Aircraft Annual Inspection Costs: What to Expect and Budget

Aircraft annual inspection costs represent a significant ownership expense varying widely by aircraft type and condition. Understanding typical airplane annual costs helps owners budget appropriately and avoid financial surprises during mandatory inspections.

Typical Costs by Aircraft Type

Single-Engine Piston Aircraft:

• Cessna 150/152: $1,200-$2,000
• Cessna 172: $1,500-$2,500
• Cessna 182: $1,800-$3,000
• Piper Cherokee/Archer: $1,500-$2,500
• Piper Arrow (complex): $2,000-$3,500
• Cirrus SR20/SR22: $3,500-$6,000
• Bonanza: $2,500-$4,500
• Mooney: $2,000-$3,500

Twin-Engine Aircraft:

• Piper Seneca: $4,000-$7,000
• Baron: $5,000-$9,000
• Cessna 310: $4,500-$8,000
• Diamond DA62: $5,500-$9,500

Turboprop Aircraft:

• TBM 850/900/960: $15,000-$30,000
• Pilatus PC-12: $18,000-$35,000
• King Air 90: $12,000-$25,000
• King Air 200/350: $25,000-$50,000

Review our Ownership Cost Analysis for complete budgeting.

What's Included in Annual Inspection

Base annual inspection includes mandatory FAA requirements only.

Standard Annual Inspection Scope:

• Airframe inspection per manufacturer checklist
• Engine visual inspection
• Control systems inspection
• Logbook review and AD compliance check
• Required testing (pitot-static, transponder, ELT)
• Oil change typically included
• Basic systems functional checks
• Annual sign-off in logbooks

NOT Typically Included:

• Repairs or parts replacement
• AD compliance work
• Oil filter inspection/cutting
• Compression tests (extra $200-$400)
• Borescope inspection (extra $300-$800)
• Corrosion treatment
• Paint touchups or cosmetic work

Common Additional Items Found

Most annuals discover items requiring additional work beyond base inspection.

Typical Additional Costs:

• Tire replacement: $150-$400 each
• Brake work: $300-$1,200
• Battery replacement: $200-$600
• Vacuum pump: $400-$800
• Alternator belt: $50-$150
• Hoses/lines: $200-$800
• Spark plugs: $300-$800
• Air filter: $50-$200
• Exhaust repairs: $500-$3,000
• Landing light: $100-$500

Major Items Occasionally Found:

• Cylinder replacement: $3,000-$8,000 each
• Magneto overhaul: $800-$1,500 each
• Fuel bladder replacement: $3,000-$8,000
• Control cable replacement: $1,500-$4,000
• Corrosion repair: $2,000-$10,000+
• Prop overhaul: $2,500-$5,000

Factors Affecting Annual Cost

Aircraft Condition:

• Well-maintained: Lower annual costs
• Deferred maintenance: Higher costs catch-up
• Neglected aircraft: Dramatically higher
• First annual after purchase: Often highest

Flight Hours:

• High hours (150+/year): More wear items
• Low hours (under 50/year): Corrosion/deterioration issues
• Moderate (75-125/year): Typically lowest annual costs

Storage:

• Hangared: Fewer issues, lower costs
• Tie-down: More corrosion, weather damage
• Climate: Harsh environments increase costs

Shop Labor Rates:

• Rural areas: $65-$95/hour
• Suburban: $85-$125/hour
• Major metros: $110-$160/hour
• Labor is 60-70% of annual cost typically

Minimizing Annual Inspection Costs

Proactive Maintenance:

• Address squawks immediately, not at annual
• Replace wear items before failure
• Monitor trends (oil analysis, compressions)
• Keep aircraft clean and well-maintained
• Hangar if possible to reduce corrosion

Owner-Assisted Annuals:

• Open inspection panels yourself
• Remove interior for inspection access
• Clean aircraft thoroughly before inspection
• Perform oil changes under supervision
• Can save 20-40% on labor costs
• Requires cooperative A&P/IA willing to supervise

Shop Selection:

• Get quotes from 2-3 shops
• Consider reputation over lowest price
• Type-specific shops often more efficient
• Establish relationship with one shop
• Avoid switching shops annually

Timing Strategy:

• Schedule during shop slow periods (winter)
• Avoid peak flying season
• Allow flexibility for shop scheduling
• Don't wait until annual expires

Budgeting for Annual Inspection

Conservative Budget Approach:

• Base inspection cost + 50% buffer minimum
• Example: $2,000 base + $1,000 buffer = $3,000 budgeted
• First annual: Budget 100% extra (double base cost)
• Well-maintained: 25-30% buffer acceptable

Annual Reserve Fund:

• Set aside monthly for annual
• Example: $2,500 annual ÷ 12 months = $210/month
• Smooths cash flow impact
• Builds cushion for unexpected items

Reference our Affordability Guide for complete budgeting strategies.

Choosing an Inspection Shop

Evaluation Criteria:

• Type-specific experience with your aircraft
• A&P mechanic with IA (Inspection Authorization)
• Clean, organized facility
• Transparent pricing and processes
• Good communication during inspection
• References from other owners
• Type club recommendations

Questions to Ask Shops:

• What's base annual cost for my aircraft type?
• What does base inspection include/exclude?
• Hourly labor rate?
• Estimated timeline for completion?
• Do you allow owner-assisted work?
• Parts markup policy?
• Payment terms (deposit, final payment)?

Owner-Assisted Annual Details

Participating in annual can significantly reduce costs.

Tasks Owners Can Perform:

• Remove interior panels and seats
• Open inspection panels
• Clean aircraft thoroughly
• Remove and clean wheel pants
• Drain and sample fuel
• Service landing gear (under supervision)
• Lubricate hinges and components
• Reinstall panels after inspection

Cannot Perform (A&P Required):

• Actual inspection sign-off
• Compression tests
• AD compliance work
• Repairs requiring log entries
• Adjustments to flight controls
• Safety-wired installations

Typical Savings:

• Light participation: 10-15% savings
• Moderate participation: 20-30% savings
• Heavy participation: 30-40% savings
• Value beyond cost: Learning your aircraft

Frequently Asked Questions

How much does an annual inspection cost for a Cessna 172?

Cessna 172 annual inspections typically cost $1,500-$2,500 for base inspection, plus $500-$2,000 for additional items discovered. Total annual typically runs $2,000-$4,500 depending on aircraft condition and shop location.

What's included in aircraft annual inspection?

Base annual includes airframe inspection, engine visual inspection, control systems check, logbook review, AD compliance verification, and required systems testing. Does NOT include repairs, parts replacement, or comprehensive engine analysis unless specified.

Can I do my own annual inspection?

No. FAA requires A&P mechanic with Inspection Authorization (IA) to perform and sign off annual inspection. However, owners can assist with many tasks under supervision to reduce labor costs 20-40%.

How long does annual inspection take?

Typical timeline: 3-7 days for singles, 7-14 days for twins/complex aircraft. Timeline extends if parts needed or major repairs discovered. Schedule 2-3 weeks total including shop backlog and potential delays.

What happens if I skip annual inspection?

Aircraft becomes unairworthy and illegal to fly. Operating without current annual violates FAA regulations, voids insurance, and may result in FAA enforcement action including fines and certificate suspension. Always maintain current annual.