Modifying an airplane to add additional performance, comfort or usefulness can be one of the most fun aspects of aircraft ownership. It can also be one of the most stressful. While modification developers do everything they can to simplify the experience, there are many pitfalls that can accompany the process. Going into a project with your eyes wide open can minimize the stress while preparing you for the unexpected.
We asked aircraft owners for their perspective on pitfalls they have seen and were willing to share.
Do Your Homework
One owner recommended you do your homework before investing money in mods, saying you can make some smart choices by doing so. For example, even though a 3-bladed prop looks nice, question whether you need the climb performance versus the 3-knot cruise penalty. Asking questions about how you operate your airplane and evaluating the options will help you make the right decision.
Not As Easy As Anticipated
Another owner mentioned how he added a Garmin G5 HSI to replace his old Bendix/King HSI. The interface to the Bendix/King autopilot was not as easy as anticipated. As it turned out, one wire needed to be included in the interface and they inadvertently had removed that wire. It took about two days for them to figure out the problem and fix.
Another owner suggested that you be prepared for a project getting stuck and stopping for an extended period. More complex installations have more interfaces and can sometimes take longer to complete if unexpected issues come up.
Having the Right Attitude
Just having a naysayer attitude. Both yours and an installer’s. This owner said that some inspectors and technicians will tell you an idea is not possible, without putting a finger on why. He said they want to stay in the comfortable middle of the envelope.
Maintaining the airworthiness of an airplane is an enormous responsibility. Maintaining the right attitude and having open conversations will help your project stay on track and increase the likelihood you will build the airplane you are dreaming about.
Past Work May Complicate the Project
Depending on how much work has been done to your airplane previously may well impact how any new modifications are integrated into the airframe.
The necessity of correcting previous bad maintenance practices can add a lot of time when trying to install upgrades. Examples include finding automotive connectors and wire, and sloppy sheet metal 'repairs' that drilled holes on top of other holes and ignoring edge distance requirements, so parts must be replaced or repaired correctly before proceeding.
Compatibilities
Not all engine monitors are certified as “primary replacement.“ This means that if it’s not, you can’t remove or have the original equipment inoperative. Many mods, especially engine related ones, may not be compatible with other previously or future installed STC’s. Many autopilots may not be compatible with other STC’s such as certain STOL kits.
This respondent also made an import point; the owner needs to take possession of ALL documents and installation information and store it with the logbooks. Many times, the installation shop keeps it, or the owner loses it. It will be necessary to have access to this information at some point in the future, especially if you are considering future modifications.
What Can You Do to Minimize These Pitfalls?
Being aware of the potential pitfalls is first and foremost. Being prepared and having an open mindset will set you up for the best experience.
Do your homework and asking the right questions about your operations as well as the anticipated benefits a modification is said to deliver.
Be prepared for things to not go as smoothly as you might like. These are complex machines in a heavily regulated environment.
Engage in fully transparent communications with your installer about yours as well as their expectations to ensure any and all concerns are on the table. This will help you have the best installation experience possible.
Research and understand the previous work that has been done to your airplane so you can better understand the implications for installation of the current project.
Research and talk with your installer about compatibilities. Depending on how your airplane is equipped, certain modifications may not be compatible with what you want to do. Or these mods may need to be reconfigured to enable compatibility.
Keep good records with documentation and logbooks. Your future self and future owners will thank you for it.
Adding modifications to your airplane can be one of the most fun experiences you have in owning an airplane. Especially if you are aware of the potential pitfalls and proactively work to minimize their impact.
What other pitfalls have you experienced and what did you do to minimize their impact?
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