Cirrus Factory Tour

Monday, September 10, 2007

Key Takeaways:

Cirrus aircraft production involves a modular approach, constructing major components like fuselage halves and wing sections using composites, bonding them with heat-curing processes, and utilizing specialized fixtures to enhance efficiency.
The SR22 G3 model incorporates advanced materials like expensive carbon fiber spars for significant weight reduction, alongside a blend of composite and conventional components, including Continental engines and Hartzell propellers.
The assembly process follows a sequential line, integrating internal systems, engines, and critical safety features such as the parachute system's rocket motors towards the final stages, followed by installations like glass and pre-delivery flight testing.

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cirrus factory tour010.jpg — A fuselage half ready for a little time in the Easy-Bake. Note the grey channels built into the fuselage side for the parachute harness straps.

cirrus factory tour017.jpg — A fuselage half ready for additional assembly.

cirrus factory tour023.jpg — One of the components that defines the SR22 G3 model is the carbon fiber spar. Very expensive and built by a U.S. subcontractor, the spar helps cut a substantial amount of weight from the new ’22.

cirrus factory tour016.jpg — The right half of the fuselage, with many components already installed, sitting in a fixture almost ready to have the other half bonded onto it. This fixture was introduced with the G3 model, and it has cut production time substantially.

cirrus factory tour027.jpg — Local heater/blowers help cure a hand laid-up bond on the tail.

cirrus factory tour041.jpg — The fixture in which the major structure of the wing is assembled.

cirrus factory tour032.jpg — A wing section ready to go into the oven.

cirrus factory tour039.jpg — A fixture designed to remove excess bonding material from a partially built-up wing skin.

cirrus factory tour034.jpg — Temporary inspection covers double as handhold for this wing in a fixture. There’s no chance of leaving these optic orange babies in place by mistake.

cirrus factory tour035.jpg — Right and left wing sections ready to be joined.

cirrus factory tour037.jpg — Three airplanes worth of wings awaiting a fuselage on the Cirrus line.

cirrus factory tour044.jpg — Airplanes begin to take shape on the Cirrus line. Note the order form taped to the tail. It describes in exact detail what optional features each airplane gets or doesn’t get.

cirrus factory tour045.jpg — The firewall nearly ready to accept the most expensive component in the airplane, the Continental IO-550.

cirrus factory tour046.jpg — Getting ready to install the lights in the wingtip of a ’22.

cirrus factory tour069.jpg — Cirruses aren’t made completely out of composites. Completed flap assemblies await installation.

cirrus factory tour054.jpg — An engine assembly ready to bolt to a waiting firewall.

cirrus factory tour051.jpg — Engine mated successfully, this Cirrus is only hours away from the paint shop.

cirrus factory tour055.jpg — This one won’t be flying anywhere. This SR22 forward fuselage is bound for a fixed base simulator.

cirrus factory tour063.jpg — Guess what they keep here. Installation of the rocket motors for the chute are left for the end of the line.

cirrus factory tour057.jpg — Installing the glass, a job that’s left for one of the final jobs, to keep expensive scratches to a minimum.

cirrus factory tour058.jpg — Hartzell three-bladers await installation.

cirrus factory tour059.jpg — Cirrus production test pilots getting ready to go flying the latest airplane off the line.

cirrus factory tour074.jpg — Heading home from Duluth in a newly completed SR22 G3.

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