Aerostar Aircraft Corporation – Aircraft Involved
Aerostar Aircraft Corporation is renowned for producing high-performance, pressurized twin-engine propeller aircraft, primarily developing and refining the Aerostar series originally designed by the gifted aeronautical engineer Ted Smith. The Aerostar family — characterised by its distinctive low-wing, mid-fuselage engine configuration and exceptional cruise performance — passed through several corporate owners before Aerostar Aircraft Corporation took stewardship of the type, continuing production, support, and development of the 600 series through the 1980s and beyond.
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Historical Note
The Aerostar lineage begins with Ted Smith, who had previously designed the Aero Commander series before founding Ted Smith Aircraft Company in the late 1960s. His Aerostar design broke new ground in the twin-engine piston market by placing the engines in the mid-fuselage rather than on the wings, dramatically reducing asymmetric thrust effects and improving aerodynamic efficiency. The result was one of the fastest piston twins of its era, capable of cruise speeds competitive with early turboprops.
Following Ted Smith’s death in 1976, the type certificate passed to Piper Aircraft, which produced the PA-60 series (Piper Aerostar) from 1978 until Piper’s bankruptcy in 1991. Aerostar Aircraft Corporation, based in Coeur d’Alene, Idaho, subsequently acquired the type certificate and continued to support, modify, and develop the aircraft, offering factory refurbishment programmes, engine upgrades, and new variants. The Aerostar remains in active service today, supported by a dedicated owner community and specialist maintenance network.
Primary Aerostar Aircraft Models
📊 Primary Production Models — Click to collapse
| Model | Engines | Key Feature | Also Known As |
|---|---|---|---|
| Aerostar 600 | Lycoming IO-540 (naturally aspirated) | Base production model; unpressurised | Ted Smith Aerostar 600 |
| Aerostar 601 | Lycoming TIO-540 (turbocharged) | Turbocharged for higher altitude performance; unpressurised | Ted Smith Aerostar 601 |
| Aerostar 601P | Lycoming TIO-540 (turbocharged) | Pressurised cabin; most widely produced variant | Piper PA-60-601P |
| Aerostar 602P (Sequoia) | Lycoming TIO-540 (turbocharged, uprated) | Refined 601P with improved systems; frequently called the Superstar | Piper PA-60-602P, Superstar |
| Aerostar 700P | Lycoming TIO-540 (counter-rotating) | Counter-rotating engines eliminate P-factor; pressurised | Piper PA-60-700P |
| Aerostar 702P | Lycoming TIO-540 (counter-rotating, uprated) | Further refinement of the 700 series | — |
| Aerostar FJ-80 | Turbine (experimental) | Experimental turbine-powered conversion of the Aerostar airframe | — |
🔽 Piper-Era Designations (PA-60 Series) — Click to expand
During Piper Aircraft’s ownership of the type certificate (1978–1991), the Aerostar was marketed under the PA-60 designation. The following Piper-era model codes correspond to the Aerostar variants:
| Piper Designation | Aerostar Equivalent | Notes |
|---|---|---|
| PA-60-600 | Aerostar 600 | Naturally aspirated base model |
| PA-60-601 | Aerostar 601 | Turbocharged, unpressurised |
| PA-60-601P | Aerostar 601P | Turbocharged, pressurised — most common variant |
| PA-60-602P | Aerostar 602P / Sequoia | Uprated 601P; marketed as Superstar |
| PA-60-700P | Aerostar 700P | Counter-rotating engines, pressurised |
🔽 Marketing Names & Upgrade Programmes — Click to expand
- Superstar 650 / 680 / 700 — Marketing designations applied to upgraded 601P and 602P variants, typically reflecting engine output or modification level rather than distinct type certificate changes.
- Speedstar 850 — A single-engine modification programme applied to the Aerostar airframe, converting the twin to a high-performance single for reduced operating costs.
- Factory Refurbishment Programme — Aerostar Aircraft Corporation offered comprehensive factory refurbishment and upgrade programmes, returning aircraft to near-new condition with updated avionics, interior, and engine overhauls.
🔽 Associated Aircraft — Click to expand
Aerostar Yak-52 (SC Aerostar SA, Romania)
The Aerostar Yak-52 is a turboprop-powered aerobatic aircraft manufactured by SC Aerostar SA, a Romanian aerospace company based in Bacău. Despite sharing the Aerostar name, SC Aerostar SA is an entirely separate entity from the US Aerostar Aircraft Corporation and has no corporate or design relationship with the Ted Smith Aerostar series. SC Aerostar SA produces the Yak-52 under licence from the Yakovlev Design Bureau, and the aircraft is widely used for aerobatic training and competition flying.
Engineering Norms and Standards
Aerostar aircraft were developed and certified under the following regulatory frameworks:
- FAR Part 23 — FAA airworthiness standard for normal category aircraft, under which all production Aerostar variants were certified
- Ted Smith mid-engine configuration — The defining engineering innovation of the Aerostar: engines mounted in the mid-fuselage driving wing-mounted propellers via extension shafts, reducing asymmetric thrust and improving single-engine handling compared to conventional wing-mounted engine twins
- Counter-rotating propellers (700P/702P) — The 700 series introduced counter-rotating engines to eliminate propeller P-factor and torque effects, further improving handling and single-engine safety margins
- Pressurisation system — 601P, 602P, 700P, and 702P variants feature a pressurised cabin certified to maintain a cabin altitude of approximately 10,000 ft at the aircraft’s maximum operating altitude
- Lycoming TIO-540 engine family — The turbocharged variants use the Lycoming TIO-540 series, a well-documented engine with extensive overhaul manual coverage and a broad service network
Where to Find Additional Documentation
- Official Support: Aerostar Aircraft Corporation (Coeur d’Alene, Idaho) — current type certificate holder and primary source for approved data, STCs, and factory support
- Historical Archives: The International Aerostar Club (IAC) maintains an active owner community with technical resources, logbooks, and service history documentation
- Specialty Vendors: Online Aviation Library and specialist twin-engine piston documentation providers carry service manuals, parts catalogues, and overhaul documentation for the Lycoming TIO-540 engine family used across the Aerostar range
Format and Delivery
All documentation in this collection is provided as high-resolution digital PDF files, optimised for both screen viewing and printing. Files are delivered via instant download upon purchase and are compatible with all standard PDF readers on desktop and mobile platforms.
Disclaimer
This material is sold for historical and reference purposes only. Documentation reflects the engineering and regulatory standards of the original development period and is not intended for use in current airworthiness, certification, or maintenance activities. For current airworthiness data, consult the type certificate holder. This digital compilation, structure, indexing and presentation are © Sicuro Publishing.