Pre-Buy Inspection Checklist: Complete Guide for Aircraft Buyers

Why Pre-Buy Inspections Are Essential

Aircraft are complex machines with thousands of components subject to wear, corrosion, and damage. Visual inspections only reveal surface-level conditions. Pre-buy inspections involve:

• Detailed logbook review spanning the aircraft's entire history
• Comprehensive physical inspection of airframe, engine, and systems
• Functional testing of equipment and avionics
• Identification of current issues and upcoming maintenance
• Assessment of overall condition and value

Consider common discoveries during pre-buy inspections:

• Cylinder compression issues indicating needed engine work ($15,000-$40,000)
• Corrosion in wing spars or fuselage requiring extensive repair ($20,000-$60,000+)
• Propeller requiring overhaul ($3,000-$8,000)
• Avionics malfunctions needing replacement ($5,000-$20,000)
• Upcoming Airworthiness Directives requiring compliance ($2,000-$30,000)
• Damage history not disclosed by seller
• Missing or incomplete logbook entries affecting value and insurability

A $2,500 pre-buy revealing a $35,000 engine problem lets you renegotiate price, require repairs, or walk away. Without inspection, you discover the problem post-purchase when it's too late.

Choosing the Right Pre-Buy Mechanic

Select a Type-Specific Expert

Use a mechanic experienced with your specific aircraft type. A Cessna 172 specialist might not be ideal for a Beechcraft Bonanza pre-buy. Type-specific experience means the mechanic knows:

• Common problem areas for that model
• Applicable Airworthiness Directives
• Normal wear patterns versus concerning issues
• Parts availability and typical maintenance costs
• Model-specific inspection procedures

Ensure Independence

Never use the seller's mechanic or a shop with financial interest in completing the sale. The mechanic should work for you, providing objective assessment without pressure to approve questionable aircraft.

Some sellers resist independent mechanics, viewing it as distrust. This is irrelevant—insist on your chosen mechanic. Sellers refusing independent inspection are raising red flags.

Verify Credentials

Confirm the mechanic holds appropriate certifications:

• FAA Airframe and Powerplant (A&P) certificate
• Inspection Authorization (IA) for annual inspection authority
• Manufacturer training for specific aircraft type (if available)
• Good standing with the FAA (no enforcement actions)

Check References and Reputation

Ask for references from recent pre-buy customers. Contact type clubs or online forums asking about specific mechanics. Look for:

• Thorough, detailed inspection reports
• Clear communication and explanation of findings
• Reasonable pricing without hidden fees
• Willingness to be contacted with follow-up questions
• Reputation for objectivity and thoroughness

Comprehensive Pre-Buy Inspection Checklist

Logbook Review

Logbooks are the aircraft's history. Thorough review should verify:

• Completeness: Airframe, engine, and propeller logbooks present with continuous history
• Total Time: Airframe total time matches advertised time
• Engine Time: Time since major overhaul (SMOH), time since new, overhaul documentation
• Propeller Time: Time since overhaul, strike inspections after prop strikes
• Annual Inspections: Completed annually with proper sign-offs
• Airworthiness Directives: All applicable ADs complied with and documented
• Major Repairs and Alterations: Form 337s filed for major work
• Damage History: Any accident or incident repairs properly documented
• Modification History: STCs and documentation for equipment additions
• Service Bulletins: Compliance with mandatory and recommended SBs

Missing or incomplete logbooks dramatically affect value and may make the aircraft unfinanceable or uninsurable. Learn more about understanding aircraft logbooks.

Airframe Inspection

• Fuselage: Check for cracks, corrosion, skin damage, dents, wrinkles indicating hard landings
• Wings: Inspect wing spars, attach points, skins for corrosion or cracks; check fuel tanks for leaks
• Empennage: Examine tail surfaces, attach points, control surfaces for damage or excessive wear
• Landing Gear: Inspect struts, mounting points, wheels, brakes, tires; check for hard landing damage
• Control Surfaces: Check ailerons, elevator, rudder for excessive play, damage, proper operation
• Control Cables: Inspect for fraying, proper tension, smooth operation throughout range
• Windows and Windscreen: Check for cracks, crazing, proper sealing
• Doors and Hatches: Verify proper fit, latching, sealing

Engine and Powerplant

• Compression Test: All cylinders should be 70/80 or better; low compression indicates wear or damage
• Borescope Inspection: Internal cylinder examination revealing scoring, carbon buildup, valve condition
• Oil Analysis: Lab analysis of oil sample detecting metal particles indicating wear
• External Inspection: Check for oil leaks, exhaust leaks, corrosion, security of mounts
• Magnetos: Inspect timing, condition, spark plug wear
• Fuel System: Check fuel pumps, lines, filters for leaks or contamination
• Oil System: Inspect oil cooler, lines, filter for condition and leaks
• Induction System: Check intake, carburetor or fuel injection, air filter
• Exhaust System: Inspect for cracks, leaks, security of mounts
• Engine Mounts: Check for cracks, wear, proper torque

Engine condition is critical. Engines nearing TBO (Time Between Overhaul) or showing low compression may need imminent overhaul costing $25,000-$50,000 for typical piston singles. Factor this into your purchase decision.

Propeller

• Visual inspection for nicks, dents, erosion, cracks
• Check propeller logs for time since overhaul
• Verify proper strike inspections if applicable
• Test governor operation (constant-speed props)
• Check spinner and backing plate condition

Avionics and Electrical Systems

• Communications: Test all radios (COM, NAV, transponder) for proper operation
• Navigation: Verify GPS, VOR, ILS, ADF functionality
• Autopilot: Test all modes and functions during flight (if included)
• Instruments: Check all flight and engine instruments for accuracy and operation
• Lighting: Test all interior and exterior lights
• Electrical System: Check alternator/generator output, battery condition, circuit breakers
• Pitot-Static System: Verify proper operation of airspeed, altimeter, VSI
• Vacuum System: Test vacuum pump and instruments (if applicable)

Avionics obsolescence is real. Older equipment may need replacement for ADS-B compliance or functionality. Budget for upgrades if the panel is dated.

Interior

• Inspect seats for condition, security of mounting, seatbelt integrity
• Check interior panels and headliner for condition and security
• Test all switches, controls, and knobs for proper operation
• Verify proper operation of heating and ventilation
• Check for evidence of water intrusion or corrosion
• Inspect carpeting and insulation condition

Exterior and Paint

• Assess paint quality and condition
• Check for signs of repainting that might hide damage
• Inspect registration markings for compliance
• Note any corrosion visible under paint

Poor paint isn't a deal-breaker but affects value. Budget $10,000-$20,000+ for complete repaint if needed.

Flight Test

If possible, conduct a flight test (with you as passenger or pilot if insured):

• Engine start, warm-up, and ground operations
• Takeoff performance and acceleration
• Climb performance and engine temperatures
• Cruise performance, speed, and fuel burn
• Avionics and autopilot functionality
• Handling characteristics, control feel, trim
• Descent and landing performance
• Any unusual noises, vibrations, or behaviors

Flight testing reveals issues ground inspections can't detect. Some lenders and insurance companies require flight testing before final approval.

Documentation Review

• Current and valid airworthiness certificate
• Aircraft registration
• Weight and balance documentation
• Equipment list
• POH or AFM (Pilot's Operating Handbook/Approved Flight Manual)
• Supplements for installed equipment
• Maintenance manuals and service documentation

Interpreting Pre-Buy Results

No Aircraft Is Perfect

Every pre-buy finds some issues. The question is severity and cost. Categorize findings:

• Safety Issues: Items affecting safe operation (serious corrosion, engine problems, control issues). These must be addressed before purchase or are deal-breakers.
• Airworthiness Issues: Items preventing legal flight (expired AD compliance, missing required equipment). Must be fixed to fly legally.
• Significant Maintenance: Expensive items needed soon (engine approaching TBO, propeller overdue, major avionics failures). Factor costs into negotiations.
• Minor Squawks: Small issues that are annoying but not critical (minor leaks, worn interior, cosmetic issues). Typical for used aircraft.
• Future Concerns: Items to monitor but not immediately critical (moderate compression, early corrosion, aging components).

Red Flags That Should Stop Purchase

• Major structural damage or corrosion requiring extensive repair
• Engine problems indicating imminent failure
• Undisclosed accident or damage history
• Missing or incomplete logbooks with no acceptable explanation
• Non-compliance with mandatory Airworthiness Directives
• Evidence of poor or deferred maintenance throughout history
• Seller unwilling to address serious safety issues

Using Pre-Buy Results in Negotiations

Request Repairs Before Closing

For significant issues, request the seller make repairs before closing. Get written estimates and ensure repairs are completed by qualified mechanics with proper documentation.

Negotiate Price Reduction

If the seller won't make repairs, negotiate price reduction covering repair costs plus some margin for your hassle. For example, if the inspection reveals $12,000 in needed work, requesting a $15,000 price reduction is reasonable.

Walk Away if Necessary

Don't fall in love with an aircraft to the point you overlook serious problems. If issues are too severe or costly, exercise your inspection contingency and walk away. Other aircraft exist, and you'll avoid inheriting someone else's problems.

Your purchase agreement should include clear contingencies allowing you to withdraw if the pre-buy reveals significant issues. Have an aviation attorney review purchase agreements.

Pre-Buy Inspection Costs and Timeline

Typical Costs

• Basic Pre-Buy: $1,500-$2,500 for simple single-engine aircraft
• Comprehensive Pre-Buy: $2,500-$4,000 for complex singles or light twins
• Additional Tests: Borescope ($200-$400), oil analysis ($50-$100), compression test (usually included)
• Travel Costs: If the aircraft is distant, you may cover mechanic travel expenses

Timeline

• Scheduling: 1-2 weeks to get on mechanic's schedule
• Inspection: 2-5 days for thorough inspection
• Report Preparation: 1-3 days for detailed written report
• Total: Plan for 2-4 weeks from scheduling to final report

Build adequate time into your purchase agreement. Rushing pre-buy inspections leads to missed issues.

Questions to Ask Your Pre-Buy Mechanic

• What is your experience with this specific aircraft type?
• What does your pre-buy inspection include? (Get detailed scope)
• Will you provide a detailed written report with photos?
• Can I be present during the inspection?
• What is your fee structure and estimated total cost?
• How long will the inspection take?
• Will you be available after purchase for ongoing maintenance?
• What are common problems with this aircraft model?
• Based on the inspection, would you buy this aircraft?
• What upcoming maintenance should I expect?

What Lenders and Insurers Look For

Your lender will likely require a pre-buy inspection before final loan approval. They want to verify:

• Aircraft is in airworthy condition
• No hidden damage affecting value
• No major issues requiring immediate expensive repairs
• Aircraft value supports the loan amount
• Complete logbooks and documentation

Insurance companies similarly want assurance the aircraft is well-maintained and safe. Poor pre-buy results can lead to insurance denial or very high premiums.

A clean pre-buy inspection facilitates smooth financing and insurance approval. Significant issues can derail financing or require larger down payments to compensate for reduced aircraft value.