Client: VAZAR

Client Request: The DHC-3 Otter had a history of failures in the elevator servo-tab bellcrank.  VAZAR agreed to address this issue on their turbine conversion to increase safety of the aircraft and meet the newer 23.629 requirement of flutter free after a single failure.  Volant Technica was asked to develop the fix for the servo tab.

Project Summary:  Volant Technica, (a precursor company to Fliegen Works,) worked with the FAA to address this service difficulty and produced the design data, developed loads and a structural test proposal, then DER witnessed the structural test.  We also wrote the flight test plan and helped with the issuance of the TIA.  The STC is a method of compliance to AD 2004-05-01.  Fliegen Works currently holds PMA for fabrication of the redundant servo tab. that includes a 2^nd control rod and other modification to fix in-service failure problem.

Results: STC SA01059SE was granted to VAZAR (as American Aeromotives) and is licensed to Fliegen Works for manufacture under PMA PQ2380NM.

Client:  Mountain View Aviation

Client Request:  Assistance with the certification and structural aspects of the Door Steward on multiple aircraft.

Project Summary: Structural Substantiation and DER approval, PMA Supplement assistance, AML revisions, Compliance Reports.

Results: STC  SA01120SE approved for multiple aircraft including an ever expanding Approved Model List (AML)

 Client: Wilson Construction Company

 Client Request: The linemen working from a rotorcraft needed a handle with an anchor point for their safety harness.

Project Summary: We provided design, detail drawings, structural substantiation, as well as a rotorcraft flight manual supplement –(RFMS).  This included enough data for a coordinated field approval with the assistance of Dave Swan.

Results: Multiple 337 approvals to install handle on helicopters owned by the client.

 Project Name: Rudder Tab On A-1 Series Blimps

 Client: American Blimp Company

 Client Request:  The client requested a fix to balance the aerodynamic torque created by an installed Lightsign on the left side of the blimp’s envelope. 

 Project Summary: We did the preliminary sizing and worked with ABC on the detail design.  Fliegen Works developed the aerodynamic loads, produced a structural test proposal and then DER witnessed the tests.  The design of a fixed tab on a Rudder of  ABC A-1 series airship was a challenge since a number of engineering estimations were made.  From minimal available blimp flight and aerodynamic data and old NACA data an analysis was performed to design a fixed rudder tab that biased the rudder to compensate for the unsymmetrical drag on  the airship due to the Lightsign on one side of the airship.  This was a major change to the type design by the type certificate holder. 

Results: Successful flight testing, installation and approval of rudder tab on A-1 series blimp.  Pilot force required to maintain straight flight reduced acceptable levels. Rather than complex CFD a simple method combined with a little guesswork was applied.  Minimal time and cost was required to produce the required results in this manner.

Summary: Conversion of a CASA C-212 from the passenger only configuration, to a combined passenger and cargo configuration, (Combi).  

———–

Project Name: CASA C-212 Combi Conversion

Client:  FS Air Service

Client Request: Get an STC to modify the CASA C212 for carrying cargo with passengers in the same cabin with multiple configurations.

Project Summary: Fliegen Works Inc. provided a certification plan, compliance checklist, structural substantiation, smoke testing, and DER services in support of an STC project to convert the CASA C-212 aircraft from the original passenger-only or cargo only configurations to a combined passenger and cargo configuration.  The project included a novel approach of using fire containment blankets to segregate the cargo within the passenger compartment using data from the FAA tech center.  This project required the design and installation of new emergency equipment for installation in the cabin as well as a thorough Aircraft Flight Manual Supplement (AFMS). 

Fliegen Works coordinated with the FAA to grant an Exemption to allow the use of building type smoke detectors for fire detection within the fire containment blankets.  This project culminated in TIA for demonstration of smoke detection per 25.857 and ventilation per 25.831.  Fliegen Works built a smoke box per AC 25-9A appendix II, which generates a precise amount of smoke and is available for other projects.

Results:  STC ST02257AK approved for change in type design.