Fleet Readiness Center East artisans and engineers working the H-1 Program have completed more than 30 percent of the work required to transform the first of three Marine Corps UH-1N Hueys into the Air Force version of the aircraft.  They’ve been working on the aircraft about 60 days.

The Hueys are all around 40 years old, and arrived here from the bone yard at Davis-Monthan Air Force Base, Ariz., in July.  The Air Force plans to take possession of a total of 26 retired Marine UH-1Ns to replenish its fleet, but will convert and place only these three in operating squadrons. Some of the Hueys the Air Force has asked for are still being flown by Marine units.

Transforming each of the aircraft requires five significant modifications, according to AIR-4.5 H-1 Avionics System Engineer Lead Paul Aheimer.  He said two of the modifications will require both electrical and structural alterations.

“Installing the new VOR (VHF Omnirange Receiver)/ILS (Instrument Landing System) and FLIR (Forward Looking Infrared) systems are probably the most difficult modifications, because integrating these systems into the aircraft requires extensive rewiring,” Aheimer said.  “We also have to reconfigure the cockpit console between the pilot and copilot.  The VOR/ILS being installed is the primary navigation system – once it’s added to the two systems already onboard, it will give Air Force pilots the same setup they’re used to.”

Aheimer said replacing Marine FLIR with the Air Force version requires removal of the existing video cassette recorder and video display unit and installing a new  cockpit display unit, a new flight engineer display unit, a new central electronics unit, a new hand control unit, and a new VCR.

“We’re making it as much like the Air Force configuration as we can,” he said.  “The Air Force system has a smaller display in the instrument panel and a larger one in the overhead, and the VCR is in the pedestal, not overhead.”

Artisans will redo the overhead lighting panel and add a strobe light on the aircraft’s belly to mirror the Air Force’s top and bottom, two strobe light configuration. They are also removing the infrared ring lighting and night vision goggle heads up display as Air Force Hueys are not NVG compatible.  Other systems being removed include the radar warning system, the missile warning system, the countermeasure dispensing set, the IR transmitter system, the aural alerting unit, and the position locating reporting system.

“We’re removing any equipment the Air Force doesn’t need, or doesn’t want to introduce because it requires additional training and logistics support,” Aheimer said.  “Removing excess equipment reduces overall weight, which is always a plus.”

Aheimer said the package also calls for replacing the Marine Corps water-activated accoustic beacon with a portable emergency locator transmitter crew members can detach and carry with them.  Workers will also install the Air Force version of the T400 engine, swap out high-time components, and fill holes with needed components where parts had been harvested prior to the helicopters going to the bone yard.  Aheimer said artisans have been using Air Force or locally produced engineer drawings to build parts when required, and have produced a number of relays, brackets, mounts and cover plates.   The aircraft will also be stripped, painted, and flight checked before going back to the customer.  FRC East is completing the package for about $1 million per aircraft.

“Our goal is to make these aircraft look, feel, and fly like the Air Force originals,” Aheimer said.  “But let’s face it, this is a hybrid – it’s not Marine, and it’s not Air Force, it’s something in between.”

Aheimer said the first Marine to Air Force Huey should be delivered in September.

NAVAIR press release