A $0.60 O-ring on a 737 bleed valve ate my whole Saturday
Spent 9 hours chasing a pressurization write-up at the hangar in Tulsa only to find the O-ring I reused during the last check had a nick the size of a hair, and now I want to know if anyone else has a rule for when to toss a seal versus when to gamble on it.
Oof, that hurts. Nine hours for a hair nick is brutal, and I feel for you. I used to gamble on seals all the time until one bit me on a fuel pump and I spent a whole weekend on my back in a cold hangar. Now my rule is simple: if a seal has been squeezed once and I can see anything at all with a light and a magnifier, it goes in the trash. A sixty cent part is never worth a day of my life, no matter how good it looks.