This paper was withdrawn after publication because of confidentiality issues. It is no longer available for sale.Design for Assembly is the concept of carrying out critical thought early in the design stage to create assembly easement at the production stage. In the aerospace industry products have very long lives, frequently being optimised rather than introducing new products. This has meant that older products that are stable cash cows have not benefited from new Design for Assembly Methods and manufacturing equipment and tooling suffer from obsolescence. It has been established that approximately 80% of overall product cost is determined at the design stage and thus existing products suffer from preloaded costs. This paper takes existing Design for Assembly methodologies and analyses them with respect to the unique challenges involved in legacy product redesign. A tool is developed to identify potential Design for Assembly projects. The tool is then demonstrated using a butterfly bracket assembly.