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:
- Safety wire (.032″ and .041″)
- Cotter pins (assorted sizes)
- Oil (6 quarts minimum)
- Oil filter
- Spark plugs (full set)
- Fuel strainer gasket
- Rocker cover gaskets
- Degreaser and cleaners
- Shop towels
- 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.
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.
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.
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.
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.
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.
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.
As an Amazon Associate, we earn from qualifying purchases. This helps support our site at no additional cost to you.