Robinson R44 Helicopter Refurbishment Project
The Project:
In this project, we assisted an Australian maintenance organization in refurbishing a Robinson R44 helicopter for one of their clients. The refurbishment included a variety of interior components, such as seat upholstery, control boots, floor coverings, and headlinings. The parts were shipped to our New Zealand facility for fitting and then sent back to the maintenance facility for final installation.
Gallery:
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Seat Upholstery:
The seat covers and cushions were based on the Generation II style, tailored to fit the existing seat pans. The upholstery was crafted using saddle brown leather (ADI-4111), which offers a rich and sophisticated look. The inserts were quilted in a double-diamond pattern, with all stitching done in a thread that matched the leather's color, providing a seamless and elegant finish. Additionally, the same saddle brown leather was used to create collective and cyclic control boots, ensuring consistency throughout the interior. -
Floor Coverings:
The floor coverings were made from coal city carpet, precision-cut into segments using a CNC laser cutter. The carpet pieces were custom-fit for the cockpit floor and surrounding areas, with the edges finished in a matching mesh binding. This ensured both durability and a professional look. -
Headlining:
The headlining consisted of four panels wrapped with black fabric and fitted into the aircraft’s ceiling. The panels were designed with cutouts for features such as the window and hand holds above the doors, allowing for a clean and functional installation that integrates well with the aircraft's design.
This project significantly upgraded the Robinson R44, enhancing both its aesthetic appeal and comfort while maintaining the highest standards of functionality and durability. The client was pleased with the seamless integration of the new interior components, which have now been tailored to enhance the overall experience for pilots and passengers alike.
