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Presorted StandardU.S. PostagePAIDLincoln, NEPermit No. 730

A P U B L I C A T I O N O F D U N C A N A V I A T I O N • A P R I L 2 0 0 0

“Unforgettable People–Legendary Service” Shapes Duncan’s Hawker Support

Duncan Aviation’s “UnforgettablePeople–Legendary Service” is not just agreat theme for our company, but a way oflife at our facilities. That way of life isshaping Duncan’s Hawker support both inLincoln, Nebraska, and Battle Creek,Michigan.

We continue toexpand our Hawkerexpertise and supportthrough our unforget-table people.

In early January,Dan Fuoco joinedDuncan Aviation’s service sales group asa Hawker ServiceSales Specialist,adding experienceand depth to theHawker team. Danspent 25 years atCAMP Systems inRonkonkoma, NewYork, where he wasmost recently theRaytheon AircraftTeam Leader. He joinsJeff Manion and Pete Kilmartin to provide maintenance scheduling, planning and budgeting services forHawker customers.

“Dan brings a wealth of knowledge onthe Hawker products,” says Tom Burt, VicePresident of Engine and Airframe ServiceSales. “He will add to our ability as a salesteam to help customers plan their mainte-nance and get the best value for theirmoney. Because of his strong Hawkerbackground and personality, Dan perfectlyfits our philosophy of having service salespeople who are helpful and very knowledgeable.”

Dan has this to say about his appoint-ment: “I was very impressed with theDuncan facility, the enthusiasm of theemployees, and the quality of work thatDuncan performs. I am happy to be a partof Duncan’s Hawker team and look forward to serving Hawker customers.”

Unforgettable people aren’t the only mixto Duncan’s Hawker success. Legendaryservice at the Duncan facilities also con-tributes to a way of life here as DuncanAviation and Raytheon Aircraft recentlysigned an agreement designating DuncanAviation–Battle Creek as a RaytheonAuthorized Service Center for all Hawker aircraft.

“We are pleased to have DuncanAviation’s Battle Creek, Michigan, facilityjoin our network of Raytheon AuthorizedHawker Service Centers,” says Steve Porte,Manager of Global Service Centers. “Basedon our customers’ experiences with Duncan

Aviation–Lincoln’s com-prehensive support andour confirmation that theBattle Creek location isstaffed and equipped todeliver the same excellentlevel of service, thisannouncement fits wellwith our strategy of posi-tioning Raytheon AircraftCompany with partnerswho will offer the bestcustomer support in the industry.”

Both full-serviceDuncan facilities (BattleCreek and Lincoln) arenow Authorized HawkerService Centers. Eachreceives all of the supportservices and warrantyauthorization privilegesassociated with the

factory service center designation.

“We are honored to receive the Hawkerdesignation for the Battle Creek location,”says Aaron Hilkemann, President ofDuncan Aviation. “In the last three years,we have focused on offering excellentHawker service and support by investingin training, tooling, and experienced teammembers. This announcement confirmsthat we have been successful. It is also testimony to Raytheon Aircraft’s commit-ment to customer service by being respon-sive to the feedback of their customers.”

Hawker maintenance is not new toDuncan Aviation–Battle Creek. Both theBattle Creek and Lincoln facilities havethe in-house capabilities and trained personnel to perform all major inspectionson Hawker aircraft. Duncan also offersexperience on the TFE731 and P&W 305engines, as well as complete paint, interior,modifications and avionics work onHawker aircraft.

For more information about our Hawkerservices, call Pete Kilmartin in BattleCreek at 800.525.2376 or 616.969.8400 orJeff Manion and Dan Fuoco in Lincolnat 800.228.4277 or 402.475.2611.

Duncan's new Hawker Service SalesRepresentative, Dan Fuoco.

Duncan Receives Hamilton Sundstrand

APU Service CenterAuthorization

Duncan has also been named anauthorized Hamilton Sundstrand LineMaintenance Service Center for T-62T-39and T-62T-40C Series APU’s. With theAugust 1999 agreement, our facilities inLincoln and Battle Creek are authorizedto perform APU Line maintenance,including installed operational testsafter repair or overhaul.

Our experienced three-person APUrepair and overhaul team is led by JohnKennedy, who came to Lincoln in 1998after spending several years in the APUprogram of another major independentservice center. His experience is comprisedof APU maintenance and overhauls, APUshop inspection, APU technician training,APU test cell operation and logbook research.

In addition to Hamilton SundstrandAPUs, we are Line authorized to workon all Honeywell APU products andhave experience servicing these productsfrom on-site aircraft as well as send-in units.

Duncan Aviation–Lincoln NamedCitation 650 Service Center

Duncan Aviation and Cessna AircraftCompany recently signed an agreementdesignating Duncan Aviation–Lincoln asa Cessna Citation 650-Series AuthorizedService Center.

The Lincoln, Nebraska, facility is nowthe only independent authorized servicecenter in the United States to receivethe designation. This authorization willallow Duncan Aviation to work with 650operators as the only authorized U.S.service center beyond the network ofCessna-owned facilities.

“Designation of Duncan Aviation–Lincoln as a Cessna Citation 650-SeriesAuthorized Service Center rounds outour nose-to-tail support services forCitation 650 operators,” says AaronHilkemann, president of DuncanAviation. “We are excited about theannouncement, and look forward to continuing our partnership with Cessnaas we provide our mutual customerswith the best possible service.”

As the Lincoln facility will receive allof the warranty authorization privilegesassociated with the factory service centerdesignation, the new authorization willadd the full service approach of DuncanAviation to the existing Cessna networkand help keep valued Cessna customerswithin that network.

“Cessna could not be more pleased tobuild upon our long-time relationshipwith Duncan Aviation,” says Ron Chapman,Cessna Senior Vice President ofCustomer Service. “Over the past 27 years, Duncan Aviation has consis-tently provided world-class service to 500-Series operators. Duncan’s added650-Series capabilities will clearly provide numerous benefits to the customers operating the 350 Citation650-Series aircraft worldwide.”

Citation maintenance is not new toDuncan Aviation. Both Duncan Aviation’sLincoln and Battle Creek facilities havebeen Cessna 500-Series Authorized formany years. Each facility has the in-house capabilities and trained personnel to perform major or minorCitation aircraft maintenance.

Please join us at the following trade shows:

AS3 – Tampa, FL AEA – Reno, NVMay 9-11 May 7-10Booth #922 Booth #400/402

Duncan AviationStandardizes withAvfuel, Plans SummerKick-Off Celebration

With nearly 45 years of experienceproviding line service to corporate aircraft operators, Duncan Aviationoffers complete and reliable fuel andpilot services 24 hours a day at its Battle Creek and Kalamazoo, Michigan, and Lincoln, Nebraska, locations. Inaddition to uncongested skies, longrunways and short taxi time, our full-service facilities have now standardized on one fuel provider —Avfuel Corporation.

Effective April 1, all threeof Duncan Aviation’s linesupport locations will usethe fuel services of Avfuel.Battle Creek and Kalamazoohave used these services since 1992.Now, the Lincoln facility is joining them.

In honor of this conversion, all threelocations will celebrate during June,July and August with special programsthat include prize drawings, specialgiveaways and double AVTRIP pointsfor purchases. AVTRIP is Avfuel’sFrequent Refueling Program wherepilots earn points for each gallon offuel they take on at participatingAVTRIP dealers. The points are creditedto individual pilot accounts and accu-mulate toward U.S. Savings Bonds orinternational equivalents.

“Changing fuel vendors is not some-thing that we take lightly,” says KrisPatrick, Support Services Manager atDuncan Aviation’s Lincoln facility. “We have always taken pride in our top-notch quality control procedures.All of our facilities are underGovernment Fuels Contracts and provide fuel for major airlines, so quality is a big concern for us.

“At our Michigan facilities, Avfuelhas been very supportive of our quality-control procedures and equipmentneeds,” Kris continues. “Beyond that,we have been pleased with Avfuel’scustomer support, which enables us toprovide the level of service our customersdeserve and expect. We are excitedabout the greater consistency andlevel of service this standardization toone fuel supplier will provide.”

In addition to high-quality fuel,operators who stop at any Duncanlocation receive access to severalamenities. These include the following:

We accept all major credit cards,including AvCard and MultiService. Inaddition, AirBP cards will continue tobe honored at the Lincoln facilitythrough August 1. For more informationabout our line services, please contactMike Ross in Battle Creek/ Kalamazooat 800.525.2376 or 616.969.8400 orKris Patrick in Lincoln at800.228.4277/402.475.2611.

• Pilot’s lounge with entertainment and refreshments

• Snooze/reading rooms• Quick-turn fueling• Certified line technicians• De-ice (Lincoln only)• Airstart (Lincoln only) • Preheat• Detailing and lavatory service• Free coffee and ice• Free ramp space (Lincoln & Battle

Creek only—with limited ramp space, Kalamazoo does have to charge for overnight parking)

• Free APU starts• Baggage handling• On-site car rentals• Discounted hotel rooms• Catering service• Courtesy cars• Weather-planning radar• Conference rooms• Charter service• Avionics loaners

UNFORGETTABLE PEOPLE — LEGENDARY SERVICE

“A customer just bought a Falcon 900. We need toschedule it for a 2C inspection, a triple MPI, paint,complete interior and EGPWS installation. He needsa quick turntime in mid-summer. What can we do for him?”

— Shelley EwaltCompletions Marketing Manager, Duncan Aviation-BTL

www.DuncanAviation.com

Duncan Aviation-LNKLincoln, Nebraska800.228.4277402.475.2611

Duncan Aviation-BTLBattle Creek, Michigan

800.525.2376616.969.8400

MULTIPLE RESOURCES — FLEXIBLE OPTIONS

“We have the capacity and resources here in Battle Creek for all the work except the avionicsinstallation because our Falcon install teams arealready scheduled for other projects. Do you haveany ideas, Doug?”

— Dan ChillaScheduling Manager, Duncan Aviation-BTL

“Duncan Aviation-Teterboro has performed thatinstallation. Their experience will help cut turntime.We can also fly some Duncan Aviation-Lincoln Falconinstall technicians to Battle Creek for the project.Tell him we can do it.”

— Doug SchmittScheduling Manager, Duncan Aviation-LNK

Since 1956, business aircraft operators have turned to DuncanAviation for reliable, complete support services. Now a network

of more than 1,600 aviation experts, we provide complete airframe,engine, avionics installation, paint and completions work. Withnose-to-tail support facilities in Battle Creek, Michigan, andLincoln, Nebraska, and 13 avionics satellite facilities across NorthAmerica, we offer the best scheduling options and the fastest turn-times available. For your best option, call Duncan Aviation.

Fifteen years of constructing AuxiliaryPower Unit (APU) kits for Falcon, Astra,Citation, and SAAB aircraft broughtDuncan Aviation’s Fabrication Team to amajor milestone late last year. OurSeptember installation of an APU in anAstra SPX marked the 100th kit constructedat our Lincoln facility.

Duncan Aviation owns STCs forinstalling APUs in Falcon 20s, Astra1125s, Astra SPXs, Citation 650s andSAAB 340s. In addition, the Duncan-designed APU has received PMA (PartsManufacturer Approval) Authority, whichlets us provide a kit version of the APU tooperators who wish to install it themselves.Our APU can be found in 66 Falcons, 27 Astra 1125 and SPXs, five Citation650s and four Saab 340s.

The Duncan-designed APU provides 28VDC power that parallels with the mainengine generators and provides bleed airfor the airplane environmental system. Itis the only APU verified for take-off, in-flightand on-ground operation, providing electrical power and bleed air to 30,000feet with starts certified to 20,000 feet.

Customers tell us that one of the bestfeatures of our APU is its high/low bleedair provisions. This lets operators providemaximum airflow to quickly cool or heatthe airplane, and then cut the bleed air byapproximately one-half to allow for a moresubtle airflow and quieter operation in thecabin. The main engine bleed air cannotbe controlled like this and has been a common complaint among operators.

Other benefits of Duncan’s APU includeconsiderably quieter operation and anoverall lighter installation—up to 90pounds lighter—than comparable systeminstalls. (This weight reduction is attributable to the use of smaller, lighterbatteries, which we can install because the

Duncan’s Fabrication Team Constructs 100th APU

APU provides additional power for mainengine starts.) A Duncan-designed inter-face computer monitors the APU and generates 32 different “BITE” codes thatare displayed on the APU’s cockpit controlhead. In addition, the installation allowsfor easy APU removal and access throughthe aft equipment door.

Besides APUs, our Fabrication Teammakes baggage compartments, floorwarmers, water tanks, ice liners, trashcontainers and beyond . . . there is littlethis crafty team of 15 McGuyvers can’t do with a sheet of stainless steel. Andthey’re always on the lookout for ways toimprove business aircraft safety, operation, profitability and comfort.

If you’d like to share ideas or makeproduct suggestions for our FabricationTeam, call Spencer McPherrin at800.228.4277 or 402.475.2611. For moreinformation about our APUs, contact Ron Hall in Lincoln at 800.228.4277 or402.475.2611 or Brad Snowball in BattleCreek at 800.525.2376 or 616.969.8400.

Scott Stenka, Fabrications Team Leader,constructs an APU enclosure for aFalcon 20.

Lincoln AirportP.O. Box 81887Lincoln, Nebraska 68501www.DuncanAviation.comwww.avpac.com

A Message From The Tower

Over the last few years, DuncanAviation has created an unbelievable synergy and growth momentum in thenumber of facilities we have, the numberof people we employ, the variety of services we offerand the numberof customers weserve. This growthhas been espe-cially excitingfor those of uswho have beenwith the compa-ny for decades.We have tempered

that excitement, however, with a healthydose of caution for one main reason: Wewant to be sure that our growth positivelyimpacts our employees, customers and services.

I have always believed that excellenceand individual personal service are compatible with a large corporation. AsChairman of a company that now employsmore than 1,600 people, I know this to be true.

Duncan Aviation has more than doubled in size over the last three years.However, we have improved employeeand customer satisfaction. That is onereason so many airframe, engine andavionics manufacturers have partneredwith us by making us one of their authorized service centers. Over the lastsix months, our facilities have added several authorizations, includingRaytheon Hawker in Battle Creek,Cessna Citation 650 in Lincoln, HamiltonSundstrand APU Line for the T-62T-39and T-62T-40C Series at both facilitiesand Rockwell Collins at our Dallas avionics satellite shop. We provide detailsof these additional authorizations in thisissue of the Duncan Debrief.

This issue also keeps you up to speedwith some of our important changes andservice enhancements. By reading thisissue, you will learn more about the construction of a new hangar at ourLincoln location, the completion of a newfinish area in Battle Creek, and the addition of a weekend shift for our accessory and avionics line services. Wetell you about the continuing education ofour employees and how we share ourtechnical knowledge through special customer classes and industry internetconferences. We explain how we ensureNESHAP and EPA compliance in ourpaint facilities and how our fabricationteam installed its 100th APU. We alsointroduce you to Gene Maddux, who hastaken over the reins at AVPAC for recently retired Wayne Matthes.

By perusing through this newsletter, we hope that you will get a sense of theactivity occurring at all of DuncanAviation’s locations. As you can see, themomentum started over the last fewyears continues in 2000. We can assureyou that the outstanding personal serviceand excellent quality we have practicedfor nearly 45 years will continue as well.

J. Robert Duncan

“I have always believedthat excellence and individual personal

service are compatible with a large corporation.”

Defining the leading edge of aircraft cabinet technology requires exceptionaleffort every day. Duncan Aviation’s cabinetand finish teams meet this challenge withproven processes and machinery. Our dedication and expertise allow us to offerthe latest finishes and some of the mostaggressive turntimes in the industry.

While many factors contribute to oursuccess, our people make the biggest difference. Every year we spend nearly$125,000 training our cabinet technicianson the latest production and finish techniques. In addition to training, wekeep them on the leading edge by equipping them with the finest facilitiesand machinery.

The planned purchase of a CNC(Computer Numeric Controlled) machinelater this year will help make our cabinetartisans even more precise. This cuttingmachine will be accurate to within thou-sandths of an inch for every cut, allowingus to focus efforts on fits, not cuts. The$230,000 investment will also let us entera previously untapped cabinet productionmarket.

Today’s business aircraft cabinets arelighter and stronger than those made justa few years ago. Honeycomb compositesand veneers comprise contoured cabinetrywhile faux and high-gloss, real woodveneer finishes transform stale cabins intostylish dwellings that define their owners.Increased labor rates and hours arerequired to produce today’s flashiestdesigns. Our team understands thattoday’s aircraft cabinets are much morethan storage spaces. They are works of artthat require meticulous attention to detail,rigorous certifications and craftsmanshiprivaling that of traditional artists.

Duncan Aviation Adds New Finish FacilitiesDuncan Aviation’s Battle Creek,

Michigan, facility recently completed anadditional 3,000-square-foot finish areathat will allow the six-member team todouble in size by the end of the year. Thenew area includes a “prep station” and afinish booth, both of which offer 365square feet of floor space and feature100% downdraft airflow to ensure thefinest finish— every time.

The prep station affords an ideal environment for applying sealer, paintand faux finishes. In addition to down-draft, the finish booth also offers 100%climate control with a 150-degree “fullbake” cycle, which can reduce curing timeby half without sacrificing quality. BradHewitt, BTL Finish Team Leader, saysthe new area could reduce total finishturntime by as much as a third on large projects.

Our Lincoln facility anticipates growthin the finish area as a result of construction as well. Thenew hangar (see thearticle entitled “UnderConstruction” on pages4 and 5) will createadditional workspaceand enable us to nearlydouble the Lincoln FinishTeam—and its output—during the next five years.The new facility will alsoincrease efficiency.Ergonomic projections suggest as much as a 10%productivity increase for individual Finish Team members.

Cabinet specialists Eric Walter, Ryan Laws and

Tony Francis work in the new finish area at

Duncan Aviation—BTL.

Duncan Contracts withFlightSafety

As part of our ongoing commitmentto employee training, we recentlysigned a full-service maintenancetraining contract with FlightSafety.The contract, in excess of $1 millionfor a three-year period, includes training for employees in Lincoln,Battle Creek, Kalamazoo and thesatellite shops. It is the largest corporate aviation maintenancetraining contract in the history ofboth Duncan Aviation and FlightSafety.

Duncan Cal Lab is Fast, AccurateIn 1999, Duncan Aviation calibrat-

ed more than 3,200 units and repairedabout 890. Average turntimes were 3.8days for calibrations and less than 10days for repairs. With the capabilityto calibrate more than 2,200 differentpieces of equipment—includingmicrometers, calipers, scales, torquewrenches and oscilloscopes—we hopeto introduce our maintenance, componentsand completions customers toDuncan service for calibrations, too.

Customers Race For DuncanDuncan’s on-site maintenance and

completions customers in Lincoln aregiven special certificates for redemp-tion at Speed Indoor Racing, a Lincolnestablishment that is one of America’slargest indoor racing facilities. Eachcertificate is good for one “Arrive &Drive” session in go-karts that canreach speeds of 47 miles per hour.Here is a list of some customers whoparticipated in this fun activity andtheir record lap times:

Duncan–BTL Adds AuthorizationsLate last year, our Battle Creek facility

was designated an Authorized ServiceCenter for Line maintenance on the CFE738engine, which powers the Falcon 2000 aircraft. In addition, Duncan–BTL andHoneywell added Line Authorization forthe TFE731-20/-40 and -60 engines andrenewed Authorization for TFE731 Lineand TPE331 Major. The facility is alsoauthorized to work on the HamiltonSundstrand line of APUs and Pratt &Whitney’s PT6 and JT15D engines.

Customers Rely On Nomadic ExpertiseDuncan engine technicians spent

more time on the road last year thanthey ever have before. One and two-technician teams helped 87 customerswith in-the-field service. Destinationsincluded the east and west coasts andseveral trips to Canada. This more thandoubled the number of trips taken theprevious year. So far, we have providedseveral off-site engine service calls in2000, including a project in Manila, Philippines.

Duncan Receives STC for Interior KitWe were recently awarded an STC for

an executive interior for Galaxy AerospaceSPX aircraft. The interior kit, whichwas based on Galaxy Aerospace concep-tual design and features four floor planoptions, was developed for SPX s/n 111and subsequent new aircraft. Over thenext two years, Duncan will produceone kit approximately every four weeks.

Interior SWAT Team Hits Bull’s EyeDuncan’s Interior SWAT team added

value to more than 200 customer visitsthis year by performing seat and cabi-net repairs, replacing worn carpet andother coverings on short notice. The SWATTeam was developed in 1998 to providenon-scheduled interior repair needs andensure that every aircraft we see—eventhose scheduling maintenance-only work —leaves looking better than it did when itcame in. The SWAT concept is incorpo-rated at both our Lincoln and Battle Creekfacilities. Your project manager is the bestpoint of contact for further information.

Eddie Todd, Finish Specialist, applies ahigh-gloss finish to an aircraft cabinet.Duncan Aviation's Finish Team appliesexotic woods, finish processes and meticulous faux painting to create beautiful aircraft cabinetry.

The custom galley and lavatory cabinetry found in this Challenger601 aircraft show how honeycombcomposites and veneers can beshaped to create beautiful contouredcabinets with the ability to transform an aircraft interior.

Today’s Aircraft Cabinetry—Much More than Boxes with Doors

Readers of Professional PilotMagazine…

Best Maintenance Shop#1 Duncan Aviation – Lincoln#2 Duncan Aviation – Battle Creek

Best Avionics Shop#1 Duncan Aviation – Lincoln#4 Duncan Aviation – Battle Creek#6 Duncan Aviation – Teterboro

Billy Dennis, Blastco Services Inc., 26.24 secCraig Wollmerhauser, TAG Aviation, 26.53 sec

Dave Colbert, ACM Aviation Inc., 26.80 secKen Bowen, TAG Aviation, 26.81 sec

Tom Ward, Pacific Marine Management, 26.88 secPat Silveus, TAG Aviation, 27.06 secDave Moll, Hotel Aviation, 27.53 sec

Dave Smith, U.S. Filter Corp., 27.74 secRalph Gentile, U.S. Filter Corp., 27.95 sec

Jim McCrosky, Exxon, 29.39 secButch Wunderlin, Hill Air Corp., 30.47 sec

Joe Voskhul, CTC of Dayton, 31.80 sec

…Give Duncan Aviation Top Ratings.

Duncan Aviation has always believedthat the quality of a company’s work isdirectly related to the quality of its technicians and employees. That is whywe have always hired the best in theindustry and invested heavily in their continued training.

Recently, the FAA rewarded theseefforts by presenting Duncan Aviation’sLincoln, Nebraska, facility with theDiamond Award for Aircraft MaintenanceTechnician Training. Although not yetpresented, Duncan’s Battle Creek facilitymet the requirement for the Ruby Award.

“Continued employee training hasalways been something that DuncanAviation has focused on and invested in,”says Duncan President Aaron Hilkemann.“In 1999, Duncan Aviation spent morethan $2 million to expand in-house andoutside training programs. We feel thatcontinued education is an importantinvestment in the future of our employ-ees, the growth of our services and thesafety of our customers.”

The Diamond Award is the top award inan annual FAA program that recognizestechnicians and their employers. For tech-nicians to qualify for an award, they mustattend a specified number of hours oftraining over one calendar year. Companyawards are given according to how manytechnicians qualify for the individual

awards. In order to qualify for theDiamond Award, at least 25% of a company’s technicians must receive anindividual award.

Duncan’s Lincoln facility surpassed theDiamond participation level with 144technicians receiving awards. DuncanAviation’s Michigan facilities had a totalof 53 technicians receive awards. All inall, three Duncan technicians received theindividual Diamond Award, 49 receivedthe Ruby Award, 50 attained the Goldlevel, 56 received the Silver Award and 39met the Bronze Award requirements. Toreceive an individual Diamond Award, a

technician must attend 100 hours of training. The other award plateaus are:Ruby, 60 hours; Gold, 26 hours; Silver, 12 hours; and Bronze, 6 hours.

Duncan Aviation sponsored hundreds of training classes during 1999, includingcontract maintenance for various modelsof the Falcon, Citation, Learjet, Hawkerand Astra airframes, various engine models and a variety of avionics includingProLine 4 and Primus II. Additional train-ing included composites, air conditioning,troubleshooting, aircraft systems, electricalwiring, sheet metal and print reading.

Curt Campbell is one of Duncan Aviation’smany Unforgettable People who loves totalk about and work on avionics systems.And true to Duncan Aviation’s LegendaryService, he knows about more than oneoperating system. He holds an associatedegree in electrical engineering, has anadditional two years of electrical engi-neering studies, and has studied at virtu-ally every manufacturer’s avionics school.Curt’s familiarity with Collins, Honeywell,JET, King, ARC, Edo, Bendix and a multitude of other OEMs makes hisexpertise highly sought after by otherDuncan employees and customers alike.

For years, Curt has taught Duncantechnicians at Duncan’s Lincoln, BattleCreek and avionics satellite locations thesubtle nuances of avionics. He has alsoconducted seminars at PAMA conventionsand, most importantly, has traveled tocustomer locations in order to keep themup-to-date concerning the latest in avionics. He keeps classes small with sixto 10 participants and discussions haveincluded theory of operation, system integration, system utilization, flight control system diagnostics, introduction toEFIS and artificial intelligence. Classesare confined to lecture and note-takingand usually require a minimal charge fortraveling expenses.

Curt is also a history teacher, of sorts.With 25 years of experience, he routinelyreceives calls from customers and trou-bleshoots old avionic units that few othercompanies know anything about. Main-taining a systematic approach to troubleshooting is Curt’s teaching methodfor helping customers and students alikeunderstand these older units.

Keeping up-to-date with the rapid pace of electronics is a challenge for Curt.

However, he maintains close contact withDuncan technicians and helps them withreally tough problems, which helps himkeep his problem-solving skills sharp.Curt also gets extremely difficult problems from Duncan customers. Someof the toughest involve intermittent failures, which usually take several phonecalls and sometimes a couple of weeks to solve.

If you feel you need to go back to schoolabout your avionics, Curt’s the personwith whom you should speak. Give him acall at 800.LOANERS (800.562.6377) or402.475.2611, extension 4220.

Curt Campbell, a Components TechnicalRepresentative with Duncan Aviation,teaches classes to keep Duncan employeesand customers up-to-date on their avionics.

Duncan Intelli-ConferencesEducate Customers Throughthe Internet

Through the Internet, DuncanAviation now has the ability to commu-nicate directly with customers to providemore timely and convenient education,regardless of location. “Internet confer-encing” is a way for customers to simultaneously watch educational presentations while we answer questionsas they are asked. We call these mini-seminars Duncan Intelli-Conferences.

In January, we shared our first liveIntelli-Conference on Duncan Aviation’stechnical tips and guidance for planninga Challenger 120-month landing gearrestoration. It included information onturntimes, scheduling, and staying under the cap.

If you would like to see a replay ofthis or any of our live Intelli-Conferences,we provide links to these archived conferences at our website, found atwww.DuncanAviation.com in the“News & Information” section under“Intelli-Conferences.” In order to view apast conference, click on the conferencetitle of your choice. It will link youdirectly to the archive. (In order to lis-ten to the archived audio, however, youmust have a sound card and “RealPlayer” installed on your computer. Real Player is available for free down-load at www.real.com. To downloadthe player, follow the step-by-stepinstructions provided at thewww.real.com website.)

Upcoming Intelli-Conference topicsinclude TFE731 tips and informationabout aircraft acquisition. Be on thelookout for invitations to these conferences.

“You have oil pressure following the throttle. The problem is a regulator or possibly a leakingmainline carbon seal. I’ll e-mail some things foryou to check. Or we can send a technician to help.I’ll also put you on the list to receive our nextDuncan Intelligence fax.”

By fax, over the phone, through the Internet, on the road oron-site at our service centers, Duncan Aviation has technical

experts who can work wonders. With quick responses, we answer technical questions about unexpected performance dilemmas, MPIs, APU work, and much more. Through our “Tech Tip” Duncan Intelligence newsletters, over Internet Intelli-Conferences and our engine symposiums, many know us as the industry’s “technical experts.” We’d love to fix yourengine problem and enlighten you. To speak with one of our technical experts, contact Doug Alleman in Lincoln, Nebraska,Ken Kuchenreuther in Battle Creek, Michigan, or look us up on the Internet at www.DuncanAviation.com.

www.DuncanAviation.com

Duncan Aviation-LNKLincoln, Nebraska800.228.4277402.475.2611

Duncan Aviation-BTLBattle Creek, Michigan

800.525.2376616.969.8400

UNFORGETTABLE PEOPLE — LEGENDARY SERVICE

TECHNICAL EXPERTS — PRECISE SOLUTIONS

— Doug AllemanEngine Shop Supervisor

Duncan Aviation-LNK

More Duncan Engineers Named DERs

Dan Buzz and Joe Huffman, engi-neers at our Lincoln facility, recentlyreceived Systems & Equipment andFlight Analyst DesignatedEngineering Representative (DER)credentials from the FAA. They jointhe ranks of three existing DER’slocated at our Battle Creek facility.

Making Aircraft Europe-ReadyAs of January 1, 2000, all civil,

fixed-wing, turbine-engine aircraftwith a maximum certificated take-offmass exceeding 15,000 kg (33,000 lbs),or a seating configuration for morethan 30 passengers, must be equippedwith ACAS II (Change 7) or obtain an extension from Eurocontrol to fly inEuropean airspace. We can answer questions about this requirement, fillout a Eurocontrol ACAS extension orschedule your TCAS II installationand ACAS upgrade. Check out theinformation at www.DuncanAviation.com/news/intops.html or call DavePleskac in Lincoln (800.228.4277) orDennis DeCook in Battle Creek(800.525.2376).

Satcom STC and Phone InfoWe recently completed the first STC

for the installation of a HoneywellAero-I MCS 3000i Satcom system onthe Citation X. The Honeywell Aero-IMCS-3000i provides digital, multi-channel telephone and data coverageusing the INMARSAT III satellite system and a fuselage-mounted antenna. The STC was completed byDuncan’s Battle Creek DesignatedAlteration Station (DAS). If you wouldlike information about in-flight telephone options, check out our websiteat www.DuncanAviation.com/phones.

EGPWS STCWe were recently awarded one of

the first STCs for the installation of aHoneywell Enhanced GPWS with display in the Falcon 900EX. TheEGPWS with display uses GPS position and air data information toprovide warning of impending terrain

far in advance of the Falcon 900EX’s exist-ing MK-V GPWS system. The EGPWS waswired into the existing MK-V I/Os and has additional interfaces to the FMS and EFIS.

Challenger Landing Gear OverhaulWe have been performing the new

120-month landing gear inspection andrestoration requirements for CanadairChallenger aircraft. Duncan technicianshave been completing a range of landinggear services and repairs since 1979. Ourcapabilities also include Learjets, Astras,Westwinds, King Airs, Citations, Jetstarsand Hawkers. Recognized by BombardierAerospace and Messier-Dowty as a quali-fied and reputable provider of these services, Challenger gear can be removedfrom an aircraft on-site in Lincoln orBattle Creek, or can be shipped to us bythe operator. For more information, log onto www.DuncanAviation.com/news/intellicon.html

Duncan-DAL Collins Service CenterOur Dallas avionics satellite facility

was recently named a Rockwell CollinsAuthorized Service Center. With this designation, Duncan-DAL is factory autho-rized to repair and service Collins avionicequipment, including warranty work. Withthis addition, Duncan Aviation has 12facilities that are factory-authorized forCollins avionics repairs and overhauls.The other authorized Duncan facilitiesinclude Lincoln, Battle Creek, Denver, Ft. Lauderdale, Las Vegas, Long Island,Santa Ana, Scottsdale, Seattle, Teterboro,Van Nuys, White Plains.

Duncan-FXE, Other Satellites On MoveDuncan Aviation’s Ft. Lauderdale satel-

lite shop has moved to a new location—inside Personal Jet—at Ft. LauderdaleExecutive Airport (FXE). Under the leadership of Dave Molsberry, former manager of Duncan’s Santa Ana satelliteshop, the FXE facility will perform repairsand overhauls of avionics units and willsoon join Duncan’s growing list of avionicsinstallation locations. In addition to Dave, the shop has four techs and anadministrative assistant.

Other satellite shop changes includethe opening of a subsatellite in AVJETat Burbank Airport (BUR) and therelocation of the Chicago satellite shopto Atlantic Aviation at MDW.

Rotable Exchange Pool AdditionsOur Accessory Time & Material

Exchange Rotable Pool has addedAstra/Westwind Bleed SwitchingValve part numbers 3213894-4-1 and3213894-5-1 to its already extensivelist of rotables. The addition of thesetwo parts will help -4-1 operators control the costs that were formallyassociated with upgrades to -5-1s. Formore information about Duncan’sAccessory Time & Material Exchangeprogram, please contact Chris Gressat 800.228.4277.

Additional Accessory CapabilityOur Accessory shop can now repair

and overhaul the Crane Hydro-AireHydraulic Anti-Skid Control Valvefound on various business aircraft,including Learjets. The unit, partnumber 39-309-1, is used in thehydraulic system. For more informa-tion, call Chris Gress at 800.228.4277.

Components Pricing On InternetOur Internet Components Services

Directory, which includes capabilityand part number listings for theavionics, instruments and accessoriesthat we overhaul and repair, has beenupdated to include pricing informa-tion. To access this list, go to www.DuncanComponents.com.

Cessna 650 STCsWe recently obtained three safety

system STCs pertaining to the Cessna650 Series aircraft. Honeywell TCAS2000 with EFIS display, HoneywellEnhanced GPWS with EFIS displayand Honeywell NZ-2000 FlightManagement System with 5.2 software approved for GPS PrimaryMeans of Navigation. These certifica-tions, which enhance the safety of theaircraft and reduce pilot workload,were completed at our Lincoln,Nebraska, facility.

AT-A-GLANCE

* Figures do not include cost of travel and lodging, where applicable. In 1999, these expenses pushed the training expenditure above $2 million.** Some informal, on-the-job training is not included in these figures.

Another experiment was underway. Thespecimen: A Learjet 55 dripping with sixdifferent chemical strippers, bathed insterile tungsten light. The scientists: Fournervous paint representatives silentlycheering for their products while paintteams, ours and those of other businessaircraft paint facilities, looked on critical-ly. The experiment: A 26-millimeter racefrom the paint surface to the metal below.

Conducted more than a year ago, thisexperiment was just one of countless testsrun by Duncan Aviation’s paint teamsover the past 20 years to identify the bestproducts and techniques for our customers.The scenario described above focused onpaint strippers. Additional tests havebeen conducted on paints, applicationtechnology, and other paint removalmethods.

Duncan Aviation’s Dan Svoboda hasalways tried to think far ahead of thespray patterns. His foresight revealedregulatory changes looming on the aircraftpaint industry horizon and prompted searches for environmentally friendlystrippers, primers and paints long beforethey were required. Having paint facilities in two parts of the country—Nebraska and Michigan—allows theseteams to form and test hypotheses independently. The paint teams in Lincolnand in Battle Creek tweak and challengetheir respective theories until the tech-nique or chemical earns a page inDuncan’s FAA-approved StandardOperating Procedures manual, shared byboth facilities.

Testing new products is a lengthyprocess involving EPA-approved productsand several experiments under variousconditions. It often takes a month fromthe time we order a product until we getto test it. Changes also require constantexperimentation. Often, changing onecomponent in the paint process requireschanging three or four others to maintain equilibrium.

Duncan’s Paint Scientists Experiment to Find Effective Products Thatare Easy on the Environment

Gene Maddux Takes Over AVPAC Reins Upon Retirement of Wayne Matthes

One example is the management of the drafts required to eliminate paint overspray. Left unchecked, these draftscause a phenomenon we call “hangar turbulence,” which adversely affects paintfinishes. Experimenting with airflow systems and aircraft positioning, we havelearned to control hangar turbulence andavoid its adverse affects. Another examplerevolves around the use of HSPs (HighSolids Paint). These paints and primerscreate fewer HAPs (Hazardous AirPollutants). However, they require radically different application techniquesto accomplish the same high-quality finishas conventional paint.

The most time-consuming step in anaircraft repaint is stripping of the oldpaint coat, or coats. To complicate matters, today’s EPA-compliant strippersare milder and require up to twice theworking time as those used five years ago.To combat this problem, we now applystripper on Friday afternoon and allow itto work over the weekend when feweremployees are on hand. This keeps laborhours to a minimum and stripping qualityto a maximum.

During the past five years, Duncan—LNK has used EPA-approved strippers tocut HAPs waste by more than half whilepainting 20 additional aircraft each year!Stripper use has been reduced from 12 drums to 4 drums per month. Our Battle Creek facility has experienced similar success.

The research Dan has performed overthe years has profound benefits to ourcustomers. First, it means high quality.We experiment with different products tofind those that will provide the bestresults. That’s probably why we have thereputation of providing the best paint inthe industry. Second, it means reducedturntimes. Our exhaustive experimenta-tion leads us to products and techniquesthat let us offer the most aggressive paintturntimes in the industry while protectingour environment.

For more information about our paintservices, call Tracey Boesch in Lincolnat 800.228.4277 or 402.475.2611 orShelley Ewalt in Battle Creek at800.525.2376 or 616.969.8400.

This Learjet 55 was the center of a chemical stripping experiment to find products thatare safe for the environment yet provide the results the corporate aviation industry demands.

People who know how to fly, knowabout the aircraft parts world and haveplayed semi-pro baseball are rare; howev-er, the new manager of AVPAC is one suchperson. Gene Maddux learned to fly anS2A aircraft and pitch a mean knuckleball during his Navy days in the late1960s. After leaving the Navy, and base-ball, Gene learned even more about air-craft parts, holding positions with bothAviall and Cessna before ultimately com-ing to the former Kal-Aero in 1996.

Because of Duncan’s purchase of Kal-Aero in 1998 and the retirement ofAVPAC Vice President Wayne Matthes, anopportunity soon arose for Gene toassume leadership of Duncan Aviation’sAVPAC parts division. Gene spent the lastfew months of 1999 learning aboutAVPAC from Wayne, who spent nearly 20years with Duncan Aviation and was onthe ground floor when AVPAC was startedin 1984. Wayne’s dedication to AVPAC hasleft Gene in a strong position going for-ward. And Wayne believes that Gene willcontinue AVPAC’s momentum.

“Gene has an extensive background inaviation parts and his work experienceputs him in a favorable position to leadAVPAC into the future,” Wayne says.

Being an aviation parts professional formore than 25 years, Gene has studied theprogressive success of AVPAC as an out-sider. Now, as AVPAC’s manager, he isamazed at the scope of customer commit-ment he sees in AVPAC’s parts experts.

“I had no idea that AVPAC had such aworld class inventory of avionics and rotables until I got here,” he says. “What’seven more amazing is that the extensiveinventory is backed by excellent customerservice and parts experts with the knowl-edge to find what our customers need—even if it’s not in our inventory.”

Gene sees many challenges and oppor-

tunities on the horizon for AVPAC. In onedevelopment, AVPAC has begun listing its$90 million inventory with PartsBase.com,the largest search engine for aircraftparts on the Internet. Other ideas thenew manager of AVPAC is exploringinclude OEM partnerships, increasedbusiness with regional airlines and newdistribution lines.

Gene is a 1979 graduate of OklahomaState University. He is married withthree children and enjoys golfing and fish-ing. AVPAC welcomes Gene Maddux.Please feel free to give Gene a call at402.479.4200 or 800.228.1836 and seewhat AVPAC can do for you.

Duncan AviationMakes Your WeekendsMore Productive

When you’re AOG, does your calendarseem to have only Saturday and Sundayprinted on it? Do you have trouble sleep-ing on Friday nights knowing that youraircraft has an unfortunate tendency togo AOG only on the weekends? Do otheraccessory shops constantly say, “We’lltalk to you on Monday,” and then hangup the phone?

If these types of weekend problemsseem to haunt you, then you need to takea closer look at Duncan Aviation’s totalcommitment to customer satisfaction and

our can-do attitude. Our accessory techni-cians are available to serve you sevendays a week, including 10 a.m. to 10 p.m.every Saturday and Sunday. We can takeyour unit counter-to-counter immediatelyon Saturday or Sunday or you may shipyour late Friday afternoon problems

Federal Express for Saturday delivery.

By utilizing two shifts during the week and our special weekend team,Duncan Aviation not only provides youwith the most capabilities on the unitsyou need, but also the best turntimes inthe industry.

Quality is not a five-day-a-week optionat Duncan Aviation. It’s a seven-day-a-week reality for customers who not onlydemand quality service, but demand itevery day.

For more information about DuncanAviation’s weekend accessory team or toschedule in your AOG unit, call ChrisGress at 800.228.4277 or 402.479.1664.

UNDERCONSTRUCTION

Demolition of the former General Aviationbuilding began in early September 1999.(Above)

The site was prepared for the foundationfootings in late September 1999. It reflectsthe removal of nearly 18,000 cubic yards of dirt—1,800 dump truck loads. (Right)

The hangar foundation and the basementarea walls were poured in early December1999. They contain 296,363 pounds of rein-forcing steel and 19,440,000 pounds (9.720tons) of concrete. (Right)

uncan Aviation’s Lincoln, Nebraska, facility is in the middle of its biggest construction project ever—a 123,000-square-foot facility consisting of a 60,000-square-foot hangar (Duncan’s largest yet) and 63,000 square feet ofadditional shop space. The new three-level shop area will house the sheetmetal, completions, installations,

upholstery, finish and cabinet shops as well as engineering and design. The hangar is scheduled for completion thisfall. Watch future editions of the Duncan Debrief for more information.

DSteel for the hangar and shop spacestructures began arriving in earlyJanuary 2000. The metal weighs2,818,000 pounds (1,406 tons) and wasdelivered in 75 truckloads. (Left and Bottom)

The magnitude of the project becomesmore apparent as the steel superstruc-ture begins to take shape. The steel structure should be completed by springtime. (Right)

Wayne Matthes (right) bids AVPAC “goodbye”and Gene Maddux (left) comes to Lincoln asAVPAC’s new manager.