MARINE CORPS AIR STATION MIRAMAR, Calif. -- When one thinks of high-tech fighter aircraft technology-jet engines, avionics, computers and mechanical systems-exterior painting and the effects of corrosion rarely come to mind.
Over the past two months, the Red Devils of Marine Fighter Attack Squadron 232 have received 12 replacement F/A-18C Hornets in preparation for future operations at sea. But before the Hornets can continue to operate in the harsh marine environment in the fleet, it's been up to VMFA-232's corrosion control team to paint and get the new Hornets ready for duty with the Red Devils.
"The Hornets we had reached their cat-trap lifespan," said Lt. Col. Michael H. Burt, commanding officer, VMFA-232. "Essentially the launch bar and the tail hook experience enough wear that the airframe can't handle carrier landing anymore."
The new Hornets, previously with the Navy's Strike Fighter Squadron 137, have not reached their cat-trap lifespan and were delivered to Miramar from VFA-137, but were in need of repainting, said Staff Sgt. Markus Lill, fixed-wing aircraft airframe mechanic and corrosion control supervisor, VMFA-232.
"Basically what we're doing is stripping down the base-coat, repainting it and putting on new tactical markings using stencils," said Lill. "The paint we use is a high-tech polyurethane that coats and protects the aircraft from the corrosive effects of the sea environment. Fighting corrosion is a constant battle."
Lill, a native of Nurnberg, Germany, said before any painting can be done, the aircraft is cleaned and looked over for any signs of corrosion and if any is found it has to be removed, usually using rotary sanders or hand sanding.
Some of the aircraft from VFA-137 needed a lot of touch-up work, said Lill, who added that if the aircraft is in poor enough condition, it is sent to Naval Air Station North Island for further work.
"The whole process takes a lot of time," explained Lill. "First we prep, then paint, repaint and stencil. We spend roughly 10 hours a day for six days before one aircraft is done and so far we've completed eight including the flagship."
The first aircraft to be completed was the Red Devils' flagship flown by their commanding officer, and previews a new look-a black and red airbrushed devil complete with pitchfork.
"The new devil looks awesome," said Burt. "They really did a great job."
Lill, who joined the Marines to experience military life before getting a job with Boeing, said Sgt. Santos N. Marrero, airframes night crew supervisor, VMFA-232, painted the new devil.
"Not only do these jets look better, but the repainting also adds to their lifespan in the fleet," said Lill.
According to www.globalsecurity.org/military/systems/aircraft/f-18cd.htm the F/A-18 C/D aircraft are reaching their specified design limits faster due to increased operational usage. The Hornet was originally forecast to have a service life of 20 years. This life estimate was based on an average of 100 carrier landings per year and aircraft experiencing normal loads resulting in aircraft fatigue.
After the Gulf War, the A-6E Intruder retired and the F/A-18C assumed its mission on carrier decks. National commitments required increased operational capability, so the F/A-18A was gradually replaced at sea by the more capable F/A-18C, which has become the carrier workhorse during the past decade, causing an accelerated wear rate.