Annual Inspections: What Happens Behind the Hangar Doors?

When it comes to keeping your aircraft safe, airworthy, and ready to fly, few things are more important than the annual inspection. Mandated by the FAA and essential for responsible ownership, the annual inspection is more than a box to check—it’s a deep dive into the health of your aircraft.

But what exactly happens during this process? Here’s a behind-the-hangar-doors look at how our expert technicians at Clipper Aviation approach every annual.

What Is an Anuual Inspection?

An annual inspection is a comprehensive review of the entire aircraft, required once every 12 calendar months for most general aviation aircraft under FAR Part 91. Whether you’re flying a Cirrus SR22, a Piper Archer, or a King Air, this inspection ensures your aircraft continues to meet all safety, structural, and regulatory standards.

At Clipper Aviation Maintenance, our FAA-certified A&P and IA technicians follow a rigorous checklist rooted in manufacturer guidance and FAA regulations, tailored to your aircraft’s make, model, and mission profile.

Step-by-Step Walkthrough:

1. Open-Up and Initial Visual Inspection

We begin to remove cowlings, inspection panels, fairings, and access covers. The aircraft is opened up from nose to tail, allowing technicians to gain access to internal components, wirings, linkages, and fluid systems.

2. Airframe and Structural Checks

We inspect the aircraft’s frame for:

• Corrosion or cracking
• Rivets and fasteners integrity
• Control surfaces for secure attachment and smooth operation
• Landing gear systems (tires, brakes, struts)

3. Powerplant and Propeller System

This includes:

• Engine compression checks
• Magneto timing
• Inspection of spark plugs, filters, hoses, and mounts
• Oil sample analysis
• Propeller hub and blade condition

4. Systems and Avionics

We examine:

• Fuel system for leaks or contamination
• Pitot-static system for accurate airspeed and altitude reporting
• Electrical wiring and alternator/generator operation
• Flight instruments, audio panels, and GPS units

5. AD Compliance and Logbook Review

We verify that all Airworthiness Directives (ADs) and Service Bulletins are up to date. Maintenance records and logbooks are reviewed for accuracy and completeness.

6. Final Clean-Up and Functional Tests

After discrepancies are resolved and components reassembled, we perform:

• Operational checks of all systems
• Ground run-up (if applicable)
• Cleaning and corrosion prevention

Why Annual Inspections Matter

An Annual inspection isn’t just about staying legal—it’s about catching issues early, maintaining resale value, and ensuring you and your passengers stay safe. Delaying or rushing through the process can lead to costly surprises down the road.

At Clipper Aviation, we take pride in our detailed approach and clear communication. If we find something, you’ll know exactly what it means, what your options are, and how to move forward.

Ready for Your Next Annual?

Whether you’re planning your first annual or your fifteenth, our maintenance team is ready to support you. We offer transparent estimates, real-time updates, and quick turnarounds designed to keep you flying without compromising safety.