The Duncan Download Blog: Business Aviation Advice & Observations

Duncan Aviation Releases March Duncan Intelligence

Posted by Duncan Download Blog on Thu, Mar 09, 2017 @ 09:00 AM

Have you heard about the Honeywell HTF7500E Stator Vane Seal Inspection Program? How about the cause behind those intermittent software failures on your Avidyne EX-500 MFD? 

No? Then you haven't read the March issue of the Duncan Intelligence. 

 March Duncan Intelligence

Falcon 7X Flap Rigging Precautions

 Caution is needed when rigging the flaps on a Dassaut Falcon 7X aircraft.

ADS-B Solution for Bombardier Challenger 800/850 SE Aircraft

 This was an industry-first installation in the United States and was performed in the customer’s hangar.

Honeywell HTF7500E Stator Vane Seal Inspection Program

 This inspection program is applicable to the HTF750E model engine.

Why Is My Avidyne EX-500 MFD Experiencing Intermittent Software Failures?

 Completing a proper shutdown every time will prevent this.

Got a crack in your APU Exhaust Support? Don’t Replace It. Repair It.

 Duncan Aviation has AWS D17.1 certified welders and inspectors on-site, all capable of welding all types of materials for aerospace applications.

The NBAA Tech Committee Wants To Hear From You

Progress can only be accomplished if we have regular interaction with and feedback from you, the Citation operator.

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The Duncan Intelligence is a free, technical newsletter for business aircraft owners and operators. Written in-house by Duncan Aviation's technical representatives, each edition includes technical tips and advice on topics and trends in business aviation. It is a free, monthly e-mail subscription for aviation enthusiasts around the world.

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Tags: Avionics & Instruments, Engine Maintenance, ADS-B, Falcon, Challenger

An Industry First: STC for CPDLC/FANS Systems on a Challenger 601 3A/3R

Posted by Mark Francetic on Wed, Jan 27, 2016 @ 01:58 PM

FANS.jpgDuncan Aviation recently received Supplemental Type Certification (STC) from the Federal Aviation Administration (FAA) for an industry-first Controller Pilot Data Link Communications/Future Air Navigation System (CPDLC/FANS) 1/A+ installation.

The installation is an affordable solution that features the upgraded NZ-2000 Honeywell Flight Management System (FMS) that integrates with current Challenger 601 3A/3R Original Equipment Manager (OEM) flight decks.

We believe our installation is unique to the industry being a completely integrated Honeywell FMS solution for the Challenger 601.This upgraded Honeywell FMS satisfies all current NextGen mandates for FANS/CPDLC, and is an integral part of our ADS-B OUT, and WAAS LPV programs. This solution provides Challenger 601 operators with a cost effective solution to meet the coming mandates.

The CPDLC/FANS upgrade also demonstrates Duncan Aviation’s commitment to its customers to keep their aircraft flying in airspace around the world. The Honeywell system integrates with current Challenger 601 3A/3R flight decks and is forward-fit compatible with future mandates.

We’re committed to offering our customers cutting-edge solutions. This Honeywell system is designed to accommodate future mandates we may see for United-States airspace. We’re anticipating mandates for ADS-B IN and an updated version of Link2000 and CPDLC in the United States. Right now, these systems are used primarily when flying over water and through EU airspace, but when future mandates are issued for U.S. airspace, this Honeywell system will already be ready for the upgraded equipment.

For more information about this unique solution, visit for program details.

For more information about NextGen requirements and solutions, please visit Duncan Aviation’s NextGen page at

Mark Francetic is Duncan Aviation's Regional Avionics Sales Manager.He specializes in educating business aviation operators about NextGen Mandates by hosting Free seminars across the United States. 


Tags: Challenger, NextGen, FANS 1A

Challenger! Learjet! King Air! Oh My! Gear Sets Are Landing at Duncan Aviation

Posted by Diane Heiserman on Thu, Feb 05, 2015 @ 12:16 PM

Landing-gear-shop-fullA near-record number of landing gear sets and components are in-house at Duncan Aviation’s accessories shop in Lincoln, NE.

According to Tony Curtis, landing gear team leader, seven full sets of landing gear and a “whole slew” of individual components, such as struts and oleos, have filled the shop and kept the schedule very busy. All shifts are working tirelessly overhauling or inspecting gear sets and components from Challenger 300, Challenger 604, Challenger 601, Learjet and King Air aircraft.

Although three sets have been completed and already shipped back to operators, Jon Hein, accessories service sales rep, says the workload doesn’t appear to be letting up anytime soon. “Over the next several weeks, many more sets and component parts are scheduled to arrive.”

Because an aircraft can’t go anywhere without its legs, Duncan Aviation has invested heavily in the landing gear customer more than doubling its Accessories shop area, gaining approximately 6,300 square feet of service area, doubling its work benches and adding new tooling and in-house capabilities, including an overhead crane and a new paint booth with curing room.

In 2014, they acquired the capabilities to completely overhaul and repair landing gear for both commercial and business Embraer aircraft. With the necessary technical data, maintenance manuals and aircraft landing gear parts, Duncan Aviation’s Accessories Services has received and successfully overhauled two sets of Embraer gear to comply with the 144-month landing gear restoration.

Take a moment and watch this before and after ERJ-145 overhaul video.



Tags: Parts & Accessories, Learjet, Landing Gear, Challenger

Duncan Aviation Receives Award for the Second Consecutive Year

Posted by Diane Heiserman on Wed, Oct 23, 2013 @ 07:00 PM

Contributed by Kaela Paseka, graphic design lead

Bombardier ASF Award 2013(2)

L to R: Bombardier Aerospace Vice President, Aircraft Service Centers, Stan Younger, Duncan Aviation’s John Biever, Aaron Hilkemann, Rod Christensen—Manager Airframe Service and Bombardier’s Director, Authorized Service Facilities, Chris Milligan.

On Wednesday during the National Business Aviation Association (NBAA) Meeting and Convention in Las Vegas, Nevada, Duncan Aviation was again recognized by Bombardier as a top authorized service facility for its support of Bombardier customers. Judged on a set of criteria that included quality, compliance, customer satisfaction and customer influence, Duncan Aviation’s Battle Creek, MI, facility was named the winner of the North America category of the 2013 Bombardier Authorized Service Facility Excellence Awards.

Bombardier Aerospace Vice President, Aircraft Service Centers, Stan Younger spoke to the award winners at a private ceremony at NBAA. “It is our ASFs attention to quality and their dedication in providing customers world-class service and support that is being recognized today. Each winner demonstrates a commitment to putting customers first,” said Younger.  

Duncan Aviation President Aaron Hilkemann and John Biever, Vice President Airframe Services in Battle Creek, Michigan, accepted the award from Stan Younger and Chris Milligan, Director, Authorized Service Facilities for Bombardier.

“We enjoy representing Bombardier and their products in supporting of our mutual customers. It is a great mutually beneficial partnership that has worked for many years,” says John Biever.

More than 30 Duncan Aviation representatives are attending NBAA this year, representing several Duncan Aviation services, including airframe and engine servicespaint and interior modificationsavionics and parts support and aircraft sales and acquisitions.

Stop by the Duncan Aviation NBAA booth #C8543 to congratulate Aaron, John and the rest of the Duncan Aviation team.

Kaela Paseka is Duncan Aviation's Marketing Graphic Design Lead, and is currently attending NBAA 2013 at Duncan Aviation booth #C8543. She began her career in aviation in 2006.

Tags: Conventions & Exhibitions, Announcements, Learjet, Challenger

Duncan Aviation Represents on a World Stage at Ebace 2013

Posted by Diane Heiserman on Tue, May 28, 2013 @ 12:02 PM

Submitted by Diane Heiserman, Web Marketing

Duncan Aviation at EBACE

Duncan Aviation representatives stayed busy during EBACE 2013.


A week ago the 2013 European Business Aviation Convention and Exhibition (EBACE) in Geneva, Switzerland, got underway with 460 exhibitors lining the halls of the Palexpo ready to meet and greet all the delegates attending the show. Duncan Aviation, in Stand #327, was among them.

According to Arjen Groeneveld, Duncan Aviation’s Regional Manager for Europe and Russia, because EBACE is the biggest show in Europe, it is very important that Duncan Aviation be at the show and have representatives on-site available to talk with customers. “Every year Duncan Aviation’s name recognition in the European business aviation market is more well-known than the year before. This is because, as a company, Duncan Aviation works hard to make the connections, offer the best value in aircraft maintenance and then follows through with the highest quality of work promised.”

Arjen goes on to say, “because the European business aviation market is so small, everyone knows and talks to others and passes along their opinions and critiques of who and where they did business, both good and bad.” Duncan Aviation has a good reputation in Europe and many customers have let us know how much they enjoy working with us.

Arjen had specific goals during the show to establish and strengthen relationships with European customers and business aircraft management companies by introducing them to Duncan Aviation’s representatives in attendance from from Battle Creek, Michigan, and Lincoln, Nebraska.

Interior Craftsmanship in Action

Challenger 350 mockup

A Challenger interior mockup completed by Duncan Aviation on display at EBACE 2013.

During EBACE, Duncan Aviation was pleased to provide attendees with the opportunity to see some of the company’s interior craftsmanship and capabilities as Bombardier Aerospace unwrapped their Challenger 350, an upgraded Challenger 300 with a new wing, more powerful engines, larger windows and redesigned interior. The Challenger 350 aircraft mockup was completed by Duncan Aviation and was on display in Bombardier’s stand.

“Collaborating with Bombardier for the mockup display of its Challenger 350 aircraft was an honor,” says Mark Cote, Duncan Aviation’s Vice President of Completions and Modifications. “The aircraft promises to be an astounding addition to the Bombardier business aircraft line-up and we are pleased that we could help them share their vision with this beautifully completed interior mockup.”

Business Aircraft Service & Support

Duncan Aviation provides premier business aircraft services–delivered on time–for a wide variety of business aircraft to customers around the world. Download Duncan Aviation's International brochure here.

Diane Heiserman leads Duncan Aviation's blog, and attended EBACE 2013 in Geneva, Switzerland. She began her career in aviation in 2006.

Tags: International Considerations, Interior Refurbishment, Conventions & Exhibitions, Customer Service, Challenger

Challenger Landing Gear Hidden Corrosion

Posted by Diane Heiserman on Tue, Feb 26, 2013 @ 08:02 AM

Contributed by Jerry Cable, Accessory Tech Rep

Challenger landing gear requires a detailed inspection at 60 months for the 600 and 601 and 96-months for the 604 and 605. It must then undergo a 120-month restoration for the 600 and 601 and 192 month for the 604/605.

The reason for these inspections is to check for cracks, wear and corrosion. Years of water, dirt, salt air, fluid and various other electrolytes have taken their toll. The gear is very susceptible to corrosion and even though steps may have been taken to lessen the effects, some corrosion still forms.

Corrosion is normally found throughout the gear but can often be repaired using standard repair schemes available in the CMM or through engineering concessions. Sometimes, however, the corrosion has exceeded the limits of those repair tolerances.

Some of the more severe corrosion found during these inspections is detailed in the following photographs.

Challenger MLG Trailing Link

MLG Trailing Link CL600/601

  • Axle Bore corrosion found in 35% of the restorations we perform.*

Challenger MLG Side Strut Pin

MLG Side Strut Pin CL600/601

  • Corrosion on OD radius found in 50% of restorations.*

Challenger MLG Hinge Pin

MLG Hinge Pin CL600/601

  • Corrosion on the ID mating with brake line swivels found in 70% of the restorations.*

Challenger MLG Oleo Pin

MLG Oleo Pin CL600/601

  • Corrosion on the ID found in 65% of the overhauls.*

Challenger MLG Oleo Cylinder

MLG Oleo Cylinder CL600/601

  • ID corrosion found in 50% of the restorations.*

Challenger NLG Main Fitting

NLG Main Fitting CL600/601

  • Corrosion under steering sleeve found in 50% of restorations.*

Challenger NLG Plunger Tube

NLG Plunger Tube CL600/601

  • Corrosion, lower band mating with axle found on 75% of restorations.*

NLG Axle Barrel CL600/601

  • Corrosion mating with plunger tube found on 75% of restorations.*

Challenger NLG Stering Cuff

NLG Steering Cuff CL600/601

  • Corrosion in the ID Bore found in 60% of restorations.*

Challenger NLG Axle Transverse Bore

NLG Axle Transverse Bore CL600/601

  • Corrosion found on 50% of the restorations.*

Challenger NLG Steering Rack

NLG Steering Rack CL600/601

  • Tooth damage going to caster mode found during 90% of restorations.*

Challenger MLG Side Strut Rod End

MLG Side Strut Rod End CL600/601

  • Bearing bore corrosion found in 85% of the restorations.*

Challenger MLG Side Strut

MLG Side Strut CL600/601

  •  Bearing bore corrosion found in 85% of the restorations.*

*Percentages are based on Duncan Aviation data.

Jerry Cable is an Accessories Tech Rep located at Duncan Aviation’s Lincoln, Nebr., facility. He is a landing gear and accessory components and systems specialist. His aviation career began in 1991.

Tags: Parts & Accessories, Landing Gear, Challenger

Do Not Overlook the Adel Clamps (MS21919)

Posted by Diane Heiserman on Wed, Feb 06, 2013 @ 09:01 AM

Contributed by Scott Shefke, Airframe Tech Rep

Adel Clamps

Error on the side of replacing when you have suspicions about an Adel Clamp (MS21919) on your business aircraft.

The wires that run throughout the aircraft and engine compartment need to be secured into bundles to prevent interfering with moving parts or chafing. During visual inspections, work cards will state to verify routing of electrical wiring, wiring harnesses, fuel lines, hydraulic lines and oxygen lines.

Adel Clamps, AKA MS21919 aircraft clamps, are key components used in line support, vibration dampening and maintaining proper clearance for lines or harnesses running throughout the aircraft structure. The Adel Clamp is a metal band constructed from aluminum, corrosion-resistant steel and low-carbon steel, covered by a white rubber lining or cushion made from silicone. Older Adel Clamps made from low-carbon steel had different colored cushions depending on what materials they were constructed from: silicone (red), ethylene propylene (purple), chloroprene cushion (black).

A visual inspection, no matter how trivial, needs to include the inspection of these clamps; and when necessary they need to be replaced. These cushions are exposed to heat, vibration, ozone and a variety of petroleum-based and synthetic-based fluids. Over the years, inspections have found cushions torn or missing, exposing the metal bands. In cases where the cushion is made from Teflon polyamide glass, dust gathered around the hardware or in the immediate vicinity indicates wear. These should be replaced.

We have found conditions were the cushion’s wrapping edge is in good condition, however, a more detailed examination reveals the cushion has worn away on the inside of the band, creating a bare-band-to-line or -wire condition.

When Adel clamps fail in these conditions, it has been noted on fuel systems to cause non-designed fuel migration, or a low fuel pressure situation. In hydraulic lines, Adel Clamp bands have been found rubbing through hydraulic system lines resulting in a loss of hydraulic quantity. Intermittent electrical faults have lead technicians to find an Adel clamp cutting into an electrical harness.

The MS21919 aircraft clamp is used safely by many aircraft OEMs with very little trouble. However, a skilled technician will be looking closely at these clamps and know that their replacement is not trivial nor being too picky. The repair costs of the many systems they support vastly outweighs the cost of this simple preventive maintenance approach.

Duncan Aviation has teams of experienced airframe mechanics provide service for almost every airframe maintenance event, scheduled or unscheduled. Emergency AOG service is available through our mobile Rapid Response teams. Technical support is available 24 / 7. We are authorized by several aircraft OEMs and foreign agencies around the world.

Scott Shefke is an Airframe Tech Rep located at Duncan Aviation’s Lincoln, Nebr., facility, specializing in the Challenger airframe. He sits on the OEM Advisory Committee reviewing fleet and maintenance issues reported by operators working to improve the Challenger aircraft. His aviation career began in 1991.

Tags: Airframe Maintenance, Challenger

How to Avoid Challenger 600 Epoxy Ramp Removal Damage

Posted by Diane Heiserman on Fri, Aug 03, 2012 @ 03:02 PM

Submitted by Scott Shefke, Airframe Tech Rep

Challenger 600 Door Epoxy Ramp Removal

Duncan Aviation Maintenance Tech using the Aero 40 Series dry ice blasting machine.

Bombardier has released Service Bulletin (SB) for all Challenger 600 model aircraft. SB ATA 55-11 titled "SPECIAL CHECK/MODIFICATION – PASSENGER DOOR –EPOXY RAMP REMOVAL AND CORROSION PREVENTION."

According to the SB ATA 55-11:

There have been several reports of corrosion in the lower structural elements of the passenger door. It was determined that the epoxy ramp installed to prevent water accumulation could deteriorate with time and retain moisture. The purpose of this Service Bulletin is to remove the epoxy ramp to prevent further corrosion, add additional draining holes and modify the door structure to allow access to facilitate scheduled inspections.

Avoiding Collateral Damage

To help support our customers in performing this SB, all three of Duncan Aviation’s maintenance facilities (Lincoln, Nebr.; Battle Creek, Mich. and Provo, Utah) have obtained a cold jet Aero 40 Series dry ice blasting machine. This dry ice blasting machine is integral in removing the epoxy ramp in an efficient manner while ensuring no collateral damage to existing door structure occurs.

Technicians at all locations have been properly trained by Cold Jet, the blasting machine’s OEM. Duncan Aviation has successfully completed this SB in-the-field and have several more in-the-field events scheduled through the remainder of 2012.

For more information about the Aero 40 Series dry ice blasting machine and to schedule the completion of this SB, please contact Duncan Aviation’s Airframe Service Sales.

Scott Shefke serves as an Airframe Technical Representative at Duncan Aviation's full-service facility in Lincoln, Nebr., specializing in Challenger, Global and Learjet aircraft. His aviation career began in 1991.

Tags: Airframe Maintenance, Challenger, airframe corrosion

Duncan Aviation Technicians Travel the World in 2011

Posted by Diane Heiserman on Wed, Jan 25, 2012 @ 10:04 AM

In 2011, Duncan Aviation team members made hundreds of trips around the world providing AOG services. While providing the most-needed AOG services to our customers on nearly every Continent, team members also took in some local culture, food and sites.

Berlin, Germany

Berlin, Germany

In March, Scott Shefke, Challenger/Global Tech Rep, traveled to Berlin,Germany, to perform and assess the viability of restoring a Challenger CL 604 to airworthiness status. The project included performing engine boroscopes, performance runs, system operations checks, fuel sampling and general condition of aircraft.

“Berlin is a magnificent city to visit,” says Scott. “It is rich with history.”

Cairo, Egypt

Cairo, Egypt

In Cairo, Egypt, Dan Soderstrom, Master Turbine Engine Mechanic, and Bill Walker, Engine Tech Rep, were in the right place at the right time when one project turned into two. While troubleshooting a faulty fuel control unit on a Hawker 800XP, a local Hawker 850XP operator approached them for assistance in fixing leaking starter/generator seals.

Both Dan and Bill said that everyone they had contact with in Egypt were very nice and helpful. Dan hopes to have more opportunity to see the great city if he gets the chance to go in the future.  

Bordeaux, France

St. Emilion, France

Ron Grose, Falcon Tech Rep, attended the annual Falcon 7X Steering Committee meeting in May, in Bordeaux, France, a beautiful old city located in southwestern France along the Garonne River, surrounded by elite vineyards. As a member of the steering committee, Ron and others oversee the development of the scheduled maintenance program for the Falcon 7X aircraft.

One of Ron’s favorite places to visit was the small village of Saint Emilion. It is a 1,700 year old village which was, at one time, surrounded by a large moat used for protection against the warring tribes. This quaint village had narrow cobblestone streets, great restaurants and many wine tasting shops.

Brisbane, Australia

Brisbane, Australia

Duncan Aviation Fuel System Lead Technician, Jon Abrahamsen, took a week long trip to Australia in May. He was dispatched to repair a wing junction plate fuel leak on a Falcon 2000EX.

Jon used one of his days to drive two hours down to Surfers Paradise, a large tourist beach. He also took the train downtown to the south shore for dinner and a couple of local beers. Jon says the area was beautiful.

Shanghai, China

Shanghai, China

Scott Howell, Airframe Lead Mechanic, along with three other fellow Duncan Aviation team members, traveled to Shanghai, China to complete a crucial fix on a Falcon 7X. Getting tools and equipment through customs posed a challenge, but the team stuck to the task, completing the project early.

On the first full day of their trip, the group made their way to The Bund, a mile long street lined with shopping. A local gentleman led them beyond the glamour of these stores to another area. Here, they had the adventure of walking up steep wooden stairs, entering into random people’s homes, where they bargained with local merchants for various items. It is an experience they will not soon forget. Scott describes the city’s transportation as very convenient and clean. The food was not what he would have suspected, but enjoyed trying the various delicacies of the region. 

Santo Domingo, Dominican Republic

Ned Shanks, Engine Rapid Response Tech out of Fort Lauderdale, FL, made a trip to Santo Domingo, Chile, in October to assist a customer. The #1 engine on their Lear 35 would not start. Having seen this squawk many times before, Ned suspected there was an issue with the aircraft’s igniter box and prepared for his trip with this in mind. This was a very important job because the aircraft was an air ambulance and was scheduled to fly a sick infant back to the United States for medical care.

After arriving, clearing Customs and making it to the aircraft, Ned quickly discovered his suspicions were correct, a failed igniter box. As soon as he complied with the removal and replacement of the box, ground runs and required paperwork, they were airborne and on their way back to Ft. Lauderdale. Shortly after arrival back home, the aircraft was prepped and sent out on another rescue mission.

Tags: Learjet, Falcon, AOG, Hawker, Challenger

Avoid Hawker Landing Gear Exchanges During Maintenance Events

Posted by Diane Heiserman on Wed, Dec 28, 2011 @ 09:57 AM

Contributed by Dan Fuoco, Hawker Airframe Service Sales Rep.

Hawker Landing Gear

Hawker roll-around nose landing gear (NLG) and main landing gear (MLG) used to keep aircraft moving through maintenance.

I’ve worked with Hawker maintenance events for a long time, and I make it my business to make sure everything is in place for an aircraft to deliver on time (if not ahead of schedule). It’s common knowledge that combining Hawker landing gear overhauls with scheduled maintenance and paint saves downtime. What isn’t commonly known is a simple piece of equipment can reduce that downtime by another few weeks.

That piece of equipment is called a roll-around landing gear, which serves as a temporary stand-in for the original gear when it goes in for overhaul during a combined maintenance event.

Roll-Around Landing Gear

Typically, a maintenance event will finish weeks ahead of a landing gear overhaul. Since an aircraft can’t be painted without a landing gear, operators typically have two options: let the aircraft sit for two weeks while the original gear is overhauled, or exchange the gear for another unit. A roll-around landing gear presents a third, more efficient option.

When an aircraft arrives for maintenance, the original landing gear can be immediately replaced with the roll-around gear. This allows the aircraft to be moved through all phases of maintenance, including paint, while the original gear is overhauled. When the aircraft paint process is finished, the original landing gear is usually ready for reinstallation.

2 Weeks of Downtime Savings

I strongly recommend that operators choose a Hawker service center that has roll-around landing gear, especially when planning for a combined maintenance event. Operators will probably save about two weeks of downtime if they work with a service center that has roll-around landing gear available.

Roll-around landing gear are available at Duncan Aviation for all series of Hawker aircraft; Challenger 600s, 601s and 604s; and Falcon 50s, 900s and 2000s. Duncan Aviation has a Hawker Authorized Service Center, and a Hawker-authorized accessory shop for landing gear overhauls in Lincoln, NE (LNK). Please contact me, Dan Fuoco, or a member of Duncan Aviation’s Hawker team for more information.

Dan Fuoco serves as a Airframe Service Sales Rep. at Duncan Aviation’s full-service facility in Lincoln, NE (LNK), specializing in Citation and Hawker aircraft. He started his aviation career in 1974.

Tags: Airframe Maintenance, Maintenance Event Planning, Falcon, Hawker, Challenger


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