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Airplane owners or mechanics should expand the checklist form to include items of special concern that result from the records research. When available, manufacturer service bulletins and service letters usually provide directions about how to perform specific inspections (visual, magnifying lens, dye penetrant, eddy current, etc.) or modifications along with special precautions. If special inspections or modifications are developed independently, then you should include or attach this information to the form. Ideally, this information would be tied back to the airplane records research. You should also document special inspections required by the ICA of a field approval here as well.
When working through this process, owners or mechanics may determine that normal visual inspection techniques are not practical. In that case, you may need more intrusive inspections. Inspection methods continuously improve or become more affordable. Borescopes provide high-quality methods for visual inspections to some inaccessible areas. Other techniques, like eddy current, are becoming more popular for assessing a wide range of concerns. Standbys like dye penetrant and magnetic particle remain effective for detecting cracks.
When access to a critical area is a problem, you may need panels installed. This should not deter an owner from having it done. Type clubs may have knowledge of modifications that enable easier inspection or alternative inspection techniques.
When developing a special inspection program for an airplane, an owner or mechanic should keep in mind how often any inspection should be done. Some areas may be easy to inspect and can be added to the annual inspection list. More difficult inspections may need to be done once every 5 or 10 years. Of course, this would depend on the usage and environmental variables discussed earlier. You should give consideration to any harm that could be done in order to inspect an area versus the frequency such an inspection is needed. (For instance, repeated removal of fasteners can damage the holes, causing a higher likelihood of cracking. Removal of control surfaces requires re-rigging, which, if not done properly, creates a safety concern.)
Tailoring the checklist form to an individual airplane or model helps the owner keep good records of the special inspection items or other actions that pertain to their airplane. Coupled with the findings of the records research, this becomes an important part of an airplane’s maintenance history. It is wise to keep these completed checklists with the airplane maintenance logs and other records.
Documents listed in the references section of this guide are excellent resources that will provide more ideas for a comprehensive checklist. Advisory Circular AC 20-106, Aircraft Inspection for the General Aviation Aircraft Owner, contains an enormous amount of detailed information that directly applies to special inspections. AC 20-64, Maintenance Inspection Notes for Lockheed L-188 is basically an inspection checklist for that model. Although it's for a large airplane, its content and document layout serve as a good example.
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Best Practices Guide for Maintaining Aging General Aviation Airplanes(8)
