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Freedom One Detail Project
"Freedom One" was the name given to the Boeing 707 that normally served as Air Force One to the President of the United States, but was used to retrieve the 52 American hostages following 444 days of captivity in Iran. Meguiar's was honored to sponsor a project spearheaded by Jose Fernandez of Superior Shine to restore this significant and historic aircraft to the honorable state she deserves. The plane is now on display at the Pima Air & Space Museum in Tucson, AZ.
When: Feb 9-13
Where: Pima Air and Space Museum, Tucson, AZ
What: SAM 86971 Freedom One, Air Force One, Air Force Two. Paint reconditioning and protecting. Aluminum polishing.
How: Jose Fernandez leading and organizing a volunteer detail team with costs covered by sponsors (Ace Clearwater, AutoGeek, Meguiar’s, AMMO.)
Who: 15 independent professional detailers and detail company representatives
1. Jose Fernandez
2. Jason Rose
3. Kevin Brown
4. Larry Kosilla
5. Chris Jankowski
6. Paul Sparks
7. Anthony Alverado
8. Marcus Godo
9. Felix Nances
10. Eric Harris
11. Nicko Koutavas
12. Greg Nichols
13. Cougar Elfervig
14. Scott Perkin
15. Tommy Salazar
16. Russ Brownfield
17. Bradley Otellio
18. Miguel Robles
19. Christopher Castillo
Safety Certification:
Important to Joe, the team, and the museum was that we had no injuries or vehicle damage on this project. So the OSHA compliance to Fall Protection and Prevention Certification was a big deal on the first day. Before anyone got near the aircraft, we all learned about safety equipment and gear…and practiced using it prior. The museum loaned us some incredible safety apparatus to get on top the aircraft and up high on the sides. This is the only proper way to do aircraft. We did not even have a slip. Had zero injuries or aircraft damage.
Paint work:
Single stage. Very oxidized and chalky. 3 step process on most areas. Sometimes 4 steps on certain areas.
1. D114 Rinsefree Wash, long handle MF mops
2. DA tool, DFC6, M205
3. D156 spray and wipe for protection
Optionally, M205 might have been applied again after the first cut step, but switched to DFP6. This was done on dark color when water marks were still visible after oxidation removal.
Due to surface temp, wind, and lack of humidity…M205 was the choice since it remained long cycle and removed oxidation effectively. M105 short cycled in this environment. M205 was a rock star and the team was amazed at it’s performance and results under the circumstances.
The weapon of choice was primarily the 21mm DA, with some of the work being done with limited availability of MT300 (only 2ea.) A few hard to reach areas were done with PC.
Joe and I did a test spot in early October….that looked like we did it yesterday. So we know this process will be durable for many many months…perhaps years? Dunno.
Metal work:
Uncoated raw aluminum that was scratched up, swirled up from previous rotary process, and severely oxidized. Initially, was polished using metal polish product that Joe brought but it was extremely messy and used it all up. Kevin Brown jumped in with M105/M205 process that produced a better finish, less time, and a lot cleaner buffing. Sum severe parts were buffed with rotary as a first cut step. All finish work was done with DA. The engine covers were removed from the aircraft and polished inside the hanger. This provided a more desirable environment to work in, as well allowed for after dark work with inside lighting.
Process:
1. Rotary/wool pad with M105 or DA 21mm tool with DFC6/M105
2. DA 21mm tool with DFP6/M205
SWA process:
Both metal work and paint work got somewhat challenging in direct sunlight due to surface temp. A spray mist of water while polishing and prior to residue wipe off proved to be a very helpful technique. Thus you will see some spray bottles of water in pics.
Man hours:
Estimated over 560 man hours on the aircraft.
New DA foam discs:
Performed incredibly well. Lower surface temps. Useful functional pad rotations under pressure. Resists loading of the pad. Easy clean up! We cleaned and reused discs 2X daily. Used pad washer and drying rack with the help of the Tucson sun to dry pads.
Post detail paint work:
The museum is currently (as as of this post) repainting the belly and gold stripe down the sides. These areas were not repairable with a reconditioning process as they were too far gone. But after painting this week, the plane will go back on display and look like new.
Special note: A huge thank you to Jason Rose for the write up on the project and for all the images.
"Freedom One" was the name given to the Boeing 707 that normally served as Air Force One to the President of the United States, but was used to retrieve the 52 American hostages following 444 days of captivity in Iran. Meguiar's was honored to sponsor a project spearheaded by Jose Fernandez of Superior Shine to restore this significant and historic aircraft to the honorable state she deserves. The plane is now on display at the Pima Air & Space Museum in Tucson, AZ.
When: Feb 9-13
Where: Pima Air and Space Museum, Tucson, AZ
What: SAM 86971 Freedom One, Air Force One, Air Force Two. Paint reconditioning and protecting. Aluminum polishing.
How: Jose Fernandez leading and organizing a volunteer detail team with costs covered by sponsors (Ace Clearwater, AutoGeek, Meguiar’s, AMMO.)
Who: 15 independent professional detailers and detail company representatives
1. Jose Fernandez
2. Jason Rose
3. Kevin Brown
4. Larry Kosilla
5. Chris Jankowski
6. Paul Sparks
7. Anthony Alverado
8. Marcus Godo
9. Felix Nances
10. Eric Harris
11. Nicko Koutavas
12. Greg Nichols
13. Cougar Elfervig
14. Scott Perkin
15. Tommy Salazar
16. Russ Brownfield
17. Bradley Otellio
18. Miguel Robles
19. Christopher Castillo
Safety Certification:
Important to Joe, the team, and the museum was that we had no injuries or vehicle damage on this project. So the OSHA compliance to Fall Protection and Prevention Certification was a big deal on the first day. Before anyone got near the aircraft, we all learned about safety equipment and gear…and practiced using it prior. The museum loaned us some incredible safety apparatus to get on top the aircraft and up high on the sides. This is the only proper way to do aircraft. We did not even have a slip. Had zero injuries or aircraft damage.
Paint work:
Single stage. Very oxidized and chalky. 3 step process on most areas. Sometimes 4 steps on certain areas.
1. D114 Rinsefree Wash, long handle MF mops
2. DA tool, DFC6, M205
3. D156 spray and wipe for protection
Optionally, M205 might have been applied again after the first cut step, but switched to DFP6. This was done on dark color when water marks were still visible after oxidation removal.
Due to surface temp, wind, and lack of humidity…M205 was the choice since it remained long cycle and removed oxidation effectively. M105 short cycled in this environment. M205 was a rock star and the team was amazed at it’s performance and results under the circumstances.
The weapon of choice was primarily the 21mm DA, with some of the work being done with limited availability of MT300 (only 2ea.) A few hard to reach areas were done with PC.
Joe and I did a test spot in early October….that looked like we did it yesterday. So we know this process will be durable for many many months…perhaps years? Dunno.
Metal work:
Uncoated raw aluminum that was scratched up, swirled up from previous rotary process, and severely oxidized. Initially, was polished using metal polish product that Joe brought but it was extremely messy and used it all up. Kevin Brown jumped in with M105/M205 process that produced a better finish, less time, and a lot cleaner buffing. Sum severe parts were buffed with rotary as a first cut step. All finish work was done with DA. The engine covers were removed from the aircraft and polished inside the hanger. This provided a more desirable environment to work in, as well allowed for after dark work with inside lighting.
Process:
1. Rotary/wool pad with M105 or DA 21mm tool with DFC6/M105
2. DA 21mm tool with DFP6/M205
SWA process:
Both metal work and paint work got somewhat challenging in direct sunlight due to surface temp. A spray mist of water while polishing and prior to residue wipe off proved to be a very helpful technique. Thus you will see some spray bottles of water in pics.
Man hours:
Estimated over 560 man hours on the aircraft.
New DA foam discs:
Performed incredibly well. Lower surface temps. Useful functional pad rotations under pressure. Resists loading of the pad. Easy clean up! We cleaned and reused discs 2X daily. Used pad washer and drying rack with the help of the Tucson sun to dry pads.
Post detail paint work:
The museum is currently (as as of this post) repainting the belly and gold stripe down the sides. These areas were not repairable with a reconditioning process as they were too far gone. But after painting this week, the plane will go back on display and look like new.
Special note: A huge thank you to Jason Rose for the write up on the project and for all the images.
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