In a significant technical achievement, the Brazilian Air Force (FAB) delivered the F-5FM fighter jet (serial FAB 4808) back to the 1° Grupo de Aviação de Caça (1° GAVCA) at Santa Cruz Air Base, Rio de Janeiro, following an unprecedented structural repair at Parque de Material Aeronáutico de São Paulo (PAMA-SP). The aircraft, operational since 1982 with nearly 4,900 flight hours, had entered the PAMA-SP facilities in April 2022 for a scheduled overhaul, during which unexpected structural cracks were discovered in four spars near the cockpit.
Faced with this technical challenge, PAMA-SP developed an innovative approach to replacing the spars, leveraging high-precision machining and modern CNC (Computer Numeric Control) technologies. Specialists performed meticulous three-dimensional measurements, engineered precise technical drawings, identified the correct aluminum alloy, and conducted exact thermal treatments, ensuring that the newly manufactured components matched original specifications perfectly.
Given the critical location of these components in a pressurized area, extreme care was taken during installation. Technicians carefully sealed the rivets to prevent air leaks and used a theodolite to confirm alignment, ensuring optimal aerodynamic symmetry and safety in flight operations. This groundbreaking process represented a new capability milestone for PAMA-SP, demonstrating their expertise not only in aircraft maintenance but also in sophisticated aircraft structural manufacturing and refurbishment.
This remarkable accomplishment highlights the skill, dedication, and innovation of the Brazilian Air Force’s maintenance teams, reinforcing their ability to independently sustain critical defense assets. The return of the FAB 4808 to flight status, especially during the month commemorating 50 years of F-5 operations in Brazil, is emblematic of the enduring legacy and ongoing relevance of the F-5 Tiger II within the FAB.
Source: FAB (PAMA-SP and BASC)
