Have a DIY project in mind? Read these eight simple tips before you start.
June 2015-
As pilots, we have a responsibility to know our aircraft as well as we can, and one great way to learn about our airplanes is to complete a restoration project. Things like replacing bulbs, installing new seatbelts and new seats, repairing upholstery and decorative furnishings; as well as simple repairs and adjustments—and many other service actions which don’t involve disassembly of the primary structure—are all permitted under the preventive maintenance section of FAR part 43, Appendix A. (We’ve recently added a link to the U.S. Government Publishing Office on PiperFlyer.org. Look for “Browse e-CFR Data” under the Knowledge Base tab. There you can review FAR part 43, Appendix A and other regulations. —Ed.)
Here are some general tips to keep in mind if you’re contemplating a DIY project.
01 Define the scope of your project, and be realistic about your restoration skills and budget.
If this is your first restoration project, you’ll want to keep your project small and inexpensive.
When you’re planning, keep in mind that if you run into trouble you could have your plane down for weeks (or longer) while you get help. Talk to your A&P before you start any work, and if you have difficulty after you begin your project, get your mechanic’s advice. You can also reach out to your fellow members through the PFA forums by logging in to PiperFlyer.org.
02 Consult the parts catalog for your airplane.
The manual contains drawings of every part of your airplane with each part identified in a parts list. This is paramount to making your project easier, accurate, safe and legal. (If you don’t already have a parts manual, check with a source such as eflightmanuals.com.)
Some part specifications have changed over the last few decades. Piper occasionally improves certain parts and issues a new part number; however, the parts manual that you purchase will be dated when your airplane was manufactured so it won’t contain these updated parts numbers. If you have trouble finding a certain part number, be on the lookout for a new part number.
03 Sourcing of parts.
The companies mentioned in the Q&As and restoration articles in Piper Flyer magazine and online in the Piper Yellow Pages are quality companies that supply great products. PFA recommends you check with these folks first. Don’t forget, the parts locating service offered by Piper Flyer Association is included as one of your membership benefits and is just a phone call away.
Much like carpentry where you measure twice and cut once, for aircraft restoration projects you will need to double-check and confirm your part numbers before placing an order. If you get a part number wrong and have to return one of the products, you risk paying a sizable restocking fee in addition to shipping—up to 25 percent of the purchase price.
If you run into confusion, I recommend that you call or email the supplier. You can also check with your mechanic and refer to the PFA online forums for all kinds of aviation-related information and help.
04 Order your parts.
The items may show up in less than a week, or they might take quite a bit longer to arrive. Occasionally a vendor will show a product is in stock but at the time of your order it’s already unavailable. A back ordered part can take anywhere from a few days to a few months to arrive.
Sometimes a part number specified in the part manual is incorrect, or the vendor ships the wrong part. This is why you should check each part upon arrival for accuracy. Is it the correct part number? Is it for the correct airplane? And does the part actually work? If it’s at all possible, check each part or device for quality, too.
05 Start your project.
Don’t begin your project until all of the parts have arrived and they pass the accuracy and quality tests. If you start your project before all of the parts arrive, you risk having your aircraft down for weeks or months if there are any hiccups.
06 Go Slow. Better yet, go slower. Errors that occur during restoration can often be attributed to fatigue and impatience. If you are getting frustrated or the project isn’t going as well as you’d like, take a break for a few hours or overnight. It’s better to go slow and have a result that you’re proud of.
07 Consult with experienced restorers.
Whether you call on your A&P, your best friend, a neighbor in the hangar next to you, a fellow PFA member or a vendor; ask for help! Let’s say that again: Ask for help!
08 When your project is complete, admire your handiwork and call all of your hangar buddies over to see the finished product.
This will give you something to brag about next time you’re hangar flying and perhaps encourage you to try another project. Don’t forget to take a picture and post it on the PFA forum, too.
Piper Flyer Association member Scott Sherer is a multi-engine and instrument rated private pilot. He’s logged 2,600 hours and is the owner of a 1977 PA-34-200T based at Burlington Municipal (KBUU) in Burlington, Wis. Sherer anxiously awaits the day when N344TB finally gets new paint. Send questions or comments to editor@piperflyer.org.
Do’s and Don’ts
Don’t throw any old parts away
No matter how big, small or seemingly inconsequential, do not throw anything away. You’ll probably need to look at it later.
Do use the right tool for the job
For example, if one of your projects has to do with replacing plastic, plexiglass or fiberglass, always trim very carefully using vendor-recommended tools. Sandpaper, a file, a drill with the correct bit and a Dremel tool can help greatly. And remember: always trim and fit perfectly before painting.
Do disconnect the power source
If one of your projects has to do with anything electrical, disconnect your battery before you start. Failure to do so could result in an entire airplane of nonfunctional electric and electronic devices. In some airplanes this would be over $100,000 dollars in damage. If in doubt, consult your A&P or avionics repair facility.
Don’t expect perfection
There will always be little places in your project with tiny errors. These likely won’t cause problems—except with your expectations. Chances are very good that your project will look orders of magnitude better than it did before you started. Be proud of your work and if there’s a little goof, don’t get frustrated. On the next project you’ll do even better.
