Kit Pack

Kit Pack is a specialized partner supporting the U.S. Department of Defense (DOD) with the critical supply of replacement parts that keep America’s legacy aircraft flying. With roots dating back to the 1960s, Kit Pack has been crucial in maintaining some of the most iconic aircraft, including the B-1, B-52, and KC-135.

Kit Pack was an independent California corporation (CAGE 30842) before moving to New Mexico in response to increasing service demand. As a key player in maintaining America’s military aircraft, it specializes in furnishing replacement parts, assemblies and kits for repair and overhaul (MRO) services for various military aircraft and helicopters.

Kit Pack currently has IDIQ (indefinite delivery/ indefinite quantity) contracts totaling $115,000,000, with a growing backlog of over 600 active contracts scheduled to ship through 2027. These numbers are driven by its proficiency in managing over 800 National Stock Numbers (NSN) under its growing IDIQ contracts, which makes Kit Pack the go-to partner in helping the Defense Logistics Agency (DLA) handle the complex logistics of supplying critical parts.

“At Kit Pack, we understand that every mission begins with the right part at the right time. That’s why, as a key player, we’ve taken on the responsibility of managing large blocks of NSNs to support the defenders of America’s airspace,” says Doug Bailey, president.

Everything You Need in One Complete Package

When dealing with transportation vibration fatigue, parts might look fine even after being subjected to thousands of operational hours. To prevent failures, the DOD replaces these parts.

Kit Pack shines with its kits—a set of parts designed to repair or replace specific components on an aircraft. Each kit simplifies the MRO process by consolidating multiple parts needed for a particular restoration into one package. One of the distinguishing features is the wide variety of products Kit Pack manages. Its extensive inventory includes over 10,000 line items, ranging from hardware to ground support equipment.

For example, if a section of the fuselage needs mending, instead of purchasing 100 different parts separately, Kit Pack supplies a kit with an assigned NSN, parts are acquired, assembled and shipped to the required site in a timely fashion. This ensures that when a depot needs to conduct a repair or replacement, everything they require is contained within a single package, markedly streamlining the process.

Kit Pack’s offerings are also backed by long-standing industry partnerships. As a Boeing licensee on the B-1, it has experience producing wire bundles for use throughout the aircraft, from its nose to the tail. The company also specializes in replenisher units, which are complex systems used to link and de-link 20 mm rounds. These linked 20mm rounds are used for ammunition in the aircraft such as the F-16. These units are comprised of machined castings and hundreds of components.

A Legacy of Expedited Deliveries, No Matter the Demand

Kit Pack was established as a division of H.N. Bailey & Associates (CAGE 99871) to support Tinker Air Force Base (OCAMA) under the U.S. Air Force’s “Operation Breakout.” This program was designed to create parts kits for various aircraft systems—such as constant speed drives, generators, starters, and many other systems—without rebuying brand-new units. Its success in this initiative laid the foundation for cost effective overhaul for the U.S. Air Force and of course Kit Packs longevity.

Kit Pack has played a crucial role in supporting the U.S. air fleet in wartime scenarios. During the Vietnam War, it provided kits for major aircraft overhauls, including but not limited to wing overhauls for F-5 fighter jets. The company also manufactured a kit facilitating air-to-air challenging for the F-4 Phantom.
Kit Pack continued demonstrating its superior MRO capabilities during Operation Desert Storm, where it expedited the delivery of $1.26 million worth of kits and spares by 200 days. This effort included critical programs such as producing a fuel cell seal kit for the F-15 and a helical spline for the UH-60 Black Hawk helicopter.

In support of the Afghanistan mission, Kit Pack adapted its operations to meet new requirements. Notably, it produced a kit to install a 20mm gun turret in the passenger seats of convoy trucks to significantly enhance vehicle defense. To support this project, Kit Pack upgraded its former machine shop and production area’s electrical capabilities to operate a paint booth and two welding stations. This investment reduced the need for outsourcing and increased efficiency.

These successes built Kit Pack’s reputation as a reliable parts supply partner. In response to the rising demand, the company expanded its facilities, adding two 5,000-square-foot warehouses, including one with a loading dock, to manage the growing inventory and truck traffic. Kit Pack also partnered with International^® Truck—a leading producer of medium-duty, heavy-duty and severe-service trucks—to produce gun turrets for use on the Marine Corps Mine-Resistant Ambush Protected (MRAP) vehicles.

“When the U.S. military calls, we deliver. Our expertise in assembling and delivering custom kits ensures that maintenance and repairs happen on time, every time,” adds Keith Stearns, vice president of programs and business development.

As Kit Pack expands into supply chain with additional critical parts for military aircraft, including structural components, engine parts and accessories, Kit Pack expects to strengthen its position as a trusted partner to the U.S. military.

Old Planes, New Tech

Technology has evolved over the last 50 years, and aircraft have changed dramatically. Building parts originally designed in the 1950s and 1960s is challenging because they were based on drawings and specifications that have since become outdated. Further complicating it are new-age manufacturing capabilities, which rely on advanced tools like five-axis CNC machines and CAD models.

“To put it into perspective, it’s similar to trying to build a 1960 Cadillac today,” says Bailey.

Kit Pack adeptly overcomes this hurdle. It bridges the gap between design specifications and technology to ensure the DOD and DLA receive the needed parts on time. The company’s ability in partnership with the customer to navigate the tricky landscape and deliver parts that align with their original drawings while using today’s manufacturing practices is pivotal to its consistent success.

In a recent case, it worked with a depot to overcome testing challenges for an aging aircraft’s indicator panel. The old specifications didn’t align with modern testing equipment, so Kit Pack collaborated with a subject matter expert to design a new testing methodology. This innovative solution that was approved by the customer enabled the successful testing of the electrical output, resulting in the delivery of fully functional units and ensuring minimal impact on their fleet.

The U.S. Government’s Trusted Partner

Kit Pack’s evolution has been shaped by its adaptability to handle various kits and meet the DOD’s needs. In terms of performance, the company this year was acknowledged for its 93.3 percent on-time delivery rate across all the NSNs it manages. This superior reliability has been sustained across multiple contracts, including its current multi-year agreement with a growing ceiling of $110 million.

Kit Pack continues to provide solutions for the most complex challenges in the defense supply chain, whether assembling a kit for an overhaul or designing new methodologies to test outdated components. With a deep understanding of the past and the proficiency to shape the future of aviation technology, Kit Pack is not just a supplier—it’s a strategic ally in maintaining the operational readiness of America’s military aircraft.