Production, authorized modification sites and RVSM package availability top news

Spirit Wing Aviation of Edmond (OK) has announced that it will begin producing its “virtually new” SpiritLear early in 2005. The SpiritLear should be priced at around $2,200,000 for a fully modified aircraft including the airframe without the original engines, a price the company claims is below any other airplane offering its combination of speed, range, and passenger capacity. It will cruise at Mach .81 at altitudes up to FL 450 while offering operating economies 20 to 30% lower than the competition.

The SpiritLear has been created by utilizing the “no life limit” airframe of the durable Learjet 25, replacing the original GE CJ610 engines with Williams FJ44-2C powerplants, revitalizing the pressurization, hydraulic, electrical and fuel systems and updating the avionics to meet Revised Vertical Separation Minimum (RVSM) requirements.

“While the other companies have been selling the concept and introducing the idea of a very light, economical business jet, we’ve built it and flown an airplane that offers better range, speed and performance with a passenger load of up to eight people,” said Calvin Burgess, president of Spirit Wing Aviation, at the 57th National Business Aviation Association (NBAA) Annual Meeting & Convention in Las Vegas (NV).

Burgess noted that the aircraft is now in full FAA certification testing and the STC is expected from the FAA during the first or second quarter of 2005. The company will begin modifications at three authorized service locations immediately upon receipt of the STC.

“We have accomplished more than 85% of the flight testing and are on schedule to finish the certification process by early next year,” he pointed out, adding that “we’ve done so on time and on budget and without incurring any debt. That fact, alone, makes us unique among light jet development efforts because it means we don’t have to wait for funding or reach a specific number of orders before launching production. We can and will offer our customers exceptional response and an airplane that will be in productive service literally years before much of the competition.”

A proven platform with no life limits on the airframe

Utilizing the Learjet 20 series (excluding the Lear 23) as the basis for the SpiritLear provides another, easily overlooked benefit—structural integrity and durability that surpasses much newer designs. The first business aircraft to be certified to the same FAR Part 25 standards applied to airliners, the original Learjets were derived from the “battle tolerant” design of the Swiss P-16 fighter.

Also like airliners, their 8-spar wings and extremely durable fuselages are not life limited. Spirit Wing’s only modification to the airframe consists of damage-tolerant design improvements to the engine beams and associated structure and the rebalancing of controls as required.

“Based on the Learjet’s original design and the inspection and preparation process we perform on the aircraft prior to beginning the modification, the age of the airframe is a ‘non-issue’ for SpiritLear owners,” Burgess noted. “In point of fact, the SpiritLear has an expected life of up to 80,000 hours, much longer than more contemporary designs.”

Improved aerodynamics, lower stall speeds Because the new Williams FJ44-2C engines are dimensionally different from the General Electric CJ610 engines originally installed on the Learjet 20 series aircraft, the SpiritLear’s front engine beam has been modified and a new rear engine support beam has been installed, effectively moving the engine nacelle aft sixteen inches and outboard four inches. A detailed eddy-current and X-ray inspection of the beam structure and critical fastener holes ensures that the aircraft satisfies the FAA’s damage tolerance regulations.

An added feature of the modification is a dramatic reduction in drag which results from the repositioned engine providing more engine-induced airflow, thus improving lift over the critical inboard portion of the wing which, in turn, reduces the angle of attack, resulting in lower fuel burn and reduced power requirements for high speed cruise.

Super efficient engines extend range, enhance safety

The Williams FJ44-2C engines utilized on the SpiritLear are specially modified for this application to allow their thrust to be reduced to 100 lbs. at idle, resulting in shorter landing distances. Additionally, by incorporating the FJ44-3 power turbine sections into the SpiritLear’s engines, more thrust is available under high altitude, hot day conditions. The engine features wide chord fan technology, vastly reduced fuel consumption, and sound attenuation features that ensure the airplane’s compliance with Stage III noise requirements.

The efficiency of the engine and modifications associated with its installation further enhance the SpiritLear’s overall safety. Since current FAR Part 25 requirements prohibit the coexistence of flammable fluids and ignition sources with engine rotor burst zones, the original Learjet fuselage fuel tank and its associated plumbing have been removed. This can be accomplished without any performance penalty, because the FJ44-2C engines actually extend the aircraft’s range by approximately 70 percent.

“The development and certification of the SpiritLear has gone extremely well and we have been pleasantly surprised by its performance in flight-testing. In a number of instances, it has exceeded our projections dramatically. We’re extremely pleased to be able to offer an aircraft that provides exceptional performance, capacity, safety and economy combined with proven technology and durability,” concluded Burgess.

Three sites authoritzed to perform SpiritLear mods

Spirit Wing Aviation has authorized three sites to perform the extensive modifications which transform existing Learjet 25 aircraft into the “virtually new” SpiritLear light business jet. Three highly-regarded business aviation maintenance facilities, West Star Aviation of Grand Junction (CO), Banyan Air Service of Ft. Lauderdale (FL) and General Dynamics Flight and Aerospace Research Unit in Niagara Falls (NY), will begin reserving customer slots immediately for the conversions which are expected to begin during the first or second quarter of 2005, once the SpiritLear receives a STC from the FAA.

“We are very pleased to have established relationships with these highly-qualified maintenance and support sites. Their extensive capabilities, outstanding facilities and experienced technicians met our strict requirements and will allow us to offer multiple locations and more rapid turn-times for our customers," said Calvin Burgess, president of Spirit Wing.

“We also anticipate converting several of our own aircraft at our facilities at Guthrie, Oklahoma. In addition, Banyan’s location and the fact that they hold repair station approvals from Brazil, Venezuela and Argentina will allow us to better service potential customers from South America, where a significant number of Learjet 20 series aircraft are currently based,” he continued.

About West Star

West Star Aviation is a full-service repair, maintenance, and modification facility specializing in Learjets, Hawkers, Falcons, and Cessna Conquests and Citations. Located adjacent to the 10,500 foot runway at Walker Field in Grand Junction (CO) West Star also provides avionics installation and repair and paint and interior refurbishment for aircraft up to Challenger and Falcon 2000 in size.

The company employs over 325 skilled technicians and support staff and is recognized industry-wide for its technical expertise and commitment to superior customer service. It ranked eighth in the 2004 PRO PILOT Maintenance facility rankings and in the Top 10 in avionics. Recognized as a leader in Learjet maintenance, West Star has compiled an enviable record over the past six years, having completed approximately 25% of Learjet 12-year inspections.

About Banyan

Founded in 1979, Banyan began in a small 4,000 square foot hangar which served as an aircraft sales and maintenance facility at the Fort Lauderdale Executive Airport. The firm received FAA certified repair station approval, and shortly thereafter, moved to a larger location and began offering fueling and FBO services.

In 1990, Banyan began offering comprehensive avionics services, including technical repairs and installations, under its newly obtained FAA and JAA repair station approval. To compliment the maintenance department, in 1993, Banyan opened a turbine engine shop. Located on the Ft. Lauderdale Executive Airport, Banyan is both an FAA and JAA approved repair station (WD4R618M), holding additional Venezuelan, Brazilian and Argentinean DGAC maintenance approvals.

About General Dynamics Flight and Aerospace Research

“General Dynamics Flight and Aerospace Research is uniquely qualified to serve as an authorized modification site for the Spirit Lear,” said Calvin Burgess, president of Spirit Wing Aviation, in announcing the agreement. “When they heard that we were pursuing a Supplemental Type Certificate to install Williams engines on Learjet 25s, they contacted us to secure an early position for their two Learjet ‘in-flight simulator’ aircraft.

As our discussions progressed, we realized that General Dynamics’ F&AR unit possessed the capability and capacity to perform the entire SpiritLear modification and would be an ideal site for customers in that region. We are very pleased to add them to our list,” he added.

“This is a unique, but logical opportunity for us, “ noted Lou Knotts, senior manager of the General Dynamics business unit. “Our primary focus is not aircraft modification, of course, but we do have 20 years of experience doing system modifications and integration on Learjets. We have two Lear 25s in our fly-by-wire testing program, as well as a dozen experienced technicians and available hangar capacity at our Niagara Falls site. We will also be among the initial SpiritLear customers, since the airplane is an ideal platform for our ‘in-flight simulation’ activities.”

The General Dynamics Flight and Aerospace Research department also operates a Transonic Wind Tunnel in Buffalo (NY). Its staff also conducts training at Edwards Air Force Base in California, in Jacksonville, Florida and Roswell, New Mexico.

RVSM upgrade also available

Spirit Wing Aviation is also offering owners and operators of Learjet 20 series aircraft an economical and timely way to comply with the FAA’s Reduced Vertical Separation Minimum (RVSM) requirements. The company is offering the package as independent installation or, at a substantial savings, as a part of its SpiritLear conversion.

“With the FAA’s January deadline for implementation of new RVSM standards, there are limited sites available where Learjet 20 series operators can get the necessary modifications done at a reasonable price,” said Calvin Burgess, president of Spirit Wing Aviation.

“We’ve nearly completed the requirements for a Supplemental Type Certificate (STC) on our SpiritLear conversion, and another on RVSM, as well. It only makes sense that we would make RVSM modification slots at our authorized service centers available to Learjet 20 series operators, regardless of whether they are SpiritLear customers,” he added.

Spirit Wing will offer its STC through its network of three authorized SpiritLear conversion locations. The STC is expected to be granted to Spirit Wing in the first quarter of 2005. It may be installed by authorized service centers as a component of the SpiritLear conversion at a cost of $125,000 or independently of the conversion for $150,000.

FMI: www.spiritwing.com, www.banyanair.com, www.gd-ais.com, www.westaraviation.com