The request for the part originated on USS Carl Vinson and was relayed by FRCSW Production Officer CAPT Jason Martinson. He referred the urgent requirement for a centreline weapons bay fitting on an F-35 assigned to VFA-97 to Mr. George Nacker, FRCSW Manufacturing Program Manager.
The most significant challenge was sourcing the necessary raw material within the short timeframe. When the original supply could not arrive in time, FRCSW Planner and Estimator Adam Giesen located an alternative material in internal stock, which was approved by the F-35 Operations Center for use.
Once approved, FRCSW CNC Programmer Mr. Nang Huynh programmed the unit, and fabrication was carried out using a Water Jet machine. Two fittings were produced, one with pre-drilled holes and one without, to give the ship’s maintenance crew flexibility during installation.
Sheet Metal Work Lead Mr. Ellis Jones and his team loaded and cut the raw stock with precision, while Mr. Nacker coordinated with Deputy IPT for Services Keyon Marshall to secure funding and work documentation. The parts were then processed under the supervision of Production Line Manager Mr. Dan Doyle, who hand-carried them through cleaning, non-destructive inspection, blasting and painting.
The fittings were painted with F-35-specific coatings by the night shift, usually tasked with F-18 canopy work, and cured for 12 hours before final inspection. Quality acceptance was completed by Machinist Work Lead Mr. Charles “Todd” Critchlow and QA inspector Mr. Giovanni Balangan.
Standard Navy logistics could not guarantee timely delivery, prompting Mr. Marshall to personally transport the fittings to USS Carl Vinson. By noon the following day, he had hand-delivered the parts along with a Certificate of Performance, enabling immediate installation and avoiding the crane-off.
“FRCSW really came through when it counted. Their team didn’t just build a critical engine fitting on short notice, they hand-carried it all the way to Hawaii. Without their support, we would’ve been looking at a complicated and time-consuming crane evolution in San Diego. This is the kind of teamwork and dedication that keeps the fleet moving,” said CDR Chad Jelsema, COMPACFLT N432 Fleet Maintenance & Readiness Officer.
The aircraft was restored to full mission capability, demonstrating FRCSW’s ability to deliver precision, speed and excellence in direct support of the fleet. The operation highlighted the effectiveness of command-wide coordination and commitment to Naval Aviation Readiness.
