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Pacer Classic III mods give T-38 new life

T-38C Talon Instructor Pilot (front), Lt. Col Edward Stapanon III, and Combat Systems Officer (rear), Maj. Brion Nielsen, begin their take-off roll for a training mission April 18, 2018, at Joint Base San Antonio-Randolph, Texas. The aircraft recently completed the Pacer Classic III modification package and still shows its distinctive tiger stripes that will be removed when the aircraft receives its next scheduled complete paint job. (U.S. Air Force photo by Alex R. Lloyd)

T-38C Talon Instructor Pilot (front), Lt. Col Edward Stapanon III, and Combat Systems Officer (rear), Maj. Brion Nielsen, begin their take-off roll for a training mission April 18, 2018, at Joint Base San Antonio-Randolph, Texas. The aircraft recently completed the Pacer Classic III modification package and still shows its distinctive tiger stripes that will be removed when the aircraft receives its next scheduled complete paint job. (U.S. Air Force photo by Alex R. Lloyd)

After being lifted into place using the overhead crane, a T-38 Talon fuselage is bolted in-place on a specialized jig April 17, 2018, at Joint Base San Antonio-Randolph, Texas, to ensure that the frame stays in alignment during the Pacer Classic III modification package. (U.S. Air Force photo by Alex R. Lloyd)

After being lifted into place using the overhead crane, a T-38 Talon fuselage is bolted in-place on a specialized jig April 17, 2018, at Joint Base San Antonio-Randolph, Texas, to ensure that the frame stays in alignment during the Pacer Classic III modification package. (U.S. Air Force photo by Alex R. Lloyd)

Jason Moore, 575th Aircraft Maintenance Squadron maintenance support flight, inspects the inside of T-38 Talon boat tail section April 17, 2018, at Joint Base San Antonio-Randolph, Texas. (U.S. Air Force photo by Alex R. Lloyd)

Jason Moore, 575th Aircraft Maintenance Squadron maintenance support flight, inspects the inside of T-38 Talon boat tail section April 17, 2018, at Joint Base San Antonio-Randolph, Texas. (U.S. Air Force photo by Alex R. Lloyd)

Hundreds of clecos are used to maintain alignment and structural strength after the normal screws have been removed. (U.S. Air Force photo by Alex R. Lloyd)

Hundreds of clecos are used to maintain alignment and structural strength after the normal screws have been removed. (U.S. Air Force photo by Alex R. Lloyd)

Lloyd Fellbaum, 575th Aircraft Maintenance Squadron sheet metal technician, works inside the confined space of what is normally the forward fuel bladder on a T-38 Talon April 18, 2018, at Joint Base San Antonio-Randolph, Texas. (U.S. Air Force photo by Alex R. Lloyd)

Lloyd Fellbaum, 575th Aircraft Maintenance Squadron sheet metal technician, works inside the confined space of what is normally the forward fuel bladder on a T-38 Talon April 18, 2018, at Joint Base San Antonio-Randolph, Texas. (U.S. Air Force photo by Alex R. Lloyd)

Melanie Blackstock, 575th Aircraft Maintenance Squadron fuels technician, removes screws from a fuel quantity probe April 17, 2018, at Joint Base San Antonio-Randolph, Texas. (U.S. Air Force photo by Alex R. Lloyd)

Melanie Blackstock, 575th Aircraft Maintenance Squadron fuels technician, removes screws from a fuel quantity probe April 17, 2018, at Joint Base San Antonio-Randolph, Texas. (U.S. Air Force photo by Alex R. Lloyd)

Michael Ramirez, 575th Aircraft Maintenance Squadron sheet metal technician, checks the alignment on a new left hand upper center longeron being installed on a T-38 Talon during the Pacer Classic III modification package April 17, 2018, at Joint Base San Antonio-Randolph, Texas. (U.S. Air Force photo by Alex R. Lloyd)

Michael Ramirez, 575th Aircraft Maintenance Squadron sheet metal technician, checks the alignment on a new left hand upper center longeron being installed on a T-38 Talon during the Pacer Classic III modification package April 17, 2018, at Joint Base San Antonio-Randolph, Texas. (U.S. Air Force photo by Alex R. Lloyd)

Gilbert De La O uses a forklift April 19, 2018, at Joint Base San Antonio-Randolph, Texas, to retrieve a crate of parts needed on the Pacer Classic III production line. (U.S. Air Force photo by Alex R. Lloyd)

Gilbert De La O uses a forklift April 19, 2018, at Joint Base San Antonio-Randolph, Texas, to retrieve a crate of parts needed on the Pacer Classic III production line. (U.S. Air Force photo by Alex R. Lloyd)

Complete wing sets along with crates holding up to 600 parts from each aircraft are kept safe and ready at Joint Base San Antonio-Randolph, Texas, to be returned to the main production building within minutes compared to hours or days before the new storage rack system was installed. (U.S. Air Force photo by Alex R. Lloyd)

Complete wing sets along with crates holding up to 600 parts from each aircraft are kept safe and ready at Joint Base San Antonio-Randolph, Texas, to be returned to the main production building within minutes compared to hours or days before the new storage rack system was installed. (U.S. Air Force photo by Alex R. Lloyd)

Ricardo Tarin, 575th Aircraft Maintenance Squadron aircraft maintenance machinist, drills new holes into an upper center longeron April 18, 2018, at Joint Base San Antonio-Randolph, Texas, that will be installed on a T-38 Talon during the Pacer Classic III upgrades.  (U.S. Air Force photo by Alex R. Lloyd)
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Ricardo Tarin, 575th Aircraft Maintenance Squadron aircraft maintenance machinist, drills new holes into an upper center longeron April 18, 2018, at Joint Base San Antonio-Randolph, Texas, that will be installed on a T-38 Talon during the Pacer Classic III upgrades. (U.S. Air Force photo by Alex R. Lloyd)

The 575th Aircraft Maintenance Squadron at Joint Base San Antonio-Randolph, Texas, has established a well-used training area for squadron new-hires and Pacer Classic III proof-of-concept ideas used on the main production line. The training area houses a disused fuselage along with other major aircraft parts and tabletop work space for up to eight students at a time. (U.S. Air Force photo by Alex R. Lloyd)
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The 575th Aircraft Maintenance Squadron at Joint Base San Antonio-Randolph, Texas, has established a well-used training area for squadron new-hires and Pacer Classic III proof-of-concept ideas used on the main production line. The training area houses a disused fuselage along with other major aircraft parts and tabletop work space for up to eight students at a time. (U.S. Air Force photo by Alex R. Lloyd)

T-38C Talon Instructor Pilot (front), Lt. Col Edward Stapanon III, and Combat Systems Officer (rear), Maj. Brion Nielsen, taxi out from under the protective sunshades for a training mission April 18, 2018, at Joint Base San Antonio-Randolph, Texas. The aircraft recently completed the Pacer Classic III modification package and still shows its distinctive tiger stripes. (U.S. Air Force photo by Alex R. Lloyd)
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T-38C Talon Instructor Pilot (front), Lt. Col Edward Stapanon III, and Combat Systems Officer (rear), Maj. Brion Nielsen, taxi out from under the protective sunshades for a training mission April 18, 2018, at Joint Base San Antonio-Randolph, Texas. The aircraft recently completed the Pacer Classic III modification package and still shows its distinctive tiger stripes. (U.S. Air Force photo by Alex R. Lloyd)

On an overcast morning, building 100 at Joint Base San Antonio-Randolph, Texas, nicknamed the Taj Mahal, glows brightly to welcome a new day. The building was completed in 1931 and is actually a 500,000-gallon water tank along with office space, base movie theater and is the most prominent location on base. (U.S. Air Force photo by Alex R. Lloyd)
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On an overcast morning, building 100 at Joint Base San Antonio-Randolph, Texas, nicknamed the Taj Mahal, glows brightly to welcome a new day. The building was completed in 1931 and is actually a 500,000-gallon water tank along with office space, base movie theater and is the most prominent location on base. (U.S. Air Force photo by Alex R. Lloyd)

HILL AIR FORCE BASE, Utah -- What do you do with airplanes that were built in the early 1960s and are planned to be flying well past their 70th birthday? You give them a structural makeover that will provide the strength and longevity to go the distance.

Designed in the 1950s, the T-38 Talon is a tandem, two-seat aircraft that became the world’s first and most produced supersonic trainer with over 1,100 being built and, thus far, trained an estimated 72,000 pilots from the U.S. Air Force, foreign nations and NASA, that have affectionately nicknamed it “white rocket” due to its thrust-to-weight ratio.

Since entering flying service, each active aircraft has received structural, avionic and propulsion upgrades that have kept them up-to-date and have allowed many airframes to accumulate as many as 20,000 hours of high-G supersonic flight.

With its replacement still to be chosen and the only advanced supersonic trainer available, it has once again become necessary to extend each airframes service life and to that answer is the 575th Aircraft Maintenance Squadron, the only geographically-separated aircraft maintenance, stand-alone squadron within Air Force Materiel Command.

Located at Joint Base San Antonio-Randolph Air Force Base, Texas, the 575th AMXS T-38 Talon depot maintenance team has been providing current upgrade modifications known as Pacer Classic III since 2015 and have to date successfully completed them on 40 aircraft.

The PCIII modification package is more extensive than any previous T-38 depot overhaul, inspection and repair and are scheduled to take approximately 9,700 hours with a goal of completing each aircraft in 240 days, which is down from 600 days that each of the first two aircraft required for completion.

“We are replacing 185 separate primary structures such as longerons, bulkheads, skins and former assemblies; inspecting and assessing the life of a 155 additional components, and repairing or replacing hundreds of other parts,” said Joe Lopez, 575th AMXS director.

To maximize work efficiency, the 575th has relentlessly sought process improvements and speed through implementation of the Air Force Sustainment Center’s Art of the Possible, or AoP, constraint management methodology. This ensured all operations were completed in a safe and timely manner and allowed the squadron to reach full-rate production of 18 PCIII aircraft per year in fiscal year 2017 while simultaneously closing out four smaller modification programs.

To begin the modifications, each aircraft has paint stripped from designated areas on the fuselage, which gives the aircraft what looks like tiger stripes. After the paint is stripped, the canopies and ejection seats are removed, and the wing and tail assemblies are separated from the fuselage. The wings and more than 600 removed parts are then stored in an 8,500 square foot warehouse that was once the base fitness center.

Using AoP visual monitoring metrics, the squadron was able to quickly identify a constraint in the accounting and organization of the many removed parts. This was one the largest issues impacting the production machine goal of 240 flow days. Parts that were initially removed from each aircraft were being packed in crates and stored in a manner that made it difficult to track and locate when needed.

With the installation of an advanced ACTIVRAC 16 high-density mobile storage shelving system along with non-movable permanent shelves, crate retrieval that once took multiple man hours to locate and retrieve now only takes one person as little as five minutes.

Today, the squadron is in full-rate PCIII production and is managing the T-38 Talon production schedule in a manner that allows for the completion of an aircraft roughly every 23 days which is putting aircraft back in the hands of the pilots and students that rely on them for maintaining their flying training program.
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