"Sheet-metal artist" applies his talents to the Super Star

The Lockheed Super Star project is a unique catalyst for bringing out the specialist knowledge available within the Lufthansa Technik Group. From the production of fuselage bulkheads to the overhaul of landing gears or the spot welding of door elements – again and again specialist technicians and engineers from within the Group are demonstrating their outstanding skills within the context of the Super Star project.

A good example of this knowledge pool that resides within the Lufthansa Group is the team recently sent over to Auburn from Lufthansa Technik Budapest. The six skilled metalworkers currently working on site are primarily occupied with the fabrication of metal panels for the fuselage. These are being teased into shape using an "English wheel" in the production hangar next to the aircraft. To build the dolphin-shaped, curved fuselage with its different radii and curves, the Hungarian team are having to exercise all their skills on a daily basis.

For a long time it was unclear how to recreate Super Star's rear pressure bulkheads, with their extremely complex shape. The first few attempts proved fruitless until Gyula Nagy (46) of Lufthansa Technik Budapest offered his services and proved a true master of his profession. Within just three weeks he built what previously had appeared impossible, at the same time adhering to all the strict requirements of Project Engineering and the FAA. When asked about the recipe of his success, Gyula Nagy explained: "Before I joined Lufthansa Technik Budapest in 2002 I worked in a family-owned car body business. There I learned the best way of getting metal panels into the required shape."

The secret of his success consists basically in stretching the sheets to be shaped into a specially built wooden frame, as a result of which they retain their stability when worked on manually. The execution, which is of excellent quality and also meets all the safety requirements, is entirely down to his personal talents. This he demonstrated additionally during the production of the door frame for crew door one right. His "work of art", which for a long time looked as if it would be virtually impossible to produce without a deep drawing press, came from a single piece, apparently effortlessly.