Iron Maiden's Ed Force One is Back in Just Ten Days After Replacing Two 11,000 Pound Engines

When an Iron Maiden tour is in progress, there's nothing that's going to stop its forward progress and that includes two engines being literally ripped apart on their jet.

The band has announced that their plane, Ed Force One, is back in the air just ten days after it was heavily damaged in an transport and refueling incident at the airport in Santiago, Chile. While the plane was being moved for refueling, the steering pin became disconnected and sent the plane, without any way to steer it, into a ground tug, damaging the undercarriage and the two engines. Pictures showed that the bottom section of the engines were ripped apart with jagged metal along the edges. In addition, two airport workers were injured and required hospitalization.

The company that actually owns the plane, Air Atlanta, jumped into action right away and had two engines, weighing 11,000 pounds each, were trucked from Hannover, Germany to Luxembourg where they were put on a plane and flown to Santiago where repairs were done.

The press release from Iron Maiden lays out the entire complex operation:
ED FORCE ONE ONWARDS AND UPWARDS AGAIN

MAIDEN PLANE SET TO REJOIN THE BOOK OF SOULS TOUR IN BRASILIA TOMORROW AFTER MASSIVE REPAIRS COMPLETED IN JUST 10 DAYS

TWO 5000kg, FOUR MILLION DOLLAR JET ENGINES FLOWN 12,000 KM TO REPLACE DAMAGED ENGINES

Following the major accident in Chile (link to previous release on this) on the morning of Saturday March 12, we are delighted to announce that a fully repaired Ed Force One will take off tomorrow afternoon, Tuesday March 22, from Santiago Airport to rejoin the tour at Brasília Presidente Juscelino Kubitschek International Airport. Following the show at Nilsen Nelson Arena, the plane will be loaded up once again on Wednesday with over 20 tons of equipment and our tour personnel to fly to Fortaleza for the concert on Thursday and on from there to Sao Paulo then New York and onwards round the World on The Book of Souls World Tour which visits 36 countries in the five month period.

The accident required the replacing of both of the Boeing 747’s port side jet engines, a tough proposition at the best of times but not made any easier by the fact of the distances involved in getting such huge components, parts, tools and technical crew to Chile as quickly as possible to get Ed Force One back in the air. The engines alone weigh 5000kg each, and cost around four million dollars each.

Ed Force One is leased from Air Atlanta who went into immediate action following the incident, with technical assistance from Boeing. An emergency meeting on the Sunday was called to create a comprehensive detailed plan for this complex operation – locating suitable engines, thrust reversers, cowlings and parts, working out necessary tooling and technical team, logistics of ground and freight transport and tech team travel and a myriad of other detail. All from scratch. The next couple of days were spent putting these plans meticulously into place
The result was that on Thursday last, March 17, a Cargolux chartered 747 freighter left Luxembourg carrying two huge replacement jet engines, trucked there from Hannover, Germany. The Charter stopped over at Stansted Airport, Essex, UK to collect two more consignments. Cowlings and thrust reversers were trucked there in huge boxes from Kemble, UK, along with tooling and consumables flown in specially from Jeddah to Heathrow and hauled to Stansted.

The chartered 747 then completed the 12,000km (7410 miles) flight to Santiago , arriving at 9am Friday morning. The technicians were flown there from Iceland and from Atlanta Air’s base in Jeddah, Saudi Arabia, six in total, to join with EF1’s own two onboard techs, Bjorn Bjarnason and Sigurbjarni ( Barney) Thormundsson, and Jeremy Smith of Rock It Cargo Ltd, who is on tour with us supervising the freight and customs aspects.

The engines were cleared by Chilean Customs Friday lunchtime and they were transferred to the LAN Chile maintenance area of the airport arriving just before 2pm. Working in shifts 24 hours a day the techs were then able to start removing Engine number 1 and then on Saturday Engine number 2. Using hoists and cranes the damaged engines had to be detached then lowered into a cradle in order to swap with the new replacement engines. The replacement engines were then lifted up and into a place. Once the support pylons had been inspected and x-rayed and damage assessed, both of which passed with flying colours, then the new engines were attached with, as one of the techs said, a “ million” wires. Both were finally in place and attached by Sunday lunchtime and then the thrust reversers fitted overnight, almost as complex an operation as fitting the actual engines due to being right under the wing. Final piece of the jigsaw was for the Eddie decals to be fitted and then both engines tested by running to full power.

Comments Bruce Dickinson, Maiden vocalist and pilot of Ed Force One : “The speed and thoroughness of this incredibly complex operation was stunning and we are so very pleased to get our plane back! We would like to thank Air Atlanta and their terrific rescue team for a fantastic effort in achieving this in the time they did, and to Boeing, LAN Chile. ACS and Rock It Cargo for all their invaluable support. We are sorry though for our fans in Cordoba, Buenos Aires, Rio and Belo Horizonte who missed out seeing the plane, but we hope they enjoyed the concerts as much as we did.

We should also thank our Killer Krew who found themselves at lunchtime on the Saturday of the accident with over 20 tons of equipment at the airport in Santiago and over 60 people all to get to Cordoba for early the next day to set up the huge show we are carrying. The distance is “only” 1000km, but with a small matter of the Andes in between! They did it , by the skin of the teeth, and all went very well for the show in Cordoba and the other cities EF1 just missed. It’s quite a feat of logistics to find and put into action at such short notice all the transport, replacement air-charters, schedule flights etcetera to enable us to play those next four shows on time without EF1, our transport for everything. Great effort, team, many thanks from all of us. And to our promoter MOVE and ACS for all their assistance and time with this too“
The original damage:

ED FORCE ONE BADLY DAMAGED ON THE GROUND IN COMODORO ARTURO MERINO BENITEZ (SANTIAGO, CHILE) AIRPORTCONCERTS IN...
Posted by Iron Maiden on Saturday, March 12, 2016

Ed Force One today:


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