Logistics of Aero L-39 Skyfox Deliveries: Precision, Safety, and Efficiency at Every Step

Vodochody, November 26, 2024 – AERO Vodochody AEROSPACE, a leader in the production of training aircraft, unveils the details of the sophisticated logistical process ensuring the transportation of L-39 Skyfox aircraft to customers. The aircraft are delivered either by self-ferry or by air transport. The process involves comprehensive planning and, if necessary, professional disassembly and reassembly.

“A finished aircraft is not the end of the process. It is rather the start of a long journey, as these aircraft serve customers for 40 years, during which we remain closely connected with them,” says Viktor Sotona, Chairman of the Board and President of Aero. “After manufacturing, testing, and flight trials, we still have to complete many additional steps that are part of the delivery contract. These contracts are very extensive. Customers must receive full support with the product, including a complete description of the aircraft, manuals for technicians and pilots, a set of spare parts, ground equipment, and, not least, assistance with training and test flights.”

Shadow Aircraft for Training
Deliveries often include a flight simulator. Customers may request a Full Mission Simulator, which offers the most realistic experience and simulates all controls and aspects of flight, including aircraft behavior under various flight conditions. Another type of simulator focuses on cockpit procedures and is often designed with a fixed fuselage. Pilots use this to learn specific procedures, such as takeoffs, landings, or emergency scenarios. “We frequently prepare, design, and equip entire classrooms for customers where pilots and mechanics are trained to operate all aircraft systems,” explains Miroslav Kozel, PMO Director Defence & MRO, Aero. “Deliveries also include spare parts and ground equipment, which can weigh tens of tons. These include various carts, chocks, tarps, and similar items.”

A 1.2-meter-high Stack of Manuals
A 1.2-meter-high stack of paper, totaling around 40,000 pages of text, would represent the documentation for a new aircraft if Aero printed it. Instead, an interactive manual is used, prepared by Aero’s team of experts during the aircraft’s development and production. This complex document is designed to guide the customer as clearly as possible through resolving various situations. If a repair is needed, the documentation specifies the necessary tools and their proper use. When a replacement is required, the manual directs the customer to a parts list with codes, ensuring maximum intuitiveness and logic. Another document is the pilot manual, which is similarly extensive but focuses on operating procedures and various scenarios involving the aircraft.

Safety and Quality First
“Every step of the process for transporting and delivering L-39 Skyfox aircraft is meticulously planned and executed with an emphasis on precision and safety. Our specialists conduct thorough inspections before and after transport to ensure each aircraft arrives to the customer in perfect condition,” says Viktor Sotona, Chairman of the Board and President of Aero.

Self-ferry or Air Transport
For countries closer to Aero’s production facility in Vodochody, the aircraft can be ferried directly, minimizing the time and costs associated with disassembly and transport. For distant destinations, arranging air transport is a highly complex process due to the military nature of the aircraft, requiring overflight permissions from each country along the route. While sea and truck transport can involve significant vibrations, aircraft are shipped by air in disassembled form, secured in specialized transport frames. These frames allow for basic crane handling or rolling on wheels. Technicians can disassemble and package an aircraft in protective wrap within a week.

“We fly from Pardubice or Ruzyně airports. We often use IL-76 transport aircraft, carrying two disassembled L-39 Skyfox units. Each aircraft requires four transport frames—one for the fuselage, one for the wings, another for the tail section, and one for the stabilizer. We also use Boeing 747 Cargo aircraft, primarily loaded through the nose opening and via rear side doors for the upper deck. Spare parts and ground equipment are loaded into the lower deck. A single B747 can accommodate three of our aircraft, ground equipment, and spare parts,” explains Miroslav Kozel, PMO Director Defence & MRO, Aero.

Aero representatives are, of course, present for unloading. Typically, within three weeks, the aircraft is assembled and flight-tested. A team of specialists is on-site to ensure the safety of both Aero personnel and the customer’s pilots. The team consists of 10 to 12 members, including experts in seats and armament, airframes, avionics, and a test pilot. The test pilot performs a flight check after assembly to confirm the aircraft is fully operational. Contracts also often specify that Aero will assist with pilot training throughout the warranty period.

How Aircraft Are Disassembled for Transport
The professional disassembly of the aircraft includes:
• Removing the main wings, horizontal tailplanes, and vertical stabilizer: These parts are carefully detached, packed, and transported separately.
• Detailed labeling and documentation of components: Every part is meticulously identified and documented to ensure quick and error-free assembly at the destination.
• Inspection and packaging of components: Key aircraft parts, including avionics, hydraulics, and power units, are protected with special anti-static and shock-resistant packaging.
• Certified transport frames: The aircraft fuselage is secured in specialized transport frames that provide maximum stability and protection during transport. Mounted wheels allow for easy handling.

On-Site Assembly and Test Flights
After delivery, Aero’s team handles:
• Reassembly of the aircraft: Using original tools and certified procedures, the wings, tail sections, and other components are reattached and integrated with the fuselage.
• System diagnostics and calibration: Avionics, hydraulics, and other systems are thoroughly calibrated to meet the customer’s operational specifications.
• Test flights: A test pilot conducts flight trials to confirm the aircraft is fully operational, often in the presence of the customer.

The first L-39 Skyfox aircraft were delivered to Vietnam in collaboration with Omnipol, under a contract signed in 2021 for 12 units. Omnipol, a co-owner of Aero, facilitated the agreement, marking a significant milestone in Aero’s international reach.

AERO Vodochody AEROSPACE a.s. specializes in the development, production, maintenance, and modernization of civil and military aircraft. It is the largest aviation manufacturer in the Czech Republic and one of the oldest aerospace companies in the world. In the field of proprietary aircraft, Aero is a long-standing partner to numerous military air forces and holds a strong position in the market for military training and light combat aircraft. With 11,000 aircraft produced over its century-long history, hundreds of L-39 Albatros aircraft still in service with various military operators and aerobatic teams, and its new L-39 Skyfox, Aero has established itself as a global leader in the market for jet training aircraft. In the civil aviation sector, Aero collaborates with the largest aerospace manufacturers on a wide range of projects and is a partner in several risk-sharing programs, where it is responsible not only for the production and assembly of aircraft components but also for their development.

Contact:
Radka Černá, PR & Communications Manager
Email: radka.cerna@aero
Phone: +420 608 974 258
Website: www.aero.cz

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