From the onset, Precision Conversions’ focus has been to design a superior freighter product.  The engineering approach was to perform an original structural analysis based on newly derived loads coupled with a 100,000+ node Finite Element Model of all relevant structures to demonstrate positive margins. 

In conjunction with STC issuance, final validation of our Finite Element Model (FEM) was accomplished and this important engineering model exceeds 100,000 nodes. An FEM this substantial would have been unheard of 10 years ago let alone 25 years ago when the B757 was designed.  Additionally, we built a scale wind tunnel (pressure model) and tested it in Boeing’s transonic wind tunnel in order to develop aerodynamic load data. Also Boeing Technical was contracted to perform many other tests including GVT, wing deflection, wing bending as well as a pre-modification (instrumented) flight test and landing impact tests with Boeing Test flight instrumentation and flight crew. Additionally, an entire aircraft stiffness matrix was developed and a comprehensive, center wing box analysis was accomplished.

Precision Conversions worked diligently to show compliance, and substantiate the modification design through rigorous testing and validation. As a result, the FAA views Precision Conversions as the exemplar for current day conversion programs.  Precision Conversions also recognized that the industry needed to see and operate a conversion that clearly represented innovation and a major step forward in terms of operational performance. 

The success of the Precision Conversions engineering efforts in developing the 757-200PCF led to the company spinning off the engineering group to not only continue to support the flagship product but to also offer its engineering expertise and capabilities to industry customers.