1-218-444-4478 PO BOX 847, BEMIDJI, MN 56619
1-218-444-4478 PO BOX 847, BEMIDJI, MN 56619

Legacy Aircraft Replacement Part Fabrication

We Engineer/Build/Create the Parts You Need
AirCorps Aviation > Legacy Aircraft Replacement Part Fabrication

Our Capabilities

Reverse Engineering

CAD / CAM

Metal Forming

CNC Machining

Assembly & Inspection

Fixtures & Jigs

Quick Turn Around

Our team works diligently to ensure timely completion so you receive your part as soon as possible.

No Project Too Big or Small

Our experienced staff and state-of-the-art equipment can handle almost any job you could imagine.

FAA/PMA

We adhere to all FAA/PMA standards and produce parts of exceptional quality.

Available Fabrication Processes

Stretch Forming

Hydro Pressing

Drop Hammered

Machined Parts

Castings & Forgings

Assemblies

3D Scanning

Tooling

Case Studies

PROBLEM

AOG (Aircraft On Ground) forced the necessity for an immediate part.  The client needed a complex formed sheet metal part ASAP.

SOLUTION

AirCorps Fabrication was able to fabricate tooling and the replacement part within several days.

PROBLEM

A regional air cargo carrier wanted a more affordable and faster repair solution for a cracking engine cowl.

SOLUTION

Utilizing 3D scanning to capture highly accurate dimensions.  A doubler was engineered in CAD and fabricated by spin forming.

PROBLEM

An aircraft repair company needed a source that could reverse engineer and fabricate short runs of obsolete damaged ribs.

SOLUTION

AirCorps Fabrication is capable of taking an original part without drawings and reproduce perfectly fitting replacements.

PROBLEM

Tasked with restoring an aircraft and with very little parts and only original hand drawings, the project required 3D drawing formats to utilize modern manufacturing equipment.

SOLUTION

With AirCorps aviation experienced CAD technicians, AirCorps has converted thousands of 2D drawings into 3D CAD models that can easily translate to modern machining file formats.

PROBLEM

A client that engineers modifications to aircraft needed a supplier that could fabricate and deliver finished assemblies.

SOLUTION

Beyond simply fabricating an individual part, AirCorps Fabrication can provide a fully finished, multi-part assembly.

Frequently Asked Questions

Do you only fabricate parts for WWII aircraft?

No, we fabricate and manufacture parts for a large variety of legacy to modern aircraft types.

I have a “certified aircraft” but can not obtain original drawings for a replacement part. Can you help me?

Yes, we can reverse engineer and provide assistance working with the FAA and DER’s to obtain the necessary approved data to fabricate most parts.

How long does it take to get a part reverse engineered and fabricated?

Due to the varying complexity of every part it is something that is quantified in the quoting process.

I have the resources capable to fabricate the part, however, I need reverse engineering services.

We cater to our customers needs and can provide individual services upon request.

Shop Highlights

  • Specialization in formed aluminum structural components
  • FAA PMA Quality System
  • Full repertoire of CNC equipment
  • 3D Scanning to CAD model creation
  • Full service engineering to fabrication part delivery
  • 3,000 sq. ft. machine shop
  • Specialize in low volume orders

The AirCorps fabrication team specializes in the use of traditional and state-of-the-art methods to manufacture and produce aircraft parts. Our adherence to the FAA-PMA Quality System, range of capabilities, and exacting detail are evident in the award-winning work for which AirCorps is known.

Benefits of AirCorps Fabrication

Expertise: experienced team producing parts under an approved FAA-PMA quality control system. Our diversity of clients and world class restorations have guided our comprehensive understanding parts fabrication. 

Capabilities: the range of capabilities we manage both internal and external defines who we are. We are staffed and equipped with the experience and equipment necessary to produce finished and ready for install components. 

Quality Control: We are proud to manage a FAA-PMA Quality Control System and will continue to develop our quality management systems to further expand our opportunities and offerings.

Customer Service: client relationships are rooted in our knowledge of being both an world class restorer of aircraft, consumer, and by supporting outside customers. Our interactions are relationship driven, long-term, and valued.

Portfolio of Resources: our growing library of original manufacturer blueprints, manuals, and resources allows us to quickly access rare technical data important to understanding, reproducing, and delivering exacting components.

Honoring Techniques & Methods: our team understands and embraces manufacturing techniques of vendors not in business today. We strive to reproduce that historic look while balancing the cost and efficiency afforded by modern technologies.

Consistency: having fabricated thousands of parts, we know what works and what doesn’t. We deliver parts organized and labeled professionally that integrate seamlessly into a shop setting.

Current Customers

Shop Equipment Details

Metal Forming Equipment

Sheet Metal Stretcher Table
250 Ton – 102″x 70″ Capacity

570 & 1500 TON RUBBER PRESS
24 x 34 ″&  30 x 72

80 and 55 Ton Shop Presses

Digital Control Heat Treat Oven
24″x 18 x 43″ &  60 x 60 x 60

CecoStamp Drop Hammer
32″x 32″

CNC Press Brake
6 foot – 35 Ton

Various Sheet Metal Shears

Various Box and Pan Brakes

Farnham Roller
12 Foot Capacity

 

CAD / CAM

Dassault Solidworks
 CAM Works
Creaform VX Model

Machine Shop Equipment

CNC Vertical Mill
XYZ: 30 x16 x 20″

CNC Vertical Mill
XYZ: 40″x 20 x 25″

CNC Lathe
10 Diameter x 20 Length
4 axis live tooling″

Bridgeport Mill
XYZ: 36 x 13″x 20″

CNC Chucker Lathe
6 Diameter – 6″Length

Engine Lathe
15″Diameter – 48″Length

Welding

Tig Welding
Ferrous & Non-Ferrous AWS D17.1
300 Amp Miller Aerowave

Aluminum Spotwelding
Sciaky 90KVA Mil-spec
3/16 2024-T3 Capacity

Inspection

Nortec 500S, FM-140, ED-520
Digital & Analog Flow Detection & Conductivity Testing

Zyglo ZL-60D, 2L-67
Water-Washable Fluorescent Penetrants