JACKSONVILLE, Fla. — Despite setbacks during an extensive repair cycle, Fleet Readiness Center Southeast (FRCSE) returned a heavily modified NP-3D “Billboard” Orion with its distinctive radar panel to the Fleet Jan. 15.

The Naval Weapons Test Squadron (VX) 30, based in Point Mugu, Calif., took receipt of the specialized aircraft built by Lockheed in 1963 and modified in 1979 with Extended Area Test System (EATS) radar. The “Bloodhounds” fly the only two Billboards in the Fleet.

The aircraft’s over-the-horizon telemetry assists the squadron with its vital mission of clearing the Pacific Missile Test Range, the Department of Defense’s largest overwater missile test range with 36,000 square miles of controlled sea and airspace.

The Billboard’s phased array antenna is capable of receiving data from various locations throughout the Pacific and providing vital information to tactical users and sea and shore command centers.

The aircraft’s sophisticated telemetry system is used to locate and track targets for weapons testing and missile-range clearance. A distinctive radar panel approximately 6 feet high and 12 feet long sits atop the fuselage just forward of the vertical stabilizer.

FRCSE inducted the 46-year-old aircraft for phased depot maintenance in September 2006. Artisans initially estimated the project would take about 30,000 man-hours to inspect and repair.

Non-Destructive Inspection (NDI) technicians conducted a special structural inspection, which led to additional NDI testing revealing stress corrosion cracks in seven metal planks. These planks comprise the outer wing and run from the fuselage to the wingtip.

Planned Maintenance Interval Program Manager Clark Huffman oversaw the sustainment action to extend the aircraft’s service life. “The more we peeled the onion, the greater the scope of repair,” he said. “Sometimes when you’re repairing one failed part, you expose adjacent parts that would have not been inspected or repaired due to limited access.”

Former first-line supervisor Clinton Batten and his team were immediately faced with challenges. Batten said, “Aging aircraft require extensive measures. There were no structural repair manual references that covered this kind of extended damage.”

The second challenge dealt with parts availability. “When there are no parts on the shelves, you have to make them,” said Batten. A commercial vendor fabricated seven wing planks, which took more than 18 months.

FRCSE artisans continued the work out of sequence, a necessary but inefficient way to execute repairs. Sheet metal mechanics repaired extensive corrosion damage using numerous plank patches, the largest covering 21 square feet.

When FRCSE finally returned the aircraft to VX-30, artisans had expended more than 65,000 man-hours. The lengthy rework not only had a severe impact on the aircraft’s turnaround time but also hindered progress on other P-3 aircraft undergoing phased maintenance at the facility.

FRCSE P-3 Project Officer Cmdr. Joseph Buckler and VX-30 Navy test pilot Lt. Cmdr. Rick Foster flew the aircraft to Point Mugu, Calif. Foster said, “We are the only squadron that operates this aircraft. We use them for in-flight telemetry for the Tomahawk and other long-range missiles.”

Until the Navy brings in a new generation of aircraft, the older models must be maintained to support the maritime mission. With only two Billboards serving the Fleet, the successful return of this asset greatly contributes to VX-30’s mission success.

//USN//
Photo Captions:

10-24A:
Following extensive repairs, FRCSE returns one of only two heavily modified NP-3D “Billboard” Orion aircraft serving the Fleet to Naval Weapons Test Squadron (VX) 30 Jan. 15. (Photo by Marsha Childs)

10-24B:
Test pilots Cmdr. Joseph Buckler (FRCSE) and Lt. Cmdr. Rick Foster (VX-30) taxi down the NAS Jacksonville runway as they prepare to fly the P-3 “Billboard” with its distinctive radar panel to Point Mugu, Calif. where it is home-based. (Photo by Marsha Childs)

10-24C:
An NP-3D “Billboard” Orion taxis down the NAS Jacksonville runway as it prepares to depart for the long trip to NAS Point Mugu, Calif. (Photo by Vic Pitts)

10-24D:
VX-30 test pilot Lt. Cmdr. Rick Foster in the cockpit of an NP-3D “Billboard” Orion prepares for a functional flight check Dec. 8. The specialized aircraft with its over-the-horizon telemetry system is being used by the “Bloodhounds” to clear the Pacific Missile Test Range in California. (Photo by Vic Pitts)

10-24E:
Aircraft Mechanic Stephen Depay installs a wing-to-fuselage fillet fairing on a P-3 “Billboard” undergoing an extensive sustainment action at FRCSE. (Photo by Vic Pitts)

10-24F:
Avionics Mechanic John Dzioba checks for static air pressure leaks on the P-3 “Billboard” in October 2009. (Photo by Vic Pitts)

10-24G:
An NP-3D “Billboard” Orion aircraft, one of two in the Navy’s Fleet, sits on the back tarmac awaiting paint in early December 2009. (Photo by Vic Pitts)

10-24H:
FRCSE inducted the NP-3D “Billboard” Orion for repairs to extend the service life of the aircraft and ensure air worthiness. The specialized aircraft is equipped with phased array antenna to enhance navigation capabilities. (Photo by Vic Pitts)

10-24I:
FRCSE encountered many challenges during the sustainment action of the 46-year-old “Billboard.” Artisans must maintain older aircraft as the Navy brings in new replacements. (Photo by Vic Pitts)

10-24J:
The “Billboard” sits outside the FRCSE Paint Hangar in early November 2009. The Paint Shop paints aircraft to protect the asset from corrosion. The artisans also install unit insignias and identifying markings. (Photo by Vic Pitts)

10-24K:
Electronics Mechanic Dan Harper performs a remote-controlled test of the Pitot Static System, which provides the aircrew with pressure information such as airspeed and altitude changes. (Photo by Vic Pitts)

10-24L:
The “Billboard’s” outer wing is composed of metal planks that run from the fuselage to the wingtip. FRCSE artisans perform plank insertions to repair extensive damage caused by corrosion. (Photo by Vic Pitts)

10-24M:
FRCSE artisans repair corrosion to the “Billboard” wing planks with metal patches during extensive phased depot maintenance. (Photo by Vic Pitts)

Source: Navair