TL:DR Was hoping for an aircraft that could do 150 kts, purchased for $150k, spent another $150k, took 150 weeks to achieve
Finished product
Once upon a time during a global pandemic I got the bright idea to purchase a DA-40, it had been sitting fairly unloved and unflown for a few years due to needing a new engine.
Hurdle 1: Unpaid parking charges
After agreeing on terms of sale it became known that there was unpaid parking charges going back a few years, this took a few months to resolve due to some very slow and fairly unhelpful Airport managment corporation
Hurdle 2: Supply chain problems
Due to COVID, a new engine lead time was 26 weeks, order placed with maintenace company who agreed to do the work.
Engine arrived June 2022, I (naively) thought that work would have been done on the aircraft before the engine arrived, nope. Come November the old engine still on the airframe, minimal work completed apart from disassembly to fit the airframe in the corner of the hangar
2023
January Out with the old, a long way off the new, slow progress
March Sad news
Unfortunately the chief engineer for the business, and the main person controlling my project dies unexpectedly, the whole project goes on hold.
To be continued....
Project 150
Moderators: Rick, Lance Murray
- Skywayman
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Project 150
April Interior and new engineer
The interior had been water damaged due to the canopy window being open during its prolonged stay outside at the airport.
It had been sent to an upholsterer for a quote on reupholstery, it took a few weeks to get a response, verdict, "not less than $28,000"
I decided to do it myself.
Before After A new engineer is appointed with an apparent mandate for no work on 'external' planes which are not part of the flight school. The plan was for work to be done on my aircraft after hours.
May
The maintenance business closes abruptly leaving my plane locked in their hangar. Numerous phone calls and visits to work out what to do. In the end no other maintenance organisations on the airport could take on the work at short notice. As a consequence of having a Continental diesel the next centre that could help me was 1000 miles away so in a container it goes. June
The logbooks went missing after the business closed down, they turned up 100 miles away after a month of being missing
July A New Home
The plane arrived safe and sound with only a few bruises from transport.
Unfortunately in the midst of the previous troubles the autopilot head unit had gone missing, it later turned up in another aircraft, someone must have 'borrowed' it.
August-October The dark ages
A few minor things happened with the aircraft during this time, but it still remained on the transport frame, no engine, no wings, no landing gear.
November Another move
The business where it was being worked on closed, thankfully another maintenance organisation on the same airport came to the rescue and agreed to help with the work. A nice parting gift from the closing business was a very large bill, including over 120 labour hours, despite all those man hours there seemed to be very little material progress.
December A new hope
Initial optimism slowly dragged on, as being the lowest rung on the totem pole at a new shop started again, with seemingly minimal progress for months
2024 The year it takes flight
It took until late April for the landing gear to go on, followed by the engine in May, and by June it was starting to look like a plane again. There would be a few teething problems with a new fuel tank that leaked that delayed the first flight until September, but after a long, long process, it is airborne, a few more issues to get to the bottom of, but for a while there I thought I would never see it fly.
Keep the clean side up!
The interior had been water damaged due to the canopy window being open during its prolonged stay outside at the airport.
It had been sent to an upholsterer for a quote on reupholstery, it took a few weeks to get a response, verdict, "not less than $28,000"
I decided to do it myself.
Before After A new engineer is appointed with an apparent mandate for no work on 'external' planes which are not part of the flight school. The plan was for work to be done on my aircraft after hours.
May
The maintenance business closes abruptly leaving my plane locked in their hangar. Numerous phone calls and visits to work out what to do. In the end no other maintenance organisations on the airport could take on the work at short notice. As a consequence of having a Continental diesel the next centre that could help me was 1000 miles away so in a container it goes. June
The logbooks went missing after the business closed down, they turned up 100 miles away after a month of being missing
July A New Home
The plane arrived safe and sound with only a few bruises from transport.
Unfortunately in the midst of the previous troubles the autopilot head unit had gone missing, it later turned up in another aircraft, someone must have 'borrowed' it.
August-October The dark ages
A few minor things happened with the aircraft during this time, but it still remained on the transport frame, no engine, no wings, no landing gear.
November Another move
The business where it was being worked on closed, thankfully another maintenance organisation on the same airport came to the rescue and agreed to help with the work. A nice parting gift from the closing business was a very large bill, including over 120 labour hours, despite all those man hours there seemed to be very little material progress.
December A new hope
Initial optimism slowly dragged on, as being the lowest rung on the totem pole at a new shop started again, with seemingly minimal progress for months
2024 The year it takes flight
It took until late April for the landing gear to go on, followed by the engine in May, and by June it was starting to look like a plane again. There would be a few teething problems with a new fuel tank that leaked that delayed the first flight until September, but after a long, long process, it is airborne, a few more issues to get to the bottom of, but for a while there I thought I would never see it fly.
Keep the clean side up!
- Steve
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Re: Project 150
Skywayman - Oh My God! Thank you so much for posting! You have done something I thought impossible - immunized me against any future maintenance-induced AOG periods I may encounter with my aircraft. After reading your saga, any issues I might have will pale in comparison. I can barely now remember the 4 month AOG period I experienced in 2020-21.
- TimS
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Re: Project 150
Skywayman,
Wow. And I thought I could be stubborn. may you enjoy your newly flying plane.
Tim
Wow. And I thought I could be stubborn. may you enjoy your newly flying plane.
Tim
- jwx96
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Re: Project 150
That’s an amazing story! I’m so sorry for what you had to go through! It really makes me hesitant to do any upgrades that aren’t strictly necessary - and I’m thinking about a few. I wonder if anyone has some easier upgrades stories to share? If so could you comment on what led to your success? Skywayman, congratulations on your achievement and ultimate success. I hope your new plane brings you many hours of enjoymen!.
- Skywayman
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Re: Project 150
If I was speaking to younger (and wealthier) me, I would probably say:
- Don't buy a currently unairworthy plane as a first time owner
- Unless you own a dozen planes and will have a large amount of repeat business be prepared to never be a priority.
- There is no accountability, or recourse for any promises made and broken, or for theft of components for that matter.
- It will take the shine off GA for a long time
In terms of straightforward upgrades, LED lights are a fairly straight forward. I have Whelen Orion 600 nav strobes, AeroLED sunbeam taxi/landing (can't comment on night time brightness yet)
Currently I have an ECU fault problem to troubleshoot after ~10 hrs flying, how hard can that be to fix!
- Don't buy a currently unairworthy plane as a first time owner
- Unless you own a dozen planes and will have a large amount of repeat business be prepared to never be a priority.
- There is no accountability, or recourse for any promises made and broken, or for theft of components for that matter.
- It will take the shine off GA for a long time
In terms of straightforward upgrades, LED lights are a fairly straight forward. I have Whelen Orion 600 nav strobes, AeroLED sunbeam taxi/landing (can't comment on night time brightness yet)
Currently I have an ECU fault problem to troubleshoot after ~10 hrs flying, how hard can that be to fix!
- dant
- 4 Diamonds Member
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- First Name: Dan
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Re: Project 150
That sounds like a small saga in an of itself!The logbooks went missing after the business closed down, they turned up 100 miles away after a month of being missing
Your patience with maintenance shops is saintly.