Upondisassembly itwasdiscovered thatthecardstiffener framehadfractured, allowing greater card deflections, whichresulted inafatiguefailureoftheleadsofthesametransistor thatwasknocked offthe boardontheprevious unit.Thistime,adetailed investigation andanalysis ofthesituation was performed. Thestiffener wasoriginally designed andanalyzed fortheheritage GGSdevice. Initialanalysis ofthe SeaWinds dynamic environments indicated thattheheritage GGSdesignwassufficient tohandlethe somewhat higherSeaWinds levels. Theresolution ofthisanalysis wasinsufficient andfailedtodetectthe narrowmarginofthecardstiffener tothenewenvironment. Whentheinductor, whichhasarelatively largefootprint, wasbonded tothecard,itresulted inalocalincrease instiffness. Thischanged the fundamental modeofthecardanddirected thedynamic energytothestiffener. Thesituation wasmade worsebyapre-stressed condition ofthestiffener thatresulted fromthetorques applied totheboltsused tofastenittothecard.Thispre-stressed condition inparticular wouldhavebeendifficulttoforesee duringtheoriginal analysis. Theresultoftheinvestigation ledtoaredesign ofthestiffener making itthickerandchanging itscross section tomakeitstifferinlateralbending inordertoresistthestresses induced fromassembly. Retrofit ofthenewcardstiffeners tothepowerconditioning boardsofbothflightunitsfinallysolvedtheproblem. Thereareseveral lessons learned here.First,makesurethatanalyses of"delta"environments areof sufficient resolution andprovide adequate margins. Second, timemustbetakentoconsider the consequences andpossible impacts ofevenseemingly simplechanges. Conclusion TheSeaWinds Scatterometer Antenna Subsystem hasbeendemonstrated tobeareliable, flight-proven mechanism formission criticalapplications. Itson-orbit performance todatehasbeenexceptional. TheSeaWinds SASdemonstrates thatevenacustom device, ifitisrobustandwelldesigned, canevolve foruseinentirely newapplications. Theendapplication oftheSeaWinds deviceasaclosed-loop antenna spinner isconsiderably different thanthatoftheGGSdespun platform mechanism. Yetthe designwassuccessfully developed through addition ofnewstructure (theBSA),newelectronics (theEA), modification oftheexisting designbyeliminating thesliprings,addinganRFrotaryjointandantenna, andadapting thedesigntonewlifeandthermal requirements. Judicious useof"redline"drawing controls andanengineering unitwereusefulinthisprocess. Thisexample ofre-useofprevious flight hardware designs showsaneffective waytoreducecostsandmeettherequirements ofthe"better, faster,cheaper' paradigm. Theredesign ofexisting hardware isnotwithout hazards. Whenhardware isreordered fromanearlier program, changes inmanufacturing techniques cancauseproblems. Payattention totheconsequences ofthesemanufacturing "improvements". Significant changes inquotesfrommanufacturers tofabricate anestablished partshouldactasaflagtoinquireaboutchanges inprocesses. TheV-band problem described inthispaperisanexample ofthisfromtheSeaWinds effort.Thespecific lessons learned from thisproblem aretobeware oflocalized heating of6AI-6V-2Sn titanium duringmanufacturing, andthat abrasive waterjettechniques canbeusedinplaceoflasercuttingtominimize localized heating. Thecurrent successful flightoftheSeaWinds instrument ontheQuikScat spacecraft isagoodexample ofawell-adapted design. Thisredesign ofheritage hardware foranewanddifferent application illustrates acost-effective approach, whileillustrating theneedtoconsider hazards andlearnfrom previous programs. 285