USAF T-37B, 1989-1994:

The T-37 is the U.S. Air Force's primary pilot trainer, and every student begins in this aircraft regardless of later specialization. Without a near-term replacement (which has only recently been procured, as the "JPATS" or Texan II), the T-37 fleet was rapidly nearing the end of its projected life in the late 1980's. Sabreliner successfully designed, developed and provided 571 SLEP kits for an Air Force T-37B rehabilitation effort that extended the structural life of the aircraft by 8,000 hours each. The contract required:

• Structural modification of the wing spars
• Structural modification of the wing/fuselage carry-through structure
• Redesign of the horizontal stabilizer
• Redesign of the major mold line forgings that attach the empennage to the aft fuselage

Sabreliner and its subcontractors utilized loft data from Cessna Aircraft Corporation (the OEM) to fabricate new tools, modify existing tools and manufacture more than 3,300 parts. Four full-scale production aircraft were utilized for static tests, fatigue (durability) and damage tolerance tests, flight tests, and production kit proof installations. All T-37B testing required detailed test plans to be developed, coordinated with the Air Force and carried out to an extremely tight schedule, with overlapping non-recurring engineering design, analysis, and test phases occurring prior to initial production deliveries. In addition to this testing, a verification "proof kit" installation was performed by the Air Force, using production line tooling designed and delivered by Sabreliner to accommodate USAF production of 26 aircraft per month.

Pakistani Air Force T-37B/C, 1992-1994:

Sabreliner tested and produced 47 SLEP kits for the Pakistani air force. This effort required kits and installations similar to those developed for the U.S. Air Force T-37B SLEP contract. In addition to the USAF requirements, a portion of the Pakistan fleet needed new leading edge kits for the wings. This required the extensive use of aerodynamic loft contour data, fabrication of additional detail tools, and development of a new leading edge assembly and check fixture. Under this contract, Sabreliner maintained a long-term presence in Pakistan for installation training and supervision of the customer's personnel.