Unexpected findings during aircraft maintenance rarely follow a standard path. Corrosion inside or on top of a fuel tank is usually more than just a technical issue. It directly affects structural integrity, repair timelines, and ultimately the aircraft’s return to service. In these situations, the ability to adapt becomes as important as the repair itself.
This project on a Dassault Falcon 7X demonstrates how JetSupport approaches complex airframe work with flexibility, in-house engineering, and full control over execution.
From Water Ingress to Structural Corrosion
The project started with the identification of water ingress in the right-hand wing bolt recesses. Rainwater had entered through a fairing panel that was not fully sealed, allowing water to collect inside the wing bolt recess area.
Over time, this standing water affected the protective corrosion inhibiting compound (CIC) applied to the structure. As the protection degraded, corrosion developed around fasteners located in the wing critical bolt recesses. These areas are structurally sensitive and require precise handling to ensure continued airworthiness.
Accessing the Critical Structure
To properly assess and treat the corrosion, access to the affected areas was required through the RH wing feeder tank . This meant removing internal components from the fuel tank structure, including parts that contribute to the overall load distribution of the airframe.
Once these components are removed, the aircraft structure can no longer support itself in the same way. Without proper support, there is a risk of deformation or structural damage.
At this stage, standard tooling was not sufficient. JetSupport’s response did not involve waiting for external solutions. Instead, the internal R&D team designed and manufactured custom adapters that could be integrated with existing support equipment.
This work was completed in-house, allowing the project to continue without delay.
Safe Airframe Support Through In-House Engineering
With the custom adapters in place, the airframe was safely supported, creating the conditions needed to proceed with the repair.
This step is critical in complex work. It ensures that while one part of the aircraft is disassembled, the overall integrity of the structure remains intact.
The ability to design and implement such solutions internally reflects JetSupport’s experience across a wide range of aircraft types and maintenance scenarios.
Corrosion Removal and Surface Preparation
With access secured, the affected fasteners in critical bolt recesses 38 and 39 were removed to allow proper treatment of the corrosion.
The entire existing CIC layer was fully removed using dry ice blasting. This method eliminates protective coatings without damaging the underlying paint or structure. The result is a clean surface that allows accurate inspection and proper reapplication of protection.
This action ensures that no corrosion remains hidden beneath previous layers.
Restoring Protection with Improved Materials
After cleaning, a new protection scheme was applied. The updated process included the use of Sprayseal, a modern corrosion protection compound, applied to the critical bolt recesses.
This upgrade improves long-term resistance in areas that are exposed to moisture risk.
By combining precise removal techniques with improved materials, the repair not only resolves the issue but also strengthens the protection against future exposure.
Adaptability as a Standard
Projects like this are not defined by the initial finding, but by how the situation is handled once complexity increases.
JetSupport’s ability to design tooling, adapt processes, and execute structural repairs internally ensures that unexpected challenges do not translate into extended downtime.
This flexibility is built on experience across an extensive fleet of business jets, where each project brings different technical requirements and operational constraints.
Outcome for the Operator
The corrosion was fully treated, the structure restored, and protection upgraded without introducing unnecessary delays into the maintenance schedule. The aircraft returned to service with a predictable timeline and with improved protection in a critical area of the wing structure.
For operators, this level of adaptability means that even complex findings can be managed without losing control over planning and aircraft availability.
