Mt Hutt Aviation Completes First MD500 Super D Conversion

December 23, 2025

Mt Hutt Aviation has successfully completed its first MD500 Super D conversion, marking a significant expansion of the company’s MD Helicopters capability and service offering.

The milestone achievement reflects the technical expertise and precision of Mt Hutt Aviation’s engineering team, who have delivered a comprehensive upgrade that transforms the MD500 into a significantly more capable aircraft.

Mark Kershaw, CEO at Mt Hutt Aviation, commented on the achievement: “This conversion represents another step forward in our MD Helicopters capability. Our team has worked meticulously to deliver a genuine performance upgrade that extends the operational value of the MD500 platform. We’re excited to now offer this conversion to operators who want to unlock more capability from their existing aircraft.”

“A genuine performance upgrade that extends the operational value of the MD500 platform.” Andrew Duff

What the Super D Conversion Delivers

The Super D modification integrates proven MD530F components into the MD500 airframe, delivering measurable improvements in performance, stability, and control. The conversion transforms a capable helicopter into a genuinely versatile workhorse without compromising the simplicity and reliability the platform is known for.

Key upgrades include:

Longer main rotor blades — Increased rotor diameter delivers improved lift, better hover margins, and stronger performance in hot, high, and heavy conditions.

Larger F-model tail rotor — Enhanced tail rotor authority provides improved yaw control, particularly at high power settings and during demanding operational manoeuvres.

F-model vertical and horizontal stabilisers — These components enhance directional stability and handling, reducing pilot workload and improving overall aircraft feel across the flight envelope.

Tail boom extension — The extension improves tail rotor efficiency and completes the aerodynamic package.

Increased useful load — The combined aerodynamic and rotor system improvements translate directly into up to 350 lb of additional payload, giving operators more flexibility, better margins, and greater mission capability.

Measurable improvements in performance, stability, and control.

Why Upgrade to Super D?

For operators considering fleet upgrades, the Super D conversion offers a cost-effective alternative to aircraft replacement. The modification delivers increased power and improved margins, stronger hot and high performance, and a proven upgrade path that extends the life and operational value of existing MD500 helicopters.

Mt Hutt Aviation is now actively offering MD500 Super D conversion kits, with support available for discussing kit availability, configuration options, and lead times.

High-quality photography and video documentation of the completed aircraft has been captured, with a full video release planned for early next year. Selected images will be shared in the coming months to showcase the final product and conversion quality.

About MD Helicopters:

MD Helicopters is an American manufacturer of high-performance light helicopters, known for models like the iconic MD 500 series and NOTAR® technology. Serving military, law enforcement, commercial, and air-rescue operations globally, the company produces versatile and reliable aircraft rooted in a legacy from Hughes and McDonnell Douglas. MD Helicopters offers a range of helicopters prized for speed, safety, agility, and utility, with thousands in service worldwide.

About Mt Hutt Aviation:

Established in 2013, Mt Hutt Aviation delivers fleet management support and maintenance between two purpose-built facilities in Canterbury. In addition to maintenance capabilities, MHA offers 24/7 support on time-critical projects and parts, as well as on-site engineering, avionics, and paint services.

For media inquiries, please contact
Andrew Duff
Manager
Mt Hutt Aviation
andrew@mthuttaviation.co.nz
+64272755770