THE ORION RECOVERY

April 2018 - December 2020

by Bruce Small

 

18APR18
A9-760 arrived at Sunshine Coast Airport on delivery to QAM.
AUG 18
Ground works for the grass parking bay for the aircraft carried out.
31AUG18
Aircraft moved from the tarmac at Sunshine Coast Airport to the grass parking bay. Security fencing installed.
23OCT18
Aircraft de-fuelled.
05FEB19
Shipping Container & Security Camera Trailer delivered.
12FEB19
Commenced removal of external antennae. Flap drive mechanism disconnected in preparation for the lowering of the flaps. Centre fuel tank (5A) access cover removed. Mesh cover fitted to allow the tank to be vented.
19FEB19
Flaps lowered manually.
26FEB19
Loosening Port Wing over wing fillet panels.
Loosening STBD wing over wing fillet panels.
27FEB19
Loosening Port Wing under wing fillet panels.
Loosening STBD Wing under wing fillet panels
06-20MAR19
Service bay between Tank 5 & 5A opened for access to engine push pull and fire handle cables and wing electrical harnesses.
26MAR19
Port and Starboard Main Landing Gear Doors removed.
27MAR19
Nose Landing Gear Doors removed.
02-16APR19
Loosening Leading Edge Fillet panels between Port Wing and fuselage.
Loosening Leading Edge Fillet panels between STBD Wing and fuselage.
Loosening Trailing Edge Fillet panels between Port Wing and fuselage.
Loosening Trailing Edge Fillet panels between STBD Wing and fuselage.
17APR19
Port Wing Trailing Edge Electrically, hydraulically and mechanically disconnected.
STBD Wing Trailing Edge Electrically, hydraulically and mechanically disconnected.
24APR19
Removed Leading Edge Fillet panels between Port Wing and fuselage.
Removed Leading Edge Fillet panels between STBD Wing and fuselage.
24APR19
Port Wing Leading Edge Electrically and mechanically disconnected. STBD Wing Leading Edge Electrically and mechanically disconnected.
24APR19
Service bay between Tank 5 & 5A. Engine push pull and fire handle cables and wing electrical harnesses disconnected.
30APR19
STBD Inboard Leading Edge opened for access to the External Bleed Air Duct.
07MAY19
Single Point Refuelling panel removed from the STBD wing trailing edge.
Nose Landing Gear electrically disconnected.
Nose wheel steering cables disconnected.
External power connector removed from its bracing and tied back.
External bleed air connector disconnected.
22MAY19
Generator cables in Port & STBD leading edges electrically disconnected.
STBD wing tip electrically disconnected & removed.
STBD Aileron disconnected & removed.
29MAY19
Port wing tip electrically disconnected & removed.
Port Aileron disconnected & removed.
30MAY19
Port & STBD wing tips & ailerons transported to QAM.
All antennae and cover panels transported to QAM.
05JUN19
Port & STBD Flaps disconnected.
13JUN19
Port & STBD Flaps removed.
10JUL19
Enlarged Tank 5A access panel opening to allow entry to tank.
16AUG19
Port Leading Edge panels removed.
17AUG19
STBD leading edge panels removed.
Port trailing edge to wing attachments rivets and bolts removed.
STBD trailing edge to wing attachments rivets and bolts removed.
25-26AUG19
Port & STBD over & under wing fillets removed.
15-16SEP19
Engines # 1 - 4 disconnected ready for removal & access panels removed.
17SEP19
Screws attaching galley floor removed, floors raised.
Flight control cables under Galley floor disconnected.
Propellers # 1 - 3 removed.
18SEP19
Flight control cables disconnected in the empennage.
Electrical cables disconnected in the empennage.
Lower Empennage to fuselage attachment bolts removed.
19SEP19
MAD Boom removed.
Remaining empennage to fuselage attachment bolts removed.
Empennage removed.
24SEP19
Orion moved to Tarmac in front of Hangar #2. Tank 5A cross bracing removed for access.
27SEP19
Port and STBD wing trestles positioned.
01OCT19
Engines # 1 - 4 removed.
02OCT19
Aircraft jacked, wing and fuselage trestles installed.
03OCT19
Engines & props transported to QAM.
07OCT19
Commenced removal of fuel sealant from STBD Wing within Tank 5A, over wing attachment plates and leading and trailing edge.
08OCT19
STBD Main Landing Gear removed.
Port Main Landing Gear removed.
09OCT19
Nose Landing Gear removed.
11OCT19
Commenced removal of fuel sealant from Port Wing within Tank 5A, over wing attachment plates and leading and trailing edge.
18OCT19
STBD wing Hi Lock bolts loosened.
4 Main STBD Wing attachment bolts removed.
18OCT19
Port wing Hi Lock bolts loosened.
4 Main Port Wing attachment bolts removed.
20OCT19
STBD wing Hi Lock bolts removed.
21OCT19
STBD wing Leading and trailing edge bolts removed.
21OCT19
Port wing Hi Lock bolts removed.
22OCT19
STBD wing removed.
22OCT19
Port wing leading and trailing edge bolts removed.
23OCT19
Port wing removed.
23OCT19
Commenced removal of Dorsal Fin.
24OCT19
Aft section of the Dorsal Fin removed.
25OCT19
Forward section of the Dorsal Fin removed.
Upper anti-collision light removed.
All antennae on upper surface of fuselage removed.
29OCT19
Port Wing loaded for transport to QAM.
STBD Wing loaded for transport to QAM.
Fuselage loaded for transport to QAM.
29OCT19
Fuselage transported to QAM.
29OCT19
Fuselage placed on trestles.
30OCT19
Port & STBD wings transported to QAM.
Wings placed on wing trestles.
31OCT19
Nose jacks positioned to prevent aircraft rolling.
05NOV19
Reassembly started
The removal of the fuel sealant from around the wing to fuselage mating surfaces has started.
12NOV19
Removed corrosion from the wing to fuselage mating surfaces. (Port trailing edge had delamination that required extensive work).
NOV19
Port wing refitted.
NOV19
STBD wing refitted.
NOV19
Port Main Landing Gear refitted.
NOV19
STBD Main Landing Gear refitted.
NOV19
Nose Landing Gear refitted.
07JAN20
Port wing trestle removed.
07JAN20
STBD wing trestle removed.
08JAN20
Fuselage trestles removed.
08JAN20
Aircraft lowered.
JAN20
Port Main Landing Gear Doors refitted.
JAN20
STBD Main Landing Gear Doors refitted.
JAN20
Nose Landing Gear Doors refitted.
29JAN20
Empennage placed in transport cradle at SCA.
Airport compound fencing at SCA removed.
04FEB20
Port Wing Flap installed.
05FEB20
STBD Wing Flap installed.
11-19FEB20
Port Wing Aileron Installed.
STBD Wing Aileron Installed.
Refitted STBD wing leading edges.
Refitted Port wing leading edges.
Refitted Port wing to fuselage over wing fillet panel.
Refitted STBD wing to fuselage over wing fillet panel.
Refitted Port wing to fuselage trailing edge over wing fillet panel.
Refitted STBD wing to fuselage trailing edge over wing fillet panel.
11MAR20
Engines installed.
MAR20
Engines # 1 - 4 reconnected & access panels refitted.
MAR20
Propellers # 1 - 3 refitted.
25MAR20
Vertical fin removed from the empennage at SCA.
Rudder removed from the Vertical Fin.
Rudder, vertical fin and empennage transported to QAM.
28MAR20
Propeller after bodies refitted.
MAR20
Port Main Landing Gear Doors adjusted.
MAR20
STBD Main Landing Gear Doors adjusted.
19JUL20
Port Wing Tip installed.
20JUL20
STBD Wing Tip installed.
30JUL20
Scaffolding installed at rear of fuselage.
05AUG20
Repairs carried out to vertical fin.
Rudder refitted to the vertical fin.
Corrosion treated and repairs carried out to the empennage.
07AUG20
Dorsal Fin installed on fuselage.
Upper anti-collision light installed.
07AUG20
Vertical fin re-fitted and secured to the empennage.
AUG20
Elevators fitted to the empennage.
AUG20
Tips refitted to the horizontal stabilizers.
AUG20
Mad Boom support ring refitted.
09SEP20
Empennage installed.
MAD Boom fitted.
15SEP20
Empennage attachment bolt installation completed.
MAD Boom latched and secured.
16SEP20
Port & STBD over & under wing fillets fitted.
22SEP20
Commenced sealing of all the wing leading edge and fillet seams.
05OCT20
Sealed the joint between fuselage & empennage.
13OCT20
Started installing external antennae on upper and lower surface of the fuselage.
10NOV20
Galley floors refitted and screwed down.
01DEC20
Cabin cleaned and swept, galley cleared.
08DEC20
Aircraft washed and oxidation removed.

 

 

The Orion Disassembly / Reassembly Team

Bruce Small
Dave Mitchell
Chris Buley
Michael Bingham
Peter Scovell
Dennis Bugney
Chris Weingarth
Marthinus Koekemoer
Ian McLaughlin
Tony Johnstone

 

Bill Edwards
Co-ordination of GSE, transport of the GSE, crane hire, cherry picker and scissor lift hire and purchasing officer.
 
Bob Meredith
Transport of the fuselage, wings, engines, propellers, undercarriage, flight control surfaces, antennae, overwing fairings and the empennage from the Sunshine Coast Airport to QAM.
 
Mal Bird
Construction of hard stand at QAM for the aircraft and the manufacture of the transport cradles used on the truck to transport the aircraft from Sunshine Coast Airport to QAM.
 
We were also assisted by the welding shop team, the painters, grounds maintenance team, the Neptune team and numerous others from QAM without whose help we would have struggled to complete the project.
 
At the conclusion of the Orion project we sadly bid farewell to the Project Leader, Bruce Small, who is moving to Cairns to be near family. Thank you Bruce for your outstanding contribution to the project.

 

The Orion Member Sponsors

Barry Admans
David Bussey
Ron & Maureen Cuskelly
Cameron Elmes
Julie Hammer
Michael Hinsbey
Brian Lenz
Bob Livingstone
Bryan Matthews
Robert Phillips
Geoff Roach
Nick Sayer
Mal Sayers

 

The Orion Commercial Sponsors

 

 

 

ISSUE
DATE
REMARKS
1
26FEB21
Original issue.