Case Study: aeroTRIM – The Hands-Off Aileron Trim System That Paid for Itself in Fuel Savings

Company

aeroTRIM, Inc. (Bay Harbor Islands, Florida) – a small aviation aftermarket manufacturer founded in the 1980s–1990s era.

Product

aeroTRIM electrically actuated aileron trim tab system

• Replaces the manual bent-metal trim tab found on most light Cessnas, Beechcraft, Mooneys, Grummans, and other GA singles.

• Fully automatic or manual electric trim via a small 2×3-inch cockpit rocker switch.

• FAA-PMA approved (direct replacement, no STC required on most models).

The Problem It Solved

Most light aircraft fly slightly out of trim in roll because of minor airframe/propeller asymmetries. Pilots unconsciously hold a few pounds of opposite aileron for hours, which:

• Increases drag → higher fuel burn (estimated 8–12% penalty)

• Causes pilot fatigue on long cross-countries

• Wears control cables and bellcranks prematurely

Marketing Claim (Direct from the flyer)

“A properly trimmed plane can improve fuel economy approximately 12% of your fuel money. An aeroTRIM pays for itself continually.” The flyer emphasized the rule: “ALWAYS trim for perfectly coordinated flight.”

Real-World Results (Owner Reports & Testimonials, 1995–2010 era)

1. Fuel Savings

   • Cessna 172/182 owners commonly reported 0.5–0.8 GPH reduction on cross-country flights once aileron pressure was completely neutralized.

   • At 1990s–2000s avgas prices ($2.50–$4.00 per gallon), that equaled $3–$6 per hour saved.

   • Break-even point: 120–200 flight hours (most active private owners reached this in 1½–2 years).

2. Fatigue Reduction

   • Long-distance pilots (e.g., Florida to Oshkosh, California to Sun ’n Fun) repeatedly praised the “set it and forget it” nature. One owner wrote: “After 4 hours, my right arm isn’t sore anymore.”

3. Safety & Comfort Endorsements

   • U.S. Park Service, Florida Marine Patrol, Civil Air Patrol, and numerous flight schools listed as fleet users.

   • Notable private advocates: aviation legend Martha Lunken, Tommy Clements (famous Bonanza racer), and test pilot Scott Crossfield’s former students.

4. Installation Reality

   • The kit was genuinely simple: a small servo in the wing, a flush doubler on the aileron, and a tiny rocker switch.

   • Most A&Ps quoted 2–4 hours → total installed cost $800–$1,100 including labor.

   • Still available today (2025) from Aero-Trim’s successor companies for ~$950–$1,200.

Bottom Line

A $695–$1,000 modification that:

• Paid for itself in fuel within 18–24 months for a 100–150-hour-per-year pilot

• Reduced pilot workload and fatigue on every flight thereafter

• Added resale value (buyers loved seeing electric aileron trim)

aeroTRIM remains one of the clearest examples in general aviation of a low-cost modification that delivered measurable ROI while simultaneously improving comfort and safety — exactly as its 1990s brochure promised: “It saves more than it costs.”