Magneto Failure Overview

Magneto Failure Overview

Magneto technology is some of the oldest and most trusted in the aviation industry!
However, what happens when a pilot has magneto failure? When one magneto fails, there are a few things a pilot might notice. First, there will be a decrease in engine power, but the engine will remain running thanks to the second system being independent of the first. Second, sometimes a magneto can malfunction in its failure to ignite the spark plugs, or the internal timing may malfunction. In this instance, the pilot will notice the engine beginning to run rough and will need to switch to the remaining magneto and see if that clears the problem. 
Even though an engine will continue to run with the loss of one magneto, there are several problems with having a magneto failure mid-flight. With the loss of one magneto comes the security of redundancy. They are a vital piece of equipment, and there is a reason that aircraft are built with two. Additionally, the loss of engine power can be potentially problematic, though in most cases does not pose a serious threat to the safety of pilots and guests. 

Aircraft-Magneto-Engine-Replacement-Parts2


Even in the case of magneto failure, only a very few accidents are a direct result of magneto failure, according to statistics provided by the National Transportation Safety Board. NRSB reports 16 recorded cases of aviation accidents due to magneto failure, with two of those sixteen being fatal. Most of these failures were listed as being caused by lack of maintenance or non-compliance with servicing and inspections. 
With attention to detail and a history of reliability, Kelly Aero has made sure that the magnetos produced to be dependable and safe. Our products are designed and engineered using in-house resources, with additional tooling and manufacturing for aftermarket magnetos occurring at our facilities. We offer an FAA and PMA approved quality system, which is readily available with low wait times. We both meet and exceed the standard industry testing with our own set of criteria for the product, whether it be the full system or a replacement part. We want to work with customers to ensure the delivery of a product that is first and foremost high quality and reliable, and that meets their needs.

Aircraft-Magnetos
Kelly Aerospace Energy Systems Announces Company Name Change.

Kelly Aerospace Energy Systems Announces Company Name Change.

Montgomery, Alabama. March 1, 2021 – Kelly Aerospace Energy Systems LLC, an industry
leader in general aviation ignition systems, has announced today that the company will begin
operating under a new name and will be known as Kelly Aero LLC, effective immediately. This
rebranding strategy consolidates our company name while encompassing our 37-year history in
general aviation. The company’s ownership, location, and staff have not changed.
Company President, Jeffrey Kelly stated “This rebrand of our company gives us a modern
streamlined brand while paying homage to our strong family commitment to aviation. Our core
values and commitment to deliver premium quality and value to our customers will continue to
hallmark to our success.”

Photo of Bendix CMI Aircraft Magneto FAA-PMA Replacement Parts 2

For more information about the name change or to learn more about Kelly Aero LLC please
visit: www.KellyAero.com.

About Kelly Aero LLC
Kelly Aero LLC is an industry leader with over 37 years of manufacturing and overhauling
products for general aviation. Kelly Aero’s facility, located in Montgomery, Alabama, is not only
an FAA-approved repair station that overhauls general aviation magnetos, but it is also an FAA
MIDO approved Production Approval Holder, with an FAA & OEM approved quality system.

Kelly Aerospace Energy Systems Announces Company Name Change.

Kelly Aerospace Energy Systems announces name change to Kelly Aero, LLC.

Montgomery, Alabama. March 1, 2021 – Kelly Aerospace Energy Systems LLC, an industry leader in general aviation ignition systems, has announced today that the company will begin operating under a new name and will be known as Kelly Aero LLC, effective immediately. This rebranding strategy consolidates our company name while encompassing our 37 year history in general aviation. The company’s ownership, location and staff have not changed.

Company President, Jeffrey Kelly stated “This rebrand of our company gives us a modern streamlined brand while paying homage to our strong family commitment to aviation. Our core values and commitment to deliver premium quality and value to our customers will continue to be hallmarks to our success.”

For more information about the name change or to learn more about Kelly Aero LLC please visit: www.KellyAero.com.

About Kelly Aero LLC

Kelly Aero LLC is an industry leader with over 37 years of manufacturing and overhauling products for general aviation. Kelly Aero’s facility, located in Montgomery, Alabama, is not only an FAA-approved repair station that overhauls general aviation magnetos, but it is also an FAA MIDO-approved Production Approval Holder, with an FAA & OEM approved quality system.

Piper Air Conditioning

Piper Air Conditioning

Believe it or not, the majority of the flight schools and colleges offering aviation-related degrees are in the Southern United States.
If there is a weather-related term that is synonymous with the south it is HEAT.

This particular install is a brand new Piper PA44, when completed it will head to CAE in Phoenix, Arizona.
The PA-44 is one of the most prolific and widely used twin-engine trainers on the market today.

The Piper Seminole has amazing dependability and value.
Generation of pilots have trained on this platform and along with other Piper models.
To see our full Piper STC list visit www.kellythermal.com or contact KATS at 440.951.4744.

Features:​

  • Ground pre-cooling with GPU
  • 20° plus temp drop in 5 minutes
  • No take-off, landing, or in-flight restrictions
  • No impact on cruising speeds
  • Easy-read digital temp/fan control – set it and forget it
  • Full use of the baggage area
  • Very efficient cooling – only 45 amps
  • Lightweight – Under 50lbs.
  • Reliable and efficient hermetically-sealed, brushless DC compressor – R134A
  • One week or less installation time

At KATS, we are quickly realizing that aside from our core customers installing our systems in their own aircraft, the flight schools are requiring our kits and seeing great results.

To receive a free quote or schedule and time to see one of our systems in person, call Walter Dodge at 334-224-0313 or wdodge@kellyaerospace.com.
Walter is our personal Renaissance man and is the VP of Operations for our Thermal Division.



Cessna Air Conditioning

Cessna Air Conditioning

Congratulations, you just purchased or have owned for some time, one of the most successful designs in aviation history.
The problem is in the heat of the summer it’s sweltering waiting as you find yourself #3 for departure and it’s 102 degrees on the tarmac.
For most pilots, air conditioning is a creature comfort, with the vast majority of the GA fleet not having this as an option, Kelly Aerospace decided to change that.

Now STC’d for Cessna 172, 182T, T182T, 182S, and 206. Kelly Aerospace Thermal Systems provide​ an all-electric solution to the summer heat that we all hate.

This system has zero effect on engine performance and keeps you cool and refreshed as you fly about for enjoyment or travel for work.
Our system was designed to be fully electric and not affect the performance of your aircraft whatsoever.

To receive a free quote or schedule and time to see one of our systems in person, call Walter Dodge at 334-224-0313.

Walter is our personal Renaissance man and is the VP of Operations for our Thermal Division.

Ways Pilots can keep flying during an economic downturn.

Ways Pilots can keep flying during an economic downturn.

Whether you have been a victim of a round of layoffs or a private pilot trying to find creative ways to keep flying on a budget, we all are experiencing some unprecedented times right now.
Here are some simple ways to stay in the aviation industry and keep flying during this time of economic uncertainty.

Put that extra rating to good use!

Whether you hold a CFI rating, IA, or A&P certificate, you might find that now is the time to get to work.
As challenging as it is to be a CFI, now might be the time to start picking up a few lessons at your local flight school.
With the airlines pushing for more pilots in the next 3-5 years, you can make a few extra bucks and build hours teaching during this time.
Know someone wanting to do an upgrade or an installation?
Now might be the time to take on a few side projects if you are qualified to do so.

As you are well aware, an individual with a PPL may NOT transport personnel or cargo, “for hire”.  However, splitting the cost of fuel is permitted between the PIC and passengers, so now might be a great time to pull the trigger on that fishing trip.

Do you have a Commercial Rating? Get creative!


Have you checked into property surveys or aerial photography?
Think of individuals or cargo that you could possibly transport or ways to fill logistical needs in your area.

Right now there also seems to be a huge shortage of IA’s and A&P’s.
Even if you don’t hold one of those certifications right now, investing in this would be a great option during this time of uncertainty as there is always a demand for these services.

KEEP FLYING IF YOU CAN AFFORD TO DO SO! 


Encouraging those who can afford to keep flying…It helps the FBOs, mechanics, and the entire industry.
Now is a great time to get your aircraft in for annuals, maintenance, and repairs.

Quality Upgrades at Kelly Aero

Quality Upgrades at Kelly Aero

One of the great additions to our processes in 2020 is a high power AmScope Microscope to our final inspection process.
This allows every our inspection team to get take a high power look at our finished units before they leave our facility.

Our new 80 power microscope allows us to inspect our block components for carbon tracking, carbon particles can collect in small cracks and develop into problems down the road.

“The Kelly Aerospace Quality Team is committed to adding new technologies to our final inspection process,” says Neil Clark (VP Sales & Marketing) “This addition allows us to go one step further in catching minor imperfections before they leave our facility.”

Doubling down our commitment to quality, this addition allows for a 99.9% rating on all blocks that leaving our facility free of imperfections.
Our engineering and development team has made major strides over the last few years to ensure that our processes at Kelly Aerospace continue to improve.

BeechCraft Baron Air Conditioning Components

BeechCraft Baron Air Conditioning Components

For most aircraft owners in General Aviation, your beloved aircraft is not equipped with an Air Conditioning System.
Most often, the problem of adding extra weight exceeds the desire for creature comfort.
The Kelly Aerospace Thermal System solves the weight issue at an affordable price with their complete electric system.

Kelly Thermal System’s THERMACOOL All-Electric Air Conditioning technology is pending FAA Certification for the Baron 55 series aircraft. There is no need to wait for the STC as field approvals are available today. field approval is now available. The highly reliable and efficient 28 volt brushless DC motor /compressor which runs on either a ground power supply or the aircraft electrical system provides a 20°  F.+  drop in cabin temperature within 5 minutes.

Features:

  • Ground pre-cooling with GPU
  • 20° plus temp drop in 5 minutes
  • No take-off, landing, or in-flight restrictions
  • No impact on cruising speeds
  • Easy-read digital temp/fan control – set it and forget it
  • Full use of the baggage area
  • Very efficient cooling – only 45 amps

Cool Air Where You Need It

COOL AIR is ducted through a center duct to deliver the air where it is most appreciated. Adjustable vents are installed for each passenger to Fine Tune the flow!

Baron_55_Headliner.jpg

Inlet and outlet air are ducted inboard and overboard by a vent on each side of the aft fuselage, precluding exhaust ingestion. 

Pilot Friendly

Digital Temperature controller is easy to use.  Set the desired temperature and forget it. Freeze protection is built in!  The controller has an LED screen, a three-speed fan, and fits nicely into your panel.

Mooney Aircraft Air Conditioning System Now Available

Mooney Aircraft Air Conditioning System Now Available

An Amazing Aircraft Just got COOL!!!

Kelly Aerospace Thermal Systems has received STC certification for its All-Electric Air Conditioning System for the Mooney R, S, TN, U, and V models.  The Electric System offers freedom from flight restrictions and introduces Ground Cooling to the General Aviation Market. You can now call ahead and have your aircraft “Pre-Cooled” without unlocking the cabin.

This 65-pound system is completely installed in the aft section of the fuselage and has a factory look.  The cool air is introduced to the cabin from the overhead for more complete cooling.  The system has no scoops, therefore, no airspeed penalties so this incredibly fast airplane is still just as fast.

A digital controller allows for carefree operation of the system while managing your flight.  The system is only available for 28-volt aircraft for now.

The receipt of the STC was formally announced at the Mooney Summit in Panama City Beach in September 2019.


Features:

  • Ground cooling with GPU.
  • Piezo switch included for effortless ground startup
    Minimum of 20° temperature drop in five minutes.
  • No take-off or in-flight restrictions.
  • Maximum of 50 amps at peak load, 45 amps at continuous normal operation.
  • The entire system weighs estimated at 65.6 pounds installed.
  • System can be operated on the ground, during taxi, takeoff, cruising, and landing.
  • Cabin-side components occupy only ½ of hat rack compartment leaving remaining space for storage.
  • AC system integrated into existing headliner distribution ports.
  • Simple operation via digital display mounted in the control panel.
  • The system runs using an 11,500 BTU hermetically sealed, 28-volt brushless DC Compressor Motor.

Enjoy some of the recent pictures of our first installation in a Mooney Ovation.

500hr Magneto Inspection/Overhaul

500hr Magneto Inspection/Overhaul

So your prized aircraft is down for an annual and your A&P says it’s time for your 500hr inspection.
Some pilots choose to overlook the importance of the inspection.
However, the 500-hour inspection is the single most important magneto service event.

Whether you are an owner, flight school, commercial operator, or engine overhaul shop, you can ensure continuing trouble-free and safe service of an aircraft magneto.

The 500-hour magneto inspection is critical to the safe operation of magnetos. While not a required service action as an airworthiness directive, it is considered critical and
mandatory by magneto OEM’s and is considered a good, common-sense maintenance practice by aircraft mechanics.

The 500 hour is scheduled preventative maintenance and to avoid expensive unscheduled maintenance. If a magneto is not inspected every 500 hours, then the risk of an unplanned component failure that can cause inconvenient and unplanned maintenance at a location far from an aircraft owner’s home airport is certain to occur.
The cost of one or more nights of hotel, car rental, meals, missed work, lost flight revenue will easily be offset by the relatively small cost of a 500-hour inspection.
The inspection is not limited to magnetos which have accumulated 500 hours in service. A 500
hour inspection can be accomplished at any hours of magneto total time in service. In some cases, some magneto and engine combinations may result in the need to perform magneto maintenance more frequently than 500 hours. Pressurized magnetos used on Continental and Lycoming engines operate in demanding, high altitude environments and require more maintenance than other types of magnetos.
Dual contact, or retard breaker magnetos that use the Shower of Sparks starting system typically require more frequent maintenance. Magnetos used in Shower of Spark applications require frequent
inspections to ensure that fuel-injected Lycoming and Continental engines do not experience hard
starting problems.


To begin the 500-hour inspection process, an inspection return form is downloaded from the Kelly Aerospace website. Complete one form for each magneto that is returned. Before boxing the magneto, remove the drive gears attached to the magneto. Return the complete magneto, with the drive gears removed, and do not forget to include the completed 500-hour inspection form. The magneto is returned directly to Kelly Aerospace, 1400 East South Blvd, Montgomery, AL 36116 with Attn
500-hour inspection marked on the box.
When the magneto is received, work starts within 24 hours of receipt. Plan for four working days to complete the inspection, plus shipping time to return to the customer. Kelly Aerospace ships via UPS or
FedEx and can ship worldwide. Check your shipper delivery zone time chart to determine the duration of shipping time to and from Montgomery AL.
The magneto is disassembled by a magneto technician so that the parts can be inspected and cleaned.
The magneto parts are cleaned and polished as needed. Magneto frames and housings are not repainted but can be repainted if the magneto is upgraded to an overhaul. The magneto parts are
inspected by visual and non-destructive testing, and must meet the criteria established in the Bendix
and Slick Maintenance and Overhaul manuals.
The 500-hour inspection for Bendix magnetos includes new replacement hardware, new contact points,
oil slinger, oil seal, (2) ball bearings, carbon brush, o-ring, felt strip, felt washer, and impulse coupling spring. The 500-hour inspection for the Slick magnetos includes new replacement hardware, new
contact points, and cam, oil seal, (2) ball bearings, carbon brush, distributor gear to comply with

Champion Slick Service Bulletin SB1-15A and impulse coupling spring. An FAA Form 8130 will be provided to document the 500-hour inspection.
Depending upon the condition and service history of the magneto, extra work or parts may be required.
Some of the extra parts would include worn distributor gear, worn distributor block, faulty coil, faulty
capacitor, worn impulse coupling, worn rotor shaft, or parts affected by airworthiness directives.
If any other parts are required, the customer will be contacted for additional charge approval prior to work
being completed.