Here are  

Don't know what eventually happened but I had heard that the cost estimate exceeded the cost of a new 407:

LETTER FROM BELL HELICOPTER

SPECIAL INSPECTION PROCEDURES

ATTACHMENT A to Letter August 30, 2004


The following actions will be required in order to evaluate the continued airworthiness of Model 407 Serial Number 53078

A. Permanent removal from service is required for the following components:

a. All metal components of the main rotor hub assembly including
the elastomeric components and blade bolts
b. Main rotor mast assembly
c. Boosted main rotor fixed and rotating controls, including the
swashplate assembly and support.
d. Main rotor control hydraulic actuators, and the support casting.
e. Flight control bolts in the boosted control system.
f. Drive system components to include tail rotor drive shafts,
bearings, hangers, flex couplings and splined adapters.
g. Input (Ka-Flex) drive shaft
h. Transmission top case
i. Transmission-mounted flight control bellcranks and support
brackets.
j. Tail rotor mast
k. Tail boom and attach hardware
l. Pylon support structure including the pylon side beams, corner
mounts, longitudinal pitch restraints, stop fittings and
associated attachment hardware.

B. Components requiring complete inspection and overhaul at
Bell Helicopter:

a. Main and tail rotor blades
b. Main rotor yoke assembly
c. Tail rotor yoke assembly

C. Components to be overhauled by a facility suitable to Bell (Bell
Tennessee/CSR):

a. Transmission assembly
b. Freewheel assembly
c. Tail rotor gearbox
D. Airframe inspection by qualified personnel suitable to Bell:
a. Fuselage structure for evidence of cracks or distortion
b. Instrument panel console for evidence of distortion
c. Battery and ballast weight supports
d. Cabin roof beam assembly
e. Roll-over bulkheads

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f. Vertical control tunnel
g. Engine deck for cracks, distortion evidence
h. Tail boom attachment fittings and longerons
i. Horizontal stabilizer
j. Vertical and auxiliary fins

In support of the above return to service action, the aircraft interior shall be removed and other systems and controls as necessary to permit close and rigid visual inspection of the entire fuselage structure as recommended above. Prior to release for return to service, items not listed above shall be inspected in accordance with the basic aircraft 300 hour / annual inspection.

Any material abnormalities or discrepancies identified during the conditional inspection are to be reported to Product Support Engineering - Light Helicopters, for evaluation.

Items listed above that are to be permanently removed from service are deemed unsuitable for use, and shall be destroyed, permanently marked or otherwise disfigured so as to prevent inadvertent installation on an operational helicopter.

Upon completion of the actions above, a written statement should be provided to PSE Light by responsible person(s). Upon review and agreement, Bell Helicopter will issue a Special Conditional Acceptance (SCA) statement to cover the continued airworthiness of the helicopter. This SCA will be provided to the appropriate Regulatory authority with the recommendation to return the ship to flightworthy service.

Reference: Attachment A, JD2004-039