Aerospace Structural Assembler, Sikorsky Cockpit Systems

Build the heart of flight

Flextrades is seeking expert-level structural assemblers for 3–5 month travel contracts supporting our manufacturing clients on Sikorsky cockpit programs. These roles require out-of-state travel; current needs are in Florida. We cover travel pay, hotel, per diem, and offer overtime.

To be considered, you should bring 5–10 years of structural assembly experience, with recent hands-on work within the past 2 years.

A day in the life

You’ll step into a fast-paced, fixture-driven environment where multiple cockpit sections are built across coordinated cells. Working alongside up to five mechanics on a unit, you’ll locate and install floors, seat tracks, structural panels, and related components while holding demanding aerospace tolerances.

• Thin-gauge aluminum is your primary medium, with composites and fiberglass also in play.
• Tight tolerances: 0.005–0.008" on solid fasteners, 0.003" on HI-LOKs, 0.003" on holes, and 0.005" on location.
• No electrical, harness, or hydraulic system work—this is pure structure.

How you’ll build

• Follow detailed work instructions (text and sequential images via PowerPoint) for build sequence, hole locations, and drill sizes. You’ll determine appropriate tools/fasteners when not explicitly called out.
• Use specialized tooling, precision alignment methods, and pinned fixture setups to meet engineering specs. Approximately 80% of tasks are fixtured; remaining details are installed off-fixture at the end.
• Perform structural drilling, hole prep, fastening, and assembly to aerospace standards with strong blueprint interpretation.
• Complete required sealing operations (face sealing, encapsulation, fillet seals) and pass an onsite sealant certification that includes classroom training and a hands-on, in-process test.
• Burnish using sanders, Scotch-Brite, burnishing wheels, and brushes to achieve finishes of ~125 (see surface roughness guide).
• Operate remote-controlled overhead cranes in designated areas after training provided by the Safety Training Manager.

Your toolkit

• Countersinks, reamers, rivet guns
• 90-degree sanders, pencil grinders
• Calipers, scales, micrometers
• Rubber mallets, punches, chisels
• Hand and pneumatic squeezes, bucking bars, and select wrenches
• All required torque values are documented for assemblers when torquing is needed

Quality, cadence, and collaboration

• Expect a 32-day average build per cockpit. Most stations/cells run 2–6 takt times totaling ~45–50 hours.
• Quality Department manages inspection requirements; you own first-time quality and throughput on critical flight hardware.
• Assemblies are fixture-based; coordination with up to 5 mechanics on the same unit is common.

Materials and fasteners

• Materials: aluminum, composites, fiberglass
• Fasteners: ABS bolts, Cherry bolts, Lockbolts, HI-LOKs, Jo-Bolts
• Fastener volume: ~50,000 per full cockpit; a sub-assembly often carries 500–600 fasteners; per assignment you may install 3,000–4,000 fasteners

Readiness checks

• Rivet Plate Test required to verify skill, instruction-following, drilling, and fastener installation—including understanding of edge distance, pitch, scales, hole size, and fastener selection. Typical duration: 4 hours to 1 day, faster for fluent sheet-metal pros.
• Experience with tooling fixtures, part placement, and hole location on fixtures is expected.

Preferred background

Aviation structural assembler (no license required) with new build/new manufacturing experience rather than repair.

Core proficiencies

• GD&T
• Advanced Inspection & Gauge Measurement
• Machine Geometry & Alignment
• Machine Setups for Production Runs
• Blueprint Reading

Machines & technologies

• Boring Mill
• Jig Grinder

Why Flextrades

Travel assignments with strong support: paid travel, lodging, per diem, and overtime—so you can focus on building world-class cockpits.