Preparing Your Aircraft for Annual FAA Inspections

The FAA requires most general aviation aircraft to undergo an annual inspection to maintain airworthiness certification. This detailed examination evaluates airframe condition, powerplant performance, avionics operation, and recordkeeping compliance. For aircraft owners, proper preparation streamlines the inspection process, minimizes downtime, and helps maintain a clean insurance profile.

A proactive approach to the annual inspection not only saves time and money—it also reassures insurers that you’re maintaining your aircraft according to regulatory and manufacturer standards. Below is a comprehensive checklist and guide to help you prepare for your next FAA annual inspection with confidence and clarity.

Why FAA Inspections Matter for Insurance

Insurance carriers consider FAA-mandated inspections as part of their risk assessment process. Aircraft with lapses in annual inspections may lose coverage eligibility, and poor records can complicate claim resolution. A clean, well-prepared inspection record helps support your insurability, valuation, and resale position.

Proper documentation of the annual inspection also ensures your aircraft remains compliant with FAR Part 91.409 and is legally permitted to operate. A lack of preparation can delay return-to-service, increase labor costs, or trigger findings that reduce policy favorability.

Pre-Inspection Preparation Checklist

Use the checklist below to prepare your aircraft and paperwork before delivering it to the mechanic or IA (Inspection Authorization):

• Maintenance Records and Documents
  • Organize and present airframe, engine, and propeller logbooks
  • Include AD (Airworthiness Directive) compliance records
  • Attach current weight and balance data and equipment list
  • Bring copies of recent repairs, overhauls, or modifications
• Interior and Accessibility
  • Remove floor mats, seat cushions, and cargo items for access
  • Unlock compartments and baggage bays
  • Remove cowling and inspection panels if requested
• Avionics and Instrumentation
  • Ensure all avionics power up correctly
  • Bring manuals or paperwork for any recent avionics upgrades
  • Update database subscriptions (if applicable)
• Exterior and Airframe
  • Wash aircraft and remove grease or dirt for visual access
  • Note visible defects to discuss with the mechanic
  • Apply lubrication to hinges and access points per POH
• Powerplant and Systems
  • Check and top off oil levels
  • Replace filters if nearing service interval
  • Run engine briefly before delivery for easier diagnostics

Tips for Working With Your Mechanic or IA

• Communicate any squawks or operational anomalies upfront
• Label new or replaced parts if you’ve installed any owner-permitted equipment
• Clarify whether discrepancies should be fixed during inspection or deferred
• Provide your contact info and preferred method of approval for additional work

Insurance and Inspection Records

Insurers may request copies of annual inspection sign-offs during underwriting, audits, or claims. Keeping these in a digital backup as well as your logbook ensures you’re never caught off guard. If your inspection turns up an issue that affects airworthiness, communicate with your broker or carrier promptly—especially if the aircraft must remain grounded past your renewal date.

Common Oversights That Cause Delays

• Missing documentation for STCs (Supplemental Type Certificates)
• Failure to address recurring ADs from previous inspections
• Dirty or cluttered aircraft that hinders access and increases labor time
• Outdated transponder or ELT inspection intervals

Conclusion

Preparing for your annual FAA inspection isn’t just about compliance—it’s about preserving airworthiness, supporting your insurance coverage, and showing stewardship over your aircraft. By taking a checklist-driven approach and partnering proactively with your mechanic or IA, you’ll minimize surprises, downtime, and risk exposure.

With strong documentation, a clean presentation, and attention to detail, you not only pass your inspection—you protect your aircraft’s value and your peace of mind.