Service Bulletin: Verification of Rescue System Cover Installation

Service Bulletin

Verification of Rescue System Cover



Dear Partner,

Flight Design has just released new Service Bulletin for the CT series of aircraft. Please pay attention to the exact applicability of this bulletin.

The bulletin refers to an inspection of the Airframe Emergency Parachute Egress Hatch for correct installation. This SB is applicable to CTSW aircraft up to serial number D-11-07-08 (including) and CTLS up to serial number F-13-11-02 (including). The bulletin is in response to an observation that was made as part of an accident investigation, where it was noticed that the hatch was incorrect installed. The incorrect installation did not contribute to the accident under investigation. But as a negative impact cannot be included from such a way of installation, and knowing that hatches are sometimes re-installed in-field, we have decided to mandate this inspection. In case of a incorrect installation, this SB requires removal and subsequent correct installation of the hatch. Compliance must be shown latest within 3 months following the issue date of this Notification, or at the next annual inspection of the aircraft, whichever comes first.

This SB is available for download: link

Warning: Non-compliance with these instructions could result in further damage, personal injuries or death.

We ask you to forward this documentation to all of your clients for their information and compliance.

Thank you for your cooperation.

Flight Design USA Team

Flight Design USA 
91 Route 169, P.O. Box 325,
South Woodstock, CT 06267, USA
Tel. 860-963-7272
Fax. 860-963-7152

CTLS Dynon Skyview Update From 6.2 to 11.1 Now Available

Dynon is currently no longer supporting software version 6.2, which is the previous version available from Flight Design.  Flight Design has now released an official update to the Dynon Skyview which brings us to 11.1.

Instructions for download:

1. Follow the download link below.  This will bring you to the Flight Design download page.

2. In the folder tree, navigate to your file by clicking on the folder names which are applicable to your aircraft and download the appropriate file.

*Note: There are four options for avionics listed.  They are the Garmin GNC 255A, GTR 225, Dynon 261 transponder, and Garmin GTX330 transponder.  If you have a component which is not listed, you may download any file.  However, if you have one, but not the other component, you may only download one of the two files which has your component.  For example, if you have an SL30 or SL40 with a GTX327, you may download any file and it will not affect the function; but if you have an SL30 or SL40 and a Dynon 261, you must download either of the files with a Dynon 261.

3. You must unzip the file in order to load it onto the Dynon.  Detailed instructions are on the download page.

If you have any questions, please e-mail

Here is the download link:

Jim McCord Master CFI

James Edward “Jim” MC CORD Jr, Master CFI    (Renew: 15Aug15)
Santa Rosa  CA

James E McCord, a 2-time Master and SAFE member, recently renewed his Master CFI accreditation.  A former volunteer Angel Flight pilot, Jim serves on the Sonoma County Aviation Commission and is a FAASTeam representative in the FAA’s Oakland FSDO area.  Additionally, he is an independent flight instructor with North Coast Air ( at Santa Rosa’s Charles M Schulz – Sonoma County Airport (STS).  (Photo: MCFI Jim McCord of Santa Rosa, CA)   
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Master Instructors LLC takes great pride in announcing a significant aviation accomplishment on the part of James E McCord, a Santa Rosa area flight instructor and a resident of Santa Rosa, California.  Recently, Jim’s accreditation as a Master CFI (Certificated Flight Instructor) was renewed by Master Instructors LLC, the international accrediting authority for the Master Instructor designation as well as the FAA-approved Master Instructor Programä.  He first earned this national professional accreditation in 2013, has held it continuously since then, and is one of only 151 worldwide to earn the credential two (2) or more times.

To help put these achievements in their proper perspective, there are approximately 101,000 CFIs in the United States.  Fewer than 800 of those aviation educators have achieved that distinction thus far.  The last 21 National Flight Instructors of the Year or National FAASTeam Representatives of the Year were Master CFIs (see: while Jim is one of only 56 California teachers of flight to earn this prestigious “Master” title.

In the words of former FAA Administrator Marion Blakey, “The Master Instructor accreditation singles out the best that the right seat has to offer.”

The Master Instructor designation is a national accreditation recognized by the FAA.  Candidates must demonstrate an ongoing commitment to excellence, professional growth, and service to the aviation community, and must pass a rigorous evaluation by a peer Board of Review.  The process parallels the continuing education regimen used by other professionals to enhance their knowledge base while increasing their professionalism.  Designees are recognized as outstanding aviation educators for not only their excellence in teaching, but for their engagement in the continuous process of learning — both their own, and their students’.  The designation must be renewed biennially and significantly surpasses the FAA requirements for renewal of the candidate’s flight instructor certificate.

Please feel free to disseminate this information widely.  Questions regarding the Master Instructor Programä may be directed to 303-485-8136 or   For more information about the Master Instructor Programä and to locate other Masters, please visit the “Find a Master Instructor” section of  To learn more about the Society of Aviation and Flight Educators (SAFE), visit

Kings County Sheriff’s Department CTLEi

Please check out the latest article in Air Beat regarding the Kings County Sheriff’s Department CTLEi operations:

Kings County Sheriff’s Dept. CTLEi



2015 EAA Airventure C4 Video

EAA Article on C4 Certification

Flight Design Breaks New Ground with C4 Certification Approach

C4 Progress Report III

Dear Partner,

       Many new things have been going on with the C4 program recently and we thought it would be an appropriate time to bring you up to speed. As most of you know, The Flight Design C4, the new advanced four-place GA aircraft, achieved its first flight on April 9th 2015 at Kamenz airfield (EDCM) in Kamenz, Germany.  The successful test flight was performed by Damian Hischier an FAA and EASA approved test pilot living in Switzerland.
    The flight lasted one hour and the C4 was tested for basic handling, longitudinal trim, spiral stability in 20 and 30 degree banks, approach to stall and practice go–arounds. The primary engine operating parameters were also confirmed.  The test flight was performed in a special test area at an altitude of 5500 Ft. MSL.    

       The process for flights by a non-certified aircraft in Europe is different than in the U.S. The plane is issued a “Permit to Fly” under a process involving EASA and the local CAA, in this case the German LBA. In meetings with EASA managers the basic design is reviewed, the load tests and aerodynamic calculations are verified and the flight-conditions for the test plan are approved.   
      Prior to the first flight, the C4 passed numerous ground tests including control stiffness tests, a ground vibration test from an independent engineering firm and a powerplant installation audit by a Continental Motors engineering representative.

    Since the first flight, additional flight tests have been performed to open up the weight and center of gravity envelope to establish a baseline stall speed at gross weight and the most forward center of gravity for stall speed determination. The C4 has now flown at 2640 Lbs. (1300 Kg) and shown a stall speed of less than 54 kts. The rate of climb has been demonstrated to be in excess of 950 FPM at gross weight and a cruise speed can now be projected of 145 Kts. The airplane is still in very basic condition aerodynamically (no fairings, rough wing profile) and as such the top and cruise speed can only be projected at this time. Upcoming tests are planned during the next few months to further open up the center of gravity envelope aft, more stability tests and more detailed performance testing.            
A photo Essay of the C4 first flight Day 4-9-15 By Tom Peghiny Flight Design USA
                  FD Engineer Robert Adam conducts                    Damian Hischier heads for the test hangar
                                the pre-flight briefing 
​                                                    after the briefing

       After a very careful pre-flight, the first flight               Seat belts, check. Quick-egress door, check
                                process begins

      Taxing out to the departure end of runway 21          The C4 climbing out over the German countryside
                                     at Kamenz 
 30 degree banks were spirally neutral as expected   Looking good EZFD, how about a formation break? 

                                                                                         See you on the ground!                    Back in the hangar for disassembly for the Aero Expo


The Continental IO-360AF FAA Type Certified                                               
     Continental Motors announced in early 2015 that the IO-360-AF (alternative fuel) engine model received type certification from the FAA. The 6-cylinder IO-360-AF is certified for standard 100LL as well as unleaded 91UL avgas, which is widely available in Europe. The IO-360-AF is the first in its class to be certified for alternative fuels benefitting certain markets where 100LL avgas is very expensive.
Beyond the alternative fuel advantage, the IO-360 series has an excellent reputation for reliability, long life and smooth operation.  It is the lightest of all Continental’s six-cylinder aircraft power plants making it a perfect solution for the new Flight Design C4. The IO-360-AF engine family offers a maximum power output of 195 horsepower at 2800 RPM, a 2200 hour Time Between Overhaul (TBO) and is backed by Continental’s industry leading warranty and service support. Flight Design will use the IO-360-AF engine de-rated to 180 horsepower as required for the C4, producing power at a reduced 2550 RPM, resulting in quieter operation.
     “Our engineering team has worked diligently to move the IO-360-AF from opportunity to reality; and we are very excited to have it certified, meeting the needs of our customers,” stated Rhett Ross, Vice President, AVIC International and Director, Continental Motors Group.  “The IO-360-AF is a nice addition to our fuels capabilities and further demonstrates our ongoing commitment to advancing technology” continued Ross.

Safety Box Program Update                                                                                     Additional development work involving the C4 is continuing on the advanced occupant protection research and testing called the “Safety Box”.   
   The German Ministry of Economic Affairs granted funding for the research project that aims at development of a modular “Safety Box” cabin safety system for light aircraft. The new system provides a safety cage around the occupants of an aircraft that builds upon several concepts, such as intelligently designed and located crash absorbing components, a stiff cabin structure with dedicated load paths for the majority of high load cases, advanced seat installation and restraint systems. In addition, the Safety Box team is working to integrate improved ergonomic cabin designs and enhanced fire protection concepts. Some of the concepts put forward for the C4 project are displayed below. Please note that these images shown are concepts only and cannot be considered as final specifications.   


C4 Conforming Design Work Continues                             
    Design work continues by the staff of Flight Design engineering to complete the design of the conforming C4 with the expectation to achieve EASA certification in mid-2016. A conforming model of an aircraft is one that is used to show compliance to EASA or the FAA. Expert consultants from Germany and the USA have been participating in the design review process to optimize the C4 design for performance, stability and control.       Work on production specification molds has begun at Flight Design’s facility using an in-house 5-axis CAM machining center. Going directly from CAD design to CAM machining is the most up-to-date method to ensure high fidelity of the final parts to the drawings. The result are parts that achieve better fit and conformity which can reduce airframe weight and cost through a reduction in composite fillers as a part of airframe finish.           

C4 Production Facilities Expand        
   In addition to the facilities in Kamenz Germany and Kherson Ukraine, Flight Design has partnered with Taiwan based GSEO to help create AeroJones Aviation in Xiamen, China. AeroJones will be building complete CTLS and C4 aircraft from their facility there. Flight Design has shipped complete mold sets and has been training AeroJones staff composite construction techniques. Parent GSEO has been working in Xiamen since 1992 and has significant experience with commercial production and quality control. Aircraft produced in Xiamen will be delivered to customers in China and the Asian pacific region.
    In late March 2015, Flight Design was pleased to announce that a second full-scale production facility for the CTLS series has completed a full manufacturing evaluation before starting serial production of the popular LSA for the Asia region.
Flight Design GmbH CEO Matthias Betsch, Director Christian Wenger, and Flight Design USA President Tom Peghiny went to Xiamen, China to witness the completion of the first conforming CTLS by AeroJones. The German and American team toured the AeroJones facility in Xiamen, located directly across the sea from Taiwan.
    At AeroJones, all materials are identical to those used by Flight Design production facilities in Europe. AeroJones demonstrated it is a fully competent manufacturer of the LSA airplane with all manufacturing processes except for heat treating and plating done in house. All welding, laser and high-pressure water cutting is done in house at AeroJones. 
    AeroJones parent company GSEO, although a Taiwanese company, has worked in China for 20 years building high-tech optical products. GSEO President Jones Chen brought his personal experience and his passion for aviation into AeroJones.
     In cooperation with the province of Jiangsu, AeroJones is breaking ground on a 250,000 square foot, brand-new production facility based in the city of Changzhou. AeroJones will produce airframes for the Light-Sport CTLS as well as Flight Design’s certified four-seat C4.
Test Pilot Damian Hischier                                                                                       Damian did the certification flight testing for the EASA certified version of the CTLS and is a graduate of the National Test Pilot School (NPTS) located at Mojave, CA. USA. Damian is an accomplished engineer, project manager and test pilot. He has experience with experimental and certification flight tests on Part 25, Part 23, LSA and Experimental aircraft. He holds an EASA Category 1 Flight Test Rating, an EASA Class 1 Medical (FAA equivalent) is a current ATPL, has flown 102 aircraft types. In addition he is a Bachelor of Information Sciences and Software Engineering and has provided technical expertise related to flight test and aircraft operational issues in support of design development activities. In addition to Flight Test duties for Flight Design GmbH., Damian works with other light aviation companies including, Stemme and Aquila. 

Thank you for your continued interest in the C4. With the first flight of the C4 proof-of-concept, we are excited to be able to stay in communication with all interested C4 customers. We will continue to print new information about the program as it becomes available.    

Thank you for your cooperation.

Flight Design Team

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Flight Design GmbH
Zum Tower 4, D-01917 Kamenz
Tel.: +49 (0)3578 / 37335 – 0
Fax: +49 (0)3578 / 37335 - 69
Commercial Register: Dresden HRB 32961 VAT ID No.: DE 147857992
Board of Directors: Matthias Betsch(CEO)-Oliver Reinhardt-Christian Wenger

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Flight Design Completed First Flight of new C4

Four Seat General Aviation Entry Successfully Takes to the Air

Kamenz, GERMANY / 14 April 2015 — Last fall, Flight Design GmbH, manufacturer of the popular CT-series of Light-Sport Aircraft, promised to fly its new, certified four seater called C4 by the opening of the Aero Friedrichshafen show. On Friday, April 9th, the development team achieved their goal. The weekend was spent reviewing initial results (see below) and preparing to set up at the event that start April 15th.

“The C4 really performed as expected,” reported Tom Peghiny, President of Flight Design USA, importer of the German company’s products and test flight director for the C4 development. Peghiny flew alongside the C4 non-conforming prototype. “It appeared and test pilot Damian Hischier confirmed that the C4 is stable about all axes.”

Hischier also reported, “The spiral stability of C4 is good and its directional stability is good.” While noting that engine operating temperatures were acceptable he acknowledged that further work may be necessary for operations in the hottest climates. “But don’t change a thing aerodynamically,” Hischier enthused! Engine temperatures will be remedied primarily with cowl changes focused on cooling, yet Flight Design is pleased with the Continental IO-360-AF engine that performed very well.

“Flight Design engineers can work on reducing some friction in the controls,” Hischier noted, “but leave the rest alone.” Most prototype airplanes go through refinements after the initial flight verifications even while most of the group working to achieve the first flight were pleased that the new airplane performed so well.

“We observed the C4 accelerate away from the C-172 chase plane during simulated approaches to landing and in simulated go-arounds,” commented Peghiny, observing from the Cessna.
“I could also see that during the 30 degree bank turns the test pilot needed no control correction and he reported that pitch forces were light,” added Peghiny. “The plane appeared to be on rails, it looked very stable. Damian said he was comfortable getting close to us for the photos and videos shot during the maiden flight.” On board avionics are supplied by Garmin with the G3X Touch augmented with TSO analog instruments. Garmin has become a vital partner to Flight Design as C4 moves forward.

“Very few first flights proceed through the entire test card,” explained flight director Peghiny. “Yet we completed all of the points permitted under the EASA-established Flight Conditions as specified in our initial Permit to Fly authorization.”

“We are all exceedingly pleased to have reached this benchmark as forecast a few months back,” said Christian Wenger, a Flight Design corporate board member and procurement manager for the German manufacturer. “This is going to make for a very enjoyable show for us.” Wenger spoke to early arriving media reporters as he lead the team positioning the test article C4 at the front of the company’s display in Hall B-1 of the Aero Friedrichshafen show.

“Our whole team put in long hours and formed a cohesive team as they rallied behind the C4 first flight effort,” said Matthias Betsch, CEO of Flight Design. “All team members are very pleased with the results of the development effort.” Flight Design has been at work on the C4 project since 2011.

“In coming days and weeks, we will add more details about this project,” added Betsch. “For now, part of our team is working to prepare the C4 for display at Aero while engineers like Technical Director Oliver Reinhardt remain at headquarters preparing the next steps in the development project.

“We will release more data and will provide more detail on the C4 development schedule after we get through Aero and Sun ‘n Fun,” Peghiny said. The two important airshows, one in Europe and one in the USA, run nearly back to back starting Wednesday April 15th, 2015. “Meanwhile, we are very pleased to show the actual plane at Aero.” The prototype will immediately continue development flight evaluations and will not be seen in the USA until later this year.

For Preliminary flight data download full press release.

Service Bulletins BRS, Dynon, Rotax and Revisions

Flight Design has just released a Service Bulletin for the inspection the BRS handle bracket for the absence of cracks in the bend radius at the base plate.

is applicable to all CTSW, CTSW-LSA and CT Supralight with Airframe Emergency Parachute System BRS 1050 and 1350 installed, from S/N 05-01-01 / D-05-01-01 and E-09-02-11 without country limitation.

periodic inspection of float buoyancy for 912/914 equipped CTLS/CTsw and MC aircraft



SAFETY ALERT- Installation Verification of BRS Pickup Collar

A safety Alert applicable to All aircrafts with Airframe Emergency Parachute System BRS 1350 HS installed, and with S/N up to F-13-09-04, C-11-11-02,A-12-04-33, included.


Please refer to This Alert


Aircraft with higher S/N are not affected.