How much does it cost to maintain a plane properly? My answer: it depends. Maintenance varies by aircraft year, model and operational mission.
There are many schools of thought on aircraft maintenance. Because perception is reality, they are all true for the most part. Here’s how I break it down.
- Preventive maintenance = fixed costs
- Scheduled maintenance = fixed/variable costs
- Unscheduled maintenance = variable costs
Preventive maintenance
An owner/operator changes the engine oil in his airplane. Because his application has an oil screen instead of a spin filter, Cessna 172 owner Corey Sampson changes the oil every 25 hours. Your logbook reflects the intervals at which this maintenance should occur. A case of Phillips 66 X/C 20W50 is about $93, no filter to buy and he saved money on labor by doing the job himself. There will be a few quarters left for next time. Right now, Corey is on track to fly 400 hours this year. That’s a lot of oil changes.
For perspective, an AA48108-2 rotary oil filter for this model costs about $35 and mechanical labor would cost another $100.
Scheduled maintenance has a fixed cost but can also have variable cost factors. During my time in corporate aviation, I supported Southern Company Services and their fleet of King Air 200. Their maintenance crew religiously performed scheduled brush changes on their starter generators. They were also taken out for exchange at the time between review recommendations (TBO).
Because of this action plan, they never had a starter generator failure in service. Finance knew that with X number of flying hours, they would spend Y number of dollars. If mechanics find damage during generator removal and replacement (R&R), this repair is unscheduled maintenance with a variable cost based on condition.
The annual inspection is one of the biggest cost drivers for Cessna 172 owners. Because an A&P/IA is required, the labor cost is a tick higher than standard maintenance. In my experience you can expect to spend around $1,700.00 for the inspection. The amount is only the inspection fee and is a fixed cost. Findings are additional and have a variable cost.
Unscheduled maintenance is just that, something has stopped working properly and you need to figure it out. A twin Cessna once came to my client Savannah Aviation. The pilot required replacement of a light bulb in the instrument panel. A log check showed that the engines needed an oil change. This is strange; this oil filter is full of metal. Have you ever read “If you give a mouse a cookie?”
Engine overhaul cost
There comes a time in every airplane owner’s life, a reckoning, if you will, when the sands of the TBO life dwindle down to the last grains of the hourglass. I’m talking about that key moment in aircraft maintenance; a major engine overhaul.
I called Pinnacle Aircraft Engines and asked how much it costs to overhaul a Cessna 172 engine. The answer (and you should have seen this coming): “It depends.”
Let’s break it down. Corey has a 1966 Model 172 equipped with an O-300-D, six-cylinder Continental engine. Pinnacle’s estimated base price is $38,000. I did a 2014 estimate at my motor shop, and this same motor was $28,500. The later 172 models cost $32,000 for the O-320-E2D and $33,500 for the IO-360-L2A.
Included in the review estimate:
- New Champion Ignition Kit
- New Superior cylinders
- New lightweight starter motor
- Overhauled carburetor/fuel system
- Other accessories, such as a vacuum pump, have an additional charge
Other factors to consider are the factory cylinder option, engine disconnect, new oil/fuel lines, engine mounts, propeller, air ducts and a reworked firewall.
Cessna 172 supply chain
The economics of aircraft maintenance come down to three factors: location, labor and parts.
Location-wise, stick to the maintenance plan to avoid getting stuck in a remote airport on the outer rim. This is where they take you. Work is what it is. Work with someone you can trust, even if it’s a little more expensive than Slippery Pete’s Air Service.
Replacement spare parts can affect the total annual maintenance expense of the aircraft.
Cessna will direct you to their parts portal. Go for it if you have to, but know you’re paying top dollar. No one gets a factory deal.
Finding the right part for your type certificated aircraft is mission critical. For Corey’s O-300, the IPC is X30014. You can access this manual by visiting Continental Motors.
Aircraft cylinders are a maintenance constant and can be expensive to repair. New PMA options are available and price is negotiable if you are in good standing.
Here are some examples:
- Aircraft Specialty Services Millennium Cylinder — SA10200-A20P MSRP: $1,318.91 FBO PRICE: $1,160.63 — Save $158.28
- Air Power, Inc. Superior Air Parts Aircraft Products Part Number: SA10200-A20P $1,155. Continental Aircraft Engine Part Number: 658319A2 $2,069
Overhauled cylinders cost about $1200, so you’re better off buying new ones.
There are also other options for joinery, consumables and accessories.
Aircraft Spruce & Specialty has a section for Cessna 172 parts.
New surplus parts can save money, but be careful on places like eBay. Things are only sometimes what they seem. Make sure you have a mechanic check them out.
Here are some better options:
I hope you have a clearer idea of ​​not only the cost but the value of aircraft maintenance.
