Date: 201505
Local time of day: 1201-1800
Location: ZZZ.Airport, US
Light: Daylight
Aircraft: Eurocopter AS 350/355/EC130 - Astar/Twinstar/Ecureuil
Operator: Air Taxi
Operating under: Part 135
Mission: Other TV Broadcast
Flight phase: Parked
Aircraft component: Air/Ground Communication
Reporter organization: Air Taxi
Reporter function: Inspector
Reporter qualification: Maintenance Airframe; Maintenance Powerplant
Human factors: Communication Breakdown; Workload; Time Pressure
Anomaly: Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural Published Material / Policy; Deviation / Discrepancy - Procedural FAR
Detector: Person Maintenance
When detected: Routine Inspection; Pre-flight
Result: General Maintenance Action
Contributing factors: Logbook Entry; Company Policy; Human Factors; Environment - Non Weather Related; Procedure
Primary problem: Human Factors

Narrative: A prearranged scheduling of an equipped helicopter for broadcasting a national sports bicycle race was changed two weeks before the event. I was tasked with configuring another aircraft to accomplish the same job. This required constructing an aluminum 'mission box' that could be secured in the aft cabin. The mission box required a 24 to 12 Volts DC (Vdc) converter; a RF transmitter; RF amplifier; dual UHF coms; a selectable audio panel; an Interconnect Solutions (ICS) [Cannon plug] connection to the aircrafts audio system and dual impedence converters to allow the UHF radios to be compatible with the audio panel. Dual UHF antennes had to be installed on the aircrafts lower fuselage and a RF transmitting antenna on the upper cabin exterior. A Supplemental Type Certificated (STC) camera mount and camera system were installed to provide the video source. In May; one day before the scheduled departure; I was informed by management that the aircraft needed to leave in two hours. The mission box was not complete and not secured at this point. I was in the process of testing the UHF coms when I was notified. I informed management it was scheduled to be completed the next day and was not finished. Management insisted I secure the box and it would leave immediately. Holes were drilled through the cabin floor floor and Army/Navy (AN) hardware was used to secure the box. I informed the pilot that the work was not completed and there was no [FAA Major Repair and Alterations Form] 337 completed at this time. He did not care and just wanted to leave to be onsite for an afternoon meeting. A Log entry was created with a Form 337 detailing the STCd equipment only and the pilot / management was informed of such.  The aircraft departed.Results: Poor planning by management and pressure to get an aircraft back in service without work completion resulted in a Return to Service (RTS) [aircraft] without proper maintenance documentation and project completion. Repair Station procedures were not followed and the Part 135 Operations manual section concerning Return to Service (RTS) were not complied with.

Callback: Reporter stated the short notice need to equip one of their AS-350 Eurocopter's was due to one of the news networks helicopter had been struck while parked on the ramp by an aircraft with a mechanical steering control problem. The 'Mission Box' is an industry term in aviation for an STC designed box with racks for electronic equipment; audio; video receivers and transceivers that can be quickly reconfigured for a customer doing high altitude photography with a control panel that allows switching when receiving or sending audio/video.   Reporter stated he had tested the Mission Box in the hangar; but did not have an opportunity to do the same after the box was installed in the AS-350 helicopter. The Lead Mechanic had signed-off the Maintenance Release prior to departure.



Synopsis: A Quality Assurance Inspector reports a company helicopter departed with a Supplemental Type Certificate (STC) not complied with; resulting in a Return to Service (RTS) of their AS350 Eurocopter without proper maintenance documentation or project completion and Part 135 Operations Manual and Repair Station procedures not being followed. Management had insisted the aircraft depart even with an incomplete STC and FAA Form 337.