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Bombardier Q100/200/300 Lower Cowl Debris Cones Redesigned for Greater Durability

 

The objective of the project was to design, manufacture and stock a durable PDA debris cone that would reduce or eliminate the need for replacement.

Bombardier Dash-8 Q100-200-300 debris cones redesigned for greater durability











 

Project Overview
 

Over the years, Comtek has received many lower cowl repairs from various aircraft operators.
 

The lower cowls were sent to Comtek for numerous repairs, such as delamination, pulley reels worn, de-ice boot replacement, latch box frames and a replacement of the original aluminum debris cones due to cracking and corrosion. Although the debris cones are a relatively simple part, they are expensive to purchase, carry long lead times, and their replacement requires the removal of the lower cowl’s titanium firewall. Removing the countless rivets which hold the firewall in place is a difficult task and carries the risk of damage to the firewall itself, resulting in a much more costly repair.
 

Because of this recurring issue, customers turned to Comtek Advanced Structures to purchase their PDA debris cones. In doing so, they reduced the initial inventory cost, the number of times it needed to be replaced and the lead times associated with replacing the part.
 

Comtek’s customers now have peace of mind knowing no aircraft modifications are required, corrosion, fatigue and cracking problems are eliminated and the parts have a 4 year warranty on material and workmanship.

 

Project Objectives


The objective of the project was to design, manufacture and stock a durable PDA debris cone that would reduce or eliminate the need for replacement. The parts, originally designed for use as part of Comtek’s repair service, could then be made available to the airlines to order and replace themselves.


 

Strategies

 

Comtek developed a new PDA product using a Kevlar prepreg laminate design to eliminate any corrosion and/or cracking issues. The Kevlar prepreg laminate is more durable, crack resistant, and is inherently impervious to corrosion. “We’ve seen several lower cowls come in for repair but our debris cones are not showing any sign of damage even years after they’ve been installed” says Dennis Cicci, P.Eng, Business Development Manager.

 

Results Delivered
 

The new Kevlar debris cone was designed and offered the following solutions:

 

  • The Kevlar design eliminated cracking and the need to replace the part frequently.

  • The debris cones are now offered as a spare to airlines so they can be purchased directly from Comtek.

  • Parts in stock and ready to ship eliminate long lead times for the airlines

 


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