A little over a year ago, Sen. Tim Sheehy floated an audacious proposal to reshape the way the federal government fights wildfires. It called for expanding the use of private planes and helicopters to quickly attack blazes while also eliminating the U.S. Forest Service’s rigorous airworthiness inspections for those aircraft.

The idea stood to benefit Sheehy, a Montana Republican, personally. Before running for Congress, he founded and ran an aerial firefighting company called Bridger Aerospace, which is known for its scoopers, aircraft built to retrieve water from lakes or oceans and drop it onto fires. Since 2021, the Forest Service has paid Bridger more than $235 million for use of its scoopers, according to public records.

Sheehy’s ownership of Bridger is well known, but what hasn’t been reported is that the same month the proposal leaked, a Forest Service inspector had discovered a crack in a wing of an aircraft Bridger had presented as ready for service. The scooper had failed the very inspection Sheehy sought to eliminate.

Forest Service inspectors have flagged problems with Bridger’s scoopers for years, according to sources and documents obtained by ProPublica under the Freedom of Information Act. The records were heavily redacted by the agency, including the problem that the inspector discovered last April. But a former government official with direct knowledge of the inspection told ProPublica it had revealed a crack in a wing. “It was a big crack,” the official said. Other experts said that kind of finding is rare and could have proved catastrophic.

“Very seldom do you find a crack in a major component,” said Paul Markowitz, a former national aviation maintenance manager for the Forest Service. Detecting such problems is the reason the Forest Service operates an airworthiness program, he added: “It’s to keep people alive.”

Veteran fire officials noted that Sheehy’s proposals would eliminate costly oversight of the company he founded and others like it while increasing spending on aerial firefighting. At the time the document leaked, he owned Bridger stock worth between $13 million and $15 million.

Within the Forest Service, the company was known to resist oversight, officials told ProPublica. Five current and former Forest Service officials say Bridger Aerospace has chafed at the agency’s rigorous inspections, even as records and sources indicate the company has presented aircraft in need of maintenance and repairs as ready to fight fires. The sources asked not to be named for fear of reprisal.

Bridger did not answer questions about the failed inspection but said in a statement, “Safety is the bedrock of our company, and we spare no expense.” It added, “Our investment in maintenance and training runs into the tens of millions annually and reflects the high safety standard we believe this work demands.”

Bridger’s aircraft have never been involved in a crash, according to records maintained by the National Transportation Safety Board.

Sheehy’s office did not respond to interview requests. But he has been open about his frustration with the Forest Service’s inspections and contended that Bridger’s scoopers, because they are built to fight fire, require less oversight than other firefighting aircraft that were originally designed for other purposes.

In response to detailed questions about Sheehy’s role in reshaping the fire service, a spokesperson for the senator said he stands by his efforts to eliminate Forest Service inspections. The process is “a relic of a bygone era and has become an unnecessary barrier to asset availability,” the spokesperson said in an email. The spokesperson also said that Sheehy has no conflict of interest because he has since moved his assets into blind trusts, adding, “The senator will continue to be adversarial toward anyone protecting a broken status quo that has allowed cities to burn to the ground.”

Former Forest Service officials say it’s common for companies to complain about inspections. What sets Bridger apart is its connection to a senator who is seeking to change how wildfire aviation is managed. A spokesperson for the Department of Agriculture, which oversees the Forest Service,........

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