Overhauling and updating a Cherokee or similar modest project

[cluttonfred]

Much as I love homebuilts and vintage aircraft, a reality check of my budget suggest that I might want to tackle restoring and updating a modest 1960s-1970s GA aircraft, especially if I want to take more than one family member at a time or much baggage up in the air with me. Not that I will stop dreaming and perhaps buidling a single- or two-seater on the side, but that's another thread. ;-)


I would think that you could start with a time-worn but airworthy Piper Cherokee and then overhaul and update it so it's actually lighter and better performing than it came from the factory. I don't mean putting in glass panels or anything radical, just complete inspections and overhaul, a thorough tear-down and cleaning, new interior and exterior, new lightweight electronics to replace the boat-anchor period ones, removing unwanted IFR equipment for a basic modern VFR panel, lightweight starter and battery, etc. Of course, the mechanical bits would all need to be done and the whole project overseen by an A&P, but there is a lot of elbow grease work that I could do myself.


Does anyone have any links to sites or articles documenting this kind of restoration and update on a modest budget?

[martymayes]

Does anyone have any links to sites or articles documenting this kind of restoration and update on a modest budget?

Define "modest budget."
Restoring a 40 y/o factory airplane isn't cheap but in the end you get a known quantity. I haven't seen many end up "lighter" than before either, usually it's the opposite. But I agree with your overall assessment.

[Tom Downey]

Define "modest budget."
Restoring a 40 y/o factory airplane isn't cheap but in the end you get a known quantity. I haven't seen many end up "lighter" than before either, usually it's the opposite. But I agree with your overall assessment.

Here is what I did as the latest project, It's a 1948 Cessna rag wing 170. we bought it for $5k, and we are in it now at $27K, every thing is new, the aircraft was completely disassembled stripped repainted, new windows, new interior, new wiring, new wheels tires and brakes, PeePonk gear mod, tail pull handles, 1 piece windscreen, shoulder harness, new instrument panel, new radios, Engine up grade to a 0-300-D, with a vac pump, 60 Amp Alternator, 6 new cylinders, engine rebuilt to factory new spec. new carb, mounts, oil filter kit, new prop, Whelen 3 light strobe kit, landing light mod to leading edge and the light blinker mo
.




we started with a derelict barn find.



new prop spinner

[cluttonfred]

Looks fantastic, Tom. Sell it to me? Seriously!

On the restoration, are you (or one of the "we") an A&P or did you have to pay someone to do those parts of the restoration that require sign-off?

[Tom Downey]

Looks fantastic, Tom. Sell it to me? Seriously!

On the restoration, are you (or one of the "we") an A&P or did you have to pay someone to do those parts of the restoration that require sign-off?

I am the A&P-IA, this is a "we" effort, the wife and I.
We have decided to keep it for a while, gotta get a little flying out of all that work. It took 15 months Nov. 12 to Feb 14,

[cluttonfred]

Ah, there's the rub, you clearly know how to do the things that 1) I can't do on a certified plane and 2) I don't know how to do, anyway. If you do decide to sell, please shoot me a PM--I really was not kidding. Cheers, Matthew

[MickYoumans]

I would think that you could start with a time-worn but airworthy Piper Cherokee and then overhaul and update it so it's actually lighter and better performing than it came from the factory. I don't mean putting in glass panels or anything radical, just complete inspections and overhaul, a thorough tear-down and cleaning, new interior and exterior, new lightweight electronics to replace the boat-anchor period ones, removing unwanted IFR equipment for a basic modern VFR panel, lightweight starter and battery, etc. Of course, the mechanical bits would all need to be done and the whole project overseen by an A&P, but there is a lot of elbow grease work that I could do myself.

You are describing pretty much what I have been doing. Some people enjoy restoring an old car but I prefered that it be an airplane. I purchased a low hour Piper Cherokee that was in reasonable flying condition but not a real 'looker'. The first two annual inspections we concentrated on getting the plane in first class shape mechanically. Last fall I gutted the radio stack and put in a PS Engineering 8000BT audio panel, Garmin com radio and Garmin transponder. This annual we will be doing the control cable inspection AD. This inspection will require a good portion of the interior be removed so I figured this was the perfect time to fully gut the interior and replace it with new leather seating, headliner, carpet and wall panels. I am still waiting for portions of the interior to arrive before we start. My mechanic wanted to wait until all of the parts and materials were on hand before gutting the plane. After I save up and recover from the interior, the final step will be to chemically strip and paint the plane. When that is complete my airplane should be in great shape.

For me it is fun going through the refurbishment process. I know in the long run it will probably cost a little more than buying a plane that has already been upgraded. The big difference for me is that I was able to pay cash for the plane and will be able to save up and pay cash for everything else I have done to it. When I get through I will have THE radio stack that I want, THE interior I want and THE paint scheme and colors I want and not have to live with something marginally close. The best part of all is that I will have done it without going into debt.

Keep in mind that in the long run you may have more money in the plane than you would if you bought someone elses already refurbished plane, but you can spread the cost out over as long a period of time as you need to refurbish it (other than required maintenance).

[cluttonfred]

Thanks, Mick, how about some pics of your project and, if you don't mind, some numbers on initial cost, what you've put in and what you expect to put in to get the plane where you want it to be? Cheers, Matthew

[MickYoumans]

Matthew, I have less than 20K in the initial invenstment for the airplane. The radio stack upgrade cost me $6500. I have attached before and after pictures of the radio stack. The interior parts I have ordered from AirTex, Plane Plastics and Knots2U is around $3500. I'm not sure what the total labor will be for all of the interior work. I can update that after this annual is complete.
Here is a link to the interior I ordered:
http://www.airtexinteriors.com/portf...per PA28 R200#

Down the line, after I get most of my other checklist items done, I want to go back and take out the old com radio I kept for a backup and replace it with something like a Garmin 430W or whatever is current at that time.

After the interior is done I will come back and update this with before and after pictures.

[Mike Switzer]

The interior parts I have ordered from AirTex, Plane Plastics and Knots2U is around $3500. I'm not sure what the total labor will be for all of the interior work.

Well, it could be $0.00, since you can do all that yourself legally.