When I started my internship at Basler Turbo Conversions in June, I knew I was stepping into an opportunity that would allow me to take what I had been learning in the classroom and apply it to real aircraft. What I didn't fully understand was that working on an aircraft is much different from learning about aircraft maintenance in school.

As an intern and maintenance technician, I have had the opportunity to work on one of aviation's most recognizable aircraft: the Douglas DC-3. At Basler, these aircraft receive a new life through conversion and modernization, and being able to contribute to that process has given me a completely different perspective on aircraft maintenance.

Starting With the Basics

One of my first training tasks was learning how to properly drill and remove a rivet. It may seem like a relatively small skill, especially when looking at the enormous amount of work involved in a DC-3 conversion, but it taught me an important lesson right away.

Aircraft maintenance requires patience and precision. A mistake on something as simple as removing a rivet can create additional work or damage a component that needs to be preserved. Learning to do the job correctly rather than simply doing it quickly was one of my first lessons on the production floor. From there, I quickly moved into much larger tasks.

The conversion I was working on was just beginning, and I became involved in removing the wings and interior panels. Watching an aircraft of that size gradually come apart was an experience in itself. Parts that had been part of a complete, functioning airplane were being carefully removed as the aircraft began its transformation.

Learning What School Can't Teach You

One of the biggest surprises for me has been how willing my coworkers are to share their knowledge.  Coming into the job, I expected that I would have a lot to learn. What I didn't necessarily expect was how willing experienced technicians would be to stop, explain something, demonstrate a technique, or offer advice about how to approach a problem. That willingness to teach has made a huge difference in my experience.

School provides an important foundation. It teaches you the principles behind aircraft systems, maintenance practices, regulations, materials, and procedures. But once you are standing in front of an actual aircraft, you quickly discover that there isn't always a textbook answer for every problem. Real aircraft don't always cooperate.

Sometimes you have to figure out how to reach a particular fastener. Sometimes a component doesn't come apart the way you expected. Sometimes the obvious solution isn't possible because of the surrounding structure. That is where ingenuity becomes important.

The ability to look at a problem, understand the limitations you are working with, and come up with a safe and practical solution is something that is difficult to fully teach in a classroom. It is something you develop through experience, observation, and working alongside people who have solved those kinds of problems before.

Learning From Experience

My supervisor, Paul Rice, has probably had the biggest influence on what I have learned so far. Having someone with experience who is willing to explain not only what needs to be done, but why it needs to be done a certain way, has helped me develop my skills much faster.

Working alongside experienced technicians has also shown me how much knowledge comes from years of actually working on aircraft. There are techniques, habits, and ways of thinking that you don't fully appreciate until you see them being used on a real maintenance job. Every day has given me something new to take away.

Being Part of Something Bigger

The coolest part of my internship has been being a significant part of the enormous task of restoring and converting such a large aircraft. There is something different about looking at a DC-3 and knowing that you personally helped take part in its transformation.

Aircraft can seem almost timeless when you see them sitting on the ramp. But working on one gives you a different perspective. You begin to appreciate the amount of work, knowledge, planning, and craftsmanship required to keep an aircraft like that flying. Being able to contribute (even as an intern) has made the work especially rewarding. I'm not simply studying aircraft maintenance anymore. I'm actually participating in it.

Looking Toward the Future

My internship at Basler Turbo Conversions has given me a much better understanding of what it means to work in aviation maintenance. I've learned that technical knowledge is only one part of being a good technician. Patience, attention to detail, problem-solving, communication, and the willingness to learn from others are just as important. I still have a lot to learn, and that's one of the things I enjoy most about the job.

My goal is to continue building my skills and expanding my knowledge as I gain more experience. Eventually, I hope to continue with Basler and become part of a production crew, where I can take on greater responsibilities and contribute to more of the conversion process. Starting my aviation career at Basler has shown me that the path from the classroom to becoming a skilled aviation technician is built one task at a time. Sometimes that task is learning how to properly remove a rivet. Sometimes it is figuring out how to remove a stubborn component. Sometimes it is standing in the summer heat wearing a Tyvek suit. But every one of those experiences adds another piece to the bigger picture.

And for me, getting to help give yet another DC-3 back in the air has made every one of those lessons worth it.

-Nate Woodard

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CONTINUING MY JOURNEY AT
BASLER TURBO CONVERSIONS

Building Skills, Gaining Independence, and Embracing New Challenges

Since writing my first article about my internship at Basler Turbo Conversions, I have continued to gain valuable hands-on experience in the aviation maintenance industry. What began as an opportunity to learn the fundamentals of aircraft maintenance has developed into an experience that has strengthened my technical abilities, expanded my understanding of the industry, and given me a greater sense of responsibility in my work.

One of the most exciting developments since my last article has been the opportunity to begin working on Basler’s newest DC-3 conversion. My primary responsibility has been fabricating and installing adjustable cargo rail supports. Although this may sound like a relatively straightforward task, each support is custom-made and must be individually fabricated to fit its specific location. This process requires careful measurements, precision metalworking, and the ability to adapt to challenges as they arise.

Working on these supports has greatly refined my metalworking skills. In fact, the experience I have gained at Basler has helped me develop my abilities to the point where I am now preparing to test out of the Metallic Structures course at Fox Valley Technical College. This is particularly rewarding because it demonstrates how much practical knowledge I have gained through my internship. Being able to apply what I have learned in school to real aircraft, while also bringing knowledge from the workplace back into the classroom, has been an invaluable part of my education.

Beyond the technical skills, this project has also challenged me to become a more independent problem solver. Because each cargo rail support is different, there is not always a simple, repetitive process to follow. Instead, I must evaluate each situation, determine the best approach, and fabricate a component that meets the requirements of the installation. This has taught me the importance of patience, adaptability, and attention to detail.

Perhaps one of the most meaningful changes since my first article has been the level of responsibility I have been entrusted with. I have been given the opportunity to work on my assigned tasks largely independently. Knowing that my coworkers and supervisors trust me to complete this work has been incredibly encouraging. It has also helped me recognize the importance of taking ownership of my work, maintaining high standards, and understanding that even seemingly small components contribute to the success of the overall aircraft conversion.

Of course, not every memorable experience has taken place at a workbench. One of my favorite moments so far involved working from a boom lift to install rivets on the aircraft. After securing myself with the appropriate fall-protection equipment, I was able to work high above the ground while completing the installation. It was certainly a mixture of excitement and nervousness, but it was also an experience I will not soon forget. Moments like these remind me of how unique and rewarding a career in aviation maintenance can be.

Another significant area of growth has been my understanding of the aviation industry itself. Between my coursework at Fox Valley Technical College and my daily experiences at Basler, I have become increasingly immersed in the culture of aviation maintenance. I have gained a greater appreciation for the standards, practices, teamwork, and problem-solving abilities that are essential to keeping aircraft safe and operational. There are many lessons that can be taught in a classroom, but experiencing how those principles are applied in a professional maintenance environment has given me a much deeper understanding of the industry.

Looking ahead, I hope to continue working at Basler Turbo Conversions and further develop my skills as an aircraft maintenance technician. One of my biggest goals is to be involved in at least one complete aircraft conversion, from the early stages of disassembly and modification through the finished product. With a conversion taking approximately a year and a half, this would provide an incredible opportunity to witness and participate in the entire process of transforming a historic DC-3 into a modernized aircraft.

Alongside my work at Basler Turbo Conversions and my studies at Fox Valley Technical College, I have also continued making steady progress in my flight training. I am currently conducting cross-country and night flights, both of which have helped me develop my navigation, flight planning, and aeronautical decision-making skills. These experiences have challenged me to become a more confident and capable pilot while expanding my understanding of aviation from both the cockpit and the maintenance hangar. I am also actively studying and preparing for my upcoming FAA Private Pilot Practical Test. As I approach this important milestone, I am grateful for the opportunities and support that have allowed me to pursue my passion for aviation. I look forward to continuing to develop my skills as both a pilot and an aircraft maintenance technician.

Reflecting on my experience so far, I am grateful for the opportunities, challenges, and responsibilities I have been given. Each new task has helped me become more capable and confident in my abilities, while also showing me how much there is still to learn. What started as an internship has become an important part of my development as an aviation professional, and I look forward to seeing where the next stages of this journey will take me.

 

Fly high,
Nathaniel Woodard
EAA Chapter 533 Ray Scholar