Aircraft Subassemblies

Our careful attention to design detail ensures that our subassemblies meet the demands of both specialized function and ease of installation and removal. Whether it's the use of aluminum honeycomb for light-weight strength, or accessible nuts and bolts for rapid installation, our subassemblies are designed and built for functionality and convenience.

Completed and Certified Projects

Tow Reel:

Problem: Design and fabricate a mechanism to unwind, tow and rewind a small, in-flight target behind a corporate jet.

Solution: We built a winch that could reel in 10,000 feet of cable in 10 minutes (approximately 17 feet per second). Part of the design challenge was to develop a level-wind mechanism that could receive the cable at high speed and in continuous, evenly distributed coils. The gears are designed to precisely synchronize the spooling speed with the width of the cable, and a system of pulleys compensates for cable that is angularly disposed to the axis of the spool. A manual brake mechanism protects the motor when the winch is not in use. Accessible nuts and bolts allow quick and easy attachment to a removable escape hatch on the lower fuselage.

Heat Exchanger:

Problem: Design and fabricate a versatile heat exchanger to air cool LRU's (Line Replaceable Units) and interface with the available, liquid-based cooling system.

Solution: This removable, self-contained heat exchanger uses a built-in blower to force ambient air across the liquid-cooled radiator and into a multi-port plenum. The air exits the unit through three generic holes that have flanges and clamps for SCAT tubing hookup to the LRU's. The unit is attached to the plane's built-in, liquid cooling system with hydraulic fittings.

Antenna mount

Problem: Design and build a versatile, light-weight, interface structure from which to mount large antennae to the side of a fuselage.

Solution: This unit had to be strong, light-weight and rigid. Honeycomb aluminum sheeting was custom-designed and fabricated with a skin thickness that was strong enough to meet the bearing load requirements of the attachment bolts. The large structure accommodates a variety of antennae configurations and is covered by a side-looking radome when operational.

more images...