Apprentices work on Super Star cabin

Cabin components are being prepared on the Hamburg mock-up

In a collaborative effort involving Super Star Cabin Engineering, instructors Juergen Peters and Axel Panier from the Hamburg training workshop and selected second- and third-year apprentices, cabin components are being prepared on the Hamburg mock-up for future installation in "the real aircraft".

In the team headed up by Joerg Paisen, the experts Burkhard Linke, Henning Huehne and Hans-Christian Ahrenstorf, who all have many years' experience of cabin upgrades, have tight control on the design of the cabin of the Deutsche Lufthansa Berlin-Stiftung's (DLBS) future historic aircraft, along with Sebastian Kannengiesser of Design Engineering Modifications.

The mock-up landscape created by Peter Eppendorfer will help the DLBS recruit additional sponsors and partners for the restoration of the aircraft and implementation of the historic cabin. In addition to this representative function, the Super Star mock-up also plays an essential role in making the engineering and design of the Lockheed L-1649A cabin efficient and helping to contain costs when the cabin is installed later on, with cabin components prepared here for the later "fit check" and final installation. The apprentices are not only working on the modifications but are also helping Henning Huehne and Sebastian Kannengiesser to devise the best possible implementation solution, working closely with the engineers. In this connection the team is maintaining a balance between the necessary engineering and supporting production. Burkhard Linke is in charge of adherence to all the aviation regulations relating to certification and the demonstration of compliance.

Acting on instructions from Engineering, the apprentices are adapting cabin components to the dimensions of the Super Star fuselage on a workstation right next to the mock-up. To reduce costs and save time, components from retired Boeing 737 jets belonging to Lufthansa and components from Airbus A320 family aircraft are also being used. These include the overhead baggage racks above the seats with passenger service units, air ducts, the front galley section and the toilets. And once the modified cabin parts have been trimmed to the correct size and fitted in the new Super Star design, they will be temporarily pre-installed in the three mock-ups, so that cabin designer Michael Reichenecker of Product Sales & Design and the DLBS can gain as realistic an impression as possible of how things will look later on in the real aircraft.

Another key area is the fabrication of the cabin fairing by the apprentices, with extended engineering requirements on the part of Hans-Christian Ahrenstorf. He is responsible for the systems "behind-the-scenes", for example, for the cabin air distribution and the passenger oxygen system. As the shape of the Super Star fuselage has a variable geometry, the sandwich material was "baked" directly onto the contour of the bulkheads. This made it possible to dispense with the time-consuming and expensive construction of a mold. 75 percent of the area to be occupied by the cabin crew in the original aircraft has already been manufactured in Auburn. The plan is to finally fit the pre-prepared cabin elements into the original aircraft in a "fit check". Once the L-1649A cabin is ready for installation of the cabin in the second phase of the project, the Hamburg cabin engineers will be well-placed to install the components rapidly thanks to the highly motivated and skilled support of the apprentices.