Aircraft conversions: specialist freighter conversions work expands

Citation

Allen, R. (2001), "Aircraft conversions: specialist freighter conversions work expands", Aircraft Engineering and Aerospace Technology, Vol. 73 No. 6. https://doi.org/10.1108/aeat.2001.12773faf.002

Aircraft conversions: specialist freighter conversions work expands

Aircraft conversions: specialist freighter conversions work expands

Keywords: XS Aviation, Aeronavali, Fabrication

A new name in the aviation community put the spotlight on an old company with the launch of XS Aviation Ltd, which entered into a work programme with Aeronavali of Italy. Newly-formed XS Aviation is an aircraft investment management company, whose particular expertise is the acquisition and conversion of DC-10-30 aircraft from passenger to freight use. Aeronavali of Italy, formed in 1947, is the specialist repair, maintenance and conversion organisation charged with the actual work.

The airliner conversion business is now very large, and believed by the Boeing Company shortly to be worth $15 billion for its practitioners. Currently, there are some 234 DC-10s of all models flying and available for freighter conversion. XS Aviation has acquired 20 DC-10-30 aircraft and some of these are already serving, in converted cargo form, through operating or other leases with Gemini Air Cargo, Emery Worldwide, VARIG and World Airways. Aeronavali is now engaged in the modification programme for a further 11 in the contract.

Aeronavali's procedure is to take a DC-10-30 and tear down the aircraft entirely, removing all seats and interior cabin fittings to generally obliterate all traces of the aircraft's previous passenger service life. Depending on its condition, this can take from three to five months. Early constructed aircraft, for example, can require complete replacement of the floor beams.

A main feature of the remodelling is the installation of a forward main deck cargo door, and this is manufactured and fitted by Aeronavali in Naples, as are all the parts relevant to the conversion programme. Work will include complete stripping of previous paintwork, which will be reapplied in new customer livery on completion of all structural work. The major final task will be installation of the on-board cargo loading system. Made by the American company ANCRA, this is usually provided directly by the customer and regarded as buyer furnished equipment BFE).

The degree of expertise gained in DC-10 modification work by Aeronavali is reflected in the fact that cargo kits are now manufactured and have been supplied to Boeing Airplane Services, amongst others, for DC-10s and MD-11s converted by that company.

Gross weight of the DC-10-30 is raised by some 10,000lbs (4,545kg) to 575,000lb (261,364kg) after conversion, giving a cargo payload of some 71 short tons. A DC-10-30 will cost XS Aviation approximately $7.5 million on the second-hand market and some $3 million will be spent on maintenance of the aircraft in the retention period prior to conversion. After the conversion programme the aircraft will be offered to the market and in its new form could be worth up to $25 million as a long-range freighter with extended life. Leasing terms and costs will then be arranged at the time of hand-over to an operator.

Giacomo Perfetto explained that Aeronavali has gained great expertise in the conversion of DC-10s but this represents only a part of the company's freighter conversion programme, having converted 47 DC-8s, 54 DC-10s and four MD-11s since 1985. Originally incorporated in Venice in 1947, the company today has three operational facilities, at Venice, Naples and Brindisi, providing in total 86,500 square metres of workshop space.

Venice is the largest of these and has been so committed in recent times to the conversion of DC-10s for FedEx (Federal Express) that it is expected that this will become the base's prime function. An FAA approved repair station since 1963 and gaining ISO 9001 -94 certification in January 2001, Aeronavali performs overhaul and maintenance services also on DC-8, DC-10, MD-11, ND-80, B727, A300 and ATR-42/72 aircraft, as well as a range of military models including B707s, E-3A AWACs and C-130s.

DC-10 conversion has covered all models, with FedEx work involving DC-10-10s and a contract with the Ten Forty Corporation for the entire fleet of ex-Japan Air Lines DC-10-40s. Under the FedEx contract the agreement is between Aeronavali and Boeing.

In July 2000, Aeronavali contracted a new agreement with Boeing for the modification of B767-200s to special freighters, and this will see the provision of modification kits, tool design and fabrication and engineering support. Of the 226 B767-200s in service, Boeing believes that approximately half will become freighters over the next 20 years. For XS Aviation, Mr Ian Taylor, senior vice-president technical, said the company is looking at newer aircraft for its conversion programme and this could include B767s and B757s. With noise regulations at airports driving the need for more modern aircraft, he believed the B757 could replace the B727 as a freighter, and XS Aviation has in fact already acquired two 757s to add to its portfolio.

Further details are available from XS Aviation Ltd, London. Tel: +44 (0) 20 7409 7575; Fax: +44 (0) 20 7409 2862. Or contact Giacomo Perfetto, Marketing Manager, Aeronavali Naples, Italy. Tel: + 39 081 2344863; Fax: + 39 018 2344873.

Roy AllenXS Aviation, London, UK