Author: Mike Reynolds

Mike Reynolds is an A&P certified mechanic with over 15 years of experience in general aviation maintenance. He specializes in piston aircraft and has worked on everything from Cessna 150s to Beechcraft Bonanzas. Mike is passionate about helping aircraft owners find the right parts and maintain their planes safely.
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Aviation Supply Chain Crisis Costs Airlines $11 Billion in 2025

Aircraft and airline operations

A new study by IATA and Oliver Wyman reveals that aviation supply chain disruptions will cost airlines more than $11 billion in 2025. The findings highlight ongoing challenges that show no signs of abating—and significant implications for aircraft operators at every level.

Breaking Down the $11 Billion

The costs break down across four major categories:

  • Excess fuel costs: $4.2 billion — Airlines are flying older, less fuel-efficient aircraft because new deliveries are delayed
  • Maintenance costs: $3.1 billion — Aging fleets require more frequent and expensive maintenance
  • Engine leasing: $2.6 billion — Lease rates have jumped 20-30% since 2019
  • Surplus inventory: $1.4 billion — Airlines are stockpiling spare parts to guard against unpredictable shortages

MRO Industry Under Pressure

For the Maintenance, Repair, and Overhaul (MRO) sector, parts shortages translate directly into longer turnaround times. A recent industry survey found that 75% of respondents reported worse turnaround times for engines and APUs compared to last year.

No part of the aircraft has been spared. Half or more of survey respondents reported deteriorating performance across nearly all component categories—from avionics to landing gear.

Wait times for engine repairs have surged by 150% for modern powerplants and 35% for older models. The result: aircraft sitting idle while airlines scramble to find available shop slots and parts.

The Backlog Problem

The unfilled aircraft order backlog now exceeds 17,000 jets—its highest level ever. At current production rates, clearing this backlog would take 14 years, double the wait time that existed before 2019.

More than half of industry respondents expect supply chain challenges to persist for at least another 18 months. Some executives predict disruptions lasting three to five years.

Labor Adds to the Challenge

Parts availability is only part of the equation. The average age of a U.S. aircraft mechanic exceeds 50, and the shortage of certified mechanics is projected to reach 19% by 2028. Fewer hands means longer maintenance queues, regardless of parts availability.

What Operators Can Do

Smart operators are adapting to the new reality:

  • Strategic stockpiling: Building inventory of high-demand parts before they’re needed
  • Diversified suppliers: Reducing dependence on single-source components
  • Predictive maintenance: Using data to anticipate failures before they ground aircraft
  • Alternative sourcing: Exploring PMA parts and approved repairs where appropriate

The Bottom Line

Aviation’s supply chain challenges aren’t going away soon. For aircraft owners and operators, proactive parts management is no longer optional—it’s essential for keeping aircraft flying and costs under control.

The industry’s fragility has been exposed. Those who adapt their procurement strategies now will be better positioned to weather continued turbulence in the years ahead.

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FAA MOSAIC Rule: Sport Pilots Can Now Fly Cessna 172s and Piper Cherokees

Cessna 172 on mountain runway

The FAA’s MOSAIC rule, which took effect October 22, 2025, represents the biggest change to light sport aviation since the category was created in 2004. Sport pilots can now fly approximately three-quarters of the general aviation fleet—including popular aircraft like the Cessna 172 and Piper Cherokee.

What Changed

Previously, sport pilots were limited to aircraft weighing no more than 1,320 pounds with a maximum of two seats. The new rules eliminate weight-based restrictions entirely, replacing them with performance criteria.

Under MOSAIC, Light Sport Aircraft must have:

  • Maximum stall speed of 59 knots (or 61 knots with a clean wing configuration)
  • No more than four seats
  • Single pilot operation capability

This means aircraft like the Cessna 172 Skyhawk, Piper PA-28 Cherokee, and many other four-seat singles now qualify for sport pilot operations.

What This Means for Pilots

Sport pilots can still use a valid driver’s license in lieu of an FAA medical certificate for daytime VFR operations. Night flying requires either a FAA medical or BasicMed compliance, plus additional instructor endorsements.

While sport pilots can now fly four-seat aircraft, they remain limited to carrying one passenger. The additional seats could be used for baggage or removed entirely.

The rule also opens limited commercial operations to sport pilots, including pipeline patrol, aerial photography, and glider towing—with appropriate training and endorsements.

Impact on Flight Training

Flight schools are expected to see increased demand for sport pilot training. With access to more capable aircraft, the sport pilot certificate becomes a more attractive option for recreational flyers who don’t want to pursue a full private pilot certificate.

Instructors will need to provide specific endorsements for sport pilots transitioning to higher-performance aircraft, creating new training opportunities throughout the industry.

Aircraft Owners Take Note

If you own a qualifying aircraft, you may see increased demand from sport pilots wanting to rent or purchase. Aircraft values for MOSAIC-eligible models could see upward pressure as the pool of potential operators expands significantly.

The key specification to watch is stall speed. Aircraft with Vs1 at or below 59 knots CAS (at max gross weight) qualify under the new rules. Check your POH for specific numbers.

Looking Ahead

The second phase of MOSAIC, affecting airworthiness certification for new aircraft, takes effect July 24, 2026. This will allow manufacturers to produce new LSA designs with capabilities that would have been impossible under the old rules—including retractable gear, higher speeds, and electric propulsion systems.

The FAA’s MOSAIC rule represents a fundamental shift in how America regulates recreational aviation. For pilots, aircraft owners, and the aviation parts industry, the ripple effects will be felt for years to come.

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DC-3 Turns 90: Celebrating Aviations Most Legendary Aircraft

Classic DC-3 propeller aircraft

Today marks the 90th anniversary of one of aviation’s most legendary aircraft. On December 17, 1935, the Douglas DC-3 took to the skies for the first time, forever changing commercial aviation and military airlift operations.

90 Years and Still Flying

Remarkably, more than 150 DC-3s remain airworthy today. The aircraft that revolutionized air travel in the 1930s continues to serve operators around the world, a testament to its rugged design and timeless engineering.

The DC-3 Society is marking this milestone with a week-long broadcast series featuring pilots, historians, and enthusiasts who keep the “Gooney Bird” flying. Today’s main event, “Wings of Legacy,” includes a screening of the award-winning documentary Into Flight Once More, narrated by Gary Sinise.

The Aircraft That Changed Everything

Before the DC-3, commercial air travel was expensive, uncomfortable, and often unreliable. The DC-3 changed all of that. Its 21-passenger capacity, reliable twin-engine design, and unprecedented range made profitable airline operations possible for the first time.

During World War II, the military version (designated C-47 Skytrain) became the backbone of Allied transport operations. General Dwight D. Eisenhower called it one of the four most important tools that won the war, alongside the bulldozer, jeep, and 2.5-ton truck.

Parts and Maintenance: A Living Legacy

Keeping DC-3s flying requires a dedicated community of mechanics, parts suppliers, and restoration specialists. Original parts are increasingly scarce, leading to a thriving market for PMA (Parts Manufacturer Approval) components and careful restoration of salvaged airframes.

The aircraft’s radial engines—typically Pratt & Whitney R-1830 Twin Wasps—require specialized knowledge that fewer mechanics possess each year. Organizations like the DC-3 Society work to preserve this expertise through training programs and documentation efforts.

What’s Next

The DC-3 Society has launched a $19,350 fundraising campaign (a nod to 1935) to support preservation efforts and educational programs. Their goal: ensuring the DC-3 continues inspiring future generations of aviators and aviation enthusiasts.

As we celebrate 90 years of the DC-3, the aircraft stands as proof that great engineering transcends generations. Here’s to the next chapter in the remarkable story of aviation’s most enduring workhorse.

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10 Essential Tools Every Aircraft Owner Needs in Their Hangar

Aviation tools and equipment

Whether you’re performing owner-assisted maintenance or building your first tool kit for annual inspections, having the right tools makes all the difference. Here are the essential tools every aircraft owner should have in their hangar.

1. Aviation-Grade Safety Wire Pliers

Safety wiring is everywhere in aircraft—from oil filters to turnbuckles. A quality pair of safety wire pliers with a built-in twister saves hours of frustration. Look for pliers with automatic return springs and comfortable grips. The Milbar brand has been an industry standard for decades.

What to Look For:

  • Automatic return mechanism
  • Reversible rotation direction
  • Long nose for tight spaces
  • Durable construction (expect to pay $40-80 for quality)

2. Torque Wrench

Proper torque is critical in aviation. Under-torqued fasteners work loose; over-torqued ones stretch and fail. A quality torque wrench in the 10-150 inch-pound range covers most light aircraft applications. For larger bolts (like engine mount bolts), you may need a foot-pound wrench as well.

Recommended Types:

  • Click-type: Most popular, provides audible “click” at set torque
  • Beam-type: Less expensive, requires visual reading
  • Digital: Most accurate, also most expensive

3. Inspection Mirror and Light

You can’t fix what you can’t see. A telescoping inspection mirror with an integrated LED light lets you peer into dark corners, behind panels, and inside wheel wells. Articulating mirrors are even better for hard-to-reach areas.

4. Borescope

Modern borescopes have revolutionized engine inspections. These camera-tipped probes let you examine cylinder walls, valve seats, and combustion chambers without removing the engine. USB models that connect to your phone or tablet start around $50 and provide excellent images.

5. Multimeter

Electrical troubleshooting is part of aircraft ownership. A digital multimeter measures voltage, resistance, and continuity—essential for diagnosing avionics issues, checking wiring, and testing batteries. Aviation-specific features to look for include:

  • Auto-ranging capability
  • Continuity beeper
  • Temperature probe
  • Clamp-on ammeter function

6. Spark Plug Tools

Servicing spark plugs requires specialized tools:

  • Spark plug socket (7/8″ deep well): Often with rubber insert to protect ceramic
  • Gapping tool: For setting electrode gaps accurately
  • Thread chaser: For cleaning cylinder threads
  • Spark plug tray: Keeps plugs organized by cylinder

7. Cowling/Panel Fastener Tools

Aircraft use various quick-release fasteners that require specific tools:

  • Dzus tool: For quarter-turn fasteners on cowlings
  • Camloc tool: For camlock-style fasteners
  • Screwdriver set: Phillips, flat, and Pozidriv in multiple sizes

8. Tire Pressure Gauge

Aircraft tires operate at much higher pressures than automotive tires—often 30-60 PSI for main gear and even higher for nose wheels. Use a calibrated gauge designed for the pressure range of your aircraft. Digital gauges provide the most accurate readings.

9. Compression Tester

Differential compression testing reveals cylinder health. While your A&P will perform official tests during annual inspections, having your own tester lets you monitor trends between annuals. A basic tester includes a regulator, gauge, and cylinder adapter fittings.

10. Oil Filter Cutter

Cutting open your oil filter at each oil change reveals engine health. Metal particles, bearing material, and other debris tell a story about internal wear. A proper filter cutter makes clean cuts without contaminating the filter element.

Building Your Tool Kit

Starter Kit (Budget: $200-400)

  • Basic safety wire pliers
  • Beam-type torque wrench
  • Inspection mirror and flashlight
  • Multimeter
  • Tire pressure gauge

Intermediate Kit (Budget: $500-800)

Add to starter kit:

  • Click-type torque wrench
  • USB borescope
  • Spark plug tools
  • Oil filter cutter
  • Dzus and Camloc tools

Complete Kit (Budget: $1,000+)

Add to intermediate kit:

  • Compression tester
  • Digital torque wrench
  • Professional borescope
  • Calibration tools

Tool Care and Storage

Aviation tools are an investment. Proper care ensures accuracy and longevity:

  • Store torque wrenches at lowest setting
  • Calibrate measuring tools annually
  • Keep tools clean and dry
  • Use a dedicated toolbox with foam inserts
  • Inventory tools before and after each maintenance session

A Note on Quality

In aviation maintenance, quality matters. Cheap tools can strip fasteners, provide inaccurate readings, or break at critical moments. Buy the best tools you can afford—they’ll last longer, work better, and potentially prevent costly mistakes on your aircraft.

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How to Choose the Right Oil for Your Aircraft Engine

Vintage aircraft engine with propeller

Selecting the right oil for your aircraft engine is one of the most important decisions you’ll make as an owner. The wrong choice can lead to accelerated wear, reduced engine life, and even engine failure. This guide covers everything you need to know about aviation oils.

Understanding Aviation Oil Grades

Aviation oils use a different grading system than automotive oils. You’ll see designations like W80, W100, and W120, where the “W” stands for “weight” (not “winter” as in automotive oils) and the number indicates viscosity.

Common Aviation Oil Grades

  • W80: Lighter weight, often used in cold climates or for break-in
  • W100: The most common grade for Continental and Lycoming engines
  • W120: Heavier weight for hot climates or high-time engines
  • 15W-50: Multi-viscosity, popular year-round choice

Straight Weight vs. Multi-Viscosity

The debate between single-grade and multi-viscosity oils has continued for decades. Each has advantages depending on your operating environment.

Single Grade Oils (W100, W80)

Single grade oils maintain consistent viscosity at operating temperature. Many engine manufacturers recommend single grade oils, and they’re typically required for engine break-in. They’re also generally less expensive than multi-viscosity options.

Multi-Viscosity Oils (15W-50, 20W-50)

Multi-viscosity oils provide better cold-start protection while maintaining proper viscosity at operating temperatures. They’re excellent for aircraft that operate in varying climates or see infrequent use where cold starts are common.

Mineral Oil vs. Ashless Dispersant

Mineral Oil

Straight mineral oil is required during engine break-in (typically the first 25-50 hours). It allows piston rings to properly seat against cylinder walls. Using ashless dispersant oil during break-in can prevent proper ring seating and lead to high oil consumption.

Ashless Dispersant (AD) Oil

After break-in, most aircraft transition to ashless dispersant oil. AD oils contain additives that:

  • Suspend contaminants and carry them to the oil filter
  • Reduce sludge and varnish formation
  • Provide better corrosion protection
  • Extend time between oil changes

Popular Aviation Oil Brands

AeroShell

AeroShell is the most widely used aviation oil brand worldwide. Their lineup includes:

  • AeroShell W100: Standard single-grade AD oil
  • AeroShell 15W-50: Popular multi-viscosity option
  • AeroShell 100: Mineral oil for break-in
  • AeroShell W100 Plus: Contains anti-wear additive LW-16702

Phillips 66

Phillips offers a complete line of aviation oils:

  • X/C 20W-50: Multi-viscosity AD oil
  • Type A: Single-grade AD oils
  • Victory AW: Premium anti-wear formulation

Exxon/Mobil

Exxon produces the Elite series of aviation oils, offering both single and multi-grade options with advanced additive packages.

Oil Change Intervals

Most manufacturers recommend oil changes every 50 hours or 4 months, whichever comes first. However, oil analysis can help optimize your change intervals. Factors affecting intervals include:

  • Flight frequency (more frequent flying is better)
  • Climate and operating temperatures
  • Engine condition and oil consumption
  • Oil filter type (full-flow vs. spin-on)

Oil Analysis: Your Engine’s Report Card

Regular oil analysis is one of the best investments you can make. For about $30 per sample, you get detailed information about:

  • Wear metals (iron, copper, aluminum, chrome)
  • Contamination (silicon, sodium, water)
  • Oil condition (viscosity, oxidation)

Trending this data over time reveals developing problems before they become expensive failures.

What Your Engine Manufacturer Recommends

Continental

Continental engines typically call for single-grade AD oil (W100 in most climates) after break-in. Multi-viscosity is approved but single-grade is preferred. Always consult your specific engine’s operator’s manual.

Lycoming

Lycoming approves both single and multi-viscosity AD oils after break-in. They specifically recommend their own brand (now marketed by Phillips 66) but approve equivalent products from other manufacturers.

Making Your Choice

For most aircraft owners, here’s a simple decision tree:

  1. New or overhauled engine: Use mineral oil until break-in is complete
  2. Year-round, moderate climate: W100 ashless dispersant
  3. Cold climate or infrequent flying: 15W-50 or 20W-50 multi-viscosity
  4. Hot climate or high-time engine: Consider W100 Plus or W120

When in doubt, consult your A&P mechanic. They know your engine’s history and operating conditions better than anyone. And whatever oil you choose, change it regularly—consistent maintenance is more important than brand selection.

Recommended Products

Based on our recommendations above, here are some of the most popular aviation oils and filters available. These products are trusted by aircraft owners and mechanics worldwide.

AeroShell Oil W100 Plus

The W100 Plus is an enhanced version of the classic AeroShell W100, featuring the anti-wear additive LW-16702. This additive provides extra protection against cam and lifter wear, making it an excellent choice for high-performance piston engines. Ideal for year-round use in moderate climates.

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AeroShell Oil W 15W-50

For aircraft owners who fly in varying temperatures or don’t fly as frequently, the 15W-50 multi-viscosity is an excellent choice. It provides superior cold-start protection while maintaining proper viscosity at operating temperatures. Great for seasonal flyers and those in northern climates.

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Tempest AA48110-2 Spin-On Oil Filter

Don’t forget the oil filter! The Tempest AA48110-2 is a popular spin-on replacement for many Continental and Lycoming engines. Quality filtration is essential for protecting your engine and extending oil life. Always change your filter with every oil change.

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The Complete Annual Inspection Supplies Checklist for Aircraft Owners

Aircraft maintenance inspection

Every aircraft owner knows that the annual inspection is the most important maintenance event of the year. Whether you’re preparing your Cessna, Piper, or Beechcraft for its yearly checkup, having the right supplies on hand can save time and money while ensuring your aircraft meets all airworthiness requirements.

What is an Annual Inspection?

An annual inspection is a comprehensive examination of your aircraft required by FAR 91.409. Only an IA (Inspection Authorization) holder can perform and sign off an annual inspection, though aircraft owners can assist with disassembly and reassembly under supervision. The inspection covers every system: airframe, powerplant, propeller, and all installed equipment.

Essential Supplies for Your Annual

Safety Wire and Hardware

Safety wire is critical for securing bolts, nuts, and turnbuckles throughout your aircraft. You’ll need .032″ stainless steel safety wire for most applications, along with safety wire pliers. Don’t forget cotter pins in various sizes for securing castellated nuts on control systems.

Oil and Filters

Your annual is the perfect time for an oil change. Stock up on the correct grade of aviation oil for your engine—whether that’s straight mineral oil for break-in or ashless dispersant oil for normal operation. Don’t forget a new oil filter and the proper O-ring.

Filters and Gaskets

Beyond oil filters, you may need fuel filters, air filters, and various gaskets. Inspect your gasket inventory before the annual begins. Common items include rocker cover gaskets, oil sump gaskets, and exhaust gaskets.

Spark Plugs and Ignition

While spark plugs don’t always need replacement at every annual, they do need inspection and cleaning. Have a complete set of new plugs available in case any show excessive wear or damage. Massive electrode and fine wire plugs each have their advocates.

Cleaning Supplies

A thorough annual requires a clean aircraft. Stock up on:

  • Aircraft-approved degreasers for engine cleaning
  • Aluminum-safe cleaners for airframe surfaces
  • Lint-free cloths and shop towels
  • Inspection mirrors and borescopes

Lubricants

Proper lubrication extends component life and prevents corrosion. Essential lubricants include:

  • Aeroshell 33MS grease for wheel bearings
  • LPS-2 or equivalent for control cables
  • Corrosion preventive compounds for battery terminals
  • Silicone spray for door seals and weatherstripping

Creating Your Annual Inspection Kit

Smart aircraft owners maintain a dedicated annual inspection kit. Store all your supplies together so nothing is forgotten when inspection time arrives. Replace items as they’re used throughout the year.

Recommended Kit Contents:

  1. Safety wire (.032″ and .041″)
  2. Cotter pins (assorted sizes)
  3. Oil (6 quarts minimum)
  4. Oil filter
  5. Spark plugs (full set)
  6. Fuel strainer gasket
  7. Rocker cover gaskets
  8. Degreaser and cleaners
  9. Shop towels
  10. Grease and lubricants

Working With Your IA

Communication with your IA is key to a successful annual. Discuss any squawks or concerns before the inspection begins. If you plan to assist with the work, clarify which tasks you can perform under supervision. Owner-assisted annuals can significantly reduce costs while giving you deeper knowledge of your aircraft.

Documentation

Keep records of all parts used during your annual. Serial numbers from filters, part numbers from replaced components, and lot numbers from consumables should all be documented. This information is valuable for warranty claims and helps track component life.

Plan Ahead

Don’t wait until the last minute to gather supplies. Order parts at least two weeks before your scheduled annual to account for shipping delays and potential backorders. Having everything ready when your IA arrives maximizes efficiency and minimizes aircraft downtime.

A well-prepared annual inspection protects your investment, ensures safe flight operations, and often catches small problems before they become expensive repairs. Stock your maintenance kit with quality parts and supplies, and your annual will go smoothly year after year.

Recommended Annual Inspection Supplies

Here are the essential supplies every aircraft owner should have on hand for annual inspection time. These products are trusted by A&P mechanics and aircraft owners nationwide.

Safety Wire Kit with Pliers

This complete kit includes 50 feet of .032″ stainless steel safety wire plus professional-grade safety wire pliers. The pliers feature a reversible twist mechanism for both left and right-hand applications—essential for properly securing bolts, castle nuts, and turnbuckles throughout your aircraft.

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Aviation Grade Safety Wire (1 lb Spool)

For those who go through more wire, this 1-pound spool of APP aviation-grade .032″ stainless steel safety wire meets MS20995C and ASTM A580 specifications. Made from genuine 302/304 stainless steel, this is the same quality wire used by professional maintenance shops.

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AeroShell 33 Airframe Grease

AeroShell Grease 33 is the industry-standard multipurpose airframe grease meeting MIL-PRF-23827C specifications. This 14oz cartridge is perfect for wheel bearings, control system bearings, and general airframe lubrication. Every hangar should have a tube ready for annual inspection time.

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Tempest Oil Filter Torque Wrench

The Tempest AA472 oil filter torque wrench is preset to the correct 17 ft-lbs torque specification for spin-on aviation oil filters. The 1″ hex drive fits all standard aircraft oil filters and includes a built-in torque limiter to prevent over-tightening. Essential for proper filter installation.

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Aviation Oil Filter Cutter

Cutting open your oil filter to inspect for metal contamination is a critical part of any annual inspection. This heavy-duty filter cutter cleanly opens any spin-on aviation oil filter, including Champion, Tempest, and Continental filters. Look for metal particles that could indicate internal engine wear.

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Articulating Inspection Borescope

A quality borescope allows you to inspect cylinder walls, valve seats, and other hard-to-reach areas without disassembly. This 360° articulating model features a 5-inch IPS display, 6 LED lights, and 5X zoom—ideal for engine cylinder inspections and checking for corrosion in airframe cavities.

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Champion Spark Plug REM40E

The Champion REM40E is one of the most common aviation spark plugs, fitting many Continental and Lycoming engine applications. These massive electrode plugs are known for reliability and long service life. Always have a spare set available for your annual in case any plugs show wear or damage.

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