You want to modify your private production of light aircraft?
Many people would love to learn a little bit about aeronautical engineering and build their own plane. They want to start with a solid platform. The best platforms are those with decades-long manufacturing lines. These include Piper, Beechcraft and Cessna. They can then make modifications to their aircraft to improve performance, speed, weight, or stall speed. This makes perfect sense, right?
It's not as simple as you might think. Most of the available modification kits have been approved by FAA. However, if they haven't, it's not a simple task. For instance, the FAA may consider your aircraft an experimental aircraft. This could affect your private jet insurance costs and increase the aircraft's value when you sell it.
James E. Ellis' book, "Buying and Owning Your Own Airplane" was just out. He had some interesting remarks to make reminding aircraft buyers and owners to be careful about modifying their aircraft. This could void warranties, invalidate your insurance policy and violate FARs (Federal Air Regulations of the FAA, Federal Aviation Administration). You must re-register your aircraft as an experimental aircraft if you make any modifications to it.
The author lists approved minor modifications and lists what is prohibited without changing registration or the airworthiness certificate. If you are looking to modify your aircraft and make it a living-size model, you will want to start with an experimental plane. This will prevent you from being in trouble with the Federal Aviation Administration and get you started with your aviation insurance company. It will also allow you to obtain the aircraft at a lower cost because it is an experiment.
A friend of mine from the airport had a Moody Executive. He was also an ex-Rockwell aerospace engineer. Although he made many modifications to the aircraft, mainly fairings to improve the airspeed, he also took the liberty to redesign parts of the aircraft. He had to return the modifications to the aircraft when he sold it. Otherwise, he would have been in serious trouble with the FAA. He probably had his insurance cancelled the whole time he flew his plane, even though he didn't know it. Yes, I do hope that you will consider this information and reflect on it.
General aviation manufacturers are currently facing increased liability due to potential lawsuits. Even if the cause of an aircraft accident is pilot error, lawyers often get involved with the families and that can lead to a lawsuit. Lawsuits can be costly so additional staff will be needed at the Aircraft Manufacturer's legal department.
Mooney, a Florida company, has a problem. They have a better safety record than the "Doctor Killer", Bonanza Vtails, or Piper Malibu. There are also issues with the power curve, which can cause a lot of jerking when you go from zero to full throttle. Cessna, which produces 39,000 C-172s, has the advantages of scale but high legal and insurance costs.
