The process sees the aircraft modified from the most commonly configured eight-passenger layout to accommodate 10 passengers. West Star has completed 10 projects of this nature to date.

George Euler, Corporate Aircraft Interior sales manager, said: “I’ve had the pleasure of reconfiguring several Falcon 2000’s. It starts with our 3D designers and quickly engages our engineering team, allowing us to unleash our creativity. By focusing on the customer’s needs, we tailor the design to meet their operational requirements. We provide the additional seating capacity that is crucial for charter companies. This process ignites creativity, enabling us to innovate and achieve amazing outcomes.”

Floor plan reconfigurations are no small task, with several elements needing to be modified or replaced during the course of the work, according to the company. For example, a typical eight-passenger layout would include a forward four-place club arrangement and a conference group set up in the aft section of the cabin. This area would also have a credenza or kibitzer that is located on the right-hand side.

This credenza is removed and replaced with new aluminum plates mounted in the floor to pick up the existing seat track line. This allows new seat tracks to be installed that are narrower, to accommodate the new narrow-style seats in the area.

Next a new set of narrow-style double conference seats are installed on the left-hand side of the cabin. In most cases, the existing conference table can be used. The table will likely need to be modified in order to allow for egress requirements. Once this equipment is fitted and installed, a new side-ledge and table assembly is built and installed on the right side for the new narrow-style club group.

There are several key cost-driving elements to consider when planning for the 10-passenger configuration change, according to West Star. “Providing your technical sales manager with as much information as you have available at the initial request will expedite their ability to provide you with an accurate proposal. Though it would be great to be able to provide a firm price for the reconfiguration without much detail, each aircraft is like a snowflake—they are rarely identical,” said a spokesperson for West Star.

Some of those elements include a need to obtain the part numbers of the existing four-place club grouping to verify whether the seats that are being retained have been dynamically tested with the new narrow seating. 

Then West Star will determine whether the aircraft has an existing flight data Rrcorder (FDR) and then confirm that the FDR complies with the additional passenger requirements. The company says technical sales manager will need to understand which oxygen bottle is installed for capacity purposes and whether it is positioned in the existing credenza, or outboard, or below the entertainment cabinet. New switching is typically needed, so the existing cabin management system will need to be considered for either modification or upgrade.

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Gama Aviation went public in 2014 when it acquired Hangar8 which was already listed on London’s Alternative Investment Market. In theory, the reverse takeover gave the company access to more capital for acquisitions. At the time, Gama Aviation was managing all of Wheels Up’s King Air flights and the merged company had almost 150 aircraft under management. (It later sold its share of its US aircraft management business to Wheels Up.)

Many listed company CEOs believe that the market does not truly understand or value their business. But Khalek was able to prove this last year when Gama Aviation sold Jet East, its fast-growing US maintenance business. Jet East made up a third of Gama Aviation. At the time Gama Aviation had a market capitalisation of about £60m.

In November Gama Aviation sold West Star for $131m (netting $100m). Steve Maiden, who led the fast growth of Jet East, was this week appointed CEO of West Star.

Some of the cash from this sale has been used to take Gama Aviation private. Perhaps surprisingly a significant number of investors have chosen to keep their shares even though they are no longer easily tradable. One high-profile UK investor bought 2% of Gama Aviation after the de-listing was announced. 

Khalek is excited to be back running a private company. He estimates that between 25% and 40% of his work life has been taken up by the demands of being listed.  Now freed up, he wants to grow Gama Aviation. “I am not sure everyone in the business is as excited that I will have more time,” he jokes.

Gama Aviation is looking to grow its FBO business. It has just completed a parking apron at Sharjah Airport, near Dubai, and is now starting on a new 14,000 sqm hangar and FBO due to open next year. The company is working through planning for its Jersey FBO in the Channel Islands. 

It has also hired Graham Williamson, formerly of ACASS Europe and TAG Aviation, to grow its aircraft management business. Williamson, who has been a competitor of Gama Aviation for many years, likes growing companies. He was at Emirates Airlines when it had three aircraft.

“It is exciting when you are growing and the opportunity for Gama Aviation is huge,” says Williamson.

Gama Aviation is in talks to buy Austrian operator Tyrolean Jet Services (one of its last stock exchange announcements was on this deal). Tyrolean Jet Services was the first Austrian business jet operator.

“We want to create bespoke operations in different locations like Four Seasons does with hotels”

“We want to create bespoke operations in different locations like Four Seasons does with hotels,” says Williamson. “We want to develop local presence in combination with our engine room in Farnborough. We want to provide great service, great product and be more focused on small numbers of highly bespoke clients.”

Khalek says it is not about trying to build one global operator. “One of the reasons that consolidation is tough is that aircraft management is a very personal business. You don’t want to grow into a big monster chain, you want guests to feel that they are staying at a boutique hotel where everyone knows their name.”

It is looking to build a series of small management companies – with no more than 25 aircraft – with local management. Gama Aviation believes that it can get economies of scale in back-office functions like finance, trip planning, maintenance and purchasing. Khalek adds another simile: “It is like a Michelin Star restaurant – you want a unique maitre d’ but the kitchen needs to be producing a consistently strong product.”

Khalek never hid his frustrations with running a public company (including to the Wheels Up team before they floated). He is clearly excited about the freedom the business now has. “We have all been weighed down with regulatory issues, things like Brexit, Covid, supply chain issues and others,” he says. “We need to shake ourselves out of this and go back to why people go into this industry. People do it because they love it and they are passionate about it. We need to remember how enjoyable this industry is.”

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Jim Rankin, who has served as CEO since 2018, has been named executive chairman of the board, Stephen Maiden has been appointed his successor as the West Star’s CEO, and Allen McReynolds, who currently serves as chief operating officer, will also take on the role of president.

“Stephen and Allen bring a unique set of skills and experiences to their leadership roles. I’m excited to support them as they build on West Star’s long-standing guiding principle of taking care of customers and employees,” said Rankin. “Stephen and Allen have a rich understanding of where the company is headed, and I look forward to achieving new milestones with them as they assume these leadership roles.”

Stephen Maiden joined the West Star team in November of 2023 when Jet East, where he served as president and CEO, was acquired by West Star Aviation. Maiden’s career in aviation maintenance began when he served in the US Air Force as an Electrical and Environmental Specialist on F-16s. Throughout his career, Maiden has served in a variety of roles with increasing responsibility from an avionics technician to team lead and manager, to director of Quality and Operations. He spent the last 18 years serving as a CEO in the area of maintenance, repair and overhaul (MRO).

Maiden said: “I am deeply honoured to have the opportunity to lead this remarkable team and express my sincere gratitude for all the hard work and dedication that has contributed to the legacy of West Star Aviation. The history of 77 years is truly special. Our people, who are the heart of our organisation, will remain our top priority as we strive to deliver exceptional experiences to our valued customers.” 

McReynolds was announced as West Star’s chief operating officer in September of 2023. As part of the recent leadership restructure, McReynolds will assume increased responsibility and oversight of all business operations in his new role of president and chief operating officer. He has spent more than two decades in and around maintenance covering business aviation, commercial airlines and defence. Prior to joining West Star, McReynolds served as a managing partner at SeaTec Consulting and has held leadership positions at firms including Textron Aviation and Hawker Beechcraft. 

“I am humbled and honoured to have the opportunity of leading West Star across multiple business lines,” McReynolds said. “The opportunity represents a professional and personal privilege to collaborate with a team of experts. I am excited about what the future holds for West Star.”

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For $131m.

It is a good deal for its owner Gama Aviation and its London Stock Exchange investors. After paying off debt, it will bank $100m. Shareholders will get some of this as a dividend.

“After interest from several parties, we are delighted to have agreed the sale of Jet East to West Star Aviation. I believe the new owner will be an excellent guardian of our valued strategic relationships and, importantly, the people that deliver critical services to our customers every day,” said Marwan Khalek, CEO of Gama Aviation.

Gama Aviation bought Jet East in January 2021. It paid $8.7m in cash and took on $3.2m of debt. It invested in the company. Jet East had sales of $118.2m in 2022 and earnings of $1.3m. Its sales in the first six months of 2023 were up 27%. In 2019 it had sales of $29.5m.

The Sterling Group, the private equity owner of West Star, approached Jet East last year. “This combination represents a truly unique opportunity to bring together two completely complementary businesses in terms of capabilities and geographic footprint,” said Jim Rankin, CEO of West Star Aviation. “Most importantly, the cultures of both organizations proudly prioritize customer service and a commitment to our people.”  

Latham & Watkins was West Star’s legal adviser with Jefferies financial adviser.

“Joining forces with West Star provides so much optimism for everyone involved. As a combined entity, we will be able to provide unparalleled service and support to our collective customer-base with greater depth in providing maintenance solutions,” said Stephen Maiden, CEO of Jet East. “The combination enhances opportunities for our talented workforce as our capabilities increase in size and scope. I am incredibly proud of our team, and the opportunity to partner with West Star is truly amazing,”

Jet East had hoped to tell staff earlier but minor delays meant it had to make the sudden announcement.  

“I would like to thank the entire Jet East team for their considerable efforts and achievements under the leadership of Stephen Maiden,” said Khalek. “We wish them continued success as they embark on their own new chapter.”

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Technicians traveller to Texas from the West Star Aviation Perryville (PCD) MRO facility, and began an evaluation. After documenting the extent of the damage, the West Star AOG/MRT (aircraft-on-ground/mobile repair team) contacted an outside DER (designated engineering representatives) team. But, due to the damage location, it was unable to support a temporary repair to facilitate a ferry.

Instead, West Star’s onsite DER team was used to provide the required support. Working with the West Star Aviation engineering team, it designed a repair that ensured a safe ferry. Materials and equipment that could be sourced locally, were located and procured. All other items were found by the West Star Aviation Parts Team and shipped on-site.

The temporary repair required that they straighten the bent frame so the door would close normally. Then, a combination of existing fasteners was used and rows were added to secure a doubler for the ferry flight.

West Star Aviation created a transfer template with plexiglass and used that to locate the repair doubler to the fuselage. After sealing it down and installing it with blind and solid rivets, the aircraft was ready to be transported to the company’s repair station for permanent repair before being returned to service.

The AOG/MRT responders were Chad Head and Patrick Presnell. Don Carver was the Perryville DER specialist.

Repair of birdstike damage on a Challenger 601.

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MSP Aero is an established, well-respected FAA Part 145 Certified repair Station that has been providing avionics, interior, minor paint and aircraft window repair services at Minneapolis and surrounding areas since 2009.

The Minneapolis location will join the existing five West Star Satellite location network that provides highly-trained and experienced technicians that aid in troubleshooting problems and provide solutions that are best suited to get you back in the air as quickly as possible. They can even assist in obtaining ferry permits for relocating your aircraft to one of West Star Aviation’s full service locations, if necessary.

“West Star Aviation’s Satellite network locations are also bases for our expanded AOG Mobile Repair Team (AOG/MRT) services that provide The West Star Experience to our customers wherever they are located,” stated John Mansfield, Manager of Satellite Operations and Mobile Repair.

“Additionally, we can coordinate any repair or service that is not capable to be performed in the field, from one of our four full service facilities,” Mansfield continued.

“We continue to refine and strengthen our geographic MRO network to support customers’ operational needs, while bringing added value and capabilities throughout the Twin Cities, as well as the Minnesota, Wisconsin, Iowa and both North and South Dakota areas,” said Rodger Renaud, President & COO, West Star Aviation.

West Star Aviation specialises in the repair and maintenance of airframes, windows, and engines, as well as major modifications, avionics installation and repair, interior refurbishment, surplus avionics sales, accessory services, paint and parts.

In addition to its primary facilities in East Alton, IL; Grand Junction, CO; Chattanooga, TN; and Perryville, MO, West Star Aviation also maintains satellite facilities at Aspen-Pitkin County Airport in Aspen, CO; Chicago Executive Airport in Chicago, IL; Centennial Airport in Denver, CO; Conroe-North Houston Regional Airport in Houston, TX; Minneapolis/St. Paul International Airport in Minneapolis, MN and Scottsdale Airport in Scottsdale, AZ.

The company also provides complete FBO services for transient aircraft at its East Alton and Grand Junction facilities. West Star Aviation is an industry leader in technical experience and expertise while providing world-class customer services in all the organisation’s divisions.

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The hangar features 40,000 sq. ft. of hangar space and 20,000 sq ft. of back shop and office space which supports West Star’s growing capabilities, allowing the company to fully expand upon existing aircraft maintenance programs. This additional growth will initially employ 28 technicians to support the expansion, in addition to their existing hiring efforts.

“We are excited to expand our East Alton facility. With the new hangar completion, we occupy over 380,000 sq. ft. of space at the St. Louis Regional Airport,” said Scott Sweeney, General Manager, West Star Aviation. “Having a new hangar provides us the added capacity to continue offering world-class service to our customers and ensure we meet requested deadlines,” Sweeney continued.

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Krell has 5+ years of aviation marketing and communications experience, previously holding various marketing positions with Jet Aviation. Prior to that, Krell held positions at CBS Radio as an Account Executive and Lindenwood University as Campus Director. Additionally, she holds both a BA and MBA in Business Administration from Lindenwood University.

“I am extremely excited to be joining this amazing team as it grows and expands its MRO services that are so focused on exceeding customer expectations on every project,” said Krell. “Great things are happening at West Star Aviation across all locations and I look forward to telling our story.”

“We are extremely pleased to welcome Tommi to the West Star Aviation team. With a renewed company‐wide initiative to improve and expand internal and employee communications, she will no doubt be an asset to West Star Aviation,” said Jim Rankin, CEO, West Star Aviation.

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Flite Components specialises in aerostructure and composite repair in addition to the overhaul and repair of thrust reversers, control surfaces, engine cowls, engine inlets, pylon and floor panels, as well as radome repair and testing.

“We see great synergies between Flite and Dallas Aeronautical Services. I look forward to this partnership and growing the entire one-stop maintenance theme throughout our companies,” said Jim Rankin, CEO of West Star Aviation.

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With over 300 people in attendance at the open house, including Mayor Jim Coppinger and Charles Wood, VP of Economic Development with the Chattanooga Chamber of Commerce who both gave remarks at the open house, the expansion is a welcome addition to the local community.

With the completion of these new facilities, West Star now occupies over 175,000 sq. ft. of space at the Chattanooga Metropolitan Airport. “The open house was a great way to showcase our new facilities, and to demonstrate to our customers in this area of the country that we are continuing with our heritage of quality, world-class service,” said Jim Rankin, CEO, West Star Aviation.

The recently completed expansion includes a new 65,000 sq. ft. maintenance facility that includes 40,000 sq. ft. of hangar space, and over 25,000 sq. ft. of office and support space. This completion also includes a 45,000 sq. ft. state-of-the-art paint facility that can accommodate the paint needs of most business aircraft flying today, including Gulfstream G550, Embraer Lineage, and Embraer Legacy 600.

They have input their first customer paint & maintenance project at their newly expanded Chattanooga facility. The first customer project to be completed will include a 3C Inspection, Service Bulletins, an avionics installation and a full paint job on a Falcon 2000. This project is anticipated for completion before Q1 of 2019.

“We are pleased to have our first customer in service at the new expansion to our Chattanooga facility. This completed expansion provides our team the capacity to ensure we are working efficiently, and meeting deadlines to get our customers back in the air as quickly as possible,” said Steve Goede, General Manager of West Star Aviation, Chattanooga.

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