Sabreliner operates aircraft maintenance, repair, overhaul, manufacturing and assembly operations in Perryville and Ste. Genevieve, MO
The flagship of Sabreliner's operating facilities is in Perryville, Mo., 90 miles south of St. Louis. Based at the Perryville Municipal Airport, which has a 7,000-foot runway, the complex comprises a dozen buildings with more than 200,000 square feet under roof. It is the company's largest and most comprehensive maintenance and repair facility.
Perryville is the birthplace for a generation of Sabreliner business jets, but today the complex bustles with work on a wide variety of aircraft, ranging from U.S. Army Black Hawk helicopters to U.S. Air Force C-21 Learjets, from propeller-driven T-34 and T-44 trainers flown by U.S. Navy, Coast Guard and Marine pilot candidates, to Vietnam-era A-4 Skyhawk attack aircraft, which were stored for decades in the desert before being carefully restored to flying condition by our skilled technicians.
In addition to the diverse array of aircraft always on site, Sabreliner also frequently hosts the executives and officers who are responsible for them. In a Sabreliner hangar, a visitor may see a U.S. Air Force officer in uniform as well as technicians wearing Sabreliner work shirts
The Perryville operation is a FAA-authorized Class IV repair station, and consistently is awarded the Gold Certificate of Excellence for meeting and exceeding FAA training requirements. It holds special certifications in composite manufacturing and repair, and structural repair.
Sabreliner's aviation technicians average in excess of 20 years in aircraft maintenance, sheet metal, electrical work, engines and hydraulics, back-shop and quality assurance. Most hold FAA airframe and/or power plant licenses or equivalent certifications.
Technicians at Perryville specialize in a long list of services to the aviation industry, such as component maintenance, inspection, repair and corrosion control; major modifications including service life extension, and the installation of special-purpose systems. Expertise is also abundant in hydraulic, electrical and environmental control components and systems; avionics maintenance, installation and modifications; aircraft interior completions and renewals, as well as exterior cleaning, stripping and painting.
Sabreliner's professional engineering staff includes FAA-Designated Airworthiness Representatives (DARs) and Designated Engineering Representatives (DERs) fully versed in shop floor liaison for maintenance, repair, assembly and manufacturing activities; design of special repairs; aircraft configuration control; and the design, development and testing of major aircraft modifications and obtaining FAA approvals, including Supplemental Type Certificates and material review board activities. Sabreliner also has the engineering data on many other aircraft, allowing technicians to repair components that otherwise would need to be replaced.
The bottom line is that, if customers want it for their aircraft, Sabreliner can provide it through the Perryville facility and associated operations.
At Perryville, Sabreliner provides full-spectrum avionics installation, engineering, troubleshooting and repair capabilities on numerous aircraft, with a special emphasis on Sabreliner models and Learjet 30-series planes. As an authorized dealer for most of the leading avionic parts producers, including Collins, Honeywell, L3 Communications and others, Sabreliner technicians provide modifications and product support for virtually all types of avionic equipment, including custom entertainment and lighting systems. Avionics specialists also produce custom-made systems for entertainment, communications and lighting.
Sabreliner is an authorized service center for Honeywell TFE731, General Electric CF700 and Pratt & Whitney JT12 power plants and conducts corrosion/hot section inspections for the CF700 and JT12 engines. The company also overhauls the JT12 and services thrust reversers for Rohr, Aeronca and Grumman power plants.
Sabreliner's test cell for the JT12 is one of the most advanced in the industry, equipped with Howell's Automated Engine Data Acquisition Test System III (AEDATS III), used to monitor and record engine performance. The company has worked on more JT12/JFTD12 power plants than anyone else in the world.
As the original equipment manufacturer for the famed civilian Sabreliner aircraft and its military T-39 counterpart, Sabreliner continues to provide engineering support for aircraft still in use by the U.S. Air Force and Navy. In fact, the company maintains current FAA Production Certification and FAA Type Certification for those aircraft. Even today, Sabreliner can manufacture more than 90 percent of the airplane's structural parts, and outside suppliers can do the rest.
Many Sabreliners routinely return "home" to Perryville for maintenance and modifications. Here, Sabreliners and T-39s are often seen wingtip to wingtip with C-21A Learjets receiving major inspections and new interiors and with other civilian Learjets being maintained. In fact, few service providers in the country have as much experience with Learjet 30-series aircraft as Sabreliner.
With a solid reputation for the maintenance, repair and overhaul of fixed-wing business jets such as the Sabreliner and Learjet and for training aircraft such as the T-34 and T-44, Sabreliner has added sophisticated rotary-wing aircraft work to its capabilities at Perryville.
For instance, the Perryville crew designed and installed VIP interiors in a fleet of Black Hawk VH-60 helicopters used around the Washington D.C. metropolitan district and continues that VIP interior work on S-70 model helicopters used by foreign ally government officials. Paint crew members have also applied distinctive exterior paint on brand-new twin-engine medium lift helicopters.
Perryville is home to a 32,000 square foot state-of-the art paint facility that offers paint services to a wide variety of aircraft.
Perryville is ISO 9001:2008/AS9110:2003 and AS9100 Rev. B certified, and is Nadcap-certified for Non-Destructive Testing
Perryville Municipal Airport
1390 Highway H
Perryville, Mo. 63775-7319
Phone: (573) 543-2212
Sabreliner's aerospace assembly center, component repair and other facilities at Ste. Genevieve, Mo. are where Sabreliner workers often breathe new life into older aircraft operated by the U.S. Air Force, Navy and others.
At Ste. Genevieve, Sabreliner technicians conduct exhaustive inspections and make repairs to critical flight control components for the Air Force KC-135 and Navy E-6B, both military derivatives of the Boeing 707 aircraft. Flaps, ailerons, horizontal stabilizers and other structural components are removed from the aircraft elsewhere and delivered to Sabreliner facilities, where technicians strip the existing paint, conduct extensive inspections, including peeling back the sheet metal skin to look for any damage or weaknesses. The components are restored to like-new condition; many are repainted, and all are returned to military bases and other facilities, where they are reinstalled on the original aircraft, making the aircraft ready for more years of service to the nation.
Ste. Genevieve also is where Sabreliner is building replacement KC-135 rudders and E-3 Sentry elevators; manufacturing other replacement parts for the KC-135, and assembling replacement center wing assemblies for the P-3 Orion anti-submarine aircraft flown by the U.S. Navy, other U.S. agencies and allied governments.
Opened in 2002, the Ste. Genevieve operation initially was dedicated to overhauling the KC-135 and E-6B components. In 2008, Sabreliner purchased an adjacent 40,000-square-foot building, increasing Ste. Genevieve space by more than half, and moved P-3 work there from Perryville. The company also consolidated tooling fabrication and specialized welding activities under one roof.
The original 72,000-square-foot operation includes a Sabreliner-designed monorail system that is used for handling and moving the aircraft's horizontal stabilizer, which is the largest of the components currently being overhauled. With the monorail, the stabilizer is lifted from its delivery truck and moved throughout the operation for inspection and overhaul, and back into a truck – all without ever touching the floor. The innovative system saves time and reduces the potential for damage to the stabilizer and injury to technicians.
The center wing assembly work is being conducted in conjunction with Lockheed Martin, the Navy, ARINC and L3, and the rudder and elevator manufacturing work is being undertaken for The Boeing Company.
In addition, Sabreliner is a primary subcontractor to Boeing for the remanufacture of KC-135 flight control components as part of the Air Force's Management of Items Subject to Repair (MISTR) program, which designates qualified facilities to remanufacture specific aircraft components.
The Ste. Genevieve operation is Nadcap-certified for manufacture of composite materials and for Non-Destructive Testing.
1040 Rozier St.
Ste. Genevieve, Mo. 63670-1859
Phone: (573) 883-3729