This quote is also from my addendum (supplement) to my first report. (Continued from previous day's quote. These quotes should explain more why I dubbed myself "The Last Inspector". Another item the FAA chose to ignore, at your peril.):
Getting an expert (and ethical in that he will tell you the unvarnished truth, no matter how much that truth will hurt Boeing) tubing inspector from the "Tubes and Cables" group of BCAG, that only inspects tube fabrication all day long, to help you audit our inspection of tubing fabrication at PSD, may be helpful. If the inspectors cannot show you what tool they use to inspect those features, and react in much the same way I said they would react when asked the same question in the above clearance inspection item, then please write us up. Here is a cheat sheet of tools I found while looking for ST tools for the prior item, of tools that we should probably have to do inspections in the tube shop. I realize that ST tools are not valid for inspectors to use unless they have been checked with certified tools. I seem to remember an incident with Boeing "ST" Hilok gauges having to have a green dot on them to be used, I guess meaning that they had been "certified" as OK to use to inspect Hilok pin protrusion by checking their dimensions with a certified measuring device...This issue also has raised it’s head during our Pre-ACSEP cover-up activities. One of the issues our management has identified as a "threat" to getting a finding is this issue of inspection using non-certified "ST" gauges to inspect product, as we have been doing for years on the 747 strut Wiggins fittings installations with the STXXXX (from memory) and STXXXX tools. Of course, if using ST tools to inspect product, the appropriate controls, as we have never had at PSD, will have to be put in place to ensure that these ST tools are valid for inspection use. I believe, from chatter at a previous crew meeting, that (our QA supervisor) has told the 747 strut people that use the Wiggins fitting tools to measure them with calipers when using them as the "fix" to ensure no write-up by you in this area. At least that is what they are supposed to tell you if asked about the subject. Back to the subject at hand. Ask if we have any of these:
STXXXXX-X-X Flareless fitting gage.
STXXXX Ovality gage for 21-6-9 steel tubing.
STXXXXX Ovality Calipers
STXXXXX Ovality Go/No Go Gage
Note: The above ovality tools should probably be available at PSD for inspection of tubing installations also. Ovality of the tube can change due to allowable preload upon tube installation, and I believe our PIs or the (docuiment I.D.) spec states that tubing must still meet ovality requirements upon installation (so the I.D. of the tube is not reduced enough to impact liquid flow design requirements by installation).
The Last Inspector