their job. Every step, minor or major, has been completed without error. But I trust these guys, so at the end of the day it's a relief to sign that work order and send it to test fly."

Whether in the shop or in the sky, Hale said he doesn't expect any issues.

"We have an excellent team here who have so many years of experience combined, so we look at this big task as just another day on the job," said Hale. "I have faith the pilot in that cockpit will have a top-notch aircraft at his or her disposal."