B717 (Formerly MD-95)
Maintenance Repairman
Maintenance Technician 8.5
Communication Breakdown; Time Pressure
Aircraft Equipment Problem Critical; Deviation / Discrepancy - Procedural Published Material / Policy; Deviation / Discrepancy - Procedural FAR; Deviation / Discrepancy - Procedural Maintenance
General None Reported / Taken
Aircraft; Human Factors
Boeing B717 being refurbished by a 145-Contract Repair Station at ZZZ. Aircraft had an Aft Flap Upper Vane repair that is defective.  Per the Boeing B717 Structural Repair Manual (SRM); the final step in a Bonded Metal Repair is that if you find any defect in the repair; remove the repair and start over.  This did not happen.  Because of time restraints; the repair was passed by the Technician; Management; and Non-Destructive Testing (NDT) Inspection.  The repair to Aft Flap Upper Vane is still disbonded and during the post inspection process the repair was discovered to be disbonded in a quarter inch area in the leading edge area of the repair.  Back Shop Manager had convinced NDT Inspector X that the disbond area was not of concern and the NDT Inspector bought [accepted] the repair.  I have huge concerns with the repair.  Not only because it is a flight control; but the area in which it falls; if the repair would fail.  My part in the repair process was very small.  I was instructed by the Back Shop Manager to get this repair done and if I needed any help with Inspection; to call him.  The only thing I needed to do was to install mechanical fasteners and restore [surface] finish.   After the paint had cured; I tap tested the repair; we are supposed to go three steps back; and I found the disbond.  I tested [questioned] Technician X who had worked the bond and asked him if he knew his repair was disbonded.  His reply was that he knew and our boss was made aware of it and convinced NDT to buy-off on the repair because it a 1/4' of an inch disbond.  I am a Non-Certificated (N/C) Mechanic and the Lead Mechanic who signed-off behind me had no notice that this was going on.  I would like to note that both the Back Shop Manager and N/C Technician X knew that this repair was defective and tried to pass it off to secure time; within the time to repair the structure.
A Repairman at an FAA-145 Contract Maintenance Repair Station reports he found a Bonded Metal Repair to a B717 Aft Flap Upper Vane to be defective during a Tap Test in the leading edge area of the vane repair. Repairman also raised concerns the Back Shop Manager pressured the repairing Mechanic and Inspector; who all knew of the disbond; to approve the repair. Safety concerns about an inflight failure of repair also noted by Reporter.