A Fuel-Saving Propeller Upgrade for the Basler BT-67 (Basler DC-3)
Improving efficiency, reducing vibration, and lowering operating costs
The Basler BT-67, developed from the legendary Douglas DC-3 platform, remains one of the most capable and versatile utility aircraft in operation today. Known for its rugged performance, strong payload capability, and reliability in remote and demanding environments, it continues to serve in surveillance, transport, special mission, and scientific roles around the world.
As operators continue to rely on the platform, upgrades that improve efficiency, reduce vibration, and lower operating costs become increasingly valuable. One area where those gains can be realized is the propeller system.
Why Propeller Upgrades Matter
Legacy aluminum propeller blades have served operators well, but newer composite propeller technology offers meaningful performance and maintenance advantages. Reduced weight, smoother operation, and lower vibration can all contribute to improved aircraft performance while helping reduce wear throughout the airframe.
For operators flying long distances, fuel efficiency is also a major factor. Even a modest reduction in fuel burn can translate into significant savings over time. For long-range operators, a 3% improvement can add up to millions over the aircraft’s life.
For operators flying missionized aircraft or carrying sensitive onboard equipment, vibration reduction can be especially important. Improvements in thrust response, ground handling, and takeoff and landing performance can also make a noticeable difference in day-to-day operations.
The iAERO Propeller Replacement Kit
The iAERO propeller replacement kit for the Basler BT-67 replaces the aluminum Hartzell blades with lighter MT Propeller composite blades. Proven across a wide range of aircraft and operating environments, MT Propeller is well known for delivering reliable performance with the added benefits of composite blade technology.
By switching to carbon composite blades with a wood core, operators gain significant weight savings, smoother propeller performance, and improved flight characteristics, while also reducing long-term operating costs.
Key Benefits
Fuel Savings
The upgrade can improve fuel efficiency by up to 3%, helping reduce overall fuel burn and operating expense. For operators flying long-range missions, that level of savings can have a major financial impact over time.
Significant Weight Savings
The system reduces weight by 56 lb per propeller assembly, for a total aircraft savings of 112 lb.
Improved Starting and Reduced Engine Wear
Lower rotating mass can contribute to faster start times, increased starter life, and reduced wear associated with engine starting.
Better Aircraft Handling and Performance
Operators can expect improvements in takeoff and landing performance, smoother thrust application, and better ground handling control.
Reduced Vibration
A 2.5% g(m/s2) reduction in vibration levels helps improve comfort, reduce stress on the airframe, and support the operation of sensitive payloads such as survey equipment.
Certified Solution
The propeller replacement kit is approved under Transport Canada STC O-LSA20-139.
A Practical Upgrade for DC-3 Operators
For operators looking to get more performance and efficiency from the Basler BT-67, the iAERO propeller replacement kit offers a practical path forward. With measurable fuel savings, significant weight reduction, smoother operation, better handling, and lower long-term operating costs, it is a valuable upgrade for aircraft expected to keep performing in demanding environments for years to come.
Better efficiency. Lower vibration. Reduced operating cost.
To learn more about the iAERO propeller replacement kit for the Basler BT-67, contact iAERO today.
