That time a senior inspector told me to stop cleaning spark plugs

I used to always clean fouled spark plugs with a wire brush and some solvent, thinking I was saving the airline money. Then about 6 months ago at a 737 gate call in Denver, a senior inspector watched me do it and just said 'You're just wasting your time and risking the threads.' He explained the micro-abrasions from the brush can create hot spots and lead to pre-ignition. Now I just replace them on the spot and send the old ones back for proper reconditioning. Has anyone else had old-timer advice that actually changed your daily workflow?

2 comments

2 Comments

diana15521d agoTop Commenter

Had a similar lesson about 10 years ago with a hydraulic line. Used to just clean up old O-rings if they looked okay and slap them back in. Old mechanic named Hank caught me doing that on a flap actuator and pretty much took the O-ring right out of my hand. He showed me how even a tiny scratch you can barely see with your eyes can turn into a leak at 3000 PSI. Now I never reuse any seal or O-ring, no matter how good it looks. Been zero comebacks on my hydraulic work since then.

ray_mitchell21d ago

Diana155’s story about O-rings really hits home with this idea that a lot of maintenance shortcuts just aren't worth the gamble. It’s funny how the same lesson applies to stuff outside work too, like not reusing old screws when assembling furniture because they strip easier. The senior guys have usually learned the hard way that doing it right the first time saves more time and money in the long run.