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.