Aircraft Pre-Purchase Inspection: Complete Checklist

A thorough aircraft pre-purchase inspection protects buyers from hidden defects and provides negotiation leverage. This comprehensive pre-buy inspection checklist ensures nothing critical escapes examination before purchasing an airplane.

Selecting the Right Inspector

Inspector choice significantly affects inspection quality and buyer protection.

Ideal Inspector Qualifications:

• Type-specific experience (Cessna, Piper, Cirrus, etc.)
• A&P license with Inspection Authorization (IA)
• No relationship with seller or aircraft
• Reputation in aircraft community
• Detailed inspection protocol
• References from previous pre-buy clients

Inspector Options:

• Type club recommended mechanics: Deep model knowledge
• Specialized pre-buy shops: Efficient process, experience
• Manufacturer service centers: Factory training, specialized tools
• Independent A&P/IA: Personalized attention, flexibility

See our Complete Buying Guide for inspector selection details.

Pre-Buy Inspection Cost Expectations

Understanding costs helps budget appropriately and avoid cheap inadequate inspections.

Typical Inspection Costs:

• Basic singles (Cessna 172, Piper Cherokee): $1,500-$2,500
• Complex singles (Cirrus SR22, Bonanza): $2,500-$4,000
• Light twins (Baron, Seneca): $3,500-$5,500
• Turboprops (King Air, TBM): $5,000-$10,000+

Additional Costs:

• Borescope inspection: $300-$800
• Oil analysis: $30-$100
• Compressions test: Included in most
• Test flight fuel: $100-$300
• Ferry to inspector: $500-$2,000+
• Inspector travel: $500-$1,500 if needed

Reference our Inspection Financing Guide for funding options.

Airframe Inspection Components

Comprehensive airframe examination reveals structural integrity and corrosion issues.

Exterior Inspection:

• Skin condition: dents, buckles, corrosion, repairs
• Paint condition and evidence of recent paint covering damage
• Control surfaces: alignment, balance, hinge condition
• Landing gear: cracks, wear, proper rigging
• Tires: tread depth, sidewall condition, age codes
• Propeller: nicks, cracks, hub condition
• Windows/windscreen: crazing, cracks, seal condition

Interior Inspection:

• Seat rails and stops: cracks, wear, security
• Interior condition: tears, stains, overall wear
• Carpet removal to inspect floor structure
• Belly inspection access panels
• Firewall penetrations and condition

Critical Corrosion Areas:

• Wing attach points and spars
• Tail cone and empennage attach
• Battery box area
• Belly and lower fuselage
• Wing root fillets
• Gear attach points

Engine Inspection Essentials

Engine condition significantly affects aircraft value and near-term operating costs.

Visual Engine Inspection:

• Oil leaks: severity and source identification
• Exhaust system: cracks, security, condition
• Baffling: tears, security, gaps
• Hoses and lines: age, condition, security
• Ignition system: magneto condition, harness
• Accessories: alternator, vacuum pump, fuel pump

Compression Test:

• All cylinders tested hot
• Acceptable: 70/80 or better typically
• Marginal: 65-69/80 (monitor closely)
• Poor: Below 65/80 (investigate cause)
• Differential between cylinders significant
• Air leakage source identification (valves vs rings)

Borescope Inspection:

• Cylinder walls: scoring, wear patterns
• Valves: carbon buildup, guide wear
• Piston condition: cracks, erosion
• Combustion chamber: deposits, cracks
• Recommended for engines near TBO
• Costs $300-$800 but worth investment

Oil Analysis:

• Metal content analysis
• Trend data if available from seller
• Immediate sample if no recent analysis
• Results interpretation by expert

Avionics and Systems Testing

Functional testing confirms expensive avionics work properly.

Avionics Functionality:

• GPS navigation: operation, database currency
• Autopilot: modes, coupling, engagement
• Communication radios: clarity, frequency coverage
• Navigation radios: VOR/ILS function, accuracy
• Transponder: altitude encoding, mode functionality
• ADS-B Out: compliance verification
• Audio panel: intercom, marker beacon, all functions

Electrical System:

• Battery: voltage, condition, age
• Alternator: output, voltage regulation
• Circuit breakers: condition, no signs of overheating
• Wiring: chafing, improper repairs, corrosion
• Lights: all exterior and interior lighting functional

Fuel System:

• Tanks: cap seals, drain function, sumps
• Fuel selector: smooth operation, detents
• Lines and hoses: condition, age, security
• Fuel pump(s): operation, pressure
• Water contamination check

Flight Controls and Systems

Control System Inspection:

• Cable tension: proper specification
• Pulleys and fairleads: wear, alignment
• Bellcranks: cracks, wear, security
• Trim system: operation, indicator accuracy
• Flap system: symmetry, rigging, operation
• Landing gear: if retractable, full cycle test

Instruments:

• Engine instruments: accuracy, operation
• Flight instruments: pitot-static leak check
• Gyro instruments: smooth operation
• Compass: swing date, deviation card
• Vacuum system: pressure, filter condition

Test Flight Procedures

Flight testing reveals issues impossible to detect on ground.

Pre-Flight Evaluation:

• Preflight walk-around with inspector
• Engine start and warm-up observation
• Taxi handling and brake effectiveness
• Run-up: magneto drop, engine parameters

Flight Test Maneuvers:

• Takeoff performance and handling
• Climb rate at various power settings
• Cruise performance verification
• Stall characteristics and speeds
• Autopilot engagement and tracking
• GPS and navigation functionality
• Descent and approach performance
• Landing gear operation (if retractable)

Performance Documentation:

• Actual vs published performance
• Fuel flow at cruise settings
• Oil temperature and pressure
• Unusual vibrations or noises
• Avionics operation under load

Logbook Compliance Review

Thorough logbook review ensures regulatory compliance and reveals maintenance quality.

Airworthiness Directives:

• All applicable ADs identified
• Compliance documented in logbooks
• Recurring ADs tracked properly
• One-time ADs signed off correctly
• No open or overdue ADs

Maintenance Documentation:

• Annual inspections current and proper
• Major repairs properly documented
• 337 forms for major repairs/alterations
• STC paperwork for modifications
• Weight and balance current
• Altimeter/transponder certifications current
• ELT battery within expiration

Using Inspection Findings for Negotiation

Inspection results provide factual basis for price negotiation or deal structure.

Categorizing Findings:

• Safety items: Must repair before purchase or walk away
• Airworthiness items: Required for annual, negotiate repairs
• Discretionary items: Nice to fix, use for price reduction
• Future maintenance: Engine near TBO, upcoming ADs

Negotiation Strategies:

• Request seller repairs before closing
• Negotiate price reduction equal to repair quotes
• Split costs on major items
• Accept as-is with appropriate price discount
• Walk away if issues too extensive

Repair Cost Documentation:

• Obtain written estimates from shops
• Use inspector's professional opinion
• Reference parts prices from suppliers
• Factor in downtime for repairs
• Consider future implications (engine run-out)

Frequently Asked Questions

How long does a pre-purchase inspection take?

Typical pre-buy inspection requires 2-5 days: 1-2 days for physical inspection, 1 day for test flight and systems checks, 1-2 days for logbook review and report writing. Complex aircraft or extensive issues may extend timeline.

Should I attend the pre-buy inspection?

Highly recommended. Attending allows you to see aircraft condition firsthand, ask inspector questions in real-time, understand findings context, and build relationship with potential future mechanic if purchase proceeds.

What if inspection reveals major problems?

Options: (1) Request seller repairs before closing, (2) Negotiate price reduction equal to repair costs, (3) Walk away using inspection contingency. Most purchase agreements include contingency allowing buyers to cancel if inspection unsatisfactory.

Can I use the seller's annual inspection instead of pre-buy?

Not recommended. Annual inspections verify minimum airworthiness standards. Pre-buy inspections are more thorough, buyer-focused, and examine items beyond annual scope. Invest in independent inspection for protection.

How much should I negotiate based on inspection findings?

Negotiate dollar-for-dollar on safety and airworthiness items. Request 50-75% discount on discretionary items. Factor in future maintenance like engine TBO approaching. Market conditions affect negotiating leverage—seller's market reduces buyer power.