Aircraft Modifications

We design and fabricate modifications for all types of aircraft, including military and experimental aircraft, airliners, turbo-props and light planes. Examples include skin and bulkhead penetration, reinforcements, feed-throughs, hard-points, mounts and attachments. FAA forms 8110-3 and 337 available.

Completed and Certified Projects

Hard Points Structure:

Problem: Design, fabricate and install on an airliner a removable hard points structure to support an external stores rack.

Solution: This structure was designed to attach to existing baggage bin tie-down points. The point load data for these tie-down locations are available in the manual and their use minimized the structural alteration of the aircraft. The modification involved cutting holes in the aircraft skin and reinforcing the surface structure with external doublers. Rubber seals were added between the external stores rack and the internal structure. This unit weighs 230 pounds and can be removed by two people in about 20 minutes.

Heat Exchanger:

Problem: Develop and build a heat exchanger for cooling R&D equipment with high heat production.

Solution: The heat exchanger supplies equipment cooling capacity with cooling air from three different sources; all flow configurations use the same exit vent on the side of the aircraft. In-flight cooling is obtained by directing cold, ambient air through an external scoop, across the heat exchanger and out the exit vent. This modification involved cutting holes in the aircraft skin to serve as intake and exit vents and reinforcing the surface structure with doublers. Fifteen intake and twelve exit holes were spaced between the stringers and frames so that the internal structure of the aircraft remained intact. Ground cooling is accomplished in two ways: the unit includes a hook-up for hoses to a standard, ground cooling cart and also a blower fan that routes outside air through the unit. This multi-functional, high-capacity heat exchanger weighes less than 125 pounds and can be installed quickly and easily.

Fuselage Opening:

Problem: Add two, large pressurized windows to aircraft fuselage for camera portal.

Solution: The project involved cutting a large hole in the skin of the aircraft; modifying and strengthening the surface structure with three large doublers; cutting and removing the stringers and replacing four of the original frames with thicker, machined frames; and adding structures to hold the large camera and stabilize the camera platform. This project was done while strictly maintaining the structural integrity and shape of the aircraft with custom shoring and pressure sensors to monitor the low deformation requirement of the fuselage.

more images...