Fabricating F-16 Fighting Falcons

  • Published
  • By Senior Airman Derek VanHorn
  • 35th Fighter Wing Public Affairs
MISAWA AIR BASE, Japan --  You hear the adage "team effort" in reference to all sorts of operations.

A running back finding the end zone is the result of a team effort that began with a play call from the quarterback and was executed by linemen and receivers blocking defenders to create an opening. Rushing to the rescue of millions across the world after a natural disaster is the team effort of Airmen through the air, Sailors over water and Soldiers and Marines on the ground.

Here at Misawa, successfully flying thousands of F-16 Fighting Falcon sorties is the result of the team effort of hundreds of Airmen working together before takeoff.

One group of Airmen here that help make up that team, and make the sorties look good - literally - is the 35th Maintenance Squadron Fabrication Flight.

Every sticker, decal, panel, paint job, wing number - basically, anything you can see on an F-16 -- is made right here in their warehouse workspace. About 20 Airmen, working around the clock, make more than 40 jets flight-ready and keep them looking factory-new.

Staff Sgt. Montez Lee, 35 MXS, said part of the job is "a lot like doing body work on a car, except on a jet.

"If something cosmetic goes wrong - there's a dent in the hood, bumper, or a crack in the frame - it comes to us and we repair it," he said.

Lee said crew chiefs inspect each aircraft before and after flights, and reach out to necessary shops for fixes. The fabrication flight is one of the most-called shops on the flight line, illustrating their importance to the jets.

"We're responsible for every part; from the metal aspect, tubing, the hydraulics, fuel lines, air lines and more," Lee said.

Along with repairs, the crew - which includes facets of corrosion, nondestructive inspection and metals technology - also has the capability to create critical parts of the jet from the ground up.

"We can make whatever we need to," said Senior Airman Phillip McDaniel, 35 MXS. "Typically, we use each machine every day."

The crew inherits jobs that can last a few minutes or sometimes even a few months, McDaniel said.

Airmen here work specifically with F-16s, the primary aircraft that drives the 35th Fighter Wing's Suppression of Enemy Air Defenses mission.

"If this shop didn't exist, these jets wouldn't fly," Lee said. "Structural integrity is a huge part of our mission here. If anything is structurally wrong, jets can't get in the air. Without it, it's a bad day."

The phrase "structural integrity" is used often around the folks who work sheet metal, and rightfully so. It's the simple way of breaking down the intricate details that are required for the aircraft's prevention and maintenance demands.

"The structural integrity of an aircraft lies in corrosion control," said Staff Sgt. John Wyatt, 35 MXS corrosion control manager. "Just like anything else, degradation and rust happens over time. If the jet isn't protected, it's not going to last."

The final stop for many parts is the metals technology section, where Airman 1st Class Montana Engelking, 35 MXS, said they focus primarily on machine welding.

"If no one else can repair a part, we can," said Airman 1st Class Jonathan Brown, 35 MXS. "We're multi-faceted and can fabricate parts for all different types of jobs."

These Airmen make these jets last, and for some F-16s here, they've helped keep them efficient for more than 20 years. Though they know their importance in the Wild Weasel mission, fabrication Airmen are quick to share the spotlight with a team that's made of many parts.

"This line of work takes everybody," said McDaniel. "No one shop is the best; we're all one team. Everyone does what they need to do to keep our jets flying."

The flexibility of these aircraft and all the necessary moving parts make the variety of each task always-changing. The workload, however, usually remains the same - and that's not necessarily a bad thing.

"The work it takes to keep every jet in the air is never-ending," said Lee. "But when a job comes in and you meet a deadline, and someone comes by to inspect your work and can't tell the difference between parts made here or straight from the factory - that's when you can take ownership and know you helped to make that sortie happen."