Celebrations for NZ Aero with the launch of the SuperPac 750XL-II

We were delighted to attend the launch of the SuperPac 750XL-II at NZ Aero, New Zealand’s only aircraft manufacturer on Wednesday 22nd November.

The SuperPac is the newest and improved version of the 750XL aircraft - with a Pratt & Whitney PT6A-140A 900 SHP engine and Hartzell 4 blade 100” propeller. In addition, the aircraft features a state of the art Garmin G600 TXi EFIS and GTN 650 avionics suite.

The extensive flight testing programme has proven that this aircraft is quieter than the basic 750XL and uses 10% less fuel, whilst still having excellent short take off and landing abilities.

In addition, on display was the SuperFalco, created by Andy Stevenson Aviation, the agricultural variant of the aircraft with a Pratt & Whitney PT6A-140AG 900 SHP engine and Hartzell 4 blade 100” propeller.

These new aircraft are suited for utility, parachuting, agricultural use, fire fighting, medevac or providing aid into remote locations.

Flight Structures staff the Design Office for NZ Aero and have done so since the new ownership in 2021. We have had a team of up to six people involved at peak times, scaling up and down as needed. Achieving a Type Certificate amendment is a big deal - there are only a handful of Type Certificates in the history of aviation in NZ. We also acknowledge staff and contractors from previous years who contributed to this project.

Flight Structures have worked with Andy Stevenson for many years and helped him gain the STC for the first Falco aircraft, currently in use around NZ. The contribution of Andy was honoured on the day along with that of Brian Hare, a previous owner.

There were a fleet of aircraft on display representing the history of the predecessors to the 750XL.

There was significant media coverage for this wonderful event and we offer our congratulations to the team at NZ Aero both for the launch event and for the tenacity to see this project to completion.

For the One News article please view here

For the Newstalk ZB interview with NZ Aero CEO Stephen Burrows please listen here.

For the Newshub coverage please view here

For the Waikato Times article please read here

To view some coverage of the launch event please click here

Two STC for the FALCO XL

Flight Structures was delighted to receive confirmation of the upgraded Supplemental Type Certificates (STC) for the FALCO XL from the Civil Aviation Authority of NZ.

The FALCO XL was originally developed in 2011 when Andy Stevenson identified the need for an aircraft with a hopper with greater capacity, larger opening and greater endurance to suit the Farmers Air terrain around Gisborne and the East Coast.  Since the development and issue of the original STC, several Falcos have been in operation up and down NZ. But up until now, the FALCO upgrade was only embodied on older aircraft that were converted to agricultural use.  The 2020 STC allow for embodiment in brand new aircraft with the partnership with the OEM, Pacific Aerospace Ltd.

The STC are both owned by Andy Stevenson Aviation. Partners on this significant project include Flight Structures Ltd, Andy Stevenson Aviation, Pacific Aerospace Ltd, and Hamilton Aero Maintenance. Flight Structures role was to lead the design, certification and liaison with the CAANZ.

The FALCO XL has a 3000L Hopper with a  hydraulically actuated hopper lid, hydraulic gatebox, and a wire strike kit.  The payload is 2200 kg and the aircraft has full factory airframe support.

If you are interested in more information about the FALCO XL please contact Andy Stevenson on +64 212 463 355 or andy@asal.co.nz

Thank you to David Roberts from Pacific Aerospace Ltd for the photos.

STC GAINED FOR MODIFICATION OF 750XL FLAP SYSTEM.

Farmers Air, one of New Zealand’s leading agricultural aircraft operators, came to Flight Structures to design a new flap system for their PAL 750XL aircraft.  The standard flap actuation system is electrically actuated contained under the cabin floor, which is practical for utility aircraft.  However this was proving to be mechanically unreliable due to the high cycle nature of agricultural operations and maintenance intensive. 

Flight Structures redesigned the flap system to be located above the cabin floor and hydraulically actuated.  The flap system and hydraulic components were sourced locally in Hamilton. 

Flight Structures was responsible for the design and certification of the hydraulic flap system.  We worked closely with Farmers Air Personnel for design advice and Aeromotive who were responsible for embodiment.  

The result of this project has been a significant improvement in aircraft reliability and reduced maintenance costs. 

FALCO 3000XL AGRICULTURAL AIRCRAFT SET TO IMPROVE PRODUCTIVITY, CREW COMFORT, AND SAFETY.

Flight Structures, working with Farmers Air Ltd, have designed and approved a major modification to the PAL 750XL airframe, christened the FALCO 3000XL. The main design features are a lightweight 3000 litre carbon fibre hopper, 2000 kg payload and a new streamlined light weight cowling with improved air filtration.

The FALCO 3000XL builds upon the proven ability of the Pacific Aerospace aircraft, including the Fletcher, Cresco, and 750XL to offer a replacement aircraft for those no longer in production. The 750XL cockpit has been further improved and offers excellent leg room, a quieter environment and better ergonomics for a less fatigued pilot.

The aircraft also features a large hopper lid to minimise spillage, Agricultural GPS and GPS Tracking equipment, and a substantially revised fuselage structure which integrates the hopper as load bearing structure.

The Supplementary Type Certificate for the Farmers Air Ag Conversion of the 750 XL has been issued.   Flight Structures completed all the design, project management, flight testing and CAA requirements, working closely with Farmers Air pilots and engineers.  Partnering companies were Aeromotive, Pacific Aerospace Limited, Av Parts and Composites International.

The 750XL was modified by removing unnecessary weight, installing a light weight high strength carbon fibre hopper, and incorporating a barrier air filter into the streamlined cowl.  Farmers Air pilots were heavily involved in the design and their input influenced modifications to increase the rudder power for improved cross wind performance and reducing the elevator forces to reduce pilot fatigue.   The aircraft has a 2200 litre hopper capacity with a 2200kg payload.  Crunch the numbers and you will find the Falco3000 is the least expensive platform to spread fertilizer by air.