Unexpected Opportunities That Shaped an Aviation Career

When Dave Keily looks back on his career, he still finds it remarkable how it all unfolded.

"If someone had told me years ago, while I was driving a truck in the UK, that I would end up working in aviation, moving my family halfway around the world and supervising a blades and composites team in New Zealand, I probably wouldn't have believed them."

Today, Dave is the Blades & Composites Supervisor at Salus Aviation, leading a highly skilled team responsible for repairing and restoring helicopter rotor blades. But his journey into aviation wasn't something he planned.

A Career That Started by Chance

Growing up in the military town of Warminster in the United Kingdom, Dave had always been fascinated by aviation. Despite that interest, his career initially took a very different path.

He spent several years working as a contractor on some very large construction sites throughout the UK, installing a hygienic wall cladding product called Whiterock. While he enjoyed the work, it often meant spending long periods away from home.

When he and his wife started a family, Dave decided it was time for a change. He obtained his truck licence and found a role that allowed him to be home every evening. It solved one problem but quickly created another.

"I realised that sitting in UK traffic every day wasn't something I wanted to do long term."

Not far from where Dave lived was Rotor Blades Limited, a Bell Approved Service Centre specialising in helicopter blade repairs. After a recommendation from a friend already working there, Dave submitted his CV.

Six months passed with no response.

Then, completely out of the blue, his phone rang while he was driving his truck.

What Dave thought would be a quick conversation after work turned into a full interview with senior management, followed by a second interview and practical assessment a few weeks later. Soon after, he was offered the position that would launch an entirely new career.

Developing Specialist Skills

Dave spent the next seven years learning the highly specialised craft of helicopter blade repair.

His career provided opportunity to train at Bell's blade facility in the United States, where he developed a deeper understanding of world-class blade repair operations.

"The scale of their operation was incredible, and I was fortunate to learn from some very experienced blade technicians."

Beyond the workshop, Dave also supported field deployments across Europe, including Spain, Germany and Czechia, gaining valuable experience working in different environments.

Although he later stepped away from aviation to return to the building industry for greater financial security while raising a young family, he soon realised something was missing.

"It didn't take long before I realised how much I missed working on helicopter blades."

Then another unexpected opportunity appeared.

A LinkedIn message from a recruitment company seeking experienced blade technicians in New Zealand would once again change the direction of Dave's life.

Within four months, he, his wife and their family had packed up their lives in England and relocated to New Zealand to join what is now Salus Aviation.

Continuing to Grow

Since arriving nearly seven years ago, Dave has progressed from Blade Technician to Production Leader before stepping into his current role as Blades & Composites Supervisor in 2023.

Along the way, he has continued expanding his own technical capability.

"When I first arrived, I couldn't paint blades, which is an important part of being a well-rounded blade technician. Since then, I've learnt that skill as well, so I now have experience across the full repair process."

For Dave, continuous learning remains one of aviation's greatest attractions.

"No matter how much experience you gain, there is always someone who can teach you something new."

Taking Pride in Every Repair

What motivates Dave most is seeing heavily damaged blades transformed into components that look and perform as though nothing ever happened.

"There is a lot of satisfaction in seeing blades arrive in poor condition and leave the workshop looking like new again."

The work involves a wide range of specialist repairs, including leading-edge strip replacements, skin patches, trim tab replacements, paint refinishing and static balancing.

For Dave, one of the biggest rewards comes after the work has left the workshop.

"When customers tell us their blades require very little adjustment during dynamic balancing, it shows the work we've carried out throughout the repair process has been done to a high standard."

Expanding Capability in New Zealand

Dave has also seen the workshop continue to evolve.

While the team may be smaller than some of the operations he has worked with overseas, he believes its capability continues to grow.

One recent milestone has been completing the workshop's first BK117 main rotor blade leading-edge strip replacement here in New Zealand, work that had previously been sent offshore.

"This is an important step for our workshop because these repairs have traditionally been completed overseas."

Projects like this also reflect how repair techniques continue to evolve. Throughout his career, Dave has seen significant advancements in tooling and processes, particularly in composite blade repairs.

"When I was working at Rotor Blades Limited in the UK, leading-edge strip replacements were completed using vacuum bagging techniques. Since moving to New Zealand, I've had the opportunity to work with positive pressure fixtures for these repairs, and the results have been very impressive."

These developments have improved the consistency and quality of repairs while giving the team greater confidence to take on increasingly complex work. For Dave, it's another reminder that aviation is an industry where learning never stops.

"Even after many years in the industry, there is always something new to learn and ways to improve how we work."

A Team Built on Quality

Having worked and trained in specialist blade repair facilities in both the United Kingdom and the United States, Dave has developed a strong appreciation for what makes the Salus Aviation team unique.

"The quality of the finished product is what really sets this team apart."

Despite being a relatively small team, Dave says every technician takes pride in producing work that meets the highest standards while understanding the responsibility that comes with returning critical aviation components safely back into service.

He also values the collaborative culture within the workshop.

"We support each other, share knowledge and work together to find solutions when we come across challenging repairs."

Advice for the Next Generation

As a leader, Dave enjoys helping newer technicians develop their skills just as others invested time in him throughout his own career.

His advice for anyone entering the aviation industry is straightforward.

"Stay curious, ask questions and never be afraid to learn from the people around you."

He also encourages new engineers to take pride in every repair they complete.

"In aviation, attention to detail matters, and the quality of your work is a reflection of you."

Looking back, Dave's career is proof that the most significant opportunities often arrive when they're least expected.

What began with an unexpected phone call and, years later, an equally unexpected LinkedIn message has become a career shaped by unexpected opportunities, continual learning and a commitment to excellence.

"I'm proud of what our team achieves and the role we play in keeping aircraft safe and serviceable for our customers."