The Aerostar Story: From Prototype to Aviation Icon Aviacionline

In the history of general aviation, few names resonate with innovation and revolutionary design like that of Theodore Raymond Smith. An American aeronautical engineer (graduate of the Boeing School of Aeronautics in 1931), he built his career in companies such as Douglas Aircraft and Rockwell. Smith stood out for his ability to break design paradigms and take general aviation to new horizons. His masterpiece, the Aerostar, is not only a testament to his genius but also an aircraft that marked a before and after in the light twin-engine aircraft market. This article delves into the history of this emblematic creation, the Aerostar.

The development of the Aerostar

Before conceiving the Aerostar, Smith worked at Rockwell, where he actively participated in the development of the Aero Commander, the Turbo Commander, and the Jet Commander. However, due to differences with Rockwell’s corporate and design policies, he decided to embark on the Aerostar project. It all began in the 1960s, aiming to design a twin-engine aircraft based on three principles: speed, efficiency, and sleek aesthetics.

Explaining the conception of the aircraft, Smith stated: «The Aerostar project is my idea; I have been working on it since June 1963. It is a simple concept inspired by the automotive industry. The Aerostar’s philosophy was to design a twin-engine aircraft from scratch, with 25% interchangeable parts, saving resources in engineering and tooling.»

To bring his vision to life, he hired young, recently graduated engineers, some of whom were also pilots. One of his iconic phrases was: «When we have something new, we will show it to you. There is nothing new here, just the plane.» Beyond his expertise in aeronautical engineering and design, Smith was also a shrewd businessman and marketing expert.

The interchangeable parts included the nose cone, nacelles, empennage, landing gear, windows, front and rear fuselage sections, wings, rudders, elevators, flaps, and vertical stabilizer. This approach, borrowed from the automotive industry, was complemented by the «Heavy Skyn» method, which reduced the number of components compared to other aircraft. For example, the wings had fewer than 50 parts, and the fuselage fewer than 100, improving safety by reducing cracks, material fatigue, and the likelihood of loose fasteners.

Ted Smith applied innovative design principles that set the Aerostar apart, such as its sleek, elongated fuselage that minimized aerodynamic drag and maximized flight efficiency. Aesthetics were not neglected, featuring elegant and aerodynamic lines.

Another crucial element was the wings, with a thin profile and high aspect ratio that optimized airflow and enabled high speeds. Additionally, the engine placement, close to the fuselage, improved balance and reduced drag caused by the propellers. The oval cabin, forward door, and long, pointed nose gave it a jet-like appearance. In fact, both the Aerostar and the Learjet shared NACA 64 series wing sections, with a dihedral of only two degrees and one degree of incidence.

Compared to its competitors, such as the Beechcraft Baron and the Cessna 310, the Aerostar outperformed its closest rivals by at least 80 knots in cruising speed. No other piston twin-engine aircraft in its category could match its combination of speed, efficiency, and aerodynamic design, making it the ideal choice for demanding users seeking maximum performance and reliability. The Aerostar was not only the fastest aircraft of its time in general aviation but also a testament to Ted Smith’s visionary approach to aircraft design.

The prototype and certifications

The Aerostar prototype, identified as N320TS, made its first flight at Van Nuys Municipal Airport (KVNY-VNY) in 1966, although sources do not confirm whether it occurred in October or November. The registration referenced the Lycoming 320 engines of 160 HP used at that stage. Later, the aircraft was tested with Lycoming 360 engines and finally with IO-540 engines of 290 HP, which would become the standard for serial production.

FAA certifications were as follows:

• Aerostar Model 360: May 1967
• Aerostar 600: March 1968
• Aerostar 601: November 1968
• Superstar II: 1980
• Superstar I: 1982
• Aerostar 700P: 1984

The following video shows the test flight of the Aerostar prototype, registration N540TS, in December 1967

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