< PreviousBased in the ‘Super Air’ hangar at the entrance to Hamilton Airport, Central Aero Engineering is a perpetually busy and interesting place to be. Company owner Paul Waterhouse says the hangar is always full of a wide variety of day to day maintenance and interesting project work. It’s true that you never know quite what you’ll see when walking through the door. Most likely there will be a helicopter of some sort perhaps undergoing a major check or overhaul, an amateur build project will be on show (the team offer lot of support to homebuilders), something from GA will be in for a check, there might be a Fletcher or Air Tractor waiting to return to topdressing duties, something vintage made of wood and fabric might be in one corner, and there might also be a balloon basket or inflated envelope undergoing an inspection. Most of this work is in the capable hands of Manager and Chief Engineer Stephen Grainger and his team, allowing Paul to spend time on the consultancy side of the business and supporting clients seeking help with “all things aviation, including managing regulatory requirements”. Services and Capabilities Central Aero’s services cover everything from pre-purchase inspections worldwide, shipping handling, CoA preparation and issue, airworthiness reviews, maintenance, repair and restoration of all flying machines, 24 month avionics checks, dynamic prop balancing, weight and balance services, maintenance control Hamilton’s Central Aero Engineering covers the maintenance spectrum for private and air transport operators, accident and incident investigation, parts and materials supply, and builder support. Central Aero is microlight and recreational friendly and sees various home-builts (fixed-wing and rotary) in for annuals and other support on a regular basis, as well as the same for hot air balloons and gliders. Support is also provided to owner/builders when time comes for initial CAA inspection and registration requirements. Maintenance control is provided for a variety of local Waikato operators, as well as a “logbook fixing” service for private operators who need assistance from time to time. Independent maintenance auditing and logbook auditing services are also available by request. Central Aero’s approach is one of ‘Delivering fair value’. It’s an approach that draws commercial and private operators, and a regular stream of home builders and microlight aircraft owners needing advice from time to time. “We’ll always try to help,” says Paul. “If you own it, or fly it, no matter what it is, from hot air balloons, to twins and helicopters, piston engines and turbines, give us a call for any advice or support you need.” Paul is also willing to provide support to trainee engineers sitting their exams, particularly from the point of view of covering legislation and how logbook entries should be made. “We can help explain what is being achieved with correct logbook completion and what they should be looking for,” says Paul. Stewart Systems Distributorship Central Aero are distributors for Stewart Systems waterborne systems for covering and painting aircraft. The Central Aero Team are very experiencd in fabric work from minor repairs to restoration projects requiring a complete fuselage strip and repaint. Enough stock is carried to cover at least a whole aircraft though it is always a good idea for customers to get in touch ahead of requirements to ensure specific stock can be ready when needed. Paul says he has found Stewart Systems to be great to use and wouldn’t go back to the alternatives; “If you make sure the viscosity and application method is exactly to the instructions then you can expect a great finish. We really enjoy using it.” For more information Phone the office on 07 843 1200. Contact Paul on 021 743 033 email: paul@centralaero.nz or contact Stephen on 027 278 8765 email: stephen@centralaero.nz or visit www.centralaero.nz Vintage wood and fabric repairs. KiwiFlyer Magazine Issue 95 40 Helicopter Maintenance Aeroplane Maintenance Maintenance Control Services Light Sport Aircraft Maintenance Amateur Built Aircraft Maintenance Microlight and Autogyro Maintenance Rotax Maintenance Balloon Inspections Avionics Checks Propeller Balancing Airworthiness Reviews Digital Vibration Analysis Advice and support for all things aviation or visit centralaero.nz for more information KEEPING YOU FLYING Now distributing Stewart Systems waterborne products for covering and painting aircraft Balloon maintenance. KiwiFlyer Supply and Maintenance Annual Feature 07 843 1200 1 Ingram Rd, Rukuhia, Hamilton 021 743 033 paul@centralaero.nz 027 278 8765 stephen@centralaero.nz Office Paul StephenAlongside, but independent of Central Aero Engineering, is Central Aero Electrical Limited. Central Aero Electrical was founded by Martin Ross in 2008. In 2019 Martin’s son Hamish took over as CEO of the company. Hamish is a LAME who has several years of aircraft servicing experience and of repair and overhaul of electrical components, including mechanical actuators and “running a company with an emphasis on service”. The company has extensive experience in starter/generator overhauls from 150 to 400 amp models of the three main manufacturers, with Hamish fostering business relationships with many overseas companies in support of this and the variety of other work that Central Aero Electrical undertakes. “There’s always a lot happening on the workbenchs,” says Hamish. “We’ve developed a useful reputation for getting our minds around unusual problems and designs.” There are many occasions on the books where components that might normally have been replaced, have instead been repaired (at considerable cost saving), delivering satisfaction to the Central Aero team and also their customers. And if they don’t already have an answer, the team’s connections can usually help. Central Aero Electrical has a comprehensive range of diagnostic equipment and a large test bench that will handle up to 12 cylinder magnetos. Capabilities cover a good range of starter/ Central Aero Electrical exchange components. Central Aero Electrical solve all kinds of problems generator, control unit rectification and overhaul work, along with 500 hour magneto inspections (usually completed with a one to two day turnaround). Mechanical actuator overhauls for various rotary and fixed wing types are also a regular job. Starter/generator work is also a common request, from helicopters through to Saab 340s. Dimmer control and EPO box (engine power out) test equipment is also to hand. An extensive equipment list includes a balancing machine utilised for dynamic balancing of armatures for optimal performance of each generator and electric motor. This dynamic balancer has very high accuracy and can be used for armatures and rotating machinery of many different sizes. Numerous exchange items are available, and Central Aero Electrical also stock a variety of parts for re-sale including starters, batteries, alternators, strobe units, starter/generators, GCUs, voltage regulators, ignition switches, and HT ignition harnesses. In many cases the company is able to deal directly with a component supplier, thus bypassing the aircraft manufacturer’s mark-up which they are happy to pass on as a saving to the customer. For more information Contact Central Aero Electrical on 07 843 2936, Hamish on 027 493 9975, Martin on 027 733 0208, or email: hamish@centralaero.nz Major inspections. Project support. Helicopter servicing. Amateur-built support. 41 2023 #8KiwiFlyer Magazine Issue 95 42 Martin, Josh and Tony with the finished 500 outside their hangar. Aircraft Painting the way it should be For many aircraft owners their aircraft is likely to be one of the highest value items they own. When time comes to refinish the aircraft with a new coat of paint, the job deserves to be done exceptionally well. However aircraft are big and controlled- environment painting facilities are small, so compromises are often made and work is often done in less than ideal conditions. Also to consider is the question of who is doing the painting; do they understand aircraft and have aviation in their heart, or are they just working on whatever turns up on the day. There are professionals out there, but there are certainly times when anyone with an attentive eye could look at paintwork on a million dollar helicopter and wonder who did that… and not from a complimentary point of view. It’s the opposite case at Tony Antonievich and Josh Adams’ company, Auto and Aero Refinishers Limited. Work coming out of their expansive facility at Waiau Pa near Ardmore will have people asking who did that, from the point of view of (insert favourite expletive) that looks good. Aviation and painting experience With 40 years of painting experience behind him and having worked in the industry for many years as an aircraft engineer, Tony is well known in aviation circles. Tony holds a CPL(H) and a PPL, has owned various helicopters over the years (500s being the favourite) and is the current keeper of Boeing Stearman ZK-TGA. Tony says he “retired” to the rural Waiua Pa property 20 years ago, but kept accepting work and subsequently developed the facilities that are now on the property including a 600 metre airstrip. Nephew Josh who is a 50% partner in the business with Tony brings 20 years of painting experience. They’re supported by Martin and Taylor with another 50 years of experience between them. Alongside the aircraft, the team are also car enthusiasts and as Tony says on a tour of the hangars, “Our focus is on refinishing aeroplanes and helicopters, though there is quite a bit of car restoration going on here too.” As Tony also says, “There aren’t many shops where the painter owns and flies aircraft so as well as the benefit of our aircraft engineering and painting experience, customers also get the passion and care for the job that comes from being an aircraft owner. You can be sure that we’ll look after your aircraft very well.” Facilities to do the job right Tony explains the importance of painting in a controlled environment: “For years aircraft have been painted in sub-standard conditions because aircraft are so big - often in dusty cold hangars or outside. But modern high-performance coatings demand a controlled environment if they are to perform as intended. Coats needs to be applied within specified timeframes and with uniform temperatures and conditions so they properly key to each other - and to achieve the quality of finish an aircraft deserves. “There’s a lot more science to it now than when I started my career and there are an infinite number of options for customers to consider. Just about everyone wants a special colour which will require a base coat and then a two-pack epoxy clear. Prior to all of that we will have applied an etch-primer and then a two-pack epoxy primer. Most aircraft have graphics and the best outcome is always to paint these on which can require more layers and some very complicated masks. “It is imperative to be applying paint in perfect conditions to manage the curing process and avoid issues with the immediate finish and appearance of the job - and also later after the aircraft has been exposed to the elements over time. “All the coatings we use are approved for aircraft. We have paint suppliers involved in the process and providing guidance if required, and because of their confidence in our work they also warrant their product for our customers. “On site at Waiau Pa we have a 4 x 8.5 x 3.5 metre high controlled-environment helicopter and parts booth. For fixed- wings we’re about to complete a 12 x 12 metre prep booth completely separated from the fixed-wing painting facility which is even larger at 18 x 15 m and is also heated as a controlled environment. We also have a 5 x 8.5 metre media- blasting room. “And it’s worth noting that we have a dedicated painting team. The whole team can devote to a job to get it done quickly if required. Two of us live on site here.” Recent work Recently leaving the hangar is HTZ, a 500E operated by Eastern Heli Services out of Gisborne. The owner’s proposed scheme was of metallic grey with a camouflage pattern over the tail and fading into the fuselage. There were uncertainties however, regarding how KiwiFlyer Supply and Maintenance Annual Feature43 2023 #8 to achieve this and how the transition between solid colour and camouflage would look. In a show of dedication to the cause, Josh spent a weekend painting the very same scheme onto his own ute as a practice run. The result looked stunning and convinced the 500 owner that his job was in the best possible hands. Another easily recognisable aircraft which the team had a hand in completing (they painted the fuselage) is Richard Hood’s Pitts Special, recently on the cover of KiwiFlyer issue 92. Also worth a mention is an exotic creation taking place alongside Tony’s Stearman in the hangar which melds a Cessna fuselage to a Rotec radial engine and an RV tail… For more information If the decision factors are aircraft engineering and painting experience, an aircraft-sized controlled environment to ensure a perfect finish, a passion for aviation, and a fair deal, then Auto and Aero Refinishers are an obvious solution when looking for the right person to paint your aircraft. In Tony’s words, “We’ve got the facilities and experience, low overheads, our own airstrip and we can offer real value for money.” Get in contact with Josh on 027 913 7530 or Tony on 027 290 5400, email: autoandaerorefinishers@gmail.com One of Martin’s specialties is air-brushed artwork. Everything in this image is painted. Layer one of the camouflage scheme.Spraying a Pitts Special fuselage.KiwiFlyer Magazine Issue 95 44 KiwiFlyer Supply and Maintenance Annual Feature Aquamax has been using its unique process to strip paint and corrosion from aircraft for over twenty years. During that time the company has stripped many hundreds of fixed and rotary wing aircraft across a wide range of types. The process involves using very high pressure (25,000 psi) water directed through very fine nozzles on a rotating head to effectively cut the coatings from the substrate. Unlike regular water blasting, low flow rates are used so that the reaction load on panels is minimal. The results are described as stunning with little or no abrasion to the surface and corrosion ‘dug out’ of pitted areas. As well, the needle jets are able to excavate pitting which can be very difficult with manual methods. The process uses only filtered, clean water without chemicals, abrasives or scrapers and can be easily completed outside. Aquamax has been employed to work on a number of historic aircraft as part of the restoration process. The most spectacular of these was the complete stripping of the Short Solent Mk IV Aircraft Paint Stripping using High Pressure Water ‘Aranui’ which was undertaken for MOTAT in 2018. The aircraft was operated by TEAL between 1951 and 1960 on the Coral Route, regarded as one of the most romantic scheduled air services in the world linking Auckland through to Tahiti via Suva and Apia. A valuable benefit of using this method was the uncovering of the Solent’s original livery set out which was revealed beneath the existing paintwork. Details of this amazing discovery have now been added to the aircraft’s record. “Any other paint stripping technique would have destroyed this livery and we may never have known it was there,” says MOTAT’s Collection Project Manager Peter Fisk. “As the only remaining Short Solent Mk IV in the world, ‘Aranui’ is incredibly precious and important to New Zealand’s aviation history. The technical advice, specialised equipment and highly skilled operators supplied by Aquamax have been invaluable to the success of this project.” Further information is available on Aquamax’s website www.aquamax.co.nz or contact Chris MacKenzie on 021 586 322. Original EMPIRE markings exposed on the Short Solent.Stripping progress on a helicopter. 45 2023 #8 Call Liviu: (09) 296 2354 or (09) 268 1199 or 021 048 7055 e: liviu.filimon@liviuavionics.com For all aircraft Avionics and Instrument Equipment l Biennial avionics inspections, repair, calibration and tests l Part 145 certificated l 27 years work experience in New Zealand www.liviuavionics.com Est. 2003When it’s time for a Prop Overhaul Your prop is coming due for overhaul, but what is involved and can you stretch its current life a little longer? As with most aircraft maintenance, the overhaul process is comprehensive and neglecting or extending manufacturer TBO limits could lead to larger costs down the line or in the worst case, unsafe operating conditions. Oceania Aviation’s Prop Shop located in Hamilton is a Part 145 certificated facility with over 41 years of collective experience working on fixed, variable/controllable pitch and feathering props for major brands such as Hartzell, McCauley, Sensenich and MT. KiwiFlyer recently caught up with Carey Pyper, Production Lead at the Prop Shop, to discuss the specialty work they do. Carey describes the process from arrival to departure in nine steps: 1. The measuring bench Aluminium alloy has long been the propeller material of choice and it is the most common type we see at Oceania, ahead of steel. With the industry utilising composite-based material more than ever before, we are also seeing composite blades appearing on more aircraft as owners make the switch to capitalise on weight savings, noise reduction and longer service life. In the case of the aluminium prop, it is first fixed onto a measuring bench and set-up angles are recorded. Leading edge and face alignments are checked, while chord width and thickness is measured at pre-determined stations and compared to manufacturer minimums. 2. Disassembly In some cases, the use of special tooling is required for disassembly of specific propeller models. We’re on the lookout for damage at this time because it isn’t necessarily obvious and may only become apparent during a complete propeller disassembly and overhaul. The process always follows a strict procedure, for example in the case of hydraulically controlled constant speed props, care must be taken to ensure associated pitch change components are kept with the corresponding blade which they relate to. 3. Prep for visual inspection The propeller blades, hub and internal components are cleaned so that they are free of grease and sealants, in preparation for visual inspection according to the overhaul manual. All O-rings, gaskets and attaching hardware are mandatory replacement parts and therefore are scrapped during this process. Any paint on the blades or hub is removed in our strip bay. 4. Visual inspection At this stage, the internal components are checked for wear and inspected in accordance with manufacturer overhaul documentation. Any items showing signs of wear beyond limits will also be replaced with some manufacturers offering overhaul kits that make ordering replacement parts an easy process. 5. Non-Destructive Testing Once the aluminium blades and hub have been stripped of paint, they are taken through an etch process in preparation for non-destructive testing (NDT). Most manufacturers require that aluminium blades, hub and specific internal components are fluorescent dye penetrant inspected while the internal steel components and in some cases steel hubs, are magnetic particle inspected for signs of cracking/stress. These processes work by identifying any cracks or damage that has formed during the propeller’s previous overhaul cycle. In the case of aluminium blades, indications will show up from any stone chips or nicks, and in some cases, slight cracking can be seen in the tip region of the blade, emanating from a nick in the leading edge. If any evidence of cracking can be found near the blade ferrule, this is cause for concern and the blade will be retired from service. 6. Rework A special twisting jig is used to tweak and twist any blades that require the blade-to-blade angles adjusted slightly. This jig brings the necessary blades back into specification and aligns them with the other blades. 7. Protection from corrosion At this stage the blades are ready to be ground down and all traces of corrosion, pitting, nicks and gouges are removed. Once all defects are removed, the blades are balanced against each other to ensure they are the same weight. After a hand polish, the blades and hub are cleaned, then a chemical conversion coating is applied to ensure adequate protection against corrosion. This coating also works as a suitable surface for the application of paint. External steel components such as counterweights and hub clamps receive a cadmium plating to ensure a great level of corrosion protection until the next TBO. 8. Paint The blades and hub are painted to the manufacturer’s specifications and left to cure overnight before final assembly. 9. Final assembly The job finishes with a final assembly and then the propeller angles are set. A bench test is carried out to ensure that everything operates as it should before a final static balance on the balance rig to ensure that one blade doesn’t weigh more than the other. Decals are applied and the job is dispatched back to the customer. If required, the hangar team can also carry out dynamic balancing – measuring and attending to the vibration of prop and engine assembly while in operation. For more information For all propeller repair and overhaul requirements, contact Carey Pyper at Oceania Aviaiton on +64 7 858 0338, email: carey.pyper@oal.co.nz To find out more about Oceania Aviation’s extensive range of rotary and fixed-wing MRO services, visit oceania-aviation.com KiwiFlyer Magazine Issue 95 46 KiwiFlyer Supply and Maintenance Annual Feature47 2023 #8 Carey PyperSet of 4 Hartzell blades ready for final paint. McCauley prop being static balanced after assembly. Five Hartzell blades bent in a prop strike, ready to be straightened out and overhauled. Inspection of a Hartzell 2-bladed compact hub during final assembly. DC-3 propeller undergoing inspection. www.aerofix.co.nz Helicopter & Aeroplane Maintenance Microlight & Homebuilt Maintenance I.A. - Review of Airworthiness Maintenance Controlling & SMS Insurance Assessments Structural Repair/Rebuild Specialists Aircraft & Component Painting Capability Remote/Mobile Maintenance Services CONTACT JAMIE ROBERTSON ENGINEER - DIRECTOR - NZ/AUS LAME & I.A. 027 467 8908 | engineering@aerofix.co.nz Located at Rangiora AirfieldKiwiFlyer Magazine Issue 95 48 Located at Rangiora Airfield, Plane Worx is a maintenance organisation backed by the extensive military and civil experience of its two principal engineers Chris Burton and Mark Saunders. Chris started Plane Worx in 2019 initially contracting his services overseas on ATR aircraft. More recently he has teamed up at Rangiora with Mark and his company, Air Repair Taranaki which Mark founded in 2004. Together, they offer: l Aircraft and helicopter maintenance l Accident and damage repairs and rebuilds l Component Overhauls and Upgrades l Avionics installations and maintenance l Annual and hour-based checks including magnetos l Reviews of Airworthiness l Aircraft and helicopter refurbishment and painting l Maintenance planning l SID and pre-purchase inspections l Free advice Chris began his career in the RNZAF, working on the Aermacchi MB 339CB. After leaving the Air Force he worked on GA and topdressing aircraft, and the smaller airliners. A contracting period followed in Australia on C130 Hercules for Qantas Defence and F18 Hornets for Boeing. As well as undertaking Quality Management and Chief Engineer roles, plus being a licensed engineer and IA, Chis also holds a PPL and enjoys recreational flying, with shares in several aircraft. Also a licensed engineer and IA, Mark got his first taste of aviation in the RNZAF some 50 years ago, carrying out group servicing and structural repairs on transport and fighter wing aircraft. That led to servicing the Iroquois fleet with the Multi National Force and observers in the Sinai Peninsula. He was later attached to the HMNS Canterbury, servicing the Wasp Helicopter. 1984 saw a shift to the civilian world, with an organisation undertaking refurbishment and repair work on Bell 206 Jet Rangers for corporate clients. Chief Engineer roles followed for ag companies operating all manner of helicopters from the Sikorsky S55, Bell & Kawasaki 47s, Bell UH-1 series, the Hughes 300 & 500 series and Robinson R22 & R44s. Work with other operators involved Long Rangers and the Eurocopter Range including the EC120, plus Agusta 109 and 119s. Mark’s focus Maintenance by Plane Worx at Rangiora “You do the flying. We’ll sort everything else.” hasn’t been entirely rotary wing however. He is also rated on many fixed-wing aircraft from small Cessnas to the Saab 340. Between them and with closer to 100 years aviation experience than they like to admit, Chris and Mark hold ratings on: l All fixed wing aircraft below 5700kg - Metal aircraft - Tube and fabric aircraft - Composite aircraft - Microlight aircraft - Single and twin engine aircraft - Normally aspirated piston engines - Turbo / supercharged piston engines - Rotax engines - Radial engines - Fixed and retractable undercarriage aircraft l All piston powered helicopters l Most turbine Helicopters Although based at Rangiora, Plane Worx looks after aircraft for private and commercial operators all over the South Island. Fixed- price annual inspections are available for most aircraft and ARAs. Chris says, “We can tell you how much your inspection will cost - including up to four hours of defect rectification - before you roll it into our hangar. If the inspection reveals large defects, we will always contact you to talk over the options before any repairs.” Plane Worx can also undertake Janitrol heater annual checks and pressure tests, and also offers a comprehensive pre-purchase service. Chris strongly encourages customers to discuss their plans to acquire an aircraft with them before going out looking or purchasing themselves; “We can offer advice on what to look for on a particular model - we’ve worked on most of them - and if the customer is warming to a particular aircraft then we can have a look at the machine and offer advice on its maintenance status. “We’re a small operation – boutique perhaps – but we have huge experience, we offer personal service and we do quality work.” For more information Contact Chris on 021 615 401 or planeworx@gmail.com. Mark is available on 0274 508 132 or airrepair@xtra.co.nz Visit Hangar 93 at Rangiora Airfield or go to www.planeworx.co.nz “ Whether you operate a single aircraft or manage a large fleet, we can tailor a maintenance programme for your specific needs. Customer satisfaction and safety are at the core of our values alongside exceptional service, transparent communication, and competitive pricing. We offer the utmost care for your aircraft! ” Maintenance Accident repairs & rebuilds Component Overhauls & Upgrades Avionics installations & maintenance Annual Reviews of Airworthiness Annual & hour-based checks incl. magnetos Refurbishment & painting Maintenance planning SID and pre-purchase inspections Free advice Visit us at Hangar 93, Rangiora Airfield Chris Burton 021 615 401 planeworx@gmail.com Mark Saunders 0274 508 132 airrepair@xtra.co.nz KiwiFlyer Supply and Maintenance Annual Feature49 2023 #8 Visit us at 6 Mustang Lane, Wanaka helicraft.co.nz Modifications and Role Equipment for MD369 and AS350 Snow shoes, Instrument panels, Pneumatic door openers, Frost lights, Position lights, and more. Helicopter Maintenance at Wanaka for 25 years + Specialists for R44, Bell 204/UH-1, Bell 206, AS350, MD500/520. Helicopter Parts in stock now New, used-serviceable and overhauled parts for AS350, MD500 and R44 including many critical items for AOG support. Rod Price 021 400523 rod@helicraft.co.nz Andrew Dennison 027 7537831 chief.engineer@helicraft.co.nz Factory engines cylinder Kits genuine spare parts autHorised distriButors For lycoMing and continental aerospace tecHnologies CONTACT US AT AVIATIONPOWERSUPPLY.COM.AU or by email to: bob@aviationpowersupply.com.au NEW ZEALAND Contact our NZ Agent Superior Air Parts NZ on 09 298 8992 for a quotationNext >