FAA Updates Ballast Rules for Bell Helicopters
Published Date: 11/5/2025
Rule
Summary
If you fly certain Bell Model 505 helicopters, listen up! The FAA is updating safety rules by requiring a new fix to the ballast box door, replacing the old rule that banned ballast weights. This change starts November 20, 2025, and helps keep your chopper safe without extra hassle or big costs.
Analyzed Economic Effects
4 provisions identified: 2 benefits, 2 costs, 0 mixed.
Mandatory ballast-box door modification
If you operate certain Bell Model 505 helicopters, you must install a modification to the aft movable ballast box door assembly. This AD (which replaces AD 2025-06-51) is effective November 20, 2025, and requires the installation described in Transport Canada AD CF-2025-35 to address hinge deformation that could let ballast weights escape and strike the tail rotor.
Estimated compliance costs to operators
The FAA estimates this AD affects 174 U.S.-registered helicopters. Estimated per-helicopter costs are $43 to remove ballast weights, $513 to modify the ballast box (labor $213 + parts $300), and $85 to revise the rotorcraft flight manual; aggregate U.S. operator costs are estimated as $7,482, $89,262, and $14,790 respectively. The manufacturer stated some costs may be covered under warranty.
Pilot allowed to update flight manual
An owner/operator who holds at least a private pilot certificate may revise the existing rotorcraft flight manual (RFM) by inserting the applicable flight manual supplement and must record compliance in the helicopter maintenance records per 14 CFR 43.9(a) and 91.417(a)(2)(v). The AD explicitly permits this pilot action as an exception to standard maintenance rules.
Special flight permits banned
The AD states that special flight permits are prohibited for affected helicopters. Operators cannot use special flight permits to conduct flights that would otherwise bypass compliance with this AD.
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