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Piper remains sole manufacturer offering new planes with manual flap handles

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Piper remains sole manufacturer offering new planes with manual flap handles
Policy
Webp piper
John Calcagno, CEO | Piper Aircraft

Manual flap handles, often called "Johnson Bars," are mechanical levers that directly control wing flaps using cables and pulleys. Once common in general aviation, these manual systems have largely been replaced by electric switches and handles in modern aircraft. Today, only a few planes in the United States still use Johnson Bars, mostly limited to vintage models.

Some pilots value the reliability and simplicity of manual flap handles, comparing their appeal to that of a manual transmission in cars. While most new aircraft use electric flap controls, there is one general aviation plane still produced with a Johnson Bar: the Piper PA-28.

In early general aviation history, manual flap handles were standard on aircraft such as the Cessna 140 and Piper PA-22. These levers allowed pilots to move flaps easily but required them to reach down or reposition themselves during flight, which could be awkward or distracting. As manufacturers sought greater convenience and cost savings, companies like Cessna phased out Johnson Bars in favor of electric flaps starting in the 1960s. For example, the Cessna 172 has used electric flaps since 1965.

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Electric flap systems simplified manufacturing and became popular among pilots for their ease of use. Competitors like Piper introduced electric flaps on turboprop models, while newer manufacturers such as Cirrus and Diamond never used manual systems at all. Mooney adopted hydraulic flaps for later versions of its M20 series.

Despite this shift toward automation, Piper continues to equip its PA-28 model with a Johnson Bar. The PA-28 has maintained this feature throughout its 65-year production run. Buyers can also find manual flaps on Piper’s twin-engine PA-44 Seminole and on some kit planes like the ICP Savannah, which offers both manual and electric options.

The Piper PA-28 is notable as one of the most widely produced aircraft globally. Since its introduction in 1960, it has been popular with private pilots and flight schools alike due to its low-wing design and single engine configuration. The current lineup includes five variants—all equipped with Garmin glass cockpits and Johnson Bars for flap control.

Flap settings on the PA-28 can be adjusted between three positions: 10°, 25°, or 40°. The lever is flush with the floor when retracted; Flaps 10° is typically used for takeoff while Flaps 40° is standard for landing.

According to General Aviation News, Piper sold 182 examples of the PA-28 in 2024, making it the second-best-selling piston general aviation aircraft behind only the Cirrus SR22T and ahead of long-time rival Cessna 172 Skyhawk.

While many manufacturers have moved away from manual flaps due to cost and weight considerations—such as Van's Aircraft discontinuing its manual option—some pilots continue to prefer them for their tactile feedback and direct control. Manual systems also tend to be quicker to deploy than electric ones—a potential advantage during critical maneuvers like go-arounds—and are generally less expensive to maintain because they lack complex electrical components.

To address ergonomic concerns associated with traditional Johnson Bars (which require reaching down), aftermarket solutions like the EZ flap handle extension allow easier operation without sacrificing mechanical feel.

Piper has not announced any plans to introduce electric flaps on either the PA-28 or PA-44 models. This leaves Piper as one of the last major manufacturers offering new aircraft with this traditional mechanism—a unique distinction as most other companies prioritize cost reduction and weight savings through electrification.

Industry-wide trends suggest that manual flap handles may soon disappear entirely from newly manufactured planes. For now, however, they remain available for those who value their distinctive flying experience.

Organizations Included in this History
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