Tag Archives: repair

No Flying this Weekend

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It could be worse.

Robinson Mixture ControlThe other day, I reported a mechanical problem with my helicopter. In summary, the mixture control had been kind of stiff and it made a weird noise when I pulled it out. When my mechanic attempted to lubricate it, the mixture cable snapped.

The photo here shows a Robinson Raven II instrument panel very similar to mine. I’ve circled the mixture control. Remember: push in to allow fuel flow, pull out to stop fuel flow. Airplanes have similar controls. Airplane pilots adjust this in flight — that’s called leaning the engine. Helicopter pilots generally do not do this. It’s either in and the engine is running or out and the engine is stopped.

I didn’t make a big deal out of it then because it seemed to be a simple enough fix. We ordered the replacement cable from the factory and I figured that Ed, my local mechanic, would get that sucker installed not long after it arrived.

The more amazing thing to me — at least at the time — is that I’d proactively found and set about resolving a minor mechanical problem before it got me stranded somewhere inconvenient. The timing couldn’t have been better. The day before, I’d written an article for HeliNews about that exact topic. I was pleased that I’d learned a lesson.

Mixture Control SchematicWell, things are never as easy as they should be. Ed got the cable and went to work installing it. He soon ran into problems. The cable wouldn’t move smoothly. It wouldn’t go in all the way. He’s pretty sure we’ll have to order the entire cable assembly today. (This image, taken from Robinson SB-55, shows where the mixture cable attaches to the fuel mixture control. I highlighted the cable and its sheath in red. We ordered just the cable and it is apparently having trouble moving in the original sheath.)

Today is Friday. Although they could overnight the part for Saturday delivery, Ed doesn’t normally work on Saturdays. So I’ll save a few bucks on shipping and get it delivered Monday. With luck, it’ll be just what Ed needs and he can install it then.

Until it’s installed, there’s no flying for me.

But that doesn’t seem to matter much. I have no flights scheduled for this week and I have plenty of writing work to do. (I’m developing my third course for Lynda.com and have an open request for short how-to articles to fill for one of my publishers.) This weekend, I’m volunteering at the annual Land of the Sun Endurance Ride by marking horse butts with numbers, making my famous vegetarian bean soup, and timing in the 50-milers at the 25-mile manditory break. It’s almost a good thing that the helicopter is down for maintenance; less of a distraction for me.

I do want it running soon, though. Murphy’s Law of helicopter charter operations states that the most calls for your service will come in when you’re least able to meet customer needs. It must be a sign of the economy that my phone hasn’t started ringing off the hook yet.

How do you make a million dollars in aviation?

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Start with two million dollars.

That isn’t my joke — it’s standard aviation humor. And if you think it isn’t true, start an aviation-based business.

Yesterday, against all odds, UPS actually delivered the auxiliary fuel pump I needed to get Zero-Mike-Lima up and running again. Yes, on Saturday. In Wickenburg.

The UPS guy was at our neighbor’s house, looking for ours when we spotted him. Mike gave a New York hail-a-cab style whistle and the driver saw us waving at him from our hillside. Moments later, he was on our driveway in front of the house.

“How many deliveries did you have to Wickenburg today?” I asked.

“Two,” he replied. “And you’re lucky it was me driving. I was out for four weeks. If the other Saturday driver can’t find a house, he just doesn’t deliver.”

Yes, I was lucky. I needed the part to replace the fuel pump that had gasped its final gasp on Friday, right at the end of a flight. Although the pump is redundant in flight (so there was no danger during the flight), I do need it to prime the engine at startup. I couldn’t fly without it. And I had three relatively lucrative gigs lined up between Sunday and Thursday.

The fuel pump cost $1,500. Add another $40 or $50 for overnight Saturday delivery by UPS. Then add the cost of the mechanic who graciously agreed to come in on Saturday — one of his usual days off — to install it. I told him to charge me extra. He said he would. Hell, it’s only fair. He could have said it would have to wait until Monday. Then I’d miss out on one (which turned into two) of my gigs.

Doing the Math

Unexpected repairs like this are only part of what makes operating an aviation business a lot more expensive than people think. How many times have I been at a rides gig where people asked how much fuel the helicopter burned? Every single one. I tell them it’s 16 to 18 gallons an hour and sometimes they ask how much fuel costs. I tell them $4 a gallon. They do some math in their head to come up with $64 per hour. Then they see us loading people on board for $30 a head, sometimes three at a time, and figure I can get 6 10-minute flights in per hour. That number comes out to $540/hour. Jeez! I must be making a fortune!

The truth of the matter is, fuel is among the least of my expenses.

What people always fail to consider is insurance (at about $11,500 per year); regular maintenance like oil changes ($120 each), 100-hour inspections ($2,000 each), annual inspections ($2,000 each); and the cost of the oh-so-important overhaul due at 2,200 hours that costs (currently) a whopping $182,000. (Do the math on that: $182,000 ÷ 2200 = $83/hour.)

And then there are things like this fuel pump. The original pump lasted only 416 hours. If the final cost of replacement is $1,700 (with all labor and expenses), that works out to another $4/hour. Add that to the cost of replacing my primary radio, which is currently in the shop and may be declared dead: $2,100 for a used one plus several hundred for troubleshooting the old one and swapping them out. And the cost of that clutch down-limit switch that had to be replaced 200 hours ago: the $8 part with $800 labor. And, oh yeah, let’s not forget $120 just to make sure my transponder is working right — that’s something I’ll be paying for every two calendar years.

How about the support stuff that doesn’t go on my helicopter? Like the $1,200 tow bar and the $600 golf cart (used, thank heaven) to pull it? And monthly rent for the hangar to keep it safe and dry and out of the sun? And the charts and other FAA publications I’m required to keep up to date, including sectionals (twice a year per chart), terminal area charts (twice a year per chart), airport/facilities directories (every 56 days), and the FAR/AIM (once a year)? Or how about my annual medical exam, which is required just to keep my license? Or credit card fees just so I can accept credit cards for payment?

And how about marketing? The $1,600 I just spent on 4-color, tri-fold brochures and the $459/month I spend during the high season to get them in brochure racks throughout the Phoenix area? And the cost of the trade show I’ll be attending later this month to sell my multi-day excursions to folks looking for a different kind of vacation?

And how about the cost of my ground crew on those outdoor ride gigs and the cost of permits and commissions just so I can do them? And the cost for operating the helicopter just to get to and from the gig — sometimes more than an hour each way? And the cost of the table and chairs and shade structure and signs that we use on those gigs? And those orange cones and all that yellow Caution tape? And overnight lodging and meals for me and the ground crew on distant, multi-day gigs?

Don’t get me wrong. I’m not complaining. I knew I was in for it when I launched this business.

But it does explain why I have to charge $450/hour for flight time. I’m not pocketing nearly $400 in profits as most people may think. I’m barely covering my costs.

Paying for It

Today is Sunday and Zero-Mike-Lima is sitting snug in its hangar, all ready to fly. I picked up a second tour today, one of my Ghost Towns & Mines air tours. Right after that, I’m doing my first ever Swansea Town site day trip. On Tuesday, I’m taking a winter visitor to Scottsdale for some upscale shopping. And on Thursday, I’m taking some folks to Sky Harbor so they can catch a flight to Canada. The total revenue for these four flights is estimated at $1,895. That’s revenue, not net income.

Just enough to cover the cash outlay for that fuel pump and labor.

Would I give it all up? Hell, no! But I do hope the new fuel pump lasts longer than 416 hours.

A Helicopter Repair Story

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Including a happy ending.

On Tuesday, I flew out to Robson’s Mining World in Aguila, AZ. I was scheduled to appear there on Saturday for their anniversary celebration and I wanted to make sure my usual landing zone was in good shape.

It was a windy day and I was tossed around a bit on the 8-minute flight from Wickenburg (vs. a 30-minute drive). But the winds were calmer closer to the ground. I circled Robson’s once, then set down on what I thought was a spot closer to the road. Turned out, it was the same spot I’d occupied the year before. It just looked closer to the road from the air. The quartz rocks Mike and John had laid out in a line for me were still there. The idea was to land with the helicopter’s cockpit over the line. That would keep my tail rotor away from the bushes behind us. But since the bushes looked bigger than they had the year before, I positioned the helicopter a little bit closer to the road.

I cooled down the helicopter and shut down the engine. Then I went out to assess the landing zone on foot. I discovered that the quartz line was still quite workable for me. The bushes were farther back than I’d thought on landing. (I always estimate the helicopter’s tail longer than it really is.) So the landing zone was fine. No trimming would be required. That’s good because I don’t like the idea of cutting any desert vegetation unless absolutely necessary.

I put on my jacket — it was still quite cool at 9 AM — and walked through Robson’s front gates. The place looked deserted. I headed toward the restaurant, planning on having a piece of pie for breakfast. The door was locked but as I was starting to turn away, Rosa, who works in the restaurant, hurried out from the kitchen and opened the door. I settled down at a table and she talked me into having a real breakfast of bacon and eggs. She set me up with a small pot of hot tea and went back into the kitchen to prepare my food.

I had a few awkward moments when the teapot’s lid fell into my cup and became stuck there. If I’d been with someone, we would have been laughing hard. But I was alone and laughed at myself more quietly. I had to pour all the tea back into the pot and wait for the lid in the cup to cool and contract a tiny bit before I could get it out.

Rosa brought me a plate of fresh fruit — grapefruit, pineapple, grapes, and oranges — then disappeared back into the kitchen. I busied myself by reading the history of Robson’s and some information about the equipment and vehicles on display. When she brought out my breakfast a while later, I gobbled down the two eggs over medium, three slices of bacon, and two slices of wheat toast with real butter. (Don’t you hate when restaurants use mystery spread on toast?)

The person I was hoping to see there, Rebecca, wasn’t in yet. She lives in Wickenburg and drives out five days a week to manage the place. I saw her drive in just as I was starting the engine for the helicopter at about 9:45. Since the engine was already running and the blades were already turning, I didn’t shut down. I had another stop to make.
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