From Datsun to Hangars, Propel Aviation Keeps on Trucking

 In 1996, a young airline mechanic began an aircraft maintenance business at Miami Executive Airport (KTMB, then known as Kendall-Tamiami Executive Airport), out of the back of his Datsun pickup truck. This year, that company—celebrating its 30th anniversary—now occupies a 60,000-sq-ft hangar that can handle the latest ultra-long-range business jets and expects to do more than $15 million in business.

Propel Aviation has always had a presence at KTMB, moving from a 1,200-sq-ft hangar to a 12,000-sq-ft one, and having outgrown that facility on the southeast corner of the field, is now in its purpose-built home on the northeast corner, part of a new $30 million complex that also houses its sister FBO, International Flight Center.

The FAA Part 145 repair station has a staff of 56, including 32 AMTs, six of whom have inspection authorization. Alex Amor, who runs the business as operations manager, noted their skill. “We have a number of what I would term ‘old timers,’ some guys that had probably been working on aircraft with the Wright Brothers,” joked Amor. “I know that’s a bit of an exaggeration, but most of the guys average at least 15 to 16 years of experience.”

In the shop, business is booming with up to a dozen aircraft under maintenance at a time and a four-week backlog. “Right now, we’ve been focusing on the [Bombardier] Challenger and [Dassault] Falcon markets,” said Amor. “We’ve gotten a good reputation with the Dassault products.” Currently, the company is in the midst of a major inspection on a Challenger 604, as well as a C check on a Falcon 7X, involving the removal of the engines, landing gear, and interior, along with a new cockpit avionics suite, which will span four months. Propel can perform OEM-approved repairs for both jet manufacturers and is a factory authorized service center for Textron, performing warranty work on its pistons and turboprop aircraft. “We have a lot of talent on King Airs and Citations,” noted Amor. “I have two techs who probably have 35 years of experience on Citations.”

Last year, the company’s revenues increased by more than 50% over the previous year, as a result of its move to the new hangar. Propel runs one work shift from 8 a.m. until 5 p.m., and it is looking to expand to a second shift, but like many in the aviation industry, it is encountering some staffing headwinds. “The problem is finding enough A&Ps to run a second shift,” Amor acknowledged. “We have the work to justify it, absolutely; we just need the manpower, really.”

As well, the company is discovering that despite moving to a much larger facility little more than a year ago, its business is still growing to the point that its owners intend to build two additional 60,000-sq-ft hangars within the next two years.

“Miami Executive was a pretty quiet little airport, and all of a sudden in the last year, year and a half, the jet traffic has just exploded,” Amor told AIN, adding that it is seeing spillover from crowded Miami–Opa Locka Executive Airport (KOPF). “Folks are now looking for another airport to go with, which can cater to them.” Also, he noted that KTMB is the closest airport with U.S. Customs to the Miami area when arriving from the south, bringing airplanes from Central and South America.

In terms of its customers, Amor breaks it down to three general sectors: governmental agencies such as the DEA and the Florida Highway Patrol; Part 135 operators; and some Part 91 corporates. For variety, one long-time customer has a de Havilland Beaver on floats and an ex-U.S. military T-28 Trojan piston-engined trainer.

Late last year, Amor stood up Propel’s mobile AOG service. “We have a brand-new truck that we dispatch anywhere from Key West up to Fort Pierce,” about a 60-mile radius, he explained. “I think the van has been on the road for probably 30 to 40 trips already.” It can handle anything from line service to component replacement.