NORTH ISLAND, Calif. –
Fleet Readiness Center Southwest (FRCSW) has launched one of the most ambitious and groundbreaking new initiatives in the FRC enterprise: the full overhaul and recoating of F/A-18 nose landing gear (NLG) shipsets. What began in 2021 as a seemingly impossible task, one with no existing technical data, processes or playbook, has evolved into a model of innovation, teamwork and enterprise-level problem-solving that directly supports the president’s National Defense Strategy.
Until recently, FRCSW repaired landing gear components individually as they came off the aircraft. Now, the command processes entire shipsets of landing gear at once, inspecting, disassembling, recoating, reassembling and returning them to the fleet as complete, tested assemblies. The overhaul cycle, performed every six to eight years, represents a fundamental transformation in how FRCSW supports readiness.
When this new workload began, no organization—not FRCSW artisans, the original equipment manufacturers (OEMs) or any other military commands—had established processes for these repairs. FRCSW engineers, artisans and leaders developed everything from scratch: technical data, tools and standard operating procedures. Every element, from how to transport the landing gear to how to reassemble it, had to be created. More than 150 new routers were generated for previously untouched parts. A router, a type of work order, is an internal document that tells personnel where a part is going and what needs to be repaired. FRCSW personnel translated complex external technical data into precise, executable steps. The team’s creativity shone through on every front. Dan Doyle, FRCSW production manager, devised a colored coding system that streamlined part tracking. Angela Gutierrez, FRCSW production manager, restructured limited shop space and personnel to support the new workload. Gary Rice kept production control and logistics on track, Spencer Leonard coordinated the project to ensure visibility of every task and Aaron Wilcher engineered efficient kitting systems that cut turnaround times.
Even amid government shutdowns and logistical challenges, the team identified alternate facilities, adapted timelines and sustained mission-critical tempo.
Under the leadership of John Kucharski, F/A-18 Fleet Support Team (FST) landing gear engineer, and the materials lab, FRCSW developed a revolutionary primer-wipe technique to replace an unavailable, specialized chrome seal, a major breakthrough validated by the OEMs and now considered a huge engineering win for the Navy, Marine Corps and industry partners.
The command also leveraged the expertise of its award-winning Cold Spray team, using advanced “supersonic metal spraying” to rebuild corroded aluminum housings and bridge shortages in manufacturing new parts. This innovation is another readiness multiplier for the fleet.
FRCSW’s success is rooted in strong, collaborative partnerships. The command’s ongoing partnership with Boeing on NLG shipsets is now entering its second contract, with weekly meetings and a workload that has more than doubled.
Collaboration with Heroux-Devtek Incorporated, Safran and Naval Supply Systems Command ensures parts move to whichever organization can execute each part of the process most efficiently, creating a fully integrated enterprise system focused on speed, accuracy and warfighter impact.
To date, FRCSW has completed three main landing gear shipsets and one NLG shipset, with production increasing to 18 full sets per year. This is in addition to the command’s established workload of more than 2,400 parts processed annually, a testament to the workforce’s tireless commitment and technical mastery.
Through determination, skill and teamwork, FRCSW has set a new standard in readiness and operational support, demonstrating that when challenges arise, Americans rise higher.
