Date: 201205
Local time of day: 1201-1800
Location: ZZZ.Airport, US
Light: Daylight
Aircraft: B767-300 and 300 ER
Operator: Air Carrier
Operating under: Part 121
Mission: Passenger
Flight phase: Parked
Aircraft component: Recirculation Fan
Reporter organization: Air Carrier
Reporter function: Inspector
Reporter qualification: Maintenance Airframe; Maintenance Powerplant
Human factors: Communication Breakdown; Confusion; Situational Awareness; Training / Qualification; Troubleshooting
Anomaly: Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural Published Material / Policy
Detector: Person Maintenance
When detected: Routine Inspection
Result: Aircraft Aircraft Damaged; General Flight Cancelled / Delayed; General Maintenance Action
Contributing factors: Aircraft; Company Policy; Human Factors; Procedure
Primary problem: Aircraft

Narrative: This is a follow-up to a previous report. Following discovery of damage to the Recirculation (Recirc) Fan Filter box support [rods] on Aircraft X and Y; I submitted the aforementioned report to recommend a repair and/or inspection procedure for the B767-300 fleet. Engineering came back with the following response: 'After discussion within engineering; our position is that neither an Inspection Program; nor redesign of the installation is warranted.'May 2012; I discovered the same support rods damaged on Aircraft Z; [another B767-300]; while performing a Galley Spill Inspection. The damage on both rods exceeded the limits in Maintenance Manual (MM) 21-25-05-6. The support rods on Aircraft A were cannibalized (robbed) for Aircraft Z. [But the support rods from Aircraft A] were also found damaged beyond MM limits. We tried to obtain a Line Engineering Authorization (LEA) for Aircraft Z to allow the damaged support rods; but were denied by Engineering.The May 2012 incident; culminating in two Out of Service (OTS) aircraft for damaged support rods; substantiates my previous concerns. The Recirc Filter Box support rods are prone to damage from containers in the Forward Cargo Compartment. Only a nylon curtain separates the support rods from a bulging container. I suspect a large number of the B767-300 aircraft are flying with damaged support rods. Suggest an ankle-high barrier across the width of the Recirc Fan compartment would protect the support rods.

Callback: Reporter stated he is a Line Inspector and has been finding damaged/bent Recirc Fan Filter Box support rods on many of their B767-300 aircraft whenever he accomplishes a Galley Spill Inspection. That Inspection requires a Visual Inspection of the Lower fuselage areas for fluid accumulation. The last two B767-300s could not be released for service until the damaged support rods were replaced.Reporter stated there is a left and right Recirc Fan Filter Box and each Filter box has four support rods on the forward side that are inches away from the aft side of the Aft Bulkhead; in the Forward Cargo compartment. Damage up to twenty-five percent of the rod's Outside Diameter (O/D) is allowed. There are two rods approximately three feet long and two that are approximately 18' inches long. Although the base of the Cargo pallets are secured at the aft stops; they often overpacked and extend aft into the nylon curtain that separates the cargo compartment from the Air Conditioning Mix Manifold; Recirc Fans and filter Boxes. He has noticed that most of the damage to the support rods is at the lower third of the rod length.Reporter stated there are inconsistencies with their Engineering department as to when relief may; or may not be given by a Line Engineer that would allow the aircraft to continue in-service beyond the maximum damage limits. Recently; one of their Engineer's had issued an Engineering Order (E/O) to wrap damaged support rods with Speed Tape; the purpose was still unclear; but the B767-300 was released from Maintenance.  A lot of their Engineers are basically structure 'Engineers' and have little experience in Aerodynamics.Reporter stated since he wrote his report; their Engineering Department is reconsidering his suggestion to design an 'ankle-high' barrier across the width of the Forward Cargo compartment Aft bulkhead to protect the Filter Box support rods.



Synopsis: A Line Inspector reports he has found numerous B767-300 aircraft with damaged Recirculation Fan Filter Box support rods behind the aft bulkhead nylon curtain in the forward cargo compartment. Damaged rods were noted while he was accomplishing Galley Spill Inspections.