Get FinancingAAI: How We Create FAA-Certified Specialized Repairs For King Air Landing Gear
Watch the Interview Footage Used for this Article Featuring Kevin Allen, President of AAI:
Keeping King Air aircraft flying safely and efficiently isn’t just about replacing worn parts. It’s about knowing when and how to repair them the right way. At Aircraft Accessories International (AAI), we’ve built our reputation on developing FAA-certified specialized repairs that save operators time, reduce costs, and minimize downtime without compromising safety.
In this article, we’ll walk you through how we approach King Air landing gear overhauls, how specialized repairs are developed and approved, and why they’ve become such a critical solution for today’s aging fleets.
Understanding The Challenges In King Air Landing Gear Overhauls
When a King Air landing gear assembly comes in for overhaul, we consistently see a few common issues:
- Cracking
- Corrosion
- Wear and physical damage
These problems are often the result of:
- Thousands of flight cycles
- Environmental exposure
- Delayed maintenance
- Runway incidents or operational stress
No matter the cause, the priority is always the same: returning the landing gear to a safe, airworthy condition.
Repair vs. Replace: A Smarter Approach
Traditionally, damaged components are simply replaced. But in today’s market, that’s likely the slowest (thanks to ridiculously long lead times) and most expensive (new part prices have skyrocketed) path forward.
For operators and maintenance teams, safety is the priority, but downtime and unexpected high costs are the constant frustrations.
At AAI, we take a different approach. In roughly 90% of King Air landing gear inspection events, we can:
- Use an existing FAA-approved repair, or
- Develop a new specialized repair tailored to the issue
This approach allows us to:
- Keep existing landing gear safe and in service
- Reduce overhaul costs
- Get aircraft back in the air faster
Why Beechcraft OEM Repairs Aren’t Always Enough
Beechcraft has provided solid guidance through structural repair manuals, particularly for corrosion and wear. However, as the King Air fleet continues to age, we’re seeing conditions that go beyond those original limits.
That’s where AAI steps in.
We’ve developed hundreds of specialized repairs specifically for landing gear components (more than 50 for King Air alone), including:
- Oversized bushing repairs
- Piston rechrome solutions
- Axle journal restoration
- Fabrication and manufacturing of replacement parts
These engineered repairs allow us to save components that would otherwise be scrapped, avoiding unnecessary costs for operators.
What Is An FAA-Certified Specialized Repair?
In aviation maintenance, no repair can be performed without approved data. Most approved repairs come directly from the manufacturer in the form of manuals and service documents.
So, what happens when damage exceeds those guidelines?
That’s where specialized repairs come in.
Example: Trunnion Bore Repair
If we find corrosion or damage in a trunnion bore:
- We carefully remove the damaged material
- Engineer and manufacture a precision bushing
- Restore the bore to OEM tolerances
- Return the component to service
This isn’t guesswork. it’s a fully engineered, tested, and documented repair.
The FAA Approval Process: Built On Safety
Every specialized repair goes through a structured engineering and approval process. This step is critical because safety and compliance are always the priority.
The process includes close coordination between our engineering team and the FAA. Each repair must be validated to ensure that it does not compromise the structural integrity of the component.
The evaluation focuses on several key areas:
- Structural fatigue characteristics of the repaired part
- The amount of material removed during the repair process
- Whether the repair will affect the life limit of the component
Only after all engineering requirements are met and FAA approval is obtained can the repair be used. Once approved, it becomes a certified solution that can be applied in future cases.
Key considerations include:
- Will the repair maintain structural integrity?
- Does it impact the part’s fatigue life?
- Are we removing too much material?
Only after passing all checks does the repair become FAA-approved data.
Managing Turnaround Time With Smart Repair Strategies
Turnaround time is one of the biggest concerns for any operator. Developing a new repair typically requires a few weeks, especially when engineering and FAA coordination are involved.
Developing a new repair typically takes:
- 2–3 weeks for standard components
- Longer for life-limited parts, due to additional scrutiny
To keep aircraft moving, we use two different strategies. In urgent situations, we can pursue a one-off repair that is approved for a specific aircraft serial number. This allows us to act quickly and get that aircraft back in service.
At the same time, we invest in developing multiple-use repairs. These take longer to approve up front, but they become part of our permanent repair portfolio. When the same issue comes in again, we can immediately move into production without waiting on additional approvals.
This balance between speed and long-term efficiency is a big part of how we reduce downtime for our customers.
At AAI, we prioritize building a library of reusable repairs to reduce delays over time.
Here’s an outline of our two primary approaches:
- One-Off Repairs
- Approved for a specific aircraft serial number
- Faster to implement
- Ideal for urgent situations
- Multiple-Use Repairs
- Designed for repeat application across the fleet
- Take longer initially
- Provide long-term efficiency and faster future turnarounds
The Impact Of King Air Landing Specialized Repairs On Turnaround Time
We’ve already developed 50+ King Air-specific landing gear repairs, with hundreds more across our broader capabilities.
What this means for operators:
- Repairs are ready when your gear arrives
- Less waiting on engineering approvals
- Faster movement from teardown to completion
This readiness is a major advantage in minimizing aircraft downtime.
Innovation Beyond The Repair Itself
Innovation at AAI is not limited to the repair itself. We also look closely at the processes and tooling that support those repairs.
A good example is the work we have done on nose landing gear pistons. While rechroming was already an approved repair, the turnaround time for that process had become too long due to external factors.
To improve the situation, we developed a specialized tool that allows us to remove and replace the tube within the fork using a pre-repaired component. By doing that, we reduced downtime from several weeks to roughly ten days.
This type of improvement has a real impact on operators who can’t afford extended delays.
Sometimes, improving turnaround time isn’t just about the repair data. It’s about the tools required to do the job and the process for completing it efficiently.
Why Engineered Repairs Matter More Than Ever
Aircraft parts are more expensive than they have ever been. Lead times are longer, and availability is often limited. For many operators, replacing components during every overhaul is no longer a practical option.
Engineered repairs offer a better path forward. Engineered repairs provide:
- Cost control
- Reduced downtime
- Reliable, repeatable solutions
At AAI, we have built our processes around this model. Our engineering team, machine shop, and internal procedures all support the development and execution of certified repairs. Each repair follows a detailed workflow that ensures proper documentation, traceability, and compliance at every step.
Most importantly, they ensure the aircraft remains safe and compliant.
Supporting The King Air Fleet Now & Into The Future
The King Air platform continues to be one of the most reliable and widely used aircraft in the industry. At the same time, these aircraft are working hard in sometimes harsh operating environments, which naturally leads to wear over time.
As a result, the demand for specialized repairs continues to grow. We see new challenges regularly, and that drives us to keep developing solutions that meet the needs of operators and maintenance teams.
At AAI, we’re constantly developing new solutions because we see these challenges firsthand every day.
Partnering With AAI: A Better Way To Keep Aircraft Flying Safely
If you are maintaining a King Air, you already understand the challenges. Finding parts can be difficult. Costs can climb quickly. Long lead times can stretch downtime longer than expected.
Our goal at AAI is to make that process easier and more predictable.
We keep it simple:
- Call AAI – Share your part details
- Get a Quote – Clear pricing and timelines
- Get Certified Parts Fast – Repair or exchange options
In many cases, the part you thought needed to be replaced can be repaired and returned to service faster than expected.
We Can Help Support Your King Air Aircraft
At the end of the day, it’s simple: Aircraft belong in the air – not waiting on parts.
Specialized FAA-certified repairs are one of the most effective ways to:
- Extend component life
- Control maintenance costs
- Reduce downtime
If you’re dealing with a landing gear issue that seems beyond repair, don’t assume replacement is your only option.
There’s a good chance we’ve seen it and fixed it. Or if not, we can engineer a new specialized repair for it.