Twin Otter Seaplane Soda Blasting
Aircraft Corrosion Removal & Surface Preparation
The Twin Otter has long been recognized as one of Canada’s most reliable and versatile float planes, serving both commercial and recreational aviation for decades.
Originally introduced in 1965 as a utility bush plane for Canada’s North, the aircraft quickly became a staple of regional airlines and remote operations due to its durability, short takeoff capabilities, and rugged airframe design.
Between 1965 and 1988, hundreds of Twin Otters were built, and the aircraft remains in production today. Thanks to the strength and longevity of the airframe, older Twin Otters are rarely scrapped. Instead, they are routinely refurbished and overhauled to extend their service life—often flying for decades beyond their original build date.
This particular Twin Otter float plane was flown in from Ontario to undergo a complete overhaul.
Corrosion from Harsh Operating Conditions
Years of operation in Ontario’s winter climate had taken a toll on the aircraft. Exposure to moisture, freeze-thaw cycles, and de-icing conditions led to corrosion buildup on several key components.
Affected areas included:
Undercarriage assemblies
Wing surfaces
Aluminum pontoons
Because these components are critical to both flight performance and safety, corrosion removal had to be thorough while protecting the integrity of the aluminum panels.
Soda Blasting Selected for Aircraft Surfaces
Ocean Pacific Media Blasting was called in to perform soda blasting on the aircraft. Soda blasting was selected specifically for its gentle abrasive properties, making it well-suited for sensitive aluminum surfaces commonly found on aircraft.
Unlike more aggressive media, soda blasting removes corrosion and surface contamination without pitting, warping, or thinning aluminum panels. This makes it ideal for aviation applications where material preservation is essential.
Advantages of soda blasting for this project included:
Safe removal of corrosion without damaging aluminum
No heat transfer or structural stress
Minimal surface abrasion
Easy cleanup with water-soluble residue
Precision Work on Critical Aircraft Components
Ocean Pacific crews carefully soda blasted the undercarriage, wings, and pontoons to remove corrosion that had accumulated over years of service. The controlled process ensured that only corrosion and surface contaminants were removed, leaving the underlying aluminum intact and ready for inspection, repair, and refinishing as part of the overhaul.
This approach allowed maintenance teams to assess the true condition of the airframe without the need for unnecessary material replacement.
Supporting Long-Term Aircraft Service Life
By using soda blasting rather than mechanical grinding or harsh abrasives, the project preserved the structural integrity of the aircraft while significantly improving surface condition. The result was a clean, corrosion-free foundation ready for the next phases of maintenance and refurbishment.
This project demonstrates how specialized media blasting plays an important role in aviation restoration—supporting safety, extending service life, and protecting high-value aircraft components through controlled, non-destructive cleaning methods.
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“Saleem is a very safe, dedicated, conscientious, and talented worker in this field.
-Greg Cruickshank
Project Brief
Soda blasting gently removed years of corrosion from a Twin Otter seaplane, protecting aluminum aircraft surfaces during overhaul.
Client Name
Twin Otter Float Plane
Category
Abrasive Blasting
Location
BC, Canada
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