Steps of an Annual Inspection

What To Expect

When an aircraft arrives for an annual inspection, the first step is to determine the full scope of work required. For a first-time aircraft, this involves intense airworthiness and logbook research to verify the status of Airworthiness Directives, calendar/hourly timed items, and total/TBO times. For returning aircraft, all times are verified. After completing the initial research, we will contact you to discuss any timed items found due or coming due. Customers bringing an aircraft in for the first time will receive an Oil Change Questionnaire to record their preferences.

Owner-reported squawks, 1-year inspection items, and any timed items found due during the research process are recorded in a work order packet that outlines the full scope of work for that aircraft. This work order packet follows the aircraft throughout its entire annual inspection.

For a first-time aircraft, this process could take 5 or more business days to complete. Returning aircraft usually can be completed in less time, depending on certain variables.

Once the work order packet has been completed, the aircraft is nearing the end of this phase of the inspection and is ready to move on to Step 2. First-time aircraft will have their logbooks and supporting documents rigorously scrutinized and catalogued into a labeled binder system. This organization event enhances the value of your aircraft by transforming the aircraft records into an easy to understand, all-inclusive display of the chronological maintenance history of your aircraft. Much of this work takes place during Step 1 but may also be completed in tandem with the other Steps.

An incoming ground run is completed to check all aircraft systems and engine performance; creating a baseline to work from during the annual inspection. The engine compressions are checked and recorded upon completion of the ground runs. This is completed early in the process since it is the foremost method for identifying a bad cylinder. If this occurs, you will be sent a Cylinder Questionnaire to aid in determining what method of addressing the bad cylinder is best for you.

In Step 3, technicians will disassemble and inspect a section, address squawks, complete all service work, and then reassemble that section. The sections include nose, engine, cabin, wings, tail, and gear. To best utilize shop resources, multiple sections may be inspected at once, or a Tech may inspect a section, accomplish the needed repairs, and move to the next section. The ability to vary the intricate details of inspection and repairs allows us to maximize our efficiency.

Owner-reported squawks will be addressed at this time, along with squawks found by technicians during inspection. Most squawks that arise during an annual inspection are related to airworthiness and must be addressed for the aircraft to achieve airworthy status. Sometimes, squawks are discovered that are recommended, but would not prevent the annual sign-off if deferred. If this occurs, we will contact you to ask how you’d like to proceed.

During this step, you will typically receive regular email communications. Periodically, a squawk list and parts list will be included to advise you of squawks added by the technicians and the parts used to correct them. These emails will also have a summary of the labor hours and parts used on the aircraft, accurate as of the date of the email. More details on what those lists do and do not cover are included in the email.

To expedite communications, updates are generated via an unmonitored email address. It will show up as no-reply@doublemaviation.com. If you have questions, please make sure to call or email our office staff directly rather than replying to the update email.

At this point the aircraft has been fully reassembled with the exception of the engine cowling. The aircraft moves out of the maintenance hangar and engine runs are completed to verify the engine(s) are operating within the manufacturer’s parameters. Additionally, certain squawks may need an engine run to verify they have been corrected. Depending on the results of the engine runs, the aircraft may move back to Step 3 for further maintenance, or it may move forward to Step 5 for cowling installation.

Once the result of the engine runs is satisfactory, the cowling may be installed, and a final inspection of the aircraft may be completed by the Inspector. The aircraft is now ready for its post-maintenance flight.

During this step, the aircraft is flown to check that all systems are operating properly and all squawks have been resolved. As in Step 3, certain squawks must be checked in flight to ensure they have been corrected. Once the first flight is accomplished, you will receive an email with a list of all remaining squawks. This list may include:

  • Owner- or technician-reported squawks that require further maintenance
  • New squawks discovered during flight
  • Items to re-check once back on the ground
  • Informational items for the owner’s knowledge

At this point, the aircraft may either move back to Step 3 or on to Step 6.

In this Step, our in-house detail department cleans the aircraft while the paperwork, logbook entries, etc. are all finalized. Upon completion, you will receive a work order with a final invoice. The reservation fee paid when scheduling your annual inspection will show as a credit on this final invoice.

Payment in full is required before an aircraft can be released from maintenance. Our preferred payment method is ACH, which can be accomplished using the link in the work order transmission email. Payment via wire transfer, check, or credit card is also accepted. Credit card payments will incur a 3% convenience charge.

Once payment has been received, a pick-up date can be scheduled between 10am and 4pm, Monday through Thursday. To be considerate of our customer’s time, we do not schedule pick ups on Fridays.

Aircraft Storage

During Steps 3 through 5, your aircraft is located in the Double M Aviation hangar, and no storage charges are incurred. If you choose to have your aircraft tied down on the ramp during Steps 1 and 2 or 6 and 7, no storage charges are added to your final work order.

If you would prefer your aircraft stay hangered the entire time it is at our facility for maintenance, Double M has secured slots in an on-site storage hangar that we are able to offer for a negotiated daily rate while your aircraft is not in the main hangar.

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Deposits

Double M will request a deposit each time the projected total of the final invoice increases by $10,000. These deposit invoices will correlate with the work order and parts list estimates you've been receiving weekly. They are generated automatically, so if you ever have any questions, please reach out to our office and let us know.

Post-Maintenance Check-in

Your satisfaction and confidence in your aircraft are extremely important to us. After your annual inspection, we will contact you to answer any questions that might have come up during the first few post-inspection flights.

Aircraft Maintenance

Additional Services

Many times, aircraft have additional needs that merit attention simultaneously with an annual inspection. This could be an IFR certification that is expiring, updating a physical weight and balance report, avionics issues, or even cosmetic concerns such as paint or interior work. Double M has established relationships with local vendors who will work directly with you and your aircraft to resolve these issues. To enhance your peace of mind, when these additional items are accomplished in tandem with the annual inspection, one of our certified Aircraft Maintenance Technicians is both inspecting and flying the aircraft after the third-party work is completed to ensure your aircraft is both safe and reliable.

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