H922420-13-R-8000_ATTACHMENT_2_Work_Packages.rtf

H92240-13-R-8000

ATTACHMENT 2

WORK PACKAGES

FOR

11M RIB REPAIRS, MAINTENANCE AND UPGRADES

WORK PACKAGE 0001 – LOW LEVEL MAINTENANCE – TRAILER REPAIRS

Note: Report any defective parts found to the SBT IMD supervisors.

Block trailer and remove all wheels.

Support axles and disconnect "U" bolts holding axles to springs.

Disconnect flexible brake lines at caliper and frame ends and drain brake fluid from system. Lines should be blown clean with air.

Remove bleeder fittings from each caliper assembly.

Remove six (6) leaf springs and equalizers from trailer.

Remove three (3) axles from trailer.

Protect and remove brake components on axles prior to sandblasting.

Sandblast equalizers (4 ea), and U-bolt back plates (6 ea) to white metal.

Paint equalizers (4 ea), and U-bolt back plates (6 ea) with gray CeRam Kote 54® in accordance with manufacturer’s specifications.

Prepare and preserve external surfaces of six new MYCO springs with ZRC Worldwide ZRC® cold galvanizing paint in accordance with the manufacturer’s specifications.

Prepare and preserve new axle “U” bolts (24 ea) with CeRam Kote 54® in accordance with manufacturer’s specifications. “U” bolts will be sandblasted and CeRam Kote 54® in accordance with manufacturers specifications taking care to protect the threaded area.

Power tool clean rusty spots and preserve up to ten square feet of trailer frame with ZRC Worldwide ZRC® cold galvanizing paint in accordance with the manufacturers specifications.

Remove existing and install all new reflective tape on trailers IAW OEM.

Install axles and springs with new CeRam Kote’d "U" bolts, nuts, spring bolts, spring bushings and hanger bushings from MYCO Trailers, Inc.

Remove existing and install new wheel bearing seals, wheel bearings, bearing races, disc brakes pads, and brake hoses. Install new hub (six each per trailer) diaphragm, air cap and super sealkit. Refer to NECP 026.

Remove existing and install new brake line hoses Fill brake system (new DOT 5 fluid) and bleed air from lines. Test for zero leaks.

Remove all bunk boards, replacing damaged boards, padding and sail cloth IAW OEM and re-install.

Prepare and preserve bunk brackets and trailer support wheel.

Polish outer surfaces of aluminum wheels, fenders and stowage box to a level greater than 60 GU at 60 degrees and reinstall using anti-seize on lug nuts. Polish type is at contractor discretion.

WORK PACKAGE 0002– MEDIUM LEVEL MAINTENANCE – TRAILER REPAIRS

Note: Report any defective parts found to the SBT IMD supervisors.

Block trailer and remove all wheels.

Support axles and disconnect "U" bolts holding axles to springs.

Disconnect flexible brake lines at caliper and frame ends and drain brake fluid from system. Lines should be blown clean with air.

Remove bleeder fittings from each caliper assembly.

Remove six (6) leaf springs and equalizers from trailer.

Remove three (3) axles from trailer.

Protect and remove brake components on axles prior to sandblasting.

Sandblast axles, springs, spring perches, equalizers (4 ea), and U-bolt back plates (6 ea) to white metal.

Paint equalizers (4 ea), and U-bolt back plates (6 ea) with gray CeRam Kote 54® in accordance with manufacturer’s specifications.

Prepare and preserve external surfaces of six new MYCO springs with ZRC Worldwide ZRC® cold galvanizing paint in accordance with the manufacturer’s specifications.

Prepare and preserve new axle “U” bolts (24 ea) with CeRam Kote 54® in accordance with manufacturer’s specifications. “U” bolts will be sandblasted and CeRam Kote 54® in accordance with manufacturers specifications taking care to protect the threaded area.

Power tool clean and preserve twenty square feet of trailer frame with ZRC Worldwide ZRC® cold galvanizing paint in accordance with the manufacturers specifications.

Remove existing and install all new reflective tape on trailers IAW OEM.

Install axles and springs with new CeRam Kote’d "U" bolts, nuts, spring bolts, spring bushings and hanger bushings from MYCO Trailers, Inc.

Remove existing and install new wheel bearing seals, wheel bearings, bearing races, disc brakes pads, and brake hoses. Install new hub (six each per trailer) diaphragm, air cap and super sealkit. Refer to NECP 026.

Remove existing and install new brake line hoses Fill brake system (new DOT 5 fluid) and bleed air from lines. Test for zero leaks.

Remove all bunk boards, replacing damaged boards, padding and sail cloth IAW OEM and re-install.

Prepare and preserve bunk brackets and trailer support wheel.

Remove existing tilt and jacking cylinders, protect rams and zerk fitting, prepare and preserve with CeRam Kote 54® and install.

WORK PACKAGE 0003 – HIGH LEVEL MAINTENANCE – TRAILER REPAIRS

Note: Report any defective parts found to the SBT IMD supervisors.

Note: No GFM is associated with this work package.

Block trailer and remove all wheels.

Support axles and disconnect "U" bolts holding axles to springs.

Disconnect flexible brake lines at caliper and frame ends and drain brake fluid from system. Blow lines clean with air.

Remove bleeder fittings from each caliper assembly.

Remove six (6) leaf springs and four equalizers from trailer.

Remove three (3) axles from trailer.

Protect and remove brake components on axles prior to sandblasting.

Sandblast axles (3 ea), equalizers (4 ea), and U-bolt back plates (6 ea) to white metal.

Paint axles (3 ea), equalizers (4 ea), and U-bolt back plates (6 ea) with gray CeRam Kote 54® in accordance with manufacturer’s specifications.

Prepare and preserve external surfaces of six new MYCO springs with ZRC Worldwide ZRC® cold galvanizing paint in accordance with the manufacturer’s specifications.

Provide new “U” bolts, nuts, spring bolts, spring bushings, hanger bushings from MYCO Trailers, Inc. Prepare and preserve new axle “U” bolts (24 ea) with CeRam Kote 54® in accordance with manufacturer’s specifications. “U” bolts will be sandblasted and CeRam Kote 54® in accordance with manufacturers specifications taking care to protect the threaded area.

Power tool clean and preserve entire trailer frame with ZRC Worldwide ZRC® cold galvanizing paint in accordance with the manufacturers specifications.

Provide and install all new reflective tape on trailers.

Install axles and springs with new CeRam Kote’d "U" bolts, nuts, spring bolts, spring bushings and hanger bushings from MYCO Trailers, Inc.

Remove existing and install new wheel bearing seals, wheel bearings, bearing races, disc brakes pads, and brake hoses. Install new hub (six each per trailer) diaphragm, air cap and super seal kit. Refer to NECP 026.

Remove existing and install all hydraulic system hoses with new hoses having SS (stainless steel) end fittings. Test for Zero leaks.

Remove existing and install new bleeder fittings.

Remove existing and install new brake line hoses Fill brake system (new DOT 5 fluid) and bleed air from lines. Test for zero leaks.

Polish aluminum wheels, stowage box and reinstall using anti-seize on lug nuts and torque to OEM specs.

Remove existing and install two new fenders. Install new “NO STEP” stickers on both fenders IAW OEM.

Replace all bunks and recover with the new sailcloth material/padding IAW OEM and install with new SST nuts. All nuts will be double nutted and paint striped.

Remove existing and install new winch, cable (1/4” 30’ SST) and hook.

Remove existing and install new air flask.

Remove existing and install new air pressure relief valve. Refer to NECP 028.

Remove existing and install new glad hand pairs of flexible air lines and stowage clips.

Remove existing and install new forward wheel hydraulic cylinder.

Prepare and preserve with CeRam Kote 54® master cylinder, tilt and jacking cylinders, and hydraulic pump, spool valve, and relay valve.

Prepare and preserve bunk brackets and trailer support wheel.

Remove existing and install new jack arm pin (1 each) and tilt pins (2 each) to include chain and retaining pins (OEM specs).

Provide and install new bow chock blocks and SST fasteners. (double nut and paint stripe) Refer to NECP 027.

Remove existing and install new tilt/jack three way valve (total of two valves per trailer). Test for zero leaks.

WORK PACKAGE 0004– LOW LEVEL MAINTENANCE - BOAT PRESERVATION

Remove the following metal components from boat for preservation: (1) Water jet compartment hatches and frames (see note below); (2) 3rd and 4th row slick bolster handrails; (3) fuel priming pumps; (4) console Drop In Communications Package (DICP) breaker bezels and (5) fuel priming pumps.

NOTE: Water jet hatches and frames will only be removed if tread master repairs are also required for that area. If no tread master repairs are required, water jet hatches and frames will be prepared and preserved in-place.

Sandblast all removed components to near white metal.

Apply gray CeRam Kote 54® in accordance with manufacturers specifications to all components Reinstall all components using new SST hardware and pins.

Prepare and preserve the exterior of both water jets with Interlux Trilux 33 Antifouling Bottom Paint in accordance with the manufacturer’s specifications.

Replace drive shaft bearings and seals.

WORK PACKAGE 0005 – HIGH LEVEL MAINTENANCE - BOAT PRESERVATION

Remove the following metal components from boat for preservation:

(1) Hold #1 hatch and frame; (2) Hold #2 hatch and frame; (3) Console hatch and frame; (4) Console handrails (3ea); (5) battery tray; (6) console terminal board plate; (7) console arch securing brackets; (8) Water jet compartment hatches and frames (see note below); (9) engine compartment hatch hinges; (10) Comm station plates; (11) Swim platform strut; (12) swim platform backing plates; (13) 3rd and 4th row slick bolster handrails; (14) 2nd row bolster handrail; (15) 3rd row bolster handrail and mounts (5 ea); (16) fuel priming pumps; (17) console DICP breaker bezels; (18) Radar arch and ground plane; (19) port and stbd engine compartment air intake louvers; (20) forward and aft gun mounts; (21) kingpost; (22) Comm Box foundation; (23) 5 ea. bolster seat mounting brackets; (24) IR strobe/mast light and BFT/MARBAN antenna standoff platforms (2 ea); (25) arch handrail, engine compartment aft hand rail (26) COMM Box foundation.

NOTE: Water jet hatches and frames will only be removed if tread master repairs are also required for that area. If no tread master repairs are required, water jet hatches and frames will be prepared and preserved in-place.

Sandblast all removed components to near white metal.

Apply gray CeRam Kote 54® in accordance with manufacturers specifications to all components

Government Check point: After all arch components have been replaced, SBT-12 will provide test equipment and conduct an air tight test of the RADOM to check for zero leaks.

Reinstall all components using new SST hardware and pins.

Prepare and preserve the exterior of both water jets with Interlux Trilux 33 Antifouling Bottom Paint in accordance with the manufacturer’s specifications.

WORK PACKAGE 0006 – LOW LEVEL PLANNED MAINTENANCE AVAIL (PMA) - BOAT PRESERVATION HULL AND TOPSIDE

Repair damaged bolster upholstery (four square feet).

Repair hull scratches, gouges and nicks caused by trailering and other miscellaneous damage (four square feet).

Repair topside scratches, gouges and nicks (three square foot).

Apply Armorcote Gel Coat, CCP FV 951-AA-438 Gray to all repaired areas in accordance with the manufacturers specifications Apply Armorcote Gel Coat, CCP FV 951-AA-438 Gray to bottom side of engine compartment hatches and around perimeter in trough in accordance with the manufacturers specifications Apply Armorcote Gel Coat, CCP FV 951-AA-438 Gray to forward bolster frames and the five (5) bolster shells in accordance with the manufacturers specifications. Provide and install new foam covers for all hand rails.

Accomplish an all over buff of the boat.

WORK PACKAGE 0007 – MEDIUM LEVEL MAINTENANCE – BOAT REPAIRS HULL and TOPSIDE

Remove sponsons (2 each) and bra Repair hull scratches, gouges and nicks caused by trailering and other miscellaneous damage (four square feet).

Repair topside scratches, gouges and nicks (three square feet) Prepare, sand and preserve throttle, bucket & gearbox bezels.

Apply Armorcote Gel Coat, CCP FV 951-AA-438 Gray to all repaired areas in accordance with manufacturer’s specifications.

Clean Hold #1, remove interferences, apply Armorcote Gel Coat, CCP FV 951-AA-438 Gray to compartment completely in accordance with manufacturers specifications and reinstall interferences.

Clean Hold #2, remove interferences, apply Armorcote Gel Coat, CCP FV 951-AA-438 Gray to compartment completely in accordance with manufacturers specifications and reinstall interferences.

Clean console interior deck, apply Armorcote Gel Coat, CCP FV 951-AA-438 Gray to compartment deck in accordance with manufacturer’s specifications.

Clean under-console bilge area.

Apply Armorcote Gel Coat, CCP FV 951-AA-438 Gray to bottom side of engine compartment hatches and around perimeter in trough, to include port and stbd air intake hoods, in accordance with manufacturer’s specifications.

Remove existing and provide and install all new engine compartment insulation.

Provide and install stainless steel ratchet straps and securing straps in Hold #2 (5 ea) and 72" console securing strap.

Provide and install new canvas radar arch covers (2 each).

Provide and install port and starboard console bags.

Provide and install Global Positioning System (GPS) and Radar monitor cover and track.

Apply Armorcote Gel Coat, CCP FV 951-AA-438 Gray to 3rd and 4th row slick bolsters in accordance with manufacturer’s specifications.

Accomplish cleaning and apply Armorcote Gel Coat, CCP FV 951-AA-438 Gray to engine and water jet compartments (all upper, lower and side horizontal and vertical surfaces) completely in accordance with manufacturer’s specifications.

Strip down, prepare and apply Armorcote Gel Coat, CCP FV 951-AA-438 Gray to bolster frames and the five (5) each bolster shells in accordance with manufacturers specifications Provide and install new velcro and edging and upholstery for bolster shells Remove existing and install new Treadmaster non-skid on forward deck, swim platform and engine covers (GFM Treadmaster sheets) Accomplish an all over buff of the boat.

WORK PACKAGE 0008 – HIGH LEVEL MAINTENANCE - BOAT REPAIRS HULL and TOPSIDE

Remove sponsons (2 each) and bra.

Replace low bow (SST) sponson bra track.

Repair hull scratches, gouges and nicks caused by trailering and other miscellaneous damage (six square feet).

Repair topside scratches, gouges and nicks (four square feet).

Prepare, sand and preserve throttle, bucket & gearbox bezels.

Remove interferences to port and stbd blower motor mount bracket, sandblast to white metal, power coat grey, install brackets using new SST fasteners and install all interferences.

Apply Armorcote Gel Coat, CCP FV 951-AA-438 Gray to all repaired areas to match base in accordance with manufacturer’s specifications.

Clean Hold #1, remove interferences, apply Armorcote Gel Coat, CCP FV 951-AA-438 Gray to compartment completely in accordance with manufacturers specifications and reinstall interferences.

Clean Hold #2, remove interferences, apply Armorcote Gel Coat, CCP FV 951-AA-438 Gray to compartment completely in accordance with manufacturer’s specifications and reinstall interferences.

Clean console interior deck, gunnels, and bulkheads, apply Armorcote Gel Coat, CCP FV 951-AA-438 Gray to compartment deck in accordance with manufacturer’s specifications.

NOTE: Special care should be taken around electrical components and wiring.

Clean under-console bilge area (all surfaces).

Apply Armorcote Gel Coat, CCP FV 951-AA-438 Gray to forward vertical side of transom aft of 4th row slick bolster in accordance with manufacturers specifications.

Accomplish cleaning and apply Armorcote Gel Coat, CCP FV 951-AA-438 Gray to engine and waterjet compartments (all upper, lower and side horizontal and vertical surfaces) completely in accordance with manufacturer’s specifications.

Apply Armorcote Gel Coat, CCP FV 951-AA-438 Gray to bottom side of engine compartment hatches and around perimeter in trough, to include port and stbd air intake hoods, in accordance with manufacturer’s specifications.

Remove existing and provide and install all new engine compartment insulation.

Provide and install a new anchor chain bag in Hold #1.

Provide and install port and starboard Teflon anchor protective tracks in Hold #1.

Provide and install stainless steel ratchet straps and securing straps in Hold #2 (5 ea) and 72" console securing strap.

Provide and install hydraulic container bag in Hold #2.

Provide and install new radar arch covers (2 each).

Provide and install foot pump bag.

Provide and install port and starboard console bags.

Provide and install Global Positioning System (GPS) and Radar cover and track.

Provide and install console splash shield.

Provide and install Port and Starboard aft rope bags.

Provide and install engine compartment stowage bags.

Provide and install 5 each bolster seat pad latch cover straps.

Remove existing and reinstall all Treadmaster non-skid and Ensulite foam on entire deck and on the outboard section of bolster number four. (GFE) Apply Armorcote Gel Coat, CCP FV 951-AA-438 Gray to 3rd and 4th row slick bolsters in accordance with manufacturer’s specifications.

Strip down, prepare and apply Armorcote Gel Coat, CCP FV 951-AA-438 Gray to bolster frames and the 5 each bolster shells in accordance with manufacturer’s specifications.

Provide and install all new upholstery for bolster shells with new velcro and edging and upholstery for slick bolsters.

Remove existing and install new NAV and ENG gauge panels (2 each) and replace with GFE.

Accomplish an all over buff of the boat.

Reinstall sponsors’.

WORK PACKAGE 0009 – MEDIUM LEVEL MAINTENANCE – BOAT REPAIRS MECHANICAL

Provide and install a new acrylic scratch resistant windshield.

Provide and install new DIN rails for the console terminal boards. Remove corrosion, preserve and paint mounting platforms.

Inspect and replace all electrical wafers, spacers and end pieces that show any visual corrosion on wafer/spacer/end piece components or lead connections (GFM).

Government Check point: SBT12 will inspect prior to repairs to damaged lead connections to determine course of action.

Clean the terminals on all console terminal boards, switches and miscellaneous components.

Remove the guide vane chamber disassembling steering nozzle and reversing bucket and replace new (GFM) bushings, locking plates and associated fasteners from port and stbd jets.

Government Check point: SBT12 will inspect scratches/gouges and make determination if port/stbd impeller housings are to be replaced.

If directed, remove existing and install new (GFM) port/stbd impeller housings.

Shim impellers as required to provide proper clearance in accordance with OEM.

Government Check point: SBT to verify proper clearance. (Clearance specification is .004mm to .008mm).

Assemble jets in accordance with OEM.

Remove existing and install blower hoses with new orange hose and aluminum vents (OEM).

Power tool clean and preserve all hydraulic hose fittings in engine compartment and jet compartment.

Flush and replenish jet bearing housings with clean oil as specified by OEM.

WORK PACKAGE 0010 – HIGH LEVEL MAINTENANCE – BOAT REPAIRS MECHANICAL

Provide and install a new acrylic scratch resistant windshield.

Provide and install new DIN rails for the console terminal boards. Remove corrosion, preserve and paint mounting platforms.

Inspect and replace all electrical wafers, spacers and end pieces that show any visual corrosion on wafer/spacer/end piece components or lead connections (GFM).

Government Check point: SBT12 will inspect prior to repairs to damaged lead connections to determine course of action.

Clean the terminals on all console terminal boards, switches and miscellaneous components.

Remove the guide vane chamber disassembling steering nozzle and reversing bucket and replace new (GFM) bushings, locking plates and associated fasteners from port and stbd jets.

Government Check point: SBT12 will inspect scratches/gouges and make determination if port/stbd impeller housings are to be replaced.

If directed, remove existing and install new (GFM) port/stbd impeller housings.

Shim impellers as required to provide proper clearance in accordance with OEM.

Government Check point: SBT to verify proper clearance. (Clearance specification is .004mm to .008mm).

Assemble jets in accordance with OEM.

Remove existing and install blower hoses with new orange hose and aluminum vents (OEM).

Power tool clean and preserve all hydraulic hose fittings in engine compartment and jet compartment.

Flush and replenish jet bearing housings with clean oil.

Replace control cables for port and stbd throttle, shift and bucket. (Total of six cables per craft) Provide and install port and stbd trim tab indicator cables.

Provide and install new port and stbd backflush cables.

NOTE: Ensure backflush valves do not bind. Must operate freely and fully open and close as per OEM.

Provide and install forward & aft spotlight connector caps and chains (2 each).

Remove the battery parallel solenoid and recondition and reinstall.

WORK PACKAGE 0011 – ENGINEERING CHANGE PROPOSAL (ECP) 82

1 Complete ECP 82: Install Impeller Housing Zincs on KaMeWa FF280 Port and Starboard Water Jets OR as designated in each individual task order against this Work Package.

WORK PACKAGE 0012 – PORT AND STARBOARD F/O BLADDER FLANGE

NOTE: ECP 148 provides a point of reference to sections of the repair but not intended as the sole procedure.

Remove existing interferences on port and stbd fuel tank decking/soft patch.

Remove existing port and stbd soft patch lid outer ring fasteners.

After removing the soft patches, clean the top of the fuel cell area as much as possible.

CAUTION: If using any kind of solvent to clean this area, do not allow any solvent to leak in between the fuel cell and the bladder as it could possibly harm the fuel cell bladder and/or foam.

Tag, disconnect and plug hoses as necessary to prevent fuel system contamination.

Remove fuel hoses from plates and console bulkhead.

Remove fuel bladder plates by evenly loosening the ¼” bolts holding the plates to the fuel bladder.

NOTE: OEM recommends media-blasting fuel bladder plates to clean off all of contamination.

Remove all items listed as GFM and install new.

NOTE: When removing gaskets from the fuel plates ensure fuel tank does not get contaminated.

Install new gasket and new fasteners.

Install existing port and stbd soft patch using new hardware Install new Ensulite foam (GFM), treadmaster (GFM) and interferences in console compartment.

Paint any disturbed surfaces as required.

Dispose of all hazardous material IAW required laws and regulations.

WORK PACKAGE 0013 – PORT AND STARBOARD BLADDER REPLACEMENT

NOTE: Replacement of fuel oil bladders may be completed in conjunction with WP 0013A (if required). ECP 148 provides a point of reference to sections of the repair but not intended as the sole procedure.

Remove existing interferences on port and stbd fuel tank decking/soft patch.

Remove existing port and stbd fuel tank tops.

Disconnect and plug hoses as necessary to prevent fuel system contamination.

Remove existing port and stbd fuel bladders and fuel tank block insulation.

NOTE: KTR will document and report damaged areas found on bladders.

Remove all fuel/water and debris from port and stbd fuel tank compartments.

Inspect fuel tank bulkheads for cracks and submit one legible copy, in hard copy or electronic media, of a report listing results.

Install new port and stbd fuel tank block insulation (GFM), fuel bladders (GFM), and fuel foam (GFM) using new hardware and wedges (GFM).

Install new port and stbd tank tops (GFM) and all interferences.

Install existing port and stbd soft patch using (GFM) hardware

Install new Ensulite foam (GFM), treadmaster (GFM) and interferences in console compartment.

Sand glassed areas and clean.

Paint any disturbed surfaces as required.

Dispose of all hazardous material IAW required laws and regulations.

WORK PACKAGE 0013A – NON-ENGINEERING CHANGE PROPOSAL (NECP) 025

Complete ECP 025: NSWRIB Fuel Compartment Bilge Bypass Tube Sealant

NOTE: This item (work package 0013A) will only be accomplished as an ‘if required’ and in conjunction with work package 0013.

WORK PACKAGE 0014 – ENGINEERING CHANGE PROPOSAL ECP 161

Complete ECP 161: Bilge System Vented Loop Installation

WORK PACKAGE 0015 – ENGINEERING CHANGE PROPOSAL ECP 159

Complete ECP 159: Replace marine gear temperature gauge with a marine gear oil pressure gauge.

WORK PACKAGE 0016 – BOLSTER AND FORWARD GUN MOUNT GUN BAGS

1 Manufacturer bolster and forward gun mount gun bags as per provided sample.