Project 150

Any DA40 related topics

Moderators: Rick, Lance Murray

Post Reply
User avatar
Skywayman
1 Diamond Member
1 Diamond Member
Posts: 6
Joined: Sat Jun 05, 2021 12:04 pm
First Name: JONATHAN
Aircraft Type: DA40D
Aircraft Registration: UUV
Airports: YBLT
Been thanked: 8 times

Project 150

Post by Skywayman »

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
PXL_20241106_031246754.jpg
PXL_20241106_031303056.jpg
PXL_20241117_005625165.jpg
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
PXL_20221118_022406275.jpg

2023
January Out with the old, a long way off the new, slow progress
PXL_20230118_041704751.jpg
PXL_20230118_042206377.jpg

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....
User avatar
Skywayman
1 Diamond Member
1 Diamond Member
Posts: 6
Joined: Sat Jun 05, 2021 12:04 pm
First Name: JONATHAN
Aircraft Type: DA40D
Aircraft Registration: UUV
Airports: YBLT
Been thanked: 8 times

Project 150

Post by Skywayman »

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
PXL_20230411_061551243.jpg
After
PXL_20230625_110235406.jpg
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.
IMG_20241130_213904.jpg
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.
PXL_20240626_235255743.jpg
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!
PXL_20241117_060205819.jpg
User avatar
Steve
5 Diamonds Member
5 Diamonds Member
Posts: 2049
Joined: Thu Aug 12, 2010 1:23 am
First Name: Steve
Aircraft Type: DA40
Aircraft Registration: N432SC
Airports: 1T7
Has thanked: 94 times
Been thanked: 537 times

Re: Project 150

Post by Steve »

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.
User avatar
TimS
5 Diamonds Member
5 Diamonds Member
Posts: 598
Joined: Thu Dec 02, 2010 1:10 am
First Name: Timothy
Aircraft Type: OTHER
Aircraft Registration: N1446C
Airports: 6B6 Stowe MA
Has thanked: 130 times
Been thanked: 117 times

Re: Project 150

Post by TimS »

Skywayman,

Wow. And I thought I could be stubborn. may you enjoy your newly flying plane.

Tim
User avatar
jwx96
4 Diamonds Member
4 Diamonds Member
Posts: 247
Joined: Mon Jul 22, 2019 9:54 pm
First Name: John
Aircraft Type: DA40
Aircraft Registration: N193JP
Airports: KFCM
Has thanked: 108 times
Been thanked: 61 times

Re: Project 150

Post by jwx96 »

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!.
User avatar
Skywayman
1 Diamond Member
1 Diamond Member
Posts: 6
Joined: Sat Jun 05, 2021 12:04 pm
First Name: JONATHAN
Aircraft Type: DA40D
Aircraft Registration: UUV
Airports: YBLT
Been thanked: 8 times

Re: Project 150

Post by Skywayman »

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! 😛
User avatar
dant
4 Diamonds Member
4 Diamonds Member
Posts: 329
Joined: Wed Jul 21, 2021 4:45 am
First Name: Dan
Aircraft Type: DA40
Aircraft Registration: N787DM
Airports: KPAE
Has thanked: 73 times
Been thanked: 76 times

Re: Project 150

Post by dant »

The logbooks went missing after the business closed down, they turned up 100 miles away after a month of being missing
That sounds like a small saga in an of itself!

Your patience with maintenance shops is saintly.
Post Reply